Hyundai Tiburon/Coupe 2000–2003 Service & Repair Manual

Hyundai Motor Company’s July 2001 Coupe/Tiburon shop manual covers the 1.6L Alpha DOHC I4, 2.0L Beta DOHC I4, and 2.7L Delta V6 configurations. The separately referenced Electrical Troubleshooting Manual, Pub. No. A2CE-EG18A, is not included.

PDF Bookmarks and Diagram Detail

Navigation and small labels: PDF text search is not available. Embedded bookmarks provide access to the main sections, but many topic bookmarks return to their section’s opening page. Small wiring labels require zooming.

Supplied as one printable 1,218-page PDF, including the foreword, section indexes, BCM troubleshooting section, and two blank pages.

Powertrain, Chassis, and Control-System Repair

The following selected topics preview the manual’s contents rather than reproduce its full index. Additional subjects include audio-system troubleshooting and seat-warmer checks.

• Engine repair: Engine/transaxle removal, cylinder-head and valve service, internal component inspection, timing-system work, cooling-system service, and lubrication-system repair.

• Fuel and engine management: Four-cylinder MFI and V6 Siemens EMS diagnosis, DTC charts, sensor and actuator checks, harness testing, and fuel-delivery repair.

• Clutch and transaxles: Clutch hydraulic service, automatic-transaxle pressure testing and electrical diagnosis, manual-transaxle removal, and six-speed internal overhaul procedures.

• Driveshafts and chassis: CV-joint repair, axle-hub service, front and rear suspension work, wheel alignment, and power-steering diagnosis and repair.

• Brakes and electronic controls: Disc-brake and parking-brake service, bleeding procedures, ABS fault isolation, and TCS/EBD operating and diagnostic information.

• Body and restraints: Glass, trim, doors, tailgate, sunroof, bumpers, and seats, plus SRS circuit diagnosis, airbag service, and disposal procedures.

• Body electrical and HVAC: ETACS and BCM tests, switch and connector checks, immobilizer diagnosis, and manual or full-auto heating and air-conditioning service.

The manual is written for service technicians at authorized Hyundai dealers and assumes access to the specified tools and diagnostic equipment.

Vehicle Identification and Workshop Reference

Hyundai’s factory group codes keep specifications, troubleshooting, and repair procedures with the relevant system. The identification pages show VIN and engine-number locations and explain engine-family markings, model-series labels, driver-side configuration, coupe-body identification, and restraint coding.

These identification details help establish the vehicle configuration before parts or procedures are selected. Component-specific torque tables, capacities, electrical test values, wear limits, clearances, and adjustment data accompany the repair material.

Engine Internals, Valve Gear, and Cooling

Step-by-step instructions cover complete engine/transaxle assembly removal, cylinder-head and camshaft service, cylinder measurement, piston and bearing inspection, and oil-pump repair. Compression-testing procedures and oil-pressure specifications support engine assessment.

Valve gear: The 2.0L mechanical-lash section includes valve-clearance inspection and shim-selection charts. The V6 uses hydraulic lash adjusters; its section addresses tappet-noise checks and adjuster bleeding or replacement rather than routine clearance adjustment.

Cooling material covers coolant-pump service, thermostat testing, radiator pressure checks, and cooling-flow diagrams. Timing-mark and belt-routing views distinguish the four-cylinder and V6 layouts.

Special-tool references include valve-clearance tool set 09220-2D000, camshaft oil-seal installer 09221-21000, valve-stem seal remover 09222-29000, and piston-pin remover/installer 09234-33001.

The alternator-belt adjustment section warns that excessive tension can damage the coolant-pump bearing or alternator.

Fuel, Ignition, and Electrical Diagnosis

The four-cylinder MFI and V6 Siemens EMS sections provide component-location views, connector checks, circuit tests, inspection charts, and code-specific fault trees. Fuel-delivery material covers pump and pressure checks, injector inspection, and fuel-rail service, including residual-pressure and injector-seal precautions.

Engine electrical chapters address ignition, alternator and starter testing, and cruise-control diagnosis. Emissions coverage includes crankcase ventilation, evaporative controls, and exhaust-emission systems.

Transaxle Diagnosis and Overhaul Limits

Automatic-transaxle coverage combines shift-pattern and road-test checks with solenoid and sensor testing, hydraulic-pressure diagnosis, TCM circuit diagrams, and removal/installation procedures. Symptom charts distinguish faults such as engagement delay, shift shock, poor acceleration, and failure to move.

The six-speed manual transaxle has section views and internal repair procedures for shafts, synchronizers, housings, reverse gears, and the differential, including shim and snap-ring selection.

Internal overhaul of the five-speed manual and automatic transaxles requires separate manuals, as stated at the opening of the transaxle section.

Chassis, Brakes, and Restraints

Chassis procedures cover clutch master and release cylinders, CV joints and driveshafts, front and rear hubs, trailing-arm bushing replacement, tire-wear diagnosis, and rear-wheel alignment. Steering material includes gear and pump service, pressure testing, and bleeding.

Driveshaft-removal cautions explain how excessive prying can damage transaxle oil seals and how pulling on the shaft can damage joint components.

Brake material includes caliper inspection, parking-brake repair, ABS hydraulic and external-wiring diagrams, HECU terminal checks, and scan-tool-assisted bleeding. The restraint section adds SRSCM connector data, DTC and circuit diagnosis, clock-spring inspection, pretensioner information, and driver/passenger airbag procedures.

Body Electronics and Climate Control

Body electrical coverage includes switch-continuity tables, connector and pin views, ETACS operating logic, instrument-cluster checks, and immobilizer fault diagnosis.

BCM troubleshooting: Hi-Scan (Pro) input/output monitoring and actuation tests help distinguish switch-input, module, wiring, and load faults. Function-specific flowcharts cover locks, key reminder, mirror folding, flashers, windows, lighting, defogging, wipers, and keyless entry.

HVAC chapters distinguish manual and full-auto systems. They include leak checks, refrigerant charging, compressor and receiver/drier service, self-diagnosis, fail-safe charts, blower and heater-unit repair, and control-circuit diagrams.

Engine/transaxle removal and under-vehicle repair require properly rated lifting and support equipment. The applicable factory precautions cover battery isolation, SRS handling, hot coolant, pressurized fuel, brakes, and refrigerant work.

Selected Valve-Clearance and Synchronizer Specifications

For the 2.0L mechanical-lash valvetrain, the valve-clearance section specifies 0.20 mm intake and 0.28 mm exhaust with engine coolant at 20°C. Shim-selection charts accompany the adjustment procedure.

The six-speed manual-transaxle service table lists 0.9–1.45 mm standard clearance between the third or fourth gear and its synchronizer ring, with a 0.7 mm service limit. The overhaul material relates internal measurements to shim and retaining-ring selection.