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

The Shop Manual directs electrical troubleshooting to the ETM, which connects circuit diagrams with component locations, connector configurations, and harness routing. The body repair volume adds structural measurements and collision-repair procedures.

Transaxle overhaul coverage: Complete 5-speed manual and automatic transaxle overhaul procedures require separate manuals outside this set. The included transmission chapter provides diagnosis, service adjustments, removal/installation, and detailed internal repair procedures for the 6-speed manual transaxle.

PDF Files, Bookmarks and Wiring Detail

Text search and diagram access: Text search is unavailable in all 26 PDFs. Embedded bookmarks cover the main sections, although the separate BCM document has only contents-level entries. Small wiring labels require zooming to read comfortably.

The RAR download contains 26 printable English-language PDFs totaling 1,652 pages, arranged in the original section folders plus the body repair file. This total includes both one-page title/contents PDFs and the body volume’s seven section dividers and three blank pages.

Engine, Electrical and Collision Repair Coverage

The following selected contents outline the main workshop areas rather than reproduce the complete contents lists. Other topics include crankcase ventilation and evaporative-emission testing.

• Engine mechanical and fuel: Step-by-step timing-belt and cylinder-head procedures, engine removal, valvetrain repair, lower-end inspection, cooling/lubrication service, fuel-pressure testing, and MFI/DTC diagnosis.

• Transaxle and driveline: Clutch hydraulics, transaxle removal/installation, automatic diagnosis and pressure testing, 6-speed internal repair, driveshaft/CV-joint service, and hub-bearing procedures.

• Electrical and BCM diagnosis: Hi-Scan (Pro) input/output monitoring and actuation tests, plus ignition, charging, starting, cruise-control, instrument, lighting, audio, and immobilizer checks.

• Brakes, steering and suspension: Master-cylinder and booster repair, disc brakes, bleeding, parking-brake adjustment, ABS/EBD/TCS diagnosis, HECU checks, and suspension/steering service.

• Wiring diagrams: SRS, ABS/TCS, MFI, automatic-transaxle control, manual/automatic HVAC, and power/ground distribution schematics, supported by component locations, connector views, and harness layouts.

• Body and collision repair: Doors, glass, sunroof, trim, seats, bumpers, restraints, heater/A/C assemblies, structural dimensions, panel sectioning, welding, seam sealing, and corrosion restoration.

The Shop Manual and ETM were written for Hyundai dealer service technicians; the diagnostic procedures assume workshop knowledge, measuring equipment, and access to the specified tools.

Engine Inspection and Fuel-Management Differences

Mechanical coverage extends to piston, connecting-rod and crankshaft inspection, oil-pump and water-pump service, and intake/exhaust assemblies. Component-specific torque, clearance and wear-limit tables accompany compression checks, cooling-system tests, lubricant specifications, and capacity data.

The 2.0L valvetrain section explains mechanical lash-adjuster clearance checks and shim selection; the V6 section includes hydraulic lash-adjuster troubleshooting.

Fuel-system specifications distinguish Bosch management for the 1.6L I4 from Siemens management for the 2.0L I4. The 2.7L V6 has a separate Siemens EMS diagnostic section.

Transaxle Internals and Variant Selection

Six-speed repair material covers input/output shafts, synchronizers, reverse idlers, the differential, bearing C-rings, and adjusting shims. Automatic-transaxle service information includes brake end-play and differential-preload adjustments alongside electronic and hydraulic testing.

Identification material distinguishes LHD/RHD layouts and Standard, Deluxe (GL), and Super Deluxe (GLS) series coding. Match the engine, transaxle, steering layout, and installed systems before selecting a procedure.

Circuit Tracing, BCM and Immobilizer Service

Connector drawings identify cavities, wire colors, and terminal numbers; harness views show routing, in-line connectors, and splices. These references let a technician follow a circuit from its schematic to the corresponding connector and physical component.

BCM diagnosis addresses locking, key reminder, folding mirrors, flashers, power windows, timed lamps, auto lights, wipers, keyless entry, and the burglar alarm. It relies on input/output monitoring and forced actuation rather than conventional BCM failure-code output.

The body-electrical chapter also documents transmitter-code storage, immobilizer key teaching, user-password changes, ECM neutralization, and limp-home functions. Separate descriptions distinguish SMARTRA and stand-alone immobilizer systems.

Chassis, Brakes and Restraints

The MacPherson-strut front and dual-link rear suspension sections cover strut/spring disassembly, arms, stabilizers, and tire/wheel data. Steering procedures address the column, rack, pump, hoses, pressure testing, and adjustment.

Brake diagnosis adds proportioning-valve tests, wheel-speed sensors, HECU terminal checks, fail-safe operation, hydraulic diagrams, and symptom/DTC charts. Conventional bleeding and Hi-Scan (Pro) ABS air bleeding are covered separately.

Restraint material includes SRSCM and airbag-circuit diagnosis, clock-spring service, and pretensioner procedures. Use the designated jacking points and safety stands before working beneath the vehicle.

Body Fittings, Climate Control and Structural Repair

Body procedures include hood, tailgate and door adjustment; regulator/latch service; sunroof disassembly, reassembly and initial adjustment; and windshield/tailgate-glass work. Tool tables identify the 09411-25000 clutch disc guide, 09793-21000 door-hinge adjusting wrench, and 09861-31100 windshield sealant cut-out tool.

HVAC coverage includes refrigerant service, leak diagnosis, manifold-gauge interpretation, compressor clutch/pulley service, the condenser, evaporator/heater unit, blower, and manual/automatic controls. Automatic climate-control material includes self-diagnostic codes and sensor checks.

The collision volume identifies galvanized and high-strength steel panels, replacement boundaries, and structural sectioning for front side members, pillars, sills, quarter panels, rear floors, and rear members. Its repair methods specify MIG welding and address seam sealing, cavity wax, underbody coatings, and corrosion restoration.

SRS, Welding and CV-Joint Precautions

The SRS retains backup power after battery isolation, while welding current can damage ECM, TCM, ABS, and SRS modules without the prescribed isolation precautions.

Pulling on a driveshaft can dislodge joint components, tear a boot, or damage a bearing; the joint section also prohibits substituting another grease type.

A Preview of Engine Inspection Limits

For the 2.0L engine, the cylinder-block specifications list a standard bore of 82.00–82.03 mm and piston-to-bore fitting clearance of 0.02–0.04 mm for new parts.

The 2.7L V6 cylinder-head table distinguishes a maximum standard surface-flatness deviation of 0.03 mm from a service limit of 0.05 mm.