Tiburon 2003

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > General Information > General Information > General Information, TIBURON(GK)
> 2003 > G 2.7 V6 DOHC > General Information > General Information > General Information
IDENTIFICATION NUMBER LOCATIONS
IDENTIFICATION NUMBER DESCRIPTION

VEHICLE IDENTIFICATION NUMBER
1. Geographic zone
- K : Korea
2. Manufacturer
- M : Hyundai motor company
3. Vehicle type
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- H : Passenger
4. Vehicle line
- H : TIBURON
5. Model & Series
- L : STANDAD (L)
- M : DELUXE (GL)
- N : SUPER DELUXE (GLS)
- P : GRAND SALON
- R : SUPER GRAND SALON
6. Body type
- 6 : Coupe
7. Restraint system
- 3 : Drive side - Active belt and air bag
Passenger side - Active belt or passive belt
- 4 : Both side - Active belt and air bag
- 5 : Depowered - Air bag
8. Engine type
- D : Gas 2.0 DOHC
- F : Gas 2.7 V6
9. Check digit
- 0 ~ 9, X
10. Production year
- 3: 2003, 4 : 2004, 5 : 2005, 6 : 2006
11. Plant of production
- U : Ulsan (Korea)
12. Vehicle production sequence number
- 000001 ~ 999999
PAINT CODE
CODE
COLOR
NW
Noble White
EB
Ebony Black
VX
Samba Red
YY
Sunny Yellow
LS
Smart Silver
TS
Odd Purple
UC
Carbon Blue
MS
Mystic Teal
NR
Elm Green
XX
Exciting Blue
UE
Gold Savor
TW
New Silver
WN
Dark Navy Blue
AH
Amabile Rose
VZ
Triton Green
ENGINE IDENTIFICATION NUMBER
1. Engine fuel
- G : Gasoline

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2. Engine range
- 4 : In line 4 cycle 4 cylinder
- 6 : In line 4 cycle 6 cylinder
3. Engine development order
- B : Delta engine
- G : Beta engine
4. Engine capacity
- A : 2656 cc
- C: 1975 cc
5. Production year
- 3 : 2003, 4 : 2004, 5 : 2005, 6 : 2006
6. Engine production sequence number
- 000001 ~ 999999
TRANSMISSION IDENTIFICATION NUMBER

MANUAL
1. Model
- L : M5GF1 (2.7 V6)
- J : M5BF2 (2.0 DOHC)
2. Production year
- 2 : 2002, 3 : 2003, 4 : 2004
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- N : 4.063
- 1873 : 4.056
4. Transmission production sequence number
- 000001 ~ 999999
AUTOMATIC
1. Model
- N : F4A42-2
- M : F4A42-1
2. Production year
- 2 : 2002, 3 : 2003, 4 : 2004
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- N : 4.042
-Q : 4.407
4. Detailad classification
- CD : 2.0/2.7 Engine
5. Spare
6. Transmission production sequence number

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- 000000 ~ 999999
WARNING / CAUTION LABEL LOCATIONS
AIR BAG WARNING / CAUTION LABEL

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AIR BAG WARNING / CAUTION LABEL (CONT'D)

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WARNING / CAUTION LABEL (CON'T)

A : SRS INFORMATION
WARNING
Death or serious injury can occur.
Children 12 and under can occur.
The back seat is the safest place for children.
Never put a rear-facing child seat in the front.
Sit as far back as possible from the airbag.
Alway use seat belts and child restraints.
B : WARNING
SEE OWNER'S MANUAL
This car is equipped a side airbag for each front seat.
Do not use any accessory seat covers.
Use of other seat covers could reduce the effect of the system.
Do not install any accessories on the side or rear the side airbag.
Do not use excessive force on the side of the seal.

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For further information, see the owner's manual.
C : CAUTION
AIRBAG ESPE UNIT
Detach connector before unmounting. Assemble strictly according to manual instructions.
D : PASSENGER MODULE CAUTION

CAUTION
Don't open, remove or transfer to another vehicle.
Risk of malfunction and bodily injury!
This unit is to be installed and/or dismantled by trained personnel only. This item contains an explosive to be installed igniter.
E : SUPPLEMENTAL RESTRAINT SYSTEM

(AIRBAG) INFORMATION
The airbag is a Supplement Restraint System (SRS).
You must always wear the seat belts.
The airbag system condition is normal when the "SRS" lamp in the cluster flashes approximately 6 times after the ignition key is
turned on and then goes off.
If any of the following condition occur, the system must be serviced.
"SRS" lamp dose not light up when the key is turned on.
"SRS" lamp stays lit or flashes continuously.
The airbag has inflated.
The airbag system must be inspected by an authorized dealer ten years after the vehicle manufacture date shown on the
certification label, located on left front door opening area.
WARNING
Failure to the above instructions may result injury to you or other occupants in the vehicle.
See the "SRS" section in owner's Manual for more information about airbags.
EMISSION CONTROL LABEL

Emission Grop Identification
EXAMPLE :
A:
B:

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1. Model Year
- 4 : 2004
2. Manufacturer Subcode
- HYX : HYUNDAI MOTOR
3. Family Type
- V : Passenger car
4. Displacement
5. Sequence Characters
C:
1. Model Year
- 4 : 2004
2. Manufacturer Subcode
- HYX : HYUNDAI MOTOR
3. Family Type
- R : EVAP/ORVR
4. Canister Work Capacity
5. Sequence Characters
LIFT AND SUPPORT POINT
When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place
additional weight in the luggage area before hoisting . When substatial weight is removed from the rear of the vehicle the, center
of gravity may change and cam cause the vehicle to tip forward on the hoist.
Since each tire/wheel assembly weights approximately 30lbs 14kg), placing the front wheels in the luggage area can assist
with weight distribution.
Use the same support points to support the vehicle on safely stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimerers) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.

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TOWING
If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous.
- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
- The tow truck uses two pivoting arms that go under the tires (front or rear) and lift them off the ground. The other two wheels remain
on the ground.
If the vehicle cannot be transported by flat-bed, if should be towed with the front wheels off the ground. If due to damage, the vehicle
must be toward with the front wheels on the ground, do not following :
Manual Transmission
Release the parking brake.
Shift the transmission to neutral.
Automatic Transmission
Release the parking brake.
Start the engine.
Shift to [D] position, then [N] position.
Turn off the engine.
Improper towing preparation will damage the transmission. Follow the above procedure exactly. Follow the above
procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), your vehicle must be
transported on a flat-bed.
It is best to tow vehicle no farther than 19miles (30km), and keep the speed below 30mph (50km/h).
Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to support
the vehicle's weight.
FRONT :

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REAR :
TIGHTENING TORQUE TABLE OF STANDARD PARTS

Torque Nm (kg.cm, lb.ft)
Bolt nominal diameter

(mm)
Pitch (mm)
M5
Head Mark 4
Head Mark 7
0.8
3 ~ 4 (30 ~ 40, 2.2 ~ 2.9)
5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)
M6
1.0
5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)
9 ~ 11 (90 ~ 110, 6.5 ~

8.0)
M8
1.25
12 ~ 15 (120 ~ 150, 9 ~
11)
20 ~ 25 (200 ~ 250, 14.5 ~

18.0)
M10
1.25
25 ~ 30 (250 ~ 300, 18 ~
22)
30 ~ 50 (300 ~ 500, 22 ~
36)
M12
1.25
35 ~ 45 (350 ~ 450, 25 ~
33)
60 ~ 80 (600 ~ 800, 43 ~
58)
M14
1.5
75 ~ 85 (750 ~ 850, 54 ~
61)
120 ~ 140 (1,200 ~ 1,400,

85 ~ 100)
M16
1.5
110 ~ 130 (1,100 ~ 1,300,

80 ~ 94)
180 ~ 210 (1,800 ~ 2,100,

130 ~ 150)

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M18
1.5
160 ~ 180 (1,600 ~ 1,800,

116 ~ 130)
260 ~ 300 (2,600 ~ 3,000,

190 ~ 215)
M20
1.5
220 ~ 250 (2,200 ~ 2,500,

160 ~ 180)
360 ~ 420 (3,600 ~ 4,200,

260 ~ 300)
M22
1.5
290 ~ 330 (2,900 ~ 3,300,

210 ~ 240)
480 ~ 550 (4,800 ~ 5,500,

350 ~ 400)
M24
1.5
360 ~ 420 (3,600 ~ 4,200,

260 ~ 300)
610 ~ 700 (6,100 ~ 7,000,

440 ~ 505)
1. The torques shown in the table are standard values under the following conditions :
Nuts and bolts are made of galvanized steel bar.
Galvanized plain steel washers are inserted.
All nuts, bolts, and plain washers are dry.
2. The torques shown in the table are not applicable :
When spring washers, toothed washers and the like are inserted.
If plastic parts are fastened.
If self - tapping screws or self - locking nuts are used.
If threads and surfaces are coated with oil.
3. If you reduce the torques in the table to the percentage inddcated below, under the following conditions, if will be the
standard value.
If spring washers are used. : 85%
If threads and braring sufaces are stained with oil : 85%
LUBRICANTS
RECOMMENDED LUBRICANTS
Parts
OIL & GREASE STANDARD

Hot Climate : SAE 20W -40, 20W-50 (ABOVE 32F
For 0C)
Engine oil
API SH, SG or SG/CD
Normal Climate : SAE 10W-30, 10W-40, 10W-50

(ABOVE -10C For -23C)
Cold Climate : SAE 5W-30, 5W-30, 5W-40
(BELOW100 FoR 38C)
Manual
HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)
Auto
DIAMOND ATF SP-3, SK ATF SP-3
Transaxle
Power Steering
Brake Fluid
Coolant
PSF-3
DOT 3, DOT 4 or equivalent
Ethylene glycol base for aluminium radiator.
Transaxle linkage, parking brake cable mechanism,

hood lock and hook, door latch, seat adjust, tailgate Multipurpose grease NLGI grade #2
latch, door hinges, tailgate hinges
Always use Genuine Hyundai parts and recommedended fluid.

Using any other type of parts and fluid can cause serious damage of the vehicle.
LUBRICANTS CAPACITIES
Capacities [liter (U.S. qus., Imp.qts.)]
Description
2.4
Oil pan
Engine oil
Cooling system
Manual transaxle
3.7 (3.91, 3.26)
Oil filter
Total
2.7
4.2 (4.44, 3.69)
0.3 (0.32, 0.26)
4.0 (4.23, 3.52)
4.5 (4.76, 3.95)
7.3 (7.71, 6.42)
8.6 (9.09, 7.57)

2.15 (2.3, 1.86)

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Automatic transaxle
Power steering
7.8 (8.2, 6.8)

0.9 (0.95, 0.79)
SELECTION OF ENGINE OIL

Recommended SAE viscosity grades :
For best performance and maximum protection of all types of operation, select only those lubricants which :
1. Satisfy the requirements of the API classification.
2. Have the proper SAE grade number for expected ambient temperature range.
GENERAL SERVICE INFORMATION

PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting work.
The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to
prevent the hood from falling and possibly causing injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is firmly latched
before driving the vehicle.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT

Be sure that all necessary tools and measuring equipment are available before starting work.
SPECIAL TOOLS
Use special tools when they are required.

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REMOVAL OF PARTS
First find the cause of the problem and then determine whether removal or disassembly before starting the job.
DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that
will not affect their performance or external appearance.
1. Inspection of parts
Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.
3. Cleaning parts for reuse

All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.
PARTS

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When replacing parts, use HYUNDAI genuine parts.
REPLACEMENT
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
Depending on their location.

7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before assembly.
ADJUSTMENT
Use gauges and testers to correctly adjust the parts to standard values.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

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RUBBER PARTS AND TUBES

Always prevent gasoline or from touching rubber parts or tubing.
MEASURING BODY DIMENSIONS

1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensioners and actualmeasurement dimensions are used in this manual.
PROJECTED DIMENSIONS
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the
reference dimensions used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the difference
value in height of the two surface.
MEASURING ACTUAL DIMENSIONS

1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference dimensions
when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.
Check the probes and gauge itself to make sure there is no free play.
MEASUREMENT POINT

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Measurements should be taken at the center of the hole.
CHECKING CABLES AND WIRES

1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts firmly that there is complete continuity between their attaching bolt(s) and the vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is clamped to prevent contact with sharp corners of the vehicle body or hot parts (exhaust manifold, etc.).
9. Check that the wiring is clamped firmy to provide enough clearance from the fan pulley, fan belt and other rotating or moving
parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body and the
engine.
CHECK FUSES
A blade type fuse test leads provided to allow checking the fuse itself without removing it from the fuse box. The fuse is good if the
test lamp lights up when one lead is connected to the test leads (one at a time) and the other lead is grounded. (Turn on the ignition
switch so that the fuse circuit becomes operative)
SERVICING THE ELECTRICAL SYSTEM

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.
In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by
the computer will be cleared. Therefore, if necessary, read the diagnostic before removing the battery cable.

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2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other
vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to
come into contact with any of the surrounding parts and then secure the harness by using a clamp.
3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or
something similar in order to protect it from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that
may cause the temperature to exceed 80C (176F), r emove the electronic parts beforehand.

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7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
9. Disconnect connector which have catches by pressing in the direction of the arrows shown in the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the
connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal, being careful
not to damage the insulation of the wires.

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12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the
appropriate wire size.
Permissible current
Nominal
size
SAE gauge No.
0.3mm
AWG 22
In engine compartment
Other areas
5A
0.5mm
AWG 20
7A
13A
0.85mm
AWG 18
9A
17A
1.25mm
AWG 16
12A
22A
2.0mm
AWG 14
16A
30A
3.0mm
AWG 12
21A
40A
5.0mm
AWG 10
31A
54A
PRECAUTIONS FOR CATALYTIC CONVERTER
If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this
observe the following precations and explain them to your customer.
1. Use only unleaded gasoline.
2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than 10minutes and idle
speed for more than 20 minutes.
3. Avoid start-jump tests. Do start-jumps only when absolutely necessary. Perform this test as rapidly as possible and, while testing,
never race the engine.
4. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as possible.
5. Avoid coasting with the ignition turned off and during prolonged braking.
6. Do not dispose of used catalytic converter with parts contaminated by gasoline or oil.
BODY DIMENSION

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24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information > General
Information, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information >
General Information
THE MICRO 570 ANALYZER
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection
when working with batteries.
KEYPAD
BATTERY TEST PROCEDURE

1. Connect the tester to the battery.
A. Red clamp to battery positive (+) terminal.
B. Black clamp to battery negative (-) terminal.
Connect clamps securely. If "CHECK CONNECTION" message is displyed on the screen, reconnect
clamps securely.

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2. The tester will ask if the battery is connected "IN A VEHICLE" or "OUT OF A VEHICLE".
Make your selection by pressing the arrow buttons; then press ENTER.
3. Choose either CCA or CCP and press the ENTER button.
- CCA : Cold cranking amps, is an SAE specification for cranking batteried at 0F (-18C).
- CCP : Cold cranking power, is an SAE specification for korean manufacturer's for cranking batteries
at 0F (-18C)
4. Set the CCA value displyed on the screen to the CCA value marked on the battery label by pressing up and
down buttons and press ENTER.
The battery ratings(CCA) displyed on the tester must be identical to the ratings marked on the battery
label.
5. The tester (Micro570) displays battery test results including voltage and battery ratings.
A relevant action must be taken according to the test results by referring to the battery test results as shown in
the table below.

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6. To conduct starter test, continuously, press ENTER.

BATTERY TEST RESULTS
RESULT ON PRINTER
Good battery
Good recharge
REMEDY
No action is required
Battery is in a good state
Recharge the battery and use
Charge & Retest
Battery is not charged properly

Charge and test the battery again (Failure to charge the battery fully may
read incorrect measurement value)
Replace battery
Replace battery and recheck the charging system. (Improper connection

between battery and vehicle cables may cause "REPLACE BATTERY",
retest the battery after removing cables and connecting the tester to the
battery terminal directly prior to replacing the battery)
Bad cell-replace
Charge and retest the battery.
Whenever filing a claim for battery, the print out of the battery test results must be attached.
STARTER TEST PROCEDURE

1. After the battery test, press ENTER immediately for the starter test.
2. After pressing ENTER key, start the engine.

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3. Cranking voltage and starter test results will be displayed on the screen.
Take relevant action according to the test results by referring to the starter test results as given below.
4. To continue charging system test, press ENTER.

STARTER TEST RESULTS
RESULT ON PRINTER
Cranking voltage normal
REMEDY
System shows a normal starter draw
Cranking voltage low
Cranking voltage is lower than normal level

Check starter
Charge battery
The state of battery charge is too low to test

Charge the battery and retest
Replace battery
Replace battery
Check wiring for open circuit, battery cable connection, starter and repair
or replace as necessary.
If the engine does crank, check fuel system.
CHARGING SYSTEM TEST PROCEDURE

1. Press ENTER to begin charging system test.
2. If ENTER button is pressed, the tester displays the actual voltage of alternator.
Press ENTER to test the charging system.

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3. Turn off all electrical load and rev engine for 5 seconds.
4. Press ENTER.
5. The MICRO 570 analyzer charging system output at idle for comparision to other readings.
6. Take relevant action according to the test results by referring to the table below after shutting off the engine
and disconnect the tester clamps from the battery.

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CHARGING SYSTEM TEST RESULTS

RESULT ON PRINTER
REMEDY
Charging system normal/Diode

Charging system is normal
ripple normal
No charging voltage
Generator does not supply charging current to battery

Check belts, connection between generator and battery
Replace belts or cable or generator as necessary
Low charging voltage
Generator does not supply charging current to battery and electrical load to
system fully
Check belts and generator and replace as necessary
High charging voltage
The voltage from generator to battery is higher than normal limit during
voltage regulating.
Check connection and ground and replace regulator as necessary
Excess ripple detected
One or more diodes in the generator is not functioning properly

Check generator mounting and belts and replace as necessary

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General
Information > Troubleshooting
TROUBLESHOOTING
IGNITION SYSTEM
Symptom
Suspect Area
Remedy (See Page)
Engine will not start or is hard to

start (Cranks OK)
Ignition lock switch

Ignition coil
Spark plugs
Ignition wiring disconnected or broken
Spark plug cable
Inspect
See page EE-14
See page EE-13
Repair
See page EE-13
Rough idle or stalls
Ignition wiring
Ignition coil
Spark plug cable
Inspect
See page EE-14
See page EE-13
Engine hesitates/poor acceleration
Spark plugs and spark plug cable

Ignition wiring
See page EE-13

Inspect
Poor mileage
Spark plugs and spark plugs cable
See page EE-13
CHARGING SYSTEM
Symptom
Suspect Area
Remedy (See Page)
Charging warning indicator Fuse blown

does not light with ignition Light burned out
switch "ON" and engine off Wiring connection loose
Electronic voltage regulator
Check fuses
Replace light
Tighten loose connections
See page EE-20
Charging warning indicator

does not go out with
engine running (Battery
requires frequent
recharging)
Drive belt loose or worn

Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
Electronic voltage regulator or generator
Wiring
See page EE-19, 29

See page EE-32
Check fuses
Replace fusible link
See page EE-20
Repair wiring
Engine hesitates/poor
acceleration
Overcharge
Drive belt loose or worn

Wiring connection loose or open circuit
Fusible link blown
Poor grounding
Electronic voltage regulator or generator
Worn battery
Electronic voltage regulator
Voltage sensing wire
See page EE-19, 29

Tighten loose connection or repair
wiring
Repair
See page EE-20
Replace battery
See page EE-20
Repair wire
STARTING SYSTEM
Symptom
Suspect Area
Remedy (See Page)
Engine will not crank
Battery charge low

Battery cables loose, corroded or worn out
Transaxle range switch (Vehicle with
automatic transaxle only)
Fusible link blown
Starter motor faulty
Ignition switch faulty
Charge or replace battery

Repair or replace cables
See page TR group-automatic
transaxle
See page EE-38
Inspect
Engine cranks slowly
Battery charge low

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Battery cables loose, corroded or worn out

Starter motor

See page EE-38
Starter keeps running
Starter motor
Ignition switch
See page EE-38

Inspect
Starter spins but engine

will not crank
Short in wiring
Pinion gear teeth broken or starter motor
Ring gear teeth broken
Repair wiring
See page EE-40
See page EM group-fly wheel

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General
Information > Specifications
SPECIFICATION
IGNITION SYSTEM
Specifications
Items
2.0
2.7
Type
Ignition coil
Spark plugs
Mold coil type
Primary resistance
0.58 10% ()
0.74 10% ()
Secondary resistance
8.8 15% (k)
13.3 15% (k)
NGK
BKR5ES-11
PFR5N-11
CHAMPION
RC10YCPB4
RC10YCPB4
Gap
1.0 ~ 1.1 mm (0.039 ~ 0.043 in.)
STARTING SYSTEM
Specifications
Items
2.0
Starter
2.7
Type
Reduction drive (with planetary gear)
Rated voltage
12V, 1.2KW
No.of pinion teeth
Voltage
11V
Amperage
90A, MAX
No-load
characteristics
Speed
3,000rpm, MIN
2,800rpm, MIN
CHARGING SYSTEM
Specifications
Items
2.0
Type
Rated voltage
Generator
2.7
Battery boltage sensing
13.5V, 90A
12V, 120A
Speed in use
1,000 ~ 18,000 rpm
Voltage regulator
Electronic built-in type
Regulator setting voltage
14.4 0.2V
14.55 0.2V
Temperature
compensation
-10 3mV/C
-3.5 1mV/C
Type
MF 60 AH
MF 68 AH
Cold cranking amperage

[at -18C (0F)]
550A
600A
Reserve capacity
92min
110min
Specific gravity [at 25C

(77F)]
1.280 0.01
1.280 0.01
Battery

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- COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2V or greater at a specified temperature.
- REVERSE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum
terminal voltage of 10.5V at 26.7C(80F)
AUTO CRUISE CONTROL SYSTEM
Items
Specification
Setting error
Within 1.5Km/h on level road ( 1MPH)
Vehicle speed memory variation
No variation
Setting time
0.1sec max.
Resuming time
0.1sec max.
Minimum operating speed
40 2Km/h (25 1.2MPH)
Cancel speed range
15 2Km/h (9 1.2MPH)
Maximum memorized speed
160 2Km/h (99 1.2MPH)
Pulling force
127N(13Kgf)(28.6 Ib-force)
Main switch serial resistance value
3.9k 1%
SET switch : 220 1%
Command switch serial resistance value

RESUME switch : 910 1%
TIGHTENING TORQUE
Items
Generator terminal (B+)
Starter motor terminal (B+)
Battery terminal
Spark plug
Nm
kgcm
lbft
5~7
10 ~ 12
4~6
20 ~ 30
50 ~ 70
100 ~ 120
40 ~ 60
200 ~ 300
3.6 ~ 5.1
7.3 ~ 8.8
2.9 ~ 4.3
15 ~ 22

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Ignition System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Ignition System >
Description and Operation
DESCRIPTION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Ignition System > Repair procedures, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Ignition System > Repair procedures
ON-VEHICLE INSPECTION
INSPECT SPARK TEST
1. Remove the spark plug cable.
2. Using a spark plug socket, remove the spark plug.
3. Install the spark plugs to each spark plug cable.
4. Ground the spark plugs.
5. Check if spark occurs while engine is being cranked.
To prevent gasoline from being injected from injectors during this test, disconnect the injector connectors.
Be sure to clean away DTC codes the timing is complete after.
6. Using a spark plug socket, install the spark plugs.

7. Install the spark plug cable.
INSPECT SPARK PLUG AND SPARK PLUG CABLE

1. Remove the spark plug cable(A).

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When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.
2. Using a spark plug socket, remove the spark plug(B).
Be careful that no contaminats enter through the spark plug holes.

3. Inspect the electrodes(A) and ceramic insulator(B).
INSPECTION FO ELECTRODES
CONDITION
DESCRIPTION
DARK DEPOSITS
- Fuel mixture too rich
- Low air intake
WHITE DEPOSITS
- Fuel mixture too lean
- Advanced ignition timing
- Insufficient plug tightening
4. Check the electrode gap(A).

Standard (New)
1.0~1.1 mm (0.039~0.043 in.)
5. Carefully remove the spark plug cable by pulling on the rubber boots(A).
Check the condition of the spark plug cable terminals(B), If any terminal is corroded, clean it, and if it's broken or distorted,
replace the spark plug cable.
6. Connect the ohmmeter probes and measure resistance.

RESISTANCE : 5.6K/m 20%

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7. Resistance should not be higher than 2.6k per meter of cable.

If resistance is higher, replace the cable.
INSPECT IGNITION COIL

1. Measure the primary coil resistance between terminals 1, 2 and 1,3.
Standard value : 0.58 10%

2. Measure the secondary coil resistance between the high-voltage terminal for the No.1 and No.4 cylinders, and between the
high-voltage terminals for the No.2 and No.3 cylinders.
Standard value : 8.8k 15%
Be sure, when measuring the resistnace of the secondary coil, to disconnect the connector of the ignition coil.
1. Measurement of the primary coil resistance

Measure the resistance between connector terminals 1 and 2 (the coils at the No.3 and No.6 cylinder sides) fo the ignition
coil, and between terminals 2 and 4 (the coils at the No.2 and No.5 cylinder sides), and between terminals 2 and 3 (the coils
at the No.1 and No. 4 cylinder sides).
2. Measurement of the secondary coil resistance

Measure the resistance between the high-voltage terminal for the No.3 and No.6 cylinders, between the high-voltage

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terminals for the No.1 and No.4 cylinders and between the high-voltage terminals for the No.2 and No.5 cylinders.
When measuring the resistance of the secondary coil, be sure to disconnect the connector of the ignition coil.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Schematic Diagrams
CIRCUIT DIAGRAM FOR CHARGING SYSTEM

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Description
and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System >
DESCRIPTION
The charging system includes a battery, generator with a built-in regulator, The charging indicator light and
wiring.
The generator has eight built-in diodes (four positive and four negtive), each rectifying AC current to DC current.
Therefore, DC curent appears at generator "B" terminal.
In addition, the charging voltage of this generator is regulated by the battery voltage detection system.
The generator is regulated by the battery voltage detection system. The main components of the generator are
the rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a builtin electronic voltage regulator.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Repair procedures,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Repair procedures
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
CHECK BATTERY VOLTAGE

1. if 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical system
(headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.
Standard voltage : 12.5~12.9V at 20C (68C)
If the voltage is less than specification, charge the battery.
CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES

1. Check that the battery terminals are not loose or corroded.
2. Check the fusible link and fuses for continuity.
INSPECT DRIVE BELT

1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be
replaced.
2. Using a belt tension gauge, measure the drive belt tension.

DRIVE BELT TENSION
New belt
690~880 N (150~200 lb)
Used belt
340~490 N (77~110 lb)
If the belt tension is not as specified, adjust it.

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"New belt" refers to a belt which has been used less than 5 minutes on a running engine.
"Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
After installing a belt, check that it fits properly in the ribbed grooves.
Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.
VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the generator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT

1. Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light goes off.
INSPECT CHARGING SYSTEM

PREPARATION
1. Turn the ignition switch to "OFF".
To find abnormal conditions of the connection, actions should not be taken on the two terminals and each connection
during the test.
2. Connect a digital voltmeter between the generator "B" terminal and battery (+) lead wire to the battery (+) terminal. Connect
the (+) lead wire of the voltmeter to the "B" terminal and the (-) lead wire to the battery (+) terminal.
CONDITIONS FOR THE TEST

1. Start the engine.
2. Switch on the headlamps, blower motor and so on. And then, read the voltmeter under this condition.
RESULT
1. The voltmeter may indicate the standard value.
0.2V max.
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case check the
wiring from the generator "B" terminal to the fusible link to the battery (+) terminal. Check for loose connections, color
change due to an overheated harness, etc. Correct them before testing again.

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3. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition switch.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is described in
"BATTERY".
The battery that is used to test the output current should be one that has been partially discharged. With a fully charged
battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the generator drive belt. The belt tension check method is described in the section "COOLING".
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the generator output wire from the generator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure to
connect the (-) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the generator "B"
terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.
TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open
circuit in the wire between the generator "B" terminal and battery (-) terminal, a blown fusible link or poor grounding is
suspected.
2. Start the engine and turn on the headlights.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm and
read the maximum output current value indicated by the ammeter.
After the engine starts up, the charging current quickly drops. Therefore, the above operation must be done quickly to
read the maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good condition,
remove the generator from the vehicle and test it.

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63A min.
84A min
The nominal output current value is shown on the nameplate affixed to the generator body.
The output current value changes with the electrical load and the temperature of the generator itself. Therefore, the
nominal output current may not be obtained. If such is the case, keep the headlights on to cause discharge of the
battery.
The nominal output current may not be obtained if the temperature of the generator itself or ambient temperature is
too high.
In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the generator output wire to the generator "B" terminal.
6. Connect the battery ground cable.
PREPARATION
1. Prior to the test, check the following items and correct if necessary.
Check that the battery installed in the vehicle is fully charged. For battery checking method, see "BATTERY".
Check the generator drive belt tension. For belt tension check, see "COOLING" section.
2. Turn ignition switch to "OFF".
4. Connect a digital voltmeter between the "B" terminal of the generator and ground. Connect the (+) lead of the voltmeter to
the "B" terminal of the generator. Connect the (-) lead to good ground or the battery (-) terminal.
5. Disconnect the generator output wire from the generator "B" terminal.
6. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Connect the (-)
lead wire of the ammeter to the disconnected output wire.
7. Attach the engine tachometer and connect the battery ground cable.
TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.
Battery voltage

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If it reads 0V, there is an open circuit in the wire between the generator "B" terminal and the battery (-), or the fusible link is
blown.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to 10A or
less.
RESULT
1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the generator is faulty.
Regulating Voltage Table
Voltage regulator ambient temperature C (F)
Regul ating voltage (V)
-20 (-4)
20 (68)
60 (140)
80 (176)
14.2 ~ 15.4
14.0 ~ 15.0
13.7 ~ 14.9
13.5 ~ 14.7
2.
3.
4.
5.
6.
1.
Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
Disconnect the battery ground cable.
Remove the voltmeter and ammeter and the engine tachometer.
Connect the generator output wire to the generator "B" terminal.
Connect the battery ground cable.
Be sure to check the following before testing:
Generator installation and wiring connections
Generator drive belt tension
Fusible link
Abnormal noise from the generator while the engine is running
2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range of 0-150A in
series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the "B" terminal.
Connect the (-) lead of the ammeter to the disconnected output wire).
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator output wire
is recommended. Using this equipment will lessen the possibility of a voltage drop caused by a loose "B" terminal
connection.
5. Connect a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal. (Connect the (+) lead of
the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+) cable.)
6. Reconnect the negative battery cable.
7. Connect a tachometer or the scan tool.
9. With the engine running at approx. 2500 r/min, turn the headlights and other lights on and off to adjust the generator load
on the ammeter slightly above 30A.
max. 0.3V
When the generator output is high and the value displayed on the ammeter does not decrease to 30A, set the value to
40A.Read the value displayed on the voltmeter. In this case the limit becomes max. 0.4V.
10. If the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may exist. Check
the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link). If a terminal is not
sufficiently tight or if the harness has become discolored due to overheating, repair, the test again.
11. After the test, run the engine at idle.
12. Turn off all lights and turn the ignition switch to the OFF position.
13. Disconnect the tachometer or the scan tool.
14. Disconnect the negative battery cable.
15. Disconnect the ammeter and voltmeter.

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16. Connect the generator output wire to the generator "B" terminal.
17. Connect the negative battery cable.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Alternator >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System >
Charging System > Alternator > Components and Components Location
COMPONENTS

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Page 2 of 2

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Alternator >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging
System > Alternator > Repair procedures
REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the generator connector(A) and "B" terminal cable(B) from the generator(C).
3. Remove the adjusting bolt(A) and mounting bolt(B), then remove the generator belt(C).
4. Pull out the through bolt(C), then remove the generator(D).
5. Installation is the reverse of removal.

6. Adjust the generator belt tension after installation (See page EE-33 ).
1. Disconnect the battery negative terminal first then the positive terminal.
2. Loosen the drive belt tension adjusting bolt, then remove the drive belt(A).
3. Disconnect the connector(A) and "B" terminal cable(B).

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4. Pull out the through bolts(A) and nuts(B) then remove the generator(C).
5. Installation is reverse of removal.
Adjust the generator belt. (Refer to EM)

Place the alternator and insert a support bolt (Do not insert a nut this time).
After pushing the alternator forward, count that how many spacers (a spacer thickness : 0.198 mm)
should be inserted between the alternator front leg and front case as shown in "A".
After inserting spacers, insert and tighten a nut securely.
ALTERNATOR BELT INSPECTION AND ADJUSTMENT
When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the
deflection or tension to the values for the used belt after running engine for five minutes.
Deflection method :
Apply a force of 98N (10 kgf, 22 lbf), and measure the deflection between the alternator and crankshaft pulley.
Deflection
Used Belt : 8.5 ~ 11.5 mm (0.33 ~ 0.345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0.361 in)

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If the belt is worn or damaged, replace it.
Belt tension gauge method :

Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 690~880 N (70~90 kgf, 150~200 lbf)
Deflection
Used Belt : 8.5 ~ 11.5 mm (0.33 ~ 0.345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0.361 in)
If the belt is worn or damaged, replace it.
If adjustment is necessary :
1. Loosen the adjusting bolt(A) and the lock bolt(B).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.
3. Recheck the deflection or tension of the belt.
It is not necessary to adjust the tension of the drive belt because of the auto-tensioner.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Battery >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System >
Charging System > Battery > Description and Operation
DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery
cell caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Battery > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Battery >
Repair procedures
INSPECTION
BATTERY DIAGNOSTIC TEST (1)
1. CHECKING FLOW
2. CHECKING SHEET
Responsibility
Inspection Items & contents
Judgment criteria
Remarks
User
1. Acid Leakage
* Type of acid leakage
- Leakage on the fusion part for
joining the case and cover.
- Leakage on the terminal part
- Leakage on other parts
* Conduct a visual inspection for
breakage, deformation, or cracks.
2. Outside damage and breakage
1. Damage in the case or cover due to

outside impact.
Manufacturer
2. Acid leakage on the molding part of

the case or cover.
(weld line or gate hole)
3. Damage on the terminal or cracks in

the cover.
4. Acid leakage due to the tipped

battery or slant storage.
5. Acid leakage due to poor welding of

the cover.
(with no damage)
1. Outside damage due to causes

without damage due to mistreatment.
2. Outside damage due to

mistreatment.
3. Damage due to a spark between
terminals.

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3. Measure the voltage for the

battery
; Wait at least one day before
measuring in case of recharging.
4. Damage and breakage due to heat.
1. 12.0V
Refer to
load test
2. 11.0V< battery voltage<12.0V due

to over-discharge.
Refer to
load test
3. Below 11.0V due to charge

condition failure.
Refer to
load test
4. Below 11.0V due to discharged for a

long period.
Refer to
load test
5. Below 11.0V due to internal short

circuit.
4. Load test
; For 15 seconds with half of the CCA
1. Load test result: below 9.5V
value.
The voltage on the dischaarging stage
should be above 9.6V (819F)
- Conduct the test with a battery
2. Load test result: above 9.6V
tester.
(Refer to the tester manual)
Refer to
load test
3. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow :
A. If the battery has been on charge, remove the surface charge by connecting a 300 ampere load for 15 seconds.
B. Connect the voltmeter and apply the specified load.
C. Read the voltage after the load has been applied for 15 seconds.
D. Disconnect the load.
E. Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that shown in
the voltage table.
Voltage
Temperature
9.6
20C (70F) and above
9.5
16 C (60 F)
9.4
10 C (50 F)
9.3
4 C (40 F)
9.1
-1 C (30 F)
8.9
-7 C (20 F)
8.7
-12 C (10 F)
8.5
-18 C (0 F)
- If the voltage is higher than shown in the table, the battery is good.
- If the voltage is lower than shown in the table, replace the battery.
BATTERY DIAGNOSTIC TEST (2)

1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.
Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the electrolyte.

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Heavy rubber gloves (not the household type) should be worn when removing the battery.
4. Inspect the battery carrier for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary to
clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe off with a
cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described in Step(4).
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post cleaming tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged cables and
broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure the tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke near
batteries being charged or which have recently been charged. Do not break live circuits at the terminals of
batteries being charged. A spark will occur when the circuit is broken. Keep open flames away from the battery.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Schematic Diagrams
CIRCUIT DIAGRAM FOR STARTING SYSTEM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System >
DESCRIPTION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T),
ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System >
Repair procedures
INSPECTION
START TEST
The air temperature must be between 59 and 100F (1 5 and 38C) before testing.
Recommended procedure :
Use a starter system tester.
Connect and operate the equipment in accordance with the manufacturer's instructions.
Test and troubleshoot as described.
Alternate Procedure :
Use the following equipment :
- Ammeter, 0~400A
- Voltmeter, 0~20V (accurate within 0.1 volt)
- Tachometer, 0~1,200 rpm
After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.
Check the Starter Engagement :
1. Remove the No.8(10A) fuse from the fuse/relay box.
2. Turn the ignition switch to START (III) with the shift lever in "P" or " N" position (A/T) or with the clutch pedal
depressed (M/T). The starter should crank the engine.
A. If the starter does not crank the engine, go to step 3.
B. If it cranks the engine erratically or too slowly, go to "Check for Wear and Damage" on the next page.
3. Check the battery, battery positive cable, ground, starter cut relay, and the wire connections for looseness and
corrosion. Test again.
If the starter still does not crank the engine, go to step 4.
4. Unplug the connector from the starter.
5. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal.
The starter should crank the engine.
A. If the starter still does not crank the engine, remove it, and diagnose its internal problem.
B. If the starter cranks the engine, go to step 6.
6. Check the ignition switch.
7. Check the starter relay (see page EE-46 ).
8. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
9. Check for an open in the wire between the ignition switch and starter.
If cranking voltage is too low, or current draw too high, check for :

24.04.2008
Page 2 of 3
dead or low battery.

open circuit in starter armature commutator segments.
starter armature dragging.
shorted armature winding.
excessive drag in engine.
Check Cranking rpm
Engine speed during cranking should be above 100 rpm.
If speed is too low, check for :
loose battery or starter terminals.
excessively worn starter brushes.
open circuit in commutator segments.
dirty or damaged helical splines or drive gear.
defective drive gear overrunning clutch.
Check starter disengagement
With the shift lever in N or P position (A/T) or with the clutch pedal depressed (M/T), turn the ignition switch to
START(III), and release to ON(II).
The starter drive gear should disengage from the flywheel or flywheel ring gear when you release the key.
If the drive gear hangs up on flywheel ring gear, check for :
solenoid plunger and switch malfunction.
dirty drive gear assembly or damaged overrunning clutch.
STARTER SOLENOID TEST

1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). The coil is OK
if there is continuity.
2. Check the pull-in coil for continuity between the S and M terminals. The coil is OK if there is continuity.
FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and connecta fully-charged 12-volt battery to starter
motor as follows :
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostatas shown in the illustration.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate carbon pile to the off position.
5. Connect the battery cable from battery's negative post to the startermotor body.
6. Adjust the carbon pile until battery voltage shown on the voltmeter reads 11 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and
freely :
: Max. 90 Amps
: Min. 2,800 rpm

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Starter > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System
> Starter > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Starter > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System >
Starter > Repair procedures
REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal(B) on the solenoid(C), then disconnect the connecto(D)
from the S terminal(E).
3. Remove the 2 bolts holding the starter, then remove the starter.
5. Connect the battery negative cable to the battery.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Starter Relay >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting
System > Starter Relay > Repair procedures
INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay(A).
3. Inspect the relay continuity.

A. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
If there is no continuity, replace the relay.
B. Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.
4. Inspect the relay operation.

A. Apply battery positive voltage across terminals 2 and 4.
B. Using an ohmmeter, check that there is continuity between terminals 1 and 5.
If there is no continuity, replace the relay.
5. Install the starter relay.

6. Install the fuse box cover.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System >
Schematic Diagrams
CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise
Control System > Description and Operation
DESCRIPTION
FUNCTIONS OF INSIVIDUAL SWITCHS
1. SET(Vehicle Speed Set)
When SET switch is turned "ON" and "OFF" while the vehicle is running at a speed within the range of the
lowest running speed to the highest memory speed, specified in the Performance Standards, the speed is
instantaneously registered in memory(memory speed) and actuator is there after regulated to maintain vehicle
speed at the memory speed.
2. COAST(Self-Retardation)
When SET switch is turned "ON" while the vehicle is running at regulated speed, vehicle speed is retarded
while the switch is "ON". When it is turned "OFF", the then prevailing speed is instantaneously registered in
memory and actuator is regulated to maintain vehicle speed at the newly registered value.
3. RESUME(Auto Recovery)
After regulated speed run is released according to according to the conditions specified in 5.2, 5.3 and 5.4
below, when RESUME switch is turned "ON" during motion at a speed faster than the lowest running speed
shown in 4.5 above, actuator is recover and maintain the memory speed set prior to release.
A. IG. KEY. SW. OFF
B. ACC MAIN SW. OFF
4. ACCEL(Selt-Acceleration)
When RESUME switch is turned "ON" during regulated speed run, vehicle speed is increased as long at it is
"ON". When the switch is turned "OFF", the then prevailing speed is registered in memory to regulate actuator
to maintain that speed thereafter.
CANCELLATION
1. Stop lamp switch is turned "ON".
(Brake pedal is depressed)
This also applies to the disconnection of the input wire.
2. Brake switch or CANCEL switch is turned "ON". (Brake pedal is depressed)
3. Inhibitor switch is turned "ON".
(Gear shift lever is in either P or N position.)
4. Ignition key switch is turned "OFF".
5. Main switch is turned "OFF".
AUTO CANCELLATION
1. When vehicle speed falls down below the lowest running speed. (40Km/h)
2. When regulated speed falls below memory speed by the width of theredundant brake speed range of more.
3. When vehicle speed during resume operatin falls below memory speedby width of the redundant brake speed
range of more after once rising abovethe speed of memory speed-10Km/h.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control
System > Components and Components Location
COMPONENTS LOCATION

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control
System > Troubleshooting
TROUBLE SHOOTING
Before troubleshooting :
- Check the No.3(10A), No.13(15A) and No.17(10A) fuse in the under-hood fuse/relay box.
- Check that the horn sounds.
- Check the tachometer to see if it works properly.
Symptom
Cruise control cannot be set
Suspect Area
Main switch
SET/RESUME/CANCEL switch
Brake switch
A/T gear position switch
Cruise control nuit
Cruise control cannot be set but indicator light does not Dimming circuit in gauge
go on
Cruise control unit
Cruise speed is noticeably higher or lower than what
was set
Vehicle speed sensor

Cruise control unit and actuator cable deflection
Cruise control nuit
Excessive overshooting or undershooting when trying

to set speed

Cruise control unit
Speed fluctuation on a flat road with cruise control set
Vhicle speed sensor

Cruise control nuit
Vehicle does not decelerate or accelerate accordingly

when SET/RESUME/CANCEL button is pushed
Main switch
Cruise control unit
Cruise control does not cancel when shift lever is

moved to N position (A/T)
A/T gear position switch

Cruise control unit
Set speed is not cancelled when brake pedal is pushed Brake switch
Cruise control unit
Cruise control will not cancel when main switch is
pushed OFF
Main switch
Cruise control unit
Cruise control will not cancel when CANCEL button is

pushed
Main switch
Cruise control unit
Set speed will not resume when RESUME button (with Main switch
main switch on, when set speed is temporarily
cancelled)
Cruise control unit
The transmission shifts down slower than normal when Troubleshooting the cruise control communication
going up a hill with the cruise control on (A/T)
circuit

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control
System > Repair procedures
INSPECTION
CRUISE CONTROL SWITCH TEST
1. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbag (See page RT).
3. Disconnect the control switch connector.
4. Check the continuity between the terminals of the connector in each switch position according to the table.
A. If there is continuity, and it matches the table, the switch is O.K.
B. If there is no continuity, replace the control switch.
BRAKE SWITCH TEST

1. Disconnect the connector from the brake switch.
2. Remove the brake switch.

24.04.2008
Page 2 of 4
3. Check for continuity between the terminals according to the table.
4. If necessary, replace the switch or adjust the pedal height.
ACTUATOR CABLE ADJUSTMENT

1. Check that the actuator cable (A) moves smoothly with no binding or sticking.
2. position, M/T in neutral) until the radiator fan comes on, then let it idle.
3. Measure the amount of movement of the output linkage (B) until the engine speed starts to increase.
At first, the output linkage should be located at the fully closed position (C).
4. If the free play is not within specs, move the cable to the point where the engine speed starts to increase, and
tighten the locknut (A) and adjusting nut (B).
5. Turn the adjusting nut (A) until it is 3.750.5 mm (0.150.02 in.) away from the bracket (B).
6. Pull the cable assembly so that the adjusting nut (A) touches the bracket, and tighten the locknut (B).

24.04.2008
Page 3 of 4
REPLACEMENT
CRUISE CONTROL UNIT AND CABLE
1. Loosen the locknuts(A) and disconnect the actuator cable (B) from the throttle linkage(C).
2. Disconnect the cruise control unit connector(D).

3. Loosen the three mounting bolts(E), and remove the cruise control unit with the bracket(F).
4. Loosen the locknuts(A) and disconnect the actuator cable(B) from the cruise control unit.
CRUISE CONTROL SWITCH REPLACEMENT

1. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbg (See page RT).
3. Disconnect the control switch connector(A).

24.04.2008
Page 4 of 4
4. Loosen the two mounting screws(B), and remove the cruise control switch.

6. Connect the battery positive cable and negative cable to the battery.

24.04.2008
Page 1 of 12
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information > General Information,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information > General Information
SPECIFICATIONS
Description
Specification
General
Type
Number of cylinders
Bore
Stroke
Total displacement
Compression ratio
Firing order
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
Closes (ATDC)
V-type, DOHC
6
86.7mm (3.4133in.)
75mm (2.9528in.)
2,656cc
10 : 1
1-2-3-4-5-6
6
46
44
8
Camshaft
Drive mechanism
Cam height
Intake
Exhaust
Journal diameter
Bearing oil clearance
End play
Cogged type belt

43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
25.964 ~ 25.980mm (1.0222 ~ 1.0228in.)
0.02 ~ 0.61mm (0.0007 ~ 0.0024in.)
0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)
Cylinder head
Flatness of cylinder head surface
Flatness of manifold mounting surface
Intake
Exhaust
Valve guides hole diameter
0.05 (0.002) O.S.
0.25 (0.010) O.S.
0.50 (0.020) O.S.
Intake valve seat ring hole diameter
0.3 (0.012) O.S
Exhaust valve seat ring hole diameter
0.3 (0.012) O.S.
Max. 0.03mm (0.0012in.)

Max. 0.15mm (0.0059in.)
Max. 0.15mm (0.0059in.)
11.05 ~ 11.068mm (0.435 ~ 0.436in.)
11.25 ~ 11.268mm (0.443 ~ 0.444in.)
11.50 ~ 11.518mm (0.453 ~ 0.453in.)
33.300 ~ 33.325mm (1.311 ~ 1.312in.)
28.600 ~ 28.621mm (1.126 ~ 1.127in.)
Valve
Overall length
Intake
Exhaust
Stem diameter
Intake
Exhaust
Face angle
Margin
Intake
Exhaust
Clearance (Stem-to-guide)
Intake
Exhaust
96.1mm (3.783in.)
97.15mm (3.825in.)
5.965 ~ 5.98mm (0.235 ~ 0.2354in.)
5.95 ~ 5.965mm (0.234 ~ 0.235in.)
45 ~ 45.5
1.0mm (0.0394in.)
1.3mm (0.0512in.)
0.02 ~ 0.05mm (0.0008 ~ 0.0020in.)
0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)
Valve spring
Free height
Load
Out of squareness
42.5mm (1.6732in.)
21kg/35mm (48.4lb/1.3780in.)
Max 1.5
Limit
43.45mm (1.7106in.)
43.45mm (1.7106in.)
25.914m(1.0202in.)
0.1mm (0.0039in.)
0.05mm (0.0020in.)
0.15mm (0.0059in.)
0.15mm (0.0059in.)
0.5mm (0.0197in.)
0.8mm (0.0315in.)
0.10mm (0.0039in.)
0.15mm (0.0059in.)
41.5mm (1.6339in.)
21.9kg/34mm
(48.4lb/1.3386in.)
Max. 3
Piston

24.04.2008
Page 2 of 12
Diameter (Standard)
Clearance (Piston-to-cylinder)
Ring groove width
No. 1
No. 2
Oil
Piston for service
86.68 ~ 86.71mm (3.413 ~ 3.414in.)

0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
1.230 ~ 1.250mm (0.0484 ~ 0.0492in.)
1.220 ~ 1.250mm (0.0480 ~ 0.0488in.)
2.515 ~ 2.535mm (0.0990 ~ 0.0998in.)
0.25mm (0.010in.), 0.50mm (0.020in.)
Piston ring
Number of rings per piston
Compression ring
Oil ring
Compression ring type
No. 1
No. 2
Oil ring type
Ring end gap
No. 1
No. 2
Oil ring side rail
Ring side clearance
No.1
No.2
Rings for service
3
2
1
Inner bevel type
Under cut type
3-piece type
0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)
0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
0.03 ~ 0.07mm (0.0012 ~ 0.0028in.)
0.25mm (0.010in.), 0.50mm (0.020in.)
Connecting rod
Piston pin installation force
Side clearance (big end)
Bend
Bearing oil clearance
2,450 ~ 12,255N
(250 ~ 1,250kg, 551 ~ 2,755lb)
0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)
0.05mm or less/100mm
(0.0020in. or less/3.937in.)
0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)
Crankshaft
Journal O.D.
Pin O.D.
Out-of-round of journal and pin
Taper of journal and pin
End play
Main bearing oil clearance
61.982 ~ 62.000 (2.4402 ~ 2.4409 in.)

47.982 ~ 48.000 (1.8891 ~ 1.8898in.)
Max. 0.003mm (0.00012in.)
Max. 0.005mm (0.00020in.)
0.070 ~ 0.250mm (0.0028 ~ 0.0098in.)
0.004 ~ 0.022mm (0.0002 ~ 0.0009in.)
Cylinder block
Cylinder bore
Flatness of gasket surface
Out-of-round of cylinder bore
Oil pump
Side clearance
Body clearance
Side clearance
Relief spring
Free length
Load
Oil filter
Type
Engine oil pressure
Cooling method
Cooling system quantity
Theromstat
Type
Normal opening temperatrure
Opening temperature range
Wide open temperature
86.7mm (3.4134in.)
Max. 0.03mm (0.0012in.)
Max. 0.02mm (0.0008in.)
0.8mm (0.031in.)
0.8mm (0.031in.)
1.0mm (0.039in.)
0.1mm (0.004in.)
0.1mm (0.004in.)
0.4mm (0.016 in.)

0.1mm (0.004in.)
0.4mm (0.016in.)
0.1mm (0.004in.)
0.05mm (0.002in.)
0.100 ~ 0.181mm (0.0039 ~ 0.0071 in.)

0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)
43.8,, (1.724in.)
4.6kg/39.3mm (10lb/1.547in.)
Cartridge, full flow
50kPa (7.3psi) or more
[Conditions : Oil temperature is 75 to 90C (167
to 194C)]
Engine coolant cooling, forced circulation with
electric fan
7.0lit (7.4U.S.qts., 6.1lmp.qts.) [For V6]
wax pellet type with jiggle valve
82 2.0C (179.6 35.6F)
80 ~ 84C (176 ~ 183.2F)
95C (203F)

24.04.2008
Page 3 of 12
Radiator cap
Main valve opening pressure
Main valve closing pressure
Vacuum valve opening pressure
107.9 14.7kPa (1.1 0.15kg/cm, 15.65

2.13psi)
83.4kPa (0.85kg/cm, 12.1psi)
-6.86kPa (-0.07kg/cm, -1.00psi)
Air cleaner
Type
Element
Dry
Paper type
Exhaust pipe
Muffler
Suspension system
Expansion reaonance type

Rubber hangers
SERVICE STANDARD
Standard value
Coolant concentration
Tropical areas
40%
Other areas
50%
COOLANT
Engine coolant
Ethylence glycol base for aluminum radiator
SEALANT
Engine coolant temperature sensor
LOCTITE 262 or equivalent, Three bond No. 1324 or

equivalent.
Oil pressure switch
3M ATD No. 8660 or Three bond No. 1141E
PCV valve
LOCTITE 242 or equivalent
TIGHTENING TORQUE
Item
Nm
kg.cm
lb.ft
Camshaft sprocket bolt
90 ~ 110
900 ~ 1,100
65 ~ 80
Cylinder head cover bolt
8 ~ 10
80 ~ 100
5.8 ~ 7.2
Main bearing cap bolt

M10
M8
27~33 + (90~94)
13~19 + (90~94)
270~330 + (90~94)
130~190 + (90~94)
19.5 ~24 +
(90 ~ 94
10~14 +
(90~94)
Connecting rod bolt
16~20 + (90~94)
160~200 + (90~94 )
12~15 +
(90~94)
25 + (58~92) + (43~47 )
250 + (58~92) + (43~47)
18 + (58
~92) +
(43~47)
Cylinder head bolt (Cold engine)

Oil pan drain plug
35 ~ 45
350 ~ 450
25 ~ 33
Lower oil pan bolt
10 ~ 12
100 ~ 120
7~9
Upper oil pan bolt

[1038mm (0.9371.4961in.)]
[822mm (0.31500.8661in.)]
[161.5mm(6.3582in.)]
[152.5mm (6.0039in.)]
30 ~ 42
19 ~ 28
5~7
5~7
300 ~ 420
190 ~ 280
50 ~ 70
50 ~ 70
22 ~ 30
14 ~ 20
4~5
4~5
Oil screen bolt
15 ~ 22
150 ~ 220
11 ~ 16
Oil pump case bolt
12 ~ 15
120 ~ 150
9 ~ 11
Oil relief valve plug
40 ~ 50
400 ~ 500
29 ~ 36
Oil pressure switch
15 ~ 22
150 ~ 220
11 ~ 16

24.04.2008
Page 4 of 12
Oil pump cover screw
8 ~ 12
80 ~ 120
6~9
Oil filter
12 ~ 16
12 ~ 160
9 ~ 12
Fly wheel bolt
73 ~ 77
730 ~ 770
53 ~ 56
Drive plate and adaptor plate bolt
73 ~ 77
730 ~ 770
53 ~ 56
Air cleaner body installation bolt
8 ~ 12
80 ~ 120
6~9
Surge tank stay
15 ~ 20
150 ~ 200
11 ~ 14
Air intake surge tank to intake manifold (bolt)
15 ~ 20
150 ~ 200
11 ~ 14
Air intake surge tank to intake manifold (nut)
15 ~ 20
150 ~ 210
11 ~ 14
Intake manifold to cylinder head
19 ~ 21
190 ~ 150
14 ~ 15
Heat protector to exhaust manifold
12 ~ 15
120 ~ 350
9 ~ 11
Exhaust manifold to cylinder head (Self-locking

nut)
30 ~ 35
300 ~ 150
22 ~ 26
Oil level gauge guide to engine
12 ~ 15
120 ~ 200
9 ~ 11
Water outlet fitting bolt
17 ~ 20
170 ~ 260
12 ~ 14
Power steering oil pump bracket to cylinder head
17 ~ 26
170 ~ 260
12 ~ 19
Power steering oil pump bracket
17 ~ 26
170 ~ 260
12 ~ 19
Crank position sensor wheel screw
5~6
50 ~ 60
3.6 ~ 4.3
Engine mounting insulator bolt
40 ~ 55
400 ~ 550
29 ~ 40
Engine mounting bracket nut
60 ~ 80
600 ~ 800
43 ~ 58
Engine mounting bracket bolt
60 ~ 80
600 ~ 800
43 ~ 58
Engine support bracket stud
30 ~ 40
300 ~ 400
22 ~ 59
Front roll stopper bracket to sub cross member

bolt
40 ~ 55
400 ~ 550
29 ~ 40
Front roll stopper insulator bolt and nut
50 ~ 65
500 ~ 650
36 ~ 47
Rear roll stopper bracket to cross member bolt
40 ~ 55
400 ~ 550
29 ~ 40
Rear roll stopper insulator bolt and nut
50 ~ 65
500 ~ 650
36 ~ 47
Transaxle mounting bracket bolt
40 ~ 55
400 ~ 550
29 ~ 40
Transaxle mounting insulator bolt
90 ~ 110
900 ~ 1,100
65 ~ 80
Fuel hose clamp to rear cylinder head assembly
12 ~ 15
120 ~ 150
9 ~ 11
Transaxle mounting plate
10 ~ 12
100 ~ 120
7~9
Rear plate
10 ~ 12
100 ~ 120
7~9
Oil seal case
10 ~ 12
100 ~ 120
7~9
Crankshaft pulley bolt
180 ~ 190
1,800 ~ 1,900
130 ~138
Timing belt cover bolt
10 ~ 12
100 ~ 120
7~9
Engine hanger bracket to engine
20 ~ 27
200 ~ 270
14 ~ 20
Alternator mounting bracket to engine
20 ~ 30
200 ~ 300
14 ~ 22
Alternator mounting nut (Engine front case side)
20 ~ 30
200 ~ 300
14 ~ 22
Alternator mounting bolt (Alternator mounting

bracket side)
20 ~ 30
200 ~ 300
14 ~ 22
Starter to transmission (Nut)
20 ~ 30
200 ~ 300
14 ~ 22
Starter to transmission (Bolt)
27 ~ 34
270 ~ 340
20 ~ 25
Driver belt pulley bolt
35 ~ 55
350 ~ 550
25 ~ 40
Driver belt tensioner bolt
20 ~ 27
200 ~ 270
14 ~ 20
Engine coolant pump to cylinder block bolt

(Head mark "7" mark)
15 ~ 22
150 ~ 220
11 ~ 16
20 ~ 40
200 ~ 400
14 ~ 29

24.04.2008
Page 5 of 12
Engine coolant inlet fitting attaching bolt
17 ~ 20
170 ~ 200
12 ~ 14
Throttle body to surge tank bolt
15 ~ 20
150 ~ 200
11 ~ 14
Oxygen sensor to exhaust manifold
40 ~ 50
400 ~ 500
29 ~ 36
Front exhaust pipe to exhaust manifold nut
30 ~ 40
300 ~ 400
22 ~ 29
Front exhaust pipe to catalytic converter bolt
40 ~ 60
400 ~ 600
29 ~ 43
Catalytic converter to center exhaust pipe nut
30 ~ 40
300 ~ 400
22 ~ 29
Center exhaust pipe to main muffler nut
30 ~ 40
300 ~ 400
22 ~ 29
Main muffler hanger support bracket bolt
10 ~ 15
100 ~ 150
7 ~ 11
Delivery pipe installation boly
10 ~ 15
100 ~ 150
7 ~ 11
Timing belt tensioner pulley bolt
43 ~ 55
430 ~ 550
31 ~ 40
Timing belt idler pulley bolt
50 ~ 60
500 ~ 600
36 ~ 43
Timing belt tensioner arm fixed bolt
35 ~ 55
350 ~ 550
25 ~ 40
Auto tensioner fixed bolt
20 ~ 27
200 ~ 270
14 ~ 20
Accelerator cable bracket
4~6
40 ~ 60
3~4
20 ~ 30
200 ~ 300
14 ~ 22
Spark plug
CHECKING ENGINE OIL

1. Position a vehicle on a level surface.
2. Turn off the engine.
In the case of a vehicle that has not been used for a prolonged period, run the engine for several minutes.
Turn off the engine and wait for 5 minutes at least, then check the oil level.
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is found to have fallen to
the lowerlimit (the "L" mark), refill to the "F" mark.
When refilling, use the proper grade of engine oil.

4. Check that the oil is not dirty or mixed with coolant or gasoline, and that it has the proper viscosity.
SELECTION OF ENGINE OIL

Recommended API classification: SH OR ABOVE
Recommended SAE viscosity grades :

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Page 6 of 12
1. Satisfy the requirements of the API classification.

2. Have the proper SAE grade number for expected ambient temperature range.
CHANGE ENGINE OIL

1. Run the engine until it reaches normal operating temperature.
2. Turn off the engine.
3. Remove the oil filler cap and oil filter and then drain plug.
Drain the engine oil.
4. Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug :
35 ~ 45Nm (350 ~ 450kg.cm, 25 ~ 33lb.ft)
Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill the new engine oil through the oil filler cap.
Drain and Refill
Oil quantity : 4.5lit (4.74U.S.qts., 3.95lmp.qts.)

24.04.2008
Page 7 of 12
Do not over fill. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.
7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.
REPLACEMENT OIL FILTER

High quality of replacement filters should be used to assure the most efficient service. Make sure that the rubber gasket from
the old oil filter is completely removed from the contact surface on the engine block beforeinstalling a new filter.
Procedure for Replacing Oil Filter

1. Use a filter wrench to remove the oil filter.
2. Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. Tighten the oil filter of the specified torque.
Tightening torque
Oil filter : 12 ~ 16Nm (120 ~ 160kg.cm, 9 ~ 12lb.ft)
4. Start and run the engine and check engine oil leaks.
5. After stopping the engine, check the oil level and add oil as necessary.
CHECKING COOLANT LEAK CHECK

1. Loosen the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 KPa (21psi, 1.53 kg/cm) pressure. Hold for two
minutes, then checkfor leakage from the radiator, hoses or connections.

24.04.2008
Page 8 of 12
1. Radiator coolant may be extremely hot. Do not open the system while hot, or scalding engine coolant could gush
out, causing personal injury. Allowthe vehicle to cool before servicing this system.
2. When the tester is removed, be careful not to spill any coolant from it.
3. Be sure to clean away completely any coolant from the area.
4. Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator.
4. If there is leakage, repair or replace with the apropriate part.
RADIATOR CAP PRESSURE TEST

1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving.
Main valve opening pressure :
107.9 14.7kPa (1.1 0.15kg/cm , 15.64 2.13psi)
Main valve closing pressure :
83.4 kPa (0.85 kg/cm, 12.1 psi
3. Check that the pressure level is maintained at or above the limit.
4. Replace the radiator cap if the reading does not remain at or above the limit.
Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect
reading.
SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and
temperature. Use the followingtable for reference.
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

24.04.2008
Page 9 of 12
Coolant temperature C (F) and specific gravity

10 (50)
20 (68)
30 (86)
40 (104)
50 (122)
1.054
1.050
1.046
1.042
1.036
1.063
1.058
1.054
1.049
1.044
1.071
1.067
1.062
1.057
1.052
1.079
1.074
1.069
1.064
1.058
1.087
1.082
1.076
1.070
1.095
1.090
1.084
1.103
1.098
1.092
Safe
Coolant
Freezing
operating concentration
temperature
(Specific
temperature
C(F)
volume)
C(F)
-16 (3.2)
-11 (12.2)
30%
-20 (-4)
-15 (5)
35%
-25 (-13)
-20 (-4)
40%
-30 (-22)
-25 (-13)
45%
1.064
-36 (-32.8)
-31 (-23.8)
50%
1.077
1.070
-42 (-44)
-37 (-35)
55%
1.084
1.076
-50 (-58)
-45 (-49)
60%
The safe operating temperature is -15C (5F) when the measured specific gravity is 1.058 at coolant temperature of 20C
(68F).
If the concentration of the coolant is below 30%, its anti-corrosion property will be adversely affected.
If the concentration is above 60%, the engine cooling property will decrease, affecting the engine adversely. For
these reasons, be sure to maintainthe concentration level within the specified range.
Do not mix types of anti - freeze.
RECOMMENDED COOLANT
Antifreeze
Mixture ratio of antifreeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM
50% [Except tropical areas]

40% [Tropical areas]
CHECKING COMPRESSION PRESSURE

1. Before checking the engine compression, check the engine oil level. Also check that the starter motor and battery are all in
normal operatingcondition.
2. Start the engine and wait until the engine coolant temperature reaches 80 ~ 95C (176 ~ 205F).
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign material in the cylinders.
6. Insert the compression gauge into the spark plug hole.
7. Depress the accelerator pedal to open the throttle fully.
8. Crank the engine and read the gauge.
Standard value : 1,200kpa (12.2 kg/cm , 170psi)
Limit : 1,050kpa (10.7kg/cm , 149psi)
9. Repeat steps 6 to 8 for all cylinders, making sure that the pressure difference for each of the cylinders is within the
specified limit.
Limit

24.04.2008
Page 10 of 12
Max. 100kpa (1.0 kg/cm, 14psi) between cylinders

10. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through the spark
plug hole, andrepeat steps 6 to 9.
(1) If the addition of oil causes the compression to rise, it is possible that the piston ring is worn.
(2) If the compression remains the same, valve seizure, poor valve seating or a compression leak in the cylinder head
gasket are all possible causes.
Tightening torque
Spark plug : 20 ~ 30Nm (200 ~ 300kg.cm, 14 ~ 22 lb.ft)
TIGHTENING CYLINDER HEAD BOLTS

1. First loosen slightly and then tighten to the specified torque.
Tightening torque
Cylinder head bolts cold [Engine temperature approximately 20C (68F)] :
25Nm (250kg.cm, 18lb.ft) + (58 ~ 62) + (43 ~ 47)
2. Use the torque - angle method to torque the head bolts.

3. Be sure to follow the specific torque sequence as shown in the illustration.
Run the engine to normal operating temperature and let it cool, then re-torque the bolts to specifications.
ADJUSTING VALVE CLEARANCE

As the intake and exhaust valves are equipped with hydraulic lash adjusters, there is no need to adjust the valve clearance.
The proper function of the hydraulic lash mechanism may be determined by checking for tappet noise. When there is a tappet
noise or any unusual noise, check the hydraulic lash adjusterby removing and bleeding or replacing it.
ADJUSTING DRIVE BELT AND TENSIONER

1. Hang the belt on the pulley of the tensioner and install the tensioner.
(If the tensioner is already installed, loosen its mounting bolts to allow belt installation.)
Tightening torque
Tensioner assembly bolt :
20 ~ 27 Nm (200 ~ 270 kg.cm, 14 ~ 20 lb.ft)

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2. Install the belt in the fllowing order.

[Alternator Power steering Crankshaft pulley Air conditioner pulley.]
3. Rotate the tensioner arm clockwise (about 14) with a spaner (16 mm ) and fit the belt to the idler pulley.
4. When installing the belt on the pulley, make sure it is centered on the pulley.

24.04.2008
Page 12 of 12
5. The tensioner mark should be between the "MIN" and "MAX" position. If not, replace the belt.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information > Special
Service Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General
Information > Special Service Tools
SPECIAL TOOLS
Tool (Number and name)
Illustration
Use
Crankshaft front oil seal installer

(09214-33000)
Installation of the crankshaft

front oil seal
Camshaft oil seal installer

(09221-21000)
Installation of the camshaft oil

seal
Valve guide installer

(09221-3F100 A/B)
Removel and installation of the

valve guide
Valve stem oil seal installer

(09222-22001)
Installation of the valve stem oil

seal
Valve spring compressor

(09222-28000)
(09222-28100)
Remove and installation of the

intake or exhaust valve
Valve stem oil seal remover

(09222-29000)
Removeal of the valve stem oil

seal
Crankshaft rear oil seal installer

(09231-33000)
Installation of the crankshaft

rear oil seal
Crankshaft wrench
(09231-33100)
Used if the crankshaft needs to

be rotated to attach the tming
belt, etc.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General
TROUBLESHOOTING
Symptom
Crankshaft bearing knock
Probable cause
Remedy
Worn main bearing

Seized bearing
Bent crakshaft
Excessive crankshaft end play
Replace
Repalce
Replace
Replce thrust bearing
Worn bearing
Seized bearing
Worn piston pin
Worn piston in cylinder
Broken piston ring
Improper connecting rod alignment
Replace
Repalce
Replace piston and pin or
connecting rod
Recondition cylinder
Replace
Repalce
Noisy valves
Faulty auto-lash adjuster

Thin or diluted engine oil (low oil pressure)
Worn or damaged valve stem or valve
guide
Replace
Change
Repalce
Excessively worn cylinder and

piston
Shorted or engine oil

Dirty engine oil
Poor quality of engine oil
Improperly assembled piston and
connecting rod
Improper piston ring end clearance
Dirty air cleaner
Add or replace
Repalce
Use proper oil
Repair or replace
Replace
Clean air cleaner assembly and
replace the air filter
Connecting rod and main

bearing noise
Insufficient oil supply

Thin or diluted engine oil
Excessive bearing clearnace
Check engine oil level

Change and find out cause
Replace
Shorted of engine oil

Low oil pressure
Poor quality of engine oil
Worn or out-of-round of crankshaft journal
Restricted oil passage in crankshaft
Worn bearing
Faulty oil pump
Bearing improperly installed
Non-concentric crankshaft or bearing
Add or replace
Adjust or repair
Use proper engine oil
Replace
Clean
Replace bearing and check
engine oil and lubrication
system
Repair or replace
Repaur or replace
Replace
Incorrect belt tension
Adjust belt tension
Damaged cylinder head gasket

Worn or damaged piston rings
Worn piston or cylinder
Worn or damaged valve seat
Replace gasket
Replace rings
Repair or replace piston and/or
cylinder block
Repair or replace valve and/or
seat ring
Low engine oil level

Faulty oil pressure switch
Clogged oil filter
Worn oil pump gears or cover
Check engine oil level

Repalce
Replace
Replace
Piston and connecting rod knock
Damaged crankshaft bearing
Timing belt noise

Low compression
Oil pressure drop

24.04.2008
Page 2 of 2
Thin or diluted engine oil

Oil relief valve stuck (open)
Excessive bearing clearance
Change and find out cause

Repair
Replace
High oil pressure
Oil relief valve stuck (closed)
Repair or replace
Excessive engine rolling and

vibration
Misfire
Loose engine roll stopper (front, rear)
Loose transaxle mount bracket
Loose center member
Broken transaxle mount insulator
Broken engine mount insulator
Broken engine roll stopper insulator
Correct
Re-tighten
Re-tighten
Re-tighten
Re-tighten
Replace
Repalce or repalce
Low coolant level
Leakage of coolant
Damaged radiator core joint
Corroded or cracked hoses (Radiator hose,
heater hose, etc.)
Faulty radiator cap valve or setting or
spring
Faulty thermostat
Faulty engine coolant pump
Correct
Replac
Replace
Replace
Repacle
Repalce
Clogged radiator
Foreign material in coolant
Replace
Abnormally high coolant

temperature
Faulty thermostat
Faulty radiator cap
Restriction of flow in cooling system
Loose or missing drive belt
Faulty engine coolant pump
Faulty thermostat seder or wiring
Faulty electric fan
Faulty thermo-sensor on radiator
Insufficient coolant
Replace parts
Replace
Clear restriction or replace parts
Adjust or replace
Replace
Repair or repalce
Repair or replace
Replace
Refill coolant
Abnormally low coolant

temperature
Faulty thermostat
Faulty temperature gauge or wiring
Replace
Repair or replace
Leakage from oil cooling system Loose hose and pipe connection
Blocked or collapsed hose and pipe
Replace
Repair or replace
Inoperative electrical cooling fan Damaged

Loose pipe or in operative sensor
Replace or repair
Repair or replace
Exhaust gas leakage
Loose connections
Broken pipe or muffler
Re-tighten
Repair or replace
Abnormal noise
Detached baffler plate in muffler

Broken rubber hanger
Pipe or muffler contacting vehicle body
Broken pipe or muffler
Replace
Replace
Correct
Repair or replace

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Timing System > Timing Belt >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Timing System > Timing Belt > Components and Components Location
COMPONENTS
Timing belt

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Timing System > Timing Belt >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Timing
System > Timing Belt > Repair procedures
REMOVAL
1. Remove the engine cover.
2. Using a [16 mm], rotate the tensioner arm clockwise (about 14 )and remove the belt from the pulley.
3. Remove the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
4. Remove the upper and lower timing belt covers.
5. Remove the auto tensioner.
Rotate the crankshaft clockwise and align the timing mark to set the No.1 cylinder's piston to TDC
(compression stroke).
At this time, the timing marks of the camshaft sprocket and cylinder head cover should coincide with each
other.

24.04.2008
Page 2 of 5
6. Unbolt the tensioner to remove the timing belt.
If you plan to use the timing belt again, mark the rotation direction on the belt so you reinstall it correctly.
INSTALLATION
1. Install the idler pulley to water pump boss.
Insert and install the idler pulley to the roll pin that is pressed in the water pump boss.
2. Install the tensioner arm and plain washer to the cylinder block.
3. Install the tensioner pulley to the tensioner arm.
4. Install the camshaft sprockets and align the timing marks.

24.04.2008
Page 3 of 5
When installing the camshaft sprockets, fasten them tightly while holding the hexagonal part of the
camshaft.
Before installing the timing belt, if the timing marks of the cam sprocket and the cylinder head cover
do not coincide, do not rotate thecam sprocket more than 3 teeth in either direction.
Rotating the sprocket more than 3 teeth may allow the valve and piston to touch each other.
If the cam sprocket is rotated more than 3 teeth unavoidably, rotate the crankshaft counter-clock wise
a bit before rotating the cam sprocket.
5. Install the auto tensioner to the front case.
At this time auto tensioner's set pin should be compressed and secured with set pin.
6. Align the timing marks of each sprocket and install the timing belt in the following order.
1.Crankshaft sprocket 2.Idler pulley 3.camshaft sprocket (LH side) 4.Water pump pulley
5.camshaft sprocket (RH side) 6.Tensionerpulley.
In this step, No. 1 cylinder is in the TDC (Compression stroke).

Be very careful if you use your fingers.
7. Pull out the set pin of the auto tensioner.

24.04.2008
Page 4 of 5
8. Install the upper and lower timing belt covers.

9. Install the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
10. Using the wrench [16mm], rotate the tensioner arm clockwise (about 14) and install the belt to the pulley.
11. Install the engine cover.
How to adjust the tension of the timing belt

1. Rotate the crankshaft 2 turns clockwise and measure the projected length of the auto tensioner at TDC ( #1
Compression stroke) after 5 minutes.
2. The projected length should be 7 ~ 9mm (0.27 ~ 0.31in.).
3. Verify that the timing marks of each sprocket are in their specified position.
If the timing marks are not in their specified position, repeat from 6 above.
INSPECTION
1. Inspect the belt closely. If the following problems are evident, replace the belt with a new one.
(1) Hardened back surface of rubber
Back surface is glossn, non-elastic and so hardthat when the nail of your finger is pressed into it, no mark
is produced.
(2) Cracked back surface of rubber.

24.04.2008
Page 5 of 5
(3) Side of belt is badly worn.
A belt in good condition should have clear-cut sides as if it were cut with a sharp knife.
(4) Teeth are badly worn out.

Last stage : Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width
reduced).
(5) Missing tooth
2. If backlash or an irregular noise is observed when rotating the pulley, replace the timing belt tensioner and
idler pulley.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly > Camshaft >
Cylinder Head Assembly > Camshaft > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly >
Camshaft > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Cylinder Head Assembly > Camshaft > Repair procedures
DISASSEMBLY
1. Remove the engine cover and intake manifold.
2. Disconnect the breather hose and the engine harness.

3. Remove the power steering pulley, air conditioner pulley, crankshaft pulley, idler pulley and tensioner pulley.
4. Remove the timing belt cover.
5. Loosen the auto tensioner.
6. Remove the timing belt from the camshaft sprocket.
7. Remove the spark plug cables.
8. Loosen the cylinder head cover bolts and then remove it.
9. Remove the camshaft sprockets.

10. Remove the camshaft bearing caps.
11. Remove the camshafts.

24.04.2008
Page 2 of 6
INSPECTION
1. Check the camshaft journals for wear. If the journals are badly worn out, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or excessively worn out, replace the camshaft.
Cam height
[Standard]
Intake : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
Exhaust : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
[Limit]
Intake/Exhaust : 43.45mm (1.7106 in.)
3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head
assembly or camshaft bearing cap, as necessary.
Camshaft end play : 0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)
Oil Seal (Camshaft front)

1. Check the lips for wear. If lip threads are worn out, replace the oil seal with new one.
2. Check a contact surface of oil seal lip on camshaft. If there stratified wear, replace the camshaft.
HLA (Hydraulic Lash Adjuster)

With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.

24.04.2008
Page 3 of 6
Problem
1. Temporary noise when starting a
cold engine
Possible cause
Normal
Action
This noise will disappear after the oil
in the engine reaches the normal
pressure.
2. Continuous noise when the engine

is started after parking more than 48
hours.
Oil leakage of the high pressure Noise will disappear within 15 minutes
chamber on the HLA,allowing
when engine runs at 2000-3000 rpm.
air to get in.
If it doesn't disappear, refer to step 7
below.
Insufficient oil in cylinder head
is first started after rebuilding cylinder
oil gallery.
head.
is started after excessivly craking the
engine by the starter motor or band.
Oil leakage of the high-pressure

chamber in the HLA, allowing air
to get in.
Insufficient oil in the HLA.

is running after changing the HLA.
6.Continuous noise during idle after

high engine speed.
Do not run engine at a speed

higher than 3000 rpm, as this may
damage the HLA.
Engine oil level too high or too
low.
Check oil level.

Drain or add oil as necessary.
Excessive amount of air in the

oil at high engine speed.
Check oil supply system.
Deteriorated oil.
7. Noise cotinues for more than 15

minutes.
Low oil pressure.

Faulty HLA.
Check oil quality.

If deteriorated, replace with specitied
type.
Check oil pressure and oil supply
syste, of each part of engine.
Remove the cylinder head cover and
press HLA down by hand.
If it moves, replace the HLA.
Timing chain
Check the bushing and plate of timing chain for wear. Replace if there is severe wear.
REASSEMBLY
1. Install the HLA.
2. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as
shown in the illustration.

24.04.2008
Page 4 of 6
3. Install the camshafts after lubricating the journals of the camshaft with engine oil.
To check the press fit, the camshaft (IN) and timing chain sprocket should be separable by a force
greater than 1000kg (MIN.)at room temperature.
4. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
I : Intake camshaft
E : Exhaust camshaft
5. Tighten the bearing caps to the specified torque in two or three increments as shown.
Tightening torque
Bearing cap bolt
M6 (50mm) : 14 ~ 16Nm (140 ~ 160kg.cm, 10 ~ 12lb.ft)
M6 (38mm) : 10 ~ 12Nm (100 ~ 120kg.cm, 7 ~ 9lb.ft)

24.04.2008
Page 5 of 6
6. Using the special tool, the camshaft oil seal installer (09221-21000), install the camshaft oil seal. Be sure to
apply engine oil to the externalsurface of the oil seal.
Insert the oil seal along the camshaft front end and install it with a hammer until it is seated.
7. Install the camshaft sprocket to the specified torque.

Tightening torque
Camshaft sprocket bolt :
90 ~ 110Nm (900 ~ 1100kg.cm, 65 ~ 80lb.ft)
8. Install the cylinder head cover.
Tightening torque
Cylinder head cover bolts :
8 ~ 10Nm (80 ~ 100kg.cm, 5.8 ~ 7.2lb.ft)
(1) Tighten all bolts temporarily to half of the specified torque in the sequence 1.2.3.4.5.6.7.8.
(2) Retighten all bolts to the specified torque.
9. Install the spark plug cables and, center cover.

10. Install the timing belt and then tighten the auto tensioner pulley.
11. Install the timing belt cover.
12. Install the power steering pulley, air conditioner pulley, crankshaft pulley and tensioner pulley.

24.04.2008
Page 6 of 6
13. Connect the breather hose and engine harness.

14. Install the intake manifold and engine cover.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly > Valve >
Cylinder Head Assembly > Valve > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 8
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly > Valve
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder
Head Assembly > Valve > Repair procedures
DISASSEMBLY
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose and air-intake hose.
3. Remove the vacuum hose, fuel hose and coolant hose.
4. Remove the intake manifold.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the upper and lower timing belt cover.
8. Remove the timing belt and camshaft sprockets.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and head cover.
11. Remove the intake and exhaust camshaft.
12. Remove the cylinder head assembly. The cylinder head bolts should be removed using the S12 mm socket,
in two or three steps.
13. Clean the gasket pieces from the cylinder block top surface and cylinder head bottom surface.
Make sure that fragments from the gasket do not fall in the engine.

24.04.2008
Page 2 of 8
INSPECTION
1. Remove scale, sealing compound and carbon deposits. After cleaning oil passages, apply compressed air to
make certain that the passages are notclogged.
2. Visually check the cylinder head for cracks, damage or water leakage.
3. Check the cylinder head surface for flatness with a straight edge and feeler gauge as shown in the illustration.
Cylinder head flatness
Standard dimensions : Max. 0.03mm (0.0059 in.)
Service limit : 0.05mm (0.0020 in.)
Valve Guides
Valve stem-to-guide clearance
Standard value
Intake : 0.02 ~ 0.05mm (0.0009 ~ 0.0020in.)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026 in.)
Service limit
Intake : 0.10mm(0.0039 in.)
Exhaust : 0.15mm(0.0059 in.)

24.04.2008
Page 3 of 8
Valve
1. Replace the valve if its stem is bent, worn or damaged. Also replace it if the stem end (the surface contacting
the hydraulic-lash adjuster) ishollowed out.
2. Check the valve face contact area, and recondition or replace as necessary.
3. Replace the valve if the width of the margin (thickness of the valve head) is less than the minimum specified.
Valve margin
Standard value
Intake : 1.0mm(0.0394 in.)
Exhaust : 1.3mm(0.0512 in.)
Service limit
Intake : 0.5mm (0.0197in.)
Exhaust : 0.8mm (0.0315in.)

24.04.2008
Page 4 of 8
Valve Spring
1. Check the free height of each valve spring and replace if necessary.
2. Using a square, test the squareness of each valve spring. If the spring is excessively out-of-square, replace it.
Valve spring
Standard value
Free height : 42.5mm (1.6732 in.)
Load : 21.9kg/35mm (48.4 lb/1.3780in.)
Out of squareness : Max. 1.5
Service limit
Load : 21.9kg/34mm (48.4 lb/1.3386in.)
Out of squareness : Max. 3
Replacing Valve Guide

1. Using the special tool (09221-3F100 A/B), withdraw the old valve guide out the bottom of the cylinder head.
2. Recondition the valve guide hole so that it can receive the newly press-fitted oversize valve guide.
Valve Guide Oversizes
Size mm (in.)
Size mark
Oversize valve guide hole size

mm(in.)
0.05 (0.002) O.S.
11.050 ~ 11.068
(0.435 ~ 0.4357)
0.25 (0.010) O.S.
25
11.250 ~ 11.268
(0.443 ~ 0.4436)
0.50 (0.020) O.S.
50
11.500 ~ 11.518
(0.453 ~ 0.4535)

24.04.2008
Page 5 of 8
3. Using the special tool (09221-3F100 A/B) press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guidesare different in
length.
4. After the valve guide is press-fitted, insert a new valve and check for proper clearance.
5. After the valve guide is replaced, check that the valve is fully seated. Recondition the valve seats as
necessary.
Do not install a valve guide unless it is oversize.
Replacing Valve Seat Ring

1. Cut away the inner face of the valve seat to reduce the wall thickness.
2. Enlarge the diameter of the valve seat so that it matches the specified hole diameter of the new valve seat
ring.

24.04.2008
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Valve Seat Ring Oversizes

Description
Size mm (in.)
Size
mark
Seat ring height H mm

(in.)
Oversize hole diameter

I.D. mm(in.)
Intake valve
Seat ring
0.3 (0.012) O.S.
30
7.9 ~ 8.1 (0.311 ~ 0.319)
33.300 ~ 33.325
(1.311 ~ 1.312)
Exhaust valve
Seat ring
0.3 (0.012) O.S.
30
7.9 ~ 8.1 (0.311 ~ 0.319)
28.600 ~ 28.625
(1.126 ~ 1.127)
3. Heat the cylinder head to about 250C (480F) and press-fit an oversize seat ring for the bore in the cylinder
head.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width
Intake : 1.1 ~ 1.5mm (0.043 ~ 0.059in.)
Exhaust : 1.3 ~ 1.7mm(0.051 ~ 0.067 in.)
REASSEMBLY
1. Install the spring seats.
2. Using special tool (09222-22001), lightly tap the seal in position.
Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage of from the valve guides.
3. Apply engine oil to each valve. Insert the valve into their guides. Avoid pushing the valve into the seal by
force. After installing the valve,check that it moves smoothly.
4. Place valve springs so that the side coated with enamel faces toward the valve spring retainer.

24.04.2008
Page 7 of 8
5. Using the special tool (09222-28000, 09222-28100), compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are correctly in place before releasing the valvespring
compressor.
When the spring is compressed, check that the valve stem seal is not pressed against the bottom of the
retainer.
6. Clean both gasket surfaces of the cylinder head and cylinder block.
7. Verify the identification marks on the cylinder head gasket.
8. Install the gasket so that the surface with the identification mark faces toward the cylinder head.
Do not apply sealant to these surfaces.
9. Tighten the cylinder head bolts in the sequence shown in the illustration with a torque wrench.

24.04.2008
Page 8 of 8
10. Tighten the cylinder head bolts using the torque-angle method. Starting at top center, tighten all cylinder
head bolts in sequence as shown in the illustration, using the 12 mm socket.
Tightening procedure
Cylinder head bolt :
25Nm (250kg.cm, 18.1lb.ft) + (58~62) + (43~47)

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Engine And Transaxle Assembly
> Engine And Transaxle Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly >
Repair procedures
REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the engine harness connectors.

A. Engine wiring connectors (alternator, starter, etc.)
B. TPS connector
C. Power steering switch connector, oil pressure gauge connector.
D. Back up lamp switch connector.
E. A/T solenoid, inhibitor switch connector.
F. Coolant temperature sensor.
G. Ignition coil, power TR connector.
H. Idle speed control valve (ISC) connector.
I. MAP and ATS connectors.
J. Oxygen sensor connector.
4. Drain the engine coolant.

5. For a vehicle with automatic transaxles, disconnect the transaxle oil cooler hoses.
When disconnecting hoses, make identification marks to avoid making any mistake when installing them
again.
Be careful not to spill any of oil or fluid out of the hoses. Plug the openings to prevent the entry of foreign
material.
6. Disconnect the radiator upper and lower hoses on the engine side then remove the radiator assembly.

24.04.2008
Page 2 of 5
7. Disconnect the engine ground.

8. Disconnect the brake booster vacuum hose.
9. Disconnect the heater hoses (inlet and outlet) on the engine side.
10. Disconnect the accelerator cable at the engine side.
11. Using a special tool, remove the main fuel line at the delivery pipe (supply/return).
12. Disconnect the speedometer cable from the transaxle.
13. Disconnect the clutch cable or control cable from the transaxle.
14. Disconnect the power steering suction hose and return hose from the pump.
15. Detach the steering dust cover in the engine compartment and then disconnect the gear box universal joint
bolt.
Make sure to make identification marks between the universal joint and the gear box for reassembly.

24.04.2008
Page 3 of 5
16. Raise the vehicle and then remove the front tire.
17. Attaching the wheel speed sensor and caliper to the body. Remove the kunckle mounting bolts.
18. Drain the transaxle oil.
19. Remove the front muffler bolts.

20. Remove the transaxle control rod and extension rod (M/T only).
21. Put the special fixture on the T/M jack and then adjust it to the sub-frame.
Check that all the cables, harness connector and hose are disconnected from the engine and transaxle
assembly.
22. Remove the engine mounting bracket and the transaxle mounting bracket.

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Page 4 of 5
23. Remove the sub-frame installation bolts.
24. After removing the drive shaft, lower the engine and transaxle assembly on the jack then, remove the front
roll stopper and the rear roll stopper.

24.04.2008
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25. Remove the engine and transaxle assembly as a unit.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Piston and Connecting
Rod > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Cylinder Block > Piston and Connecting Rod > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Piston and
Connecting Rod > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Cylinder Block > Piston and Connecting Rod > Repair procedures
DISASSEMBLY
CONNECTING ROD CAP
Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for
proper reassembly.
1. Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing mark for
reassembly.
2. Push each piston connecting rod assembly toward the top of the cylinder.
DISASSEMBLY AND REASSEMLY OF THE PISTON PIN

1. Using the special tools 09234 - 33001 and 09234 - 3002, disassemble and reassemble the piston and
connecting rod.
2. The piston pin is a press fit in the rod little end, and the piston floats on the pin.
3. The tool consists of a support fixture with fork inserts, guides, adapters, an installer and a remover. The piston
is supported in the support fixture while the pin is being installed or removed. Guides help position the pin as it
is installed or removed, while the rod is supported by fork inserts.
4. To remove the pin from the piston, place the piston in the support fixture with the rod resting on the fork
inserts. Pass the remover tool through the top of the support fixture and use it to press out the pin.

24.04.2008
Page 2 of 6
5. To install a new pin, the proper fork inserts must be in place to support the rod.
6. Position the rod inside the piston. Insert the proper pin guide through one side of the piston and through the
rod. Hand tap the pin guide so it is held by the piston. Insert the new pin into the piston from the other side
and set the assembly into the support fixture with the pin guide facing down.
The pin guide should be centered on the connecting rod through the piston. If assembled correctly, the
pin guide will sit exactly under the center of the hole in the tool's arch, and rest evenly on the fork inserts.
If the wrong size pin guide is used, the piston and pin will not up with the support fixture.
7. Insert the installer tool through the hole in the arch of the support fixture and use an hydraulic press to force
the piston pin through the rod little end. Continue pressing until the pin guide falls free and the installer tool
seats against the top of the arch.
Do not exceed 1250 500 kg (2765 1100 lb) of force when the installing tool seats angainst the top of
the arch.
INSPECTION
Pistons and Piston Pins
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the
piston requires replacement, its rings should also be replaced.
3. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective. The
piston pin must be pressed smoothly by hand into the pin hole (at room temperature).
Piston Rings
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in
the ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the
piston and rings together. If it is less than the service limit, replace only the piston rings.
Piston ring side clearance
No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.)
[Limit]
No.1 : 0.1 mm (0.004 in.)
No.1 : 0.1 mm (0.004 in.)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles
to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap
exceeds the service limit, replace the piston ring.
Piston ring end gap

24.04.2008
Page 3 of 6
[Standard dimensions]
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
[Limit]
No.1, No.2 : 0.8mm (0.031in.)
Oil ring side rail : 1.0mm (0.039in)
When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the lower
part of cylinder that is less worn out.
Piston ring service size and mark
Standard
None
0.25mm (0.010in.) O.S

0.50mm (0.020in.) O.S
25
50
The mark can be found on the upper side of the ring next to the end.
Connecting Rods
1. When the connecting rod cap is installed, make sure that the cylinder numbers, marked on rod end cap at
disassembly, match. When a new connecting rod is installed, make sure that the notches holding the bearing
in placeare on the same side.
2. Replace the connecting rod if it is damaged at either end of the thrust faces. If it has a stratified wear, or if the
surface of the inside diameter of the small end is severely rough, replace the rod.
REASSEMBLY
1. Install the spacer.

24.04.2008
Page 4 of 6
2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring
groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove (as
illustrated).
Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure described in Step 2.
4. Apply engine oil around the piston and piston grooves.

5. Using a piston ring expander, install the No.2 piston ring.
6. Install the No. 1 piston ring.
7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps
are not positioned in the thrust and pin directions.

24.04.2008
Page 5 of 6
8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
9. Install the upper main bearings in the cylinder block.

10. Install the lower main bearings in the main bearing caps.
Install the bearing so it matches the oil hole in the block.
11. Install the thrust washers in the No. 3 main bearing cap with the oil grooves facing outward.
12. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are
directed toward the front of the engine.
13. When the connecting rod cap is installed, make sure that any cylinder numbers placed on the rod and cap at
disassembly match.
14. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on
the same side.
15. When assembling, bolts should be fastened using the plastic angle technique as follows.
(1) Apply oil to the threads and matching areas.
(2) Tighten the connecting rod bolt.
Tightening torque
Connecting rod bolt :
16 ~ 20Nm (160~200kg.cm, 12~15lb.ft) + (90~94)

24.04.2008
Page 6 of 6
After removing the connecting rod bolt, do not use it again.

When using a new bolt, do not tighten the bolt more than 3 times.
16. Check the connecting rod side clearance.

Connecting rod side clearance
Standard : 0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)
Limit : 0.4mm (0.0157in.)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Crankshaft >
Cylinder Block > Crankshaft > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Crankshaft >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder
Block > Crankshaft > Repair procedures
DISASSEMBLY
1. Remove the timing belt train, front case, flywheel, cylinder head assembly and oil pan. For details, refer to the
respective chapters.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
Mark the main bearing caps to be able to reassemble in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the cap
number.
INSPECTION
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective parts.
2. Inspect the crankshaft journal and pin for out-of-round and taper.
Standard value
Crankshaft journal O.D :
61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crankshaft pin O.D :
47.982 ~ 48.000mm (1.8890 ~ 1.8898in)
Main Bearings and Connecting Rod Bearings

Visually inspect each bearing for peeling, melting, seizure and improper contact. Replace any defective bearings.
Measuring Oil Clearance

Standard value
Oil clearance
Crankshaft main bearing :
0.004 ~ 0.022mm (0.00015 ~ 0.00087in.)
Connecting rod bearing :
0.018 ~ 0.036mm (0.00071 ~ 0.00141in.)
Limit : 0.1mm (0.004 in.)

24.04.2008
Page 2 of 5
Plastic gauge Method

Plastic gauge may be used to measure the clearance.
1. Remove oil, grease and any other dirt from the bearings and journals.
2. Cut the plastic gauge the same length as the width of the bearing and place it in parallel with the journal,
avoiding the oil holes.
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do
not turn the crankshaft. Remove the caps. Measure the width of the plasticgauge at the widest part by
usingthe scale printed on the gauge package.
If the clearance exceeds the service limit, the bearing should be replaced or an undersize bearing should be
used. When installing a new crankshaft,be sure to use standard size bearings.
If the standard clearance can not be obtained even after replacing the bearing, the journal and pin should be
ground to the undersize and a bearing of the corresponding size should be installed.
Oil Seal
Check the front and rear oil seals for damage or worn surfaces. Replace any seat that is defective.
Drive Plate (A/T)

Replace distorted, damaged, or cracked drive plates.
FLYWHEEL (M/T)
See EM section.
REASSEMBLY
Main Bearing
1. Install a grooved main bearing (upper bearing) on the cylinder block side.
2. Install a grooveless main bearing (lower bearing) on the main bearing cap side.
3. Install the crankshaft. Apply engine oil to journal and pin.
4. Install the bearing caps with the arrow mark directed toward the front of the engine. Cap number must be
correct.
5. Tighten the cap bolts to the specified torque.
Tightening torque
Main bearing cap bolts

24.04.2008
Page 3 of 5
M8(9~16) : 13~19Nm (130~190kg.cm, 10~14lb.ft) + (90~94)

M10(1~8) : 27~33Nm (270~330kg.cm, 19.5~24 lb.ft) + (90~94)
6. Cap bolts should be tightened evenly in stages 4 to 5 increments before they are tightened to the specified
torque.
7. Make certain that crankshaft turns freely and check the end play of the crankshaft.
Crankshaft end play
Standard : 0.070 ~ 0.250mm (0.0028 ~ 0.0098in.)
Limit : 0.4mm (0.016in.)
8. Using special tool(09231-33000), install the rear oil seal in oil seal case.
9. Apply sealant to the area shown in the illustration. Install the oil seal case in the cylinder block.
Tightening torque
Oil seal case bolt :
10 ~ 12Nm (100 ~ 120kg.cm, 7 ~ 9 lb.ft)

24.04.2008
Page 4 of 5
10. Tighten the rear plate to the specified torque.

Tightening torque
Rear plate : 10 ~ 12Nm (100 ~ 120kg.cm, 7 ~ 9 lb.ft)
11. Tighten the drive plate and the adapter plate (A/T).
Tightening torque
Drive plate and adapter plate bolt :
73 ~ 77Nm (730 ~ 770kg.cm, 53 ~ 56 lb.ft)
12. Tighten the fly wheel (M/T).

Tightening torque
Fly wheel installation bolt :
73 ~ 77Nm (730 ~ 770kg.cm, 53 ~ 56lb.ft)

24.04.2008
Page 5 of 5

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Cylinder Block >
Cylinder Block > Cylinder Block > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Cylinder Block
Block > Cylinder Block > Repair procedures
DISASSEMBLY
For further details, refer to the appropriate section.
INSPECTION
Cylinder Block
1. Check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Replace
the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated, in the directions A and B.
Level 2: Center of cylinder
3. If the cylinder bores show more than the specified out-of-round or taper, or if the cylidner walls are badly
scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings should be
installed.
Standard value
Cylinder bore : 86.7 mm (3.41 in.)
Out-of-round and taper of cylinder bore :
Max. 0.02 mm (0.0008 in.)
4. If a ridge exists at the top of the cylinder, cut it off with a ridge reamer.
5. Oversize pistons are available in two sizes.
Piston service size and mark mm (in.)
0.25 (0.010) O.S : 0.25
0.50 (0.010) O.S : 0.50
6. To rebore the cylinder bore to the oversize, maintain the specified clearance between the oversize piston and
the bore and make sure that all used pistons are the same oversize. The standard measurement of the piston
outside diameter is taken at a level of 15.5mm (0.61in.) above the bottom ofthe piston skirt and across the
thrust faces.
Piston-to-cylinder clearance
0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

24.04.2008
Page 2 of 3
7. Check for damage or cracks in the cylinders.

8. Check the top surface of the cylinder block for flatness. If the top surface exceeds the limit, grind to the
minimum limit or replace.
Standard value
Flatness of gasket surface : Max. 0.03mm (0.0012in.)
Service limit
Flatness of gasket surface : 0.05mm (0.0020in.)
When the cylinder head is assembled, grinding less than 0.2mm (0.008in.) is permissible.
Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark
Size
0.25
0.50
0.25mm (0.010in.)
0.50mm (0.020in.)
The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.01 to 0.03 mm (0.0004 to 0.0012 in.) (clearance between piston and cylinder)
- 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the
firing order.

24.04.2008
Page 3 of 3
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder
to the oversize.
REASSEMBLY
Install the following parts by referring to their respective sections.
1. Crankshaft
2. Drive plate
3. Piston
4. Cylinder head
5. Timing belt
6. Oil pump case

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Engine Mounts >
Cylinder Block > Engine Mounts > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Engine Mounts
Block > Engine Mounts > Repair procedures
REMOVAL
Attach a chain or cable to the engine hooks and lift enough so that there is no pressure on the motor mounts.
Engine Mounting
1. Remove the engine mounting insulator bolts.
2. Remove the engine mounting bracket from the engine.
Transaxle Mounting
1. Remove the transaxle mounting insulator bolts.
2. Remove the tranaxle mounting bracket from the transaxle.
Front Roll Stopper

Remove the front roll stopper bracket from the sub-frame.

24.04.2008
Page 2 of 2
Rear Roll Stopper

1. Remove the bolt from the rear roll stopper.
2. Remove the rear roll stopper from the subframe.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Description
and Operation
COOLING SYSTEM
INLET CONTROL
FLOW CHART

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Water pump >
Cooling System > Water pump > Components and Components Location
COMPONENTS
ENGINE COOLANT PUMP

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Water pump >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Water pump > Repair procedures
REMOVAL
1. Using the drain plug, drain the coolant.
2. Remove the drive belt and the engine coolant pump pulley.
3. Remove the timing belt cover, the auto tensioner and idler pulley.
4. Remove the engine coolant pump mounting bolts.
5. Remove the engine coolant pump assembly from the cylinder block.
INSTALLATION
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.
2. Install the new engine coolant pump gasket and pump assembly. Tighten the bolts to the specified torque.
Tightening torque
Engine coolant pump bolt
Head mark "7" :
15 ~ 22Nm (150 ~ 220kg.cm, 11 ~ 16lb.ft)
3. Install the auto tensioner and timing belt. Adjust the timing belt tension, then install the timing belt cover.
4. Install the drive belt, coolant pump pulley and then adjust the auto tensioner.
5. Refill the radiator with coolant.
6. Run the engine and check for leaks.
INSPECTION
1. Check the engine coolant pump for cracks, damage or wear, and replace the pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation and replace the pump assembly if
necessary.
3. Check the seal for leaks and replace the pump assembly if necessary.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Thermostat >
Cooling System > Thermostat > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Thermostat >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Thermostat > Repair procedures
REMOVAL
1. Drain the coolant to thermostat level or below.
2. Remove the inlet fitting and gasket.
3. Remove the thermostat.
INSTALLATION
1. Check that the flange of the thermostat is correctly placed in the socket of the thermostat housing.
2. Install the inlet fitting.

Tightening torque
Engine coolant inlet fitting bolt :
17 ~ 20Nm (170 ~ 200kg.cm, 12 ~ 14lb.ft)
3. Refill the coolant.
INSPECTION
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
3. Verify the temperature at which the valve begins to open.
Valve opening temperature : 80 ~ 84C (176 ~ 183.2 F)
Full opening temperature : 95C (203C)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Radiator > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator >
Repair procedures
REMOVAL
1. Disconnect the ground cable from the battery terminal.
2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose clamp.
5. For vehicles with automatic transaxles, disconnect the oil cooler hoses from the automatic transaxle.
Cover or plug the hose and inlets of the radiator so that dust and other foreign materials can not enter after the hose
is disconnected from the radiator.
6. Remove the radiator upper mounting bolt.
7. Remove the radiator together with the fan motor.

8. Remove the radiator fan motor and condenser fan motor from the radiator.
INSTALLATION
1. Fill the radiator and reservoir tank with a clean coolant mixture.
2. Run the engine until the coolant warms up enough so that the thermostat valve opens and then turn off the engine.
3. Remove the radiator cap and pour the coolant up to the filler neck of the radiator. Fill the reservoir tank to the upper level.
4. Check that there are no leaks from the radiator, hoses or connections.
INSPECTION
1. Check for foreign material between the radiator fins.
2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reservoir tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration (only A/T).

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator Cap >
Cooling System > Radiator Cap > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator Cap
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Radiator Cap > Repair procedures
INSPECTION
1. Check the radiator cap for damage, cracks or weakening.
2. Connect the tester to the radiator cap.

3. Increase the pressure until the indicator of the gauge stops moving.
4. Replace the radiator cap if the reading does not hold steady for about 10 seconds.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Engine Coolant Hose /
Pipes > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Cooling System > Engine Coolant Hose / Pipes > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Engine
Coolant Hose / Pipes > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Cooling System > Engine Coolant Hose / Pipes > Repair procedures
COOLANT TEMPERATURE SENSOR REPLACEMENT

REMOVAL
1. Drain the engine coolant.
2. Remove the engine harness after disconnecting the ground cable of the battery.
3. Remove the engine coolant sensor.
INSTALLATION
1. Apply sealant to the sensor's threads. Tighten it to the specified torque.
Recommended sealant
Three bond NO. 1324 or LOCTITE 262
Tightening torque
The coolant sensor :
20 ~ 40Nm (200 ~ 400kg.cm, 14 ~ 29lb.ft)
2. Connect the coolant sensor to the harness.
3. Connect the ground cable of battery.
4. Refill radiator with the coolant.
INSPECTION
Check the engine coolant pipe and hose for cracks, damage and restrictions. Replace if necessary.
REASSEMBLY
Fit the O-ring in the groove of the engine coolant inlet pipe end. Wet the periphery of the O-ring with water and
insert the engine coolant inlet pipe.
1.
2.
3.
4.
Do not apply oil or grease to the engine coolant pipe O-ring.

Keep the engine coolant pipe connections free of sand, dust, etc.
Insert the engine coolant pipe into the end of the engine coolant pump inlet.
Whenever installing the engine coolant inlet pipe, always replace the O-ring with a new one.

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Lubrication System > Oil Pump >
Lubrication System > Oil Pump > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Lubrication System > Oil Pump >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Lubrication
System > Oil Pump > Repair procedures
DISASSEMBLY
1. Remove the oil pressure switch, using 24 mm deep socket.
Since a sealant is used on the threaded area, be careful not to damage the oil pressure switch.
2. Remove the oil filter and the oil pan.
3. Remove the oil screen and gasket.
4. Remove the three bracket securing bolts and remove the oil filter bracket and gasket.
5. Remove the oil relief valve plug from the oil pump case.
6. Remove the oil pump case.
INSPECTION
Oil Pump
1. Visually check the parts of the oil pump case for cracks and damage.
2. Assemble the rotor on the oil pump and then check the clearance with a thickness gauge.
Oil pump side clearance
Standard value
Body clearance : 0.100 ~ 0.181mm (0.0039 ~ 0.0071 in.)
Side clearance : 0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)

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Relief Plunger and Spring

1. Check the relief plunger for smooth operation.
2. Check the relief spring for deformation or breaks.
Oil Filter Bracket

1. Make sure that there is no damage on the surface that mates with the oil filter.
2. Check the oil filter bracket for oil leaks or cracks.
Oil pressure Switch

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity
even when the fine wire is pushed,replace the switch.
3. If there is no continuity when a 50 kpa (7 psi) vacuum is applied through the oil hole, the switch is operating
properly.
Check for air leakage. If air leaks, the diaphragm is broken replace it.
Operation Pressure
Oil pressure switch :
20 ~ 40kpa (0.2 ~ 0.4kg/cm. 2.9 ~ 5.8 psi)
REASSEMBLY

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1. Install the oil pump case with the gasket.

Tightening torque
Oil pump case bolt :
12 ~ 15Nm (120 ~ 150kg.cm, 9 ~ 11lb.ft)
Oil pump cover screw :
8 ~ 12Nm (80 ~ 120kg.cm, 6 ~ 9lb.ft)
2. Install the oil seal into the oil pump case as tightly as possible, using the special tool (09214-33000).
3. Install the relief plunger and spring, and tighten the oil relief valve plug to the specified torque.
Tightening torque
Oil relief valve plug :
40 ~ 50Nm (400 ~ 500kg.cm, 29 ~ 36lb.ft)
4. Install the oil screen and a new gasket.

Tightening torque
Oil screen bolt :
15 ~ 22Nm (150 ~ 220kg.cm, 11 ~ 15lb.ft)
5. Clean the gasket surfaces of the cylinder block and the oil pan.
6. Apply sealant to the groove of the oil pan flange.

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1. Make the first cut approx. 4 mm from the end of the nozzle furnished with the sealant. After
application of the sealant, do not exceed 15 minutesbefore installing the oil pan.
2. Make sure that the sealant doesn't enter the inside of the oil pan.
7. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt
* : 19 ~ 28Nm (190 ~ 280kg.cm, 14 ~ 20lb.ft)
** : 5 ~ 7Nm (50 ~ 70kg.cm, 4 ~ 5lb.ft
*** : 30 ~ 42Nm (300 ~ 420kg.cm, 22 ~ 30lb.ft)
8. Tighten the oil pan bolts as shown in the illustration.
9. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.
Sealant
Three bond No.1141E or 3M ATD No. 8660 or equivalent
Do not torque the oil pressure switch too much.
Tightening torque
Oil pressure switch
15 ~ 22Nm (150 ~ 220kg.cm, 11 ~ 16lb.ft)

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Page 5 of 5
Sealant
Three bond No.1141E or 3M ATD No. 8660 or equivalent
10. Tighten the lower oil pan bolts as shown in figure.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Air Cleaner
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System
> Intake And Exhaust System > Air Cleaner > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Air
Cleaner > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Intake And Exhaust System > Air Cleaner > Repair procedures
REMOVAL
1. Disconnect the air flow sensor connector.
2. Remove the air intake hose and air duct connected to the air cleaner.
3. Remove the three bolts attaching the air cleaner mounting brackets.
4. Detach the air cleaner.
5. Remove the air flow sensor from the air intake hose.
Do not pull on the air flow sensor wires.
INSTALLATION
1. Install the air cleaner assembly following the reverse order of removal.
INSPECTION
1. Check the air intake hose, air cleaner cover for damage.
2. Check the air duct for damage.
3. Check the air cleaner element for restriction, contamination or damage.

If the element is slightly restricted, remove dust and debris by blowing compressed air from the inside of the
element. Replace the element if it cannotbe cleaned.

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Intake
Manifold > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Intake And Exhaust System > Intake Manifold > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System >
Intake Manifold > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Intake And Exhaust System > Intake Manifold > Repair procedures
REMOVAL
1. Remove the air intake hose connected to the throttle body.
2. Remove the accelerator and cruise control cables.
3. Remove the engine coolant hose and throttle body.

4. Remove the P.C.V. hose and brake booster vacuum hoses.
5. Disconnect the vacuum hose connections.
6. Remove the surge tank stay.
7. Bleed off the pressure in the fuel pipe line to prevent the fuel from spilling.
8. Disconnect the connector from high pressure hose.

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Page 2 of 4
9. Remove the surge tank.
10. Remove the surge tank and gasket.
11. Disconnect the fuel injector harness connector.
12. Remove the delivery pipe with the fuel injector and the pressure regulator.
When the delivery pipe is removed, be careful not to drop an injector.

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13. Disconnect the wiring harness of the coolant sensor assembly.
INSTALLATION
1. Install the intake manifold and delivery pipe reversing the order of the removal procedure.
Tightening torque
Intake manifold :
19 ~ 21Nm (190 ~ 210kg.cm, 14 ~ 15lb.ft)
INSPECTION
SURGE TANK AND INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage, cracking or restriction of the vacuum outlet port, water
or gas passages.

24.04.2008
Page 4 of 4
2. Check for distortion on the surface using a straight edge and feeler gauge.
Standard value : 0.15 mm (0.006 in.) or less
Service limit : 0.2 mm (0.0078 in.)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Exhaust
Manifold > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Intake And Exhaust System > Exhaust Manifold > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System >
Exhaust Manifold > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Intake And Exhaust System > Exhaust Manifold > Repair procedures
REMOVAL
1. Remove the heat protector.
2. Remove the exhaust manifold.

3. Remove the exhaust manifold gasket.
INSTALLATION
1. Install the exhaust manifold with gasket.
Tightening torque
Exhaust manifold :
30 ~ 35Nm (300 ~ 350kg.cm, 22 ~ 26lb.ft)
Do not re - use an exhaust manifold gasket.

2. Install the heat protector.
INSPECTION
1. Check for damage or cracks.
2. Using a straight edge and feeler gauge, check for distortion on the cylinder head matching surface.
Standard value : 0.15 mm (0.006 in.) or less
Service limit : 0.3 mm (0.012 in.) or less

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3. Check the exhaust manifold for damage and cracks.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Muffler >
Intake And Exhaust System > Muffler > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Muffler >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust
System > Muffler > Repair procedures
REMOVAL
Main Muffler
Before removing or inspecting the exhaust system, ensure that the exhaust system is cool.
1. Disconnect the main muffler from the center exhaust pipe.
2. Remove the rubber hangers and the main muffler.
Front Exhaust Pipe (Including catalytic converter)

1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe bolt and the exhaust manifold pipe mounting nuts.
3. Remove the front exhaust pipe.
INSTALLATION
1. Temporarily install the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe and the main
muffler, in this order.
2. Install the rubber hangers so that they hang equally left and right.
3. Tighten the parts securely and then confirm that there is no interference with any components.
INSPECTION
1. Check the mufflers and pipes for leaks, corrosion and damage.
2. Check the rubber hangers for deterioration and cracks.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information >
Schematic Diagrams
SCHEMATIC DRAWING [2.7 V6]

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Flow Diagram,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Flow Diagram
VACUUM HOSES LAYOUT

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information
> Components and Components Location
COMPONENTS
A. PCV valve
B. EVAP Canister Purge Solenoid Valve
C. Two-way Valve
D. Catalytic Converter (MCC)
E. Catalytic Converter (UCC)
F. Evap. Canister

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General
TROUBLESHOOTING
Symptom
Probable cause
Remedy
Engine will not start or hard to

start
Vacuum hose disconnected or damaged
Repair or replace
Malfunction of the EVAP Canister Purge

Solenoid Valve
Repair or replace
Rough idle or engine stalls
Vacuum hose disconnected or damaged
Repair or replace
Malfunction of the PCV valve
Replace
Malfunction of the evaporative emission

canister purge system
Check the system; if there is a

problem, check related
components parts
Positive crankcase ventilation line clogged
Check positive crankcase

ventilation system
Excessive oil consumption

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General
SPECIFICATIONS
Components
Function
Remarks
Crankcase Emission System

HC reduction
Positive Crankcase Ventilation (PCV) valve
Variable flow rate type
Evaporative Emission System

EVAP Canister
EVAP Canister Purge Solenoid Valve
Duty control solenoid valve
HC reduction
Exhaust Emission System

CO, HC, NOx reduction
MFI system (air-fuel mixtrue control device) CO, HC, NOx reduction
Three-way catalytic converter
Heated oxygen sensor feedback type

Monolithic type
MFI : Multiport Fuel Injection

EVAP : Evaporative Emission
SERVICE STANDARD
Item
Evaporative emission canister purge solenoid
valve
Coil resistance
Specifications
26 [at 20C (68F)]
TIGHTENING TORQUE
Item
Positive Crankcase Ventilation Valve
Nm
kgcm
lbft
8 ~ 12
80 ~ 120
6~8

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control System >
Flow Diagram, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control
System > Flow Diagram
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control
System > Positive Crankcase Ventilation (PCV) Valve > Description and Operation, TIBURON(GK) >
2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control System > Positive
Crankcase Ventilation (PCV) Valve > Description and Operation
OPERATION
Intake manifold side (No vacuum)
Intake manifold side (High vacuum)
Rocker cover side
Rocker cover side
Engine condition
Not running
Engine condition
Idling or decelerating
PCV valve
Not running
PCV valve
Fully operating
Vacuum passage
Restricted
Vacuum passage
Small
Intake manifold side (Moderate vacuum)
Intake manifold side (Low vacuum)
Rocker cover side
Rocker cover side
Engine condition
Normal operation
Engine condition
Accelerating and high load
PCV valve
Properly operating
PCV valve
Slightly operating
Vacuum passage
Large
Vacuum passage
Much large

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control
System > Positive Crankcase Ventilation (PCV) Valve > Repair procedures, TIBURON(GK) > 2003 > G
2.7 V6 DOHC > Emission Control System > Crankcase Emission Control System > Positive Crankcase
Ventilation (PCV) Valve > Repair procedures
REMOVAL
1. Disconnect the ventilation hose from the positive crankcase ventilation(PCV) valve. Remove the PCV valve
from the rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum is felt.
The plunger inside the PCV valve will move back and forth.
3. If vacuum is not felt, clean the PCV valve and ventilation hose in cleaning solvent, or replace if necessary.
INSTALLATION
Install the positive crankcase ventilation valve and tighten to the specified torque.
Tightening torque PCV valve:
8~12 Nm (80~120 kgcm, 6~8 lbft)
INSPECTION
1. Remove the positive crankcase ventilation valve.
2. Insert a thin stick into the positive crankcase ventilation valve from the threaded side to check that the plunger
moves.
3. If the plunger does not move, the positive crankcase ventilation valve is clogged. Clean or replace it.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control System >
Flow Diagram, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission
Control System > Flow Diagram
COMPONENTS

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Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative
Emission Control System > Description and Operation
DESCRIPTION
On-Board Refueling Vapor Recovery(ORVR) system is properly designed to prevent the fuel tank vapor(HC) emission
during refueling at the gas station. This system consists of fill vent valve(ORVR), fuel shut-off valve, fuel cut valve(roll
over), two way valve(pressure/vacuum relief), fuel liquid/vapor separator which is installed beside the filler pipe, charcoal
canister which is mounted under the rear floor LH side member with protector, tubes and miscellaneous connections. While
refueling, the flow and column of the refueling draws the ambient air into the filler pipe so as not to emit fuel vapor in the
air. The fuel vapor in the tank is then forced to flow into the canister via the fill vent valve and the fuel liquid/vapor separator
which isolates liquid fuel ingredient and transfers the pure vapor to the carbon canister. While the engine is operating, the
trapped vapor emission in the canister is drawn and fed by the intake manifold vacuum into the engine combustion
chamber. According to this purge process, the carbon canister is purged and recovers its absorbing capability.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control
System > Canister > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control
System > Evaporative Emission Control System > Canister > Repair procedures
INSPECTION
For monitor, there are a CCV and an air filter as the illustration.
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel leakage.
3. After removing the EVAP Canister, inspect for cracks or damage.
CHECK OF CANISTER CLOSE VALVE OPERATING

1. Connect the CCV pins to a wire as shown.
2. At idle, disconnect the CCV connector.
3. Inspect that CCV is close when attaching the wire to(-) of battery.
4. Inspect that CCV is open when detaching the wire from(-) of battery.
In this case, if you use a very thin paper and attach it to hose to CCV, you can check easy the CCV
condition.
(1) If the paper is absorbed into or out, CCV is open.
(2) If not, CCV is close.

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AIR FILTER
Look for distortion, cracks.

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Purge Control Solenoid Valve (PCSV) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission
Control System > Evaporative Emission Control System > Purge Control Solenoid Valve (PCSV) > Repair
procedures
INSPECTION
EVAP CANISTER PURGE SOLENOID VALVE
The EVAP Canister Purge Solenoid Valve is controlled by the ECM; when the engine coolant temperature is low, and
also during idling, the valve closes so that evaporated fuel is not drawn into the surge tank. After engine warm-up
during ordinary driving, it opens to let the stored vapors flow into the surge tank.
When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original
position.
1. Disconnect the vacuum hose(black with red stripe) from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected.
4. Apply vacuum and check when voltage is applied to the EVAP Canister Purge Solenoid Valve and when the voltage is

24.04.2008
Page 2 of 3
discontinued.
Battery voltage
Normal condition
When applied
Vacuum is released
When discontinued
Vacuum is maintained
5. Measure the current between the terminals of the solenoid valve.

EVAP Canister Purge Solenoid Valve
Coil at 20C (68F) : 0.45A or below (at 12V)
Coil resistance : 26 [at 20C (68F)]
VACUUM HOSE
Engine coolant temperature : 80~95C (176~205F)
1. Disconnect the vacuum hose from the intake manifold purge hose nipple and connect a hand vacuum pump to the
nipple.
2. Start the engine and check that, after raising the engine speed by racing the engine, vacuum remains fairly constant.
If there is no vacuum created the intake manifold port may be clogged and require cleaning.

24.04.2008
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24.04.2008
Page 1 of 1
System > Fuel Tank Pressure Sensor (FTPS) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Emission Control System > Evaporative Emission Control System > Fuel Tank Pressure
Sensor (FTPS) > Repair procedures
INSPECTION
This is the sensor to detect the fuel tank leakage in way which it measures the differential pressure between the
inside and outside of the fuel tank.
Check that fuel level is over 15%. If not, this inspection is not available. The vehicle must be running and at idle.
Don't forget it.
1. Prepare a voltmeter and connect it to FTP pins as shown.
2. After 20 min.' idling , inspect the voltage.

System voltage : 5V
At acceleration : Max. 4.5, Min. 0.5V
3. At idle make sure that voltage changes as rpm changes.
If voltage is not within specification, there is a leak. Inspect the fuel tank and hoses toward canister and
fuel neck. Then repair or replace relevant parts.

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Page 1 of 1
System > Fuel Filler Cap > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Emission Control System > Evaporative Emission Control System > Fuel Filler Cap > Description and
Operation
OPERATION
Check the gasket of the fuel filler cap, and the filler cap itself, for damage or deformation. Replace the cap if
necessary.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Special Service Tools
SPECIAL TOOLS
09353-38000
Fuel pressure gauge adapter
Illustration
Use
Connection of fuel pressure gauge to
delivery pipe for measurement of fuel
pressure.
09353-24100
Fuel pressure gauge & hose

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Description and Operation,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Description and Operation
MULTIPORT FUEL INJECTION (MFI)

GENERAL INFORMATION
FUEL INJECTION CONTROL
IDLE SPEED CONTROL

IGNITION TIMING CONTROL
OTHER CONTROL FUNCTIONS

1. Fuel Pump Control :
Turns the fuel pump relay ON so that current is supplied to the fuel pumpwhile the engine is cranking or running.
2. A/C Compressor Clutch Relay Control :
Turns the compressor clutch of the A/C ON and OFF.
3. Fan Relay Control :
The radiator fan and condenser fan speeds are controlled in response to theengine coolant temperature and vehicle
speed.
4. Evaporative Emission Purge Control (Refer to GROUP EC).
DIAGNOSTIC TEST MODE

When an abnormality is detected in one of the sensors or actuators relatedto emission control, the CHECK
ENGINE/MALFUNCTION INDICATOR LAMP illuminatesas a warning to the driver.
When an abnormality is detected in one of the sensors or actuators, a diagnostictrouble code corresponding to the
abnormality is output.
The RAM data inside the PCM that is related to the sensors and actuators canbe read by means of the scan tool. In
addition, the actuators can be controlledunder certain circumstances.
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

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Page 2 of 4
1. Ask the customer about the malfunction.

Ask what it feels like, what it sounds like, etc. Then ask about driving conditions,weather, frequency of occurrence, and
so on.
2. Determine the conditions from the customer's responses.
Typically, almost all intermittent malfunctions occur from conditions likevibration, temperature and/or moisture change,
poor connections. From thecustomer's replies, it should be deduced which condition exists.
3. Use the simulation test
In the cases of vibration or poor connections, use the simulation tests belowto attempt to duplicate the customer's
complaint. Determine the most likelycircuit(s) and perform the simulation tests on the connectors and parts ofthat circuit
(s). Be sure to use the inspection procedures provided for diagnostictrouble codes and trouble symptoms. For
temperature and/or moisture conditionsrelated intermittent malfunctions, using common sense, try to change the
conditionsof the suspected circuit components, then use the simulation tests below.
4. Verify that the intermittent malfunction is eliminated.
Repair the malfunctioning part and try to duplicate the condition(s) againto verify that the intermittent malfunction has
been eliminated.
Shake the connector up-and-down, right-and-left.
Shake the wiring harness up-and-down, right-and-left.
Vibrate the part or sensor.
SERVICE POINTS IN INSPECTING A BLOWN FUSE
Harness being crushed by the vehicle body.

Damage to the outer casing of the harness due to wear or heat.
Water getting into the connector or circuitry.
Human error (mistakenly shorting a circuit, etc.).
INSPECTING THE MFI SYSTEM

1. Engine is hard to start or does not start at all
2. Unstable idle
3. Poor driveability
ON-BOARD DIAGNOSTICS
Diagnostic trouble codes are set as follows:
After the PCM first detects a malfunction, a diagnostic trouble code is recorded when the engine is restarted and the
same malfunction is re-detected. (Themalfunction is detected in driving cycle). However, for fuel system rich/lean
misfiring, a diagnostic trouble code is recorded on the first detection of the malfunction.
Erasing diagnostic trouble codes:
After recording the diagnostic trouble code, if the PCM does not re-detect the malfunction for 40 driving cycles, the
diagnostic trouble code will be erased from the PCM memory. However, for fuel system rich/lean or misfiring,the
diagnostic trouble code will be erased if both of the following conditions are met:
- When driving conditions (engine speed, engine coolant temperature, etc.) are identical to those when the
malfunction was first recorded.
- When the PCM does not re-detect the malfunction for 80 driving cycles.
A "driving cycle" is complete as soon as the vehicle goes into closed-loop operation.
Catalyst
Fuel system
Air flow sensor (MAF sensor)
Intake Air Temperature Sensor (IAT sensor)
Engine Coolant Temperature Sensor (ECT sensor)
Throttle Position Sensor (TPS)
Front Oxygen Sensor
Rear Oxygen Sensor Heater
Rear Oxygen Sensor
Front Oxygen Sensor Heater
Injector
Misfire
Crankshaft Position Sensor (CKP sensor)

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Page 3 of 4
Camshaft Position Sensor (CMP sensor)

Evaporative Emission Control System
Vehicle Speed Sensor (VSS)
Idle Speed Control
PCM
1. After turning the ignition key on, check that the light illuminates for 5 seconds without the engine running.
2. If the light does not illuminate, check for an open circuit in the harness,blown fuse and blown bulb.
When battery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery for
voltage and the charging system before starting the test.
Codes are erased if the battery or the PCM connector is disconnected. Do not disconnect the battery before the
diagnostic trouble codes are completely read and recorded.
1.
2.
3.
4.
5.
6.
7.
Turn OFF the ignition switch.

Connect the scan tool to the data link connector on the lower crash pad.
Turn ON the ignition switch.
Use the Hi-Scan Pro to check the diagnostic trouble code.
Repair the faulty part from the diagnosis chart.
Erase the diagnostic trouble code.
Disconnect the Hi-Scan Pro.
TROUBLESHOOTING
DIAGNOSTIC TROUBLESHOOTING FLOW

24.04.2008
Page 4 of 4

24.04.2008
Page 1 of 10
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Troubleshooting, TIBURON(GK) >
2003 > G 2.7 V6 DOHC > Fuel System > General Information > Troubleshooting
TROUBLESHOOTING
1. Power supply
Battery
Fusible link
Fuse
2. Body ground
3. Fuel supply
Fuel line
Fuel filter
Fuel pump
4. Ignition system
Spark plug
High-tension cable
Ignition coil
5. Emission control system
PCV system
Vacuum leak
6. Others
Ignition timing
Idle speed
TROUBLESHOOTING GUIDE CHART

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Page 2 of 10

24.04.2008
Page 3 of 10
The number herein means the check order.
MFI TROUBLESHOOTING PROCEDURES

PROBLEM

24.04.2008
Page 4 of 10
Scan tool communication with PCM is not possible

Comment
One of the following causes may be suspected
No power supply to PCM
Defective ground circuit of PCM
Defective PCM
Improper communication line between PCM and scan
tool
Probable cause
Malfunction of PCM power supply circuit.
Malfunction of the PCM.
Open circuit between PCM and DLC.
Engine will not start
Difficult to start (Engine Cranks)

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24.04.2008
Page 6 of 10
ROUGH IDLE OR ENGINE STALLS

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Page 7 of 10

24.04.2008
Page 8 of 10
Engine hesitates or accelerates poorly

24.04.2008
Page 9 of 10
TROUBLESHOOTING
Trouble symptom
Engine will not crank
Engine cranks slowly
Probable cause
Remedy
Battery charge low
Transaxle range switch faulty

(Vehicle with automatic transaxle only)
Adjust or replace switch
Fusible link blown
Repair starter motor
Replace ignition switch
Battery charge low

24.04.2008
Page 10 of 10
Starter keeps running
Starter spins but engine will not

crank
Replace ignition switch
Pinion gear teeth broken or starter motor Repair starter motor

faulty
Ring gear teeth broken
Replace flywheel ring gear or torque

converter
FUEL TANK AND FUEL LINE

Trouble symptom
Engine malfunctions due to
insufficient fuel supply
Evaporative emission system

malfunction (when fuel filler cap is
removed,pressure is released)
Probable cause
Bent or kinked fuel pipe or hose
Remedy
Repair or replace
Clogged fuel pipe or hose
Clean or replace
Clogged fuel filter of in-tank fuel filter
Replace
Water in fuel filter
Replace the fuel filter or clean the fuel

tank and fuel lines
Dirty or rusted fuel tank interior
Clean or replace
Malfunctioning fuel pump

(clogged filter in the pump)
Replace
Incorrect routing of a vapor line
Correct
Disconnected vapor line
Correct
Folded, bent, cracked or clogged vapor

line
Replace
Faulty fuel tank cap
Replace
Malfunctioning overfill limiter

(two-way valve)
Replace

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Specifications, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Specifications
GENERAL SPECIFICATIONS
Items
Throttle body
Sensors
Throttle position
sensor (TPS)
Type
Variable resistor
Resistance at
curb idle
2.7 V6
1.6 ~ 2.4 K
Output voltage
at curb idle
2.7 V6
250 ~ 800 mV
Idle speed control

(ISC) actuator
Type
Double Coil
Resistance
90 ~ 110 Hz
Air flow sensor
Type
2.7 V6
Hot Film sensor
Intake air
temperature (IAT)
sensor
Type
2.7 V6
Thermistor
Engine coolant
temperature (ECT)
sensor
Actuators
Specifications
Resistance
2.33 ~ 2.97 K at 20C (68F)
Type
Thermistor
Resistane
2.5 K at 20C (68F)

0.3 K at 80C (176F)
Heated oxygen
sensor (HO2S)
Type
Vehicle speed
sensor
Type
Hall effect
Camshaft position
(CMP) sensor
Type
Hall effect
Injectors
Type, number
Evaporative
emission purge
control solenoid
valve
2.7 V6
2.7 V6
Zirconium
Electromagnetic type, 6
Resistance
13 ~ 16 at 20C (68F)
Type
Duty cycle type
Fuel pressure
regulator
Pressure regulator
300 1.5 kPa

(3.35 0.06 kg/cm)
Fuel tank
Tank capacity
Return system
55 lit (12.1 lmp.gal)

Equipped
Canister
Volume/Nominal working capacity
3.0 liter/150g
SERVICE STANDARD
Items
Basic ignition timing
2.7 V6
2.7 V6
Curb idle speed (rpm)
Fuel pressure kPa (psi)
Standard value
BTDC 12 5 at curb idle
D-range (A/T)
650 100
P,N-range
750 100 (A/C OFF)
(A/T, M/T)
800 100 (A/C ON)
Vacuum hose disconnection
330 ~ 350 (47 ~ 50) at curb idle
Vacuum hose connection
Approx. 270 (38) at curb idle

24.04.2008
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Evap canister purge control solenoid valve resistance
20 ~ 32
TIGHTENING TORQUE
Items
Delivery pipe installation bolts
Heated oxygen sensor
Heated oxygen sensor connector bracket bolt
Fuel pressure regulator installation bolt
High pressure hose and fuel main pipe
High pressure hose and fuel filter
High pressure hose to delivery pipe
Fuel pump assembly to fuel tank
High pressure hose at fuel tank
Throttle body to surge tank
Accelerator arm bracket bolts
ISC actuator
Fuel sender to fuel tank
Nm
Kgcm
lbft
10 ~ 15
20 ~ 40
40 ~ 50
8 ~12
7 ~ 11
30 ~ 40
25 ~ 35
3~4
2~3
30 ~ 40
15 ~ 20
8 ~ 12
6~8
2~3
100 ~ 150
200 ~ 400
400 ~ 500
80 ~ 120
70 ~ 110
300 ~ 400
250 ~ 350
30 ~ 40
20 ~ 30
300 ~ 400
150 ~ 200
80 ~ 120
60 ~ 80
20 ~ 30
7 ~ 11
14 ~ 29
29 ~ 36
5.8 ~ 8.7
5.2 ~ 8.1
22 ~ 29
18 ~ 25
2.2 ~ 3
1.4 ~ 2.2
1.4 ~ 2.2
11 ~ 14
5.8 ~ 8.7
4.4 ~ 5.8
1.4 ~ 2.2
SEALANT
Item
Specified sealant
LOCTITE 962T or equivalent

24.04.2008
Page 1 of 14
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System >
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (FOR 2.7 V6)

DTC NO.
CONTENT
Memory MIL
P0101
Mass Air Flow Circuit Range/performance Problem
P0102
Mass Air Flow Circuit Low Input
P0103
Mass Air Flow Circuit High Input
P0112
Intake Air Temperature Circuit Low Input
P0113
Intake Air Temperature Circuit High Input
P0116
Engine Coolant Temperature Sensor Circuit Range/Performance

Problem
P0117
Engine Coolant Temperature Circuit Low Input
P0118
Engine Coolant Temperature Circuit High Input
P0119
Engine Coolant Temperature Circuit Intermittent
P0121
Throttle Position Sensor Circuit Range/Performance Problem
P0122
Throttle Position Sensor Circuit Low Input
P0123
Throttle Position Sensor Circuit High Input
P0125
Insufficient Coolant Temperature For Closed Loop Fuel Control
P0128
Coolant thermostat stuck
P0131
HO2S Circuit Low Input (Bank 1, Sensor 1)
P0132
HO2S Circuit High Input (Bank 1, Sensor 1)
P0133
HO2S Circuit Slow Responsive (Bank 1, Sensor 1)
P0134
HO2S Circuit No Activity Detected (Bank 1, Sensor 1)
P0030
HO2S Heater Control Circuit (Bank 1, Sensor 1)
P0031
HO2S Heater Circuit Low (Bank 1, Sensor 1)
P0032
HO2S Heater Circuit High (Bank 1, Sensor 1)
P0137
P0138
P0140
P0037
P0038
P0151
P0152
P0153
HO2S Circuit Slow Responsive (Bank 2, Sensor 1)
P0154
P0050
P0051
P0052
P0157
P0158

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P0160
P0057
P0058
P0171
Fuel System Too Lean (Bank 1)
P0172
Fuel System Too Rich (Bank 1)
P0174
P0175
P0230
Fuel Pump Circuit Malfunction
P0261
Injector Circuit Low Input (Cylinder -1)
P0264
P0267
P0270
P0273
P0276
P0262
Injector Circuit High Input (Cylinder -1)
P0265
P0268
P0271
P0274
P0277
P0300
Random Misfire Detected
P0301
Misfire Detected (Cylinder -1)
P0302
P0303
P0304
P0305
P0306
P0325
Knock Sensor Circuit Malfunction (Bank 1)
P0330
Knock Sensor Circuit Malfunction (Bank 2)
P0335
Crankshaft Position Sensor Circuit Malfunction
P0340
Camshaft Position Sensor Circuit Malfunction
P0420
Main catalyst efficiency deterioration (Bank 1)
P0430
Main catalyst efficiency deterioration (Bank 2)
P0441
EVAP Emission Control System Incorrect Purge Flow
P0442
EVAP Emission Control System Small Leak (1 mm)
P0444
EVAP Emission Control System Purge Control Valve Circuit Open
P0445
EVAP Emission Control System Purge Control Valve Circuit Shorted
P0449
EVAP Emission Control System Vent Valve/Solenoid Circuit
P0447
EVAP Emission Control System Vent Circuit Open
P0448
EVAP Emission Control System Vent Circuit Shorted

24.04.2008
Page 3 of 14
P0451
EVAP Emission Control System Pressure Sensor Range/Performance

Problem
P0452
EVAP Emission Control System Pressure Sensor Low Input
P0453
EVAP Emission Control System Pressure Sensor High Input
P0454
Evaporative Emission Control System - Pressure Sensor Intermittent
P0455
EVAP Emission Control System - Large Leak
P0456
Evaporative Emission Control System - Small Leak Detected (0.5mm)
P0461
Fuel Level Sensor Circuit Range/Performance
P0462
Fuel Level Sensor Circuit Low Input
P0463
Fuel Level Sensor Circuit High Input
P0464
Fuel Level Sensor Circuit Intermittent
P0501
Vehicle Speed Sensor Range/Performance
P0506
Idle Control System Rpm Lower than Expected
P0507
Idle Control System rpm Higher than Expected
P1134
HO2S Circuit - Transition Switch Malfunction/Slip (Bank 1, Sensor 1)
P1154
HO2S Circuit - Transition Switch Malfunction/Slip (Bank 2, Sensor 1)
P1166
Lambda Bank Control Limit (Bank 1)
P1167
Lambda Bank Control Limit (Bank 2)
P0036
P0056
P1372
Segment Time Acquisition Incorrect
P1505
Idle Speed Actuator Signal Low of Coil #1
P1506
Idle Speed Actuator Signal High of Coil #1
P1507
Idle Speed Actuator Signal Low of Coil #2
P1508
Idle Speed Actuator Signal High of Coil #2
P1521
Power Steering Switch Malfunction
P1529
TCU Request for MIL ON/Freeze Frame to ECU via CAN
P1602
Serial Communication Problem with TCU (Timeout)
P0605
Internal CONTROL module ROM error
P0560
System Voltage Malfunction
P0562
System Voltage Low
P0563
System Voltage High
P0650
Malfunction Indication Lamp (MIL) Control Circuit Malfunction
P1624
Cooling Fan Relay Circuit Malfunction (LOW)
P1625
Cooling Fan Relay Circuit Malfunction (HIGH)
TROUBLE AREA RELATED TO DTC
Check items for each diagnostic item do not list all probable causes.
DTC No.
Diagnostic items
Trouble area

24.04.2008
Page 4 of 14
P0101
Mass Air Flow Circuit

Range/performance Problem
Dirty air cleaner

Oil cap or dipstick missing or not installed correctly
Air leak in intake system
Contaminated, deteriorated or damaged mass air flow sensor
Faulty mass air flow sensor or throttle position sensor
Poor connections between ECM and MAFS or TPS
If any codes relating to MAFS are present, do all repairs

associated with them before proceeding with this
troubleshooting area.
P0102
Mass Air Flow Circuit Low Input
Short to ground between MAFS and ECM

Signal line open between MAFS and ECM
Faulty MAFS
P0103
Mass Air Flow Circuit High Input
Short to Battery between MAFS and ECM

Ground open between MAFS and EGI main relay
Ground open or Poor connections between open or short to
battery between MAFSand ECM
Faulty MAFS
P0112
Intake Air Temperature Circuit

Low Input
Short to ground between IAT sensor and ECM

Short between IAT sensor wires
Faulty IAT sensor
P0113
Intake Air Temperature Circuit

High Input
Open or short to battery between IAT sensor and ECM

Faulty IAT sensor
P0115
Engine Coolant Temperature

Circuit Malfunction
P0116

Sensor Circuit
Range/Performance Problem
After engine start-up, the measured coolant temperature

shows no variation after detecting the calculated coolant
temperature variation (engine coolant temperature sensor
input is stuck.)
Poor connections between ECT sensor and ECM
Misplaced, loose or corroded terminals
Foreign materials fouled ECTS
Faulty ECTS
Open or short to battery between ECTS and ECM

Short to ground between ECTS and ECM
Short between ECTS wires
Faulty ECTS
If any codes relating to ECTS are present, do all repairs

associated with them before proceeding with this
troubleshooting area.
P0117

Circuit Low Input
Short to ground between ECTS and ECM

Short between ECTS wires
Faulty ECTS
P0118

Circuit High Input
Open or short to battery between ECTS and ECM

Faulty ECTS
P0119
Poor connections between ECTS and ECM

24.04.2008
Page 5 of 14

Circuit Intermittent

Foreign materials fouled ECTS
P0121
Throttle Position Sensor Circuit

P0122

Low Input
Short to GND between TPS and ECM

Open short to GND between TPS and ECM
Short to RND between ECM and fuel tank pressure sensor
(FTPS)
Faulty TPS or FTPS
P0123

High Input
Open or short to battery between TPS and ECM

Open between and ECM
Faulty TPS
P0125
Insufficient Coolant
Temperature For Closed Loop
Fuel Control
After engine start-up, the elapsed time before feedback

operation is initiated is too long (engine coolant temperature
sensor input is insufficient for closed loop operation)
Poor connections between ECT sensor and ECM
Faulty ECTS
Thermostat
P0128
Coolant thermostat stuck
Thermostat stuck opened
P0131
HO2S Circuit Low Input (Bank

1, Sensor 1)
Short to GND between HO2S and ECM

Faulty front HO2S
P0132
HO2S Circuit High Input (Bank

1, Sensor 1)
Short to battery between HO2S and ECM

Faulty front HO2S
P0133
HO2S Circuit Slow Responsive

(Bank 1, Sensor 1)
Poor connections between TPS and ECM

Misplaced, loose or corrodes terminals
Contaminated, deteriorated TPS
Open or short between TPS 5V reference and ECM
Open or short between TPS signal and ECM
Short between TPS wires
Faulty TPS
Front and rear HO2S connections reversed

Faulty fuel delivery system
Leak in intake system
Leak in exhaust system
Faulty MAFS ground circuit
Faulty HO2S
If any misfire, purge solenoid valve, MAFS or HO2S heater

codes are present,do all repairs associated with those codes
before proceeding with this trouble area.
P0134
HO2S Circuit No Activity

Detected (Bank 1, Sensor 1)
Contaminated, deteriorated or aged HO2S

Misplaced, bent, loose or corroded connector terminals
Faulty HO2S
If any misfire, purge solenoid valve or HO2S heater codes are

present, do all repairs associated with those codes before
proceeding this trouble area.

24.04.2008
Page 6 of 14
P0135
HO2S Heater Circuit

Malfunction (Bank 1, Sensor 1)
Blown or missing HO2S fuse

Short to battery between front HO2S and ECM
Open between front HO2S and ECM
Faulty front HO2S
P0030
HO2S Heater Control Circuit

(Bank 1, Sensor 1)

Heater Resistance out of Reasonable Range
Faulty HO2S
P0031
HO2S Heater Circuit Low (Bank

1, Sensor 1)
Blown or mission HO2S fuse

Open or short to GND between HO2S and ECM
Faulty HO2S
P0032
HO2S Heater Circuit High (Bank

1, Sensor 1)

Faulty HO2S
P0136
HO2S Circuit Malfunction (Bank

1, Sensor 2)
Short between rear HO2S and ECM

Faulty rear HO2S
P0137

1, Sensor 2)

Faulty front HO2S
P0138

1, Sensor 2)
Open or short to battery between HO2S and ECM

Faulty front HO2S
P0139

(Bank 1, Sensor 2)

Faulty HO2S

before proceeding with this troublearea.
P0140


Faulty HO2S

proceeding with this trouble area.
P0141
HO2S Heater Circuit

Malfunction (Bank 1, Sensor 2)
P0037

1, Sensor 2)

Faulty HO2S
P0038

Short to battery between rear HO2S and ECM
Open between rear HO2S and ECM
Faulty rear HO2S

24.04.2008
Page 7 of 14
1, Sensor 2)
Faulty HO2S
P0151

2, Sensor 1)

Faulty front HO2S
P0152

2, Sensor 1)

Faulty front HO2S
P0153

(Bank 2, Sensor 1)

Faulty HO2S

before proceeding with this troublearea.
P0154


Faulty HO2S

proceeding this trouble area.
P0050

(Bank 2, Sensor 1)
P0051

2, Sensor 1)

Faulty HO2S
P0052

2, Sensor 1)

Faulty HO2S
P0157

2, Sensor 2)

Faulty rear HO2S
P0158

2, Sensor 2)
Open or short to battery between HO2S and ECM

Faulty rear HO2S
P0160


Faulty HO2S

Heater Resistance out of reasonable range
Faulty HO2S


24.04.2008
Page 8 of 14
P0057

2, Sensor 2)

Open or Short to GND between HO2S and ECM
Faulty HO2S
P0058

2, Sensor 2)

Faulty HO2S
P0171
Faulty ignition system (Ignition coil/spark plug/Ignition cable)

Faulty fuel delivery system (Fuel tank/Pressure
regulator/Canister purge valve)
Clogged fuel injectors
Faulty fuel injectors
Faulty MAFS
If any codes relating to injectors, HO2S, ECTS or MAFS are

stored, do all repairs associated with those codes before
P0172

Faulty MAFS

P0174
Faulty ignition system (Ignition coil/spark plug/Ignition cable)

Clogged fuel injectors
Faulty MAFS

P0175

Faulty MAFS


24.04.2008
Page 9 of 14

P0230
Fuel Pump Circuit Malfunction
P0261
Injector Circuit Low Input

(Cylinder -1)
Short to GND between injector and ECM

Faulty fuel injector
P0264

(Cylinder -2)
P0267

(Cylinder -3)
P0270

(Cylinder -4)
P0273

(Cylinder -5)
P0276

(Cylinder -6)
P0262
Injector Circuit High Input

(Cylinder -1)
P0265

(Cylinder -2)
P0268

(Cylinder -3)
P0271

(Cylinder -4)
P0274

(Cylinder -5)
P0277

(Cylinder -6)
P0300
Random Misfire Detected
P0301
P0302
P0303
P0304
P0305
P0306
Blown or missing fuse/relay

Short to battery between fuel pump relay and ECM
Open between fuel pump relay and ECM
Faulty fuel pump relay
Open between injector fuse and injector

Open or short to battery between injector and ECM
Vacuum leak in air intake system

CKP sensor circuit malfunction
Faulty CKP sensor
Ignition circuit malfunction
Faulty ignition coil or plug wire
Spark plug malfunction
Low compression due to blown head gasket, leaking valve or
piston ring
Low/high fuel pressure due to faulty pressure regulator,
restricted fuel lines,plugged fuel filter or faulty fuel pump
Fuel injector circuit malfunction
If any fuel injector codes (or pending codes) are present, do all
repairs associated with those codes before proceeding with
this trouble area.

24.04.2008
Page 10 of 14
P0325
Knock Sensor Circuit

Malfunction (Bank 1)
P0330
Knock Sensor Circuit

Malfunction (Bank 2)
P0335
Crankshaft Position Sensor

Circuit Malfunction
P0340
Camshaft Position Sensor

Circuit Malfunction
P0420
Main catalyst efficiency

deterioration (Bank 1)
Catalytic converter deteriorated
Open or short to GND between knock sensor and ECM

Source of high resistance between knock sensor and ECM
Faulty knock sensor
Short to GND between CKP sensor and ECM

Open or short to battery between CKP and ECM
Short between CKP sensor wires
Poor connection between CKP connector & harness connector
Out of allowable air gap
Faulty target wheel tolerance
Faulty CKP sensor
Short to GND between CMP sensor and ECM

Open or short to battery between CMP and ECM
Short between CMP sensor wires
Poor connection between CMP connector & harness
connector
Faulty CMP sensor
If any codes relating to HO2S sensor. MAFS, injectors, a

P0170 or a P0173are present, do all repairs associated with
them before proceeding with thistrouble area.
P0430
Main catalyst efficiency

deterioration (Bank 2)
Catalytic converter deteriorated
If any codes relating to HO2S sensor. MAFS, injectors, P0171,

P0172, P0174 or P0175 are present, do all repairs associated
with them before proceeding with this trouble area.
P0441
EVAP Emission Control System

Incorrect Purge Flow
Stuck in valve open position
P0442

Small Leak (1 mm)
Fuel filler cap loose or missing

Fuel filler cap o-ring missing or damaged
Faulty or damaged fuel filler pipe
Leaking, disconnected or plugged fuel vapor lines
Fuel in lines due to faulty rollover valve, on-board refueling
vapor recoveryvalve or stuck closed CCV
Canister close valve clogged, struck open or closed
Improperly installed purge solenoid valve
PSV stuck open or closed
Faulty fuel tank pressure sensor
Leaking canister or catch tank
If any codes relating to FTPS, CCV or PSV circuits are present,

do all repairs associated with those codes before proceeding
with this troubles area.

24.04.2008
Page 11 of 14
P0444

Purge Control Valve Circuit
Open
P0445

Purge Control Valve Circuit
Shorted
Faulty PSV
Short to GND or battery between PSV and ECM
P0449

Vent Valve/Solenoid Circuit
Stuck in valve closed position (CCV)

Faulty CCV
P0447

Vent Circuit Open
Open or short to battery between CCV and ECM

Faulty CCV
P0448

Vent Circuit Shorted
Short to GND between CCV and ECM

Faulty CCV
P0451

Pressure Sensor
High resistance or open between fuel tank pressure sensor

and ECM
Stuck closed canister close valve
Blocked vapor hose between canister and CCV
Open or short to battery between FTPS and ECM
Faulty FTPS
P0452

Pressure Sensor Low Input
Short to GND between FTPS and ECM

Faulty FTPS
P0453

Pressure Sensor High Input
Open or short to battery between fuel tank pressure sensor

and ECM
Short to battery in ECM
Open in ECM
Faulty FTPS
P0454
Evaporative Emission Control

System - Pressure Sensor
Intermittent
Poor connections between FTPS and ECM

Foreign materials fouled FTPS
Faulty FTPS
P0455

- Large Leak
Fuel filler cap loose or missing

Fuel filler cap o-ring missing or damaged
Faulty or damaged fuel filler pipe
Leaking, disconnected or plugged fuel vapor lines
Fuel in lines due to faulty rollover valve, on-board refueling
vapor recoveryvalve or stuck closed CCV
Canister close valve clogged, stuck open or closed
Improperly installed purge solenoid valve
PSV stuck open or closed
Faulty fuel tank pressure sensor
Leaking canister or catch tank
P0456
Evaporative Emission Control

System - Small Leak Detected
(0.5mm)
Faulty PSV
Open between PSV and ECM
If any codes relating to FTPS, CCV or PSV circuits are present,

do all repairs associated with those codes before proceeding
with this troubles area.
If DTC P0455 is stored and MIL is illuminated, before
proceeding to evaporative system test and repair, verify
whether the customer was running the engine during refueling.

24.04.2008
Page 12 of 14
If an obvious cause for DTC P0455 is an engine running during

refueling, erase the DTC P0455 using Hi-Scan and do not
repair the evaporative system. However,the vehicle should be
monitored to find reoccurrence of the concern whichmay come
from actual evaporative system.
P0461
Fuel Level Sensor Circuit

Range/Performance
P0462
Fuel Level Sensor Circuit Low

Input
Open or short to GND between FTLS and ECM

Short to GND or open in ECM
Faulty FTLS
P0463
Fuel Level Sensor Circuit High

Input
Short to battery between FTLS and ECM

Short to battery
Faulty FTLS
P0464
Fuel Level Sensor Circuit

Intermittent
Poor connections between ECTS and ECM

Faulty FTLS
P0501
Vehicle Speed Sensor

Range/Performance
Open between fuse and wheel speed sensor (WSS)

Open between WSS and GND
Open between WSS and ECM
Short to battery or GND between WSS and ECM
Faulty WSS
P0506
Idle Control System rpm Lower

than Expected
High resistance between injector fuse and IAC valve

High resistance between IAC and ECM
Faulty IAC valve
Carbon fouled throttle plate
Poor connection
Contaminated, deteriorated or aged FTLS
Faulty FTLS
If any TPS, MAFS, fuel injector or IAC valve circuit codes (or
pending codes)are present, do all repairs associated with them
before proceeding with thistrouble area.
P0507
Idle Control System rpm Higher

than Expected
Improperly adjusted accelerator cable

Air leak in intake system between head and throttle plate
Faulty PCV valve or PSV
Poor connections in TPS circuit or faulty TPS
High resistance between IAC valve and ECM
Faulty IAC valve
If any codes relating to TPS, MAFS, fuel injector or IAC valve

are present,do all repairs associated with them before
proceeding with this troubleshootingarea.
P1134
HO2S Circuit - Transition Switch

Malfunction/Slip (Bank 1,
Sensor 1)
HO2S Deteriorated
Foreign Material Deposit

24.04.2008
Page 13 of 14
P1154
HO2S Circuit - Transition Switch

Malfunction/Slip (Bank 2,
Sensor 1)
P1166
Lambda Bank Control Limit

(Bank 1)
P1167
Lambda Bank Control Limit

(Bank 2)
P0036

(Bank 1, Sensor 2)

Heater resistance out of reasonable range
Faulty HO2S
P0056

(Bank 2, Sensor 2)

Heater resistance out of reasonable range
Faulty HO2S
P1372
Segment Time Acquisition

Incorrect
Bad installation of tone wheel to crankshaft

Bad signal of the CKP sensor
Bad connection of connectors/bad wiring (between ECM and
CKP)
P1505
Idle Charge Actuator Signal Low

of Coil #1
Open or short to GND between ISC and ECM

Faulty ISC
P1506
Idle Charge Actuator Signal

High of Coil #1
Short to battery between ISC and ECM

Faulty ISC
P1507
Idle Charge Actuator Signal Low

of Coil #2
Open or short to GND between ISC and ECM

Faulty ISC
P1508
Idle Charge Actuator Signal

High of Coil #2
Short to battery between ISC and ECM

Faulty ISC
P1521
Power Steering Switch

Malfunction
P1529
TCU Request for MIL

ON/Freeze Frame to ECU via
CAN
This is only a request from TCM to turn the MIL ON. The fault
code is stored in the TCM. The freeze frame data is stored in
the ECM under the P1529 request code. Be sure to retrieve
freeze frame data before clearing code P1529 from ECM.
P1602
Serial Communication Problem

with TCU (Timeout)
Open or short to serial communication line

CAN message timeout
Faulty TCU
P0560
System Voltage Malfunction
P1166 is case for HO2S (Bank 1, Sensor 1) Signal line open

P1167 is case for HO2S (Bank 2, Sensor 1) Signal line open
Fuel system (Fuel tank/Pressure regulator/Fuel pump/PSV)
Failure
Poor connection to fuel line hose/Sealing/Cut
Sealing between purge valve and fuel tank
Air leakage in exhaust system
Ignition system (Ignition coil, spark plug, cable) failure
Surge tank and intake port failure
Open or short to battery between switch and ECM

Short to GND between switch and ECM
Open between switch and ECM
Faulty power steering switch
Short between main relay and ECM

Open between main relay and ECM
Poor connection
Faulty main relay

24.04.2008
Page 14 of 14
P0562
System Voltage Low
P0563
System Voltage High
Reverse battery cable connection (+/- reverse)

Faulty alternator
P0650
Malfunction Indication Lamp

(MIL) Control Circuit Malfunction
Open or short between lamp and ECM

Faulty lamp
P1624
Cooling Fan Relay Circuit

Malfunction (LOW)
P1625
Cooling Fan Relay Circuit

Malfunction (HIGH)
Open or short between relay and ECM

Short to GND between relay and ECM
Open between relay and ECM
Faulty relay
MAJOR SENSOR REFERENCE WAVE-FORMS

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System > Components and Components
Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System > Components and
Components Location
LOCATION OF MFI COMPONENTS

24.04.2008
Page 2 of 3
ECT Sensor
Power Steering Oil Pressure Switch
Vehicle Speed Sensor
Ignition Timing Adjustment Terminal
EVAP Solenoid Valve
MAP, TPS, ISA, TR
CMP Sensor
CKP

24.04.2008
Page 3 of 3
Data Link Connector
Heated Oxygen Sensor (HO2S)
Transaxle Range (TR) Switch
Injectors
Knock Sensor

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Special Service
Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Special
Service Tools
SPECIAL TOOLS
Tool (Number and Name)
Use
Illustration
09216-21100
Mount bushing remover and
installer
Removal & installation of lower arm

bushing (G)
(Use with 09216-21200, 0954502000)
09216-21200
Mount bushing remover and
installer base
Removal & installation of the lower

arm bushing (G)
(Use with 09216-21100, 0954502000)
09532-11600
Preload socket
Measurement of the lower arm ball

joint & stabilizer link starting torque
09545-02000
Lower arm bushing remover and
installer
Removal & installation of the lower

arm bushing (G)
(Use with 09216-21100, 0921621200)
09545-11000
Ball joint remover and installer
Installation of the lower arm ball joint
09545-21100
Ball joint dust cover installer
Installation of the lower arm ball joint

dust cover
09551-25000
Trailing arm bushing remover and
installer
Removal & installation of the trailing

arm bushing
09551-25000
Rear suspension arm remover and
installer
Removal & installation of the rear

suspension arm bushing
(Use with 09545-28100)
09568-34000
Ball joint puller
Separation of the lower arm ball joint

24.04.2008
Page 2 of 2
09546-26000
Strut spring compressor
or
J38402
Strut spring compressor
Compression of front coil spring

Compression of the front and rear
coil spring
(Use with A-42 or A-20)

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Troubleshooting
TROUBLESHOOTING
Symptom
Hard steering
Possible cause
Remedy
Improper front wheel alignment

Excessive turning resistance of
lower arm ball joint
Low tire pressure
No power assist
Correct
Replace
Adjust
Repair and replace
Correct
Poor or rough ride

Malfunctioning shock absorber
Broken or worn stabilizer
Broken or worn coil spring
Worn lower arm bushing
Correct
Repair or replace
Replace
Replace
Replace the lower arm assembly
Abnormal tire wear

Improper tire pressure
Correct
Adjust
Replace
Wandering

Correct
Poor turning resistance of lower arm
Repair
ball joint
Retighten or replace
Loose or worn lower arm bushing
Vehicle pulls to one side

Excessive turning resistance of
lower arm ball joint
Bent lower arm
Correct
Replace
Replace
Repair
Steering wheel shimmy

Poor turning resistance of lower arm
ball joint
Broken or worn stabilizer
Worn lower arm bushing
Correct
Replace
Replace
Replace
Replace
Replace
Bottoming

Replace
Replace
Poor return of steering wheel to

center
WHEEL AND TIRE DIAGNOSIS

Rapid wear at the center
Center- tread down to fabric due

to excessive over inflated tires
Lack of rotation
Excessive toe on drive wheels
Rapid wear at both shoulders
Underinflated tires
Worn suspension components
Excessive cornering speeds
Lack of rotation
Wear at one shoulder
Toe adjustment out of

specification
Camber out of specification
Damaged strut

24.04.2008
Page 2 of 2
Heavy acceleration on drive
Damaged lower arm
WHEEL AND TIRE DIAGNOSIS

Partial wear
Cansed by irreqular burrs on

brak drums.
Feather edges wheels
Toe adjustment out of

specification
Damaged or worn tie rods
Damaged knuckle
Wear pattern
Excessive toe on non-drive

wheels
Lack of rotation

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Specifications, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Specifications
SPECIFICATIONS

24.04.2008
Page 2 of 3
SERVICE STANDARD

24.04.2008
Page 3 of 3
When rotating the "215/45 ZR17" Tires, ensure to follow the "ROTATION" direction marked on the sidewall of tires
(see page SS-30).
TIGHTENING TORQUE
Items
Nm
kgcm
lbft
Wheel nut
90~110
900~1100
67~82
Driveshaft nut
2.0L
2.7L
200~260
200~280
2000~2600
2000~2800
148~192
148~207
Front strut upper installation nut
45~60
450~600
33~44
Front strut assembly to knuckle
140~160
1400~1600
104~118
Front strut mounting self-locking nut
40~50
400~500
29~37
Lower arm ball joint to knuckle
60~72
600~720
43~52
Lower arm bushing (A) mounting bolt
130~150
1300~1500
96~111
Lower arm bushing (G) mounting bolt
130~150
1300~1500
96~111
Stabilizer bar bracket mounting bolt
30~45
300~450
22~33
Tie rod end ball joint to knuckle
24~34
240~340
18~25
Tie rod end lock nut
50~55
500~550
37~41
Stabilizer link nut
35~45
350~450
26~33
Rear strut upper mounting nut
30~40
300~400
22~30
Rear strut lower mounting nut
110~130
1100~1300
81~96
Rear strut mounting self locking nut
40~60
400~600
30~44
Rear stabilizer link to stabilizer bar
35~45
350~450
26~33
Rear stabilizer bar bracket bolt
17~26
170~260
13~19
Rear suspension arm tie rod nut
50~60
500~600
37~43
Rear suspension arm (A,B) mounting bolt
160~180
1600~1800
118~133
Rear cross member mounting bolt
100~120
1000~1200
74~88
Trailing arm to bracket nut
40~50
400~500
30~37
Trailing arm bracket to body frame
40~50
400~500
30~37
100~120
1000~1200
74~88
Trailing arm mounting
Replace the self-locking nuts with new ones after removal.
LUBRICANTS
In ball joint of lower arm
Recommended lubricant
Quantity
Variant R-2 grease or poly lub gly 801K
As required

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Strut
Assembly > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension
System > Front Suspension System > Front Strut Assembly > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Strut
Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Strut Assembly > Repair procedures
REMOVAL
1. Remove the front wheel.
2. Detach the brake hose bracket from the strut assembly.
Do not apply excessive force to the components.

3. Remove the stabilizer link.
4. Remove the strut upper mounting bolts(3).
5. Remove the strut assembly.
INSTALLATION
1. When installing the front strut, be sure to clear the conneting surface.
2. Install the strut assembly so the identification label on the strut insulator faces toward the inside of vehicle.

24.04.2008
Page 2 of 4
3. Tighten the components below to the specified torque as follows.

Items
Torque Nm (kgfcm, lbfft)
Front strut upper mounting nut

Front strut to knuckle
45~60 (450~600, 33~44)

140~160 (1400~1600, 104~118)
Stabilizer link nut
35~45 (350~450, 26~33)
4. Install the brake hose and front wheel speed sensor wire on the front strut assembly.
DISASSEMBLY
1. Using the special tools (09546-26000 or J38402), compress the coil spring until there is only a little tension on
the strut.
Do not use an impact gun.
2. Remove the nut at the top end of shock absorber.

3. Remove the insulator, spring seat, coil spring, dust cover from the strut assembly.
INSPECTION
1. Check the strut insulator bearing for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Check the coil spring for sagging and weakness.
4. Check the shock absorber for abnormal resistance or unusual sound.

24.04.2008
Page 3 of 4
DISPOSAL
1. Fully extend the shock absorber rod.
2. Drill a hole on the A section to remove gas from the cylinder.
The gas coming out is harmless, but be careful of chips that may fly when drilling.
Be sure to wear face shield and safety goggles.
REASSEMBLY
1. Install lower spring pad so that the protrusions fit in the holes of the spring lower seat.
2. Install the dust cover on the shock absorber.

3. Using the special tools (09546-26000 or J38402), compress the coil spring.
After the spring is fully compressed, install it on the shock absorber.
Install the coil spring with the identification mark directed toward the knuckle.
4. After fully extending the piston rod, install the spring upper seat and insulator assembly.
Align the D-shaped hole in the spring seat upper assembly with the protrusion on the piston rod.

24.04.2008
Page 4 of 4
5. After seating the upper and lower ends of the coil spring in the upper and lower spring seat grooves correctly,
tighten the newself-locking nut temporarily.
6. Remove the special tool (09546-26000 or J38402).

7. Tighten the self-locking nut to the specified torque.
Tightening torque
50~70 Nm (500~700 kgfcm, 37~51 lbfft)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Lower Arm >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Lower Arm > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front
Lower Arm > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Lower Arm > Repair procedures
REMOVAL
2. Remove the driveshaft split pin, nut and washer.
3. Loosen the lower arm ball joint nut, but do not remove it.
4. Remove the strut lower mounting bolts(2).
5. Push the axle hub toward the outside to disconnect the driveshaft from the axle hub.
6. Using the special tool (09568 - 34000), disconnect the lower arm ball joint from the lower arm.
7. Temporarily install the strut lower mounting bolt.

8. Remove the lower arm bushing (A) and bushing (G) mounting bolts(2).
9. Remove the lower arm assembly.
REPLACEMENT
BALL JOINT AND DUST COVER
1. Using a flat-tipped screwdriver, remove the dust cover from the lower arm ball joint.
2. Remove the snap ring.

3. Using a plastic hammer, tap the ball joint out of the lower arm.

24.04.2008
Page 2 of 4
4. Using special tool (09545 - 11000), press-fit the ball joint into the lower arm assembly.
5. Install the snap ring.

6. Using the special tool (09545 - 21100), install the dust cover.
LOWER ARM BUSHING (G)

1. Install the special tools (09545-02000, 09216-21100 and 09216-21200) on the lower arm.
2. Press out the bushing.
3. Apply soap solution to the following parts.

A. Outer surface of the bushing
B. Inner surface of the lower arm bushing mounting part.
4. Install the new bushing on the lower arm by using special tools (09216-21100, 09624-34000).

24.04.2008
Page 3 of 4
Press-in the lower arm bushing (G) in the same direction as shown in illustration.
Pull out force for the bushing
80 N [800 kg(f), 11.9 lb(f)] or more
INSTALLATION
Installation is in the reverse order of removal.
Tighten the components below to the specified torque as follows.

Items
Wheel nut
Driveshaft nut
Strut lower mounting

90~110 (900~1100, 67~82)
2.0 L : 200~260
(2000~2600, 148~192)
2.7 L : 200~280
(2000~2600, 148~192)
140~160 (1400~1600, 104~118)
Lower arm ball joint nut
60~72 (600~720, 43~52)
Lower arm bushing(A)
130~150 (1300~1500, 96~111)
Lower arm bushing(G)
130~150 (1300~1500, 96~111)
Stabilizer link nut
35~45 (350~450, 26~33)
INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for bending or breakage.
3. Check the ball joint dust cover for cracks and damage.

24.04.2008
Page 4 of 4
4. Check all bolts for damage and deformation.

5. Check the lower arm ball joint for rotating torque.
A. If there is a crack in the dust cover, replace the ball joint assembly.
B. Shake the ball joint stud several times.
C. Measure the balll joint rotating torque.
Standard value
2.0~3.5 Nm (20~35 kgfcm, 1.48~2.58 lbfft)
D. If the rotating torque is above the upper limit of the standard value, replace the ball joint assembly.
E. Even if the rotating torque is below the lower limit of the standard value, the ball joint may be reused
unless it has drag and excessive play.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Stabilizer Bar
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Stabilizer Bar > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front
Stabilizer Bar > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Front Suspension System > Front Stabilizer Bar > Repair procedures
REMOVAL
2. Remove the stabilizer link assembly.
3. Remove the stabilizer bracket and bushing
4. Remove the stabilizer bar.
INSTALLATION
1. Install the bushing on the stabilizer bar.
1) When installing the stabilizer bar, follow the identification color (ID color) as below.
Model
ID color
Outer diameter
2.0L Sports
(HARD)
21.8mm (0.86 in.)
2.0L Normal
(SOFT)
White
18.8mm (0.74 in.)
2.7L Sports
(HARD)
Yellow
21.8mm (0.86 in.)
2.7 Normal
(SOFT)
Red
18.8mm (0.74 in.)
ID : Identification
2) Position the bushing on the outside of the stabilizer bar clamp so as to install it.

24.04.2008
Page 2 of 2
3) Let the selection of the bushings be able to be decided by customers.

2. Install the bracket on the bushing.
3. After tightening the bolts of the bushing bracket temporarily, install the bushing bracket on the opposite side.
INSPECTION
1. Check the stabilizer bar for deterioration and damage.
2. Check all bolts for damage and deformation.
3. Check the stabilizer link dust cover for cracks or damage.
4. Check the stabilizer link ball joint for rotating torque.
A. If there is a crack in the dust cover, replace it and add grease.

B. Shake the stabilizer link ball joint stud several times.
C. Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque.
Standard value
0.7~2 Nm (7~20 kgfcm, 0.52~1.48 lbfft)
D. If the rotating torque is higher than the upper limit of the standard value, replace the stabilizer link.
E. If the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it
has drag and excessive play.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear Strut Assembly
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear
Suspension System > Rear Strut Assembly > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear Strut
Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear
Suspension System > Rear Strut Assembly > Repair procedures
REMOVAL
1. Remove the covering self side trim, rear seat belt retractor, luggage side trim and covering self mounting
bracket.
2. Remove the rear strut upper mounting nuts (3).
3. Remove the wheel and tire.

4. Disconnect the brake hose and wheel speed sensor wiring from the rear strut.
5. Remove the stabilizer bar link.
6. Remove the strut and carrier mounting bolts(2).
Be careful not to drop the rear strut.

7. Remove the rear strut assembly.
DISASSEMBLY
1. Using the special tools (09546-26000 or J38402), compress the coil spring until there is only a little tension on
the strut.

24.04.2008
Page 2 of 3
Do not use an impact gun.
2. Remove the self-locking nut at the top end of the shock absorber.
3. Remove the insulator, coil spring and dust cover from strut assembly.
INSPECTION
1. Check the strut insulator for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Check the coil spring and strut assembly for sagging and deformation.
4. Check the shock absorber for abnornal resistance or unusual sound.
REASSEMBLY
1. Install the lower spring pad so that the protrusions fit in the holes in the spring lower seat.
2. Install the dust cover on the shock absorber.

3. Using the special tools (09546-26000 or J38402), compress the coil spring.

24.04.2008
Page 3 of 3
4. After extending the piston rod fully, install the insulator assembly and pipe.
Align the D-shaped hole in the spring seat upper assembly with the protrusion of the piston rod.
5. After seating the lower ends of the coil spring in the lower spring seat grooves correctly, tighten the new selflocking nut temporarily.
Replace the self-locking nut with new ones after removal.
6. Remove the special tools (09546-26000 or J38402).

7. Tighten the self-locking nut to the specified torque.
Tightening torque
40~55 Nm (400~550 kgfcm, 29.6~40.7 lbfft)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear Suspension
Arm > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Rear Suspension System > Rear Suspension Arm > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear
Suspension Arm > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Rear Suspension System > Rear Suspension Arm > Repair procedures
REMOVAL
2. Remove the stabilizer link.
3. After loosening the rear trailing arm mounting bolts, remove the trailing arm.
4. Remove the rear suspension arm mounting bolt from the rear axle carrier.
5. After supporting the center of the rear crossmember assembly with a jack, remove the rear crossmember
mounting bolts to the body.
6. Remove the rear crossmember and suspension arm.
INSTALLATION
1. Installation is in the reverse order of removal.
Items
* Trailing arm mounting

100~120 (1000~1200, 74~88)
Trailing arm bracket mounting
40~50 (400~500, 29~37)
Stabilizer bar bracket mounting
17~26 (170~260, 13~19)
Stabilizer link nut
34~45 (340~450, 25~33)

24.04.2008
Page 2 of 2
*Front/Rear suspension arm mounting

Rear crossmember mounting
160~180 (1600~1800, 118~133)

100~120 (1000~1200, 74~88)
INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the trailing arm and suspension arm for bent or deterioration.
3. Check the bolts for damage or rust.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Trailing
Arm > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear
Suspension System > Trailing Arm > Repair procedures
REMOVAL
1. Detach the parking brake cable from the rear trailing arm bracket.
2. After loosening the rear trailing arm mounting bolts, remove the trailing arm.
3. Remove the rear suspension arm mounting bolt from the rear axle carrier.
4. After supporting the center of the rear crossmember assembly with a jack, remove the rear crossmember
mounting bolts to the body.
5. Remove the rear crossmember and suspension arm.
REPLACEMENT
TRAILING ARM BUSHING
1. Install the special tool (09551 - 25000) on the trailing arm.
2. Remove the trailing arm bushing.

3. Using the special tool (09551 - 25000), press-fit the rear trailing arm bushing.

24.04.2008
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Press-fit the bushing in the same way as shown in the illustration.
REAR SUSPENSION ARM BUSHING

1. Install the special tools (09545-28100, 09545-25000) on the rear suspension arm.
2. Remove the rear suspension bushing.

3. Apply soap solution to the new bushing and the rear suspension arm.
4. Using the special tool (09552-25000), press-fit the the bushing.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear
Stabilizer Bar > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Rear Suspension System > Rear Stabilizer Bar > Repair procedures
REMOVAL
1. Remove the stabilizer bar link from the rear strut assembly.
2. Remove the rear stabilizer bar mounting brackets.
3. Remove the stabilizer bar.
INSTALLATION
1. Install the bushing on the stabilizer bar.
1) When installing the stabilizer bar, follow the identification color (ID color) as below.
Model
ID color
Outer diameter
GL/GLS
Yellow
16.8mm (0.66 in.)
Sports/Top
Green
17.8mm (0.70 in.)
2) After matching the bushing in the inside of the white painted part on the stabilizer bar, install the them.
2. Install the bracket on the bushing.

Rear stabilizer bar mounting bracket :
17~26 Nm (170~260 kgfcm, 13~19 lbfft)
Rear stabilizer bar link mounting :
35~45 Nm (350~450 kgfcm, 26~33 lbfft)

24.04.2008
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INSPECTION
1. If there is a crack in the dust cover, replace it and add grease.

2. Shake the stabilizer link ball joint stud several times.
3. If the rotating torque is above the upper limit of the standard value, replace the stabilizer link.
4. If the rotating torque is below the lower limit of the standard value, the ball joint may be reused unless it has
drag and excessive play.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Description
and Operation
DESCRIPTION
There are two matching ways about the wheel & tire and front suspension on this vehicle. It follows,
Standard equipment with 2.0L/2.7L engines :
Normal (Soft) suspension and 16wheel & tire
Optional equipment with 2.0L/2.7L engines :
Sports (Hard) suspension and 17wheel & tire
The front suspension identification mark can be seen when the front wheel & tire is removed.
The following degeneration in vehicle performance may occur when installing the 17tires to the 2.0L
vehicle models equipped with the normal front suspension.
The handling may be inferior to the vehicles with 16tires. However installing 17tires to the vehicles with
hard suspensions does not affect the driving performance.
The 17tire is for summer season.
Therefore, its performance in snow is inferior to the 16tire for all seasons.
The 17 tire is directional
An unexpected noise and vibration may occur if tires are not installed correctly according to the rotational
direction.
The snow chain with the thickness lower than 10mm is recommended to use on vehicles with 17tires.

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Tire > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Tire >
Repair procedures
FRONT WHEEL ALIGNMENT

FRONT WHEEL ALIGNMENT
Standard value
Toe-in(B-A) mm (in.) : 0 2 mm (0 0.08 in.)
Toe-in adjustment should be made by turning the right and left tie rods at the same amount.
When adjusting toe-in, loosen the outer bellows clip to prevent twisting the bellows.
After the adjustment, tighten the tie rod end lock nuts firmly and reinstall the bellows clip.
Adjust each toe-in to be the range of 1mm.
Tightening torque
Tie rod end lock nuts :
50~55 Nm (500~550 kgfcm, 37~41 lbfft)
Camber : 013 30
Standard value
Caster : 258 30
Standard value
Camber : 013 30

24.04.2008
Page 2 of 3
REAR WHEEL ALIGNMENT

TOE-IN
Adjust the toe-in by turning the tie rod end of the rear suspension arm..
Left tie rod : Clockwise direction toe-in
Right tie rod : Clockwise direction toe-out
A variation of toe by a rotation of the tie rod : About 6mm (0.6)
The cam bolt should be adjusted to a maximum of 90 left or right from the center position.
After adjusting the tie rod, tighten both nuts to the specified torque.
Specified torque
50~60 Nm (500~600 kgfcm, 37~43 lbfft)
TIRE WEAR
1. Measure the tread depth of the tires.
Tread depth of tire [Limit] : 1.6 mm (0.06 in.)
2. If the remaining tread depth is less than the limit, replace the tire.
When the tread depth of the tires is less than 1.6 mm (0.06 in.) the wear indicators will appear.

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Wheel > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Wheel >
Repair procedures
WHEEL ROTATION
Rotate the tires in the pattern illustrated.
When rotating the 215/45 ZR17 tires, ensure to follow the "ROTATION"direction marked on the sidewall of
tires.
When rotating the tires of the left and right, seperate the wheel from the tire and then re-assemble them.
Checking for pull and wander

1. If the steering pulls to one side, rotate the tires according to the following wheel rotation procedure.
A. Rotate the front right and front left tires, and perform a road test in order to confirm vehicle stability.
B. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again.
C. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road
test.

24.04.2008
Page 2 of 4
D. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
WHEEL RUNOUT
1. Jack up the vehicle and support it with jack stands.
2. Measure the wheel runout with a dial indicator as illustrated.
3. Replace the wheel if the wheel runout exceeds the limit.

Wheel runout [Limit]
Steel wheeel
Radial 0.6mm (0.028 in.) : (Average of LH & RH)
Axial 1.0mm (0.039 in.)
Aluminum wheel
Radial 0.3mm (0.012 in.)
Axial 0.3mm (0.012 in.)
LH : Left Hand side, RH : Right Hand side
TIGHTENING WHEEL NUT

1. Tightening torque
Steel and aluminum alloy wheel
Specified torque
90~110 Nm (900~1,100 kgfcm, 65~80 lbfft)

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When using an impact gun, final tightening torque should be checked using a torque wrench.
2. Tightening order
Check the torque again after tightening the wheel nuts diagonally.
WHEEL ROTATION
Rotate the tires in the pattern illustrated.
When rotating the 215/45 ZR17 tires, ensure to follow the "ROTATION"direction marked on the sidewall of
tires.
When rotating the tires of the left and right, seperate the wheel from the tire and then re-assemble them.
CHECKING FOR PULL AND WANDER

1. If the steering pulls to one side, rotate the tires according to the following wheel rotation procedure.
A. Rotate the front right and front left tires, and perform a road test in order to confirm vehicle stability.
B. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again.

24.04.2008
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C. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road
test.
D. If the steering continues to pull to the opposite side, replace the front wheels with new ones.
2. On some vehicles which dirft or pull to the right only, the following procedure may be applied for fixing.
A. Adjust tire pressure as recommended below (4 tire) prior to conducting road test.
Tire inflation pressure : 2.1 kgf/cm (30 psi)
Front 215/45 ZR 17 tire only : 2.2 kgf/cm (32 psi)
B. To eliminate the pulling, rotate the front tires and test drive the vehicle to see if the pulling returns.
C. If a vehicle still exhibits the pulling to the right, replace the right front strut insulator with the redesigned
new part (Part No. 54610-2C000A) which increases the caster angle. (see page SS-11)
This procedure applies to the vehicle pulls to the right only.

Confirm the direction of the vehicle pulling by road testing prior to performing the repair procedure.
If 'Michelin' tires are installed, do not rotate the tires because they are directional. Replace the
right front strut insulator only.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Special Service
Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Special
Service Tools
SPECIAL TOOLS
Illustration
Use
09216-21100
Mounting bushing remover and
installer
Removal of the center bearing (Use with

09495-33100)
09495-33000
Puller
Removal of wheel bearing inner race from

the hub.
09495-33100
Center bearing remover and
installer
1. Removal of wheel bearing from the

knuckle. (Use with 09517-29000)
2. Installation of hub to the knuckle.
3. Removal of the center bearing (Use with
09216-21100)
09517-21500
Front hub remover and installer
1. Removal of front hub from the knuckle.

(Use with 09517-29000)
2. Measurement of front wheel bearing
pre-load. (Use with 09532-11600)
09517-29000
Knuckle arm bridge
1. Removal of wheel bearing outer race

from the knuckle. (Use with 0949533100)
09517-43001
Bearing puller
Removal of the center bearing bracket
09532-11600
Preload socket
Measurement of front wheel bearing preload. (Use with 09517-21500)
09532-11500
Pinion bearing outer race
Installation of wheel bearing to the knuckle.
09568-34000
Ball joint puller
Separation of front lower arm and tie rod

end ball joint.

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Troubleshooting
TROUBLESHOOTING
Symptom
Possible cause
Remedy
Vehicle pulls to one side
Galling of drive shaft ball joint

Wear, rattle or galling of wheel bearing
Defective front suspension and steering
Replace
Replace
Adjust or replace
Vibration
Wear, damage or bending of drive shaft

Drive shaft rattle and hub serration
Wear, rattle or scratching of wheel bearing
Replace
Replace
Replace
Shimmy
Improper wheel balance

Adjust or replace
Adjust or replace
Excesive noise
Wear, damage or bent drive shaft

Drive shaft rattle and hub serration
Drive shaft rattle and side gear serration
Wear, rattle or galling of wheel bearing
Loose hub nut
Replace
Replace
Replace
Replace
Adjust or replace
Adjust or replace

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Specifications
SPECIFICATIONS
Driveshaft
Joint type
2.0L M/T
2.0L A/T
2.0L 6M/T
2.7L
Outer
B.J.
B.J.
B.J.
B.J.
Inner
D.O.J.
T.J.
T.J.
T.J.
Maximum permissible joint angle

B.J.
46 or more
D.O.J.
22 or more
T.J.
45.8 or
more
46.5 or
more
23 or more 23 or more 23 or more
Hub end play mm(in.)
0.008 (0.0003) or less
Wheel bearing starting torque

Nm (kgcm, lbfft)
1.8 (18, 1.33) or less
B. J. : Birfield joint
D.O.J. : Double offset joint
T. J. : Tripod joint
46 or more
M/T : 5 Speed Manual transaxle

6M/T : 6 Speed Manual transaxle
A/T : Automatic transaxle
TIGHTENING TORQUE
Nm
Kgfcm
lbfft
Driveshaft nut
2.0L
2.7L
200 ~ 260
200 ~ 280
2000 ~ 2600
2000 ~ 2800
148 ~ 192
148 ~ 207
Knuckle to strut assembly nut
140 ~ 160
1400 ~ 1600
104 ~ 118
Lower arm ball joint to knuckle nut
60 ~ 72
600 ~ 720
44 ~ 53
Tie rod end to knuckle
24 ~ 34
240 ~ 340
18 ~ 25
Front brake caliper to knuckle
69 ~ 85
690 ~ 850
51 ~ 63
Wheel nut
90 ~ 110
900 ~ 1100
66 ~ 81
Rear hub bearing flange nut
200 ~ 260
2000 ~ 2600
148 ~ 192
65 ~ 75
650 ~ 750
48 ~ 56
Rear strut to carrier nut
110 ~ 130
1100 ~ 1300
81 ~ 96
Trailing arm to rear axle carrier mounting

nut
100 ~ 120
1000 ~ 1200
74 ~ 88
160 ~ 180
1600 ~ 1800
118 ~ 133
Rear brake to rear axle carrier mounting

bolt
Rear suspension arm to rear axle carrier

mounting nut
Replace self-locking nuts with new ones after removal.

24.04.2008
Page 2 of 2
LUBRICANTS
Items
Recommended
Quantity
Birfield joint + Double offset joint Type driveshaft (For 2.0L M/T)
Birfield joint boot grease
CENTOPLEX 278M/136K
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2
115 6gr.
Double offset joint boot greasE
AMBLYGON TA 10/2A
CASMOLY DOJ
DURALUBE DOJ
Variant SD-R2
100 6gr.
Birfield joint +Tripod joint Type driveshaft (For 2.0L A/T, 2.0L 6M/T)
CENTOPLEX 278M/136K
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2
110 6gr.
Tripod joint boot greas
KLK TJ 41-182
CASMOLY TJ
ROLLUBE TJ
Oneluber MK
145 6gr.
Birfield joint + Tripod joint Type driveshaft (For 2.7L)

CENTOPLEX 278M/136K
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2
135 6gr.
Tripod joint boot grease
KLK TJ 41-182
CASMOLY TJ
ROLLUBE TJ
Oneluber MK
145 6gr.

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Front Driveshaft >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle >
Driveshaft Assembly > Front Driveshaft > Components and Components Location
COMPONENTS
COMPONENTS

24.04.2008
Page 2 of 3
COMPONENTS

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 8
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Front Driveshaft
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft
Assembly > Front Driveshaft > Repair procedures
REMOVAL
1. Raise the vehicle and remove the front wheel.
2. Remove the split pin and driveshaft nut from the front hub.
3. Drain the transaxle fluid.
4. Disconnect the tie rod end ball joint from knuckle, and the knuckle from strut assembly.
5. Using a plastic hammer, disconnect the driveshaft from the axle hub.
6. Push the axle hub toward the outside of the vehicle, and separate the driveshaft from the axle hub.
7. Insert a pry bar between the transaxle case and joint case, and separate the driveshaft from the transaxle
case.
1. Use a pry bar being careful not to damage the transaxle and joint.
2. Do not insert the pry bar too deep, as this may cause damage to the oil seal. [max. depth : 7 mm
(0.28 in.)]
3. Do not pull the driveshaft by excessive force it may cause components inside the double offset joint or
tripod joint kit to dislodge resulting in a torn boot ora damaged bearing.
8. Insert a pry bar between the center bearing bracket and the driveshaft, and then pry the driveshaft from the
center bearing. (2.7L engine)
Do not pull on the driveshaft; doing so will damage the tripod joint : be sure to use the pry bar.

24.04.2008
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9. Remove the center bearing bracket mounting bolts. Insert the pry bar between the center bearing bracket and
the cylinder block to disconnect thebracket from the cylinder block. (for 2.7L engine)
10. Remove the inner shaft from the center bearing. (for 2.7L engine)
11. Using the special tool (09432-11000), remove the tone wheel.
Before removing the tone wheel, be sure to remove the B.J. assembly side dust cover.
INSTALLATION
1. After installing the birfield joint assembly side tone wheel, install the dust cover, keeping the specified
clearance as below.
2. Apply gear oil on the driveshaft splines and differential case contacting surface.

24.04.2008
Page 3 of 8
3. Before installing the driveshaft, set the opening side of the circlip facing downward.
4. After installation, check that the driveshaft cannot be removed by hand.
5. Position the convex side of the washer to face outside and install the nut and split pin.
6. Replace the self-locking nuts and split pin with new ones after removal.
7. Tighten the below parts to the specified torque

Driveshaft nut
2.0L : 200~260Nm (2000~2600 kgfcm, 148~192 lbfft)
2.7L : 200~280Nm (2000~2800 kgfcm, 148~207 lbfft)
Lower arm ball joint nut
60~72Nm (600~720 kgfcm, 44~53 lbfft)
INSPECTION
1. Check the driveshaft boots for damage and deterioration.
2. Check the ball joints for wear and damage.
3. Check the splines for wear and damage.
4. Check the dynamic damper for cracks and wear.
INSPECTION
1. Check the driveshaft spline for wear or damage.
2. Check that there is no water or foreign material in the birfield joint.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside the tripod joint case for wear or corrosion.
5. Check the dynamic damper for damage or cracks.

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Page 4 of 8
DISASSEMBLY
1. Do not disassemble the birfield joint assembly.

2. Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
3. The boot band should be replaced with a new one.
1. Remove the double offset joint boot bands and pull the double offset joint boot from the double offset joint
outer race.
Be careful not to damage the boot.
2. Remove the circlip with a flat-tipped screwdriver.
3. Pull out the driveshaft from the double offset joint outer race.
4. Remove the snap ring and take out the inner race, cage and balls as an assembly.

24.04.2008
Page 5 of 8
5. Clean the inner race, cage and balls without disassembling.

6. Remove the birfield joint boot bands and pull out the double offset joint boot and birfield joint boot.
If the boot is to be reused, wrap tape around the driveshaft splines to protect the boot.
DISASSEMBLY
Do not disassemble the birfield joint assembly.

Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
The boot band should be replaced with a new one.
1. Remove the tripod joint boot bands and pull the tripod joint boot from the tripod joint case.
Be careful not to damage the boot.
2. Remove the snap ring and spider assembly from the driveshaft.

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3. Clean the spider assembly.

4. Remove the birfield joint boot bands and pull out the tripod joint boot and birfield joint boot.
If the boot is to be reused, wrap tape around the driveshaft splines to protect the boot.
REASSEMBLY
1. Wrap tape around the driveshaft splines (tripod joint side) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the boots. (see page DS-3)
3. To install the dynamic damper, keep the B.J. and driveshaft in a straight line and secure the dynamic damper
with the dynamic damper band inthe direction illustrated.
4. Apply grease into the tripod joint boot and install the boot.
Tripod joint boot grease (gr.)

(2.0L A/T, 2.0 L 6M/T, 2.7L)

24.04.2008
Page 7 of 8
Total : 145 6
In the joint : 100 3
In the boot : 45 3
A/T : Automatic Transmission M/T : Manual Transmission
5. Tighten the tripod joint boot bands.
6. Add the specified grease to the birfield joint as much as was wiped away at inspection.
7. Install the boots.
8. Tighten the new birfield joint boot bands.
Keep the specified distance (A) between the bellows when they are clampped with an Oetiker crimping
tool (P/No. : 1094)or a commercially available hand pincers (2.7L).
Specified distance (A) : 1.8 mm (0.071 in.) or less
9. To control the air in the tripod joint boot, keep the specified distance between the boot bands when they are
tightened.
Standard value (A) mm(in.)
LH
RH
2.0L A/T
514 2
(20.24 0.08)
799.2 2
(31.47 0.08)
2.0L 6M/T
492.6 2
(19.39 0.08)
803.6 2
(31.64 0.08)
2.7L 6M/T
514.2 2
(19.43 0.08)
508.7 2
(20.03 0.08)
2.7L M/T, A/T
515 2
(20.28 0.08)
508.7 2
(20.03 0.08)
LH : Left Hand side, RH : Right Hand side

A/T : Automatic Transmission
M/T : Manual transmission

24.04.2008
Page 8 of 8

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Center Bearing And Inner
Shaft > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle >
Driveshaft Assembly > Center Bearing And Inner Shaft > Components and Components Location
COMPONENTS (2.7L)

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Center Bearing
And Inner Shaft > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle >
Driveshaft Assembly > Center Bearing And Inner Shaft > Repair procedures
DISASSEMBLY
1. Using the special tool (09517-43001), disassemble the center bearing bracket from the inner shaft.
2. Using the special tools (09216-21100, 09495-33100), press out the center bearing from the outside to the
inside direction of the center bearingbracket as shown in the illustration.
INSPECTION
1. Check the inner shaft for damage, bending or rust.
2. Check the inner shaft splines for wear or damage.
3. Check the center bearing for scoring, discoloration and roughness of the roller journals moving surfaces.
REASSEMBLY
1. Apply multipurpose grease to the center bearing and inside the center bearing bracket.
2. Using the special tool (09495-33100), press the center bearing into the center bearing bracket.

24.04.2008
Page 2 of 2
3. Apply multipurpose grease to the rear surface of all dust seals.

Recommended grease : Sunlight No.2
Inner dust seal : 7~10 gr.
Outer dust seal : 4~6 gr.
4. Install the inner shaft into the center bearing bracket.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Front Axle Assembly > Front Hub / Axle >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Front
Axle Assembly > Front Hub / Axle > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Front Axle Assembly > Front Hub / Axle
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Front Axle
Assembly > Front Hub / Axle > Repair procedures
REMOVAL
2. Remove the split pin and driveshaft nut from the front hub.
3. Remove the front brake assembly from the knuckle and suspend it with a wire.
4. Remove the vehicle speed sensor from the knuckle.
5. Disconnect the tie rod end ball joint from the knuckle by using the special tool (09568 - 34000).
Be sure to tie the special tool (09568 - 34000) to the near part with a cord not to fall.
6. Disconnect the strut assembly from the knuckle.
7. Disconnect the driveshaft from the hub.

8. Disconnect the lower arm ball joint from the knuckle by using the special tool (09568 - 34000).
9. Remove the hub and knuckle as an assembly.
INSTALLATION

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Page 2 of 5
1. Tighten the components below to the specified torque as follows :

Items
Torque Nm (kgfcm, lbft)
Driveshaft nut (2.0L)

Driveshaft nut (2.7L)
Lower arm ball joint to knuckle nut
Knuckle to strut assembly nut
200~260
(2000~2600, 148~192)
200~280
(2000~2800, 148~207)
60~72 (600~720, 44~53)
140~160
(1400~1600, 103~118)
2. Install the washer behind the driveshaft nut with the convex side outward as shown in the illustration.
DISASSEMBLY
1. After removing the screws(2) mounting the brake disc, remove the brake disc from the hub.
2. Remove the snap ring.
3. Install the special tools as illustrated.
4. Remove the hub from the knuckle by turning the special tool.
5. Remove the special tool and dust cover.
6. Remove the bearing inner race from the hub by using the special tool.

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Page 3 of 5
7. Using the special tool (09495-33100, 09517-29000), remove the wheel bearing outer race from the knuckle.
INSPECTION
1. Check the hub for cracks and the splines for wear.
2. Check the brake disc for scoring and damage.
3. Check the knuckle for cracks.
4. Check the bearing for cracks or damage.
REASSEMBLY
1. Apply multi-purpose grease to the contacting surface of the knuckle hub and bearing thinly.
2. Using the special tools (09495-33100, 09517-29000), press-in the bearing to the knuckle.
1. Press-in the outer race of the wheel bearing to prevent damage to the bearing assembly.
2. When installing a bearing assembly, always use a new one.
3. Install the dust cover.

4. Using the special tool (09495-33100), press-in the hub to the knuckle.
Press-in the inner race of the wheel bearing to prevent damage to the bearing assembly.

24.04.2008
Page 4 of 5
5. Install the brake disc.

6. Tighten the hub and the knuckle to the specified torque by using the special tool (09517-21500).
Specified torque Nm (kgfcm, lbfft)
2.0L : 200~260 (2000~2600, 148~192)
2.7L : 200~280 (2000~2800, 148~207)
7. Rotate the hub several times to seat the bearing.

8. Measure the hub bearing starting torque.
Hub bearing starting torque [Limit]
1.8 Nm (18 kgfcm, 1.33 lbfft) or less
9. If the starting torque is 0 Nm (0 kgfcm, 0 lbfft), measure the hub bearing axial play.

24.04.2008
Page 5 of 5
10. If the hub axial play exceeds the limit while the nut is tightened to 200~260 Nm (2000~2600Kgfcm, 148~192
lbfft), the bearing, hub and knuckle are not installed correctly. Repeat the disassembly and
assemblyprocedure.
Hub bearing axial play [Limit]
0.008 mm (0.0003 in.) or less
11. Remove the special tool (09517-21500).

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Rear
Axle Assembly > Rear Hub / Carrier > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Rear Axle
Assembly > Rear Hub / Carrier > Repair procedures
REMOVAL
1. Remove the rear wheel speed sensor (for vehicles equipped with ABS(Anti-lock Brake System)).
When removing the speed sensor from the adapter, be careful so that the end of the pole piece doesn't
strike teeth on the rotor or other components.
2. Remove the caliper assembly and suspend it with a wire.
3. Remove the brake disc.
4. Remove the hub cap, wheel bearing nut and tongue washer.
5. Remove the hub assembly.
The rear hub assembly should not be disassembled.

(For vehicles equipped with ABS(Anti-lock Brake System))
Care must be taken not to scratch or damage the teeth of the rotor. The rotor must never be dropped.
If the teeth of the rotor are chipped, it results in deformation of the rotor. It will make it impossible to
detectthe wheel rotation speed accurately and to operate the system normally.
INSTALLATION
1. After tightening the flange nut, caulk the concave portion of the spindle by crimping the nut.
Replace the flange nut with new ones after removal.
2. Installation of the rear speed sensor (For vehicles equipped with ABS(Anti-lock Brake System)) :
Insert a feeler gauge into the space between the pole piece of the speed sensors and the rotor teeth surface,
and then tighten the speed sensors at the position where the clearance at all places is within the standard
value.

24.04.2008
Page 2 of 2
Standard value
Clearance : 0.2~1.3 mm (0.008~0.051 in.)
3. Install the hub cap.
INSPECTION
1. Check the oil seal for cracks or damage.
2. Check the rear hub bearing for wear or damage.
3. Check the rear rotor for chipped teeth.
4. Check the rear carrier for cracks.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > General Safety
Information and Caution, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information
> General Safety Information and Caution
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake system and
result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Special Service Tools
SPECIAL TOOLS
Illustration
Use
09581 - 11000
Piston expander
Spreading the front brake piston
09580 - 34000
Rear brake piston adjuster
Removal and installation of the rear

brake piston

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Components and Components
Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Components and
Components Location
Component Locating Index

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Troubleshooting
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom
Suspect Area
Remedy
Lower pedal or spongy pedal
1.
2.
3.
4.
Brake system (Fluid leaks)

Brake system (Air in)
Piston seals (Worn or damaged)
Master cylinder (Faulty)
Correct
Bleeding
Replace
Replace
Brake drag
1.
2.
3.
4.
5.
6.
7.
8.
Brake pedal freeplay (Minimal)

Parking brake lever travel (Out of adjustment)
Parking brake wire (Sticking)
Pad (Cracked or distorted)
Piston (Stuck)
Piston (Frozen)
Booster system (Vacuum leaks)
Master cylinder (Faulty)
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Brake pull
1.
2.
3.
4.
Pad (Oily)
Piston (Frozen)
Disc (Scored)
Replace
Replace
Replace
Replace
Hard pedal but brake inefficient
1.
2.
3.
4.
5.
6.
7.
8.
Brake system (Fluid leaks)

Brake system (Air in)
Pad (Worn)
Pad (Oily)
Pad (Glazed)
Disc (Scored)
Booster system (Vacuum leaks)
Correct
Bleeding
Replace
Replace
Replace
Replace
Replace
Replace
Noise from brake
1.
2.
3.
4.
5.
6.
7.
8.

Installation bolt (Loosen)
Disc (Scored)
Pad retainers (Loosen)
Sliding pin (Worn)
Pad (Dirty)
Pad (Glazed)
Brake pad shim (Damage)
Replace
Retighten
Replace
Replace
Replace
Clearing
Replace
Replace

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > All Scheduled Maintenance
Instructions, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > All Scheduled
Maintenance Instructions
Operation and Leakage Check

Check all of the following items:
Component
Brake Booster (A)
Piston cup and pressure cup

inspection (B)
Procedure
Check brake operation by applying the brakes during a test drive. If the brakes do not work
properly, check the brake booster. Replace the brake booster as an assembly if it does not
work properly or if there are signs of leakage.
Check brake operation by applying the brakes. Look for damage or signs of fluid
leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.
Brake hoses (C)
Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it
isdamaged or leaking.
Caliper piston seal and

piston boots (D)
Check brake operation by applying the brakes.

Look for damage or signs of fluid leakage. If the pedal does not work properly, the brakes
drag, or there is damage or signs of fluid leakage, disassemble and inspect the brake
caliper. Replace the boots and seals with new ones whenever the brake caliper is
disassembled.

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Repair procedures,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Repair procedures
Brake Pedal and Brake Switch Adjustment

Pedal Height
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and back off the brake switch (B)
until it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center
of the pedal pad (D).
Standard pedal height (with carpet removed):
170 mm (6.69 in.)
3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the
pushrod depressed.
BRAKE SWITCH CLEARANCE
Pedal Free Play

1. With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.

24.04.2008
Page 2 of 4
3~8 mm (0.11~0.31in.)
2. If the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it
may result in brake drag.
Parking brake check and adjustment

CHECK
1. Pull the parking brake lever (A) with 196 N (20 kgf, 44lbf) force to fully apply the parking brake. The parking
brake lever should be locked within the specified number of clicks (B)
6~7
2. Adjust the parking brake if the lever clicks are out of specification.
ADJUSTMENT
After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the
brake pedalseveral times to set the self-adjusting brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
2. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).
3. Pull the parking brake lever up one click.

24.04.2008
Page 3 of 4
4. Remove the console.

5. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.
6. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
7. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
8. Reinstall the console.
Brake System Bleeding
Do not reuse the drained fluid.

Always use Genuine DOT 3 or DOT 4 Brake Fluid. Using a non-Genuine DOT3 or DOT 4 brake fluid can
cause corrosion and decrease the life of the system.
Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash
it off immediately with water.
The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding
procedure and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A).
2. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw
securely.

24.04.2008
Page 4 of 4
4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the
fluid.
5. Refill the master cylinder reservoir to the MAX (upper) level line.
Front disc brake:
Rear disc brake:

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Specifications
SPECIFICATIONS
Master cylinder
- Type
- I.D. mm(in.)
- Fluid level warning sensor
Tandem type
23.81 (0.94) : CBS
25.4 (1.0) : ABS (TCS)
Provided
Brake booster
- Type
- Effective dia.mm(in.)
- Boosting ratio
Vacuumtype with tandem booster

Tandem type with 7+8 in. (CBS)
Tandem type with 8+9 in. (ABS, TCS)
7.0 : 1
Proportioning valve
- Cut-in pressure (Split point)
- Decompression ratio
3.4 MPa (35 kg/cm, 498 psi)

0.27 : 1
Front disc brake

- Type
- Disc O.D.
- Disc thickness
- Pad thickness
- Cylinder I.D.
Floating type with ventilated disc

280 mm (11.02 in.)
26 mm (1.024 in.)
11 mm (0.433 in.)
57.2 mm (2.25 in.)
Rear disc brake

- Type
- Disc O.D.
- Clearance adjustment
- Disc thickness
- Pad thickness
- Cylinder I.D
Floating type with solid disc

258 mm (10.16 in.)
Automatic
10 mm (0.394 in.)
9 mm (0.354 in.)
33.96 mm (1.34 in.)
Parking brake
- Actuation
- Type
Mechanical brake acting on rear wheels

Lever
Auti-lock brake system (ABS)

ECU type
ABS & EBD Warning lamp / TCS lamp
- Operating voltage
- Current
Wheel speed sensor
- Internal resistance
- Output range
- Output voltage
- Tone wheel teeth
- Air-gap mm (in.)
HECU (HU + ECU)
- Pump type
- Motor type
- Motor type
- LPA volume
- HPA volume
- Inlet valve (Front / Rear) mm (in.)
- Outlet valve (Front / Rear) mm (in.)
Motor, valve relay integrated type

12V
80 mA
1,385 110 (at 23 5C)
15 ~ 2,000 Hz
Min. 130 mVpp
44 EA
0.2 ~ 1.3 (0.008 ~ 0.051)
Radial pistons (2 pistons)
4-pole DC motor
180W
MCS : 3.0cc / MCP : 3.0cc
0.13cc
0.56 (0.022) / 0.315 (0.0124)
0.56 (0.022) / 0.355 (0.0140)
60 ~ 90 bar

24.04.2008
Page 2 of 2
- TC valve relief pressure
O.D = Outer Diameter

I.D = Inner Diameter
CBS = Conventional Brake System
ABS = Anti-lock Brake System
TC Valve = Traction Control Valve
SERVICE STANDARD
Standard value
Service limit
Brake pedal height
170 mm (6.69 in.)
Brake pedal stroke
128 mm (5.04 in.)
Stop lamp switch outer case to pedal stopper

clearance
0.5~1.0 mm (0.02~0.04
in.)
Brake pedal free play
3~8 mm (0.11~0.31 in.)
Brake pedal to floorboard clearance
61 mm (2.40 in.) or more
Booster push rod to master cylinder piston clearance
0 (at 500 mmHg vacuum)
Parking brake lever stroke when lever assembly is

pulled with 196N (20kg, 44lb force)
6~7 clicks
Front disc brake pad thickness
11 mm (0.43 in.)
2 mm (0.079 in.)
Front disc thickness (minimum )
26 mm (1.02 in.)
22.4 mm (0.96 in.)
Rear disc brake pad thickness
9 mm (0.35 in.)
2 mm (0.08 in.)
Rear disc thickness
10 mm (0.4 in.)
8 mm (0.315 in.)
TIGHTENING TORQUE
Nm
Kgfcm
lbfft
Master cylinder to booster mounting nut
8~12
80~120
6~9
Brake booster mounting nut
13~16
130~160
9.6~11.8
Brake booster vacuum hose fitting to surge tank
15~18
150~180
11.1~13.3
Bleeder screw
7~13
70~130
5.2~9.6
Brake tube flare nut, brake hose
13~17
130~170
9.6~12
Caliper guide rod bolt
22~32
220~320
16.2~23.6
Caliper assembly to knuckle
65~75
650~750
48~55
Brake hose to front caliper
25~30
250~300
18~22
Wheel speed sensor mounting bolt
8~9
80~90
6~7
Hydraulic & electronic control unit mounting bolt
8~10
80~100
6~7.4
Hydraulic & electronic control unit mounting bracket bolt
17~26
170~260
13~19
Replace self-locking nuts with new ones after removal.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster
COMPONENT

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster >
Repair procedures
REMOVAL
1. Remove the air cleaner.
2. Disconnect the brake tube from the master cylinder.

3. Remove the master cylinder.
If there is any brake fluid on any painted surface, wash it off immediately.
4. Disconnect the vacuum hose from the booster.

5. Remove the operating rod from the brake pedal.
6. Loosen the booster mounting nuts.
7. Lift out the booster assembly.
INSTALLATION
1. When the booster assembly is installed, replace the packing at each end of the booster mounting holder, if
necessary.
2. Install the brake booster and tighten the mounting nuts.
Tightening torque:
13~16 Nm (130~160 kgfcm, 9.6~11.8 lbfft)

24.04.2008
Page 2 of 2
3. Apply sufficient grease inside the brake pedal hole.

4. Connect the clevis to the brake pedal with the clevis pin and install the split pin to the clevis pin.
5. Install the master cylinder and connect the brake tube to the master cylinder.
6. Connect the vacuum hose to the brake booster.
7. Fill the brake reservoir with brake fluid and bleed the system.
8. Check for fluid leakage.
9. Check and adjust the brake pedal.
10. After installation, apply sufficient grease to contact points of the clevis and brake pedal.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master Cylinder > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master
Cylinder > Components and Components Location
COMPONENT

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master Cylinder > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master Cylinder
> Repair procedures
REMOVAL
1. Remove the fluid level warning device connector.
2. Detach the brake tubes from the master cylinder, and then install the plug.
3. Remove master cylinder mounting nuts and then lift out the master cylinder.
INSTALLATION
1. Install the master cylinder to the brake booster.
2. Install the booster and master cylinder to the dash panel.
3. Connect the brake tubes to the master cylinder.
4. Install the vacuum hose tightly.
5. Connect the operating rod to the brake pedal.
6. After filling the brake reservoir with the brake fluid, bleed the system.
Don't disassemble the brake booster.
DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. After disconnecting the mounting screws, pry the reservoir free from the master cylinder.
3. Using a snap ring pliers, remove the retainer ring.

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Page 2 of 3
4. Remove the primary cylinder pin, pushing the primary piston with a screwdriver and remove the primary piston
assembly.
5. Remove the secondary cylinder pin. Push the secondary piston with a screwdriver and remove the secondary
piston assembly.
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1. Check the master cylinder bore for rust or scoring.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
1. If the cylinder bore is damaged, replace the master cylinder assembly.

2. Wash the parts in alchohol.
REASSEMBLY

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Page 3 of 3
1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.

3. Press against the pistons with a screwdriver and install the retainer ring.
4. With the piston pushed completely by a screwdriver, install the cylinder pin.
5. Mount two grommets.

6. Install the reservoir on the cylinder.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Proportioning Valve >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System >
Proportioning Valve > Description and Operation
Description

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Proportioning Valve > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Proportioning
Valve > Repair procedures
REMOVAL
INSTALLATION
1. Install the master cylinder according to the illustration.
2. Tighten the flare nuts and bleed the system.

Tightening torque
Brake tube flare nut:
13~17 Nm (130~170 kgfcm, 9~12 lbfft)
Proportioning valve mounting nut:
35~55 Nm (350~550 kgfcm, 30~40 lbfft)
INSPECTION
1. Connect two pressure gauges; one to the input side, and one to the output side.
Be sure to bleed the system after connecting the pressure gauges.

2. With the brakes applied, measure the input pressure and the output pressure. If the measured pressures are
within the specified range as illustrated, theproportioning valve is good.
3. Reconnect the brake lines in their original positions and bleed the system.
This figure shows characteristics of the proportioning valve as the pressure incrases.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Line > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Line >
Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Line > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Line >
Repair procedures
Inspection
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.
Replace the brake hose clip whenever the brake hose is serviced.
Replacement
Before reassembling, check that all parts are free of dust and other foreign particles.
Replace parts with new ones whenever specified to do so.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks.
2. Disconnect the brake hose from the brake line (B) using a 10mm flare-nut wrench (C).
3. Remove and discard the brake hose clip (A) from the brake hose (B).
4. Remove the connector bolt (C), and disconnect the brake hose from the caliper.
5. Remove the brake hose from the knuckle.
6. Install the brake hose (A) on the knuckle with 12mm flange bolt (B) first, then connect the brake hose to the
caliper with the connector bolt (C) and new sealing washers (D).

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Page 2 of 2
7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).
8. Connect the brake line (D) to the brake hose

9. After installing the brake hose, bleed the brake system.
10. Perform the following checks.
A. Check the brake hose and line joint for leaks, and tighten if necessary.
B. Check the brake hoses for interference and twisting.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal >
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal >
Repair procedures
REMOVAL
1. Remove the stop lamp switch.
2. Remove the split pin and clevis pin.
3. Remove the flange nuts of the brake mounting bracket.
4. Remove the brake pedal assembly.
INSTALLATION
Be sure to install the split pin on the operating rod clevis pin.
2. Install the brake pedal assembly and tighten the flange nuts (booster mounting nuts) and bolt.
Tightening torque:
13~16 Nm (130~160 kgfcm, 6~9 lbfft)
3. Adjust the brake pedal height and free play.

4. Install the stop lamp switch.
INSPECTION
1. Check the bushing for wear.
2. Check the brake pedal for distortion.
3. Check the brake pedal return spring for damage.
4. Check the stop lamp switch.
(1) With an ohmmeter connected to the stop lamp switch terminals, check for continuity.
(2) If there is no continuity when the plunger is depressed and there is continuity when the plunger is
released, the stop lamp switch is normal.

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc Brake > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc
Brake > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc Brake > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc Brake
> Repair procedures
REPLACEMENT
Brake pad removal
1. Remove the 2 guide pin bolt, remove the caliper assembly from the knuckle and secure it with a wire or some
other retaining method.
2. Remove the pads.
Do not depress the brake pedal while disassembling the pads.
Brake pad inspection

1. Check the pads for wear or oil contamination and replace, if necessary.
The pads for the right and left wheels should be replaced at the same time. Never "drop" or intermix
brake pad sets.
All four pads must be replaced as a complete set.
When replacing the brake pad, check for deformation. When replacing the guide spring, use a new
one or the used one after cleaning away foreignmaterial.
2. Check the pad for damage or deformation.
Brake pad thickness:
Standard value: 11mm (0.43 in.)
Service limited value: 2mm (0.079 in.)
Brake pad installation

1. Install the pad clips.
2. Install the pads onto each pad clip.

24.04.2008
Page 2 of 6
Position the pad with its pad wear indicator upward on the piston side.
3. Insert the piston in the cylinder using the Special Tool (09581-11000).
4. Install the new pads. The shims are attached to the each pad as illustrated.
Be careful so that the disc or pad isn't contaminated by grease.
5. Install the bolt and tighten to the specified value.

Tightening torque
Guide rod bolt: 22~32 Nm (220~320 kgfcm, 16~24 lbfft)

24.04.2008
Page 3 of 6
REMOVAL
2. Disconnect the brake hose.
3. Remove the cylinder mounting bolt.
4. Remove cylinder and pads.
5. Remove the caliper mounting bolts (2EA) from the knuckle.
6. Remove the caliper.
INSTALLATION
1. Install the pads and brake cylinder.
2. Install the brake hose to the caliper.
Bleeder screw tightening torque:
7~13 Nm (70~130 kgfcm, 5.2~9.6 lbfft)
3. Fill the brake reservoir withe brake fluid.

4. Bleed the system.
DISASSEMBLY
1. Remove the piston boot.
2. Remove the piston using compressed air.
1. Do not put your fingers in front of the piston when using compressed air.
2. Be careful not to splatter the brake fluid.

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3. Remove the piston seal from the caliper by using a screwdriver.
INSPECTION
1. Check the caliper for wear, damage, cracks and dust.
2. Check the piston for dust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and dust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, dust, wear and cracks.
1. Do not use sand paper on the piston surface.

2. All rubber parts must be replaced with new parts.
6. Inspect the disc by using a calipers and a dial gauge.
Thickness of disc mm (in.)
Standard value : 26 (1.024)
Service limit : 24.4 (0.961)
Runout of the disc mm (in.) : 0.08 (0.003)
Difference of thickness : 0.01mm (0.0004 in.)

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1. Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the
outer edge of the disc and at 45 intervals.
If you substract the minimum of measurements from the maximum, you get the difference of the disc
thickness.
2. When measuring the disc runout, fix a dial gauge approximately 5mm from the outer edge of the disc,
and rotate the disc 360.
At this time, if you subtract the minimum of measurements from the maximum, you get the disc
runout.
7. If necessary, replace the brake disc.
REASSEMBLY
1. Clean all components except the pads and shims with isopropyl alcohol.
2. Apply rubber grease on the piston seal and install the piston seal in the cylinder.
3. Assemble the piston and piston boots according to the following procedure.
(1) Apply rubber grease to the caliper bore, the outside surface of the piston and the piston boot.
(2) Install the piston boot on the piston as illustrated.
(3) Insert the piston boot in the inner groove of the caliper and push the piston into the caliper.
4. Assemble the sliding parts according to the following procedure.

(1) Apply rubber grease to the outside surface of the sleeve and pin, pin and sleeve bore of the caliper, pin
boot and sleeve boot.
(2) Insert the boot into the groove of the caliper.

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5. Install the pads.
Be careful so that the disc or pad is contaminated by grease
6. Tighten the brake hose connecting bolt.

Tightening torque
Nm (kgfcm, lbfft)
Sliding pin
34~44 (350~450, 26~33)
Carrier mounting bolt
64~74 (650~750, 48~54)
Brake hose mounting oil bolt
25~29 (250~300, 18~22)
1. Check that the surface of the pin and bolts is not damaged before tightening.
2. Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting
parts.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake > General
Information, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake
> General Information
General information
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your
health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies.
Remove, disassemble, inspect, reassemble, and install the caliper and note these items:
Do not spill brake fluid on the vehicle; it may damage the paint; If brake fluid gets on the paint, wash it off
immediately with water.
Clean all parts in brake fluid and air dry; blow out all passages with compressed air.
Before reassembling, check that all parts are free of dirt and other foreign particles.
Replace parts with new ones as specified in the illustration.
Make sure no dirt or other foreign matter gets into the brake fluid.
Make sure no grease or oil gets on the brake discs or pads.
When reusing pads, always reinstall them in their original positions to prevent loss of braking efficiency.
Do not reuse drained brake fluid.
Always use Genuine DOT 3 or DOT 4 brake fluid. Non Genuine DOT 3 or DOT 4 brake fluid cause corrosion
and shorten the life of the system.
Coat the piston, piston seal groove, and caliper bore with clean brake fluid.
Replace all rubber parts with new ones.
After installing the caliper, check the brake hose and line for leaks, interference, interference, and twisting.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc
Brake > Components and Components Location
COMPONENTS

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake
> Repair procedures
REPLACEMENT
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your
health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies.
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
2. Release the parking brake.
3. Remove the brake hose (A) from the suspension arm by removing the brake hose clip (B).
Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
Support the caliper with a piece of wire so that it does not hang from the brake hose.
4. Remove the two guide rods (C) and caliper (D) from the bracket.
5. Remove the pad shim (A) and brake pads (B).
6. Using vernier calipers, measure the thickness of each brake pad lining. Measurement does not include pad
backing plate (A) thickness.
Brake pad thickness:
Standard: 9 mm (0.35 in.)
Service limit: 2 mm (0.08 in.)

24.04.2008
Page 2 of 4
7. Remove the pad retainers.
8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
9. Check the brake disc for damage and cracks.
10. Install the pad retainers.
11. Check the foreign material at the pad shim (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.
12. Install the brake pads (B) and pad shim (A) on the caliper bracket. Install the inner pad with its wear indicator
(C) facing down ward.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary
loss of braking efficiency.
13. Rotate the caliper piston (A) clockwise into the cylinder, the align the cutout (B) in the piston with the tab (C)
on the inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston
boot. If the piston boot is twisted, back it out so it is positioned properly.

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14. Install the brake caliper (D).

15. Install and torque the guide rods (E) to proper specification.
16. Install the brake hose (F) onto the suspension arm with the brake hose clip (G).
17. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
18. Depress the brake pedal several times to make sure the brakes work, then test-drive.
Engagement of the brake may require a greater pedal stroke immediately after the brake pads have
been replaced as a set.Several applications of the brake pedal will restore the normal pedal stroke.
INSPECTION
Runout
1. Raise the rear or the vehicle, and make sure it is securely supported.
2. Remove the brake pads.
3. Inspect the disc surface for damage and cracks clean the disc thoroughly and remove all rust.
4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial
indicator (B) as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc.
5. If the disc is beyond the service limit, refinish the brake disc.
8.0 mm (0.315 in.)
A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.)
Thickness and parallelism

1. Loosen the rear wheel nuts slightly, then raise the vehicle, and make sure it is securely supported.
Remove the rear wheels.

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2. Remove the brak pads.

3. Using a micrometer (A), measure disc thickness at eight points, approximately 45 apart and 10 mm (0.4 in.) in
from the outer edge of the disc. Replace the brake disc if the smallest measurement is less than the max.
refinishinglimit.
Brake disc thickness:
Standard: 10 mm (0.4 in.)
Max. Refinishing limit: 8.0 mm (0.315 in.)
Brake disc parallelism: Max. 0.015 mm (0.0006 in.)
This is the maximum allowable difference between the thickness measurements.
4. If the disc is beyond the service limit for parallelism, refinish the brake disc.
If the brake disc is beyond the service limit for refinishing, replace it (see DS group-rear axle).

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking Brake System > Parking Brake Assembly >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking
Brake System > Parking Brake Assembly > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking Brake System > Parking Brake
Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking
Brake System > Parking Brake Assembly > Repair procedures
REMOVAL
The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature
failure.
Refer to the component as needed during this procedure.
Rear disc brake

1. Release the parking brake lever fully, and remove the parking cable clip (A) from the parking brake cable.
2. Disconnect the parking brake cable (B) from the lever (C).

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams
HYDRAULIC SYSTEM DIAGRAM
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM (1)

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CIRCUIT DIAGRAM (2)
CIRCUIT DIAGRAM (3)

24.04.2008
Page 3 of 3

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Description
and Operation
DESCRIPTION
This specification applies to Hydraulic and Electronic Control Unit (HECU) of the Anti lock Braking System(ABS) and
Traction Control System(TCS).
This HECU has the functions as follows:
- Input of signal from the wheel speed sensors attached to each wheel.
- Control of braking force and traction force
- Failsafe function
- Self diagnosis function
- Interface with the external diagnosis tester
Operation
The HECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the HECU shall be ready for operation.
In the operating condition, the HECU shall be ready, within the specified limits (voltage and temperature), to process the
signals offered by the various sensors and switches in accordance with the control algorithm defined by the software and to
control the hydraulic and electrical actuators.
The HECU shall receive wheel speed signal from the four inductive wheel sensors.
The wheel signals are converted to square wave by the signal conditioning circuit and given as input to the - processor.
The sensor connections shall be monitored for short-circuit and inter-ruption and then in the event of 2 sensor failures, the
HECU shall shut down the system.
When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the other
side is connected to the ground by the MOSFET, the solenoid valve goes into operation.
The electrical function of the valves are always monitored by the valve test pulse under normal operation conditions.
When overvoltage is detected(above 16V), the HECU switches off the valve relay and shuts down the system. When
voltage is returned to operating range, the system goes back to the normal condition after the initialization phase.
In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and the HECU returns to normal operating
mode.
The pump motor operates when the ABS is functioning.
The HECU performs a pump motor test at a speed of 20km/h once after turned the Ignition switch on. You may hear the
motor operate at this time, but it is normal.
Malfunctions or failures detected by the HECU are encoded on the HECU, stored in a EEPROM and read out by diagnostic
equipment (hi-scan pro) when the ignition switch is turned on.
Warning lamp control
1. ABS warning lamp module

The ABS warning lamp module indicates the operating condition of the ABS.
The ABS warning lamp is turned on under the following conditions.
A. During the initialization phase after ignition switch ON (3 seconds).
B. In the event of inhibition of ABS functions by failure.
C. When the system ECU is shut down even though ignition power is applied.
D. During diagnostic mode.
E. When the HECU connector is disconnected.
2. EBD warning lamp module
The EBD warning lamp module indicates the operating condition of the EBD. However, in case the parking brake switch
is turned on, the EBD warning lamp is always turned on regardless of EBD functions.

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The EBD warning lamp is turned on under the following conditions.

A. During the initialization phase after ignition switch ON. (3 seconds).
B. When the system ECU is shut down even though ignition power is applied.
C. When the parking brake switch is ON or brake fluid is low level.
D. In the event of inhibition of EBD functions by failure.
3. TCS lamp module
The TCS warning lamp module indicates the operating condition of the TCS.
The TCS warning lamp is turned on under the following conditions:
A. During the initialization phase after ignition switch ON (3 seconds).
B. In the event of inhibition of TCS functions by failure.
C. When the TCS OFF switch is turned on.
TCS function lamp is turned on when the TCS functions are operating (Blinking-2Hz).
Diagnostic trouble code (DTC)

1. If the CPU cannot be activated or the CPU fails, the ABS indicator comes on, but the DTC is not memorized.
2. The memory can hold any number of DTCs. However, when the same DTC is detected more than once, the later one is
written over the old one.
Therefore, when the same problem is detected repeatedly, it is memorized as one DTC.
3. The DTCs are indicated in the order they occur.
4. The DTCs are memorized in the EEPROM (non - volatile memory). Therefore, the memorized DTCs cannot be
canceled by disconnecting the battery. Perform the specified procedures to erase the DTCs.
Self-diagnosis
1. Self diagnosis can be classified into two categories:
A. Initial diagnosis:
Performed right after the engine starts and until the ABS indicator goes off.
B. Regular diagnosis:
Performed right after the initial diagnosis until the ignition switch is turned OFF.
2. When a problem is detected by self-diagnosis, the system:
A. Turns the solenoid valve OFF
B. Turns the pump motor OFF
C. Turns the ABS indicator ON
How to troubleshoot ABS DTC

1. Question the customer about the conditions when the problem occured, and try to reproduce the same conditions for
troubleshooting. Find out when the ABS indicator came on, such as during initial diagnosis, during ABS control, after
ABS control, when vehicle speed was at a certain speed, etc.
2. When the ABS indicator does not come on during the test-drive, but troubleshooting is performed based on the DTC.
check for loose connectors, poor contact of the terminals, etc. before you start troubleshooting.
3. After troubleshooting, erase the DTC and test-drive the vehicle. Be sure the ABS indicator does not come on.
HI-SCAN (PRO) CHECK

1. Turn the ignition switch OFF.
2. Connect the Hi-scan (pro) to the 16P data link connector located underneath the lower crash pad panel.

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3. Turn the ignition switch ON.

4. Check for diagnostic trouble codes using the Hi-scan (pro).
5. After completion of the repair or correction of the problem, erase the stored fault codes using the clear key on the Hiscan (pro).
6. Disconnect the Hi-scan (pro) from the 16P data link connector.
SYSTEM FUNCTION
ABS OPERATION
1. NORMAL BRAKING
Solenoid valve
State
Valve
IN (NO)
OFF
OPEN
OUT (NC)
OFF
CLOSE
Passage
Master cylinder
Pump motor
Wheel cylinder
OFF
Wheel cylinder
Reservoir
Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.
When the brake is depressed, brake fluid is supplied to the wheel cylindervia solenoid valve to activate the brake.
When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
2. DUMP MODE
Solenoid valve
State
Valve
IN (NO)
ON
CLOSE
OUT (NC)
ON
OPEN
Passage
Master cylinder
Pump motor
Wheel cylinder
ON
Wheel cylinder
Reservoir
Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease
the brakefluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked
from the mastercylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to reservoir,
resulting in pressure decrease.
3. HOLD MODE
Solenoid valve
State
Valve
IN (NO)
ON
CLOSE
OUT (NC)
OFF
CLOSE
Passage
Master cylinder
Pump motor
Wheel cylinder
ON
Wheel cylinder
Reservoir
When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to
keep the fluidpressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and outlet
valves are closed and brake fluid is kept in wheel cylinder.
4. INCREASE MODE
Solenoid valve
State
Valve
IN (NO)
OFF
OPEN
OUT (NC)
OFF
CLOSE
Passage
Master cylinder
Pump motor
Wheel cylinder
ON
Wheel cylinder
Reservoir

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If HECU determines there's no lock-up in the wheel, HECU cuts voltage to solenoid valve. So voltage is not supplied
to each solenoid valve, brake fluid passes through the inlet valve to wheel cylinder, resulting in pressure increase.
TRACTION CONTROL SYSTEM (TCS) OPERATION

1. NORMAL MODE
Solenoid valve
State
Valve
IN (NO)
OFF
OPEN
OUT (NC)
OFF
CLOSE
Motor pump
TC valve
OFF
OFF
In the normal driving condition, TC valve (normally open) is the passage between the master cylinder and the each
wheel cylinder.
When brake pedal is applied, brake pressure is delivered to the wheel cylinders via NO-TC valve and all solenoid
valves inside the hydraulic unit are deactivated.
In case of TCS malfunction it does not affect brake operation.
2. PRESSURE INCREASE MODE

Solenoid valve
State
Valve
Motor pump
TC valve
IN (NO)
FRONT: OFF
REAR: ON
FRONT: OPEN
REAR: CLOSE
ON
ON
OUT (NC)
OFF
CLOSE
If a front wheel spin is detected, TCS begins a brake control to decrease a wheel spin.
Hydraulic shuttle valve (HSV) is opened.
Brake fluid is supplied from the master cylinder by motor operation to the spin wheel via HSV.
TC valve is closed (ON).
Brake pressure generated from motor pump is delivered only to the front wheel.
Inlet valve remains open to deliver the brake pressure generated from motor pump to the spinning wheels.
3. PRESSURE DUMP MODE

Solenoid valve
State
Valve
IN (NO)
ON
CLOSE
OUT (NC)
FRONT: ON
REAR: OFF
FRONT: OPEN
REAR: CLOSE
Motor pump
TC valve
ON
ON
When the wheel deceleration is under the threshold and the wheel spin is reduced under a slip threshold, applied
brake pressure is reduced to get a optimum traction force.
Outlet valve is open to release the brake pressure and inlet valve is closed to block the pressure increase from the
motor pump.
Hydraulic shuttle valve (HSV) remains opened, TC valve is ON.
Motor is ON, to dump the brake fluid being released from the lock-up wheel.
4. PRESSURE HOLD MODE

Solenoid valve
State
Valve
IN (NO)
ON
CLOSE
OUT (NC)
OFF
CLOSE
Motor pump
TC valve
ON
ON
TRACTION CONTROL SYSTEM (TCS) FUNCTION

1. Main performance

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A. Traction: Lower vibration and higher launchability, accelerationand climbability by slip control.
B. Cornering and passing: Stable cornering and passing.
C. Steering stability: Control traction force traverse vector prior to provide easy turning when turning the steering wheel.
2. General TCS features
A. Improved drivability. Minor operation of acceleration is not necessary in launching and acceleration on slippery road.
B. More stable cornering by stable acceleration on normal road condition.
C. TCS system will compare vehicle speed received from rear wheel speed sensor and driving wheel speed from front
wheel speed sensor on slippery road condition, and provide optimum slipping rate of driving wheels.
FULL TRACTION CONTROL SYSTEM (FTCS)

1. The ABS control module (HECU) controls TCS control too.
2. HECU will compare signals from front (driving) and rear wheel speed sensors to detect driving wheels slip.
3. Upon detecting driving wheels slip, HECU will perform TCS control. The TCS control will include brake TCS (BTCS)
control.
4. HECU will transmit engine torque reduction request, fuel cut cylinder number, and TCS control request signals in
accordance with slip level to engine ECM and TCM through BUS line which will provide CAN communication for TCS
control.
5. Engine ECM will perform fuel cut as requested by HECU and retard ignition timing as per engine torque reduction
request signal.
6. TCM will hold shift position by TCS control time according to TCS operation signal. Then enhanced acceleration by
kick-down will not occur.
BRAKE TRACTION CONTROL SYSTEM (BTCS)

1. On TCS control, only brake control will be performed. (engine and TCM control will not happen)
2. Controlled by motor pump output pressure.
EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION

ADVANTAGES
-
Function improvement of the base-brake system.

Compensation for the different friction coefficients.
Elimination of the proportioning valve.
Failure recognition by the warning lamp.

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Comparison between Proportioning valve and EBD
FAIL SAFE
SYSTEM
WARNING LAMP
FAIL CAUSE
ABS
EBD
ABS
EBD
None
ON
ON
OFF
OFF
1-Wheel speed sensor failure
OFF
ON
ON
OFF
Pump malfunction
OFF
ON
ON
OFF
Low voltage
OFF
ON
ON
OFF
2 or more wheel speed sensor failure

Solenoid valve failure
HECU malfunction
Valve relay failure
Over voltage
Other failure
OFF
OFF
ON
ON

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System)
COMPONENTS

24.04.2008
Page 1 of 24
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Troubleshooting
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
NOTES WITH REGARD TO DIAGNOSIS

Phenomenon
System check sound
ABS operation sound
Explanation
When starting the engine, a thudding sound can sometimes be heard coming from
inside the engine compartment. This is because the system operation checkis being
performed.
1. Sound of the motor inside the ABS hydraulic unit operation (whine).
2. Sound is generated along with vibration of the brake pedal (scraping).
3. When ABS operates, sound is generated from the vehicle chassis due torepeated
brake application and release
(Thump : suspension; squeak: tires)
ABS operation (Longbraking

distance)
For road surfaces such as snow-covered and gravel roads, the braking distance for
vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly,
advisethe customer to drive safely on such roads by lowering the vehicle speed.
Pedal kick back
Pedal kick back is normal operation.
Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after the
diagnosis code has been erased,ensure that the requirements listed in "Comment" are met.
ABS CHECK SHEET

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TROUBLE SYMPTOMS TABLE

Symptom
Suspect Area
See page
Communication with Hi-scan (pro) is not

possible.
(Communication with any system is not possible)
1. Power source circuit

2. Diagnosis line
Communication with Hi-scan (pro) is not

possible.
(Communication with ABS only is not possible)
1. Power source circuit

2. Diagnosis line
3. HECU
BR - 63
When ignition key is turned ON (engine OFF),

the ABS warning lamp does not light up.
1. ABS warning lamp circuit

2. HECU
BR - 64
Even after the engine is started, the ABS

warning lamp remains ON.
1. ABS warning lamp circuit

2. HECU
BR - 65
ABS does not operate.
Only when 1. -4. are all normal and the problem

is still occurring, replace the HECU.
1. Check the DTC reconfirming that the normal
code is output.
2. Power source circuit.

BR - 63
BR - 66
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3. Wheel speed sensor circuit.

4. Check the hydraulic circuit for leakage.
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to
intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an
abnormality.
DIAGNOSTIC TROUBLE CODE CHART

DTC No.
Detection Item
MIL*
Memory
See page
C1101
Battery voltage over volt: 18V or more
BR - 70
C1102
Battery voltage low volt: 9.5V or less
BR - 70
C1200
FL wheel sensor: open or short to ground
BR - 67
C1201
- Range/Performance: speed jump or damaged exciter
BR - 68
C1202
- No signal: air-gap error or wrong excite
BR - 69
C1203
FR wheel sensor: open or short to ground
BR - 67
C1204
BR - 68
C1205
- No signal excite: air-gap error or wrong excite
BR - 69
C1206
RL wheel sensor: open or short to ground
BR - 67
C1207
BR - 68
C1208
- No signal excite: air-gap error or wrong excite
BR - 69
C1209
RR wheel sensor: open or short to ground
BR - 67
C1210
BR - 68
C1211
No signal: air-gap error or wrong excite
BR - 69
C1604
ECU hardware: ECU internal or valve failure
BR - 71
C2112
Valve relay: valve relay or fuse failure
BR - 71
C2402
Motor-Electrical: open or short to battery, motor relay, fuse or

motor lock fail
BR - 72
C1503
TCS switch failure
C1605
CAN Hardware failure
BR - 72
C1610
CAN Bus off failure
BR - 72
C1611
EMS Time-out failure
BR - 72
C1612
TCM Time-out failure
BR - 72
C1613
TCM Un-matching failure
BR - 72
C2227
Brake disc overheat
*MIL : Malfunction Indication Lamp

: ABS warning lamp
: TCS warning lamp
FAILSAFE SPECIFICATION
DETECT MODE
THE ABILITY OF DETECTING A FAILURE
THE MANAGEMENT OF FAILURE DETECTION
1. System down. Both the ABS (TCS) and the EBD function are inhibited and the ABS (TCS) and the EBD warning lamps are
activated.

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If this happens, the valve relay and all solenoids are prevented from being switched on.
2. Only the ABS (TCS) function is inhibited. The ABS (TCS) warning lamp is activated and the EBD warning lamp is not
activated.
3. Sensor failure outside the ABS control cycle.
(1) Only one sensor fails: take the same action as management 2.
(2) More than two sensors fail: take the same action as management 1.
4. Sensor failure inside the ABS control cycle.
(1) One front sensor fails: inhibit the ABS control of the failed-wheel and maintain ABS control of the normal wheels.
After the controller completes the ABS control, take the same action as in management 2.
(2) One rear sensor fails: inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased.
(3) More than two sensor fail: take the same action as in management 1.
5. Low operating voltage
(1) Outside the ABS control cycle: inhibit the ABS (TCS) control of front wheels and allow ABS control of rear wheels,
deactivating the motor.
The ABS (TCS) warning lamp is directly switched on.
When the voltage recovers to the normal operating range, enable the ABS function and the ABS (TCS) warning lamp
is switched off and erases the error code of low voltage.
(2) Inside the ABS control cycle: inhibit the ABS control of the front wheels and allow the the ABS control of rear wheels,
The ABS (TCS) warning lamp is directly switched on and remains on. The error code is always stored.
6. Motor error during the ABS control cycle. Inhibit the ABS control of front wheels, allow ABS control of the rear wheels and
ABS (TCS) warning lamp is switched ON at the end of ABS control.
7. TCS failure
Inhibit the TCS control and allow the ABS/EBD control. Meanwhile, stop checking the TCS switch failure under the TCS
control.

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Page 6 of 24

24.04.2008
Page 7 of 24

24.04.2008
Page 8 of 24
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Communication with Hi-Scan (Pro) is not possible.
(Communication with any systems is not possible.)
Possible defect in the power supply system (including ground) for the
diagnosis line.
Probable cause
Faulty power source circuit
Faulty diagnosis line

24.04.2008
Page 9 of 24
Communication with Hi-Scan (Pro) is not possible.

(Communication with ABS only is not possible.)
When communication with Hi-Scan (Pro) is not possible, the cause may
be probably an open circuit in the HECU power circuit or an open circuit in
the diagnosis output circuit.
Probable cause
Faulty diagnosis line
Faulty HECU
When ignition key is turned "ON" (engine OFF), the ABS warning
lamp does not illuminate
When current flows in the HECU, the ABS relay turns from on to off as the
initial check. The ABS warning lamp will illuminate when the ABS relay is
off even if there is a problem with the circuit between the ABS warning
lamp and the HECU.
Therefore, if the lamp does not illuminate, the cause may be an open
circuit in the lamp power supply circuit, a blown bulb, an open circuit in
both the circuits between the ABS warning lamp and the HECU, and in
the circuit between the ABS warning lamp and the ABS relay.
Probable cause
Blown fuse
Burnt out ABS warning lamp bulb
Faulty ABS warning lamp circuit
Faulty HECU

24.04.2008
Page 10 of 24
Even after the engine is started, the ABS warning lamp remains
illuminated
A possible short-circuit in the ABS warning lamp illumination circuit
Probable cause
Faulty combination meter
Faulty ABS warning lamp circuit
Faulty HECU
This trouble symptom is limited to cases where communication with the Hi-Scan (Pro) is possible (HECU power
supply is normal) and DTC is normal.
ABS does not operate
Brake operation varies depending on
driving conditions and road surface
conditions, so diagnosis can be difficult.
However, if a normal DTC is displayed,
carry out the following inspection.
Probable cause
Improper installation of wheel speed
sensor
Incorrect sensor harness contact
Foreign material on wheel speed
sensor
Faulty wheel speed sensor

Faulty rotor
Faulty wheel bearing
Faulty HECU

24.04.2008
Page 11 of 24
INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES

DTC No. C1200, C1203, C1206, C1209
Wheel speed sensor open or short to GND circuit
The HECU determines that an open or short circuit has occured in more
than one wire of a wheel speed sensor.
Probable cause
Faulty wiring harness or connector
Faulty HECU

24.04.2008
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DTC No. C1201, C1204, C1207, C1210

(Speed jump or wrong exciter)
Abnormal output signal from a wheel speed sensor other than an open or
short circuit.
DTC No. C1202, C1205, C1208, C1211

(Large air gap)
Probable cause
Improper installation of wheel speed sensor

Faulty rotor
Faulty wheel bearing
Faulty HECU
Probable cause

24.04.2008
Page 13 of 24
No wheel speed sensor output signal.
DTC No. C1101, C1102 Voltage out of range

(Low and over voltage)
The voltage of the HECU power supply drops lower than or rises higher
than the specified value. If the voltage returns to the specified value, this
code is no longer output.

Faulty rotor (excitor)
Faulty HECU
Probable cause
Faulty HECU
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to thestandard
value, the code is no longer output. Before carrying out the following inspection, check the battery level, and refill if
necessary.
DTC No. C1604 HECU Hardware

(EEPROM and ECU failure)
The HECU always monitors the solenoid valve drive circuit. It determines
that there is an open or short-circuit in the solenoid coil or in a harness
even if no current flows in the solenoid or through the HECU.
Probable cause
Faulty wiring harness
Faulty HECU

24.04.2008
Page 14 of 24
DTC No. C2112 Valve relay

(Including fuse failure)
When the ignition switch is turned ON, the HECU switches the valve relay
on and off during its initial check. During this time, voltage sent to the
valve relay is compared to the voltage in the valve power monitor line. If
no current is detected in the valve power monitor line, the HECU
determines that there is an open circuit and DTC C2112 is recorded.
DTC No. C1605 CAN hardware error

Replace the HECU.
DTC No. C1611 CAN timeout EMS, C1612 CAN timeout TCU, C1613
CAN wrong matched transmission
Inspect the EMS or TCU according to the instructions of Engine or T/M
group.
DTC No. C1610 bus off error

Check CAN bus wiring.
Check E37, C33, C133-4 or M42 connectors
DTC No. C2402 motor pump failure

(Motor relay, motor)
When the motor power line is normal but no signal is in detected in the
motor monitor line.
Probable cause
Faulty HECU
Probable cause
Interference by means of electronic wave
Mismatching of the calculation between main
and sub processor
Defects of the valve coil and valve coil
operating circuit element
Probable cause
No message from EMS or TCU for 500ms
Message from A/T or M/T signal mismatch
the message from ECM or TCU
Probable cause
CAN bus cable open, or short to ground or
battery
Probable cause
Faulty wiring harness
Faulty HECU
Powering the motor with the Hi-Scan (Pro) will discharge the battery. Start and run the engine for a while after testingis
complete.

24.04.2008
Page 15 of 24
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES

DTC
Trouble Location
Remarks
C1101
Battery voltage over volt
: 18V or more
C1102
Battery voltage low volt
: 9.5V or less
C1200
FL wheel sensor
: open or short to ground
C1201
- Range/Performance
: speed jump or damaged

exciter
C1202
- No signal
: air-gap error or wrong excite
C1203
FR wheel sensor
C1204
- Range/Performance

exciter
C1205
- No signal excite
C1206
RL wheel sensor
C1207
- Range/Performance

exciter
C1208
- No signal excite
C1209
RR wheel sensor
C1210
- Range/Performance

exciter
C1211
- No signal
C1604
ECU hardware
: ECU internal or valve failure
C2112
Valve relay
: valve relay or fuse failure
C2402
Motor-Electrical
: open or short to battery,

motor relay, fuse or motor
lock fail
C2227
Brake disc overheat
Only TCS
C1503
TCS switch failure
With TCS switch
C1610
CAN bus off failure
Only TCS
C1611
EMS time-out failure
Only TCS
C1612
TCU time-out failure
Only TCS

24.04.2008
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C1613
TCU un-matching failure
Only TCS
C1605
CAN hardware failure
Only TCS
FAILSAFE SPECIFICATION
DETECT MODE
THE ABILITY OF DETECTING A FAILURE
THE MANAGEMENT OF FAILURE DETECTION
1. System down. Both the ABS (TCS) and the EBD function are inhibited and the ABS (TCS) and the EBD warning lamps are
activated.
If this happens, the valve relay and all solenoids are prevented from being switched on.
2. Only the ABS (TCS) function is inhibited. The ABS (TCS) warning lamp is activated and the EBD warning lamp is not
activated.
3. Sensor failure outside the ABS control cycle.
(1) Only one sensor fails : take the same action as management 2.
(2) More than two sensors fail : take the same action as management 1.
4. Sensor failure inside the ABS control cycle.
(1) One front sensor fails : inhibit the ABS control of the failed-wheel and maintain ABS control of the normal wheels.
(2) One rear sensor fails : inhibit ABS control of both front wheels and the pressure of both rear wheels is decreased.
(3) More than two sensor fail : take the same action as in management 1.
5. Low operating voltage
(1) Outside the ABS control cycle : inhibit the ABS (TCS) control of front wheels and allow ABS control of rear wheels,
The ABS (TCS) warning lamp is directly switched on.
When the voltage recovers to the normal operating range, enable the ABS function and the ABS (TCS) warning lamp
is switched off and erases theerror code of low voltage.
(2) Inside the ABS control cycle : inhibit the ABS control of the front wheels and allow the the ABS control of rear wheels,
The ABS (TCS) warning lamp is directly switched on and remains on. The error code is always stored.
6. Motor error during the ABS control cycle. Inhibit the ABS control of front wheels, allow ABS control of the rear wheels and
ABS (TCS) warning lampis switched ON at the end of ABS control.
7. TCS failure
Inhibit the TCS control and allow the ABS/EBD control. Meanwhile, stop checking the TCS switch failure under the TCS
control.

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24.04.2008
Page 18 of 24

24.04.2008
Page 19 of 24

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Page 20 of 24
INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES

DTC No. C1200, C1203, C1206, C1209
Wheel speed sensor open or short to GND circuit
The HECU determines that an open or short circuit has
occured in more than one wire of a wheel speed sensor.
Probable cause
Malfunction of wheel speed sensor
Malfunction of wiring harness or connector
Malfunction of HECU

24.04.2008
Page 21 of 24
DTC No. C1201, C1204, C1207, C1210

(Speed jump or wrong exciter)
Abnormal output signal from a wheel speed sensor other
than an open or short circuit.
DTC No. C1202, C1205, C1208, C1211

(Large air gap)
Probable cause

Malfunction of rotor
Malfunction of wheel bearing
Malfunction of HECU
Probable cause

24.04.2008
Page 22 of 24
No wheel speed sensor output signal.
DTC No. C1101, C1102 Voltage out of range

(Low and over voltage)
The voltage of the HECU power supply drops lower than or
rises higher than the specified value. If the voltagereturns to
the specified value, this code is no longer output.

Malfunction of rotor (excitor)
Malfunction of HECU
Probable cause
Malfunction of HECU.
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to the standard
value, the code is no longer output. Before carrying out the followinginspection, check the battery level, and refill if
necessary.
DTC No. C1604 HECU Hardware

(EEPROM and ECU failure)
The HECU always monitors the solenoid valve drive circuit. It
determines that there is an open or short-circuit in the
solenoid coil or in a harness even if no current flows in the
solenoidor through the HECU.
Probable cause
Malfunction of wiring harness
Malfunction of HECU

24.04.2008
Page 23 of 24
DTC No. C2112 Valve relay

(Including fuse failure)
When the ignition switch is turned ON, the HECU switches
the valve relay on and off during its initial check. During this
time, voltage sent to the valve relay is compared to the
voltage in the valve power monitor line. If no current is
detected in the valve power monitor line, the HECU
determines that there is an open circuit and DTC C2112is
recorded.
DTC No. C1605 CAN hardware error

Replace the HECU.
DTC No. C1611 CAN timeout EMS, C1612 CAN timeout

TCU, C1613 CAN wrong matched transmission
Inspect the EMS or TCU according to the instructions of
Engine or T/M group.
DTC No. C1610 bus off error

Check CAN bus wiring.
Check E37, C33, C133-4 or M42 connectors
DTC No. C2402 motor pump failure

(Motor relay, motor)
When the motor power line is normal but no signal is in
detected in the motor monitor line.
Probable cause
Malfunction of HECU
Probable cause
Interference by means of electronic wave
Mismatching of the calculation between main and sub
processor
Defects of the valve coil and valve coil operating circuit
element
Probable cause
No message from EMS or TCU for 500ms
Message from A/T or M/T signal mismatch the message
from ECM or TCU
Probable cause
CAN bus cable open, or short to ground or battery
Probable cause
Malfunction of wiring harness
Malfunction of HECU
Powering the motor with the Hi-Scan (Pro) will discharge the battery. Start and run the engine for a while after testingis
complete.

24.04.2008
Page 24 of 24

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) >
Repair procedures
BLEEDING OF BRAKE SYSTEM

1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
When pressure bleeding, do not depress the brake pedal.

Recommended fluid ......... DOT3 or DOT4
2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half
filled clear plastic bottle.
3. Connect the Hi-Scan (Pro) to the Data Link Connector located underneath the dash panel.
4. Select and operate according to the instructions on the Hi-Scan (Pro) screen.
You must obey the maximum operating time of the ABS motor with the Hi-Scan (Pro) to prevent the

24.04.2008
Page 2 of 3
motor pump from burning.

(1) Select hyundai vehicle diagnosis.
(2) Select vehicle name.

(3) Select Anti-Lock Brake system.
(4) Select air bleeding mode.
(5) Press 'YES' to operate motor pump and solenoid valve.
(6) Wait 60 sec. before operating the air bleeding.

(If not, you may damage the motor).
5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.

24.04.2008
Page 3 of 3
6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.
7. Tighten the bleeder screw.

Bleeder screw tightening torque:
7~13 Nm (70~130 kgcm, 5~9.5 lbft)

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > ABS Control Module >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) >
ABS Control Module > Schematic Diagrams
HECU BLOCK DIAGRAM

1. ABS ECU BLOCK DIAGRAM
2. TCS ECU BLOCK DIAGRAM
CIRCUIT DIAGRAM

24.04.2008
Page 2 of 4

24.04.2008
Page 3 of 4
INSPECTION OF HECU TERMINALS
Terminals No.
25 - GND (8,24)
Condition
Always
Standard Voltage (V)

10 - 14

24.04.2008
Page 4 of 4
9 - GND (8,24)
Always
10 - 14
4 - GND (8,24)
Ignition switch ON
10 - 14
16 - GND (8,24)
Ignition switch ON, ABS warning lamp ON
3-5
Stop lamp switch OFF
Below 1.0
Stop lamp switch ON
10 - 14
18 - GND (8,24)
19 - 20
Ignition switch ON, slowly turn right front wheel
AC voltage generation
1-2
Ignition switch ON, slowly turn left front wheel
22 - 23
Ignition switch ON, slowly turn right rear wheel
Ignition switch ON, slowly turn left rear wheel
5-6
14 - GND (8,24)
GND (8,24) - Body ground
Ignition switch ON, TCS switch ON

Always
10 - 14
Continuity

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > ABS Control Module >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(AntiLock Brake System) > ABS Control Module > Components and Components Location
COMPONENTS
HECU

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > ABS Control
Module > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock
Brake System) > ABS Control Module > Repair procedures
REMOVAL
1. Disconnect the double lock connector (A) from the HECU.
2. Disconnect the brake tubes from the HECU.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it
off immediately with water.
Take care not to damage or deform the brake lines during removal and installation.
To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or
equivalent material.
3. Remove the HECU bracket mounting bolts and remove the HECU.
1. Never attempt to disassemble the HECU.

2. The HECU must be transported and stored in an upright position and with the ports sealed. The
HECU must not be drained.

24.04.2008
Page 2 of 3
Tightening torque
HECU bracket mounting bolts:
17~26 Nm (170~260 kgcm, 12.5~19.1 lbft)
INSTALLATION
2. Tighten the HECU mounting bolts and brake tube nuts to the specified torque.
Tightening torque
HECU mounting bolt:
8~10 Nm (80~100 kgcm, 5.9~7.3 lbft)
HECU bracket mounting bolt:
17~26 Nm (170~260 kgcm, 12.5~19.1 lbft)
Brake tube nut:
13~17 Nm (130~170 kgcm, 9.5~12.5 lbft)
INSPECTION
WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK
1. Raise the vehicle and release the parking brake.
2. Disconnect the HECU harness connector's and measure from the harness side connector.
Be sure to remove the connector's double lock and insert the probe into the harness side (back-probe).
Inserting itinto the terminal side may result in a bad connection.
3. Rotate the wheel to be measured approximately 1/2 to 1 rotation per second, and check the output voltage
using a circuit tester or an oscilloscope.
Wheel speed
sensor
Front left
Front right
Rear left
Rear right
19
22
20
23
Terminal
Output voltage:
When measuring with an oscilloscope:
130mV pp or more

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed
Sensor > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS
(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Front Wheel
Speed Sensor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS
(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures
REMOVAL
FRONT WHEEL SPEED SENSOR
1. Remove the front wheel speed sensor mounting bolt.
2. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.
REAR WHEEL SPEED SENSOR

1. Remove the rear wheel speed sensor mounting bolt.
2. Remove the luggage trim and disconnect the wire connector from the rear wheel speed sensor.
INSPECTION

24.04.2008
Page 2 of 2
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard
Front, Rear: 1,385 110
2. Connect a voltmeter between the wheel speed sensor terminals and measure the voltage by turning the
wheel.
Set the voltmeter to measure AC voltage.

Service standard : AC voltage detected.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information > Special
Service Tools (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General
Information > Special Service Tools (M5GF1)
SPECIAL TOOLS (6-SPEED M/T)

Illustration
Use
Engine support fixture

J28467-B
Removal and installation of transaxle

assembly
Engine support adapters

J28467-125
Use with J28467-B
09431-2C000
Oil seal installer
Installation of differential side oil seal

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information >
Troubleshooting (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System >
General Information > Troubleshooting (M5GF1)
TROUBLESHOOTING (M/T)
Symptom
Vibration, noise
Probable cause
Remedy
Loose or damaged transaxle and engine mounts
Tighten or replace mounts
Inadequate shaft end play
Correct end play
Worn or damaged gears
Replace gears
Inadequate grade of oil
Replace with specified oil
Low oil level
Replenish
Inadequate engine idle speed
Adjust idle speed
Oil leakage
Broken or damaged, oil seal or O-ring
Replace oil seal or O-ring
Hard shift
Faulty control cable
Replace control cable
Poor contact or wear of synchronizer ring and

gear cone
Correct or replace
Weakened synchronizer spring
Replace synchronizer spring
Inadequate grade of oil
Replace with specified oil
Worn gear shift fork or broken poppet spring
Replace shift fork or poppet

spring
Synchronizer hub-to-sleeve spline clearance too

large
Replace synchronizer hub and

sleeve
Jumps out of gear

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information > Specifications
(M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information >
Specifications (M5GF1)
SPECIFICATIONS (M/T)
Model
M5BF2
(5-speed)
M5GF1
(5-speed)
Engine
2.0 DOHC
2.7 DOHC
2.0 DOHC
2.7 DOHC
1st
3.462
3.231
3.153
2nd
2.053
1.952
1.944
3rd
1.393
1.296
1.333
4th
1.061
0.943
1.055
5th
0.837
0.775
0.857
6th
0.704
Reverse
3.250
3.455
3.002
Final gear ratio
4.056
4.063
4.678
4.428
2.15
2.1
Gear ratio
Oil quantity ()
MFA60
(6-speed)
2.2 0.1
SERVICE STANDARD (6-SPEED M/T)

Item
Standard
Limit
Input shaft 6th gear end play
0 ~ 0.1
Output shaft 6th gear end play
0 ~ 0.1
Output shaft 6th gear bearing play
0 ~ 0.06
Clearance between 3rd gear and synchronizer

ring
0.9 ~ 1.45
0.7
Clearance between 4th gear and synchronizer

ring
0.9 ~ 1.45

ring
0.95 ~ 1.4

ring
0.95 ~ 1.4
Clearance between reverse gear and

synchronizer ring
0.95 ~ 1.4
TIGHTENG TORQUE (6-SPEED M/T)

Item
Nm
kgcm
lbft
Manual transaxle case to clutch housing bolt
63 ~ 67
630 ~ 670
46 ~ 49
Drain plug
30 ~ 39
300 ~ 390
22 ~ 28
Reverse lever
11.8 ~ 15.6
118 ~ 156
8.7 ~ 11.5
Shift check plug
12.7 ~ 17.0
127 ~ 170
9.3 ~ 12.5
Shift check
22.5 ~ 25.5
225 ~ 255
16.6 ~ 18.8
Stopper bolt
26.5 ~ 30.4
26.5 ~ 304
19.6 ~ 22.4
6.3 ~ 8.3
63 ~ 83
4.6 ~ 6.0
Control shaft bolt

Shift lever mounting plate
2~3
20 ~ 30
1~2
Differential final gear bolt
112.7 ~ 127.4
1127 ~ 1274
83 ~ 94

24.04.2008
Page 1 of 10
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > Manual Transaxle System >
Manual Transaxle > Repair procedures (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual
Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures (M5GF1)
REMOVAL
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.

(1) Upper

25.04.2008
Page 2 of 10
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.

25.04.2008
Page 3 of 10
9. Remove the speedometer driven gear connector.

10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).

25.04.2008
Page 4 of 10
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.

17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.

25.04.2008
Page 5 of 10
19. Separate the start motor.
20. Install the engine support fixture.

21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.

25.04.2008
Page 6 of 10
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.

(1) Insulator bolt

25.04.2008
Page 7 of 10
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.

(1) Insulator bolt

25.04.2008
Page 8 of 10
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.

(1) Insulator bolt
(2) Stopper bolt

25.04.2008
Page 9 of 10
30. Remove the drive shaft.

31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.

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35. Remove the transaxle assembly.
INSTALLATION
Installation is the reverse of the removal.
SERVICE ADJUSTMENT PROCEDURES

TRANSAXLE GEAR OIL LEVEL INSPECTION
1. Remove oil filler plug and check level with finger.
2. Oil level must be up to fill the hole, add oil until it runs over. Then reinstall plug.
3. Replace the oil so that the transaxle gear oil is not dirty, and so that it is of a suitable viscosity.
REPLACEMENT OF TRANSAXLE GEAR OIL

1. With the vehicle parked on a level surface, remove the drain plug and drain the transaxle oil.
2. Replace the gasket with a new one and install the drain plug.
3. Add new oil through the filler plug and, fill it to just below the plug opening.
Standard value
Transaxle oil total capacity :
M5BF2 : 2.15 lit
M5GF1 : 2.1 lit
MFA60 : 2.2 0.1 lit
DRIVE SHAFT OIL SEAL REPLACEMENT

1. Disconnect the drive shaft from the transaxle (Refer to "DS" group).
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool (09431-2C000), tap the drive shaft oil seal into the transaxle.
4. Apply a coating of gear oil to the oil seal.

25.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > Manual Transaxle Control System >
Manual Transaxle Shift Control > Components and Components Location (M5GF1), TIBURON(GK) > 2003 > G 2.7
V6 DOHC > Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Components and Components Location (M5GF1)
COMPONENTS
5-SPEED M/T
6-SPEED M/T

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24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > Manual Transaxle Control System
> Manual Transaxle Shift Control > Repair procedures (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC
> Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Repair procedures (M5GF1)
REMOVAL
1. Remove the shift knob.
2. Remove the spring and the cap (for 6-speed M/T).
3. Remove the skirt (for 6-speed M/T).
4. Remove the console upper cover.
5. Remove the console assembly.

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6. Remove the shift cable clip.
7. Remove the select cable clip.
8. Remove the snap pin of the select cable.
9. Remove the shift cable.

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10. Remove the shift lever assembly.
For 6-speed M/T, push the plate shaft outward with a driver or equivalent through the hole in the shift
lever bracket to remove it.
INSTALLATION
Install the shift lever assembly.
INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boot for damage.
4. Check each bushing for wear, abrasion, sticking, restricted movement or damage.
5. Check for a weak or damaged spring.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > General Information > Special
Service Tools (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System >
General Information > Special Service Tools (F4A42-2)
SPECIAL TOOLS (A/T)

Illustration
Use
Engine support fixture

J28467-B
Removal and installation of transaxle

assembly
Engine support adapters

J28467-125
Use with J28467-B
09452-21001
Oil pressure gauge adapter
Measurement of the oil pressure.

(use with 09452-21500 and 0945221002)
09452-21002

use with 09452-21500 and 0945221001)
09452-21500
Oil pressure gauge

(use with 09452-21001 and 0945221002)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > General Information >
Specifications (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System >
General Information > Specifications (F4A42-2)
SPECIFICATIONS (A/T)
Item
F4A42-1
F4A42-2
Torque converter type
3-element, 1-stage, 2-phase type
Transaxle type
4-speed forward, 1-speed reverse
Engine displacement
2.0 DOHC
2.7 DOHC
Gear ratio
1st
2nd
3rd
4th
2.842
1.529
1.000
0.712
2.842
1.529
1.000
0.712
Reverse
2.480
2.480
Final gear ratio
4.407
4.402

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System >
Schematic Diagrams (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System >
Automatic Transaxle System > Schematic Diagrams (F4A42-2)
TCM CIRCUIT DIAGRAM (2.0L)

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TCM CIRCUIT DIAGRAM (2.7L)

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Page 6 of 6

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System > Flow
Diagram (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > Flow Diagram (F4A42-2)
AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT

PARK & NEUTRAL
FIRST

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SECOND

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THIRD

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FOURTH

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REVERSE

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24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System > General
Information (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > General Information (F4A42-2)
TROUBLESHOOTING (A/T)
(F4A42 Model)
DIAGNOSIS FUNCTION
1. Connect the Hi Scan Pro to the connector for diagnosis.
2. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TROUBLE CODE DESCRIPTION" on the following pages.
A maximum of 8 diagnostic trouble codes (in the sequence of occurrence) can be stored in the Random Access
Memory (RAM) incorporated within the control module.

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The same diagnostic trouble code can be stored one time only.
If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 8, already stored
diagnostic trouble codes will be erased in sequence, beginning with the oldest.
Do not disconnect the battery until all diagnostic trouble codes or diagnostic trouble patterns have been read
out, because all stored diagnostic trouble codes or diagnostic trouble patterns will be cancelled when the
battery is disconnected.
3. If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the Fail-safe
code description will be stored in the RAM. Three of these diagnostic trouble codes can be stored.
4. The cancellation will occur if, with the transaxle locked in third gear, the ignition key is turned to the OFF position, but
the diagnostic trouble code is stored in the RAM.
5. Memorization.
A. Up to 8 diagnosis items and 3 fail-safe items can be memorized.
B. If the memory capacity is exceeded, diagnosis and fail-safe items in the memory are overwritten, starting with the
oldest.
C. No code can be memorized more than once.
6. Diagnosis Code Deletion.
(1) Automatic Deletion
All diagnosis codes are deleted from memory the 200 th time the ATF temperature reaches 50C after mem orization
of the most recent diagnosis code.
(2) Forced Deletion
Memorized diagnosis codes can be deleted using the scan-tool, provided the following conditions are satisfied :
A. The ignition switch is ON
B. There is no detection pulse from the crank angle sensor
C. There is no detection pulse from the output shaft speed sensor
D. There is no detection pulse from the vehicle speed sensor
E. The fail-safe function is not operational
ROAD TEST
No.
1
Condition
Ignition switch : OFF
Ignition switch : ON
Engine : Stopped
Selector lever
position : P
Operation
Judgment value
Ignition switch
(1) ON
Battery voltage (mV)
Control relay
Selector lever position

(1) P, (2) R, (3) N, (4) D
(1) P, (2) R, (3) N, (4)

D
Transaxle range switch
Accelerator pedal
(1) Released
(2) Half depressed
(3) Depressed
(1) 400~1,000 mV
Throttle position sensor
(2)Gradually rises from
(1)
(3) 4,500~5,000 mV
Brake pedal
(1) Depressed
(2) Released
(1) ON
(2) OFF
Ignition switch : ST Starting test with lever P or N Starting should be

range
possible
Engine : Stopped
Warming up
Engine : Idling
Selector lever
position : N
Check item
Stop lamp switch
Starting possible or
impossible
Drive for 15 minutes or more Gradually rises to

so that the automatic fluid
70~90C
temperature becomes
70~90C
Oil temperature sensor
A/C switch
(1) ON
(2) OFF
(1) ON
(2) OFF
Triple pressure switch
Accelerator pedal
(1) Released
(2) Half depressed
(1) ON
(2) OFF
Idle position switch
(1) 600~925 rpm

(2) Gradually rises

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from (1)
(1) Data changes
5
Selector lever
position : N (Carry out
on a flat and straight
road)
Communication with engineECU

(1) ND
(2) NR
Should be no
abnormal shifting
shocks
Time lag should be
within 2 seconds
Malfunction when starting
Selector lever position and

vehicle speed
1. Idling in 1st gear (Vehicle
stopped)
2. Driving at constant speed
of 20 km/h in 1st gear
of 30 km/h in 2nd gear
4. Driving at 50 km/h in 3rd
gear with accelerator fully
closed
of 50 km/h in 4th gear
(Each condition should
be maintained for 10
seconds or more)
(2) 1st, (4) 3rd, (3)

2nd, (5) 4th
Shift condition
(2) 0%, (4) 100%, (3)

100%, (5) 100%
Low and reverse solenoid

valve
(2) 0%, (4) 0%, (3) 0% Underdrive solenoid valve

(5) 100%
(2) 100%, (4) 100%,
(3) 0% (5) 0%
Second solenoid valve
(2) 100%, (4) 0%, (3)

100% (5) 0%
Overdrive solenoid valve
(1) 0km/h
(4) 50km/h
(4) 1,800 ~ 2,100rpm
Input shaft speed sensor
(4) 1,800 ~ 2,100rpm
Output shaft speed sensor
(3) 0%
(5) Approx. 70~90%
Damper clutch control

solenoid valve
(3) Approx.
100~300rpm
(5) Approx. 0~10rpm
Selector lever
position : D (Carry out
road)
Selector lever
position : N (Carry out
road)
1. Accelerate to 4th gear at

a throttle position sensor
output of 1.5V
(accelerator opening
angle of 30 %).
2. Gently decelerate to a
standstill.
3. Accelerate to 4th gear at
a throttle position sensor
output of 2.5 V
(accelerator opening
angle of 50%).
4. While driving at 60 km/h
in 4th gear, shif down to
3rd gear.
in 3rd gear, shift down to
2nd gear.
in 2nd gear, shift down to
1st gear.
Move selector lever to R
range drive at constant
speed of 10km/h
For (1), (2) and (3), the

reading should be the
same as the specified
output shaft torque,
and no abnormal
shocks should occur.
For (4), (5) and (6),
downshifting should
occur immediately
after the shifting
operation is made.
Malfunction when shifting
Displaced shift points
Does not shift
Does not shift from 1 to 2 or

2 to 1

3 to 2

4 to 3
The ratio between

Does not shift
input and output shaft
speed sensor data
should be the same as
the gear ratio when
reversing.

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DIAGNOSTIC TROUBLE CODE DESCRIPTION

DTC No
P1704
Diagnosis item
Throttle position sensor
P1703
P1702
P0713
Fluid temperature sensor
P0712
Possible cause
Short circuit
TPS output > 4.8 V with

engine idling
Open circuit
TPS output < 0.2V with

engine not idling
Sensor misadjustment
TPS output < 0.2V or > 1.2V

with engine idling
Open circuit
Oil temperature sensor

output > 4.57 V for 1 second
or longer (oil temperature
does not increase)
Short circuit
Output < 0.49V for 1 second
P0725
CKP sensor
Open circuit
No crankshaft position
sensor output pulse detected
for 5 seconds at vehicle
speed of 25 km/h
P0715
Input speed sensor
Short circuit/open circuit
No input speed sensor output

pulse detected for > 1
second at vehicle speed of >
30 km/h
P0720
Output speed sensor
At vehicle speed of > 30

km/h, output speed sensor
output < 50% of vehicle
speed sensor output for > 1
second
P0703
Stop lamp switch
At vehicle speed of 6 km/h,

stop lamp switch is ON
continuously for 5 minutes
P0750
LR solenoid valve
P0755
UD solenoid valve
With relay voltage > 10V,

open or short circuit is
continuously for 0.3 second
P0760
2nd solenoid valve
P0765
OD solenoid valve
P0743
TCC solenoid valve
P0731
Gear shift incomplete
1st
P0732
2nd
P0733
3rd
P0734
4th
P0736
Reverse
After gear shift, output shaft

speed sensor output x gear
ratio of new gear input
shaft speed sensor output
P1749
Serial communication
With ignition ON, battery

voltage > 10V, and engine
speed > 450 r/min,
communication is
continuously irregular for 1
second or communication
error signal is received for >
4 seconds continuously
P0740
TCC
System defect/stuck on
DCC solenoid valve drive

duty ratio is 100% for 4
seconds continuously
P1723
A/T control relay
Earth short circuit/open
After ignition ON, A/T control

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P0707
P0708
circuit
relay voltage < 7V
Open circuit
No signal is continuous for >

30 seconds
Short circuit
Above 2 kinds signals are

continuous for 30 seconds
P1630
CAN-BUS OFF
TCM Fail/open/short
Receive BUS-OFF
information from CAN
CONTROLLER
P1631
CAN-TIME OUT ECM
ECM Fail/open/short
No output signal for 1.5

second
P1764
CAN MI-COM CIRCUIT
TCM internal circuit

malfunction
Communication error output

is continuously for > 1
second
INSPECTION CHART FOR DIAGNOSIS CODES

Code
P1704
Diagnosis item
Probable cause
Throttle position sensor system

Short circuit
If the TPS output voltage is 4.8V or higher
when the engine is idling, the output is judged
to be too high and diagnosis code P1704 is set.
Open circuit
If the TPS output voltage is 0.2V or lower at
times other than when the engine is idling, the
output is judged to be too low and diagnosis
code P1703 is set. If the TPS output voltage is
Sensor misadjusted
0.2V or lower or if it is 1.2V or higher when the
engine is idling, the TPS adjustment is judged
to be incorrect and diagnosis code P1702 set.
Malfunction of the throttle

position sensor
Malfunction of connector
Malfunction of the TCM
Open circuit
Fluid temperature sensor system
If the fluid temperature sensor output voltage is Short circuit
4.57V or more even after driving for 10 minutes
or more (if the fluid temperature does not
increase), it is judged that there is an open
circuit in the fluid temperature sensor and
diagnosis code P0713 is set.
Malfunction of the oil

temperature sensor
P0725
CKP sensor system

If no output pulse is detected from the crank
shaft position sensor for 5 seconds or more
while driving at 25 km/h or more, it is judged
that there is an open circuit in the crank shaft
position sensor and diagnosis code P0725 is
set.
Malfunction of the crank angle

sensor
P0715
Input speed sensor system

Short circuit/open
If no output pulse is detected from the input
circuit
shaft speed sensor for 1 second or more while
driving in 3rd or 4th gear at a speed of 30 km/h
or more, there is judged to be an open circuit or
short circuit in the input shaft speed sensor and
diagnosis code P0715 is set. If diagnosis code
P0715 is set four times, the transmission is
locked into 3rd gear (D range) or 2nd gear as a
fail-safe measure.
Malfunction of the input shaft

speed sensor
Malfunction of the underdrive
clutch retainer
P0720
Output speed sensor system

Short circuit/open
If the output from the output shaft speed sensor circuit
is continuously 50% lower than the vehicle
speed for 1 second or more while driving in 3rd
or 4th gear at a speed of 30 km/h or more,
Malfunction of the outputs shaft

speed sensor
Malfunction of the transfer drive
P1703
P1702
P0713
P0712
Open circuit

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there is judged to be an open circuit or shortcircuit in the output shaft speed sensor and
diagnosis code P0720 is set. If diagnosis code
P0720 is set four times, the transmission is
locked into 3rd gear (D range) or 2nd gear as a
fail-safe measure.
gear or driven gear
P0703
Stop lamp switch system

If the stop lamp switch is on for 5 minutes or
more while driving, it is judged that there is a
short circuit in the stop lamp switch and
diagnosis code P0703 is set.
Short circuit/open
circuit
Malfunction of the stop lamp

switch
P0750
Low and reverse solenoid valve system
Short circuit/Open
circuit
P0755
Underdrive solenoid valve system
Short circuit/Open
circuit
Malfunction of solenoid valve

P0760
Second solenoid valve system
Short circuit/Open
circuit
P0765
Overdrive solenoid valve system

Short circuit/Open
If the resistance value for a solenoid valve is
circuit
too large or too small, it is judged that there is a
short circuit or an open circuit in the solenoid
valve and the respective diagnosis code is set.
The transmission is locked into 3rd gear as a
fail-safe measure.
P0743
Short circuit/Open
Torque converter clutch solenoid valve
circuit
system
If the resistance value for a solenoid valve is
too large or too small, it is judged that there is a
short circuit or an open circuit in the solenoid
valve and the respective diagnosis code is set. Defective system
The transmission is locked into 3rd gear as a
fail-safe measure.
Malfunction of the torque

converter clutch solenoid valve
P0731
1st gear ratio does not meet the specification

If the output from the output shaft speed sensor multiplied by the 1st
gear ratio is not the same as the output from the input shaft speed
sensor after the shift to 1st gear has been completed, diagnosis code
P0731 is set. If diagnosis code P0731 is set four times, the transmission
is locked into 3rd gear as a fail-safe measure.

speed sensor
Malfunction of the output shaft
speed sensor
clutch retainer
gear or driven gear
Malfunction of the low and
reverse brake system
clutch system
Noise generated
P0732
2nd gear ratio does not meet the specification

If the output from the output shaft speed sensor multiplied by the 2nd
sensor after the shift to 3rd gear has been completed, diagnosis code

speed sensor
speed sensor
clutch retainer
gear or driven gear
clutch system
Malfunction of the second
P0740

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brake system
Noise generated
P0733
3rd gear ratio does not meet the specification

If the output from the output shaft speed sensor multiplied by the 3rd
sensor after the shift to 3rd gear has been completed, diagnosis code

speed sensor
speed sensor
clutch retainer
gear or driven gear
clutch system
Malfunction of the overdrive
clutch system
Noise generated
P0734
4th gear ratio does not meet the specification

If the output from the output shaft speed sensor multiplied by the 4th
sensor after the shift to 4th gear has been completed, diagnosis code

speed sensor
speed sensor
clutch retainer
gear or driven gear
Malfunction of the second
brake system
Malfunction of the overdrive
clutch system
Noise generated
P0736
Reverse gear ratio does not meet the specification

If the output from the output shaft speed sensor multiplied by the
reverse gear ratio is not the same as the output from the input shaft
speed sensor after the shift to reverse gear has been completed,
diagnosis code P0736 is set. If diagnosis code P0736 is set four times,
the transmission is locked into 3rd gear as a fail-safe measure.

speed sensor
speed sensor
clutch retainer
gear or driven gear
Malfunction of the low and
reverse brake system
Malfunction of the reverse
clutch system
Noise generated
P1749
Serial communication
If normal communication is not possible for a continuous period of 1
second or more when the ignition switch is at the ON position, the
battery voltage is 10V or more and the engine speed is 450r/min or
more, diagnosis code No.P1749 is set. Diagnosis code No.P1749 is
also set if the data being received is abnormal for a continuous period of
4 seconds under the same conditions.
Malfunction of the ECM
P1723
A/T control relay system

Short circuit to ground/
If the A/T control relay voltage is less than 7V
Open circuit
after the ignition switch has been turned ON, it
is judged that there is an open circuit or a shortcircuit in the A/T control relay ground and
diagnosis code P1723 is set. Then the
transmission is locked into 3rd gar as a fail-safe
measure.
Malfunction of the A/T control

relay

24.04.2008
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P0707

No signal is continuous for > 30 seconds
P0708
Above 2 signals are continuous for > 30 seconds
P1630
CAN-BUS OFF
No 3 speed hold fail
No PG-A, B fail
Battery voltage > 10V continuously for 0.5 second
No engine stop
Receive BUS OFF information from CAN CONTROLLER
TCM Fail
TCM side open & short
P1631
CAN-TIME OUT ECM

No PG-A, B fail
No engine stop
No output signal for 1.5 second
ECM fail
ECM side open & short
P1764
TCM CAN MI-COM

No PG-A, B fail
No engine stop
Communication error output is continuously for > 1 second
CAN MI-COM CIRCUIT
Malfunction of transaxle range

switch
INSPECTION CHART FOR THROUBLE SYMPTOMS

Trouble symptom
Probable cause
Communication with HI-SCAN is not possible

is not functioning.
Malfunction of diagnosis line

Driving impossible
Starting impossible
Starting is not possible when the selector lever
is in P or N range. In such cases, the cause is
probably a defective engine system, torque
converter or oil pump.
Malfunction of the engine system

Malfunction of the torque converter
Malfunction of the oil pump
Does not move forward

If the vehicle does not move forward when the
selector lever is shifted from N to D range while
the engine is idling, the cause is probably
abnormal line pressure or a malfunction of the
underdrive clutch or valve body.
Does not reverse

If the vehicle does not reverse when the
selector lever is shifted from N to R range while
abnormal pressure in the reverse clutch or low
and reverse brake or a malfunction of the
reverse clutch, low and reverse brake or valve
body.
Abnormal reverse clutch pressure

Abnormal low and reverse brake pressure
Malfunction of the low and reverse brake
solenoid valve
Malfunction of the reverse clutch
Malfunction of the valve body
Does not move (forward or reverse)

If the vehicle does not move forward or reverse
when the selector lever is shifted to any
position while the engine is idling, the cause is
probably abnormal line pressure or a
malfunction of the power train, oil pump or
valve body.
Engine stalling when shifting
Malfunction when
Abnormal line pressure

Malfunction of the underdrive solenoid valve
Malfunction of the underdrive clutch

Malfunction of power train

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starting
If the engine stalls when the selector lever is

shifted from N to D or R range while the engine
is idling, the cause is probably a malfunction of
the engine system, damper clutch solenoid
valve, valve body or torque converter (damper
clutch malfunction).
Malfunction of the damper clutch control

solenoid valve
(Malfunction of the damper clutch)
Shocks when changing from N to D and

large time lag
If abnormal shocks or a time lag of 2 seconds
or more occur when the selector lever is shifted
from N to D range while the engine is idling, the
cause is probably abnormal underdrive clutch
pressure or a malfunction of the underdrive
clutch, valve body.
Shocks when changing from N to R and

large time lag
from N to R range while the engine is idling, the
cause is probably abnormal reverse clutch
pressure or low and reverse brake pressure, or
a malfunction of the reverse clutch, low and
reverse brake, valve body or idle position
switch.

Malfunction of the low and reverse solenoid
valve
Malfunction of the idle position switch
Shocks when changing from N to D, N to R

and large time lag
from N to D range and from N to R range while
abnormal line pressure or a malfunction of the
oil pump or valve body.

Malfunction when
shifting
Shocks and running up

If shocks occur when driving due to upshifting
or downshifting and the transmission speed
becomes higher than the engine speed, the
cause is probably abnormal line pressure or a
malfunction of a solenoid valve, oil pump, valve
body, brake or clutch.
Displaced shifting
points
All points
If all shift points are displaced while driving, the
cause is probably a malfunction of the output
shaft speed sensor, TPS or solenoid valve.
Malfunction of the output shaft speed

sensor
Malfunction of the throttle position sensor
Malfunction of each solenoid valve
Some points
If some of the shift points are displaced while
driving, the cause is probably a malfunction of
the valve body, or it is related to control and is
not an abnormality.
Does not shift
No diagnosis codes
If shifting does not occur while driving and no
diagnosis codes are set, the cause is probably
a malfunction of the transaxle range switch, or
TCM
Malfunction of the transaxle range

Malfunction while
Poor a acceleration
Abnormal underdrive clutch pressure


Malfunction of each brake or each clutch

24.04.2008
Page 10 of 11
driving
If acceleration is poor even if downshifting

occurs while driving, the cause is probably a
malfunction of the engine system, brake or
clutch.
Malfunction of the brake of clutch
Malfunction while
driving
Vibration
If vibration occurs when driving at constant
speed or when accelerating and deceleration in
top range, the cause is probably abnormal
damper clutch pressure or a malfunction of the
engine system, damper clutch control solenoid
valve, torque converter or valve body.
Abnormal damper clutch pressure

Malfunction of the damper clutch control
solenoid valve
Transaxle range switch system

The cause is probably a malfunction of the inhibitor switch circuit,
ignition switch circuit or a defective TCM.
Idle position switch system

The cause is probably a defective idle position switch circuit, or a
defective TCM.

Triple pressure switch system

The cause is probably a defective triple pressure switch circuit or a
defective TCM.
Vehicle speed sensor system

The cause is probably a defective vehicle speed sensor circuit or a
defective TCM.
Malfunction of the vehicle speed sensor

Malfunction of the transaxle range switch

Malfunction of the ignition switch
Malfunction of the triple pressure switch

Malfunction of A/C system
ELEMENTS IN USE IN EACH GEAR

Operating element
Underdrive
Reverse
Overdrive
clutch (UD) clutch (REV) clutch (OD)
Low-and
reverse
brake (LR)
Second
brake (2nd)
One way
clutch
(OWC)
Parking
Reverse
Neutral
1st
2nd
3rd
4th
1st
2nd
3rd
1st
2nd
1st
2
L
OPERATING ELEMENTS AND THEIR FUNCTION

Operating element
Code
Function
Underdrive clutch
UD
Connects input shaft and underdrive sun gear
Reverse clutch
REV
Connects input shaft and reverse sun gear
Overdrive clutch
OD
Connects input shaft and overdrive planetary carrier

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Page 11 of 11
Low-and-reverse brake
Second brake
LR
2ND
Locks low-and-reverse annulus gear and overdrive

planetary carrier
Locks reverse sun gear

24.04.2008
Page 1 of 8
Troubleshooting (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > Troubleshooting (F4A42-2)
INSPECTION PROCESS FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with the scan tool
If communication with the scan tool is not possible, the
cause may be a defective diagnostic trouble line or the TCM
is not functioning.
Possible cause
Malfunction of diagnostic trouble line
Starting impossible
Starting is not possible when the selector lever is in P or N
range. In such cases, the cause may be a defective engine
system, torque converter or oil pump.
Possible cause

24.04.2008
Page 2 of 8
Does not move
If the vehicle does not move forward when the selector lever
is shifted from N to D range while the engine is idling, the
cause may be abnormal line pressure or a malfunction of
the underdrive clutch or valve body.
Possible cause

Does not reverse
If the vehicle does not reverse when the selector lever is
shifted from N to R range while the engine is idling, the
cause may be abnormal pressure in the reverse clutch or
low and reverse brake or a malfunction of the reverse
clutch, low and reverse brake or valve body.
Possible cause

Malfunction of the low and reverse solenoid valve

24.04.2008
Page 3 of 8
Does not move (forward or reverse)
If the vehicle does not move forward or reverse when the
selector lever is shifted to any position while the engine is
idling, the cause may be abnormal line pressure, or a
malfunction of the power train, oil pump or valve body.
Possible cause
Abonormal line pressure

Engine stalling when shifting
If the engine stalls when the selector lever is shifted from N
to D or R range while the engine is idling, the cause may be
a malfunction of the engine system, torque converter clutch
soledoid, valve body or torque converter (torque converter
clutch malfunction).
Possible cause

Malfunction of the torque converter clutch solenoid
Malfunction of the torque converter (Malfunction of the
torque converter clutch)
Shocks when changing from N to D and range time lag
If abnormal shocks or a time lag of 2 second or more occurs
when the selector lever is shifted from N to D range while
Possible cause

24.04.2008
Page 4 of 8
the engine is idling, the cause may be abnormal underdrive

clutch pressure or a malfunction of the underdrive clutch,
valve body or closed throttle position switch.

Malfunction of the closed throttle position switch
Shock when changing from N to R and large time lag
If abnormal shocks or a time lag of 2 seconds or more
occurs when the selector lever is shifted from N to R range
while the engine is idling, the cause may be abnormal
reverse clutch pressure or low and reverse brake pressure,
or a malfunction or the reverse clutch, low and reverse
brake, valve body.
Possible cause

Malfunction of the low and reverse solenoid valve

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Page 5 of 8
Shocks when changine from N to D, N to R and large
time lag
If abnormal shocks or a time lag of 2 seconds or more
occurs when the selector lever is shifted from N to D, N to R
range while the engine is idling, the cause may be abnormal
line pressure or a malfunction of the oil pump or valve body.
Possible cause
Shocks and running up
If shocks occur when driving due to upshifting or
downshifting and the transaxle speed becomes higher than
the engine speed, the cause may be abnormal line pressure
or a malfunction of a solenoid valve, oil pump, valve body or
of a brake or clutch.
Possible cause

Malfunction of each brake or each clutch

24.04.2008
Page 6 of 8
All points (Displaced shifting points)
If all shift points are displaced while driving, the cause may
be a malfunction of the output shaft speed sensor, TPS or a
solenoid valve.
Possible cause
Malfunction of the output shaft speed sensor

Malfunction of the throttle position sensor

24.04.2008
Page 7 of 8
Some points (Displaced shifting points)

If some of the shift points are displaced while driving, the
cause may be a malfunction of the valve body, or it is
related to control and is not an abnormality.
Possible cause
No diagnostic trouble codes (Does not shift)
If shifting does not occur while driving and no diagnostic
trouble codes are given, the cause may be a malfunction of
the Park/Neutral position switch, or TCM.
Possible cause
Malfunction of the Park/Neutral position switch
Poor acceleration
If acceleration is poor even if downshifting occurs while
driving, the cause may be a malfunction of the engine
system or of a brake or clutch.
Possible cause
Malfunction of the brake or clutch

24.04.2008
Page 8 of 8
Vibration
If vibration occurs when driving at constant speed or when
accelerating in top range, the cause may be abnormal
torque converter clutch pressure or a malfunction of the
engine system, torque converter clutch solenoid, torque
converter or valve body.
Possible cause
Abnormal torque converter clutch pressure

Malfunction of the torque converter clutch solenoid

24.04.2008
Page 1 of 13
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System > Repair
procedures (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > Repair procedures (F4A42-2)
BASIC INSPECTION ADJUSTMENT

AUTOMATIC TRANSAXLE FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then
move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, reinsert and remove the oil level gauge and check the condition of
the fluid.
If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the bushes
and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, add more fluid
until the level reaches the HOT mark.
Automatic transaxle fluid : DIAMOND ATF SP-III., SK ATF SP-III.
If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form inside the
hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping
of the clutches and brakes. If there is too much fluid, the gears can churn it up into foam and cause the same
conditions that can occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of
the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid
escaping from the transaxle vent, in which case it may be mistaken for a leak.
6. Insert the oil level gauge securely.
7. The fluid and the oil filters should always be replaced when overhauling the transaxle or after the vehicle has been
driven under severe conditions. The replacement procedures are given below. Furthermore, the oil filters are special
filters which are only to be used for the automatic transaxle.
When new, automatic transmission fluid should be red. The red dye is added so distinguish it from engine oil or
antifreeze. As the vehicle is driven the transmission fluid will begin to look darker. The color may eventually appear
light brown
Also, the dye, which is not an indicator of fluid quality, is not permanent
Therefore, further investigation of the automatic transaxle is required if,
the fluid is dark brown or black.
the fluid smells burnt.
metal particles can be seen or felt on the dipstick.
AUTOMATIC TRANSAXLE FLUID

1. Remove the drain plug from the bottom of the transaxle case to drain the fluid.
2. Install the drain plug and gasket, and tighten to the specified torque.
Tightening torque : 32 Nm (320 kgcm, 23 lbft)
3. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured in.

4. Repeat the procedure in step 1 if too much fluid was added.
5. Reconnect the hose that was disconnected in step 1 above, and firmly replace the oil level gauge.

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6. Start the engine and run it at idle for 1-2 minutes.

7. Move the select lever through all positions, and then move it to the N position.
8. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C), and then ch eck the fluid level
again. The fluid level must be at the HOT Mark.
9. Firmly insert the oil level gauge into the oil filler tube.
TRANSAXLE RANGE SWITCH CONTINUITY CHECK
TRANSAXLE RANGE SWITCH AND CONTROL CABLE ADJUSTMENT

1. Set the selector lever to the "N" position.
2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever.

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3. Set the manual control lever to the neutral position.
4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole in the
end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle range switch
body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Be careful at this time that the position
of the switch body does not change.
6. Gently pull the transaxle control cable in the direction of the arrow, then tighten the adjusting nut.
7. Check that the selector lever is in the "N" position.
8. Check that each range on the transaxle side operates and functions correctly for each position of the selector lever.
A/T CONTROL COMPONENT CHECK

1. THROTTLE POSITION SENSOR CHECK
The TPS is a variable resistor type that rotates with the throttle body shaft to sense the throttle valve angle. As the
throttle shaft rotates, the output voltage of the TPS changes. The ECM detects the throttle valve opening based on
voltage change. (Refer to FL-section).
2. OIL TEMPERATURE SENSOR CHECK
(1) Remove the oil temperature sensor.
(2) Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector.
STANDARD VALUE

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Page 4 of 13
Oil temperature (C)
Resistance (K)
16.7 ~ 20.5
100
0.57 ~ 0.69
3. VEHICLE SPEED SENSOR CHECK

(1) Remove the vehicle speed sensor and connect a 3~10 K resistance as shown in the illustration.
(2) Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2-3 (1 turn=4 pulses).
4. A/T CONTROL RELAY CHECK

(1) Remove the A/T control relay.
(2) Use jumper wires to connect A/T control relay terminal 2 to the battery (+) terminal and terminal 4 to the battery (-)
terminal.
(3) Check the continuity between terminal 1 and terminal 3 of the A/T control relay when the jumper wires are
connected and disconnected from the battery.
(4) If there is a problem, replace the A/T control relay.
Jumper wire
Continuity between terminal No.1
Connected
Continuity
Disconnected
No continuity
5. SOLENOID VALVE CHECK

(1) Remove the valve body cover.
(2) Disconnect the connectors of each solenoid valve.

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(3) Measure the resistance between terminals 1 and 2 of each solenoid valve.
STANDARD VALUE
Name
Resistance
Damper clutch solenoid valve
2.7 ~ 3.4
(at 20C)
Low and reverse solenoid valve

Underdrive solenoid valve
(4) If the resistance is outside the standard value, replace the solenoid valve.
Resistance of the solenoid valve connector.

Terminal No.
Name
7 & 10
10 & 6
9&4
9&3
9&5
Resistance
2.7 ~ 3.4
(at 20C)

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Page 6 of 13
BASIC INSPECTION ADJUSTMENT

AUTOMATIC TRANSAXLE FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then
move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, reinsert and remove the oil level gauge and check the condition of
the fluid.
If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the bushes
and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, add more fluid
until the level reaches the HOT mark.
Automatic transaxle fluid : DIAMOND ATF SP-III., SK ATF SP-III.
If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form inside the
hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping
of the clutches and brakes. If there is too much fluid, the gears can churn it up into foam and cause the same
conditions that can occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of
the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid
escaping from the transaxle vent, in which case it may be mistaken for a leak.
6. Insert the oil level gauge securely.
7. The fluid and the oil filters should always be replaced when overhauling the transaxle or after the vehicle has been
driven under severe conditions. The replacement procedures are given below. Furthermore, the oil filters are special
filters which are only to be used for the automatic transaxle.
When new, automatic transmission fluid should be red. The red dye is added so distinguish it from engine oil or
antifreeze. As the vehicle is driven the transmission fluid will begin to look darker. The color may eventually appear
light brown
Also, the dye, which is not an indicator of fluid quality, is not permanent
Therefore, further investigation of the automatic transaxle is required if,
the fluid is dark brown or black.
the fluid smells burnt.
metal particles can be seen or felt on the dipstick.
AUTOMATIC TRANSAXLE FLUID

1. Remove the drain plug from the bottom of the transaxle case to drain the fluid.
2. Install the drain plug and gasket, and tighten to the specified torque.
Tightening torque : 32 Nm (320 kgcm, 23 lbft)
3. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured in.

4. Repeat the procedure in step 1 if too much fluid was added.
5. Reconnect the hose that was disconnected in step 1 above, and firmly replace the oil level gauge.
6. Start the engine and run it at idle for 1-2 minutes.
7. Move the select lever through all positions, and then move it to the N position.

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8. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C), and then ch eck the fluid level
again. The fluid level must be at the HOT Mark.
9. Firmly insert the oil level gauge into the oil filler tube.
TRANSAXLE RANGE SWITCH CONTINUITY CHECK
TRANSAXLE RANGE SWITCH AND CONTROL CABLE ADJUSTMENT

1. Set the selector lever to the "N" position.
2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever.
3. Set the manual control lever to the neutral position.

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Page 8 of 13
4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole in the
end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle range switch
body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Be careful at this time that the position
of the switch body does not change.
6. Gently pull the transaxle control cable in the direction of the arrow, then tighten the adjusting nut.
7. Check that the selector lever is in the "N" position.
8. Check that each range on the transaxle side operates and functions correctly for each position of the selector lever.
A/T CONTROL COMPONENT CHECK

1. THROTTLE POSITION SENSOR CHECK
The TPS is a variable resistor type that rotates with the throttle body shaft to sense the throttle valve angle. As the
throttle shaft rotates, the output voltage of the TPS changes. The ECM detects the throttle valve opening based on
voltage change. (Refer to FL-section).
2. OIL TEMPERATURE SENSOR CHECK
(1) Remove the oil temperature sensor.
(2) Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector.
STANDARD VALUE

24.04.2008
Page 9 of 13
Oil temperature (C)
Resistance (K)
16.7 ~ 20.5
100
0.57 ~ 0.69
3. VEHICLE SPEED SENSOR CHECK

(1) Remove the vehicle speed sensor and connect a 3~10 K resistance as shown in the illustration.
(2) Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2-3 (1 turn=4 pulses).
4. A/T CONTROL RELAY CHECK

(1) Remove the A/T control relay.
(2) Use jumper wires to connect A/T control relay terminal 2 to the battery (+) terminal and terminal 4 to the battery (-)
terminal.
(3) Check the continuity between terminal 1 and terminal 3 of the A/T control relay when the jumper wires are
connected and disconnected from the battery.
(4) If there is a problem, replace the A/T control relay.
Jumper wire
Continuity between terminal No.1
Connected
Continuity
Disconnected
No continuity
5. SOLENOID VALVE CHECK

(1) Remove the valve body cover.
(2) Disconnect the connectors of each solenoid valve.

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Page 10 of 13
(3) Measure the resistance between terminals 1 and 2 of each solenoid valve.
STANDARD VALUE
Name
Resistance
2.7 ~ 3.4
(at 20C)

(4) If the resistance is outside the standard value, replace the solenoid valve.
Resistance of the solenoid valve connector.

Terminal No.
Name
7 & 10
10 & 6
9&4
9&3
9&5
Resistance
2.7 ~ 3.4
(at 20C)

24.04.2008
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SERVICE ADJUSTMENT PROCEDURES

BRAKE REACTION PLATE END PLAY ADJUSTMENT
Standard value : 0 ~ 0.16mm
SECOND BRAKE END PLAY ADJUSTMENT
Standard value : 0.79 ~ 1.25mm
LOW-REVERSE BRAKE END PLAY ADJUSTMENT

24.04.2008
Page 12 of 13
IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS

O.D.
I.D.
Thickness
Symbol
O.D.
I.D.
Thickness
Symbol
59
47
1.8
#1
48.9
37
1.6
#8
59
47
2.0
#1
48.9
37
1.7
#8
59
47
2.2
#1
48.9
37
1.8
#8
59
47
2.4
#1
48.9
37
1.9
#8
59
47
2.6
#1
48.9
37
2.0
#8
59
47
2.8
#1
48.9
37
2.1
#8
49
36
3.6
#2
48.9
37
2.2
#8
49
36
3.6
#3
48.9
37
2.3
#8
45.3
31
3.3
#4
48.9
37
2.4
#8
49
36
3.6
#5
48.9
37
2.5
#8
49
36
3.6
#6
48.9
37
2.6
#8
59
37
2.8
#7
UNDERDRIVE SUN GEAR END PLAY ADJUSTMENT


24.04.2008
Page 13 of 13
Installing the underdrive clutch hub makes it easy to measure the underdrive sun gear end play.
DIFFERENTIAL CASE PRELOAD ADJUSTMENT

Place a piece of solder (approx. 10 mm in length, 3mm in diameter) on the torque converter housing as shown in the
figure.
Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts to the
specified torque. Loosen the bolts, and remove the solder. Use a micrometer to measure the thickness(T) of the pressed
solder. Select a spacer with a thickness that is within the following value.
Standard value : (T + 0.045mm) to (T + 0.105mm)

24.04.2008
Page 1 of 1
Automatic Transaxle > Components and Components Location (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location (F4A42-2)
COMPONENTS

24.04.2008
Page 1 of 9
Automatic Transaxle > Repair procedures (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures (F4A42-2)
REMOVAL
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.

(1) Upper

24.04.2008
Page 2 of 9
(2) Lower
6. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
7. Remove the speedometer sensor connector.

8. Remove the transaxle range switch.
9. Remove the oil cooler hose.

24.04.2008
Page 3 of 9
10. Remove the clip(transaxle side) of the shift cable.
11. Separate the steering column shaft joint.
12. Separate the power steering oil pump hose.
Be careful not to leak after separating.

13. Separate the hose after removing the clip of the power steering return hose.

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Page 4 of 9
14. Remove the upper connecting transaxle bolt.
15. Separate the start motor.
16. Install the engine support fixture.

17. After removing the tire, remove the caliper.
18. Remove the transaxle side cover.

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19. Remove the transaxle under cover.
20. Separate the tie rod end.
21. Remove the wheel speed sensor and the knuckle mounting bolt.
22. Drain the oil.

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23. Remove the transaxle mounting bracket.

(1) Insulator bolt
(2) Body mounting bolt (Upper)
(3) Body mounting bolt (Side)
(4) Transaxle side mounting bolt
24. Remove the front roll stopper.

(1) Insulator bolt

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(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
25. Remove the rear roll stopper.

(1) Insulator bolt
(2) Stopper bolt

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Page 8 of 9
26. Remove the drive shaft.

27. Remove the front muffler.
28. Remove the sub frame mounting bolt.
29. Install the jack under the transaxle assembly.
30. Remove the transaxle lower mounting bolt to the engine.

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Page 9 of 9
INSTALLATION
1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine.
If the torque converter is mounted first on the engine, the oil seal on the transaxle may be damaged.
Therefore, first be sure to assemble the torque converter to the transaxle.
2. Install the transaxle control cable and adjust as follows:
(1) Move the shift lever and the transaxle range switch to the "N" position and install the control cable.
(2) When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts to the
control cable.
(3) Remove any free-play in the control cable by adjusting the nut and then check to see that the selected
lever moves smoothly.
(4) Check to see that the control cable has been adjusted correctly.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle Control System >
Transaxle Shift Control > Components and Components Location (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control >
Components and Components Location (F4A42-2)
COMPONENTS

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle Control
System > Transaxle Shift Control > Repair procedures (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control
> Repair procedures (F4A42-2)
REMOVAL
1. Remove the push button, the spring and the cap.
2. Remove the knob mounting nut.
3. Remove the shift knob.

6. Remove the indicator panel.

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7. Remove the indicator lower cover.
8. Remove the indicator plate.
9. Remove the key lock cable nut.
10. Remove the shift lock cable nut.

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11. Remove the control cable snap pin.
12. Remove the control cable clip and the control cable.
13. Remove the shift lever bracket bolt.
14. Remove the shift lever.
INSTALLATION
PROCEDURE TO INSTALL THE LOCK CAM

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Page 4 of 5
1. Move A/T lever to "P" position to set the key lock cam and the shift lock cam as shown in the figure.
(1) Check that the key lock cam is located at "B" by the detent pin.
(2) Check that the shift lock cam is located at "A".
2. Check that the key cylinder is at "LOCK".
PROCEDURE FOR ADJUSTING SHIFT LOCK AND KEY LOCK CABLE

1. Check that each lock cam is as shown in the figure.
2. Install the shift lock and key lock cable in position. In this case, the shift lock cable must be fixed to the brake
pedal and the key lock cable must be fixed to the key cylinder.
3. Temporarily install each cable to the A/T lever assembly as shown in the figure. Securely insert the cable end
into the fixing pin of each cam.
4. Slightly pull the shift lock cable in the direction "E".

5. After checking that the portion of the cable end touches the cable fixing pin, fix with the self-tapping bolt.
6. Slightly push the key lock cam to direction "Q".
7. Slightly pull the key lock cable in the direction "G" to stretch the cable. Then fix the cable with the self-tapping
bolt.
8. Check that the key lock and the shift lock cable are secure.

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PROCEDURE FOR CHECKING THE SHIFT LOCK

1. When the brake pedal is not depressed, the push button of the shift lever at "P" position must not be operable.
(Shift lever cannot be shifted at the other positions from "P".)
2. When the brake pedal stroke is 15~22mm (with shift lever at "P" position), the push button should be operable
without catching and the shift lever should shift smoothly to other positions.
3. When the brake pedal is not depressed, the shift lever should shift smoothly to "P" position from all heading
other positions.
4. The brake pedal must operate smoothly without catching.
5. When the ignition key is at the "LOCK" position, although rake pedal is depressed, the push button should be
operable.
6. The Ignition key must not be able to be turned to the "LOCK" position except in the "P" position.
7. If the shift lever is shifted to the "P" position, the ignition key must turn to the "LOCK" position smoothly.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Special Service Tools
SPECIAL TOOLS
09411-25000 Clutch disc guide
Illustration
Use
Installation of the clutch disc

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Troubleshooting
TROUBLESHOOTING
Symptom
Clutch slipping
Car will not respond to
engine speed during
acceleration
Insufficient vehicle
speed
Lack of power during
uphill driving
Probable cause
Insufficient clutch pedal free play
Adjust
Clogged hydraulic system
Correct or replace parts
Excessive wear of clutch disc facing
Replace
Hardened clutch disc facing, or oil on surface
Replace
Damaged pressure plate or flywheel
Replace
Weak or broken pressure spring
Replace
Difficult gear shifting (gear Excessive pedal free play

noise during shifting)
Hydraulic system fluid leaks, air trapping or clogging
Clutch
noisy
Remedy
Adjust
Repair or replace parts
Unusual wear or corrosion of clutch disc spline
Replace
Excessive vibration (distortion) of clutch disc
Replace
When clutch is
not used
Insufficient play of clutch pedal
Adjust
Excessive wear of clutch disc facing
Replace
A noise is heard
after clutch is
disengaged
Unusual wear and/or damage of release bearing
Replace
A noise is heard
when clutch is
disengaged
Insuffcient grease on the sliding surface of bearing

sleeve
Repair
Improperly installed clutch assembly or bearing
Repair
A noise is heard Damaged pilot bushing

when car is
suddenly rolled
with clutch
partially engaged
Difficult to depress clutch
pedal
Difficult to shift gear or

cannot shift at all
Clutch slips
Replace
Insufficient lubrication of clutch pedal
Repair
Insufficient lubrication of the clutch disc spline
Repair
Insufficient lubrication of the clutch release lever shaft
Repair
Insufficient lubrication of front bearing retainer
Repair
Excessive clutch pedal free play excessive
Adjust pedal free play
Clutch release cylinder faulty
Repair release cylinder
Clutch disc out of true, runout is excessive or lining

broken
Inspect clutch disc
Spline on input shaft or clutch disc dirty or burred
Repair as necessary
Clutch pressure plate faulty
Replace clutch cover
Clutch pedal free play insufficient
Adjust pedal free play
Clogged hydraulic system
Repair or replace parts
Clutch disc lining oily or worn out
Inspect clutch disc
Pressure plate faulty
Release fork binding
Inspect release fork

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Clutch grabs/chatters
Clutch noisy
Clutch disc lining oily or worn out
Inspect clutch disc
Pressure plate faulty
Clutch diaphragm spring bent
Worn or broken torsion spring
Replace clutch disc
Engine mounts loose
Repair as necessary
Damaged clutch pedal bushing
Replace clutch pedal

bushing
Loose part inside housing
Repair as necessary
Release bearing worn or dirty
Replace release bearing
Release fork or linkage sticks
Repair as necessary

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Specifications
SPECIFICATIONS
Clutch operating method
Hydraulic type
Clutch disc
- Type
- Facing diameter (Outside x Inside) mm (in.)
Single dry with diaphragm.

215 x 145 (8.5 x 5.7)
Clutch cover assembly

- Type
Diaphragm spring strap
Clutch release cylinder

* I.D. mm (in.)
2.0L : 19.05 (0.76)

2.7L : 20.64 (0.82)
Clutch master cylinder

* I.D. mm (in.)
15.87(0.62)
* I.D. : Inside Diameter
SERVICE STANDARD
Clutch pedal free play
6~13 mm (0.24~0.52 in.)
Clutch pedal height
166.9 mm (6.676 in.)
Clutch pedal stroke
2.0L : 145 mm (5.7 in.)

2.7L : 152 mm (6.1 in.)
Limit
Clutch disc rivet sink
Diaphragm spring end height difference
Clutch release cylinder clearance to piston
Clutch master cylinder clearance to piston
1.1 mm (0.044 in.)

0.5 mm (0.02 in.)
0.15 mm (0.006 in.)
0.15 mm (0.006 in.)
TIGHTENING TORQUE
Item
Nm
kgcm
lbft
Clutch pedal to pedal support member

(Clutch pedal bracket)
19~28
190~280
14~20
Clutch pedal support member to master cylinder
8~10
80~100
6~7
Clutch tube flare nut
13~17
130~170
9~13
Clutch tube bracket
4~6
40~60
3~4
Reservoir band
13~17
130~170
9~13
Clutch release cylinder
15~22
150~220
11~16
Clutch release cylinder union bolt
20~25
200~250
15~18
Clutch cover assembly

Single mass flywheel
Dual mass flywheel
15~22
20~27
150~220
200~270
11~16
14~19
LUBRICANTS
Items
Specified lubricants
CASMOLY L 9508
Quantity
As required
Contact surface of release bearing and fulcrum of

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clutch release fork

Inner surface of clutch release bearing
CASMOLY L 9508
As required
Inner surface of clutch release cylinder and outer Brake fluid DOT 3 or DOT 4
circumference of piston and cup
As required
Inner surface of clutch disc spline
CASMOLY L 9508
As required
Inner surface of clutch master cylinder and outer

circumference of piston assembly
Brake fluid DOT 3 or DOT 4
As required
Clutch master cylinder push rod, clevis pin and

washer
Wheel bearing grease SAE J310a,

NLGI No.2
As required
Clutch pedal shaft and bushings
SAE J310a, Chassis grease, NLGINo.1
As required
Contact portion of release fork to release cylinder CASMOLY L 9508

push rod
As required
Input shaft spline
As required
CASMOLY L 9508

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Cover And Dinode >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch
System > Clutch Cover And Dinode > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Cover And Dinode >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch
Cover And Dinode > Repair procedures
REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
3. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from falling.
4. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
5. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.
DO NOT clean the clutch disc or release bearing with cleaning solvent.
INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of
the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can
cause clutchslippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.

CASMOLY L9508

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3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork
assembly.
CASMOLY L9508
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and
make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
CASMOLY L9508
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool (09411-25000), install the clutch disc to the flywheel. When installing the clutch disc, be
sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into
the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal
torquing sequence indicated below.
TIGHTENING TORQUE

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Single mass flywheel:

15~22 Nm (150~220 kgcm, 11~16 lbft)
Dual mass flywheel:
20~27 Nm (200~270 kgcm, 14~19 lbft)
9. Remove the special tool.

10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
CLUTCH COVER ASSEMBLY
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
0.3 mm (0.012 in.)
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or
grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
1.1 mm (0.044 in.)

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3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points
for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
CLUTCH RELEASE FORK

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Master Cylinder >
System > Clutch Master Cylinder > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Master Cylinder >
Master Cylinder > Repair procedures
DISASSEMBLY
1. Remove the reservoir band, reservoir tank and reservoir cap.
2. Remove the piston stop ring.
3. Pull out the push rod and piston assembly.
Be careful not to damage the master cylinder body and piston assembly.
INSPECTION
1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for obstructions.
5. Measure the clutch master cylinder inside diameter with a cylinder gauge and the piston outside diameter with
a micrometer.
Measure the inside diameter of the clutch master cylinder in three places (bottom, middle, and top), in
perpendicular directions.
6. If the clutch master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston
assembly.
0.15 mm (0.006 in.)
REASSEMBLY
1. Apply the specified fluid to the inner surface of the cylinder body and to the outside of the piston assembly.
BRAKE FLUID DOT 3 or DOT 4
2. Install the piston assembly.
3. Install the piston stop ring.
4. Install the push rod assembly.

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5. Install the reservoir band, reservoir tank and reservoir cap.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal >
Repair procedures
REMOVAL
1. Remove the cotter pin, washer and clevis pin.
2. Remove the clutch pedal mounting bolt.
INSTALLATION
2. Apply multi-purpose grease to the bushings.
3. Apply multi-purpose grease to the clevis pin and washer.

4. Install the push rod to the clutch pedal.
5. Adjust the clutch pedal clevis pin play.
INSPECTION
1. Check the clutch pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or distortion.
3. Check the return spring for damage or deterioration.
4. Check the clutch pedal pad for damage or wear.
IGNITION LOCK SWITCH INSPECTION

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Release Cylinder >
System > Clutch Release Cylinder > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Release Cylinder >
Release Cylinder > Repair procedures
REMOVAL
1. Disconnect the clutch tube.
2. Remove the clutch release cylinder mounting bolt.
INSTALLATION
1. Coat the clevis pin with the specified grease.
CASMOLY L9508
2. Install the clutch release cylinder, and the clutch tube.
INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.
DISASSEMBLY
1. Remove the clutch hose, valve plate, spring, push rod and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
3. Remove the piston from the release cylinder using compressed air.
1. Cover the release cylinder with rags to prevent the piston from popping out and causing injury.
2. Apply compressed air slowly to prevent the fluid from splashing in your eyes or on your skin.

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REASSEMBLY
1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and
push the piston cup assembly into the cylinder.
Use the specified fluid:
Brake fluid DOT 3 or DOT 4
2. Install the valve plate, push rod and boot.
INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > The Other Clutch System
Component > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch
System > The Other Clutch System Component > Repair procedures
SERVICE ADJUSTMENT PROCEDURE

CLUTCH PEDAL INSPECTION AND ADJUSTMENT
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis
pin play (measured at the face of the pedal pad).
(A) 166.9 mm
2. If the clutch pedal clevis pin free-play is not within the standard value range, adjust as follows:
A. Turn and adjust the bolt, then secure by tightening the lock nut.
After the adjustment, tighten the bolt until it reaches the pedal stopper, and then tighten the lock nut.
Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.
When adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to push the
push rod towardthe master cylinder.
3. After completing the adjustments, check that the clutch pedal free play (measured at the face of the pedal
pad) is within the standard value ranges.
Standard value:
(B) 6~13 mm (0.24~0.52 in.)
(C) 50 mm (1.5 in.)
4. If the clutch pedal free play, and the distance between the clutch pedal and the floor board when the clutch is
disengaged, do not meet with the standard values, it may be the result of either air in the hydraulic system or
a faulty clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.

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BLEEDING
Use the specified fluid. Avoid mixing different brands of fluid.

SAE J1703 (DOT 3 or DOT 4)
1. Loosen the bleeder screw at the clutch release cylinder.

2. Push the clutch pedal down slowly until all is expelled.
3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.
The rapidly-repeated operation of the clutch pedal in B-C range may cause the release cylinder's position
to be forcedout from the release cylinder body during air bleeding, Repress the clutch pedal after it
returns to the "A" point completely.

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > General Information,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > General Information
SERVICE ADJUSTMENT PROCEDURE

CHECKING STEERING WHEEL FREE PLAY
1. Start the engine with the steering wheel in the straight ahead position.
2. Measure the play at the circumference of the steering wheel.
Standard value
Steering wheel free play : 0~30 mm (0~1.1 in.)
3. If the play exceeds the standard value, inspect the connection between the steering shaft and steering
linkage.
CHECKING STEERING ANGLE

1. Place the front wheel on a turning radius gauge and measure the steering angle.
Standard value
Wheel angle
Inner wheel : 3476 2
Outer wheel : 3019
2. If the measured value is not within the standard value, adjust the toe and inspect again.
CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE

1. Disconnect the tie rod and knuckle by using the special tool.

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2. Move the ball joint stud in a circular motion several times to check for looseness.
3. Mount the nuts on the ball joint, and then measure the ball joint starting torque.
Standard value
0.5~2.5 Nm (5~25 kgcm, 0.36~1.78 lbft)
4. If the starting torque exceeds the upper limit of the standard value, replace the tie rod end.
5. Even if the starting torque is below the lower limit of the standard value, check the play of the ball joint and
replace if necessary.
CHECKING STATIONARY STEERING EFFORT

1. Position the vehicle on a level surface and place the steering wheel in the straight ahead position.
2. Increase the engine speed to 1000 100 rpm.
After checking, reset the engine speed to the standard value (idling speed).
3. Measure the turning force with a spring scale by turning the steering wheel clockwise and counterclockwise
one and a half turns.
Standard value
Stationary steering effort : 29 N (3.0 kg, 6.5lbs)
4. Check that there is no sudden change of force while turning the steering wheel.
5. If the stationary steering effort is excessive, check and adjust the following points.
(1) Damage or cracks on the dust cover and tie rod end ball joint.
(2) Pinion preload of the steering gear box and starting torque of the tie rod end ball joint.

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(3) Starting torque of the ball joint.
CHECKING STEERING WHEEL RETURN

1. The force required to turn the steering wheel and the wheel return should be the same for both left and right in
case of moderate or sharp turns.
2. When the steering wheel is turned 90 and held fo r a couple of seconds while the vehicle is being driven at
35kph, the steering wheel shouldreturn at least 70 from the neutral position when it is released.
If the steering wheel is turned very quickly, steering may be momentarily difficult. This is not a malfunction
because the oil pump output will be somewhatdecreased.
CHECKING POWER STEERING BELT TENSION

1. Press the V belt, applying a pressure of 98N (10kg, 22lb) at the specified point and measure the deflection to
confirm that it is within the standardvalue.
Standard value
V belt deflection
New belt : 8.8~11.0mm (0.35~0.43 in.)
Used belt : 12.5~14.3mm (0.49~0.56 in.)
2. If the belt deflection is beyond the standard value, adjust the belt tension as follows.
(1) Loosen the bolt adjusting the power steering "V" belt tension.

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(2) Put a bar or equivalent, between the bracket and the oil pump and adjust the tension so that the belt
deflection is within the standard value.
(3) Tighten the bolt adjusting the power steering "V" belt tension.
(4) Check the belt deflection and adjust it again if necessary.
After turning the V belt in the normal rotation direction more than once, recheck the belt deflection.
CHECKING POWER STEERING FLUID LEVEL

1. Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise
the fluid temperature to 50~60C (122 to 140F).
3. With the engine at idle, turn the steering wheel fully clockwise and counterclockwise several times.
4. Make sure there is no foaming or cloudiness in the reservoir fluid.
5. Stop the engine to check for any difference in fluid level between a stationary and a running engine.
1. If the fluid level varies 5mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve,
and lead to decreased durability of the pump.
REPLACING POWER STEERING FLUID

1. Jack up the front wheels and support them with rigid racks.
2. Disconnect the return hose from the oil reservoir and plug the oil reservoir.

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3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Disconnect the high-tension cable at the ignition coil side.
While operating the starter motor intermittently, turn the steering wheel all the way to the left and then to the
right several times to drain the fluid.
5. Connect the return hose and fix it with a clip securely.
6. Fill the power steering fluid reservoir with the specified fluid.
PSF-3 : 0.75~0.8 lit.
8. Check for fluid leaks from the hose, then stop the engine.
9. Pour the fluid into the bottom of the oil filter in the power steering fluid reservoir.
10. Bleed the air.
AIR BLEEDING
1. Disconnect the ignition coil high tension cable, and then, while operating the starter motor intermittently (for 15
to 20 seconds), turn the steering wheel all the way to the left and then to the right five or six times.
1. During air bleeding, replenish with the fluid so that the level does not fall below the lower position of
the filter.
2. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid.
Be sure to do the bleeding only while cranking.
2. Connect the high tension cable, and then start the engine (idling).
3. Turn the steering wheel to the left and then to the right, until there are no air bubbles in the oil reservoir.
4. Confirm that the fluid is not milky and that the level is between "MAX" and "MIN" marks on the reservoir.
5. Check that there is a little change in the fluid level when the steering wheel is turned left and right.
1. If the fluid level varies 5mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve,
and lead to decreased durability of the pump.

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OIL PUMP PRESSURE TEST

1. Disconnect the pressure hose from the pump. Connect the special tool between the pump and the pressure
hose as illustrated.
2. Bleed the air, and then start the engine and turn the steering wheel several times so that the fluid temperature
can rise to approximately 50~60C (122~132F) opera ting temperature.
3. Increase the engine speed to 1,000 100 rpm.
4. Close the shut-off valve of the special tool and measure the fluid pressure to confirm that it is within the
standard value range.
Standard value
Relief pressure :
8.3~8.8 MPa (85~90 kg.cm, 1209~1280 psi)
Do not keep the shut-off valve on the pressure gauge closed for more than ten seconds.
5. Remove the special tools, and tighten the pressure hose to the specified torque.

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Tightening torque
55~65 Nm (550~650 kgcm, 40.6~47.9 lbft)
6. Bleed the system.

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Special Service
Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Special
Service Tools
SPECIAL TOOLS
Illustration
Use
09222-32100
Valve stem oil seal installer
1. Installation of the ball bearing to rack

housing
2. Installation of the oil seal to oil pump
09432-21600
Bearing installer
1. Installation of the needle bearing to

rack housing
2. Installation of the ball bearing and oil
seal to valve body
09434-14200
Counter shaft bearing installer
Installation of the oil seal to rack

bushing and valve body
09555-21000
Bar
Removal and installation the oil seal.
09561-11002
Steering wheel puller
Removal of the steering wheel.
09565-11100
Preload socket
Measurement of the mainshaft preload.
09568-31000
Tie rod end puller
Seperation of the tie rod end ball joint.
09572-21000
Oil pressure gauge
Measurement of the power steering oil

pressure.
(use with 09572-22100, 09572-21200)
09572-21200
(Hose side)

pressure.
(use with 09572-21000, 09572-22100)

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Page 2 of 2
09572-22100
(Pump side)

pressure.
(use with 09572-21000, 09572-21200)
09573-21000
Oil seal installer guide
Installation of the oil seal

(use with 09573-21100, 09573-21200,
09517-11000, 09555-21000)
09573-21100
Oil seal installer
Installation of the oil seal

(use with 09573-21000, 09573-21200,
09555-21000)
09573-21200
Oil seal guide
Removal and installation of the oil seal

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Troubleshooting
TROUBLESHOOTING
POWER STEERING
Symptom
Probable cause
Remedy
Loose yoke plug

Loose steering gear mounting bolts
Loose or worn tie rod end
Retighten
Retighten
Retighten or place as
necessary
Steering wheel operation

is not smooth (Insufficient
power assist)
V-belt slippage
Damaged V-belt
Low fluid level
Air in the fluid
Twisted or damaged hoses
Insufficient oil pump pressure
Sticky flow control valve
Excessive internal oil pump leakage
Excessive oil leaks from rack and pinion in gear box
Distorted or damaged gear box or valve body seale
Readjust
Replace
Replenish
Bleed air
Correct the rougting or
replace
Repair or replace the oil
pump
Replace
Replace the damaged
parts
Replace the damaged
parts
Replace
Steering wheel does not

return properly
Excessive turning resistance of tie-rod end

Yoke plug excessively tight
Inner tie rod and/or ball joint cannot turn smoothly
Loose mounting of gear box and crossmember
Worn steering shaft joint and/or body grommet
Distorted rack
Damaged pinion bearing
Twisted or damaged hoses
Damaged oil pressure control valve
Damaged oil pump input shaft bearing
Replace
Adjust
Replace
Retighten
Correct or replace
Replace
Replace
Reposition or replace
Replace
Replace
Noise
Hissing Noise in Steering Gear

There is some noise with all power steering systems.
One of the most common is a hissing sound when the
steering wheel is turned and the car is not moving.
This noise will be most evident when turning the wheel
while the brakes are being applied.
There is no relationship between this noise and
steering performance.
Do not replace the valve unless the "hissing" noise
becomes extreme.
A replaced valve will also make a slight noise, and is
not always a solution for the condition.
Rattling or chucking noise

in the rack and pinion
Interference with hoses from vehicle body

Loose gear box bracket
Loose tie rod end and/or ball joint
Worn tie rod and/or ball joint
Reposition
Retighten
Retighten
Replace
Noise in the oil pump
Low fluid level

Air in the fluid
Loose pump mounting bolts
Replenish
Bleed air
Retighten
Excessive play in steering

wheel

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Specifications
SPECIFICATIONS
Item
Steering gear type
Rack stroke
Power steering pump type
Oil pump displacement
Specification
Rack and pinion
132mm
Vane type
9.6 cm/rev.MAX. (0.59 in/rev.MAX.)
SERVICE STANDARD
Item
Steering wheel free play
Steering angle
Inner wheel
Outer wheel
Stationary steering effort
Belt deflection
New belt
Used belt
Oil pump relief pressure
Total pinion preload
Tie rod swing resistance
Tie rod end ball joint starting torque
Specification
0~30 mm (0~1.1 in.)
3476 2
3019
29N (3.0kg, 6.5lbs)
8.8~11.0
12.5~14.3
8.3~8.8 MPa (85~90 kg/cm, 1209~1280 psi
0.6~1.3 Nm (6~13 kgcm, 5.2~11.3 lbin.)
2~5 Nm (20~50 kgcm, 1.4~3.6 lbft)
0.5~2.5 Nm (5~25 kgcm, 0.36~1.78 lbft)
TIGHTENING TORQUE
Item
Nm
kgcm
lbft
Power steering column and shaft

Steering column and shaft assembly mounting bolt
Power steering wheel lock nut
Pinion gear and joint assembly
Steering column shaft and universal joint assembly
Dust cover mounting bolt
13 ~ 18
35 ~ 45
15 ~ 20
18 ~ 20
17 ~ 26
130 ~ 80
350 ~ 450
150 ~ 200
180 ~ 200
170 ~ 260
9.6 ~ 13.3
25.8 ~ 33.2
11 ~ 15
13.3 ~ 15
125. ~ 19.2
Power steering gear box

Gear box mounting bolt
Tie rod end lock nut
Tie rod end ball joint and knuckle arm mounting nut
Feed tube to gear box
Gear box to valve body
Yoke plug lock nut
60 ~ 80
50 ~ 55
24 ~ 34
10 ~ 16
20 ~ 30
50 ~ 70
600 ~ 800
500 ~ 550
240 ~ 340
100 ~ 160
200 ~ 300
500 ~ 700
44 ~ 59
37 ~ 40.6
17.7 ~ 25
7.4 ~ 11.8
15 ~ 22
37 ~ 52
Power steering oil pump

Pressure hose to oil pump
Oil pump adjusting bolt
Oil pump mounting bolt
Oil pump bracket mounting bolt
55 ~ 65
35 ~ 50
35 ~ 50
35 ~ 50
550 ~ 650
350 ~ 500
350 ~ 500
350 ~ 500
40.6 ~ 47.9
25.8 ~ 37
25.8 ~ 37
25.8 ~ 37
4~6
4~6
4~6
40 ~ 60
40 ~ 60
40 ~ 60
3.0 ~ 4.4
3.0 ~ 4.4
3.0 ~ 4.4
Power steering hose

Power steering reservoir mounting bolt
Power steering hose mounting bolt
Power steering tube mounting bolt
LUBRICANTS

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Recommended lubricant
Quantity
Horn contact ring of steering wheel
CENTOPLX278
(KLUBER KOREA)
Bearing of steering shaft
ALVANIA #2 or #3
(KEUK DONG SHELL, KOREA)
Ball joint of tie rod end
SHOWA SUNLIGHT
MB-2 or equivalent
Steering gear housing
ONE-LUBER RP GREASE
(KYODOYUSHI, JAPAN)
As required
Inner ball joint of gear box
LONG TIME PD2

(OPTIMOL, GERMAN)
As required
Contact area of gear box bellows & tie rod
SILICON GREASE
(SPEC NO : MS511-41)
As required
Power steering fluid
PSF-3
1.5g
As required
1.5g
0.75 ~ 0.8 liter

(0.79 ~ 0.84 qts.)

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power Steering
Gear Box > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Gear Box > Components and Components Location
COMPONENTS
DISASSEMBLY AND ASSEMBLY

24.04.2008
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24.04.2008
Page 1 of 14
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power
Steering Gear Box > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures
REMOVAL
1. Detach the power steering pressure hose mounting clamp and the return tube mounting clamp.
2. Drain the power steering fluid.
3. Disconnect the pressure tube and the return tube fittings from the gear box.
4. Disconnect the shaft assembly from the gear box inside the passenger compartment.
5. Remove the strap and push out the dust cover and remove the dust cover mounting plate.
6. Raise up the vehicle.
7. Remove the front tires (RH/LH).
8. After removing the split pin, disconnect the tie rod from the knuckle by using the special tool (09568-31000).
9. Remove the stabilizer bar (RH side) mounting bracket and link nut.
10. After removing the rear roll stopper bracket mounting bolt from the sub frame, remove the rear roll stopper.

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11. After loosing the sub frame mounting bolts a little so as to be the sub frame assembly hung down slightly.
12. Remove the power steering gear box mounting bolts, pressure tube and the return tube clamp.
13. Pull the power steering gear box assembly toward the right side of the vehicle.
When removing the gear box, pull it out carefully and slowly to avoid damaging.
INSTALLATION
1. Push in the power steering gear box assembly in the right side of the vehicle.

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2. Install the dust cover mounting plate.

3. Connect the dust cover to its mounting plate with a new strap.
4. Connect the steering gear box assembly to the steering column and shaft assembly.

6. After installation, bleed the system.
DISASSEMBLY
1. Remove the tie rod end from the tie rod.
2. After mounting the tie rod end in a vise, remove the dust cover from the ball joint.
3. Remove the bellows band.

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4. Remove the bellows clip.
5. Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are replaced.
6. Remove the feed tube from the rack housing.
7. While moving the rack slowly, drain the fluid from the rack housing.
8. Unstake the tab washer which fixes the tie rod and rack with a chisel.
9. Remove the tie rod from the rack.
Remove the tie rod from the rack, taking care not to twist the rack.

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10. Remove the yoke plug locking nut.
11. Remove the yoke plug with a 14mm socket.
12. Remove the lock nut, yoke plug, rack support spring, rack support yoke and bushing from the gear box.
13. Remove the valve body housing by loosening the two bolts.
14. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.

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15. When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove thecirclip.
Be careful not to damage the rack.
16. Remove the rack stopper, rack bushing and rack from the rack housing.
17. Remove the O-ring from the rack bushing.
18. Remove the oil seal from the rack bushing.
19. Remove the valve body from the valve body housing with a soft hammer.

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20. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
21. Remove the oil seal and O-ring from the rack housing.
Be careful not to damage the pinion valve cylinder bore of the rack housing.
22. Using the special tool, remove the oil seal from the rack housing.
Be careful not to damage the rack cylinder bore of the rack housing.
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY
When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is
fixed, the gear box may be damaged.
TOTAL PINION PRELOAD

1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 Nm (6~13 kgcm, 0.4~1.0 lbft)

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Measure the pinion preload through the entire stroke of the rack.
2. If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.
TIE ROD SWING RESISTANCE

1. Rotate the tie rod severely ten times.
2. Measure the tie rod swing resistance with a spring scale.
Standard value
Total rod swing resistance :
2~5 Nm (20~50 kgcm, 17~43 lbin)
3. If the measured value exceeds the standard value, replace the tie rod assembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without
excessive play may be used. If the measuredvalue is below 0.44 kgcm, replace the tie rod.
BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.
REASSEMBLY
1. Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
2. Install the oil seal to the specified position in the rack housing.

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3. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF-3
4. Install the oil seal in the rack bushing.
5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
6. Apply the specified grease to the rack teeth.
Recommended grease
Multipurpose grease SAE J310a, NLGI #2 EP
Do not plug the vent hole in the rack with grease.
7. Insert the rack into the rack housing and install the rack bushing and rack stopper.

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8. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack
housing. Install the circlip while turning the rack stopper.
The circlip end should not be visible through the notched hole of the rack housing.
9. Using a special tool, install the oil seal and the ball bearing in the valve body housing.
10. After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing
assembly.
11. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly
and O-ring in the gear box.

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12. Install the tab washer and the tie rod and stake the tab washer end at two points over the tie rod.
13. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the
illustration. Apply semi-drying sealantto the threaded section of the yoke plug before installation.
14. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to
12 Nm (120 kgcm, 8.9 lbft), with a 14mm socket. Loosen the yoke plug approximately from 30 to 60an d
tighten the yoke nut to the specified torque.
Tightening torque
50~70 Nm (500~700 kgcm, 37~52 lbft)

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15. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
16. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Silicone grease
17. Install the new attaching band to the bellows.
When the bellows are installed, a new band must be used.

18. Install the bellows in position, taking care not to twist it.
19. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip
ring attached in the grooveof the tie rod end.
Recommended grease
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND

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20. Install the tie rods so that the length of the left and right tie rods equals the standard value.
Standard value
Tie rod free length : 204.5mm
21. Check for total pinion preload.
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY
When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is
fixed, the gear box may be damaged.
TOTAL PINION PRELOAD

1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 Nm (6~13 kgcm, 0.4~1.0 lbft)
Measure the pinion preload through the entire stroke of the rack.

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2. If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.
TIE ROD SWING RESISTANCE

1. Rotate the tie rod severely ten times.
2. Measure the tie rod swing resistance with a spring scale.
Standard value
Total rod swing resistance :
2~5 Nm (20~50 kgcm, 17~43 lbin)
3. If the measured value exceeds the standard value, replace the tie rod assembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without
excessive play may be used. If the measuredvalue is below 0.44 kgcm, replace the tie rod.
BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.

24.04.2008
Page 1 of 1
Hoses > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Hoses > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 3
Steering Hoses > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Hoses > Repair procedures
REMOVAL AND INSTALLATION
PRESSURE HOSE AND TUBE

1. After draining the power steering fluid, remove the pressure hose mounting clamp.
2. Lift up the vehicle and remove the mounting clamp which is holding both the pressure tube and the return
tube.
3. Detach the pressure tube fitting in the gear box.

4. Lower the vehicle and remove the connector.
5. Remove the pressure hose and tube assembly.

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1. Install the pressure hose and tube so that they are not twisted and they do not come in contact with
any other parts.
2. After installation, bleed the system.
RETURN TUBE AND HOSE

1. Detach the hose from the power steering fluid reservoir.
2. Remove the return tube and hose mounting clamps.

3. Raise the vehicle and remove the mounting clamp which is holding both the pressure tube and the return
tube.
4. Remove the pressure tube and the return tube fitting in the gear box.
5. Lower the vehicle and disconnect the clamp holding the return tube and hoses.
6. Remove the return tube and hoses.
1. Install the return tube and hoses so that they are not twisted and they do not come in contact with any
other parts.
2. After installation, air bleed the system.
INSPECTION

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1. Twisting the hose by hand, check for cracks.

2. Check that the hose does not contact with other components
HOW TO FILL WITH POWER STEERING FLUID

1. Fill the power steering reservoir with the power steering fluid to the "Max." position.
2. Lift the front wheels with a jack and turn the steering wheel fully to the left and right, 5~6 times for 15~20 sec.,
while driving the pulleyonly by operating the start motor.
3. Start the engine, let it idle and turn the steering wheel fully left and right several times until bubbles disappear
from the power steering reservoir.
4. If the oil color does not become milk-white and the oil level is constant at the "MAX" position, fluid level is O.K.
If the oil level changes when turning the steering wheel, and the oil overflows when stopping the engine, it
shows that air bleeding wasn't performed perfectly. As it can cause noise and early damage, you must
repeat the aboveprocedures.

24.04.2008
Page 1 of 1
Oil Pump > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Oil Pump > Components and Components Location
COMPONENTS

24.04.2008
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Steering Oil Pump > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures
REMOVAL
1. Remove the pressure hose from the oil pump.
Disconnect the suction hose from the suction connector and drain the fluid into a container.
2. Loosen the power steering "V" belt tension adjusting bolt.
3. Remove the "V" belt from the power steering oil pump pulley.
4. After remove the power steering oil pump mounting bolts and the tension adjusting bolt, remove the power
steering oil pump assembly.

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5. Remove the power steering oil pump mounting bracket.
INSTALLATION
1. After installing the oil pump to the oil pump bracket, install the "V" belt and tighten the bolt adjusting tension to
the specified torque.
Standard value
Oil pump adjusting bolt
3.5~5.0 Nm (350~500 kgcm, 25.8~37 lbft)
2. Install the suction hose.
Install the pressure hose to the oil pump, facing the painted part on the hose toward the oil pump.
3. Install the pressure hose to the oil pump.

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Install the pressure hose being careful so that it does not twist and come in contact with other
components.
4. Add power steering fluid (PSF-3).

5. Air bleed the system.
6. Check the oil pump pressure.
DISASSEMBLY
1. After removing the 2 bolts, remove the suction pipe and the O-ring from the oil pump body.
2. Loosen the four bolts and remove the oil pump cover assembly.
3. Remove the cam ring.
4. Remove the rotor and vanes.
5. Remove the oil pump side plate.
6. Remove the inner and outer O-ring.

7. Remove the side plate spring.

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When assembling, use a new gasket and O-ring.
8. Mount the pulley in a vise and remove the pulley nut and the spring washer.
9. Pull the pulley out.

10. After removing the snap ring of the shaft with snap ring pliers, remove the dust spacer.
11. Tap the rotor side of the shaft slighty with a plastic hammer to remove the shaft.
12. Remove the oil seal from the oil pump body.

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13. Remove the connector from the oil pump body, and take out the flow control valve and the flow control
spring.
14. Remove the O-ring from the connector.
Do not disassemble the flow control valve.
INSPECTION
1. Check the free length of the flow control spring.
Free length of the flow control spring : 36.5mm

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2. Check that the flow control valve is not bent.

3. Check the shaft for wear and damage.
4. Check the V-belt for wear and deterioration.
5. Check the grooves of the rotor and vanes for stratified abrasion.
6. Check the contact surface of the cam ring and vanes for stratified abrasion.
7. Check vanes for damage.
8. Check that there is no striped wear in the side plate or contacting part between the shaft and the pump cover
surface.
REASSEMBLY
1. Install the flow control spring, the flow control valve and the connector into the pump body.
2. Install the oil seal in the pump body by using the special tool.
3. After inserting the shaft assembly into the pump body, install the dust spacer and snap ring.
4. Install the pump pulley.

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5. Install the spring and inner O-ring.

6. Insert the outer O-ring in the oil pump side plate and then install it in the pump body.
7. After inserting the lock pin into the groove of the front housing, install the cam ring attending to the direction.
8. Install the rotor.

9. Install vanes so that the rounded edges face outward.
10. Install the gasket and oil pump cover assembly.

11. Install the suction pipe and O-ring.

24.04.2008
Page 8 of 8

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information > Flow
Diagram, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Flow Diagram
REFRIGERATION CYCLE

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
General Safety Information and Caution, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation,
Air Conditioning > General Information > General Safety Information and Caution
PRECAUTIONS
The air conditioning system uses R-134a refrigerant and FD46XG (PAG) refrigerant oil, which are not compatible
with R-12 refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt
to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result.
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment
Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.
Compressed air mixed with R-134a forms a combustible vapor.

The vapor can burn or explode causing serious injury.
Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning
systems.
Always disconnect the negative cable from the battery whenever replacing air conditioning parts.
Keep moisture and dirt out of the system, When disconnecting any lines, plug or cap the fittings immediately;
don t remove the caps or plugs until just before you reconnect each line.
Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring.
When tightening or loosening a fitting, use a second wrench to support the matching fitting.
When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don t release
refrigerant into the atmosphere.

24.04.2008
Page 1 of 1
Special Service Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
General Information > Special Service Tools
SPECIAL TOOLS
09977-29000
Pressure plate bolt remover
Illustration
Use
Removal and installation of pressure
plate

24.04.2008
Page 1 of 3
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > General Information > Components and Components Location
SELF-DIAGNOSIS
The Full Automatic Temperature Control (F.A.T.C) module self test feature will detect electrical malfunctions and provide error
code for system components with suspected failures.
CONTROL PANEL
SELF-DIAGNOSIS HETHOD
HOW TO READ SELF-DIAGNOSTIC CODE

1. After the display panel flickers three times every 0.5 second, the corresponding error code flickers on the setup
temperature display panel every 0.5 second and will show two figures.
2. If error code is more than two, each code flicker 2 times in sequence.

24.04.2008
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FAULT CODE DISPLAY

1. Normal
2. One error code
3. More error codes than two
4. Checking each error code
DTC CHART
If malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.
DTC code
Detection item
Trouble area

24.04.2008
Page 3 of 3
00
11
12
13
14
15
16
17
18
19
20
21
22
Normal
Open INCAR Sensor circuit
Incar sensor
Harness or connector between incar sensor and A/C
control assembly
A/C control assembly
Shorted INCAR Sensor circuit

Open Ambient sensor circuit
Ambient sensor
Harness or connector between ambient sensor and A/C
control assembly
Shorted Ambient sensor circuit

Open water temp. sensor
Water temp. sensor

Harness or connector between water temp. sensor and
Shorted water temp. sensor

Open thermistor
Pin thermistor
Harness or connector between evap. sensor and A/C
control assembly
Shorted thermistor
Open or shorted temp. door potentiometer
Harness or connector between temp. door potentiometer

and A/C control assembly
Defective temp. door potentiometer
Temp. door potentiometer
Open or shorted mode door potentiometer
Harness or connector between mode door potentiometer

Defective mode door potentiometer
Mode door potentiometer
FAIL SAFE FUNCTION

No.
Item
Failure
FAIL SAFE Function
IN-CAR temperature sensor
Open/Short
25C alternate value control
Ambient temperature sensor
Open/Short
20C alternate valu e control
Thermistor sensor
Open/Short
-2C alternate value contr ol
Water temperature sensor
Open/Short
-20C alternate valu e control
Temperature door potentiometer
Open/Short setup
temperature
For 17C to 24.5C, set to maximum cooling

position.
For 25C to 32C, set to maximum heating
position.
Mode door potentimeter
Open/Short setup
mode
Vent mode, at vent mode

Def mode, at except vent mode

24.04.2008
Page 1 of 3
Conditioning > General Information > Components and Components Location
SELF-DIAGNOSIS
The Full Automatic Temperature Control (F.A.T.C) module self test feature will detect electrical malfunctions and provide error
code for system components with suspected failures.
CONTROL PANEL
SELF-DIAGNOSIS HETHOD
HOW TO READ SELF-DIAGNOSTIC CODE

1. After the display panel flickers three times every 0.5 second, the corresponding error code flickers on the setup
temperature display panel every 0.5 second and will show two figures.
2. If error code is more than two, each code flicker 2 times in sequence.

24.04.2008
Page 2 of 3
FAULT CODE DISPLAY

1. Normal
2. One error code
3. More error codes than two
4. Checking each error code
DTC CHART
If malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.
DTC code
Detection item
Trouble area

24.04.2008
Page 3 of 3
00
11
12
13
14
15
16
17
18
19
20
21
22
Normal
Open INCAR Sensor circuit
Incar sensor
Harness or connector between incar sensor and A/C
control assembly
Shorted INCAR Sensor circuit

Open Ambient sensor circuit
Ambient sensor
Harness or connector between ambient sensor and A/C
control assembly
Shorted Ambient sensor circuit

Open water temp. sensor
Water temp. sensor

Harness or connector between water temp. sensor and
Shorted water temp. sensor

Open thermistor
Pin thermistor
Harness or connector between evap. sensor and A/C
control assembly
Shorted thermistor
Open or shorted temp. door potentiometer
Harness or connector between temp. door potentiometer

Defective temp. door potentiometer
Temp. door potentiometer
Open or shorted mode door potentiometer
Harness or connector between mode door potentiometer

Defective mode door potentiometer
Mode door potentiometer
FAIL SAFE FUNCTION

No.
Item
Failure
FAIL SAFE Function
IN-CAR temperature sensor
Open/Short
25C alternate value control
Ambient temperature sensor
Open/Short
20C alternate valu e control
Thermistor sensor
Open/Short
-2C alternate value contr ol
Water temperature sensor
Open/Short
-20C alternate valu e control
Temperature door potentiometer
Open/Short setup
temperature
For 17C to 24.5C, set to maximum cooling

position.
For 25C to 32C, set to maximum heating
position.
Mode door potentimeter
Open/Short setup
mode
Vent mode, at vent mode

Def mode, at except vent mode

24.04.2008
Page 1 of 2
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
General Information > Troubleshooting
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts
STANDARD
Symptom
Suspect Area
No blower operation
1.
2.
3.
4.
5.
6.
No air temperature control
1. Engine coolant capacity

2. Heater control assembly
No compressor operation
1.
2.
3.
4.
5.
6.
7.
8.
HTR Fuse
Blower relay
Blower motor
Blower resistor
Blower speed control switch
Wire harness
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Add coolant
Replace
Refrigerant capacity
A/C Fuse
Magnetic clutch
Compressor
A/C switch
Thermistor
Wire harness
Add refrigerant
Replace
Replace
Replace
Replace
Replace
Replace
Replace
No cool comes out
1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
6. Triple pressure switch
7. Thermistor
8. A/C switch
10. Wire harness
Add refrigerant
Apply a vacuum and add
refrigerant
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Insufficient cooling
1. Refrigerant capacity
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
6. Expansion valve
7. Evaporator
8. Refrigerant lines
9. Triple pressure switch
Add refrigerant
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1. Engine (and ECT) ECU

2. Wire harness
Replace
No engine idle-up when A/C switch

ON

24.04.2008
Page 2 of 2
No air inlet control
Heater control assembly, cable, door
Replace
No mode control
Heater control assembly, cable, door
Replace
No condenser fan operation
1.
2.
3.
4.
ECU-IG Fuse
Fan motor
Engine (and ECT) ECU
Wire harness
Replace
Replace
Replace

24.04.2008
Page 1 of 7
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Repair procedures
This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the
these conditions are established.
TEST CONDITIONS
Temperature at the air inlet with the switch set at RECIRC is 30~35C (86~95F)
Engine running at 1,500rpm
Blower speed control knob on "4" position
Temperature control knob on "COOL" position
It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.
1. Normally functioning refrigeration system.
Gauge reading :
Low pressure side :
0.15~0.25 MPa (21.8~36.3 psi, 1.5~2.5 kgf/cm)
High pressure side :
1.37~1.57 MPa (199~228 psi, 14~16 kgf/cm)
2. Moisture present in refrigeration system.
Symptom seen in
refrigeration system
During operation, pressure
on low pressure side
sometimes become a
vacuum and sometime
normal
Probable cause
Diagnosis
Remedy
Moisture entered in
refrigeration system freezes
at expansion valve orifice
and temporarily stops cycle,
but normal state is restored
after a time when the ice
melts
Drier in oversaturected
state
Moisture in refrigeration
system freezes at
expansion valve orifice
and block circulation of
refrigerant
- Raplace drier
- Remove moisture in
cycle through repeatedly
evacuating air
- Charge proper amount of
new refrigerant
3. Insufficient cooling

24.04.2008
Page 2 of 7
Symptom seen in
Probable cause
Pressure low on both low Gas leakage at some place

and high pressure sides in refrigeration system
Insufficient cooling
performance
Diagnosis
Remedy
Insufficient refrigerant in
system
Refrigerant leaking
- Check for gas leakage

with gas leak detector
and repair if necessary
- Charge proper amount of
refrigerant
- If indicated pressure
value is near 0 when
connected to gauge,
create the vacuum after
inspecting and repairing
the location of the leak
Diagnosis
Remedy
4. Poor circulation of refrigerant
Symptom seen in
Pressure low in both low
and high pressure sides
Frost on tube from
receiver to unit
Probable cause
Refrigerant flow obstructed
by dirt in drier
Condenser clogged
Replace drier
5. Refrigerant does not circulate

24.04.2008
Page 3 of 7
Symptom seen in
Vacuum indicated on low
pressure side, very low
pressure indicated on
high pressure side
Frost or dew seen on
piping before and after
receiver/drier or
expansion valve
Probable cause
Diagnosis
Refrigerant does not

Refrigerant flow
obstructed by moisture or circulate
dirt in refrigeration
system
Refrigerant flow
obstructed by gas
leakage from expansion
valve
Remedy
- Check expansion valve
- Clean out dirt in
expansion valve by
blowing with air
- Replace drier
- Evacuate air and charge
new refrigerant to proper
amount
- For gas leakage from
expansion valve, replace
expansion valve
6. Refrigerant overcharged or insufficient cooling of condenser
Symptom seen in
Press too high on both low
and high pressure sides
Probable cause
Unable to develop
sufficient performance
due to excessive
Insufficient cooling of
condenser
Diagnosis
Remedy
Excessive refrigerant in
cycle refrigerant
overcharged
Condenser cooling
condenser fins clogged
or condenser fan faulty
- (1) Clean condenser

- (2) Check cooling fan
with fluid coupling
operation.
- (3) If (1) and (2) are in
normal state, check
amount of refrigerant
Charge proper amount of
refrigerant
7. Air present in refrigeration system

24.04.2008
Page 4 of 7
Symptom seen in
Press too high on both
low and high pressure
sides
The low pressure piping
hot to the touch
Probable cause
Air entered in refrigeration
system
Diagnosis
Air present in
Insufficient vacuum
purging
Remedy
- Check compressor oil to
see if it is see if it is dirty
or insufficient
- Evacuate air and charge
new refrigerant
8. Expansion valve improperly
Symptom seen in
Pressure too high on
both low and high
pressure sides
Frost or large amount of
dew on piping on low
pressure side
Probable cause
Trouble in expansion valve
Diagnosis
Remedy
Excessive refrigerant in
low pressure piping
Expansion valve opened
too wide
- Check expansion valve

- Replace if defective
9. Defective compression compressor

24.04.2008
Page 5 of 7
Symptom seen in
Pressure too high on low
high pressure sides
Pressure too low to on
high pressure side
Probable cause
Internal leak in compressor
Diagnosis
Compression defective
Valve leaking or broken
sliding parts
Remedy
Repair or replace
compressor
INSPECT FOR LEAKAGE OF REFRIGERANT

Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.
In order to use the leak detector properly, read the manual supplied by the manufacturer.
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a
leak detector.
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the
fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again
A/C SYSTEM TESTS
Be careful when connecting service equipment.
Compressed air mixed with R-134a forms a combustible vapor.

The vapor can burn or explode causing serious injury.
Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-pressure
service port, following the equipment manufacturer s instructions.
2. Insert a thermometer in the center vent.
Determine the relative humidity and air temperature.

24.04.2008
Page 6 of 7
3. Test conditions :
A. Avoid direct sunlight.
B. Open the hood.
C. Open the front doors.
D. Set the temperature control dial on MAX COOL, the mode control switch on VENT and the recirculation control switch
on RECIRCULATE.
E. Turn the A/C switch on and the fan switch on MAX.
F. Run the engine at 1,500 rpm.
G. No driver or passengers in vehicle.
4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the
thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low
system pressure from the A/C gauges.
REFRIGERANT RECOVERY
1. Connect a R-134a refrigerant recovery/recycling/charging station(A) to the high-pressure service port(B) and the lowpressure service port(C), as shown, following the equipment manufacturer s instruction.
2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to
put the same amount of new refrigerant oil back into the A/C system before charging.
SYSTEM EVACUATION
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated
using a R-134a refrigerant recover/recycling/charging station (If the system has been open for several days, the
receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect a R-134a refrigerant recovery/recycling/charging station(A) to the high-pressure service port(B) and the lowpressure service port(C), as shown, following the equipment manufacturer s instruction. Evacuate the system.

24.04.2008
Page 7 of 7
3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in
the system. Partially charge the system, and check for leaks.
SYSTEM CHARGING
1. Connect a R-134a refrigerant recover/recycling/charging station(A) to the high-pressure service port(B) and the lowpressure service port(C), as shown, following the equipment manufacture s instructions.
2. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only FD46XG (PAG)
refrigerant oil
3. Carge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be
damaged.
Refrigerant capacity : 600 25g

24.04.2008
Page 1 of 1
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General
SPECIFICATIONS
Item
Specification
Heating
Heater
Type
Capacity
Air mix type

4,500 10% kcal/hr
Air conditioning
Evaporator
Cooling capacity
4,100 10% kcal/hr
Compressor
Type
Oil capacity
Pressure relief valve
Voltage
Swash plate (HS-15)

140 ~ 160cc
Operating pressure : 35 ~ 42.2kg/cm
D.C 12.8 0.2V
Magnetic clutch
Voltage & wattage
Torque
D.C 12.8 0.2V, Max. 54W

Min. 4.4kgm
Refrigerant & capacity
R-134a (600 25g)
High pressure
ON 32.0 2.0kg/cm
OFF 26.0 2.0kg/cm
Middle pressure
ON 18.0 0.8kg/cm
OFF 14.0 1.2kg/cm
Low pressure
ON 2.3 + 0.25 / -0.29kg/cm
OFF 2.0 0.2kg/cm
Thermistor
Heater control assembly
OFF 1.5 0.6C

ON 3.0 0.6C
MANUAL Type, AUTOMATIC Type

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning System >
Compressor > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and Components
Location
COMPONENT LOCATION
COMPONENTS

24.04.2008
Page 2 of 3

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Compressor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
REPLACEMENT
1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a
few minutes, then shut the engine off.
2. Disconnect the negative cable from the battery.
3. Recover the refrigerant with a recovery/charging station.
4. Loosen the drive belt.
5. Remove the nuts, then disconnect the suction line(A) and discharge(B) line from the compressor.Plug or cap
the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Disconnect the compressor clutch connector(A), then remove the mounting bolts and the compressor(B).
7. Using a hexagon wrench(6mm) remove the bolts, the manifold assembly(A) and the gasket(B) from the
compressor.
8. Install in the reverse order of removal, and note these items.

A. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and
measure its volume, Subtract the volume of drained oil from 150ml the result is the amount of oil you
should drain from the new compressor (through the suction fitting).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.

24.04.2008
Page 2 of 4
C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
E. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the
paint, wash it off immediately.
F. Adjust the drive belt.
G. Charge the system, and test its performance.
INSPECTION
1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage,
replace the clutch set.
2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one
if it is noisy or has excessive play/drag.
3. Measure the clearance between the pulley(A) and the pressure plate(B) all the way around. If the clearance is
not within specified limits, remove the pressure plate and add or remove shims as needed to increase or
decrease clearance.
Clearance : 0.5 0.15mm (0.020 0.006 in.)
The shims are available in seven thicknesses : 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and
1.3mm.
4. Check operating of the magnetic clutch.

Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the
compressor body.
Check the magnetic clutch operating noise to determine the condition.

24.04.2008
Page 3 of 4
DISASSEMBLY
1. Remove the center bolt(A) while holding the pressure plate with a commercially available pressure plate bolt
remover(B); Special tool number 09977-2900.
2. Remove the pressure plate(A) and shim(B), taking care not to lose the shims. If the clutch needs adjustment,
increase or decrease the number and thickness of shims as necessary, then reinstall the pressure plate, and
recheck its clearance.
3. If you replacing the field coil, remove snap ring(A) with snap ring pliers.
Be careful not to damage the pulley(B) and compressor during remove/installation.

Once snap ring(A) is removed, replace it with a new one.
4. Remove the screw from the field coil ground terminal.

24.04.2008
Page 4 of 4
Remove the field coil(A) from the shaft with a puller(B). Be careful not to damage the coil and compressor.
5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
A. Install the field coil with the wire side facing down, and align the boss on the coil with the hole in the
compressor.
B. Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
C. Install new snap rings, and make sure they are fully seated in the groove.
D. Make sure that the pulley turns smoothly after it's reassembled.
E. Route and clamp the wires properly or they can be damaged by the pulley.

24.04.2008
Page 1 of 1
System > Condenser > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures
REPLACEMENT
1. Recover the refrigerant with a recovery/recycling/charging station.
2. Remove the coolant reservoir, but do not disconnect the reservoir hose from the coolant reservoir and the
radiator.
3. Remove the bolts(A), then remove the upper mount brackets(B) from the radiator.
4. Remove the bolts(A), then disconnect the discharge line and condenser line from the condenser.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
5. Remove the bolts, then remove the condenser by lifting it up. Be careful not to damage the radiator and
condenser fins when removing the condenser.
6. Install in the reverse order of removal, and note these items :
A. If you're installing a new condenser, add refrigerant oil FD46XG.
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.

24.04.2008
Page 1 of 1
System > Receiver/Drier > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Receiver/Drier > Repair procedures
INSPECTION
1. Check the fusible plug and the fittings for leakage, using a leak detector.
2. Run the engine at fast idle with the air conditioning "ON", and check both the inlet and outlet temperatures. If
the difference in temperatures between the inlet and outlet is large, replace the receiver-drier.
Plug all the open fittings immediately to keep moisture out of the system.
Do not remove plugs until ready for connection.
If the receiver-drier is replaced with a new unit, add 40cc of compressor oil to the compressor.
Evacuate, charge and test the refrigeration system.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning System >
Refrigerant line > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Components and
Components Location
COMPONENT LOCATION

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
System > Triple pressure switch > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Schematic
Diagrams
CONNECTOR
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
System > Triple pressure switch > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Description
and Operation
DESCRIPTION
-
Rating load : Inductive loacl DC 12V, 10~250mA

Applicable voltage range : DC 8V ~ DC 16V
Applicable temperature range : -30C ~ 120C
Applicable refrigerant : R-134a
Insulation resistance : Min. 100M at DC 500V
Pressure
ON
OFF
High
32.0 2.0
26.0 2.0
Low
2.3 + 0.25 / -0.29
2.0 0.2
Medium
18.0 0.8
14.0 1.2
LOW & HIGH
MEDIUM

24.04.2008
Page 1 of 1
System > In-car sensor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Description and
Operation
DESCRIPTION
It will detect interior temperature, which will be used for discharge temperature control, sensor failsafe,
temperature door control, blower motor level control, and A/C auto control.
CHARACTERISTICS

24.04.2008
Page 1 of 1
System > Photo sensor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description and
Operation
DESCRIPTION
The photo sensor is located by the driver side defrost nozzle. In response to the photo intensity level in the
vehicle, the sensor will send signals to control module to control the blower level and discharge temperature.
Emit intensive light toward driver side and passenger side using a lamp and check the current change
between terminals 1 & 2.

24.04.2008
Page 1 of 1
System > Ambient sensor > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Schematic
Diagrams
CONNECTOR

24.04.2008
Page 1 of 1
System > Ambient sensor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation
DESCRIPTION
1. The air temperature sensor, located at the front of the engine radiator, detects ambient air temperature. It is a
negative type thermistor; resistance will increase with lower temperatures, and decrease with higher
temperatures.
2. The sensor output will be used for discharge temperature sensor, sensor fail-safe, temperature regulation
door control, blower motor level control, mix mode control and in-car humidity control.
A. R25C : 30K 3%
B. B(0/25) : 3754K 2%
C. Operation Temp. range : -30C ~ 80C

24.04.2008
Page 1 of 1
System > Ambient sensor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures
INSPECTION
Measure the resistance.
RESISTANCE-TEMP. CHARACTERISIC TABLE
Temp (C)
Rmin (k )
R (k)
Rmax (k)
-20
261.090
271.120
281.150
92.617
95.089
97.656
25
29.550
30.000
30.450
50
10.676
10.950
11.224
80
3.964
3.828
3.366
CHARACTERISTICS

24.04.2008
Page 1 of 1
System > A.Q.S (Air Quality Sensor) > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) >
Schematic Diagrams
CONNECTOR

24.04.2008
Page 1 of 1
System > A.Q.S (Air Quality Sensor) > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) >
DESCRIPTION
1. The A.Q.S. sensor, located at the center support in front of the engine radiator, detects hazardous elements in
ambient air and provides output signals to the control module.
2. It will detect sulfurous acid gas, carbon dioxide, carbon monoxide, hydrocarbon and allergen.
3. Sensitivity of used gas sensor
A. Sensitivity at NO2 0.3PPM : more than 2.8
B. Sensitivity at gasoline 10PPM : less than 0.45
4. Delay time
A. ON time (on) : 5sec.
B. OFF time (off) : 0sec.
SENSOR OUTPUT
Condition
Resistance
Normal condition
5V
Hazardous gas detection
0V

24.04.2008
Page 1 of 1
System > A.Q.S (Air Quality Sensor) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) > Repair
procedures
INSPECTION
CHECKING METHOD OF GAS DETECTING BENCH
1. Put the sensor part of AQS toward the air inflow (intake) direction.
2. Connect all of the power supply line and output line to AQS.
3. Close the chamber lid after putting the lines in order.
4. Connect the air outlet part of vacuum pump with the air inlet door of chamber by using air hose.
5. Turn on the power of vacuum pump.

6. Supply the power to the AQS. (DC 12V)
7. LED of AQS is kept "ON" for the first 35 2 seconds after supplying the power.
8. Wait until all of the LEDs are "OFF". Put the diesel engine exhaust gas into the chamber. Then check the
LEDs of number 1 to 10 are "ON".
9. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".
10. Wait until all of the LEDs are "OFF".
11. And then put the gasoline engine exhaust gas into the chamber, then check the LEDs of number 1 to 10 are
"ON".
12. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Heater Unit >
Conditioning > Heater > Heater Unit > Components and Components Location
COMPONENT LOCATION
COMPONENTS

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Heater Unit >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Heater > Heater Unit > Repair procedures
REMOVAL
1. Disconnect the negative (-) battery terminal.
2. Drain the cooling water of the radiator.
3. Remove the heater hose and the drain hose.
4. Drain the refrigerant.

5. Disconnect the air conditioning suction hose and the liquid tube.
6. Remove the driver's seat and the passenger's seat.
7. Remove the cowl side trim and the front pillar trim.
8. Remove the air bag module.

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Page 2 of 5
9. Remove the steering wheel.
10. Remove the steering lower and upper shroud.
11. Remove the multi-function switch.
12. Remove the crash pad under cover for the driver side.

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Page 3 of 5
13. Remove the cluster housing.
14. Remove the cluster.
15. After removing the center facia panel, disconnect the connectors.
16. Remove the audio.
17. Remove the floor console upper cover.

18. Remove the floor console.
19. Remove the glove box.

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20. Remove the glove box lamp connector and the lamp.
21. Remove the main crash pad mounting bolt.
22. Remove the main crash pad.

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Page 5 of 5
23. Remove the heater unit mounting nut.

24. Remove the heater unit.
INSTALLATION
Installation is the reverse of the removal.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Temperature
Control Actuator > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation,
Air Conditioning > Heater > Temperature Control Actuator > Schematic Diagrams
CONNECTOR
Teminal No.
Mode
WARM
COOL
VCC(+)
F/B
SENSOR
GND(-)

24.04.2008
Page 1 of 1
Control Actuator > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and
Operation
DESCRIPTION
-
Operating temp. : -30C ~ +80C

Operating voltage : DC 9V ~ 16V
Rated voltage : DC 12V
Rated load : 4kgf/cm
Rated watt. : 0.25W (at 40C)
Opration volt : DC 5V 0.5V
Total resistance : 5k 10%
Output lock torque : Min 1.76Nm (18kgf/cm) (at DC 12V)
Rated AMP : Max. 150mA
Lock vol. : Max. 400ma
Characteristics

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Temperature Control
Actuator > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Components and Components
Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
Control Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Temperature Control Actuator > Repair procedures
REPLACEMENT
1. Disconnect the 7P connector (A) from the temp. actuator (B). Remove the self-tapping screws and the temp.
actuator from the heater unit.
2. Install in the reverse order of removal. After installation, make sure temp. actuator runs smoothly.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Mode Control
Actuator > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Schematic Diagrams
CONNECTOR
Teminal No.
Mode
VENT
DEF
VCC (+)
F/B
SENSOR
GND (-)

24.04.2008
Page 1 of 1
Actuator > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Description and Operation
DESCRIPTION
-

Rated watt. : 0.25W (at 40C)
Opration volt : DC 5V 0.5V
Total resistance : 5k 10%
Output lock torque : Min 1.76Nm (18kgf/cm) (at DC 12V)
Rated AMP. : Max 150mA
Lock vol. : Max. 400mA
Characteristics

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Repair procedures
REPLACEMENT
1. Remove the 7P connector (A) from the mode actuator (B). Remove the self-tapping screws and the mode
actuator from the heater unit.
2. Install in the reverse order of removal. After installation, make sure the mode actuator runs smoothly.

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Schematic Diagrams
CIRCUIT DIAGRAM

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Page 2 of 3

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Page 3 of 3

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Unit >
Conditioning > Blower > Blower Unit > Components and Components Location
COMPONENT LOCATION
COMPONENTS

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Page 2 of 2

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Unit >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Unit > Repair procedures
REMOVAL
1. Disconnect the negative cable from the battery.
2. Remove the crash pad (see BD group - crash pad).
3. Disconnect the connectors(A) from the blower relay the blower motor, the blower resistor (or power transistor)
and the fresh and recirculation actuator.
Remove the self-tapping screws(B), the mounting nut(C), the mounting bolts(D) and the blower unit(E).
Make sure that there is no air leaking out of the blower and duct joints.
AIR FILTER REPLACEMENT

1. Remove the mounting screws on the downside of the glove box.
2. Open the glove box and remove the mounting screws on the upside of the glove box.
3. Remove the filter cover.

24.04.2008
Page 2 of 2
4. Replace the air filter with a new one.
5. Installation is the reverse of the removal.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Motor
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Motor > Schematic Diagrams
CONNECTOR

24.04.2008
Page 1 of 1
> Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Motor > Description and Operation
DESCRIPTION
Moter : Magnet 70
Item
Type
Speccifications
DC ferrite
Rated voltage
DC 12 volts
No load speed
Min. 3300rpm
No load current
Max. 3.0A
Rated load
5.0kgfcm
20C or 68F
Speed in rated load
2900 250rpm
Current in rated load
Continuous
Insulation resistance
Min. 1M
Rotation direction viewed from output (Mtr.

shaft)
Operation temp. range
CCW
-30 ~ +80

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Motor >
Conditioning > Blower > Blower Motor > Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Motor > Repair procedures
INSPECTION
Connect the battery voltage and check the blower motor rotation.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Relay
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Relay > Schematic Diagrams
CONNECTOR
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Relay
> Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Relay > Description and Operation
DESCRIPTION
There should be continuity between No.3 and No.4 terminals when power and ground are connected to the No.1
and No.2 terminals, and there should be no continuity when power is disconnected.
- Rated voltage : DC 12V
- Operation voltage range : DC 10V ~ DC 15V
- Rated load current : DC 12V, 25A (Motor lord)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Relay >
Conditioning > Blower > Blower Relay > Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Power
Transistor > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Power Transistor > Schematic Diagrams
CONNECTOR
CIRCUIT DIAGRAM AND IMPORTANT PERFORMANCE OF PARTS COMPOSED

CIRCUIT
1) Power transistor :
Equivalent to MOTOROLA MJ11032 (Pc = 300W, Ic = 50A)
2) Fuse : 250V, 15A, 128C
Condenser : 0.22 , 50V

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Power
Transistor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation,
Air Conditioning > Blower > Power Transistor > Description and Operation
DESCRIPTION
-

Power consumption : Max. 240W
Operating assurance range : -30C ~ +70C, 10 ~ 15 V
Performance assurance range : -30C ~ +60C, 10 ~ 15V

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Power Transistor >
Conditioning > Blower > Power Transistor > Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower
Resistor > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Resistor > Schematic Diagrams
CONNECTOR
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
Resistor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Resistor > Description and Operation
DESCRIPTION
-

Rated load : Blower motor
Standard test Temp. : 20DEG
Operation Temp. : -30DEG ~ +70DEG
Resistor off - Time requierment for blower motor locking
Mode
Resistor off time (sec)
200 30
100 20
55 15
CHARACTERISTICS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Resistor >
Conditioning > Blower > Blower Resistor > Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
Resistor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Resistor > Repair procedures
INSPECTION
Measure terminal-to-terminal resistance of the blower resistor.
If measured resistance is not within specification, the blower resistor must be replaced. (After removing the
resistor)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Intake
Actuator > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Intake Actuator > Schematic Diagrams
CONNECTOR
Teminal No.
Mode
FRE
REC
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
Actuator > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Intake Actuator > Description and Operation
DESCRIPTION
-


24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Intake Actuator >
Conditioning > Blower > Intake Actuator > Components and Components Location
COMPONENT LOCATION

24.04.2008
Page 1 of 1
Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Intake Actuator > Repair procedures
REPLACEMENT
1. Disconnect the 7P connector (A) from the inlet actuator (B). Remove the self-tapping screws and the inlet
actuator from the blower unit.
2. Install in the reverse order of removal. After installation, make sure the inlet actuator runs smoothly.

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Control Panel >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower >
Control Panel > Schematic Diagrams
CONNECTOR CONFIGURATIONS
Connector
Pin No.
Blower switch
Main switch
Name
MIDDLE HIGH
Connector
Main switch
Pin No.
Name
11
SENSOR GROUND
COMMON
12
FRE.
GROUND
13
REC.
HIGH
14
ILL+
MIDDLE LOW
15
ILL-
LOW
16
COMMON (BLOWER)
IGN2
17
A/C OUTPUT
B+
18
HUMIDITY (Rear defogger)
GROUND
19
S/W (Rear defogger)
MODE ACT. (VENT)
20
MODE ACT. (DEF)
21
MODE F/B
22
TEMP ACT. (WARM)
23
TEMP ACT. (COOL)
TEMP F/B
10
VCC
SCHEMATIC DIAGRAM
BLOWER S/W

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WIRING DIAGRAM

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Page 3 of 3

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Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Control Panel > Description and Operation
DESCRIPTION
1. BLOWER SWITCH
The blower switch controls the blowing level of the air conditioning system by controlling blower motor speed. The
switch has an electrical circuit containing a resister that will regulate blower motor input voltage to control the motor
speed.
2. MODE SWITCH
The mode switch controls air conditioning system discharge location. The switch contains an electrical circuit to control
an actuator that is connected to the mode door for discharge control.
3. TEMPERATURE SWITCH
The temperature switch controls the temperature door position that will be used to regulate the air conditioning system's
discharge air temperature. The switch includes a rack & pinion and a cable.
4. INTAKE SWITCH
The intake switch controls the intake door used to regulate the intake air flow of the air conditioning system. The switch
contains an electrical circuit used to control the actuator that is connected to the intake door.
5. AIR CONDITIONING SWITCH
The air conditioning switch controls the on/off position of the air conditioning system compressor. The switch contains
an electrical circuit that will switch on/off the power supply to the relay that is connected to the compressor.
6. REAR DEFOGGER SWITCH
The rear defogger switch is used to defog the rear glass. Switching the switch on, ETACS will output a signal to operate
the rear glass heat wire.

24.04.2008
Page 1 of 1
Conditioning > Blower > Control Panel > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller >
Schematic Diagrams
CIRCUIT DIAGRAM

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Page 2 of 4

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Page 3 of 4

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Page 4 of 4

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Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Manual Controller >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller
> Manual Controller > Schematic Diagrams
CONNECTOR CONFIGURATIONS
I/NO
PIN
CIRCUIT
REMARK
RHEOSTAT
TAIL LAMP
I/NO
PIN
CIRCUIT
ILL (-)
INCAR SENSOR IN
ILL (+)
A/C SELECT
BATTERY
AMB SENSOR (+)
POWER TR(B)
EVA. SENSOR (+)
POWER TR(C)
HUMDITY
SENSOR REF (+5V)
REMARK
HI OUTPUT
B
9
TEMP ACT'R (CCW)
COOL
INCAR SENSOR OUT
10
INTAKE ACT'R (CCW)
FRESH
10
TEMP F/B SIGNAL
11
HTD
11
MODE F/B SIGNAL
12
IGN 2
12
13
GND
13
14
MODE ACT'R (CW)
VENT
14
15
MODE ACT'R (CCW)
OFF
15
16
16
SENSOR GND
17
A/CON OUTPUT
HI OUTPUT
18
HI SPEED RELAY
LOW OUTPUT
19
PHOTO SENSOR (+)
20
PHOTO SENSOR (GND)
21
REAR DEFOG
LOW OUTPUT
22
TEMP ACT'R (CW)
WARM
23
INTAKE ACT'R (CW)
REC
24
AQS SIGNAL
25
IGN 2
26
GND
WIRING DIAGRAM

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Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Controller > Manual Controller > Description and Operation
DESCRIPTION
BUTTON CONTROL AND OPERATION LOGIC

1. All buttons should be back-up.
2. Push the button, then the operation sound is made for 0.1 sec. When a S/W is selected, and operation sound is made
as well).
NO
1
BUTTON
TEMP
BUTTON
FUNCTION
TEMP
UP/DOWN
DISPLAY
Set
temperature:
Display
SYSTEM OPERATION
1. Control the discharge air temperature by adjusting the
mixture ratio of cold & hot air with the TEMP DOOR.
2. Whenever press the SWITCH, temperature is changed
0.5C up/down each time. (Each time the operation
sound is made for 0.1 sec.)
3. Set 17C (62F) as MAX COOL, 32C (90F) as MAX
HOT.
4. When the switch is turned ON from OFF, the set
temperature is displayed as the same before OFF.
5. When changing the set temperature from 17.5C to
17C or from 31.5C to 32C, the operation sound is
made.
6. At 17C, if the temperature is set below than 17 C or
at 32C , if it is above than 32C , the operation sound
is made 5times at an interval of 0.15 sec.
7. When pushing the TEMP button several times, the set
temperature is shifted to another step at an interval of
0.7sec., When engaging the button continuously (keep
pushing), only the first shift takes 0.7 sec. but the next
shifts take 0.3 sec.
OFF SW AND SYSTEM OPERATION
- OFF: SYSTEM OFF
- TEMP: SET TEMPERATURE UP/DOWN
AUTO
AUTO
CONTROL
"AUTO": Display
1. Automatically control the following items

corresponding to theset temperature.

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TEMP DOOR
MODE DOOR
INTAKE DOOR
BLOWER FAN SPEED
A/C
2. When the AUTO mode is off, the word AUTO should
not appear.
3. After off the AUTO mode, the system is automatically
controlled except for the manually selected SW.
- OFF: SYSTEM OFF
- FAN UP/DOWN: BLOWER FAN SPEED MANUAL
CONTROL
- MODE: DISCHARGE MODE MANUAL CONTROL
- A/C: A/C ON/OFF MANUAL CONTROL
- FRE.: FRE. MODE MANUAL CONTROL
- REC.: REC. MODE MANUAL CONTROL
- DEF.: DEF. MODE MANUAL CONTROL, A/C ON,
FRE.
3
AMB
Ambient
temperature
display
"AMB":
Display
Ambient
temperature:
Display
The other
signals: OFF
1. System is operated as the same before the AMB SW

turned on.
2. When the AMB SW is pushed, the other signals are
not appearedbut the word AMB and the ambient
temperature are displayed for 5 sec., andthen the
display become the same as the AMB SW is not
pushed.
- AMB: If the AMB SW is pushed once more when the
ambient temperatureis displayed, the ambient
temperature does not appear and the display
becomethe same as the AMB SW is not pushed.
- OTHER SWITCHES: If the other switch is pushed
except for REARDEF and in-car & ambient /AQS,
ambient temperature does not appear and the pushed
switch is displayed.
A/C
A/C ON/OFF
CONTROL
"A":
1. A/C ON/OFF
Display/OFF
"AUTO":
OFF
- OFF: SYSTEM OFF
- AUTO: AUTO MODE AUTOMATIC CONTROL
MODE
MODE DOOR
CONTROL
VENT
B/L
FOOL
MIX
"MODE":
Display/OFF
"AUTO": Off
DEF MODE
"DEF": ON
"A/C":
Display
REC. IND:
OFF
DEF
1. Fix the MODE DOOR to one among VENT, B/L,

FLOOR and MIX.
2. MODE SW MANUAL CONTROL ORDER : VENT
B/L FLOOR MIX VENT ...
3. At MIX MODE: MIX LOGIC (MIX, FRE., A/C ON)
- DEF: DEF MODE MANUAL CONTROL
- MODE: VENT, B/L, FLOOR & MIX (repeat the order)
1. MODE DOOR: Fix to "DEF"
2. INTAKE DOOR: Fix to "FRE." (REC. can be selected)
3. A/C: ON
A/C OUTPUT ON/OFF control: Corresponding to
the detected temperatureby EVAP SENSOR.

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"AUTO":
OFF
A/C output should be cut off at 3.5C or below

(ambient temperature).
(DISPLAY OFF, A/C SELECT SIGNAL OFF)
4. DEF is prior to "MAX HOT/COOL" function.
5. DEF is prior to "MIX MODE" control.
- AUTO: ALL SYSTEM AUTOMATIC CONTROL
- MODE: DISCHARGE MODE MANUAL CONTROL
(DEF Function off)
- DEF: Return to the mode before the DEF S/W
selection
OFF
SYSTEM OFF
LCD: ON
1.
2.
3.
4.
5.
6.
BLOWER FAN SPEED OFF

A/C OFF
TEMP. DOOR: Fix to the mode before OFF
MODE DOOR: Fix to the mode before OFF
INTAKE CONTROL: Fix to the mode before OFF
After "OFF", at REC, REC. S/W ON (NON-AQS type)
- Shift to FRE. MODE
- REC. INDICATOR ON
- LCD OFF
- OTHERS: OFF
7. After "OFF", at FRE, FRE. S/W ON (NON-AQS type)
- Shift to FRE. MODE
- REC. INDICATOR ON
- LCD OFF
- OTHERS: OFF
8. After "OFF", at AQS, AQS/REC. S/W ON (AQS type)
- Shift to REC. MODE
- AQS OFF
- REC. INDICATOR ON
- LCD OFF
- OTHERS: OFF
9. After "OFF", AQS ONAQS LOGIC
10. After "OFF", AMB S/W ON
- OFF: The word "AMB" & ambient temperature
displays for 5 sec. and then off.
AUTO: AUTO MODE AUTOMATIC CONTROL
BLOWER
- SPEED: Return to MANUAL LOW
- OTHERS: Return to the mode before OFF
A/C
- A/C ON
MODE
- MODE: The mode before OFF
DEF
- MODE: DEF
- A/C ON
- INTAKE: FRE.
TEMP

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- TEMP: The mode before OFF

8
REC. (NONAQS type)
REC. MODE
IND ON
"AUTO"
display
FRE. MODE
IND OFF
"AUTO"
display
FAN UP/DOWN BLOWER FAN

SPEED
UP/DOWN
FAN IND
ON/OFF
1. When operating the REC. S/W from FRE. MODE, fix

the INTAKE DOORto REC. MODE or when operating
the REC. S/W from REC., fix the INTAKE DOORto
FRE. MODE.
- REC.: FRE./REC. MODE CONTROL
- OFF SW: ALL MODES (POSSIBLE TO MANUALLY
SELECT)
- AUTO: AUTOMATIC CONTROL (FRE. or REC.)
1. BLOWER MOTOR's rotation speed is controlled by the
current variationof the POWER TRANSISTOR.
2. At AUTO MODE, if FAN is operated UP/DOWN, the
FAN SPEED is UP/DOWNon the basis of the present
FAN LEVEL.
3. At OFF, if the other SW except for "FAN" is turned ON,
the FAN SPEED is gradually increased from LOW to
TARGET SPEED
4. Fan speed level and voltage
AUTO AIR CONDITIONER: No level (4.5V - B+)
AUTO HEATER: No level (4.5V - B+)
MANUAL FAN SPEED: 7th level (3.8V - B+)
5. The first shift to another step takes 0.7 sec. If the
button iscontinually engaged, the first shift takes 0.7
sec. And then the next ones take 0.3 sec per each.
The operation sound is made for 0.1 sec.
6. At MANUAL 7th level when the UP SW is pushed or at
MANUAL 1st level when the DOWN SW is pushed, the
operation sound is made 5 times at an interval of 0.15
sec.
7. When shifting 6 to 7 level, or 2 to 1 level, the operation
soundis intervally made each 0.15 sec.
- OFF: SYSTEM OFF
- FAN UP/DOWN: BLOWER FAN SPEED MANUAL
CONTROL
10
DEFOG
Rear glass
defogger
DEFOG IND
ON/OFF
1. If the DEFOG SW is pushed, the rear glass defogger

operation signal is output to the ETACS and the
ETACS turns the DEFOG IND on by the HTD input.
2. While operating the rear glass defogger, if DEFOG SW
is pushed, ETACS stops operating the rear glass
defogger and turns the DEFOG IND off.
3. After operating the rear glass defogger for 15 minutes
by EATCS, DEFOG function is automatically off.
- DEFOG: Push the second DEFOG SW, DEFOG
function is off.
SYSTEM CONTROL FEATURES

SIGNAL I/O FOR EACH CONTROL FEATURE
Control item
Required discharge
Input
Auto SW, A/C SW, TEMP SW, INCAR
Output
Remarks
TEMP actuator

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Page 5 of 8
temperature control
sensor,AMB sensor, Photo sensor, Water

temperature sensor, thermo sensor, TEMP
actuator.
Mode control
AUTO SW, MODE SW, TEMP SW, DEF

Blower motor
SW,Blower SW, OFF SW, INCAR sensor, AMB Power TR
sensor, Photo sensor, Water
HI-blower relay
temperaturesensor, thermo sensor, Power TR.
Mode door control
AUTO SW, MODE SW, DEF SW, Blower

SW,OFF SW, TEMP SW, INCAR sensor, AMB
sensor, Photo sensor.
Mode actuator
Intake control
AUTO SW, A/C SW, DEF SW, TEMP SW,OFF

SW, Intake SW, INCAR sensor, AMB sensor,
Photo sensor, Power TR.
Mode actuator
Compressor control
AUTO SW, A/C SW, DEF SW, TEMP SW,OFF

SW, IN-CAR sensor, AMB sensor, Photo
sensor.
Compressor relay
Blower Switch
Manual selection
Control in priority
During mode control, the A/C may operate during DEF or MIX mode.In order to enable dehumidification, the driver may
select A/C OFF duringthe A/C on condition.
CONTROL SPECIFICATION
Control item
Control features
Required
discharge
temperature
Required temperature determined by the set temperature and the

inputted sensor value.
Auto control
Required discharge temperature is determined by the set temperature

and the inputted sensor value. The feature will use the required
discharge temperature to perform the auto control of temp. actuator,
mode actuator, intake actuator, blower motor and compressor, and
maintain the set temperature stably.
IN-CAR
temperature
correction
Upon detecting rapid changes of temperature from the INCAR sensor, it

will gradually correct the incar temperature value.
AMB
temperature
correction
Upon detecting rapid changes of temperature from the AMB sensor, it

will gradually correct the ambient temperature value.
Photo correction Upon detecting rapid changes of photo intensity from the PHOTO
sensor, it will gradually correct the photo intensity value.
TEMP door
control
It does the automatic control to maintain the optimum TEMP door

opening (0%-100%).It will be computed by the temperature set and the
input signal from each sensor.
Blower speed
Automatic control of the blower speed. The target value will be

computed by the set temperature and the input signal from each sensor.
(7 levels may be selected in case of manual selection.)
Electro-motive
mode control
During auto control, it will raise the permitted voltage of blower motor
gradually in order to improve comfortability.
Photo
compensation
During auto control, it will compensate the blower level and the
discharge temperature according to the photo intensity detected from
the PHOTO sensor at VENT or B/L mode. PHOTO compensation will
begin after 5 seconds when ignition on.
Mode door
Automatic control of air discharge based on the required discharge
Remarks
- 1C UP/4sec delay
- 1C DOWN/4sec delay
- 1C UP/3min delay
- 1C DOWN/4sec delay
- 350 1000(W/m)/1min
delay
- 350 1000(W/m)/5min
delay
The set temperature range
17C 32C, 0.5C step
(62F 90F, 1F step)
- Auto mode blower low
voltage (Manual low
voltage: 3.8)
- Auto mode heater blower
HI speed: 10.6V
6 seconds for shifting LO
MAX
- At OFF in AUTO mode,

24.04.2008
Page 6 of 8
control
temperature. It will be computed by the temperature setting and the

VENT B/L FLOOR VENT)
In case of manual selection (VENT B/L FLOOR MIX VENT)
MODE door will maintain

the AUTO
controlcondition.
- At OFF in manual mode,
MODE door will maintain
the manual
controlcondition.
MIX mode
control (in auto
control)
If the ambient temperature is -13C or less in AUTO mode, discharge

mode will be controlled at MIX. (When front window glass is defogged.)
Entering MIX mode, A/C will

operate.
INTAKE door
control
Auto control of intake mode based on the required discharge

temperature that will be computed by the temperature setting and the
- Shift to REC when

selecting REC button at
FRE condition (LED on).
- Shift to FRE when
selecting FRE button at
REC condition (LED off).
INTAKE control
at OFF
The intake door will shift to the REC position when switching the system
off in auto-condition, and maintain the previous condition at OFF at
manual condition.
- FRE./REC. manual
selection will be enabled
at OFF.
- REC indicator will come
on at OFF at AUTO
mode.
Compressor
auto control
Control automatically the compressor on/off state corresponding to the

set temperatureand the input signal from each sensor.
- When selection the

AUTO SW, the
compressor is controlled
to ON/OFF.
- When selection the DEF
SW, the compressor is
controlled to "ON".
If EVAP sensor temperature is below than 0.5C, the compressor will be

Compressor
ON and the temperature is 3C, or higher, with the compressor OFF.
clutch on/off
control based on
refrigerant
temperature
MAX HOT
When selecting the set temperature 32C at AUTO mod e, MAX HOT will
be performed. It will prevail over MIX mode control.
- TEMP door: MAX HOT

- MODE door: FLOOR
mode
- INTAKE door: FRE mode
- Compressor: OFF
- Blower speed: AUTO HI
(10.6V)
MAX COOL
When selecting the set temperature 17C at AUTO mode, MAX COOL
will be performed.
- TEMP door: MAX COOL

- MODE door: FLOOR
mode
- INTAKE door: REC mode
- Compressor: ON
- Blower speed: MAX HI
Electromotive
heating control
If the set temperature >the in-car temperature by 3C at B/L or FLOOR

in AUTO mode, and the water temperature sensor input is 58C or less,
it willeffect the electromotive heating control to prevent outside cold air
from flowing toward the feet of passengers.
- Blower speed: Controlled

at AUTO LOW (0.5V)
As the coolant temperature rises, the MODE door will shift to DEF
MIX AUTO.
Operation release
10 minutes after ignition
on(In case of
temperature sensor fail,it

24.04.2008
Page 7 of 8
MODE: Manual selection is enabled.

INTAKE door: At AUTO control or at manual selection mode.
Blower speed: Manual selection is enabled (No re-entry).
will apply the substitute

value, 20C).
After pressing blower
switch when water
temperature sensor
detectionis 58C or
higher
In pressing MODE
switch.
In Upon pressing DEF
switch.
Electromotive
cooling control
In order to prevent hot air from the VENT or B/L in AUTO mode (A/C on
mode), the blower speed will be operated at LOW for approx. 9 seconds
before enteringthe AUTO control if the EVAP sensor detection is
temperature 30C or higher.
MAX HOT
If the above condition is satisfied, electromotive cooling control will

operate at any time.
Air Quality
System (AQS)
The AQS system will detect the hazardous elements and odors
contained in the air.If the harmful element concentration is higher than
standard, the system willoutput a LOW signal (0V) to the FATC.
- When the initial battery

connection and ignition is
ON, it will operate at
AUTO mode. (AQS will
not operate).
If the concentration is within the standard value, the system will output a
HI signal(3V) the FATC.
- When IGN 2 ON, the

AQS assembly will be
preheated for 34.5
5seconds.During the
preheating, AQS will
output 0V (ground). (REC
mode)
Corresponding to the signal from the AQS, it will control the INTAKE
door as follows toprevent the inflow of harmful gas in FATC :
- IGN 2 ON: It will check

circuit break on the AQS
assembly's signal line for
approx. 7 seconds during
the preheating,
irrespective to the AQS
switch condition.
Condition : INTAKE door position
- When AQS is selected

prior to IGN2 OFF and
IGN2 is turned OFF
ON: AQS indicator will
come on, and the system
will operate at AQS
mode. (Storethe previous
condition before IGN 2
OFF)
LOW : REC
HI : FRE
Initialization
Upon battery-on
When supplying the initial power, it will operate in the initial condition.
- When the initial ignition

ON after battery
connection, the
systemwill operate at the
set temperature 25C
and at AUTO mode.
Memory
When removing the ignition key, it will store FATC's operating condition.
- When IGN ON after IGN

OFF during FATC
operation, the system
willoperate at the
previous before the
ignition off.

24.04.2008
Page 8 of 8

24.04.2008
Page 1 of 1
Conditioning > Controller > Manual Controller > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 8
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller >
Manual Controller > Troubleshooting
CONTROL PANEL TESTS
1.
2.
3.
4.
5.
6.
7.
Power supply check

Back light and Rear glass heat rays check
Blower check
Air conditioner check
Intake check and AQS check
Mode check
Temp check
POWER SUPPLY CHECK

In turning off IGN, battery supplies power for ordinary power, FATC connector A-3 through battery fuse. FATC performs
memory function by means of battery power supplied as described above. In turning on IGN, alternator is driven. At this
time, IG2 power generated in alternator FATC connector A-12 and A-25 terminal through IG1 fuse and air conditioner fuse
(10A). FAT carried out actual system operation by means of IG2 power supplied as described above.
ERROR DIAGNOSTICS
Symptoms
Causes
How to check
When IG is ON, memory function

error occurs
Battery power supply error
Check voltage of battery after turning off IG. If

10V and more, check FATC connector and if no
problem, check the inside of controller. If 10V
and less, check fuse or wiring state of battery
power source.
When IG is ON, system running

error occurs
IG2 power supply error
Check voltage of IG2 after turning on IG. If 10V

and more, check FATC connector and if no
problem, check the inside of controller. If 10V
and less, check fuse or wiring state of IG2
power source.

24.04.2008
Page 2 of 8
BACK LIGHT AND REAR GLASS HEAT RAYS CHECK

In turning on IG and then light switch, battery power is supplied for FATC connector A-2 terminal through wiring. The
supplied power passes connector A-1 terminal through light bulb in FATC and flows into reostart as shown in the above
figure. The brightness is adjusted according to resistance value of reostart.
ERROR DIAGNOSTICS
Symptoms
Causes
When light switch is ON, partial error

occurs in back light
Light bulb lighting error in FATC
When light switch is ON, entire error

occurs in back light
Light power supply error
How to check
Measure voltage of tail light shown in

the above figure after switching on light.
If 10V and more, check FATC connector
and if no problem, measure signal
voltage of reostart shown in the above
figure. If 8V and more, check reostart
wiring and reostart.
If tail light is below 1V, check tail light
wiring.

24.04.2008
Page 3 of 8
BLOWER CHECK
Perform the blower check in manual blower running state because it is difficult to check blower at automatic control. Blower
is controlled from level l to level 7 equally as in button operation and running logic. In turning on IG, blower relay is ON and
voltage of 0.1 to 1.4V is transferred from FATC connector A-4 terminal to base source of power TR according to FATC
control (selectable from level 1 to level 7). At this time, voltage of blower motor's both ends is determined according to
collector voltage of FATC connector A-5 terminal. If FATC is controlled in level 7, GND(0V) is supplied for FATC
connectorA-18 terminal and high blower relay is driven.
ERROR DIAGNOSTICS
Symptoms
Causes
How to check
Amount of wind is wrong at manual Power TR error

selection of blower
Check voltage of blower motor's both ends.

(Level 1: 3.8V, Level 2: 5.2V, Level 3: 6.5V,
Level 4: 7.9V, Level 5: 9.2V, Level 6: 10.6V,
Level 7: 13.5V [high-relay operation])
Measure voltage of each terminal and if there is
difference more than 0.6V, check power TR.
Blower wind is discharged despite

pressing OFF switch
Power TR change
Power TR error

24.04.2008
Page 4 of 8
AIR CONDITIONER CHECK

11V is outputted from connector A-17 terminal in turning on INSULATING and pressing air conditioner switch. However,
although 11V is outputted from FATC connector A-17 terminal, compressor clutch isn't driven. Wind of air conditioner is
discharged if only compressor clutch works. Output signal from air conditioner is inputted in engine computer through triple
switch. Then, the engine computer considers several conditions and when output of air conditioneris judged to be practical,
it gives GND to signal terminal of air conditioner relay. Accordingly, relay of air conditioner is ON and compressor clutch
works. Triple switch checks pressure of refrigerant flowing through pipe and turnson/off switches in it according to
standard. So, it controls that output signalof air conditioner outputted from FATC is inputted into engine computer, and also
speed of condenser fan according to pressure level. (For high pressure, high-speed and for low pressure, low-speed.
ERROR DIAGNOSTICS
Symptoms
Wind of air conditioner isn't
discharged into vehicle despite
switching on air conditioner.
Causes
Signal output error of air
conditioner
How to check
Switch on air conditioner and measure voltage
of FATC connector A-17 terminal as shown in
the above figure. If 9V and more, check triple
switch,air conditioner relay and ECM.
Switch on air conditioner and measure voltage
of FATC connector A-17 terminal as shown in
the above figure. If 1V and less, check input
value ofevaporator sensor.
Input error of evaporator sensor
If evaporator sensor is disconnected or short or

voltage of its inputsource is more than 3.0V
(below 0.5C), output of air conditioner isn't
made.

24.04.2008
Page 5 of 8
INTAKE AND AQS CHECK

In turning on IG and selecting outdoor mode with indoor switch, 12V is outputted from FATC connector A-23 terminal, 0V is
supplied for A-10 terminaland motor works in direction of outdoor. In selecting indoor mode with indoorswitch, 12V is
outputted from FATC connector A-10 terminal, 0V is supplied for A-23 terminal and motor works in direction of indoor.
ERROR DIAGNOSTICS
Symptoms
Causes
How to check
Outdoor mode running error
Power supply error in actuator
Separate connector linked with actuator,

select outdoor mode with indoor switch
and measure voltage of FATC
connector A-23 terminal. If 8V and
more, check actuator or wiring state and
if 9V and less, check the inside of
controller.
Indoor mode running error
Power supply error in actuator
Select indoor mode in the above method

and measure voltage of FATC
connector A-10 terminal. If 8V and
more, check actuator or wiring state and
if 9V andless, check the inside of
controller
Fixed in outdoor or indoor mode at

AQS selection
AQS signal terminal output error
Select AQS switch and measure AQS

signal terminal as shown in the above
figure. If there is no change of voltage
over 10 min, check AQS.

24.04.2008
Page 6 of 8
MODE CHECK
In turning on IG and selecting mode switch, sequential operation begins in order of Vent Bi-level Blower Mix. DIP
mode works regardless of order at selecting it. In selecting Vent mode as mode switch, GND(0V) is supplied for FATC
connector A-14(Vent) terminal. Voltage of 9V and more is set in the rest terminal A-15(DEF) and motor drive IG in mode
actuator which receives the signal, works in direction of vent mode setup. Vent, Built-in-level, Blower, Mix and Defrost
mode can be selected in themethod described above.
ERROR DIAGNOSTICS
Symptoms
Specific mode isn't selected.
Mode selection is impossible
Causes
How to check
Signal transmission error of selected

mode
Measure voltage of selected mode wiring

without separating connector linked with
actuator. If 8V and more, check the inside of
controller.
Mode actuator running error
If 1V and less at measuring in the above

method, check mode actuator and wiring
state.
Internal error of mode actuator
If motor driver IG built in mode actuator is

bad, mode selection is impossible. When
mode isn't selected though GND(0V) is
supplied for selected mode wiring after
selecting mode in controller, its cause is
internal failureof mode actuator.

24.04.2008
Page 7 of 8
TEMP CHECK
In adjusting temp switch from 32C to 17C, 11V is outputted from FATC connector A-9 terminal, 0V is supplied for A-22
terminal and temp motor works in direction of COOL. In adjusting temp switch from 17C to 32C, 11V is outputted from
FATC connector A-22 terminal, 0V is supplied for A-9 terminal and temp motor works in direction of WARM. When temp
actuator has to move to a certain location for its automatic control, temp feedback signal terminal moves equally in temp
actuator and informs controller of location of temp actuator through FATC connector B-10 terminal. Comparing original
value with inputted value, it works until they are same. If 4.9V and more is inputted in B-10 terminal, it is regarded as
disconnection. If 0.1V and less is inputted in B-10 terminal, it is regarded as short-circuit. In the case of disconnection or
short-circuit as a result of self-diagnostic, substitute control is carried out as follows.
If setup temperature is 17C to 24.5C, set to MAX COOL.
If setup temperature is 25C to 32.0C, set to MAX WARM.
ERROR DIAGNOSTICS
Symptoms
Temp actuator running error
Causes
How to check
Power supply error in temp actuator
After altering 17C to 32C and advers ely,

measure voltage ofA-22 terminal. If Both of
them are 9V and more, check temp actuator
and peripheral wiring state and if one or
both of them are 5V and less, its cause is
internal failure of FATC.
Sensor (+5) power supply error
If automatic control isn't operated smoothly,

measure voltage of FATC connector B- 8
terminal. If under 4.8V or over 5.2V, its
cause is internal failure of FATC.
Driver error of temp actuator
If No. 20 is outputted as a result of selfdiagnostic, check temp actuatordriver.

24.04.2008
Page 8 of 8

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > General Information,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > General Information
GENERAL
The SRS (Airbag) consists of : a driver airbag module located in the center of the steering wheel, which contains
a folded cushion and an inflator unit ; a passenger airbag module located in the passenger side crash pad which
contains a folded cushion together with an inflator unit ; side airbag modules located in the driver and passenger
seat which contain folded cushions and inflator units; SRSCM located on the floor center console core which
monitors the system,; an accelerometer which senses vehicle deceleration,; a spring interconnection (clock
spring) located within the steering column; system wiring and wiring connectors; and a knee bolster located
under the steering column. The impact sensing function of the SRSCM is carried out by the electronic
accelerometer that continuously measures the vehicle's acceleration and delivers a corresponding signal through
an amplifying and filtering circuit to the microprocessor. Deployment of the airbag is designed to occur in frontal
or near-frontal side impacts of moderate to severe force.
CUSTOMER CAUTIONS
Further, if a mistake is made in servicing the airbag system, it is possible that the airbag may fail to operate when
required.
1. Be sure to proceed with airbag related service only after approx. 30 seconds or longer from the time the
ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the
battery. The airbag system is equipped with a back-up power source to assure the deployment of airbags
when the battery cable is disconneted during an accident. The back-uppower is available for approx. 150ms.
2. When the negative(-) terminal cable is disconnected from the battery, the clock and audio system's memory
will be wiped out. So before starting work, make a record of the contents of the audio system's memory. When
the work is finished, reset the audio system and adjust the clock.
3. Symptoms of malfunction of the airbag system are difficult to detect, so the diagnostic codes become the most
important source of information when troubleshooting.
4. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the
battery.
5. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
6. Never attempt to disassemble and repair the airbag modules (DAB, PAB, SAB, BPT), clock spring and wiring
in order to reuse them.
7. If any component of SRS has been dropped, or if there are cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
8. After work on the airbag system is completed, perform the SRS SRI check. The airbag indicator lamp can be
triggered by faults in other circuit in some cases. Therefore if the airbag indicator lamp goes on, be sure to
erase the DTC codes using Hi-scan just after repairing or replacing the troubled parts,including the fuse.
9. Especially when carring out body welding, never fail to disconnect the battery's negative (-) terminal.
SRSCM
The SRS airbag system has sophisticated electrical and electronic components. Therefore the airbag operating
components should be handled very carefully.
The SRSCM will deploy the airbag modules by sensing the frontal impact sensed by the sensor built in to the
SRSCM.
1. DC/DC convertor : The DC/DC converter in the power supply includes a step-up and a step-down converter,
which provides the firing voltage for four firing circuits and the internal operating voltage. If the internal
operatingvoltage falls below a defined threshold, a reset is executed.
2. Arming sensor/safing sensor : The arming/safing sensor built in to the airbag firing circuit has the function of
arming the airbag circuit under all required deployment conditions and maintaining the airbag firing circuits
unarmed under normal driving conditions. The safing sensor is a dual-contact electromechanical switch that
closes if it experiences a deceleration exceedinga specified threshold.
3. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period
when the vehicle voltage is low or if lost in avehicle frontal crash.

24.04.2008
Page 2 of 2
4. Malfunction detection : The SRSCM continuously monitors SRS operating status while the ignition key is
turned on and detects possible malfunctions in the system. The malfunction can be displayed in the form of a
diagnostictrouble code using the Hi-Scan Pro.
5. MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends a signal to the
indicator lamp on the instrument cluster towarn the vehicle driver.
The MIL indicator is the key item in notifying the driver of SRS faults. It verifies lamp and SRSCM operation by
flashing 6 times when the ignitionswitch is first turned on.
6. Malfunction recording : Once a fault occurs in the system, the SRSCM records the fault in memory in the form
of a DTC, which can only be erasedby the Hi-Scan Pro.
7. Data link connector : SRSCM memory stored is linked through this connector located underneath the driver
side crash pad to an external output devicesuch as the Hi-Scan Pro.
8. What if only BPT's deploy
9. Crash output
The crash output is used to unlock the doors in case of a crash. The crash output is : 0-200 A in OFF mode
and 200mA in ON mode. During theunlock command, the switch is closed for 200 mS.
SRSCM (SUPPLEMENTAL RESTRAINTS SYSTEM CONTROL MODULE)

1. When removing the airbag module or handling a new airbag module, it should be placed with the pad top
surface facing up. In this case, the twin-lock type connector lock lever should be in the locked state and care
should be taken to place it so the connecter will not be damaged. Do not store a steering wheel pad on top of
another one. (Storing the pad with its metallic surface up may lead to a serious accident if the airbag should
inflate accidentally.)
2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
3. Store the airbag module where the ambient temperature remains below 93C (200F), without high humid ity
and away from electrical noise.
4. During electric welding, disconnect the airbag under the steering column near the MULTI-FUNCTION
SWITCH connector before starting work.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > Special Service Tools
SPECIAL SERVICE TOOL

Illustration
Use
0957A-34100A
Deployment tool
Airbag deployment tool

PAB, SAB : 0957A-38100
DAB, BPT : 0957A-38500
0957A-38200
Dummy
Simulator to check the

resistance of each wiring
harness
Dummy adapter
PAS, SAB : 0957A-38300
DAB, BPT : 0957A-1C000
0957A-38100
Deployment adapter
Use with deployment tool.
0957A-38500
Deployment adapter
Use with deployment tool.
0957A-38300
Dummy adapter
Use with dummy.
0957A-1C000
Dummy adapter
Use with dummy.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control Module (SRnodeM)
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System
Control Module (SRnodeM) > Schematic Diagrams
SRSCM CONNECTOR DAB+PAB+SAB+BPT
PIN NO.
Function
Input/output
Driver belt pretensioner, High
Output
Driver belt pretensioner, Low
Output
Passenger belt pretensioner, High
Output
passenger belt pretensioner, Low
Output
Battery supply
Input
GND
Input
Warning lamp
Driver seat belt buckle switch, High
K-diagnostic line
10
Driver airbag, High
Output
11
Driver airbag, Low
Output
12
Passenger seat belt buckle switch, High
13
Passenger airbag, High
Output
14
Passenger airbag, Low
Output
15
Not used
16
Driver side airbag, High
Output
17
Driver side airbag, Low
Output
18
Passenger side airbag, Low
Output
19
Passenger side airbag, High
Output
20
Driver satellite sensor, High
Input
21
Passenger satellite sensor, High
Input
22
Not used
23
Not used
24
Not used
25
Not used
26 ~ 27
Shorting bar
28 ~ 29
Shorting bar
30
31 ~ 32
Battery voltage output for seat buckle switch
Output
Input
Input/output
Input
Output
Shorting bar
33
Driver seat belt buckle switch, Low
34
Crash output
Output
35 ~ 36
Shorting bar
37
Passenger seat belt buckle switch, Low
Input
Input

24.04.2008
Page 2 of 2
38 ~ 39
40
41 ~ 42
43 ~ 44
Shorting bar
Not used
Shorting bar
Shorting bar
45
Driver satellite sensor, Low
Input
46
Passenger satellite sensor, Low
Input
47
Not used
48
Not used
49
Not used
50
Not used

24.04.2008
Page 1 of 4
> Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint
System Control Module (SRnodeM) > Description and Operation
SRS HARNESS
SRSCM INDEPENDENT LAMP ACTIVATION
1. Loss of ignition voltage supply to the SRSCM : lamp turned on continuously.

2. Loss of internal operating voltage : lamp turned on continuously.
3. SRSCM not connected : lamp turned on through shorting bar in wiring harness connector.
MIL OPERATING METHOD
CLOCK SPRING
The clock spring (coil spring) consists of two current carrying coils. It is attached between the steering column and the
steering wheel. It allows rotation of the steering wheel while maintaining continuous contact of the deployment loop through
the inflator module.
SATELLITE SENSOR
The SRSCM is supported with the side airbag function by two satellites, which act as intelligent acceleration sensors and
as such back up the central airbag controller. Both the satellites continuously report the system statuson the left and righthand sides of the vehicle to the SRSCM.
When the ignition is ON, never cause a sudden shock around the installation area of the satellite sensor by a hammer,

24.04.2008
Page 2 of 4
etc. Otherwise it could cause the airbag system to unexpectedly deploy during servicing.
SRSCM
The SRS airbag system has sophisticated electrical and electronic components. Therefore the airbag operating
components should be handled very carefully.
The SRSCM will deploy the airbag modules by sensing the frontal impact sensed by the sensor built in to the SRSCM.
1. DC/DC convertor : The DC/DC converter in the power supply includes a step-up and a step-down converter, which
provides the firing voltage for four firing circuits and the internal operating voltage. If the internal operating voltage falls
below a defined threshold, a reset is executed.
2. Arming sensor/safing sensor : The arming/safing sensor built in to the airbag firing circuit has the function of arming the
airbag circuit under all required deployment conditions and maintaining the airbag firing circuits unarmed under normal
driving conditions. The safing sensor is a dual-contact electro mechanical switch that closes if it experiences a
deceleration exceeding a specified threshold.
3. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period when the
vehicle voltage is low or if lost in a vehicle frontal crash.
4. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period when the
vehicle voltage is low or if lost in a vehicle frontal crash.
5. Malfunction detection : The SRSCM continuously monitors SRS operating status while the ignition key is turned on and
detects possible malfunctions in the system. The malfunction can be displayed in the form of a diagnostic trouble code
using the Hi-Scan Pro.
6. MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends a signal to the indicator lamp
on the instrument cluster to warn the vehicle driver.
The MIL indicator is the key item in notifying the driver of SRS faults. It verifies lamp and SRSCM operation by flashing
6 times when the ignition switch is first turned on.
7. Malfunction recording : Once a fault occurs in the system, the SRSCM records the fault in memory in the form of a
DTC, which can only be erased by the Hi-Scan Pro.
8. Data link connector : SRSCM memory stored is linked through this connector located under neath the driver side crash
pad to an external output device such as the Hi-Scan Pro.
9. What if only BPT's deploy.
10. Crash output
The crash output is used to unlock the doors in case of a crash. The crash output is : 0 ~ 200 A in OFF mode and
200mA in ON mode. During the unlock command, the switch is closed for 200 mS.
DIAGNOSIS WITH SCAN TOOL

CHECK PROCEDURES
1. Connect the Hi-Scan Pro DLC to the vehicle's data link connector located underneath the dash panel.
2. Turn the ignition key to the "ON" position and turn the Hi-Scan Pro ON.
3. Perform the SRS diagnosis according to the vehicle model configuration.
4. If a fault code is assured, then replace the component. Never attempt to repair the component.
5. If the Hi-Scan Pro finds that a component of the system is faulty, there is a possibility that the fault is not in the
component, but in SRS wiringor connector.
SPECIFICATION

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AIRBAG SQUIB RESISTANCE LIMITS

DAB
R 1.06
1.80 R 3.40
R 6.70
1.06 < R < 1.80
3.40 < R < 6.70
Resistance too low
Fault definitely detected
Resistance whithin tolerance
Definitely no fault detected
Resistance too high
Tolerance band
Fault may or may not be detected
Resistance too low
Resistance too high
Tolerance band
PAB, SAB, BPT

R 0.4
1.6 R 2.8
R 5.4
0.4 < R < 1.6

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2.8 < R < 5.4

24.04.2008
Page 1 of 1
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental
Restraint System Control Module (SRnodeM) > Components and Components Location
SYSTEM COMPONENT AND LAYOUT

24.04.2008
Page 1 of 34
> Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control
Module (SRnodeM) > Troubleshooting
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE

OPTIONS : DAB + PAB + SAB + BPT
DTC No.
Fault description
B1111
Battery voltage too high
B1112
Battery voltage too low
B1346
Driver airbag (DAB), Resistance too high
B1347
Driver airbag (DAB), Resistance too low
B1348
Driver airbag (DAB), Short to GND
B1349
Driver airbag (DAB), Short to Battery
B1352
Passenger airbag (PAB), Resistance too high
B1353
Passenger airbag (PAB), Resistance too low
B1354
Passenger airbag (PAB), Short to GND
B1355
Passenger airbag (PAB), Short to Battery
B1361
Driver seat belt pretensioner (DBPT), Resistance too high
B1362
Driver seat belt pretensioner (DBPT), Resistance too low
B1363
Driver seat belt pretensioner (DBPT), Short to GND
B1364
Driver seat belt pretensioner (DBPT), Short Battery
B1367
Passenger seat belt prestensioner (PBPT), Resistance too

high
B1368
Passenger seat belt prestensioner (PBPT), Resistance too

low
B1369
Passenger seat belt prestensioner (PBPT), Short to GND
B1370
Passenger seat belt prestensioner (PBPT), Short to Battery
B1378
Driver side airbag (DSAB), Resistance too High
B1379
Driver side airbag (DSAB), Resistance t0o Low
B1380
Driver side airbag (DSAB), Short to GND
B1381
Driver side airbag (DSAB), Short to Battery
B1382
Passenger side airbag (PSAB), Resistance too high
B1383
Passenger side airbag (PSAB), Resistance too low
B1384
Passenger side airbag (PSAB), Short to GND
B1385
Passenger side airbag (PSAB), Short to Battery
B1400
Satellite left side sensor defect
B1401
Satellite sensor left side short to GND
B1402
Satellite sensor left side open/short to battery
B1403
Satellite right side sensor defect
B1404
Satellire sensor right side short to GND
B1405
Satellire sensor right side open/short to battery
B1409
Satellite left side sensor communication error
B1410
Satellite right side sensor communication error
B1511
Driver seat belt buckle switch open/short to battery
B1512
Driver seat belt buckle switch short to GND

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B1513
Passenger seat belt buckle switch open/short to battery
B1514
Passenger seat belt buckle switch short to GND
B1620
Airbag unit internal failure
B1650
SRSCM crash recorded
B1655
Side airbag crash recorded
B1657
Crash recorded-Belt pretensioner only
B1661
ECU mismatching
B2500
Warning lamp failure
The DAB is located in the steering wheel.

The PAB is located in the crash pad.
The DSAB is located in the left side of driver's seat.
The PSAB is located in the right side of passenger's seat.
CIRCUIT INSPECTION
DTC
B1111
B1112
Battery voltage too high (Vbaft 19.2V)

Battery voltage too low (Vbaft 7.2V)
CIRCUIT DESCRIPTION
INSPECTION PROCEDURE
1. Preparation
(1) Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
(2) Remove the DAB module.
(3) Disconnect the connectors of the PAB, left and right side airbags, belt pretensioners and satellite sensors.
(4) Disconnect the SRSCM connector.
Place the DAB with the front surface facing upward.

2. Check source voltage.
(1) Connect the negative (-) terminal cable to the battery.
(2) Turn the ignition switch ON.

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3. Does the SRS warning light turn off ?

[PREPARATION]
(1) Turn the ignition switch to LOCK.
(2) Connect the DAB module.
(3) Connect the PAB connector, left and right side airbag, belt pretensioner and satellite connectors.
(4) Connect the SRSCM connector.
(5) Turn the ignition switch ON.
CIRCUIT INSPECTION
DTC
B1348
DAB short to
ground
B1354
PAB short to
ground
B1363
DBPT short to
ground
B1369
PBPT short to
ground
B1380
DSAB short to
ground
B1384
PASB short to
ground

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B1401
Satellite sensor left

side short to
ground
B1404
Satellite sensor
right side short to
ground
CIRCUIT DESCRIPTION
DTC Detecting Condition
Short circuit in squib wire harness (to ground)

Squib malfunction
Clock spring malfunction
SRSCM malfunction
Trouble Area
DAB squib
PAB squib
DSAB squib
PSAB squib
BPT squib
Satellite sensor
Clock spring
SRSCM
Wire harness
WIRING DIAGRAM
1. Preparation
(1) Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
(3) Disconnect the connectors of the PAB, left and right side airbag, space belt pretensioner and satellite sensor.
(4) Disconnect the connector of the SRSCM.

2. Check DAB squib circuit.

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[CHECK]
For the connector (on the clock spring side) between clock spring and DAB, measure the resistance between DAB high
and body ground.
Resistance :
3. Check the PAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and PAB, measure the resistance between PAB high and
body ground.
Resistance :
4. Check PSAB and DSAB squib circuits.
[CHECK]
For the connector (on the SRSCM side) between SRSCM and the SABs, measure the resistance between the SABs
high and body ground.
Resistance :

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5. Check the BPTs squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and BPT, measure the resistance between the BPTs high
and body ground.
Resistance :
6. Check the Satellite sensor circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the Satellite sensor, measure the resistance between
the Satellite high and body ground.
Resistance :
7. Check the SRSCM.

[PREPARATION]
A. Connect the connector to SRSCM.
B. Using a service wire, connect the DAB high and DAB low on the clock spring side of connector.
C. Using a service wire, connect the PAB high and low on SRSCM side of connector.
D. Connect the SABs and BPT using the same method.
E. Connect the negative (-) terminal cable to battery, and wait it least 30 seconds.

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[CHECK]
A. Turn ignition switch to ON, and wait for at least 30 seconds.
B. Clear any codes stored in the memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait for 30 seconds.
D. Turn the ignition switch to ON, and wait for 30 seconds.
E. Using the Hi-Sacn Pro, check for DTCs.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this check.
8. Check the DAB squib.

[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the DAB connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.
[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory of the Hi-Scan Pro.
E. Using the Hi-Scan Pro, check for DTCs.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

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9. Check the PAB squib.

[PREPARATION]
C. Connect the PAB connector.
D. Connect the negative (-) terminal cable from the battery, and wait for 30 seconds.
[CHECK]
B. Clear the malfunction code stored in the memory with the Hi-Scan Pro.
There is no DTC.
[HINT]
10. Check the SABs squib.

[PREPARATION]
C. Connect the SAB connector.
[CHECK]
D. Turn the ignition switch ON, and wait for 30 seconds.
There is no DTC.
[HINT]
Codes other than these ones may be output at this time, but they are not relevant to this checking procedure.

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Check the DSAB using the same procedure.
11. Check BPT squib.

[PREPARATION]
A. Turn the ignition swich to LOCK.
C. Connect the BPTs connector.
[CHECK]
A. Turn the ignition switch to ON, and wait for 30 seconds.
There is no DTC.
[HINT]
12. Check the Satellite sensors.

[PREPARATION]
A. Turn ignition switch to LOCK.
B. Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the Satellite sensor connector.
D. Connect the negative (-) terminal cable from the battery, and wait at least 30 seconds.

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[CHECK]
A. Turn the ignition switch to ON, and wait at least 30 seconds.
B. Clear the malfunction code stored in memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait at least 30 seconds.
D. Turn the ignition switch to ON, and wait at least 30 seconds.
There is no DTC.
[HINT]
13. Check clock spring circuit.

[PREPARAION]
Disconnect connector between SRSCM and clock spring.
[CHECK]
Measure resistance between the DAB high on the clock spring side of connector between clock spring and DAB and
body ground.
Resistance :
CIRCUIT INSPECTION
B1349
DAB short to
battery
B1355
PAB short to
battery

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B1364
DBPT short to
battery
B1370
PBPT short to
battery
B1381
DSAB short to
battery
B1385
PSAB short to
battery
B1402
Satellite left side

short to battery
B1405
Satellite right side

short to battery
DTC
CIRCUIT DESCRIPTION
Short circuit in squib wire harness (to B+)

Squib malfunction
Clock spring cable malfunction
SRSCM malfunction
Trouble Area
DAB squib
PAB squib
DSAB or PSAB squib
BPT squib
Satellite sensor
Wire harness
WIRING DIAGRAM
1. Preparation
(1) Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
(3) Disconnect the connectors of the PAB, left and right side airbag,belt pretensioner and satellite sensor.
(4) Disconnect the connector of the SRSCM.

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2. Check the DAB squib circuit.
[CHECK]
For the connector (on the clock spring side) between the clock spring and DAB, measure the voltage between the DAB
high and body ground.
Voltage : 0 V
3. Check the PAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and PAB, measure the voltage between the PAB high
and body ground.
Voltage : 0 V
4. Check the SAB squib circuit.
[CHECK]
For the connector (on the SRSCM side) between the SRSCM and SAB, measure the voltage between the SAB high
and body ground.
Voltage : 0 V

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5. Check the BPTs squib circuits.
[CHECK]
For the connector between SRSCM and the BPTs, measure the voltage between the BPTs high and body ground.
Voltage : 0 V
6. Check the Satellite sensor circuit.
[CHECK]
For the connector between the SRSCM and the Satellite sensor, measure the voltage between the Satellite sensor high
and body ground.
Voltage : 0 V
7. Check the SRSCM.

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[PREPARATION]
A. Connect the connector to the SRSCM.
B. Using a service wire, connect the DAB high and low on the clock spring side of connector between the clock spring
and the DAB.
C. Using a service wire, connect the PAB high and low on the SRSCM side of the connector between the SRSCM and
the PAB.
D. Using a service wire, connect the SAB high and low on the SRSCM side connector between the SRSCM and the
SAB.
E. Using a service wire, connect the BPT high and low on the SRSCM side connector between the SRSCM and the
BPT.
F. Using a service wire, connect the satellite high and low on the SRSCM side connector between the SRSCM and the
satellite sensor.
G. Connect negative (-) terminal cable to battery, and wait at least 30 seconds.
[CHECK]
B. Clear the malfunction code stored in memory with the Hi-Scan Pro.
There is no DTC.
[HINT]

[PREPARATION]
[CHECK]
A. Turn the ignition switch ON, and wait for at least 30 seconds.

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There is no DTC.
[HINT]

[PREPARATION]
[CHECK]
There is no DTC.
[HINT]
10. Check the SAB squib.

[PREPARATION]

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[CHECK]
There is no DTC.
[HINT]
11. Check the BPTs squib.

[PREPARATION]
A. Turn the ignition swich to LOCK.
C. Connect the BPTs connector.
[CHECK]
A. Turn the ignition switch to ON, and wait for 30 seconds.
There is no DTC.
[HINT]

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12. Check the Satellite sensors.

[PREPARATION]
A. Turn ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the Satellite sensor connector.
D. Connect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
[CHECK]
B. Clear the malfunction code stored in memory with Hi-scan.
There is no DTC.
[HINT]
13. Check the Clock spring.

[PREPARAION]
B. Disconnect the connector between the SRSCM and the clock spring.
[CHECK]
Turn the ignition switch ON, and measure the voltage between the DAB high side and the body ground.
Voltage : 0V

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CIRCUIT INSPECTION
B1346
B1347
DTC
DAB resistance too high (R 6.70 )

DAB resistance too low (R 1.06 )
CIRCUIT DESCRIPTION
Trouble Area
Too high or low resistance between DAB high (+) wiring

harness and DAB low (-) wiring harness of squib.
DAB squib
DAB malfunction
Clock spring malfunction
SRSCM malfunction
Clock spring
SRSCM
Wire harness
WIRING DIAGRAM
1. Preparation

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2. Check the DAB resistance.
[PREPARATION]
Release the airbag activation prevention mechanism on SRSCM side of airbag squib side. Connect the dummy (0957A38200) and dummy adapter (0957A-38400)to the clock spring side connector.
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester.
Before checking the resistance, you have to insert the shorting bar insert plastic that is attached to the diagnosis
checker into the SRSCM connector.
[CHECK]
Measure the resistance between the DAB high (+) and low (-).
1.80 R 3.40

[PREPARATION]
[CHECK]
E. Using Hi-Scan Pro, check the DTC.

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There is no DTC.
[HINT]
4. Check the clock spring.

[PREPARAION]
Disconnect the connector between the SRSCM clock spring, and connect the dummy connector (0957A-38200) and
dummy adapter (0957A-38400) to the clockspring side connector.
[CHECK]
Measure the resistance between the DAB high (+) and low (-).
1.80 R 3.40
CIRCUIT INSPECTION
B1352
B1353
DTC
PAB resistance too high (R 5.4 )

PAB resistance too low (R 0.4 )
CIRCUIT DESCRIPTION
Trouble Area
Too high or low resistance between PAB high (+) wiring

harness and PAB low (-) wiring harness of squib.
PAB squib
PAB malfunction
SRSCM malfunction
SRSCM
Wire harness
WIRING DIAGRAM

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1. Preparation

2. Check the PAB resistance.
[PREPARATION]
Release the airbag activation prevention mechanism on the SRSCM side of the airbag squib side. Connect the dummy
(0957A-38200) and dummy adapter(0957A-38300) to PAB connector of the SRSCM connector side.
checkerinto the SRSCM connector.

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[CHECK]
Measure the resistance between the PAB high (+) and the PAB low (-).
1.6 R 2.8

[PREPARATION]
[CHECK]
There is no DTC.
[HINT]
CIRCUIT INSPECTION
DTC
B1378
B1379
B1382
B1383
DSAB Resistance too high (R 5.4 )

DSAB Resistance too low (R 0.4 )
PSAB Resistance too high (R 5.4 )
PSAB Resistance too low (R 0.4 )

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CIRCUIT DESCRIPTION
Trouble Area
Too high or low resistane between SAB high (+) wiring

harness and SAB low (-) wiring harness of squib.
SAB squib
SAB malfunction
SRSCM malfunction
SRSCM
Wire harness
WIRING DIAGRAM
1. Preparation

2. Check the SAB resistance.
[PREPARATION]

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(0957A-38200) and dummy adapter(0957A-38300) to the SAB connector of the SRSCM connector side.
checkerinto the SRSCM connector.
[CHECK]
Measure the resistance between the SAB high (+) and the SAB low (-).
1.6 R 2.8
3. Check the SAB squib.

[PREPARATION]
[CHECK]
There is no DTC.
[HINT]

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CIRCUIT INSPECTION
B1361
B1362
B1367
B1368
DTC
DBPT Resistance too high (R 5.4 )

DBPT Resistance too low (R 0.4 )
PBPT Resistance too high (R 5.4 )
PBPT Resistance too low (R 0.4 )
CIRCUIT DESCRIPTION
Trouble Area
Too high or low resistane between BPT high (+) wiring

harness and BPT low (-) wiring harness of squib.
BPT squib
BPT malfunction
SRSCM malfunction
SRSCM
Wire harness
WIRING DIAGRAM
1. Preparation

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2. Check the BPT resistance.
[PREPARATION]
(0957A-38200) and dummy adapter(0957A-38300) to the BPT connector of the SRSCM connector side.
[CHECK]
Measure the resistance between the BPT high (+) and the BPT low (-).
1.6 R 2.8
3. Check the BPT squib.

[PREPARATION]
C. Connect the BPT connector.
[CHECK]

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A.
B.
C.
D.
E.
Turn the ignition switch to ON, and wait for at least 30 seconds.
Clear the malfunction code stored in the memory with the Hi-Scan Pro.
Turn the ignition switch to LOCK, and wait for 30 seconds.
Turn the ignition switch to ON, and wait for 30 seconds.
Using Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
CIRCUIT INSPECTION
B1400
Satellite left side

defect
B1403
Satellite right side

defect
B1409
Satellite left
communication
error
B1410
Satellite right
communication
error
DTC
CIRCUIT DESCRIPTION
WIRING DIAGRAM
1. Preparation

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2. Check satellite circuit (communication error).
[PREPARATION]
Check continuity between the SRSCM connector and the satellite connector as high (+) and high, low (-) and low (-).
OK : Continuity
3. Check the satellite sensor (defect).

[PREPARATION]
C. Connect the satellite connector.
[CHECK]
E. Using the Hi-Scan Pro, check DTC.

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There is no DTC.
[HINT]
CIRCUIT INSPECTION
DTC
B1511
B1512
B1513
B1514
Driver seat belt switch open/short to

Battery
Driver seat belt switch short to GND
Passenger seat belt switch open/short
to Battery
Passenger seat belt switch short to
GND
CIRCUIT DESCRIPTION
1. Preparation
2. Check buckle switch sensor circuit (Short to GND/Battery).
[CHECK]
Measure the voltage and resistance of the seat belt switch high and body ground between the SRSCM connector and
the seat belt switch connector.
Resistance :
Voltage : 0V
3. Check the seat belt switch

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[CHECK]
Check the resistance with the switch on and off.
SWITCH OPEN : R = 4K 10% (Belted)
SWITCH OPEN : R = 1K 10% (Unbelted)
CIRCUIT INSPECTION
DTC
B2500
CIRCUIT DESCRIPTION
1. Check the fuse.
[PREPARATION]
A. Remove airbag fuse and airbag warning lamp fuse from the junction block.
B. Inspect the state of the fuses.
C. Replace if necessary.
2. Check the SRS warning lamp circuit.
[PREPARATION]
A. Connect the negative (-) terminal cable to the battery.
B. Turn the ignition switch to ON.
[CHECK]
A. Measure voltage at the harness side connector of the SRSCM.
Voltage : 9-16 V

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B. Check the SRS SRI (Service Reminder Indicator).

OK : SRS SRI ON
CIRCUIT INSPECTION
DTC
B1620
B1650
B1655
B1657
B1661

Side airbay crash recorded
ECU mismatching
CIRCUIT DESCRIPTION
1. Functional readiness of the firing circuit activation transistors.
2. Adequacy of deployment energy reserves.
3. Safing sensor integrity : detection of faulty closure.
4. Plausibility of accelerometer signal.
5. Operation of SRSCM components.
DIAGNOSIS WITH SCAN TOOL

CHECK PROCEDURES
1. Connect the Hi-Scan Pro DLC to the vehicle's data link connector located under neath the dash panel.
2. Turn the ignition key to the "ON" position and turn the Hi-Scan Pro ON.
3. Perform the SRS diagnosis according to the vehicle model configuration.
4. If a fault code is assured, then replace the component. Never attempt to repair the component.
5. If the Hi-Scan Pro finds that a component of the system is faulty, there is a possibility that the fault is not in the
component, but in SRS wiring or connector.

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SPECIFICATION

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AIRBAG SQUIB RESISTANCE LIMITS

DAB
R 1.06
1.80 R 3.40
R 6.70
1.06 < R < 1.80
3.40 < R < 6.70
Resistance too low
Resistance too high
Tolerance band
Resistance too low
Resistance too high
Tolerance band
PAB, SAB, BPT

R 0.4
1.6 R 2.8
R 5.4
0.4 < R < 1.6
2.8 < R < 5.4
INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE

OPTIONS : DAB + PAB + SAB + BPT
DTC No.
Fault description
B1111
Battery voltage too high
B1112
Battery voltage too low
B1346
Driver airbag (DAB), Resistance too high
B1347
Driver airbag (DAB), Resistance too low
B1348
Driver airbag (DAB), Short to GND
B1349
Driver airbag (DAB), Short to Battery
B1352
Passenger airbag (PAB), Resistance too high
B1353
Passenger airbag (PAB), Resistance too low
B1354
Passenger airbag (PAB), Short to GND
B1355
Passenger airbag (PAB), Short to Battery
B1361
Driver seat belt pretensioner (DBPT), Resistance too high

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B1362
Driver seat belt pretensioner (DBPT), Resistance too low
B1363
Driver seat belt pretensioner (DBPT), Short to GND
B1364
Driver seat belt pretensioner (DBPT), Short Battery
B1367
Passenger seat belt prestensioner (PBPT), Resistance too high
B1368
Passenger seat belt prestensioner (PBPT), Resistance too low
B1369
Passenger seat belt prestensioner (PBPT), Short to GND
B1370
Passenger seat belt prestensioner (PBPT), Short to Battery
B1378
Driver side airbag (DSAB), Resistance too High
B1379
Driver side airbag (DSAB), Resistance too Low
B1380
Driver side airbag (DSAB), Short to GND
B1381
Driver side airbag (DSAB), Short to Battery
B1382
Passenger side airbag (PSAB), Resistance too high
B1383
Passenger side airbag (PSAB), Resistance too low
B1384
Passenger side airbag (PSAB), Short to GND
B1385
Passenger side airbag (PSAB), Short to Battery
B1400
Satellite sensor driver side defect
B1401
Satellite sensor driver side short to GND
B1402
Satellite sensor driver side open/short to battery
B1403
Satellite sensor passenger side defect
B1404
Satellire sensor passenger side short to GND
B1405
Satellire sensor passenger side open/short to battery
B1409
Satellite sensor driver side communication error
B1410
Satellite sensor passenger side communication error
B1511
Driver seat belt buckle switch open/short to battery
B1512
Driver seat belt buckle switch short to GND
B1513
Passenger seat belt buckle switch open/short to battery
B1514
Passenger seat belt buckle switch short to GND
B1620
B1650
B1655
Side airbag crash recorded
B1657
B1661
ECU mismatching
B2500
The DAB is located in the steering wheel.

The PAB is located in the crash pad.
The DSAB is located in the out side of driver's seat.
The PSAB is located in the out side of passenger's seat.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control Module
(SRnodeM) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental
Restraint System Control Module (SRnodeM) > Repair procedures
REMOVAL
1. Disconnect the battery negative cable, and wait at least 30seconds before begining work.
2. Disconnect the airbag connectors.
3. Remove the center console. (see BD group).
4. Disconnect the connector from the SRS unit.
5. Remove the three bolts from the SRS unit, than pull out the SRS unit from the bracket.

24.04.2008
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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Description and Operation,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Description and Operation
FIELD DEPLOYMENT PROCEDURES
When handling the deployed airbag be careful that not the dust enters your eyes and always wear gloves to
avoid direct contact with the dust.
AIRBAG MODULE DISPOSAL PROCEDURES

Before disposing of a vehicle equipped with an airbag, or prior to disposing of the airbag module, be sure to first
follow the procedures described below to deploy the airbag.
AIRBAG REMOTE DEPLOYMENT DEVICES
Tool, Number, Name
Deployment tool (0957A-34100A)
SRS DEPLOYMENT ADAPTER HARNESS
DAB, BPT : 0957A-38500
PAB, SAB : 0957A-3810
Use
Deployment inside the vehicle (if the vehicle will no
longer be driven)
DISPOSAL PLAN
Take the following disposal steps.
CASE
DISPOSAL PLAN
Abnormal problems in airbag module
Deploy and discard
Car scrappinG
Deploy the airbag module with the SST
DAB, PAB, SAB, BPT
Crash (Deployed)
Discard
UNDEPLOYED AIRBAG MODULE DISPOSAL
1. If the vehicle is to be scrapped, junked, or otherwise disposed of, deploy the airbag inside the vehicle.
2. Since there is a loud noise when the airbag is deployed, avoid residential areas whenever possible. If
anyone is nearby, give warning of the impending noise.
3. Since a large amount of smoke is produced when the airbag is deployed, select a well-ventilated site.
Moreover, never attempt the test near a fireor smoke sensor.
DEPLOYMENT INSIDE THE VEHICLE

1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot.
2. Disconnect the negative (-) and positive (+) battery cables from the battery terminals, and then remove the
battery from the vehicle

24.04.2008
Page 2 of 3
Wait at least 30 seconds after disconnecting the battery cable before doing any further work.
3. Remove the center crash pad side cover.
4. Remove Airbag SRSCM connector.
5. Connect deployment tool to the connector of each module.
6. At location as far away from the vehicle as possible, press the push button (removed from the vehicle) to
deploy the airbag.
1. Before deploying the airbag in this manner, first check to be sure that there is no one in or near the
vehicle. Wear safety glasses.
2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow
it to cool before attempting to handle it. Although not poisonous, do not inhale gas from airbag
deployment. See Deployed Airbag Module Disposal Procedures for post-deployment handling
instructions.
3. If the airbag fails to deploy when the procedures above are followed, do not go near the module.
Contact your local distributor.
DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURES

1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool
before attempting to handle it.
2. Do not put water or oil on the airbag after deployment.
3. There may be adhered to the deployed airbag module, material that could irritate the eyes and/or skin, so
wear gloves and safety glasses when handling a deployed airbag module. If despite these precautions, the
material does get into your eyes or on your skin, immediately rinse the affected area with a large amount of
clean water. If any irritation develops, seek medical attention.
4. Tightly seal the airbag module in a strong vinyl bag for disposal.

24.04.2008
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5. Be sure to always wash your hands after completing this operation.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Components and Components Location,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Repair procedures, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Repair procedures
REMOVAL
1. Disconnect the negative battery cable and keep secure from battery.
2. Remove the side protect cover of steering wheel and airbag module mounting bolts using a hexagonal
wrench.
3. When disconnecting the connector of the clock spring from the airbag module, pull the airbag's lock toward
the outer side to spread it open.
When disconnecting the airbag module-clock spring connector, take care not to apply excessive force to
it.
4. Remove the drive airbag module.
The removed airbag module should be stored in a clean, dry place with the pad cover face up.

24.04.2008
Page 2 of 4
5. Remove the steering wheel using SST (09561-11002).
Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism.
REMOVAL
1. Never attempt to disassemble or repair the airbag module.

2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing
upward. Do not place anything on top of it.
4. Do not expose the airbag module to temperature over 93C (200F)
5. An undeployed airbag module should only be disposed in accordance with the procedures.
6. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester. If the circuit resistance is measured with a tester, accidental airbag deployment will
result in seriouspersonal injury.
7. Whenever the PAB is deployed it should be replaced with a new one assembled with an extension wire.
The squib is melt down if the PAB is deployed makingthe extension wire useless.
1. Disconnect the battery negative (-) terminal cable.
Wait at least 30 seconds.

24.04.2008
Page 3 of 4

3. Disconnect the PAB module connector.
4. Remove the crash pad assembly and then undo the PAB module. (Refer to the BD section)
5. The skin of the passenger airbag module is integrated with the crash pad, therefore, the crash pad must be
replaced if the PAB deploys.
INSPECTION
AIRBAG MODULE
Dispose the old one according to the specified procedure.
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in
serious personal injury.
1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for deformities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.
CLOCK SPRING
1. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a
new one.
2. Check connectors and protective tube for damage, and terminals for deformities.

24.04.2008
Page 4 of 4

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Passenger Airbag (PAB) Module >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module >
Passenger Airbag (PAB) Module > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Passenger Airbag (PAB) Module
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Passenger
Airbag (PAB) Module > Repair procedures
REMOVAL

4. Do not expose the airbag module to temperature over 93C (200F)
5. An undeployed airbag module should only be disposed in accordance with the procedures.
result in serious personal injury.
7. Whenever the PAB is deployed it should be replaced with a new one assembled with an extension wire.
The squib is melt down if the PAB is deployed making the extension wire useless.

3. Disconnect the PAB module connector.
4. Remove the crash pad assembly and then undo the PAB module. (Refer to the BD section)

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5. The skin of the passenger airbag module is integrated with the crash pad, therefore, the crash pad must be
replaced if the PAB deploys.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Side Airbag (SAB) Module >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Side Airbag
(SAB) Module > Repair procedures
REMOVAL
2. Disconnect the side airbag harness 2p connector.
3. Remove the seat assembly and seat-back cover.

4. Remove the two mounting nuts and the side airbag.

result in serious personal injury.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Satellite Sensor > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Satellite Sensor >
Repair procedures
REMOVAL
1. Disconnect the negative battery cable and keep secure from battery.
2. Remove the front seat.

3. Remove the door scuff trim.
4. Remove the guarter trim. After removing seat belt lower anchor bolt.
5. Remove the floor carpet.

6. Disconnect the satellite sensor connector and remove the satellite sensor.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Seat Belt Pretensioner > Seat Belt Retractor
Pretensioner (BPT) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Seat Belt
Pretensioner > Seat Belt Retractor Pretensioner (BPT) > Repair procedures
REMOVAL
1. Disconnect the battery negative (-) terminal.
3. Remove the quarter trim after removing seat belt lower anchor bolt.
4. Remove the upper anchor plate cover and upper anchor plate.
5. Remove the lower anchor plate and front seat belt.

24.04.2008
Page 2 of 2
1. Never attempt to disassemble or repair the BPT.

2. Do not drop the BPT or allow contact with water, grease, oil.
Replace it if a dent, crack, deformation or rust are detected.
3. Do not place anything on the BPT.
4. Do not expose the BPT to temperature over 93C(20 0F).
5. BPT functions one time only. Be sure to replace the BPT after it is deployed.
6. Be sure to wear gloves and safety goggles when handling the deployed BPT.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General Information > Special
Service Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General
Information > Special Service Tools
SPECIAL TOOLS
Illustration
Use
09793-21000
Door hinge adjusting wrench
Adjustment, removal, and installation of the

door hinge
09800-21000
Ornament remover
Trim removal
09853-31000
Headliner clip remover
Removal of the headliner clip
09861-31100
Sealant cut-out tool
Cutting the sealant of the windshield (use

with 09861-31200)
09861-31200
Sealant cutting blade
Cutting the sealant of the windshield (use

with 09861-31100)
09861-31300
Sealant gun
Application of the sealant to the windshield
09861-31400
Glass holder
Removal and installation of the windshield
09861-31000
Windshield moulding remover
Removal of the windshield moulding

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General
TROUBLESHOOTING
Trouble symptom
Probable cause
Water leaks from sunroof
Dirt accumulated in drain tube
Clear dirt inside of drain
Clogged drain tube
Blow air into drain to remove dirt
Broken or dislocated drain tube, defective

or cracked clip
Check tube installation and

flange contact
Deteriorated roof lid weatherstrip
Replace
Excessive roof lid-to-body clearance and

improperly fitted weatherstrip
Adjust
Wind noise around sunroof
Loose or deformed deflector, gaps in body

work
Retighten adjust or replace
Sunroof makes a noise when

moved
Foreign particles lodged in guide rail
Check drive cable and guide

rails for foreign particles
Loose guide rails and lid
Retighten
Motor runs but sunroof does not Foreign particles lodged in guide rail
move or moves only halfway
Noise in motor (clutch slipping

noise from motor when sunroof
is fully opened or closed is not
an unusual noise.)
Remedy
Check drive cable and guide

rails for foreign particles
Incorrect engagement of motor pinion with

drive cable
Check for loose motor

installation and damaged pinion
Decrease in motor's clutch slipping force
Adjust
Increased sunroof sliding resistance or

interference of sunroof with drive cables,
weatherstrip, etc. due to maladjustment of
sunroof
Adjust or replace
Incorrect engagement of motor pinion with

drive cable
Check pinion installation and

retighten motor
Worn out or damaged motor pinion bearing Replace motor assembly

Worn out or deformed drive cable
Replace
Incorrect window glass installation
Adjust position
Damaged or faulty regulator arm or

regulator
Correct or replace
Incorrect door installation
Adjust position
Defective door check assembly
Correct or replace
Door hinge requires grease
Apply grease
Striker and latch not properly aligned
Adjust
Incorrectly installed hood
Adjust
Incorrect hood bumper height
Adjust
Water leak through windshield

and rear window
Defective seal
Fill with sealant
Defective flange
Correct
Wind noise around door
Weatherstrip not holding firmly
Adjust fit of door
Improperly installed weatherstrip
Repair or replace
Improperly closed door
Adjust
Door glass fails to operate up

and down
Door does not open or close

completely
Hood does not open or close

completely

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Improperly fit door
Adjust
Improper clearance between door glass

and division channel
Adjust
Deformed door
Repair or replace

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General
SPECIFICATIONS
Hood
- Type
Rear hinged, front opening type (gaslifter type)
Door
- Construction
- Regulator system
- Locking system
Front hinged, full door construction

Wire drum type
Pin-fork system
Tailgate
- Type
Inner hinged, gas lifter type
Glass thickness mm(in.)

- Windshield glass
- Door glass
- Quarter fixed glass
- Tailgate glass
5 (0.20)
5 (0.20)
3.2 (0.13)
3.5 (0.14)
Seat belt
3 point type with E.L.R
E.L.R. : Emergency Locking Retractor
TIGHTENING TORQUE
Nm
Kgcm
lbft
Door
- Door hinge to body
- Door hinge to door
- Door striker mounting bolt
35~42
10~12
17~22
350~420
100~120
170~220
25~31
7~8
12~16
Tailgate
- Tailgate hinge to body
- Tailgate hinge to tailgate
- Tailgate latch mounting bolt
- Tailgate striker mounting bolt
22~27
7~9
7~11
9~14
220~270
70~90
70~110
90~140
16~19.5
5~7
5~8
6.5~10
Hood
- Hood hinge to body
- Hood hinge to hood
- Hood latch to body
- Gas lifter mounting bolt
22~27
22~27
7~11
9~14
220~270
220~270
70~110
220~270
16~19.5
16~19.5
5~8
16~19.5
Seat
- Front seat to floor, Bolt
- Rear seat back center bracket, Bolt
- Rear seat back lower side bracket, Bolt
- Rear seat cushion mounting, Bolt
35~55
17~26
17~26
17~26
350~550
170~260
170~260
170~260
25~40
12~19
12~19
12~19
40~55
40~55
40~55
40~55
400~550
400~550
400~550
400~550
29~40
29~40
29~40
29~40
Seat belt
- Front seat belt retractor mounting bolt
- Front seat belt upper anchor mounting bolt
- Front seat belt sliding bar mounting bolt
- Front seat belt height adjuster mounting bolt

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Page 2 of 2
- Rear seat belt retractor mounting bolt

- Rear seat belt upper anchor mounting bolt
- Front seat belt buckle mounting bolt
Sunroof
- Sunroof lid panel mounting, Nut
- Sunroof assembly mounting, Bolt
40~55
40~55
40~55
400~550
400~550
400~550
29~40
29~40
29~40
7~9
7~11
70~90
70~110
5~6.5
5~8

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender >
Repair procedures

FENDER
1. Remove the front mud guard and wheel guard.
2. Remove the 3 bolts holding the head lamp and disconnect the wire connector.
Remove the head lamp assembly.
3. Remove the front bumper. (refer to front bumper group)

4. Remove the fender mounting bolts and remove the fender panel assembly.
Use care to avoid damaging the paint.
In order to prevent the fender mounting bolt area from forming rust, apply tape sealer between the fender
and the bodypanel.
FENDER GARNISH
1. Remove the wheel guard.

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2. Loosen the fender garnish mounting screws and then remove the fender garnish.
1. When installing garnish, be careful not to deform the fender panel.

2. Engage the clip part on the garnish into the fender panel securely until it makes "click" sound.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood >
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood >
Repair procedures
ADJUSTMENT
Hood Hinge
1. Loosen the hood hinge mounting bolt.
2. Adjust the longitudinal and lateral positions of the hood by utilizing the holes in the hinge.
3. Adjust front edge of hood in vertical direction by adjusting the hood stop and adjusting bumpers.
Hood Latch
1. Loosen the hood lock mounting bolts.
2. Adjust the alignment of the hood latch by adjusting the vertical and lateral position of the lock and by adjusting
the height of the hood.

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > tail gate > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > tail gate
> Repair procedures

1. Remove the tailgate frame upper trim.
2. Remove the tailgate glass side trim.
3. Remove the tailgate trim panel.
4. Remove the rear wiper arm.
5. Remove the hexagonal nut.

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6. Remove the rear wiper motor mounting 3 bolts and disconnect the wire connector.
Remove the rear wiper motor.
7. Remove the tailgate lifter with ball joint.
When replacing the tailgate lifter, the ball joint should be replaced at the same time.
Tightening torque:
11~16 Nm (110~160 kgcm, 8~12 lbft)
ADJUSTMENT
1. Adjust the striker upward or downward, and rightward or leftward until the tailgate is flush with the rear edge of
the body.

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2. Adjust the tailgate hinges rightward or leftward as necessary to equalizer the gap between the tailgate and
body.

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > front door > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > front
door > Repair procedures

1. Remove the grip handle using a remover.
2. Remove the inside handle housing.
3. Remove the tweeter speaker using a remover.
4. Remove the mounting screws and remove the door trim panel.
Disconnect the wire connectors.
5. Remove the door grip handle mounting bracket, speaker and door trim seal.

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6. Remove the door tooling hole cover.
7. Remove the door glass stopper catch.
Tightening torque:
4~6 Nm (40~60 kgcm, 3~5 lbft)
8. Remove the door delta chassis.
9. Remove the glass stopper bolts, remove the window glass.

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10. Remove the door side weather strip.
11. Loosen the mounting nuts and remove the regulator assembly.
Tightening torque:
9~14 Nm (90~140 kgcm, 6.5~10 lbft)
12. Disconnect the cable, after loosening the inner handle mounting screw, push the inner handle toward the
direction shown in the illustrationand remove it.
13. Remove the door outside belt.

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Install the door outside belt to the inside of groove of the door panel.
14. Remove the door outside handle and key cylinder.
15. Remove the door latch assembly mounting screws and remove the door latch assembly.
Tightening torque:
17~22 Nm (170~220 kgcm, 12~16 lbft)
16. Remove the door checker.

24.04.2008
Page 5 of 5

When installing the door vapor barrier, butyl tape should not be placed so it blocks the door trim fastener
holes.
ADJUSTMENT
DOOR POSITION
Attach protective tape to the fender edges where the hinge is installed.
DOOR STRIKER
1. Draw a line around the striker plate for reference.
2. Loosen the striker screws and move the striker IN or OUT to make the latch fit tighter or looser. Move the
striker UP or DOWN to align it withthe latch opening. Then lightly tighten the screws and recheck.
Hold the outside handle out and push the door aginst the body to ensure the striker allows a flush fit.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror >
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror >
Repair procedures

OUTSIDE REARVIEW MIRROR
1. Remove the outside rearview mirror cover.
2. Loosen the mounting bolts, disconnet the connector and then remove the outside rearview mirror.
Tightening torque:
7~11 Nm (70~110 kgcm, 5~8 lbft)
INSIDE REARVIEW MIRROR

1. Remove the rearview mirror.
DISASSEMBLY
Wear gloves to remove and install the mirror holder.

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Page 2 of 2
1. Insert a flat tip screwdriver between the outside rear view mirror holder and mirror assembly.
When prying with a flat tip screwdriver, wrap it with a shop towel to prevent damage.
2. Remove the outside rear view mirror actuator from outside rear view mirror housing.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof assembly >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) >
Sun Roof > sun roof assembly > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 8
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof assembly >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
sun roof assembly > Repair procedures
REMOVAL
1. Remove the sun-roof as the following order.
(1) Over head console
(2) Sun visor and clips
(3) Trims
(4) Roof side rain force trim
(5) Seat and seat belt

2. After removing the decoration cover, remove the glass.
Tightening torque:
4~6 Nm (40~60 kgcm, 2.9~4.4 lbft)
3. Disconnect the drain hose.

4. Remove the sun-roof mounting bolts and nuts, and then remove the sun-roof.
Be care ful not to damage the other parts, while removing the sun-roof.

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Page 2 of 8
Tightening torque:
4~6 Nm (40~60 kgcm, 2.9~4.4 lbft)
DISASSEMBLY
1. Remove the motor.
2. Remove the front drip.

3. Remove the sun shade.
4. Remove the drive unit and the guide assembly.
5. Remove the deflector.

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6. Remove the spring.
REASSEMBLY
1. Install the spring base.
2. Install the deflector assembly (After installing the clip, install the link base stopper.)
3. Insert the shutting into the rail.

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Page 4 of 8
Do not confuse the left and right sides.

4. Install the cable to the guide assembly.
5. Move the timing front edge to be aligned with the slide of the guide assembly.
6. Align the protrusion of the slide with the groove of the shutting.
7. Grab the pin by finger to avoid inteference with other parts.
8. Face the protrusion of "shoe A" upward, the cushion of "shoe B" downward.

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Page 5 of 8
9. Fully insert the guide assembly into the rail.
10. Completely push the slide until it touches the timing front using a screw driver.
11. Insert the motor cable into the drive unit assembly tube.
12. Install the drive unit assembly to the rail.

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13. Install the sun shade.
14. Install the sun shade cam to the groove of the sun-roof rail.
15. Install the front drip.

16. Install the motor and controller, and connect the connestor.
INSPECT SUNROOF GLASS ALIGNMENT
1. Start the engine and check the operating time of the sunroof.
Operating time: Approx. 5 secs.
2. Check for abnormal noise or bending during operation.

3. With the sunroof fully closed, check for water leakage.

24.04.2008
Page 7 of 8
4. The roof panel (A) should be even with the glass (B) weatherstrip (C), to within the standard value "E" all the
way around. If not, make the following adjustment.
Standard value "E"
Front edge: 2+0/-1mm (0.08+0/-0.04in.)
Rear edge: 2+1/-0mm (0.08+0.04/-0in.)
5. If the position is not as specified, lightly loosen the glass adjusting screw (A) to adjust the glass height and
tighten it.
Tightening torque: 2~4Nm (20~40kgfcm, 1.5~2.9 lbfft)
6. Check for overlap between the sunroof weatherstrip (A) and the roof panel (B).
Standard value: 1.1 mm
ADJUSTMENT
INITIAL SETTING (GENERAL, OPERATION)

24.04.2008
Page 8 of 8
- Always initiates the sunroof in the following condition.

After manual operation
After parts replacement including motor, controller, harness
Malfunction of sunroof wiring
Abnormal operation after battery and fuse replacement
- Follow the general operation produce for inital sefting after reassembliny.
OPERATING THE SUNROOF EMERGENCY HANDLE

1. Use the sunroof emergency handle to close and open the sunroof manually for the following case only:
A. To close the sunroof before driving a vehicle in a rainy day or on the highway if the sunroof cannot be
closed due to failure of the sunroof motor or controller.
2. Operating method
A. Remove the overhead console.
B. Push the emergency handle up into the hexagonal drive (A) of the sunroof motor (B). You must push hard
enough to disengage the motor clutch; otherwise the emergency handle will slip due to uncompletely fit in
the motor.
C. Carefully turn the emergency handle clockwise to close the sunroof.
D. After closing the sunroof, wiggle the handle back and forth as you remove the tool from the motor, to
ensure the motor clutch reengages.
E. A 5mm hex socket may be used in place of the emergency handle, with a "Speeder" type handle.
Do not use power tools to operate the sunroof.

Damage to the components may occur.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof switch >
sun roof switch > Repair procedures
INSPECTION
2. Detach the lamp lens then remove the mounting screws (2EA) and open the overhead console case cover
then remove the mounting screws (2EA).
3. After disconnecting the roof wiring and sunroof wiring connector then remove the overhead console lamp
assembly from the headliner.
4. Using an ohmmeter, check for continuity between the terminals.

If the continuity is not as specified, replace the sun roof switch.
5. Verify power and ground continuity between the M95 and M96 terminals.

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof moter >
sun roof moter > Repair procedures
INSPECTION
1. Pull down the rear headliner.
2. Disconnect the motor side connector from the sunroof controller.
Remove the sunroof motor after removing 3 screws.
3. Connect the positive (+) lead from the battery to terminal 2 and the nagative (-) lead to terminal 1, check that
the motor turns counterclockwise (moves toward the close and down position).
4. Reverse the polarity, check that the motor turns clockwise (moves toward the up and open position).
If operation is not as specified, replace the motor.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > Sunroof Relay >
Sunroof Relay > Repair procedures
INSPECTION
1. Pull down the rear headliner.
2. Disconnect the sunroof switch side connector from the sunroof controller.
3. Inspect the connectors on the wire harness side from the controller, as shown in the table.
Connector
M97
M99
Tester
connection
Condition
Specified condition
1-Ground
Constant
Continuity
2-Ground
Sunroof switch is in the close position
Continuity
3-Ground
Sunroof switch is in the open position
Continuity
4-Ground
Constant
Battery voltage
6-Ground
Ignition switch ON
Battery voltage
7-Ground
Sunroof switch is in the tilted up position
Continuity
8-Ground
Sunroof switch is in the tilted down

position
Continuity
3-Ground
Constant
Continuity
1(+) ~ 2(-)
Apply the battery voltage to the terminal

No.1 and ground to terminal No.2
Motor turns clockwise
1(-) ~ 2(+)
Apply the battery voltage to the terminal

No.2 and ground to terminal No.1
Motor turns counter-clockwise

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console >
Repair procedures

1. Remove the front seat.
3. Remove the console front mounting screws.
4. Remove the floor console.

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > crash pad > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > crash pad
> Repair procedures

1. Disconnect the negative battery teminal.
2. Disconnect the wire connectors from the front seats and then remove the front seats.
Take care not to scratch the trim when removing the fronts seats.
3. Remove the cowl side trim, front pillar.

24.04.2008
Page 2 of 5
For instructions on the removal of the air bag module and clock spring, refer to RT group.
6. The steering wheel mounting nut, and remove the steering wheel.
Tightening torque:
40~50 Nm (400~500 kgcm, 29.5~36.9 lbft)
7. Remove the 3 screws holding the steering column lower shroud and then remove the steering column lower
and upper shroud.
8. Disconnect the connectors and remove the multifunction switch (3 screws).
9. Disconnect the hood release cable and connectors from the cover. After removing the 2 screws, remove the
crash pad under cover of the passengercompartment.

24.04.2008
Page 3 of 5
10. After loosening the 2 screws, remove the cluster housing.
11. After loosening the 4 screws, remove the cluster.
12. Open the ashtray. Insert a screw driver into the area between the center facia panel lower portion and
ashtray, and then pull out the center facia panel lower portion. Lift up the center facia panel with hand.
13. After disconnecting the switch connectors, remove the center facia panel.
14. Remove the audio mounting screws and the gauge mounting screws to remove the audio assembly.

24.04.2008
Page 4 of 5
15. After loosening the 6 mounting screws shown in the illustration, remove the glove box.
16. Disconnect the glove box lamp connector and then remove the lamp.
17. Remove the main crash pad mounting bolts.

24.04.2008
Page 5 of 5
18. Remove the crash pad.
19. Installation is the reverse of removal and connect all connectors securely.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior trim > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior
trim > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior trim > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior
trim > Repair procedures

DOOR SCUFF TRIM AND STEP PLATE TRIM
2. Remove the step plate trim.
COWL SIDE TRIM
COVERING SHELF CENTER TRIM AND SIDE TRIM
QUARTER LNNER TRIM

1. Remove the rear seat cushion mounting bolts from the rear seat cushion.

24.04.2008
Page 2 of 5
Tightening torque:
17~26 Nm (170~260 kgcm, 12~19 lbft)
2. Remove the rear seat back mounting bolts from the rear seat back.
Tightening torque:
17~26 Nm (170~260 kgcm, 12~19 lbft)
3. Remove the rear seat belt upper anchor mounting bolt.

4. Remove the rear sear back lower anchor mounting bolt and remove rear seat belt.
Tightening torque:
40~55 Nm (400~550 kgcm, 29~40 lbft)

24.04.2008
Page 3 of 5
5. Remove the quarter inner trim mounting screws(4EA) from the quarter inner trim and remove the inner trim
assembly.
CENTER PILLAR TRIM

1. Remove the front seat belt upper anchor mounting bolt.
2. Remove the center pillar upper trim mounting screws. Remove the seat belt webbing guide mounting screws
and coat hook mounting screws fromthe center pillar upper trim.
FRONT PILLAR TRIM
REAR TRANSVERSE TRIM

24.04.2008
Page 4 of 5
LUGGAGE BOARD CENTER TRIM
LUGGAGE BOARD FRONT TRIM
LUGGAGE SIDE TRIM

Remove the mounting screws from the luggage side trim.
Disconnect the trunk room lamp connector.
HEAD LINING
1. To remove the headlining, first remove the following parts :
(1) Rear seat cushion.
(2) Rear seat back.
(3) Rear seat belt upper anchor mounting bolt.
(4) Rear seat back lower side bracket.

24.04.2008
Page 5 of 5
(5) Quarter inner trim.

(6) Front seat belt upper anchor mounting bolt.
(7) Center pillar upper trim.
(8) Front pillar trim.
2. Ramove the mounting screws from the over head console lamp.
Disconnect the over head console lamp.
3. Remove the mounting screws from the sunvisor.
4. Remove the mounting clips from the roof rear cover trim.
5. Remove the headlining mounting clips and remove the headlining.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > windshield glass > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior >
windshield glass > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > windshield glass >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior >
windshield glass > Repair procedures
REMOVAL
1. To remove the windshield, first remove the following parts:
(1) Front pillar trims
(2) Inside rear view mirror
(3) Wiper arms
(4) Weatherstrip and cowl top cover
(5) Windshield glass molding
2. Use the special tool (09861-31100) to cut through the sealant.
3. Make mating marks on the glass and body if the glass is to be reinstalled.
4. Take out the windshield glass with the special tool (09861-31400).

24.04.2008
Page 2 of 5
INSTALLATION
1. Using a cutter knife or the special tool (09861-31200), scrape the old sealant smoothly to a thickness of about
2 mm (0.08 in.) on the bonding surfacearound the entire windshield flange.
Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the
body surface with the knife. If the paintworkis damaged, repair the damaged area with touch-up paint.
2. Clean the body bonding surface with a sponge dampened in alcohol or wax and grease remover.
3. Install the spacer in the windshield aperture.
4. Center a new windshield glass in the opening. Mark the location by marking lines across the glass and body
with a grease pencil at the four points asshown.
5. Install the windshield glass molding without any gaps.

24.04.2008
Page 3 of 5
6. Glue the rubber dam to the inside surface of the windshield glass around the entire edge as shown, to contain
the sealant during installation.
Part
"A"
Upper
13.5 mm
Side
13.5 mm
Remarks
Glass molding sub
7. Apply a light coat of glass primer to the outside of the dam.
1. Never touch the surface applied primer with your hand.

If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield glass
is installed.
2. Do not apply body primer to the glass.
3. Keep water, dust, and abrasive materials away from the surface applied primer.
8. Apply a primer to the lower glass as shown.

24.04.2008
Page 4 of 5
9. Apply a sealant around the edge of the glass.
Apply the adhesive within 5 minutes after applying the primer to the glass.
10. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The
glass should be installed within 5 minutesafter you apply the primer.
11. Using suction cups or the special tool (09861-31400), lower the glass over the opening, align it with the
marks made in step 4 and set it down onthe sealant.

24.04.2008
Page 5 of 5
12. Scrape or wipe excess adhesive off with a putty knife or gauze. Fill all cavities around the windshield glass.
13. Perform a water-leak test for the windshield. Use a cold water spray, being careful not to direct a powerful
stream of water on the new adhesivematerial. Allow water to spill over the edges of the glass.
14. If there are leaks, dry the affected area, then apply sealant.
15. Install the removed parts.
1. Keep the windshield dry for the first hour after installation.
2. Let the car stand for at least four hours after windshield installation. If the car has to be used winthin
the first 8 hours, it must be driven slowly.
3. Take care not to slam the doors with all the windows rolled up.
4. Take care not to twist the vehicle excessively (such as when going in and out of driveways at an
angle or driving over rough, uneven roads).

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > tailgate glass > Components
tailgate glass > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > tailgate glass > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > tailgate
glass > Repair procedures
REMOVAL
1. To remove the tailgate glass, first remove the following parts:
(1) Rear window defogger wire connector.
(2) Tailgate trims.

(3) Rear wiper and wiper motor.
2. Remove the tailgate glass in the same manner as the windshield glass.
INSTALLATION
1. Using a cutter knife or the special tool (09861-31200), scrape the old sealant smoothly to a thickness of about
2 mm (0.08 in.) on the bondingsurface around the entire tailgate glass.
Be careful not to remove more adhesive than necessary, and also not to damage the paintwork on the
body surface with the knife. If the paintwork is damaged, repair the damaged area with touch-uppaint.
2. Clean the body bonding surface with a sponge dampened in alcohol or wax and grease remover.
3. Center a new tailgate glass in the opening. Mark the location by marking lines across the glass and body with
a grease pencil at the four pointsas shown.
4. Install the tailgate glass molding without any gaps.

24.04.2008
Page 2 of 3
5. Apply a light coat of glass primer around the tailgate glass.
1. Never touch the surface applied primer with your hands.

If you do, the adhesive may not bond to the glass properly, causing a leak after the tailgate glass has
been installed.
2. Do not apply body primer to the glass.
3. Keep water, dust, and abrasive materials away from the surface applied primer.
6. Apply a sealant around the edge of the glass.

Part
Remarks
23.5mm
Glass molding sub
Upper
Side
Lower
Apply the adhesive within 5 minutes after applying the primer to the glass.
7. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The
glass should be installed within 5 minutesafter you apply the primer.
8. Use suction cups or the special tool (09861-31400), lower the glass over the opening, align it with the marks
made in step 3 and set it down onthe sealant.

24.04.2008
Page 3 of 3
9. Scrape or wipe excess adhesive off with putty knife or gauze. Fill all cavities around the tailgate glass.
10. Perform a water-leak test for the tailgate glass. Use a cold water spray, being careful not to direct a powerful
stream of water on the new adhesivematerial. Allow water to spill over the edges of the glass.
11. If there are leaks, dry the affected area, then apply sealant.
1. Keep the tailgate glass dry for the first hour after installation.
2. Let the car stand for at least four hours after tailgate glass installation. If the car has to be used
winthin the first 8 hours, it mustbe driven slowly.
3. Take care not to slam the doors with all the windows rolled up.
4. Take care not to twist the vehicle excessively (such as when going in and out of driveways at an
angle or driving over rough, uneven roads).

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > quarter glass > Components
quarter glass > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > quarter glass > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > quarter
glass > Repair procedures
REMOVAL
1. To remove the quarter fixed glass, first remove the following parts:
(1) Covering shelf center trim and side trim.
(2) Rear speaker grill and speaker.
(3) Rear seat cushion.
(4) Rear seat back.
(5) Rear seat belt upper anchor mounting bolt.
(6) Rear seat back lower side bracket.
(7) Rear quarter inner trim.
(8) Front seat belt upper anchor mounting bolt.
(9) Center pillar trim.
2. After removing the quarter fixed glass molding, cut the sealant using the Special Tool.
3. Remove the quarter fixed glass mounting clips.

4. Remove the quarter fixed glass.
INSTALLATION
1. Using a cutter knife or the Special Tool, scrape the old sealant smoothly to a thicknes of about 2 mm (0.08 in)
on the bonding surface aroundthe entire quarter fixed glass flange.

24.04.2008
Page 2 of 3
Be careful not to remove more adhesive than nesessary, and also not to damage the paintwork on the
body surface with the knife. If the paintwork is damaged, repair the damage area with touch-up paint.
2. Clean the body flange surface of quarter fixed glass flange with a sponge dampened in isopropyl alchol.
A. Clean completely the contaminats such as oil and dust in the primer-applied part of body flange.
B. After cleaning body flange surface, pass a minute or more then, apply the body primer to body flange.
3. Apply the body primer to body flange surface of quarter fixed glass.
A. To use the body primer, shake the vessel enough.
4. Apply the glass primer to the glass and the glass moulding assembly.
5. Apply the sealant to the entire circumferenco of the quarter fixed glass.

24.04.2008
Page 3 of 3
Install the glass to the body within five minutes.

6. Install the guarter fixed glass.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper > front bumper > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper >
front bumper > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper > front bumper > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper > front
bumper > Repair procedures

1. Remove the front bumper upper cover.
2. Loosen the head lamp mounting bolts, disconnect the connector, and remove the head lamp assembly.
3. Disconnect the fog lamp connectors.
4. Remove the front bumper upper mounting bolt and screws.
Tightening torque:
4~6 Nm (40~60 kgcm, 2.9~4.4 lbft)
5. Remove the mounting screws in the corner of front bumper.

24.04.2008
Page 2 of 2
Tightening torque:
4~6 Nm (40~60 kgcm, 2.9~4.4 lbft)
6. Loosen the front bumper lower mounting screws and remove the front bumper cover.
7. Remove the front bumper upper mesh.
8. After loosening the front bumper beam stay mounting bolts and nuts and remove the front bumper beam stay.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper > rear bumper > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper >
rear bumper > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper > rear bumper > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Bumper > rear
bumper > Repair procedures

1. Loosen the luggage side cover mounting screws and remove the luggage side cover.
2. Remove the rear combination lampl.

Disconnect the combination lamp connector.
3. Loosen the rear bumper cover mounting screw from the rear wheel house.
4. Loosen the rear bumper cover mounting screw from the rear wheel house.
5. Loosen the rear bumper upper part mounting screws.

24.04.2008
Page 2 of 2
6. Loosen the rear bumper lower part mounting screws.
When installing, align the protrusion of the bumper cover with the groove of the panel.
7. Disconnect the licence lamp connector from the rear bumper cover and remove the rear bumper beam
assembly.
Tightening torque:
25~30 Nm (250~300 kgcm, 18.0~21.6 lbft)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt > front seat belt > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt >
front seat belt > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt > front seat belt >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt >
front seat belt > Repair procedures
REMOVAL AND INSTAIIATION

1. Loosen the front seat belt upper anchor mounting bolt.
2. Loosen the sliding bar mounting bolts.
3. Loosen the seat belt webbing guide and remove the front seat belt.
4. Remove the center piller trim and front seat belt height adjuster.
Tightening torque:
40~50 Nm (400~500 kgcm, 25~40 lbft)
1. A pretensioner functions one time only. Be sure to replace the pretensioner seat belt after it is
deployed.
2. Do not attempt to disassemble or repair the seat belt pre-tensioner. When it malfunctions, replace
with a new pre-tensioner seat belt.
3. Be cautious in handling a pre-tensioner seat belt, and do not drop it in water, or oil. If crushed,
damaged, or deformed, replace it with a newone.
4. Only connect the battery after installation of the pretensioner seat belt has been correctly completed.
5. Removal of the pretensioner seat belt :
Make sure that ignition is "Off".
Disconnect the negative (-) battery terminal and make sure it does not come into contact with the
body.
Wait for about 1 minute.
Pull the plug out from the appropriate connector at the gas generator.
Loosen the bolt and remove the belt from the vehicle body.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt > rear seat belt > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt >
rear seat belt > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt > rear seat belt >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Seat Belt >
rear seat belt > Repair procedures

1. Remove the mounting bolts from the rear seat cushion.
2. Remove the mounting bolts from the rear seat back.
3. Remove the rear seat back lower side mounting bracket.
Tightening torque:
40~55 Nm (400~500 kgcm, 25~40 lbft)
4. Loosen the rear seat belt upper, lover mounting bolts, and remove the rear seat belt.

24.04.2008
Page 2 of 2
REAR SEAT BELT BUCKLE

1. Remove the mounting bolts from the rear seat cushion.
Tightening torque:
17~26 Nm (170~260 kgcm, 12~19 lbft)
2. Remove the rear seat belt buckle.

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > General Information > General
Information, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > General Information >
General Information
GENERAL TROUBLESHOOTING INFORMATION

BEFORE TROUBLESHOOTING
1. Check applicable fuses in the appropriate fuse/relay box.
2. Check the battery for damage, state of charge, and clean and tight connections.
Do not quick-charge a battery unless the battery ground cable has been disconnected, otherwise you
will damage the alternator diodes.
Do not attempt to crank the engine with the battery ground cable loosely connected or you will
severely damage the wiring.
3. Check the alternator belt tension.
HANDLING CONNECTORS
1. Make sure the connectors are clean and have no loose wire terminals.
2. Make sure multiple cavity connectors are packed with grease (except watertight connectors).
3. All connectors have push-down release type locks (A).
4. Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another
component. This clip has a pull type lock.
5. Some mounted connectors cannot be disconnected unless you first release the lock and remove the
connector from its mount bracket (A).
6. Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
7. Always reinstall plastic covers.

24.04.2008
Page 2 of 4
8. Before connecting connectors, make sure the terminals (A) are in place and not bent.
9. Check for loose retainer (A) and rubber seals (B).
10. The backs of some connectors are packed with grease. Add grease if necessary. If the grease is
contaminated, replace it.
11. Insert the connector all the way and make sure it is securely locked.
12. Position wires so that the open end of the cover faces down.

24.04.2008
Page 3 of 4
HANDLING WIRES AND HARNESSES

1. Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
2. Remove clips carefully; don't damage their locks (A).
3. Slip pliers(A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to
release the clip.
4. After installing harness clips, make sure the harness doesn't interfere with any moving parts.
5. Keep wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes,
and from exposed screws and bolts.
6. Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
TESTING AND REPAIRS

1. Do not use wires or harnesses with broken insulation.

24.04.2008
Page 4 of 4
Replace them or repair them by wrapping the break with electrical tape.
2. After installing parts, make sure that no wires are pinched under them.
3. When using electrical test equipment, follow the manufacturer's instructions and those described in this
manual.
4. If possible, insert the probe of the tester from the wire side (except waterproof connector).
5. Use a probe with a tapered tip.
FIVE-STEP TROUBLESHOOTING
1. Verify the complaint
Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not
begin disassembly or testing until you have narrowed down the problem area.
2. Analyze the schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work by tracing the current paths from the power feed through the
circuit components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause.
Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes
of the problem.
3. Isolate the problem by testing the circuit
Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is
the key to efficient troubleshooting.
Test for the most likely cause of failure first. Try to make tests at points that are easily accessible.
4. Fix the problem
Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.
5. Make sure the circuit works
Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the
problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up
and the original problem does not recur.

24.04.2008
Page 1 of 15
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > General Information > Troubleshooting
TROUBLESHOOTING
INSTRUMENTS AND WARNING SYSTEM
Symptom
Possible cause
Remedy
Tachometer does not operate
No.17 fuse (10A) blown

Tachometer faulty
Wiring faulty
Check for short and replace fuse

Check tachometer
Repair if necessary
Fuel gauge does not operate

Fuel gauge faulty
Fuel sender faulty
Wiring faulty

Check gauge
Check fuel sender
Repair if necessary
Low fuel warning lamp does not light

Bulb burned out
Fuel level sensor faulty
Wiring or ground faulty

Replace bulb
Check sensor
Repair if necessary
Water temperature gauge does not

operate

Water temperature gauge faulty
Water temperature sender faulty

Check gauge
Check sender
Repair if necessary
Oil pressure warning lamp does not

light

Bulb burned out
Oil pressure sender faulty

Replace bulb
Check sender
Repair if necessary
Low brake fluid warning lamp does not

light

Bulb burned out
Brake fluid level warning switch faulty
Parking brake switch faulty

Replace bulb
Check switch
Check switch
Repair if necessary
Open door warning lamp does not light No.18 fuse (10A) blown
Bulb burned out
Door switch faulty

Replace bulb
Check switch
Repair if necessary
Seat belt warning lamp does not light

Replace bulb
Check switch
Repair if necessary

Bulb burned out
Buckle switch faulty
LIGHTING SYSTEM
Symptom
Possible cause
Remedy
One lamp does not light

(all exterior)
Bulb burned out

Socket, wiring or ground faulty
Replace bulb
Repair if necessary
Head lamps do not light
Bulb burned out

Head lamp fuse (15A) blown
Head lamp relay faulty
Lighting switch faulty
Replace bulb
Replace fuse and check for short
Check relay
Check switch
Repair if necessary
Tail lamps and license plate lamps do

not light
No.9, No.14 fuse (10A) blown

Battery fusible link (50A) blown
Tail lamp relay faulty
Lighting switch faulty

Replace the fusible link
Check relay
Check switch
Repair if necessary
Stop lamps do not light

24.04.2008
Page 2 of 15
Stop lamp switch faulty


Repair if necessary
Stop lamps stay on
Stop lamp switch faulty
Instrument lamps do not light

(Tail lamps light)
Rheostat faulty
Check rheostat
Repair if necessary
Turn signal lamp does not flash on one Bulb burned out
side
Turn signal switch faulty
Replace bulb
Check switch
Repair if necessary
Turn signal lamps do not operate

Body control module faulty
Hazard relay faulty
Turn signal switch faulty

Check body control module
Replace relay
Check switch
Repair if necessary
Hazard warning lamps do not operate

Hazard switch faulty
Hazard relay faulty

Check switch
Replace relay
Repair if necessary
Flasher rate too slow or too fast
Lamps' wattages are smaller or larger

than specified
Defective body control module
Replace lamps
Back up lamps do not light up

Back up lamp switch faulty

Check switch
Repair if necessary
Overhead console lamp does not light

up


Repair if necessary
AUDIO

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Page 3 of 15
CHART 1

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CHART 2
CHART 3

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CHART 4

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CHART 5

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CHART 6

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CHART 7
CHART 8

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CHART 9
CHART 10

24.04.2008
Page 13 of 15
WINDSHIELD WIPER
Symptom
Possible cause
Remedy
Wipers do not operate or return to off

position
No.27 Wiper fuse (15A) blown

Wiper motor faulty
Wiper switch faulty

Check motor
Check switch
Repair if necessary
Wipers do not operate in INT position

Wiper switch faulty
Wiper motor faulty

Check switch
Check motor
Repair if necessary
POWER WINDOW
Symptom
No windows operate from the main
switch on the driver's door
Possible cause
Poor ground
Defective power window main switch
Open circuit in wires or loose or
disconnected connector
Remedy
Clean and retighten the ground
terminal mounting bolt
Check the switch
Replace if necessarh
Repair or replace

24.04.2008
Page 14 of 15
Driver's side window does not operate
Defective power window main switch

Defective motor or circuit breaker
Passenger's side window does not

operate
Defective power window sub switch

Replace the switch
Defective motor or circuit breaker
Replace the motor
Wiring faulty or disconnected connector Repair if necessary
Check for driver's window switch

Replace the motor
Check the harness and the connector
POWER DOOR MIRROR

Symptom
Possible cause
No mirrors operate
One mirror does not operate
Remedy

Poor ground
Defective mirror switch
Check the circuit and replace fuse

Clean and retighten the ground
terminal mounting bolt
Check the switch
Replace if necessary
Repair or replace
Defective mirror switch

Defective mirror actuator
Open circuit wires or loose or
Check the switch

Replace if necessary
Replace the actuator
Repair or replace
BURGLAR ALARM SYSTEM

Symptom
Possible cause
Remedy
The system is not armed

(The siren doesn't sound)
Transmitter faulty
Damaged or disconnected wiring of
door switch input circuit
Replace the transmitter

Check the body control module
Repair the harness
The siren sounds in error when a door

or tailgate is unlocked with the key
while thesystem is armed
Damaged or disconnected wiring of a

door key cylinder and tailgate key
cylinder switch input circuit
Repair the harness or replace a door

key cylinder and the tailgate key
cylinder switch
Replace the body control module
Engine does not start in disarm state
Burglar alarm relay faulty

Replace the burglar alarm relay
Damage or disconnected wiring of
Repair the harness
burglar alarm relay activation circuit
Malfunction of the body control module
There is no alarm when, as an alarm

test, a door is opened without using the
key
(The arming and disarming are normal,
and the alarm is activated when the
tailgate or hood is opened)

door switch (all doors) input circuit
Malfunction of the door switch
Repair the harness or replace the door

switch
Check the door switch

test, the tailgate is opened without
using thekey
(The alarm is activated, however, by
opening a door or the hood)

luggage compartment light switch input
circuit
Malfunction of the tailgate switch
Repair the harness or replace the

luggage compartment light switch
Check the tailgate switch

test the hood is opened from within the
vehicle
(The alarm is activated, however, by
opening a door or tailgate)

hood switch input circuit
Malfunction of the hood switch
Repair the harness or replace the hood

switch
Check the hood switch
KEYLESS ENTRY SYSTEM

Symptom
Possible cause
Check
Remedy

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Page 15 of 15
Operation range is unstable
Discharged transmitter
battery
Check the transmitter, red

lamp blinking upon pressing
the transmitter switch
Transmitter or receiver faulty

Central locking device
operates but keyless entry
does not work
Discharged transmitter
battery
Replace the battery
Replace the transmitter or

the receiver
Check the transmitter, red
lamp blinking upon pressing
the transmitter switch
Faulty signal code

registration
Replace the battery
Ensure normal door

opening/closing by using the
door key and register the
code again
Faulty keyless entry circuit
Repair the connector or the

Check the BCM connector,
and the harness between the harnese
BCM and the door lock
actuator
Faulty receiver
Check the receiver output

using the oscilloscope
Faulty body control module
Replace the receiver

Replace the faulty control
unit and module
If central lock and keyless entry do not operate simultaneously, systems other than the keyless entry may be
considered faulty.
Then check related systems.

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > General Information > Specifications
SPECIFICATIONS
MULTIFUNCTION SWITCH
Items
Specifications
Rated Voltage
DC 12V
Operating temperature range
-30C ~ +80C (-22 ~ +1 76F)
Rated load
Dimmer & passing switch
Lighting switch
Turn signal & lane change switch
Wiper switch
Wiper mist switch
Washer switch
Variable intermittent wiper volume switch
Rear wiper & washer switch
Horn switch
High : 1A (Relay load)

Low : 1A (Relay load)
Passing : 1A (Relay load)
Lighting : 1A (Relay load)
6.6 0.5A (Lamp load)
Low, High : 4.5A (Motor load)
Int. : 0.22 0.05A (Relay load)
Lock : Max. 28A (Motor load)
4.5A (Motor load)
4A (Motor load)
Max. 25mA
Rear wiper : 0.2A (Relay load)
Rear washer : 4A (Motor load)
1A (Relay load)
INSTRUMENTS AND WARNING SYSTEM

Warning lamps
High beam
Low fuel
Turn signal (LH, RH)
Battery (charge)
Oil pressure
Air bag
Parking brake
Seat belt
Check engine
ABS
Door ajar
Trunk lid open
Cruise
TCS
TCS OFF
Bulb wattage (W)
Color
LED
LED
LED
LED
LED
Bulb (1.4W)
LED
LED
Bulb (1.4W)
LED
LED
LED
LED
LED
LED
Blue
Amber
Green
Red
Red
Red
Red
Red
Amber
Amber
Red
Red
Green
Amber
Amber
INDICATORS AND GAUGES

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LIGHTING SYSTEM
Items
Head lamp
Front turn signal/position lamp
Bulb wattage (W)

55W / 55W (High / Low beam)
28W / 8W
Front position lamp
5W
Front fog lamp
51W
Rear combination lamps

Tail/stop lamp
Back up lamp
Turn signal lamp
8W / 27W
27W
27W
Side marker lamp
5W
Luggage lamp
5W
Center high mounted stop lamp
Internal type : 2.4W (LED)

External spoiler type : 3.5W (LED)
Overhead console lamp
10W x 2
License plate lamp
5W x 2
AUDIO

24.04.2008
Page 4 of 4
Items
H250
H260
H280
Rated output
Max. 20W x 4
Max. 20W x 4
Max. 24W x 4
Load impedance
4 x 4
4 x 4
4 x 4
Band
AM/FM
AM/FM
AM/FM
Tuning type
PLL Synthesized type
Dark current
Max. 2mA
Max. 3.8mA
Max. 2mA
AM : 530~1710KHZ/10KHZ
AM : 530~1710KHZ/10KHZ
AM : 530~1710KHZ/10KHZ
FM :
87.9~107.9MHZ/200KHZ
FM :
87.9~107.9MHZ/200KHZ
FM :
87.9~107.9MHZ/200KHZ
Frequency range / Channel
WINDSHIELD WIPER AND WASHER

Items
Specifications
Wiper motor
Rated voltage
Operating voltage range
Insulation resistance
Speed/current at 1Nm load test
Torque/current when parking
DC 12V
DC 10~15V
Min. 1M
Low : 44~52 rpm / 3.5A or less
High : 64~78 rpm / 4.5A or less
Low : 39~47 rpm / 5.5A or less
High : 56~68 rpm / 7.0A or less
Low : 28Nm / 24A or less
High : 23Nm / 28A or less
Windshield washer
Motor type
Pump type
Rated voltage
Discharge pressure
Flow rate
Current
Overload capacity (Continuous operation)
With water
Without water (Racing)
DC ferrite magnet
Centrifugal
12V
1.8kg/cm or more
1,450cc/min. or more
5.0A or less
60sec. or less
20sec. or less
Rear wiper motor

Speed/current at no load test
Torque/current when parking
Wiping angle at no load
35rpm/2.2A or less
30~40rpm/3.5A or less
8Nm/14A or less
170 3

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Audio > Audio Unit > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Audio > Audio Unit >
COMPONENTS

24.04.2008
Page 2 of 4

24.04.2008
Page 3 of 4

24.04.2008
Page 4 of 4

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Audio > Audio Unit > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Audio > Audio Unit >
Repair procedures
REMOVAL
1. Disconnect the negative(-) battery terminal.
2. Remove the center facia panel and disconnect the wire connectors.
3. Remove the 4 screws holding the audio and multi-gauge unit then remove the audio assembly.
AUTO CD CHANGER
1. Remove the right side quarter trim.
2. Remove the auto CD changer from the right side quarter panel.
INSPECTION
TAPE HEAD AND CAPSTAN CLEANING
1. To obtain optimum performance, clean the head, and capstan as often as necessary, depending on frequency
of use and tape cleanness.
2. To clean the tape head and capstan, use a cotton swab dipped in ordinary rubbing alcohol. Wipe the head
and capstan.

24.04.2008
Page 2 of 2
AUDIO FAULT CODE

If you see any error indication in the display while using the CD or Tape mode, find the cause in the chart below.
INDICATION
CAUSE
SOLUTION
Er2
CDP deck mechanical error

(eject error, loading error)
After resetting the audio, push the eject button.

If disc is not ejected, consult your hyundai dealer.
Er3
Focus error
Data read error
Make sure the disc is not scratched or damaged.

Press the eject button and pull out the disc.
Then insert a normal CD disc.
Er6
Disc error
Check if the disc is inserted correctly in the CD player.

Make sure the disc is not scratched or damaged.
Er8
Tape deck error

Tape eject error
After resetting the audio, push the eject button.

If tape is not ejected, consult your hyundai dealer.
Temperature is too high
Fault code will reset automatically when the

temperature returns to normal.
No disc in magazine
No CD magazine in the auto change
Insert disc in magazine or insert CD magazine in the

auto changer.
HHH
no CD
In order to reset the audio, pull out the audio fuse (10A) in the body control module after waiting at least 10
seconds, then insert the audio fuse.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multifunction switch > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multifunction switch >
COMPONENTS

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multifunction switch > Multi
Function Switch > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System
> Multifunction switch > Multi Function Switch > Repair procedures
REMOVAL
Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace if a
dent, crack, deformation or rust is detected.
The air bag module should be stored on a flat surface and placed so that the pad surface is facing
Do not expose the air bag module to temperatures over 93C(200F).
After deployment of an air bag, replace the clock spring with a new one.
Wear gloves and safety glasses when handing an air bag that has been deployed.
An undeployed air bag module should only be disposed of in accordance with the procedures mentioned
in the restraints section.
When you disconnect the air bag module-clock spring connector, take care not to apply excessive force.
The removed air bag module should be stored in a clean, dry place.
Prior to installing the clock spring, align the mating mark and "NEUTRAL" position indicator of the clock
spring, and after turning the front wheels to the straight-ahead position, install the clock spring to the
column switch. If the mating mark of the clock spring is not properly aligned, the steering wheel may not
completely rotate during a turn, or the flat cable within the clock spring may be broken obstructing normal
operation of the SRS and possibly leading to serious injury to the vehicle's driver. To inspect the clock
spring,refer to the restraints section.
2. Remove the steering wheel.
3. Remove the steering column upper shroud and steering column lower shroud.

24.04.2008
Page 2 of 3
4. Remove the 3 screws holding the multi function switch and disconnect the connectors. Remove the multi
function switch assembly.
INSPECTION
LIGHTING SWITCH [M01-2]
DIMMER AND PASSING SWITCH [M01-2]
TURN SIGNAL AND LANE CHANGE SWITCH [M01-2]
WIPER AND INTERMITTENT VOLUME SWITCH [M01-1]

24.04.2008
Page 3 of 3
WASHER SWITCH [M01-1]
REAR WIPER AND WASHER SWITCH [M01-1]

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Horn > Horn > Repair procedures,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Horn > Horn > Repair procedures
REMOVAL
1. Remove the bolt holding the horn and remove the horn assembly.
INSPECTION
1. Test the horn by connecting battery voltage to the 1 terminal and ground the 2 terminal.
2. The horn should make a sound. If the horn fails to make a sound, replace it.
ADJUSTMENT
After adjustment, apply a small amount of paint around the screw head to keep it from loosening.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And > Description
and Operation
DESCRIPTION
Body Control Module (BCM) unify the functions of ETACS
module, mirror folding unit, immobilizer unit, flasher unit,
door lock relay, chime belland keyless antenna.
BCM practices diagnosis with hi-scan to find out input or
output error.
BCM BLOCK DIAGRAM

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And >
BODY CONTROL MODULE (BCM)
BCM TERMINAL CONNECTION

Connector
Terminal No.
Description
NC
NC
Not used
ESPS (IG1)
SEAT BELT BUCKLE (RH)

24.04.2008
Page 2 of 6
SEAT BELT BUCKLE (LH)
CRASH SIGNAL
NC
A/BAG DIAG (FROM ESPS)
10
A/BAG WARN'G IND
H/LAMP LOW RLY (S2)
Not used
FRONT WIPER RLY CONTROL
FRONT FOG RLY-S2
TURN SIGNAL (FR)
Not used
Not used
FRONT WIPER RLY (IG2)
TURN SIGNAL (FL)
10
POSITION LAMP (RH)
11
POSITION LAMP (LH)
12
ABS MODULE (IG1)
13
ALT 'L'
14
FUSE & RLY BOX (IG2)
15
WIPER PARK OUTPUT
16
WASHER MOTOR
17
NC
18
NC
B+ 50A
NC
TAILGATE LOCK SW
ASSIST DOOR LOCK SW
ASSIST DOOR SW
Not used
TAILGATE SW
NC
DRIVER DOOR LOCK SW
DRIVER DOOR SW
10
SEAT BELT SW
11
NC
12
NC
Not used
BACKUP LAMP
Not used
OUTSIDE MIRROR
TAIL LAMP (RH)
DOOR LOCK FEED
NC
DOOR UNLOCK FEED

24.04.2008
Page 3 of 6
NC
10
TAIL LAMP (LH)
11
4 DOOR SW
12
Not used
13
TURN SIGNAL (RL)
14
NC
15
LUGGAGE LAMP
16
NC
17
TURN SIGNAL (RR)
18
AMP
19
OUTSIDE MIRROR HEATER
20
Not used
21
REAR WIPER MOTOR (IG2)
22
TAILGATE OPEN SW
REAR HEATED
POWER WINDOW SW
IMMOBILIZER ANTENNA 1
NC
TURN SIGNAL SW (RH)
DOOR WARN'G SW
TAIL SW
Not used
CODE SAVER
NC
HOOD SW
10
NC
11
IMMOBILIZER ANTENNA 2
12
EXPORT GND INPUT
13
TURN SIGNAL SW (LH)
14
AUTO LIGHT SW INPUT
15
NC
16
HEAD LAMP SW
17
FRONT FOG SW
18
HAZARD SW
19
REAR DEFOG SW
20
Not used
AIR CONDITIONER SW
CLUSTER BATTERY CHARGE
Not used
TCS SW (IG1)
CLUSTER (IG1)
CLUSTER (IG1)
CLUSTER (T/SIG LH OUT)
ECU (IG1)

24.04.2008
Page 4 of 6
CLUSTER (T/SIG RH OUT)
10
RR HTD SW (FOR INDICATOR)
11
CLUSTER (A/BAG IND)-IG1
12
HI-SCAN (B+)
13
DIGITAL CLOCK (ACC)
14
IMMOBILIZER INDICATOR
15
EXTERNAL TAIL LAMP (RH)
16
HI-SCAN (A/BAG DIAGNOSIS)
17
AIR CONDITIONER (IG2)
18
AUTO LIGHT GND
19
DIAGNOSIS & CODE SAVING
20
IMMOBILIZER W LINE
MULTI-FUNCTION INT(T) GND
SIREN CONTROL
KEY HOLE ILL.
SPEED SENSOR
INTERIOR ILL.
CLUSTER (A/BAG WARN'G IND)
DCT
DOOR AJAR
MULTI-FUNCTION INT
10
MULTI-FUNCTION INT (T)
11
AUTO LIGHT SIGNAL
12
Not used
13
OVER SPEED GND (CLUSTER)
14
NC
15
AUTO LIGHT SUPPLY
16
TAILGATE OPEN IND
CIGAR LIGHTER
WIPER LOW
WIPER HI
BACKUP SW
AUDIO (ACC)
MULTI-FUNCTION WASHER SW
BACKUP LAMP SW
START INHIBIT RELAY
SEAT HEATER SW (IG2)
10
JOINT MAIN 3 (B+)
11
STOP SW (B+)
12
IGNITION COIL (V6)
13
Not used
14
WIPER PARK'G
GND 1
NC

24.04.2008
Page 5 of 6
BLOWER MOTOR
IG SW (IG1)
GND 2
WIPER SW POWER
IG SW (ACC)
IG SW (IG2)
SUNROOF (IG2)
ROOM LAMP (B+)
ROOF LAMP DECAY CONTROL
ECM
Not used
S/ROOF & ROOM LAMP GND
ECM MIRROR
SUNROOF MOTOR (B+)
FUSE
Fuse No.
Capacity
Connection circuit
20A
Ignition coil (2.7L), Electronic chrome

mirror
20A
AMP
10A
Back-up lamp switch, Transaxle range

switch, Cruise control module, Stop
lamp switch
10A
Instrument cluster (A/BAG IND.)
15A
Air bag control module, Seat belt buckle

switch
10A
Mirror defogger
10A
Hazard relay
15A
Rear wiper motor, Rear wiper relay
10A
Right tail lamps, Glove box lamp
10
20A
Front wiper motor, Front wiper relay
11
10A
Blower relay, Blower motor
12
30A
Defogger relay
13
15A
Stop lamp switch, Burglar alarm horn

relay
14
10A
Left tail lamps
15
10A
A/C control module, Blower relay
16
10A
ECM, Multi gauge unit, TCM, Vehicle

speed sensor
17
10A
Instrument cluster (Power), Preexcitation resistor, DRL control module,

Generator
18
10A
Room lamp, Clock, Audio, Data link

connector, Multi gauge unit
19
30A
Power window relay
20
15A
Trunk lid switch

24.04.2008
Page 6 of 6
21
10A
A/C relay, AQS sensor, Head lamp

relay, DRL control module
22
10A
Not used
23
15A
Cigarette lighter, Outside mirror switch
24
15A
Sunroof, Power door lock/unlock relay
25
20A
Seat warmer
26
10A
ABS control module, TCS switch
27
10A
Audio, Digital clock
10/15A
20/30A
Spare fuse

24.04.2008
Page 1 of 5
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And
> Troubleshooting
TROUBLESHOOTING
BCM practices input/output actuation test with the hi-scan to find out input/output errors.
INPUT/OUTPUT MONITORING
POWER
FLASHER
LAMP
INPUT / OUTPUT
NAME
DISPLAY
INPUT
Battery voltage
Voltage
INPUT
Key warning switch
Key removal
Key insert
INPUT
Accessory switch
OFF
ON
INPUT
IGN1 switch
OFF
ON
INPUT
IGN2 switch
OFF
ON
INPUT
Alternator voltage
Voltage
OUTPUT
Start inhibitor
Enable
Disable
INPUT
Turn signal switch (LH)
OFF
ON
INPUT
Turn signal switch (RH)
OFF
ON
OUTPUT
Turn signal lamp (LH)
OFF
ON
OUTPUT
Turn signal lamp (RH)
OFF
ON
INPUT
Hazard swtich
OFF
ON
INPUT
Hazard detection current
Current
INPUT
Tail lamp switch
OFF
ON
OUTPUT
Tail lamp
OFF
ON
INPUT
Head lamp switch
OFF
ON
INPUT
Auto light area option
Domestic
Export
INPUT
Auto light sensor
Voltage
OUTPUT
Head lamp
OFF
ON
INPUT
Front fog lamp switch
OFF
ON
INPUT
Rear fog lamp switch
CONDITION
Control the head

lamp at the auto light
mode
OFF

24.04.2008
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ON
DOOR
LOCK &
FOLING
WIPER
OUTPUT
Rear fog lamp
OFF
ON
INPUT
Driver's door switch
CLOSE
OPEN
INPUT
Assist door switch
CLOSE
OPEN
INPUT
All door switch
CLOSE
OPEN
OUTPUT
Key hole illumination
OFF
ON
OUTPUT
Room lamp
OFF
ON
INPUT
Hood switch
CLOSE
OPEN
INPUT
Tailgate switch
CLOSE
OPEN
INPUT
Tailgate key unlock switch
OFF
ON
INPUT
Driver's door lock switch
LOCK
UNLOCK
INPUT
Assist door lock switch
LOCK
UNLOCK
OUTPUT
Lock output
OFF
ON
OUTPUT
Unlock output
OFF
ON
INPUT
Folding switch
OFF
ON
OUTPUT
Folding output
OFF
ON
OUTPUT
Unfolding output
OFF
ON
INPUT
Front washer switch
OFF
ON
INPUT
Intermittent wiper switch
OFF
ON
OUTPUT
Intermittent wiper relay
OFF
ON
INPUT
Intermittent wiper
resistance
Resistance
INPUT
Low/high wiper input
OFF
ON
INPUT
Wiper parking switch
Motor operation
The key hole

illumination is turned
off when the ignition
switch is turned on.
When open the

tailgate with other
key.

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Parking position
OTHERS
OUTPUT
Snow safe relay
OFF
ON
Snow safety
operation
OUTPUT
Power window power
OFF
ON
INPUT
Seat belt switch
Seat belt removal

Seat belt installation
OUTPUT
Seat belt indicator
OFF
ON
OUTPUT
Chime bell
OFF
ON
INPUT
Over speed signal
OFF
ON
INPUT
Rear window defogger

switch
OFF
ON
OUTPUT
Rear widnow defogger
OFF
ON
On starting state
INPUT
Crash sensor
OFF
ON
On crash state
OUTPUT
Burglar alarm horn
OFF
ON
When the vehicle

speed is over 120km
The components which is on and off as like turn signal lamp, seat belt indicator, burglar alarm horn, chime bell
and front wiper relay are displayed "ON"while controlling.
MENU COMPOSITION
1. INPUT/OUTPUT MONITORING
2. INPUT ACTUATION TEST

3. OUTPUT ACTUATION TEST
INPUT SIGNAL ACTUATION TEST
NUMBER
INPUT /
OUTPUT
NAME
OPERATION
INPUT
Turn signal switch (LH)
INPUT
Turn signal switch (RH)
INPUT
Hazard switch
Hazard lamp
INPUT
Turn signal lamp

detection current
Double flash
INPUT
Tail lamp switch
Tail lamp
INPUT
Auto light switch
Tail/head lamp
INPUT
Auto light sensor voltage
CONDITION
Turn signal lamp switch

ON
Auto light switch ON

24.04.2008
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Tail lamp and front fog

lamp ON or head lamp
ON
INPUT
Rear fog lamp switch
Rear fog lamp
INPUT
Driver's door lock switch
Door lock/unlock output
10
INPUT
Assist's door lock switch
Door lock/unlock output
11
INPUT
Folding switch
Mirror folding/unfolding
12
INPUT
Front washer switch
Front wiper relay
13
INPUT
Intermittent wiper switch
Front wiper relay
14
INPUT
Seat belt switch
Seat belt indicator
15
INPUT
Over speed signal
Chime
16
INPUT
Crash sensor
Door unlock output
Only one time when IGN

ON
17
INPUT

switch

output
Starting state
Actuation test is turned off under the following conditions.

1. When the [STOP] switch is pressed.
2. When the [ESC] switch is pressed.
3. When the hi-scan is turned off.
4. When the hi-scan is disconnected.
5. When the actuation test is turned off by the hi-scan timer.
OUTPUT SIGNAL ACTUATION TEST
NUMBER
INPUT /
OUTPUT
NAME
OPERATION
CONDITION
OUTPUT
Start inhibitor
Starting disable
Timer (15 sec.)
OUTPUT
OUTPUT
OUTPUT
Tail lamp
Tail lamp
OUTPUT
Head lamp
Head lamp
OUTPUT
Rear fog lamp
Rear fog lamp
OUTPUT
OUTPUT
Room lamp
Room lamp
OUTPUT
Door lock output
Door lock
10
OUTPUT
Door unlock output
Door unlock
11
OUTPUT
Folding output
Mirror folding
12
OUTPUT
Unfolding output
Mirror unfolding
13
OUTPUT
Intermittent wiper relay
Wiper output
14
OUTPUT
Snow safe relay
Wiper not operating
15
OUTPUT
Power window power
Power window power
16
OUTPUT
17
OUTPUT
Burglar alarm horn
Burglar alarm horn
Actuation test is turned off under the following conditions.

1. When the [STOP] switch is pressed.

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2.
3.
4.
5.
When the [ESC] switch is pressed.

When the hi-scan is turned off.
When the hi-scan is disconnected.
When the actuation test is turned off by the hi-scan timer.

24.04.2008
Page 1 of 11
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And >
Repair procedures
REMOVAL
1. Disconnect the negative (-) battery terminal
2. Remove the lower crash pad panel.
3. Remove the BCM after removing the bolt and disconnect the wire connectors.
INSPECTION
BCM FUNCTION
1. Vehicle speed sensing intermittent wiper
Vehicle speed is determined by number of speed sensor pulses input in one second. The current speed and
the previous speed for the vehicle is to be compared. The higher of the two values is to be used in the
intermittenttime calculation. The previous value is updated every second.
When Ignition 2 is on and the wiper switch is in the intermittent position, the wiper shall operate with speed
dependant intermittent time. A single wipe is achieved by driving the wiper relay until the park switch is able to
take over unless the dwell time between wipes is too short. In this case it wouldbe on all the time. This avoids
unnecessary clicking of the wiper relay.
Time specification
T1 : Max. 0.5 sec.
T2 : 0.6~0.7 sec. (Time of wiper motor 1 rotation)
T3 : At vehicle speed = 0km/h.
2.60.7 sec. (VR=0k)~18.01sec (VR=50K)
At vehicle speed = 100km/h or more.
1.00.2sec (VR=0k)~10.01sec (VR=50K)
2. Washer linkage wiper
IG2 must be on for this function to operate.
When the washer switch is on for more than 0.3 sec, the wiper output is activated immediately. The length of
time the washer switch is held foris then evaluated to determine the number of swipes required.
If the washer switch is on for more than 0.2 but less than 0.6 sec, then wiper performs a single swipe.
Alternatively, if the washer switch is held for more than 0.6s then the wipers must finish the current swipe
theperform another two swipes.
If washer switch is on less than 0.2 seconds make no wiper action.
During intermittent wiping, a washer linkage wipe has higher priority.

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During start condition (IG1 on and IG2 off) washer input to be ignored. This is to prevent quality problem of
single wipe occurring during startingof car.
A. Time specification
T1 : 0.3 sec.
T2 : 0.6~0.8 sec.
(Time to complete current swipe only)
T3 : 0.2 - 0.6 sec.
B. Time specification
T1 : 0.3 sec.
T2 : 2.5~3.8 sec.
(Time to complete current swipe plus 2 swipes)
T3 : 0.6 sec. or more
3. Snow build up wiper bounce prevention (snow mode)
Without this feature, as snow builds up at the base of the windscreen, it becomes more difficult for the wiper
arms to completely reach the park position. Once the wipers have been turned off and the wipers have
returned to the park position, the compacted snow is able to drive the wiper arms back up and reactivate the
park switch. This, in turn, drives the wiper arms towardspark again and the cycle repeats itself.
This feature is required to prevent wiper bounce from happening when snow has accumulated on the
windscreen.
Detection of wiper bounce
If the BCM detects that the wipers have parked more than a maximum amount times within a time period then
wiper bounce is detected. The maximum amount of times can be set in EEPROM using the variable wipe
snow parks. The time can also be set in EEPROM using the variable wipe snow time. The units ofwipe snow
time is milliseconds.
Bounce prevention
If wiper bounce has been detected then the wiper bounce prevention relay is driven to open circuit. The wiper
bounce relay is in series with the park switch and thus can prevent automatic parking. This relay is normally
closed.
Termination of bounce prevention
Termination is achieved by ceasing to drive the wiper bounce relay to open circuit. Bounce prevention can be
terminated in the following ways:
A. Ignition off. The power source for the wiper motor is derived from IG2, thus there will be no drive to park
with ignition off. As such bounceprevention is not required.
B. The wiper stalk has moved from the OFF position.
4. Wiper motor stall protection
This feature offers some protection to the wiper motor if ice has frozen the wiper blades to the windscreen or
the wipers have jammed for some other reason. During low and high wiper selection, no protection is offered
sincethe stalk drives the wiper motor directly.
If the wiper motor has not parked within wipe stall time, then wiper motor is considered to have stalled. In this
case, the wiper bounce relayis driven to open circuit until either of the following events occurs:
A. The ignition has been switched to the off position.
B. The wipers have returned the park position by a manual operation (Low or high speed selected)
C. The wiper stalk has moved from the OFF position.
Wipe stall time can be set in EEPROM and it's units are 100ms.
During INT operation, if the time between initiating and concluding a wipe is greater than Wipe stall time then
the wiper motor is also considered to have stalled. In this case, the current wipe is terminated and INT
operationis cancelled until either of the following events occurs:

24.04.2008
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A. The wiper stalk has moved from the OFF position.

B. The ignition has been switched off.
5. Knob activated central locking
If either the drivers door lock or the assistant door lock is moved from the locked position to the unlocked
position then all other door locks will follow, but the tailgate will not change state. Conversely, if the drivers
door lock or the assistant door lock is moved from the unlocked position to the locked position then all other
door locks will follow. Locking and unlocking is achieved by driving the door lock motors in the respective
direction for0.5 seconds.
Installation of the battery should not change the state of the locks.
Time specification
T1 : 0.50.1 sec.
6. Ignition key reminder (Locking of key in vehicle prevention)
If the key is in the ignition and the driver's door or assist door is open and the vehicle is locked using driver's
knob or assist knob, then the central locking system will issue an unlock pulse of duration 1 second tothe all
doors thus preventing locking of the vehicle.
If a Knob remains locked, then the central locking shall issue a maximum of 3 pulses of 0.5 second duration to
unlock the vehicle. If during thesepulses, the door lock knob becomes unlocked, stop the next pulse.
If vehicle speed is greater than 3 km/h, ignition key reminder function is disabled.
If door warning switch is off and ignition input is on then ignition key reminder function is disabled.
Time specification
T1 : 1 sec.
T2 : 0.5 sec.
T3 : Max. 0.5 sec.
7. Key operated warning (key in ignition reminder chime)
If the key is in ignition key cylinder and the drivers door is opened, the chime bell sounds. This tone is the
same as the seatbelt warning chime and over speed warning chime. The chime sound is generated with a
800Hz drive, amplitude modulated with an exponentially decaying envelope of time constant 10.25 seconds.
If the door is closed or the key is removed,the chime stops immediately.
8. Crash detection - Unlock

If IG1 is on and a crash signal is received, send an unlock pulse to the door locks. Unlock signal must occur

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within 12 5 msec after crash signal is received. Unlock pulse is 5 sec period. If crash unlock is not usedin a
particular variant then the crash input is to be left floating.
The crash sensor is normally high. A crash signal is defined as when voltage is below 1.5V. Crash input signal
characteristic: Normal hi & 200msec period ground after crash. Only one crash unlock can occur duringone
ignition on cycle.
Time specification
T1 : 200 msec.
T2 : 12 5 msec.
T3 : 5 sec.
9. Auto light control
Lights must be turned on 500100 msec. after the input light to the light sensor has been received.
Lights must be turned off 31 sec. after the input light to the light sensor has been removed. Head lamps must
be turned off 300msec before the tail lamps are switched off. When the headlight switch is in the auto position
and light intensity fulfilling the table below is detected, the tail lamp and the head lamps will be turned on.
These figures are based upon theuse of untinted solar glass.
The headlamps must remain on when the headlamp switch is rotated from the ON to the AUTO position until
such time that the light sensor input isevaluated as per the following table.
If the option select input is grounded, both the headlamps and the tail lamps shall illuminate when the voltage
drops below the tail lamp threshold. When the voltage rises above the tail lamp threshold, both the
headlampsand the tail lamps shall extinguish.
Tail lamp
Head lamp
ON
1.77 008V
0.61 0.06V
OFF
3.47 0.10V
1.00 0.06V
10. Tail lamp auto cut

When key is in the ignition key cylinder and tail lamp switch is on, followed by removing key from ignition and
then opening of the drivers doors will turn off the tail lamp relay. If driver door is opened first, followedby
removing key from ignition, then tail lamp is switched off.
If tail lamps have been cut automatically, and then the tail lamp switch is turned off and on, then tail lamp is
switched on and auto cut function is cancelled. If tail lamps have been cut automatically, and the ignitionkey
is inserted, then tail lamps are turned on.
11. Power window timer

When Ignition 2 is on, the power window relay output is turned on.
When Ignition 2 is turned off the power window feed is maintained on for 30 seconds and then turned off.
If the driver door or assist door is opened during 30 sec interval the output shall be turned off immediately.
If doors are open and ignition 2 is then turned on, the output shall be turned on immediately. If doors are
open and ignition 2 is then turnedoff, the output shall be turned off immediately.

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Time specification
T1 : 303 sec.
12. Rear defog control (Rear demister control)
When the engine is running (Alternator"L"is high) a contact of the rear defog switch (momentary action) will
switch the rear defog relayoutput on for 20 minutes duration.
If the rear defog switch is pressed again during this time, or if the engine stops, the rear defog relay is
immediately switched off.
Time specification
T1 : 201 min.
13. Ignition key hole illumination
When the drivers door is open, the ignition key illumination is turned on.
When driver door is closed, illumination is on for 10 sec., then off.
When the assist door is open, the ignition key illumination is turned on.
When assist door is closed, illumination is on for 10 sec., then off.
The key illumination is extinguished immediately when the ignition 1 comes on.
Locking of the vehicle from the transmitter (arm state) shall extinguish ignition key Illumination.
Time specification
T1 : 101 sec.
T2 : 0~10 sec.
14. Decayed room lamp (Illuminated entry with fade out)
When the first door (driver, or assist) is opened, the interior light shall brighten to full intensity in less than 0.5
seconds.
When the last door is closed, the room lamp will drop to 75% intensity then fade out over 5.50.5 seconds.
If the ignition 2 is switched on when room light is fading out, the room lights switch off immediately.
If the door open signal is on for less than 0.1 seconds, then no illumination occurs.
Lamps must not flicker during fade operation, If a door open or ignition on.
When transmitter (TX) unlock is received, room lamps are turned on in less than 0.5 second for maximum 30
seconds.

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While room lamp is on due to TX unlock, if another TX unlock is received, then room lamp is again on for 30
sec.
When TX lock(arm state) is received during 30 second from TX unlock, lamp is turned off immediately.
If TX lock (arm state) is received during fade out, the room lamp is switched off immediately.
Door locking functions should not be influenced by room lamp decay functions.
Time specification
T1 : 5.50.5 sec.
T2 : 30 sec.
15. Seat belt warning
(1) Seat belt warning indicator
Whenever the ignition 1 is turned on the seat belt warning indicator is illuminated for total time 6 seconds,
with period 0.6 sec and duty rate50%. It is not extinguished if the seat belt is sensed as fastened.
If ignition 1 is already on and the seat belt is removed, the indicator is illuminated for total time 6 seconds,
with period 0.6 sec and duty rate50%.
If ignition 1 is switched off in while the indicator is illuminated, the illumination is switched off immediately.
(2) Seat belt warning chime
Whenever the ignition 1 is turned on the seat belt warning chime is sounded for total time 6 seconds, with
period 0.9 sec and duty rate 50%. Itis silenced immediately if the seat belt is sensed as fastened.
If ignition 1 is already on and the seat belt is removed, the chime is sounded for total time 6 seconds, with
period 0.9 sec and duty rate 50%.
If ignition 1 is switched off in while the chime is sounding, the chime is switched off immediately.
Time specification
T1 : 61 sec.
T2 : 0.450.1 sec.
T3 : 0.30.1 sec.
16. Over speed warning chime
If the IGN2 is on, and the over speed input is grounded by cluster, chime is sounded until over speed input
by cluster is opened.
17. Folding mirror unit

If ACC is on, with each press of the folding mirror switch, the mirror fold and unfold outputs will operate

24.04.2008
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alternatively for 166 sec. A second press of the fold switch during an output shall cause the oppositeoutput
to occur.
If the folding mirror switch is pressed within 30 seconds after the ACC signal is removed, the mirror outputs
(folding or unfolding) will operate for 166 sec. If during the mirror operation, the folding mirror switch is
pressed again then the opposite operation will commence again. If after the ACC signal is removed, the
folding mirror switch is repressed within the 166 sec, the mirror outputs will operate for a further 166sec.
Time specification
T1 : 30 sec.
T2 : 166 sec.
18. Rear fog lamp control
When IGN1 is on and:
A. Tail lamps are on by switch or auto light
B. Headlamps are on by switch or auto light or front fog switch is on, then if rear fog switch is contacted the
rear fog lamps are turned on.
ANTI-THEFT FUNCTION
1. Arm function
Pressing the remote key lock button will result in a 0.5-second pulse issued to lock all doors.
Pressing the remote keypad unlock button once will result in a 0.5-second unlock pulse issued to unlock all
doors.
As part of the arming sequence the alarm first enters a pre-armed state before falling into the armed state.
During this pre-armed state alarm triggers are ignored. Pre-armed state can be reached from the alarmed
state, the start inhibit state or the disarmed state. Pre-Arming of the alarm can be achievedby a press of the
lock button on the remote key.
In the pre-armed state the visible and audible warnings are disabled.
This system enters the armed state if it is in the pre-armed state and, after 0.6 sec, check actuator lock and
each door, hood and tail gate close,and no door warning switch (no key in ignition).
On entering the arm state, a single flash of the hazard lamps is given, period of cycle 2 second, duty rate
50%.
If TX lock signal is received when a door, tail gate or hood is open, then lock output is given and a flash of
hazard is not given.
After the armed state is entered, if a lock signal is received then a single flash of the hazard lamps is given,
period of cycle 2 second, dutyrate 50%.
The armed state cannot be reached by locking the car with the keys.

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Time specification
T1 : 0.5sec.
T2 : Max 2sec.
T3 : 1.00.2sec.
2. Disarm function
Disarming can be performed while the alarm is armed, or alarming, or after alarming. The alarm can be
disarmed by the following methods:
A. Pressing the unlock button on the TX key. The hazard lamps shall be flashed twice for 1sec period (of
cycle), 50% duty rate.
B. If door warning switch is on, IGN1 and IGN2 are on in arm state, then arm state should be immediately
cancelled. This means that the driveris inside the vehicle before pushing TX lock, so system should not
arm.
In the disarm state the visible and audible warnings are disabled and start is enabled.
In the disarm state, if TX key unlock command is received, then the hazard lamps shall be flashed twice for
period of cycle 1 sec, 50% duty rate.
Disarm state cannot be reached using the door locks by key.
Time specification
T1, T2 : 0.50.1sec.
3. Alarm function
(1) European countries
Once armed, should any door, hood or the tailgate be opened, then:
A. Start relay drive output is disabled, so starting is inhibited.
B. Audible (horn) and visual (hazard lamp) warnings are issued, for 27seconds duration. The horn
warning is continuously occurring in this period.The hazard lamps operate with 1 sec period, 50 % duty
rate.
The alarm is given in the case where a door is opened with a key.
Time specification
T1 : 272 sec.
T2 : 0.50.1 sec.
(2) Non European countries

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Once armed, should any door, hood or the tailgate be opened, then:
A. Start relay drive output is disabled, so starting is inhibited.
B. Audible (horn) and visual (hazard lamp) warnings are issued, for three cycles, each cycle 271 sec.
duration on, 101 sec. off. The horn warning is continuously occurring during the on period. The
hazardlamps operate with 1 sec period, 50 % duty rate during the on period.
The alarm is given in the case where a door is opened with a key.
After this time, the system maintains the start inhibit state, where no audible and visual warnings are
issued but engine starting is not possible.
Time specification
T1 : 272 sec.
T2 : 101 sec.
T3 : 0.50.1 sec.
4. Operation during alarm conditions
(1) Cancelling audible alarm with the remote transmitter
CASE 1 : Door closed
During or after alarming and then closing all doors and a TX lock signal is received Then
A. The lock command is executed with 0.5 sec. ON
B. Horn and start inhibition are OFF
C. Hazard lamp is flashed one time (period : 2 sec., duty: 50%, within 2 sec.)
D. The state goes to arming mode (after a lock state check)
E. The start is enabled
Time specification
T1 : 0.5 sec.
T2 : 1.00.2 sec.
CASE 2 : Door Open
During or after alarming, with a door open and a TX lock signal is received Then
A. The lock command is executed with 0.5 sec. ON
B. Horn is disabled and start is enabled after confirmation of actuator lock
At this time, when the door is closed,
A. Hazard lamp is flashed one time (period : 2 sec., duty 50%)
B. The state goes to arming mode

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Time specification
T1 : 0.5 sec.
T2 : 1.00.2 sec.
(2) New alarm conditions
Second alarm condition during alarming.
When another alarm occurs during alarming, the starting is disabled, and the alarm continues to sound for
the remained time of warning signal. The alarm continues to sound after the second alarm condition is
removed.
New alarm condition occurs after alarming (with all entrances closed)
If any entrance is opened again then
A. The horn is ON 3 times (EC area : one time for 27sec.)
B. Start is disabled
C. Hazard lamps flash during the ON time of horn
New alarm condition occur after alarming (with any entrance open).
If another entrance is opened, the BCM keeps start disabled and there is no horn output.
(3) Key operation during alarm

After the alarm state or start inhibit state are entered, if door warning switch on (key in ignition) & IGN 2
ON, if IGN 2 state is changed to OFFwithin 30sec, remain in alarm state.
(4) Disarming using the key
During alarming, in case that door warning switch (key in) is ON and then IGN1 and IGN2 are both ON for
30 sec continuously, the alarm is cancelled,and the system enters the disarm state.
After alarming, in case that door warning switch (key in) is ON and then IGN1 and IGN2 are both ON for
30 sec continuously, the alarm is cancelled,and the system enters the disarm state.
5. Alarm state in power down

If the battery is disconnected to the BCM in the following states:
A. Alarm
B. After alarming
Upon restoring the battery, the alarm state shall be entered and the alarm cycle shall restarted (timer reset to
0).

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If the battery is disconnected in arm state, upon restoring the battery, arm state is resumed.
6. Automatic relocking
If either:
A. Car is unlocked but all doors closed, or
B. Car is closed and locked by keys, or
C. Car is closed, locked and in armed state.
Then if an unlock command sent from the TX key is received by the BCM, and within 30 seconds no door,
hood or tail gate has been opened or TX lock received, then the BCM will instigate a lock doors function and
enter arm state. A single flash of the hazard lamps is given, period of cycle 2 second,duty rate 50%.
If another unlock command is sent within this time then reset timer.
If a door is already open and an unlock command is received, then the auto relocking function shall be
disabled. Even in the case where the dooris closed within 30 seconds.
7. Tail gate alarm triggers
During the armed state, if the tail gate is opened by the key switch, the car remains in the armed state and
does not enter the alarm state. Whilst the tailgate is open, the hood, drivers and passenger doors are still
armed and capable of causing an alarm trigger. Once the tail gate is closed, the tailgate trigger rearms after
two seconds. If the interior tailgate release switch is pressed whilst the car is armed and the tailgate has been
closedand armed, the alarm state will be entered.
If the tailgate is unlocked and not opened within 25 seconds, the tailgate section will once again be armed and
capable of trigger.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry And > Transmitter >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Keyless Entry
And > Transmitter > Repair procedures
INSPECTION
1. Check that the red light flickers when the door lock button or unlock button is pressed on the transmitter.
2. Remove the battery and check voltage if the red light doesn't flicker.
Standard voltage : 3V
3. Replace the battery if voltage is below 3V and replace the remote control switch if it is inoperable after
replacing the battery.
Battery : Lithium CR2032 (3V, 220mA/h)
TRANSMITTER CODE SAVING METHOD

1. To store transmitter code, first connect the hi-scan (pro) to the Data Link Connector (DLC) in driver side crash
pad lower panel.
2. Turn the power on hi-scan (pro) with the ignition switch ON.
3. Select the vehicle model on hi-scan (pro).
4. After selecting "CODE SAVING" menu then button "ENTER" key.
5. Proceed as follow steps and then code saving is completed.
(1) Press [ENTER] key, if you are ready.
(2) Press the transmitter [LOCK] button above 1 second.
(3) If you save transmitter one more, press other transmitter [LOCK] button above 1 second.
(4) Turn the hi-scan (pro) off, and check the keyless entry system.
INSPECTION
1. Check that the red light flickers when the door lock button or unlock button is pressed on the transmitter.

24.04.2008
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2. Remove the battery and check voltage if the red light doesn't flicker.
Standard voltage : 3V
3. Replace the battery if voltage is below 3V and replace the remote control switch if it is inoperable after
replacing the battery.
Battery : Lithium CR2032 (3V, 220mA/h)
PROGRAMMING TRANSMITTER CODE

1. To program the transmitter code, first connect the hi-scan (pro) to the Data Link Connector (DLC) in drive side
crash pad lower panel.
2. Turn the power on hi-scan (pro) with the ignition switch ON.
3. Select the vehicle model on hi-scan (pro).
4. After selecting "CODE SAVING" menu then button "ENTER" key.
5. Proceed as follow steps and then code saving is completed.
(1) Press [ENGER] key, if you are ready.
(2) Press the transmitter [LOCK] button above 1 second.
(3) If you save transmitter one more, press other transmitter [LOCK] button above 1 second.
(4) Turn the hi-scan (pro) off, and check the keyless entry system.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Fuses And Relays > Relay Box (Engine
Compartment) > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body
Electrical System > Fuses And Relays > Relay Box (Engine Compartment) > Components and Components
Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Fuses And Relays > Relay Box
(Engine Compartment) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical
System > Fuses And Relays > Relay Box (Engine Compartment) > Repair procedures
INSPECTION
1. Check for a blown fusible link with an ohmmeter.
2. If a fusible link burns out, there is a short or some other problem in the circuit. Carefully determine the cause
and correct it before replacingthe fusible link.
The fusible link will burn out within 15 seconds if a higher than specified current flows through the circuit.

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Fuses And Relays > Relay Box (Passenger
Compartment) > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body
Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Components and Components
Location
COMPONENTS
FUSE
Fuse No.
Capacity
Connection circuit
20A
Ignition coil (2.7L), Electronic chrome

mirror
20A
AMP
10A
Back-up lamp switch, Transaxle range

switch, Cruise control module, Stop

24.04.2008
Page 2 of 2
lamp switch
4
10A
Instrument cluster (A/BAG IND.)
15A
Air bag control module, Seat belt buckle

switch
10A
Mirror defogger
10A
Hazard relay
15A
Rear wiper motor, Rear wiper relay
10A
Right tail lamps, Glove box lamp
10
20A
Front wiper motor, Front wiper relay
11
10A
Blower relay, Blower motor
12
30A
Defogger relay
13
15A
Stop lamp switch, Burglar alarm horn

relay
14
10A
Left tail lamps
15
10A
A/C control module, Blower relay
16
10A
ECM, Multi gauge unit, TCM, Vehicle

speed sensor
17
10A
Instrument cluster (Power), Preexcitation resistor, DRL control module,

Generator
18
10A
Room lamp, Clock, Audio, Data link

connector, Multi gauge unit
19
30A
Power window relay
20
15A
Trunk lid switch
21
10A
A/C relay, AQS sensor, Head lamp

relay, DRL control module
22
10A
Not used
23
15A
Cigarette lighter, Outside mirror switch
24
15A
Sunroof, Power door lock/unlock relay
25
20A
Seat warmer
26
10A
ABS control module, TCS switch
27
10A
Audio, Digital clock
10/15A
20/30A
Spare fuse

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Fuses And Relays > Relay Box
(Passenger Compartment) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body
Electrical System > Fuses And Relays > Relay Box (Passenger Compartment) > Repair procedures
INSPECTION
1. Check for a burnt relay with an ohmmeter.
2. If a relay burns out, there is a short or some other problem in the circuit. Carefully determine the cause and
correct it before replacing therelay.
INSPECTION OF FUSES
1. Fuse blown due to over-current.
Prior to replacing the fuse with a new one, check the circuit for a short and the related parts for abnormal
conditions. Only after the correction of a short or replacement of abnormal parts, should a fuse with the same
ampererating be installed.
2. Fuse blown due to repeated on-off current.

Normally, this type of problem occurs after a fairly long period of use, and is less frequent than #1 above. In
this case, you may simply replacewith a new fuse of the same capacity.
A blade type fuse is identified by the numbered value in amperes. If the fuse is blown, be sure to replace a
fuse with the same ampere rating. If a fuse of higher capacity than specified is used, parts may be damaged
and a danger of fire exists. To remove or insert a fuse, use the fuse pullerin the fuse box.

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Indicators And Gauges > Instrument Cluster
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Indicators And
Gauges > Instrument Cluster > Schematic Diagrams
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Indicators And Gauges > Instrument Cluster
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System >
Indicators And Gauges > Instrument Cluster > Components and Components Location
COMPONENTS

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Indicators And Gauges > Instrument
Cluster > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System >
Indicators And Gauges > Instrument Cluster > Repair procedures
REMOVAL
2. Remove the cluster housing after removing 2 screws.
3. Remove the 4 screws holding the cluster and remove the instrument cluster.
INSPECTION
SPEEDOMETER
1. Adjust the pressure of the tires to the specified level.
2. Drive the vehicle onto a speedometer tester. Use wheel chocks as appropriate.
3. Check if the speedometer indicator range is within the standard values.
Do not operate the clutch suddenly or increase/ decrease speed rapidly while testing.
Tire wear and tire over or under inflation will increase the indication error.
Velocity
(Km/h)
20
40
60
80
100
120
140
Tolerance
(Km/h)
20~24.4
40~43
60~64.4
80~85.5
100~105.5
120.5~126
140.5~146
Tolerance
(Km/h)
20~24.4
40~44.4
60~65.4
81~86.5
102~107.5
123~128.5
144~149.5
Velocity
(Km/h)
160
180
200
220
240
Area

24.04.2008
Page 2 of 6
Tolerance
(Km/h)
160.5~166 181~186.5 201~206.5
Tolerance
(Km/h)
165~170.5 186~191.5 207~212.5 227.7~233.5 248.5~254.3
221~226.7
241~246.7
Others
EEC & General
Velocity (MPH)
10
20
40
60
80
Tolerance (MPH)
10~14.4
20~23
40~44.4
60~65.5
80~85.5
Tolerance (MPH)
8.5~11.5
18.5~21.5
38.5~41.5
58.3~61.7
78.3~81.7
Velocity (MPH)
100
120
140
160
Area
Tolerance (MPH)
100.5~106
120.5~126
140.5~147
160.5~167
Except U.S.A
Tolerance (MPH)
98.3~101.7
118.3~121.7
138.1~141.9
158.1~161.9
U.S.A
TACHOMETER
1. Connect the scan tool to the diagnostic link connector or install a tachometer.
2. With the engine started, compare the readings of the tester with that of the tachometer. Replace the
tachometer if the tolerance is exceeded.
1. Reversing the connections of the tachometer will damage the transistor and diodes inside.
2. When removing or installing the tachometer, be careful not to drop it or subject it to severe shock.
Revolution (RPM)
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
Tolerance (RPM)
100
125
150
150
150
180
210
240
FUEL GAUGE
1. Disconnect the fuel sender connector from the fuel sender.
2. Connect a 3.4 watt, 12V test bulb to terminals 1 and 3 on the wire harness side connector.
3. Turn the ignition switch to the ON, and then check that the bulb lights up and the fuel gauge needle moves to
full.
FUEL SENDER
1. Using an ohmmeter, measure the resistance between terminals 1 and 3 at each float level.

24.04.2008
Page 3 of 6
2. Also check that the resistance changes smoothly when the float is moved from "E" to "F".
Position
Gauge Angle()
Resistance ( )
Sender (E)
-47.5
110.0 2
Gauge (E)
-45.0
97.0 1
Warning lamp
-43.0
89.4 1
1/2
32.5 1
Gauge (F)
45.0
6.0 1
Sender (F)
47.5
3.0 2
3. If the resistance is unsatisfied, replace the fuel sender as an assembly.
After completing this test, wipe the sender dry and reinstall it in the fuel tank.
ENGINE COOLANT TEMPERATURE GAUGE

1. Disconnect the wiring connector from the engine coolant temperature sender in the engine compartment.
2. Turn the ignition switch ON. Check that the gauge needle indicates cool. Turn the ignition switch OFF.
3. Connect a 12V, 3.4 watt test bulb between the harness side connector terminal 2 and ground.
4. Turn the ignition switch ON.

5. Verify that the test bulb flashes and that the indicator moves to HOT.
ENGINE COOLANT TEMPERATURE SENDER

24.04.2008
Page 4 of 6
1. Using an ohmmeter, measure the resistance between the terminal 2 and ground.
2. If the resistance value is not as shown in the table, replace the temperature sender.
Temperature(C)
60
85
110
125
Resistance ()
143.4
58.1
26.9
17.5
OIL PRESSURE SWITCH

1. Check that there is continuity between the switch's terminal and ground with the engine stopped.
2. Check that there is no continuity between the terminal and ground with the engine running.
3. If operation is not as specified, replace the switch.
OIL PRESSURE WARNING LAMP

1. Disconnect the connector from the warning switch and ground the terminal on the wire harness side
connector.
2. Turn the ignition switch ON. Check that the warning lamp lights up. If the warning lamp doesn't light, test the
bulb or inspect wire harness.
BRAKE FLUID LEVEL WARNING SWITCH

1. Remove the connector from the switch located at the brake fluid reservoir.
2. Verify that continuity exists between switch terminals 1 and 2 while pressing down the switch (float) with a rod.
BRAKE FLUID LEVEL WARNING LAMP

24.04.2008
Page 5 of 6

2. Release the parking brake.
3. Remove the connector from the brake fluid level warning switch.
4. Ground the connector at the harness side.
5. Verify that the warning lamp lights.
PARKING BRAKE SWITCH

1. Check that there is continuity between the terminal and switch body with the switch ON (Lever is pulled).
2. Check that there is no continuity between the terminal and switch body with the switch OFF (Lever is
released).
DOOR SWITCH
SEAT BELT SWITCH

1. Remove the connector from the switch.
2. Check for continuity between terminals.
Seat belt condition
Continuity
Fastened
Non-conductive ()

24.04.2008
Page 6 of 6
Not fastened
Conductive(0)
SEAT BELT WARNING LAMP

Seat belt condition
Warning lamp
Fastened
OFF
Not fastened
ON

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multi Gauge > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multi Gauge > Schematic Diagrams
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multi Gauge > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multi Gauge >
DESCRIPTION
1. Engine torque gauge
It indicates the instantaneous torque variation according RPM of the vehicle. Driver can notice the
instantaneous torque variation with oscillation and outrunning speed, recently a lot of comsumers want their
sports car with performance tuning. They can discern the torque level easily. Engine torque gauge indicates
the engine torque value by communicating CAN signals from engine ECU.
2. Instantaneous fuel consumption gauge
It indicates instantaneous fuel consumption according the driving condition.
Instantaneous fuel consumption gauge inputs the speed signal and fuel injection signal.
Speed signal comes directly from the speed sensor and fuel injection signal is from the engine ECU.
Multi-gauge reads the two signals for 500msec. and calculates the instantaneous fuel consumption. If the
vehicle speed is increasing by constant fuel quantityper hour, the gauge indicates the value increasingly.
It doesn't show the average fuel consumption but only the instantaneous one.
3. Volt gauge
Volt gauge makes a driver properly response during low voltage, informing the vehicle voltage.
Before ignition turned on, when the key is inserted into "ingnition switch on" position, it displays the battery
voltage, after ignition key turnedon, it displays the ignition voltage( battery voltage).
If the voltage is at 8.5V or below, the pointer of the gauge moves to the lower than 8V and if it is at 16V or
more, it moves to the lower than16V.
If the input value is between 8.5V and 16V, the volt gauge points the battery voltage (Ignition voltage is
displayed during the ignition key turned on ).
SPECIFICATIONS
Items
Display range
Input signal
Gauge operating type
Engine torque
0~400 Nm
ECU engine torque (CAN

communication)
Stepper motor
Instantaneous fuel
consumption
0~30 MPG
Speed signal, Fuel

injection signal
(CAN communication)
Stepper motor
Battery voltage
8~16V
Battery voltage
Stepper motor

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multi Gauge > Components and Components
Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Multi Gauge > Components and
Components Location
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Locks > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Locks >
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Locks > Power Door
Lock Actuators > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System
> Power Door Locks > Power Door Lock Actuators > Repair procedures
INSPECTION
DOOR LOCK ACTUATOR INSPECTION
1. Remove the door trim panel.
2. Disconnect the 6P connector from the actuator.
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
DOOR LOCK SWITCH INSPECTION

3. Check for continuity between the terminals in each switch position according to the table.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Locks > Power Door
Lock Actuators > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System
> Power Door Locks > Power Door Lock Actuators > Repair procedures
INSPECTION
DOOR LOCK ACTUATOR INSPECTION
3. Check actuator operation by connecting power and ground according to the table. To prevent damage to the
actuator, apply battery voltage only momentarily.
DOOR LOCK SWITCH INSPECTION


24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Mirrors > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Mirrors >
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Mirrors > Power out side mirror
switch > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door
Mirrors > Power out side mirror switch > Schematic Diagrams
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Mirrors > Power out
side mirror switch > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical
System > Power Door Mirrors > Power out side mirror switch > Repair procedures
INSPECTION
1. Remove the power door mirror switch from the door trim panel.
If continuity is not as specified, replace the power door mirror switch.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Door Mirrors > Power Door
Mirror Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System
> Power Door Mirrors > Power Door Mirror Actuator > Repair procedures
INSPECTION
1. Disconnect the power door mirror connector from the harness.
2. Apply battery voltage to each terminal as shown in the table and verify that the mirror operates properly.
MIRROR FOLDING INSPECTION
MIRROR HEATER INSPECTION

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Windows > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Windows >
COMPONENTS

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Windows > Power Window
Motor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power
Windows > Power Window Motor > Repair procedures
INSPECTION

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Windows > Power Window Switch >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Windows >
Power Window Switch > Schematic Diagrams
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power Windows > Power Window
Switch > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Power
Windows > Power Window Switch > Repair procedures
INSPECTION
POWER WINDOW MAIN SWITCH
1. Remove the switch from the door trim panel.
2. Check for continuity between the terminals. If continuity is not as specified in the table, replace the power
window switch.
WINDOW LOCK SWITCH
MIRROR FOLDING SWITCH
POWER WINDOW SUB SWITCH

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear Window Defogger > Rear
Window Defogger Printed Heater > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body
Electrical System > Rear Window Defogger > Rear Window Defogger Printed Heater > Repair
procedures
INSPECTION
Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger
pressure on the tin foil, moving the tin foil along the grid line to check for open circuits.
1. Turn on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass
center point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window
is consideredsatisfactory.
2. If a heater line is burned out between the center point and (+) terminal, the voltmeter will indicate 12V.
3. If a heater line is burned out between the center point and (-) terminal, the voltmeter will indicate 0V.

24.04.2008
Page 2 of 3
4. To check for open circuits, slowly move the test lead in the direction that the open circuit seems to exist. Try to
find a point where a voltage is generated or changes to 0V. The point where the voltage has changed isthe
open-circuit point.
5. Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid
line, and between the same terminal and the center of one adjacent heater line. The section with a broken
heater line will have a resistance twice as that in other sections. In the affected section, move the test lead to
a position where the resistance sharplychanges.
REPAIR OF BROKEN HEATER LINE

1. Conductive paint.
2. Paint thinner.
3. Masking tape.
4. Silicone remover.
5. Using a thin brush :
Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as
shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15
minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish,
scrape away excess deposits with a knife afterthe paint has completely dried. (Allow 24 hours).

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Windshield Wiper/Washer > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Windshield
Wiper/Washer > Components and Components Location
COMPONENTS
WINDSHIELD WASHER INSTALLATION

24.04.2008
Page 2 of 2

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Windshield Wiper/Washer >
Windshield Wiper/Washer Switch > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body
Electrical System > Windshield Wiper/Washer > Windshield Wiper/Washer Switch > Repair procedures
INSPECTION
Remove the multifunction switch and disconnect the wire connectors.
Check the switch for continuity between the terminals.
If continuity is not as specified, replace the wiper and washer switch.
WIPER AND INTERMITTENT VOLUME SWITCH [M01-1]
WASHER SWITCH [M01-1]

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Windshield Wiper/Washer > Front
Wiper Motor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System >
Windshield Wiper/Washer > Front Wiper Motor > Repair procedures
REMOVAL
1. Remove the wiper arm.
Care must be taken not to scratch the engine hood.
Tightening torque
23~28 Nm (230~280 kgcm, 16.9~20.6 lbft)
2. Remove the weatherstrip and cowl top cover after removing the retainers.
3. Disconnect the windshield wiper motor connector and remove the 3 bolts holding the windshield wiper motor
and linkage assembly.
Tightening torque
7~11 Nm (70~110 kgcm, 5.1~8.0 lbft)
INSTALLATION
1. Install the wiper arm to the specified position.

24.04.2008
Page 2 of 3
Specified position
Distance (mm)
30~40
30~40
2. Set the washer nozzle on the specified spray position.
INSPECTION
SPEED OPERATION CHECK
1. Remove the connector from the wiper motor.
2. Attach the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 4.
3. Check that the motor operates at low speed.
4. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 5.
5. Check that the motor operates at high speed.
AUTOMATIC STOP OPERATION CHECK

1. Operate the motor at low speed using the stalk control.
2. Stop the motor operation anywhere except at the off position by disconnecting terminal 4.
3. Connect terminals 2 and 4.
4. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 1.
5. Check that the motor stops running at the off position.

24.04.2008
Page 3 of 3

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Windshield Wiper/Washer > Front
Washer Motor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System >
Windshield Wiper/Washer > Front Washer Motor > Repair procedures
INSPECTION
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Connect positive (+) and negative (-) battery cables to terminals 2 and 1 respectively to see that the washer
motor runs and water sprays fromthe front nozzles.
3. Check that the motor operates normally.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear Wiper/Washer > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear Wiper/Washer >
COMPONENTS

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear Wiper/Washer > Rear Wiper
Motor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear
Wiper/Washer > Rear Wiper Motor > Repair procedures
REMOVAL
1. Remove the upper and side trim from the tailgate frame.
2. Remove the tailgate trim panel after removing 4 screws.
3. Remove the rear wiper arm after removing a nut.
Tightening torque
14~17 Nm (140~170 kgcm, 10.3~12.5 lbft)
4. Remove the hexagonal nut after removing pivot cover.
Tightening torque

24.04.2008
Page 2 of 2
14~17 Nm (140~170 kgcm, 10.3~12.5 lbft)

5. Remove the rear wiper motor after removing 3 bolts, and disconnect the motor's connector.
INSTALLATION
2. Set the washer nozzle on the specified spray position.
INSPECTION
1. Remove the connector from the rear wiper motor.
2. Connect battery positive (+) and negative (-) cables to terminals 3 and 4 respectively.
3. Check that the motor operates normally. Replace the motor if it operates abnormally.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear Wiper/Washer > Rear Washer
Switch > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear
Wiper/Washer > Rear Washer Switch > Repair procedures
INSPECTION
1. Disconnect the connector from the rear wiper and washer switch.
2. Check for continuity between the terminals.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear Wiper/Washer > Rear Washer
Motor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Rear
Wiper/Washer > Rear Washer Motor > Repair procedures
INSPECTION
1. With the washer motor connected to the reservoir tank, fill the reservoir tank with water.
2. Connect positive(+) and negative(-) battery cables to terminals 3 and 1 respectively to see that the washer
motor runs and water is pumped.
3. Check that the motor operates normally.

Replace the motor if it operates abnormally.

24.04.2008
Page 1 of 6
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Lighting System > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Lighting System >
Repair procedures
REPLACEMENT OF LAMPS
HEAD LAMP/TURN SIGNAL LAMP
1. Disconnect the negative battery terminal.
2. Remove the front bumper upper cover.
3. Remove the head lamp and turn signal lamp mounting bolts (3EA) and remove the lamp assembly.
FRONT FOG LAMP

2. Remove the turn signal lamp and head lamp assembly.

24.04.2008
Page 2 of 6
3. Remove the front bumper cover (Refer to BD group).

Disconnect the wire connector and remove the front fog lamp.
REAR COMBINATION LAMP

2. Remove the luggage trim side cover.
3. Remove the 3 screws holding the rear combination lamp and disconnect the wire connectors.
4. Remove the rear combination lamp assembly.
CENTER HIGH MOUNTED STOP LAMP


24.04.2008
Page 3 of 6
2. Remove the rear spoiler after removing 4 nuts. (External spoiler type)
3. Remove the center high mounted stop lamp assembly.
LICENSE PLATE LAMP

2. Remove the mounting screws and disconnect the lamp connector.
OVERHEAD CONSOLE LAMP

2. Detach the map lamp lens from the lamp assembly with a flat-tip screwdriver.
3. Detach the lamp assembly from the headliner after removing the 4 screws.
4. Disconnect the wiring connectors from the headliner.
LUGGAGE LAMP
2. Detach the luggage lamp assembly from the luggage side trim with a flat-tip screwdriver.
INSPECTION OF COMPONENTS

24.04.2008
Page 4 of 6
HEAD LAMP RELAY

1. Remove the head lamp relay from the relay box in the engine compartment.
2. Check for continuity between terminals on the relay.
HAZARD SWITCH
2. Remove the center facia panel with a flat-tip screwdriver.
3. Detach the hazard lamp switch from the center facia panel.
4. Operate the switch and check for continuity between terminals with an ohmmeter.

24.04.2008
Page 5 of 6
RHEOSTAT
2. Disconnect the rheostat connector from the crash pad panel.
3. Check for intensity. If the light intensity of the lamps changes smoothly without any flickering when the
rheostat is turned, it can be assumed that the rheostat is normal.
FRONT FOG LAMP SWITCH

2. Detach the switch connector from the center facia panel.
3. Operate the switch and check for continuity between the terminals with an ohmmeter.
MAP LAMP SWITCH

24.04.2008
Page 6 of 6

24.04.2008
Page 1 of 3
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Lighting System > Head Lamps > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Lighting System > Head Lamps >
Repair procedures
AIMING INSTRUCTIONS
If there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used, adjust so as
to meet those requirements.
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective headlamp centers) and a horizontal line (Horizontal line
passing through center of headlamps) on the screen.
4. With the headlamp and battery in normal condition, aim the headlamps so the brightest portion falls on the horizontal and
vertical lines.
Make vertical and horizontal adjustments to the lower beam using the adjusting wheel.
FRONT FOG LAMP

With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting gear.

24.04.2008
Page 2 of 3
HEAD LAMP AND FOG LAMP AIMING POINT
1. Turn the low beam on without driver aboard.

The cut-off line should be projected in the allowable range (shaded region).
2. Turn the high beam on without driver aboard.

The hot-zone should be projected in the allowable range (shaded region).

24.04.2008
Page 3 of 3
3. Turn the front fog lamp on without driver aboard.

The cut-off line should be projected in the allowable range (shaded region).

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Auto Lighting Control System > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Auto Lighting Control System >
Schematic Diagrams
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Auto Lighting Control System >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Auto
Lighting Control System > Description and Operation
DESCRIPTION
The auto light control system operates by using the auto light switch and the auto light sensor detect the
illumination then turns the head lamp and tail lamp on or off automatically in accordance with the detection
illumination.
SPECIFICATIONS
Items
Rated voltage
DC 5V
Operating current
Detection illumination
Specifications
Max. 1mA
Tail lamp
ON : 23.1 3.4 (Lux), 1.77 0.08 (V)

OFF : 48.0 3.4 (Lux), 3.47 0.10 (V)
Head lamp
ON : 6.2 1.4 (Lux), 0.63 0.06 (V)

OFF : 12.0 1.4 (Lux), 1.02 0.06 (V)

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Auto Lighting Control System >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Auto Lighting
Control System > Repair procedures
INSPECTION
1. Detach the auto light sensor in the upper crash pad.
2. Check the continuity between terminal 2(+) and terminal 1 (-).
3. Check the continuity between the terminals while operating the switch.
AUTO LIGHT SWITCH [M01-2]

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Daytime Running Lights > DRL Control
Module > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Daytime
Running Lights > DRL Control Module > Schematic Diagrams
CIRCUIT DIAGRAM

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Daytime Running Lights > DRL
Control Module > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System
> Daytime Running Lights > DRL Control Module > Repair procedures
INSPECTION
OPERATION CHECK
INSPECT CIRCUITS FOR DAYTIME RUNNING LIGHT SYSTEM

1. Disconnect the wire connector to DRL module from engine compartment.
2. Inspect the connector on wire harness side as shown.
Check For
Test Connect
4-Ground
5-Ground
Condition
Parking brake
switch
ON (Pull up)
No continuity
Continuity
OFF
No continuity
ON
Continuity
Head lamp switch
Continuity
6-Ground
Constant
9-Ground
Dimmer&passing
switch
9-Ground
OFF (Released)
Test Specification
Ignition switch
Continuity
Head light ON
Continuity
Head light OFF
No continuity
ON
Battery voltage

24.04.2008
Page 2 of 2
ACC or LOCK
ON
5-Ground
No voltage
Battery voltage
Ignition switch
ACC or LOCK
No voltage
Voltage
7-Ground
Constant
3-Ground
Engine
Battery voltage
Stop
Running
No voltage
Battery voltag
3. If circuit is not as specified, refer to schematic diagram and inspect for short circuits.

24.04.2008
Page 1 of 4
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Immobilizer System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Immobilizer System > Description
and Operation
DESCRIPTION
There are two types of immobilizer functions available on the Body Control Module (BCM). The first is a "SMARTRA (SMART
TRansponder Antenna)"type and the second is a "stand alone" type that will emulate the system known as the "SCE
immobilizer". The hardware to support both types of immobilizer systems in the BCM is identical. The selection of immobilizer
type withinthe BCM is effected by setting the appropriate EEPROM byte.
All communications between the BCM and the ECM (Engine Control Module) for the purposes of immobilization will be over
the W line.
The diagnostics communication for the SMARTRA system will be performed by communicating with the ECM on it's K line.
The ECM will then perform diagnosticson the BCM via the W line.
At the time of Transponder validation, the BCM devotes 100% processing power to the validation process in order to respond
in the required time.During transponder validation, other BCM functions may be influenced.
1. SMARTRA type immobilizer
The "SMARTRA" type immobilizer system is applied to the 2.0 engine.
The immobilizer system consists of a passive challenge-response (mutual authentication) transponder inside the key head,
a stand alone antenna, the BCM unit and the ECM. The BCM unit shall emulate the original SMARTRA immobilizer as
closely as possible. In this document, the BCM emulating the originalSMARTRA shall just be known as SMARTRA.
In the SMARTRA system, the immobilizer is contained within the ECM. The BCM shall provide the low-level routines and
hardware necessary to communicatewith the transponder.
2. Stand alone type immobilizer
The "Stand alone" type immobilizer system is applied to the 2.7 engine.
The immobilizer system consists of a passive challenge-response (mutual authentication) transponder inside the key head,
a stand alone antenna, the BCM unit and the ECM. The BCM unit shall emulate the original SCE type immobilizerto ECM
protocol as closely as possible.
In the Stand alone immobilizer system, the immobilizer is contained within the BCM. The ECM shall request the BCM for
permission to start the vehicle. The BCM shall perform the immobilisation functions and reply "start"or no start" permission
to the ECM.
SYSTEM BLOCK DIAGRAM

24.04.2008
Page 2 of 4
IMMOBILIZER STATES
1. Engine Control Module (ECM) States
The ECM has three defined states. These are described below.
State
Virgin State
Learnt State
Description
The ECM is delivered to HMC in virgin state

There is no Vehicle Identification Number (VIN) stored in the ECM
It can only be in virgin state once
The ECM will allow starting on the second cycle of ignition
Virgin state is exited when a VIN has successfully been taught by the BCM
Engine start is possible only when the received VIN from the BCM matches that
stored in the ECM
VIN has been deleted

24.04.2008
Page 3 of 4
Neutral State
Same as virgin state except engine starting not possible on the second cycle of
ignition
Neutral state is entered if the BCM changes to neutral state
2. Body Control Module (BCM) states

The Body Control Module (BCM) has three defined states. These are described below.
State
Virgin State
Learnt State
Neutral State
Description
The BCM is set to virgin state during manufacture

The BCM can be set back to virgin state by issuing an 'Initiate BCM' command
The diagnostics password is set to the default
No VIN is stored
Virgin state is exited only after the VIN been learned
The BCM contains a VIN

The BCM is set to neutral state by issuing a 'Teaching ECM' command
The purpose of the neutral state is to allow the ECM to be set to neutral state
The BCM neutral state expires 10 seconds after an ignition ONOFF cycle
TEACHING PROCEDURES
THE USER PASSWORD CAN BE IN THE STATUS
LIMP HOME FUNCTION
The password and the pin code are not the same. Pin code is scanned from a bar code at the End Of Line (EOL). The
passwordis a number chosen by the owner for the purposes of limp starting.

24.04.2008
Page 4 of 4

24.04.2008
Page 1 of 2
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Immobilizer System > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System >
Immobilizer System > Components and Components Location
COMPONENTS
COMPONENT
TRANSPONDER (Built-in keys)
COIL ANTENNA
BODY CONTROL MODULE (BCM)
ENGINE CONTROL MODULE (ECM)
DATA LINK CONNECTOR (DLC)
DESCRIPTION
When ignition is ON, the coil supplies energy to the
transponder, which in turn accumulates energy in the
condenser.
Once the energy supplied from the coil has stopped,
using the stored energy in the condenser, the
transponder transmits the secret data.
The transponder has an advanced encryption
algorithm. During the key teaching procedure, the
transponder will be programmed with vehicle specific
data. The vehicle specific data are written into the
transponder memory. The write procedure is once
only ; therefore, the contents of the transpondercan
never be modified or changed.
Supplies energy to the transponder.
Receives signal from the transponder.
Sends transponder signal to the BCM.
The BCM carries out communication with the built - in

transponder in the ignition key. This wireless
communication runs on RF (Radio Frequency). The RF
signal from the transponder, received by the antenna
coil, is converted into messages for serial
communication by the BCM. And, the received
messages from the ECM are converted into an RF
signal, which is transmitted to thetransponder by the
antenna.
In case of "SMARTRA" type immobilizer system the
BCM does not carry out the validity check of the
transponder or the calculation of encryption algorithm.
This device is only an advanced interface, which
converts the RF data flow of the transponder into serial
communication to the ECM andvice versa.
In case of "SMARTRA" type immobilizer system the
ECM carries out a check of the ignition key using a
special encryption algorithm, which is programmed into
the transponder as well as the ECM simultaneously.
Only if the results are equal can the engine be started.
The data of all transponders,which are valid for the
vehicle, are stored in the ECM.
By connecting the voltmeter or Hi-scan, the control
module diagnostic code can be read.

24.04.2008
Page 2 of 2
DIAGNOSTIC TESTER
Has the function BCM, ECM, and key diagnosis and

change.

24.04.2008
Page 1 of 1
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Immobilizer System >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body Electrical System > Immobilizer
System > Troubleshooting
DIAGNOSIS OF IMMOBILIZER FAULTS

Communication between the ECM and the BCM
Function of the BCM and the transponder, and
Data (stored in the ECM) related to the immobilizer function.
Type
Diasnostic
Codes
Immobilizer Related Faults
No answer from the BCM

Invalid message from BCM to ECM
P1610
P1800
BCM fault
P1803
SMARTRA
(2.0 ENGINE)
Antenna error
Invalid request from ECM or corrupted data
Transponder fault
Invalid transponder data

Passive mode invalid
Programming error
EEPROM
Inconsistent data of EEPROM

Invalid write operation to EEPROM
ECM fault
No valid data from ECM after 3 attempts by

ECM
Invalid tester message or unexpected
requests by tester
01
Untaught transponder
Untaught transponder
02
Transponder communication
error
Transponder error due to a wrong code or

bad read (wrong transponder in field, or
more than one transponder in the field).
03
ECM communication error
ECM error due to bad Service ID (SID), Bad

Message ID (MID) or protocol errors
04
Immobilizer antenna - open
Open Immobilizer antenna
05
BCM internal fault or EEPROM
BCM internal fault (smart driver failure) or

BCM EEPROM error
06
ECM not detected
ECM not detected
P1801
P1805
STAND ALONE
(2.7 ENGINE)
Fault Types
REPLACEMENT OF ECM AND BCM

NEUTRALISING ECM

24.04.2008

Tiburon 2003

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Page 1 of 20

IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER DESCRIPTION

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Dark Navy Blue

ENGINE IDENTIFICATION NUMBER

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TRANSMISSION IDENTIFICATION NUMBER

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WARNING / CAUTION LABEL LOCATIONS

AIR BAG WARNING / CAUTION LABEL

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AIR BAG WARNING / CAUTION LABEL (CONT'D)

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WARNING / CAUTION LABEL (CON'T)

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For further information, see the owner's manual.

D : PASSENGER MODULE CAUTION

E : SUPPLEMENTAL RESTRAINT SYSTEM

EMISSION CONTROL LABEL

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LIFT AND SUPPORT POINT

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TIGHTENING TORQUE TABLE OF STANDARD PARTS

Bolt nominal diameter

3 ~ 4 (30 ~ 40, 2.2 ~ 2.9)

5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

9 ~ 11 (90 ~ 110, 6.5 ~

20 ~ 25 (200 ~ 250, 14.5 ~

120 ~ 140 (1,200 ~ 1,400,

110 ~ 130 (1,100 ~ 1,300,

180 ~ 210 (1,800 ~ 2,100,

Downloaded from www.Manualslib.com

160 ~ 180 (1,600 ~ 1,800,

260 ~ 300 (2,600 ~ 3,000,

220 ~ 250 (2,200 ~ 2,500,

360 ~ 420 (3,600 ~ 4,200,

290 ~ 330 (2,900 ~ 3,300,

480 ~ 550 (4,800 ~ 5,500,

360 ~ 420 (3,600 ~ 4,200,

610 ~ 700 (6,100 ~ 7,000,

OIL & GREASE STANDARD

API SH, SG or SG/CD

Normal Climate : SAE 10W-30, 10W-40, 10W-50

HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)

DIAMOND ATF SP-3, SK ATF SP-3

Transaxle linkage, parking brake cable mechanism,

Always use Genuine Hyundai parts and recommedended fluid.

3.7 (3.91, 3.26)

4.0 (4.23, 3.52)

4.5 (4.76, 3.95)

7.3 (7.71, 6.42)

8.6 (9.09, 7.57)

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7.8 (8.2, 6.8)

SELECTION OF ENGINE OIL

GENERAL SERVICE INFORMATION

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

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3. Cleaning parts for reuse

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