2003–2005 Hyundai Tiburon GS, GT, and SE Factory Service & Repair Manual SET (P/N A2CE-EG18A)

This 26-file, 1,652-page PDF set combines the July 2001 Hyundai Coupe/Tiburon Shop Manual and Electrical Troubleshooting Manual with a separate Body Repair Manual. The ETM is identified as Pub. No. A2CE-EG18A, and the material remains divided into its original mechanical, electrical, body, HVAC, restraint, and collision-repair groups.

• Engine mechanical and fuel: Covers the 1.6L/2.0L DOHC inline-four and 2.7L V6, including engine removal, timing-system work, cylinder-head and valvetrain repair, lower-end inspection, cooling/lubrication service, fuel-pressure testing, and MFI/DTC diagnosis.
• Transaxle and driveline: Separates 5-speed manual, 6-speed manual, and F4A42 automatic variants, with clutch hydraulic service, transaxle removal/installation, automatic diagnosis and pressure testing, 6-speed internal repair, driveshaft/CV-joint work, and hub-bearing procedures.
• Electrical and BCM diagnosis: Includes Hi-Scan (Pro) BCM input/output monitoring and actuation tests for locking, key reminder, folding mirrors, flashers, power windows, timed lamps, auto lights, wipers, keyless entry, and the burglar alarm.
• Brakes, steering, and suspension: Covers master cylinder and booster repair, front/rear disc brakes, bleeding, parking-brake adjustment, ABS/EBD/TCS diagnosis, HECU checks, MacPherson-strut front and dual-link rear suspension service, and power-steering testing.
• Electrical diagrams: Provides schematics, component-location indexes, connector cavity/terminal views, and harness layouts for SRS, ABS/TCS, 2.0L/2.7L automatic-transaxle control, 1.6L/2.0L/2.7L MFI, manual/automatic HVAC controls, and power/ground distribution.
• Body, HVAC, and collision repair: Covers doors, glass, sunroof, trim, seats, bumpers, restraints, heater and A/C assemblies, structural dimensions, panel sectioning, welding, seam sealing, and corrosion restoration.

Coverage identification: The BCM diagnostic section is labeled HD Coupe 2002MY ALL. Vehicle-identification and specification material distinguishes 1.6L I4, 2.0L I4, and 2.7L V6 engines; 5-speed manual, 6-speed manual, and automatic transaxles; LHD/RHD layouts; and Standard, Deluxe (GL), and Super Deluxe (GLS) series coding. Match these identifiers to the car before purchase. Use the designated jacking points and safety stands before working beneath the vehicle.

Verifying engine and drivetrain specifications

The engine chapters cover compression and cooling-system checks, timing-belt removal/installation, cylinder-head and valvetrain repair, engine/transaxle removal, piston, connecting-rod and crankshaft inspection, oil-pump and water-pump service, intake/exhaust assemblies, and the related torque, clearance, wear-limit, lubricant, and capacity tables. Fuel-system coverage distinguishes Bosch management for the 1.6L I4 from Siemens management for the 2.0L I4; the 2.7L V6 has its own Siemens EMS and DTC section.

The transmission chapter states that full 5-speed manual and automatic transaxle overhaul procedures are provided in separate manuals. This set still covers specifications, troubleshooting, service adjustments, automatic-transaxle electronic and hydraulic tests, and removal/installation. Detailed internal transaxle disassembly and reassembly in this set applies to the 6-speed manual unit.

Navigating electrical and wiring diagrams

The ETM links schematic diagrams with component-location indexes and illustrations, connector configurations, and harness layouts. Indexes identify physical locations and page references; connector drawings show cavities, wire colors, and terminal numbers; harness views trace routing, in-line connectors, and splices.

The shop manual adds ignition, charging, starting, cruise-control, instrument, lighting, audio, immobilizer, and body-electrical tests. BCM diagnosis uses Hi-Scan (Pro) input/output monitoring and forced actuation; the chapter states that conventional BCM failure-code output is not provided.

Chassis, suspension, and brake setups

The suspension is identified as MacPherson strut at the front and dual-link at the rear. Coverage includes strut and spring disassembly, arms, stabilizers, hubs, bearings, tires/wheels, steering-column and rack service, power-steering pump and hose work, pressure testing, inspection, and adjustment data.

Brake material covers pedal and booster testing, master-cylinder overhaul, front and rear caliper service, brake lines, proportioning-valve testing, parking-brake work, conventional bleeding, ABS air bleeding with Hi-Scan (Pro), wheel-speed sensors, HECU terminal checks, fail-safe operation, hydraulic diagrams, and symptom/DTC charts.

Body structure, interior, and climate control

Body procedures cover hood, tailgate, and door adjustment; window regulators and latches; sunroof removal, reassembly, and initial adjustment; trim; windshield and tailgate glass; seats, belts, and bumpers. HVAC material includes refrigerant service and leak diagnosis, manifold-gauge use, compressor and shaft-seal work, condenser, evaporator/heater unit, blower, manual controls, and automatic climate-control diagnosis.

The body repair manual maps galvanized and high-strength steel panels, replacement-part boundaries, body dimensions, and structural sectioning for front side members, pillars, sills, quarter panels, rear floors, and rear members. It also covers weld methods, seam sealing, cavity wax, underbody coatings, and corrosion restoration. Tool tables identify the 09411-25000 clutch disc guide, 09793-21000 door-hinge adjusting wrench, and 09861-31100 windshield sealant cut-out tool.

Manual-specific repair cautions

The SRS retains backup power after battery isolation; beginning restraint or body work too soon can deploy an air bag. Electric welding without the required isolation can damage the ECM, TCM, ABS, and SRS control modules, and the body manual specifies MIG rather than gas welding for its panel repairs. During driveshaft removal, pulling on the shaft can dislodge joint components, tear a boot, or damage a bearing; the joint section also prohibits substituting another grease type.