Cooling System - Engine Overheating Concerns
Group ENGINE ELECTRICALNumber 09-EE-001
Date APRIL, 2009
Model 2004-2006 SANTA FE
Subject
RADIATOR FAN MOTOR CONNECTOR SERVICE PART
DESCRIPTION:
A replacement connector is available for the radiator fan connector (E25). This bulletin provides the procedure to replace the radiator fan motor connector with the replacement connector.
^ Some Santa Fe (SM) vehicles may exhibit an overheating engine and inoperative A/C.
^ Inspection of the radiator fan connection finds it is abnormal.
^ Repair action of this TSB is to replace the incident radiator fan motor connector with the new connector of the parts kit by following the Service Procedure below.
APPLICABLE VEHICLES:
^ 2004 - 2006 SANTA FE (SM)
PARTS INFORMATION/Components of Kit
SERVICE PROCEDURE:
1. Disconnect the negative battery cable from the battery post.
2. Disconnect the radiator fan connector.
A: Harness side of connector
B: Fan motor side of connector
3. Pull away the wiring fixed to the radiator fan shroud.
4. Open the fan motor side connector cover by releasing 4 cover locks (C).
5. Remove the connector cover (C1).
6. Using a cutter, vertically cut the corrugated tube (D) 120mm (4.7 inches) from the end of the connector.
7. Partially remove the cut corrugated tube (E1) from the wire (E).
8. Cut off the black wire 30mm (1.2 in.) and the green wire 50mm (2.0 in.) from the end of the connector. Discard the connector.
9. Strip the wire coverings 8mm (0.3 in.) from the cut ends.
CAUTION:
Be careful not to damage the
wires.
10. Insert the stripped wires into the solder sleeve tubes (F).
11. Overlap the green wires by squeezing them into each other; do not twist them. Place the solder sleeve tube (G) over the overlapped wires.
12. Align the solder part (H) of the solder sleeve tube with the center of the overlapped wires.
CAUTION:
Make sure to keep the stripped wires overlapped by holding them with both hands.
13. Subject the solder part (I) to heat. Once the solder is melted, evenly heat the entire solder.
14. After the solder part is melted completely, wait approximately 10 seconds until the solder sleeve tube becomes cold. Pull both ends of the solder sleeve tube outside slightly, then subject both ends of the solder sleeve tube to heat.
15. Apply the above procedures (step 11 to 14) to the black wire.
16. Insert the wires of the new fan motor side connector into the cut corrugated tube, then tape the cut corrugated tube and install the connector cover.
17. Apply the above procedures (step 4 to 15) to the fan motor harness side connector.
18. Fix the fan motor side connector (B) to the fan shroud, then connect it to the fan motor harness side connector (A).
19. Reconnect the battery cable to negative terminal of the battery
20. With engine running at idle turn on the A/C or Defroster and verify that the cooling fan connection was repaired properly the cooling fan should come on.
WARRANTY INFORMATION