1999-2008 Hyundai Trajet Service & Repair Manual

I DEC. 1999, Printed in Korea FOREWORD CONTENTS TITLE GROUP General Information GI I Engine Mechanical System EM I Engine Mechanical System EMA I Engine Electrical System EE I Emissions Control System EC I Fuel System FL I CI utch System CH I TransaxlelTransmission TR I Driveshaft and Axle DS I Suspension System 5S I Steering System ST I Restraints RT Brake System SR I Body (I.nterior & Exterior) BD I Body Electrical System BE I Heating, Ventilation & Air Conditioning HA I I This shop manual is intended for use by service technicians of authorized Hyundai dealers to help them provide efficient and correct service and maintenance on Hyundai vehicle. All the contents of this manual, including photographs, drawings, and specifications, are the latest available at the time of printing. As modifications affecting service occur, dealers will be provided technical service bulletins or supplementary volumes. This manual should be kept carefully up-to date upon receipt of the new information. To ensure customer satisfaction with Hyundai products, proper service and maintenance by Hyundai technicians is essential. Consequently, it is important that service per- sonnel fully understand the contents of this manual, which should be kept in a handy place for quick and easy reference. Hyundai Motor Company reserves the right to make changes in design orto makeadditions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured. This book may not be reproduced or copied, as a whole or as a part, without the written permission of the publisher.

.. I III I I GENERAL BD -2 EXTERIOR BD -7 INTERIOR BD' ..23 BUM PER BD ..3'7 SEAT BD .. 41 I

SD -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) 3.2 (0.13) 3.2 (0.13) E.L.R

GENERAL SD -3 TIGHTENING TORQUE ESHAOO50 Nm 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

SO -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 SD -5 Trouble symptom Probable cause Remedy Water leaks from sunroof Dirt accumulated in drain pipe Clear dirt inside of drain pipe Clogged drain pipe Blow air into drain pipe to 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 a noise when Foreign particles lodged in 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 in 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 in 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 in motor (Clutch Incorrect engagement of motor pinion with Check pinion installation and slipping noise from motor drive cable retighten motor when lid is fully opened or I closed is not an 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 up 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 EXTERIOR HOOD COMPONENTS ESHA0200 SO -7 TORQUE: N·m (kg·em, Ib·ft) HOOD ALIGNMENT ADJUSTMENT ESHA0250 Hood bumper ESHA005C 1. Adjust the longitudinal and lateral positions of the hood by utilizing the holes in the hinge. 2. Turn the hood bumpers either clockwise or counter- clockwise to adjust the height of the hood. ESHA005A 3. Loosen the bolts holding the hood latch.

SO -8 4. Adjust the alignment of the hood striker and the hood latch by adjusting the horizontal and vertical position of the latch and the height of the hood. ESHAO05B BODY (INTERIOR & EXTERIOR)

EXTERIOR TAILGATE REMOVAL AND INSTALLATION ESHA0300 1. Remove the upper trim from the tailgate frame. ESHA010A 2. Remove the side trim from the tailgate frame. ESHA010B 3. Remove the tapping screw and the trim grip and then the tailgate trim panel. ESHA010C 4. Remove the license lamp 8D·-9 ===--- -======- ESHA010E 5. Remove the back panel molding. ESHA010F 6. Remove the high mounted stop lamp. ESHA010H 7. Remove the rear wiper motor. ESHA0101

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1999-2008 Hyundai Trajet Service & Repair Manual

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