W.I.C. (World manufacturer's Identification Code)

KM8 - Hyundai Motor Company, Korea

Vehicle Line

S : SANTAFE

Model & Series

A : Standard(L)

B : Deluxe (GL)

C : Super deluxe (GLS)

D : Grand salon (GDS)

E : Super grand salon (HGDS)

Body Type

8 : Wagon

Restraint system or brake system

0 - Both side (NONE)

1 - Active Belt (Driver side + Passenger side)

2 - Passive Belt (Driver side + Passenger side)

Engine type

A : G 2.0 I4

B : G 2.4 I4

D : G 2.7 V6

V : D 2.0 TCI

Driver side

P : LHD (Left hand driver)

R : RHD (Reft hand driver)

Production year

1 - 2001 Model Year, 3 - 2003 Model yeal

2 - 2002 Model Year, 4 - 2004 Model yeal

Production plant

U - Ulsan (Korea)

Vehicle production sequence number

000001 - 999999

Engine fuel

G - Gasoline

D - Diesel

Engine range

4 - In line 4 cycle 4 cylinder

6 - V type 4 cycle 6 cylinder

Engine development order

B - V6 delta Engine

E - D - Engine

J - SIRIUS II DOHC Engine

Engine capacity

P - 1977cc

S - 2351cc

A - 2656cc (gasoline), 1991cc (diesel)

Production year

1 - 2001

2 - 2002

3 - 2003

4 - 2004

Engine production sequence number

000001 - 999999

Production year

1 : 2001

2 : 2002

3 : 2003

Production month

09 - 9 (September)

12 - 12 (December)

Transmission production sequence number

000001 ~ 999999

T/M Model

S : F4A51 - 2 (2.4I4, 2.7V6)

Production year

1 : 2001, 2 : 2002

3 : 2003, 4 : 2004

Final gear ratio

N : 4.018 (F4A51)

Classification of detail

AD : Damper spring type

Spare

Transmission production sequence number.

000001 ~ 999999

Block the wheels.

Place a jack under the specified jacking point.

Support the vehicle with safety stands (jack stands) Refer to page GI-10.

Start the engine when engine compartment is clean.

Inspection of parts

Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other problems.

Arrangement of parts

All disassembled parts should be carefully arranged for effective reassembly.

Be sure to separate and correctly identify the parts to be replaced from those that will be used again.

Cleaning parts for reuse

All parts to be used again should be carefully and thoroughly cleaned by the appropriate method.

Oil seals

Gaskets

O-rings

Lock washers

Cotter pins (split pins)

Plastic nuts

Sealant should be applied to gaskets.

Oil should be applied to the moving components of parts.

Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before assembly.

Be sure to disconnect the battery cable from the negative (-) terminal of the battery.

Never pull on the wires when disconnecting connectors.

Locking connectors will click when the connector is secure.

Handle sensors and relays carefully. Be careful not to drop them or hit them against other parts.

Basically, all measurements in this manual are taken with a tracking gauge.

When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

For measuring dimensions, both projected dimensions and actual-measurement dimensions are used in this manual.

These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the reference dimensionsused for body alterations.

If the length of the tracking gauge probes is adjustable, measure it by lengthening one of the two probes as long as the height of the two surfacesare different.

These dimensions indicate the actual linear distance between measurement points, and are used as the reference dimensions when a tracking gauge isused for measurement.

First adjust both probes to the same length (A=A') before measurement.

Check the terminal for tightness.

Check terminals and wires for corrosion from battery electrolyte, etc.

Check terminals and wires for open circuits.

Check wire insulation and coating for damage, cracks and degrading.

Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).

Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's body.

Check for incorrect wiring.

Check that the wiring is clamped firmly to prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust manifold, etc.)

Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating or moving parts.

Check that the wiring has a little space so that it can vibrate between the fixed and moving parts such as the vehicle body and the engine.

Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.

Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surroundingparts, and then secure the harness by using a clamp.

If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness with tape or somethingsimilar in order to protect it from damage.

When installing any parts, be careful not to pinch or damage any of the wiring harnesses.

Never throw relays, sensors or electrical parts, or expose them to strong shock.

The electronic parts used in the computer, relays, etc. are readily 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 partsbeforehand.

Loose connectors cause problems. Make sure that the connectors are always securely fastened.

When disconnecting a connector, be sure to grip only the connector, not the wires.

Disconnect connectors which have catches by pressing in the direction of the arrows shown the illustration.

Connect connectors which have catches by inserting the connectors until they make a clicking sound.

When, using a circuit tester, to check continuity or voltage on connector terminals, 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 insulationof the wires.

To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropriatewire size.

Use only unleaded gasoline.

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 atidle speed for more than 20 minutes.

Avoid spark- jump tests. Do spark- jumps only when absolutely necessary. Perform this test as rapidly as possible and, while testing, neverrace the engine.

Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as possible.

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.

Avoid coasting with the ignition turned off and during prolonged braking.

Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.

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 airbag 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 beforeand adjust the clock.

Malfunction symptoms of the airbag system are difficult to confirm, so diagnostic codes become the most important source of information when troubleshooting. When troubleshooting the airbag system, always read the diagnostic codes beforedisconnecting the battery.

Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.

Never attempt to disassemble and repair the airbag modules, SRSCM, clock spring and airbag wiring harness in order to reuse it.

If the SRSCM or airbag module has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replacethem with new ones.

After work on the airbag system is completed, re-set the SRS SRI.

If the engine is cold, run the engine until it reaches normal operating temperature.

Turn off the engine.

Remove the oil filler cap and drain plug. Drain the engine oil.

Tighten the drain plug to the specified torque.

Fill new engine oil through the oil filler cap opening.

Install the oil filler cap.

Start and run the engine.

Turn off the engine and then check the oil level. Add oil if necessary.

Use a filter wrench to remove the oil filter.

Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.

Tighten the oil filter to the specified torque.

Start and run the engine and check for engine oil leaks.

After turning off the engine, check the oil level and add oil as necessary.

Disconnect the clip holding air cleaner filter cover.

Remove the air filter cover.

Remove the air cleaner filter.

Install a new air cleaner filter and replace the air cleaner filter cover.

Set the temperature control lever to the hot position.

Remove the radiator cap.

Loosen the drain plug to drain the coolant.

Drain the coolant from the reserve tank.

After draining the coolant, tighten the drain plug securely.

Fill the radiator with the coolant up to its filler neck.

Fill the reserve tank with the coolant.

Warm up the engine until the thermostat opens, remove the radiator cap and check the coolant level.

When the radiator is filled up to its filler neck, install the radiator cap securely.

Fill the reserve tank with coolant up to the "FULL" line.

Check for damage or leakage in the fuel lines and connections.

Inspect the surface of fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swellingindicate deterioration of the rubber.

If the fabric casing of the rubber hose is damaged by cracks and abrasions in the fuel system, the hoses should be changed.

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.

Check that the transaxle oil is not dirty.

With the vehicle parked at a level place, remove the magnetic plug and drain transaxle oil.

Replace the washer with a new one and reinstall the plug.

Fill with transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole.

Check the steering wheel freeplay.

Check the steering linkage for looseness and damage.

Park the vehicle on a level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluidto approximately 50°C (122°F).

With the engine idling, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming, and its level. Replenish the fluid in the oil reservoir through the oil filterif necessary.

Check the hose connections for fluid leaks.

The power steering hoses should be replaced if there is severe surface cracking, pulling, scuffing or worn steps. Deterioration of the hosescould cause premature failure.

These components, which are permanently lubricated at the factory, do not require lubrication. Damaged seals and boots should be replaced toprevent leakage or contamination of the grease.

Inspect the dust covers and boots for proper sealing, leakage and damage. Replace them if defective.

Check all brake lines and hoses for damage, wear, cracks, corrosion, leaks, bends and twists.

Check all clamps for tightness.

Check that the lines are clear of sharp edges, moving parts and the exhaust system.

Remove the brake drum and check the thickness of the brake shoe lining for wear. Check the automatic brake adjusting system by hand to see that it operates smoothly, and gears are in proper mesh with each other. To assure smoth function, apply a very thin coat of grease to the friction surfaceof the adjuster and link shaft.

Inspect the wheel cylinder boots for fluid leaks. Visually check the boots for cuts, tears or heat cracks. (A small amount of fluid on theboot may not be a leak but preservative fluid used at assembly.)

Check the level of the brake fluid in the reserve tank of the master cylinder.

The level should be between the "MAX" and "MIN" mark.

If the level is lower than the "MIN" mark, add new brake fluid up to the "MAX" mark.

Refer to BR-Section for air-bleeding procedures.

With a vehicle equipped with ABS(Anti-lock Brake System), refer to BR-section.

Connect a vinyl tube to the bleeder screw of each wheel cylinder. Put the other end of the vinyl tube in a vessel to receive the brake fluid.

Depress the brake pedal a few times. Then loosen the bleeder screw(with the brake pedal still depressed), and tighten it after the brake fluid stopsflowing.

Repeat the above operation until there are no air bubbles in the brake fluid.

Repeat these steps for the other cylinders.

Add new brake fluid up to the "MAX" level in the reserve tank.

Check oil, fluid, fuel, water and exhaust gas leaks.

Check free play of clutch pedal and brake pedal.

Check operation of brake booster.

Check the operation of service brake and parking brake systems.

Check the stroke of parking brake lever.

Check the driveability of engine.

Check the condition of instruments, gauges, indicators, exterior lamps, heater and ventilators.

Check the abnormal noises from each part.

Aluminum wheels require special attention. If salt or chemicals adhere to the wheels, they need to be rinsed off as soon as possible. After cleaning the wheels, apply a coating of wax to them to prevent corrosion.

When cleaning the vehicle with steam, do not direct steam onto the aluminum wheels.

Use tire chains only on the front wheels. Do not use tire chains on rear wheels.

When using snow tires, use them on all four wheels for added maneuverability and safety.