I have a 04 sante fe 2.7l 4 cylinder.The problem is the radiator cooling fansare not coming on,even once the engine has warmed up past the half way mark on the guage.The car has been overheating sporadically.I changed the thermostat and the top radiator hose and it ran fine for 2-3 days and then the overheating started again.Checked the water pump and it showed no signs of leaking and isn't making any noises.,Is there a sensor or relay that I need to replace?

Only the 4 cylinder uses a stand alone ICM. If you have a 4 cyl then the module may be attached to the valve cover. See picture.

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AIr lock in system = could also be stuck thermostat but if so engine would overheat

Have a cooling system pressure test done. If you have a head problem the car will over heat very quickly I would be checking the radiator for blockage or part blockage. Check the fins on the radiator core and if they crumble easily that will also point to a fault. Check for expanded hose or collapsed bottom hose.

What motor ??? L4-2.4L, V6-2.7L or V6-3.5L...

First of all, why was the O2 snsr replaced?... Check Engine light? What DTC (diagnostic trouble code) did you find stored in the ECU (Engine Control Unit)? The drivability you seem to be describing can have multiple causes -- faulty sensors, malfunctioning computer, clogged catalytic converter, leaky injectors, vacuum leaks, etc.

Ok... this is gonna take some time. The 04 Santa Fe came with 3 (three) different/possible engines -- the 4 Cylinder 2.4 lit, the 2.7 V6, and the 3.5 V6. Only the 2.4 (4 cyl) and the 3.5 V6 are equipped with EGR. The 2.7 does NOT have EGR. To answer part of your question, the EGR system on the 4 Cyl is known to develop restriction(s) in the EGR port (from the # 4 cylinder exhaust port to the EGR valve at the intake manifold). This port travels through the head (front to rear, i.e., Left to Right when viewing the engine from the transmission end). This port cannot be seen at the # 4 cylinder exhaust port unless you remove the exhaust manifold.

It would be very helpful if you could provide more detailed/specific information regarding the drivability issue & what/which codes were found related to the Check Engine light.

The 4 cylinder engine is 2.4 litre, and the v-6 is 2.7 litre.

If you are standing in front with hood open # 2 cylinder is the front cylinder to your left, the cylinders go like this, the front cylinders from left to right are cyl 2, cyl 4 and cyl 6 then then rear cylinders from left to right go cyl 1 , cyl 3 and cyl 5. so the cylinder you are looking for is in the front first one on your left good luck, hope this helps.

It's not on top or bottom... it's on the 'SIDE' of the engine.... and depending on which engine you have, it could be on the left SIDE or the right SIDE. On the four (4) cylinder engine, it's on the Right Side (firewall side), and on the other two V6 engines, it's on the Left Side (radiator side).

If your car is running hot after replacing the thermostat try flushing the radiator which will usually make the car run cooler. Antifreeze raises the temperature of cars a bit and is not needed during the summer months if you live in a warm area. Make sure you put some in though by the time it becomes winter. There may be a lot of gunk in there that is causing it to heat up especially if any radiator leak was ever added to the system.