Hyundai Coupes/Sedans 1986-1993 Repair Guide

Adjustments

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The disc brakes require no adjustment. The rear drum and disc brakes are automatically adjusted by pulling and returning the parking brake lever, then stepping on the brake pedal.

BRAKE PEDAL HEIGHT ADJUSTMENT



See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Checking the brake pedal height-Excel



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Fig. Fig. 2: Checking the brake pedal height-Sonata



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Fig. Fig. 3: When adjusting the brake pedal height on 1986-89 Excel, set the stoplight switch clearance as shown

  1. Measure the distance from the top of the pedal pad to the firewall. The distance should be 183--188mm on 1986-89 Excel and 4-cylinder Sonata. On 1990-93 Excel and Scoupe it should be 165mm. On V6 Sonata and Elantra, it should be 178mm. If not, continue.
  2.  



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Fig. Fig. 4: Brake pedal height adjustment-Elantra and Sonata

  1. Back off the brake light switch, located above the pedal arm, until it no longer touches the pedal arm.
  2.  



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Fig. Fig. 5: Checking the brake pedal free-play-Excel and Scoupe

  1. Loosen the locknut on the pedal pushrod and turn the pushrod with a pliers until the proper pedal height is reached. Tighten the locknut.
  2.  



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Fig. Fig. 6: Checking the brake pedal free-play-Elantra and Sonata

  1. Adjust the brake light switch until the distance, B, between the outer case of the switch and the pedal arm is 0.5-l.0mm on all models. Tighten the locknut.
  2.  

BRAKE PEDAL FREE-PLAY ADJUSTMENT



See Figures 5 and 6

  1. With the engine shut off, depress the brake pedal two or three times to release any vacuum pressure.
  2.  
  3. Depress the brake pedal by hand until resistance is felt. This motion before resistance is the pedal free-play. Proper free-play should be 10-15mm on Excel and 2.5-7.5mm on 4-cylinder Sonata and 5-10mm on V6 Sonata.
  4.  
  5. Free-play is adjusted at the stop light switch. Loosen the locknut and adjust the switch until the free-play is within specification.
  6.  

Stop Light Switch

The switch is located on a bracket above the brake pedal arm.

ADJUSTMENT



  1. Disconnect the negative battery cable.
  2.  
  3. The stop light switch works off the brake pedal lever. To adjust, disconnect the electrical connection and loosen the switch locknut.
  4.  
  5. Screw the switch inward until it contacts the stop on the brake pedal arm. Back out the switch 1 / 2 -1 full turn. The distance between the end of the switch plunger bore and the brake lever stop should be 0.020-0.040 in. (0.5-1.0mm).
  6.  
  7. Tighten the locknut and connect the wires.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Make sure the stop lights come on when the brake pedal is depressed and go out when the pedal is released. Also, make sure the cruise control system operates properly.
  12.  

REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable.
  2.  
  3. Locate the stop light switch above the brake pedal lever.
  4.  
  5. Disconnect the wiring connectors from the switch and unscrew the switch.
  6.  
  7. Thread the stop light switch into the switch holding bracket. Adjust the switch to achieve correct operation.
  8.  
  9. Connect the stop light wires.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Make sure the stop lights come on when the brake pedal is depressed and go out when the pedal is released. Also, make sure the cruise control system operates properly.
  14.  

 
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