Hyundai Coupes/Sedans 1986-1993 Repair Guide

Adjustments

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PEDAL HEIGHT AND FREE-PLAY



1986-89 Excel

See Figures 1, 2 and 3



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Fig. Fig. 1: Clutch pedal height adjustment-1986-89 Excel



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Fig. Fig. 2: Clutch cable adjustment-1986-89 Excel



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Fig. Fig. 3: Clutch pedal adjustments: A is the pedal height; the small measurement is the pedal free-play; B is the pedal stroke, which is found by subtracting the free-play from the pedal height

  1. Measure the distance between the floor and the top of the clutch pedal (dimension "A"). This is clutch pedal height. The distance should be 185-193mm. If the clutch pedal height is not as specified, first disconnect the clutch switch connector. Then, loosen the clutch switch locknut and move the pedal stop bolt as necessary until the pedal height is as specified. After the adjustment is complete, tighten the locknut and connect the clutch switch connector.
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  3. Gently pull the cable out from the firewall and measure the distance between the clutch cable adjusting nut and the cable retainer. Turn the adjusting wheel on the cable until the play between the wheel and the cable retainer is 0.20-0.25 as checked with a feeler gauge. Release the cable and make sure that the end of the tension spring engages the adjusting wheel, so that it won't turn.
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  5. Check the clutch pedal free-play. Free-play is the distance that the pedal will travel before any resistance is felt. Free-play should be 20-30mm. If not, adjust it by means of the adjusting wheel on the cable as described above.
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  7. Check the clutch pedal stroke. It should be 145mm. If the stroke is greater than the specified value, suspect that the clutch is worn. Repair or replace the clutch as necessary.
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1990-93 Excel with Cable Clutch

See Figures 4, 5 and 6



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Fig. Fig. 4: Clutch pedal height-1990-93 Excel with cable clutch



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Fig. Fig. 5: Clutch free-play adjustment on 1990-93 Excel with cable clutch



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Fig. Fig. 6: Clutch pedal-to-floor board clearance-1990-93 Excel with cable clutch

  1. Measure the distance between the floor and the top of the clutch pedal (dimension "A"). The distance should be 178mm.
  2.  

Clutch pedal height cannot be adjusted on the 1990 Excel with cable clutch. If the clutch pedal height is not within specs, check the pedal stopper of the pedal support member for deterioration.

  1. Check the clutch pedal free-play. Free-play is the distance that the pedal will travel before any resistance is felt. Free-play should be 20-30mm. If not, adjust it by means of the adjusting wheel on the cable. If the free-play is not as specified, gently pull the cable out from the firewall. Next, turn the adjusting wheel on the cable until the play between the wheel and the cable retainer is 0.20-0.25mm as checked with a feeler gauge. Release the cable and make sure that the end of the tension spring engages the adjusting wheel, so that it won't turn.
  2.  
  3. After making the free-play adjustment, depress the clutch pedal several times and measure the clutch pedal-to-floor board clearance. It should be 33mm. If the clearance is less than specified, the clutch may be worn. Repair or replace the clutch as necessary.
  4.  

1990-93 Excel with Hydraulic Clutch

See Figures 7, 8 and 9

  1. Measure the distance between the floor and the top of the clutch pedal. This is clutch pedal height. The distance should be 178mm. If the clutch pedal height is not as specified, make the following adjustments depending on whether the pedal height is greater or less than the specified value:
    1. If the pedal height is greater than the specified value, loosen the clutch switch locknut and move the pedal stop bolt as necessary until the pedal height is as specified. Tighten the locknut after the adjustment is complete.
    2.  
    3. If the pedal height is less than the specified value, first loosen pedal stop bolt locknut. Then, adjust the pedal height by turning the clutch release cylinder push rod. After the adjustment turn the adjusting bolt until it contacts the pedal stop and tighten the locknut.
    4.  

  2.  
  3. Check the clutch pedal free-play and the distance between the clutch pedal and the toe board with the clutch disengaged. Free-play is the distance that the pedal will travel before any resistance is felt. Free-play should be 613mm. Clutch pedal-to-toe board distance should be 40mm. If the free-play or pedal-to-toe board distances are not as specified value, this may be a result of air in the hydraulic system or a bad master cylinder or clutch. In this case bleed the hydraulic system as described in this section or disassemble and inspect the master cylinder or clutch.
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Fig. Fig. 7: Clutch pedal height adjustment bolt-1990-93 Excel, Elantra, Scoupe and Sonata



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Fig. Fig. 8: Clutch release pushrod adjustment-1990-93 Excel, Elantra, Scoupe and Sonata



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Fig. Fig. 9: Clevis pin adjustment-Elantra, Scoupe and Sonata

Elantra

Measure the pedal height from the top of the pedal pad to the closest point on the floor. The distance should be 7.0 in. (182mm). If incorrect and the vehicle is not equipped with cruise control, adjust the height by loosening the locknut on the pedal stop bolt and adjusting the bolt to the proper length. Secure the adjustment by tightening the locknut. If the vehicle is equipped with cruise control, adjust as follows:

  1. Disconnect the clutch switch wiring.
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  3. Loosen the locknut and turn the switch, as required.
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  5. Tighten the locknut.
  6.  

Scoupe

Measure the pedal height from the top of the pedal pad to the closest point on the floor. The distance should be 7 in. (178mm). Loosen the clutch switch locknut and move the pedal stop bolt. Then, tighten the locknut.

Sonata
  1. Measure the distance between the floor and the top of the clutch pedal. This is clutch pedal height. The distance should be 173-178mm. If the clutch pedal height is not within specs, the clevis pin play must be adjusted as described as follows:
    1. To check clevis pin play, lightly depress the clutch pedal and visually approximate the amount of pedal travel until resistance is felt. Clevis pin play should be 1.0-3.0mm.
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    3. To adjust the clevis pin play, disconnect the clutch switch connector (cruise control only), loosen the master cylinder push rod locknut and rotate the pushrod until the clevis pin play is within the 1.0-3.0mm, then tighten the pushrod locknut and connect the clutch switch connector. Lubricate the clevis pin with a small amount of wheel bearing or multi-purpose grease.
    4.  

  2.  

When adjusting the clevis pin play, do not push the push rod into the master cylinder or damage will be result.

Check the clutch pedal free-play and the distance between the clutch pedal and the firewall with the clutch disengaged. To check clutch pedal free-play, lightly depress the clutch pedal and visually approximate the amount of pedal travel until resistance is felt. Clutch pedal free-play should be 5.0-12.0mm. The clutch pedal-to-firewall distance should be 56mm. If the free-play or clevis pin play are not within the specified values, adjust the clevis pin play as described above. If, after the clevis pin adjustment, the free-play is still not within specs, this may be a result of air in the hydraulic system or a bad master cylinder or clutch. In this case bleed the hydraulic system as described in this section or disassemble and inspect the master cylinder or clutch.

 
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