Table Of Contents - Hyundai trajet Shop Manual

Table of Contents

Contents1
Body (Interior & Exterior)2
Specifications3
Tightening Torque4
Special Tools5
Troubleshooting6
Exterior8
Hood8
Components8
Hood Alignment Adjustment8
Tailgate Removal And Installation10
Front Door Removal And Installation12
Adjustment13
Door Position13
Door Striker13
Rear Door Removal And Installation15
Body Side Moldings Removal And Installation18
Waistline Molding18
Roof Side Garnish18
Sun Roof Components19
Check Operating Condition After Installation22
Outside Rear View Mirror Components23
Outside Rear View Mirror Removal And Installation23
Interior24
Console Components24
Console Removal And Installation24
Crash Pad Removal And Installation25
Crash Pad Removal Outdoors25
Interior Trim Removal30
Front Pillar Trim30
Front Door Scuff Trim30
Rear Door Scuff Trim30
Quarter Trim31
Headlining Rear Cover31
Rear Pillar Trim31
Headlining31
Windshield Glass Components32
Windshield Glass Removal33
Windshield Glass Installation33
Tailgate Glass Removal36
Tailgate Glass Installation36
Front Bumper Components38
Front Bumper Removal And Installation39
Rear Bumper Components40
Rear Bumper Removal And Installation41
Front Seat Removal And Installation42
Rear Seat Removal And Installation43
Front Seat Belt Removal And Installation44
Rear Seat Belt Removal And Installation45
Body Electrical System46
Instruments And Warning System47
Service Specifications48
Audio Unit Components63
Audio Unit Removal And Installation66
Tape Head And Capstan Cleaning66
Speakers Removal And Installation67
Front Speaker67
Rear Speaker67
Speaker Checking67
Multi Function Switch Components(Without Air Bag)68
Multi Function Switch Components(With Air Bag)69
Multi Function Switch Removal And Installation70
Multi Function Switch Inspection71
Lighting Switch [M26=1]71
Front Fog Lamp Switch [M26-1]71
Dimmer And Passing Switch [M26=1]71
Horns Removal And Installation72
Horns Inspection72
Horns Adjustment72
Etacs (Electronic Time And Alarm Control System)73
Electronic Time And Alarm Control Module Operation Check Of Components73
Fuses And Relays79
Relay Box (Engine Compartment)79
Fusible Link79
Fuses Inspection80
Indicators And Gauges81
Instrument Cluster Components81
Instrument Cluster Removal And Installation82
Circuit Diagram83
Fuel Gauge Inspection84
Engine Coolant Temperature Gauge Inspection85
Tachometer Inspection86
Speedometer Component Check87
Power Door Mirrors88
Power Door Mirror Switch Inspection88
Power Door Mirror Actuator Inspection89
Mirror Folding89
Outside Mirror Folding Switch90
Power Windows91
Power Window Motor Inspection91
Power Window Switch Inspection92
Door Lock Switch [008]92
Window Lock Switch [008]92
Power Window Sub Switch [028]93
Rear Window Defogger94
Rear Window Defogger Printed Heater Inspection94
Repair Of Broken Heater Line94
Windshield Wiperiwasher Components96
Rainsensing Windshield Wiper System Description98
Rainsensing Windshield Wiper System Operating Modes98
Off Mode98
Automatic Mode98
Rainsensing Windshield Wiper System Replacement99
Rainsensing Windshield Wiper System Troubleshooting99
Wash Mode99
Manual Mode99
Windshield Wiper/Washer Switch Inspection100
Wiper And Intermittent Volume Switch100
Washer Switch [M26-2]100
Windshield Wiper/Washer Switch Installation101
Front Wiper Motor Inspection101
Speed Operation Check101
Automatic Stop Operation Check101
Front Washer Motor Inspection102
Rear Wiper/Washer Components103
Rear Wiper Motor Removal104
Rear Wiper Motor Inspection104
Rear Wiper Motor Installation104
Rear Washer Switch Inspection105
Rear Washer Motor Inspection106
Seat Warmer System107
Seat Warmer Switch Inspection107
Sun Roof Switch Inspection108
Sun Roof Relay Inspection109
Sun Roof Motor Inspection110
Head Lamps111
Lighting System111
Pre-Aiming Instructions111
Head Lamp And Fog Lamp Aiming Point112
Head Lamp Relay Inspection114
Auto Light Control Module Description115
Auto Light Control Module Circuit Diagram115
Pin Connection116
Detection Illumination116
Turn/Hazard Lamps117
Turn/Hazard Switch Inspection117
Flasher Unit Inspection118
Courtesy And Trunk Lamps119
Overhead Console Lamp Inspection119
Overhead Console Lamp Circuit Diagram120
Immobilizer Control System122
Immobilizer System122
Key Registration124
Id Code Registration Sequence124
Master Key Correction124
Electronic Time And Alarm153
Control Module Operation Check Of Components153
Brake System206
Service Brake Pedal Inspection And Adjustment211
Brake Booster Operation Test Without A Tester211
Bleeding Of The Brake System211
Brake Booster Components213
Check Valve Operating Test213
Brake Pedal Components215
Brake Pedal Removal216
Brake Pedal Inspection216
Brake Pedal Installation216
Front Disc Brake Components217
Replacement Of Brake Pads217
Caliper Assembly Removal219
Caliper Assembly Disassembly219
Caliper Assembly Inspection220
How To Check Front Disc Runout And Thickness220
Front Brake Disc Run-Out Check220
Front Brake Disc Thickness Check220
Master Cylinder Components222
Master Cylinder Removal222
Master Cylinder Disassembly222
Master Cylinder Assembly223
Master Cylinder Installation223
Rear Disc Brake Components224
Rear Disc Brake Inspection224
Caliper Disassembly224
Caliper Assembly225
Parking Brake Components226
Parking Brake Removal228
Parking Brake Installation228
Parking Brake Service Adjustment228
Abs (Anti-Lock Brake System) Specification229
Abs (Anti-Lock Brake System) Tightening Torque230
Abs System Component231
Ebd (Electronic Brake-Force Distribution)232
Comparison Between Proportioning Valve And Ebd232
Inspection At Hecu Terminals233
Terminal Voltage Chart233
Diagram Of Input/Output For Hecu235
Standard Flow Of Diagnostic Troubleshooting237
Abs Check Sheet238
Hi-Scan Check239
Inspection Chart For Diagnostic Trouble Codes240
Current Data243
Additional Explanation Of Failsafe250
Term Commentary250
Abs Circuit251
Inspection Procedure For Diagnostic Trouble Codes253
Abs Warning Lamp Inspection258
Inspection Chart For Trouble Symptoms258
Inspection Procedure For Trouble Symptoms259
Anti-Lock Braking System Control Module Components263
Anti-Lock Braking System Control Module Removal263
Anti-Lock Braking System Control Module Installation264
Anti-Lock Braking System Modulator265
Hydraulic Module Inspection265
Anti-Lock Braking System Wheel Speed Sensor Components266
Front Wheel Speed Sensor266
Rear Wheel Speed Sensor266
Abs Operation Check267
Wheel Speed Sensor Output Voltage Check267
Lspv Components268
Lspv Summary269
Clutch System272
Clutch System Specifications273
Clutch System Tightening Torque274
Clutch System Lubricants274
Clutch System Special Tools274
Clutch System Troubleshooting275
Clutch System Service Adjustment277
Clutch Pedal Inspection And Adjustment277
Bleeding277
Clutch Cover And Disc Components279
Clutch Cover Assembly Inspection280
Clutch Release Bearing281
Clutch Release Fork281
Clutch Master Cylinder Components283
Clutch Master Cylinder Disassembly283
Clutch Master Cylinder Reassembly284
Clutch Pedal Components288
Clutch Pedal Disassembly288
Clutch Pedal Inspection289
Ignition Lock Switch Inspection289
Clutch Pedal Reassembly289
Clutch Release Cylinder Components290
Clutch Release Cylinder Removal290
Clutch Release Cylinder Inspection291
Clutch Release Cylinder Reassembly291
Clutch Release Cylinder Installation291
Driveshaft And Axle292
Driveshaft And Axle Specifications293
Driveshaft And Axle Tightening Torque294
Driveshaft And Axle Lubricants294
Driveshaft And Axle Special Tools295
Driveshaft298
Front Driveshaft Assembly Components298
Front Driveshaft Assembly Removal299
Front Driveshaft Assembly Inspection300
Front Driveshaft Assembly Installation300
Front Driveshaft Components301
Front Driveshaft Disassembly301
Front Driveshaft Inspection302
Front Driveshaft Reassembly302
Front Driveshaft Inspection After Disassembly305
Center Bearing And Inner Shaft Components308
Center Bearing And Inner Shaft Disassembly309
Center Bearing And Inner Shaft Inspection309
Center Bearing And Inner Shaft Reassembly309
Front Axle311
Front Hub/Knuckle Components311
Front Hub/Knuckle Removal312
Front Hub/Knuckle Disassembly312
Front Hub/Knuckle Inspection313
Front Hub/Knuckle Reassembly313
Rear Axle/Hub Components315
Inspection Of Wheel Bearing And Play316
Checking Starting Torque Of Rear Hub Rotation316
Emissions Control System318
Emission Controls Location320
Schematic Drawing324
Vacuum Hoses Layout330
Crankcase Emission Control System331
Positive Crankcase Ventilation (Pcv) Valve331
Positive Crankcase Ventilation (Pcv) Valve Components332
Pcv Valve Operating333
Evaporative Emission Control System Components335
Evaporative (Evap) Canister Purge Solenoid Valve336
Evap Canister Purge Solenoid Valve336
Vacuum Hose337
Evaporative (Evap) Canister337
Two-Way Valve338
Overfill Limiter (Two Way Valve)338
Fuel Filer Cap338
Exhaust Emission Control System339
Air/Fuel Mixture Ratio Control System339
Engine Electrical System340
Cruise Control System Pre-Troubleshooting345
Ignition System General Information349
Ignition Coil349
Ignition System Removal And Installation350
Spark Plug Test352
Spark Plug Cables Test352
Installation Of Spark Plug Cable353
Charging System General Information355
Voltage Drop Test Of Generator Output Wire355
Conditions For The Test355
Output Current Test356
Regulated Voltage Test357
Regulating Voltage Table358
Generator Output Line Voltage Drop Test359
Charging System Removal And Installation364
Charging System Disassembly And Reassembly365
Stator367
Rectifiers367
Positive Rectifier Test367
Negative Rectifier Test367
Brush Replacement368
Diode Trio Test368
Battery Visual Inspection372
Load Test373
Starting System375
Check Clutch Pedal375
Check Starter Relay375
Check Ignition Lock Switch375
Service Adjustment Procedures For Pinion Gap Adjustment379
Magnetic Switch Pull-In Test379
Magnetic Switch Hold-In Test379
Free Running Test380
Magnetic Switch Return Test380
Checking The Commutator380
Brush Holder381
Front And Rear Bracket Bushing381
Reassembly Of The Stop Ring And Snap Ring381
Cleaning Starter Motor381
Cruise Control System Components Location382
Cruise Control System Components383
Cruise Control Main Switch384
Stop Lamp Switch384
Cable Adjustment384
Engine Mechanical System386
Checking Engine Oil401
Selection Of Engine Oil402
Changing Engine Oil402
Replacing The Oil Filter403
Procedure For Replacing The Oil Filter403
Checking Coolant Leak403
Radiator Cap Pressure Test404
Specific Gravity Test405
Relation Between Coolant Concentration And Specific Gravity405
Checking Compression Pressure405
Recommended Coolant405
Adjusting Drive Belt Tension407
A Type Of Tension Gauge408
B Type Of Tension Gauge408
Adjusting The Alternator Belt408
Adjusting The Belt Of Power Steering And Air Conditioner408
Engine Block409
Cylinder Block409
Boring Cylinder410
Piston Service Size And Mark Mm410
Engine Mounts412
Engine Mounting413
Transaxle Mounting413
Front Roll Stopper413
Rear Roll Stopper413
Inspection Items414
Engine And Transaxle Assembly415
Front Case420
Oil Pump Case, Oil Pump And Counter Balance Shaft420
Counter Balance Shaft422
Oil Seal422
Oil Pressure Switch422
Counter Balance Shaft Bearing423
Main Moving System427
Camshafts And Rocker Arms427
Piston And Connecting Rod431
Connecting Rod Cap431
Piston And Piston Pins433
Piston Rings433
Connecting Rods433
Crankshaft, Flywheel436
Main Bearings And Connecting Rod Bearings437
Measuring Oil Clearance437
How To Use Plastic Gauge437
Standard Value437
Bearing Caps438
Flywheel438
Cooling System440
Engine Coolant Hose/Pipes440
The Coolant Sensor441
Engine Coolant Pump442
Radiator444
Radiator Pan Motor446
Radiator Fan Motor Relay447
Radiator Cap448
Thermostat449
Intake And Exhaust System451
Exhaust Pipe451
Exhaust Manifold451
Intake Manifold453
Muffler457
Main Muffler458
Center Exhaust Pipe458
Front Exhaust Pipe458
Air Cleaner460
Cylinder Head And Valves462
Cylinder Head Inspection463
Valves464
Valve Springs464
Valve Guides464
Reconditioning Valve Seat465
Replacing Valve Seat Ring465
Valve Seat Insert Oversizes466
Replacing Valve Guide466
Valve Guide Oversizes466
Timing System468
Timing Belt468
Sprockets, Tensioner Pulley And Idler Pulley470
Fuel System564
Fuel System General Specifications565
Sealant566
Fuel System Tightening Torque566
Fuel System Special Tools567
Fuel System Troubleshooting568
Mfi Troubleshooting Procedures571
Scan Tool Communication With Ecm Is Not Possible571
Engine Will Not Start572
Difficult To Start573
Rough Idle Or Engine Stalls575
Engine Hesitates Or Accelerates Poorly577
Multiport Fuel Injection580
Fuel Injection Control580
Idle Speed Control580
Ignition Timing Controls580
Service Points In Inspecting A Blown Fuse581
Simulation Tests581
Inspecting The Mfi System581
Malfunction Indicator Light581
Inspecting The Malfunction Indicator Lamp582
Mfi Control System583
Mfi Component Inspection597
Location Of Mfi Components597
Engine Coolant Temperature (Ect) Sensor601
Sensor Checking602
Using Multi-Meter602
Harness Inspection602
Using Voltmeter604
Manifold Absolute Pressure (Map) & Intake Air Temperature (Iat) Sensor605
Hardness Inspection Procedure606
Sensor Inspection607
Mass Air Flow (Maf) Sensor608
Intake Air Temperature Sensor611
Using Hi-Scan612
Harness Inspection Procedure613
Throttle Position Sensor614
Heated Oxygen Sensor620
Camshaft Position Sensor626
Crankshaft Position Sensor630
General Information724
Vehicle Identification Number Location725
Vehicle Identification Number725
Service Limit725
Engine Identification Number Location726
Description Of Engine Identification Number726
Transaxle Identification Number Location726
Protection Of The Vehicle727
Preparation Of Tools And Measuring Equipment727
Rubber Parts And Tubes729
Measuring Body Dimensions729
Dimensions Projected729
Measuring Actual Dimensions729
Checking Fuses730
Servicing The Electrical System730
Srs System Components Information732
Tightening Torque Table Of Standard Parts734
Recommended Lubricants735
Lubricants Capacities735
Replacing The Engine Oil Filter736
Replacing The Air Cleaner Filter736
Checking Belt Tension736
Antifreeze737
Measuring Of Antifreeze Concentration737
Replacing Of The Coolant737
Replacing Ignition Cables738
Replacing Oxygen Sensor738
Manual Transaxle738
Transaxle Oil738
Power Steering Fluid Level739
Power Steering Hoses739
Ball Joint And Steering Linkage Seals, Steering And Drive Shaft Boots739
Front Disc Brake Pads739
Checking The Brake Fluid Level740
Changing Brake Fluid740
Checking Tire Inflation Pressure740
Road Test740
Steering And Drive Shaft Boots741
Tire Chains And Snow Tires741
Heating, Ventilation & Air Conditioning742
Malfunction Causes And Remedies745
Refrigeration Cycle749
Installation Of Manifold Gauge Set751
Refrigerant Discharging Procedure751
Evacuating Refrigerant System751
Handling Refrigerant Service Tap Valve752
Charging Refrigerant System (Vapor)753
Performance Test754
How To Read The Graph755
Compressor Oil756
Handling Of Oil756
Oil Return Operation756
Checking And Adding Of Compressor Oil Level756
Blower Unit Air Filter757
Performance Test Diagnosis Using Manifold Gauge758
Manual A/C Compressor Controls760
Air Conditioner Switch760
Switch Configuration761
Blower Switch761
Mode Switch761
Temperature Switch761
Blower Switch Check762
Air Conditioning Switch Check762
Intake Switch Check762
Mode Switch Check763
Temperature Switch Check763
Checking Of The Control Panel Assembly768
Mode Control Switch768
Fresh/Recirculation Button768
Compressor Components769
Compressor Removal And Installation769
Clutch Hub And Pulley Disassembly771
Clutch Hub And Pulley Assembly771
Clutch Field Coil771
Thermal Fuse772
Clutch Air Gap Checking772
Magnetic Clutch, Operation Check772
Condenser Fan And Relay Components773
Condenser Checking773
Condenser Fan773
Condenser And Radiator Fan Operation Condition774
Ecu Operation Condition774
Receiver/Drier775
Triple Switch776
Full Auto A/C Compressor777
Switch Operation And Features782
Control Panel Switches Will Generate Buzzer Sound On Operation782
System Control Features787
Signal I/O For Each Control Feature787
Control Specification788
Diagnosis System Operation Method791
Fail Safe Function792
How To Read Self-Diagnostic Code792
Faul Code Display793
Dtc Chart793
Checkpoint By Type794
Power Supply Check795
Back Light And Rear Glass Heat Rays Check796
Blower Check797
Air Conditioner Check798
Intake And Aqs Check799
Mode Check800
Temp Check801
Each Sensor Check802
In Car Sensor802
In-Car Air Temperature Sensor802
Photo Sensor803
Ambient Temperature Sensor804
Ambient Air Temperature Sensor804
A.q.s. Sensor805
Vacuum System806
Ventilator Components806
Heater Unit Components807
Heater Unit809
Temperature Control Actuator809
Mode Control Actuator809
Blower Controls811
Blower Unit And Evaporator Components811
Thermistor And Pin Sensor813
Water Temperature Sensor814
Blower Motor814
Fresh Recirculation Switching Actuator814
Power Tr Checking815
Blower Motor Checking815
Blower Relay816
Relay Checking816
Inspection Of Air Conditioning Relay816
Inspection Of Blower Relay And Hi-Blower Relay816
Restraints818
Electrical System823
Srscm823
Inflator Module824
Srs Harness824
Srscm Independent Lamp Activation824
Mil Operating Method825
Clock Spring825
Srscm Component851
Srscm Connector852
Air Bag Module (Drive Side) And Clock Spring853
Air Bag Module Removal856
Passive Seat Belt System857
Function Of Pretensionser857
Load Limiter858
Suspension System860
Front Suspension System867
Strut Assembly Components867
Strut Assembly Removal868
Strut Assembly Installation868
Strut Assembly Disassembly868
Strut Assembly Inspection868
Strut Assembly Disposal869
Strut Assembly Reassembly869
Lower Arm Components871
Lower Arm Removal872
Lower Arm Disassembly872
Lower Arm Inspection872
Lower Arm Reassembly873
Rear Suspension System875
Rear Suspension Arm Components875
Upper Arm, Lower Arm, And Assist Link876
Rear Suspension Arm Removal876
Rear Lower Arm Bushing Replacement876
Rear Suspension Arm Installation877
Suspension Crossmember Bushing Replacement877
Rear Cross Member Reassembly878
Tire879
Front Wheel Alignment879
Toe-In879
Side Slip And Wheel Steering Angle Adjustment879
Rear Wheel Alignment880
Tire Wear880
Wheel Runout881
Wheel Nut Tightening881
Steering System882
Steering System Specifications883
Steering System Tightening Torque883
Steering System Lubricants884
Steering System Special Tools885
Steering Column/Shaft Components888
Steering Column/Shaft Removal889
Steering Column/Shaft Inspection890
Steering Column/Shaft Assembly890
Steering Column/Shaft Installation890
Power Steering System891
Checking Steering Wheel Free Play891
Checking Steering Angle891
Checking Steering Wheel Return891
Checking Power Steering Fluid Level892
Replacing Power Steering Fluid892
Air Bleeding893
Checking Power Steering Belt Tension893
Oil Pump Pressure Test894
Power Steering Hose Components895
Power Steering Gear Box Components896
Power Steering Gear Box Removal897
Power Steering Gear Box Disassembly897
Power Steering Oil Pump Components904
Power Steering Oil Pump Removal905
Power Steering Oil Pump Disassembly905
Power Steering Oil Pump Inspection906
Power Steering Oil Pump Assembly906
Power Steering Oil Pump Installation907
Transaxle/Transmission908
Transaxle/Transmission Specifications909
Transaxle/Transmission Service Standard909
Transaxle/Transmission Tightening Torque910
Transaxle/Transmission Lubricants910
Transaxle/Transmission Special Tools911
Transaxle/Transmission Troubleshooting911
Transaxle/Transmission Sealants914
Automatic Transaxle System Troubleshooting920
Automatic Transmission Fluid Check921
Automatic Transmission Fluid Replacement921
Oil Filter Replacement922
Transaxle Range Switch Continuity Check922
Transaxle Range Switch And Control Cable Adjustment922
A/T Control Component Check923
Throttle Position Sensor Check923
Oil Temperature Sensor Check923
Vehicle Speed Sensor Check923
A/T Control Relay Check924
Solenoid Valve Check924
Torque Converter Stall Test925
Torque Converter Stall Test Judgement Results925
Hydraulic Pressure Test926
Standard Hydraulic Pressure Test926
Standard Hydraulic Pressure Test Diagnosis Table927
Element In Use At Each Position Of Selector Lever939
Operating Element And Their Functions940
Inspection Process For Diagnostic Trouble Codes941
Brake Reactionplate End Play Adjustment970
Second Brake End Play Adjustment970
Low-Reverse Brake End Play Adjustment970
Identification Of Thrust Bearing, Thrust Races And Thrust Washers971
Underdrive Sun Gear End Play Adjustment972
Differential Case Preload Adjustment972
Automatic Transaxle Hydraulic Circuit973
Tcm Circuit Diagram979
Automatic Transaxle Components985
Automatic Transaxle Installation987
Automatic Transaxle Shift Control988
Automatic Transaxle Control System988
Tcm Replacement989
Manual Transaxle System990
Transaxle Gear Oil Level Inspection990
Replacement Of Transaxle Gear Oil990
Drive Shaft Oil Seal Replacement990
Manual Transaxle Components991
Manual Transaxle Removal992
Manual Transaxle Installation993
Manual Transaxle Shift Control Components994
Manual Transaxle Shift Control Inspection995
Manual Transaxle Shift Control Reassembly995
Shift Lever Components996
Shift Lever Inspection996
Shift Lever Reassembly996