Hyundai Santa Fe
Many things come with marriage; mine came a 2010 Hyundai Santa
Fe. It was a nice little soccer-mom SUV that throughout its first
70,000 miles, gave us no problems whatsoever. The only thing I had
to fix on this vehicle in the 8 years we had it was a bad oil pressure
switch. Here's the story.
When the switch goes, so does a lot of oil. The switch is buried under the intake
manifold, so when the seal in the switch broke loose, it flooded the "valley" where
the intake sits. Excess oil ends up here:
To get to the switch, the intake manifold has to come off. The manifold is buried
under the "surge tank". There are about 20 electronic sensors that have to be
disconnected to get at the manifold and remove it.
Here's a pic with the intake manifold removed:
Below is the intake manifold, after removing the surge tank. I have a
bootleg copy of the Santa Fe service manual, which recommended a
lot more things come off the engine than what was totally necessary.
This is as far as I had to go to get access to the intake manifold.
The service manual recommended removing the coolant pipe. It gets
in the way of the oil pressure switch, but I found a way to get a
24mm socket on the switch.
When I first heard that I would have to take off the intake manifold, I
was not very excited. After doing this twice to replace the lower
intake gaskets on both my 1996 GMC Sonoma and my 2004 Chevy
Blazer, I figured the Santa Fe project would take a couple days. But
thankfully, it was much, much easier. The GM 4.3L V-6 engines
require the distributor to be removed, which requires that the timing
be set correctly when the distributor goes back in. The 4.3's also
have very tight clearance on the forward side of the manifold, which
requires certain bolts to be removed or loosened on various engine

None of this was required on the Santa Fe. If I did this project again,
I could probably knock it out in a couple hours. However, I would
have to say I was a little disappointed that the oil pressure switch
wasn't covered under the 100,000 mile power train warranty.
Apparently, anything attached to a wire isn't considered part of the
power train, regardless of how much oil is spewing out of your
engine. The local Hyundai dealer wanted $935 to fix it, which
included replacing a couple of parts that I don't believe were
necessary. I did it for $16 and about 5 hours of my time. Not a bad