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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

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24.04.2008

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Summary of Contents for 2003 Tiburon

Page 1: ... 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 Page 1 of 20 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 2: ...ck 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 ...

Page 3: ... 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...

Page 4: ... 000000 999999 WARNING CAUTION LABEL LOCATIONS AIR BAG WARNING CAUTION LABEL Page 4 of 20 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 5: ...AIR BAG WARNING CAUTION LABEL CONT D Page 5 of 20 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 6: ... 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 Page 6 of 20 24 04 2008 http www hmaservice com ...

Page 7: ...on 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 ve...

Page 8: ...ed 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 ill...

Page 9: ...nsmission Automatic Transmission TOWING Release the parking brake Shift the transmission to neutral 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 transmi...

Page 10: ... 4 3 9 11 90 110 6 5 8 0 M8 1 25 12 15 120 150 9 11 20 25 200 250 14 5 18 0 M10 1 25 25 30 250 300 18 22 30 50 300 500 22 36 M12 1 25 35 45 350 450 25 33 60 80 600 800 43 58 M14 1 5 75 85 750 850 54 61 120 140 1 200 1 400 85 100 M16 1 5 110 130 1 100 1 300 80 94 180 210 1 800 2 100 130 150 Page 10 of 20 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 11: ... If threads and braring sufaces are stained with oil 85 LUBRICANTS Parts OIL GREASE STANDARD Engine oil API SH SG or SG CD Hot Climate SAE 20W 40 20W 50 ABOVE 32 F For 0 C Normal Climate SAE 10W 30 10W 40 10W 50 ABOVE 10 C For 23 C Cold Climate SAE 5W 30 5W 30 5W 40 BELOW100 FoR 38 C Transaxle Manual HYUNDAI GENUINE PARTS MTF 75W 90 API GL 4 Auto DIAMOND ATF SP 3 SK ATF SP 3 Power Steering PSF 3 B...

Page 12: ...which 1 Satisfy the requirements of the API classification 2 Have the proper SAE grade number for expected ambient temperature range GENERAL SERVICE INFORMATION 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 clo...

Page 13: ...rts 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 thorough...

Page 14: ...ocation 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 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 wil...

Page 15: ...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...

Page 16: ...tinuity 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 th...

Page 17: ...dge 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 s...

Page 18: ...onnectors 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 P...

Page 19: ...plain 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 ...

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Page 21: ...nal 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 Page 1 of 6 24 04 2008 http www hmaservice com vi...

Page 22: ...ies 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 t...

Page 23: ...harging system Improper connection between battery and vehicle cables may cause REPLACE BATTERY retest the battery after removing cables and connecting the tester to the battery terminal directly prior to replacing the battery Bad cell replace Charge and retest the battery Whenever filing a claim for battery the print out of the battery test results must be attached STARTER TEST PROCEDURE 1 After ...

Page 24: ...normal level Check starter Charge battery The state of battery charge is too low to test Charge the battery and retest Replace battery Replace battery Check wiring for open circuit battery cable connection starter and repair or replace as necessary If the engine does crank check fuel system CHARGING SYSTEM TEST PROCEDURE 1 Press ENTER to begin charging system test 2 If ENTER button is pressed the ...

Page 25: ...m 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 Page 5 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 26: ...pply charging current to battery and electrical load to system fully Check belts and generator and replace as necessary High charging voltage The voltage from generator to battery is higher than normal limit during voltage regulating Check connection and ground and replace regulator as necessary Excess ripple detected One or more diodes in the generator is not functioning properly Check generator ...

Page 27: ...indicator does not go out with engine running Battery requires frequent recharging Drive belt loose or worn Battery cables loose corroded or worn Fuse blown Fusible link blown Electronic voltage regulator or generator Wiring See page EE 19 29 See page EE 32 Check fuses Replace fusible link See page EE 20 Repair wiring Engine hesitates poor acceleration Overcharge Drive belt loose or worn Wiring co...

Page 28: ...er motor Ignition switch See page EE 38 Inspect Starter spins but engine will not crank Short in wiring Pinion gear teeth broken or starter motor Ring gear teeth broken Repair wiring See page EE 40 See page EM group fly wheel Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 29: ... 2 7 Starter Type Reduction drive with planetary gear Rated voltage 12V 1 2KW No of pinion teeth 8 No load characteristics Voltage 11V Amperage 90A MAX Speed 3 000rpm MIN 2 800rpm MIN Items Specifications 2 0 2 7 Generator Type Battery boltage sensing Rated voltage 13 5V 90A 12V 120A Speed in use 1 000 18 000 rpm Voltage regulator Electronic built in type Regulator setting voltage 14 4 0 2V 14 55 ...

Page 30: ...riation 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 Command switch serial resistance value SET switch 220Ω 1 RESUME switch 910Ω 1 Items Nm kg cm lb ft Generator terminal B Sta...

Page 31: ...em 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 32: ...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 Rem...

Page 33: ...o rich Low air intake Fuel mixture too lean Advanced ignition timing Insufficient plug tightening 4 Check the electrode gap A Standard New 1 0 1 1 mm 0 039 0 043 in 5 Carefully remove the spark plug cable by pulling on the rubber boots A Check the condition of the spark plug cable terminals B If any terminal is corroded clean it and if it s broken or distorted replace the spark plug cable 6 Connec...

Page 34: ...ce 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 M...

Page 35: ...gh 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 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 36: ...arging System Schematic Diagrams TIBURON GK 2003 G 2 7 V6 DOHC Engine Electrical System Charging System Schematic Diagrams CIRCUIT DIAGRAM FOR CHARGING SYSTEM Page 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 38: ...ction 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 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 ...

Page 39: ...d turn off the electrical systems 3 Measure the battery voltage between the negative and positive terminals of the battery If the voltage is less than specification charge the battery Standard voltage 12 5 12 9V at 20 C 68 C 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 BEL...

Page 40: ... warning light is lit 4 Start the engine Check that the light goes off INSPECT CHARGING SYSTEM 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 vo...

Page 41: ...urely 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 1 Check to see that the voltmeter reads as the same value as the battery voltage If the voltmeter read...

Page 42: ... 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 3 Disconnect the battery ground cable 4 Connect a digital voltmeter between the B terminal of the generator and...

Page 43: ... 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 ter...

Page 44: ...16 Connect the generator output wire to the generator B terminal 17 Connect the negative battery cable Page 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 45: ...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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 47: ...erator 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 ...

Page 48: ...ny 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 en...

Page 49: ...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 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 ...

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Page 51: ...iption 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 52: ...sion part for joining the case and cover Leakage on the terminal part Leakage on other parts 1 Damage in the case or cover due to outside impact 2 Acid leakage on the molding part of the case or cover weld line or gate hole 3 Damage on the terminal or cracks in the cover 4 Acid leakage due to the tipped battery or slant storage 5 Acid leakage due to poor welding of the cover with no damage 2 Outsi...

Page 53: ...low 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 Te...

Page 54: ...lean 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 tighteni...

Page 55: ...arting 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 56: ...vated 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 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...

Page 57: ... 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 ...

Page 58: ...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 vo...

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Page 60: ...em 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 61: ...nect 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 4 Installation is the reverse of removal 5 Connect the battery negative cable to the battery Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnu...

Page 62: ...ontinuity 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 Instal...

Page 63: ...rol 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 64: ...E 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 r...

Page 65: ...ystem 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 66: ...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 when SET RESUME CANCEL button is pushed Main switch SET RESUME CANCEL switch Cruise control unit Cruise control does not cancel when shift lever is moved to N position A T A T gear position switch Cruise c...

Page 67: ... 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 R...

Page 68: ...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 th...

Page 69: ...acket F 4 Loosen the locknuts A and disconnect the actuator cable B from the cruise control unit 5 Installation is the reverse of removal 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 3 of 4 24 04 2008 http www hmase...

Page 70: ...move the cruise control switch 5 Installation is the reverse of removal 6 Connect the battery positive cable and negative cable to the battery Page 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 71: ...ounting surface Intake Exhaust Valve guides hole diameter 0 05 0 002 O S 0 25 0 010 O S 0 50 0 020 O S Intake valve seat ring hole diameter 0 3 0 012 O S Exhaust valve seat ring hole diameter 0 3 0 012 O S Max 0 03mm 0 0012in Max 0 15mm 0 0059in Max 0 15mm 0 0059in 11 05 11 068mm 0 435 0 436in 11 25 11 268mm 0 443 0 444in 11 50 11 518mm 0 453 0 453in 33 300 33 325mm 1 311 1 312in 28 600 28 621mm 1...

Page 72: ...0 1mm 0 004in Crankshaft Journal O D Pin O D Out of round of journal and pin Taper of journal and pin End play Main bearing oil clearance 61 982 62 000 2 4402 2 4409 in 47 982 48 000 1 8891 1 8898in Max 0 003mm 0 00012in Max 0 005mm 0 00020in 0 070 0 250mm 0 0028 0 0098in 0 004 0 022mm 0 0002 0 0009in 0 4mm 0 016in 0 1mm 0 004in Cylinder block Cylinder bore Flatness of gasket surface Out of round ...

Page 73: ...TENING TORQUE Item Nm kg cm lb ft Camshaft sprocket bolt 90 110 900 1 100 65 80 Cylinder head cover bolt 8 10 80 100 5 8 7 2 Main bearing cap bolt M10 M8 27 33 90 94 13 19 90 94 270 330 90 94 130 190 90 94 19 5 24 90 94 10 14 90 94 Connecting rod bolt 16 20 90 94 160 200 90 94 12 15 90 94 Cylinder head bolt Cold engine 25 58 92 43 47 250 58 92 43 47 18 58 92 43 47 Oil pan drain plug 35 45 350 450 ...

Page 74: ...r bolt 40 55 400 550 29 40 Front roll stopper insulator bolt and nut 50 65 500 650 36 47 Rear roll stopper bracket to cross member bolt 40 55 400 550 29 40 Rear roll stopper insulator bolt and nut 50 65 500 650 36 47 Transaxle mounting bracket bolt 40 55 400 550 29 40 Transaxle mounting insulator bolt 90 110 900 1 100 65 80 Fuel hose clamp to rear cylinder head assembly 12 15 120 150 9 11 Transaxl...

Page 75: ...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 che...

Page 76: ...p 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 6 of 12 24 04 2008 http www hmaservice...

Page 77: ...r 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 ca...

Page 78: ...gauge stops moving Main valve opening pressure 107 9 14 7kPa 1 1 0 15kg cm 15 64 2 13psi Main valve closing pressure 83 4 kPa 0 85 kg cm 12 1 psi 3 Check that the pressure level is maintained at or above the limit 4 Replace the radiator cap if the reading does not remain at or above the limit Be sure that the cap is clean before testing since rust or other foreign material on the cap seal will cau...

Page 79: ...ntration level within the specified range Do not mix types of anti freeze 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...

Page 80: ...der 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 spe...

Page 81: ...ioner 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 11 of 12 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 82: ...5 The tensioner mark should be between the MIN and MAX position If not replace the belt Page 12 of 12 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 83: ...ide installer 09221 3F100 A B Removel and installation of the valve guide Valve stem oil seal installer 09222 22001 Installation of the valve stem oil seal Valve spring compressor 09222 28000 09222 28100 Remove and installation of the intake or exhaust valve Valve stem oil seal remover 09222 29000 Removeal of the valve stem oil seal Crankshaft rear oil seal installer 09231 33000 Installation of th...

Page 84: ...lace Clean air cleaner assembly and replace the air filter Connecting rod and main bearing noise Insufficient oil supply Thin or diluted engine oil Excessive bearing clearnace Check engine oil level Change and find out cause Replace Damaged crankshaft bearing Shorted of engine oil Low oil pressure Poor quality of engine oil Worn or out of round of crankshaft journal Restricted oil passage in crank...

Page 85: ...lty radiator cap Restriction of flow in cooling system Loose or missing drive belt Faulty engine coolant pump Faulty thermostat seder or wiring Faulty electric fan Faulty thermo sensor on radiator Insufficient coolant Replace parts Replace Clear restriction or replace parts Adjust or replace Replace Repair or repalce Repair or replace Replace Refill coolant Abnormally low coolant temperature Fault...

Page 86: ...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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 88: ... 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 wi...

Page 89: ...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 2 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 90: ...kshaft 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 sid...

Page 91: ...ression 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 glos...

Page 92: ...ut 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 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 93: ...y Camshaft Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cylinder Head Assembly Camshaft Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 94: ...ne 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 t...

Page 95: ... 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 Che...

Page 96: ...er in the HLA allowing air to get in Insufficient oil in the HLA 5 Continuous noise when the engine is running after changing the HLA Do not run engine at a speed higher than 3000 rpm as this may damage the HLA 6 Continuous noise during idle after high engine speed Engine oil level too high or too low Check oil level Drain or add oil as necessary Excessive amount of air in the oil at high engine s...

Page 97: ...nstall 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 4 of 6 24 04 2008 http www hmaservice com viewer content asp I...

Page 98: ...nstall 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...

Page 99: ...13 Connect the breather hose and engine harness 14 Install the intake manifold and engine cover Page 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 100: ...mbly Valve Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cylinder Head Assembly Valve Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 101: ...ding 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 t...

Page 102: ...or 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 2 of 8 24 04 2008 http www...

Page 103: ...t 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 3 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 104: ... of squareness Max 3 Replacing Valve Guide 1 Using the special tool 09221 3F100 A B withdraw the old valve guide out the bottom of the cylinder head 2 Recondition the valve guide hole so that it can receive the newly press fitted oversize valve guide Valve Guide Oversizes Size mm in Size mark Oversize valve guide hole size mm in 0 05 0 002 O S 5 11 050 11 068 0 435 0 4357 0 25 0 010 O S 25 11 250 ...

Page 105: ... 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 Pag...

Page 106: ... 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 int...

Page 107: ... 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 wre...

Page 108: ...p 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 8 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 109: ... 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 t...

Page 110: ...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 Pag...

Page 111: ...ve 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 3 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgn...

Page 112: ...4 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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 113: ...25 Remove the engine and transaxle assembly as a unit Page 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 114: ...ecting 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 115: ...IN 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 ...

Page 116: ...h 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 smoothl...

Page 117: ...pper 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 o...

Page 118: ...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 4 of...

Page 119: ...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 follow...

Page 120: ...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 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 121: ...Crankshaft Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cylinder Block Crankshaft Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 122: ... 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 6...

Page 123: ...rvice 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 Drive Plate A T FLYWHEEL M T REASSEMBLY Main ...

Page 124: ...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 3 of 5 24 04 2008 http www hmaser...

Page 125: ...ive 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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 127: ...nder Block Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cylinder Block Cylinder Block Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 128: ...e 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 5...

Page 129: ... largest bore cylinder Identification Mark Size 0 25 0 50 0 25mm 0 010in 0 50mm 0 020in The size of piston is stamped on top of the piston 2 Measure the outside diameter of the piston to be used 3 According to the measured O D calculate the new bore size New bore size Piston O D 0 01 to 0 03 mm 0 0004 to 0 0012 in clearance between piston and cylinder 0 01 mm 0 0004 in honing margin 4 Bore each of...

Page 130: ...arance 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 1 Crankshaft 2 Drive plate 3 Piston 4 Cylinder head 5 Timing belt 6 Oil pump case Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 131: ...ine Mounts Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cylinder Block Engine Mounts Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 132: ... TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cylinder Block Engine Mounts Repair procedures REMOVAL 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 Page 1 of 2 24 04 2008 http www...

Page 133: ...Roll Stopper 1 Remove the bolt from the rear roll stopper 2 Remove the rear roll stopper from the subframe Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 134: ...stem 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 135: ... Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cooling System Water pump Components and Components Location COMPONENTS ENGINE COOLANT PUMP Page 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 137: ...t 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 eng...

Page 138: ...Thermostat Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cooling System Thermostat Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 139: ... 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 ...

Page 140: ...m 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 141: ...tor 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 rese...

Page 142: ...diator Cap Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Cooling System Radiator Cap Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 143: ...ap 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 144: ...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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 145: ... 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 REAS...

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Page 147: ...m Oil Pump Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Lubrication System Oil Pump Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 148: ...move 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 clea...

Page 149: ... 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 i...

Page 150: ...lief 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 3 of 5 24 0...

Page 151: ...an 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 swi...

Page 152: ...t Three bond No 1141E or 3M ATD No 8660 or equivalent 10 Tighten the lower oil pan bolts as shown in figure Page 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 153: ...ir 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 154: ... 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 restri...

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Page 156: ...e 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 157: ...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 1 of 4 24 04 20...

Page 158: ... 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 2 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 159: ... 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 3 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 160: ...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 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 161: ...t 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 162: ...ifold 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 ...

Page 163: ...3 Check the exhaust manifold for damage and cracks Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 164: ...em Muffler Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Engine Mechanical System Intake And Exhaust System Muffler Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 165: ... 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 secu...

Page 166: ...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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 167: ... 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 168: ... 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 169: ...ion of the EVAP Canister Purge Solenoid Valve Repair or replace Rough idle or engine stalls Vacuum hose disconnected or damaged Repair or replace Malfunction of the PCV valve Replace Malfunction of the evaporative emission canister purge system Check the system if there is a problem check related components parts Excessive oil consumption Positive crankcase ventilation line clogged Check positive ...

Page 170: ...on System EVAP Canister EVAP Canister Purge Solenoid Valve HC reduction Duty control solenoid valve Exhaust Emission System MFI system air fuel mixtrue control device Three way catalytic converter CO HC NOx reduction CO HC NOx reduction Heated oxygen sensor feedback type Monolithic type SERVICE STANDARD Item Specifications Evaporative emission canister purge solenoid valve Coil resistance 26Ω at 2...

Page 171: ...rankcase 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 172: ...side High vacuum 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 Rocker cover side Intake manifold side Low vacuum Rocker cover side Engine condition Normal operation Engine condition Accelerating and high load PCV valve Properly...

Page 173: ...se 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 Tightening torque PCV valve 8 12 Nm 80 120 kg cm 6 8 lb ft INSPECTION 1 Remove the positive ...

Page 174: ...porative 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 175: ...l 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 th...

Page 176: ... 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 t...

Page 177: ...Look for distortion cracks AIR FILTER Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 178: ...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 vacuu...

Page 179: ...A or below at 12V Coil resistance 26Ω at 20 C 68 F VACUUM HOSE 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 2 of 3 ...

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Page 181: ...res TIBURON GK 2003 G 2 7 V6 DOHC Emission Control System Evaporative Emission Control System Fuel Tank Pressure Sensor FTPS Repair procedures INSPECTION 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 ...

Page 182: ...DOHC Emission Control System Evaporative Emission Control 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 Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 183: ...mation Special Service Tools SPECIAL TOOLS Tool Number and name Illustration Use 09353 38000 Fuel pressure gauge adapter Connection of fuel pressure gauge to delivery pipe for measurement of fuel pressure 09353 24100 Fuel pressure gauge hose Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 184: ...peeds 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 actuato...

Page 185: ...o 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 th...

Page 186: ...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 co...

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Page 188: ... 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 1 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 190: ...The number herein means the check order MFI TROUBLESHOOTING PROCEDURES PROBLEM Page 3 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 191: ...tive ground circuit of PCM Defective PCM Improper communication line between PCM and scan tool Malfunction of PCM power supply circuit Malfunction of the PCM Open circuit between PCM and DLC Engine will not start Difficult to start Engine Cranks Page 4 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 192: ...Page 5 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 193: ...ROUGH IDLE OR ENGINE STALLS Page 6 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 194: ...Page 7 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 195: ...Engine hesitates or accelerates poorly Page 8 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 196: ...icle with automatic transaxle only Adjust or replace switch 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 9 of 10 24 04 2008 http www hmaservice com viewer content asp IsPrint true im...

Page 197: ...lace Clogged fuel pipe or hose Clean or replace Clogged fuel filter of in tank fuel filter Replace Water in fuel filter Replace the fuel filter or clean the fuel tank and fuel lines Dirty or rusted fuel tank interior Clean or replace Malfunctioning fuel pump clogged filter in the pump Replace Evaporative emission system malfunction when fuel filler cap is removed pressure is released Incorrect rou...

Page 198: ... sensor HO2S Type 2 7 V6 Zirconium Vehicle speed sensor Type Hall effect Camshaft position CMP sensor Type Hall effect Actuators Injectors Type number 2 7 V6 Electromagnetic type 6 Resistance 13 16Ω at 20 C 68 F Evaporative emission purge control solenoid valve Type Duty cycle type Fuel pressure regulator Pressure regulator 300 1 5 kPa 3 35 0 06 kg cm Fuel tank Tank capacity Return system 55 lit 1...

Page 199: ...to fuel tank High pressure hose at fuel tank Throttle body to surge tank Accelerator arm bracket bolts ISC actuator Fuel sender to fuel tank 10 15 20 40 40 50 8 12 7 11 30 40 25 35 3 4 2 3 30 40 15 20 8 12 6 8 2 3 100 150 200 400 400 500 80 120 70 110 300 400 250 350 30 40 20 30 300 400 150 200 80 120 60 80 20 30 7 11 14 29 29 36 5 8 8 7 5 2 8 1 22 29 18 25 2 2 3 1 4 2 2 1 4 2 2 11 14 5 8 8 7 4 4 ...

Page 200: ... 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 P0137 HO2...

Page 201: ...O P0300 Random Misfire Detected O O P0301 Misfire Detected Cylinder 1 O O P0302 Misfire Detected Cylinder 2 O O P0303 Misfire Detected Cylinder 3 O O P0304 Misfire Detected Cylinder 4 O O P0305 Misfire Detected Cylinder 5 O O P0306 Misfire Detected Cylinder 6 O O P0325 Knock Sensor Circuit Malfunction Bank 1 O X P0330 Knock Sensor Circuit Malfunction Bank 2 O X P0335 Crankshaft Position Sensor Cir...

Page 202: ...trol Limit Bank 1 O O P1167 Lambda Bank Control Limit Bank 2 O O P0036 HO2S Heater Control Circuit Bank 1 Sensor 2 O O P0056 HO2S Heater Control Circuit Bank 2 Sensor 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 Si...

Page 203: ... Circuit High Input Open or short to battery between IAT sensor and ECM Faulty IAT sensor P0115 Engine Coolant Temperature Circuit Malfunction Open or short to battery between ECTS and ECM Short to ground between ECTS and ECM Short between ECTS wires Faulty ECTS P0116 Engine Coolant Temperature Sensor Circuit Range Performance Problem After engine start up the measured coolant temperature shows no...

Page 204: ... is insufficient for closed loop operation Poor connections between ECT sensor and ECM Faulty ECTS Thermostat P0128 Coolant thermostat stuck Thermostat stuck opened P0131 HO2S Circuit Low Input Bank 1 Sensor 1 Short to GND between HO2S and ECM Faulty front HO2S P0132 HO2S Circuit High Input Bank 1 Sensor 1 Short to battery between HO2S and ECM Faulty front HO2S P0133 HO2S Circuit Slow Responsive B...

Page 205: ...Responsive Bank 1 Sensor 2 Front and rear HO2S connections reversed Faulty fuel delivery system Leak in intake system Leak in exhaust system Faulty MAFS ground circuit Faulty HO2S If any misfire purge solenoid valve MAFS or HO2S heater codes are present do all repairs associated with those codes before proceeding with this troublearea P0140 HO2S Circuit No Activity Detected Bank 1 Sensor 2 Contami...

Page 206: ...oceeding this trouble area P0050 HO2S Heater Control Circuit Bank 2 Sensor 1 Contaminated deteriorated or aged HO2S Heater Resistance out of reasonable range Misplaced bent loose or corroded connector terminals Faulty HO2S P0051 HO2S Heater Circuit Low Bank 2 Sensor 1 Blown or missing HO2S fuse Open or short to GND between HO2S and ECM Faulty HO2S P0052 HO2S Heater Circuit High Bank 2 Sensor 1 Sho...

Page 207: ...ulty fuel injectors Faulty MAFS If any codes relating to injectors HO2S ECTS or MAFS are stored do all repairs associated with those codes before proceeding with this trouble area P0174 Fuel System Too Lean Bank 2 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 ...

Page 208: ...t High Input Cylinder 4 P0274 Injector Circuit High Input Cylinder 5 P0277 Injector Circuit High Input Cylinder 6 P0300 Random Misfire Detected Vacuum leak in air intake system CKP sensor circuit malfunction Faulty CKP sensor Ignition circuit malfunction Faulty ignition coil or plug wire Spark plug malfunction Low compression due to blown head gasket leaking valve or piston ring Low high fuel pres...

Page 209: ...ssociated with them before proceeding with thistrouble area P0430 Main catalyst efficiency deterioration Bank 2 Catalytic converter deteriorated If any codes relating to HO2S sensor MAFS injectors P0171 P0172 P0174 or P0175 are present do all repairs associated with them before proceeding with this trouble area P0441 EVAP Emission Control System Incorrect Purge Flow Stuck in valve open position P0...

Page 210: ...nk pressure sensor and ECM Short to battery in ECM Open in ECM Faulty FTPS P0454 Evaporative Emission Control System Pressure Sensor Intermittent Poor connections between FTPS and ECM Misplaced loose or corroded terminals Foreign materials fouled FTPS Faulty FTPS P0455 EVAP Emission Control System Large Leak Fuel filler cap loose or missing Fuel filler cap o ring missing or damaged Faulty or damag...

Page 211: ...pen between WSS and GND Open between WSS and ECM Short to battery or GND between WSS and ECM Faulty WSS P0506 Idle Control System rpm Lower than Expected High resistance between injector fuse and IAC valve High resistance between IAC and ECM Faulty IAC valve Carbon fouled throttle plate If any TPS MAFS fuel injector or IAC valve circuit codes or pending codes are present do all repairs associated ...

Page 212: ...ectors bad wiring between ECM and CKP P1505 Idle Charge Actuator Signal Low of Coil 1 Open or short to GND between ISC and ECM Faulty ISC P1506 Idle Charge Actuator Signal High of Coil 1 Short to battery between ISC and ECM Faulty ISC P1507 Idle Charge Actuator Signal Low of Coil 2 Open or short to GND between ISC and ECM Faulty ISC P1508 Idle Charge Actuator Signal High of Coil 2 Short to battery...

Page 213: ...r short between lamp and ECM Faulty lamp P1624 Cooling Fan Relay Circuit Malfunction LOW Open or short between relay and ECM Short to GND between relay and ECM Open between relay and ECM Faulty relay P1625 Cooling Fan Relay Circuit Malfunction HIGH MAJOR SENSOR REFERENCE WAVE FORMS Page 14 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 214: ...em 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 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 215: ... Oil Pressure Switch Vehicle Speed Sensor Ignition Timing Adjustment Terminal EVAP Solenoid Valve MAP TPS ISA TR CMP Sensor CKP Page 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 216: ...Data Link Connector Heated Oxygen Sensor HO2S Transaxle Range TR Switch Injectors Knock Sensor Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 217: ...oint stabilizer link starting torque 09545 02000 Lower arm bushing remover and installer Removal installation of the lower arm bushing G Use with 09216 21100 09216 21200 09545 11000 Ball joint remover and installer Installation of the lower arm ball joint 09545 21100 Ball joint dust cover installer Installation of the lower arm ball joint dust cover 09551 25000 Trailing arm bushing remover and ins...

Page 218: ...r or J38402 Strut spring compressor Compression of front coil spring Compression of the front and rear coil spring Use with A 42 or A 20 Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 219: ... lower arm ball joint Loose or worn lower arm bushing Correct Repair Retighten or replace Vehicle pulls to one side Improper front wheel alignment Excessive turning resistance of lower arm ball joint Broken or worn coil spring Bent lower arm Correct Replace Replace Repair Steering wheel shimmy Improper front wheel alignment Poor turning resistance of lower arm ball joint Broken or worn stabilizer ...

Page 220: ... edges wheels Wear pattern Cansed by irreqular burrs on brak drums Toe adjustment out of specification Damaged or worn tie rods Damaged knuckle Excessive toe on non drive wheels Lack of rotation Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 221: ...n System General Information Specifications TIBURON GK 2003 G 2 7 V6 DOHC Suspension System General Information Specifications SPECIFICATIONS Page 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 222: ...SERVICE STANDARD Page 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 223: ...ck 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 sus...

Page 224: ...t 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 225: ... 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 1 of 4 24 04 20...

Page 226: ... 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 we...

Page 227: ...all 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 ...

Page 228: ...rectly 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 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 229: ... 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 230: ...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 ...

Page 231: ...al 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 2 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 p...

Page 232: ... 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 Stabilizer link nut 35 45 350 450 26 33 INSPECTION 1 Check the bushing for wear and deterioration 2 Check the lower arm for bending or breakage 3 Check t...

Page 233: ...lll 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 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPr...

Page 234: ...ilizer 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 235: ...ove 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 ID Identification Model ID color Outer diameter 2 0L Sports HARD 21 8mm 0 86 in 2 0L Normal SOFT White 18 8mm 0 74 in 2 7L Sports HARD Yellow 21 8mm 0 86 in 2 7 Normal SOFT Red 18 8mm 0 74 in 2 Position the bushing on the outside of ...

Page 236: ...or 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 I...

Page 237: ...t 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 238: ...t 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 the...

Page 239: ...n 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 2 of 3 24 04 2008 http www...

Page 240: ...il 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 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true img...

Page 241: ...ension 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 242: ...rrier 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 2 Tighten the components below to the specified torque as follows Items Torque Nm kgf cm lbf ft Trailing arm mounting 100 120 1000 1200 74 88 Trailing a...

Page 243: ...0 120 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 244: ...rm 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 specia...

Page 245: ...ls 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 246: ...en 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 3 Tighten the components below to the specified torque as follows Rear stabilizer...

Page 247: ... 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 248: ...neration 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 f...

Page 249: ... 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 Toe in B A mm in 0 2 mm 0 0 08 in Caster 2 58 30 Standard value To...

Page 250: ...ght 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...

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Page 252: ...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 st...

Page 253: ... the wheel runout exceeds the limit LH Left Hand side RH Right Hand side 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 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 2 of 4 24 04 2008 http www hmaservice com v...

Page 254: ...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 fr...

Page 255: ... 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 pu...

Page 256: ...3 Removal of the center bearing Use with 09216 21100 09517 21500 Front hub remover and installer 1 Removal of front hub from the knuckle Use with 09517 29000 2 Measurement of front wheel bearing pre load Use with 09532 11600 09517 29000 Knuckle arm bridge 1 Removal of wheel bearing outer race from the knuckle Use with 09495 33100 09517 43001 Bearing puller Removal of the center bearing bracket 095...

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Page 258: ...ending of drive shaft Drive shaft rattle and hub serration Wear rattle or scratching of wheel bearing Replace Replace Replace Shimmy Improper wheel balance Defective front suspension and steering Adjust or replace Adjust or replace Excesive noise Wear damage or bent drive shaft Drive shaft rattle and hub serration Drive shaft rattle and side gear serration Wear rattle or galling of wheel bearing L...

Page 259: ...e A T Automatic transaxle TIGHTENING TORQUE Nm Kgf cm lbf ft Driveshaft nut 2 0L 2 7L 200 260 200 280 2000 2600 2000 2800 148 192 148 207 Knuckle to strut assembly nut 140 160 1400 1600 104 118 Lower arm ball joint to knuckle nut 60 72 600 720 44 53 Tie rod end to knuckle 24 34 240 340 18 25 Front brake caliper to knuckle 69 85 690 850 51 63 Wheel nut 90 110 900 1100 66 81 Rear hub bearing flange ...

Page 260: ...iveshaft For 2 0L A T 2 0L 6M T Birfield joint boot grease CENTOPLEX 278M 136K CASMOLY BJ ROLLUBE BJ Sunlight SW 2 110 6gr Tripod joint boot greas KLK TJ 41 182 CASMOLY TJ ROLLUBE TJ Oneluber MK 145 6gr Birfield joint Tripod joint Type driveshaft For 2 7L Birfield joint boot grease CENTOPLEX 278M 136K CASMOLY BJ ROLLUBE BJ Sunlight SW 2 135 6gr Tripod joint boot grease KLK TJ 41 182 CASMOLY TJ ROL...

Page 261: ...haft 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 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 262: ...COMPONENTS Page 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 263: ...Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 264: ... 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 tr...

Page 265: ... 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 2 of 8 24 04 2008 http www hmas...

Page 266: ... 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 ...

Page 267: ... 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 4 of 8 24 04 2008 http www hmaservice com viewer content as...

Page 268: ...assemble 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 5 of 8 24 04 2008...

Page 269: ...de 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 6 of 8 24 ...

Page 270: ...mmercially 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 LH Left Hand side RH Right Hand side A T Automatic Transmission M T Manual transmission Standard value A mm in LH RH 2 0L A T 514 2 20 24 0 08 799 2 2 31 47 0 08 2 0L 6M T 492 6 2 19 39 0 08 803 ...

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Page 272: ...r 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 273: ... 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 t...

Page 274: ...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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 275: ...t 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 276: ...icle 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 ...

Page 277: ...ehind 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...

Page 278: ...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 whee...

Page 279: ...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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 280: ...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 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 281: ...ub 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 282: ...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 spind...

Page 283: ...NSPECTION 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 284: ...ion 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_tit...

Page 285: ... Information Special Service Tools SPECIAL TOOLS Tool Number and Name Illustration Use 09581 11000 Piston expander Spreading the front brake piston 09580 34000 Rear brake piston adjuster Removal and installation of the rear brake piston Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 286: ...ion 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 287: ...ks 8 Master cylinder Faulty Adjust Adjust Correct Replace Replace Replace Replace Replace Brake pull 1 Pad Oily 2 Piston Frozen 3 Disc Scored 4 Pad Cracked or distorted Replace Replace Replace Replace Hard pedal but brake inefficient 1 Brake system Fluid leaks 2 Brake system Air in 3 Pad Worn 4 Pad Cracked or distorted 5 Pad Oily 6 Pad Glazed 7 Disc Scored 8 Booster system Vacuum leaks Correct Ble...

Page 288: ...e 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 le...

Page 289: ...easure 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 ...

Page 290: ...ing 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 ...

Page 291: ...m 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...

Page 292: ...own 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 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 293: ...ke Type Disc O D Clearance adjustment Disc thickness Pad thickness Cylinder I D Floating type with solid disc 258 mm 10 16 in Automatic 10 mm 0 394 in 9 mm 0 354 in 33 96 mm 1 34 in Parking brake Actuation Type Mechanical brake acting on rear wheels Lever Auti lock brake system ABS ECU type ABS EBD Warning lamp TCS lamp Wheel speed sensor HECU HU ECU Operating voltage Current Internal resistance O...

Page 294: ... 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 ...

Page 295: ...ke Booster Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Brake System Brake System Brake Booster Components and Components Location COMPONENT Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 296: ...urface 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...

Page 297: ...he 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_ti...

Page 298: ...r 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 299: ... 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 t...

Page 300: ...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 2 of 3 24 04 2008 http www hmaservice com viewer content asp...

Page 301: ...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 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 302: ...roportioning 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 303: ... 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 th...

Page 304: ...e 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 305: ... 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 bra...

Page 306: ...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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 307: ...rake Pedal Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Brake System Brake System Brake Pedal Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 308: ...l 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 la...

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Page 310: ...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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 311: ...r 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...

Page 312: ...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 2 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 313: ...all 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 3 of 6 24 04 2008 http www hma...

Page 314: ...d 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 4 of 6 24 04 2008 htt...

Page 315: ...h 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...

Page 316: ...0 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 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 317: ...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 no...

Page 318: ...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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 320: ...lease 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 vernie...

Page 321: ...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 gre...

Page 322: ...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 beyo...

Page 323: ...imum allowable difference between the thickness measurements 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 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 4 of 4 24 04 2008 http www hm...

Page 324: ...e 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 325: ... 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 1 24 04 2008 http www hmaservice com viewer content asp Is...

Page 326: ...em 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 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 327: ...CIRCUIT DIAGRAM 2 CIRCUIT DIAGRAM 3 Page 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 329: ...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 i...

Page 330: ...morized 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 ...

Page 331: ...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 press...

Page 332: ... shuttle valve HSV is opened Brake fluid is supplied from the master cylinder by motor operation to the spin wheel via HSV TC valve is closed ON Brake pressure generated from motor pump is delivered only to the front wheel Inlet valve remains open to deliver the brake pressure generated from motor pump to the spinning wheels 3 PRESSURE DUMP MODE Solenoid valve State Valve Motor pump TC valve IN NO...

Page 333: ...riving 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 ...

Page 334: ...l speed sensor failure OFF ON ON OFF Pump malfunction OFF ON ON OFF Low voltage OFF ON ON OFF 2 or more wheel speed sensor failure Solenoid valve failure HECU malfunction Valve relay failure Over voltage Other failure OFF OFF ON ON Page 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 335: ...ake System Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Brake System ABS Anti Lock Brake System Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 336: ... brake pedal scraping 3 When ABS operates sound is generated from the vehicle chassis due torepeated brake application and release Thump suspension squeak tires ABS operation Longbraking distance For road surfaces such as snow covered and gravel roads the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles Accordingly advisethe customer to drive safely on su...

Page 337: ...ECU BR 63 When ignition key is turned ON engine OFF the ABS warning lamp does not light up 1 ABS warning lamp circuit 2 HECU BR 64 Even after the engine is started the ABS warning lamp remains ON 1 ABS warning lamp circuit 2 HECU BR 65 ABS does not operate Only when 1 4 are all normal and the problem is still occurring replace the HECU 1 Check the DTC reconfirming that the normal code is output 2 ...

Page 338: ...Performance speed jump or damaged exciter BR 68 C1208 No signal excite air gap error or wrong excite BR 69 C1209 RR wheel sensor open or short to ground BR 67 C1210 Range Performance speed jump or damaged exciter BR 68 C1211 No signal air gap error or wrong excite BR 69 C1604 ECU hardware ECU internal or valve failure BR 71 C2112 Valve relay valve relay or fuse failure BR 71 C2402 Motor Electrical...

Page 339: ... 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 v...

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Page 343: ... Pro is not possible Communication with any systems is not possible Probable cause Possible defect in the power supply system including ground for the diagnosis line Faulty power source circuit Faulty diagnosis line Page 8 of 24 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 344: ...lows in the HECU the ABS relay turns from on to off as the initial check The ABS warning lamp will illuminate when the ABS relay is off even if there is a problem with the circuit between the ABS warning lamp and the HECU Therefore if the lamp does not illuminate the cause may be an open circuit in the lamp power supply circuit a blown bulb an open circuit in both the circuits between the ABS warn...

Page 345: ...wer supply is normal and DTC is normal ABS does not operate Probable cause Brake operation varies depending on driving conditions and road surface conditions so diagnosis can be difficult However if a normal DTC is displayed carry out the following inspection Improper installation of wheel speed sensor Incorrect sensor harness contact Foreign material on wheel speed sensor Faulty wheel speed senso...

Page 346: ...t to GND circuit Probable cause The HECU determines that an open or short circuit has occured in more than one wire of a wheel speed sensor Faulty wheel speed sensor Faulty wiring harness or connector Faulty HECU Page 11 of 24 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 347: ...n open or short circuit Improper installation of wheel speed sensor Faulty wheel speed sensor Faulty rotor Faulty wheel bearing Faulty wiring harness or connector Faulty HECU DTC No C1202 C1205 C1208 C1211 Large air gap Probable cause Page 12 of 24 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 348: ...HECU If battery voltage drops or rises during inspection this code will be output as well If the voltage returns to thestandard value the code is no longer output Before carrying out the following inspection check the battery level and refill if necessary DTC No C1604 HECU Hardware EEPROM and ECU failure Probable cause The HECU always monitors the solenoid valve drive circuit It determines that th...

Page 349: ...ing circuit element DTC No C1611 CAN timeout EMS C1612 CAN timeout TCU C1613 CAN wrong matched transmission Probable cause Inspect the EMS or TCU according to the instructions of Engine or T M group No message from EMS or TCU for 500ms 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 Check E37 C33 C133 4 or M42 conne...

Page 350: ...07 Range Performance speed jump or damaged exciter C1208 No signal excite air gap error or wrong excite C1209 RR wheel sensor open or short to ground C1210 Range Performance speed jump or damaged 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 C2402 Motor Electrical open or short to battery motor r...

Page 351: ...oth rear wheels is decreased After the controller completes the ABS control take the same action as in management 2 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 th...

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Page 355: ...cuit Probable cause The HECU determines that an open or short circuit has occured in more than one wire of a wheel speed sensor Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of HECU Page 20 of 24 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 356: ...uit Improper installation of wheel speed sensor Malfunction of wheel speed sensor Malfunction of rotor Malfunction of wheel bearing Malfunction of wiring harness or connector Malfunction of HECU DTC No C1202 C1205 C1208 C1211 Large air gap Probable cause Page 21 of 24 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 357: ... Malfunction of HECU If battery voltage drops or rises during inspection this code will be output as well If the voltage returns to the standard value the code is no longer output Before carrying out the followinginspection check the battery level and refill if necessary DTC No C1604 HECU Hardware EEPROM and ECU failure Probable cause The HECU always monitors the solenoid valve drive circuit It de...

Page 358: ...ing circuit element DTC No C1611 CAN timeout EMS C1612 CAN timeout TCU C1613 CAN wrong matched transmission Probable cause Inspect the EMS or TCU according to the instructions of Engine or T M group No message from EMS or TCU for 500ms 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 Check E37 C33 C133 4 or M42 conne...

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Page 360: ...eding 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...

Page 361: ...rate 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 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 362: ...o 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 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 363: ... 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 1 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 365: ...INSPECTION OF HECU TERMINALS Terminals No Condition Standard Voltage V 25 GND 8 24 Always 10 14 Page 3 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 366: ...el 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 4 of 4 24 04 2008 http www hmaservice com viewer content ...

Page 367: ... 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 369: ...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 ...

Page 370: ...elease 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 t...

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Page 372: ...eed 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 373: ... 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 1 of 2 24 04 2008 http www hmaservice com viewer cont...

Page 374: ... 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 375: ...rvice Tools M5GF1 SPECIAL TOOLS 6 SPEED M T Tool Number and name Illustration Use Engine support fixture J28467 B Removal and installation of transaxle assembly Engine support adapters J28467 125 Use with J28467 B 09431 2C000 Oil seal installer Installation of differential side oil seal Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 376: ...l level Replenish Inadequate engine idle speed Adjust idle speed Oil leakage Broken or damaged oil seal or O ring Replace oil seal or O ring Hard shift Faulty control cable Replace control cable Poor contact or wear of synchronizer ring and gear cone Correct or replace Weakened synchronizer spring Replace synchronizer spring Inadequate grade of oil Replace with specified oil Jumps out of gear Worn...

Page 377: ...ear bearing play 0 0 06 Clearance between 3rd gear and synchronizer ring 0 9 1 45 0 7 Clearance between 4th gear and synchronizer ring 0 9 1 45 Clearance between 5th gear and synchronizer ring 0 95 1 4 Clearance between 6th gear and synchronizer ring 0 95 1 4 Clearance between reverse gear and synchronizer ring 0 95 1 4 TIGHTENG TORQUE 6 SPEED M T Item N m kg cm lb ft Manual transaxle case to clut...

Page 378: ...V6 DOHC Manual Transaxle System Manual Transaxle System Manual Transaxle Repair procedures M5GF1 REMOVAL 1 Remove the engine cover 2 Remove the battery terminal 3 Remove the air duct 4 Remove the battery tray 5 Remove the air cleaner 1 Upper Page 1 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 379: ...r removing the CKP sensor O2 sensor and oil pressure switch wiring bracket separate the connectors 8 Remove the brake fluid leveling sensor connector Page 2 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 380: ... 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 3 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 381: ...il 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 4 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 382: ...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 5 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 383: ...emove the wheel speed sensor and the knuckle mounting bolt 26 Drain the oil 27 Remove the transaxle mounting bracket 1 Insulator bolt Page 6 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 384: ...bolt Upper 3 Body side mounting bolt Side 4 Transaxle side mounting bolt 28 Remove the front roll stopper 1 Insulator bolt Page 7 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 385: ...Stopper bolt Upper 3 Stopper bolt Lower 29 Remove the rear roll stopper 1 Insulator bolt 2 Stopper bolt Page 8 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 386: ... 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 9 of 10 25 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 387: ...rface 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 ...

Page 388: ...nts 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 389: ...Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 390: ...ransaxle 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 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 391: ...shift cable clip 7 Remove the select cable clip 8 Remove the snap pin of the select cable 9 Remove the shift cable Page 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 392: ...ve it INSTALLATION 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 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 393: ...l and installation of transaxle assembly Engine support adapters J28467 125 Use with J28467 B 09452 21001 Oil pressure gauge adapter Measurement of the oil pressure use with 09452 21500 and 09452 21002 09452 21002 Oil pressure gauge adapter Measurement of the oil pressure use with 09452 21500 and 09452 21001 09452 21500 Oil pressure gauge Measurement of the oil pressure use with 09452 21001 and 09...

Page 394: ...SPECIFICATIONS A T Item F4A42 1 F4A42 2 Torque converter type 3 element 1 stage 2 phase type Transaxle type 4 speed forward 1 speed reverse Engine displacement 2 0 DOHC 2 7 DOHC Gear ratio 1st 2nd 3rd 4th 2 842 1 529 1 000 0 712 2 842 1 529 1 000 0 712 Reverse 2 480 2 480 Final gear ratio 4 407 4 402 Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_titl...

Page 395: ...axle 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 1 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 396: ...Page 2 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 397: ...TCM CIRCUIT DIAGRAM 2 7L Page 3 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 401: ...m 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 1 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 402: ...SECOND Page 2 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 403: ...THIRD Page 3 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 404: ...FOURTH Page 4 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 405: ...REVERSE Page 5 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 406: ...Page 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 407: ...CTION 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 1 of 11 24 04 2008 http ...

Page 408: ...n 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 i...

Page 409: ...x 0 10rpm 7 Selector lever position D Carry out on a flat and straight road 1 Accelerate to 4th gear at a throttle position sensor output of 1 5V accelerator opening angle of 30 2 Gently decelerate to a standstill 3 Accelerate to 4th gear at a throttle position sensor output of 2 5 V accelerator opening angle of 50 4 While driving at 60 km h in 4th gear shif down to 3rd gear 5 While driving at 40 ...

Page 410: ... 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 continuously for 0 3 second P0755 UD solenoid valve Short circuit open circuit P0760 2nd solenoid valve Short circuit open circuit P0765 OD solenoid valve Short circuit open circuit P0743 TCC solenoid valve Short ci...

Page 411: ...it in the fluid temperature sensor and diagnosis code P0713 is set Open circuit Short circuit Malfunction of the oil temperature sensor Malfunction of connector Malfunction of the TCM P0712 P0725 CKP sensor system If no output pulse is detected from the crank shaft position sensor for 5 seconds or more while driving at 25 km h or more it is judged that there is an open circuit in the crank shaft p...

Page 412: ...ansmission is locked into 3rd gear as a fail safe measure Short circuit Open circuit Malfunction of the torque converter clutch solenoid valve Malfunction of connector Malfunction of the TCM P0740 Defective system P0731 1st gear ratio does not meet the specification If the output from the output shaft speed sensor multiplied by the 1st gear ratio is not the same as the output from the input shaft ...

Page 413: ...tput from the output shaft speed sensor multiplied by the reverse gear ratio is not the same as the output from the input shaft speed sensor after the shift to reverse gear has been completed diagnosis code P0736 is set If diagnosis code P0736 is set four times the transmission is locked into 3rd gear as a fail safe measure Malfunction of the input shaft speed sensor Malfunction of the output shaf...

Page 414: ...t move forward If the vehicle does not move forward when the selector lever is shifted from N to D range while the engine is idling the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body Abnormal line pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Does not reverse If the vehicle ...

Page 415: ...and large time lag If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range 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 Abnormal line pressure Malfunction of the oil pump Malfunction of the valve body Malfunction when shifting Shocks and running u...

Page 416: ...a defective TCM Malfunction of the idle position switch Malfunction of connector Malfunction of the TCM Triple pressure switch system The cause is probably a defective triple pressure switch circuit or a defective TCM Malfunction of the triple pressure switch Malfunction of connector Malfunction of A C system Malfunction of the TCM Vehicle speed sensor system The cause is probably a defective vehi...

Page 417: ...brake LR Locks low and reverse annulus gear and overdrive planetary carrier Second brake 2ND Locks reverse sun gear Page 11 of 11 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 418: ...an tool is not possible the cause may be a defective diagnostic trouble line or the TCM is not functioning Malfunction of diagnostic trouble line Malfunction of connector Malfunction of the TCM Starting impossible Possible cause Starting is not possible when the selector lever is in P or N range In such cases the cause may be a defective engine system torque converter or oil pump Malfunction of th...

Page 419: ...es not reverse Possible cause If the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling the cause may be abnormal pressure in the reverse clutch or low and reverse brake or a malfunction of the reverse clutch low and reverse brake or valve body Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and r...

Page 420: ...ever is shifted from N to D or R range while the engine is idling the cause may be a malfunction of the engine system torque converter clutch soledoid valve body or torque converter torque converter clutch malfunction Malfunction of the engine system Malfunction of the torque converter clutch solenoid Malfunction of the valve body Malfunction of the torque converter Malfunction of the torque conve...

Page 421: ...e lag of 2 seconds or more occurs when the selector lever is shifted from N to R range while the engine is idling the cause may be abnormal reverse clutch pressure or low and reverse brake pressure or a malfunction or the reverse clutch low and reverse brake valve body Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunc...

Page 422: ...ion of the oil pump Malfunction of the valve body Shocks and running up Possible cause If shocks occur when driving due to upshifting or downshifting and the transaxle speed becomes higher than the engine speed the cause may be abnormal line pressure or a malfunction of a solenoid valve oil pump valve body or of a brake or clutch Abnormal line pressure Malfunction of each solenoid valve Malfunctio...

Page 423: ...malfunction of the output shaft speed sensor TPS or a solenoid valve Malfunction of the output shaft speed sensor Malfunction of the throttle position sensor Malfunction of each solenoid valve Abnormal line pressure Malfunction of the valve body Malfunction of the TCM Page 6 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 424: ...g does not occur while driving and no diagnostic trouble codes are given the cause may be a malfunction of the Park Neutral position switch or TCM Malfunction of the Park Neutral position switch Malfunction of the TCM Poor acceleration Possible cause If acceleration is poor even if downshifting occurs while driving the cause may be a malfunction of the engine system or of a brake or clutch Malfunc...

Page 425: ...or a malfunction of the engine system torque converter clutch solenoid torque converter or valve body Abnormal torque converter clutch pressure Malfunction of the engine system Malfunction of the torque converter clutch solenoid Malfunction of the torque converter Malfunction of the valve body Page 8 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 426: ...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 af...

Page 427: ...id 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 2 of 13 24 04 2008 http www hmaservice com viewe...

Page 428: ... 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 o...

Page 429: ...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 VA...

Page 430: ...ive 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 5 of 13 24 04 2008 http www hmaservice com viewer conten...

Page 431: ...ult 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 t...

Page 432: ... 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 7 of 13 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 prin...

Page 433: ...tor 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 d...

Page 434: ...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 VA...

Page 435: ...ve 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 10 of 13 24 04 2008 http www hmaservice com viewer conten...

Page 436: ...ADJUSTMENT Standard value 0 0 16mm SECOND BRAKE END PLAY ADJUSTMENT Standard value 0 79 1 25mm LOW REVERSE BRAKE END PLAY ADJUSTMENT Standard value 1 35 1 81mm Page 11 of 13 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 437: ...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 Standard value 0 25 0 45mm Page 12 of 13 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 438: ...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 Installing the underdrive clutch hub makes it easy to measure the underdrive sun gear end play DIFFERENTIAL CASE PRELOAD ADJUSTMENT Standard value T 0 045mm to T 0 105mm Page 13 of 13 24 04 2008 http www hmaservice com v...

Page 439: ...le 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 440: ... V6 DOHC Automatic Transaxle System Automatic Transaxle System Automatic Transaxle Repair procedures F4A42 2 REMOVAL 1 Remove the engine cover 2 Remove the battery terminal 3 Remove the air duct 4 Remove the battery tray 5 Remove the air cleaner 1 Upper Page 1 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 441: ...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 2 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 442: ...olumn 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 3 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 443: ... 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 4 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 444: ...le under cover 20 Separate the tie rod end 21 Remove the wheel speed sensor and the knuckle mounting bolt 22 Drain the oil Page 5 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 445: ...sulator 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 6 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 446: ... Stopper bolt Upper 3 Stopper bolt Lower 25 Remove the rear roll stopper 1 Insulator bolt 2 Stopper bolt Page 7 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 447: ...ffler 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 8 of 9 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 448: ...rol 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...

Page 449: ...ol 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 450: ...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 4 Remove the console upper cover 5 Remove the console assembly 6 Remove the indicator panel Page 1 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 451: ...ndicator lower cover 8 Remove the indicator plate 9 Remove the key lock cable nut 10 Remove the shift lock cable nut Page 2 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 452: ...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 3 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 453: ...e 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 di...

Page 454: ...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 ...

Page 455: ...N GK 2003 G 2 7 V6 DOHC Clutch System General Information Special Service Tools SPECIAL TOOLS Tool Number and name Illustration Use 09411 25000 Clutch disc guide Installation of the clutch disc Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 456: ...lease bearing Replace A noise is heard when clutch is disengaged Insuffcient grease on the sliding surface of bearing sleeve Repair Improperly installed clutch assembly or bearing Repair A noise is heard when car is suddenly rolled with clutch partially engaged Damaged pilot bushing Replace Difficult to depress clutch pedal Insufficient lubrication of clutch pedal Repair Insufficient lubrication o...

Page 457: ...ion 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 458: ...pring end height difference Clutch release cylinder clearance to piston Clutch master cylinder clearance to piston 1 1 mm 0 044 in 0 5 mm 0 02 in 0 15 mm 0 006 in 0 15 mm 0 006 in TIGHTENING TORQUE Item Nm kg cm lb ft Clutch pedal to pedal support member Clutch pedal bracket 19 28 190 280 14 20 Clutch pedal support member to master cylinder 8 10 80 100 6 7 Clutch tube flare nut 13 17 130 170 9 13 ...

Page 459: ...inder and outer circumference of piston assembly Brake fluid DOT 3 or DOT 4 As required Clutch master cylinder push rod clevis pin and washer Wheel bearing grease SAE J310a NLGI No 2 As required Clutch pedal shaft and bushings SAE J310a Chassis grease NLGI No 1 As required Contact portion of release fork to release cylinder push rod CASMOLY L 9508 As required Input shaft spline CASMOLY L 9508 As r...

Page 460: ...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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 461: ...ar 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...

Page 462: ...er 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 av...

Page 463: ...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 an...

Page 464: ...nd 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 4 of 4 24 04 2008 http www hmaservice com viewer content ...

Page 465: ...r Cylinder Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Clutch System Clutch System Clutch Master Cylinder Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 466: ...coring 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 ...

Page 467: ...5 Install the reservoir band reservoir tank and reservoir cap Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 468: ...utch Pedal Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Clutch System Clutch System Clutch Pedal Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 469: ...ply 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 ...

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Page 471: ...e Cylinder Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Clutch System Clutch System Clutch Release Cylinder Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 472: ... 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 pop...

Page 473: ...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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 474: ...per 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 standa...

Page 475: ...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 2 of 2 24 04 2008 http www hmaservice com viewer conten...

Page 476: ...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 CHECKI...

Page 477: ...n 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 ...

Page 478: ...kly 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 ...

Page 479: ...dle 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 ...

Page 480: ...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 unt...

Page 481: ...perature 3 Increase the engine speed to 1 000 100 rpm 4 Close the shut off valve of the special tool and measure the fluid pressure to confirm that it is within the standard value range Standard value Relief pressure 8 3 8 8 MPa 85 90 kg cm 1209 1280 psi Do not keep the shut off valve on the pressure gauge closed for more than ten seconds 5 Remove the special tools and tighten the pressure hose to...

Page 482: ...Tightening torque 55 65 Nm 550 650 kg cm 40 6 47 9 lb ft 6 Bleed the system Page 7 of 7 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 483: ...e body 09434 14200 Counter shaft bearing installer Installation of the oil seal to rack bushing and valve body 09555 21000 Bar Removal and installation the oil seal 09561 11002 Steering wheel puller Removal of the steering wheel 09565 11100 Preload socket Measurement of the mainshaft preload 09568 31000 Tie rod end puller Seperation of the tie rod end ball joint 09572 21000 Oil pressure gauge Meas...

Page 484: ...uide Installation of the oil seal use with 09573 21100 09573 21200 09517 11000 09555 21000 09573 21100 Oil seal installer Installation of the oil seal use with 09573 21000 09573 21200 09555 21000 09573 21200 Oil seal guide Removal and installation of the oil seal Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 485: ...Loose mounting of gear box and crossmember Worn steering shaft joint and or body grommet Distorted rack Damaged pinion bearing Twisted or damaged hoses Damaged oil pressure control valve Damaged oil pump input shaft bearing Replace Adjust Replace Retighten Correct or replace Replace Replace Reposition or replace Replace Replace Noise Hissing Noise in Steering Gear There is some noise with all powe...

Page 486: ...umn and shaft assembly mounting bolt Power steering wheel lock nut Pinion gear and joint assembly Steering column shaft and universal joint assembly Dust cover mounting bolt 13 18 35 45 15 20 18 20 17 26 130 80 350 450 150 200 180 200 170 260 9 6 13 3 25 8 33 2 11 15 13 3 15 125 19 2 Power steering gear box Gear box mounting bolt Tie rod end lock nut Tie rod end ball joint and knuckle arm mounting...

Page 487: ...IGHT MB 2 or equivalent 1 5g Steering gear housing ONE LUBER RP GREASE KYODOYUSHI JAPAN As required Inner ball joint of gear box LONG TIME PD2 OPTIMOL GERMAN As required Contact area of gear box bellows tie rod SILICON GREASE SPEC NO MS511 41 As required Power steering fluid PSF 3 0 75 0 8 liter 0 79 0 84 qts Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 p...

Page 488: ...mponents 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 490: ...gs 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 ...

Page 491: ...nd 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 2 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 492: ...mn and shaft assembly 5 Installation is the reverse of removal 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 3 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 493: ... 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 4 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 494: ...rt 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 5 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 495: ...eful 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 6 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 496: ...linder 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 ...

Page 497: ...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 defe...

Page 498: ...ce 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 9 of 14 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 499: ...ng 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 10 of 14 24 04 2008 http www hmaservice...

Page 500: ... 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 11 of 14 24 04 2008 http www hmaservice...

Page 501: ...ed 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 12 of 14 24 0...

Page 502: ...stallation 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 13 of 14 24 04 2008 http w...

Page 503: ...tance 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 se...

Page 504: ...ring 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 505: ...UBE 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 6 Installation is the reverse of removal Page 1 of 3 24 04 20...

Page 506: ...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 7 Installation is the reverse of removal 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 Aft...

Page 507: ...or 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...

Page 508: ...g 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 509: ...re 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 1 of 8 24 04 2008 http www...

Page 510: ...nsion 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 2 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 511: ...Y 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 3 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print...

Page 512: ... 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 4 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 513: ...trol 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 5 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 514: ...heck 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...

Page 515: ...k 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 7 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 517: ...tioning 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 518: ... lubricant vapor can irritate your eyes nose or throat Be careful when connecting service equipment Do not breathe refrigerant or vapor 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 bat...

Page 519: ...G 2 7 V6 DOHC Heating Ventilation Air Conditioning General Information Special Service Tools SPECIAL TOOLS Tool Number and name Illustration Use 09977 29000 Pressure plate bolt remover Removal and installation of pressure plate Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 520: ...Heating Ventilation Air Conditioning General Information Components and Components Location SELF DIAGNOSIS 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 co...

Page 521: ... two 4 Checking each error code 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 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 522: ...door potentiometer and A C control assembly 20 Defective temp door potentiometer Temp door potentiometer 21 Open or shorted mode door potentiometer Harness or connector between mode door potentiometer and A C control assembly 22 Defective mode door potentiometer Mode door potentiometer No Item Failure FAIL SAFE Function 1 IN CAR temperature sensor Open Short 25 C alternate value control 2 Ambient ...

Page 523: ...Heating Ventilation Air Conditioning General Information Components and Components Location SELF DIAGNOSIS 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 co...

Page 524: ... two 4 Checking each error code 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 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 525: ...door potentiometer and A C control assembly 20 Defective temp door potentiometer Temp door potentiometer 21 Open or shorted mode door potentiometer Harness or connector between mode door potentiometer and A C control assembly 22 Defective mode door potentiometer Mode door potentiometer No Item Failure FAIL SAFE Function 1 IN CAR temperature sensor Open Short 25 C alternate value control 2 Ambient ...

Page 526: ...ant capacity 2 A C Fuse 3 Magnetic clutch 4 Compressor 5 Triple pressure switch 6 A C switch 7 Thermistor 8 Wire harness Add refrigerant Replace Replace Replace Replace Replace Replace Replace No cool comes out 1 Refrigerant capacity 2 Refrigerant pressure 3 Drive belt 4 Magnetic clutch 5 Compressor 6 Triple pressure switch 7 Thermistor 8 A C switch 9 Heater control assembly 10 Wire harness Add re...

Page 527: ...mode control Heater control assembly cable door Replace No condenser fan operation 1 ECU IG Fuse 2 Fan motor 3 Engine and ECT ECU 4 Wire harness Replace Replace Replace Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 528: ...unctioning refrigeration system Gauge reading Low pressure side 0 15 0 25 MPa 21 8 36 3 psi 1 5 2 5 kgf cm High pressure side 1 37 1 57 MPa 199 228 psi 14 16 kgf cm 2 Moisture present in refrigeration system Symptom seen in refrigeration system Probable cause Diagnosis Remedy During operation pressure on low pressure side sometimes become a vacuum and sometime normal Moisture entered in refrigerat...

Page 529: ...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 refrigeration system Probable cause Diagnosis Remedy Pressure low in both low and high pressure sides Frost on tube from receiver to unit Refrigerant flow obstructed by dirt in drier Condenser clogge...

Page 530: ... gas leakage from expansion valve replace expansion valve 6 Refrigerant overcharged or insufficient cooling of condenser Symptom seen in refrigeration system Probable cause Diagnosis Remedy Press too high on both low and high pressure sides Unable to develop sufficient performance due to excessive Insufficient cooling of condenser Excessive refrigerant in cycle refrigerant overcharged Condenser co...

Page 531: ... Evacuate air and charge new refrigerant 8 Expansion valve improperly Symptom seen in refrigeration system Probable cause Diagnosis Remedy Pressure too high on both low and high pressure sides Frost or large amount of dew on piping on low pressure side Trouble in expansion valve Excessive refrigerant in low pressure piping Expansion valve opened too wide Check expansion valve Replace if defective ...

Page 532: ...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 Air conditioning refrigerant or lubricant vapor can irritate your eyes nose or throat Be careful when connectin...

Page 533: ...ow 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 Air conditioning refrigerant or lubricant vapor can irritate your eyes nose or throat Be car...

Page 534: ... 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 overcharg...

Page 535: ...pacity Pressure relief valve Voltage Swash plate HS 15 140 160cc Operating pressure 35 42 2kg cm D C 12 8 0 2V Magnetic clutch Voltage wattage Torque D C 12 8 0 2V Max 54W Min 4 4kg m Refrigerant capacity R 134a 600 25g Triple pressure switch High pressure ON 32 0 2 0kg cm OFF 26 0 2 0kg cm Middle pressure ON 18 0 0 8kg cm OFF 14 0 1 2kg cm Low pressure ON 2 3 0 25 0 29kg cm OFF 2 0 0 2kg cm Therm...

Page 536: ... 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 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 539: ...sconnecting 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 fro...

Page 540: ... 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 shi...

Page 541: ...r 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 3 of 4 24 04 ...

Page 542: ...nd 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 4 of 4 24 04 2008 http www hmaservice co...

Page 543: ...ely 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 an...

Page 544: ...t 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 compre...

Page 545: ...t 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 547: ...le 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 548: ...e 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 24 04 2008 http www hmaservice com viewe...

Page 549: ...ON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Air conditioning 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 CHARACTERISTICS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 550: ... Ventilation Air Conditioning Air conditioning 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 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 24 04 2008 http www hmaservice...

Page 551: ...ning 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 552: ... 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 O...

Page 553: ... GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Air conditioning System Ambient sensor Repair procedures INSPECTION 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 554: ...m 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 555: ...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 SENSOR OUTPUT A ON time on 5sec B OFF time off 0sec Condition...

Page 556: ...ith 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 ...

Page 557: ... Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Heater Heater Unit Components and Components Location COMPONENT LOCATION COMPONENTS Page 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 559: ...egative 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 1 of 5 24 04 2008 http www hmaservice com viewer content as...

Page 560: ...emove the steering lower and upper shroud 11 Remove the multi function switch 12 Remove the crash pad under cover for the driver side Page 2 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 561: ...oving 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 3 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 562: ...he glove box lamp connector and the lamp 21 Remove the main crash pad mounting bolt 22 Remove the main crash pad Page 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 563: ...ion is the reverse of the removal 23 Remove the heater unit mounting nut 24 Remove the heater unit INSTALLATION Page 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 564: ...matic 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 Mode X X WARM COOL VCC F B SENSOR GND Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 565: ...r Description and Operation DESCRIPTION Operating temp 30 C 80 C Operating voltage DC 9V 16V Rated voltage DC 12V Rated load 4kgf cm Rated voltage DC 12V 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 24 04 2008 http www hmaservice com viewer content asp Is...

Page 566: ...tuator 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 567: ...ter 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 568: ...matic 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 Mode X X VENT DEF VCC F B SENSOR GND Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 569: ...iption and Operation DESCRIPTION Operating temp 30 C 80 C Operating voltage DC 9V 16V Rated voltage DC 12V Rated load 4kgf cm Rated voltage DC 12V 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 24 04 2008 http www hmaservice com viewer content asp IsPrint t...

Page 570: ...tuator 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 571: ...ter 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 572: ...Air Conditioning Blower Schematic Diagrams TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Schematic Diagrams CIRCUIT DIAGRAM Page 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 575: ... Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Unit Components and Components Location COMPONENT LOCATION COMPONENTS Page 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 577: ...ay 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 s...

Page 578: ...4 Replace the air filter with a new one 5 Installation is the reverse of the removal Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 579: ...ioning 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 580: ...ation DESCRIPTION Item Speccifications Type DC ferrite 20 C or 68 F Rated voltage DC 12 volts No load speed Min 3300rpm No load current Max 3 0A Rated load 5 0kgf cm Speed in rated load 2900 250rpm Current in rated load Continuous Insulation resistance Min 1MΩ Rotation direction viewed from output Mtr shaft CCW Operation temp range 30 80 Page 1 of 1 24 04 2008 http www hmaservice com viewer conten...

Page 581: ... Motor Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Motor Components and Components Location COMPONENT LOCATION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 582: ...HC Heating Ventilation Air Conditioning Blower Blower Motor Repair procedures TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Motor Repair procedures INSPECTION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 583: ...lower 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 584: ... 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 Rated voltage DC 12V Operation voltage range DC 10V DC 15V Rated load current DC 12V 25A Motor lord Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum ...

Page 585: ... Relay Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Relay Components and Components Location COMPONENT LOCATION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 586: ...tilation 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 587: ...6 DOHC Heating Ventilation Air Conditioning Blower Power Transistor Description and Operation DESCRIPTION Rated voltage DC 12V 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 588: ...sistor Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Power Transistor Components and Components Location COMPONENT LOCATION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 589: ...er 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 590: ...g Blower Blower Resistor Description and Operation DESCRIPTION Rated voltage DC 12V 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 591: ...sistor Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Resistor Components and Components Location COMPONENT LOCATION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 592: ...fter removing the resistor TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Resistor Repair procedures TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Blower Resistor Repair procedures INSPECTION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 593: ...atic 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 594: ...IBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Intake Actuator Description and Operation DESCRIPTION Operating temp 30 C 80 C Operating voltage DC 9V 16V Rated voltage DC 12V Rated load 4kgf cm Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 595: ...tuator Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Intake Actuator Components and Components Location COMPONENT LOCATION Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 596: ... 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 597: ...o 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 1 of 3 24 04 200...

Page 598: ...WIRING DIAGRAM Page 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 600: ...e 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 t...

Page 601: ...trol Panel Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Blower Control Panel Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 602: ...Conditioning Controller Schematic Diagrams TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Controller Schematic Diagrams CIRCUIT DIAGRAM Page 1 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 606: ...AMB SENSOR 4 POWER TR B 4 EVA SENSOR 5 POWER TR C 5 6 6 7 HUMDITY 7 8 8 SENSOR REF 5V 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 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 OUTP...

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Page 608: ...ound 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 ...

Page 609: ...emperatureis 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 CONTROL A Display OFF AUTO OFF 1 A C ON OFF OFF SW AND SYSTEM OPERATION A C A C ON OFF MANUAL CONTROL O...

Page 610: ...ype 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 OFF SW AND SYSTEM ...

Page 611: ...aged 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 SW AND SYSTEM OPERA...

Page 612: ...sor it will gradually correct the incar temperature value 1 C UP 4sec delay 1 C DOWN 4sec delay AMB temperature correction Upon detecting rapid changes of temperature from the AMB sensor it will gradually correct the ambient temperature value 1 C UP 3min delay 1 C DOWN 4sec delay Photo correction Upon detecting rapid changes of photo intensity from the PHOTO sensor it will gradually correct the ph...

Page 613: ... set temperatureand the input signal from each sensor When selection the AUTO SW the compressor is controlled to ON OFF When selection the DEF SW the compressor is controlled to ON Compressor clutch on off control based on refrigerant temperature If EVAP sensor temperature is below than 0 5 C the compressor will be ON and the temperature is 3 C or higher with the compressor OFF MAX HOT When select...

Page 614: ...within the standard value the system will output a HI signal 3V the FATC When IGN 2 ON the AQS assembly will be preheated for 34 5 5seconds During the preheating AQS will output 0V ground REC mode Corresponding to the signal from the AQS it will control the INTAKE door as follows toprevent the inflow of harmful gas in FATC IGN 2 ON It will check circuit break on the AQS assembly s signal line for ...

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Page 616: ...Controller Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Heating Ventilation Air Conditioning Controller Manual Controller Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 617: ...er 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 Symptoms Causes How to check When IG is ON memory function error occurs Battery power supply error Check voltage of battery after turning off IG If 10V and more check FATC connector a...

Page 618: ... How to check When light switch is ON partial error occurs in back light Light bulb lighting error in FATC When light switch is ON entire error occurs in back light Light power supply error Measure voltage of tail light shown in the above figure after switching on light If 10V and more check FATC connector and if no problem measure signal voltage of reostart shown in the above figure If 8V and mor...

Page 619: ...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 BLOWER CHECK Symptoms Causes How to check Amount of wind is wrong at manual selection of blower Power TR error Check voltage of blower motor s both ends Level 1 3 8V Level 2 5 2V Level 3 6 5V Level 4 7 9V Level 5 9 2V Level 6 10 6V Lev...

Page 620: ...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 AIR CONDITIONER CHECK Symptoms Causes How to check Wind of air conditioner isn t discharged into vehicle despite switching on air conditioner Signal output error of air conditioner Switch on air conditioner an...

Page 621: ...r 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 insi...

Page 622: ...toms Causes How to check Specific mode isn t selected Signal transmission error of selected mode Measure voltage of selected mode wiring without separating connector linked with actuator If 8V and more check the inside of controller Mode actuator running error If 1V and less at measuring in the above method check mode actuator and wiring state Mode selection is impossible Internal error of mode ac...

Page 623: ...ircuit In the case of disconnection or short circuit as a result of self diagnostic substitute control is carried out as follows ERROR DIAGNOSTICS TEMP CHECK 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 Symptoms Causes How to check Temp actuator running error Power supply error in temp actuator After altering 17 C to 32 C and advers ...

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Page 625: ...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 troubleshoot...

Page 626: ...put 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 connecto...

Page 627: ...t tool PAB SAB 0957A 38100 DAB BPT 0957A 38500 0957A 38200 Dummy Simulator to check the resistance of each wiring harness Dummy adapter PAS SAB 0957A 38300 DAB BPT 0957A 1C000 0957A 38100 Deployment adapter Use with deployment tool 0957A 38500 Deployment adapter Use with deployment tool 0957A 38300 Dummy adapter Use with dummy 0957A 1C000 Dummy adapter Use with dummy Page 1 of 1 24 04 2008 http ww...

Page 628: ...ver 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 ...

Page 629: ...ng bar 45 Driver satellite sensor Low Input 46 Passenger satellite sensor Low Input 47 Not used 48 Not used 49 Not used 50 Not used DIAGNOSTIC TROUBLESHOOTING FLOW Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 630: ...03 G 2 7 V6 DOHC Restraint Supplemental Restraint System Control Module SRnodeM 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 co...

Page 631: ... 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 lam...

Page 632: ...detected 1 06Ω R 1 80Ω 3 40Ω R 6 70Ω Tolerance band Fault may or may not be detected R 0 4Ω Resistance too low Fault definitely detected 1 6Ω R 2 8Ω Resistance whithin tolerance Definitely no fault detected R 5 4Ω Resistance too high Fault definitely detected 0 4Ω R 1 6Ω Tolerance band Fault may or may not be detected Page 3 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true i...

Page 633: ...2 8Ω R 5 4Ω Page 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 634: ...M 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 635: ...sistance too high B1368 Passenger seat belt prestensioner PBPT Resistance too low B1369 Passenger seat belt prestensioner PBPT Short to GND B1370 Passenger seat belt prestensioner PBPT Short to Battery B1378 Driver side airbag DSAB Resistance too High B1379 Driver side airbag DSAB Resistance t0o Low B1380 Driver side airbag DSAB Short to GND B1381 Driver side airbag DSAB Short to Battery B1382 Pas...

Page 636: ...ight side of passenger s seat DTC B1111 B1112 Battery voltage too high Vbaft 19 2V Battery voltage too low Vbaft 7 2V CIRCUIT DESCRIPTION INSPECTION PROCEDURE 1 Preparation 1 Disconnect the negative terminal cable from the battery and wait at least 30 seconds 2 Remove the DAB module 3 Disconnect the connectors of the PAB left and right side airbags belt pretensioners and satellite sensors 4 Discon...

Page 637: ...e airbag belt pretensioner and satellite connectors 4 Connect the SRSCM connector 5 Turn the ignition switch ON DTC B1348 DAB short to ground B1354 PAB short to ground B1363 DBPT short to ground B1369 PBPT short to ground B1380 DSAB short to ground B1384 PASB short to ground Page 3 of 34 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 638: ... sensor Clock spring SRSCM Wire harness WIRING DIAGRAM INSPECTION PROCEDURE 1 Preparation 1 Disconnect 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 airbag space belt pretensioner and satellite sensor 4 Disconnect the connector of the SRSCM Place the DAB with the front surface facing upward 2...

Page 639: ...nnector 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 5 of 34 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 640: ...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 ...

Page 641: ...this time but they are not relevant to this procedure 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 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 H...

Page 642: ... Hi Sacn Pro check for DTCs There is no DTC 10 Check the SABs squib PREPARATION CHECK HINT Codes other than these ones may be output at this time but they are not relevant to this checking procedure A Turn the ignition switch to LOCK B Disconnect the negative terminal cable from the battery and wait for 30 seconds C Connect the SAB connector D Connect the negative terminal cable from the battery a...

Page 643: ...t for 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 the Hi Scan Pro check for DTCs There is no DTC 12 Check the Satellite sensors PREPARATION A Turn ignition switch to LOCK B Disconnect negative terminal cable from the battery and wait at l...

Page 644: ...econds D Turn the ignition switch to ON and wait at least 30 seconds E Using the Hi Scan Pro check for DTCs There is no DTC 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 B1349 DAB short to battery B1355 PAB short ...

Page 645: ...SRSCM malfunction DAB squib PAB squib DSAB or PSAB squib BPT squib Satellite sensor Wire harness WIRING DIAGRAM INSPECTION PROCEDURE 1 Preparation 1 Disconnect 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 airbag belt pretensioner and satellite sensor 4 Disconnect the connector of the SRSCM P...

Page 646: ...uit 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 12 of 34 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 pr...

Page 647: ... 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 13 of 34 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 648: ...e SRSCM and the satellite sensor G Connect negative terminal cable to battery and wait at least 30 seconds 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 E Using the Hi Scan Pro check for DTCs...

Page 649: ...ector D Connect the negative terminal cable from the battery and wait for 30 seconds 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 ON and wait for 30 seconds E Using the Hi Sacn Pro check for DTCs There is no DTC 10 Check t...

Page 650: ... output at this time but they are not relevant to this procedure A Turn the ignition swich to LOCK B Disconnect the negative terminal cable from the battery and wait for 30 seconds C Connect the BPTs connector D Connect the negative terminal cable from the battery and wait for 30 seconds A Turn the ignition switch to ON and wait for 30 seconds B Clear the malfunction code stored in the memory with...

Page 651: ... and wait at least 30 seconds B Clear the malfunction code stored in memory with Hi scan 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 E Using the Hi Scan Pro check for DTCs There is no DTC 13 Check the Clock spring PREPARAION CHECK Turn the ignition switch ON and measure the voltage between the DAB high side and the b...

Page 652: ... Clock spring malfunction SRSCM malfunction Clock spring SRSCM Wire harness WIRING DIAGRAM 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 Page 18 of 34 24 04 20...

Page 653: ...insert plastic that is attached to the diagnosis checker into the SRSCM connector 3 Check the DAB squib PREPARATION CHECK 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 A Turn the ignition switch to ON and wait for at least 3...

Page 654: ... and low 1 80 Ω R 3 40 Ω Before checking the resistance you have to insert the shorting bar insert plastic that is attached to the diagnosis checker into the SRSCM connector DTC B1352 B1353 PAB resistance too high R 5 4 Ω PAB resistance too low R 0 4 Ω CIRCUIT DESCRIPTION DTC Detecting Condition Trouble Area Too high or low resistance between PAB high wiring harness and PAB low wiring harness of s...

Page 655: ...ont surface facing upward 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 Before checking the resistance you have to insert the shorting bar insert plastic that is attached to the diagnosis checkerinto the SRSC...

Page 656: ...inal cable to the battery and wait for 30 seconds 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 DTC B1378 B1379 B1382 B1383 DSAB Resistance too...

Page 657: ...reparation 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 the SAB resistance PREPARATION Page 23 of 34 24 04 2008 http www hmaservice co...

Page 658: ...e may be output at this time but they are not relevant to this procedure A Turn the ignition switch to LOCK B Disconnect the negative terminal cable from the battery and wait for 30 seconds C Connect the SAB connector D Connect the negative terminal cable to the battery and wait for 30 seconds A Turn the ignition switch to ON and wait for at least 30 seconds B Clear the malfunction code stored in ...

Page 659: ...BPT low wiring harness of squib BPT squib BPT malfunction SRSCM malfunction SRSCM Wire harness WIRING DIAGRAM 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 Pag...

Page 660: ... and the BPT low 1 6 Ω R 2 8 Ω Before checking the resistance you have to insert the shorting bar insert plastic that is attached to the diagnosis checker into the SRSCM connector 3 Check the BPT squib PREPARATION CHECK A Turn the ignition switch to LOCK B Disconnect the negative terminal cable from the battery and wait for 30 seconds C Connect the BPT connector D Connect the negative terminal cab...

Page 661: ...ition switch to ON and wait for 30 seconds E Using Hi Scan Pro check the DTC There is no DTC DTC B1400 Satellite left side defect B1403 Satellite right side defect B1409 Satellite left communication error B1410 Satellite right communication error CIRCUIT DESCRIPTION WIRING DIAGRAM INSPECTION PROCEDURE 1 Preparation 1 Disconnect the negative terminal cable from the battery and wait at least 30 seco...

Page 662: ...ECK A Turn the ignition switch to LOCK B Disconnect the negative terminal cable from the battery and wait for 30 seconds C Connect the satellite connector D Connect the negative terminal cable to the battery and wait for 30 seconds 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 C Turn the ignition switch to LOC...

Page 663: ...n short to Battery Passenger seat belt switch short to GND CIRCUIT DESCRIPTION INSPECTION PROCEDURE 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 29 of 34 24 04 2008 htt...

Page 664: ...e 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 CHECK A Connect the negative terminal cable to the battery B Turn the ignition switch to ON A Measure voltage at the harness side connector of the SRSCM Voltage 9 16 V Page 30 of 34 24 04 2008 http www hmaservice com viewer cont...

Page 665: ... 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 t...

Page 666: ...SPECIFICATION Page 32 of 34 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 667: ...4Ω R 1 6Ω 2 8Ω R 5 4Ω Tolerance band Fault may or may not be detected INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE 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 Resista...

Page 668: ...lite 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 ...

Page 669: ...rocedures 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum...

Page 670: ...er be driven DISPOSAL PLAN 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 residen...

Page 671: ...eployment 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 deploy...

Page 672: ...5 Be sure to always wash your hands after completing this operation Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 673: ...bag Module Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Restraint Airbag Module Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 674: ... 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 i...

Page 675: ...le 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 shoul...

Page 676: ...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 a...

Page 677: ...Page 4 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 678: ...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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 679: ...ployed 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 serious personal injury 7 Whenever the PAB is deployed it should be replaced with a new one assembled wit...

Page 680: ...e passenger airbag module is integrated with the crash pad therefore the crash pad must be replaced if the PAB deploys Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 681: ...mble 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 Never attempt to measure the circuit resistance of the airbag module squib even if you ar...

Page 682: ...secure from battery Wait at least 30 seconds after disconnecting the battery cable before doing any further work 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 1 24 04 2008 http www hmaservice com viewer content a...

Page 683: ...ner BPT Repair procedures REMOVAL 1 Disconnect the battery negative terminal Wait at least 30 seconds 2 Remove the door scuff trim 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1...

Page 684: ... 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 685: ...Trim removal 09853 31000 Headliner clip remover Removal of the headliner clip 09861 31100 Sealant cut out tool Cutting the sealant of the windshield use with 09861 31200 09861 31200 Sealant cutting blade Cutting the sealant of the windshield use with 09861 31100 09861 31300 Sealant gun Application of the sealant to the windshield 09861 31400 Glass holder Removal and installation of the windshield ...

Page 686: ...tor s clutch slipping force Adjust Increased sunroof sliding resistance or interference of sunroof with drive cables weatherstrip etc due to maladjustment of sunroof Adjust or replace Noise in motor clutch slipping noise from motor when sunroof is fully opened or closed is not an unusual noise Incorrect engagement of motor pinion with drive cable Check pinion installation and retighten motor Worn ...

Page 687: ...fit door Adjust Improper clearance between door glass and division channel Adjust Deformed door Repair or replace Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 688: ... 31 7 8 12 16 Tailgate Tailgate hinge to body Tailgate hinge to tailgate Tailgate latch mounting bolt Tailgate striker mounting bolt 22 27 7 9 7 11 9 14 220 270 70 90 70 110 90 140 16 19 5 5 7 5 8 6 5 10 Hood Hood hinge to body Hood hinge to hood Hood latch to body Gas lifter mounting bolt 22 27 22 27 7 11 9 14 220 270 220 270 70 110 220 270 16 19 5 16 19 5 5 8 16 19 5 Seat Front seat to floor Bol...

Page 689: ...eat belt buckle mounting bolt 40 55 40 55 40 55 400 550 400 550 400 550 29 40 29 40 29 40 Sunroof Sunroof lid panel mounting Nut Sunroof assembly mounting Bolt 7 9 7 11 70 90 70 110 5 6 5 5 8 Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 690: ...ior fender Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Exterior fender Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 691: ...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 5 Installation is the reverse of the removal In order to prevent the fender mounting bolt area from forming rust apply tape sealer between the fender and the bodypanel FENDER GARNISH 1 Rem...

Page 692: ... is the reverse of the removal 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 693: ...erior hood Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Exterior hood Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 694: ...nal 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 1 24 04 2008 http www hmaser...

Page 695: ...and Exterior Exterior tail gate Repair procedures REMOVAL AND INSTALLATION 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 1 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 696: ...acing 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 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 697: ...st the tailgate hinges rightward or leftward as necessary to equalizer the gap between the tailgate and body Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 698: ...ND INSTALLATION 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 1 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_titl...

Page 699: ... 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 2 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 700: ...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 3 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 701: ...tside 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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 702: ...ER 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 5 of 5 24 04 2008 http www hmas...

Page 703: ...ior mirror Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Exterior mirror Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 704: ...iew 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 3 Installation is the reverse of removal INSIDE REARVIEW MIRROR 1 Remove the rearview mirror 2 Installation is the reverse of removal DISASSEMBLY Wear gloves to remove and install the mirror holder Page 1 of 2 24 04 2008 http www hmaservi...

Page 705: ...rying 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 3 Installation is the reverse of removal Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 706: ...r Sun Roof Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Sun Roof Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 707: ...f 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 708: ...ad 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 1 of 8 24 04 2008 http www...

Page 709: ...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 2 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 710: ... 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 3 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 711: ...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 4 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 712: ...he 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 5 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 713: ... connestor ON VEHICLE INSPECTION 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 6 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 714: ... 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 7 of 8 24 04 2008 http www hmaservice com viewer content asp IsPrint...

Page 715: ...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 ...

Page 716: ...EA 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 M...

Page 717: ...Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 718: ...oof 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 ...

Page 719: ...nt Continuity 2 Ground Sunroof switch is in the close position Continuity 3 Ground Sunroof switch is in the open position Continuity 4 Ground Constant Battery voltage 6 Ground Ignition switch ON Battery voltage 7 Ground Sunroof switch is in the tilted up position Continuity 8 Ground Sunroof switch is in the tilted down position Continuity M99 3 Ground Constant Continuity 1 2 Apply the battery volt...

Page 720: ...or console Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Interior console Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 721: ...nd Exterior Interior console Repair procedures REMOVAL AND INSTALLATION 1 Remove the front seat 2 Remove the console upper cover 3 Remove the console front mounting screws 4 Remove the floor console 5 Installation is the reverse of removal Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 722: ...NSTALLATION 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 4 Remove the console assembly 5 Remove the air bag module Page 1 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_ti...

Page 723: ...ws 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 2 of 5 24 04 2008 http www hmaservice com viewer content asp IsP...

Page 724: ...nel 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 3 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 725: ... 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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 726: ...18 Remove the crash pad 19 Installation is the reverse of removal and connect all connectors securely Page 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 727: ...erior 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 728: ...pair procedures REMOVAL AND INSTALLATION DOOR SCUFF TRIM AND STEP PLATE TRIM 1 Remove the door scuff 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 1 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 729: ... 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 2 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 730: ...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 3 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 731: ...AGE BOARD FRONT TRIM LUGGAGE SIDE TRIM 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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 732: ... 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 6 Installation is the reverse of removal Page 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 733: ...ield 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 734: ...ove 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 1 of 5 24 04 2008 http www hmaservice com view...

Page 735: ...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 m...

Page 736: ...utside 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 3 of 5 24 04 2008 http www hmaservice com vie...

Page 737: ...ealant 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 4 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 738: ...n 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 ...

Page 739: ...gate glass Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Interior tailgate glass Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 740: ...d 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...

Page 741: ...the edge of the glass Part A Remarks Upper 23 5mm Glass molding sub Side Lower Apply the adhesive within 5 minutes after applying the primer to the glass 7 Apply a light coat of body primer to the original sealant remaining around the window opening flange The glass should be installed within 5 minutesafter you apply the primer 8 Use suction cups or the special tool 09861 31400 lower the glass ove...

Page 742: ...ply sealant 12 Install the removed parts 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 a...

Page 743: ...rter glass Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Interior and Exterior Interior quarter glass Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 744: ... 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 sm...

Page 745: ...inats 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 circumf...

Page 746: ...ll the glass to the body within five minutes 6 Install the guarter fixed glass 7 Install the removed parts Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 747: ...ont 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 748: ...e 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrin...

Page 749: ...e 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 9 Installation is the reverse of removal Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 750: ...ear 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 751: ... 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 1 of 2 24 04 2008 http www hmaservice com viewer content as...

Page 752: ...ove 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 8 Installation is the reverse of removal Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 753: ... 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 754: ...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...

Page 755: ... 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 756: ...e 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 5 Installation is the reverse of removal Page 1 of 2 24 04 2008 http www hmaservice com viewer content asp...

Page 757: ...om the rear seat cushion Tightening torque 17 26 Nm 170 260 kg cm 12 19 lb ft 2 Remove the rear seat belt buckle 3 Installation is the reverse of removal Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 758: ...everely 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 ano...

Page 759: ...s 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 2 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 760: ...se 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 P...

Page 761: ... 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 ...

Page 762: ...fuse 10A blown Bulb burned out Brake fluid level warning switch faulty Parking brake switch faulty Wiring or ground faulty Check for short and replace fuse Replace bulb Check switch Check switch Repair if necessary Open door warning lamp does not light No 18 fuse 10A blown Bulb burned out Door switch faulty Wiring or ground faulty Check for short and replace fuse Replace bulb Check switch Repair i...

Page 763: ...elay Check switch Repair if necessary Hazard warning lamps do not operate No 7 fuse 10A blown Body control module faulty Hazard switch faulty Hazard relay faulty Wiring or ground faulty Replace fuse and check for short Check body control module Check switch Replace relay Repair if necessary Flasher rate too slow or too fast Lamps wattages are smaller or larger than specified Defective body control...

Page 764: ...CHART 1 Page 3 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 766: ...CHART 2 CHART 3 Page 5 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 767: ...CHART 4 Page 6 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 769: ...CHART 5 Page 8 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 770: ...Page 9 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 771: ...CHART 6 Page 10 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 772: ...CHART 7 CHART 8 Page 11 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 773: ...CHART 9 CHART 10 Page 12 of 15 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 774: ...motor faulty Wiring or ground faulty Check body control module Check switch Check motor Repair if necessary Symptom Possible cause Remedy No windows operate from the main switch on the driver s door No 19 fuse 30A blown Poor ground Defective power window main switch Open circuit in wires or loose or disconnected connector Check for short and replace fuse Clean and retighten the ground terminal mou...

Page 775: ...r the harness or replace a door key cylinder and the tailgate key cylinder switch Replace the body control module Engine does not start in disarm state Burglar alarm relay faulty Damage or disconnected wiring of burglar alarm relay activation circuit Malfunction of the body control module Replace the burglar alarm relay Repair the harness Replace the body control module There is no alarm when as a...

Page 776: ...tion Ensure normal door opening closing by using the door key and register the code again Faulty keyless entry circuit Check the BCM connector and the harness between the BCM and the door lock actuator Repair the connector or the harnese Faulty receiver Check the receiver output using the oscilloscope Replace the receiver Faulty body control module Replace the faulty control unit and module If cen...

Page 777: ...gh 1A Relay load Low 1A Relay load Passing 1A Relay load Lighting 1A Relay load 6 6 0 5A Lamp load Low High 4 5A Motor load Int 0 22 0 05A Relay load Lock Max 28A Motor load 4 5A Motor load 4A Motor load Max 25mA Rear wiper 0 2A Relay load Rear washer 4A Motor load 1A Relay load Warning lamps Bulb wattage W Color High beam Low fuel Turn signal LH RH Battery charge Oil pressure Air bag Parking brak...

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Page 779: ...Rear combination lamps Tail stop lamp Back up lamp Turn signal lamp 8W 27W 27W 27W Side marker lamp 5W Luggage lamp 5W Center high mounted stop lamp Internal type 2 4W LED External spoiler type 3 5W LED Overhead console lamp 10W x 2 License plate lamp 5W x 2 Page 3 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 780: ...ad test Torque current when parking DC 12V DC 10 15V Min 1MΩ Low 44 52 rpm 3 5A or less High 64 78 rpm 4 5A or less Low 39 47 rpm 5 5A or less High 56 68 rpm 7 0A or less Low 28Nm 24A or less High 23Nm 28A or less Windshield washer Motor type Pump type Rated voltage Discharge pressure Flow rate Current Overload capacity Continuous operation With water Without water Racing DC ferrite magnet Centrif...

Page 781: ...Audio Unit Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Audio Audio Unit Components and Components Location COMPONENTS Page 1 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 785: ...ve the audio assembly 4 Installation is the reverse of removal 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...

Page 786: ...c is inserted correctly in the CD player Make sure the disc is not scratched or damaged Er8 Tape deck error Tape eject error After resetting the audio push the eject button If tape is not ejected consult your hyundai dealer HHH Temperature is too high Fault code will reset automatically when the temperature returns to normal no CD No disc in magazine No CD magazine in the auto change Insert disc i...

Page 787: ...ion switch Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Multifunction switch Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 788: ...le 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 fr...

Page 789: ...ion switch assembly 5 Installation is the reverse of removal 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 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 790: ...WASHER SWITCH M01 1 REAR WIPER AND WASHER SWITCH M01 1 Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 791: ...embly 2 Installation is the reverse of removal 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 24 04 2008 http www hmaservice com viewer content asp IsPr...

Page 792: ...ption 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 793: ...ation TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Keyless Entry And Components and Components Location BODY CONTROL MODULE BCM Connector Terminal No Description A 1 NC 2 NC 3 Not used 4 ESPS IG1 5 SEAT BELT BUCKLE RH Page 1 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 794: ...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 E 1 NC 2 TAILGATE LOCK SW 3 ASSIST DOOR LOCK SW 4 ASSIST DOOR SW 5 Not used 6 TAILGATE SW 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 2 of 6 24 04 20...

Page 795: ...L SW RH 4 DOOR WARN G SW 5 TAIL SW 6 Not used 7 CODE SAVER 8 NC 9 HOOD SW 10 NC 11 IMMOBILIZER ANTENNA 2 12 EXPORT GND INPUT 13 TURN SIGNAL SW LH 14 AUTO LIGHT SW INPUT 15 NC 16 HEAD LAMP SW 17 FRONT FOG SW 18 HAZARD SW 19 REAR DEFOG SW 20 Not used 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 3 of 6 24 04 20...

Page 796: ... INTERIOR ILL 6 CLUSTER A BAG WARN G IND 7 DCT 8 DOOR AJAR 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 K 1 CIGAR LIGHTER 2 WIPER LOW 3 WIPER HI 4 BACKUP SW 5 AUDIO ACC 6 MULTI FUNCTION WASHER SW 7 BACKUP LAMP SW 8 START INHIBIT RELAY 9 SEAT HEATER SW IG2 10 JOINT MAIN 3 B 11 STOP SW B 12 IGN...

Page 797: ... 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 13 15A Stop lamp switch Burglar alarm horn relay 14 10A Left tail lamps 15 10A A C control module Blower relay 16 10A ECM Multi gauge unit TCM Vehicle speed sensor 17 10A Instrument ...

Page 798: ...garette lighter Outside mirror switch 24 15A Sunroof Power door lock unlock relay 25 20A Seat warmer 26 10A ABS control module TCS switch 27 10A Audio Digital clock 10 15A 20 30A Spare fuse Page 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 799: ...itch OFF ON INPUT Alternator voltage Voltage OUTPUT Start inhibitor Enable Disable FLASHER INPUT Turn signal switch LH OFF ON INPUT Turn signal switch RH OFF ON OUTPUT Turn signal lamp LH OFF ON OUTPUT Turn signal lamp RH OFF ON INPUT Hazard swtich OFF ON INPUT Hazard detection current Current LAMP INPUT Tail lamp switch OFF ON OUTPUT Tail lamp OFF ON INPUT Head lamp switch OFF ON INPUT Auto light...

Page 800: ...lgate with other key LOCK FOLING INPUT Driver s door lock switch LOCK UNLOCK INPUT Assist door lock switch LOCK UNLOCK OUTPUT Lock output OFF ON OUTPUT Unlock output OFF ON INPUT Folding switch OFF ON OUTPUT Folding output OFF ON OUTPUT Unfolding output OFF ON WIPER INPUT Front washer switch OFF ON INPUT Intermittent wiper switch OFF ON OUTPUT Intermittent wiper relay OFF ON INPUT Intermittent wip...

Page 801: ...switch OFF ON OUTPUT Rear widnow defogger OFF ON On starting state INPUT Crash sensor OFF ON On crash state OUTPUT Burglar alarm horn OFF ON MENU COMPOSITION 1 INPUT OUTPUT MONITORING 2 INPUT ACTUATION TEST 3 OUTPUT ACTUATION TEST NUMBER INPUT OUTPUT NAME OPERATION CONDITION 1 INPUT Turn signal switch LH Turn signal lamp LH 2 INPUT Turn signal switch RH Turn signal lamp RH 3 INPUT Hazard switch Ha...

Page 802: ...s turned off 4 When the hi scan is disconnected 5 When the actuation test is turned off by the hi scan timer NUMBER INPUT OUTPUT NAME OPERATION CONDITION 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 lam...

Page 803: ...ed 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 5 of 5 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 804: ...ark 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 linkag...

Page 805: ...eries 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 s...

Page 806: ...e 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...

Page 807: ... 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 ope...

Page 808: ...nguished 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 ...

Page 809: ...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 t...

Page 810: ...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 I...

Page 811: ...d 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 3 Alarm function 1 European countries Once armed should any door hood or the tailgate be opened then The alarm is given in the case where a door is opened with a key Ti...

Page 812: ...ons 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 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 At this time when the door is closed A The lock command is executed with 0 5 sec ON B Horn...

Page 813: ... 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 Af...

Page 814: ...ds 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 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 ala...

Page 815: ...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 t...

Page 816: ...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 LOC...

Page 817: ...ompartment 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 818: ...s 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 1 24 04 2008 http www hmaservice com viewer content asp...

Page 819: ...ctrical System Fuses And Relays Relay Box Passenger Compartment Components and Components Location COMPONENTS Fuse No Capacity Connection circuit 1 20A Ignition coil 2 7L Electronic chrome mirror 2 20A AMP 3 10A Back up lamp switch Transaxle range switch Cruise control module Stop Page 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 820: ...6 10A ECM Multi gauge unit TCM Vehicle speed sensor 17 10A Instrument cluster Power Pre excitation resistor DRL control module Generator 18 10A Room lamp Clock Audio Data link connector Multi gauge unit 19 30A Power window relay 20 15A Trunk lid switch 21 10A A C relay AQS sensor Head lamp relay DRL control module 22 10A Not used 23 15A Cigarette lighter Outside mirror switch 24 15A Sunroof Power ...

Page 821: ...ted 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 ...

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Page 823: ...uges 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 824: ...nt 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 825: ...essure of the tires to the specified level 2 Drive the vehicle onto a speedometer tester Use wheel chocks as appropriate 3 Check if the speedometer indicator range is within the standard values Do not operate the clutch suddenly or increase decrease speed rapidly while testing Tire wear and tire over or under inflation will increase the indication error Velocity Km h 20 40 60 80 100 120 140 Tolera...

Page 826: ...hometer 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...

Page 827: ... 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 bu...

Page 828: ...s 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 ...

Page 829: ...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 5 of 6 24 04 2008 http www hmaservice com view...

Page 830: ...astened Conductive 0Ω SEAT BELT WARNING LAMP Seat belt condition Warning lamp Fastened OFF Not fastened ON Page 6 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 831: ...ical 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 832: ...eous 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...

Page 833: ...ulti 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 834: ...Door Locks Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Power Door Locks Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 835: ... 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 1 Remove the door trim panel 2 Disconnect the 6P connector from the actuator 3 Check for continuity between the terminals in each switch position according to the table ...

Page 836: ... 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 1 Remove the door trim panel 2 Disconnect the 6P connector from the actuator 3 Check for continuity between the terminals in each switch position according to the table ...

Page 837: ...or Mirrors Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Power Door Mirrors Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 838: ... 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 839: ...rors Power out side mirror switch Repair procedures INSPECTION 1 Remove the power door mirror switch from the door trim panel 2 Check for continuity between the terminals in each switch position according to the table If continuity is not as specified replace the power door mirror switch Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 840: ...irrors 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 841: ...er Windows Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Power Windows Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 842: ... 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 843: ...ows 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 844: ...ch 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 846: ...he 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...

Page 847: ...he 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 ...

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Page 849: ...nents 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

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Page 851: ...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 WIPER AND INTERMITTENT VOLUME SWITCH M01 1 WASHER SWITCH M01 1 Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 pr...

Page 852: ...tening 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 4 Installation is the reverse of removal INSTALLATION 1 Install the wiper arm to the specif...

Page 853: ...ttery 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 termina...

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Page 855: ...epair 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum ...

Page 856: ...per Washer Components and Components Location TIBURON GK 2003 G 2 7 V6 DOHC Body Electrical System Rear Wiper Washer Components and Components Location COMPONENTS Page 1 of 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 857: ...edures 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 1 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print...

Page 858: ...l 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 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 859: ...K 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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 860: ...PECTION 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true im...

Page 861: ...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 4 Installation is the reverse of removal FRONT FOG LAMP 1 Disconnect the negative battery terminal 2 Remove the turn signal lamp and head lamp assembly Page 1 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint t...

Page 862: ...attery terminal 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 5 Installation is the reverse of removal CENTER HIGH MOUNTED STOP LAMP 1 Disconnect the negative battery terminal Page 2 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_titl...

Page 863: ...e battery terminal 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 5 Installation is the reverse of removal LUGGAGE LAMP 1 Disconnect the negative battery terminal 2 Detach the luggage lamp assembly from the luggage side trim with a flat tip ...

Page 864: ... SWITCH 1 Disconnect the negative battery terminal 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 4 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 865: ...ckering when the rheostat is turned it can be assumed that the rheostat is normal FRONT FOG LAMP SWITCH 1 Disconnect the negative battery terminal 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 5 of 6 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_...

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Page 867: ...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 h...

Page 868: ... 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 2 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 869: ...front fog lamp on without driver aboard The cut off line should be projected in the allowable range shaded region Page 3 of 3 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 870: ...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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 871: ... 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 Items Specifications Rated voltage DC 5V Operating current Max 1mA Detection illumination Tail lamp ON 23 1 3 4 Lux 1 77 0 08 V OFF 48 0 3 4 Lux 3 47 0 10 V Head lamp ON 6 2 1 4 Lux 0 63 0 06 V OFF 12 0 1 4 Lux 1 02 0 06 V P...

Page 872: ...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 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 873: ...ghts 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 1 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 874: ... module from engine compartment 2 Inspect the connector on wire harness side as shown Check For Test Connect Condition Test Specification Continuity 4 Ground Parking brake switch OFF Released No continuity ON Pull up Continuity 5 Ground Head lamp switch OFF No continuity ON Continuity 6 Ground Constant Continuity 9 Ground Dimmer passing switch Head light ON Continuity Head light OFF No continuity ...

Page 875: ...o voltage 7 Ground Constant Battery voltage 3 Ground Engine Stop No voltage Running Battery voltag 3 If circuit is not as specified refer to schematic diagram and inspect for short circuits Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 876: ...PTION 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 originalSMARTR...

Page 877: ...mber VIN stored in the ECM It can only be in virgin state once The ECM will allow starting on the second cycle of ignition Virgin state is exited when a VIN has successfully been taught by the BCM Learnt State Engine start is possible only when the received VIN from the BCM matches that stored in the ECM VIN has been deleted Page 2 of 4 24 04 2008 http www hmaservice com viewer content asp IsPrint...

Page 878: ...stored Virgin state is exited only after the VIN been learned Learnt State The BCM contains a VIN Neutral State The BCM is set to neutral state by issuing a Teaching ECM command The purpose of the neutral state is to allow the ECM to be set to neutral state The BCM neutral state expires 10 seconds after an ignition ON OFF cycle TEACHING PROCEDURES THE USER PASSWORD CAN BE IN THE STATUS LIMP HOME F...

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Page 880: ...h 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...

Page 881: ...DIAGNOSTIC TESTER Has the function BCM ECM and key diagnosis and change Page 2 of 2 24 04 2008 http www hmaservice com viewer content asp IsPrint true imgnum 1 print_title ...

Page 882: ...amming error P1805 EEPROM Inconsistent data of EEPROM Invalid write operation to EEPROM ECM fault No valid data from ECM after 3 attempts by ECM Invalid tester message or unexpected requests by tester STAND ALONE 2 7δ ENGINE 01 Untaught transponder Untaught transponder 02 Transponder communication error Transponder error due to a wrong code or bad read wrong transponder in field or more than one t...

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