1989–1994 Hyundai Excel Repair Manual (P/N HXE-126789)

• Hyundai Motor Company 1989–1994 Excel Shop Manual, dated April 1990 and printed in Korea, with 1,066 unique PDF pages for 3-door, 4-door, and 5-door models; VIN data identifies Standard, Deluxe (GL), and Super Deluxe (GLS) versions, left- and right-hand drive, and MPI/FBC configurations.
• Engine chapters document engine/transaxle removal, timing-belt service, cylinder-head and valve-train repair, FBC jet-valve work, oil-pump service, and internal inspection of pistons, connecting rods, crankshaft, flywheel, and cylinder block.
• Drivetrain coverage includes complete KM200 four-speed and KM201 five-speed manual-transaxle service, plus KM176 electronically controlled four-speed automatic-transaxle diagnosis, pressure and stall testing, internal disassembly, clutch-pack and valve-body repair, reassembly, and hydraulic-circuit information.
• Chassis and body sections address drive shafts and hubs, front and rear suspension, manual and power steering, hydraulic and cable clutches, front disc brakes, Bendix and Mando rear drum brakes, body dimensions, glass and door service, sunroof and passive-restraint components, and R-12 air-conditioning diagnosis and repair.
• Electrical and reference material supplies MPI and FBC circuit diagrams, connector views, body-style-specific wiring-harness layouts, troubleshooting charts, exploded assembly views, Hyundai special-tool numbers, component torque tables, capacities, wear limits, clearances, pressure-test data, and electrical test specifications.

Inside the Manual

The 20-section manual and its electrical-wiring appendix start with the information needed to identify the car before parts or procedures are selected. The General Information chapter decodes Excel VIN positions for body style, trim level, restraint type, engine code, model year, assembly plant, and serial number. It also shows the engine-number format, approved lifting points, general service precautions, and standard fastener torque classifications.

The maintenance section adds U.S. and Canadian normal- and severe-service schedules, lubricant and capacity tables, and recurring checks for valve clearance, ignition, idle, belts, fluids, brakes, steering, and HVAC.

The VIN table identifies both 1298 cc and 1468 cc engine codes. The detailed engine overhaul chapter itself specifies the 1468 cc OHC four-cylinder and separates MPI and FBC differences where the hardware or adjustment procedure changes. Coverage extends through engine mounting and complete engine/transaxle removal, timing-belt installation and tensioning, rocker shafts, camshaft, cylinder head, valves and springs, FBC jet valves, front case and oil pump, pistons and rods, crankshaft, flywheel, cylinder block, and oil-pressure switch service.

Fuel and emissions information is divided cleanly between the two systems. MPI coverage includes fault-code retrieval, Multi-Use Tester data checks, sensor and actuator testing, fuel-pressure diagnosis, injectors, throttle body, ISC servo, fuel tank and lines, and engine-control linkage. FBC coverage adds the FBC checker, throttle-opener, dashpot, TPS, electric-choke and fast-idle adjustment, fuel-pump testing, and carburetor removal, teardown, calibration, reassembly, and installation. Emissions chapters address PCV, evaporative controls, EGR, catalytic converters, secondary-air hardware, heated-air intake, and Federal, Canadian, and California arrangements.

Engine-electrical chapters cover MPI/FBC ignition, distributor service, coil and spark testing, alternator output and regulator diagnosis, alternator overhaul, battery checks, and starter, solenoid, armature, and overrunning-clutch inspection.

Drivetrain, Chassis, and Body Repair

The manual-transaxle chapter covers the KM200 four-speed and KM201 five-speed from external controls through internal teardown. It includes the fifth-speed synchronizer, input, intermediate, and output shafts, shift forks, differential, clutch housing, speedometer drive, and factory selection of snap rings and spacers for bearing end play, shaft preload, and differential adjustment.

The KM176 automatic-transaxle section includes stored fault codes and fail-safe functions, Multi-Use Tester checks, shift-pattern charts, oil-pressure tests, converter stall testing, control adjustments, and internal repair of the oil pump, front, rear, and end clutches, planetary set, transfer gearing, differential, valve body, kickdown servo, case, and hydraulic circuit. A key scope limit applies to the FBC-equipped KM171 three-speed: the manual directs the main overhaul procedure to the 1989 Excel Shop Manual, Pub. No. SEAS-880612, then supplies update information and the three-speed electronic lock-up circuit in the appendix.

Chassis chapters cover clutch bleeding and cylinder service, clutch-disc replacement, struts, lower arms, rear suspension and hubs, drive-shaft joints, hub and knuckle bearings, steering columns, manual and power steering gearboxes, pump testing and bleeding, brake hydraulics, booster checks, disc-caliper repair, both rear-drum designs, and parking-brake adjustment. Body and HVAC sections add body dimensions, paneling, bonded glass, doors, trunk lid and tailgate, trim, seats and restraints, sunroof repair, heater and ventilation work, and R-12 evacuation, charging, leak detection, pressure diagnosis, compressor, evaporator, condenser, blower, and accumulator service.

Wiring, Tools, and Factory Specifications

Named electrical references include MPI and FBC circuit diagrams, separate automatic- and manual-transaxle starting circuits, four-speed and three-speed electronic lock-up control diagrams, U.S. headlamp and Canadian daytime-running-light circuits, MPI and FBC air-conditioning diagrams, connector configurations, and floor-harness layouts for all three body styles. Tool tables identify equipment such as the 09391-33200 Multi-Use Tester, 09222-21300 jet-valve socket wrench, 09411-11000 clutch-disc guide, and automatic-transaxle oil-pressure gauge adapters.

The repair cautions are equally specific. Disconnecting the battery while the ignition is on or the engine is running can damage the ECU. Rapidly pumping the hydraulic-clutch pedal during bleeding can force the release-cylinder piston out of its bore, while holding the FBC jet-valve socket at an angle can bend the valve stem. Fuel-pressure, brake, lifting, electrical-isolation, and R-12 work should be carried out with the correct shop equipment and the exact procedure for the vehicle’s configuration.