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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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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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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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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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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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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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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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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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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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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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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%

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