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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > General Information > General Information > General Information, TIBURON(GK)
> 2003 > G 2.7 V6 DOHC > General Information > General Information > General Information

IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER DESCRIPTION


VEHICLE IDENTIFICATION NUMBER

1. Geographic zone
- K : Korea
2. Manufacturer
- M : Hyundai motor company
3. Vehicle type

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- H : Passenger
4. Vehicle line
- H : TIBURON
5. Model & Series
- L : STANDAD (L)
- M : DELUXE (GL)
- N : SUPER DELUXE (GLS)
- P : GRAND SALON
- R : SUPER GRAND SALON
6. Body type
- 6 : Coupe
7. Restraint system
- 3 : Drive side - Active belt and air bag
Passenger side - Active belt or passive belt
- 4 : Both side - Active belt and air bag
- 5 : Depowered - Air bag
8. Engine type
- D : Gas 2.0 DOHC
- F : Gas 2.7 V6
9. Check digit
- 0 ~ 9, X
10. Production year
- 3: 2003, 4 : 2004, 5 : 2005, 6 : 2006
11. Plant of production
- U : Ulsan (Korea)
12. Vehicle production sequence number
- 000001 ~ 999999
PAINT CODE
CODE

COLOR

NW

Noble White

EB

Ebony Black

VX

Samba Red

YY

Sunny Yellow

LS

Smart Silver

TS

Odd Purple

UC

Carbon Blue

MS

Mystic Teal

NR

Elm Green

XX

Exciting Blue

UE

Gold Savor

TW

New Silver

WN

Dark Navy Blue

AH

Amabile Rose

VZ

Triton Green

ENGINE IDENTIFICATION NUMBER

1. Engine fuel
- G : Gasoline

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

TRANSMISSION IDENTIFICATION NUMBER


MANUAL

1. Model
- L : M5GF1 (2.7 V6)
- J : M5BF2 (2.0 DOHC)
2. Production year
- 2 : 2002, 3 : 2003, 4 : 2004
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- N : 4.063
- 1873 : 4.056
4. Transmission production sequence number
- 000001 ~ 999999

AUTOMATIC

1. Model
- N : F4A42-2
- M : F4A42-1
2. Production year
- 2 : 2002, 3 : 2003, 4 : 2004
- 5 : 2005, 6 : 2006, 7 : 2007
3. Gear ratio
- N : 4.042
-Q : 4.407
4. Detailad classification
- CD : 2.0/2.7 Engine
5. Spare
6. Transmission production sequence number

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- 000000 ~ 999999

WARNING / CAUTION LABEL LOCATIONS

AIR BAG WARNING / CAUTION LABEL

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AIR BAG WARNING / CAUTION LABEL (CONT'D)

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WARNING / CAUTION LABEL (CON'T)


A : SRS INFORMATION
WARNING
Death or serious injury can occur.
Children 12 and under can occur.
The back seat is the safest place for children.
Never put a rear-facing child seat in the front.
Sit as far back as possible from the airbag.
Alway use seat belts and child restraints.

B : WARNING
SEE OWNER'S MANUAL
This car is equipped a side airbag for each front seat.
Do not use any accessory seat covers.
Use of other seat covers could reduce the effect of the system.
Do not install any accessories on the side or rear the side airbag.
Do not use excessive force on the side of the seal.

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For further information, see the owner's manual.

C : CAUTION
AIRBAG ESPE UNIT
Detach connector before unmounting. Assemble strictly according to manual instructions.

D : PASSENGER MODULE CAUTION


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

E : SUPPLEMENTAL RESTRAINT SYSTEM


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

EMISSION CONTROL LABEL


Emission Grop Identification

EXAMPLE :

A:

B:

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1. Model Year
- 4 : 2004
2. Manufacturer Subcode
- HYX : HYUNDAI MOTOR
3. Family Type
- V : Passenger car
4. Displacement
5. Sequence Characters

C:

1. Model Year
- 4 : 2004
2. Manufacturer Subcode
- HYX : HYUNDAI MOTOR
3. Family Type
- R : EVAP/ORVR
4. Canister Work Capacity
5. Sequence Characters

LIFT AND SUPPORT POINT

When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place
additional weight in the luggage area before hoisting . When substatial weight is removed from the rear of the vehicle the, center
of gravity may change and cam cause the vehicle to tip forward on the hoist.

Since each tire/wheel assembly weights approximately 30lbs 14kg), placing the front wheels in the luggage area can assist
with weight distribution.
Use the same support points to support the vehicle on safely stands.
1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimerers) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.

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TOWING
If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous.
- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
- The tow truck uses two pivoting arms that go under the tires (front or rear) and lift them off the ground. The other two wheels remain
on the ground.
If the vehicle cannot be transported by flat-bed, if should be towed with the front wheels off the ground. If due to damage, the vehicle
must be toward with the front wheels on the ground, do not following :
Manual Transmission
Release the parking brake.
Shift the transmission to neutral.
Automatic Transmission
Release the parking brake.
Start the engine.
Shift to [D] position, then [N] position.
Turn off the engine.

Improper towing preparation will damage the transmission. Follow the above procedure exactly. Follow the above
procedure exactly. If you cannot shift the transmission or start the engine (automatic transmission), your vehicle must be
transported on a flat-bed.
It is best to tow vehicle no farther than 19miles (30km), and keep the speed below 30mph (50km/h).
Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to support
the vehicle's weight.

FRONT :

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REAR :

TIGHTENING TORQUE TABLE OF STANDARD PARTS


Torque Nm (kg.cm, lb.ft)

Bolt nominal diameter


(mm)

Pitch (mm)

M5

Head Mark 4

Head Mark 7

0.8

3 ~ 4 (30 ~ 40, 2.2 ~ 2.9)

5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6

1.0

5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

9 ~ 11 (90 ~ 110, 6.5 ~


8.0)

M8

1.25

12 ~ 15 (120 ~ 150, 9 ~
11)

20 ~ 25 (200 ~ 250, 14.5 ~


18.0)

M10

1.25

25 ~ 30 (250 ~ 300, 18 ~
22)

30 ~ 50 (300 ~ 500, 22 ~
36)

M12

1.25

35 ~ 45 (350 ~ 450, 25 ~
33)

60 ~ 80 (600 ~ 800, 43 ~
58)

M14

1.5

75 ~ 85 (750 ~ 850, 54 ~
61)

120 ~ 140 (1,200 ~ 1,400,


85 ~ 100)

M16

1.5

110 ~ 130 (1,100 ~ 1,300,


80 ~ 94)

180 ~ 210 (1,800 ~ 2,100,


130 ~ 150)

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M18

1.5

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


116 ~ 130)

260 ~ 300 (2,600 ~ 3,000,


190 ~ 215)

M20

1.5

220 ~ 250 (2,200 ~ 2,500,


160 ~ 180)

360 ~ 420 (3,600 ~ 4,200,


260 ~ 300)

M22

1.5

290 ~ 330 (2,900 ~ 3,300,


210 ~ 240)

480 ~ 550 (4,800 ~ 5,500,


350 ~ 400)

M24

1.5

360 ~ 420 (3,600 ~ 4,200,


260 ~ 300)

610 ~ 700 (6,100 ~ 7,000,


440 ~ 505)

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

LUBRICANTS
RECOMMENDED LUBRICANTS
Parts

OIL & GREASE STANDARD


Hot Climate : SAE 20W -40, 20W-50 (ABOVE 32F
For 0C)

Engine oil

API SH, SG or SG/CD

Normal Climate : SAE 10W-30, 10W-40, 10W-50


(ABOVE -10C For -23C)
Cold Climate : SAE 5W-30, 5W-30, 5W-40
(BELOW100 FoR 38C)

Manual

HYUNDAI GENUINE PARTS MTF 75W/90 (API GL-4)

Auto

DIAMOND ATF SP-3, SK ATF SP-3

Transaxle
Power Steering
Brake Fluid
Coolant

PSF-3
DOT 3, DOT 4 or equivalent
Ethylene glycol base for aluminium radiator.

Transaxle linkage, parking brake cable mechanism,


hood lock and hook, door latch, seat adjust, tailgate Multipurpose grease NLGI grade #2
latch, door hinges, tailgate hinges

Always use Genuine Hyundai parts and recommedended fluid.


Using any other type of parts and fluid can cause serious damage of the vehicle.
LUBRICANTS CAPACITIES
Capacities [liter (U.S. qus., Imp.qts.)]
Description
2.4
Oil pan
Engine oil

Cooling system
Manual transaxle

3.7 (3.91, 3.26)

Oil filter
Total

2.7
4.2 (4.44, 3.69)
0.3 (0.32, 0.26)

4.0 (4.23, 3.52)

4.5 (4.76, 3.95)

7.3 (7.71, 6.42)

8.6 (9.09, 7.57)


2.15 (2.3, 1.86)

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Automatic transaxle
Power steering

7.8 (8.2, 6.8)


0.9 (0.95, 0.79)

SELECTION OF ENGINE OIL


Recommended SAE viscosity grades :

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

GENERAL SERVICE INFORMATION


PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting work.

The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to
prevent the hood from falling and possibly causing injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is firmly latched
before driving the vehicle.

PREPARATION OF TOOLS AND MEASURING EQUIPMENT


Be sure that all necessary tools and measuring equipment are available before starting work.

SPECIAL TOOLS
Use special tools when they are required.

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REMOVAL OF PARTS
First find the cause of the problem and then determine whether removal or disassembly before starting the job.

DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that
will not affect their performance or external appearance.
1. Inspection of parts
Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other problems.

2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.

3. Cleaning parts for reuse


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

PARTS

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When replacing parts, use HYUNDAI genuine parts.

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

Depending on their location.


7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of parts.
9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before assembly.

ADJUSTMENT
Use gauges and testers to correctly adjust the parts to standard values.

ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

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RUBBER PARTS AND TUBES


Always prevent gasoline or from touching rubber parts or tubing.

MEASURING BODY DIMENSIONS


1. Basically, all measurements in this manual are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensioners and actualmeasurement dimensions are used in this manual.

PROJECTED DIMENSIONS
1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the
reference dimensions used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the difference
value in height of the two surface.

MEASURING ACTUAL DIMENSIONS


1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference dimensions
when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement.

Check the probes and gauge itself to make sure there is no free play.

MEASUREMENT POINT

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Measurements should be taken at the center of the hole.

CHECKING CABLES AND WIRES


1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts firmly that there is complete continuity between their attaching bolt(s) and the vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is clamped to prevent contact with sharp corners of the vehicle body or hot parts (exhaust manifold, etc.).
9. Check that the wiring is clamped firmy to provide enough clearance from the fan pulley, fan belt and other rotating or moving
parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body and the
engine.

CHECK FUSES
A blade type fuse test leads provided to allow checking the fuse itself without removing it from the fuse box. The fuse is good if the
test lamp lights up when one lead is connected to the test leads (one at a time) and the other lead is grounded. (Turn on the ignition
switch so that the fuse circuit becomes operative)

SERVICING THE ELECTRICAL SYSTEM


1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.

In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by
the computer will be cleared. Therefore, if necessary, read the diagnostic before removing the battery cable.

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2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other
vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to
come into contact with any of the surrounding parts and then secure the harness by using a clamp.

3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or
something similar in order to protect it from damage.

4. When installing any parts, be careful not to pinch or damage any of the wiring harness.

5. Never throw relays, sensors or electrical parts, or expose them to strong shock.

6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that
may cause the temperature to exceed 80C (176F), r emove the electronic parts beforehand.

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7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.

8. When disconnecting a connector, be sure to grip only the connector, not the wires.

9. Disconnect connector which have catches by pressing in the direction of the arrows shown in the illustration.

10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.

11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the
connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal, being careful
not to damage the insulation of the wires.

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12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the
appropriate wire size.
Permissible current

Nominal
size

SAE gauge No.

0.3mm

AWG 22

In engine compartment

Other areas

5A

0.5mm

AWG 20

7A

13A

0.85mm

AWG 18

9A

17A

1.25mm

AWG 16

12A

22A

2.0mm

AWG 14

16A

30A

3.0mm

AWG 12

21A

40A

5.0mm

AWG 10

31A

54A

PRECAUTIONS FOR CATALYTIC CONVERTER

If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this
observe the following precations and explain them to your customer.
1. Use only unleaded gasoline.
2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than 10minutes and idle
speed for more than 20 minutes.
3. Avoid start-jump tests. Do start-jumps only when absolutely necessary. Perform this test as rapidly as possible and, while testing,
never race the engine.
4. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as possible.
5. Avoid coasting with the ignition turned off and during prolonged braking.
6. Do not dispose of used catalytic converter with parts contaminated by gasoline or oil.

BODY DIMENSION

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Page 1 of 6

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information > General
Information, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information >
General Information

THE MICRO 570 ANALYZER

Because of the possibility of personal injury, always use extreme caution and appropriate eye protection
when working with batteries.

KEYPAD

BATTERY TEST PROCEDURE


1. Connect the tester to the battery.
A. Red clamp to battery positive (+) terminal.
B. Black clamp to battery negative (-) terminal.

Connect clamps securely. If "CHECK CONNECTION" message is displyed on the screen, reconnect
clamps securely.

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2. The tester will ask if the battery is connected "IN A VEHICLE" or "OUT OF A VEHICLE".
Make your selection by pressing the arrow buttons; then press ENTER.

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

- CCA : Cold cranking amps, is an SAE specification for cranking batteried at 0F (-18C).
- CCP : Cold cranking power, is an SAE specification for korean manufacturer's for cranking batteries
at 0F (-18C)
4. Set the CCA value displyed on the screen to the CCA value marked on the battery label by pressing up and
down buttons and press ENTER.

The battery ratings(CCA) displyed on the tester must be identical to the ratings marked on the battery
label.
5. The tester (Micro570) displays battery test results including voltage and battery ratings.
A relevant action must be taken according to the test results by referring to the battery test results as shown in
the table below.

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


BATTERY TEST RESULTS
RESULT ON PRINTER
Good battery
Good recharge

REMEDY
No action is required
Battery is in a good state
Recharge the battery and use

Charge & Retest

Battery is not charged properly


Charge and test the battery again (Failure to charge the battery fully may
read incorrect measurement value)

Replace battery

Replace battery and recheck the charging system. (Improper connection


between battery and vehicle cables may cause "REPLACE BATTERY",
retest the battery after removing cables and connecting the tester to the
battery terminal directly prior to replacing the battery)

Bad cell-replace

Charge and retest the battery.

Whenever filing a claim for battery, the print out of the battery test results must be attached.

STARTER TEST PROCEDURE


1. After the battery test, press ENTER immediately for the starter test.

2. After pressing ENTER key, start the engine.

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3. Cranking voltage and starter test results will be displayed on the screen.
Take relevant action according to the test results by referring to the starter test results as given below.

4. To continue charging system test, press ENTER.


STARTER TEST RESULTS
RESULT ON PRINTER
Cranking voltage normal

REMEDY
System shows a normal starter draw

Cranking voltage low

Cranking voltage is lower than normal level


Check starter

Charge battery

The state of battery charge is too low to test


Charge the battery and retest

Replace battery

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

CHARGING SYSTEM TEST PROCEDURE


1. Press ENTER to begin charging system test.

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

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3. Turn off all electrical load and rev engine for 5 seconds.

4. Press ENTER.

5. The MICRO 570 analyzer charging system output at idle for comparision to other readings.

6. Take relevant action according to the test results by referring to the table below after shutting off the engine
and disconnect the tester clamps from the battery.

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CHARGING SYSTEM TEST RESULTS


RESULT ON PRINTER

REMEDY

Charging system normal/Diode


Charging system is normal
ripple normal
No charging voltage

Generator does not supply charging current to battery


Check belts, connection between generator and battery
Replace belts or cable or generator as necessary

Low charging voltage

Generator does not supply charging current to battery and electrical load to
system fully
Check belts and generator and replace as necessary

High charging voltage

The voltage from generator to battery is higher than normal limit during
voltage regulating.
Check connection and ground and replace regulator as necessary

Excess ripple detected

One or more diodes in the generator is not functioning properly


Check generator mounting and belts and replace as necessary

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General
Information > Troubleshooting

TROUBLESHOOTING
IGNITION SYSTEM
Symptom

Suspect Area

Remedy (See Page)

Engine will not start or is hard to


start (Cranks OK)

Ignition lock switch


Ignition coil
Spark plugs
Ignition wiring disconnected or broken
Spark plug cable

Inspect
See page EE-14
See page EE-13
Repair
See page EE-13

Rough idle or stalls

Ignition wiring
Ignition coil
Spark plug cable

Inspect
See page EE-14
See page EE-13

Engine hesitates/poor acceleration

Spark plugs and spark plug cable


Ignition wiring

See page EE-13


Inspect

Poor mileage

Spark plugs and spark plugs cable

See page EE-13

CHARGING SYSTEM
Symptom

Suspect Area

Remedy (See Page)

Charging warning indicator Fuse blown


does not light with ignition Light burned out
switch "ON" and engine off Wiring connection loose
Electronic voltage regulator

Check fuses
Replace light
Tighten loose connections
See page EE-20

Charging warning indicator


does not go out with
engine running (Battery
requires frequent
recharging)

Drive belt loose or worn


Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
Electronic voltage regulator or generator
Wiring

See page EE-19, 29


See page EE-32
Check fuses
Replace fusible link
See page EE-20
Repair wiring

Engine hesitates/poor
acceleration
Overcharge

Drive belt loose or worn


Wiring connection loose or open circuit
Fusible link blown
Poor grounding
Electronic voltage regulator or generator
Worn battery
Electronic voltage regulator
Voltage sensing wire

See page EE-19, 29


Tighten loose connection or repair
wiring
Replace fusible link
Repair
See page EE-20
Replace battery
See page EE-20
Repair wire

STARTING SYSTEM
Symptom

Suspect Area

Remedy (See Page)

Engine will not crank

Battery charge low


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

Charge or replace battery


Repair or replace cables
See page TR group-automatic
transaxle
Replace fusible link
See page EE-38
Inspect

Engine cranks slowly

Battery charge low

Charge or replace battery

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Battery cables loose, corroded or worn out


Starter motor

Repair or replace cables


See page EE-38

Starter keeps running

Starter motor
Ignition switch

See page EE-38


Inspect

Starter spins but engine


will not crank

Short in wiring
Pinion gear teeth broken or starter motor
Ring gear teeth broken

Repair wiring
See page EE-40
See page EM group-fly wheel

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > General
Information > Specifications

SPECIFICATION
IGNITION SYSTEM
Specifications
Items
2.0

2.7

Type
Ignition coil

Spark plugs

Mold coil type

Primary resistance

0.58 10% ()

0.74 10% ()

Secondary resistance

8.8 15% (k)

13.3 15% (k)

NGK

BKR5ES-11

PFR5N-11

CHAMPION

RC10YCPB4

RC10YCPB4

Gap

1.0 ~ 1.1 mm (0.039 ~ 0.043 in.)

STARTING SYSTEM
Specifications
Items
2.0

Starter

2.7

Type

Reduction drive (with planetary gear)

Rated voltage

12V, 1.2KW

No.of pinion teeth

Voltage

11V

Amperage

90A, MAX

No-load
characteristics

Speed

3,000rpm, MIN

2,800rpm, MIN

CHARGING SYSTEM
Specifications
Items
2.0
Type
Rated voltage

Generator

2.7
Battery boltage sensing

13.5V, 90A

12V, 120A

Speed in use

1,000 ~ 18,000 rpm

Voltage regulator

Electronic built-in type

Regulator setting voltage

14.4 0.2V

14.55 0.2V

Temperature
compensation

-10 3mV/C

-3.5 1mV/C

Type

MF 60 AH

MF 68 AH

Cold cranking amperage


[at -18C (0F)]

550A

600A

Reserve capacity

92min

110min

Specific gravity [at 25C


(77F)]

1.280 0.01

1.280 0.01

Battery

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- COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a
terminal voltage of 7.2V or greater at a specified temperature.
- REVERSE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum
terminal voltage of 10.5V at 26.7C(80F)
AUTO CRUISE CONTROL SYSTEM
Items

Specification

Setting error

Within 1.5Km/h on level road ( 1MPH)

Vehicle speed memory variation

No variation

Setting time

0.1sec max.

Resuming time

0.1sec max.

Minimum operating speed

40 2Km/h (25 1.2MPH)

Cancel speed range

15 2Km/h (9 1.2MPH)

Maximum memorized speed

160 2Km/h (99 1.2MPH)

Pulling force

127N(13Kgf)(28.6 Ib-force)

Main switch serial resistance value

3.9k 1%
SET switch : 220 1%

Command switch serial resistance value


RESUME switch : 910 1%
TIGHTENING TORQUE
Items
Generator terminal (B+)
Starter motor terminal (B+)
Battery terminal
Spark plug

Nm

kgcm

lbft

5~7
10 ~ 12
4~6
20 ~ 30

50 ~ 70
100 ~ 120
40 ~ 60
200 ~ 300

3.6 ~ 5.1
7.3 ~ 8.8
2.9 ~ 4.3
15 ~ 22

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

DESCRIPTION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Ignition System > Repair procedures, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Ignition System > Repair procedures

ON-VEHICLE INSPECTION
INSPECT SPARK TEST
1. Remove the spark plug cable.
2. Using a spark plug socket, remove the spark plug.
3. Install the spark plugs to each spark plug cable.
4. Ground the spark plugs.
5. Check if spark occurs while engine is being cranked.

To prevent gasoline from being injected from injectors during this test, disconnect the injector connectors.
Be sure to clean away DTC codes the timing is complete after.

6. Using a spark plug socket, install the spark plugs.


7. Install the spark plug cable.

INSPECT SPARK PLUG AND SPARK PLUG CABLE


1. Remove the spark plug cable(A).

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When removing the spark plug cable, pull on the spark plug cable boot (not the cable), as it may be damaged.
2. Using a spark plug socket, remove the spark plug(B).

Be careful that no contaminats enter through the spark plug holes.


3. Inspect the electrodes(A) and ceramic insulator(B).

INSPECTION FO ELECTRODES
CONDITION
DESCRIPTION

DARK DEPOSITS
- Fuel mixture too rich
- Low air intake

WHITE DEPOSITS
- Fuel mixture too lean
- Advanced ignition timing
- Insufficient plug tightening

4. Check the electrode gap(A).


Standard (New)
1.0~1.1 mm (0.039~0.043 in.)

5. Carefully remove the spark plug cable by pulling on the rubber boots(A).
Check the condition of the spark plug cable terminals(B), If any terminal is corroded, clean it, and if it's broken or distorted,
replace the spark plug cable.

6. Connect the ohmmeter probes and measure resistance.


RESISTANCE : 5.6K/m 20%

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


If resistance is higher, replace the cable.

INSPECT IGNITION COIL


1. Measure the primary coil resistance between terminals 1, 2 and 1,3.

Standard value : 0.58 10%


2. Measure the secondary coil resistance between the high-voltage terminal for the No.1 and No.4 cylinders, and between the
high-voltage terminals for the No.2 and No.3 cylinders.
Standard value : 8.8k 15%

Be sure, when measuring the resistnace of the secondary coil, to disconnect the connector of the ignition coil.

1. Measurement of the primary coil resistance


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

2. Measurement of the secondary coil resistance


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

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terminals for the No.1 and No.4 cylinders and between the high-voltage terminals for the No.2 and No.5 cylinders.

When measuring the resistance of the secondary coil, be sure to disconnect the connector of the ignition coil.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Schematic Diagrams

CIRCUIT DIAGRAM FOR CHARGING SYSTEM

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

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Repair procedures,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Repair procedures

ON-VEHICLE INSPECTION

Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.

CHECK BATTERY VOLTAGE


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

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES


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

INSPECT DRIVE BELT


1. Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be
replaced.

2. Using a belt tension gauge, measure the drive belt tension.


DRIVE BELT TENSION
New belt

690~880 N (150~200 lb)

Used belt

340~490 N (77~110 lb)

If the belt tension is not as specified, adjust it.

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

VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES


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

CHECK DISCHARGE WARNING LIGHT CIRCUIT


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

INSPECT CHARGING SYSTEM


PREPARATION
1. Turn the ignition switch to "OFF".

To find abnormal conditions of the connection, actions should not be taken on the two terminals and each connection
during the test.
2. Connect a digital voltmeter between the generator "B" terminal and battery (+) lead wire to the battery (+) terminal. Connect
the (+) lead wire of the voltmeter to the "B" terminal and the (-) lead wire to the battery (+) terminal.

CONDITIONS FOR THE TEST


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

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3. Upon completion of the test, set the engine speed at idle. Turn off the head lamps, blower motor and the ignition switch.
PREPARATION
1. Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is in good condition. The battery checking method is described in
"BATTERY".
The battery that is used to test the output current should be one that has been partially discharged. With a fully charged
battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the generator drive belt. The belt tension check method is described in the section "COOLING".
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the generator output wire from the generator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure to
connect the (-) lead wire of the ammeter to the disconnected output wire.

Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the generator "B"
terminal and (-) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

TEST
1. Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the open
circuit in the wire between the generator "B" terminal and battery (-) terminal, a blown fusible link or poor grounding is
suspected.
2. Start the engine and turn on the headlights.
3. Set the headlights to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500 rpm and
read the maximum output current value indicated by the ammeter.

After the engine starts up, the charging current quickly drops. Therefore, the above operation must be done quickly to
read the maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit value. If it is lower but the generator output wire is in good condition,
remove the generator from the vehicle and test it.

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63A min.
84A min

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

TEST
1. Turn on the ignition switch and check to see that the voltmeter indicates the following value.

Battery voltage

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If it reads 0V, there is an open circuit in the wire between the generator "B" terminal and the battery (-), or the fusible link is
blown.
2. Start the engine. Keep all lights and accessories off.
3. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the generator output current drops to 10A or
less.
RESULT
1. If the voltmeter reading agrees with the value listed in the Regulating Voltage Table below, the voltage regulator is
functioning correctly. If the reading is other than the standard value, the voltage regulator or the generator is faulty.
Regulating Voltage Table
Voltage regulator ambient temperature C (F)

Regul ating voltage (V)

-20 (-4)
20 (68)
60 (140)
80 (176)

14.2 ~ 15.4
14.0 ~ 15.0
13.7 ~ 14.9
13.5 ~ 14.7

2.
3.
4.
5.
6.
1.

Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
Disconnect the battery ground cable.
Remove the voltmeter and ammeter and the engine tachometer.
Connect the generator output wire to the generator "B" terminal.
Connect the battery ground cable.
Be sure to check the following before testing:
Generator installation and wiring connections
Generator drive belt tension
Fusible link
Abnormal noise from the generator while the engine is running
2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range of 0-150A in
series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the "B" terminal.
Connect the (-) lead of the ammeter to the disconnected output wire).

An inductive-type ammeter which enables measurements to be taken without disconnecting the generator output wire
is recommended. Using this equipment will lessen the possibility of a voltage drop caused by a loose "B" terminal
connection.
5. Connect a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal. (Connect the (+) lead of
the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+) cable.)
6. Reconnect the negative battery cable.
7. Connect a tachometer or the scan tool.
8. Start the engine.
9. With the engine running at approx. 2500 r/min, turn the headlights and other lights on and off to adjust the generator load
on the ammeter slightly above 30A.
max. 0.3V

When the generator output is high and the value displayed on the ammeter does not decrease to 30A, set the value to
40A.Read the value displayed on the voltmeter. In this case the limit becomes max. 0.4V.
10. If the value displayed on the voltmeter is still above the limit, a malfunction in the generator output wire may exist. Check
the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link). If a terminal is not
sufficiently tight or if the harness has become discolored due to overheating, repair, the test again.
11. After the test, run the engine at idle.
12. Turn off all lights and turn the ignition switch to the OFF position.
13. Disconnect the tachometer or the scan tool.
14. Disconnect the negative battery cable.
15. Disconnect the ammeter and voltmeter.

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

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Alternator >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging
System > Alternator > Repair procedures

REPLACEMENT
1. Disconnect the battery negative terminal first, then the positive terminal.
2. Disconnect the generator connector(A) and "B" terminal cable(B) from the generator(C).

3. Remove the adjusting bolt(A) and mounting bolt(B), then remove the generator belt(C).
4. Pull out the through bolt(C), then remove the generator(D).

5. Installation is the reverse of removal.


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

3. Disconnect the connector(A) and "B" terminal cable(B).

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4. Pull out the through bolts(A) and nuts(B) then remove the generator(C).

5. Installation is reverse of removal.

Adjust the generator belt. (Refer to EM)


Place the alternator and insert a support bolt (Do not insert a nut this time).
After pushing the alternator forward, count that how many spacers (a spacer thickness : 0.198 mm)
should be inserted between the alternator front leg and front case as shown in "A".
After inserting spacers, insert and tighten a nut securely.

ALTERNATOR BELT INSPECTION AND ADJUSTMENT

When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the
deflection or tension to the values for the used belt after running engine for five minutes.
Deflection method :
Apply a force of 98N (10 kgf, 22 lbf), and measure the deflection between the alternator and crankshaft pulley.
Deflection
Used Belt : 8.5 ~ 11.5 mm (0.33 ~ 0.345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0.361 in)

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If the belt is worn or damaged, replace it.

Belt tension gauge method :


Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.
Tension
Used Belt : 340~490 N (35~50 kgf, 77~110 lbf)
New Belt : 690~880 N (70~90 kgf, 150~200 lbf)
Deflection
Used Belt : 8.5 ~ 11.5 mm (0.33 ~ 0.345 in)
New Belt : 5.5 ~ 8.0 mm (0.22 ~ 0.361 in)

If the belt is worn or damaged, replace it.

If adjustment is necessary :
1. Loosen the adjusting bolt(A) and the lock bolt(B).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.

3. Recheck the deflection or tension of the belt.

It is not necessary to adjust the tension of the drive belt because of the auto-tensioner.

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

DESCRIPTION
1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery
cell caps.
2. Water never needs to be added to the maintenance-free battery.
3. The battery is completely sealed, except for small vent holes in the cover.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Battery > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Charging System > Battery >
Repair procedures

INSPECTION
BATTERY DIAGNOSTIC TEST (1)
1. CHECKING FLOW

2. CHECKING SHEET
Responsibility
Inspection Items & contents

Judgment criteria

Remarks
User

1. Acid Leakage
* Type of acid leakage
- Leakage on the fusion part for
joining the case and cover.
- Leakage on the terminal part
- Leakage on other parts
* Conduct a visual inspection for
breakage, deformation, or cracks.

2. Outside damage and breakage

1. Damage in the case or cover due to


outside impact.

Manufacturer

2. Acid leakage on the molding part of


the case or cover.
(weld line or gate hole)

3. Damage on the terminal or cracks in


the cover.

4. Acid leakage due to the tipped


battery or slant storage.

5. Acid leakage due to poor welding of


the cover.
(with no damage)

1. Outside damage due to causes


without damage due to mistreatment.

2. Outside damage due to


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

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3. Measure the voltage for the


battery
; Wait at least one day before
measuring in case of recharging.

4. Damage and breakage due to heat.

1. 12.0V

Refer to
load test

2. 11.0V< battery voltage<12.0V due


to over-discharge.

Refer to
load test

3. Below 11.0V due to charge


condition failure.

Refer to
load test

4. Below 11.0V due to discharged for a


long period.

Refer to
load test

5. Below 11.0V due to internal short


circuit.
4. Load test
; For 15 seconds with half of the CCA
1. Load test result: below 9.5V
value.
The voltage on the dischaarging stage
should be above 9.6V (819F)
- Conduct the test with a battery
2. Load test result: above 9.6V
tester.
(Refer to the tester manual)

Refer to
load test

3. LOAD TEST
1. Perform the following steps to complete the load test procedure for maintenance free batteries.
2. Connect the load tester clamps to the terminals and proceed with the test as follow :
A. If the battery has been on charge, remove the surface charge by connecting a 300 ampere load for 15 seconds.
B. Connect the voltmeter and apply the specified load.
C. Read the voltage after the load has been applied for 15 seconds.
D. Disconnect the load.
E. Compare the voltage reading with the minimum and replace the battery if battery test voltage is below that shown in
the voltage table.
Voltage

Temperature

9.6

20C (70F) and above

9.5

16 C (60 F)

9.4

10 C (50 F)

9.3

4 C (40 F)

9.1

-1 C (30 F)

8.9

-7 C (20 F)

8.7

-12 C (10 F)

8.5

-18 C (0 F)

- If the voltage is higher than shown in the table, the battery is good.
- If the voltage is lower than shown in the table, replace the battery.

BATTERY DIAGNOSTIC TEST (2)


1. Make sure the ignition switch and all accessories are in the OFF position.
2. Disconnect the battery cables (negative first).
3. Remove the battery from the vehicle.

Care should be taken in the event the battery case is cracked or leaking, to protect your skin from the electrolyte.

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Heavy rubber gloves (not the household type) should be worn when removing the battery.

4. Inspect the battery carrier for damage caused by the loss of electrolyte. If acid damage is present, it will be necessary to
clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff brush and wipe off with a
cloth moistened with baking soda and water.
5. Clean the top of the battery with the same solution as described in Step(4).
6. Inspect the battery case and cover for cracks. If cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post cleaming tool.
8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged cables and
broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure the tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.

When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke near
batteries being charged or which have recently been charged. Do not break live circuits at the terminals of
batteries being charged. A spark will occur when the circuit is broken. Keep open flames away from the battery.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Schematic Diagrams

CIRCUIT DIAGRAM FOR STARTING SYSTEM

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

DESCRIPTION
The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch(A/T),
ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion gear overruns.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System >
Repair procedures

INSPECTION
START TEST

The air temperature must be between 59 and 100F (1 5 and 38C) before testing.
Recommended procedure :
Use a starter system tester.
Connect and operate the equipment in accordance with the manufacturer's instructions.
Test and troubleshoot as described.
Alternate Procedure :
Use the following equipment :
- Ammeter, 0~400A
- Voltmeter, 0~20V (accurate within 0.1 volt)
- Tachometer, 0~1,200 rpm

After this test, or any subsequent repair, reset the ECM/PCM to clear any codes.
Check the Starter Engagement :
1. Remove the No.8(10A) fuse from the fuse/relay box.
2. Turn the ignition switch to START (III) with the shift lever in "P" or " N" position (A/T) or with the clutch pedal
depressed (M/T). The starter should crank the engine.
A. If the starter does not crank the engine, go to step 3.
B. If it cranks the engine erratically or too slowly, go to "Check for Wear and Damage" on the next page.
3. Check the battery, battery positive cable, ground, starter cut relay, and the wire connections for looseness and
corrosion. Test again.
If the starter still does not crank the engine, go to step 4.
4. Unplug the connector from the starter.
5. Connect a jumper wire from the battery positive (+) terminal to the solenoid terminal.
The starter should crank the engine.

A. If the starter still does not crank the engine, remove it, and diagnose its internal problem.
B. If the starter cranks the engine, go to step 6.
6. Check the ignition switch.
7. Check the starter relay (see page EE-46 ).
8. Check the A/T gear position switch (A/T) or the clutch interlock switch (M/T).
9. Check for an open in the wire between the ignition switch and starter.
If cranking voltage is too low, or current draw too high, check for :

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dead or low battery.


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

STARTER SOLENOID TEST


1. Check the hold-in coil for continuity between the S terminal and the armature housing (ground). The coil is OK
if there is continuity.

2. Check the pull-in coil for continuity between the S and M terminals. The coil is OK if there is continuity.

FREE RUNNING TEST


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Starter > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System
> Starter > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Starter > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System >
Starter > Repair procedures

REPLACEMENT
1. Disconnect the battery negative cable.
2. Disconnect the starter cable(A) from the B terminal(B) on the solenoid(C), then disconnect the connecto(D)
from the S terminal(E).

3. Remove the 2 bolts holding the starter, then remove the starter.
4. Installation is the reverse of removal.
5. Connect the battery negative cable to the battery.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting System > Starter Relay >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Starting
System > Starter Relay > Repair procedures

INSPECTION
1. Remove the fuse box cover.
2. Remove the starter relay(A).

3. Inspect the relay continuity.


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

4. Inspect the relay operation.


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

5. Install the starter relay.


6. Install the fuse box cover.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System >
Schematic Diagrams

CIRCUIT DIAGRAM FOR CRUISE CONTROL SYSTEM

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

DESCRIPTION
FUNCTIONS OF INSIVIDUAL SWITCHS
1. SET(Vehicle Speed Set)
When SET switch is turned "ON" and "OFF" while the vehicle is running at a speed within the range of the
lowest running speed to the highest memory speed, specified in the Performance Standards, the speed is
instantaneously registered in memory(memory speed) and actuator is there after regulated to maintain vehicle
speed at the memory speed.
2. COAST(Self-Retardation)
When SET switch is turned "ON" while the vehicle is running at regulated speed, vehicle speed is retarded
while the switch is "ON". When it is turned "OFF", the then prevailing speed is instantaneously registered in
memory and actuator is regulated to maintain vehicle speed at the newly registered value.
3. RESUME(Auto Recovery)
After regulated speed run is released according to according to the conditions specified in 5.2, 5.3 and 5.4
below, when RESUME switch is turned "ON" during motion at a speed faster than the lowest running speed
shown in 4.5 above, actuator is recover and maintain the memory speed set prior to release.
A. IG. KEY. SW. OFF
B. ACC MAIN SW. OFF
4. ACCEL(Selt-Acceleration)
When RESUME switch is turned "ON" during regulated speed run, vehicle speed is increased as long at it is
"ON". When the switch is turned "OFF", the then prevailing speed is registered in memory to regulate actuator
to maintain that speed thereafter.

CANCELLATION
1. Stop lamp switch is turned "ON".
(Brake pedal is depressed)
This also applies to the disconnection of the input wire.
2. Brake switch or CANCEL switch is turned "ON". (Brake pedal is depressed)
3. Inhibitor switch is turned "ON".
(Gear shift lever is in either P or N position.)
4. Ignition key switch is turned "OFF".
5. Main switch is turned "OFF".

AUTO CANCELLATION
1. When vehicle speed falls down below the lowest running speed. (40Km/h)
2. When regulated speed falls below memory speed by the width of theredundant brake speed range of more.
3. When vehicle speed during resume operatin falls below memory speedby width of the redundant brake speed
range of more after once rising abovethe speed of memory speed-10Km/h.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control
System > Components and Components Location

COMPONENTS LOCATION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control
System > Troubleshooting

TROUBLE SHOOTING

Before troubleshooting :
- Check the No.3(10A), No.13(15A) and No.17(10A) fuse in the under-hood fuse/relay box.
- Check that the horn sounds.
- Check the tachometer to see if it works properly.
Symptom
Cruise control cannot be set

Suspect Area
Main switch
SET/RESUME/CANCEL switch
Brake switch
A/T gear position switch
Cruise control nuit

Cruise control cannot be set but indicator light does not Dimming circuit in gauge
go on
Cruise control unit
Cruise speed is noticeably higher or lower than what
was set

Vehicle speed sensor


Cruise control unit and actuator cable deflection
Cruise control nuit

Excessive overshooting or undershooting when trying


to set speed

Cruise control unit and actuator cable deflection


Vehicle speed sensor
Cruise control unit

Speed fluctuation on a flat road with cruise control set

Vhicle speed sensor


Cruise control unit and actuator cable deflection
Cruise control nuit

Vehicle does not decelerate or accelerate accordingly


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 control unit

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

Main switch
SET/RESUME/CANCEL switch
Cruise control unit

Cruise control will not cancel when CANCEL button is


pushed

Main switch
SET/RESUME/CANCEL switch
Cruise control unit

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control System > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Electrical System > Cruise Control
System > Repair procedures

INSPECTION
CRUISE CONTROL SWITCH TEST
1. Disconnect the battery negative cable, then disconnect the positive cable, and wait at least three minutes.
2. Remove the driver's airbag (See page RT).
3. Disconnect the control switch connector.

4. Check the continuity between the terminals of the connector in each switch position according to the table.
A. If there is continuity, and it matches the table, the switch is O.K.
B. If there is no continuity, replace the control switch.

BRAKE SWITCH TEST


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

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3. Check for continuity between the terminals according to the table.

4. If necessary, replace the switch or adjust the pedal height.

ACTUATOR CABLE ADJUSTMENT


1. Check that the actuator cable (A) moves smoothly with no binding or sticking.
2. position, M/T in neutral) until the radiator fan comes on, then let it idle.
3. Measure the amount of movement of the output linkage (B) until the engine speed starts to increase.
At first, the output linkage should be located at the fully closed position (C).

4. If the free play is not within specs, move the cable to the point where the engine speed starts to increase, and
tighten the locknut (A) and adjusting nut (B).

5. Turn the adjusting nut (A) until it is 3.750.5 mm (0.150.02 in.) away from the bracket (B).

6. Pull the cable assembly so that the adjusting nut (A) touches the bracket, and tighten the locknut (B).

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REPLACEMENT
CRUISE CONTROL UNIT AND CABLE
1. Loosen the locknuts(A) and disconnect the actuator cable (B) from the throttle linkage(C).

2. Disconnect the cruise control unit connector(D).


3. Loosen the three mounting bolts(E), and remove the cruise control unit with the bracket(F).

4. Loosen the locknuts(A) and disconnect the actuator cable(B) from the cruise control unit.

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).

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

5. Installation is the reverse of removal.


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information > General Information,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information > General Information

SPECIFICATIONS
Description

Specification

General
Type
Number of cylinders
Bore
Stroke
Total displacement
Compression ratio
Firing order
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
Closes (ATDC)

V-type, DOHC
6
86.7mm (3.4133in.)
75mm (2.9528in.)
2,656cc
10 : 1
1-2-3-4-5-6
6
46
44
8

Camshaft
Drive mechanism
Cam height
Intake
Exhaust
Journal diameter
Bearing oil clearance
End play

Cogged type belt


43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
25.964 ~ 25.980mm (1.0222 ~ 1.0228in.)
0.02 ~ 0.61mm (0.0007 ~ 0.0024in.)
0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)

Cylinder head
Flatness of cylinder head surface
Flatness of manifold mounting surface
Intake
Exhaust
Valve guides hole diameter
0.05 (0.002) O.S.
0.25 (0.010) O.S.
0.50 (0.020) O.S.
Intake valve seat ring hole diameter
0.3 (0.012) O.S
Exhaust valve seat ring hole diameter
0.3 (0.012) O.S.

Max. 0.03mm (0.0012in.)


Max. 0.15mm (0.0059in.)
Max. 0.15mm (0.0059in.)
11.05 ~ 11.068mm (0.435 ~ 0.436in.)
11.25 ~ 11.268mm (0.443 ~ 0.444in.)
11.50 ~ 11.518mm (0.453 ~ 0.453in.)
33.300 ~ 33.325mm (1.311 ~ 1.312in.)
28.600 ~ 28.621mm (1.126 ~ 1.127in.)

Valve
Overall length
Intake
Exhaust
Stem diameter
Intake
Exhaust
Face angle
Margin
Intake
Exhaust
Clearance (Stem-to-guide)
Intake
Exhaust

96.1mm (3.783in.)
97.15mm (3.825in.)
5.965 ~ 5.98mm (0.235 ~ 0.2354in.)
5.95 ~ 5.965mm (0.234 ~ 0.235in.)
45 ~ 45.5
1.0mm (0.0394in.)
1.3mm (0.0512in.)
0.02 ~ 0.05mm (0.0008 ~ 0.0020in.)
0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)

Valve spring
Free height
Load
Out of squareness

42.5mm (1.6732in.)
21kg/35mm (48.4lb/1.3780in.)
Max 1.5

Limit

43.45mm (1.7106in.)
43.45mm (1.7106in.)
25.914m(1.0202in.)
0.1mm (0.0039in.)
0.05mm (0.0020in.)
0.15mm (0.0059in.)
0.15mm (0.0059in.)

0.5mm (0.0197in.)
0.8mm (0.0315in.)
0.10mm (0.0039in.)
0.15mm (0.0059in.)
41.5mm (1.6339in.)
21.9kg/34mm
(48.4lb/1.3386in.)
Max. 3

Piston

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Diameter (Standard)
Clearance (Piston-to-cylinder)
Ring groove width
No. 1
No. 2
Oil
Piston for service

86.68 ~ 86.71mm (3.413 ~ 3.414in.)


0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)
1.230 ~ 1.250mm (0.0484 ~ 0.0492in.)
1.220 ~ 1.250mm (0.0480 ~ 0.0488in.)
2.515 ~ 2.535mm (0.0990 ~ 0.0998in.)
0.25mm (0.010in.), 0.50mm (0.020in.)

Piston ring
Number of rings per piston
Compression ring
Oil ring
Compression ring type
No. 1
No. 2
Oil ring type
Ring end gap
No. 1
No. 2
Oil ring side rail
Ring side clearance
No.1
No.2
Rings for service

3
2
1
Inner bevel type
Under cut type
3-piece type
0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)
0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
0.03 ~ 0.07mm (0.0012 ~ 0.0028in.)
0.25mm (0.010in.), 0.50mm (0.020in.)

Connecting rod
Piston pin installation force
Side clearance (big end)
Bend
Bearing oil clearance

2,450 ~ 12,255N
(250 ~ 1,250kg, 551 ~ 2,755lb)
0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)
0.05mm or less/100mm
(0.0020in. or less/3.937in.)
0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)

Crankshaft
Journal O.D.
Pin O.D.
Out-of-round of journal and pin
Taper of journal and pin
End play
Main bearing oil clearance

61.982 ~ 62.000 (2.4402 ~ 2.4409 in.)


47.982 ~ 48.000 (1.8891 ~ 1.8898in.)
Max. 0.003mm (0.00012in.)
Max. 0.005mm (0.00020in.)
0.070 ~ 0.250mm (0.0028 ~ 0.0098in.)
0.004 ~ 0.022mm (0.0002 ~ 0.0009in.)

Cylinder block
Cylinder bore
Flatness of gasket surface
Out-of-round of cylinder bore
Oil pump
Side clearance
Body clearance
Side clearance
Relief spring
Free length
Load
Oil filter
Type
Engine oil pressure
Cooling method
Cooling system quantity
Theromstat
Type
Normal opening temperatrure
Opening temperature range
Wide open temperature

86.7mm (3.4134in.)
Max. 0.03mm (0.0012in.)
Max. 0.02mm (0.0008in.)

0.8mm (0.031in.)
0.8mm (0.031in.)
1.0mm (0.039in.)
0.1mm (0.004in.)
0.1mm (0.004in.)

0.4mm (0.016 in.)


0.1mm (0.004in.)

0.4mm (0.016in.)
0.1mm (0.004in.)

0.05mm (0.002in.)

0.100 ~ 0.181mm (0.0039 ~ 0.0071 in.)


0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)

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

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Radiator cap
Main valve opening pressure
Main valve closing pressure
Vacuum valve opening pressure

107.9 14.7kPa (1.1 0.15kg/cm, 15.65


2.13psi)
83.4kPa (0.85kg/cm, 12.1psi)
-6.86kPa (-0.07kg/cm, -1.00psi)

Air cleaner
Type
Element

Dry
Paper type

Exhaust pipe
Muffler
Suspension system

Expansion reaonance type


Rubber hangers

SERVICE STANDARD
Standard value
Coolant concentration
Tropical areas

40%

Other areas

50%

COOLANT
Engine coolant

Ethylence glycol base for aluminum radiator

SEALANT
Engine coolant temperature sensor

LOCTITE 262 or equivalent, Three bond No. 1324 or


equivalent.

Oil pressure switch

3M ATD No. 8660 or Three bond No. 1141E

PCV valve

LOCTITE 242 or equivalent

TIGHTENING TORQUE
Item

Nm

kg.cm

lb.ft

Camshaft sprocket bolt

90 ~ 110

900 ~ 1,100

65 ~ 80

Cylinder head cover bolt

8 ~ 10

80 ~ 100

5.8 ~ 7.2

Main bearing cap bolt


M10
M8

27~33 + (90~94)
13~19 + (90~94)

270~330 + (90~94)
130~190 + (90~94)

19.5 ~24 +
(90 ~ 94
10~14 +
(90~94)

Connecting rod bolt

16~20 + (90~94)

160~200 + (90~94 )

12~15 +
(90~94)

25 + (58~92) + (43~47 )

250 + (58~92) + (43~47)

18 + (58
~92) +
(43~47)

Cylinder head bolt (Cold engine)


Oil pan drain plug

35 ~ 45

350 ~ 450

25 ~ 33

Lower oil pan bolt

10 ~ 12

100 ~ 120

7~9

Upper oil pan bolt


[1038mm (0.9371.4961in.)]
[822mm (0.31500.8661in.)]
[161.5mm(6.3582in.)]
[152.5mm (6.0039in.)]

30 ~ 42
19 ~ 28
5~7
5~7

300 ~ 420
190 ~ 280
50 ~ 70
50 ~ 70

22 ~ 30
14 ~ 20
4~5
4~5

Oil screen bolt

15 ~ 22

150 ~ 220

11 ~ 16

Oil pump case bolt

12 ~ 15

120 ~ 150

9 ~ 11

Oil relief valve plug

40 ~ 50

400 ~ 500

29 ~ 36

Oil pressure switch

15 ~ 22

150 ~ 220

11 ~ 16

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Oil pump cover screw

8 ~ 12

80 ~ 120

6~9

Oil filter

12 ~ 16

12 ~ 160

9 ~ 12

Fly wheel bolt

73 ~ 77

730 ~ 770

53 ~ 56

Drive plate and adaptor plate bolt

73 ~ 77

730 ~ 770

53 ~ 56

Air cleaner body installation bolt

8 ~ 12

80 ~ 120

6~9

Surge tank stay

15 ~ 20

150 ~ 200

11 ~ 14

Air intake surge tank to intake manifold (bolt)

15 ~ 20

150 ~ 200

11 ~ 14

Air intake surge tank to intake manifold (nut)

15 ~ 20

150 ~ 210

11 ~ 14

Intake manifold to cylinder head

19 ~ 21

190 ~ 150

14 ~ 15

Heat protector to exhaust manifold

12 ~ 15

120 ~ 350

9 ~ 11

Exhaust manifold to cylinder head (Self-locking


nut)

30 ~ 35

300 ~ 150

22 ~ 26

Oil level gauge guide to engine

12 ~ 15

120 ~ 200

9 ~ 11

Water outlet fitting bolt

17 ~ 20

170 ~ 260

12 ~ 14

Power steering oil pump bracket to cylinder head

17 ~ 26

170 ~ 260

12 ~ 19

Power steering oil pump bracket

17 ~ 26

170 ~ 260

12 ~ 19

Crank position sensor wheel screw

5~6

50 ~ 60

3.6 ~ 4.3

Engine mounting insulator bolt

40 ~ 55

400 ~ 550

29 ~ 40

Engine mounting bracket nut

60 ~ 80

600 ~ 800

43 ~ 58

Engine mounting bracket bolt

60 ~ 80

600 ~ 800

43 ~ 58

Engine support bracket stud

30 ~ 40

300 ~ 400

22 ~ 59

Front roll stopper bracket to sub cross member


bolt

40 ~ 55

400 ~ 550

29 ~ 40

Front roll stopper insulator bolt and nut

50 ~ 65

500 ~ 650

36 ~ 47

Rear roll stopper bracket to cross member bolt

40 ~ 55

400 ~ 550

29 ~ 40

Rear roll stopper insulator bolt and nut

50 ~ 65

500 ~ 650

36 ~ 47

Transaxle mounting bracket bolt

40 ~ 55

400 ~ 550

29 ~ 40

Transaxle mounting insulator bolt

90 ~ 110

900 ~ 1,100

65 ~ 80

Fuel hose clamp to rear cylinder head assembly

12 ~ 15

120 ~ 150

9 ~ 11

Transaxle mounting plate

10 ~ 12

100 ~ 120

7~9

Rear plate

10 ~ 12

100 ~ 120

7~9

Oil seal case

10 ~ 12

100 ~ 120

7~9

Crankshaft pulley bolt

180 ~ 190

1,800 ~ 1,900

130 ~138

Timing belt cover bolt

10 ~ 12

100 ~ 120

7~9

Engine hanger bracket to engine

20 ~ 27

200 ~ 270

14 ~ 20

Alternator mounting bracket to engine

20 ~ 30

200 ~ 300

14 ~ 22

Alternator mounting nut (Engine front case side)

20 ~ 30

200 ~ 300

14 ~ 22

Alternator mounting bolt (Alternator mounting


bracket side)

20 ~ 30

200 ~ 300

14 ~ 22

Starter to transmission (Nut)

20 ~ 30

200 ~ 300

14 ~ 22

Starter to transmission (Bolt)

27 ~ 34

270 ~ 340

20 ~ 25

Driver belt pulley bolt

35 ~ 55

350 ~ 550

25 ~ 40

Driver belt tensioner bolt

20 ~ 27

200 ~ 270

14 ~ 20

Engine coolant pump to cylinder block bolt


(Head mark "7" mark)

15 ~ 22

150 ~ 220

11 ~ 16

Engine coolant temperature sensor

20 ~ 40

200 ~ 400

14 ~ 29

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Engine coolant inlet fitting attaching bolt

17 ~ 20

170 ~ 200

12 ~ 14

Throttle body to surge tank bolt

15 ~ 20

150 ~ 200

11 ~ 14

Oxygen sensor to exhaust manifold

40 ~ 50

400 ~ 500

29 ~ 36

Front exhaust pipe to exhaust manifold nut

30 ~ 40

300 ~ 400

22 ~ 29

Front exhaust pipe to catalytic converter bolt

40 ~ 60

400 ~ 600

29 ~ 43

Catalytic converter to center exhaust pipe nut

30 ~ 40

300 ~ 400

22 ~ 29

Center exhaust pipe to main muffler nut

30 ~ 40

300 ~ 400

22 ~ 29

Main muffler hanger support bracket bolt

10 ~ 15

100 ~ 150

7 ~ 11

Delivery pipe installation boly

10 ~ 15

100 ~ 150

7 ~ 11

Timing belt tensioner pulley bolt

43 ~ 55

430 ~ 550

31 ~ 40

Timing belt idler pulley bolt

50 ~ 60

500 ~ 600

36 ~ 43

Timing belt tensioner arm fixed bolt

35 ~ 55

350 ~ 550

25 ~ 40

Auto tensioner fixed bolt

20 ~ 27

200 ~ 270

14 ~ 20

Accelerator cable bracket

4~6

40 ~ 60

3~4

20 ~ 30

200 ~ 300

14 ~ 22

Spark plug

CHECKING ENGINE OIL


1. Position a vehicle on a level surface.
2. Turn off the engine.

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

When refilling, use the proper grade of engine oil.


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

SELECTION OF ENGINE OIL


Recommended API classification: SH OR ABOVE

Recommended SAE viscosity grades :

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1. Satisfy the requirements of the API classification.


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

CHANGE ENGINE OIL


1. Run the engine until it reaches normal operating temperature.
2. Turn off the engine.
3. Remove the oil filler cap and oil filter and then drain plug.
Drain the engine oil.
4. Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug :
35 ~ 45Nm (350 ~ 450kg.cm, 25 ~ 33lb.ft)

Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill the new engine oil through the oil filler cap.
Drain and Refill
Oil quantity : 4.5lit (4.74U.S.qts., 3.95lmp.qts.)

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

REPLACEMENT OIL FILTER


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

Procedure for Replacing Oil Filter


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

CHECKING COOLANT LEAK CHECK


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

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

RADIATOR CAP PRESSURE TEST


1. Use an adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving.
Main valve opening pressure :
107.9 14.7kPa (1.1 0.15kg/cm , 15.64 2.13psi)
Main valve closing pressure :
83.4 kPa (0.85 kg/cm, 12.1 psi
3. Check that the pressure level is maintained at or above the limit.
4. Replace the radiator cap if the reading does not remain at or above the limit.

Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect
reading.

SPECIFIC GRAVITY TEST


1. Measure the specific gravity of the coolant with a hydrometer.
2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and
temperature. Use the followingtable for reference.

RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

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Coolant temperature C (F) and specific gravity


10 (50)

20 (68)

30 (86)

40 (104)

50 (122)

1.054

1.050

1.046

1.042

1.036

1.063

1.058

1.054

1.049

1.044

1.071

1.067

1.062

1.057

1.052

1.079

1.074

1.069

1.064

1.058

1.087

1.082

1.076

1.070

1.095

1.090

1.084

1.103

1.098

1.092

Safe
Coolant
Freezing
operating concentration
temperature
(Specific
temperature
C(F)
volume)
C(F)
-16 (3.2)

-11 (12.2)

30%

-20 (-4)

-15 (5)

35%

-25 (-13)

-20 (-4)

40%

-30 (-22)

-25 (-13)

45%

1.064

-36 (-32.8)

-31 (-23.8)

50%

1.077

1.070

-42 (-44)

-37 (-35)

55%

1.084

1.076

-50 (-58)

-45 (-49)

60%

The safe operating temperature is -15C (5F) when the measured specific gravity is 1.058 at coolant temperature of 20C
(68F).

If the concentration of the coolant is below 30%, its anti-corrosion property will be adversely affected.
If the concentration is above 60%, the engine cooling property will decrease, affecting the engine adversely. For
these reasons, be sure to maintainthe concentration level within the specified range.
Do not mix types of anti - freeze.
RECOMMENDED COOLANT
Antifreeze

Mixture ratio of antifreeze in coolant

ETHYLENE GLYCOL BASE FOR ALUMINUM

50% [Except tropical areas]


40% [Tropical areas]

CHECKING COMPRESSION PRESSURE


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

9. Repeat steps 6 to 8 for all cylinders, making sure that the pressure difference for each of the cylinders is within the
specified limit.
Limit

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Max. 100kpa (1.0 kg/cm, 14psi) between cylinders


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

TIGHTENING CYLINDER HEAD BOLTS


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

2. Use the torque - angle method to torque the head bolts.


3. Be sure to follow the specific torque sequence as shown in the illustration.

Run the engine to normal operating temperature and let it cool, then re-torque the bolts to specifications.

ADJUSTING VALVE CLEARANCE


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

ADJUSTING DRIVE BELT AND TENSIONER


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

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2. Install the belt in the fllowing order.


[Alternator Power steering Crankshaft pulley Air conditioner pulley.]

3. Rotate the tensioner arm clockwise (about 14) with a spaner (16 mm ) and fit the belt to the idler pulley.

4. When installing the belt on the pulley, make sure it is centered on the pulley.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information > Special
Service Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General
Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name)

Illustration

Use

Crankshaft front oil seal installer


(09214-33000)

Installation of the crankshaft


front oil seal

Camshaft oil seal installer


(09221-21000)

Installation of the camshaft oil


seal

Valve guide installer


(09221-3F100 A/B)

Removel and installation of the


valve guide

Valve stem oil seal installer


(09222-22001)

Installation of the valve stem oil


seal

Valve spring compressor


(09222-28000)
(09222-28100)

Remove and installation of the


intake or exhaust valve

Valve stem oil seal remover


(09222-29000)

Removeal of the valve stem oil


seal

Crankshaft rear oil seal installer


(09231-33000)

Installation of the crankshaft


rear oil seal

Crankshaft wrench
(09231-33100)

Used if the crankshaft needs to


be rotated to attach the tming
belt, etc.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > General
Information > Troubleshooting

TROUBLESHOOTING
Symptom
Crankshaft bearing knock

Probable cause

Remedy

Worn main bearing


Seized bearing
Bent crakshaft
Excessive crankshaft end play

Replace
Repalce
Replace
Replce thrust bearing

Worn bearing
Seized bearing
Worn piston pin
Worn piston in cylinder
Broken piston ring
Improper connecting rod alignment

Replace
Repalce
Replace piston and pin or
connecting rod
Recondition cylinder
Replace
Repalce

Noisy valves

Faulty auto-lash adjuster


Thin or diluted engine oil (low oil pressure)
Worn or damaged valve stem or valve
guide

Replace
Change
Repalce

Excessively worn cylinder and


piston

Shorted or engine oil


Dirty engine oil
Poor quality of engine oil
Improperly assembled piston and
connecting rod
Improper piston ring end clearance
Dirty air cleaner

Add or replace
Repalce
Use proper oil
Repair or replace
Replace
Clean air cleaner assembly and
replace the air filter

Connecting rod and main


bearing noise

Insufficient oil supply


Thin or diluted engine oil
Excessive bearing clearnace

Check engine oil level


Change and find out cause
Replace

Shorted of engine oil


Low oil pressure
Poor quality of engine oil
Worn or out-of-round of crankshaft journal
Restricted oil passage in crankshaft
Worn bearing
Faulty oil pump
Bearing improperly installed
Non-concentric crankshaft or bearing

Add or replace
Adjust or repair
Use proper engine oil
Replace
Clean
Replace bearing and check
engine oil and lubrication
system
Repair or replace
Repaur or replace
Replace

Incorrect belt tension

Adjust belt tension

Damaged cylinder head gasket


Worn or damaged piston rings
Worn piston or cylinder
Worn or damaged valve seat

Replace gasket
Replace rings
Repair or replace piston and/or
cylinder block
Repair or replace valve and/or
seat ring

Low engine oil level


Faulty oil pressure switch
Clogged oil filter
Worn oil pump gears or cover

Check engine oil level


Repalce
Replace
Replace

Piston and connecting rod knock

Damaged crankshaft bearing

Timing belt noise


Low compression

Oil pressure drop

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Thin or diluted engine oil


Oil relief valve stuck (open)
Excessive bearing clearance

Change and find out cause


Repair
Replace

High oil pressure

Oil relief valve stuck (closed)

Repair or replace

Excessive engine rolling and


vibration

Misfire
Loose engine roll stopper (front, rear)
Loose transaxle mount bracket
Loose center member
Broken transaxle mount insulator
Broken engine mount insulator
Broken engine roll stopper insulator

Correct
Re-tighten
Re-tighten
Re-tighten
Re-tighten
Replace
Repalce or repalce

Low coolant level

Leakage of coolant
Damaged radiator core joint
Corroded or cracked hoses (Radiator hose,
heater hose, etc.)
Faulty radiator cap valve or setting or
spring
Faulty thermostat
Faulty engine coolant pump

Correct
Replac
Replace
Replace
Repacle
Repalce

Clogged radiator

Foreign material in coolant

Replace

Abnormally high coolant


temperature

Faulty thermostat
Faulty radiator cap
Restriction of flow in cooling system
Loose or missing drive belt
Faulty engine coolant pump
Faulty thermostat seder or wiring
Faulty electric fan
Faulty thermo-sensor on radiator
Insufficient coolant

Replace parts
Replace
Clear restriction or replace parts
Adjust or replace
Replace
Repair or repalce
Repair or replace
Replace
Refill coolant

Abnormally low coolant


temperature

Faulty thermostat
Faulty temperature gauge or wiring

Replace
Repair or replace

Leakage from oil cooling system Loose hose and pipe connection
Blocked or collapsed hose and pipe

Replace
Repair or replace

Inoperative electrical cooling fan Damaged


Loose pipe or in operative sensor

Replace or repair
Repair or replace

Exhaust gas leakage

Loose connections
Broken pipe or muffler

Re-tighten
Repair or replace

Abnormal noise

Detached baffler plate in muffler


Broken rubber hanger
Pipe or muffler contacting vehicle body
Broken pipe or muffler

Replace
Replace
Correct
Repair or replace

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Timing System > Timing Belt >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Timing System > Timing Belt > Components and Components Location

COMPONENTS

Timing belt

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Timing System > Timing Belt >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Timing
System > Timing Belt > Repair procedures

REMOVAL
1. Remove the engine cover.

2. Using a [16 mm], rotate the tensioner arm clockwise (about 14 )and remove the belt from the pulley.
3. Remove the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.

4. Remove the upper and lower timing belt covers.

5. Remove the auto tensioner.

Rotate the crankshaft clockwise and align the timing mark to set the No.1 cylinder's piston to TDC
(compression stroke).
At this time, the timing marks of the camshaft sprocket and cylinder head cover should coincide with each
other.

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6. Unbolt the tensioner to remove the timing belt.

If you plan to use the timing belt again, mark the rotation direction on the belt so you reinstall it correctly.

INSTALLATION
1. Install the idler pulley to water pump boss.

Insert and install the idler pulley to the roll pin that is pressed in the water pump boss.

2. Install the tensioner arm and plain washer to the cylinder block.
3. Install the tensioner pulley to the tensioner arm.
4. Install the camshaft sprockets and align the timing marks.

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When installing the camshaft sprockets, fasten them tightly while holding the hexagonal part of the
camshaft.
Before installing the timing belt, if the timing marks of the cam sprocket and the cylinder head cover
do not coincide, do not rotate thecam sprocket more than 3 teeth in either direction.
Rotating the sprocket more than 3 teeth may allow the valve and piston to touch each other.
If the cam sprocket is rotated more than 3 teeth unavoidably, rotate the crankshaft counter-clock wise
a bit before rotating the cam sprocket.
5. Install the auto tensioner to the front case.

At this time auto tensioner's set pin should be compressed and secured with set pin.

6. Align the timing marks of each sprocket and install the timing belt in the following order.
1.Crankshaft sprocket 2.Idler pulley 3.camshaft sprocket (LH side) 4.Water pump pulley
5.camshaft sprocket (RH side) 6.Tensionerpulley.

In this step, No. 1 cylinder is in the TDC (Compression stroke).


Be very careful if you use your fingers.

7. Pull out the set pin of the auto tensioner.

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8. Install the upper and lower timing belt covers.


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

How to adjust the tension of the timing belt


1. Rotate the crankshaft 2 turns clockwise and measure the projected length of the auto tensioner at TDC ( #1
Compression stroke) after 5 minutes.
2. The projected length should be 7 ~ 9mm (0.27 ~ 0.31in.).
3. Verify that the timing marks of each sprocket are in their specified position.

If the timing marks are not in their specified position, repeat from 6 above.

INSPECTION
1. Inspect the belt closely. If the following problems are evident, replace the belt with a new one.
(1) Hardened back surface of rubber
Back surface is glossn, non-elastic and so hardthat when the nail of your finger is pressed into it, no mark
is produced.

(2) Cracked back surface of rubber.

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(3) Side of belt is badly worn.

A belt in good condition should have clear-cut sides as if it were cut with a sharp knife.

(4) Teeth are badly worn out.


Last stage : Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width
reduced).
(5) Missing tooth

2. If backlash or an irregular noise is observed when rotating the pulley, replace the timing belt tensioner and
idler pulley.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly > 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly >
Camshaft > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Cylinder Head Assembly > Camshaft > Repair procedures

DISASSEMBLY
1. Remove the engine cover and intake manifold.

2. Disconnect the breather hose and the engine harness.


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

9. Remove the camshaft sprockets.


10. Remove the camshaft bearing caps.

11. Remove the camshafts.

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INSPECTION
1. Check the camshaft journals for wear. If the journals are badly worn out, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or excessively worn out, replace the camshaft.
Cam height
[Standard]
Intake : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
Exhaust : 43.95 ~ 44.15mm (1.7303 ~ 1.7382in.)
[Limit]
Intake/Exhaust : 43.45mm (1.7106 in.)

3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head
assembly or camshaft bearing cap, as necessary.
Camshaft end play : 0.1 ~ 0.15mm (0.0039 ~ 0.0059in.)

Oil Seal (Camshaft front)


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

HLA (Hydraulic Lash Adjuster)


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

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Problem
1. Temporary noise when starting a
cold engine

Possible cause
Normal

Action
This noise will disappear after the oil
in the engine reaches the normal
pressure.

2. Continuous noise when the engine


is started after parking more than 48
hours.

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

Oil leakage of the high-pressure


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

5. Continuous noise when the engine


is running after changing the HLA.

6.Continuous noise during idle after


high engine speed.

Do not run engine at a speed


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

Check oil level.


Drain or add oil as necessary.

Excessive amount of air in the


oil at high engine speed.

Check oil supply system.

Deteriorated oil.

7. Noise cotinues for more than 15


minutes.

Low oil pressure.


Faulty HLA.

Check oil quality.


If deteriorated, replace with specitied
type.
Check oil pressure and oil supply
syste, of each part of engine.
Remove the cylinder head cover and
press HLA down by hand.
If it moves, replace the HLA.

Timing chain
Check the bushing and plate of timing chain for wear. Replace if there is severe wear.

REASSEMBLY
1. Install the HLA.
2. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as
shown in the illustration.

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3. Install the camshafts after lubricating the journals of the camshaft with engine oil.

To check the press fit, the camshaft (IN) and timing chain sprocket should be separable by a force
greater than 1000kg (MIN.)at room temperature.

4. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
I : Intake camshaft
E : Exhaust camshaft

5. Tighten the bearing caps to the specified torque in two or three increments as shown.
Tightening torque
Bearing cap bolt
M6 (50mm) : 14 ~ 16Nm (140 ~ 160kg.cm, 10 ~ 12lb.ft)
M6 (38mm) : 10 ~ 12Nm (100 ~ 120kg.cm, 7 ~ 9lb.ft)

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

7. Install the camshaft sprocket to the specified torque.


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

9. Install the spark plug cables and, center cover.


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

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13. Connect the breather hose and engine harness.


14. Install the intake manifold and engine cover.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly > 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Head Assembly > Valve
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder
Head Assembly > Valve > Repair procedures

DISASSEMBLY
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose and air-intake hose.
3. Remove the vacuum hose, fuel hose and coolant hose.
4. Remove the intake manifold.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the upper and lower timing belt cover.
8. Remove the timing belt and camshaft sprockets.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and head cover.
11. Remove the intake and exhaust camshaft.

12. Remove the cylinder head assembly. The cylinder head bolts should be removed using the S12 mm socket,
in two or three steps.
13. Clean the gasket pieces from the cylinder block top surface and cylinder head bottom surface.

Make sure that fragments from the gasket do not fall in the engine.

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INSPECTION
1. Remove scale, sealing compound and carbon deposits. After cleaning oil passages, apply compressed air to
make certain that the passages are notclogged.
2. Visually check the cylinder head for cracks, damage or water leakage.
3. Check the cylinder head surface for flatness with a straight edge and feeler gauge as shown in the illustration.
Cylinder head flatness
Standard dimensions : Max. 0.03mm (0.0059 in.)
Service limit : 0.05mm (0.0020 in.)

Valve Guides
Valve stem-to-guide clearance
Standard value
Intake : 0.02 ~ 0.05mm (0.0009 ~ 0.0020in.)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026 in.)
Service limit
Intake : 0.10mm(0.0039 in.)
Exhaust : 0.15mm(0.0059 in.)

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

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

Replacing Valve Guide


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

Size mark

Oversize valve guide hole size


mm(in.)

0.05 (0.002) O.S.

11.050 ~ 11.068
(0.435 ~ 0.4357)

0.25 (0.010) O.S.

25

11.250 ~ 11.268
(0.443 ~ 0.4436)

0.50 (0.020) O.S.

50

11.500 ~ 11.518
(0.453 ~ 0.4535)

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3. Using the special tool (09221-3F100 A/B) press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guidesare different in
length.
4. After the valve guide is press-fitted, insert a new valve and check for proper clearance.
5. After the valve guide is replaced, check that the valve is fully seated. Recondition the valve seats as
necessary.

Do not install a valve guide unless it is oversize.

Replacing Valve Seat Ring


1. Cut away the inner face of the valve seat to reduce the wall thickness.

2. Enlarge the diameter of the valve seat so that it matches the specified hole diameter of the new valve seat
ring.

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Valve Seat Ring Oversizes


Description

Size mm (in.)

Size
mark

Seat ring height H mm


(in.)

Oversize hole diameter


I.D. mm(in.)

Intake valve
Seat ring

0.3 (0.012) O.S.

30

7.9 ~ 8.1 (0.311 ~ 0.319)

33.300 ~ 33.325
(1.311 ~ 1.312)

Exhaust valve
Seat ring

0.3 (0.012) O.S.

30

7.9 ~ 8.1 (0.311 ~ 0.319)

28.600 ~ 28.625
(1.126 ~ 1.127)

3. Heat the cylinder head to about 250C (480F) and press-fit an oversize seat ring for the bore in the cylinder
head.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width
Intake : 1.1 ~ 1.5mm (0.043 ~ 0.059in.)
Exhaust : 1.3 ~ 1.7mm(0.051 ~ 0.067 in.)

REASSEMBLY
1. Install the spring seats.
2. Using special tool (09222-22001), lightly tap the seal in position.

Do not reuse old valve stem seals.


Incorrect installation of the seal could result in oil leakage of from the valve guides.

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

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5. Using the special tool (09222-28000, 09222-28100), compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are correctly in place before releasing the valvespring
compressor.

When the spring is compressed, check that the valve stem seal is not pressed against the bottom of the
retainer.

6. Clean both gasket surfaces of the cylinder head and cylinder block.
7. Verify the identification marks on the cylinder head gasket.
8. Install the gasket so that the surface with the identification mark faces toward the cylinder head.

Do not apply sealant to these surfaces.

9. Tighten the cylinder head bolts in the sequence shown in the illustration with a torque wrench.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Engine And Transaxle Assembly
> Engine And Transaxle Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Engine Mechanical System > Engine And Transaxle Assembly > Engine And Transaxle Assembly >
Repair procedures

REMOVAL
1. Remove the battery.
2. Detach the air cleaner.

3. Disconnect the engine harness connectors.


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

4. Drain the engine coolant.


5. For a vehicle with automatic transaxles, disconnect the transaxle oil cooler hoses.

When disconnecting hoses, make identification marks to avoid making any mistake when installing them
again.

Be careful not to spill any of oil or fluid out of the hoses. Plug the openings to prevent the entry of foreign
material.
6. Disconnect the radiator upper and lower hoses on the engine side then remove the radiator assembly.

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7. Disconnect the engine ground.


8. Disconnect the brake booster vacuum hose.
9. Disconnect the heater hoses (inlet and outlet) on the engine side.
10. Disconnect the accelerator cable at the engine side.
11. Using a special tool, remove the main fuel line at the delivery pipe (supply/return).
12. Disconnect the speedometer cable from the transaxle.
13. Disconnect the clutch cable or control cable from the transaxle.

14. Disconnect the power steering suction hose and return hose from the pump.

15. Detach the steering dust cover in the engine compartment and then disconnect the gear box universal joint
bolt.

Make sure to make identification marks between the universal joint and the gear box for reassembly.

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16. Raise the vehicle and then remove the front tire.
17. Attaching the wheel speed sensor and caliper to the body. Remove the kunckle mounting bolts.

18. Drain the transaxle oil.

19. Remove the front muffler bolts.


20. Remove the transaxle control rod and extension rod (M/T only).
21. Put the special fixture on the T/M jack and then adjust it to the sub-frame.

Check that all the cables, harness connector and hose are disconnected from the engine and transaxle
assembly.

22. Remove the engine mounting bracket and the transaxle mounting bracket.

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23. Remove the sub-frame installation bolts.

24. After removing the drive shaft, lower the engine and transaxle assembly on the jack then, remove the front
roll stopper and the rear roll stopper.

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

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Page 1 of 1

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Piston and
Connecting Rod > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Cylinder Block > Piston and Connecting Rod > Repair procedures

DISASSEMBLY
CONNECTING ROD CAP

Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for
proper reassembly.
1. Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing mark for
reassembly.
2. Push each piston connecting rod assembly toward the top of the cylinder.

DISASSEMBLY AND REASSEMLY OF THE PISTON PIN


1. Using the special tools 09234 - 33001 and 09234 - 3002, disassemble and reassemble the piston and
connecting rod.

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

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Page 2 of 6

5. To install a new pin, the proper fork inserts must be in place to support the rod.
6. Position the rod inside the piston. Insert the proper pin guide through one side of the piston and through the
rod. Hand tap the pin guide so it is held by the piston. Insert the new pin into the piston from the other side
and set the assembly into the support fixture with the pin guide facing down.

The pin guide should be centered on the connecting rod through the piston. If assembled correctly, the
pin guide will sit exactly under the center of the hole in the tool's arch, and rest evenly on the fork inserts.
If the wrong size pin guide is used, the piston and pin will not up with the support fixture.

7. Insert the installer tool through the hole in the arch of the support fixture and use an hydraulic press to force
the piston pin through the rod little end. Continue pressing until the pin guide falls free and the installer tool
seats against the top of the arch.

Do not exceed 1250 500 kg (2765 1100 lb) of force when the installing tool seats angainst the top of
the arch.

INSPECTION
Pistons and Piston Pins
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the
piston requires replacement, its rings should also be replaced.
3. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective. The
piston pin must be pressed smoothly by hand into the pin hole (at room temperature).

Piston Rings
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in
the ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the
piston and rings together. If it is less than the service limit, replace only the piston rings.
Piston ring side clearance
No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in.)
[Limit]
No.1 : 0.1 mm (0.004 in.)
No.1 : 0.1 mm (0.004 in.)
2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles
to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap
exceeds the service limit, replace the piston ring.

Piston ring end gap

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[Standard dimensions]
No.1 : 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.)
No.2 : 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.)
[Limit]
No.1, No.2 : 0.8mm (0.031in.)
Oil ring side rail : 1.0mm (0.039in)
When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the lower
part of cylinder that is less worn out.
Piston ring service size and mark
Standard

None

0.25mm (0.010in.) O.S


0.50mm (0.020in.) O.S

25
50

The mark can be found on the upper side of the ring next to the end.

Connecting Rods
1. When the connecting rod cap is installed, make sure that the cylinder numbers, marked on rod end cap at
disassembly, match. When a new connecting rod is installed, make sure that the notches holding the bearing
in placeare on the same side.
2. Replace the connecting rod if it is damaged at either end of the thrust faces. If it has a stratified wear, or if the
surface of the inside diameter of the small end is severely rough, replace the rod.

REASSEMBLY
1. Install the spacer.

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2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring
groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove (as
illustrated).

Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure described in Step 2.

4. Apply engine oil around the piston and piston grooves.


5. Using a piston ring expander, install the No.2 piston ring.
6. Install the No. 1 piston ring.

7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps
are not positioned in the thrust and pin directions.

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8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.

9. Install the upper main bearings in the cylinder block.


10. Install the lower main bearings in the main bearing caps.

Install the bearing so it matches the oil hole in the block.

11. Install the thrust washers in the No. 3 main bearing cap with the oil grooves facing outward.

12. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are
directed toward the front of the engine.
13. When the connecting rod cap is installed, make sure that any cylinder numbers placed on the rod and cap at
disassembly match.
14. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on
the same side.
15. When assembling, bolts should be fastened using the plastic angle technique as follows.
(1) Apply oil to the threads and matching areas.
(2) Tighten the connecting rod bolt.
Tightening torque
Connecting rod bolt :
16 ~ 20Nm (160~200kg.cm, 12~15lb.ft) + (90~94)

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After removing the connecting rod bolt, do not use it again.


When using a new bolt, do not tighten the bolt more than 3 times.

16. Check the connecting rod side clearance.


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Crankshaft >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Cylinder Block > Crankshaft > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Crankshaft >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder
Block > Crankshaft > Repair procedures

DISASSEMBLY
1. Remove the timing belt train, front case, flywheel, cylinder head assembly and oil pan. For details, refer to the
respective chapters.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.

Mark the main bearing caps to be able to reassemble in the original position and direction.
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the cap
number.

INSPECTION
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective parts.
2. Inspect the crankshaft journal and pin for out-of-round and taper.
Standard value
Crankshaft journal O.D :
61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crankshaft pin O.D :
47.982 ~ 48.000mm (1.8890 ~ 1.8898in)

Main Bearings and Connecting Rod Bearings


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

Measuring Oil Clearance


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

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Plastic gauge Method


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

Oil Seal
Check the front and rear oil seals for damage or worn surfaces. Replace any seat that is defective.

Drive Plate (A/T)


Replace distorted, damaged, or cracked drive plates.

FLYWHEEL (M/T)
See EM section.

REASSEMBLY
Main Bearing
1. Install a grooved main bearing (upper bearing) on the cylinder block side.
2. Install a grooveless main bearing (lower bearing) on the main bearing cap side.
3. Install the crankshaft. Apply engine oil to journal and pin.
4. Install the bearing caps with the arrow mark directed toward the front of the engine. Cap number must be
correct.
5. Tighten the cap bolts to the specified torque.

Tightening torque
Main bearing cap bolts

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


M10(1~8) : 27~33Nm (270~330kg.cm, 19.5~24 lb.ft) + (90~94)

6. Cap bolts should be tightened evenly in stages 4 to 5 increments before they are tightened to the specified
torque.
7. Make certain that crankshaft turns freely and check the end play of the crankshaft.
Crankshaft end play
Standard : 0.070 ~ 0.250mm (0.0028 ~ 0.0098in.)
Limit : 0.4mm (0.016in.)

8. Using special tool(09231-33000), install the rear oil seal in oil seal case.
9. Apply sealant to the area shown in the illustration. Install the oil seal case in the cylinder block.
Tightening torque
Oil seal case bolt :
10 ~ 12Nm (100 ~ 120kg.cm, 7 ~ 9 lb.ft)

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10. Tighten the rear plate to the specified torque.


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

12. Tighten the fly wheel (M/T).


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Cylinder 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Cylinder Block
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder
Block > Cylinder Block > Repair procedures

DISASSEMBLY
For further details, refer to the appropriate section.

INSPECTION
Cylinder Block
1. Check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Replace
the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated, in the directions A and B.
Level 2: Center of cylinder

3. If the cylinder bores show more than the specified out-of-round or taper, or if the cylidner walls are badly
scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings should be
installed.
Standard value
Cylinder bore : 86.7 mm (3.41 in.)
Out-of-round and taper of cylinder bore :
Max. 0.02 mm (0.0008 in.)
4. If a ridge exists at the top of the cylinder, cut it off with a ridge reamer.
5. Oversize pistons are available in two sizes.
Piston service size and mark mm (in.)
0.25 (0.010) O.S : 0.25
0.50 (0.010) O.S : 0.50
6. To rebore the cylinder bore to the oversize, maintain the specified clearance between the oversize piston and
the bore and make sure that all used pistons are the same oversize. The standard measurement of the piston
outside diameter is taken at a level of 15.5mm (0.61in.) above the bottom ofthe piston skirt and across the
thrust faces.
Piston-to-cylinder clearance
0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

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7. Check for damage or cracks in the cylinders.


8. Check the top surface of the cylinder block for flatness. If the top surface exceeds the limit, grind to the
minimum limit or replace.
Standard value
Flatness of gasket surface : Max. 0.03mm (0.0012in.)
Service limit
Flatness of gasket surface : 0.05mm (0.0020in.)

When the cylinder head is assembled, grinding less than 0.2mm (0.008in.) is permissible.

Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark

Size

0.25
0.50

0.25mm (0.010in.)
0.50mm (0.020in.)

The size of piston is stamped on top of the piston.


2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.01 to 0.03 mm (0.0004 to 0.0012 in.) (clearance between piston and cylinder)
- 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.

To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the
firing order.

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5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder
to the oversize.

REASSEMBLY
Install the following parts by referring to their respective sections.
1. Crankshaft
2. Drive plate
3. Piston
4. Cylinder head
5. Timing belt
6. Oil pump case

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Engine 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder Block > Engine Mounts
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cylinder
Block > Engine Mounts > Repair procedures

REMOVAL
Attach a chain or cable to the engine hooks and lift enough so that there is no pressure on the motor mounts.

Engine Mounting
1. Remove the engine mounting insulator bolts.
2. Remove the engine mounting bracket from the engine.

Transaxle Mounting
1. Remove the transaxle mounting insulator bolts.
2. Remove the tranaxle mounting bracket from the transaxle.

Front Roll Stopper


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

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Rear Roll Stopper


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Description
and Operation

COOLING SYSTEM
INLET CONTROL

FLOW CHART

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Water pump >
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

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Page 2 of 2

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Water pump >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Water pump > Repair procedures

REMOVAL
1. Using the drain plug, drain the coolant.
2. Remove the drive belt and the engine coolant pump pulley.
3. Remove the timing belt cover, the auto tensioner and idler pulley.
4. Remove the engine coolant pump mounting bolts.
5. Remove the engine coolant pump assembly from the cylinder block.

INSTALLATION
1. Clean the gasket surfaces of the engine coolant pump body and the cylinder block.

2. Install the new engine coolant pump gasket and pump assembly. Tighten the bolts to the specified torque.
Tightening torque
Engine coolant pump bolt
Head mark "7" :
15 ~ 22Nm (150 ~ 220kg.cm, 11 ~ 16lb.ft)
3. Install the auto tensioner and timing belt. Adjust the timing belt tension, then install the timing belt cover.
4. Install the drive belt, coolant pump pulley and then adjust the auto tensioner.
5. Refill the radiator with coolant.
6. Run the engine and check for leaks.

INSPECTION
1. Check the engine coolant pump for cracks, damage or wear, and replace the pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation and replace the pump assembly if
necessary.
3. Check the seal for leaks and replace the pump assembly if necessary.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Thermostat >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Cooling System > Thermostat > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Thermostat >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Thermostat > Repair procedures

REMOVAL
1. Drain the coolant to thermostat level or below.
2. Remove the inlet fitting and gasket.
3. Remove the thermostat.

INSTALLATION
1. Check that the flange of the thermostat is correctly placed in the socket of the thermostat housing.

2. Install the inlet fitting.


Tightening torque
Engine coolant inlet fitting bolt :
17 ~ 20Nm (170 ~ 200kg.cm, 12 ~ 14lb.ft)
3. Refill the coolant.

INSPECTION
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
3. Verify the temperature at which the valve begins to open.
Valve opening temperature : 80 ~ 84C (176 ~ 183.2 F)
Full opening temperature : 95C (203C)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Radiator > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator >
Repair procedures

REMOVAL
1. Disconnect the ground cable from the battery terminal.
2. Disconnect the fan motor connector.
3. Loosen the radiator drain plug to drain the coolant.
4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose clamp.

5. For vehicles with automatic transaxles, disconnect the oil cooler hoses from the automatic transaxle.

Cover or plug the hose and inlets of the radiator so that dust and other foreign materials can not enter after the hose
is disconnected from the radiator.
6. Remove the radiator upper mounting bolt.

7. Remove the radiator together with the fan motor.


8. Remove the radiator fan motor and condenser fan motor from the radiator.

INSTALLATION
1. Fill the radiator and reservoir tank with a clean coolant mixture.
2. Run the engine until the coolant warms up enough so that the thermostat valve opens and then turn off the engine.
3. Remove the radiator cap and pour the coolant up to the filler neck of the radiator. Fill the reservoir tank to the upper level.
4. Check that there are no leaks from the radiator, hoses or connections.

INSPECTION
1. Check for foreign material between the radiator fins.
2. Check the radiator fins for damage and straighten if necessary.
3. Check the radiator for corrosion, damage, rust or scale.
4. Check the radiator hoses for cracks, damage or deterioration.
5. Check the reservoir tank for damage.
6. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration (only A/T).

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Radiator Cap
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling
System > Radiator Cap > Repair procedures

INSPECTION
1. Check the radiator cap for damage, cracks or weakening.

2. Connect the tester to the radiator cap.


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

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Cooling System > Engine
Coolant Hose / Pipes > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Cooling System > Engine Coolant Hose / Pipes > Repair procedures

COOLANT TEMPERATURE SENSOR REPLACEMENT


REMOVAL
1. Drain the engine coolant.
2. Remove the engine harness after disconnecting the ground cable of the battery.
3. Remove the engine coolant sensor.

INSTALLATION
1. Apply sealant to the sensor's threads. Tighten it to the specified torque.
Recommended sealant
Three bond NO. 1324 or LOCTITE 262
Tightening torque
The coolant sensor :
20 ~ 40Nm (200 ~ 400kg.cm, 14 ~ 29lb.ft)
2. Connect the coolant sensor to the harness.
3. Connect the ground cable of battery.
4. Refill radiator with the coolant.

INSPECTION
Check the engine coolant pipe and hose for cracks, damage and restrictions. Replace if necessary.

REASSEMBLY
Fit the O-ring in the groove of the engine coolant inlet pipe end. Wet the periphery of the O-ring with water and
insert the engine coolant inlet pipe.

1.
2.
3.
4.

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


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Lubrication System > 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Lubrication System > Oil Pump >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Lubrication
System > Oil Pump > Repair procedures

DISASSEMBLY
1. Remove the oil pressure switch, using 24 mm deep socket.

Since a sealant is used on the threaded area, be careful not to damage the oil pressure switch.
2. Remove the oil filter and the oil pan.
3. Remove the oil screen and gasket.
4. Remove the three bracket securing bolts and remove the oil filter bracket and gasket.
5. Remove the oil relief valve plug from the oil pump case.
6. Remove the oil pump case.

INSPECTION
Oil Pump
1. Visually check the parts of the oil pump case for cracks and damage.
2. Assemble the rotor on the oil pump and then check the clearance with a thickness gauge.
Oil pump side clearance
Standard value
Body clearance : 0.100 ~ 0.181mm (0.0039 ~ 0.0071 in.)
Side clearance : 0.040 ~ 0.095mm (0.0016 ~ 0.0037in.)

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Relief Plunger and Spring


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

Oil Filter Bracket


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

Oil pressure Switch


1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity
even when the fine wire is pushed,replace the switch.
3. If there is no continuity when a 50 kpa (7 psi) vacuum is applied through the oil hole, the switch is operating
properly.
Check for air leakage. If air leaks, the diaphragm is broken replace it.

Operation Pressure
Oil pressure switch :
20 ~ 40kpa (0.2 ~ 0.4kg/cm. 2.9 ~ 5.8 psi)

REASSEMBLY

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1. Install the oil pump case with the gasket.


Tightening torque
Oil pump case bolt :
12 ~ 15Nm (120 ~ 150kg.cm, 9 ~ 11lb.ft)
Oil pump cover screw :
8 ~ 12Nm (80 ~ 120kg.cm, 6 ~ 9lb.ft)

2. Install the oil seal into the oil pump case as tightly as possible, using the special tool (09214-33000).

3. Install the relief plunger and spring, and tighten the oil relief valve plug to the specified torque.
Tightening torque
Oil relief valve plug :
40 ~ 50Nm (400 ~ 500kg.cm, 29 ~ 36lb.ft)

4. Install the oil screen and a new gasket.


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

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1. Make the first cut approx. 4 mm from the end of the nozzle furnished with the sealant. After
application of the sealant, do not exceed 15 minutesbefore installing the oil pan.
2. Make sure that the sealant doesn't enter the inside of the oil pan.
7. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt
* : 19 ~ 28Nm (190 ~ 280kg.cm, 14 ~ 20lb.ft)
** : 5 ~ 7Nm (50 ~ 70kg.cm, 4 ~ 5lb.ft
*** : 30 ~ 42Nm (300 ~ 420kg.cm, 22 ~ 30lb.ft)

8. Tighten the oil pan bolts as shown in the illustration.

9. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.
Sealant
Three bond No.1141E or 3M ATD No. 8660 or equivalent

Do not torque the oil pressure switch too much.

Tightening torque
Oil pressure switch
15 ~ 22Nm (150 ~ 220kg.cm, 11 ~ 16lb.ft)

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Sealant
Three bond No.1141E or 3M ATD No. 8660 or equivalent

10. Tighten the lower oil pan bolts as shown in figure.

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Air
Cleaner > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System >
Intake And Exhaust System > Air Cleaner > Repair procedures

REMOVAL
1. Disconnect the air flow sensor connector.
2. Remove the air intake hose and air duct connected to the air cleaner.
3. Remove the three bolts attaching the air cleaner mounting brackets.
4. Detach the air cleaner.

5. Remove the air flow sensor from the air intake hose.

Do not pull on the air flow sensor wires.

INSTALLATION
1. Install the air cleaner assembly following the reverse order of removal.

INSPECTION
1. Check the air intake hose, air cleaner cover for damage.
2. Check the air duct for damage.

3. Check the air cleaner element for restriction, contamination or damage.


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

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System >
Intake Manifold > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Intake And Exhaust System > Intake Manifold > Repair procedures

REMOVAL
1. Remove the air intake hose connected to the throttle body.

2. Remove the accelerator and cruise control cables.

3. Remove the engine coolant hose and throttle body.


4. Remove the P.C.V. hose and brake booster vacuum hoses.
5. Disconnect the vacuum hose connections.

6. Remove the surge tank stay.

7. Bleed off the pressure in the fuel pipe line to prevent the fuel from spilling.
8. Disconnect the connector from high pressure hose.

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9. Remove the surge tank.

10. Remove the surge tank and gasket.

11. Disconnect the fuel injector harness connector.

12. Remove the delivery pipe with the fuel injector and the pressure regulator.

When the delivery pipe is removed, be careful not to drop an injector.

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13. Disconnect the wiring harness of the coolant sensor assembly.

INSTALLATION
1. Install the intake manifold and delivery pipe reversing the order of the removal procedure.
Tightening torque
Intake manifold :
19 ~ 21Nm (190 ~ 210kg.cm, 14 ~ 15lb.ft)

INSPECTION
SURGE TANK AND INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage, cracking or restriction of the vacuum outlet port, water
or gas passages.

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

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System >
Exhaust Manifold > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical
System > Intake And Exhaust System > Exhaust Manifold > Repair procedures

REMOVAL
1. Remove the heat protector.

2. Remove the exhaust manifold.


3. Remove the exhaust manifold gasket.

INSTALLATION
1. Install the exhaust manifold with gasket.
Tightening torque
Exhaust manifold :
30 ~ 35Nm (300 ~ 350kg.cm, 22 ~ 26lb.ft)

Do not re - use an exhaust manifold gasket.


2. Install the heat protector.

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

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3. Check the exhaust manifold for damage and cracks.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust System > Muffler >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Engine Mechanical System > Intake And Exhaust
System > Muffler > Repair procedures

REMOVAL
Main Muffler

Before removing or inspecting the exhaust system, ensure that the exhaust system is cool.
1. Disconnect the main muffler from the center exhaust pipe.
2. Remove the rubber hangers and the main muffler.

Front Exhaust Pipe (Including catalytic converter)


1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe bolt and the exhaust manifold pipe mounting nuts.

3. Remove the front exhaust pipe.

INSTALLATION
1. Temporarily install the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe and the main
muffler, in this order.
2. Install the rubber hangers so that they hang equally left and right.
3. Tighten the parts securely and then confirm that there is no interference with any components.

INSPECTION
1. Check the mufflers and pipes for leaks, corrosion and damage.
2. Check the rubber hangers for deterioration and cracks.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information >
Schematic Diagrams

SCHEMATIC DRAWING [2.7 V6]

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Flow Diagram,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Flow Diagram

VACUUM HOSES LAYOUT

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information
> Components and Components Location

COMPONENTS

A. PCV valve

B. EVAP Canister Purge Solenoid Valve

C. Two-way Valve

D. Catalytic Converter (MCC)

E. Catalytic Converter (UCC)

F. Evap. Canister

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General
Information > Troubleshooting

TROUBLESHOOTING
Symptom

Probable cause

Remedy

Engine will not start or hard to


start

Vacuum hose disconnected or damaged

Repair or replace

Malfunction of the EVAP Canister Purge


Solenoid Valve

Repair or replace

Rough idle or engine stalls

Vacuum hose disconnected or damaged

Repair or replace

Malfunction of the PCV valve

Replace

Malfunction of the evaporative emission


canister purge system

Check the system; if there is a


problem, check related
components parts

Positive crankcase ventilation line clogged

Check positive crankcase


ventilation system

Excessive oil consumption

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > General
Information > Specifications

SPECIFICATIONS
Components

Function

Remarks

Crankcase Emission System


HC reduction
Positive Crankcase Ventilation (PCV) valve

Variable flow rate type

Evaporative Emission System


EVAP Canister
EVAP Canister Purge Solenoid Valve

Duty control solenoid valve

HC reduction

Exhaust Emission System


CO, HC, NOx reduction
MFI system (air-fuel mixtrue control device) CO, HC, NOx reduction
Three-way catalytic converter

Heated oxygen sensor feedback type


Monolithic type

MFI : Multiport Fuel Injection


EVAP : Evaporative Emission

SERVICE STANDARD
Item
Evaporative emission canister purge solenoid
valve
Coil resistance

Specifications
26 [at 20C (68F)]

TIGHTENING TORQUE
Item
Positive Crankcase Ventilation Valve

Nm

kgcm

lbft

8 ~ 12

80 ~ 120

6~8

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control System >
Flow Diagram, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control
System > Flow Diagram

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control
System > Positive Crankcase Ventilation (PCV) Valve > Description and Operation, TIBURON(GK) >
2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control System > Positive
Crankcase Ventilation (PCV) Valve > Description and Operation

OPERATION
Intake manifold side (No vacuum)

Intake manifold side (High vacuum)

Rocker cover side

Rocker cover side

Engine condition

Not running

Engine condition

Idling or decelerating

PCV valve

Not running

PCV valve

Fully operating

Vacuum passage

Restricted

Vacuum passage

Small

Intake manifold side (Moderate vacuum)

Intake manifold side (Low vacuum)

Rocker cover side

Rocker cover side

Engine condition

Normal operation

Engine condition

Accelerating and high load

PCV valve

Properly operating

PCV valve

Slightly operating

Vacuum passage

Large

Vacuum passage

Much large

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Crankcase Emission Control
System > Positive Crankcase Ventilation (PCV) Valve > Repair procedures, TIBURON(GK) > 2003 > G
2.7 V6 DOHC > Emission Control System > Crankcase Emission Control System > Positive Crankcase
Ventilation (PCV) Valve > Repair procedures

REMOVAL
1. Disconnect the ventilation hose from the positive crankcase ventilation(PCV) valve. Remove the PCV valve
from the rocker cover and reconnect it to the ventilation hose.
2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold
vacuum is felt.

The plunger inside the PCV valve will move back and forth.
3. If vacuum is not felt, clean the PCV valve and ventilation hose in cleaning solvent, or replace if necessary.

INSTALLATION
Install the positive crankcase ventilation valve and tighten to the specified torque.
Tightening torque PCV valve:
8~12 Nm (80~120 kgcm, 6~8 lbft)

INSPECTION
1. Remove the positive crankcase ventilation valve.
2. Insert a thin stick into the positive crankcase ventilation valve from the threaded side to check that the plunger
moves.
3. If the plunger does not move, the positive crankcase ventilation valve is clogged. Clean or replace it.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control System >
Flow Diagram, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission
Control System > Flow Diagram

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control System >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative
Emission Control System > Description and Operation

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control
System > Canister > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control
System > Evaporative Emission Control System > Canister > Repair procedures

INSPECTION
For monitor, there are a CCV and an air filter as the illustration.
1. Look for loose connections, sharp bends or damage to the fuel vapor lines.
2. Look for distortion, cracks or fuel leakage.
3. After removing the EVAP Canister, inspect for cracks or damage.

CHECK OF CANISTER CLOSE VALVE OPERATING


1. Connect the CCV pins to a wire as shown.
2. At idle, disconnect the CCV connector.
3. Inspect that CCV is close when attaching the wire to(-) of battery.
4. Inspect that CCV is open when detaching the wire from(-) of battery.

In this case, if you use a very thin paper and attach it to hose to CCV, you can check easy the CCV
condition.
(1) If the paper is absorbed into or out, CCV is open.
(2) If not, CCV is close.

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AIR FILTER
Look for distortion, cracks.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control System >
Purge Control Solenoid Valve (PCSV) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission
Control System > Evaporative Emission Control System > Purge Control Solenoid Valve (PCSV) > Repair
procedures

INSPECTION

EVAP CANISTER PURGE SOLENOID VALVE

The EVAP Canister Purge Solenoid Valve is controlled by the ECM; when the engine coolant temperature is low, and
also during idling, the valve closes so that evaporated fuel is not drawn into the surge tank. After engine warm-up
during ordinary driving, it opens to let the stored vapors flow into the surge tank.

When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original
position.

1. Disconnect the vacuum hose(black with red stripe) from the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected.
4. Apply vacuum and check when voltage is applied to the EVAP Canister Purge Solenoid Valve and when the voltage is

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discontinued.
Battery voltage

Normal condition

When applied

Vacuum is released

When discontinued

Vacuum is maintained

5. Measure the current between the terminals of the solenoid valve.


EVAP Canister Purge Solenoid Valve
Coil at 20C (68F) : 0.45A or below (at 12V)
Coil resistance : 26 [at 20C (68F)]

VACUUM HOSE
Engine coolant temperature : 80~95C (176~205F)
1. Disconnect the vacuum hose from the intake manifold purge hose nipple and connect a hand vacuum pump to the
nipple.

2. Start the engine and check that, after raising the engine speed by racing the engine, vacuum remains fairly constant.

If there is no vacuum created the intake manifold port may be clogged and require cleaning.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Emission Control System > Evaporative Emission Control
System > Fuel Tank Pressure Sensor (FTPS) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Emission Control System > Evaporative Emission Control System > Fuel Tank Pressure
Sensor (FTPS) > Repair procedures

INSPECTION
This is the sensor to detect the fuel tank leakage in way which it measures the differential pressure between the
inside and outside of the fuel tank.

Check that fuel level is over 15%. If not, this inspection is not available. The vehicle must be running and at idle.
Don't forget it.
1. Prepare a voltmeter and connect it to FTP pins as shown.

2. After 20 min.' idling , inspect the voltage.


System voltage : 5V
At acceleration : Max. 4.5, Min. 0.5V
3. At idle make sure that voltage changes as rpm changes.

If voltage is not within specification, there is a leak. Inspect the fuel tank and hoses toward canister and
fuel neck. Then repair or replace relevant parts.

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TIBURON(GK) > 2003 > G 2.7 V6 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
Check the gasket of the fuel filler cap, and the filler cap itself, for damage or deformation. Replace the cap if
necessary.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name)
09353-38000
Fuel pressure gauge adapter

Illustration

Use
Connection of fuel pressure gauge to
delivery pipe for measurement of fuel
pressure.

09353-24100
Fuel pressure gauge & hose

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Description and Operation,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Description and Operation

MULTIPORT FUEL INJECTION (MFI)


GENERAL INFORMATION
FUEL INJECTION CONTROL

IDLE SPEED CONTROL


IGNITION TIMING CONTROL

OTHER CONTROL FUNCTIONS


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

DIAGNOSTIC TEST MODE


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

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

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1. Ask the customer about the malfunction.


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

SERVICE POINTS IN INSPECTING A BLOWN FUSE

Harness being crushed by the vehicle body.


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

INSPECTING THE MFI SYSTEM


1. Engine is hard to start or does not start at all
2. Unstable idle
3. Poor driveability

ON-BOARD DIAGNOSTICS
Diagnostic trouble codes are set as follows:
After the PCM first detects a malfunction, a diagnostic trouble code is recorded when the engine is restarted and the
same malfunction is re-detected. (Themalfunction is detected in driving cycle). However, for fuel system rich/lean
misfiring, a diagnostic trouble code is recorded on the first detection of the malfunction.
Erasing diagnostic trouble codes:
After recording the diagnostic trouble code, if the PCM does not re-detect the malfunction for 40 driving cycles, the
diagnostic trouble code will be erased from the PCM memory. However, for fuel system rich/lean or misfiring,the
diagnostic trouble code will be erased if both of the following conditions are met:
- When driving conditions (engine speed, engine coolant temperature, etc.) are identical to those when the
malfunction was first recorded.
- When the PCM does not re-detect the malfunction for 80 driving cycles.

A "driving cycle" is complete as soon as the vehicle goes into closed-loop operation.

Catalyst
Fuel system
Air flow sensor (MAF sensor)
Intake Air Temperature Sensor (IAT sensor)
Engine Coolant Temperature Sensor (ECT sensor)
Throttle Position Sensor (TPS)
Front Oxygen Sensor
Rear Oxygen Sensor Heater
Rear Oxygen Sensor
Front Oxygen Sensor Heater
Injector
Misfire
Crankshaft Position Sensor (CKP sensor)

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Camshaft Position Sensor (CMP sensor)


Evaporative Emission Control System
Vehicle Speed Sensor (VSS)
Idle Speed Control
PCM

1. After turning the ignition key on, check that the light illuminates for 5 seconds without the engine running.
2. If the light does not illuminate, check for an open circuit in the harness,blown fuse and blown bulb.

When battery voltage is excessively low, diagnostic trouble codes can not be read. Be sure to check the battery for
voltage and the charging system before starting the test.
Codes are erased if the battery or the PCM connector is disconnected. Do not disconnect the battery before the
diagnostic trouble codes are completely read and recorded.
1.
2.
3.
4.
5.
6.
7.

Turn OFF the ignition switch.


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

TROUBLESHOOTING
DIAGNOSTIC TROUBLESHOOTING FLOW

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Troubleshooting, TIBURON(GK) >
2003 > G 2.7 V6 DOHC > Fuel System > General Information > Troubleshooting

TROUBLESHOOTING
1. Power supply
Battery
Fusible link
Fuse
2. Body ground
3. Fuel supply
Fuel line
Fuel filter
Fuel pump
4. Ignition system
Spark plug
High-tension cable
Ignition coil
5. Emission control system
PCV system
Vacuum leak
6. Others
Ignition timing
Idle speed

TROUBLESHOOTING GUIDE CHART

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The number herein means the check order.

MFI TROUBLESHOOTING PROCEDURES


PROBLEM

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Scan tool communication with PCM is not possible


Comment
One of the following causes may be suspected
No power supply to PCM
Defective ground circuit of PCM
Defective PCM
Improper communication line between PCM and scan
tool

Probable cause
Malfunction of PCM power supply circuit.
Malfunction of the PCM.
Open circuit between PCM and DLC.

Engine will not start

Difficult to start (Engine Cranks)

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ROUGH IDLE OR ENGINE STALLS

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Engine hesitates or accelerates poorly

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TROUBLESHOOTING
Trouble symptom
Engine will not crank

Engine cranks slowly

Probable cause

Remedy

Battery charge low

Charge or replace battery

Battery cables loose, corroded or worn

Repair or replace cables

Transaxle range switch faulty


(Vehicle 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

Battery charge low

Charge or replace battery

Battery cables loose, corroded or worn

Repair or replace cables

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Starter keeps running

Starter spins but engine will not


crank

Starter motor faulty

Repair starter motor

Starter motor faulty

Repair starter motor

Ignition switch faulty

Replace ignition switch

Pinion gear teeth broken or starter motor Repair starter motor


faulty
Ring gear teeth broken

Replace flywheel ring gear or torque


converter

FUEL TANK AND FUEL LINE


Trouble symptom
Engine malfunctions due to
insufficient fuel supply

Evaporative emission system


malfunction (when fuel filler cap is
removed,pressure is released)

Probable cause
Bent or kinked fuel pipe or hose

Remedy
Repair or replace

Clogged fuel pipe or hose

Clean or replace

Clogged fuel filter of in-tank fuel filter

Replace

Water in fuel filter

Replace the fuel filter or clean the fuel


tank and fuel lines

Dirty or rusted fuel tank interior

Clean or replace

Malfunctioning fuel pump


(clogged filter in the pump)

Replace

Incorrect routing of a vapor line

Correct

Disconnected vapor line

Correct

Folded, bent, cracked or clogged vapor


line

Replace

Faulty fuel tank cap

Replace

Malfunctioning overfill limiter


(two-way valve)

Replace

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Specifications, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > General Information > Specifications

GENERAL SPECIFICATIONS
Items
Throttle body

Sensors

Throttle position
sensor (TPS)

Type

Variable resistor

Resistance at
curb idle

2.7 V6

1.6 ~ 2.4 K

Output voltage
at curb idle

2.7 V6

250 ~ 800 mV

Idle speed control


(ISC) actuator

Type

Double Coil

Resistance

90 ~ 110 Hz

Air flow sensor

Type

2.7 V6

Hot Film sensor

Intake air
temperature (IAT)
sensor

Type

2.7 V6

Thermistor

Engine coolant
temperature (ECT)
sensor

Actuators

Specifications

Resistance

2.33 ~ 2.97 K at 20C (68F)

Type

Thermistor

Resistane

2.5 K at 20C (68F)


0.3 K at 80C (176F)

Heated oxygen
sensor (HO2S)

Type

Vehicle speed
sensor

Type

Hall effect

Camshaft position
(CMP) sensor

Type

Hall effect

Injectors

Type, number

Evaporative
emission purge
control solenoid
valve

2.7 V6

2.7 V6

Zirconium

Electromagnetic type, 6

Resistance

13 ~ 16 at 20C (68F)

Type

Duty cycle type

Fuel pressure
regulator

Pressure regulator

300 1.5 kPa


(3.35 0.06 kg/cm)

Fuel tank

Tank capacity
Return system

55 lit (12.1 lmp.gal)


Equipped

Canister

Volume/Nominal working capacity

3.0 liter/150g

SERVICE STANDARD
Items
Basic ignition timing

2.7 V6
2.7 V6

Curb idle speed (rpm)

Fuel pressure kPa (psi)

Standard value
BTDC 12 5 at curb idle
D-range (A/T)

650 100

P,N-range

750 100 (A/C OFF)

(A/T, M/T)

800 100 (A/C ON)

Vacuum hose disconnection

330 ~ 350 (47 ~ 50) at curb idle

Vacuum hose connection

Approx. 270 (38) at curb idle

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Evap canister purge control solenoid valve resistance

20 ~ 32

TIGHTENING TORQUE
Items
Delivery pipe installation bolts
Engine coolant temperature sensor
Heated oxygen sensor
Heated oxygen sensor connector bracket bolt
Fuel pressure regulator installation bolt
High pressure hose and fuel main pipe
High pressure hose and fuel filter
High pressure hose to delivery pipe
Fuel pump assembly to fuel tank
High pressure hose at fuel tank
Throttle body to surge tank
Accelerator arm bracket bolts
ISC actuator
Fuel sender to fuel tank

Nm

Kgcm

lbft

10 ~ 15
20 ~ 40
40 ~ 50
8 ~12
7 ~ 11
30 ~ 40
25 ~ 35
3~4
2~3
30 ~ 40
15 ~ 20
8 ~ 12
6~8
2~3

100 ~ 150
200 ~ 400
400 ~ 500
80 ~ 120
70 ~ 110
300 ~ 400
250 ~ 350
30 ~ 40
20 ~ 30
300 ~ 400
150 ~ 200
80 ~ 120
60 ~ 80
20 ~ 30

7 ~ 11
14 ~ 29
29 ~ 36
5.8 ~ 8.7
5.2 ~ 8.1
22 ~ 29
18 ~ 25
2.2 ~ 3
1.4 ~ 2.2
1.4 ~ 2.2
11 ~ 14
5.8 ~ 8.7
4.4 ~ 5.8
1.4 ~ 2.2

SEALANT
Item

Specified sealant

Engine coolant temperature sensor

LOCTITE 962T or equivalent

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System >
Description and Operation

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (FOR 2.7 V6)


DTC NO.

CONTENT

Memory MIL

P0101

Mass Air Flow Circuit Range/performance Problem

P0102

Mass Air Flow Circuit Low Input

P0103

Mass Air Flow Circuit High Input

P0112

Intake Air Temperature Circuit Low Input

P0113

Intake Air Temperature Circuit High Input

P0116

Engine Coolant Temperature Sensor Circuit Range/Performance


Problem

P0117

Engine Coolant Temperature Circuit Low Input

P0118

Engine Coolant Temperature Circuit High Input

P0119

Engine Coolant Temperature Circuit Intermittent

P0121

Throttle Position Sensor Circuit Range/Performance Problem

P0122

Throttle Position Sensor Circuit Low Input

P0123

Throttle Position Sensor Circuit High Input

P0125

Insufficient Coolant Temperature For Closed Loop Fuel Control

P0128

Coolant thermostat stuck

P0131

HO2S Circuit Low Input (Bank 1, Sensor 1)

P0132

HO2S Circuit High Input (Bank 1, Sensor 1)

P0133

HO2S Circuit Slow Responsive (Bank 1, Sensor 1)

P0134

HO2S Circuit No Activity Detected (Bank 1, Sensor 1)

P0030

HO2S Heater Control Circuit (Bank 1, Sensor 1)

P0031

HO2S Heater Circuit Low (Bank 1, Sensor 1)

P0032

HO2S Heater Circuit High (Bank 1, Sensor 1)

P0137

HO2S Circuit Low Input (Bank 1, Sensor 2)

P0138

HO2S Circuit Low Input (Bank 1, Sensor 2)

P0140

HO2S Circuit No Activity Detected (Bank 1, Sensor 2)

P0037

HO2S Heater Circuit Low (Bank 1, Sensor 2)

P0038

HO2S Heater Circuit High (Bank 1, Sensor 2)

P0151

HO2S Circuit Low Input (Bank 2, Sensor 1)

P0152

HO2S Circuit High Input (Bank 2, Sensor 1)

P0153

HO2S Circuit Slow Responsive (Bank 2, Sensor 1)

P0154

HO2S Circuit No Activity Detected (Bank 2, Sensor 1)

P0050

HO2S Heater Control Circuit (Bank 2, Sensor 1)

P0051

HO2S Heater Circuit Low (Bank 2, Sensor 1)

P0052

HO2S Heater Circuit High (Bank 2, Sensor 1)

P0157

HO2S Circuit Low Input (Bank 2, Sensor 2)

P0158

HO2S Circuit High Input (Bank 2, Sensor 2)

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P0160

HO2S Circuit No Activity Detected (Bank 2, Sensor 2)

P0057

HO2S Heater Circuit Low (Bank 2, Sensor 2)

P0058

HO2S Heater Circuit High (Bank 2, Sensor 2)

P0171

Fuel System Too Lean (Bank 1)

P0172

Fuel System Too Rich (Bank 1)

P0174

Fuel System Too Lean (Bank 2)

P0175

Fuel System Too Rich (Bank 2)

P0230

Fuel Pump Circuit Malfunction

P0261

Injector Circuit Low Input (Cylinder -1)

P0264

Injector Circuit Low Input (Cylinder -2)

P0267

Injector Circuit Low Input (Cylinder -3)

P0270

Injector Circuit Low Input (Cylinder -4)

P0273

Injector Circuit Low Input (Cylinder -5)

P0276

Injector Circuit Low Input (Cylinder -6)

P0262

Injector Circuit High Input (Cylinder -1)

P0265

Injector Circuit High Input (Cylinder -2)

P0268

Injector Circuit High Input (Cylinder -3)

P0271

Injector Circuit High Input (Cylinder -4)

P0274

Injector Circuit High Input (Cylinder -5)

P0277

Injector Circuit High Input (Cylinder -6)

P0300

Random Misfire Detected

P0301

Misfire Detected (Cylinder -1)

P0302

Misfire Detected (Cylinder -2)

P0303

Misfire Detected (Cylinder -3)

P0304

Misfire Detected (Cylinder -4)

P0305

Misfire Detected (Cylinder -5)

P0306

Misfire Detected (Cylinder -6)

P0325

Knock Sensor Circuit Malfunction (Bank 1)

P0330

Knock Sensor Circuit Malfunction (Bank 2)

P0335

Crankshaft Position Sensor Circuit Malfunction

P0340

Camshaft Position Sensor Circuit Malfunction

P0420

Main catalyst efficiency deterioration (Bank 1)

P0430

Main catalyst efficiency deterioration (Bank 2)

P0441

EVAP Emission Control System Incorrect Purge Flow

P0442

EVAP Emission Control System Small Leak (1 mm)

P0444

EVAP Emission Control System Purge Control Valve Circuit Open

P0445

EVAP Emission Control System Purge Control Valve Circuit Shorted

P0449

EVAP Emission Control System Vent Valve/Solenoid Circuit

P0447

EVAP Emission Control System Vent Circuit Open

P0448

EVAP Emission Control System Vent Circuit Shorted

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P0451

EVAP Emission Control System Pressure Sensor Range/Performance


Problem

P0452

EVAP Emission Control System Pressure Sensor Low Input

P0453

EVAP Emission Control System Pressure Sensor High Input

P0454

Evaporative Emission Control System - Pressure Sensor Intermittent

P0455

EVAP Emission Control System - Large Leak

P0456

Evaporative Emission Control System - Small Leak Detected (0.5mm)

P0461

Fuel Level Sensor Circuit Range/Performance

P0462

Fuel Level Sensor Circuit Low Input

P0463

Fuel Level Sensor Circuit High Input

P0464

Fuel Level Sensor Circuit Intermittent

P0501

Vehicle Speed Sensor Range/Performance

P0506

Idle Control System Rpm Lower than Expected

P0507

Idle Control System rpm Higher than Expected

P1134

HO2S Circuit - Transition Switch Malfunction/Slip (Bank 1, Sensor 1)

P1154

HO2S Circuit - Transition Switch Malfunction/Slip (Bank 2, Sensor 1)

P1166

Lambda Bank Control Limit (Bank 1)

P1167

Lambda Bank Control Limit (Bank 2)

P0036

HO2S Heater Control Circuit (Bank 1, Sensor 2)

P0056

HO2S Heater Control Circuit (Bank 2, Sensor 2)

P1372

Segment Time Acquisition Incorrect

P1505

Idle Speed Actuator Signal Low of Coil #1

P1506

Idle Speed Actuator Signal High of Coil #1

P1507

Idle Speed Actuator Signal Low of Coil #2

P1508

Idle Speed Actuator Signal High of Coil #2

P1521

Power Steering Switch Malfunction

P1529

TCU Request for MIL ON/Freeze Frame to ECU via CAN

P1602

Serial Communication Problem with TCU (Timeout)

P0605

Internal CONTROL module ROM error

P0560

System Voltage Malfunction

P0562

System Voltage Low

P0563

System Voltage High

P0650

Malfunction Indication Lamp (MIL) Control Circuit Malfunction

P1624

Cooling Fan Relay Circuit Malfunction (LOW)

P1625

Cooling Fan Relay Circuit Malfunction (HIGH)

TROUBLE AREA RELATED TO DTC

Check items for each diagnostic item do not list all probable causes.
DTC No.

Diagnostic items

Trouble area

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P0101

Mass Air Flow Circuit


Range/performance Problem

Dirty air cleaner


Oil cap or dipstick missing or not installed correctly
Air leak in intake system
Contaminated, deteriorated or damaged mass air flow sensor
Faulty mass air flow sensor or throttle position sensor
Poor connections between ECM and MAFS or TPS

If any codes relating to MAFS are present, do all repairs


associated with them before proceeding with this
troubleshooting area.
P0102

Mass Air Flow Circuit Low Input

Short to ground between MAFS and ECM


Signal line open between MAFS and ECM
Faulty MAFS

P0103

Mass Air Flow Circuit High Input

Short to Battery between MAFS and ECM


Ground open between MAFS and EGI main relay
Ground open or Poor connections between open or short to
battery between MAFSand ECM
Faulty MAFS

P0112

Intake Air Temperature Circuit


Low Input

Short to ground between IAT sensor and ECM


Short between IAT sensor wires
Faulty IAT sensor

P0113

Intake Air Temperature Circuit


High Input

Open or short to battery between IAT sensor and ECM


Faulty IAT sensor

P0115

Engine Coolant Temperature


Circuit Malfunction

P0116

Engine Coolant Temperature


Sensor Circuit
Range/Performance Problem

After engine start-up, the measured coolant temperature


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

Open or short to battery between ECTS and ECM


Short to ground between ECTS and ECM
Short between ECTS wires
Faulty ECTS

If any codes relating to ECTS are present, do all repairs


associated with them before proceeding with this
troubleshooting area.
P0117

Engine Coolant Temperature


Circuit Low Input

Short to ground between ECTS and ECM


Short between ECTS wires
Faulty ECTS

P0118

Engine Coolant Temperature


Circuit High Input

Open or short to battery between ECTS and ECM


Faulty ECTS

P0119

Poor connections between ECTS and ECM

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Engine Coolant Temperature


Circuit Intermittent

Misplaced, loose or corroded terminals


Foreign materials fouled ECTS

P0121

Throttle Position Sensor Circuit


Range/Performance Problem

P0122

Throttle Position Sensor Circuit


Low Input

Short to GND between TPS and ECM


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

P0123

Throttle Position Sensor Circuit


High Input

Open or short to battery between TPS and ECM


Open between and ECM
Faulty TPS

P0125

Insufficient Coolant
Temperature For Closed Loop
Fuel Control

After engine start-up, the elapsed time before feedback


operation is initiated is too long (engine coolant temperature
sensor input is insufficient for closed loop operation)
Poor connections between ECT sensor and ECM
Faulty ECTS
Thermostat

P0128

Coolant thermostat stuck

Thermostat stuck opened

P0131

HO2S Circuit Low Input (Bank


1, Sensor 1)

Short to GND between HO2S and ECM


Faulty front HO2S

P0132

HO2S Circuit High Input (Bank


1, Sensor 1)

Short to battery between HO2S and ECM


Faulty front HO2S

P0133

HO2S Circuit Slow Responsive


(Bank 1, Sensor 1)

Poor connections between TPS and ECM


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

Front and rear HO2S connections reversed


Faulty fuel delivery system
Leak in intake system
Leak in exhaust system
Faulty MAFS ground circuit
Faulty HO2S

If any misfire, purge solenoid valve, MAFS or HO2S heater


codes are present,do all repairs associated with those codes
before proceeding with this trouble area.
P0134

HO2S Circuit No Activity


Detected (Bank 1, Sensor 1)

Contaminated, deteriorated or aged HO2S


Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

If any misfire, purge solenoid valve or HO2S heater codes are


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

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P0135

HO2S Heater Circuit


Malfunction (Bank 1, Sensor 1)

Blown or missing HO2S fuse


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

P0030

HO2S Heater Control Circuit


(Bank 1, Sensor 1)

Contaminated, deteriorated or aged HO2S


Heater Resistance out of Reasonable Range
Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

P0031

HO2S Heater Circuit Low (Bank


1, Sensor 1)

Blown or mission HO2S fuse


Open or short to GND between HO2S and ECM
Faulty HO2S

P0032

HO2S Heater Circuit High (Bank


1, Sensor 1)

Short to battery between HO2S and ECM


Faulty HO2S

P0136

HO2S Circuit Malfunction (Bank


1, Sensor 2)

Short between rear HO2S and ECM


Faulty rear HO2S

P0137

HO2S Circuit Low Input (Bank


1, Sensor 2)

Short to GND between HO2S and ECM


Faulty front HO2S

P0138

HO2S Circuit Low Input (Bank


1, Sensor 2)

Open or short to battery between HO2S and ECM


Faulty front HO2S

P0139

HO2S Circuit Slow 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)

Contaminated, deteriorated or aged HO2S


Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

If any misfire, purge solenoid valve or HO2S heater codes are


present, do all repairs associated with those codes before
proceeding with this trouble area.
P0141

HO2S Heater Circuit


Malfunction (Bank 1, Sensor 2)

P0037

HO2S Heater Circuit Low (Bank


1, Sensor 2)

Blown or missing HO2S fuse


Open or short to GND between HO2S and ECM
Faulty HO2S

P0038

HO2S Heater Circuit High (Bank

Short to battery between HO2S and ECM

Blown or missing HO2S fuse


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

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1, Sensor 2)

Faulty HO2S

P0151

HO2S Circuit Low Input (Bank


2, Sensor 1)

Short to GND between HO2S and ECM


Faulty front HO2S

P0152

HO2S Circuit High Input (Bank


2, Sensor 1)

Short to battery between HO2S and ECM


Faulty front HO2S

P0153

HO2S Circuit Slow Responsive


(Bank 2, Sensor 1)

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.
P0154

HO2S Circuit No Activity


Detected (Bank 2, Sensor 1)

Contaminated, deteriorated or aged HO2S


Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

If any misfire, purge solenoid valve or HO2S heater codes are


present, do all repairs associated with those codes before
proceeding this trouble area.
P0050

HO2S Heater Control Circuit


(Bank 2, Sensor 1)

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)

Short to battery between HO2S and ECM


Faulty HO2S

P0157

HO2S Circuit Low Input (Bank


2, Sensor 2)

Short to GND between HO2S and ECM


Faulty rear HO2S

P0158

HO2S Circuit High Input (Bank


2, Sensor 2)

Open or short to battery between HO2S and ECM


Faulty rear HO2S

P0160

HO2S Circuit No Activity


Detected (Bank 2, Sensor 2)

Contaminated, deteriorated or aged HO2S


Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

Contaminated, deteriorated or aged HO2S


Heater Resistance out of reasonable range
Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

If any misfire, purge solenoid valve or HO2S heater codes are


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

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P0057

HO2S Heater Circuit Low (Bank


2, Sensor 2)

Blown or missing HO2S fuse


Open or Short to GND between HO2S and ECM
Faulty HO2S

P0058

HO2S Heater Circuit High (Bank


2, Sensor 2)

Short to battery between HO2S and ECM


Faulty HO2S

P0171

Fuel System Too Lean (Bank 1)

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


Faulty fuel delivery system (Fuel tank/Pressure
regulator/Canister purge valve)
Clogged fuel injectors
Faulty fuel injectors
Leak in intake system
Leak in exhaust system
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.
P0172

Fuel System Too Rich (Bank 1)

Faulty fuel delivery system (Fuel tank/Pressure


regulator/Canister purge valve)
Faulty fuel injectors
Faulty MAFS

If any codes relating to injectors, HO2S, ECTS or MAFS are


stored, do all repairs associated with those codes before
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
Leak in intake system
Leak in exhaust system
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.
P0175

Fuel System Too Rich (Bank 2)

Faulty fuel delivery system (Fuel tank/Pressure


regulator/Canister purge valve)
Faulty fuel injectors
Faulty MAFS

If any codes relating to injectors, HO2S, ECTS or MAFS are


stored, do all repairs associated with those codes before

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proceeding with this trouble area.


P0230

Fuel Pump Circuit Malfunction

P0261

Injector Circuit Low Input


(Cylinder -1)

Short to GND between injector and ECM


Faulty fuel injector

P0264

Injector Circuit Low Input


(Cylinder -2)

P0267

Injector Circuit Low Input


(Cylinder -3)

P0270

Injector Circuit Low Input


(Cylinder -4)

P0273

Injector Circuit Low Input


(Cylinder -5)

P0276

Injector Circuit Low Input


(Cylinder -6)

P0262

Injector Circuit High Input


(Cylinder -1)

P0265

Injector Circuit High Input


(Cylinder -2)

P0268

Injector Circuit High Input


(Cylinder -3)

P0271

Injector Circuit High Input


(Cylinder -4)

P0274

Injector Circuit High Input


(Cylinder -5)

P0277

Injector Circuit High Input


(Cylinder -6)

P0300

Random Misfire Detected

P0301

Misfire Detected (Cylinder -1)

P0302

Misfire Detected (Cylinder -2)

P0303

Misfire Detected (Cylinder -3)

P0304

Misfire Detected (Cylinder -4)

P0305

Misfire Detected (Cylinder -5)

P0306

Misfire Detected (Cylinder -6)

Blown or missing fuse/relay


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

Open between injector fuse and injector


Open or short to battery between injector and ECM
Faulty fuel injector

Vacuum leak in air intake system


CKP sensor circuit malfunction
Faulty CKP sensor
Ignition circuit malfunction
Faulty ignition coil or plug wire
Spark plug malfunction
Low compression due to blown head gasket, leaking valve or
piston ring
Low/high fuel pressure due to faulty pressure regulator,
restricted fuel lines,plugged fuel filter or faulty fuel pump
Fuel injector circuit malfunction
Faulty fuel injector

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

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P0325

Knock Sensor Circuit


Malfunction (Bank 1)

P0330

Knock Sensor Circuit


Malfunction (Bank 2)

P0335

Crankshaft Position Sensor


Circuit Malfunction

P0340

Camshaft Position Sensor


Circuit Malfunction

P0420

Main catalyst efficiency


deterioration (Bank 1)

Catalytic converter deteriorated

Open or short to GND between knock sensor and ECM


Source of high resistance between knock sensor and ECM
Faulty knock sensor

Short to GND between CKP sensor and ECM


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

Short to GND between CMP sensor and ECM


Open or short to battery between CMP and ECM
Short between CMP sensor wires
Poor connection between CMP connector & harness
connector
Faulty CMP sensor

If any codes relating to HO2S sensor. MAFS, injectors, a


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

Main catalyst efficiency


deterioration (Bank 2)

Catalytic converter deteriorated

If any codes relating to HO2S sensor. MAFS, injectors, P0171,


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

EVAP Emission Control System


Incorrect Purge Flow

Stuck in valve open position

P0442

EVAP Emission Control System


Small Leak (1 mm)

Fuel filler cap loose or missing


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

If any codes relating to FTPS, CCV or PSV circuits are present,


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

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P0444

EVAP Emission Control System


Purge Control Valve Circuit
Open

P0445

EVAP Emission Control System


Purge Control Valve Circuit
Shorted

Faulty PSV
Short to GND or battery between PSV and ECM

P0449

EVAP Emission Control System


Vent Valve/Solenoid Circuit

Stuck in valve closed position (CCV)


Faulty CCV

P0447

EVAP Emission Control System


Vent Circuit Open

Open or short to battery between CCV and ECM


Faulty CCV

P0448

EVAP Emission Control System


Vent Circuit Shorted

Short to GND between CCV and ECM


Faulty CCV

P0451

EVAP Emission Control System


Pressure Sensor
Range/Performance Problem

High resistance or open between fuel tank pressure sensor


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

P0452

EVAP Emission Control System


Pressure Sensor Low Input

Short to GND between FTPS and ECM


Faulty FTPS

P0453

EVAP Emission Control System


Pressure Sensor High Input

Open or short to battery between fuel tank pressure sensor


and ECM
Short to battery in ECM
Open in ECM
Faulty FTPS

P0454

Evaporative Emission Control


System - Pressure Sensor
Intermittent

Poor connections between FTPS and ECM


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

P0456

Evaporative Emission Control


System - Small Leak Detected
(0.5mm)

Faulty PSV
Open between PSV and ECM

If any codes relating to FTPS, CCV or PSV circuits are present,


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

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If an obvious cause for DTC P0455 is an engine running during


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

Fuel Level Sensor Circuit


Range/Performance

P0462

Fuel Level Sensor Circuit Low


Input

Open or short to GND between FTLS and ECM


Short to GND or open in ECM
Faulty FTLS

P0463

Fuel Level Sensor Circuit High


Input

Short to battery between FTLS and ECM


Short to battery
Faulty FTLS

P0464

Fuel Level Sensor Circuit


Intermittent

Poor connections between ECTS and ECM


Misplaced, loose or corroded terminals
Faulty FTLS

P0501

Vehicle Speed Sensor


Range/Performance

Open between fuse and wheel speed sensor (WSS)


Open between WSS and GND
Open between WSS and ECM
Short to battery or GND between WSS and ECM
Faulty WSS

P0506

Idle Control System rpm Lower


than Expected

High resistance between injector fuse and IAC valve


High resistance between IAC and ECM
Faulty IAC valve
Carbon fouled throttle plate

Poor connection
Contaminated, deteriorated or aged FTLS
Misplaced, bent, loose or corroded connector terminals
Faulty FTLS

If any TPS, MAFS, fuel injector or IAC valve circuit codes (or
pending codes)are present, do all repairs associated with them
before proceeding with thistrouble area.
P0507

Idle Control System rpm Higher


than Expected

Improperly adjusted accelerator cable


Air leak in intake system between head and throttle plate
Faulty PCV valve or PSV
Poor connections in TPS circuit or faulty TPS
High resistance between IAC valve and ECM
Faulty IAC valve

If any codes relating to TPS, MAFS, fuel injector or IAC valve


are present,do all repairs associated with them before
proceeding with this troubleshootingarea.
P1134

HO2S Circuit - Transition Switch


Malfunction/Slip (Bank 1,
Sensor 1)

HO2S Deteriorated
Foreign Material Deposit

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P1154

HO2S Circuit - Transition Switch


Malfunction/Slip (Bank 2,
Sensor 1)

P1166

Lambda Bank Control Limit


(Bank 1)

P1167

Lambda Bank Control Limit


(Bank 2)

P0036

HO2S Heater Control Circuit


(Bank 1, Sensor 2)

Contaminated, deteriorated or aged HO2S


Heater resistance out of reasonable range
Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

P0056

HO2S Heater Control Circuit


(Bank 2, Sensor 2)

Contaminated, deteriorated or aged HO2S


Heater resistance out of reasonable range
Misplaced, bent, loose or corroded connector terminals
Faulty HO2S

P1372

Segment Time Acquisition


Incorrect

Bad installation of tone wheel to crankshaft


Bad signal of the CKP sensor
Bad connection of connectors/bad wiring (between ECM and
CKP)

P1505

Idle Charge Actuator Signal Low


of Coil #1

Open or short to GND between ISC and ECM


Faulty ISC

P1506

Idle Charge Actuator Signal


High of Coil #1

Short to battery between ISC and ECM


Faulty ISC

P1507

Idle Charge Actuator Signal Low


of Coil #2

Open or short to GND between ISC and ECM


Faulty ISC

P1508

Idle Charge Actuator Signal


High of Coil #2

Short to battery between ISC and ECM


Faulty ISC

P1521

Power Steering Switch


Malfunction

P1529

TCU Request for MIL


ON/Freeze Frame to ECU via
CAN

This is only a request from TCM to turn the MIL ON. The fault
code is stored in the TCM. The freeze frame data is stored in
the ECM under the P1529 request code. Be sure to retrieve
freeze frame data before clearing code P1529 from ECM.

P1602

Serial Communication Problem


with TCU (Timeout)

Open or short to serial communication line


CAN message timeout
Faulty TCU

P0560

System Voltage Malfunction

P1166 is case for HO2S (Bank 1, Sensor 1) Signal line open


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

Open or short to battery between switch and ECM


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

Short between main relay and ECM


Open between main relay and ECM
Poor connection
Faulty main relay

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P0562

System Voltage Low

P0563

System Voltage High

Reverse battery cable connection (+/- reverse)


Faulty alternator

P0650

Malfunction Indication Lamp


(MIL) Control Circuit Malfunction

Open or short between lamp and ECM


Faulty lamp

P1624

Cooling Fan Relay Circuit


Malfunction (LOW)

P1625

Cooling Fan Relay Circuit


Malfunction (HIGH)

Open or short between relay and ECM


Short to GND between relay and ECM
Open between relay and ECM
Faulty relay

MAJOR SENSOR REFERENCE WAVE-FORMS

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Page 1 of 3

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System > Components and Components
Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Fuel System > Engine Control System > Components and
Components Location

LOCATION OF MFI COMPONENTS

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ECT Sensor

Power Steering Oil Pressure Switch

Vehicle Speed Sensor

Ignition Timing Adjustment Terminal

EVAP Solenoid Valve

MAP, TPS, ISA, TR

CMP Sensor

CKP

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Data Link Connector

Heated Oxygen Sensor (HO2S)

Transaxle Range (TR) Switch

Injectors

Knock Sensor

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Special Service
Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Special
Service Tools

SPECIAL TOOLS
Tool (Number and Name)

Use

Illustration

09216-21100
Mount bushing remover and
installer

Removal & installation of lower arm


bushing (G)
(Use with 09216-21200, 0954502000)

09216-21200
Mount bushing remover and
installer base

Removal & installation of the lower


arm bushing (G)
(Use with 09216-21100, 0954502000)

09532-11600
Preload socket

Measurement of the lower arm ball


joint & stabilizer link starting torque

09545-02000
Lower arm bushing remover and
installer

Removal & installation of the lower


arm bushing (G)
(Use with 09216-21100, 0921621200)

09545-11000
Ball joint remover and installer

Installation of the lower arm ball joint

09545-21100
Ball joint dust cover installer

Installation of the lower arm ball joint


dust cover

09551-25000
Trailing arm bushing remover and
installer

Removal & installation of the trailing


arm bushing

09551-25000
Rear suspension arm remover and
installer

Removal & installation of the rear


suspension arm bushing
(Use with 09545-28100)

09568-34000
Ball joint puller

Separation of the lower arm ball joint

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09546-26000
Strut spring compressor
or
J38402
Strut spring compressor

Compression of front coil spring


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Troubleshooting

TROUBLESHOOTING
Symptom
Hard steering

Possible cause

Remedy

Improper front wheel alignment


Excessive turning resistance of
lower arm ball joint
Low tire pressure
No power assist

Correct
Replace
Adjust
Repair and replace

Improper front wheel alignment

Correct

Poor or rough ride

Improper front wheel alignment


Malfunctioning shock absorber
Broken or worn stabilizer
Broken or worn coil spring
Worn lower arm bushing

Correct
Repair or replace
Replace
Replace
Replace the lower arm assembly

Abnormal tire wear

Improper front wheel alignment


Improper tire pressure
Malfunctioning shock absorber

Correct
Adjust
Replace

Wandering

Improper front wheel alignment


Correct
Poor turning resistance of lower arm
Repair
ball joint
Retighten or replace
Loose or worn lower arm bushing

Vehicle pulls to one side

Improper front wheel alignment


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
Worn lower arm bushing
Malfunctioning shock absorber
Broken or worn coil spring

Correct
Replace
Replace
Replace
Replace
Replace

Bottoming

Broken or worn coil spring


Malfunctioning shock absorber

Replace
Replace

Poor return of steering wheel to


center

WHEEL AND TIRE DIAGNOSIS


Rapid wear at the center

Center- tread down to fabric due


to excessive over inflated tires
Lack of rotation
Excessive toe on drive wheels

Rapid wear at both shoulders

Underinflated tires
Worn suspension components
Excessive cornering speeds
Lack of rotation

Wear at one shoulder

Toe adjustment out of


specification
Camber out of specification
Damaged strut

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Heavy acceleration on drive

Damaged lower arm

WHEEL AND TIRE DIAGNOSIS


Partial wear

Cansed by irreqular burrs on


brak drums.

Feather edges wheels

Toe adjustment out of


specification
Damaged or worn tie rods
Damaged knuckle

Wear pattern

Excessive toe on non-drive


wheels
Lack of rotation

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Specifications, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > General Information > Specifications

SPECIFICATIONS

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SERVICE STANDARD

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When rotating the "215/45 ZR17" Tires, ensure to follow the "ROTATION" direction marked on the sidewall of tires
(see page SS-30).

TIGHTENING TORQUE
Items

Nm

kgcm

lbft

Wheel nut

90~110

900~1100

67~82

Driveshaft nut
2.0L
2.7L

200~260
200~280

2000~2600
2000~2800

148~192
148~207

Front strut upper installation nut

45~60

450~600

33~44

Front strut assembly to knuckle

140~160

1400~1600

104~118

Front strut mounting self-locking nut

40~50

400~500

29~37

Lower arm ball joint to knuckle

60~72

600~720

43~52

Lower arm bushing (A) mounting bolt

130~150

1300~1500

96~111

Lower arm bushing (G) mounting bolt

130~150

1300~1500

96~111

Stabilizer bar bracket mounting bolt

30~45

300~450

22~33

Tie rod end ball joint to knuckle

24~34

240~340

18~25

Tie rod end lock nut

50~55

500~550

37~41

Stabilizer link nut

35~45

350~450

26~33

Rear strut upper mounting nut

30~40

300~400

22~30

Rear strut lower mounting nut

110~130

1100~1300

81~96

Rear strut mounting self locking nut

40~60

400~600

30~44

Rear stabilizer link to stabilizer bar

35~45

350~450

26~33

Rear stabilizer bar bracket bolt

17~26

170~260

13~19

Rear suspension arm tie rod nut

50~60

500~600

37~43

Rear suspension arm (A,B) mounting bolt

160~180

1600~1800

118~133

Rear cross member mounting bolt

100~120

1000~1200

74~88

Trailing arm to bracket nut

40~50

400~500

30~37

Trailing arm bracket to body frame

40~50

400~500

30~37

100~120

1000~1200

74~88

Trailing arm mounting

Replace the self-locking nuts with new ones after removal.

LUBRICANTS
In ball joint of lower arm

Recommended lubricant

Quantity

Variant R-2 grease or poly lub gly 801K

As required

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Strut
Assembly > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension
System > Front Suspension System > Front Strut Assembly > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Strut
Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Strut Assembly > Repair procedures

REMOVAL
1. Remove the front wheel.
2. Detach the brake hose bracket from the strut assembly.

Do not apply excessive force to the components.


3. Remove the stabilizer link.

4. Remove the strut upper mounting bolts(3).

5. Remove the strut assembly.

INSTALLATION
1. When installing the front strut, be sure to clear the conneting surface.
2. Install the strut assembly so the identification label on the strut insulator faces toward the inside of vehicle.

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3. Tighten the components below to the specified torque as follows.


Items

Torque Nm (kgfcm, lbfft)

Front strut upper mounting nut


Front strut to knuckle

45~60 (450~600, 33~44)


140~160 (1400~1600, 104~118)

Stabilizer link nut

35~45 (350~450, 26~33)

4. Install the brake hose and front wheel speed sensor wire on the front strut assembly.

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

Do not use an impact gun.

2. Remove the nut at the top end of shock absorber.


3. Remove the insulator, spring seat, coil spring, dust cover from the strut assembly.

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

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DISPOSAL
1. Fully extend the shock absorber rod.
2. Drill a hole on the A section to remove gas from the cylinder.

The gas coming out is harmless, but be careful of chips that may fly when drilling.
Be sure to wear face shield and safety goggles.

REASSEMBLY
1. Install lower spring pad so that the protrusions fit in the holes of the spring lower seat.

2. Install the dust cover on the shock absorber.


3. Using the special tools (09546-26000 or J38402), compress the coil spring.
After the spring is fully compressed, install it on the shock absorber.

Install the coil spring with the identification mark directed toward the knuckle.
4. After fully extending the piston rod, install the spring upper seat and insulator assembly.

Align the D-shaped hole in the spring seat upper assembly with the protrusion on the piston rod.

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5. After seating the upper and lower ends of the coil spring in the upper and lower spring seat grooves correctly,
tighten the newself-locking nut temporarily.

6. Remove the special tool (09546-26000 or J38402).


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Lower Arm >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Lower Arm > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front
Lower Arm > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Lower Arm > Repair procedures

REMOVAL
1. Remove the front wheel.
2. Remove the driveshaft split pin, nut and washer.
3. Loosen the lower arm ball joint nut, but do not remove it.
4. Remove the strut lower mounting bolts(2).

5. Push the axle hub toward the outside to disconnect the driveshaft from the axle hub.
6. Using the special tool (09568 - 34000), disconnect the lower arm ball joint from the lower arm.

7. Temporarily install the strut lower mounting bolt.


8. Remove the lower arm bushing (A) and bushing (G) mounting bolts(2).
9. Remove the lower arm assembly.

REPLACEMENT
BALL JOINT AND DUST COVER
1. Using a flat-tipped screwdriver, remove the dust cover from the lower arm ball joint.

2. Remove the snap ring.


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

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4. Using special tool (09545 - 11000), press-fit the ball joint into the lower arm assembly.

5. Install the snap ring.


6. Using the special tool (09545 - 21100), install the dust cover.

LOWER ARM BUSHING (G)


1. Install the special tools (09545-02000, 09216-21100 and 09216-21200) on the lower arm.
2. Press out the bushing.

3. Apply soap solution to the following parts.


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

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Press-in the lower arm bushing (G) in the same direction as shown in illustration.
Pull out force for the bushing
80 N [800 kg(f), 11.9 lb(f)] or more

INSTALLATION
Installation is in the reverse order of removal.

Tighten the components below to the specified torque as follows.


Items
Wheel nut
Driveshaft nut

Strut lower mounting

Torque Nm (kgfcm, lbfft)


90~110 (900~1100, 67~82)
2.0 L : 200~260
(2000~2600, 148~192)
2.7 L : 200~280
(2000~2600, 148~192)
140~160 (1400~1600, 104~118)

Lower arm ball joint nut

60~72 (600~720, 43~52)

Lower arm bushing(A)

130~150 (1300~1500, 96~111)

Lower arm bushing(G)

130~150 (1300~1500, 96~111)

Stabilizer link nut

35~45 (350~450, 26~33)

INSPECTION
1. Check the bushing for wear and deterioration.
2. Check the lower arm for bending or breakage.
3. Check the ball joint dust cover for cracks and damage.

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4. Check all bolts for damage and deformation.


5. Check the lower arm ball joint for rotating torque.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front Stabilizer Bar
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front
Suspension System > Front Stabilizer Bar > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Front Suspension System > Front
Stabilizer Bar > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Front Suspension System > Front Stabilizer Bar > Repair procedures

REMOVAL
1. Remove the front wheel.
2. Remove the stabilizer link assembly.

3. Remove the stabilizer bracket and bushing

4. Remove the stabilizer bar.

INSTALLATION
1. Install the bushing on the stabilizer bar.

1) When installing the stabilizer bar, follow the identification color (ID color) as below.
Model

ID color

Outer diameter

2.0L Sports
(HARD)

21.8mm (0.86 in.)

2.0L Normal
(SOFT)

White

18.8mm (0.74 in.)

2.7L Sports
(HARD)

Yellow

21.8mm (0.86 in.)

2.7 Normal
(SOFT)

Red

18.8mm (0.74 in.)

ID : Identification
2) Position the bushing on the outside of the stabilizer bar clamp so as to install it.

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


2. Install the bracket on the bushing.
3. After tightening the bolts of the bushing bracket temporarily, install the bushing bracket on the opposite side.

INSPECTION
1. Check the stabilizer bar for deterioration and damage.
2. Check all bolts for damage and deformation.
3. Check the stabilizer link dust cover for cracks or damage.
4. Check the stabilizer link ball joint for rotating torque.

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


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear Strut Assembly
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear
Suspension System > Rear Strut Assembly > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear Strut
Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear
Suspension System > Rear Strut Assembly > Repair procedures

REMOVAL
1. Remove the covering self side trim, rear seat belt retractor, luggage side trim and covering self mounting
bracket.

2. Remove the rear strut upper mounting nuts (3).

3. Remove the wheel and tire.


4. Disconnect the brake hose and wheel speed sensor wiring from the rear strut.
5. Remove the stabilizer bar link.

6. Remove the strut and carrier mounting bolts(2).

Be careful not to drop the rear strut.


7. Remove the rear strut assembly.

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

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Do not use an impact gun.

2. Remove the self-locking nut at the top end of the shock absorber.
3. Remove the insulator, coil spring and dust cover from strut assembly.

INSPECTION
1. Check the strut insulator for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Check the coil spring and strut assembly for sagging and deformation.
4. Check the shock absorber for abnornal resistance or unusual sound.

REASSEMBLY
1. Install the lower spring pad so that the protrusions fit in the holes in the spring lower seat.

2. Install the dust cover on the shock absorber.


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

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4. After extending the piston rod fully, install the insulator assembly and pipe.

Align the D-shaped hole in the spring seat upper assembly with the protrusion of the piston rod.

5. After seating the lower ends of the coil spring in the lower spring seat grooves correctly, tighten the new selflocking nut temporarily.

Replace the self-locking nut with new ones after removal.

6. Remove the special tools (09546-26000 or J38402).


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear Suspension
Arm > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Rear Suspension System > Rear Suspension Arm > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear
Suspension Arm > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Rear Suspension System > Rear Suspension Arm > Repair procedures

REMOVAL
1. Remove the wheel and tire.
2. Remove the stabilizer link.

3. After loosening the rear trailing arm mounting bolts, remove the trailing arm.

4. Remove the rear suspension arm mounting bolt from the rear axle carrier.

5. After supporting the center of the rear crossmember assembly with a jack, remove the rear crossmember
mounting bolts to the body.
6. Remove the rear crossmember and suspension arm.

INSTALLATION
1. Installation is in the reverse order of removal.
2. Tighten the components below to the specified torque as follows.
Items
* Trailing arm mounting

Torque Nm (kgfcm, lbfft)


100~120 (1000~1200, 74~88)

Trailing arm bracket mounting

40~50 (400~500, 29~37)

Stabilizer bar bracket mounting

17~26 (170~260, 13~19)

Stabilizer link nut

34~45 (340~450, 25~33)

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*Front/Rear suspension arm mounting


Rear crossmember mounting

160~180 (1600~1800, 118~133)


100~120 (1000~1200, 74~88)

INSPECTION
1. Check the rubber parts for damage or deterioration.
2. Check the trailing arm and suspension arm for bent or deterioration.
3. Check the bolts for damage or rust.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Trailing
Arm > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear
Suspension System > Trailing Arm > Repair procedures

REMOVAL
1. Detach the parking brake cable from the rear trailing arm bracket.

2. After loosening the rear trailing arm mounting bolts, remove the trailing arm.
3. Remove the rear suspension arm mounting bolt from the rear axle carrier.

4. After supporting the center of the rear crossmember assembly with a jack, remove the rear crossmember
mounting bolts to the body.
5. Remove the rear crossmember and suspension arm.

REPLACEMENT
TRAILING ARM BUSHING
1. Install the special tool (09551 - 25000) on the trailing arm.

2. Remove the trailing arm bushing.


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

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Press-fit the bushing in the same way as shown in the illustration.

REAR SUSPENSION ARM BUSHING


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

2. Remove the rear suspension bushing.


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Rear Suspension System > Rear
Stabilizer Bar > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System >
Rear Suspension System > Rear Stabilizer Bar > Repair procedures

REMOVAL
1. Remove the stabilizer bar link from the rear strut assembly.
2. Remove the rear stabilizer bar mounting brackets.

3. Remove the stabilizer bar.

INSTALLATION
1. Install the bushing on the stabilizer bar.

1) When installing the stabilizer bar, follow the identification color (ID color) as below.
Model

ID color

Outer diameter

GL/GLS

Yellow

16.8mm (0.66 in.)

Sports/Top

Green

17.8mm (0.70 in.)

2) After matching the bushing in the inside of the white painted part on the stabilizer bar, install the them.

2. Install the bracket on the bushing.


3. Tighten the components below to the specified torque as follows.
Rear stabilizer bar mounting bracket :
17~26 Nm (170~260 kgfcm, 13~19 lbfft)
Rear stabilizer bar link mounting :
35~45 Nm (350~450 kgfcm, 26~33 lbfft)

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INSPECTION

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


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Description
and Operation

DESCRIPTION
There are two matching ways about the wheel & tire and front suspension on this vehicle. It follows,
Standard equipment with 2.0L/2.7L engines :
Normal (Soft) suspension and 16wheel & tire
Optional equipment with 2.0L/2.7L engines :
Sports (Hard) suspension and 17wheel & tire

The front suspension identification mark can be seen when the front wheel & tire is removed.
The following degeneration in vehicle performance may occur when installing the 17tires to the 2.0L
vehicle models equipped with the normal front suspension.
The handling may be inferior to the vehicles with 16tires. However installing 17tires to the vehicles with
hard suspensions does not affect the driving performance.
The 17tire is for summer season.
Therefore, its performance in snow is inferior to the 16tire for all seasons.
The 17 tire is directional
An unexpected noise and vibration may occur if tires are not installed correctly according to the rotational
direction.
The snow chain with the thickness lower than 10mm is recommended to use on vehicles with 17tires.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Tire > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Tire >
Repair procedures

FRONT WHEEL ALIGNMENT


FRONT WHEEL ALIGNMENT
Standard value
Toe-in(B-A) mm (in.) : 0 2 mm (0 0.08 in.)

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

Camber : 013 30
Standard value
Toe-in(B-A) mm (in.) : 0 2 mm (0 0.08 in.)

Caster : 258 30
Standard value
Toe-in(B-A) mm (in.) : 0 2 mm (0 0.08 in.)
Camber : 013 30

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REAR WHEEL ALIGNMENT


TOE-IN

Adjust the toe-in by turning the tie rod end of the rear suspension arm..
Left tie rod : Clockwise direction toe-in
Right tie rod : Clockwise direction toe-out
A variation of toe by a rotation of the tie rod : About 6mm (0.6)
The cam bolt should be adjusted to a maximum of 90 left or right from the center position.

After adjusting the tie rod, tighten both nuts to the specified torque.
Specified torque
50~60 Nm (500~600 kgfcm, 37~43 lbfft)

TIRE WEAR
1. Measure the tread depth of the tires.
Tread depth of tire [Limit] : 1.6 mm (0.06 in.)
2. If the remaining tread depth is less than the limit, replace the tire.

When the tread depth of the tires is less than 1.6 mm (0.06 in.) the wear indicators will appear.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Wheel > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Suspension System > Tires/Wheels > Wheel >
Repair procedures

WHEEL ROTATION
Rotate the tires in the pattern illustrated.

When rotating the 215/45 ZR17 tires, ensure to follow the "ROTATION"direction marked on the sidewall of
tires.
When rotating the tires of the left and right, seperate the wheel from the tire and then re-assemble them.

Checking for pull and wander


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

B. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again.

C. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road
test.

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D. If the steering continues to pull to the opposite side, replace the front wheels with new ones.

WHEEL RUNOUT
1. Jack up the vehicle and support it with jack stands.
2. Measure the wheel runout with a dial indicator as illustrated.

3. Replace the wheel if the wheel runout exceeds the limit.


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

TIGHTENING WHEEL NUT


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

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When using an impact gun, final tightening torque should be checked using a torque wrench.

2. Tightening order
Check the torque again after tightening the wheel nuts diagonally.

WHEEL ROTATION
Rotate the tires in the pattern illustrated.

When rotating the 215/45 ZR17 tires, ensure to follow the "ROTATION"direction marked on the sidewall of
tires.
When rotating the tires of the left and right, seperate the wheel from the tire and then re-assemble them.

CHECKING FOR PULL AND WANDER


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

B. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again.

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C. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road
test.

D. If the steering continues to pull to the opposite side, replace the front wheels with new ones.

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

This procedure applies to the vehicle pulls to the right only.


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Special Service
Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Special
Service Tools

SPECIAL TOOLS
Tool (Number and Name)

Illustration

Use

09216-21100
Mounting bushing remover and
installer

Removal of the center bearing (Use with


09495-33100)

09495-33000
Puller

Removal of wheel bearing inner race from


the hub.

09495-33100
Center bearing remover and
installer

1. Removal of wheel bearing from the


knuckle. (Use with 09517-29000)
2. Installation of hub to the knuckle.
3. Removal of the center bearing (Use with
09216-21100)

09517-21500
Front hub remover and installer

1. Removal of front hub from the knuckle.


(Use with 09517-29000)
2. Measurement of front wheel bearing
pre-load. (Use with 09532-11600)

09517-29000
Knuckle arm bridge

1. Removal of wheel bearing outer race


from the knuckle. (Use with 0949533100)

09517-43001
Bearing puller

Removal of the center bearing bracket

09532-11600
Preload socket

Measurement of front wheel bearing preload. (Use with 09517-21500)

09532-11500
Pinion bearing outer race

Installation of wheel bearing to the knuckle.

09568-34000
Ball joint puller

Separation of front lower arm and tie rod


end ball joint.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Troubleshooting

TROUBLESHOOTING
Symptom

Possible cause

Remedy

Vehicle pulls to one side

Galling of drive shaft ball joint


Wear, rattle or galling of wheel bearing
Defective front suspension and steering

Replace
Replace
Adjust or replace

Vibration

Wear, damage or bending of drive shaft


Drive shaft rattle and hub serration
Wear, rattle or scratching of wheel bearing

Replace
Replace
Replace

Shimmy

Improper wheel balance


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
Loose hub nut
Defective front suspension and steering

Replace
Replace
Replace
Replace
Adjust or replace
Adjust or replace

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > General Information > Specifications

SPECIFICATIONS
Driveshaft
Joint type

2.0L M/T

2.0L A/T

2.0L 6M/T

2.7L

Outer

B.J.

B.J.

B.J.

B.J.

Inner

D.O.J.

T.J.

T.J.

T.J.

Maximum permissible joint angle


B.J.

46 or more

D.O.J.

22 or more

T.J.

45.8 or
more

46.5 or
more

23 or more 23 or more 23 or more

Hub end play mm(in.)

0.008 (0.0003) or less

Wheel bearing starting torque


Nm (kgcm, lbfft)

1.8 (18, 1.33) or less

B. J. : Birfield joint
D.O.J. : Double offset joint
T. J. : Tripod joint

46 or more

M/T : 5 Speed Manual transaxle


6M/T : 6 Speed Manual transaxle
A/T : Automatic transaxle

TIGHTENING TORQUE
Nm

Kgfcm

lbfft

Driveshaft nut
2.0L
2.7L

200 ~ 260
200 ~ 280

2000 ~ 2600
2000 ~ 2800

148 ~ 192
148 ~ 207

Knuckle to strut assembly nut

140 ~ 160

1400 ~ 1600

104 ~ 118

Lower arm ball joint to knuckle nut

60 ~ 72

600 ~ 720

44 ~ 53

Tie rod end to knuckle

24 ~ 34

240 ~ 340

18 ~ 25

Front brake caliper to knuckle

69 ~ 85

690 ~ 850

51 ~ 63

Wheel nut

90 ~ 110

900 ~ 1100

66 ~ 81

Rear hub bearing flange nut

200 ~ 260

2000 ~ 2600

148 ~ 192

65 ~ 75

650 ~ 750

48 ~ 56

Rear strut to carrier nut

110 ~ 130

1100 ~ 1300

81 ~ 96

Trailing arm to rear axle carrier mounting


nut

100 ~ 120

1000 ~ 1200

74 ~ 88

160 ~ 180

1600 ~ 1800

118 ~ 133

Rear brake to rear axle carrier mounting


bolt

Rear suspension arm to rear axle carrier


mounting nut

Replace self-locking nuts with new ones after removal.

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LUBRICANTS
Items

Recommended

Quantity

Birfield joint + Double offset joint Type driveshaft (For 2.0L M/T)
Birfield joint boot grease

CENTOPLEX 278M/136K
CASMOLY BJ
ROLLUBE BJ
Sunlight SW-2

115 6gr.

Double offset joint boot greasE

AMBLYGON TA 10/2A
CASMOLY DOJ
DURALUBE DOJ
Variant SD-R2

100 6gr.

Birfield joint +Tripod joint Type driveshaft (For 2.0L A/T, 2.0L 6M/T)
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
ROLLUBE TJ
Oneluber MK

145 6gr.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Front Driveshaft >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle >
Driveshaft Assembly > Front Driveshaft > Components and Components Location

COMPONENTS

COMPONENTS

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COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Front Driveshaft
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft
Assembly > Front Driveshaft > Repair procedures

REMOVAL
1. Raise the vehicle and remove the front wheel.
2. Remove the split pin and driveshaft nut from the front hub.
3. Drain the transaxle fluid.
4. Disconnect the tie rod end ball joint from knuckle, and the knuckle from strut assembly.
5. Using a plastic hammer, disconnect the driveshaft from the axle hub.

6. Push the axle hub toward the outside of the vehicle, and separate the driveshaft from the axle hub.
7. Insert a pry bar between the transaxle case and joint case, and separate the driveshaft from the transaxle
case.

1. Use a pry bar being careful not to damage the transaxle and joint.
2. Do not insert the pry bar too deep, as this may cause damage to the oil seal. [max. depth : 7 mm
(0.28 in.)]
3. Do not pull the driveshaft by excessive force it may cause components inside the double offset joint or
tripod joint kit to dislodge resulting in a torn boot ora damaged bearing.

8. Insert a pry bar between the center bearing bracket and the driveshaft, and then pry the driveshaft from the
center bearing. (2.7L engine)

Do not pull on the driveshaft; doing so will damage the tripod joint : be sure to use the pry bar.

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9. Remove the center bearing bracket mounting bolts. Insert the pry bar between the center bearing bracket and
the cylinder block to disconnect thebracket from the cylinder block. (for 2.7L engine)

10. Remove the inner shaft from the center bearing. (for 2.7L engine)
11. Using the special tool (09432-11000), remove the tone wheel.

Before removing the tone wheel, be sure to remove the B.J. assembly side dust cover.

INSTALLATION
1. After installing the birfield joint assembly side tone wheel, install the dust cover, keeping the specified
clearance as below.

2. Apply gear oil on the driveshaft splines and differential case contacting surface.

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

7. Tighten the below parts to the specified torque


Driveshaft nut
2.0L : 200~260Nm (2000~2600 kgfcm, 148~192 lbfft)
2.7L : 200~280Nm (2000~2800 kgfcm, 148~207 lbfft)
Lower arm ball joint nut
60~72Nm (600~720 kgfcm, 44~53 lbfft)

INSPECTION
1. Check the driveshaft boots for damage and deterioration.
2. Check the ball joints for wear and damage.
3. Check the splines for wear and damage.
4. Check the dynamic damper for cracks and wear.

INSPECTION
1. Check the driveshaft spline for wear or damage.
2. Check that there is no water or foreign material in the birfield joint.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside the tripod joint case for wear or corrosion.
5. Check the dynamic damper for damage or cracks.

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DISASSEMBLY

1. Do not disassemble the birfield joint assembly.


2. Special grease must be applied to the driveshaft joint. Do not substitute with another type of grease.
3. The boot band should be replaced with a new one.
1. Remove the double offset joint boot bands and pull the double offset joint boot from the double offset joint
outer race.

Be careful not to damage the boot.

2. Remove the circlip with a flat-tipped screwdriver.

3. Pull out the driveshaft from the double offset joint outer race.
4. Remove the snap ring and take out the inner race, cage and balls as an assembly.

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5. Clean the inner race, cage and balls without disassembling.


6. Remove the birfield joint boot bands and pull out the double offset joint boot and birfield joint boot.

If the boot is to be reused, wrap tape around the driveshaft splines to protect the boot.

DISASSEMBLY

Do not disassemble the birfield joint assembly.


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

Be careful not to damage the boot.

2. Remove the snap ring and spider assembly from the driveshaft.

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3. Clean the spider assembly.


4. Remove the birfield joint boot bands and pull out the tripod joint boot and birfield joint boot.

If the boot is to be reused, wrap tape around the driveshaft splines to protect the boot.

REASSEMBLY
1. Wrap tape around the driveshaft splines (tripod joint side) to prevent damage to the boots.
2. Apply grease to the driveshaft and install the boots. (see page DS-3)
3. To install the dynamic damper, keep the B.J. and driveshaft in a straight line and secure the dynamic damper
with the dynamic damper band inthe direction illustrated.

4. Apply grease into the tripod joint boot and install the boot.

Tripod joint boot grease (gr.)


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

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Total : 145 6
In the joint : 100 3
In the boot : 45 3
A/T : Automatic Transmission M/T : Manual Transmission
5. Tighten the tripod joint boot bands.
6. Add the specified grease to the birfield joint as much as was wiped away at inspection.
7. Install the boots.
8. Tighten the new birfield joint boot bands.

Keep the specified distance (A) between the bellows when they are clampped with an Oetiker crimping
tool (P/No. : 1094)or a commercially available hand pincers (2.7L).
Specified distance (A) : 1.8 mm (0.071 in.) or less

9. To control the air in the tripod joint boot, keep the specified distance between the boot bands when they are
tightened.
Standard value (A) mm(in.)
LH

RH

2.0L A/T

514 2
(20.24 0.08)

799.2 2
(31.47 0.08)

2.0L 6M/T

492.6 2
(19.39 0.08)

803.6 2
(31.64 0.08)

2.7L 6M/T

514.2 2
(19.43 0.08)

508.7 2
(20.03 0.08)

2.7L M/T, A/T

515 2
(20.28 0.08)

508.7 2
(20.03 0.08)

LH : Left Hand side, RH : Right Hand side


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Center Bearing And Inner
Shaft > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle >
Driveshaft Assembly > Center Bearing And Inner Shaft > Components and Components Location

COMPONENTS (2.7L)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Driveshaft Assembly > Center Bearing
And Inner Shaft > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle >
Driveshaft Assembly > Center Bearing And Inner Shaft > Repair procedures

DISASSEMBLY
1. Using the special tool (09517-43001), disassemble the center bearing bracket from the inner shaft.

2. Using the special tools (09216-21100, 09495-33100), press out the center bearing from the outside to the
inside direction of the center bearingbracket as shown in the illustration.

INSPECTION
1. Check the inner shaft for damage, bending or rust.
2. Check the inner shaft splines for wear or damage.
3. Check the center bearing for scoring, discoloration and roughness of the roller journals moving surfaces.

REASSEMBLY
1. Apply multipurpose grease to the center bearing and inside the center bearing bracket.

2. Using the special tool (09495-33100), press the center bearing into the center bearing bracket.

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


Recommended grease : Sunlight No.2
Inner dust seal : 7~10 gr.
Outer dust seal : 4~6 gr.

4. Install the inner shaft into the center bearing bracket.

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Front Axle Assembly > Front Hub / Axle
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Front Axle
Assembly > Front Hub / Axle > Repair procedures

REMOVAL
1. Remove the front wheel.
2. Remove the split pin and driveshaft nut from the front hub.
3. Remove the front brake assembly from the knuckle and suspend it with a wire.
4. Remove the vehicle speed sensor from the knuckle.
5. Disconnect the tie rod end ball joint from the knuckle by using the special tool (09568 - 34000).

Be sure to tie the special tool (09568 - 34000) to the near part with a cord not to fall.

6. Disconnect the strut assembly from the knuckle.

7. Disconnect the driveshaft from the hub.


8. Disconnect the lower arm ball joint from the knuckle by using the special tool (09568 - 34000).

9. Remove the hub and knuckle as an assembly.

INSTALLATION
1. Installation is the reverse of removal.

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1. Tighten the components below to the specified torque as follows :


Items

Torque Nm (kgfcm, lbft)

Driveshaft nut (2.0L)


Driveshaft nut (2.7L)
Lower arm ball joint to knuckle nut
Knuckle to strut assembly nut

200~260
(2000~2600, 148~192)
200~280
(2000~2800, 148~207)
60~72 (600~720, 44~53)
140~160
(1400~1600, 103~118)

2. Install the washer behind the driveshaft nut with the convex side outward as shown in the illustration.

DISASSEMBLY
1. After removing the screws(2) mounting the brake disc, remove the brake disc from the hub.
2. Remove the snap ring.

3. Install the special tools as illustrated.

4. Remove the hub from the knuckle by turning the special tool.
5. Remove the special tool and dust cover.
6. Remove the bearing inner race from the hub by using the special tool.

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7. Using the special tool (09495-33100, 09517-29000), remove the wheel bearing outer race from the knuckle.

INSPECTION
1. Check the hub for cracks and the splines for wear.
2. Check the brake disc for scoring and damage.
3. Check the knuckle for cracks.
4. Check the bearing for cracks or damage.

REASSEMBLY
1. Apply multi-purpose grease to the contacting surface of the knuckle hub and bearing thinly.
2. Using the special tools (09495-33100, 09517-29000), press-in the bearing to the knuckle.

1. Press-in the outer race of the wheel bearing to prevent damage to the bearing assembly.
2. When installing a bearing assembly, always use a new one.

3. Install the dust cover.


4. Using the special tool (09495-33100), press-in the hub to the knuckle.

Press-in the inner race of the wheel bearing to prevent damage to the bearing assembly.

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5. Install the brake disc.


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

7. Rotate the hub several times to seat the bearing.


8. Measure the hub bearing starting torque.
Hub bearing starting torque [Limit]
1.8 Nm (18 kgfcm, 1.33 lbfft) or less

9. If the starting torque is 0 Nm (0 kgfcm, 0 lbfft), measure the hub bearing axial play.

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

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Rear Axle Assembly > Rear Hub / Carrier
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Driveshaft and axle > Rear Axle
Assembly > Rear Hub / Carrier > Repair procedures

REMOVAL
1. Remove the rear wheel speed sensor (for vehicles equipped with ABS(Anti-lock Brake System)).

When removing the speed sensor from the adapter, be careful so that the end of the pole piece doesn't
strike teeth on the rotor or other components.
2. Remove the caliper assembly and suspend it with a wire.
3. Remove the brake disc.
4. Remove the hub cap, wheel bearing nut and tongue washer.
5. Remove the hub assembly.

The rear hub assembly should not be disassembled.


(For vehicles equipped with ABS(Anti-lock Brake System))
Care must be taken not to scratch or damage the teeth of the rotor. The rotor must never be dropped.
If the teeth of the rotor are chipped, it results in deformation of the rotor. It will make it impossible to
detectthe wheel rotation speed accurately and to operate the system normally.

INSTALLATION
1. After tightening the flange nut, caulk the concave portion of the spindle by crimping the nut.

Replace the flange nut with new ones after removal.

2. Installation of the rear speed sensor (For vehicles equipped with ABS(Anti-lock Brake System)) :
Insert a feeler gauge into the space between the pole piece of the speed sensors and the rotor teeth surface,
and then tighten the speed sensors at the position where the clearance at all places is within the standard
value.

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Standard value
Clearance : 0.2~1.3 mm (0.008~0.051 in.)

3. Install the hub cap.

INSPECTION
1. Check the oil seal for cracks or damage.
2. Check the rear hub bearing for wear or damage.
3. Check the rear rotor for chipped teeth.
4. Check the rear carrier for cracks.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > General Safety
Information and Caution, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information
> General Safety Information and Caution

PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake system and
result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and Name)

Illustration

Use

09581 - 11000
Piston expander

Spreading the front brake piston

09580 - 34000
Rear brake piston adjuster

Removal and installation of the rear


brake piston

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Components and Components
Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Components and
Components Location

Component Locating Index

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Troubleshooting

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Symptom

Suspect Area

Remedy

Lower pedal or spongy pedal

1.
2.
3.
4.

Brake system (Fluid leaks)


Brake system (Air in)
Piston seals (Worn or damaged)
Master cylinder (Faulty)

Correct
Bleeding
Replace
Replace

Brake drag

1.
2.
3.
4.
5.
6.
7.
8.

Brake pedal freeplay (Minimal)


Parking brake lever travel (Out of adjustment)
Parking brake wire (Sticking)
Pad (Cracked or distorted)
Piston (Stuck)
Piston (Frozen)
Booster system (Vacuum leaks)
Master cylinder (Faulty)

Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace

Brake pull

1.
2.
3.
4.

Pad (Oily)
Piston (Frozen)
Disc (Scored)
Pad (Cracked or distorted)

Replace
Replace
Replace
Replace

Hard pedal but brake inefficient

1.
2.
3.
4.
5.
6.
7.
8.

Brake system (Fluid leaks)


Brake system (Air in)
Pad (Worn)
Pad (Cracked or distorted)
Pad (Oily)
Pad (Glazed)
Disc (Scored)
Booster system (Vacuum leaks)

Correct
Bleeding
Replace
Replace
Replace
Replace
Replace
Replace

Noise from brake

1.
2.
3.
4.
5.
6.
7.
8.

Pad (Cracked or distorted)


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

Replace
Retighten
Replace
Replace
Replace
Clearing
Replace
Replace

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > All Scheduled Maintenance
Instructions, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > All Scheduled
Maintenance Instructions

Operation and Leakage Check


Check all of the following items:
Component
Brake Booster (A)

Piston cup and pressure cup


inspection (B)

Procedure
Check brake operation by applying the brakes during a test drive. If the brakes do not work
properly, check the brake booster. Replace the brake booster as an assembly if it does not
work properly or if there are signs of leakage.
Check brake operation by applying the brakes. Look for damage or signs of fluid
leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.

Brake hoses (C)

Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it
isdamaged or leaking.

Caliper piston seal and


piston boots (D)

Check brake operation by applying the brakes.


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Repair procedures,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Repair procedures

Brake Pedal and Brake Switch Adjustment


Pedal Height
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and back off the brake switch (B)
until it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center
of the pedal pad (D).
Standard pedal height (with carpet removed):
170 mm (6.69 in.)

3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height
from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the
pushrod depressed.

BRAKE SWITCH CLEARANCE

Pedal Free Play


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

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3~8 mm (0.11~0.31in.)

2. If the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it
may result in brake drag.

Parking brake check and adjustment


CHECK
1. Pull the parking brake lever (A) with 196 N (20 kgf, 44lbf) force to fully apply the parking brake. The parking
brake lever should be locked within the specified number of clicks (B)
6~7

2. Adjust the parking brake if the lever clicks are out of specification.

ADJUSTMENT

After rear brake caliper servicing, loosen the parking brake adjusting nut, start the engine and depress the
brake pedalseveral times to set the self-adjusting brake before adjusting the parking brake.
1. Block the front wheels, then raise the rear of the vehicle and make sure it is securely supported.
2. Make sure the parking brake arm (A) on the rear brake caliper contacts the brake caliper pin (B).

3. Pull the parking brake lever up one click.

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4. Remove the console.


5. Tighten the adjusting nut (A) until the parking brakes drag slightly when the rear wheels are turned.

6. Release the parking brake lever fully, and check that parking brakes do not drag when the rear wheels are
turned. Readjust if necessary.
7. Make sure that the parking brakes are fully applied when the parking brake lever is pulled up fully.
8. Reinstall the console.

Brake System Bleeding

Do not reuse the drained fluid.


Always use Genuine DOT 3 or DOT 4 Brake Fluid. Using a non-Genuine DOT3 or DOT 4 brake fluid can
cause corrosion and decrease the life of the system.
Make sure no dirt of other foreign matter is allowed to contaminate the brake fluid.
Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash
it off immediately with water.
The reservoir on the master cylinder must be at the MAX (upper) level mark at the start of bleeding
procedure and checked after bleeding each brake caliper. Add fluid as required.
1. Make sure the brake fluid level in the reservoir is at the MAX (upper) level line (A).

2. Have someone slowly pump the brake pedal several times, then apply steady pressure.
3. Loosen the right-rear brake bleed screw to allow air to escape from the system. Then tighten the bleed screw
securely.

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4. Repeat the procedure for each wheel in the sequence shown below until air bubbles no longer appear in the
fluid.
5. Refill the master cylinder reservoir to the MAX (upper) level line.

Front disc brake:

Rear disc brake:

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > General Information > Specifications

SPECIFICATIONS
Master cylinder
- Type
- I.D. mm(in.)
- Fluid level warning sensor

Tandem type
23.81 (0.94) : CBS
25.4 (1.0) : ABS (TCS)
Provided

Brake booster
- Type
- Effective dia.mm(in.)
- Boosting ratio

Vacuumtype with tandem booster


Tandem type with 7+8 in. (CBS)
Tandem type with 8+9 in. (ABS, TCS)
7.0 : 1

Proportioning valve
- Cut-in pressure (Split point)
- Decompression ratio

3.4 MPa (35 kg/cm, 498 psi)


0.27 : 1

Front disc brake


- Type
- Disc O.D.
- Disc thickness
- Pad thickness
- Cylinder I.D.

Floating type with ventilated disc


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

Rear disc brake


- Type
- Disc O.D.
- Clearance adjustment
- Disc thickness
- Pad thickness
- Cylinder I.D

Floating type with solid disc


258 mm (10.16 in.)
Automatic
10 mm (0.394 in.)
9 mm (0.354 in.)
33.96 mm (1.34 in.)

Parking brake
- Actuation
- Type

Mechanical brake acting on rear wheels


Lever

Auti-lock brake system (ABS)


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

Motor, valve relay integrated type


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

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- TC valve relief pressure

O.D = Outer Diameter


I.D = Inner Diameter
CBS = Conventional Brake System
ABS = Anti-lock Brake System
TC Valve = Traction Control Valve

SERVICE STANDARD
Standard value

Service limit

Brake pedal height

170 mm (6.69 in.)

Brake pedal stroke

128 mm (5.04 in.)

Stop lamp switch outer case to pedal stopper


clearance

0.5~1.0 mm (0.02~0.04
in.)

Brake pedal free play

3~8 mm (0.11~0.31 in.)

Brake pedal to floorboard clearance

61 mm (2.40 in.) or more

Booster push rod to master cylinder piston clearance

0 (at 500 mmHg vacuum)

Parking brake lever stroke when lever assembly is


pulled with 196N (20kg, 44lb force)

6~7 clicks

Front disc brake pad thickness

11 mm (0.43 in.)

2 mm (0.079 in.)

Front disc thickness (minimum )

26 mm (1.02 in.)

22.4 mm (0.96 in.)

Rear disc brake pad thickness

9 mm (0.35 in.)

2 mm (0.08 in.)

Rear disc thickness

10 mm (0.4 in.)

8 mm (0.315 in.)

TIGHTENING TORQUE
Nm

Kgfcm

lbfft

Master cylinder to booster mounting nut

8~12

80~120

6~9

Brake booster mounting nut

13~16

130~160

9.6~11.8

Brake booster vacuum hose fitting to surge tank

15~18

150~180

11.1~13.3

Bleeder screw

7~13

70~130

5.2~9.6

Brake tube flare nut, brake hose

13~17

130~170

9.6~12

Caliper guide rod bolt

22~32

220~320

16.2~23.6

Caliper assembly to knuckle

65~75

650~750

48~55

Brake hose to front caliper

25~30

250~300

18~22

Wheel speed sensor mounting bolt

8~9

80~90

6~7

Hydraulic & electronic control unit mounting bolt

8~10

80~100

6~7.4

Hydraulic & electronic control unit mounting bracket bolt

17~26

170~260

13~19

Replace self-locking nuts with new ones after removal.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster
> Components and Components Location

COMPONENT

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Booster >
Repair procedures

REMOVAL
1. Remove the air cleaner.

2. Disconnect the brake tube from the master cylinder.


3. Remove the master cylinder.

If there is any brake fluid on any painted surface, wash it off immediately.

4. Disconnect the vacuum hose from the booster.


5. Remove the operating rod from the brake pedal.
6. Loosen the booster mounting nuts.
7. Lift out the booster assembly.

INSTALLATION
1. When the booster assembly is installed, replace the packing at each end of the booster mounting holder, if
necessary.
2. Install the brake booster and tighten the mounting nuts.
Tightening torque:
13~16 Nm (130~160 kgfcm, 9.6~11.8 lbfft)

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3. Apply sufficient grease inside the brake pedal hole.


4. Connect the clevis to the brake pedal with the clevis pin and install the split pin to the clevis pin.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master Cylinder > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master
Cylinder > Components and Components Location

COMPONENT

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master Cylinder > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Master Cylinder
> Repair procedures

REMOVAL
1. Remove the fluid level warning device connector.
2. Detach the brake tubes from the master cylinder, and then install the plug.

If there is any brake fluid on any painted surface, wash it off immediately.
3. Remove master cylinder mounting nuts and then lift out the master cylinder.

INSTALLATION
1. Install the master cylinder to the brake booster.
2. Install the booster and master cylinder to the dash panel.
3. Connect the brake tubes to the master cylinder.
4. Install the vacuum hose tightly.
5. Connect the operating rod to the brake pedal.
6. After filling the brake reservoir with the brake fluid, bleed the system.

Don't disassemble the brake booster.

DISASSEMBLY
1. Remove the reservoir cap and drain the brake fluid into a suitable container.
2. After disconnecting the mounting screws, pry the reservoir free from the master cylinder.

3. Using a snap ring pliers, remove the retainer ring.

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4. Remove the primary cylinder pin, pushing the primary piston with a screwdriver and remove the primary piston
assembly.

5. Remove the secondary cylinder pin. Push the secondary piston with a screwdriver and remove the secondary
piston assembly.

Do not disassemble the primary and secondary piston assembly.

INSPECTION
1. Check the master cylinder bore for rust or scoring.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.

1. If the cylinder bore is damaged, replace the master cylinder assembly.


2. Wash the parts in alchohol.

REASSEMBLY

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1. Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.

2. Carefully insert the springs and pistons in the proper direction.


3. Press against the pistons with a screwdriver and install the retainer ring.

4. With the piston pushed completely by a screwdriver, install the cylinder pin.

5. Mount two grommets.


6. Install the reservoir on the cylinder.

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

Description

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Proportioning Valve > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Proportioning
Valve > Repair procedures

REMOVAL
INSTALLATION
1. Install the master cylinder according to the illustration.

2. Tighten the flare nuts and bleed the system.


Tightening torque
Brake tube flare nut:
13~17 Nm (130~170 kgfcm, 9~12 lbfft)
Proportioning valve mounting nut:
35~55 Nm (350~550 kgfcm, 30~40 lbfft)

INSPECTION
1. Connect two pressure gauges; one to the input side, and one to the output side.

Be sure to bleed the system after connecting the pressure gauges.


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

This figure shows characteristics of the proportioning valve as the pressure incrases.

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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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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Line > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Line >
Repair procedures

Inspection
1. Inspect the brake hoses, for damage, deterioration, leaks, interference and twisting.
2. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines.
3. Check for leaks at hose and line joints or connections, and retighten if necessary.
4. Check the master cylinder for damage and leakage.

Replace the brake hose clip whenever the brake hose is serviced.

Replacement

Before reassembling, check that all parts are free of dust and other foreign particles.
Replace parts with new ones whenever specified to do so.
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it off
immediately with water.
1. Replace the brake hose (A) if the hose is twisted, cracked, or if it leaks.

2. Disconnect the brake hose from the brake line (B) using a 10mm flare-nut wrench (C).
3. Remove and discard the brake hose clip (A) from the brake hose (B).

4. Remove the connector bolt (C), and disconnect the brake hose from the caliper.
5. Remove the brake hose from the knuckle.
6. Install the brake hose (A) on the knuckle with 12mm flange bolt (B) first, then connect the brake hose to the
caliper with the connector bolt (C) and new sealing washers (D).

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7. Install the brake hose (A) on the upper brake hose bracket (B) with a new brake hose clip (C).

8. Connect the brake line (D) to the brake hose


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal >
Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Brake Pedal >
Repair procedures

REMOVAL
1. Remove the stop lamp switch.
2. Remove the split pin and clevis pin.
3. Remove the flange nuts of the brake mounting bracket.
4. Remove the brake pedal assembly.

INSTALLATION
1. Installation is the reverse of removal.

Be sure to install the split pin on the operating rod clevis pin.
2. Install the brake pedal assembly and tighten the flange nuts (booster mounting nuts) and bolt.
Tightening torque:
13~16 Nm (130~160 kgfcm, 6~9 lbfft)

3. Adjust the brake pedal height and free play.


4. Install the stop lamp switch.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc Brake > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc
Brake > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc Brake > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Front Disc Brake
> Repair procedures

REPLACEMENT
Brake pad removal
1. Remove the 2 guide pin bolt, remove the caliper assembly from the knuckle and secure it with a wire or some
other retaining method.
2. Remove the pads.

Do not depress the brake pedal while disassembling the pads.

Brake pad inspection


1. Check the pads for wear or oil contamination and replace, if necessary.

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

Brake pad installation


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

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Position the pad with its pad wear indicator upward on the piston side.

3. Insert the piston in the cylinder using the Special Tool (09581-11000).

4. Install the new pads. The shims are attached to the each pad as illustrated.

Be careful so that the disc or pad isn't contaminated by grease.

5. Install the bolt and tighten to the specified value.


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

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REMOVAL
1. Remove the wheel and tire.
2. Disconnect the brake hose.
3. Remove the cylinder mounting bolt.
4. Remove cylinder and pads.
5. Remove the caliper mounting bolts (2EA) from the knuckle.
6. Remove the caliper.

INSTALLATION
1. Install the pads and brake cylinder.
2. Install the brake hose to the caliper.
Bleeder screw tightening torque:
7~13 Nm (70~130 kgfcm, 5.2~9.6 lbfft)

3. Fill the brake reservoir withe brake fluid.


4. Bleed the system.

DISASSEMBLY
1. Remove the piston boot.
2. Remove the piston using compressed air.

1. Do not put your fingers in front of the piston when using compressed air.
2. Be careful not to splatter the brake fluid.

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3. Remove the piston seal from the caliper by using a screwdriver.

INSPECTION
1. Check the caliper for wear, damage, cracks and dust.
2. Check the piston for dust, damage, cracks and wear on the outer surface.
3. Check the sleeve and pin for damage and dust.
4. Check the pad spring and boots for damage.
5. Check the carrier for damage, dust, wear and cracks.

1. Do not use sand paper on the piston surface.


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

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1. Using a micrometer, measure the disc thickness at eight positions approximately 10mm from the
outer edge of the disc and at 45 intervals.
If you substract the minimum of measurements from the maximum, you get the difference of the disc
thickness.
2. When measuring the disc runout, fix a dial gauge approximately 5mm from the outer edge of the disc,
and rotate the disc 360.
At this time, if you subtract the minimum of measurements from the maximum, you get the disc
runout.
7. If necessary, replace the brake disc.

REASSEMBLY
1. Clean all components except the pads and shims with isopropyl alcohol.
2. Apply rubber grease on the piston seal and install the piston seal in the cylinder.

3. Assemble the piston and piston boots according to the following procedure.
(1) Apply rubber grease to the caliper bore, the outside surface of the piston and the piston boot.
(2) Install the piston boot on the piston as illustrated.
(3) Insert the piston boot in the inner groove of the caliper and push the piston into the caliper.

4. Assemble the sliding parts according to the following procedure.


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

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5. Install the pads.

Be careful so that the disc or pad is contaminated by grease

6. Tighten the brake hose connecting bolt.


Tightening torque

Nm (kgfcm, lbfft)

Sliding pin

34~44 (350~450, 26~33)

Carrier mounting bolt

64~74 (650~750, 48~54)

Brake hose mounting oil bolt

25~29 (250~300, 18~22)

1. Check that the surface of the pin and bolts is not damaged before tightening.
2. Bleed the system. Depress the pedal several times and check for fluid leakage from all connecting
parts.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake > General
Information, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake
> General Information

General information

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc
Brake > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Brake System > Rear Disc Brake
> Repair procedures

REPLACEMENT

Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your
health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies.
1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel.
2. Release the parking brake.
3. Remove the brake hose (A) from the suspension arm by removing the brake hose clip (B).
Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside.
Support the caliper with a piece of wire so that it does not hang from the brake hose.

4. Remove the two guide rods (C) and caliper (D) from the bracket.
5. Remove the pad shim (A) and brake pads (B).

6. Using vernier calipers, measure the thickness of each brake pad lining. Measurement does not include pad
backing plate (A) thickness.
Brake pad thickness:
Standard: 9 mm (0.35 in.)
Service limit: 2 mm (0.08 in.)

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7. Remove the pad retainers.

8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.
9. Check the brake disc for damage and cracks.
10. Install the pad retainers.
11. Check the foreign material at the pad shim (A) and the back of the pads (B).
Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads.

12. Install the brake pads (B) and pad shim (A) on the caliper bracket. Install the inner pad with its wear indicator
(C) facing down ward.
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary
loss of braking efficiency.
13. Rotate the caliper piston (A) clockwise into the cylinder, the align the cutout (B) in the piston with the tab (C)
on the inner pad by turning the piston back. Lubricate the boot with rubber grease to avoid twisting the piston
boot. If the piston boot is twisted, back it out so it is positioned properly.

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14. Install the brake caliper (D).


15. Install and torque the guide rods (E) to proper specification.
16. Install the brake hose (F) onto the suspension arm with the brake hose clip (G).
17. After installation, check for leaks at hose and line joints and connections, and retighten if necessary.
18. Depress the brake pedal several times to make sure the brakes work, then test-drive.

Engagement of the brake may require a greater pedal stroke immediately after the brake pads have
been replaced as a set.Several applications of the brake pedal will restore the normal pedal stroke.

INSPECTION
Runout
1. Raise the rear or the vehicle, and make sure it is securely supported.
2. Remove the brake pads.
3. Inspect the disc surface for damage and cracks clean the disc thoroughly and remove all rust.
4. Use wheel nuts and suitable flat washers (A) to hold the disc securely against the hub, then mount a dial
indicator (B) as shown, and measure the runout at 10 mm (0.4 in.) from the outer edge of the disc.

5. If the disc is beyond the service limit, refinish the brake disc.
8.0 mm (0.315 in.)

A new disc should be refinished if its runout is greater than 0.10 mm (0.004 in.)

Thickness and parallelism


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

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2. Remove the brak pads.


3. Using a micrometer (A), measure disc thickness at eight points, approximately 45 apart and 10 mm (0.4 in.) in
from the outer edge of the disc. Replace the brake disc if the smallest measurement is less than the max.
refinishinglimit.
Brake disc thickness:
Standard: 10 mm (0.4 in.)
Max. Refinishing limit: 8.0 mm (0.315 in.)
Brake disc parallelism: Max. 0.015 mm (0.0006 in.)
This is the maximum allowable difference between the thickness measurements.

4. If the disc is beyond the service limit for parallelism, refinish the brake disc.

If the brake disc is beyond the service limit for refinishing, replace it (see DS group-rear axle).

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking Brake System > Parking Brake Assembly >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking
Brake System > Parking Brake Assembly > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking Brake System > Parking Brake
Assembly > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > Parking
Brake System > Parking Brake Assembly > Repair procedures

REMOVAL

The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature
failure.
Refer to the component as needed during this procedure.

Rear disc brake


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

2. Disconnect the parking brake cable (B) from the lever (C).

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Schematic Diagrams

HYDRAULIC SYSTEM DIAGRAM

CIRCUIT DIAGRAM
CIRCUIT DIAGRAM (1)

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CIRCUIT DIAGRAM (2)

CIRCUIT DIAGRAM (3)

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Page 3 of 3

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Description and
Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Description
and Operation

DESCRIPTION
This specification applies to Hydraulic and Electronic Control Unit (HECU) of the Anti lock Braking System(ABS) and
Traction Control System(TCS).
This HECU has the functions as follows:
- Input of signal from the wheel speed sensors attached to each wheel.
- Control of braking force and traction force
- Failsafe function
- Self diagnosis function
- Interface with the external diagnosis tester

Operation
The HECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the HECU shall be ready for operation.
In the operating condition, the HECU shall be ready, within the specified limits (voltage and temperature), to process the
signals offered by the various sensors and switches in accordance with the control algorithm defined by the software and to
control the hydraulic and electrical actuators.
The HECU shall receive wheel speed signal from the four inductive wheel sensors.
The wheel signals are converted to square wave by the signal conditioning circuit and given as input to the - processor.
The sensor connections shall be monitored for short-circuit and inter-ruption and then in the event of 2 sensor failures, the
HECU shall shut down the system.
When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the other
side is connected to the ground by the MOSFET, the solenoid valve goes into operation.
The electrical function of the valves are always monitored by the valve test pulse under normal operation conditions.
When overvoltage is detected(above 16V), the HECU switches off the valve relay and shuts down the system. When
voltage is returned to operating range, the system goes back to the normal condition after the initialization phase.
In the event of undervoltage(below 10V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and the HECU returns to normal operating
mode.
The pump motor operates when the ABS is functioning.
The HECU performs a pump motor test at a speed of 20km/h once after turned the Ignition switch on. You may hear the
motor operate at this time, but it is normal.
Malfunctions or failures detected by the HECU are encoded on the HECU, stored in a EEPROM and read out by diagnostic
equipment (hi-scan pro) when the ignition switch is turned on.

Warning lamp control

1. ABS warning lamp module


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

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


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

Diagnostic trouble code (DTC)


1. If the CPU cannot be activated or the CPU fails, the ABS indicator comes on, but the DTC is not memorized.
2. The memory can hold any number of DTCs. However, when the same DTC is detected more than once, the later one is
written over the old one.
Therefore, when the same problem is detected repeatedly, it is memorized as one DTC.
3. The DTCs are indicated in the order they occur.
4. The DTCs are memorized in the EEPROM (non - volatile memory). Therefore, the memorized DTCs cannot be
canceled by disconnecting the battery. Perform the specified procedures to erase the DTCs.

Self-diagnosis
1. Self diagnosis can be classified into two categories:
A. Initial diagnosis:
Performed right after the engine starts and until the ABS indicator goes off.
B. Regular diagnosis:
Performed right after the initial diagnosis until the ignition switch is turned OFF.
2. When a problem is detected by self-diagnosis, the system:
A. Turns the solenoid valve OFF
B. Turns the pump motor OFF
C. Turns the ABS indicator ON

How to troubleshoot ABS DTC


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

HI-SCAN (PRO) CHECK


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

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3. Turn the ignition switch ON.


4. Check for diagnostic trouble codes using the Hi-scan (pro).
5. After completion of the repair or correction of the problem, erase the stored fault codes using the clear key on the Hiscan (pro).
6. Disconnect the Hi-scan (pro) from the 16P data link connector.

SYSTEM FUNCTION
ABS OPERATION
1. NORMAL BRAKING
Solenoid valve

State

Valve

IN (NO)

OFF

OPEN

OUT (NC)

OFF

CLOSE

Passage
Master cylinder

Pump motor

Wheel cylinder
OFF

Wheel cylinder

Reservoir

Under the normal braking, voltage is not supplied to solenoid valve, inlet valve is opened and outlet valve is closed.
When the brake is depressed, brake fluid is supplied to the wheel cylindervia solenoid valve to activate the brake.
When the brake is released, brake fluid is back to the master cylinder via inlet valve and check valve.
2. DUMP MODE
Solenoid valve

State

Valve

IN (NO)

ON

CLOSE

OUT (NC)

ON

OPEN

Passage
Master cylinder

Pump motor

Wheel cylinder
ON

Wheel cylinder

Reservoir

Under the emergency braking, if the wheels start to lock up, HECU sends a signal to the solenoid valve to decrease
the brakefluid, then voltage is supplied to each solenoid. At this time inlet valve is closed and brake fluid is blocked
from the mastercylinder. Conversely outlet valve is opened and brake fluid passes through wheel cylinder to reservoir,
resulting in pressure decrease.
3. HOLD MODE
Solenoid valve

State

Valve

IN (NO)

ON

CLOSE

OUT (NC)

OFF

CLOSE

Passage
Master cylinder

Pump motor

Wheel cylinder
ON

Wheel cylinder

Reservoir

When the brake fluid pressure is maximally decreased in wheel cylinder, HECU sends a signal to solenoid valve to
keep the fluidpressure, voltage is supplied to inlet valve but it is not supplied to outlet valve. At this time inlet and outlet
valves are closed and brake fluid is kept in wheel cylinder.
4. INCREASE MODE
Solenoid valve

State

Valve

IN (NO)

OFF

OPEN

OUT (NC)

OFF

CLOSE

Passage
Master cylinder

Pump motor

Wheel cylinder
ON

Wheel cylinder

Reservoir

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

TRACTION CONTROL SYSTEM (TCS) OPERATION


1. NORMAL MODE
Solenoid valve

State

Valve

IN (NO)

OFF

OPEN

OUT (NC)

OFF

CLOSE

Motor pump

TC valve

OFF

OFF

In the normal driving condition, TC valve (normally open) is the passage between the master cylinder and the each
wheel cylinder.
When brake pedal is applied, brake pressure is delivered to the wheel cylinders via NO-TC valve and all solenoid
valves inside the hydraulic unit are deactivated.
In case of TCS malfunction it does not affect brake operation.

2. PRESSURE INCREASE MODE


Solenoid valve

State

Valve

Motor pump

TC valve

IN (NO)

FRONT: OFF
REAR: ON

FRONT: OPEN
REAR: CLOSE

ON

ON

OUT (NC)

OFF

CLOSE

If a front wheel spin is detected, TCS begins a brake control to decrease a wheel spin.
Hydraulic shuttle valve (HSV) is opened.
Brake fluid is supplied from the master cylinder by motor operation to the spin wheel via HSV.
TC valve is closed (ON).
Brake pressure generated from motor pump is delivered only to the front wheel.
Inlet valve remains open to deliver the brake pressure generated from motor pump to the spinning wheels.

3. PRESSURE DUMP MODE


Solenoid valve

State

Valve

IN (NO)

ON

CLOSE

OUT (NC)

FRONT: ON
REAR: OFF

FRONT: OPEN
REAR: CLOSE

Motor pump

TC valve

ON

ON

When the wheel deceleration is under the threshold and the wheel spin is reduced under a slip threshold, applied
brake pressure is reduced to get a optimum traction force.
Outlet valve is open to release the brake pressure and inlet valve is closed to block the pressure increase from the
motor pump.
Hydraulic shuttle valve (HSV) remains opened, TC valve is ON.
Motor is ON, to dump the brake fluid being released from the lock-up wheel.

4. PRESSURE HOLD MODE


Solenoid valve

State

Valve

IN (NO)

ON

CLOSE

OUT (NC)

OFF

CLOSE

Motor pump

TC valve

ON

ON

TRACTION CONTROL SYSTEM (TCS) FUNCTION


1. Main performance

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

FULL TRACTION CONTROL SYSTEM (FTCS)


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

BRAKE TRACTION CONTROL SYSTEM (BTCS)


1. On TCS control, only brake control will be performed. (engine and TCM control will not happen)
2. Controlled by motor pump output pressure.

EBD (ELECTRONIC BRAKE-FORCE DISTRIBUTION) OPERATION


ADVANTAGES
-

Function improvement of the base-brake system.


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

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Comparison between Proportioning valve and EBD

FAIL SAFE
SYSTEM

WARNING LAMP

FAIL CAUSE
ABS

EBD

ABS

EBD

None

ON

ON

OFF

OFF

1-Wheel speed sensor failure

OFF

ON

ON

OFF

Pump malfunction

OFF

ON

ON

OFF

Low voltage

OFF

ON

ON

OFF

2 or more wheel speed sensor failure


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

OFF

OFF

ON

ON

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Page 1 of 1

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

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Troubleshooting

TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

NOTES WITH REGARD TO DIAGNOSIS


Phenomenon
System check sound

ABS operation sound

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

ABS operation (Longbraking


distance)

For road surfaces such as snow-covered and gravel roads, the braking distance for
vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly,
advisethe customer to drive safely on such roads by lowering the vehicle speed.

Pedal kick back

Pedal kick back is normal operation.

Diagnosis detection conditions can vary depending on the diagnosis code. When checking the trouble symptom after the
diagnosis code has been erased,ensure that the requirements listed in "Comment" are met.

ABS CHECK SHEET

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TROUBLE SYMPTOMS TABLE


Symptom

Suspect Area

See page

Communication with Hi-scan (pro) is not


possible.
(Communication with any system is not possible)

1. Power source circuit


2. Diagnosis line

Communication with Hi-scan (pro) is not


possible.
(Communication with ABS only is not possible)

1. Power source circuit


2. Diagnosis line
3. HECU

BR - 63

When ignition key is turned ON (engine OFF),


the ABS warning lamp does not light up.

1. ABS warning lamp circuit


2. HECU

BR - 64

Even after the engine is started, the ABS


warning lamp remains ON.

1. ABS warning lamp circuit


2. HECU

BR - 65

ABS does not operate.

Only when 1. -4. are all normal and the problem


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

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BR - 63

BR - 66

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3. Wheel speed sensor circuit.


4. Check the hydraulic circuit for leakage.

During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to
intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an
abnormality.

DIAGNOSTIC TROUBLE CODE CHART


DTC No.

Detection Item

MIL*

Memory

See page

C1101

Battery voltage over volt: 18V or more

BR - 70

C1102

Battery voltage low volt: 9.5V or less

BR - 70

C1200

FL wheel sensor: open or short to ground

BR - 67

C1201

- Range/Performance: speed jump or damaged exciter

BR - 68

C1202

- No signal: air-gap error or wrong excite

BR - 69

C1203

FR wheel sensor: open or short to ground

BR - 67

C1204

- Range/Performance: speed jump or damaged exciter

BR - 68

C1205

- No signal excite: air-gap error or wrong excite

BR - 69

C1206

RL wheel sensor: open or short to ground

BR - 67

C1207

- Range/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: open or short to battery, motor relay, fuse or


motor lock fail

BR - 72

C1503

TCS switch failure

C1605

CAN Hardware failure

BR - 72

C1610

CAN Bus off failure

BR - 72

C1611

EMS Time-out failure

BR - 72

C1612

TCM Time-out failure

BR - 72

C1613

TCM Un-matching failure

BR - 72

C2227

Brake disc overheat

*MIL : Malfunction Indication Lamp


: ABS warning lamp
: TCS warning lamp

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

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

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INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS


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

Probable cause
Faulty power source circuit
Faulty diagnosis line

Inspection Procedure 2

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


(Communication with ABS only is not possible.)
When communication with Hi-Scan (Pro) is not possible, the cause may
be probably an open circuit in the HECU power circuit or an open circuit in
the diagnosis output circuit.

Probable cause
Faulty power source circuit
Faulty diagnosis line
Faulty HECU

Inspection Procedure 3
When ignition key is turned "ON" (engine OFF), the ABS warning
lamp does not illuminate
When current flows in the HECU, the ABS relay turns from on to off as the
initial check. The ABS warning lamp will illuminate when the ABS relay is
off even if there is a problem with the circuit between the ABS warning
lamp and the HECU.
Therefore, if the lamp does not illuminate, the cause may be an open
circuit in the lamp power supply circuit, a blown bulb, an open circuit in
both the circuits between the ABS warning lamp and the HECU, and in
the circuit between the ABS warning lamp and the ABS relay.

Probable cause

Blown fuse
Burnt out ABS warning lamp bulb
Faulty ABS warning lamp circuit
Faulty HECU

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Inspection Procedure 4
Even after the engine is started, the ABS warning lamp remains
illuminated
A possible short-circuit in the ABS warning lamp illumination circuit

Probable cause
Faulty combination meter
Faulty ABS warning lamp circuit
Faulty HECU

This trouble symptom is limited to cases where communication with the Hi-Scan (Pro) is possible (HECU power
supply is normal) and DTC is normal.

Inspection Procedure 5
ABS does not operate
Brake operation varies depending on
driving conditions and road surface
conditions, so diagnosis can be difficult.
However, if a normal DTC is displayed,
carry out the following inspection.

Probable cause
Improper installation of wheel speed
sensor
Incorrect sensor harness contact
Foreign material on wheel speed
sensor

Faulty wheel speed sensor


Faulty rotor
Faulty wheel bearing
Faulty HECU
Faulty power source circuit

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INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES


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

Probable cause
Faulty wheel speed sensor
Faulty wiring harness or connector
Faulty HECU

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DTC No. C1201, C1204, C1207, C1210


(Speed jump or wrong exciter)
Abnormal output signal from a wheel speed sensor other than an open or
short circuit.

DTC No. C1202, C1205, C1208, C1211


(Large air gap)

Probable cause

Improper installation of wheel speed sensor


Faulty wheel speed sensor
Faulty rotor
Faulty wheel bearing
Faulty wiring harness or connector
Faulty HECU

Probable cause

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No wheel speed sensor output signal.

DTC No. C1101, C1102 Voltage out of range


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

Faulty wheel speed sensor


Improper installation of wheel speed sensor
Faulty rotor (excitor)
Faulty wiring harness or connector
Faulty HECU

Probable cause
Faulty wiring harness or connector
Faulty HECU

If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to thestandard
value, the code is no longer output. Before carrying out the following inspection, check the battery level, and refill if
necessary.

DTC No. C1604 HECU Hardware


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

Probable cause
Faulty wiring harness
Faulty HECU

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DTC No. C2112 Valve relay


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

DTC No. C1605 CAN hardware error


Replace the HECU.

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

DTC No. C1610 bus off error


Check CAN bus wiring.
Check E37, C33, C133-4 or M42 connectors

DTC No. C2402 motor pump failure


(Motor relay, motor)
When the motor power line is normal but no signal is in detected in the
motor monitor line.

Probable cause
Faulty wiring harness or connector
Faulty HECU

Probable cause
Interference by means of electronic wave
Mismatching of the calculation between main
and sub processor
Defects of the valve coil and valve coil
operating circuit element

Probable cause
No message from EMS or TCU for 500ms
Message from A/T or M/T signal mismatch
the message from ECM or TCU

Probable cause
CAN bus cable open, or short to ground or
battery

Probable cause
Faulty wiring harness
Faulty HECU

Powering the motor with the Hi-Scan (Pro) will discharge the battery. Start and run the engine for a while after testingis
complete.

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INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES


DTC

Trouble Location

Remarks

C1101

Battery voltage over volt

: 18V or more

C1102

Battery voltage low volt

: 9.5V or less

C1200

FL wheel sensor

: open or short to ground

C1201

- Range/Performance

: speed jump or damaged


exciter

C1202

- No signal

: air-gap error or wrong excite

C1203

FR wheel sensor

: open or short to ground

C1204

- Range/Performance

: speed jump or damaged


exciter

C1205

- No signal excite

: air-gap error or wrong excite

C1206

RL wheel sensor

: open or short to ground

C1207

- 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 relay, fuse or motor
lock fail

C2227

Brake disc overheat

Only TCS

C1503

TCS switch failure

With TCS switch

C1610

CAN bus off failure

Only TCS

C1611

EMS time-out failure

Only TCS

C1612

TCU time-out failure

Only TCS

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C1613

TCU un-matching failure

Only TCS

C1605

CAN hardware failure

Only TCS

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

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INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES


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

Probable cause
Malfunction of wheel speed sensor
Malfunction of wiring harness or connector
Malfunction of HECU

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DTC No. C1201, C1204, C1207, C1210


(Speed jump or wrong exciter)
Abnormal output signal from a wheel speed sensor other
than an open or short circuit.

DTC No. C1202, C1205, C1208, C1211


(Large air gap)

Probable cause

Improper installation of wheel speed sensor


Malfunction of wheel speed sensor
Malfunction of rotor
Malfunction of wheel bearing
Malfunction of wiring harness or connector
Malfunction of HECU

Probable cause

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No wheel speed sensor output signal.

DTC No. C1101, C1102 Voltage out of range


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

Malfunction of wheel speed sensor


Improper installation of wheel speed sensor
Malfunction of rotor (excitor)
Malfunction of wiring harness or connector
Malfunction of HECU

Probable cause
Malfunction of wiring harness or connector
Malfunction of HECU.

If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to the standard
value, the code is no longer output. Before carrying out the followinginspection, check the battery level, and refill if
necessary.

DTC No. C1604 HECU Hardware


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

Probable cause
Malfunction of wiring harness
Malfunction of HECU

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DTC No. C2112 Valve relay


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

DTC No. C1605 CAN hardware error


Replace the HECU.

DTC No. C1611 CAN timeout EMS, C1612 CAN timeout


TCU, C1613 CAN wrong matched transmission
Inspect the EMS or TCU according to the instructions of
Engine or T/M group.

DTC No. C1610 bus off error


Check CAN bus wiring.
Check E37, C33, C133-4 or M42 connectors

DTC No. C2402 motor pump failure


(Motor relay, motor)
When the motor power line is normal but no signal is in
detected in the motor monitor line.

Probable cause
Malfunction of wiring harness or connector
Malfunction of HECU

Probable cause
Interference by means of electronic wave
Mismatching of the calculation between main and sub
processor
Defects of the valve coil and valve coil operating circuit
element

Probable cause
No message from EMS or TCU for 500ms
Message from A/T or M/T signal mismatch the message
from ECM or TCU

Probable cause
CAN bus cable open, or short to ground or battery

Probable cause
Malfunction of wiring harness
Malfunction of HECU

Powering the motor with the Hi-Scan (Pro) will discharge the battery. Start and run the engine for a while after testingis
complete.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) >
Repair procedures

BLEEDING OF BRAKE SYSTEM


1. Remove the reservoir cap and fill the brake reservoir with brake fluid.

If there is any brake fluid on any painted surface, wash it off immediately.

When pressure bleeding, do not depress the brake pedal.


Recommended fluid ......... DOT3 or DOT4

2. Connect a clear plastic tube to the wheel cylinder bleeder plug and insert the other end of the tube into a half
filled clear plastic bottle.

3. Connect the Hi-Scan (Pro) to the Data Link Connector located underneath the dash panel.

4. Select and operate according to the instructions on the Hi-Scan (Pro) screen.

You must obey the maximum operating time of the ABS motor with the Hi-Scan (Pro) to prevent the

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motor pump from burning.


(1) Select hyundai vehicle diagnosis.

(2) Select vehicle name.


(3) Select Anti-Lock Brake system.
(4) Select air bleeding mode.
(5) Press 'YES' to operate motor pump and solenoid valve.

(6) Wait 60 sec. before operating the air bleeding.


(If not, you may damage the motor).

5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without
bubbles. Then close the bleeder screw.

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6. Repeat step 5 until there are no more bubbles in the fluid for each wheel.

7. Tighten the bleeder screw.


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > ABS Control Module >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) >
ABS Control Module > Schematic Diagrams

HECU BLOCK DIAGRAM


1. ABS ECU BLOCK DIAGRAM

2. TCS ECU BLOCK DIAGRAM

CIRCUIT DIAGRAM

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INSPECTION OF HECU TERMINALS

Terminals No.
25 - GND (8,24)

Condition
Always

Standard Voltage (V)


10 - 14

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9 - GND (8,24)

Always

10 - 14

4 - GND (8,24)

Ignition switch ON

10 - 14

16 - GND (8,24)

Ignition switch ON, ABS warning lamp ON

3-5

Stop lamp switch OFF

Below 1.0

Stop lamp switch ON

10 - 14

18 - GND (8,24)
19 - 20

Ignition switch ON, slowly turn right front wheel

AC voltage generation

1-2

Ignition switch ON, slowly turn left front wheel

AC voltage generation

22 - 23

Ignition switch ON, slowly turn right rear wheel

AC voltage generation

Ignition switch ON, slowly turn left rear wheel

AC voltage generation

5-6
14 - GND (8,24)
GND (8,24) - Body ground

Ignition switch ON, TCS switch ON


Always

10 - 14
Continuity

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > ABS Control Module >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(AntiLock Brake System) > ABS Control Module > Components and Components Location

COMPONENTS

HECU

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > ABS Control
Module > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock
Brake System) > ABS Control Module > Repair procedures

REMOVAL
1. Disconnect the double lock connector (A) from the HECU.

2. Disconnect the brake tubes from the HECU.

Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid gets on the paint, wash it
off immediately with water.
Take care not to damage or deform the brake lines during removal and installation.
To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or
equivalent material.
3. Remove the HECU bracket mounting bolts and remove the HECU.

1. Never attempt to disassemble the HECU.


2. The HECU must be transported and stored in an upright position and with the ports sealed. The
HECU must not be drained.

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Tightening torque
HECU bracket mounting bolts:
17~26 Nm (170~260 kgcm, 12.5~19.1 lbft)

INSTALLATION
1. Installation is the reverse of removal.
2. Tighten the HECU mounting bolts and brake tube nuts to the specified torque.
Tightening torque
HECU mounting bolt:
8~10 Nm (80~100 kgcm, 5.9~7.3 lbft)
HECU bracket mounting bolt:
17~26 Nm (170~260 kgcm, 12.5~19.1 lbft)
Brake tube nut:
13~17 Nm (130~170 kgcm, 9.5~12.5 lbft)

INSPECTION
WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK
1. Raise the vehicle and release the parking brake.
2. Disconnect the HECU harness connector's and measure from the harness side connector.

Be sure to remove the connector's double lock and insert the probe into the harness side (back-probe).
Inserting itinto the terminal side may result in a bad connection.
3. Rotate the wheel to be measured approximately 1/2 to 1 rotation per second, and check the output voltage
using a circuit tester or an oscilloscope.
Wheel speed
sensor

Front left

Front right

Rear left

Rear right

19

22

20

23

Terminal

Output voltage:
When measuring with an oscilloscope:
130mV pp or more

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Front Wheel Speed
Sensor > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS
(Anti-Lock Brake System) > Front Wheel Speed Sensor > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS(Anti-Lock Brake System) > Front Wheel
Speed Sensor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Brake System > ABS
(Anti-Lock Brake System) > Front Wheel Speed Sensor > Repair procedures

REMOVAL
FRONT WHEEL SPEED SENSOR
1. Remove the front wheel speed sensor mounting bolt.

2. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector.

REAR WHEEL SPEED SENSOR


1. Remove the rear wheel speed sensor mounting bolt.

2. Remove the luggage trim and disconnect the wire connector from the rear wheel speed sensor.

INSPECTION

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

2. Connect a voltmeter between the wheel speed sensor terminals and measure the voltage by turning the
wheel.

Set the voltmeter to measure AC voltage.


Service standard : AC voltage detected.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information > Special
Service Tools (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General
Information > Special Service Tools (M5GF1)

SPECIAL TOOLS (6-SPEED M/T)


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information >
Troubleshooting (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System >
General Information > Troubleshooting (M5GF1)

TROUBLESHOOTING (M/T)
Symptom
Vibration, noise

Probable cause

Remedy

Loose or damaged transaxle and engine mounts

Tighten or replace mounts

Inadequate shaft end play

Correct end play

Worn or damaged gears

Replace gears

Inadequate grade of oil

Replace with specified oil

Low oil level

Replenish

Inadequate engine idle speed

Adjust idle speed

Oil leakage

Broken or damaged, oil seal or O-ring

Replace oil seal or O-ring

Hard shift

Faulty control cable

Replace control cable

Poor contact or wear of synchronizer ring and


gear cone

Correct or replace

Weakened synchronizer spring

Replace synchronizer spring

Inadequate grade of oil

Replace with specified oil

Worn gear shift fork or broken poppet spring

Replace shift fork or poppet


spring

Synchronizer hub-to-sleeve spline clearance too


large

Replace synchronizer hub and


sleeve

Jumps out of gear

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information > Specifications
(M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > General Information >
Specifications (M5GF1)

SPECIFICATIONS (M/T)
Model

M5BF2
(5-speed)

M5GF1
(5-speed)

Engine

2.0 DOHC

2.7 DOHC

2.0 DOHC

2.7 DOHC

1st

3.462

3.231

3.153

2nd

2.053

1.952

1.944

3rd

1.393

1.296

1.333

4th

1.061

0.943

1.055

5th

0.837

0.775

0.857

6th

0.704

Reverse

3.250

3.455

3.002

Final gear ratio

4.056

4.063

4.678

4.428

2.15

2.1

Gear ratio

Oil quantity ()

MFA60
(6-speed)

2.2 0.1

SERVICE STANDARD (6-SPEED M/T)


Item

Standard

Limit

Input shaft 6th gear end play

0 ~ 0.1

Output shaft 6th gear end play

0 ~ 0.1

Output shaft 6th gear bearing play

0 ~ 0.06

Clearance between 3rd gear and synchronizer


ring

0.9 ~ 1.45

0.7

Clearance between 4th gear and synchronizer


ring

0.9 ~ 1.45

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

Nm

kgcm

lbft

Manual transaxle case to clutch housing bolt

63 ~ 67

630 ~ 670

46 ~ 49

Drain plug

30 ~ 39

300 ~ 390

22 ~ 28

Reverse lever

11.8 ~ 15.6

118 ~ 156

8.7 ~ 11.5

Shift check plug

12.7 ~ 17.0

127 ~ 170

9.3 ~ 12.5

Shift check

22.5 ~ 25.5

225 ~ 255

16.6 ~ 18.8

Stopper bolt

26.5 ~ 30.4

26.5 ~ 304

19.6 ~ 22.4

6.3 ~ 8.3

63 ~ 83

4.6 ~ 6.0

Control shaft bolt


Shift lever mounting plate

2~3

20 ~ 30

1~2

Differential final gear bolt

112.7 ~ 127.4

1127 ~ 1274

83 ~ 94

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > Manual Transaxle System >
Manual Transaxle > Repair procedures (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual
Transaxle System > Manual Transaxle System > Manual Transaxle > Repair procedures (M5GF1)

REMOVAL
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

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(2) Lower

6. Remove the back-up lamp switch.

7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.

8. Remove the brake fluid leveling sensor connector.

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9. Remove the speedometer driven gear connector.


10. Remove the clutch release cylinder mounting bolt.

11. Remove the cotter pin of the shift cable (transaxle side).

12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).

14. Remove the clip of the select cable (transaxle side).

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15. Separate the steering column shaft joint.

16. Separate the power steering oil pump hose.

Be careful not to leak after separating.


17. Separate the hose after removing the clip of the power steering return hose.

18. Remove the upper connecting transaxle bolt.

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19. Separate the start motor.

20. Install the engine support fixture.


21. After removing the tire, remove the caliper.

22. Remove the transaxle side cover.

23. Remove the transaxle side under cover.

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24. Separate the tie rod end.

25. Remove the wheel speed sensor and the knuckle mounting bolt.

26. Drain the oil.

27. Remove the transaxle mounting bracket.


(1) Insulator bolt

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(2) Body side mounting bolt (Upper)

(3) Body side mounting bolt (Side)

(4) Transaxle side mounting bolt.

28. Remove the front roll stopper.


(1) Insulator bolt

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(2) Stopper bolt (Upper)

(3) Stopper bolt (Lower)

29. Remove the rear roll stopper.


(1) Insulator bolt

(2) Stopper bolt

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30. Remove the drive shaft.


31. Remove the front muffler.

32. Remove the sub frame mounting bolt.

33. Install the transaxle jack.

34. Remove the transaxle lower mounting bolt to the engine.

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35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

SERVICE ADJUSTMENT PROCEDURES


TRANSAXLE GEAR OIL LEVEL INSPECTION
1. Remove oil filler plug and check level with finger.
2. Oil level must be up to fill the hole, add oil until it runs over. Then reinstall plug.
3. Replace the oil so that the transaxle gear oil is not dirty, and so that it is of a suitable viscosity.

REPLACEMENT OF TRANSAXLE GEAR OIL


1. With the vehicle parked on a level surface, remove the drain plug and drain the transaxle oil.
2. Replace the gasket with a new one and install the drain plug.
3. Add new oil through the filler plug and, fill it to just below the plug opening.
Standard value
Transaxle oil total capacity :
M5BF2 : 2.15 lit
M5GF1 : 2.1 lit
MFA60 : 2.2 0.1 lit

DRIVE SHAFT OIL SEAL REPLACEMENT


1. Disconnect the drive shaft from the transaxle (Refer to "DS" group).
2. Using a flat-tip screwdriver, remove the oil seal.
3. Using the special tool (09431-2C000), tap the drive shaft oil seal into the transaxle.
4. Apply a coating of gear oil to the oil seal.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > Manual Transaxle Control System >
Manual Transaxle Shift Control > Components and Components Location (M5GF1), TIBURON(GK) > 2003 > G 2.7
V6 DOHC > Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Components and Components Location (M5GF1)

COMPONENTS
5-SPEED M/T

6-SPEED M/T

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Manual Transaxle System > Manual Transaxle Control System
> Manual Transaxle Shift Control > Repair procedures (M5GF1), TIBURON(GK) > 2003 > G 2.7 V6 DOHC
> Manual Transaxle System > Manual Transaxle Control System > Manual Transaxle Shift Control >
Repair procedures (M5GF1)

REMOVAL
1. Remove the shift knob.

2. Remove the spring and the cap (for 6-speed M/T).

3. Remove the skirt (for 6-speed M/T).

4. Remove the console upper cover.

5. Remove the console assembly.

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6. Remove the shift cable clip.

7. Remove the select cable clip.

8. Remove the snap pin of the select cable.

9. Remove the shift cable.

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10. Remove the shift lever assembly.

For 6-speed M/T, push the plate shaft outward with a driver or equivalent through the hole in the shift
lever bracket to remove it.

INSTALLATION
Install the shift lever assembly.

INSPECTION
1. Check the select cable for proper operation and for damage.
2. Check the shift cable for proper operation and for damage.
3. Check the boot for damage.
4. Check each bushing for wear, abrasion, sticking, restricted movement or damage.
5. Check for a weak or damaged spring.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > General Information > Special
Service Tools (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System >
General Information > Special Service Tools (F4A42-2)

SPECIAL TOOLS (A/T)


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

09452-21001
Oil pressure gauge adapter

Measurement of the oil pressure.


(use with 09452-21500 and 0945221002)

09452-21002
Oil pressure gauge adapter

Measurement of the oil pressure.


use with 09452-21500 and 0945221001)

09452-21500
Oil pressure gauge

Measurement of the oil pressure.


(use with 09452-21001 and 0945221002)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > General Information >
Specifications (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System >
General Information > Specifications (F4A42-2)

SPECIFICATIONS (A/T)
Item

F4A42-1

F4A42-2

Torque converter type

3-element, 1-stage, 2-phase type

Transaxle type

4-speed forward, 1-speed reverse

Engine displacement

2.0 DOHC

2.7 DOHC

Gear ratio
1st
2nd
3rd
4th

2.842
1.529
1.000
0.712

2.842
1.529
1.000
0.712

Reverse

2.480

2.480

Final gear ratio

4.407

4.402

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System >
Schematic Diagrams (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System >
Automatic Transaxle System > Schematic Diagrams (F4A42-2)

TCM CIRCUIT DIAGRAM (2.0L)

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TCM CIRCUIT DIAGRAM (2.7L)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System > Flow
Diagram (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > Flow Diagram (F4A42-2)

AUTOMATIC TRANSAXLE HYDRAULIC CIRCUIT


PARK & NEUTRAL

FIRST

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SECOND

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THIRD

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FOURTH

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REVERSE

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System > General
Information (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > General Information (F4A42-2)

TROUBLESHOOTING (A/T)
(F4A42 Model)

DIAGNOSIS FUNCTION
1. Connect the Hi Scan Pro to the connector for diagnosis.
2. Read the output diagnostic trouble codes. Then follow the remedy procedures according to the "DIAGNOSTIC
TROUBLE CODE DESCRIPTION" on the following pages.

A maximum of 8 diagnostic trouble codes (in the sequence of occurrence) can be stored in the Random Access
Memory (RAM) incorporated within the control module.

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The same diagnostic trouble code can be stored one time only.
If the number of stored diagnostic trouble codes or diagnostic trouble patterns exceeds 8, already stored
diagnostic trouble codes will be erased in sequence, beginning with the oldest.
Do not disconnect the battery until all diagnostic trouble codes or diagnostic trouble patterns have been read
out, because all stored diagnostic trouble codes or diagnostic trouble patterns will be cancelled when the
battery is disconnected.
3. If the fail-safe system is activated and the transaxle is locked in third gear, the diagnostic trouble code in the Fail-safe
code description will be stored in the RAM. Three of these diagnostic trouble codes can be stored.
4. The cancellation will occur if, with the transaxle locked in third gear, the ignition key is turned to the OFF position, but
the diagnostic trouble code is stored in the RAM.
5. Memorization.
A. Up to 8 diagnosis items and 3 fail-safe items can be memorized.
B. If the memory capacity is exceeded, diagnosis and fail-safe items in the memory are overwritten, starting with the
oldest.
C. No code can be memorized more than once.
6. Diagnosis Code Deletion.
(1) Automatic Deletion
All diagnosis codes are deleted from memory the 200 th time the ATF temperature reaches 50C after mem orization
of the most recent diagnosis code.
(2) Forced Deletion
Memorized diagnosis codes can be deleted using the scan-tool, provided the following conditions are satisfied :
A. The ignition switch is ON
B. There is no detection pulse from the crank angle sensor
C. There is no detection pulse from the output shaft speed sensor
D. There is no detection pulse from the vehicle speed sensor
E. The fail-safe function is not operational

ROAD TEST
No.
1

Condition
Ignition switch : OFF
Ignition switch : ON
Engine : Stopped
Selector lever
position : P

Operation

Judgment value

Ignition switch
(1) ON

Battery voltage (mV)

Control relay

Selector lever position


(1) P, (2) R, (3) N, (4) D

(1) P, (2) R, (3) N, (4)


D

Transaxle range switch

Accelerator pedal
(1) Released
(2) Half depressed
(3) Depressed

(1) 400~1,000 mV
Throttle position sensor
(2)Gradually rises from
(1)
(3) 4,500~5,000 mV

Brake pedal
(1) Depressed
(2) Released

(1) ON
(2) OFF

Ignition switch : ST Starting test with lever P or N Starting should be


range
possible
Engine : Stopped
Warming up

Engine : Idling
Selector lever
position : N

Check item

Stop lamp switch

Starting possible or
impossible

Drive for 15 minutes or more Gradually rises to


so that the automatic fluid
70~90C
temperature becomes
70~90C

Oil temperature sensor

A/C switch
(1) ON
(2) OFF

(1) ON
(2) OFF

Triple pressure switch

Accelerator pedal
(1) Released
(2) Half depressed

(1) ON
(2) OFF

Idle position switch

(1) 600~925 rpm


(2) Gradually rises

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from (1)
(1) Data changes
5

Selector lever
position : N (Carry out
on a flat and straight
road)

Communication with engineECU

Selector lever position


(1) ND
(2) NR

Should be no
abnormal shifting
shocks
Time lag should be
within 2 seconds

Malfunction when starting

Selector lever position and


vehicle speed
1. Idling in 1st gear (Vehicle
stopped)
2. Driving at constant speed
of 20 km/h in 1st gear
3. Driving at constant speed
of 30 km/h in 2nd gear
4. Driving at 50 km/h in 3rd
gear with accelerator fully
closed
5. Driving at constant speed
of 50 km/h in 4th gear
(Each condition should
be maintained for 10
seconds or more)

(2) 1st, (4) 3rd, (3)


2nd, (5) 4th

Shift condition

(2) 0%, (4) 100%, (3)


100%, (5) 100%

Low and reverse solenoid


valve

(2) 0%, (4) 0%, (3) 0% Underdrive solenoid valve


(5) 100%
(2) 100%, (4) 100%,
(3) 0% (5) 0%

Second solenoid valve

(2) 100%, (4) 0%, (3)


100% (5) 0%

Overdrive solenoid valve

(1) 0km/h
(4) 50km/h

Vehicle speed sensor

(4) 1,800 ~ 2,100rpm

Input shaft speed sensor

(4) 1,800 ~ 2,100rpm

Output shaft speed sensor

(3) 0%
(5) Approx. 70~90%

Damper clutch control


solenoid valve

(3) Approx.
100~300rpm
(5) Approx. 0~10rpm
Selector lever
position : D (Carry out
on a flat and straight
road)

Selector lever
position : N (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 km/h
in 3rd gear, shift down to
2nd gear.
6. While driving at 20 km/h
in 2nd gear, shift down to
1st gear.
Move selector lever to R
range drive at constant
speed of 10km/h

For (1), (2) and (3), the


reading should be the
same as the specified
output shaft torque,
and no abnormal
shocks should occur.
For (4), (5) and (6),
downshifting should
occur immediately
after the shifting
operation is made.

Malfunction when shifting

Displaced shift points

Does not shift

Does not shift from 1 to 2 or


2 to 1

Does not shift from 2 to 3 or


3 to 2

Does not shift from 3 to 4 or


4 to 3

The ratio between


Does not shift
input and output shaft
speed sensor data
should be the same as
the gear ratio when
reversing.

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DIAGNOSTIC TROUBLE CODE DESCRIPTION


DTC No
P1704

Diagnosis item
Throttle position sensor

P1703
P1702
P0713

Fluid temperature sensor

P0712

Possible cause

Short circuit

TPS output > 4.8 V with


engine idling

Open circuit

TPS output < 0.2V with


engine not idling

Sensor misadjustment

TPS output < 0.2V or > 1.2V


with engine idling

Open circuit

Oil temperature sensor


output > 4.57 V for 1 second
or longer (oil temperature
does not increase)

Short circuit

Output < 0.49V for 1 second

P0725

CKP sensor

Open circuit

No crankshaft position
sensor output pulse detected
for 5 seconds at vehicle
speed of 25 km/h

P0715

Input speed sensor

Short circuit/open circuit

No input speed sensor output


pulse detected for > 1
second at vehicle speed of >
30 km/h

P0720

Output speed sensor

Short circuit/open circuit

At vehicle speed of > 30


km/h, output speed sensor
output < 50% of vehicle
speed sensor output for > 1
second

P0703

Stop lamp switch

Short circuit/open circuit

At vehicle speed of 6 km/h,


stop lamp switch is ON
continuously for 5 minutes

P0750

LR solenoid valve

Short circuit/open circuit

P0755

UD solenoid valve

Short circuit/open circuit

With relay voltage > 10V,


open or short circuit is
continuously for 0.3 second

P0760

2nd solenoid valve

Short circuit/open circuit

P0765

OD solenoid valve

Short circuit/open circuit

P0743

TCC solenoid valve

Short circuit/open circuit

P0731

Gear shift incomplete

1st

P0732

2nd

P0733

3rd

P0734

4th

P0736

Reverse

After gear shift, output shaft


speed sensor output x gear
ratio of new gear input
shaft speed sensor output

P1749

Serial communication

Short circuit/open circuit

With ignition ON, battery


voltage > 10V, and engine
speed > 450 r/min,
communication is
continuously irregular for 1
second or communication
error signal is received for >
4 seconds continuously

P0740

TCC

System defect/stuck on

DCC solenoid valve drive


duty ratio is 100% for 4
seconds continuously

P1723

A/T control relay

Earth short circuit/open

After ignition ON, A/T control

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P0707

Transaxle range switch

P0708

circuit

relay voltage < 7V

Open circuit

No signal is continuous for >


30 seconds

Short circuit

Above 2 kinds signals are


continuous for 30 seconds

P1630

CAN-BUS OFF

TCM Fail/open/short

Receive BUS-OFF
information from CAN
CONTROLLER

P1631

CAN-TIME OUT ECM

ECM Fail/open/short

No output signal for 1.5


second

P1764

CAN MI-COM CIRCUIT

TCM internal circuit


malfunction

Communication error output


is continuously for > 1
second

INSPECTION CHART FOR DIAGNOSIS CODES


Code
P1704

Diagnosis item

Probable cause

Throttle position sensor system


Short circuit
If the TPS output voltage is 4.8V or higher
when the engine is idling, the output is judged
to be too high and diagnosis code P1704 is set.
Open circuit
If the TPS output voltage is 0.2V or lower at
times other than when the engine is idling, the
output is judged to be too low and diagnosis
code P1703 is set. If the TPS output voltage is
Sensor misadjusted
0.2V or lower or if it is 1.2V or higher when the
engine is idling, the TPS adjustment is judged
to be incorrect and diagnosis code P1702 set.

Malfunction of the throttle


position sensor
Malfunction of connector
Malfunction of the TCM

Open circuit
Fluid temperature sensor system
If the fluid temperature sensor output voltage is Short circuit
4.57V or more even after driving for 10 minutes
or more (if the fluid temperature does not
increase), it is judged that there is an open
circuit in the fluid temperature sensor and
diagnosis code P0713 is set.

Malfunction of the oil


temperature sensor
Malfunction of connector
Malfunction of the TCM

P0725

CKP sensor system


If no output pulse is detected from the crank
shaft position sensor for 5 seconds or more
while driving at 25 km/h or more, it is judged
that there is an open circuit in the crank shaft
position sensor and diagnosis code P0725 is
set.

Malfunction of the crank angle


sensor
Malfunction of connector
Malfunction of the TCM

P0715

Input speed sensor system


Short circuit/open
If no output pulse is detected from the input
circuit
shaft speed sensor for 1 second or more while
driving in 3rd or 4th gear at a speed of 30 km/h
or more, there is judged to be an open circuit or
short circuit in the input shaft speed sensor and
diagnosis code P0715 is set. If diagnosis code
P0715 is set four times, the transmission is
locked into 3rd gear (D range) or 2nd gear as a
fail-safe measure.

Malfunction of the input shaft


speed sensor
Malfunction of the underdrive
clutch retainer
Malfunction of connector
Malfunction of the TCM

P0720

Output speed sensor system


Short circuit/open
If the output from the output shaft speed sensor circuit
is continuously 50% lower than the vehicle
speed for 1 second or more while driving in 3rd
or 4th gear at a speed of 30 km/h or more,

Malfunction of the outputs shaft


speed sensor
Malfunction of connector
Malfunction of the TCM
Malfunction of the transfer drive

P1703

P1702

P0713

P0712

Open circuit

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there is judged to be an open circuit or shortcircuit in the output shaft speed sensor and
diagnosis code P0720 is set. If diagnosis code
P0720 is set four times, the transmission is
locked into 3rd gear (D range) or 2nd gear as a
fail-safe measure.

gear or driven gear

P0703

Stop lamp switch system


If the stop lamp switch is on for 5 minutes or
more while driving, it is judged that there is a
short circuit in the stop lamp switch and
diagnosis code P0703 is set.

Short circuit/open
circuit

Malfunction of the stop lamp


switch
Malfunction of connector
Malfunction of the TCM

P0750

Low and reverse solenoid valve system

Short circuit/Open
circuit

P0755

Underdrive solenoid valve system

Short circuit/Open
circuit

Malfunction of solenoid valve


Malfunction of connector
Malfunction of the TCM

P0760

Second solenoid valve system

Short circuit/Open
circuit

P0765

Overdrive solenoid valve system


Short circuit/Open
If the resistance value for a solenoid valve is
circuit
too large or too small, it is judged that there is a
short circuit or an open circuit in the solenoid
valve and the respective diagnosis code is set.
The transmission is locked into 3rd gear as a
fail-safe measure.

P0743

Short circuit/Open
Torque converter clutch solenoid valve
circuit
system
If the resistance value for a solenoid valve is
too large or too small, it is judged that there is a
short circuit or an open circuit in the solenoid
valve and the respective diagnosis code is set. Defective system
The transmission is locked into 3rd gear as a
fail-safe measure.

Malfunction of the torque


converter clutch solenoid valve
Malfunction of connector
Malfunction of the TCM

P0731

1st gear ratio does not meet the specification


If the output from the output shaft speed sensor multiplied by the 1st
gear ratio is not the same as the output from the input shaft speed
sensor after the shift to 1st gear has been completed, diagnosis code
P0731 is set. If diagnosis code P0731 is set four times, the transmission
is locked into 3rd gear as a fail-safe measure.

Malfunction of the input shaft


speed sensor
Malfunction of the output shaft
speed sensor
Malfunction of the underdrive
clutch retainer
Malfunction of the transfer drive
gear or driven gear
Malfunction of the low and
reverse brake system
Malfunction of the underdrive
clutch system
Noise generated

P0732

2nd gear ratio does not meet the specification


If the output from the output shaft speed sensor multiplied by the 2nd
gear ratio is not the same as the output from the input shaft speed
sensor after the shift to 3rd gear has been completed, diagnosis code
P0732 is set. If diagnosis code P0732 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 shaft
speed sensor
Malfunction of the underdrive
clutch retainer
Malfunction of the transfer drive
gear or driven gear
Malfunction of the underdrive
clutch system
Malfunction of the second

P0740

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brake system
Noise generated
P0733

3rd gear ratio does not meet the specification


If the output from the output shaft speed sensor multiplied by the 3rd
gear ratio is not the same as the output from the input shaft speed
sensor after the shift to 3rd gear has been completed, diagnosis code
P0733 is set. If diagnosis code P0733 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 shaft
speed sensor
Malfunction of the underdrive
clutch retainer
Malfunction of the transfer drive
gear or driven gear
Malfunction of the underdrive
clutch system
Malfunction of the overdrive
clutch system
Noise generated

P0734

4th gear ratio does not meet the specification


If the output from the output shaft speed sensor multiplied by the 4th
gear ratio is not the same as the output from the input shaft speed
sensor after the shift to 4th gear has been completed, diagnosis code
P0734 is set. If diagnosis code P0734 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 shaft
speed sensor
Malfunction of the underdrive
clutch retainer
Malfunction of the transfer drive
gear or driven gear
Malfunction of the second
brake system
Malfunction of the overdrive
clutch system
Noise generated

P0736

Reverse gear ratio does not meet the specification


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

Malfunction of the input shaft


speed sensor
Malfunction of the output shaft
speed sensor
Malfunction of the underdrive
clutch retainer
Malfunction of the transfer drive
gear or driven gear
Malfunction of the low and
reverse brake system
Malfunction of the reverse
clutch system
Noise generated

P1749

Serial communication
If normal communication is not possible for a continuous period of 1
second or more when the ignition switch is at the ON position, the
battery voltage is 10V or more and the engine speed is 450r/min or
more, diagnosis code No.P1749 is set. Diagnosis code No.P1749 is
also set if the data being received is abnormal for a continuous period of
4 seconds under the same conditions.

Malfunction of connector
Malfunction of the ECM
Malfunction of the TCM

P1723

A/T control relay system


Short circuit to ground/
If the A/T control relay voltage is less than 7V
Open circuit
after the ignition switch has been turned ON, it
is judged that there is an open circuit or a shortcircuit in the A/T control relay ground and
diagnosis code P1723 is set. Then the
transmission is locked into 3rd gar as a fail-safe
measure.

Malfunction of the A/T control


relay
Malfunction of connector
Malfunction of the TCM

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P0707

Transaxle range switch


No signal is continuous for > 30 seconds

P0708

Above 2 signals are continuous for > 30 seconds

P1630

CAN-BUS OFF
No 3 speed hold fail
No PG-A, B fail
Battery voltage > 10V continuously for 0.5 second
No engine stop
Receive BUS OFF information from CAN CONTROLLER

TCM Fail
TCM side open & short

P1631

CAN-TIME OUT ECM


No 3 speed hold fail
No PG-A, B fail
Battery voltage > 10V continuously for 0.5 second
No engine stop
No output signal for 1.5 second

ECM fail
ECM side open & short

P1764

TCM CAN MI-COM


No 3 speed hold fail
No PG-A, B fail
Battery voltage > 10V continuously for 0.5 second
No engine stop
Communication error output is continuously for > 1 second

CAN MI-COM CIRCUIT

Malfunction of transaxle range


switch

INSPECTION CHART FOR THROUBLE SYMPTOMS


Trouble symptom

Probable cause

Communication with HI-SCAN is not possible


is not functioning.

Malfunction of diagnosis line


Malfunction of connector
Malfunction of the TCM

Driving impossible

Starting impossible
Starting is not possible when the selector lever
is in P or N range. In such cases, the cause is
probably a defective engine system, torque
converter or oil pump.

Malfunction of the engine system


Malfunction of the torque converter
Malfunction of the oil pump

Does not move forward


If the vehicle does not move forward when the
selector lever is shifted from N to D range while
the engine is idling, the cause is probably
abnormal line pressure or a malfunction of the
underdrive clutch or valve body.

Does not reverse


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

Abnormal reverse clutch pressure


Abnormal low and reverse brake pressure
Malfunction of the low and reverse brake
solenoid valve
Malfunction of the reverse clutch
Malfunction of the low and reverse brake
Malfunction of the valve body

Does not move (forward or reverse)


If the vehicle does not move forward or reverse
when the selector lever is shifted to any
position while the engine is idling, the cause is
probably abnormal line pressure or a
malfunction of the power train, oil pump or
valve body.

Engine stalling when shifting

Malfunction of the engine system

Malfunction when

Abnormal line pressure


Malfunction of the underdrive solenoid valve
Malfunction of the underdrive clutch
Malfunction of the valve body

Abnormal line pressure


Malfunction of power train
Malfunction of the oil pump
Malfunction of the valve body

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starting

If the engine stalls when the selector lever is


shifted from N to D or R range while the engine
is idling, the cause is probably a malfunction of
the engine system, damper clutch solenoid
valve, valve body or torque converter (damper
clutch malfunction).

Malfunction of the damper clutch control


solenoid valve
Malfunction of the valve body
Malfunction of the torque converter
(Malfunction of the damper clutch)

Shocks when changing from N to D and


large time lag
If abnormal shocks or a time lag of 2 seconds
or more occur when the selector lever is shifted
from N to D range while the engine is idling, the
cause is probably abnormal underdrive clutch
pressure or a malfunction of the underdrive
clutch, valve body.

Shocks when changing from N to R and


large time lag
If abnormal shocks or a time lag of 2 seconds
or more occur when the selector lever is shifted
from N to R range while the engine is idling, the
cause is probably abnormal reverse clutch
pressure or low and reverse brake pressure, or
a malfunction of the reverse clutch, low and
reverse brake, valve body or idle position
switch.

Abnormal reverse clutch pressure


Abnormal low and reverse brake pressure
Malfunction of the low and reverse solenoid
valve
Malfunction of the reverse clutch
Malfunction of the low and reverse brake
Malfunction of the valve body
Malfunction of the idle position switch

Shocks when changing from N to D, N to R


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 up


If shocks occur when driving due to upshifting
or downshifting and the transmission speed
becomes higher than the engine speed, the
cause is probably abnormal line pressure or a
malfunction of a solenoid valve, oil pump, valve
body, brake or clutch.

Displaced shifting
points

All points
If all shift points are displaced while driving, the
cause is probably a malfunction of the output
shaft speed sensor, TPS or solenoid valve.

Malfunction of the output shaft speed


sensor
Malfunction of the throttle position sensor
Malfunction of each solenoid valve
Abnormal line pressure
Malfunction of the valve body
Malfunction of the TCM

Some points
If some of the shift points are displaced while
driving, the cause is probably a malfunction of
the valve body, or it is related to control and is
not an abnormality.

Malfunction of the valve body

Does not shift

No diagnosis codes
If shifting does not occur while driving and no
diagnosis codes are set, the cause is probably
a malfunction of the transaxle range switch, or
TCM

Malfunction of the transaxle range


Malfunction of the TCM

Malfunction while

Poor a acceleration

Malfunction of the engine system

Abnormal underdrive clutch pressure


Abnormal low and reverse brake pressure
Malfunction of the underdrive solenoid valve
Malfunction of the valve body
Malfunction of the idle position switch

Abnormal line pressure


Malfunction of each solenoid valve
Malfunction of the oil pump
Malfunction of the valve body
Malfunction of each brake or each clutch

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driving

If acceleration is poor even if downshifting


occurs while driving, the cause is probably a
malfunction of the engine system, brake or
clutch.

Malfunction of the brake of clutch

Malfunction while
driving

Vibration
If vibration occurs when driving at constant
speed or when accelerating and deceleration in
top range, the cause is probably abnormal
damper clutch pressure or a malfunction of the
engine system, damper clutch control solenoid
valve, torque converter or valve body.

Abnormal damper clutch pressure


Malfunction of the engine system
Malfunction of the damper clutch control
solenoid valve
Malfunction of the torque converter
Malfunction of the valve body

Transaxle range switch system


The cause is probably a malfunction of the inhibitor switch circuit,
ignition switch circuit or a defective TCM.

Idle position switch system


The cause is probably a defective idle position switch circuit, or a
defective TCM.

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.

Vehicle speed sensor system


The cause is probably a defective vehicle speed sensor circuit or a
defective TCM.

Malfunction of the vehicle speed sensor


Malfunction of connector
Malfunction of the TCM

Malfunction of the transaxle range switch


Malfunction of the ignition switch
Malfunction of connector
Malfunction of the TCM

Malfunction of the triple pressure switch


Malfunction of connector
Malfunction of A/C system
Malfunction of the TCM

ELEMENTS IN USE IN EACH GEAR


Operating element
Selector lever position

Underdrive
Reverse
Overdrive
clutch (UD) clutch (REV) clutch (OD)

Low-and
reverse
brake (LR)

Second
brake (2nd)

One way
clutch
(OWC)

Parking

Reverse

Neutral

1st

2nd

3rd

4th

1st

2nd

3rd

1st

2nd

1st

2
L

OPERATING ELEMENTS AND THEIR FUNCTION


Operating element

Code

Function

Underdrive clutch

UD

Connects input shaft and underdrive sun gear

Reverse clutch

REV

Connects input shaft and reverse sun gear

Overdrive clutch

OD

Connects input shaft and overdrive planetary carrier

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Low-and-reverse brake
Second brake

LR
2ND

Locks low-and-reverse annulus gear and overdrive


planetary carrier
Locks reverse sun gear

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System >
Troubleshooting (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > Troubleshooting (F4A42-2)

INSPECTION PROCESS FOR TROUBLE SYMPTOMS


INSPECTION PROCEDURE 1
Communication with the scan tool
If communication with the scan tool is not possible, the
cause may be a defective diagnostic trouble line or the TCM
is not functioning.

Possible cause
Malfunction of diagnostic trouble line
Malfunction of connector
Malfunction of the TCM

INSPECTION PROCEDURE 2
Starting impossible
Starting is not possible when the selector lever is in P or N
range. In such cases, the cause may be a defective engine
system, torque converter or oil pump.

Possible cause
Malfunction of the engine system
Malfunction of the torque converter
Malfunction of the oil pump

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INSPECTION PROCEDURE 3
Does not move
If the vehicle does not move forward when the selector lever
is shifted from N to D range while the engine is idling, the
cause may be abnormal line pressure or a malfunction of
the underdrive clutch or valve body.

Possible cause

Abnormal line pressure


Malfunction of the underdrive solenoid valve
Malfunction of the underdrive clutch
Malfunction of the valve body

INSPECTION PROCEDURE 4
Does not reverse
If the vehicle does not reverse when the selector lever is
shifted from N to R range while the engine is idling, the
cause may be abnormal pressure in the reverse clutch or
low and reverse brake or a malfunction of the reverse
clutch, low and reverse brake or valve body.

Possible cause

Abnormal reverse clutch pressure


Abnormal low and reverse brake pressure
Malfunction of the low and reverse solenoid valve
Malfunction of the reverse clutch
Malfunction of the low and reverse brake
Malfunction of the valve body

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INSPECTION PROCEDURE 5
Does not move (forward or reverse)
If the vehicle does not move forward or reverse when the
selector lever is shifted to any position while the engine is
idling, the cause may be abnormal line pressure, or a
malfunction of the power train, oil pump or valve body.

Possible cause

Abonormal line pressure


Malfunction of the underdrive solenoid valve
Malfunction of the underdrive clutch
Malfunction of the valve body

INSPECTION PROCEDURE 6
Engine stalling when shifting
If the engine stalls when the selector lever is shifted from N
to D or R range while the engine is idling, the cause may be
a malfunction of the engine system, torque converter clutch
soledoid, valve body or torque converter (torque converter
clutch malfunction).

Possible cause

Malfunction of the engine system


Malfunction of the torque converter clutch solenoid
Malfunction of the valve body
Malfunction of the torque converter (Malfunction of the
torque converter clutch)

INSPECTION PROCEDURE 7
Shocks when changing from N to D and range time lag
If abnormal shocks or a time lag of 2 second or more occurs
when the selector lever is shifted from N to D range while

Possible cause
Abnormal line pressure
Malfunction of the underdrive solenoid valve

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the engine is idling, the cause may be abnormal underdrive


clutch pressure or a malfunction of the underdrive clutch,
valve body or closed throttle position switch.

Malfunction of the underdrive clutch


Malfunction of the valve body
Malfunction of the closed throttle position switch

INSPECTION PROCEDURE 8
Shock when changing from N to R and large time lag
If abnormal shocks or a time lag of 2 seconds or more
occurs when the selector lever is shifted from N to R range
while the engine is idling, the cause may be abnormal
reverse clutch pressure or low and reverse brake pressure,
or a malfunction or the reverse clutch, low and reverse
brake, valve body.

Possible cause

Abnormal reverse clutch pressure


Abnormal low and reverse brake pressure
Malfunction of the low and reverse solenoid valve
Malfunction of the reverse clutch
Malfunction of the low and reverse brake
Malfunction of the valve body

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INSPECTION PROCEDURE 9
Shocks when changine from N to D, N to R and large
time lag
If abnormal shocks or a time lag of 2 seconds or more
occurs when the selector lever is shifted from N to D, N to R
range while the engine is idling, the cause may be abnormal
line pressure or a malfunction of the oil pump or valve body.

Possible cause
Abnormal line pressure
Malfunction of the oil pump
Malfunction of the valve body

INSPECTION PROCEDURE 10
Shocks and running up
If shocks occur when driving due to upshifting or
downshifting and the transaxle speed becomes higher than
the engine speed, the cause may be abnormal line pressure
or a malfunction of a solenoid valve, oil pump, valve body or
of a brake or clutch.

Possible cause

Abnormal line pressure


Malfunction of each solenoid valve
Malfunction of the oil pump
Malfunction of the valve body
Malfunction of each brake or each clutch

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INSPECTION PROCEDURE 11
All points (Displaced shifting points)
If all shift points are displaced while driving, the cause may
be a malfunction of the output shaft speed sensor, TPS or a
solenoid valve.

Possible cause

Malfunction of the output shaft speed sensor


Malfunction of the throttle position sensor
Malfunction of each solenoid valve
Abnormal line pressure
Malfunction of the valve body
Malfunction of the TCM

INSPECTION PROCEDURE 12

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Some points (Displaced shifting points)


If some of the shift points are displaced while driving, the
cause may be a malfunction of the valve body, or it is
related to control and is not an abnormality.

Possible cause
Malfunction of the valve body

INSPECTION PROCEDURE 13
No diagnostic trouble codes (Does not shift)
If shifting does not occur while driving and no diagnostic
trouble codes are given, the cause may be a malfunction of
the Park/Neutral position switch, or TCM.

Possible cause
Malfunction of the Park/Neutral position switch
Malfunction of the TCM

INSPECTION PROCEDURE 14
Poor acceleration
If acceleration is poor even if downshifting occurs while
driving, the cause may be a malfunction of the engine
system or of a brake or clutch.

Possible cause
Malfunction of the engine system
Malfunction of the brake or clutch

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INSPECTION PROCEDURE 15
Vibration
If vibration occurs when driving at constant speed or when
accelerating in top range, the cause may be abnormal
torque converter clutch pressure or a malfunction of the
engine system, torque converter clutch solenoid, torque
converter or valve body.

Possible cause

Abnormal torque converter clutch pressure


Malfunction of the engine system
Malfunction of the torque converter clutch solenoid
Malfunction of the torque converter
Malfunction of the valve body

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System > Repair
procedures (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic
Transaxle System > Repair procedures (F4A42-2)

BASIC INSPECTION ADJUSTMENT


AUTOMATIC TRANSAXLE FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then
move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, reinsert and remove the oil level gauge and check the condition of
the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the bushes
and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, add more fluid
until the level reaches the HOT mark.
Automatic transaxle fluid : DIAMOND ATF SP-III., SK ATF SP-III.

If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form inside the
hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping
of the clutches and brakes. If there is too much fluid, the gears can churn it up into foam and cause the same
conditions that can occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of
the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid
escaping from the transaxle vent, in which case it may be mistaken for a leak.
6. Insert the oil level gauge securely.
7. The fluid and the oil filters should always be replaced when overhauling the transaxle or after the vehicle has been
driven under severe conditions. The replacement procedures are given below. Furthermore, the oil filters are special
filters which are only to be used for the automatic transaxle.

When new, automatic transmission fluid should be red. The red dye is added so distinguish it from engine oil or
antifreeze. As the vehicle is driven the transmission fluid will begin to look darker. The color may eventually appear
light brown
Also, the dye, which is not an indicator of fluid quality, is not permanent
Therefore, further investigation of the automatic transaxle is required if,
the fluid is dark brown or black.
the fluid smells burnt.
metal particles can be seen or felt on the dipstick.

AUTOMATIC TRANSAXLE FLUID


1. Remove the drain plug from the bottom of the transaxle case to drain the fluid.
2. Install the drain plug and gasket, and tighten to the specified torque.
Tightening torque : 32 Nm (320 kgcm, 23 lbft)
3. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.


4. Repeat the procedure in step 1 if too much fluid was added.
5. Reconnect the hose that was disconnected in step 1 above, and firmly replace the oil level gauge.

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6. Start the engine and run it at idle for 1-2 minutes.


7. Move the select lever through all positions, and then move it to the N position.
8. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C), and then ch eck the fluid level
again. The fluid level must be at the HOT Mark.
9. Firmly insert the oil level gauge into the oil filler tube.

TRANSAXLE RANGE SWITCH CONTINUITY CHECK

TRANSAXLE RANGE SWITCH AND CONTROL CABLE ADJUSTMENT


1. Set the selector lever to the "N" position.
2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever.

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3. Set the manual control lever to the neutral position.

4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole in the
end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle range switch
body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Be careful at this time that the position
of the switch body does not change.

6. Gently pull the transaxle control cable in the direction of the arrow, then tighten the adjusting nut.
7. Check that the selector lever is in the "N" position.
8. Check that each range on the transaxle side operates and functions correctly for each position of the selector lever.

A/T CONTROL COMPONENT CHECK


1. THROTTLE POSITION SENSOR CHECK
The TPS is a variable resistor type that rotates with the throttle body shaft to sense the throttle valve angle. As the
throttle shaft rotates, the output voltage of the TPS changes. The ECM detects the throttle valve opening based on
voltage change. (Refer to FL-section).
2. OIL TEMPERATURE SENSOR CHECK
(1) Remove the oil temperature sensor.
(2) Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector.
STANDARD VALUE

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Oil temperature (C)

Resistance (K)

16.7 ~ 20.5

100

0.57 ~ 0.69

3. VEHICLE SPEED SENSOR CHECK


(1) Remove the vehicle speed sensor and connect a 3~10 K resistance as shown in the illustration.
(2) Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2-3 (1 turn=4 pulses).

4. A/T CONTROL RELAY CHECK


(1) Remove the A/T control relay.
(2) Use jumper wires to connect A/T control relay terminal 2 to the battery (+) terminal and terminal 4 to the battery (-)
terminal.
(3) Check the continuity between terminal 1 and terminal 3 of the A/T control relay when the jumper wires are
connected and disconnected from the battery.
(4) If there is a problem, replace the A/T control relay.
Jumper wire

Continuity between terminal No.1

Connected

Continuity

Disconnected

No continuity

5. SOLENOID VALVE CHECK


(1) Remove the valve body cover.
(2) Disconnect the connectors of each solenoid valve.

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(3) Measure the resistance between terminals 1 and 2 of each solenoid valve.
STANDARD VALUE
Name

Resistance

Damper clutch solenoid valve

2.7 ~ 3.4
(at 20C)

Low and reverse solenoid valve


Second solenoid valve
Underdrive solenoid valve
Overdrive solenoid valve

(4) If the resistance is outside the standard value, replace the solenoid valve.

Resistance of the solenoid valve connector.


Terminal No.

Name

7 & 10

Damper clutch solenoid valve

10 & 6

Low and reverse solenoid valve

9&4

Second solenoid valve

9&3

Underdrive solenoid valve

9&5

Overdrive solenoid valve

Resistance
2.7 ~ 3.4
(at 20C)

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BASIC INSPECTION ADJUSTMENT


AUTOMATIC TRANSAXLE FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then
move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, reinsert and remove the oil level gauge and check the condition of
the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the bushes
and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, add more fluid
until the level reaches the HOT mark.
Automatic transaxle fluid : DIAMOND ATF SP-III., SK ATF SP-III.

If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form inside the
hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping
of the clutches and brakes. If there is too much fluid, the gears can churn it up into foam and cause the same
conditions that can occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of
the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid
escaping from the transaxle vent, in which case it may be mistaken for a leak.
6. Insert the oil level gauge securely.
7. The fluid and the oil filters should always be replaced when overhauling the transaxle or after the vehicle has been
driven under severe conditions. The replacement procedures are given below. Furthermore, the oil filters are special
filters which are only to be used for the automatic transaxle.

When new, automatic transmission fluid should be red. The red dye is added so distinguish it from engine oil or
antifreeze. As the vehicle is driven the transmission fluid will begin to look darker. The color may eventually appear
light brown
Also, the dye, which is not an indicator of fluid quality, is not permanent
Therefore, further investigation of the automatic transaxle is required if,
the fluid is dark brown or black.
the fluid smells burnt.
metal particles can be seen or felt on the dipstick.

AUTOMATIC TRANSAXLE FLUID


1. Remove the drain plug from the bottom of the transaxle case to drain the fluid.
2. Install the drain plug and gasket, and tighten to the specified torque.
Tightening torque : 32 Nm (320 kgcm, 23 lbft)
3. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.


4. Repeat the procedure in step 1 if too much fluid was added.
5. Reconnect the hose that was disconnected in step 1 above, and firmly replace the oil level gauge.
6. Start the engine and run it at idle for 1-2 minutes.
7. Move the select lever through all positions, and then move it to the N position.

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8. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C), and then ch eck the fluid level
again. The fluid level must be at the HOT Mark.
9. Firmly insert the oil level gauge into the oil filler tube.

TRANSAXLE RANGE SWITCH CONTINUITY CHECK

TRANSAXLE RANGE SWITCH AND CONTROL CABLE ADJUSTMENT


1. Set the selector lever to the "N" position.
2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever.
3. Set the manual control lever to the neutral position.

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4. Loosen the transaxle range switch body mounting bolts and then turn the transaxle range switch body so the hole in the
end of the manual control lever and the hole (cross section A-A in the figure) in the flange of the transaxle range switch
body flange are aligned.
5. Tighten the transaxle range switch body mounting bolts to the specified torque. Be careful at this time that the position
of the switch body does not change.

6. Gently pull the transaxle control cable in the direction of the arrow, then tighten the adjusting nut.
7. Check that the selector lever is in the "N" position.
8. Check that each range on the transaxle side operates and functions correctly for each position of the selector lever.

A/T CONTROL COMPONENT CHECK


1. THROTTLE POSITION SENSOR CHECK
The TPS is a variable resistor type that rotates with the throttle body shaft to sense the throttle valve angle. As the
throttle shaft rotates, the output voltage of the TPS changes. The ECM detects the throttle valve opening based on
voltage change. (Refer to FL-section).
2. OIL TEMPERATURE SENSOR CHECK
(1) Remove the oil temperature sensor.
(2) Measure the resistance between terminals 1 and 2 of the oil temperature sensor connector.
STANDARD VALUE

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Oil temperature (C)

Resistance (K)

16.7 ~ 20.5

100

0.57 ~ 0.69

3. VEHICLE SPEED SENSOR CHECK


(1) Remove the vehicle speed sensor and connect a 3~10 K resistance as shown in the illustration.
(2) Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2-3 (1 turn=4 pulses).

4. A/T CONTROL RELAY CHECK


(1) Remove the A/T control relay.
(2) Use jumper wires to connect A/T control relay terminal 2 to the battery (+) terminal and terminal 4 to the battery (-)
terminal.
(3) Check the continuity between terminal 1 and terminal 3 of the A/T control relay when the jumper wires are
connected and disconnected from the battery.
(4) If there is a problem, replace the A/T control relay.
Jumper wire

Continuity between terminal No.1

Connected

Continuity

Disconnected

No continuity

5. SOLENOID VALVE CHECK


(1) Remove the valve body cover.
(2) Disconnect the connectors of each solenoid valve.

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(3) Measure the resistance between terminals 1 and 2 of each solenoid valve.
STANDARD VALUE
Name

Resistance

Damper clutch solenoid valve

2.7 ~ 3.4
(at 20C)

Low and reverse solenoid valve


Second solenoid valve
Underdrive solenoid valve
Overdrive solenoid valve

(4) If the resistance is outside the standard value, replace the solenoid valve.

Resistance of the solenoid valve connector.


Terminal No.

Name

7 & 10

Damper clutch solenoid valve

10 & 6

Low and reverse solenoid valve

9&4

Second solenoid valve

9&3

Underdrive solenoid valve

9&5

Overdrive solenoid valve

Resistance
2.7 ~ 3.4
(at 20C)

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SERVICE ADJUSTMENT PROCEDURES


BRAKE REACTION PLATE END PLAY ADJUSTMENT
Standard value : 0 ~ 0.16mm

SECOND BRAKE END PLAY ADJUSTMENT

Standard value : 0.79 ~ 1.25mm

LOW-REVERSE BRAKE END PLAY ADJUSTMENT

Standard value : 1.35 ~ 1.81mm

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IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS


O.D.

I.D.

Thickness

Symbol

O.D.

I.D.

Thickness

Symbol

59

47

1.8

#1

48.9

37

1.6

#8

59

47

2.0

#1

48.9

37

1.7

#8

59

47

2.2

#1

48.9

37

1.8

#8

59

47

2.4

#1

48.9

37

1.9

#8

59

47

2.6

#1

48.9

37

2.0

#8

59

47

2.8

#1

48.9

37

2.1

#8

49

36

3.6

#2

48.9

37

2.2

#8

49

36

3.6

#3

48.9

37

2.3

#8

45.3

31

3.3

#4

48.9

37

2.4

#8

49

36

3.6

#5

48.9

37

2.5

#8

49

36

3.6

#6

48.9

37

2.6

#8

59

37

2.8

#7

UNDERDRIVE SUN GEAR END PLAY ADJUSTMENT


Standard value : 0.25 ~ 0.45mm

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Installing the underdrive clutch hub makes it easy to measure the underdrive sun gear end play.

DIFFERENTIAL CASE PRELOAD ADJUSTMENT


Place a piece of solder (approx. 10 mm in length, 3mm in diameter) on the torque converter housing as shown in the
figure.
Install the torque converter housing to the transmission case without applying sealant. Tighten its mounting bolts to the
specified torque. Loosen the bolts, and remove the solder. Use a micrometer to measure the thickness(T) of the pressed
solder. Select a spacer with a thickness that is within the following value.
Standard value : (T + 0.045mm) to (T + 0.105mm)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System >
Automatic Transaxle > Components and Components Location (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Components and
Components Location (F4A42-2)

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle System >
Automatic Transaxle > Repair procedures (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Automatic Transaxle System > Automatic Transaxle System > Automatic Transaxle > Repair
procedures (F4A42-2)

REMOVAL
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

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(2) Lower

6. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.

7. Remove the speedometer sensor connector.


8. Remove the transaxle range switch.

9. Remove the oil cooler hose.

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10. Remove the clip(transaxle side) of the shift cable.

11. Separate the steering column shaft joint.

12. Separate the power steering oil pump hose.

Be careful not to leak after separating.


13. Separate the hose after removing the clip of the power steering return hose.

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14. Remove the upper connecting transaxle bolt.

15. Separate the start motor.

16. Install the engine support fixture.


17. After removing the tire, remove the caliper.

18. Remove the transaxle side cover.

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19. Remove the transaxle under cover.

20. Separate the tie rod end.

21. Remove the wheel speed sensor and the knuckle mounting bolt.

22. Drain the oil.

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23. Remove the transaxle mounting bracket.


(1) Insulator bolt

(2) Body mounting bolt (Upper)

(3) Body mounting bolt (Side)

(4) Transaxle side mounting bolt

24. Remove the front roll stopper.


(1) Insulator bolt

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(2) Stopper bolt (Upper)

(3) Stopper bolt (Lower)

25. Remove the rear roll stopper.


(1) Insulator bolt

(2) Stopper bolt

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26. Remove the drive shaft.


27. Remove the front muffler.

28. Remove the sub frame mounting bolt.

29. Install the jack under the transaxle assembly.

30. Remove the transaxle lower mounting bolt to the engine.

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31. Remove the transaxle assembly.

INSTALLATION
1. Attach the torque converter on the transaxle side and mount the transaxle assembly onto the engine.

If the torque converter is mounted first on the engine, the oil seal on the transaxle may be damaged.
Therefore, first be sure to assemble the torque converter to the transaxle.
2. Install the transaxle control cable and adjust as follows:
(1) Move the shift lever and the transaxle range switch to the "N" position and install the control cable.
(2) When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts to the
control cable.
(3) Remove any free-play in the control cable by adjusting the nut and then check to see that the selected
lever moves smoothly.
(4) Check to see that the control cable has been adjusted correctly.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle Control System >
Transaxle Shift Control > Components and Components Location (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control >
Components and Components Location (F4A42-2)

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Automatic Transaxle System > Automatic Transaxle Control
System > Transaxle Shift Control > Repair procedures (F4A42-2), TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Automatic Transaxle System > Automatic Transaxle Control System > Transaxle Shift Control
> Repair procedures (F4A42-2)

REMOVAL
1. Remove the push button, the spring and the cap.

2. Remove the knob mounting nut.

3. Remove the shift knob.

4. Remove the console upper cover.


5. Remove the console assembly.

6. Remove the indicator panel.

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7. Remove the indicator lower cover.

8. Remove the indicator plate.

9. Remove the key lock cable nut.

10. Remove the shift lock cable nut.

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11. Remove the control cable snap pin.

12. Remove the control cable clip and the control cable.

13. Remove the shift lever bracket bolt.

14. Remove the shift lever.

INSTALLATION
PROCEDURE TO INSTALL THE LOCK CAM

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1. Move A/T lever to "P" position to set the key lock cam and the shift lock cam as shown in the figure.
(1) Check that the key lock cam is located at "B" by the detent pin.
(2) Check that the shift lock cam is located at "A".

2. Check that the key cylinder is at "LOCK".

PROCEDURE FOR ADJUSTING SHIFT LOCK AND KEY LOCK CABLE


1. Check that each lock cam is as shown in the figure.
2. Install the shift lock and key lock cable in position. In this case, the shift lock cable must be fixed to the brake
pedal and the key lock cable must be fixed to the key cylinder.
3. Temporarily install each cable to the A/T lever assembly as shown in the figure. Securely insert the cable end
into the fixing pin of each cam.

4. Slightly pull the shift lock cable in the direction "E".


5. After checking that the portion of the cable end touches the cable fixing pin, fix with the self-tapping bolt.
6. Slightly push the key lock cam to direction "Q".
7. Slightly pull the key lock cable in the direction "G" to stretch the cable. Then fix the cable with the self-tapping
bolt.
8. Check that the key lock and the shift lock cable are secure.

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PROCEDURE FOR CHECKING THE SHIFT LOCK


1. When the brake pedal is not depressed, the push button of the shift lever at "P" position must not be operable.
(Shift lever cannot be shifted at the other positions from "P".)
2. When the brake pedal stroke is 15~22mm (with shift lever at "P" position), the push button should be operable
without catching and the shift lever should shift smoothly to other positions.
3. When the brake pedal is not depressed, the shift lever should shift smoothly to "P" position from all heading
other positions.
4. The brake pedal must operate smoothly without catching.
5. When the ignition key is at the "LOCK" position, although rake pedal is depressed, the push button should be
operable.
6. The Ignition key must not be able to be turned to the "LOCK" position except in the "P" position.
7. If the shift lever is shifted to the "P" position, the ignition key must turn to the "LOCK" position smoothly.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name)
09411-25000 Clutch disc guide

Illustration

Use
Installation of the clutch disc

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Troubleshooting

TROUBLESHOOTING
Symptom
Clutch slipping
Car will not respond to
engine speed during
acceleration
Insufficient vehicle
speed
Lack of power during
uphill driving

Probable cause
Insufficient clutch pedal free play

Adjust

Clogged hydraulic system

Correct or replace parts

Excessive wear of clutch disc facing

Replace

Hardened clutch disc facing, or oil on surface

Replace

Damaged pressure plate or flywheel

Replace

Weak or broken pressure spring

Replace

Difficult gear shifting (gear Excessive pedal free play


noise during shifting)
Hydraulic system fluid leaks, air trapping or clogging

Clutch
noisy

Remedy

Adjust
Repair or replace parts

Unusual wear or corrosion of clutch disc spline

Replace

Excessive vibration (distortion) of clutch disc

Replace

When clutch is
not used

Insufficient play of clutch pedal

Adjust

Excessive wear of clutch disc facing

Replace

A noise is heard
after clutch is
disengaged

Unusual wear and/or damage of release bearing

Replace

A noise is heard
when clutch is
disengaged

Insuffcient grease on the sliding surface of bearing


sleeve

Repair

Improperly installed clutch assembly or bearing

Repair

A noise is heard Damaged pilot bushing


when car is
suddenly rolled
with clutch
partially engaged
Difficult to depress clutch
pedal

Difficult to shift gear or


cannot shift at all

Clutch slips

Replace

Insufficient lubrication of clutch pedal

Repair

Insufficient lubrication of the clutch disc spline

Repair

Insufficient lubrication of the clutch release lever shaft

Repair

Insufficient lubrication of front bearing retainer

Repair

Excessive clutch pedal free play excessive

Adjust pedal free play

Clutch release cylinder faulty

Repair release cylinder

Clutch disc out of true, runout is excessive or lining


broken

Inspect clutch disc

Spline on input shaft or clutch disc dirty or burred

Repair as necessary

Clutch pressure plate faulty

Replace clutch cover

Clutch pedal free play insufficient

Adjust pedal free play

Clogged hydraulic system

Repair or replace parts

Clutch disc lining oily or worn out

Inspect clutch disc

Pressure plate faulty

Replace clutch cover

Release fork binding

Inspect release fork

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Clutch grabs/chatters

Clutch noisy

Clutch disc lining oily or worn out

Inspect clutch disc

Pressure plate faulty

Replace clutch cover

Clutch diaphragm spring bent

Replace clutch cover

Worn or broken torsion spring

Replace clutch disc

Engine mounts loose

Repair as necessary

Damaged clutch pedal bushing

Replace clutch pedal


bushing

Loose part inside housing

Repair as necessary

Release bearing worn or dirty

Replace release bearing

Release fork or linkage sticks

Repair as necessary

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > General Information > Specifications

SPECIFICATIONS
Clutch operating method

Hydraulic type

Clutch disc
- Type
- Facing diameter (Outside x Inside) mm (in.)

Single dry with diaphragm.


215 x 145 (8.5 x 5.7)

Clutch cover assembly


- Type

Diaphragm spring strap

Clutch release cylinder


* I.D. mm (in.)

2.0L : 19.05 (0.76)


2.7L : 20.64 (0.82)

Clutch master cylinder


* I.D. mm (in.)

15.87(0.62)

* I.D. : Inside Diameter

SERVICE STANDARD
Clutch pedal free play

6~13 mm (0.24~0.52 in.)

Clutch pedal height

166.9 mm (6.676 in.)

Clutch pedal stroke

2.0L : 145 mm (5.7 in.)


2.7L : 152 mm (6.1 in.)

Limit
Clutch disc rivet sink
Diaphragm spring end height difference
Clutch release cylinder clearance to piston
Clutch master cylinder clearance to piston

1.1 mm (0.044 in.)


0.5 mm (0.02 in.)
0.15 mm (0.006 in.)
0.15 mm (0.006 in.)

TIGHTENING TORQUE
Item

Nm

kgcm

lbft

Clutch pedal to pedal support member


(Clutch pedal bracket)

19~28

190~280

14~20

Clutch pedal support member to master cylinder

8~10

80~100

6~7

Clutch tube flare nut

13~17

130~170

9~13

Clutch tube bracket

4~6

40~60

3~4

Reservoir band

13~17

130~170

9~13

Clutch release cylinder

15~22

150~220

11~16

Clutch release cylinder union bolt

20~25

200~250

15~18

Clutch cover assembly


Single mass flywheel
Dual mass flywheel

15~22
20~27

150~220
200~270

11~16
14~19

LUBRICANTS
Items

Specified lubricants
CASMOLY L 9508

Quantity
As required

Contact surface of release bearing and fulcrum of

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clutch release fork


Inner surface of clutch release bearing

CASMOLY L 9508

As required

Inner surface of clutch release cylinder and outer Brake fluid DOT 3 or DOT 4
circumference of piston and cup

As required

Inner surface of clutch disc spline

CASMOLY L 9508

As required

Inner surface of clutch master cylinder and outer


circumference of piston assembly

Brake fluid DOT 3 or DOT 4

As required

Clutch master cylinder push rod, clevis pin and


washer

Wheel bearing grease SAE J310a,


NLGI No.2

As required

Clutch pedal shaft and bushings

SAE J310a, Chassis grease, NLGINo.1

As required

Contact portion of release fork to release cylinder CASMOLY L 9508


push rod

As required

Input shaft spline

As required

CASMOLY L 9508

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Cover And Dinode >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch
System > Clutch Cover And Dinode > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Cover And Dinode >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch
Cover And Dinode > Repair procedures

REMOVAL
1. Drain the clutch fluid and transaxle gear oil.
2. Remove the transaxle assembly.
3. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from falling.
4. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
5. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

DO NOT clean the clutch disc or release bearing with cleaning solvent.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of
the clutch release fork assembly.

When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can
cause clutchslippage and judder.

2. Apply multipurpose grease into the groove of the release bearing.


CASMOLY L9508

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3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork
assembly.
CASMOLY L9508

4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and
make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
CASMOLY L9508

Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool (09411-25000), install the clutch disc to the flywheel. When installing the clutch disc, be
sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into
the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal
torquing sequence indicated below.

TIGHTENING TORQUE

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Single mass flywheel:


15~22 Nm (150~220 kgcm, 11~16 lbft)
Dual mass flywheel:
20~27 Nm (200~270 kgcm, 14~19 lbft)

9. Remove the special tool.


10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)

INSPECTION
CLUTCH COVER ASSEMBLY
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
0.3 mm (0.012 in.)
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or
grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
1.1 mm (0.044 in.)

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3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points
for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

CLUTCH RELEASE FORK

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Master 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Master Cylinder >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch
Master Cylinder > Repair procedures

DISASSEMBLY
1. Remove the reservoir band, reservoir tank and reservoir cap.
2. Remove the piston stop ring.
3. Pull out the push rod and piston assembly.

Be careful not to damage the master cylinder body and piston assembly.

INSPECTION
1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check the clutch tube line for obstructions.
5. Measure the clutch master cylinder inside diameter with a cylinder gauge and the piston outside diameter with
a micrometer.

Measure the inside diameter of the clutch master cylinder in three places (bottom, middle, and top), in
perpendicular directions.
6. If the clutch master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston
assembly.
0.15 mm (0.006 in.)

REASSEMBLY
1. Apply the specified fluid to the inner surface of the cylinder body and to the outside of the piston assembly.
BRAKE FLUID DOT 3 or DOT 4
2. Install the piston assembly.
3. Install the piston stop ring.
4. Install the push rod assembly.

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5. Install the reservoir band, reservoir tank and reservoir cap.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal
> Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Pedal >
Repair procedures

REMOVAL
1. Remove the cotter pin, washer and clevis pin.
2. Remove the clutch pedal mounting bolt.

INSTALLATION
1. Installation is the reverse of removal.
2. Apply multi-purpose grease to the bushings.

3. Apply multi-purpose grease to the clevis pin and washer.


4. Install the push rod to the clutch pedal.
5. Adjust the clutch pedal clevis pin play.

INSPECTION
1. Check the clutch pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or distortion.
3. Check the return spring for damage or deterioration.
4. Check the clutch pedal pad for damage or wear.

IGNITION LOCK SWITCH INSPECTION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Release 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch Release Cylinder >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > Clutch
Release Cylinder > Repair procedures

REMOVAL
1. Disconnect the clutch tube.
2. Remove the clutch release cylinder mounting bolt.

INSTALLATION
1. Coat the clevis pin with the specified grease.
CASMOLY L9508

2. Install the clutch release cylinder, and the clutch tube.

INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.

DISASSEMBLY
1. Remove the clutch hose, valve plate, spring, push rod and boot.
2. Remove any dirt from the piston bore opening of the release cylinder.
3. Remove the piston from the release cylinder using compressed air.

1. Cover the release cylinder with rags to prevent the piston from popping out and causing injury.
2. Apply compressed air slowly to prevent the fluid from splashing in your eyes or on your skin.

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REASSEMBLY
1. Apply specified brake fluid to the release cylinder bore and the outer surface of the piston and piston cup, and
push the piston cup assembly into the cylinder.
Use the specified fluid:
Brake fluid DOT 3 or DOT 4

2. Install the valve plate, push rod and boot.

INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch System > The Other Clutch System
Component > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Clutch System > Clutch
System > The Other Clutch System Component > Repair procedures

SERVICE ADJUSTMENT PROCEDURE


CLUTCH PEDAL INSPECTION AND ADJUSTMENT
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis
pin play (measured at the face of the pedal pad).
(A) 166.9 mm

2. If the clutch pedal clevis pin free-play is not within the standard value range, adjust as follows:
A. Turn and adjust the bolt, then secure by tightening the lock nut.

After the adjustment, tighten the bolt until it reaches the pedal stopper, and then tighten the lock nut.
Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.

When adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to push the
push rod towardthe master cylinder.
3. After completing the adjustments, check that the clutch pedal free play (measured at the face of the pedal
pad) is within the standard value ranges.
Standard value:
(B) 6~13 mm (0.24~0.52 in.)
(C) 50 mm (1.5 in.)

4. If the clutch pedal free play, and the distance between the clutch pedal and the floor board when the clutch is
disengaged, do not meet with the standard values, it may be the result of either air in the hydraulic system or
a faulty clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.

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BLEEDING

Use the specified fluid. Avoid mixing different brands of fluid.


SAE J1703 (DOT 3 or DOT 4)

1. Loosen the bleeder screw at the clutch release cylinder.


2. Push the clutch pedal down slowly until all is expelled.
3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.

The rapidly-repeated operation of the clutch pedal in B-C range may cause the release cylinder's position
to be forcedout from the release cylinder body during air bleeding, Repress the clutch pedal after it
returns to the "A" point completely.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > General Information,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > General Information

SERVICE ADJUSTMENT PROCEDURE


CHECKING STEERING WHEEL FREE PLAY
1. Start the engine with the steering wheel in the straight ahead position.
2. Measure the play at the circumference of the steering wheel.
Standard value
Steering wheel free play : 0~30 mm (0~1.1 in.)

3. If the play exceeds the standard value, inspect the connection between the steering shaft and steering
linkage.

CHECKING STEERING ANGLE


1. Place the front wheel on a turning radius gauge and measure the steering angle.
Standard value
Wheel angle
Inner wheel : 3476 2
Outer wheel : 3019

2. If the measured value is not within the standard value, adjust the toe and inspect again.

CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE


1. Disconnect the tie rod and knuckle by using the special tool.

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2. Move the ball joint stud in a circular motion several times to check for looseness.
3. Mount the nuts on the ball joint, and then measure the ball joint starting torque.
Standard value
0.5~2.5 Nm (5~25 kgcm, 0.36~1.78 lbft)

4. If the starting torque exceeds the upper limit of the standard value, replace the tie rod end.
5. Even if the starting torque is below the lower limit of the standard value, check the play of the ball joint and
replace if necessary.

CHECKING STATIONARY STEERING EFFORT


1. Position the vehicle on a level surface and place the steering wheel in the straight ahead position.
2. Increase the engine speed to 1000 100 rpm.

After checking, reset the engine speed to the standard value (idling speed).
3. Measure the turning force with a spring scale by turning the steering wheel clockwise and counterclockwise
one and a half turns.
Standard value
Stationary steering effort : 29 N (3.0 kg, 6.5lbs)
4. Check that there is no sudden change of force while turning the steering wheel.
5. If the stationary steering effort is excessive, check and adjust the following points.
(1) Damage or cracks on the dust cover and tie rod end ball joint.
(2) Pinion preload of the steering gear box and starting torque of the tie rod end ball joint.

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(3) Starting torque of the ball joint.

CHECKING STEERING WHEEL RETURN


1. The force required to turn the steering wheel and the wheel return should be the same for both left and right in
case of moderate or sharp turns.
2. When the steering wheel is turned 90 and held fo r a couple of seconds while the vehicle is being driven at
35kph, the steering wheel shouldreturn at least 70 from the neutral position when it is released.

If the steering wheel is turned very quickly, steering may be momentarily difficult. This is not a malfunction
because the oil pump output will be somewhatdecreased.

CHECKING POWER STEERING BELT TENSION


1. Press the V belt, applying a pressure of 98N (10kg, 22lb) at the specified point and measure the deflection to
confirm that it is within the standardvalue.
Standard value
V belt deflection
New belt : 8.8~11.0mm (0.35~0.43 in.)
Used belt : 12.5~14.3mm (0.49~0.56 in.)

2. If the belt deflection is beyond the standard value, adjust the belt tension as follows.
(1) Loosen the bolt adjusting the power steering "V" belt tension.

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(2) Put a bar or equivalent, between the bracket and the oil pump and adjust the tension so that the belt
deflection is within the standard value.

(3) Tighten the bolt adjusting the power steering "V" belt tension.
(4) Check the belt deflection and adjust it again if necessary.

After turning the V belt in the normal rotation direction more than once, recheck the belt deflection.

CHECKING POWER STEERING FLUID LEVEL


1. Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise
the fluid temperature to 50~60C (122 to 140F).
3. With the engine at idle, turn the steering wheel fully clockwise and counterclockwise several times.
4. Make sure there is no foaming or cloudiness in the reservoir fluid.
5. Stop the engine to check for any difference in fluid level between a stationary and a running engine.

1. If the fluid level varies 5mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve,
and lead to decreased durability of the pump.

REPLACING POWER STEERING FLUID


1. Jack up the front wheels and support them with rigid racks.
2. Disconnect the return hose from the oil reservoir and plug the oil reservoir.

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3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Disconnect the high-tension cable at the ignition coil side.
While operating the starter motor intermittently, turn the steering wheel all the way to the left and then to the
right several times to drain the fluid.
5. Connect the return hose and fix it with a clip securely.
6. Fill the power steering fluid reservoir with the specified fluid.
PSF-3 : 0.75~0.8 lit.
7. Start the engine.
8. Check for fluid leaks from the hose, then stop the engine.
9. Pour the fluid into the bottom of the oil filter in the power steering fluid reservoir.
10. Bleed the air.

AIR BLEEDING
1. Disconnect the ignition coil high tension cable, and then, while operating the starter motor intermittently (for 15
to 20 seconds), turn the steering wheel all the way to the left and then to the right five or six times.

1. During air bleeding, replenish with the fluid so that the level does not fall below the lower position of
the filter.
2. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid.
Be sure to do the bleeding only while cranking.
2. Connect the high tension cable, and then start the engine (idling).
3. Turn the steering wheel to the left and then to the right, until there are no air bubbles in the oil reservoir.
4. Confirm that the fluid is not milky and that the level is between "MAX" and "MIN" marks on the reservoir.
5. Check that there is a little change in the fluid level when the steering wheel is turned left and right.

1. If the fluid level varies 5mm (0.2 in.) or more, bleed the system again.
2. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve,
and lead to decreased durability of the pump.

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OIL PUMP PRESSURE TEST


1. Disconnect the pressure hose from the pump. Connect the special tool between the pump and the pressure
hose as illustrated.

2. Bleed the air, and then start the engine and turn the steering wheel several times so that the fluid temperature
can rise to approximately 50~60C (122~132F) opera ting temperature.
3. Increase the engine speed to 1,000 100 rpm.
4. Close the shut-off valve of the special tool and measure the fluid pressure to confirm that it is within the
standard value range.
Standard value
Relief pressure :
8.3~8.8 MPa (85~90 kg.cm, 1209~1280 psi)

Do not keep the shut-off valve on the pressure gauge closed for more than ten seconds.
5. Remove the special tools, and tighten the pressure hose to the specified torque.

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Tightening torque
55~65 Nm (550~650 kgcm, 40.6~47.9 lbft)
6. Bleed the system.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Special Service
Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Special
Service Tools

SPECIAL TOOLS
Tool (Number and name)

Illustration

Use

09222-32100
Valve stem oil seal installer

1. Installation of the ball bearing to rack


housing
2. Installation of the oil seal to oil pump

09432-21600
Bearing installer

1. Installation of the needle bearing to


rack housing
2. Installation of the ball bearing and oil
seal to valve body

09434-14200
Counter shaft bearing installer

Installation of the oil seal to rack


bushing and valve body

09555-21000
Bar

Removal and installation the oil seal.

09561-11002
Steering wheel puller

Removal of the steering wheel.

09565-11100
Preload socket

Measurement of the mainshaft preload.

09568-31000
Tie rod end puller

Seperation of the tie rod end ball joint.

09572-21000
Oil pressure gauge

Measurement of the power steering oil


pressure.
(use with 09572-22100, 09572-21200)

09572-21200
Oil pressure gauge adapter
(Hose side)

Measurement of the power steering oil


pressure.
(use with 09572-21000, 09572-22100)

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09572-22100
Oil pressure gauge adapter
(Pump side)

Measurement of the power steering oil


pressure.
(use with 09572-21000, 09572-21200)

09573-21000
Oil seal installer guide

Installation of the oil seal


(use with 09573-21100, 09573-21200,
09517-11000, 09555-21000)

09573-21100
Oil seal installer

Installation of the oil seal


(use with 09573-21000, 09573-21200,
09555-21000)

09573-21200
Oil seal guide

Removal and installation of the oil seal

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Troubleshooting,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Troubleshooting

TROUBLESHOOTING
POWER STEERING
Symptom

Probable cause

Remedy

Loose yoke plug


Loose steering gear mounting bolts
Loose or worn tie rod end

Retighten
Retighten
Retighten or place as
necessary

Steering wheel operation


is not smooth (Insufficient
power assist)

V-belt slippage
Damaged V-belt
Low fluid level
Air in the fluid
Twisted or damaged hoses
Insufficient oil pump pressure
Sticky flow control valve
Excessive internal oil pump leakage
Excessive oil leaks from rack and pinion in gear box
Distorted or damaged gear box or valve body seale

Readjust
Replace
Replenish
Bleed air
Correct the rougting or
replace
Repair or replace the oil
pump
Replace
Replace the damaged
parts
Replace the damaged
parts
Replace

Steering wheel does not


return properly

Excessive turning resistance of tie-rod end


Yoke plug excessively tight
Inner tie rod and/or ball joint cannot turn smoothly
Loose mounting of gear box and crossmember
Worn steering shaft joint and/or body grommet
Distorted rack
Damaged pinion bearing
Twisted or damaged hoses
Damaged oil pressure control valve
Damaged oil pump input shaft bearing

Replace
Adjust
Replace
Retighten
Correct or replace
Replace
Replace
Reposition or replace
Replace
Replace

Noise

Hissing Noise in Steering Gear


There is some noise with all power steering systems.
One of the most common is a hissing sound when the
steering wheel is turned and the car is not moving.
This noise will be most evident when turning the wheel
while the brakes are being applied.
There is no relationship between this noise and
steering performance.
Do not replace the valve unless the "hissing" noise
becomes extreme.
A replaced valve will also make a slight noise, and is
not always a solution for the condition.

Rattling or chucking noise


in the rack and pinion

Interference with hoses from vehicle body


Loose gear box bracket
Loose tie rod end and/or ball joint
Worn tie rod and/or ball joint

Reposition
Retighten
Retighten
Replace

Noise in the oil pump

Low fluid level


Air in the fluid
Loose pump mounting bolts

Replenish
Bleed air
Retighten

Excessive play in steering


wheel

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Specifications,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > General Information > Specifications

SPECIFICATIONS
Item
Steering gear type
Rack stroke
Power steering pump type
Oil pump displacement

Specification
Rack and pinion
132mm
Vane type
9.6 cm/rev.MAX. (0.59 in/rev.MAX.)

SERVICE STANDARD
Item
Steering wheel free play
Steering angle
Inner wheel
Outer wheel
Stationary steering effort
Belt deflection
New belt
Used belt
Oil pump relief pressure
Total pinion preload
Tie rod swing resistance
Tie rod end ball joint starting torque

Specification
0~30 mm (0~1.1 in.)
3476 2
3019
29N (3.0kg, 6.5lbs)
8.8~11.0
12.5~14.3
8.3~8.8 MPa (85~90 kg/cm, 1209~1280 psi
0.6~1.3 Nm (6~13 kgcm, 5.2~11.3 lbin.)
2~5 Nm (20~50 kgcm, 1.4~3.6 lbft)
0.5~2.5 Nm (5~25 kgcm, 0.36~1.78 lbft)

TIGHTENING TORQUE
Item

Nm

kgcm

lbft

Power steering column and shaft


Steering column and shaft assembly mounting bolt
Power steering wheel lock nut
Pinion gear and joint assembly
Steering column shaft and universal joint assembly
Dust cover mounting bolt

13 ~ 18
35 ~ 45
15 ~ 20
18 ~ 20
17 ~ 26

130 ~ 80
350 ~ 450
150 ~ 200
180 ~ 200
170 ~ 260

9.6 ~ 13.3
25.8 ~ 33.2
11 ~ 15
13.3 ~ 15
125. ~ 19.2

Power steering gear box


Gear box mounting bolt
Tie rod end lock nut
Tie rod end ball joint and knuckle arm mounting nut
Feed tube to gear box
Gear box to valve body
Yoke plug lock nut

60 ~ 80
50 ~ 55
24 ~ 34
10 ~ 16
20 ~ 30
50 ~ 70

600 ~ 800
500 ~ 550
240 ~ 340
100 ~ 160
200 ~ 300
500 ~ 700

44 ~ 59
37 ~ 40.6
17.7 ~ 25
7.4 ~ 11.8
15 ~ 22
37 ~ 52

Power steering oil pump


Pressure hose to oil pump
Oil pump adjusting bolt
Oil pump mounting bolt
Oil pump bracket mounting bolt

55 ~ 65
35 ~ 50
35 ~ 50
35 ~ 50

550 ~ 650
350 ~ 500
350 ~ 500
350 ~ 500

40.6 ~ 47.9
25.8 ~ 37
25.8 ~ 37
25.8 ~ 37

4~6
4~6
4~6

40 ~ 60
40 ~ 60
40 ~ 60

3.0 ~ 4.4
3.0 ~ 4.4
3.0 ~ 4.4

Power steering hose


Power steering reservoir mounting bolt
Power steering hose mounting bolt
Power steering tube mounting bolt

LUBRICANTS

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Recommended lubricant

Quantity

Horn contact ring of steering wheel

CENTOPLX278
(KLUBER KOREA)

Bearing of steering shaft

ALVANIA #2 or #3
(KEUK DONG SHELL, KOREA)

Ball joint of tie rod end

SHOWA SUNLIGHT
MB-2 or equivalent

Steering gear housing

ONE-LUBER RP GREASE
(KYODOYUSHI, JAPAN)

As required

Inner ball joint of gear box

LONG TIME PD2


(OPTIMOL, GERMAN)

As required

Contact area of gear box bellows & tie rod

SILICON GREASE
(SPEC NO : MS511-41)

As required

Power steering fluid

PSF-3

1.5g
As required
1.5g

0.75 ~ 0.8 liter


(0.79 ~ 0.84 qts.)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power Steering
Gear Box > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Gear Box > Components and Components Location

COMPONENTS

DISASSEMBLY AND ASSEMBLY

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Page 1 of 14

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power
Steering Gear Box > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures

REMOVAL
1. Detach the power steering pressure hose mounting clamp and the return tube mounting clamp.
2. Drain the power steering fluid.
3. Disconnect the pressure tube and the return tube fittings from the gear box.
4. Disconnect the shaft assembly from the gear box inside the passenger compartment.

5. Remove the strap and push out the dust cover and remove the dust cover mounting plate.
6. Raise up the vehicle.
7. Remove the front tires (RH/LH).
8. After removing the split pin, disconnect the tie rod from the knuckle by using the special tool (09568-31000).

9. Remove the stabilizer bar (RH side) mounting bracket and link nut.

10. After removing the rear roll stopper bracket mounting bolt from the sub frame, remove the rear roll stopper.

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11. After loosing the sub frame mounting bolts a little so as to be the sub frame assembly hung down slightly.

12. Remove the power steering gear box mounting bolts, pressure tube and the return tube clamp.

13. Pull the power steering gear box assembly toward the right side of the vehicle.

When removing the gear box, pull it out carefully and slowly to avoid damaging.

INSTALLATION
1. Push in the power steering gear box assembly in the right side of the vehicle.

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2. Install the dust cover mounting plate.


3. Connect the dust cover to its mounting plate with a new strap.
4. Connect the steering gear box assembly to the steering column and shaft assembly.

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.

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4. Remove the bellows clip.

5. Pull the bellows out toward the tie rod.

Check for rust on the rack when the bellows are replaced.
6. Remove the feed tube from the rack housing.
7. While moving the rack slowly, drain the fluid from the rack housing.
8. Unstake the tab washer which fixes the tie rod and rack with a chisel.

9. Remove the tie rod from the rack.

Remove the tie rod from the rack, taking care not to twist the rack.

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10. Remove the yoke plug locking nut.

11. Remove the yoke plug with a 14mm socket.

12. Remove the lock nut, yoke plug, rack support spring, rack support yoke and bushing from the gear box.

13. Remove the valve body housing by loosening the two bolts.

14. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.

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15. When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove thecirclip.

Be careful not to damage the rack.

16. Remove the rack stopper, rack bushing and rack from the rack housing.
17. Remove the O-ring from the rack bushing.

18. Remove the oil seal from the rack bushing.

19. Remove the valve body from the valve body housing with a soft hammer.

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20. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
21. Remove the oil seal and O-ring from the rack housing.

Be careful not to damage the pinion valve cylinder bore of the rack housing.
22. Using the special tool, remove the oil seal from the rack housing.

Be careful not to damage the rack cylinder bore of the rack housing.

INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY

When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is
fixed, the gear box may be damaged.

TOTAL PINION PRELOAD


1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 Nm (6~13 kgcm, 0.4~1.0 lbft)

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Measure the pinion preload through the entire stroke of the rack.

2. If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.

TIE ROD SWING RESISTANCE


1. Rotate the tie rod severely ten times.
2. Measure the tie rod swing resistance with a spring scale.
Standard value
Total rod swing resistance :
2~5 Nm (20~50 kgcm, 17~43 lbin)

3. If the measured value exceeds the standard value, replace the tie rod assembly.

Even if the measured value is below the standard value, the tie rod that swings smoothly without
excessive play may be used. If the measuredvalue is below 0.44 kgcm, replace the tie rod.

BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.

REASSEMBLY
1. Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
2. Install the oil seal to the specified position in the rack housing.

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3. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF-3
4. Install the oil seal in the rack bushing.

5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
6. Apply the specified grease to the rack teeth.
Recommended grease
Multipurpose grease SAE J310a, NLGI #2 EP

Do not plug the vent hole in the rack with grease.

7. Insert the rack into the rack housing and install the rack bushing and rack stopper.

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8. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack
housing. Install the circlip while turning the rack stopper.

The circlip end should not be visible through the notched hole of the rack housing.

9. Using a special tool, install the oil seal and the ball bearing in the valve body housing.

10. After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing
assembly.

11. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly
and O-ring in the gear box.

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12. Install the tab washer and the tie rod and stake the tab washer end at two points over the tie rod.

13. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the
illustration. Apply semi-drying sealantto the threaded section of the yoke plug before installation.

14. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to
12 Nm (120 kgcm, 8.9 lbft), with a 14mm socket. Loosen the yoke plug approximately from 30 to 60an d
tighten the yoke nut to the specified torque.
Tightening torque
50~70 Nm (500~700 kgcm, 37~52 lbft)

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15. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
16. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Silicone grease

17. Install the new attaching band to the bellows.

When the bellows are installed, a new band must be used.


18. Install the bellows in position, taking care not to twist it.
19. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip
ring attached in the grooveof the tie rod end.
Recommended grease
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND

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20. Install the tie rods so that the length of the left and right tie rods equals the standard value.
Standard value
Tie rod free length : 204.5mm

21. Check for total pinion preload.

INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY

When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is
fixed, the gear box may be damaged.

TOTAL PINION PRELOAD


1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 Nm (6~13 kgcm, 0.4~1.0 lbft)

Measure the pinion preload through the entire stroke of the rack.

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2. If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.

TIE ROD SWING RESISTANCE


1. Rotate the tie rod severely ten times.
2. Measure the tie rod swing resistance with a spring scale.
Standard value
Total rod swing resistance :
2~5 Nm (20~50 kgcm, 17~43 lbin)

3. If the measured value exceeds the standard value, replace the tie rod assembly.

Even if the measured value is below the standard value, the tie rod that swings smoothly without
excessive play may be used. If the measuredvalue is below 0.44 kgcm, replace the tie rod.

BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.

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Page 1 of 1

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power Steering
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power
Steering Hoses > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Hoses > Repair procedures

REMOVAL AND INSTALLATION

PRESSURE HOSE AND TUBE


1. After draining the power steering fluid, remove the pressure hose mounting clamp.
2. Lift up the vehicle and remove the mounting clamp which is holding both the pressure tube and the return
tube.

3. Detach the pressure tube fitting in the gear box.


4. Lower the vehicle and remove the connector.

5. Remove the pressure hose and tube assembly.

6. Installation is the reverse of removal.

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1. Install the pressure hose and tube so that they are not twisted and they do not come in contact with
any other parts.
2. After installation, bleed the system.

RETURN TUBE AND HOSE


1. Detach the hose from the power steering fluid reservoir.

2. Remove the return tube and hose mounting clamps.


3. Raise the vehicle and remove the mounting clamp which is holding both the pressure tube and the return
tube.

4. Remove the pressure tube and the return tube fitting in the gear box.
5. Lower the vehicle and disconnect the clamp holding the return tube and hoses.
6. Remove the return tube and hoses.

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. After installation, air bleed the system.

INSPECTION

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1. Twisting the hose by hand, check for cracks.


2. Check that the hose does not contact with other components

HOW TO FILL WITH POWER STEERING FLUID


1. Fill the power steering reservoir with the power steering fluid to the "Max." position.
2. Lift the front wheels with a jack and turn the steering wheel fully to the left and right, 5~6 times for 15~20 sec.,
while driving the pulleyonly by operating the start motor.
3. Start the engine, let it idle and turn the steering wheel fully left and right several times until bubbles disappear
from the power steering reservoir.
4. If the oil color does not become milk-white and the oil level is constant at the "MAX" position, fluid level is O.K.

If the oil level changes when turning the steering wheel, and the oil overflows when stopping the engine, it
shows that air bleeding wasn't performed perfectly. As it can cause noise and early damage, you must
repeat the aboveprocedures.

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Page 1 of 1

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power Steering
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System > Hydraulic Power Steering System > Power
Steering Oil Pump > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Steering System >
Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures

REMOVAL
1. Remove the pressure hose from the oil pump.
Disconnect the suction hose from the suction connector and drain the fluid into a container.

2. Loosen the power steering "V" belt tension adjusting bolt.

3. Remove the "V" belt from the power steering oil pump pulley.

4. After remove the power steering oil pump mounting bolts and the tension adjusting bolt, remove the power
steering oil pump assembly.

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5. Remove the power steering oil pump mounting bracket.

INSTALLATION
1. After installing the oil pump to the oil pump bracket, install the "V" belt and tighten the bolt adjusting tension to
the specified torque.
Standard value
Oil pump adjusting bolt
3.5~5.0 Nm (350~500 kgcm, 25.8~37 lbft)

2. Install the suction hose.

Install the pressure hose to the oil pump, facing the painted part on the hose toward the oil pump.
3. Install the pressure hose to the oil pump.

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Install the pressure hose being careful so that it does not twist and come in contact with other
components.

4. Add power steering fluid (PSF-3).


5. Air bleed the system.
6. Check the oil pump pressure.

DISASSEMBLY
1. After removing the 2 bolts, remove the suction pipe and the O-ring from the oil pump body.

2. Loosen the four bolts and remove the oil pump cover assembly.
3. Remove the cam ring.
4. Remove the rotor and vanes.
5. Remove the oil pump side plate.

6. Remove the inner and outer O-ring.


7. Remove the side plate spring.

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When assembling, use a new gasket and O-ring.

8. Mount the pulley in a vise and remove the pulley nut and the spring washer.

9. Pull the pulley out.


10. After removing the snap ring of the shaft with snap ring pliers, remove the dust spacer.

11. Tap the rotor side of the shaft slighty with a plastic hammer to remove the shaft.

12. Remove the oil seal from the oil pump body.

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13. Remove the connector from the oil pump body, and take out the flow control valve and the flow control
spring.
14. Remove the O-ring from the connector.

Do not disassemble the flow control valve.

INSPECTION
1. Check the free length of the flow control spring.
Free length of the flow control spring : 36.5mm

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2. Check that the flow control valve is not bent.


3. Check the shaft for wear and damage.
4. Check the V-belt for wear and deterioration.
5. Check the grooves of the rotor and vanes for stratified abrasion.
6. Check the contact surface of the cam ring and vanes for stratified abrasion.
7. Check vanes for damage.
8. Check that there is no striped wear in the side plate or contacting part between the shaft and the pump cover
surface.

REASSEMBLY
1. Install the flow control spring, the flow control valve and the connector into the pump body.

2. Install the oil seal in the pump body by using the special tool.

3. After inserting the shaft assembly into the pump body, install the dust spacer and snap ring.

4. Install the pump pulley.

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5. Install the spring and inner O-ring.


6. Insert the outer O-ring in the oil pump side plate and then install it in the pump body.

7. After inserting the lock pin into the groove of the front housing, install the cam ring attending to the direction.

8. Install the rotor.


9. Install vanes so that the rounded edges face outward.

10. Install the gasket and oil pump cover assembly.


11. Install the suction pipe and O-ring.

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Page 8 of 8

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Page 1 of 1

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information > Flow
Diagram, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Flow Diagram

REFRIGERATION CYCLE

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
General Safety Information and Caution, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation,
Air Conditioning > General Information > General Safety Information and Caution

PRECAUTIONS
The air conditioning system uses R-134a refrigerant and FD46XG (PAG) refrigerant oil, which are not compatible
with R-12 refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt
to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result.

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment
Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
R-134a service equipment or vehicle air conditioning systems should not be pressure tested or leak tested with
compressed air.

Compressed air mixed with R-134a forms a combustible vapor.


The vapor can burn or explode causing serious injury.
Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning
systems.
Always disconnect the negative cable from the battery whenever replacing air conditioning parts.
Keep moisture and dirt out of the system, When disconnecting any lines, plug or cap the fittings immediately;
don t remove the caps or plugs until just before you reconnect each line.
Before connecting any hose or line, apply a few drops of refrigerant oil to the O-ring.
When tightening or loosening a fitting, use a second wrench to support the matching fitting.
When discharging the system, use a R-134a refrigerant recovery/recycling/charging station; don t release
refrigerant into the atmosphere.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Special Service Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
General Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name)
09977-29000
Pressure plate bolt remover

Illustration

Use
Removal and installation of pressure
plate

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > General Information > Components and Components Location

SELF-DIAGNOSIS
The Full Automatic Temperature Control (F.A.T.C) module self test feature will detect electrical malfunctions and provide error
code for system components with suspected failures.

CONTROL PANEL

SELF-DIAGNOSIS HETHOD

HOW TO READ SELF-DIAGNOSTIC CODE


1. After the display panel flickers three times every 0.5 second, the corresponding error code flickers on the setup
temperature display panel every 0.5 second and will show two figures.
2. If error code is more than two, each code flicker 2 times in sequence.

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FAULT CODE DISPLAY


1. Normal

2. One error code

3. More error codes than two

4. Checking each error code

DTC CHART
If malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.

DTC code

Detection item

Trouble area

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Page 3 of 3

00
11
12
13
14
15
16
17
18
19
20
21
22

Normal

Open INCAR Sensor circuit

Incar sensor
Harness or connector between incar sensor and A/C
control assembly
A/C control assembly

Shorted INCAR Sensor circuit


Open Ambient sensor circuit

Ambient sensor
Harness or connector between ambient sensor and A/C
control assembly
A/C control assembly

Shorted Ambient sensor circuit


Open water temp. sensor

Water temp. sensor


Harness or connector between water temp. sensor and
A/C control assembly
A/C control assembly

Shorted water temp. sensor


Open thermistor

Pin thermistor
Harness or connector between evap. sensor and A/C
control assembly
A/C control assembly

Shorted thermistor
Open or shorted temp. door potentiometer

Harness or connector between temp. door potentiometer


and A/C control assembly

Defective temp. door potentiometer

Temp. door potentiometer

Open or shorted mode door potentiometer

Harness or connector between mode door potentiometer


and A/C control assembly

Defective mode door potentiometer

Mode door potentiometer

FAIL SAFE FUNCTION


No.

Item

Failure

FAIL SAFE Function

IN-CAR temperature sensor

Open/Short

25C alternate value control

Ambient temperature sensor

Open/Short

20C alternate valu e control

Thermistor sensor

Open/Short

-2C alternate value contr ol

Water temperature sensor

Open/Short

-20C alternate valu e control

Temperature door potentiometer

Open/Short setup
temperature

For 17C to 24.5C, set to maximum cooling


position.
For 25C to 32C, set to maximum heating
position.

Mode door potentimeter

Open/Short setup
mode

Vent mode, at vent mode


Def mode, at except vent mode

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > General Information > Components and Components Location

SELF-DIAGNOSIS
The Full Automatic Temperature Control (F.A.T.C) module self test feature will detect electrical malfunctions and provide error
code for system components with suspected failures.

CONTROL PANEL

SELF-DIAGNOSIS HETHOD

HOW TO READ SELF-DIAGNOSTIC CODE


1. After the display panel flickers three times every 0.5 second, the corresponding error code flickers on the setup
temperature display panel every 0.5 second and will show two figures.
2. If error code is more than two, each code flicker 2 times in sequence.

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FAULT CODE DISPLAY


1. Normal

2. One error code

3. More error codes than two

4. Checking each error code

DTC CHART
If malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below.

DTC code

Detection item

Trouble area

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00
11
12
13
14
15
16
17
18
19
20
21
22

Normal

Open INCAR Sensor circuit

Incar sensor
Harness or connector between incar sensor and A/C
control assembly
A/C control assembly

Shorted INCAR Sensor circuit


Open Ambient sensor circuit

Ambient sensor
Harness or connector between ambient sensor and A/C
control assembly
A/C control assembly

Shorted Ambient sensor circuit


Open water temp. sensor

Water temp. sensor


Harness or connector between water temp. sensor and
A/C control assembly
A/C control assembly

Shorted water temp. sensor


Open thermistor

Pin thermistor
Harness or connector between evap. sensor and A/C
control assembly
A/C control assembly

Shorted thermistor
Open or shorted temp. door potentiometer

Harness or connector between temp. door potentiometer


and A/C control assembly

Defective temp. door potentiometer

Temp. door potentiometer

Open or shorted mode door potentiometer

Harness or connector between mode door potentiometer


and A/C control assembly

Defective mode door potentiometer

Mode door potentiometer

FAIL SAFE FUNCTION


No.

Item

Failure

FAIL SAFE Function

IN-CAR temperature sensor

Open/Short

25C alternate value control

Ambient temperature sensor

Open/Short

20C alternate valu e control

Thermistor sensor

Open/Short

-2C alternate value contr ol

Water temperature sensor

Open/Short

-20C alternate valu e control

Temperature door potentiometer

Open/Short setup
temperature

For 17C to 24.5C, set to maximum cooling


position.
For 25C to 32C, set to maximum heating
position.

Mode door potentimeter

Open/Short setup
mode

Vent mode, at vent mode


Def mode, at except vent mode

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
General Information > Troubleshooting

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts
STANDARD
Symptom

Suspect Area

No blower operation

1.
2.
3.
4.
5.
6.

No air temperature control

1. Engine coolant capacity


2. Heater control assembly

No compressor operation

1.
2.
3.
4.
5.
6.
7.
8.

HTR Fuse
Blower relay
Blower motor
Blower resistor
Blower speed control switch
Wire harness

Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Add coolant
Replace

Refrigerant capacity
A/C Fuse
Magnetic clutch
Compressor
Triple pressure switch
A/C switch
Thermistor
Wire harness

Add refrigerant
Replace
Replace
Replace
Replace
Replace
Replace
Replace

No cool comes out

1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
6. Triple pressure switch
7. Thermistor
8. A/C switch
9. Heater control assembly
10. Wire harness

Add refrigerant
Apply a vacuum and add
refrigerant
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Insufficient cooling

1. Refrigerant capacity
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
6. Expansion valve
7. Evaporator
8. Refrigerant lines
9. Triple pressure switch
10. Heater control assembly

Add refrigerant
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

1. Engine (and ECT) ECU


2. Wire harness

Replace

No engine idle-up when A/C switch


ON

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No air inlet control

Heater control assembly, cable, door

Replace

No mode control

Heater control assembly, cable, door

Replace

No condenser fan operation

1.
2.
3.
4.

ECU-IG Fuse
Fan motor
Engine (and ECT) ECU
Wire harness

Replace
Replace
Replace

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Repair procedures

ON-VEHICLE INSPECTION
This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the
these conditions are established.

TEST CONDITIONS

Temperature at the air inlet with the switch set at RECIRC is 30~35C (86~95F)
Engine running at 1,500rpm
Blower speed control knob on "4" position
Temperature control knob on "COOL" position

It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.
1. Normally functioning refrigeration system.
Gauge reading :
Low pressure side :
0.15~0.25 MPa (21.8~36.3 psi, 1.5~2.5 kgf/cm)
High pressure side :
1.37~1.57 MPa (199~228 psi, 14~16 kgf/cm)

2. Moisture present in refrigeration system.

Symptom seen in
refrigeration system
During operation, pressure
on low pressure side
sometimes become a
vacuum and sometime
normal

Probable cause

Diagnosis

Remedy

Moisture entered in
refrigeration system freezes
at expansion valve orifice
and temporarily stops cycle,
but normal state is restored
after a time when the ice
melts

Drier in oversaturected
state
Moisture in refrigeration
system freezes at
expansion valve orifice
and block circulation of
refrigerant

- Raplace drier
- Remove moisture in
cycle through repeatedly
evacuating air
- Charge proper amount of
new refrigerant

3. Insufficient cooling

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Symptom seen in
refrigeration system

Probable cause

Pressure low on both low Gas leakage at some place


and high pressure sides in refrigeration system
Insufficient cooling
performance

Diagnosis

Remedy

Insufficient refrigerant in
system
Refrigerant leaking

- Check for gas leakage


with gas leak detector
and repair if necessary
- Charge proper amount of
refrigerant
- If indicated pressure
value is near 0 when
connected to gauge,
create the vacuum after
inspecting and repairing
the location of the leak

Diagnosis

Remedy

4. Poor circulation of refrigerant

Symptom seen in
refrigeration system
Pressure low in both low
and high pressure sides
Frost on tube from
receiver to unit

Probable cause
Refrigerant flow obstructed
by dirt in drier

Condenser clogged

Replace drier

5. Refrigerant does not circulate

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Symptom seen in
refrigeration system
Vacuum indicated on low
pressure side, very low
pressure indicated on
high pressure side
Frost or dew seen on
piping before and after
receiver/drier or
expansion valve

Probable cause

Diagnosis

Refrigerant does not


Refrigerant flow
obstructed by moisture or circulate
dirt in refrigeration
system
Refrigerant flow
obstructed by gas
leakage from expansion
valve

Remedy
- Check expansion valve
- Clean out dirt in
expansion valve by
blowing with air
- Replace drier
- Evacuate air and charge
new refrigerant to proper
amount
- For gas leakage from
expansion valve, replace
expansion valve

6. Refrigerant overcharged or insufficient cooling of condenser

Symptom seen in
refrigeration system
Press too high on both low
and high pressure sides

Probable cause
Unable to develop
sufficient performance
due to excessive
Insufficient cooling of
condenser

Diagnosis

Remedy

Excessive refrigerant in
cycle refrigerant
overcharged
Condenser cooling
condenser fins clogged
or condenser fan faulty

- (1) Clean condenser


- (2) Check cooling fan
with fluid coupling
operation.
- (3) If (1) and (2) are in
normal state, check
amount of refrigerant
Charge proper amount of
refrigerant

7. Air present in refrigeration system

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Symptom seen in
refrigeration system
Press too high on both
low and high pressure
sides
The low pressure piping
hot to the touch

Probable cause
Air entered in refrigeration
system

Diagnosis
Air present in
refrigeration system
Insufficient vacuum
purging

Remedy
- Check compressor oil to
see if it is see if it is dirty
or insufficient
- Evacuate air and charge
new refrigerant

8. Expansion valve improperly

Symptom seen in
refrigeration system
Pressure too high on
both low and high
pressure sides
Frost or large amount of
dew on piping on low
pressure side

Probable cause
Trouble in expansion valve

Diagnosis

Remedy

Excessive refrigerant in
low pressure piping
Expansion valve opened
too wide

- Check expansion valve


- Replace if defective

9. Defective compression compressor

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Symptom seen in
refrigeration system
Pressure too high on low
high pressure sides
Pressure too low to on
high pressure side

Probable cause
Internal leak in compressor

Diagnosis
Compression defective
Valve leaking or broken
sliding parts

Remedy
Repair or replace
compressor

INSPECT FOR LEAKAGE OF REFRIGERANT


Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.

In order to use the leak detector properly, read the manual supplied by the manufacturer.
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a
leak detector.
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the
fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again

A/C SYSTEM TESTS

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.

Compressed air mixed with R-134a forms a combustible vapor.


The vapor can burn or explode causing serious injury.
Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
1. Connect a R-134a refrigerant recover/recycling/charging station to the high-pressure service port and the low-pressure
service port, following the equipment manufacturer s instructions.
2. Insert a thermometer in the center vent.
Determine the relative humidity and air temperature.

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3. Test conditions :
A. Avoid direct sunlight.
B. Open the hood.
C. Open the front doors.
D. Set the temperature control dial on MAX COOL, the mode control switch on VENT and the recirculation control switch
on RECIRCULATE.
E. Turn the A/C switch on and the fan switch on MAX.
F. Run the engine at 1,500 rpm.
G. No driver or passengers in vehicle.
4. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the
thermometer in the dash vent, the intake temperature near the blower unit behind the glove box and the high and low
system pressure from the A/C gauges.

REFRIGERANT RECOVERY

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
1. Connect a R-134a refrigerant recovery/recycling/charging station(A) to the high-pressure service port(B) and the lowpressure service port(C), as shown, following the equipment manufacturer s instruction.

2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to
put the same amount of new refrigerant oil back into the A/C system before charging.

SYSTEM EVACUATION

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated
using a R-134a refrigerant recover/recycling/charging station (If the system has been open for several days, the
receiver/dryer should be replaced, and the system should be evacuated for several hours.)
2. Connect a R-134a refrigerant recovery/recycling/charging station(A) to the high-pressure service port(B) and the lowpressure service port(C), as shown, following the equipment manufacturer s instruction. Evacuate the system.

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3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 15 minutes, there is probably a leak in
the system. Partially charge the system, and check for leaks.

SYSTEM CHARGING

Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
Be careful when connecting service equipment.
Do not breathe refrigerant or vapor.
1. Connect a R-134a refrigerant recover/recycling/charging station(A) to the high-pressure service port(B) and the lowpressure service port(C), as shown, following the equipment manufacture s instructions.

2. Add the same amount of new refrigerant oil to the system that was removed during recovery. Use only FD46XG (PAG)
refrigerant oil
3. Carge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the compressor will be
damaged.
Refrigerant capacity : 600 25g

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > General
Information > Specifications

SPECIFICATIONS
Item

Specification

Heating

Heater
Type
Capacity

Air mix type


4,500 10% kcal/hr

Air conditioning

Evaporator
Cooling capacity

4,100 10% kcal/hr

Compressor
Type
Oil capacity
Pressure relief valve
Voltage

Swash plate (HS-15)


140 ~ 160cc
Operating pressure : 35 ~ 42.2kg/cm
D.C 12.8 0.2V

Magnetic clutch
Voltage & wattage
Torque

D.C 12.8 0.2V, Max. 54W


Min. 4.4kgm

Refrigerant & capacity

R-134a (600 25g)

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

Thermistor
Heater control assembly

OFF 1.5 0.6C


ON 3.0 0.6C
MANUAL Type, AUTOMATIC Type

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning System >
Compressor > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and Components
Location

COMPONENT LOCATION

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Compressor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures

REPLACEMENT
1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a
few minutes, then shut the engine off.
2. Disconnect the negative cable from the battery.
3. Recover the refrigerant with a recovery/charging station.
4. Loosen the drive belt.
5. Remove the nuts, then disconnect the suction line(A) and discharge(B) line from the compressor.Plug or cap
the lines immediately after disconnecting them to avoid moisture and dust contamination.

6. Disconnect the compressor clutch connector(A), then remove the mounting bolts and the compressor(B).

7. Using a hexagon wrench(6mm) remove the bolts, the manifold assembly(A) and the gasket(B) from the
compressor.

8. Install in the reverse order of removal, and note these items.


A. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and
measure its volume, Subtract the volume of drained oil from 150ml the result is the amount of oil you
should drain from the new compressor (through the suction fitting).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.

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C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
E. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the
paint, wash it off immediately.
F. Adjust the drive belt.
G. Charge the system, and test its performance.

INSPECTION
1. Check the plated parts of the pressure plate for color changes, peeling or other damage. If there is damage,
replace the clutch set.
2. Check the pulley bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one
if it is noisy or has excessive play/drag.

3. Measure the clearance between the pulley(A) and the pressure plate(B) all the way around. If the clearance is
not within specified limits, remove the pressure plate and add or remove shims as needed to increase or
decrease clearance.
Clearance : 0.5 0.15mm (0.020 0.006 in.)

The shims are available in seven thicknesses : 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and
1.3mm.

4. Check operating of the magnetic clutch.


Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the
compressor body.
Check the magnetic clutch operating noise to determine the condition.

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DISASSEMBLY
1. Remove the center bolt(A) while holding the pressure plate with a commercially available pressure plate bolt
remover(B); Special tool number 09977-2900.

2. Remove the pressure plate(A) and shim(B), taking care not to lose the shims. If the clutch needs adjustment,
increase or decrease the number and thickness of shims as necessary, then reinstall the pressure plate, and
recheck its clearance.

3. If you replacing the field coil, remove snap ring(A) with snap ring pliers.

Be careful not to damage the pulley(B) and compressor during remove/installation.


Once snap ring(A) is removed, replace it with a new one.

4. Remove the screw from the field coil ground terminal.

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Remove the field coil(A) from the shaft with a puller(B). Be careful not to damage the coil and compressor.

5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
A. Install the field coil with the wire side facing down, and align the boss on the coil with the hole in the
compressor.
B. Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
C. Install new snap rings, and make sure they are fully seated in the groove.
D. Make sure that the pulley turns smoothly after it's reassembled.
E. Route and clamp the wires properly or they can be damaged by the pulley.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Condenser > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures

REPLACEMENT
1. Recover the refrigerant with a recovery/recycling/charging station.
2. Remove the coolant reservoir, but do not disconnect the reservoir hose from the coolant reservoir and the
radiator.
3. Remove the bolts(A), then remove the upper mount brackets(B) from the radiator.

4. Remove the bolts(A), then disconnect the discharge line and condenser line from the condenser.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

5. Remove the bolts, then remove the condenser by lifting it up. Be careful not to damage the radiator and
condenser fins when removing the condenser.
6. Install in the reverse order of removal, and note these items :
A. If you're installing a new condenser, add refrigerant oil FD46XG.
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Receiver/Drier > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Receiver/Drier > Repair procedures

INSPECTION
1. Check the fusible plug and the fittings for leakage, using a leak detector.
2. Run the engine at fast idle with the air conditioning "ON", and check both the inlet and outlet temperatures. If
the difference in temperatures between the inlet and outlet is large, replace the receiver-drier.

Plug all the open fittings immediately to keep moisture out of the system.
Do not remove plugs until ready for connection.
If the receiver-drier is replaced with a new unit, add 40cc of compressor oil to the compressor.
Evacuate, charge and test the refrigeration system.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning System >
Refrigerant line > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Components and
Components Location

COMPONENT LOCATION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Triple pressure switch > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Schematic
Diagrams

CONNECTOR

CIRCUIT DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Triple pressure switch > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Triple pressure switch > Description
and Operation

DESCRIPTION
-

Rating load : Inductive loacl DC 12V, 10~250mA


Applicable voltage range : DC 8V ~ DC 16V
Applicable temperature range : -30C ~ 120C
Applicable refrigerant : R-134a
Insulation resistance : Min. 100M at DC 500V
Pressure

ON

OFF

High

32.0 2.0

26.0 2.0

Low

2.3 + 0.25 / -0.29

2.0 0.2

Medium

18.0 0.8

14.0 1.2

LOW & HIGH

MEDIUM

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TIBURON(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
It will detect interior temperature, which will be used for discharge temperature control, sensor failsafe,
temperature door control, blower motor level control, and A/C auto control.

CHARACTERISTICS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,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
The photo sensor is located by the driver side defrost nozzle. In response to the photo intensity level in the
vehicle, the sensor will send signals to control module to control the blower level and discharge temperature.

Emit intensive light toward driver side and passenger side using a lamp and check the current change
between terminals 1 & 2.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Ambient sensor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation

DESCRIPTION
1. The air temperature sensor, located at the front of the engine radiator, detects ambient air temperature. It is a
negative type thermistor; resistance will increase with lower temperatures, and decrease with higher
temperatures.
2. The sensor output will be used for discharge temperature sensor, sensor fail-safe, temperature regulation
door control, blower motor level control, mix mode control and in-car humidity control.
A. R25C : 30K 3%
B. B(0/25) : 3754K 2%
C. Operation Temp. range : -30C ~ 80C

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > Ambient sensor > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures

INSPECTION
Measure the resistance.
RESISTANCE-TEMP. CHARACTERISIC TABLE
Temp (C)

Rmin (k )

R (k)

Rmax (k)

-20

261.090

271.120

281.150

92.617

95.089

97.656

25

29.550

30.000

30.450

50

10.676

10.950

11.224

80

3.964

3.828

3.366

CHARACTERISTICS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > A.Q.S (Air Quality Sensor) > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) >
Schematic Diagrams

CONNECTOR

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > A.Q.S (Air Quality Sensor) > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6
DOHC > Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) >
Description and Operation

DESCRIPTION
1. The A.Q.S. sensor, located at the center support in front of the engine radiator, detects hazardous elements in
ambient air and provides output signals to the control module.
2. It will detect sulfurous acid gas, carbon dioxide, carbon monoxide, hydrocarbon and allergen.
3. Sensitivity of used gas sensor
A. Sensitivity at NO2 0.3PPM : more than 2.8
B. Sensitivity at gasoline 10PPM : less than 0.45
4. Delay time
A. ON time (on) : 5sec.
B. OFF time (off) : 0sec.
SENSOR OUTPUT
Condition

Resistance

Normal condition

5V

Hazardous gas detection

0V

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Air conditioning
System > A.Q.S (Air Quality Sensor) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Air conditioning System > A.Q.S (Air Quality Sensor) > Repair
procedures

INSPECTION
CHECKING METHOD OF GAS DETECTING BENCH
1. Put the sensor part of AQS toward the air inflow (intake) direction.
2. Connect all of the power supply line and output line to AQS.
3. Close the chamber lid after putting the lines in order.
4. Connect the air outlet part of vacuum pump with the air inlet door of chamber by using air hose.

5. Turn on the power of vacuum pump.


6. Supply the power to the AQS. (DC 12V)
7. LED of AQS is kept "ON" for the first 35 2 seconds after supplying the power.
8. Wait until all of the LEDs are "OFF". Put the diesel engine exhaust gas into the chamber. Then check the
LEDs of number 1 to 10 are "ON".
9. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".
10. Wait until all of the LEDs are "OFF".
11. And then put the gasoline engine exhaust gas into the chamber, then check the LEDs of number 1 to 10 are
"ON".
12. After check LEDs are "ON". Put the clean air into the chamber. Then check LEDs are "OFF".

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Heater Unit >
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Heater Unit >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Heater > Heater Unit > Repair procedures

REMOVAL
1. Disconnect the negative (-) battery terminal.
2. Drain the cooling water of the radiator.
3. Remove the heater hose and the drain hose.

4. Drain the refrigerant.


5. Disconnect the air conditioning suction hose and the liquid tube.

6. Remove the driver's seat and the passenger's seat.

7. Remove the cowl side trim and the front pillar trim.

8. Remove the air bag module.

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9. Remove the steering wheel.

10. Remove the steering lower and upper shroud.

11. Remove the multi-function switch.

12. Remove the crash pad under cover for the driver side.

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13. Remove the cluster housing.

14. Remove the cluster.

15. After removing the center facia panel, disconnect the connectors.

16. Remove the audio.

17. Remove the floor console upper cover.


18. Remove the floor console.
19. Remove the glove box.

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20. Remove the glove box lamp connector and the lamp.

21. Remove the main crash pad mounting bolt.

22. Remove the main crash pad.

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23. Remove the heater unit mounting nut.


24. Remove the heater unit.

INSTALLATION
Installation is the reverse of the removal.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Temperature
Control Actuator > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation,
Air Conditioning > Heater > Temperature Control Actuator > Schematic Diagrams

CONNECTOR

Teminal No.

Mode

WARM

COOL

VCC(+)

F/B

SENSOR
GND(-)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Temperature
Control Actuator > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and
Operation

DESCRIPTION
-

Operating temp. : -30C ~ +80C


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Temperature Control
Actuator > Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC >
Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Components and Components
Location

COMPONENT LOCATION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Temperature
Control Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Temperature Control Actuator > Repair procedures

REPLACEMENT
1. Disconnect the 7P connector (A) from the temp. actuator (B). Remove the self-tapping screws and the temp.
actuator from the heater unit.

2. Install in the reverse order of removal. After installation, make sure temp. actuator runs smoothly.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Mode Control
Actuator > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Schematic Diagrams

CONNECTOR

Teminal No.

Mode

VENT

DEF

VCC (+)

F/B

SENSOR
GND (-)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Mode Control
Actuator > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Description and Operation

DESCRIPTION
-

Operating temp. : -30C ~ +80C


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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator
> Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Components and Components Location

COMPONENT LOCATION

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Heater > Mode Control
Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Heater > Mode Control Actuator > Repair procedures

REPLACEMENT
1. Remove the 7P connector (A) from the mode actuator (B). Remove the self-tapping screws and the mode
actuator from the heater unit.

2. Install in the reverse order of removal. After installation, make sure the mode actuator runs smoothly.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Schematic Diagrams,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Schematic Diagrams

CIRCUIT DIAGRAM

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Page 3 of 3

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Unit >
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Unit >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Unit > Repair procedures

REMOVAL
1. Disconnect the negative cable from the battery.
2. Remove the crash pad (see BD group - crash pad).
3. Disconnect the connectors(A) from the blower relay the blower motor, the blower resistor (or power transistor)
and the fresh and recirculation actuator.
Remove the self-tapping screws(B), the mounting nut(C), the mounting bolts(D) and the blower unit(E).

Make sure that there is no air leaking out of the blower and duct joints.

AIR FILTER REPLACEMENT


1. Remove the mounting screws on the downside of the glove box.

2. Open the glove box and remove the mounting screws on the upside of the glove box.

3. Remove the filter cover.

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4. Replace the air filter with a new one.

5. Installation is the reverse of the removal.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Motor
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Motor > Schematic Diagrams

CONNECTOR

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Motor
> Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Motor > Description and Operation

DESCRIPTION
Moter : Magnet 70
Item
Type

Speccifications
DC ferrite

Rated voltage

DC 12 volts

No load speed

Min. 3300rpm

No load current

Max. 3.0A

Rated load

5.0kgfcm

20C or 68F

Speed in rated load

2900 250rpm

Current in rated load

Continuous

Insulation resistance

Min. 1M

Rotation direction viewed from output (Mtr.


shaft)
Operation temp. range

CCW
-30 ~ +80

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > 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
Connect the battery voltage and check the blower motor rotation.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Relay
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Blower Relay > Schematic Diagrams

CONNECTOR

CIRCUIT DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Relay
> Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Relay > Description and Operation

DESCRIPTION
There should be continuity between No.3 and No.4 terminals when power and ground are connected to the No.1
and No.2 terminals, and there should be no continuity when power is disconnected.
- Rated voltage : DC 12V
- Operation voltage range : DC 10V ~ DC 15V
- Rated load current : DC 12V, 25A (Motor lord)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Power
Transistor > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Power Transistor > Schematic Diagrams

CONNECTOR

CIRCUIT DIAGRAM AND IMPORTANT PERFORMANCE OF PARTS COMPOSED


CIRCUIT

1) Power transistor :
Equivalent to MOTOROLA MJ11032 (Pc = 300W, Ic = 50A)
2) Fuse : 250V, 15A, 128C
Condenser : 0.22 , 50V

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Power
Transistor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation,
Air Conditioning > Blower > Power Transistor > Description and Operation

DESCRIPTION
-

Rated voltage : DC 12V


Power consumption : Max. 240W
Operating assurance range : -30C ~ +70C, 10 ~ 15 V
Performance assurance range : -30C ~ +60C, 10 ~ 15V

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Power Transistor >
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower
Resistor > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Blower Resistor > Schematic Diagrams

CONNECTOR

CIRCUIT DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower
Resistor > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > 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)

200 30

100 20

55 15

CHARACTERISTICS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Blower Resistor >
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

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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
Measure terminal-to-terminal resistance of the blower resistor.
If measured resistance is not within specification, the blower resistor must be replaced. (After removing the
resistor)

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Intake
Actuator > Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Intake Actuator > Schematic Diagrams

CONNECTOR

Teminal No.

Mode

FRE

REC

CIRCUIT DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Intake
Actuator > Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Intake Actuator > Description and Operation

DESCRIPTION
-

Operating temp. : -30C ~ +80C


Operating voltage : DC 9V ~ 16V
Rated voltage : DC 12V
Rated load : 4kgf/cm

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Intake Actuator >
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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Intake
Actuator > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air
Conditioning > Blower > Intake Actuator > Repair procedures

REPLACEMENT
1. Disconnect the 7P connector (A) from the inlet actuator (B). Remove the self-tapping screws and the inlet
actuator from the blower unit.

2. Install in the reverse order of removal. After installation, make sure the inlet actuator runs smoothly.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Control Panel >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower >
Control Panel > Schematic Diagrams

CONNECTOR CONFIGURATIONS

Connector

Pin No.

Blower switch

Main switch

Name

MIDDLE HIGH

Connector
Main switch

Pin No.

Name

11

SENSOR GROUND

COMMON

12

FRE.

GROUND

13

REC.

HIGH

14

ILL+

MIDDLE LOW

15

ILL-

LOW

16

COMMON (BLOWER)

IGN2

17

A/C OUTPUT

B+

18

HUMIDITY (Rear defogger)

GROUND

19

S/W (Rear defogger)

MODE ACT. (VENT)

20

MODE ACT. (DEF)

21

MODE F/B

22

TEMP ACT. (WARM)

23

TEMP ACT. (COOL)

TEMP F/B

10

VCC

SCHEMATIC DIAGRAM
BLOWER S/W

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WIRING DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Control Panel >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Blower > Control Panel > Description and Operation

DESCRIPTION

1. BLOWER SWITCH
The blower switch controls the blowing level of the air conditioning system by controlling blower motor speed. The
switch has an electrical circuit containing a resister that will regulate blower motor input voltage to control the motor
speed.
2. MODE SWITCH
The mode switch controls air conditioning system discharge location. The switch contains an electrical circuit to control
an actuator that is connected to the mode door for discharge control.
3. TEMPERATURE SWITCH
The temperature switch controls the temperature door position that will be used to regulate the air conditioning system's
discharge air temperature. The switch includes a rack & pinion and a cable.
4. INTAKE SWITCH
The intake switch controls the intake door used to regulate the intake air flow of the air conditioning system. The switch
contains an electrical circuit used to control the actuator that is connected to the intake door.
5. AIR CONDITIONING SWITCH
The air conditioning switch controls the on/off position of the air conditioning system compressor. The switch contains
an electrical circuit that will switch on/off the power supply to the relay that is connected to the compressor.
6. REAR DEFOGGER SWITCH
The rear defogger switch is used to defog the rear glass. Switching the switch on, ETACS will output a signal to operate
the rear glass heat wire.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Blower > Control 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Schematic
Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller >
Schematic Diagrams

CIRCUIT DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Manual Controller >
Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller
> Manual Controller > Schematic Diagrams

CONNECTOR CONFIGURATIONS

I/NO

PIN

CIRCUIT

REMARK

RHEOSTAT

TAIL LAMP

I/NO

PIN

CIRCUIT

ILL (-)

INCAR SENSOR IN

ILL (+)

A/C SELECT

BATTERY

AMB SENSOR (+)

POWER TR(B)

EVA. SENSOR (+)

POWER TR(C)

HUMDITY

SENSOR REF (+5V)

REMARK

HI OUTPUT

B
9

TEMP ACT'R (CCW)

COOL

INCAR SENSOR OUT

10

INTAKE ACT'R (CCW)

FRESH

10

TEMP F/B SIGNAL

11

HTD

11

MODE F/B SIGNAL

12

IGN 2

12

13

GND

13

14

MODE ACT'R (CW)

VENT

14

15

MODE ACT'R (CCW)

OFF

15

16

16

SENSOR GND

17

A/CON OUTPUT

HI OUTPUT

18

HI SPEED RELAY

LOW OUTPUT

19

PHOTO SENSOR (+)

20

PHOTO SENSOR (GND)

21

REAR DEFOG

LOW OUTPUT

22

TEMP ACT'R (CW)

WARM

23

INTAKE ACT'R (CW)

REC

24

AQS SIGNAL

25

IGN 2

26

GND

WIRING DIAGRAM

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Manual Controller >
Description and Operation, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning >
Controller > Manual Controller > Description and Operation

DESCRIPTION

BUTTON CONTROL AND OPERATION LOGIC


1. All buttons should be back-up.
2. Push the button, then the operation sound is made for 0.1 sec. When a S/W is selected, and operation sound is made
as well).
NO
1

BUTTON
TEMP

BUTTON
FUNCTION
TEMP
UP/DOWN

DISPLAY
Set
temperature:
Display

SYSTEM OPERATION
1. Control the discharge air temperature by adjusting the
mixture ratio of cold & hot air with the TEMP DOOR.
2. Whenever press the SWITCH, temperature is changed
0.5C up/down each time. (Each time the operation
sound is made for 0.1 sec.)
3. Set 17C (62F) as MAX COOL, 32C (90F) as MAX
HOT.
4. When the switch is turned ON from OFF, the set
temperature is displayed as the same before OFF.
5. When changing the set temperature from 17.5C to
17C or from 31.5C to 32C, the operation sound is
made.
6. At 17C, if the temperature is set below than 17 C or
at 32C , if it is above than 32C , the operation sound
is made 5times at an interval of 0.15 sec.
7. When pushing the TEMP button several times, the set
temperature is shifted to another step at an interval of
0.7sec., When engaging the button continuously (keep
pushing), only the first shift takes 0.7 sec. but the next
shifts take 0.3 sec.
OFF SW AND SYSTEM OPERATION
- OFF: SYSTEM OFF
- TEMP: SET TEMPERATURE UP/DOWN

AUTO

AUTO
CONTROL

"AUTO": Display

1. Automatically control the following items


corresponding to theset temperature.

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TEMP DOOR
MODE DOOR
INTAKE DOOR
BLOWER FAN SPEED
A/C
2. When the AUTO mode is off, the word AUTO should
not appear.
3. After off the AUTO mode, the system is automatically
controlled except for the manually selected SW.
OFF SW AND SYSTEM OPERATION
- OFF: SYSTEM OFF
- FAN UP/DOWN: BLOWER FAN SPEED MANUAL
CONTROL
- MODE: DISCHARGE MODE MANUAL CONTROL
- A/C: A/C ON/OFF MANUAL CONTROL
- FRE.: FRE. MODE MANUAL CONTROL
- REC.: REC. MODE MANUAL CONTROL
- DEF.: DEF. MODE MANUAL CONTROL, A/C ON,
FRE.
3

AMB

Ambient
temperature
display

"AMB":
Display
Ambient
temperature:
Display
The other
signals: OFF

1. System is operated as the same before the AMB SW


turned on.
2. When the AMB SW is pushed, the other signals are
not appearedbut the word AMB and the ambient
temperature are displayed for 5 sec., andthen the
display become the same as the AMB SW is not
pushed.
OFF SW AND SYSTEM OPERATION
- AMB: If the AMB SW is pushed once more when the
ambient temperatureis displayed, the ambient
temperature does not appear and the display
becomethe same as the AMB SW is not pushed.
- OTHER SWITCHES: If the other switch is pushed
except for REARDEF and in-car & ambient /AQS,
ambient temperature does not appear and the pushed
switch is displayed.

A/C

A/C ON/OFF
CONTROL

"A":
1. A/C ON/OFF
Display/OFF
OFF SW AND SYSTEM OPERATION
"AUTO":
- A/C: A/C ON/OFF MANUAL CONTROL
OFF
- OFF: SYSTEM OFF
- AUTO: AUTO MODE AUTOMATIC CONTROL

MODE

MODE DOOR
CONTROL
VENT
B/L
FOOL
MIX

"MODE":
Display/OFF
"AUTO": Off

DEF MODE

"DEF": ON
"A/C":
Display
REC. IND:
OFF

DEF

1. Fix the MODE DOOR to one among VENT, B/L,


FLOOR and MIX.
2. MODE SW MANUAL CONTROL ORDER : VENT
B/L FLOOR MIX VENT ...
3. At MIX MODE: MIX LOGIC (MIX, FRE., A/C ON)
OFF SW AND SYSTEM OPERATION
- DEF: DEF MODE MANUAL CONTROL
- MODE: VENT, B/L, FLOOR & MIX (repeat the order)
- AUTO: AUTO MODE AUTOMATIC CONTROL
1. MODE DOOR: Fix to "DEF"
2. INTAKE DOOR: Fix to "FRE." (REC. can be selected)
3. A/C: ON
A/C OUTPUT ON/OFF control: Corresponding to
the detected temperatureby EVAP SENSOR.

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"AUTO":
OFF

A/C output should be cut off at 3.5C or below


(ambient temperature).
(DISPLAY OFF, A/C SELECT SIGNAL OFF)
4. DEF is prior to "MAX HOT/COOL" function.
5. DEF is prior to "MIX MODE" control.
OFF SW AND SYSTEM OPERATION
- AUTO: ALL SYSTEM AUTOMATIC CONTROL
- MODE: DISCHARGE MODE MANUAL CONTROL
(DEF Function off)
- A/C: A/C ON/OFF MANUAL CONTROL
- DEF: Return to the mode before the DEF S/W
selection

OFF

SYSTEM OFF

LCD: ON

1.
2.
3.
4.
5.
6.

BLOWER FAN SPEED OFF


A/C OFF
TEMP. DOOR: Fix to the mode before OFF
MODE DOOR: Fix to the mode before OFF
INTAKE CONTROL: Fix to the mode before OFF
After "OFF", at REC, REC. S/W ON (NON-AQS type)
- Shift to FRE. MODE
- REC. INDICATOR ON
- LCD OFF
- OTHERS: OFF
7. After "OFF", at FRE, FRE. S/W ON (NON-AQS type)
- Shift to FRE. MODE
- REC. INDICATOR ON
- LCD OFF
- OTHERS: OFF
8. After "OFF", at AQS, AQS/REC. S/W ON (AQS type)
- Shift to REC. MODE
- AQS OFF
- REC. INDICATOR ON
- LCD OFF
- OTHERS: OFF
9. After "OFF", AQS ONAQS LOGIC
10. After "OFF", AMB S/W ON
- OFF: The word "AMB" & ambient temperature
displays for 5 sec. and then off.
OFF SW AND SYSTEM OPERATION
AUTO: AUTO MODE AUTOMATIC CONTROL
BLOWER
- SPEED: Return to MANUAL LOW
- OTHERS: Return to the mode before OFF
A/C
- A/C ON
- OTHERS: Return to the mode before OFF
MODE
- MODE: The mode before OFF
- OTHERS: Return to the mode before OFF
DEF
- MODE: DEF
- A/C ON
- INTAKE: FRE.
- OTHERS: Return to the mode before OFF
TEMP

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- TEMP: The mode before OFF


- OTHERS: Return to the mode before OFF
8

REC. (NONAQS type)

REC. MODE

IND ON
"AUTO"
display

FRE. MODE

IND OFF
"AUTO"
display

FAN UP/DOWN BLOWER FAN


SPEED
UP/DOWN

FAN IND
ON/OFF

1. When operating the REC. S/W from FRE. MODE, fix


the INTAKE DOORto REC. MODE or when operating
the REC. S/W from REC., fix the INTAKE DOORto
FRE. MODE.
OFF SW AND SYSTEM OPERATION
- REC.: FRE./REC. MODE CONTROL
- OFF SW: ALL MODES (POSSIBLE TO MANUALLY
SELECT)
- AUTO: AUTOMATIC CONTROL (FRE. or REC.)
1. BLOWER MOTOR's rotation speed is controlled by the
current variationof the POWER TRANSISTOR.
2. At AUTO MODE, if FAN is operated UP/DOWN, the
FAN SPEED is UP/DOWNon the basis of the present
FAN LEVEL.
3. At OFF, if the other SW except for "FAN" is turned ON,
the FAN SPEED is gradually increased from LOW to
TARGET SPEED
4. Fan speed level and voltage
AUTO AIR CONDITIONER: No level (4.5V - B+)
AUTO HEATER: No level (4.5V - B+)
MANUAL FAN SPEED: 7th level (3.8V - B+)
5. The first shift to another step takes 0.7 sec. If the
button iscontinually engaged, the first shift takes 0.7
sec. And then the next ones take 0.3 sec per each.
The operation sound is made for 0.1 sec.
6. At MANUAL 7th level when the UP SW is pushed or at
MANUAL 1st level when the DOWN SW is pushed, the
operation sound is made 5 times at an interval of 0.15
sec.
7. When shifting 6 to 7 level, or 2 to 1 level, the operation
soundis intervally made each 0.15 sec.
OFF SW AND SYSTEM OPERATION
- AUTO: AUTO MODE AUTOMATIC CONTROL
- OFF: SYSTEM OFF
- FAN UP/DOWN: BLOWER FAN SPEED MANUAL
CONTROL

10

DEFOG

Rear glass
defogger

DEFOG IND
ON/OFF

1. If the DEFOG SW is pushed, the rear glass defogger


operation signal is output to the ETACS and the
ETACS turns the DEFOG IND on by the HTD input.
2. While operating the rear glass defogger, if DEFOG SW
is pushed, ETACS stops operating the rear glass
defogger and turns the DEFOG IND off.
3. After operating the rear glass defogger for 15 minutes
by EATCS, DEFOG function is automatically off.
OFF SW AND SYSTEM OPERATION
- DEFOG: Push the second DEFOG SW, DEFOG
function is off.

SYSTEM CONTROL FEATURES


SIGNAL I/O FOR EACH CONTROL FEATURE
Control item
Required discharge

Input
Auto SW, A/C SW, TEMP SW, INCAR

Output

Remarks

TEMP actuator

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temperature control

sensor,AMB sensor, Photo sensor, Water


temperature sensor, thermo sensor, TEMP
actuator.

Mode control

AUTO SW, MODE SW, TEMP SW, DEF


Blower motor
SW,Blower SW, OFF SW, INCAR sensor, AMB Power TR
sensor, Photo sensor, Water
HI-blower relay
temperaturesensor, thermo sensor, Power TR.

Mode door control

AUTO SW, MODE SW, DEF SW, Blower


SW,OFF SW, TEMP SW, INCAR sensor, AMB
sensor, Photo sensor.

Mode actuator

Intake control

AUTO SW, A/C SW, DEF SW, TEMP SW,OFF


SW, Intake SW, INCAR sensor, AMB sensor,
Photo sensor, Power TR.

Mode actuator

Compressor control

AUTO SW, A/C SW, DEF SW, TEMP SW,OFF


SW, IN-CAR sensor, AMB sensor, Photo
sensor.

Compressor relay

Blower Switch
Manual selection
Control in priority

During mode control, the A/C may operate during DEF or MIX mode.In order to enable dehumidification, the driver may
select A/C OFF duringthe A/C on condition.
CONTROL SPECIFICATION
Control item

Control features

Required
discharge
temperature

Required temperature determined by the set temperature and the


inputted sensor value.

Auto control

Required discharge temperature is determined by the set temperature


and the inputted sensor value. The feature will use the required
discharge temperature to perform the auto control of temp. actuator,
mode actuator, intake actuator, blower motor and compressor, and
maintain the set temperature stably.

IN-CAR
temperature
correction

Upon detecting rapid changes of temperature from the INCAR sensor, it


will gradually correct the incar temperature value.

AMB
temperature
correction

Upon detecting rapid changes of temperature from the AMB sensor, it


will gradually correct the ambient temperature value.

Photo correction Upon detecting rapid changes of photo intensity from the PHOTO
sensor, it will gradually correct the photo intensity value.

TEMP door
control

It does the automatic control to maintain the optimum TEMP door


opening (0%-100%).It will be computed by the temperature set and the
input signal from each sensor.

Blower speed

Automatic control of the blower speed. The target value will be


computed by the set temperature and the input signal from each sensor.
(7 levels may be selected in case of manual selection.)

Electro-motive
mode control

During auto control, it will raise the permitted voltage of blower motor
gradually in order to improve comfortability.

Photo
compensation

During auto control, it will compensate the blower level and the
discharge temperature according to the photo intensity detected from
the PHOTO sensor at VENT or B/L mode. PHOTO compensation will
begin after 5 seconds when ignition on.

Mode door

Automatic control of air discharge based on the required discharge

Remarks

- 1C UP/4sec delay
- 1C DOWN/4sec delay
- 1C UP/3min delay
- 1C DOWN/4sec delay
- 350 1000(W/m)/1min
delay
- 350 1000(W/m)/5min
delay
The set temperature range
17C 32C, 0.5C step
(62F 90F, 1F step)
- Auto mode blower low
voltage (Manual low
voltage: 3.8)
- Auto mode heater blower
HI speed: 10.6V
6 seconds for shifting LO
MAX

- At OFF in AUTO mode,

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control

temperature. It will be computed by the temperature setting and the


input signal from each sensor.
VENT B/L FLOOR VENT)
In case of manual selection (VENT B/L FLOOR MIX VENT)

MODE door will maintain


the AUTO
controlcondition.
- At OFF in manual mode,
MODE door will maintain
the manual
controlcondition.

MIX mode
control (in auto
control)

If the ambient temperature is -13C or less in AUTO mode, discharge


mode will be controlled at MIX. (When front window glass is defogged.)

Entering MIX mode, A/C will


operate.

INTAKE door
control

Auto control of intake mode based on the required discharge


temperature that will be computed by the temperature setting and the
input signal from each sensor.

- Shift to REC when


selecting REC button at
FRE condition (LED on).
- Shift to FRE when
selecting FRE button at
REC condition (LED off).

INTAKE control
at OFF

The intake door will shift to the REC position when switching the system
off in auto-condition, and maintain the previous condition at OFF at
manual condition.

- FRE./REC. manual
selection will be enabled
at OFF.
- REC indicator will come
on at OFF at AUTO
mode.

Compressor
auto control

Control automatically the compressor on/off state corresponding to the


set temperatureand the input signal from each sensor.

- When selection the


AUTO SW, the
compressor is controlled
to ON/OFF.
- When selection the DEF
SW, the compressor is
controlled to "ON".

If EVAP sensor temperature is below than 0.5C, the compressor will be


Compressor
ON and the temperature is 3C, or higher, with the compressor OFF.
clutch on/off
control based on
refrigerant
temperature
MAX HOT

When selecting the set temperature 32C at AUTO mod e, MAX HOT will
be performed. It will prevail over MIX mode control.

- TEMP door: MAX HOT


- MODE door: FLOOR
mode
- INTAKE door: FRE mode
- Compressor: OFF
- Blower speed: AUTO HI
(10.6V)

MAX COOL

When selecting the set temperature 17C at AUTO mode, MAX COOL
will be performed.

- TEMP door: MAX COOL


- MODE door: FLOOR
mode
- INTAKE door: REC mode
- Compressor: ON
- Blower speed: MAX HI

Electromotive
heating control

If the set temperature >the in-car temperature by 3C at B/L or FLOOR


in AUTO mode, and the water temperature sensor input is 58C or less,
it willeffect the electromotive heating control to prevent outside cold air
from flowing toward the feet of passengers.

- Blower speed: Controlled


at AUTO LOW (0.5V)

As the coolant temperature rises, the MODE door will shift to DEF
MIX AUTO.

Operation release
10 minutes after ignition
on(In case of
temperature sensor fail,it

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MODE: Manual selection is enabled.


INTAKE door: At AUTO control or at manual selection mode.

Blower speed: Manual selection is enabled (No re-entry).

will apply the substitute


value, 20C).
After pressing blower
switch when water
temperature sensor
detectionis 58C or
higher
In pressing MODE
switch.
In Upon pressing DEF
switch.

Electromotive
cooling control

In order to prevent hot air from the VENT or B/L in AUTO mode (A/C on
mode), the blower speed will be operated at LOW for approx. 9 seconds
before enteringthe AUTO control if the EVAP sensor detection is
temperature 30C or higher.

MAX HOT

If the above condition is satisfied, electromotive cooling control will


operate at any time.

Air Quality
System (AQS)

The AQS system will detect the hazardous elements and odors
contained in the air.If the harmful element concentration is higher than
standard, the system willoutput a LOW signal (0V) to the FATC.

- When the initial battery


connection and ignition is
ON, it will operate at
AUTO mode. (AQS will
not operate).

If the concentration is within the standard value, the system will output a
HI signal(3V) the FATC.

- When IGN 2 ON, the


AQS assembly will be
preheated for 34.5
5seconds.During the
preheating, AQS will
output 0V (ground). (REC
mode)

Corresponding to the signal from the AQS, it will control the INTAKE
door as follows toprevent the inflow of harmful gas in FATC :

- IGN 2 ON: It will check


circuit break on the AQS
assembly's signal line for
approx. 7 seconds during
the preheating,
irrespective to the AQS
switch condition.

Condition : INTAKE door position

- When AQS is selected


prior to IGN2 OFF and
IGN2 is turned OFF
ON: AQS indicator will
come on, and the system
will operate at AQS
mode. (Storethe previous
condition before IGN 2
OFF)

LOW : REC

HI : FRE

Initialization
Upon battery-on

When supplying the initial power, it will operate in the initial condition.

- When the initial ignition


ON after battery
connection, the
systemwill operate at the
set temperature 25C
and at AUTO mode.

Memory

When removing the ignition key, it will store FATC's operating condition.

- When IGN ON after IGN


OFF during FATC
operation, the system
willoperate at the
previous before the
ignition off.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Manual 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller > Manual Controller >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Heating,Ventilation, Air Conditioning > Controller >
Manual Controller > Troubleshooting

CONTROL PANEL TESTS

1.
2.
3.
4.
5.
6.
7.

Power supply check


Back light and Rear glass heat rays check
Blower check
Air conditioner check
Intake check and AQS check
Mode check
Temp check

POWER SUPPLY CHECK


In turning off IGN, battery supplies power for ordinary power, FATC connector A-3 through battery fuse. FATC performs
memory function by means of battery power supplied as described above. In turning on IGN, alternator is driven. At this
time, IG2 power generated in alternator FATC connector A-12 and A-25 terminal through IG1 fuse and air conditioner fuse
(10A). FAT carried out actual system operation by means of IG2 power supplied as described above.
ERROR DIAGNOSTICS
Symptoms

Causes

How to check

When IG is ON, memory function


error occurs

Battery power supply error

Check voltage of battery after turning off IG. If


10V and more, check FATC connector and if no
problem, check the inside of controller. If 10V
and less, check fuse or wiring state of battery
power source.

When IG is ON, system running


error occurs

IG2 power supply error

Check voltage of IG2 after turning on IG. If 10V


and more, check FATC connector and if no
problem, check the inside of controller. If 10V
and less, check fuse or wiring state of IG2
power source.

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BACK LIGHT AND REAR GLASS HEAT RAYS CHECK


In turning on IG and then light switch, battery power is supplied for FATC connector A-2 terminal through wiring. The
supplied power passes connector A-1 terminal through light bulb in FATC and flows into reostart as shown in the above
figure. The brightness is adjusted according to resistance value of reostart.
ERROR DIAGNOSTICS
Symptoms

Causes

When light switch is ON, partial error


occurs in back light

Light bulb lighting error in FATC

When light switch is ON, entire error


occurs in back light

Light power supply error

How to check

Measure voltage of tail light shown in


the above figure after switching on light.
If 10V and more, check FATC connector
and if no problem, measure signal
voltage of reostart shown in the above
figure. If 8V and more, check reostart
wiring and reostart.
If tail light is below 1V, check tail light
wiring.

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BLOWER CHECK
Perform the blower check in manual blower running state because it is difficult to check blower at automatic control. Blower
is controlled from level l to level 7 equally as in button operation and running logic. In turning on IG, blower relay is ON and
voltage of 0.1 to 1.4V is transferred from FATC connector A-4 terminal to base source of power TR according to FATC
control (selectable from level 1 to level 7). At this time, voltage of blower motor's both ends is determined according to
collector voltage of FATC connector A-5 terminal. If FATC is controlled in level 7, GND(0V) is supplied for FATC
connectorA-18 terminal and high blower relay is driven.
ERROR DIAGNOSTICS
Symptoms

Causes

How to check

Amount of wind is wrong at manual Power TR error


selection of blower

Check voltage of blower motor's both ends.


(Level 1: 3.8V, Level 2: 5.2V, Level 3: 6.5V,
Level 4: 7.9V, Level 5: 9.2V, Level 6: 10.6V,
Level 7: 13.5V [high-relay operation])
Measure voltage of each terminal and if there is
difference more than 0.6V, check power TR.

Blower wind is discharged despite


pressing OFF switch

Power TR change

Power TR error

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AIR CONDITIONER CHECK


11V is outputted from connector A-17 terminal in turning on INSULATING and pressing air conditioner switch. However,
although 11V is outputted from FATC connector A-17 terminal, compressor clutch isn't driven. Wind of air conditioner is
discharged if only compressor clutch works. Output signal from air conditioner is inputted in engine computer through triple
switch. Then, the engine computer considers several conditions and when output of air conditioneris judged to be practical,
it gives GND to signal terminal of air conditioner relay. Accordingly, relay of air conditioner is ON and compressor clutch
works. Triple switch checks pressure of refrigerant flowing through pipe and turnson/off switches in it according to
standard. So, it controls that output signalof air conditioner outputted from FATC is inputted into engine computer, and also
speed of condenser fan according to pressure level. (For high pressure, high-speed and for low pressure, low-speed.
ERROR DIAGNOSTICS
Symptoms
Wind of air conditioner isn't
discharged into vehicle despite
switching on air conditioner.

Causes
Signal output error of air
conditioner

How to check
Switch on air conditioner and measure voltage
of FATC connector A-17 terminal as shown in
the above figure. If 9V and more, check triple
switch,air conditioner relay and ECM.
Switch on air conditioner and measure voltage
of FATC connector A-17 terminal as shown in
the above figure. If 1V and less, check input
value ofevaporator sensor.

Input error of evaporator sensor

If evaporator sensor is disconnected or short or


voltage of its inputsource is more than 3.0V
(below 0.5C), output of air conditioner isn't
made.

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INTAKE AND AQS CHECK


In turning on IG and selecting outdoor mode with indoor switch, 12V is outputted from FATC connector A-23 terminal, 0V is
supplied for A-10 terminaland motor works in direction of outdoor. In selecting indoor mode with indoorswitch, 12V is
outputted from FATC connector A-10 terminal, 0V is supplied for A-23 terminal and motor works in direction of indoor.
ERROR DIAGNOSTICS
Symptoms

Causes

How to check

Outdoor mode running error

Power supply error in actuator

Separate connector linked with actuator,


select outdoor mode with indoor switch
and measure voltage of FATC
connector A-23 terminal. If 8V and
more, check actuator or wiring state and
if 9V and less, check the inside of
controller.

Indoor mode running error

Power supply error in actuator

Select indoor mode in the above method


and measure voltage of FATC
connector A-10 terminal. If 8V and
more, check actuator or wiring state and
if 9V andless, check the inside of
controller

Fixed in outdoor or indoor mode at


AQS selection

AQS signal terminal output error

Select AQS switch and measure AQS


signal terminal as shown in the above
figure. If there is no change of voltage
over 10 min, check AQS.

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MODE CHECK
In turning on IG and selecting mode switch, sequential operation begins in order of Vent Bi-level Blower Mix. DIP
mode works regardless of order at selecting it. In selecting Vent mode as mode switch, GND(0V) is supplied for FATC
connector A-14(Vent) terminal. Voltage of 9V and more is set in the rest terminal A-15(DEF) and motor drive IG in mode
actuator which receives the signal, works in direction of vent mode setup. Vent, Built-in-level, Blower, Mix and Defrost
mode can be selected in themethod described above.
ERROR DIAGNOSTICS
Symptoms
Specific mode isn't selected.

Mode selection is impossible

Causes

How to check

Signal transmission error of selected


mode

Measure voltage of selected mode wiring


without separating connector linked with
actuator. If 8V and more, check the inside of
controller.

Mode actuator running error

If 1V and less at measuring in the above


method, check mode actuator and wiring
state.

Internal error of mode actuator

If motor driver IG built in mode actuator is


bad, mode selection is impossible. When
mode isn't selected though GND(0V) is
supplied for selected mode wiring after
selecting mode in controller, its cause is
internal failureof mode actuator.

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TEMP CHECK
In adjusting temp switch from 32C to 17C, 11V is outputted from FATC connector A-9 terminal, 0V is supplied for A-22
terminal and temp motor works in direction of COOL. In adjusting temp switch from 17C to 32C, 11V is outputted from
FATC connector A-22 terminal, 0V is supplied for A-9 terminal and temp motor works in direction of WARM. When temp
actuator has to move to a certain location for its automatic control, temp feedback signal terminal moves equally in temp
actuator and informs controller of location of temp actuator through FATC connector B-10 terminal. Comparing original
value with inputted value, it works until they are same. If 4.9V and more is inputted in B-10 terminal, it is regarded as
disconnection. If 0.1V and less is inputted in B-10 terminal, it is regarded as short-circuit. In the case of disconnection or
short-circuit as a result of self-diagnostic, substitute control is carried out as follows.
If setup temperature is 17C to 24.5C, set to MAX COOL.
If setup temperature is 25C to 32.0C, set to MAX WARM.
ERROR DIAGNOSTICS
Symptoms
Temp actuator running error

Causes

How to check

Power supply error in temp actuator

After altering 17C to 32C and advers ely,


measure voltage ofA-22 terminal. If Both of
them are 9V and more, check temp actuator
and peripheral wiring state and if one or
both of them are 5V and less, its cause is
internal failure of FATC.

Sensor (+5) power supply error

If automatic control isn't operated smoothly,


measure voltage of FATC connector B- 8
terminal. If under 4.8V or over 5.2V, its
cause is internal failure of FATC.

Driver error of temp actuator

If No. 20 is outputted as a result of selfdiagnostic, check temp actuatordriver.

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Page 1 of 2

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > General Information,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > General Information

GENERAL
The SRS (Airbag) consists of : a driver airbag module located in the center of the steering wheel, which contains
a folded cushion and an inflator unit ; a passenger airbag module located in the passenger side crash pad which
contains a folded cushion together with an inflator unit ; side airbag modules located in the driver and passenger
seat which contain folded cushions and inflator units; SRSCM located on the floor center console core which
monitors the system,; an accelerometer which senses vehicle deceleration,; a spring interconnection (clock
spring) located within the steering column; system wiring and wiring connectors; and a knee bolster located
under the steering column. The impact sensing function of the SRSCM is carried out by the electronic
accelerometer that continuously measures the vehicle's acceleration and delivers a corresponding signal through
an amplifying and filtering circuit to the microprocessor. Deployment of the airbag is designed to occur in frontal
or near-frontal side impacts of moderate to severe force.

CUSTOMER CAUTIONS
Further, if a mistake is made in servicing the airbag system, it is possible that the airbag may fail to operate when
required.
1. Be sure to proceed with airbag related service only after approx. 30 seconds or longer from the time the
ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the
battery. The airbag system is equipped with a back-up power source to assure the deployment of airbags
when the battery cable is disconneted during an accident. The back-uppower is available for approx. 150ms.
2. When the negative(-) terminal cable is disconnected from the battery, the clock and audio system's memory
will be wiped out. So before starting work, make a record of the contents of the audio system's memory. When
the work is finished, reset the audio system and adjust the clock.
3. Symptoms of malfunction of the airbag system are difficult to detect, so the diagnostic codes become the most
important source of information when troubleshooting.
4. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the
battery.
5. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
6. Never attempt to disassemble and repair the airbag modules (DAB, PAB, SAB, BPT), clock spring and wiring
in order to reuse them.
7. If any component of SRS has been dropped, or if there are cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
8. After work on the airbag system is completed, perform the SRS SRI check. The airbag indicator lamp can be
triggered by faults in other circuit in some cases. Therefore if the airbag indicator lamp goes on, be sure to
erase the DTC codes using Hi-scan just after repairing or replacing the troubled parts,including the fuse.
9. Especially when carring out body welding, never fail to disconnect the battery's negative (-) terminal.

SRSCM
The SRS airbag system has sophisticated electrical and electronic components. Therefore the airbag operating
components should be handled very carefully.
The SRSCM will deploy the airbag modules by sensing the frontal impact sensed by the sensor built in to the
SRSCM.
1. DC/DC convertor : The DC/DC converter in the power supply includes a step-up and a step-down converter,
which provides the firing voltage for four firing circuits and the internal operating voltage. If the internal
operatingvoltage falls below a defined threshold, a reset is executed.
2. Arming sensor/safing sensor : The arming/safing sensor built in to the airbag firing circuit has the function of
arming the airbag circuit under all required deployment conditions and maintaining the airbag firing circuits
unarmed under normal driving conditions. The safing sensor is a dual-contact electromechanical switch that
closes if it experiences a deceleration exceedinga specified threshold.
3. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period
when the vehicle voltage is low or if lost in avehicle frontal crash.

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4. Malfunction detection : The SRSCM continuously monitors SRS operating status while the ignition key is
turned on and detects possible malfunctions in the system. The malfunction can be displayed in the form of a
diagnostictrouble code using the Hi-Scan Pro.
5. MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends a signal to the
indicator lamp on the instrument cluster towarn the vehicle driver.
The MIL indicator is the key item in notifying the driver of SRS faults. It verifies lamp and SRSCM operation by
flashing 6 times when the ignitionswitch is first turned on.
6. Malfunction recording : Once a fault occurs in the system, the SRSCM records the fault in memory in the form
of a DTC, which can only be erasedby the Hi-Scan Pro.
7. Data link connector : SRSCM memory stored is linked through this connector located underneath the driver
side crash pad to an external output devicesuch as the Hi-Scan Pro.
8. What if only BPT's deploy
9. Crash output
The crash output is used to unlock the doors in case of a crash. The crash output is : 0-200 A in OFF mode
and 200mA in ON mode. During theunlock command, the switch is closed for 200 mS.

SRSCM (SUPPLEMENTAL RESTRAINTS SYSTEM CONTROL MODULE)


1. When removing the airbag module or handling a new airbag module, it should be placed with the pad top
surface facing up. In this case, the twin-lock type connector lock lever should be in the locked state and care
should be taken to place it so the connecter will not be damaged. Do not store a steering wheel pad on top of
another one. (Storing the pad with its metallic surface up may lead to a serious accident if the airbag should
inflate accidentally.)
2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
3. Store the airbag module where the ambient temperature remains below 93C (200F), without high humid ity
and away from electrical noise.
4. During electric welding, disconnect the airbag under the steering column near the MULTI-FUNCTION
SWITCH connector before starting work.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > Special Service Tools,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > General Information > Special Service Tools

SPECIAL SERVICE TOOL


Tool (Number and name)

Illustration

Use

0957A-34100A
Deployment tool

Airbag deployment tool


PAB, SAB : 0957A-38100
DAB, BPT : 0957A-38500

0957A-38200
Dummy

Simulator to check the


resistance of each wiring
harness
Dummy adapter
PAS, SAB : 0957A-38300
DAB, BPT : 0957A-1C000

0957A-38100
Deployment adapter

Use with deployment tool.

0957A-38500
Deployment adapter

Use with deployment tool.

0957A-38300
Dummy adapter

Use with dummy.

0957A-1C000
Dummy adapter

Use with dummy.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control Module (SRnodeM)
> Schematic Diagrams, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System
Control Module (SRnodeM) > Schematic Diagrams

SRSCM CONNECTOR DAB+PAB+SAB+BPT

PIN NO.

Function

Input/output

Driver belt pretensioner, High

Output

Driver belt pretensioner, Low

Output

Passenger belt pretensioner, High

Output

passenger belt pretensioner, Low

Output

Battery supply

Input

GND

Input

Warning lamp

Driver seat belt buckle switch, High

K-diagnostic line

10

Driver airbag, High

Output

11

Driver airbag, Low

Output

12

Passenger seat belt buckle switch, High

13

Passenger airbag, High

Output

14

Passenger airbag, Low

Output

15

Not used

16

Driver side airbag, High

Output

17

Driver side airbag, Low

Output

18

Passenger side airbag, Low

Output

19

Passenger side airbag, High

Output

20

Driver satellite sensor, High

Input

21

Passenger satellite sensor, High

Input

22

Not used

23

Not used

24

Not used

25

Not used

26 ~ 27

Shorting bar

28 ~ 29

Shorting bar

30
31 ~ 32

Battery voltage output for seat buckle switch

Output
Input
Input/output

Input

Output

Shorting bar

33

Driver seat belt buckle switch, Low

34

Crash output

Output

35 ~ 36

Shorting bar

37

Passenger seat belt buckle switch, Low

Input

Input

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38 ~ 39
40
41 ~ 42
43 ~ 44

Shorting bar

Not used

Shorting bar

Shorting bar

45

Driver satellite sensor, Low

Input

46

Passenger satellite sensor, Low

Input

47

Not used

48

Not used

49

Not used

50

Not used

DIAGNOSTIC TROUBLESHOOTING FLOW

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TIBURON(GK) > 2003 > 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 continuously.
3. SRSCM not connected : lamp turned on through shorting bar in wiring harness connector.

MIL OPERATING METHOD

CLOCK SPRING
The clock spring (coil spring) consists of two current carrying coils. It is attached between the steering column and the
steering wheel. It allows rotation of the steering wheel while maintaining continuous contact of the deployment loop through
the inflator module.

SATELLITE SENSOR
The SRSCM is supported with the side airbag function by two satellites, which act as intelligent acceleration sensors and
as such back up the central airbag controller. Both the satellites continuously report the system statuson the left and righthand sides of the vehicle to the SRSCM.

When the ignition is ON, never cause a sudden shock around the installation area of the satellite sensor by a hammer,

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etc. Otherwise it could cause the airbag system to unexpectedly deploy during servicing.

SRSCM
The SRS airbag system has sophisticated electrical and electronic components. Therefore the airbag operating
components should be handled very carefully.
The SRSCM will deploy the airbag modules by sensing the frontal impact sensed by the sensor built in to the SRSCM.
1. DC/DC convertor : The DC/DC converter in the power supply includes a step-up and a step-down converter, which
provides the firing voltage for four firing circuits and the internal operating voltage. If the internal operating voltage falls
below a defined threshold, a reset is executed.
2. Arming sensor/safing sensor : The arming/safing sensor built in to the airbag firing circuit has the function of arming the
airbag circuit under all required deployment conditions and maintaining the airbag firing circuits unarmed under normal
driving conditions. The safing sensor is a dual-contact electro mechanical switch that closes if it experiences a
deceleration exceeding a specified threshold.
3. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period when the
vehicle voltage is low or if lost in a vehicle frontal crash.
4. Back-up power : The SRSCM reserves an energy reserve to provide deployment energy for a short period when the
vehicle voltage is low or if lost in a vehicle frontal crash.
5. Malfunction detection : The SRSCM continuously monitors SRS operating status while the ignition key is turned on and
detects possible malfunctions in the system. The malfunction can be displayed in the form of a diagnostic trouble code
using the Hi-Scan Pro.
6. MIL (Malfunction Indication Lamp) notification : If any fault is detected, the SRSCM sends a signal to the indicator lamp
on the instrument cluster to warn the vehicle driver.
The MIL indicator is the key item in notifying the driver of SRS faults. It verifies lamp and SRSCM operation by flashing
6 times when the ignition switch is first turned on.
7. Malfunction recording : Once a fault occurs in the system, the SRSCM records the fault in memory in the form of a
DTC, which can only be erased by the Hi-Scan Pro.
8. Data link connector : SRSCM memory stored is linked through this connector located under neath the driver side crash
pad to an external output device such as the Hi-Scan Pro.
9. What if only BPT's deploy.
10. Crash output
The crash output is used to unlock the doors in case of a crash. The crash output is : 0 ~ 200 A in OFF mode and
200mA in ON mode. During the unlock command, the switch is closed for 200 mS.

DIAGNOSIS WITH SCAN TOOL


CHECK PROCEDURES
1. Connect the Hi-Scan Pro DLC to the vehicle's data link connector located underneath the dash panel.
2. Turn the ignition key to the "ON" position and turn the Hi-Scan Pro ON.
3. Perform the SRS diagnosis according to the vehicle model configuration.
4. If a fault code is assured, then replace the component. Never attempt to repair the component.
5. If the Hi-Scan Pro finds that a component of the system is faulty, there is a possibility that the fault is not in the
component, but in SRS wiringor connector.

SPECIFICATION

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AIRBAG SQUIB RESISTANCE LIMITS


DAB
R 1.06
1.80 R 3.40
R 6.70
1.06 < R < 1.80
3.40 < R < 6.70

Resistance too low

Fault definitely detected

Resistance whithin tolerance

Definitely no fault detected

Resistance too high

Fault definitely detected

Tolerance band

Fault may or may not be detected

Resistance too low

Fault definitely detected

Resistance whithin tolerance

Definitely no fault detected

Resistance too high

Fault definitely detected

Tolerance band

Fault may or may not be detected

PAB, SAB, BPT


R 0.4
1.6 R 2.8
R 5.4
0.4 < R < 1.6

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2.8 < R < 5.4

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control Module (SRnodeM)
> 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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control Module (SRnodeM)
> Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control
Module (SRnodeM) > Troubleshooting

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE


OPTIONS : DAB + PAB + SAB + BPT
DTC No.

Fault description

B1111

Battery voltage too high

B1112

Battery voltage too low

B1346

Driver airbag (DAB), Resistance too high

B1347

Driver airbag (DAB), Resistance too low

B1348

Driver airbag (DAB), Short to GND

B1349

Driver airbag (DAB), Short to Battery

B1352

Passenger airbag (PAB), Resistance too high

B1353

Passenger airbag (PAB), Resistance too low

B1354

Passenger airbag (PAB), Short to GND

B1355

Passenger airbag (PAB), Short to Battery

B1361

Driver seat belt pretensioner (DBPT), Resistance too high

B1362

Driver seat belt pretensioner (DBPT), Resistance too low

B1363

Driver seat belt pretensioner (DBPT), Short to GND

B1364

Driver seat belt pretensioner (DBPT), Short Battery

B1367

Passenger seat belt prestensioner (PBPT), Resistance too


high

B1368

Passenger seat belt prestensioner (PBPT), Resistance too


low

B1369

Passenger seat belt prestensioner (PBPT), Short to GND

B1370

Passenger seat belt prestensioner (PBPT), Short to Battery

B1378

Driver side airbag (DSAB), Resistance too High

B1379

Driver side airbag (DSAB), Resistance t0o Low

B1380

Driver side airbag (DSAB), Short to GND

B1381

Driver side airbag (DSAB), Short to Battery

B1382

Passenger side airbag (PSAB), Resistance too high

B1383

Passenger side airbag (PSAB), Resistance too low

B1384

Passenger side airbag (PSAB), Short to GND

B1385

Passenger side airbag (PSAB), Short to Battery

B1400

Satellite left side sensor defect

B1401

Satellite sensor left side short to GND

B1402

Satellite sensor left side open/short to battery

B1403

Satellite right side sensor defect

B1404

Satellire sensor right side short to GND

B1405

Satellire sensor right side open/short to battery

B1409

Satellite left side sensor communication error

B1410

Satellite right side sensor communication error

B1511

Driver seat belt buckle switch open/short to battery

B1512

Driver seat belt buckle switch short to GND

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B1513

Passenger seat belt buckle switch open/short to battery

B1514

Passenger seat belt buckle switch short to GND

B1620

Airbag unit internal failure

B1650

SRSCM crash recorded

B1655

Side airbag crash recorded

B1657

Crash recorded-Belt pretensioner only

B1661

ECU mismatching

B2500

Warning lamp failure

The DAB is located in the steering wheel.


The PAB is located in the crash pad.
The DSAB is located in the left side of driver's seat.
The PSAB is located in the right side of passenger's seat.

CIRCUIT INSPECTION
DTC

B1111
B1112

Battery voltage too high (Vbaft 19.2V)


Battery voltage too low (Vbaft 7.2V)

CIRCUIT DESCRIPTION
INSPECTION PROCEDURE
1. Preparation
(1) Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
(2) Remove the DAB module.
(3) Disconnect the connectors of the PAB, left and right side airbags, belt pretensioners and satellite sensors.
(4) Disconnect the SRSCM connector.

Place the DAB with the front surface facing upward.


2. Check source voltage.
(1) Connect the negative (-) terminal cable to the battery.
(2) Turn the ignition switch ON.

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3. Does the SRS warning light turn off ?


[PREPARATION]
(1) Turn the ignition switch to LOCK.
(2) Connect the DAB module.
(3) Connect the PAB connector, left and right side airbag, belt pretensioner and satellite connectors.
(4) Connect the SRSCM connector.
(5) Turn the ignition switch ON.

CIRCUIT INSPECTION

DTC

B1348

DAB short to
ground

B1354

PAB short to
ground

B1363

DBPT short to
ground

B1369

PBPT short to
ground

B1380

DSAB short to
ground

B1384

PASB short to
ground

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B1401

Satellite sensor left


side short to
ground

B1404

Satellite sensor
right side short to
ground

CIRCUIT DESCRIPTION
DTC Detecting Condition

Short circuit in squib wire harness (to ground)


Squib malfunction
Clock spring malfunction
SRSCM malfunction

Trouble Area

DAB squib
PAB squib
DSAB squib
PSAB squib
BPT squib
Satellite sensor
Clock spring
SRSCM
Wire harness

WIRING DIAGRAM

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. Check DAB squib circuit.

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[CHECK]
For the connector (on the clock spring side) between clock spring and DAB, measure the resistance between DAB high
and body ground.
Resistance :

3. Check the PAB squib circuit.

[CHECK]
For the connector (on the SRSCM side) between SRSCM and PAB, measure the resistance between PAB high and
body ground.
Resistance :

4. Check PSAB and DSAB squib circuits.

[CHECK]
For the connector (on the SRSCM side) between SRSCM and the SABs, measure the resistance between the SABs
high and body ground.
Resistance :

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5. Check the BPTs squib circuit.

[CHECK]
For the connector (on the SRSCM side) between the SRSCM and BPT, measure the resistance between the BPTs high
and body ground.
Resistance :

6. Check the Satellite sensor circuit.

[CHECK]
For the connector (on the SRSCM side) between the SRSCM and the Satellite sensor, measure the resistance between
the Satellite high and body ground.
Resistance :

7. Check the SRSCM.


[PREPARATION]
A. Connect the connector to SRSCM.
B. Using a service wire, connect the DAB high and DAB low on the clock spring side of connector.
C. Using a service wire, connect the PAB high and low on SRSCM side of connector.
D. Connect the SABs and BPT using the same method.
E. Connect the negative (-) terminal cable to battery, and wait it least 30 seconds.

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[CHECK]
A. Turn ignition switch to ON, and wait for at least 30 seconds.
B. Clear any codes stored in the memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait for 30 seconds.
D. Turn the ignition switch to ON, and wait for 30 seconds.
E. Using the Hi-Sacn Pro, check for DTCs.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this check.

8. Check the DAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the DAB connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory of the Hi-Scan Pro.
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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

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9. Check the PAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the PAB connector.
D. Connect the negative (-) terminal cable from the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait for 30 seconds.
D. Turn the ignition switch to ON, and wait for 30 seconds.
E. Using the Hi-Sacn Pro, check for DTCs.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

10. Check the SABs squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the SAB connector.
D. Connect the negative (-) terminal cable from the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory 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.
[HINT]
Codes other than these ones may be output at this time, but they are not relevant to this checking procedure.

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Check the DSAB using the same procedure.

11. Check BPT squib.


[PREPARATION]
A. Turn the ignition swich to LOCK.
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.

[CHECK]
A. Turn the ignition switch to ON, and wait 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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

12. Check the Satellite sensors.


[PREPARATION]
A. Turn ignition switch to LOCK.
B. Disconnect negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the Satellite sensor connector.
D. Connect the negative (-) terminal cable from the battery, and wait at least 30 seconds.

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[CHECK]
A. Turn the ignition switch to ON, and wait at least 30 seconds.
B. Clear the malfunction code stored in memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait at least 30 seconds.
D. Turn the ignition switch to ON, and wait at least 30 seconds.
E. Using the Hi-Scan Pro, check for DTCs.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

13. Check clock spring circuit.


[PREPARAION]
Disconnect connector between SRSCM and clock spring.

[CHECK]
Measure resistance between the DAB high on the clock spring side of connector between clock spring and DAB and
body ground.
Resistance :

CIRCUIT INSPECTION
B1349

DAB short to
battery

B1355

PAB short to
battery

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B1364

DBPT short to
battery

B1370

PBPT short to
battery

B1381

DSAB short to
battery

B1385

PSAB short to
battery

B1402

Satellite left side


short to battery

B1405

Satellite right side


short to battery

DTC

CIRCUIT DESCRIPTION
DTC Detecting Condition

Short circuit in squib wire harness (to B+)


Squib malfunction
Clock spring cable malfunction
SRSCM malfunction

Trouble Area

DAB squib
PAB squib
DSAB or PSAB squib
BPT squib
Satellite sensor
Wire harness

WIRING DIAGRAM

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.

Place the DAB with the front surface facing upward.

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2. Check the DAB squib circuit.

[CHECK]
For the connector (on the clock spring side) between the clock spring and DAB, measure the voltage between the DAB
high and body ground.
Voltage : 0 V

3. Check the PAB squib circuit.

[CHECK]
For the connector (on the SRSCM side) between the SRSCM and PAB, measure the voltage between the PAB high
and body ground.
Voltage : 0 V

4. Check the SAB squib circuit.

[CHECK]
For the connector (on the SRSCM side) between the SRSCM and SAB, measure the voltage between the SAB high
and body ground.
Voltage : 0 V

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5. Check the BPTs squib circuits.

[CHECK]
For the connector between SRSCM and the BPTs, measure the voltage between the BPTs high and body ground.
Voltage : 0 V

6. Check the Satellite sensor circuit.

[CHECK]
For the connector between the SRSCM and the Satellite sensor, measure the voltage between the Satellite sensor high
and body ground.
Voltage : 0 V

7. Check the SRSCM.

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[PREPARATION]
A. Connect the connector to the SRSCM.
B. Using a service wire, connect the DAB high and low on the clock spring side of connector between the clock spring
and the DAB.
C. Using a service wire, connect the PAB high and low on the SRSCM side of the connector between the SRSCM and
the PAB.
D. Using a service wire, connect the SAB high and low on the SRSCM side connector between the SRSCM and the
SAB.
E. Using a service wire, connect the BPT high and low on the SRSCM side connector between the SRSCM and the
BPT.
F. Using a service wire, connect the satellite high and low on the SRSCM side connector between the SRSCM and the
satellite sensor.
G. Connect negative (-) terminal cable to battery, and wait at least 30 seconds.
[CHECK]
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.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this check.

8. Check the DAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the DAB connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory of the Hi-Scan Pro.

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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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

9. Check the PAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the PAB connector.
D. Connect the negative (-) terminal cable from the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory 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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

10. Check the SAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the SAB connector.
D. Connect the negative (-) terminal cable from the battery, and wait for 30 seconds.

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[CHECK]
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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

11. Check the BPTs squib.


[PREPARATION]
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.

[CHECK]
A. Turn the ignition switch to ON, and wait 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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

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12. Check the Satellite sensors.


[PREPARATION]
A. Turn ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
C. Connect the Satellite sensor connector.
D. Connect the negative (-) terminal cable from the battery, and wait at least 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, 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.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

13. Check the Clock spring.


[PREPARAION]
A. Turn the ignition switch to LOCK.
B. Disconnect the connector between the SRSCM and the clock spring.

[CHECK]
Turn the ignition switch ON, and measure the voltage between the DAB high side and the body ground.
Voltage : 0V

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CIRCUIT INSPECTION
B1346
B1347

DTC

DAB resistance too high (R 6.70 )


DAB resistance too low (R 1.06 )

CIRCUIT DESCRIPTION
DTC Detecting Condition

Trouble Area

Too high or low resistance between DAB high (+) wiring


harness and DAB low (-) wiring harness of squib.

DAB squib

DAB malfunction
Clock spring malfunction
SRSCM malfunction

Clock spring
SRSCM
Wire harness

WIRING DIAGRAM

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.

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Place the DAB with the front surface facing upward.


2. Check the DAB resistance.
[PREPARATION]
Release the airbag activation prevention mechanism on SRSCM side of airbag squib side. Connect the dummy (0957A38200) and dummy adapter (0957A-38400)to the clock spring side connector.

Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester.

Before checking the resistance, you have to insert the shorting bar insert plastic that is attached to the diagnosis
checker into the SRSCM connector.

[CHECK]
Measure the resistance between the DAB high (+) and low (-).
1.80 R 3.40

3. Check the DAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the DAB connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory 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.

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There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

4. Check the clock spring.


[PREPARAION]
Disconnect the connector between the SRSCM clock spring, and connect the dummy connector (0957A-38200) and
dummy adapter (0957A-38400) to the clockspring side connector.

Before checking the resistance, you have to insert the shorting bar insert plastic that is attached to the diagnosis
checker into the SRSCM connector.

[CHECK]
Measure the resistance between the DAB high (+) and low (-).
1.80 R 3.40

CIRCUIT INSPECTION
B1352
B1353

DTC

PAB resistance too high (R 5.4 )


PAB resistance too low (R 0.4 )

CIRCUIT DESCRIPTION
DTC Detecting Condition

Trouble Area

Too high or low resistance between PAB high (+) wiring


harness and PAB low (-) wiring harness of squib.

PAB squib

PAB malfunction
SRSCM malfunction

SRSCM
Wire harness

WIRING DIAGRAM

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INSPECTION PROCEDURE
1. Preparation
(1) Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
(2) Remove the DAB module.
(3) Disconnect the connectors of the PAB, left and right side airbags, belt pretensioners and satellite sensors.
(4) Disconnect the SRSCM connector.

Place the DAB with the front surface facing upward.


2. Check 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 SRSCM connector.

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[CHECK]
Measure the resistance between the PAB high (+) and the PAB low (-).
1.6 R 2.8

3. Check the PAB squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the PAB connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait for 30 seconds.
D. Turn the ignition switch to ON, and wait for 30 seconds.
E. Using Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

CIRCUIT INSPECTION

DTC

B1378
B1379
B1382
B1383

DSAB Resistance too high (R 5.4 )


DSAB Resistance too low (R 0.4 )
PSAB Resistance too high (R 5.4 )
PSAB Resistance too low (R 0.4 )

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CIRCUIT DESCRIPTION
DTC Detecting Condition

Trouble Area

Too high or low resistane between SAB high (+) wiring


harness and SAB low (-) wiring harness of squib.

SAB squib

SAB malfunction
SRSCM malfunction

SRSCM
Wire harness

WIRING DIAGRAM

INSPECTION PROCEDURE
1. Preparation
(1) Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
(2) Remove the DAB module.
(3) Disconnect the connectors of the PAB, left and right side airbags, belt pretensioners and satellite sensors.
(4) Disconnect the SRSCM connector.

Place the DAB with the front surface facing upward.


2. Check the SAB resistance.
[PREPARATION]

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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 the SAB 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 SRSCM connector.
[CHECK]
Measure the resistance between the SAB high (+) and the SAB low (-).
1.6 R 2.8

3. Check the SAB squib.


[PREPARATION]
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.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory with the Hi-Scan Pro.
C. Turn the ignition switch to LOCK, and wait for 30 seconds.
D. Turn the ignition switch to ON, and wait for 30 seconds.
E. Using Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

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CIRCUIT INSPECTION
B1361
B1362
B1367
B1368

DTC

DBPT Resistance too high (R 5.4 )


DBPT Resistance too low (R 0.4 )
PBPT Resistance too high (R 5.4 )
PBPT Resistance too low (R 0.4 )

CIRCUIT DESCRIPTION
DTC Detecting Condition

Trouble Area

Too high or low resistane between BPT high (+) wiring


harness and BPT low (-) wiring harness of squib.

BPT squib

BPT malfunction
SRSCM malfunction

SRSCM
Wire harness

WIRING DIAGRAM

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.

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Place the DAB with the front surface facing upward.


2. Check the BPT 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 the BPT 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
checker into the SRSCM connector.

[CHECK]
Measure the resistance between the BPT high (+) and the BPT low (-).
1.6 R 2.8

3. Check the BPT squib.


[PREPARATION]
A. Turn the ignition switch to LOCK.
B. Disconnect the negative (-) terminal cable from the battery, and wait for 30 seconds.
C. Connect the BPT connector.
D. Connect the negative (-) terminal cable to the battery, and wait for 30 seconds.

[CHECK]

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A.
B.
C.
D.
E.

Turn the ignition switch to ON, and wait for at least 30 seconds.
Clear the malfunction code stored in the memory with the Hi-Scan Pro.
Turn the ignition switch to LOCK, and wait for 30 seconds.
Turn the ignition switch to ON, and wait for 30 seconds.
Using Hi-Scan Pro, check the DTC.
There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this procedure.

CIRCUIT INSPECTION
B1400

Satellite left side


defect

B1403

Satellite right side


defect

B1409

Satellite left
communication
error

B1410

Satellite right
communication
error

DTC

CIRCUIT DESCRIPTION
WIRING DIAGRAM

INSPECTION PROCEDURE
1. Preparation
(1) Disconnect the negative (-) terminal cable from the battery, and wait at least 30 seconds.
(2) Remove the DAB module.

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(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 satellite circuit (communication error).

[PREPARATION]
Check continuity between the SRSCM connector and the satellite connector as high (+) and high, low (-) and low (-).
OK : Continuity

3. Check the satellite sensor (defect).


[PREPARATION]
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.

[CHECK]
A. Turn the ignition switch to ON, and wait for at least 30 seconds.
B. Clear the malfunction code stored in the memory of the Hi-Scan Pro.
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 DTC.

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There is no DTC.
[HINT]
Codes other than these may be output at this time, but they are not relevant to this check.

CIRCUIT INSPECTION

DTC

B1511
B1512
B1513
B1514

Driver seat belt switch open/short to


Battery
Driver seat belt switch short to GND
Passenger seat belt switch open/short
to Battery
Passenger seat belt switch short to
GND

CIRCUIT DESCRIPTION
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

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[CHECK]
Check the resistance with the switch on and off.
SWITCH OPEN : R = 4K 10% (Belted)
SWITCH OPEN : R = 1K 10% (Unbelted)

CIRCUIT INSPECTION
DTC

B2500

Warning lamp failure

CIRCUIT DESCRIPTION
INSPECTION PROCEDURE
1. Check the fuse.
[PREPARATION]
A. Remove airbag fuse and airbag warning lamp fuse from the junction block.
B. Inspect the state of the fuses.
C. Replace if necessary.
2. Check the SRS warning lamp circuit.
[PREPARATION]
A. Connect the negative (-) terminal cable to the battery.
B. Turn the ignition switch to ON.

[CHECK]
A. Measure voltage at the harness side connector of the SRSCM.
Voltage : 9-16 V

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B. Check the SRS SRI (Service Reminder Indicator).


OK : SRS SRI ON

CIRCUIT INSPECTION

DTC

B1620
B1650
B1655
B1657
B1661

Airbag unit internal failure


SRSCM crash recorded
Side airbay crash recorded
Crash recorded-Belt pretensioner only
ECU mismatching

CIRCUIT DESCRIPTION
1. Functional readiness of the firing circuit activation transistors.
2. Adequacy of deployment energy reserves.
3. Safing sensor integrity : detection of faulty closure.
4. Plausibility of accelerometer signal.
5. Operation of SRSCM components.

DIAGNOSIS WITH SCAN TOOL


CHECK PROCEDURES
1. Connect the Hi-Scan Pro DLC to the vehicle's data link connector located under neath the dash panel.
2. Turn the ignition key to the "ON" position and turn the Hi-Scan Pro ON.
3. Perform the SRS diagnosis according to the vehicle model configuration.
4. If a fault code is assured, then replace the component. Never attempt to repair the component.
5. If the Hi-Scan Pro finds that a component of the system is faulty, there is a possibility that the fault is not in the
component, but in SRS wiring or connector.

DIAGNOSTIC TROUBLESHOOTING FLOW

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SPECIFICATION

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AIRBAG SQUIB RESISTANCE LIMITS


DAB
R 1.06
1.80 R 3.40
R 6.70
1.06 < R < 1.80
3.40 < R < 6.70

Resistance too low

Fault definitely detected

Resistance whithin tolerance

Definitely no fault detected

Resistance too high

Fault definitely detected

Tolerance band

Fault may or may not be detected

Resistance too low

Fault definitely detected

Resistance whithin tolerance

Definitely no fault detected

Resistance too high

Fault definitely detected

Tolerance band

Fault may or may not be detected

PAB, SAB, BPT


R 0.4
1.6 R 2.8
R 5.4
0.4 < R < 1.6
2.8 < R < 5.4

INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODE


OPTIONS : DAB + PAB + SAB + BPT
DTC No.

Fault description

B1111

Battery voltage too high

B1112

Battery voltage too low

B1346

Driver airbag (DAB), Resistance too high

B1347

Driver airbag (DAB), Resistance too low

B1348

Driver airbag (DAB), Short to GND

B1349

Driver airbag (DAB), Short to Battery

B1352

Passenger airbag (PAB), Resistance too high

B1353

Passenger airbag (PAB), Resistance too low

B1354

Passenger airbag (PAB), Short to GND

B1355

Passenger airbag (PAB), Short to Battery

B1361

Driver seat belt pretensioner (DBPT), Resistance too high

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B1362

Driver seat belt pretensioner (DBPT), Resistance too low

B1363

Driver seat belt pretensioner (DBPT), Short to GND

B1364

Driver seat belt pretensioner (DBPT), Short Battery

B1367

Passenger seat belt prestensioner (PBPT), Resistance too high

B1368

Passenger seat belt prestensioner (PBPT), Resistance too low

B1369

Passenger seat belt prestensioner (PBPT), Short to GND

B1370

Passenger seat belt prestensioner (PBPT), Short to Battery

B1378

Driver side airbag (DSAB), Resistance too High

B1379

Driver side airbag (DSAB), Resistance too Low

B1380

Driver side airbag (DSAB), Short to GND

B1381

Driver side airbag (DSAB), Short to Battery

B1382

Passenger side airbag (PSAB), Resistance too high

B1383

Passenger side airbag (PSAB), Resistance too low

B1384

Passenger side airbag (PSAB), Short to GND

B1385

Passenger side airbag (PSAB), Short to Battery

B1400

Satellite sensor driver side defect

B1401

Satellite sensor driver side short to GND

B1402

Satellite sensor driver side open/short to battery

B1403

Satellite sensor passenger side defect

B1404

Satellire sensor passenger side short to GND

B1405

Satellire sensor passenger side open/short to battery

B1409

Satellite sensor driver side communication error

B1410

Satellite sensor passenger side communication error

B1511

Driver seat belt buckle switch open/short to battery

B1512

Driver seat belt buckle switch short to GND

B1513

Passenger seat belt buckle switch open/short to battery

B1514

Passenger seat belt buckle switch short to GND

B1620

Airbag unit internal failure

B1650

SRSCM crash recorded

B1655

Side airbag crash recorded

B1657

Crash recorded-Belt pretensioner only

B1661

ECU mismatching

B2500

Warning lamp failure

The DAB is located in the steering wheel.


The PAB is located in the crash pad.
The DSAB is located in the out side of driver's seat.
The PSAB is located in the out side of passenger's seat.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental Restraint System Control Module
(SRnodeM) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Supplemental
Restraint System Control Module (SRnodeM) > Repair procedures

REMOVAL
1. Disconnect the battery negative cable, and wait at least 30seconds before begining work.
2. Disconnect the airbag connectors.
3. Remove the center console. (see BD group).
4. Disconnect the connector from the SRS unit.

5. Remove the three bolts from the SRS unit, than pull out the SRS unit from the bracket.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Description and Operation,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Description and Operation

FIELD DEPLOYMENT PROCEDURES

When handling the deployed airbag be careful that not the dust enters your eyes and always wear gloves to
avoid direct contact with the dust.

AIRBAG MODULE DISPOSAL PROCEDURES


Before disposing of a vehicle equipped with an airbag, or prior to disposing of the airbag module, be sure to first
follow the procedures described below to deploy the airbag.
AIRBAG REMOTE DEPLOYMENT DEVICES
Tool, Number, Name
Deployment tool (0957A-34100A)
SRS DEPLOYMENT ADAPTER HARNESS
DAB, BPT : 0957A-38500
PAB, SAB : 0957A-3810

Use
Deployment inside the vehicle (if the vehicle will no
longer be driven)

DISPOSAL PLAN
Take the following disposal steps.
CASE

DISPOSAL PLAN

Abnormal problems in airbag module

Deploy and discard

Car scrappinG

Deploy the airbag module with the SST

DAB, PAB, SAB, BPT

Crash (Deployed)

Discard

UNDEPLOYED AIRBAG MODULE DISPOSAL

1. If the vehicle is to be scrapped, junked, or otherwise disposed of, deploy the airbag inside the vehicle.
2. Since there is a loud noise when the airbag is deployed, avoid residential areas whenever possible. If
anyone is nearby, give warning of the impending noise.
3. Since a large amount of smoke is produced when the airbag is deployed, select a well-ventilated site.
Moreover, never attempt the test near a fireor smoke sensor.

DEPLOYMENT INSIDE THE VEHICLE


1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot.
2. Disconnect the negative (-) and positive (+) battery cables from the battery terminals, and then remove the
battery from the vehicle

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Wait at least 30 seconds after disconnecting the battery cable before doing any further work.
3. Remove the center crash pad side cover.
4. Remove Airbag SRSCM connector.
5. Connect deployment tool to the connector of each module.

6. At location as far away from the vehicle as possible, press the push button (removed from the vehicle) to
deploy the airbag.

1. Before deploying the airbag in this manner, first check to be sure that there is no one in or near the
vehicle. Wear safety glasses.
2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow
it to cool before attempting to handle it. Although not poisonous, do not inhale gas from airbag
deployment. See Deployed Airbag Module Disposal Procedures for post-deployment handling
instructions.
3. If the airbag fails to deploy when the procedures above are followed, do not go near the module.
Contact your local distributor.

DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURES


1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool
before attempting to handle it.
2. Do not put water or oil on the airbag after deployment.
3. There may be adhered to the deployed airbag module, material that could irritate the eyes and/or skin, so
wear gloves and safety glasses when handling a deployed airbag module. If despite these precautions, the
material does get into your eyes or on your skin, immediately rinse the affected area with a large amount of
clean water. If any irritation develops, seek medical attention.
4. Tightly seal the airbag module in a strong vinyl bag for disposal.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Components and Components Location,
TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Repair procedures, TIBURON
(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Repair procedures

REMOVAL
1. Disconnect the negative battery cable and keep secure from battery.

Wait at least 30 seconds after disconnecting the battery cable before doing any further work.

2. Remove the side protect cover of steering wheel and airbag module mounting bolts using a hexagonal
wrench.

3. When disconnecting the connector of the clock spring from the airbag module, pull the airbag's lock toward
the outer side to spread it open.

When disconnecting the airbag module-clock spring connector, take care not to apply excessive force to
it.
4. Remove the drive airbag module.

The removed airbag module should be stored in a clean, dry place with the pad cover face up.

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5. Remove the steering wheel using SST (09561-11002).

Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism.

REMOVAL

1. Never attempt to disassemble or repair the airbag module.


2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing
upward. Do not place anything on top of it.
4. Do not expose the airbag module to temperature over 93C (200F)
5. An undeployed airbag module should only be disposed in accordance with the procedures.
6. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester. If the circuit resistance is measured with a tester, accidental airbag deployment will
result in seriouspersonal injury.
7. Whenever the PAB is deployed it should be replaced with a new one assembled with an extension wire.
The squib is melt down if the PAB is deployed makingthe extension wire useless.
1. Disconnect the battery negative (-) terminal cable.

Wait at least 30 seconds.

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2. Remove the glove box.


3. Disconnect the PAB module connector.
4. Remove the crash pad assembly and then undo the PAB module. (Refer to the BD section)
5. The skin of the passenger airbag module is integrated with the crash pad, therefore, the crash pad must be
replaced if the PAB deploys.

INSPECTION
AIRBAG MODULE
Dispose the old one according to the specified procedure.

Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in
serious personal injury.
1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for deformities, and harness for binds.
4. Check airbag inflator case for dents, cracks or deformities.
5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel.

CLOCK SPRING
1. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a
new one.
2. Check connectors and protective tube for damage, and terminals for deformities.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Passenger Airbag (PAB) Module >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module >
Passenger Airbag (PAB) Module > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Passenger Airbag (PAB) Module
> Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Passenger
Airbag (PAB) Module > Repair procedures

REMOVAL

1. Never attempt to disassemble or repair the airbag module.


2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing
upward. Do not place anything on top of it.
4. Do not expose the airbag module to temperature over 93C (200F)
5. An undeployed airbag module should only be disposed in accordance with the procedures.
6. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the
specified tester. If the circuit resistance is measured with a tester, accidental airbag deployment will
result in serious personal injury.
7. Whenever the PAB is deployed it should be replaced with a new one assembled with an extension wire.
The squib is melt down if the PAB is deployed making the extension wire useless.
1. Disconnect the battery negative (-) terminal cable.

Wait at least 30 seconds.

2. Remove the glove box.


3. Disconnect the PAB module connector.

4. Remove the crash pad assembly and then undo the PAB module. (Refer to the BD section)

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5. The skin of the passenger airbag module is integrated with the crash pad, therefore, the crash pad must be
replaced if the PAB deploys.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Side Airbag (SAB) Module >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Side Airbag
(SAB) Module > Repair procedures

REMOVAL
1. Disconnect the battery negative (-) terminal cable.

Wait at least 30 seconds.

2. Disconnect the side airbag harness 2p connector.

3. Remove the seat assembly and seat-back cover.


4. Remove the two mounting nuts and the side airbag.

1. Never attempt to disassemble or repair the airbag module.


2. Do not drop the airbag module or allow contact with water, grease or oil. Replace it if a dent, crack,
deformation or rust are detected.
3. The airbag module should be stored on a flat surface and placed so that the pad surface is facing
upward. Do not place anything on top of it.
4. 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.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Satellite Sensor > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Airbag Module > Satellite Sensor >
Repair procedures

REMOVAL
1. Disconnect the negative battery cable and keep secure from battery.

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.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Seat Belt Pretensioner > Seat Belt Retractor
Pretensioner (BPT) > Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Restraint > Seat Belt
Pretensioner > Seat Belt Retractor Pretensioner (BPT) > Repair procedures

REMOVAL
1. Disconnect the battery negative (-) terminal.

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.

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1. Never attempt to disassemble or repair the BPT.


2. Do not drop the BPT or allow contact with water, grease, oil.
Replace it if a dent, crack, deformation or rust are detected.
3. Do not place anything on the BPT.
4. Do not expose the BPT to temperature over 93C(20 0F).
5. BPT functions one time only. Be sure to replace the BPT after it is deployed.
6. Be sure to wear gloves and safety goggles when handling the deployed BPT.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General Information > Special
Service Tools, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General
Information > Special Service Tools

SPECIAL TOOLS
Tool (Number and name)

Illustration

Use

09793-21000
Door hinge adjusting wrench

Adjustment, removal, and installation of the


door hinge

09800-21000
Ornament remover

Trim removal

09853-31000
Headliner clip remover

Removal of the headliner clip

09861-31100
Sealant cut-out tool

Cutting the sealant of the windshield (use


with 09861-31200)

09861-31200
Sealant cutting blade

Cutting the sealant of the windshield (use


with 09861-31100)

09861-31300
Sealant gun

Application of the sealant to the windshield

09861-31400
Glass holder

Removal and installation of the windshield

09861-31000
Windshield moulding remover

Removal of the windshield moulding

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General Information >
Troubleshooting, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General
Information > Troubleshooting

TROUBLESHOOTING
Trouble symptom

Probable cause

Water leaks from sunroof

Dirt accumulated in drain tube

Clear dirt inside of drain

Clogged drain tube

Blow air into drain to remove dirt

Broken or dislocated drain tube, defective


or cracked clip

Check tube installation and


flange contact

Deteriorated roof lid weatherstrip

Replace

Excessive roof lid-to-body clearance and


improperly fitted weatherstrip

Adjust

Wind noise around sunroof

Loose or deformed deflector, gaps in body


work

Retighten adjust or replace

Sunroof makes a noise when


moved

Foreign particles lodged in guide rail

Check drive cable and guide


rails for foreign particles

Loose guide rails and lid

Retighten

Motor runs but sunroof does not Foreign particles lodged in guide rail
move or moves only halfway

Noise in motor (clutch slipping


noise from motor when sunroof
is fully opened or closed is not
an unusual noise.)

Remedy

Check drive cable and guide


rails for foreign particles

Incorrect engagement of motor pinion with


drive cable

Check for loose motor


installation and damaged pinion

Decrease in motor's clutch slipping force

Adjust

Increased sunroof sliding resistance or


interference of sunroof with drive cables,
weatherstrip, etc. due to maladjustment of
sunroof

Adjust or replace

Incorrect engagement of motor pinion with


drive cable

Check pinion installation and


retighten motor

Worn out or damaged motor pinion bearing Replace motor assembly


Worn out or deformed drive cable

Replace

Incorrect window glass installation

Adjust position

Damaged or faulty regulator arm or


regulator

Correct or replace

Incorrect door installation

Adjust position

Defective door check assembly

Correct or replace

Door hinge requires grease

Apply grease

Striker and latch not properly aligned

Adjust

Incorrectly installed hood

Adjust

Incorrect hood bumper height

Adjust

Water leak through windshield


and rear window

Defective seal

Fill with sealant

Defective flange

Correct

Wind noise around door

Weatherstrip not holding firmly

Adjust fit of door

Improperly installed weatherstrip

Repair or replace

Improperly closed door

Adjust

Door glass fails to operate up


and down

Door does not open or close


completely

Hood does not open or close


completely

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Improperly fit door

Adjust

Improper clearance between door glass


and division channel

Adjust

Deformed door

Repair or replace

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General Information >
Specifications, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > General
Information > Specifications

SPECIFICATIONS
Hood
- Type

Rear hinged, front opening type (gaslifter type)

Door
- Construction
- Regulator system
- Locking system

Front hinged, full door construction


Wire drum type
Pin-fork system

Tailgate
- Type

Inner hinged, gas lifter type

Glass thickness mm(in.)


- Windshield glass
- Door glass
- Quarter fixed glass
- Tailgate glass

5 (0.20)
5 (0.20)
3.2 (0.13)
3.5 (0.14)

Seat belt

3 point type with E.L.R

E.L.R. : Emergency Locking Retractor

TIGHTENING TORQUE
Nm

Kgcm

lbft

Door
- Door hinge to body
- Door hinge to door
- Door striker mounting bolt

35~42
10~12
17~22

350~420
100~120
170~220

25~31
7~8
12~16

Tailgate
- Tailgate hinge to body
- Tailgate hinge to tailgate
- Tailgate latch mounting bolt
- Tailgate striker mounting bolt

22~27
7~9
7~11
9~14

220~270
70~90
70~110
90~140

16~19.5
5~7
5~8
6.5~10

Hood
- Hood hinge to body
- Hood hinge to hood
- Hood latch to body
- Gas lifter mounting bolt

22~27
22~27
7~11
9~14

220~270
220~270
70~110
220~270

16~19.5
16~19.5
5~8
16~19.5

Seat
- Front seat to floor, Bolt
- Rear seat back center bracket, Bolt
- Rear seat back lower side bracket, Bolt
- Rear seat cushion mounting, Bolt

35~55
17~26
17~26
17~26

350~550
170~260
170~260
170~260

25~40
12~19
12~19
12~19

40~55
40~55
40~55
40~55

400~550
400~550
400~550
400~550

29~40
29~40
29~40
29~40

Seat belt
- Front seat belt retractor mounting bolt
- Front seat belt upper anchor mounting bolt
- Front seat belt sliding bar mounting bolt
- Front seat belt height adjuster mounting bolt

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- Rear seat belt retractor mounting bolt


- Rear seat belt upper anchor mounting bolt
- Front seat belt buckle mounting bolt
Sunroof
- Sunroof lid panel mounting, Nut
- Sunroof assembly mounting, Bolt

40~55
40~55
40~55

400~550
400~550
400~550

29~40
29~40
29~40

7~9
7~11

70~90
70~110

5~6.5
5~8

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender
> Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > fender >
Repair procedures

REMOVAL AND INSTALLATION


FENDER
1. Remove the front mud guard and wheel guard.

2. Remove the 3 bolts holding the head lamp and disconnect the wire connector.
Remove the head lamp assembly.

3. Remove the front bumper. (refer to front bumper group)


4. Remove the fender mounting bolts and remove the fender panel assembly.

Use care to avoid damaging the paint.

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. Remove the wheel guard.

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2. Loosen the fender garnish mounting screws and then remove the fender garnish.

3. Installation 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.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood >
Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > hood >
Repair procedures

ADJUSTMENT
Hood Hinge
1. Loosen the hood hinge mounting bolt.
2. Adjust the longitudinal and lateral positions of the hood by utilizing the holes in the hinge.
3. Adjust front edge of hood in vertical direction by adjusting the hood stop and adjusting bumpers.

Hood Latch
1. Loosen the hood lock mounting bolts.
2. Adjust the alignment of the hood latch by adjusting the vertical and lateral position of the lock and by adjusting
the height of the hood.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > tail gate > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > tail gate
> Repair procedures

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.

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6. Remove the rear wiper motor mounting 3 bolts and disconnect the wire connector.
Remove the rear wiper motor.

7. Remove the tailgate lifter with ball joint.

When replacing the tailgate lifter, the ball joint should be replaced at the same time.
Tightening torque:
11~16 Nm (110~160 kgcm, 8~12 lbft)

ADJUSTMENT
1. Adjust the striker upward or downward, and rightward or leftward until the tailgate is flush with the rear edge of
the body.

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

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > front door > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > front
door > Repair procedures

REMOVAL AND 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.

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6. Remove the door tooling hole cover.

7. Remove the door glass stopper catch.

Tightening torque:
4~6 Nm (40~60 kgcm, 3~5 lbft)

8. Remove the door delta chassis.

9. Remove the glass stopper bolts, remove the window glass.

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10. Remove the door side weather strip.

11. Loosen the mounting nuts and remove the regulator assembly.

Tightening torque:
9~14 Nm (90~140 kgcm, 6.5~10 lbft)

12. Disconnect the cable, after loosening the inner handle mounting screw, push the inner handle toward the
direction shown in the illustrationand remove it.

13. Remove the door outside belt.

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Install the door outside belt to the inside of groove of the door panel.

14. Remove the door outside handle and key cylinder.

15. Remove the door latch assembly mounting screws and remove the door latch assembly.

Tightening torque:
17~22 Nm (170~220 kgcm, 12~16 lbft)

16. Remove the door checker.

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17. Installation is the reverse of removal.


When installing the door vapor barrier, butyl tape should not be placed so it blocks the door trim fastener
holes.

ADJUSTMENT
DOOR POSITION

Attach protective tape to the fender edges where the hinge is installed.

DOOR STRIKER
1. Draw a line around the striker plate for reference.
2. Loosen the striker screws and move the striker IN or OUT to make the latch fit tighter or looser. Move the
striker UP or DOWN to align it withthe latch opening. Then lightly tighten the screws and recheck.

Hold the outside handle out and push the door aginst the body to ensure the striker allows a flush fit.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror >
Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Exterior > mirror >
Repair procedures

REMOVAL AND INSTALLATION


OUTSIDE REARVIEW MIRROR
1. Remove the outside rearview mirror cover.

2. Loosen the mounting bolts, disconnet the connector and then remove the outside rearview mirror.

Tightening torque:
7~11 Nm (70~110 kgcm, 5~8 lbft)

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.

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1. Insert a flat tip screwdriver between the outside rear view mirror holder and mirror assembly.

When prying with a flat tip screwdriver, wrap it with a shop towel to prevent damage.
2. Remove the outside rear view mirror actuator from outside rear view mirror housing.

3. Installation is the reverse of removal.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof assembly >
Components and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) >
Sun Roof > sun roof assembly > Components and Components Location

COMPONENTS

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Page 1 of 8

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof assembly >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
sun roof assembly > Repair procedures

REMOVAL
1. Remove the sun-roof as the following order.
(1) Over head console
(2) Sun visor and clips
(3) Trims
(4) Roof side rain force trim

(5) Seat and seat belt


2. After removing the decoration cover, remove the glass.

Tightening torque:
4~6 Nm (40~60 kgcm, 2.9~4.4 lbft)

3. Disconnect the drain hose.


4. Remove the sun-roof mounting bolts and nuts, and then remove the sun-roof.

Be care ful not to damage the other parts, while removing the sun-roof.

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Tightening torque:
4~6 Nm (40~60 kgcm, 2.9~4.4 lbft)

DISASSEMBLY
1. Remove the motor.

2. Remove the front drip.


3. Remove the sun shade.

4. Remove the drive unit and the guide assembly.

5. Remove the deflector.

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6. Remove the spring.

REASSEMBLY
1. Install the spring base.

2. Install the deflector assembly (After installing the clip, install the link base stopper.)

3. Insert the shutting into the rail.

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Do not confuse the left and right sides.


4. Install the cable to the guide assembly.

5. Move the timing front edge to be aligned with the slide of the guide assembly.
6. Align the protrusion of the slide with the groove of the shutting.

7. Grab the pin by finger to avoid inteference with other parts.

8. Face the protrusion of "shoe A" upward, the cushion of "shoe B" downward.

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9. Fully insert the guide assembly into the rail.

10. Completely push the slide until it touches the timing front using a screw driver.

11. Insert the motor cable into the drive unit assembly tube.

12. Install the drive unit assembly to the rail.

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13. Install the sun shade.

14. Install the sun shade cam to the groove of the sun-roof rail.

15. Install the front drip.


16. Install the motor and controller, and connect the connestor.

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.

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4. The roof panel (A) should be even with the glass (B) weatherstrip (C), to within the standard value "E" all the
way around. If not, make the following adjustment.
Standard value "E"
Front edge: 2+0/-1mm (0.08+0/-0.04in.)
Rear edge: 2+1/-0mm (0.08+0.04/-0in.)

5. If the position is not as specified, lightly loosen the glass adjusting screw (A) to adjust the glass height and
tighten it.
Tightening torque: 2~4Nm (20~40kgfcm, 1.5~2.9 lbfft)

6. Check for overlap between the sunroof weatherstrip (A) and the roof panel (B).
Standard value: 1.1 mm

ADJUSTMENT
INITIAL SETTING (GENERAL, OPERATION)

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- Always initiates the sunroof in the following condition.


After manual operation
After parts replacement including motor, controller, harness
Malfunction of sunroof wiring
Abnormal operation after battery and fuse replacement
- Follow the general operation produce for inital sefting after reassembliny.

OPERATING THE SUNROOF EMERGENCY HANDLE


1. Use the sunroof emergency handle to close and open the sunroof manually for the following case only:
A. To close the sunroof before driving a vehicle in a rainy day or on the highway if the sunroof cannot be
closed due to failure of the sunroof motor or controller.

2. Operating method
A. Remove the overhead console.
B. Push the emergency handle up into the hexagonal drive (A) of the sunroof motor (B). You must push hard
enough to disengage the motor clutch; otherwise the emergency handle will slip due to uncompletely fit in
the motor.
C. Carefully turn the emergency handle clockwise to close the sunroof.
D. After closing the sunroof, wiggle the handle back and forth as you remove the tool from the motor, to
ensure the motor clutch reengages.
E. A 5mm hex socket may be used in place of the emergency handle, with a "Speeder" type handle.

Do not use power tools to operate the sunroof.


Damage to the components may occur.

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Page 1 of 2

TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof switch >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
sun roof switch > Repair procedures

INSPECTION
1. Disconnect the negative (-) battery terminal.
2. Detach the lamp lens then remove the mounting screws (2EA) and open the overhead console case cover
then remove the mounting screws (2EA).

3. After disconnecting the roof wiring and sunroof wiring connector then remove the overhead console lamp
assembly from the headliner.

4. Using an ohmmeter, check for continuity between the terminals.


If the continuity is not as specified, replace the sun roof switch.

5. Verify power and ground continuity between the M95 and M96 terminals.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > sun roof moter >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
sun roof moter > Repair procedures

INSPECTION
1. Pull down the rear headliner.
2. Disconnect the motor side connector from the sunroof controller.
Remove the sunroof motor after removing 3 screws.

3. Connect the positive (+) lead from the battery to terminal 2 and the nagative (-) lead to terminal 1, check that
the motor turns counterclockwise (moves toward the close and down position).

4. Reverse the polarity, check that the motor turns clockwise (moves toward the up and open position).
If operation is not as specified, replace the motor.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof > Sunroof Relay >
Repair procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Sun Roof >
Sunroof Relay > Repair procedures

INSPECTION
1. Pull down the rear headliner.
2. Disconnect the sunroof switch side connector from the sunroof controller.

3. Inspect the connectors on the wire harness side from the controller, as shown in the table.
Connector

M97

M99

Tester
connection

Condition

Specified condition

1-Ground

Constant

Continuity

2-Ground

Sunroof switch is in the close position

Continuity

3-Ground

Sunroof switch is in the open position

Continuity

4-Ground

Constant

Battery voltage

6-Ground

Ignition switch ON

Battery voltage

7-Ground

Sunroof switch is in the tilted up position

Continuity

8-Ground

Sunroof switch is in the tilted down


position

Continuity

3-Ground

Constant

Continuity

1(+) ~ 2(-)

Apply the battery voltage to the terminal


No.1 and ground to terminal No.2

Motor turns clockwise

1(-) ~ 2(+)

Apply the battery voltage to the terminal


No.2 and ground to terminal No.1

Motor turns counter-clockwise

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24.04.2008

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console
> Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > console >
Repair procedures

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.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > crash pad > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > crash pad
> Repair procedures

REMOVAL AND INSTALLATION


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.

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For instructions on the removal of the air bag module and clock spring, refer to RT group.
6. The steering wheel mounting nut, and remove the steering wheel.

Tightening torque:
40~50 Nm (400~500 kgcm, 29.5~36.9 lbft)

7. Remove the 3 screws holding the steering column lower shroud and then remove the steering column lower
and upper shroud.

8. Disconnect the connectors and remove the multifunction switch (3 screws).

9. Disconnect the hood release cable and connectors from the cover. After removing the 2 screws, remove the
crash pad under cover of the passengercompartment.

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10. After loosening the 2 screws, remove the cluster housing.

11. After loosening the 4 screws, remove the cluster.

12. Open the ashtray. Insert a screw driver into the area between the center facia panel lower portion and
ashtray, and then pull out the center facia panel lower portion. Lift up the center facia panel with hand.

13. After disconnecting the switch connectors, remove the center facia panel.
14. Remove the audio mounting screws and the gauge mounting screws to remove the audio assembly.

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15. After loosening the 6 mounting screws shown in the illustration, remove the glove box.

16. Disconnect the glove box lamp connector and then remove the lamp.

17. Remove the main crash pad mounting bolts.

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18. Remove the crash pad.

19. Installation is the reverse of removal and connect all connectors securely.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior trim > Components and
Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior
trim > Components and Components Location

COMPONENTS

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior trim > Repair
procedures, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > interior
trim > Repair procedures

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.

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Tightening torque:
17~26 Nm (170~260 kgcm, 12~19 lbft)

2. Remove the rear seat back mounting bolts from the rear seat back.

Tightening torque:
17~26 Nm (170~260 kgcm, 12~19 lbft)

3. Remove the rear seat belt upper anchor mounting bolt.


4. Remove the rear sear back lower anchor mounting bolt and remove rear seat belt.

Tightening torque:
40~55 Nm (400~550 kgcm, 29~40 lbft)

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5. Remove the quarter inner trim mounting screws(4EA) from the quarter inner trim and remove the inner trim
assembly.

CENTER PILLAR TRIM


1. Remove the front seat belt upper anchor mounting bolt.

2. Remove the center pillar upper trim mounting screws. Remove the seat belt webbing guide mounting screws
and coat hook mounting screws fromthe center pillar upper trim.

FRONT PILLAR TRIM

REAR TRANSVERSE TRIM

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LUGGAGE BOARD CENTER TRIM

LUGGAGE BOARD FRONT TRIM

LUGGAGE SIDE TRIM


Remove the mounting screws from the luggage side trim.
Disconnect the trunk room lamp connector.

HEAD LINING
1. To remove the headlining, first remove the following parts :
(1) Rear seat cushion.
(2) Rear seat back.
(3) Rear seat belt upper anchor mounting bolt.
(4) Rear seat back lower side bracket.

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(5) Quarter inner trim.


(6) Front seat belt upper anchor mounting bolt.
(7) Center pillar upper trim.
(8) Front pillar trim.
2. Ramove the mounting screws from the over head console lamp.
Disconnect the over head console lamp.

3. Remove the mounting screws from the sunvisor.

4. Remove the mounting clips from the roof rear cover trim.

5. Remove the headlining mounting clips and remove the headlining.

6. Installation is the reverse of removal.

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TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior > windshield glass > Components
and Components Location, TIBURON(GK) > 2003 > G 2.7 V6 DOHC > Body (Interior and Exterior) > Interior >
windshield glass > Components and Components Location

COMPONENTS

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