Summary
The Hyundai Excel has 9 recalls spanning the 1986-1990 production run, with the most serious being a fuel tank vulnerability on 1990 models where a side impact can cause the rear spring seat to puncture the tank, spilling fuel that can ignite if it contacts an ignition source.
The 1990 model year also has a second fuel system concern: the gas tank can exceed allowable fuel spillage limits in a side impact test, again creating a fire risk. Separately on 1990 models, the front hub lock washer can crack, leading to wheel bearing play, bearing damage, and possible loss of vehicle control through wheel failure. On 1988 models sold in Canada, a reed valve inside the air control valve can corrode and fail, allowing hot exhaust gases to flow backward into a plastic air filter housing and melt it, which can start an engine compartment fire. Going back to the 1986 model year, a steering column U-joint bolt on five-door models can be under-torqued and loosen over time, resulting in total loss of steering without warning. The 1986 model also has a fuel return hose clip that can be incorrectly installed, allowing the hose to wear against ignition components and eventually leak fuel into the engine compartment. On the brake side, 1986 vehicles may be missing or have a misinstalled cotter pin that retains the brake clevis pin; if the pin works free, the brakes can fail without warning. There is also a separate 1986 braking concern where front brake fade can occur under certain conditions, reducing stopping ability. These earlier 1986 vehicles fall within a specific range of vehicle identification numbers for the fuel return hose issue, but the brake and steering defects cover the 1986 model year broadly.
