2004 Hyundai Santa FE Owners Manual

CAUTION:

When inspecting or servicing the engine, you should handle tools and other heavy objects carefully so that the plastic cover of the engine is not damaged.

10

11

1. Coolant reservoir cap 2. Engine oil filler cap 3. Brake & Clutch fluid reservoir 4. Air cleaner

5. Fuse and Relay box 6. Windshield washer fluid reservoir 7. Power steering fluid reservoir 8. Engine oil level dipstick

9. Radiator cap 10. Automatic transaxle fluid level dipstick

(Vehicle with Automatic Transaxle)

11. Battery

HSM241

G010B01O-AAT (2.7 V6)

DO-IT-YOURSELF MAINTENANCE

CAUTION:

When inspecting or servicing the engine, you should handle tools and other heavy objects carefully so that the plastic cover of the engine is not damaged.

5 6

1. Coolant reservoir cap 2. Brake & Clutch fluid reservoir 3. Air cleaner 4. Fuse and Relay box

11

10

5. Windshield washer fluid reservoir 6. Power steering fluid reservoir 7. Engine oil level dipstick 8. Radiator cap

G010B01O

9. Engine oil filler cap 10. Automatic transaxle fluid level dipstick

(Vehicle with Automatic Transaxle)

11. Battery

6 DO-IT-YOURSELF MAINTENANCE

G010C01O-AAT (3.5 V6)

CAUTION:

When inspecting or servicing the engine, you should handle tools and other heavy objects carefully so that the plastic cover of the engine is not damaged.

10

11

1. Coolant reservoir cap 2. Engine oil filler cap 3. Brake fluid reservoir 4. Air cleaner

5. Fuse and Relay box 6. Windshield washer fluid reservoir 7. Power steering fluid reservoir 8. Radiator cap

9. Engine oil level dipstick 10. Automatic transaxle fluid level dipstick 11. Battery

HSM424

GENERAL

CHECKS

G020A01A-AAT Engine Compartment

G020B01A-AAT Vehicle Exterior

G020C01A-AAT Vehicle Interior

DO-IT-YOURSELF MAINTENANCE

The following should be checked regularly:

The following should be checked monthly:

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

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)

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.

6 DO-IT-YOURSELF MAINTENANCE

CHECKING THE ENGINE OIL

G030A01A-AAT Engine oil is essential to the performance and service of the engine. It is suggested that you check the oil level at least once a week in normal use and more often if you are on a trip or driving in severe conditions.

G030C02A-AAT To Check the Oil Level

2.4 DOHC

2.7 V6

G030B01A-AAT Recommended Oil

Before checking the oil, warm up the engine to the normal operating temperature and be sure your car is parked on level ground. Turn the engine off.

Wait five minutes , then remove the dipstick, wipe it off, fully reinsert the dipstick and withdraw it again. Then note the highest level the oil has reached on the dipstick. It should be between the upper ("FULL") and lower ("LOW") range.

G030D01A-AAT Adding Oil

HSM389

2.4 DOHC

2.7 V6

3.5 V6

HSM395
SH, SG or SG/CD (API) multi-grade and fuel efficient oil is recommended.

HSM427

HSM387

3.5 V6

CHANGING THE OIL AND FILTER

G040A03A-GAT

2.4 DOHC

2.7 V6

DO-IT-YOURSELF MAINTENANCE

The engine oil and filter should be changed at those intervals specified in the maintenance schedule in Section 5. If the car is being driven in severe conditions, more frequent oil and filter changes are required.

The procedure for changing the oil and filter is as follows:

If the oil level is close to or below the "L" mark, add oil until it reaches the "F" mark. To add oil:

3.5 V6

HSM426

1. Remove the oil filler cap by turning it counter-

2. Add oil, then check the level again. Do not

clockwise.

overfill.

3. Replace the cap by turning it clockwise.

The distance between the "F" and "L" marks is equal to about 1 quart of oil.

1. Park the car on level ground and set the parking brake. Start the engine and let it warm up until the needle on the coolant temperature gauge moves above the lowest mark. Turn the engine off and place the gear selector lever in "P" (automatic) or reverse gear (manual transaxle).

2. Open the hood and remove the engine oil

filler cap.

3. Slide underneath the car and loosen the drain plug by turning it counterclockwise with a wrench of the proper size. Be sure that a drain pan is in position to catch the oil as it drains out, then remove the drain plug.

WARNING:

Be very careful when draining the engine oil as it may be hot enough to burn you!

HSM394

G040A02L

!

PROPOSITION 65 WARNING: Used engine oil may cause irritation or cancer of the skin if left in contact with the skin for prolonged periods of time. Used engine oil contains chemicals that have caused cancer in laboratory animals. Al- ways protect your skin by washing your hands thoroughly with soap and warm water as soon as possible after handling used oil.

CHECKING AND CHANGING THE ENGINE COOLANT

G050A01A-AAT

WARNING:

Do not remove the radiator cap when the engine is hot. When the engine is hot, the engine coolant is under pressure and may erupt through the opening if the cap is removed. You could be seriously burned if you do not observe this precaution. Do not remove the radiator cap until the radiator is cool to the touch.

WARNING:

Used motor oil may cause irritation or can- cer of the skin if left in contact with the skin for prolonged periods of time. Wash your hands thoroughly with soap and warm water as soon as possible after handling used oil.

6 DO-IT-YOURSELF MAINTENANCE

4. When the oil has stopped draining, replace the drain plug using a new washer and retighten by turning it clockwise.

Oil pan drain plug tightening torque: 3.5 ~ 4.5 kgf.m

6.

5. Remove the oil filter by turning it counter- clockwise with a oil filter wrench of the proper size. A certain amount of oil will come out when you remove the filter. So be sure to have your drain pan in place underneath it. Install a new oil filter in accordance with the instructions on the carton or on the filter itself. Do not over-tighten. (Tightening torque : 1.2 ~ 1.6 kgf.m) Be sure that the mounting surface on the engine is clean and that the old gasket is removed completely. Lubricate the new gasket on the filter with clean engine oil before installation.

7. Refill the crankcase with the recommended engine oil. Refer to the specification in chap- ter 9 for engine oil capacity.

8. Start the engine and check to be sure no oil

is leaking from the drain plug or oil filter.

9. Shut off the engine and recheck the oil level.

NOTE: Always dispose of used engine oil in an environmentally acceptable manner. It is suggested that it be placed in a sealed container and taken to a service station for reclamation. Do not pour the oil on the ground or put it in with the household trash.

G050B01A-AAT Recommended Engine Coolant

G050C01A-AAT To Check the Coolant Level

G050D02A-AAT To Change the Engine Coolant

DO-IT-YOURSELF MAINTENANCE

Use a high quality ethylene-glycol coolant in a 50/50 mix with water. The engine coolant should be compatible with aluminum engine parts. Additional corrosion inhibitors or additives should not be used. The cooling system must be maintained with the correct concentration and type of engine coolant to prevent freezing and corrosion. Never allow the concentration of antifreeze to exceed the 60% level or go below the 35% level, or damage to the cooling system may result. For proper concentration when adding or replacing the engine coolant, refer to the following table.

Ambient

Engine Coolant concentration

temperature

°F (°C) 5 (-15) -13 (-25) -31 (-35) -49 (-45)

Antifreeze solution

35% 40% 50% 60%

Water

65% 60% 50% 40%

G050C01O The coolant level can be seen on the side of the plastic coolant reservoir. The level of the cool- ant should be between the "L" and "F" lines on the reservoir when the engine is cool. If the level is below the "L" mark, add engine coolant to bring it up between "L" and "F". If the level is low, inspect for coolant leaks and recheck the fluid level frequently. If the level drops again, visit your Hyundai dealer for an inspection and diagnosis of the reason.

The engine coolant should be changed at those intervals specified in the vehicle maintenance schedule in Section 5. CAUTION: Engine coolant can damage the finish of your car. If you spill engine coolant on the car, wash it off thoroughly with clean water.

1. Park the car on level ground, set the park- ing brake and remove the radiator cap when cool.

G050D01O 2. Turn the radiator cap counterclockwise with- out pressing down on it, until it stops. This relieves any pressure remaining in the cool- ing system. And remove the radiator cap by pushing down and turning counterclock- wise.

6 DO-IT-YOURSELF MAINTENANCE 1 0

3. Be sure your drain receptacle is in place. Open the drain cock on the radiator. Allow all the engine coolant to drain from the cooling system, then securely close the drain cock. 4. Check Section 9 for the capacity of the cooling system in your car. Then, following the manufacturer's directions on the engine coolant container, add the appropriate quan- tity of coolant to the radiator.

5. Fill the radiator with clean demineralized or distilled water. Continue to add clean dem- ineralized or distilled water in small quantities until the fluid level stays up in the radiator neck.

G050D02O 6. Start the engine, top off the radiator with water and then add coolant to the reservoir until the level is between "L" and "F".

7. Replace the radiator and reservoir caps and check to be sure the drain cocks are fully closed and not leaking.

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 coolant 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.

SPARK PLUGS

G060A02Y-AAT

2.4 DOHC

2.7 V6 / 3.5 V6

HSM392

Your engine was originally equipped with plati- num-tipped spark plugs. Platinum-tipped spark plugs will last longer than conventional type spark plugs and can be identified by blue lines on the ceramic shell.

NOTE: Do not clean or regap platinum-tipped spark plugs.

G060B02O-AAT Replacing the Spark Plugs

G060C0IO-AAT Changing the Spark Plugs

The spark plugs should be changed at the intervals specified in the vehicle maintenance schedule in Section 5 or whenever engine performance indicates they should be changed. Symptoms that suggest poor spark plug perfor- mance include engine misfiring under load, loss of fuel economy, poor acceleration, etc. When spark plugs are replaced, always use spark plugs recommended by Hyundai. The use of other spark plugs can result in loss of perfor- mance, radio interference or engine damage.

NOTE: o When replacing the spark plug, genuine Hyundai replacement parts are recom- mended.

o It is recommended that the spark plug should be changed by an authorized Hyundai dealer. (2.7 L, 3.5 L)

Recommended Spark Plugs:

Type

RN10PYP4 PGR5C-11 (NGK) RC10PYPB4 PFR5N-11 (NGK)

(CHAMPION)

(CHAMPION)

Remark

2.4 L

2.7 L / 3.5 L

G060C01O You will find it easier to change spark plugs if the engine is cold. Always change one spark plug at a time. This helps avoid getting the wires mixed up.

1. Remove the center cover (2.4 L) on the

engine rocker cover.

2. Using a clean cloth, remove any dirt that has accumulated around the base of the spark plug so it cannot fall into the cylinder when the spark plug is removed.

3. To remove the spark plug cable, pull straight up on the insulated connector, not the cable. Pulling on the cable may damage the carbon core conductor.

DO-IT-YOURSELF MAINTENANCE

1 1

G060C02O

WARNING:

It is recommended that the engine be cool or cold when changing the spark plugs. If the engine is hot, you could burn yourself on the insulated connector, the spark plug or the engine itself.

4. When preparing to remove the old spark plug, guide the socket down over the spark plug, being careful not to damage the ce- ramic insulator.

5. To remove the old spark plug, turn the wrench handle in a counterclockwise direc- tion.

6 DO-IT-YOURSELF MAINTENANCE 1 2

6. To install the new spark plug, guide the socket down over the spark plug, being careful not to damage the ceramic insulator.

CHANGING THE AIR CLEANER FILTER G070A01E-AAT

WINDSHIELD WIPER BLADES

G080A02A-AAT

G060C03O

NOTE: Spark plugs should be tightened to speci- fication. Over-tightening can damage the threads in the aluminum cylinder head. Also, leaving them too loose can cause the spark plug to get very hot and possibly result in damage to the engine.

7. Replace the cable by pushing the insulated connector directly down onto the electrode. Check to be sure it has snapped into place and can't fall off.

G070A01O To change the filter, unsnap the clips around the cover. When this is done, the cover can be lifted off, the old filter removed and the new filter put in its place. Genuine Hyundai Replacement Parts are recommended.

CAUTION:

o Operating your vehicle without a proper air filter in place can result in excessive engine wear.

o When removing the air cleaner filter, be careful that dust or dirt does not enter the air intake. These may result in dam- age to the air cleaner filter.

HEF119
The wiper blades should be carefully inspected from time to time and cleaned to remove accu- mulations of road film or other debris. To clean the wiper blades and arms, use a clean sponge or cloth with a mild soap or detergent and water. If the wipers continue to streak or smear the glass, replace them with genuine Hyundai re- placement parts or their equivalent.

CAUTION:

o Do not operate the wipers on dry glass. This can result in more rapid wear of the wiper blades and may scratch the glass. o Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc.

FILLING THE WASHER RESERVOIR

G090A01O-AAT

CAUTION:

o Radiator anti-freeze (engine coolant) should not be used in the washer system because it will damage the car's finish. o The washer should not be operated if the washer reservoir is empty. This can dam- age the washer fluid pump.

G090A01O The washer fluid reservoir supplies fluid to the windshield washer system. A good quality washer fluid should be used to fill the washer reservoir. The fluid level should be checked more frequently during inclement weather or whenever the washer system is in more frequent use. The capacity of the washer reservoir is 3.59
U.S. quarts (3.4 Liters).

DO-IT-YOURSELF MAINTENANCE

CHECKING THE TRANSAXLE OIL (MANUAL)

G100A02O-AAT

1 3

Filler plug

Drain plug

HSM435
Transaxle lubricant in the manual transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

Recommended Oil

Use only HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4) or EQUIVALENT in the manual transaxle.

Manual Transaxle Oil Capacity

The oil capacity of the manual transaxle is 2.43
U.S. quarts (2.3 liters).

Park the car on level ground with the engine off.

1. Using a wrench of the correct size, loosen the oil filler plug by turning it counterclock- wise and remove it with your fingers.

2. Use your finger or suitable tool to feel inside the hole. The oil level should be at its bottom edge. If it is not, check for leaks before adding oil. To refill the transaxle or bring the oil level up,add oil slowly until it reaches the proper level. Do not overfill.

3. Replace the plug and washer, screw it in with your fingers and then tighten securely with the wrench.

(AUTOMATIC)

CHECKING THE TRANSAXLE FLUID G110A01E-AAT Transaxle fluid in the automatic transaxle should be checked at those intervals specified in the vehicle maintenance schedule in Section 5.

NOTE: Automatic transaxle fluid is basically red color. As driving distance increases, the fluid color turns darkish red gradually. It is a normal condition and you should not judge the need to replace based upon the changing color. You must replace the automatic transaxle fluid in accordance with intervals specified in the vehicle maintenance schedule in section 5.

6 DO-IT-YOURSELF MAINTENANCE 1 4

WARNING:

It is always better to check the transaxle oil level when the engine is cool or cold. If the engine is hot, you should exercise great caution to avoid burning yourself on hot engine or exhaust parts.

G100B02A-AAT To Check the Manual Transaxle Fluid Level

SSA6100B

G110B03A-AAT Recommended Fluid

G110D02O-AAT To Check the Transaxle Fluid Level

DO-IT-YOURSELF MAINTENANCE

1 5

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.

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.

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. 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.

3.

C090A01O 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.

6 DO-IT-YOURSELF MAINTENANCE 1 6

CHECKING THE BRAKES

G120A01A-AAT

Fluid level should be within "HOT" range

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.

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

G120B01A-AAT Checking 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.

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.

G120D01A-AAT To 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.

CHECKING THE CLUTCH FLUID

DO-IT-YOURSELF MAINTENANCE

1 7

G120E02A-AAT Adding Brake Fluid

G130A01A-AAT To Check the Clutch Fluid

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.

HSM158
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

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.

6 DO-IT-YOURSELF MAINTENANCE 1 8

AIR CONDITIONING CARE

G140A01A-AAT Keeping the Condenser Clean

G140C01A-AAT Lubrication

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.

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.

3.5 V6
Power steering pulley

Generator

G140D02A-AAT Checking the Compressor Drive Belt

2.7 V6

2.4 DOHC

Auto tensioner

G140B01A-AAT Checking 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. If the air coming out of the in-dash vents is not cold, have the air conditioning system inspected by your Hyundai dealer.

2.

CAUTION:

Running the air conditioning system for extended periods of time with a low refrig- erant level may damage the compressor.

COMP

Eng.pulley

Eng.pulley

0.315 in.

COMP HSM396

Crank shaft apulley

A/C pulley

G140D02L 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.

CHECKING THE FREE-PLAY

DO-IT-YOURSELF MAINTENANCE

1 9

G150A01A-AAT STEERING WHEEL

G160A01A-AAT CLUTCH PEDAL

G170A01A-AAT BRAKE PEDAL

1.18 in. (30 mm)

0.24 ~ 0.51 in. (6 ~ 13 mm)

0.12 ~ 0.31 in. (3 ~ 8 mm)

G150A01O

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.

G160A01E 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.

HXGS508
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.

6 DO-IT-YOURSELF MAINTENANCE 2 0

CHECKING BRAKE PEDAL CLEARANCE

G180A01A-AAT

CHECKING DRIVE BELTS

G190A01A-AAT

2.7 V6

Power steering

Auto tensioner

2.4 DOHC

Power steering

Eng.coolant

0.30~0.48 in. 0.24~0.35 in.

2.95 in. (75 mm)

Generator

Generator

COMP

G180A01L 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.

Eng.pulley

Eng.pulley

0.315 in.

COMP

HSM396

3.5 V6
Power steering pulley

Generator

Crank shaft apulley

A/C pulley

G140D02L

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.

DO-IT-YOURSELF MAINTENANCE

2 1

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.

CAUTION:

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.

G200B01A-AAT Replacing Accessory Fuses

CHECKING AND REPLACING FUSES G200A02A-AAT Replacing a Fusible Link

Good Open-

Replace

G200A01L

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.

HSM391
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.

HSM390

6 DO-IT-YOURSELF MAINTENANCE 2 2

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.

CHECKING THE BATTERY

G210A01A-AAT

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.

NOTE: See page 6-34 for the fuse panel descrip- tions.

D010B01Y

WARNING:

Batteries can be dangerous! When working with batteries, carefully observe the follow- ing precautions to avoid serious injuries.

Good

Open-Replace

G200B03Y

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:

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:

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.

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.

DO-IT-YOURSELF MAINTENANCE

CHECKING ELECTRIC COOLING FANS G220A01A-AAT

2 3

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.

o Charge batteries only in a well ventilated

o Do not permit flames, sparks or smoking in

area.

the area.

o Keep children away from the area.

6 DO-IT-YOURSELF MAINTENANCE 2 4

POWER STEERING FLUID LEVEL

G220B01A-AAT Checking Engine Cooling Fan

G230A03A-AAT

The engine cooling fan should come on auto- matically if the engine coolant temperature is high.

G220C01A-AAT Checking Condenser Cooling Fan

The condenser cooling fan should come on automatically whenever the air conditioning is in operation.

G230A01O 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.

Recommended Use PSF-3 type fluid

Fluid

NOTE: Do not start the engine when the power steering oil reservoir is empty.

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.

G250A01A-AAT FOR MORE YOUR HYUNDAI

INFORMATION ABOUT

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.

HEADLIGHT AIMING ADJUSTMENT

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.

Vertical aiming

DO-IT-YOURSELF MAINTENANCE

2 5

G290B01O-AAT Adjustment After Headlight Assembly Replacement

Vertical line

Horizontal line

Cut-off line

"P"

G290A01O

Ground 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.

G290A03O 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.

6 DO-IT-YOURSELF MAINTENANCE 2 6

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).

REPLACEMENT 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.

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.

CAUTION:

Keep the lamps out of contact with petro- leum products, such as oil, gasoline, etc.

4. Using a socket wrench of the correct size, remove the headlight assembly mounting bolts.

HSM353

6. Turn the plastic cover counterclockwise

and remove it.

DO-IT-YOURSELF MAINTENANCE

2 7

HSM328
5. Disconnect the power cord from the bulb

base in the back of the headlight.

HSM329
7. Disconnect the connector from the bulb

base in the back of the headlight.

HSM330
8. Push the bulb spring to remove the headlight

bulb.

G270A01O

6 DO-IT-YOURSELF MAINTENANCE 2 8

HSM331
9. Remove the protective cap from the re- placement bulb and install the new bulb by matching the plastic base with the headlight hole. Reattach the bulb spring and recon- nect the connector.

10.Use the protective cap and carton to prompt-

ly dispose of the old bulb.

11.Check for proper headlight aim.

HSM332
12.To replace the front turn signal light bulb, remove from the bulb holder and install the new bulb.

G270A03O

WARNING:

This halogen bulb contains gas under pres- sure and if impacted could shatter, result- ing in flying fragments. Always wear eye protection when servicing the bulb. Protect the bulb against abrasions or scratches and against liquids when lighted. Turn the bulb on only when installing in a headlight. Replace the headlight if damaged or cracked. Keep the bulb out of the reach of children and dispose of the used bulb with care.

G270B01O-AAT Rear Combination Light

1. Open the tail gate. 2. Remove the mounting screws as shown

with a phillips screwdriver.

G270C01O-AAT Luggage Compartment Light

DO-IT-YOURSELF MAINTENANCE

2 9

(3)

(2)

(1)

(4)

(2)

(1)

(4)

(3)

HSM423
3. To replace the rear combination light (stop/ tail light, turn signal light, back-up light, side mark light), take it out from the bulb holder by turning it counterclockwise.

(1) Stop/Tail light (2) Turn signal light (3) Back-up light (4) Side mark light

4.

Install the new bulb.

HSM352

HSM337

1. Open the tail gate. 2. Remove the cover with a flat-head screw-

driver.

HSM341

6 DO-IT-YOURSELF MAINTENANCE 3 0

G270E01O-AAT Front Side Mark Light

3. Replace with a new bulb.

HSM342

HSM334
1. Remove the cover with a phillips screw-

driver.

2. Disconnect the connector.

HSM335

3. Replace with a new bulb.

HSM336

G270G01O-AAT Interior Light

G270H01O-AAT Glove Box Illuminated Light

DO-IT-YOURSELF MAINTENANCE

3 1

HSM343
1. Remove the cover with a flat-head screw-

driver.

2. Replace with a new bulb.

HSM344

1. Open the glove box. 2. Remove the cover with a flat-head screw-

driver.

HSM366

6 DO-IT-YOURSELF MAINTENANCE 3 2

3. Disconnect the connector.

G270E02L

4. Replace with a new bulb.

HTB284

BULB WATTAGE

G280A02O-AAT

10

11

DO-IT-YOURSELF MAINTENANCE

3 3

12

G280A01O

No.

Part Name

Wattage

No.

Part Name

Wattage

Head Light (Low/High)

Front Fog Light (If installed)

Turn Signal Light

Side Mark Light

Front Door Edge Warning Light (If installed)

Glove Box Illuminated Light

Map Light

Interior Light

55/60

27

28

10

15

10

10

11

12

High Mounted Rear Stop Light

Luggage Compartment Light

License Plate Light

Rear Combination Light

Stop/Tail Light

Turn Signal Light

Back-up Light

Rear Side Mark Light

17

10

27/8

27

27

6 DO-IT-YOURSELF MAINTENANCE 3 4

FUSE PANEL DESCRIPTION

G200C01O-AAT Engine Compartment

DESCRIPTION

FUSE

RATING

PROTECTED

COMPONENTS

FUSIBLE

LINK

FUSE

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

120A 50A 50A 40A 30A 30A 40A 30A 40A 20A 15A 10A 10A 20A 20A 10A 15A 20A 10A 10A 10A

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

NOTE: 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.

G200C01O-A

G200E01O-AAT Inner Panel

FUSE

FUSE RATING

PROTECTED

COMPONENTS

DO-IT-YOURSELF MAINTENANCE

3 5

F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18

F19

F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31

20A 10A 15A 10A 10A 25A 10A 10A 10A 10A 10A 15A 20A 10A 10A 25A 20A 30A

10A

15A 10A 10A 10A 10A 10A 20A 10A 10A 15A 10A 20A

Cigarette lighter & Power outlet Audio, Power outside mirror Digital clock, Rear power outlet Cruise control Head lamp relay Seat warmer Rear wiper motor control Rear window defogger, Power outside mirror A/C control, Sunroof controller, Electrical chrome mirror (Not used) Room lamp, Door warning switch, Door lamp, Manual A/C control, Homelink controller Digatal clock, ETACM, Audio, Siren AMP speakers Stop lamp, Data link connector, Multipurpose check connector Hazard lamp Power seat, Rear wiper motor control Sunroof controller Defogger relay Instrument cluster, Pre-excitation resistor, ETACM, Auto light sensor, DRL control module, Generator SRS control module ECM (V6 2.7L), PCM (I4 with A/T), ECM (I4 with M/T) Instrument cluster (Air bag IND) ABS control module, G-Sensor, Air bledding connector, 4WD control module Turn signal lamp Back-up lamps, TCM, Vehicle speed secsor, ETS control module, Ignition failure sensor Door lock/unlock relay, Key lock/unlock relay Tail & parking lamp (LH), Turn signal lamp, License lamp Tail & parking lamp (RH), Fog lamp relay, Switch illumination ETS control module (V6 3.5L), Fail safety relay Radiator fan relay, Condenser fan relay Front wiper motor, Wiper relay, Washer motor

G200E01O-A

EMISSION CONTROL SYSTEMS

Emission Control System ...................................................... 7-2
EGR System ............................................................................ 7-3
Catalytic Converter ................................................................. 7-3

7 EMISSION CONTROL SYSTEMS

EMISSION CONTROL SYSTEM

H010A02O-AAT Your Hyundai is equipped with an emission control system to meet all requirements of the U.S. Environmental Protection Agency or Cali- fornia Air Resources Board. There are three emission control systems which are as follows.

(1) Crankcase emission control system (2) Evaporative emission control system (3) Exhaust emission control system

In order to assure the proper function of the emission control systems, it is recommended that you have your car inspected and main- tained by an authorized Hyundai dealer in ac- cordance with the maintenance schedule in this manual.

Caution for the Inspection and Maintenance Test (V6 Vehicle with Traction Control Sys- tem)

o To prevent the vehicle from misfiring during dynamometer testing, discon- nect the ABS connector in the engine compartment. (2.7 V6 only)

o For more information, see shop manual

(Wheel Speed Sensor).

o After dynamometer testing is completed, erase (Diagnotic Trouble Code) with a GST (Generic Scan Tool) or Hi-Scan Pro.

the ABS/TCS DTC

H010B01A-AAT 1. Crankcase Emission Control

Canister

System

The positive crankcase ventilation system is employed to prevent air pollution caused by blow-by gases being emitted from the crank- case. This system supplies filtered air to the crankcase through the air intake hose. Inside the crankcase, the fresh air mixes with blow-by gases, which then pass through the PCV valve and into the induction system.

H010C01S-AAT 2. Evaporative Emission Control (Includ- ing ORVR: Onboard Refueling Vapor Recovery) System

The Evaporative Emission Control System is designed to prevent fuel vapors from escaping into the atmosphere. (The ORVR system is designed to allow the vapors from of the fuel tank to be loaded into a canister while refueling at the gas station, pre- venting the escape of fuel vapors into the atmosphere.)

Fuel vapors generated inside the fuel tank are absorbed and stored in the canister. When the engine is running, the fuel vapors absorbed in the canister are drawn into the induction system through the purge control solenoid valve.

Purge Control Solenoid Valve (PCSV)

The purge control solenoid valve is controlled by the Engine Control Module (ECM); when the engine coolant temperature is low during idling, the PCSV closes so that evaporated fuel is not taken into the engine. After the engine warms- up during ordinary driving, the PCSV opens to introduce evaporated fuel to the engine.

H010D01A-AAT 3. Exhaust Emission Control System

The Exhaust Emission Control System is a highly effective system which controls exhaust emissions while maintaining good vehicle performace.

EGR SYSTEM

CATALYTIC

CONVERTER

H010E01Y-AAT (If installed)

H020A01A-AAT

This system helps reduce nitrogen oxides by recirculating a part of the exhaust gas into the engine, thereby reducing cylinder combustion temperature, which results in lower output of oxides of nitrogen.

Catalytic Converter

H020A01O All Hyundai vehicles are equipped with a mono- lith type three-way catalytic converter to re- duce the carbon monoxide, hydrocarbons and nitrogen oxides contained in the exhaust gas. Exhaust gases passing through the catalytic converter cause it to operate at a very high temperature. The introduction of large amounts of unburned gasoline into the exhaust may cause the catalytic converter to overheat and create a fire hazard. This risk may be reduced by observing the following:

EMISSION CONTROL SYSTEMS

WARNING:

o Use unleaded fuel only. o Maintain the engine in good operating condition. Extremely high catalytic con- verter temperatures can result from im- proper operation of the electrical, igni- tion or multiport electronic fuel injec- tion.

o If your engine stalls, pings, knocks, or is hard to start, have your Hyundai dealer inspect and repair the problem as soon as possible.

o Avoid driving with a very low fuel level. Running out of gasoline may cause the engine to misfire and result in damage to the catalytic converter.

o Avoid

idling the engine for periods

longer than 10 minutes.

o The vehicle should not be pushed or pulled to get started. This may cause the catalytic converter to overheat and cre-