1993-Onwards Hyundai Scoupe Service & Repair Manual

HYUNDAI 1993 CONTENTS 10 Volume 1 & 2 Shop Manual 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. JUN. 1992, Printed in Korea NOTE : This PDF Manual contains the contents of both printed Volumes 1 & 2. TITLE SECTION GENERAL INFORMATION 00 ENGINE MECHANICAL 20 LUBRICATION AND MAINTENANCE COOLING SYSTEM 25 ENGINE ELECTRICAL SYSTEM 27 INTAKE & EXHAUST SYSTEM 28 EMISSION CONTROL SYSTEM 29 FUEL SYSTEM 31 CLUTCH 41 MANUAL TRANSAXLE 43 AUTOMATIC TRANSAXLE 45 DRIVE SHAFT AND FRONT AXLE 49 FRONT SUSPENSION 54 REAR SUSPENSION STEERING SYSTEM BRAKE SYSTEM BODY (Interior and Exterior) BODY ELECTRICAL SYSTEM AIR CONDITIONING SYSTEM APPENDIX (Electrical Wiring System) 55 56 58 60 90 97 WS

GENERAL INFORMATION

00-2 GENERAL INFORMATION GENERAL INFORMATION HOW TO USE THIS MANUAL This manual is divided into 20 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 ECFI : Electronically Controlled Fuel Injection system

GENERAL INFORMATION 00-3 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 1. World manufacturer’s identifier code KMH - Hyundai Motor Co., Korea 2HM - Bromont Assembly Plant, Canada 2. Drive line type V - For LHD U - For RHD 3. Body Type F - 2 Door sedan 4. Body style & version 1 - Standard 2 - Deluxe (GL) 3 - Super deluxe (GLS) 5. Restraint type 1 - Active system 2 - Passive system 6. Engine type N - 1495 cc 7. Check digit Mathematically determined to validate frame numbers 8. Model year L- 1990 M - 1991 N - 1992 P - 1993 R - 1994 9. Plant code U - Ulsan plant B - Bromont plant 10. Serial number 000001 through 999999

00-4 GENERAL INFORMATION TRANSAXLE NUMBER IDENTIFICATION Description 1 2 3 4 5 6 I 6 1. Model G : A4AF1 2. Product year M : 1991 N : 1992 P : 1993 R : 1994 3. Final gear ratio T : 4.029 4. Classification of detail A : Scoupe 5. Spare D : Damper Spring type 6. Serial No.

GENERAL INFORMATION 00-5 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 11 digits. 1. Engine fuel G : Gasoline 2. Engine range 4 : In line 4 cycle 4 cylinder 3. Engine development order A-Z : 4. Engine capacity E: 1495 cc 5. Product year L: 1990 M : 1991 N : 1992 P: 1993 R : 1994 6. Engine production sequence number 000001-999999

00-6 GENERAL INFORMATION 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. 2. Use only specified jacking positions. 3. Support vehicle with safety stands (jack stands) Refer to the page 00-10. 4. Start the engine only after making certain the engine compartment is clear of tools and people.

GENERAL INFORMATION 00-7 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 pat-t 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 pans to be replaced from those that will be reused.

00-8 GENERAL INFORMATION 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; 1. Sealant should be applied to gaskets. 2. Oil should be applied to moving components of parts. 3. 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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1993-Onwards Hyundai Scoupe Service & Repair Manual

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