Hyundai Tucson 2011 Service Manual Set – 2.0L & 2.4L

Each volume contains vehicle-wide repair information for its engine configuration, including 2WD and 4WD systems. Choose the volume that matches the engine, then follow the applicable drivetrain and equipment sections.

Transmission scope: Neither volume provides a complete internal transaxle overhaul procedure.

PDF Search, Chapter Bookmarks and Diagram Limits

Text and diagram access: Both files have searchable text and 17 embedded chapter bookmarks; labels within diagram images are not searchable. Some small connector numbers remain difficult to read when enlarged. Portions of the ESC circuit diagrams are clipped at the right edge.

The ZIP contains two printable PDFs totaling 2,577 pages. Each volume's 102-page fuel-system chapter is already included in its listed page count.

Engine, Driveline and Vehicle-System Repair

The following selected coverage highlights are a preview rather than a full contents list. Other topics include audio/AVN troubleshooting and windshield wiper/washer service.

• Engine repair: Step-by-step engine/transaxle removal, timing-chain service, cylinder-head and cylinder-block disassembly and reassembly, cooling-system refill and air bleeding, lubrication service, and intake/exhaust work.

• Transmission and driveline: A6MF1 valve-body, solenoid and speed/temperature-sensor service; manual-clutch inspection and bleeding; transfer assembly, propeller shafts, drive axles, hubs, rear differential, and both 4WD coupling designs.

• Brakes and chassis: Disc and parking-brake service, ABS/ESC/DBC diagnosis, electric power steering, suspension repairs, wheel alignment, and TPMS component procedures.

• Body and comfort equipment: Body dimensions, panel and glass replacement, smart key/push-button start, panoramic roof, power windows, back-view camera, A/C compressor service, and manual or dual climate controls.

• Factory setup: ECM VIN writing, key teaching where equipped, TCM learning, HECU/SRSCM variant coding, PODS re-zero, EPS absolute-steering-position calibration, and TPMS vehicle/VIN writing.

• Schematics and references: ECM input/output and terminal mapping, A6MF1 TCM connector functions, 4WD ECU harness terminals, ESC circuit diagrams, SRSCM circuits, and the smart-key unit schematic.

The depth of the repair procedures—and their reliance on Hyundai GDS, electrical test equipment, pressure gauges, lifting equipment, and specified service tools—makes the set best suited to professional technicians and experienced owners already comfortable with factory workshop information.

Engine Management and Fault Isolation

Engine-management coverage explains OBD-II driving, warm-up, and trip cycles; MIL logic; DTC structure; freeze-frame data; and readiness monitoring for catalysts, misfire, fuel control, cooling, oxygen sensors, and EVAP. ULEV and SULEV details are identified where they differ.

Sensor and actuator chapters pair circuit diagrams and connector locations with inspection methods and reference values for MAP, intake-air and coolant temperature, crank/cam position, throttle and accelerator position, oxygen sensing, fuel-tank pressure, injectors, purge control, CVVT, variable intake, and charge-motion systems.

Symptom charts connect starting, idle, stalling, surge, fuel-economy, knock, and refueling complaints to the relevant checks, helping trace a complaint through the appropriate circuit or component tests. Intermittent-fault checks address connectors, vibration, heat, and moisture.

Separate electrical sections cover starter-circuit troubleshooting, starter disassembly and inspection, and battery/charging-system tests.

Mechanical Repair Depth and Special Tools

The engine sections include bearing and valve inspection data, timing and sealing references, bolt-tightening sequences, and final checks. Component-location views accompany torque tables, capacities, pressure tests, inspection limits, alignment data, and electrical specifications.

Lubrication procedures distinguish the 2.0L oil pump from the 2.4L balance-shaft/oil-pump module. The latter is removed and installed as an assembly; internal disassembly is prohibited.

Named tools include Fuel Pressure Gauge 09353-24100, Fuel Pump Locking Ring Remover 09310-2S200, Timing Chain Tensioner Ratchet Holder 09240-2G000, and engine support fixtures 09200-2S000 / 09200-38001.

Transaxle Service and 4WD Build Breaks

The A6MF1 six-speed automatic section covers both engines, including unit removal/installation and fluid-level service. Manual-transaxle coverage pairs the 2.0L with the M5GF1 five-speed and the 2.4L with the M6GF2 six-speed; procedures cover external controls, fluid service, and unit removal/installation.

For 4WD vehicles, the manual separates the Intelligent Torque Controlled Coupling used through November 30, 2010 from the Direct Electro Hydraulic Actuator Coupling used from December 1, 2010. This distinction helps match coupling service and controller-learning information to the installed system.

The later coupling's handling cautions address loss of lifetime-fill fluid when tilted after dipstick removal and oil-seal damage during installation. Its replacement procedures include the required GDS clutch-learning reset.

Steering Calibration and SRS Cautions

EPS setup includes Hi-Scan Pro procedures for ASP calibration and EPS type recognition.

The steering-column and subframe cautions address clock-spring inner-cable damage if the steering wheel moves out of its centered, locked position. SRS warnings prohibit resistance testing at an airbag module.

Fuel-pressure, brake, refrigerant, and lifting work requires appropriate shop equipment and prior service experience.

Valve Clearance and Brake Disc Specification Preview

Valve inspection: For both Theta-II engines, standard cold valve clearances at 20°C (68°F) are 0.17–0.23 mm intake and 0.27–0.33 mm exhaust. The engine sections also provide separate inspection limits and tappet-selection data.

Brake variants: Standard front-disc thickness is 26 mm for 2WD and 28 mm for 4WD. The brake chapters pair these variant-specific specifications with disc-inspection and service procedures.