Xe ô tô hyundai excel toàn tập hyundai excel - P4

Tài liệu xe ô tô hyundai excel toàn tập hyundai excel

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BODY (INTERIOR

AND EXTERIOR)

Return To Main Table of Contents

GENERAL 2 BODY PANELING 7 BODY DIMENSIONS 1 4 HOOD 1 9 RADIATOR GRILLE 2 0 BUMPER 21 FENDER 2 2 WINDSHIELD 2 4 REAR GLASS 2 9 QUARTER FIXED GLASS 3 1 QUARTER SWIVELLING GLASS 3 4 FRONT DOOR 3 6 REAR DOOR 4 2 TRUNK LID 4 7 TAIL GATE 4 8 BACK PANEL MOULDING 5 1 INTERIOR TRIM 5 3 CRASH PAD 5 8 CONSOLE 6 4 HEAD LINING 6 5 FRONT SEAT 6 7 REAR SEAT 68 SEAT BELT 7 0 PASSIVE SEAT BELT 72 SUNROOF 7 4

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GENERAL GENERAL

Quarter swivelling window

Front hinged, rear opening type

Front hinged, sash construction X-arm type

Quarter fixed glass

Front hinged, rear opening type

Inner hinged, gas damper type

mm (in.)

Torsion bar type

Zone tempered clear Laminated clear, tinted Full tempered clear

5 (0.20) 5.4 (0.21)

5 (0.20) 3.2 (0.13) Tailgate window glass 4.0 (0.16)

Quarter swivelling glass 4.0 (0.16) Distance between door upper side hinge Front door 348 mm (13.9 in.)

and lower side hinge Rear door 323 mm (12.9 in.)

Seat travel (rearmost - - - foremost) 180 mm (7.2 in.) by 20 mm steps.

60-2

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TIGHTENING TORQUE

Nm kg.cm Ib.ft Front and rear doors

Door hinge to body

Door hinge to door

Tailgate

Tailgate hinge to body

Tailgate hinge to tailgate

Ball stud to body

Ball stud to tailgate

Hood

Hood latch to body

Hood striker to hood

Hood stay rod to hood

Hood hinge to body

Hood hinge to hood

Seat

Front seat to floor

Rear seatback striker

Rear seatback tilting bracket

Rear seat cushion

Seat belt

Front seatbelt retractor to center pillar

Rear seatbelt anchorage

Passive seat belt anchorage

36-42 360-420 26-30 13-26 130-260 9-19

28-35 280-350 20.2-25.3 28-35 280-350 20.2-25.3 22-27 220-270 16-19.5 22-27 220-270 16-19.5

7-9 70-90 5-6.5 7-9 70-90 5-6.5 7-9 70-90 5-6.5 22-27 220-270 16-19.5 22-27 220-270 16-19.5

15.4-19.0 15.4-19.0 15.4-19.0 15.4-19.0

30-44 306-448 22-32.5 30-44 306-448 22-32.5 40-45 400-450 29-33

154-190 154-190 154-190 154-190

11.0-13.5 11.0-13.5 11.0-13.5 11.0-13.5

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SPECIAL TOOLS

60-4

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Motor runs but lid does

not move or moves only

halfway

Noise in motor (Clutch

slipping noise made in

motor when lid is fully

opened or closed is not

unusual noise.)

Door glass fails to operate

up and down

Door glass operates up

and down hardly

Probable cause

Dust accumulated in drainage of housing assembly

Clogged drain pipe

Broken or dislocated drain pipe, defective

or cracked clip Deteriorated roof lid weatherstrip Excessive roof lid-to-body clearance and improperly fitted weatherstrip

Loose or deformed deflector Foreign matter lodged in guide rail Loose guide rails and lid

Foreign matter lodged in guide rail

Incorrect engagement of motor pinion with drive cable

Decrease in clutch slipping force of motor Increased lid sliding resistance or interference

of lid with drive cables, weatherstrip, etc due

to maladjustment of lid Incorrect engagement of motor pinion with drive cable

Worn or damaged motor pinion bearing Worn or deformed drive cable

Dismount window glass regulator Detached sash

Broken sash Collapsed sash Collapsed window glass regulator arm Broken window glass regulator Improper window glass position

Remedy

Keep off dust from inside of

‘drain pipe Blow air into drain pipe to remove dust

Check pipe installation and flange contact

Replace Adjust

Retighten or replace Check drive cable and guide rails for foreign matter

Retighten Check drive cable and guide rails for foreign matter

Check for loose motor installation and damaged pinion

Adjust Adjust or replace

Check pinion installation and retighten motor

Replace motor assembly Replace

Adjust Attach Replace Repair or replace Repair or replace Replace

Adjust

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Symptom

Wind noise around door

Wind noise around liftgate

Probable cause Weatherstrip not holding firmly Improperly installed weatherstrip or setting

of weatherstrip Improperly closed door Improperly fit door Improper clearance between door glass and run channel

Deformed door Weatherstrip not holding firmly Improperly installed weatherstrip or setting

of weatherstrip Uneven clearance between body and liftgate Deformed liftgate

Remedy Adjust fit of door Repair or replace

Adjust Adjust Adjust Repair or replace Adjust fit of liftgate Repair or replace

Adjust Repair or replace

60-6

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BODY PANELING BODY PANELING

COMPONENTS

3-Door model

1 Panel assy, radiator support

2 Panel assy, fender apron

3 Panel assy, cowl top front

4 Panel assy, cowl inner lower

5 Panel assy, cowl top outer

6 Panel assy, cowl side inner

7 Panel assy, front door

8 Panel assy, dash complete

9 Panel assy, cowl side inner upper

10 Panel, roof

11 Rail assy, roof front

12 Rail assy, roof center

13 Rail assy, roof side

14 Panel assy, front floor

15 Pillar assy, front

16 Member, front floor side

17 Panel assy, side sill

18 Member assy, rear floor

19 Panel assy, rear floor

20 Panel assy, quarter outer

21 Panel assy, quarter inner

22 Panel assy, back

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BODY PANELING

COMPONENTS

10 Panel, roof

13 Rail assy, roof rear

14 Panel assy, rear door

21 Pillar assy, center

24 Panel assy, back

25 Door, fuel filler

26 Panel assy, rear package tray

27 Frame, rear window opening outer

28 Frame, rear window opening inner

29 Front side member outer

60-8

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BODY PANELING

COMPONENTS

5-Door model

10 Panel, roof

13 Rail assy, roof rear

14 Panel assy, rear door

21 Pillar assy, center

24 Panel assy, back

25 Door, fuel filler

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BODY PANELING

Section Z-Z

Section Y-Y Section A'-A'

Section B’-B’

1 Panel assy, hood

2 Panel assy, radiator support

3 Panel assy, fender

4 Pillar assy, front

5 Panel assy, front door

6 Panel assy, roof

7 Pillar assy, center

8 Panel assy, rear door

9 Panel assy, side sill

10 Panel assy, quarter

11 Panel assy, wheel house

12 Panel assy, tailgate

13 Panel assy, back

14 Panel assy, cowl top

15 Rail assy, roof side

16 Panel assy, trunk lid

17 Panel assy, rear package tray

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BODY DIMENSIONS BODY DIMENSIONS

3/5 DOOR

I

60-14

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BODY DIMENSIONS

4 DOOR

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BODY DIMENSIONS

Rear towing hook mounting hole and

bumper mounting hole (ø 16)

60-16

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BODY DIMENSIONS

3 / 4 / 5 D O O R

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BODY DIMENSIONS

3 / 5 D O O R

4 DOOR

Tailgate hinge mounting hole (ø 12)

Tailgate striker mounting hole (ø 9)

Trunk lid hinge mounting hole (ø 6.3)

Trunk lid striker mounting hole (ø 9)

60-18

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H O O D

HOOD

COMPONENTS

ADJUSTMENT

1 Adjust hood in forward/rearward and left/right directions.

Loosen the hood side hinge bolts to adjust.

2 Adjust front edge of hood in vertical direction by adjusting the

hood stop adjusting bolts.

3 Loosen the mounting bolts to adjust the hood latch.

NOTE

Apply chassis grease to the sliding part, the rotating part and

the spring of the hood latch.

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REMOVAL

1 Remove the bumper assembly-to-body bolts.

2 Remove the bumper cover-to-bumper stay nuts.

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1 Remove the position lamps and side marker lamps.

2 Remove the mud guards.

3 Remove the front wheel guards and front wheel end guards.

60-22

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3 Remove the antenna.

4 Remove the fender mounting bolts and remove the fender.

When installing the fenders, apply drying sealant between

the fenders and the body panels, so that there are no gaps

when the fenders are mounted.

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WINDSHIELD WINDSHIELD

(c) Cowl top cover.

(d) Side mouldings and upper moulding.

NOTE

Apply protective tape along the edge of the dashboard and body.

2 Using an awl, make a hold through the windshield sealant.

3 Push piano wire through the hole and wrap end around a piece

of wood or using special tool, Sealant Cut-out Tool 31100).

(09861-4 With an assistant, carefully cut ‘through adhesive material by pulling wire along windshield alternately from inside and outside the car.

CAUTION

Hold the piano wire as close to the glass as possible to vent damage to the body and dashboard.

pre-6 0 - 2 4

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1 Using a cutter knife or special tool, Sealant Cutting Blade

(09861-31200) scrap the old sealant smoothly to a thickness of

about 2 mm on the bonding surface around the entire

wind-shield flange.

2 Finish the flange surfaces so that they are smooth.

CAUTION

Be careful not to remove more adhesive than necessary, and

also not to damage the paintwork on the body surface with

the knife If the paintwork is damaged, repair the damaged

area with touch-up paint.

3 Clean the body bonding surface with a sponge dampened in

alcohol.

4 Install the cowl top cover mounting retainers and washers at the

locations as shown in illustration.

5 Center a new windshield in the opening.

‘Mark the location by scribing lines across the glass and body

with a grease pencil at the four points as shown.

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6 If the glass is to be reinstalled, use a putty knife to scrape off all trace of old adhesive, clean the glass surface with alcohol where new adhesive is to be applied.

8 Apply a light coat of glass primer to the surface outboard of the dam.

NOTE

(a) Do not apply body primer to the glass.

(b) Never touch the primed surfaces with your hand.

If you do, the adhesive may not bond to the glass erly, causing a leak after the windshield is installed (c) Keep water, dust, and abrasive materials away from the primed surface.

prop-9 Apply is light coat of body primer to original sealant remaining around the window opening flange The glass should be installed 10 minutes after you apply the primer.

60-26

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10 Thoroughly mix all the sealant and hardener together on a

glass or metal plate with a putty knife.

NOTE

(a) Clean the plate with a sponge and alcohol before mixing.

(b) Follow the instructions that come with the sealant.

11 Pack adhesive into the cartridge without air pockets, to ensure

continuous delivery Put the cartridge in a caulking gun or

Sealant Gun (09861-31300), and run a bead of adhesive

around the edge of the glass as shown.

NOTE

Apply the adhesive within 5 minutes after applying the glass

primer.

12 Use suction cups or special tool, Glass Holder (09861-31400)

glass over the opening, align it with the marks made in step 5

and set it down on the sealant and insert two lower spacer to

avoid moving the windshield downward.

13 Scrape or wipe excess adhesive off with putty knife or gauze.

Fill all cavities around the windshield.

14 Perform the water-test for the windshield.

Use cold water spray, being careful not to direct a powerful

stream of water on the new adhesive material Allow water to

spill over the edges of the glass.

15 If there are leaks, apply sealant at the leak points.

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16 Install the upper moulding

17 install the side mouldings.

18 Install the cowl top cover.

19 Reinstall the inside rear view mirror, pillar trims and wiper arms

CAUTION

After installation of the windshield glass, leave it until the adhesive sets sufficiently.

QUARTER FIXED GLASS

Removal and installation of quarter fixed glass can be carried out in the same manner as in the windshield.

60-28

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REAR GLASS REAR GLASS

COMPONENTS

REMOVAL

1 Remove the tailgate wiper arm and defogger terminals and high

mounting stop lamp terminal.

2 Turn up the lip of weatherstrip, and force it out of body flange.

This is to be carried out on the top and along about half of the

side of the glass.

3 Push out glass along with weatherstrip.

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REAR GLASS

INSTALLATION

1 Apply soap solution to weatherstrip.

2 Attach weatherstrip to glass, and then fit work cords into the grooves of weatherstrip.

NOTE

(a) Overlap the end of work cord at the bottom of glass (b) After work cords are fitted to weatherstrip, apply soap solution to the entire edge of weatherstrip.

3 Position glass properly from outside, and bring work cords inside.

4 Pull out the lip of weatherstrip for the end of roof trim, and then fit weatherstrip in such a manner that the lip moves over body flange while tapping glass with hand or rubber hammer from the outside and pulling work cord from inside.

NOTE

(a) Work should proceed from the center of the glass to left and right.

(b) Fit weatherstrip correctly to the body.

5 Set the whole glass in the body, tapping by hand or a rubber hammer.

6 Apply sealant to the entire circumference of weatherstrip.

7 Reinstall the wiper arm and defogger terminals and high ing stop lamp terminal.

mount-60-30

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Do not proceed with the service procedure until they are

completely dry, and do not touch cleaned surface with

fin-ger, dust, water, etc.

2 Install the rubber dam to the entire circumference of the glass.

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3 Install the front moulding to the glass and then apply the primer

(# 435-40) to the entire circumference of the glass with a brush.

4 Apply the sealant (# 551) to the entire circumference of the

glass.

CAUTION

Install the glass to the body within five minutes.

5.

6 Apply the primer (#435-95) to the body flange with a brush.

Clean the body flange with white gasoline.

CAUTION

Do not proceed with the service procedures until they are

completely dry.

60-32

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7 Install the glass to the body.

8 Install the rear moulding to the body.

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QUARTER SWIVELLING GLASS QUARTER SWIVELLING GLASS

COMPONENTS

REMOVAL

1 Remove the hinge mounting screws, handle mounting screws

and glass-hinge-handle assembly.

INSTALLATION

1 Install weatherstrip to the body with rubber hammer.

6 0 - 3 4

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QUARTER SWIVELLING GLASS

2 Place the glass-hinge-handle assembly to the body shown.

3 Tighten the screw to the hinge and then attach hinge cover.

4 Open the handle as shown in the illustration and tighten the

screws.

5 Check open-close condition of the glass and lock the handle.

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FRONT DOOR FRONT DOOR

COMPONENTS

60-36

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FRONT DOOR

DOOR POSITION ADJUSTMENT

Check for flush fit with the body, then check for equal gap between the front and rear, top and bottom door edges and the body.

The door and body edges should also be parallel Adjust at the hinge with Special Tool (09793-21000).

CAUTION

Attach protective tape to the fender edges near the place where the hinge is installed.

DOOR STRIKER ADJUSTMENT

Make sure the door is not loose, and latches securely without slamming If it needs adjustment;

1 Draw a line around the striker plate for reference.

2 Loosen the striker screws, and move the striker IN or OUT to make the latch fit together or looser Move the striker UP or DOWN to align it with the latch opening Then lightly tighten the screws and recheck.

INSIDE HANDLE ADJUSTMENT

1 Adjust the inside handle play by adjusting the mounting position

in the IN-to-OUT direction.

FULL STROKE [A] 48°

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FRONT DOOR

REMOVAL

1 Using a screwdriver, remove the clip located in the illustration to remove the regulator handle.

2 Remove the quadrant inner cover.

3 Remove the rear view mirror mounting screws and then remove the rear view mirror.

60-38

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FRONT DOOR

6 Remove the plastic door trim seal.

7 Remove the glass grip from the regulator.

8 Remove the door trim with a screwdriver.

9 Pull the door glass out through the window slot.

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