Hyundai Trajet Installationsanleitung

DEC. 1999, Printed

Korea

FOREWORD

CONTENTS

TITLE GROUP

General

Information

GI I

Engine

Mechanical System

Engine

Mechanical System EMA I

Engine

Electrical

System

EE I

Emissions

Control

System EC I

Fuel

System

FL I

utch

System

TransaxlelTransmission

TR I

Driveshaft

and

Axle

DS I

Suspension

System

Steering

System

ST I

Restraints

Brake

System

SR I

Body

(I.nterior &Exterior) BD I

Body

Electrical System BE I

Heating,

Ventilation

Air

Conditioning

This shop manual

intended for use by service techni-

cians of authorized Hyundai dealers

help them provide

efficient and correct service and maintenance

Hyundai

vehicle.

All the contents of this manual, including photographs,

drawings, and specifications, are the latest available at the

time of printing.

modifications affecting service occur,

dealers will

provided technical service bulletins or

supplementary volumes. This manual should

kept

carefully up-to date upon receipt of the new information.

To ensure customer satisfaction with Hyundai products,

properserviceand maintenanceby Hyundai technicians

essential. Consequently,

important that service per-

sonnel fully understand the contents of this manual, which

should

kept

ahandy place for quick and easy

reference.

Hyundai Motor Company reserves the right to make

changes

design

orto

makeadditionsto orimprovements

its products without imposing any obligations upon itself

to install them

its products previously manufactured.

This book may not be reproduced or copied, as awhole or

apart, without the written permission of the publisher.

III

GENERAL BD

-2

EXTERIOR BD

-7

INTERIOR BD'

BUMPER BD

SEAT BD

-2

GENERAL

SPECIFICATIONS

Hood

Type

Front door

Construction

Regulator system

Locking system

Rear door

Construction

Regulator system

Locking system

Tailgate

Type

Glass thickness

mm (in)

Windshield glass

Front door glass

Rear door glass

Tailgate glass

Seat belt

E.L.R. :Emergency Locking Retractor

BODY (INTERIOR &EXTERIOR)

ESHA0010

Rear hinged, front opening type

Front hinged, full door construction

Wire drum type

Pin-fork system

Front hinged, full

door

construction

Wire drum type

Pin-fork system

Inner hinged, gas lifter type

5(0.20)

3.2 (0.13)

E.L.R

GENERAL SD

-3

TIGHTENING TORQUE

ESHAOO50

kgf·cm Ib·ft

Front and rear doors

Door hinge to body 34-42 340-420 24.6-30.4

Door hinge to door 13-26 130-260 9.4-18.8

Tailgate

Tailgate lid hinge to body 7-9 70-90 5.1-6.5

Tailgate lid hinge to tailgate 7-9 70-90 5.1-6.5

Gas lifter to body 7-9 70-90 5.1-6.5

Gas lifter to tailgate 7-9 70-90 5.1-6.5

Hood

Hood hinge to body 22

27 220-270 16-19.5

Hood hinge to hood 22-27 220-270 16-19.5

Hood latch to body 7-11 70-110 5.1-8.0

Seat belt

Front seat belt upper anchor 40-55 400-550 28.9-39.8

Front seat belt retractor 40-55 400-550 28.9-39.8

Height adjuster 40-55 400-550 28.9-39.8

Second and third seat belt upper anchor 40-55 400-550 28.9-39.8

Second and third seat belt lower anchor 40':55 400-550 28.9-39.8

Second and third seat belt retractor anchor 40-55 400-550 28.9-39.8

Seat

Front seat mounting bolts and nuts 35-55 350-550 25.4-40

-4

SPECIAL TOOLS

Tool

(Number and name)

09793-21000

Door hinge adjusting

wrench

09800-21000

Ornament remover

Illustration

BODY (INTERIOR &EXTERIOR)

ESHA0100

Use

Adjustment, removal, and installation of the

door hinge

ESA901OF

Trim

removal

ESA9010G

09853-31 000

Headlining clip remover Removal of the headlining clip

09861-31100

Sealant cut-out tool

ESA9010H

Cutting the sealant for the windshield glass

(use with 09861-31200)

ESA90101

09861-31200

Sealant cutting·blade Cutting the sealant for the windshield glass

(use with 09861-31100)

09861-31300

Sealant gun

ESA9010J

Application of the sealant to the windshield

glass

ES.A9010K

09681-31400

Glass holder Removal and installation of the windshield

glass

ES,u.9010L

09681-31000

Windshield glass moulding

remover

Removal of the windshield glass moulding

ESA9010M I

GENERAL

TROUBLESHOOTING ESHA0150

-5

Trouble symptom Probable cause Remedy

Water leaks from sunroof Dirt accumulated

drain pipe Clear dirt inside of drain pipe

Clogged drain pipe Blow air into drain pipe

remove

dirt

Broken or dislocated drain pipe, defective or Check pipe installation and flange

cracked clip contact

Deteriorated roof

lid

weatherstrip Replace

Excessive roof lid-to-body clearance and Adjust

improperly fitted weatherstrip

Wind noise Loose or deformed deflector Retighten or replace

Roof lid makes anoise when Foreign particles lodged

guide

rail

Check drive cable and guide rails for

moved foreign particles

Loosed guide rails and lid Retighten

Motor runs but

lid

does not Foreign particles lodged

guide

rail

Check drive cable and guide rails for

move or moves only halfway foreign particles

Incorrect engagement of motor pinion with Check for loose motor installation

drive cable and damaged pinion

Decrease

clutch slipping force of motor Adjust

Increased lid sliding resistance or Adjust or replace

interference of lid with drive cables,

weatherstrip, etc. due to maladjustment of lid

Noise

motor (Clutch Incorrect engagement of motor pinion with Check pinion installation and

slipping noise from motor drive cable retighten motor

when

lid

fully opened or I

closed

not

unusual Worn out or damaged motor pinion bearing Replace motor assembly I

noise.) Worn out or deformed drive cable Replace

Door glass fails to operate Incorrect window glass installation Adjust position

and down Damaged or faulty regulator arm or regulator Correct or replace

Door does not open or close Incorrect door installation Adjust position

completely Defective door check Correct or replace

Door hinge required grease Apply grease

Hood does not open or Striker and latch not properly aligned Adjust

close completely Incorrectly installed hood Adjust

Incorrect hood bumper height Adjust

Water leak through Defective seal Fill with sealant

windshield and rear window Defective flange Correct

SD -6 BODY (INTERIOR &EXTERIOR)

Trouble symptom Probable cause Remedy

Wind noise around door Weatherstrip not holding firmly Adjust fit of door

Improperly installed weatherstrip or setting of Repair or replace

weatherstrip setting of weatherstrip

Improperly closed door Adjust

Improperly fit door Adjust

Improper clearance between door glass and Adjust

division channel

Deformed door Repair or replace

EXTERIOR

HOOD

COMPONENTS ESHA0200

SO -7

TORQUE: N·m (kg·em, Ib·ft)

HOOD ALIGNMENT ADJUSTMENT ESHA0250 Hood bumper

ESHA005C

Adjust the longitudinal and lateral positions of the

hood

utilizing the holes

the hinge.

Turn

the hood bumpers either clockwise or counter-

clockwise to adjust the height of the hood.

ESHA005A

Loosen the bolts holding the hood latch.

SO -8

Adjust the alignment of the hood striker and the

hood latch by adjusting the horizontal and vertical

position

the latch and the height of the hood.

ESHAO05B

BODY (INTERIOR &EXTERIOR)

EXTERIOR

TAILGATE

REMOVAL AND INSTALLATION ESHA0300

Remove the upper trim from the tailgate frame.

ESHA010A

Remove the side trim from the tailgate frame.

ESHA010B

Remove the tapping screw and the trim grip and

then the tailgate trim panel.

ESHA010C

Remove the license lamp

8D·-9

===---

-======-

ESHA010E

Remove the back panel molding.

ESHA010F

Remove the high mounted stop lamp.

ESHA010H

Remove the rear wiper motor.

ESHA0101

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