Hyundai SANTA FE 2024 Manual

Initial Response: Identify, Immobilize and Disable
The following procedures should be used whenever you are dealing with a SANTA FE at an emergency scene. However, all operations should be consistent with your department's standard operating procedures, guidelines, and any applicable laws. When SANTA FE is damaged in a crash, the high voltage safety systems may have been compromised and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate personal protective equipment (PPE), including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings.
This document handle with the two propulision variants of SANTA FE. Hybrid (HEV) and Plug-In Hybrid (PHEV). If something is special for one varinant you will find the emblem at this topic:
→ Hybrid (HEV )
→ Plug-In Hybrid (PHEV)

Dimensions:

Identify
The SANTA FE is a hybrid electric vehicle. Emergency responders should respond to emergency scenarios involving the SANTA FE accordingly, exercising extreme care and caution to avoid contact with the high voltage system within the vehicle.
Identify
Due to a lack of engine sounds, the "SANTA FE" can move silently using the electric motor, when the "READY" mode light is illuminated on the Instrument Panel
Identify
LACK OF ENGINE NOISE DOES NOT MEAN VEHICLE IS OFF: SILENT MOVEMENT OR INSTANT RESTART CAPABILITY EXISTS UNTIL VEHICLE IS FULLY SHUT DOWN. WEAR APPROPRIATE PPE

Identifying a Hyundai SANTA FE

Front and rear view of Hyundai SANTA FE
The Brand Logo placed on the hood and on the tailgate

Model name on Tailgate "SANTA FE"
The model name "SANTA FE" is placed in the middle of the tailgate.
The font of the trim emblem is Silver.

Propulsion Logo on Tailgate
The two version of SANTA FE can be easily identified by the different logo attached on the tailgate. The logo may be missing or hidden after a crash due to damage to the vehicle. Always be sure to utilize additional methods of identification before determining that the vehicle is not a hybrid car.

Fuel filler door
The SANTA FE has a fuel filler door on the rear right side.

Charging door
The SANTA FE Plug-In Hybrid has additional charging door located on the rear left side, which include the state of charge (SOC).

Immobilization / Stabilization / Lifting

Open the cover of the box and find the "Service Interlock"

1. HV connected
2. HV disconnected

"Service Interlock" is not completely removable.
There is the capacitor inside the HPCU. Wait 5+ minutes for the capacitor to discharge after removing the service plug.

Stored Energy / Liquid / Gases / Solids

Both Hybrid versions of SANTA FE are equipped with electric and combust engine. Therefore additional to the HV-battery normal gasonline tank is installed in the rear of the SANTA FE.

Combust Engine
SANTA FE HEV has a 1.6L 4-cylinder engine. The fuel type is gasoline that is stored in the fuel tank and delivered through the fuel line. When dealing with an emergency situation, be careful not to cut the fuel line and tank.

High Voltage System
HPCU
HPCU (Hybrid Power Control Unit) is a device that combines Inverter, LDC, and HCU in one package. Inverter converts the High Voltage DC power of the battery into AC power to control the speed of the motor. LDC (Low voltage DC-DC converter) converts the High Voltage DC power into a Low Voltage (12V) to supply power to the vehicle electronic system. HCU (hybrid control unit) is a control tower that oversees the operation of a hybrid vehicle.

Capacitor in HPCU
There is the capacitor inside the HPCU. Wait 5+ minutes for the capacitor to discharge after removing the service plug.

HSG
The HSG is short for hybrid starter generator. It acts as a starter motor when a SANTA FE HEV starts and also acts as a alternator as well.

Motor
The electric motor of the HEV converts electrical energy into motive force with a Max. power of 43.2Hp (32kW) and Max. torque of 125lb-ft (170Nm).

High Voltage Battery
The HV lithium-ion battery supplies and stores electric energy from the traction motor, and is located under the SANTA FE HEV floor Body, outside of the vehicle.

High Voltage Battery
The HV lithium-ion battery supplies and stores electric energy from the traction motor, and is located under the SANTA FE PHEV center floor.

12V Auxiliary Battery1
The 12V auxiliary battery1 is located under the luggage, and powers all of the vehicle's standard electronics like radio, lights, door locks, power windows, etc. Also, it powers the HPCU (Hybrid Power Control Unit) which controls the high voltage current to main electronic systems like the motor and high voltage junction box.

12V Auxiliary Battery2
The 12V auxiliary battery2 is located under the luggage, and If you are doing OTA or the voltage of the 12V battery1 is low, supplementary power supply is provided.

Specification HV-System
Motor	Type	Permanent magnet synchronous motor	Permanent magnet synchronous motor
	Max. Output (kW)	47.7 kW	72.0 kW
	Max Torque (Nm)	264 Nm	304 Nm
HSG	Max. Output (kW)	13.0 kW	13.0 kW
	Max Torque (Nm)	43.2 Nm	43.2 Nm
High Voltage Battery	Type	Lithium-ion	Lithium-ion
	Rated Voltage (V)	270 V	360 V
	Energy (kWh)	1.49 kWh	13.8 kWh
	Quantity for Pack (Cell / Module)	8 Cells X 9 Modules	24 Cells X 4 Modules

Electrolyte Irritation
The high/low voltage battery contains electrolyte solution. To avoid exposure to electrolyte solution and serious personal injury, always wear appropriate solvent resistant PPE (Personal Protective Equipment) and SCBA (Self-Contained Breathing Apparatus).

• Electrolyte solution is an eye irritant. In the event of contact with eyes, rinse with plenty of water for 15 minutes.
• Electrolyte solution is a skin irritant. Therefore, in the event of contact with skin, wash off with soap.
• Electrolyte liquid or fumes coming into contact with water will create vapors in the air from oxidization. These vapors may irritate skin and eyes. In the event of contact with vapors, rinse with plenty of water and consult a doctor immediately.
• Electrolyte fumes (when inhaled) can cause respiratory irritation and acute intoxication. Inhale fresh air and wash mouth with water. Consult a doctor immediately.

Vehicle Fire

• Use a large volume of water (max. 10,000 liter). Water must cool down the battery.
• If water is applied directly onto the high/low voltage battery module inside the casing, it will better cool the battery. (But, never attempt to penetrate the HV battery or its casing to apply water.)
• Putting water into the high/low voltage battery can be difficult due to the battery case.
• Put water through the hole that might be made due to the accident or fire.

High/Low Voltage Battery Damage and Fluid Leaks
If electrolyte solution leakage or any damage to the Lithium ion battery casing is observed, the first responders should attempt to neutralize the battery by applying a large volume of water to the battery pack while wearing appropriate Personal Protective Equipment (PPE). The neutralization process helps stabilize the thermal condition of the battery pack but does not discharge the battery.

• Do not put any smoke, spark, flame around the vehicle.
• Do not touch or step on the spilled electrolyte.
• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use soil, sand, or a dry cloth to clean up the spilled electrolyte.
  Be sure to adequately ventilate the area.

High/Low Voltage Battery Re-ignition by Stranded Energy
Damaged cells in the high/low voltage battery can experience thermal runaway* and re-ignition.

Use Infrared Camera (IR-Cam) to observe thermal runaway. Focus the battery with the IR-Cam the whole time. Increase of the temperature could indicate a thermal runaway. To prevent re-ignition, the first responder and second responder need to be aware of the risk of stranded energy* which remains in the damaged cells and can lead to re-ignition. Therefore disconnect the 12V battery (-) terminal to depower the battery management system (BMS). After that shut off the HV-System explained in Disable Direct Hazards / Safety Regulations chapter and discharge the HV-Battery refer in Towing / Transportation / Storage chapter.

*Thermal Runaway
The originating cause of thermal runaway is generally short-circuiting inside a battery cell and a resulting increase in the cell's internal temperature.
Battery produces heat with thermal runaway and it can spread from one battery cell to many cells, in a domino effect.

*Stranded energy
Energy remains inside any undamaged battery cells after the accident. Stranded energy can cause a high/low voltage battery to reignite multiple times after a fire has been extinguished.

In Case of Submersion

Submerged or Partially Submerged Vehicles
Some emergency responses can involve a submerged vehicle. The SANTA FE does not have high voltage components on the vehicle's body or framework. It is safe to touch the vehicle's body or framework if there is no severe damage to the vehicle, whether it is in water or on land. In the event that the vehicle is submerged or partially submerged, remove the vehicle from the water before attempting to disable the vehicle. Drain the water from the vehicle. Use the methods described in Disable Direct Hazards / Safety Regulations chapter. to disable the vehicle. Then, discharge the battery by referring to chapter.

Safety Risk
If severe damage causes high/low voltage components to become exposed, responders should take appropriate precautions and wear appropriate insulated personal protective equipment. Do not attempt to remove a high voltage cable while the vehicle is in water.

Towing / Transportation / Storage

Towing service
If towing the SANTA FE is necessary, it is recommend to having it done by an authorized HYUNDAI dealer or a commercial tow-truck service. To prevent damage to the vehicle, proper lifting and towing procedures are necessary. 4WD vehicles must be towed with a wheel lift and dollies (1) or flatbed with all the wheels off the ground. The use of wheel dollies (1) or flatbed is recommended. If any of the loaded wheels or suspension components are damaged or the vehicle is towed with the front wheels on the ground, use a towing dolly (1) under the front wheels When the vehicle is being towed, take care that the engine is OFF or in ACC position, to prevent accidental deployment of undeployed airbags. In the event of an accident, the high voltage system must be disabled.

Do NOT

• Do not lift using the trailer hitch or body and chassis parts.
• Do not tow with sling-type equipment. Use wheel lift or flatbed equipment. (1)
  
• Do not tow the vehicle with the front wheels on the ground (forward or backward), as this may cause fire or damage to the motor. (2)
  

Removable towing hook
If emergency towing is necessary, it is recommend that you contact an authorized HYUNDAI dealer or a commercial tow-truck service. If tow-truck service is not available in an emergency, your vehicle can be temporarily towed using a cable or chain secured to the removable towing hook at the front (or rear) of the vehicle. Perform emergency towing using cables or chains on hard-surfaced roads for a short distance and at low speeds. The wheels, axles, powertrain, steering, and brakes must all be in good working condition. In that case use the removable towing hook from the vehicle by following the installation instructions.

• Open the tailgate and remove the towing hook from the tool case.
• Remove the hole cover pressing the lower part of the cover on the bumper.
• Install the towing hook by turning it clockwise into the hole until it is fully secured.
• Remove the towing hook and install the cover after use.

For emergency towing place the Engine Start/ Stop button into the ACC position to unlock the steering wheel and shift the gear in N (neutral) position.

Storage of damaged vehicle with the damaged battery

• Drain fluids and water, then disconnect the negative (-) terminal of the 12 V battery before storing a damaged vehicle.
• In addition, remove the water inside the battery or vehicle, then remove the service plug from the high voltage battery before storing a damaged vehicle.
• Place the vehicle in an open space away from any structure, vehicle, or building.
• Then, keep on eye on the vehicle until the discharging procedures are completed.
• If the battery can be removed from the vehicle by moving the vehicle on the lift, remove and discharge the battery.
• If the battery can't be removed, set the water pool and pouring water until the entire battery is submerged.

Battery discharging in water pool

• Tap water or pond water that does not contain salt
• Maintain this water level for at least 90 hours.
• Then, put salt into the water pool to make 3.5% salt water.
• Wait for additional 48 hours in salt water.
• Drain the water and dry it.

Battery discharging

• DO NOT USE SALT WATER for the first step.
• A large volume of flammable hydrogen gas can be generated in salt water due to electrolysis.
• After submerging the vehicle in pure water for at least 90 hours, put salt in the water pool.

Damaged Battery Storage

• To store the damaged battery safely, the battery must be discharged.
• If the battery can be removed from the vehicle, discharge the battery to prevent re-ignition.
• Prepare water that does not contain salt such as tap water or pond water.
• Leave the battery in water for at least 90 hours.
• Then, put salt in water to make 3.5% salt water.
• Wait for additional 48 hours in salt water.
• Take out the battery from the container and dry it.

Safety Risk

• Extinguish all smoke, spark, flame around the vehicle.
• Electrolyte solution is a skin irritant.
• Do not touch or step on the spilled electrolyte.
• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use soil, sand, or a dry cloth to clean up the spilled electrolyte. Be sure to adequately ventilate the area.

Important Additional Information

The SANTA FE comes standard with airbags, seatbelt pre-tensioners and gas struts, see picture below. Some of teh futures are explain in this chapter.

Safety Equippment
	Airbags
	Gas Inflator
	Pre-tensioner
	Gas strut
	SRS control unit

Emergency Starting
Jump Starting
Do not attempt to jump start the high voltage battery, as it cannot be jump started. In case of full discharge of the high voltage battery, the vehicle must be towed as mentioned on the previous page. In case the 12V auxiliary battery is discharged, connect a starting device to the jump terminal in the engine room as you would any 12V battery (see image). Refer to the "Emergency Starting" section of the Owner's Manual for additional information. Connect jumper cables in the order shown in the image and disconnect in reverse order.

Jump Starting Procedure

1. Make sure the booster battery is 12-Volt and that its negative terminal is grounded.
2. If the booster battery is in another vehicle, do not allow the vehicles to come in contact.
3. Turn off all unnecessary electrical loads.
4. Connect the jumper cables in the exact sequence shown in the illustration. First connect one end of a jumper cable to the positive terminal of the discharged battery (1), then connect the other end to the positive terminal on the booster battery (2). Proceed to connect one end of the other jumper cable to the negative terminal of the booster battery (3), then the other end to a solid, stationary, metallic point away from the fuse box (4).

Risk
Do not attempt to jump start the SANTA FE HEV high voltage battery. Failure to follow these instructions will lead to serious bodily injury or death by electrical shock.

Airbag system (SRS: Supplemental Restraint System)
Airbag
10 airbags are installed in the SANTA FE, located in the areas shown in the image below. Before performing any emergency procedure, make sure the vehicle ignition switch is turned off and disconnect the negative connector from the 12V auxiliary battery (located in the left side motor compartment) to prevent accidental deployment of undeployed airbags.

Type

1. Driver's front air bag
2. Passenger's front air bag
3. Side air bag 1 st row (left/ right)
4. Side air bag 2 nd row (left/ right)
5. Curtain air bag (left/ right)
6. Driver's knee airbag
7. Front center side air bag only driver seat

❈ The actual air bags and seats in the vehicle may differ from the illustration.

Seat Belt Pre-tensioner
In the SANTA FE HEV, the driver's, front passenger's and rear(except center seating position) seat belts are equipped with pre-tensioners. When the seat belt pre-tensioners are activated in a collision, a loud noise may be heard and fine dust, which may appear to be smoke, may be visible in the passenger compartment. These are normal operating conditions and are not hazardous. The seat belt pre-tensioner assembly mechanisms may become hot during activation, and may need several minutes to cool down after they have been activated.

Undeployed Airbags

• Do not cut the red colored part shown in the image above.
  
• Make sure the vehicle ignition switch is turned off, disconnect the negative cable from the 12V auxiliary battery (located in the left side of motor room) and wait 3 minutes or longer to allow the system to deactivate.
  

Explanation of pictograms used

Tabel of used pictograms in this document.

	Gasoline vehicle		Fuel tank content gasoline/ ethanol		Bonnet
	General warning sign		Air-conditioning component		Boot
	Corrosives		Hazardous to the human health		Flammable
	Explosives		Acute toxicity		Environmental hazard
	Infrared Camera		Use water to extinguish the fire		Warning, Electricity
	Steering wheel, tilt control		Seat adjustment longitudinal		Seat height adjustment
	Battery pack, high-voltage		Battery pack, low-voltage		Use ABC powder to extinguish the fire
	High-voltage component		SRS control unit		LV-device disconnects high voltage
	Remove smart key		Zone requiring special attention
	Hybrid Electric Vehicle on fuel of liquid group 2