Table Of Contents - Hyundai Tiburon 2003 Workshop Manual

Table of Contents

Vehicle Identification Number1
Identification Number Locations/Decription1
Engine Identification Number2
Transmission Identification Number3
Automatic3
Warning/Caution Label Locations4
Emission Control Label7
Lift And Support Point8
Towing9
Tightening Torque Table Of Standard Parts10
Recommended Lubricants11
Lubricants Capacities11
Selection Of Engine Oil12
General Service Information12
Special Tools12
Recommended Sae Viscosity Grades12
Removal Of Parts13
Disassembly13
Electrical System14
Rubber Parts And Tubes15
Measuring Body Dimensions15
Projected Dimensions15
Measuring Actual Dimensions15
Checking Cables And Wires16
Check Fuses16
Servicing The Electrical System16
Precautions For Catalytic Converter19
The Micro 570 Analyzer21
Keypad21
Battery Test Procedure21
Battery Test Results23
Starter Test Procedure23
Charging System Test Procedure24
Starter Test Results24
Charging System Test Results26
Troubleshooting27
Specification29
Auto Cruise Control System30
Tightening Torque30
On-Vehicle Inspection32
Inspect Spark Test32
Inspect Spark Plug And Spark Plug Cable32
Inspect Ignition Coil34
Circuit Diagram For Charging System36
Check Battery Voltage39
Check Battery Terminals, Fusible Link And Fuses39
Inspect Drive Belt39
Visually Check Generator Wiring And Listen For Abnormal Noises40
Check Discharge Warning Light Circuit40
Inspect Charging System40
Components45
Alternator Belt Inspection And Adjustment48
Battery Diagnostic Test52
Circuit Diagram For Starting System55
Start Test57
Check The Starter Engagement57
Starter Solenoid Test58
Free Running Test58
Circuit Diagram For Cruise Control System63
Functions Of Individual Switches64
Auto Cancellation64
Components Location65
Brake Switch Test67
Cruise Control Switch Test67
Actuator Cable Adjustment68
Change Engine Oil76
Replacement Oil Filter77
Radiator Cap Pressure Test78
Specific Gravity Test78
Checking Compression Pressure79
Tightening Cylinder Head Bolts80
Adjusting Valve Clearance80
Adjusting Drive Belt And Tensioner80
How To Adjust The Tension Of The Timing Belt91
Oil Seal (Camshaft Front)95
Hla (Hydraulic Lash Adjuster)95
Timing Chain96
Valve Guides102
Valve103
Valve Spring104
Replacing Valve Guide104
Replacing Valve Seat Ring105
Connecting Rod Cap115
Disassembly And Reassembly Of The Piston Pin115
Pistons And Piston Pins116
Piston Rings116
Connecting Rods117
Main Bearings And Connecting Rod Bearings122
Measuring Oil Clearance122
Plastic Gauge Method123
Oil Seal123
Main Bearing123
Cylinder Block128
Boring Cylinder129
Engine Mounting132
Transaxle Mounting132
Front Roll Stopper132
Rear Roll Stopper133
Cooling System134
Inlet Control134
Flow Chart134
Cooling System Components135
Coolant Temperature Sensor Replacement145
Oil Pump148
Relief Plunger And Spring149
Oil Filter Bracket149
Oil Pressure Switch149
Air Cleaner Components153
Air Cleaner Removal154
Air Cleaner Installation154
Air Cleaner Inspection154
Intake Manifold Components156
Intake Manifold Removal157
Intake Manifold Installation159
Intake Manifold Inspection159
Surge Tank And Intake Manifold159
Exhaust Manifold Components161
Exhaust Manifold Removal/Installation162
Exhaust Manifold Inspection162
Muffler Components164
Muffler Removal/Installation165
Muffler Inspection165
Front Exhaust Pipe (Including Catalytic Converter)165
Emission Control System Schematic Drawing166
Vacuum Hoses Layout167
Emission Control System Components168
Emission Control System Troubleshooting169
Emission Control System Specifications170
Crankcase Emission Control System Components171
Positive Crankcase Ventilation (Pcv) Valve Operation172
Positive Crankcase Ventilation (Pcv) Valve Removal/Installation173
Positive Crankcase Ventilation (Pcv) Valve Inspection173
Evaporative Emission Control System Components174
Evaporative Emission Control System Description175
Evaporative Emission Control System Inspection176
Check Of Canister Close Valve Operating176
Air Filter177
Purge Control Solenoid Valve (Pcsv) Inspection178
Evap Canister Purge Solenoid Valve178
Vacuum Hose179
Fuel Tank Pressure Sensor (Ftps) Inspection181
Fuel Filler Cap Operation182
Fuel System Special Tools183
Multiport Fuel Injection (Mfi) General Information184
Fuel Injection Control184
Idle Speed Control184
Ignition Timing Control184
Service Points In Inspecting A Blown Fuse185
Inspecting The Mfi System185
On-Board Diagnostics185
Fuel System Troubleshooting188
Scan Tool Communication With Pcm Is Not Possible191
Engine Will Not Start191
Difficult To Start (Engine Cranks)191
Rough Idle Or Engine Stalls193
Engine Hesitates Or Accelerates Poorly195
Fuel System General Specifications198
Fuel System Service Standard198
Fuel System Tightening Torque199
Fuel System Sealant199
Inspection Chart For Diagnostic Trouble Codes200
Trouble Area Related To Dtc202
Major Sensor Reference Wave-Forms213
Location Of Mfi Components214
Suspension System Special Tools217
Suspension System Troubleshooting219
Wheel And Tire Diagnosis219
Suspension System Specifications221
Suspension System Service Standard222
Suspension System Tightening Torque223
Suspension System Lubricants223
Suspension System Components224
Front Strut Assembly Removal/Installation225
Front Strut Assembly Disassembly226
Front Strut Assembly Inspection226
Front Strut Assembly Disposal227
Front Strut Assembly Reassembly227
Front Lower Arm Components229
Front Lower Arm Removal/Replacement230
Ball Joint And Dust Cover230
Lower Arm Bushing231
Front Lower Arm Installation232
Front Lower Arm Inspection232
Front Stabilizer Bar Components234
Front Stabilizer Bar Removal/Installation235
Front Stabilizer Bar Inspection236
Rear Strut Assembly Components237
Rear Strut Assembly Removal/Disassembly238
Rear Strut Assembly Inspection239
Rear Strut Assembly Reassembly239
Rear Suspension Arm Components241
Rear Suspension Arm Removal/Installation242
Rear Suspension Arm Inspection243
Trailing Arm Removal/Replacement244
Trailing Arm Bushing244
Rear Suspension Arm Bushing245
Rear Stabilizer Bar Removal/Installation246
Rear Stabilizer Bar Inspection247
Tires/Wheels Description248
Front Wheel Alignment249
Rear Wheel Alignment250
Tire Wear250
Wheel Rotation252
Checking For Pull And Wander252
Wheel Runout253
Tightening Wheel Nut253
Driveshaft And Axle Special Tools256
Driveshaft And Axle Troubleshooting258
Driveshaft And Axle Specifications259
Driveshaft And Axle Tightening Torque259
Driveshaft And Axle Lubricants260
Front Driveshaft Components261
Front Driveshaft Removal264
Front Driveshaft Installation265
Front Driveshaft Inspection266
Front Driveshaft Disassembly267
Front Driveshaft Reassembly269
Center Bearing And Inner Shaft Components (2.7L)272
Center Bearing And Inner Shaft Disassembly273
Center Bearing And Inner Shaft Reassembly273
Front Hub / Axle Components275
Front Hub / Axle Removal/Installation276
Front Hub / Axle Disassembly277
Front Hub / Axle Inspection278
Front Hub / Axle Reassembly278
Rear Hub / Carrier Components281
Rear Hub / Carrier Removal/Installation282
Rear Hub / Carrier Inspection283
Brake System Precaution284
Brake System Special Tools285
Brake System Component Locating Index286
Brake System Troubleshooting287
Brake System Operation And Leakage Check288
Brake Pedal And Brake Switch Adjustment289
Pedal Height289
Brake Switch Clearance289
Pedal Free Play289
Parking Brake Check And Adjustment290
Brake System Bleeding291
Front/Rear Disc Brake292
Brake System Specifications293
Brake System Service Standard294
Brake System Tightening Torque294
Brake Booster Components295
Brake Booster Removal/Installation296
Master Cylinder Component298
Master Cylinder Removal/Installation299
Master Cylinder Disassembly299
Master Cylinder Inspection300
Master Cylinder Reassembly300
Proportioning Valve Removal/Installation303
Proportioning Valve Inspection303
Brake Line Components Location304
Brake Line Inspection305
Brake Line Replacement305
Brake Pedal Components307
Brake Pedal Removal/Installation308
Brake Pedal Inspection308
Front Disc Brake Components310
Front Disc Brake Replacement311
Brake Pad Removal/Installation311
Brake Pad Inspection311
Front Disc Brake Removal/Installation313
Front Disc Brake Disassembly313
Front Disc Brake Inspection314
Front Disc Brake Reassembly315
Rear Disc Brake General Information317
Rear Disc Brake Components318
Rear Disc Brake Replacement320
Rear Disc Brake Inspection322
Rear Disc Brake Thickness And Parallelism322
Parking Brake Assembly Components324
Parking Brake Assembly Removal325
Abs(Anti-Lock Brake System) Hydraulic System Diagram326
Abs(Anti-Lock Brake System) Circuit Diagram326
Abs(Anti-Lock Brake System) Description329
Abs(Anti-Lock Brake System) Operation329
Abs(Anti-Lock Brake System) Warning Lamp Control329
Abs(Anti-Lock Brake System) Diagnostic Trouble Code (Dtc)330
Abs(Anti-Lock Brake System) Self-Diagnosis330
How To Troubleshoot Abs Dtc330
Hi-Scan (Pro) Check330
Abs(Anti-Lock Brake System) System Function331
Traction Control System (Tcs) Operation332
Traction Control System (Tcs) Function332
Full Traction Control System (Ftcs)333
Brake Traction Control System (Btcs)333
Ebd (Electronic Brake-Force Distribution) Operation333
Comparison Between Proportioning Valve And Ebd334
Abs(Anti-Lock Brake System) Components335
Abs(Anti-Lock Brake System) Troubleshooting336
Abs(Anti-Lock Brake System) Check Sheet336
Abs(Anti-Lock Brake System) Diagnostic Trouble Code Chart338
Failsafe Specification338
The Management Of Failure Detection338
Inspection Procedure For Diagnostic Trouble Codes346
Bleeding Of Brake System360
Hecu Block Diagram363
Hecu Circuit Diagram364
Inspection Of Hecu Terminals365
Abs Control Module Components367
Abs Control Module Removal369
Abs Control Module Installation370
Abs Control Module Inspection370
Wheel Speed Sensor Output Voltage Check370
Front Wheel Speed Sensor Components372
Front Wheel Speed Sensor Removal373
Rear Wheel Speed Sensor373
Manual Transaxle System Special Tools (6-Speed M/T)375
Manual Transaxle System Troubleshooting (M/T)376
Manual Transaxle System Specifications (M/T)377
Manual Transaxle System Service Standard (6-Speed M/T)377
Manual Transaxle System Tightening Torque (6-Speed M/T)377
Manual Transaxle System Removal378
Manual Transaxle System Installation387
Manual Transaxle System Service Adjustment Procedures387
Transaxle Gear Oil Level Inspection /Replacement387
Drive Shaft Oil Seal Replacement387
Manual Transaxle Shift Control Components388
Manual Transaxle Shift Control Removal390
Manual Transaxle Shift Control Installation392
Manual Transaxle Shift Control Inspection392
Automatic Transaxle Shift Control Special Tools393
Automatic Transaxle Shift Control Specifications394
Automatic Transaxle System Tcm Circuit Diagram395
Automatic Transaxle System Hydraulic Circuit Park & Neutral401
Automatic Transaxle System Troubleshooting407
Automatic Transaxle System Diagnosis Function407
Automatic Transaxle System Road Test408
Automatic Transaxle System Inspection Chart For Diagnosis Codes411
Automatic Transaxle System Inspection Chart For Trouble Symptoms414
Automatic Transaxle System Elements In Use In Each Gear416
Automatic Transaxle System Operating Elements And Their Function416
Automatic Transaxle System Inspection Process For Trouble Symptoms418
Automatic Transaxle System Basic Inspection Adjustment426
Automatic Transaxle System Fluid Check426
Automatic Transaxle Fluid426
Transaxle Range Switch Continuity Check427
Transaxle Range Switch And Control Cable Adjustment427
A/T Control Component Check428
Vehicle Speed Sensor Check429
A/T Control Relay Check429
Solenoid Valve Check429
Brake Reaction Plate End Play Adjustment436
Second Brake End Play Adjustment436
Low-Reverse Brake End Play Adjustment436
Underdrive Sun Gear End Play Adjustment437
Differential Case Preload Adjustment438
Automatic Transaxle Components439
Automatic Transaxle Removal440
Automatic Transaxle Installation448
Transaxle Shift Control Components449
Transaxle Shift Control Removal450
Procedure To Install The Lock Cam452
Procedure For Adjusting Shift Lock And Key Lock Cable453
Procedure For Checking The Shift Lock454
Clutch System Special Tools455
Clutch System Troubleshooting456
Clutch System Specifications458
Clutch System Service Standard458
Clutch System Tightening Torque458
Clutch System Lubricants458
Clutch Cover And Dinode Components460
Clutch Cover And Dinode Removal/Installation461
Clutch Cover Assembly463
Clutch Disc463
Clutch Release Bearing464
Clutch Release Fork464
Clutch Master Cylinder Components465
Clutch Master Cylinder Disassembly466
Clutch Master Cylinder Inspection466
Clutch Master Cylinder Reassembly466
Clutch Pedal Components468
Clutch Pedal Removal/Installation469
Clutch Pedal Inspection469
Ignition Lock Switch Inspection469
Clutch Release Cylinder Components471
Clutch Release Cylinder Removal/Installation472
Clutch Release Cylinder Inspection472
Clutch Release Cylinder Disassembly472
Clutch Release Cylinder Reassembly473
Clutch Pedal Inspection And Adjustment474
Bleeding475
Checking Steering Wheel Free Play476
Checking Steering Angle476
Checking The Tie Rod End Ball Joint Starting Torque476
Checking Stationary Steering Effort477
Checking Steering Wheel Return478
Checking Power Steering Belt Tension478
Checking Power Steering Fluid Level479
Replacing Power Steering Fluid479
Air Bleeding480
Oil Pump Pressure Test481
Steering System Special Tools483
Steering System Troubleshooting485
Steering System Specifications486
Steering System Service Standard486
Steering System Tightening Torque486
Steering System Lubricants486
Power Steering Gear Box Components488
Power Steering Gear Box Disassembly And Assembly488
Power Steering Gear Box Removal490
Power Steering Gear Box Installation491
Power Steering Gear Box Disassembly492
Power Steering Gear Box Inspection And Adjustment Before Disassembly496
Total Pinion Preload496
Tie Rod Swing Resistance497
Bellows Inspection497
Power Steering Hoses Components504
Power Steering Hoses Removal/Installation505
Pressure Hose And Tube505
Return Tube And Hose506
How To Fill With Power Steering Fluid507
Power Steering Oil Pump Components508
Power Steering Oil Pump Removal509
Power Steering Oil Pump Installation510
Power Steering Oil Pump Disassembly511
Power Steering Oil Pump Inspection513
Power Steering Oil Pump Reassembly514
Refrigeration Cycle517
Heating,Ventilation, Air Conditioning Precautions518
Heating,Ventilation, Air Conditioning Special Tools519
Heating,Ventilation, Air Conditioning Self-Diagnosis520
Heating,Ventilation, Air Conditioning Control Panel520
How To Read Self-Diagnostic Code520
Heating,Ventilation, Air Conditioning Troubleshooting526
Heating,Ventilation, Air Conditioning On-Vehicle Inspection528
Heating,Ventilation, Air Conditioning Test Conditions528
Inspect For Leakage Of Refrigerant532
A/C System Tests532
Refrigerant Recovery533
System Evacuation533
Compressor Component Location536
Compressor Replacement539
Compressor Inspection540
Compressor Disassembly541
Receiver/Drier Inspection544
Refrigerant Line Component Location545
Triple Pressure Switch Schematic Diagrams547
Triple Pressure Switch Connector547
Triple Pressure Switch Circuit Diagram547
Triple Pressure Switch Description548
In-Car Sensor Description549
In-Car Sensor Characteristics549
Photo Sensor Description550
Ambient Sensor551
Ambient Sensor Description552
Ambient Sensor Inspection553
Ambient Sensor Characteristics553
A.q.s (Air Quality Sensor) Description555
Checking Method Of Gas Detecting Bench556
Heater Unit Component Location557
Heater Unit Removal559
Temperature Control Actuator Connector564
Temperature Control Actuator Description565
Temperature Control Actuator Component Location566
Temperature Control Actuator Replacement567
Mode Control Actuator Connector568
Mode Control Actuator Description569
Mode Control Actuator Component Location570
Mode Control Actuator Replacement571
Blower Circuit Diagram572
Blower Unit Component Location575
Blower Unit Removal577
Blower Unit Air Filter Replacement577
Blower Motor Description580
Blower Motor Component Location581
Blower Motor Inspection582
Blower Relay Connector583
Blower Relay Circuit Diagram583
Blower Relay Description584
Blower Relay Component Location585
Power Transistor Connector586
Power Transistor Circuit Diagram And Important Performance Of Parts Composed Circuit586
Power Transistor Description587
Power Transistor Component Location588
Blower Resistor Connector589
Blower Resistor Circuit Diagram589
Blower Resistor Description590
Blower Resistor Characteristics590
Blower Resistor Component Location591
Blower Resistor Inspection592
Intake Actuator Connector593
Intake Actuator Circuit Diagram593
Intake Actuator Description594
Intake Actuator Component Location595
Intake Actuator Replacement596
Control Panel Connector Configurations597
Control Panel Description600
Control Panel Components601
Controller Circuit Diagram602
Controller Connector Configurations606
Manual Controller Description608
Manual Controller Components616
Manual Controller Control Panel Tests617
Manual Controller Power Supply Check617
Back Light And Rear Glass Heat Rays Check618
Manual Controller Blower Check619
Manual Controller Air Conditioner Check620
Intake And Aqs Check621
Manual Controller Mode Check622
Manual Controller Temp Check623
Restraint625
Srscm (Supplemental Restraints System Control Module)626
Restraint Special Service Tool627
Srscm Connector Dab+Pab+Sab+Bpt628
Srscm Diagnostic Troubleshooting Flow629
Srscm Independent Lamp Activation630
Clock Spring630
Satellite Sensor630
Srscm Diagnostic With Scan Tool631
Air Bag Squib Resistance Limits632
Supplemental Restraint System Control Module (Srnodem) Component And Layout634
Supplemental Restraint System Control Module (Srnodem) Inspection Chart For Diagnostic Trouble Code635
Supplemental Restraint System Control Module (Srnodem) Circuit Description636
Airbag Module Disposal Procedures670
Undeployed Airbag Module Disposal670
Deployment Inside The Vehicle670
Deployed Airbag Module Disposal Procedures671
Passenger Airbag (Pab) Module Components678
Passenger Airbag (Pab) Module Removal679
Side Airbag (Sab) Module Removal681
Satellite Sensor Removal682
Seat Belt Pretensioner Removal683
Body (Interior And Exterior) Special Tools685
Body (Interior And Exterior) Troubleshooting686
Body (Interior And Exterior) Specifications688
Body (Interior And Exterior) Tightening Torque688
Body (Interior And Exterior) Components690
Body (Interior And Exterior) Removal/Installation691
Fender Garnish691
Body (Interior And Exterior) Adjustment694
Hood Hinge/Latch694
Exterior Tail Gate Removal And Installation695
Exterior Front Door Removal And Installation698
Door Position702
Door Striker702
Exterior Mirror Components703
Exterior Mirror Removal And Installation704
Outside/Inside Rearview Mirror704
Sun Roof Components706
Sun Roof Removal708
Sun Roof Disassembly709
Sun Roof Inspection716
Sun Roof Moter Inspection718
Sun Roof Relay Inspection719
Interior Console Components720
Interior Console Removal And Installation721
Crash Pad Removal And Installation722
Interior Trim Components727
Interior Trim Removal And Installation728
Door Scuff Trim And Step Plate Trim728
Cowl Side Trim728
Covering Shelf Center Trim And Side Trim728
Luggage Board Center Trim731
Luggage Board Front Trim731
Luggage Side Trim731
Head Lining731
Windshield Glass Components733
Windshield Glass Removal734
Windshield Glass Installation735
Tailgate Glass Components739
Tailgate Glass Components Removal740
Quarter Glass Components743
Quarter Glass Removal/Installation744
Front Bumper Components747
Bumper Removal And Installation748
Rear Bumper Components750
Rear Bumper Removal And Installation751
Front Seat Belt Components753
Front Seat Belt Removal And Installation754
Rear Seat Belt Components755
Rear Seat Belt Removal And Installation756
Rear Seat Belt Buckle757
Body Electrical System General Troubleshooting Information758
Body Electrical System Troubleshooting762
Audio Unit Components781
Audio Unit Removal785
Audio Unit Auto Cd Changer785
Tape Head And Capstan Cleaning785
Audio Fault Code786
Multifunction Switch Components787
Multifunction Switch Removal788
Multifunction Switch Inspection789
Horn Removal791
Horn Inspection791
Horn Adjustment791
Keyless Entry Description792
Bcm Block Diagram792
Body Control Module (Bcm)793
Keyless Entry Troubleshooting799
Keyless Entry Removal804
Keyless Entry Inspection804
Bcm Function804
Keyless Entry Transmitter Code Saving Method815
Keyless Entry Programming Transmitter Code816
Relay Box (Engine Compartment) Components817
Relay Box (Engine Compartment) Inspection818
Relay Box (Passenger Compartment) Inspection821
Relay Box (Passenger Compartment) Inspection Of Fuses821
Instrument Cluster Circuit Diagram823
Instrument Cluster Components824
Instrument Cluster Removal825
Instrument Cluster Inspection825
Speedometer825
Tachometer826
Fuel Gauge826
Fuel Sender826
Engine Coolant Temperature Gauge827
Engine Coolant Temperature Sender827
Oil Pressure Warning Lamp828
Brake Fluid Level Warning Switch828
Brake Fluid Level Warning Lamp828
Parking Brake Switch829
Seat Belt Switch829
Multi Gauge Description832
Multi Gauge Components833
Power Door Locks Components834
Power Door Locks Inspection835
Door Lock Actuator Inspection835
Door Lock Switch Inspection835
Power Out Side Mirror Switch Inspection839
Power Windows Components841
Power Window Motor Inspection842
Power Window Switch Circuit Diagram843
Power Window Switch Inspection844
Power Window Main Switch844
Rear Window Defogger Printed Heater Inspection846
Repair Of Broken Heater Line847
Windshield Wiper/Washer Components849
Windshield Washer Installation849
Windshield Wiper/Washer Switch Inspection851
Front Wiper Motor Removal/Installation852
Front Washer Motor Inspection855
Rear Wiper/Washer Components856
Rear Wiper Motor Removal857
Rear Wiper Motor Installation858
Rear Wiper Motor Inspection858
Rear Washer Switch Inspection859
Rear Washer Motor Inspection860
Lighting System Replacement Of Lamps861
Head Lamp/Turn Signal Lamp861
Front Fog Lamp861
Rear Combination Lamp862
License Plate Lamp863
Overhead Console Lamp863
Luggage Lamp863
Head Lamp Relay864
Hazard Switch864
Rheostat865
Front Fog Lamp Switch865
Map Lamp Switch865
Head Lamps Aiming Instructions867
Head Lamps Front Fog Lamp867
Head Lamp And Fog Lamp Aiming Point868
Auto Lighting Control System Circuit Diagram870
Auto Lighting Control System Description871
Auto Lighting Control System Inspection872
Daytime Running Lights Circuit Diagram873
Drl Control Module Inspection874
Drl Control Module Operation Check874
Drl Control Module Inspect Circuits For Daytime Running Light System874
Immobilizer System Description876
Immobilizer System Block Diagram876
Immobilizer System Components880
Diagnosis Of Immobilizer Faults882