warning Hyundai Tiburon 2003 Workshop Manual

DO-IT-YOURSELF MAINTENANCE
6-6
35% 65%
40% 60%
50% 50%
60% 40%
Ambient
temperature
°C ( °F)
-15 (5)
-25 (-13)
-35 (-31)
-45 (-49)
Antifreeze
solutionWater Engine Coolant concentration
G050C01A-AAT
To Check the Coolant Level
The coolant level can be seen on the side of the
plastic coolant reservoir. The level of the cool-
ant should be between the "LOW" and "FULL"
lines on the reservoir when the engine is cold.
If the level is below the "LOW" mark, add
engine coolant to bring it up between "LOW"
and "FULL". If the level is low, inspect for
coolant leaks and recheck the fluid level fre-
quently. If the level drops again, visit your
Hyundai dealer for an inspection and diagnosis
of the reason.
G050D02A-AATTo Change the Engine Coolant
The engine coolant should be changed at those
intervals specified in the vehicle maintenance
schedule in Section 5.
CAUTION:Engine coolant can damage the finish of
your car. If you spill engine coolant on the
car, wash it off thoroughly with clean water.
1. Park the car on level ground, set the park-
ing brake and remove the radiator cap when
cool.
2. Be sure your drain receptacle is in place.
Open the drain cock on the radiator. Allow
all the engine coolant to drain from the
cooling system, then securely close the drain
cock.
3. Check Section 9 for the capacity of the
cooling system in your car. Then, following
the manufacturer’s directions on the engine
coolant container, add the appropriate quan-
tity of coolant to the radiator.
4. Turn the radiator cap counterclockwise with-
out pressing down on it, until it stops. This
relieves any pressure remaining in the cool-
ing system. And remove the radiator cap by
pushing down and turning counterclockwise.
Now fill the radiator with clean demineral-
ized or distilled water. Continue to add clean
demineralized or distilled water in small quan-
tities until the fluid level stays up in the
radiator neck.5. Replace the radiator and reservoir caps and
check to be sure the drain cocks are fully
closed and not leaking.
WARNING:The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper-
ate even when the engine is not running.
Use extreme caution when working near the
blades of the coolant fan so that you are not
injured by a rotating fan blade. As the en-
gine coolant temperature decreases, the fan
will automatically shut off. This is a normal
condition.
G060A01GK-AATSPARK PLUGS
YN60100A
V6 DOHC
Your engine was originally equipped with plati-
num-tipped spark plugs. Platinum-tipped spark
plugs will last longer than conventional type

DO-IT-YOURSELF MAINTENANCE
6-7
WARNING:It is recommended that the engine be cool
or cold when changing the spark plugs. If
the engine is hot, you could burn yourself
on the insulated connector, the spark plug
or the engine itself.
4. When preparing to remove the old spark
plug, guide the socket down over the spark
plug, being careful not to damage the ce-
ramic insulator.
5. To remove the old spark plug, turn the
wrench handle in a counterclockwise direc-
tion.
6. To install the new spark plug, guide the
socket down over the spark plug, being
careful not to damage the ceramic insulator.
G060C02GK
G060B01GK-AAT
Replacing the Spark PlugsThe spark plugs should be changed at the
intervals specified in the vehicle maintenance
schedule in Section 5 or whenever engine per-
formance indicates they should be changed.
Symptoms that suggest poor spark plug perfor-
mance include engine misfiring under load, loss
of fuel economy, poor acceleration, etc. When
spark plugs are replaced, always use spark
plugs recommended by Hyundai. The use of
other spark plugs can result in loss of perfor-
mance, radio interference or engine damage.
NOTE:When replacing the spark plug, always use
the genuine parts recommended.
Recommended Spark Plugs:
Type
RC10YC4(CHAMPION)
BKR5ES-11(NGK)
RC10PYPB4(CHAMPION)
PFR5N-11(NGK)Remark
G060C01GK-GETChanging the Spark Plugs
G060C01GK
You will find it easier to change spark plugs if
the engine is cold. Always change one spark
plug at a time. This helps avoid getting the wires
mixed up.
1. Remove the center (2.0 L) cover on the
engine rocker cover.
NOTE:It is recommended that the spark plugs (For
2.7L Engines) should be changed by an
authorized Hyundai dealer.
2. Using a clean cloth, remove any dirt that has
accumulated around the base of the spark
plug so it cannot fall into the cylinder when
the spark plug is removed.
3. To remove the spark plug cable, pull straight
up on the insulated connector, not the cable.
Pulling on the cable may damage the carbon
core conductor.
2.0L
2.7L
spark plugs and can be identified by blue lines
on the ceramic shell.
NOTE:Do not clean or regap platinum-tipped spark
plugs.

DO-IT-YOURSELF MAINTENANCE
6-9
G100B01A-AATTo Check the Manual Transaxle
Fluid Level
SSA6100B
Park the car on level ground with the engine off.
1. Using a wrench of the correct size, loosen
the oil filler plug by turning it counterclock-
wise and remove it with your fingers.
2. Use your finger or suitable tool to feel inside
the hole. The oil level should be at its bottom
edge. If it is not, check for leaks before
adding oil. To refill the transaxle or bring the
oil level up,add oil slowly until it reaches the
proper level. Do not overfill.
3. Replace the plug, screw it in with your fin-
gers and then tighten securely with the
wrench.
G090A01A-AATFILLING THE WASHER RESERVOIR
The washer fluid reservoir supplies fluid to the
windshield washer system.
A good quality washer fluid should be used to fill
the washer reservoir. The fluid level should be
checked more frequently during bad weather or
whenever the washer system is in more fre-
quent use.
The capacity of the washer reservoir is 3.2 U.S.
quarts (3.0 Liters).
CAUTION:o Radiator anti-freeze (engine coolant)
should not be used in the washer system
because it will damage the car’s finish.
o The washer lever should not be pulled
and the washer should not be operated
if the washer reservoir is empty. This can
damage the washer fluid pump.
Transaxle lubricant in the manual transaxle should
be checked at those intervals specified in the
vehicle maintenance schedule in Section 5.
Recommended OilUse only HYUNDAI GENUINE PARTS MTF
75W/90 (API GL-4) or equivalents in the manual
transaxle.
Manual Transaxle Oil CapacityThe oil capacity of the manual transaxle:
2.3 us quarts (2.15L)
WARNING:It is always better to check the transaxle oil
level when the engine is cool or cold. If the
engine is hot, you should exercise great
caution to avoid burning yourself on hot
engine or exhaust parts.
G100A02GK-AATCHECKING THE TRANSAXLE OIL
(MANUAL)
G110A01E
Filler plug
Drain plugHGK217

DO-IT-YOURSELF MAINTENANCE
6-10
While the engine is idling, apply the brakes and
move the gear selector lever from "P" to each
of its other positions — "R", "N", "D" — and
then return to "N" or "P". With the engine still
idling:
1. Open the hood, being careful to keep hands,
long hair and clothing clear of any moving
parts.
2. Remove the transaxle dipstick, wipe it clean,
reinsert the dipstick as far as it will go, then
remove it again. Now check the fluid level on
the dipstick. It should be in the "HOT" range
on the dipstick.
3. If the transaxle fluid level is low, use a funnel
to add transaxle fluid through the dipstick
tube until the level reaches the "HOT" range.
Do not overfill.G110A01A-AATCHECKING THE TRANSAXLE FLUID
(AUTOMATIC)
Transaxle fluid in the automatic transaxle should
be checked at those intervals specified in the
vehicle maintenance schedule in Section 5.
G110B03A-AATRecommended Fluid
Your Hyundai automatic transaxle is specially
designed to operate with HYUNDAI GENUINE
ATF, DIAMOND ATF SP-III or SK ATF SP-III.
Damage caused by a nonspecified fluid is not
covered by your new vehicle limited warranty.
G110C02Y-AATTransaxle Fluid Capacity
The fluid capacity of the automatic transaxle is
8.2 U.S. quarts (7.8 liters).
WARNING:The transaxle fluid level should be checked
when the engine is at normal operating tem-
perature. This means that the engine, radia-
tor, exhaust system etc., are very hot. Exer-
cise great care not to burn yourself during
this procedure.DOHC V6
HGK212 G110D02Y-AAT
To Check the Transaxle Fluid Level
HGK174
Park the car on level ground with the parking
brake engaged. When the transaxle fluid level
is checked, the transaxle fluid should be at
normal operating temperature and the engine
idling.
Fluid level should be within this range
HGK249

DO-IT-YOURSELF MAINTENANCE
6-11
G120C02A-AATRecommended Brake Fluid
Use only hydraulic brake fluid conforming to
DOT 3 or DOT 4 specifications in your braking
system. Follow the instructions printed on the
container.
G120D01A-AAT
To Check the Fluid LevelThe fluid level in the brake fluid reservoir should
be checked periodically. The level should be
between the "MIN" and "MAX" marks on the
side of the reservoir. If the level is at or below
the "MIN" mark, carefully add fluid to bring it up
to "MAX". Do not overfill.
G120E02A-AAT
Adding Brake FluidWARNING:
Handle brake fluid carefully. It can damage
your vision if it gets into your eyes. Use only
DOT 3 or DOT 4 specification fluid from a
sealed container. Do not allow the fluid can
or reservoir to remain open any longer than
required. This will prevent entry of dirt and
moisture which can damage the brake sys-
tem and cause improper operation.
To add brake fluid, first wipe away any dirt then
unscrew the fluid reservoir cap. Slowly pour the
recommended fluid into the reservoir. Do not
overfill. Carefully replace the cap on the reser-
voir and tighten.
G130A01S-AAT
CHECKING THE CLUTCH FLUID
To Check the Clutch Fluid
HGK215
HGK216
G120A01A-AATCHECKING THE BRAKES
CAUTION:
Because brakes are essential to the safe
operation of the car, it is suggested that
they be checked and inspected by your
Hyundai dealer. The brakes should be
checked and inspected for wear at those
intervals specified in the vehicle mainte-
nance schedule in Section 5.
G120B01A-AAT
Checking the Brake Fluid Level
WARNING:
Use caution when handling brake fluid. It
can damage your vision if it gets into your
eyes. It will also damage your vehicle’s paint
if spilled on it and not removed immediately.
WARNING:The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper-
ate even when the engine is not running.
Use extreme caution when working near the
blades of the cooling fan, so that you are not
injured by a rotating fan blade. As the en-
gine coolant temperature decreases, the fan
will automatically shut off. This is a normal
condition.

DO-IT-YOURSELF MAINTENANCE
6-12
G140B01A-AATChecking the Air Conditioning Opera-
tion
1. Start the engine and let it run at a fast idle for
several minutes with the air conditioning set
at the maximum cold setting.
2. If the air coming out of the in-dash vents is
not cold, have the air conditioning system
inspected by your Hyundai dealer.
CAUTION:Running the air conditioning system for
extended periods of time with a low refriger-
ant level may damage the compressor.
G140C01A-AAT
LubricationTo lubricate the compressor and the seals in
the system, the air conditioning should be run
for at least 10 minutes each week. This is
particularly important during cool weather when
the air conditioning system is not otherwise in
use.
G140D01A-AATChecking the Compressor Drive Belt
When the air conditioning is being used regular-
ly, the compressor drive belt tension should be
checked at least once a month with the engine
turned off.
To check the drive belt tension, press down on
the belt halfway between the engine crankshaft
and compressor pulleys. Pressing with your
finger, you should not be able to deflect this belt
anymore than 1/3 of an inch. If you have the
instruments to check it, with a force of 22 lb.
(98N), the deflection should be 0.315 inches
(approx 8.0 mm). If the belt is too loose, have it
adjusted by your Hyundai dealer. accumulation of dirt, dead insects, leaves, etc.
These can interfere with maximum cooling effi-
ciency. When removing such accumulations,
brush or hose them away carefully to avoid
bending the cooling fins.
G140D01GK
A/C
CRANK PULLEY
TENSION PULLEYG130B02A-AAT
To Replace the Fluid
Recommended brake fluid conforming to DOT
3 or DOT 4 specification should be used. The
reservoir cap must be fully tightened to avoid
contamination from foreign matter or moisture.
NOTE:Do not allow any other liquids to contami-
nate the brake fluid. Seal damage will result.
WARNING:Use caution when handling brake fluid. It
can damage your vision if you get it in your
eyes. It will also damage your vehicle’s paint
if spilled on it and not removed immediately.
G140A01A-AATAIR CONDITIONING CARE
Keeping the Condenser Clean
The air conditioning condenser (and engine
radiator) should be checked periodically for
The clutch fluid level in the master cylinder
should be checked when performing other un-
der hood services. The system should be
checked for leakage at the same time.
Check to make certain that the clutch fluid level
is always between the "MAX" and "MIN" level
markings on the fluid reservoir. Fill as required.
Fluid loss indicates a leak in the clutch system
which should be inspected and repaired imme-
diately. Consult your Hyundai dealer.
DOHC
V6
Auto
tensioner
Eng.pulleyCOMP 0.315 in.
(8 mm)

DO-IT-YOURSELF MAINTENANCE
6-16o Charge batteries only in a well ventilated
area.
o Do not permit flames, sparks or smoking in
the area.
o Keep children away from the area.
G220B01A-AATChecking Engine Cooling Fan
The engine cooling fan should come on auto-
matically if the engine coolant temperature is
high.
G220C01A-AAT
Checking Condenser Cooling Fan
The condenser coolant fan should come on
automatically whenever the air conditioning is
in operation.
G210B02A-AAT
Checking the BatteryKeep the battery clean. Any evidence of corro-
sion around the battery posts or terminals should
be removed using a solution of household bak-
ing soda and warm water. After the battery
terminals are dry, cover them with a light coat-
ing of grease.
PROPOSITION 65 WARNING:Battery posts, terminals, and related acces-
sories contain lead and lead compounds,
chemicals known to the state of California
to cause cancer and reproductive harm.
Wash hands after handling.
G230A03A-AATPOWER STEERING FLUID LEVEL
The power steering fluid level should be checked
regularly. To check the power steering fluid
level, be sure the engine is "OFF", then check
to make certain that the power steering fluid
level is between the "MAX" and "MIN" level
markings on the fluid reservoir.
HGK214 G220A01A-AAT
CHECKING ELECTRIC COOLING
FANS
WARNING:
The cooling fan is controlled by engine cool-
ant temperature and may sometimes oper-
ate even when the engine is not running.
Use extreme caution when working near the
blades of the coolant fan, so that you are not
injured by a rotating fan blade. As the en-
gine coolant temperature decreases the fan
will automatically shut off. This is a normal
condition.
G210A01A-AATCHECKING THE BATTERY
WARNING:
Batteries can be dangerous! When working
with batteries, carefully observe the follow-
ing precautions to avoid serious injuries.
The fluid in the battery contains a strong solu-
tion of sulfuric acid, which is poisonous and
highly corrosive. Be careful not to spill it on
yourself or the car. If you do spill battery fluid on
yourself, immediately do the following:
o If battery fluid is on your skin, flush the
affected areas with water for at least 15
minutes and then seek medical assistance.
o If battery fluid is in your eyes, rinse out your
eyes with water and get medical assistance
as soon as possible. While you are being
driven to get medical assistance, continue
to rinse your eyes by using a sponge or soft
cloth saturated with water.
o If you swallow battery fluid, drink a large
quantity of water or milk followed by milk of
magnesia, eat a raw egg or drink vegetable
oil. Get medical assistance as soon as
possible.
While batteries are being charged (either by a
battery charger or by the vehicle’s generator),
they produce explosive gases. Always observe
these warnings to prevent injuries from occur-
ring:

DO-IT-YOURSELF MAINTENANCE
6-17 manual used by dealership technicians and
while it is highly technical it can be useful in
obtaining a better understanding of your car
and how it works.
G260A02A-AATREPLACING HEADLIGHT BULBS
Before attempting to replace a headlight bulb,
be sure the switch is turned to the "OFF"
position.
The next paragraph shows how to reach head-
light bulbs so they may be changed. Be sure to
replace the burned-out bulb with one of the
same number and wattage rating.
CAUTION:Keep the lamps out of contact with petro-
leum products such as oil, gasoline etc.
NOTE:Grinding noise from the power steering
pump may be heard immediately after the
engine is started in extremely cold condi-
tions (below - 4°F). If the noise stops during
warm up, there is no abnormal function in
the system. It is due to a power steering
fluid characteristic in extremely cold condi-
tions.
Recommended Fluid
Use PSF-3 type fluid
NOTE:Do not start the engine when the power
steering oil reservoir is empty.
G240A01A-AAT
POWER STEERING HOSES
It is suggested that you check the power steer-
ing hose connections for fluid leakage at regular
intervals. The power steering hoses should be
replaced if there is severe surface cracking,
scuffing or worn spots. Deterioration of the
hose could cause premature failure.
G250A01A-AAT
FOR MORE INFORMATION ABOUT
YOUR HYUNDAI
If you desire additional information about main-
taining and servicing your Hyundai, you may
purchase a factory Shop Manual at your Hyundai
dealer's parts department. This is the same
G270A02A-GATHEADLIGHT BULB
Replacement instructions:
HGK225
1. Allow the bulb to cool. Wear eye protection.
2. Always grasp the bulb by its plastic base,
avoid touching the glass.
3. Disconnect the power cord from the bulb
base in the back of the headlight.
4. Remove the dust cover.
5. Push the bulb spring for removing the head-
light bulb.
6. Remove the protective cap from the re-
placement bulb and install the new bulb by
matching the plastic base with the headlight
hole. Install the dust cover after retightening
the bulb spring and reconnect the power
cord.
7. Use the protective cap and carton to dis-
pose of the old bulb.
8. Check for proper headlight aim.
WARNING:The halogen bulb contains gas under pres-
sure and if impacted could shatter, resulting
in flying fragments. Always wear eye pro-
tection when servicing the bulb. Protect the
bulb against abrasions or scratches and
against liquids when lighted. Turn the bulb
on only when installed in a headlight. Re-
place the headlight if damaged or cracked.
Keep the bulb out of the reach of children
and dispose of the used bulb with care.
High BeamLow Beam Turn signal Light

DO-IT-YOURSELF MAINTENANCE
6-18
G290A02GK-AATHEADLIGHT AIMING ADJUSTMENT
Before performing aiming adjustment, make sure
of the following.
1. Keep all tires inflated to the correct pres-
sure.
2. Place the vehicle on level ground and press
the front bumper & rear bumper down sev-
eral times. Place vehicle at a distance of 118
in. (3m) from the test wall.
3. See that the vehicle is unloaded (except for
full levels of coolant, engine oil and fuel, and
spare tire, jack, and tools).
4. Clean the head light lenses and turn on the
headlights (low beam).
5. Open the hood.
6. Draw the vertical line (through the center of
each headlight beam pattern) and the hori-
zontal line (through the center of each head-
light beam pattern) on the aiming screen.And then, draw the parallel line at 0.827 in.
(21 mm) under the horizontal line.
7. Adjust each cut-off line of the low beam to
the parallel line with a phillips screwdriver -
VERTICAL AIMING.
8. Adjust each cut-off line of the low beam to
the each vertical line with a phillips screw-
driver - HORIZONTAL AIMING.
WARNING:Horizontal aiming should be adjusted by an
authorized Hyundai Dealer.
G290B01GK-AATAdjustment After Headlight Assembly
Replacement
G290B01GK
Vertical
line
Cut-off line
Ground line Horizontal line
LW
H
H
"P"
0.827in.(21mm)
If the vehicle has had front body repair and the
headlight assembly has been replaced, the
headlight aiming should be checked using the
aiming screen as shown in the illustration. Turn
on the headlight switch.
Horizontal
aiming
G290A03GK
Vertical
aiming
Low Beam1. Adjust headlights so that main axis of light is
parallel to center line of the body and is
aligned with point "P" shown in the illustra-
tion.
2. Dotted lines in the illustration show the cen-
ter of headlights.
SPECIFICATION:"H"
Horizontal center line of headlights from ground:
Low Beam: 26.7 in. (679mm)
High Beam: 26.5 in. (672mm)
"W"
Distance between each headlight center :
Low Beam: 47.3 in. (1,202mm)
High Beam: 38.0 in. (966mm)
"L"
Distance between the headlights and the wall
that the lights are tested against : 118 in. (3,000
mm)

DO-IT-YOURSELF MAINTENANCE
6-19
Wattage
55/55
10
5
51
28/8
5
5
G280A02GK-AAT
Part Name
Head Light (High/Low)
Map Light
Front Position Light
Front Fog Light (If installed)
Front Turn Signal Light/ Side Marker
Front Door Edge Warning Light
Luggage Compartment Light No.
1
2
3
4
5
6
7No.
8
9
10
11
12
13Part Name
High Mounted Without spoiler
Stop Light With spoiler
Rear Side-Marker
CombinationTurn Signal Light
Stop/Tail Light
Back-up Light
License Plate LightWattage
2.4W (LED)
3.5W (LED)
5
27
27/8
27
5
51213346
HGK035A
117
82
(High)(Low)
10
911