2004 Hyundai Santa Fe Service and Repair Manual

This 2004 Hyundai Santa Fe Service & Repair Manual Covers

• Complete factory workshop procedures
• Factory diagnostic information
• Inspection and testing procedures
• Removal and installation procedures
• Repair and overhaul procedures
• Technical specifications
• Component locations
• Factory maintenance schedules
• Factory wiring diagrams
• Torque specifications
• Fuse and relay information

Engine Options

Petrol

• 2.4L DOHC Inline-4 (G4JS)
• 2.7L Delta V6 (G6BA)

Transmission Options

• 5-speed manual transmission
• 4-speed automatic transmission

Engine and Drivetrain Repair Coverage

• Engine overhaul procedures
• Cylinder head servicing
• Timing belt replacement procedures
• Camshaft and crankshaft timing procedures
• Fuel injection system diagnostics
• Ignition system servicing
• Cooling system repairs
• Lubrication system servicing
• Intake and exhaust system repairs
• Emissions control system diagnostics
• Manual transmission servicing
• Automatic transmission diagnostics
• Clutch servicing
• Transfer case servicing (4WD models)
• Front and rear differential repairs
• Driveshaft servicing
• CV joint inspection and repair

4WD and AWD Technologies

• Electronic 4WD system diagnostics
• Transfer case diagnostics
• Rear differential servicing
• Propeller shaft inspection
• Wheel speed sensor diagnostics

Chassis, Steering and Suspension

• Front MacPherson strut suspension servicing
• Rear multi-link suspension servicing
• Shock absorber replacement
• Coil spring inspection
• Steering rack servicing
• Hydraulic power steering diagnostics
• Wheel alignment specifications
• Wheel bearing servicing
• Stabiliser bar servicing

Braking Systems

• ABS diagnostics
• Electronic Brakeforce Distribution (EBD) diagnostics
• Front and rear disc brake servicing
• Brake master cylinder servicing
• Brake booster inspection
• Brake hydraulic system bleeding
• Parking brake adjustment
• Wheel speed sensor testing

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine management system diagnostics
• Starting system testing
• Charging system diagnostics
• Battery testing procedures
• Alternator servicing
• Starter motor servicing
• Lighting system diagnostics
• Instrument cluster diagnostics
• Immobiliser system diagnostics
• Power window diagnostics
• Power mirror diagnostics
• Central locking diagnostics
• Audio system wiring

Air Conditioning and HVAC

• Manual air conditioning servicing
• Automatic climate control diagnostics (where fitted)
• Compressor diagnostics
• Refrigerant circuit repairs
• Condenser servicing
• Blower motor servicing
• HVAC control system diagnostics
• Air distribution system servicing

Body, Interior and Restraint Systems

• Body panel removal and installation
• Door component servicing
• Tailgate servicing
• Interior trim removal
• Dashboard removal procedures
• Seat adjustment mechanisms
• SRS airbag diagnostics
• Seat belt pretensioner servicing
• Wiper and washer servicing

Diagnostics and Troubleshooting

• Factory diagnostic flowcharts
• Symptom-based troubleshooting
• Scan tool diagnostic procedures
• Sensor testing procedures
• Actuator testing
• Electrical fault isolation
• Component inspection procedures

Common Error Codes Covered

Engine Codes

• P0101 — Mass Air Flow (MAF) Sensor Range/Performance
• P0118 — Engine Coolant Temperature Sensor Circuit High Input
• P0128 — Coolant Thermostat Temperature Below Regulating Temperature
• P0171 — System Too Lean (Bank 1)
• P0174 — System Too Lean (Bank 2)
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0301 — Cylinder 1 Misfire Detected
• P0335 — Crankshaft Position Sensor “A” Circuit
• P0420 — Catalyst System Efficiency Below Threshold (Bank 1)
• P0442 — EVAP System Leak Detected (Small Leak)

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0715 — Input/Turbine Speed Sensor Circuit Malfunction
• P0720 — Output Speed Sensor Circuit Malfunction
• P0732 — Gear 2 Incorrect Ratio
• P0741 — Torque Converter Clutch Circuit Performance or Stuck Off

ABS and Chassis Codes

• C1200 — Front Left Wheel Speed Sensor Signal Fault
• C1205 — Front Right Wheel Speed Sensor Signal Fault
• C1210 — Rear Left Wheel Speed Sensor Signal Fault
• C1215 — Rear Right Wheel Speed Sensor Signal Fault

Body Control Codes

• B1102 — Driver Airbag Circuit Resistance High
• B1326 — Battery Voltage Low

Plus many other codes included in the manual.

Fuse Box Diagram

• Engine compartment fuse box layout
• Passenger compartment fuse box layout
• Fuse identification charts
• Relay locations
• Fuse amperage specifications
• Power distribution diagrams

Wiring Diagrams

• Engine management system
• Fuel injection system
• Starting and charging systems
• Automatic transmission
• Manual transmission
• ABS system
• 4WD system
• Air conditioning system
• SRS airbag system
• Lighting system
• Instrument cluster
• Immobiliser system
• Audio system
• Power windows
• Central locking
• Exterior mirrors
• Wiper and washer systems

Serpentine Belt and Timing System Information

• Accessory drive belt routing
• Serpentine belt replacement procedures
• Belt tension inspection
• Timing belt replacement procedures
• Timing belt alignment marks
• Camshaft timing specifications
• Timing component inspection

Torque Specifications

• Engine fastener torque values
• Cylinder head tightening specifications
• Connecting rod torque values
• Main bearing cap torque values
• Flywheel and flexplate torque values
• Suspension fastener torque values
• Steering component torque values
• Brake system torque values
• Wheel nut torque specifications
• Drivetrain torque specifications

Maintenance and Service Information

• Factory scheduled maintenance intervals
• Engine oil and filter replacement
• Transmission fluid servicing
• Transfer case fluid replacement
• Differential oil servicing
• Coolant replacement
• Brake fluid replacement
• Power steering fluid servicing
• Air filter replacement
• Cabin air filter replacement
• Drive belt inspection
• Timing belt replacement interval
• Tyre rotation procedures
• Wheel alignment checks

Who Is This Manual For?

• New Zealand automotive workshops
• Independent repair garages
• Automotive technicians
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions