2004 Hyundai Santa Fe Engine

3
2
WHAT TO DO IN AN EMERGENCY
IF THE ENGINE WILL NOT START
!
D010A01A-AAT D010B02A-AAT
If Engine Doesn't Turn Over or Turns
Over Slowly
D010C01Y-AAT
If Engine Turns Over Normally but Does
Not Start
1. Check fuel level.
2. With the key in the "OFF" position, check all
connectors at ignition, coil and spark plugs.
Reconnect any that may be disconnected or
loose.
3. Check the fuel line in the engine room.
4. If engine still refuses to start, call a Hyundai
dealer or seek other qualified assistance.
D010D01A-AAT
If Engine Stalls While Driving
1. Reduce your speed gradually, keeping a
straight line. Move cautiously off the road to
a safe place.
2. Turn on your emergency flashers.
3. Try to start the engine again. If your vehicle
will not start, contact a Hyundai dealer or
seek other qualified assistance.
WARNING:If the engine will not start, do not push or
pull the car to start it. This could result in a
collision or cause other damage. In addi-
tion, push or pull starting may cause the
catalytic converter to be overloaded and
create a fire hazard.
1. If your car has an automatic transaxle, be
sure the gear selector lever is in "N" or "P"
and the emergency brake is set.
2. Check the battery connections to be sure
they are clean and tight.
3. Turn on the interior light. If the light dims or
goes out when you operate the starter, the
battery is discharged.
4. Check the starter connections to be sure
they are securely tightened.
5. Do not push or pull the vehicle to start it. See
instructions for "Jump Starting".
D010B01Y

3WHAT TO DO IN AN EMERGENCY
3JUMP STARTING
!
o If you should accidentally get acid on your
skin or in your eyes, immediately remove
any contaminated clothing and flush the area
with clear water for at least 15 minutes. Then
promptly obtain medical attention. If you
must be transported to an emergency facil-
ity, continue to apply water to the affected
area with a sponge or cloth.
o The gas produced by the battery during the
jump-start operation is highly explosive. Do
not smoke or allow a spark or an open flame
in the vicinity.
o The battery being used to provide the jump
start must be 12-volt. If you cannot deter-
mine that it is a 12-volt battery, do not attempt
to use it for the jump start.
o To jump start a car with a discharged battery,
follow this procedure exactly:
1. If the booster battery is installed in another
vehicle, be sure the two vehicles are not
touching.
2. Turn off all unnecessary lights and acces-
sories in both vehicles.
3. Attach the clamps of the jumper cable in the
exact location shown on the illustration. First,
attach one clamp of the jumper cable to the
positive (+) post or cable of the discharged
battery.Then attach the other end of the same cable
to the positive (+) post or cable of the booster
battery. Next, using the other cable, attach
one clamp to the negative (-) post or cable
of the booster battery. Then attach the other
end of that cable to a solid metal part of the
engine away from the battery. Do not con-
nect the cable to any moving part.
4. Start the engine in the car with the booster
battery and let it run for a few minutes. This
will help to assure that the booster battery is
fully charged. During the jumping operation,
run the engine in this vehicle at about 2,000
rpm.
5. Start the engine in the car with the dis-
charged battery using the normal starting
procedure. After the engine starts, leave the
jumper cables connected and let the engine
run at fast idle or about 2,000 rpm for several
minutes.
6. Carefully remove the jumper cables in the
reverse order of attachment.
If you do not know why your battery became
discharged (because the lights were left on,
etc.), have the charging system checked by
your Hyundai dealer.D020A02A-AAT
WARNING:The gas produced by the battery during the
jump-start operation is highly explosive. If
these instructions are not followed exactly,
serious personal injury and damage to the
vehicle may occur! If you are not sure how
to follow this procedure, seek qualified
assistance. Automobile batteries contain
sulfuric acid. This is poisonous and highly
corrosive. When jump starting, wear pro-
tective glasses and be careful not to get
acid on yourself, your clothing or on the car.
HSMJ401
Booster
batteryDischarged
battery

3
4
WHAT TO DO IN AN EMERGENCY
IF THE ENGINE OVERHEATS
!
!
!
WARNING:While the engine is running, keep hair,
hands and clothing away from moving parts
such as the fan and drive belts to prevent
injury.
5. If the water pump drive belt is broken or
engine coolant is leaking out, stop the engine
immediately and call the nearest Hyundai
dealer for assistance.
WARNING:Do not remove the radiator cap when the
engine is hot. This can allow coolant to be
blown out of the opening and cause seri-
ous burns.6. If you cannot find the cause of the overheat-
ing, wait until the engine temperature has
returned to normal. Then, if coolant has been
lost, carefully add coolant to the reservoir
(page 6-9) to bring the fluid level in the
reservoir up to the halfway mark.
7. Proceed with caution, keeping alert for fur-
ther signs of overheating. If overheating
happens again, call a Hyundai dealer for
assistance.
CAUTION:Serious loss of coolant indicates there is a
leak in the cooling system and this should
be checked as soon as possible by a Hyundai
dealer.
D030A02A-AAT
If your temperature gauge indicates overheat-
ing, you experience a loss of power, or hear loud
pinging or knocking, the engine is probably too
hot. If this happens, you should:
1. Pull off the road and stop as soon as it is safe
to do so.
2. Place the gear selector lever in "P" (auto-
matic), or neutral (manual transaxle) and set
the parking brake. If the air conditioning is on,
turn it off.
3. If engine coolant is running out under the car
or steam is coming out from the hood, stop
the engine. Do not open the hood until the
coolant has stopped running or the steaming
has stopped. If there is no visible loss of
engine coolant and no steam, leave the
engine running and check to be sure the
engine cooling fan is operating. If the fan is
not running, turn the engine off.
4. Check to see if the water pump drive belt is
missing. If it is not missing, check to see that
it is tight. If the drive belt seems to be
satisfactory, check for coolant leaking from
the radiator, hoses or under the car. (If the
air conditioning had been in use, it is normal
for cold water to be draining from it when you
stop).

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WHAT TO DO IN AN EMERGENCY
D080D01O-AAT
EMERGENCY TOWINGFor emergency towing when no commercial
tow vehicle is available, attach a tow cable,
chain or strap to one of the towing hooks under
the front/rear of your car. Be very careful when
attempting this procedure when the vehicle is on
any unpaved surface to avoid damage to your
vehicle.
Nor should towing be attempted if the wheels,
drive train, axles, steering or brakes are dam-
aged. Before towing, be sure the transaxle is in
neutral and the key is in "ACC" (with the engine
off) or in the "ON" position (with the engine
running). A driver must be in the towed car to
steer it and operate the brakes.
NOTE:To avoid serious damage to your 4WD ve-
hicle, limit the towing to 10 mph and not for
more than 1 mile at ANY TIME.
NOTE:Before towing, check the level of the
transaxle fluid. If it is below the "HOT" mark
on the dipstick, add fluid. If you cannot add
fluid, a towing dolly must be used as de-
scribed above.
D080C02O
o OK FOR AUTOMATIC OR MANUAL
TRANSAXLE EQUIPPED VEHICLE and for more than 15 miles (25 km). Be
sure the steering is unlocked by placing
the key in the "ACC" position.
A driver must be in the towed vehicle to
operate the steering and brakes.
HSM430
HSM235-1

Towing HookTowing Hooks

If the car is being towed with the rear wheels on
the ground, be sure the parking brake is re-
leased.

5VEHICLE MAINTENANCE REQUIREMENTS
2
F010C01A-AAT
Specified Scheduled Procedures
These are the procedures such as inspections,
adjustments and replacements that are listed in
the maintenance charts starting on page 5-4.
These procedures must be performed at the
intervals shown in the maintenance schedule to
assure that your warranty remains in effect.
Although it is strongly recommended that they
be performed by the trained technicians at your
Hyundai dealer, these procedures may be per-
formed at any qualified service facility.
It is suggested that genuine Hyundai service
parts be used for any required repairs or re-
placements. Other parts of equivalent quality
such as engine oil, engine coolant, manual or
auto transaxle oil, brake fluid and so on which
are not supplied by Hyundai Motor Company or
its distributor may be used without affecting
your warranty coverage but you should always
be sure these are equivalent to the quality of the
original Hyundai parts. Your Owner's Hand-
book provides further information about your
warranty coverage.
F010A01A-AAT
Service Requirements
To ensure that you receive the greatest number
of miles of satisfying operation from your Hyundai,
certain maintenance procedures must be per-
formed. Although careful design and engineer-
ing have reduced these to a minimum, those that
are required are of the utmost importance.
It is your responsibility to have these mainte-
nance procedures performed to comply with
the terms of the warranties covering your new
Hyundai. The Owner's Handbook supplied with
your new vehicle provides further information
about these warranties.
F010B01A-AAT
Maintenance Requirements
The maintenance required for your Hyundai
can be divided into three main areas:
o Specified scheduled procedures
o General checks
o Do-it-yourself maintenance
MAINTENANCE INTERVALS

5VEHICLE MAINTENANCE REQUIREMENTS
4SCHEDULED MAINTENANCE
F030B01O-AATR :Replace I : Inspect and, after Inspection, clean, adjust, repair or replace if necessary.
DESCRIPTION
EMISSION CONTROL ITEMS
ENGINE OIL AND FILTER
FUEL FILTER
FUEL LINES, FUEL HOSES AND CONNECTIONS
VACUUM HOSES
CRANKCASE VENTILATION HOSE
VAPOR HOSE AND FUEL FILLER CAP
AIR CLEANER FILTER
SPARK PLUGS (PLATINUM COATED) No.
1
2
3
4
5
6
7
8MILES X 1000
KILOMETERS X 1000
MONTHS7.5
12
6
R15
24
12
R22.5
36
18
R30
48
24
R
I
I
I
R37.5
60
30
R45
72
36
R52.5
84
42
R
R
I60
96
48
R
I
I
I
R
R67.5
108
54
R75
120
60
R82.5
132
66
R90
144
72
R
I
I
I
R97.5
156
78
R105
168
84
R
R
I112.5
180
90
R120
192
96
R
I
I
I
R
R127.5
204
102
R135
216
108
R142.5
228
114
R150
240
120
R
I
I
I
R
F030A01A-AAT
The following maintenance services must be performed to ensure good emission control and performance. Keep receipts for all vehicle emission services
to protect your warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

5VEHICLE MAINTENANCE REQUIREMENTS
6MAINTENANCE UNDER SEVERE USAGE CONDITIONS
SEVERE DRIVING CONDITIONS
A - Repeated short distance driving
B - Extensive idling
C - Driving in dusty, rough roads
D - Driving in areas using salt or other corrosive materials or in
very cold weather
E - Driving in sandy areas
F040A02O-AAT
The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate
maintenance intervals.
R : Replace I : Inspect and, after inspection, clean, adjust, repair or replace if necessary
*1. Transfer case Oil and Rear Axle Oil should be changed anytime they have been submerged in water.
F - More than 50% driving in heavy city traffic during hot weather
above 90°F (32°C)
G - Driving in mountainous areas
H - Towing a trailer
I - Driving as a patrol car, taxi, other commercial use and vehicle towing
J - Driving over 100 mph
ENGINE OIL AND FILTER
AIR CLEANER FILTER
SPARK PLUGS
BRAKE PADS, CALIPERS AND ROTORS
REAR BRAKE DRUMS/LININGS/PADS, PARKING BRAKE
STEERING GEAR BOX, LINKAGE & BOOTS/
LOWER ARM BALL JOINT
DRIVESHAFTS AND BOOTS
MANUAL TRANSAXLE OIL
AUTOMATIC TRANSAXLE FLUID AND FILTER
TRANSFER CASE OIL (4WD) *
1
REAR AXLE OIL (4WD) *1
MAINTENANCE ITEM
R
R
R
I
I
I
I
R
R
R
REVERY 3,000 MILES (4,800 KM) OR 3 MONTHS
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
MORE FREQUENTLY
EVERY 7,500 MILES (12,000 KM) OR 6 MONTHS
EVERY 60,000 MILES (96,000 KM)
EVERY 30,000 MILES (48,000 KM)
EVERY 25,000 MILES (40,000 KM)
EVERY 25,000 MILES (40,000 KM)
EVERY 50,000 MILES (80,000 KM)
With LSD
Without LSD
DRIVING
CONDITION MAINTENANCE
INTERVALS MAINTENANCE
OPERATION
A, B, C, F, H
C, E
B, H
C, D, G, H
C, D, G, H
C, D, E, F, G
C, E, F
A, C, D, E, F, G, H, I, J
A, C, E, F, G, H, I
C, E, G, I
C, E, G, I

5VEHICLE MAINTENANCE REQUIREMENTS
7
F060D01A-AATo Fuel Lines, Fuel Hoses and Connec-
tions
Check the fuel lines, fuel hoses and connec-
tions for leakage and damage. Have a trained
technician replace any damaged or leaking
parts immediately.
F060A01A-AAT F060B01A-AAT
o Drive Belts
Inspect all drive belts for evidence of cuts,
cracks, excessive wear or oil saturation and
replace if necessary. Drive belts should be
checked periodically for proper tension and
adjusted as necessary.F060M01A-AATo Engine Oil and Filter
The engine oil and filter should be changed at the
intervals specified in the maintenance sched-
ule. If the car is being driven in severe condi-
tions, more frequent oil and filter changes are
required.
F060C01A-AATo Fuel Filter
A clogged filter can limit the speed at which the
vehicle may be driven, damage the emission
system and cause hard starting. If an exces-
sive amount of foreign matter accumulates in
the fuel tank, the filter may require replacement
more frequently.
After installing a new filter, run the engine for
several minutes, and check for leaks at the
connections. Fuel filters should be installed by
trained technicians.
F060F01O-AAT
o Vacuum Hoses
Inspect the surface of hoses for evidence of
heat and/or mechanical damage. Hard and
brittle rubber, cracking, tears, cuts, abrasions,
and excessive swelling indicate deterioration.
Particular attention should be paid to examine
those hose surfaces nearest to high heat
sources, such as the exhaust manifold.
Inspect the hose routing to assure that the
hoses do not come in contact with any heat
source, sharp edges or moving component
which might cause heat damage or mechanical
wear. Inspect all hose connections, such as
clamps and couplings, to make sure they are
secure, and that no leaks are present. Hoses
should be replaced immediately if there is any
evidence of deterioration or damage.
EXPLANATION OF SCHEDULED MAINTENANCE ITEMS