Cold Start Stalling Repair Kit\1.5L W/At Excel SCOUP (92-36-002)

WARNING: This page is about the Excel Base, 2D Hatchback, Automatic, which is a different variant/trim than selected.

Publication date: 1992-06-01
Reference number: 92-36-002

INTERMITTENT "NO START" FIELD FIX\EXCEL & SCOUPE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 92-36-001, 93-36-002, Date of Issue: May, 1992 & April, 1993

HYUNDAI:	1991-92 Excel, Scoupe
GROUP:	Engine Electrical

DESCRIPTION

INTERMITTENT "NO START" FIELD FIX

SERVICE INFORMATION

You may encounter customer complaints regarding intermittent "no starts". The customer typically states that the car will intermittently not crank; just a "click" is heard when the ignition key is turned to the start position. After turning the key off and waiting a period of time, the vehicle will then start normally.

EFFECTIVE PRODUCTION DATES

Excel X2: From the beginning of production through September 16,1991

Scoupe: From the beginning of production through November 30, 1991

PARTS INFORMATION

Part Description	Part Number
No Start Repair Kit	91401-24Q00

PROCEDURES

This concern can be remedied by using the repair kit as follows:

Fig 1: Engine Compartment

Record the customer's preset radio stations.
Disconnect the battery cables.
Remove the battery from the vehicle.
Remove the 10mm mounting bolts for the air duct and the G01 ground cable. Refer to Fig 1 , items A and B, and Fig 2 .

Fig 2: Air Duct Mounting Bolt/G01 Ground Cable Locations
Install the relay of the repair kit to the front RH fender panel with the air duct. See Fig 3 and Fig 4 .
Install the No. 4 ring connector (0.85BLK) of the repair kit to the G01 ground position along with the battery ground wire harness. See Fig 3 and Fig 4 .

Fig 3: Intermittent No Start Repair Kit

Fig 4: Repair Kit Relay/No. 4 Ring Connector Installation
Remove the 10mm mounting bolt for the 8.0 WHT wire in the fusible link box. Refer to Fig 1 , Item C and Fig 5 .

Fig 5: 8.0 WHT Wire Mounting Bolt Location
Install the No. 5 ring connector (2.0 RED/YEL) of the repair kit to the fusible link box along with the 8.0 WHT wire. See Fig 3 and Fig 6 .

Fig 6: Repair Kit No. 6 Ring Connector Installation
Disconnect the connector for the starter motor solenoid (C31 for Excel, C18 for Scoupe). Refer to Fig 1 , Items D and E, and Fig 7 .

Fig 7: Starter Motor Solenoid Connector Location
Connect the No. 2 round connector (0.85 BLK/YEL) of the repair kit to the existing connector for the starter motor solenoid (+). See Fig 3 and Fig 8 .

Fig 8: Connecting Repair Kit No. 2 Round Connector
Connect the No. 3 round connector (2.0 BLK/WHT) of the repair kit to the existing connector for the starter motor solenoid (-). See Fig 3 and Fig 9 .

Fig 9: Connecting Repair Kit No. 3 Round Connector
Using the straps included in the kit, secure the repair kit harness to the existing harness. See Fig 10 .

Fig 10: Securing Repair Kit Harness
Reinstall the battery and connect the battery cables.
Test drive the vehicle and confirm operation of the starter motor.
Reset the vehicle clock and radio stations.