Tiburon 2003 PDF

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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

Bolt nominal diameter Torque Nm (kg.cm, lb.ft)
Pitch (mm)
(mm) Head Mark 4 Head Mark 7
M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

9 ~ 11 (90 ~ 110, 6.5 ~
M6 1.0 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)
8.0)
12 ~ 15 (120 ~ 150, 9 ~ 20 ~ 25 (200 ~ 250, 14.5 ~
M8 1.25
11) 18.0)
25 ~ 30 (250 ~ 300, 18 ~ 30 ~ 50 (300 ~ 500, 22 ~
M10 1.25
22) 36)
35 ~ 45 (350 ~ 450, 25 ~ 60 ~ 80 (600 ~ 800, 43 ~
M12 1.25
33) 58)
75 ~ 85 (750 ~ 850, 54 ~ 120 ~ 140 (1,200 ~ 1,400,
M14 1.5
61) 85 ~ 100)
110 ~ 130 (1,100 ~ 1,300, 180 ~ 210 (1,800 ~ 2,100,
M16 1.5
80 ~ 94) 130 ~ 150)

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160 ~ 180 (1,600 ~ 1,800, 260 ~ 300 (2,600 ~ 3,000,

M18 1.5
116 ~ 130) 190 ~ 215)
220 ~ 250 (2,200 ~ 2,500, 360 ~ 420 (3,600 ~ 4,200,
M20 1.5
160 ~ 180) 260 ~ 300)
290 ~ 330 (2,900 ~ 3,300, 480 ~ 550 (4,800 ~ 5,500,
M22 1.5
210 ~ 240) 350 ~ 400)
360 ~ 420 (3,600 ~ 4,200, 610 ~ 700 (6,100 ~ 7,000,
M24 1.5
260 ~ 300) 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 32°F
For 0°C)
Normal Climate : SAE 10W-30, 10W-40, 10W-50
Engine oil API SH, SG or SG/CD
(ABOVE -10°C For -23°C)
Cold Climate : SAE 5W-30, 5W-30, 5W-40
(BELOW100° FoR 38°C)
Manual HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)
Transaxle
Auto DIAMOND ATF SP-3, SK ATF SP-3
Power Steering PSF-3
Brake Fluid DOT 3, DOT 4 or equivalent
Coolant 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 2.7
Oil pan 3.7 (3.91, 3.26) 4.2 (4.44, 3.69)
Engine oil Oil filter 0.3 (0.32, 0.26)
Total 4.0 (4.23, 3.52) 4.5 (4.76, 3.95)
Cooling system 7.3 (7.71, 6.42) 8.6 (9.09, 7.57)
Manual transaxle 2.15 (2.3, 1.86)

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Automatic transaxle 7.8 (8.2, 6.8)

Power steering 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 80°C (176°F), 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.
Nominal Permissible current

SAE gauge No.
size In engine compartment Other areas
0.3mm² AWG 22 - 5A
0.5mm² AWG 20 7A 13A
0.85mm² AWG 18 9A 17A
1.25mm² AWG 16 12A 22A
2.0mm² AWG 14 16A 30A
3.0mm² AWG 12 21A 40A
5.0mm² 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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Page 1 of 6
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 0°F (-18°C).
- CCP : Cold cranking power, is an SAE specification for korean manufacturer's for cranking batteries
at 0°F (-18°C)
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 REMEDY

Good battery No action is required
Battery is in a good state
Good recharge
Recharge the battery and use
Battery is not charged properly
Charge & Retest → Charge and test the battery again (Failure to charge the battery fully may
read incorrect measurement value)
→ Replace battery and recheck the charging system. (Improper connection
between battery and vehicle cables may cause "REPLACE BATTERY",
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

Cranking voltage normal System shows a normal starter draw
Cranking voltage is lower than normal level
Cranking voltage low
→ Check starter
The state of battery charge is too low to test
Charge battery
→ Charge the battery and retest
→ Replace battery
→ Check wiring for open circuit, battery cable connection, starter and repair
Replace battery
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

Charging system normal/Diode
Charging system is normal
ripple normal
Generator does not supply charging current to battery
No charging voltage → Check belts, connection between generator and battery
Replace belts or cable or generator as necessary
Generator does not supply charging current to battery and electrical load to
Low charging voltage system fully
→ Check belts and generator and replace as necessary
The voltage from generator to battery is higher than normal limit during
High charging voltage voltage regulating.
→ Check connection and ground and replace regulator as necessary
One or more diodes in the generator is not functioning properly
Excess ripple detected
→ Check generator mounting and belts and replace as necessary

Page 1 of 2
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 Ignition lock switch Inspect
start (Cranks OK) Ignition coil See page EE-14
Spark plugs See page EE-13
Ignition wiring disconnected or broken Repair
Spark plug cable See page EE-13
Rough idle or stalls Ignition wiring Inspect
Ignition coil See page EE-14
Spark plug cable See page EE-13
Engine hesitates/poor acceleration Spark plugs and spark plug cable See page EE-13
Ignition wiring Inspect
Poor mileage Spark plugs and spark plugs cable See page EE-13
CHARGING SYSTEM

Charging warning indicator Fuse blown Check fuses
does not light with ignition Light burned out Replace light
switch "ON" and engine off Wiring connection loose Tighten loose connections
Electronic voltage regulator See page EE-20
Charging warning indicator Drive belt loose or worn See page EE-19, 29
does not go out with Battery cables loose, corroded or worn See page EE-32
engine running (Battery Fuse blown Check fuses
requires frequent Fusible link blown Replace fusible link
recharging) Electronic voltage regulator or generator See page EE-20
Wiring Repair wiring
Engine hesitates/poor Drive belt loose or worn See page EE-19, 29
acceleration Wiring connection loose or open circuit Tighten loose connection or repair
Overcharge Fusible link blown wiring
Poor grounding Replace fusible link
Electronic voltage regulator or generator Repair
Worn battery See page EE-20
Electronic voltage regulator Replace battery
Voltage sensing wire See page EE-20
Repair wire
STARTING SYSTEM

Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch (Vehicle with See page TR group-automatic
automatic transaxle only) transaxle
Fusible link blown Replace fusible link
Starter motor faulty See page EE-38
Ignition switch faulty Inspect
Engine cranks slowly Battery charge low Charge or replace battery

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Battery cables loose, corroded or worn out Repair or replace cables

Starter motor See page EE-38
Starter keeps running Starter motor See page EE-38
Ignition switch Inspect
Starter spins but engine Short in wiring Repair wiring
will not crank Pinion gear teeth broken or starter motor See page EE-40
Ring gear teeth broken See page EM group-fly wheel

Page 1 of 2
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 Mold coil type
Ignition coil Primary resistance 0.58 ± 10% (Ω) 0.74 ± 10% (Ω)
Secondary resistance 8.8 ± 15% (kΩ) 13.3 ± 15% (kΩ)
NGK BKR5ES-11 PFR5N-11
Spark plugs CHAMPION RC10YCPB4 RC10YCPB4
Gap 1.0 ~ 1.1 mm (0.039 ~ 0.043 in.)
STARTING SYSTEM
Specifications
Items
2.0 2.7
Type Reduction drive (with planetary gear)
Starter Rated voltage 12V, 1.2KW
No.of pinion teeth 8
Voltage 11V
No-load
Amperage 90A, MAX
characteristics
Speed 3,000rpm, MIN 2,800rpm, MIN
CHARGING SYSTEM
Specifications
Items
2.0 2.7
Type Battery boltage sensing
Rated voltage 13.5V, 90A 12V, 120A
Speed in use 1,000 ~ 18,000 rpm
Generator Voltage regulator Electronic built-in type
Regulator setting voltage 14.4 ± 0.2V 14.55 ± 0.2V
Temperature
-10 ± 3mV/°C -3.5 ± 1mV/°C
compensation
Type MF 60 AH MF 68 AH
Cold cranking amperage
550A 600A
[at -18°C (0°F)]
Battery
Reserve capacity 92min 110min
Specific gravity [at 25°C
1.280 ± 0.01 1.280 ± 0.01
(77°F)]

Page 2 of 2
- 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 26.7°C(80°F)
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 3.9kΩ ± 1%
SET switch : 220Ω ± 1%
Command switch serial resistance value
RESUME switch : 910Ω ± 1%
TIGHTENING TORQUE
Items Nm kg·cm lb·ft

Generator terminal (B+) 5~7 50 ~ 70 3.6 ~ 5.1
Starter motor terminal (B+) 10 ~ 12 100 ~ 120 7.3 ~ 8.8
Battery terminal 4~6 40 ~ 60 2.9 ~ 4.3
Spark plug 20 ~ 30 200 ~ 300 15 ~ 22

Page 1 of 1
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

Page 1 of 4
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).

Page 2 of 4
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 DARK DEPOSITS WHITE DEPOSITS

- Fuel mixture too rich - Fuel mixture too lean
DESCRIPTION - Low air intake - 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 : 5.6KΩ/m ± 20%

Page 3 of 4
7. Resistance should not be higher than 2.6kΩ 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 : 0.58Ω ± 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 : 8.8kΩ ± 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

Page 4 of 4
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.

Page 1 of 2
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

Page 2 of 2

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 built-
in electronic voltage regulator.

Page 1 of 6
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 20°C (68°C)
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.

Page 2 of 6
- "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.

Page 3 of 6
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.

Page 4 of 6
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

Page 5 of 6
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) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7
2. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
4. Remove the voltmeter and ammeter and the engine tachometer.
6. Connect the battery ground cable.
1. 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.

Page 6 of 6
17. Connect the negative battery cable.

Page 1 of 2
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

Page 2 of 2

Page 1 of 4
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).

Page 2 of 4
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)

Page 3 of 4
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.

Page 4 of 4

Page 1 of 1
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.

Page 1 of 3
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 Manufacturer
1. Acid Leakage 1. Damage in the case or cover due to
○
* Type of acid leakage outside impact.
- Leakage on the fusion part for 2. Acid leakage on the molding part of
joining the case and cover. the case or cover. ○
- Leakage on the terminal part (weld line or gate hole)
- Leakage on other parts
3. Damage on the terminal or cracks in
* Conduct a visual inspection for ○
the cover.
breakage, deformation, or cracks.
4. Acid leakage due to the tipped
○
battery or slant storage.
5. Acid leakage due to poor welding of
the cover. ○
(with no damage)
2. Outside damage and breakage 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.

Page 2 of 3
4. Damage and breakage due to heat. ○

3. Measure the voltage for the Refer to
1. 12.0V ○
battery load test
; Wait at least one day before
2. 11.0V< battery voltage<12.0V due Refer to
measuring in case of recharging. ○
to over-discharge. load test
3. Below 11.0V due to charge Refer to
○
condition failure. load test
4. Below 11.0V due to discharged for a Refer to
○
long period. load test
5. Below 11.0V due to internal short Refer to
○
circuit. load test
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 (81±9°F)
- Conduct the test with a battery
tester. 2. Load test result: above 9.6V ○
(Refer to the tester manual)
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 20°C (70°F) 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.

Page 3 of 3
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.

Page 1 of 1
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

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.

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 100°F (1 5 and 38°C) 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 :

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

Page 3 of 3

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

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.

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.

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

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.

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

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 Suspect Area

Cruise control cannot be set 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 Vehicle speed sensor
was set Cruise control unit and actuator cable deflection
Cruise control nuit
Excessive overshooting or undershooting when trying Cruise control unit and actuator cable deflection
to set speed Vehicle speed sensor
Cruise control unit
Speed fluctuation on a flat road with cruise control set Vhicle speed sensor
Cruise control unit and actuator cable deflection
Cruise control nuit
Vehicle does not decelerate or accelerate accordingly Main switch
when SET/RESUME/CANCEL button is pushed SET/RESUME/CANCEL switch
Cruise control unit
Cruise control does not cancel when shift lever is A/T gear position switch
moved to N position (A/T) 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 Main switch
pushed OFF SET/RESUME/CANCEL switch
Cruise control unit
Cruise control will not cancel when CANCEL button is Main switch
pushed SET/RESUME/CANCEL switch
Cruise control unit
Set speed will not resume when RESUME button (with Main switch
main switch on, when set speed is temporarily SET/RESUME/CANCEL switch
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

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.

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 3.75±0.5 mm (0.15±0.02 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).

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).

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.

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 Limit
General
Type
Number of cylinders V-type, DOHC
Bore 6
Stroke 86.7mm (3.4133in.)
Total displacement 75mm (2.9528in.)
Compression ratio 2,656cc
Firing order 10 : 1
Valve timing 1-2-3-4-5-6
Intake valve 6°
Opens (BTDC) 46°
Closes (ABDC) 44°
Exhaust valve 8°
Opens (BBDC)
Closes (ATDC)
Camshaft
Drive mechanism Cogged type belt
Cam height 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
Intake 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
Exhaust 25.964 ~ 25.980mm (1.0222 ~ 1.0228in.) 43.45mm (1.7106in.)
Journal diameter 0.02 ~ 0.61mm (0.0007 ~ 0.0024in.) 43.45mm (1.7106in.)
Bearing oil clearance 0.1 ~ 0.15mm (0.0039 ~ 0.0059in.) 25.914m(1.0202in.)
End play 0.1mm (0.0039in.)
Cylinder head 0.05mm (0.0020in.)
Flatness of cylinder head surface 0.15mm (0.0059in.)
Flatness of manifold mounting surface 0.15mm (0.0059in.)
Max. 0.03mm (0.0012in.)
Intake
Max. 0.15mm (0.0059in.)
Exhaust
Max. 0.15mm (0.0059in.)
Valve guides hole diameter
11.05 ~ 11.068mm (0.435 ~ 0.436in.)
0.05 (0.002) O.S.
11.25 ~ 11.268mm (0.443 ~ 0.444in.)
0.25 (0.010) O.S.
11.50 ~ 11.518mm (0.453 ~ 0.453in.)
0.50 (0.020) O.S.
33.300 ~ 33.325mm (1.311 ~ 1.312in.)
Intake valve seat ring hole diameter
28.600 ~ 28.621mm (1.126 ~ 1.127in.)
0.3 (0.012) O.S
Exhaust valve seat ring hole diameter
0.3 (0.012) O.S.
Valve
Overall length
Intake
96.1mm (3.783in.)
Exhaust
97.15mm (3.825in.)
Stem diameter
5.965 ~ 5.98mm (0.235 ~ 0.2354in.)
Intake
5.95 ~ 5.965mm (0.234 ~ 0.235in.)
Exhaust
45° ~ 45.5°
Face angle
1.0mm (0.0394in.)
Margin
1.3mm (0.0512in.)
Intake
0.02 ~ 0.05mm (0.0008 ~ 0.0020in.)
Exhaust 0.5mm (0.0197in.)
0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)
Clearance (Stem-to-guide) 0.8mm (0.0315in.)
Intake 0.10mm (0.0039in.)
Exhaust 0.15mm (0.0059in.)
Valve spring 41.5mm (1.6339in.)
42.5mm (1.6732in.)
Free height 21.9kg/34mm
21kg/35mm (48.4lb/1.3780in.)
Load (48.4lb/1.3386in.)
Max 1.5°
Out of squareness Max. 3°
Piston

Page 2 of 12
Diameter (Standard)
86.68 ~ 86.71mm (3.413 ~ 3.414in.)
Clearance (Piston-to-cylinder)
0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
Ring groove width
1.230 ~ 1.250mm (0.0484 ~ 0.0492in.)
No. 1
1.220 ~ 1.250mm (0.0480 ~ 0.0488in.)
No. 2
2.515 ~ 2.535mm (0.0990 ~ 0.0998in.)
Oil
0.25mm (0.010in.), 0.50mm (0.020in.)
Piston for service
Piston ring
Number of rings per piston
Compression ring 3
Oil ring 2
Compression ring type 1
No. 1 Inner bevel type
No. 2 Under cut type
Oil ring type 3-piece type
Ring end gap 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No. 1 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
No. 2 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)
Oil ring side rail 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.) 0.8mm (0.031in.)
Ring side clearance 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.) 0.8mm (0.031in.)
No.1 0.25mm (0.010in.), 0.50mm (0.020in.) 1.0mm (0.039in.)
No.2 0.1mm (0.004in.)
Rings for service 0.1mm (0.004in.)
2,450 ~ 12,255N
Connecting rod
(250 ~ 1,250kg, 551 ~ 2,755lb)
Piston pin installation force
0.10 ~ 0.25mm (0.0039 ~ 0.0098in.) 0.4mm (0.016 in.)
Side clearance (big end)
0.05mm or less/100mm 0.1mm (0.004in.)
Bend
(0.0020in. or less/3.937in.)
Bearing oil clearance
0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)
Crankshaft
61.982 ~ 62.000 (2.4402 ~ 2.4409 in.)
Journal O.D.
47.982 ~ 48.000 (1.8891 ~ 1.8898in.)
Pin O.D.
Max. 0.003mm (0.00012in.)
Out-of-round of journal and pin
Max. 0.005mm (0.00020in.)
Taper of journal and pin
0.070 ~ 0.250mm (0.0028 ~ 0.0098in.)
End play 0.4mm (0.016in.)
0.004 ~ 0.022mm (0.0002 ~ 0.0009in.)
Main bearing oil clearance 0.1mm (0.004in.)
Cylinder block
86.7mm (3.4134in.)
Cylinder bore
Max. 0.03mm (0.0012in.) 0.05mm (0.002in.)
Flatness of gasket surface
Max. 0.02mm (0.0008in.)
Out-of-round of cylinder bore
Oil pump
Side clearance 0.100 ~ 0.181mm (0.0039 ~ 0.0071 in.)
Body clearance 0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)
Side clearance
Relief spring
43.8,, (1.724in.)
Free length
4.6kg/39.3mm (10lb/1.547in.)
Load
Cartridge, full flow
Oil filter 50kPa (7.3psi) or more
Type [Conditions : Oil temperature is 75 to 90°C (167
Engine oil pressure to 194°C)]
Cooling method Engine coolant cooling, forced circulation with
Cooling system quantity electric fan
7.0lit (7.4U.S.qts., 6.1lmp.qts.) [For V6]
Theromstat
wax pellet type with jiggle valve
Type
82 ± 2.0°C (179.6 ± 35.6°F)
Normal opening temperatrure
80 ~ 84°C (176 ~ 183.2°F)
Opening temperature range
95°C (203°F)
Wide open temperature

Page 3 of 12
Radiator cap 107.9 ± 14.7kPa (1.1 ± 0.15kg/cm², 15.65 ±

Main valve opening pressure 2.13psi)
Main valve closing pressure 83.4kPa (0.85kg/cm², 12.1psi)
Vacuum valve opening pressure -6.86kPa (-0.07kg/cm², -1.00psi)
Air cleaner
Dry
Type
Paper type
Element
Exhaust pipe
Expansion reaonance type
Muffler
Rubber hangers
Suspension system
SERVICE STANDARD
Standard value
Coolant concentration
Tropical areas 40%
Other areas 50%
COOLANT
Engine coolant Ethylence glycol base for aluminum radiator
SEALANT
LOCTITE 262 or equivalent, Three bond No. 1324 or

Engine coolant temperature sensor
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
19.5 ~24 +
Main bearing cap bolt
27~33 + (90°~94°) 270~330 + (90°~94°) (90° ~ 94°
M10
13~19 + (90°~94°) 130~190 + (90°~94°) 10~14 +
M8
(90°~94°)
12~15 +
Connecting rod bolt 16~20 + (90°~94°) 160~200 + (90°~94 °)
(90°~94°)
18 + (58°
Cylinder head bolt (Cold engine) 25 + (58°~92°) + (43°~47° ) 250 + (58°~92°) + (43°~47°) ~92°) +
(43°~47°)
Oil pan drain plug 35 ~ 45 350 ~ 450 25 ~ 33
Lower oil pan bolt 10 ~ 12 100 ~ 120 7~9
Upper oil pan bolt
30 ~ 42 300 ~ 420 22 ~ 30
[10×38mm (0.937×1.4961in.)]
19 ~ 28 190 ~ 280 14 ~ 20
[8×22mm (0.3150×0.8661in.)]
5~7 50 ~ 70 4~5
[161.5mm(6.3582in.)]
5~7 50 ~ 70 4~5
[152.5mm (6.0039in.)]
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

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
30 ~ 35 300 ~ 150 22 ~ 26
nut)
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
40 ~ 55 400 ~ 550 29 ~ 40
bolt
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
20 ~ 30 200 ~ 300 14 ~ 22
bracket side)
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
15 ~ 22 150 ~ 220 11 ~ 16
(Head mark "7" mark)
Engine coolant temperature sensor 20 ~ 40 200 ~ 400 14 ~ 29

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
Spark plug 20 ~ 30 200 ~ 300 14 ~ 22
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 :

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.)

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/cm²) pressure. Hold for two
minutes, then checkfor leakage from the radiator, hoses or connections.

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/cm² , 15.64 ± 2.13psi)
Main valve closing pressure :
83.4 kPa (0.85 kg/cm², 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

Page 9 of 12
Safe Coolant
Coolant temperature °C (°F) and specific gravity Freezing
operating concentration
temperature
temperature (Specific
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) °C(°F)
°C(°F) volume)
1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058 1.054 1.049 1.044 -20 (-4) -15 (5) 35%
1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074 1.069 1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55%
1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60%
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C
(68°F).
• 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 ~ 95°C (176 ~ 205°F).
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/cm² , 170psi)

Limit : 1,050kpa (10.7kg/cm² , 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

Page 10 of 12
Max. 100kpa (1.0 kg/cm², 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 20°C (68°F)] :
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)

Page 11 of 12
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.

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

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 Installation of the crankshaft
(09214-33000) front oil seal
Camshaft oil seal installer Installation of the camshaft oil

(09221-21000) seal
Valve guide installer Removel and installation of the

(09221-3F100 A/B) valve guide
Valve stem oil seal installer Installation of the valve stem oil
(09222-22001) seal
Valve spring compressor Remove and installation of the

(09222-28000) intake or exhaust valve
(09222-28100)
Valve stem oil seal remover Removeal of the valve stem oil
(09222-29000) seal
Crankshaft rear oil seal installer Installation of the crankshaft

(09231-33000) rear oil seal
Crankshaft wrench Used if the crankshaft needs to

(09231-33100) be rotated to attach the tming
belt, etc.

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 Probable cause Remedy
Crankshaft bearing knock Worn main bearing Replace
Seized bearing Repalce
Bent crakshaft Replace
Excessive crankshaft end play Replce thrust bearing
Piston and connecting rod knock Replace
Worn bearing
Repalce
Seized bearing
Replace piston and pin or
Worn piston pin
connecting rod
Worn piston in cylinder
Recondition cylinder
Broken piston ring
Replace
Improper connecting rod alignment
Repalce
Noisy valves Faulty auto-lash adjuster
Replace
Thin or diluted engine oil (low oil pressure)
Change
Worn or damaged valve stem or valve
Repalce
guide
Excessively worn cylinder and Shorted or engine oil Add or replace
piston Dirty engine oil Repalce
Poor quality of engine oil Use proper oil
Improperly assembled piston and Repair or replace
connecting rod Replace
Improper piston ring end clearance Clean air cleaner assembly and
Dirty air cleaner replace the air filter
Connecting rod and main Insufficient oil supply Check engine oil level
bearing noise Thin or diluted engine oil Change and find out cause
Excessive bearing clearnace Replace
Damaged crankshaft bearing Add or replace
Shorted of engine oil Adjust or repair
Low oil pressure Use proper engine oil
Poor quality of engine oil Replace
Worn or out-of-round of crankshaft journal Clean
Restricted oil passage in crankshaft Replace bearing and check
Worn bearing engine oil and lubrication
Faulty oil pump system
Bearing improperly installed Repair or replace
Non-concentric crankshaft or bearing Repaur or replace
Replace
Timing belt noise Incorrect belt tension Adjust belt tension
Low compression Replace gasket
Damaged cylinder head gasket Replace rings
Worn or damaged piston rings Repair or replace piston and/or
Worn piston or cylinder cylinder block
Worn or damaged valve seat Repair or replace valve and/or
seat ring
Oil pressure drop Low engine oil level Check engine oil level
Faulty oil pressure switch Repalce
Clogged oil filter Replace
Worn oil pump gears or cover Replace

Page 2 of 2
Thin or diluted engine oil Change and find out cause

Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace
High oil pressure Oil relief valve stuck (closed) Repair or replace
Excessive engine rolling and Misfire Correct
vibration Loose engine roll stopper (front, rear) Re-tighten
Loose transaxle mount bracket Re-tighten
Loose center member Re-tighten
Broken transaxle mount insulator Re-tighten
Broken engine mount insulator Replace
Broken engine roll stopper insulator Repalce or repalce
Low coolant level Leakage of coolant
Damaged radiator core joint Correct
Corroded or cracked hoses (Radiator hose, Replac
heater hose, etc.) Replace
Faulty radiator cap valve or setting or Replace
spring Repacle
Faulty thermostat Repalce
Faulty engine coolant pump
Clogged radiator Foreign material in coolant Replace
Abnormally high coolant Faulty thermostat Replace parts
temperature Faulty radiator cap Replace
Restriction of flow in cooling system Clear restriction or replace parts
Loose or missing drive belt Adjust or replace
Faulty engine coolant pump Replace
Faulty thermostat seder or wiring Repair or repalce
Faulty electric fan Repair or replace
Faulty thermo-sensor on radiator Replace
Insufficient coolant Refill coolant
Abnormally low coolant Faulty thermostat Replace
temperature Faulty temperature gauge or wiring Repair or replace
Leakage from oil cooling system Loose hose and pipe connection Replace
Blocked or collapsed hose and pipe Repair or replace
Inoperative electrical cooling fan Damaged Replace or repair
Loose pipe or in operative sensor Repair or replace
Exhaust gas leakage Loose connections Re-tighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffler plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle body Correct
Broken pipe or muffler Repair or replace

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

Page 2 of 2

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.

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.

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.

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.

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.

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

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.

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.

Page 3 of 6
Problem Possible cause Action

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

Do not run engine at a speed
is running after changing the HLA.
higher than 3000 rpm, as this may
damage the HLA.
6.Continuous noise during idle after Engine oil level too high or too Check oil level.
high engine speed. low. Drain or add oil as necessary.
Excessive amount of air in the
Check oil supply system.
oil at high engine speed.
Deteriorated oil. Check oil quality.
If deteriorated, replace with specitied
type.
7. Noise cotinues for more than 15 Check oil pressure and oil supply
Low oil pressure.
minutes. syste, of each part of engine.
Faulty HLA. 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.

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)

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.

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

14. Install the intake manifold and engine cover.

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

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.

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.)

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.)

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
Oversize valve guide hole size

Size mm (in.) Size mark
mm(in.)
11.050 ~ 11.068
0.05 (0.002) O.S. 5
(0.435 ~ 0.4357)
11.250 ~ 11.268
0.25 (0.010) O.S. 25
(0.443 ~ 0.4436)
11.500 ~ 11.518
0.50 (0.020) O.S. 50
(0.453 ~ 0.4535)

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.

Page 6 of 8
Valve Seat Ring Oversizes
Size Seat ring height H mm Oversize hole diameter

Description Size mm (in.)
mark (in.) I.D. mm(in.)
Intake valve 33.300 ~ 33.325
0.3 (0.012) O.S. 30 7.9 ~ 8.1 (0.311 ~ 0.319)
Seat ring (1.311 ~ 1.312)
Exhaust valve 28.600 ~ 28.625
0.3 (0.012) O.S. 30 7.9 ~ 8.1 (0.311 ~ 0.319)
Seat ring (1.126 ~ 1.127)
3. Heat the cylinder head to about 250°C (480°F) 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.

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.

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°)

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.

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.

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.

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.

Page 5 of 5
25. Remove the engine and transaxle assembly as a unit.

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

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.

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

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 25
0.50mm (0.020in.) O.S 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.

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.

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°)

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.)

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

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.)

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

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)

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)

Page 5 of 5

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

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.)

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 0.25mm (0.010in.)
0.50 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.

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

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

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.

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.

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

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

Page 2 of 2

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.

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

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 ~ 84°C (176 ~ 183.2° F)

Full opening temperature : 95°C (203°C)

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

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).

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

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.

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

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. Do not apply oil or grease to the engine coolant pipe O-ring.

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

Page 2 of 2

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

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.)

Page 2 of 5
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/cm². 2.9 ~ 5.8 psi)
REASSEMBLY

Page 3 of 5
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.

Page 4 of 5
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)

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.

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

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.

Page 2 of 2

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

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.

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.

Page 3 of 4
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.

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.)

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

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

Page 2 of 2
3. Check the exhaust manifold for damage and cracks.

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

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.

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]

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

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

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
Engine will not start or hard to Vacuum hose disconnected or damaged Repair or replace
start
Malfunction of the EVAP Canister Purge Repair or replace
Solenoid Valve
Rough idle or engine stalls Vacuum hose disconnected or damaged Repair or replace
Malfunction of the PCV valve Replace
Malfunction of the evaporative emission Check the system; if there is a
canister purge system problem, check related
components parts
Excessive oil consumption Positive crankcase ventilation line clogged Check positive crankcase
ventilation system

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 Variable flow rate type
Positive Crankcase Ventilation (PCV) valve
Evaporative Emission System HC reduction Duty control solenoid valve
EVAP Canister
EVAP Canister Purge Solenoid Valve
Exhaust Emission System CO, HC, NOx reduction Heated oxygen sensor feedback type
MFI system (air-fuel mixtrue control device) CO, HC, NOx reduction Monolithic type
Three-way catalytic converter
MFI : Multiport Fuel Injection

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

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

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

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 kg·cm, 6~8 lb·ft)
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.

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

Page 1 of 1
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.

Page 1 of 2
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.

Page 2 of 2
AIR FILTER
Look for distortion, cracks.

Page 1 of 3
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

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 20°C (68°F) : 0.45A or below (at 12V)
Coil resistance : 26Ω [at 20°C (68°F)]
VACUUM HOSE
Engine coolant temperature : 80~95°C (176~205°F)
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.

Page 3 of 3

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.

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.

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 Connection of fuel pressure gauge to
Fuel pressure gauge adapter delivery pipe for measurement of fuel
pressure.
09353-24100
Fuel pressure gauge & hose

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

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)

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. Turn OFF the ignition switch.

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

Page 4 of 4

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

Page 2 of 10

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

PROBLEM

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

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

Page 5 of 10

Page 6 of 10
ROUGH IDLE OR ENGINE STALLS

Page 7 of 10

Page 8 of 10
Engine hesitates or accelerates poorly

Page 9 of 10
TROUBLESHOOTING
Trouble symptom Probable cause Remedy

Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
Transaxle range switch faulty Adjust or replace switch
(Vehicle with automatic transaxle only)
Fusible link blown Replace fusible link
Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables

Page 10 of 10
Starter motor faulty Repair starter motor

Starter keeps running Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Starter spins but engine will not Pinion gear teeth broken or starter motor Repair starter motor
crank faulty
Ring gear teeth broken Replace flywheel ring gear or torque
converter
FUEL TANK AND FUEL LINE

Engine malfunctions due to Bent or kinked fuel pipe or hose Repair or replace
insufficient fuel supply
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 Replace
(clogged filter in the pump)
Evaporative emission system Incorrect routing of a vapor line Correct
malfunction (when fuel filler cap is
Disconnected vapor line Correct
removed,pressure is released)
Folded, bent, cracked or clogged vapor Replace
line
Faulty fuel tank cap Replace
Malfunctioning overfill limiter Replace
(two-way valve)

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 Specifications
Throttle body Throttle position Type Variable resistor
sensor (TPS)
Resistance at
2.7 V6 1.6 ~ 2.4 KΩ
curb idle
Output voltage
2.7 V6 250 ~ 800 mV
at curb idle
Idle speed control Type Double Coil

(ISC) actuator Resistance 90 ~ 110 Hz
Sensors Air flow sensor Type 2.7 V6 Hot Film sensor
Intake air Type 2.7 V6 Thermistor
temperature (IAT)
sensor Resistance 2.33 ~ 2.97 KΩ at 20°C (68°F)
Type Thermistor
Engine coolant
temperature (ECT) Resistane 2.5 KΩ at 20°C (68°F)
sensor
0.3 KΩ at 80°C (176°F)
Heated oxygen
Type 2.7 V6 Zirconium
sensor (HO2S)
Vehicle speed
Type Hall effect
sensor
Camshaft position Type Hall effect
(CMP) sensor
Actuators Injectors Type, number 2.7 V6 Electromagnetic type, 6
Resistance 13 ~ 16Ω at 20°C (68°F)
Evaporative Type Duty cycle type
emission purge
control solenoid
valve
Fuel pressure Pressure regulator 300 ± 1.5 kPa
regulator (3.35 ± 0.06 kg/cm²)
Fuel tank Tank capacity 55 lit (12.1 lmp.gal)
Return system Equipped
Canister Volume/Nominal working capacity 3.0 liter/150g
SERVICE STANDARD
Items Standard value
Basic ignition timing 2.7 V6 BTDC 12° ± 5° at curb idle
2.7 V6 D-range (A/T) 650 ± 100
Curb idle speed (rpm) P,N-range 750 ± 100 (A/C OFF)
(A/T, M/T) 800 ± 100 (A/C ON)
Fuel pressure kPa (psi) Vacuum hose disconnection 330 ~ 350 (47 ~ 50) at curb idle
Vacuum hose connection Approx. 270 (38) at curb idle

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

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 O O
P0102 Mass Air Flow Circuit Low Input O O
P0103 Mass Air Flow Circuit High Input O O
P0112 Intake Air Temperature Circuit Low Input O O
P0113 Intake Air Temperature Circuit High Input O O
Engine Coolant Temperature Sensor Circuit Range/Performance
P0116 O O
Problem
P0117 Engine Coolant Temperature Circuit Low Input O O
P0118 Engine Coolant Temperature Circuit High Input O O
P0119 Engine Coolant Temperature Circuit Intermittent O O
P0121 Throttle Position Sensor Circuit Range/Performance Problem O O
P0122 Throttle Position Sensor Circuit Low Input O O
P0123 Throttle Position Sensor Circuit High Input O O
P0125 Insufficient Coolant Temperature For Closed Loop Fuel Control O O
P0128 Coolant thermostat stuck O O
P0131 HO2S Circuit Low Input (Bank 1, Sensor 1) O O
P0132 HO2S Circuit High Input (Bank 1, Sensor 1) O O
P0133 HO2S Circuit Slow Responsive (Bank 1, Sensor 1) O O
P0134 HO2S Circuit No Activity Detected (Bank 1, Sensor 1) O O
P0030 HO2S Heater Control Circuit (Bank 1, Sensor 1) O O
P0031 HO2S Heater Circuit Low (Bank 1, Sensor 1) O O
P0032 HO2S Heater Circuit High (Bank 1, Sensor 1) O O
P0153 HO2S Circuit Slow Responsive (Bank 2, Sensor 1) O O

Page 2 of 14

P0171 Fuel System Too Lean (Bank 1) O O
P0172 Fuel System Too Rich (Bank 1) O O
P0174 Fuel System Too Lean (Bank 2) O O
P0175 Fuel System Too Rich (Bank 2) O O
P0230 Fuel Pump Circuit Malfunction O X
P0261 Injector Circuit Low Input (Cylinder -1) O O
P0262 Injector Circuit High Input (Cylinder -1) O O
P0300 Random Misfire Detected O O
P0301 Misfire Detected (Cylinder -1) O O
P0325 Knock Sensor Circuit Malfunction (Bank 1) O X
P0330 Knock Sensor Circuit Malfunction (Bank 2) O X
P0335 Crankshaft Position Sensor Circuit Malfunction O O
P0340 Camshaft Position Sensor Circuit Malfunction O O
P0420 Main catalyst efficiency deterioration (Bank 1) O O
P0430 Main catalyst efficiency deterioration (Bank 2) O O
P0441 EVAP Emission Control System Incorrect Purge Flow O O
P0442 EVAP Emission Control System Small Leak (1 mm) O O
P0444 EVAP Emission Control System Purge Control Valve Circuit Open O O
P0445 EVAP Emission Control System Purge Control Valve Circuit Shorted O O
P0449 EVAP Emission Control System Vent Valve/Solenoid Circuit O O
P0447 EVAP Emission Control System Vent Circuit Open O O
P0448 EVAP Emission Control System Vent Circuit Shorted O O

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

P0451 O O
Problem
P0452 EVAP Emission Control System Pressure Sensor Low Input O O
P0453 EVAP Emission Control System Pressure Sensor High Input O O
P0454 Evaporative Emission Control System - Pressure Sensor Intermittent O O
P0455 EVAP Emission Control System - Large Leak O O
P0456 Evaporative Emission Control System - Small Leak Detected (0.5mm) O O
P0461 Fuel Level Sensor Circuit Range/Performance O O
P0462 Fuel Level Sensor Circuit Low Input O O
P0463 Fuel Level Sensor Circuit High Input O O
P0464 Fuel Level Sensor Circuit Intermittent O O
P0501 Vehicle Speed Sensor Range/Performance O O
P0506 Idle Control System Rpm Lower than Expected O O
P0507 Idle Control System rpm Higher than Expected O O
P1134 HO2S Circuit - Transition Switch Malfunction/Slip (Bank 1, Sensor 1) O O
P1154 HO2S Circuit - Transition Switch Malfunction/Slip (Bank 2, Sensor 1) O O
P1166 Lambda Bank Control Limit (Bank 1) O O
P1167 Lambda Bank Control Limit (Bank 2) O O
P1372 Segment Time Acquisition Incorrect O X
P1505 Idle Speed Actuator Signal Low of Coil #1 O O
P1506 Idle Speed Actuator Signal High of Coil #1 O O
P1507 Idle Speed Actuator Signal Low of Coil #2 O O
P1508 Idle Speed Actuator Signal High of Coil #2 O O
P1521 Power Steering Switch Malfunction O X
P1529 TCU Request for MIL ON/Freeze Frame to ECU via CAN O O
P1602 Serial Communication Problem with TCU (Timeout) O O
P0605 Internal CONTROL module ROM error O O
P0560 System Voltage Malfunction O X
P0562 System Voltage Low O O
P0563 System Voltage High O O
P0650 Malfunction Indication Lamp (MIL) Control Circuit Malfunction O X
P1624 Cooling Fan Relay Circuit Malfunction (LOW) O X
P1625 Cooling Fan Relay Circuit Malfunction (HIGH) O X
TROUBLE AREA RELATED TO DTC
Check items for each diagnostic item do not list all probable causes.
DTC No. Diagnostic items Trouble area

Page 4 of 14
P0101 Mass Air Flow Circuit • Dirty air cleaner

Range/performance Problem • 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 • Short to ground between IAT sensor and ECM
Low Input • Short between IAT sensor wires
• Faulty IAT sensor
P0113 Intake Air Temperature Circuit • Open or short to battery between IAT sensor and ECM
High Input • Faulty IAT sensor
P0115 Engine Coolant Temperature • Open or short to battery between ECTS and ECM
Circuit Malfunction • Short to ground between ECTS and ECM
• Short between ECTS wires
• Faulty ECTS
P0116 Engine Coolant Temperature • After engine start-up, the measured coolant temperature
Sensor Circuit shows no variation after detecting the calculated coolant
Range/Performance Problem 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
If any codes relating to ECTS are present, do all repairs

associated with them before proceeding with this
troubleshooting area.
P0117 Engine Coolant Temperature • Short to ground between ECTS and ECM
Circuit Low Input • Short between ECTS wires
• Faulty ECTS
P0118 Engine Coolant Temperature • Open or short to battery between ECTS and ECM
Circuit High Input • Faulty ECTS
P0119 • Poor connections between ECTS and ECM

Page 5 of 14
Engine Coolant Temperature • Misplaced, loose or corroded terminals

Circuit Intermittent • Foreign materials fouled ECTS
P0121 Throttle Position Sensor Circuit • Poor connections between TPS and ECM
Range/Performance Problem • 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
P0122 Throttle Position Sensor Circuit • Short to GND between TPS and ECM
Low Input • Open short to GND between TPS and ECM
• Short to RND between ECM and fuel tank pressure sensor
(FTPS)
• Faulty TPS or FTPS
P0123 Throttle Position Sensor Circuit • Open or short to battery between TPS and ECM
High Input • Open between and ECM
• Faulty TPS
P0125 Insufficient Coolant • After engine start-up, the elapsed time before feedback
Temperature For Closed Loop operation is initiated is too long (engine coolant temperature
Fuel Control 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 • Short to GND between HO2S and ECM
1, Sensor 1) • Faulty front HO2S
P0132 HO2S Circuit High Input (Bank • Short to battery between HO2S and ECM
P0133 HO2S Circuit Slow Responsive • Front and rear HO2S connections reversed
(Bank 1, Sensor 1) • 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 • Contaminated, deteriorated or aged HO2S

Detected (Bank 1, Sensor 1) • 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.

Page 6 of 14
P0135 HO2S Heater Circuit • Blown or missing HO2S fuse

Malfunction (Bank 1, Sensor 1) • Short to battery between front HO2S and ECM
• Open between front HO2S and ECM
• Faulty front HO2S
P0030 HO2S Heater Control Circuit • Contaminated, deteriorated or aged HO2S
(Bank 1, Sensor 1) • Heater Resistance out of Reasonable Range
• Misplaced, bent, loose or corroded connector terminals
• Faulty HO2S
P0031 HO2S Heater Circuit Low (Bank • Blown or mission HO2S fuse
1, Sensor 1) • Open or short to GND between HO2S and ECM
• Faulty HO2S
P0032 HO2S Heater Circuit High (Bank • Short to battery between HO2S and ECM
1, Sensor 1) • Faulty HO2S
P0136 HO2S Circuit Malfunction (Bank • Short between rear HO2S and ECM
1, Sensor 2) • Faulty rear HO2S
P0138 HO2S Circuit Low Input (Bank • Open or short to battery between HO2S and ECM
• Faulty HO2S

before proceeding with this troublearea.

• Faulty HO2S

proceeding with this trouble area.
P0141 HO2S Heater Circuit • Blown or missing HO2S fuse

Malfunction (Bank 1, Sensor 2) • Short to battery between rear HO2S and ECM
• Open between rear HO2S and ECM
• Faulty rear HO2S
P0037 HO2S Heater Circuit Low (Bank • Blown or missing HO2S fuse
• Faulty HO2S

Page 7 of 14

P0152 HO2S Circuit High Input (Bank • Short to battery between HO2S and ECM
• Faulty HO2S

before proceeding with this troublearea.

• Faulty HO2S

proceeding this trouble area.

(Bank 2, Sensor 1) • Heater Resistance out of reasonable range
• Faulty HO2S
• Faulty HO2S
P0158 HO2S Circuit High Input (Bank • Open or short to battery between HO2S and ECM
• Faulty HO2S


Page 8 of 14
2, Sensor 2) • Open or Short to GND between HO2S and ECM
• Faulty HO2S
P0171 Fuel System Too Lean (Bank 1) • 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 Fuel System Too Rich (Bank 1) • Faulty fuel delivery system (Fuel tank/Pressure
• Faulty MAFS

P0174 Fuel System Too Lean (Bank 2) • Faulty ignition system (Ignition coil/spark plug/Ignition cable)
• Faulty fuel delivery system (Fuel tank/Pressure
• Clogged fuel injectors
• Faulty MAFS

P0175 Fuel System Too Rich (Bank 2) • Faulty fuel delivery system (Fuel tank/Pressure
• Faulty MAFS


Page 9 of 14
P0230 Fuel Pump Circuit Malfunction • 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
Injector Circuit Low Input • Short to GND between injector and ECM
P0261
(Cylinder -1) • Faulty fuel injector
Injector Circuit Low Input
P0264
(Cylinder -2)
P0267
(Cylinder -3)
P0270
(Cylinder -4)
P0273
(Cylinder -5)
P0276
(Cylinder -6)
Injector Circuit High Input • Open between injector fuse and injector
P0262
(Cylinder -1) • Open or short to battery between injector and ECM
Injector Circuit High Input • Faulty fuel injector
P0265
(Cylinder -2)
Injector Circuit High Input
P0268
(Cylinder -3)
P0271
(Cylinder -4)
P0274
(Cylinder -5)
P0277
(Cylinder -6)
• Vacuum leak in air intake system
P0300 Random Misfire Detected
• CKP sensor circuit malfunction
• Faulty CKP sensor
P0301 Misfire Detected (Cylinder -1) • Ignition circuit malfunction
• Faulty ignition coil or plug wire
• Spark plug malfunction
P0302 Misfire Detected (Cylinder -2)
• Low compression due to blown head gasket, leaking valve or
piston ring
P0303 Misfire Detected (Cylinder -3) • Low/high fuel pressure due to faulty pressure regulator,
restricted fuel lines,plugged fuel filter or faulty fuel pump
• Fuel injector circuit malfunction
P0304 Misfire Detected (Cylinder -4) • Faulty fuel injector
P0305 Misfire Detected (Cylinder -5)

If any fuel injector codes (or pending codes) are present, do all
P0306 Misfire Detected (Cylinder -6) repairs associated with those codes before proceeding with
this trouble area.

Page 10 of 14
P0325 Knock Sensor Circuit • Open or short to GND between knock sensor and ECM
Malfunction (Bank 1) • Source of high resistance between knock sensor and ECM
P0330 Knock Sensor Circuit • Faulty knock sensor
Malfunction (Bank 2)
P0335 Crankshaft Position Sensor • Short to GND between CKP sensor and ECM
Circuit Malfunction • 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
P0340 Camshaft Position Sensor • Short to GND between CMP sensor and ECM
Circuit Malfunction • Open or short to battery between CMP and ECM
• Short between CMP sensor wires
• Poor connection between CMP connector & harness
connector
• Faulty CMP sensor
P0420 Main catalyst efficiency • Catalytic converter deteriorated
deterioration (Bank 1)
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 • Catalytic converter deteriorated

deterioration (Bank 2)
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 • Stuck in valve open position

Incorrect Purge Flow
P0442 EVAP Emission Control System • Fuel filler cap loose or missing
Small Leak (1 mm) • 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.

Page 11 of 14
P0444 EVAP Emission Control System • Faulty PSV

Purge Control Valve Circuit • Open between PSV and ECM
Open
P0445 EVAP Emission Control System
• Faulty PSV
Purge Control Valve Circuit
• Short to GND or battery between PSV and ECM
Shorted
P0449 EVAP Emission Control System • Stuck in valve closed position (CCV)
Vent Valve/Solenoid Circuit • Faulty CCV
P0447 EVAP Emission Control System • Open or short to battery between CCV and ECM
Vent Circuit Open • Faulty CCV
P0448 EVAP Emission Control System • Short to GND between CCV and ECM
Vent Circuit Shorted • Faulty CCV
P0451 EVAP Emission Control System • High resistance or open between fuel tank pressure sensor
Pressure Sensor and ECM
Range/Performance Problem • Stuck closed canister close valve
• Blocked vapor hose between canister and CCV
• Open or short to battery between FTPS and ECM
• Faulty FTPS
P0452 EVAP Emission Control System • Short to GND between FTPS and ECM
Pressure Sensor Low Input • Faulty FTPS
P0453 EVAP Emission Control System • Open or short to battery between fuel tank pressure sensor
Pressure Sensor High Input and ECM
• Short to battery in ECM
• Open in ECM
• Faulty FTPS
P0454 Evaporative Emission Control • Poor connections between FTPS and ECM
System - Pressure Sensor • Misplaced, loose or corroded terminals
Intermittent • Foreign materials fouled FTPS
• Faulty FTPS
P0455 EVAP Emission Control System • Fuel filler cap loose or missing
- Large Leak • 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
P0456 Evaporative Emission Control • Leaking canister or catch tank
System - Small Leak Detected
(0.5mm)
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.

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 • Poor connection

Range/Performance • Contaminated, deteriorated or aged FTLS
• Faulty FTLS
P0462 Fuel Level Sensor Circuit Low • Open or short to GND between FTLS and ECM
Input • Short to GND or open in ECM
• Faulty FTLS
P0463 Fuel Level Sensor Circuit High • Short to battery between FTLS and ECM
Input • Short to battery
• Faulty FTLS
P0464 Fuel Level Sensor Circuit • Poor connections between ECTS and ECM
Intermittent • Misplaced, loose or corroded terminals
• Faulty FTLS
P0501 Vehicle Speed Sensor • Open between fuse and wheel speed sensor (WSS)
Range/Performance • 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 • High resistance between injector fuse and IAC valve
than Expected • High resistance between IAC and ECM
• Faulty IAC valve
• Carbon fouled throttle plate
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 • Improperly adjusted accelerator cable
than Expected • 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 • HO2S Deteriorated

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

Page 13 of 14
P1154 HO2S Circuit - Transition Switch

Malfunction/Slip (Bank 2,
Sensor 1)
P1166 Lambda Bank Control Limit • P1166 is case for HO2S (Bank 1, Sensor 1) Signal line open
(Bank 1) • 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
P1167 Lambda Bank Control Limit • Sealing between purge valve and fuel tank
(Bank 2)
• Air leakage in exhaust system
• Ignition system (Ignition coil, spark plug, cable) failure
• Surge tank and intake port failure
(Bank 1, Sensor 2) • Heater resistance out of reasonable range
• Faulty HO2S
(Bank 2, Sensor 2) • Heater resistance out of reasonable range
• Faulty HO2S
P1372 Segment Time Acquisition • Bad installation of tone wheel to crankshaft
Incorrect • Bad signal of the CKP sensor
• Bad connection of connectors/bad wiring (between ECM and
CKP)
P1505 Idle Charge Actuator Signal Low • Open or short to GND between ISC and ECM
of Coil #1 • Faulty ISC
P1506 Idle Charge Actuator Signal • Short to battery between ISC and ECM
High of Coil #1 • Faulty ISC
P1507 Idle Charge Actuator Signal Low • Open or short to GND between ISC and ECM
of Coil #2 • Faulty ISC
P1508 Idle Charge Actuator Signal • Short to battery between ISC and ECM
High of Coil #2 • Faulty ISC
P1521 Power Steering Switch • Open or short to battery between switch and ECM
Malfunction • Short to GND between switch and ECM
• Open between switch and ECM
• Faulty power steering switch
P1529 TCU Request for MIL • This is only a request from TCM to turn the MIL ON. The fault
ON/Freeze Frame to ECU via code is stored in the TCM. The freeze frame data is stored in
CAN the ECM under the P1529 request code. Be sure to retrieve
freeze frame data before clearing code P1529 from ECM.
P1602 Serial Communication Problem • Open or short to serial communication line
with TCU (Timeout) • CAN message timeout
• Faulty TCU
P0560 System Voltage Malfunction • Short between main relay and ECM
• Open between main relay and ECM
• Poor connection
• Faulty main relay

Page 14 of 14
P0562 System Voltage Low • Reverse battery cable connection (+/- reverse)
P0563 System Voltage High • Faulty alternator
P0650 Malfunction Indication Lamp • Open or short between lamp and ECM
(MIL) Control Circuit Malfunction • Faulty lamp
P1624 Cooling Fan Relay Circuit • Open or short between relay and ECM
Malfunction (LOW) • Short to GND between relay and ECM
P1625 Cooling Fan Relay Circuit • Open between relay and ECM
Malfunction (HIGH) • Faulty relay
MAJOR SENSOR REFERENCE WAVE-FORMS

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

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

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

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 Removal & installation of lower arm
Mount bushing remover and bushing (G)
installer (Use with 09216-21200, 09545-
02000)
09216-21200 Removal & installation of the lower

Mount bushing remover and arm bushing (G)
installer base (Use with 09216-21100, 09545-
02000)
09532-11600 Measurement of the lower arm ball

Preload socket joint & stabilizer link starting torque
09545-02000 Removal & installation of the lower

Lower arm bushing remover and arm bushing (G)
installer (Use with 09216-21100, 09216-
21200)
09545-11000 Installation of the lower arm ball joint

Ball joint remover and installer
09545-21100 Installation of the lower arm ball joint

Ball joint dust cover installer dust cover
09551-25000 Removal & installation of the trailing

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

Rear suspension arm remover and suspension arm bushing
installer (Use with 09545-28100)
09568-34000 Separation of the lower arm ball joint

Ball joint puller

Page 2 of 2
09546-26000 Compression of front coil spring

Strut spring compressor Compression of the front and rear
or coil spring
J38402 (Use with A-42 or A-20)
Strut spring compressor

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 Possible cause Remedy
Hard steering Improper front wheel alignment
Correct
Excessive turning resistance of
Replace
lower arm ball joint
Adjust
Low tire pressure
Repair and replace
No power assist
Poor return of steering wheel to
Improper front wheel alignment Correct
center
Poor or rough ride Improper front wheel alignment Correct
Malfunctioning shock absorber Repair or replace
Broken or worn stabilizer Replace
Broken or worn coil spring Replace
Worn lower arm bushing Replace the lower arm assembly
Abnormal tire wear Improper front wheel alignment Correct
Improper tire pressure Adjust
Malfunctioning shock absorber Replace
Wandering Improper front wheel alignment
Correct
Poor turning resistance of lower arm
Repair
ball joint
Retighten or replace
Loose or worn lower arm bushing
Vehicle pulls to one side Improper front wheel alignment
Correct
Excessive turning resistance of
Replace
lower arm ball joint
Replace
Broken or worn coil spring
Repair
Bent lower arm
Steering wheel shimmy Improper front wheel alignment
Correct
Poor turning resistance of lower arm
Replace
ball joint
Replace
Broken or worn stabilizer
Replace
Worn lower arm bushing
Replace
Malfunctioning shock absorber
Replace
Broken or worn coil spring
Bottoming Broken or worn coil spring Replace
Malfunctioning shock absorber Replace
WHEEL AND TIRE DIAGNOSIS

Rapid wear at the center Rapid wear at both shoulders Wear at one shoulder
• Center- tread down to fabric due • Underinflated tires • Toe adjustment out of
to excessive over inflated tires • Worn suspension components specification
• Lack of rotation • Excessive cornering speeds • Camber out of specification
• Excessive toe on drive wheels • Lack of rotation • Damaged strut

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

Partial wear Feather edges wheels Wear pattern
• Cansed by irreqular burrs on • Toe adjustment out of • Excessive toe on non-drive

brak drums. specification wheels
• Damaged or worn tie rods • Lack of rotation
• Damaged knuckle

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

Page 2 of 3
SERVICE STANDARD

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 kg·cm lb·ft
Wheel nut 90~110 900~1100 67~82
Driveshaft nut
200~260 2000~2600 148~192
2.0L
200~280 2000~2800 148~207
2.7L
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
Trailing arm mounting 100~120 1000~1200 74~88
Replace the self-locking nuts with new ones after removal.
LUBRICANTS
Recommended lubricant Quantity
In ball joint of lower arm Variant R-2 grease or poly lub gly 801K As required

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

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.

Page 2 of 4
3. Tighten the components below to the specified torque as follows.
Items Torque Nm (kgf·cm, lbf·ft)

Front strut upper mounting nut 45~60 (450~600, 33~44)
Front strut to knuckle 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.

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.

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 kgf·cm, 37~51 lbf·ft)

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

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.

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).

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.

Wheel nut 90~110 (900~1100, 67~82)
Driveshaft nut 2.0 L : 200~260
(2000~2600, 148~192)
2.7 L : 200~280
(2000~2600, 148~192)
Strut lower mounting 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)
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.

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 kgf·cm, 1.48~2.58 lbf·ft)
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.

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

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
- 21.8mm (0.86 in.)
(HARD)
2.0L Normal
White 18.8mm (0.74 in.)
(SOFT)
2.7L Sports
Yellow 21.8mm (0.86 in.)
(HARD)
2.7 Normal
Red 18.8mm (0.74 in.)
(SOFT)
ID : Identification
2) Position the bushing on the outside of the stabilizer bar clamp so as to install it.

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 kgf·cm, 0.52~1.48 lbf·ft)
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.

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

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.

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.

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 self-
locking 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 kgf·cm, 29.6~40.7 lbf·ft)

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

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.

* 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)

Page 2 of 2
*Front/Rear suspension arm mounting 160~180 (1600~1800, 118~133)

Rear crossmember mounting 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.

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.

Page 2 of 2
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.

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 kgf·cm, 13~19 lbf·ft)
Rear stabilizer bar link mounting :
35~45 Nm (350~450 kgf·cm, 26~33 lbf·ft)

Page 2 of 2
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.

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 16″wheel & tire
• Optional equipment with 2.0L/2.7L engines :
Sports (Hard) suspension and 17″wheel & 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 17″tires to the 2.0L
vehicle models equipped with the normal front suspension.
The handling may be inferior to the vehicles with 16″tires. However installing 17″tires to the vehicles with
hard suspensions does not affect the driving performance.
The 17″tire is for summer season.
Therefore, its performance in snow is inferior to the 16″tire 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 17″tires.

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 kgf·cm, 37~41 lbf·ft)
Camber : 0°13´ ± 30´

Standard value
Caster : 2°58´ ± 30´

Standard value
Camber : 0°13´ ± 30´

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 kgf·cm, 37~43 lbf·ft)
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.

Page 3 of 3

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.

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 kgf·cm, 65~80 lbf·ft)

Page 3 of 4
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.

Page 4 of 4
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/cm² (30 psi)

Front 215/45 ZR 17 tire only : 2.2 kgf/cm² (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.

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
Tool (Number and Name) Illustration Use
09216-21100 Removal of the center bearing (Use with
Mounting bushing remover and 09495-33100)
installer
09495-33000 Removal of wheel bearing inner race from

Puller the hub.
09495-33100 1. Removal of wheel bearing from the

Center bearing remover and knuckle. (Use with 09517-29000)
installer 2. Installation of hub to the knuckle.
3. Removal of the center bearing (Use with
09216-21100)
09517-21500 1. Removal of front hub from the knuckle.
Front hub remover and installer (Use with 09517-29000)
2. Measurement of front wheel bearing
pre-load. (Use with 09532-11600)
09517-29000 1. Removal of wheel bearing outer race

Knuckle arm bridge from the knuckle. (Use with 09495-
33100)
09517-43001 Removal of the center bearing bracket

Bearing puller
09532-11600 Measurement of front wheel bearing pre-

Preload socket load. (Use with 09517-21500)
09532-11500 Installation of wheel bearing to the knuckle.

Pinion bearing outer race
09568-34000 Separation of front lower arm and tie rod

Ball joint puller end ball joint.

Page 2 of 2

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
Vehicle pulls to one side Galling of drive shaft ball joint Replace
Wear, rattle or galling of wheel bearing Replace
Defective front suspension and steering Adjust or replace
Vibration Wear, damage or bending of drive shaft Replace
Drive shaft rattle and hub serration Replace
Wear, rattle or scratching of wheel bearing Replace
Shimmy Improper wheel balance Adjust or replace
Excesive noise Wear, damage or bent drive shaft Replace
Drive shaft rattle and hub serration Replace
Drive shaft rattle and side gear serration Replace
Wear, rattle or galling of wheel bearing Replace
Loose hub nut Adjust or replace

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 45.8° or 46° or more 46.5° or
more more
D.O.J. 22° or more
T.J. 23° or more 23° or more 23° or more
Hub end play mm(in.) 0.008 (0.0003) or less
Wheel bearing starting torque 1.8 (18, 1.33) or less
Nm (kg·cm, lbf·ft)
B. J. : Birfield joint M/T : 5 Speed Manual transaxle

D.O.J. : Double offset joint 6M/T : 6 Speed Manual transaxle
T. J. : Tripod joint A/T : Automatic transaxle
TIGHTENING TORQUE
Nm Kgf·cm lbf·ft
Driveshaft nut 200 ~ 260 2000 ~ 2600 148 ~ 192
2.0L 200 ~ 280 2000 ~ 2800 148 ~ 207
2.7L
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
Rear brake to rear axle carrier mounting 65 ~ 75 650 ~ 750 48 ~ 56
bolt
Rear strut to carrier nut 110 ~ 130 1100 ~ 1300 81 ~ 96
Trailing arm to rear axle carrier mounting 100 ~ 120 1000 ~ 1200 74 ~ 88
nut
Rear suspension arm to rear axle carrier
160 ~ 180 1600 ~ 1800 118 ~ 133
mounting nut
Replace self-locking nuts with new ones after removal.

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 115 ± 6gr.
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2
Double offset joint boot greasE AMBLYGON TA 10/2A 100 ± 6gr.
CASMOLY DOJ
DURALUBE DOJ
Variant SD-R2
Birfield joint +Tripod joint Type driveshaft (For 2.0L A/T, 2.0L 6M/T)
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2
Tripod joint boot greas KLK TJ 41-182 145 ± 6gr.
CASMOLY TJ
ROLLUBE TJ
Oneluber MK
Birfield joint + Tripod joint Type driveshaft (For 2.7L)
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2
Tripod joint boot grease KLK TJ 41-182 145 ± 6gr.
CASMOLY TJ
ROLLUBE TJ
Oneluber MK

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

Page 2 of 3
COMPONENTS

Page 3 of 3

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.

Page 2 of 8
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.

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 kgf·cm, 148~192 lbf·ft)
2.7L : 200~280Nm (2000~2800 kgf·cm, 148~207 lbf·ft)
Lower arm ball joint nut
60~72Nm (600~720 kgf·cm, 44~53 lbf·ft)
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.

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.

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.

Page 6 of 8
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)

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
514 ± 2 799.2 ± 2
2.0L A/T
(20.24 ± 0.08) (31.47 ± 0.08)
492.6 ± 2 803.6 ± 2
2.0L 6M/T
(19.39 ± 0.08) (31.64 ± 0.08)
514.2 ± 2 508.7 ± 2
2.7L 6M/T
(19.43 ± 0.08) (20.03 ± 0.08)
515 ± 2 508.7 ± 2
2.7L M/T, A/T
(20.28 ± 0.08) (20.03 ± 0.08)
LH : Left Hand side, RH : Right Hand side

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

Page 8 of 8

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)

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.

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.

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

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

Page 2 of 5
1. Tighten the components below to the specified torque as follows :
Items Torque Nm (kgf·cm, lb·ft)

200~260
Driveshaft nut (2.0L) (2000~2600, 148~192)
Driveshaft nut (2.7L) 200~280
(2000~2800, 148~207)
Lower arm ball joint to knuckle nut 60~72 (600~720, 44~53)
Knuckle to strut assembly nut 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.

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.

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 (kgf·cm, lbf·ft)

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 kgf·cm, 1.33 lbf·ft) or less
9. If the starting torque is 0 Nm (0 kgf·cm, 0 lbf·ft), measure the hub bearing axial play.

Page 5 of 5
10. If the hub axial play exceeds the limit while the nut is tightened to 200~260 Nm (2000~2600Kgf·cm, 148~192
lbf·ft), 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).

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

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.

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.

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.

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
Tool (Number and Name) Illustration Use
09581 - 11000 Spreading the front brake piston
Piston expander
09580 - 34000 Removal and installation of the rear

Rear brake piston adjuster brake piston

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

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

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

Correct
2. Brake system (Air in) Bleeding
3. Pad (Worn) Replace
5. Pad (Oily) Replace
6. Pad (Glazed) Replace
Replace
8. Booster system (Vacuum leaks)
Noise from brake 1. Pad (Cracked or distorted)
Replace
2. Installation bolt (Loosen) Retighten
4. Pad retainers (Loosen) Replace
5. Sliding pin (Worn) Replace
6. Pad (Dirty) Clearing
7. Pad (Glazed) Replace
Replace
8. Brake pad shim (Damage)

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 Procedure
Brake Booster (A) 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.
Piston cup and pressure cup • Check brake operation by applying the brakes. Look for damage or signs of fluid
inspection (B) 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 Check brake operation by applying the brakes.
piston boots (D) 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.

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.

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.

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.

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:

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 Tandem type
- Type 23.81 (0.94) : CBS
- I.D. mm(in.) 25.4 (1.0) : ABS (TCS)
- Fluid level warning sensor Provided
Brake booster Vacuumtype with tandem booster

- Type Tandem type with 7+8 in. (CBS)
- Effective dia.mm(in.) Tandem type with 8+9 in. (ABS, TCS)
- Boosting ratio 7.0 : 1
Proportioning valve
3.4 MPa (35 kg/cm², 498 psi)
- Cut-in pressure (Split point)
0.27 : 1
- Decompression ratio
Front disc brake
- Type Floating type with ventilated disc
280 mm (11.02 in.)
- Disc O.D.
26 mm (1.024 in.)
- Disc thickness
11 mm (0.433 in.)
- Pad thickness
57.2 mm (2.25 in.)
- Cylinder I.D.
Rear disc brake
- Type Floating type with solid disc
- Disc O.D. 258 mm (10.16 in.)
Automatic
- Clearance adjustment
10 mm (0.394 in.)
- Disc thickness
9 mm (0.354 in.)
- Pad thickness 33.96 mm (1.34 in.)
- Cylinder I.D
Parking brake
Mechanical brake acting on rear wheels
- Actuation
Lever
- Type
Auti-lock brake system (ABS)

ECU type
ABS & EBD Warning lamp / TCS lamp
Motor, valve relay integrated type
- Operating voltage 12V
- Current 80 mA
Wheel speed sensor 1,385 ± 110Ω (at 23 ± 5°C)
- Internal resistance 15 ~ 2,000 Hz
- Output range Min. 130 mVp·p
- Output voltage 44 EA
- Tone wheel teeth 0.2 ~ 1.3 (0.008 ~ 0.051)
- Air-gap mm (in.) Radial pistons (2 pistons)
4-pole DC motor
HECU (HU + ECU)
180W
- Pump type
MCS : 3.0cc / MCP : 3.0cc
- Motor type
0.13cc
- Motor type 0.56 (0.022) / 0.315 (0.0124)
- LPA volume 0.56 (0.022) / 0.355 (0.0140)
- HPA volume 60 ~ 90 bar
- Inlet valve (Front / Rear) mm (in.)
- Outlet valve (Front / Rear) mm (in.)

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 0.5~1.0 mm (0.02~0.04
clearance 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
6~7 clicks
pulled with 196N (20kg, 44lb force)
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 Kgf·cm lbf·ft
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.

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

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 kgf·cm, 9.6~11.8 lbf·ft)

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.

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

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.

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

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.

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

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 kgf·cm, 9~12 lbf·ft)
Proportioning valve mounting nut:
35~55 Nm (350~550 kgf·cm, 30~40 lbf·ft)
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.

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

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).

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.

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

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 kgf·cm, 6~9 lbf·ft)
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.

Page 2 of 2

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

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.

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 kgf·cm, 16~24 lbf·ft)

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 kgf·cm, 5.2~9.6 lbf·ft)
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.

Page 4 of 6
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.)

Page 5 of 6
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.

Page 6 of 6
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 (kgf·cm, lbf·ft)

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.

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.

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

Page 2 of 2

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.)

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.

Page 3 of 4
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.

Page 4 of 4
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).

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

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).

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)

Page 2 of 3
CIRCUIT DIAGRAM (2)
CIRCUIT DIAGRAM (3)

Page 3 of 3

Page 1 of 6
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 µ- 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.

Page 2 of 6
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.

Page 3 of 6
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 Hi-
scan (pro).
6. Disconnect the Hi-scan (pro) from the 16P data link connector.
SYSTEM FUNCTION
ABS OPERATION
1. NORMAL BRAKING
Solenoid valve State Valve Passage Pump motor

IN (NO) OFF OPEN Master cylinder Wheel cylinder
OFF
OUT (NC) OFF CLOSE 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

IN (NO) ON CLOSE Master cylinder Wheel cylinder
ON
OUT (NC) ON OPEN 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

IN (NO) ON CLOSE Master cylinder Wheel cylinder
ON
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

IN (NO) OFF OPEN Master cylinder Wheel cylinder
ON

Page 4 of 6
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 Motor pump TC valve

IN (NO) OFF OPEN
OFF OFF
OUT (NC) OFF CLOSE
• 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

FRONT: OFF FRONT: OPEN
IN (NO)
REAR: ON 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

IN (NO) ON CLOSE
FRONT: ON FRONT: OPEN ON ON
OUT (NC)
REAR: OFF REAR: CLOSE
• 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

IN (NO) ON CLOSE
ON ON
OUT (NC) OFF CLOSE
TRACTION CONTROL SYSTEM (TCS) FUNCTION

1. Main performance

Page 5 of 6
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.

Page 6 of 6
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
OFF OFF ON ON
Valve relay failure
Over voltage
Other failure

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

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 Explanation
System check sound 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.
ABS operation sound 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 For road surfaces such as snow-covered and gravel roads, the braking distance for
distance) 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

Page 2 of 24
TROUBLE SYMPTOMS TABLE

Symptom Suspect Area See page
Communication with Hi-scan (pro) is not 1. Power source circuit
possible. 2. Diagnosis line BR - 63
(Communication with any system is not possible)
Communication with Hi-scan (pro) is not 1. Power source circuit
possible. 2. Diagnosis line BR - 63
(Communication with ABS only is not possible) 3. HECU
When ignition key is turned ON (engine OFF), 1. ABS warning lamp circuit
BR - 64
the ABS warning lamp does not light up. 2. HECU
Even after the engine is started, the ABS 1. ABS warning lamp circuit
warning lamp remains ON. BR - 65
2. HECU
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
BR - 66
code is output.
2. Power source circuit.

Page 3 of 24
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
C1205 - No signal excite: air-gap error or wrong excite ○ ○ BR - 69
C1206 RL wheel sensor: open or short to ground ○ ○ BR - 67
C1208 - No signal excite: air-gap error or wrong excite ○ ○ BR - 69
C1209 RR wheel sensor: open or short to ground ○ ○ BR - 67
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
Motor-Electrical: open or short to battery, motor relay, fuse or
C2402 ○ ○ BR - 72
motor lock fail
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.

Page 4 of 24
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.

Page 5 of 24

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Page 8 of 24
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection Procedure 1
Communication with Hi-Scan (Pro) is not possible.

Probable cause
(Communication with any systems is not possible.)
Possible defect in the power supply system (including ground) for the • Faulty power source circuit
diagnosis line. • Faulty diagnosis line

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

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

Page 10 of 24
Even after the engine is started, the ABS warning lamp remains
Probable cause
illuminated
A possible short-circuit in the ABS warning lamp illumination circuit • 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 Probable cause

Brake operation varies depending on • Improper installation of wheel speed • Faulty wheel speed sensor
driving conditions and road surface sensor • Faulty rotor
conditions, so diagnosis can be difficult. • Incorrect sensor harness contact • Faulty wheel bearing
However, if a normal DTC is displayed, • Foreign material on wheel speed • Faulty HECU
carry out the following inspection. sensor • Faulty power source circuit

Page 11 of 24
INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES

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

Page 12 of 24
DTC No. C1201, C1204, C1207, C1210

Probable cause
(Speed jump or wrong exciter)
Abnormal output signal from a wheel speed sensor other than an open or • Improper installation of wheel speed sensor
short circuit. • Faulty wheel speed sensor
• Faulty rotor
• Faulty wheel bearing
• Faulty wiring harness or connector
• Faulty HECU
DTC No. C1202, C1205, C1208, C1211

Probable cause
(Large air gap)

Page 13 of 24
No wheel speed sensor output signal. • Faulty wheel speed sensor

• Improper installation of wheel speed sensor
• Faulty rotor (excitor)
• Faulty wiring harness or connector
• Faulty HECU
DTC No. C1101, C1102 Voltage out of range

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

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

Page 14 of 24
DTC No. C2112 Valve relay

Probable cause
(Including fuse failure)
When the ignition switch is turned ON, the HECU switches the valve relay • Faulty wiring harness or connector
on and off during its initial check. During this time, voltage sent to the • Faulty HECU
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 Probable cause

Replace the HECU. • 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
DTC No. C1611 CAN timeout EMS, C1612 CAN timeout TCU, C1613
Probable cause
CAN wrong matched transmission
Inspect the EMS or TCU according to the instructions of Engine or T/M • No message from EMS or TCU for 500ms
group. • Message from A/T or M/T signal mismatch
the message from ECM or TCU
DTC No. C1610 bus off error Probable cause

Check CAN bus wiring. • CAN bus cable open, or short to ground or
Check E37, C33, C133-4 or M42 connectors battery
DTC No. C2402 motor pump failure

Probable cause
(Motor relay, motor)
When the motor power line is normal but no signal is in detected in the • Faulty wiring harness
motor monitor line. • 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.

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
: speed jump or damaged
C1201 - Range/Performance
exciter
C1202 - No signal : air-gap error or wrong excite
C1203 FR wheel sensor : open or short to ground
exciter
C1205 - No signal excite : air-gap error or wrong excite
C1206 RL wheel sensor : open or short to ground
exciter
C1208 - No signal excite : air-gap error or wrong excite
C1209 RR wheel sensor : open or short to ground
exciter
C1211 - No signal : air-gap error or wrong excite
C1604 ECU hardware : ECU internal or valve failure
C2112 Valve relay : valve relay or fuse failure
: open or short to battery,
C2402 Motor-Electrical 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

Page 16 of 24
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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Page 20 of 24
INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES

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

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

Probable cause
(Speed jump or wrong exciter)
Abnormal output signal from a wheel speed sensor other • Improper installation of wheel speed sensor
than an open or short circuit. • Malfunction of wheel speed sensor
• Malfunction of rotor
• Malfunction of wheel bearing
• Malfunction of wiring harness or connector
DTC No. C1202, C1205, C1208, C1211

Probable cause
(Large air gap)

Page 22 of 24
No wheel speed sensor output signal. • Malfunction of wheel speed sensor

• Improper installation of wheel speed sensor
• Malfunction of rotor (excitor)
• Malfunction of wiring harness or connector
DTC No. C1101, C1102 Voltage out of range

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

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

Page 23 of 24
DTC No. C2112 Valve relay

Probable cause
(Including fuse failure)
When the ignition switch is turned ON, the HECU switches • Malfunction of wiring harness or connector
the valve relay on and off during its initial check. During this • Malfunction of HECU
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 Probable cause

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

Probable cause
TCU, C1613 CAN wrong matched transmission
Inspect the EMS or TCU according to the instructions of • No message from EMS or TCU for 500ms
Engine or T/M group. • Message from A/T or M/T signal mismatch the message
from ECM or TCU
DTC No. C1610 bus off error Probable cause

Check CAN bus wiring. • CAN bus cable open, or short to ground or battery
Check E37, C33, C133-4 or M42 connectors
DTC No. C2402 motor pump failure

Probable cause
(Motor relay, motor)
When the motor power line is normal but no signal is in • Malfunction of wiring harness
detected in the motor monitor line. • 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.

Page 24 of 24

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

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.

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 kg·cm, 5~9.5 lb·ft)

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

Page 2 of 4

Page 3 of 4
INSPECTION OF HECU TERMINALS
Terminals No. Condition Standard Voltage (V)

25 - GND (8,24) Always 10 - 14

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
18 - GND (8,24)
Stop lamp switch ON 10 - 14
19 - 20 Ignition switch ON, slowly turn right front wheel AC voltage generation
1-2 Ignition switch ON, slowly turn left front wheel AC voltage generation
22 - 23 Ignition switch ON, slowly turn right rear wheel AC voltage generation
5-6 Ignition switch ON, slowly turn left rear wheel AC voltage generation
14 - GND (8,24) Ignition switch ON, TCS switch ON 10 - 14
GND (8,24) - Body ground Always Continuity

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(Anti-
Lock Brake System) > ABS Control Module > Components and Components Location
COMPONENTS
HECU

Page 2 of 2

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.

Page 2 of 3
Tightening torque
HECU bracket mounting bolts:
17~26 Nm (170~260 kg·cm, 12.5~19.1 lb·ft)
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 kg·cm, 5.9~7.3 lb·ft)
HECU bracket mounting bolt:
17~26 Nm (170~260 kg·cm, 12.5~19.1 lb·ft)
Brake tube nut:
13~17 Nm (130~170 kg·cm, 9.5~12.5 lb·ft)
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
Front left Front right Rear left Rear right
sensor
1 19 5 22
Terminal
2 20 6 23
Output voltage:
When measuring with an oscilloscope:
130mV p·p or more

Page 3 of 3

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

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

Page 2 of 2
1. Connect an ohmmeter between the wheel speed sensor terminals and measure the resistance.
Service standard
Front, Rear: 1,385 ± 110Ω
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.

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)

Engine support fixture Removal and installation of transaxle
J28467-B assembly
Engine support adapters Use with J28467-B

J28467-125
09431-2C000 Installation of differential side oil seal

Oil seal installer

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)
Vibration, noise 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 Correct or replace
gear cone
Weakened synchronizer spring Replace synchronizer spring
Inadequate grade of oil Replace with specified oil
Jumps out of gear Worn gear shift fork or broken poppet spring Replace shift fork or poppet
spring
Synchronizer hub-to-sleeve spline clearance too Replace synchronizer hub and
large sleeve

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)
M5BF2 M5GF1 MFA60
Model
(5-speed) (5-speed) (6-speed)
Engine 2.0 DOHC 2.7 DOHC 2.0 DOHC 2.7 DOHC
Gear ratio 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
Oil quantity (ℓ) 2.15 2.1 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
0.9 ~ 1.45 0.7
ring
Clearance between 4th gear and synchronizer
0.9 ~ 1.45 ↑
ring
0.95 ~ 1.4 ↑
ring
0.95 ~ 1.4 ↑
ring
Clearance between reverse gear and
0.95 ~ 1.4 ↑
synchronizer ring
TIGHTENG TORQUE (6-SPEED M/T)

Item N·m kg·cm lb·ft
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
Control shaft bolt 6.3 ~ 8.3 63 ~ 83 4.6 ~ 6.0
Shift lever mounting plate 2~3 20 ~ 30 1~2
Differential final gear bolt 112.7 ~ 127.4 1127 ~ 1274 83 ~ 94

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

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.

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).

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.

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.

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

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(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

Page 8 of 10
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.

(1) Insulator bolt
(2) Stopper bolt

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.

Page 10 of 10
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.

Page 1 of 2
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

Page 2 of 2

Page 1 of 3
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.

Page 2 of 3
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.

Page 3 of 3
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.

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)

Engine support fixture Removal and installation of transaxle
J28467-B assembly
Engine support adapters Use with J28467-B

J28467-125
09452-21001 Measurement of the oil pressure.

Oil pressure gauge adapter (use with 09452-21500 and 09452-
21002)

Oil pressure gauge adapter use with 09452-21500 and 09452-
21001)

Oil pressure gauge (use with 09452-21001 and 09452-
21002)

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 2.842 2.842
1st 1.529 1.529
2nd 1.000 1.000
3rd 0.712 0.712
4th
Reverse 2.480 2.480
Final gear ratio 4.407 4.402

Page 1 of 6
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)

Page 2 of 6

Page 3 of 6
TCM CIRCUIT DIAGRAM (2.7L)

Page 4 of 6

Page 5 of 6

Page 6 of 6

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

Page 2 of 6
SECOND

Page 3 of 6
THIRD

Page 4 of 6
FOURTH

Page 5 of 6
REVERSE

Page 6 of 6

Page 1 of 11
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.

Page 2 of 11
• 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 50°C 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. Condition Operation Judgment value Check item
Ignition switch : OFF Ignition switch Battery voltage (mV) Control relay
1
(1) ON
• Ignition switch : ON Selector lever position (1) P, (2) R, (3) N, (4) Transaxle range switch
• Engine : Stopped (1) P, (2) R, (3) N, (4) D D
• Selector lever Accelerator pedal (1) 400~1,000 mV Throttle position sensor
position : P (1) Released (2)Gradually rises from
2 (2) Half depressed (1)
(3) Depressed (3) 4,500~5,000 mV
Brake pedal (1) ON Stop lamp switch
(1) Depressed (2) OFF
(2) Released
• Ignition switch : ST Starting test with lever P or N Starting should be Starting possible or
3
• Engine : Stopped range possible impossible
Warming up Drive for 15 minutes or more Gradually rises to Oil temperature sensor
so that the automatic fluid 70~90°C
4
temperature becomes
70~90°C
• Engine : Idling A/C switch (1) ON Triple pressure switch
• Selector lever (1) ON (2) OFF
position : N (2) OFF
Accelerator pedal (1) ON Idle position switch
(1) Released (2) OFF
(2) Half depressed
(1) 600~925 rpm
(2) Gradually rises

Page 3 of 11
from (1)
Communication with engine-
(1) Data changes
ECU
5 Selector lever position Should be no Malfunction when starting
(1) N→D abnormal shifting
(2) N→R shocks
Time lag should be
within 2 seconds
Selector lever Selector lever position and (2) 1st, (4) 3rd, (3) Shift condition
position : N (Carry out vehicle speed 2nd, (5) 4th
on a flat and straight 1. Idling in 1st gear (Vehicle (2) 0%, (4) 100%, (3) Low and reverse solenoid
road) stopped) 100%, (5) 100% valve
2. Driving at constant speed
of 20 km/h in 1st gear (2) 0%, (4) 0%, (3) 0% Underdrive solenoid valve
(5) 100%
of 30 km/h in 2nd gear (2) 100%, (4) 100%, Second solenoid valve
4. Driving at 50 km/h in 3rd (3) 0% (5) 0%
gear with accelerator fully (2) 100%, (4) 0%, (3) Overdrive solenoid valve
closed 100% (5) 0%
6
(1) 0km/h Vehicle speed sensor
of 50 km/h in 4th gear
(4) 50km/h
(Each condition should
be maintained for 10 (4) 1,800 ~ 2,100rpm Input shaft speed sensor
seconds or more) (4) 1,800 ~ 2,100rpm Output shaft speed sensor
(3) 0% Damper clutch control
(5) Approx. 70~90% solenoid valve
(3) Approx.
100~300rpm
(5) Approx. 0~10rpm
Selector lever 1. Accelerate to 4th gear at For (1), (2) and (3), the Malfunction when shifting
position : D (Carry out a throttle position sensor reading should be the
on a flat and straight output of 1.5V same as the specified
road) (accelerator opening output shaft torque, Displaced shift points
angle of 30 %). and no abnormal
2. Gently decelerate to a shocks should occur.
Does not shift
standstill. For (4), (5) and (6),
3. Accelerate to 4th gear at downshifting should
a throttle position sensor occur immediately Does not shift from 1 to 2 or
output of 2.5 V after the shifting 2 to 1
7 (accelerator opening operation is made.
angle of 50%).
4. While driving at 60 km/h
Does not shift from 2 to 3 or
in 4th gear, shif down to
3 to 2
3rd gear.
5. While driving at 40 km/h
in 3rd gear, shift down to
2nd gear. Does not shift from 3 to 4 or
6. While driving at 20 km/h 4 to 3
in 2nd gear, shift down to
1st gear.
Selector lever Move selector lever to R The ratio between Does not shift
position : N (Carry out range drive at constant input and output shaft
on a flat and straight speed of 10km/h speed sensor data
8
road) should be the same as
the gear ratio when
reversing.

Page 4 of 11
DIAGNOSTIC TROUBLE CODE DESCRIPTION

DTC No Diagnosis item Possible cause
P1704 Throttle position sensor TPS output > 4.8 V with
Short circuit
engine idling
P1703 TPS output < 0.2V with
Open circuit
engine not idling
P1702 TPS output < 0.2V or > 1.2V
Sensor misadjustment
with engine idling
P0713 Fluid temperature sensor Open circuit Oil temperature sensor
output > 4.57 V for 1 second
or longer (oil temperature
does not increase)
P0712 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 Short circuit/open circuit At vehicle speed of > 30
km/h, output speed sensor
output < 50% of vehicle
speed sensor output for > 1
second
P0703 Stop lamp switch Short circuit/open circuit At vehicle speed of 6 km/h,
stop lamp switch is ON
continuously for 5 minutes
P0750 LR solenoid valve Short circuit/open circuit With relay voltage > 10V,
open or short circuit is
P0755 UD solenoid valve Short circuit/open circuit
continuously for 0.3 second
P0760 2nd solenoid valve Short circuit/open circuit
P0765 OD solenoid valve Short circuit/open circuit
P0743 TCC solenoid valve Short circuit/open circuit
P0731 Gear shift incomplete 1st After gear shift, output shaft
speed sensor output x gear
P0732 2nd
ratio of new gear ≠ input
P0733 3rd shaft speed sensor output
P0734 4th
P0736 Reverse
P1749 Serial communication Short circuit/open circuit 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

Page 5 of 11
circuit relay voltage < 7V

P0707 Transaxle range switch Open circuit No signal is continuous for >
30 seconds
P0708 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 Communication error output
malfunction is continuously for > 1
second
INSPECTION CHART FOR DIAGNOSIS CODES

Code Diagnosis item Probable cause
P1704 Throttle position sensor system Short circuit • Malfunction of the throttle
If the TPS output voltage is 4.8V or higher position sensor
when the engine is idling, the output is judged • Malfunction of connector
to be too high and diagnosis code P1704 is set. • Malfunction of the TCM
P1703 If the TPS output voltage is 0.2V or lower at Open circuit
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
P1702 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.
P0713 Fluid temperature sensor system Open circuit • Malfunction of the oil
If the fluid temperature sensor output voltage is Short circuit temperature sensor
4.57V or more even after driving for 10 minutes • Malfunction of connector
or more (if the fluid temperature does not • Malfunction of the TCM
P0712 increase), it is judged that there is an open
circuit in the fluid temperature sensor and
diagnosis code P0713 is set.
P0725 CKP sensor system Open circuit • Malfunction of the crank angle
If no output pulse is detected from the crank sensor
shaft position sensor for 5 seconds or more • Malfunction of connector
while driving at 25 km/h or more, it is judged • Malfunction of the TCM
that there is an open circuit in the crank shaft
position sensor and diagnosis code P0725 is
set.
P0715 Input speed sensor system Short circuit/open • Malfunction of the input shaft
If no output pulse is detected from the input circuit speed sensor
shaft speed sensor for 1 second or more while • Malfunction of the underdrive
driving in 3rd or 4th gear at a speed of 30 km/h clutch retainer
or more, there is judged to be an open circuit or • Malfunction of connector
short circuit in the input shaft speed sensor and
• Malfunction of the TCM
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.
P0720 Output speed sensor system Short circuit/open • Malfunction of the outputs shaft
If the output from the output shaft speed sensor circuit speed sensor
is continuously 50% lower than the vehicle • Malfunction of connector
speed for 1 second or more while driving in 3rd • Malfunction of the TCM
or 4th gear at a speed of 30 km/h or more,
• Malfunction of the transfer drive

Page 6 of 11
there is judged to be an open circuit or short- gear or driven gear

circuit 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.
P0703 Stop lamp switch system Short circuit/open • Malfunction of the stop lamp
If the stop lamp switch is on for 5 minutes or circuit switch
more while driving, it is judged that there is a • Malfunction of connector
short circuit in the stop lamp switch and • Malfunction of the TCM
diagnosis code P0703 is set.
P0750 Low and reverse solenoid valve system Short circuit/Open • Malfunction of solenoid valve
circuit • Malfunction of connector
P0755 Underdrive solenoid valve system Short circuit/Open • Malfunction of the TCM
circuit
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 Torque converter clutch solenoid valve Short circuit/Open • Malfunction of the torque
system circuit converter clutch solenoid valve
If the resistance value for a solenoid valve is • Malfunction of connector
too large or too small, it is judged that there is a • Malfunction of the TCM
short circuit or an open circuit in the solenoid
P0740 valve and the respective diagnosis code is set. Defective system
The transmission is locked into 3rd gear as a
fail-safe measure.
P0731 1st gear ratio does not meet the specification • Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the 1st speed sensor
gear ratio is not the same as the output from the input shaft speed • Malfunction of the output shaft
sensor after the shift to 1st gear has been completed, diagnosis code speed sensor
P0731 is set. If diagnosis code P0731 is set four times, the transmission • Malfunction of the underdrive
is locked into 3rd gear as a fail-safe measure. clutch retainer
gear or driven gear
• Malfunction of the low and
reverse brake system
• Malfunction of the underdrive
clutch system
• Noise generated
P0732 2nd gear ratio does not meet the specification • Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the 2nd speed sensor
sensor after the shift to 3rd gear has been completed, diagnosis code speed sensor
gear or driven gear
clutch system
• Malfunction of the second

Page 7 of 11
brake system
• Noise generated
P0733 3rd gear ratio does not meet the specification • Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the 3rd speed sensor
sensor after the shift to 3rd gear has been completed, diagnosis code speed sensor
gear or driven gear
clutch system
• Malfunction of the overdrive
clutch system
• Noise generated
P0734 4th gear ratio does not meet the specification • Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the 4th speed sensor
sensor after the shift to 4th gear has been completed, diagnosis code speed sensor
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 • Malfunction of the input shaft
If the output from the output shaft speed sensor multiplied by the speed sensor
reverse gear ratio is not the same as the output from the input shaft • Malfunction of the output shaft
speed sensor after the shift to reverse gear has been completed, speed sensor
diagnosis code P0736 is set. If diagnosis code P0736 is set four times, • Malfunction of the underdrive
the transmission is locked into 3rd gear as a fail-safe measure. 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 • Malfunction of connector
If normal communication is not possible for a continuous period of 1 • Malfunction of the ECM
second or more when the ignition switch is at the ON position, the • Malfunction of the TCM
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.
P1723 A/T control relay system Short circuit to ground/ • Malfunction of the A/T control
If the A/T control relay voltage is less than 7V Open circuit relay
after the ignition switch has been turned ON, it • Malfunction of connector
is judged that there is an open circuit or a short- • Malfunction of the TCM
circuit 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.

Page 8 of 11
P0707 Transaxle range switch • Malfunction of transaxle range

No signal is continuous for > 30 seconds switch
P0708 Above 2 signals are continuous for > 30 seconds
P1630 CAN-BUS OFF • TCM Fail
• No 3 speed hold fail • TCM side open & short
• No PG-A, B fail
• Battery voltage > 10V continuously for 0.5 second
• No engine stop
• Receive BUS OFF information from CAN CONTROLLER
P1631 CAN-TIME OUT ECM • ECM fail
• No 3 speed hold fail • ECM side open & short
• No PG-A, B fail
• No engine stop
• No output signal for 1.5 second
P1764 TCM CAN MI-COM • CAN MI-COM CIRCUIT
• No 3 speed hold fail
• No PG-A, B fail
• No engine stop
• Communication error output is continuously for > 1 second
INSPECTION CHART FOR THROUBLE SYMPTOMS

Trouble symptom Probable cause
Communication with HI-SCAN is not possible • Malfunction of diagnosis line
is not functioning. • Malfunction of connector
Driving impossible Starting impossible • Malfunction of the engine system
Starting is not possible when the selector lever • Malfunction of the torque converter
is in P or N range. In such cases, the cause is • Malfunction of the oil pump
probably a defective engine system, torque
converter or oil pump.
Does not move forward • Abnormal line pressure
If the vehicle does not move forward when the • Malfunction of the underdrive solenoid valve
selector lever is shifted from N to D range while • Malfunction of the underdrive clutch
the engine is idling, the cause is probably
• Malfunction of the valve body
abnormal line pressure or a malfunction of the
underdrive clutch or valve body.
Does not reverse • Abnormal reverse clutch pressure
If the vehicle does not reverse when the • Abnormal low and reverse brake pressure
selector lever is shifted from N to R range while • Malfunction of the low and reverse brake
the engine is idling, the cause is probably solenoid valve
abnormal pressure in the reverse clutch or low
• Malfunction of the reverse clutch
and reverse brake or a malfunction of the
• Malfunction of the low and reverse brake
reverse clutch, low and reverse brake or valve
body. • Malfunction of the valve body
Does not move (forward or reverse) • Abnormal line pressure

If the vehicle does not move forward or reverse • Malfunction of power train
when the selector lever is shifted to any • Malfunction of the oil pump
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.
Malfunction when Engine stalling when shifting • Malfunction of the engine system

Page 9 of 11
starting If the engine stalls when the selector lever is • Malfunction of the damper clutch control
shifted from N to D or R range while the engine solenoid valve
is idling, the cause is probably a malfunction of • Malfunction of the valve body
the engine system, damper clutch solenoid • Malfunction of the torque converter
valve, valve body or torque converter (damper
• (Malfunction of the damper clutch)
clutch malfunction).
Shocks when changing from N to D and • Abnormal underdrive clutch pressure
large time lag • Abnormal low and reverse brake pressure
If abnormal shocks or a time lag of 2 seconds • Malfunction of the underdrive solenoid valve
or more occur when the selector lever is shifted
from N to D range while the engine is idling, the
• Malfunction of the idle position switch
cause is probably abnormal underdrive clutch
pressure or a malfunction of the underdrive
clutch, valve body.
Shocks when changing from N to R and • Abnormal reverse clutch pressure
large time lag • Abnormal low and reverse brake pressure
If abnormal shocks or a time lag of 2 seconds • Malfunction of the low and reverse solenoid
or more occur when the selector lever is shifted valve
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 • Malfunction of the valve body
reverse brake, valve body or idle position • Malfunction of the idle position switch
switch.
Shocks when changing from N to D, N to R • Abnormal line pressure
and large time lag • Malfunction of the oil pump
If abnormal shocks or a time lag of 2 seconds • Malfunction of the valve body
or more occur when the selector lever is shifted
from N to D range and from N to R range while
the engine is idling, the cause is probably
abnormal line pressure or a malfunction of the
oil pump or valve body.
Malfunction when Shocks and running up • Abnormal line pressure
shifting If shocks occur when driving due to upshifting • Malfunction of each solenoid valve
or downshifting and the transmission speed • Malfunction of the oil pump
becomes higher than the engine speed, the
cause is probably abnormal line pressure or a
• Malfunction of each brake or each clutch
malfunction of a solenoid valve, oil pump, valve
body, brake or clutch.
Displaced shifting All points • Malfunction of the output shaft speed
points If all shift points are displaced while driving, the sensor
cause is probably a malfunction of the output • Malfunction of the throttle position sensor
shaft speed sensor, TPS or solenoid valve. • Malfunction of each solenoid valve
• Abnormal line pressure
Some points • Malfunction of the valve body
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 • Malfunction of the transaxle range
If shifting does not occur while driving and no • Malfunction of the TCM
diagnosis codes are set, the cause is probably
a malfunction of the transaxle range switch, or
TCM
Malfunction while Poor a acceleration • Malfunction of the engine system

Page 10 of 11
driving If acceleration is poor even if downshifting • Malfunction of the brake of clutch

occurs while driving, the cause is probably a
malfunction of the engine system, brake or
clutch.
Malfunction while Vibration • Abnormal damper clutch pressure
driving If vibration occurs when driving at constant • Malfunction of the engine system
speed or when accelerating and deceleration in • Malfunction of the damper clutch control
top range, the cause is probably abnormal solenoid valve
damper clutch pressure or a malfunction of the
• Malfunction of the torque converter
engine system, damper clutch control solenoid
valve, torque converter or valve body.
Transaxle range switch system • Malfunction of the transaxle range switch
The cause is probably a malfunction of the inhibitor switch circuit, • Malfunction of the ignition switch
ignition switch circuit or a defective TCM. • Malfunction of connector
Idle position switch system • Malfunction of the idle position switch
The cause is probably a defective idle position switch circuit, or a • Malfunction of connector
defective TCM. • Malfunction of the TCM
Triple pressure switch system • Malfunction of the triple pressure switch
The cause is probably a defective triple pressure switch circuit or a • Malfunction of connector
defective TCM. • Malfunction of A/C system
Vehicle speed sensor system • Malfunction of the vehicle speed sensor
The cause is probably a defective vehicle speed sensor circuit or a • Malfunction of connector
defective TCM. • Malfunction of the TCM
ELEMENTS IN USE IN EACH GEAR

Operating element Low-and One way
Underdrive Reverse Overdrive Second
reverse clutch
clutch (UD) clutch (REV) clutch (OD) brake (2nd)
Selector lever position brake (LR) (OWC)
P Parking - - - O - -
R Reverse - O - O - -
N Neutral - - - O - -
1st O - - O - O
2nd O - - - O -
D
3rd O - O - - -
4th - - O - O -
1st O - - O - O
3 2nd O - - - O -
3rd O - O - - -
1st O - - O - O
2
2nd O - - - O -
L 1st O - - O - O
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

Page 11 of 11
Low-and-reverse brake LR Locks low-and-reverse annulus gear and overdrive

planetary carrier
Second brake 2ND Locks reverse sun gear

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 Possible cause

If communication with the scan tool is not possible, the • Malfunction of diagnostic trouble line
cause may be a defective diagnostic trouble line or the TCM • Malfunction of connector
is not functioning. • Malfunction of the TCM
Starting impossible Possible cause

Starting is not possible when the selector lever is in P or N • Malfunction of the engine system
range. In such cases, the cause may be a defective engine • Malfunction of the torque converter
system, torque converter or oil pump. • Malfunction of the oil pump

Page 2 of 8
Does not move Possible cause

If the vehicle does not move forward when the selector lever • Abnormal line pressure
is shifted from N to D range while the engine is idling, the • Malfunction of the underdrive solenoid valve
cause may be abnormal line pressure or a malfunction of • Malfunction of the underdrive clutch
the underdrive clutch or valve body.
Does not reverse Possible cause

If the vehicle does not reverse when the selector lever is • Abnormal reverse clutch pressure
shifted from N to R range while the engine is idling, the • Abnormal low and reverse brake pressure
cause may be abnormal pressure in the reverse clutch or • Malfunction of the low and reverse solenoid valve
low and reverse brake or a malfunction of the reverse
clutch, low and reverse brake or valve body.

Page 3 of 8
Does not move (forward or reverse) Possible cause

If the vehicle does not move forward or reverse when the • Abonormal line pressure
selector lever is shifted to any position while the engine is • Malfunction of the underdrive solenoid valve
idling, the cause may be abnormal line pressure, or a • Malfunction of the underdrive clutch
malfunction of the power train, oil pump or valve body.
Engine stalling when shifting Possible cause

If the engine stalls when the selector lever is shifted from N • Malfunction of the engine system
to D or R range while the engine is idling, the cause may be • Malfunction of the torque converter clutch solenoid
a malfunction of the engine system, torque converter clutch • Malfunction of the valve body
soledoid, valve body or torque converter (torque converter
• Malfunction of the torque converter (Malfunction of the
clutch malfunction).
torque converter clutch)
Shocks when changing from N to D and range time lag Possible cause
If abnormal shocks or a time lag of 2 second or more occurs • Abnormal line pressure
when the selector lever is shifted from N to D range while • Malfunction of the underdrive solenoid valve

Page 4 of 8
the engine is idling, the cause may be abnormal underdrive • Malfunction of the underdrive clutch
clutch pressure or a malfunction of the underdrive clutch, • Malfunction of the valve body
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 Possible cause
If abnormal shocks or a time lag of 2 seconds or more • Abnormal reverse clutch pressure
occurs when the selector lever is shifted from N to R range • Abnormal low and reverse brake pressure
while the engine is idling, the cause may be abnormal • Malfunction of the low and reverse solenoid valve
reverse clutch pressure or low and reverse brake pressure,
or a malfunction or the reverse clutch, low and reverse
brake, valve body.

Page 5 of 8
Shocks when changine from N to D, N to R and large

Possible cause
time lag
If abnormal shocks or a time lag of 2 seconds or more • Abnormal line pressure
occurs when the selector lever is shifted from N to D, N to R • Malfunction of the oil pump
range while the engine is idling, the cause may be abnormal • Malfunction of the valve body
line pressure or a malfunction of the oil pump or valve body.
Shocks and running up Possible cause

If shocks occur when driving due to upshifting or • Abnormal line pressure
downshifting and the transaxle speed becomes higher than • Malfunction of each solenoid valve
the engine speed, the cause may be abnormal line pressure • Malfunction of the oil pump
or a malfunction of a solenoid valve, oil pump, valve body or
of a brake or clutch.
• Malfunction of each brake or each clutch

Page 6 of 8
All points (Displaced shifting points) Possible cause

If all shift points are displaced while driving, the cause may • Malfunction of the output shaft speed sensor
be a malfunction of the output shaft speed sensor, TPS or a • Malfunction of the throttle position sensor
solenoid valve. • Malfunction of each solenoid valve
• Abnormal line pressure

Page 7 of 8
Some points (Displaced shifting points) Possible cause

If some of the shift points are displaced while driving, the • Malfunction of the valve body
cause may be a malfunction of the valve body, or it is
related to control and is not an abnormality.
No diagnostic trouble codes (Does not shift) Possible cause

If shifting does not occur while driving and no diagnostic • Malfunction of the Park/Neutral position switch
trouble codes are given, the cause may be a malfunction of • Malfunction of the TCM
the Park/Neutral position switch, or TCM.
Poor acceleration Possible cause

If acceleration is poor even if downshifting occurs while • Malfunction of the engine system
driving, the cause may be a malfunction of the engine • Malfunction of the brake or clutch
system or of a brake or clutch.

Page 8 of 8
Vibration Possible cause

If vibration occurs when driving at constant speed or when • Abnormal torque converter clutch pressure
accelerating in top range, the cause may be abnormal • Malfunction of the engine system
torque converter clutch pressure or a malfunction of the • Malfunction of the torque converter clutch solenoid
engine system, torque converter clutch solenoid, torque
• Malfunction of the torque converter
converter or valve body.

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 (70~80°C).
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 kg·cm, 23 lb·ft)
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.

Page 2 of 13
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 (70~80°C), 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.

Page 3 of 13
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

Page 4 of 13
Oil temperature (°C) Resistance (KΩ)

0 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 KΩ 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.

Page 5 of 13
(3) Measure the resistance between terminals 1 and 2 of each solenoid valve.
STANDARD VALUE
Name Resistance
Damper clutch solenoid valve 2.7 ~ 3.4Ω
(at 20°C)
Low and reverse solenoid valve
Second solenoid valve
Underdrive solenoid valve
Overdrive solenoid valve
(4) If the resistance is outside the standard value, replace the solenoid valve.
Resistance of the solenoid valve connector.
Terminal No. Name Resistance

7 & 10 Damper clutch solenoid valve 2.7 ~ 3.4Ω
(at 20°C)
10 & 6 Low and reverse solenoid valve
9&4 Second solenoid valve
9&3 Underdrive solenoid valve
9&5 Overdrive solenoid valve

Page 6 of 13
BASIC INSPECTION ADJUSTMENT

AUTOMATIC TRANSAXLE FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C).
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 kg·cm, 23 lb·ft)
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.

Page 7 of 13
8. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C), 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.

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

Page 9 of 13
Oil temperature (°C) Resistance (KΩ)

0 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 KΩ 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.

Page 10 of 13
(3) Measure the resistance between terminals 1 and 2 of each solenoid valve.
STANDARD VALUE
Name Resistance
Damper clutch solenoid valve 2.7 ~ 3.4Ω
(at 20°C)
Low and reverse solenoid valve
Second solenoid valve
Underdrive solenoid valve
Overdrive solenoid valve
(4) If the resistance is outside the standard value, replace the solenoid valve.
Resistance of the solenoid valve connector.
Terminal No. Name Resistance

7 & 10 Damper clutch solenoid valve 2.7 ~ 3.4Ω
(at 20°C)
10 & 6 Low and reverse solenoid valve
9&4 Second solenoid valve
9&3 Underdrive solenoid valve
9&5 Overdrive solenoid valve

Page 11 of 13
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

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

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)

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

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

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.

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.

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.

Page 5 of 9
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.

Page 6 of 9
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

Page 7 of 9
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
25. Remove the rear roll stopper.

(1) Insulator bolt
(2) Stopper bolt

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.

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.

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

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.

Page 2 of 5
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.

Page 3 of 5
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

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.

Page 5 of 5
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.

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 Installation of the clutch disc

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
Clutch slipping Insufficient clutch pedal free play Adjust
• Car will not respond to
Clogged hydraulic system Correct or replace parts
engine speed during
acceleration Excessive wear of clutch disc facing Replace
• Insufficient vehicle Hardened clutch disc facing, or oil on surface Replace
speed
Damaged pressure plate or flywheel Replace
• Lack of power during
uphill driving Weak or broken pressure spring Replace
Difficult gear shifting (gear Excessive pedal free play Adjust
noise during shifting)
Hydraulic system fluid leaks, air trapping or clogging Repair or replace parts
Unusual wear or corrosion of clutch disc spline Replace
Excessive vibration (distortion) of clutch disc Replace
Clutch When clutch is Insufficient play of clutch pedal Adjust
noisy not used
Excessive wear of clutch disc facing Replace
A noise is heard Unusual wear and/or damage of release bearing Replace
after clutch is
disengaged
A noise is heard Insuffcient grease on the sliding surface of bearing Repair
when clutch is sleeve
disengaged
Improperly installed clutch assembly or bearing Repair
A noise is heard Damaged pilot bushing Replace
when car is
suddenly rolled
with clutch
partially engaged
Difficult to depress clutch Insufficient lubrication of clutch pedal Repair
pedal
Insufficient lubrication of the clutch disc spline Repair
Insufficient lubrication of the clutch release lever shaft Repair
Insufficient lubrication of front bearing retainer Repair
Difficult to shift gear or Excessive clutch pedal free play excessive Adjust pedal free play
cannot shift at all
Clutch release cylinder faulty Repair release cylinder
Clutch disc out of true, runout is excessive or lining Inspect clutch disc
broken
Spline on input shaft or clutch disc dirty or burred Repair as necessary
Clutch pressure plate faulty Replace clutch cover
Clutch slips 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 Replace clutch cover
Release fork binding Inspect release fork

Page 2 of 2
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect clutch disc
Pressure plate faulty Replace clutch cover
Clutch diaphragm spring bent Replace clutch cover
Worn or broken torsion spring Replace clutch disc
Engine mounts loose Repair as necessary
Clutch noisy 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

Page 1 of 2
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
Single dry with diaphragm.
- Type
215 x 145 (8.5 x 5.7)
- Facing diameter (Outside x Inside) mm (in.)
Clutch cover assembly
Diaphragm spring strap
- Type
Clutch release cylinder 2.0L : 19.05 (0.76)
* I.D. mm (in.) 2.7L : 20.64 (0.82)
Clutch master cylinder
15.87(0.62)
* I.D. mm (in.)
* 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
1.1 mm (0.044 in.)
Clutch disc rivet sink
0.5 mm (0.02 in.)
Diaphragm spring end height difference
0.15 mm (0.006 in.)
Clutch release cylinder clearance to piston
0.15 mm (0.006 in.)
Clutch master cylinder clearance to piston
TIGHTENING TORQUE
Clutch pedal to pedal support member 19~28 190~280 14~20
(Clutch pedal bracket)
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
15~22 150~220 11~16
Single mass flywheel
20~27 200~270 14~19
Dual mass flywheel
LUBRICANTS
Items Specified lubricants Quantity
CASMOLY L 9508 As required
Contact surface of release bearing and fulcrum of

Page 2 of 2
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 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L 9508 As required
Inner surface of clutch master cylinder and outer Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Clutch master cylinder push rod, clevis pin and Wheel bearing grease SAE J310a, As required
washer NLGI No.2
SAE J310a, Chassis grease, NLGI-
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to release cylinder CASMOLY L 9508 As required
push rod
Input shaft spline CASMOLY L 9508 As required

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

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

Page 2 of 4
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

Page 3 of 4
Single mass flywheel:

15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
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.)

Page 4 of 4
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

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

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.

Page 2 of 2
5. Install the reservoir band, reservoir tank and reservoir cap.

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

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

Page 2 of 2

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

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.

Page 2 of 2
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.

Page 1 of 2
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.

Page 2 of 2
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.

Page 1 of 7
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 : 34°76´ ± 2°
Outer wheel : 30°19´
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.

Page 2 of 7
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 kg·cm, 0.36~1.78 lb·ft)
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.

Page 3 of 7
(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.

Page 4 of 7
(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 50~60°C (122 to 140°F).
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.

Page 5 of 7
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.

Page 6 of 7
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 50~60°C (122~132°F) 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.cm², 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.

Page 7 of 7
Tightening torque
55~65 Nm (550~650 kg·cm, 40.6~47.9 lb·ft)
6. Bleed the system.

Page 1 of 2
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
09222-32100 1. Installation of the ball bearing to rack
Valve stem oil seal installer housing
2. Installation of the oil seal to oil pump
09432-21600 1. Installation of the needle bearing to

Bearing installer rack housing
2. Installation of the ball bearing and oil
seal to valve body
09434-14200 Installation of the oil seal to rack

Counter shaft bearing installer bushing and valve body
09555-21000 Removal and installation the oil seal.

Bar
09561-11002 Removal of the steering wheel.

Steering wheel puller
09565-11100 Measurement of the mainshaft preload.

Preload socket
09568-31000 Seperation of the tie rod end ball joint.

Tie rod end puller
09572-21000 Measurement of the power steering oil

Oil pressure gauge pressure.
(use with 09572-22100, 09572-21200)
Measurement of the power steering oil

09572-21200 pressure.
Oil pressure gauge adapter (use with 09572-21000, 09572-22100)
(Hose side)

Page 2 of 2
09572-22100 Measurement of the power steering oil

Oil pressure gauge adapter pressure.
(Pump side) (use with 09572-21000, 09572-21200)
09573-21000 Installation of the oil seal

Oil seal installer guide (use with 09573-21100, 09573-21200,
09517-11000, 09555-21000)
09573-21100 Installation of the oil seal

Oil seal installer (use with 09573-21000, 09573-21200,
09555-21000)
09573-21200 Removal and installation of the oil seal

Oil seal guide

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

Retighten
Loose yoke plug
Excessive play in steering Retighten
Loose steering gear mounting bolts
wheel Retighten or place as
Loose or worn tie rod end
necessary
Readjust
Replace
V-belt slippage Replenish
Damaged V-belt Bleed air
Low fluid level Correct the rougting or
Air in the fluid replace
Steering wheel operation
Twisted or damaged hoses Repair or replace the oil
is not smooth (Insufficient
Insufficient oil pump pressure pump
power assist)
Sticky flow control valve Replace
Excessive internal oil pump leakage Replace the damaged
Excessive oil leaks from rack and pinion in gear box parts
Distorted or damaged gear box or valve body seale Replace the damaged
parts
Replace
Excessive turning resistance of tie-rod end Replace
Yoke plug excessively tight Adjust
Inner tie rod and/or ball joint cannot turn smoothly Replace
Loose mounting of gear box and crossmember Retighten
Steering wheel does not Worn steering shaft joint and/or body grommet Correct or replace
return properly Distorted rack Replace
Damaged pinion bearing Replace
Twisted or damaged hoses Reposition or replace
Damaged oil pressure control valve Replace
Damaged oil pump input shaft bearing Replace
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.
Noise
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.
Interference with hoses from vehicle body Reposition
Rattling or chucking noise Loose gear box bracket Retighten
in the rack and pinion Loose tie rod end and/or ball joint Retighten
Worn tie rod and/or ball joint Replace
Low fluid level Replenish
Noise in the oil pump Air in the fluid Bleed air
Loose pump mounting bolts Retighten

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 Specification
Steering gear type Rack and pinion
Rack stroke 132mm
Power steering pump type Vane type
Oil pump displacement 9.6 cm³/rev.MAX. (0.59 in³/rev.MAX.)
SERVICE STANDARD
Item Specification
Steering wheel free play
Steering angle 0~30 mm (0~1.1 in.)
Inner wheel 34°76´ ± 2°
Outer wheel 30°19´
Stationary steering effort 29N (3.0kg, 6.5lbs)
Belt deflection 8.8~11.0
New belt 12.5~14.3
Used belt 8.3~8.8 MPa (85~90 kg/cm², 1209~1280 psi
Oil pump relief pressure 0.6~1.3 Nm (6~13 kg·cm, 5.2~11.3 lb·in.)
Total pinion preload 2~5 Nm (20~50 kg·cm, 1.4~3.6 lb·ft)
Tie rod swing resistance 0.5~2.5 Nm (5~25 kg·cm, 0.36~1.78 lb·ft)
Tie rod end ball joint starting torque
TIGHTENING TORQUE

Power steering column and shaft
13 ~ 18 130 ~ 80 9.6 ~ 13.3
Steering column and shaft assembly mounting bolt
35 ~ 45 350 ~ 450 25.8 ~ 33.2
Power steering wheel lock nut
15 ~ 20 150 ~ 200 11 ~ 15
Pinion gear and joint assembly
18 ~ 20 180 ~ 200 13.3 ~ 15
Steering column shaft and universal joint assembly
17 ~ 26 170 ~ 260 125. ~ 19.2
Dust cover mounting bolt
Power steering gear box
60 ~ 80 600 ~ 800 44 ~ 59
Gear box mounting bolt
50 ~ 55 500 ~ 550 37 ~ 40.6
Tie rod end lock nut
24 ~ 34 240 ~ 340 17.7 ~ 25
Tie rod end ball joint and knuckle arm mounting nut
10 ~ 16 100 ~ 160 7.4 ~ 11.8
Feed tube to gear box
20 ~ 30 200 ~ 300 15 ~ 22
Gear box to valve body
50 ~ 70 500 ~ 700 37 ~ 52
Yoke plug lock nut
Power steering oil pump
55 ~ 65 550 ~ 650 40.6 ~ 47.9
Pressure hose to oil pump
35 ~ 50 350 ~ 500 25.8 ~ 37
Oil pump adjusting bolt
35 ~ 50 350 ~ 500 25.8 ~ 37
Oil pump mounting bolt
35 ~ 50 350 ~ 500 25.8 ~ 37
Oil pump bracket mounting bolt
Power steering hose
4~6 40 ~ 60 3.0 ~ 4.4
Power steering reservoir mounting bolt
4~6 40 ~ 60 3.0 ~ 4.4
Power steering hose mounting bolt
4~6 40 ~ 60 3.0 ~ 4.4
Power steering tube mounting bolt
LUBRICANTS

Page 2 of 2
Recommended lubricant Quantity

CENTOPLX278
Horn contact ring of steering wheel 1.5g
(KLUBER KOREA)
ALVANIA #2 or #3
Bearing of steering shaft As required
(KEUK DONG SHELL, KOREA)
SHOWA SUNLIGHT
Ball joint of tie rod end 1.5g
MB-2 or equivalent
ONE-LUBER RP GREASE
Steering gear housing As required
(KYODOYUSHI, JAPAN)
LONG TIME PD2
Inner ball joint of gear box As required
(OPTIMOL, GERMAN)
SILICON GREASE
Contact area of gear box bellows & tie rod As required
(SPEC NO : MS511-41)
0.75 ~ 0.8 liter
Power steering fluid PSF-3
(0.79 ~ 0.84 qts.)

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

Page 2 of 2

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.

Page 2 of 14
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.

Page 3 of 14
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.

Page 4 of 14
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.

Page 5 of 14
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.

Page 6 of 14
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.

Page 7 of 14
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 kg·cm, 0.4~1.0 lb·ft)

Page 8 of 14
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 kg·cm, 17~43 lb·in)
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 kg·cm, 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.

Page 9 of 14
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.

Page 10 of 14
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.

Page 11 of 14
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 kg·cm, 8.9 lb·ft), with a 14mm socket. Loosen the yoke plug approximately from 30° to 60°an d
tighten the yoke nut to the specified torque.
Tightening torque
50~70 Nm (500~700 kg·cm, 37~52 lb·ft)

Page 12 of 14
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

Page 13 of 14
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 kg·cm, 0.4~1.0 lb·ft)
Measure the pinion preload through the entire stroke of the rack.

Page 14 of 14
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 kg·cm, 17~43 lb·in)
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 kg·cm, 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.

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

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.

Page 2 of 3
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

Page 3 of 3
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.

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

Page 1 of 8
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.

Page 2 of 8
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 kg·cm, 25.8~37 lb·ft)
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.

Page 3 of 8
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.

Page 4 of 8
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.

Page 5 of 8
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

Page 6 of 8
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.

Page 7 of 8
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.

Page 8 of 8

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

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.

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 Removal and installation of pressure
Pressure plate bolt remover plate

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.

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

Page 3 of 3
00 Normal -
Open INCAR Sensor circuit • Incar sensor
11
• Harness or connector between incar sensor and A/C
Shorted INCAR Sensor circuit control assembly
12
• A/C control assembly
Open Ambient sensor circuit • Ambient sensor
13
• Harness or connector between ambient sensor and A/C
Shorted Ambient sensor circuit control assembly
14
Open water temp. sensor • Water temp. sensor
15
• Harness or connector between water temp. sensor and
Shorted water temp. sensor A/C control assembly
16
Open thermistor • Pin thermistor
17
• Harness or connector between evap. sensor and A/C
Shorted thermistor control assembly
18
Open or shorted temp. door potentiometer • Harness or connector between temp. door potentiometer
19
and A/C control assembly
20 Defective temp. door potentiometer • Temp. door potentiometer

Open or shorted mode door potentiometer • Harness or connector between mode door potentiometer
21
22 Defective mode door potentiometer • Mode door potentiometer
FAIL SAFE FUNCTION
No. Item Failure FAIL SAFE Function

1 IN-CAR temperature sensor Open/Short 25°C alternate value control
2 Ambient temperature sensor Open/Short 20°C alternate valu e control
3 Thermistor sensor Open/Short -2°C alternate value contr ol
4 Water temperature sensor Open/Short -20°C alternate valu e control
Temperature door potentiometer Open/Short setup For 17°C to 24.5°C, set to maximum cooling
temperature position.
5
For 25°C to 32°C, set to maximum heating
position.
Mode door potentimeter Open/Short setup Vent mode, at vent mode
6
mode Def mode, at except vent mode

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.

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

Page 3 of 3
00 Normal -
Open INCAR Sensor circuit • Incar sensor
11
• Harness or connector between incar sensor and A/C
Shorted INCAR Sensor circuit control assembly
12
Open Ambient sensor circuit • Ambient sensor
13
• Harness or connector between ambient sensor and A/C
Shorted Ambient sensor circuit control assembly
14
Open water temp. sensor • Water temp. sensor
15
• Harness or connector between water temp. sensor and
Shorted water temp. sensor A/C control assembly
16
Open thermistor • Pin thermistor
17
• Harness or connector between evap. sensor and A/C
Shorted thermistor control assembly
18
Open or shorted temp. door potentiometer • Harness or connector between temp. door potentiometer
19
20 Defective temp. door potentiometer • Temp. door potentiometer

Open or shorted mode door potentiometer • Harness or connector between mode door potentiometer
21
22 Defective mode door potentiometer • Mode door potentiometer
FAIL SAFE FUNCTION
No. Item Failure FAIL SAFE Function

1 IN-CAR temperature sensor Open/Short 25°C alternate value control
2 Ambient temperature sensor Open/Short 20°C alternate valu e control
3 Thermistor sensor Open/Short -2°C alternate value contr ol
4 Water temperature sensor Open/Short -20°C alternate valu e control
Temperature door potentiometer Open/Short setup For 17°C to 24.5°C, set to maximum cooling
temperature position.
5
For 25°C to 32°C, set to maximum heating
position.
Mode door potentimeter Open/Short setup Vent mode, at vent mode
6
mode Def mode, at except vent mode

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 Remedy

No blower operation 1. HTR Fuse Replace
2. Blower relay Replace
3. Blower motor Replace
4. Blower resistor Replace
5. Blower speed control switch Replace
6. Wire harness Replace
No air temperature control 1. Engine coolant capacity Add coolant

2. Heater control assembly Replace
No compressor operation 1. Refrigerant capacity

Add refrigerant
2. A/C Fuse Replace
3. Magnetic clutch Replace
4. Compressor Replace
5. Triple pressure switch Replace
6. A/C switch Replace
7. Thermistor Replace
Replace
8. Wire harness
No cool comes out 1. Refrigerant capacity Add refrigerant
2. Refrigerant pressure Apply a vacuum and add
3. Drive belt refrigerant
4. Magnetic clutch Adjust
Replace
5. Compressor
Replace
6. Triple pressure switch
Replace
7. Thermistor Replace
8. A/C switch Replace
9. Heater control assembly Replace
Insufficient cooling 1. Refrigerant capacity
Add refrigerant
2. Drive belt
Adjust
3. Magnetic clutch Replace
4. Compressor Replace
5. Condenser Replace
6. Expansion valve Replace
7. Evaporator Replace
8. Refrigerant lines Replace
Replace
9. Triple pressure switch
Replace
10. Heater control assembly
No engine idle-up when A/C switch 1. Engine (and ECT) ECU -
ON 2. Wire harness Replace

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. ECU-IG Fuse Replace
2. Fan motor Replace
3. Engine (and ECT) ECU -

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 30~35°C (86~95°F)
• 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/cm²)
High pressure side :
1.37~1.57 MPa (199~228 psi, 14~16 kgf/cm²)
2. Moisture present in refrigeration system.
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
During operation, pressure Moisture entered in • Drier in oversaturected - Raplace drier
on low pressure side refrigeration system freezes state - Remove moisture in
sometimes become a at expansion valve orifice • Moisture in refrigeration cycle through repeatedly
vacuum and sometime and temporarily stops cycle, system freezes at evacuating air
normal but normal state is restored expansion valve orifice - Charge proper amount of
after a time when the ice and block circulation of new refrigerant
melts refrigerant
3. Insufficient cooling

Page 2 of 7
Symptom seen in
• Pressure low on both low Gas leakage at some place • Insufficient refrigerant in - Check for gas leakage
and high pressure sides in refrigeration system system with gas leak detector
• Insufficient cooling • Refrigerant leaking and repair if necessary
performance - 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
4. Poor circulation of refrigerant
Symptom seen in
• Pressure low in both low Refrigerant flow obstructed Condenser clogged Replace drier
and high pressure sides by dirt in drier
• Frost on tube from
receiver to unit
5. Refrigerant does not circulate

Page 3 of 7
Symptom seen in
• Vacuum indicated on low • Refrigerant flow Refrigerant does not - Check expansion valve
pressure side, very low obstructed by moisture or circulate - Clean out dirt in
pressure indicated on dirt in refrigeration expansion valve by
high pressure side system blowing with air
• Frost or dew seen on • Refrigerant flow - Replace drier
piping before and after obstructed by gas - Evacuate air and charge
receiver/drier or leakage from expansion new refrigerant to proper
expansion valve valve 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 • Unable to develop • Excessive refrigerant in - (1) Clean condenser
and high pressure sides sufficient performance cycle → refrigerant - (2) Check cooling fan
due to excessive overcharged with fluid coupling
• Insufficient cooling of • Condenser cooling → operation.
condenser condenser fins clogged - (3) If (1) and (2) are in
or condenser fan faulty normal state, check
amount of refrigerant
Charge proper amount of
refrigerant
7. Air present in refrigeration system

Page 4 of 7
Symptom seen in
• Press too high on both Air entered in refrigeration • Air present in - Check compressor oil to
low and high pressure system refrigeration system see if it is see if it is dirty
sides • Insufficient vacuum or insufficient
• The low pressure piping purging - Evacuate air and charge
hot to the touch new refrigerant
8. Expansion valve improperly
Symptom seen in
• Pressure too high on Trouble in expansion valve • Excessive refrigerant in - Check expansion valve
both low and high low pressure piping - Replace if defective
pressure sides • Expansion valve opened
• Frost or large amount of too wide
dew on piping on low
pressure side
9. Defective compression compressor

Page 5 of 7
Symptom seen in
• Pressure too high on low Internal leak in compressor • Compression defective Repair or replace
high pressure sides • Valve leaking or broken compressor
• Pressure too low to on sliding parts
high pressure side
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.

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 low-
pressure 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 low-
pressure service port(C), as shown, following the equipment manufacturer s instruction. Evacuate the system.

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 low-
pressure 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

Page 1 of 1
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General
SPECIFICATIONS
Item Specification
Heating Heater Air mix type
Type 4,500 ± 10% kcal/hr
Capacity
Air conditioning Evaporator 4,100 ± 10% kcal/hr
Cooling capacity
Compressor Swash plate (HS-15)
Type 140 ~ 160cc
Oil capacity Operating pressure : 35 ~ 42.2kg/cm²
Pressure relief valve D.C 12.8 ± 0.2V
Voltage
Magnetic clutch D.C 12.8 ± 0.2V, Max. 54W
Voltage & wattage Min. 4.4kg·m
Torque
Refrigerant & capacity R-134a (600 ± 25g)
Triple pressure switch High pressure
ON 32.0 ± 2.0kg/cm²
OFF 26.0 ± 2.0kg/cm²
Middle pressure
ON 18.0 ± 0.8kg/cm²
OFF 14.0 ± 1.2kg/cm²
Low pressure
ON 2.3 + 0.25 / -0.29kg/cm²
OFF 2.0 ± 0.2kg/cm²
Thermistor OFF 1.5 ± 0.6°C
ON 3.0 ± 0.6°C
Heater control assembly MANUAL Type, AUTOMATIC Type

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

Page 2 of 3

Page 3 of 3

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.

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.

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.

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.

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.

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.

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

Page 2 of 2

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

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 : -30°C ~ 120°C
- Applicable refrigerant : R-134a
- Insulation resistance : Min. 100MΩ 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

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

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.

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

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. R25°C : 30K Ω ± 3%
B. B(0/25) : 3754K ± 2%
C. Operation Temp. range : -30°C ~ 80°C

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 Ω) R (kΩ) Rmax (kΩ)

-20 261.090 271.120 281.150
0 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

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

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

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".

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

Page 2 of 2

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.

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.

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.

Page 4 of 5
20. Remove the glove box lamp connector and the lamp.
21. Remove the main crash pad mounting bolt.
22. Remove the main crash pad.

Page 5 of 5
23. Remove the heater unit mounting nut.

24. Remove the heater unit.
INSTALLATION
Installation is the reverse of the removal.

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. 1 2 3 4 5 6 7
SENSOR
Mode X X WARM COOL VCC(+) F/B
GND(-)

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. : -30°C ~ +80°C
- Operating voltage : DC 9V ~ 16V
- Rated voltage : DC 12V
- Rated load : 4kgf/cm
- Rated watt. : 0.25W (at 40°C)
- Opration volt : DC 5V ± 0.5V
- Total resistance : 5kΩ ± 10%
- Output lock torque : Min 1.76Nm (18kgf/cm) (at DC 12V)
- Rated AMP : Max. 150mA
- Lock vol. : Max. 400ma
- Characteristics

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

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.

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. 1 2 3 4 5 6 7
SENSOR
Mode X X VENT DEF VCC (+) F/B
GND (-)

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 40°C)
- Opration volt : DC 5V ± 0.5V
- Total resistance : 5kΩ ± 10%
- Output lock torque : Min 1.76Nm (18kgf/cm) (at DC 12V)
- Rated AMP. : Max 150mA
- Lock vol. : Max. 400mA
- Characteristics

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

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.

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

Page 2 of 3

Page 3 of 3

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

Page 2 of 2

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.

Page 2 of 2
4. Replace the air filter with a new one.
5. Installation is the reverse of the removal.

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

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 ø70
Item Speccifications
Type DC ferrite
Rated voltage DC 12 volts
No load speed Min. 3300rpm
No load current Max. 3.0A
Rated load 5.0kgf·cm
20°C or 68°F
Speed in rated load 2900 ± 250rpm
Current in rated load Continuous
Insulation resistance Min. 1MΩ
Rotation direction viewed from output (Mtr.
CCW
shaft)
Operation temp. range -30° ~ +80°

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

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.

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

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.
- Operation voltage range : DC 10V ~ DC 15V
- Rated load current : DC 12V, 25A (Motor lord)

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

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, 128°C
Condenser : 0.22 , 50V

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 : -30°C ~ +70°C, 10 ~ 15 V
- Performance assurance range : -30°C ~ +60°C, 10 ~ 15V

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

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

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)

1 200 ± 30
2 100 ± 20
3 55 ± 15
CHARACTERISTICS

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

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)

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. 1 2 3 4 5 6 7
Mode FRE REC X X X X X
CIRCUIT DIAGRAM

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

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

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.

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. Name Connector Pin No. Name

Blower switch 1 MIDDLE HIGH Main switch 11 SENSOR GROUND
2 COMMON 12 FRE.
3 GROUND 13 REC.
4 HIGH 14 ILL+
5 MIDDLE LOW 15 ILL-
6 LOW 16 COMMON (BLOWER)
Main switch 1 IGN2 17 A/C OUTPUT
2 B+ 18 HUMIDITY (Rear defogger)
3 GROUND 19 S/W (Rear defogger)
4 MODE ACT. (VENT) 20 -
5 MODE ACT. (DEF) 21 -
6 MODE F/B 22 -
7 TEMP ACT. (WARM) 23 -
8 TEMP ACT. (COOL)
9 TEMP F/B
10 VCC
SCHEMATIC DIAGRAM
BLOWER S/W

Page 2 of 3
WIRING DIAGRAM

Page 3 of 3

Page 1 of 1
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.

Page 1 of 1
Conditioning > Blower > Control Panel > Components and Components Location
COMPONENTS

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

Page 2 of 4

Page 3 of 4

Page 4 of 4

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 I/NO PIN CIRCUIT REMARK

1 RHEOSTAT ILL (-) 1 INCAR SENSOR IN
2 TAIL LAMP ILL (+) 2 A/C SELECT HI OUTPUT
3 BATTERY 3 AMB SENSOR (+)
4 POWER TR(B) 4 EVA. SENSOR (+)
5 POWER TR(C) 5 -
6 - 6 -
7 HUMDITY 7 -
8 - 8 SENSOR REF (+5V)
B
9 TEMP ACT'R (CCW) COOL 9 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 -
A
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

Page 2 of 2

Page 1 of 8
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).
BUTTON
NO BUTTON DISPLAY SYSTEM OPERATION
FUNCTION
1 TEMP TEMP Set 1. Control the discharge air temperature by adjusting the
UP/DOWN temperature: mixture ratio of cold & hot air with the TEMP DOOR.
Display 2. Whenever press the SWITCH, temperature is changed
0.5°C up/down each time. (Each time the operation
sound is made for 0.1 sec.)
3. Set 17°C (62°F) as MAX COOL, 32°C (90°F) 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 17.5°C to
17°C or from 31.5°C to 32°C, the operation sound is
made.
6. At 17°C, if the temperature is set below than 17° C or
at 32°C , if it is above than 32°C , 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
2 AUTO AUTO "AUTO": Display 1. Automatically control the following items
CONTROL corresponding to theset temperature.

Page 2 of 8
• 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 • "AMB": 1. System is operated as the same before the AMB SW
temperature Display turned on.
display • Ambient 2. When the AMB SW is pushed, the other signals are
temperature: not appearedbut the word AMB and the ambient
Display temperature are displayed for 5 sec., andthen the
• The other display become the same as the AMB SW is not
signals: OFF 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.
4 A/C A/C ON/OFF • "A": 1. A/C ON/OFF
CONTROL Display/OFF
• "AUTO":
OFF
- OFF: SYSTEM OFF
- AUTO: AUTO MODE AUTOMATIC CONTROL
5 MODE MODE DOOR • "MODE": 1. Fix the MODE DOOR to one among VENT, B/L,
CONTROL Display/OFF FLOOR and MIX.
• VENT • "AUTO": Off 2. MODE SW MANUAL CONTROL ORDER : VENT →
• B/L B/L → FLOOR → MIX → VENT → ...
• FOOL 3. At MIX MODE: MIX LOGIC (MIX, FRE., A/C ON)
• MIX OFF SW AND SYSTEM OPERATION
- DEF: DEF MODE MANUAL CONTROL
- MODE: VENT, B/L, FLOOR & MIX (repeat the order)
6 DEF DEF MODE • "DEF": ON 1. MODE DOOR: Fix to "DEF"
• "A/C": 2. INTAKE DOOR: Fix to "FRE." (REC. can be selected)
Display 3. A/C: ON
• REC. IND: • A/C OUTPUT ON/OFF control: Corresponding to
OFF the detected temperatureby EVAP SENSOR.

Page 3 of 8
• "AUTO": • A/C output should be cut off at 3.5°C or below

OFF (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
7 OFF SYSTEM OFF LCD: ON 1. BLOWER FAN SPEED OFF
2. A/C OFF
3. TEMP. DOOR: Fix to the mode before OFF
4. MODE DOOR: Fix to the mode before OFF
5. INTAKE CONTROL: Fix to the mode before OFF
6. 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 ON→AQS 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

Page 4 of 8
- TEMP: The mode before OFF

8 REC. (NON- REC. MODE • IND ON 1. When operating the REC. S/W from FRE. MODE, fix
AQS type) • "AUTO" the INTAKE DOORto REC. MODE or when operating
display the REC. S/W from REC., fix the INTAKE DOORto
FRE. MODE.
FRE. MODE • IND OFF OFF SW AND SYSTEM OPERATION
• "AUTO" - REC.: FRE./REC. MODE CONTROL
display - OFF SW: ALL MODES (POSSIBLE TO MANUALLY
SELECT)
- AUTO: AUTOMATIC CONTROL (FRE. or REC.)
9 FAN UP/DOWN BLOWER FAN FAN IND 1. BLOWER MOTOR's rotation speed is controlled by the
SPEED ON/OFF current variationof the POWER TRANSISTOR.
UP/DOWN 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 DEFOG IND 1. If the DEFOG SW is pushed, the rear glass defogger
defogger ON/OFF 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 Input Output Remarks

Required discharge Auto SW, A/C SW, TEMP SW, INCAR TEMP actuator

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 Blower Switch
SW,Blower SW, OFF SW, INCAR sensor, AMB Power TR Manual selection
sensor, Photo sensor, Water HI-blower relay Control in priority
temperaturesensor, thermo sensor, Power TR.
Mode door control AUTO SW, MODE SW, DEF SW, Blower Mode actuator
SW,OFF SW, TEMP SW, INCAR sensor, AMB
sensor, Photo sensor.
Intake control AUTO SW, A/C SW, DEF SW, TEMP SW,OFF Mode actuator
SW, Intake SW, INCAR sensor, AMB sensor,
Photo sensor, Power TR.
Compressor control AUTO SW, A/C SW, DEF SW, TEMP SW,OFF Compressor relay
SW, IN-CAR sensor, AMB sensor, Photo
sensor.
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 Remarks

Required Required temperature determined by the set temperature and the
discharge inputted sensor value.
temperature
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 Upon detecting rapid changes of temperature from the INCAR sensor, it
- 1°C UP/4sec delay
temperature will gradually correct the incar temperature value.
- 1°C DOWN/4sec delay
correction
AMB Upon detecting rapid changes of temperature from the AMB sensor, it
- 1°C UP/3min delay
temperature will gradually correct the ambient temperature value.
- 1°C DOWN/4sec delay
correction
Photo correction Upon detecting rapid changes of photo intensity from the PHOTO - 350 → 1000(W/m²)/1min
sensor, it will gradually correct the photo intensity value. delay
- 350 → 1000(W/m²)/5min
delay
TEMP door It does the automatic control to maintain the optimum TEMP door The set temperature range
control opening (0%-100%).It will be computed by the temperature set and the 17°C → 32°C, 0.5°C step
input signal from each sensor. (62°F → 90°F, 1°F step)
Blower speed Automatic control of the blower speed. The target value will be - Auto mode blower low
computed by the set temperature and the input signal from each sensor. voltage (Manual low
(7 levels may be selected in case of manual selection.) voltage: 3.8)
- Auto mode heater blower
HI speed: 10.6V
Electro-motive During auto control, it will raise the permitted voltage of blower motor 6 seconds for shifting LO →
mode control gradually in order to improve comfortability. MAX
Photo During auto control, it will compensate the blower level and the
compensation 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 - At OFF in AUTO mode,

Page 6 of 8
control temperature. It will be computed by the temperature setting and the MODE door will maintain
input signal from each sensor. the AUTO
VENT → B/L → FLOOR → VENT) controlcondition.
In case of manual selection (VENT → B/L → FLOOR → MIX → VENT) - At OFF in manual mode,
MODE door will maintain
the manual
controlcondition.
MIX mode If the ambient temperature is -13°C or less in AUTO mode, discharge Entering MIX mode, A/C will
control (in auto mode will be controlled at MIX. (When front window glass is defogged.) operate.
control)
INTAKE door Auto control of intake mode based on the required discharge - Shift to REC when
control temperature that will be computed by the temperature setting and the selecting REC button at
input signal from each sensor. FRE condition (LED on).
- Shift to FRE when
selecting FRE button at
REC condition (LED off).
INTAKE control The intake door will shift to the REC position when switching the system - FRE./REC. manual
at OFF off in auto-condition, and maintain the previous condition at OFF at selection will be enabled
manual condition. at OFF.
- REC indicator will come
on at OFF at AUTO
mode.
Compressor Control automatically the compressor on/off state corresponding to the - When selection the
auto control set temperatureand the input signal from each sensor. AUTO SW, the
compressor is controlled
to ON/OFF.
- When selection the DEF
SW, the compressor is
controlled to "ON".
Compressor If EVAP sensor temperature is below than 0.5°C, the compressor will be
clutch on/off ON and the temperature is 3°C, or higher, with the compressor OFF.
control based on
refrigerant
temperature
MAX HOT When selecting the set temperature 32°C at AUTO mod e, MAX HOT will - TEMP door: MAX HOT
be performed. It will prevail over MIX mode control. - MODE door: FLOOR
mode
- INTAKE door: FRE mode
- Compressor: OFF
- Blower speed: AUTO HI
(10.6V)
MAX COOL When selecting the set temperature 17°C at AUTO mode, MAX COOL - TEMP door: MAX COOL
will be performed. - MODE door: FLOOR
mode
- INTAKE door: REC mode
- Compressor: ON
- Blower speed: MAX HI
Electromotive If the set temperature >the in-car temperature by 3°C at B/L or FLOOR - Blower speed: Controlled
heating control in AUTO mode, and the water temperature sensor input is 58°C or less, at AUTO LOW (0.5V)
it willeffect the electromotive heating control to prevent outside cold air
from flowing toward the feet of passengers.
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

Page 7 of 8
MODE: Manual selection is enabled. will apply the substitute

INTAKE door: At AUTO control or at manual selection mode. value, 20°C).
• After pressing blower
switch when water
temperature sensor
detectionis 58°C or
Blower speed: Manual selection is enabled (No re-entry). higher
• In pressing MODE
switch.
• In Upon pressing DEF
switch.
Electromotive In order to prevent hot air from the VENT or B/L in AUTO mode (A/C on
cooling control mode), the blower speed will be operated at LOW for approx. 9 seconds
before enteringthe AUTO control if the EVAP sensor detection is
temperature 30°C or higher.
MAX HOT If the above condition is satisfied, electromotive cooling control will
operate at any time.
Air Quality The AQS system will detect the hazardous elements and odors - When the initial battery
System (AQS) contained in the air.If the harmful element concentration is higher than connection and ignition is
standard, the system willoutput a LOW signal (0V) to the FATC. ON, it will operate at
AUTO mode. (AQS will
not operate).
If the concentration is within the standard value, the system will output a - When IGN 2 ON, the
HI signal(3V) the FATC. 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 - IGN 2 ON: It will check
door as follows toprevent the inflow of harmful gas in FATC : 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 →
LOW : REC ON: AQS indicator will
come on, and the system
will operate at AQS
HI : FRE mode. (Storethe previous
condition before IGN 2
OFF)
Initialization When supplying the initial power, it will operate in the initial condition. - When the initial ignition
Upon battery-on ON after battery
connection, the
systemwill operate at the
set temperature 25°C
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.

Page 8 of 8

Page 1 of 1
Conditioning > Controller > Manual Controller > Components and Components Location
COMPONENTS

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. Power supply check

2. Back light and Rear glass heat rays check
3. Blower check
4. Air conditioner check
5. Intake check and AQS check
6. Mode check
7. 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 Battery power supply error Check voltage of battery after turning off IG. If
error occurs 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 IG2 power supply error Check voltage of IG2 after turning on IG. If 10V
error occurs 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.

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

When light switch is ON, partial error Light bulb lighting error in FATC
occurs in back light
When light switch is ON, entire error Light power supply error Measure voltage of tail light shown in
occurs in back light 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.

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

Amount of wind is wrong at manual Power TR error Check voltage of blower motor's both ends.
selection of blower (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 Power TR error Power TR change
pressing OFF switch

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

Wind of air conditioner isn't Signal output error of air Switch on air conditioner and measure voltage
discharged into vehicle despite conditioner of FATC connector A-17 terminal as shown in
switching on air conditioner. 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 0.5°C), output of air conditioner isn't
made.

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

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 signal terminal output error Select AQS switch and measure AQS
AQS selection signal terminal as shown in the above
figure. If there is no change of voltage
over 10 min, check AQS.

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

Specific mode isn't selected. Signal transmission error of selected Measure voltage of selected mode wiring
mode 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.
Mode selection is impossible 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.

Page 7 of 8
TEMP CHECK
In adjusting temp switch from 32°C to 17°C, 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 17°C to 32°C, 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 17°C to 24.5°C, set to MAX COOL.
• If setup temperature is 25°C to 32.0°C, set to MAX WARM.
ERROR DIAGNOSTICS

Temp actuator running error Power supply error in temp actuator After altering 17°C to 32°C 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 self-
diagnostic, check temp actuatordriver.

Page 8 of 8

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.

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 λA 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 93°C (200°F), 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.

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

0957A-34100A Airbag deployment tool
Deployment tool PAB, SAB : 0957A-38100
DAB, BPT : 0957A-38500
0957A-38200 Simulator to check the

Dummy resistance of each wiring
harness
Dummy adapter
PAS, SAB : 0957A-38300
DAB, BPT : 0957A-1C000
0957A-38100 Use with deployment tool.

Deployment adapter
0957A-38500 Use with deployment tool.

Deployment adapter
0957A-38300 Use with dummy.

Dummy adapter
0957A-1C000 Use with dummy.

Dummy adapter

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

1 Driver belt pretensioner, High Output
2 Driver belt pretensioner, Low Output
3 Passenger belt pretensioner, High Output
4 passenger belt pretensioner, Low Output
5 Battery supply Input
6 GND Input
7 Warning lamp Output
8 Driver seat belt buckle switch, High Input
9 K-diagnostic line Input/output
10 Driver airbag, High Output
11 Driver airbag, Low Output
12 Passenger seat belt buckle switch, High Input
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 -
30 Battery voltage output for seat buckle switch Output
33 Driver seat belt buckle switch, Low Input
34 Crash output Output
37 Passenger seat belt buckle switch, Low Input

Page 2 of 2
40 Not used -
45 Driver satellite sensor, Low Input
46 Passenger satellite sensor, Low Input
47 Not used -
48 Not used -
49 Not used -
50 Not used -

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 right-
hand 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,

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 µA 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

Page 3 of 4
AIRBAG SQUIB RESISTANCE LIMITS

DAB
R ≤ 1.06Ω Resistance too low Fault definitely detected

1.80Ω ≤ R ≤ 3.40Ω Resistance whithin tolerance Definitely no fault detected
R ≥ 6.70Ω Resistance too high Fault definitely detected
1.06Ω < R < 1.80Ω
Tolerance band Fault may or may not be detected
3.40Ω < R < 6.70Ω
PAB, SAB, BPT

0.4Ω < R < 1.6Ω Tolerance band Fault may or may not be detected

Page 4 of 4
2.8Ω < R < 5.4Ω

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

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
Passenger seat belt prestensioner (PBPT), Resistance too
B1367
high
Passenger seat belt prestensioner (PBPT), Resistance too
B1368
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

Page 2 of 34
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
B1111 Battery voltage too high (Vbaft ≥ 19.2V)

DTC
B1112 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.

Page 3 of 34
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
DAB short to
B1348
ground
PAB short to
B1354
ground
DBPT short to
B1363
ground
DTC PBPT short to
B1369
ground
DSAB short to
B1380
ground
PASB short to
B1384
ground

Page 4 of 34
Satellite sensor left

B1401 side short to
ground
Satellite sensor
B1404 right side short to
ground
CIRCUIT DESCRIPTION
DTC Detecting Condition Trouble Area
• Short circuit in squib wire harness (to ground) • DAB squib
• Squib malfunction • PAB squib
• Clock spring malfunction • DSAB squib
• SRSCM malfunction • 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.

Page 5 of 34
[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 : ∞

Page 6 of 34
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.

Page 7 of 34
[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.

Page 8 of 34
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.

Page 9 of 34
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.

Page 10 of 34
[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
DAB short to
B1349
battery
PAB short to
B1355
battery

Page 11 of 34
DBPT short to
B1364
battery
PBPT short to
B1370
battery
DSAB short to
B1381
battery
DTC
PSAB short to
B1385
battery
Satellite left side
B1402
short to battery
Satellite right side
B1405
short to battery
CIRCUIT DESCRIPTION
• Short circuit in squib wire harness (to B+) • DAB squib
• Squib malfunction • PAB squib
• Clock spring cable malfunction • DSAB or PSAB squib
• SRSCM malfunction • 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.

Page 12 of 34
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

Page 13 of 34
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.

Page 14 of 34
[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.

Page 15 of 34

There is no DTC.
[HINT]

[PREPARATION]
[CHECK]
There is no DTC.
[HINT]
10. Check the SAB squib.

[PREPARATION]

Page 16 of 34
[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]

Page 17 of 34
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

Page 18 of 34
CIRCUIT INSPECTION
B1346 DAB resistance too high (R ≥ 6.70 Ω)

DTC
B1347 DAB resistance too low (R ≤ 1.06 Ω)
CIRCUIT DESCRIPTION
• Too high or low resistance between DAB high (+) wiring • DAB squib
harness and DAB low (-) wiring harness of squib.
• DAB malfunction • Clock spring

• Clock spring malfunction • SRSCM
• SRSCM malfunction • Wire harness
WIRING DIAGRAM
1. Preparation

Page 19 of 34
2. Check the DAB resistance.

[PREPARATION]
Release the airbag activation prevention mechanism on SRSCM side of airbag squib side. Connect the dummy (0957A-
38200) 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 Ω ≤ R ≤ 3.40 Ω

[PREPARATION]
[CHECK]
E. Using Hi-Scan Pro, check the DTC.

Page 20 of 34
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 Ω ≤ R ≤ 3.40 Ω
CIRCUIT INSPECTION
B1352 PAB resistance too high (R ≥ 5.4 Ω)

DTC
B1353 PAB resistance too low (R ≤ 0.4 Ω)
CIRCUIT DESCRIPTION
• Too high or low resistance between PAB high (+) wiring • PAB squib
harness and PAB low (-) wiring harness of squib.
• PAB malfunction • SRSCM

WIRING DIAGRAM

Page 21 of 34
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.

Page 22 of 34
[CHECK]
Measure the resistance between the PAB high (+) and the PAB low (-).
1.6 Ω ≤ R ≤ 2.8 Ω

[PREPARATION]
[CHECK]
There is no DTC.
[HINT]
CIRCUIT INSPECTION
B1378 DSAB Resistance too high (R ≥ 5.4 Ω)

B1379 DSAB Resistance too low (R ≤ 0.4 Ω)
DTC
B1382 PSAB Resistance too high (R ≥ 5.4 Ω)
B1383 PSAB Resistance too low (R ≤ 0.4 Ω)

Page 23 of 34
CIRCUIT DESCRIPTION
• Too high or low resistane between SAB high (+) wiring • SAB squib
harness and SAB low (-) wiring harness of squib.
• SAB malfunction • SRSCM

WIRING DIAGRAM
1. Preparation
2. Check the SAB resistance.

[PREPARATION]

Page 24 of 34
(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 Ω ≤ R ≤ 2.8 Ω
3. Check the SAB squib.

[PREPARATION]
[CHECK]
There is no DTC.
[HINT]

Page 25 of 34
CIRCUIT INSPECTION
B1361 DBPT Resistance too high (R ≥ 5.4 Ω)

B1362 DBPT Resistance too low (R ≤ 0.4 Ω)
DTC
B1367 PBPT Resistance too high (R ≥ 5.4 Ω)
B1368 PBPT Resistance too low (R ≤ 0.4 Ω)
CIRCUIT DESCRIPTION
• Too high or low resistane between BPT high (+) wiring • BPT squib
harness and BPT low (-) wiring harness of squib.
• BPT malfunction • SRSCM

WIRING DIAGRAM
1. Preparation

Page 26 of 34
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 Ω ≤ R ≤ 2.8 Ω
3. Check the BPT squib.

[PREPARATION]
C. Connect the BPT connector.
[CHECK]

Page 27 of 34
A.Turn the ignition switch to ON, and wait for at least 30 seconds.
B.Clear the malfunction code 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 Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
CIRCUIT INSPECTION
Satellite left side

B1400
defect
Satellite right side
B1403
defect
DTC Satellite left

B1409 communication
error
Satellite right
B1410 communication
error
CIRCUIT DESCRIPTION
WIRING DIAGRAM
1. Preparation

Page 28 of 34
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.

Page 29 of 34
There is no DTC.
[HINT]
CIRCUIT INSPECTION
Driver seat belt switch open/short to

Battery
B1511
Driver seat belt switch short to GND
B1512
DTC Passenger seat belt switch open/short
B1513
to Battery
B1514
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

Page 30 of 34
[CHECK]
Check the resistance with the switch on and off.
SWITCH OPEN : R = 4KΩ ± 10% (Belted)
SWITCH OPEN : R = 1KΩ ± 10% (Unbelted)
CIRCUIT INSPECTION
DTC B2500 Warning lamp failure
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

Page 31 of 34
B. Check the SRS SRI (Service Reminder Indicator).

OK : SRS SRI ON
CIRCUIT INSPECTION

DTC B1655 Side airbay crash recorded
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.

Page 32 of 34
SPECIFICATION

Page 33 of 34
AIRBAG SQUIB RESISTANCE LIMITS

DAB

1.06Ω < R < 1.80Ω
3.40Ω < R < 6.70Ω
PAB, SAB, BPT

0.4Ω < R < 1.6Ω
2.8Ω < R < 5.4Ω
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

Page 34 of 34
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
B1655 Side airbag crash recorded
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 out side of driver's seat.
• The PSAB is located in the out side of passenger's seat.

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.

Page 1 of 3
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 Use

Deployment tool (0957A-34100A) Deployment inside the vehicle (if the vehicle will no
SRS DEPLOYMENT ADAPTER HARNESS longer be driven)
DAB, BPT : 0957A-38500
PAB, SAB : 0957A-3810
DISPOSAL PLAN
Take the following disposal steps.
CASE DISPOSAL PLAN

Abnormal problems in airbag module Deploy and discard
Car scrappinG DAB, PAB, SAB, BPT Deploy the airbag module with the SST
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

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.

Page 3 of 3
5. Be sure to always wash your hands after completing this operation.

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

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.

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 93°C (200°F)
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.

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.

Page 4 of 4

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

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 93°C (200°F)
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)

Page 2 of 2
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.

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.

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.

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.

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 93°C(20 0°F).
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.

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
09793-21000 Adjustment, removal, and installation of the
Door hinge adjusting wrench door hinge
09800-21000 Trim removal

Ornament remover
09853-31000 Removal of the headliner clip

Headliner clip remover
09861-31100 Cutting the sealant of the windshield (use

Sealant cut-out tool with 09861-31200)
09861-31200 Cutting the sealant of the windshield (use

Sealant cutting blade with 09861-31100)
09861-31300 Application of the sealant to the windshield

Sealant gun
09861-31400 Removal and installation of the windshield

Glass holder
09861-31000 Removal of the windshield moulding

Windshield moulding remover

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
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 Check tube installation and
or cracked clip flange contact
Deteriorated roof lid weatherstrip Replace
Excessive roof lid-to-body clearance and Adjust
improperly fitted weatherstrip
Wind noise around sunroof Loose or deformed deflector, gaps in body Retighten adjust or replace
work
Sunroof makes a noise when Foreign particles lodged in guide rail Check drive cable and guide
moved rails for foreign particles
Loose guide rails and lid Retighten
Motor runs but sunroof does not Foreign particles lodged in guide rail Check drive cable and guide
move or moves only halfway rails for foreign particles
Incorrect engagement of motor pinion with Check for loose motor
drive cable installation and damaged pinion
Decrease in motor's clutch slipping force Adjust
Increased sunroof sliding resistance or Adjust or replace
interference of sunroof with drive cables,
weatherstrip, etc. due to maladjustment of
sunroof
Noise in motor (clutch slipping Incorrect engagement of motor pinion with Check pinion installation and
noise from motor when sunroof drive cable retighten motor
is fully opened or closed is not
Worn out or damaged motor pinion bearing Replace motor assembly
an unusual noise.)
Worn out or deformed drive cable Replace
Door glass fails to operate up Incorrect window glass installation Adjust position
and down
Damaged or faulty regulator arm or
Correct or replace
regulator
Door does not open or close Incorrect door installation Adjust position
completely
Defective door check assembly Correct or replace
Door hinge requires grease Apply grease
Hood does not open or close Striker and latch not properly aligned Adjust
completely
Incorrectly installed hood Adjust
Incorrect hood bumper height Adjust
Water leak through windshield Defective seal Fill with sealant
and rear window
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

Page 2 of 2
Improperly fit door Adjust

Improper clearance between door glass Adjust
and division channel
Deformed door Repair or replace

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
Rear hinged, front opening type (gaslifter type)
- Type
Door
Front hinged, full door construction
- Construction
Wire drum type
- Regulator system
Pin-fork system
- Locking system
Tailgate
Inner hinged, gas lifter type
- Type
Glass thickness mm(in.)
- Windshield glass 5 (0.20)
5 (0.20)
- Door glass
3.2 (0.13)
- Quarter fixed glass
3.5 (0.14)
- Tailgate glass
Seat belt 3 point type with E.L.R
E.L.R. : Emergency Locking Retractor
TIGHTENING TORQUE
Nm Kg·cm lb·ft
Door
35~42 350~420 25~31
- Door hinge to body
10~12 100~120 7~8
- Door hinge to door
17~22 170~220 12~16
- Door striker mounting bolt
Tailgate
- Tailgate hinge to body 22~27 220~270 16~19.5
7~9 70~90 5~7
- Tailgate hinge to tailgate
7~11 70~110 5~8
- Tailgate latch mounting bolt
9~14 90~140 6.5~10
- Tailgate striker mounting bolt
Hood
- Hood hinge to body 22~27 220~270 16~19.5
22~27 220~270 16~19.5
- Hood hinge to hood
7~11 70~110 5~8
- Hood latch to body
9~14 220~270 16~19.5
- Gas lifter mounting bolt
Seat
- Front seat to floor, Bolt 35~55 350~550 25~40
17~26 170~260 12~19
- Rear seat back center bracket, Bolt
17~26 170~260 12~19
- Rear seat back lower side bracket, Bolt
17~26 170~260 12~19
- Rear seat cushion mounting, Bolt
Seat belt
- Front seat belt retractor mounting bolt
40~55 400~550 29~40
- Front seat belt upper anchor mounting bolt
40~55 400~550 29~40
- Front seat belt sliding bar mounting bolt 40~55 400~550 29~40
- Front seat belt height adjuster mounting bolt 40~55 400~550 29~40

Page 2 of 2
- Rear seat belt retractor mounting bolt 40~55 400~550 29~40

- Rear seat belt upper anchor mounting bolt 40~55 400~550 29~40
- Front seat belt buckle mounting bolt 40~55 400~550 29~40
Sunroof
7~9 70~90 5~6.5
- Sunroof lid panel mounting, Nut
7~11 70~110 5~8
- Sunroof assembly mounting, Bolt

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

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.

Page 2 of 2
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.

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

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.

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.

Page 2 of 3
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 kg·cm, 8~12 lb·ft)
ADJUSTMENT
1. Adjust the striker upward or downward, and rightward or leftward until the tailgate is flush with the rear edge of
the body.

Page 3 of 3
2. Adjust the tailgate hinges rightward or leftward as necessary to equalizer the gap between the tailgate and
body.

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.

Page 2 of 5
6. Remove the door tooling hole cover.
7. Remove the door glass stopper catch.
Tightening torque:
4~6 Nm (40~60 kg·cm, 3~5 lb·ft)
8. Remove the door delta chassis.
9. Remove the glass stopper bolts, remove the window glass.

Page 3 of 5
10. Remove the door side weather strip.
11. Loosen the mounting nuts and remove the regulator assembly.
Tightening torque:
9~14 Nm (90~140 kg·cm, 6.5~10 lb·ft)
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.

Page 4 of 5
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 kg·cm, 12~16 lb·ft)
16. Remove the door checker.

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.

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

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 kg·cm, 5~8 lb·ft)
INSIDE REARVIEW MIRROR

1. Remove the rearview mirror.
DISASSEMBLY
Wear gloves to remove and install the mirror holder.

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.

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

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

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 kg·cm, 2.9~4.4 lb·ft)
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.

Page 2 of 8
Tightening torque:
4~6 Nm (40~60 kg·cm, 2.9~4.4 lb·ft)
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.

Page 3 of 8
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.

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.

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.

Page 6 of 8
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.

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 (20~40kgf·cm, 1.5~2.9 lbf·ft)
6. Check for overlap between the sunroof weatherstrip (A) and the roof panel (B).
Standard value: 1.1 mm
ADJUSTMENT
INITIAL SETTING (GENERAL, OPERATION)

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.

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.

Page 2 of 2

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.

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.
Tester
Connector Condition Specified condition
connection
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
M97
6-Ground Ignition switch ON Battery voltage
7-Ground Sunroof switch is in the tilted up position Continuity
Sunroof switch is in the tilted down
8-Ground Continuity
position
Apply the battery voltage to the terminal
1(+) ~ 2(-) Motor turns clockwise
M99 No.1 and ground to terminal No.2
Apply the battery voltage to the terminal
1(-) ~ 2(+) Motor turns counter-clockwise
No.2 and ground to terminal No.1

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

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.

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.

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 kg·cm, 29.5~36.9 lb·ft)
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.

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.

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.

Page 5 of 5
18. Remove the crash pad.
19. Installation is the reverse of removal and connect all connectors securely.

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

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.

Page 2 of 5
Tightening torque:
17~26 Nm (170~260 kg·cm, 12~19 lb·ft)
2. Remove the rear seat back mounting bolts from the rear seat back.
Tightening torque:
17~26 Nm (170~260 kg·cm, 12~19 lb·ft)
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 kg·cm, 29~40 lb·ft)

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

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.

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.

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

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).

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.

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" Remarks

Upper 13.5 mm Glass molding sub
Side 13.5 mm
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.

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.

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).

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

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.

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 A Remarks
Upper
Side 23.5mm Glass molding sub
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.

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).

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

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.

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.

Page 3 of 3
Install the glass to the body within five minutes.
6. Install the guarter fixed glass.

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

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 kg·cm, 2.9~4.4 lb·ft)
5. Remove the mounting screws in the corner of front bumper.

Page 2 of 2
Tightening torque:
4~6 Nm (40~60 kg·cm, 2.9~4.4 lb·ft)
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.

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

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.

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 kg·cm, 18.0~21.6 lb·ft)

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

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 kg·cm, 25~40 lb·ft)
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.

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

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 kg·cm, 25~40 lb·ft)
4. Loosen the rear seat belt upper, lover mounting bolts, and remove the rear seat belt.

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 kg·cm, 12~19 lb·ft)
2. Remove the rear seat belt buckle.

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.

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.

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.

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.

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

Tachometer does not operate No.17 fuse (10A) blown Check for short and replace fuse
Tachometer faulty Check tachometer
Wiring faulty Repair if necessary
Fuel gauge does not operate No.17 fuse (10A) blown Check for short and replace fuse
Fuel gauge faulty Check gauge
Fuel sender faulty Check fuel sender
Wiring faulty Repair if necessary
Low fuel warning lamp does not light No.17 fuse (10A) blown Check for short and replace fuse
Bulb burned out Replace bulb
Fuel level sensor faulty Check sensor
Wiring or ground faulty Repair if necessary
Water temperature gauge does not No.17 fuse (10A) blown Check for short and replace fuse
operate Water temperature gauge faulty Check gauge
Water temperature sender faulty Check sender
Oil pressure warning lamp does not No.17 fuse (10A) blown Check for short and replace fuse
light Bulb burned out Replace bulb
Oil pressure sender faulty Check sender
Low brake fluid warning lamp does not No.17 fuse (10A) blown Check for short and replace fuse
light Bulb burned out Replace bulb
Brake fluid level warning switch faulty Check switch
Parking brake switch faulty Check switch
Open door warning lamp does not light No.18 fuse (10A) blown Check for short and replace fuse
Door switch faulty Check switch
Seat belt warning lamp does not light No.17 fuse (10A) blown Check for short and replace fuse
Buckle switch faulty Check switch
LIGHTING SYSTEM

One lamp does not light Bulb burned out Replace bulb
(all exterior) Socket, wiring or ground faulty Repair if necessary
Head lamps do not light Bulb burned out Replace bulb
Head lamp fuse (15A) blown Replace fuse and check for short
No.21 fuse (10A) blown Check for short and replace fuse
Head lamp relay faulty Check relay
Lighting switch faulty Check switch
Tail lamps and license plate lamps do No.9, No.14 fuse (10A) blown Replace fuse and check for short
not light Battery fusible link (50A) blown Replace the fusible link
Tail lamp relay faulty Check relay
Lighting switch faulty Check switch
Stop lamps do not light
No.13 fuse (15A) blown Replace fuse and check for short

Page 2 of 15
Stop lamp switch faulty Adjust or replace switch

Stop lamps stay on Stop lamp switch faulty Adjust or replace switch
Instrument lamps do not light Rheostat faulty Check rheostat
(Tail lamps light) Wiring or ground faulty Repair if necessary
Turn signal lamp does not flash on one Bulb burned out Replace bulb
side Turn signal switch faulty Check switch
Turn signal lamps do not operate No.7 fuse (10A) blown Replace fuse and check for short
Body control module faulty Check body control module
Hazard relay faulty Replace relay
Turn signal switch faulty Check switch
Hazard warning lamps do not operate No.7 fuse (10A) blown Replace fuse and check for short
Body control module faulty Check body control module
Hazard switch faulty Check switch
Hazard relay faulty Replace relay
Flasher rate too slow or too fast Lamps' wattages are smaller or larger
Replace lamps
than specified
Check body control module
Defective body control module
Back up lamps do not light up No.3 fuse (10A) blown Replace fuse and check for short
Back up lamp switch faulty Check switch
Overhead console lamp does not light No.18 fuse (10A) blown Replace fuse and check for short
up Wiring or ground faulty Repair if necessary
AUDIO

Page 3 of 15
CHART 1

Page 4 of 15

Page 5 of 15
CHART 2
CHART 3

Page 6 of 15
CHART 4

Page 7 of 15

Page 8 of 15
CHART 5

Page 9 of 15

Page 10 of 15
CHART 6

Page 11 of 15
CHART 7
CHART 8

Page 12 of 15
CHART 9
CHART 10

Page 13 of 15
WINDSHIELD WIPER

Wipers do not operate or return to off No.27 Wiper fuse (15A) blown Check for short and replace fuse
position Wiper motor faulty Check motor
Wiper switch faulty Check switch
Wipers do not operate in INT position Body control module faulty Check body control module
Wiper switch faulty Check switch
Wiper motor faulty Check motor
POWER WINDOW

No windows operate from the main Check for short and replace fuse
No.19 fuse (30A) blown
switch on the driver's door Clean and retighten the ground
Poor ground
terminal mounting bolt
Defective power window main switch
Check the switch
Open circuit in wires or loose or
Replace if necessarh
disconnected connector
Repair or replace

Page 14 of 15
Driver's side window does not operate Defective power window main switch
Check for driver's window switch
Defective motor or circuit breaker
Replace the motor
Check the harness and the connector
Passenger's side window does not Defective power window sub switch Replace the switch
operate Defective motor or circuit breaker Replace the motor
Wiring faulty or disconnected connector Repair if necessary
POWER DOOR MIRROR

No mirrors operate Check the circuit and replace fuse
No.23 fuse (15A) blown
Clean and retighten the ground
Poor ground
terminal mounting bolt
Defective mirror switch
Check the switch
Replace if necessary
Repair or replace
One mirror does not operate Defective mirror switch Check the switch
Defective mirror actuator Replace if necessary
Open circuit wires or loose or Replace the actuator
disconnected connector Repair or replace
BURGLAR ALARM SYSTEM

The system is not armed Transmitter faulty
Replace the transmitter
(The siren doesn't sound) Body control module faulty
Check the body control module
Damaged or disconnected wiring of
Repair the harness
door switch input circuit
The siren sounds in error when a door Damaged or disconnected wiring of a Repair the harness or replace a door
or tailgate is unlocked with the key door key cylinder and tailgate key key cylinder and the tailgate key
while thesystem is armed cylinder switch input circuit cylinder switch
Body control module faulty 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
Replace the body control module
Malfunction of the body control module
There is no alarm when, as an alarm
test, a door is opened without using the Damaged or disconnected wiring of Repair the harness or replace the door
key door switch (all doors) input circuit switch
(The arming and disarming are normal, Malfunction of the door switch Check the door switch
and the alarm is activated when the Malfunction of the body control module Replace the body control module
tailgate or hood is opened)
There is no alarm when, as an alarm Damaged or disconnected wiring of
Repair the harness or replace the
test, the tailgate is opened without luggage compartment light switch input
luggage compartment light switch
using thekey circuit
Check the tailgate switch
(The alarm is activated, however, by Malfunction of the tailgate switch
Replace the body control module
opening a door or the hood) Malfunction of the body control module
There is no alarm when, as an alarm
Damaged or disconnected wiring of Repair the harness or replace the hood
test the hood is opened from within the
hood switch input circuit switch
vehicle
Malfunction of the hood switch Check the hood switch
(The alarm is activated, however, by
Malfunction of the body control module Replace the body control module
opening a door or tailgate)
KEYLESS ENTRY SYSTEM
Symptom Possible cause Check Remedy

Page 15 of 15
Operation range is unstable Discharged transmitter Check the transmitter, red Replace the battery
battery lamp blinking upon pressing
the transmitter switch
Transmitter or receiver faulty Replace the transmitter or
the receiver
Central locking device Discharged transmitter Check the transmitter, red Replace the battery
operates but keyless entry battery lamp blinking upon pressing
does not work the transmitter switch
Faulty signal code Ensure normal door
registration opening/closing by using the
door key and register the
code again
Faulty keyless entry circuit Check the BCM connector, Repair the connector or the
and the harness between the harnese
BCM and the door lock
actuator
Faulty receiver Check the receiver output Replace the receiver
using the oscilloscope
Faulty body control module 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.

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
Rated Voltage DC 12V
Operating temperature range -30°C ~ +80°C (-22 ~ +1 76°F)
High : 1A (Relay load)
Low : 1A (Relay load)
Rated load Passing : 1A (Relay load)
Dimmer & passing switch Lighting : 1A (Relay load)
Lighting switch 6.6 ± 0.5A (Lamp load)
Turn signal & lane change switch Low, High : 4.5A (Motor load)
Wiper switch Int. : 0.22 ± 0.05A (Relay load)
Wiper mist switch Lock : Max. 28A (Motor load)
Washer switch 4.5A (Motor load)
Variable intermittent wiper volume switch 4A (Motor load)
Rear wiper & washer switch Max. 25mA
Horn switch Rear wiper : 0.2A (Relay load)
Rear washer : 4A (Motor load)
1A (Relay load)
INSTRUMENTS AND WARNING SYSTEM
Warning lamps Bulb wattage (W) Color

High beam LED Blue
Low fuel LED Amber
Turn signal (LH, RH) LED Green
Battery (charge) LED Red
Oil pressure LED Red
Air bag Bulb (1.4W) Red
Parking brake LED Red
Seat belt LED Red
Check engine Bulb (1.4W) Amber
ABS LED Amber
Door ajar LED Red
Trunk lid open LED Red
Cruise LED Green
TCS LED Amber
TCS OFF LED Amber
INDICATORS AND GAUGES

Page 2 of 4

Page 3 of 4
LIGHTING SYSTEM
Items Bulb wattage (W)

Head lamp 55W / 55W (High / Low beam)
Front turn signal/position lamp 28W / 8W
Front position lamp 5W
Front fog lamp 51W
Rear combination lamps
8W / 27W
Tail/stop lamp
27W
Back up lamp
27W
Turn signal lamp
Side marker lamp 5W
Luggage lamp 5W
Internal type : 2.4W (LED)
Center high mounted stop lamp
External spoiler type : 3.5W (LED)
Overhead console lamp 10W x 2
License plate lamp 5W x 2
AUDIO

Page 4 of 4
Items H250 H260 H280

Rated output Max. 20W x 4 Max. 20W x 4 Max. 24W x 4
Load impedance 4Ω x 4 4Ω x 4 4Ω x 4
Band AM/FM AM/FM AM/FM
Tuning type PLL Synthesized type PLL Synthesized 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
Frequency range / Channel FM : FM : FM :
87.9~107.9MHZ/200KHZ 87.9~107.9MHZ/200KHZ 87.9~107.9MHZ/200KHZ
WINDSHIELD WIPER AND WASHER
DC 12V
Wiper motor DC 10~15V
Rated voltage Min. 1MΩ
Operating voltage range Low : 44~52 rpm / 3.5A or less
Insulation resistance High : 64~78 rpm / 4.5A or less
Speed/current at 1Nm load test Low : 39~47 rpm / 5.5A or less
Speed/current at 4Nm load test High : 56~68 rpm / 7.0A or less
Torque/current when parking Low : 28Nm / 24A or less
High : 23Nm / 28A or less
Windshield washer
Motor type DC ferrite magnet
Pump type Centrifugal
Rated voltage 12V
Discharge pressure 1.8kg/cm² or more
Flow rate 1,450cc/min. or more
Current 5.0A or less
Overload capacity (Continuous operation) 60sec. or less
With water 20sec. or less
Without water (Racing)
Rear wiper motor
35rpm/2.2A or less
Speed/current at no load test
30~40rpm/3.5A or less
Speed/current at 1Nm load test
8Nm/14A or less
Torque/current when parking
170° ± 3°
Wiping angle at no load

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

Page 2 of 4

Page 3 of 4

Page 4 of 4

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.

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

CDP deck mechanical error After resetting the audio, push the eject button.
Er2
(eject error, loading error) If disc is not ejected, consult your hyundai dealer.
Make sure the disc is not scratched or damaged.
Focus error
Er3 Press the eject button and pull out the disc.
Data read error
Then insert a normal CD disc.
Check if the disc is inserted correctly in the CD player.
Er6 Disc error
Make sure the disc is not scratched or damaged.
Tape deck error After resetting the audio, push the eject button.
Er8
Tape eject error If tape is not ejected, consult your hyundai dealer.
Fault code will reset automatically when the
HHH Temperature is too high
temperature returns to normal.
No disc in magazine Insert disc in magazine or insert CD magazine in the
no CD
No CD magazine in the auto change auto changer.
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.

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

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 93°C(200°F).
• 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.

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]

Page 3 of 3
WASHER SWITCH [M01-1]
REAR WIPER AND WASHER SWITCH [M01-1]

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.

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

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

1 NC
2 NC
A 3 Not used
4 ESPS (IG1)
5 SEAT BELT BUCKLE (RH)

Page 2 of 6
6 SEAT BELT BUCKLE (LH)

7 CRASH SIGNAL
8 NC
9 A/BAG DIAG (FROM ESPS)
10 A/BAG WARN'G IND
1 H/LAMP LOW RLY (S2)
2 Not used
3 FRONT WIPER RLY CONTROL
4 FRONT FOG RLY-S2
5 TURN SIGNAL (FR)
6 Not used
7 Not used
8 FRONT WIPER RLY (IG2)
9 TURN SIGNAL (FL)
C
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
D 1 B+ 50A
1 NC
2 TAILGATE LOCK SW
3 ASSIST DOOR LOCK SW
4 ASSIST DOOR SW
5 Not used
6 TAILGATE SW
E
7 NC
8 DRIVER DOOR LOCK SW
9 DRIVER DOOR SW
10 SEAT BELT SW
11 NC
12 NC
1 Not used
2 BACKUP LAMP
3 Not used
4 OUTSIDE MIRROR
5 TAIL LAMP (RH)
6 DOOR LOCK FEED
7 NC
8 DOOR UNLOCK FEED

Page 3 of 6
9 NC
10 TAIL LAMP (LH)
11 4 DOOR SW
12 Not used
13 TURN SIGNAL (RL)
14 NC
15 LUGGAGE LAMP
F
16 NC
17 TURN SIGNAL (RR)
18 AMP
19 OUTSIDE MIRROR HEATER
20 Not used
21 REAR WIPER MOTOR (IG2)
22 TAILGATE OPEN SW
1 REAR HEATED
G
2 POWER WINDOW SW
1 IMMOBILIZER ANTENNA 1
2 NC
3 TURN SIGNAL SW (RH)
4 DOOR WARN'G SW
5 TAIL SW
6 Not used
7 CODE SAVER
8 NC
9 HOOD SW
10 NC
H
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
1 AIR CONDITIONER SW
2 CLUSTER BATTERY CHARGE
3 Not used
4 TCS SW (IG1)
5 CLUSTER (IG1)
6 CLUSTER (IG1)
7 CLUSTER (T/SIG LH OUT)
8 ECU (IG1)

Page 4 of 6
9 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
I
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
1 MULTI-FUNCTION INT(T) GND
2 SIREN CONTROL
3 KEY HOLE ILL.
4 SPEED SENSOR
5 INTERIOR ILL.
6 CLUSTER (A/BAG WARN'G IND)
7 DCT
8 DOOR AJAR
J
9 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
1 CIGAR LIGHTER
2 WIPER LOW
3 WIPER HI
4 BACKUP SW
5 AUDIO (ACC)
6 MULTI-FUNCTION WASHER SW
7 BACKUP LAMP SW
K
8 START INHIBIT RELAY
9 SEAT HEATER SW (IG2)
10 JOINT MAIN 3 (B+)
11 STOP SW (B+)
12 IGNITION COIL (V6)
13 Not used
14 WIPER PARK'G
1 GND 1
2 NC

Page 5 of 6
3 BLOWER MOTOR
4 IG SW (IG1)
5 GND 2
L
6 WIPER SW POWER
7 IG SW (ACC)
8 IG SW (IG2)
1 SUNROOF (IG2)
2 ROOM LAMP (B+)
3 ROOF LAMP DECAY CONTROL
4 ECM
M
5 Not used
6 S/ROOF & ROOM LAMP GND
7 ECM MIRROR
8 SUNROOF MOTOR (B+)
FUSE
Fuse No. Capacity Connection circuit

Ignition coil (2.7L), Electronic chrome
1 20A
mirror
2 20A AMP
Back-up lamp switch, Transaxle range
3 10A switch, Cruise control module, Stop
lamp switch
4 10A Instrument cluster (A/BAG IND.)
Air bag control module, Seat belt buckle
5 15A
switch
6 10A Mirror defogger
7 10A Hazard relay
8 15A Rear wiper motor, Rear wiper relay
9 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
Stop lamp switch, Burglar alarm horn
13 15A
relay
14 10A Left tail lamps
15 10A A/C control module, Blower relay
ECM, Multi gauge unit, TCM, Vehicle
16 10A
speed sensor
Instrument cluster (Power), Pre-
17 10A excitation resistor, DRL control module,
Generator
Room lamp, Clock, Audio, Data link
18 10A
connector, Multi gauge unit
19 30A Power window relay
20 15A Trunk lid switch

Page 6 of 6
A/C relay, AQS sensor, Head lamp

21 10A
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
- Spare fuse
20/30A

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
INPUT / OUTPUT NAME DISPLAY CONDITION

POWER INPUT Battery voltage Voltage
Key removal
INPUT Key warning switch
Key insert
OFF
INPUT Accessory switch
ON
OFF
INPUT IGN1 switch
ON
OFF
INPUT IGN2 switch
ON
INPUT Alternator voltage Voltage
Enable
OUTPUT Start inhibitor
Disable
FLASHER OFF
INPUT Turn signal switch (LH)
ON
OFF
INPUT Turn signal switch (RH)
ON
OFF
OUTPUT Turn signal lamp (LH)
ON
OFF
OUTPUT Turn signal lamp (RH)
ON
OFF
INPUT Hazard swtich
ON
INPUT Hazard detection current Current
LAMP OFF
INPUT Tail lamp switch
ON
OFF
OUTPUT Tail lamp
ON
OFF
INPUT Head lamp switch
ON
Domestic
INPUT Auto light area option
Export
Control the head
INPUT Auto light sensor Voltage lamp at the auto light
mode
OFF
OUTPUT Head lamp
ON
OFF
INPUT Front fog lamp switch
ON
INPUT Rear fog lamp switch

OFF

Page 2 of 5
ON
OFF
OUTPUT Rear fog lamp
ON
DOOR CLOSE
INPUT Driver's door switch
OPEN
CLOSE
INPUT Assist door switch
OPEN
CLOSE
INPUT All door switch
OPEN
The key hole
OFF illumination is turned
OUTPUT Key hole illumination
ON off when the ignition
switch is turned on.
OFF
OUTPUT Room lamp
ON
CLOSE
INPUT Hood switch
OPEN
CLOSE
INPUT Tailgate switch
OPEN
When open the
OFF
INPUT Tailgate key unlock switch tailgate with other
ON
key.
LOCK & LOCK
INPUT Driver's door lock switch
FOLING UNLOCK
LOCK
INPUT Assist door lock switch
UNLOCK
OFF
OUTPUT Lock output
ON
OFF
OUTPUT Unlock output
ON
OFF
INPUT Folding switch
ON
OFF
OUTPUT Folding output
ON
OFF
OUTPUT Unfolding output
ON
WIPER OFF
INPUT Front washer switch
ON
OFF
INPUT Intermittent wiper switch
ON
OFF
OUTPUT Intermittent wiper relay
ON
Intermittent wiper
INPUT Resistance
resistance
OFF
INPUT Low/high wiper input
ON
INPUT Wiper parking switch Motor operation

Page 3 of 5
Parking position
OFF Snow safety
OUTPUT Snow safe relay
ON operation
OTHERS OFF
OUTPUT Power window power
ON
Seat belt removal
INPUT Seat belt switch
Seat belt installation
OFF
OUTPUT Seat belt indicator
ON
OFF
OUTPUT Chime bell
ON
OFF When the vehicle
INPUT Over speed signal
ON speed is over 120km
Rear window defogger OFF
INPUT
switch ON
OFF
OUTPUT Rear widnow defogger On starting state
ON
OFF
INPUT Crash sensor On crash state
ON
OFF
OUTPUT Burglar alarm horn
ON
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
INPUT /
NUMBER NAME OPERATION CONDITION
OUTPUT
1 INPUT Turn signal switch (LH) Turn signal lamp (LH)
2 INPUT Turn signal switch (RH) Turn signal lamp (RH)
3 INPUT Hazard switch Hazard lamp
Turn signal lamp Turn signal lamp switch
4 INPUT Double flash
detection current ON
5 INPUT Tail lamp switch Tail lamp
6 INPUT Auto light switch Tail/head lamp
7 INPUT Auto light sensor voltage Auto light switch ON

Page 4 of 5
Tail lamp and front fog

8 INPUT Rear fog lamp switch Rear fog lamp lamp ON or head lamp
ON
9 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
Only one time when IGN
16 INPUT Crash sensor Door unlock output
ON
Rear window defogger Rear window defogger
17 INPUT Starting state
switch output
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
INPUT /
NUMBER NAME OPERATION CONDITION
OUTPUT
1 OUTPUT Start inhibitor Starting disable Timer (15 sec.)
2 OUTPUT Turn signal lamp (LH) Turn signal lamp (LH)
3 OUTPUT Turn signal lamp (RH) Turn signal lamp (RH)
4 OUTPUT Tail lamp Tail lamp
5 OUTPUT Head lamp Head lamp
6 OUTPUT Rear fog lamp Rear fog lamp
7 OUTPUT Key hole illumination Key hole illumination
8 OUTPUT Room lamp Room lamp
9 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 Rear window defogger Rear window defogger
17 OUTPUT Burglar alarm horn Burglar alarm horn
Actuation test is turned off under the following conditions.

1. When the [STOP] switch is pressed.

Page 5 of 5
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.

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.
2.6±0.7 sec. (VR=0kΩ)~18.0±1sec (VR=50KΩ)
At vehicle speed = 100km/h or more.
1.0±0.2sec (VR=0kΩ)~10.0±1sec (VR=50KΩ)
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.

Page 2 of 11
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:

Page 3 of 11
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 : 0.5±0.1 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 1±0.25 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

Page 4 of 11
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 500±100 msec. after the input light to the light sensor has been received.
Lights must be turned off 3±1 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.

Page 5 of 11
Time specification
T1 : 30±3 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 : 20±1 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 : 10±1 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 5.5±0.5 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.

Page 6 of 11
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 : 5.5±0.5 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 : 6±1 sec.
T2 : 0.45±0.1 sec.
T3 : 0.3±0.1 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

Page 7 of 11
alternatively for 16±6 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 16±6 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 16±6 sec, the mirror outputs will operate for a further 16±6sec.
Time specification
T1 : 30 sec.
T2 : 16±6 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.

Page 8 of 11
Time specification
T1 : 0.5sec.
T2 : Max 2sec.
T3 : 1.0±0.2sec.
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 : 0.5±0.1sec.
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 : 27±2 sec.
T2 : 0.5±0.1 sec.
(2) Non European countries

Page 9 of 11
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 27±1 sec.
duration on, 10±1 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 : 27±2 sec.
T2 : 10±1 sec.
T3 : 0.5±0.1 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 : 1.0±0.2 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

Page 10 of 11
Time specification
T1 : 0.5 sec.
T2 : 1.0±0.2 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).

Page 11 of 11
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.

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.

Page 2 of 2
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.

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

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.

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

Ignition coil (2.7L), Electronic chrome
1 20A
mirror
2 20A AMP
3 10A Back-up lamp switch, Transaxle range

switch, Cruise control module, Stop

Page 2 of 2
lamp switch
4 10A Instrument cluster (A/BAG IND.)
Air bag control module, Seat belt buckle
5 15A
switch
6 10A Mirror defogger
7 10A Hazard relay
8 15A Rear wiper motor, Rear wiper relay
9 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
Stop lamp switch, Burglar alarm horn
13 15A
relay
14 10A Left tail lamps
15 10A A/C control module, Blower relay
ECM, Multi gauge unit, TCM, Vehicle
16 10A
speed sensor
Instrument cluster (Power), Pre-
17 10A excitation resistor, DRL control module,
Generator
Room lamp, Clock, Audio, Data link
18 10A
connector, Multi gauge unit
19 30A Power window relay
20 15A Trunk lid switch
A/C relay, AQS sensor, Head lamp
21 10A
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
- Spare fuse
20/30A

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.

Page 2 of 2

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

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

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
20 40 60 80 100 120 140
(Km/h)
Tolerance
20~24.4 40~43 60~64.4 80~85.5 100~105.5 120.5~126 140.5~146
(Km/h)
Tolerance
20~24.4 40~44.4 60~65.4 81~86.5 102~107.5 123~128.5 144~149.5
(Km/h)
Velocity
160 180 200 220 240 Area
(Km/h)

Page 2 of 6
Tolerance
160.5~166 181~186.5 201~206.5 221~226.7 241~246.7 Others
(Km/h)
Tolerance
165~170.5 186~191.5 207~212.5 227.7~233.5 248.5~254.3 EEC & General
(Km/h)
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.

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 ( Ω)

Sender (E) -47.5 110.0 ± 2
Gauge (E) -45.0 97.0 ± 1
Warning lamp -43.0 89.4 ± 1
1/2 0 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

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 (Ω) 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

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 (∞Ω)

Page 6 of 6
Not fastened Conductive(0Ω)
SEAT BELT WARNING LAMP

Seat belt condition Warning lamp
Fastened OFF
Not fastened ON

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

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

ECU engine torque (CAN
Engine torque 0~400 Nm Stepper motor
communication)
Speed signal, Fuel
Instantaneous fuel
0~30 MPG injection signal Stepper motor
consumption
(CAN communication)
Battery voltage 8~16V Battery voltage Stepper motor

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

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

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.

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


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

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

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.

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

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

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

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

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

Page 2 of 2

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.

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).

Page 3 of 3

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

Page 2 of 2

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]

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 kg·cm, 16.9~20.6 lb·ft)
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 kg·cm, 5.1~8.0 lb·ft)
INSTALLATION
1. Install the wiper arm to the specified position.

Page 2 of 3
Specified position A B
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.

Page 3 of 3

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.

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

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 kg·cm, 10.3~12.5 lb·ft)
4. Remove the hexagonal nut after removing pivot cover.
Tightening torque

Page 2 of 2
14~17 Nm (140~170 kg·cm, 10.3~12.5 lb·ft)
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.

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.

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.

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.

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


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

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.

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

Page 6 of 6

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.

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).

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).

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

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
Rated voltage DC 5V
Operating current Max. 1mA
Detection illumination ON : 23.1 ± 3.4 (Lux), 1.77 ± 0.08 (V)
Tail lamp
OFF : 48.0 ± 3.4 (Lux), 3.47 ± 0.10 (V)
ON : 6.2 ± 1.4 (Lux), 0.63 ± 0.06 (V)
Head lamp
OFF : 12.0 ± 1.4 (Lux), 1.02 ± 0.06 (V)

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]

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

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 Condition Test Specification
Parking brake OFF (Released) No continuity

4-Ground
switch ON (Pull up) Continuity
OFF No continuity
5-Ground Head lamp switch
Continuity ON Continuity
Dimmer&passing Head light ON Continuity

9-Ground
switch Head light OFF No continuity
ON Battery voltage
9-Ground Ignition switch

Page 2 of 2
ACC or LOCK No voltage

ON Battery voltage
5-Ground Ignition switch
ACC or LOCK No voltage
Voltage
7-Ground Constant Battery voltage
Stop No voltage
3-Ground Engine
Running Battery voltag
3. If circuit is not as specified, refer to schematic diagram and inspect for short circuits.

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 2.0β 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 2.7δ 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

Page 2 of 4
IMMOBILIZER STATES
1. Engine Control Module (ECM) States
The ECM has three defined states. These are described below.
State Description
• The ECM is delivered to HMC in virgin state
• There is no Vehicle Identification Number (VIN) stored in the ECM
Virgin State • 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
Learnt State
stored in the ECM
• VIN has been deleted

Page 3 of 4
• Same as virgin state except engine starting not possible on the second cycle of
Neutral State 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 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
Virgin State • The diagnostics password is set to the default
• No VIN is stored
• Virgin state is exited only after the VIN been learned
Learnt State The BCM contains a VIN
• The BCM is set to neutral state by issuing a 'Teaching ECM' command
Neutral State • 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 ON→OFF 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.

Page 4 of 4

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 DESCRIPTION
TRANSPONDER (Built-in keys) 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.
COIL ANTENNA Supplies energy to the transponder.
Receives signal from the transponder.
Sends transponder signal to the BCM.
BODY CONTROL MODULE (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.
ENGINE CONTROL MODULE (ECM) 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.
DATA LINK CONNECTOR (DLC) By connecting the voltmeter or Hi-scan, the control
module diagnostic code can be read.

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DIAGNOSTIC TESTER Has the function BCM, ECM, and key diagnosis and
change.

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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.
Diasnostic
Type Immobilizer Related Faults Fault Types
Codes
No answer from the BCM
P1610
Invalid message from BCM to ECM
BCM fault
P1800 Antenna error
P1803 Invalid request from ECM or corrupted data
Invalid transponder data
SMARTRA P1801 Transponder fault Passive mode invalid
(2.0β ENGINE) Programming error
Inconsistent data of EEPROM
EEPROM
Invalid write operation to EEPROM
P1805 No valid data from ECM after 3 attempts by

ECM
ECM fault
Invalid tester message or unexpected
requests by tester
01 Untaught transponder Untaught transponder
Transponder error due to a wrong code or
Transponder communication
02 bad read (wrong transponder in field, or
error
more than one transponder in the field).
STAND ALONE ECM error due to bad Service ID (SID), Bad

03 ECM communication error
(2.7δ ENGINE) Message ID (MID) or protocol errors
04 Immobilizer antenna - open Open Immobilizer antenna
BCM internal fault (smart driver failure) or
05 BCM internal fault or EEPROM
BCM EEPROM error
06 ECM not detected ECM not detected
REPLACEMENT OF ECM AND BCM

NEUTRALISING ECM


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Page 1 of 20

IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER DESCRIPTION

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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

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

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160 ~ 180 (1,600 ~ 1,800, 260 ~ 300 (2,600 ~ 3,000,

Parts OIL & GREASE STANDARD

Always use Genuine Hyundai parts and recommedended fluid.

Capacities [liter (U.S. qus., Imp.qts.)]

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Automatic transaxle 7.8 (8.2, 6.8)

SELECTION OF ENGINE OIL

1. Satisfy the requirements of the API classification.

GENERAL SERVICE INFORMATION

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

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3. Cleaning parts for reuse

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When replacing parts, use HYUNDAI genuine parts.

Depending on their location.

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RUBBER PARTS AND TUBES

MEASURING BODY DIMENSIONS

MEASURING ACTUAL DIMENSIONS

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Measurements should be taken at the center of the hole.

CHECKING CABLES AND WIRES

SERVICING THE ELECTRICAL SYSTEM

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Nominal Permissible current

PRECAUTIONS FOR CATALYTIC CONVERTER

1. Use only unleaded gasoline.

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THE MICRO 570 ANALYZER

BATTERY TEST PROCEDURE

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3. Choose either CCA or CCP and press the ENTER button.

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