Thanks for the files - they were a help. We replaced the purge control valve, and it solved the problem. (Took the Santa Fe to the gas station right afterward and filled it up. Then started it up just fine.)
Just in case someone else finds this post via an internet search like I was trying to do when researching this problem, I'll give a bit more info about the fix.
We purchased the part at a Hundai dealer, in stock, for the same or less (only $39 + tax) as quoted at O'Reilly's where it would have been a same-day special order. (If, btw, you are asked at a parts store about whether you need the straight one or the one w/ the elbow. The '04 2.7L uses the straight one. In fact the dealership only listed the straight one for all but I think the 3.5L.)
Here's how the rest of the job progressed:
Disconnected the battery first thing.
Removed the big plastic cowling or cover over the main part of the engine. Six small screws on top hold it down - needed an extension on the socket to get to them, but this was very easy.
The purge control valve on the 2004 2.7Liter Santa Fe was directly behind the manifold. At the very back of the engine - between it and the firewall, close to the top.
One hose (roughly 1/2" dia.) Attaches to it from the left/drvrs side and one attaches to it going toward the pssgr side. There is also an electronic connection plugged into it.
We had to remove another small electronic connector plugged into another part to gain better access. Most difficult part of this job is reaching back there and working round a couple of cables that run across the top.
First disconnected the elec. Plug to the valve.
Then loosened/removed the clamp from the hose on first one end of the valve, then the other.
The valve itself sits in a sort of rubber sleeve which has a slot underneath that holds the whole thing in place. Work the rubber sleeve toward the drivers slide to get it loose. Remove the valve from the sleeve, and replace it with the new part. Reconnect the hoses, slide the rubber sleeve back onto its "holder". Replace the engine cover. Re-connect the battery.
Head to a gas station for a fill-up and confirmation that your starting problems are fixed.
Monday, August 16th, 2010 AT 11:40 AM