Hyundai Excel 1993 Install guide

HYUNDAI

1993

Shop Manual

Volume 1 & 2

FOREWORD

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 drawings and

specifications, are the latest available at the time of

publication. However, specifications and procedures are

subject to change without any notice.

As for the modifications affecting service performance,

dealers shall be provided technical service bulletins or

supplementary volumes.

This book may not be reproduced or copied, as a whole

or as a part, without the written permission of publisher.

JULY 1992. Printed in Korea

NOTE : This PDF Manual contains the contents of

both printed Volumes 1 & 2.

CONTENTS

TITLE

GENERAL INFORMATION

LUBRICATION AND MAINTENANCE

ENGINE MECHANICAL

COOLING SYSTEM

ENGINE ELECTRICAL SYSTEM

INTAKE & EXHAUST SYSTEM

EMISSION CONTROL SYSTEM

FUEL SYSTEM

CLUTCH (Hydraulic type)

CLUTCH (Cable type)

MANUAL TRANSAXLE

AUTOMATIC TRANSAXLE [KM176]

AUTOMATIC TRANSAXLE [KM171]

DRIVE SHAFT AND FRONT AXLE

FRONT SUSPENSION

REAR SUSPENSION

STEERING SYSTEM (Manual & Power)

BRAKE SYSTEM

BODY (INTERIOR AND EXTERIOR)

BODY ELECTRICAL SYSTEM

AIR CONDITIONING SYSTEM

APPENDIX (Electrical Wiring System)

SECTION

41A

45D

GENERAL

INFORMATION

00-2

GENERAL INFORMATION

HOW TO USE THIS MANUAL

This manual is divided into 23 sections. This first page of each

section is marked with a black tab at the edge of the page. You can

quickly find the first page of each section without looking through

a full table of contents.

Each section includes the essential removal, installation, adjust-

ment and maintenance procedures for servicing all body styles.

This information is current as of time of publication.

An INDEX is provided on the first page of each section to guide you

to the item to be replaced.

TROUBLESHOOTING tables are included for each system to help

you diagnose the system problem and find the cause. The repair for

each possible cause is referenced in the remedy column to quickly

lead you to the solution.

DEFINITION OF TERMS

Standard Value

Indicates the value use as the standard for judging the quality of

a part or assembly on inspection or the value to which the part

or assembly is corrected and adjusted. It is given by a tolerance.

Limit

Shows the standard for judging the quality of a part or assembly on

inspection and means the maximum or minimum value within which

the part or assembly must be kept functionally or in strength. It is

a value established outside the range of standard value.

NOTE, WARNING AND CAUTION

NOTE

A point of information.

WARNING

Information about an activity that could cause damage to the

vehicle.

CAUTION

Information about an activity that could cause injury or

damage to the driver, occupants or repair personnel.

ABBREVIATIONS

MPI: Indicates Multi Point Fuel Injection system.

FBC: Indicates Feedback Carburetor system.

VEHICLE IDENTIFICATION NUMBER

LOCATION

The vehicle identification number (V.I.N.) is stamped on the

upper right side of the cowl top front panel.

VEHICLE IDENTIFICATION NUMBER

KMH

2J9

000047

1. World manufacturer’s identifier code

KMH - Hyundai Motor Co., Korea

2. Drive line type

V - For LHD (EXCEL)

3. Body Type

F - 4 Door sedan

D - 3 Door sedan

4. Body style & version

1 - Standard

2 - Deluxe

3 - Super deluxe

5. Restraint type

1 - Active system

2 - Passive system

6. Engine type

J - 1468 cc

7. Check digit

Mathematically determined to validate frame numbers

8. Model year

R - 1994 P - 1993

9. Plant code

U - Ulsan plant

10. Serial number 000001 through 999999

00-4

TRANSAXLE NUMBER IDENTIFICATION

Description (Automatic transaxle)

1. Model

B: KM 176 A: KM 171

2. Product year

M : 1991

N : 1992

P : 1993

R : 1994

3. Final gear ratio

F : 4.062

E : 3.600

4. Classification of detail

A : Excel

5. Spare

D : Damper Spring type

6. Serial No.

ENGINE IDENTIFICATION PLATE

The engine identification plate is stamped at the right front side on

the top edge of the cylinder block.

ENGINE IDENTIFICATION NUMBER

Engine identification number consists of 10 digits.

Engine fuel

G : Gasoline

Engine range

4 : In line 4 cycle 4 cylinder

Engine development order

A-Z :

Engine capacity

J : 1468 cc

Product year

Engine production sequence number

000001 - 999999

00-6

PROTECTION OF THE VEHICLE

Always be sure to cover fenders, seats, and floor areas before

starting work.

CAUTION:

The support rod must be inserted into the hole near the edge

of the hood whenever you inspect the engine compartment to

prevent the hood from falling and possibly injuring you.

Assure that the support rod has been released prior to closing

the hood. Always double check to be sure the hood is firmly

latched before driving away.

A WORD ABOUT SAFETY

The following precautions must be followed when jacking up the

vehicle.

1. Block wheels.

Use only specified jacking positions.

Support vehicle with safety stands (jack stands)

Refer to the page 00-10.

Start the engine only after making certain the engine com-

partment is clear of tools and people.

PREPARATION OF TOOLS AND MEASURING

EQUIPMENT

Be sure that all necessary tools and measuring equipment are

available before starting work activity.

SPECIAL TOOLS

Use special tools when they are required.

REMOVAL OF PARTS

First find the cause of trouble and then make sure whether

removing or disassembling is required before starting the job.

DISASSEMBLY

If the disassembly procedure is complex, requiring many parts to

be disassembled, all parts should be disassembled in a way that will

not affect their performance or external appearance and be iden-

tified so that reassembly can be performed efficiently.

1. Inspection of parts

Each part when removed should be carefully inspected for

wear, deformation, damage, and other problems.

2. Arrangement of parts

All disassembled parts should be carefully arranged for

reassembly.

Be sure to separate or otherwise identify the parts to be

replaced from those that will be reused.

00-8

3. Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly

cleaned by the appropriated method.

PARTS

When replacing parts, use HYUNDAI genuine parts

REASSEMBLY

Standard values, such as torques and certain adjustments, must

be strictly observed in the reassembly of all parts.

If removed, these parts should be replaced with new ones.

1. Oil seals

2. Gaskets

3. O-rings

4. Lock washers

5. Cotter pins (split pins)

6. Nylon nuts

Depending on where they are;

Sealant should be applied to gaskets.

Oil should be applied to moving components of parts.

Specified oil or grease should be applied at the prescribed

locations (oil seals, etc.) before assembly.

ADJUSTMENTS

Use gauges and testers to correct adjustments to standard values.

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