Hyundai trajet Install guide

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 techni-
cians 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,
properserviceand maintenanceby Hyundai technicians
is
essential. Consequently, it is important that service per-
sonnel fully understand the contents of this manual, which
should
be kept in ahandy place for quick and easy
reference.
Hyundai Motor Company reserves the right to make
changes
in design orto makeadditionsto orimprovements
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 awhole or
as apart, without the written permission of the publisher.

..
I
III
I
I
GENERAL BD -2
EXTERIOR BD -7
INTERIOR BD' .. 23
BUMPER 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 anoise 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

SD -10
ESHA010J
8. Remove the tailgate outside handle, the tailgate
actuator, the tailgate latch, and the key cylinder.
ESHA010G
ESHA010M
9. Remove the tailgate lifter.
10. Installation
is the reverse of the removal process.
BODY (INTERIOR &EXTERIOR)

EXTERIOR SD
-11
~==============
ESHA015E
ESHA015D
Trim panel
remover
ESHA015F
5. Remove the front speaker and the door trim seal.
6. Remove the front door glass from the front door
module.
7. Remove the front door window glass run.
ESHA0158
Disconnect the wire connectors from the front door.
ESHA015C
ESHA015A
FRONT DOOR
2. Remove the tapping screw cap and loosen the
tapping screws.
REMOVAL AND INSTALLATION ESHA0350
1. Loosen the screw holding the handle inside door.
3. Loosen the screws holding the door trim panel.
4. Insert atrim panel remover between the trim fasten-
ers and the door trim panel to pry
off.
ESHA015G
8. Remove the front channel and the rear channel from
the front door.

BD -12
ESHA015H
9. Remove the door key cylinder.
ESHA015J
10. Loosen the bolts holding the handle outside front
door, the latch, and the door lock actuator.
Remove the wire harness and the front door module.
ESHA015K
11. Remove the weather strip outside door belt.
ESHA015L
12. Remove the outside rear view mirror.
BODY (INTERIOR &EXTERIOR)
ESHA015M
13. Installation is the reverse of the removal process.
When installing the door trim seal, butyl tape should
not
be placed over the area when installing the door
trim fastener.
ADJUSTMENT ESHA0400
DOOR POSITION
Check for aflush fit with the body, then check for an
equal gap between the front and rear, top and bottom
door edges and the body. The door and body edges
should also
be parallel.
CAUTION
Attach protective tape to the fender edges where the
hinge is installed.
ESA9095A
DOOR STRIKER
Make sure the door is not loose, and that it latches
securely without slamming.
If necessary, adjust the door
as follows:
1. Draw aline around the striker plate for reference.
2. Loosen the striker screws, and move the striker IN
and OUT to make the latch fit tighter or looser.
Move the striker UP and DOWN to align
it with the
latch opening. Then lightly tighten the screws and
recheck.

EXTERIOR
ESHA015N
NOTE
Hold the outside handle outward and push the door
against the body to ensure the striker has a tight fit.
ESA9095B
BO -13

SO -14 BODY (INTERIOR &EXTERIOR)
Trim panel
remover
ESHA020D
ESHA020F
ESHA020E
5. Remove the door trim seal.
6. Remove the delta cover from the rear door.
7. Remove the rear door glass from the rear door
module.
ESHA0450
-----
ESHA020C
ESHA020A
ESHA020B
Disconnect the wire connectors from the rear door.
REAR DOOR
REMOVAL AND INSTALLATION
1. Loosen the screw holding the handle inside the door.
2. Remove the tapping screw cap and then loosen the
tapping screws.
3. Remove the screws holding the door trim panel.
4. Insert atrim panel remover between the trim fasten-
ers and the door trim panel
to pry off.
ESHA020G

/
«;;:
EXTERIOR
8. Remove the rear door glass run.
ESHA020H
9. Remove the rear panel from the rear door.
ESHA0201
10. Disconnect the rod from the outside handle.
Remove the latch and the wire harness and the rear
door module.
ESHA020K
11. Remove the rear door front panel.
ESHA020L
SO -15
12. Remove the rear door outside handle.
ESHA020J
13. Remove the weather strip outside rear door belt.
ESHA020M
14. Installation is the reverse of the removal process.
When installing the door trim seal, butyl tape should
not
be placed over the area installing the door trim
fastener.

BD-16
ADJUSTMENT ESHA0500
DOOR POSITION
Check for atight fit with the body, then check for an
equal gap between the front and rear, top and bottom
door edges and the
body. The door and body edges
should also
be parallel.
DOOR STRIKER
Make sure the door is not loose, and that it latches
securely without slamming.
If necessary, adjust the door
as follows:
1. Draw aline around the striker plate for reference.
2. Loosen the striker screws, and move the striker IN
and OUT to make the latch fit tighter or looser.
Move the striker
UP and DOWN to align it with the
latch opening. Then lightly tighten the screws and
recheck.
ESHA015N
BODY (INTERIOR &EXTERIOR)

EXTERIOR
BODY SIDE MOLDINGS
REMOVAL AND INSTALLATION ESHA0550
WAISTLINE MOLDING
Beginning from either end, remove the waistline molding
using the special tool (09800-21000) from the front and
rear doors.
CAUTION
Take care not to scratch or bend the door moldings.
ESHA025C
ROOF SIDE GARNISH ESHA0600
1. Remove the roof side garnish by using aflat bladed
screwdrive
r.
CAUTION
When prying with a flat bladed screwdriver, wrap it
with protective tape to prevent damage.
In
order not to scratch the body and roof side
garnish, use protective tape on the body.
2. Pull the roof side garnish up, then remove the roof
side garnish.
3. Installation is the reverse of the removal process.
NOTE
If necessary, replace any damaged clips.
ESHA025B
BD -17

8D-18
BODY (INTERIOR &EXTERIOR)
SUN ROOF
COMPONENTS ESHA0650
Glass panel
Slider assembly
Drip
rail assembly
Screw
Stopper
1::1---- Clip
Screw
Frame assembly
.:,\ Deflector link
Screw
Drive unit assembly
----\~:---~
Motor assembly ~
~ II
sYew ibHarness assembly
Relay
Deflector assembly
--------'~.
Screw
Guide assembly
--------'~
Screw ----...J........li
ESHA065A

EXTERIOR
BO -19
REMOVAL ESHA0700 NOTE
1. To remove the sunroof, first remove the following
parts:
When removing the sunroof assembly, carefully pull
out the sunroof assembly to avoid damage to the
other parts.
1) Overhead console lamp.
2) Sunvisor and grip handle.
3) Pillar trims.
2. Remove the decoration cover and the glass panel.
Tightening torque
Glass panel mounting nuts:
4-6 Nm (40-60 kg·cm, 2.9-4.4 Ib·ft) ESA9011B
ESA9011C
1. Remove the drip rail.
DISASSEMBLY ESHA0750
2. Remove the stopper.
ESA9011K
ESHA027A
Disconnect the drain hose.
3.
4. Loosen the bolts and nuts holding the sunroof and
then remove the sunroof assembly.
ESA9011D
Tightening torque
Sunroof mounting bolts:
7-11 Nm (70-110 kg·cm, 5.1-8.0 Ib·ft)
Sunroof mounting nuts:
4-6
Nm (40-60 kg·cm, 2.9-4.4 Ib·ft)