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CONTENTS
Shop ManualVolume 1 & 2
HYUNDAl1 9 9 4
E l a n t r a
FOREWORD
This shop manual is intended for use by service techniciansof authorized Hyundai dealers to help them provide efficientand correct service and maintenance on Hyundai vehicles.
To ensure customer satisfaction with Hyundai products,proper service and maintenance by Hyundai technicians isessential. Consequently, it is important that service person-nel fully understand the contents of this manual, which shouldbe kept in a handy place for quick and easy reference.
All the contents of this manual, including photographs,drawings, and specifications, are the latest available at thetime of printing. As modifications affecting service occur,dealers will be provided technical service bulletins or supple-mentary volumes. This manual should be kept carefully up-to-date upon receipt of the new information.
Hyundai Motor Company reserves the right to make changesin design or to make additions to or improvements in itsproducts without imposing any obligations upon itself toinstall them on its products previously manufactured.
This book may not be reproduced or copied, as a whole or asa part, without the written permission of publisher.
MAY. 1993, Printed in Korea
NOTE : This PDF Manual contains the contents ofboth printed Volumes 1 & 2
TITLE
INTAKE & EXHAUST SYSTEM
ANTI-LOCK BRAKE SYSTEM
BODY (Interior and exterior)
BODY ELECTRICAL SYSTEM
AIR CONDITIONING SYSTEM
APPENDIX (Electrical Wiring System)
BRAKE SYSTEM
STEERING SYSTEM (Manual and Power)
SRS AIR-BAG
REAR SUSPENSION
FRONT SUSPENSION
DRIVE SHAFT AND FRONT AXLE
AUTOMATIC TRANSAXLE
MANUAL TRANSAXLE
CLUTCH
FUEL SYSTEM
EMISSION CONTROL SYSTEM
ENGINE ELECTRICAL SYSTEM
COOLING SYSTEM
ENGINE MECHANICAL
LUBRICATION AND MAINTENANCE
GENERAL INFORMATION
SECTION
10
20
25
27
28
29
31
41
43
45
49
54
55
56
56A
58
58A
60
90
97
WS
00
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The acronyms, terminology, abbreviations used in this manual have been changed tostandardize naming vehicle systems and components.
The followings are list of current terms and new (recommended) ones based on SAE J1930
RECOMMENDEDRECOMMENDED TERMS EXISTING ACRONYM/ABBREVIATION
ABS Control Module ABSCMAccelerator Pedal Accelerator APAir Cleaner Air Cleaner, ACI, Air Cleaner ACL
Housing, Thermac Air Cleaner
Air Cleaner Filter Air Cleaner Element, ACL FilterAir Filter
Air Conditioning A/CON, AC, ACC, Air Conditioner A/CBarometric Pressure BARO, Atmospheric Pressure BARO
Barometric Pressure Sensor BPS, Atmospheric Pressure BAR0 SensorSensor
Battery Positive Voltage B+, VSS, VCC, Battery Voltage B+Bypass Air BPA
Camshaft Position Sensor No.1 TDC Sensor CMP Sensor Canister Purge CANPCarburetor Carb CARBCharge Air Cooler Inter Cooler, After Cooler CACClosed Loop CL, CLS, EEC, CLClosed Throttle Position Closed Throttle CTPClutch Pedal Position Switch CES, Clutch Start Switch, CPP SwitchCrankshaft Position Sensor Crank Angle Sensor CKP SensorCruise Control Automatic Speed Control c cCruise Control Module Electronic Control Unit CCMData Link Connector Self-Test connector, DLC
Diagnosis Connector
Diagnostic Test Mode Modes DIMDiagnostic Trouble Code Self Test Codes, Fault Codes DTCDistributor Ignition DIS, EDIS, El, ESAC, HEI, TFI, DIElectronic Ignition DLI, Distributorless Ignition ElEngine Coolant Level ECL, Engine Coolant Level ECLEngine Control Module ECU, Electronic Control Unit ECMEngine Coolant Temperature Water Temperature ECTEngine Speed Crankshaft Speed, Revolutions RPM
per MinuteEvaporative Emission EECS EVAP
Evaporative Emission System EECS, Evaporative Emission EVAP SystemControl System
Exhaust Gas Recirculation EGRVC, EGR Diagnostic Valve EGRFan Control EDF, Engine Coolant Fan, FC
HEDFFlexible Fuel Alcohol Concentration, FF
Flexible FuelFourth Gear 4th Gear 4GRFuel Pump Fuel Pump FPGenerator Alternator, ALT GENGround Ground, GRD GNDHeated Oxygen Sensor HEGO, HOS, Oxygen Sensor HO2SIdle Speed Control ISC ISCIgnition Control Electronic Spark Timing, EST ICIgnition Control Module DIS Module, TFI Module ICM
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RECOMMENDEDRECOMMENDED TERMS EXISTING ACRONYM/ABBREVIATION
Intake Air Temperature MAT, ACT, IAT, VAT, TBT I ATKnock Sensor KS, Detonation Sensor, DS KSMalfunction Indicator Lamp Check Engine, Service Engine MIL
SoonManifold Absolute Pressure MAP MA-P
Manifold Vacuum Zone Switch Vacuum Switch MVZ SwitchMass Air Flow MAF, MFC, AFS, Air Flow Meter, MAF
AFC, Hot Wire Anemometer
Mixture Control MCS, M/C, FBC MCMultiport Fuel Injection MPI, D-Jetronic, DFI, EFI, ECFI, MFI
LH-Jetronic, PFI, MotronicOn-Board Diagnostic OBD, Self-Test OBDOpen Loop OL OLOxygen Sensor EGO, O2, EOS, EGS, OS, O2S
Lambda sensor, EGOS,Park/Neutral Position PNPPower Steering Pressure PSP PSPPower-train Control Module ECA, ECU4, EEC Processor, PCM
MCU, SBEC, SMECRandom Access Memory RAM, KAM RAMRead Only Memory ROM ROMRelay Module Integrated Relay Module RMScan Tool Diagnostic Tester, MUT, Multi ST
use Tester
Service Reminder Indicator SRISRS Control Module Air Bag Control Module, ESPS SRSCMStop Lamp Switch Brake Switch, Stop Switch SL SwitchSupercharger SC SCSupercharger Bypass SBS SCBThermal Vacuum Valve Thermal Vacuum Switch, TVV
Thermo ValveThird Gear 3th Gear 3GRThree Way Catalytic Converter TWC TWCThrottle Body Fuel Charging Station TBThrottle Position TP, Throttle Potentiometer TPThrottle Position Sensor TPS TP SensorTorque Converter Clutch TCC, CCO, LUS TCCTransaxle Control Module TCU, EATX TCMTransaxle Range PRNDL, SLP, Transmission TR
PositionTransaxle Range Switch Inhibitor Switch TR SwitchTurbocharger TC, Turbo TCVehicle Speed Sensor
PG, Distance Sensor VSSVoltage Regulator VR VRVolume Air Flow AFC, AFS, Air Flow Meter VAFWide Open Throttle Full, WOT WOT
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GENERAL
INFORMATION
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00-2 GENERAL INFORMATION
GENERAL INFORMATION
HOW TO USE THIS MANUAL
This manual is divided into 22 sections. This first page of each sectionis marked with a black tab at the edge of the page. You can quicklyfind 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. Thisinformation is current as of time of publication.
An INDEX is provided on the first page of each section to guide youto the item to be replaced.
TROUBLESHOOTING tables are included for each system to helpyou diagnose the system problem and find the cause. The repair foreach possible cause is referenced in the remedy column to quicklylead you to the solution.
DEFINITION OF TERMS
Standard Value
Indicates the value use as the standard for judging the quality of a partor assembly on inspection or the value to which the part or assemblyis corrected and adjusted. It is given by a tolerance.
Limit
Shows the standard for judging the quality of a part or assembly oninspection and means the maximum or minimum value within whichthe part or assembly must be kept functionally or in strength. It is avalue 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 thevehicle.
CAUTION
Information about an activity that could cause injury or dam-
age to the driver, occupants or repair personnel.
ABBREVIATIONS
MFI: Indicates Multiport Fuel Injection system.
DOHC: Indicates Double Overhead Camshaft Engine system
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GENERAL INFORMATION 00-3
VEHICLE IDENTIFICATION NUMBERLOCATION
The vehicle identification number (VIN) is stamped on the upper leftside of the crash pad.
VEHICLE IDENTIFICATION NUMBER
1.World manufacturers identifier codeKMH - Hyundai Motor Co., Korea
2. Drive line typeJ - ELANTRA
3. Body TypeF - 4 Door sedan
4. Body style & version1 - Standard2 - Deluxe3 - Super deluxe
5. Restraint type1 - Active system2 - Passive system
6. Engine typeR - 1596 ccM - 1836 cc
7. Check digitMathematically determined to validate frame numbers
8. Model yearP - 1993 R - 1994 S - 1995 T - 1996
9. Plant codeU - Ulsan plant
10. Serial number 000001 through 999999
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00-4 GENERAL INFORMATION
ENGINE IDENTIFICATION PLATE
The engine identification plate is stamped at the right front side on thetop edge of the cylinder block.
ENGINE IDENTIFICATION NUMBER
Engine identification number consists of 10 digits.
1.
2.
3.
4.
5.
6.
Engine fuelG - Gasoline
Engine range4 - In line 4 cycle 4 cylinder
Engine development orderA - Z
Engine capacityR - 1596 cc M - 1836 cc
Product yearP - 1993 R - 1994 S - 1995
Serial number000001 through 999999
T - 1996
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GENERAL INFORMATION 00-5
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before startingwork.
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 thevehicle.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 compart-ment is clear of tools and people.
PREPARATION OF TOOLS AND MEASURINGEQUIPMENT
Be sure that all necessary tools and measuring equipment areavailable 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 removingor disassembling is required before starting the job.
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00-6 GENERAL INFORMATION
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to bedisassembled, all parts should be disassembled in a way that will notaffect their performance or external appearance and be identified sothat reassembly can be performed efficiently.
1. Inspection of parts
Each part when removed should be carefully inspected forwear, deformation, damage, and other problems.
2. Arrangement of partsAll disassembled parts should be carefully arranged forreassembly.Be sure to separate or otherwise identify the parts to bereplaced from those that will be reused.
3. Cleaning parts for reuse
All parts to be reused should be carefully and thoroughlycleaned by the appropriate method.
REASSEMBLY
Standard values, such as torques and certain adjustments, must bestrictly observed in the reassembly of all parts.If removed, these parts should be replaced with new ones.1. Oil seals2. Gaskets3. O-rings4. Lock washers5. 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.
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GENERAL INFORMATION 00-7
ADJUSTMENTS
Use gauges and testers to correct adjustments to standard values.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-)terminal of the battery.
2. Never pull on the wiring when disconnecting connectors.3. Locking connectors will click when the connector is secure.4. Handle sensors and relays carefully. Be careful not to drop
them or hit them against other parts.
RUBBER PARTS AND TUBING
Always prevent gasoline or oil from touching rubber parts or tubing.
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00-8 GENERAL INFORMATION
PRECAUTIONS FOR A CATALYTIC CONVERTER
CAUTION:
If large amounts of unburned gasoline flow into the converter,
it may overheat and create a fire hazard. To prevent this,
observe the following precautions and explain them to your
customer.
1. Use unleaded gasoline only.2. Avoid prolonged idling.
3.
4.
5.
6.7.
Avoid running the engine at fast idle speed for more than 10minutes and at idle speed for more than 20 minutes.
Avoid spark jump test.Spark jump only when absolutely necessary. Perform this testas rapidly as possible and, while testing, never race the engine.
Avoid prolonged engine compression measurement. Enginecompression tests must be made as rapidly as possible.Do not run engine when fuel tank is nearly empty. This maycause the engine to misfire and create an extra load on theconverter.
Avoid coasting with ignition turned off and prolonged braking.Do not dispose of used catalyst along with parts contaminatedwith gasoline or oil.
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GENERAL INFORMATION 00-9
SRS SYSTEM COMPONENTS INFORMATION
CUSTOMER CAUTIONS
Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy duringservicing, possibly leading to a serious accident.Further, if a mistake is made in servicing the airbag system, it is possible the airbag may fail to operate when required.Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the
following items carefully, then follow the correct procedure described in the repair manual.
1. Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the LOCK positionand the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-uppower source so that if work is started within 30 seconds of disconnecting the negative (-) terminal cable of the battery,the airbag may be deployed.)When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems willbe cancelled. So before starting work, make a record of the contents memorized by the audio memory system. Thenwhen work is finished, reset the audio system as before and adjust the clock.
2.
3.
4.
Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most importantsource of information when troubleshooting.When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery.
Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
Never attempt to disassemble and repair the airbag modules, SRSCM, Clock spring and Air-bag wiring harnessin order to reuse it.
5. If the SRSCM or air-bag module have been dropped, or if there are cracks, dents or other defects in the case, bracketor connector, replace them with new ones.
6. After work on the airbag system is completed, perform the SRS SRI check.
SRS SERVICE REMINDER INDICATOR CHECK
When the ignition key is turned to ON position, the SRS servicereminder indicator will illuminate for 6 seconds and then turn off.This means that the system is functioning properly.
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00-10 GENERAL INFORMATION
AIR-BAG MODULE (with AIRBAG)
1.
2.
3.
4.
When removing the air-bag module or handling a new air-bagmodule, it should be placed with the pad top surface facing up.In this case, the twin-lock type connector lock lever should be inthe lock state and care should be taken to place it so theconnector will not be damaged. And do not store a steering
wheel pad on top of another one. (Storing the pad with its metallicsurface up may lead to a serious accident if the airbag inflatesfor some reason.)
Never measure the resistance of the airbag squib.(This may cause the airbag to deploy, which is very danger-ous.)
Store the air-bag module where the ambient temperature re-mains below 93C (200
oF), without high humidity and away from
electrical noise.
When using electric welding, first disconnect the airbag connec-
tor (red color and 2 pins) under the steering column near theMULTI-FUNCTION SWITCH connector before starting work.
SRSCM(SRS Control Module)
Install the SRSCM with the arrow on the SRSCM facing toward thefront of the vehicle.
CLOCK SPRING (in MULTI-FUNCTION SWITCH)
The steering wheel must be fitted correctly to the steering columnwith the clock spring at the neutral position, otherwise cable discon-nection and other troubles may result. Refer to page 56A-13 of thismanual concerning correct steering wheel installation.
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GENERAL INFORMATION 00-11
JACK POINT
When using a single-post lift When using a free wheel type auto lift
When using double-post lift
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00-12 GENERAL INFORMATION
JACK POINT
When using a floor jack
When using the jack
provided with the
vehicle (for reference)
NOTE
Do not support car at locations other than
the specified support points.
This will cause damage etc. to the body.
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GENERAL INFORMATION 00-13
STANDARD PARTS TIGHTENING TORQUE TABLE
NOTES
1. The torques shown in the table are standard values applicable to tightening performed under the following
conditions:
1) Nuts and bolts are made of steel bar, and galvanized.
2) Galvanized plain steel washers are inserted.
3) All nuts, bolts, and plain washers are dry.
2. The torques shown in the table are not applicable:
1) Spring washers, toothed washers and the like are inserted.
2) If plastic parts are fastened.
3) If self-tapping screws or self-locking nuts are used.
4) If threads and surface are coated with oil.
3. It should be standard practice to reduce the torques given in the table to the percentage indicated below:
1) If spring washers are used. 85%
2) If threads and bearing surfaces are stained with oil 85%
Recommended