1991 Hyundai Excel Service and Repair Manual

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Factory-Grade Data

1991 Hyundai Excel service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • GL Sedan 4-Door
  • L Hatchback 2-Door
  • GS Hatchback 2-Door
  • Base Sedan 4-Door
  • GLS Sedan 4-Door
  • Base Hatchback 2-Door

Engines covered

  • 1.5L 1468CC 90Cu. In. l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Hyundai Excel Recalls & Complaints

NHTSA #93V19200023/11/1993Component: FUEL SYSTEM, GASOLINE

THE VEHICLES FAILED THE LATERAL MOVING BARRIER IMPACT TEST REQUIREMENTS OF FMVSS 301, "FUEL SYSTEM INTEGRITY." THE FUEL LEAKAGE FROM THE GAS TANK EXCEEDED THE MAXIMUM ALLOWABLE AMOUNT OF SPILLAGE.

Consequence

IN THE EVENT OF AN ACCIDENT, THE FUEL SPILLAGE CAN RESULTIN A FIRE IF EXPOSED TO A SOURCE OF IGNITIO

Remedy

HYUNDAI HAS DEVELOPED AN APPROPRIATE COUNTERMEASURE THAT WILL COMPLY WITH ALL REQUIREMENTS OF FMVSS

TSB #10230904

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside th

TSB #10189989

This bulletin provides the inspection procedure and repair guidelines for certain vehicles listed below.

TSB #10183963

This bulletin describes the procedure to inspect and identify fluid which may appear around the brake caliper area.

TSB #10183960

This bulletin provides tire vibration service procedures, including how to optimize vehicle vibration performance. For all wheel/tire balance claims, the Tire Balance Data Sheet must be fully completed including imbalance and Road Force Var

TSB #10174808

This bulletin provides information on identifying dealer stock vehicles with either: A Battery SOC alert - low Battery State of Charge (SOC) at or below 50%. A 30 Day alert - vehicle has not started and reported an SOC in 30 days.

TSB #51905

SHIFT CONDITION CAUSED BY SHORT CIRCUIT IN INHIBITOR SWITCH. *TW

19970806Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDERCrash reported

UPON DEPRESSING THE BRAKE PEDAL THE PEDAL WENT TO THE FLOORBOARD/COMPLETE LOSS OF BRAKING ABILITY, RESULTING IN AN ACCIDENT. CONSUMER HAS NOTICED THE PROBLEM, THE MASTER CYLINDER WAS REPLACED DUE TO A

19960611Component: ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASHFire reported

THE VEHICLE CAUGHT ON FIRE WHILE PARKED, FIRE UNDER THE DASH. FIRE DEPT. SAYS IT WAS AN ELECTRICAL FIRE. PLEASE DESCRIBE. *AK

19950308Component: ELECTRICAL SYSTEM:IGNITION:MODULEFire reported

ELECTRICAL SYSTEM FAILURE, BRAIN CELL MELTED DOWN, FUSES BLOWN. TT

19950308Component: ELECTRICAL SYSTEM:IGNITION:SWITCHFire reported

ELECTRICAL SYSTEM FAILURE, BRAIN CELL MELTED DOWN, FUSES BLOWN. TT

19950301Component: ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOODFire reported

ENGINE ELECTRICAL FIRE IN ENGINE COMPARTMENT; WHILE DRIVING, STALLED, BURST INTO FLAMES; VEHICLE TOTALLED. TT

Showing the 5 most serious of 44 complaints filed with NHTSA.

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