96 98 Civic

General
Information
Chassi s and Pai nt Godes .' .' ..' .....' ..' ..' .."
1-2
l denti fi cati on
Number Locati ons' ..' .' .
" 1
-2O
Warning/Caution
Label Locations
'..'..' 1-21
Under-hood
Emissions
Control Label ..........
......1' 25
Lift and Support Points
Li ft and Safety Stands .' ..".' ..' ..' .' .' .".'
1-21
Fl oor Jack
. . . . , . . . . . . . . . . . . . . . . . .
1' 28
Towi ng
' .' ....' 1-29
Chassis and
U.S. 1996 Model
Paint Codes
l2-door
Hatchback)
Vehicle ldentification Number
and Federal Motor Vehicle
Safety Standard Certification
Paint Code
COLOR
GY. l 6P
t - z
00001 2AG
2HG: HONDA OF CANADA
H: Al l i ston Pl ant, Ontari o, Canada
Destin.iions
D16Y7: 1600 SOHC 16-val ves
Sequenti al Mul ti port
Fuel -i nj ected Engi ne
A4RA: 4-speed Automati c Transmi ssi on
S40 : s-speed Manual Transmi ssi on
GY-16P
NH-503P
NH.583M
R-97
Mi dori Green Pearl
Granada Bl ack Pearl
New Vogue Si l ver Metal l i c
Roma Red
.\a
U.S. 1996 Model
{4-door
Sedanl
Saf ety Sta ndard Cortif ication
Paint Code
COLOR
B.73M
JHM EJ6 52*TS 000001
Lino, Body 8nd Engine Typ
EJ6: CIVIC 4-door/D l6Y7
EJ8: CIVIC 4-door/D'16Y8
Body Typo and Transmission Type
5: Sedan/s-speed Manual
3: DX with Ay'C
4: DX wi th ABS, EX
5: DX with ABS and A,/C
6: LX
7; LX with Ay'C
8: LX wi th ABS
9: LX with ABS and A,/C
Chck Digit
Model Year
T: 1996
L: East Li bertv. Ohi o Pl ant, U.S.A.
S: Suzuka Pl ant. Mi e Prefecture, Japan
D16Y7: 1600 SOHC 16-val ves Sequenti al
Mul ti pon Fuel -i nj ected Engi ne
D16Y8; 1600 SOHC VTEC 16-val ves Sequenti al
Mul ti port Fuel -i nj ected Engi ne
JAPAN: D16Y7. D16Y8
-
1300001-
U.S.A : D16Yt, D16Y8- 1500001-
S4C : s-soeed Manual Transmi ssi on
A4RA {U.S.A.) : 5000001-
S40. SaC
(JAPAN):
1000001-
Cycl one Bl ue Metal l i c
Cypress Green Pearl
Frost White
l sl and Coral Pearl
B-73M
G-82P
NH-538
NH-503P
NH-583M
R-95P
1- i
Chassis and Paint Codes
U.S. 1996 Model
(2-door
Coupe)
Safety Standard Certif ication
l HG EJ6 12* TL 000001
Lino, Body and Engina Typc
EJ6; Cl vl Cz-door/D16Y7
EJ7: Cl Vl C2-door/D16Y5
Body Type and Tranrmission Type
Chock Digit
Modol Year
T: 1996
L: East Li berty, Ohi o Pl ant, U.S.A.
3; OX with ABS, HX with ABS
4: DX with Ay'C, HX with Ay'C, EX
5: DX with ABS and Ay'C, HX with ABS
and A"/C EX with ABS
D16Y5: 1600 SOHC WEC-E 16-val ves
Dl 6Y7: 1600 SOHC 16-val ves
D16Y8: 1600 SOHC VTEC 16-val ves
JAPAN: D16Y5
-
1300001-
U.S.A. : D16Y7. D16Y8
-
15OOO01-
A4RA : 4-speod Automati c Transmi ssi on
S40, S4C: s-speed Manual Transmi ssi on
M4VA ; Conti nuousl v Vari abl e
Transmission
(CVT)
A4RA :5000001-
s40, s4c
M4VA: 1000001-
G-82P
NH.5O3P
NH-538
NH-583M
B-81
R.95P
Cypress Green Pesrl
Frosl Whi te
Mi l ano Red
l sl and Coral Pearl
Paint Code
COLOR
1- 4
G-82P
2HG EJ632*TH 000001
Line, Body and Engino Typs
Body Type and Transmission Type
Check Digit
Modol Ysar
T: 1996
a
CANADA 1996 Model l2-door Hatchbackl
and Canadian Motor Vehicle
Paint Code
COLOR
GY.16P
D16Y/
-
1700001
A4RA:,t-speed Automatic Transmission
S40 :s-soeed Manual Transmi ssi on
GY-T6P
NH-503P
NH.583M
R-97
Mi dori Green Pearl
Roma Red
1- 5
CANADA 1996 Model
(4-door
Sedan)
l HG EJ 653* TL 800001
Lino, Body and Engino Typ6
Body Typo and Transmission Typo
5; Sedan/s-soeed Manual
4; LX wi th ABS
6: EX
7: EX wi th ABS
Check Digit
Model Year
T: 1996
L: Esst Li berty, Ohi o Pl ant, U.S.A.
A4RA; 4-speed Automati c Transmi ssi on
S40 : 5-soeed Manual Transmi ssi on
A4RA: 5000001-
S40 : 1000001-
w
Saf ety Standard Gertif ication
Paint Code
COLOR
8.73M
.'rr
F'.i!
B-73M
G-82P
NH-503P
NH-538
NH-583M
Cypress Green Pearl
Frost White
1- 6
CANADA 1996 Model
(2-door
Coupel
1HG EJ6 12* TL 000001
Lins, Body and Engine Typa
EJ6: Cl Vl C2-door/D16\' /
EJ8: Cl Vl C2-doo./D16Y8
Body Typ6 and Transmi3sion Type
3: Si wi th ABS
5: DX wi th ABS
Chock Digit
Model Yeat
T: 1996
1600 SOHC 16-val ves
1600 SOHC WEC 16-valves
Sequenti al Mul ti pon
Transmission Number
Transmission l
A4RA I
s40, s4c:
Serial Numbor
A4RA :
s40, s4c:
Vehicle ldentif ication Number
Paint Code
COLOR
NH-538
A4RA
-
5000001
4-soeed Automati c Transmi ssi on
s-soeed Manual Transmi ssi on
G-82P
NH-503P
NH-538
NH-583M
R-81
R-95P
Cypress Green Pearl
Frost White
Mi l ano Red
lsland Coral Pearl
1-7
U.S. 1997 Model
(2-door
Hatchback)
Paint Code
a
2HG EJ6 32
*VH
1 00001
Type ol Vohicl
Lino, Body and Engino Typr
Body Typo rnd Tranrmission Typc
3: CX with Ay'C
4: DX
5: DX with Ay'C
6: DX wi th ABS
7: DX with Ay'C and ABS
Chcck Digit
Model Yoar
V; 1997
H; Al l i ston Pl ant, Ontari o, Canada
D16Y7i 1600 SOHC 16-val ves
A4RA: 4-sDeed Automati c Transmi ssi on
B4RA: 4-speed Automati c Transmi ssi on
A4RA: 600000'l-
B4RA: 6000001-
S40 : 1000001-
q
COLOR
NH.583M
NH.503P
NH.583M
Pg-l 4P
R-97
Dark Amethyst Pearl
Roma Red
1- 8
U.S. 1997 Model
l4-door
Sedanl
and Federal Motol Vehicle
Paint Code
COLOR
8.73M
JHM EJ6 s2*VS 000001
Lino, Body snd Engine Typo
EJ6: Cl Vl C4-door/D16Y/
Body Typo and Trsnsmission Type
5: Sedan/s-sDeed Manual
3: DX with Ay'C
4: DX wi th ABS, EX
5: DX with ABS and Ay'C
7: LX with Ay'C
8: LX wi th ABS
9; LX with ABS and Ay'C
Chock Digit
Modol Ycsr
V: 1997
L: East Li bertv, Ohi o Pl ant, U.S.A.
S: Suzuka Pl ant, Mi e Prefecture. Japan
H: Al l i ston Pl ant. Ontari o, Canada
Dl6Y/: 1600 SOHC l$valves Sequentisl
D16Y8: 1600 SOHC WEC 16-valves Sequential
JAPAN: D16Y7, D16Y8
-
2300001-
U.S.A. : D16Yt, Dl 6Y8
-
2500001-
A4RA : 4-soesd Automatic Transmission
B4RA : 4-spe6d Automatic Transmission
M4RA: 4-speed Automati c Transmi ssi on
S40 :s-speed Manual Transmi ssi on
A4RA
(U.S.A.)
: 6000001-
B4RA {U.S.A.) : 6000001-
M4RA UAPAN): 2000001-
S40
(JAPAN)
: 1000001-
Cypress Green Pesrl
Frost White
l nza Red
B.73M
G-82P
NH-538
NH-503P
NH-583M
R.96P
1- 9
Vehicle Grade
2: DX, HX
U.S. 1997 Model
(2-door
Coupe)
' t HG
EJ6 14* VL 000001
Manutaqturer, Make and
Type ol Vehicle
l HG: HONDA OF AMERICA
MFG, , I NC.
HONDA Passenger
vehi cl e
Line, Body and Engine Type
EJ6; Cl Vl C2-door/D16Y7
EJ8: Cl vl C2' door/D16Ya
Body Typ and Transmission Type
1: Coupe/s-speed
Ma nua I
2; Coupe/4-speed Automatic, CVT
Engine Number
Engine Type
D16Y5: 1600 SOHC WEC-E 16-val ves
D16Y8: 1600 SOHC VTEC 16-val ves
Serial Numbr
JAPAN: Dl 6Y5
-
2300001-
U.S.A. : D16Y7, D16Y8
-
2500001-
Transmission Number
Paint Gode
a
D16Y5
-
2300001
3: DX wi th ABS, HX wi th ABS
4: DX with A,./C, HX with A,./C. EX
5: DX wi th ABS and A,i C, HX wi th ABS
and A'lC, EX with ABS
Chsck Digit
Model Year
V: 1997
Factory Code
Serial Number
a
COLOR
A4RA
-
6000001
Transmission Type
A4RA : 4-speed Automati c Transmi ssi on
B4RA : 4-speed Automati c Transmi ssi on
M4VA: Conti nuousl y Vari abl e
Transmi ssi on {CVT)
Serial Number
A4RA : 6000001-
B4RA : 6000001-
S40 : 1000001-
M4VA: 2000001-
G-82P
NH.5O3P
NH-538
NH.583M
R-81
Cypress Green Pearl
Frost White
N4i l ano Red
t ,
1 - 1 0
G.82P
CANADA 1997 Model
(2-door
Hatchbackl
2HG EJ6 32
* VH
000001
Line, Body lnd Engin Typo
EJ6; Cl Vl C3-door/D16Y7
D16fr: 1600 SOHC 16-val ves
B4RA: 4-sDeed Automati c Transmi ssi on
S40 : s-sDeed Msnual Transmi ssi on
and Ganadian Motor Vehicle
Paint Code
COLOR
NH-503P
NH-503P
NH.583M
PB-74P
R-97
G.anada Bl ack Pearl
Dark Amethyst Pearl
Roma Red
1- 11
7
Chassis and Paint Godes
CANADA 1997 Model
(4-door
Sedan)
1HG EJ 653+VL 800001
Lino, Body and Engine Typs
EJ6: Cl Vl C4-door/Dl 6Y7
Body Type and TEnlmLrion Type
5: Sedan/s-soeed Manual
4: LX With ABS
5: LX with ABS and ly'C
7: EX with ABS
8: EX with ABS and !y'C
L: East Li bertv, Ohi o Pl ant, U.S.A.
D16\.t: 1600 SOHC 16-val ves
Fuel i ni ected Engi ne
84RA: 4-speed Automati c Transmi ssi on
S40 : s-sDeed Manual Transmi ssi on
B-73M
G.82P
NH-503P
NH-538
NH-583M
Cypress Green Pearl
Frost White
Safety Standard Certif ication
Paint Code
COLOR
B-73M
v-
1-12
CANADA 1997 Model
(2-door
Coupel
l HG EJ 6 12* VL 800001
Lino. Eody and Engins Type
EJ6: CIVIC 2-doorl D16W
EJ8: Cl Vl C2-door/D16Yg
Body Type lnd Tran3mission Type
3: Si wi th ABS
5: DX with ABS
6: OX with ABS and Ay'C
7: Si with ABS and Ay'C
L: East Liberty, Ohio Plant. U.S.A.
D16Y7: 1600 SOHC 16-vsl ves
D16Y8: 1600 SOHC WEC 16-val ves
44RA: 4-speed Automatic Transmission
A4RA: 6000001-
B4RA: 6000001-
S40 : 1000001-
Vehicle ldentif ication Numbel
Paint Code
COLOR
NH-538
Cypress Green Pearl
Granada Bl ack Poarl
Frost White
Mi l ano Red
G-82P
NH-503P
NH-538
NH-583M
R-81
1 - 1 3
U.S. 1998 Model
(2-door
Hatchbackl
Safety Standard Certif icataon
Paint Codo
2HG EJ6 32
*WH
1 00001
EJ6: Cl vl C3-door/D16Y7
Body Type and Transmission Typ
3: CX with Ay'C
4: DX
5: DX with Ay'C
6: DX with ABS
7: DX with Ay'C and ABS
Check Digit
Modl Year
W: 1998
H: Al l i ston Pl ant. Ontari o. Canada
B4RA; 4-speed Automati c Transmi ssi on
B4RA: 7000001-
S40 : 1000001-
NH.592P
NH-583M
PB-74P
R-97
Fl amenco Bl ack Pearl
Dark Amethyst Pearl
Roma Red
t
COLOR
NH.583M
{i"
1- 14
U.S. 1998 Model
(4-door
Sedanl
Vehicle ldentification Numbel
Paint Code
COLOR
8.73M
JHM EJ6 52* WS 000001
EJ6: CIVIC4-door/D16Y7
5: Sedan/5-speed Manual
3: DX with A"/C
4: DX Wi th ABS, EX
5: DX wi th ABS and Ay' C
7: LX with A,/C
8: LX wi th ABS
9: LX wi th ABS and Ay' C
S: Suzuka Pl ant, Mi e Prefecture, Japan
000001: JAPAN, U.S.A.
500001: CANADA
Engino Typ
D16Y/:
D16Y8;
' 1600
SOHC 16-val ves Sequenti al
1600 SOHC VTEC 16-vsl ves Squenti al
JAPAN: D16Y7. D16Y8
-
3300001-
U.S.A : D16Y7, Dl 6Y8
-
3500001-
84RA : 4-soeed Automati c Transmi ssi on
M4RA: 4-sDeed Automati c Transmi ssi on
S40 : s-soeed Manusl Transmi ssi on
B4RA
(U.S.A.)
: 7000001-
M4RA
(JAPAN):
3000001'
S40
(JAPAN)
: 1000001-
Cypress Green Pearl
Taffeta White
l nza Red Pearl
8.73M
NH-578
NH-592P
NH.583M
R.96P
1 - 1 5
I
Ghassis
and Paint
Codes
U.S. 1998 Model
(2-door
Coupe)
Vehicle ldentification
Number
and Fedoral
Motor Vehicle
Safety Stsndard
Certifi cation
1HG EJ6 12+WL 000001
Lin., Body and Engina Typo
EJ6: Cl Vl C 2-door/Dt 6y7
EJ7: Cl Vl C2-door/D16y5
EJ8: Cl Vl C2-door/Dt6y8
Body Type and Transmbsion Type
Chack Digit
Model Year
W: 1998
1:Coupe/s-speed
Manual
2: Coupe/4-speed Automatic. CVT
3: DX wi th ABS, HX wi th ABS
4: DX with !VC, HX with A,/C. EX
5; DX with ABS and Ay'C, HX with ABS
and Ay'C. EX with ABS
Engine Number
Engins Typ
D16Y5: 1600 SOHC VTEC-E t6-vatves
D16Yr: 1600 SoHC 16-val ves
Fuel -i nj ected
Engi ne
D16Y8: 1600 SOHC WEC l 6-vatves
Fuel -i nj ectd Engi ne
Serial Numbor
JAPAN: D16Y5
-
3300001-
U.S.A. : D16Y7, 016Y8
-
350OOO1-
Paint Code
D16Y5
-
3300001
COLOR
B4RA : 4-speed Automati c Transmi ssron
M4VA: Conti nuousl y Vari abl e
Transmi ssi on
(CVT)
B4RA; 7000001-
S40 : 1000001-
M4VA: 4000001-
NH-592P
NH-578
NH.583M
R-81
Cypress Green Pearl
Taffeta White
New Vogue Si l ver Metsl l i c
Mi l ano Red
1 - 1 6
G-82P
CANADA 1998 Model
l2-door
Hatchbackl
Vehicle ldentifi cation Numbsr
and Canadian Motor Vchicle
Srfoty Standard Certifi cation
Paint Code
COLOR
NH.592P
2HG EJ6 32
*WH
000001
Manufacturr. M!ke and
Typ ot V6hicle
MFG., INC.
HONDA Passenger
vehi cl e
Lins, Body 8nd Engino Typo
EJ6: Cl Vl C3-door/Dl 6Yt
Body Typo and Transmi$ion Typ6
3: Hatchbacld5-speed
Manual
4: Hatchbacl(4-speed
Automatic
Vchiclo G18d.
2: CX
3: CX-G
Chock Digit
Modol Yoar
W; 1998
Factory Codo
Sarial Number
B4RA: 7000001-
S40 : 1000001-
Fl amenco Bl ack Peafl
Dark Amethyst Pearl
Roma Red
1- 17
T
CANADA 1998 Model
(4-door
Sedan)
Manutacturei. Make and
Number
Type of Vehicle
MFG. , I NC,
HONDA Passenger
vehi cl e
JHM: HONDA MOTOR CO..
LTD.
HONDA Passenger
vehi cl e
Line. Body and Engine Type
EJ6: Cl Vl C4-door/Dl 6Y7
5: Sedan/s-speed Manual
6: Sedan/4-speed
Automati c
,
\-
2HG EJ6 53
+W
H 900001
Vehicle Grade
0: EX
3: LX
Transmission Number
Paint Code
4: LX wi th ABS
7: EX wi th ABS
8: EX with ABS and Ay'C
Chock Digit
Model Yoar
W: 1998
Factory Code
S: Suzuka Pl ant, Mi e Prefecture, Jaoan
Seri al Numb6r
800001-: JAPAN
900001-: CANADA
Number
COLOR
B-73M
t
Fuel i nj ected Engi ne
3750001-: U.S.A.
3700001-: JAPAN
B4RA
-
7000001
Transmission Type
B4RA : 4-speed Automati c Transmi ssron
M4RA: 4-speed Automati c Transmi ssi on
Ssrial Number
B4RA
(U.S.A.)
: 7000001-
M4RA
(JAPAN):3000001-
S40
(JAPAN)
: 1000001-
B.73M
G.82P
NH.592P
NH-s78
NH.583M
Cypress Green Pearl
Taffeta White
1 - 1 8
1HG EJ6 12
* W
L 800001
Line, Body and Engin Type
EJ6: Cl Vl C2-door/D16Y/
EJ8: Cl vl C2-door/D' 16Y8
Body Type and Tlansmission TyPe
Vehicle Grade
2: DX, Si
3: Si wi th ABS
5: DX wi th ABS
6: DX wi th ABS and AVC
7: Si wi th ABS and A,/C
Check Digit
Modsl Yoar
W: 1998
L: East Li bertv, Ohi o Pl ant. U.S.A.
a
CANADA 1998 Model
(2-door
GouPe)
and Canadian Motor Vehlcle
Safety Standard Gertification
Paint Code
COLOR
NH-578
Sequenti al Mul ti Port
D16Y8: 1600 SOHC WEC 16-val ves
D16Y7: 3750001-
D16Y8: 3780001-
S40 : s- speed Manual Tr ansmi ssi on
84RA: 7000001-
S40 : 1000001-
Cypress Green Pearl
Taffeta White
Mi l ano Red
G-82P
NH-592P
NH-578
NH.583M
R-81
1 - 1 9
ldentification Number Locations
V6hicl6 ldontif ication
Numbor l Vl N)
\_
t
Transmission
Numb6r
*:.,
Y- Numbl
1-20
Warning/Caution
Label Locations
C: DRIVER MOoULE DANGER
DANGER
EXPLOSIVE/FLAMMABLE
CONTACT WITH ACID, WATER OR HEAVY METALS SUCH
AS COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL
AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.
STORAGE TEMPERATURES MUST NOT EXCEED 2OO"F
{l(x}"CI, FOR PROPER HANDLING, STORAGE AND DISPOS.
AL PROCEDURES REFEi TO SERVICE MANUAI- SRS SUP-
PLEMENT.
POTSON
CONTAINS POISONOUS SOOIUM AZIDE AND POTASSIUM
NITBATE.
FIRST AID:
IF CONTENTS ARE SWALLOWED, INDUCE VOMMNG, FOR
EYE COI{TACT. FLUSIJ EYES w|TH WATER FOR 15 MINUIES.
IF GASES
(FROM
ACIO OR WATER CONTACI) ARE INHAI.ED,
SEEK FRESH AIR. IN EVERY CASE, GET PROMPT MEDICAL
ATTENNON.
KEEP OUT OF REACH OF CHILDREN.
A: CABLE REEL CAUTION A
REFER TO SERVI CE MANUAL FOR DETAI LED I NSTRUC.
noNs.
{cont' d)
1-21
a: DRIVER MODUTI WARNING
WARNING
THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN.
TALLY DEPLOYED, CAN SERIOUSLY HURT OR KILL YOU.
. DO NOT USE ELECTRICAL TEST EOUIPMENT OR PROB'
ING DEVICES,
THEY CAN CAUSE ACCIDENTAL DEPLOYMENT.
o NO SEnVICEABLE PARTS lNSlOE. DO NOT OISASSEM'
8t E.
. PLACE AIBBAG UPRIGHT WHEN REMOVED.
. FOIIOW SERVICE MANUAL INSTRUC'TIONS CAREFULLY.
Warning/Caution Label Locations
(cont' dl
'
Exc6m CANADA CX
E: SRS INFORMATION: U.S. modol {96, 9? mod.l)
cAunoN
TO AVOID SERIOUS INJURY:
. FOR MAXIMUM SAFEW PROTECNON IN ALL TYPES OF
CMSHES. YOU MUST ALWAYS WEAR YOUB SAFETY
BELT.
. DO NOT INSTALL REARWARD-FACING CHILD SEATS IN
ANY FRONT PASSENGER SEAT POSITION.
. DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THE
ANBAG.
. DO NOI PLACE ANY OBJECTS OVEn THE AIRBAG OR
BETWEEN THE AIRBAG ANO YOURSELF.
. SEE THE OWNER'S MANUAL FOR FURTHER INFORMA.
TION AND EXPLANATIONS.
. THE SRS MUST BE INSPECTED TEN YEARS AFTEN |l |s
INSTALLED.
. TTIE DATE OF INSTALLATION IS SIIOWN OF THE DRIV.
ER'S DOORJAMB,
E
=-+:
) F
W
(
o. E
l----_l
D: DRIVER INFORMATION: CANADA MODEI-
4!8q{Gt ALwAYs WEAR
youR
SEAT BELT
. THIS CAR IS EOUIPPED WITH A DRIVER AIRBAG AND A
FRONT SEAT PASSENGER AIFBAGT AS A SUPPLEMEN-
TAL RESTRAINT SYSTEM ISRSI.
. IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT.
U.S. mod.l 198 modell
WASNING
DEATH OR SERIOUS INJURY CAN
(rcCUR.
. CHI LDREN 12 AND UNDER CAN BE KI I -LED BY THE
AIRBAG.
. THE BACK SEAT lS THE SAFEST PLACE FOB CHILDREN.
. NEVER PUT A REAR. FACI NG CHI LD SEAT I N TI I E
FRONT.
. SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG.
. ALWAYS USE SEAT BELTS AND CHILD RESTRAINIS.
. THE SRS MUST BE INSPECTED TEN YEARS AFTER 1T IS
INSTALLED.
. THE OATE OF INSTALLANON IS SHOWN ON THE DRIV.
ER'S DOORJAMB.
1-22
F: ASSISTANT INFORMATIONT US MOOEL {96, 97 modell
AIRBAG SEE OTHER SIDE.
U.S. model 198 modell
AIRBAG WARNING
FLIP VISER OVER
G: STEERING COLUMN NOTICE
NOTICE
TO PREVENT SRS DAMAGE, REMOVE STEERING WHEEL
BEFORE REMOVI NG STEERI NG SHAFT CONNECTI NG
BOLT.
H: MONITOR CAUTION
NONCE
. NO SERVICEABLE PAFTS INSIDE.
. REFER TO SERVICE MANUAL FOR DETAILED INSTRUC.
TtoNs.
I: FRONT SEAT PASSENGER MODULE DANGER
DANGER
EXPLOSIVE/FLAMMABLE
CONTACT WITH ACID, WATER OR HEAVY METALS SUCH
AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM.
FUL AND I FRI TATI NG GASES OR EXPLOSI VE COM-
POUNDS. STOBAGE TEMPERATURES MUST NOT EXCEED
2OO"F I l OO"CI . FOR PROPER HANDLI NG. STORAGE AND
DI SPOSAL PROCEDURES REFER TO SERVI CE MANUAL,
SRS SUPPLEMENT.
POTSON
CONTAINS POISONOUS SODIUM AZIDE ANO POTASSIUM
NITRATE.
FIRST AID
IF CONTENTS ARE SWALLOWED, INDUCE VOMITING. FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR 15 MIN.
UTES, IF GASES IFROM ACID OR WATER CONTACTI ARE
INHALED, SEEK FRESH AIR IN EVERY CASE. GET PROMPT
MEDICAL ATTEiITION.
KEEP OUT OF REACI{ OF CHILDREN.
WARNING
THE AIBBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN.
TALLY OEPLOYED, CAN SERIOUSLY HURT OR KILL YOU.
o DO NOT USE El-ECTRICAL TEST EOUIPMENI OR PRO&
ING DEVICES.
THEY CAN CAUSE ACCIDENTAL DEPLOYMENT.
. NO SERVICEABLE PARTS INSIDE. OO NOT DISASSEM.
BLE,
. PLACE AIRBAG UPRIGHT WHEN REMOVEO.
. FOLLOW SERVICE MANUAL INSTRUCNONS CAREFULLY.
J: SRS WARNING IHOODI
SUPPLEMENTAI- RESTRAINT SYSTEM ISRSI
THI S VEHI CLE I S EOUI PPED WI TH DNI VER AND FBONT
SEAT PASSENGER AIRBAGS*.
ALL SRS ELECTRI CAL WI RI NG AND CONNECTORS ARE
COLORED YELLOW.
TAMPERING WITH, OISCONNECTING OR USING ELECTRI.
CAL TEST EOUIPMENT ON THE SRS WIRING CAN MAKE
THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIR.
ING OF THE INFLATOR.
WARNING
THE AIRBAG INFLATOR IS EXPLOSIVE ANO. IF ACCIDEN-
TALLY OEPI-OYED. CAN SERIOUSLY HURT YOU. FOLLOW
SERVICE MANUAL INSTRUCTIONS CAREFULLY.
'
Exc.et CANADA CX
f: PASSENGER AIRBAG CAUnON
U.S. rnodol 198 mod.l)
WARNING
CHILDREN CAN BE KILLED OR INJURED 8Y PASSENGER
AIRBAG.
THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12
AND UNDER, MAKE SURE ALL CHILDRN USE SEAT BELTS
OR CHILO SEATS.
(cont' d)
1-23
Warning/Caution Label Locations
(cont'd)
I
1-24
Under-hood Emissions Control Label
(19!16,
1997 modell
Emission Group ldentification
Example:
tsF COOUNI, USE 'o'EO SOLUTION
VACUUM HOSE ROUTING DIAGRAM
VEHICLE EMISSION CONTROL INFORMATION
ENGlrlE FAM|LY vHNl6vJcrcr D.SB-ACEME{T ls90.F}q? O0 CIVIC
EvApoMtrvt FAMrry vHNroTTByMAc
p:9
CATALYST
rwcHo2s{2)sFl
Hrr.n u stcv' ct MA\uAr ro' aDofl ror{A,
' N.oRMA
ro\. ff-Tl
TUN! LP CO\DNOIIS: ENGIN! AT NOFMAI OPFMTING TTM' EqA-U8!.
I I|rf '
ALt ACCESSoRTESTUq{Eo oFf,CooUNG FAN oFf,
TiANSMISSION IN NEUIML
N0 ollrEF aDJUSTT,TENTS NE!DEo.
oBD

CERTtftED
IOLESPEED
TMNSMISSION
12" l I3TDC
T!
e+l r r
_9.,.'
THIS VTHICLE CONFORMS IO U.S. EPA ANO SIAIE
OF CALIFO8NIA REGULAIIO1TS APPLICAELE TO 1997
MOOEL YEAN NEI1 MOTON VEHICIES.
ililulIl
CEBT]FICANON NtR 1
IN.USE NEA 1FUTL
112 nE-N2 H0N0A MOTO8 C0., tTD.
50ST {50 States}:
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALI FORNI A REGULATI ONS APPLI CABLE TO 1997
MODEL YEAR NEW MOTOR VEHICLES.
49ST
(49
States/Fodoral):
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1997 MODEL YEAR NEW MOTOR VEHI-
CAL
(Californis):
MODEL YEAR NEW PASSENGER CARS PROVI DED
THAT THIS VEHICLE IS ONLY INTRODUCED INTO COM.
MERCE FOR SALE IN THE STATE OF CALIFORNIA.
Engine and Evaporative Families
Engine Family: V HN 1 . 6 VJ GKGK
Model Ysar
T: 1996
V; 1997
Manufacturer
HN: Honda
Di3placomont
Clsss
V: Light Duty Vehicle/Passenger Car
Fuol Systsm and Numbsr of Valvo3
J: El ectroni c Sequenti al Mul ti pon Inj ecti on
(three
or more val ves per cyl i nder)
Fuol Typ
G: Gasol i ne
Standard
F; 49 or 50 States Ti er 1
K: 49 or 50 States Tier 1
1: Cal i forni a Ti er 1
2: Cal i forni a TLEV
3: Cal i forni a LEV
4: Cal i forni a ULEV
ModetYsar
T
T
T: 1996
|
V: 1997
]
Manutaqturer
Catalyst
E, F, G, H: Three Way Catalyst
OBD
K
-
T: OBD Equi pped
Evaporative Family:
HN: Honda
Storage System
1: Cani st er
Canirtor Wolking Caprcity lgrEmsl
Canister Contigurstion
A: Pl asti c Housi ng
(Cl osed
Bottom)
B: Pl asti c Housi ng {Open Eottom)
Ful System
Y: Fuel Inj ecti on
Fuel Tank
M: Metal
Standard
A: Current Evap
E: Enhanced Evap
Wild Card
V HN 1 077 BYMAC
(cont' d)
1-25
Under-hood Emi ssi ons Control Label
(1998
model l
(cont'd)
Emission Group ldentification
Example:
50ST {50 States):
CALI FORNI A REGULATI ONS APPTI CABLE TO I 998
MODEL YEAR NEW MOTOR VEHICLES.
49ST
(49
States/Fedral):
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHI.
LLEJ.
CAL
(Calilornial:
MODEL YEAR NEW PASSENGER CARS PROVI DED
THAT THIS VEHICLE IS ONLY INTRODUCED INTO COM-
MERCE FOR SALE IN THE STATE OF CALIFORNIA,
VEHICTE EMISSION CONTROL INFORIVIATION
STAT OF CAL TORNLA RECULATIONSAPPLICABLE
TO 1933 MOOELYEAR NEW TLFV PASSENGEfr
INTBOOUCEOINTO COMMERCE FOR SALE N TNE
CATALYST
two1r02s1?tEcR/sFt/0B0 | cEBTtF E0
VAIV LASH
NONDAMOTORCO LTD
1-26
Engine and Evaporative Families
L
Engine Family: W HNX V 01.6 JL2
Model Y6ar
W: 1998
Manutacturer
HNX: Honda
Type
V: Li ght Duty Vehi cl e/Passenger Car
Displacment
Sequence Charaqters
Evaporative Family:
Modl Year
0065 AAD
W: 1998
Manufacturar
HNX: Honda
Type
E: EVAP
Caniater Work Capacity lgrams)
Squonca Chrract6ls
WH N X E
Lift and Safety Stands
@
When heavy rear componnts such as suspension, ful tank, spar6 tir, hatch, and trunk lid ara to bo
romovod, placa
ldditional woight in the luggage rrea before hoisting. Whon substantial woight b ramovod from the r6a1
ot thc vohlcle, tha center of
gravlty
mty changa and can causs the vehiclo to tip forwsld on tho hoist.
NOTE:
. Si nce each ti re/whel assembl y wei ghs approxi matel y 30 l bs {14 kg). pl aci ng
the front wheel s i n the l uggage area can
assi st wi th the wei ght di stri buti on.
. Use the same support
poi nts
to support the vehi cl e on safety stands.
1. Pl ace the l i ft bl ocks as shown.
2. Rai set he hoi st af ewi nches
( cent i met er s)
andr ockt hevehi cl et obesur ei t i sf i r ml ysuppor t ed.
3. Rai se the hoi sttol ul l hei ght, and i nspect l i ft poi ntstorsol i d
support.
REAR SUPPORT POINT
(cont' d)
1- 27
l .
(cont'dl
Floor Jack
Set the parki ng brake and bl ock the wheel s that are
not bei ng l i fted.
When l i fti ng the rear of the vehi cl e, put the gearshi ft
lever in reverse
(Automatic
transmission/CW in
E
posi ti on).
Rai se the vehi cl e hi gh enough to i nsert the safety
stands.
Adj ust and pl ace the safety stands so the vehi cl e
wi l l be approxi matel y l evel . then l ower the vehi cl e
onto them.
Alway3 u3a safoty stand3 whcn working on 01 undol
anv vchiclo that b 3upportod by only a
iack.
Nover attompt to uso a bumper
iack
for lifting or
supporting tho vohicl.
Center the
jacking
bracket in the middle
of the
jack lift platform.
LIFT PLA
REAR:
Center the
jack
b. acket i n t he mi ddl e
of t he
j ack
l i f r pl at t orm.
k-
l l
1-28
Towing
It the vehi cl e needs to be towed, cal l a professi onal tow-
i ng servi ce. Never tow the vehi cl e behi nd another vehi -
cl e wi th
j ust
a rope or chai n, l t i s very dangerous,
Em6rgency Towing
There are three
popul ar methods of towi ng a vehi cl e:
Flat-bed Equipment
-
The operator loads the vehicle on
the back of a truck. This is the best way oftransponing the
vehi cl e.
Wh6d Lift Equipmont
-
The tow truck uses two pivoting
a.ms that go under the ti res
(front
or rear) and l i fts them
of f t he
gr ound. The ot her t wo wheel s r emai n on t he
ground,
Sling-typ6 Equipmnt
-
The tow truck uses metal cables
wi th hooks on the ends. These hooks go around parts of
the frame oJ suspensi on, and the cabl es l i ft that end of
the vehi cl e off the ground. The vehi cl e' s suspensi on and
body can be seri ousl y damaged i t thi s method of towi ng
is attemDted.
l f the vehi cl e cannot be transported by fl at-bed, i t shoul d
be towed wi th the front wheel s off the
ground. l f due to
damage, t he vehi cl e must be t owed wi t h t he f r ont
wheel s on the ground, do the fol l owi ng:
Manusl Transmi ssi on and CVT
. Rel ease the
parki ng brake.
.
Shi ft the transmi ssi on to neutral
(CVT
to
E
posi ti on).
Automati c Transmi ssi on
. Rel ease the parki ng brake.
. Start the engi ne.
. Shi ftto l pl
posi ti on,
then
E
posi ti on.
. Turn off the engi ne.
CAUTION:
. lmproper towing propantion will damsgo the trans-
mi3sion, Follow tho above
procodur x6ctly. It you
cannot 3hi ft the l ransmi ssi on 01 start th engi ne
(automltic
trsnsmissionl. your vhicl9 mu3t be trang
portod on a ffot-bd.
It is best to tow tho vshicls no farthol th.n 5{t mibs
(80
km), lnd kosp tho sped bdow 35 mph
(55
km/h).
Trying to lift or tow
your vehicle by ths bumpeB will
causa sorious damage. The bumpers are not d*ignod
to support tho vohicl6'3 weight.
1-29
Front:
Roar:
TI E OOWN HOOKS
TOWING
Specifications
Standards and Servi ce Li mi ts .............. 3-2
Desi gn Speci f i cat i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 5
Body Speci fi cati ons .......... 3-18
-
arlilil,r(rrr o
MEASUREMENT STANOARD {NEW}
SERVICE UMIT
Compressi on 250 rpm and wide open throttle
kPa
(kgf/cm', psi) Nominal
Mi ni mum
Maxi mum vari at i on
' 1, 270
{13. 0,
184)
930
(9.5, 135)
200 Q.0,2al
Cylinder h6ad Warpage
Hei ght
o*
- gs.or
ta.arr
-
r.66gt
0.05 {0.002)
Camshaft End
pl ay
Camshaf t -t o-hol der oi l cl earance
Total runout
Cam l obe hei ght D16Y7 l N
EX
D16Y5 I N
D16Y8 I N
Pri mary
Scondary
Pri mary
Mi d
Socondary
0. 05
-
0
0.050
-
0. 03
(0.
35.299
37.241
38.127
32. 193
38,784
36.774
38.211
37.065
38.008
. 15
(0. 002 -
0. 006)
0.089
(0.002 -
0.004)
001) max.
11. 3897)
11. 4678)
11. 5129)
i 1. 267 4l
11. 5269)
11. 4479)
11. 50681
11. 4592)
11. 4964)
0.5 {0.02)
0.15
(0.0061
0.04
(0.0021
Val ve cl earance
(Col d)
Val ve st em O. D.
Stem-to-guide clearance
I N
EX
I N
EX
I N
EX
0. 18
-
0. 22 {0. 007
-
0. 009}
0. 23
-
0. 27
(0. 009 -
0. 0111
5. 48
-
5. 19
(0. 2157 -
0. 2161)
5. 45
-
5. 46
(0. 2146 -
0. 2150)
0. 02
-
0. 05
(0. 001 -
0. 002)
0.05
-
0.08
(0.002 -
0.003)
iEi.rtnut
5.12 10.21341
0.08 {0.003)
0. 11
(0. 004)
widrh
St em i nst al l ed hei ght
I N
EX
I N
EX
0. 85
-
1. 15
(0. 033 -
0. 045)
1. 25
-
1. 55
(0. 049 -
0. 061)
53.17
-
53.61 12.093
-
2.112)
53. 17
-
53. 64
(2. 093 -
2. 112)
1. 6
(0. 063)
2. 0 {0. 079}
53.49 Q.1221
53. 89
(2. 122)
Vsl ve spri ng Free l engt h Dl 6Yt
D16Y5
D,I6Y8
I N
EX
I N
EX
57. 9
(2. 28)
56,512.221
57.9
(2.28)
58. 0
(2. 28)
58. 7
(2. 31)
Val ve gui de l . D.
I nst al l ed hei ght
I N
EX
I N
5. 51
-
5. 53
(0. 217 -
0. 218)
5. 51
-
5. 53
(0. 217 -
0. 218)
17 .45
-
18.35
(0.703 -
0.722)
18. 65
-
19. 15
(0. 734
-
0. 754)
5. s5
(0. 219)
5. 55 {0. 219}
Rocker arm Arm-to-shaft clearance I N
EX
0.0r7
-
0.050
(0.0007 -
0.0020)
0.018
-
0.054 10.0007
-
0.0021 )
0.08
(0.003)
0.08
(0.003)
Standards and Service Limits
Cylinder Head/Valve Train
-
Section 6
/
{ L
t r
3-2
Engine Block
-
Seaion 7
Engine Lubrication Soction 8
Uni t ot l engt h: mm
(i n)
MEASUREMET'lT STA]TDARD INEWI SERVICE UMIT
Cyl i nder bl ock Warpage of deck surface
Eore diameter
Bore taPer
Rbori ng l i mi t
0.07
(0.003)
max.
75.00
-
75.02
(2.953 -
2.954)
0. 10
(0. 001)
75.07
(2.956)
0. 05
(0. 002)
0. 5
(0. 02)
Pi st on Ski rt O. D. at 5 mm
(0. 2
i n)
from bottom of skirt
Cloa16nce in cylindor
Groove width {tor ring) Top
Second
oi l
7 4.940
-
7 4.990 t2.9520
-
2.95241
0. 010
-
0. 040 {0. 0004
-
0. 0016)
't.020
-
1.030
(0.0402 -
0.0406)
1. 220
-
1. 230
(0. 0480 -
0. 0484)
2. 805
-
2. 820
(0. 1104 -
0. 1110)
74.970
(2.9516)
0.05 {0.002)
1.05 {0.041)
1.2s
(0.049)
2.85
(0.112)
Pi sl on ri ng Ri ng-t o-groovecl earance Top
Second
0.035
-
0.060 {0.0014
-
0.0024)
0.030
-
0.055 {0.0012
-
0,0022)
0.13
(0.005)
0.13
(0.005)
Ri ng end gap Top
Second
oi l
0. 15
-
0. 30
(0. 006 -
0. 012)
0. 30
-
0. 45
(0. 012 -
0. 018)
0.20
-
0.70
(0.008 -
0.028)
0.60
(0.024)
0.70
(0.028)
0. 80
(0. 03r)
Pi st on pi n o.D.
Pin-to-piston clearance
18.994
-
19.000
(0.7478 -
0.7480)
0. 010
-
0. 022
(0. 0004 -
0. 0009)
Connect i ng
roo
Pin-to-rod interlerence
Small end bore diameter
Large end bore di amet er Nomi nal
End play installed on crankshaft
0.014
-
0.040
(0.0006 -
0.0016)
18. 96- 18. 98 {0. 746
-
0. 747}
48. 0
(1. 89)
0. 15
-
0. 30
(0. 006 -
0. 012) oro ro.o'tur
Crankshat t Mai n
j ournal
di amet er
Rod
i ournal
di amet er
Taper
Out-ot'round
End pl ay
Tot al runout
54. 976
-
55. 000
(2. 16, 14 -
2. 1654)
44.976
-
45.000 /.1.1701
-1.17171
0. 0025
(0. 0001)
m6x.
0. 0025
(0. 0001)max.
0. 10
-
0. 35
(0. 004 -
0. 014)
0. 03 {0. 001) max.
ooos to.ooort
0.005 {0.0002)
0.45 {0.018)
0.04
(0.002)
Bearings Mai n beari ng-t o-j ournal oi l cl earance
No. 1 and 5j ournal s
No. 2. 3 and 4j our nal s
Rod bearing-to-journ8l oil clarance
0.018
-
0.036 10.0007
-
0.00'14)
0. 024
-
0. 042
(0. 0009 -
0. 0017)
0.020
-
0.038
(0.0008 -
0.0015)
0.05
(0.002)
0.05
(0.002)
0.05
(0.002)
MEASUREMENT STANDARD
(NEW)
SERVICE LIM]T
Engi ne oi l Capaci t y f
(uS qt , l mp ql )
D16Y7
Dl6Y5, D16Y8
4. 3 (4. 5.
3. 8) t or engi ne overhaul
3. 6
(3. 8,
3. 2)f or oi l change. i ncl udi ng f i l t er
3. 3
(3. 5, 2. 9)f or
oi l change. wi t hout f i l t er
3.7
(3.9,
3.3) for engine overhaul
3. 3
(3. 5,
2. 9) f or oi l change, i ncl udi ng f i l t er
3. 0
(3. 2,
2. 6)I or oi l change, wi t hout f i l t er
Oi l
pump
lnner-to-outer rotor radial clearance
Pump housi ng-t o' out er rot or radi al cl earance
Pump housing-to rotor axial clearance
0.02
-
0.14
(0.001 -
0.006)
0.10
-
0.18
(0.004 -
0.007)
0.03
-
0.08
(0.001 -
0.003)
0.20 {0.008)
0.20 {0.008)
0.' 15
(0.006)
Rel i of val ve Pressure setting with oil temperature 176'F
(80'C)
kPa
(kg7cm,, psi) at idle
at 3,000 rpm
70
( 0. 7. ' 10) mi n.
340
(3. 5, 50)
mi n.
3-3
MEASUREMENT STAiIDARO INEWI
Radiator Engine coolant capacity ,
(US qt, lmp qt) Mll
i ncl udi ng engi n6, heat er, cool i ng
line and reservoir Nf
Rosorvoir capacity:
0. 41
(0. 42
US
qt , 0. 35l mp qt ,
CVT
4.2
(4.4,
3.7) tor overhaul
3.1
(3.3,
2.7) tor coolsnt change
D16Y/
4.1
(4.3,
3.6) tor overhaul
3. 0
(3. 2,
2. 6)t or cool ant change
D16Y8
4.3
(4.5,
3.8) for oveIhaul
3.2
(3.3,
2.8) for coolant change
4. 3
(4. 5,
3. 8)f or overhaul
3.2
(3.3,
2.8) tor coolant chango
Radiator cap Opening
pressure kPa
(kgf/cm'. psi) 93
-
123 {0. 95
-
1. 25, 13. 5
-
17. 8}
Thermostat Start to opening
'F
('C)
Ful l y open
' F
(' C)
valve lift al tully open
169
-
176
(76 -
80)
194
(90)
8. 0
( 0. 311mi n.
Cool i ng f an Thermoswitch
"ON"
temperature
Thermoswitch
"OFF"
t6mperature
. F
(. C)
"F
(.C)
'196
-
203
(91 -
95)
Subtract 5
-
15
(3 -
8) from actual
"ON"
temperatur
Cooling
-
Section 10
Fuel and Emission
-
Section 11
Clutch
-
Section 12
L i
L . r
ti."
MEASUREMENT STANDARD {i{EWI
Fuel pr6ssu16
regulator
Pressure with fuel
pressure regulator vacuum hose
disconnected kPa {kg7cm',
psi)
260
-
310
(2. 7 -
3. 2, 38
-
46)
Fuol t ank CaDacity /
(US qal , l mp gal ) 15
( 11. 9, 9. 9)
Engi ne ldle speed rpm
016Y5
D 16\.'
D16Y8
M/T
(neutral)
M or CVr
(E
or
E
position)
u.s.A. Canada u.s.A. Canada
670 r 50
670 I 50
670 I 50
750 r 50
750 i 50
700 I 50
700 r 50
700 f 50
750 + 50
750 r 50
l dl e CO % 0. 1 mx.
MEASUREMENT STA'{DAND INEW) SERVICE UMIT
Cl ut ch
pedal Pedal hei ght t o f l oo.
Stroko
Pedal pl ay
Disengaggment height to floor
t o carpet
165
(6
1/2)
130
-
140
(5
1,4
-
5 1/2)
12
-
21 l1t2
-
13t161
83 t3 r/4)
44
(1
3/4) min. Reterence
Clutch surfac6 runout 0.05 {0.002} max. 0.15
(0.005)
cl ut ch di sc Rivet head depth
Thickness
1.3
-
1.9 {0.05
-
0.07)
8.5
-
9.1 {0.33
-
0.36)
0.2
(0.01)
5.510.221
Pressure plat Warpage
Di aphragm spri ng f i ngers al i gnment
0.03
(0.001)
max.
0.6 {0.02} max.
0.15
(0.(X)61
1.0
(0.04)
3-4
Unit of length: mm
(inl
Manual Transmission Section 13
MEASUREMET'lT STANDAND INEWI SERVICE Ui T
Transmi ssi on oi l Capacity f
(US qt, lmp qt)
1. 9
(2. 0,
1. 7) f or overhaul
1. 8
(1. 9,
1. 6) f o. oi l changs
Mai nshaf t End pl ay .
Diameter of ball bearing contact arsa A
(Transmi ssi on
housi ng si ds)
Diameter of 4th, sth gear contact area B
Diameter of 3rd gear contact ar6a C
Diameter of ball bearing contac't area D
l Cl ut ch housi ng si del
Runout
0.r1-0.18
(0.004 -
0.007)
21.987
-
22.000
(0.8656 -
0.8661)
26.980
-
26.993
(1.0622 -
1.0627)
33.984
-
3..000 fi.3380
-
1.33861
25.917
-
25.990 11.0221
-
1.02321
0.02 {0.001) max.
Adjust
21.930
(0.8634)
26.930
(1.0602)
33.930 t1.3358)
25. 920
(1. 0205)
0.05
(0.002)
Mai nshaf t 3rd and
4th gears
t . D.
End pl ay
Thickness
3rd
4th
3rd
4th
39.009
-
39.025 {1.5358
-
'1.5364)
0.06
-
0.21 {0.002
-
0.008)
0.06
-
0.19 {0.002
-
0.007)
30.22
-
30.27 11.190
-
1.1921
30.' t2
-
30.17
(1.186 -
1.188)
39.07
(1.538)
0.33 {0.013}
0.31
(0.012)
30.15
(1.187)
30.05
(1.183)
Mainshaft 5th
gear
t.0.
End pl ay
Thickness
37 .009
-
37 .025 t1 .4510
-
1 .15711
0.06
-
0.19 {0.002
-
0.007)
24.42
-
28.17 t1 .119
-
1 .1211
37.07
(1.459)
0.31
(0.012)
28.35
(1.1161
Countershaft Diameter of needle b6aring contact area A
Diameter of 1st gear contact area B
Diameter ol ball bearing contact area C
Runout
30. 000
-
30. 015
(1. 1811 -
1. 1817)
35.98,1- 36.000
(1.4167 -
1.4173)
24.980
-
24.993
(0.9835 -
0.9840)
0. 02
(0. 001)
max.
29. 950 {1. 1791)
35. 930
(1. 4146)
24.930
(0.98151
0.05 {0.002)
Countershaft lst
gar
l .D.
End
play (When
tightened by lhe specifld torque)
Thi ckness
41.009
-
41.025 t1.6145
-
1.6152)
0.03
-
0.10 {0.001
-
0.004}
30.41
-
30.44
(1.197 -
1.198)
41. 07 {1. 617)
0.22 {0.009}
30. 36
(1. 195)
Countershaft 2nd
gear
t.D.
End play (When
tightened by the spocitid torque)
Thickness
44.009
-
44.025
(1.7326 -
1.7333)
0.04
-
0.12 {0.002
-
0.@5)
31.91
-
3' 1.96
(1.256 -
1.258'
44.07
(1.735)
0.24
(0.009)
31.85
(1.254)
Spacer col l ar
(Countershaft
2nd
gar)
LD.
o.D.
Lengt h
33.000
-33.0r0
fi.2992
-
1.2996)
38.989
-39.000
{1.5350
-
1.535,r)
32.03
-
32.06
(1.261 -
1.262)
33.04 fi .3011
3{'.93
(1.533)
32.01
(1.260t
Spacer collar
(Mainshaft
4th
and sth goar)
t.D.
o.D.
Length
4th
5rh
ath
5rh
27.002
-
27.012
(1.0631-
1.0635)
33.989
-
34.000
(1.3381 -
1.3386)
31.989
-
32.000
(1.2594 -
1.2598)
22.83
-
22.86 t0.899
-
0.9(X))
23.53
-
23.56 {0.926
-
0.928)
27.05 {1.065)
33. 93
(1. 336)
31. 93
(1. 257)
22.81
(0.898)
23.51
(0.926)
Reverse i dl er gear t.o.
Gear-to-revsrs6 gear shaft clearance
15. 016
-
15. 043 t 0. 59' 12
-
0. 5922)
0.032
-
0.077 {0.0013
-
0.0030)
15.08 {0.594)
0. r4
(0. 006)
Synchro ring Ring-to-gear clearance {Ring
pushed
against
gear) 0.73
-
1.'r8
(0.029 -
0.046) 0.4
(0.016)
Shitt fork Fork tinger thickness lstnnd
3rd/4th
Fork-to-synchro sleeve clea16nce
6.2
-
6.1 1O.211- O.2521
7.4
-
7.6
(0.291 -
0.299)
0. 35
-
0. 65
(0. 014-
0. 026) to roonr
Reverse shift fork Fork pawl groove width
Fork-to-revrse idler gear clarance
L-groove width
Fork-to-5th/reverse shift oic6 oin cl6a16nce
12.7
-
13.0
(0.50 -
0.5' l )
0.5
-
1.1
(0.020 -
0.043)
7.15
-
7.35
(0.281 -
0.289)
0.05
-
0.35
(0.002 -
0.014)
1. 8
(0. 07)
0. 5
(0. 02)
Shi f t arm A Inner diameter of shift arm C contact point
Shift arm A-to-shift arm C clearance
13. 05
-
' 13. ' t 3
(0. 514 -
0. 517)
0.05
-
0.23
(0.002 -
0.009) 0.35 {0.014}
Shift arm B Inner diameter of shift arm B shaft contact point
Shift arm B-to-shaft clearance
Shift arm B-to-shitt piece clearance
Diam6ter ot shift Diece contact Doint
13.973
-
14.000 {0.550r
-
0.5512}
0.013
-
0.070 {0.0005
-
0.0028)
0.2
-
0.5
(0.008 -
0.020)
12.9
-
13.0
(0.508-
0.512)
0. 16
(0. 006)
0.62
(0.02441
' t 2. 78
(0. 5031)
Fi nal dri ven gear Backl ash 0.07
-
0.130 {0.0028
-
0.0051) 0.180
(0.007r)
Differentielcarrier Pinion shaft boro diamter
Carrier-to-pinion shaft clearance
Driveshaft bore diameter
CarrieFto-driveshaft clearance
18.010
-
18.028
(0.7091 -
0.7@81
0.023
-
0.057 t0.0009
-
0.0022)
26.025
-
26.04s
(1.0246 -
1.0254)
0.045
-
0.086
(0.0018 -
0.0034)
o.ogu to.ooot
0.11 {0.006)
Di f f erent i al pi ni on
gear
Backlash
Pinion gear bore diameter
Pinion gear-to-pinion
shaft cl6aranca
0.05
-
0.15 {0.002
-
0.006}
18.042
-
' I8.066
{0.7103
-
0.7113)
0.055
-
0.095
(0.0021 -
0.0037) 0.15
(0.006)
Set ring.to-bearing orrter race 0
-
0.1
(0 -
0.004) Adjust with shim
3-5
-
ct l ; t t t t t t . l
MEASUREMENT STANDARO {NEWI
SERVTC UM]T
Transmi ssi on
f l u i d
Capacity f {US
qt, lmp q0
5. 9
(6. 2,
5. 2)t or overheul
2. 7 {2, 9, 2. 4}l or f l ui d change
Hydraul i c
pressure
(kgtcm', psi)
Line
pressure
at 2,OOo rpm in
E
or
E
position
830
-
880
(8. 5 -
9. 0, 120
-
130) 780
(8. 0, 110)
lst clutch
pressure at 2,000 rpm in
Pll
position
.2nd
clutch pressure at 2,000 rpm in
E
position 800
-
850
(8.2 -
8.7, 120
-
'124)
wi t h l i near sol enoi d connect or
disconnected
0 - 1 5 0
( 0 -
1 . 5 , 0 - 2 1 )
with linear solsnoid connected to
battery voltage
760
(7. 7,
110)
with linsar solenoid
connctor disconnected
150 { 1. 5, 21)
with linar solenoid
connected to baftory
voltage
3.d and 4th clutch
pressure at 2,000 rpm in
lQl
posi'
ti on
810
-
860
(8. 3 -
8. 8. 1' 18
-
125)
with linear solenoid connector
disconnected
0 - 1 5 0 ( 0 - 1 . 5 , 0 - 2 1 )
with linear solenoid connecled to
battery voltage
760
(7. 8,
11 1)
wi t h l i near sol enoi d
connector disconnocted
150
( 1. 5, 21)
with linear solnoid
connectecl to battery
voltage
St al l speed rpm
(Chck
wi t h vehi cl e on l evel ground) 2,700 2,550
-
2,450
Clutch Cl ut ch i ni t i al cl earance l st , 2nd
3rd, 4th
Clutch return spring free longth
{A4RA, B4RA Transmission) lst
2nd, 3rd, 4t h
(M4RA
Transmi ssi on) l st
2nd, 3rd, 4t h
Clutch disc thickness
Clutch
plate thickness lst
2nd, 3r d, 4t h
0.6s
-
0.85
(0.026 -
0.033)
0. 40
-
0. 60
(0. 016 -
0. 024)
32. 0
(1. 26)
30. 5 {1. 20)
31 .1 11.22)
30. 5
(1. 20)
1. 88
-
2. 00
(0. 074 -
0. 079)
1. 55
-
1. 65
(0. 061 -
0. 065)
1. 95
-
2. 05 10. 077
-
0. 081)
30, 0 { 1. 18)
2a.s t1.12)
29. 1
( 1. 1s)
28.5 fi .12)
Until grooves worn out
Discoloration
Clutch end
plate
thickness Mark 1
(A4RA,
B4RA Transmi ssi on) Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mark 8
Mark 9
2. 05
-
2. 10
(0. 081 -
0. 083)
2. 15
-
2. 20
(0. 085 -
0. 087)
2. 25
-
2. 30 {0. 089
-
0. 091)
2. 35, 2. 40
(0. 093 -
0. 094)
2.{5
-
2.50
(0.096 -
0.098}
2. 55
-
2. 60
(0. 100 -
0. 102)
2. 65
-
2. 70
(0. 104 -
0. 106)
2. 75
-
2. 80
(0. r08 -
0. 110)
2. 85
-
2. 90
(0. 112 -
0. 114)
Discoloration
I
I
l
I
Discoloration
Cl ut ch end pl at e t hi ckness Mark 1
{M4RA Transmi ssi on) Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mark 8
Mark 9
Mark 10
Mar k 1l
Mar k 12
Mark 13
Mar k 14
Mark 15
Mark' 16
Mark 17
Mark 18
2.3
-
2.4
(0.091 -
0.094)
2. 4- 2. 510. 094- 0. 098)
2. 5
-
2. 6
(0. 098 -
0. 102)
2. 6
-
2. 7
(0. 102 -
0. r06)
2. 7
-
2. 8
(0. 106 -
0, 110)
2. 8
-
2. 9
(0. 110 -
0. 114)
2. 9
-
3. 0
(0. 114 -
0. 118)
3. 0
-
3. 1
( 0. 118 -
0. 122)
3. 1
-
3. 2
(0. 122 -
0. 126)
3. 2
-
3. 3
(0. 126 -
0. 130)
2.0
-
2.1
(0.079 -
0.083)
2. r
, 2. 2 (0. 083 -
0. 087)
2. 2
-
2. 3
(0. 087 -
0. 091)
3. 3
-
3. 4 {0. 130
-
0. 134}
3. 4
-
3. 5 {0. 134
-
0. 138)
. 5
-
3. 6
(0. 138 -
0. 1421
3. 6
-
3. 7
(0. 142 -
0, 146)
3. 7
-
3. 8
(0. 146 -
0. 150)
Discoloration
Di scol orat i on
Automatic Transmission
-
Section 14
L {
L (
\-
3- 6
Automatic Transmission Section 14
uni t of l ngt h: mm
(i n)
MEASUREMEifl STANDAND NEWI SERVICE LIM]T
Transmi ssi on Diameter of needle bearing contsct arsa
on mainshaft stator shaft bearing
On mai nshaf t 2nd gear
On mainshaft 4th gear collar
On mai nshaf t 1st gear col l ar
On countershaft
(left
side)
On countershaft 3rd gear collar
On countershaft 4th gear
On countershaft r6verse gear collar
On countrshaft lst gear collar
On reverse idler gear shaft
lnside diameter of noodle bearing contact area
On mai nshaf t 1st gear
On mai nshaf t 2nd gear
On mainshaft 4th gear
on countershatt 1st gear
On countershaft 3rd
96ar
On countershaft 4th gear
On countorshaft reverse gear
On reverse idler gear
On stator shaft
(ATF pump sid)
On stator shaft
(stator
side)
Reverse idler gear shaft holder l.D.
End
pl ay
Mai nshat t 1st gear
Mai nshaf t 2nd gear
Mainshaft 4th gear
Countelshaft 1st gear
Countershaft 3rd gear
Countershaft 4th gear
Reverse idler gear
Countershaft reverse gear
Selector hub O.D.
Mainshaft 4th gear collar lngth
Mainshatt 4th gear collar flange thickness
Mai nshat t 1st gear col l ar l engt h
22.980
-
22.993
(0.9047 -
0.9052)
3s. 97s
-
3s. 991
(1. 4163 -
r. 4169)
31. 975
-31. 991 (1. 2589 -
1. 2595)
30.975
-
30.99'l
(1
.2195
-
1.2201l-
36. 004
-
36. 017
(1. 4175 -
1. 4180)
35. 980
-
35. 996
(1. 4165 -
1. 4172)
27. 980
-
27. 993
(1. 1016 -
1. 1021)
31. 975
-31. 991 (1. 2589 -
1. 2595)
31. 975
-
31. 99' ]
(1. 2589-
1. 2595)
13. 990
-
14. 000
(0. 5508 -
0. 5512)
35. 000
-
35. 016
(1. 3780 -
1. 3786)
41. 000
-
41. 0' t 6
(1. 6142 -
1. 6148)
38. 000
-
38. 016
(1. 4961 -
r. 4967)
38. 000
-
38. 016
(1. 4961 -
1. 4967)
41. 000
-
41. 016
(1. 6142 -
1. 61481
33. 000
-
33. 0r6
(1. 2992 -
r. 2998)
38. 000
-
38. 016
(1. 4961 -
1. 43671
18.007
-
18.020
(0.7089 -
0.7094)
29. 000
-29. 01311. 1411 -
1. 14221
27 .O00
-
27 .021
(1.0630 -
1.0638)
14. 416
-
14. 434
(0. 5676 -
0. 5683)
0.08
-
0.19 {0.003
-
0.007)
0. 05
-
0. 13
(0. 002 -
0. 005)
0. 075
-
0. 185
(0. 003 -
0. 0071
0.'1
-
0.5
(0.004 -
0.020)
0. 05
-
0. 17
(0. 002 -
0. 007)
0. 10
-
0. 18
(0. 004 -
0. 007)
0. 05
-
0. 18
(0. 002 -
0. 007)
0. 10
-
0. 25
(0. 004 -
0. 010)
5r. 87
-
51. 90
(2. 042 -
2. 0)
45. 00
-
45. 03 f l . 771
-
1. 773)
4. 435
-
4. 525
(0. 1746 -
0. 178' l )
27. 00
-
27. 15 {1. 063
-
1. 069}
Wear or damage
Wear or damage
Wear or damage
War or damage
wuu, o, du-"n"
Wear or damage
Countershaft distance collar length 38.87
-
38.90
38.92
-
38.95
38.97
-
39.00
39.02
-
39.05
39.07
-
39.'t 0
39. 12
-
39. 15
39.'17
-
39.20
39.22
-
39.25
39.27
-
39.30
1. 530
-
1. 5311
1. 532
-
! . 533)
1. 534
-
1, 535)
1. 536
-
1. 537)
1. 538
-
1. 539)
1. 540
-
1. 541)
1. 542
-
1. 543)
1. 544
-
1. 545)
1. 546
-
1. 547)
Countershaft 3rd gear collar length
'96, '97
models
'98
model
Countershaft reverss gear collar length
Countershalt reverse gear collar flange
thickness
Countershaft 1st gear collar length
Countershaft 1st gear collar flange thickness
21. 15
-
21. 20
(0. 833 -
0. 835)
20. 65
-
20. 70 {0. 813
-
0. 825)
14. 5
-
14. 6
(0. 571 -
0. 575)
2. 4
-
2. 6 {0. 094
-
0. 102)
14. 5
-
14. 6
(0. 571 -
0. 575)
2. 4- 2. 6 {0. 094
-
0. 102)
Wear or damage
Wear or damage
(cont' d)
3-7
Standards and ServiceLimits
Section 14 Automatic Transmission {cont'd}
MEASUREi'ENT STANDARD INEWI SERVICE UMIT
Taansmission Mainshaft 2nd
gar
thrust washgrthicknegs 3.97
-
4.00
(0.r56 -
0.157)
4. 02
-
4. 05
(0. 158 -
0. 159)
4. 07
-
4. 10
(0. 160 -
0. 161)
4. 12
-
4. 15
(0. 162 -
0. 163)
4. 17
-
4. 20
(0. 164 -
0. t 651
4. 22
-
4. 25
(0. 166 -
0. ' t 67)
4.27
-
4.30
(0.168 -
0.1691
4. 32
-
4. 35 {0. 170
-
0. 171}
4. 37
-
4. 1010. 172
-0. 1131
1.12
-
1.15 10.171-0.1751
Wear or damage
1
I
I
Wear or damage
Thrust wash6r thickngss
Mainehsfl ball boaring loft side
Mainshaft 1st gear
Counte6haft 3rd gar splined washer
'96, '97
models
'98
model
2.95
-
3.05
(0.116-
0.120)
2.
-
2.50
(0.096-
0.098)
4.15
-
4.50
(0.175 -
0.177)
4.95
-
5.00
(0.195 -
0.197) ;""i":,":","
One-way clutch contact area
Countershaft lst gea. l.D.
Parking gear O.D.
Mainshaft leed
pipe
A, O.D.
(at
15 mm
(0.59
in) trom
end)
Mainshaft foed
pipe
B. O.D.
(at
30 mm {1.2 in)trom end}
Countershaft feed pipe
O.D. {at 15 mm
(0.59
in}trom
ndl
Mainshatt sealing ring thickness
( 29
mm ( 1. 1
i n) and 35 mm
( 1. 4
i n) )
Mai nshaf t bushi ng l . D.
Mai nshaf t bushi ng l . D.
Couni6rhaft bu6hing l.D.
Mainshaft sealing ring goovo widlh
83.339
-
83.365 {3.2810
-
3.282r)
66.685
-
66.698
(2.6254 -
2.6259)
8.97
-
8.98 t0.353
-
0.354)
5.97
-
5.98
(0.2350 -
0.2354)
7.97
-
7.98
(0.3138 -
0.3142)
1.87
-
r.97 {0.074
-
0.078)
6.018
-
6.030
(0.2359 -
0.2374)
9.000
-
9.015 {0.3543
-
0.3549)
8.000
-
8.015 {0.3150
-
0.3156t
2.025
-
2.075
(0.0797 -
0.04171
Wear or damage
Wsr or damag
8.95
(0.3s2)
5.95
(0.234)
7. 95
(0. 313)
1. 80 {0. 071)
6.045
(0.2380)
9.03
(0.356)
8. 03
(0. 316)
2.08
(0.082)
Rogulstor
valve body
Sealing ring contact argo LD. 35.000
-
35.025 t1.3780
-
1.3782) 35. 050
(1. 3799)
Shifting device and
parking br6ke con-
trol
Reverse shift fork finger thickhoss
Parking brako
pawl
Parking ggar
5.90
-
6.00
(0.232 -
0.236) s.40 {0.213}
lWear
or other defect
Servo body Shift fork shaft bore l.D.
Shift tork shaft valvo bore i.D.
14. 000
-
14. 010 {0. 5512
-
0. 5516)
37.000
-
37.039
(1.4567 -
1.4582) 37. 045 {1. 4585}
ATF pump
ATF pump gear side clearance
ATF pump gear-to-body
clearance Drive
Drivan
ATF pump driven gesr
l.D.
ATF pump driven gar shaft O.D.
0.03
-
0.05 {0.00t
-
0.002)
0.r050
-
0.1325 {0.0041
-
0.0052}
0.0350
-
0.0625
(0,00'14 -
0.0025)
14.016
-
14.034 {0.5518
-
0.5525}
r3.980
-
13.990
(0.5504 -
0.5508)
0.07
(0.003)
Wear or damage
Wear or damage
Differsntla I
cat not
Pinion shaft contact aroa l.D.
Carier-to-pinion cle616nc6
Driveshaft contscl 8re LD.
Carrier-to-driveshatt cloaranco
18, 010
-
18. 028 {0. 7091
-
0. 7098)
0.023
-
0.057
(0.0009 -
0.0022)
26. 02s
-
26. 045 {1. 0246
-
1. 0254)
0.045
-
0.086 {0.00r8
-
0.0034}
0. 1
(0. 004)
0. 12 {0. 005)
Diffsrential
pi ni on gear
Eacklash
l .D.
Pinion gear-to-pinion shrftclearance
0.05
-
0.15 t0.002
-
0.006)
18.042
-
18.066
(0.7103 -
0.7113)
0.055
-
0.095
(0.0022 -
0.0037) o"r to.ooot
Set ring-to-bsaring out6r race clearance 0
-
0.15 {0
-
0.006} Adjusr
L
-
Seqtion ltt
MEASUREMENT
cw Sostion 14
STANDARD
(NEWI
Uni t ot l engt h: mm {i n)
87. 8
(3. 4s7)
44. 0
(1. 732)
30. 3
(1. 193)
35. 0
(1. 378)
33. 8
(1. 331)
33. 8 { 1. 331)
37. 1 { 1. 461)
34. 8 {1. 370)
4' 1. 3
(' 1. 626)
57 .0 t2.2441
57 .0 12.2441
89.1 {3.508)
51. 6 {2. 031)
a1 .0 13.4251
39. 0
(1. 535)
89. 3
(3. 5161
20. 7 {0. 815)
35. 1
(1. 382)
68. 0
(2. 677)
73.7 12.9021
80. 7
(3. r77)
38. 0
(1. 4961
37. 5
(
1. 4751
52. 1 {2. 051)
12. 2 {0. 480)
47. 211. 858)
36. 4
(1. 433)
16. 5
1 1 . 0
1. 9
10. 9
8, 2
13. 4
22. 0
26.8
26.8
13. 8
14.2
2. 9
15. 6
6. 1
2. 4
13. 9
32. 0
45.8
14. 1
21.6
20.4
5. 5
18. 3
19. 5
1.8
(0.071)
1. 8
( 0. 071)
4.5
(0.177)
1.4
(0.055)
1.0
(0.039)
1.0
(0.039)
1.1 {0.043)
0.7
(0.028)
0.9 {0.035)
0.9
(0.03s)
0.9
(0.035)
2.1
(0.083)
2.3
(0.09r)
2.6
(0.102)
2.4
(0.094)
2.8
(0.110)
1.6
(0.063)
2.2
(0.087)
2.210.0811
0.9 {0.035)
0.9
(0.035)
0.7
(0.028)
0.7
(0.028)
1.0
(0.039)
0.6
(0.024)
0.9
(0.035)
0.9
(0.0351
14. 7
(0. 584)
9. 6
(0. 381)
35. 4
(1. 407)
9. 4
(0. 374)
8. 4
(0. 334)
8. 4 {0. 334)
8. 6 {0. 342)
6. 6
(0. 262)
7. 6 {0. 302)
7. 6 {0. 302)
7. 6
(0. 302)
16. 0 {0. 636}
r0. 2 {0. 402}
r7. 0
(0. 676)
29. 0
(1. 152)
17. s
(0. 695)
9. 0
(0. 3s8)
3r . 0 11. 220)
14. 5 {0. 576}
7. 610. 3021
8. 1
(0. 3' 19)
6.6
(0.262)
6. 6
(0. 262)
8. 1
(0. 322)
5. 6
(0. 223)
8. 1
(0. 322)
6.1t0.2421
Spri ngs Regulator valve spring A
Regul at or val ve spri ng B
Stator reaction spring
Modul at or val ve spri ng
Torque convoner check valve spring
Cool er rel i ef val ve spri ng
Reliel valve spring
2nd orifico control valve spring
1-2 shift valve spring
2-3 shi f t val ve spri ng
3-4 shift valve spring
1st accumulator spring
4th accumulator spring B
4t h accumul at or spri ng A
2nd accumul al or spri ng A
3rd accumul at or spri ng A
2nd accumul at or spri ng I
3rd accumulator spring B
2nd accumul at or spri ng C
Lock-up shilt valve spring
Lock-up timing v6lv6 spring
Lock-up cont.ol valve spring
3-4 orifico controlvalve spring
Servo control valve 6pring
CPC valve spring
CPB valve spring
MEASUBEMENT STANDABD INEWI SERVICE LIMIT
Transmiasion
f l ui d
Capacity f
(US qt.
lmp.
qr)
6.4
(6.8,
5.6) for overhaul
3. 9 {4. 1, 3. 4) f or f l ui d change
Hydraul i c
pressure
MPa
(kg7cm,, psi)
Forward clutch
prssure at 1,500 rpm in
Lql
position 1. 4
-
1. 75 114. 3
-
17. A. 203
-
2531
Reverse brake
pressur
at 1,500 rpm in
El
position 1 .4
-
1 .7 5 114.3
-
17 .8, 203
-
2331
Drive
pulley pre$ure at 1,500 rpm in
E
position
0. 2
- 0. 7
12. 0
- 1. 1, 28 -
1011
Drivgn pulley pressure at 1,500 rpm in
Lll
position 1. 5
-
2. 3
(15. 3 -
23. 5. 218
-
334)
Lubrication pressure at 3.000 rpm in
E
position Above 0. 2
(2,
30)
Stall sp6d rpm {Ch6ck with vehicle on levsl ground)
E
position
E, E, B
posi t i ons
2,500
3,000
2.350
-
2,650
2, 800
-
3, 100
Clutch Clutch initisl clearance Forward clutch
Start clutch
Reverse brake
Clutch return spring lree length Forward clutch
Start clutch
Reverse brake
Clutch disc thicknss Forward clutch
Stan clutch
Rovers brake
Clutch plate thicknss Forward clutch
Start clutch
Roverse brake
0. 6
-
0. 8
(0. 024 -
0. 031)
0. 5- 0. 7 {0. 020
-
0. 028)
0. 45
-
0. 75
(0. 018 -
0. 030)
30. 5
( 1. 201)
40. 9 {1. 6' t 0)
29.4 t1.1571
1. 88
-
2. 00 {0. 074
-
0. 079)
1. 88
-
2, 00
(0. 074 -
0. 079)
1. 94
-
2. 06 {0. 076
-
0. 081}
1. 95
-
2. 05
(0. 077 -
0. 081)
2. 25
-
2. 35 {0. 089
-0. 093}
1. 90
-
2. 00
(0. 075 -
0. 079)
28.5 t1.122)
38. 9
(1. 531)
27 .4 11.O79J
Until grooves worn out
Unt i l
grooves worn out
Oiscoloration
Discoloration
Discoloration
(cont' d)
3- 9
MEASUREMENT STANDARD IiIEW} SERVICE LMTT
Clutch Forward clutch end piate thickness Mark 1 or 15
vl ark 2 or' 16
Mark 3 or 17
Mark 4 or 18
Mark 5 or 19
Mark6 or 20
Mar k7 or 2l
Mark 8 or 22
N4ark 9 or 23
Mark 10 or 24
Mark 11 or 25
Msrk
'12
or 26
Mark 13 or 27
3. 4
-
3. 5
(0. 134 -
0. 138)
3. 5
-
3. 6
(0. 138 -
0. 142)
3. 6
-
3. 7
(0. r42 -
0. r46)
3. 7
-
3. 8
(0. 146 -
0. 150)
3. 8
-
3. 9
(0. 150 -
0. 1s4)
3. 9
-
4. 0 {0. 154
-
0. 157)
4. 0- 4. t
( 0. 157 -
0. 161)
4. 1
-
4. 2
(0. 161 -
0. 165)
4. 2
-
4. 3 {0. 165
-
0. 169}
4. 3
-
4. 4
(0. 169 -
0. 1731
4. 4
-
4. 5
(0. 173
-
0. ' 177)
4. 5
-
4. 6
(0. 177
-
0. r81)
4. 6
-
4. 7
(0. r81 -
0. 185)
Disco
Disco
loration
oralron
Reverse brake end plate thickness
U::I I
vlark 3
vlark 4
Vlark 5
vlark 6
t4ark 7
vlark 8
3.55
-
3.65
(0.140
-
0.'|44)
3. 75
-
3. 85
(0. 1 -
0. 152)
3. 95
-
4. 05
(0. r56 -
0. 1591
4. 15
-
4. 2s
(0. r63 -
0. t 67)
4. 35
-
4. 45 {0. 171
-
0. 175)
4. 55
-
4. 65
(0. r79 -
0. 1831
4. 75
-
4. 85
(0. 187 -
0. 1911
4. 95
-
5. 05 {0. 19s
-
0. 199)
Disco
Disco
otalton
loration
ATF pump ATF pump drive
gear shaft O.D.
ATF
pump
dri ven
gear shaf t O. D.
ATF pump body bushing LD. Driv gar shaft
Dri ven gear shaf t
ATF pump gear si de cl earance
ATF pump gear-to-body clearance Drive gear
Ori ven gear
9.98
-
9.99
(0.3929 -
0.3933)
9.98
-
9.99 {0.3929
-
0.3933}
10.000 10.015
(0.3937 -
0.3943)
10.000
-
10.015 t0.3937
-
0.3943)
0. 015
-
0. 035 {0. 0006
-
0. 0014}
0.035
-
0.0505 {0.0014-0.0020)
0.035
-
0.0505
(0.0014-0.0020)
Woar or damaged
Wsar or dmagd
Wear or damaged
W6ar or damagad
0.050
(0.0021
Transmi ssi on Diameter of needle bearing contact are
lnout shaft
-
flvwheel side
Input shaft
-
forward clutch side
Drive Dullev shaft
-
start clutch side
Drive pulley shaft
-
flywheel side
Drive oullev shaft
-
forward clutch side
Thrust clearance
Carri er and ri ng
gear
Driven
pulley
shaft and start clutch hub
Input shaft and ATF
pump
drivon sprocket
Secondary
goar
shaft and flywheel ball bearing
19.987
-
20.000
(0.7869 -
0.7874)
19.987
-
20.000
(0.7869 -
0.7874)
43. 981
-
43. 991 {1. 7315
-
1. 7319)
24.007
-
24.020
(0.945 -
0.946)
24.007
-
24.020
(0.945 -
0.946)
0.050
-
0.r 10
(0.0020 -
0.004:))
0.000
-
0.130
(0.000- 0.005)
0. 370
-
0. 650 {0. 015- 0. 026}
0. 00
-
0. 1s
(0. 00 -
0, 006)
Wear or damaged
Wear or damaged
Wear or damaged
Wear or damagod
Wear or damagod
CvT {cont'dl
-
Section 14
\-- {
L {
3- 10
L (
cw Saction 14
Uni t of l engt h: mm
(i n)
MEASUREMENT STANDARO INEWI SERVICE UMTT
_.an3mission
conld)
Thrust shi m. 25 x 31 mm t hi ckness 1. 02
-
1. 05
(0. 040 -
0. 041)
1. 09
-
1. 12
(0, 043
-
0. 044)
' 1. 16
-
1. 19
( 0. 046- 0. 047)
1. 23
-
1. 26
(0, 048 -
0. 050)
1. 30
-
1. 33
(0. 051-
0. 052)
1. 37
-
1. 40
(0. 054 -
0. 055)
1. 44
-
1. 47 {0. 057
-
0. 058)
1. 51
-
1. 54
(0. 0s9 -
0. 061)
1. 58- 1. 61 {0, 062
-
0. 063)
1. 65
-
1. 68
(0. 065 -
0, 066)
1. 72
-
1. 75
(0. 068 -
0. 069)
1. 79
-' ! . 82 (0. 070
-
0. 072)
1. 05s
-
1. 085
(0. 0415 -
0. 0427)
1. 125
-
1. 155
(0. 0443 -
0. 0454)
1. 195
-
1. 225
(0. 0470 -
0. 0482)
1. 265
-
1. 295
(0. 0498 -
0. 0510)
1.335
-
1.365
(0.0s26 -
0.0537)
1. 405
-
1. 435
(0. 0553 -
0. 0565)
1. 475
-
1. 505
(0. 0580 -
0. 0593)
1.545
-
1.575
(0.0608 -
0.0620)
1. 615
-
1. 645
(0. 0636 -
0. 0648)
1. 685
-
1. 715
(0. 0663 -
0. 0675)
1. 755
-
1. 785 {0. 0691
-
0. 0703)
or oamageo
or damaged
Cottelslhickness 2. 87
-
2. 90
(0. 113 -
0. 114)
2. 97
-
3. 00
(0. 117 -
0. 118)
3. 07
-
3. 10
(0. 121 -
0. 122)
3. 17
-
3. 20
(0. 125 -
0. 126)
Wear or damaged
Wear or damaged
ATF
pump
drive sprocket thrust shim, 22 x 28 mfi
thickness
1.12
-
1.15
(0.044 -
0.04st
1.37
-
1.40
(0.054 -
0.055)
1.62
-
1.65 {0.064
-
0.065)
r.87
-
1.90
(0.074 -
0.075)
2.' t2
-
2.15
(0.083 -
0.085)
2.37
-
2.40
(0.093 -
0.094)
Wear or damagsd
+
I
I
Wear or damaged
Secondary
gear
shaft thrust shim, 25 x 35 mm
thickngss
2.80
-
2.85 {0.110
-
0.112)
2. 90
-
2. 95
( 0. 114 -
0. 116)
3.00
-
3.05
(0.118
-
0.120)
3. 10
-
3. 15
( 0. 122 -
0. 124)
3.20
-
3.25
(0.126 -
0.128)
3.30
-
3.35
(0.r30 -
0.1321
3.40
-
3.45 10.134
-
0.136t
3.50
-
3.5s 10.138
-
0.140)
3.60
-
3.65
(0.142 -
0.1441
3.70
-
3.75 10.146
-
0.148)
3.80
-
3.85
(0.150 -
0.1521
or damaged
or oafiaqeo
Input shaft l6ed
pip
O.D.
Drivs
pulloy leed pipe
Forward clutch feed
pipe
I nput shaf t bushi ng l . D.
Dri ve
pul l y f oed pi pe bushi ng
Forward clutch feed pip bushing
Driven shaft teed
pipe
O.D.
Start clutch f66d pipe (right
side cover side)
Dri ven pul l ey t eed
pi p
Start clutch feed
pipe (flywhel
housing side)
Dri ven
pul l sy shaf t bushi ng LO.
Start clutch feed pip6 (right
side cover sidel
Drive
pulley
feed
pipe
Stan clutch feed pipe (fl)'wheel
housing sido)
Secondary dri ven gear seal i ng ri ng groove wi dt h
Stan clutch e-nd
plate l.D.
I nput shaf t seal i ng ri ng groove wi dt h
Dri ve pul l ey shaf t l . D. at seal i ng ri ng
6. 97
-
6. 98
(0. 274-0. 275)
11. 47
-
11. 48
(0. 4516 -
0. 4520)
7. 000
-
7, 015
(0. 2756 -
0. 2762)
11. 500
-
11. 518
(0. 4528 -
0. 4535)
6. 97
-
6. 98
(0. 274 -
0. 275)
11. 47
-
11. 48
(0. 4516 -
0. 4520)
8.97
-
8.98
(0.353 -
0.354)
7. 000
-
7. 015 {0. 2756
-
0. 2762)
11. 500
-
' t
1. 518
(0. 4528
-
0. 45351
9. 000
-
9. 015 {0. 3s4
-
0. 355)
2. 50
-
2. 65 {0. 098
-
0. 104)
88.900
-
88.935
(3.500 -
3.5011
2. 00
-
2. 10 {0. 079
-
0. 083)
24.007
-
24.020
(0.945 -
0.946)
6.95
(0.274)
11. 45
(0. 45' I )
7 .030 10.2171
11. 533
(0. 454)
6. 9510. 27{}
11. 45 { 0. 451)
8. 95 {0. 352}
7.030
(0.277)
1' 1. 533
(0. 454)
9.03
(0.3561
2. 655
(0. 105)
Wear or damaged
2. 105
(0. 083)
Wear or damagsd
Shifting device
and parki ng
brake control
Parking brako cone
Parking brake pawl
Parki ng
gear
W6ar or other defect
Wear or other dafct
Wear or other defect
(cont' d)
3 - 1 1
MEASUREMEiTT STANDARD {NEW} SERVICE LIMTT
D iffe rontia I
carier
Pinion shaft contact area l.D.
Carri eFt o-pi ni on cl 6arance
Drive shaft contact area l.D.
Carrier-to-driveshaft clearance
18. 010
-
18. 028
(0. 7091 -
0. 7098)
0.023
-
0.057
(0.0009 -
0.0022)
26. 025
-
26. 045
(1. 0246 -
1. 0254)
0.045
-
0.086
(0.0018 -
0.0034)
0.1
(0.004)
0.12
(0.005)
Differential pinion
gear
Backlash
t.D.
Pi ni on gear-to-pi ni on
shaft cl earance
0.0s
-
0.15
(0.002 -
0.006)
r8.042
-
18.066 (0.7103 -
0.71r3)
0.05s
-
0.095
(0.0022 -
0.0037) nru to.oout
Set ring'to-bearing outer race clearance 0
- 0. 15 ( 0-
0. 006) Adjust
MEASUREMENT Wir. Dia. o.D. FJ.. Longth No. of Coilt
Spri ngs PH 169ulator valve spring
PH control valvo spring
PL 169ulator valve spring
PH-PL cont rol val ve spri ng
Cl ut ch rduci ng val ve spri ng
Lubri cat i on val ve spri ng
Shift valve spring
Shift control valve spring
Start clutch control valve spring
Pitot regulator valve spring
Start clutch valve accumulator spring
Rgverse control valv6 spring
Shift inhibitor valve spring
1.2 t0.0471
1.7
(0.067)
0.9 {0.035)
1.0
(0.039)
1.9
(0.075)
1.6 t0.063)
1.4 {0.055}
1.0 {0.039)
0.4
(0.016)
0.6
(0.024)
1.2
{0.047)
1.2
(0.047)
1.3 {0.051)
9.0
(0.354)
13.4
(0.528)
7.2 t0.283')
10.0
(0.391)
16.8 {0.661}
13.4
(0.528)
8.2
(0.323)
7.4 {0.29r)
4. 1 { 0. 161)
5.7 10.2211
8.3
(0.327)
9.4
(0.370)
13.2
(0.s20)
25. 7 {1. 051}
39. 4
(1. 5511
14. 6
(0. 5751
31. 4 {1. 236)
41.4 i'1.7 481
51. 6 {2. 031}
34. 1
(1. 343)
19. 3
{0. 760}
12. 1
(0. 476)
9. 5
(0. 374)
29. 8
(' t . 173)
31. 4
(1. 236)
48. 3 {1. 902)
10. 0
4. 7
8. 6
8. 0
1 1 . 6
13. 0
6. 8
5. 0
12.3
1 1 . 0
10. 6
I
CW {cont'd}
-
Sectaon 14
Steering
-
Section 17
M/S: Manual steering, P/S: Power steering
*:
When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minut6s then turn it off.
Readjust the deflection or tonsion to used belt values.
L i
\ - l
MEASUREMENT
STANDARD
(NEwl
Steering wheel Play at steering wheel circumference
Starting load at steering wheel circumference
N {kgt. lbf)
l vl anual st eeri ng
Power st eeri ng Engi ne runni ng
0- 10{ 0- 0, 4)
15 (1. 5,
3. 3)
29 {3.0, 6.5)
G6ar box Angle of rack guide
screw loosened
trom locked position
Preload at pinion gear shaft N.m
(kgf.cm,
lbtin)
M/S
M/S
2 0 1 5 "
20 Max
0. 5
-
1. 7 {5
-
17, 4. 3
-
14. 8)
0. 6- 1. 2
( 6-
12, 5. 20
-
10. 42)
Pump
Pump pressure
with valve closed
{oi l t emp. / speed: 40' C (105' F)
mi n. , 4dl e.
Do not run f or moret han 5 seconds).
kPa {kgflcmr,
psi)
6,400
-
7,400
(65 -
75, 920
-
1.070)
Power stee ng
f l ui d
Recommended power
steering tluid
Fluid capacity f
(US qt,
lmp qt)
Reservoir
HONDA Power St eeri ng Fl ui d-V or S
0. 85
(0. 90, 0. 75)
at di sassembl y
0. 4 {0. 42, 0. 35)
Power steering
belt*
Deflection with 98 N
('10
kgf, 22 lbt)
between pulleys
10.5
-
14.0 {0.4'l
-
0.55) with usod belt
7.5
-
10.0
(0,30 -
0.39) with new belt
Tonsion measured with belt tension gauge
N
(kgt.
lbf) 816A2 Engine Typ only
Ot her Engi n Types
816A2 Engi ne Type onl y
Othor Engine Types
390
-
540
(40 -
55, 88
-
120) with used belt
340
-
490
(35 -
50, 77
-
110) with used belt
740
-
880
(75 -
90, 170
-
200) with new belt
640
-
780 {65
-
80, 143
-
'176}
wirh new belt
3-12
Suspension Sestion 18
Brakes Section 19
*1.
5410 St amped on t he cal i per body.
*2.
2056 St amped on t he cal i per body.
Air Conditioning
-
Section 22
*:
When using a new belt. adjust deflection or tension to new values. Run the engin tor 5 minutes then turn it off.
Roadjust deflection or tension to used belt values.
Unit ot lgngth: mm
(in)
MEASUREMENT STANDARD I EWI SERV|CE UitlT
al agnment
Camber
Caster
Tot al t oe
Front wheel t urni ng angl e I nward wheel
Outward wheel
Front
Rear
Front
Front
Rear
0.00' l
'1"
1. 40' r 1.
I n 1. 0 t 2. 0
(1/ 16
t 1/ 16)
I n 2. 0 : i 3 {1/ 161 1/ 15)
39"50'
33' 10' (Ref erence)
Ri m runout Al umi num wheel Axi al
Radi al
St eel wheel Axi al
Radi al
0
-
0.7 {0
-
0.03)
0
-
0.7
(0 -
0.03)
0
-
1.0
(0 -
0.04)
0
-
1.0
(0 -
0.04)
2.0
(0.08)
1.5 {0.05}
2.0
(0.08t
1.5
(0.06)
Wheel bearing End pl ay Front
Rear
0
-
0.05
(0 -
0.002)
0
-
0.05
(0 -
0.0021
MEASUREMENT STANDANO INEWI SERV|CE Ui,llT
Parki ng brake
lever
Play in stroke at 196 N
(20
kgf. 44 lbfl lover force
To be locked when pulled
6
-
9 notchos
Foot brake
pedal
Pedal hoight
(with
floor mat refioved) M/T
A,/T, CW
Free
pl ay
156. 5
(6. 16)
161
(6
5/ 16)
1 - 5 ( 1 / 1 6 - 3 / 1 6 )
Mast er cyl i nder Piston-to-pushrod clarance 0
-
0.4
(0 -
0.02)
Disc brake Disc thickness Front
Oisc runout Front
Rear
Di sc paral l el i sm Front and rear
Pad thickness Front
20. 9
-
21. 8
(0. 82 -
0. 86)
9. 5
-
r0. 5r1
8. 5
-
9. 5*'
19.0 {0.75}
0.1s,(0.004)
0.10
(0.004)
0.015
(0.00061
1.6 {0.06)
1.6
(0.06)
Rear brake
drum
t.D.
Li ni ng t hi ckness
200 0 .a7l
4.0
(0.16)
201
(7. 911
2.0
(0.08)
MEASUREMENT STANDARD {l{EW)
Condi t i oni ng
Lubricant type: SP-'10
(P/N
38897
-
P13
-
AoIAH or 3889
Lubricant capacity Condenser
m? l l l oz, l mp oz) Evaporat or
Line or hose
Feceivr
-
P13
-
A01l {For ret ri gerant HFC-134a
(R-134a})
20 l2/3 0.71
45 11 2f3, 1 .61
10
(1/ 3,
0. 4)
10
( 1/ , 0. 4)
Compressor Lubricant type: SP-10
Lubricant capacity mf
(ll
oz, lmp 02)
Field coil resistance at 68"F {20'C} o
Pulley-to-pressure plate clearance
130
-
1s0
(4
r/3
-
4.6, 5.0
-
5.3)
3. 05- 3. 35
0.5 r 0.15
(0.020
r 0.006 )
Compressor
bel t *
Deffection with 98 N
(1O
kgf,22lbtl
between pulleys
7.5
-
9.5 {0.30
-
0.37) with used belt
5.0
-
6.5 {0.20
-
0.26) wilh new bolt
Belt tension N
(kgf,
lbf)
Measured with belt tension gauge
340
-
490
(35 -
50, 77
-
'110)
with usod belt
690
-
830
(70 -
85, 150
-
190) with new blt
3- 13
MEASUREMENT STANDARD INEWI
l gni t i on coi l Rated voltage V
Pri mary wi ndi ng resi st ance at 68' F
(20' C)
0
HITACH I
TEC
Scondary winding resistance at 68'F
(20"C)
kO
HI TACHI
1 2
0, 45
-
0. 55
0. 63
-
0. 77
22.4
-
33.6
12. 4- 19. 2
l gni t i on wi re Resistance at 68"F
(20"C)
k0
Fi ri ng order 1 - 3 - 4 - 2
Spark pl ug Tvpe
Gap
See section 23
1, 0- 1, 1
(0. 043
_i
oo. )
l gni t i on t i mi ng Ar i dl e
"
BTDC
(Red)
12+2
Alternator belt* Oetlection with 98 N 11okgl,22lbf'l
betlveen
pulleys
8. 0
-
10. 5 {0. 31
-
0. 41) wi t h usod bel t
6. 0 8. 5
(0. 26
0. 33)wi t h new bel t
Belt tension N lkgf, lbf)
Measured with belt tension
gauge
340
-
490
(35 -
50, 77
-
110) wi t h used bel t
540
-
740
(55 -
75, 121
-
165) wi t h new bel t
Alternator
(MI TSUBI SHI }
Output 13.5 v at hot A
Coil resistance
(rotor)
at 68'F 120"C) k0
Sl i p ri ng O. D.
Brush l engt h
Brush spri ng t onsi on g (oz)
STANDARD
(NEWI
SERVICE UM]T
3. 4
-
3. 8
22.7 t'.agl | 22.210.87)
1 q n r o 7 6 l | 5 0 { 0 . 2 0 )
t - - '
300
-
450
(10. 6 -
15. 9)
Starter motor
(MI TSUBA
1. 0 kw
1. 2 kW)
Type
Commutator mica depth
Commut at or runout
Commut at or O, D.
Brush l.ngth
Brush spri ng t ensi on
(new)
N
(ksl,
lbf)
Gear reduclion
0. 4
-
0. 5
(0. 016 -
0. 020)
0
-
0.02
(0 -
0.0008)
28. 0
-
28. 1
( 1. 102 -
1. 106)
15. 8 16. 2
(0. 62 -
0. 64)
15. 7
-
17 . 7
(1. 60 -
1. 80, 3. 5
-
4. 0)
0. 15
(0. 006)
0. 05
(0. 002)
27. 5
(1. 083)
11. 0
(0. 43)
Electrical
-
Section 23
*:
When using a new belt, adjust deflection or tension to new values. flun the engine lor 5 minutes then turn it off.
Readjust deflection or tension to used belt values.
{
3-14
L {
Design Specifications
a
I
Unit ot lengthi mm {in)
METBIC ENGUSH NOIES
lTEM
DI MENSI ONS Overall Length 2 door Coupe/+door Sedan
2-door Hatchback {1996,
1997)
(1998)
Overal l Wi dt h
Overall Height 2-door Coupe/2-door
Hatchback
tl-door
Sedan
Wheel base
Track FronvRear
Ground Cl earance
Seat i ng Capaci t y
4,445 mm
4, 170 mm
4, 180 mm
1, 705 mm
1. 375 mm
1, 390 mm
2, 620 mm
1 , 47511 , 175
mm
' 150
mm
' 175. 0
i n
164. 2 i n
164. 6 i n
67. 1 i n
54.'1 in
54. 7 i n
103. 1 i n
58. 1/ 58. 1 i n
5. 9 i n
WEI GHT
(USA)
Gross Vehicle Weight Rsting {GVWR)
2-door Coupe DX, HX M/I
HX A,/T
EX
HX CVT
(1996)
HX CVT
(1997)
2-door Hat chback CX. DX
(1996,
1997)
DX with ABS
(1998)sMT
4AT
4-door Sedan OX, LX M/T, LX Ay'T
LX A,/T with ABS, EX
3, 290l bs
3,330 rbs
3,440 tbs
3,220 tbs
3,330l bs
3,285 tbs
3,290 tbs
3,300 lbs
3,330l bs
3,460l bs
WEI GHT
(CANADA)
Gross Vehicle Weight Rating {GVWR)
2-door Coupe DX
(1996)
DX
(1997)
si ( 1996)
si ( 1997)
2-door Hat chback cX
(1996),
cX-G
(1996)
cx
(1997),
CX-G
(1997)
cx
(1998),
DX {1998)
4-door Sedan LX, EX M/T
EX A/T
1, 500 kg
1, 510 kg
1,560 kg
1. 570 kg
1, 495 kg
1, 505 kg
1, 510 kg
1, 510 kg
't,540
kg
E NGINE
Cyl i nder Arrangement
Bore and Stroke
Di spl acement
Compressi on Rat i o D16Y7, Dl 6Y5
016Y8
Valve Train
Lubrication System
Oil Pump Displacement at 6,800 engine rpm
Water Pump Displacement
at 6,000 engine rpm
Fuel Requi red
wat6r-cooled, +stroke SOHC*', SOHC
VTEC'3, SOHC WEC-E*1 gasoline engine
Inline 4-cylinder, transverse
75. 0 x 90. 0 mm
1
2. 95 x 3. 54 i n
' 1, 590
cm3
(m/ )
1 97. 0 cu-i n
9. 4
9. 6
Bel t dri ven, SOHC 4 val ve per cvl i ndr
Forced and wet sump, trochoid pump
33. 4 f {35. 3 US
qt , 29. 4l mp qt )/ mi nut e
1251
(132
US qt , 110 l mp
qt )/ mi nut
UNLEADED
gasoline wilh 86 Pump
Oct ane Numbsr or hi gher
*, :
Dl 6Y7
*3:
Dl 6Y8
*+:
D'|6Y5
STARIER Type/Make
Normal Out put
Nomi nal Vol t age
Hour Rat i no
Direction of notation
Gear reduction/MITSU
gA
1.0 kw, 1.2 kw
12V
30 seconds
Clockwise as vigwed from gear end
(cont' d)
3- 15
|TEM METRIC ENGLISH NOTES
STARTER
(cont'd)
Wei ght MI TSUBA 1. 0, 1. 2 kW 3. 4 kg 7. 5 t bf
CLUTCH Clutch Type
Clutch Facing Area
Mlf
CW
Single
plate
dry, diaphraom spring
Torque converter
Multi plates wet sanp, hydraulic
160 crn'
|
25 sq-in
TRANSMI SSI ON Transmission Type
Primary Reduction
CW
Synchronized 5-speed forward, 1 reverse
4-speed automatic, 1 reverse
Non-stage speed forward, 1 reverse
Direct 1 : 1
TRANSMI SSI ON Manual t ransmi ssi on
Gear Rat i o 1st
2nd
Jro
4th
5th
Beverse
Fi nal Reduct i on Gearrat i o
Gar tYPe
Engi ne t yp
D16Y5 D16r' D16Y8
3.250
1. 742
1. 172
0.909
0.102
3. 153
3. 250
1. 182
1. 172
0.909
0.102
3. 153
3.250
1.909
1. 250
0.909
0.702
3.153
*1:
2' door Hat ch
oacx
*2:
2-door Coup6,
and 4-door
Sedan
3. 722 3.7 22'' 11.034*' 4.250
Si ngl e hel i cal gear
Automatic transmission
Goar Ralio lst
2nd
3rd
4th
Reverse
Final Reductaon Gear ratio
Gear type
Engi ne t ype
D,I6Y' D16Y8
2.600
'L468
0.926
0.638
1. 954
2. 722
0. 975
0.638
1. 954
1.35"1 4. 357
Si ngl e hel i cal gear
cw
Gear Ratio Low
-
O.D.
Revelse
Secondary Reduction Gear Ratio
Fi nal Rgduct i on Gear Rat i o
2.466
-
0.449
2.466
4. 357
AI R
CONDI TI ONI NG
Cooling Capacity 3,530 Kcal/h 14,000 BTU/h
Compressor Type/Make
No. of Cylinder
Cspacity
Max. Speed
Lubricant Capacity
Scrol l / SANDEN
u5, / mt / t ev I i . zz cu-rn/ rev
10,000 rpm
' 130
mf
|
4 1/ 3l l oz.
|
4. 6l mp oz
sP- 10
Condenser Type Corrugat ed f i n
Evaporator Type Corrugated fin
Blower Type
Mot or I nput
Speed Control
Max. Capacity
Si rocco I an
200w112v
4-speed variable
460 m3/h
|
16.200 cu-Vh
Tgmprature Control
Compressor Clutch Type
Power Consumption
Dry. single plate, poly-V-bell drive
40 W max./12 V at 68'F
(20'C)
Refrigerant Type
Ouantity
HFC-134a
6so hs
(R-134a)
22.9 -laoz
Design Specifications
(cont'dl
L !
L J
3- 16
L {
Uni t of l engt h mm l i n)
ITEM METRIC ENGLISH NOTES
STEEBI NG
SYSTEM
Type
Overall Ratio
Turns, Lock-to-Lock
St eeri ng Wheel Di a.
P/S
M/S
Powsr assi st ed, r ack and pi ni on
Sack and pi ni on
P/ S: 17. 7, l t 4/ Sr 20. 3
P/ S: 3. 6, M/ S: 4. 1
380 r nm
i
15 i n
SUSPENSI ON Type Front and Rear
Shock Absor ber Fr ont and Rear
I ndependent doubl e wi shbone, coi l spr i ns
Tel escopi c, hydr aul i c ni t r ogen gas f i l l ed
WHEEL
ALI GNMENT
Camber Fr ont
Rear
Caster Front
Tot al Toe Fr ont
Bear
0.00'
1'40'
I n 1. 0 mm l / 16 i n
I n 2. 0 mm I n 1/ 16 i n
BRAKE SYSTEM
Rear
Parking Brake Type
Rear
Power-assisted sel{-adiusting
ventilated disc
Powe.assisted self-adjusting solid disc
37. 5 cm, \ 2 5. 8 sq- i n x 2
44. 1cm, x2 6. 94 sq- i n x 2
67. 2 c m, x 2 10. 4s q- i nx 2
50. 2 cm, x2 7. 8 sq- i n x 2
l,lechanical actuating, rear Nvo wheel brakes
Uni t : mm
( i n)
5,110 Stamped on ths
2056 St amped on t he
caliper body
Or um l . D. : 200
( 7. 9)
Dr um l . D. : 180
( 7. ' ! )
TIRE Size Front and Rear 2-door Coupe
2-door Hatchback
4- door Sedan
Spar e Ti r e
P175D0R13 82S: DX
P185/ 65R' 14 85S: EX, HX
( USA) ,
Si
( Canada)
P175t 0R13 82S: CX, DX
( USA) ,
CX G { Canada)
P175t 0Rr 3 82S: DX
( USA) ,
LX
( Canada)
Pl85/65R14 85S: LX/EX
(USA),
EX
( canada)
T105/ 80D13 Car s wi t hout ABS Except
2- door Coupe EX
( uSA) ,
Si
( Canada)
T105t 0D14 2' door Coupe EX
( USA) ,
S;
( Canada)
Car s wi t hout ABS
T115/ 70D14 DX
( USA) ,
4' door Sedan LX l USA) ,
2- door Coupe DX
( Canada)
Car s
wi t h ABS
T125r 0O14 Car s wi t h ABS 2 door Coupe,
4 door Sodan LX, EX
( USA) ,
4' door Sedan EX
( Canada) ,
2- door Coupe Si
( Canada)
Car s
with ABS
WASHER
RESERVOIR
Capacity |
(uS qt, lmp qt) 2-doot coupe 2.5 l.2.6,2.21
4'door Sedan 4.5 {4.8, 4.0}
2- door hat chback 2. 5
( 2. 6,
4. 5
( 4. 8,
2.2)
4. 0)
USA model
Canada model
DX
Except OX
ELECTRICAL Battry
Staner
I n Under dash Fuse/ Rel ay Box
In Under-hood Fuse/Relay Box
In Under-hood ABS Fuse/Relay Box
Headl i ght s Hi ghAow
Fr ont Tur n Si gnal / Par ki ng Li ght s
ReEr Tur n Si gnal Li ght s
Brek/Taillights
I nner Tai l l i ght s*'
Hi gh Mount Br ak Li ght
Back up Lights
License Plate Lights
Cei l i ng Li ght
Tr unk Li ght s
Gauge Li ght s
Indicator Lights
l l l umi nat i on and Pi l ot Li ght s
Heater Control Panel Lights
12 V
-
38AH/5HR
12 V
-
1. 0 kW, 1. 2 kW
1 2 V - 1 5 4
7. 5 A, 10 A, 15 A, 20 A
7.5 A, 10 A, 15 A, 20 A,30 A, 40 A, 80 A
7. 5 4, 20 A, 40 A
1 2 V - 6 0 A s W
12V 21t sW
' t 2
v
-
21W
12V
-21/ 5
W
1 2 V 5 W
12 V_ 18 W*" 21 Wrl .
+3
1 2 V - 2 1 W
1 2 V 5 W
12 V- 8 W
(Wi t h
moonroof )
12 V-5 W
(Wi t hol t moonroof )
1 2 v - 1 . 4 W, 3 W
1 2 V- 1 . 1 2 W, 1 . 4 W
1 2 V- 0 . 8 4 W, 1 . 4 W
1 2 V - 1 . 4 W
t
P/ S: Power st eeri ng, M/ S: Manual st eeri ng
*l :
2-door Coupe
*2:
2-door Hat chback
*3:
4-door Sedan
*4:
USA
(HAM),
Canada
(HCM) produced
*5: JAPAN
oroduced
3-17
Body Specifications
L
Uni t : mm
( i n)
2-door Coup:
L
3- 18
\,
2-door Hatchback:
l r' tgl 91e' l
3- 19
Body Specifications
(cont' d)
4-door S6dan:
L r '
Uni t: mm
(i n)
L
(
3-20
Mai ntenance
Lubri cati on Poi nts ............4-2
Maintenance Schedule for 1996 Model
Normal Condi t i ons . . . . . . . . 4-4
Severe Condi ti ons ......... 4-6
Normal Condi ti ons ........ 4-8
Severe Condi ti ons ......... 4-10
Normal Condi ti ons ........4-12
Severe Condi ti ons .........4-14
Lubrication Points
No. LUBRICANON POINIS LUBRICANT
'I
Engi ne API Servi ce Grade: Use SJ
' Energy
Conservi ng"
grade oi l .
The oil container m8y also displsy the API Cenification mark
shown below. Make sure it says
"For
Gasoline Engines,"
SAE Viscosity: Se6 chart below.
2 Transmi ssi on Manual Genui ne Honda MTF*1
Automatic Genui ne Honda Premi um Formul a
Automati c Transmi ssi on Fl ui d
(ATF)*,
CW Genui ne Honda CVT Fl ui d' 3
3 BrEka Li ng Genui ne Hond8 DOT3 Brake Fl ui d*.
1 clutch Lin Genui ne Honda DOT3 Brske Fl ui d' a
c Powr stering
gesrbox
Stesring
grease P/N 08733
-
8070E
6 Shi ft l ever pi vots
{manual transmi ssi on) Gresse with molvbdenum disulfide
7 Rel ease tork
(manual
transmi ssi on) Super High Temp Urea Grease {P/N 08798
-
9002)
I
o
10
1 1
12
13
Steering boots
Tailgate hinges and latches
(2-door
Hatchbackl
Steeri ng bal l
j oi nts
Shift lever
(sutomatic
transmission)
P6dal l i nkage
Braks mast6r cylind6r
pushrod
Mul ti -purpose grease
l ' [
15
16
17
Trunk hi nges and l stch
(,| -door
Sedan and 2-door
Couoe)
Door hinges upper and lower
Door opening dstents
Hood hings and hood latch
Honda White Lithim Grease
18
19
20
21
22
Fuel fi l l or l i d
Clutch m8st6r cylinder
pushrod
Throttl e cabl ond and thronl 6l i nksge
Rear brakg shoe linkages
Steeri ng wheel
(back
si de)
Mul ti -purpose grease
23
21
Caliper
piston
seal, dust seal,
cal i per
pi n, pi ston
Throttle cable end
(dsshboard
lower Danel)
Si l i cons grease
25 Pow6r st66ring system
(for
cars with P/Sl Genui ne Honda Power Steeri ng Fl ui d-V or S' 5
26 Ai r condi ti oni ng comprsssor Comoressor oi l :
SANDEN: SP-10 P/N 38At
-
P13
-A01AH
or3@9- P13-A01
(For
R6fri gsrant: HFC-1348
(R-f
34a))
\-
I
For th6 details of lubrication
points
and types of lubricants to b applied, rsfsr to the lllustrated Index and various work
procdurss (such
as Asssmbly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section.
API SEFVICE LABCL Recornmendod Engi ne Oi l
L
q
API CERTIFICAIIOII SEAL
ffi
NOTE: Th following information as marked
*1, *2, 13, *4
and
15
on above chart details for 1997 model.
Il :
Al wsys use Genui ne Honda Maoual Transmi ssi on Fl ui d
(MTF).
Usi ng motor oi l can cause sti ffer shi fti ng because i t
dogs not contain the
propor
additivs,
*2:
Al ways use Genui ne Honda Premi um Formul a Automati c Transmi ssi on Fl ui d
(ATF).
Usi ng a non-Honda ATF can affect
shi ft
qual i ty.
*3:
Us6 Genuin6 Honda CVT fluid only. Using other fluid csn aftect transmission operation and may reduce transmission lif6.
r,l:
Always uss Genuine Honda DOT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decresse the life
ot the system.
:5:
Alwsys use Gonuine Honda Pow6r Stooring Fluid-V or S. Using 8ny other type of
pow6r
stssring fluid or sutomstic
transmi ssi on fl ui d can cause i ncrass war 8nd
poor
steori ng i n col d weathsr.
r ,--;--i------ t
Engi ne oi l vi scosi t y f or
ambrent t empet ure ranges
(
4-2
\
@
(4{oo.
s.d.n)
@
NOTE: Lubri cate al l hi nges, l atches and l ocks once a year.
In corrosi ve areas. more frequent l ubri cati on i s necessary.
We recommend Honda Whi te Li thi um Grease.
4-3
I
Normal Conditions
c + t
_ N i . j
6 X
+ r ;
E E
3 . . ;
) t a=
5 : !
{
! : a :
I
e = > : *
E E* ='
x ; ; - 3
E E E E E
+ . i ( * - ;
E 6 6 E 6
i ;
F 9
9 ;
: 6
! :
5 :
BE
, 9 Q
; ;
} E
s 9
l 9
E
.!
;
3
. 2
E =
f ;
q
a = l
l i ? : i J
= Ei Sd
; 9 9
|
;
; E : : E
E N ; : :
i
*; e
E;
F; E: : *
: : ; e 3 E
; i f
. ; ! 3
* E 1! t $
EE, E' 9 g g
; E I
q : 8
; ; , u*B?
. - i E
E E
. : = b;
Et zl ct z]
= F . . i 5
E S 3 i S e
: 6 6 - 9 6 6 6 6 . ! 6 6
= + r + ; N + r
3EF5FF
: ) l l l
q q r ' ? c ? :
:at ct ci ci
; , j i - - F "
g>E
3i
3
l - o
; E
; : * F
t r . < q
>
E c i ;
i " . 6 d c i 6
5 P4 s- ;
s E E = q 3
E; E
3: ;
; - : r - =
I aE ci 33
: i EEE
.E
, .
q. r
6 E q
= N <
: 6 e
9 f a
; q c )
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Mai ntenance Schedul e for 1998 Model
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4-15
Engi ne
Engi ne Removal /l nstal l ati on
......".' .' .... 5-1
Cyl i nder Head/Val ve Trai n ........' ..' .' .".. 6-1
Engi ne Bl ock . . . . . . . . . . . . . . . ' . ' . . ' 7-1
Engi ne Lubri cati on
........... 8-1
lntake Manifold/Exhaust System ........ 9-1
Gool i ng
. . . . . . . . . 10-1
Engi ne RemovaUl nstal l ati on
Removal . . . . . . . 5- 2
f nstal fati on ...5-12
Engine RemovaUlnstallation
Removal
@
. Mako surs
iacks
and 3atety stands ar6 placed properly
and hoist brackets aro attached to ihe corroct posi-
tions on th engine.
.
Mako surc the
brehiclo
will not roll olf rtands and fall
whilo you are working und.r it.
CAUTION:
. Uso tandar covors to ayoid damaging
painted
sur-
face.
. Unplug the wiri||g connoctors carefully whilo holding
the conn6ctor
poiion
to ayoid damago.
. Mrrk all wiring and hosss to lvoid misconnoction.
Abo, be sur6 that thoy do not contact other wiring or
hoss or interf?ro with othor
parts,
1, Secure the hood as oDen as
possi bl e.
2.. Di sconnect the battery negati ve termi nal fi rst, then
the posi ti ve termi nal .
3. Disconnect the battery cables from the under-hood
fuse/relay box and battery
positive
terminal.
BATTERY CABLES
TERMINAL
5-2
{
4. Remove the battery and battery base.
I x 1. 25 mm
21 N.m l2.1kgl.m, 17 lbf-ftl
I
(
Di sconnect the connectors from the ECM/PCM.
Di sconnect the mai n wi re harness connsctor.
MAIN WIRE HARNESS
CONNECTOR
{
ECM/PCM
\}
L
7. Remove the i ntake ai r duct and ai r cl eaner housi ng.
D16Y7 enqi ne:
a. Remove the resonator and i ntake ai r duct.
INTAKE AIR
DUCT
RESONATOR
Di sconnect the i ntake ai r temperature
(l AT)
sen-
sor connector, then remove the ai r cl eaner hous-
i ng.
o.
AIR CLEANER
6 x 1 . 0 mm
9.8 N.m 11.0 kgf.m, t.2lbtft)
6 x 1 . 0 mm
D16Y5, Dl5Y8 engines:
a. Di sconnect t he I AT sensor connect or , t hen
remove the i ntake ai r duct and ai r cl eaner hous-
I ng.
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgt . m, 7. 2l bt . f t )
INTAKE AIR
OUCT
IAT SENSOR
CONNECTOR
8. Di sconnect the engi ne wi re harness connector
the l eft si de of the engi ne compartment.
(cont' d)
5-3
Removal
(cont'dl
9. Rel i eve fuel pressure (see
secti on 11),
!@
uo not smot(e whde working on th tuol
system. Kogp open flams or spark away from tho
work arga. Drain fuel only into an approved coDtainer.
10. Remove the evaporati ve emi ssi on
(EVAp)
control
cani ster hose and fuel feed hose
D16Y7 engin:
FUEL FEED HOSE
Dl6Y5. D16Y8 engines:
BANJO EOLT
33 N.m
(3.4
kg{.m,
2s tbf.ftl
5-4
11. Remove the brake booster vacuum hose, fuel return
hose and vacuum hose.
D16Y7 engi ne:
Dl6Y5, D16Y8 engines:
VACUUM HOSE
I
12. Remove the throttl e cabl e by l ooseni ng the l ocknut,
then sl i p the cabl e end out of the accel erator l i nk
age.
NOTE:
a Take care not to bend the cabl e when removi ng
i t. Al ways repl ace any ki nked cabl e wi th a new
one.
. Adj ust the throttl e cabl e when i nstal l i ng
(see
sec-
t i on 1 1) .
D16Y7 engi ne:
Dl6Y5, D16Y8 engines:
LOCKNUT
NUT
LOCKNUT
13. Remove t he gr ommet and wi r e har ness cl amps,
then pul l out the ECM/PCM connectors.
6 x 1 . 0 mm
14.
[ocK aoLT
8 x 1.25 mm
24 N.m (2.4
kgf.m, 17 lbt.ftl
MOUNTING BOLT
8 x 1. 25 mm
24 N.m
(2.4
kgf.m, 17 lbf.ftl
Remove the mounti ng bol t and l ock bol t, then remove
the power steeri ng
(P/S) pump bel t and pump.
NOTE: Do not di sconnect the P/S hoses.
(cont' d)
5- 5
Removal
(cont'dl
15. Loosen t he i dl er pul l ey cent er nut and adj ust i ng
bol t, then remove the ai r condi ti oni ng
(A/C)
com-
pressor bel t.
Remove t he t ransmi ssi on
cl amp.
HOSE CLAMP
gr ound cabl e and hose 16.
IOLER PULLEY CENTER
NUT
10 x 1. 25 mm
4,r N'm 14.5 ksf.m.33 lbl.ftl
6 x 1 . 0 mm
GROUND CABLE
,
5- 6
17. Remove t he cl ut ch sl ave cyl i nder and l i ne/ hose
assembl y
(M/T).
NOTE:
. Do not di sconnect the pi pe/hose assembl y.
. Do not operate the cl utch pedal once the sl ave
cyl i nder has been removed.
. Take care not to bend the l i ne.
6x f . 0mm
8x 1. 25f i f i
,t N.m
(t.1
kg
,m,
21N.m l2.1kgr.m,
6 tbr.ft) 17 lbnftl
18. Remove the shi ft cabl e
(CVT).
WASHER
LOCKNUT
29 N.m {3.0 kgt m, 22 lbtft)
PLASTIC
SHIFT CABLE
\
19. Di sconnect t he power
swi t ch con nect or , and
cl amp.
st eer i ng pr essur e
( PS
P)
r emove t he wi r e har ness
20. Remove t he radi at or cap.
2 1 .
22.
E@@
use care when removing the radiator
cap to avoid scalding by hot coolant or steam.
Rai se the hoi st to ful l hei ght.
Remove the front ti res/wheel s and spl ash shi el d.
9. 8 N. m
(1. 0 kd m,
7.2 rbl.ft)
6 x 1 . 0 mm
SHIELD
23. Drai n the engi ne cool ant
(see page 10-6), Loosen
the drai n pl ug i n the radi ator.
24. Drai n the transmi ssi on fl ui d. Rei nstal l the drai n pl ug
usi ng a new washer
(see
secti on 13. 14).
25. Drai n the engi ne oi l . Rei nstal l the drai n bol t usi ng a
new washer
(see page 8-5).
26. Remove the shi ft rod and extensi on rod
(M,/T).
SHIFT ROO
8 x 1.25 mm
22 N.m
(2-2 kgf.m, 16 lbf,ft)
27. Remove the A,/C compressor.
NOTE: Do not di sconnect the A,/C hoses.
8 x 1. 25 mm
2,r N.m {2.{ kgf.m, 17 lbf.ft}
(cont' d)
5-7
A/C COMPRESSOR
l
Removal
(cont'd)
28. Remove the shi ft cabl e
(A,/T).
NOTE:
. Take care not to bend the cabl e when removi ng
i t. Al ways repl ace any ki nked cabl e wi th a new
one,
. Adj ust the shi ft cabl e when i nstal l i ng
(see
sec-
t i on 14) .
I x 1.25 mm
22 N.m 12.2 kgd.m. 16lbtft)
6 x 1 . 0 mm
14 N.m {1.4 kgf.m. 10 lbf.ft)
L
29. Remove exhaust pi pe A.
D16Y5, D16Y7 engi nes:
8 x 1.25 mm
22 N.m
(2.2
kgt m, 16 lbl.ftl
Repl ace.
SELF-LOCKING
8 x 1. 25 mm
16 N. m 11. 6 kgt . m,
12 tbf'ft|
Repl ace.
Dl 6Y8 engi ne:
8 x' 1. 25 mm
22 N.m 12,2
kgf.m, 16lbtftl
GASKET
Fepl ace.
SELF.LOCKING NUT
8 x' 1. 25 mm
16 N.m
(1.6 kg'i.m,
'12lbf'ftI
Repl ace.
SELF.LOCKING NUT
PIPE A 10 x 1.25 m.n
33 N. m (3. 4
kgt m,
25 tbt.ftt
Repl ace.
{
EXHAUST
PIPE A
SELF,LOCKING NUT
10 x 1. 25 mm
5{ N.m {5.5 kgt.m,
,10
lbf.tt}
Repl ace.
5- 8
\
30.
J t ,
Remove the damper l orks
(see
secti on
' 18).
Di sconnect t he suspensi on l ower ar m bal l
j oi nt s
(see
secti on 18).
Remove the dri veshafts.
CAUTION:
o Do not pull on the driveshaft, the CV
ioini
may
com apart.
. Use care when prying out the assembly.
Pull il straight to avoid damaging the difterential
oil seal or intermediats shaft dust seal.
NOTE; Coat al l or eci si on- f i ni shed sur f aces wi t h
cl ean engi ne oi l . Ti e pl asti c bags over the dri veshaft
enos.
34.
Lower the hoi st.
Remove t he upper and l ower r adi at or hoses and
heater hoses.
Remove t he ATF cool er hoses, t hen pl ug t he
cool er hoses and Di pes
(Ay' T).
ATF 35.
RADIATOR HOSE
HOSES
(cont' d)
5- 9
En
gine
Remov aUlnstaf lation
Removal
(cont'd)
36. Attach the chai n hoi st to the engi ne,
l nst al l on t he cyl i nder head
wi t h a 8 x l . 2 5 mmb o l r .
5- 10
HOISTING BRACKET
37. Remove the l eft and ri qht front mount and bracket.
FROI{T
MOUNT/BRACKET
Repl ace.
38. Remove t he rear mount bracket .
39. Remove the uooer bracket.
40. Remove t he t r ansmi ssi on mount br acket , t hen
remove the transmi ssi on mount.
TRANSMISSIOt{
MOUNT
T
TRANSMISSION
MOUNT
BRACKET
42.
41. Check t hat t he engi ne/ t r ansmi ssi on i s compl et el y
free of vacuum hoses, fuel and cool ant hoses and
el ect r i cal wi r i no.
Sl owl y rai se t he engi ne approxi mat el y 150 mm
(6
i n).
Check once agai n t hat al l hoses and wi res are di scon-
nect ed f rom t he engi ne/ t ransmi ssi on
Rai se t he engi ne al l t he way, and r emove i t f r om t he
car ,
UPPER
43.
5 - 1 1
t '
Installation
Bracket Bolts Torque Specifications:
D16Y5. O16Y8 engi nGs
(M/Tl :
I
REAR STIFFENER
8 x 1. 25 mm
24 N.m
12.4 kgf.m, 17 lbtft)
EXCEPT D16Y5, D16Y8 engi nes
{M/ T):
STIFFENER
Ti ght en t he bol t s on t he st i f f ener
i n t he numbered sequence as shown
10 x 1, 25 mm
44 N.m
{4.5 kgl.m,
33 tbtft)
10 x 1. 25 mm
,14
N.m {4.5 kgt m,
33 rbtftl
ALTERNATOF
BRACKET
10 x 1. 25 mm
44 N.m {4.5 kgf.m,
33 rbtft)
10 x 1. 25 mm
54 N.m
(5.5
kgf.m,
a0 lbf.ftl
10 x 1 . 25 mm
/t4
N.m {4.5 kgf.m,
33 rbtft)
( O- O) .
e) 8x 1. 25mm
24 N.m
(2.4
kg[.m.
17 rbt.ftl
\ {
O 10 x 1. 25 mm
44 N.m
{4.5 kgf.m.
33 rbf.ft)
8 x 1. 25 mm
24 N.m {2.4 kgf.m,
17 rbf.ft)
A/C COMPRESSOR
BRACKET
D16Y5. O16Y8
engine3
lM/Tl:
FRONT
STIFFENER
10 x 1. 25 mm
44 N.m
{i1.5 kgf.m,
33 tbtft)
{
8 x 1. 25 mm
24 N.m
{2.4 kgf.m,
17 tbf.ftl
10x 1. 25 mm
44 N.m (4.5
kg,t m.
33 rbf.ft,
E 4 6
c - t z
t
Engine Installation:
Instal l the engi ne i n the reverse order of removal .
Rei nstal l the mount bol ts/nuts i n the fol l owi ng sequence.
Fai l ure to fol l ow these procedures may cause excessi ve
noi se and vi brati on, and reduce bushi ng l i fe.
1. I nst al l t he t r ansmi ssi on mount and br acket , t hen
ti ghten the bol ts on the frame si de.
NOTE: Do not ti ghten the bol ts/nuts on the trans-
mi ssi on si de.
CW:
TNANSMISSION
MOUNT BRACKET
38 N.m 13.9 kgf.m, 28 lbf.ftl
Except Cw:
TRANSMISSION
MOUNT
(412x1.25mm
?4 N.m {7.5 kgt m,
54 tbf.ftl
(i l
12 x 1. 25 mm
74 N. m 17. 5 kg{. m,
54 rbf.ftl
12 x l 25 mm
64 N.m {6.5 kgf.m,
17 tbt.ftl
UPPER
BRACKET
2. l nstal l the upper bracket, then ti ghten the nuts i n
the numbered sequence shown
(O
-
@).
(cont' d)
5- 13
Instal l ati on
(cont' d)
Instal l the rear mount bracket, then ti ghten the bol ts
i n the numbered sequence shown
(O -
@).
cvT:
O
12 x 1. 25 mm
59 N.m
(6.0 kgJ m,
(}
rbt frl
Repl ace.
12 x 1.25 mm
59 N.m 16.0
kgt'm,
a:l lbt ft)
Repl ace.
O
12 x 1. 25 mm
59 N.m 16.0
kgJ m,
tbf.fr)
Repl ace.
Except CVT:
O
' t 2
x 1. 25 mm
59 N.m 16.0 kg{.m.
$ tbt.ft)
Repl ace.
O1 4 x t . 5 mm
tB N.m 18.5 kgf.m,
61 tbf.ftl
Repl ace.
5- 14
I
-
4. Ti ght en t he bol t / nut s on t he t r ansmi ssi on mount
bracket i n the numbered sequence shown
(Ot
-
@).
O
12 x t.25 mm
74 N.m {7.5 kg{.m, 5il lbtft)
Ti ghten the bol ts on the ri ght front mounvbracket i n
the numbered sequence shown
(O -
O).
CW:
O to x t.zs mm
54 N.m
15.5 kgt.m,
/r0
lbf.ftl
5.
12 x 1. 25 mm
64 N.m (6.5
kgt.m,
47 tbtftl
Except CVT:
Ti ghten the bol ts/nut on the l eft front mount i n the
numbered sequence shown
(O -
O)
O
12 x 1. 25 mm
83 N. m
(8. 5
kgl . m, 61
44 N' m 14. 5 kgt . m,
33 rbf.ftl
@
12 x 1. 25 mm
59 N. m 16. 0 kgt . m,
43 lbf'frl
Repl ace.
10 x L25 mm
a4 N.m 14.5
kgf.m,
33 tbt f0
7. Perform the fol l owi ng:
Cl ean the areas where the dri veshaft(s) and the
i ntermedi ate shaft contact the transmi ssi on
(di f-
ferenti al ) thoroughl y wi th sol vent or carburetor
cl eaner. and drv wi th compressed ai r.
Check that the set ri ngs on the ends of the dri ve-
shaft and i ntermedi ate shaft cl i ck i nto Dl ace.
CAUTION: Use new set rings.
Adj ust the shi ft cabl e
(see
secti on
' 14,.
Adj ust the throttl e cabl e
(see
secti on 11).
Adj ust the crui se control cabl e
(see
secti on 23).
Refi l l the engi ne wi th engi ne oi l
(see page 8-5).
Refi l l the transmi ssi on wi th fl ui d
(see
secti on 13,
14) .
Refi l l the radi ator wi th engi ne cool ant
(see page
10- 6) .
Bl eed ai r from the cool i ng system wi th the heater
val ve open
(see page 10-6).
Cl ean the battery
posts
and cabl e termi nal s wi th
sandpaper. assembl e them, then appl y
grease to
prevenr corroston.
Inspect for fuel Ieakage
(see
secti on 11).
After assembl i ng the tuel l i ne, turn on {l l )
the i gni -
ti on swi tch
(do
not operate the starter) so that the
fuel
pump runs for approxi matel y two seconds
and the fuel l i ne
pressuri zes. Repeat thi s opera-
ti on two or three ti mes, then check for fuel l eak-
age at any poi nt i n the fuel l i ne.
a
a
a
a
a
(cont' d)
5- 15
Instal l ati on
(cont' d)
Mount and Eracket Bolts/Nuts Torque Value Specifications:
A: 10 x
' 1. 25
mm
64 N.m
(6.5
kgf.m, 47 lbnft)
Br 10 x 1. 25 mm
44 N.m
(4.5
kgnm, 33 lbift)
C: 12 x 1. 25 mm
83 N. m
(8. 5
kgf . m, 61 l bl . f t )
D: 12 x 1. 25 mm
59 N.m
(6.0
kgt m, 43 lbl.ft)
Repl ace.
\
SIDE ENGINE
MOUNT
RIGHT FRONT
MOUNT
5- 16
Special Tools
g
\
\ - J
\ a
6-2 .;*'
Rel . No. Tool Number Description oty Page Retsrsnce
o
@
@
@
@
@
o
o r O- 1
a n d O- 2
@
o
OTHAH
-
PJTOl OB
07JAA
-
001010A
07JAB
-
0010204
OTLAJ
.
PR3O2OB
07NAB
-
0010404
07NAJ
-
P07010A
07406
-
0020201
OTMAJ
-
PY4O1 1A
OTMAJ PY4O120
07406
-
0070300
07742
-
0010100
Val ve Gui de Reamer, 5.5 mm
Socket, 17 mm
Hol der Handl e
Ai r Stopper
Hol der Attachment, 50 mm
Pressure Gauge Adapter
A/'I Pressure Hose
A"/T Pressure Hose, 2.210 mm
A/T Pressure Adapter
A/f Low Pressure Gauge W/Panel
Val ve Gui de Dr i ver , 5. 5 mm
6,43
6-8, 10
6-4
6-4
6-4
6-4
6-4
6-41, 42
e='T------_ts
o
@ @
@
@
@
I
VTEC Control System
Troubleshootin g
Flowchart
tFl 2Egl Il "-:1"".
tool i ndi cates Di asnosti c Troubl e Code
(DTC)
Pl 259: A probl em i n the VTEC Pressure Swi tch ci rcui t or
- - - -
V I t C So l e n o r d Va l v e c r r c u i t .
Ref er t o page 1 1 38 t hrough 1 1' 55 bef ore t roubl eshoot i ng.
*
Road Test:
Accel er at e i n l st gear t o an engi ne speed over 3, 000 r pm
(D16Y5
engi ne) or 6, 000 rpm
(D16Y8
engi ne).
Hol d t hat engi ne speed f or at l east t wo seconds.
l f t he DTC P1259 i s not repeat ed duri ng t he f i rst road t est ,
repeat t hi s t est t wo more t i mes.
VTEC PRESSURE SWITCH
CONNECTOR
TERMINAL SIDE OF MALE
TERMINALS
vTM
/Ta
{sr-ulelrt
fll
\3-l
I
I
{9)
Y
I
-L
WIFE SIOE OF FEMALE
TERMINALS
(cont' d)
6-3
The MIL has been reported on.
DTC P1259 is stored.
Check the VTEC Control System:
1. Do t he engi ne cont rol modul e
(ECM)/powertrain
control mod
ule
(PCM)
Reset ProcedLrre
(see
sect i on 11).
2. St art t he engi ne.
3. Warm up t he engi ne t o normal
operal i ng t emperat ure
(cool -
i ng f an comes on).
4. Do t he Road Test . *
Intermittent failure. system is OK
at this time.
Check t or poor conneql i ons or
l oose wi res at VTEC oressure
switch. VTEC solenoid valve and
ECM/PCM.
l s DTC P1259 i ndi cat ed?
Test the VTEC Presslre Switch:
' 1.
Turn t he i gni t i on swi t ch OFF.
2. Disconnect the VTEC Pressure
swrtch connector.
3. Check f or cont i nui t y bet ween
VTEC pressure
swi t ch connec-
t or t ermi nal No. 1 and No. 2.
l s t her e cont i nui t y? fleplace the VTEC pressrre switch.
T6st the VTEC Pressur Switch
Wi 16:
1. Turn t he i gni t i on swi t ch ON
(l l ).
2. Measure t he vol t ag bet ween
VTEC pressure
swi t ch connec'
t or No. 1 and body ground.
Inspect for an open oa short to
ground in the wir betweon tho
VTEC pressure
switch and ECM/
PCM t Cl s).
I t t he wi re i s OK. sub3t i t ut e a
known- good ECM/ PCM r nd
rech6ck.
l s t here approx. 12 V?
YES
(To page 6-4)
VTEC Control System
Troubleshooting Flowchart
(cont'dl
(From page 6-3)
VTEC PRESSURE SWITCH
CONNECTOR
WIRE SIDE OF FEMALE
TERMINAL
A/T LOW PRESSURE
W/PAiIEL
07406-0070300
L-
NOTE: Keep measur i ng t i me as shor t as
possi bl e because engi ne i s runni ng wi t h no
l oad
(l ess
t han one mi nut e).
A/T PRESSURE HOSE
07406
-
0020201
A/T PRESSURE HOSE,
2,210 nn
A/I PRESSURE HOSE
07i106
-
0020201
A/T PRESSURE HOSE,
2-210 mm
07MAJ
-
PY4O11A and
A/T PRESSURE ADAPTER
OTMAJ
-
PY|{}l20
PRESSURE GAUGE
ADAPTER
07NAJ
-
P07010A
IOW PRESSURE GAUGE WPANEL
07406
-O070300
07MAJ
-
PYlOltA .nd
A/T PRESSURE ADAPTER
OTMAJ
-
PYO12O
PRESSURE
GAUGE ADAPTER
07NAJ
-
P07010A
.-,,-t
Tost the VTEC Pt.ssure Switch
Wire:
Measure vol t age across t he VTEC
pressure swi t ch connect or.
Ropair open in the wire batwe'n
VTEC Dr66ure switch and A10 or
A23 ot tho ECM/FCM.
l l t he wi re i a OK, 3ubst i l ut a
known- good ECM/ PCM . nd
rochock.
Test the VTEC Solonoid Valve:
1. Turn t he i gni t i on swi t ch OFF.
2. Remove t he VTEC pr essur e
swi t ch and i nst al l t he speci al
t ool as shown, t hen rei nst al l
t he VTEC pressure swi t ch.
3. Connect a tachometer
(see
sec-
t i on 11) .
5- War m up engi ne t o nor mal
operat i ng t emperat ure
(cool i ng
f an comes on).
6. Check oi i pressure at t he f ol -
l owi ng engi ne speeds: D16Y5
engi ne: 1000 and 3000 r pm,
Dl 6Y8 engi ne: 1000, 3000 and
5000 rpm.
ls pressure below 49 kPa
{0. 5 kgf l cm' , 7
psi )?
Insoect ihe VTEC solenoid valv6.
Test the VTEC Solenoid Valvel
2. Di sconnect t he VTEC sol enoi d
val ve connect or.
3. Attach the baftery
positive ter
mi nal t o t he GFNI YEL t ermi '
nal .
4. St art t he engi ne and check t he
oi l pressure at t he f ol l owi ng
engi ne speed: D16Y5 engi ne
3000 rpm, D16YB engi ne 5000
rpm.
l s t he
pressure
above: D16Y5
engi ne: 250 kPa
(2. 5
kgvcm?,
36
psi ), D16Y8 engi ner390 kPa
(4. 0
kgf / cm' , 57 psi )?
In3ooct tha VTEC solonoid valve.
(To page
6 5)
6-4
l From
page
6-4)
T6t lhe VTEC Pr6.sure Switch:
1. Turn the ignition switch OFF.
2. Reconnect the VTEC
pressure
swrtch connector,
3. St af t t he engi ne.
4. Wi t h t he bat t ery posi t i ve t er-
mi nal connect ed t o t he VTEC
sol enoi d val ve, measure vol t -
age bet ween C15 and A' 10 or
A.23
ls thsre approx.
'12
V above
5,000 rpm?
Rplac the VTEC pressure
switch.
Test th. VTEC Solenoid Valve:
2. Disconnect the battery positive
t ermi nal f rom t he VTEC sol e-
noi d val ve,
t he VTEC sol noi d val ve con-
necl ort ermi nal No. 1 and body
grouno.
l s t here 14
-
30 O? ReDlace the VTEC solonoid valve.
Tosi t ho VTEC Sol enoi d Val v
Wi.e:
Check for continuity between the
VTEC sol enoi d val ve connect or
t ermi nal No. I and A8.
Rpair open in the wiro botweon
the ECM/PCM {48} and VTEC aote-
noid valvo connoclor.
l s t here cont i nuhy?
Tost t ho VTEC Sol enoi d Val vo
Whe:
VTEC solenoid valve connector ter-
mi n6l No. 1 and body ground.
RoDair 3hort in the wire betwoon
rho cM/PcM
(A8l
and VIEC sot-
noid valv6 connoctor,
l s t here cont i nui t y?
Sub3tituto a known-good ECM/
PCM and roch6ck. l f sympt om/
i ndi c. t i on goo3 away, . opl ace
th. originel ECM/PCM.
ECM CONNECTORS
A
(32P1 c
( 3r P)
VTEC SOLENOID
VALVE
CONNECTOR
ECM CONNECTOR
A
(32P1
ws
{GRN/ YELI
6- 5
WIRE SIDE OF FEMALE
TERMINALS
VTEC SOLENOID VALVE
CONNECTON
tT------ I
l[-]f-r
I
I
I
-L
TERMINAL SIDE OF MALE
TERMINAL
WIRE SIOE OF FEMALE
TERMINALS
VTEC SOLENOID VALVE
CONNECTOR
r=
I t--l
I
I
r5'
Y
I
WIRE SIDE OF FEMALE
TERMINAL
VTEC Solenoid Valve
2. Measure resi stance between the termi nal and body
gr ouno.
Resistance: 14
-
30 O
l f the resi stance i s wi thi n speci fi cati ons, remove the
VTEC sol enoi d val ve assembl y f r om t he cyl i nder
head. and check the VTEC sol enoi d val ve fi l ter for
cl oggr ng.
. l f t her e i s cl oggi ng, r epl ace t he engi ne oi l f i l t er
and t he engi ne oi l .
VTEC SOLENOID VALVE ASSEMBLY
Inspection
' 1.
Di sconnect the
' l P
connector from the VTEC sol e-
noi d val ve.
VTEC SOLENOID
VALVE FILTER
Repl ace.
6 x 1 . 0 mm
12 N.m {1.2 ksf.m,8.7 lbf.tr}
o- o
4. If the fi l ter i s not cl ogged,
push
the VTEC sol enoi d
val ve wi th your fi nger and check i ts movement.
. l f the VTEC sol enoi d val ve i s normal , check the
engi ne oi l pressure.
6 x 1 . 0 mm
12 N. m
(1. 2
kgt m, 8. 7 l bt f t l
{
VTEC Rocker Arms
Manual Inspecti on
(D16Y5
engi ne)
2.
1 . Set the No. 1 pi ston at TDC.
Remove the cyl i nder head cover.
NOTE: Refer to page 6-46 when i nstal l i ng the cyl i n-
der head cover.
l vl ove the i ntake secondary rocker arm on the No. 1
cyl i nder manual l y.
Check that the i ntake secondary rocker arm moves
i ndependentl y of the pri mary i ntake rocker arm.
SECONDARY
PBIMARY ROCKER ARM
ROCKER ARM
.
Push and pul l .
Check t he i nt ake secondar y r ocker ar m of each
cyl i nder at TDC.
. l f the i ntake secondary rocker arm does not move,
remove the pri mary and secondary i ntake rocker
arms as an assembl y and check that the pi stons i n
t he secondar y and pr i mar y r ocker ar ms move
smoothl y.
. l f any rocker arm needs repl aci ng. repl ace the pri -
mary and secondary rocker arms as an assembl y.
PBIMARY ROCKER ARM
2.
3.
Manual Inspecti on
(D16Y8
engi ne)
' 1.
Set the No. I pi ston at TDC.
NOTE: Refer to page
6-46 when i nstal l i ng the cyl i n-
der head cover.
Push the i ntake mi d rocker arm on the No, I cyl i n-
der manual l y.
Check that the i ntake mi d rocker arm moves i ndepen-
dentl y of the pri mary and secondary i ntake rocker
arms.
MID ROCKER
ARM
SECONOARY
ROCKER ARM
Check the i ntake mi d rocker arm of each cyl i nder at
TDC.
. l f t he i nt ake mi d r ocker ar m does not move,
remove the mi d, pri mary and secondary i ntake
rocker arms as an assembl y and check that the pi s-
tons i n the mi d and pri mary rocker arms move
smoothl y.
. l f any rocker arm needs repl aci ng, repl ace the
pri mary, mi d, and secondary rocker arms as an
assemol y.
6-7
VTEC Rocker Arms
Inspecti on Usi ng Speci al Tool s
(D16Y5
engi ne)
CAUTION:
. Eelore using the Valve Inspection Tool. make sure
that the ai r pressure gaugs on the ai r compressor
indicates over
iloo
kPa {4 kgt/cm', 57 psil.
a tnspect the valve clearance bgfore rocker arm inspec-
tl on.
. Cover the timing belt with a shop towalto protect the
belt.
.
Check the intake pdmary rocker arm of each cylinder at
TDC.
NOTE: Refer to page 6-46 when i nstal l i ng the cyl i n-
der head cover.
Pl ug the rel i ef hol e wi th the speci al tool .
1 .
6- 8
Y '
OTLAJ
_
PR3O2OB
3. Remove t he seal i ng bol t t rom t he i nspect i on hol e
and connect t he Val ve I nspect i on Tool .
10 x 1. 0 mm
SEALING BOLT
20 N'm {2 0 kgf'm, 14lbf'ft}
AIR STOPPER
OTLAJ
-
PR3O2OB
VALVE INSPECTION
TOOL
(Commerci al l y
avai l abl e)
l0 x 1.0 mm
TNSPECTTON HOLE
ADAPTER
.
Pul l t he di al and
turn to adj ust,
Loosen the regul ator val ve on the val ve i nspecti on
tool and appl y speci fi ed ai r pressure to the i ntake
rocker a.m ti mi ng
pi ston.
Specified Air Prossure:
250 kPa {2.5 kgt/cm,, 36 psil
5. Wi th the speci fi ed ai r pressure appl i ed, push up the
ti mi ng pl ate; the synchroni zi ng pi ston wi l l pop out
and engage the i ntake secondary rocker arm.
Vi sual l y check the engagement of the synchroni zi ng
pi ston.
NOTE:
. The synchroni zi ng pi ston can be seen i n the
gap
betl veen the secondary and pri mary rocker arms,
. Wi t h t he t i mi ng pl at e engaged i n t he gr oove on
t he t i mi ng pi st on, t he pi st on i s l ocked i n t he
pushed
out posi ti on.
TIMII{G
PLATE
SPRII{G
SECONDARY
ROCKER ARM
A|R PNESSURE
$
PRIMARY
ROCKEB ARM
TIMING
SYNCHRONIZI''IG
PISTON
TIMI]TG PLATE
TIMING SPRING
6-9
6. Stop appl yi ng ai r pressure
and push up the ti mi ng
pl ate; the synchroni zi ng pi ston wi l l snap back to i ts
ori gi nal posi ti on.
Vi sual l y check the di sengagement of the synchro-
ni zi ng pi stons.
NOTE:
. When the ti mi ng pl ate i s pushed
up, i t rel eases
the ti mi ng pi ston, l etti ng the return spri ng move
the synchroni zi ng pi ston
to i ts ori gi nal posi ti on.
. Repl ace the i ntake rocker arms as an assembl y i f
ei ther does not work correctl t.
TIMII{G PLATE
otL PASSAGE --il.
PRIMARY ROCKER
ARM
1.
SECO'{OAFY
ROCKER ARII
TIMING SPRIIIIG
RETURIT SPRI G
SY CHRONIZING
PISTON
Remove the speci al tool s.
After i nspecti on, check that the mal functi on i ndi cator
l amp
(Ml L)
does not come on.
TIMING PISTO
I
VTEC Rocker Arms
Inspecti on Usi ng Speci al Tool s
(D16Y8
engi ne)
CAUTION:
. Before using the Valve Inspection Tool, make sure
that the ai r pressure gauge on the ai r compressor
indicales over
il00
kPa
(4
kgt/cm,, 57 psi).
a Inspect the valve clearance belore rocker arm inspec.
ti on,
. Cover the timing belt with a shop towel to protect
the belt.
. Check the intake primary
rocker arm of each cylinder
at TDC.
NOTE: Refer to page 6-46 when i nstal l i ng the cyl i nder
neao cover.
Pl ug the rel i ef hol e wi th the speci al tool .
1 .
6- 10
RELIEF HOLE
Y '
OTLAJ
-
PR3O2OB
3. Remove the seal i ng bol t from the i nspecti on hol e
and connect the Val ve Inspecti on Tool .
10 x 1. 0 mm
SEALING BOI-T
20 N.ln 12.0 kgt.m, 14 lbf.ft)
\
TOOL
(Commerci al l y
avai l abl e)
.
Pul l t he di al and
t urn t o adl ust ,
\
q
4. Loosen the regul ator val ve on the val ve i nspecti on
tool and apply the specified air pressure to the rocker
arm synchronizing piston AVB.
SDecified Air Prsssure:
250 kPa {2.5 kgf/cm,. 36 psi)
PRIMARY ROCKER
ARM
MID ROCKER SECONDARY
ARM ROCKER ARM
TIMING
PISTON
SYNCHRONIZING SYNCHRONIZING
PISTON A PISTON B
Make sure that the i ntake pri mary
and secondary
rocker arms are mechanically connected by the piston
and that the mi d rocker arm does not move when
pushed manual l y.
lf any intake mid rocker arm moves independently of
the primary
and secondary rocker arms. replace the
rocker arms as a set.
7.
Use a 10 mm di amet er r od t o depr ess each l ost
moti on assembl y through i ts ful l movement.
Repl ace any l ost moti on assembl y that does move
smoothl y.
ASSEMBLY
After i nspecti on, check that the MIL does not come
on.
6 - 1 1
Val ve Cl earance
Adjustment
NOTE:
. Val ves shoul d be adj ust ed onl y when t he cyl i nder
head temperature i s l ess than 100"F
(38"C).
. Al ter adj usti ng, retorque the crankshaft
pul l ey bol t
(see page 6-16).
' 1.
NOTE; Referto page G46when i nstal l i ng the cyl i nder
neao cover.
Remove the upper cover
(see page 5-19).
Set the No. 1 pi ston at TDC.
"UP"
mark on the cam-
shaft
pul l ey shoul d be at top, and TDC marks shoul d
align with the cylinder head surface.
TOC MARKS
4. Adi ust val ves on No. 1 cyl i nder.
Intake: 0.18
-
0.22 mm 10.007
-
0.009 i n)
Exhaust: 0.23
-
0.27 mm
(0.009 -
0.011 i nl
"UP"
MARK
\ {
5. Loosen the l ocknut, and turn the adj ustment screw
unti l the feel er gauge sl i des back and forth wi th a
sl i ght amount of dr ag.
D16Y7 engi ne:
CAUTIONT Do not overti ghten the l ocknuts; the
rockgr arms are made ol al umi num.
INTAKE and ExHAUST VALVE
LOCKNUTS
D16Y5, Dl 6Yg engi nes:
INTAKE and EXHAUST VALVE
LOCKNUTS
20 N.m 12.0 kgf.m, 14 lbnft)
{
Adiusting 3crew locations:
\
t 6 a t ^
o - t z
"/
18 N.m
(1.8
kgt m, 13 lbf.ftl
INTAKE
No. 4 No, 3 o. 2
6. Ti ghten the l ocknut, and check the cl earance agai n.
Repeat the adj ustment i f necessary.
FEELER
GAUGE
Rotate the crankshaft 180" countercl ockwi se
(cam-
shaft
pul l ey
turns 90"). The
"UP"
mark shoul d be on
the exhaust si de. Adj ust val ves on No. 3 cyl i nder.
. UP' MARK
7.
8. Rot at e t he cr ankshaf t 180" count er cl ockwi se t o
br i ng No. 4 pi st on t o TDC. Bot h TDC gr ooves ar e
once agai n vi si bl e. Adj ust val ves on No. 4 cyl i nder.
9. Rotate the crankshaft 180" countercl ockwi se to bri ng
No. 2 pi ston to TDC. The
"UP"
mark shoul d be on
the i ntake si de. Adj ust val ves on No. 2 cyl i nder.
-UP"
MARK
6- 13
Val ve Seal s
q
Repl acement
(Cyl i nder
head removal not requi red)
NOTE: Cyl i nder head r emoval i s not r equi r ed i n t hi s
procedure.
The
procedure shown bel ow appl i es when usi ng the i n-
car val ve spr i ng compr essor
( Snap- on YA8845 wi t h
YA8845 2A7l 8" attachment).
!@
Alway wear approved eye protection when
usi ng the i n-car val ve spri ng compressol .
1. Turn the crankshaft so that the No.
' l
and the No. 4
pi stons are at top dead center
(TDC).
2. Remove the cyl i nder head cover and the rocker arm
assemoty.
NOTE:
. Ref er t o page 6 30 f or r ocker ar m assembl y
removal .
When r emov i ng or i ns t al l i ng t he r oc k er ar m
assembl y, do not r emove t he camshaf t hol der
bol t s. The bol t s wi l l keep t he hol der s, spr i ngs
and rocker arms on the shaft.
Refer to page 6-46 when i nstal l i ng the cyl i nder
head cover.
Remove the fuel i nj ectors and the wi re harness.
Usl ng the 8 mm bol ts suppl i ed wi th the tool , mount
t he t wo upr i ght s t o t he cyl i nder head at t he end
camshal t hol der s. The upr i ght s f i t over t he cam-
shaft as shown.
5. I nser t t he cr oss shaf t t hr ough t he t op hol e of t he
t wo uPf l ght s.
3.
L
6- 14
7.
lntake Valve Sealsi
6, Sel ect the 7/8 i n di ameter short compressor attach-
ment, and fasten the attachment to the No. 4 hol e of
the l ever arm wi th the speed
pi n suppl i ed.
l nsert an ai r adaptor i nto the spark pl ug hol e. Pump
ai r i nto the cyl i nder to keep the val ve cl osed whi l e
compressi ng spri ngs and removi ng the val ve keep-
er s.
Posi ti on the l ever arm under l he cross shaft so the
l ever i s perpendi cul ar to the shaft and the compres-
sor attachment rests on top of the retai ner for the
spri ng bei ng compressed. Use the front posi ti on
sl ot on the l ever as shown.
NOTE: Put shop t owel s over t he oal passages t o
prevent t he val ve keepers f rom f al l i ng i nt o t he cyl i n-
OIL PASSAGES
IN-CAR SPRING COMPRESSOR
OIL PASSAGES
J
9. Usi ng a downward moti on on the l ever arm. com-
press the val ve spri ng and remove the keepers from
t he val ve st em. Sl owl y r el ease pr essur e on t he
sPri ng.
Remove the val ve seal s
(see page 6-38).
Instal l the val ve seal s
(see page 6-43,.
Instal l the spri ngs, the retai ners and the keepers i n
reverse order of removal .
10.
12.
t 5 .
1 1 .
14.
Exhaust Valve Seals:
Sel ect the 7/8 i n. di ameter short compressor attach-
ment, and fasten the attachment to the No.2 hol e of
the l ever arm wi th the speed pi n suppl i ed.
Posi ti on the l ever arm under the cross shaft so the
l ever i s
perpendi cul ar
to the shaft and the compres-
sor attachment rests on top of the retai ner for the
spri ng bei ng compressed. Use the front posi ti on
sl ot on the l ever as shown.
NOTE: Put shop t owel s over t he oi l passages t o
prevent
the val ve keepers from fal l i ng i nto the cyl i n-
der head.
IN.CAB SPRING COMPRESSOR
7/8 in SHORT A
6- 15
16.
17.
18.
19.
15, Usi ng a downward moti on on the l ever arm, com-
press the val ve spri ng and remove the keepers from
t he val ve st em. Sl owl y r el ease pr essur e on t he
spnng.
Remove the val ve seal s
(see page 6-38).
l nstal l the val ve seal s
(see page 6-43).
Instal l the spri ngs, the retai ners and the keepers i n
Repeat steps 6 to 18 on the other cyl i nders,
Crankshaft Pulley and Pulley Bolt
Replacement
When i nst al l i ng and
procedure
bel ow,
Cl ean, r emove any
bel ow.
O: Cl ean
x: Remove any oi l
a: Lub.i cate
ti ghteni ng the
pul l ey,
fol l ow the
oi l , and l ubr i cat e poi nt s shown
TIMING BELT
GUIDE PLATE
Crankshaft pully bolt siz and torque value:
14 x 1.25 mm
20 N.m
(2.0
kgf'm. lil lbf'ft] + 90"
NOTE: Do not use an i mpact wrench when i nstal l i ng.
}IOI.DER HANDII
o'JAB
-
tD1020A
HOLDER ATTACHMENT. 50 mm
07 AB
-
00100A
SOCKET, 17 mm
o'JAA
-
@1010A ot
lComm.rcillly rv.ihbl.)
t ^ a t ^
o - t o
L-
CRANKSHAFT
1 . Ti ghten the pul l ey bol t to the speci fi ed torque.
Torque: 20 N'm
(2.0
kgf.m, 14 lbf.ftl
Use a fel t ti p pen to mark the pul l ey bol t head and
wasner.
EMBOSSING MARKS
3. Ti ghten the pul l ey bol t an addi ti onal 90' .
MARKING
\
Ti mi ng Bel t
lllustrated Index
NOTE:
. Refer to page 6-20 for how to posi ti on
the crankshaft and pul l ey before i nstal l i ng the bel t.
. Mark t he di rect i on of rot at i on on t he bel t bef ore removi ng.
a Do not use t he upper cover and l ower cover f or st ori ng removed i t ems.
. Cl ean t he upper cover and l ower cover bef ore i nst al l i ng.
. Repl ace t he camshaf t seal s and crankshaf t seal s i f t here i s oi l l eakage.
. Ref er t o page 6-16 bef ore i nst al l i ng t he t i mi ng bel t .
CYLINDER HEAD
COVER
Refer to page 6 46
when i nst al l i ng.
HEAD COVER GASKET
Repl ace when l eaki ng,
damaged or det eri oral ed.
Appl y l i qui d gasket at
t he t our corners of t he
recesses.
@y
@
TIMING BELT
I nspect aon, page
6-18
Adj ust ment , page 6-18
Removal , page
6-19
l nst al i at i on, page
6, 20
8 x 1. 25 mm
37 N.m
(3.8
kg{.m.27 lbf.ftl
Appl y engi ne oi l t o t he bol t
t hreads.
CRANKSHAFT SPEED FLUCTUATION
ICKF) SENSOR
Repl acement , page 6' 22
UPPER COVER
6 x 1 . 0 mm
9.8 N.m 11.0 kgf.m,
1.2 tbl.trl
RUBAER SEALS
Repl ace when damaged
or deterioratod.
LOWER COVER
RUBBER
PLUG
CRANKSHAFT PULIEY
Repl acement , page 6-16
PULLEY BOLT
1a x 1. 25 mm
20 N.m {2.0 kgl.m,
lia lbf.ft) + 90'
Do not use an impact
wranch when i nst al l i ng.
TIMING BELT
DRIVE PULLEY
Repl acement , page
6-16
10 r 1. 25 mm
4,1 N.m
{4.5 kgf.m, 33 lbtft)
O.RING
Repl ace.
6 x 1 . 0 mm
12Nm11. 2kgl ' m,
8.7 lbf.ftl
6 x 1 . 0 mm
9.8 N.m ll.0 kgf.m,
7.2 tbtftt
6-17
Timing Belt
1 .
Inspection
. Refer to page 6-46 when i nstal l i ng.
Remove the rtpper cover
(see page 6-19).
Inspect the ti mi ng bel t for cracks and oi l or cool ant
soaki ng.
NOTE:
. Repl ace the bel t i f oi l or cool ant soaked.
. Remove any oi l or sol vent that gets on the bel t.
?
Rotate pulley
and i nspect bel t .
After inspecting, retorque the crankshaft pulley bolt
(see page 6-16).
Tension Adjustment
CAUTION: Always adiust the timing belt tension wiih
th engine cold.
NOTE:
. The tensi oner i s spri ng-l oaded to appl y tensi on to the
bel t automati cal l y after maki ng the fol l owi ng adj ust-
menr.
. Al wavs rotate the crankshaft countercl ockwi se when
vi ewed f r om t he
pul l ey si de. Rot at i ng i t cl ockwi se
may resul t i n i mproper adj ustment of the bel t ten-
si on.
. Inspect the ti mi ng bel t before adj usti ng the bel t ten-
ston.
1 . Remove the cyl i nder head cover,
. Refer to page 6-46 when i nstsl l i ng.
Remove the upper cover
(see page 6-19).
Rotate the crankshaft fi ve or si x revol uti ons to set
the bel t.
Set the No. 1 pi ston at TDC
(see page 6-2' 1).
Loosen the adj usti ng bol t 180' .
4.
5.
ADJUSTING BOLT
44 N.m {4.5 kgf m,
33 tbtft)
7.
Rotate the crankshaft countercl ockwi se three teeth
on the camshaft pul l ey.
Ti ghten the adj usti ng bol t.
After i nspecti ng, retorque the crankshaft pul l ey bol t
(see page 6-16).
\
Removal
NOTE:
. Repl ace the ti mi ng bel t at 105.000 mi l es {168,000 km)
accordi ng to the mai ntenance schedul e
(normal
con-
di ti ons/severe condi ti on).
l f the vehi cl e regul ary i s dri ven i n one or more of the
fol l owi ng condi ti ons, repl ace th ti mi ng bel t at 60,000
mi l es
(U.S.A.)
100,000 km
(Canada).
.
In very hi gh temperatures
(over
110' F, 43"C).
.
In very l ow temperatures {under
-20"F, -29"C).
. Turn the crankshaft pul l ey so the No. 1 pi ston i s at
top dead center
(TDC)
before removi ng the bel t
(see
page 6- 21) .
. Inspect the water pump before i nstal l i ng the ti mi ng
bel t {see
page 10-12).
1 . Remove the spl ash shi el d
(see page
5-7).
Loosen the mounti ng bol t and l ock bol t. then remove
the powe. steeri ng
(P/Sl pump bel t and pump.
MOUNTING EOLT
8 x
' l . 25
mm
24 N m {2.4 kgf.m, 17 lbt.ft)
P/S PUMP
BELT
8 x 1.25 mm
24 N.m
(2.4
kgf m, 17 lbnftl
Loosen t he i dl er pul l ey cent er nut and adj ust i ng
bol t, then remove the ai r condi ti oni ng
(A,/C)
com-
pressor belt
(see page 5-6).
Loosen the mounti ng nut and l ock bol t, then remove
the alternator belt.
ALTERNATOR
BELT
8 x 1. 25 mm
2ir N.m 12.4 kgt.m,
17 tbt.ft)
MOUNTING NUT
10 x
' l . 25
mm
44 N.m
(4.5
ksf.m,
33 tbtft)
LOCK BOLT
5. Remove the di psti ck, then remove the upper cover
and i dl er pul l ey
bracket.
NOTE: Do not use the upper cover to store removed
| tems.
UPPER COVER
6 x 1 . 0 mm
9. 8 N. m {1. 0
kgf . m,
7. 2
IDLER
BRACKET
8 x 1. 25 mm
24 N.m l2.il kgf.m. 17 lbf.ft)
6. Remove the upper bracket
(see page
6-29).
NOTE:
. Use a
j ack
to suppon the engi ne before the upper
bracket is removed.
a Make sure to pl ace a cushi on between the oi l
pan and the
j ack.
7.
8.
Remove the crankshaft pul l ey (see page 6-' 16).
Remove the l ower cover and di psti ck pi pe.
NOTE: Do not use the lower cover to store removed
tems.
LOWER
5 x l . 0 mm
9. 8Nm( 1. 0kgf . m.
7.2 tbt.ftl
(cont' d)
6- 19
Ti mi ng Bel t
Removal
(cont' dl
9. Remove the CKF sensor from the oi l oumo.
10. Loosen the adj usti ng bol t 180".
t o r emov e t ens i on f r om t he
reti ghten the adj usti ng bol t.
12 N. m l r. 2 kgl m,
8.7 tbt.trl
Push the tensi oner
t i mi ng be l t , t hen
ADJUSTING BOLT
+l N.m 14.5 kgl.m,
33 tbtftt
1 1. Remove the ti mi ng bel t.
Installation
Instal l the ti mi ng bel t i n the reverse order of removal ;
Onl y key poi nts are descri bed here.
1. Set the ti mi ng bel t dri ve pul l ey so that the No. 1 pi s-
ton i s at top dead center
(TDC).
Al i gn the groove on
the ti mi ng bel t dri ve pul l ey to the poi nter on the oi l
oumo.
FOINTER
TIMING BELT KEY
ORIVE PULLEY
Cl ean.
2. Set t he camshaf t pul l ey t o TDC. Al i gn t he TDC
marks on t he camshaf t pul l ey t o t he cyl i nder head
surface.
'i
TDC MABK
a
3. Instal l the ti mi ng bel t ti ghtl y i n the sequence shown.
oTi mi ng
bel t dri ve
pul l ey (crankshaft) j @Adj usti ng
pul l ey
-)@Water
pump pul l ey
' -r@Camshaft
pul l ey.
NOTE: Make sur e t he t i mi ng bel t dr i ve pul l ey and
camshaft Dul l ev are at TDC.
Loosen and reti ghten the adj usti ng bol t to tensi on
the ti mi ng bel t.
Instal l the l ower cover and upper cover.
NOTE: Cl ean t he upper and l ower cover s bef or e
i nstal l ati on.
Instal l the crankshaft pul l ey, then ti ghten the pul l ey
bol t
(see page 6-16).
Rotate the crankshaft pul l ey about fi ve or sj x turns
countercl ockwi se so that the ti mi ng bel t posi ti ons
on the pul l eys.
Adj ust the ti mi ng bel t tensi on
(see page 6-18).
6.
7.
9. Check that the crankshaft pul l ey and camshaft pul -
l ey are both at TDC.
CRANKSHAFT PULLEY:
CAMSHAFT PULLEY:
l f t he camshaf t or cr ankshaf t pul l ey i s not posi -
ti oned at TDC, remove the ti mi ng bel t and adj ust
the posi ti on fol l owi ng the procedure on
page 6-20.
Then rei nstal l the ti mi ng bel t.
After i nstal l ati on, adj ust the tensi on of each bel t.
. See secti on 23 for al ternator bel t tensi on adj ust-
ment.
. See secti on 22 fot NC compressor bel t tensi on
adJustment.
. See secti on 17 for P/S pump bel t tensi on adj ust-
ment.
' 10.
(WHITEI
"UP"
MARK
TOC MARK
' I
t .
6-21
Crankshaft Speed Fluctuation
(CKF)
Sensor
Repl acement
1. Remove the cyl i nder head cover.
NOTE: Refer to page 6 46 when i nstal l i ng.
Remove the crankshaft pul l ey (see page 6 16).
Remove t he upper cover and di pst i ck/ pi pe
( see
page 6 19) .
Remove t he l ower cover and i dl er pul l ey br acket
(see page 6-19).
Di sconnect the CKF sensor connector, then remove
the CKF sensor.
CKF SENSOR
CONNECTOR
6 x 1 . 0 mm
12 N. m {' 1. 2
kgf . m,
8.7 tbtftl
6. Instal l the CKF sensor i n reverse order of removal .
CKF SENSOR
6-22
Cyl i nder Head
l l l ustrated Index
CAUTION:
. To avoid damage, wait until the engine coolant temperature drops below 100"F 138'Cl betore removing the cylinder
head.
. When handling a metal gaskel, take care not to told it or damage the contact surface.
NOTE: Use new O-ri ngs and gaskets when reassembl i ng.
HEAD COVER GASKET
Repl ace when l eaki ng,
damaged or det6riorated.
Appl y l i qui d gasket at
t he f our corners of t he
WASHER
Repl ace when damaged
or deteriorated.
OOWEL
PINS
6 x 1 . 0 mm
9. 6 N. m (1. 0
kgf . m, 7. 2l bt f t )
Appl y soapsuds t o t hreads and cyl i nder head
contact surface when replacing the rubber
seal, then remove any soapsuds after install-
i ng rubber seal .
RUBBER SEAI.
Replace when damaged
or deteriorated.
CYLINDER HEAD BOLT
10 x 1:25 mm
67 N.m 16.8 kgt.m, a9 lbf.ftl
Ti ght eni ng,
page
&46
Appl y ongi n6 oi l t o t he t hreads.
CYLINDER
HEAD
CYLINDER HEAO
COVEB
Befer to page 6-46, when
i nst al l i ng cyl i nder head cover.
recesses.
OISTRIBUTOR
See section 23.
8 x 1 .25 mm
24 N.m {2.4 kqf.m,
17 tbf.ftl
CYLINDER HEAD
GASKET
Replace.
8 x 1. 25 mm
24 N.m
(2.,0
kgf.m, 17 lbfft)
{cont' d)
6-23
Cylinder Head
lllustrated Index
(cont'dl
Pri or to. reassembl i ng, cl ean al l the parts i n sol vent, dry them and appl y l ubri cant to any contact parts.
D16Y7 engi ne:
I x 1. 25 mm
20 N.m 12.0 kgf.m, 14 lbf.ftl
Appl y engi ne oi l 10 t he
ROCKER ARM
ASSEMELY
Bemoval , page 6-30
I nspect i on, page 6-35
6 x 1 . 0 mm
12 N.m
(1.2
kgf.m, 8.7 lbf.ft)
Appl y engi ne oi l t o t he
t hreaos.
VALVE KEEPERS
c
" B
INTAKE VALVE
Removal , page
6-38
I nst al l at i on, page
6-43
AKE VALVE
SPRI NG
OIL CONTROL
ORIFICE
Cl ean.
AKE VALVE SEAL
Repl ace-
VALVE SPRING
SEAT
O-RING
Repl ace.
INTAKE VALVE
GUI DE
VALVE KEEPERS
SPRING RET
EXHAUST VAL
SPRI NG
EXHAUST VALVE
SEAL
Repl ace.
VALVE SPRING
SEAT
EXHAUST VALVE
GUI DE
Reami ng, page
6, 43
8 x 1. 25 mm
37 N. m
(3. 8
kgt m,
27 tbt.ftl
Appl y engi ne oi l t o
t he t hreads.
EXHAUST
VALVE
Removal , page
6 27
Warpage, page 6-40
Val ve seat recondi t i oni ng,
page 6-40
6 45
,
6-24
D16Y5 engi ne:
wEc solENoro
VALVE
8 x 1. 25 mm
20 N.m 12.0 kg{.m, 14 lbf.ft)
t hreads,
ROCKER ARM
ASSEMBLY
Removal , page 6-30
I nspect i on,
page 6-34
6 x 1 . 0 mm
12 N.m {1.2 kgf.m.8.7 lbf.ftl
t hreads,
CAMSHAFT
6 x 1 . 0 mm
12 N. m 11. 2
8.7 rbt.ftl
VALVE KEEPERS
SPBING RETAINER
INTAKE VALVE
SPRING
INTAKE VALVE SEAL
Repl ace.
VALVE SPRING
SEAT
INTAKE VALVE
GUIDE
VTEC SOLENOID
VALVE FILTER
Repl ace.
OIL CONTROL
ORIFICE
CAMSHAFT
PULLEY
Cl ean.
VALVE KEEPERS
SPRING RETAINER
EXHAUST V
SPRING
EXHAUST VALVE
SEAL
Beol ace.
'
VALVE
SEAT
8 x 1. 25 mm
37 N.m 13.8 kgf.m,
27 lbl-ltl
t he t hreads.
Repl ace.
GUI DE
I nspect i on, page 6 39
Repl acement ,
page 6-41
Reami ng,
page 6-43
INTAKE VALVE
OIL SEAL
Repl ace.
HEAD
Removal , page 6' 27
Warpage,
page 6-40
page 6-40
I nst al l at i on,
page 6-45
EXHAUST
VALVE
Removal, page 6-38
I nst al l at i on, page 6-43
(cont' d)
6-25
Cyl i nder Head
' E
Pri or to reassembl i ng, crean al l the parts i n sorvent, dry them and appl y rubri cant to any contact parts.
D16Y8 engi ne:
LOST MOTION
ASSEMBLY
ROCKER ARM
ASSEMBLY
Bemoval , page
6 30
I nspect i on, page
6-34
lllustrated Index
(cont'd)
VALVE KEEPERS
EXHAUST VALVE O-R|NG
cUt DE Rept ace
l nspect i on, page
6-39
Repl acement , page
6-41
Reami ng, page
6-43
INTA(E VALVE EXHAUST
Removal , page
6 38
VALVE
6, 43
I x 1. 25 mm
20 N. m
{ 2. 0 kgf . m, 14l bf f t l
t hr eads.
6 x 1 . 0 mm
12 N,m 11.2 kgf m, 8.7 lbl ft)
t hreads.
6 x 1 . 0 mm
12 N. m (1. 2
8,7 tbf.fil
CAMSHAFT
l nspect i on, page
6 36
VAI-VE KEEPERS
SPRING RETAINEF
F
" E
INTAKE VALVE
SPRING
WEC SOLENOID
VALVE FILTER
Repl ace.
OIL CONTROL
ORIFICE
Cl ean.
INTAKE VALVE SEAL
Repl ace.
VALVE SPRING
SEAT
INTAKE VALVE
GUI OE
\$
SPRING RET
@
6-26
EXHAUST VALVE
SPRING
EXHAUST VALVE
SEAL
Repl ace.
8 x 1. 25 mm
37 N.m 13.8 kgtm.
21 tbt.ftl
t he t hreads_
otL
Repl ace.
CYLINDER HEAD
Removal , page
6-27
Warpage, page
6 40
page
6' 40
lnsta,'ation, page
6-45
Removal
Engi ne removal i s not requi red for thi s
procedure.
@
Make surs
l acks
and safety stands are
placed properly and hoist brackets are aftached to the
corrcct positions on ihe engins,
CAUTION:
. Uso fonder covers lo avoid damaging painted sur-
facss.
. Unplug the wiring conneqtors carefully while holding
th9 conngctol portion to avoid damage.
. To avoid damaging the cylinder head, wait until the
engi ne cool anl t empor at ur o dr ops bel ow 100' F
(38"G)
before loosening the retaining bolts,
NOTE:
o Mark al l wi ri ng and hoses to avoi d mi sconnecti on.
Al so. be sure that they do not contact other wi ri ng or
hoses. or interfere with other parts.
. Inspect the ti mi ng bel t before removi ng the cyl i nder
head.
. Turn the crankshaft
pul l ey
so that the No. 1 pi ston i s at
top dead center
(see page 6-21).
L
7.
Di sconnect the negati ve termi nal from the battery.
Drai n the engi ne cool ant
(see page 10-6).
. Remove the radi ator cap to speed drai ni ng.
Remove the i ntake ai r duct and ai r cl eaner housi ng
(see page
5-3).
Remove t he mount i ng bol t and l ock bol t , t hen
remove the power steeri ng
(P/S) pump bel t and
pump (see page 5-5).
Loosen t he i dl er pul l ey cent er nut and adj ust i ng
bol t, then remove the ai r condi ti oni ng {Ay' C) com-
pressor
bel t
(see page 5-6).
Loos en t he mount i ng nut and l oc k bol t . t hen
remove the al ternator bel t
(see page 6-19).
Remove the P/S pump bracket {see
page 5-12).
8. Remove the throttl e cabl e by l ooseni ng the l ocknut,
then sl i p the cabl e end out of the throttl e l i nkage.
NOTE:
. Take care not to bend the cabl e when removi ng i t.
Al ways repl ace any ki nked cabl e wi th a new one.
. Adj ust the throftl e cabl e when i nstal l i ng
(see
sec-
t i on 11) .
D16Y7 engi ne:
LOCKNUT
{cont' d)
6-27
Cyl i nder Head
Removal
(cont' dl
9. Rel i eve fuel pressure (see
secti on l 1).
E@
Do not smoke while working on the fuel
systgm. Keep opn flame or 3park away from th9
work area. Drain tuel only into an approved containgr.
10. Remove the evaporati ve emi ssi on
(EVAP)
control
cani ster hose, fuel feed hose and breather hose.
D16Y7 engi ne:
BANJO BOLT
33 N.m {3.4 kgf.m,
25 tbtftl
BREAIHER HOSE
BANJO BOLT
33 N.m 13.4 kgf.m,
2s tbf.ft)
\
11. Remove the brake booster vacuum hose, fuel return
hose and vacuum hose
(see page
5-4).
12. Remove the water bypass hose and posi ti ve crank-
case venti l ati on (PCV)
hose.
D16Y7 engi ne:
WATEB BYPASS
PCV HOSE
6-28
',l
13. Remove t he upper
wat er bypass hose.
WATER
BYPASS
HOSE
radi ator hose, heater hose and
UPPER
RADIATOR
HOSE
1 4 .
HEATER
HOSE
Remove t he engi ne wi r e har ness connect or s and
wi re harness cl amps from the cyl i nder head and the
i ntake mani tol d.
Four fuel i nj ector connectors
Engi ne cool ant t emper at ur e
( ECT)
sensor con-
nector
ECT swi tch connector
ECT gauge sendi ng uni t connector
Throttl e posi ti on sensor connector
Mani f ol d absol ut e pr essur e ( MAP)
sensor con
nector
Pr i mar y heat ed oxygen sensor
( pr i mar y
HO2S)
connector
Secondar y heat ed oxygen sensor
( secondar y
HO2S) connector
(D16Y7
engi ne)
Exhaust gas reci rcul ati on
(EGR)
val ve l i ft sensor
connector
(D16Y5
engi ne)
VTEC sol enoi d val ve connector
(Dl 6Y5,
D16Y8
engr nes)
VTEC pressure swi tch connector
(D16Y5,
D16Y8
engr nes,
l dl e ai r control
(l AC)
val ve connector
a
a
a
a
a
15. Remove t he spar k pl ug caps and di st r i but or f r om
the cyl i nder head.
16. Remove the upper bracket.
NOTE:
. Us e a
j ac k
t o s uppor t t he engi ne bef or e t he
upper bracket i s removed.
. Make sur e t o pl ace a cushi on bet ween t he oi l
pan and the
j ack.
12x 1. 25 f i m
7{ N.m
(7.5
kgt m,
54 tbf.ftl
UPPER
BRACKET
17. Remove the cyl i nder head cover.
(cont ' d)
6-29
Cyl i nder Head Rocker Arms
Removal
(cont' d)
Remove the ti mi ng bel t
(see page 6-19).
Remove the camshaft pul l ey and back cover.
18.
19.
6 x l . 0 mm
CAMSHAFT
PULLEY
Cl ean when i nst al l i ng.
8 x 1. 25 mm
37 N.m {3.8 kgf.m,
2't tbftr)
f:,f'In:J$::'"''n"
20. Remove the exhaust mani fol d
(see pages 9-5 and 9-6).
21. Remove the i ntake mani fol d
(see pages 9-2 thru 4).
22. Remove the cyl i nder head bol ts, then remove the
cyl i nder head.
CAUTION: To prevnt
warpage, unscrew the bolts
in sequence l/3 turn at a time; repeat the sequence
unti l al l bol ts are l oossned.
CYLINDER HEAD BOLTS LOOSENING SEOUENCE:
6- 30
\
1. Loosen the adj usti ng screws.
2. Unscrew the camshaft hol der bol ts, then remove
the rocker arm assembl y.
NOTE:
. Unscrew the camshaft hol der bol ts two turns at a
ti me, i n a cri sscross pattern,
to prevent damag
i ng the val ves or rocker arm assembl y.
. When removi ng the rocker arm assembl y, do not
remove the camshaft hol der bol ts. The bol ts wi l l
keep the camshaft hol ders, the spri ngs and the
rocker arms on the shaft.
CAMSHAFT HOLDER SOLTS LOOSENING
SEOUENCE:
Removal
ADJUSTING SCREWS
Disassembly/Reassembly
NOTE:
. l denti fy parts as they are removed to ensure rei nstal l ati on i n ori gi nal l ocati ons.
. Inspect rocker shafts and rocker arms
(see page 6-35).
. Rocker arms must be i nstal l ed i n the same posi ti on i f reused.
. When removi ng or i nstal l i ngthe rockerarm assembl y, do not removethe camshaft hol der bol ts. The bol tswi l l keepthe
hol ders, spri ngs and rocker arms on the shaft.
Pri or to reassembl i ng, cl ean al l the parts i n sol vent, dry them and appl y l ubri cant to any contact poi nts.
D16Y7 engi ne:
Letter
"8"
is stamped
on rocker arm.
INTAKE ROCKER
ARM B
(4 pl.corl
INTAKE ROCKER
ARM A
la
pl.c$l
ROCKER
I
I
i
B A \ " A
ofr
dT*,.\ft ffi*
" ' r ' l J l l - -
t G t I
No. 3CAMSHAFT
| |
No. 2CAMSHAFT
I l
HoLDER
Lal
HoLDER
_
t
.l
[6] i
;
n]
[n,
,d"h]
UTU
\d*hl
" l ^ a A
INTAKE
R(rcKER SHAFT
SPRING
(4 plac.Bl
ROCKER SHAFT
COLLAR
14
placesl
I
H
ru
B
(cont' d)
6- 31
Rocker Arms
Di sassembl y/Reassembl y
(cont' d)
NOTE:
. l denti fy pans as they are removed to ensure rei nstal l ati on i n ori gi nal l ocati ons.
. Inspect rocker shafts and rocker arms
(see page
6-34).
. Rocker arms must be i nstal l ed i n the same posi ti on
i f reused.
. When removi ng or i nstal l i ng the rocker arm assembl y, do not remove the camshaft hol der bol ts. The bol ts wi l l keep the
hol ders, spri ngs and rocker arms on the shaft.
/ E
Pr i or t o r eassembl i ng, cl ean al l t he par t s i n sol vent , dr yt hem and appl y l ubr i cant t o any cont act poi nt s.
INTAKE ROCKER SHAFT
D16Y5 engi ne:
ROCKER ARMS
ROCKER SHAFT
COLLAR
\
No. 5 CAMSHAFT
HOLOER
EXHAUST ROCKER
ARM 8
{4
placesl
[u
Hlw
l
' l
I
I
IR SHAFT
EXHAUST
ROCKER ARM A
14
placesl
Let t er
"8"
i s st amped
on rocker arm.
Letter
"A"
is stamped
EXHAUST ROCKER SHAFT
6-32
INTAKE ROCKER SHAFT
D16Y8 engi ne:
ROCKER SHAFT
COLLAB
INTAK
BOCKER ARM
ASSEMBLY
/
coLLAR
t r e /
0lluIJllt LF
rs,urtg
]
l-
,fxll^\
r vni <
NO, 1 CAMSHNFT HI I
H.LDER
r-{W
l -
-t
fll
)rJfi F
t v t
\
XHAUST
ROCKEB A8M
-.\
{4
placesl
RUBBER AAND
ROCKER ARMS
\
"o,_.-o"
, mi l
f l a
H+nllf{ -
lu!4
u
t
Etue
I
J
No. 3 CAMSHAFT
HOLDEB
No. 2 CAMSHAFT
HOLDER
No. 4 CAMSHAFT
HOLDER
l-Jf
I
FOCKEB SHAFT
SPRING
(4 place3)
ARM B
Let t er
"A"
i s st amped
Let t er
"B"
i s st amped
EXHAUST ROCKER SHAFT
6- 33
Rocker Arms and Lost Motion Assemblies
Inspecti on
(D16Y5,
D16Y8 engi nesl
NOTE: When r eassembl i ng t he
pr i mar y r ocker ar m,
car ef ul l y appl y ai r pr essur e t o t he oi l
passage of t he
rocker arm.
1. Inspect the rocker arm pi ston. Push i t manual l y.
-
l f i t does not move smoothl y, repl ace the rocker
arm assemory.
D16Y5 engi ne:
PRIMARY ROCKER ARM
TIMING PISTON
TIMI G SPRING
SYNCHRO ENG
PISTOI{
MIO ROCKEB ARM
PRIMARY ROCKER
sYt{cHRof$ztlrlc
PISTON A
NOTE:
. Appl y oj l to the pi stons when reassembl i ng.
a Bundl e the rocker arms wi th a band to prevent them
from separati ng.
6-34
\.
D16Y5 engi ne:
NOTE: Set the ti mi ng pl ate and return spri ng as shown
RETURN
CAMSHAFT HOI.DER
D16Y8 engi ne:
2. Remove the l ost moti on assembl y from the hol der
and i nspect i t. Test i t by pushi ng the pl unger wi th
your fi nger.
-
l f t he l ost mot i on assembl y
pl unger does not
move smoothl y, repl ace i t.
LOST MOTON ASSEMBLY
Pu!h
t
\
.{
{
Rocker Arms and Shafts
Cl earance l nspecti on
Measure both the i ntake rocker shaft and exhaust rocker
shaft.
1. Measure the di ameter of the shaft at the fi rst rocke.
tocauon.
2. Zero the gauge to the shaft di ameter.
3. Measure the i nsi de di ameter of the rocker arm and
check for an out-of-round condi ti on.
Rocker Arm-to-Shaft Clearance:
Standard lNew):
Intake: 0.017
-
0.050 mm
(0.0007 -
0.0020 i n)
Exhaust: 0.018
-
0.054 mm
(0.0007 -
0.0021 in)
Servi ce Li mi t:0.08 mm
(0.003
i n)
I nspect rocker arm
Reoeat these measurements on al l the rockers.
-
l f the cl eara nce i s over the servi ce l i m i t, repl ace the
rocker shaft and al l over tol erance rocker arms.
6-35
r,
Camshaft
Inspection
NOTE:
. Do not rotate the camshaft duri ng i nspecti on.
. Remove the rocker arms and rocker shafts.
L Put the camshaft and the camshaft hol ders on the
cyl i nder head, then ti ghten the bol ts to the speci fi ed
torque.
Spocifiod torqu:
8 mm bolts: 20 N.m 12.0 kgf.m 14 lbf'ft)
Apply engine oil to the threads.
6 mm bolts: 12 N.m
(1.2
kgf.m 8.7 lbf.ft)
Apply engine oil to the th.eads.
6 mm bol ts:
@, @ @, @
6- 36
'u
Seat the camshaft by pushi ng i t toward the rear of
the cyl i nder head.
Zero the dial indicator against the end ofthe camshaft.
Push the camshaft back and forth, and .ead the end
ol av.
Camshaft End Play:
Standard {New):0.05
-
0.15 mm
(0.002 -
0.006 in)
Service Limit: 0.5 mm
(0.02
in)
Remove the bol ts. then remove the camshaft hol d-
ers from the cvl i nder head.
-
Li ft the camshaft out of the cyl i nder head, wi pe i t
cl ean. then i nspect the l i ft ramps, Repl ace the
camshaf t i f any l obes ar e
pi t t ed.
scor d, or
excessl vel y worn.
-
Cl ean the camshaft beari ng surfaces i n the cyl i n-
der head, then set the camshaft back i n
pl ace.
-
Pl ace a
pl asti gage
stri p across each
j ournal .
Instal l the camshaft hol ders, and ti ghten the bol ts to
the soeci fi ed torque.
.g
7.
6. Remove the camshaft hol ders, then measure the
wi dest porti on of the pl asti gage on each
j ournal .
Camshaft-to-Holder Oil Cloarance:
Standard {New}:0.050
-
0.089 mm
{0.002
-
0'004 in)
Sorvi ce Li mi t: 0.15 mm
(0.006
i n)
l f the camshaft-to-hol der oi l cl earance i s out of tol -
erance:
-
And t he camshaf t has al r eady been r epl aced,
you must repl ace the cyl i nder head,
-
l f the camshaft has not been repl aced, fi rst check
the total runout wi th the camshaft suDDorted on
V-bl ocks.
Camshaft Toial Runout:
Standard {Nw): 0.03 mm {0.001 in) max.
Service Limit: 0.0,t mm {0.002 in)
Botate camshaft
whi l e measuri ng.
-
l f the total runout of the camshai t i s wi thi n tol er-
ance, repl ace the cyl i nder head.
-
l f the total runout i s out of tol erance, repl ace the
camshaft and recheck. l f the beari ng cl earance i s
sti l l out of tol erance, repl ace the cyl i nder head,
INTAKE EXHAUST
D 16Y7 engi ne 35.299 {1.3897) 37.281
(1.4678)
D16Y5
engi ne
PRI 38. 427
( 1. 5129)
38.784
(1.5269)
sEc 32.193 \1 .267 4l
D16Y8
engr ne
PRI 36.774 11.44191
38.008
(1.4964)
MI D 38.274
(1.5068)
37.065
(1.45921
8. Check the cam l obe hei ght wear.
Cam l obe hei ght standard {New)
,/a
EX tN EX
+ Dl6YS engine
PRI: Pri mary cam l obe, SEC: Secondary cam l obe.
MID: Mi d cam l obe, T/B: Ti mi ng bel t.
l N: Intake, EX: Exhaust
I I B
- D16Y8 engine
Uni t mm
( i n)
PRI MI DSEC
Check t hi s ar ea f or wear .
6-37
Valves, Valve Springs and
lalve
Seals
Removal
NOTE: l dent i f y val ves and val ve spr i ngs as t hey ar e
removed so that each i tem can be rei nstal l ed
i n i ts ori gi -
nal posi ti on.
1. Usi ng an appropri ate-si zed socket and pl asti c mal -
l et, l i ghtl y tap the val ve retai ner to l oosen the val ve
keepers before i nstal l i ng the val ve spri ng compres-
sor.
Instal l the spri ng compressor. Compress the spri ng
and .emove the val ve keeper.
VALVE SPRING COMPRCSSOR
SnlD-on CF7'l I or KD-383
rYlth t32 JAWS
PLASTIC IIIALLET
SOCKET
6- 38
3. Instal l the val ve gui de seal remover.
SEAL REMOVER
VALVE GUIDE SEAL REMOVER
LISLE P/N 57900 or KD3350
avai l abl e)
VALVE SEAL
4. Remove t he val ve seal .
\
Valve Guides
Intake Valve Dimensions
A Standard
(New):
29.9
-
30.1 mm
B Standard lNewl:
C Standard
{NBw):
C Service Limit:
D Standard
(New):
D Service Limil:
{ 1. 18
-
1. 19 i nl
117.Q.
-
117.72 mm
(4.623 - il.635
in)
5.'18
-
5.49 mm
10.2157
-
0.2161 i n)
5.,t5 mm {0.2146 in}
0.85
-
1.15 mm
{0.033
-
0.045 inl
0.65 mm
(0.026
inl
ExhaustVal ve Di mensi ons
A St8ndard
(Newl :
25.9
-
26.1 mm
B Standsrd
lNew):
C Standard {Newl:
C Service Limit:
D Standard
(New):
D Service Limit:
(1.02 -
1.03 i nl
114.60
-
114.90 mm
14.512
-
4.521in1
5.45
-
5.'16 mm
(0.2146 -
0.2150 i nl
5.42 mm
10.213,[ i n]
1.05
-
1.35 mm
l0.0il1
-
0.053 inl
0.95 mm
(0.037
i n)
Valve Movement
Measure the gui de-to-stem
cl earance wi th a di al i ndi -
cator whi l e rocki ng the stem i n the di recti on of normal
thrust
(wobbl e
method).
Intake Vslve Stem-to-Guide Clearance:
Standard {Newl : 0.04
-
0.10 mm
(0.002 -
0.004 i n)
Servi ce Li mh: 0.16 mm {0.006 i nl
Exhaust Valve Stem-to-Guide Clarance:
Standard l Newl : 0.10
-
0.16 mm
(0.00i1 -
0.fi)6 in)
Service Limit: 0.22 mm {0.009 inl
. l f t he measur ement exceeds t he ser vi ce l i mi t .
recheck usi ng a new val ve.
l f t he measur ement i s now wi t hi n t he ser vi ce
l i mi t, reassembl e usi ng a new val ve.
l f t he meas ur ement s t i l l ex c eeds r he l i mi t .
recheck usi ng the al ternate method bel ow. then
repl ace the val ve and gui de, i f necessary.
NOTE: An al ternate method of checki ng gui de to
stem cl earance i s to subtract the O.D. of the val ve
stem, measured wi th a mi crometer, from the l .D. of
t he v al v e gui de, meas ur ed wl t h an i ns i de
mi crometer or bal l gauge. Take the measurements
i n t hr ee pl aces al ong t he val ve st em and t hr ee
pl aces i nsi de the val ve gui de. The di fference be-
t ween t he I ar gest gui de measur ement and t he
smal l est stem measurement shoul d not exceed the
servi ce l i mi t,
Int8ke Valve Stem-to-Guide Clearancs:
Standard
(Nsw):
0.02
-
0.05 mm
{0.001
-
0.002 inl
10.003 in)
Exhaust Valve Stem-to-Guide Clearance:
Standard
(New):
0.05
-
0.08 mm
(0.002 -
0.003 inl
Servi ce Li mi t 0.11 mm
10.004 i n)
Val ve ext ended 10 mm out f rom seat .
.:I
6-39
Gylinder Head Valve Seats
Warpage
NOTE: l f t he camshaf t - t o- hol der oi l cl ear ances
( see
page 6-36) are not wi thi n speci fi cati on, the cyl i nder head
cannot be resurfaced.
l f the camshaft-to-hol der oi l cl earances are wi thi n sDeci -
fi cati ons. check the cyl i nder head for warpage.
l f warpage i s l ess than 0.05 mm
(0.002
i n), cyl i n-
der head resurfaci ng i s not requi red.
l f warpage i s between 0.05 mm
(0.002
i n) and
0.2 mm
(0.008
i n), resurface the cyl i nder head.
Maxi mum r esur i ace l i mi t i s 0. 2 mm
( 0. 008
i n)
based on a hei ght ot 93 mm
(3.66
i nl .
Measure al ong edges, and three ways across center.
Cylinder Head Height:
Standard {Nowl: 92.95
-
93.05 mm
(3.669 -
3.66i1 inl
6-40
Recondi ti oni ng
1. Renew the val ve seats i n the cyl i nder head usi ng a
val ve seat cuner.
NOTE: l f t he gui des ar e wor n
( see page 6- 39) ,
r epl ace t hem
( see page 6- 41) bef or e cut t i ng t he
val ve seats.
VALVE SEAT
CUTTER
l Commerci al l y avai l abl e)
s
/ - . \ O
3.
Car ef ul l y cut a 45" seat , r emovi ng onl y enough
materi al to ensure a smooth and concentri c seat,
Bevel the upper edge of the seat wi th the 30' cutter
and the l ower edge of the seat wi th the 60' cutter.
Check the wi dth of the seat and adj ust accordi ngl y.
Make one more very light pass with the 45" cutter to
remove any possi bl e burrs caused by the other cut-
ters.
Valv Seat Width:
Standard lNow):
Intake: 0.85
-
1.15 mm 10.033
-
0.0,15 in)
Exhaust 1.25
-
1.55 mm
(0.0/l!' -
0.061 in)
Service Limit:
Intake: 1.6 mm {0.06i1 inl
Exhaust: 2.0 mm {0.079 in)
5. After resurfaci ng the seat, i nspect for even val ve
s eat i ng: Appl y Pr us s i an Bl ue c ompound t o t he
val ve face, and i nsert the val ve i n i ts ori gi nal l oca
ti on i n the head, then l i ft and snap i t cl osed agai nst
the seat several ti mes.
o
--\
. , o
:-e>
Valve Guides
!
I
VALVE
SEAT
PRUSSIAN BLUE COMPOUND
The actual val ve seati ng surface, as shown by the
bl ue compound, shoul d be centered on the seat.
. l f i t i s too hi gh
(cl oser
to the val ve steml , you
must make a second cut wi th the 60" cutter to
move i t down, then one more cut wi th the 45"
cutter to restore seat width.
. l f i t i s too l ow
(cl oser
to the val ve edge), you
must make a second cut wi th the 30' cuuer to
move i t up, then one more cut wi th the 45' cutter
to restore seat width.
NOTE: The fi nal cut shoul d al wavs be made wi th
the 45' cutter.
Insert the i ntake and exhaust val ves i n the head and
measure the val ve stem i nstal l ed hei oht.
Intako. Exhaust Stem Installed Height:
Standard {Newl : 53.17
-
53.6i 1mm
12.W3
-
2.112 inl
Service Limh: 53.89 mm
(2.122
in)
l f the val ve stem i nstal l ed hei ght i s over the servi ce
l i mi t, repl ace the val ve and recheck. l f i ts sti l l over
t he ser vi ce l i mi t , r epl ace t he cyl i nder head; t he
val ve seat i n the head i s too deeD.
7.
Replacement
1. As i l l ustrated bel ow, use a commerci al l y-avai l abl e
ai r-i mpact val ve gui de dri ver attachment modi fi ed
to fit the diameter of the valve guides. In most cases,
the same procedure can be done usi ng the speci al
tool and a conventi onal hammer.
VALVE GUIDE DRIVER
(Commerci al l y
avai l abl e)
5. 3 mm
t-
-]+- s7 mm
| i'2,24 inl
tr_r
1O. 8 mm
10. 42 i nl
or
VALVE GUIDE DRlVEn, 5.5 mm
077i+2
-
0010100
Sel ect the proper repl acement gui des. and chi l l them
in the freezer section of a refrigerator for about an
hour.
Use a hot pl ate
or oven to evenl y heat the cyl i nder
head to 300' F
(150' C).
Moni tor the temperature wi th
a cooki ng thermometer.
CAUTION:
. Do nol use a torch; it may warp the head.
Do not gst the head hottor than 300'F
(150'C);
excessive haai may looson the valvc seats.
To avoid burns, use heavy gloves when handling
the heatod cylinder hoad.
(cont' d)
87 mm
13. 43 i nl
6-41
Valve Guides
Replacement
(cont'd)
Worki ng from the camshaft si de. use the dri ver and
an ai r hammer to dri ve the
gui de about 2 mm {0.1 i n}
towards the combustion chamber. This will knock off
some oJ the carbon and make removal easi er.
GAUTION:
. Always wear safety
goggles ot a tacs shield whon
driving valve guides.
. Hol d the ai r hammer di tectl y i n l i ne wi th i ho
valve guido to
prevent damaging tho driver.
Turn the head over, and dri ve the
gui de out toward
the camshaft si de of the head.
l f a val ve gui de sti l l won' t move, dri l l i t out wi th a
8 mm {5/16 i n) bi t, then try agai n.
CAUTION: Drill guides only in extremo cases;
You
could damag the cylinder head il the guide breaks.
6. Remove the new gui des from the treezer, one at a
ti me, as vou need them.
6-42
7. Appl y a thi n coat of cl ean engi ne oi l to the outsi de
of the new val ve
gui de. Instal l the gui de from the
camshaft si de of the head; use the speci al tool to
dri ve the
gui de i n to the speci fi ed i nstal l ed hei ght. l f
you have al l 16 gui des to do, you may have to reheat
the head,
Valvo Guide Installd Height:
l ntake: 17.85
-
18.35 mm 10.703
-
0.722 i nl
Exhaust: 18.65
-
19.15 mm
(0.734 -
0.754 i n)
VALVE GUIDE
Valves
Reami ng
NOTE; For new val ve gui des onl y.
1. Coat both the reamer and val ve gui de wi th cutti ng
or l ,
2. Rotate the reamer cl ockwi se the ful l l ength of the
valve guide
bore.
3. Cont i nue t o r ot at e t he r eamer cl ockwi se whi l e
removi ng i t l rom the bore,
4. Thoroughl y wash the gui de i n detergent and water
to remove any cutti ng resi due.
Check the cl earance wi th a val ve
(see page 6-39).
Veri fy that the val ve sl i des i n the val ve gui de wi th-
out exenrng pressure.
Turn reamer i n
cl ockwi se di rect i on
REAMER. 5.5 mm
OTHAH
-
PJ'OIOB
REAMER
o-.:
- c )
______---
l .
Installation
Coat val ve stems wi th engi ne oi l . Insert the val ves
i n the val ve gui des.
NOTE: Make sure the val ves move up and down
smoothl y.
Instal l the spri ng seats on the cyl i nder head.
I nst al l t he val ve seal s usi ng t he val ve gui de seal
i nst al l er .
NOTE: Exhaust and i ntake val ve seal s are not i nter-
changeabl e.
WHITE
SPRING
INTAKE VALVE SEAL
2.
3.
BLACK
SPRING
EXHAUST VALVE SEAL
VALVE GUIDE SEAL
INSTALLER
KD2899 (Commerci al t v
avai t abl e)
NOTE: Use smal l t D end ot
(cont' d)
6-43
Valves
Camshaft/Rocker
Arms and
Camshaft Seal /Pul l ey
lnstallation
(cont'd)
I nst al l t he val ve spr i ng and val ve r et ai ner , t hen
i nstal l the val ve spri ng compressor. Compress the
spri ng and i nstal l the val ve keepers.
NOTE: Pl ace the end of the val ve spri ng wi th cl ose-
l y wound coi l s toward the cyl i nder head.
VALVE SPRING COMPBESSOR
{Commerci al l y avai l abl e)
Snao-on CF711 or KD
-
383
with *32 JAWS
Li ghtl y tap the end of each val ve stem two or three
ti mes wi th a
pl asti c mal l et to ensure proper seati ng
of the val ve and val ve keepers.
NOTE: Tap the val ve stem onl y al ong i ts axi s so you
do not bend the stem.
6-44
\'
lnstallation
CAUTION:
. Mske sure that all rockers are in alignmnt with theil
valves whon torquing ths rockor a3sembly bolts.
. Val ve l ocknuts shoul d be l oosgngd .nd sdi usi i ng
screws backed off belore installation.
. To prevent the rocksr arm as3ombly tlom coming
apart, leavs the camshaft holder bohs in the holde6.
1. After wi pi ng down the camshaft. camshaft seal and
j our nal s
i n t he cyl i nder head, l ubr i cat e bot h sur
faces and i nstal l the camshaft.
Cl ean and i nst al l t he oi l cont rol ori f i ce wi t h a new
O-ri ng.
CAMSHAFT SEAL
Seal housi ng surf ace shoul d be dry.
Appl y a l i ght coat of oi l t o camshaf t
and i nner l i p of seal .
3. Turn t he camshaf t unt i l i t s keyway i s f aci ng up
(No.
1
pi st on TDC).
I
OIL CONTROL ORIFICE
Cyl i nder Head
4. Appl y l i qui d gasket (Part
No. 08718
-
0001 or 08718
-
0003) to the head mal i ng surfaces of the No.
' 1
and
No. 5 camshaft hol ders.
-
Appl y l i qui d gasket to the shaded areas.
No. 1
Set the rocker arm assembl y i n pl ace and l oosel y
i nstal l the bol ts.
-
Make sure that the rocker arms are properl y posi -
ti oned on the val ve stems.
Ti ghten each bol t two turns at a ti me i n the sequence
shown bel ow to ensure that the rockers do not bi nd
on the val ves.
Spocitied torque:
I mm bolts:20 N.m
(2.0
kgf.m. 1'l lbf.ft)
Appl y engi ne oi l to the threads.
5 mm bolts: 12 N.m
(1.2
kgil.m, 8.7 lbf.ft)
Apply engine oil to the threads.
6 mm bol ts:
O, @, @, @
o
+
7. Instal l the back cover, then i nstal l the camshaft pul -

tey.
o
/6\
o @
Instal l ati on
Instal l the cyl i nder head i n the reverse order of removal :
NOTE:
. Al ways use a new head gasket.
.
Cyl i nder head and cyl i nder bl ock sur f ace must be
cl ea n.
.
"
UP" mark on the camshaft pul l ey shoul d be at the top.
. Turn the crankshaft so the No. 1 pi ston
i s at TDC
(see
page 6 20) .
. Cl ean the oi l control ori fi ce before i nstal l i ng.
a Do not use the upper cover and l owea cover to store
removeo rl ems.
Cl ean t he upper cover and l ower cover bef ore i nst al -
t at on.
Cyl i nder head dowel pi ns must be al i gned.
1 .
CYLINDER HEAD
' t
(cont' d)
PINS
6-45
Cylinder Head
Installation
(cont'dl
2. Posi ti on the camshaft correctl y
(see page 6-20).
3. Ti ghten the cyl i nder head bol ts sequenti al l y i n four
steps.
lsr step: O
-
@
20 N.m
{2.0
kgt'm, 14 lbl.fr}
2nd step:
G)
-
@
49 N.m
{5.0
kgf.m, 36 lbf.ftl
3rd srop:
O
-
@
67 N'm 16.8 kgf.m, 49 lbf ftl
,lth
step:
o, o
67 N.m
(6.8
kgf.m, 49 tbt.ftl
NOTE:
. We r ec ommend us i ng a beam- t y pe t or que
wrench. When using a preset-type torque wrench,
be sure to tj ghten sl owl y and not to overti ghten.
. l f a bol t makes any noi se whi l e you are torqui ng i t,
l oosen the bol t, and reti ghten i t from the 1st step.
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Instal l the i ntake mani fol d and ti ghten the nuts i n a
cri sscross pattern i n two or three steps, begi nni ng
wi th the i nner nuts
(see pages 9-2 thru 9-4).
. Al ways use a new i ntake mani fol d
gasket.
Instal l the exhaust mani fol d and ti ghten the nuts i n
a cri sscross pattern i n two or three steps, begi nni ng
wi th the i nner nut
(see pages 9-5 and 9-6).
. Al ways use a new exhaust mani fol d gasket.
I nst al l t he exhaust mani f ol d br acket . I nst al l t he
exhaust pi pe A and the bracket, then i nstal l thd cover,
6-46
Instal l the ti mi ng bel t l see
page 6-20).
Adj ust the val ve cl earance {see
page 6-12).
9. Instal l the head cover gasket i n the groove of the
cyl i nder head cover . Seat t he r ecesses f or t he
camshaft fi rst, then work i t i nto the groove around
the outsi de edges.
NOTEI
. Bef or e i nst al l i ng t he head cover gasket , t hor -
oughl y cl ean the seal and the groove.
. When i nstal l i ng, make sure the head cover gas-
ket i s seat ed secur el y i n t he cor ner s of t he
recesses wrtn no gap.
CORNERS OF
THE RECESS
rxe iicess
covER
Appl y l i qui d gasket to the head cover gasket at the
four corners of the recesses.
NOTE:
. Use l i qui d gasket, Part No. 08718
-
0001 or08718
-
0003.
. Check that the mati ng surfaces are cl ean and dry
before appl yi ng l i qui d gasket.
. Do not i nstal l the parts i f fi ve mi nutes or more
hav e el aps ed s i nc e appl y i ng l i qui d gas k er .
Instead, reappl y l i qui d gasket after removi ng ol d
resi due.
o After assembl y, wai t at l east 30 mi nutes before
fi l l i ng the engi ne wi th oi l .
7.
10.
HEAD COVER GASI(ET
11. When i nstal l i ng the cyl i nder head cover, hol d the
head cover gasket i n l he groove by pl aci ng your fi n-
gers on the camshaft hol der contacti ng surfaces
(top
of the semi ci rcl es).
Set tho spark pl ug seal on the spark pl ug pi pe.
Once t he cyl i nder head cover i s on t he cyl i nder
head, sl i de the cover sl i ghtl y back and forth to seat
the head cover gasket.
NOTE:
. Before i nstal l i ng the cyl i nder head cover, cl ean
t he cyl i nder head cont act i ng sur f aces wi t h a
shop towel ,
. Do not touch the
parts where l i qui d gasket was
aDol i ed.
. Take care not to damage the spark pl ug seal s
when i nstal l i ng the cyl i nder head cover.
. Vi sual l y check the spark
pl ug
seal s for damage.
. Repl ace the washer when damaged or deteri o-
rated.
6 x 1 . 0 mm
9.8 N.m 11.0 kgf.m, 7.2 lbf.ftl
SEAL
6-47
t l
12. Ti ghten the nuts i n two or three steps. In the fi nal
step, ti ghten al l bol ts, i n sequence. to 9.8 N.m
(1.0
kgf.m,7.2 l bf.ft).
NOTE: After assembl y, wai l at l east 30 mi nutes
before fi l l i ng the engi ne wi th oi l .
After i nstal l ati on, check that al l tubes, hoses and
connectors are installed correctly.
I
Engi ne Bl ock
Speciaf Tools .............7-2
l l l ust rat ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Flywheel and Drive Plate
Replacement .........7-G
Connecting Rod and Crankshaft
End Pl ay . . . . . . . . . . . . . . . . . 7-6
Main Bearings
Cf earance . . , , , , , , , , , . . . . 7
-7
Selection ................ 7-8
Connecting Rod Bearings
^ Cl earance . . . . . . . . . . . . . . . 7-B
|J
Selection ................ 7-9
Pistons and Crankshaft
Removal . . . . . . . . . . . . . . . . . 7-9
Crankshaft
f nspect i on . . . . . . . . . . . . . . 7-11
Pistons
f nspect i on . , , , , . , , , . . . . , 7-12
Installation ............. 7-20
Cylinder Block
lnspection .............. 7-13
Bore Honi ng . . . . . . . . . . 7-11
Piston Pins
Removal . . . . . . . . . . . . . . . . . 7-14
lnstallation ............. 7-15
Inspection .............. 7-16
Connecting Rods
Seleetion ................ 7-15
Piston Rings
End Gap . . . . . . . . . . . . . . . . . 7-17
Repfacement .........7-11
Ring-to-Groove Clearance ............... 7-18
Alignment .............. 7-18
Crankshaft Oil Seal
Installation ............. 7-19
Crankshaft
fnstaffation .............7-2O
Oil Pan
fnstaffation .............7-22
Oil Seals
lnstaffation .............7-24
Speci al Tool s
Raf. No. Tool Numbor DBcription
(Ny
I
Pag6 Rotorence
o
@
@
@
@
@
o
o
@
@
@
07LAB
-
PV00100
07749
-
0010000
079i17
-
S800200
07948
-
S800101
07973
-
P800200
07973
-
PE00310
07973
-
PE00320
0t913
-
PE00400
07973
-
S800100
07973
-
6570500
07973
-
5570600
Ri ng Gear Hol der
Dri ver
Seal Dri ver
Driver Attachment
Pi l ot Col l ar
Pi ston Pi n Dri ver Shaft
Piston Pin Driver Head
Piston Pin Base lnsen
Piston Base Head
Piston Base
Pi ston Base Spri ng
1
1
1
1
1
I
1
1
1
1
1
7-6
7
-19,
25
7-24
7- ' t 9, 25
7- 14, 15
7- 14. 15
l - 14, 15
l - ' 14, 15
7
- 14,
15
7-' t4, 15
7- ' t 4. 15
@ o @
o
o o
@
@ c,
0
t - 1
!
I
\
L
lllustrated lndex
D16Y7 engi ne:
I
Lrori ""t" "tl i nternal parts wi th engi ne oi l duri ng reassembl y.
NOTE:
. Appl y l i qui d gaskettothe mati ng surfaces ofthe ri ght si de cover and oi l
pumpcase
before i nstal l i ng them.
.
Use l i qui d gasket. part No. 08718
-
0001 or 08718
-
0003.
. Cl ean the oi l pan gasket mati ng surfaces before i nstal l i ng i t.
DRAI N BOLT
44 N. m
(4. 5
kgf . m, 33 l bf . f t l
6 x 1. O mm
12 N. m {1 . 2 kgf . m,
8 7 l bt ' f t l
FLYwHEEL covER
6 x 1 . 0 mm
12 N. m
(1. 2
kgt . m, 8. 7 l bt . f t )
o[ rlt cnsrer
\
,::::T:^ I \
Hii,ilJ
"i'.''
\
'y"
y"::::-
I $5./
OIL PAN
Refet to page 7
-22
ffi::: I fR..r'
.*"' " I
gNliJ' J.f--
><-BL
%S
,t/, o ksf'm,87 rbt'ttr
@ff
t hreads.
NOT: After torquing
each cap, turn the crankshaft
t o check l or bi ndi ng.
Appl y l i qui d gasket t o
t hese poi nt s.
MAI BEARING CAP
CRANKSHAFT
l nst al l at i on, page 7-' 11
MAIN BEARINGS
Selection, page 7-8
11 x 1. 5 mm
51 N.m
(5. 2
kgt m, 3E
6 x 1. 0 mm
1 1 N. m l 1 . 1
OIL PUMP
NOTE: New mai n beari ngs must
be selected by rnatching crank
and block identilication markings.
6 x 1 . 0 mm
1' l N. m (1. 1
kgf . m, 8 l bf . f t )
OI I SCREEN
kgf.m, a lbt.tt)
CRANKSHAFT OIL SEAL
lnstallation,
pages 7-19 and 7-25
\{ePlace
GASKET
Repl ace.
Overhaul . page 8-9
Removal/lnspection,
page
8-10.
CRANKSHAFTSEAL
/.\
lnstallation, pages 7-24--rS)
Repl ace.
6 x 1 . 0 m m
1 1 N, m 1 1 . 1
8 tbr.ftl
DOWEL PIN
6 x 1 . O mm
1' l N. m
( l
. 1 kgf . m,
8 tbt.ftl
RI GHT SI DE COVER
Appl y l i qui d gasker
t o m6t i ng surf ace.
WASHERS
Grooved si des f ace out ward.
NOTE: I hrusr washer t hi ckness
i s f i xed and must not be changed
by gri ndi ng or shi mmi ng.
BRATHING PORT COVER
MOUNT BOLTS
6 x 1. O mm
11 N. m 11. 1 kgf . m, I l bt . f t )
t he bol t t hreads.
(cont' d)
O-RI NG
Repl ace.
kgt.ni,
DOWEL PIN
7-3
lllustrated Index
(cont'dl
I
rubri cate al t i nternal parts wi th engi ne oi l duri ng reassembl y.
NOTE:
. Appl y l i qui d gaskettothe mati ng surfaces ofthe ri ght si de cover and oi l pump case before i nstal l i ng them.
! Use l i qui d gasket, pan No. 08718
-
0001 or 08718
-
0003.
. Cl ean the oi l pan gasket mati ng surfaces before i nstal l i ng i t.
D16Y5. Dl 6Y8 engi n"",
DnAtN BoL,
39 N.m 14.0 kgf' m,
WASHER
OII. PAN
Reler to page 7-23
when i nstal l i ng.
Appl y l i qui d gasker t o
t hese pot nt s,
29 tbf.f!)
\
\
\,-,
6 r 1 . o mm
\ %
12 N. m
( 1. 2
kgf ' m,
8. 7 l bf . t rl
FLYWHEEL COVER
I M/ T)
1 2 x 1 . 0 mm
1 1 8 N. m
(12. O
kst . m, 87 l bl . f t l
1 1 x 1 . 5 mm
51 N.m
15.2 kgt m, 38 lbf.{t)
t hreads.
NOTE: Af t er t orqui ng
each cap, turn crankshaft
t o check l or bi ndi ng.
\s
FLYWHEEL I M/ TI
OIL PAN GASKET
Repl ace.
MAI N
BEARI NG
MAIN BEARINGS
Sel ect i on, page 7-8
NOTE: New mai n beari ngs must
be selected by matching crank
6 x 1. 0 mrn
11 N. m { 1. 1 kgt . m, 8 l bf . f r l
DRIVE PLATE COVER
lA/T or CVTI
1 2 x 1 . O mm
74 N. m
(7. 5
kgf . m, 54 l bf . f t )
DRIVE PLAYE
(A/T
or CVTI
Check for cracks.
OI L SCREEN
GASKET
Repl ace.
pages 7-19 and 7-25
Replace.
RIGHT SIDE COVER
Appl y l i qui d gasket
t o mat i ng surf ace.
6 x 1. 0 mm
11 N. m 11. 1 kgt . m,
8 tbf.frl
DOWEL PIN
CRANKSHAFT OIL SEAL
OI L PUMP
Over haul , page I 9
Removal / l nspect i on,
page 8- 10
to mating surface.
THRUST WASHERS
Grooved si des f ace out ward.
NOTE: Thrust washer t hi ckness
i s f i xed and must not be changed
by gri ndi ng or shi mmi ng.
CRANKSHAFT SEAL
I nst al l at i on, pages 7-24
and 8- 11
Fepl ace.
DOWEL PIN BREATHING PORT COVER
MOUNT BOLTS
6 x 1 . 0 mm
11 N. m {1. 1 kgf . m, 8 l bf . f rl
6 x
'1
.0 mm
' 11
N. m 11 . 1 kgf . m,
I lbt.fr)
7-4
\
NOTE: New rod beari ngs must be sel ected by matchi ng connecl i ng rod assembl y and crankshaft i denti fi cati on marki ngs
(see page 7-9).
Lubri cat e al l i nt ernal part s wi t h engi ne oi l duri ng
reassembl v.
PISTON INSTALLATION DIRECTION:
EXHAUST
4\A6\/A
l o
o
l t . - l
.
t l
v\ y\ 7v
I NTAKE
tl,^t , PISTON RINGS
w,
* a l
@ )
ol i snment, pase 7-18
PISTON
NOTE: Belore removing piston, inspect the
t op of t he cyl i nder bore f or carbon bui l d, up or
ridge. Remove ridge il necessary, page 7-'10
PISTON PIN
Removal , page
7-14
hspect i on, page 7-16
CONNECTING ROD
End play, page 7-6
Sel ect i on, page 7- 15
CONNECNNG ROD
BEARINGS
ENGINE BLOCK
Cyl i nder bore i nspect i on, page 7-13
Warpage i nspect i on, page 7-' 13
Cyl i nder bore honi ng, page 7' 14
Inspect top of each cylinder bore
f or c6rbon bui l d-up or ri dge
before removing piston.
Remove ridge if necessary,
page 7-'10
CONNECNNG ROD CAP NUT
8 x 0, 75 mm
31 Nm( 3, 2kgf . m,
23 tbt.ft)
NOTE: After torquing each bearing
cap, rotate crankshaft to
check t or bi ndi ng.
Clearance. page 7-8
Selection, page 7-9
CONNECTING ROO BEARING
l nst al l at i on. page 7-20
NOTE: Install caps so the
bearing recess is on the
same side as the recess
i n t he rod.
7- 5
Gonnecting Rod and
Flywheel and Drive Plate Crankshaft
Replacement
Manual Transmission:
Remove the si x fl ywheel bol ts, then separate the fl y-
wheel f r om t he cr ankshaf t f l ange. Af t er i nst al l at i on,
ti ghten the bol ts i n a cri sscross pattern.
RING GEAR HOLDER
07LAB
-
PV00100
--4T-1
Htr
ENGINE BLOCK
RI NG GEAR
I nspect ri ng gear
teeth for wear or
damage.
12 x 1. 0 mm
118 N,m 112.0 kgtm,87 lbl.ftl
RING GEAR HOLDER
07LAB
-
PV(x'l00
Automatic Transmission:
Remove the si x dri ve pl ate
bol ts, then separate the dri ve
pl ate from the crankshaft fl ange. After i nstal l ati on, ti ght-
en the bol ts i n a cri sscross oattern.
12 x 1. 0 mm
7- 6
74 N. m {7. 5 kgf m, 54l bl f t l
End Pl ay
ConnGting Rod End Play:
Standard
(New):
0.15
-
0.30 mm {0.006
-
0.012 i nl
Service Limit: 0.,[|) mm {0.016 inl
. l l out-of-tol erance, i nstal l a new connecti ng rod.
. l f sti l l out-of-tol erance. repl ace the crankshaft
(see
pages 7-9 and 7-20).
Push the crankshaft fi rml y away from the di sl i ndi cator,
and zero the di al agai nst the end of the crankshaft. Then
pul l the crankshaft fi rml y back toward the i ndi cator; di al
readi ng shoul d not exceed servi ce l i mi t.
Crankshaft End Play:
Stsndard
{Nw): 0.10
-
0.35 mm {0.004
-
0.0lit in}
ServicE Limit: 0.45 mm
(0.018
inl
. l f end pl ay i s excessi ve, i nspect the thrust wsshers
and thrust surface on the crankshaft.
Repl ace pans as necessary.
NOTE: Thrust washer thi ckness i s fi xed and must not be
changed ei ther by gri ndi ng
or shi mmi ng.
Thrust washers are i nstal l ed wi th grooved
si des faci ng
outward.
I
I
Mai n Beari ngs
Clearance
1 . To check mai n bear i ng- t o- j our nal oi l cl ear ance,
remove the mai n caps and beari ng hal ves.
Cl ean each mai n
j our nal
and bear i ng hal t wi t h a
cl ean shop towel .
Pi ace one stri p of
pl asti gage across each mai n
j our-
nal .
NOTE: tt the engi ne i s sti l l i n the car when you bol t
the mai n cap down to check cl earance, the wei ght
of the crankshaft and fl ywheel wi l l fl atten the pl asti -
gage further than
j ust
the torque on the cap bol t,
and gi ve you an i ncorrect readi ng. For an accurate
r eadi ng, suppor t t he cr ank wi t h a
j ack
under t he
count er wei ght s and check onl y one bear i ng at a
ti me.
Rei nst al l t he bear i ngs and caps, t hen t or que t he
bolts.
lst step: 25 N.m 12.5
kgf'm, 18 lbf'ft)
Final step: 51 N'm 15.2
kgl.m, 38 lbf'ft)
NOTE: Do not rotate the crankshaft duri ng i nspec-
tton.
Remove the cap and beari ng agai n. and measure
the wi dest
pad of the
Pl asti gage.
Main Bearing-to-Journal Oil Clearance:
Standard lNew):
No. 1,5 Journal s:
0.018
-
0.036 mm
(0.0007 -
0'001,+ inl
No- 2, 3,
i[
Jou]nals:
0.02/t
-
0.0,[2 mm {0.0009
-
0.0017 in)
Ssrvice Limit: 0-05 mm {0.002
inl
7.
l f the
pl asti gage measures too wi de or too narrow,
(remove the engi ne i f i t' s sti l l i n the carl . remove the
crankshaft, and remove the upper hal f ol the bear-
i ng. Instal l a new, compl ete beari ng wi th the same
col or code
(sel ect
the col or as shown on the next
page), and recheck the cl earance.
CAUTION: Do not file, shim, or sqape the bearings
or the caps to adiust clearance.
It the pl asti gage shows the cl earance i s sti l l i ncor-
rect, try the next l arger or smal l er beari ng
(the
col or
l i sted above or bel ow that one), and check agai n.
NOTE: l f the oroper cl earance cannot be obtai ned
by usi ng the appropri ate l arger or smal l er beari ngs'
repl ace the crankshaft and start over.
Mai n Beari ngs Connecti ng Rod Beari ngs
Selection
CAUTION: lf the codes are indeciDherable because of an
accumulation ot dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or
detergent.
Crankshaft Bore Code Location
Letters have been stamped on the end of the bl ock as a
code for the si ze of each of the 5 mai n
j ournal
bores.
Use them, and the numbers stamDed on the crankshaft
(codes for mai n
j ournal
si zel , to choose the correct bear-
i nos.
Mai n Joul nal Code Locati on
(Numbers)
Bearin g ldentif ication
Col or code i s
on t he
edge of
t he beari ng.
7- 8
I f-i--l I
l l - - J l
t l . . - l
t t
3
t l
+ t
n
t +
Smal l er Smal l er
mai n beari ng
j ourn8l (t hi cker)
B c D
crank oore
Smal l er beari ng {t hi cker)
Red Pi nk G.een
Gr en Brown
Green Bl ack
Green Brown Elack Bl ue
Clearance
1, Remove the connecti ng rod cap and beari ng hal f.
2. Cl ean t he cr ankshaf t r od
j our nal
and bear i ng hal f
wi th a cl ean shop towel .
3. Pl ace a stri p of pl asti gage across the rod
j ournal .
4. Rei nst al l t he bear i ng hal f and cap, and t or que t he
nut s.
Torque
31 N.m (3.2
kgf.m. 23 lbf.ftl
NOTE: Do not rotate the crankshaft duri ng i nspec-
t t on.
Remove the rod cap and beari ng hal f, and measure
the wi dest part of the pl asti gage.
Conncting Rod Eearing-to-JouJnal Oil Clearance:
Standard l Newl : 0.020
-
0.038 mm
(0.0008 -
0.0015 i n)
(0.(X)2
in)
l f the pl asti gage measures too wi de or too narrow,
remove the upper hal f of the beari ng, i nstal l a new,
compl ete beari ng wi th the same col or code
(sel ect
the col or as shown on the next page), and recheck
the cl earance.
CAUTION: Do not l i l e, shi m. or scrape the boari ngs
or the caps to adiust clearance.
l f the pl asti gage shows the cl earance i s sti l l i ncor-
rect, try the next l arger or smal l er beari ng
(the
col or
l i st ed above or bel ow t hat one) , and check cl ear -
ance agai n.
NOTE; l f the
prooer
cl earance cannot be obtai ned
by usi ng the appropri ate l arger or smal l er beari ngs,
repl ace the crankshaft and stan over.
t
7.
I
I
I
PLASTIGAGE STRIP
\
Pistons and
Crankshaft
Selection
CAUTION: l f the codes are i ndeci pherabl e because of
an accumul ati on ol di rt and dust, do not scrub them
with a wire brush or scraper, Clean them only with sol-
vgnt or detorgent.
Connecting Rod Code Location
Numbers have been stamped on the si de of each con-
necti ng rod as a code for the si ze of the bi g end. Use
them, and the l etters stamped on the crankshaft
(codes
for rod
j ournal
si ze), to choose the correct bearl ngs.
Baring ldentif ication
Col or code i s on t he
Lar ger bi g end bor e
edge of
t he bear i ng.
2 3 4
Smal l er beari ng {t hi cker)
I F; . ' l I
l l B o r l l l l
l l . - . - - - - - - . l l
I I Co r l l l | |
l - l
I
l Do , r r r r l +
Smal l er Smal l er
rod bearing
i ournal
(t hi cker)
Hal f of t he number i s
stamped on bearing
cap and t he ot her
hal l i s st amped on t he
rod.
connecting Rod Journal code Locations lLettersl
Red Pi nk Green
Pi nk Green Erown
Green Brown Bl ack
Gren Brown Black Bl ue
7- 9
Removal
Remove the oi l
pan assembl y.
Remove the ri ght si de cover.
1 .
RIGHT SIDE
COVER
OIL SCREEN
O-RING
RePl ace
4. Remove t he oi l pump.
Pistons and Crankshaft
Removal
(cont'dl
5. Remove the bol ts and the beari ng cap.
CAUTION: To prev6nt warpago, unscrew the bohs
in soquence l/3 turn at a tims; rgpoat the sequenco
until 8ll bolts ara loosonsd.
MAIN BEARING CAP BOLTS LOOSENING SEOUENCE
Remove the rod caps/beari ngs and mai n caps/bear-
i ngs. Keep al l caps/beari ngs i n order
Li ft the crankshaft out of the engi ne, bei ng careful
not to damage
j ournal s.
7- 10
7.
CRANKSHAFT
' 10.
Remove the upper bearing halves from the connect-
ing rods and set them aside with their respective caps.
Rei nstal l the mai n caps and beari ngs on the engi ne
In proper
order.
l f you can feel a ri dge of metal or hard carbon around
t he t op of each cyl i nder , r emove i t wi t h a r i dge
reamer. Fol l ow the reamer manufacturer' s i nstruc-
ti ons.
CAUTION: lf the ridgo is not removed, it may dam-
age tho plstons
as they are pushed
out.
Use the wooden handl e of a hammer to dri ve the
pi stons
out.
Rei nstal l the connecti ng rod beari ngs and caps after
removi ng each pi ston/connecti ng
rod assembl y.
Mark each pi ston/connecti ng rod assembl y wi th i ts
cyl i nder number to avoi d mi xup on reassembl y.
NOTE: The exi sti ng number on the connecti ng rod
does not i ndi cate i ts posi ti on
i n the engi ne, i t i ndi -
cates the rod bore size.
' t1.
12.
13.
\
Grankshaft
Inspection
. Cl ean the crankshaft oi l passages wi th pi pe cl eaners
or a sui tabl e brush.
. Check the keywav and threads.
Alignmont
. Measur e r unout on al l mai n i our nal s t o make
sure the crank i s not bent.
. The di fference between measurements on each
j ournal
must not be more than the servi ce l i mi t.
Crankshaft Total Indicatad Runout:
Standard {Nowl: 0.03 mm 10.001 in} max.
Sorvice Limh: 0.04 mm 10.002 in)
DIAL INOICATOR
Rotate lwo complete
revol ut i ons.
Suppon wi t h l at he
l ype t ool or V-bl ocks.
Out-of-Round and Tapel
. Measure out-o{-round at the mi ddl e of each rod
and mai n
j ournal
i n two
pl aces.
. The di fference between measurements on each
j ournal
must not be more than the servi ce l i mi t,
Journal Out-ot-Round:
Standard
(Now):
0.0025 mm
(0.0001
inl max.
(0.0002
inl
round at mi ddl e.
Measure l aPer
at edges.
. Measure taper at edges of each rod and mai n
j our nal .
. The di fference betl veen measurements on each
j ournal
must not be more than the servi ce l i mi t.
Journal Taper:
Standard {Newl : 0.0025 mm
(0.0001
i n) max.
Service Limit: 0.005 mm 10.0002 in)
7- 11
Pistons
Inspection
1 .
2.
Check the pi ston
for di storti on or cracks.
NOTE: l f cyl i nder i s bored, an oversi zed pi ston
must
be used.
Measur e pi st on
di amet er at di st ance A t r om t he
bottom of the skirt.
A: 5 mm
(0.2
i n)
Piston Diameter:
Standard
(Nw):
74.990
-
74.990 mm
12.9520
-
2.952it inl
Service Limh: 7i1.970 mm
{2.9516 in}
SKI RT DI AMETER
7- 12
3. Calculate the difference between the cvlinder bore
di ameter
(see page 7-131 and pi ston
di ameter.
Piston-to-Cylindr Clearanca
Standsrd
{New): 0.010
-
0.0i|() mm
(0.000'l -
0.0016 inl
Service Limit: 0.05 mm {0.002 inl
l f the cl earance i s near or exceeds the servi ce l i mi t,
i nspect the pi ston
and cvl i nder bl ock for excessi ve
wear.
Oversiz Piston Dismatel
0.25175.23
-75.21mn
(2.9618 -
2.9622 inl
0.50: 75.48
-
75.49 mm 12.9716
-
2.9720 in)
Cylinder Block
Inspection
'1.
Measure wear and taDer in directions X and Y at th ree
l evel s i n each cvl i nder as shown.
Cylinder Bore Size
Standard {New): 75.00
-
75.02 mm
(2.953 -
2.95,1 in)
Srvico Limit: 75.07 mm {2.955 inl
OvsFize
O.25t 75.25
-
75.27 mm
(2.9626 -
2.963,[ in]
0.50: 75.50
-
75.52 mm 12.9721-2.9732in1
Bore Taper
Limit
(Difference
betwoen tirst and third measure.
m6nt) 0.05 mm
(0.002
in)
).
7- 13
. l f measurements i n any cyl i nder are beyond the
Oversi ze Bore Servi ce Li mi t, repl ace the bl ock.
. lf the block is to be rebored. refer to Piston Clear-
ance Inspecti on (see page 7 12) after rebori ng.
NOTE; Scored or scratched cyl i nder bores must be
honed.
Reboring Limit: 0.50 mm
(0.020
in)
2. Check the top of the bl ock for warpage.
Measure al ong the edges and across the center as
shown.
SURFACES TO 8E MEASURED
Engine Block Warpage:
Standard
(New):0.07
mm
(0.003
i n) max.
Service Limit: 0.10 mm 10.004 in)
PRECI SI ON STRAI GHT EDGE
Gylinder Block Piston Pins
l .
Bore Honi ng
Measure cyl i nder bores as shown on page 7-13. l f the
bl ock i s to be reused, hone the cyl i nders and remea-
sure the bores.
Hone cyl i nder bores wi th honi ng oi l and a fi ne
(400
gri t) stone i n a 60 dagree cross-hatch pattern.
NOTEi
. Use onl y a ri gi d hone wi th 400 gri t or ti ner stone
such as Sunnen, Ammco, or equi val ent.
. Do not use stones that are worn or broken.
When honi ng i s compl et e. t hor oughl y cl ean t he
engi ne bl ock of al l metal parti cl es. Wash the cyl i n-
der bores wi th hot soapy water, then dry and oi l
i mmedi atel y to prevent rusti ng.
NOTE: Never use sol vent, i t wi l l onl y redi stri bute the
gri t on the cyl i nder wal l s.
l f scori ng or scratches are sti l l present i n cyl i nder
bores after honi ng to the servi ce l i mi t. rebore the
cyl i nder bl ock,
NOTE: Some l i ght verti cal scori ng and scratchi ng i s
acceptabl e i f i t i s not deep enough to catch your fi n-
gernai l and does not run the ful l l ength of the bore.
CYLI NDER BLOCK
CYLI NDER HONE
NOTE:
. After honi ng, cl ean the cyl i nder thoroughl y wi th
soapy waler.
. Onl y a scored or scratched cyl i nder bore must be
noned.
7- 14
Removal
1. Assembl e t he speci al t ool as shown.
PISTON BASE HEAD
07973
-
SB00100
2. Assembl e and adj ust the l ength of the pi ston
dri ver and shaft to 53 mm
(2.1
i n) as shown.
PISTON PIN DRIVER HEAD
07973
-
PE00320
Pres3
f t
PISTON PIN BASE
INSERT
07973
-
PE00a00
g
E .
g \
Y
.,rro")". rr*,"o
079?3
-
6570600
53 mm
(21
in)
NOTE| Use a hydraul i c press.
When pressi ng t he pi n i n or out ,
make sure that the recessed
poni on of t he pi st on al i gns
wi t h t he l i ps on t he col l ar.
Pl ace the pi ston on the speci al tool and press the
pi n out wi th the speci al tool s and a hydraul i c press.
p t n
+
PISTON PIN
DRIVER SHAFT
0?973
-
PE00310
PILOT OOLLAR
07973
-
PE00200
Gonnecting Rods Piston Pins
Seleetion
Each rod falls into one of four tolerance ranges
(from
0 to
+ 0.024 mm
(0
to + 0.0009 i n), i n 0.006 mm
(0.0002
i n)
i ncrementsl dependi ng on the si ze of i ts bi g end bore. l t' s
then stamped wi th a number 11, 2, 3, or 4l i ndi cati ng the
ran9e.
You may l i nd any combi nat i on ol 1, 2, 3, or 4 i n any
engi ne.
Normal Bore Size:
,18.0
mm
(1.89
inl
NOTE:
Reference numbeG are for bi g end bore si ze and do
NOT i ndi cato the posi ti on of the rod i n the engi ne,
Inspect connecti ng rod for cracks and heat damage.
I
)
Installation
1. Use a hvdraul i c Dress for i nstal l ati on.
a When pressing the pin in or out, be sure you posi-
tion the rscessed flat on the piston against the lugs
on the base attachment,
The arrow must face the
t i mi ng bel t si de ol t he
engi ne and t he connect i ng
rod oil hole must face the
rear of the
PISTOI{ P|r{ DRIVER HEAD
07973
-
PEOO320
Adjust the length of the
piston pin driver to
53 mm
(2. 09
i n)
PISTO PII{ DRIVER SHAFT
07973-PE00310
ffi--Z
PFroI{Prr{
PILOT COTLAR
07973
-
PEq)200
PISTOI{ PIN BASE I SERT
07973
-
PCOO400
PISTOI{ BASE HEAD
07973
-
SB(xtl
(xt
7- 15
Piston Pins
Inspection
' 1.
Measure the di ameter ot the pi ston pi n.
Piston Pin Diamcter:
Standard
(New):
18.994
-
19.000 mm
OveIsiz:
(0.7,078 -
0.7{80 inl
18.997
-
19.003
{0.7,u9
-
0.7,181 in)
NOTE: Al l repl acement pi ston pi ns
are oversi ze.
2. Zero the di al i ndi cator to the
pi ston pi n di ameter.
7- 16
\ {
3. Measure the pi ston pi n-to-pi ston cl earance.
NOTE: Check the pi ston for di storti on or cracks.
l f the pi ston pi n cl earance i s greater than 0.024 mm
( 0. 0009
i n) , r emeasur e usi ng an over si zed
pi st on
pi n.
Piston Pin-to-Piston Clsarance:
Standard {Newl: 0.010
-
0.022 mm
{0.0004
-
0.0009 inl
Check the di fference between the pi ston pi n di ame-
ter and the connecti ng rod smal l end di ameter,
Piston Pin-to-Connecting Rod Intrferonc:
Standard
(New):
0.014
-
0.040 mm
10.0006
-
0.0016 i nl
Piston Rings
1 .
End Gap
Usi ng a pi ston, push a new ri ng i nto the cyl i nder
bore 15
-
20 mm
(0.6 -
0.8 i n) trom the bottom.
Measure the pi ston ri ng end-gap wi th a feel er gauge:
. l f the gap i s too smal l , check to see i f you have
the proper ri ngs for your engi ne.
. l f the gap i s too l arge, recheck the cyl i nder bore
di ameter agai nst the wear l i mi ts on page 7-13.
l f the bore i s over the servi ce l i mi t. the cvl i nder
bl ock must be rebored.
Piston Ring End-Gap:
Top Ring
St8ndard l Nswl : 0.15
-
0.30 mm
{0.006
-
0.012 i n)
Service Limit: 0.60 mm 10.024 inl
Second Ring
Standard lN6wl: 0.30
-
0.,l5mm
{0.012
-
0.018 i nl
(0.028
inl
Oi l Ri ng
Standard lNewl: 0.20
-
0.70 mm
{0.008
-
0.028 inl
Sorvice Limit: 0.80 mm
(0.031
in)
15- 20 mm
{0. 6
-O. 8
i nl
Replacement
2.
1 . Usi ng a ri ng expander, remove the ol d pi ston ri ngs.
Cl ean al l ri ng grooves
thoroughl y.
NOTE:
. Use a squar ed' of f br oken r i ng or r i ng gr oove
cl eaner wi th bl ade to fi t pi ston grooves.
. Top ri ng groove i s 1.0 mm
(0.039
i n) wi de.
. Second ri ng groove i s 1.2 mm
(0.047
i n) wi de.
. Oi l r i ng gr oove i s 2. 8 mm
( 0. 1I
i n) wi de.
. Fi l e down the bl ade i f necessary.
CAUTION: Do not uso a wi re brush to cl ean ri ng
lands, or cut ring lands doeper with cleaning tool.
NOTE: l f the
pi ston
i s to be separated from the con-
necti ng rod, do not i nstal l new ri ngs yet.
Instal l new ri ngs i n the proper
sequence and posi -
ti on {see
page 7-18).
NOTE: Do not reuse ol d pi ston ri ngs.
RING EXPANDER
{Commerci al l y avai l abl e)
7- 17
Piston Rings
Ring-to-Groove
Clearance
After i nstal l i ng a new set of ri ngs, measure the ri ng-to-
groove cl earances:
Top Ring Clearance
Standard lNew): 0.035
-
0.060 mm
{0.0014
-
0.0024 in}
Servic. Limit: 0.13 mm
(0.005
inl
Second Ring Clearance
Standard
(Now):
0.030
-
0.055 mm
(0.0012 -
0.0022 io)
Service Limit: 0.13 mm 10.005
inl
7- 18
Al i gnment
1, Instal l the ri ngs as shown.
Piston Ring Dimensions:
r-T- f
I l r '
I I '
| . - !
A
Top Ring
(Standatd):
A: 2.6 mm {0.10
i n}
B: 1.0 mm
(0.0/t
i n)
Second Ring {Standard):
A: 3.0 mm
(0.12
i nl
B: 1.2 mm
(0.05
i nl
NOTE: The manufacturi ng marks must be faci ng
upward.
,orrrno--"-@
SECONO RING.>
TOP BING lchromo)
Crankshaft Oi l Seal
2. Rotate the ri ngs i n thei r grooves to make sure they
do not bi nd.
Posi ti on the ri ng end gaps as shown
SECOND RING GAP
Approx. 90"
TOP RING GAP
DO NOT
posi t i on any rrng gap
at
pi st on t hrust surf aces,
DO NOT posi t i on sny ri ng gaP
i n l i ne wi t h t he
pi st on pi n hol e.
OIL RING GAP
I
l nstal l ati on
The seal surface on the bl ock shoul d be dry.
Appl y a l i ght coat of oi l to the crankshaft and to
the l i o of the seal .
Dri ve the crankshaft oi l seal i nto the ri ght si de cover
usi ng the speci al tool s.
NOTE: Dri ve the crankshaft oi l seal i n squarel y.
DRIVER
07749
-
0010000
1 .
I nst al l seal wi t h t he
part number si de
f aci ng oui .
Confi rm equal cl earance al l the way around wi th a
feel er gauge.
Cl earance: 0.5
-
0.8 mm
{0.02
-
0.03 i nl
NOTE: Refer to pages' I-24 and 8-11 for i nstal l ati on
of the oi l oumo si de crankshaft oi l seal .
0. 5
- 0. 8
mm
10.02-O.03
i n)
7- 19
Pistons
Crankshaft
{
{
d
lnstallation
Before i nstal l i ng the pi stons, appl y a coat of
engi ne oi l to the ri ng grooves and cyl i nder
bores.
l f t he crankshaf t i s al ready i nst al l ed:
. Set the crankshaft to BDC for each cylinder.
. Remove the connecti ng rod caps. and sl i p short
secti ons of rubber hose over the threaded ends
of the connecti ng rod bol ts.
. Instal l the ri ng compressor, check that the bear
i ng i s securel y i n pl ace, then posi ti on the pi ston
i n t he cyl i nder . and t ap i t i s usi ng t he wooden
handl e of a hammer .
. Stop after the ri ng compressor
pops free, and
check the connecti ng rod-to-crank
j ournal
al i gn-
ment before
pushi ng the
pi ston i nto
pl ace.
. Instal l the rod caps wi th beari ngs, and torque the
nuts to:
31 N.m 13.2 ksl .m,23 l bf.ti )
Appl y engi ne oi l to the bol t threads.
l f the crankshaft i s not i nstal l ed:
. Remove t he r od caps and bear i ngs, i nst al l t he
ri ng compressor, then
posi ti on the
pi ston i n the
cyl i nder and tap i t i n usi ng the wooden handl e of
a hammer .
. Posi ti on al l Di stons at top dead center.
1 .
2.
RUBEER
NOTE: Mai ntai n downward force on the ri ng com-
pr essor t o pr event r i ngs f r om expandi ng bef or e
enteri ng the cyl i nder bore.
RING
The arrow must f ace
t he t i mi ng bel t si de
of t he engj ne.
\ '
COMPRESSOR
(Commerci al l y avai l abl e)
7-20
rod
lnstallation
Betore i nstal l i ng the crankshaft, appl y a coat ot
engi ne oi l to the mai n beari ngs and rod bear-
i ngs,
Instal l the thrust washers i n the No. 4
j ournal
of the
cyl i nder bl ock.
Insert beari ng hal ves i n the cyl i nder bl ock and con-
necti ng rods.
Hol d the crankshaft so the rod
j ournal s
for cyl i nders
No. 2 and No.3 are strai ght down.
Lower the crankshaft i nto the bl ock, seati ng the rod
j our nal s i nt o connect i ng r ods No, 2, No. 3. I nst al l
the rod caps and nuts fi nger-ti ght.
\
1 .
THRUST WASHERS
Grooved si des t ace
L
Rotate the crankshaft cl ockwi se. seat
j ournal s
i nto
connecti ng rods No. 1 and No.4. l nstal l the rod caps
and nuts fi nger-ti ght.
NOTE: Instal l the caps so the beari ng recess i s on
the same si de as the recess i n the rod.
Check rod beari ng cl earance wi th pl asti gage (see
page 7-8). then torque the capnuts.
Torque:
31 N.m
(3.2
kgf.m,23 lbf,ft)
Appl y engi ne oi l to the bol t threads.
NOTE: Reference numbers on the connecti ng rod
are for bi g-end bore tol erance and do not i ndi cate
the
posi ti on of the
pi ston i n the engi ne.
Li ne up t he marks when
i nst al l i ng t he connect i ng
cap.
l - rrn
-
)-
---1l
t--l
-'--tllf
-l
l t l l
7. Instal l the mai n beari ng caps.
Check cl earances wi th pl asti gage (see page
7-7),
then ti ghten the beari ng cap bol ts i n 2 steps.
Fi6t st6p: 25 N'm
(2.5
kgf'm. 18 lbt.ft)
Second stsp: 5t N.m
(5.2
kgf.m, 38 lbf,ft)
NOTE: Coat the thrust washer surfaces and bol t
thresds wi th oi l .
MAN BEAHNG CAP BOLTS TIGHTENING SEOUENCE
CAUTION: Whenever any crankshaft beari ng or
connecting rod bgajing is rgplacad, it is neces3ary
aft6r roassembly to run the ongino at idling spood
until it reaches normal operating temperalure, thon
continuo to run it for approximalely 15 minutes.
8. Appl y l i qui d gasket
to the bl ock mati ng surface of
the ri ght si de cover, then i nstal l i t on the cyl i nder
bl ock.
NOTE:
.
Use l i qui d gasket, part No. 08718
-
0001 or 08718
-
0003.
before appl yi ng l i qui d gasket
. Appl y l i qui d gasket evenl y, b6i ng careful to cover
al l the mati ng surface.
. To prevent oi l l eakage. appl y l i qui d gasket to the
i nner threads of the bol t hol es.
have el apsed si nce appl yi ng the l i qui d gasket,
Instead reappl y l i qui d gasket
after removi ng the
ol d resi due,
. After assembl v, wai t at l east 30 mi nutes before
RI GHT SI DE COVEB
kgl . m,
(cont' d)
7- 21
6 x 1 . 0 mm
1 1 N . m { 1 . 1
8 t bt . f t l
DOWEL PIN
Crankshaft Oi l Pan
{
Instal l ati on
(cont' d)
9. Appl y l i qui d gasket to the oi l pump mati ng surface
of t he bl ock, t hen i nst al l t he oi l pump on t he cyl i n-
der bl ock.
Appl y grease to the l i ps of the oi l seal s.
Then, i nst al l t he oi l pump whi l e al i gni ng t he i nner
r ot or wi t h t he cr ankshaf t . When t he pump i s i n
pl ace, cl ean any excess grease off the crankshaft,
then check that the oi l seal l i ps are not di storted.
NOTE:
. Appl y a l i ght coat of oi l to the crankshaft and to
t he l i p of t he seal .
. Use new O- r i ngs and appl y oi l when i nst al l i ng
t hem.
10. I nst al l t he oi l pump and oi l scr een.
6 x 1 . 0 mm
11 N. m { 1. 1 kgf . m,
a t bt . {t }
6 x 1 . 0 mm
DOWEL PIN
6 x 1 . 0 mm
1 1 N. m
{' l . 1 kgl . m, 8 l bf , l t }
OII- SCREEN
DOWEL PI N
O-RI NG
Repl ace.
.,
,.t ,.i
r
- zz
Appl y l aqui d gasket
al ong t he broken
OI L PUMP HOUSI NG
11 N. m {1. 1 kgf . m,
Instal l ati on
O16Y7 engi nc:
1. Appl y l i qui d gasket on the oi l pump and ri ght si de
cover mati ng areas as shown bel ow.
NOTE:
. Use l i qui d gasket, part No.08718
-
0001 or 08718
-
0003.
. Appl y l i qui d gasket as an even bead. centered
between the edges of the mati ng surface.
. l o prevent oi l l eakage, appl y l i qui d gasket to the
have el apsed si nce appl yi ng t he l i qui d gasket .
Instead reappl y l i qui d gasket after removi ng the
ol d resi due.
.
After assembl y, wai t at l east 30 mi nutes before
CYLI NOER
Br_ocK
L
t o t hese por nt s,
Apply liquid gasket
to these
pornts.
2. I nst al l t he oi l pan gasket and oi l pan.
NOTE:
. Use a new oi l pan gasket.
. Instal l the oi l pan no more than fi ve mi nutes after
appl yi ng l i qui d gasket.
OIL PAN
Appl y l i qui d
gasket t o
t hese poant s.
PAN
GASKET
Repl ace. to these poi nts.
3. Ti ghten the bol ts and
as shown bel ow.
nut s f i nger t i ght at si x poi nt s
Ti ghten al l bol ts and nuts, starti ng from bol t O, cl ock-
wi se i n three steps.
NOTE: Excessi ve ti ghteni ng can cause di stoni on of
oi l pan gasket and oi l l eakage.
Torque: 12 N.m
(1.2
kgl .m,8.7 l bt.ft)
1. I nst al l t he oi l pan gasket on t he oi l pan.
NOTE:
. Use l i qui d gasket, part No. 08718
-
0001 or 08718
,
0003.
.
Check that the mati ng surfaces are cl ean and dry
o Appl y l i qui d gasket as an even bead. cent er ed
between the edges of the mati ng surface.
. To prevent oi l l eakage appl y l i qui d gasket to the
have el apsed si nce appl yi ng the l i qui d gasket.
Instead, reappl y l i qui d gasket after removi ng the
ol d resi due.
. After assembl y, wai t at l east 30 mi nutes before
OIL PAN
GASKET
Repl ace.
(cont' d)
7-23
OI L PAN
Oi l Pan Oi l Seal s
Instal l ati on
(cont' d)
2. Appl y l i qui d gasket to the bl ock mati ng surfaces,
t hen i nst al l t he oi l pan. Appl y l i qui d gasket t o t he
shaded areas.
3. Ti ght en t he nut s f i nger{i ght at si x poi nt s as shown
o
4. Ti ghten al l bol ts and nuts, starti ng from nut
O,
cl ock-
wi se i n three steps.
NOTEr Excessi ve ti ghteni ng can cause di storti on of
oi l pan gasket and oi l l eakage.
Torque: 12 N.m
(1.2
kgf' m,8.7 l bl .ft)
o a
t - z+
OIL PAN
Installation
NOTE:
. Engi ne removal i s not requi red.
. The crankshaft oi l seal housi ng shoul d be dry.
Appl y a l i ght coat of grease to the crankshaft and to
the l i ps of the seal s.
1. Usi ng the speci al tool , dri ve i n the ti mi ng pul l ey-end
seal unti l the dri ver bottoms agai nst the oi l pump.
When the seal i s i n pl ace, cl ean any excess grease
off the crankshaft and check that the oi l seal l i p i s
not di storted.
L
07947-SB00200
l nst al l seal wi t h t he
part number side
f aci ng out .
2. Measure the fl ywheel -end seal thi ckness and the oi l
seal housi ng depth. Usi ng the speci al tool . dri ve the
fl ywheel -end seal i nto the rear cover to the poi nt
where the cl earance between the boftom of the oi l
seal and the ri ght si de cover i s 0.5
-
0.8 mm
(0.02 -
0.03 i n)
(see page 7-191.
NOTE: Al i gn the hol e i n the dri ver attachment wi th
the pi n on the crankshaft.
07749-0010000
DRIVER ATTACHMENT
07948-S800101
l nst al l seal wat h t he
part number si de
f aci ng out .
7-25
IHI
I
/
Special Tools
{
Ref. No. I Tool Numbel Description Oty Page Roforance
o
a2)
07746
-
0010400
07749
-
0010000
07912
-
61 1000' ]
Attachment.52 x 55 mm
Dri ver
Oi l Fi l ter Wrench
1
I
1
a- 12
a- 12
8-7
o
t
\
I
8-2
lllustrated Index
NOTE:
o Use new O-ri ngs when reassembl i ng.
. Appl y oi l to O-ri ngs before i nstal l ati on.
-
0001 or 08718
-
0003.
. Cl ean the oi l pan gasket mati ng surfaces before i nstal l -
I ng.
. Appl y l i qui d gasket to the recesses of the oi l pan gas-
ket
(see page 7-22).
D16Y7 engi n:
OI L PUMP
Overhaul , page
8-9
I nspect aon, page
8-10
t o t he mat i ng surf ace
of t he bl ock.
CAUTION: Do not overtighten the drain bolt.
ENGINE OIL PRESSURE SWITCH
18 N.m {1.8 ksf m, 13 lbf.ft)
1/ 8 i n. BSPT
(Eri t i sh
St andard Pi pe Taper)
2S l hreads/ i nch. Use
proper
l i qui d seal ant .
O-RING
Repl ace.
OIL BREATHER
CHAMBER
6 x 1 . 0 mm
11 N. m { 1. 1
8 lbl.fr)
kst.m,
O.RING
Repl ace.
t o
t hese pornt s.
OIL PAN
GASKET
Repl ace.
OIL FILTER
Repl acement , page
8-7
(cont' d)
6 x 1 . 0 mm
11 N. m
(1. 1
kgl , m,
8 tbf.ft)
GASKET
Repl ace.
PAN
Bef ert o page 7 22
6 x 1 . 0 mm
6 x 1. 0 mm
12 N m (1. 2
kgl m, 8. 7 t bf . f t l
1l N. m {1. 1 kgf . m,
Appt v t i qui d
qasket
ro
8l bf f t )
rhese poi nt s.
DRAIN BOLT
44 N.m
14.5 kgf.m, 33 lbtftl
Do not overt i ght en.
8-3
lllustrated Index
(cont'd)
NOTE:
. Use new O-ri ngs when reassembl i ng.
. Use l i qu;d gasket, Part No. 08718
-
0001 or 08718
-
0003.
. Cl ean the oi l pan gasket mati ng surfaces before i nstal l ,
i ng.
OI L PUMP
Overhaul , page
8-g
I nspect i on, page
8-10
DOWEL
pl N
CAUTION: Do not overtighten the dlain bolt.
18 N.m
11,8 kgf.m, 13 lbt.ft)
1/ 8 i n. BSPT
(Bri t i sh
Standard Pipe Taper)
28 Threads/ i nch. Use
proper
l i qui d seal ant .
t o t he mat i ng surf ace
of t he bl ock.
6 x 1 , 0 mm
11 N. m 11. 1 kgf . m,
8 tbf.ttl
6 x 1 . 0 mm
11 N. m 11. 1 kgt m.
8 tbf.ftl
Repl acement , page
8, 7
BAFFLE PLATE
SCREEN
OIL PAN
GASKET
Repl ace.
6 x 1 . 0 mm
11 N. m 11. 1 kgf . m.
8 tbf.ft)
6 x 1 . 0 mm
11 N. m 11. 1 kgl . m,
8 tbf.ftl
OIL PAN
Ref er t o page 7-23
39 N.m {,r.0 kgl.m, 29 lbf.ft}
Do not overt i ght en.
8-4
urr.o-*tn
12 N'm 11.2 kgl.m,8.7 lbf.ftl
t.
I
Engi ne Oi l
Inspection
1 . Park the vehi cl e on l evel ground, and turn off the
engi ne. Al l ow the oi l a few mi nutes to drai n back
i nto the oi l
pan
so the di psti ck wi l l show the actual
l evel .
Make cenai n that the oi l l evel i ndi cated on the di p-
sti ck i s between the upper and l ower marks.
l f the l evel has droDped cl ose to the l ower mark,
add oi l unti l i t reaches the uooer mark.
CAUTION: Insert the dipstick carefully to avoid bend-
ing it.
Replacement
CAUTION: Removo lhe drain bolt carfully whilo tho
engine is hot; tho hct oil may cau36 scalding,
1. Warm up the engi ne.
2. Drai n the engi ne oi l .
DRAIN BOLT
a,l N.m 14.5 kgt'm, 33 lbf.ft)
Do not overtighten.
D16Y5. Dl6Y8 6ngines:
Bepl ace.
DRAIN BOLT
39 N.m
(,1.0
kgl'm, 29 lbt frl
Do not ovenighten.
(cont' d)
Engi ne Oi l
Requi rement
API Service Grade: Use an
"Energy
Conservi ng" SJ grade oi l or an
"Energy
Conservi ng l l " SH grade oi l ,
SAE 5W
-
30 preferred.
You can al so use an oi l that bears the
API CERTIFICATION mark.
Capaci ty D16Yt engi ne:
3.6 f
(3.8
US qt, 3.2 l mp qt)
at change, i ncl udi ng fi l ter.
3.3 f
(3.5
US qt,
2.9 l mp qt)
at change, wi thout fi l ter.
4. 31
( 4. 5
US qt , 3. 8 l mp qt )
after engi ne overhaul .
Dl 6Y5, D16Y8 engi nes:
3.3 /
(3.5
US qt. 2.9 l mp qt)
at change, i ncl udi ng fi l ter.
3.0 /
(3.2
US qt, 2.6 l mp qt)
at change. wi thout fi l ter.
3.7 /
(3.9
US qt,3.3
tmp qt)
after engi ne overhaul .
Change Every 7,500 miles
(12,000
km) or
12 months (Normal
Condi ti ons).
Ev6ry 3,750 miles
(6.000
km) or
6 months
(Severe
Conditions).
Replacement
{cont'd)
3. Reinstall the drain bolt with a new washer, and refill
the engi ne wi th the rcommendd oi l .
NOTE: Under normal condi ti ons, the oi l fi l ter shoul d be
repl aced at every other oi l change.
Under severe condi ti ons, the oi l fi l ter shoul d be repl aced
at each oi l change.
The numbers i n the mi ddl e of the Apl Servi ce l abel tel l
you the oi l ' s SAE vi scosi ty or wei ght. Sel ect the oi l for
your
car accordi ng to thi s chart:
Ambienl Temperature
An oi l wi t h a vi scosi t y of 5W
-
30 i s pr ef er r ed
f or
improved fuel economy and year-round protection
in the
car. You may use a 10W
-
30 oi l i f the cl i mate i n
your
area
is limited to the temperature range shown on the chart.
20
- 30
8-6
API CERTIFICATION MARK
API SERVICE LABEL
Fi l l the engi ne wi th oi l up to the speci fi ed l evel , run
the engi ne for more than three mi nutes, then check
fof oi l l eakage,
62\"'
\
Oi l Fi l ter
Replacement
2.
1 .
Aftr the engine has been run, the exhaust pipe will
be hot; be careful when working around the exhaust
pi pe.
Be careful when loosening the drain bolt while the
engine is hot. Burns can result because the oil tem.
perature is very high.
Remove the oi l fi l ter wi th the oi l fi l ter wrench.
Inspect the threads and rubber seal on the new fi l ter.
Wi pe oi f the seat on the engi ne bl ock, then appl y a
l i ght coat of oi l to the new fi l ter' s rubber seal .
NOTE: Use onl y fi l ters wi th a bui l t-i n bypass sys-
r em.
Appl y oi l t o rubber seal
bef ore i nst al l i ng.
8-7
Instal l the oi l fi l ter by hand.
After the rubber seal seats, ti ghten the oi l fi l ter cl ock-
wi se wi th the oi l fi l ter wrench.
Tighten: 7/8 turn clockwise.
Ti ghteni ng torque:22 N.m
(2.2
kgf.m, 16l bt.ftl
Oil Filter Oil Pressure
\
Replacement
(cont'dl
Number when rubber
seal is seated,
Use thi s procedure
to ti ghten the fi l ter i f ei ght num-
bers
(1
to 8) are Dri nted on the surface ofthe fi l ter.
1) Make a mark on the oi l fi l ter base under the num,
ber that shows at the bottom of the filter when
the rubber seal is seated.
2) Ti ghten the fi l ter by turni ng i t cl ockwi se seven
numbers from the marked point. For example, if a
mark i s made under the number 2 when the rub-
ber seal i s seated, the fi l ter shoul d be ti ghtened
unti l the number 1 comes up to the marked poi nt.
7, turn
clockwise.
Number af t er t i ght eni ng.
MARK
Number when rubber
seal i s seated
4 5 6 7 at
Number after ti ghteni ng 8 2 3 4 5 6 7
CAUTION: Usi ng any procedure
ol her than those
shown coul d rsul t i n seri ous engi ne damsge due
to oi l l eakage.
5. After i nstal l ati on, fi l l the engi ne wi th oi l up to the spec-
i fi ed l evel , run the engi ne for more than three mi nutes.
then check for oi l l eakage.
8-8
Testing
l f the oi l pressure warni ng l i ght stays on wi th the engi ne
runni ng, check the engi ne oi l l evel . l f the oi l l evel i s cor
rect:
1. Connect a tachometer.
2. Remove the engi ne oi l pressure swi tch, and i nstal l an
orl pressure gauge.
MOUNTING HOLE
ADAPTER
{1/8'r28, BSPT}
(Commerci al l y
avsi l abl e)
OIL PRESSURE GAUGE
l Commerci al l v avai l abl e)
4.
Stan the engi ne. Shut i t off i mmedi atel y i f the gauge
regi sters no oi l pressure.
Repai r the probl em before
cont r nur ng.
Al l ow the engi ne to reach operati ng temperature (fan
comes on at l east twi ce). The pressure
shoul d be:
Engi ne Oi l Temperature: 176' F
(80.C1
Engine Oil Pressure:
Ar l dl e: 59 kPa
10.7 kgf/cm,, 10 psi )
mi ni mum
At 3,000 rpm: 3,t0 kPa
(3.5
kgt/cm,, 50 psi)
mi ni mum
l f oi l pressure i s wi thi n speci fi cati ons, repl ace the
oi l
pressure
swi tch and recheck.
l f oi l pressure i s NOT wi thi n speci fi cati ons, i nspect
t he oi l pump ( see page 8 10) .
Oi l Pump
Overhaul
NOTE:
a Use new O-ri ngs when reassembl i ng.
. Use l i qui d gasket , Par t No. 08718- 0001 or 08718- 0003.
. The rotors must be i nstal l ed to the same di recti on.
. After reassembl y, check that the rotors move wi thout bi ndi ng.
PUMP HOUSING
I nspect i on,
Page
8-10
to mating surface of
t he cyl i nder bl ock
6 x 1 . 0 mm
7 N.m
(0.7 kgf m, 5 lbt'ft)
OUTER ROTOR
I nspect i on,
page 8_10
INNER ROTOR
l nspect i on,
page 8_10
6 x 1 . 0 mm
11 N.m
(1.1
kgt m. 8 lbt.ft)
OIL SEAL
Repl ace.
DOWEL PIN
PUMP COVER
O-RING
Fepl ace.
Val ve must sl i de f t eel y
i n hous, ng bore.
Repl ace i t scored.
I nst al l at i on,
page 8-1 1
g
@
E
.Hwlsren
-/SEALING BOLT
-
39 N.- l{o kgf.m,
29 tbtftl
SPRING
8-9
Oi l Pump
'L
2.
3.
4.
RemovaUl nspecti on/l nstal l ati on
Dr ai n t he engi ne oi l .
Turn the crankshaft and al i gn the whi te groove on
the crankshaft pul l ey wi th the poi nter on the l ower
cover.
Remove the cyl i nder head cover and upper cover.
Remove t he power
st eer i ng pump bel t , ai r condi ,
ti oner bel t and the ai ternator bel t.
Remove the crankshaft pul l ey
and remove the l ower
cover.
6. Remove the ti mi ng bel t.
7. Remove the dri ve pul l ey.
8. Remove the oi l pan and oi l screen.
O. RI NG
Repl ace. DOWEL PIN
9. Remove t he oi l pump.
8- 10
OIL SCREEN
10. Remove the screws from the pump hausi ng, then
separate the housi ng and cover.
Check the i nner-to' outer rotor radi al cl earance on
the pump rotor. l f the i nner-to-outer rotor cl earance
exceeds t he ser vi ce l i mi t . r epl ace t he i nner and
ourer rorors.
Inner Rotor-to-Outer Rotor Radial Clarsnce
Standard
(New):
0.02
-
0.14 mm
{0.001
-
0.006 i nl
Service Limit: 0.20 mm {0.008 in)
OUTER ROTOR
INNER ROTOR
Cnecl i the housi ng-to-rotor axi al cl earance on the
pump rotor, l f the housi ng-to-rotor axi al cl earance
exceeds the servi ce Ii mi t, repl ace the set of i nner
and outer rotors and/or the pump housi ng.
Housing-to-Rotor Axial Clearance
Standard
(New):
0.03
-
0.08 mm
(0.001 -
0.003 i nl
Servi ce Li mi t: 0.15 mm {0.006 i n)
1 1 .
1 t
ROTORS
\
13. Check the housi ng-to-outer rotor radi al cl earance.
It the housi ng-to-outer rotor radi al cl earance exceeds
the servj ce l i mi t, repl ace the set of i nner and outer
rotors and/or the pump housi ng
Hoqsing.to.Outor Botor Radial Clearance:
Standard {New): 0.10
-
0.18 mm
(0.004 -
0.007 in)
(0.008
in)
HOUSING
Inspect both rotors and the pump housi ng for scor-
i ng or other damage. Repl ace parts i f necessary.
Remove the ol d oi l seal from the oi l pump.
Usi ng the speci al tool , gentl y tap i n the new oi l seal
unti l the dri ver bottoms agai nst the pump.
NOTE: The oi l seal al one can be repl aced wi thout
removi ng the oi l pump.
DRtvER
0?7i19
-
0010000
1 4 .
15.
t o.
ATTACHMENT.
5 2 x 5 5 mm
07746
-
0010i100
18.
19.
20.
21.
' 17.
Reassembl e t he oi l pump, appl yi ng t hr ead l ock t o
the pump housi ng screws.
Check that the oi l pump turns treel y.
Appl y a l i ght coat of oi l to the seal l i p.
Instal l the two dowel pi ns and new O-ri ng on the oi l
pump.
Appl y l i qui d gasket to the cyl i nder bl ock mati ng sur-
face of the oi l pump.
NOTE:
-
0001 or 08718
-
0003
. Appl y l i qui d gasket evenl y, i n a narrow bead cen
tered on the mati ng surface.
. To prevent oi l l eakage, appl y l i qui d gasket to the
. Do not i nstal l the pans i f fi ve mi nutes or more
hav e el aps ed s i nc e appl y i ng l i qui d gas k et .
Instead reappl y l i qui d gasket
after removi ng the
ol d resi due.
.
After assembl y, wai t at l east 30 mi nutes before
(cont' d)
al ong t he broken l i ne.
8 - 1 1
Oi l Pump
RemovaUl nspecti on/l nstal l ati on
(cont' d)
22. Instal l the oi l pump on the cyl i nder bl ock.
Appl y grease to the l i p of the oi l pump seal .
Then, i nstal l the oi l pump onto the crankshaft.
When the pump i s i n pl ace, cl ean any excess grease
off the crankshaft and check that the oi l seal l i p i s
not di storted.
6 x 1 . 0 mm
11 N. m 11. 1 kgf m,
I rbt.ftt
23.
24.
6 x' l .O mm
11 N.m
(1.1
kgf.m,
11 N' m
(1.1
kgtm,
8l bf ftl
8 tbt.ftl
l nst al l t he oi l scr een.
I nst al l t he oi l pan ( see page 7, 22) .
NOTE: Cl ean the oi l pan gasket mati ng surfaces.
8-12
Intake Manifold/Exhaust System
lntake Manifold
Repl acement . . . . . . . . . . -. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Exhaust Manifold
Rep| acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Exhaust Pipe and Muffler
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Three Way Catalytic Converter
(TWC)
I nspect i on . . . . . . . . . . . . . . . . . . . . . . 9-9
Heated Oxygen Sensor {HO2S)
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Intake Mani fol d
Replacement
NOTE: Use new O-ri ngs and gaskets when reassembl i ng,
CAUTION:
. Chck for lolds or scratches on the surtace of the gasket.
. Replace with a new gasket if damaged.
D16Y7 engi ne:
8 x 1. 25 mm
22 N.m 12.2 kgl.m, 16lbfftl
INTAKE MANIFOLO
Replace if cracked or
i t mat i ng surt aces are
oama9eo,
8 x 1. 25 mm
23 N.m
(2.3
kgt.m,
1? tbt.ftl
INTAKE MANIFOLD
ERACKET
E x 1. 25 mm
2a N.m 12./t kgf.m, 17 lbtftl
g-2
D16Y5 engi ne:
6 x 1 . 0 mm
12 N.m l'1.2 kgt.m,8.7 lbtftl
EGR CHAMBER
INTAKE MANIFOLD
Replace if cracked or
if mating surfaces arc
oamageo.
8 x 1. 25 mm
21 N.m {2.1 kgf.m,
15 tbf f0
INTAKE AIR CONTROL
IIAC} VALVE
(M/TI
8 x 1. 25 mm
22 N.m
(2.2
kqf.m, 16 lbf.ftl
INTAKE MANIFOLD
BRACKET
EXHAUST GAS
RECIRCULATION
{EGRI VALVE
8 x 1. 25 mm
22 N.m
(2.2 kgf.m,
16 tbt tr)
8 x 1. 25 mm
23 N.m 12.3 kgf.m,
17 tbf.frl
(cont' d)
9-3
Intake Manifold
Replacement (cont'dl
NOTE: Use new O-ri ngs and gaskets
when reassembl i ng.
CAUTION:
. Check for folds or scraichss on the surface of the gasket.
. Replace with a new gasket it damaged.
D16Y8 engi ne:
INTAKE MANIFOLD
Replace it cracked or
il mating surfaces are
oamageo.
INTAKE AIR CONTROL
{IAC) VALVE
(M/T)
GASKET
Replace.
THROTTLE
BODY
See sect i on 11.
I x 1. 25 mm
23 N.m {2.3 kgf.m,
17 rbt.ftl
INTAKE MANIFOLD
BRACKET
9-4
$"^
N
Exhaust Mani fol d
Replacement
NOTE: Use new gaskets and sel f-l ocki ng nuts when reassembl i ng.
CAUTION:
. Check for folds or scraiches on the surtace of lhe gasket.
. Replace with a new gaskei if damaged.
I x 1. 25 mm
24 N.m
{2,4 kgtm, 17 lbf,ft}
PRIMARY HEATED
OXYGEN SENSOR
{PRIMARY HO2SI
44 N.m (4.5
kgf.m, 33 lbt.ft)
Repl acement , page
9 9
10 x 1. 25 mm
44 N.m 14.5 kgt.m,
33 tbf.ftl
GASKET
Fepl ace.
8 x 1. 25 mm
31 N.m 13.2 kgf.m.
23 tbt.ft)
Repl ace.
THREE WAY CATALYTIC
CONVERTER {TWC)
I nspect i on, page 9' 9
6 x 1 , 0 mm
11 N. m
(1. 1
kgf . m, 8l bt f t )
SECONDARY HEATED
OXYGEN SENSOR
ISECONDARY HO2S}
4zl N.m 14.5 kgf.m, 33 lbl.ftl
Bepl acement , page 9-10
MANIFOLD
BRACKET
{cont' d)
9- 5
)
Exhaust Manifold
Replacement (cont'd)
NOTE: Use new gaskets
and sel f-l ocki ng nuts when reassembl i ng.
CAUTION:
.
Check tor lolds or scratches on thg surfac6 ol the gaskgt.
o
Replace with a new gasket if damaged.
D16Yg sngi ne:
8 x 1 .25 mtn
2a N.m {2.4 kgf.m,
t7 tbf.ft)
L
E x 1.25 mm
3l t&m 13.2 kgf.m,
23 tbt'ftt
Rplacs.
PNIMARY HO2S
14 N.m 14.5 kgt.m, 33 lbt.ft)
EXXAUST MANIFOLD
BRACKET
10 x 1. 25 mm
44 N.m (4.5
kgf.m,33 lbf.ft,
9-6
Repl acement
NOTE: Use new gaskets and sel f-l ocki ng nuts when reassembl i ng.
MUFFI.ER
HEAT SHIEI.I)
6 x t . 0 mf i
9.E N.ft
(1.0 kst'm, 7.2 lbl'ftl
"e*......------------
EXHAUST PIP NP
6 x 1.0 m.n
9.8 N.m {1.0 kgt.m, 7.2 lbf.ftl
8 x 1. 25 mm
22 N.m 12.2 kgt.m.
16 tbf.frl
Repl ace.
Ti ght en t he bol t s i n
st eps, al t . nal i ng
side-to-side.
8 x 1. 25 mm
22 N.m {2.2 kgf.m, 16 |bfftl
Repl ace.
Tighten the bolts in steps,
akernat i ng si de-t o-si de.
GASKET
Repl ace.
SELF.I-OCKING NUl
8 x 1.25 mm
16 N.m
(1.6
kg
.m.
12 lbf.tt)
Repl ace.
(cont' d)
9-7
)
s
Replace.
------------->@
SEI.f.LOCKING NUT
10 x 1.25 mm
33 N.m 13.4 kgtm,
25 tbt ftl
Replace.
Replacement
(cont'd)
NOTE: Use new gasket s
and sel f -l ocki ng nut s when reassembl i ng.
Dl 6Yg engi ne:
MUFFLER
HEAT SHIELD
6 x 1 . 0 mm
9.8 N.m {1.0 kgf.m, 7.2 lbt.ftl
EXHAUST PIPE
EXHAUST PIPE TIP
I
o.4/
- 6 r 1 . 0 m m
9.8 N.m {1.0 kgf.m, 7.2 lbf.ftl
8 x 1. 25 mm
22Nm12. 2kgt m,
16 tbt.ft)
Fepl ace.
Ti ght en t he bol t s i n
st ePs, al t ernat i ng
si de-t o si de.
SELF.LOCKING NUT
l 0 x 1. 25 mm
33 N.m {3.4 kgf.m,
25 tbt.ft)
Repl ace.
L
SECONDARY H()2S
a4 N.m (4.5
kgf.m, 33lbf.ftl
Repl acement , page
9-10
GASKET
Repl ace.
TWC
GASKETS
Repl ace.
EXHAUST PIPE A
8 x 1. 25 mm
22 N.m
(2.2
kgt.m, 16 lbf.ftl
Repl ace.
Ti ght en t he bol t s i n st eps,
al t ernat i ng si de-t o-si de.
SELF.LOCKING NUT
t 0 x 1. 25 mm
54 N. m
15. 5 kgt m, 40 t bt f t l
Replace.
9-8
16 N.m {1.6 kgl.m, 12lbt.ft)
Repl ace.
GASKET
Repl ace.
\
TWC
HO2S
Inspection
1. Usi ng a fl ashl i ght, make a vi sual check for pl uggi ng,
mel ti ng and cracki ng of the catal yst.
D16Y5, D16Y7 engi nss:
D16Y8 engi ne:
a-
/)
FLASHLIGHT
A
Replacement
Primary HO2S:
1. Remove the pri mary HO2S.
a. Di sconnect the pri mary HO2S connector, then
remove the cover.
8 x 1.25 mm
2i l Nm12.4kgt' m,
b. Remove the pri mary HO2S.
I
l
I
PRIMARY
44 N.m 14 33 tbtftl
(cont' d)
9- 9
H02S
t kgf.m,
HO2S
Replacement
(cont'dl
Dl6Y8 engine:
a. Di sconnect the pri mary HO2S connector then
remove the pri mary H02S.
2. l nstal l the Dri marv HO2S i n reverse order of removal .
9- 10
PRIMARY HO2S
4,0 N.m {4.5 kgI.m, 33 lbt.ftl
\
Socondary HO2S:
1. Remove the secondary HO2S.
Dl 6Y5, Dl 6Y7 engi n6:
a. Di sconnect t he secondar y HO2S connect or ,
then remove the secondary HO25.
D16Y8 engi ne:
a. Remove the grommet,
and pul l out the secondary
HO2S connector, then disconnect the secondary
HO2S connector.
SECONDABY HO2S
CONNECTOR
()2
SENSOR
WRENCH
(Commerci al l y
a
b. Remove the secondarv HO2S.
02 SENSOR WRENCH
l Commerci al l y avai l abl e)
SECONDARY HO2S
{rr N.m
(4.5
kgf.m, 33 lbf.frl
2. I nst al l t he secondar y HO2S i n r ever se or der of
removal .
9- 1
Cool i ng
fl fustrated l ndex ...........
"." 10-2
Radiator
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . ". ". . . . . . " " I 0-5
Engi ne Cool ant Refi l l i ng and
Bl eedi ng
. . . . . . . . "". . . . . . . ' . '
10-6
Cap Test i ng
. . . . . . . . . . . ' . . . . ' . . '
10-8
Testi ng
.' ..' . 10-8
Thermostat
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . ' . . ". . . . . . " " 1 0-9
Test i ng
". . . . 10-10
Engine Goolant TemPerature
(ECT)
Switch
Test i ng
. . . . ' . 10-10
Water Pump
l l l ustrated Index .....".' .
.. 10-11
fnspecti on
.10-12
Repl acement . . . . . . . . . . . . . . . . . . . . . . . ' . ' . ' . . . . . . . ' . "
10-12
!@@
system is under high pressure when the
engi ne i s hot. To avoi d danger of rel easi ng scal di ng
engi ne cool ant, remove the cap onl y when the engi ne i s
coor.
Total Cool i ng System Capaci ty ncl udi ng heater and
reservoi r {0.41
(0.,12
US
qt,0.35 l mp qt))l :
* 1:
D16Y7 engi ne
x2:
D16Yg engi ne
CAUTION: l f any engi ne cool ant spi l l s on
pai nted por-
tions ol the body, rinse it off immediately.
NOTE:
. Check al l cool i ng system hoses for damage. l eaks or
deteri orati on and repl ace i f necessary.
. Check al l hose cl amps and reti ghten i f necessary.
.
Use new O-ri ngs when reassembl i ng.
BADIATOR CAP
Pressure test,
Page
10-8
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt m,
7.2 tbt.ftl
COOLANT
RESERVOIR
LOWER
CUSHION
\
\
\
\
-E-
RADIATOR
Engi ne cool ant ref i l l i ng and bl eedi ng,
page 10 6
Leak t est , page 10-8
I nspect sol dered
j oi nt s
and
seams f or l eaks,
UPPEN
RADIATOR
HOSE
Bl ow out di rt f rom bet ween
core f i ns wi t h compressed ai r.
l f i nsect s, et c. , are cl oggi ng
radi at or, wash t hem of f wi t h
l ow pressure wat er,
5 x 0 . 8 mm
5. 4 N. m {0. 55 kgt m, 4. 0l bf f i }
6 x 1 . 0 mm
7. 2 N. m {0. 73 kgJ. m,
5.3 tbf.f0
DRAIN
PLUG
O-RING
Repl ace.
Ref er t o sect i on l 4
,
10-2
M/I 4. 2 f
( 4. 4
Afi
4. 1 i
( 4. 3
US qt , 3. 6 l mp qt ) * 1
4. 3 f
{ 4. 5 US qt , 3. 8 l mp qt ) * '
CVT 4. 3 f 14. 5 US qt . 3. 8 l mp qt )
,.l
Engine Hose Connoction3:
Dl6Y7 engin:
IAC VALVE
HEATER
VALVE
(cont' d)
10- 3
HEATER
HOSES
lllustrated Index
tAc vAtvE
IA/T)
(cont' dl
Engi ng Hosg Connecti ons:
Repl ace.
IAC VALVE
I M/ T)
CONNECTING
PIPE
WATER BYPASS
HOSE
THEBMOSTAT
HOUSING
O.RING
Repl ace.
\
\
\
\
rn
HEATEB
VALVE
/
O.RING
Repl ace.
CONNECTING
PIPE
HATER
HOSES
10-4
Radiator
Repl acement
Drai n the engi ne cool ant.
Remove t he upper and l ower r adi at or hoses, and
ATF cool er hoses.
Di sconnect the fan motor connector.
Remove the radi ator upper bracket, then pul l up the
raqtal or.
RAOIA
ATF COOLER
HOSES
{A/TI
Refer to section
UPPER RADIATOR HOSE
6 x 1 . 0 mm
7.2 N.m (0.73
kgt.m,
5.3 tbl.fr)
DRAIN PLUG
5, Remove the fan shroud assembl i es and other parts
from the radi ator.
Instal l the radi ator i n the reverse order of removal :
NOTE:
. Set the upper and l ower cushi ons securel y,
. Fi l l t he r adi at or wi t h engi ne cool ant and bl eed
the ai r.
1 .
2.
3.
4.
6 x 1 . 0 mm
9.8 N.m
(1.0
kg[.m,
7.2 tbl.trl
O.RING
Repl ace.
LOWER RADIATOR HOSE
RESERVOIR TANK
LOWEB CUSHION
10- 5
Radiator
Engi ne Cool ant Refi l l i ng and Bl eedi ng
CAUTION: When pouri ng engi ne cool ant, be sure to
shut the rolay box lid and not to let coolant spill on the
slcirical parts or thc paint. ll any coolant spills. rinse it
off immdiatslv.
1. Sl i de the heater temperature control l ever to maxi
mum heat. Make sure the engi ne and radi ator are
cool to the touch,
2. Remove the radi ator cao.
3. Loosen the drai n pl ug, and drai n the cool ant.
4. Remove the drai n bol t from the cvl i nder bl ock.
7E N.m 18.0 kgl m, 58 lbf ft)
ORAIN PLUG
</on
10- 6
7.
Appl y l i qui d gasket to the drai n bol t threads, then
rei nstal l the bol t wi th a new washer and ti ghten i t
securery.
Ti ghten the radi ator drai n pl ug securel y.
Remove, drai n and rei nstal l the reservoi r. Fi l l the
tsnk hal fway to the MAX mark wi th water, then up
to MAX the mark wi th anti freeze.
MAX MARK
8. Mi x t he r ecommended ant i Jr eeze wi t h an equal
amount of water i n a cl ean contai ner.
NOTEI
.
Use onl y genui ne Honda anti freeze/cool ant.
. For best corrosi on protecti on,
the cool ant con-
cent r at i on must be mai nt ai ned year - r ound
at
50% mi ni mum. Cool ant concentrati ons l ess than
50% may not pr ov i de
s uf f i c i ent pr ot ec t i on
agai nst corrosi on or freezi ng
. Cool ant concent r at i ons gr eat er
t han 60% wi l l
i mpai r cool i ng ef f i ci ency and ar e not r ecom-
menoeo.
CAUTION:
.
Do not mix differcd brands of antifreeze/coolants.
. Do not use additional rust inhibitors or anti.rust
produsts;
thcy may not be compatible with the
coolant.
Engine Coolant Refill Capacity Iincluding reservoir
(0.4
f
10.42 US qt, 0.35 l m' qt)l l .
* 1: D16Y7
engi ne
* 2:
D 16Y8 engi ne
M/I 3. 8 {
{ 4, 0 US qt , 3. 3 l mp qt )
A/T
3.7 /
(3.9
US qt,3.3 l mp qt)*'
3. 9 /
( 4. 1
US qt , 3. 4 l mp qt ) * ,
CVT 3. 9 {
( 4. 1
)
10.
1 1 .
9. Pour cool ant i nto the radi ator up to the base of the
fi l l er neck, and i nstal l the radi ator cap l oosel v.
Start the engi ne and l et i t run unti l i t warms up
(the
radi ator fan comes on at l east twi ce).
Turn off the engi ne. Check the l evel i n the radi ator.
add cool ant i f needed.
Put the radi ator cap on ti ghtl y, then run the engi ne
agai n and check for l eaks,
10-7
Radiator
Cap Testing
1. Remove the radi ator cap, wet i ts seal wi th engi ne
cool ant, then i nstal l i t on the Dressure tester.
RADIATOR
ADAPTOR
{for 32 mm neck, low
Profile)
Appl y a pressure of 93
-
123 kPa
(0.95 -
1.25 kgfl cm' .
14
-
18 psi ) .
Check for a d.op i n pressure.
l f the pressure drops. repl ac the cap.
10- 8
Testing
' 1.
Wai t unti l the engi ne i s cool , then careful l y remove
t he r adi at or cap and f i l l t he r adi at or wi t h engi ne
cool ant to the top of the fi l l er neck.
Attach the pressure tester to the radi ator and appl y
a pressure of 93
-
123 kPa
(0.95 -
1.25kgt/cm?,' 14
-
18 osi ).
RAOIATOR PRESSURE
TESTER
(Commerci al l y
avai l abl e)
ADAPTOR
(f or
32 mm neck, l ow prof i l e)
4.
Inspect for engi ne cool ant l eaks and a drop i n pres-
sure.
Remove the tester and rei nstal l the radi ator cap.
NOTE: Check for engi ne oi l i n the cool ant and/or
cool ant i n the engi ne oi l .
Thermostat
NOTE: Use a new O-ri ng when reassembl i ng.
Replacement
THERMOSTAT
HOUSING
THERMOSTAT
I nst al l wi t h pi n
up.
RUEBER SEAL
THERMOSTAT
6 x l . 0 mm
12 N. m
11. 2 kgf . m, 8. 7 t bt f t )
TEMPERATURE IECTI
swtTcH
24 N.m 12.{ kgt.m, 17 lbl.ftl
10- 9
Thermostat
ECT Switch
Testing
Repl ace the thermostat i f i t i s open at room temperature.
To test a closed thermostat:
' L
Suspend the thermostat i n a contai ner of water as
shown.
THERMOMETER
THERMOSTAT
tl
Heat the water, and check the temperature wi th a
thermometer. Check the temperature at whi ch the
thermostat fi rst opens. and at whi ch i t i s ful l y open.
CAUTION: Do not l et the thermometer touch the
bottom ot the hot container.
Measur e l i f t hei ght of t he t her most at when f ul l y
open.
STANDARD THERMOSTAT
Li ft hei ght: above 8.0 mm
(0.31
i n)
Starts openi ng: 169' - 176"F
(75" -
80"C)
Ful l y open: 194"F
(90' C)
1 0 - 1 0
Testing
@
Removing the EcT switch while the engine
is hot can cause the coolant to spray out, seriously scald-
ing you. Always let the engine and radiator cool down
betore removing the ECT switch,
NOTE: Bl eed ai r from the cool i ng system after i nstal l i ng
the ECT swi tch {see
page 10-6}.
Remove the ECT swi tch from the thermostat hous-
i ng
(see page 10-9).
Suspend the ECT swi tch i n a contai ner ot water as
shown.
1 .
4.
Heat the water, and check the temperature wi th a
thermometer.
CAUTION: Do not l et l he thormometer touch the
bottom of the hot container.
Measure the resi stance between the A and B termi -
nal s accordi ng to the tabl e.
\
Termi nal
Op"r"ffi
B
SWITCH
ON
196"
-
203"F
O_
OFF
5"
-
15.F
(3" -
8"C)
lower than the tempera-
ture when I goes on
Fuel and Emi ssi ons
Speci al Tool s
Component Location3
lndex
Systom Description
Vacuum Connections
Electricrl Connaqtions
Systom Description
Troubleshooting Flowcharts
Engino Control Module/Powrtrain
Control Module
Msnifold Absolute Pre3sure Sen3or .............
Intak Air Tempraturo Sensor
Engine Coolant Temperature Sensor ...........
Throttl e Posi ti on Sensor ...............................
Prim8ry Heated Orygen Sensor
(Sensor
1) ...
Socondrry Hoatd Orygon Sonsor
l Sensor 2)................
Heated Oxygen Sensor Heatel
Fuel Supply System
Misfire Detectod in One Gylinder
Random Misfire
Knock Sensot
CKP/TDC/CYP Sensor .......................-....-.-.....
Vehi cl o Spesd Sensor,......,...,....,.....,.,...........
Barometric Pressure Sen3or
Electrical Load Detectol
CKF Sensor
.............. 11-2 ldle Control System
System Description
11. 8
11- 19
................. 1 1
-122
System Conneqtors .........................,,.,..,...,.,. I 1.29
Troubleshooting
Troubfsshooti ng Procoduro! ...............,........ 71.42
Engine Contlol Module/Poworft ain
Control Module Terminal
Arrangement 11-' 19
Di agnosti c Troubl Code Chart .................... 11-53
How to Read Fl owcharG ............................... 1 f
-59
PGM-Fl System
. . . 11. 3 Troublshooting Flowchart3
ldle Control System . . . . . . 11- 124
ldle Air Control Valve 11- 126
Starter Switch Signal . . . 11- 130
Ai rCondi ti oni ng Si gnsl ................................. 11-131
Al ternator FR Si gnal ...................................... t1-133
Brake Switch Signal 11-13i 1
Power Stoaring Pressurc Switch Signal ...... 11.135
A/T Gear Position Signal ....
Cl utch Swi tch Si gnal ..........
ldle Speed Setting
Fuel Supply System
Fuel Lines
Fusl Tube/Ouick.ConnectFi tti n9s ................,....
System Description ........
11.60
11.(x'
11-67
11-73
1I-76
11- 79
11-8' l
11- 95
11- 98
11- 103
11- 105
11- 108
11- 109
11- 1 t 0
11-'112
1t - 113
11- 115
11-117
11-137
11- 139
11- 141
t 1-1i [5
11-117
1t - 150
11- 150
11-152
Fuel PressurG .........,.
EGM/FCM Internal Ci rcui t ............................. 11-120
A/T Si snal [rvl A/TMB] .................................. 1 1-121
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11_155
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 156
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 160
Intake Air System
System Description t 1- 161
Emission Control System
Systm Description 11- 167
11- 167
11- 167
Tailpipe Emission
Exhaust Gas Reci rcul ati on System ................... 11-169
Positive Crankcase Ventilation System ..-......-.. 11-171
Evaporati ve Emi ssi on Control s .......................... I 1-178
Fuel Iniectors .......
Fuel Pressure Regul ator .....,.,.............,..,...,..,..... I 1-15i 1
Fuel Fiher
Fuel Pump
PGM-Fl Mai n Rel ay . . . 11- 157
Speci al Tool s
{ t
Speci al Tool s
I
Rsl. No. Tool Number Description Oty
I
Page Refelnc
o
6
o
A973X- 041
_XXXXX
07JAZ
-
0010008
07PAZ
-
0010100
07sAz
-
0010004
07406
-
0040001
07406
-
0040304
Vacuum Pump/Gauge, 0
-
30 i n.Hg
Vacuum/Pressure Gauge, 0
-
4 i n.Hg
SCS Servi ce Connector
Backprobe Set
Fuel Pressure Gauge
Fuel Pressure Adapter,6 x 15 mm
1
1
1
a
1
1
' t1-171,
112, 145,
186, 188, 192. 193
11- 192, 193
11-42
1 1-44
11- 150, 15r , 154
1 1- 150
(^
@
./.
u
),
11- 2
Component Locati ons
l ndex
D16Y5 engi ne:
THROTTLE POSITION ITPI
SENSOR
Troubl eshoot i ng, page 11 79
MANIFOLD ABSOLUTE
PRESSURE IMAPI SENSOR
Troubl eshoot i ng, page
' l
1-67
EXHAUST GAS NECIRCULATION
{EGR) VALVE and EXHAUST GAS
RECIRCULATION IEGR} VALVE
LIFT SENSOR
Troubl eshoot i ng, page l 1 170
IDLE AIR CONTROL IIACI VAI-VE
{M/TI
Troubl eshooti ng, page 1 1-126
ELECTRICAL LOAD
DETECTOR
IELD) {USA model)
Troubl eshoot i ng, page 1 1-1 15
INIAKE AIR TEMPERATURE
IIAT} SENSOR
1 1-73
EXHAUST GAS RECIRCULATION
IEGR' CONTROL SOLENOID
valvE tcwt
Troubl eshoot i ng, page 11 I 70
EVAPORATIVE EMISSION
{EVAP} PURGE CONTROL
SOLENOID VALVE
Troubl eshoot i ng, pag 1 1-190
CRANKSHAFT
POStTTON/
TOP DEAD CENTER/
POWER STEERING PRESSURE
tPsP) swlTcH {usal
CYLINDER
POStTtON
(CKP/TDC/CYP}
(Bui k
i nro t he di st ri but or)
Tr oubl eshoot i ng, page
11- 110 . /
roubl eshoot i ng, page
1 1-135
KNOCK SENSOR {KSI
(cw)
Troubl eshoot i ng, page 1 1-109
CRANKSHAFT SPEED
FLUCTUATION ICKFI SENSOR
Troubl eshoot i ng, page 1' 1 117
1 = -
VEHICLE SPEED SENSOR
Troubl eshoot i ng. page 1' l 112
ENGI NE
TEMPERATURE
{ECT) SENSOR
Troubl eshooti ng, page 1 1-76
IOLE AIR CONTROL
(IAC)
VALVE
tcwt
PRIMARY HEATED
WAY CATALYTIC
CONVERTER ITWC}
Troubl eshoot i ng, page t 1
-168
SENSOR
(PRIMARY
HO2SI
{SENSOR 1) {M/Tt
Troubl eshoot i ng, page 1' 1-88
PRIMARY HEATED OXYGEN
SENSOR {PRIMARY HO2S'
{SENSOR 1t {CWl
SECONDARY HEATED OXYGEN
SENSOR ISECONDARY HO2SI
{SENSOR 2l
(cont' d)
1 1 - 3
Component Locations
Index
(cont'dl
D16Y8 engi ns:
THROTTLE POSITION ITP}
SENSOR
INTAXE AIR TEMPERATURE
IIAT} SENSOR
Troubl eshoot i ng, page 1' 1
-73
MANIFOLO ABSOLUTE
PRESSURE {MAPI SENSOR
IOLE AIR CONTROL IIACI VALVE
{M/ T}
EI."ECTRICAL LOAO
DETECTOR {ELDI
(USAI
Troubl eshooti ng, page
I1-t 15 EVAPORATIVE EMISSION
IEVAP) PURGE CONTROL
SOLENOID VALVE
CRANKSHAFT
POStTtON/
TOP DEAD CENTER/
CYLINOEF
POStTtON
Troubl eshoot i ng, page 11-185, 190
POWER STEERING PRESSURE
{PSP| SWTTCH {USA)
KNOCK SENSOR {KSI
Troubl eshoot i ng, page 1 1- 109
CRANKSHAFT SPEED
FLUCTUANON ICKFI SENSOR
Troubl eshooti ng, page 1 1-' l 17
VEHICI."E SPEED SENSOR
Troubl eshoot i ng, page 11-112
IDLE AIR CONTROL IIACI VALVE
IA/TI
Troubl eshooti ng, page 1' l
-
128
TEMPERATURE
tEcTt sENson
PRIMARY I{EATED OXYGEN SENSOR
(PRIMARY
HO2SI ISENSOR 1}
1 1-84
THREE WAY CATALYTIC
CONVERTER {TWCI
Troubl eshoot i ng, page 1 l ' 168
SEOONDARY HEATED OXYGEN
SENSOB
ISECONDABY HO2S} {SENSOR 2I
11- 4
(CKP/TDC/CYP}
SENSOR
l 8ui l t i nt o t he di st ri but ori
1 1' 1 10/ '
t?\..==.--
-
--L------
--- - ----:
D16Y7 engi n6:
SENSOR
MANIFOLO ABSOLUTE
PRESSURE
(MAP)
SENSOR
1 1-67
VEHICLE SPEEO SENSOR {VSSI
Troubl eshoot i ng, page 1 ! -112
INTAKE AIR TEMPERATURE
{IATI SENSOR
CRANKSHAFT
POStTtoir/
TOP DEAD CENTER/
CYLINDER
POSTT|ON
ELECTRICAL LOAD
DETECTOR IELDI IUSAI
Troubl oshooti ng, page 1 1' ' 1' !5
POWER SIEERING PRESSURE
{PSP) SWTTCH |USA}
CRANKSHAFT SPEED
FLUCTUATION {CKF} SENSOR
TroLrbl eshoot i ng, page 11 117
-
--....-
SECONDARY HATED OXYGEN
SENSOR ISECONDARY HO2SI
{SENSOR 2t
roubl eshoot i ng, page 1 1-135
IDLE AIR CONTROL {IACI VALVE
r oubl eshoot i ng, page 11
' ! 28
ICKP/TDC/CYPI SENSOR
{Bui l t i nt o t he di st ri but or)
Troubl eshoot i ng. page 11-110
i
ENGINE COOLANT
TEMPERATURE
IECTI SENSOR
PRIMARY HEATED OXYGEN
SENSOR IPRIMARY H02SI
l sENsoR 1)
Troubl eshoot i ng, page 11 84 Troubl eshoot i ng, page 11-76
IEVAP) PURGE CONTROL
SOLENOID VALVE
Troubl eshoot i ng, page' l 1
-190
THREE WAY CATALYTIC
CONVERTER {TWC)
Troubl eshooti ng, page I 1
-168
CLUTCH SWITCH {D16Y5 6ngine
M,/T)
PGM.FI MAIN RELAY
Rel ay Test i ng,
page 11-157
Troubl eshoot i ng. pag 1 1-158
Selt-diagnostic Procedures,
page 11-42
t2Pl
Sel f-di agnosti c Procedures,
page 11-42
(cont' d)
1 1- 5
ENGINE CONTROL MODULE
IECMI/POWERTRAIN
CONTROL MODULE {PCM}
Component Locations
Index
(cont' dl
'96
Dl6Y8 engine
{coupe),
'97
Dl6Y7 engiDs
(coupe:
KL mod|, sedan: KL
{LX)
modell,
' 97
Dl 6YB engi ne
(coupo:
al l model s, sedan: KL model l ,' 98-al l model s:
FUEL VAPOR PIPE
FUEL FEEO PIPE
\
FUEL FILTER
Repl acement . page 1 1-155
FUEL GAUGE SENDI NG UNI T
Test i ng, see sect i on 23
FUEL PUMP
Test i ng, page 11-156
EVAPORANVE EMISSION
IEVAPI CONTROL CANISTER
VENT S}IUT VALVE
Troubl eshooti ng. page' l 1-185
IEVAP) CONTROL CANISTER
FUEL INJECTORS
Ropl acement , page 1 1-152
FUEL TANK
Repl acement , page 1 1-160
TANK PRESSURE
SENSOR
1 1-181
APORATIVE EMISSION
TIVE EMISSION
{EVAPI BYPASS SOLENOID
VALVE
Tr oubl eshoot i ng. page' l 1- ' 185
TIVE EMISSION
{EVAPI TWO WAY VALVE
Testi ng, page 11-193
FUEI
REGULATOR
Test i ng, page' l l -154
Repl acement , page 1 1- 154
'96
Dl6Y5 engino,'96 Dt6Y7 lngin,'96 Dl6Y8 ngin. {sedan),
'97
D16Y5 .ngine,
'97
D16Y7 ongine
(coupe:
KA, KC mod6ls,
sedan: KA, KC, KL {DX) modls, hatchback: 8ll modlsl.
'97
D16Y8 engine
(sed!n:
KA, KC modls):
FUEL
FITTINGS
FUEL VAPOR PIPE
Precaut i ons, page 11 147
Di sconnect i on, page 11 147
Connect i on, page 1 1-148
IEVAPI CONTROL CANISTER
FUEL
FUEL FILTER
Repl acement, page 11 155
FUEL PUMP
Test i ng, page 11 156
Repl acement , page I 1-156
FUEL FILL
CAP
FUEL TANK
Repl acement , page 1 1-160
IEVAP) TWO WAY VALVE
Test i ng, page 11 193
TUBE/OUICK.CONNECT
FITTINGS
FUEL PRESSURE
REGULATOR
Test i ng,
page 11-154
Repl acement , page I 1-154
Precaut i ons, page 1 1-147
Di sconnect i on, page 1' 1 147
Connect i on,
page 11 148
1 1 - 6
D16Y5, D16Y8 engi ne:
TITROTTLE BODY ITB}
Inspecti on, page 11-164
Remov al , page 11- 165
THROTTLE CABLE
I nspect i on/ Adj ust ment , page 1 1-' 162
I nst al l at i on, page 11, 163
AIR CLEANER IACL)
Repl acement ,
Di sassembl y, page 1l 166
VENTILATION {PCV} VALVE
I nspect i on, page I 1- 177
D16Y7 engi ne:
AIR CLEANER {ACL}
Repl acement , page 1 1-' 162
THROTTLE CABLE
I nspect i on/ Adj ust ment , page 1' l -162
I nst al l at i on, page 1l 163
THROTTLE BODY
(TBI
I nspect i on, page' l 1-16, 4
Di sassembl y.
page 11 166
POSITIVE CRANKCASE
VENIILATION {PCVI VALVE
I nspect i on. page' l
1-177
RESONATOR
11- 7
System Description
Vacuum Connecti ons
D16Y5 engi ne {' 96,
' 97
model s):
To EvAPORATIVE EMISSION
{EVAPI
TWO WAY VALVE
MANIFOLO
ABSOLUTE
PRESSURE
(MAPI
SENSOR
IEVAP) PURGE
CONTROL CANISTER
(EGRI
CONTROL SOLENOIO
VALVE IA/TI
\
\
\ ^ \
Tre) l.--
M
-.'ry
\
(EGRI
VALVE and EXHAUST GAS
RECIRCULATION {EGRI VALVE
LIFT SENSOR
(A/TI
EMISSION
(EVAP}
PURGE CONTROL SOLENOID
VAI-VE
EXHAUST GAS RECIRCULA
EVAPORA
To CRUISE
CONTROL
DIAPHRAGM
(wi t h
crui se cont rol i
FRONT OF VEHICLE
REGULATOR
O: Vacuum hose No.
1 1 - 8
D16Y5 ongi ne 1,98 model l :
EVAPORATIVE EMISSION {EVAP)
CONTROL CANISTER
VENT SHUT VALVE
To EVAPORATIVE MISSION
{EVAPI THREE WAY VALVE
To EVAPORATIVE EMISSION
(EVAP}
TWO WAY VALVE
PURGE
JOINT
I EGRI VALVE and EXHAUST GAS
IEGRI VALVE
LIFT SENSOR
tatfl
{CVT onlyl
EXHAUST GAS RECIRCULANON
{EGRI COiITROL SOLENOID
VALVE
EV nvE
i,ff------\
I M, lin.;rrdio-
-
I SP llesolure
-
--
L. . -. . -. . -. . -r
PRESSURE t MAPI
EMISSION {EVAP}
PURGE CONTNOL
CANISTER
EVAPORATIVE
EMISSION {EVAP'
VALVE
SENSOR
I
I
I
To CRUISE
CONTROL
DIAPHBAGM
(wi t h
crui se cont rol )
FRONT OF VEHICLE
FUEL PRSSURE REGULATOR
O: Vacuum hose No.
(conr' d)
1 1- 9
System Description
Vacuum Connections
(cont'd)
D16Y8 engi ne:
To EVAPOnATVE EMISSION
{EVAPI THFEE WAY VALVE
l'96 coupo,
'97
coupo: all mod6b,
'97
sedan: KL model,
'g8-modols)
EVAPORATIVE EMISSION IEVAPI
CONTROL CANISTER
VENT SI{UT VALVE
('96
coup., 37 coup.: all models,
'97
aed.n: KL model,
'g8-modelsl
IEVAPI
TWO WAY VALVE
{'96 coupe, 37 coupe: ell modek,
3edan: KL model)
EVAPORATIVE
EMISSION IEVAPI
PURGE CONTROL
CANISTER
EVAPORANVE EMISSION
IEVAPI PURGE
CO]TTROL CANISTER
('96
3.d.n, 37 r.drn: KA,
FUEL PRESSURE
REGULATOR
MANIFOLD AESOLUTE
PRESSURE
(MAP}
SENSOR
KC mod.lrl
EVAPORATIVE
EMISSION {EVAP}
Qo
To CRUISE
CONTROL
OIAPHRAGM
(wi t h
crui se cont rol )
VALVE
FNONT OF VEHICLE
1 1 - 1 0
D16Y7 ongine l'96
modek,'97 coups: KA, KC models.'97 sedsn: KA, KC. KL {DX}
models,'97 hatchback: all modolsl:
EVAPORATIVE
EMISSION IEVAP'
PURGE CONTROL
FUEL
PRESSURE
REGULATOR
To EVAPORATIVE
EMISSION
(EVAPI
TWO WAY VALVE
MANIFOLD AASOLUTE
PRESSURE IMAP)
SENSOB
To CRUISE
CONTROL
DIAPHRAGM
{wi t h crui so
cont rol )
EVAPORATIVE
EMISSION IEVAPI
PURGE CONTROL
CANISTER
FRONT OF
vEHtcl-E
(cont' d)
11- 11
r
System Description
Vacuum Connections
(cont'dl
Dl 6Y7 engi ne
(' 97
coupe: KL modcl ,' 97 sedan: KL {LX) model ,' 98 model s}:
(EVAPI
CONTROL CANISTER
VENT SHUT VALVE
IEVAPI THREE WAY VALVE
IEVAP)
TWO WAY VALVE
FUEL PRESSURE
REGULATOR
MANIFOLD AASOLUTE
PRESSURE
IMAPI SENSOR
EVAPORATIVE
EMISSION IEVAPI
PURGE CONTFOL
CANISTER
\
To CRUISE
coNTROt
DIAPHRAGM
(with
cruis control)
EVAPORATIVE
EMISSION
(EVAPI
PURGE CONTROL SOI."ENOID
VALVE
FRONT OF VEHICLE
11- 12
D16Y5 engi nen l ' 95,
' 97
model sl :
, r ; - - - l
I
ENGINE
I
i COOLANTi
l ( D l + |
t/6r IUI t
i Lf f i i
i -I]Fn- i
L l - r - I
l - , 4 I
:l: Vacuum ho3o No.
':
CVT only
o
6i
aal
@
o
@
6\
[E
o
@
@
(0
@
PRIMARY HCATED OXYGEN SENSOR IPRIMARY HOzS,
SENSOR 1l
SECONDARY HEATEO OXYGEN SENSOR ISECONDARY
HOzS. SENSOR 2l
MANIFOLD ABSOLUTE PRESSURE
(MAP}
SENSOR
ENGINE COOLANT TEMPERATURE IECTI SENSON
INTAKE AIR TEMPERATURE {IATI SENSOR
KNOCK SENSOR IKS}
CRAITIKSHAFT SPEED FLUCTUATION
(CKFI
SENSOR
IDLE AIR CONTROL
(IACI
VALVE
THROTTLE BOOY
(TBI
FUEL INJECTOR
FUEL PULSATION DAMPER
FUEL FILTER
FUEL PRESSURE REGULATOR
FUEL PUMP
(FP)
FUEL TANK
FUEL TANK EVAPORATIVE EMISSION IEVAP} VALVE
AIB CLEANER
RESONATOR
POSITIVE CRANKCASE VENTILAIION {PCVI VALVE
EXHAUST GAS RECIRCULANON IEGRI CONTROL
SOLENOID VALVE
EXHAUST GAS RECIRCULANON {EGRI VALVE
EXHAUST GAS RECIRCULANON
IEGRI VALVE LIFT
SENSOR
EVAPORANVE EMISSION {EVAPI PURGE CONTNOL
sottNotD vALvE
EVAPORATIVE EMISSION {EVAPI CONTROL CANISTER
EVAPORATIVE EMISSION IEVAPI TWO WAY VALVE
THREE WAY CATALYTIC CONVERTEF ITWCI
@
a
(D
@
0
@)
@
a
@
6
(cont' d)
1 1 - 1 3
System Description
Vacuum Connections
(cont'd)
D16Y5 engi ne
l ' 98 model ):
\
I
O PRIMARY HEATED OXYGEN SENSOR
(PRIMARY
HO2S.
SENSOR 1l
O SECoNDARY HEATED oxYGEN sENsoR ISEGoNDARY
HO2S. SENSOR 2)
O MANIFoLD ABSoLUTE PRESSURE
|MAP} sENsoF
(' ENGINC COOLANT TEMPERATURE ICCI) SENSOR
O
INTAKE AIF TEMPERATUBE
{IAT} sENsoR
G) KNOCK SENSOR IKSI
O CRANKSHAFT spEED FLUCTUAT|oN
tcKFt sENsoR
@
IDI.E AIR coNTRoL {IACI VALVE
O THRoTTLE BoDY trBl
(O
FUEL INJECToR
O
FUEL PULSATION DAMPER
@ FUEL FILTER
(}
FUEL PRESSURE REGULAToR
(}
FUEL PUMP {FP)
@ FUEL TANK
@
FUE|- TANK EvApoRATtvE EMtsstoN tEvapl vALvE
@ AIR CLEANER
@ RESoNAToR
-: Vacuum hoao No.
*:
CW onl y
@
posrnvE
cRANKcasE vENnLATtoN {pcvt vALvE
@ EXHAUST GAs RECIRCULATIoN IEGn) coNTRoL
SOLENOID VALVE
@
EXHAUST GAs RECIBCULATIoN {EGRI vALvE
@ ExHAUsr GAs REctRcuLATtoN {EGRt valvE L|FT
SENSOR
@ EVAPoRATIVE EMISSIoN IEVAPI PUnGE coNTRoL
SOLENOID VALVE
8]
PURGE JOTNT
@ EVAPoRATIVE EMIsstoN IEVAPI coNTRoL CANISTER
@
EvApoRATtvE EMrsstoN (EvAp)
BypAss soLENoD
VALVE
@
EVAPoRATIVE EMtssIoN
{EVAP) THREE wAY vALvE
@ EVAPoRATIVE EMISSIoN IEVAPI coNTRoL CANISTER
VENT SHUT VALVE
@ FUE|- TANK
pREssuRE
sENsoR
@
EVApoRATtvE EMtsstoN
tEvAp) two wAy valvE
@ THREE wAY cATALYTIC coNvERTER ITwcI
D16Y8 engi ne
(' 96
coupe,' 97 coupe: al l model s,
' 97
sdan: KL model ,
' 98
model s):
{M/ T)
| - : - l
i ( ' l
I
F@, i
i
liiffis
r
: . . - - ' ' - - - I
{A/T)
-
E-NGim
-l
6)toofl'!
O
PRIMARY HEATED oxYGEN sENsoR IPRIMARY Hozs,
SENSOR 1l
) SECoNDARY HEATED oxYGEN sENsoR {SECoNDARY
HO2S. SENSOR 2r
O MANIFoLD ABSoLUTE PRESSURE IMAP) sENsoR
@
ENGINE COOLANT TEMPERATURE IECTI SENSOR
O
(IAT)
sENsoR
@ KNocK sEt{soR tKs)
O CMNKSHAFT spEED FLUcruATroN
(cKFl
sENsoR
@
|DLE AtR coNTnoL ltacl vALvE
@
THRofiLE BoDY ITB)
@ FUEL INJEcToR
O
FUEL FILTER
@
G)
FUEL PUMP {FP)
@
FUEL TANK
@
FUEL TANK EVAPORATIVE EMISSION
(EVAP)
VALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE VENTILATION {PCV) VALVE
EVAPORATIVE EMISSION IEVAPI PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE EMISSION {EVAP) CONIROL CANISTER
EVAPORATIVE EMISSION IEVAPI EYPASS SOLENOID
VALVE
EVAPORATIVE EMISSION IEVAPI THREE WAY VALVE
EVAPORATIVE EMISSION {EVAPI CONTROL CANISTER
VENT SHUT VALVE
FUEL TANK PRESSURE SENSOR
EVAPORATIVE EMISSION {EVAPI TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER
(TWC)
(1-6)
o
@
@
@
E1l
@
@
@
c!
ad
(cont' d)
System Description
Vacuum Connections
(cont'dl
Dl5Y8 engine
('96
sedan,'97 sedan: KA, KC modets):
l,'
\
.'
PRIMARY HEAIED OXYGEN SENSOR IPfiIMARY HO2S,
SENSOn lt
] sEcoNDARy HEATED oxycEN sENsoR rsEcoNDABy
HO2S. SENSOR 2l
O MANIFoLD ABSoLUTE PRESSURE
(MAPI
sENsoB
O ENGINE cooLANT TEMPERATURE tEcD sCNsoR
O
INTAKE AIR TEMPERATURE IIATI sENsoR
@ KNocK sENsoR {Ksl
O CRANKSHAFf spEED FLUcruATtoN {cKFt sENsoR
@
|DLE AtR coNTRoL flAct VALVE
O
THROTTI.I BODY ITBI
@
FUEL INJECToR
@ FUEL FILTER
@
@
@
@
@
(x
@
@
@
@
@
FUEL PRESSURE REGULATOR
FUEL PUMP IFPI
FUEL TANK
FUEL TANK EVAP,ORATwE EMISSION {EVAPI VALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE VENNIANON
{FCV} VAIVE
VAFORATIVE EMISSION IEVAP} PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE EMISSON IEVAPI CONTBOL CANIS1ER
EVAPORATIVE EMISSION (EVAP}
TWO WAY VAVE
IHREE WAY CATALYTIC CONVERTER ITWC}
1 1 - 1 6
-
IM/T)
I - @- l
i r ' f f i i
' _._:_..i
D16Y7 engi ne l ' 96 model s,' 97 coupe: KA, KC modets,' 97 sedan: KA, KC, KL
(DXl
model s,' 97 h8tchback: al l model s):
COOLANT
o
FUEL PUMP IFPI
FUEL TANK
FUEL TANK EVAPORATIVE EMISSION (EVAP)
VALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE VENTILATION
{PCV) VALVE
EVAPOMTIVE EMISSION IEVAPI PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE EMISSION IEVAP) CONTNOL CANISTER
EVAPORATIVE EMISSION IEVAP} TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER {TWC)
@
@
(}
@
@
all
@
@
@
O PRIMARY HEATED OXYGEN SENSOR {PRIMARY HO2S,
SGNSOR 1l
O sEcoNDARy HEATED oxyGEN sENsoR
(sEcoNDARy
HO2S. SENSOR 2)
O MAN|FoLD ABSoLUTE
pREssuRE
(MApt
sENsoF
)
ENGINE COOLANT TEMPERATURE
{ECTI SENSOR
@
(IAT)
sENsoR
@ CRANKSHAFT SPECD FLUCTUANON ICKF} SENSOR
O
|DLE AtR coNTRoL {tAct vALvE
@ THRoTTLE BoDY ITBI
@
FUEL INJEcTon
@ FUEL FTLTER
O
(cont' d)
System Description
Vacuum Connections
(cont'd)
D16Y7 ongine l'97 coupe: KL modol, sed8n: KL
(LX)
model,
g8.modols):
--[-
RESONATOR
POSMVE CRANKCASE VENTILATION (PCVI
VALVE
EVAPORATIVE EMISSION (EVAPI
PURGE CONTROL
SOLENOID VALVE
(EVAP)
CONTROL CANISTER
EVAPORANVE EMISSION {EVAPI BYPASS SOI.-ENOID
VALVE
EVAPORANVE EMISSION (EVAP)
THREE WAY VALVE
EVAPORANVE EMISSION IEVAPI CONTROL CANISTER
VENT SHUT VALVE
EVAPORATIVE EMISSION IEVAPI TWO WAY VALVE
THREE WAY CATALYTIC CONVERTR
IIWC}
O
PRIMARY HEATED oxYGCN sENsoR IPRIMARY Ho2s,
SENSOR 1)
O
SEGoNDARY HEATED oxYGEN sENsoR {SECoNDARY
HO2S, SENSOR 2l
O
MANIFoLD ABSoLUTE PBESSURE IMAPI sENsoB
@
ENGINE cooLANT TEMPERATURE
tEcTI sENsoR
O
INTAKE AIR IEMPERATURE {IATI sENsoR
@ CRANKSHAFT SPEED FLUCTUATION
(CKFI
SENSOR
O
IDLE AIR CONTROL |IAC) VAI.VE
@
THRoTTLE BoDy tTBt
O
FUEL INJECToR
@
FUEL FILTER
O FUEL PRESSUFE REGULAToR
.IA
FUEL PUMP {FP)
{9 FUEL TANK
Ii4 FUEL TANK EVAPORANVE EMISSION {EVAP} VALVE
f,,
AIR GLEANER
@
@
@
@
@
@
@
@
@
@
1 1 - 1 8
Electrical Connections
- 9
I
!
r?:
CVT lDi6Y5 ooln.l .nd O16Y3 .nsin.
ra:96
Di6Ya dgln. Ic@p.|, 37 Dl6Y3.t 96 Di6Ya dgln. Ic@p.|, 37 Dl6Y3.n9ln. O iIIEES UCHI
lco!p.: .ll mod.l." t d.n: XL mod.il
'$
Ol6Y5 .n9in., O tAC( lr? lt.6 A,i
lo C*iCA6OR Cl,UlCtt FIAY
lo A./C PfiC8dUiE a|lrTCH
ECr SW'ICtl
N., 13 fUEL tlr$t lll Al
t'|. rt &lEr|{AlOi A? *i.3oi tr.a Al
llo. 3t 6ta8fEi stol{^t tt.6 at
CHEC|(
.2:
AII (Dlovt,
Dr6Y8 .neln.l
ra:
AfI.nd OioYt.hgl..
r5:
ElDt A/I.n<l Dr6Y7 ft9ir.
Oi l n
O tâ
o xox
o rAt
or ct
tAtttl
' 10:
M/I lD16Y5 mdn.l
11
l: Eropt M/r OlaY5 .tr!4..1
.12:
DiCY5, DltYgmdn.
'15: '9t
Dl6lt d9ln. (@qp.:
K- mo.Ll, ..d.n:
KL lLxl mod.ll, 16 D16rt .nein.
{cont' d)
1 1 - 1 9
r:
h ii. lndr.lb.d lr-/nld 5.r
System Description
.l
{
{
(cont'dl
T: I
+
FUEL
PACITST'R
sEt{Bon
gEN90fi
EGN
EGN
lo f,lEnJOCK
@fttiot utrtt
A: EVA' tUiG clr||liol aorliloo VAIVE
a: EvAr cotltioa c tr*slEi wm $(rr vavE
qEv
P av?ats aolEioo valvE
O: CCi Coraliol Sotlltlolo VAIVE
E: VIEC 6otli|oa V IVE
t: r,iEAns{r(EilOrOV IVE
c: LOO(.I P Ot Ltxt! SOt'lilOlO VAYE A
tt toc(.(t@ lf,ot aot.iloD vAlvE I
r SHfT @tvtioi, aottlllxt v^lvE A
J: at||f @lvriol8OlIiIXt VAIVE !
2; A/t lolart, Olava rCDl
ra:
AfI .nd Dlart ddn.
15:
Espr A/T.nd Dttr, dsa.
.7:
CVI iD' lav6 milDl.nd DilV,.ndd
r3: ga
Ol6Y3 dct lcoup.),
'97
DtaYS .|'|tu
ldD...t mort lr..d..: l(l n .Ul, ! DtaYE osl..,
'ror
M/r tDrat6 oCn l
rll:
Erc.pl M/T lDlaYt .nsl..l
'12:
D'laY5, DlaYa..dD
rl5:
It Oiart ddm ldrp.: IL h.d.l,..d.n:
xL lL]xl hodJ' ,' S Dlart odd
tnAt(C tt{ltcH
11-20
- r------t -
Lll.J
1t!r!]J
l
l
l 6
' r r D 1 1 ' ?
|
t,' r,,
st
l l l l
MAP Si60f,
EGi VAVE
cl'!t uF sENsoB
l-
""fi""-_
I
stu
l__.!-sru/YEL
sivtcE cHEcx
cot{NEcToi
a6scoNriol u r,
@l{t{cToi
(cont ' d)
11-21
System Description
\i
{cont'dl
ro?aF c.,l
8lx/YyHTl
so2SHTC
ltvwHT,
iED/YEL"I
FOzSHTC.x
cl3r ca46
.2:
a/t IOl6Yt, Dl6Y, .n!in.l
.a:
a/I .nd OlaYt .n!i..
.6
Esoi Art.d Dt6r, .n!ln.
.7:
CW
(Oia\6
ociml.nd DI6YS.nciM
.3:'94
OlaYl ncin. l.o{Fl, !7 ol6Ya 6ci..
tcour:.amod.lr..d.n: Xtmod.ll,' 9aOl6Y5.ngh,
sEcotD aY
HO2S iSE|!SOR 2l
.10:
M/t lDl6YE osin.l
.lr:
Erc.rt MtI lot5Y5 min.l
rl2:
ol6Yt, Dl6Yaogin.
.t5:
9? D16Yt dgi..ldp.: KL tFd.l. t d.n;
lG ltxl mod.D,
' 93
O|6YT.nsim
PAIMANY
sol.E|lo|D
cror
11-22
LT GAiYWHT
:rva
--f|:F-l
wtfii
l-,1
/ffi|
| |
L__.dJ
I
8LX' -1FJ
I
CAI'IISTEA VEM
SHUT VALVE{.i$
F--+,
Ks"-I
-
aeo'--
Jl---l
8rx--
1t+l
clurcH swrrcHn.
{cont' d)
11-23
NCD/ - U
' ' _ _ _- _ ___ ' ' ' - ' - _- __ __ _-
System Description
.a
{
{
Electrical Connectors
(cont'd)
H?,H,?,"iI
BLX
t30
scr{90fi
rDc
stofi
cr(?
BFN/IL(I
BRN/BIXI
&
t . l
B A /
alx1
r*
L ]
l Top. l . t t - 2al
r1:USAmod .9i
D' 16Y5 mgim
.2:
Arr tD' r6\r, Dr5Y3 dsin. l0: Mfl lDl6Y5.rsitul
.3:
C\/T tot6y6 net..l
.11:
r..ct M/I lD'laY5 osim)
.a:
A/I .nd Dl6r, .nC,.
r12:
OtaY5, OtSYt .natr.
.E:
Erc.ptA/T.nd Oi6Y' .ryin.
.13:
DltYa osin.
.arA/t
tDt6y8 dctn.t
rla:
DlaYt.nlln.
.7r
CVt
(Dl6V6
.nelal .nd DiOYs .ncin.
116:
t7 Dl6ft .n!Nm l@p. XL nod.l, ..d..:
' 0:' 96Dl5Y0.nc.{dp.l,37Di6Y3.nsim
|(!tlxlh.d.ll,' !cDlaftosid
lcoup.:.llmod.L,..d.n:Klmod.ll,' 9aot6Y5.nrin.,
11-24
BtU'
MAINSHAFI SPEED SENSOf,
"
t 3
COUNT:RSHAFI SPIED SENSOR-
c121
l l e l I
l l 3 |
(cont' d)
11-25
System Description
,a
Electrical Gonnectors
(cont'dl
cr3r caa6
orrr c*,2
oll0 cSlta
GRT/ATI: T
d YCL
I
rr GFl{l
----
Brx/Bru
-
w{F-
-
FEo
l
I
GRN
--
uru,-
1
fi
NtEn|-OCX
coifliot uttr
.10:
Mlt loloY5.ncitul
.i'l:
Erc.Dr M/r ID|6Y5 ddn.l
' rA
DiAY5, Dli\,t melm
r15:
'et
Dl6rt oslo loop.: KL mo.bl,..d.n:
xl lDo m.<bll,' S olsYt.ncln.
T*-
a/r GE i fo6no|l swTcll
;.,
-
cnr'--
--.1
l
.lc
ilr
mffimi#
t'i
BLU/BEB--
-
- f
arun:u--
--
j' ro ^/c s$rcH
U
cr3r c/r46
' 2:
A/T
(Dl6Y7, Dl6Y3.ngin.t
.a:
A/T .nd Di6rr.ncitu
rt:
Erc.pt Alt .nd Dl6Yt .nsi..
.t:
Cw lol6Y5 6ein.l ..d D16YO .nsin.
.8i' 96
Ot6yt.ntin. l6uD.l, 97 Dt6Y3.nCln.
tcoup.: .ll mod.lr..d.n: xt mod.ll,' 96 o16Y5.n!in.,
11-26
WHT/BLU
lcr l/to al
]lonx tl6al
A/C CTUTCH
REIAY
No. 3l STABTEn
srct{ar
(7.5
al
[ " *
--o_
Fr,ISE/REI.AY
BOX
FCir-Fl
I'AIN REIAY
1- 27
f-
System
DescriPtion
ii
Electrical Connectors
(cont'dl
Hiriffi+
BEAXf, SWTTCX
.2:
A/T {Or6Y?, Dl5Y8.nsin.l
'3:
Cvr {Dl6Y5.ngi.}
.4:
A/T .nd DlYr.ngin.
.5:
ExDt A/T tnd Dl6Y7.ngin.
.5:
A/T {D16Y8.ngln.l
17r
CW tDtoYs !ngln.) lnd ol6YE .ngin.
r8:'96
Dl5Y8.nsin. {coupol, 37 Dl6Y8!.sin.
lcouo.r .ll mod.b, ..d.o: Nl mod.tl,
'98
D16Y5 .nsin.,
'$O16Y8login.
.9:
D16Y5.ngin.
'10:
Mff lDr6Y5.ngin.l
.tt:
Exc.pi M/r {Dl6Y5.nein.,
.t2:
Dl6Y5, Dt6Ya.ngin.
.13:
D16YE..gin.
'15:,97
O'16Y7 .ngin.lcoup.r XL mod.l ..d.n:
KL {LXlood.ll,'98
Dl6Yt msin.
t"-l
T
FED
t:l
T
FED/
GRN
[t
l " l
clit5
-
tT GRn
GR /ALK'
o|or c555
YEUBI-U
ITGRts-
GA /a|.x
AUUWHI
3LU'-
F
t-
t
F
F
F
VREFI
wxT/nED,
11-28
System Connectors
[Fuel
Pumpl
,i
t:
l
I
I
c565
E
ffi
c792r.,r1s
@
IITYT!BLU-___l
I"TGRN/BLx -
f'li-BN' -
c793r3.rE
fr
NOTE: . Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLKI
and YEUBLK, are not the same).
O: Bel ated to Fuel and Emi ssi ons System.
.
-
Connector wi th mal e termi nal s
(doubl e
outl i ne): Vi ew from termi nal si de
-
Connector wi th femal e termi nal s
(si ngl e
outl i ne)r Vi ew from wi re si de
(cont,d)
t l r
USA model
*2:
A/T {D16Y7, D16Y8 engine}
*3:
CvT {D16Y5 enginel
*4:
A/ T and Dl 6Y7 engi ne
*5:
Except A/T and D16Y7 enginc
16:
A/ T l Dl 6Y8 ensi ne)
*7:
CVT {D16Y5 engine} and D16Y8 engine
*8: ' 96
D16Y8 engi ne {coupel , ' 97 D16Y8 engi ne
{coupe: all models, sedan: KL model),
'98
D16Y5 engine,
'98
O'16Y7 engine
' 9:
D16Y5 engi ne
*10:
M/ T {D16Y5 engi nel
*11:
Except M/ T (D16Y5
engi ne)
*12:
D16Y5, D16Y8 engi ne
*13:
Dl 6Yg engi ne
' 14:
D16Y7. ngi ne
*15: ' 97
D16Y7 engi ne l coupe : KL mod6l . sdan:
KL {LX) model l , ' 98 D16Y7 en9i n6
c792+r.*'5
11-29
System Description
System Connectors [Engine
Gompartmentl
(cont'dl
D16Y5, D16Y8 sngi ne:
1 1- 30
c101
.",t
oo
l- Irl
l . l . l
c102
F'fftt
ItrlwHr/RED,--l
Fl8iNiB.,. I
16l BLrr,f Ec"
1
c104
(Canada,
f'frf
lolwHr,nED"
.l
ttlBLvyEL -
ItlwHlBLrJ -
c106 c105
c10?
c109r.
c' | 13+1
c l 1a
ffi ffi
r'ft]
16loRN---l
l ) l YEUsrK' I
bI BLX/ BLt l -
c136..
c137r'
c138r5
Di fferent wi res wi th the same col or have been gi ven
a number suffi x to di sti ngui sh them (for
exampl e,
yEUBLKT
O: Rel ated l o Fuel and Emi ssi ons System.
-
Connector wi th mal e termi nal s (doubl e
outl i ne): Vi ew from termi nal sroe
-
{si ngl e outl i ne): Vi ew from wi re si de
(cont' d)
C1,r2r'
fr
NOTE: .
cl 10
1 1 - 3 1
System Description
System Connectors
[Engine
Compartmentl
(cont'dl
c14113 c112
cl23
11-32
c117
r'tra
FfBL{-l
i ? l 8 L | ( YEL I
f3-l-
surwHr
-
c125
ffi
ti|wHr
FED.__l
fiTGRN/BLF
I]l
l-3_
ELK.YEL
I
lalir-r1wii'
l]]l
cl al rl
F T' I
tilLr
cnvwnl
I-IBLKCi
Il
c 111
16lcRr.yYEL;_l
EBrx,r/yf,p I5T
----_--.l
l-T-
.-
wH si_l
f-Fr
6 BL'q^/rf__l
l 2 l B t K l 6 l wHT l l 2
wHT B L U
a w' r T B . l r I l 2 B t Ul / v HT 7
-
|
I 3
GFN, ELK'
7
BL( ' I I 3
I t H] GRN 9 WFTCFN I I 1 WFI BLK S WHI GRN I
l 4 l wHl '
8 l q E D"
I 1 4
8 - k 1 0 -
| l ! wHr B L K e wr r l I
I .
* " ' " c o
- 1
BL- \ / r -
| | u l er
r c ar o
f6-wrr
Rr o
f---
NOTEI . Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e,
yEUBLKI
and YEVBLK, are not the same).
O: Rel ated to Fuel and Emi ssi ons Svstem.
c12E.'
fr
l6lELU/vEL-l
lETcRr^rHil
l-t
l 1 l , I
t f ; l
L4
6l;I;l
c121"
-_Et_
F I ' I
|6FED,--__-l
lSlwHl
l_l
;c;*
l r l 2 l 3 l
t i T l
It'|wHr/BLx_l
l l ? GFN/ BLKr I
I a TYELisLt -
lel
Bra-----l
FT_
- 1
j6FNF
-_-
c118* '
fr
lDlGRr,P
--__l
lEl-Lur-- -
c126r'
ffi
FT-wHr-7---l
l Dl FEp . I
glnn
A
[ ' l r l . )
v
16]wHrigLa_--l
l ?l i FN/BIK, I
ItrItEUBLU
---1
c35{'1
r'ft]
fclBtKi,,iHr
-.l
loleLK--'-l
1ol GRNFEo
l ]l
c t 15
c116
cl 20
o
-
(doubl e
-
(si ngl e
outl i ne): Vi ew from wi re si de
c112
fr
c124"
fr
c123
ffi
c14{}*f
fr
trTBLF---__-]
l ?l ne
o,
I
c139*
E
(cont' d)
1 1- 33
l a 8LK
YEUBLKI i9, BLK'
G) YEUBLK' ELKI
@ YEVE!KI 8LK'
YEUBLI I .!3 ELKI
,!] YEVBLK] !l BLK'
YEUELK' SLK
c122
o YEVGAN
8LU5
tJ)
RED5
o BIK'
YELI BLU
5 10 ElxrYEL
System Description
V., J
System Gonnectors
[Engine
Compartment]
(cont'd)
D16Y7 engi ne:
11-34
c105
ffi
c108
Etr
c112
ffi
NOTE: o
a
Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLK1
O: Rel ated to Fuel and Emi ssi ons System.
-
(doubl e
-
(si ngl e
(cont' d)
11- 35
C'loil
{C. nada)
r'1rtr
16lwHr/RED"
-l
ETBLX/vEr
---1
lTlwHrsru
-'1
9,''on
r+
|
1 l 2 l
|jIJ
c102
r,frt
lSlwHr/RED;_l
16TBuNsLKr--l
EfBLUmEo.
_-l
c107
ffi
c106
ffi
c113* !
t=t
/ 1 \
\2
I6ERN--l
Idfsr-r---
ll
c10l
System Description
System Gonnectors
[Engine
Compartment]
(cont'dl
D16Y7 sngi ne:
1 1- 36
c l 16
c' | 10
c115
(for
exampl e, YEUBLKT
and YEVBLK' are not the same).
O; Rel ated to Fuel and Emi ssi ons System.
.
-
(doubl e
-
(si ngl e
c114
fr
c109
r'ff;r
fSloRN---__l
I aI YEUBLK, I
lb]-Bar<,jLu I
cl23
ffi
cl 18
(A/Tl
ffi
ffi
cI17
r'frfl
lllBLr----l
l t
ELK,YEL
I
I-TBLUIrvHT
_-l
c12r lalf I
ffi
ftERN/Br-r;_-l
lElYEL;---_-l
c141. r5
l ' l z I
lEl
LicRN^
,Hrl
l6fsar<
'EL
I
c126 lA/T)
fr
ItrlwHr'--__l
l Ol BEp. I
c125
FF-'
l r l 2 l
[ ' l . l
I6liHT/REo'-_-l
lolREo,YEF-_-l
lofBr-r</YEL I
lSlBLK/wHTi-l
l BLK
.1) YEUELKI BLK'
ttl YEVBLK' o BLK'
YEVBLK' BLKI
YUBLK' BLK'
o YEUELK' BLK'
'|
YEUBLK' BLK'
fiil
RrD ,vHr--
IdIGBIvBLK' I
c12A |dfil
-t+-t
I r I
2 l
ITTTBLI
YEL--I
l.afcrll-NlrHT,ll
c35{*'
l 1 l 2 l 3 l
16lBL&l"Hr__-l
l6lBLK I
l O
cRNi REo
I
c127
(A/Tl
ffi
l6lwHr'
-l
l @l REo, I
11-37
System Description
System Connectors
lDash
and Floorl
1 1 - 3 8
12 13 15
c'15
ottT'r
-r=l- ,-F- |
l [TTtT;l l
l r l , I
t
l l . |
5
|
6
|
7
I l
I
l l BL( vEr . I l a FFo' I
TiTsuqv/ir---'l litEli l
ftl
B.u,"Ep
---l
l Ol wHr, Lr I
t . 8 l x I
tilwHr/6RN I
':
scu.rYarrm sFtem
0125 ct|:|5
lwnhout crui! contolt
(wtth ctuir controll
-F- F-
f f i f f i
I !' IGRNAI/HF I I 1 LLT GiN I
l l WHI / GRN I 12 GnY I
13 | l O cFNeHr ' I
f.T_ - ltrlwHT/GRN-
(for
exampl e, YEL,/BLK1
.
-
Connector wi th mal e termi nal s {doubl e outl i ne): Vj ew from termi nal si de
-
(si ngl e
,|
a 5 6 7 E 9 10
't2
13 t a 15 16 1l 1E 20
(cont' d)
1 1- 39
m
6 l 7 l 8 l et 0 t 1 1 12
BLU,rvL
11
YEL
BLX' EL
't2
1)
3
5
o
System Description
{
{
System Connectors
[Dash
and Floor]
(cont'dl
\
c412 C131 C135
c446
11-40
c130
t 5 6 7 I t 0
't'l
12 l 3 l 5 1 6 1 7 t a
't9
20
lD16Y5, Dl6Ya.ngin6l
YEL
cr32 tEcM/PCM-A)
5 6 7 8 9 t 0 1 l
12 t 3 lit t 5 l 6 t t I E t 9 2l 23 2a
25 27 2a 29 30
Ct33.,
(FCM-B)
cr3a {EcM/PcM-ct
cr!5 tEcM/FcM-Dl
r'TftI;I
ItTniKrysr I
l-"rlcnN^v'tr
I-l
Itmsrneo l
f.. ErlwHr'--l
ffi
fiTwr/Brt- l
TtltErnrx
-l
lfsri------l
rnwHr
I]]l
flwHrnEF l
aaFlBa( I
fr
(for
exampl e, YEUBLK1
.
-
Connector wl th mal e termi nal s
(doubl e
outl i ne): Vi ew from terml nal si de
-
(si ngl e
rfir
ITFI
l-tlwr/nEd-
I;TcRN^,Nr--l
lrfttK,/,/H
lilBrx,v/Hr l
Cr|]lil
ffi
! a l 5 E 9 t o
t l
't2
1 3
't1
t 8 19
11- 41
Troubl eshooti ng
Troubleshooting Procedures
How To Begi n Troubl eshooti ng
When the Mal functi on Indi cator Lamp
(Ml L)
has been reported on. or there i s a dri veabi l i ty probl em, use the appropri -
ate procedure bel ow to di agnose and repai r the probl em.
A. When t he MI L has come on:
' 1.
Connect the Honda PGM Tester or an OBD l l scan tool to the 16P Data Li nk Connector {DLC} l ocated near the l eft
ki ck Danel .
Turn t he i gni t i on swi t ch ON
(l l ).
Check t he DTC and not e i t . Al so check and not e
t he t reeze f rame dat a.
Ref er t o t he Di agnost i c Troubl e Code Chart and
begi n t roubl eshoot i ng.
2,
B.
c.
NOTE:
. See the OBD l l scan tool or Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
. The scan tool or tester can read the Di agnosti c Troubl e Codes
(DTC),
freeze frame data, current data. and other
Engi ne Control Modul e
(ECM)/Powertrai n
Control Modul e
(PCM)
data
. Freeze frame data i ndi cates the engi ne condi ti ons when the fi rst mal functi on, mi sfi re or fuel tri m mal functi or
was detected. l t can be useful i nformati on when troubl eshooti no.
When the MIL has not come on , but there i s a dri veabi l i ty
probl em, reter to the Symptom Chart on page 11-46.
DTCS wi l l be i ndi cated by the bl i nki ng of the Mal functi on Indi cator Lamp
(Ml L)
wi th the SCS servi ce connector con-
nected.
Connect the SCS servi ce connector to Servi ce Check Connector as shown.
(The
2P Servi ce Check Connector i s
l ocated under the dash on the passenger' s si de of the vehi cl e.) Turn the i gni ti on swi tch ON {l l }.
OBD ll SCAN TOOL or
HONDA PGM TESTER
SERVICE CHECK
CONNECTOR I2P}
SCS SERVICE CONNECTOR
07PAZ
-
001011X'
DATA LINK CONNECTOR {16PI
11-42
l l . Engi ne Control Modul e
(ECM)/Powertrai n
Control Modul e
(PCM)
Reset Procedure
Ei ther of the fol l owi ng acti ons wi l l reset the ECM/PCM.
. Use the OBD l l scan tool or Honda PGM Tester to cl ear the EcM' s/PcM' s memorv.
NOTE: See the OBD l l scan tool or Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
. Turn the i gni ti on swi tch OFF, Remove the BACK UP
(7,5
A) fuse from the under-hood fuse/rel ay box for 10 sec-
onds.
NOTE: Removi ng the BACK UP {7.5 A) fuse cancel s the cl ock and the radi o presets. Make note of the customer' s
oresets so vou can reset them.
l l l . Fi nal Procedure
(thi s procedure must be done after any troubl eshooti ng)
1, Remove the SCS Servi ce Connector i f i t i s connected.
NOTE: l f the SCS servi ce connector i s connected and there are no DTCS stored i n the ECM/PCM, the MIL wi l l stay
on when the i gni ti on swi tch i s turned ON
(l l ).
Do the ECM/PCM Reset Procedure,
Turn the i gni ti on swi tch OFF.
(cont' d)
2.
11-43
Troubleshooting
Troubl eshooti ng Procedures
(cont' d)
l f the i nspecti on for a parti cul ar code requi res vol tage or resi stance checks at the ECM/PCM connectors, remove the ri ght
ki ck panel . Pul l the carpet back to expose the ECM/PCM. Remove the ABS control uni t i f so equi pped. Unbol t the ECM/
PCM bol t. Turn the i gni ti on swi tch OFF, and connect the backprobe sets and a di gi tal mul ti meter as descri bed bel ow.
Check the system accordi ng to the procedure descri bed for the appropri ate code(s) l i sted on the fol l owi ng pages.
)
l
How to Use the Backprobe Sets
Connect the backprobe adapters to the stacki ng patch cords, and connect the cords to a mul ti meter. Usi ng the wi re i nsul a-
ti on as a gui de for the contoured ti p of the backprobe adapter, gentl y sl i de the ti p i nto the connector trom the wi re si de
unti l i t comes i n contact wi th termi nal end of the wi re.
Backprobo Adapter
BACKPFOBE SET
07SAZ
-
001000A lTwo
OIGITAL MULTIMETER
{Commcrcially.vaitablel
or
KS- AHM- 32- 003
KICK PANEL
11- 44
CAUTION:
. Puncturing the insulation on a wire can cause poor
or intermittcnt elesttical connestions.
. Bring th tester probe into contaqt with the terminal lrom the terminal sid6 of wire harnoss connectors in the enging
compadment. For Ismale connectors,
iust
touch lightly with ihe tester probe and do not ingert the probe.
RUBBER SEAL TESTER PBOBE
{cont' d}
TERMINAL
11-45
Troubleshooting
{cont'd)
Symptom Chart
Li sted bel ow are symptoms and probabl e
causes for probl ems that DO NOT cause the l vl al functi on i ndi cator Lamp
(Ml L)
to
come on. l i t he MI Lwas r epor t ed on, got o page' 11- 42.
Troubl eshoot each probabl e cause i n the order l i sted
l from l eft to ri ght) unti l the symptom i s el i mi nated.
The probabl e
cause and troubl eshooti ng page reference can be found bel ow.
Other Probabl e Causes for an engi ne that wi l l not start:
-
Compressi on
-
Starti ng system
-
Intake ai r l eakage
-
Overheati ng
-
Engi ne l ocked up
-
Battery
-
Ti mi ng bel t
Probable Cause List
(For
the DTC Chart, see page 11-531
\
SYMPTOM
PROEABLE CAUSE
Engi ne wi l l not start 4, 2, 3, 5, 20, 14, 1
Hard stani ng
2, 4. 11, 16, 13, ' t 9
Col d fast i dl e too l ow 7, 8, 6, 16
Col d f ast i dl e t oo hi gh
7 , 8 , 1 0 , 9
l dl e speed tl uctuates
7, 8, 10, 9
Mi sf i r e or r ough r unni ng
Troubl eshoot tor mi sfi re on pages 11-105, 108
Low power
2, 9, 10, ' t 2, 11, 16, 18, 20
Engi ne st al l s
2, 4, 11, 7, 20, A, 5, 15
Probable Cause Page
System
1 I t - o J Engi ne Control Modul e
(ECM)/Powertrai n
Controt Modul e
(PCM)
1
' t - 150,
1s1 Fuel pressure
1 I
-157
PGM-Fl mai n rel ay
4 Secti on 23 l gni ti on system
1 1 - 1 1 0 , 1 1 7
Crankshaft Posi ti on/Top Dead Center/Cyl i nder Posi ti on sensor ci rcui t, CKF sensor
ci rcui t
6 11-73 Intake Ai r Temperature {l AT) sensor ci rcui t
7 11- ' t 26, 128 l dl e Ai r Control Val ve
(IACV)
8
11-141, 142,
143, 144
l dl e speed adj ustment
9 1t - 164 Throttle body
10 11-162 Thronl e cabl e
' t 1
11-67 Mani fol d Absol ute Pressure
(MAP)
sensor
12 1' t-79 Throttl e Posi ti on (TP)
sensor
I J 1 11 1 3 Barometri c pressure (BARO)
sensor
1 4 Secti on 14, 1' l -139 A/T gear posi l i on si gnal
(see page
' 1' l -137)
or cl utch swi tch si gnal
1 1- 134 Brake swi tch si gnal
11-162 Ai r Cl eaner
11 Intake ai r pi pe
18 1l - 168 Three Way Catalytic Converter
(TWC)
19 11- 181 Evaporati ve emi ssi on
(EVAP)
control
20 Cont ami nat ed f uel
11- 46
ECM/FCM Data
By connecti ng the OBD l l scan tool or the Honda PGM Tester to the 16P data l i nk connector
(DLC),
vari ous data can be
retri eved from the ECM/PCM. The i tems l i sted i n the tabl e bel ow conform to the SAE recommended practi ce.
The Honda PGM Tester al so reads data bevond that recommended by SAE.
Understandi ng thi s data wi l l hel p to fi nd the causes of i ntermi ttent fai l ures or engi ne probl ems.
NOTE:
a The
"operati ng
val ues" gi ven bel ow are approxi mate val ues and may be di fferent dependi ng on the envi ronment and
the i ndi vi dual vehi cl e.
. Unl ess noted otherwi se,
"at
i dl e speed" means i dl i ng wi th the engi ne compl etel y warmed up, A//T i n pe5i ti on
@
or
@,
M/T i n neutral , and the A/C and al l accessori es turned oi f.
Data Description Operati ng Val ue Freeze Data
Di agnosti c
Troubl e Code
(DTC)
l f the Ecl \4 /PcM derects a probl em, i t wi l l store i t as a
code consi sti ng of one l etter and four numbers.
Dependi ng on the probl em, an SAE-deti ned code
(P0xxx)
or a Honda-defi ned code
(P1xxx)
wi l l be output to the
rester.
l f no probl em i s detected,
there i s no output.
YES
Engi ne Speed The ECM/PCM computes engi ne speed from the si gnal s
sent from the Crankshaft Posi ti on sensor.
Thi s data i s used for determi ni ng the ti me and amount ot
fuel i nj ecti on.
Nearl y t he same as
t achomet er i ndi cat i on.
YES
Vehi cl e Speed The ECl vl /PcM converts pul se si gnal s from the Vehi cl e
Soeed Sensor
(VSS)
i nto speed data
Nearl y the same as
speedometer i ndi cati on
YES
Mani f ol d
Absol ute
Pressure
(MAP)
The absol ute pressure caused i n the i ntake mani fol d by
engi ne l oad and speed.
Wi th engi ne stopped:
Nearl y the same as atmo-
sphenc pressure
At i dl e speed:
24
-
37 kPa
(180 -
280
mmHg, 7. 1
-
' 11. 0
i nHg)
YES
Engi ne Cool ant
Temperature
(ECT)
The ECT sensor convens cool ant temperature i nto vol t-
age and si gnal s the ECM/PCM. The sensor i s a thermi stor
whose i nternal resi stance changes wi th cool ant tempera-
ture. The ECM/PCM uses the vol tage si gnal s from the
ECT sensor to determi ne the amount of i ni ected fuel .
Wi th col d engi ne:
Same as ambi ent temper-
ature and IAT
Wi th engi ne warmed up:
' 176
194.F
(80
-
90"C)
YES
Heated Oxygen
Sensor
(H02S)
(Pri mary,
Sensor 1)
(Secondary
Sensor 2)
The Heated Oxygen Sensor detects the oxygen content
i n the exhaust gas and sends vol tage si gnal s to the
ECM/PCM. Based on these si gnal s, the ECM/PCM con
trol s the ai rfuel rati o. When the oxygen content i s hi gh
{that i s. when the rati o i s l eaner than the stoi chi ometri c
rati o), the vol tage si gnal i s l ower.
When the oxygen content i s l ow
(that
i s, when the rati o
i s ri cher than the stoi chi ometri c rati o), the vol tage si gnal
i s hi oher .
0. 0
-
1. 25 V
At i dl e speed:
about 0. 1
-
0. 9 V
NO
( Sensor
1)
(cont' d)
11- 47
Troubl eshooti ng
(cont'dl
Data Description
Operating Value Freeze Data
HO2S
Feedback
Loop Status
Loop status i s i ndi cated as
"open"
or
"cl osed".
Cl osed: Based on the HO2S output, the ECM/PCM deter-
mi nes the ai rl fuel rati o and control s the amount of i nj ect-
ed fuel .
Open: l gnori ng HO2S output, the ECM/PCM refers to si g-
nal s from the TP, MAP, and ECT sensors to control the
amount ol i ni ected fuel .
At i dl e speed: cl osed
YES
Shon Term
Fuel Tr i m
The ai rfi uel rati o correcti on coeffi ci ent for correcti ng the
amount of i ni ected fuel when HO2S feedback i s i n the
cl osed l oop status. When the si gnal from the HO2S i s
weak, short term fuel tri m gets hi gher, and the ECM/PCM
i ncreases the amount ot i nj ected fuel . The ai rl fuel rati o
gradual l y gets ri cher, causi ng a hi gher HO2S output.
Consequentl y, the short term l uel tri m i s l owered, and
the ECM/PCM reduces the amount ot i nj ected fuel .
Thi s cvcl e keeDs the ai rl fuel rati o cl ose to the stoi chi o-
metri c rati o when i n cl osed l oop status.
! 20%
YES
Long Term
Fuel Tr i m
Long term l uel tri m i s computed from short term fuel
tri m and i ndi cates changes occurri ng i n the fuel suppl y
system over a l ong peri od.
l f l ong t er m f uel t r i m i s hi gher t han 1. 00, t he amount of
i nj ected fuel must be i ncreased. l f i t i s l ower than 1.00,
the amount of i nj ected fuel must be reduced.
+ 200/o
YES
Inl ake Ai r
Temperature
(IAT)
The IAT sensor converts i ntake ai r temperature i nto vol t-
age and si gnal s the ECM/PCM. When i ntake ai r tempera-
ture i s l ow, the i nternal resi stance of the sensor
i ncreases, and the vol tage si gnal i s hi gher.
Wi th col d engi ne:
Same as ambi ent temper-
ature and ECT
YES
Th rottl e
Posi ti on
Based on the accel erator
pedal posi ti on, the openi ng
anql e of the throttl e val ve i s i ndi cated.
At i dl e speed:
approx. 10 %
YES
l gni t i on
Ti mi ng
l gni ti on ti mi ng i s the i gni ti on advance angl e set by the
ECM/PCM. The ECM/PCM matches i gni ti on ti mi ng to the
dri vi ng condi ti ons.
At i dl e speed: 12' t 2"
E' I UL Wtrn rne 5L5 Ser-
vi ce connector connected.
NO
Cal cul ated
Load Val ue
(CLV)
CLV i s the engi ne l oad cal cul ated from the MAP data. At i dl e speed:
15- 35%
At 2,500 rpm wi th no l oad:
12
-
30%
YES
Engi ne/Powertrai n Control Modul e Termi nal Arrangement
ECM/PCM CONNECTOR A {32P)
1
I NJ4
2
I NJ3INJ2
a
I NJl
5 6 7 8 I
LG1
1 0
PGl
t 1
I GPl
1 2
ACV
't3
1 4 1 5
PCS
16
FLR
17
acc
18
MI L
19
AtTC
20
tcM
22
LG2 PG2
21
IGP2
25 21 2a E
vsv
30
SLU
Wi re si de of f emal e t ermi nal s
ECM/PCM CONNECTOR A {32P1
NOTE: Standardbat t ery vol t age t s
*2:
A/T (D16\./.
Dl6YSensine)
* 3: CW
( 016Y5
engi ne)
14:
A"/T and D16Y7 ensine
' 5:Except
A/T and 016\./ engine
16:
AtlT lD16Y8 engine)
r Tr CVT
( O16Y5
onqi ne) and Dl 6YBensi ne
' 8:' 96
016Y8 ensine {oupel. 97 Dl6YSensine (coupe:
all modols, sd.niKl moder),
' 98
D' I6Y5 sngin,' 98 016Y8 engine
r 10:
M/ T ( D16Y5
engi ne)
. 11:
Excepl M/ I ( 016Y5
engi ne)
i 12:
O16Y5, D16Y8 engi ne
' 15: ' 9t
016Y7 engi ne
( coup:
KL mode
, sedanr KL l LXl modet ) ,
' 98
D16Y7 engine
{cont ' d)
Sig.al
YEL l NJ4 { No a FUEL I NJECTOB} Dr i vesNo. 4i uel ni ecr or .
Wi t h engi ne f unn n9: pul ses
2 BLU l NJ3 ( No.
3 FUEL I NJCTORI
3 FED l NJ2 ( No, 2
f UEL I NJECTOR) Drives No. 2 fuel injecto..
88N I NJI 1No. 1 FUELI NJECTOF) Onves No. 1 l uel ' nt ect or
5 BLI(WHT
SO2SHTC (SECONOARY
HEATED
OXYGEN SENSOF HEATER CON
TSOL)
Drives secondary hated oxygen sensor Wi i h i gni l i on swi t ch ON
( l l ) : baner y
vot age
Wi l h i ul l y war med up engi ne r unni ng: dut y conr f ot t ed
6 BLK^/VHT
PO2SHTC IPSIMARY HEATED
OXYGEN SENSOE HEATER
CONTROL)
Drives prihary
heated orygen s6nsor Wirh ignitio. swhch ON
(ll):
batery vohage
Wi l h t Jl l / war med up engi l e .
r 1. nS. dJr \ , , or t . ol eo
FED* 3
ESOL I EGF CONTROL
SOLENOI O VALVEI
Orives EGF conto solenoid valve. Wn5 EGR oo- , dr ' n9 du. i r S d i vi ag wr F
. Jf y
wa' r - d
up engine: duty controlled
Wi l h EGR nor oper at i nq: 0 V
E EGR
Wi l l - FCF oper af i ng du' , n9 dr ' v, r g wr h t ul l y wd npd
! p en9r ner dul y cont r ol l ed.
Wl h EGR not oper at i nq: 0 V
GBN/YEL
WS
(WC
SOIENOID VALVE) Drives VTEC soleno d valve.
Wi l h engi ne at l owengi ne speed: 0 V
Wilh enqine at hlqh enqine sD6ed:batre.v vokaoe
9 BRN/BLK LG1 ( LOGI C
G8OUND) Ground for lhe ECi!4/PCM conlrolclrcuit. Less l han I 0 V at ar l r i mes
I O BLK PG1
(POWER
GBOUNO) G' ound l or t he ECM/ PCM power ( t r c! f .
l l YEUBLK
IGPl (POWER
SOURCE) Pow6rsource tor the ECM/PCM co.trol Wlth ignit on swilch ON
(ll):
batrerv vo taqe
wi t h r gnni on swhch OFF: 0 V
12" SLVALU IACV (IDLE
AIR CONTAOLVALVE)
Wi l h engi ne r u. ni ng: pul ses
ORN
IACV N lIDLE AI8 CONTROL
VALVE NEGATIVE SID)
Drives lhe IAC valve lnegai ve side).
BLVBLU
IACV P
(IDTE
AIR CONTFOL
VALVE POSITIVE SIDE)
D' i ves I AC val ve l posr t r v sr de) .
1 5 FEOTYEL
PCS {EVAP PUsGE CONTROL
SOLENOID VALVE)
Orives EVAP purge contro soleno d vaive. Wl l h engi ne r unni ng, engi ne cool ant be ow 154 F
(64' Cl:
battery vohage Wilh engine running eng ne
cocrant above 154' F {68' C): 0 V
1 6 GRNAEL
FLR { FUEL PUMP FELAY) Dr ves t ue pump r el ay. 0 v for ndo *(onds dier rJ .{ g ' gr' t on sw ! h oN
1 7 BLK/ FED
ACC ( A, / C
CLUTCH FELAY) Dr i vesA, / C cl ul ch. et ay. wr t h compr essor ON: 0 V
Wth compressorOFF: battery vohaoe
1 8 G8N/ORN
MILlMALFUNCTION INDICATOR
Wi i h Ml Lr ur ned ON: 0V
Wi l h Ml Lt ur ned OFF: bat t er y vohase
WHI/GFN
ALTC
(ALTEFNATOB
CONTNOL) Sends alle.nator cohtrol signa Wilh lully warmed up engine running: b.ftery voltsge
Du . i n g d r i v i n g wi l h s ma l l e l e c t r c a l l o a d : 0 V
20 YEVGRN
rclvr 0GNrI|oN coNTfloL
t!'IODULE)
With ignition switch ON
(ll):baltery
voltage
Wt h engi ne r ! nni ng: about 10 V
( dependi ng
on
22 BRN/ ALK LG2 ( LOGi C
GFOUND) Ground fof lhe EC^4/PCM conrrolcncuil Losst han l . 0Var al l i i mos
23 BLX PG2I POWER GFOUND) Gr ound f or l he ECM/ PCM powef ci r cui t .
YE|JLK
I GP2 ( POWER
SOUFCE) Powe. source fof rhe ECM/PCM cont.ol Wirh igniiion switch ON
(lll:
banery vohage
Wi t h i 9ni t i on swi t ch OFF: 0 V
25' 3 WHf/BED
VREF ( REFENENCE
VOTTAGE) Provides rslerence vo ltage to TCM. Wi t h i gni t i on swi t ch ON
( l l ) : aboLt
5 V
Wi t h l gni l i on swi l ch OFF: 0 V
27' r GRN
FANC iRAOIATOS FAN
CONTFOL)
Orives radiarorfan relay. Wiih radiato. f8n running: 0 V
Wirh radialor tan stopped: banery vohaoe
8LU
2WBS
(EVAP
BYPASS
SOIENOID VALVE)
Drives EVAP bypass sol6nord valve wnh i gni t i on swt ch ON
( l t ) : bal l er y
vot r age
VSV {EVAP CONTBOL CANISTEB
VENI SHUT VATVE)
Drives E VAP control can isrer v6nish!t With ignilron swilch ON lll): battery vohage
S!U
(lNTEELOCK
CONTROL
UNI T)
Derecb lnter ock convol unit sisnal. Wt h i sn t i on swi i ch ON { 11) and br a( e pedal
dpressed: batieryvohaae
11-49
Troubleshooting
Engine/Powertrain Control Module Terminal Arrangement
(cont'dl
NOTE
Wi rg si de of f emal e t ermi nal s
PCM CONNECTOR B {25P)*'
: St andard bat t ery vol t age i s l 2
Telminal
numoer
Wire
color
Terminsl
De3cription Si gnal
1 WHT
LS-
(LI NEAR
SOLENOI D
VALVE
_
SIDE)
Ground t or l i near sol enoi d val ve. Wi t h i gni t i on swi t ch ON
(l l ): pul ses
2 RED
LS+
(LINEAR
SOLENOID
VALVE + SIDE)
Dri ves l i near sol enoi d val ve. Wi t h i gni t i on swi t ch ON
(l l ): pul ses
3 BLU/ YEL
SHA
(SHIFT
CONTROL
SOLENOID VALVE A}
Drives shift control solenoid valve A. Wi t h engi ne runni ng i n 2nd, 3rd gears:
battery voltage
Wi t h engi ne runni ng i n 1st , 4t h gears:
about 0 V
4 GRN/ BLK
LC B
(LOCK. UP
CONTROL
SOLENOI D VALVE B)
Drives lock-rrp control solenoid
val ve B-
With lock-up ON: battery voltage
Wi t h l ock-up OFF: 0 V
5 YEL
LC A
(LOCK. UP
CONTROL
SOLENOI D VALVE A)
Drives lock-up control solenoid Wi t h l ock-up ON: bat t ery vol t age
Wi t h l ock-up OFF: 0 V
8 PNK
ATPD3 IA,/T GEAR POSI-
TI ON SWI TCH)
Detects A,/T gear position
switch
srgnat .
I n Ep o s i t i o n : 0 V
I n any ot her posi t i on:
bat t ery vol t aqe
1 t GRNA/VHT
SHB
(SHI FT
CONTROL
SOLENOI D VALVE B)
Drives shift control solenoid valve 8. Wat h engi ne runni ng i n 1st , 2nd: baf t ery
vol t age
Wi t h engi ne runni ng i n 3rd, 4t h: about 0 V
WHT/RED
SLU
(I NTERLOCK
CON-
TROL UNI T}
Dri ves i nt erl ock cont rol uni t . Wi t h i gni t i on swi t ch ON
(l l )
and brake
pedal depressed: 0 V
GRN/ BLK
D4 I ND (D4I NDI CATOR
LI GHT)
Dri ves D4 i ndi cat or l i ght .
Wi t h D. i ndi cat or l i ghr rurned ON: bat t er),
vol t age
Wi t h
E
i ndi cat or l i ght t urned OFF: O V
1 4 WHT
NMSG
(MAINSHAFT
SPEED SENSOR GROUND)
Ground for mainshaft soeed sensor.
RED
NM {MAI NSHAFT SPEED
SENSOR)
Detects mainshaft speed sensor
srgnal ,
Wi t h engi ne runni ng: pul ses
WHT
ATPR {!VT GEAR POSI-
TI ON SWI TCH}
Detects Ay'T gear position switch
si gnal
I n Ep o s i t i o n : o V
bat t ery vol t age
1 7 8LU
ATP2
(A"/T
GEAR POSI-
TION SWITCH}
Detects Ay'T gear position
switch
srgnal ,
I n Ap o s i t i o n : 0 V
I n any ot her
posi t i on:
bat t ery vol t age
22 GRN
NCSG {COUNTERSHAFT
SPEED SENSOR GROUND)
Ground lor countershatt speed
sensor.
BLU
NC {COUNTERSHAFT
SPEED SENSOR}
Detects countershaft speed sensor
srgnal .
Wi t h i gni t i on swi t ch ON {l l ), and f ront
wheel s rot at i ng: pul ses
24 YEL
ATPD4 {A"/T GEAR POSI-
TION SWITCH)
Detocts A./T gear position
switch
sr gnal .
I n
El
posi t i on:
O V
5 V
25 LT GRN
ATPNP iAlT GEAF POSI-
TI ON SWI TCH)
Detects A.rT gear position switch
srgnal .
l n
m
orE posi ti on:
O V
l n any other posi ti on: battery vol tage
*1:
USA model
*2:
A,/T {D16Yr, Dl6Y8 engine)
*3:
CVT
(D16Y5
engi ne)
*4:
A*/T and Dl6Yl engine
*5:
Except A,rf and 016Y, ongine
*6r
IVT {D16Y8 ngine}
*7:
CW
(D16Y5
engi ne) and D16Y8 engi ne
* 8: ' 96
D16Y8 enoi n6 ( coupe) , ' 97
D16Y8
model s. sedan: KL model ), ' 98 D16Y5
on9ine
' 9:
016Y5 engi ne
*10:
M/ T l D16Y5 engi ne)
*11:
Except M/ T
(D16Y5
engi ne)
*
12: D16Y5, D' | 6Y8 engi ne
*13r
Dl 6Y8 engi ne
i 14:
Dl 6Y7 engi ne
*15: ' 97
016Y7 engi ne {coupe: KL model , sedan: KL
(LX)
model ),
' 98D16Y7
engi ne ehgi ne {coupe: al l
engi ne,
' 98
D16Y8
1 1- 50
ECM/PCM CONNECTOR C 131PI
1
CKfP
2
CKPP TIrcP
a
ACS sTs
1
scs
a 9
TMA
10
vBu
1 1
CKFM
12 13 1 4 15
vTM
16
ALTf
1 7 18
vss
lP+
21
25
z) 30
TMB
Torminal
numbot
T6rminal
Description Signrl
l BLU/RED CKFP {CKF SENSOR P SIDE} Detects CKF sensor. Wi t h engi ne r unni ng: pul ses
2 BLU CKPP
( CKP
SENSOR PSI DE) Detects CKP sensor. Wi t h ongi ne runni ng: pul ses
3 GRN TDCP {TOC SENSOR P SIDE} Detects TDC sensor, With engine running: prils6s
YEL CYPP {CYP SENSOR P SI DE) Detects CYP snsor. Wi t h engi ne runni ng: pul ss
5 BLU/ RED
ACS
(P,/C
SWITCH SIGNAL) Oetects Ay'C switch signal. With,!y'C switch ON: 0 V
With ,y'C switch OFF: battery voltage
6 BLU/ ORN
STS {STARTER SWITCH
SI GNAL)
Detects starter switch signal, With starter switch ON
(lll):
battery vollage
With starler switch OFF: 0 V
1 BRN
SCS
( SERVI CE
CHECK
SI GNAL)
Detects service check connector signal
( t he
si gnal causi ng a DTC i ndi cat i on)
With the connector connected: 0 V
With the connector disconn6ct6d: 5 V
8 LT 8LU K- LI NE
( DLC)
Sends and r ecer ves scan t ool si gnat , Wi t h i gni t i on swi t ch ON
( l l ) :
about 5 V
GRY
Dat a communi cat i on wi t h TCM: ECM
cont r ol dat a out put
Wi t h i gni t i on swi t ch ON
( l l ) : pul s6s
1 0 WHT/BLU
VBU
(VOLTAGE
BACK UP) Power sourc6 for the ECM/PCM
control circuit. Power source for the
DTC memory
8.ttery voltage at alltimos
t 1 WHT/RED
CKFI\4 {CKF SENSOB M
SI DE)
Gr ound f or CKF sensor si gnal .
CKPI\4
(CKP
SENSOR M
SI OE}
Gr ound f or CKP ssnsor si gnal .
RED
TDCM
(TDC
SENSOR M
SI DE)
Gr ound f o. TDC sensor si gnal .
1 4 BLK
CYPM
( CKP
SENSOR I V
SI DE)
Gr ound f or CYP sensor si gnal .
BLU/ 8LK
VTM {VTEC PRESSURE
swrTcH)
Detects VTEC pressure switch signal. With engine at low6n9in6 spdr0 V
With engine at high engin speed: battery voltEge
, I 6
GRN
PSPSW
( P/ S
OI L PRESSURE
SWI TCH)
Detects PSP switch signal. At idle with steering wheel in sk6ight ahaad
posi t i oni 0 V
At rdle with st6ring whsel at full lock: battery
voltage
1 7 WHT/RED
ALTF
(ALTERNATOE
FR
SI GNAL)
Detects alternator FR signal, With fully warmed up 6ngine running:
0V- battery voltage {depsnding on electrical
load)
1 8 BLU/WHT
VSS
( VEHI CLE
SPEED SEN.
soR)
Detects VSS signal. Wi t h i gni t ' on swi t ch ON { l l ) and f r ont wheel s
r ot at i ng: c y c l es 0V- 5V
23' to BLK l P+
( HO2S
PUMP CELL +) Cont r ol s HO2S pump
cel l . Wr t h r gni t i on swhch ON t l l ) : about 0. 5
-
5. 3 V
RED
IP-, VS- {HO2S COMMON) Ref er ence vol t age suppl y, With fully warmed up 6ngin6 at idle:
about 2. 6- 2. 8 V
25*
ta
VS+
(VS
CELL VOLTA6E) Det ect s VS cel l vol t age. Wi t h i gni t i on swi t ch ON
( l l ) :
about T V
29
LT GRN*3
ATPNP {4,/T GEAR POSI.
TroN swrTcH)
Detects
py'T
gear position switch signal. I nE or E posi t i on: 0 V
ln any other position: battery voltage
BED* r 0
CLSW
(CLUTCH
SWITCH) Detects clutch switch signal. Wi t h cl ut ch pedal rel easd: about 5 V
With clutch oedal deoressed: 0 V
30 PNK
TM8 Dat a communi cat i on wi t h TCM:
ECM cont r ol dat a i nput
Wi t h i gni t i on swi t ch ON { l l ) :
pul ses
ECM/PCM CONNECTOR C {31PI
*1:
USA modl
+2rAl T
(Dl 6Yl ,
D16Y8 engi ne)
'3:
CVT
(D16Y5
engine)
'4:
A,/T and D16Y7 engine
'5:
Except A,/T and Dl6Yl engine
*6:
Ay'T
(D16YB
engine)
*7:
CVT
(016Y5
engi ne)and D16YB engi ne
*8: ' 96
D16Y8 engi ne
(coupel , ' 97
D16Y8 engi ne
(coupe:
al l model s,
sedan: KL model ), ' 98 D16Y5 engi ne, 98 D16YB ongi ne
*9:
D 16Y5 engi ne
r 10:
M/ T { D16Y5 engi ne)
*11:
Except l vl / T
( 16Y5
engi ne)
' 12:
*13:
D16Yg engi ne
' 14:
O16Y7 engi ne
*15: ' 97
D16Y7 engi ne
( coupe:
KL model , sedan: KL
( LX)
model ) ,
' 98D16Y7
engi ne
NOTE: Standard battery vol tage i s 12 V,
{cont' d)
1 1 - 5 1
Troubleshooting
Engi ne/Powertrai n
Control Modul e Termi nal Arrangement
(cont' dl
ECM/PCM CONNECTOR O {16P)
ECI BXSW
KS
a l o
13 1 1 1 5
EL
ECM/PCM CONNECTOR D
(16P}
NOTE: Standard battery vol tage i s 12 V.
Terminal Wire T.minal
Description
Signal
I RE D/BLK
IPS
(THROTTLE
POSITION
SENSOR)
Det ect s TP sensor si gnal . Wi t h t hrot t l e f ul l y open: about 4. 8 V
Wi t h t hrof t l e t ul l y cl osed: about 0. 5 V
2 RED^^/HT
ECT (ENGI NE
COOLANT
TEMPEFATURE SENSOB
Det ect s ECT sensor si gnal . Wi t h i gni t i on swi t ch ON(U): about 0. 1
-
4. 8 V
(dependi ng
on engi ne cool ant t emperat ure)
3 RED/G B N
MAP
(MANI FOLD
ABSO-
LUTE PRESSURE SENSOR)
Det ect s MAP sensor si gnal . Wi t h i gni t i on swi t ch ON(l l ): about 3 V
At i dl e: about 1. 0 V
(dopendi ng
on engi ne speed)
YEURED
vccl
(SENSOR
VOLTAGE) Power source f or MAP sensor. Wi t h i gni t i on swi t ch ON
( l l ) :
abour 5 V
Wi t h i gni t i on swi t ch OFFr 0 V
5 GRNîVHT
EKSW
(BRAKE
SWTCH) Det ect s brake swi t ch si gnal . With brake Dedal released: 0 V
With brake pedaldepressed:
battery voltage
6* ?
RED/BLU KS
(KNOCK
SENSOR) Det ect s KS si gnal . Wi t h engi ne knocki ng: pul ses
1
PH02S (PRI MARY
HEAT
ED OXYGEN SENSOR,
SENSOR 1)
Detects primary
heated oxygen
sensor {sensor 1) si gnal .
Wi t h t hronl e f ul l y opened f rom i dl e wi t h
f ul l y warmed up engi ne: above 0. 6 V
Wi t h t hrot t l e
qui ckl v
cl osed: bel ow 0. 4 V
LABEL Det ect s LABEL resi st ance. Wi t h engi ne runni ng: about 0. 3
-
4. 9 V
8 BED/YEL
I AT
(I NTAKE
AI R TEM,
PERATURE SENSOR}
Det ect s I AT sensor si gnal .
Wi t h i gni t i on swi t ch ON {l l ): about 0. 1
-
4. 8 V
(dependi ng
on i nt ake ai rt emperat ure)
9* WHT/8LK
EGRL
(EGR
VALVE LI FT
SENSOR}
Det ect s EGF val ve l i f t sensor si onal . At i dl e wi t hout vacuum: about 1. 2 V
With 27 kPa
(200
mmHg, 8 in. Hg): about 4.3 V
1 0 YEL/BLU
VCC2
(SENSOR
VOLTAGE) Pr ovi des sensor vol t age, Wi t h i gni t i on swi t ch ON(l l ): about 5 V
Wi t h i gni t i on swi t ch OFF: 0 V
l l GRN/ BLK (SENSOR
GROUNDi Sensor ground.
Les s t han 1. 0 V at al l t i mes
12 GRNAr'VHTSG1
(SENSOR
GROUND) Ground f or MAP sensor. Less t han 1. 0 V at al l t i mes
GRN/ 8LK+I '
REDt/EL*14
SHO2SG
(SECONDARY
HEATED OXYGEN SEN.
SOF, SENSOR 2 GROUND)
Ground for secondary heated oxy-
gen
sensor {sensor 2),
1 4 WHT/RED
SHO2S
(SECONDARY
HEATED OXYGEN SEN-
SOR, SENSOR 2)
Detects secondary heated oxygen
sensor
(sensor
2) si gnal .
With throttle fully opened from idle with
t ul l y warmed up engi ne: above 0. 6 V
Wi t h t hronl e
qui ckl v
cl osed: bel ow 0. 4 V
LT GRN
PTANK
(FUEL
TANK PRES-
SURE SENSOR)
Det ect s f uel t ank oressure sensor, With fuel fill caD ooend: about 2.5 V
16* ,
GB N/RED
EL
(ELD)
Det ect s ELD si gnal . Wi t h parki ng
l i ght s t urned on at i dl e: about
Wi t h l ow beam headl i ght s t urned on at
i dl e: about 1. 5- 2. 5 V
*1:
USA model
*2:
IVT {D16Y7, D16Y8 ensine)
*3:
CW
(D16Y5
engi ne)
*4:
, VT and D16Y7 6ngi ne
+5:
Except Ay'T and D16W engine
*6:
A/ T 1D16Y8 engi ne)
*7:
CW
(O16Y5
engi ne) and 016Y8 engi ne
18: ' 96
D16Y8 engi ne
( coupe) , ' 97
D16Y8 engi ne
model s, sedan: KL model ) , ' 98 D16Y5 ngi ne,
engrne
r9:
D16Y5 engi ne
*
10r M/ T
(D16Y5
engi ne)
*11: Excopt
M/ T
(Dl 6Y5
engi ne)
*12:
*13:
D16Y8 engane
' 14:
Dl 6Y7 engi ne
*15: ' 97
016Y7 engi ne {coupe: KL model , sedan: KL
(LX)
modet ),
' 98D16Y7
engi ne:
( coupo:
al l
' 98
D16Y8
11-52
Diagnostic Trouble Code
(DTC)
Chart
*:
These DTCS wi l l be i ndi cated
connected
* 1:
Dl 6Y5 engi ne
( CVT)
*2:
Except Dl 6Y5 engi ne
(M/T)
*14:
' 97
model
* 15: ' 96
model
*16: ' 98
model
by the bl i nki ng of the Mal functi on Indi cator Lamp
(Ml L)
wi th the SCS servi ce connector
(cont ' d)
1 1- 53
DTC
(Ml L
i ndi cati onr)
Dtection ltem Probable Cause Page
P0106* 15 ( 5)
Mani fol d Absol ute
Pressure C:rcui t
Range/Performance Probl em
.
Vacu um connect i on
.
MAP sensor
1 1 6 7
P0' 107 (3)
Pressure Ci rcui t
Low Input
Open or short i n MAP sensor ci rcui t
MAP sensor
ECMiPCt\,4
TCM* I
1 1 6 9
P0108 (3)
Pressure Ci rcui t
Hi gh I nput
Open i n MAP sensor ci rcui t
MAP sensor
ECM/PCM
11-71
P01 11+r , 4.
* 15
{
10)
Intake Ai r Temperature
Ci r cui t
.
IAT sensor
11-73
P01' t2
(10)
Intake Ai r
Temperature Ci rcui t
Low Input
Short i n IAT sensor ci rcui t
IAT sensor
ECM/PCM
1l - 74
P01' t 3 ( 10)
l ntake Ai r
Hi gh I nput
Open i n IAT sensor ci rcui t
IAT sensor
ECM/PCM
11-75
P0116
( 86)
Engi ne Cool ant
.
ECT sensor
.
Cool i ng system
11-76
P0117
(6)
Engi ne Cool ant
Low Input
Short i n ECT sensor ci rcui t
ECT sensor
ECM/PCM
11- 17
P0118
( 6)
Engi ne Cool ant
Hi gh I nput
Open i n ECT sensor ci rcui t
ECT sensor
ECM/PCM
l 1 - 7 8
P0'122 (71
Throttl e Posi ti on
Ci rcui t
Low Input
Open or shon i n TP sensor ci rcui t
TP sensor
ECM/PCM
TCM* 1
11-79
P0123
t7l
Throttl e Posi ti on
Ci rcui t
Hi gh Input
Open i n TP sensor ci rcui t
TP sensor
ECMiPCM
I 1- 81
P0131* '
( 1)
Pri mary Heated Oxygen Sensor
Ci rcui t Low Vol tage
( Sensor
1)
Short i n Pri mary HO2S {Sensorl ) ci rcui t
Pri mary HO2S
(Sensor
1)
Fuel suppl y system
ECM/PCM
11-84
PO132+' (1)
Ci rcui t Hi gh Vol tage
(Sensor
1)
Open i n Pri mary HO2S (Sensor
1) ci rcui t
Pri mary HO2S
(Sensor
1)
ECtVr/PCM
11- 86
P0133*'
(61)
Sl ow Besponse
{Sensor I )
.
Pri mary HO2S
(Sensorl
)
' Exhaust
syst em
11- 8J
P0135* ' ( 41)
Pri mary Heated Oxygen
Sensor Heal er
Ci rcui t Mal functi on
( Sensor ' l )
.
Open or short i n Pri mary HO2S
( Sensor
1) heat er ci r cui t
.
ECM
11, 98
Troubleshooting
(DTC)
Chaft
(cont'd)
*3r
Dl 6Y5 engi ne
(CVT)
and Dl 6Y8 engi ne
*4:
D16Y5 engi ne
* 16: ' 98
model
DTC
{MlL indication)
Detection ltem Probable Cause Page
P0137
(63)
Secondary Heated Oxygen Sensor
Ci rcui t Low Vol tage
(Sensor
2)
Short i n Secondary HO2S
(Sensor
2) ci rcui t
Secondary HO2S l Sensor 2)
ECM/PCM
11- 95
P0138
(63)
Secondary Heat ed Oxygen Sensor
Ci rcui t Hi gh Vol t age
(Sensor
2)
Open i n Secondary HO2S i Sensor 2)ci rcui t
Secondary HO2S
(Sensor
2)
ECt\4/PCM
1 1-96
P0139
(63)
Sl ow Response
(Sensor
2)
Secondary H02S
(Sensor
2)
11-97
P0141
(65)
Secondary Heat ed Oxygen Sensor
Heater
Ci rcui t Mal f unct i on
(Sensor
2)
Open or short i n Secondary HO25
(Sensor
2) heat er ci rcui t
ECM/ PCM
1 1 9 8
P0171 {45)
Syst em Too Lean Fuel suppl y syst em
Pri mary H02S
(Sensor
1)
l vl AP sensor
Cont ami nat ed f uel
Val ve cl earance
Exhaust l eakage
1 1 - 1 0 3
P0172
(45)
System Too Rich Fuel suppl y syst em
Pri mary HO2S
(sensor
1)
MAP sensor
Cont ami nat ed f uel
Val ve cl earance
1 1 , 1 0 3
P0300*16
and
some of
P0301
P0302
P0303
P0304
l#\
l 73l
\741
Random Mi sfi re
l gni ti on system
Fuel suppl y system
MAP sensor
EGR system
IAC val ve
Contami nated fuel
Lack of fuel
1 1- 108
P0301
P0302
P0303
P0304
tr\
173 |
\741
-
Cyl i nder 1
-
Cyl i nder 2
-
Cyl i nder 3
-
Cyl i nder 4
Mi sf i re Det ect ed
Fuel I nj ect or
Fuel I nj ect or ci rcui l
l gni t i on syst em
Low compressron
Val ve cl earance
11- 105
P0325' 3
(23)
Knock Sensor
(KS)
Ci rcui t
Mal t unct i on
Open or short i n Knock Sensor
(KS)
ci rcui t
Knock Sensor
(KS)
ECM/ PCM
11, 109
P0335
(4)
Crankshaft Posi ti on
Sensor Ci rcui t
Mal l uncti on
Crankshaf t Posi t i on Sensor
Crankshaf t Posi t i on Sensor ci rcui t
ECM/ PCM
11- 110
P0336 {4)
Crankshaft Posi ti on
Sensor
Range/Performance
.
Crankshaft Position Sensor
.
Ti mi ng bel t ski pped teeth
' 1
1- 110
P0401. 1
(80)
Exhaust Gas
Reci rcul at i on
lnsufficient Flow Detected
.
EGR l i ne 11-170
P0420 (67)
Catalyst System
Efficiency Below
Threshol d
.
Three Way Cat al yt i c convert er
.
Secondary H02S 1 1 - 1 6 8
11-54
DTC
(MlL
indicationl
P0441*5
{92)
Evaporat i ve Emi ssi on Cont rol
Syst em l nsuf f i ci ent
Purge Fl ow
EVAP Purge Cont rol Sol enoi d Val ve
Open or short i n EVAP Purge Cont rol
Sol enoi d Val ve ci rcui t
EVAP Cont rol Cani st er
Vacuum l i nes
ECM/PCM
11- ' 190
P0452*6
( 91)
Fuel Tank Pressure Sensor Ci rcui t
Low Input
Short i n Fuel Tank Pressure Sensor ci rcui t
Fuel Tank Pressure Sensor
ECM/PCIV
1 1 - 1 8 1
P0453*6 (91)
Fuel Tank Pressure Sensor Ci rcui t
Hi gh I nput
Open i n Ful Tank Pressure Sensor cj rcui t
Fuel Tank Pressure Sonsor
ECM/PCM
1 1- 183
P0500. 1, (17)
Vehj cl e Speed
Sensor Ci rcui t
l vl al functi on
Vehi cl e Speed Sensor
Vehi cl e Speed Sensor ci rcui t
ECM
11-112
P0501* 13
( 17)
Vehi cl e Speed
Sensor Ci rcui t
Range/Performance
Vehi cl e Speed Sensor ci rcui t
PCM
1 1112
P0505 (14)
l dl e Cont rol Syst em
Mal f unct i on
.
IAC valve
.
Throttle Body
11-124
P0700*E
and some of
P0715
P0720
P0730 (70)*
P0740
P0753
P0758
Aut omat i c
Transaxl e
Sect i on 14
P0700*1
and {70)*
P0725
Aut omat i c Transaxl e
Sect i on 14
Barometri c Pressure
Ci rcui t
.
bCM/PCM (tsaro
sensorl
11 1
'13
P1 1 0 7 ( 1 3 )
Barometri c
Pressure Ci rcui t
Low Input
.
ECM/ PCM {8aro sensor}
' ' |
14
P1108 ( 13)
Earomet ri c
Pressure Ci rcui t
Hi gh I nput
.
ECM/ PCM
(Baro
sensor)
11-1' t 4
Pl 121+M. +16
17)
Throttl e Posi ti on Lower Than
Expected
.
TP sensor
11-82
P1122*14
*15
l 7l
Throt t l e Posi t i on Hi gher Than
Expect ed
.
TP sensor
11- 83
P1128* 14.
* ' 6
( 51
Mani f ol d Absol ut e Pressure
Lower Than Expect ed
.
MAP sensor
11-72
Mani l ol d Absol ut e Pressure
Hi gher Than Expect ed
.
MAP sensor
11-72
*:
The
LD. j
i ndi cat or l i ght and t he Mal l unct i on I ndi cat or Lamp
(Ml L)
may come on si mul t aneousl y.
*1:
D16Y5 engi ne
(CVT)
*5j
' 96
D16Y5 engi ne, D16Y7 engi ne, Dt 6Y8 engi ne
(sedanl ,
, 97
O1dy5 engi ne, O16y7 engi ne
(coupe:
KA, KC model s, sedan: KA,
KC, KL
(DX)
model s, hat chback: a

model s), D16yg engi ne
(sedan:
KA; KC model s)
*6: ' 96
D16Y8 engi ne
(coupe), ' 97
D16Y7 engi ne {coupe: KL modet , sedanr KL
(LX)
model ), ' 97 D16y8 engi ne (coupe:
al l model s,
sedan: KL model ),
' 98-al l
model s
*12:
Except A/ T
(D16Y7,
D16Y8 engi nel
*' 13:
A"/ T
(D16Y7,
D16Y8 engi ne)
+14: ' 97
modet
*T6:
, 98
model
{cont' d)
1 1- 55
Troubl eshooti ng
Di agnosti c Troubl e Code
(DTGI
Chart
(cont' dl
*7:
D16Y5 engi ne
(M/ T)
*8:
*9:
USA model
* 14r
' 97
model
+15r
' 96
model
DTC
{Ml L
i ndi cati on}
P1162*1
(48)
Pri mary Heat ed Oxygen Sensor
( Sensor 1) Ci r cui t
Mal {unct i on
.
Open or short i n Pri mary HO2S l sensor 1
.
Pri mary HO2S
(Sensor
l )
' 1 1 8 8
P1163* '
( 61)
( Sensor 1) Ci r cui t
Sl ow Response
Pri mary HO25
(Sensor
1)
11-87
P1164* ' i 61)
(Sensor
' l
) Ci rcui t Range/
Performance Probl em
.
Pri mary HO2S
(Sensor 1)
11-92
P1165* ?
( 61)
(Sensor
' 1)
Ci rcui t Range/
Perf ormance Prob em
Pri mary HO2S
(Sensor
1)
11-92
P1166* ?
( 41)
(Sensor 1) Heat er Syst em El ect ri cal
Probl em
Open or short i n Pri mary HO2S
(Sensor' l )
heat er ci rcui t
Pri mary HO2S
(Sensor 1|
ECM/PClvl
1 1 - 1 0 0
P1167*1
(41)
(Sensor 1) Heat er Syst em
Mal f unct i on
Open i n Pri mary HO2S
(Sensor
l i VS+ ci rcui t
Pri mary HO2S
(Sensor
1) Heater
Pri mary HO2S
(Sensor
1i
11-102
P 1168* ?
( 48)
( Sensor
1) LABEL Low I nput
.
Shon i n Pri mary Ho2S
(Sensor 1) LABEL
carcui t
P1169* 7
( 48)
{ Sensor
1) LABEL Hi gh I nput
.
Open i n Pri mary HO2S
(Sensor
1) LABEL
ci rcui t
.
Short i n ground ci rcui t
' 11- 94
P1259*3 \ 22)
VTEC Syst em Mal f unct i on VTEC Sol enoi d Val ve
Open or short i n VTEC Sol enoi d
Val ve ci rcui t
v I t L Pressure Swt t cn
Open or short i n VTEC Pressure Swi t ch
crrcurt
ECM/ PCM
Sect i on 6
P1297*'
(20)
El ect ri cal Load
Det ect or Ci rcui t
Low I nPut
El ect ri cal Load Det ect or
El ect ri cal Load Det ect or ci rcui t
ECM/PCrvl
1 1-1 15
P1298*'
(20)
El ect ri cal Load
Det ect or Ci rcui t
Hi gh I nput
El ect ri cal Load Det ect or
El ect ri cal Load Det ect or ci rcui t
ECM/PCIV
1 1 - 1 1 6
and
some of
P0301
P0302
P0303
P0304
171 I
pr l
l 73l
\ 7 4l
Random Mi sf i r e l gni ti on system
Fuel suppl y system
MAP sensor
EGR system
IAC val ve
contami nated fuel
Lack ol fuel
1 1- 108
1 1- 56
DTC
lMlL indicrtionl
Detoction hem Probable Cause Page
P1336
(54)
Crankshaf t Speed
Fl uct uat i on Sensor
I nt ermi f t ent I nt errupt i on
.
CKF sensor
11 117
P1337 (54)
Crankshaf t Speed
Fl uct uat i on Sensor
No Si gnal
CKF sensor
CKF sensor ci rcui t
ECM/PCM
11 117
P1359
(8)
Crankshaft Position/Top
Dead Center Sensor
Di sconnected
CKP/TDC sensor ci rcui t
1 11 1 9
P1361
(8)
Top Dead Cent er
Sensor I nt ermi t t ent
I nt errupt ron
.
TDC sensor
1 1 1 1 0
P1362 (8)
Top Dead Cent er
Sensor No Si gnal
TDC sensor
TDC sensor ci rcui t
ECM/PCM
1 1 - 1 1 0
P1381
( 91
Cyl i nder Posi t i on Sensor
I nt ermi f t ent I nt errupt i on
.
CYP sensor
1 1-' ]
' 10
P1382
(9)
Cyl i nder Posi t i on Sensor
No Si gnal
CYP sensor
CYP sensor ci rcui t
ECM/PCM
11 1 1 0
P1456*6 (90)
Evaporati ve Emi ssi on Cont.ol
System Leak Detected
(Fuel Tank
Area)
Fuel f i l l cap
Vacuum connect i on
Fuel t ank
Fuel t ank pressure sensor
EVAP bypass sol enoi d val ve
EVAP two way valve
EVAP cont rol cani st er vent shut val ve
EVAP cont rol cani st er
EVAP purge cont rol sol enoi d val ve
11- 185
P1457+6 (e0)
Evaporati ve Emi ssi on Control
System Leak Detected (EVAP
Control Cani ster Area)
Vacuum connect i on
EVAP cont rol cani st er
Fuel t ank pressure
sensor
EVAP two way valve
Fuel Tank
EVAP purge
cont rol sol enoi d val ve
1 1 , 1 8 5
*6: ' 96
Dl 6Y8 engi ne
(coupe), ' 97
D16Y7 engi ne
(coupe:
KL model , sedan: KL 1LX) model ), ' 97 D16Y8 engi ne
(coupe:
al l model s,
sedan: KL model ),
' 98-al l
model s
{cont' d)
11-57
Troubl eshooti ng
(DTC)
Chart
(cont'dl
DTC
l Ml L
i ndi cati onl
Detection ltem Probablc Cause Pags
P1 4 9 1 * . l 1 2 l
EGR Val ve
Li f t I nsuf f i ci ent
Detected
EGR val ve
(wi t h
l i f t sensor)
EGR val ve l i f t sensor ci rcui t
EGR cont rol sol enoi d val ve
(4, / T)
EGR cont rol sol enoi d val ve ci rcui t
EGR val ve ci rcui t
(M/ T)
ECIV
11-171
P1498*. \ 12)
EGR Val ve
Li f t Sensor
Hi gh Vol t age
EGR val ve l wi t h l i f t sensor)
EGR val ve l i f t sensor ci rcui t
ECt\4
1 1- 176
P1508* ' 0
( 14)
l dl e Ai r Cont rol Val ve
Ci rcui t Fai l Lrre
I AC val ve
I AC val ve ci rcui t
ECM
1 1-126
P1s09* 11 114)
l dl e Ai r Cont rol Val ve
Ci r cui t Fai l ur e
Open or shon i n IAC val ve ci rcui t
IAC val ve
ECM/PCt\,,|
1 1 ' 1 2 8
P1607
Engi ne Cont rol
Modul e/ Powenrai n Cont rol Modul e
l nt ernal
.
ECM/PCM
11-120
P1655* 1
( 30) TMA, / TMB Si snal Li ne Fai l ure Open or short i n TMA/ TMB ci rcui t 11-121
P1705
P1706
P 1753
P1758
P1768
P1785
P1790
P1791
P1793
(70)*
P1870
P1873
P1879
P1885
P1886
P1888
P1890
P1891
Aut omat i c Transaxl e
Sect i on 14
*:
The
[D!]
i ndi cator l i ght and the Mal l uncti on Indi cator Lamp
(Ml L]
may come on si mul taneousl y.
*1:
D' 16Y5 engi ne
(CVT)
*4:
D16Y5 engi ne 1N4/T)
*10:
Except A/T and D' 16Y7 engi ne
*11:
A,/T and D16Y7 engi ne
1 1- 58
How to Read Flowcharts
A fl owchart i s desi gned to be used from start to fi nal repai r. l t' s l i ke a map showi ng you the shortest di stance. But beware:
l f you go off the
"map"
anywhere but a
"stop"
symbol , you can easi l y get l ost.
ISTARN
{bol d type)
jAcroNl
Descri bes the condi ti ons or si tuati on to start a troubl eshooti nq fl owchart.
Asks you to do somethi ng; perform
a test. set up a condi ti on etc.
QE!E]!!,
Asks you about the resul t of an acti on, then sends you i n the appropri ate troubl eshooti ng di recti on.
The end of a seri es of acti ons and deci si ons, descri bes a fi nal repai r acti on and someti mes di rects
you
to
an earl i er pan ot the fl owchart to confi rm
your
repai r.
fsro-l
(bol d
type)
NOTE:
. The term
"l ntermi ttent
Fai l ure" i s used i n these charts. l t si mpl y means a system may have had a fai l ure, but i t checks
out OK at thi s ti me. l f the Mal functi on Indi cator Lamp
{Ml L) on the dash does not come on, check for poor connectrons
or l oose wi res at al l connectors rel ated to the ci rcui t that you are troubl eshooti ng
(see
i l l ustrati on bel ow).
. Most of the troubl eshooti ng fl owcharts have you reset the Engi ne Control Modul e
(ECM)/Powertrai n
Control Modul e
{PC[/) and try to dupl i cate the Di agnosti c Troubl e Code
(DTC).
It the probl em i s i ntermi ttent and you can' t dupl i cate the
code, do not conti nue though the fl owchart. To do so wi l l onl y resul t i n confusi on and,
possi bl y,
a needl essl v reDi aced
ECM/PCM.
o
"Open"
and
"Short"
are common el ectri cal terms. An open i s a break i n a wi re or at a connecti on. A short i s an acci -
dental connecti on of a wi re to ground or to another wi re. In si mpl e el ectroni cs, thi s usual l y means somethi ng won' t
work at al l . In compl ex el ectroni cs
(l i ke
ECM' S/PCM' S), thi s can someti mes mean somethi ng works, but not the way i t' s
suoDosed to.
LOOSE
PGM-FI System
System Description
I NPUTS
ENGI NE CONTROL MODULE
( ECM) i
POWERTRAIN CONTROL MODULE
(PCM)
OUTPUTS
CKP/TDC/CYP Sensor
CKF Sensor
MAP Sensor
ECT Senso.
I AT Sensor
TP Sensor
EGR Val ve Li f t Sensor*1
Pri mary HO2S
Secondary HO2S
VSS
EARO Sensor
ELD*'
KS*3
St art er Si gnal
ALT FR Si gnal
Ai r Condi t i onj ng Si gnal
A, / T Gear Posi t i on Si gnal
Baf t ery Vol t age
(l GN. 1)
Srake Swi t ch Si gnal
PSP Swi t ch Si gnal
Fuel Tank Pressure Ssnsor*a
VTEC Pressure Switch*t
Cl ut ch Swi t ch Si gnal *6
Countershaft Speed Sensor*3
Mainshalt Speed Sensor*3
F*l
|.r*a"r. Tl .i l g ""d Dr*i ";l
E
r""t'.',' l" ld b c-o-l*il
F,h*J--r---l
Fr"*il]
Effi;r"sc;;il
FcM/PcM
B""k,up Fr*,or'sl
Fuel I nj ect ors
PGM Fl Mai n Rel ay {Fuel Pump)
MI L
IAC Valve
A,/C Compressor Clutch Relay
Radi at or Fan Rel ay*'
Condenser Fan Rel ay
ALT*?
rcM
EVAP Purge Cont rol Sol enoi d
Pri mary HO25 Heat er
Secondary H02S Heat er
EGR Cont rol Sol enoi d Val ve*7
EGR val ve*6
EVAP Bypass Sol enoi d Val ve*a
EVAP Control Canister Vent Shut
VTEC Sol enoi d Val ve*5
DLC
Lock-up Cont rol Sol enoi d Val ve*3
Shi f t Cont rol Sol enoi d Val v6*3
Li near Sol enoi d Val ve*3
' 1:
D16Y5 engi ne
*2:
USA model
*3r
CW
(D16Y5
engi nel and 016Y8 engi ne
*4:
' 96
016Y8 engi ne {coupe},' 97 D16Y7 engi ne {coupe: KL model , sedan: KL {LX) model ),' 97 D16Y8 engi ne
(coupe:
al l model s, sedan: KL
model ).' 98' al l model s
15:
Dl 6Y5, D l 6Y8 engi ne
*6:
M/T
(016Y5
engi ne)
*7:
CVT
(D16Y5
engi ne)
*8:
A/T
(D16Y7,
D16Y8 ensi ne)
*9:' 96
Dl 6Y5 engi ne,' 96 D16Y7 engi ne,' 96 D16Y8 engi ne
(sedan),' 97
D16Y5 engi ne,' 97 D16Y7 engi ne
(coupe:
KA, KC model s, sedan:
KA, KC, KL
(LX)
model s, hatchback: al l model s),' 97 D16Y8 engi ne
(sedan:
KA, KC model s)
PGM-FI System
The PGM-Fi system on thi s model i s a sequenti al mul ti port fuel i nj ecti on system.
Fuol inisstor Timing and Duration
The ECM/PCM contai ns memori es for the basi c di scharge durati ons at vari ous engi ne speeds and mani fol d ai r l l ow rates.
The basi c di scharge durati on, after bei ng read out from the memory, i s further modi fi ed by si gnal s sent from vari ous sen-
sors to obtai n the fi nal di scharge durati on.
ldlo Air Control
l dl e Ai r Control Val ve
(l AC
Val ve)
When the engi ne i s col d, the Ay' C compressor i s on, the transmi ssi on i s i n gear, the brake pedal i s depressed, the P/S l oad
i s hi gh, or the al ternator i s chargi ng, the ECM/PCM control s current to the IAC Val ve to mai ntai n the correct i dl e speed.
lgnition Timing Co||trol
. The ECM/PCM contai ns memori es l or basi c i gni ti on ti mi ng at vari ous engi ne speeds and mani fol d ai r fl ow rates.
l gni ti on ti mi ng i s al so adj usted for engi ne cool ant temperature.
. A knock control system was adopted whi ch sets the i deal i g n i ti on ti mi ng for the octane rati ng of the gasol i ne used.
*3
Other Control Functions
1. Stani ng Control
When the engi ne i s started, the ECM/PCM provi des a ri ch mi xture by i ncreasi ng tuel i nj ector durati on
2. Fuel Pump Control
. When the i gni ti on swi tch i s i ni ti al l y turned on, the ECM/PCM suppl i es ground to the PGM-FI mai n rel ay that sup-
pl i es current to the tuel pump for two seconds to pressuri ze the fuel system.
. When the engine is running, the ECM/PCM supplies ground to the PGM-FI main relay that supplies current to the fuel
pump.
. When the engi ne i s not runni ng and the i gni ti on i s on, the ECM/PCM cuts ground to the PGM-FI mai n rel ay whi ch
cuts current to the fuel pump.
11- 60
3. Fuel Cut-off Control
. Duri ng decel erati on wi th the throttl e val ve cl osed, current to the fuel i nj ectors i s cut off to i mprove fuel economy at
speeds over the {ol l owi ng rpm:
.
D16Y5 engi ne
(M/T):
850 rpm
.
D16Y5 engi ne l CVT), D16Y8 engi ne (USA
M/T)r 920 rpm
'
D16Y8 engi ne
(USA
A,/T), Dl 6Y7 ensi ne
(USA
A"/T):910 rpm
.
D16Y8 engi ne
(Canada
M//T), Dl 6Y7 engi ne
(Canada):990
rpm
.
D' 16Y8 engi ne
(Canada
M/T): 1,000 rpm
. Fuel cut-off acti on al so takes pl ace when engi ne speed exceeds 6,900 rpm
(D16Y5,
Dl 6Y7 engi ne; D16Y8 engi ne:
7,000 rpm), regardl ess of the posi ti on ot the throttl e val ve, to protect the engi ne from over-rewi ng.
Ay' C Compressor Cl utch Rel ay
When the ECM/PCM recei ves a demand for cool i ng from the ai r condi ti oni ng system, i t del ays the compressor from
bei ng energi zed, and enri ches the mi xture to assure smooth transi ti on to the Ay' C mode.
Evaporati ve Emi ssi on
(EVAP)
Purge Control Sol enoi d Val ve+s
When the engi ne cool ant temperature i s above
' 154.F
(68"C).
the ECM/PCM control s the EVAP purge control sol enoi d
val ve whi ch control s vacuum to the EVAP purge
control cani ster.
(EVAP)
Purge Control Sol enoi d Val ve*a
When the engi ne cool ant temperature above 154"F
(68"Ci ,
i ntake ai r temperature above 32"F
(0"C)
and vehi cte speeo
above 0 mi l e 10 km/h) or [A,/C compressor cl utch on and i ntake ai r temperature above 160"F
141.C)1, the ECM/PCM
control s the EVAP purge control sol enoi d val ve whi ch control s vacuum to the EVAP purge
control cani ster.
Exhaust Gas Reci rcul ati on (EGR)
Control Sol enoi d Val ve*?
When EGR i s requi red for control of oxi des of ni trogen
(NOx)
emi ssi ons. the ECM control s the EGR control sol enoi d
val ve whi ch suppl i es regul ated vacuum to the EGR val ve.
Al ternator Control
The system control s the vol tage generated at the al ternator i n accordance wi th the el ectri cal l oad and dri vi ng mode,
whi ch reduces the engi ne l oad to i mprove the fuel economV.
(cont' d)
1 1 - 6 1
5.
6.
7.
CM/PCM Fail-safe/Back-up Functions
' L
Fai l -safe Functi on
when an abnormal i ty occurs i n a si gnal from a sensor, the ECM/PCN4 i gnores that si gnsl and assumes a pre-pro-
grammed val ue for that sensor that al l ows the engi ne to conti nue to run.
2. Back-up Functi on
When an abnormal i ty occurs i n the ECM/PCM i tsel f. the fuel i nj ectors are control l ed by a back-up ci rcui t i ndependent
of the system i n order to permi t mi ni mal dri vi ng.
3. Sel f-di agnosi s Functi on
[r4al functi on Indi cator Lamp
(Ml L)]
When an abnormal i l y occurs i n a si gnal from a sensor, the ECM/PCM suppl i es ground for the MIL and stores the DTC
i n erasabl e memory. When the i gni ti on i s i ni ti al l y turned on, the ECM/PCM suppl i es ground for the MIL for two sec-
onds to check the MIL bul b condi ti on.
4. Two Tri p Detecti on Method
To prevent
fal se i ndi cati ons, the Two Tri p Detecti on Method i s used for the HO2S, fuel meteri ng-rel ated, i dl e control
system, ECT sensor. EGR system and EVAP control system sel f-di agnosti c functi ons. When an abnormal i ty occurs,
the ECM/PCM stores i t i n i ts memory. When the same abnormal i ty recurs after the i gni ti on swi tch i s turned OFF and
ON
(l l )
agai n, the ECM/PCM i nforms the dri ver by l i ghti ng the Ml L. However, to ease troubl eshooti ng, thi s functi on i s
cancel l ed when you j ump
the servi ce check connector. The MIL wi l l then bl i nk i mmedi atel v when an abnormal i tv
occurs.
5. Two
(or
Three) Dri vi ng Cycl e Detecti on Method
A
"Dri vi ng
Cycl e" consi sts of starti ng the engi ne, begi nni ng cl osed l oop operati on, and stoppi ng the engi ne. l f mi sfi r-
i ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es, or TWC deteri orati on i s detected dur-
i ng three consecuti ve dri vi ng cycl es, the ECM/PCM turns the l /l L on. However, to ease troubl eshooti ng, thi s functi on
i s cancel l ed when you j ump
the servi ce check connector. The MIL wi l l then bl i nk i mmedi atel y when an abnormal i tv
occurs.
PGM-FI System
System Description
(cont'd)
Loan Eurn Control
(D16Y5
engi ner CVT)
The l ean burn control system i s based on the characteri sti c i ncrease i n crankshaft angul ar accel erati on whi ch occurs i n
when the ai r-fuel rati o gets l eaner.
The CKF sensor, whi ch i s mounted on the crankshaft, moni tors engi ne speed. l f crankshaft angul ar accel erati on fal l s bel ow
a certai n l evel
(target
ai r-fuel rati o l evel ), the amount of i nj ected fuel i s reduced.
l f crankshaft angul ar accel erati on exceeds thi s l evel . the amount of fuel i s i ncreased.
Thi s system i mproves tuel economy and dri veabi l i ty by control l i ng the amount of i ni ected fuel i n the l ean burn range
i mmedi atel y before combusti on starts to deteri orate,
11-62
\.
TDC/CKP/CYP SENSOR
MAP SENSOR
CKF SENSOB
ECM
Compari son of current ai r
fuel ratio to target ratio
Selection oI basic fuel
i ni ect i on durat i on
Engine Gontrol Module/Powertrain
Gontrol Module
{ECM/PCM)
NOTE: l f t hi s sympt om i s i nt ermi t t ent , check f or a l oose l use No. 25 l l rETER 7. 5 A) i n t he
underdash fuse/relay box, a
poor
connection at ECN4/PCM terminal Al8, or an intermit,
t ent open i n t he GRN/ ORN wi re bet weon t he ECM/ PCM
(Al 8)
and t he gauge
assembl y.
ECM/PCM CONNECTOR A
(32P}
PGl {BLKI
ECM/PCM CONNECTOR A {32PI
The Maltunction Indicato. Lamp
{MlL) nover com.s on {even to.
t wo secondsl . t t er i gni t i on i !
tutned on.
(l l ).
-
Rgpai r short or open i n t ho
wire betwo.n No. 25
(METER)
(7.5
A)fusc rnd gauge
r$om-
blv.
-
Repl eco No. 25
I METERI 17. 5
A) tu...
l s t he l ow oi l
pressure
l i ght on?
Try t o st an t he engi ne.
Ch6ck lor an open in the wiros
(PG
l i nesl r
1. Turn the ignition switch ON
(ll).
2. Measur e vo l t age bet ween
body ground and ECM/ PCM
connect or t ermi nal s A10 and
A23 i ndi vi dual l y.
Check for an open in th6 wire or
bul b l Ml L l i no):
2. Connect t he ECM/ PCM con
nect or t ermi nal 418 t o body
ground
wi t h a
j umper
wi re.
(ll).
Repai r opon i n t hc wi . . l 3)
bot wen ECM/ PCM and c10l
lloc.ted at tho tharmostat hous-
inglthrt had more th.n 1.0 V.
l s t here l ess t han 1. 0 V?
Substitute . known-good ECM/
PCM and rechock. lf 3ymptom/
i ndi cat i on goo3
away, rcpl ac6
tho o.iginal ECM/PCM.
-
Repai . open i n t ha wi r e3
betweon ECM/PCM
(A181
.nd
gaugc
a$ombly.
-
Reolace the MIL bulb.
l s t he MI L on?
Substituto a known-good ECM/
PCM and rechsck. lI symptom/
i ndi cet i on goo3 away, repl aco
the odgin.l ECM/PCM.
(cont' d)
PGM-FI System
Engine Control Module/Powertrain Control Module
(ECM/PCMI (cont'd)
NOTE:
.
When there is no Diagnostic Trouble Code
(DlC)
stored, the MIL will stay on if the SCS
service connector is connected and the ignition switch is on.
.
l f t hi s svmpt om i s i nt ermi t t ent , check f orl
-
A l oose Fl E/ M {15 A) f use i n t he under hood f use/ rel ay box
-
A l oose No. 13FUELPUMPf use( 15A) i n t he under ' dash f use/ r el ay box
-
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM
(C7)
and t he servi ce check
-
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM
(A18)
and t he
gauge
-
An intermittent short in the wire between the ECM/PCM
(D4l
and the MAP sensor
-
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM {D10}, t he TP sensor, t he
EGR val ve l i f t sensor
(D16Y5
engi ne) and/ or t he Fuel t ank pressure sensor
(' 96
016Y8 engi ne
(coupe), ' 97
Dl 6Y7 engi ne
(coupei
(LX)
model ),
' 97
D16Yg engi ne l coupe: al l model s, sedan: KL model ),
' 98-t l l
model s)
-
PGM-FI mai n rel ay
.
See t he O8D l l scan t ool or Honda PGM Test er user' s manual s f or speci f i c operat i ng
I nst ruct rons.
ECM/PCM CONNECTOR C I31PI
(To page 11-65)
scs
(BRNI
The Malfunction lndicator Lamo
lMlLl stays on or comos on after
Check t he Di agnost i c Tr oubl e
Code
(DTC):
1. Connect a scan t ool or Honda
PGM Test er.
2. Turn t he i gni t i on swi t ch ON {l l ).
3. Read t he DTC wi t h t he scan
t ool or Honda PGM Test er.
Go to troubl6hooting
procdures.
{3ee
pag611-53)
Ch6ck the DTC by MIL indication:
2. Connect t he SCS servi ce con'
nect or t o t he ser vi ce check
connect or.
(l l ).
Rpair opon or short in wire
between the EcM/PcM {c8)
and Oata Link Connector.
Go to troublashooting p.oce-
dure.
(s6e page 11-531.
Does t he MI L i ndi cat e any DTC?
Try t o st an t he engi ne.
Does t he engi ne st an?
Check l or a shor t i n t ha wi r e
I SCS l i nel :
' L
Di sconnect t he SCS servi ce
2. St op t he engi ne and t urn t he
i gni t i on swi t ch ON
(l l ).
3. N4easure vol t age bet ween t he
ECM/ PCM connect or t ermi nal
C7 and body ground.
Repair 3hoft to body ground in
th wire botwoen ECM/PCM {C7)
tnd se ice check connctor.
(To page 11-65)
11-64
Ch.ck to. . 3hort in the wirc {MlL
l i nol :
2. Disconnecr the ECM,/PCi!4 con-
nector A
(32P).
3. Turn tho ignition switch ON
(ll).
Roptir ahort to body ground in
th6 wir. b.twoon the ECM/PCM
l Al 8l snd Ml L.
Substitute a known-good ECM/
PCM and rech. ck. l l 3ympt om/
i ndi cat i on goes away, repl ace
the original ECM/PCM.
I nspect Fl E/ M
(' 10
A) f use i n t he
undeFhood tuseJrelay box.
R. pr i r 3hor t i n t hc wi . .
btw.en Fl E/M 115 A) luse
and PGM-FI m.in iolay.
Ropl.co Fl E/M
(15
A)fu.e.
I nspect No. 13 FUEL PUMP 115 A)
fuse in the undeFdash fuse/relay
box.
-
Repai r shor t i n t he wi r e
betwoen No. 13 FUEL PUMP
{15 Al tus6 and PGM-FI m.in
retay,
-
Repl ace No. 13 FUEL PUMP
115 A) l use.
Chck tor a short in a son3or:
' 1.
(l l ).
2. Di sconnect t he 3P connect or
f rom each sensor one at t i me:
.
TP sensor
.
EGR val ve l i t t sensor {Dl 6Y5
engt ne)
.
Fuel t ank
pr essur e
sensor
(' 96
D16Y8 engi ne {coupe),
' 97
D16Y7 engi ne
( coupe:
( LX)
model ) ,
' 97
D16Y8 engi ne
( coupe:
al l model s. sedan:
KL model ' 98-al l model s)
(From page 11-64)
( Fr om page 11- 64)
{cont ' d)
1
(To page 11-66)
- 65
PGM-FI System
Engine Control Module/Powertrain Control Module
(ECM/PCMI (cont'dl
\
ECM/PCM CONNECTOR D {16PI
ECM/PCM CONNECTOR A I32P}
LGl
l From
page 11-651
Rapbce the ranaor thrt cau3od
th6 light to go out,
Does t he MI L go
OFF?
Chect t or r short i n t h6 wi ras
{VCC lin.3l:
1. T{rrn t he i gni t i on swi t ch OFF.
2. Di sconnect t he ECM/ PCM
connect or D
(16P).
body ground
and ECM/ PCM
connect or t ermi nal s D4 and
D10 i ndi vi dual l y.
Repair ahon to bodY
g.ound
i n t h. wi re bat waon ECM/
PCM lD4l snd MAP s.n.or.
R.pair .hort to body ground
i n t ho wi . e bot woen ECM/
PCM lD10l, th. TP sensor, the
EGR v.lve lift son.or {D16Y5
.ngin.l and/or thc Fu.l tsnk
pra33u. e scnso.
(' 96
D16Y8
ongi nc { coup. l , ' 97 D16Y7
6ngi n6 { coupo: KL model ,
3odan: KL l LXl modcl l ,
' 97
D16Y8 ongi no l coupc: al l
model3, seden: KL modol,
'98-
all modobl,
Check tor en opcn in th. wire3
llGP linosl:
1. Di sconnect t he f uel i ni oct ors
and IAC valve connectors.
(ll).
3. Measur e vol t age bet ween
A24 i ndi vi dual l y.
-
Rapai l opan i n t he sri re{31
bot wo. n ECM/ PCM
( A11.
A24l .nd PGM-FI mrin roby.
-
Check lor poor
connaction3
or loo3. wirc! .t th. PGM-FI
main ralay.
-
Tert l ho PGM-FI mai n r. l ay
l 3ec
pag6 11-1571.
Check for an opon in the wirg!
ILG line.l:
1. Reconnect al l sensor connec-
rors,
2. Reconnect the ECM/PCM con-
nect or D
(16P).
3. Turn the ignition s,witch ON {ll).
4. N4easu r e vol t age bet ween
A22 individually.
Rapai r op. n i n t he wi r o( r l
btween ECM/PCM lA9, A22l and
G101 that had morothln 1.0 V.
ls there less than
'1.0
V?
Sub.titute . known-good ECM/
PCM and lochock. lf .ymptom/
i ndi c. t i on
9o.
awry, ropl ace
the origin.l ECM/PCM.
VCC1
(YEL/RED)
IGP
,I
( YEL/ BLK)
2 a a l 0 1 1
12 t 3 t 5 t 5 1 1 t 8 20 22 2a
25 21 2A 29 30
IGP 2
(YEL/8LKI
IERN/
BLK}
a !l t o ! l
12 t 3 t a t 5 t 6 77 t 8 t9 20 23 2a
E 21 2A 23 30
LG2
IBRN/
BLKI
11- 66
Manifold Absolute Pressure
(MAP)
Sensor
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0106: A mechani cal
probl em (vacuum
l eak) i n the
Mani fol d Absol ute Pressure
(MAP)
Sensor svstem.
The MAP sensor converts mani fol d absol ute pressure i nto el ectri cal si gnal s and i nputs the ECM/pCM.
OUTPUI
VOLTAGE
tvt 3.5
3.0
2. 5
2. O
1. 5
1, 0
lin. Hg) GAUGE
READI'{G
lln]n Hgl
o
, 5 t q . r s .
1 0
30
.25
lqt 2|x) 3(x)
i(X,
5OO 600 7ql
I
-
The MIL has bo6n rponed on.
-
OTC P0106 is stored.
-
Or from Probable Cause Urt.
Problem verilication:
1. Do t he ECM/ PCM Reset Pro-
cedure.
2. St ar t t he engi ne and keep
engi ne speed at 1, 000 rpm f or
one mi nut e wi t h t he t ransmi s,
si on i n
P
or
I
posi t i on (M/ T
i n neut ral ).
Check f or vacuum l eakage or
bl ockage bet ween t he MAP sen-
sor and throttle body.
Ch6ck the MAP sensor output:
2. Turn t he i gni t i on swi t ch ON l l l ).
3. Check t he MAP wi t h t he scan
t ool .
ls there leakage or blockage?
Check the MAP sonso. outputr
1. St op t he engi ne.
(ll).
t ool .
(To page
11-68)
{To
page 11-68)
(cont' d)
(MAPI
Sensor
(cont'dl
(From page 11-67) l From
page l 1-67)
Ch6ck for poor response:
1. St ar t t he engi ne. Hol d t he
engine at 3,000 rpm with lVT in
E or E
posi t i on, M/ T i n neu'
t ral unt i l t he radi at or l an comes
on, t hen t ur n t he i gni t i on
switch OFF.
2. St a rt t he engi ne.
3. Check t he MAP wi t h rhe scan
t ool .
l s a MAP ot 40. 0 kPa {300 mmHg,
12. 0 i n. Hg) or l ess i ndi cat ed wi t hi n
one second after starting the
engi ne?
PCM and recheck. I t sympt om/
i ndi cat i on go6s awsy, ropl ace
the originsl ECM/PCM.
Check {or poor r6ponse:
engine at 3,000 rpm with Iy'T in
E
or
E]
position, M/T in neu-
tral untilthe radiator fan comes
on, t hen t ur n t he i gni t i on
switch OFF.
2. St an t he engi ne.
3. Check t h MAP wi t h t he scan
t ool .
ls a MAP of 40.0 kPa 1300 mmHg,
12. 0 i n. Hg) or l 6ss i ndi cal ed wi t hi n
one second af t er st ar t i ng t he
engi ne?
The MAP sensor is OK at this tims.
1 1 - 6 8
(DTC)
P0107: A l ow vol tage
(hi gh
vacuum) probl em i n the
(MAP)
sensor.
MAP SENSOR 3P CONNECTOR ICTI'tI
vccl
{YEL/REDI
(cont' d)
1 1 - 6 9
The MIL has b6n reooned on.
' 1.
(l l ).
t ool .
Intermittent f.ilure, svslem b OK
at this tirne. Chock to. poor con-
nact i ons or l oose wi roa at C111
IMAP snsorl and ECM/PCM.
Check fo. an open or short in th
MAP sensor:
2. Di sconnect t he MAP sensor
3P connect or.
t ool .
Check tor an open in wi.e {VCCI
lin6l:
Measur e vol t age bet ween t he
MAP sensor connect or No, 1 t er
mi nal and No. 2 t ermi nal .
Repair opeo in the wire btwoen
ECM/PCM ltxl and MAP 3mor.
Check tor . short in the TCM:
from the TCM.
3. Tur n t he i gni t i on swi t ch ON
f l r).
t ool .
(To page 11-70)
PGM-FI System
(MAPI
Sensor
(cont'd)
MAP SENSOR 3P CONNECTOR IC111}
MAP
(RED/GRNI
Chock l or . shor t i n t ho wi Je
(MAP
linel:
2. Di sco n nect t he ECM/ PCM
connect or D
(16P).
the MAP sensor connector No. 3
terminal and body ground.
ReDair 3hort in the wire bstween
ECM/PCM {D3l and MAP sensor.
Substitute a known-good EGM/
PCM, and rechock. It norrnal MAP
b indiceted, replaco the o.iginal
ECM/PCM.
11- 70
(DTC)
P0108: A hi gh vol tage
(l ow
vacuum) probl em i n the
(MAP)
sensor.
MAP SENSOR 3P CONNECTOR {CI11I
{RED/GRNI
JUMPR WIRE
Wi re si de of temal e termi nal s
vccl
(YEL/REDI
CCM/PCM CO NECTOR D I16PI
MAP
IRED/GRNI
{GRN/WHTI
Wire side of female terminals
sG1
(cont' d)
11- 71
Tho MIL has bn reported on.
OTC P0108 is sto.ed.
Problem verification:
l . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rpm wi t h no
load
(Ay'T
in
E or
E
position,
M/ T i n neut ral ) unt i l t he radi a-
tor fan comes on, then let h idle.
t ool .
Intormittont lailwo. 3yst6m ir OK
at thia timc, Ch.ck tor poor
con-
noctions or looaa wira! at Cllt
(MAP
!nrorl and ECM/PCIV|,
l s 101 kPa
(760
mmHg, 30. 0 i n. Hg)
or hi gher i ndi cat ed?
Check f or an open i n t he MAP
1. Turn t he i gni t i on swi t ch OFF-
2. Di sconnect t he MAP sensor
3P connect or,
3. I nst al l a
j umper
wi re bet ween
t he MAP sensor 3P connect or
t ermi nal s No. 3 and No. 2.
4. Turn the ignition switch ON llll.
t ool .
l s 101 kPa {760 mmHg, 30. 0 i n. Hg}
Check Ior an open in wirs
(SGl
l i nel :
1. Remove t he
i umper
wi re.
2. Measure vol t age bet ween t he
MAP sensor 3P connect or t er-
mi nal s No.
' l
and No. 2.
Repair open in tho wir6 bctwaon
ECM/PCM lDl2l .nd MAP sonror.
Check f or an open i n l he wi re
I MAP l i nel :
2. Connect t he ECM/ PCM con-
nect or t ermi nal s D3 and 012
with a
iumPer
wire.
(l l ).
tool.
l s 10' 1 kPa
(760
mmHg, 30. 0 i n. Hg)
R.pair opn in tha wir63 botwocn
ECM/PCM lD3l .nd MAP.onsor.
PCM .nd rechock. ll normal MAP
is indicated, .oplace the originel
ECM/PCM.
JUMPER WIRE
PGM-FI System
(MAP)
Sensor
(cont'd)
(DTC)
P1128; Mani fol d Absol ute Pressure
(MAP)
l ower than
expected.
Problam vrific.tion:
(DTC)
P1129: Mani fol d Absol ute Pressure
(MAP)
hi gher than
exoected.
-
The MIL hes been.eoorted on.
-
DTC Pl128 is stored.
l s 54. 1 kPa
(406
mm Hg, 16. 0
i n. Hg) or hi gher i ndi cat ed?
Intermittont tailurc, system b OK
at thk time.
-
The MIL h.s been reported on.
-
DTC Pl'129 is stor6d.
Probl6m veritication:
1 . St a r t t h e e n g i n e . Ho l d t h e
l oad
(A, / T
i n
E
or
E
posi t i on,
t or t an comes on, t hen l et i t
i dl e.
t ool .
l s 43. 3 kPa {325 mm Hg, 12. 8
i n. Hg) or l ess i ndi cat ed?
lntermittent failure, 3y3tem i3 OX
at lhis time.
11- 72
Intake Air Temperature
(lATl
Sensor
(DTC)
P01 1 1: A range/performance probl em i n the l ntake Ai r
Temperature
(l AT)
Sensor ci rcui t.
The IAT Sensor i s a temperature dependant resi stor
(thermi stor).
The resi stance ot the thermi stor decreases as the i ntake
ai r temoerature i ncreases as shown bel ow.
RESISTAI{CE ft01
-a
32 X rO. t1a 212 24a t.jl
-20
0 20 /|o ao ao !00 t2o trcl
II{IAXE AIR TEI/IPERATURE
-
Th6 MIL has been roported on.
-
DTC P011t is stored,
-
O. from Probabl. C.us List.
Problm voritication:
1. Turn rhe i gni t i on swi t ch OFF.
2. Di sconnect t he I AT sensor 2P
connect or,
3. Remove the IAT sensor.
4. Reconnect t he I AT sensor 2P
connect or.
5. Leave the IAT sensor exposed
t o ambi ent t emperat ure.
(l l ).
7. Check t he I AT wi t h t he scan
t ool ,
Reolace tho IAT sensor.
Check the IAT snsor output:
1. Warm t he I AT sensor wi t h a
hai r dryer.
t ool ,
Interrnittent lailure, system is OK
at t hi s t i me.
Di d t he I AT ri se 2"F
(1"C)
or more
f rom t he ambi ent t emperat ure?
Reolaco the IAT sensor.
(cont' d)
1- 73
PGM-FI System
Intake Air Temperature
(lAT)
Sensor
{cont'd}
(DTC)
(hi gh
temperature) probl em i n the
Intake Ai r Temperature {l AT) sensor ci rcui t.
RESTSTANC ll0l
lo
to
I
. aa aa ro. tra 2t2 a{ frt
-
20 0 ro :|o ao ao t00 r20 tlcl
ITTAXE AN EMPERATURE
IAT SENSOR 2P CONNECTOR {Cl12I
--+-r
l l l 2 l
+
@
=
Wi re si de of f emal e
IAT
IRED/YELI
rermt nat s
Wi t h Honda PGM Test er i n Honda mode.
l f t he engi ne i s warm, i t wi l l be hi ghert han ambi ent t emperat ure.
* 1 :
*2.
-
The MIL he3 b6en Eoortcd on.
-
DTC P0112 b 3tor.d.
Problam vo.ification:
1. Turn the ignition switch ON lll).
t ool ,
l s 302' F
(150"C)
or hi gher
(or
H-Li mi t *rl i ndi cat ed?
Replace the IAT sensor.
Intormittent failurg, 3y3tem is OK
at thb tims. Chack for Door con-
ncctions or looac wi.as at C112
(lAT
sonsorl .nd ECM/PCM.
Check lor . .horl in the IAT s6n-
sot:
1. Oisconnect the IAT sensor con-
nedot,
t ool .
l s 302' F
(150' C)
or hi gher
(or
H-Li mi t *1) i ndi cat ed?
RoplacG tho IAT senio..
Chock for. short in the wiro llAT
l i n. l :
2. Disconnect the ECM/PCM con-
nect or D 116P).
3. Check t or cont i nui t y bet ween
the IAT sensor 2P connector ter-
mi nal No. 2 and body ground.
Rgpair lhort in tho wire betweon
ECM/PCM lDSl and IAT sensor.
Sub3titute e known-good ECM/
PCM and recheck. It normal IAT
is indic.lad, replaco the original
ECM/PCM.
11- 74
(DTC)
(l ow
l ntake Ai r Temperature
(l AT)
sensor ci rcui t.
IAT SENSOR 2P CONNECTOR
(C112)
----F--
t l
I ' l r l
sG2
ffi
IAT
(GRN/BLn
I I
(RED/YEL)
JUMPER
wtEE
Wi re si de oI l emal e t ermi nal s
ECM/PCM CONNECTOR D
(16PI
IAT
(RED/YELI
sG2
IGRN/8LK}
JUMPER WIRE
-
The MIL has been reportd on.
-
DTC P0113 is stord.
Ploblem veriticationi
t ool ,
Inte.mittent lailura, system is OK
at this time. Check tor poor con-
necl i ons or l oose wi res at C112
{lAT sensorl and ECM/PCM.
Check fo. an open in the IAT sen-
sor:
1. Di sconnect t he I AT sensor 2P
connector,
2. Connect the IAT sensor 2P con-
nect or t er mi nal s No,
' l
and
No. 2 wi t h a
j umperwi re.
3. Check t he i nt ake ai r t empera-
t ure wi t h t he scan t ool .
Check l or an opn i n t he wi res
{lAT, SG2 lines):
2. Connect ECM/ PCM connect or
t er mi nal s Dg and Dl 1 wi t h a
(l l ).
t ool .
Repair open in th wires between
ECM/PCM
(D8,
D11) and IAT sen-
PCM and recheck. It normal IAT
is indicated. replace the o.iginal
ECM/PCM.
*r
PGM-FI System
Engine Coolant Temperature
{ECTI Sensor
(DTC)
P0116: A range/performance probl em i n the Engrne
Cool ant Temperature (ECT)
Sensor ci rcui t.
The ECT Sensor i s a temperature dependant resi stor (thermi stor).
The resi stance of the thermi stor decreases as the enoi ne
cool ant temperature i ncreases as shown bel ow.
RESISTANCE
t kol
NOTE: l f DTC P0117 and/or P0118 are stored at the
bl eshoot DTC P0116.
Possible Causa
. ECT sensor deteri orati on
. Mal functi on i n the cool i ng system
a 32 6E 10a 1a0176 2t 2 2a8 (
. r )
- 20
0 20 ao o I t o ! 20 I c)
same ti me as DTC P0116, troubl eshoot those DTCS fi rst, then trou-
THERMISTOR
-
The MIL has ben rcportod on.
-
DTC P0116 k stored.
load {A"/T in
E or
El
position,
t or t an comes on, t hen l et i t
i dl e.
2. Wi t h t he scan t ool , check t he
ECT.
Intermittent failure, system is OK
et t hi s t i me. Check t he cool i ng
Chock the cooling systom. lf the
cooling alElam i3 OK, replaco the
ECT sensor.
11- 76
Ipfl n7' l
The.scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
(hi gh
temperature]
probl em
i n the
:
Engi ne Cool ant Temper at ur e { ECT) sensor ci r cui t .
ECT SENSOR 2P CONNECTOR {C122I
Wi re si de of f omal e t ermi nal s
(cont' d)
11- 77
The MIL hes ben reooned on.
DTC P0117 is sto.ed.
Problom veriticrtion:
1. Turn t he
j gni t i on
swi t ch ON
(l l i .
2. Check t he ECT wi t h t he scan
t ool .
Intormittent failure, lvstem k OK
at thi3 time. Check for
poor
con-
nection3 or loo3o wirg! at Cl22
IECT 3.n3or) and ECM/PCM.
Chock tor a short in the ECT son-
1. Di sconnect t he ECT sensor 2P
t ool .
l s 302"F
(150"C)
or hi gher
(or
H-Li mi t *)i ndi cat ed?
Chock t or a sho. t i n t he wi re
{ECT line):
nect or D
(l 6P).
3. Check f or cont i nui t y bet woen
the ECT sensor 2P conneclor ter
minal No. 1 and body ground.
Reoair short in th6 wir6 botwoen
ECM/PCM lD2l and ECT sensor.
Subrtituto r known-good ECM/
PCM and rochock, f nolmal ECT
i3 indicated, r6plac tha origin.l
ECM/PCM.
*r
PGM-FI System
Engi ne Cool ant Temperature
(ECTI
Sensor
(cont' dl
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P0l l 8: A hi gh vol tage
(l ow
Engi ne Cool ant Temperature
(ECT)
sensor ci rcui t.
ECT SENSOR 2P CONNECTOR {C122I
ECT
{RED/WHTI
JUMPEN WIRE
sG2
IGRN/BLK)
ECM/PCM CONNECTOR D {16P)
ECT
(RED/WHTI
{GRN/BLKI
Wi re si de oJ f emal e t ermi nal s
JUMPER WIRE
L
sG2
---l
l 3 l a l
6 1 I 9 t o 12
l 3 t 5 t 6
The MIL hrs boon reported on.
P.oblem veritication:
L Turn t he i gni t i on swi t ch ON
(l l ).
t ool .
Intormittent tailuro, svstem is OK
at this time. Chock tor poor
con-
nestions or loose wires at C122
{ECT sonsorl and ECM/PCM.
Check tor an opon in the ECT sen-
1. Di sconnect t he ECT sensor
2P connect or.
2. Connect t he ECT sensor 2P
connect or t ermi nal s No. 1 and
No. 2 wi t h a
j ! mperwi re.
t ool .
Check l or an opon i n t h6 wi r6s
{ECT, SG2 linesl:
2. Connect ECNI / PCM connect or
t er mi nal s D2 and D11 wi t h a
(ll).
t ool .
Repeir open in the wires botween
ECM/PCM {D2, Dl1) snd ECT sen-
Substiluto a known-good ECM/
PCM and rocheck. It normal ECT
is indic.ted, .splac. the original
ECM/PCM.
*:
11- 78
\
Throttle Position
{TPl
Sensor
tFo-, .Tj _:
scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P0122: A l ow vol tage probl em i n the Throftl e Posi ti on
-
t I l -l sensor crrcul l .
The TP Sensor i s a potenti ometer. l t i s connected to the throttl e val ve shaft. As the throttl e posi ti on changes, the throttl e
posi ti on sensor vari es the vol tage si gnal to the ECM/PCM.
OUTPUT VOLTAGE {VI
5
4
1
0
sG2
I GRN/ BLK}
THROTTLE
OPENING
FULL
THROTTLE
TP SENSOF 3P CONNECTOR {Cl1OI
vcc2
(YEL/BLU)
Ware si de of f emal e t ermi nal s
ECM/PCM CONNECTOR D Il6PI
SG2
(GRN/BLKI
Wi r e si de of f emal e t er mi nal s
Termi nal si de of mal e t ermi nal s
-
The MIL has been reDorted on.
-
Problom ve.ification:
(l l ).
2. Check t he t hr ot t l e posi t i on
wi t h t he scan t ool -
l s t here approx. 10% when t he
throttle is fully closed and
approx. 90% when the throttle
i s f ul l y opened?
Inlermittent tailure, system is OK
et this time. Check lor Door con-
nect i ons or l oose wi res at Cl 10
ITP senso.l and ECM/PCM.
Ch6ck f or an opcn i n l he wi re
(VCC2l i nel l
2. Di sconnect t he TP sensor 3P
connect or.
(l l ).
4. N, 4easure vol t age bet ween
the TP sensor 3P connector ter-
mi nal s No.
' l
and No. 3.
Check for an op6n in wire IVCC2
l i ne):
Measure vol t age bet ween ECM/
PCM connect or t ermi nal s D10 and
D1' ] .
Check tor an open or 3hort in TP
sensoa:
2, At t he sensor si de, measure
resistance between the TP sen-
sor t ermi nal s No. 1 and No. 2
wi t h t he t hrot t l e f ul l y cl osed.
Repair open in lhe wire between
ECM/PCM
(D10)
and TP sonsor.
PCM and r echock. I t or escr i bed
voltage is now available, replac
the originel ECM/PCM.
(To page 11-80)
(cont' d)
PGM-FI System
Throttle Position
(TP)
Sensor
(cont'dl
YES
Check Ior an open or short in the
TP sensori
Measure resi st ance bet ween t he
TP sensor t er mi nnal No. 2 and
No. 3 wi t h t he t hrof t l e f ul l y cl osed.
(D16Y5
engine
TP SENSOR 3P CONNECTOR
Termi nal si de oI mal e t ermi nal s
ECM/PCM CONNECTOR O Il6PI
TPS
(RED/
BLKI
l "
hf f i
sG2
7 I 9 10 l l 12
13 l a t a
(GRN/BLKI
Wi re si de of t 6m6l e t ermi nal s
f
-l
TPS (RED/
BLKI
l "
1r
tt
sG2
8 9 r 0 l r t 12
l a 15l
lrG
IGRN/BLKI
(From page 1' 1 79)
l s t here approx. 0. 5
-
0. 9 k0?
l s t here approx. 3. 6
-
5. 4 kO?
Check l or an open i n t he ECM/
PCM {TPS line):
1. Reconnect t he TP sensor 3p
ECM/ PCM connect or t ermi nal s
D1 a n d D1 l .
l s t here approx. 0. 5 V when t he
throttle is tully closed and
approx. 4. 5 V when t he t hrot t l e
; s f ul l y opened?
Sub3titute a known-good ECM/
PCM and recheck. It oroscribed
voltago is now availabl6, aeplace
Check tor a short in rhe TCM:
L Turn t he i gni t i on swi t ch OFF.
from the TCM.
(l l ).
4. Measure vohage between ECM
con nect or t er mi nal s D1 and
D1 1 .
ls there approx. 0.5 V when the
throule is fully closed and
approx. 4. 5 V when t he t hrot t l e
Repair short in the wire betwen
ECM/PCM {Dll, TCM and TP s6n-
1 1 - 8 0
I
The scan tool i ndi cates Di agnosl i c Troubl e Code
(DTC)
P0123: A hi gh vol tage probl em i n the Throttl e Posi ti on
(TP)
sensor ci rcui t.
TP SENSOR 3P CONNECTOR ICl lOI
sG2
(GRN/ BLKI
vcc2
IYEL/BLU)
ECM/PCM CONNECTOR D I16P)
SG2 {GRN/ 8LKI
Wi r e si de of f emal e t er mi nat s
-
The MIL has been.eoorted on.
-
Problem veritication:
(l l ).
wi t h t he scan t ool .
ls there approx. 10% when the
t hrot t l e i s f ul l y cl osed and
approx. 90% when t he t hrot t l e
Intermittent failure, system b OK
at this tim6. Check tor poor con-
neci i ons o. l oose wi res at C110
(TP
sensor] and ECM/PCM.
Check lor en open in the TP sen-
2. Di sconnect t he TP sensor 3P
connect or,
4. At t he harness si de, measure
voltage between the TP sensor
3P connect er t ermi nal s No. 1
and No. 3.
Chock f or dn open i n t he wi r e
( SG2l i ne) :
Measur e vol t age bet ween ECM/
PCM connect or l er mi nal s 010 and
D] 1 .
Repair open in the wire between
ECM/ PCM
(D11)
and TP sensor.
PCM and recheck. ll presc.ibed
vohag is now available, replace
t he ori gi nal ECM/ PCM.
Replace the thronle body.
1 1- 81
PGM-FI System
Throttle Position
(TP)
Sensor
P1121
|
The scan tool i ndi cates Di agnosti c Troubte Code
(DTC) p' I12j :
Throttl e
posi ti on
(Tp)
l ower than exeected.
* :
11. 8 l D16Y5 engi nei
12. 91D16Y7 engi ne)
12. 2 (D16Y8
engi ne)
-
-
DTC Pl121 is stord.
Problom ve.ification:
(l l l .
l s TP* % or hi gher i ndi cat ed
when t he t hrot t l e i s f ul l y opened?
Intoimiftent tailure, systam i3 OK
at this time.
11-82
[Fi l 22-l
Th" """n tool i ndi cates Di agnosti c Troubl e Code {DTC) P1122:Throttl e Posi ti on
(TP)
hi gher than expecred.
*r
16. 5 {Dl 6Y5, D16YB engi ne)
16. 9 {D16Y7 engi ne)
-
The MIL hes been reported on.
-
P.oblem verification:
2. Check t he t hr ot t l e
posi t i on
l s TP* % or l ess i ndi cat ed when
t he t hrot t l e i s f ! l l y cl osed?
Intermittent tailurc, ay3tem is OK
at this time.
11- 83
PGM-FI System
(Pri mary
HO2SI
(Sensor
1l
(Except
Dl 6Y5
engi ne
(M/Tl )
The Heated Oxygen Sensor
(HO2S)
detects the oxygen content i n the exhaust gas and si gnal s the ECM/PCM. In operati on,
the ECM/PCM recei ves the si gnal s from the sensor and vari es the durati on duri ng whi ch fuel i s i nj ected. To stabi l i ze the
sensor' s output, the sensor has an i nternal heater. The Pri mary HO2S
(Sensor
1) i s i nstal l ed i n the exhaust mani fol d.
HO25:
tFor3I
VOLTAGE {VI
The scan tool i ndi cates Di agnosti c Troubl e Code (DTC)
Oxygen Sensor {H02S)
(Sensor
1) ci rcui t.
RI CH. AI N-
-
LEAN
FUL
RATIO
probl em i n t he Pri mary Heat ed
ztRcoNrA
HEATER
SENSOR
TERMINALS
-
The MIL has bon reported on.
-
DTC P013'l is storod.
Problom veritication:
1. Do t he ECM/ PCM Feset Pro
cedure.
l oad (A/ rf
i n
E or
E
posi t i on,
M/ T i n neut ral ) unt i l t he radi a
t or f an comes on.
3. Test dri ve wi t h t he A/ T i n
E
position
lM/T in 4th geari
4. Check t he Pr i mar y HO25
(Sensor
1) output voltage with
t he scan t ool duri ng accel era
taon using wide open throttle.
Intormittent failure, systom i3 OK
at this time. Check for poor con-
nections or loos wires rt C123
l Pr i mar y HO2S, . 6n3or 1| and
ECM/PCM,
Does t he vohage st ay at 0. 1 V
or l ess?
l To
page
11-85)
11- 84
\-
(From page
11-84)
Chock for a shon in the HOzS:
2. Di sconnect t he Pri mary HO2S
(Sensor
1l 4P connect or.
3. St an t he engi ne and l et i t i dl e.
4. Check t he Pr i mar y H02S
l Sensor 1)out put vol t age wi t h
t he scan t ool .
Does i t st ay at 0. 1 V or l ess?
Check f or a short i n t he wi r
I PHO2S l i ne):
1. Turn t he i gni t aon swi t ch OFF.
2. Di sconnect t he ECM/ PCM con,
nect or D
(16P).
t he Pri mary HO2S
(Sensor
1)
4P connect or t er mi nal No. 1
and body ground.
Rpair short in the wire betwoan
ECM/PCM {D7) and Primery HO2S
{Sensor 11.
l s t her e cont i nui t yT
Substitut a known-good ECM/
PCM and rocheck. I t sympt om/
indicstion goos awey, replace the
original ECM/PCM.
PRIMARY HO2S
(Sen3or
1l aP CONNECTOR lC123l
Pr{o2s
T--
{wHTr I- I--]
f - l
1 2l
6 r l s l r l
\z r__i_l
L
{cont' d)
PGM-FI System
Primary Heated Oxygen Sensor
(Primary
HO2SI
(Sensor
1)
{Except
D16Y5
engi ne
{M/Tl l
(cont' dl
[FO13t
(DTC)
P0' 132: A hi gh vol tage probl em i n the Pri mary Heated
:
Oxygen Sensor
(Pri mary
HO2S)
(Sensor
1) ci rcui t.
PRIMARY HO2S lsensor 1l
,lP
CONNECTOR
PHO2S
{WHT)
sG2
{GRN/
BLKI
PHO2S
(WHTI (GRN/BLKI
ECM/PCM CONNECTOR D {16PI
JUMPER WIRE
ffi
sG2
I l 0 1 1 12
t 3 t 6
The MIL hes ben reooned on.
DTCP0132 b stored.
Problem vedfication:
' 1.
Do t he ECM/ PCM Reset Pro-
cedure.
l oad {A, / T i n
E
or
E
posi t i on,
t or f an comes on,
3. Test dri ve wi t h t he Arr i n
E
position (M/T
in 4th gear).
4. Check t he Pr i mar y HO2S
(Sensor
1) out put vol t age wi t h
t he scan t ool duri ng decel era-
t i on usi ng compl et el y cl osed
throttle.
Intermittent failuro, system b OK
at this time. Check tor ooor con-
nections or loose wires at C123
l Pri mary HO2S, Sonsor 1) and
ECM/PCM.
Does t he vol t age st ay at 1. 0 V
or more?
Chck for an opn in the Primary
H02S:
(Sensor
1l 4P connect or.
3. Connect t he Pr i mar y H02S
(Sensor
1) 4P connector termi-
n a l s No . ' l a n d No . 2 wi t h a
(l l ).
(Sensor
1l output voltage with
the scan iool.
l st here 1. 0 V or more?
Check t or . n open i n t he wi r e
I PHO2S l i ne):
t ermi nal s D7 and D11 wi t h a
(Sensor
1) output voltage with
the scan tool.
Repai. open in thc wire betwoen
ECM/ PCM
( D7
) end Pr i mer y
HO2S {Son3or 1} .
l s t here 1. 0 V or more?
Subltituto . known-good ECM/
PCM and roch. ck. l f 3ympt om/
i ndi c. t i on goe3
away, repl ace
the originel ECM/PCM.
11- 86
tFols3-l
P1163
l
Primary Heated Oxygen Sensor
(Primary
HO2SI
(Sensor
1l
(DTC)
P0133: A sl ow response probl em i n the Pri mary Heated
Oxygen Sensor
(Pri mary
HO25)
(Sensor
1) ci rcui t.
(DTC)
P1163: A sl ow response probl em i n the Pri mary Heated
Oxygen Sensor
(Pri mary
HO25)
(Sensor
1) ci rcui t.
DescriDtion
By control l i ng the ai rl fuel rati o wi th a Pri mary HO2S
(Sensor
I ) and a Secondary HO2S
(Sensor
2), the deteri orati on of the
Pri mary HO2S {Sensor 1) can be eval uated by i ts feedback peri od. When the feedback peri od
of the HO2S exceeds a cer,
tai n val ue duri ng stabl e dri vi ng condi ti ons, the sensor wi l l be
j udged
as deteri orated.
When deteri orati on has been detected duri ng two consecuti ve tri ps, the MIL comes on and DTC P0133 or P1' 163* wi l l be stored.
NOTE: l f DTC P0131, P0132 and/or P0' 135 are stored at the same ti me as DTC P0133, troubl eshoot those DTCS fi rst, then
troubl eshoot DTC P0133. l f DTC P1
' 162,
P1168 and/or Pl 169 are stored at the same ti me as DTC P1 163, troubl eshoot those
DTCS fi rst. then troubl eshoot DTC P1163.
Possiblo Cause
. Pr i mar y HO2S
( Sensor
1) Det er i or at i on
o Pri mary HO2S Heater (Sensor
1)Deteri orati on
. Exhaust system l eakage
-
The MIL has been reoorted on.
-
DTC P0133 and/ o. P1163. i s
stored.
Problem Vorification:
cedure.
2. Connect t he scan t ool .
l oad
(A"/ T
i n
E or
E
posi t i on,
t or f an comes on.
4. Connect t he SCS servi ce con-
nector.
5. Test - dr i ve under f ol l owi ng
condi t aons.
-
55 mph
(88
km/ hl st eady
speed
-
A/ T i n
E
posi t i on (M/ T
i n
5t h gear)
-
Until readiness code comes
Intermittent tailur6, sysiom i! OK
at this timo. Chgck for pooa
con-
nections or loose wi.ss at C123
lC1/|5)*
(Primary
HOzS. Sensor 1)
and ECM/PCM.
*:
P1163 t D16Y5 engi ne 1M/ T))
11-87
PGM-FI System
(Pri mary
HO2SI
(Sensor
1l
(D16Y5
engi ne
(M/Tt)
The scan tool i ndi cates Di agnosti c Troubl e Code l DTC)
P1162: A mal functi on i n the Pri mary Heated Oxygen
Sensor
( Pr i mar y
HO2S)
( Sensor
1) ci r cui t .
Descri pti on
The Pri mary Heated Oxygen Sensor
(Pri mary
HO2S)
(Sensor
1) operates over a wi de ai rl fuel range. The Pri mary HO2S
( Sensor
1) i s i nst al l ed i n t he exhaust mani f ol d.
SENSOR
ELEMENT
HEATER
TERMINALS
SENSOR
TERMI NALS
NOTE: l f DTC P1162 i s stored at the same ti me as DTC P1167, troubl eshoot DTC P1162 fi rst, then troubl eshoot DTC P1167.
ECM CONNECTOR C 131PI
PRIMARY HO2S
{SENSOR 1} 8P
CONNECTOR
(C1,15)
f emal e t er mi nal s
of f emal e
I er mr nat s
-
The MIL has been.eported on.
-
Problom verilication:
1. Do t he ECM Reset Procedure.
3. Wai t at l east t wo mi nut es.
Test ' dri ve f or several mi l es wi t h
t he t ransmi ssi on i n 3rd gear. Hol d
t he engi ne speed at 1, 500 rpm.
l s DTC Pl 162 i ndi cat ed?
Intermittent tailure, system is OK
at this time. Ch6ck for poo. con-
{ Pr i mar y HO2S, Sensor 1) and
ECM,
l s DTC P' l 162 i ndi cat ed?
Check f or an open i n t he wi r e
( l P+
l i ne) :
1. Tur n t he i gni t i on swi t ch OFF.
2. Di sconnect ECM connect or C
( 31P) f r om
t he ECM.
3, Di sconnect t he 8P connect or
f r om t he Pr i mar y HO2S
( Sen-
sor
' l
) .
4. Check f or cont i nui t v bet ween
t he Pr i mar y HO2S
( Sensor
1)
8P c onnec t or t er mi nal No. 7
and ECM connect or t er mi nal
c23.
Repeir open in the wire between
ECM l C23) and Pr i mar y HO2S
(Sensor
1).
Inspect for poor terminalto telmi-
nal contact at the Primarv HO2S
lsensor 1) connector and ECM.
lf terminal conlact is OK, replace
the Primary HO2S
(Sensor
1).
1 1- 88
(To page 11' 89)
(From page 11-88)
Chcck th. ECM input vohego {lP-/
VS- lino):
2 Turn t he i gni t i on swi t ch ON {l l ).
ECM connect or t ermi nal s C24
and D' ] 1.
l s t her e mor e t han 0. 5 V? Ch6ck the ECM:
{31P) f rom t he ECM.
body gr ound and ECM con
nect or t ermi nal C24.
-
Repai r open i n t he wi r e
bet ween ECM l c24l and Pri -
mary HO2S
(Sensor
'l
I.
-
Substitute a known-good ECM
and .ach.ck. It symptom/indi-
cation goes awey, replace the
originalECM.
Chock tor s short in the wire
(lP-l
V9- linel:
f rom t he Pri mary HO2S
(Sen'
sor ' l ) .
body ground
and ECM connec-
tor terminal C24.
Repl.c. the Primary HO2S {Sen-
so. 1) .
Chock t ho ECM out put vol t age
IVS+ linol:
Measure vol t age bet ween ECM
connector terminals C25 and D'11.
Check for a sho.l in tho wire {VS+
linel:
1. Turn t he i gni t i on swi t ch OFF-
(31P)f rom
t he ECM.
3. Check for continuity between
body gr ound and ECM con-
l s t here moret han 0. 5 V?
ECM CONNECTORS
c {31P} o {16P}
IP-/VS- {REDI
R6pair short in the wi.e between
the Primarv HO2S {Sensor'l) and
ECM tc24t.
f emal e t er mi nal s
sG2
{GRN/BLI(}
{cont' d)
1 1- 89
3 a 5 6 1 8 9 l 0
1 1 12 t 3 1a 15 l 6 11 18 22
23 21 25 27 2t z) 30
o-\ rP-/vs-
7 rneot
1 2 3 1 5 8 t 0
1 1 l 2 13 14 15 16 1 7 1 8
,/
?2
23 2a 25 21 2A a 30
fr)
{RED}
1 I 8 10
1 1 12 13 14 15 16 1 7 1 8 22
23 21 25 21 2a 8 30
O) vs*
! twHTt
(To page 11-90) (To page 11-90)
I
(Pri mary
HO2SI
(Sensor
1l
(Dl 6Y5
engi ne
(M/Tl ) (cont' dl
PGM-FI System
l From
page 11-89)
Check the EcM:
f rom t he Pri mary Ho2S {Sen-
sor ' l ) .
3. Measure voltage between ECM
connect or C25 and D11.
l s t here more t han 5. 0 V?
Replace the Primary HO2S lSen-
s or 11.
Subst i t ut a known-good ECM
and recheck. lf symptom/indica-
tion goes away, replac th6 origi-
nsl ECM.
Check t he ECM out put vol t age
{ VS+ l i ne) :
Measur e vol t age bet ween ECM
connect or t er mi nal s C25 and D' 11.
l s t here 2. 6
-
2. 8 V?
Subst i t ut a known- good ECM
and rccheck. lf symptom/indica-
tion
goes away, replaco tho origi-
nal ECM.
Check for a short in tha wiro {lP+
l i nel :
f r om t he Pr i mar y HO2S
( Sen
body
gr ound and ECM connec-
t or t er mi nal C25.
Rpair short in th6 wire between
t he Pri mary HO2S {Sensor 1l and
ECM tC25).
l s t here cont i nui t yT
Replace the Primary HO2S {Sen-
sor 11.
I 2 3 6 1 E 9 l 0
l 1 12 r3 l 5 t 6 1 1 r8 22
p
l fi .
w;,".i a"or
I r emar e l et mt na
Check the ECM input vohago
(lP-/
vS- linel:
l oad
(M/ T
i n neut ral ) unt i l t he
radiator fan comes on, then let
i t i dl e.
connect or t ermi nal s C24 and
01' j .
(GRN/ 8LKI
1 t 2 3 5 t 9 10
12 t 3 t 5 t 6 r l
VS+
(WHT}
sG2
2 3
to t l
't2
t 5 16
1 1- 90
( To page 11- 91)
( To page 11- 91)
l Fr om
page 11- 90) l From
page 11-90)
c
(3rP)
D t16Pl
sG2
(GRN/BLKI
lP+
I BLK)
YES
PRIMARY HO2S
tsENsoR 118P
coNNECTOR tCl{st
lP+
I BLKI
f emal e t ermi nal s
Wire side of
lP+
IBLK}
Wire side
of f emal e
t ermrnat s
NO
{cont' d}
1 1 - 9 1
Roplaco the Primary HO2S
(S6n-
sor 11.
l s t hore l ess t han 2. 8 V?
Subst i t ut e a known-good ECM
tion gos away. replace the origi-
nal ECM.
Check t he ECM out put vol t age
l l P+ l i ne):
connect or t ermi nal s C23 and D' 11.
Subst i l ut a a known-good ECM
and recheck. It symptom/indica-
tion goes aw.y, rcplace the o.igi-
nal ECM.
Check the ECM:
(31P)f rom
t he ECM.
body gr ound
and ECM con-
Check f or an open i n l h6 wi re
l l P+ l i ne):
(Sen-
sor 1) .
t he Pri mary HO2S {Sensor 1)
8P connect or t ermi nal No. 7
and ECM connect or t ermi nal
c23.
Rpair open in tho wi.o bstween
ECM
( C23) . nd
Pr i mar y HO2S
lsensor ll.
Subsi i t ut e a known-9ood ECM
and rocheck. lt symptom/indica'
tion goes eway, replace the origi-
nal ECM.
Check tor a short in the wir
(lP+
l i nel :
(Sen
sor ' l l .
R.pair shon in th6 wirc btween
th Primary HO2S lsonsor 1) and
ECM {C23).
Replece the Primary HO2S ls6n-
sor 1).
2 3 a 6 t I t 0
1 1 12 r3 t a 15 16 1 7 t 8 22
23 21 25 29 30
I
lP+
h
IBLK)
ECM CONNECTOR C 13lPI
2 3 I 5 6 8 I 10
1 1 12 13 14 16 11 18 22
23 21 25
29 30
6\
lP+
jjl
{8LKl
PGM-FI System
(Pri mary
HO2SI
(Sensor
1)
(Dl 6Y5
engi ne
(M/T)l (cont'd)
l ptrEl
(DTC)
P1164: A range/performance probl em i n the Pri mary
:
Heated Oxygen Sensor
(Pri mary HO2S)
(Sensor
1) ci rcui t.
(DTC)
P1165: A range/performance probl em the Pri mary
(Pri mary
H02S)
(Sensor
1) ci rcui t.
-
The MIL h.3 ben .sportod on.
-
DTC Pl16il ii rtorcd.
ProblGm Verific.iion:
' 1.
Do t he ECM Reset Procedure.
l o a d u n t i l t h e r a d i a t o r t a n
3. Connect the SCS service con
nector,
4. Tst-drive in 4th gear. Staning
at 1,600 rpm, accelerate using
wide opn throttle for at least 5
seconds. Then decelerate for at
least 5 seconds with the throt-
tle complot6ly closed.
Intermittent frilurc. sy3tam b OK
at this time. Chck tor
poo.
con-
nections or loos6 wire3 at C145
{Pri ma. y HO2S, Sensor 1) . nd
ECM.
l s DTC P] 164 i ndi cat ed?
Rpl.c. tho Primary HO2S
(Sen-
3or 11.
Th6 MIL has becn ooorlcd on.
DTC P1165 b 3to.ed.
Problom V.ritidtion:
1. Do the ECM Reset Procedure.
6ngi ne at 3, 000 rpm wi t h no
l oad unt i l t he r adi at or f an
3. Connect the SCS service con-
4. Test ' dr i ve undor f ol l owi ng
condi t i ons.
-
55 rnph steady spoed
-
Transmi ssi on i n 5t h gear
-
Untilreadiness cod comes
Intormitteni failure, sy3tsm ia OK
at thia tim6. Check tor poo. con-
nections or looso wiroa at c145
l Pri mary HO2S. Sent or 1l . nd
ECM.
l s DTC P1165 i ndi cat od?
Rsplrc6 th6 Primary HO2S lson-
aor 11.
11- 92
l pi ,' ;;l
(DTC)
P]168: A l ow vol tage probl em i n the Pri mary Heated
| gj gggg!ggg
Oxygen Sensor
(Pri mary
HO2S)
(Sensor
1) LABEL ci rcui t.
ECM CONNECTOR D {16PI
LABEL {WHTI
(cont' d)
1 1- 93
)
The MIL has boon ..ported on.
DTC Pl168 is stored.
Problem vedficalion:
3. Wai t at l east t wo mi nut es.
IntermittGot lailuro, 3yst.m is OK
al this tim6. Chock tor
poor
con-
nction3 or loo3e wiros at C145
{Pri mary HO2S, Sensor 1) and
ECM.
Check the ECM:
2. Di sconnect t he ECM connec-
t or D
(16P).
ECM connect or t er mi nal D7
and body ground.
.nd rcchack. lf aymptom/indica-
tion goes swsy. r6place th6 origi-
nal ECM.
Check f or a short i n t he wi res
(LABEL
lin.l:
(Sensor
1) 8P connect or-
2. Check for continuity betlveen
ECM connect or t ermi nal D7
and body ground.
Replace th6 Primary HO2S lsen-
sor 11.
Ropair short in thg wir6 botweon
tho Pfimary HO2S
(Sensor
1l and
ECM tD7).
LABEL IWHT}
PGM-FI System
(Pri mary
HO2S)
{Sensor
1l
(Dl 6Y5
engi ne
(M/Tl ) (cont' dl
[ti ,r;ol
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P1169: A hi gh vol tage probl em i n the Pri mary Heated
L]g
Oxygen Sensor {Pri mary HO2S} {Sensor 1)LABEL ci rcui t.
PRIMARY HO2S ISENSON 1} 8P CONNECTOR I145I
ECM CONNECTOF D {16PI
IGBN/8LKI
f emal e
{GRN/ 8LK}
The MIL hs3 ben r6Dorted on.
DTC P1169 is stor6d.
Problm veritication:
1. Do t he ECM Reset Procedure-
2. St art t he engi ne-
3, Wai t at l east t wo mi nut es,
Intormittent failure, system is OK
at thi3 time. Check for ooor con-
nections or loose wi.es at C145
{ Pr i mar y HO2S, Sensor l l and
ECM.
Check f or an opn i n t hg wi ro
I LABEL l i nel :
1- Turn t he i gni t i on swi t ch OFF.
2. Disconnect the Primary HO2S
(Sensor
1i 8P connect or.
(ll).
Pri mary HO2S
(Sensor
1) 8P
connect or No. 4 t ermi nal and
body ground.
Check f or an open i n t he wi re
l SG2l i ne) :
2. Di sconnect ECM connect or D
(16P)
f rom t he ECM.
3. Check f or cont i nuj t y bet ween
ECM connect or t ermi nal D11
and Pri marv HO2S
(Sensor
1)
8P connect or t ermi nal No. 3.
Repai open in tho wirs bstwen
the Piimary HO2S lsensor 1) and
ECM
(D71.
Repair open in the wire betwen
th. Primary HO2S
(Sen3or
1l and
ECM t D11l .
Wi re si de of
,|
2 3 1
6 8 9 t 0 1 l 12
1 4 15
16 sG2
si de of
l e t ermi nal s ( 11
\9
_l
;G2
I 2 3 1
6 8
11-94
(Secondary
HO2S)
(Sensor
2l
l Tol 3j i ]l l h"
scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
probl em
i n the Secondary Heated
.:
Oxygen Sensor
(Secondary
HO2SI
(Sensor
2) ci rcui t.
SECONDARY HO2S
(S.n.or
2l
/aP
CONNECTOR 1C125, C7E2r)
(cont' d)
1 1- 95
-
The MIL h.3 bo6n reported on.
-
' 1.
Do t he ECM/ PCM Reset Pro
cedure,
l oad {A/ T i n
E
or
E
posi t i on,
t or f an comes on.
Secondar y HO2S
( Sensor
2)
out put vol t age at 3, 000 rpm.
Intermittont failuro, sy3tem is OK
at thi3 time, Check tor poor con-
nections or loose wiao6 at C131'
(locrtod
under right 3ide ot da3hl.
C432r {located und.r middle of
dashl , C125
(C782l t (Secondary
HO2S) lsonlor 2l and ECM/PCM.
Does the voltage stay at 0.3 V
or l ess?
Chck fol a short in the Second!ry
HO2SI
Di sconnect t he Secondar y
HO2S
(Sensor
2) 4P connector.
St art t he engi ne.
Check t he Secondar y HO25
(Sensor
2) output with the scan
t ool .
Check l ol . 3hon i n t h. wi r o
{SH()2S linel:
2. Di scon nect t he ECM/ PCM
connect or D 116P).
t he Sgcondary HO25
(Sensor
2) 4P connect or t ermi nal No. 1
and body ground.
Rco.ir 3hort in the wire bdtw.en
ECM/PCM lDl4l and Secondary
HO2S lsonsor 21.
Substitute . known-good ECM/
PCM and r.check. lf symptom/
i ndi cat i on go03 away, repl aco
tho original ECM/PCM.
*:
D16Y8 engi ne
PGM-Fl System
(secondary
HO2SI
(Sensor
2l
(cont'dl
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC)
probl em i n the Secondary Heated
Oxygen Sensor
(Secondary
H02S)
(Sensor
2) ci rcui t.
SECONDAnY HO2S lsontor 2)
4P CONNECTOR C125
(C782lr
sH02s
IWHT/REOI
sH()2sG
(YEL/RED}
(GRN/BLKIT
sHo2sG
(YEL/RED)
(GRN/BLKP
I I
sHo2sl wHT/REol
JUMPER WIRE
*:
Dl 6Yg engi ne
1 1- 96
The MIL has been reDorted on.
1. Do t he ECM/ PCM Feset Pro-
cedure.
l oad
(A/ T
i n
E
or E
posi t i on,
t orf an comes on,
3. Wi t h t he scan t ool , checkt he
Secondar y HO2S
( Sensor 2)
outputvoltageat 3,000rpm.
Intermittent failure, 3ystem b OK
at this time. Check for
poor
con-
nections or loose wires st C131'
llocated undor right side of dashl.
C432i
(localed
undor middle ol
da3h), C125
(C?82)*
l socondary
HO2S Sensor 2) and ECM/PCM.
Does t he vol t age st ay at 0. 6 V
Check ior an opn in the Seclndary
HO2S:
2. Di sconnect t he Secondar y
HO2S
(Sensor
2) 4P connect or.
3. Connect t he Secondary HO2S
(Sensor
2) 4P connect or t er_
mi nal s No. 1 and No. 2 wi t h a
i umper
wi re.
(l l ).
5. Check t he Secondar y H02S
{Sensor 2) out put vol t age wi t h
t he scan t ool ,
Check t or an open i n t h wi re
(SHO25
l i ne):
t ermi nal s Dl 4 and D13 wi t h a
(l l i .
4. Check t he Secondar y HO2S
( Se n s o r
2 ) o u t p u t v o l t a g e
Repair op6n in the wire betweon
ECM/ PCM {D13 and, / or D14} and
Secondarv HO2S {Sensor 2).
PCM and recheck. I t sympt om/
i ndi cai i on goes away. repl ace
JUMPER WIRE
u)t
a
J
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P0139: A sl ow response probl em i n the Secondary Heated
Oxygen Sensor
(HO2S)
{Sensor 2) ci rcui t.
-
Thc MIL haa bccn rcponed on.
-
DTC P0139 i3 3iored.
P.obl6m vo.ificalion:
c60ure,
load
(A"/T
in
E
or
E
position,
tor fan comes on,
Secondary HO2S {Sensor 2)
output at 3,000 rpm.
Intermittent lailure, system is OK
at this time. Check for poor con-
nections or loose wires at C13'l*
llocated under right side ol dash),
C432' {l ocat ed under mi ddl e of
dashl C125 {C7821* {Secondary
HO2SI {Sensor 2l and ECM/PCM.
Doest he vol t age st ay wi t hi n
0. 3
-0. 6
V t or t wo mi nut es?
11-97
PGM-FI System
(HO2S)
Heater
(DTC)
P0135: An el ectri cal
probl em i n the Pri mary Heated
Oxygen Sensor
(Pri mary
HO2S)
(Sensor
1) Heater svstem {Except
D16Y5 engi ne
(M/T))'
(DTC) P0141: A probl em i n the Secondary Heated Oxygen Sensor
(Secondarv
HO2S)
(Sensor 2) Heater ci rcuat.
\,, .a
fFor35l
lFot+il
PRIMARY HO2S {S.n.ot l)]|P CONNECTOR
SECONDARY HO2s
(S6nto12) 4P CONNECTORT
Termi nal si do ot mal e t ermi nal s
PRIMARY HO2S ISENSOR
1) 'P CONNECTOR
(Cl23I
sEcoNDARY HO2S TSENSOR
2) rP COI{NECTOR lcl2s}*
/
_l=._1
i|iru I
t z
leozsxrc.
sozsxrc
YELI I-
T--
IBLK/WHTI
l - l
L--Cp
Wi 16 si de of f 6mal e t er mi nal s
sEcoNoAnY Ho2s lsENsoR
2l
lP CONNECTOR
(C782)*.
so2sHTc
(BLK/WHT)
t G1
{BLK/WHTI
*r
P0141
(To page 11-99)
**:
D16Y8 engi ne
-
The MIL haa bgon teDorted on.
-
DTC m135, and/or P0141 a.e
stored.
Problom vorification:
cedure,
lntermittont failure, swtem i5 OK
at thb time. Check fot
poor
con'
noct i on3 or l oose wi r os at
C131** {located
under right 3ide
ol dashl, C432** {located
under
mi ddl e of d. sh), C123
(P. i mary
HO2S, Sensor 1l C125 {C7821**
l Secondary HO2S, Sensot 2)*
and ECM,/PCM.
Check foi en opon or short in the
HO2S:
2. Di sconnect t he HO2S
(Pri mary
or Secondary*) l Sensor
1 or
Sensor 2)4P connector.
3. At t he H02S si de, measur e
resistance between the HO25
4P connect or t ermi nal s No. 3
and No. 4.
l s t here l 0
-
40 0?
Check f or cont i nui t y bet ween
body
gr ound and t he HO2S 4P
connect or t er mi nal s No. 3 and
No. 4 i ndi vi dual l y.
Check foi an open or short in the
wire IPO2SHTC,
SO2SXTC* lino):
1. Turn t he i gni t i on swi t ch oN
(l l ).
2. Measure voltage between the
HO25 4P connect or t ermi nal s
No. 3 and No. 4.
1 1 - 9 8
(To page 11-99) Wi re si de of l emal e t ermi nal s \, I
Check tor an open or short in the
wire
(lG1
linell
HO2S 4P connector term;nals No. 3
( D16Yg
engi ne: No. 4) and body
ground-
-
Ropai r open or short i n t he
wire between Prim.ry HO2S
{Sensor 1),
(No.
15 ALTERNA-
TOR SP SENSORI 17.5 A) tuie
and Socondery HOzS, Scnsot
2l +,
-
RoDlac. the No. 15 ALTEBNA-
TOR SP SENSOR l7.s Al tuso.
Check f o. an open i n t he wi re
{PO2SHTC, SO2SHTC* linel:
2. Reconnect t he HO2S 4P con-
3. Disconnect the ECM/PCM con
nect or A
(32P).
(l l ).
ECM/ PCM connect or t ermi nal s
46 and A10
(A5
and A10)*.
Repair open in the wire betweon
ECM/ PCM {46, A5l t and HO2S
{Primary, Secondary*1.
l s t here 0. 1 V or l ess?
Substituta a known-good ECM/
PCM and recheck. l t 3ympt om/
i ndi cat i on goes away, repl ace
PRIMARY HO2S ISENSOR 1)
ilP
CONNECTOR
(cr23t
SECONDARY HO2S
(SENSOR
2l
irP
coNNECTOR (C12s)r
1 1
2 l
- r l
t 3 t { l
lcl
L_r__.r.____J
|BLK/
O)
YELI
Y
Wi re si de ot f emal e t ermi nal s
*:
P0141
**:
D16Y8 engi ne
SECONDABY HO2S
{SENSOR 2I {P CONNECTOR
tc782t*r
IGl {BLK/WHTI
-l.
(v)
Y
Wi ro si de of f emal e t ormi nal s
Wire side ol female terminals
so2HTClBtX/WHTtr FO2SHTCIBLK/WlfTl
{From
page
' 11
98}
Chock l or a short i n l he wi re
{PO2SHTC, SO2SHTC. lino):
2. Di sconnect t he ECM/ PCM con-
nect or A {32P).
the ECM/PCM connector termi-
nal A6
(A5)*
and body ground.
ReDair short in tho wi.s bstween
ECM/ PCM (46,
As*l and HO2S
lPrimary, S.condary.l.
Subslitute r known-good ECM/
PCM and recheck. l f sympt om/
i ndi cat i on goes away. rpl ace
the original ECM/FCM.
ECM,/PCM CONNECTOR A I32PI
so2sHrc
I
tBLK/wHn-J
pozsxrc E/
IBLK/WHTI
^
r-----{vF
T-r
PG1
IBLK)
6 r l
l a l g l
r o l l
12 t 3 t 5 t 6 t a t 0 20 21 23 2a
27 2A a 3o
1 1- 99
PGM-FI System
(HO2S)
Heater
(D16Y5
engi ne
(M/Tl l
t
(DTC)
P1166: An el ectri cal
probl em i n the Pri mary Heated
Oxygen Sensor
(Pri mary
HO2S) Heater system.
PRIMARY HO2S ISENSOR 1} 8P CONNECTOR
Terminal side of
mal e t ermi nal s
-
Th MI L h. 3 bean reoon. d
-
DTC P1165 b stored.
Intermittent tailur., 3vt.m is OK
et thii time
(te3i
drive may bo
nccossaryl. Chock for poor
con-
noctions oa looie wkas bgtween
C145
(Pri f t ary
HO2S, Sonsor 1)
and ECM.
Chock th6 Primery HO2S {S6nso1
'll
re3btance:
' 1.
l Sensor 1) 8P connect or.
3. At t he Pr i mar y HO2S
( Sen-
sor 1) , measur e r esi st ance
bet ween No. 1 and No. 2 t er
mrnal .
l s t here 2
-
13 O?
Check f or a shor t sd Pr i ma. y
HO2S l ssn3or' l l :
Ch6ck f or cont i n! i t y bet ween
body ground and each t ermi nal .
Ch. ck l or . 3hort 6d Pri mery
HO2S lsensor 1):
Check for continuity between ter-
mi nal No. 1 and t ermi nal s No. 3,
4, 6, 7 and 8 i ndi vi dual l y.
Replacc tho Primary HO2S
(Scn-
sor 11,
( To page 11- 101)
1 1 - 1 0 0
(From page 11-100) PRIMARY HO2S ISENSOR 1l8P CONNECTOR {Clirsl
PO2SI{TC
{BLK/WHTI
PO2SHTC
(BLK/WHT)
V
PO2SHTC
IBLK/WHTI
ECM CONNECTOR
I emal e t ermi nal s
L
(cont' d)
1 1 - 1 0 1
ch6ck the Po2sHTc circuir:
1. St art engi ne and keep engi ne
rpm at i dl e.
2. At t he engi ne wi re harness,
measur e vo l t ag e bet ween
Pr i mar y HO2S
( Sensor 1i 8P
connect or t ermi nal No. 1 t er-
mi nal and body
ground.
Chsck f or en open' i n t h6 wi re
(PG
linel:
Measure voltage beNveen Primary
HO2S {Sensor 1) 8P connector ter'
mi nal s No. 1 and No. 2.
l s t here more t han 5 V?
Ropair open in the wire between
t hc HO2S . nd Gl 01 l l ocat ed at
thermostat housingt.
Substitute a known-good ECM
and .echock, lf symptom/indice-
lion goes rw.y, repl.c the origi-
nel ECM.
Check ror a 3hort i n t he wi re
(PO2SHTC
linel:
1. Turn t ho i gni t i on swi t ch OFF.
2. Di sconnect ECNI connect or A
(32P)
f rom t he ECM.
ECM connect or t er mi nal 46
and body ground.
Repair 3hon in th6 wiae between
t he ECM
(A6l
and t he Pri mary
HO2S l s. nso. ' l ).
(PO25HTC
lin.l:
ECM connect or t ermi nal 46 and
t he Pri mary HO2S
(Sensor
1) 8P
connect or t ermi nal No, 1,
Repair open in the wirc between
ECM lA6l and the Prim.ry HO2S
lsen3or
'l
).
Subst i i ut o . known-good ECM
and r.ch.ck. lf symptom/indica-
tion
90e3
.wry, ..pl.c the origi-
n.l ECM.
A
f)
6 , 9 L 1 0
12 l 3 t a r5 l a t 0 19 2\ 221 23 2a
25 21 2a 4 30
|,-.'
PGM-FI System
{HO2S)
Heater
(D16Y5
engine
(M/Tl) (cont'd)
l Tl Ltl l h"
scan tool i n^di cates Di sgnosti c Troubl e Code
(DTC)
P1167: A system mal functi on i n the Pri mary Heated
.....-''.--.......
Oxygen Sensor
(Primary
HO2S)
(Sensor
1) Heater circuit.
PFIMARY HO2S
(SENSOR
1) 8P CONNECTOR
lClil5l
ECM CONNECTOR C {3.IPI
The MIL he! bcofl ..oort.d on.
DTC P1167 b stored.
Problom veffication:
load 1A,/T in
N or
E
position,
M/ T i n noul ral ) unt i l t he radi a-
t or f an comes on.
Intermittent failure, systom k OK
poor
con-
noctions or looie wi.es at C145
l Pri mary HO2S, Sen3or 1l and
ECM.
l s oTC1167 i ndi cat ed?
Ch6ck f or an op. n i n t he wi re
{VS+ l i n. ):
(Sensor' 1)
8P connect or.
4. Measure vokage between the
Pr i mar y HO2S
( Sensor
1l 8P
connect or t ermi nal No, 6 and
body ground.
check rhe EcM:
ECM connect or t ermi nal C25 and
body ground.
l s t here moret han 5 V?
Repair open in thc wire ECM {C25}
and Primary HO2S lsensor 11.
Sub3t i l ut e a known-good ECM
and recheck, lf symplom/indica-
tion goes eway, leplace th origi-
nal ECM.
1 2 a 6 7 8 9 r 0
1 1 12
't3
t 4 1 5 1 1 61 1 l 8
23 21 25 2i 30
VS+
(WHT) Wire side of female
t ermi nal s
11- 102
PGM-FI System
{HO2S)
Heater
(D16Y5
engine
(M/Tl) (cont'd)
l Tl Ltl l h"
scan tool i n^di cates Di sgnosti c Troubl e Code
(DTC)
P1167: A system mal functi on i n the Pri mary Heated
.....-''.--.......
Oxygen Sensor
(Primary
HO2S)
(Sensor
1) Heater circuit.
PFIMARY HO2S
(SENSOR
1) 8P CONNECTOR
lClil5l
ECM CONNECTOR C {3.IPI
The MIL he! bcofl ..oort.d on.
DTC P1167 b stored.
Problom veffication:
load 1A,/T in
N or
E
position,
M/ T i n noul ral ) unt i l t he radi a-
t or f an comes on.
Intermittent failure, systom k OK
poor
con-
noctions or looie wi.es at C145
l Pri mary HO2S, Sen3or 1l and
ECM.
l s oTC1167 i ndi cat ed?
Ch6ck f or an op. n i n t he wi re
{VS+ l i n. ):
(Sensor' 1)
8P connect or.
4. Measure vokage between the
Pr i mar y HO2S
( Sensor
1l 8P
connect or t ermi nal No, 6 and
body ground.
check rhe EcM:
ECM connect or t ermi nal C25 and
body ground.
l s t here moret han 5 V?
Repair open in thc wire ECM {C25}
and Primary HO2S lsensor 11.
Sub3t i l ut e a known-good ECM
and recheck, lf symplom/indica-
tion goes eway, leplace th origi-
nal ECM.
1 2 a 6 7 8 9 r 0
1 1 12
't3
t 4 1 5 1 1 61 1 l 8
23 21 25 2i 30
VS+
(WHT) Wire side of female
t ermi nal s
11- 102
Fuel Supply System
]TO17i l
Th" """n tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0171: The fuet system i s too l ean.
I
P0172 The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0172: The fuel system i s too ri ch.
D6scription
By moni tori ng the Long Term Fuel Tri m, l ong term mal functi ons i n the fuel system wi l l be detected.
It a mal functi on has been detected duri ng two consecuti ve tri ps, the MIL wi l l come on and DTC P0171 and/or P0172 wi l l be
stored.
NOTE: l f some ot the DTCS l i sted bel ow are stored at the same ti me as DTC P0171 and/or P0172, troubl eshoot those DTCS
fi rst, then troubl eshoot DTC P0171 andl ot P0172.
P0106-8. P1128-9*3.
*5r
MAP Sensor
P0135: Pri mary HO2S Heater
P0137-8: Secondary HO2S
P0141: Secondary HO2S Heater
P0401: EGR Fl ow l nsuffi ci ent*1
P0441: EVAP System Insui fi ci ent Purge Fl ow*6
P1259: VTEC System*,
P1491r EGR Val ve Li ft Insufl i ci ent*l
P1498: EGR Val ve Li ft Sensor Hi gh Vol tage*1
* 1;
D16Y5 engi ne
+,:
*3:
' 97
model
*a:
' 96
model
*5:
' 98
model
*6:
' 96
Dl 6Y5 engi ne,' 96 D16Y7 engi ne,
' 96
D16YB engi ne
(sedan),' 97
D16Y5 engi ne,' 97 D16Y/ engi ne
(coupe:
KA, KC mod
el s, sedan KA. KC, KL
(DX)
model s, hatchback: al l model s),' 97 Dl 6Y8 engi ne
(sedan:
KA, KC model s)
Possible Cause
DTC P0171
DTC P0172
Fuel Pump i nsuffi ci ent fl ovpressure
Fuel Feed Li ne cl ogged, l eaki ng
Fuel Pressure Regul ator stuck open
Fuel Fi l ter cl ogged
Fuel Inj ector cl ogged, ai r i ncl usi on
Gasol i ne doesn' t meet Owner' s Manual spec.
Pri mary H02S
(Sensor
1) deteri orated
MAP Sensor range/performance*a
EGR System mal functi on
(too
much fl ow)*1
Val ve Cl earance
Exhaust l eak
Fuel Pressure Regul ator cl ogged, stuck cl osed
Fuel Return Pi pe cl ogged
Fuel Inj ector l eaki ng
Gasol i ne doesn' t meet Owner' s Manual spec.
Pri mary H02S
(Sensor
1) deteri orated
MAP Sensor range/performance+4
EGR System i nsufti ci ent fl owrl
EVAP Purge Control Sol enoi d Val ve l eaki ng, stuck opened
Val ve Cl earance
{cont' d}
1 1 - 1 0 3
PGM-FI System
Fuel Supply System
(cont'dl
YES
NO
YES
L
-
The MIL has been reoorted on.
-
DTC P0171 and/ or P0172 are
stored.
l s t he f uel pressure OK?
l s t he l uel pressure t oo hi gh Chock the fucl
p.caaure reguletor
and fuel rcturn pip.
Check the P.imary HO2SI
l oad
(. A/ T
i n
N or E
posi t i on,
t or f an comes on,
2 . Ch e c k t h e Pr i ma r y HO2 S
( Se n s o r ' l )
o u t p u t wi t h t h e
scan t ool .
Check t he f uel
pump,
l uel f e. d
pipe, fuel lilter, and fuel pressu.e
regulator.
Does i t st ay at l ess t han 0. 3 V
or more t han 0. 6 V?
Check f or a st i cki ng or l eaki ng
EVAP
pur gc
cont r ol sol enoi d
Wi t h a vacuum pump,
appl y vacu-
um t o t he EVAP pur ge cont r ol
sol enoi d val ve f r om t he i nt ake
mani f ol d si de.
Does i t hol d vacuum?
Check the MAP sensor outputl
1. Turn t he i gni t i on swi t ch ON i l l ).
2. Check t he l , 4AP wi t h t he scan
t ool ,
Check the response of the MAP
Sensot:
t ool .
l s a MAP of 40. 0 kPa
(300
mmHg,
12. 0 i nHg) or l ess i ndi cat ed wi t hi n
one second after starting the
engi ne?
-
Check th6 valve clearance,
-
Check the EGR swt6m
(D16Y5
en9i nel .
-
It they are OK, replace the luel
inlecto.s.
11- 104
v
Misfire Detected in One Cylinder
I
P0301 The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P030' 1: Cyl i nder 1 mi sfi re detected.
I
P0302
ths s636 tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0302: cyl i nder 2 mi sti re detected.
119393-.1 Th"""untool i ndi cates Di agnosti c Troubl e Code {DTC) P03O3r Cyl i nder3 mi sfi re detected.
P0304
i
ths 56sn tool i ndi cates Di agnosti c Troubl e Code {DTC) P0304: Cyl i nder 4 mi sfi re detected
Description
Mi sti re detecti on i s accompl i shed by moni tori ng the crankshaft speed wi th the crankshaft speed fl uctuati on
(CKF)
sensor
whi ch i s attached to the crankshaft.
l f mi sfi ri ng strong enough to damage the catal yst i s detected,l he MIL wi l l bl i nk duri ng the ti me ot i ts occurrence, and DTC
P0301, P0302, P0303 or P0304 wi l l be stored. Then, after the mi sfi re has ceased, the MIL wi l l come on.
l f mi sfi ri ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es, the MIL wi l l come on, and DTC
P0301. P0302. P0303 or P0304 wi l l be stored,
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as a mi sl i re DTC, troubl eshoot those DTCS fi rst, then
troubl eshoot the mi sfi re DTC.
P0106r MAP sensor
P0131, P0132: HO2S
P017' 1, P0172t Fuel suppl y system
P0335, P0336: CKF sensor
P0401, P1491, Pl 498: EGR system
P044' l : EVAP system Insuffi ci ent purge fl ow*6
P1359, P1361, P1362: TDC sensor
Pl 381, Pl 382: CYP sensor
* 6: ' 96
D' 16Y5 engi ne, ' 96 D16Y7 engi ne, ' 96 D16YB engi ne
( sedan) , ' 97
D16Y5 engi ne, ' 97 D16Y7 engi ne
( coupe:
KA,
KC model s, sedan KA, KC, KL
(DX)
model s, hatchback: al l model s),' 97 D16Y8 engi ne
(sedan:
KA, KC model s)
Possible Cause
. Fuel i nj ector cl oggi ng, fuel l eakage, ai r l eakage
. Fuel i nj ector ci rcui t open or shorted
. Spark pl ug carbon deposi ts, foul i ng, mal functi on
. l gni ti on wi res open. l eaki ng
. Di stri butor mal functi on
a Compressi on l ow
. Val ve cl earance out of spec
. VTEC system mal functi on {D16Y5, D16Y8 engi ne)
. HO2S
. HO2S ci rcui t
)/
(cont' d)
1 1 - 1 0 5
PGM-FI System
Misfire in Detected One Cylinder
(cont'dl
Troublshooting Flowchart
-
The MIL hra boen reDorted on.
-
oTc P0301, P0302, P0303, o.
P0304 i3 indicatsd.
NOTE:
' l I
t hore i s no l reeze dat a oI mi sl i ri ng,
j ust
cl ear t he DTC.
.
l f t here i s no f reeze dat a of mi sf i r; ng,
t est dri ves under vari ous condi t i ons
Chock tho luol injector tunction:
Sl art t he engi ne, and l i st en l or a
cl i cki ng sound at t he f uel i nj ect or
i n t he probl em cyl i nder.
Check f or an open or short i n t he
harness bet ween ECM/ PCM and
the fuel injector.
Repair open or short in the wire.
-
Replace the fu6l injoctoi.
-
Subsl i t ut e a known- good
ECM/ PCM and r echock. I t
sympt om/ i ndi cr t i on goos
aw.y, rcplac tho originsl ECM/
PCM.
Problem vorilicationi
1. After checking the freeze data,
do t he ECM/ PCM Reset Pro-
ceoure,
2. Exchange t he spark pl ug f rom
t he probl em cyl i nder wi t h one
of anot her cyl i nder.
nector.
4. Test ' dri ve t he vehi cl e several
times in the range ofthe lreeze
oala.
(To page 11-1071
1 1 - 1 0 6
I
/
NOTE| I t t here i s no l reeze dat a of mi s
f ; ri ng, t est dri ves under vari ous condi
tions are necessary,
T
{From
page 11-106}
Intermittent mistire due to spark
plug fouling, etc- lfiring is OK al
t hi s t i mel .
ls DTC P0301, P0302, P0303,
or P0304 indicated?
Does t he mi sf i re occur i n t he
ot her cyl i nder whose spark pl ug
was exchanged?
Replace lh6 faulty spark plug.
Ch6ck for fuol injector malfunc-
tion:
1. Exchange t he f uel i ni ect or
t r om t he
pr obl em
cyl i nder
wi t h one l rom anot her cyl i n'
der,
2. Let the engine idle for two min-
utes,
3. Test dri ve t he vehi cl e several
times in the range ot the freeze
data.
Inte.mittont misfiro due to bad
contact in the fuel injector con-
nect o. l f i ri ng i s OK at t hi s t i me).
ls DTC P0301, P0302, P0303,
or P0304 indicated?
Does t he mi sl i re occur i n t he
ot her cyl i nder whose f uel i nj ect or
was exchanged?
Rplac the faulty luel iniector.
Chock following items
-
Cylinder leak{own
-
Comoaession
-
Crank3heft soeed fluctuation
ICKFI 3ensor
11- 107
PGM-FI System
Random Misfire
[Fo3oo l*'
o'
fFl3oo l*''
*'
"nd
(DTC)
P0300* s or P1300+3
* 1
and s ome of P0301
-
P0304:
Random mi sfi re.
Dgscription
Mi sfi re detecti on i s accompl i shed by moni tori ng the crankshaft speed wi th the crankshaft speed fl uctuati on
(CKF)
sensor
whi ch i s attached to the crankshaft.
l f mi sfi ri ng strong enough to damage the catal yst i s detected, the MIL wi l l bl i nk duri ng the ti me of i ts occurrence, and DTC
P0300*5 or and some of DTCS P0301 through P0304 wi l l be stored. Then, after mi sfi re has ceased. the MIL wi l l
come on.
l f mi sfi ri ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es, the MIL wi l l come on. and DTC
P0300*5 or P1300*3.
*a
and some of DTCS P0301 through P0304 wi l l be stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as a mi sfi re DTC. troubl eshoot those DTCS fi rst, then
troubl eshoot the mi sfi re DTC.
MAP sensor
P0131. P0132: HO2S
P0171, P0172t Fuel meteri ng
P0401, Pl 491, Pl 498: EGR system*r
P0505: l dl e Control System
P1253; VTEC System*,
Pl 361. Pl 362: TDC sensor
Pl 381. P1382: CYP sensor
P1508: IAC val ve
Possible Causo
. Fuel pump
i nsuffi ci ent fuel pressure, amountoffl ow
. Fuel Ii ne cl oggi ng, bl ockage, l eakage
. Fuel fi l ter cl oggi ng
. Fuel pressure regul ator stuck open
. EGR system mal functi on*r
. Di stri butor mal functi on
. l gni ti on coi l wi re open, l eakage
. l gni ti on control modul e mal functi on
. MAP sensor range/performance, poor response*1
. Val ves carbon deposi t
. Compressi on l ow
. IAC val ve mal functi on*a
! VTEC system malfunction*,
. Fuel does not meet Owner' s Manual spec.. l ackoffuel
. HO2S
. HO2S ci rcui t
Troubleshooting
By test-dri vi ng, determi ne the condi ti ons duri ng whi ch mi sfi re occurs. Dependi ng on these condi ti ons, test i n the order
descri bed i n the tabl e bel ow.
\
Possi bl e cause
\,
,;;;
EG R* 1
system
Crankshaft
position (CKP)
sensor
Fuel
pressure
Distributor and
lgnition wires
tcM
Cl earance
rAc
Valve
MAP
sensor
Condi ti on
\
1 l - 1 7 0 secti on 6
1 1- 150,
secti on 23 section 23 section 6 1' t - 126 11- 67
Onl y l ow rpm and
t oao
o @ @ o @
Onl y accel erati ng
o @ @
Onl y hi gh r pm and
t oaq
ra\
o @ @ @
Not specific
o @ @ @ @
NOTE: l f mi sfi re doesn' t recur, some possi bl e
causes are fuel that doesn' t meet owner,s manual
spec, l ack of fuel , carbon deposi ts on spark pl ug, etc.
1 1 - 1 0 8
* 1:
D16Y5 engi ne
*2:
*3;
' 97
model
*4:
' 96
model
*5:
' 98
model
P0301
U
J
Knock Sensor
(KS) (Dl 6Y5
engi ne
{CVTI
and D16Y8 engi nel
KS
IRED/
ALU)
KS
IREO/
BLU)
(DTC)
P0325: A mal functi on i n the ci rcui t of the Knock Sensor
{KS).
DIAPHRAGM
ECM/FCM COtrl]\|CrOB D
(16P1
Wir side of femal terminals
KS 2P CONNECTOR tcl37l
KS
IRED/BLUI
-
Th MIL hes been reooned on.
-
DTC m325 is stored.
Problem v6rification:
1. Do t he ECM/ PCM Reset Proce-
dure-
l oad
(A/ T
i n
N
or E
posi t i on,
t or f an comes on, t hen l et i t
i dl e.
3. Hol d t he engi ne at 3, 000
-
4,000 rpm for at least 60 sec-
onds.
Intormittenl tailure. system is OK
at t hi s t i me l t est dri ve mev be
Ch6ck l or poor connccl i ons or
loose wi.es between C137
(knock
sensor lKSl) .nd ECM/PCM.
Check toi a shon in the wir.
(Ks
linell
2, Di sconnect t he knock sensor
2P connect or,
3. Di scon nect t he ECM/ PCM
connect or D {16P}.
4. Check tor continuity between
ECM/ PCM connect or t er mi
nal s DO and body ground.
Repair short in tho wire between
ECM/ PCM l D6| and knock sen-
sor.
Chock l or an open i n t he wi re
(KS
l i nel :
ECM/ PCM connect or t ermi nal D6
and knock sensor 2P connect or
t ermi nal No. 1.
Rapair open in the wire btwo6n
ECM/ PCM l D6) . nd knock sen-
Subst i t ut e a known-good knock
sensor and recheck.
Replace tho original knock s6nsor.
PCM and r.check. lf symptom/
i ndi cat i on goos away, 16pl ac6
thc originrl ECM/PCM.
t 1
o
terl
u
s i
ni ni
1
de of fgm
l t s
al
1 2 3 a 5
7 8
' t0
1 1 1 2
13 1a 16
1 1 - 1 0 9
PGM-FI System
il'oggsl
fFffi6l
tPr36r I
tn362l
tFtu8Tl
tPJ382l
Grankshaft Position/Top Dead Center/Cylinder
position
(CKp/TDC/Cyp)
Sensor
(DTC)
P0335: A matfuncti on i n the Crankshaft
posi ti on
(CKp)
sensor ci rcui t.
(DTC)
P0336r A range/performance probl em i n the Crankshaft
Posi ti on (CKP)
sensor ci rcui t.
(DTC)
pl 36.l :
l ntermi ttent i nterruoti on
{TDC) sensor ci rcui t.
(DTC)
P1362: No si gnal i n the Top Dead Center
(TDC)
sensor
circuit.
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P1381: Intermi ttent i nterrupti on i n the Cvl i nder
posi taon
(CYP)
sensor ci rcui t.
The scan tool i ndi cates Di agnosti c Troubl e code
(DTC)
P1382: No si gnal i n the cyl i nder
posi ti on
(cyp)
sensor
circuit.
Doscription
The CKP Sensor determi nes ti mi ng for fuel i nj ecti on and i gni ti on of each cyl i nder and al so detects engi ne speed. The TDC
Sensor determi nes i gni ti on ti mi ng at start-up
{cranki ng) and when crank angl e i s abnormal . The CyF Sensor detects the
posi ti on
of No. 1 cyl i nder for sequenti al fuel i nj ecti on to each cyl i nder. The CKpi TDCl Cyp Sensor i s bui l t i nto the dastri bu_
ror.
NOTE: l f DTC Pl 359 i s stored at the same ti me as DTC P0335, P0336, P1361, Pi 362,
pi 381
and/or
p1382,
troubteshoot DTC
P1359 first. then troubleshoot those DTCS.
Ot6y5 ongin.:
Di6y7, D16y8 ongin6:
i n the Top Dead Center
TDC
SENSOR
CKP
SENSOR
CKP
SENSOR
ROTOR
CYP
SENSOR
ROTOF
SENSOR
ROTOR
ROTOR ROTOR
DISTRIBUTOR lOP
coNNECTOR tC120t
TDC P
1 1 - 1 1 0
SENSOR oTc
SENSOR
ERMINAL
ECMPCM
IERMINAL
WI RE
COLOR
CKP P0335
m36
2 c2 8LU
6 c12
TDC P1361
P1362
3
GRN
7 cr3 RED
CYP P1381
P1382
c4 YEL
cl 4 BLK
-
Th. MIL hs. b..n roportld on.
-
DTC P0335, P0336, Pl 361.
P1362, P1381 .nd/or P't382 ero
storod.
Problcm v.riticetion:
1. Do the ECM/PCM Reset Proce-
dure.
2. St an t he engi ne,
Intgrmittont failuro, systam is OK
et this time. Chock for Door con-
ldbtributo.l and ECM,/PCM.
b DTC m35, P0336. P1361, P1362.
P1381 and/or P1382 indicated?
Chock t or an open i n t h. CKP/
TDC/CYP ..nror:
2. Disconnect the distributor 10P
connect or.
3. Measure resi st ance bet ween
th lerminals of the indicated
sensor
(rsee
t abl e).
R.pt.ce the di.tributor ignition
ho6in9 (3Ge
soction 23).
ls there 350
-
700 O?
CYPM {BLK)
-
v
( Fr om page 11- 110)
DISTRIEUTOR
10P CONNECTOR tcl20l
Termi nal si de of
mal e t ermi nal s
ECM/PCM CONNECTORS C {31P|
CKP P TDC P CYP P
{BLUI I GRN}
(YELI
Wi re si d6 of
TDC P
cYP P
CKP P
I BLUI
TDC P IGRNI
TDC
\,
T
M
Chock t or e 3hort i n t he CKP/
TDC/CYP 3en3or:
Check f or cont i nui t y t o body
ground on bot h t ermi nal s of t he
i ndi cat ed sensor i ndi vi dual l y
(' see
t abl e).
Repl ace t he di st r i but or i gni t i on
housing
(see
section 231.
Check l oJ an opgn i n t h6 wi re3
ICKP/TDC/CYP
linesl:
1. Reconnect t he di st ri but or 10P
connecror,
nect or C
(31P).
3. Measure resi st ance bet ween
t he t ermi nal s of t he i ndi cat ed
sensor on t he ECM/ PCM con
nect or
(' see
t abl e).
Repai. open in the indicated sen-
sor wiles
('see
tabl).
l s t here 350
-
700 0?
Chock t or a 3hort i n t he wi res
{CKP/TDC/CYP linosll
body ground and EcM/ PcM con-
nector terminals C2, C3 and/or C4
i ndi vi dual l y.
Ropair short in tho indicated 3on-
sor wiros
('see
tablel.
Subitituto a known-good ECM/
PCM, and recheck. lt 3ymptom/
indicdtion go6s away, repleco the
origin!l ECM/PCM,
{WHT)
11- 111
PGM-Fl System
(VSSI
LP@
(DTC)
P0500: A mal functj on probl em
i n the Vehi cl e SDeed
Sensor
(VSS)
ci rcui t l except Ay' T
(D16Y7,
D16Y8 engi ne)].
The scan tool i ndi cates Di agnosti c Troubl e Code (DTC)
P0501: A range/performance probl em
i n the Vehi cl e
SpeedSensor (VSS)
ci rcui t
l A/T
(D16Y7,
D16Y8 engi ne)1.
ECM/PCM CONNECTORS
A l32P)
lcl
VSS
{BLU/WHTI
Wire side ot fma16 tgrminals
LGl
The MIL has boon reDorted on.
DTC P0500 or P0501 is stored.
Problem verificationi
1. Test - dr i ve t he vehi cl e.
2. Check t he vehi cl e speed wi t h
t he scan t ool ,
Intermittent f.ilure, 3ystem is OK
at this time. Check tor Door con-
nections or loose wircs at C117
(VSS)
and ECM/PCM.
l s t he correct speed i ndi cat ed?
Check I or an open i n t he ECM/
PCM:
r. r urn I ne rgnrt | on swrt ch ut -t -.
2. El ock t he rear wheel s and set
t he parki ng
brake.
3. Jack up the front ot the vehicle
and si r ppor t i t wi t h saf et y
st ands.
(l l ).
5. Block the right front wheel and
sl owl y r ot at e t he l ef t t r ont
ECM/ PCM connect or t er mi
nal s C18 and A9.
PCM and recheck. lf symptom/
indication
90e3
.way, replace tho
original ECM/PCM.
Does t he vol t age pul se
0 V
and 5 V?
Check f or a short i n t he ECM/
PCM:
' 1.
2. Di sco n n ect t he ECM/ PCM
connect or C
(31P).
(l l ).
4. Bl ock t he r i ght f r ont wheel
and slowly rotate the left lront
ECM/PCM connector terminals
C18 and A9.
PCM and rech6ck. l f sympt om/
i ndi cat i on
9o6s
away, repl sco
Does t he vol t age pul se
0 V
and 5 V?
IBRN/BLKI
1 I ! 9 t 0 l l
12 l 3 t 5 15 t 3 t 9 20 2a 2a
E 27 2A 4 30
c t3l Pt
I I t r o
1t 12 13 t a t 5 16 t t I E
(BRN/BLKI
6 I 9 t 0 t t
12 t t t 6
'It
! t m 22 2a 21
E 27 2t 22 30
3 5 6 a 9 l 0
t 1 1Z l 3 t a | l 5 ] t 6 i 1 7 t a
vss
(Bt
u/wHTl
NO
-
Bepai r 3hor t i n t he wi r e
betwen ECM/PGM lC18) and
vss, TcM.
-
between ECM/PCM {C181 and
vss.
-
l f wi i e i s OK. rest t he VSS
{see
pag 23-120).
11- 112
Barometric Pressure
(Barol
Sensor
(DTC)
P1 106: A range/performance probl em i n the Barometri c
Pressure
(Baro)
Sensor ci rcui t.
I
Th6 MIL has been rooortod on.
DTC P1106 b.tor.d.
1. Do t he ECM/ PCM reset proce-
dure,
load
(A/T
in
E
or
E
position,
M/T in neutral) until the radia-
i dl e.
3. Connect t he SCS Servi ce con-
nefior.
4. Test -dri ve wi t h t he A/ T i n
E
posi t i on (M/ T
i n 4t h gear).
5. Accel erat e f or l i ve seconds
usi ng wi de open t hrot t l e.
lntermitteni tailuro. system is OK
st this timo.
Subslitute a known-good ECM/
PCM end recheck. ll symptom/
i ndi cat i on goss away. . cpl aco
(cont' d)
11- 113
PGM-FI System
Barometric Pressure
{Barol
Sensor
(cont'd}
l Ti l Oi l
Th"""untool i ndi cates Di ag nosti c Troubl e Code
(DTC)
Pl 107: Al owvol tage probl em i n the Baro sensor ci rcui t.
l P, i l OCl
The scan t ool i ndi cat es Di agnost i c Tr oubl e Code
( DTC)
P1108: A hi gh vol t age pr obl em i n t he Bar o sensor
-
crrcutl .
-
-
DTC Pl 107 or Pl 108 i s 3t ored.
1. Do t he ECM/ PCM Reset Pro
Intermittent tailure, 3ystem is OK
at this time.
l s DTC P1' 107 or P1108 i ndi cat ed?
Substitute e known-good ECM/
PCM and r 6check. l f sympt om/
i ndi cat i on gos away, r epl ace
11- 114
)
Electrical Load Detector
(ELDI
(DTC)
Pl 297; A l ow vol tage probl em i n the El ectri cal Load
Detector
(ELD)
ci rcui t.
EID 3P CONNESTOR {qtsill
Wi re si de of l emal e t ermi nal s
f t ,
L l l 2 l 3 l
-T
O)
Y
)
IGRN/RED}
ECM/FCM CONNECTOR D
(16PI
Wire side of temale terminals
t
(cont' d)
1 1 - 1 1 5
-
DTC P1297 is slored.
Problem verificationi
cedure,
3. Turn on headl i ght s.
Intermittent feilure, svdam k OK
at this time. Chck to. poor con-
noctions or looso wir.s at C131
{located under right 3id ot dashl.
Cil54 {ELD} and ECM/PCM.
Check f or an opn i n t he wi re
{l Gl l i nel :
1. Tur n t he i gni t ; on and head
l i ght s OFF.
2. Di sconnect t he ELD 3P con-
nector,
(l l ).
4. Measure voltage between body
ground and the ELD 3P connec'
t or t ermi nal No. 1.
No. 15 ALTERNATOR SP SENSOR
17. 5 Al t use i n t hc undor-dash
tuse/relay box and ELD.
Check tor short in the ELO:
Measure vol t age bet ween body
ground and t he ELO 3P connect or
t er mi nal No. 3-
l s t here approx. 4. 5 V2
Check tor a short in the wi.e
(EL
l i nel :
2. Di sconnect t he ECM/ PCM con-
nect or D
(16P).
3. Check {or cont i nui t y bet ween
body gr ound and ECM/ PCM
connect or t ermi nal D16.
Repair short in the wire betwcon
ECM/PCM {D161 and ELO.
Subst i t ut e r known-good ECM/
PCM and recheck. Ifsyrnptom/
i ndi cat i on goes away. ropl ace
PGM-FI System
Electrical Load Detector
(ELDI
{cont'd)
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P1298: A hi gh vol tage probl em i n the El ectri cal Load
Detector
(ELD)
ci rcui t.
ELD 3P CONNECTOF lc3sil,
EL
{GRN/REO)
YES
Chack for an opon in ihe wi.e
(EL
line):
Check tor continuity between the
ELD 3P connect or t ermi nal No. 3
and ECM/ PCM connect or t ermi
nal D16.
Wi re si de ol f emal e t ermi nal s
Wi re si de of t emal e t ermi nal s
1 1 - 1 1 6
L
1. Do t he ECM/ PCM Reset Pro
cedure.
3. Turn on headl i ght s.
Intermittent failuro, 3y3tem is OK
at thb time. Check lor ooor con-
nection3 o. loose wire3 at C131
(locrted
undcr right side of dashl,
C354lEtDl and ECM/PCM.
Check l or rn open i n t he wi re
(GND
l i nel l
1. Turn t he i gni t i on swi t ch and
headl i ght s OFF.
2. Di sconnect t he ELD 3P con,
necror,
3. Check l or cont i nui t y bet ween
body ground
and t he ELD 3P
connect or t ermi nal No, 2,
nepair opcn in the wirc between
El-D connector and G4l)2.
Repair open in lhe wire betwon
ECM/ PCM {D16) and t he ELO.
Chcck for a mal functi on i n tho
ELD:
1. Rec onnec t t he ELD 3P c on-
2. St ar t t he engi ne and al l ow i t
t o i dl e.
3 . Wh i l e me a s u r i n g v o l t a g e
bet ween ECM/ PCM connect or
t er mi nal s D' 16 and A9, t ur n
t he headl i ght s on
( l ow) .
Does t he vol t age dr op?
Subst i t ut e a known-good ECM/
PCM and rch6ck. lf symptom/
i ndi cat i on goes
away, repl aco
ECM/PCM CONNECTORS
{
a
Crankshaft Speed Fluctuation
(CKFI
Sensor
tPtg36-l
tP-s37
(DTC)
P1336: Intermi ttent i nterrupti on i n the Crankshaft SDeeo
Fl uctuati on (CKF)
sensor ci rcui t.
(DTC)
P1337: No si gnal i n the Crankshaft Speed Fl uctuati on (CKF)
sensor ci rcui t,
Description
The di agnosti c system has a pul ser rotor on the crankshaft and a pul se pi ck-up
sensor on the engi ne bl ock. The ECM/PCM
moni tors the crankshaft speed fl uctuati on based on the CKF sensor si gnal , and
j udges
that an engi ne mi sfi re occurred i f
the fl uctuati on goes beyond a
predetermi ned
l i mi t,
T
CKF SENSOR 3P CONNECTOR
f'
----i
l
iffil
1 1 l 2 1 3 l
cxr rrr
f--fc*r
"
lwHrl
L,,dJ
|BLU)
g/
Termi nal si de of mal e t ermanal s
l - - l
I-T--
-1
l l l
2 3 l l
. t X
Y Y
I I
CKF M
{WHT)
CKF P
(8t_ul
{cont ' d)
11- 117
-
The MIL ha3 ten reDortod on.
-
DTC P1336 and/ or P1337 are
ltored.
P.oblem velitication:
dure.
Intermittont failure, system i3 OK
at this time. Chack for poor
con-
nections or loose wires ai C102
(CKF
sensorl and ECM/PCM, and
mak6 sure CKF sensor mounting
bolt is tigt|t.
Check lor an open in the CKF sen-
301:
2. Di sconnect t he CKF sensor 3P
connector,
3. M easu r e t he r esi st ance
bet ween t he CKF sensor 3P
connect or t ermi nal s No. 1 and
No. 3.
l s t here 1. 6 3. 2 kO?
Check fo. a rhort in tho CXF son-
3(' t:
Check f or cont i nui t y bet wen
body ground
and t he CKF sensor
3P connect or t ermi nal s No. 1 and
No. 3 i ndavi dual l y-
( To page 11' l 18)
PGM-FI System
{ Fr om
page 11- 117}
Chcck for an op.n in the wires
(CKF
l i nes):
1. Reconnect t he CKF sensor 3P
nect or C
(31P).
3, Measure resi st ance bet ween
ECM/ PCM connect or i er mi -
nal s C1 and C11.
Repeir open in tho wire between
ECM/ PCM
(C1,
Cl ' l l end t he CKF
sensol.
l s t here 1. 6
-
3. 2 k0?
Chck t or a short i n t he wi re
I CKF l i n6):
body
ground and ECM/ PCM con-
Ropair short in the wire between
ECM/PCM lcl) and the CKF sen-
PCM, end rechck. lf 3ymptom/
indicrtion
90e3
away, replaco lhe
origin.l ECM/PCM.
Grankshaft Speed Fluctuation
(CKFI
Sensor
(cont'dl
ECM/PCM CONNECTOR C {31PI
CKF P
(BLU/REDI
IWHT/RED}
t ermi nal s
CKF P
(BLU/ REDI
\.
IT
a 6 1 8 I 10
1 2 13 14 15 l 6 17
' 18
23 21 25 21 2a z) 30
CKF M
1 1 - 1 1 8
\4
I
Crankshaft Position/Top Dead Center/Cylinder Position
(CKP/TDC/CYP)
Sensor
TD; aEol
(DTC)
P' 1359: A probl em i n the Crankshaft Posi ti on/Top Dead
Ll =!g
Center/Cvl i nder Posi ti on {CKP/TDC/CYP) sensor ci rcui t.
I
)
The MIL ha3 been roportad on.
2. St an t he engi ne. l f t heengi ne
won' t st art , Crank i t f or at l east
10 seconds,
Intermittem tailure, system is OK.
Ch6ck f or Door connect i on3 or
loose wires at C120 {distributorl
.nd ECM/PCM.
Check f or poor connect i ons or
loose wires between the distribu-
tor and the EcM/PcM_
PCM, and recheck. lf symptom/
i ndi cat i on go6s awaV, r gpl ace
ths original ECM/PCM.
1 1 - 1 1 9
PGM-FI System
ECM/PCM Internal Ci rcui t
I
P1607 The scan tool
j ndi cates
(DTC)
P1607: An ECM/PCM Internal Ci rcui t Probl em.
-
-
1. Do t he ECM/ PCM Reset Pro'
cedure,
(l l ).
3. Wai t 10 seconds.
PCM and recheck. l f syrnpt om/
indication goes away, replace the
ori gi nal ECM/ PCM.
1-120
v
l/
A/T Si gnal
(TMA/TMB)
{D16Y5 engi ne
(CVT))
ECM CONNECTOR C {31P)
I
fcu22P
CONNECTOR
fcu 22P
CONNECTOR
TMA
IGRY}
TMBT
{ PNK)
I
P1655
i The
scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
Pl 631: TMMMB si gnal l i ne fai ture.
Problom verilication:
2. Dri ve t he vehi cl e f or several
mi l es at varyi ng speeds.
Intermittent failure, syslm is OK
at this timo. Chock for Door con-
(located
under right side of dash),
C4:t8 {TCMI ,nd ECM.
Ch6ck t or an open i n t he wi re
{TMA linol:
{31P) f rom t he ECM.
(l l ).
ECM connect or t er mi nal Cg
and body ground.
Chcck l or a short i n t he wi re
ITMA line):
Measure vol t age bet ween TCM
22P connect or t ermi nal No. 7 and
body
ground.
ls there battery voltage?
RoDair short in the wire between
lhe ECM {C9l and th6 TCM.
Chock t or rn open i n t ho wi r
(TMB
line):
2. Reconnect ECM connect or C
( 31P) .
3. Disconnect the 22P connector
f rom TCM.
4. Turn t ho i gni t i on swi t ch ON
(l l ).
5, M easu r e vol t age bet ween
TCM 22P connect or t ermi nal
No. 6 and body ground.
the ECM lcg, and the TCM.
Check f o. a 3hor t i n t he wi r e
{TMB line}:
connoct or t ermi nal C30 and body
grouno.
Subst i t ut e r known-good ECM
and rccheck. lt 3ymptom/indica-
tion goe3
away, roplace lhe origi-
nal ECM.
Repair short in the wire between
the EcM lc30) and the TcM.
Reprir open in the wi.e bstwen
rhe EcM {c30) and rhe TcM.
Wi re si de ot t emal e
t ermrnat s
{ 6 1
8 I 10
11 12 13 l 4 1 5 16 1 7 l 8
23 21 25 29 30
t ermi nal s
11- 121
ldle Control System
System Description
The i dl e speed of the engi ne i s control l ed by the l dl e Ai r Control
(l AC)
Val ve.
The val ve changes the amount of ai r bypassi ng i nto the i ntake mani fol d i n response to el ectri c current control l ed by the
ECM/PCM. When the IAC Val ve i s acti vated, l he val ve opens to mai ntai n the proper i dl e speed.
VARIOUS
SENSOnS
IROTARY}
IAC VALVE
EIVGINE
COOLANT
INTAKE MANIFOLD
D16Y5
(CVTI,
D15Y8 engi ne
(A/T):
D16Y7 engi ne:
;[i- <l;litf,U''j
vARtous
SENSORS
D16Ys, D16Y8 ensine
(M/T):
,
,
:::/
__ _<
*f,T.ir;tJ
I
T
BLK
T
MAINRELAY
-
-
r )
aLk
11- 122
a
1 . After the engi ne starts, the IAC val ve opens for a certai n ti me, The amount of ai r i s i ncreased to rai se the i dl e speed
about 150
-
300 rpm.
When the cool ant temperature i s l ow, the IAC val ve i s opened to obtai n the proper tast i dl e speed. The amount of
bypassed ai r i s thus control l ed i n rel ati on to the engi ne cool ant temperature.
IOLE SPEED
lrpml
176
80
Et{Gt1{E
COOLANT TEMPERATURE
( oF)
t oc)
L
1 . When the i dl e speed i s out of speci fi cati on and the scan tool does not i ndi cate Di agnosti c Troubl e Code {DTC} P0505
or P1508, check the fol l owi ng i tems:
.
Adj ust t he i dl e speed
( see page 11, 141)
.
St ar t er swi t ch si gnal
( seepagel l - 130I
.
Ai r condi t i oni ng si gnal
( see page 11- 131)
.
ALT FR si gnal
(see page 11 133)
'
Brake swi tch si gnal {see
page 1' l -134)
'
PSP swi tch si gnal
(except
Canada model )
(see page 11-135)
.
A/T gear posi ti on si gnal
(see
secti on
' 14,
D16Y5 engi ne
(CVT):
page 1l - 137)
.
Cl utch swi tch si gnal
(D16Y5
engi ne
(M/T)) (see page 11-139)
.
Hoses and connecti ons
.
IAC val ve and i ts mounti ng O-ri ngs
l f the above i tems are normal . substi tute a known-good IAC val ve and readj ust the i dl e speed
(see page 11-141).
l f the i dl e speed sti l l cannot be adl usted to speci fi cati on
(and
the scan tool does not i ndi cate DTC P0505 or P1508)
after IAC val ve repl acement, substi l ute a known-good ECM/PCM and recheck. l f symptom goes away, repl ace the
ori gi nal ECM/PCM.
11- 123
ldle Control System
ldle Control System
l T05O5l
Th" """n toot i ndi cates Di agnosti c Troubl e Code {DTC) P0505: l dl e control system mal functi on.
NOTE: l f DTC P1508 or P1509 i s stored at the same ti me as DTC P0505, troubl eshoot DTC P1508 or P1509 fi rst, then trou-
bl eshoot DTC P0505.
Possible cause
. IAC val ve mechani cal mal functi on
. Throttl e body ci ogged
port, i mproper adi ustment
r l ntake mani fol d gasket i eakage
. Intake ai r hose l oose l eakage
. Vacuum l eak
. ECT sensor i ncorrect output
. Throttl e Posi ti on sensor i ncorrect output*1
Tloubleshooting Flowchart
-
Th6 MIL has been reoortod on.
-
Problsm vorificationl
load 1A,/T in
E or E
position,
M/ T i n neut ral i unt i l t he radi at or
*1 fan comes on, then let it idle.
t2.
-Wi*i
tne scan toot, checL tt e-l
-
Throt t l e
posi l i on
shoul d be
approx. 10% with the throt'
tle {ully closed.
-
Engi ne cool ant t emper a-
t ure shoul d be 194
-
205' F
(90 -
96' C).
l f t hey are not wi t hi n t he
spec. , repai r t he f aul t y sen-
L
sol 9! ! 9' l l j : -. -. -. -
- l
3. Check t he engi ne speed at
i dl e wi t h no-l oad condi t i ons:
headl i ght s, bl ower f an, r ear
def ogger, radi at or f an, and ai r
condi t i oner are not operat i ng
(see page 11 139).
Intermittnt failure, system is OK
et this time.
l s t he i dl e speed OK?
ls it 550 rpm or less?
(To page 11-125)
* 1: ' 96
model onl y
11- 124
{ To
page 11- 125)
{From
page 11-124}
Check thc IAC vrlvo:
Disconnect the 3P connector trom
the IAC valve.
Chcck th. IAC valve:
Di sconnect t he 2P connect or
from the IAC valvo.
Does t he engi ne speed drop or
t he engi ne st al l ?
Adi6t thc lbasll idle 3pa6d ls6c
p. 9 11-1391. l l i t ' . i mpo$i bl e,
cl6an th ports in tha throttle
body.
(A,/T
and D16Y7 engine)
I
{Dl6Y5, D'|6Y8 engin with M/T)
' - - - - - - - t
_ l
Dl6Y5, Dl6Y8 ongin:
Dl6Y7 engine:
UPPER
l From
page I 1-124)
Put your f i nger on t he upper port
in the throttle body.
Chack f or vacuum l aakr. make
3u. c t h. t hroi t l a val vc i s com-
plctaly
closrd, .nd ropair I nec-
ca3ary.
Does l he engi n speed drop?
Adiust tho idlo sp..d
(3e pag.
11-139). It it'5 impo$iblo, r.placo
tha IAC Yalve.
11- 125
ldle Gontrol System
ldle Air Control
(lACl
Valve
(Dl6Y5,
Dl6Y8 engine with M/T)
The scan toot i ndi cates Di agnosti c Troubl e Code
(DTC)
P1508: A probl em i n the l dl e Ai r Control
(l AC)
val ve
crrcurt.
The I AC Val ve changes t he amount of ai r bypassi ng t he t hrot t l e body i n response t o a current si gnal f rom t he ECM i n
order t o mai nt ai n t he
proper i dl e speed.
IAC VALVE 2P CONNECTOR ICl38}
/T\
rcpr
t
'--'J
rYCLrBtXl
\ 2 J -
s
r$,
Y
=
Wi re si d6 ot f emal e t ermi nal s
tAcv
IBLK/
BLUI
ECM CONNECTOR A I32PI
vat_vE
I 3 5 6 ! 1 9 t o
12 l 3 15 i 6
't,
t l t 9 ao 2a 2a
$
l zsVl ztl l z.l zel nl /l |
.,'
-
The MIL has b6n reDortgd on.
-
DTC P150a is stor.d.
Problom vorification:
cedure.
2. St art t he engi ne, and warm i t
up t o normal operat i ng t em-
perat ure.
lntc.mittent tailure, svslem i5 OK
et thb time. Check for
poor
con-
noction3 or 10036 wirg3 st C138
llAC v.lvel .nd ECM.
Check t o. . n open i n t ho wi . o
l l GPl l i n6l :
2. Di sconnect t he I AC val ve 2P
connector,
(l l ).
4. Measure voltage between body
ground and t he I AC val vo 2P
connectorterminal No. 2.
Reprir opsn in the wiro bstwcen
IAC valvo and PGM-FI main rcltY.
Chack lor rn open o. short in the
wirc {lACv linel:
1. Turn t he i gni t i on swi t ch OFF
and reconnect t he I AC val ve
connecror,
2. Disconnect the ECM connector
A
(32P).
3. Turn the ignilion switch ON lll).
body gr ound and ECM con-
nect or t ermi nal A12.
( To page 11- 127)
11- 126
(From page 11-126)
Ropair open or short in the wiro
b. t wen ECM l A12l and I AC ls ther battery voltage?
Check the IAC valve lunction:
Moment ari l y connect ECM con-
nect or t er mi nal s A12 and A' 10
wi t h a i umoer wi re several t i mes,
Does t he I AC val ve cl i ckT
Subst i t ut e . known-good ECM
and rocheck. lt 3ymptom/indica-
tion
906
away, .oplaco tho origi-
n.l ECM.
Wire side of female trrhinals
11- 127
ldle Gontrol System
l dl e Ai r Control
(l ACl
Val ve
(A/T
and Dl 6Y7 engi ne)
l Ti 509l
Th""""ntool i ndi cates Di agnostj c Troubl e Code
(DTC)
P1509:Aprobl em i nthe i dl eAi rControl
(l AC)
val ve ci rcui t.
The
(Rotary)
IAC Val ve changes the amount ot ai r bypassi ng the throttl e body i n response l o a current si gnal trom the
ECM/ PCM i n order t o mai nt ai n t he proper i dl e speed.
BIMElAL
v
Problom verification:
dure,
(l l ). SHAFT VALVE STOP?ER
ECM/PCM CONNECTOR A I32P}
IAC VALVE 3P CONNECTOB
IACV N IACV P
PGl
(BIK}
\3
tAcv N {oRNt.
(To page 11 129)
IGP
Termi nal si de of mal e
I ermt nal s
*:
I ACV N l i ne
11- 128
The MIL has been reooned on.
DTC Pl 5'lx) is sto.ed.
Intermittent failuro, svstem ia OK
at lhis time. Check for poor
con-
nections or 10036 wires at C109
{lAC valve) end ECM/PCM.
l s DTC P1509 i odi cat ed?
Check f or an open i n t he wi res
I PG l i n6):
Measure vol t age bet ween body
ground and ECM/ PCM connect or
t ermi nal s A10 and A23 i ndi vi du
Repair op6n in lhe wires between
ECM/ PCM and G101 { l ocat 6d ar
the thermostat housing.l
Check the ECM/PCM inpul volt-
age:
2. Di sconnect ECM/ PCM connec-
tor A
(32P)
from the ECM/PCM-
(l l ).
4. Measur e vol t ag e bet ween
A13+ i ndi vi dual l y.
l s t here baf t ery vohage?
Check the IAC valve:
1. Tur n t he i gni t i on swi t ch OFF.
connect or .
3. Measur e r esi st ance bet ween
I AC val ve 3P connect or t er mi '
nal No. 2 and t er mi nal s No. 1
and 3 i ndi vi dual l y.
l s t here 16- 28 O?
Substiluto a known-good ECM/
PCM and rocheck. l f sympt om/
i ndi cal i on goes away, repl ace
Wire sid ol temale terminals
2 I 8 10 1' l
1 2 l 1 31a 15 16 1 7 t 8 t9 m 22 23 2a
. l
O)
27 28 29 3o
IACV P IBLK/BLU}
{ Fr om
page 1l - 128}
' :
I ACV N l i ne
Check t or an open i n t he wi re
(l GP
l i ne):
connector.
(l l ).
4. At t he wi re harness, measure
voltage between IAC valve 3P
connect or t ermi nal No. 2 and
body ground.
l h6 I AC val vo and PGM-FI mai n
relav.
l s t here bat t ery vohage?
Check f or an open i n t ho wi res
(IACV
P, IACV N' lines):
nector A
(32P).
I AC val ve 3P connect or t ermi
nal No. 3 and ECM/ PCM con'
n e c t o r t e r mi n a l A1 4
( a n d
between IAC valve 3P connec-
t or t ermi nal No. 1 and ECM/
PCM connect or t ermi nal A13)*.
Repair opn in tho wire bctwoen
the IAC v.lve end ECM or PCM
(A14,
A13*1.
Check t or a shor t i n t h wi r es
(IACV
P, IACV Nr linesl:
Chec k t or c ont i nui t y bet ween
body gr ound and ECM/ PCM con'
nec t or t er mi nal s A14 and 413*
i ndi vi dual l y.
tho IAC valve and ECM/PCM 1A14.
A13*).
Sub3titute a known-good ECM/
PCM and reched( lf syrYFtom/indi-
cation goes away, replac th6 o.igi-
n.l ECM/PCM.
IAC VALVE 3P CONNECTOR {CIOI}
IGP {YEL/BLKI
tacv N toRNl.
IACV N
t32Pl
toRNl * IACV P
IBLK/BLUI
ECM/PCM
CONNECTOR A
IACV P
(BLK/BLU)
' t 2
3
I 7 E 9 l o t t
12 l 3 1a t 5 l 6 1 7 t a t 9 2A u 2a
25 21 2a 29 30
I 3 a 6 a 9 t 0 t l
t 2 t 3 l i l t 5 t 6 1 7 l a t 9 20 24
Lry,"*"YYO
l ,
11- 129
ldle Control System
Starter Switch Signal
Thi s si gnal s the ECM/PCM when rhe engi ne i s cranki ng.
NOTE:
. A/T: Transmi ssi on i n
E]
or
@
posni on.
. M/ T: i n neut r al
A I:PPI LGl
c t3l Pt
Wire side ot female terminsls
v
Chock for an open or ihort in the
wire {STS linol:
PCM connector terminals Ag and
C6 with the ignition switch in the
st art
(l l l ) posi t i on.
Inspect tho No. 31 STARTER StG,
NAL {7.5 A) fuse in the undeFdash
Iuse/relay box.
-
Rapl i r r hon i n t hc wi r o
b. t w. . n t he ECM l C6) and
tho No. 31 STARTER SIGNAL
(t . 5
Al l u3. or t h. PGM-FI
main relsy.
-
ReDhco tho No, 31 STARIR
SIGNAL 17.5 A1tu3..
St.rior switch sign.l b OK.
Rapair open in tha wire batwatan
tho ECM/PCM lC6|and th. No.31
STARTER SIGNAL 17.5 Al tu!..
ECM/PCM CONNECTORS
sTs tELu/oFNt
I 3 7 E 9
't0
1'| 3 a 5 7 t 9 t 0
t 2 l 3 t 4 15 16 t 7 t a r 9 20 22 23 2a t t 12 r3 t a t 5 t 6 1 l
't8
25 27 ut 29 30
2a 2a E 29 30
1 1 - 1 3 0
\,
Ai r Condi ti oni ng Si gnal
Thi s si gnal s the ECM/PCM when there i s a demand for cool i ng trom the ai r condi ti oni ng system.
ECM/PCM CONNECTORS
A l32Pl
c t3l Pl
ACS {BLU/RED}
JUMPER wlRE
{cont' d)
- 1 3 1
LGl IBRN/BLK} ACS IBLU/REDI
2 I 8 9 l 0 I t I 2 a 5 1 E 9 10
12 13 t a
't5 't6
17 t 8 19 a) 22 23 2a
't'l
12 t 3 1l t 5 t 5 17 t 8
25 27 2a xt 30 23 2a 2a z, 30
Check l or a ahort i n t h6 wi r
{ACS linel:
2. Di sconnect t he A/ C pressure
switch 2P connector
(see
sec-
t i on 22) .
(ll).
ECM/ PCN4 connect or t er mi -
nal s C5 and A9.
Chock fo. a short in the wire IACS
linol:
nect or C
(31P).
body
ground
and ECM/ PCM
connect or t ermi nal C5,
Repair short in the wire botwsn
the ECM/PCM
(Csl
.nd the A/C
pro3sura switch.
-
Subst i t ut e a known-good
ECM/PCM and rchock, lf pro-
acribgd vohago i3 now aveil-
.ble, replace the original ECM/
PCM.
-
See the sir condhione. inspc-
tion l.oc s.ction 22).
Chock t or an open i n t he wi re
IACC lin.l:
2, Reconnect t he A/ C pressure
switch 2P connector.
3. Turn the ignilion switch ON
(ll).
4. Momdnt an' l y connect ECM/
PCM connect br t ermi nal s A9
and A17 wi t h a
i umper
wi re
several t i mes.
(To page 11-132)
LGT IBRN/BLKI
- r l
1 2 3 a ; l s l r I
l s l s l ! o
l
r r l
12 l 3 t a 15 16 1
l nl tsl i l /1zzl
ze
I
z+
|
25 27
w-z-
ACC
IBLK/REDI
1 1
ldle Control System
Ai r Condi ti oni ng Si gnal
(cont' dl
( Fr om page
11- 131)
JUMPER
WIRE
UNDER.XOOD FUSE/RELAY
BOX 9P CONNECTOB tc3s2t
t 2 3 a
5 6
/ 8
9
ACC IBLK/RI
Wire side ot
t ef mr nal S
IBLK/REOI
si de ot femal e
ECM/PCM CONNECTORS
A
(32Pt
LGT
c
(31Pt
Check f or an open i n t he wi r
{ACC line):
Moment ari l y connect under-hood
f use/ rel ay box 9P connect or t er
mi nal No. 5 t o body ground
wi t h
a
j umper
wi re several t i mes.
l s t here a cl i cki ng noi se l rom
the A,/C compressor clutch?
l s t here a cl i cki ng noi se f rom
t he A/ C compressor cl ut ch?
See ai r condi t i oner i nspect i on
lsee section 22).
i h. ECM/ PCM
l A17) and t h6
under-hood t u3e/ rel ay box 9P
connector {C3521.
Check t or t he operat i on of t he
A/C:
2. Turn t he bl ower swi t ch ON.
3. Turn the A"/C switch ON.
{ACS lin6):
PCM connect or t ermi nal s Ag and
Air conditioning sign.l is OK.
Rprir open in tha wire bstween
the ECM/PCM
lcsl .nd th. A/C
swhch.
l s t here l esst han 1. 0 V?
-
Su b s t i l u t a . k n o wn - g o o d
ECM/ PCM and r echock. l I
sympt om/ i ndi cat i on goes
away, r epl ace t ho or i gi nal
ECM,/PCM,
-
See the air conditioner inspec-
tion
(see
section 22).
(BRN/ALKI
ACS IBLU/REDI
I 6 7 8 9 l 0 t l I
8 I
'to
12 13 t a t 5 t 6 17 I E 19 zo 22 23 2a t t 12 t 4 lf, 17
't8
25 27 E 30
2a 2a 29 30
Wi re si de oI f emal e t ermi nal s
11- 132
I
Alternator
(ALT)
FR Signal
Thi s si gnal s the ECM/PCM when the Al ternator
(ALT)
i s chargi ng.
A t 32Pl
LG1
(BRN/ BLKI
ECM/PCM CONNECTORS
Wi re si de ot t emal e t ermi nal s
c t31Pl
3Pr
2 3
ALT F
{WHT/BEO)
/FED)
4P
ALT CONNECTORS lcloirl
JUMPER
JUMPER
WIRE
WIRE
-+r
1 1 2
|
ffi
l 3 l l l
rr-r r
-lr
rwHr/
(V)
REot
Y
ALT F
(WHT/RED'
Wire side of female terminals
I 2 3 a 5 6 l 7
|
8 9
' t0
1 1 12 13 l 4 15 l 6 r l r l /
,/
E
/
30
,/
23 21
0)
ALr F
(wHr
lnspection ot ALI FR Signal.
Ch6ck for a sho.t in the wire {ALT
F line):
1. Di sconnect t he 4P
(3P)*
con-
nector from the ALT.
(l l ).
3, Measu r e vol t age bet ween
ECM/ PCM connect or t er mi -
nal s C' | 7 and A9.
Check tor a short in the wire IALT
F linel:
2. Di sconnect t he negat i ve bat
tery cable from the battery.
nect or C
(31P).
4. Check l or cont i nui t y bet ween
body gr ound and ECM/ PCM
connect or t ermi nal C17.
l s t here approx- 5 V?
Check the operation ot the ALT:
' 1.
2. Reconnect t he ALT 4P
(3P)*
connect or t o t he ALT.
load {A,/T in
E
or
E
position,
i dl e.
4, Measu r e vol t age bet ween
Cl 7 and A9.
Repair shon in the wire between
the ECM/PCM {C17)end the ALT.
PCM and recheck. It prescribed
voltage is now available, replace
Does t he vol t age decr ease when
headl i ght s and r ear def ogger ar e ALT FR signal i3 OK.
Chec* lor an opeo in the wire IALT
F lin):
2. Di sconnect t he 4P
(3P)*
con
nector from the ALT.
(l l ).
ALT 4P {3P}* connect or t ermi
n a l No . 4
( No .
1 ) * a n d b o d y
ground.
Repai r open wi re bet ween t he
ECM/ PCM {Cl 7) . nd t he ALT.
l s t here approx- 5 V?
' : Canada
model
1 1 - 1 3 3
ldle Control System
Brake Switch Signal
Thi s si gnal s rne ECM/PCM when the brake
pedal
i s depressed.
D tl 6Pl
Wir sid6 of lemale terminals
BKSW
IGRN/
WHT}
Inspcction ol &ak Swhch Signal.
Are t he brake l i ght s on wi t hout
depressing the brake pedal?
I nspect t he HORN (' 15
A) f u6e i n
the under hood tuse/ relay box.
Do t he brake l i ght s come on?
-
ngpai f shor l i n t he wi r e
betwoen thc br.k6 3whch and
the HoRN l't5 A) tuse.
-
R.placo the HORN {7.5 Al tuse.
bgtw6cn the brrke iwitch and
thc HORN 115 Altuse.
Inspoci tho b.ake switch lsoe
Boction l9l.
Check l or an op. n i n t h wi ro
IEKSW lin6l:
1. Depress the brake pedal.
2. Measur e vol t age bet woen
ECM/PCN4 connector terminals
A9 and D5 with the brake pedal
depressed.
Rop.il open in the wi.6 botween
tha ECM/PCM lDs) rnd thc b.ako
lwitch,
8r.ke 3witch 3ignal ia OK.
ECM,/FCM CONNECTORS
A t32P)
taRnu
1 2
t
I 6 8 I 10 t l I 3 a 5
1 2 13 14
' t5
l 6 1' l 8 t9 20 22 23 21
6 8 I 10 1 1 12
25 27 2A a 30 13 t 4 15 16
11- 134
)
Power Steering Pressure
IPSP)
Switch Signal
(USAI
Thi s si gnal s the ECM/ PCM when the power steeri ng l oad i s hi gh.
ECM/PCM CONNECTORS
PSP SW]TCH 2P CONNECTOB
PSP SW tcBf{l
JUMPER
T-1
rJJ
w r F E
- 2 /
GND IBLKI
Wir sid6 of temale terminals
t
I
(cont' d)
- 135
lNpction of PSP 3witch rignal.
Ch.d( for .n op.n in the wi..
(PSP
SW lin.l:
1. Turn the ignition switch ON {ll}.
2. Measu16 vol t age bet ween
ECM/ PCM connect or t er m i '
nal sA9 and C] 6.
Chock for .n opn in lhe wire
(PSP
SW linol:
2. Di sconnect t he PSP swi t ch 2P
connecror,
3. Turn the ignition switch ON lll).
4. At t he harness si de, connect
t he PSP swi t ch 2P connect or
t e r mi n a l s No . 1 a n d No . 2
wi t h a
j umper
wi re.
Ag and C16.
-
Bepai r opon i n t he wi r e
betwocn th6 ECM/PCM lcl6l
and the PSP switch.
-
Ropei r open i n BLK wi r
btween the PSP 3wiich .nd
G101.
Ch6ck thc opo.ation ot th6 PSP
rwhch;
1. St an t he engi ne
2. Tur n sl eer i ng wheel t o I ul l
lock.
EC 4,/PCM connector terminals
Ag and C'|6.
ls there baftery voltage?
PSP .whch tignal i3 OK.
Wire side of femalo terminals
{ To
page 11- 136)
1 1
ldle Control System
Power Steeri ng Pressure
(PSPISwi tch
Si gnal
(USA) (cont' dl
(From page 11-135)
u
ECM/PCM CONNECTORS
\-
Check t or sho. t i n t h6 PSP
switch:
f rom t he PSP swi t ch.
(l l ).
4. M easu r e vol t age bet ween
ECM/ PCl vl connect or t er mi -
nal s A9 and C16.
Check for a shon in the wir6 {PSP
SW l i nel :
nect or C
(31P).
body gr ound
and ECM/ PCM
connect ort ermi nal C16.
Rep.ir short in th6 wire between
the ECM/PCM {C16) and rhe PSP
switch.
PCM and recheck. l f p. escri bed
voltage is now available, replace
1 1 6 7 8 9 10
1 t 12 13 14 15 1 6 1 7 18
23 21 25
E 30
o
PSP SW {GRN}
1 1 - 1 3 6
Automatic Transaxle
(CW)
Gear Position Signal
(D16Y5
engine)
Thi s si gnal s t he ECM when t he t r ansmi ssi on i s i n
E
or
E
posi t i on.
ECM CONNECTORS
)
I
ATP NP
{LT GRN)
I N P
GRNI
(cont' d)
-137
Wi re si de of I emal e t ermi nal s
I 5 7 8 9 10
1 1 12 13 1 a 1 5 16 1 7 18
23 21 29 30
o
ATP
ILT
I
Check the ope.ation of th A/T
gear position switch:
(l l ).
2. Observe the A"/T shift position
indicator and select each
posi
t ron separat el y.
See the A/T g6ar position indica-
tor inspection {see section 141.
Ch6ck for a short in ihe wir
(ATP
NP linel:
' 1.
f rom t he
gauge
assembl y.
3, Disconnect the 26P connector
l rom t he TCM.
(l l ).
5. Moasure voltage between ECl/l
connect or t er mi nal s A9 and
c29.
Check for a shon in the wire IATP
NP l i ne):
2. Di sconnect t he ECM connec'
t or C
( 31P) .
Check lor .n open in th wiro IATP
NP linel:
2. Reconnect t he l 4P connect or
t o t he gauge assembl y.
3. Reconnect t he 26P connect or
t o t he TCM.
ECM connect or t ermi nal s A9
and C29 wi t h t he t r ansmi s-
si on i n
E
and
E
posi t i on.
t he EcM { c29) and r he gau96
assemblv.
and recheck. l l prescri bad vol t -
ege is now available, replace the
ori gi nal ECM.
(To page 11-138)
1 1
ldle Control System
Automatic Transaxle
(CWl
Gear Position Signal
(D16Y5
engine)
(cont'd)
ATP NP
Wire side ol female torminals
ILT GRNI
( Fr om page
11- 137)
-
btween the ECM lc29l and
the gauga a!3ombly.
-
between the gaugo assembly
r nd t he A/ T gear posi t i on
switch.
l s t her e l ess t han 1. 0 V?
Check for a short in the wire IATP
NP l i nel :
connect or t ermi nal s A9 and C29
wi t h t he t ransmi ssi on i n gear.
ECM
(C291
and gauge assembly.
A/T gear po6ilion signel is OK.
1 1 - 1 3 8
Cl utch Swi tch Si gnal
(Dl 6Y5
engi ne
(M/Tl l
Thi s si gnal s the ECM when the cl utch i s engaged.
A t32Pl
Wi re si d6 of f emal e t ermi nal s
(REDI
ECM COITNECTORS
LGl IBRN/BLK}
cLsw
(REDI
{cont' d)
1 1 - 1 3 9
Inapction of clutch .witch signal.
Ch. ck f or rn opcn i n t he wi ro
(CI..SW
lin.l:
1. Turn t he i gni t i on swi t ch oN
(l l l .
A9.
Check th. clutch 3witch:
trom the clutch switch.
(ll).
4. Measure voltage btween ECM
A9.
Check l or a shorl i n t ha wi re
(CLSW
linel:
2. Di sconnect t he EcM connec-
t or C
(31P)f rom
t he ECM.
3. Check lor continuity between
ECM connect or t ermi nal C29
and body ground.
Chock t or an opcn i n t he wi ro
(CLSW
linel:
1. Depress t he cl ut ch
pedal .
2. Mossure voltage between ECM
connect or t ermi n6l s C29 and
A9.
Ropair short in the wiro botwe.n
t ho ECM {C29} rnd t ho cl ut ch
swhch.
Subi t i t ut e a known-good ECM
and rcch6ck. ll pGacribcd vohrge
h now availabla, replaco the otig-
inrl ECM.
1 5 7 8 9
't0
t t l 2 ! 3 1a l 5 t 6 l 7 1E u
a
{To
page 11-140}
ldle Control System
Clutch Switch Signal
(Dl6YS
engine
(M/Tl) (cont'dl
(From page 11, 139)
CLUTCH SWITCH 2P OONNECTOR
t ermi nal s
CLUTCH SWITCH 2P CONNCCTOF lcillTl
r-+-r
t l t 2 l
LJ_J
I
clsw
1;\
(REDI
Y
Wire side of female
t ermi nal s
Chock thg clutch switch:
Irom the clutch switch.
t he cl ut ch swi t ch connect or
t ermi nal s No. 1 and No. 2 wi t h
the clutch pedal depressed.
l s vol t age l ess t han
' 1. 0
V?
-
Adiu.t the clutch switch.
-
Ropleco the clutch .witch.
Check tor an opon in the wiro:
(l l ).
clutch switch connector termi-
nal No. 1 and body ground with
t he cl ut ch podal
depressed.
Rcpril opon in the wirc betwocn
t h6 EcM l c29) . nd t ha cl ut ch
switch.
ls there approx. 5 V?
R.prir open in BLK wira batwaon
th. clutch 3witch snd G/O1.
Outch 3witch signal i3 OK.
11- 140
ldle Speed Setting
Inspection/Adiustment
' 96,' 97
D16Y5,' 96-' 98 Dt6Y8 engi ne {M/T}
NOTE:
. Bef or e set t i ng t he i dl e speed, check t he f ol l owi ng
i tems:
-
The MIL has not been reponed on.
-
l gni ti on ti mi ng
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
o ( Canada)
Pul l t he par ki ng br ake l ever up. St an t he
engi ne. then check that the headl i ghts are off.
' 1.
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad {transmi ssi on
i n neutral ) unti l the radi ator
fan comes on, then l et i t i dl e.
Connect a tachometer.
Di sconnect the IAC val ve connector.
l f the engi ne stal l s, restart the engi ne wi th the accel -
erator pedal sl i ghtl y depressed. Stabi l i ze the rpm at
1,000, then sl owl y rel ease the pedal unti l the engi ne
i dl es.
Check i dl i ng i n no-l oad condi ti ons: headl i ghts, bl ower
fan, rear defogger, radi ator fan. and ai r condi ti oner
are not operating.
ldl 3pd should be:
il50
t 50 rpm
7.
Adj ust the i dl e speed, i f necessary, by removi ng the
cap and turni ng the i dl e adj usti ng screw.
NOTE: After adj usti ng the i dl e speed i n thi s step,
recheck the i gni ti on ti mi ng
(see
secti on 23).
l f i t i s out of spec, go back to step 4.
IDLE
Reconnect the 2P connector on the IAC val ve, then
do the ECM reset procedure.
Restart and i dl e the engi ne wi th no-l oad condi ti ons
for one mi nute, then check the i dl e speed.
NOTE:
( Canada)
Pul l t he par ki ng br ake l ever up.
Start the engi ne, then check that the headl i ghts are
off.
ldle speed should be:
670 t 50 rpm {USA}
750 t 50 rpm lcanadal
l dl e the engi ne for one mi nute wi th headl i ghts
(Low)
ON. and check the i dl e speed.
ldl8 spd should bo:
750 I 50 rpm
Tur n t he headl i ght s of t . l dl e t he engi ne f or one
minute with heater fan switch at Hl and air conditioner
on, then checkthe i dl e speed.
810 1 50 rpm
NOTE: l f the i dl e speed i s not wi thi n speci fi cati on,
see Symptom Chart on page 11-46.
(cont' d)
10.
11- 141
ldle Control System
ldle Speed Setting
(cont'd)
'96, '97
Dt6Y5 engino {CvT),
'96-'98
Dl6Y8 engine lA/T)
rnd
'96-'98
D16Y7 engine
Adj ust the i dl e speed usi ng a Honda PGM Tester i f pos-
si bl e. l f not, use the fol l owi ng procedure:
NOTE:
. Leave the IAC val ve connected.
. Bef o. e set t i ng t he i dl e speed, check t he f ol l owi ng
i tems:
-
The MIL has not been reported on.
-
l gni t i on t i mi ng
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
1 . Connect a tachometer.
no l oad
(A/T
i n
N
or
E
posi ti on,
M/T i n neutral )
unti l the radi ator fan comes on, then l et i t i dl e,
Check the i dl e speed wi th no-l oad condi ti ons: head-
l i ghts, bl ower fan, rear defogger, radi ator fan, and
ai r condi ti oner are not operati ng.
ldlc speed should be:
USA:
Dl 6Y5 engi ne
{CVT), D16Y7 engi ne
(A/T).
Dl 6Y8
.ngi no
l A/T):
700 i 50 rpm
(in
S
or
p
position)
Dl 6Y7 engi ne {M/T):
670 I 50 rpm
Crnada:
D15Y8 engi ne, D16Y7 engi ne:
MIT 750 t 50 rpm
AIT 750 i 50 rpm {i n E
or
E
posi ti on)
Adj ust the i dl e speed, i f necessary, by removi ng the
cap and t ur ni ng t he i dl e adj ust i ng scr ew 1/ 2- t ur n
cl ockwi se or countercl ockwi se.
11- 142
Dl 6Y7 engi ne:
NOTE: When you remove the ACL housi ng, do not
di sconnect the IAT sensor connector.
Ai t er t ur ni ng t he i dl e adi ust i ng scr ew 1/ 2- t ur n,
check the i dl e speed agai n. l f i t i s out of spec, turn
the i dl e adi usti ng screw 1/2-turn agai n.
NOTE: Do not turn the i dl e adj usti ng screw more
than 1/2-turn wi thout checki ng the i dl e speed.
l dl e t he engi ne f or one mi nut e wi t h heat er f an
swi tch at Hl and ai r condi ti oner on, then check the
i dl e soeed.
MN 810 t 50 rpm
A/T. CVT 8101 50 r pm
( i n
E
or
E
posi t i on)
NOTE:
. Do not turn the i dl e adj usti ng screw when the ai r
condi ti oner i s on.
t l f the i dl e speed i s not wi thi n speci fi cati on, see
Symptom Chart on page 11-46.
Inspection/Adiustmeni
' 98
D16Y5 engi ne
(M/T)
NOTE: Before setti ng the i dl e speed, check the fol l ow-
Ing trems;
-
The MIL has not been reported on.
-
-
Spar k pl ugs
-
Ai r cl eaner
-
PCV system
no l oad
(transmi ssi on
i n neutral ) unti l the radi ator
fan comes on, then l et i t i dl e.
Di sconnect the IAC val ve 2P connector and the EVAP
purge control sol enoi d val ve 2P connector.
1 .
2.
EVAP PURGE
CONTROL
SOLENOID VALVE
l f the engi ne stal l s, restart the engi ne wi th the accel -
erator pedal
sl i ghtl y depressed. Stabi l i ze the rpm at
1,000, then sl owl y rel ease the pedal unti l the engi ne
i dl es.
Check i dl i ng i n no-l oad condi ti ons: headl i ghts, bl ower
fan, rear defogger, radi ator tan, and ai r condi ti oner
are nor operalrng.
450 I 50 rpm
8.
7.
l f necessary. adj ust t he i dl e speed. by removi ng t he
cap and t ur ni ng t he i dl e adj ust i ng scr ew.
Af t er adj ust i ng t he i dl e speed recheck t he i gni t i on
t i mi ng
(see
sect i on 23). l f i t i s out of spec, go back
t o st ep 4.
| DLE
Reconnect the 2P connectors to the IAC val ve and
the EVAP purge control sol enoi d val ve, then do the
ECM reset procedure.
Restart and i dl e the engi ne wi th no-l oad condi ti ons
for one mi nute, then check the i dl e speed.
l dl e speed shoul d be: 6701 50 rpm
NOTE: l f the i dl e speed i ncreases to 810 t 50 rpm,
thi s means the EVAP system i s purgi ng the cani ster.
To st op t he pur gi ng t empor ar i l y, r ai se t he engi ne
speed above 1,000 rpm wi th the accel erator pedal ,
then sl owl y rel ease the pedal .
l dl e t he engi ne I or one mi nut e wi t h headl i ght s
(Low)
ON, and check the i dl e speed.
l dl e speed shoul d be:
750 I 50 rpm
Tur n t he headl i ght s of f . l dl e t he engi ne f or one
mi nute wi th heater tan swi tch at Hl and ai r condi -
ti oner on, then check the i dl e speed.
l dl e speed shoul d be:
810 t 50 rpm
l f t he i dl e speed i s not wi t hi n speci f i cat i on, see
{cont' d)
10.
Symptom Chart on page 11-46.
11- 143
ldle Control System
ldle Speed Setting
(cont'dl
'98
D16Y5 engine
(CVTI
Adj ust the i dl e speed usi ng a Honda PGM Tester i f pos-
si bl e. l f not, use the fol l owi ng procedure:
NOTE:
. Leave the IAC val ve connected.
. Bef or e set t l ng t he i dl e speed, check t he f ol l owi ng
i tems:
-
The MIL has not been reponed on.
-
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
l . Connect a tachometer.
no l oad
(transmi ssi on
i n
N
or
E
posi ti on) unti l the
radi ator l an comes on, then l et i t i dl e.
Check t he i dl e speed under no- l oad condi t i ons:
head l i ghts, bl ower fan, rear defogger, radi ator fan,
and ai r condi ti oner are not operati ng.
ldle speed should be: 700 I 50 rpm
. l f the i dl e speed i s wi thi n the speci fi cati on, the
procedure i s compl ete.
. lf the idle speed is out of specification, go to step 4.
l f t he i dl e speed i s 810 1 50 r pm, t hi s means r he
EVAP system i s purgi ng the cani ster. To stop the
purgi ng temporari l y, rai se the engi ne speed above
1,000 rpm wi th the accel erator pedal . Sl owl y rel ease
the pedal , and recheck the i dl e speed.
. l f the i dl e speed i s wi thi n the speci fi cati on, the
procedure i s compl ete.
. lf the idle speed is out of specification, go to step 5.
Di sconnect the EVAP purge control sol enoi d val ve
2P connector.
4.
11- 144
SOLENOID VALVE
6. Remove the cap and turn the i dl e adj usti ng screw
1/2-turn cl ockwi se or countercl ockwi se.
IDLE
After turni ng the i dl e adj usti ng screw
' l l 2-turn,
check
the i dl e speed agai n. l f i t i s out of spec, turn the i dl e
adj usti ng screw 1/2-turn agai n,
NOTE: Do not turn the i dl e adl usti ng screw more
than 1/2-turn wi thout checki ng the i dl e speed.
Turn the i gni ti on swi tch OFF, Reconnect the EVAP
purge
control sol enoi d val ve 2P connector, then do
the ECM reset procedure.
Stan the engi ne. l dl e the engi ne tor one mi nute wi th
heater fan swi tch at Hl and ai r condi ti oner on. then
check the i dl e speed.
ldl6 speed should be:
810 1 50 rpm
(in
@
or
@
position)
l f t he i dl e speed i s not wi t hi n speci t i cat i on, see
Symptom Chart on page 1l -46.
1.
Fuel Supply System
Fuel Li nes
NOTE: Check fuel system l i nes, hoses, tuel fi l ter, and other components for damage, l eaks and deteri orati on, and repl ace
i f necessarv.
12.2 kgl.m, 16lbt.ftl
l D16Y5
engi n: 28 N m
2.8 kgl m, 21 lbf.fil
(conr' d)
11- 145
22 N..n
Fuel Supply System
Fuel Li nes
(cont' d)
NOTE: Check al l hose cl amps and reti ghten i f necessary.
PRESSUBE
NEGULATOR
10- 16 mm
10.39
-
0.63 inl
FUEL TUBE/
OUICKCONNECT
FUEL
TANK
s\s\s\s\t\
Repl ace.
FUEL
PUMP
Cl amp i n t he mi ddl e
Cl amp i n t he mi ddl e
11- 146
)
Fuel Tube/Ouick-Connect Fittings
Plecautions
@
Do not smok while working on the ful
systom. Kosp open tlamsg away from your work area.
The fuel tube/qui ck-connect fi tti ngs assembl y connects
the i n-tank fuel pump wi th the fuel feed pi pe. For remov-
i ng or i nstal l i ng the fuel pump and fuel tank, i t i s neces-
sary to di sconnect or connect the qui ck-connect fi tti ngs.
Pay attenti on to tol l owi ng:
. The fuel tube/qui ck-connect fi tti ngs assembl y i s not
heat - r esi st ant ; be car ef ul not t o damage i t dur i ng
wel di ng or other heat-generati ng procedures.
o The fuel tube/qui ck-connect fi tti ngs assembl y i s not
aci d-proof; do not touch i t wi th a shop towel whi ch
was used for wi pi ng battery el ectrol we. Repl ace the
tuel tube/qui ck-connect fi tti ngs assembl y i l i t came
i nto contact wi th el ectroi yte or somethi ng si mi l ar.
. When connect i ng or di sconnect i ng t he f uel t ube/
qui ck- connect f i t t i ngs assembl y, be car ef ul not t o
bend or twi st i t excessi vel y. Repl ace i t i f damaged.
A di sconnected qui ck-connect fi tti ng can be reconnected,
but the retai ner on the mati ng pi pe cannot be reused
once i t has been removed from the
pi pe. Repl ace the
retai ner when
! Repl aci ng the fuel pump.
. Repl aci ng the tuel feed pi pe.
. l t has been removed from the Di oe.
. l t i s damsged.
ACCESS PANEL
Disconnection
@
Do not smoke whi l e worki ng on the l uel
systgm. Keep open tlames away from your work aroa.
1. Rel i eve f uel pr essur e ( see pages 11- 150, 151) .
2. Check the tuel qui ck-connect fi tti ngs for di rt, and
cl ean i f necessary.
3. Hol d rhe connector wi th one hand and press down
the retai ner tabs wi th the other hand, then
pul l
the
connector off.
NOTE:
o Be careful not to damage the pi pe or other parts,
Do not use tool s.
. l f the connector does not move, keep the retai ner
tabs pressed down, and al ternatel y pul l and push
the connector unti l i t comes off easi l v.
. Do not remove the retai ner from the
pi pe;
once
removed, the retai ner must be repl aced wi th a
new one.
LOCKING PAWL
RETAIiIER TAA
CONNECTOR
Press down.
Check the contact area of the pi pe for di rt and dam-
age.
. l f the surface i s di rty, cl ean i t.
. l f the surface i s rusty or damaged, repl ace the
fuel pump or fuel feed pi pe.
PIPE
(cont' d)
11- 147
Fuel Supply System
Fuel Tube/Ouick-Connect Fittings
(cont'dl
5. To prevent damage and
cover t he di sconnect ed
wi th pl asti c bags.
keep out torei gn matter,
connect or and pi pe end
PLASTIC BAGS
11- 148
Connection
@
Do not smoke while working on the fuel
systom. Keep open flames away lrom your work ars!.
1. Check the pi pe contact area for di rt and damage.
and cl ean i f necessary.
I nsert a new ret ai ner i nt o t he connect or i f t he ret ai ner
i s damaged, or af t er
. repl aci ng t he f uel pump.
. repl aci ng t he f uel f eed pi pe.
. removi ng t he ret ai ner f rom t he pi pe.
NGw RETAINER
(l nsert
i nt o
t he connect or. )
CONTACT AREA
Before connecti ng a new {uel tube/qui ck-connect fi tti ng
assembl y, remove the ol d retai ner from the mati ng pi pe.
Wi t h t he
t abs pul l ed
apan, romove
and di scard t he
retainer
New FUEL IUBE/
OUICK4ONNECT
FTTTING ASSEMALY
3. Al i gn the qui ck-connect fi tti ngs wi th the pi pe, and
al i gn the retai ner l ocki ng pawl s wi th the connector
grooves. Then press the qui ck-connect
fi tti ngs onto
the pi pe unti l both retai ner pawl s l ock wi th a cl i ck-
i ng sound.
NOTE: l f i t i s hard to connect, put a smal l amount
of new engi ne oi l on the pi pe end.
Connection with new reiainer:
I
4. Make sure the connection is secure and the
pawls
are fi rml y l ocked i nto pl ace; check vi sual l y and by
pul l i ng the connector.
RETAIiIER
Reconnect the baftery negati ve cabl e. and turn the
i gni t i on swi t ch ON
( l l ) .
The f uel pump wi l l r un f or
about t wo seconds. and f uel pr essur e wi l l r i se.
Repeat two or three ti mes, and check that there i s
no l eakage i n the tuel suppl y systen..
11- 149
Fuel Supply System
System Description
The fuel suppl y system consi sts of a fuel tank, i n-tank
hi gh pressure fuel pump, PGM-Fl mai n rel ay, fuel fi l ter,
fuel pressure regul ator. fuel i nj ectors, and fuel del i very
and r et ur n l i nes. Thi s syst em del i ver s
pr essur e- r egu-
l ated fuel to the fuel i nj ectors and cuts the fuel del i very
when t he engi ne i s not r unni ng.
Fuel Pressure
('96
model)
Rel i evi ng
Before di sconnecti ng fuel pi pes or hoses, rel ease pres-
sure from the system by l ooseni ng the 6 mm servi ce
bol t on top of the tuel fi l ter.
. Do not smoke while working on the fuel system,
Keep open fl ames or sparks away l rom your work
area.
. Be sui e to rel i eve fuel pressure whi l e the i gni ti on
switch is off,
' 1.
Wri te down the frequenci es for the radi o' s preset
buttons.
2. Di sconnect the battery negati ve cabl e from the bat-
tery negati ve termi nal .
3. Remove t he f uel f i l l cap.
4. Use a box end wrench on the 6 mm servi ce bol t at
t he f uel f i l t er whi l e hol di ng t he speci al banj o bol t
wi th another wrench.
5. Pl ace a rag or shop towel over the 6 mm servi ce bol t.
6. Sl owl y l oosen the 6 mm servi ce bol t one compl ete
t ur n.
o A fuel pressure gauge can be attached at the 6 mm
servi ce bol t hol e.
. Al wavs reol ace the washer between the servi ce
bol t and the speci al banj o bol t whenever the ser-
vi ce bol t i s l oosened.
. Repl ace al l washer s whenever t he bol t s ar e
removed.
1 1 - 1 5 0
Inspeqtion
1. Rel i eve fuel pressure.
Remove the servi ce bol t on the fuel fi l ter whi l e hol d-
i ng the banj o bol t wi th another wrench. Attach the
speci al tool .
FUEL
PNESSURE
GAUGE
07405
-
0040001
FUEL PRESSURE
AoAPTER, 6x15mm
07(}6
-
00{0304
Start the engi ne. Measure the fuel pressure wi th the
engi ne i dl i ng and the vacuum hose of the fuel pres-
sure regul ator di sconnected from the fuel pressure
regul ator and pi nched. l f the engi ne wi l l not start,
turn the i gni ti on swi tch ON
(l l ),
wai t for two sec-
onds, turn i t off, then back on agai n and read the
fuel pressure,
Pressure should bs:
260
-
310 kPa
(2.7 -
3.2 kgif/cm', 38
-
46 psil
Reconnect vacuum hose to the fuel pressure regulator.
Pressure should b:
200
-
250 kPa l2-0
-2.5kgllcm2,28 -
36
psil
l f the fuel
pressure
i s not as speci ti ed, fi rst check the
fuel pump (see page 11-' 156). It the fuel pump i s OK.
check the fol l owi ng:
l f t he l uel pr essur e i s hi gher t han speci f i ed,
i nspect for:
-
Pi nched or cl ogged fuel return hose or l i ne.
-
Faulty fuel pressure regulator
(see page 1 l-'lg).
l f the fuel pressure i s l ower than speci fi ed, i nspect
for:
-
Cl ogged fuel fi l ter.
-
Faul ty fuel pressure regul ato.
(see page 11-154).
-
Fuel l i ne l eakage.
4.
NEGULATOB
1 .
Fuel Pressure
('97
and later modelsl
Rlioving
Betore di sconnecti ng fuel pi pes or hoses, rel ease pres-
sur e f r om t he syst em by l ooseni ng t he 12 mm banj o
bol t on toD of the fuel fi l ter.
Do noi smok while working on tho tuel system,
Keep open flames or sparks away from your work
area.
Bo surs to rel i eve tuel pressure whi l e the i gni ti on
switch is oft.
Wri te down the frequenci es for the radi o' s preset
buttons,
Di sconnect the battery negati ve cabl e from the bat-
tery negati ve termi nal .
Remove the i uel fi l l cap.
Use a box end wrench on the 12 mm banj o bol t at
the fuel fi l ter whi l e hol di ng the fuel fi l ter wi rh anoth-
er wrencn.
Pl ace a rag or shop towel over the 12 mm banj o bol t.
Sl owfy foosen the 12 mm banj o bol t one compl ete
I UI N.
4.
12 mm EANJO
BOLT
NOTE: Repl ace al l t he washer s whenever t he
mm banj o bol t i s l oosened or removed.
1 2
Inspec'tior
l Rel i eve tuel pressure.
2. Remove the 12 mm bani o bol t from the fuel fi l ter
whi l e hol di ng t he f uel f i l t er wi t h anot her wr ench.
Attach the special tools.
Stan the engi ne. Measure the fuel pressure wi th the
engi ne i dl i ng and the vacuum hose of the fuel pres-
sure regulator disconnected from the fuel pressu.e
regul ator and pi nched, It the engi ne wi l l not start,
turn the i gni ti on swi tch ON
(l l ),
wai t for two sec-
onds, turn i t off, then back on agai n and read the
fuel pressure.
Pressurs should be:
260
-
310 kPa
(2.7 -
3.2 kgf/cm,, 38
- '15 psil
Reconnect vacuum hose to the fuel pressure regulator.
Pressure should bo:
200
-
250 kPa
(2.0 -
2.5 kgf/cm,, 28
-
35 psi)
l f the fuel pressure i s not as speci fi ed, ti rst check the
fuel pump (see page 1
' 1-
156). l f rhe fuel pump i s OK,
check the fol l owi ng:
. l f t he f uel pr essur e i s hi gher t han speci f i ed,
inspect for:
-
Pi nched or cl ogged fuel return hose or l i ne.
-
Faul ty fuel pressure regul ator
(see page 11-
1541.
. l f the fuel pressure i s l ower than speci fi ed. i nspect
for:
-
Cl ogged tuel fi l ter.
-
Faul ty fuel pressure
regul ator
(see page 11-
154).
-
Fuel l i ne l eakage.
4.
FUEL PRESSURE
ADAPTER BOLT, 12 mm
tgflDE
-
PD6
-
0101
REGULAIOA
1 1 - 1 5 1
Fuel Supply System
Fuel lnjectors
Replacement
!@
Do not smoke when working on the luel system. Keep open flames away lrom your wotk alea.
1, Rel i eve the fuel pressure (see pages 11-150, 151),
2. Di sconnect the connectors from the fuel i ni ectors
(D16Y7
engi ne: Remove the ai r cl eaner).
3. Di sconnect the vacuum hoses from the fuel pressure regul ator. Pl ace a shop towel over the fuel return hose, then di s-
connect i t from the fuel pressure regul ator, Di sconnect the vacuum hoses and 2P connector from the EVAP purge
control sol enoi d val ve
(D16Y5,
D16Y8 engi ne).
4. Remove the retai ner nuts on the fuel rai l .
5. Di sconnect the fuel rai l .
6. Remove the fuel i ni ectors from the i ntake mani fol d.
NOTE: l l l ustrati on shows D16Y8 engi ne.
D16Y5 engi ne i s si mi l ar .
D16Y7 engi ne:
12 N. m
11. 2 kgf . m,
8.7 tbf.ft)
'r2
N.m
11.2 kg{.m,
8.7 tbtfr)
EVAP
PURGE CONTROL
SOLENOID VALVE
O-RING
Repl ace.
CUSHION
RING
Repl ace.
SEAL
RI NG
Repl ace.
O.RING
Repl ace.
CUSHION
Repl ace.
SEAL
RING
Repl ace.
ffi
g
V
V
ffi
g
Y
ffi
E
Y
ffi
E
V
7. Sl i de new cushi on ri ngs onto the fuel i nj ectors.
8. Coat new O-ri ngs wi th cl ean engi ne oi l , and
put them on the fuel i nj ectors.
9. Insert the fuel i nj ectors i nto the fuel rai l fi rst.
10. Coatnewseal ri ngswi th cl ean engi ne oi l , and press them i ntothe i ntake mani fol d.
11- 152
1 1. To prevent damage to the O-ri ngs, i nstal l the tuel i nj ectors i n the fuel rai l fi rst, then i nstal l them i n the i ntake mani -
fo l d.
Instal l and ti ghten the retai ner nuts.
Connect the vacuum hoses and fuel return hose to the fuel pressure regul ator. Connect the vacuum hoses and 2P
connector to the EVAP purge control sol enoi d val ve
(D16Y5,
D16Y8 engi ne).
Instal l the connectors on the fuel i nj ectors
(D16Y7
engi ne: Instal l the ai r cl eaner),
Turn the i gni ti on swi tch ON
(l l ),
but do not operate the starter. After the fuel pump runs for approxi matel y two seconds,
the fuel pressure
i n the tuel l i ne ri ses. Repeat thi s two or three ti mes, then check whether there i s any fuel l eakage.
' t2.
13.
14.
1 1 - 1 5 3
Fuel Supply System
Fuel Pressure Regulator
Testi ng
!@
Do not smoke during the test. Keep open
tl ames away l rom your work area.
1. Attach the speci al tool (s) to the servi ce pon on the
f uel f i l t er
( see pages 11' 150, 151) .
Pressure should be:
260
-
310 kPa {2.7
-
3.2 kgf/cm', 38
-
46 psi}
{with the fuel pressure regulator vacuum hose
disconnected and
pinched)
FUEL PRESSURE
REGULATOR
2.
3.
Reconnect t he vacuum hose t o t he f uel pr essur e
regul ator.
Check that the fuel pressure ri ses when the vacuum
hose from the fuel pressure regul ator i s di sconnected
aga I n.
l f t he f uel pr essur e di d not r i se. r epl ace t he f uel
pressure regul al or.
CLAMP
11- 154
Replacement
@
Do not smoke while working on fuel sys-
tem. Keep opsn llame away from your work area.
1. Pl ace a shop towel under the fuel pressure regul ator,
then rel i eve fuel pressure (see pages 11-150, 151).
2, Di sconnect the vacuum hose and fuel return hose.
3. Remove the two 6 mm retai ner bol ts and the fuel
pressure regul ator.
FUEL
PRESSURE
TOR
12 N. m
(1.2
kg{.m,
8.7 tbtft)
Appl y cl ean engi ne oi l to a new O-ri ng, and careful l y
i nstal l i t i nto i ts
proper posi ti on.
I nst al l t he f uel pr essur e r egul at or i n t he r ever se
order of removal ,
Repl ace.
Fuel Filter
RoplEcement
r!@
Do not smoke while working on fuel systsm. K6op
open fbme away from your
work area.
While roplacing th tusl filtar, be careful to keop a
safo di stance betwssn battGry tgrmi nal s and any
tools.
The f uel f i l t er shoul d be r epl aced whenever t he f uel
pressure drops bel ow the speci fi ed val ue 1260
-
310 kPa
12,7
-
3.2 kgtl cm,, 38
-
46 psi ) wi th the fuel pressure reg-
ul at or vacuum hose di sconnect ed and
pi nchedl
af t er
maki ng sure that the tuel pump
and the fuel pressure
regul ator are OK,
' 1.
Pl ace a shop towel under and around the fuel fi l ter.
Rel i eve fuel pressure
{see
pages 11-150, 151).
Remove t he 12 mm banj o bol t and t he t uel f eed
pi pe trom the fuel fi l ter, whi l e supponi ng i t wi th the
another wrench. as shown,
Remove the tuel fi l ter cl amp and fuel fi l ter.
I nst al l t he new f uel f i l t er i n t he r ever se or der
removal , and note these i tems:
. When assembl i ng. use new washers as shown.
. Cl ean t he f l ar ed
j oi nt
ot hi gh pr essur e
hoses
thoroughl y before reconnecti ng them.
,96
MODEL:
12 mm
BAt{JO
AOLT
33 N.m
{3.4 kg{.m,
25 rbf.ftl
(3.8
ksf.m,
27 tbf.ftl
9. 8 N. m
.0 lg{ m,
7.2 rbt.ftt
N.m
,97
AND LATER MODELS:
12 mm
BANJO
BOLT
33 N.m
(3.4
*gf.m,
25 tbf.ftl
37 N.m
13,8 kgt m,
27 tbtftl
ll.0 kg(.rn,
1.2 tbt.trl
1 1 - 1 5 5
Fuel Supply System
Fuel Pump
Testing
@
Do not smoke during the test. Keep oPen
tlame away trom you. work atea.
lf you suspect a problem with the fuel pump, check that the
fuel
pump actual l y runs; when i t i s ON
(l l ), you wi l l hear
some noi se i f
Vou
hol d your ear to the fuel fi l l port wi th the
fuel fi l l cap removed, The fuel pump shoul d run for two
seconds when i gni ti on swi tch i s fi rst turned ON
(l l ).
l f the
fuel pump does not make noise, check it as follows:
1. Remove the seat cushi on
(see
secti on 20).
2. Remove the access
panel
from the fl oor.
3. Make sure the i gni ti on swi tch i s OFF, then di scon-
nect l he fuel tank 2P connector.
4. Connect the PGM-Fl mai n rel ay 7P connector termi -
nal No. 4 and No. 5 wi th a
j umper
wi re.
PGM-FI MAIN RELAY 7P CONNECTOR {C,a,|3)
FUEL PUMP
{YEL/
GRNI
I GN 1
(YEL/GRNI
{c56sl
FUEL PUMP
(YEL/GRNI
Wire side of
female terminals
JUMPER WIRE
Wire side of temale torminals
Check that battery vol tage i s avai l abl e between the
fuel pump connector termi nal No. 1 and body ground
when the i gni ti on swi tch i s turned ON
(l l ).
CONNECTOR
tr:
I
I
l----r
El
d,
Y
l f battery vol tage i s avai l abl e, check the tuel pump
ground. l f the ground i s OK, repl ace the fuel pump.
l f there i s no vol tage. check the wi re harness
(see
page 1' l - 158) .
1 1- 1 56
L
Rolacement
!!@
Do not smoke while wotking on luel 3Y3-
tem, Koop open tlams away from your work area.
(see
secti on 20).
2. Remove the access
panel from the fl oor.
5.9 N-m
10.6 kgt m.
{.3 tbr.ftl
\,
3. Di sconnect the 2P connector from the tuei pump.
4. Remove the tuel pump mounti ng nuts.
Remove the fuel pump from the fuel tank,
Instal l parts i n the reverse order of removal .
ACCESS PANEL
PGM-FI Mai n Rel ay
Descliption
The PGM-Fl mai n rel ay actual l v contai ns two i ndi vi dual
rel ays. Thi s rel ay i s l ocated at the ri ght si de of the cowl .
One rel ay i s energi zed whenever the i gni ti on i s on whi ch
suppl i es the battery vol tage to the ECM/PCM, power to
the fuel i nj ectors, and power for the second rel ay. The
second rel ay i s energi zed for two seconds when the i gni -
ti on i s swi tched ON
(l l ),
and when the engi ne i s runni ng,
to suppl y power to the fuel pump.
FGM.FI
MAITI RELAY
FUEL PUMP
Relay Testing
NOTE:
. It the engi ne starts and conti nues to run, the PGM-Fl
mai n rel ay i s OK.
. Use t he t er mi nal number s bel ow;
i gnore the termi nal numbers mol ded i nto the rel ay.
' 1.
Remove the PGM-FI mai n rel ay.
2. Attach the battery posi ti ve termi nal to the No. 2 ter-
mi nal and the battery negati ve termi nal to the No. 1
termi nal of the PGM-Fl mai n rel ay. Then check for
conti nui ty between the No. 5 termi nal and No.4 ter-
mi nal of the PGM-FI mai n rel ay.
. l fthere i s conti nui ty. go on to step 3.
. l f there i s no conti nui ty. repl ace the PGM-Fl mai n
rel ay and retest.
No. 2
N o . 3
No. 1
No.
To l GN.
To GROUND
To ST. SWITCH
N o , 5
N o . 7
6 No.
To BAT @
To ECM,/PCM
{A1'1,
A24}
To ECM/PCM
(A To FUEL PUMP
Attach the batterv Dosi ti ve termi nal to the No. 5 ter-
mi nal and the battery negati ve termi nal to the No, 3
termi nal of the PGM-FI mai n rel ay. Then check that
there i s conti nui ty between the No, 7 termi nal and
No. 6 termi nal of the PGM-FI mai n rel av.
. l f there i s conti nui ty, go on to step 4.
. l f there i s no conti nui ty, repl ace the PGM-Fi mai n
rel ay and retest.
Attach the battery
posi ti ve
termi nal to the No. 6 ter-
mi nal and the battery negati ve termi nal to the No. 1
termi nal of the PGM-Fl mai n rel ay. Then check that
there i s conti nui ty between the No. 5 termi nal and
No. 4 termi nal of the PGM-Fi mai n rel ay.
. l f there i s conti nui ty, the PGM-Fl mai n rel ay i s OK.
l l the fuel pump sti l l does not work, go to Harness
Testi ng on the next page.
. l f there i s noconti nui ty, repl acethe PGM-Fl mai n
{cont' d)
11- 157
relay and retest.
Fuel Supply System
PGM-FI Mai n Rel ay
(cont' dl
Circuit Troubleshooting
PGM.FI MAIN RELAY 7P CONNECTOR lca,Bl
IBLU/WHTI sls
2 3
a 5 E 7
-
Engine will not siart.
-
I nspect i on ot PGM- FI mai n
relay and relay harness,
Check f or an open i n t he wi ro
I GND l i ne):
2. Di sconnect t he PGM-FI mai n
rel ay 7P connect or.
3- Check f or cont i nui t y bet ween
t he PGM-FI mai n rel ay 7P con'
nect ort ermi nal No. 3 and body
ground.
the PGM-FI m.in relay and G101.
Check for an open or short in the
wi re
(BAT
l i nel :
PGM' Fl mai n rel ay 7P connect or
terminal No. 7 and body ground.
-
Repai r open or short i n t ho
wire btw6n th6 FGM-FI main
r6l sy and t he Fl E/ M 115 Al
fu3o.
-
ReDleco the Fl E/M l'15 Alfus6
in th6 undr-hood tuso/r.lay
box.
Check for an open or short in th6
wir
(lGl
line):
(l l ).
2. Measure the voltage between
t he PGM-Fl mai n rel ay 7P con-
nect ort ermi nal No. 5 and body
ground,
-
Ropai r open o1 short i n t hg
wire bnrvon th PGM-FI main
r 6l ay and t he No. 13 FUEL
PUMP {15 A} tusc.
-
Rool ac t he No. 13 FUEL
PUMP 115 A) fus6 in th under-
dash fuso/rolay box.
Check lor an open 01 short in the
wi.e {STS line):
1. Turn t he i gni t i on swi t ch t o t he
START
(
l l l ) posi t i on.
NOTE:
.
M/ T: Cl ut ch pedal must be
depressed.
.
A"l T: Transmi ssi on i n
E
or
E
posi t i on.
2, Measure the voltage between
t h e PGM- FI ma i n r e l a y 7 P
connect or t rmi nal No, 2 and
body ground.
( To page 11- 159)
1 1 - 1 5 8
(From page 11-158|
-
Fcpr i r opon o. 3hon i n t ho
wirc baaw6.n the ftiu.Fl main
6lry .nd tho No. 31 STARTER
SIGNAL 17.5 A tuso.
-
Ropleco tho No. 31 STARTER
SI GNAL {7. 5 A} f use i n t ho
undor-dalh fu3o/rclay box.
Ch. ck t o. an op6n i n t hG wi r.
IFLR lin6l:
2. Oisconnect the ECM/PCM con,
nector A
(32P).
the PGM-FI main .elay 7P con-
nectorterminal No, 1 and ECN4/
PCM connector terminal A16.
Raprir op6n in the wire bgtwaen
t ho ECM/ PCM l A16) and i h6
PGM-FI main ..lay.
Chack for an open in the wiro3
{lGPl. lGP2 line3l:
1. Reconnect t he ECM/ PCM con-
nector A
(32P).
2. Reconnect t he PGM-Fl mai n
relay connector.
(l l ).
4. Measur vol t age bet ween
ECM,PCM connector terminals
A11 and A10, and bet wen
A24 and A10.
R.pair opon in th. wi.e bet-
w.n th. ECM/FCM {A11, A24l
.nd thc PGM-FI main lolay.
R.pleo. tho PGM-FI main relay.
Ch.ck for sn opon in th. ECM/
PCM:
' 1.
2. Measu r e vol t age bet ween
A16 and A10 when t he i gni t i on
swi t ch i s f i rst t urned ON
(l l l t or
two seconds.
Sub.titut. ! known-good ECM/
PCM and ..check. lf orcacribod
voltaga ii now rv.il.ble, rcplace
thc origin.l ECM/PCM.
l s t here' 1. 0 V or l ess?
Ch. ck l he PGM-FI mai n rel . y
lroo
pagc 11.1571.
PGM-FI MAIN RELAY 7P CONNECTOR IC'4|II
FLR
rcRNNEL]
Wi ro si de of l emal e l ermi nal s
t32Pl
IGP2
IYEL/BLKI
IELK}
FLR
IGRN/YEL)
1 2 3
o
a 6
ECM/PCM CONNECTOR A
I 2 3 5 I l l
12 t l t 5 l 6 t 7 t a t 9 20
l,/
22 23 2a
2t 21 2A 4l 30l /
PGl
(BLKI
5 8 9
l 2 t 3 t 5 t 6 1 1 t l t 9 20 22 z t
I
r l
n 2A 4 30
FLR
IGRN/YEL) PGl
2
l s
o l r l
l e l e l
r r 1 1
12 I t l a l 5 t 6 t a l 9 20 221 23 2a
21 2a
30
1 1 - 1 5 9
Fuel Supply System
Fuel Tank
Rsplacement
@
Do not smoke while working on fuel system. Keep opan flame away from
your
work aroa.
TANK
STRAPS
DRAIN BOLT
4t N.m {5.0 kgl.m, 36 lbf.ttl
1. Rel i eve the fuel pressure (see pages 11-150, 151).
(see
secti on 20).
3. Remove the access panel from the fl oor.
4. Di sconnect the 2P
(C565)
and 3P
(C564)
connectors
(96
D16Yg engi ne {coupe)
' 97
Dl 6Y7 engi ne(coupe: KL model ,
sedan: KL
(LX)
model ),' 97 D16Y8 engi ne
(coupe:
al l model s, sedan: KL model
' 98-al l
model s): and 6P
(C568)
connec-
torl .
5. Di sconnect the hose and qui ck-connect fi tti ngs
(see pages 11-146, 147).
6. Jack up the vehi cl e. and support i t wi th
j ackstands.
7. Remove the fuel tank cover
(' 96.
' 97
model ) orthefuel hose
j oi nt protector.
8. Bemove the drai n bol t, and drai nthefuel i nto an approved contai ner.
9. Di sconnect the hoses
(see page 11-146). Sl i de back the cl amps, then twi st hoses as you pul l , to avoi d damagi ng them,
10. Pl ace a
j ack,
or other suppon. under the tank,
11. Removethestrap nuts, and l et the straps fa l l free.
12. Remove the fuel tan k, l f i t sti cks on the undercoat appl i ed to i ts mount. carefu l l y pry i t off the mount.
13. Instal l the drai n bol t wi th a newwasher,then coatthedrai n bol t wi th Noxrust l 24B,Al l owthe Noxrustdryfor20 mi n-
utes.
14. Instal l the remai ni ng parts i n the reverse order of removal .
BASE GASKET
Replace.
38 N.m
(3.9
kgl.m,
28 tbtft)
BASE GASKET
Replace.
WASHER
Replace.
\
1 1 - 1 6 0
Intake Air System
System Description
The system suppl i es ai r for al l engi ne needs. l t consi sts of the i ntake ai r
pi pe, Ai r Cl eaner
(ACL),
i ntake ai r duct, Throttl e
Body {TB),
l dl e Ai r Control
(l AC)
Val ve and i ntake mani tol d. A resonator i n the i ntake ai r pi pe provi des addi ti onal si l enci ng
as ai r i s drawn i nto the svstem.
Dl6Y5, Dl6Y8 angine
(M/Tl
YEL/ - From PGM-FI
BLK
_
MAIN RELAY
VARIOUS
SENSORS
IROTARYI
IAC VALVE
ENGI NE
COOLANT
D15Y5 engine
{CWl,
D16Y8 engine lA/T)'
lrutne umrrrolo
D16Y7 sngi n:
(ROTARYI
IAC VALVE
YEL/ - From PGM-FI
BLK
I
MAIN RELAY
ORN
BLK/
8tu
VARIOUS
SENSORS
RESONATOR
BLK
BLK
1 1 - 1 6 1
lntake Air System
Ai r Cl eaner
(ACLI
NOTE; Do not cl ean t he ACL el ement i t wi t h com-
pressed ai r
(except
dry type).
Dl 6Y5, D16Y8 engi no:
ACL ELEMENT
Normal conditionsi
Replacg air cleaner element every
30,000 milos (48,000
kml or 24
months whichover comes first.
Sova.c conditionr:
(Use
normal schedul e
except in dusty conditions)
Replace every 15,000
miles
(24,000
km) or
'12
months
whichever comes firct.
HOUSING
Dl 6Y7 engi ne:
Repl ace ai r cl eaner el ement every
30, 000 mi l 6s
(48, 000
km) or 24
months whichever comes first.
Sovoro condhion3:
ACL ELEMENT
Normrl condhion3:
(Use normal schedule except
in dusty conditions)
Repl ace every' 15,000
whichever comes llrsl.
11- 162
L
Throttle Cable
Inspection/Adiustmont
1. Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(l y' T
i n
E
or
@
posi ti on,
Mff i n neutral ) unti l
the radi ator fan comes on, then l et i t i dl e.
2. Check that the throttl e cabl e operates smoothl y wi th
no bi ndi ng or sti cki ng. Repai r as necessary.
3. Check cabl e free pl ay at the throttl e l i nkage. Cabl e
defl ecti on shoul d be 10
-
12 mm l 3/8
-
1/2 i n.l .
D16Y5. D16Y8 engi ne:
DEFLECTION
10- 12 mm
13l8
-
112 inl
Dl 6Y7 engi ne:
AIUUSTING
DEFLECNON
1 0 - 1 2 mm
Bl a- 112 i ^l
It de{lection is not within specs, loosen the locknut,
turn the adj usti ng nut unti l the defl ecti on i s as speci -
fi ed, then reti ghten the l ocknut.
Wi th the cabl e properl y adj usted, check the throttl e
val ve to be sure i t opens ful l y when you push
the
accel erator
pedal
to the fl oor. Al so check the throt-
tl e val ve to be sure i t returns to the i dl e posi ti on
whenever you rel ease the accel erator pedal .
CABLE
LOCKNUT
lnstallation
' L
Open the throttl e val ve ful l y. then i nstal l the throttl e
cabl e i n t he t hr ot t l e l i nkage, and i nst al l t he cabl e
housi ng i n the cabl e bracket.
CABLE
LOCKNUT
ADJUSTING
NUT
no l oad
(A,/T
i n
E
or
E
posi ti on, M/T i n neutral ) unti l
the radi ator fan comes on, then l et i t i dl e.
Hol d the cabl e sheath, removi ng al l sl ack from the
caor e.
4. Set t he l ocknut on t he cabl e br acket . Adj ust t he
adj usti ng nut so that i ts free pl ay i s 0 mm.
5. Remove the cabl e sheath from the throttl e bracket,
reset the adj usti ng nut and ti ghten the l ocknut.
Dl 6Y5, D16Y8 engi n:
D16Y7 ngi ne:
ADJUSTING NUT
9.8 N.m
{1.0
kgf.m,
7.2 tbt'ttl
1 1 - 1 6 3
Intake Air System
Throttle Body
Doscription
The throttl e body i s ei ther a si ngl e-barrel si de-draft type
{ D16Y5, D16Y8 engi ne) or a down- dr af t t ype
( D16Y7
engi ne). The l ower porti on of the throttl e val ve i s heated
by engi ne cool ant f r om t he cyl i nder head. The i dl e
adj usti ng screw whi ch regul ates the bypass ai r i s l ocat-
ed on the top of the throttl e body.
11- 164
Inspection
1. Check t hat t he t hr qt t l e cabl e oper at es smoot hl y
wi thout bi ndi ng or sti cki ng.
It there are any abnormal i ti es, check for:
. Excessi ve wear or pl ay i n the throftl e val ve shaft.
. Sti cky or bi ndi ng throtti e l ever at the ful l y cl osed
posi ti on.
. Cl earance between throttl e stop screw and throt-
tl e l ever at the ful l y cl osed posi ti on.
D16Y5, Dl6YB engine:
THROTTLE STOP SCBEW
{Do not adi ust . }
D16Y7 engi ne:
Repl ace the throttl e body i t there i s excessi ve pl ay i n the
throttl e val ve shaft or i f the shaft i s bi ndi ng or sti cki ng.
{Do not adi ust . )
Removal
D15Y7 engi ne:
IAT SENSOR
AIF CTEANEF
IACLI
MAP SENSOB
22Nm
12.2*gl.m,
16 tbf.ftt
NOTE:
. Do not adj ust the throttl e stop screw.
o After reassembl y, adj ust the throttl e cabl e
(see page 11-162).
. The TP sensor i s not removabl e.
GASKET
Repl6ce.
(cont' d)
1 1 - 1 6 5
THROTTLE CAALE
Intake Air System
Throttle Body
(cont'dl
Disassembly
Dl 6Y5, Dl 6Y8 engi ne:
2.1 N.m
(0.21
kgf.m, 1.5 lbf.ftl
TP SENSOR
MAP SENSOR
' 11
67
IDLE ADJUSTING
SCREW
IAC VALVE
D16Y7 engi ne:
2. 1 N. m MAP
10.21 kgf.rn, SENSOR
1. 5 l bt . f t ) Troubl eshoot i ng, p6ge 11-67
O-RING
3. 5 N. m 10. 35 kgf . m, 2. 5l bt f t l
1 1 - 1 6 6
System Description
The emission control system includes a Three Way Cata-
l yti c Converter
(TWC),
Exhaust Gas Reci rcul ati on {EGR)
system*, Positive Crankcase Ventilation
(PCV)
system and
Evaporati ve Emi ssi on {EVAP) Control system. The emi s-
sion control system is designed to meet federal and state
emi ssi on standards.
*:
D16Y5 engi ne
Tai l pi pe Emi ssi on
Inspection
E@
Do not smoke during this procodure. Kep
any open flam away from your work area.
1. Stan the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(Ay' T
i n
E
or
E
posi ti on, N4/T i n neul ral ) unti l
the radi ator fan comes on. then l et i t i dl e.
Check and, i f necessary. adj ust the i dl e speed
(see
page l l - 141) .
Warm up and cal i brate the CO meter accordi ng to the
meter manufacturer' s i nstructi ons.
Check i dl e CO wi th the headl i ghts. heater bl ower,
rear wi ndow defogger, cool i ng fan, and ai r condi ti on-
er off.
NOTE:
( Canada)
Pul l t he par ki ng br ake l ever up.
Stan the engi ne, then check that the headl i ghts are
off.
CO meter shoul d i ndi cate 0.1% maxi mum.
NOTE:' 98 D16Y5 engi ne- l f the i dl e speed i ncreas-
es to 810 f 50 rpm, thi s means the EVAP system i s
purgi ng the c8ni ster. To stop the purgi ng temporari -
l y. rai se the engi ne speed above 1.000 rpm wi th the
accel erator pedal . then sl owl y rel ease the
pedal .
(TWC)
Description
The Three Way Catal yti c Converter
(TWC)
i s used to
conven hydrocarbons
(HC),
carbon monoxi de
(CO),
and
oxi des of ni trogen
(NOx)
i n the exhaust gas to carbon
di oxi de
(CO?),
di ni trogen
(Nr)
and water vapor.
Dl6Y5, Dl6Y7 engine:
D16Y8 engi ne:
ENGINE SIDE
i
(cont' d)
11- 167
HOUSING
(TWC) (cont'dl
]
P0420
I
tne scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
PO42O: Catal yst system effi ci ency bel ow threshol d.
Description
Thi s system eval uates the catal yst' s capaci ty by means of the HO2S
(Pri mary
and Secondary) output duri ng stabl e dri vi ng
condi ti ons. l f deteri orati on has been detected duri ng two consecuti ve dri vi ng cycl es, the MIL comes on and DTC P0420 wi l l
be stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as DTC P0420, troubl eshoot those DTCS fi rst, then
troubl eshoot DTC P0420.
P0137, P0138: Secondary HO2S
(Sensor
2)
P0141: Secondary H02S
(Sensor
2) Heater
Possible Cause
. TWC Deteri orati on
. Exhaust system l eakage
-
The MIL hes been reoorted on.
-
DTC P0420 b stored.
Problgm verfficationi
1. Do the ECM/PCM Reset Proce'
dure.
l oad
(A/ T
i n
E
or
E
posi t i on,
t or f an comes on.
nector.
4. Test - dr i ve 40
-
55 mph f or
appr ox. t wo mi nut es. Then
decel erat e f or at l east 3 sec
onds wi t h t he t hr ot t l e com
pl et el y
cl osed. Then reduce
t he vehi cl e speed t o 35 mph,
and t r y t o hol d i t unt i l t he
readi ness code comes on,
Intelmitlent trilure, ayrlom ia OK
at thi3 timc.
Ch.ck the TWC {see section 9}.
lf nocessary, roplace the TWC.
1 1- 1 68
\
Exhaust Gas Recirculation
{EGR)
System
(Dl6Y5
enginel
Description
The EGR system i s desi gned to reduce oxi des ot ni trogen emi ssi ons {NOx)
by reci rcul ati ng exhaust gas through the EGR
val ve and the i ntake mani fol d i nto the combusti on chambers. l t i s composed of the EGR val ve, EGR vacuum control val ve,
EGR control sol enoi d val ve, ECM and vari ous sensors.
The ECM contai ns memori es for i deal EGR val ve l i tts for varyi ng operati ng condi ti ons. The EGR val ve l i ft sensor detects
the amount of EGR val ve l i ft and sends the i ntormati on to the ECM. The ECM then compares i t wi th the i deal EGR val ve l i ft
whi ch i s determi ned by si gnal s sent from the other sensors, l f there i s any di fference between the two, the ECM cuts cur-
rent to the EGR control sol enoi d val ve to reduce vacuum aool i ed to the EGR val ve.
EGR CONTROL
cVT. SOLENOIO VALVE
BLK
4
EGR VALVE LIFT SENSOR
BLK
I
1- 169
(EGR)
System
(D16Y5
engine)
{cont'dl
(DTC)
P0401: Insuffi ci ent fl ow i n the Exhaust Gas Reci rcul ati on
(EGR)
svstem.
DescriDtion
Deteri orati on (cl oggi ng,
l eakage, etc.) i n the EGR l i ne or EGR val ve i s detected by means of the changes i n MAP before
and after the operati on of the EGR val ve.
It deteri orati on has been detected duri ng two consecuti ve dri vi ng cycl es, the MIL wi l l come on and DTC PO4O1 wi l l be
sto red.
Possible Causes
. Cl oggi ng, l eakage i n the EGR l i ne
. Faul ty EGR val ve
-
The MIL has been.eoortad on.
-
DTC P0401 b stored.
Problom veriticetion:
nector,
3. Test dri ve under t he f ol l owi ng
condi t i ons.
-
Wi t hout any el ect dcal l oad
-
Decel er at e f r om 55 mph
{88 km/h) for at least 5 sec
onds
Intermittont tlilure, sy3tcm is OK
at thb time.
Cledn th6 intake mrnifold EGR
port
with calburetor deana..
Clean the
passag
inside the
EGR val ve wi t h carburet or
cleaner ot toplac the velve.
11- 170
(DTC)
P1491: A mal functi on i n the Exhaust Gas Reci rcul ati on
(EGR)
system.
CvT
(M/T
see pao 11-174):
YES
Ch. ck t or vacuum t o t he EGR
1. Dsconnectthe No. 16 hose trom
th EGR valve.
2. Connect a vacuum
pump/
gauge t o t he hose.
3. St an t he engi ne and l et i t i dl e.
EGR VALVE
LIFT SENSOR #16 HOSE
l To
page 11- 172)
(cont' d)
11- 171
-
Tha MIL h'3 boan.eDorted on.
-
DTC P1,191 is sto.od.
Probl.m verificstion:
1. Do the ECM Reset Procedure.
2. Connct the SCS service con-
nector.
3. St ar t t he engi ne. Hol d ! he
load
(transmission
in
E]
or
E
position) until the radiator fan
comes on.
4. Dri ve t he vehi cl e on t he road
for approx. 10 minutes. Try to
keep t he engi ne speed i n t he
'1,70O
-
2,500 rpm range.
Intermittgnt failure, systom is OK
at thb tirno. Check tor Door con-
ngctions or looaa wire3 at, C144
{EGR vrlvol and ECM,
Ch. ck t or a mrl f unct i on i n t ho
EGR comrcl lolonoid v.lv.:
1. Di sconnoct t he EGR cont r ol
solenoid valve 2P connector.
2. Rcheck t he No. 16 hose f or
Check vacuum hose . out i ng ot
the entirs EGR 3y3tom. lf hose
rout i ng i s OK, . epl sce t he EGR
control solenoid vrlve.
l s t here 6ny vacuum?
Subrt i t ut e a known-good ECM
.nd rcheck. lf lymptom/indica-
tion
goar
aw.y, r.placa th6 oJigi-
nll ECM.
PUMP/ GAUGE, 0-30 i n. Hg
A973X-f i 1
-XXXXX
VALVE
(EGR)
System
(D16Y5
engine GWI
(cont'dl
,w;
VACUUM
li;El
E
l o
e l
PUMP/GAUGE,0
-
30 in.Hg
A973X-041-XXXXX
*nj-
\
EGR CONTROL SOLENOIO VALVE
2P CONNECTOR
Termi nal si de ol
mal e t ermi nal s
(To page
11-173)
11- 172
( Fr om page
11- 171)
Check t or a mal f unct i on i n t he
EGR valve:
1. Move the vacuum pump/gauge
t o t he EGR val ve.
2. Wi t h t he engi ne at ; dl e, appl y
26.7 kPa {200 mmHg, 8.0 in.Hg)
of vacuum t o t he EGR val ve.
Does t he engi ne st al l or run
rough and does t he EGR val ve
hol d vacuum?
Check the vacuum routing:
1. Reconnect t ho vacuum pump/
gauge t o t he No. 16 hose.
2. St art t he engi ne and l et i t i dt e.
3. At t he EGR cont r ol sol enoi d
valve side, connect the baftery
posi t i ve
t ermi nal t o t he EGR
control solenoid valve connec-
t ort ermi nal No, 1,
4. Whi l e wat chi ng t he vacuum
ga
uge, connect t he bat t er y
negat i ve t ermi nal t o t he EGF
cont rol sol enoi d val ve 2P con-
nect ort ermi nal No. 2.
l s t here approx. 26. 7 kPa
(200
mmHg, 8. 0 i n. Hg) of vacuum
whhi n l second?
Check the vacuum ho3a:
1. Turn t he
j gni t i on
swi t ch OFF.
2. I nspect t he No. 16andNo. 10
hoses tor leaks, restrictions or
mrsrout | ng.
#16 HOSE
\
( Fr om page 11 172)
Check for an open in the wire {E
SOL l i nel :
f rom t he EGR cont rol sol enoi d
3. Di sconnect t he ECM connect or
A
(32P)I rom
t he ECM.
ECM connect or t er manal 47
and t he EGR cont rol sol enoi d
val ve 2P connect or t er mi nal
No . 2 .
Repeir op6n in lhe wire b'twen
the EGR control 3olenoid valv6
and the ECM lA?).
Chck t or a short i n t he wi r
(ESOL
l i ne):
Check l or cont i nui t y bet ween t he
EGR control solenoid valve 2P con
nect or t ermi nal No. 2 and body
ground,
Repril short in th wi.e betwcen
t h EGR cont rol sol enoi d val ve
and the ECM lA7l.
Check f or an op6n i n t he wi r e
( GND
l i nel :
Check {or continuity between the
EGR control solenoid valve 2P con
nect or t er mi nal No.
' 1
and body
gr ound,
Bopair open in the wir betwoen
t ho EGR cont rol sol noi d val ve
and G101.
Subst i t ut e e known-good ECM
tion goes away, replace the origi-
nal ECM.
EGR CONTROL SOLENOID
VALVE 2P CONNECTOR {Cl42I
Wire side
of f emal e
t ermi nal s
ECM
CONNECTOR
A t32Pl
ESOL
I FEDI
ESOL
IREDI
GND
{8LKI
Wi re si de
oI female
terminals
(cont' d)
-173
1 1
Exhaust Gas Recirculation System
lD16Y5
enginel
(cont'd)
M/T:
EGR VA|V: 6P COI{NECTOR lC14,a)
G101
IBLKI
1 2 3
1 6
PNK
IE.EGNI
Wire side of mal torminals
EGR VALVE 5P CONNECTOR
rr-
Wire side of fem.lo terminrls
-
The MIL has ben roportod on,
-
OTC Pl{)l is stord.
Probl6m vorification:
nector.
engane at 3, 000 rpm wi t h no
l oad (t ransmi ssi on
i n neut ral )
until the radiator fan comes on.
4. Drive the vehiclo on the road
for approx. 10 minutes. Try to
keep t he engi ne speed i n t he
1,700
-
2,500 rpm rang,
Intermittont frilur., ry3tem i! OK
at this timo. Check tor poor
con-
n.c{ion3 or looa6 wiros at Clil4
IEGR vllve) lnd ECM.
l s DTC P 1491 i ndi cat ed?
Check t or r mal l unct i on i n t he
EGR valve:
L St art t he engi ne and l et i t i dl e.
2. Measure voltage between th6
EGR valve 6P connector termi
nal No. 4 and No. 6.
Chock the EGR v.lv.:
2. Di sconnect t he EGR val v6 6P
connector.
3. Connect t he bat t ery posi t i ve
t ermi nal t o EGR val ve 6P con'
nect or t ermi nal No, 6.
4. St an t he engi ne and l et i t i dl e,
then conn6ct lh battery nega-
t i ve t ermi nal t o EGR val ve 6P
connector terminal No. 4.
Sub3t i t ut e r known-good ECM
and rcch.ck. lf symplom/indica-
tion goe3 .wey, replace th origi-
nal ECM.
( To
page 11- 175)
11- 174
\
(From page 11-174)
Chock for an op6n in the wire {E
-
EGR l i nel :
2. Disconnect the ECM connector
A
(32Pl f rom
t he ECM.
ECM connect or t er mi nal 47
and t he EGR val ve 6P connec-
t or t ermi nal No. 6.
Repair opon in tho wir6 betwcon
tho EGR valvc and tho ECM lA7l.
Chock l or rn opgn i n t ho wi r6
I GND l i nol :
Check lor continuity betveen the
EGR val ve 6P connect or t ermi nal
No. 4 and body
ground.
Repsir opn in the wir btwen
th. EGR control 3olnoid v.lve
and G101.
Subrt i t ut a r known-good ECM
.nd rcchock. lt 3ymptom/indica-
lion go.3 away, .apl.ca tha origi-
nd ECM.
EGR VALVE
6P CONNECTOR tcla,al
Wire side
of female
t ermi nal s
t32Pl
Wi re si de
of lemale
t srmi nal s
1 2
I E.EGF
Iorurr
E-EGR
IPNKI
a
_j
2 3 a 8
't0
11
12 13 14 t 5 t6 17 18 19 20 22 23 21
25 21 n a 30
1 2 3
{
I G101
0) ter-xt
(cont' d)
1- 175
Exhaust Gas Reci rcul ati on System
(D16Y5
engi ne)
{cont' dl
(DTC)
P' 1498: A hi gh vol rage probl em
i n the Exhaust Gas
Reci rcul ati on
(EGR)
val ve l i ft sensor ci rcui t.
EGR VALVELIFT SENSOR 3P lM/T: SPlCONNECTOR {Ct14l
cw:
vcc2
IYEL/BLUI
SG2 IGRN/BLKI
sG2
(GRN/
BLK}
vcc2
(YEL/
ALUI
Wiro side of female teaminals
cM CoNNECTOR O tl6Pl
vcc2
(YEL/BLUI
sG2
(GRN/BLKI
Wire side of female te.minals
-
The MIL has boen reported on.
-
DTC P14)8 is sto.ed.
Problem vs.iticstionl
1. Do t he ECM Beset Procedure.
2. Start the engine.
lntermittfi failuro. 3y3tem i3 OK
at thL tim.. Chcck to. ooor con-
noctions o. loo3. wire3 at Cl/14
IEGR valv.l and ECM.
Check t or an op6n i n t he EGR
valve lift sonso.:
2. Di sconnect t he EGR val ve l i f t
sensor 3P {M/T: 6P) connector.
(l l ).
4, Measure voltage between the
EGR valve lift seosor 3P
(M/T:
6P) connect or t ermi nal s No. 3
and No. 2.
l s t here approx, 5 V?
Chock tor opcn in the wire
lSG2
l i nel ;
connect or t ermi nal s D10 and D11.
Ropair opon in th. wirg bctwoon
ECM
(D11)
and EGR val v. l i t t . cn-
sor.
and recheck. ll symptom/indica-
tion goe3
away, replac the origi-
nal ECM.
11- 176
Positive Crankcase Ventilation
(PCV)
System
Dscription
The Posi t i ve Cr ankcase Vent i l at i on
( PCV)
syst em i s
desi gned to prevent bl ow-by gas trom escapi ng to the
atmosphere. The PCV val ve contai ns a spri ng-l oaded
pl unger. When the engi ne starts, the pl unger i n the PCV
val ve i s l i fted i n proporti on
to i ntake mani fol d vacuum
and the bl ow-by gas i s drawn di rectl y i nto the i ntake
mani fol d.
O16Y5, D16Y8 engi ne:
D16Y7 engi ne:
:: ELOW-BY VAPOR
e: FRESH AIR
Inspgqtion
1 . Check the PCV hoses and connecti ons for l eaks and
cl oggi ng.
At i dl e, make sure there i s a cl i cki ng sound from the
PCV val ve when the hose between PCV val ve and
i ntake mani fol d i n l i ghtl y pi nched wi th your fi ngers
or ol ters.
D16Y5, D16Y8 ongi ne:
Gent l y pi nch
here.
PCV VALVE
D16Y7 engi ne:
Gent l y
pi nch
her e.
l f t her e i s no cl i cki ng sound, check t he PCV val ve
grommet for cracks and damage. l f the grommet i s
OK, repl ace the PCV val ve and recheck.
VALVE
11- 177
Emission Gontrol System
Evaporative Emission
(EVAP)
Controls
Dsscripiion
The evaporati ve emi ssi on control s are desi gned to mi ni mi ze the amount of fuel vapor escapi ng to the atmosphere. The
system consi sts of the fol l owi ng components:
A. Evaporative Emission (EVAP)
Control Canister
An EVAP control cani ster i s used tor the temporary storage of l uel vapor unti l the fuel vapor can be purged from the
EVAP control cani ster i nto the engi ne and burned.
B. Vapor Purge Contfol System
EVAP control cani ster purgi ng i s accompl i shed by dr6wi ng fresh ai r through the EVAP control cani ster and i nto a
pon
on the i ntake mani fol d. The purgi ng
vacuum i s control l ed by the EVAP purge control sol enoi d val ve.
I ' 96 O16Y5 engi ne, ' 96 D16Y7 engi ne, ' 96 D16Y8
engi ne
( s edan) , ' 97
D16Y5 engi ne, ' 97 D' 16Y7
engi ne (coupe:
KA, KC model s, sedan: KA, KC,
KL
( DX)
model s , hat c hbac k : al l model s ) , ' 97
D16Y8 engi ne
(sedan:
KA, KC model s)l
l ' 96 D16Y8 engi ne
( c oupe) ,
' 97
D16Y7 engi ne
( c oupe:
KL model , s edan: KL
( LX)
model ) , ' 97
D16Y8 engi ne
(coupe:
al l model s. sedan: KL model ,
' 98-al l
model sl l
\
or
A./C COMPRESSOR CLUTCH ON
and
INTAKE AIR TEMPERATURE ABOVE 160"F
(41"C}
C. Fuel Tank Vapor Control System
When fuel vapor pressure i n the fuel tank i s hi gher than the set val ue of the EVAP two way val ve, the val ve opens and
regul ates the fl ow of fuel vapor to the EVAP control cani ster.
EVAP PURGE CONTROL SOLENOID VALVE DUTY CON.
TROLLED AFTER STARTING ENGINE
ENGIN COOLANT TEMPERATURE ABOVE 154' F
(68"C)
ENGINE COOLANT TEMPERATURE ABOVE 154"F I68"C)
INTAKE AIR TEMPERATURE ABOVE 32"F
(O' C)
ano
VEHICLE SPEED ABOVE 0 MILE
(0
km/h)
11- 178
'96
D16Y8 engine lcoupe),
'97
D16Y8 engine {coupe: all models, sedan: KL model).
'98
Dt6Y5 engine
(all
models},
'98
D16Y8 engi ne
(al l
model sl :
9:I'
EVAP PURGE
CONTROL
SOLENOID VALVE
From
No. 15
ALTERNATOR
SP SENSOR
(7.s
a)
7'
YEL/
BLU
.
LT GRN
.
GRN/
BLK
r
tLl
FUEL
TANK
PRESSURE
SENSOR
\
THREE
VAPCONTROL
VENT SHUT VAI
EVAP
BYPASS
SOLENOID
VALVE
EVAP
TWO WAY
VALVE
FUEL
TANK
PRESSURE
SENSOR
VAL
BLU
LT GRN/
WHT
RED/
YEL
INTAKE
MANIFOLD
'97
Dl6Y7 engine {coupe: KL model, sedsn: KL
ILX) mod6l},'98 D16Y7 engine:
9ii
'-<
From
No. 15
ALTERNATOR
SP SENSOR
t 7. 5 Al
YEL/
BLU
LT G'
GRN/
BLK
BLU
EVAP
BYPASS
SOLENOID
VALVE
EVAP
TWO WAY
VALVE
LT GRN/
WHT
RED/
YEL
EVAP CONTROL
CANISTER
FUEL FI LL
CAP
(cont' d)
11- 179
BLK
FUEL TANK
BLK
FUEL TANK
' 96
D16YS engi ne,
' 96
D16Y8 engi ne l sedanl ,
' 97
D16Y5 engi ne,
' 97
D16YB engi ne l sedan: KA, KC model s):
Evaporative Emission Controls
(cont'dl
EVAP
TWO WAY
VALVE
EVAP
PURGE
CONTROL
SOLENOID
VALVE
EVAP
PURGE
CONIROL
sot_ENotD
VALVE
\,*ro..
\
MANIFOLD
'96
D16Y7 engine,'97 D16Y7 engine
(coupe:
KA, KC mod6ls, sedan: KA, KC, KL IDX) models, hatchback: all models):
From
No. 15
i:1"
-----
{
ALTERNAToR
SP SENSOR
VARIOUS
SENSORS
BLK
J-
1 1 - 1 8 0
MANIFOLD
Fuel Tank Pressure Senso. I' 96 D16Y8 engi ne {coupe),' 97 D16Y7 ngi ne
(coupe:
KL mod6l , sedan: KL
(LXl
modet),' 97
D16Y8 engi ns
(coupe:
al l model s, sodan: KL model ,' 98-al l model s)l :
The scan t ool i ndi cat es Di agnosl i c Troubl e Code
(DTCI
P0452: A l ow vol t age probl em i n t he Fuel Tank Pressure
sensor.
The fuel tank pressure sensor converts l uel tank absol ute pressure i nto el ectri cal si gnal s and i nputs the ECM/PCM.
OUTPUT
VOLTAGE
tv)
4. 5
0.5
-7
kPr
(-50
mmHg,
-2
i n. Hgl
+t kP8
(50
mmHg,
2 i n. Hgl
PRESSURE
PTANK
{LT GRN'
vcc2
(YEL/BLU)
Wiro side ol temale terminals
FUEL TANK
PRESSUBE SENSOB
3P CONNECTOR tC792)
Wi re si de of f emal e t rmi nal s
(cont' d)
1 1 - 1 8 1
Th6 MIL has ben .eported on.
DTC P0452 b stored,
Chck the vacuurn linos:
Check t he vacuum l i nes of t he
f uel t ank pressure sensor f or mi s-
r out i ng, l eakage, br eakage and
cl oggi ng.
Are t he vacuum l i nes OK?
Problem vorilication:
1. Do t he ECM/ PCM Reset Proce'
dure.
(l l ).
4. Moni t or t he FTP Sensor vol t -
a g e wi t h t h e Ho n d a PGM
Test er , or measur e vol t age
bet ween body gr ound and
ECM/ PCM t ermi nal D15.
Intermittent tailur6, systom is OK
at thb time. Check tor ooor con-
nections or loose wire3 at C131
{located under right sid6 of dashl,
C401
(located
above unde.-daah
t use/ rel ay boxJ. C568 l l ocat od
under acce3s
prnel),
C792
(tuel
tank
pre33ure
sonsorl and ECM/
FCM.
l s t here approx. 2. 5 V?
Chock for an opon in wire {VCC2
linel:
2. Rei nst al l t he f uel f i l l cap.
3. Di sconnect t he f uel t ank pres-
sure sensor 3P connect or.
(l l ).
5, Measure voltage between the
f uel t ank pressure
sensor 3P
connect or No, 1 t ermi nal and
No. 2 t ermi nal .
Repair open in the wire belween
tho tueltank pre3sur6
sen3o. and
t he ECM/ PCM l D10l .
YES
(To page 11-182)
{ Fr om
page 11- 181}
Check t or a shor t i n t he wi r e
I PTANK l i ne):
f uel t ank pressure sensor 3P con-
nect or No. 3 t ermi nal and No. 2
r er mt nat ,
Check f or a Short i n t he wi re
(PTANK line):
2. Di sconnect t he ECM/ PCM con
nect or D
(16P).
t he f uel t ank
pressure sensor
3P connect or No. 3 t ermi nal s
and body
ground.
Reoair Short in the wire between
the fueltank oressurc sensor and
ECM/ PCM t D15).
Sub3titut6 a known-good ECM/
PCM and recheck. l l sympt om/
indication goes away, replace the
orisinal ECM/PCM.
(cont'dl
\
FUEL TANK
PRESSURE SENSOR
3P CONNECTOR {C7921
PTANK
(LT
GRN)
sG2
{GRN/BLK)
11- 182
Fuel Tank Pressure Sensor f96 D16Y8 ongi ne {coups),' 97 D15Y7 ongi ns l coupe: KL model , sedan: KL
(LX}
model },,97
D16Y8 engi ne l coupe: al l model s, s6dan: KL model ,' 98.al l model sl l :
(DTC)
P0453: A hi gh vol tage probl em i n the Fuel Tank Pressure
sensor.
ECM/PCM CONNECTOR D
(T6P}
PTANK
ILT GRNI
Wire sids of f6mals terminals
FUEL TANK
PRESSUAE
SENSOR
3P CONNECTOR
tC792)
vcc2
(YEL/3LUI
sG2
IGRN/BLKI
Wir6 side of temale terminals
sG2
IGRN/BLKI
PTANK
IGRN/NEDI
(cont' d)
1 1- 183
1 2 3
Th6 MIL has been roportod on.
OTC P(X53 is stored.
Chack thc vacuum lines:
Check t he vacuum l i nes of t he
sensor f or mi s-
rout i ng, l eakage, breakage and
cl oggrng.
Are t he vacuum l i nes OK?
Problcm verificetion:
dure,
(l l ).
4. Moni t or t he FTP Sensor vol t ,
a g e wi t h t h e Ho n d a PGM
Test er , or m6asur e vol t age
bet ween body gr ound and
ECM/ PCM t ermi nal 015.
Intermittont tailu.e, sy3tem b OK
at this tim6. Chcck to. poor con-
noctions or loo.g wiros at C131
{locatod under right side ol d.!h},
C401 llocrtod abovo und.r-dash
t use/ rol ay boxl , C56E l l ocat od
undor accoss D6ncl ), C792
(f uel
tank prossurc
s6n3or) and ECM/
FCM.
l s t here approx. 2. 5 V?
Chock f or rn opon i n t he wi re
l SG2l i nol :
2. Rei nst al l t he f uel f i l l cap.
3. Di sconnect t he f uel t ank pres-
sure sensor 3P connect or,
(l l ).
5, Measure vol t age bet ween t he
sensor 3P
connector terminals No. 1 and
No. 2.
Repai. opn in thc wirc botwcn
the tuel tank pa633ure 36nsor end
ECM/ PCM
(D111.
Check t or an open i n t he wi ro
(PTANK
linal:
sensor 3P con-
nect or No. 3 t ermi nal and No. 2
t ermanal .
(To page 11-184)
(From page 11 183)
{PTANK line}:
PCM connect or t er mi nal s D15
a n d 0 1 1 .
Rcp.ir open in th6 wir6 betweon
ECM/ PCM { D15) and f uel t ank
pt033ute sensol.
Sub3litute a known-good ECM/
PCM . nd rechck. l f sympt om/
indication
goes
away, replace th6
original ECM/PCM.
(cont'd)
ECM/PCM CONNECTOR D
(16PI
SG2IGRN/BLK)
\
PTANK
ILT GRNI
Wire side of fsmal terminals
11- 184
[' 96 Dl 6Y8 engi ne
(coupe],' 97
Dl 6Y7 sngi ne {coupe: KL model , sedan: KL
{LX} modeU.' 97 Dl 6Y8 engi ne
(coupe:
al t mod-
els, sedan: KL model,
'98-all
modolsll:
(DTC)
P1456: Evaporati ve Emi ssi on (EVAP)
conl rol system teak
detected
(fuel
tank system).
(DTCI
P1457: Evaporati ve Emi ssi on
(EVAp)
control system reaK
detected
(EVAP
control cani ster system).
tPEs6l
tPl45?-l
Possiblo Causo
. Fuel fi l l cao
. Vacuum Connecti ons
. Fuel Tank
. EVAP Control Cani ster Vent Shut Val ve
. EVAP Control Cani ster Vent Shut Val ve Ci rcui t
o EVAP Purge Control Sol enoi d Val ve
. EVAP Purge Control Sol enoi d Val ve Ci rcui t
. EVAP Bypass Sol enoi d Val ve
. EVAP BvDass Sol enoi d Val ve Ci rcui t
. Fuel Tank Pressure Sensor
. Fuel Tank Pressure Sensor Ci rcui t
. EVAP Control Cani ster
. Throttle Body
Troublshooting Flowchart
VACUUM
PUMP/GAUGE,0-30i n.Hg
4973X
-
041
-
xxxxx
EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Repl ace.
(cont' d)
1 1 - 1 8 5
-
Th. MI L has bo. n reDoned
-
DTC P1456 or P1457 i. storcd.
Ch6ck the EVAP control c.nbtet
v.nt lhut valva:
1. Di sconnect t he vacuum hose
f r om t he EVAP t hr ee way
val ve and connect a vacuum
pump
t o t he hose.
2. Rmove t he EVAP cont r ol
cani st er vent shut val ve l rom
t he cani st er.
(l l ).
4. Appl y vacuum t o t ho hose.
Chock t or a short i n t he wi ro
{VSV linol:
Disconnect the 2P connector from
t he EVAP cont rol cani st er vent
Does the valve hold vacuum?
Rop.ir 3hort in the wirc betwen
l h6 EVAP cont rol cani st e. vnt
shut val vo and t he EcM/ PcM
la29l.
Does the valve hold vacuum?
Check tho EVAP control crnialc.
vont 3hut valvo:
t ermi nal 429 t o body ground
wi t h a
j umper
wi re.
(l l ).
4. Appl y vacuum t o t he hose.
Roplrce the EVAP control cani.-
tcr vont rhut valvo,
Does t he val v hol d vacuum?
ECM/PCM CONNECTOR A I32P)
I 2 a 7 a 9 t o l l
12 t 3 t 5 t 3 t t r8 t 3 20 2 23 2a
6 21 a 4t 30
{LT GRN/WHTI
I JUMPER WIRE
{ To page 11- 186) ( To page 1l - 186)
Emission Gontrol System
Evaporative Emission
(From page 11-185)
Controls
(cont'dl
(From page
' 1' l -185)
EVAP CONTROL
CANISTER VENT SHUT
VALVE 2P CONNECTOR {Cl41I
t Gl
IBLK/YEL)
Wire side of fmale torminal6
ECrir/FcM @NNECTOfi A {32P1
vsv
(LT
GRN^ Vlff)
Wiro sid ot lomsle
t 6rmi nal s
VACUUM
PUII'P/
GAUGE,0
-
30 i n.Hg
A973X
-
041
-
xxxxx
Check l or an op. n i n t h. wi . e
(l G1
l i nel :
f rom t he EVAP cont rol cani s-
t er v0nt shut val v.
(l l ).
4. Measure voltage betwen the
EVAP controlcanister vent shut
val ve 2P connect or t ermi nal
No. 2 and body ground.
Rcpair opon in tha wirc batwoon
tho EVAP control crnirtor vont
lhut vdw rnd tho No. 15 ALTER-
NATOR SP SENSOR {7.5 Al tu!..
Ch.d( ior an op.n in tho wirr IVSV
lin l:
2. Roconnect t he 2P connect or
t o t he EVAP cont rol cani st er
vent shut val ve.
(ll).
4, Measur e vol t age bet ween
ECM/ PCM connct or t 6r mi
nal s A29 and A10.
Rapair op6n in thc wh6 batwaan
iho EVAP control caniatar vant
shut vrl vo end t h. ECM/ PCM
tA29t.
Raolacc th6 EVAP cont.ol canis-
ter vant rhut valva.
PGl
(BLK)
I -J-
'|
2
I ' l ' l '
r r l r r l l l l l
I l r l r l
r o
I
r r
I
12 l 3 t 5
@l / l z l a l u l
a ,JAA_]{
Ch6ck tho vacuum whan cold:
1. Di sconnect t h vacuum hos6
shown from the EVAP control
canrster and connect a vacuum
gauge to the hose.
2. St an t he engi ne and al l ow i t
t o i dl e.
NOTE: Engi ne cool ant t em-
perature must bo below 154"F
(68'C)
or Iy'C switch OFF.
3. Ouickly raise the engine spegd
to 3.000 rpm.
(To page 11-187)
1 1- 1 86
Ch. ck t he EVAP purge
cont rol
robnoid velvol
f rom t he EVAP purge cont rol
sol onoi d val ve.
2. Orrickly raise the engine speed
to 3,000 rpm.
Inspect v.cuum hoae routing.
l f OK, repl aco l ho EVAP purge
contrcl solonoid valve.
Chcck t or a short i n t he wi r.
{PCS lincl:
2. Disconnect ECM/PCM connec-
t or A 132P).
3. Check for continuity botween
t he EVAP purge
cont rol sol e'
noid valve 2P connector termi-
nal No. 2 and body ground.
Chack tha vrcuum whcn hoti
2. Block the rear wheels and set
the parking
brak.
3. Jack up tho front ot the vehi-
cle and support it with salety
slands.
4. St ar t t he 6ngi ne. Hol d t he
engi n at 3, 000 rpm wi t h no
loed {A/r in
E
or
E
position,
WT in neutral) untilthe radiator
lan comes on, then let it idle.
5. Ch6ck tor vacuum at the vac'
uum hos6 wi t h l ransmi ssi on
i n ge6r
{A/ T i n
B
posi t i on,
M/T in 1st gear) after starling
t he ngi ne.
6. Ouickly raiso tho ongine sp66d
to 3,000 rpm.
Repair short in the wira bgtween
the EVAP purga
control solonoid
valvo and rhe EcM/PcM lA15l.
Sub3titut. a known-good EGM/
PCM lnd r.ch.ck. lf symptom,/
indication
eoo3
away, raplacc th.
o.iginrl ECM/FCM.
Chock t h6 EVAP purg. cont rol
.olonoid valvoi
l . Turn t he i gni t i on swi t ch OFF.
from the EVAP purgo
control
sol enoi d val ve and worm i t
up t o normal operat i ng t om
perature
again it necessary.
4. At t he ha. ness si de. moasure
vol t age bet ween t he EVAP
purgo
cont rol sol enoi d val ve
2P connect or t ermi nsl No. 1
and No. 2.
Intpct vacuum hoa! routing.
It OK, roplace EVAP purg6 con-
trol solonoid v6lvo.
ls there battery vohage?
Chcck f or an opcn i n t h6 wi re
l l cl l i nol l
At the harnoss side. measurc volt-
ago btwoen the EVAP purge con-
t rol sol enoi d val ve 2P connect or
terminal No. 1 and body ground.
Ropai. open in the wiro lrotwean
EVAP purga
control 3olcnoid valv.
ANd thC NO. 15 ALTERNATOR SP
SENSOR {7.5 Al fu36.
(From page 11-186)
tGl
IBLK/YEL}
(cont' d)
11- 187
EVAP PURGE CONTROL SOI:NOID
VALVE 2P OONNECTOR lC11,al
Wiro side ot
t emal e
trmrna|s
PCS
{RED/YELI
{To
page 11-188) (To page 11-188|
(From page 11 187)
{PCS line}:
2. Reconnect t he 2P connect or t o
t he EVAP
purge cont rol sol e_
noi d val ve.
A15 and A10.
Repair open in the wire botween
th6 EVAP purga cont.ol solenoid
v.lve and the EcM/PcM lA15l.
Subrtitute a known.good ECM/
PCM and ratest. It symptom/indi-
cat i on goe3 away, repl ace t he
original ECM/PcM.
( Fr om page' 11' 187)
Check the EVAP two way valvsl
See EVAP two way valve test
(see
page 11' 1931.
Repl.c the EVAP two way v.lve.
Check the EVAP bypa$ solenoid
1, Di sconnect t he vacuum hose
from the EVAP two way valve
and connect a vacuum
pump
t o t he hose.
2. Turn t he i gni t i on swhch ON
(l l i .
3. Appl y vacuum t o t he hose. Check t or a short i n t he wi .
I2WBS line):
Di sconnect t he 2P connect or l rom
the EVAP bypass solenoid valve. Does t he val ve hol d vacuum?
Rooair 3hort in tho wirc botween
EVAP bypass 3ol.noid valve and
rhe EcM/PcM {A281.
Does t he val ve hol d vacuum?
Evaporative Emission Controls {cont'd}
l To
pag6 11- 1891
|5
ECM/PCM CONNECTOR A {32P)
PGI
{BLKI
PCS
{RED/YELI
wire sid ot
f emal e
! ermrnat S
\
PUMP/
xxxxx
GAUGE.0
-30
i n.Hg
4973X
-
041
-
EVAP BYPASS
SOLENOID VALVE
O.RING
Repl ace.
U
EVAP TWO WAY
EVAP TWO WAY VALVE
1 1 - 1 8 8
\
(From page 11-188)
Check the EVAP bypass solenoid
t ermi nal A28 and body ground
wi t h a
i umper
wi re.
3. T! rn t he i gni t i on swi t ch ON
(l l ).
Check f or an opon i n t ha wi re
l l Gl l i nel :
f rom t he EVAP bypass sol e
(l l ).
2P connect or t er mi nal No. 1
and body ground.
Does val ve hol d vacuum?
Ropai. open in the wirc botwoon
EVAP purg6 control solonoid valve
snd the No. 15 ALTERNATOR SP
SENSOR 17.5 A) tu36.
{2WBS lin6l:
2. Reconnect t he 2P connect or
t o t he EVAP bypass sol enoi d
(l l ).
A28 and A10.
Check t he f ol l owi ng part 3 l or
l eakage t o at mospher e. and
repair or rcplace it necessary:
'
tucl till c.p
.
luel tank
.
tuel vapor pipe
.
EVAP two wav vslve
.
EVAP bypass solenoid valve
.
Iuel tank pressure sensoa
.
EVAP control cenkter
.
EVAP cont r ol cani st cr vant
shut valve
.
EVAP pu196 cont rol sol enoi d
.
vacuum hosos and connoctions
Ropai. opon in the wiro between
tha EVAP byp.33 3olenoid valv.
.nd tho ECM/PCM lA28|,
5 I I l o
'12
t 3 r5 t 6 I t t l 19 2A 23 2a
25 27 2A 29 30
2WBS
IBLUI
Wire sid of
f emal 6
ECM/PCM CONNECTOR A I32PI
t ermi nal s
JUMPER
WIRE
EVAP BYPASS SOLENOID
VALVE 2P CONNECTOR {C79i}l
t G1
(BLK/WHTI
Wire sido of
lemale
t ermi nal s
ECM/PCM CONNECTON A
(32PI
wirs side of female
l6fmrn6ls
(cont' d)
1 1- 189
PGl
(BLK}
= -J--
l r l l . l e l
r o
I
i r
I
12 l 3 t 6 1a 1 1 t t tolal.lal za
l
yl
6 21 a
2WBS IBLUI
{cont'd}
' 96
Dl 6Y5 engi ne,' 96 Dl 6Y7 engi ne,' 96 Dl 6Y8 engi ne {sedan},' 97 Dl 6Y5 engi ne,' 97 D16Y7 engi ne
l coupe:
KA, KC mod-
els, sedan: KA, KC, KL
(DX)
models, hatchback: all models),
'97
Dl6Y8 ngine
(sedan:
l(A, KC models):
-
(DTC)
P0441: Evaporati ve Emi ssi on
(EVAP)
control system
I
P0441
|
;n"r11;";.nt ouroe ftow.
Description
By moni tori ng the purge l i ne vacuum wi th the MAP sensor, the ECM/PCM can detect i nsuffi ci ent EVAP control system
purge fl ow.
Possible Cause
. EVAP Purge Control Sol enoi d Val ve
. EVAP Purge Control Sol enoi d Val ve Ci rcui t
. EVAP Control Cani ster
. Vacuum Li nes
. ECM/PCM
\
EVAP PURGE CONTROL
SOLENOIO VALVE 2P
CoNNECTOR tctla)
r+_r
' l ' l
lrci
oixrv..r
rv)
Y
wir6 side of lemslo
t ermi nal s
-
Tho MIL has b6on reported on,
-
DTC P(X4t is stored.
Problsm ve.itication:
engane at 3, 000 rpm wi t h no
load
(A,/T
in
N
or
E
poskion,
M/ T i n neut ral ) unt i l t he radi a'
t or t an comes on.
oure,
nector.
4. Test-drive under following con-
ditions on the road.
-
Without any eloctricalload
-
A/ T i n
$
or
E
posi t i on
(M/T
in 3rd-5th gear)
-
Engi ne speed bet ween
1,200
-
2,400 rpm.
-
Decelerate from 50 mph
(80
km,4') to 15 mph 124 km/h)
Intorrnittent tailu.e, 3wtem i3 OK
at thi3 timo. Chock for poor
con-
nctions or 10036 wir$ at C144
(EVAP purge
cont rol sol enoi d
valve)and ECM/PCM.
ls oTC P0441 indicated?
Chck for an opn in the wir
(lcl
linell
2. Di sconnect t he EVAP pur ge
nector,
3. Turn the ignition switch ON {ll).
4. Measure voltage between bodv
gr ound and t he EVAP pur ge
control solenoid valve 2P con-
nect ort ermi nal No. 1.
Ropair open in th wiEs botwoon
the EVAP purgo
control rolenoid
valve and th. No. 15 ALTERNA.
TOR SP SENSOF 17.5 Al fuse.
{ To page I 1- 191)
1 1- 1 90
{ Fr om
page 11- 190} ECM/PCM CONNECTOR D
(32PI
PG1IALK)
JUMPER WRE
Wi re si de oI t omal e t ermi nal s
PCS {RED/YELI
t
I 2 6 I E 9 10 l l
12 l 3
'l'a
t 5 l 6 17 I E t 9 20 23 21
25 27 26 A 30
O)
Pcs {RED/YEL}
Chock t ho EVAP purge cont rol
30lenoid valv6:
' 1.
Reconnect t he EVAP pur ge
cont rol sol enoi d val ve 2P con
nector.
2. Connect ECM/ PCI , connect or
t ermi nal s A' 15 and A10 wi t h a
Chock fol rn op6n or 3hort in th6
wirc IPCS lin6l:
PCM connect or t ermi nal A15 and
body ground.
Does t he sol enoi d val ve cl i ck
when t he
j umper i s connect ed?
Ch6ck for a shon in the wire IFCS
lin):
nect or A {32P).
3. Di sconnect t he EVAP pur ge
nector.
body
ground
and ECM/ PCM
connect or t ermi nal A15,
l s t here banery vol t age?
ReD.ir 3hort in the wire! bdtween
the EVAP purge
control 3olgnoid
vtlve .nd ECM/PCM
(415).
Ropair opon in the wires bstwson
the EVAP purge
control solenoid
valve and ECM/PCM {Al5}.
Chock tho vacuum lines:
Check t he vacuum l i nes of EVAP
syst em I or mi srout i ng, l eakage.
breakage and cl oggi ng.
Ar t he vacuum l i nes OK?
{To
page 11-192)
(cont' d)
1 1 - 1 9 1
t
(cont'd)
l Fr om page 11- 191)
D16Y5 engi ne:
PCM and recheck. l f svmpt om/
indication goes
away, replace the
original ECM/PCM.
D16Y5 engi ne:
JUMPER WIRE
D15Y7, D16Y8 ngi ne
VACUUM
PUMPI
GAUGE,
VACUUM
PUMP/
GAUGE,
0
-
30 i n. Hg
A973X
-
041
-
xxxxx
0- 30 i n. Hg
4973X
-
041
-
xxxxx
EVAP CONTROL
CANISTER
ECM/PCM CONNECTOR D I32P}
PG1IBLKI
VACUUM/
PRESSURE
GAUGE 0- 4 i n. Hg
07JAZ
-
0010008
VACUUM/PRESSURE
GAUGE
0
- il
in.Hg
07JAZ
-
0010004
Check t he EVAP purge cont rol
solenoid valve:
1. Di sconnect t he vacuum hose
from the EVAP control canister.
2. Connect t he vacuum pump t o
t he hose and appl y vacuum.
Does i t hol d vacuum?
Check the EVAP control canister:
1, Reconnect t he vacuum hose t o
t he EVAP cont rol cani st er.
2, Connect t he vacuum/ pressure
9auge
t o t he
purge
ai r hose.
t ermi nal s 415 and 410 wi t h a
4. St a rt t he engi ne.
5. Check t he vacuum.
Check t he EVAP t wo way val ve
l s ee
page 11 193) .
0oes t he EVAP t wo way val ve
Replace the EVAP two way valve.
D16Y7, Dl 6YB engi ne:
11-192
(EVAP)
Two Way Val ve Testi ng
I' 96 Dl 6Y8 engi ne {coupel ,' 97 Dl 6Y7 engi ne
(coupe:
KL
model , sedan: KL
(LX)
model ),
' 97
D16Y8 engi ne {coupe:
al l model s, sedan: KL model ,' 98-al l model sl l :
2. Remove t he vapor l i ne f r om t he EVAP t wo way
val ve, and connect i t to a T fi tti ng from a vacuum
gauge and a vacuum pump as shown.
VACUUM/ PRESSURE
GAUGE
0
-
4 i n. Hg
3.
4.
07JAZ
-
0010008
Appl y vacuum sl owl y and conti nuousl y whi l e watch-
i ng the gauge. The vacuum shoul d stabi l i ze momen-
t ar i l y at 0. 8
-
2. 1 kPa
( 6 -
16 mmHg, 0. 2 0. 6 i n. Hg) .
l f t he v ac uum s t abi l i z es
( v al v e
opens l bel ow
0. 8 k Pa
( 5
mmHg, 0. 2 i n. Hg) or abov e 2. 1 k Pa
( 16
mmHg, 0. 6 i n. Hg) , i nst al l a new val ve and r et est .
Move the vacuum pump hose from the vacuum fi t-
ti ng to the pressure fi tti ng, and move the vacuum
gauge hose from the vacuum si de to the pressure
si de as shown.
Sl owl y pressuri ze the vapor l i ne whi l e watchi ng the
gauge. The pressure shoul d be stabi l i ze momentari -
l y above 1. 0 kPa ( 8 mmHg, 0. 3 i n. Hg) .
. l f t he pr essur e moment ar i l y st abi l i zes
( val ve
opens) above 1. 0 kPa
( 8
mmHg, 0. 3 i n. Hg) , t he
val ve i s OK.
. l f the pressure stabi l i zes bel ow 1.0 kPa
(8
mmHg,
0.3 i n.Hg), i nstal l a new val ve and retest.
T-FITTING
f96 D16Y5 engi ne,' 96 D16Y7 engi ne,' 96 D16Y8 engi ne
(sedanl ,' 97
D16Y5 engi ne.' 97 D16Y7 engi ne
(coupe:
KA.
KC model s, sedan: KA, KC, KL
(DX)
model s. hatchback:
al l model sl ,' 97 D16Y8 engi ne
(sedan:
KA. KC model s)l :
2. Remove t he vapor l i ne f r om t he EVAP t wo way
val ve on the fuel tank, and connect i t to a T-fi tti ng
f r om a v ac uum gauge and a v ac uum pump as
VACUUM/
PFESSURE GAUGE,
0
- 4
i n. Hg
o?JAZ
-
0010008
VACUUM
PUMP/GAUGE,
0
-
30 i n. Hg
A973X-041
-XXXXX
3. Appl y v ac uum s l owl y and c ont i nuous l y whi l e
wat chi ng t he gauge. The vacuum shoul d st abi l i ze
moment ar i l y at 0. 7 2. 0 kPa
( 5 -
15 mmHg, 0. 2
-
0. 6
i n. Hg
) .
l f t he v ac uum s t abi l i z es
( v al v e
opens ) bel ow
0. 7 k Pa
( 5
mmHg, 0. 2 i n. Hg) or abov e 2. 0 k Pa
( ' 15
mmHg, 0. 6 i n. Hg) , i nst al l a new val ve and r et est .
4. Move the vacuum pump hose from the vacuum fi t-
ti ng to the pressure fi tti ng, and move the vacuum
gauge hose from the vacuum si de to the pressure
si de as shown.
f-E-
i
5. Sl owl y pressuri ze the vapor l i ne whi l e watchi ng the
gauge. The pressure shoul d stabi l i ze at 1.3
-
4.7 kPa
( 0 -
35 mmHg, 0. 4 1. 4 i n. Hg) .
. l f t he pr essur e moment ar i l y st abi l i zes l val ve
opens) at 1. 3
-
4. 7 kPa
( 10 -
35 mmHg, 0. 4
' 1. 4
i n. Hg), the val ve i s OK.
. l l the pressure stabi l j zes bel ow 1.3 kPa
(10
mmHg,
0.4 i n.Hg) or above 4.7 kPa
(35
mmHg, 1.4 i n.Hg),
i nstal l a new val ve and retest.
T.F|rTING
1 1 - 1 9 3
Transaxle
Cl utch
Manual
Tr ansmi ssi on
" . ' . . . . . ' . . . " " " " '
Aut omat i c
Transmi ssi on
. . . ' . . . """""'
Di f f er ent i al
. . . . .
Driveshafts
12-1
13- 1
14-1
15- 1
16- 1
I
Cl utch
Speci af Tool s . . . . . . . .
" " . - - - 12- 2
f l f ust r at ed I ndex . . . . . . . .
. "' 12- 3
cl utch Pedal
Adj ust ment
. . . """' . - ""
12' 4
Cl utch Master Cyl i nder
Removal /l nstal l ati on
' ." 12-5
Sl ave Cyl i nder
"" 12-6
Pressure Plate
Removal /l nspecti on
-' ." 12-7
Cl utch Di sc
.' ." 12-8
Fl ywheel
Inspection
' 12-9
Repl acement . . . . . . . " . . . . . " . . . . ' . . . . . . . " . 1 2- 9
Clutch Disc, Pressure Plate
I nst al l at i on
. . . " . . . . . ' . ' . . . . 12- 10
Release Bearing
..." 12-11
l nstal l ati on
12-12
#
rf,'
l l ,
)
Special Tools
Ret. No. I Tool Number Dscliption Oty
I
P89e Reference
o
l
/6
@
,A
@
OTJAF_PM701 1A
OTJAF_PM7O124
OTLAB
-
PVOO 1OO or
o7924-PD20003
07746- 0010100
07749- O010000
07936- 3710100
Cl utch Al i gnment Di sc
Cl utch Al i gnment Shaft
Ri ng Gear Hol der
Attachment, 32 x 35 mm
Dri ver
Handl e
1
1
1
1
1
1
' t
2-7
12- 7, A, 10, 11
12- 7, S, 10, 11
12-10
12- 10
12- 7 , 8, 10, 11
@
12- 2
NOTE:
a Whenever the transmi ssi on i s removed, cl ean and
grease the rel ease beari ng sl i di ng surface.
a It the parts marked wi th an asteri sk
(*)
are removed, the cl utch hydraul i c system must be bl ed
(see page 12-6).
a Inspect the hoses for damage, l eaks, i nterl erence, and twi sti ng.
ASSTST
/6t-^
@
@
*REsERvorR
r
t =/
ov
g*______-__=
Fn \ ,,'
W.*ra
TCLUTCH
LI NE
19 N. m l l . 9 kgl ' m,
14 rbt . t t l
PEDAL PI N
I x
' 1. 25
mm
25 N. m
(2. 6
kgf . m,
19 t bf . f i )
*CLUTCH
LI N
15 N. m { 1. 5 kgl . m,
11 t bt . I r)
\F
f l
\
' CLUTCH
MASTER CYLI NOER
Removal / l nst al l at i on, Page
' 12
5
CLUTCH PEDAL
Adj ust ment , page 12-4
RELEASE BEARI NG
Removal / l nspect i on, page 1 2-1 1
l nst al l at i on, page 1 2' 1 2
FLYWHEEL
Inspecti on,
page 12' 9
Repl acement,
page 12-9
CLUTCH DISC
Removal / l nspect i on,
page 12_8
I nst al l at i on,
page 12-10
1 2 x 1 . O mm
118 N. m {12. 0 kgf . m, 86. 8 l bf . t t }
PRESSURE PLATE
Removal / l nspect i on, page 12 7
6 x 1 . 0 mm
9. 8 N. m
( 1. 0
kgf , m,
7. 2 l bt . I r)
*CLUTCH
LI NE
15 N. m { 1. 5 kgl . m. 11 l bf . { r )
8 x 1. 25 mm
22 N. rn 12. 2 kgf . m, 16 l bl . t t l
*SLAVE
CYLI NDER
Removal / l nst al l at i on,
page 12-6
12-3
Clutch Pedal
Adjustment
NOTE:
a To check the cl utch i nterl ock swi tch and cl utch
swi tch, see secti on 23.
a The cl utch i s sel l -adj usti ng to compensate for wear.
CAUTION: ll thefe is no clearance between the
master cylinder
piston and
push rod, the leleaso
bearing is held against the diaphragm spring, which
can result in clutch slippage or other clutch problems,
' 1.
Loosen l ocknut A, and back off the cl utch swi tch
(or
adjusting bolt) until it no longer touches the clutch
oedal .
2. Loosen l ocknut C, and turn the push rod i n or out
to get the speci fi ed stroke
(@)
and hei ght
(O)
at the
cl utch pedal .
3. Ti ghten l ocknut C.
4. Thread i n the cl utch swi tch
(or
adj usti ng bol t) unti l
it contacts the clutch
pedal
assjyear.lc
-@{
{P/ N
PUSH ROO
CLUTCH MASTER CYLINDER
5. Turn the cl utch swi tch {or adj usti ng bol t) i n an addi -
ti onal 3/4 to 1 ful l turn.
6. Ti ghten l ocknut A.
7. Loosen l ocknut B on the cl utch i nterl ock swi tch.
8. Measure the cl earance between the fl oor board and
cl utch pedal wi th the cl utch pedal l ul l y depressed.
9. Rel ease t he cl ut ch pedal
' 15- 20
mm
( O. 59
0. 79
in) from the tully depressed position and hold it there.
Adj ust the posi ti on of the cl utch i nterl ock swi tch so
that the engi ne wi l l start wi th the cl utch pedal i n thi s
postuon.
' 10.
Thread the cl utch i nterl ock swi tch an addi ti onal i n
3/4 to 1 ful l turn.
11. Ti ght en l ocknut B.
LOCKNUT 8
9.8 N.m
(1.0
kgt.m, 7.2 l bf.ttl
INTERLOCK SWITCH
CLUTCH SWITCH
{or ADJUSTING BOLTI
LOCKNUT A
9. 8 N. m
(1. 0
kgf . m, 7. 2 l bl . l t |
LOCKNUT C
18 N. m
( 1. 8 kgf . m, 13 l bl . f t )
@
( STROKE
at PEDAL) : 130- 140 mm 15. 12- 5. 51
i n)
) {fOrl l Cl ufcx PEDAL FREE PLAYI:12-21 mm 1o.47-0.83
i n) i ncl ude the pedal pl ay 1-1o mm {0.o4-0.39
i n)
ao | CLUTCH
PEDAL HEIGHT): 165 mm
(6.50
i n) to the fl ool
o) {CLUTCH PEDAL DISENGAGEMENT HEIGHT): 83 mm 13.27
i n) mi ni mum to the fl oor
12-4
Cl utch Master Cyl i nder
CAUTION:
a Do not spill brake fluid on the vehicle; it may damage
the
paint; if brake fluid does contact the paini, wash
it off immodiately with water.
a Plug the end ot the clutch line and reservoir hose with
a shop towel to pl event brake fl ui d from comi ng out.
1. The brake fl ui d can be removed from the cl utch
master cyl i nder reservoi r wi th a syri nge.
2. Di sconnect the cl utch l i ne and reservoi r hose from
the cl utch master cyl i nder.
19N. m
( 1. 9
kgt ' m,
14 t bI . f t )
(.
Pry out the cotter pi n, and pul l the pedal pi n out
the yoke. Remove the nuts.
NUTS
8 x 1. 25 mm
of
3.
CLUTCH LI NE
13 N. m
(1. 3
kgf . m, 9. 4 l bf , f t l
4. Remove the cl utch master cyl i nder.
CLUTCH MASTER CYLI NDER
Instal l the cl utch master cyl i nder i n the reverse or-
der of r emoval .
NOTE: Bl eed the cl utch hydraul i c system {see
page12- 6) .
5.
12-5
Sl ave Cyl i nder
CAUTION:
a Do not spill brake fluid on th vohiclo; it may damagc
the paint;
it brake fluid doos contact tho paint. wash
it ott immsdiatoly whh water.
a Plug the end of the clutch line with a shop towel to
prevent
brake tluid from coming out.
- . El :
Super Hi gh Temp Ur ea Gr eas e { Pi N
08798 9002).
-=-t"*' .]:].:
Brake Assembl y Lube or equi val ent rubber
grease.
' 1.
Di sconnect the cl utch l i ne l rom the sl ave cyl i nder.
2. Remove the sl ave cyl i nder from the cl utch housi ng.
12-6
-C.
(P/N
08798
-9002)
3. Instal l the sl ave cyl i nder i n the reverse order ol
removat.
NOTE: Make sure the boot i s i nstal l ed on l he sl ave
cyl ander.
CLUTCH LINE
15 N.m
(1.5
kgf.m, 1' l l bt.ttl
SLAVE CYLI NDER
8 x 1. 25 mm
22 N. m 12. 2 k9l . n,
16 t bf ' t t t
. : ; ?L.
-=-s!!rqil
(Brake
Assembly
Lubel
Bl eed the cl utch hydraul i c system.
a Attach a hose to the bl eeder screw, and suspend
the hose i n a contai ner of brake fl ui d.
a Make sure there i s an adequate suppl y of fl ui d ar
the cl utch master cyl i nder, then sl owl y pump the
cl utch pedal unti l no more bubbl es appear at the
bl eeder hose.
a Refi l l the cl utch master cyl i nder wi th fl ui d when
done.
a Al ways use Genui ne Honda DOT 3 Brake Fl ui d.
Usi ng a non-Honda brake fl ui d can cause corro-
sion and dec.ease the liJe of the system.
a Conti rm cl utch operati on, and check for l eaki ng
f l ui d.
Pressure
Plate
Removal/lnspection
1 . Inspect the Ji ngers of the di aphragm spri ng for wear
at the rel ease beari ng contact area.
Check the di aphragm spri ng ti ngers tor hei ght us-
i ng the speci al tool s and a feel er gauge.
Standard l New): 0.6 mm
(0.02
i nl max.
Servi ce Li mi t: 1.0 mm
(O.O4
i n)
FEELR GAUGE
OTJAF-PM7O12A
HANDLE
07936_3710100
l f the hei ght exceeds the servi ce l i mi t, repl ace the
pressure pl al e.
3. Instal l the speci al tool s.
RING GEAR HOLDER
071A8-PV00100
ot
07924-PD20003
CLUTCH ALIGNMENT OISC
OTJAF_PM7O11A
CLUTCH ALIGNMENT SHAFT
OTJAF_PM7012A
HANDLE
07936- 3710100
GEAR HOLDER
ENGINE
BLOCK
NUT
ADJUSTER BOLT
4. To prevent warpi ng, unscrew the pressure pl ate
mounti ng bol ts i n a cri sscross pattern i n several
steps, then remove the pressure pl ate.
6.
Inspect the pressure pl ate
surl ace for weaf, cracks,
and burni ng.
Inspect for warpage usi ng a strai ght edge and feel -
er
gauge.
NOTE: Measure across the pressure pl ate at three
poi nts.
Standard
(New):
O.O3 mm
(0.0O1
i nl max.
Srvi co Li mi t: O.15 mm
(0.0O6
i nl
l f the warpage exceedsthe servi ce l i mi t, repl ace the
pfessure pl ate.
STRAIGHT EDGE
PRESSUBE PLATE
12- 7
Clutch
Disc
Removal/lnspection
1. Remove the cl utch di sc and speci al tool s.
CLUTCH DISC
07936- 3710100
Inspect l i ni ng of the cl utch di sc tor si gns of sl i ppi ng
or oi l . l f i t i s burned bl ack or oi l soaked, repl ace i t.
Measure the cl utch di sc thi ckness.
Clutch Oisc Thickness:
St andar d l New) : 8. 5- 9. 1 mm
( 0. 33- 0. 36
i nl
(0.22
i n)
l f the thi ckness i s l ess than the servi ce l i mi t, reol ace
the cl utch di sc.
CLUTCH DISC
12-8
4. Measure the depth l rom the l i ni ng surface to the
ri vets, on both si des.
Rivet Depth:
Standatd
(New): 1 .3
-
1 .9 mm {0.O5-O' O7
i n} mi n'
Srvi ce Li mi t: O.2 mm
(O.01
i nl
l I the depth i s l ess than the servi ce l i mi t, repl ace the
cl utch di sc.
Flywheel
Inspecti on
1. Inspect the ri ng gear teeth tor wear and damage.
2. Inspect the cl utch di sc mati ng surface on the
fl ywheel for wear, cracks, and burni ng.
3. Measure the fl ywheel runout usi ng a di al i ndi cstor
through at l east two ful l turns. Push agai nst the
fl ywheel each ti me you turn i t to take up the crank,
shaft thrust washer cl earance.
NOTE: The runout can be measured wi th engi ne i n-
stal l ed.
Standard {Now}: O.O5 mm
(0.OO2
i n) max.
Servi ca Li mi r: O.15 mm
(0.006
i nl
FLYWHEEL
l f the runout exceeds the servi ce l i mi t, reol ace the
fl ywheel .
Turn the i nner race of the bal l beari ng wi th your fi n-
ger. The bal l beari ng shoul d turn smoothl y and qui -
etl y. l f the i nner race does not turn smoothl y and
qui et l y. r epl ace t he bear i ng. Check t hat t he bal l
beari ng outer race fi ts ti ghtl y i n the fl yweel . l f i t i s
l oose. repl ace the bal l beari ng.
FLYWHEEL
,
BALL BEARING
Replacement
1. Instal l the sDeci al tool .
MOUNTING
BOLTS
RI[{G GEAR HOLOER
071A8
-PV00100
ot
07924-PO20003
2. Remove the fl ywheel mounti ng bol ts i n a cri sscross
pattern i n several steps as shown, and remove the
fl ywheel .
Remove the bal l beari ng from the fl ywheel .
FLYWHEEL
{cont' d)
12-9
Flywheel
Cl utch Di sc,
Pressure Plate
Replacement
(cont'dl
4. Dri ve the new bal l beari ng i nto the fl ywheel usi ng
the sDeci al tool s as shown.
ON|vER
07749-OOtO(xX)
ATTACHMENT,
3 2 x 3 5 mm
07746-0010r00
5.
o.
FLYWI{EEL
BEARII{G
Al i gn the hol e i n the fl ywheel wi th the crankshaft
dowel pi n
and i nstal l the tl ywheel . Instal l the mount-
i ng bol ts fi ngerti qht.
Instal l the speci al tool , then torque the fl ywheel
mounting bolts in a crisscross pattern in several steps
as shown.
MOUNTING BOLTS
118 N. m 112. 0 kst ' m,
87 tbf'ft)
YWHEEL
RING GEAR HOLDER
oTLAB-PV00100
ol
07924-PD20003
12-10
Installation
1. Instal l th speci al tool .
L
07936-37i oi oo
(P/n
08798-90{'21
RING GEAR HOLDER
07LAB-PVOOI OO
ot
07924-PD20003
CI.UTCH ALIGNME T SHAFT
OTJAF_PM7012A
l nstal l the cl utch di sc usi ng the speci al tool s.
Instal l the pressure pl ate.
RING GEAR HOLDER
oTLAB-PVOO100
ol
07924-PD20003
O7JAF. PM70l 2A
HANDLE
07936-3710100
clurcH olsc
Release Bearing
4. Torque the mounti ng bol ts i n a cri sscross pattern as
shown. Ti ghten them i n several steps to prevent
warpi ng the di aphragm spri ng.
19 t bt . f t )
RING GEAR HOLDER
oTLAB-PVOo100
ol
o7924,PD20003
CLUTCH ALI GNMENT
OTJAF_PM7O12A
HANDLE
07936- 3710100
@
MoUNTING BOLTS
8 x 1. 25 mm
25 N' m 12.6 kgf.m,
1 .
3.
Remove the rel ease fork boot from the cl utch
housi ng.
Remove the rel ease fork from the cl utch housi ng by
squeezi ng the rel ease fork set spri ng wi th pl i ers. Re-
move the rel ease beari ng.
Check the rel ease beari ng for pl ay by spi nni ng i t by
hand.
CAUTION: The lelease bearing is packed with
grease. Do not wash it in solvent
l f there i s excessi ve pl ay, repl ace the rel ease bear-
i ng wi th a new one.
RLEASE FORK
12-11
Rel ease Beari ng
Instal l ati on
NOTE: Use onl y Super Hi gh Temp Ur ea Gr ease
( P/ N
08798 9OO2) .
1. Wi l h t he rel ease f ork sl i d bet ween t he rel ease bear
i ng pawl s, i nst al l t he r el ease bear i ng on t he mai n
shaf t whi l e i nsert i ng t he rel ease l ork t hrough t he hol e
i n t he cl ut ch housi ng.
(P/N
08798-9002)
0. 3
- 0. 9
g
{ 0. 01- 0. 03 oz}
2. Al i gn the detent oJ the rel ease fork wi th the rel ease
{ork bol t, then press the rel ease fork over the rel ease
l ork bol t sequarel v.
--6i
oa798
-9002)
29 N. m 13. 0 kgf . m, 22 l bl . f r)
1 2 - 1 2
3. Move the rel ease fork ri ght and l el t to make sure that
i t fi ts properl y agai nst the rel ease beari ng, and that
the rel ease beari ng sl i des smoothl y.
4. Instal l the rel ease fork boot; make sure the boot seal s
around the rel ease fork and cl utch housi ng.
Manual Transmi ssi on
Speci af Tool s . . . . . . . . . 13-2 Shi f t Fork Assembl y
Mai nt enance I ndex . . . . . . . . . . . . . . . . . 13- 25
Tr ansmi ssi on Oi l . . . . . . . . . . . . . . . . . . . . . . . 13- 3 Cl ear ance l nspect i on . . . . . . . . . . . . . . . . . . 13- 26
Back-up Li ght Swi t ch MBS Shi f t Pi ece I nspect i on . . . . . . . . . 13-27
Repl acement . . . . . . . 13-3 Synchro Sl eeve. Synchro Hub
Troubf eshoot i ng . . . . . 13-4 I nspect i on/ l nst al l at i on . . . . . . . . . . . . . . . . 13-27
Transmission Assembly Synchro Ring, Gear
Removal . . . . . . . . . . . . . 13- 5 I nspect i on . . . . . . . . . . 13- 28
l nst al l at i on . . . . . . . . . 1 3-8 Shi f t Rod
l l l us t r at ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 10 Remov al . . . . . . . . . . . . . 13- 29
Transmission Housing Differential
Remov al . . . . . . . . . . . . . 13- 12 l ndex . . . . . . . . . . . . . . . . . 13- 30
Rever se Shi f t Hol der Backl ash I nspect i on . . . . . . . . . . . . . . . . . . . 13- 30
Cl ear ance I nspect i on . . . . . . . . . . . . . . . . . . 13- 13 Bear i ng Repl acement . . . . . . . . . . . . . . . . . 13- 31
Reverse l dl er Gear Fi nal Dri ven Gear Repl acement . . . . 13-31
Removaf . . . . . . . . . . . . . 13- 14 Thr ust Shi m Adj ust ment . . . . . . . . . . . . 13- 32
Mainshaft, Countershaft, Shift Fork Clutch Housing Bearing
Di sassembl y . . . . . . . 13- 14 Repl acement . . . . . . . 13- 34
Mainshaft Assembly Mainshaft Thrust Shim
I ndex . . . . . . . . . . . . . . . . . 13- 15 Adj us t ment . . . . . . . . . 13- 36
Cl ear ance I nspect i on . " . . . . . . . . . . . . . . . . 13- 16 Tr ansmi ssi on
Di sassembl y . . . . . . . 13- 17 Reassembl y . . . . . . . . 13- 39
I nspect i on . . . . . . . . . . 13- 18 Oi l Seal s
Reassembl y . . . . . . . . 13- 19 Repl acement . . . . . . . 13- 43
Countershaft Assembly Gearshift Mechanism
f ndex . . . . . . . . . . . . . . . . . 13- 20 Over haul . . . . . . . . . . . . 13- 44
Cf ear ance f nspect i on . . . . . . . . . . . . . . . . . . 1 3- 21
Di sassembl y . . . . . . . 13-22
l nspect i on . . . . . . . . . . 13-23
Reassembl y . . . . . . . . 1 3-23
ll
Ref. No. I Tool Number Description Oty
I
Page Relerence
o
@
o
. @
,3)
@
(j)
(q)
)
@
(,
@
@
oTGAJ- PG20110
oTGAJ- PG20120
07GAJ- PG20130
07736- AO10004
o7746- 0010300
o7746- 0010400
o7746- 0030100
o7746- 0030300
o7746-OO30400
o7749- O010000
07JAD- PH80101
07JAD- PH80200
07947- 6110501
07947- 6110500
Mai nshaft Hol der
Col l ar
Mai nshaft Base
Adj ustabl e Beari ng Pul l er, 25 40 mm
Attachment. 52 x 55 mm
Dr i ver , 40 mm l . D.
Attachment, 30 mm LD.
Attachment, 35 mm LD.
Dri ver
Dri ver Attachment
Pi l ot, 26 x 30 mm
Seal Dri ver Attachment
1
1
1
1
I
I
I
I
1
1
1
1
1
13- 38
13- 37
13- 37
13- 34, 35
13- 34, 35
13- 34, 35
13- 19, 24,
3 1 , 3 2
13- 19, 24
13- 19, 24
13- 34, 35, 43
1 3-43
13- 43
1 3-43
n
Must be used wi th commerci al l y avai l abl e 3/8
"
-' 1
6 Sl i de Hammer.
(1] at\
a
/;i
o
@
(9
\,
13-2
\
Mai ntenance Back-up Li ght Swi tch
Transmi ssi on Oi l
NOTE: Check the transmi ssi on oi l wi th the engi ne OFF
and the vehi cl e on l evel ground.
1. Remove the oi l fi l l e. pl ug, then check the l evel and
condi ti on of the oi l .
OIL FILLER PLUG
44 I{.m
(4.5
kgt.m, 33 lbl.ftl
Proper Level
WASHER
Repl ace.
The oi l l evel must be up to the fi l l er hol e. l f i t i s
bel ow the hol e, add oi l unti l i t runs out, then rei n-
stal l the oi l fi l l er pl ug wi th a new washer.
l f the transmi ssi on oi l i s di rty, remove the drai n pl ug
and drai n the oi l .
Rei nstal l the drai n pl ug wi th a new washer, and refi l l
the transmi ssi on wi th the recommended oi l to the
proper l evel .
NOTE: The drai n pl ug washer shoul d be repl aced at
every oi l change.
Rei nstal l the oi l fi l l er pl ug wi th a new washer.
Oil Capacity
1. 8 f
( 1. 9
US
qt , 1. 6 l mp qt l
at oi l change
1.9 t l 2.O US qt, 1 .7 l mp qtl
at overhaul
Al ways use Genui ne Honda Manual Transmi ssi on
Fl ui d
(MTF).
Usi ng motor oi l can cause sti ffer shi ft-
i ng because i t does not contai n the proper addi -
ttves.
Repl acement
NOTE: To test the back-up l i ght swi tch, see secti on 23.
1 . Di sconnect the connector, then remove the back up
l i ght swi tch connector l rom the connector cl amp.
2. Remove the back-up l i ght swi tch.
25 N' m 12. 5 kgf ' m, 18l bt . t t )
Repl ace.
Instal l the new washer and back-up l i ght swi tch.
Connect the back-up l i ght swi tch connector.
3.
13- 3
Troubl eshooti ng
Reverse Gear Noi se Reducti on System
Whenever the cl utch pedal i s depressed to shi ft i nto reverse, the mai nshaft conti nues to rotate because of i ts i nerti a.
The resul ti ng speed di fference between mai nshaft and reverse i dl er gear produces gear noi se.
The reverse gear noi se reducti on system empl oys a cam pl ate whi ch was added to the reverse shi ft hol der. When shi fti ng
i nto reverse, the sth/reverse shi ft
pi ece,
connected to the shi ft l ever, rotates the cam pl ate. Thi s causes the sth synchro
set to stop the rotati ng mai nshaft. As there i s no speed di fterence between mai nshaft and reverse i dl er gear, there wi l l
be l ess gear noi se.
NOTE: Thi s system i s not a ful l y-synchroni zed gear noi se reducti on system.
Therel ore, you may hear gear noi se when
!)
you
shi ft i nl o reverse wi th the vehi cl e not yet compl etel y stopped
i 2)
you shi ft qui ckl y i nto reverse duri ng fast i dl i ng.
l s t he cl earance 1. 0 mm
(0. 04
i n) or i ess?
Measur e t he MBS shi f t pi ece pi n
( s ee page 13- 27) .
l s i t 6. 8 mm { 0. 27 i n} or mor e?
Reolace the revsrso shift holder.
\
Gear noi se i s presenl when shi f t -
i ng i nt o reverse af l er l he engi ne
rs sl arl eo.
Replace tho sth synchto hub and
sEeve as a sel.
Measure t he cl earance bet ween
st h shi f t f ork and 5t h synchro
sl eeve {see
page 13 26).
l s t he gear noi se pf esent when
shilting into sth gear?
Roplace the MBs shitt
piece.
13- 4
Transmi ssi on Assembl y
Removal
@
1 .
Make sure
jacks
and satety stands are placed proper-
ly, and hoist bracksts are attached to correct
pos;lion
on the engi ne.
Apply parking brsko and block rea. wheels so cal will
nol ,ol l oft stands and l al l on you whi l s worki ng
under i t.
CAUTION: Use fender covers to avoi d damagi ng
painted surlacas.
Di sconnect the negati ve
(-)
cabl e fi rst, then the
posi ti ve (+
l cabl e from the battery.
Drai n transmi ssi on oi l
(see page 13-3).
Remove the i ntake ai r tube, i ntake ai r duct and ai r
cl eaner housi ng assembl y
(see
secti on 5).
Di sconnect the starter motor cabl es, transmi ssi on
ground wi re and back-up l i ght swi tch connector,
6xl . O mm
9. 8 N. m
(1. 0
kgt . m, 7. 2 l bf ' f t )
8t 1. 25 mm
8. 8 N. m
( 0. 9
kgf . m, 6. 5 l bl . t t l
ARTER
5. Remove the wi re harness cl amos.
13- 5
vss
CONNECTOR
6. Di sconnect the vehi cl e speed sensor
(VSS)
connec-
tor.
7. Remove the cl utch l i ne bracket, cl utch l i ne cl amp,
and sl ave cyl i nder.
CAUTION:
a Do not operate the clutch pedal once the slave
cylinder has been removed.
a Take care not to bend the clutch line.
b
( cont ' d)
Removal
(cont' d)
8. Remove the dri veshafts
(see
secti on 16).
NOTE: Coat al l the
preci si on fi ni shed sur{aces wi th
cl ean engi ne oi l or grease. Ti e pl asti c bags over the
dri vesha{t ends.
SET RI NG
1 0 x 1 . 2 5 mm
43 N. m
(4. 4
kgl . m,
DRI VESHAFT
COTTER PIN
Repl ace
12 x
' 1. 25
mm
49- 59 N. m l 5. O 6. 0 kgf ' m,
36 43 t bt . f t )
L Remove exhaust pi pe A.
Repl ace.
12 x 1 . 25 mrn
64 N. m 16. 5 kgt . m. 47 l bt . f t l
GASKETS
Repl ace.
EXHAUST
PI PE A
SELF-LOCKI NG NUT
Repl ace.
D16Y5, Dl 6Y7 engi ns:
1 0 x 1 . 2 5 mm
33 N. m
(3. 4
ksl ' m, 25 l bI ' t t l
D16Y8 engi ne:
10 x 1. 25 mm
54 N. m
(5. 5
kgf . m, 40 l bt ' f t }
sELF-LocKrNG ruur.-@
Repl ace.
I x 1 . 2 5 mm
16 N. m 11. 6
kgt ' m,
12 t bf . f t l
SELF. LOCKI NG
NUT
Repl ace.
8 x 1. 25 mm
22 N'nt. 12.2
kgl'm,
16 t bf . f r)
13- 6
10. Remove the shi tt rod and extensi on rod.
SHI FT ROD
8 x 2 2 m m
SPRING PIN
Repl ace.
10 x 1. 25 mm
44 N. m {4. 5 kgl . m,
\
1 l . Remove the engi ne sti ffeners and cl utch cover'
Dl 6Y5, Dl 6Yg ongi nos:
33 tbhl rt
8 r 1. 25 mm
24 N. m
(2. 4
kgf . m
17 t bt . t rl
COVER
8 x 1. 25 mm
24 N. m
(2. 4
kgl ' m,
'|
7 tbl.trl
O16Y7 engi ne:
8 x 1. 25 mr h
24 N. m (2. 4
kgf . m,
17 t bf . f r)
ENGI NE
STI FFENER
10 X 1. 25 mm
44 N.m 14.5 kgl .m,33 l bt.ttl
Instal l the bol ts i n the cyl i nder head and attach a
chai n hoi st to the bol ts, then l i l t the engi ne sl i ghtl y
to unl oad the engi ne and transmi ssi on mounts.
CHAIN HOIST
13. Bemove t he spl ash shi el d.
s
SPLASH SHI ELD
14. Remove t he r i ght l r ont mount br acket .
1 O x 1 . 2 5 mm
44 N. m 14. 5 kgf
. m,
33 t bf ' f r)
' 12
x 1. 25 mm
RI GHT FRONT
MOUNT/ BRACKET
64 N.m
(6.5
kgt.m,47 l bt.ttl
15. Pl ace a
j ack
under t he t r ansmi ssi on.
16. Remove the transmi ssi on mount bracket and mount.
TRANSMI SSI ON
MOUNT
TRANSMI SSI ON
BRACKET
(cont' d)
13-7
Removal
(cont' d)
1 7. Remove the three upper transmi ssi on mounti ng bol ts
and the l ower starter mounti ng bol t.
STARTER
MOUNTI NG
BOLT
1 0 x 1 . 2 5 mm
44 N. m {4. 5 kgl . m,
33 t bt . t rl
TRANSMI SSI ON
MOUNTI NG BOLTS
12 x 1 . 25 mm
64 N. m
( 6. 5
kgf . m, 47 l bt , t t )
18. Remove t he r ear mount br acket bol t s and t r ansmi s
si on mounti ng bol ts
spEcrAL BoLT
Repl ace.
14 x
' l . 5
mm
12 x 1. 25 mm
a4 N. m { a. S kgf . m, 61 t bf , t t l
64 N. m 16. 5 kgf . m, 47 l bf . f t )
WASHER
SPECI AL BOLT
Repl ace.
1 4 x 1 . 5 mm
84 N' m 18. 5 kgl . m, 61 t bf . f t )
' 1
9. Pul l t he t ransmi ssi on away f rom t he engi ne unt i l i t
cl ear s t he mai nshaf t , t hen l ower i t on t he t r ansmi s-
si on
j ack.
CAUTI ON: Take care not t o bend t he cl ut ch l i ne.
13- 8
Instal l ati on
Instal l the transmi ssi on assembl y i n the reverse order ol
r emoval .
a Before i nstal l i ng, check that the two dowel
pi ns are
i nst al l ed i n t he cl ut ch housi ng.
a When i nstal l i ng the starter cabl e, make sure that the
cri mped si de of the ri ng termi nal i s faci ng out {see
sect i on 23) .
a Appl y grease to the parts as shown, then i nstal l the
r el ease f or k and r el ease bear i ng.
NOTE: Use onl y Super Hi gh Temp Ur ea Gr ease
( P/ N
08798
-
9002) .
RELEASE FORK EOLT
1 2 x 1 . 2 5 mm
29 N. m {3. 0 kgt . m,
tPi N 08798-9002)
22 tht.trl
RELEASE
FORK
BOOT
\
{P/ N 08798 9002)
RELEASE
FORK
l P/N 08798-9002)
0. 3 0. 9
s
{ 0. O1
- 0. 03
oz)
a Torque the mounti ng bol t and nuts i n the sequence
shown.
@
12 x 1. 25 mm
74 N' m 17. 5 kgf . m,
54 lbt.tt)
a Check that the bushi ngs are not twi sted or offset.
a Instal l the cl i p as shown.
I
-/ : ' . G
, / /
EXTENSTON BOD
| ^
/.t***rrm"'i@
,z-s;c,r
oown
).,,
a Turn the boot so the hol e i s faci ng down.
a Make sure the boot i s i nstal l ed on the shi ft rod.
A
12 x 1. 2s nm
64 N.m {6.5 kgf.m,
a)
12 x 1. 25 mm
64 N.m (6.5
kgf.m,
47 tbI.tt)
8 x 1. 25 mm
22 N. m 12. 2 kgt , m, 16 l bt . f t l
g x 2 2 mm
SPBING PIN
Repl ace.
SHI FT ROD
6 x 1 . 0 mm
9. 8 N' m ( 1. 0
kgt . m,
7 .2 tbt.ltl
a Appl y grease to the sl ave cyl i nder push rod.
NOTE: Use onl y Super Hi gh Temp Urea Grease
( P/ N
O8798 9002) .
CLUTCH
PIPE
8 x 1. 25 mm
22 N. m 12. 2 kgl . m,
a
a
tP/N 08798_9002)
16 tbt.fl )
Turn the breather cap so that the
"F"
mark poi nts at
the front of the car as shown.
Ret i l l t he t ransmi ssi on wi t h t he recommended oi l
( see page 13- 3) .
Connect t he posi t i ve (+
) cabl e f i rst , t hen t he nega-
t i ve {- ) cabl e t o t he bat t ery.
Check t he cl ut ch operat i on.
Shi f t t he t r ansmi ssi on and check f or smoot h
oper at i on.
Check t he f ront wheel al i gnment
(see
sect i on
' 18).
FRONT
Refer to the drawi ng bel ow for transmi ssi on di sassembl y/reassembl y
Cl ean al l the parts thoroughl v i n sol vent and dry wi th compressed ai l
I
LuOri cate al l the parts wi th oi l bel ore reassembl y.
NOTEI
a Thi s transmi ssi on uses no gaskets between the mai or housi ngs; use l i qui d gasket
{P/N
0871 I
-
0001 or 0871 8
-
OOO3)
( see page 13- 4' l ) .
a Al ways cl ean the magnet
@
whenever the transmi ssi on housi ng i s di sassembl ed.
a Inspect al l the beari ngs for wear and operati on.
I
f
+ v
d b +
; - 6
\"
u
/
6
13- 10
Torqu Value
A
-
15 N.m {1.5 kgf' m. 11 l bf.ft)
B
-
27 N.m
(2.8
kgi m,20 l bf.ft)
C
-
31 N.m
(3.2
kgf.m, 23 l bf.ft)
O
BALL BEARING
(*1I
ANGULAR
BALL EEARING IT2)
@ sTH sYNcHRo HUB
O 5TH SYNCHRo SLEEVE
@ SYNCHRO SPRING
@
SYNCHRO RING
@
5TH GEAR
@3 2 x a z x z : . 5 mm
NEEDLE BEARING
@
SPACER coLLAR
@3 l x 3 g x z 3 mm
NEEDLE BEARING
@
4TH GEAR
O SYNCHRo RING
@
SYNCHRO SPRTNG
@
3RD/4TH SYNGHRo SLEEVE
@
3RD/4TH sYNcHRo HUB
@
3RD GEAR
@34x 39x 27. 5mm
NEEDLE BEARING
@
MAINSHAFT
@
WASHER
@
SPRING WASHER
@
BALL BEARING
Check for wear and
operal ron.
@26x 42x 7mmOl LSEAL
Repl ace.
@
28 mm PLUG BOLT
54 N.m {5.5 kgt.m, 40 lbf.ft)
@
1ST/2ND SELECT SPRING
L. 36.26 mm
(1.428
i nl
@
SHIFT ARM SHAFT
@
CLUTCH HOUSTNG
@
INTERLoCK GUIDE EoLT
39 N.m 14.0 kst.m, 29 lbf.ft)
@
REVERSE SHIFT HOLDER
@
REVERSE IDLER GEAR
@
REVERSE TDLER GEAR SHAFT
@
5 x 22 mm SPRING PIN
Repl ace.
@ 3RD/4TH SHIFI PIECE
@
sTH/REvEnsE SHIFT PIECE
@
MBS SH|FT P|ECE
@
lsT/zNo SHIFI FoRK
r 1: Dl 6Y7
ngi n.
12:
D16Y5. D16Y8 engines
@
3RD/.TH SHIFr FoRK
@
5TH/REVERSE sHIFT FoRK
O 52 mm SNAP RING
@ 65 mm THBUST SHIM l *11
70 mm THRUST SHIM l*21
Sel ecti on, page 13-36
@
OIL GUIDE PLATE
@
WASHER Replace.
@
BAcK.uP LrcHT swrrcH
25 N.m
(2.5
kgt'm, 18 lbf.ft)
@
sET scREw
22 N.m
(2.2
kgt.m, 16lblftl
@
WASHER Repl ace.
@ SPRING L.31.6 mm
(1.24
i n)
@
STEEL BALL
(5/16
in)
@
BACK.UP LIGHT
SWITCH HARNESS STAY
@
TRANSMISSION HANGER
@
32 mm SEALING BOLT
25 N.m
(2.5
kgf.m, 18 lbt,ft)
@ OIL SEAL
Repl ace.
@
OII DRAIN PLUG
39 N'm {4.0 kgf.m, 29 lbf.ftl
@
WASHER Replace.
@
OIL FILLER PLUG
44 N.m
(4.5
kgf.m. 33 tbf'ft)
@
WASHER Reptace.
@
TBANSMISSION HOUSING
@
RELEASE PIPE STAY
@
OIL GUTTER PLATE
@
REVERSE LocK cAM
@
REVERSE SELECT SPRING
L. 63.4 mm l2.i6 in)
@
REVERSE SELECT RETAINER
@ SHIFT ARM c
@
SHIFT ARM B
@
INTERLOCK
@
COLLAR
@
SHIFI ARM A
@
SPBING WASHER
@
MAGNET
@ SET EALL SPRING BOLT
22 N.m
(2.2
kgl.m, 16 lbf.ft)
@
r4 x 20 mm DOWEL PIN
@
72 mm THRUST SH| M t' 1)
80 mm THRUST SHIM {*2)
Sel ecti on,
page
13-33
@
DIFFERENTIAL ASSEMBLY
See page 13-30
@
14 x 25 x 17.5 mm OtL SEAL
Repl ace.
@35x 56x 8mmOl LSEAL
Repl ace.
@
sHrFr RoD
@
BOOr
@
oIL GUIDE PLATE
@3 0 x l z x 2 t mm
NEEDLE BEARING
('1}
30x55x21 mm
NEEDLE EEARING IT2)
@
COUNTERSHAFT
@
36x41 x 25. 5 mm
NEEDLE BEARING
Check for wear and
ooeral t on.
@
lsT GEAR
@
FRICTION DAMPER
@
sYNcHRo R|NG
@
sYNcHRo SPRTNG
@
1ST/2ND sYNcHRo HUB
@
REVERSE GEAR
@
SYNCHRO SPRTNG
@ SYNCHRO FING
@
FRICTION DAMPER
@
SPACER
@3 9 x l l x 2 z mm
NEEDLE BEARING
@
2ND GEAR
@
3RD GEAR
@
4TH GEAR
@
5TH GEAR
@
EALL BEARTNG {*1)
NEEDLE BEARING I*2I
@
BALL BEARING
@
SPRING WASHER
@ LoCKNUT Reptace.
108
+
0* 108 N. m
f r r . o
*
o* 11. 0 kgf . m, l
l rs.e
*
o- 79.6 tbtft
|
1 3 - 1 1
Transmi ssi on Housi ng
Removal
NOTE: Pl ace the cl utch housi ng on two
pi eces of wood
t hi ck enough t o keep t he mai nshaf t f r om hi t t i ng t he
workbench.
1. Remove the back-up l i ght swi tch.
2. Remove transmi ssi on hanger.
TRANSMISSION
HAt{GER
Remove the setti ng screws, washers, spri ngs, and
steel bal l s.
STEEL BALLS
D. 5 / 1 6 i n
SPRING
L. 31. 6 mm 11. 24 I nl
13-12
TRANSMISSION HOUSING
5.
Loosen the transmi ssi on housi ng attachi ng bol ts i n
a cri sscross
pattern i n several steps. then remove
them.
Remove the 32 mm seal i ng bol t.
Expand the snap ri ng on the countershaft bal l bear-
i ng, and remove i t from the
groove usi ng a
pai r
of
snap ri ng
pl i ers.
32 mm SEALING BOLT
Separate the transmi ssi on housi ng from the cl utch
housi ng, and wi pe i t cl ean ol the seal ant.
Remove the thrust shi m, oi l
gui de pl ate, and oi l gut-
ter pl ate {rom the transmi ssi on housi ng.
SNAP RIIIG
Reverse Shi ft Hol der
Cl earance Inspecti on
1 .
{
Measure the cl earance between the reverse shi ft fork
and sth/reverse shi ft Di ece oi n.
St andar d: 0. O5- O. 35 mm
( O. OO2- 0. O14
i n)
Servi ce Li mi t: 0.5 mm {0,02 i nl
l f the cl earances are more than the servi ce l i mi t,
measure the wi dths of the groove i n the reverse shi ft
fork.
Standard: 7.15
-
7.35 mm
(0.281 -
0.289 inl
l f the wi dths of the grooves are not wi thi n the
standard, repl ace the reverse shi ft hol der wi th a
new one.
l f the wi dth of the grooves are wi thi n the stan-
dard, repl ace the sth/reverse shi ft pi ece wi th a
new one.
2 .
REVERSE
REVERSE SHI FT HOLDER
3. Measure the cl earance between the reverse i dl er gear
and t he r ever se shi f t f or k.
St andar dr 0. 5- 1. 1 mm { O. 02- 0. 04 i n}
Se. vi ce Li mi t : 1. 8 mm ( 0. 07
i nt
REVERSE IDLEB GAB
l f the cl earance i s more than the servi ce l i mi t, meas-
ure the wi dth of the reverse shi ft fork.
St andar d: 12. 7
- 13. O
mm
( 0. 500- 0. 512
i n)
l f the wi dth i s not wi thi n the standard, repl ace
the reverse shi ft hol der wi th a new one.
l f the wi dth i s wi thi n the standard, reDl ace the
reverse i dl er gear wi th a new one.
REVERSE SHIFT FOBK
REVERSE SHI FT FORK
REVERSE SHI FT HOLOEB
13- 13
Reverse l dl er Gear
Mai nshaft, Countershaft,
Shift Fork
Removal
1. Remove t he reverse shi f t hol der.
REVERSE SHI FT
HOLDER
2. Remove the reverse i dl er gear shatt and reverse i dl er
geat .
REVERSE IDLER
GEAR SHAFT
1 3- 14
Di sassembl y
1 .
2.
Remove the i nterl ock gui de boh trom under the
cl utch housi ng.
SHIFT ARM 8
ATTACHING EOLT
SPRING
WASHER
CLUTCH
HOUSING
II{TERLOCK GUIDE BOLT
Remove the shi ft arm B attachi ng bol t.
Remove the mainshalt and countershaft assemblies
wi th the shi ft l ork trom the cl utch housi ng.
NOTE: Belore removing the mainshalt and counter-
shaft assembl i es. tape the mai nshaft spl i nes to pro-
tect the seal .
Tape the mainshaft
sp nes.
WASHER
SPBING
WASHER
Mainshaft Assembly
Index
Note the fol l owi ng duri ng reassembl y:
. The 3rd/4th and sth synchro hubs are i nstal l ed wi th a press.
. Instal l the angul ar bal l beari ng wi th the thi n-edge outer race faci ng the sth synchro hub.
. Instal l the bal l beari ng wi th the bsl l cage faci ng up.
Pri or to reassembl i ng. cl ean al l the parts i n sol vent. dry them and appl y l ubri cant to al l contact surfaces the 3rd/i [th
and sth svnchro hubs,
Bal l cage f aces up.
3RD/ 4TH SYNCHRO SLEEVE
BALL BEARING {T1}
ANGULAR BALL BEARING
('2I
Check f or wear and operat i on.
Note the direction of installation.
page 13 27
SYNCHRO SPRI NG
SYNCHRO RI NG
I nspect i on,
page
13- 28
sTH SYNCHRO
SLEEVE
l nspecti on, page 13 27
SYNCHRO HUB
SPRI NG
NEEOLE BEARI NG
Check f or wear and
operat i on.
SPACER COLLAR
I nspect i on, page 13-' t 6
3 4 x 3 9 x 2 3 m m
NEEDLE EEARI NG
Check f or wear
ano operal t on.
RI NG
SYNCHRO RI NG
5TH GEAR
I nspect i on, page 13- 17
3RO GEAB
34 x 39 x 27. 5 mm
NEEDLE BEARI NG
Check f or wear
ano operal ron.
MAI NSHAFT
I nspect aon, page 13- 18
4TH GEAB
CHAMFER
SPRI NG
D16Y7 engi ne
D16Y5, D16YB engi nes
13- 15
Mai nshaft Assembl y
NOTE: l I repl acement i s requi red, al ways repl ace the
svnchro sl eeve and hub as a set.
1. Measure the cl earance between 2nd and 3rd oears.
St andai d: 0. 06- O. 21 mm { O. O02- O. OO8 i n}
Ssrvi ce Li mi t: O.33 mm
(O.O13
i nl
2ND GEAR
3RD GEAB
2 . l f the cl earance i s more than the servi ce l i mat. meas-
ure the thi ckness of 3rd gear.
Standard: 30.22-30.27mm
{ 1. 190- 1. 192 i nl
Ser vi ce Li mi t : 30. 15 mm
( 1. 187
i nl
a l f the thi ckness ot 3rd
gear i s l ess than the serv-
i ce l i mi t, repl ace 3rd gear wi th a new one-
a l f the thi ckness of 3rd gear i s wi thi n the servrce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one.
: --,
t l , -
[ nI
q l
\
\-,l-LJ
3RO GEAR
13- 16
3. Measure the cl earance between 4th gear
and the
soacer col l ar.
Standard: 0.06-o.19 mm
(O.OO2-O.OO7
i nl
Servi ce Li mi t: O.31 mm {0.012 i n}
4TH GEAR
5TH GEAR
l f the cl earance i s more than the seryi ce l i mi t, meas-
ure di stance
@
on the spacer col l ar.
Standard: 22-82-22.86nm
{ 0. 898- O. 9O0 i n}
Servi ce Li mi t: 22-81 mm
(0.898
i n)
4TH GEAR
stoE
SPACEB
COLLAR
l f di stance
@
i s l ess than the servi ce l i mi t, repl ace
the spacer col l ar wi th a new one.
l f di stance
@
i s wi thi n the servi ce l i mi t, measure the
thi ckness of 4th gear.
St andar d: 3O. 12
- 30. 17
mm
11. 186- 1. 148 i n)
Ssrvi ce l i mi t: 30.05 mm {1.183 i n)
4TX GEAR
l f the thi ckness of 4th gear i s l ess than the serv-
i ce l i mi t, repl ace 4th gear wi th a new one.
It the thi ckness of 4th gear i s wi thi n the servi ce
llmit, replace the 3rd/4th synchro hub with a new
one.
/
/hm
r[Jl ] i
r
t l -l l l
\-
cltl-l
6. Measure the cl earance between the spacer col l ar and
st h gear .
St andar d: O. 06- O. 19 mm
( 0. 0O2- O. OO7
i nl
S6rvi ce l i mi t: O.31 mm
(0.O12
i n)
4TH GEAR
DI AL
INDICATOR
t
--t
*3'4>
1 .
sTH GEAR
l f the cl earance i s more than the servi ce l i mi t. meas-
ure di stance
@
on the spacer col l ar.
St andar d: 23. 53- 23. 56mm
( 0. 926- 0. 928
i nl
Servi cs Li mi t:23.51 mm
(0.926
i n)
sTH GEAR
stoE
l f di stance
@
i s l ess than the servi ce l i mi t, repl ace
the sDacer col i ar wi th a new one.
l f di stance
@
i s wi thi n the servi ce l i mi t, measure
thi ckness of sth gear.
Standal d: 28.42-28.47mm
(
1 . 1 1 9 - 1 . 1 2 1 i n l
Servi ce Li mi t: 28.35 mm l 1 . l 16 i n)
sTH GEAR
It the thi ckness of sth gear i s l ess than the serv-
i ce l i mi t, repl ace 5th
gear wi th a new one.
l f the thi ckness of sth gear i s wi thi n the servi ce
l i mi t, repl ace the 5th synchro hub wi th a new one.
Di sassembl y
1. Remove t he bal l bear i ng usi ng
shown.
a bear i ng pul l er as
BEARI NG PULLER
(Commerci al l y
avai l abl e)
CAUTION: Remove the synchro hubs usi ng a
pi ess
and steel blocks as shown. Use of a.iaw-type puller
can cause damage to the gear teeth,
2. Support 4th gear on steel bl ocks, and press the mai n'
shaft out of the sth synchro hub as shown.
{ cont ' d }
13-17
Mai nshaft Assembl y
Di sassembl y
(cont' dl
3. Support the 3rd gear on steel bl ocks, and press the
mai nshal t out of the 3rd/4th synchro hub as shown.
13- 18
Inspecti on
I . Inspect the gear surtace and bearing surface for wear
and damage, then measure the mai nshaft at poi nts
A, B, C, and D.
Standard: A: 21 .987-22.OOO mm
{ 0. 8656- 0. 8661 i n}
B: 26.980-26.993 mm
11 .0622- 1 .0627 inl
C: 33.984-34.OOO mm
( 1. 3380-
1. 3386 i n)
D: 25. 977- 25. 990 mm
11 .0227
-'l
.0232 inl
Servi ce Li mi t: A: 21.93O mm
(O.8634
i nl
B: 26. 930 mm { 1. 0602 i n}
C: 33. 930 mm { 1. 3358 i n}
D: 25. 920 mm { 1. 0205
i n}
Check tor wear and damage
l f any part of the mai nshaft i s l ess than the servi ce l i mi t,
repl ace i t wi th a new one.
2. Inspect tor runout.
Standal d: O.O2 mm {O.0O1 i n} max.
Ssrvi co Li mi t: 0.05 mm {0.0O2
i nl
NOTE: Suooort the mai nshaft at both ends as
snown.
l f the runout i s more than the servi ce l i mi t, repl ace the
mai nshaft wi th a new one.
Reassembly
CAUTION: When installing the 3rd/,lth and 5th synchro
hubs, support the shaft on steel blocks. and instsll the
synchro hubs using a press.
NOTE: Refer to page 13-15 for reassembl y sequence.
1. Support 2nd
gear on steel bl ocks, then i nstal l the
3rd/4th synchro hub usi ng the speci al tool s and a
press,
ORI VER. 40 mm l . D
o7746
-0030100
ATTACHMENT,
35 mm LO.
o7746
-OO30400
2ND GEAR
2. I nst al l t he 3r dl 4t h synchr o sl eeve by al i gni ng t he
stops of the 3rd/4th synchro sl eeve and hub.
NOTE: After i nstal l i ng, check the operati on of the
3rdl 4th synchro hub set.
SYNCHRO SLEEVE
3. Instal l the sth synchro hub usi ng the speci al tool s
ano a oress.
DRI VER, 40 mm l . O.
07746
-
0030100
ATTACHMENT,
30 mm LD.
o7746-0030300
sTH SYNCHRO HUB
Instal l the bal l beari ng usi ng the speci al tool s and a
press.
*1:
D' 16Y7 engi ne
*2r
D16Y5, D16YB engi nes
1 3 - 1 9
Gountershaft Assembly
Index
NOTE:
3
The 3rd, 4th, and sth gears are i nstal l ed wi th a press,
Pri or_to reassembl i ng, cl ean al l the parts i n sol vent, dry them and appl y l ubri cant to al l contact surfaces except the
3rd.4th, and 5th gears.
Snap r i ng gr oove l aces up.
OCKNUT Repl ace.
108- 0- l Og N. m
I
1 1. 0- 0- . 11. 0 kgf . ml
|
79.6- 0- 79.6 l bnl r
I
Check f or wear
and operat i on.
WASHER
BEARI NG
Check f or wear and
operat i on.
/
BALL EEARTNG (*
1 )
I
NEEDLE BEARTNG
(*2)
SYNCHRO SPRI NG
SYNCHRO RI NG
FRI CTI ON DAMPER
l ST GEAR
l nspect i on, page
13 21, 28
GEAR
4TH GEAR
3RO GEAR
36 x 41 x 25. 5 mm
NEEOLE BEARI NG
Check f or wear and oper at i on.
2ND GEAR
l nspect i on, page
13-21, 28
3 9 x 4 4 x 2 7 mn
NEEDLE BEARI NG
Check t or wear and
operat i on.
SPACER COLLAR
FRI CTI ON DAMPER
SYNCHRO RI NG
SYNCHRO SPRI NG
REVERSE GEAR
l nspect a. on, page
13-27
1ST/ 2ND SYNCHRO HUB
*1:
D16Y7 engi ne
' 2:
D16Y5, D16Y8 engi nes
13-20
NOTE: l f repl acement i s requi red, al ways repl ace the
synchro sl eeve and hub as a set.
1. Measur e t he cl ear ance bet ween t he count er shaf t
and l st geaf .
St andal d: O. O3- O. 1O mm
( 0. 0O1 - 0. 0O4
i n)
Servi ce Li mi t: 0.22 mm {0.0O9 i n}
2. l f the cl earance i s more than the servi ce l i mi t, meas-
ur e t he t hi ckness of 1st gear .
St andar d: 30. 41- 30. 44mm
{ 1. 197- 1 . 198 i n}
Ser vi ce Li mi t : 30. 36 mm
( 1. 195
i n)
i I t he t hi ckness of 1st gear i s l ess t han t he ser v
i ce l i mi t , r epl ace 1st gear wi t h a new one.
l f the thi ckness of l st gear i s wi thi n the servi ce
l i mi t, repl ace the 1st/2nd synchro hub wi th a new
one.
GAUGE
1ST GEAB
3. Measur e t he cl ear ance bet ween 2nd and 3r d
qear s
St anda, d: O. O4- O. 12 mm
( 0. 002- 0. 005 i n)
Servi ce Li mi t: 0.24 mm {0.009 i n)
3RD GEAR
FEELER
GAUGE
5.
SPACER
COLLAR
2NO GEAR
l f the cl earance i s more than the servi ce l i mi t, meas-
ure the thi ckness ot the spacer col l ar.
Standard: 32. 03- 32. 06 mm
11 .261
-
1 .262 inl
Servi ce Li mi t: 32.01 mm l 1 .260 i nl
SPACER
COLLAR
l f the thi ckness i s l ess than the servi ce l i mi t. reDl ace
the spacer col l ar wi th a new one.
l f the thi ckness i s wi thi n the servi ce l i mi t, measure
the thi ckness of 2nd gear.
Standard: 31.91
-
31.96 mm
11.256
-
1.258 i nl
S.rvi co Li mi t: 31.85 mm
(1.25i 1i n)
/-?:-
2rlD GEAR
/ t \ /
A-
-N/
f - l
L'rz::---h_l
t
l f the thi ckness ot 2nd gear i s l ess than the serv-
i ce l i mi t , r epl ace 2nd gear wi t h a new one.
l f the thi ckness of 2nd gear i s wi thi n the servi ce
l i mi t, repl ace the 1st/2nd synchro hub wi th a new
one.
13-21
Gountershaft Assembly
Disassembly
CAUTION: Remove the
gears using a pr6ss and stel
blocks as shown. Use of a
iaw-type
pullor
can damage
the
gear toeth.
1, Secur el y cl amp t he count er shaf t assembl y i n a
bench vi se wi th wood bl ocks.
2. Rai se the l ocknut tab from the groove of the coun-
tershaft, then remove the l ocknut and the spri ng
wasner.
WOOD BLOCKS
bear i ngs us i ng a bear i ng pul l er as 3, Rem ove t he
shown.
BEARING R'LLER
13-22
4. Suppon 4th gear
on steel bl ocks, and
press
the coun-
tershaft out of sth and 4th gears as shown.
4TH GEAR
Support 1st gear
on steel blocks, and
press
the coun-
tershaft out of 3rd gear as shown.
Inspection
t . Inspect the
gear surfaces and beari ng surfaces for
wear and damage, then measure the countershaft
at
poi nts
A. B. and C.
Standard: A: 30.000
-
30.015 mm
{ 1. 1811
-
1. 1817 i nl
B: 35.984
-
36.000 mr'
{1.4167
-
1.4r73 i nl
C: 24.980
-
24.91t3 mm
10.9835
-
0.9840 in)
Srvice Limh: A: 29.950 mm
(1.1791
in)
B: 35.930 mm
(1.41i[6
in]
C: 2/+.930 mm
(0.9815
inl
I
Check oil passages
for clogging.
. l f anv oart of the countershsft i s l ess than the
servi ce l i mi t, repl ace i t wi th a new one.
2. l nspect for runout.
Standard: 0.02 mm {0.001 in) max.
Sorvice Limh: 0.05 mm 10.002 in,
. lf the runout is more than the service limit. replace
the countershaft with a new one.
Reassembly
CAUTION:
. Prcss thc 3rd. 4th, and 5th
gelrs on thc cour*crshaft
whhoul lubrication.
. When installing the 3rd, 4th, and sth gea.5, support
the shaft on 3te6l blocks and install the gas.r uring a
prass.
NOTE: Refer to
page 13-20 for reassembly sequence.
1. Instal l the needl e beari ng on the countershaft.
36 x 41 x 25. 5 rnm
NEEDLE BEARII{G
COUNTERSHAFT
2. Assemble the Darts below as shown.
NOTE: Check that the fi ngers of the fri cti on damper
are securel y set i n the
grooves of the 1sv2nd syn-
chro hub.
2 D GEAR
3 9 r 4 4 x 2 7 mm
I{EOLE BEARIIIG
SPACER COLLAB
FRICTIOII DAMPER
SY'{CHRO RING
SYI{CHRO SPNING
REVERSE GEAB
lST/21{D
SYNCHNO HUB
SY]TCHRO SPRING
SYNCHRO RING
FRICTION DAMPER
1ST GEAR
3. Install the oarts on the countershaft.
(cont' d)
Countershaft Assembly
Reassembly
(cont'd)
4. SuoDort the countershaft on a steel bl ock as shown
and i nstal l 3rd gear usi ng the speci al tool s and a
oress,
35 mm LO.
07746
-OO30400
5. Instal l 4th gear usi ng the speci al tool s and a press.
DRIVER, 40 lnm
DRI VER, 40 mm l . D.
o7746-0030100
ATTACHMENT,
07746-0030100
ATTACHMENT,
35 mm l . D.
TH GEAR
07746-OO3O/IOO
6. Instal l sth gear usi ng the speci al tool s and a
press.
DRl vER, 40 mm l . O.
07746-0030100
ATTACHMENT,
30 mm l . O.
07746
-0030300
sTH GEAR
13-24
a
7. Instal l the beari ngs i n the di recti on shown usi ng the
speci al tool s and a
press.
CAUTION: Instal l the bari ngs wi th a maxi mum
prssure of 7.8 kN
(8m
kd. 5.786 lbf).
w
Snap ri ng
faces up,
Ball cage faces up.
*1:
D16Y/ engi ne
+2:
D16Y5, D16Y8 engi nes
Secur el y cl amp t he count er shaf t assembl y i n a
bench vi se wi th wood bl ocks.
LOCKNUT
1 0 8 * 0 - 1 0 8 N. m
111.0
*
0
*
11.0 kgf.m, 79.6+ 0+ 79.6 l bf.ft)
LOCKNUT
Repl ace.
Instal l the spri ng washer, ti ghten the l ocknut, then
stake the locknut tab into groove.
Shi ft Fork Assembl y
l ndex
---'rl
' f
erl or to reassembl i ng, cl ean al l the
parts i n sol vent, dry them, and appl y l ubri cant to anY contact
parts
3RO/ 4TH SHI FT FORK
5TH/REVERSE
SHI FT FORK
1ST/ 2ND SHI FT FORK
MBS SHI FT
PI ECE
5TH/REVERSE
SHIFT PIECE
3RO/4lH
SHI FT PI ECE
'13-25
Shift Fork Assembly
Clearance Inspection
NOTE: The synchro sl eeve and the synchro hub shoul d
be replaced as a set.
1. Measure the cl earance between each shi ft fork and
i ts matchi ng synchro sl eeve.
Standard: 0.35
-
0.65 mm
(0.014 -
0.026 in)
Service Limit 1.0 mm
(0.0{
in)
l f the cl earance i s more than the servi ce l i mi t, mea-
sure the thi ckness of the shi ft fork fi nqers.
Siandard;
3rd/,fth: 7.4
-
7.6 mm {0.291
-
0.299 in)
lst/2nd, 5th: 6.2
-
6.,f mm
(0.244 -
0.252 in)
l f the thi ckness of the shi ft fork fi ngers i s not
within the standard, reDlace the shift fork with a
new one.
l f the thi ckness of the shi ft fork fi ngers i s wi thi n
the standard. repl ace the synchro sl eeve wi th a
new one.
SHI FT FORK
13-26
3. Measure the cl earance between the shi ft oi ece or
shi ft fork and the shi ft arm B.
Standard: 0.2
-
0.5 mm
(0.008 -
0.02 in)
Service Limit: 0,62 mm {0.024if in)
SHIFT ARM B
".
l f the cl earance i s more than the servi ce l i mi t, mea-
sure the groove
of the shi ft pi ece
or shi ft fork.
Stsndard: 13.2
-
13.4 mm
{0.520
-
0.528 i n}
lf the groove
of the shift
piece
or shift fork is not
wi thi n the standard, repl ace the shi ft pi ce or
shift fork with a new one.
l f the groove of the shi ft pi ece or shi ft fork i s
wi thi n the standard, reDl ace the shi ft arm B wi th
a new one.
Synchro Sl eeve,
Synchro Hub
MBS Shi ft Pi ece Inspecti on
1. Measure the wi dth of the MBS shi l t
pi ece.
Standard: 6.9-7.1 mm
(O.272-O.2aO
Soryi ce Li mi t: 5.8 mm
(O.268
i nl
l f the wi dth of the MBS shi ft
pi ece i s l ess than
servi ce l i mi t, repl ace the MBS shi ft
pi ece.
i n)
l nspecti on/l nstal l ati on
1 . I nspect gear t eet h on al l synchr o hubs and synchr o
s l e e v e s f o r r o u n d e d o l f c o r n e r s , wh i c h i n d i c a t e
I n s t a l l e a c h s y n c h r o h u b a n i t s ma t l n g s y n c h r o
sl eeve, and check f or f reedom oI movement .
NOTE: l f r epl acement i s r equi r ed, al ways r epl ace
t he synchro sl eeve and synchro hub as a set .
SYNCHRO
SLEEVE
When assembl i ng the synchro sl eeve and synchro
hub, be sure to match the three sets of l onger teeth
(1
20 degrees apart) on the synchro sl eeve wi th the
three sets ol deeper
grooves i n the synchro hub.
CAUTION: Do not install the svnchro sleove with
its longer leeth in the synchro hub slots because it
wi l l damage the spri ng ri ng.
LONGER TEETH
13-27
Synchro Ri ng, Gear
Inspection
I nspect t he synchr o r i ng and gear .
Ar I nspect t he i nsi de of t he synchr o r i ng l or wear .
8: l nspect t he synchr o sl eeve t eet h and mat chi ng
t eet h on t he synchro ri ng f or wear
(rounded
of f ).
o o
GOOO WORN
C: I nspect t he synchr o sl eeve t eet h and mat chi ng
t eet h on t he gear f or wear
(rounded
of f ).
/\... ,,-\.
\---l
(rl
GOOO WORN
D: Inspect the gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
F: I nspect t he t eet h on al l gear s f or uneven wear ,
scor i ng, gal l i ng, and cr acks.
2. Coat the cone surface of the gear wi th oi l , and pl ace
t he synchr o r i ng on t he mat chi ng gear . Rot at e t he
synchro ri ng, maki ng sure that i t does not sl i p.
Measur e t he cl ear ance bet ween t he synchr o r i ng
and gear al l t he way ar ound.
NOTE: Hol d the synchro ri ng agai nst the gear even-
l y whi l e measur i ng t he cl ear ance.
Synchro Ri ng-to-Gear Cl earance
St andar di 0. 73- 1. 18 mm
( 0. 029- O. 046
i nl
(O.O2
i nl
l f t he cl ear ance i s l ess t han t he ser vi ce l i mi t , r eol ace
the synchro ri ng and synchro cone.
SYNCHRO
SYNCHRO
13-28
shi ft Rod
Removal
NOTE: The s t eel bal l s ar eal l of t hes ames i z e( 5/ 16i n) .
1. Remove the di ff;renti al assemory.
2. Remove the 28 mm pl ug bol t and 1st/2nd sel ect
spri ng.
Remove shi f t ar ms C and B, and t he i nt er l ock, t hen
r emove t he r ever se sel ect spr i ng and r et at ner .
Remove t he shi f t ar m A at t achi ng bol t , t he set bal l
spr i ng bol t , set spr i ng, and st eel bal l .
Remove t he shi f t r od, t hen r emove t he shi f t ar m A.
Remove the reverse l ock cam.
Remove t he magnet .
6.
3. Remove the shi tt arm C attachi ng
Remove the shi l t arm shal t.
NOTE: Be careful not to l ose the
Remove the steel bal l , spri ng, and
SHI FT ARM B
I NTERLOCK
CAM
REVERSE SELECT RETAI NER
bol t .
8 .
9 .
1 0 .
7 .
OI L SEAL
Repl ace.
SET BALL
SPRI NG BOLT
5 .
st eel bal l .
co ar .
REVESSE LOCK
I
, Y /
\s
SLECT SPRING
L. 63. 4 mm
(2. 50
i nl
SPRI NG L. 21. 4 mm
{0. 843 i n)
SHI FT ARM A
1 4 x 2 0
DOWEL PIN
COLLAR SPRI NG
L. 25. 6 mm 11. 01 i n)
DI FFERENTI AL ASSEMBLY
CLUTCH
HOUSI NG
^s* \
6p* \
ssrrr inru spnrr
\ \
\
' ,)r,r*o
"r..", "r*,*o
\
L. 36. 26 mm { 1. 428 i nl
28 mm PLUG BOLT
SHI FT BOO
SHI FT ARM C
13-29
Differential
Index
A
:'ylT'Y:-1.91"*4w
checkt or wear ^; Ul
BALL AEARI NG
Check l or wear and damage.
1 0 x 1 . 0
1 0 1 N' m
Left-hand
1O. 3 kgl . m,
t hreads
13- 30
74.5 tbt'ft1
Backl ash Inspecti on
1. Pl ace di fferenti al assembl y on V-bl ocks, and i nstal l
both dri veshafts.
2.
3.
Measure backl ash of both pi ni on gears.
Standard {Newl : 0.05-O.15 mm
(O.0O2-O.006
i n)
It the backl ash i s not wi thi n the standsrd, reol ace
the di tterenti al carri er.
PINION GEARS
Beari ng Repl acement
NOTE: Check beari ngs for wear and rough rotati on.
the beari ngs are OK, removal i s not necessary.
1. Remove t he bal l beari ngs usi ng a beari ng
pul l er as
PULLER
(Commerci al l y
avai l abl e)
BALL BEARING
2. Instal l new bal l beari ngs usi ng the speci al tool as
shown.
NOTE: Dri ve the beari ngs squarel y unti l they bot-
tom agai nst the carri er.
DRI VER, 40 mm l . O.
7746
-
0030100
BALL BEARI NG
13- 31
Fi nal Dri ven Gear Repl acement
' t
. Remove t he bol t s i n a cri sscross pat t ern i n several
st eps, t hen remove t he f i nal dri ven gear f rom t he
di f f erent i al carri er.
NOTE: The f i nal dr i ven gear bol t s have l ef t - hand
t hr eads.
FI NAL DRI VEN GEAR
Chamf er on ansi de di amet er ol
f i nal dri ven
gear f aces carri er.
10 x 1. 0 mm BOLT
101 i l .m
(10.3
kg{' tn, 74 5 l bl ' tt)
Left-hand threads.
2. Instal l the fi nal dri ven gear by ti ghteni ng the bol ts
i n a cri sscross pattern i n several steps.
Di fferenti al
Thrust Shi m Adj ustment
1. I nst al l t he di f f er ent i al assembl y, maki ng sur e i t bot -
t oms i n t he cl ut ch housi ng, usi ng t he speci al t ool as
s how n.
I nst al l t he t hr ust shi m.
NOTE: I nst al l t he same si ze t hr ust shi m t hat was
removed.
13-32
3.
5.
Instal l the transmi ssi on housi ng
(see page 13-41).
NOTE: Do not appl y l i qui d gasket to the mati ng sur-
tace of the cl utch housi ng.
Ti ghten the transmi ssi on housi ng attachi ng bol ts
( see page 13- 42) .
8 x 1. 25 mm
27 N.m
(2.8
kgt' m, 20 l bf.to
Use the special tool to bottom the differential assem-
bl y i n the cl utch housi ng.
DRI VER, 40 mm l . D.
07746
-0030100
6. Measure cl earance between thrust shi m and bear-
i ng out er r ace i n t r ansmi ssi on housi ng.
7. l l the cl earance i s more than the standard, sel ect a
new t hr ust shi m f r om t he f ol l owi ng t abl e.
NOTEr l f the cl earance measured i n step 6 i s wi thi n
t he st andar d, go t o st ep 1O.
St andar d: O- 0. 1O mm l 0- 0. OO4 i n)
72 mm THRUST SHIM: Dl 6Y7 engi ne
Part Number Thi ckness
4t 441 PL3 AOO 1 . 0 mm
( O. O394
i n)
41442 PL3 AOO 1 . 1 mm
( O. O433
i n)
41443- PL3- A00 1 .2 mm l O.0472
tn)
41444 PL3- AOO 1. 3 mm { O. 05' 12
i n)
41445- PL3- AOO 1. 4 mm
( O. O551
i n)
41446- PL3- AOO 1. 5 mm { 0. 0591 i n)
41447 PL3 AOO 1. 6 mm
( 0. 0630
i n)
41448- PL3- AOO 1. 7 mm
( 0. 0669
i n)
41449- PL3, AOO 1. 8 mm
( 0. 0709
i n)
41 450- PL3
-
AOO 1 . 05 mm
( 0. 0413
i n)
4145' 1
,
PL3
-
AOO 1 . l 5 mm
( O. O453
i n)
41 452
-
PL3
-
AOO 1. 25 mm { O. O492 i n)
41453- PL3- A00
' 1. 35
mm
( O. O532
i n)
41454- PL3 A00
' 1
. 45 mm { O. O57' 1 i n)
41455- PL3- AOO 1 . 55 mm
( 0. 06' 10
i n)
41 456
-
PL3
-
AOO 1. 65 mm { 0. 0650 i n)
41457 PL3 A00
' 1
. 75 mm
( O. 0689
i n)
80 mm THRUST SHI M: D16Y5, Dl 6Y8 engi nes
Part Numbe? Thi ckness
4r 441- PL3- 800 1 . 0 mm
( O. O394
i n)
41442-PL3 BOO 1 1 mm
( O. 0433
i n)
41443 PL3 800 1 .2 mm
l O.O472
i n' )
41444- PL3- 800 1. 3 mm
( O. O512
i n)
41445 PL3 800 1. 4 mm { O. O551
i n)
41446- PL3 800
' 1. 5
mm
( O. O591
i n)
41441 PL3 BOO 1. 6 mm
( O. 0630
i n)
41448- PL3 BOO 1. 7 mm
( 0. 0669
i nl
41449- PL3- 800 1. 8 mm
( 0. 0709
i n)
41450 PL3- 800 1 . O5 mm
( 0. 041
3 i n)
4145' t
- PL3- BO0
1 . 1 5 mm
( O. O453
i n)
41452 PL3- BO0 1. 25 mm
( O. O492
i n)
41 453
-
PL3
-
BOO 1. 35 mm
( O. O532
i n)
41454 PL3- BO0 1 . 45 mm { O. 0571 i n)
41455 PL3- BO0 1. 55 mm { 0. 0610 i n)
41456 PL3, B00 1. 65 mm
{ 0. 0650
i n)
41457 PL3 BO0 1. 75 mm
( 0. O689
i n)
8.
9.
Remove the bol ts and transmi ssi on housi ng.
Repl ace the thrust shi m sel ected i n step 7. then
recheck the cl earance.
' l O.
Remove the bol ts and transmi ssi on housi ng. Appl y
l i qui d gasket to the surface o{ the transmi ssi on hous-
i ng and reassembl e.
13- 33
Cl utch Housi ng Beari ng
Repl acement
Mai nshafl
1. Remove t he bal l bear i ng usi ng t he speci al t ool as
show n.
ADJUSTABLE EEARING
PULLER, 25-40 mm
07736-A01000A
Remove t he oi l seal t rom t he cl ut ch housi ng.
CLUTCH
HOUSI NG
)
Repl ace.
13-34
\J
3. Dri ve the new oi l seal i nto the cl utch housi ng usi ng
ATTACHMENT, 42 | 47 mm
07746-0010300
\ '
Dri ve the bal l beari ng i nto the cl utch housi ng usi ng
the speci al tool s as shown.
J
)
Countershatt
1 . Remove the needl e beari ng usi ng the speci al tool as
shown, then remove the oi l gui de pl ate.
PULLER. 25-40 mm
07736-AOtOOOA
2. I nst al l t he oi l gui de pl at e, t hen dr i ve t he needl e bear -
i ng i nt o t he cl ut ch housi ng usi ng t he speci al t ool s
as shown.
NEEDLE BEARI NG
GUI DE PLATE
* 1:
ATTACHMENT, 42x47 nn
07746-0010300
*2:
ATTACHMENT. 52 x 5s mm
o7746
-0010400
* 1:
Dl 6Y7 ngi n6
+2:
D16Y5, Dl 6Yg ongi nos
OI L GUI DE PLATE
13- 35
Mai nshaft Thrust Shi m
Adjustment
I . Remove the thrust shi m and oi l
gui de pl ate trom the
t r ansmi ssi on housi ng.
:.____ THRUST SHI M
2.
OI L GUI DE
PLATE
TRANSMI SSI ON
HOUSI NG
Instal l the 3rd/4th synchro hub, spacer col l ar, 5th
synchro hub, bal l beari ng, and thrust washer on the
mai nshaft. Instal l the assembl y i n the transmi ssi on
housrng.
@
gnol cru
sYncHRo HUB
THRUST WASHER
SPACER COLLAR
5TH SYNCHRO HUB
BALL EEARING
3. Measure the di stance
@
between the end of the
transmi ssi on housi ng and thrust washer.
NOTE:
a Use a strai ght edge and verni er cal i per.
a Measure at three l ocati ons and average the
readi ngs.
Measure the di stance
@
between the surfaces ot the
cl utch housi ng and beari ng i nner race.
NOTE:
a Use a strai ght edge and depth gauge.
a Measure at three l ocati ons and average the
readl ngs.
4.
1)/t'
i':
''7
END OF CLUTCH HOUSING
I NNER RACE OF EALL BEARI NG
13- 36
5. Sel ect t he pr oper shi m on t he basi s of t he f ol l owi ng
cal cul at r ons:
NOTE: Use onl y one t hr ust shr m
( Basi c For mul a )
( B)
+
( C)
-
O. 95
=
shi m t hi ckness
Exampl e of cal cul ati on:
Di sr ance
@
( 2. 0O
mm) + Di st ance' e
( O. 09
mm)
=
2. 09 mm
subt r act t he spr i ng washer hei ght
( 0. 95
mm)
=
t he
f equi r ed t hr ust shi m
( 1
. 1 4 mm)
65 mm THRUST SHIM: Dl 6Y7 engi ne
Part Numbet Thickness
23931 PL3 A10 0. 60 mm {0. 0236 i n}
B 23932 PL3 410 0. 63 mm 10.0284 i n)
c 23933 PL3 A10 O. 66 mm { 0. 0260; n}
D 23934 PL3 A10 0. 69 mm { 0. 0272 i n}
E 23935 PL3 Ar 0 0. 72 mm
( 0. 0283
i n)
F 23936
-
PL3
- A
10 0. 75 mm
( 0. 0295
i n)
23937 PL3 A10 O. 78 mm
( O. O3O7
anl
H 23938 PL3 A10 O. 81 mm
( 0. 0319
i n)
23939
-
PL3
-A' t
O O. 84 mm 10. 0331 i n)
J 23940- PL3
- A
10 0. 87 mm 10.0343 i nl
K 23941 PL3 A10 O. 90 mm 10. 0354 i n)
L 23942
-
PL3
- A
10 O. 93 mm { 0. 0366 i n}
M 23943 PL3 A10 O. 96 mm
( O. O378
i n)
N 23944 PL3 A10 O. 99 mm
( O. O39O
i n
o 23945 PL3 Ar O 1. O2 mm
( O. O4O2
i n
23946 PL3 A10 1. 05 mm
( 0. 0413
i n)
o 23947 PL3 A10 1. 08 mm
( 0. 0425
i n)
R 23948 PL3- A10 1. 1 1 mm ( 0. 0437
i n)
23949 PL3- A10 1 4 mm O. 0449 i n)
T 23950 PL3 A10 1 . 1 7 mm 1 0 . 0 4 6 1 i n )
23951 PL3 A10 1. 20 mm
( 0. 0472
i n)
23952 PL3 A10 l 23 mm l O. O484 i n)
23953 PL3 A10 L26 mm { 0. 0496 i n)
X 23954- PL3
- A
10 L29 mm { 0. 0508 i n)
23955 PL3 A10 1. 32 mm { 0. 0520 i n}
23956 PL3
- A
10 1. 35 mm { O. O53I i n)
23957
-
PL3
- A
10 1. 38 mm
( 0. 0543
i n)
AB 23958
-
PL3
- A
t O 1. 41 mm { 0. 0555 i n}
AC 23959 PL3- A10 1. 44 mm 10. 0567 i n)
AD 23960- PL3 A10 1. 47 mm
( 0. 0579
i n)
AE 2 3 9 6 1 - P L 3 - A 1 0 . 50 mm
( O. 0591
i n)
23962
-
PL3
- A
10 - 53 mm 0. 0602 i n)
AG 23963 PL3 A10 . 56 mm
( O. 0614
i nl
AH 23964- PL3- A 10 . 59 mm
( O. 0626
i n)
23965 PL3- A 10 L62 mm
( 0. 0638
i n)
23966
- PL3, A
10
' t . 65
mm 0. 0650 i n)
AK 2 3 9 6 7 - PL 3 - A1 0 L68 mm { 0. 0661 i n}
23968
-
PL3
- A
10 7 l mm 0. 0673 i n)
23969 PL3 A10 1. 74 mm { 0. 0685 i ni
23970 PL3 A10 1. 77 mm
( 0. 0697
i n)
AO 23971 PL3 A10 1 . 80 mm
( 0. 0709 ' n)
70 mm THRUST SHIM: D16Y5. D16Y8 enqi nes
A 23931 PL3 BOO 0. 60 mm { 0. 0236 i n}
a 23932 PL3- BOO 0. 63 mm { 0. 0284 i ni
23933- PL3 BOO O. 66 mm { 0. 0260 ' n)
D 23934 PL3 800 0 69 mm
( 0. 0272
i n)
E 23935 PL3 800 0. 72 mm
( 0. 0283
i n)
F 23936 PL3 800 0. 75 mm
( 0. 0295
I n)
G 23937 PL3 B00 0. 78 mm
( 0. 0307
i n)
H 23938 PL3 800 0 . 8 1 mm ( 0 . 0 3 1 9
i n )
23939 PL3 800 0. 84 mm
( O. 0331
i n)
J 23940
- PL3
BOO 0. 87 mm
( 0. 0343
i n)
23941- PL3 BOO O. 90 mm
( O. 0354
i n)
23942 PL3 BOO O. 93 mm { O. 0366 i n)
M 23943 PL3 BOO O. 96 mm { 0. 0378 i n)
N 23944 PL3 BO0 0. 99 mm { 0. 0390 i n}
o 23945 PL3 800 LO2 mm {0. 0402 i nl
23946 PL3- 800 1 . O5 mm
( 0. 041
3 i n)
o 23947 PL3 800 1. O8 mm { 0. O425 i n)
R 23944 PL3 800 1 . 1 1 mm
( 0 . 0 4 3 7
i n )
S 23949 PL3 800
' ]
14 mm
( O. O449
i n)
T 23950 PL3- 800 1 . 1 7 mm
( 0 . 0 4 6 1
i n )
23951 PL3 800 1. 20 mm
( 0. 0472
i n)
23Ss2 PL3 BOO L23 mm { O. O484 i n}
23953 PL3 800 1. 26 mm
{ 0. 0496 I n)
23954 PL3-BOO l 29 mm { 0. 0508 i n}
23955 PL3- 800 1. 32 mm { 0. 0520 i nl
z 23956 PL3
-
800 1. 35 mm
( 0. 0531
i n)
23957 PL3 800 1. 38 mm 10. 0543 i n)
AB 23958 PL3- 800 1. 41 mm
( 0. 0555
i n)
AC 23959
-
PL3- 800 1. 44 mm
( O. 0567
i n)
AD 23960
-
PL3- 800 1. 47 mm
( O. 0579
i n)
AE 23961 PL3 800 L50 mm
( 0. 0591
i n)
23962 PL3 800 L53 mm { 0. 0602 I n)
AG 23963- PL3- 800 . 56 mm { 0. 0614 i n}
AH 23964 PL3- BO0 1. 59 mm { 0. 0626 i n}
23965- PL3- BO0 L62 mm { 0. 0638 i n)
23966 PL3 800 1. 65 mm 10. 0650 i nl
AK 23967
-
PL3 BOO 1. 68 mm
( 0. 0661
i n)
23968- PL3 BOO . 7' l mm
( O. 0673
i n)
23369 PL3 800 1. 74 mm
( O. 0685
i n)
AN 23970- PL3, 800 1. 77 mm 1O. 0697 i n)
AO 23971 PL3 800 1. 80 mm ( O. 0709
i n)
6. Instal l the oi l gui de pl ate and sel ected thrust shi m
i n the transmi ssi on housi ng.
NOTE:
a Cl ean the thrust washer, spri ng washer and thrust
shi m thoroughl y before i nstal l ati on.
a Instal l the thrust washer, spri ng washer and
thrust shi m properl y.
THRUST SHI M
:---.._
I
'"9
OI L GUI DE
PLATE
TRANSMI SSI ON
HOUSI NG
i,
"):
a',/ ,
8.
9.
7. Instal l the thrust washer and spri ng washer i n the
mai nshaf t .
Instal l the mai nshaft i n the cl utch housi ng.
Pl ace the transmi ssi on housi ng over the mai nshaft
and onto the cl utch housi ng.
1O. Ti ghten the cl utch and transmi ssi on housi ngs wi th
several I mm bol ts.
NOTE: l t i s not necessary to use seal i ng agent
between the housi ngs.
I x 1. 25 mm
27 N' m
(2.8
kgf
.m.
20 l bf.ftl
11. Tap t he mai nshaf t wi t h a pl ast r c hammer .
12. Check the thrust cl earance i n the manner descri bed
bel ow.
CAUTION: Measurement shoul d be made at room
temperalute.
a. Sl i de the mai nshaft base and the col l ar over the
mai nshaft.
CLUTCH
HOUSI NG
MAINSHAFT BASE
07GAJ
-
PG20' t 30
COLLAR
oTGAJ
-PG20120
{ cont ' d}
THRUST WASHER
SPRI NG WASHER
---[
13-37
--
Mai nshaft
Thrust Shi m
Adj ustment
(cont' d)
b. Attach the mai nshal t hol der to the mai nshaft as
l ol l ows:
NOTE:
Back-out the mai nshaft hol der bol t and l oosen the
two hex bol ts.
Fi t t he hol der over t he mai nshaf t so i t s l i p i s
toward the transmi ssi on.
Al i gn the mai nshaft hol der' s l i p around the
groove
at the i nsi de of the mai nshaft spl i nes, then ti ghten
the hex bol ts.
MAI NSHAFT HOLDER
EOLT
MAI NSHAFT
.
HOLDR
07GAJ- PG20110
d .
Seat the mai nshaft ful l y by tappang on the end
wi th a Dl asti c hammer.
Thread the mai nshal t hol der bol t i n unti l i t
j ust
contacts the wi de surface of the mai nshaft base.
L
13-38
e. Zero a di al
gauge on the end of the mai nshal t
MAINSHAFT HOLDEF
07GAJ
-PG20t
10
Turn the mai nshal t hol der bol t cl ockwi se; stop
turni ng when the di al gauge has reached i ts max-
i mum movement, The readi ng on the di al
gauge
i s the amount ot mai nshal t end
pl ay.
CAUTION: Turning tho mainshatt hold6t bolt
mor6 than 60 dogroos atter the needls of the dial
gaugs stops moving may damage th6 trans-
mi ssi oo.
l f the readi ng i s wi thi n the standard, the cl earance
rs correcr.
l f the readi ng i s not wi thi n the standard, recheck
the shi m thi ckness.
St anda. d: O. 11- O. 18 mm { O. OO4- 0. OO7
i n)
f .
s.
Transmi ssi on
Reassembl y
NOTE: The s t eel bal l s ar eal l of r hes ames i z e( 5/ 16i n) .
1. I nst al l t he magnet and r ever se l ock cam.
2. Set shi f t ar m A on t he cl ut ch housi ng, t hen i nst al l
t he shi f t r od.
Instal l the spri ng washer and shi tt arm A attachi ng
bol t .
Instal l the steel bal l , spri ng, and set bal l spri ng bol r.
Instal l shi tt arm B i n the i nterl ock, then set i t on the
cl utch housi ng.
6.
7.
Insert shi ft arm shatt i n the cl utch housi ng
Instal l the col l ar, spri ng, and steel bal l i nto the case.
Compress the bal l and i nsert the shi ft arm shaft.
Instal l shi ft arm C i n shi tt arm A, then i nsert the shi ft
arm shal t.
Instal l the reverse sel ect retai ner and reverse sel ect
spri ng onto shi tt arm shaft.
l nstal l the di fferenti al assembl y.
8.
9.
5.
3.
A : 8 x ' l . O m m
31 N. m 13. 2 kgf . m, 23 l bf . f t ,
10. 843 i n)
SHI FT ARM A
1 0 .
SHI FT ARM C
6 x 1 . 0 mm
15 N. m { 1. 5 kgt . m, 11 l bl . f t l
REVERSE LOCK CAM
REVERSE SELECT RETAINER
sHtFT ARM "
___\..-
I NTERLOCK. TNTERLOCK,\
-b
f!ir"---
-.-.-.-...uK,
REVERSE SELECT SPRING
L. 63. 4 mm 12. 50 i nl
COLLAR
MAGNET
SET BALL SPRING BOLT
22 N. m 12. 2 kgt . m, 16 l bf . l t l
SPRING
L. 25. 6 mm
(' l . Ol
i nl
OI FFERENTI AL
ASSEMBLY
(cont' d)
CLUTCH
HOUSI NG
OI L SEAL
Repl ace.
/
K
SHIFT ROD
SHI FT ARM SHAFT
BOOT
13-39
Transmi ssi on
Reassembl y
(cont' dl
11. Posi ti on the 36 mm spri ng washer and washer onto
the mai nshaft beari ng.
MAI NSHAFT/ COUNTERSHAFT
SHI FT FORK ASSEMBLI ES
Tape t he mai nshaf t
spl rnes.
WASHER
Instal l the mai nshaft, countershaft. and shi ft fork
assembl i es.
NOTE: Al i gn the fi nger ot the i nterl ock wi th the
groove i n the shi tr fork shaft.
Instal l the spri ng washer and shi {t arm B attachi ng
bol t.
8 x 1. 0 mm
31 N' m 13.2 kgl ' m, 23 l bl ' l tl
1ST/ 2NO SELECT SPRI NG
L. 36. 26 mm 11. 428 i n)
12.
28 mm PLUG EOLT
54 N. m {5. 5 kgl . m,
40 tbf.Irl
GUI DE EOLT
39 N. m 14. 0 ksf . m, 29 l bf . f t l
14. I nst al l t he 1st / 2nd sel ect spr i ng, 28 mm pl ug bol t .
and i nterl ock gui de bol t.
NOTE: Appl y l i qui d gasket
( P/ N
08718- OOO1 or
08 7' l I 0003) to the threads of the 28 mm pl ug bol t
and i nterl ock gui de bol t.
13-40
15. l nstal l the reverse i dl er gear and reverse i dl er gear
shaf t .
REVERSE IDLER
GEAR SHAFT
16. Instal l the reverse shi ft hol der.
6 x 1 . O m m
15 N. m { 1. 5 kgl ' m,
11 l bI . f r)
GEAR
REVERSE SHI FT
t
17. I nst al l t he oi l gut t er pl at e
Instal l the oi l gui de pl ate and thrust shi m on the trans-
mi ssi on housi ng.
Appl y l i qui d gaskel to the surface of the transmi s-
si on housi ng mati ng wi th the cl utch housi ng as
shown.
NOTE:
. Use l i qui d gasket ( P/ N
O8718- OOO1 or
o8718- O003) .
a Remove the di rty oi l from the seal i ng surface.
a l f 5 mi nutes have passed after appl yi ng l i qui d
gasket. reappl y i t and assembl e the housi ngs.
a Al l ow i t to cure at l east 20 mi nutes after assem-
bl y before ti l l i ng the transmi ssi on wi th oi l .
1 8 .
1 9 .
OI L GUTTER PLATE
TRANSMI SSI ON HOUSI NG
Liquid gasker
2O. l nstal l thedowel pi ns
and the transmi ssi on housi ng.
21. Lower the transmi ssi on housi ng wi th the snap ri ng
pl i ers, and set the snap ri ng i nto the groove of the
countershaft beari ng.
NOTE: Check that the snap ri ng i s securel y seated
i n the groove of the countershaft beari ng.
32 mm SEALI NG EOLT
25 N. m
{2. 5 kgf . m, 18l bf . t t l
4. 6
-8. 3
mrr|
10. 18 0. 33 i n)
22. I nst al l t he 32 mm seal i ng bol t .
NOTE: Appl y l i qui d gasket ( P/ N
O8718- OOO1
08718- OOO3) t o t he t hr eads.
(cont ' d)
13-41
I -
Transmi ssi on
Reassembl y
(cont' dl
23. Ti ghten rhe rransmi ssi on housi ng attachi ng bol ts i n
the numbered sequence i n several steps shown
oetow.
8 x 1 . 25 mm
Totqnet 27 N' m
(2.8
kgf.m, 20 l bl ' fr)
BACK, UP LI GHT SWI TCH
HARNESS STAY
24. Instal l the steel bal l s, spri ngs, and set screws.
SETTI NG SCREW
22 N. m l ' 2. 2 ksf . m, 16 l bt . t t )
le
SPRI NG
13-42
L. 31. 6 mm
( 1
. 24 i nl
25. I nst al l t he backup l i ght swi t ch and l r ansmr ssr on
hanger .
8 x 1 . 2 5 mm
27 N. t 12. 8 kgt . m, 20 l bf . f rl
25 N. m {2. 5 kgl ' m, 18 l bf , f t l
I
t
T
Oi l Seal s
Repl acement
Transmi ssi on Housi ng:
L Bemove the oi l seal from l he transmi ssi on housi ng.
Instal l the oi l seal i nto the transmi ssi on housi nq us-
i ng the speci al tool s as shown.
SAL DRIVER
2.
ATTACHMENT
07947- 6110501 ot
07947- 6110500
OIL SEAL
Repl ace.
Cl utch Housi ng:
1. Remove the oi l seal from the cl utch housi ng.
Instal l the oi l seal i nto the cl utch housi ng usi ng the
soeci al tool s as shown.
DRIVER ATTACHMENT
oTJAD-PH80101
otL sEAt
nepl ace.
DRIVER
13-43
Gearshi ft Mechani sm
Overhaul
NOTE:
a Inspect rubber parts for wear and damage when di sassembl i ng; repl ace any worn or damaged parts.
a Instal l the cl i p as shown.
a Turn t he boot so t he hol e i s f aci ng down as shown.
a Make sure t he boot i s i nst al l ed on t he shi f t rod.
SHI FT LEVER KNOB
7. 8 N. m
(0. 8
kgl . m, 5. 8 l bf . f t l
v
EXTENSION
BOLT
)
EXTENSION
cuEr fl
xx'tt"
ffi
.,,,"1" I
iiJ?t
U
&_
e:---g
exrrfusror noo
END BUsHrr{c
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Replace.
/
CLIP
:"
t
6 x 1 o mm
sinttc
ptt't \
9.8 N.m l 1.O ksf.m, 7.2 l bt.frl
neoraci .
HOLE
13-44
t
t
Automatic
Transmission
Automati c
Transmi ssi on .' .' ......' .".... . "' 1 4-1
Conti nuousl y
Vari abl e Transmi ssi on
(cwl
. . . . . . . . . .
14-161
Speci al Toofs .............-.-....-......14-2
Descri pti on .............,.,.,..,......,.. 14-3
Power Fl ow ........................ 1i 1.6
El estroni c Control System ..,............................. 14.13
Hydraul i c Control .............. 14-18
Hydraufi c F| ow...... .,.....-..... 14-23
Lock-up System .-......-....-.-. 1+32
Eleqtrical System
Component Locati ons.......,..,....,.,......... ................. 1i 1"39
PCM Circuit Diagram
{A/T Control Systeml ......................................... 1i l .40
PCM Terminsl Voltage/Measuring Conditions
A/T Control System ..-.......14-42
Troubl eshooti ng Procedures ...........................,..,.,. 14-44
Symptom-to-Component Chart
El ectri cal System .....,.....,.,. l
i l -i l 8
Electrical Troubleshooting
Troubl eshooti ng Fl owcharts ............................. 14.50
Lock-up Control Solenoid Valve A/B Assambly
Test ...................... ............. 14-71
Repfacement ...........-.-....,.., 11-74
Shift Control Solenoid Valve A/B Assembly
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . - . 14- 75
Repl acement .......,.............. l i l -75
Linear Solenoid AssemblV
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 76
Reofacement ......,.,.,,,,.,.,,,,. 11-77
a
Mainshaft/Counter3haft Speed Sensors
t
Repfacement ...................... 1+77
Hydraulic Systcm
Hydraul i c System ...........-.- 11-78
Road Test ................................ 14-82
Stall SDeed
Test ...................... ............. 1/t-85
Fluid Level
Checki ng/Changi ng .......... l i l -86
Pressure Testi ng ......,.............. 1i l -87
Transmission
Transmission
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14. 90
lllustrated Index
Transmi ssi on/Ri ght Si de Cover ..............,..,.,.... 1+g4
Transmi s3i on Housi ng ....,......,........................,.. 14-96
Torque Converter Housi ng/Val ve Body ..,....,... 14-98
Right Side Cover
Removal ................ ............. 14-100
Transmission Housing
Removaf ................ ............. 1+102
Torque Converter Housing/Valve Body
Removal ...........,.... .......,..,.. 14-10i 1
Valve Caps
Descri pti on ......................... 14-106
Valve Body
Repai . .................... .--........-. 1+107
alve
ATF Pump
Inspecti on .......................... 14-109
Mai n Val ve Body
Di sassembl y/l nspecti on/Rea$embl y ......,......, 14-110
Secondary Valve Body
Di sassembfy/l nspecti on/Reassembl y ......-.-..-.. 11-112
Regulator Valv Body
Disassembly/lnspction/Reassembly .......,....,. 1{-'t 13
Servo Eody
Di sassembl y/l nspecti on/Beassembl y .............. 14.1 14
Lock-up Valve Body
Di sassembl y/l nspecti on/Reassembl y .............. 14.115
Mainshatt
Di sassembl y/l nspecti on Rsassembl y ............... 1,t"116
Inspecti on ........................,. 1+117
Countershaft
Di ssssembl y/l nspecti on/Reassembl y .............. 14-119
Di sassembl y/Reassembl y ................................. 14-120
fnspecti on .........-.-.............. 14-121
One-way Clutch
Di sassembl y/l nspecti on/Reassombl y .....,,....... 1,[.123
Clutch
{A'lRA. BitRA Transmission} ... 1Gl24
IM4RA Transmi ssi on) .........-.. 14.126
Di sassembl y... 11-128
Reassembl y ........................ 14-130
Differential
l l l ustroted Index ................ 1+13/t
Backl ash Inspecti on .......... 14-135
Bari ng Repl acement .............,.........,........,........ l i l -l 35
Di tferenti al Carri er Repl acement ..........,........... 1i l .136
Oi l Sal Removsl ............... 14.137
Oi l Seal Instal l ati on/Si de Cl ea.anc ................. 14-137
Torque Converter Housing Bsarings
Mainshaft Bearing/Oil Sal Replacement ........ 1,t-1,m
CounteEhaft Beari ng Repl acemsnt ................. l i l -l i [f
Transmission Housing Bearings
Mainshaft/CountGrshaft Bearings
Repfacement -..........,.,.,, 11-112
Reverse ldlr Gear
Instal l ati on ..,,.................,.,. l +t/*l
Parking Brake Stop
Inspecti on/Adi ustment ..,.......................,,...,...... l i l -l i (|
Transmission
Rea$embl y ........... ............. 14-144
Torque Convrter/Dri ve Pl ate ...................,.,..,....... 14-150
Transmission
Instal l ati on ......................... 14-151
Cool er Fl ushi ng ................. l
i l -155
Shift Cable
Removal /l nsl al l ati on ........................,................ 14-157
Adi ustment ........................ l i l -158
Shi ft Lever ............................... 1a-t5g
Shift Indicator Panel
Adiustment
lllustratsd lndex
lllustrated lndex
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1{ - 160
ATF Cooler Hoses
Special Tools
v
\l
I
Ref. No. I Tool Number Description Oty
I
Prgo Reforenc.
o
ar
@
@
@
@
o
@
@
@
@-
@
@
@
@
@
07GAB
-
PF50101
07GAE
-
PG40200
07HAC
-
PK40' l 0A
07JAD
-
PH80101
07JAD
-
PH80200
07LAE
-
PX40100
07PAZ
-
00' 10100
07sAz
-
0010004
OTMAJ
_
PY4O11A
07MAJ
-
PY40120
07406
-
0020400
07406
-
0070300
07736
-
A010004
07746
-
0010500
07746
-
0010600
07746
-
0030100
07749
-
0010000
07947- 611501
Mai nshaft Hol der
Cl utch Spri ng Compressor Bol t Assembl y
Housi ng Pul l er
Dri ver Attachment
Pi l ot, 26 x 30 mm
Cl utch Spri ng Compressor Attachment
Backprobe Set
A"/T Oi l Pressure Hose,2210 mm
A,/T Oil Pressure Hose, Adapter
A,/T Oil Pressure Gauge Set w/panel
Ay'T Low Pressure Gauge w/panel
Adj ustabl e Beari ng Pul l er, 25
-
40 mm
Dri ver 40 mm l .D.
Dri ver
Dri ver Attachment, 68 mm
1
1
1
I
I
'l
1
I
1
1
1
I
1
I
'I
14- 101, 148
't
4-128,
't31
14- 103
14-139
' 14-
139
14-124, 131
l 4-45
14-46
't
4-47
14-87
14-87
14-87
14-140,14' 1
14-140, 141,142
14-' t40,142
' 14-121.
135, 137, 138
14-139,140,141,' 142
14- 139
*Must
be used wi th commerci al l v-avai l abl e 3/8"
-
16 sl i de hammer.
o
g
\,
Edttltr-
6,
@
@ @ o @
@ @ @ @ @
14-2
t
,
t
Description
The automati c transmi ssi on i s a combi nati on of a 3-el ement torque convener and a dual -shaft el ectroni cal l y control l ed
automati c transmi ssi on whi ch provi des 4 speeds forward and 1 reverse.
Torque Converter, Geats and Clutches
The torque converter consi sts of a
pump. turbi ne and stator, assembl ed i n a si ngl e uni t. They are connected to the engi ne
crankshaft so they turn together as a uni t as the engi ne turns. Around the outsj de of the torque converter i s a ri ng gear
whi ch meshes wi th the starter pi ni on when the engi ne i s bei ng started. The enti re torque converter assembl y serves as a
fl ywheel whi l e transmi tti ng
power to the transmi ssi on mai nshaft.
The transmi ssi on has two
paral l el
shafts: the mai nshaft and the countershaft. The mai nshaft i s i n l i ne wi th the engi ne
crankshaft. The mai nshaft i ncl udes the 1st, 2nd and 4th cl utches, gears tor 2nd, 4th, reverse and 1st
(3rd gear i s i ntegral
wi th the mai nshaft, whi l e the reverse gear i s i ntegral wi th the 4th gear). The countershaft i ncl udes the 3rd cl utch, and
gears for 3rd, 2nd. 4th, reverse, 1st and parki ng. The gears on the mai nshaft are i n constant mesh wi th those on the coun-
tershaft. When certai n combi nati ons of
gears i n transmi ssi on are engaged by cl utches, power i s transmi tted from the
mai nshaft to the countershaft to provi de
p,
E, E,
and
E
posi ti ons.
Electronic Control
The el ectroni c control system consi sts of the Powertrai n Control Modul e
(PCM),
sensors, a l i near sol enoi d and four
sol enoi d val ves. Shi fti ng and l ock-up are el ectroni cal l y control l ed for comfonabl e dri vi ng under al l condi ti ons. The PCM i s
l ocated bel ow the dashboard, under the front l ower
panel
on the
passenger' s si de.
Hydraulic Control
The val ve bodi es i ncl ude the mai n val ve body, the secondary val ve body, the regul ator val ve body, the servo body and the
l ock-up val ve body through the respecti ve separator pl ates, They are bol ted on the torque converter housi ng.
The mai n val ve body contai ns the manual val ve, the 1-2 shi ft val ve, the 2nd ori fi ce control val ve, the CPB
(Cl utch
Pressure
Back-up) val ve, the modul ator val ve. the servo control val ve, the rel i ef val ve, and ATF pump gears. The secondary val ve
body contai ns the 2-3 shi ft val ve, the 3-4 shi ft val ve, the 3-4 ori fi ce control val ve, the 4th exhaust val ve and the CPC
(Cl utch
Pressure Control ) val ve. The regul ator val ve body contai ns the pressure regul ator val ve, the torque convener check val ve.
the cool er rel i ef val ve, and the l ock-up control val ve. The servo body contai ns the servo val ve whi ch i s i ntegrated wi th the
reverse shi ft fork, and the accumul ators. The l ock-up val ve body contai ns the l ock-up shi ft val ve and the l ock-up ti mi ng
val ve. The l i near sol enoi d and the shi ft control sol enoi d val ve Ay' B are bol ted on the outsi de of the transmi ssi on housi ng,
and the l ock-up control sol enoi d val ve !y' B i s bol ted on the outsi de of the torque converter housi ng. Fl ui d from regul ator
passes through the manual val ve to the vari ous control val ves. The cl utches recei ve fl ui d from thei r respecti ve i eed pi pes
or i nternal hydraul i c ci rcui t.
Shift Control Mechanism
Input from vari ous sensors l ocated throughout the car determi nes whi ch shi ft control sol enoi d val ve the PCM wi l l acti vate.
Acti vati ng a shi ft control sol enoi d val ve changes modul ator pressure, causi ng a shi ft val ve to move. Thi s pressuri zes a l i ne
to one of the cl utches, engagi ng that cl utch and i ts correspondi ng gear. The shi ft control sol enoi d val ves A and B are con-
trol l ed by the PCM.
Lock-uo Mechani sm
In
E
posi ti on, i n 3rd and 4th, and i n
E
posi ti on i n 3rd, pressuri zed fl ui d i s drai ned from the back of the torque converter
through a fl ui d passage, causi ng the l ock-up pi ston to be hel d agai nst the torque converter cover. As thi s takes
pl ace, the
mai nshaft rotates at the same as the engi ne crankshaft. Together wi th hydraul i c control . the PCM opti mi zes the ti mi ng of
the l ock-up mechani sm. The l ock-up val ves control the range of l ock-up accordi ng to l ock-up control sol enoi d val ves A and
B, and l i near sol enoi d. When l ock-up control sol enoi d val ves A and B acti vate, the modul ator pressure changes. The l ock-
uo control sol enoi d val ves A and B and the l i near sol enoi d are control l ed by the PCM.
(cont' d)
14-3
Description
(cont'd)
Gear Selction
The shi ft l ever has si x posi ti ons:
E
PARK,
E
REVERSE,
E
NEUTRAL,
E
1st through 4th gear ranges,
E
1st through 3rd
gear ranges,
P
2nd gear.
Starti ng i s possi bl e
onl y i n
E and N
posi ti ons
through the use of a sl i de-type. neutral -safety swi tch.
Automatic Transaxls lA/T) Gear Position Indicatot
The Ay' T gear posi ti on i ndi cator i n the i nstrument panel shows whi ch gear has been sel ected wi thout havi ng to l ook down
at the consol e,
Clutchs
The four-speed automati c transmi ssi on uses hydraul i cal l y-actuated cl utches to engage or di sengage the transmi ssi on gears.
When hydraul i c pressure i s i ntroduced i nto the cl utch drum, the cl utch pi ston moves. Thi s presses the fri cti on di scs and
steel pl ates together. l ocki ng them so they don' t sl i p. Power i s then transmi tted through the engaged cl utch pack to i ts
hub-mounted gear. Li kewi se, when the hydraul i c pressure i s bl ed from the cl utch pack, the pi ston rel eases the fri cti on di scs
and the steel
pl ates,
and they are free to sl i de
past
each other. Thi s al l ows the
gear
to spi n i ndependentl y on i ts shaft,
transmi tti ng no power.
. 1st Cl utch
The l st cl utch engages/di sengages l st gear, and i s l ocated at the end of the mai nshaft,
j ust
behi nd the ri ght si de cover.
The 1st cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed pi pe wi thi n the mai nshaft,
. 2nd Cl utch
The 2nd cl utch engages/di sengages 2nd gear, and i s l ocated at the mi ddl e of the mai nshaft. The 2nd cl utch i s
j oi ned
back-to-back to the 4th cl utch. The 2nd cl utch i s suppl i ed hydraul i c pressure through the mai nshaft by a ci rcui t connect-
ed to the i nternal hydraul i c ci rcui t.
. 3rd Cluich
The 3rd cl utch engages/di sengages 3rd gear, and i s l ocated at the end of the countershaft. The 3rd cl utch i s suppl i ed
hydraul i c pressure by i ts ATF feed pi pe wi thi n the countershaft.
. 4th Clutch
The 4th cl utch engages/di sengages 4th gear, as wel l as reverse gear, and i s l ocated at the mi ddl e of the mai nshaft. The
4th cl utch i s
j oi ned
back-to-back to the 2nd cl utch. The 4th cl utch i s suppl i ed hydraui i c pressure by i ts ATF feed pi pe
wi thi n the mai nshaft.
14-4
Position Description
E
PARK
E
REVERSE
E
NEUTRAL
E]
DRIVE
(1st
through 4thl
E
DRI VE
(1st
through 3rd)
E
SEcoND
Front wheel s l ocked; parki ng brake pawl engaged wi th parki ng gear
on countershaft. Al l cl utches
reteaseq,
Reverse; reverse sel ector engaged wi th countershaft.everse gear and 4th cl utch l ocked.
Al l cl utches rel eased.
General dri vi ng; stans off i n 1st, shi fts automati cal l y to 2nd.3rd, then 4th, dependi ng on vehi cl e
speed and throttl e
posi ti on. Downshi ft through 3rd, 2nd and 1st on decel erati on to stop. The Iock-up
mechani sm comes i nto operati on i n
E
posi ti on i n 3rd and 4th gear.
Use for rapi d accel erati on at hi ghway speeds and general dri vi ng; up-hi l l and down-hi l l dri vi ng; starts
off i n 1st, shi fts automati cal l y to 2nd, then 3rd, dependi ng on vehi cl e speed and throttl e posi ti on.
Downshi fts through 2nd to 1st on decel erati on to stop. The l ock-up mechani sm comes i nto operati on
i n 3rd gear.
Use for engi ne braki ng or better tracti on starti ng off on l oose or sl i ppery surfaces; stays i n 2nd
gear, does not shi ft up and down,
[ l l f l l / l
I
One-way Clutch
The one,way cl utch i s posi ti oned between the countershaft 1st gear and the parki ng gear, wi th the
parki ng gear spl i ned to the
countershaft. The l st gear provi des the outer race surface, and the parki ng gear provi des the i nner race surface. The one-
way cl utch l ocks up when
power i s transmi tted from the mai nshaft
' 1st
gear to the countershaft 1st gear. The 1st cl utch
and gears remai n engaged i n the 1st, 2nd, 3rd, and 4th gear ranges i n the E, E
or
@
posi ti on
However, the one way cl utch di sengages when the 2nd, 3rd, or 4th cl utches/gears are appl i ed i n the D.
,
o or
E
posi ti on.
Thi s i s because the i ncreased rotati onal speed of the gears on the countershaft overri des the l ocki ng
"speed
range" of the
one-way cl utch. Thereafter, the one-way cl utch free-wheel s wi th the 1st cl utch sti l l engaged.
2ND CLUTCH 4TH CLUTCH
1ST CLUTCH
MAINSHAFT
COUNTERSI{AFT
ONE-WAY CLUTCH
PABKING GEAR
INSIDE OF ONE,WAY
CLUTCH
Spl i ned wi l h count er
shaf t
The spr ags engage/
di sengage out si de
and i nsi de of t he
one way cl ut ch.
3AD CLUTCH
OUTSIDE OF ONE.WAY
CLUTCH
OVER.FIDING
LOCKING SPEEO CONDITION
LOCKING CONDITION
14-5
t-
Description
Power Flow
O: Operates, x: Doesn' t operate.
*1:
Al though the 1st cl utch engages, dri vi ng power i s not transmi tted as the one-way cl utch sl i ps.
*2:
The one-way cl utch engages when accel erati ng, and sl i ps when decel erati ng.
,,
14-6
I
L, * * , f f i - '
\enr
POSMON\.
TOROUE
CONVERTER
1ST GEAR
1sT
CLUTCH
2ND GEAR
2ND
CLUTCH
3RD GEAR
3RD
CLUTCH
4TH
REVERSE
GEAR
PARKING
GEAR
GEAR CLUTCH
E
o o
E
o o o
E
o
D-a
o 4, 2
2ND o o* i o
3RO o o*, o
4TH o o* ! o o
[o]
o o*,
2ND a o* ' o
3RD o o* ' o
E
o o* 1 o
El
Position
Hydraul i c
pressure i s not appl i ed to the cl utches. Power i s not transmi ned to the countershaft.
E
Position
Hydraul i c pressure i s not appl i ed to the cl utches. Power i s not transmi tted to the countershaft
The countershaft i s l ocked by the parki ng pawl i nterl ocki ng the parki ng gear.
TOROUE CONVERTER
1ST CLUTCH
FI NAL DRI VE
GEAR
3RD CLUTCH
(cont' d)
14-7
Description
2.
3.
Power Flow
(cont'd)
lst Gear {lP!l or .D3l
position)
tn [D.] or l al posi ti on, the opti mum gear i s automati cal l y sel ected from 1st, 2nd,3rd and 4th gears, accordi ng to condi ti ons
such as the bal ance between throttl e openi ng
(engi ne
l oad) and vehi cl e speed.
1. Hydraul i c pressure i s appl i ed to the 1st cl utch, whi ch rotates together wi th the mai nshaft, causi ng the mai nshaft l st
gear to rotate.
Power i s transmi tted to the countershaft l st gear, whi ch dri ves the countershaft vi a the one-way cl utch.
Power i s transmi tted to the fi nal dri ve gear, whi ch dri ves the fi nal dri ven gear.
TOROUE CONVEETER
MAI NSHAFT 1ST GEAR
1ST CI -UTCH
MAI NSHAFT
ONE-WAY CLUTCH
FI NAI . DRI VE GEAR
PARKI NG GEAR
COUNTERSHAFT
1ST GEAR
FINAL DRIVEN GEAR
14-8
Znd Gear {[0!,
or or
@
positionl
E
Posi ti on i s provi ded to dri ve onl y 2nd gear.
' 1.
Hydraul i c
pressure i s appl i ed to the 2nd cl utch on the mai nshaft, and power i s transmi tted vi a the 2nd cl utch to the
mai nshaft 2nd gear.
2. Power transmi fted to the mai nshaft 2nd gear i s conveyed vi a the countershaft 2nd gear, whi ch dri ves the counter-
shaft.
3. Power i s transmi tted to the fi nal dri ve gear, whi ch dri ves the fi nal dri ven gear.
NOTE: Hydraul i c pressure i s al so appl i ed to the 1st cl utch. but si nce the rotati on speed of the 2nd gear exceeds that
of 1st gear, power from 1st gear i s cut off at the one-way cl utch.
TOROUE CONVERTER
(cont' d)
2ND CLUTCH
MAIIISXAFT
COUNTERSHAFT 2ND GEAR
14-9
Description
Power Flow
{cont'dl
3rd Gear
([ll
or lg.l
position)
' 1.
Hydraul i c pressure i s appl i ed to the 3rd cl utch. Power from the mai nshaft 3rd gear i s transmi tted to the countershaft
3rd gear.
2. Power i s transmi fted to the fi nal dri ve gear, whi ch dri ves the fi nal dri ven gear.
NOTE: Hydraul i c pressure i s al so appl i ed to the 1st cl utch, but si nce the rotati on speed of 3rd gear
exceeds that of
' l st
gear, powerfrom l st gear i s cut off atthe one-way cl utch.
MAI NSHAFT 3RD GEAR
MAI NSI {AFT
COUNTERSHAFT
3RD GEAR
3RD CLUTCH
TOROUE CONVERTER
14-10
FI NAL ORI VN GEAB
I
2.
4th Gear {[t]
position)
1. Hydraul i c pressure i s appl i ed to the 4th cl utch, whi ch rotates together wi th the mai nshaft, causi ng the mai nshaft 4th
gear to rotate.
Power i s transmi tted to the countershaft 4th gear, whi ch dri ves the countershaft.
Power i s transmi tted to the fi nal dri ve
gear. whi ch dri ves the fi nal dri ven
gear.
NOTE: Hydraul i c pressure i s al so appl i ed to the 1st cl utch. but si nce the rotati on speed of 4th gear exceeds that of 1st
gear, power from 1st gear i s cut off at the one-way cl utch.
TOROUE
4TH GEAR
4TH CLUTCH
MAI NSHAFT
COUNTERSHAFT
(cont' d)
14-11
FI NAL DRI VEN GEAR
Description
4.
Power Flow
(cont'd)
E
Position
l Hydraul i c pressure i s swi tched by the manual val ve to the servo val ve. whi ch moves the reverse shi ft fork to the
reverse posi ti on. The reverse shi ft fork engages wi th the reverse sel ector, reverse sel ector hub, and the counte.shaft
reverse gear.
2 Hydraul i c pressure i s al so appl i ed to the 4th cl utch. Power i s transmi tted from the mai nshaft reverse oear vta the
reverse i dl er gear to the countershaft reverse gear.
The rotati on di recti on of the countershaft reverse gear i s changed vi a the reverse i dl er gear.
Power i s transmi tted to the fi nal dri ve gear, whi ch dri ves the fi nal dri ven gear.
MAI NSHAFT
COUNTERSHAFT
TOROUE
COUNTERSHAFT
REVERSE GEAR
REVERSE SELECTOR
HUB
REVERSE SELECTOR
REVERSE SHIFT
FORK
14-12
FINAL ORIVEN GEAR
SERVO VALVE
Electronic Control System
The el ectroni c control system consi sts of a Powertrai n Control Modul e {PCM), sensors, a l i near sol enoi d and four sol enoi d
val ves. Shi fti ng and l ock-up are el ectroni cal l y control l ed for comfortabl e dri vi ng under al l condi ti ons. The PCM i s l ocated
bel ow the dashboard. under the front l ower panel on the passenger' s si de.
(cont'd)
PGM-FI
Conirol Sy3tem
A/T Control SFtem
Shift Control
Lock-uD Control
14-13
Description
(cont'dl
Shift Control
The PCM i nstantaneousl y determi nes whi ch gear shoul d be sel ected by vari ous si gnal s sent from sensors, and actuates
the shi ft control sol enoi d val ves A and B to control shi fti ng. Al so, a Grade Logi c Control System has been adopted to con-
trol shi fti ng i n i o.r posi ti on whi l e the vehi cl e i s ascendi ng or descendi ng a sl ope, or reduci ng speed.
Posi ti on Gear
Shil't Control Solenoid
Val ve A
Shift Control Solenoid
Valve B
Dr Dr
1st OFF ON
2nd ON ON
3rd ON OFF
rq!
4t h OFF OFF
l
2nd ON ON
E- Reverse ON
*See
page 14-30for reverse i nhi bi tor control descri pti on.
Lock-uo Control
From sensor i nput si gnal s, the PCM determi nes whether to turn the l ock-up ON or OFF, and acti vates l ock-up control
sol enoi d val ve A and/or B accordi ngl y. The combi nati on of dri vi ng si gnal s to l ock-up control sol enoi d val ves A and B and
the l i near sol enoi d pressure i s shown i n the tabl e bel ow.
Lock-up Conditions
Lock-up Control
Solnoid Valve A
Lock-up Control
Solenoid Valve B
Linear Solenoid
Pressure
Lock' up OFF OFF OFF Hi g h
Lock- up, Hal f ON
Duty operati on
OFF
-
ON
Lock- up, Ful l ON ON Hi g h
LOCX- Up
duri ng decel erati on
ON
Duty operati on
OFF
*
ON
Low
14-14
. GRAOE LOGIC CONTROL SYSTEM
How i t works:
The PCM compares actual dri vi ng condi ti ons wi th dri vi ng condi ti ons memori zed i n the PCM, based on the i nput trom the
vehi cl e speed sensor, the throttl e
posi ti on sensor. the barometori c pressure sensor, the engi ne cool ant temperature sensor,
the brake swi tch si gnal and the shi ft l ever posi ti on si gnal . to control shi fti ng whi l e a vehi cl e i s ascendi ng or descendi ng a
sl ope, or reduci ng speed.
SIGNALS OETECTED
(cont' d)
Oriving Rt3ktrncc
Judgemenl ot Controlling ArGa
{Fuzzy logicl
'
Gradual A3cending mode
'
Steop Asconding mode
.
D6cnding mode
.
Gradual Oosconding mode
.
Siep Odcending mode
14-15
Description
(cont'dl
. Ascending Control
When the PCM determi nes that the vehi cl e i s cl i mbi ng a hi l l i n
El
posi ti on, the system extends the engagement area of
2nd gear and 3rd gear to prevent the transmi ssi on from frequentl y shi fti ng between 2nd and 3rd gears, and between 3rd
and 4th gears, so the vehi cl e can run smooth and have more power when needed. There are two ascendi ng modes wi th
di fferent 3rd gear dri vi ng areas accordi ng to the magni tude of a gradi ent stored i n the PCM.
NOTE:
. The PCM memory contai ns shi ft schedul es between 2nd and 3rd gears, and between 3rd and 4th gears
that enabl e the
PCM' s Iuzzy l ogi c to automati cal l y sel ect the most sui tabl e gear
accordi ng to the magni tude of a gradi ent
. Fuzzy l ogi c i s a form of arti fi ci al i ntel l i gence that l ets computers respond to changi ng condi ti ons much l i ke a human
mi nd woul d.
. Descending Control
When the PCM determi nes that the vehi cl e i s goi ng down a hi l l i n E posi ti on, the shi ft-up speed from 3rd to 4th gear
when the throttl e i s cl osed becomes faster than the set speed for fl at road dri vi ng to wi den the 3rd gear
dri vi ng area.
Thi s, i n combi nati on wi th engi ne braki ng from the decel erati on l ock-up, achi eves smooth dri vi ng when the vehi cl e i s
descendi ng. There are two descendi ng modes wi th di fferent downshi ft
(4 -
3) schedul es accordi ng to the magni tude of a
gradi ent stored i n the PCM. When the vehi cl e i s i n 4th gear, and you are decel erati ng on a gradual hi l l . or when you
are
appl yi ng the brakes on a steep hi l l , the transmi ssi on wi l l downshi ft to 3rd gear. When you accel erate, the transmi ssi on wi l l
then return to 4th gear.
ASCENDING MODE DESCENDING MOOE
,lTH
SHIFTING
F
CHARACTERISTICS
CONTROL AREA
ir'.ff}",
vehicre speod
ir'.111,",
v.hicre3ped
. Deceleration Control
When the vehicle goes around a corner, and needs to first decelerate and then accelerate, the PCM sets the data for deceleration
control to reduce the number of ti mes the transmi ssi on shi fts. When the vehi cl e i s decel erati ng from speeds above 26 mph
(41
km/h), the PCM shi fts the transmi ssi on from 4th to 2nd earl i er than normal to cope wi th upcomi ng accel erati on.
14- 16
PG2
IGPl
IGP2
vcc2
TPS
sG2
Ci rcui t Di agram and Termi nal Locati ons
IGNITION SWITCH
LOCK- UPCONT8OL
SOLENO OVALVE A
LOC( UPCONTFOL
SOLENOI DVALVEB
SNIFTCONTSOL
SOLENOI DVALVEA
SHIFICONTFOL
SOLENOID VALVE B
LNEI FSOLENOI D
POSITON
F
14-17
Description
Hydraul i c Control
The hydraul i c control system i s control l ed by the ATF pump. val ves, accumul ators, and el ectroni cal l y control l ed sol enoi ds.
The ATF pump i s dri ven by spl i nes on the end of the torque converter whi ch i s attached to the engi ne. Fl ui d from the ATF
pump fl ows through the regul ator val ve to mai ntai n speci fi ed pressure through the mai n val ve body to the manual val ve,
di recti ng pressure
to each of the cl utches. The val ve body i ncl udes the mai n val ve body, the regul ator val ve body, the
l ock-up val ve body, the secondary val ve body, the servo body. the l i near sol enoi d, the shi ft control sol enoi d val ve Ay' B
assembl y, and the l ock-up control sol enoi d val ve A,/B assembl y. The shi ft control sol enoi d val ve A,/B assembl v and the l i n-
ear sol enoi d are bol ted on the outsi de of the transmi ssi on housi ng, The l ock-up control sol enoi d val ve Ay' B assembl y i s
bol ted on the outsi de of the torque converter housi ng.
SHIFT CONTROL
SOLENOID VALVE A/B
ASSEMBLY
LINEAR SOLENOIO
VALVE
VALVE BODY
14- 18
ATF PUMP GEARS
Main Valve Body
The mai n val ve body houses t he manual val ve, t he 1-2 shi f t val ve, t he 2nd ori f i ce cont rol val ve, t he CPB val ve, t he modu-
l at or val ve, t he servo cont rol val ve, and t he rel i ef val ve. The pri mary f unct i ons of t he mai n val ve body are t o swi t ch f l ui d
pressure on and of f and t o cont rol t he hydraul ; c pressure goi ng t o t he hydraul i c cont rol syst em
2NO ORIFICE CONTROL
VALVE
1.2 SHIFT VALVE
MOOULATOF V VE
MANUAL VALVE
RELIEF
V
CONTROL
VALVE
VE
MAIN V
BODY
The secondary val ve body i s l ocated on the mai n val ve body. The secondary val ve body houses the 2-3 shi ft val ve, the 3-4
shi ft val ve, the 3-4 ori fi ce control val ve, the 4th exhaust val ve and CPC val ve
3.4 SHIFT VALVE
4TH EXHAUST
VALVE
CPC VAL
(cont' d)
2-3 SHIFT VALVE
3.4 ORIFICE CONTBOL
VALVE
VALVE
14-19
Description
Hydraul i c Control
(cont' d)
Regulator Valve Body
The regul ator val ve body i s l ocated on the mai n val ve body. The regul ator val ve body consi sts of the regul ator val ve, the
torque converter check val ve, the cool er rel i ef val ve, and the l ock-uo control val ve.
REGULA
VALVE
COOI . ER RELI EF VALVE
CONTROL VALVE
Lock-up Valve Body
The l ock-up val ve body wi th the l ock-up shi ft val ve and the l ock-up ti mi ng val ve i s l ocated on the regul ator val ve body.
LOCK-UP SHIFT VALVE
TIMING VALVE
BODY
14-20
Regul ator Val ve
The regul ator val ve mai ntai ns a constant hydraul i c pressure from the ATF pump to the hydraul i c control system, whi l e
al so furni shi ng fl ui d to the l ubri cati ng system and torque convener. The fl ui d from the ATF pump fl ows through B and B' .
The regul ator val ve has a val ve ori fi ce. The fl ui d enteri ng from B fl ows through the ori fi ce to the A cavi ty. Thi s pressure of
the A cavi ty
pushes the regul ator val ve to the ri ght si de, and thi s movement of the regul ator val ve uncovers the fl ui d port
to the torque converter and the rel i ef val ve. The fl ui d fl ows out to the torque converter, and the rel i ef val ve and regul ator
val ve moves to the l eft si de. Accordi ng to the l evel of the hydraul i c pressure through B, the posi ti on of the regul ator val ve
changes and the amount of the fl ui d from B' through D and C al so changes. Thi s operati on i s conti nued, mai ntai ni ng the
l tne pressure.
NOTE: When used,
"l eft"
or
"ri ght"
i ndi cates di recti on on the i l l ustrati on bel ow.
ENGI NE NOT RUNNI NG
STATOB SHAFT ARM
Stator Reaction Hydraulic Pressure Control
Hydraul i c
pressure i ncreases accordi ng to torque, are performed by the regul ator val ve usi ng the stator torque reacti on
The stator shaft i s spl i ned wi th the stator i n the torque converter. and i ts arm end contacts the regul ator spri ng cap. When
the vehi cl e i s accel erati ng or cl i mbi ng
(Torque
Converter Range), the stator torque reacti on acts on the stator shaft, and
the stator arm pushes the regul ator spri ng cap i n the di recti on of the arrow i n proporti on to the reacti on. The stator reac-
ti on spri ng compresses, and the regul ator val ve moves to i ncrease the l i ne pressure whi ch i s regul ated by the regul ator
val ve. The l i ne Dressure reaches i ts maxi mum when the stator torque reacti on reaches i ts maxi mum.
TOROUE CONVERTER
REGULATOR VALVE
TOR SPRING CAP
ENGI NE RUNNI NG
To TOROUE CONVERTER Lubrication
'..-
_..-7
3f
{cont' d)
STATOR SHAFT
ATOR SHAFT ARM
14-21
Description
Hydraul i c Control
(cont' d)
Servo Body
The servo body i s l ocated on the secondary val ve body. The servo body contai ns the servo val ve whi ch i s i ntegrated wi th
the reverse shi ft tork, and the accumul ators
2ND ACCUMULA
SERVO BODY
lST ACCUMULATOR
3RD ACCUMULATOR
SERVO VALVE/SHIFT
FORK SHAFT
L
14-22
.J
Hydraul i c Fl ow
Genr8l Chart of Hydraulic Pressure
ATF Pump- Regul ator Val ve
-;
Li ne Pressure
;
Modul ator Pressure
--
Li near Sol enoi d
LCl utch
Pressure
l
Torque Converter Pressure
L
Lubri cati on Pressure
Distribution of Hvdraulic Prssure
.
Regul ator Val ve
-
Torque Convener Pressure
f
Lubri cati on Pressure
L
To requl ate Li ne Pressure
.
Manual Val ve
--
To sel ect Li ne Pressu.e Cl utch Pressure
.
Modul ator Val ve Modul ator Pressure Shi ft Control Sol enoi d Val ves
l
Lock-up Control Sol enoi d Val ves
Li near Sol enoi d
.
1-2 Shift Valve
Il]l
.
2-3 Shi ft Val ve
l
Cl utch Pressure
.
3-4 Shi ft Val ve
NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE
'1
LINE 6B
MODULATE
(SHIFT
CONTROL SOLENOID
VALVE B)
41 4TH CLUTCH
LINE
MODULATE
(LOCK-UP
CONTROL
SOLENOID VALVE A)
LINEAR SOLENOID
1 " LINE 6D
MODULATE
(LOCK-UP
CONTROL
SOLENOID VALVE B)
90 TOROUE CONVERTER
2 LIN E 6D'
MODULATE
(LOCK-UP
CONTROL
SOLENOID VALVE B)
91 TOROUE CONVERTER
LI NE 7 LI NE 92 TOROUE CONVERTER
LINE 8 LINE/CPC 93 ATF COOLER
LI NE LINE 94 TOROUE CONVERTER
LINE 10 1ST CLUTCH LUBRICATION
LINE 20 2ND CLUTCH 96 TOROUE CONVERTER
4' LINE 204 2ND ACCUMULATOR 97 TOROUE CONVERTER
cPc 25 LINE 99 SUCTION
MODULATE 30 3RD CLUTCH X DRAIN
6A
MODULATE
(SHIFT
CONTROL SOLENOID
VALVE A)
40 4TH CLUTCH
(cont' d)
14-23
Description
Hydraul i c Fl ow
(cont' dl
N
Position
As the engi ne turns, the ATF pump al so starts to operate. Automati c transmi ssi on fl ui d
(ATF)
i s drawn from
(99)
and di s-
charged i nro
(1).
Then, ATF fl owi ng from the ATF pump becomes the l i ne pressure
(1)
The l i ne pressure
(1)
i s regul ated
by t;e regul ator val ve. The torque converter i nl et pressure {92) enters
(94)
of the torque converter through the l ock-up
shi ft val ve and di scharges i nto
(90). The torque converter check val ve prevents the torque converter
pressure from ri si ng'
Under thi s condi ti on, the hydraul i c
pressure i s not appl i ed to the cl utches'
NOTE: When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t'
14-24
E
Position
The l i ne pressure (1)fl ows
to the manual val ve and the modul ator val ve. The l i ne pressure (1)
changes the l i ne pressure
(4)
and
(25)
at the manual val ve, and changes to the modul ator pressure at the modul al o. val ve. But the modul ator pres-
sure
(6)
does not fl ow to each shi ft val ve because shi i t control sol enoi d val ves A and B are turned ON by the PCM. The
l i ne pressure (4) passes through the CPB val ve and the CPC val ve, and changes to the l i ne pressure (5),
then fl ows to the
1-2 shi ft val ve. The l i ne pressure (5)
from the 1-2 shi ft val ve changes to the 2nd cl utch pressure
{20) at the 2-3 shi ft val ve.
The 2nd cl utch pressure (20)
i s appl i ed to the 2nd cl utch, and the 2nd cl utch i s engaged. The l i ne pressure (4) passes
through the 1-2 shi ft val ve and the ori fi ce, and changes the 1st cl utch pressure, The 1st cl utch pressure (10)
al so fl ows to
the 1st cl utch. However, no power i s transmi tted because of the one-way cl utch.
NOTEr When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t.
(cont' d)
14-25
Description
Hydraul i c Fl ow
(cont' d)
El or lOi Position
1. l st Gear
The fl ow of fl ui d through the torque converter ci rcui t i s same as i n
N
posi ti on. The l i ne pressure fl ows to the manual
val ve and the modul ator val ve. The l i ne pressure changes to the modul ator pressure (6)
at the modul ator val ve and to
the l i ne pressure (4)
at the manual val ve. The modul ator pressure (6)
fl ows to the l eft end of the 1-2 shi ft val ve and the
3-4 shi ft val ve because shi ft control sol enoi d val ve A i s turned OFF and B i s turned ON by the PCM. The l -2 shi ft val ve
i s moved to the ri ght si de. The l i ne pressure (4)
changes to the
' l st
cl utch
pressure
110) at the 1-2 shi ft val ve and the
ori fi ce. The 1st cl utch
pressure (' t0) i s appl i ed to the l st cl utch and the 1st accumul ator; consquentl y, the vehi cl e wi l l
move as the engi ne power i s transmi tted.
NOTE: When used,
"| eft"
or
"ri ght"
2. 2nd Gear
As the speed of the vehi cl e reaches the prescri bed val ue, shi ft control sol enoi d val ve A i s turned ON by means of the
PCM. The modul ator pressure (64l
i n the l eft end of the 1-2 shi ft val ve i s rel eased by turni ng shi ft control sol enoi d
val ve A ON. The 1-2 shi ft val ve i s moved to the l eft si de and uncovers the
pon
to al l ow l i ne
pressure (5)
to the 2-3
shi ft val ve. The l i ne pressure (5)
changes to the 2nd cl utch pressure (20)
at the 2-3 shi ft val ve. The 2nd cl utch pressure
(20)
i s appl i ed to the 2nd cl utch, and the 2nd cl utch i s engaged.
Fluid flows bv wav of:
-
Li ne Pressure
(4) -
CPB Val ve
-
Li ne Pressure
(5) -
' l -2
Shi ft Val ve
-
Li ne Pressure
(5) -
2-3 Shi ft Val ve
-
2nd Cl utch Pressure
(20) t
2nd Cl utch
The hydraul i c pressure al so fl ows to the 1st cl utch. However, no power
j s
transmi tted because of the one-way cl utch.
NOTE; When used,
"| eft"
or
"ri ght"
(cont ' d)
14- 27
Description
Hydraulic Flow
(cont'd)
3. 3rd Gear
As the speed of the vehi cl e reaches the prescri bed val ue, shi ft control sol enoi d val ve B i s turned OFF by means of the
pCM.
Shi ft control sol enoi d val ve A remai ns ON. The modul ator
pressure (6)
tl ows to the ri ght end of the 1-2 shi ft
val ve and the l eft end of the 2-3 shi ft val ve. The 2-3 shi ft val ve i s moved to the ri ght si de by the modul ator
pressure
{68), The 2-3 shi ft val ve covers the port to stop l i ne pressure
(5)
to the 2nd cl utch and uncovers to the 3-4 shi ft val ve
as the 2-3 shi ft val ve i s moved to the ri ght si de. The l i ne pressure
(5)
becomes the 3rd cl utch
pressure (30)
at the 3-4
shi ft val ve. The 3rd cl utch
pressure (30)
i s appl i ed to the 3rd cl utch, and the 3rd cl utch i s engaged.
Fl ui d fl ows by way of:
-
Li ne pressure (4)
-
CPB Val ve
-
Li ne Pressure
(5)
-
1-2 Shi ft Val ve
-
Li ne Pressure
(5) +
2-3 Shi ft Val ve
-
Li ne Pressure {5)
-
3-4 Shi ft Val ve
-
3rd Cl utch Pressure
(30}
*
3rd Cl utch
The hydraul i c pressure al so fl ows to the 1st cl utch. However, no power i s transmi tted because of the one-way cl utch
as i n 2nd gear .
When used,
"l eft"
or
"ri ght"
\
14-28
i*.
4th G6ar
( qr
Positionl
Asthe speed ofthevehi cl e reaches the prescri bed val ue, shi ftcontrol sol enoi d val ve A i s turned OFF by means of the
PCM. Shi ft control sol enoi d val v6 B remai ns OFF. The modul ator pressure (6)
fl ows to the l eft end of the 1-2 shi ft
val ve and the l eft end of the 3-4 shi ft val ve. The modul ator pressure (64)
i n the l eft end of the 1-2 shi ft val ve equal s
the modul ator pressure (68)
i n the ri ght end of the 1-2 shi ft val ve, the 1-2 shi i t val ve remai ns at l eft si de by the ten-
si on of the val ve spri ng.
The 3-4 shi ft val ve i s moved to the ri ght si de by the modul ator pressure (5A).
The 3-4 shi ft val ve covers the port to the
3rd cl utch and uncovers the port to the 4th cl utch as thi s val ve i s moved to the ri ght si de. The 4th cl utch pressure (41)
from the 3-4 shi ft val ve becomes the 4th cl utch pressure (40)
at the manual val ve. The 4th cl utch pressure
{40} i s
appl i ed to the 4th cl utch, and the 4th cl utch i s engaged.
Fl ui d fl ows by way of:
-
Li ne pressur (4) -
CPB Val ve
-
Li ne Pressure
(5) +
l -2 Shi ft Val ve
-
Li ne Pressure
(5) -
2-3 Shi ft Varve
-
Li ne Pressure
(5) *
3-4 Shi ft Val ve
-
4th Cl utch Pressure
(41) +
Manual Val ve
-
4th Cl utch Pressure
(40)
+
4th Cl utch
The hydraul i c pressure al so fl ows to the 1st cl utch. However, no power i s transmi tted because of the one-way cl utch
as i n 2nd and 3rd gear.
NOTE: When used,
"| eft"
or
"ri ght"
(cont ' d)
14-29
Description
Hydraul i c Fl ow
(cont' dl
lll
Position
The fl ow of fl ui d through the torque converter ci rcui t i s the same as i n
E
posi ti on. The l i ne pressure (1)
changes to the
l i ne pressure (3)
and fl ows to the 1-2 shi ft val ve. The l i ne pressure (3)
changes to the l i ne pressure (3' )
at the 1-2 shi ft val ve
and fl ows to the servo val ve. The servo val ve i s moved to the ri ght si de
(Reverse
range posi ti on) and uncovers the pon to
al l ow l i ne pressure (3")
to the manual val ve. The l i ne pressure (3' )
from the 1-2 shi ft val ve fl ows through the servo val ve to
the manual val ve and changes the 4th cl utch pressure
{40). The 4th cl utch pressure
(40)
i s appl i ed to the 4th cl utch, and
the 4th cl utch i s engaged.
Reverse Inhibitor Control
When the
E
posi ti on i s sel ected whi l e the vehi cl e i s movi ng forward at speeds over 6 mph
(10 km/h), the PCM outputs the
1st speed si gnal to shi ft control sol enoi d val ves A and B; shi ft control sol enoi d val ve A i s turned OFF, shi ft control sol enoi d
val ve B i s turned ON. The 1-2 shi ft val ve i s moved to the ri ght si de and covers the port to stop l i ne pressure
{3' ) to the
servo val ve. The l i ne pressure (3' )
i s not appl i ed to the servo val ve, and the 4th cl utch
pressure
{40) i s not appl i ed to the
4th cl utch, as a resul t. power i s not transmi tted to the reverse di recti on.
NOTE: When used,
"| eft"
or
"ri ght"
14- 30
E
Position
The fl ow of fl ui d through the torque converter ci rcui t i s the same as i n
E
posi ti on. The l i ne pressure (11
changes to the
l i ne pressure (3)
and fl ows to the 1-2 shi ft val ve. The l i ne pressure (3)
changes to the l i ne pressure (3' )
at the 1-2 shi ft val ve
and fl ows to the servo val ve. The servo val ve i s moved to the ri ght si de {Reverse
range posi ti on) and uncovers the port to
al l ow l i ne pressure (3")to
the manual val ve as i n
E
posi ti on. The l i ne pressure (3")from
the servo val ve i s i ntercepted by
the manual val ve. However, hydraul i c pressure i s not suppl i ed to the cl utches, and the power i s not transmi tted.
When used,
"l eft"
or
"ri ght"
14-31
Description
Lock-up System
Lock-up Cl utch
1. Operati on
(cl utch
on)
Wi th the l ock up cl utch on, the fl ui d i n the chamber between the torque converter cover and the l ock-up pi ston i s drai ned
off, and the converter fl ui d exerts pressure through the pi ston agai nst the torque converter cover. As a resul t, the convert-
er turbi ne i s l ocked to the converter cover. The effect i s to bypass the converter, thereby pl aci ng the vehi cl e i n di rect dri ve.
LOCK-UP PI STON DAMPER SPRI NG
The power flows by way of:
Engi ne
I
Dri ve pl ate
t
Torque converter cover
t
Lock-up piston
t
Damper spri ng
t
Turbi ne
I
lvlainshaft
TOROUE CONVERTER
COVER
Operati on
(cl utch
off)
With the lock-up clutch off, the fluid flows in the reverse of
"clutch
on." As a result. the lock-up piston moves away from
the converter cover, and the torque converter lock-up is released.
Engi ne
t
Dri ve pl ate
{
Torque convener cover
t
Pump
t
Turbi ne
t
l vl ai nshaft
TOROUE
COVER
MAINSHAFT
TURBINE
To ATF cool el
14-32
MAI NSHAFT
TOROUE CONVERTER
In i gd posi ti on, i n 3rd and 4th, and
D3- posi ti on i n 3rd,
pressuri zed fl ui d i s drai ned from the back of the torque
converter through a fl ui d passage, causi ng the l ock-up
pi ston
to be hel d agai nst the torque converter cover. As
thi s takes pl ace, the mai nshaft rotates at the same speed
as the engi ne crankshaft. Together wi th the hydraul i c
cont r ol , t he PCM opt i mi zed t he t i mi ng of t he l ock- up
system. Under certai n condi ti ons, the l ock-up cl utch i s
appl i ed duri ng decel erati on, i n 3rd and 4th gear.
The l ock-up system control s the range ot l ock-up accord-
i ng to l ock-up control sol enoi d val ves A and B, and the
l i near sol enoi d. When l ock-up control sol enoi d val ves A
and B acti vate. modul ator
pressure changes. Lock-up
control sol enoi d val ves A and B and the l i near sol enoi d
ar e mount ed on t he out si de of t he t or que conver t er
housi ng, and are control l ed by the PCM.
Lock-up Conditions/Lock-up Control Solenoid Valves/
Linear Solenoid Pressure
MODULATOR PRESSURE
<-
LINEAR SOLENOID PRESSURE
(cont' dl
Lock-up
Condi ti ons
Lock-up Control
Solenoid Valve
Linear
Solenoid
Pressure
A B
Lock-up OFF OFF OFF Hi gh
Lock-up, Hal f ON
Duty operation
OFF
-
ON
Lock-up, Ful l ON ON H igh
LOCX-Up
duri ng
decel erati on
ON
Duty operation
OFF
-
ON
IOROUE CONVERTER
CHECK VALVE
RELIEF VAL
LOCK.UP TIMING
VALVE
",
. X, COOLER RELI EF VALVE
ATF PUMP
14- 33
Description
Lock-up System
(cont'dl
TOROUE CONVERTER
No Lock.up
. Lock-uo Control Sol enoi d Val ve A: OFF
. Lock-uo Control Sol enoi d Val ve B: OFF
. Li near Sol enoi d Pressure: Hi gh
The pressuri zed fl ui d regul ated by the modul ator works
on both ends of the l ock-up shi ft val ve. Under thi s condi -
ti on, the pressures worki ng on both ends of the l ock-up
shi ft val ve are equal , the l ock-up shi ft val ve i s moved to
the ri ght si de by the tensi on of the val ve spri ng al one.
The fl ui d from the ATF pump wi l l fl ow through the l eft
si de of the l ock-up cl utch to the torque convener; that i s,
the l ock-uo cl utch i s i n OFF condi ti on.
NOTE: When used,
"l eft"
and
"ri ght"
i ndi cates di recti on
on the hvdraul i c ci rcui t.
MOOULATOR PRESSURE
-r
TOROUE CONVERTER
I
CHECK VALVE
RELIEF VALVE
LOCK-UP TIMING
VALVE
$
I
L- -r COOLER RELTEF VALVE
ATF PUMP
TOROUE CONVERTER
Half lock-up
. Lock-up Control Sol enoi d Val ve A: ON
. Lock-up Control Sol enoi d Val ve B: Duty Operati on
OFF
*
ON
. Li near Sol enoi d Pressure: Low
The PCM swi tches the sol enoi d val ve A on to rel ease the
modul ator
pressure i n the l eft cavi ty ot the l ock-up shi ft
val ve. The modul ator pressure i n the ri ght cavi ty of the
l ock-up shi ft val ve overcomes the spri ng force; thus the
l ock-up shi ft val ve i s moved to the l eft si de.
The l i ne pressure i s then separated i nto the two pas-
sages to the torque convener:
Tor que Conver t er I nner Pr essur e: ent er s i nt o r i ght
si de to engage l ock-up cl utch
Torque Converter Back Pressure: enters i nto l eft si de
to di sengage l ock-up cl utch
The back pressure (F2)
i s regul ated by the l ock-up con-
trol val ve, whereas the
posi ti on
of the l ock-up ti mi ng
val ve i s determi ned by the l i near sol enoi d pressure and
tensi on of the val ve spri ng. Al so the posi ti on of the l ock-
up control val ve i s determi ned by the back pressure of
the l ock-up control val ve, torque converter
pressure reg-
ul ated bv the torque converter check val ve, and modul a-
tor pressure determi ned by the l ock-up control sol enoi d
val ve B. The PCM swi tches the l ock-uD control sol enoi d
val ve B on and off rapi dl y
(duty
operati on) under certai n
condi ti ons to regul ate the back pressure
{F2) to l ock the
torque converter properl y.
NOTE: When used,
"l eft"
and
"ri ght"
on the hydraul i c ci rcui t.
MODULATOR PRESSURE
(cont' d)
LOCK,UP CONTROL
SOLENOID VALVE
t
TOBOUE CONVERTEF
I
CHECK VALVE
RELIEF VALVE
LOCK.UP TIMING
VALVE
,.
^r
r*
cooLER RELTEF VALVE
ATF PUMP
14- 35
Description
{
Lock-up System
(cont'd)
TOROUE CONVERTER
Full Lock-up
. Lock-up Control Solenoid Valve A: ON
. Lock-up Control Solenoid Valve B: ON
. Li near Sol enoi d Pressure: Hi gh
When the vehi cl e speed further i nc.eases, the l i near
sol enoi d pressure i s i ncreased to hi gh i n accordance
wi th the l i near sol enoi d control l ed by the PCM.
The l ock-up ti mi ng val ve overcomes th spri ng force
and moves to the l eft si de. Al so. thi s val ve cl oses the
fluid port leading to the left side of the lock-up control
Under thi s condi ti on, the modul ator
pressure
i n the l eft
si de of t he l ock- up cont r ol val ve had al r sady bean
rel eased by the l ock-up control sol enoi d val ve 8; the
l ock-up control val ve i s moved to the l eft si de. As thi s
t akes pl ace, t he t or que conver t er back pr essur e i s
rel eased ful l y, causi ng the l ock-up cl utch to be engaged
ful l y.
NOTE: When used,
"| eft"
and
"ri ght"
i ndi cats di recti on
on the hvdraul i c ci rcui t,
MODULATOR PRESSURE
LOCK-UP CONTROL
VALVE
LOCK.UP CONTROL
SOLENOID VAI.VE
RELIEF VALVE
LOCK-UP TIMING
VALVE
^
1,,__.r'
cooLER RELTEF vALvE
14-36
ATF PUMP
TOROUE CONVEATER
Deceleration Lock-up
. Lock-up Control Sol enoi d Val ve A: ON
. Lock-up Control Sol enoi d Val ve B: Duty Operati on
OFF
-
ON
. Li near Sol enoi d Pressurer Low
The PCM swi tches sol enoi d val ve B on and off rapi dl y
under cer t ai n condi t i ons. The sl i ght l ock- up and hal f
l ock-up regi ons are mai ntai ned so as to l ock the torque
converter
properl y.
NOTE: When used,
"l eft"
and
"ri ght"
on the hydraul i c ci rcui t.
MODULATOR PFESSURE
LI NEAR SOLENOI D PRESSUBE
LOCK-UP CONTROL
SOLENOIO VALVE
,o*oua "otua"rlil
CHECK VALVE
RELIEF VAL
LOCK.UP TIMING
VALVE
s
^r
---r'1 COOLER RELIEF VALVE
ATF PUMP
14-37
Component
Locations
POWERTRAIN CONTROL
MOOULE IPCM}
TIC TRANSAXLE IA/TI
COUNTERSHAFT
SPEED SENSOR
i:.
i\
\.i.'.
(-
t r' , \ i ,
V'.:t
',
SOLENOID VALVE
ASSEMBLY
SOLENOID VALVE
ASSEMBLY
GEAR POSITION SWITCH
14- 39
PCM
Circuit Diagram
(A/T
Control System)
UNOEfl
-HOOD
FUSE/REIAY BOX
No.41 (80A)
No.42 l40A)
No. 47 { 7. 5 A)
No. 13 ( l 5A)
Ar pNp
l or ô ] sLu l nr r n l Sl t l 6l t l or *
/8tu
c10
UNOER DASH
FUSE/RELAY BOX
BtK
A1 0
BLK
423
L
'96:
BLU/RED
' 97, ' 98:
GRN/ BLK
' ,u,
,,,tro
"I
f
,at
38-'cFN/BLK
BLKETU wHT
T T T
YEL GRN BLU
NorE: rf :To 5v
T
r To 12V
14-40
8 2 4 l 8 8 I 8 1 7
YEL 96: GRN BLU
GAUGE ASSEMELY
A/T GEAR POSITION
INDICATOR
F-
BIK/BLU
|--wHT
I--
GRN
N
I
D,
I
\
VEHICLE
SPEEO SENSOR
V
l .
'1Fr
rl P
I
I
I
BLUMHT
l.' ,
RED/WHT
02
YEUBTURED/BtK
010 D1
I"
I
RED
l"'
REO
s23
1 2 2
I
I
BRN/BTK
8 3 | 8 1 1
l "
I
GRN/BLK
BLU GRN
BLU/ryEL GRN,4A/HT
T T
t l
t l
Lcl
MAINSHAFT
SPEED SENSOR
_l__L _l__l_
TTTT
p* 8
SPEoSENSoR
L|NEARSOLENo|D
f_l_ _l__l-
I T T T
LOCK
-UP
CONTROL
SOLENOIO VALVE
ASSEMBLY
SERVICE CHECK CONNECTOR
rcM TeminBl Locations
14-41
PCM Termi nal Vol tage/Measuri ng
Condi ti ons
A/T Control System
The PCM termi nal vol tage and measuri ng condi ti ons are shown for the connector termi nal s that rel ate to the A,/T control
system. The other PCN4 termi nal vol tage and measuri ng condi ti ons are descri bed i n secti on 1L
I
( 25Pl Conncr ol
C
( 3l Pl Connect or
D { 16P) Connect or
L
A l 32P) Connect or
PCM CONNECTOR A {32P}
Termi nal Number Si gnal Description Measuring Condiiions/Terminal Voltage
41 t o A8
see sect i on 11
-
A9 LGl Gr ound
A' t 0 PGl Gr ound
411 I GPl Power suppl y system Wi th i gni ti on swi tch ON
(l l ):
Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
A.12 ro 421
-
see secti on 11
-
422 LG2 Gr ound
423 PG2 G rou nd
424 I GP2 Power suppl y system Wi th i gni ti on swi tch ON
(l l ):
Battery vol tage
Wi th i gni ti on swi tch OFF:0 V
A25 to A32
-
see secl i on 11
PCM CONNECTOR B {25PI
Termi nal Number Si gnal Description Measuring Conditions/Telminal Voltage
B1 LS- Li near sol enoi d power suppl y
negati ve el ectrode
l gni t i on swi t ch ON { l l } : Pul si ng si gnal
82 LS+ Li near sol enoi d power suppl y
posi ti ve el ectrode
l gni t i on swi t ch ON t l l ) : Pul si ng si gnar
SHA Shi f t cont rol sol enoi d val ve A
cont rol
In 2nd gear and 3rd gear i n i d, Ei posi ti on,
and i n
El , E
posi ti on: Battery vol tage
In l st gear and 4th gear i n D3l , Bl l posi ti on: O V
B4 LCB Lock-up control sol enoi d val ve B
control
When ful l l ock-up: Battery vol tage
When hal f l ock up: Pul si ng si gnal
B5 LCA Lock-up control sol enoi d val ve A
control
When l ock-up i s ON: Battery vol tage
Wi th no l ock up: 0 V
86 to 87 Not used
B8 ATP D3
Ay' T gear posi ti on
swi tch !c posi -
ti on si gnal i nput
In .[D;] posi ti on: 0 V
In other than
D3l posi ti on: Battery vortage
89 t o 810 Not used
14-42
PCM CONNECTOR B
(25P) (cont'd)
PCM CONNECTOR C {31P)
PCM CONNECTOR D
(16P)
Terminal Numbel Si gnal Description
Measuring Conditions/Terminal Voltage
8 1 1 SHB Shi ft control sol enoi d val ve B
control
In 1st gear and 2nd gear i n El , E posi ti on,
and i n
E
In 3rd
gear and 4th gear i n E, l p! posi ti on: 0 V
SLU l nterl ock control
When i gni ti on swi tch i s ON
(l l ).
brake
pedal
depressed and accel erator
pedal rel eased: 0 V
B13 D4I ND D4 Indi cator l i ght control When i gni ti on swi tch i s fi rst turned ON
(l l ):
Battery voltage for two seconds
In i Da posi ti on: Battery vol tage
8 1 4 NMSG Mai nshaft speed sensor ground Al ways: 0 V
NM Mai nshaft speed sensor si gnal
Input
Dependi ng on engi ne speed: Pul si ng si gnal
When engi ne i s stopped: 0 V
B16 ATP R A,/T
gear position switch @
posi ti on si gnal i nput
I nEpos i t i on: 0V
In other than
E
817 AJP 2 A/T gear posi ti on swi tch
P
posi -
I nEpos i t i on: 0V
In other than
E
818 t o 821 Not used
B22 NCSG Countershaft speed sensor ground Al ways: 0 V
B23 NC Countershaft speed sensor si gnal
I npur
Dependi ng on vehi cl e speed: Pul si ng si gnal
When vehi cl e i s stopped: 0 V
824 ATP D4 A/T gear position switch Pj posi-
In -Drl
posi ti on:0 V
In other than E! posi ti on: 5 V
B25 ATP NP A/' f gear posi ti on swi tch
E
and
N
posi ti on si gnal s i nput
In E
and
El
posi ti ons: 0 V
In other than E
and
N
positions: Battery voltage
Terminal Number Si gnsl Description
Measuring Conditions/Terminal
voltage
Cl to C6
-
see secti on 1 1
-
c7 Servi ce check si gnal
Wi th i gni ti on swi tch ON
(l l l
and servi ce check
connector open: 5 V
Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector connected wi th speci al tool : 0 V
C8 to C9
-
see secti on 11
-
c10 VBU Back-up power system Always battery voltage
Cl 1 to C31
-
see secti on I I
-
Termi nal Number Si gnal Description
Measuring Conditions/Terminal
Voltage
D1 to D4
-
see secti on 1 l
-
D5 STOP SW Brake swi tch si gnal i nput Brake pedal depressed: Battery vol tage
Brake oedal rel eased: 0 V
DO t o D16
-
see secti on 11
-
14-43
Troubleshooting
Procedures
Checki ng the Di agnosti c Troubl e Code
{DTC)
with an OBD ll Scan tool or Honds PGM Testel
When the PCM senses an abnormal i ty i n the i nput or output systems, the
ql
i ndi cator l i ght i n the gauge assembl y wi l l
bl i nk When the 16P Data Li nk Connector
(DLC)
i l ocated under the dash on the dri ver' s si de) i s connected to the oBD l l
Scan Tool or Honda PGM Tester as shown, the scan tool or tester wi l l i ndi cate the Di agnosti c Troubl e Code
(DTC)
when
t he i gni t i on swi t ch i s t ur ned ON I ) .
when the
E ]
i ndi cator l i ght has been reported on, connect the oBD l l scan Tool conformi ng to SAE J197g or Honda
pGM
Tester to the DLC
(l 6P).
Turn the i gni ti on swi tch ON {l l ), and observe the DTC on the screen of the OBD l l Scan Tool or
Honda PGM Tester' After determi ni ng the DTc, refer to the el ectri cal system Symptom-to-component chart on pages
14-48
and 14-49.
NOTE: See the OBD l l Scan Tool or Honda PGM Tester user,s manual for speci fi c i nstructi on.
L
OBD ll SCAN TOOL or
HONDA PGM TESTER
DATA LINK CONNECTOR
(16P}
14-44
Checking the Diagnostic Trouble Code
(DTC)
with the Service Check Connestor and Special Tool
When the
pCM
senses an abnormal i ty i n the i nput or output systems. the i tj
i ndi cator l i ght i n the gauge assembl y wi l l bl i nk
When the Servi ce Check Connector
(l ocated
under the dash on the
passenger si de) i s connected wi th the speci al tool as
shown, the l D1
i ndi cator l i ght wi l l bl i nk the Di agnosti c Troubl e Code
(DTC)
when the i gni ti on swi tch i s turned ON
(l l ).
When the @
i ndi cator l i ght has been reported on, connect the Servi ce Check Connector wi th the speci al tool .
Then turn ON
(l l )
the i gni ti on swi tch and observe the [o!
i ndi cator l i ght
CONNECTOR
SERVICE CHECK
CONNECTOR I2P}
07PAZ
- (x)'10t00
See DTC 15
codes 1 through 9 are i ndi cated by i ndi vi dual short bl i nks. codes 10 and above are i ndi cated by a seri es of l ong and short
bl i nks. one l ong bl i nk equal s 10 short bl i nks. Add the l ong and short bl i nks together to determi ne the code After deter-
mi ni ng the code, refer to the el ectri cal system Symptom-to Component Chart on pages 14-48 and 14-49'
See DTC 1
See DTC 2
Long bl i nk
(cont' d)
GAUGE ASSEMBLY
.-.=
-.-..--- .
.
.-
'i''
\.....-,-..-.""
r
'
.-
c ,
a :
Short blink {once}
Short blinks lfive times)
14-45
1 .
2.
{cont'd)
Remove the ki ck panel
on the passenger' s si de
(see
secti on 20).
Remove the PCM, and turn the PCM over.
Inspect the ci rcui t on the PCM accordi ng to the troubl eshooti ng l l owchart wi th the speci al tool s and a di gi tal mul ti me-
ter as shown.
How to Use the Backprobe Set
Connect the backprobe adapters to the stacki ng patch cords, and connect the cords to a mul ti meter. Usi ng the wi re
i nsul ati on as a gui de for the contoured ti p of the backprobe adapter, gentl y sl i de the ti p i nto the connector from the
wi re si de unti l i t comes i n contact wi th the termi nal end of the wi re.
EACKPROAE
L
BACKPROAE SET
07sAz
-
001000A
(two
requi red)
OIGITAL MULTIMETER
(Commrcially
available)
- aHM- 32- 003
14-46
or equi val ent
. PCM Raset Procadure
1. Turn the i gni ti on swi tch off.
2. Remove the BACK UP fuse
(7
5 A) from the under-hood fuse/rel ay box for 10 seconds to reset the PCM'
NOTE:
. Di sconnecti ng the BACK UP fuse al so cancel s the radi o
preset stati ons and cl ock setti ng. Make note of the radi o
presets before removi ng the tuse so you can reset them.
o The PCM memory can al so be cl eared by usi ng the OBD l l Scan Tool or Honda PGM Tester'
BACK UP
(7.5 A) FUSE
. Final Procedurg
NOTE: This procedure must be done after any troubleshooting
1. Turn the i gni ti on swi tch OFF.
2. Reset the PcM.
3. Di sconnect the OBD l l Scan Tool or Honda PGM Tester from the Data Li nk Connector, or remove the speci al tool from
the Servi ce Check Connector.
4. Turn the i gni ti on swi tch ON
(l l ),
and set the radi o presets and cl ock setti ng
14-47
Symptom-to-Component
Cha rt
Electrical System
(DTC)*:
The DTcs i n parentheses
are the number of the E i ndi cator l i ght bl i nks when the servi ce check connecror rs con-
nected wi th the speci al tool
(SCS
servi ce connectorl .
Di agnosti c
Troubl e Code
(DTC)*
El Indi cator
Li ght
Symptom
Possi bl e Cause
Refer to
Page
P1753
( 1)
Bl i nks
Lock-up cl utch does not engage.
Lock-up cl utch does not di sen
gage.
Di sconnected l ock-up control sol enoi d
val ve A connector
Short or open i n l ock-up control
sol enoi d val ve A wi re
Faul ty l ock-up control sol enoi d val ve A
l 4- 50
P1758
t 2l
Bl i nks
Lock-up cl utch does not engage. Di sconnected l ock-up control sol enoi d
val ve B connector
Short or open i n l ock-up control
sol enoi d val ve B wi re
Faul ty l ock-up control sol enoi d val ve B
14-52
P1705
(s)
Bl i nks
.
Fai l s to shi ft other than 2nd
-
4th
gears.
.
.
Short i n Ay' T gear posi ti on
swi tch wrre
.
Faul ty A4
9"", Oosi ti on
swi tch 14-54
P1706
( 6)
OFF
.
Fai l s to shi ft other than 2nd
-
3rd
-
4th gears.
.
Di sconnected A/T gear posi ti on
swi tch
connector
Open i n A"/T gear posi ti on
swi l ch wi re
Faul ty Ay' T gear posi ti on
swi tch
14- s6
P0753
t7I
Bl i nks
.
Fai l s to shi ft
(between
1st
-
4th,
or 2nd
-
3r d gear onl y) .
.
Fai l s to shi ft
(stuck
i n 4th gear).
Di sconnected shi ft control sol enoi d
val ve A connector
Short or open i n shi ft control sol enoi d
Faul ty shi ft control sol enoi d val ve A
r4-58
P0758
( 8)
Bl i nks
Fai l s to shi ft
(stuck
i n 1st or 4th
gears).
Di sconnected shi ft control sol enoi d
val ve B connector
Shon or open i n shi ft control sol enoi d
val ve B wi re
Faul ty shi ft control sol enoi d val ve B
' 14-60
PO1 20
( 9)
Bl i nks
.
Lock-up cl utch does not engage. Di sconnected countershaft speed sen-
sor connector
Shon or open i n countershaft speed
sensor wrre
Faul ty countershaft speed sensor
14-62
14-48
\
Di agnosti c
Troubi e Code
(Drc).
E Indi cator
Li ght
Sym
ptom Possi bl e Cause
Refer to
Page
P07r 5
(
15)
' 96, ' 97
model s
OFF
' 98
model
Bl i n ks
.
Lock-up cl utch does not engage. Di sconnected mai nshaft speed sensor
connector
Short or open i n mai nshaft speed sen-
sor wtre
Faul ty mai nshaft speed sensor
14-64
P 1768
( 16)
Bl i nks
.
Transmi ssi on
j erks
hard when
shi fti ng. stuck i n 4th gear.
.
Di sconnected l i near sol enoi d connector
Short or open i n l i near sol enoi d wi re
Faul tv l i near sol enoi d
Di sconnected or l oosed PG termi nal
14-66
P0740
(40)
.
.
Faul ty l ock-up control system
14-68
P0730
( 4 1 )
OFF
Fails to shift
(between
1st
-
2nd,
1st
-
4th. 2nd
-
4th, znd
-
3rd, 3rd
-
4th, 1st- 2nd
-
3rd, 1st
-3rd -
4th or 2nd
-
3rd
-
4th gears only).
Fai l s to shi ft
(stuck
i n 1st or 2nd
gears).
.
Faul tv shi ft control system
14-69
P0700
( none)
Any automati c transmi ssi on
probl em,
To eliminate DTC P0700, troubleshoot the other automatic transmission
prob-
lem(s) according to the DTC(S) indicated.
(DTC)*:
The DTCS i n
parentheses are the number of the E i ndi cator l i ght bl i nks when the servi ce check connector i s con-
nected wi th the sDeci al tool
(SCS
servi ce connector).
NOTE: When the OBO l l Scan Tool or Honda PGM Tester i ndi cate the DTC(S) for the automati c transmi ssi on control sys-
tem, the scan tool or tester al so i ndi cates code P0700 si mul taneousl y. Code P0700 means detecti on of some automati c
transmi ssi on orobl em on the PGM Fl control system.
l f the sel f-di agnosti c Ei !]
i ndi cator l i ght does not bl i nk, perform an i nspecti on accordi ng to the tabl e bel ow.
NOTE: l f a customer descri bes the symptom for code P1706
(6),
i t wi l l be necessary to recreate the symptom by test-dri v-
i ng, then recheck the DTC.
Symptom
Inspecti on Ref. page
E
i ndi cator l i ght does not come on tor two seconds after i gni ti on
swi tch i s fi rst turned ON
(l l ).
14-70
E
i ndi cator l i ght i s on constantl y
(not
bl i nki ng) whenever the i gni ti on
swi tch i s ON
(l l ).
't
4-12
Shi ft l ever cannot be moved from
E
posi ti on wi th the brake pedal
oeoresseo,
Inspecti on 14-13
14-49
E lectrical Troubleshootin g
Troubleshooting
Flowchart
-
Lock-up Gontrol Solenoid Valve A
Possible Csuso
.
Di sconnect ed l ock-up cont . ol
solenoid valve A connector
.
Short or opon in lock-up control
3olenoid valve A wire
.
Faulty lock-up control solenoid
valvo A
PCM CONNECTORS
WIRE SIDE OF FEMAI.f TERMINALS
14- 50
L
.
OBD ll Scan Tool indicates Code
P1753.
.
Sel l -di agnosi 3
i -t l i ndi cat ol
light blinks once.
Check for e Short to Power:
2. Di sconnect t he A {32P) and B
( 25P)
connect or s f r om t he
PCM.
(ll).
t he 85 and A9 or A22 t ermi -
nal s.
Ropair short to power
in the wirc
betweon the 85 terminal and the
lock-up control solenoid valve A.
Measur Lock-up Cont rol Sol e-
noid Valve A R*istanc:
2, Measur e t he r esi st ance
between the 85 and Ag or A22
t ermi nal s.
Check tor loose P1CM connectoJs.
It necossary, substituto a known-
good solenoid v.lvo assombly or
PCM and r6chock.
l s t he resi st ance 12
-
25 0?
To page
14-51
\
From page 14-50
A
(32P)
Check Lock-up Control Solenoid
Valve A for a Shon Circuh:
f rom t he l ock-up cont rol sol e-
noi d val ve assembl y.
t he 85 and Ag or A22 t ermi -
nal s,
Repair 3hort to ground in the wire
between the 85 t6rminal and the
lock-uD conttol solenoid vahre A.
M6asu. e Lock-uo Cont rol Sol o-
noid Valve A Rosistance at lho
Solenoid Connector:
Measure the resistance between
t he No. 2 t ermi nal of t he l ock-up
cont rol sol enoi d connect or and
body ground.
Check f or open i n t he wi r e
btwen the 85 terminel .nd the
lock-up control solenoid valve A.
-
25 0?
Replece the lock-up control sole-
noid valve assembly.
PCM CONNECTORS
WIRE SIDE OF FEMALE TERMINALS
LOCK.UP CONTROL
SOLENOID CONNECTOR
. - F
ItrTt
*T
(o)
I
TERMINAL SIDE OF
MALE TERMINALS
YEL
14-51
Electrical Troubleshooti n
g
-
Lock-up Gontrol Solenoid Valve B
Po..iblo C!u&
.
Diaconnacted lock"up control
rolanold valv. B connector
.
Short oi opon In lock-up com.ol
rolgnoid v.lva B wiro
.
F ulty lock-up contol rolanoid
valva B
WIRE SIOE OF FEMALE TENMNALS
FCM CONNECTORS
OBD ll Scan Tool indicli.. Code
P1758.
Selt-disgnolb
E
indicltor light
blinks twice.
Chock for a Short to Power:
1. Turn thg ignition switch OFF.
2. Di sconnact t he A
(32P)
and A
( 25P)
PCM.
(ll).
4. Measure the voltagg btween
nals,
Rapair rhort to powar in tha wirc
brftv.en th. Ba tormin.l rnd th.
lock-up control aolanoid valva B.
Me!!u.e Lock-up Conlrol Sole-
noid Valvo B Rcrictlncc:
2. Measur e t he r esi st ance
bet ween t he B4 and Ag or
A22 t ermi nal s.
Ch.ck tor loo.. PrCi, conn.c'lor3,
It n6ca3t!ry. subttihrta r known-
good rolanoid valvo a$ombly or
PCM lnd rcch.ck.
-
25 O?
A t32P)
To page 14. 53
14-52
From
page 14-52
Chack Lock-up Control Solenoid
Vslve B to. a Short Citcuit:
trom the lock-up control sole-
noid valve assembly.
nal s,
Rapair 3hort to
ground in th wir
betwaen the 84 torminal and th
lock-up control solenoid valvo B.
Mea3ura lock-up Control Sole-
noid Vrlvc B Ro3irtrnc. at the
Solonoid Connoc{or:
t he No. 1 t ermi nal of t he l ock-up
cont rol sol enoi d connect or and
body
ground.
Chock f or opon i n t he wi r
botwon th. 84 torminal and the
lock-up control aolonoid valva B.
-
25 0?
R.phc. tha lock-up cont.ol solo-
noid valvc $!.mbly.
PCM CONNECTORS
LOCK-UP CONTROL
SOLENOID CONNECTOR
IFT']
t-
cnNreLxI
( o)
T
I
TERMINAL SIDE OF
MALE TERMINALS
14- 53
Troubfeshooting Flowchart- AIT Gear Position Switch
(shortl
Possible Cause
.
Shorl in A/T
96ar
position
switch
.
Faulty A/T geal po3ition switch
NOTE: Code Pl 705
(5)
i s caused when
t he PCM r ecei ves t wo gear posi t i on
, nput s at t he same t i me-
PCM CONNECTORS
.
P1?05.
.
SelI-disgno3is
E indicrror light
blinks tive tim6.
Observe t h6 A/ T Gear Po3i t i on
Indicator:
2. Observe the A,/T gear position
i ndi cat or , and shi l t t o each
post t l on.
Do any i ndi cat ors st ay on
when t he shi f t l ever i s not i n
t hose posi t i ons?
The system is OK at this time.
Check the wile harness fo. dam-
age.
Measure ATP R Voltage:
1. Shi t t t o al l posi t i ons
ot her t han
E.
2. Measure t he vol t age bet ween
nal s,
Check f or shor t i n t he wi r e
between the Bl6termineland the
A/T gear position
swilch or A/T
gear position indicator. lf wire is
OK, check lor loose PCM connec-
t ors. I t noceasary, subst i t ut e a
known-good PCM and recheck.
Measure ATP NP Voltage:
1. Shi f t t o al l posi t i ons
ot her t han
No r @.
the 825 and Ag ot A22 te(mi
nal s,
Check t or shor t i n t he wi r e
btween tho 825 terminal and the
A/T goar position
indicator, o. a
shon in the wiaes beiween the
A/T gear position indicator and
the A/T gear posilion
switch. It
wi res are OK, check f or l oose
PCM connecl ors. l f necssarv,
subst i t ut e a known-good PCM
end rechock,
l s t here bat t ery vol t age?
Measure ATP 04 Voliage:
ot her t han
O. .
nal s.
Check f or sho. t i n t he wi r o
between the B24terminal and the
A/T ge.r position
switch. lf wire
is OK, check lor loose PCM Gon-
nectoE. ff necessary, substituto a
To page
14-55
14-54
M.tsuro ATP D3 Vohage:
'1.
Shift to all positions other than
E.
nat s.
Ch6ck f or shor t i n t ho wi r e
batwen tho 88 terminel and the
A/T gear position switch ot A/T
gea. position indicator. It wire i3
OX, check for loos6 PCM connec-
lors. lf neces3ary, substitute a
known-good PCM and techeck.
Morsure ATP2 vohage:
1. Shi f t t o al l posi t i ons ot her t han
tr.
2. lvleasuro the voltage between
the 817 and A9 or 422 termi
nat s.
Check f or sho. t i n t he wi re
btwen the 817 terminal .nd thc
A/T goar position switch or A/T
gear position indicalo.. tf wire is
OK. check for loos6 PICM connec-
t ors. l f necessary, subst i t ut e a
known-good PCM .nd racheck.
Chock for loo3o PCM connGctors,
lf nccossrry, 3ubsthuto a known-
good PCM tnd r6chock.
From page 14-54
PCM CONNECTORS
BRN/ALK
BRN/BLK
WIBE SIDE OF FEMALE TERMINALS
14-55
-
A/T Gear Position Switch
(Openl
PGsibl. Causo
.
Fauhy A/T go.r position switch
.
Di sconnect od A/ T goal po3i i l on
3witch connector
.
Open in A/l gear position
awitch
.
OBD ll Scan Tool indicat$ Code
P1706.
.
Self-di.gnosis
q
indicator light
blinks six iim*.
Me8ure ATP R Voltage:
(l l ).
2. Shi f t t o E
posi t i on.
3, Measure t he vol t age bet ween
nal s,
Bepair open in the wile bstwaton
the 816 torminal and tha A/T goar
po3hion
switch.
1. Shi f t t o
N orE posi t i on.
t he 825 and Ag or A22 t ermi
nal s,
Ropail open in the wiae betweon
the B25 torminal and the A/T g.at
position indicstor oi the A/T gear
Dosition switch.
Measure ATP D4 Voltage:
1. Shi f t t o
E
posi t i on.
Repair open in the wire be4wcen
the 824 terminal and tho A/T gcrt
oosition swhch.
PCM CONNECTORS
BRN/BLK
BRN/BLK
BRN/BLK
BRN/BLK
8RN/BLK
To page 14-57
14- 56
From pag 14-56
Mqllurt ATP D3 Volt gt:
1. Shift to
@
position.
2. Measure the voltagg betwen
the 88 and A9 or A22 termi-
nat s.
Rapair opan In th6 wira b3twocn
tha 88 t.rminll snd tha A,lT go!1
Dolition .witcb.
Ma.$ra ATPz Voltaga:
1. Shift to
E
position.
2. Measurs th voltage betwesn
th Bl7 8nd Ag or A22 tsrmi-
nals.
Rop.ir opln in tha wir. b.twocn
t h. Bl 7 t l rmi nrl . nd t ho A/ T
gatr polhion switch.
Chack tor looaa PCM connactoB.
It nacoaaary, tubtihuta ! known-
good FCM .nd r.ch.ck.
PCM CONNECTORS
14-57
Electrical Troubleshootin g
-
Shift Control Solenoid Valve A
Possible Ceuse
.
Disconngcled shift cont.ol solenoid
valve A connoctot
.
Short or open in shift control sole-
noid valve A wire
.
Faulty shift control 3olenoid valve A
PCM CONNECTORS
.
OBD ll Scan Tool indicatos Code
m753.
.
Sof-di.gno.is
D; indicrtor llght
blinks 36v6n times.
Ch.rck fo. a Short to Powel:
2. Di sconnect rhe A {32P) and B
( 25P)
PCM.
(l l ).
4. Measl re t he vol t age bet ween
the 83 and Ag orA22 terminals.
Ropair short to power
in the wire
between the 83 t6.minal and tho
shift control3olenoid valve A.
Mssure Shift Control Solenoid
Vrlve A Rosidance:
between the 83 and Ag or A22
I ermrnat s.
Chock tor loose PCM connoctors.
It nace33ary, substitut a known-
good solenoid valve assembly or
PCM and .echeck.
-
25 O?
BLU/ YEL
BRN/BLK
To page
14-59
14-58
-
From page' 14-58
A {32P)
Chock Shi l t Cont rol Sol . noi d
Velv. A lor a Short Circuit:
l . Di sconnect t he 2P connect or
from the shift control solenoid
valve assemblv.
2. Chgck for continuity between
the 83 and Ag or A22 terminals.
Ropair lhort to ground in the wire
betweon the lIt torminal and lho
rhift control solenoid v6lvo A.
Me.sure Shift Control Solonoid
Valv. A R6btanco .t the Solonoid
Connoctor:
the No. 1 terminal oI the shitt con-
trol solenoid connector and body
ground.
Chack l or opon i n l he wi r e
betwoen the 83 termin.l and tho
rhift control solenoid valv6 A.
-
25 O?
PCM CONNECTORS
SHIFT CONTROL SOLENOID
CONNECTOR
BLU/YEL
TERMINAL SIDE OF MALE TERMINALS
14- 59
Electrical Troubleshootin
g
-
Shift Control Solenoid Valve B
Possibl6 Cause
.
Faulw shift control solenoid valve B
.
Disconnoctod shift contlol solenoid
velve B connector
.
Short or ooen in shift control sole-
noid valve B wire
PCM CONNECTORS
.
P0758.
.
Selt-diagnosis
Ei indicator ligln
blinks oight time6.
Chock fo. a Short to Power:
l . Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he A {32P} and B
(25P)connectors
from the PCM.
(l l i .
t he 8' 11 and Ag or A22 t ermi
nal s.
Repair short to power in th6 wire
bet ween t he 811 t ermi n. l and
the shift conlrol solenoid velve B.
Measure Shift Control Solenoid
Valve B Resistance:
bet ween t he 811 and Ag or
A22 t ermi nal s.
Ch6ck for looso PCM connectors.
lf nocessary, 3ubitituta a known-
good
sol6noid valvo a$ombly ol
PCM and rechock.
l s t he resi st ance 12 25 0?
l32Pl
Chck Shi f t Cont r ol Sol enoi d
Valve B tor a Short Circuit:
lrom the shift control solenoid
val ve assembl y.
nars,
Repair short to ground in the wira
between the 811 ierminal and the
shitt control solenoid valve B.
Measure Shift Control Solenoid
Velve B Resistance at the Solo-
noid Connec'tor:
t he No. 2 t ermi nal of t he shi f t con-
t rol sol enoi d connect or and body
oround,
Chec k f or open i n t he wi r e
between the Bll terminal and the
shift control solenoid valve 8.
l s t he r esi st ance l 2
-
25 0?
From page 14 60
BRN/ BLK
BRN/ BLK
PCM CONNECTORS
SHIFT CONTROL SOLENOID
CONNECTOR
li; tt
I GRN,/WHT
( o)
Y
I
I
WI RE SI DE OF FEMALE TERMI NALS
14-61
E lectrical Troubleshooting
-
Countershaft Speed Sensor
I
.
OBD ll Scrn Tool indicats Code
PO720.
.
Sol t -di agnosi s
Dj
i ndi cat or
light blinks ninc times,
Po$ible C.u3o
.
t "a* ". t *rl t y "". """t 1*
botwoen the PCM .nd c.r har-
noss
.
Di sconnect od count ar shaf t
soeod son3or connector
.
Short or open in countorsh.ft
sp6ed sensor wirc
.
F ulty count.shrft speod 3en-
COUNTERSHAFT SPEED SENSOR
CONNECTOR
t'-tt
TT
9 l
t l
L I
TERMINAL SIDE OF MALE TESMINALS
PCM CONNECTOR B {25P)
14-62
ls the countershaft speed sensor
i nst al l ed properl y?
Measure Countorsh.ft Soeed Sen-
sor R6istanc al ths Senror Con-
nectot:
f rom t he count ershaf t sDeed
sensof connector,
2, Measure t he resi st ance oI t he
countershaft sDeed sensor,
ls the resistance 400
-
600 0?
Chack Coume6hatt Spod Sensor
for a Short Circuit:
1. Di sconnect t he B
( 25P)
con
nect or f rom t he PCM.
2. Check l or cont i noi t y bet ween
t he body ground
and t he 823
t e r m i n a I a n d 8 2 2 t e r mi n a l
i ndi vi dual l y.
Repair short in the wires belwen
t he 823 and 822 t ormi nal s and
the countershaft soeed sensor.
To page 14-63
From page 14-62
Maasure CruntoFhaft Speod Son-
sor Rosbtrnce:
1. Connect t he count er shaf t
speed sensor 2P connect or.
2. Measu r e t he r esi st ance
between the 823 and B22 le''
mi nal s,
Ropair loose terminal or open in
tho wiies bstw66n tho B23 and
822 termin.ls and tha countor-
shaft speod sensor.
-
600 O?
Check tor loos6 PICM connectors.
lf necass{ry, substihJtg a known-
good PCM rnd roch.ck.
PCM CONNECTOR B {25PI
SIOE OF FEMALE TERMINALS
14- 63
-
Mainshaft Speed Sensor
Posible Ceuse
'
DI*.""."1"d -"l".h"ft .*.d
3en30t connctot
.
Shor t or op6n i n mai n3hat t
speed sensor wire
.
Faulty mainshaft speod sensol
NOT E : Co d e P 0 7 1 5 ( 1 5 ) o n t h e P CM
doesn' t al ways mean t her e' s an el ect r i cal
pr obl em i n l he mai nshaf l or count er shaf t
speed sensor ci r cui t : code P0715115) mat
al so i ndi cat e a mechani cal pr obl em i n t he
t r ansmt sst on.
MAINSHAFT SPEED
SENSOR CONNECTOR
TERMINAL SID OF MALE TERMINALS
PCM CONNECTOB 8 I25P}
.
P0715.
.
Sel t - di agnosi s
E
i ndi cat ol
light indic.t6 Cod 15.
Check t he mai nshaf t and count er'
shaf t speed sensor i nst al l at i on.
Are the mainshaft and countershaft
speed sensor installed properly?
Measure Mainshrft Speed Sensor
Resi st ance at t he Sensor Con-
nector:
f rom t he mai nshaf t speed sen'
sor connect or.
2. Measure t he resi st ance of t he
maj nshaf t speed sensor.
-
600 {}?
Check Mai nahaf t Speed Sensot
for a Short Circuit:
(25Pi connec-
tor from the PCM.
body ground and 815 t ermi nal
and t he 814 t ermi nal i ndi vi dn-
ReDair short in the wires between
t he 815 and Bl i l t ermi nal s and
lhe meinshrft soeed sensor.
To page 14' 65
14-64
From page 14-64
Measure Mrinshaft Speed Sensor
Resistance:
1. Connect t he mai nshaf t speed
sensor 2P connect or,
2. M easu r e t he r esi st ance
bet ween t he 8' 15 and 814 t er-
m t nal s.
Run iho Elect ical Troubleshooling
Flowchart for code m720 l9l.
Check tor loose PCM connectors.
It ncossary, substitute a known-
good PCM and recheck.
-
600 o?
Check NM Wire Continuity:
f rom t he mai nshaf t speed sen-
sor connect or.
t he 815 t ermi nal and t he No. 1
t er mi nal of t he mai nshaf t
speed sensor connector,
t he 815 t ermi nal and t he mai n'
shaft speed sensor.
Check NMSG Wire Continuity:
Check f or cont i nui t y bet ween t he
814 t ermi nal and t he No. 2 t ermi -
nal of the mainshaft speed sensor
Bepair op6n in th wire between
t h 814 t ermi nal and t he mai n-
3haft sDeed snsor.
Check lor loos PCM connectors.
It nocessarv, substitute a known-
good PCM and recheck.
PCM CONNECTOR 8
(25PI
MAINSHAFT SPEED SENSOR
CONNECTOR
14- 65
-
Linear Solenoid
\
Po$ible C.Ge
.
Oi sconnect ed l i nar sol onoi d
.
Short or op6n in linear solonoid
.
F.uhy linorr 3olonoid
SOLENOID CONNECIOR
trTt
-r-r
r d l
Y I
t l
t_i
LINEAR
PCM CONNECTOR B
(25P)
RED
WHT
.
OBD ll Scan Tool indicat6 Codo
P176a.
.
Sel f -di agnosi s
[ d
i ndi c. t ol
light indicates Code 16.
Msasure Linoar Solanoid Rosi3t-
anco at tho Solonoid Connector:
f rom t he l i near sol enoi d con-
nector,
3. Measure t ho resi st ance of t he
l i near sol enoi d.
l s t he resi st ance aoorox. 5. 0 0?
Ch6ck Linor. Sol.noid for a Short
Circuit:
l Disconnect the B
(25P)
connec,
tor from the PCM.
2. Check tor continuity between
t he body ground and t he 81
t ermi nal and 82 t ermi nal i ndi -
vi dual l y.
Repair sho.t in the wire3 bgtwoon
tho 81 and 82 termin.ls rnd th6
lineal solonoid.
Me.iuie Linoar Solenoid Rcai3t-
ance:
1. Connect t he l i n6ar sol enoi d
connector.
2. Masur e t he r esi st a nce
bet ween t he 81 and 82 t ermi -
nal s,
Ropair loo3o terminsl or open in
tho wirgs bgtween the B1 and 82
torminrl! rnd the linoar sol6noid.
l s t he resi st ance approx. 5. 0 O?
To page 14-67
14- 66
From page 14 66
Ch6ck tho Ground Cilcuit:
Ag and A10 t ermi nal s.
.
Rgpai r open i n t he wi r e
between tho torminal3 A9 .nd
A10. nd G101.
.
R6pair loo3o
junction
connector.
.
Ropair
poor ground (G1011.
Chgck loi loo3a PCM connecto.s.
lf necellrry, 3ubstituto a known-
good PCM and rochock.
PCM CONNECTOR A I32P}
14-67
OBD ll Sc{n Tool indicatss Code
m740.
Self'diagnosis ErJ indicdor light
indicatB Code
/U).
Chock for Another Code:
Check whet her t he OBD l l scan
t o o l o r t h e E i n d i c a t o r l i g h t
i ndi cat es anot her code.
Perf orm t ho Troubl a3hoot i ng
Fl owch. rt t or t ho i ndi c. t . d
Codols). Rocheck tol codo P0740
l40l aft er troublG.hooting.
Does t he OBD l l scan t ool or
t he E! i ndi cat or l ; ght i ndi cat e
anot her code?
Test Lin Piessure:
Measur e t he l i ne pr essur e
{ see
page 14-87 and 14-88).
l s t he l i ne pressure
wi t hi n t he
servi ce l i mi t ?
Repai. tho hydrrulic sy3tom a.
necdsrry l3os
pago'14-E61.
Repl ace t he Lock- up Cont r ol
Sol enoi d Val ve Assembl y end
Recheck:
1. Repl ace t he l ock- up cont r ol
sol enoi d val ve A/ B assembl y
(see page 14-74).
and reset the PCM by remov
i ng t he BACK UP {7. 5 A) t use
i n t he under-hood f use/ rel ay
box tor more than
'10
seconds.
3. Usi ng t he scan t ool , check t o
be sure t hat t he engi ne cool -
ant t emper at ur e i s i n 176" F
{80'C) and above.
4. Dri ve t he vehi cl e at 55 mph
(88
km/ h) const ant l y f or more
t han one manut e.
5- Recheck f or code P0740
(40).
Doest he OBD l l scan t ool
i ndi cat e code P0740
(401?
The syltom ii OK at thb timo.
-
Lock-up Control System
Poitible Cru..
Faulty Lock.up control ryitcm
NOTE: Do not cont i nue wi t h t hi s t roubl eshoot i no
other DTCS have been corrected.
\
unt i l t h causes of any
\
\
14- 68
-
Shift Gontrol System
Porsible Causo
F.ulty shitt contol systom
'
OBD ll Scan Tool indic.t6 cod.
m730.
'
s. l f -di . gno. i . E i ndi cat or
lig]|t Indicat . Code 41 .
Chack lor Anoth.r Codo:
Check whet her t he OBD l l scan
t ool or t he E i ndi cat or l i ght
indicate another cod6.
Parf orm t he Troubl . shoot i ng
Fl owchrrt t or t h6 i ndi cat od
Codo(s). Rochock for cod! m730
{41 | rft ol troubl.ihooting.
Doe3 the OBD ll scan tool or
t he E i ndi caro. l i ght i ndi -
cste another code?
Tcat 13t, znd, 3rd and 4th Clutch
Prctauro:
Measure the lst, 2nd, 3rd and 4th
cl ut ch pressure
{see
page 14-87
t hru' 14-891.
Rcpair tha hvdraulic aystom ra
nacaa3ary laaa
p.g. 14-88 lnd
1a-891.
ls each clutch pressure within
the service limit?
Repl.c. Shift Control Sol.noid
V.lYe A*rembly, Linorr Solonoid
A$.mbly .nd B.check:
1. Repl ace t he shi f t cont r ol
sol enoi d val ve A/ B ass6mbl v
(see page 14-?5).
2. Reol ace t he l i noar sol enoi d
assembly
(see page 14-771.
3. Turn t he i gni ri on swi t ch OFF
and rsset th PCM memory by
romoving the BACK UP
(7.5
A)
f use i n t he under-hood {use/
r el ay bor I or mor e t han 10
seconos.
4. Dri ve t he vehi cl e at ovgr 12
mph
(20
km/h) in lst, 2nd. 3rd
and 4th geal,lor more than 30
seconds at [8d oosition.
5, Recheck for code PO73O
(41).
Do6s the OBD ll scan tool or
t he E i ndi cat or l i ght i ndi -
cate code P0730
(41)?
Tho sydem b OK rt this time.
NOTE: Do not cont i nu wi t h t hi s t roubl eshoot i ng unt i l t he causes of any
other DTCg have been corrected.
14- 69
-
D.- lndicator Light Does Not Gome On
PCM CONNECTOR A
(32P)
Th6
E
indicator light doos not
come on when the ignition switch
is lirst turned ON lll). {lt should
come on Ior about two 36conds.)
Check the Service Check Connec-
tor:
Make sure t he speci al t ool
(SCS
Setuice Connector) is not connect-
ed to the service check connector.
l s t he speci al t ool
(SCS
Servi ce
Connect or) connect ed t o t he ser-
vice check connector?
Disconnect the soecial tool from
the se.vice chock connoctor and
rachock.
Check th
E
indicator Light:
Shi f t t o
E
posi t i on.
Check to. loose PCM connectors.
lf necasary, substitute a known.
good PCM end iecheck.
Check lhe Ground Circuit:
2. Disconnect the A
(32P)
connec'
t or f rom t he PCM.
t h e Ag t e r mi n a l a n d b o d y
ground and t he A22 t ermi nal
and body ground.
Repair opon in the wires botwoen
tho A9 or A22 terminals and G101.
Repai r poor ground (Gl 01).
To page 14 71
14-70
From
page 14-70
Moasure Powo. Suppl y Ci rcui t
Voltage:
(l l ).
2. Measure th voltage between
t e r mi n a l s Ag a n d A1 1 a n d
bet ween t er mi nal s A22 and
424.
R.p.ir open or short in the wire
botwoen the A11 tnd lor A2l ter-
mi nal s, t he PGM-FI mai n . el ay,
aod the fu3e box.
Moasuro D4 IND Voh.ge:
2. Connect the A
(32P)
connector
t o t he PCM.
3. Connect a di gi t al mul t i t est er
t o t he 813 and A9 or A22 t er-
mt nal s,
(l l )
and make sure that the vokage
is available for t\ivo seconds.
Check t or open i n t he wi r e
bet ween t he 813 l ermi nt l and
t he
gauge as3embl y. l f wi ro i s
OK, chock for a taulty
E
indic.-
t or l i ght bul b or s f aul t y
gsuge
r33embly
printod circuit board.
Check for loo3o PCM connedots.
Check t he A/ T ge. . posi t i on
switch. ll nec6$ary, substitute a
BRN/ 8LK
'96:
BLU/RED
'97, '98:
GRN/BLK
PCM CONNECTOR A I32P}
14-71
-
E
Indicator Light On Constantly
PCM CONNECTOR B I25PI
The
E
indic.tor light b on con-
3l ent l y {not bl i nki ng} whenever
the ignition switch b ON {lll.
Me.sure Dil IND Voltage:
2. Disconnect the B
(25P)
connec-
t or f rom t he PCM.
(l l ).
t h e 8 1 3 t e r mi n a l a n d b o d y
gr ound.
Repair short to power in the wire
bet weon t he 813 t ermi nal and
the gauge a$embly.
Measura ATP D{ Voltage;
2. Connect t he B
(25Pi connect or
t o t he PCM.
4. Shi f t t o any posi t i on
ot her t han
D;.
t he 824 t er mi nal and body
gr ound.
Check for a short to ground on the
wire. ff wire is OK. ropl.c the A/T
gear position
indicator.
14-72
Troubleshooting
Flowchart
-
Brake Switch Signal
Symptom
Shift lav6r crnnot be movod liom
E
porition whh the bt.ko
Pedal
PCM CONNECTORS
WINE S|DE OF FEMALE TERMINALS
Ch.ck Brr*. Light Op.r.tion:
Oeoress the brake
pedal.
Rapair taulty brake switch circuit
l3oo rction 231.
Are the brak lights ON?
M.arur. STOP Sw voh.gc:
2. Disconnoct th A
(32P)
and D
{ 16P) connect or s f r om t he
PCM.
3. Measure the voltage betwen
t he D5 and Ag or A22 t ermi -
nal s wi t h t he br ake
pecl al
depressd.
Rop.ir opan in thc wiro btwcen
t h. D5 t ermi nal l nd t ha brako
swit*,
ls there battory voltsge?
.
8..1. rwitch rign.l i. OK.
.
Chad( to? looaa PCM connactoB.
It nacarlary, aubatituta a known.
goodFC .nd t!d|!ck.
.
Inrp.ct th. brtlr .witch citcuit
{t . ..ction 23}.
14-73
Lock-up Gontrol Solenoid Valve A/B Assembly
Test
1. Di sconnect the 2P connector from the l ock-up con
trol sol enoi d val ve Ay' B assembl y.
TERMINAL SIDE OF
MALE TERMINALS
LOCK.UP CONTROL
SOLENOID VALVE A/B
ASSEMBLY
Measure the resi stance between the No. 2 termi nal
( sol enoi d
val ve A) of t he l ock- up cont r ol sol enoi d
val ve connector and body ground,
and between the
No. 1 termi nal {sol enoi d val ve B} and body ground.
STANDARD: 12
-
25 O
Repl ace t he l ock- up cont r ol sol enoi d val ve assem-
bl y i f the resi stance i s out of speci fi cati on.
l f the resi stance i s wi thi n the standard, connect the
No. 1 termi nal of the l ock-up control sol enoi d val ve
connector to the baftery posi ti ve termi nal . A cl i ckj ng
sound shoul d be heard. Connect the No. 2 termi nal to
the battery posi ti ve termi nal . A cl i cki ng sound shoul d
be heard. Repl ace the l ock up control sol enoi d val ve
assembl y i f no cl i cki ng sound i s heard.
Replacement
NOTE: Lock-up control sol enoi d val ves A and B must be
removed/repl aced as an assembl y.
1. Remove t he mount i ng bol t s and l ock- up cont r ol
sol enoi d val ve A,/B assembl y.
6 x 1 . 0 mm
12 N. m {1 . 2 kgt . m, 8. 7 l bl . l t l
FI LTER/ GASKET
Repl ace.
Cl ean t he mount i ng
surf ace
and f l u i d passages.
2. Cl ean the mounti ng surface and fl ui d passages of
t he l ock up cont r ol sol enoi d val ve assembl y, and
i nstal l a new l ock-up control sol enoi d val ve A,/B wi th
a new fi l ter/gasket.
Check the connector for rust, di rt or oi l , and recon-
nect rt securel y.
Shift Control Solenoid
Valve A/B Assembly
Test
1. Di sconnect the 2P connector from the shi ft control
sol enoi d val ve A' l B assembl y.
SHIFT CONTROL
SOLENOID
VALVE A/8
ASSEMBLY
Measure the resi stance between the No.
' 1
termi nal
(sol enoi d
val ve A) of the shi ft control sol enoi d val ve
connector and body
ground, and between the No. 2
termi nal
(sol enoi d val ve B) and body
ground
STANDARD: 12
-
25 O
Repl ace the shi ft control sol enoi d val ve assembl y i f
the resi stance i s out of speci fi cati on.
l f the resi stance i s wi thi n the standard, connect the
No. 1 t er mi nal of t he shi f t cont r ol sol enoi d val ve
connector to the battery
posi ti ve termi nal . A cl i cki ng
sound shoul d be heard. Connect the No. 2 termi nal
t o t he bat t er y
posi t i ve t er mi nal . A cl i cki ng sound
shoul d be heard. Repl ace the shi ft control sol enoi d
val ve assembl y i f no cl i cki ng sound i s heard.
2,
Replacement
NOTE: Shi ft control sol enoi d val ves A and B must be
removed/repl aced as an assembl y.
1. Remove the mounti ng bol ts and shi ft control sol enoi d
valve 4!/B assembly.
6 x 1 . 0 mm
12 N. m
{1.2 ksl.m,8.7 lbt'ft}
CONNECTOR BRACKET
FILTER/GASKET
Repl ace.
Cl ean t he mount i ng surf ace
and f l u i d passages.
2. Cl ean the mounti ng surface and fl ui d passages of
t he shi f t cont r ol sol enoi d val ve assembl y, and
i nstal l a new shi ft control sol enoi d val ve A,/B wi th a
new fi l ter/gasket and the cl amp bracket.
3. Check the connector for rust, di rt or oi l , and recon-
nect i t securel y.
14-75
Li near Sol enoi d Assembl y
Test
1. Di sconnect the l i near sol enoi d connector.
Measure the resi stance between the No. 1 and the
No. 2 t er mi nal s of t he l i near sol enoi d connect or .
STANDARD: approx. 5 O
l f the resi stance i s out of speci fi cati on, repl ace the
l i near sol enoi d assembl y.
Connect the No. 2 termi nal of the l i near sol enoi d con-
nector to the battery posi ti ve termi nal and connect
the No. 1 termi nal to the battery negati ve termi nal . A
cl i cki ng sound shoul d be heard.
2.
LI NEAR SOLENOI D
14-76
I
6.
7.
8.
l f not, remove the l i near sol enoi d assembl y.
Check that the l i near sol enoi d fl ui d passage for dust
or
qr n.
Connect t he No. 2 t er mi nal of t he l i near sol enoi d
connector to the battery posi ti ve termi nal and con
nect the No. 1 termi nal to the battery negati ve termi ,
nal . Check that the val ve moves.
Di sconnect one of the battery termi nal s and check
that the val ve rel eases.
NOTE: You can see the val ve movement through
the fl ui d passage i n the mounti ng surface of the l i n-
ear sol enoi d assembl y.
LINEAR SOLENOID
\
VALVE
9. l f t he val ve bi nds. or moves sl uggi shl y, or t he l i near
sol enoi d does not operat e, repl ace t he l i near sol enoi d
assemory.
, . - , .
Mainshaft/Counter-
shaft Speed Sensors
Repl acement
1. Remove t he mount i ng bol t s and t he l i near sol enoi d
assemDl y.
Cl ean t he mount i ng surf ace
and f l ui d
passages.
5 x 1 . 0 mm
12 N. m
(1. 2
kgf . m,
8.7 tbf.ftl
@
@
GASKET
LINEAR
SOLENOID
ASSEMBLY
Cl ean the mounti ng surface and fl ui d passage of the
l i near sol enoi d assembl y and transmi ssi on housi ng.
Instal l a new l i near sol enoi d assembl y wi th a new
gasket.
NOTE: Do not pi nch the gasket when i nstal l i ng the
l i near sol enoi d; make sure that the
gasket i s i nstal l ed
properl y i n the mounti ng
groove of the l i near sol e-
nor d.
Check the l i near sol enoi d connector for rust, di rt or
oi l , and connect i t securel y.
4.
Repl acement
1. Remove the 6 mm bol t and the countershaft speed
sensor from the ri ght si de cover
6 x 1 . 0 mm
12 N.m {1.2 kgJ.m,
COUNTERSHAFT
8.7 rbr.frl
SPEED SENSOF
MAINSHAFT SPEED
SENSOE WASHER
{D16Y7 engi ne)
O. RI NG
Repl ace.
MAINSHAFT
SPEED
SENSOR
6 x 1 . 0 mm
12 N. m 11. 2 kgl . m,
8.7 tM.ft)
Remove t he 6 mm bol t and t he mai nshaf t speed
senso. from the transmi ssi on housi ng.
Repi ace the O-ri ng wi th a new one before i nstal l i ng
the countershaft speed sensor or the mai nshaft speed
sensor.
NOTE: Instal l the mai nshaft speed sensor washer on
the mai nshaft speed sensor. The mai nshaft speed
sensor washer i s used on model s wi t h t he D16Y7
engi ne.
14- 77
Chart
Hydraulic System
SYMPTOM
Check these i tems on the
PROBABLE CAUSE Li St
Check these i tems on
the NOTES Li st
Engi ne runs, but vehi cl e does not move i n any gear.
1, 2, 3, 5, 6, ' t , 36, 38
K, L , R, S
Vehi cl e moves i n
p.
E,
but not i n
pel ,
@,
posi ti on.
6, 8, 9, 10, 30, 54 c , M, o
Vehi cl e moves i n
E, E, E.
but not i n
E
posi ti on. 6, 11, 12, 24
C, L
Vehi cl e moves i n
E, E, E,
but not i n
E
posi ti on. 4, 6, 14, 15
c , L, o
Vehi cl e moves i n
E
posi ti on.
10, 12,13, 14, 16, 29, 33, 34. 35 C, D
Excessi ve i dl e vi brati on.
1, 2, 19, 32, 36, 45, 47
,
48 B. K. L
Poor accel erati on; fl ares on starti ng off i n
ro..
@
posi ti on
Stal l rpm hi gh i n
l Dl , E, El
posi ti on.
1, 2, 3, 6, 3A, 4' l K. L , R
E, l ,-
posi ti on.
6, 8, 10
C, D
E
posi ti on.
6 , 1 2
C, D
i
Stal l rpm i s i n speci fi cati on. 1 4
N
Stal l rpm l ow.
17
, 32, 45, 47
.
48 R
No shi ft
' t9,20,
40, 48, 49 G , L
Fai l s to shi ft i n
@, @
posi ti on; from 1st to 3rd gear 22, 49
Fai l s to shi ft i n
pl ,
@
posi ti on; from
' l sr
to 4th gear 22, 23, 4A
Errati c upshi fti ng.
1-2 upshi ft, 2-3 upshi ft.3-4 upshi ft 58
1-2 upshi ft
21, 48
2-3 uDshi f t
22, 49
_
3-4 upshi ft
23, 48
Harsh upshi ft {1,2). 12, 19, 20, 29, 50, 51, 51
, 58
Harsh upshi ft {2-3). 13, 19, 20, 24, 21, 29, 50, 51, 57, 58 C , D , E , H , L
Harsh upshi ft
(3-4).
1 4, 19, 20, 25, 28, 29, 50, 51 . 57, 58 C, D, E, I , L
Harsh downshi ft
(2-1)
19, 20, 24, 43, 54, 57
, 58 o
Harsh downshi ft
(3-2).
12,
' 19,20,25,
43,55,57 , 58 C, D. E, H
Harsh downshi ft
(4-3).
13, 19,20, 26, 43,56,57,5A C, D, E, I
Fl ares on 2-3 upshi ft.
13, 19, 20, 24, 27, 51
Fl ares on 3-4 upshi ft.
1 4, 19
,
20, 25, 2A, 5'l E, L , N
Excessi ve shock on 2-3 uDshi ft.
13, 19, 20, 24, 27
,
43, 50, 51 , 58 E , L , N
Excessi ve shock on 3-4 upshi ft.
1 4, 19, 20, 25, 28, 43, 50, 51 , 58 E . L , N
Late shi ft from
E
posi ti on
to E or
l E!
posi ti on.
10, 30
M
Late shi ft from
E
posi ti on to
E
posi tron.
4, 14, 21, 53
o
Noi se from transmi ssi on i n al l shi ft l ever posi ti ons.
2 , 3 7 K , L , O
Vehi cl e does not accel erate more than 31 mph
(50
km/h). 1 7
Shi ft l ever does not operate smoothl y,
6, 39 P
Fai l s to shi ft; stuck i n 4th gear.
19, 48, 49
Transmi ssi on wi l l not shi ft i nto parki ng gear i n
E]
posi ti on.
6, 18. 39 P
Stal l rpm hi gh; al l cl utch pressures are i n speci fi cati on. 4 1
D. K. O
Lock-up cl utch does not di sengage. 19, 44, 45,46, 47, 50, 51, 58
F I
Lock-up cl utch does not operate smoothl y.
'19,
4't, 44, 45, 46, 47
,
50, 51, 58 L
' t9,
41, 44, 45, 46, 47, 50. 51, 57, 58 E , L
Vi brati on i n al l posi ti ons
36
\
\
\
14-78
.
PROBABLE CAUSE
2 ATF pump worn or bi ndi ng.
42 Forei gn materi al i n separator
pl ate.
Regul at or val ve st uck.
43 CPB val ve stuck.
Servo valve stuck.
44 Lock-up ti mi ng val ve stuck.
5 Mai nshaft worn/damaged.
45 Lock-up shi ft val ve stuck.
6 Shi ft cabl e broken/out of adj ustment.
46 Lock-up control val ve stuck.
7 Fi nal gears worn/damaged.
47 Lock-up
pi ston defecti ve.
I One-way {sprag) cl utch worn/damaged.
48 Shi ft control sol enoi d val ve A defecti ve.
1st gears worn/damaged
(2 gears). 49 Shi ft control sol enoi d val ve B defecti ve.
10 1st clutch defective.
5U Lock-uD control sol enoi d val ve A defecti ve.
l 1 2nd gears worn/damaged
(2 gears)- Lock-uo control sol enoi d val ve B defecti ve.
2nd clutch defective.
52 Servo control val ve stuck.
3rd cl utch defecti ve.
53 1st accumul ator defecti ve.
1 4 4th clutch defective.
54 Forei gn materi al i n 2nd exhaust ori fi ce.
t c Reverse
gears worn/damaged
(3 gears). Forei gn materi al i n 3rd exhaust ori fi ce.
16 Excessive ATF
Forei gn materi al i n 4th exhaust ori fi ce.
1 7 Torque converter one-way cl utch defecti ve.
Mai nshaft sDeed sensor defecti ve.
18 Paki ng mechani sm defecti ve.
58 Countershatt sDeed sensor defecti ve
19 Li near sol enoi d assembl y defecti ve.
20 CPC valve stuck.
21 1-2 shi ft val ve stuck.
2-3 shi ft val ve stuck.
3-4 shift valve stuck.
2nd accumul ator defecti ve.
3rd accumul ator defecti ve.
4th accumulator defective.
27 2nd ori fi ce control val ve stuck.
28 3-4 ori fi ce control val ve stuck.
29 Forei gn materi al i n mai n ori fi ce.
30 Forei gn mat eri al i n 1st ori f i ce.
31 Forei gn materi al i n reverse ori fi ce.
32 Engi ne output l ow,
33 Needl e beari ng worn/damaged.
34 Thrust washer worn/damaged.
Cl utch cl earance i ncorrect.
Dri ve pl ate defecti ve or transmi ssi on mi sas-
sembl y.
Torque converter housi ng or transml ssl on
housi ng beari ng worn/damaged.
38 ATF strai ner cl ogged.
Joi nt i n shi ft cabl e and transmi ssi on or body
40 Modul ator val ve stuck.
(cont' d)
14-79
Ghart
The fol l owi ng symptoms can be caused
by i mproper repai r or assembl y
Check these i tems on the
PROBABLE CAUSE DUE TO
IMPROPER REPAIR Li st
I t ems on t he
NOTES Li st
Vehi cl e creeps i n
N
posi ti on.
R1, R2
Vehi cl e does not move i n
.S or
@
posi ti on.
R4
Transmi ssi on l ocks up i n
E
posi ti on
R3, R1' 1
Excessi ve drag i n transmi ssi on. R6
K , R
Excessi ve vi bfati on, rDm rel ated,
R7
Noi se wi t h wheel s movi ng onl y. R5
Mai n seal pops out.
R8
s
Vari ous shi fti ng probl ems.
R9, R1O
Hydraul i c System
(cont' dl
14- 80
\
PROBABLE CAUSE DUE TO IMPROPER REPAIR
R1 l mproper cl utch cl earance.
R2. l mproper gear cl earance.
R3. Parki ng brake l ever i nstal l ed upsi de down.
R4. One-way
(sprag)
cl utch i nstal l ed upsi de down.
R5. Reverse sel ector hub i nstal l ed uDsi de down.
R6. ATF pump bi ndi ng.
R7. Torque converter not ful l y seated i n ATF
pump.
R8. Mai n seal i mproperl y i nst al l ed.
R9, Spri ngs i mproperl y i nstal l ed.
R 10. Val ves i mproperl y i nstal l ed.
R 1 1 Shi ft fork bol t not i nstal l ed.
NOTES
See fl ushi ng procedure, page 14-155 and 156.
B, set i dl e rpm i n gear t o speci f i ed i dl e speed. l f st i l l no good, adj ust mot or mount s as out l i ned i n engi ne
sect i on of t hi s manual .
l f t he l arge cl ut ch pi st on O-ri ng i s broken, i nspect t he
pi st on groove f or rough machi ni ng'
c.
D. l f the cl utch
pack i s sei zed or i s excessi vel y worn, i nspect the other cl utches for wear, and check the ori fi ce
control val ves, CPC val ve and l i near sol enoi d l or free movement
E. l f the l i near sol enoi d i s stuck, i nspect the cl utches for wear.
l f the l -2 shi ft val ve i s stuck cl osed, the transmi ssi on wi l l not upshi ft
no l st gear.
l f the 2nd ori ti ce control val ve i s stuck, i nspect the 2nd and 3rd cl utch
l f stuck open, the transmi ssi on has
packs for wear.
H.
t. It the 3-4 ori fi ce control val ve i s stuck, i nspect the 3rd and 4th cl utch
packs for wear'
J , l f the cl utch Dressure control val ve i s stuck cl osed, the transmi ssi on wi l l not shi ft out of 1st gear'
K. l mproper al i gnment or mai n val ve body and torque converter housi ng may cause ATF pump sei zure. The
symptoms are mostl y an rpm rel ated ti cki ng noi se or a hi gh-pi tched squeak-
L. l f t he ATF st rai ner i s cl ogged wi t h part i cl es of st eel or al umi num, i nspect t he ATF pump and di f f erent i al
pi ni on shaf t . l f bot h are OK and no cause f or t he cont ami nat i on i s f ound, repl ace t he t orque convener.
l f t hel s t c l ut c hf eedpi pegui dei nt her i ght s i dec ov er i s s c or edby t hemai ns haf t , i ns pec t t hebal l
bear i ng
for excessi ve movement i n the transmi ssi on housi ng. l f oK, repl ace the ri ght si de cover as i t i s dented. The
O-ri ng under the
gui de i s probabl y worn
,
Repl ace the mai nshaft i f the bushi ng for the 4th feed pi pe i s l oose or damaged. l f the 4th feed pi pe i s dam-
aged or out of round, repl ace the ri ght si de cover.
.
Repl ace the mai nshaft i f the bushi ng for the 1st feed pi pe i s l oose or damaged l l the 1st feed pi pe i s dam
aged or out of round, repl ace i t.
_
A worn or damaged sprag cl utch i s mostl y a resul t of shi fti ng the transmi ssi on i n i D1 or l Da posi ti on whi l e
the wheel s rotate i n reverse, such as rocki ng the vehi cl e i n snow.
N.
o.
P, Inspect the l rame for col l i si on damage.
Inspect for damage and wear:
1. Reverse sel ector gear teeth chamters
2. Engagement teeth chaml ers oI countershai t 4th and reverse gear'
3. Shi ft tork for scuff marks i n center.
4. Di fferenti al
pi ni on shaft for wear under
pi ni on gears
5. Bottom of 3rd cl utch for swi rl marks
Repl ace i tems 1, 2, 3 and 4 i f worn or damaged. l f transmi ssi on makes a cl i cki ng,
gri ndi ng or whi rri ng noi se,
afso repface mai nshaft 4th gear, reverse i dl er gear, and countershaft 4th gear i n addi ti on to 1,2,3 or 4'
l f di fferenti al
pi ni on shaft i s worn, overhaul di fferenti al assembl y, and repl ace ATF strai ner, and thoroughl y
cl ean transmi ssi on, Il ush torque converter, cool er and l i nes
l f bottom of 3rd cl utch i s swi rl ed and transmi ssi on makes gear noi se, repl ace the countershaft and fi nal dri ven
gear.
Be very careful not to damage the torque converter housi ng when repl aci ng the mai n bal l beari ng. You
may al so damage the ATF pump when you torque down the mai n val ve body. Thi s wi l l resul t i n ATF pump
sei zure i f not detected. Use the proper tool s.
Instal l the mai n seal fl ush wi th the torque converter housi ng. l f you push i t i nto the torque converter
housi ng unti l i t bottoms out, i t wi l l bl ock the fl ui d return passage and resul t i n damage'
o.
S.
14-81
Road Test
2.
NOTE: Warm up the engi ne to normal operati ng temperature (the
radi atorfan comes on).
' 1.
Appl y parki ng brake and bl ock the wheel s. Start the engi ne, then shi ft to
E
posi ti on whi l e depressi ng the brake
pedal . Depress the accel erator pedal
and rel ease i t suddenl y. The engi ne shoul d not stal l .
Repeat same test i n
E
posi ti on.
Test-dri ve the vehi cl e on a fl at road i n the
E]
posi ti on.
Check that the shi ft poi nts occur at approxi mate speeos snown
on a fl at road. Al so check for abnormal noi se and cl utch sl i ppage.
NOTE: Throftl e posi ti on
sensor vol tage represents the throttl e openi ng.
a. Unbol t the PCM for road testi ng; refer to page 14-46.
b Set the di gi tal mul ti tester to check vol tage between D1
(+)
termi nal and A9
{-) or A22
l .l termi nal of the
pCM
for
the throttl e posi ti on
sensor.
BACKPROBE ADAPTER
BACKPROBE SET
07sAz
-
001000A
Itwo requiredl
DIGITAL MULTIMETER
lCommercially availablel
KS- AHM- 32- 003.
or equivalent
PCM CONNECTORS
B {2sP)
1
c {31P)
Throttle Opening Unit of speed l sl
+
2nd znd
*
3rd 3rd
- ilth Lock-up ON
Throttl e posi ti on sensor
vol tage: 0.75 V
mpn 9 - 1 2
28- 32 21
- 24
km/ h 1 5 - 1 9
1t _ a'f
45- 52 34- 39
Throttl e
posi ti on sensor
vol t age: 2. 25 V
mph 21
- 25
40- 45 59- 65
km/h 34- 40 65- 73 95
-
104 99
-
108
Ful l y opened throttl e
vol tage: 4.5 V
mph 33- 38
101
-
112 99
-
109
km/ h 5 3 - 6 1 102
-
115 163 180 159
-
' t76
&l Position: Dl6Y7 engine
Upshift
Downshift
-9. Position: D16Y8 engine
Upshift
Downshift
NOTE:
o Lock- up ON: The l ock- upcont r ol sol enoi d val ve A t ur ns ON.
. Lock-uo OFF:The l ock-up control sol enoi d va l ve A tu rns OFF.
(cont' d)
Throttle Opening Unit of sDeed Lock-up OFF 4th
*
3rd 3rd
+
2nd 2nd
*
l st
Ful l y-cl osed throttl e
vol tage: 0.5 V
mpn 19- 22 17
- 20
6 - 9 ( 3 r d - 1 s t )
km/ h 30- 35
10
-
15
(3rd
*
1st)
Ful l y-opened throttl e
vol tage: 4.5 V
mph 95
-
105 85- 95 5 4 - 6 1 2 5 - 3 0
km/h 153
-
169 137
-
153 87- 98 40- 48
Throttle Opening Unit of speed l st
*
2nd 2nd
+
3rd 3rd
+ 'lth Lock-up ON
vol tage: 0.75 V
mph 9 - 1 2 20- 23 28- 32 2't
-
24
km/h 1 5 - l 9 32- 37 45- 52 34- 39
vol tage: 2.25 V
mph
40- 45 62- 67
km/h 34- 40 6 5 - 7 3 95
-
104 99
-
108
vol tage: 4.5 V
mph 62- 70 96
-
'107
95
-
106
km/h 5 2 - 6 0 100
-
113 155
-
172 153
-
170
Throttle Opening Unit of speed Lock-up OFF
ilth
-
3rd 3rd
-
2nd 2nd
-
l st
Ful l y-cl osed throttl e
Throttl e
posi ti on sensor
vol t age: 0. 5 V
mph 19- 22 11
- 20
6- 9( 3r d- 1s t )
km/h 3 0 - 3 5
' 10
-
15
( 3r d -
l st l
vol tage: 4.5 V
mpn 91 1 0 1 8 5 - 9 5 5 4 - 6 1 25-30
km/ h 147
-
163 137
-
153 8 7 - 9 8 40- 48
14- 83
Road Test
(cont' dl
Accel erate to about 35 mph
(57
km/hl so the transmi ssi on i s i n 4th, then shi ft from
E
posi ti on
to
@
posi ti on.
The
vehi cl e shoul d i mmedi stel y begi n sl owi ng down from engi ne braki ng.
CAUTION: Do not shift trom E or E
position to
E
position at speeds ovcr 6:l mph
(100
km/hl; you mly dlmlge
the tJansmission.
Check for abnormal noi se and cl utch sl i ppage i n the fol l owi ng posi ti ons
E
(2nd
cear) Posi ti on
a. Accel erate trom a stop at ful l throttl e. Check that there i s no abnormal noi se or cl utch sl i ppage.
b. Upshi fts and downshi fts shoul d not occur wi th the sel ector i n thi s oosi ti on.
E
(Reverse)
Posi ti on
Accel erate from a stop at ful l throttl e, and check tor abnormal noi se and cl utch sl i ppage.
Test i n
E {Parki ng) Posi ti on
Park the vehi cl e on sl ope {approx. 16' ), appl y the ps.ki ng
brake, and shi ft i nto
E
posi ti on.
Rel ease the brake; the vehi -
cl e shoul d not move.
Stall Speed
Test
CAUTION:
. To
prevent transmission dEmage, do nol test stall sPeed tol more than 10 secondg at 8 time.
. Do not shift th lver whils raising th sngine spoed.
. Bs sure to rsmove ths pressure gauge beforg lgting stall sPeed.
' 1.
Engage the
parki ng brake, and bl ock the front wheel s.
2. Connect a tachometer to the engi ne. and start the engi ne
3. Make sure the IVC swi tch i s OFF.
4. After the engi ne has warmed up to normal operati ng temperature {the radi ator fan comes on), shi ft i nto
E
posi ti on.
5. Ful l y depress the brake
pedal and accel erator for 6 to 8 seconds, and note engi ne speed'
6. Al l ow two mi nutes for cool i ng, then repeat the test i n
E
and E
posi ti ons.
NOTE:
. Stal l speed tests shoul d be used for di agnosti c
purposes onl y
. Stal l speed shoul d be the same i n
E, E
and
E
posi ti ons.
Stall Speed RPM:
Spocmcation: 2,700 rpm
Service Limit: 2,550
-
2,850 rpm
TROUBLE
PROEABLE CAUSE
stal l rpm hi gh i n l d, El
and
E
posi ti ons Low tl ui d l evel or ATF pump output
Cl ogged ATF strai ner
Pressure regul ator val ve stuck cl osed
Sl i ppi ng cl utch
E
posi ti on
.
Sl i ppage of 4th cl utch
E
posi ti on
.
Sl i ppage of 2nd cl utch
Stal l rpm hi gh i n E
posi ti on
.
Sl i ppag of l st cl utch or 1st gear one-way cl utch
stal l rpm l ow i n E, E
and E Posi ti ons
.
Engi ne output l ow
'
Torque convener one-way cl utch sl i ppi ng
14- 85
Fluid Level
Checki ng/Changi ng
CAUTION: While checking 8nd changing, bo sure not to
allow du3t and other foreign particles
to nter into the
transmission.
Checking
CAUTION: Keep all of th loreign particles
out of th
transmission.
NOTE: Check the fl ui d l evel wi th the engi ne at normal
operati ng temperature {the radi ator fan comes on}.
l . Par k t he vehi cl e on l evel gr ound. Tur n of f t he
engrne.
2. Remove the di psti ck
(yel
mi ssi on, and wi pe i t wi th
the trans-
UPPER MARK
LOWER MARK
3.
4.
l ow l oop) from
s cl ean cl oth.
I
\
\ \
\ V
\ l l
tl
0 -
Insert the di psti ck i nto the transmi ssi on.
Remove t he di pst i ck and check t he f l ui d l evel , l t
shoul d be between the upper and l ower marks.
l f the l evel i s bel ow the l ower ma.k, pour the recom-
mended fl ui d+ i nto the fi l l er hol e to bri no i t to the
upper marK.
Insert the di Dsti ck back i nto the trsnsmi ssi on i n the
di recti on shown.
FRONT
OIPSTICK IYELLOW LOOPI
I nst al l t he di pst i ck i n t he ext ent
ol t he di rect i on shown.
Changing
CAUTION: Keop all of the toreign particles
out of the
transmiasion,
1. Bri ng the transmi ssi on up to operati ng temperature
by dr i vi ng t he vehi cl e. Pa. k t he vehi cl e on l evel
gr ound.
t ur n t he engi ne oJf , t hen r emove dr ai n
pt ug.
NOTE: l f a cool er fl usher i s to be used, see page
14-
155 and 155.
2. Rei nstal l the drai n pl ug wi th a new seal i ng washer,
then refi l l the transmi ssi on wi th the recommended
fl ui d* to the upper mark on the di psti ck.
Automatic Transmi$ion Fluid Capacity:
2.7 I 12.9 US qa,2-1lmp qt) at chang.
5.9 / {6.2 US
$,
5.2 lmp qt} at overhaul
Recommended Automatic Transmisrion Fluid:
Genui ne Honda Pr mi um For mul a Aut omet i c
Transmission Fluid
(ATF)..
TRANSMISSION RIGHT SIOE COVEF
DRAI N PLUG
18 x 1. 5 mm
49 N. m {5. 0 kgf . m, 36l bt t r)
SEALING WASHEE
Repl ace.
*
Al ways use Genui ne Honda Premi um Formul a
Automati c Transmi ssi on Fl ui d
(ATF).
Usi ng a non-
Honda ATF can affect shift
qualitv.
Pressure Testing
@
. While tosting, be careful of the rotating tront wheels
. Maks sur lifts,
iacks,
and saloty stands are placed properlY
{see soction 11.
CAUTION:
. Betore testing, bs sure the transmission tluid is tilled to the proper level.
. Warm up the engine befote tssting.
1. Rai se the vehi cl e
(see
secti on 1).
2. Warm up the engi ne, then stop the engi ne and connect a tachometer.
3. Connect the oi l pressure gauges to each i nspecti on hol e.
TOROUE: 18 N.m {1.8
kgf'm, 13 lbf'ftl
CAUTION: Connect the oil
pressure gauges securely; be sure not to allow dust and other foreign particles to nter
th inspection holes.
A/T OIL PRESSUBE GAUGE
SET WPANEL
07406
-
0020400
A/T LOW PRESSUBE GAUGE
SET WPANEL
07'r()6
-
0070300
A/T OIL PRESSURE HOSE
ADAPTER
07MAJ
-
PY,(}l20
(4
roquirodl
A/T OIL PRESSURE HOSE
2. 10 mm
07MAJ
-
PYiOllA
{{ rsquirodl
Start the engi ne, and measure the respecti ve
pressure as fol l ows
a Li ne Pressure
. 1st Cl utch Pressure
. 2nd.3rd and 4th Cl utch Pressure
Instal l a new washer and the seal i ng bol t i n the i nspecti on hol e, and ti ghten to the speci fi ed torque.
TOROUE: 18 N.m
(1.8
kgf.m, 13 l bf' ft|
NOTE: Do not reuse ol d seal i ng washers; al ways repl ace washers
(cont' d)
14-47
Pressure Testing
(cont'd)
a Line Pressure/1st Clutch Pressure Measurement
1. Set the parki ng brake, and bl ock both rear wheel s securel y.
2. Run the engi ne at 2,000 rpm.
3. Shi ft to
E
or
E
posl ti on, then measure l i ne pressure,
NOTE: Hi gher pressure may be i ndi cated i f measurements are made i n shi ft l ever posi ti ons other than
E
or
fl
posi -
t i on.
4. Shi ft to
E
posi ti on, then measure l st cl utch pressure.
1ST CLUTCH PRESSURE
INSPECTION HOLE
(Marked
wi t h
"L")
LOCK.UP CONTROL
SOLENOID VALVE A/B
ASSEMELY
I
VALVE A/B ASSEMBLY
PRESSURE
SHIFT LEVER
POStTtON
SYMPTOM PROBABLE CAUSE
FLUID PRESSURE
Standard Srvic Limit
Li ne
Eo . E
No {or l ow)
l rne pressure
Torque converter,
ATF pump, pres-
sure regul ator,
torque converter
check val ve
830
-
880 kPa
(8.5 -
9.0 kgf/cm' ,
120
-
130 psi )
780 kPa
{8.0 kgf/cm,, 110 psi )
' 1st
Cl utch
E
No or l ow 1st
pressu re
1st Cl ut ch
14- 88
1 .
2.
3.
4.
5.
2nd, 3rd rnd 4th Clutch Ptassurc Mclrurcmanl
Set the
psrki ng brake, and bl ock both tear wheel s
sscurely.
Di sconnect the l i nsar sol enoi d connector.
Start the sngi ne, and run the engi ne at 2,000 rpm.
Shi ft to E
posi ti on, and measure each cl utch
pres-
sure,
Connect battery vol tage and ground l o the l i near
sol enoi d connectr tgrmi nal s, then msasure each
clutch
pr6ssure.
1TH CLUTCH
INSPECTION HOI.I
(M. rked
wi t h
"4")
CLUTCTI PRESSURE
INSPECTION HOLE
PRESSURE
LINEAR SOLENOID
PfiESSURE
SHIFT I.EVER
POSmON
SYMPTOM PROBABI.E CAUSE
FLUID PRESSURE
Standard Service Limit
2nd Cl utch
E
No or l ow 2nd
pressure
2nd Clutch 800
-
850 kPa
(8.2 -
8.7 kg7cm',
120
-
l 2i l psi )
wi th the l i near sol enoi d
disconnec'ted
0- 150 kPa
( 0- 1. 5kgf l cm' ,
0
-
21 psi )
connected to battery
vol tage and ground
760 kPa
(7.7
kgf/cm,, 110 psi l
disconnected
Above 150 kPa
{1.5 kg?cm,, 2l psi )
vollage and ground
3rd Clutch
E
No or l ow 3rd
pressure
3rd Cl utch
810
-
860 kPa
(8.3 -
8.8 kgflcm',
118
-
125
psi )
disconnected
0
-
150 kPa
( 0- 1. 5kgf / cm' ,
0
-
21
psi )
vol tage and
ground
765 kPa
(7.8
kgf/cm' , 111 psi )
di sconnected
Above 150 kPa
(1.5
kgf/cm' . 21 psi )
voltage and ground
ilth
clurch No or low 4th
pressure
4th clutch
ts
Servo Valve or 4th
Cl utch
14- 89
Transmi ssi on
Removal
@
Make suie lifts,
iacks
and safety stands are placed
properly, and hoist bracket are aftached to the col-
rect posi ti on on the engi ne
(see
secti on 11.
Apply paiking brske and block rear wheels so vehicle
wi l l not rol l off stands and l al l on you whi l e worki ng
undel it.
CAUTION: Use fender covers to avoid damaging paint-
ed surfaces.
1. Di sconnect t he bat t er y negat i ve
( - )
t er mi nal f r om
the battery, then remove the
posi ti ve (+)termi nal .
2. Remove the i ntake ai r duct.
D16Y7 engi ne:
Remove the i ntake ai r duct and resonator.
D16Y8 engi ne:
Remove t he i nt ake ai r duct and t he ai r cl eaner hous-
i ng assembl y.
Remove t he st ar t er cabl es and cabl e hol der f r om
the starter motor.
MOTOR CABIE
MOTOE CABLE
14- 90
4. Remove the transmi ssi on ground cabl e, and di scon-
nect the l ock up control sol enoi d connector.
(VSS)
connec,
tor and the countershaft speed sensor connector.
VEHI CLE SPEED
6. Remove the transmi ssi on housi ng mounti ng bol ts
and the rear engi ne mounti ng bol t.
7. Di sconnect the shi ft control sol enoi d, the l i near sol e-
noi d. and the mai nshaft sDeed sensor connectors.
SHIFT CONTROL
SOLENOIO CONNECTOR
LINEAR SOI.ENOID
CONNECTOR
CONNECTOR
BRACKET
8. Remove t he dr ai n pl ug, and dr ai n t he aut omat i c
t r ansmi ssi on f l ui d
( ATF) .
Rei nst al l t he dr ai n pl ug
wi th a new seal i ng washer.
DRAIN PLUG
18 x 1. 5 mm
49 N.m
(5.0
kgf.m,36 lbf ftl
9. Remove t he spl ash shi el d.
SPLASH SHIELD
(cont' d)
14-91
Transmi ssi on
Removal
(cont' dl
10. Remove the cotter pins and castle nuts. then separate
the bal l
i oi nts
from the l ower arms
(see
secti on 18).
DAMPER PINCH BOLT
NUT
:\
12.
FORK
FORK
BOLT
11. Remove t he r i ght damper f or k bol t , t hen
r i ght damper f or k and damper .
Pry the ri ght and l eft dri veshafts out of the di fferenti al .
Pul l on t he i nboar d
j oi nt
and t he r i ght and l ef t dr i ve-
shafts l see secti on 16).
Ti e pl asti c bags over the dri veshaft ends.
NOTE: Coat al l preci si on fi ni shed surfaces wi th cl ean
engi ne oi l .
Remove the exhaust pi pe A.
NOTE: D' 16Y8 engi ne i s shown; D16Y7 engi ne i s
si m i l a r .
COTTER PIN
Repl ace.
separat e
Y;
SELF.LOCKING
NUT
Repl ace.
14.
*S9e,
Repl ace.
EXHAUST PIPE A
14-92
HOSE
16. Remove the shi ft cabl e cover, then remove the shi ft
cabl e by removi ng the control l ever.
CAUTION: Take care not to bend the shift cable.
CONTROL
SHAFT
Remove the ri ght front mount/bracket.
Remove t he ATF cool er hoses at t he ATF cool er
l i nes. Turn the ends of the ATF cool er hoses up to
prevent ATF from fl owi ng out, then pl ug the ATF
cool er hoses and l i nes.
NOTE: Check t or any si gn of l eakage at t he hose
j oi nts.
ATF COOLER
LINE
,
"):
11.
18.
RIGHT FRONT
MOUNT/BRACKET
SHIFT CABLE
WASHER
19. Remove t he engi ne st i f f ener and t he t or que con-
verter cover.
STIFFENER
CONVERTER
Remove t he ei ght dr i ve pl at e bol t s one at a t i me
whi l e rotati ng the crankshaft pul l ey.
Remove the di stri butor.
Attach a hoi sti ng bracket to the engi ne. then l i ft the
engi ne sl i ght l y.
20.
22.
21.
23. Pl ace a
j ack
under the transmi ssi on, and rai se the
transmi ssi on
j ust
enough to take wei ght off of the
mounts, l hen remove the transmi ssl on mount.
TRANSMISSION
MOUNT BRACKET
24. Remove t he t r ansmi ssi on housi ng mount i ng bol t s
and t he r ear engi ne mount i ng bol t s.
25. Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the 14 mm dowel
pi ns, then l ower i t on the
transmi ssi on
i ack.
MOUNTING BOLTS
REAR ENGINE
MOUNTING BOLTS
Repl ace.
26. l f necessary, remove the torque convener and
staner motor.
the
14- 93
lllustrated lndex
Transmi ssi on/Ri ght Si de Cover
(,
ROLLER
@
COLLAR
O
o-RtNG Repl ace.
@
FEED PIPE FLANGE
O o-RING Repl ace.
@
SNAP RING
O
3RD cLUTcH FEED PIPE
@
COUNTERSHAFT LOCKNUT {FLANGE NUT)
23 x 1.25 mm Repl ace.
O
CONICAL SPRING WASHER RepIace,
@
PARKING GEAR
@
ONE-WAY CLUTCH
@ COUNTERSHAFT 1ST GEAR
@
NEEDLE BEARING
@ COUNTERSHAFT 1ST GEAR COLLAR
@
o-Rl NGs Repl ace.
@
RIGHT SIDE COVER GASKET Rep| ace.
@
DowEL PINS
@
PARKING BRAKE PAWL sToP
@
LocK WASHER Reptace.
@
PARKING BRAKE STOP Sel ecti ve part
@
PARKING BRAKE LEVEB
@)
PARKING ERAKE LEVER SPRING
@
DRAIN PLUG
@ SEALING WASHER RepIace.
@
o-RING Repl ace.
@
COUNTERSHAFT SPEED SENSOR
@
PARKING BRAKE PAWL
@
PARKING BRAKE PAWL SPRING
@
PARKING BRAKE PAWL SHAFT
@
LINEAR SOLENOTD ASSEMBLY
@
LTNEAR SOLENOID GASKET RepIace,
TOROUE SPECIFICATIONS
@
RIGHT SIDE COVER
@
l sT cLUTcH FEED PIPE
@
o-Rl NGs Repl ace.
@
FEED PIPE FLANGE
@
SNAP RING
@
MA| NSHAFT LoCKNUT
(FLANGE
NUTI 21 x 1.25 mm
Repl ace.
@ CONICAL SPRING WASHER Repl ace.
@
lsT cLuTcH ASSEMBLY
@
o-Rl NGs Repl ace.
@
THRUST WASHER
@
THRUST NEEDLE BEARING
@
NEEDLE BEARING
@
MAINSHAFT lST GEAR
@
MAINSHAFT lST GEAR COLLAR
@
ATF COOLER LINE
@
SEAL| NG wAsHERs Reptace.
@
JoINT BoLT
@
ATF DTPSTICK
@
ATF COOLER LINE
@
JOINT BOLT
@
SEAL| NG WASHERS Reptace.
@
VEHICLE SPEED SENSOR
@
O.RING Repl ace.
Bol t/Nut No. Torque Value Size Remarks
6A
6B
8F
12A'
18D
21M
12 N' m
(1.2
kgi m,8.7 l bf.ft)
' 14
N' m
(1.4
kgf.m,
' 10
l bf' ft)
22 N.m
(2.2
kgi m, 16 l bf.ft)
28 N.m
(2.9
kgf.m,21 l bf.ft)
49 N.m
(5.0
kgf.m,36 l bf.ft)
78 N.m
(8.0
kgi m,58 l bf.ft)
103 N. m
( 10. 5
kgnm, 75. 9 l bf . f t )
6 x 1 . 0 mm
6 x 1 . 0 mm
8 x
' 1. 25
mm
12 x 1. 25 mm
18 x 1. 5 mm
21 x 1. 25 mm
23 x 1. 25 mm
Joi nt bol t
Dr ai n pl ug
Mai nshaft l ocknut: Left-hand threads
Countershaft l ocknut:
Left-hand threads
14- 95
lllustrated Index
14- 96
b
6A
I
o
i l l
LOCK WASHER Repl ace.
(A
REVERSE SHIFT FORK
@ couNTERSHAFT REVERSE GEAR COLLAR
.' COUNTERSHAFT REVERSE GEAR
@
NEEDLE BEARING
(O REVERSE SELECTOR
O
REVERSE SELECTOR HUB
@
COUNTERSHAFT 4TH GEAR
O
NEEDLE BEARING
@
DISTANCE COLLAR, 28 mm Sel ecti ve part
@
COUNTERSHAFT 2ND GEAR
@
[3 COUNTERSHAFT 3RD GEAR
(iI
NEEDLE BEARING
.(3 COUNTERSHAFT 3RD GEAR COLLAR
(D
('
SPLINED WASHER
@)
3RD cLUTcH ASSEMBLY
@
o-Rl NGs Repl ace.
@
COUNTERSHAFT
@
SNAP RING
@
THRUST WASHER
@
@
MAINSHAFT 4TH GEAR/REVERSE GEAR
@
NEEDLE BEARINGS
@
)
MAINSHAFT 4TH GEAR COLLAR
@
2ND/4TH cLUTcH ASSEMBLY
@
o-Rl NGs Repl ace.
@
THRUST WASHER, 36.5 x 55 mm Sel ecti ve part
6]
THRUST NEEDLE SEARING
@
MAINSHAFT 2ND GEAR
@
NEEDLE BEARING
89
@
MAINSHAFT
60 SEALING RINGS, 35 mm
6D SEALING RING, 29 mm
6!) NEEDLE BEARING
@
SET RING
@
SHTFT CONTROL SOLENOID VALVE A/B ASSEMBLY
@
HARNESS CLAMP BRACKET
6D
sHtFT CONTROL SOLENOTD FTLTER/GASKET Reptace.
@ CONNECTOR BRACKET
.O TRANSMISSION HANGER
@
BREATHER cAP
@
MAINSHAFT sPEED sENsoR
@
MAINSHAFT SPEED SENSOR WASHER {O16Y7 ENgiNEI
@
o-RING Repl ace.
@
SNAP RING
@
MAINSHAFT TRANSMISSION HOUSING BEARING
(5]
COUNTERSHAFT TRANSMISSION HOUSING BEARING
@
REVERSE IDLER GEAR SHAFT HoLDER ASSEMBLY
D
NEEDLE BEARING
6,
ol L SEAL Repl ace.
@
SET RING, 80 mm Sel ecti ve
part
d]
TRANSMISSION HOUSTNG
@
REVERSE IDLER GEAR
@
DOWEL PINS
@
TRANsMtssl oN HoustNG GASKET Reptace.
@
@ ol L SEAL Repl ace.
62 TOROUE CONVERTER HOUSING
Bol t/Nut No. Torque Val ue Size Remarks
6A
6B
10A
' 12
N.m 1l .2 kgf.m,8.7 l bf.ft)
' 14
N. m
( 1. 4 kgf . m. 10l bnf t )
44 N m
(4.5
kgnm,33 l bnft)
6 x 1 . 0 mm
6 x 1 . 0 mm
10 x 1. 25 mm
14-97
lllustrated Index
14- 98
- - \
'98
mod.l
i l
l l
i H
t -
T)
ATF FEED PIPE
O
ATF STRAINER
@ SERVO BODY
@ sERVo SEPARAToR PLATE
.' SECONDARY VALVE BODY
a6)
DowEL PrNs
O
SECONDARY SEPARATOR PLATE
@
SERVO DETENT BASE
O
ATF FEED PIPES
(o)
ATF FEED PIPES
O
SHAFT sToP
@
coNTRoL SHAFT
(} DETENT ARM SPRING
(D DETENT ARM
@
DETENT ARM SHAFT
@
FILTER Repl ace.
O
CHECK BALLS
[o)
TOROUE CONVERTER CHECK VALVE SPRING
@
TOROUE CONVERTER CHECK VALVE
@
DOWEL PINS
@
LOCK-UP VALVE BODY
@
LOCK.UP SEPARATOR PLATE
@
REGULATOR VALVE BODY
@
DowEL PrNs
@
COOLER RELIEF VALVE SPRING
@
COOLER RELIEF VALVE
@
o-RING Repl ace.
@ STATOR SHAFT
@
STOP SHAFT
@
ATF FEED PIPE
@
MAIN VALVE BODY
O
ATF PUMP DRIVEN GEAR SHAFT
@
ATF DRIVEN GEAB
@
DOWEL PINS
@)
ATF PUMP DRIVE GEAR
@
MAIN SEPARATOR PLATE
@
SUCTION PIPE COLLAR
@
ATF MAGNET
@
COUNTERSHAFT TOROUE CONVERTER HOUSTNG
BEARING
@
ATF GUIDE PLATE
Q]
TOROUE CONVERTER HOUSING
@ ol L SEAL Repl ace.
(.}
MAINSHAFT TOROUE CONVERTER HOUSING
BEARING
@
ol L SEAL Repl ace.
@
LOCK.UP CONTROL SOLENOID FILTER/GASKET
Repl ace.
@
LocK-UP coNIRoL SoLENoID VALVE A/B ASSEMBLY
@ CONNECTOR BMCKET
a
Bol t/Nut No. Torque Val ue Si ze Remarks
6A 12 N. m { 1. 2 kgf . m, 8. 7 l bf . f t ) 6 x 1 . 0 mm
14- 99
Ri ght Si de Cover
Removal
NOTE:
. Cl ean al l parts thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r.
. Bl ow out al l passages.
. When removi ng the ri ght si de cover, repl ace the fol l owi ng:
O r i ngs
-
Mai nshaft and countershaft l ocknuts
-
Coni cal spri ng washers
-
Ri ght si de cover gasket
Lock washer
Seal i ng washer s
RIGHT SIDE
COVEB
ARAKE LEVER
WASHER
COUNTERSHAFT
lST GEAB OOLLAR
JOINT BOLT
14- 100
SEALING WASHERS
1 .
J .
Remove the
' 13
bol ts securi ng the ri ght si de cover.
then remove the ri ght si de cover.
Sl i p the speci al tool onto the mai nshaft as shown.
MAINSHAFT HOLDER
o'GAB
-
PFs0'101
Engage t he par ki ng br ake
pawl wi t h t he par ki ng
gear.
Cut the l ock tabs of the mai nshaft and countershaft
l ocknuts usi ng a chi sel as shown, then remove the
l ocknuts and coni cal spri ng washers.
CAUTION: Keep all of the chisoled
particles out of
tho transmiS3ion.
NOTE:
. Mai nshaft and countershaft l ocknuts have l eft-
hand threads.
. Always wear safety
glasses.
CHISEL
LOCKNUT
LOCK TA8
5. Remove the speci al tool from the mai nshaft after
removi ng the l ocknuts.
Remove the 1st cl utch and mai nshaft l st gear assem
bl y and mai nshaft l st gear col l ar from the mai nshaft.
Remove the parki ng brake pawl . spri ng and shaft.
Remove t he
par ki ng br ake l ever f r om t he cont r ol
shaft.
Usi ng a uni versal two
j aw pul l er, remove the parki ng
gear . one- way cl ut ch and count er shaf t 1st gear
assemoty.
7.
8.
6.
1 1 .
PULLER
(Commercially availablel
PARKII{G GEAR
' 10.
Remove t he needl e bear i ng and t he count er shaf t
1st gear col l ar from the countershaft.
Remove the ATF cool er l i nes and ATF di psti ck.
14-101
Removal
MOUNTING EOLTS
18 Bol t s
TRANSMISSION
HANGER
MAINSHAFT
SUB. ASSEMBL
MAINSHAFT
SENSOR WASHER
(D16Y7
engi ne)
SPEED SENSOR
TRANSMISSION
HOUSING GASKET
TOROUE CONVERTER
HOUSING
14-102
-
NOTE:
r Cl ean al l par t s t hor oughl y i n sol vent or car bur et or
cl eaner, and dry wi th compressed ai r.
. When r emovi ng t he t r ansmi ssi on housi ng, r epl ace
the fol l owi ng:
-
O-ri ng
-
Transmi ssi on housi ng
gasket
*
Lock washer
Remove the mai nshaft speed sensor from the trans-
mi ssi on housi ng.
Remove the transmi ssi on housi ng mounti ng bol ts
ano nanger.
Al i gn the spri ng
pi n on the control shaft wi th the
transmi ssi on housi ng
groove by turni ng the control
shaft,
2.
' t .
HOUSING PULLER
07HAC
-
PKa010A
l nstal l the speci al tool on the transmi ssi on housi ng,
then remove the housi ng as shown.
CAUTION: Make sure the mainshaft speed sensol
has been removed trom the transmission housing
before removing ihe transmission housing lrom the
torqug converter housing.
7.
Remove the countershaft reverse
gear wi th the col -
l ar and needl e beari ng.
Remove the l ock bol t securi ng the shi ft fork. then
remove the fork wi th the reverse sel ector from the
countershaft.
Remove t he count er shaf t sub- assembl y and t he
mai nshaft sub-assembl y together.
MAINSHAFT
SUB, ASSEMBLY
COUNTERSHAFT
SU8-ASSEMBLY
8. Remove the di fferenti al assembl y from the torque
converter housi ng.
14-103
Removal
6 x 1 . 0 mm
ATF FEEO PIPE
6 x 1 . 0 mm
5 Bol t s
MAIN VALVE
x 1. 0 mm
2 Bol t s
TF STRAINER
x 1. 0 mm
7 Bolts
VALVE BODY
PIN
SERVO SODY
SERVO SEPARATOR
PLATE
6 x 1 . 0 mm
3 Bol t s
1
LOCK-UP VAL
BODY
PI N
6 x 1 . 0 mm
IOCK-UP SEPARATOR
PLATE
REGULATOR
VALVE BODY
BASE
ATF FEED
CONTROL
SHAFT
DOWEL
COOLER RELIEF VALVE
TOROUE
CHECK VALVE
OETENT
ARM SHAFT
DETENT
ARM
BODY
ATF PUMP
DRI VEN
GEAR SHAFT
ATF PUMP
SHAFT
STOP
SECONDARY
SEPARATOR PLATE
MAIN SEPARA
PLATE
ATF FEED PIPE
14-104
SEBVO DETENT
ATF PUMP
ORIVE GEAR
TOROUE CONVERTER
HOUSING
NOTE:
o Cl ean al l parts thoroughl y i n sol vent o. carburetor
cl eaner, and dry wi th compressed ai r.
. When removi ng the val ve body, repl ace the O-ri ng.
1. Remove the ATF feed pi pes from the servo body,
secondary val ve body and mai n val ve body.
2, Remove the ATF strai ner and servo detent base
(two
bolts).
3. Remove the servo body and servo separator pl ate
(seven
boltsl.
Remove the secondary val ve body, shaft stop and
secondary separator
pl ate (three
bol ts).
Remove the l ock-up val ve body and separator
pl ate
{seven bol ts),
Remove the regul ator val ve body {one bol t).
Remove the stator shaft and stop shaft,
Remove the detent spri ng from the detent arm. then
remove the control shaft from the torque converter
housi ng.
Remove the detent arm and detent arm shaft from
the mai n val ve body.
Remove the mai n val ve body
(fi ve
bol ts).
NOTE: Do not l et the ei ght check bal l s fal l outofthe
mai n val ve body when r emovi ng t he mai n val ve
body.
Remove the ATF pump driven gear shaft, then remove
the ATF pump gears.
Remove the mai n separator
pl ate and two dowel
prns.
7.
10.
1 1 .
12.
13. Cl ean t he i nl et openi ng of t he ATF st r ai ner t hor -
oughl y wi th compressed ai r, then check that i t i s i n
good condi ti on, and the i nl et openi ng i s not cl ogged.
I NLET OPENI NG
Test the fi l ter by pouri ng cl ean ATF fl ui d through
t he i nl et openi ng. Repl ace t he ATF st r ai ner i f i t i s
cl ogged or damaged.
NOTE: The ATF strai ner can be reused i f i t i s not
cr oggeo.
14.
14- 105
Valve Caps
Description
Caps wi t h one pr oj ect ed t i p and one f l at end ar e
i nst al l ed wi t h t he f l at end t owar d t he i nsi de of t he
val ve body.
Caps wi t h a proj ect ed t i p on each end are i nst al l ed
wi t h t he smal l er t i D t owar d t he i nsi de oI t he val ve
body. The smal l t i p i s a spr i ng gui de.
Toward outside of valve bodv.
Toward inside of valve bodv.
Caps wi t h one pr oj ect ed t i p and hol l ow end ar e
i nstal l ed wi th the ti p toward the i nsi de of the val ve
body. The ti p i s a spri ng gui de.
Toward outside of valv6 bodv.
Toward i nsi de ot val ve bodv
14- 106
E.
Caps wi th hol l ow ends are i nstal l ed wi th the hol l ow
end away from the i nsi de of the val ve body.
CaDs wi th notched ends are i nstal l ed wi th the notch
toward the i nsi de of the val ve body.
Caps wi th l l at ends and a hol e through the center are
i nst al l ed wi t h t he smal l er hol e t owar d t he i nsi de of
the val ve bodv.
Toward outside of valve bodv.
E f l E
Toward inside of valve bodv.
Caps wi th fl at ends and a groove around the cap are
i nstal l ed wi th the grooved si de toward the outsi de of
the val ve bodv.
Toward outside ol valve body.
GROOVE
./
---'gJfr
\:7
Sectional view.
Toward inside ol valve body.
Valve Body
2.
3.
Repai r
NOTE: Thi s repai r i s onl y necessary i f one or more ot
the val ves i n a val ve body do not sl i de smoothl y i n thei r
bores. You may use thi s procedure to free the val ves i n
the val ve bodi es.
1. Soak a sheet of #600 abr asi ve paper i n ATF f or
about 30 mi nutes.
Car ef ul l y t ap t he val ve body so t he st i cki ng val ve
drops out of i ts bore.
CAUTI ON: l t may be necessar y t o use a smal l
screwdriver to pry the valve free. Be carelul not to
scratch the bore with the screwdriver.
Insoect the val ve for anv scuff marks. Use the ATF-
soaked #600 paper to pol i sh off any burrs that are
on the val ve, then wash the val ve i n sol vent and dry
i t wi th compressed ai r.
Rol l up hal f a sheet of ATF-soaked paper, and i nsen
i t i n the val ve bore of the sti cki ng val ve.
Twi st the paper sl i ghtl y, so that i t unrol l s and fi ts the
bor e t i ght l y, t hen pol i sh t he bor e by t wi st i ng t he
paper as you push i t i n and out.
CAUTION: The val ve body i s al umi num and doesn' t
require much polishing to remove any burrs.
ATF-so6ked
#0OO abrasivo
papet
5.
6.
Remove the #600 paper and thoroughl y wash the
enti re val ve body i n sol vent, then dry i t wi th com-
pressed arr.
Coat the val ve wi th ATF, then drop i t i nto i ts bore.
It shoul d drop to the bottom of the bore under i ts
own wei ght. l f not, repeat step 4, then retest.
VALVE EODY
7. Remove the val ve, then thoroughl y cl ean i t and the
val ve body wi t h sol vent . Dr y al l par t s wi t h com
pressed ai r, then reassembl e usi ng ATF as a l ubri -
cant.
ffiFS'
14-107
Val ve
Assembly
NOTE:
Coat al l parts wi th ATF before assembl y.
. I nst al l t he val ve, val ve spr i ng and cap i n t he val ve
body and secure wi th the rol l er.
ROLLER
VALVE BODY
VALVE BODY
VALVE
SPRI NG
14-108
ROLLER
. Set the spri ng i n the val ve and
body. Push t he spr i ng i n wi t h
i nstal l the spri ng seat.
i nst al l i t i n t he val ve
a scr ewdr i ver , t hen
SPRING SEAT
SPRING
VALVE BODY
Instal l the val ve, spri ng and cap i n the val ve body.
Push t he cap, t hen i nst al l t he cl i p.
\
CAP
ATF Pump
lnspection
' L
l nstal l the ATF pump gears and ATF pump dri ven
gear shaft i n the mai n val ve body.
NOTE:
. Lubri cate al l parts wi th ATF duri ng i nspecti on.
. I nst al l t he ATF pump dr i ver r
gear wi t h i t s gr ooved
and chamfered si de faci ng up as shown.
MAIN VALVE BODY
ATF PUMP DRI VEN GEAR
Grooved and chamf ered s ci e
2. Measure the si de cl earance of the ATF
pump dri ve
and dri ven
gears.
ATF Pump Geais Side
(Radiall clearance:
Standard
(New):
ATF Pump Drive Gear
0.105
-
0.1325 mm {0.00/t
-
0.005 in)
ATF Pump Dri ven Gear
0.035
-
0.0625 mm
(0.0014 -
0.0025 i n)
MAIN VALVE EODY
ATF PUMP
DRIVE GEAB
I nspect t eet h f or wear and damage-
3. Remove the ATF
pump
dri ven
gear shaft. Measure
the thrust cl earance of the ATF pump dri ven
gear-
to-val ve body.
ATF Pump Drive/D ven Goar Thrust lAxial)
Clearance:
Standard
(Newl:
0.03
-
0.05 mm 10.001
-
0.002 inl
Service Limit: 0.07 mm 10.003
in)
I nspect t eet h f or wear and damage.
ATF PUMP
14- 109
Mai n Val ve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cl ean al l parts
thoroughl y i n sol vent or carburetor cl eaner. and dry wi th compressed ai r. Bl ow out al l passages.
. Repl ace the val ve body as an assembl y i f any pans are worn or damaged.
. Check al l val ves for free movement. l f any fai l to sl i de freel y, see Val ve Body Repai r on page 14-,| 07.
. Coat al l pans wi th ATF duri ng assembl y.
CAUTION: Do not uss a magnet to remove the check balls; it may magnetize the balls.
VALVE CAP CLIP
2ND ORIFICE CONTROL VALVE
CHECK BALLS, 8
1ST ACCUMULATOf, CHOKE
MOOULATOR
VALVE
du:
RELIEF VALVE
VALVE
MAIN VALVE BODY
I nspect f or wear, scrat ches
and scori ng.
SERVO CONTROL VAL
14- 110
1-2 SHIFT VALVE
{*4
VALVE CAP
CHECK BALL
CHECK BALLS
CHCK BAI.LS
U ni t : mm
( i n)
SPRING SPECIFICATIONS
No. Spri ngs
Standard
(Newl
Wi re Di a. o.D. Free Length No. of Coils
o
\9/
@
Rel i ef val ve spri ng
Modul ator val ve sprang
CPB val ve spri ng
' 1-2
shi ft val ve spri ng
2nd ori fi ce control val ve spri ng
Servo control val ve spri ng
1. 1
( 0. 043)
1. 4
( 0. 055)
0.9
(0.035)
0.9
(0.035)
0.7
(0.028)
1.0
(0.039)
8.6
(0.342)
9.4 {0.374}
8. 1
( 0. 322)
7.6
(0.302)
6.6
(0.262)
8.1
(0.322)
37. t {
1. 461)
35. 0
( 1. 378)
47.2 {1.858)
41. 3
( 1, 626)
34.8
(1.370)
52. 1
( 2. 051)
13. 4
10. 9
18. 3
16. 3
22. 0
20.8
14- 111
Disassembly/l nspection/Reassembly
NOTE:
o Cl ean al l pans thoroughl y i n sol vent or carburetor cl eaner, and drywi th comp.essed ai r. Bl ow outal l passages.
. Repl ace the secondary val ve body ki t, P/N 27700
-
P4R
-
305
(The
secondary val ve body ki t i ncl udes the l i near sol enoi d
assembl y) i f any parts are worn or damaged.
. Checkal l val ves for free movement. l f anyfai l to sl i de freel y, see Val ve Body Repai ron page' 14-107.
. Coat al l parts wi th ATF duri ng assembl y.
. The CPC val ve i s i nstal l ed i n the secondary val ve body, hel d i n pl ace by the l ock bol t.
2.3 SHIFT
VAI.VE
3.4 SHIFT VALVE
LOCK BOLT
CAUTION: Oo not move.
SECONOARY VALVE BODY
I nspect f or wear, scrat ches and
scof i ng.
3-4 ORIFICE CONTROL VAL
VALVE
14- 112
ROLLER
Uni t : mm
( i n)
No. Springs
Standald lNewl
Wi re Di a. o.D. Free Lenglh No. oI Coils
o
6,
@
3-4 shi ft val ve spri ng
2-3 shi ft val ve spri ng
4th exhaust val ve spri ng
3-4 ori fi ce control val ve spri ng
0.9
(0.035)
0.9 {0.035)
0.9
(0.035)
0.7
(0.028)
7.6
(0.302)
7.6
(0.302)
6.1
(0.242)
6.6 10.2621
51 .0
12.2441
51 .0
\2.244)
36. 4
( 1. 433)
37. 5
( 1. 476)
26.8
26.8
19. 5
24.6
Regulator Valve Body
NOTE:
. Cl ean al l
parts thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r. Bl ow out al l passages.
. Repl ace the val ve body as an assembl y i f any parts are worn or damaged
. check al l val ves for free movement. It any {ai l to sl i de freel y, see val ve Body Repai r on page 14-107.
1. Hol d the regul ator spri ng cap i n pl ace whi l e removi ng the stop bol t. Once the stop bol t i s removed, rel ease the sprang
cap srowry.
CAUTION: Thc regulator spring cap can
pop out when the stop bolt is removed'
2. Reassembl y i s the reverse order of the di sassembl y
procedure
NOTE:
. Al i gn the hol e i n the regul ator spri ng cap wi th the hol e i n the val ve body, then press the spri ng cap i nto the val ve
body, and ti ghten the stoP bol t.
STOP BOLT
6 x 1 . Omm
12 N. m
( 1. 2
REGULATOR VALVE BODY
Inspect for wear, scratches
and scort ng,
REGULATOR VALVE
Uni t : mm
( i n)
No. Spri ngs
Standard
(New)
Wi re Di a. o.D. Free Length No. of Coils
o
@
Regul ator val ve spri ng A
Regul ator val ve spri ng B
Stator reacti on spri ng
Cool er rel i ef val ve spri ng
Torque converter check val ve spri ng
Lock-up control val ve spri ng
1. 8
( 0. 071)
1. 8
( 0. 071)
4. 5
( 0. 177)
1. 0
( 0. 039)
1.0
(0.039)
0.7 {0.028)
14.7
(0.584)
9. 6
( 0. 381)
3s. 4
( 1. 407)
8.4
(0.334)
8.4 {0.334)
6.6
(0.262)
87.8
(3.457)
44.0 l'1.7321
30. 3
( 1. 193)
33. 8 {
1. 331)
33. 8
( 1. 331)
38.0
(1.496)
1' I.0
1. 9
8. 2
8. 2
14. 1
14- 113
Servo Body
NOTE:
.
Cl ean al l parts thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r. Bl ow out al l passages.
. Repl ace the val ve body as an assembl y i f any parts are worn or damageo.
. Repl ace the O ri ngs.
SERVO BOOY
l nspect f or wear, scrat ches and scori ng.
"----.-'g
O-BING
Bepl ace.
1ST ACCUMULATOR PISTON
3RD ACCUMULATOR PISTON
4TH ACCUMULATOB PISTON
SNAP RINGS
Uni t : mm
( i n)
2ND AccuMULAroR
==p
g;li:':-Y
-^'":::#,
No. Spri ngs
Standard
(New)
Wi re Di a. o.D. Free Length No. of Coi l s
o
A)
lJl
@
o
@
1st accumul ator spri ng
4th accumul ato. spri ng A
4th accumul ator spri ng B
3rd accumul ator spri ng A
3rd accumul ator spri ng B
2nd accumul ator spri ng C
2nd accumul ator spri ng A
2nd accumul ator spri ng B
2.1
(0.083)
2. 6
( 0. 102)
2. 3
( 0. 091)
2. 8
( 0. 110)
2.2
(0.087)
2.2
(0.087)
2.4
(0.094)
1. 6
( 0. 063)
16.0 {0.636)
17.0 (0.676)
10.2 {0.402)
17.5
(0.695)
31. 0 { 1. 220)
14. 5
( 0. 576)
29. 0
( 1. 152)
9.0
(0.358)
89.1
(3.508)
87.0
(3.425)
51. 6
( 2. 031)
89.3
(3.516)
35.1
(1.382)
68.0
(2.677)
39.0
(1.535)
20.7
(0.815)
16.2
14.2
13. 8
15. 6
2.4
1 ? O
2.9
14- 114
Lock-up Valve Body
Di sassembl y/l nspecti on/Reassembl y
NOTE:
. Cl ean al l
parts thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r, Bl ow out al l
passages.
. Repl ace the val ve body as an assembl y i J any parts are worn or damaged.
. Check al l val ves for free movement. l f any fai l to sl i de freei y, see Val ve Body Repai r on page 14-107.
. Coat al l pans wi th ATF duri ng assembl y.
LOCK.UP SHIFT VALVE
LOCK-UP VALVE BODY
ano sconng,
VALVE CAP
\uo.*.or.,-,,
LOCK.UP TIMING VAL
Uni t : mm { i n)
No. Spri ngs
Standard
(New)
Wi re Di a. o. D. Free Length No. of Coils
o
Lock-up shi ft val ve spri ng
Lock up ti mi ng val ve spri ng
0.9
(0.035)
0.9
(0.035)
7.6
(0.302)
8. 1 { 0. 319)
73.1 |'2.902)
80.1 t3.1771
32.0
45.8
14- 115
t-
Mainshaft
NOTE:
. Lubri cate al l
parts
wi th ATF duri ng reassembl y.
. I nspect t het hr ust needl ebear i ngsandt heneedl ebear i ngsf or gal l i ngandr oughmovement .
. Before i nstal l i ng the O-ri ngs. wrap the shaft spl i nes wi th tape to prevent damagi ng the O-ri ngs.
. Locknut has l eft-hand threads.
LOCKNUT
(FLANGE
NUTI
21 | 1 . 25 nf i
78 N. m 18. 0 kgl . m, 58 l bl . f t l
Repl ace.
Lel t -hand t hreads
SNAP RI NG CONICAL SPRING WASHER
Repl ace.
l ST CLUTCH
ASSEMBLY
THRUST WASHEN
THRUST NEDLE
BEARI NG
4TH GEAR
NEEDI-E BEARINGS
THRUST NEEDLE
EEARI NG
4TH GEAR COLLAR
2ND/4TH CLUTCH
ASSEMBLY
O.BINGS
Repl ace.
THBUST WASHER, 36.5 r 55 mm
Sel ect i ve part .
THRUST NEEDLE
BEARI NG
2ND GEAR
O.FINGS
Repl ace.
THRUST WASHER
THRUST NEEDLE
BEARING
MAI NSHAFT
Check spl i nes t or excessi ve
wear and damage.
Check beari ng surf ace f or scori ng,
scrat ches and excessi ve wear.
BEANING
,I
ST GEAR
TRANSMISSION
HOUSING EEARING
SEALI NG RI NGS,
35 mm
I nsl al l t he seal i ng ri ng
mat l ng f aces as shown,
BEARI NG
RI NG,
BEARING
l t i
29 mm
NEEDLE BEARING
SET RING
L.
14- 116
NEEDLE
Inspection
. Cl earance Measurement
NOTE: Lubri cate al l
parts wi th ATF duri ng assembl y.
1. Remove the mai nshaft beari ng from the transmi s-
si on housi ng
(see page l 4-142).
2. Assembl e the parts bel ow on the mai nshaft.
NOTE: Do not assembl e the O-ri ngs duri ng i nspec-
ti on.
LOCKNUT
CONI CAL SPRI NG WASHER
SNAP RI NG
,I
ST CLUTCH ASSEMELY
THRUST WASHEB
1ST GEAB COLLAR
TRANSMISSION
HOUSI NG BEARI NG
THRUST WASHER
4TH GEAR COLLAR
2ND/4TH CLUTCH
ASSEMBLY
THRUST WASHER
36. 5 x 55 mm
Selective
part.
TI{RUST NEEDLE
BEARING
2ND GEAR
NEEOLE BEARI NG
THRUST t {EEDLE
BEARING
MAINSHAFT
3. Torque the mai nshaft l ocknut to 29 N' m
(3.0
kgf' m,
22 lbf.ft).
NOTE: Mai nshaft l ocknut has l eft-hand threads.
Hol d 2nd gear agai nst the 2nd cl utch, then measure
the cl earance between 2nd gear and 3rd gear wi th a
feel er gauge.
NOTE: Take measurements i n at l east three pl aces,
and use the average as the actual cl earance.
STANDARD: 0.05
-
0.13 mm {0.002
-
0.005 in)
(cont' d)
14- 117
Mainshaft
Inspection
(cont'd)
5. l f t he cl ear ance i s out of t ol er ance, r emove t he
thrust washer and measure the thi ckness.
6. Sel ect and i nstal l a new washer. then recheck.
THRUST WASHER 36.5 x 55 mm
7. Af t er r epl aci ng t he t hr ust washer , make sur e t he
cl earance i s wi thi n tol erance.
No. Part Number Thickness
1 9044' t
-
P4P
-
010 4. 00 mm
( 0. 157
i n)
2 90442-P4P-010 4. 05 mm ( 0. 159
i n)
90443- P4P- 010 4. 10 mm
( 0. 161
i n)
4 90444- P4P- 010 4. 15 mm
( 0. 163
i n)
5 90445- P4P- 010 4. 20 mm
{ 0. 165 i n)
6 90446
-
P4P, 010 4. 25 mm
( 0. 167
i n)
1 90447
-P4P-010
4. 30 mm ( 0. 169
i n)
8 90448- P4P- 010 4. 35 mm
( 0. 171
i n)
90449- P4P- 010 4. 40 mm
( 0. 173
i n)
10 90450- P4P- 000 4. 45 mm
( 0. 175
i n)
14- 118
Gountershaft
NOTE;
. Lubricate all parts with ATF before reassembly.
. I nspect t het hr ust needl ebear i ngsandt heneedl ebear i ngsf or gal l i ngandr oughmovement .
. Before i nstal l i ng the O-ri ngs, wrap the shai t spl i nes wi th tape to prevent damagi ng the O-ri ngs.
. Locknut has l eft-hand threads.
LOCKNUT
(FLANGE
NUTI
23 x 1. 25 mm
103 N. m
{10. 5 kgf . m, 75. 9 l bI . f t )
Repl ace.
Left-hand threads
CONI CAL SPRI NG
WASHER
Repl ace-
REVERSE GEAR
NEEDLE BEARI NG
SELECTOR
HUB
4TH GEAR
NEEDLE BEARI NG
DISTANCE COLLAR,
28 mm
Sel ect i ve
part .
BEARI NG
ST GEAR COLLAR
COUNTERSHAFT
Check spl i nes {or excessi ve
wear and damage,
2ND GEAR
THBUST NEEDLE
EEARING
3RD GEAR
NEEDLE BEARI NG
3RD GEAR COLLAR
Check beari ng surf ace f or scori ng,
scrat ches and excessave wear.
THRUST NEEOLE BEARI NG
SPLINED WASI.IEB
3RD CLUTCH ASSEMBLY
Repl ace.
14- 119
Gountershaft
Disassembly/Reassembly
1. Usi ng a hydraul i c
press, press out the countershaft
whi l e supporti ng 4th
gear.
NOTE: Place an attachment between the press and
the countershaft to prevent damage to the shaft.
CAUTION: Do not allow the countershaft to fall and
hit the ground when
Pressd
clear.
14-120
2. Assembl e the
parts on the countershaft as shown
Del ow.
NOTE:
. Lubri cate al l
pans
wi th ATF duri ng assembl y.
. Before installing the O-rings, wrap the shaft splines
with tape to
prevent damaging the O-rings.
4TH GEAR
NEEOLE BEARING
DISTANCE COLLAR, 28 mm
Selective
part.
2ND GEAR
3RD GEAR
NEEDLE BARING
3RD GEAR COI.LAR
TI{RUST NEEDIE AEABING
SPLINED WASHER
3RD CLUTCH ASSEMBLY
3. l nstal l the reverse sel ector hub on the countershaft
sub-assembl y, and then
press
the reverse sel ector
hub usi ng the speci al tool and a
press as shown.
DRI VER 40 mm l . D.
07746
-OO30tOO
lnspection
a Cl earance Measurement
NOTE: Lubri cate al l parts wi th ATF duri ng assembl y.
' L
Remove the countershaft beari ng trom the trans-
mi ssi on housi ng
(see page 14 142).
2. Instal l the parts bel ow on the countershaft usi ng the
speci al tool and a press as descri bed on thi s page.
NOTE: Do not assembl e the O-ri ngs duri ng i nspec
t r on.
REVERSE SELECTOR
HUB
4TH GEAR
NEEDLE BEARI NG
DISTANCE COLLAR, 28 mm
Sel ect i ve
part .
2ND GEAR
THRUST NEEDLE BEARI NG
3RD GEAR
NEEDLE BEARI NG
3RD GEAR COLLAR
THRUST NEEDLE BEARI NG
SPLI NED WASHER
3RD CLUTCH ASSEMBLY
{cont ' d)
14-121
Gountershaft
Inspection
{cont'd)
3. I nst al l t he par t s bel ow on t he count er shaf t sub,
assembl y, t hen t or que t he l ocknut t o 29 N. m ( 3. 0
kgf.m,22 bl f.ft).
NOTE: Countershaft l ocknut has l eft-hand threads.
Lef t -hand t hreads
CONI CAL SPRI NG
WASHER
PARKI NG GEAR/ ONE-WAY
CLUTCH/ 1ST GEAR
ASSEMELY
NEEDLE EEARI NG
1ST GEAE COLLAR
BEARI NG
REVERSE GEAR
COLLAR
COUNTERSHAFT
SUB-ASSEMELY
14-122
\
4. Measur e t he cl ear ance bet ween t he 2nd gear and
the 28 mm di stance col l ar wi th a feel er gauge.
STANDARD: 0.10
-
0.18 mm
(0.004 -
0.007 i nl
\
l f the cl earance i s out of tol erance, remove the 28
mm di stance col l ar and measure the wi dth.
Sel ec t and i ns t al l a new di s t anc e c ol l ar , t hen
recnecK.
DISTANCE COLLAR. 28 mm
5.
6.
1. Af t er sel ect i ng a new di st ance col l ar , r echeck t he
cl ear ance and make sur e i t i s wi t hi n t ol er ance.
OI STANCE COLLAR. 28 mm
No. Part Number wi dth
,]
90503- PCg- 000 39. 00 mm
( 1. 535
i n)
2 90504
-
PCg
,
000 39. 10 mm
( 1. 539
i n)
3 90505
-
PCg 000 39. 20 mm ( 1. 543
i n)
4 90507- PCg- 000 39. 30 mm
( 1. 547
i n)
5 90508- PCg- 000 39. 05 mm
( 1. 537
i nI
6 90509- PCg, 000 39. 15 mm
( 1. 541
i n)
7 90510- PCg- 000 39. 25 mm i 1. 545 i n)
8 90511
-
PCg 000 38. 90 mm
( 1. 531
I n )
9 90512- PCg- 000 38. 95 mm
( 1. 533
i n)
One-way Clutch
Disassembly/l nspection/Reassembly
1. Separ at e count er shaf t 1st gear f r om t he par ki ng
gear by t ur ni ng t he par ki ng gear i n t he di r ect i on
shown.
PARKI NG GEAR
2. Remove the one-way cl utch by
pryi ng i t up wi th the
end of a screwdri ver.
COUNTERSHAFT 1ST GEAR
ONE.WAY CLUTCH
ONE.WAY CLUTCH
NOTE: Instal l i n thi s di recti on.
COUNTERSHAFT
,I
ST GEAR
COUNTERSHAFT lST GEAR
SCREWDRIVER
14-123
3. Inspect the parts as fol l owsl
PARKING GEAR
I nspect t he parki ng gear
f or wear and scor i ng,
ONE-WAY CLUTCH
I nspect t he one-way
cl ut ch f or damage and
f aul t V movement .
.I
ST GEAR
I nspect count ershal l ' l
f or wear and scori ng,
4. After the
parts
are assembl ed, hol d countershaft 1st
gear and t ur n t he par k i ng gear i n t he di r ec t i on
shown to be sure
j t
turns freel y, Al so make sure the
parki ng gear does not turn i n the opposi te di recti on.
COUNTERSHAFT l ST GEAR
Cl utch
lllustrated Index
(A4RA,
B4RA Transmissionl
3RD CLUTCH
O- RI NGS
Repl ace.
CLUTCH
pt STON
CLUTCH
DRUM
DISC SPRING
CLUTCH PLATES
St andard t hi ckness:
2. 0 mm ( 0. 079
i n)
CLUTCH END
PLATE
\
SPRING RETAINER
RETURN SPNING
ISC SPRING D
I
!,L"urlcf
o-"'"cs
I
tleptace.
CLUTCH DRUM
SNAP RING
l ST CLUTCH
CLUTCH END
TE
cLurcs orscs
' 1. 94
mm {0. 076 i n)
CLUTCH PLATES
1. 6 mm 10. 063 i n)
SNAP RING
CHECK VALVE
14-124
\
{
2ND/4TH CLUTCH
SNAP
SPRING RETAINEB
RETURN SPRING
DI SC SPRI NG
O. RI NGS
Repl ace.
4TH CLUTCH DRUM
CLUTCH PLATES
St andardt hi cknessr
O-RI NGS
2. 0 mm {0. 079 i n)
Rept ace.
CLUTCH END PLA
SNAP RI NG
CLUTCH PLATES
CLUTCH PISTON
SNAP RING
14-125
Cl utch
(M4RA
Transmi ssi onl
3RD CLUTCH
CLUTCH
ORUM
CLUTCH PISTON
OISC SPRING
1ST CLUTCH
\
r l l
14-126
CLUTCH END
PLATE
SNAP RING
CLUTCH END
SNAP RING
CHECK VALVE
g
SNAP RING
2ND/4TH- CLUTCH
VALVE
CLUTCH PLATES
Standard thickness:
2. 0 mm
(0. 079
i n)
2ND CI-UTCH
DNUM
CLUTCH PISTON
\---
\ - - -
SNAP RING
RETURN SPRING
O-RINGS
Repl ace.
SNAP RING
14-127
Clutch
Disassembly
1. Remove the snap ri ng, then remove the cl utch end
pl ate.
cl utch di scs and ol ates.
SCREWORI VER
SNAP RI NG
2. Remove the di sc spri ng.
NOTE: Except 2nd cl utch.
t
CLUTCH DRUM
l i
l l
;=
_=:_-.-----
OI SC SPRI NG
14-128
g -
3. Instal l the speci al tool s as shown.
CLUTCH
COMPRESSOR
BOLT ASSEMBLY
07GAE
-
PG40200
ol
OTGAE
-
PGIO2OA
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
ol
07HAE
-
P150100
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
07HAE
-
P150100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
07GAE
-
PG40200
OI
OTGAE
_
PG4O2OA
CAUTION: It ei ther end of the speci al tool i ssetoveran
area of the spring retainer which is unsupported by the
return spring, the retainer may be damaged. Be sure the
speci al tool i s adi usted to have tul l contact wi th the
spring retainer.
SPECIAL TOOL
SPRING RETAINER
4. Compress the return spri ng.
5. Remove the snap ri ng. Then remove the speci al tool s,
spri ng retai ner and return spri ng.
6. Wrap a shop rag around the cl utch drum. and appl y
ai r pressure to the ATF passage to remove the pi s-
t on.
Pl ace a f i nger t i p on t he ot her end whi l e appl yi ng
ar r pr essur e.
OSHA-APPROVED
PI STON
14-129
Glutch
Reassembl y
NOTE:
. Cl ean al l parts thoroughl y i n sol vent or carburetor
cl eaner, and dry them wi th compressed aj r.
. Lubri cate al l parts wi th ATF before reassembl y.
1. Inspect the check val ve; i f i t' s l oose, repl ace the pi s-
ton,
CHECK VALVE
PISTON
2. I nst al l new O-ri ngs on t he cl ut ch pi st on.
O-RI NGS
PISTON
14-130
\
3. Instal l the pi ston i n the cl utch drum. Appl y pressure
and rotate to ensure proper
seati ng.
NOTE: Lubri cate the pi ston O-ri ng wi th ATF before
i nstal l i ng.
CAUTION: Do not pinch th8 O.ring by installing the
piston with too much force.
CLUTCH DRUM
I nst al l t he r et ur n spr i ng and spr i ng r et ai ner , and
posi ti on
the snap ri ng on the retai ner.
SNAP RI NG
SPRING RETAINR
RETURN SPRING
CLUTCH DRUM
5. l nstal l the soeci al tool s as shown.
CLUTCH SPRI NG
COMPRESSOB
ATTACHMENT
07LAE
-
PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
ot
07HAE
-
PL50'100
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
oTLAE-PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
07HAE
-
PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
07GAE
-
PG40200
ot
OTGAE
-
PG4O2OA
SPRING
OTGAE
-
PG4O2OA
CAUTION: l l ei ther end ot the speci al tool i s set
over an ar6a of the spring retainer which is unsup-
ported by the return spri ng, the retai ner may be
damaged. Be sure the speci al tool i s adi usted to
have tull contact with the spring retainsr.
SPECIAL TOOL
(cont' d)
Do not s6t hore.
14-131
Clutch
Reassembly
(cont'd)
7. l nstal l the snap ri ng.
Instal l the di sc spri ng.
NOTE: I ns t al l t he di s c s pr i ng i n t he di r ec t i on
shown, except 2nd cl utch.
14-132
-
8.
9.
!tf
SNAP RI NG
DI SC SPRI NG
' 10.
Soak the cl utch di scs thoroughl y i n ATF for a mi ni -
mum of 30 mi nutes.
stani ng wi th a cl utch pl ate, al ternatel y i nstal l the
cl utch pl ates and di scs. Instal l the cl utch end pl ate
wi th fl at si de toward the di sc.
NOTE: Before i nstal l i ng the pl ates and di scs, make
sure the i nsi de of the cl utch drum i s free of di n or
other forei gn matter.
CLUTCH EI{D PLATE
I nst al l i n t hi s di rect i on.
12. Instal l the snap ri ng.
SCREWDRIVER
SNAP RIIIG
1 1 .
13, Measure the cl earance between the cl utch end pl ate
and top di sc wi th a di al i ndi cator. Zero the di al i ndi -
cator with the clutch end plate lowered and lift it up
to the snap ri ng. The di stance that the cl utch end
ol ate moves i s the cl earance between the cl utch end
pl ate and top di sc,
Clutch End Plate-to-Top Disc Clearanco:
IAL INDICATOR D
tl
CLUTCH END
PLATE
Cl earance
CLUTCH DI SC
14. l f t he cl ear ance i s not wi t hi n t he ser vi ce l i mi t s,
sel ect a new cl utch end pl ate from the fol l owi ng
tabl e.
NOTE; l f the thi ckesi cl utch end
pl ate
i s i nstal l ed,
but the cl earance i s sti l l over the standard, repl ace
the cl utch di scs and cl utch DIates.
Clutch Sowico Limit
1st
2nd
3rd
4th
0.65
-
0.85 mm
(0.026 -
0.033 i n)
0.65
-
0.85 mm
(0.026 -
0.033 i n)
0.40
-
0.60 mm
(0.016 -
0.024 i n)
0.40
-
0.60 mm
(0.016 -
0.024 i nl
CLUTCH END PLATE
14-133
Plste No. Part Numbe. Thicknoss
1
2
6
7
8
I
22551
-
P4R
-
003
22552
-
P4R,003
22553- P4R- 003
22554- P4R- 003
22555- P4R- 003
22555- P4R- 003
22557
-P4R-OO3
22558- P4R- 003
22559- P4R- 003
2.1 mm
(0.083
i n
2,2 mm
(0.087
i n
2. 3 mm
( 0. 091
i n
2, 4 mm { 0. 094 i n
2.5 mm
(0.098
i n
2. 6 mm
( 0. 102
i n
2. 7 mm
( 0. 106 i n
2. 8 mm
( 0. 110
i n
2. 9 mm
( 0. 114
i n
CLUTCH END PLATE
A,[RA, B4RA Transmission:
M4RA Transmission:
15. After repl aci ng the cl utch end
pl ate, make sure that
the cl earance i s wi thi n tol erance.
Plaie No. Part Number Thicknoss
1
2
E
6
7
8
9
10
1 1
1 2
' 13
1 4
1 5
1 6
17
1 8
22551
-
PCg
-
000
22552- PCg- 000
22553- PCg- 000
22554- PCg- 000
225ss- PCg- 000
22556- PCg- 000
22557- PCg- 000
22558- PCg- 000
22559- PCg- 000
22s60- PCg- 000
22561
-
PCg
-
000
22s62- PCg- 000
22563- PCg- 000
22574-P4V
-
003
22561
-
P4V
-
003
22562
-
P4V
-
O03
22563- P4V- 003
22564- P4V- 003
2.4 mm
(0.094
i n
2.5 mm {0.098
i n
2. 6 mm
( 0. 102
i n
2. 7 mm { 0. 106I n
2. 8 mm
( 0. 110
i n
2. 9 mm
( 0. ' 114
i n
3. 0 mm
( 0. ' 118
i n
3. 1 mm
( 0.
122 i n
3. 2 mm
( 0. 126
i n
3. 3 mm
( 0. 130
i n
2.' l mm
(0.082
i n
2.2 mm
(0.086
i n
2.3 mm
(0.090
i n
3. 4 mm
( 0. 134
i n
3. 5 mm
( 0. 138
i n
3. 6 mm
( 0. 142 i n
3. 7 mm
( 0. 146
i n
3.8 mm
(0.150
i n
Differential
lllustrated lndex
BOLT
10 x 1. 0 mm
l ol N. m
(10. 3
kgt . h, 74. 5 l bf . f t l
Lett-hand threads
FIiIIAL DRIVEN GEAR
I nspect f or excessi ve wear.
I nst al l i n t hi s dl rect i on.
SET RING, 80 mm
l nspect l or t aul t y movement .
DIFFERENTIAL CARRIER
I nsoect l or cracks.
5 x 1 0 mm
SPEEDOMETER DRI VE
GEAR
SNAP RI NG
I nst al l i n t hi s di recri on.
BALL EEARING
I nspect f or f aul t y movement .
14-134
\
Backlash Inspection
1. Pl ace di fferenti al assembl y on
both axl es.
V-bl ocks and i nstal l
Check backl ash of both
pi ni on gears.
Si andard
(Ncwl :
0.05
-
0.15 mm
(0
002
-
0.006 i n)
l f backl ash i s out of tol erance, repl ace the di fferen-
ti al carri er.
Bearing Replacement
NOTE: Check beari ngs for wear and rough rotati on.
beari ngs are OK. removal i s not necessary.
1. Remove beari ngs usi ng a beari ng pul l er.
BEARING PULLER
(Commerci al l y avai l abl el
2. Instal l new bea.i ngs usi ng the speci al tool as shown.
DRI VER 40 mm l . O.
07746-OO30100
14-135
Differential
Differential Carrier Replacement
1. Remove the fi nal dri ven gear from the di fferenti al
carner.
NOTE: The fi nal dri ven gear
bol ts have l eft-hand
threads.
2. Pry the snap ri ng off di fferenti al carri er, then remove
the speedometer dri ve gear and 5 x 10 mm rol l er.
SNAP RI NG
3. Instal l the 5 x 10 mm rol l er i n the di fferenti al carri er.
SPEEDOMETER
DRIVE GEAR
I nst al l i n t hi s
di rect i on.
Frlr
tril
4. Instal l the speedometer dri ve gear wi th i ts cham-
fered si de faci ng the carri er. Al i gn the cutout on the
bore of the speedometer dri ve gear wi th the 5 x l O
mm r o er ,
14- 136
Al i gn the hooked end of the snap ri ng wi th the pi n-
i on shaft as shown, then i nstal l the snap ri ng i n the
di fferenti al carri er groove.
Hooked end
PINION SHAFT
SPBING
Instal l the fi nal dri ven gear, then ti ghten the bol ts to
the speci fi ed torque,
TOROUE: 101 N.m 110.3 kgf.m, 74.5 tbf.ft)
NOTE: The fi nal d.i ven gear
bol ts have l eft-hand
threads.
BOITS
10 x t . 0 mm
1Oi N' m 11O. 3 kgl . m,
74.5 tbf.ttl
Left-hand threads
FINAL ORIVEN
GEAR
I nst al l i n t hi s
di rect i on.
OIFFERENTIAL
CARRI ER
7. I nst al l a new bal l beari ng
(see
page' 14-' l 3S).
SNAP RI NG
I nst al l i n t hi s di recl i on.
Oil Seal Removal
1, Remove the di fferenti al assembl v.
2, Remove the oi l seal from the transmi ssi on housi ng,
OIL SEAL
Repl ace.
oi l seal f r om t he t or que conver t er Remove t he
housi ng.
TOROUE CONVERTER
HOUSING
Oil Seal Installation/Side Clearance
1. Instal l a 2.50 mm
(0.098
i n) set ri ng,80 mm i n trans-
mi ssi on housi ng.
NOTE: Do not i nstal l the oi l seal vet.
RI NG, 80 mm
TRANSMISSION
HOUSING
Instal l the di fferenti al assembl y i nto the torque con-
verter housi ng usi ng the speci al tool as shown.
TOROUE
CONVERTER
HOUSING
I nst al l t he t r ansmi ssi on housi ng
bol ts
(see page 14-146 and 14-147).
and t i ghr en t he
(cont ' d)
14-137
Differential
Oi l Seal Instal l ati on/Si de Cl earance
(cont' d)
4. Tap on the transmi ssi on housi ng si de of the di ffer-
enti al assembl v wi th the soeci al tool to seat the di f-
ferenti al assembl y i n the torque converter housi ng.
DRI VER 40 mm LD.
- 0030100
TRANSMI SSI ON
HOUSI NG
t i {
t
14- 138
\
5. Measure the cl earance between the 80 mm set ri ng
and outer race of the bal l beari ng i n the transmi s-
si on housi ng.
STANDARD: 0
-
0.15 mm
(0 -
0.006 i nl
l f the cl earance i s more than the standard, sel ect a
new set ri ng from the tabl e, and i nsta :
SET RING, 80 mm
NOTE: l f the cl earance measured i n step 5 i s stan-
dard, i t i s not necessary to perform
steps 7 and 8.
Remove the transmi ssi on housi ng.
Repl ace the 2.50 mm
(0.098
i n) 80 mm set ri ng wj th
the one of the correct thi ckness sel ected i n step 6.
6.
7.
8.
\
90414 689
-
000
90415
-
689 000
90416- 689- 000
90417 689
-
000
90418- 689- 000
90419
-
PH8 000
2.50 mm
(0.098
2. 60 mm
( 0. 102
2. 70 mm
( 0. 106
2. 80 mm
( 0. ' 110
2. 90 mm
( 0. ' 114
3. 00 mm
( 0. ' 118
n )
n )
n )
n )
n )
n l
9. l nstal l the new oi l seal fl ush wi th the transmi ssi on
housi ng usi ng the speci al tool s as shown.
ORIVER
0?7/tg
-
00'10000
PILOT,
2 6 x 3 0 mm
07JAD
-
PH80200
DRIVER ATTACHMENT, 68 mm
07947
-
6110501
10. l nst al l t he new oi l seal f l ush wi t h t he t or que con-
verter housi ng usi ng the speci al tool s as shown.
DRIVER
07749
-
0010000
14-139
Torque Gonverter Housi ng Beari ngs
Mai nshaft Beari ng/Oi l Seal Repl acement
1. Remove t he mai nshat t bear i ng and oi l seal usi ng
the speci al tool s as shown.
3/ 8' - I 6 SLI DE HAMMER
( Commer ci al l y
avai l abl e)
ADJUSTABLE
EEARING
PULLER, 25 -
40 mm
07736
-
A01000A
l ;' .r
fri
14-140
2. Dri ve i n the new mai nshaft beari ng unti l i t bottoms
i n the housi ng usi ng the speci al tool s as shown.
DBIVER
07749
-
0010000
ATTACHMENT,
6 2 x 6 8 mm
077{6
-
0010500
3. I nst al l t he new oi l seal f l ush wi t h t he housi nq
t he soeci al t ool s as shown.
usr ng
ATTACHMENT,
72 x75 t nm
07746
-
0010600
Countershaft Bearin
g
Replacement
1. Remove the countershaft beari ng usi ng the speci al
tool s as shown.
3/ 81T6 SLI DE HAMMER
(Commerci al l y
avai l abl e)
AOJUSTABLE
BEANING
PULLER,
2 5 - 4 0 mm
07736
-
A01000A
2.
3.
t
I nst al l t he ATF gui de pl at e.
Dr i ve t he new bear i ng i nt o t he housi ng usi ng t he
speci al tool s as shown.
0
-
0. 03 mm
{0
-
0. 001 i n)
ATF GUIDE PLATE
1+141
Transmi ssi on Housi ng Beari ngs
Mainshaft
/Countershaft Bearings Replacement
1. To remove the mai nshaft and countershaft beari ngs
from the transmi ssi on housi ng, expand each snap
ri ng wi th snap ri ng pl i ers,
then push the beari ng out
usi ng the speci al tool s and a press
as shown.
NOTEr Do not r emove t he snap r i ngs unl ess i t , s
necessary to cl ean the grooves i n the housi ng.
ATTACHMENT,
6 2 x 6 8 mm
PRESS
\
07146
-
MAINSHAFT BEARING
DRIVER
07749
-
00r0000
ATTACHMENT
ATTACHMENT
. Mainshaft B6aring Installation use:
ATTACHMENT, 72 x 75 mm
077'16
-
0010600
. Countershaft Bearing Installation use:
ATTACHMENT. 62 x 68 mm
07745
-
0010500
14-142
\
Expand each snap ri ng wi th snap ri ng pl i ers, i nsert
t he new bear i ng par t - way
i nt o t he housi ng usi ng
the speci al tool s and a press as shown. Instal l the
beari ng wi th the groove faci ng outsi de the housi ng.
NOTE: Coat al l parrs wi th ATF.
Rel ease the pl i ers.
then push
the beari ng down i nto
t he housi ng unt i l t he r i ng snaps i n pl ace ar ound i t .
07749
-
00r0000
ATTACHMENT
. Mainshaft Bearir|g Removal use:
07745
-
0010600
.
Countershaft Bearing Removal use:
07746
-
0010500
4. After i nstal l i ng the beari ng veri l y the fol l owi ng:
.
The snap ri ng i s seated i n the beari nq and hous-
Ing grooves.
. The ri ng end gap i s correct.
{0
-
0. 28 i nl
SNAP RING
ENOGAP: 0 - 7 mm
Reverse ldler Gear
Parking Brake Stop
Instal l ati on
1. Instal l the reverse i dl er gear.
Instal l the reverse i dl er gear shaft hol der and needl e
beari ng i nto the transmi ssi on housi ng. then ti ghten
the bol ts.
6 x 1 . 0 mm
12 N. m
( 1. 2 kgf . m,
8. 7 t bf
. f t l
1 .
2.
Inspection/Adjustment
Set the
parki ng brake l ever i n the
E
posrrron.
Measur e t he di st ance bet ween t he par ki ng br ake
pawl shaft and the parki ng brake l ever rol l er pi n as
STANDARD: 72.9
-
73.9 mm
(2.87 -
2.91 inl
-.
PARKING BRAK
PAWL SHAFT
l f the measurement i s out of tol erance, sel ecl and
i nstal l the appropri ate
parki ng brake stop from the
tabl e bel ow.
PARKING BRAKE
STOP
PARKING BRAKE STOP
After repl aci ng the parki ng brake stop. make sure
the di stance i s wi thi n tol erance.
'2:\
Measuri ng
Mark Part Number Lr L2
I 24537- PAg- 003 11. 00 mm
(0.433
i n)
1 1. 00 mm
(0.433
i n)
2 24538- PAg- 003
' 10.80
mm
( 0. 425
i n)
10. 65 mm
( 0. 419 i nl
3 24539- PAg- 003 10. 60 mm
( 0. 417
i n)
10.30 mm
(0.406 i n)
14-143
Transmission
Reasembl y
NOTE:
. Coat al l parts wi th ATF.
. Repl ace the fol l owi ng pans:
-
O-ri ngs
-
Lock washers
-
Gaskets
-
Mai nshaft and countershaft l ocknuts and coni cal spri ng washers
-
Seal i ng washers
TOROUE: 12 N.m
(1.2
kgf.m,8.7 tbf.ft)
6 x 1 . 0 mm
7 Bol t s
ATF FEED PIPE: A
LOCK-UP VALVE
BOOY
LOCK-UP SEPARATOR
PLATE
REGULATOR VALVE
EODY
DOWEL PINS. 2
TOROUE CONVERTEB
CHECK VALVE
STATOR SHAFT
O-RI NG
STOP SHAFT
ATF FEED PIPE: H
6 x 1 . 0 mm
5 Bol t s
CONTROL SHAFT
ATF STRAINER
SERVO DETENT
BASE
6 x 1 . 0 mm
7 Bohs
SERVO BODY
cooLER RE LrE F vALV e
-----------E
DETENT
ARM SHAFT
ATF FEEO
PIPES:
B
9 l
or
i l
l f n
i l : l l
Y
l l
DETENT
ARM
SERVO SEPARATOR
PLATE
SECONDARY VALVE
BOOY
i l
PI NS, 2
MAIN VALVE EODY
ATF PUMP
,
ATF FEED
PIPES:
GEAR SHAFT
ATF PUMP DBIVEN
GEAR
MAIN SEPARATOR
PLATE
DOWEL PINS,
2
\ l
SECONDARY
SEPARATOR PLATE
CONTROL
SHAFT
(' 98
model )
14-144
6 x 1 . 0 mm
2 Bol t s
2.
3.
1 .
ATF PUMP DRIVEN
GEAR SHAFT
l nstal l the ATF magnet and sucti on
pi pe col l ar i n the
tgrque converter housi ng. i f necessary.
l nstal l the mai n seoarator Dl ate and the two dowel
pi ns on the torque converter housi ng.
Instal l the ATF
pump dri ve gear, ATF pump dri ven
gear and ATF pump dri ven gear shaft on the torque
convener nousrng.
NOTE: I nst al l t he ATF pump dr i ven
gear wi t h i t s
grooved and chamfered si de faci ng down.
ATF PUMP
GEAR
ATF PUMP
DRIVEN
Grooved and chafitered
si de f aces separal ot
pl at e.
MAIN SEPARATOR
PLATE
7.
Loosel y i nstal l the mai n val ve body wi th fi ve bol ts.
Make sure the ATF pump dri ve gear rotates smoothl y
i n the normal operati ng di recti on and the ATF pump
dri ven gear shaft moves smoothl y i n the axi al and
normal operati ng di recti ons.
Instal l the secondary val ve body, separator pl ate
and two dowel pi ns on the mai n val ve body.
NOTE: Do not i nstal l the bol ts.
Instal l the control shaft i n the housi ng wi th the con-
trol shaft and manual val ve together.
l nst al l t he det ent ar m and ar m shaf t i n t he mai n
val ve body, then hook the detent arm sprang to the
detent arm.
SERVO SEPARATOR PLATE
DETENT ARM
SHAFT
OETENT ARM
MANUAL VALVE
DETENT AFM SPRING
16.
14-145
1 l .
8.
L
10.
I nst al l t he ser vo body and separ at or pl at e on t he
secondary val ve body
(seven
bol ts).
l nstal l the servo detent base and the ATF strai ner
Itwo bol ts).
Ti ghten the fi ve bol ts on the mai n val ve body to l 2
N.m
(1.2
kgi m, 8.7 l bf.ft).
Make sure the ATF pump dri ve
gear and ATF pump
dri ven gear shaft move smoothl y.
It the ATF pump dri ve gear and ATF pump dri ven
gear shaft do not move freel y, l oosen the l i ve bol ts
on the mai n val ve body. and di sassembl e the val ve
bodi es.
Real i gn the ATF pump dri ven
gear shaft and reassem-
bl e the val ve bodi es, then reti ghten the bol ts to the
speci fi ed torque.
CAUTION: Fai l ure to sl i gn l he ATF pump dri ven
gear shaft correctly will result in a seized ATF pump
drive
gear or ATF pump driven gear shaft.
/
ATF PUMP
DRIVEN GEAR
Instal l the stator shaft and stop shafi
l nstal l the bol ts and the shaft stop on the secondary
val ve body, then ti ghten the bol ts
(three bol ts).
l nstal l the torque converter check val ve, cool er rel i ef
val ve and val ve spri ngs i n the regul ator val ve body,
t hen i nst al l t he r egul at or val ve body on t he mai n
val ve body
(one
bol t).
Instal l the l ock-up val ve body on the regul ator val ve
body
(seven bol ts).
Instal l the ATF feed pi pes i n the mai n val ve body,
the three ATF feed pi pes i n the secondary val ve and
the four ATF feed pi pes i n the servo body.
(cont' d)
DRIVEN GEAR
SHAFT
12.
13.
14.
Transmission
I
I
Reassembly (cont'dl
TRANSMISSION
HANGEB
MAINSHAFT
SUE.ASSEMBLY
MOUNTING BOLTS
10 x 1. 25 mm
44 N.m (4.5
kg{.m,33 lbf.trl
TRANSMISSION
HOUSTNG
MAINSHAFT SPEED
SENSOR WASHER
(D16Y7
engi ne)
MAINSHAFT
SPEED SENSOR
TRANSMISSION
HOUSING GASKET
TOROUE CONVERTER
HOUSI NG
14-146
COUNTERSHAFT
SUB.ASSEMELY
DIFFERENTIAL
ASSEMBLY
18.
19.
17. I nst al l t he r ever se i dl er gear and t he gear shaf t
hol der
( see page 14- 143) .
Instal l the di fferenti al assembl y i n the torque con-
vener housrng.
Assembl e t he mai nshaf t sub- assembl y and t he
c ount er s haf t s ub- as s embl y , t hen i ns t al l t hem
together i n the torque converter housi ng.
COUNTERSHAFT
SU8-ASSEMBLY
20. Turn the shi ft fork so the l arge chamfered hol e i s
faci ng the fork bol t hol e, then i nstal l the shi ft fork
wi th the reverse sel ector, and torque the l ock bol t.
Send the l ock tab agai nst the bol t head.
SHI FT FORK
LOCK WASHER
Repl ace.
6 x 1 . O mm
1 4 N. m
(1. 4
kgf . m,
' 10
l bf ' f t )
Lar ge chamf er ed hol e
SPRING PIN
21.
22.
I nst al l t he needl e beari ng, count ershaf t reverse gear
and reverse gear col l ar on t he count ershaf t .
Al i gn t he spri ng pi n on t he cont rol shaf t wi t h t he
t ransmi ssi on housi ng groove by t urni ng t he cont rol
shaf t .
CONTROL SHAFT
Instal l the two dowel pi ns and a new gasket on the
torque converter housi ng.
Pl ace the transmi ssi on housi ng on the torque con-
vener nousrng.
CAUTION: Make sul e that the mai nshaft speed
snsor is not installed on the transmission housing
before i nstal l i ng the transmi ssi on housi ng on the
torque converter housing.
I nst al l t he t r ansmi ssi on housi ng mount i ng bol t s
al ong wi t h t he t r ansmi ssi on hanger . t hen t i ght en
the bol ts i n two or more steps i n the sequence as
snown.
TOROUE: 44 N.m {4.5 kgf.m, 33 lbt.ft,
24.
25.
TRANSMISSION
HANGEB
@
o
a
-&)H@
V G '
|
- _ F
" f l :
1+117
Transmi ssi on
27.
28.
29.
Reassembly
(cont'd)
26. Sl i p the speci al tool onto the mai nshaft as shown.
MAINSHAFT HOLOER
-
PF50101
l nstal l the parki ng brake l ever on the control shaft.
Assembl e the one-way cl utch and the parki ng gear
wi th the countershaft 1st gear
{see
page 14
' | .23).
Instal l the countershaft 1st gear col l ar, needl e bear
i ng, and t he count er shaf t 1st gear / par ki ng gear
assembl y on the countershaft.
l STCLUTCH
PARKING
ASSEMBLY
GEAR
PAWL
30. Instal l the parki ng brake pawl shaft, spri ng, pawl ,
and pawl st op on t he t r ansmi ssi on housi ng, t hen
engage t he par ki ng br ake pawl wi t h t he par ki ng
aear.
14-148
3 1 .
32.
33.
I nst al l t he mai nshaf t
' 1st
gear col l ar on t he mai n,
shaft.
Wrap the shaft spl i nes wi th tape to prevent
the O-
ri ngs, then i nstal l new O-ri ngs on the mai nshaft.
Assembl e the thrust washer. thrust needl e beari ng,
needl e bear i ng, and mai nshaf t 1st gear i n t he 1st
cl utch assembl y, then i nstal l them on the mai nshaft.
l nstal l new coni cal spri ng washers and l ocknuts on
each shaft.
CAUTION: Install ihe conical spring washers in lhe
dirsction shown.
34.
MAINSHAFT
LOCKNUT
Left-hand threads
COUNTERSHAFT
LOCKNUT
Lef t hand rhreads.
CONICAL SPRING WASHEBS
Instal l i n thi s di recti on-
35. Ti ghten the l ocknuts to the speci fi ed torque.
NOTE:
. Do not use an i mpact wr ench. Al ways use a
torque wrench to ti ghten the l ocknut,
. Mai nshaft and countershaft l ocknuts have l eft-
hand threads.
TOROUE:
MAINSHAFT 78 N.m {8.0 kgt.m, 58 lbl.ft}
COUNTERSHAFT 103 N.m {10.5 kgt'm, 75.9 lbt ft)
37.
36. Remove the special tool from mainshaft, then stske
each l ocknut usi ng a 3,5 mm punch as shown.
Set the
parki ng
brake l ever i n the
E
posi ti on, then
veri fy that the parki ng brake pawl engages the
park-
i ng gear.
l f the pawl does not engage tul l y, check the parki ng
brake pawl stop cl earance
(see page 14-143).
Ti ghten the l ock bol t and bend the l ock tab.
10 l bt' frl
6 r 1. O mm
14
' m
11. 4 kgt . m,
PAR(ING BRAKE PAWL
14-149
40. Instal l the ri ght si de cover wi th two dowel pi ns and
I new gasket (thi rteen
bol ts).
TOROUE: 12 N'm 11.2 kgt.m, 8.7 lbt'ft)
RIGHT SIDE COVER
Insral l rhe ATF cool er l i nes wi th new seal i ng wash-
ers.
TOROUE: 28 N'm
(2.9
kgt.m, 21 lbf.ft)
Instal l the ATF di psti ck.
41.
Torque Converter/Drive Plate
\
6 x 1 . O mm
12 r 1. 0 mm
74 N. m 17. 5 kgt . m, 54 l bl . f t l
Torque in a crisscross Dattern,
lirl
14- 150
/
E PLATE
Transmi ssi on
2,
L
Instal l ati on
Fl ush the ATF cool er as descri bed on page 14-155
and 14-156.
Instal l the torque converter assembl y securel y wi th
a new O-ri ng on the mai nshaft.
STARTER MOTOR
I nst al l t he st ar t er mot or on t he t or que conver t er
housi ng, then i nstal l the tl vo 14 mm dowel
pi ns i n
the torque converter housi ng.
Pl ace the transmi ssi on on a
i ack,
and rai se i t to the
engi ne assembl y l evel .
Aftach the transmi ssi on to the engi ne, then i nstal l
two transmi ssi on housi ng mounti ng bol ts and two
rear engi ne mounti ng bol ts.
REAR ENGINE
MOUNNNG BOLTS
14 x 1.5 mm
83 N.m 18.5 kg
'm,
G1 lbtft)
Repl ace.
64 N.m 16.5 47 tbf.ftl
ENGINE
5.
MOUNTING BOLTS
12 x 1 ,25 mm
MOUNTING
BRACKET
45 N.m 14.5 kgf.m,
1a mm DOWEL PIN
JACK
6. l nstal l the transmi ssi on mount bracket.
12 x' l . 25 mm
7il N.m (7.5
kgl.m,
54 tbf.ftt
MOUNT
7. l nstal l the remai ni ng transmi ssi on housi ng mount-
i ng bol ts and remai ni ng rear engi ne mounti ng bol t.
WASHEB
REAR ENGINE
MOUNTING BOLT
14 x 1. 5 rnm
8i] N.m 18.5 kgt'm,
61 rbf.n)
Replace.
WASHER
8.
HOUSING
MOUNTING BOLTS
12 x 1. 25 mm
64 N.m
(6.5
kgf.m, 47 lbf.ftl
Remove t he t ransmi ssi on
i ack.
{cont' d)
14-151
Transmission
Installation
(cont'd)
9. Attach the torque converter to the dri ve pl ate wi th
ei ght dri ve pl ate bol ts and torque as fol l ows:
Rotate the crankshaft pul l ey as necessary to ti ghten
the bol ts to 1/2 of the speci fi ed torque, then to the
fi nal torque, i n a cri sscross pattern.
After ti ghteni ng the l ast bol t, check that the crank-
shaft rotates freely.
TOROUE: 12 N.m
(1.2
kgf'm, 8.7 lbf.ftl
10 x 1. 25 mm
44 N.m 14.5 kgl.m, 33 lbf.ft)
6 x 1 . 0 mm
12 N.m {'1.2 kg{.m,
8.7 tbf.ftl
8 x 1. 25 mm
24 N.m {2.4 kgf.m,
17 tbf.ftt
CONVERTER
10. I nst al l t he t or que conver t er cover and t he engi ne
stiffener.
Ti ghten the crankshaft pul l ey
bol t, i f necessary
(see
secti on 6).
Connect the ATF cool er hoses to the ATF cool er l i nes
(see page 14-160).
12.
1 1 .
,4
10 x 1. 25 mm
"
44 N.m {4.5 kgt.m,
33 lbf.f0
ATF COOLER
LINE
RIGHT FRONT
MOUNT/BRACKET
12 x 1. 25 mm
64 N.m {6.5 kgf.m,
47 lbI.ft)
13. Instal l the ri ght front mounvbracket.
COVER
J
14-152
14. Instal l the control l ever wi th a new l ock washer to
the control shaft, then i nstal l the shi ft cabl e cover.
CAUTION: Tako care not to bend the shift cable.
LOCK WASHER
Repl ace.
8 x 1. 25 mm
22 N.m
{2.2 ks{.m, 16lbf.ftl
1{ N.m 11.l kgf.m,
10 tbtftt
15. Instal l the exhaust pi pe A.
NOTE: D16Y8 engi ne i s shown; D16ft engi ne i s si m-
i l ar .
Repl ace.
GASKET
Repl ace.
SELF.LOCKING NUT
Repl ace.
10 x 1 .25 mm
5,1 N.m 15.5 kgf.m,
SELF.LOCKING NUT
40 rbf.ftl
NUT
Reol ace. ReDl ace.
8 x 1. 25 mm 8 x 1. 25 mm
22 N.m
(2.2
kgt.m. 16lbf.ft) 16 N.m
('1.6
kgf.m,
12 tbf.ftt
SHIFT CABLE
SHI FTCABLE COVER 6x 1. 0mm
16. l nstal l a new set ri ng on the end of each dri veshaft.
17. Instal l the ri ght and l eft dri veshafts
(see
secti on 16).
CAUTION: Whi l e i nsl al l i ng the dri veshafts i n the
difforGntial, be sure not to allow dust and olher for-
oign particlos to enter into the transmission.
NOTE:
. Cl ean the areas where the dri veshafts contact the
transmi ssi on
(di fferenti al )
thoroughl y wi th sol -
vent or car bur et or cl eaner , and dr y wi t h com-
prssed atr.
. Turn the ri ght and l eft steeri ng knuckl e ful l y out-
ward, and sl i de each dri veshaft i nto the di fferen-
ti al unti l you teel i ts set ri ng cl i p engage the si de
gear.
18. Instal l the damper fork, then i nstal l the ri ght and l eft
bal l
j oi nts
to the each l ower arm wi th the castl e nuts
and new cotter oi ns.
DAMPER PINCH BOLT
10 x 1. 25 mm
a3 N.m {4.4 kd.m,
32 tbnft)
\
COTTER
Repl ace.
SELF-LOCKING NUT
12 x 1, 25 mm
6ir N.m
(6.5
kgf.m,
il7
lbf.ftl
Repl ace.
19. l nst al l t he sol ash shi
(5.0 -
6.0 kgf.m, 36
-
$ lbtftl
CASTLE NUT
12 \ 1. 25 nn
49
-
59 N.m
6 r 1 . 0 mm
12 N.m
(1.2
kgt'm,8.7 lbf'ft)
Instal l the spl ash shi el d,
SHI ELD
20, Connect the mai nshai t speed sensor, the l i near sol e-
noi d and the shi ft control sol enoi d connectors.
SHIFT CONTROL SOLENOID LINEAR SOLENOIO
CONNECTOR
CoNNEcToR
5 x 1 . 0 mm
1 2 Nm( 1 . 2 k g f . m,
8.7 rbf.ft)
CONNECTOR ERACKET
MAINSHAFT
SPEED SENSOR
CONNECTOR
2' t . Connect the countershaft speed sensor and the vehi -
cl e speed sensor
(VSS)
connectors.
VEHICLE SPEED
SENSORCONNECTOR VSS
COUNTERSHAFT
SPEED SENSOR
CONNECTOR
(cont' d)
14- 153
Transmission
Installation
(cont'dl
22. Connect the l ock-up control sol enoi d connector, and
i nstal l the transmi ssi on ground
cabl e.
6 x 1 . 0 mm
12 N.m {1.2 kgtm,8.7 l btftl
Connect the starter cabl es on the starter motor, and
i nstal l the cabl e hol der.
NOTE: When i nst al l i ng t he st ar t er cabl e t er mi nal ,
make sure that the cri mped si de of the ri ng termi nal
i s faci ng out
(see
secti on 23),
6 x l . 0 mm
12 N. m 11. 2 kgt m, 8. 7 l bt . f t )
{0.9 kgf.m.7 lbI.ft}
STARTER CAALE
lllri
lltl
14-154
24. Instal l the i ntake ai r duct.
D16Y7 engi ne:
Instal l the i nt6ke ai r duct and the resonator.
D15Y8 engi ne:
Instal l the i ntake ai r duct and the ai r cl eaner hous-
i ng assembl y.
Refi l l the transmi ssi on wi th ATF
(see page 14-86).
Connect the posi ti ve (+)
cabl e fi rst. then the nega-
ti ve {-) cabl e to the battery.
Check the i gni ti on ti mi ng {see secti on 23).
Stan the engi ne. Set the parki ng
brake, and shi ft the
transmi ssi on through al l gears. three ti mes. Check
the shi ft cabl e adj ustment {see
page 14-158).
Check the front wheel al i gnment {see secti on 181.
Let t he engi ne r each oper at i ng t emper at ur e
( t he
cool i ng fan comes on) wi th the transmi ssi on i n
E
or
E
posi ti on, then turn i t off and check the fl ui d
l evet.
Road test as descri bed on pages 14-82 thru 14-84.
27.
30.
3 1 .
Cool er Fl ushi ng
@
To prevent iniury to lace and eyes, always
wear safety gl asses or a face shi el d when usi ng the
transmission llusher.
NOTE: Thi s orocedure shoul d be oerformed betore rei n-
stal l i ng the transmi ssi on.
1 .
5.
3.
4.
Check tool and hoses for wear and cracks before
usi ng. l f wear or cracks are found, repl ace the hoses
before usi ng,
Usi ng the measuri ng cup, fi l l the tank wi th 21 ounces
( appr oxi mat el y
2/ 3 I ul l l ot bi odegr adabl e f l ushi ng
fl ui d
{J35944
-
20). Do not substi tute wi th any other
f l ui d. Fol l ow t he handl i ng pr ocedur e on t he f l ui d
contai ner.
Secure the fl usher fi l l er cap, and pressuri ze
the tank
wi th compressed ai r to between 550
-
829 kpa {5,6
-
8.45 kg?cm' , 80
-
120psi ).
NOTE: The ai r l i ne shoul d be equi pped wi th a water
trap to ensure a dry ai r system.
Hang t he t ool under t he vehi cl e.
Attach the tank' s di scharge hose to the return l i ne
of the transmi ssi on cool er usi ng a cl amp.
Connect the drai n hose to the i nl et l i ne on the trans-
mi ssi on cool er usi ng a cl amp.
IMPORTANT:
Securel y cl amp the opposi te end ofthe drai n hose to a
bucket or fl oor drai n.
{r
water
TRANSMISSION COOLER
FLUSHER
(Commercially
availablel
Kent-Moore J38405-A
or oquivalent
BUCKET
8.
7. With the water and air valves off, aftach the water and
ai r suppl i es t o t he t l usher.
(Hot
wat er i f avai l abl e. )
Turn on the fl usher water val ve so water wi l l fl ow
through the cool er for 10 seconds.
NOTE: l f water does not fl ow through the cool er, i t
i s compl etel y pl ugged,
cannot be fl ushed, and must
be repl aced.
Depress the tri gger to mi x the fl ushi ng fl ui d i nto the
water fl ow. Use the wi re cl i p to hol d the tri gger down.
Whi l e f l ushi ng wi t h t he wat er and f l ushi ng f l ui d f or
two mi nutes, turn the ai r val ve on for fi ve seconds
every 15
-
20 seconds to create a surgi ng acti on.
AIR PRESSURE: MAX 845 kpa
(8.45
kgf/cm,, 120 psi )
Turn the water val ve off. Rel ease the tri gger, then
reverse the hoses to the cool er so you can fl ush i n
the opposi te di recti on. Repeat steps 8 through 10.
Rel ease the tri gger, and ri nse the cool er wi th water
onl y f or one mi nut e.
Turn the water val ve off, and turn offthe water suppl y.
Turn the ai r val ve on to dry the system out wi th ai r
for two ful l mi nutes or unti l no moi sture i s vi si bl e
l eavi ng the drai n hose.
CAUTION: Residual moisture in the cooler or pipes
can damage the transmi ssi on.
Remove the fl usher from the cool er l i ne. Attach the
drai n hose to a contai ner.
I nst al l t he t r ansmi ssi on, and l eave t he dr ai n hose
attached to the cool er l l ne.
10.
12.
1 1 .
1 4 .
(cont' dI
14-155
Transmi ssi on
Cool er Fl ushi ng
(cont' d)
1 1 . Make sure the transmi ssi on i s i n the
E
posi ti on.
Fi l l t he t r ansmi ssi on wi t h ATF, and r un t he engi ne
f or 30 seconds or unt i l appr oxi mat el y 0. 95 I
( 1. 0
US
qt . , 0. 8 l mp qt . ) i s di schar ged.
Bemove t he dr ai n hose, and r econnect t he cool er
r et ur n hose t o t he t r ansmi ssi on
( see page
' 14' 160) .
Refi l l the transmi ssi on wi th ATF to the proper l evel
( see page 14- 86) .
18.
' 19.
14- 156
\,
TOOL MAINTENANCE
1. Empty and ri nse after each use. Fi l l the can wi th water
and pressuri ze the can. Fl ush the di scharge l i ne to
ensure that the uni t i s cl ean.
2. l f di scharge l i qui d does not foam, the ori fi ce may be
bl ocked.
3. To cl ean, di sconnect the pl umbi ng from the tank at
t he l ar ge coupl i ng nut .
FILTER
\
\
\
- 0- - D
I
I
O-RING
Remove the i n-l i ne fi l ter from the di scharge si de and
cl ean i t necessary.
The fl ui d ori fi ce i s l ocated behi nd the fi l ter.
Cl ean i t wi th the pi ck
stored i n the bottom of the
t ank handl e, or bl ow i t c l ean wi t h ai r . Sec ur el y
reassembl e al l parts.
COUPLING
I{UT
I
I
-sq
\
ORIFICE
4.
5.
FILLER CAP
,--
Shift Gable
f!!@
Make sure l i fts are pl aced properl y (see
secti on 11.
1. Remove the front consol e
2. Shi ft to
N
posi ti on, then
the adj uster.
(see
secti on 20).
remove the l ock pi n from
SHIFT CABLE
7 N. m
10.7 ksf.m. s lbt.ft)
3. Remove the shi ft cabl e bracket.
SHIFT CABLE
BRACKET
6 x 1 . 0 mm
9. 8 N. m
11. 0 kgl . m. 7. 2l bf . f t )
5.
6.
Remove the shi ft cabl e hol der.
Remove the shi ft cabl e cover.
Remove t he cont r ol l ever f r om t he cont r ol shaf t ,
then remove the shi ft cabl e. Take care not to bend
the cabl e when removi ng/i nstal l i ng i t.
8 x 1. 25 mm
22 N. m
12.2 kgt.m,
16 tbf.ftl
SHIFT CABLE HOLDER
SHIFT CABLE
SHIFT CABLE
COVER
6 x 1 . 0 mm
12 N. m
{1. 2 kgf . m,
8.7 tbt.ftl
LOCK WASHER
Repl ace.
CONTROL LEVER
6 x 1 . 0 mm
14 N. m
(1. 4
kgf . m. 10l bt f t )
I nst al l t he shi f t cabl e i n t he reverse order of removal .
Check t he cabl e adj ust ment on r eassembl y
( see
page 14-158).
7.
8.
14-157
Shift Cable
Adjustment
!@
Make sure l i tts are pl aced properl y (see
secti on 1).
(see
secti on 20).
2. Shi ft to
E
posi ti on, then remove the l ock pi n from
the adi uster.
7 N m1 0 . 7
5l bt f t )
kgf.m,
Ir
t ' l
14-158
^-
3. Check t hat t he hol e i n t he adj ust er i s per f ect l y
al i gned wi t h t he hol e i n t he shi f t cabl e. Ther e ar e
two hol es i n the adj uster. They are posi ti oned 90'
apar t t o al l ow cabl e adj ust ment i n 1/ 4 t ur n i nc. e-
ments.
Cabl e
Too Shorl
l f the hol e i s not perfectl y al i gned, l oosen the l ock-
nul on the adj uster and adj ust as requi red.
Ti ghten the l ocknut to 7 N.m
(0.7
kgf.m, 5 l bf.ft).
I nst al l t he l ock pi n on t he adj ust er . l f you f eel t he
l ock pi n bi ndi ng as you rei nstal l i t, the cabl e i s sti l l
out of adj ustment and must be readj usted.
Make sur e t he l ock pi n i s seat ed i n t he adj ust er
securety,
Move the shi ft l ever to each gear, and veri fy that the
shi ft posi ti on i ndi cator fol l ows the automati c trans-
axl e gear posi ti on swi tch.
St ar t t he engi ne, and check t he shi f t l ever i n al l
gears. It any gear does not work properl y, refer to
t r oubl eshoot i ng
( see page 14- 78 t hr u 14- 81) .
Insert the i gni ti on key i nto the key cyl i nder on the
Aft gear posi ti on i ndi cator panel , and veri fy that the
shi ft l ock l ever i s rel eased.
Cabl e
Too Long
Exact
Al i gnment
\
4.
5.
6.
7 .
8.
10.
Shift Lever
PUSH KNOB SPRING
LEVER KNOB
SCREW
N.m {0,3 kgnm. 2 lbI.ft)
Appl y non hardeni ng t hread l ock seal ant .
SILICONE GREASE
SCREW
3 N.m
(0.3
kgf.m, 2 lbl.ft)
SHIFT INDICATOR LAMP
GEAN POSITION INDICATOR PANEL
COVER
LEVER ASSEMBLY
BUSHING
-Gt
SILICONE GREASE
SHIFT LOCK
5 x 1 . 0 mm
LEVER
SCREW
3 N. m {0. 3
g
9.8 N.m 11.0 kgf.m,
7.2 tbt.fr)
A/T GEAR POSITION
PI-ATE
SHIFT I-EVER ERACKET BASE
SHIFT LEVER
BASE COLLAR
14- 159
2/' o"*"'
,@__-
-----
Gar
\oo.,rar.*
A/T GEAR POSITION SWITCH
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgl . m, 7. 2l bf . h)
Shift Indicator Panel ATF Cooler Hoses
I NDEX MARK
Adjustment
1 . Check t hat t he i ndex mar k on t he i ndi cat or al i gns
wi th the
E
mark on the shi ft i ndi cator panel when
t he t r ansmi ssi on i s i n NEUTRAL.
3 N' m
(0.3
kgf.m, 2l bf.ft) PANEL
l f not al i gned. remove the front consol e
(see
secti on
201.
Remove the shi ft i ndi cator panel mounti ng screws
and adj ust by movi ng the panel .
NOTE: Whenever the shi ft i ndi cator panel i s removed.
rei nstal l the panel as descri bed above.
f "
14- 160
-
Connection
l . Connect the ATF cool er hoses to the ATF cool er l i nes
and ATF cool er, and secure them wi th the cl i ps as
shown.
TRANSMISSION CLIP
ATF COOLER
HosEs
aoo' itoa
2- 4 mm
1 0 . 1 - 0 . 2 i n )
Conti nuousl y
Vari abl e Transmi ssi on
(CVT)
Speci al Tool s . . . . . . . . . . . . . . . . . 14- 162
Descr i pt i on
. . . . . . . . . . . . . . . . . . . . .
' 14- 163
Cl utches/Reverse Brake/Pl anetary
Gear / Pul l eys
. . . . . . . . . . 14- 166
Power Fl ow
. . . . . . . . . . . . . . . . . . . . 14 168
El ect r oni c Conl r ol Syst em . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 171
Hydr auf i c Cont r ol
. . . . . . 14- 173
Hydr aul i c Ff ow
. . . . . . . . . 14- 177
Par k i ng Br ak e Mec hani s m . . . . . . . . . . . . . . . . . . . . 14' 187
Electrical System
Component Locat i ons, . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . .
. . . . 14- ' t 89
TCM Ci r cui t Di agr am
. . . . . 14- 190
TCM Termi nal Vol tage/
Measur i ngCondi t i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- ' 192
Troubl eshooti ng Procedures ...... . . ... . . .. .... . . 14 194
El ect r i cal Syst em
. . . . . . . . . . 14- 198
El ectri cal Troubl eshooti ng
Tr oubl eshoot i ng Fl owchar t s . . . . . . . . . . . . . . . . . . . . . 14- 200
Li near Sol enoi ds/l nhi bi tor Sol enoi d
Test . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 14- 223
Dri ve Pul l ey/Dri ven Pul l ey/Secondary Gear
Shaft Speed Sensors
Repl acement .......... ......
' 14' 224
Start Cl utch Control
Start Cl urch Cal i brati on Procedure ........... 14-225
Hydraulic System
Hydraul i c System
.... . . .14' 226
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 224
Stal l Speed
Test . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 14' 230
Fl ui d Level
Checki ng/ Changi ng
. . . . 14' 231
Pr essur e Test i ng . . . . . . . . . . . . 14- 232
Lower Val ve Body Assembl y
Repl acement
. . . . . . . . . . . . . . . 14' 234
ATF Fi l ter
Removal / l nst al l at i on. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 14- 235
Transmi ssi on
Transmi ssi on
Removat . . . . . . . . . . . . . . . . .
. . . . . . . . 14- 236
Transmi ssi on/Lower Val ve Body
Assembl y
. . . . . . . . . . . . . . . . 14' 240
Transmi ssi on Housi ng/
Fl ywheel Housi ng . . . . . . . . . . . . . . . . . . . . . . . . . . , , . . 14- 242
Ri ght Si de Cover/
l nt er medi at e Housi n9 . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 244
Transmi ssi on Housi ng/
Lower Val ve Body Assembl Y
Remov al . . . . . . . . . . . . . . .
. . . . . ' 14- 246
Transmi ssi on Housi ng/Fl ywheel Housi ng
Removal . . . . . . . . . . . . . . . . .
. . . . . . . . 14- 244
Ri ght Si de Cover/l ntermedi ate Housi ng
Removal . . . . . . . . . . . . . . . . .
. . . . . . . . 14- 250
Manual Val ve Body
Di sassembl y/l nspecti on/Reassembl y
....... 14' 252
Forward Cl utch
l l l ust r at ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14- 253
Di sassembl y
. . . . . . . . . . . . . 14- 254
Reassembl y
. . . . . . . . . . . . . . . . . 14' 256
Secondary Gear Shaft
25 x 35 mm Thrust Shi m Sel ecti on . . .... . . . 14 260
Di fferenti al
l f l us t r at ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 261
Backl ash Inspecti on
. .,..14-261
Bear i ng Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14' 262
Di f f er ent i al Car r i er Repl acement . . . . . . . . . . . . . . ' 14- 262
Oi l Seal Removal
........... 14-263
Oi l Seal l nst al l at i on/ Si de Cl ear ance . . . . . 14- 263
Fl ywheel Housi ng I nput Shaf t Oi l Seal
Repl ac ement
. . . . . . . . . . . 14- 265
Tr ansmi ssi on Housi ng Bear i ngs
Dri ven Pul l ey Shaft Beari ng
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14- 266
Secondary Gear Shaft Beari ng
Repl acement
. . . . . . . . . . . 14- 261
Fl ywheel Housi ng Bear i ng
Secondary Gear Shaft Beari ng
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 267
Ri ng Gear Bear i ng
Repl acement
. . . . . . . . . . . . . . 14- 268
Control Shaft Assembl y
.... 14-268
Transmi ssi on
Reassembl y
. . . . . . . . . . . . . 14- 210
Fl ywheel / Dr i ve Pl at e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . . . . . 14- 279
Transmi ssi on
l nst at t at on
. . . . . . . . . . . . . . . . . . . . . 14- 280
Cool er Fl ushi ng
. . . . . . . . . . 14- 244
Shi ft Cabl e
.' .,.14-246
Adj ustment . . . . . . . . . . . . . :. . ...: . . . . . . . . . . . . . . . . . . . . .. . ... 14-2aj
shi f t Lever
. . . . . . . . . . . . . . . . . . . . . . . . . 14- 288
Shi ft Indi cator Panel
Adj ust ment
. . . . . . . . . . . . . . . . 14- 289
ATF Cool er/Hoses
l nstal l ati on ..............
........ 14-289
Special Tools
\
I
\ l
I
Ref. No. I Tool Number Description
(hy
I
Page Referenco
o
o
@
p,
o
o
6r
@
@
@
@-
(D
@
@
@
(D
@
@
07GAE
-
PG40200
07JAD
-
PH80200
07LAE
-
PX40' 100
07PM
-
0010100
07sAz
-
0010004
07TAE
-
P4V0110
07TAE
-
P4V0120
07TAE
-
P4V0130
OTMAJ
_
PY4OI l A
07MAJ
-
PY40120
07406
-
0020400
07406
-
0070300
07736
-
A010004
07746
-
0010100
07746
-
0010500
07746
-
0010600
07746
-
0030100
07749
-
0010000
07947
-
61 1050' t
07941
-
6340201
Cl utch Spri ng Compressor Bol t Assembl y
Pi l ot, 26 x 30 mm
Cl utch Spri ng Compressor Attachment
Backprobe Set
Reverse Brake Spri ng Compressor
Sta rt Cl utch Remover
Sta rt Cl utch Instal l er
A/T Oi l Pressure Hose,2210 mm
A,rI Oi l Pressure Hose. Adapter
A,/T Oi l Pressure Gauge Set Wpanel
A,/T Low Pressure Gauge w/panel
Adj ustabl e Beari ng Pul l er, 25
-
40 mm
Attachment,32 x 35 mm
Aftachment, 62 x 68 mm
Dri ver 40 mm l .D.
Dri ver
Dri ver Attachment, 68 mm
Dri ver Attachment, 58 x 72
,l
1
1
1
2
'l
1
1
4
1
1
1
I
1
1
1
'1
I
I
14-254,257
14-254,25'l
14-195,225
14-196,228
14-251,271
14-249
14- 274, 275
14-232
14-232
14-232
14-232
14-261
14-265, 268
14-267
14-266,261
14-262,263
't4-265,
266, 267
,
14-265
14-265
*Must
be used wi th commerci al l y-avai l abl e 3/8"
-
16 sl i de hammer.
E.!rnt!!---
o
g
l,
@
fi
@ o @
@ @ @
@ @
(9
@)
\
14-162
Description
The Conti nuousl y Vari abl e Transmi ssi on
(CVT)
i s a el ectroni cal l y control l ed automati c transmi ssi on wi th dri ve and dri ven
pul l eys, and a steel bel t. The CVT provi des non stage speeds forward and one reverse. The enti re uni t i s posi ti oned i n l i ne
wi t h t he engi ne.
Transmi ssi on
Around the outsi de of the fl ywheel i s a ri ng gear whi ch meshes wi th the staner pi ni on when the engi ne i s bei ng staned.
The transmi ssi on has four paral l el shafts: the i nput shaft, the dri ve pul l ey shaft, the dri ven pul l ey shaft and the secondary
gear shaft. The i nput shaft i s i n l i ne wi th the engi ne crankshaft. The dri ve pul l ey shaft and the dri ven pul l ey
shaft consi st of
movabl e and fi xed face pul l eys. Eoth pul l eys are l i nked by the steel bel t.
The i nput shaft i ncl udes the sun gear. The dri ve pul l ey shaft i ncl udes the torward cl utch whi ch mounts the carri er assem-
bl y on the forward cl utch drum. The carri er assembl y i ncl udes the pi ni on gears whi ch mesh wi th the sun gear and the ri ng
gear. The ri ng gear has a hub mounted reverse brake di sc.
The dri ven pul l ey shaft i ncl udes the start cl utch and the secondary dri ve gear whj ch i s i ntegral wi th the parki ng gear. The
secondary gear shaft i s posi ti oned between the secondary dri ve gear and the fi nal dri ven gear. The secondary gear shaft
i ncl udes the secondary dri ven gear whi ch serves to change the rotati on di recti on, because the dri ve pul l ey shaft and the
dr i ven pul l ey shaf t r ot at e t he same di r ect i on. When cer t ai n combi nat i ons of pl anet ar y gear s i n t he t r ansmi ssi on ar e
engaged by the cl utches and the reverse brake, power i s transmi tted from the dri ve pul l ey shaft to the dri ven pul l ey
shaft
to
provi de
E, E, d, and E.
El ectroni c Control
The el ectroni c control system consi sts of the Transmi ssi on Control Modul e
(TCM),
sensors, three l i near sol enoi ds, and a
i nhi bi tor sol enoi d. Shj fti ng i s el ectroni cal l y control l ed under al l condi ti ons.
The TCM i s l ocated bel ow the dashboard, behi nd the ki ck oanel on the dri ver' s si de.
Hvdraul i c Control
The l ower val ve body assembl y i ncl udes the mai n val ve body, the Pressure Low
(PL)
regul ator val ve body, the shi ft val ve
body, the start cl utch control val ve body, and the secondary val ve body. They are posi ti oned on the l ower pan of the
t r ansmi ssi on housi ng.
The mai n val ve body contai ns the Pressure Hi gh
(PH)
control val ve, the l ubri cati on val ve and the pi tot regul ator val ve.
The secondary val ve body contai ns the PH regul ator val ve, the cl utch reduci ng val ve, the start cl utch val ve accumul ator
and the shi ft i nhi bi tor val ve. The PL regul ator val ve body contai ns the PL regul ator val ve and the PH-PL control val ve
whi ch i s
j oi ned
wi th the PH-PL control l i near sol enoi d. The i nhi bi tor sol enoi d val ve i s bol ted on the PL regul ator val ve
DOOy.
The shi f t val ve body cont ai ns t he shi f t val ve and t he shi f t cont r ol val ve, whi ch i s
j oi ned
wi t h t he shi f t cont r ol l i near
sol enoi d. The stan cl utch control val ve body contai ns the start cl utch control val ve, whi ch i s
j oi ned
wi th the start cl utch
control l i near sol enoi d. The l i near sol enoi ds and the i nhi bi tor sol enoi d are control l ed by the TCM. The manual val ve body
whi ch contai ns the manual val ve and the reverse i nhi bi tor val ve, i s bol ted on the i ntermedi ate housi ng.
The ATF pump assembl y i s l ocated on the transmi ssi on housi ng, and i t i s l i nked wi th the i nput shaft by the sprockets and
the sprocket chai n. The pul l eys and the cl utch recei ve fl ui d from thei r respecti ve Ieed pi pes,
and the reverse brake recei ves
f l ui d f r om i nt er nal hydr aul i c ci r cui t .
Shi ft Control Mechani sm
I nput f r om var i ous sensor s l ocat ed t hr oughout t he vehi cl e det er mi nes whi ch l i near sol enoi d t he TCM wi l l act i vat e.
Acti vati ng the shi ft control l i near sol enoi d changes the shi ft control val ve pressure, causi ng the shi ft val ve to move. Thi s
pressuri zes the dri ve pul l ey pressure to the dri ve pul l ey and the dri ven pul l ey pressure to the dri ven pul l ey and changes
thei r effecti ve pul l ey rati o. Acti vati ng the start cl utch control l i near sol enoi d moves the start cl utch control val ve. The start
cl utch control val ve uncovers the port, provi di ng pressure to the start cl utch to engage i t.
(cont ' d)
14-163
I
Description
(cont' d)
Gear Selction
The shi ft l ever has si x
POSi ti ONS: E
PARK,
F]
REVERSE,
E
NEUTRAL,
E
DRIVE,
E SECOND, ANd
E
LOW.
Stani ng i s possi bl e
onl y i n
@
and
N
posi tj ons rhrough the use of a sl i de-type, neutral -safety swi tch.
Automatic Transaxle
{A/T) Gear Position Indicator
The A/T gear posi ti on i ndi cator i n the i nstrument panel shows whi ch gear has been sel ected wi thout havi ng to l ook down
at the consol e.
Posi ti on
Description
E
PARK
E
REVERSE
E
NEUTRAL
{d
DRrvE
E]
SECOND
E
LoW
Front wheel s l ockedj parki ng brake pawl engaged wi th the parki ng gear on the dri ven pul l ey
shai t.
The start cl utch and the forward cl utch rel eased.
Reverse; reverse brake engaged.
Neutral ; the start cl utch and the forward cl utch rel eased.
General dri vi ng; the transmi ssi on automati cal l y adj usts to keep the engi ne at the best speed for
dri vi ng condi ti ons.
For rapi d accel erati on at hi ghway speeds; the transmi ssi on shi fts i nto a l ower range of rati os for
better accel erati on and i ncreased engi ne braki ng.
For engi ne braki ng and power for cl i mbi ng; the transmi ssi on shi fts i nto the l owest range ot the
rataos.
14-164
BING GEAR
L ) /
?
STEEL BELT
FLYWHEEL
START CLUTCH
INPUT SHAFT
DRIVE PULLEY
ARY GEAR SET
FORWARD CLUTCH
REVERSE BRAKE
ATF FILTER
14-165
Description
Cl utches/Reverse Brake/Pl anetary
Gear/Pul l eys
Clutchs/Reverse Brake
The CVT uses t he hydr aul i cal l y- act uat ed cl ut ches and br ake t o engage or di sengage t he t r ansmi ssi on gear s.
When
hydraul i c pressure i s i ntroduced i nto the cl utch drum and the reverse brake pi ston cavi ty, the cl utch pi ston and the reverse
brake pi ston move. Thi s presses the fri cti on di scs and the steel pl ates
together, l ocki ng them so they don,t sl i p.
power
i s
t hen t r ansmi t t ed t hr ough t he engaged cl ut ch pack t o i t s hub- mount ed gear , and t hr ough engaged r i ng gear t o pi ni on
gears.
Li kewi se, when the hydraul i c pressure i s bl ed from the cl utch pack and the reverse brake pi ston cavi ty, the prston reteases
the fri cti on di scs and the steel pl ates,
and they are free to sl i de past
each. Thi s al l ows the gear
to spi n i ndependentl y on i ts
shaft, transmi tti ng no power.
Start Clutch
The stan cl utch, whi ch
j s
l ocated at the end of the dri ven pul l ey
shaft, engages/di sengages the secondary dri ve gear.
The stan cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed pi pes wi thi n the dri ven
pul l ev
shaft.
Forward Clutch
The forward cl utch, whi ch i s l ocated at the end of the dri ve pul l ey
shaft, engages/di sengages the sun gear.
The forward cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed pi pe wi thi n the dri ve
pul l ev
shaft.
ReveFe Brake
The reverse brake, whi ch i s l ocated i nsi de the i ntermedi ate housi ng around the ri ng gear, l ocks the ri ng gear i n
@
posi -
ti on The reverse brake di scs are mounted to the ri ng gear and the reverse brake pl ates
are mounted to the i ntermedi ate
housi ng. The reverse brake i s suppl i ed hydraul i c pressure
by a ci rcui t connected to the i nternal hydraul i c ci rcui t.
Planetary Gear
The pl anetary gear
consi sts of a sun gear,
a carri er assembl y, and a ri ng gear. The sun gear i s connected to the Input shaft
wi th spl i nes The pi ni on gears are mounted to the carri er whi ch i s mounted to the forward cl utch drum. The sun gear
i nputs the engi ne power
vi a the i nput shaft to the pl anetary gear,
and the carri er outputs the engi ne power. The ri ng gear
i s onl y used for swi tchi ng the rotati on di recti on of the
pul l ev
shafts.
In
@, $,
and
E
posi ti ons (forward
range), the pi ni on gears
don' t rotate and revol ve wi th the sun gear, so the carri er
rotates l n
S
posi ti on (reverse
range), the reverse brake l ocks the ri ng gear
and the sun gear
dri ves the prnton gears
to
rotate. The pi ni on gears rotate and revol ve i n the opposi te di recti on from the rotati on di rectl on of the sun gear, and the
carri er rotates wi th pi ni on gear revol uti on.
Pul l eys
Each pul l ey consi sts of a movabl e tace and a fi xed face, and the effecti ve pul l ey rati o changes wi th engi ne speed. The
dri ve pul l ey and the dri ven pul l ey are l i nked by the steel bel t.
To achi eve a l ow pul l ey rati o, hi gh hydraul i c pressure works on the movabl e face of the dri ven
pul l ey
and reduces the
effecti ve di ameter ot the dri ve pul l ey, and a l ower hydraul i c pressure works on the movabl e face of the dri ve
pul l ey
to
el i mi nate the steel bel t sl i ppage. To achi eve a hi gh pul l ey rati o, hi gh hydraul i c pressure works on the movabl e face of the
dri ve pul l ey and reduces the effecti ve di ameter of the dri ven pul l ey, and a l ower hydraul i c pressure works on the movabl e
face of the dri ven pul l ey to el i mi nate the steel bel t sl i ppage.
\
14- 166
ATF PUMP
DRIVEN SPROCKET
RING GEAR
FLYWHEEL
DRIVE PLATE
ATF PUMP
DRIVE PULLEY
REVERSE BRAKE
PISTON
FORWARD CLUTCH
REVERSE BRAKE
CARRIEB
RING GEAR
PLANETARY
PINION GEARS
INPUT SHAFT
ATF PUMP
DRIVE CHAIN
ATF PUMP
DRIVE SPROCKET
DRIVEN PULLEY
SHAFT
START CLUTCH
FINAL DRIVE GEAR
SECONDAFY GEAR
SHAFT
ORIVEN PULLEY
STEEL EELT
SECONDARY ORI VE GEAR
PARKING GEAR
a' -
14-167
Description
Power Flow
E
Position
. Start Cl utch: rel eased
. Forward Cl utch: rel eased
a Reverse Braket rel eased
Hydraul i c pressure
i s not appl i ed to the start cl utch, forward cl utch, and the reverse brake. Power i s not transmatted to the
secondary dri ve gear.
E
Position
.
Stan Cl utch: rel eased
. Reverse Brake: rel eased
Hydraul i c pressure i s not appl i ed to the stan cl utch, forward cl utch, and the reverse brake.
power
i s not transmi tted to the
secondary dri ve gear' The secondary dri ve gear i s l ocked by the parki ng
brake pawl
i nterl ocki ng the parki ng gear.
FLYWHEEL
START CLUTCH
FORWARD
PARKING GEAR
INPUT SHAFT
SUN GEAR
FINAL DRIVE
GEAR
DRIVEN PULLEY
SECONDARY GEAR
SHAFT
i{
B$
14-16A
FINAL ORIVEN GEAR
E, E,
8nd E
PGitions
(Forward
Range)
. Start Cl utch: engaged
. Forward Cl utch: engaged
. Reverse Brake: released
1. The hydraul i c
pressure i s appl i ed to the forward cl utch and the stan cl utch, and the sun
gear dri ves the forward
cl utch.
2. The forward cl utch dri ves the dri ve
pul l ey shaft, whi ch dri ves the dri ven pul l ey shaft l i nked by the steel bel t.
3. The dri ven pul l ey shaft dri ves the secondary dri ve gear, vi a l he sta.t cl utch.
4. Power i s transmi tted to the secondary dri ven gear. whi ch dri ves the fi nal dri ven
gear.
NOTE: The worki ng hydraul i c
pressure on the movabl e face of each shaft depends on the throttl e openi ng
posi ti on.
DRIVE PULLEY
FLYWHEEL
CLUTCH
SUN GEAR
START CLUTCH
SECONDARY DRIVEN
GEAR
(cont' d)
FINAL DRIVEN GEAR
14- 169
Description
Power Flow
(cont'd)
E
Po$ition
. Start Cl utcht engaged
. Reverse Brake: engaged
1. The hydraul i c pressure
i s appl i ed to the reverse brake and the start cl utch. The sun gear dri ves the pi nron gears, and
the pi ni on gears
revol ve around the sun gear. The carri er assembl y rotates i n the opposi te di recti on from tne rotatron
di recti on of the sun gear.
2 The carri er assembl y dri ves the dri ve pul l ey
shaft vi a the forward cl utch drum, and the dri ve
pul l ev
shaft dri ves the
dri ven pul l ey
shaft l i nked by the steel bel t.
The dri ven pul l ey shaft dri ves the secondary dri ve gear vi a the start cl utch.
Power i s transmi tted to the secondary dri ven gear, whi ch dri ves the fi nal dri ven gear.
DRIVE PULLEY STEEL BELT
3.
4.
DRIVE
PULLEY
BEVERSE BRAKE
CARRIER ASSEMBLY
INPUT SHAFT
START CLUTCH
FI NAL DRI V
SECONDARY DRIVEN
GEAR
!il
14-170
FINAL DRIVEN GEAB
The el ectroni c control system consi sts of the Transmi ssi on Control Modul e
(TCM),
sensors, three l j near sol enoi ds, and a
i nhi bi tor sol enoi d. Shi fti ng i s el ectroni cal l y control l ed under al l condi ti ons
The TCM i s l ocated bel ow the dashboard, behi nd the ki ck panel on the dri ver' s si de
The TCM control s the transmtsston to reduce engi ne speed and retai n the engi ne' s cool i ng effi ci ency when the vehi cl e i s
dri ven wi th ful l throttl e accel erati on
l f t he vehi cl e i s cont i nuousl y dr i ven at f ul l t hr ot t l e accel er at i on, t he TCM r egul at es t he
pul l ey hydr aul i c pr essur e t o
i ncrease the
pul l ey rati o, whi ch, as the resul t, reduces the engi ne speed and retai ns the desi gned cool i ng effi ci ency. After
the vehi cl e has been drj ven at a l ower engi ne speed for a whi l e, the TCM i ncreases the
pul l ey rati o to the ori gi nal rati o
For smooth starti ng i n the E
posi ti on, the TCM sends a si gnal to the ECM to cut off the A,/C cl utch {i f the IVC i s on} and
i ncreases the engi ne speed to 900 rpm when the transmi ssi on i s shi fted to the
E
posi ti on
The start cl utch functi ons to make smooth starti ng possi bl e. To l et the start cl utch functi on
properl y, the TCM regul ates
the start cl utch hvdraul i c
pressure
based on the engi ne' s negati ve pressure memori zed i n the
E
posi ti on.
=
I
E
z
z
z
S@ond.ry Gelr Sh.tr
(cont' d)
14- 171
Description
Electronic
Control System
(cont'd)
Circuit Diagram and Terminal Locations
IGNITION SWIICH
L]NEANSOLENOIO
SIAFT CLUICN CONTsOL
LINEAFSOLENOID
SIlIFTCONTROL
L]NEARSOLENOID
sNAKE SWIICN
8RA(EL]GHT
l\__ +B
i\- rcr
\
14-172
3
SC1
6
F
TXD/NXD
=
I rM8
2 3 5 1 I I 1 0 t l 1 2 1 2 5 6 I I s t o
1 4 1 6 1 1 20 23 2 5 1 2
' 14
1 7 l 8 20
-.-
Hydraul i c Control
The hydraul i c control system i s control l ed by the ATF
pump, the val ves, and the sol enoi ds. The ATF
pump i s dri ven by the
i nput shaft. The ATF
pump and the i nput shaft are l i nked by the ATF
pump dri ve chai n and the sprockets. The i nhi bi tor
sol enoi d val ve and the l i near sol enoi ds, whi ch are l ocated on thei r val ve body, are control l ed by the TCM. Fl ui d from the
ATF pump fl ows through the PH regul ator val ve to mai ntai n speci fi ed
pressure to the dri ve pul l ey, the dri ven pul l ey, and
the manual val ve.
The l ower val ve bodv assembl y i ncl udes the mai n val ve body, the PL regul ator val ve body, the shi ft val ve body, the start
cl utch control val ve body, and the secondary val ve body.
Mai n Val ve Body
The mai n val ve body contai ns the PH control val Ve, the l ubri cati on val ve, and the pi tot regul ator val ve.
PH Control Valve
The
pH
control val ve suppl i es PH control pressure (PHC) i n accordance wi th the PH-PL control
pressure (HLC),
and sup-
pl i es
pH
control
pressure to the PH regul ator val ve, whi ch al so regul ates PH pressure. At ki ck-down, i t i ncreases PH
control pressure whi ch i ncreases the hi gh
(PH) pressure. Thi s shonens the shi ft speed by rel easi ng the reverse i nhi bi tor
pressure
l Rl )
from the i nhi bi tor sol enoi d val ve.
Lubrication Valve
The Iubri cati on val ve control s the l ubri cati on
pressure to each shaft and mai ntai ns l ubri cati on
pressure. When the pres-
sure i s too hi gh, the spri ng i s compressed. Thi s moves the l ubri cati on val ve and opens the fl ui d l eak passage.
Pitot Regulator Valve
The
pi tot regul ator val ve control s the start cl utch
pressure
{SC)
i n accordance wi th the engi ne speed, when the el ectron
i c control svstem
j s
faul ty.
LOWER VALVE BODY
ASSEMELY
TION VALVE
1+173
Description
Hydraul i c Gontrol
(cont' dl
The secondary val ve body contai ns the PH regul ator val ve, the cl utch reduci ng val ve, the start ci utch val ve accumul ator,
and the shi ft i nhi bi tor val ve.
. PH Regulatol Valve
The PH regul ator val ve mai ntai ns hydraul i c pressure suppl i ed from the ATF pump, and suppl i es PH pressure to the
hydraul i c control ci rcui t and the l ubri cati on ci rcui t. PH pressure i s regul ated at the PH regul ator val ve by the PH control
pressure (PHC)
from the PH control val ve.
Clutch Reducing Valve
The cl utch reduci ng val ve recei ves PH pressure from the PH regul ator val ve and regul ates the cl utch reduci ng pressure
l CR). The cl utch redLrci ng val ve suppl i es cl utch pressure (CR)
to the manual val ve and the start cl utch control val ve, and
suppl i es si gnal pressure
to the PH-PL pressure control val ve, the shi ft control val ve, and the i nhi bi tor sol enoi d val ve.
Start Clutch Valve Accumulator
The start cl utch val ve accumul ator stabi l i zes the hydraul i c pressure that i s suppl i ed to the start cl utch.
Shift lnhibitor Valve
The shi ft i nhi bi tor val ve swi tches the fl ui d passage to swi tch the start cl utch control from el ectroni c control to hydraul i c
control when the el ectroni c control system i s faul ty. l t al so suppl i es cl utch reduci ng pressure (CR)
to the pi tot regul ator
val ve and the pi tot l ubri cati on pi pe.
START CLUTCH VALVE
SECONDARY VALVE
BOOY
SHIFT INHIBITOR VALVE
CLUTCH REDUCING VALVE
PH REGULATOR VAL
\
fi
1i
14- 174
L
,,-
PL Regulator Valve Body
The
pL
regul ator val ve body contai ns the PL regul ator val ve and the PH-PL control val ve, whi ch i s
j oi ned wi th the PH-PL
control l i near sol enoi d. The i nhi bi tor sol enoi d i s bol ted on the PL regul ator val ve body
PL Regulator Valve
The PL regul ator val ve suppl i es l ow pressure
(PL)
to the pul l ey to el i mi nate steel bel t sl i ppage'
The PL pressure i s control l ed by the PH-PL control
pressure
(HLC).
PH-PL Control Valve
The
pH-pL
control val ve control s the PL regul ator val ve accordi ng to engi ne torque. The PH-PL control val ve suppl i es
pH-pL
control pressure
(HLC)
to the PH control val ve to regul ate PH pressure hi gher than PL pressure. The PH-PL con-
trol val ve i s control l ed by the PH-PL control l i near sol enoi d, whi ch i s control l ed by the TCM'
l nhi bi tor Sol enoi d
The i nhi bi tor sol enoi d control s the reverse i nhi bi tor val ve by turni ng on and off, Al so, the i nhi bi tor sol enoi d control s PH
control
pressure (PHC)
by appl yi ng reverse i nhi bi tor pressure
(Rl )
to the PH control val ve The i nhi bi tor sol enoi d i s con-
trol l ed by the TCM.
Start Clutch Control Valve Body
The start cl utch control val ve body contai ns the start cl utch control val ve. Both are
i oi ned
to the start cl utch control l i near
sol enoi d.
. Start Clutch Control Valve
The start cl utch control val ve control s start cl utch engagement accordi ng to the throttl e openi ng. The start cl utch con-
trol val ve i s control l ed by the stan cl utch control l i near sol enoi d, whi ch i s control l ed by the TcM.
START CLUTCH CONTROL
LINEAR SOLENOID
START CLUTCH CONIROL
VALVE
INHIBITOR SOLENOID
PL REGULATOR
VALVE BODY
LOWER VALVE BOOY
ASSEMBLY
PL REGULATOR
VALVE
PH.PL CONTROL
LINEAR SOLENOID
(cont' d)
14-175
)
Description
Hydraul i c
Control
(cont' dl
Shift Valve Body
The shi ft val ve body contai ns the shi ft val ve and the shi ft control val ve. Both are
j oi ned
to the shi ft control l i near sotenoi d.
e Shift Valve
The shi ft val ve i s control l ed by shi ft val ve pressure (SV)
from the shi ft control val ve. The shj ft val ve di stri butes
pH
pressure
and PL pressure
to dri ve pul l ey
and the dri ven pul l ey,
to shi ft the transmi ssi on.
.
Shi ft ControtVal ve
The shi ft control val ve control s the shi ft val ve i n accordance wi th the throftl e openi ng and vehi cl e speed. The shi ft
control val ve i s control l ed by the shi ft control l i near sol enoi d, whi ch i s control l ed oy tne rcv. wnen tne el ectroni c
control system i s faul tv, the shi ft control val ve swi tches the shi ft i nhi bi tor val ve to uncover the pon l eadi ng the pi tot
regul ator pressure
to the start cl utch.
LOWER VALVE BODY
ASSEMBLY
CONTROL VALVE
VALVE BODY
Manual Valve Body
The manual val ve body contai ns the manual val ve and the reverse i nhi bi tor val ve. The manual val ve body i s bol ted to the
i nt er medi at e
housi ng.
. Manual Val ve
The manual varve mechani caty
uncovers/covers
the frui d passage
accordi ng to the shi ft rever posi ti on.
. Reverse Inhibitor Valve
The reverse i nhi bi tor val ve i s control l ed by the reverse i nhi bi tor pressure (Rt).
l t i ntercepts the hydraul i c ci rcui t to the
reverse brake whi l e the vehi cl e i s movi ng forward at speeds over approxi matel y
6 mph (10
km/h).
MANUAL VALVE
BODY
14- 176
SHIFT CONTROL
REVERSE INHIBITOR
Hydraul i c Fl ow
General Chart of Hydraulic Pressure
.
Shift Valve
.
Shi f t l nhi bi t or Val ve
,,/
SHIFT VALVE
PL REGULATOR
VALVE
PH REGULATOR
VALVE
NO. DESCRIPTION OF PRESSURE NO. DESCRIPTION OF PRESSURE
CLUTCH CONTROL PP PITOT PIPE
coL ATF COOLER PR PITOT REGULATOR
CR CLUTCH REDUCI NG RCC RECIRCULATION
DN DRIVEN PULLEY RI REVERSE INHIBITOR
DR DRIVE PULLEY RVS REVERSE BRAKE
FWD FORWARD CLUTCH START CLUTCH
HLC PH-PL CONTROL sl SHI FT I NHI BI TOR
LUB LUBRICATION SUC SUCTION
PH PRESSURE HI GH SV SHIFT VALVE
PHC PH CONTROL X LEAK
PL PRESSURE LOW
(cont' d)
L
14-177
Description
Hydraul i c Fl ow
(cont' dl
llj
Position
As the engi ne turns, the ATF pump al so starts to operate. Fl ui d from the ATF pump fl ows to the PH regul ator val ve and the
cl utch reduci ng val ve. The PH regul ator val ve regul ates hi gh pressure (pH),
and send, i t to the shi ft val ve and the
pL
regu-
l ator val ve. The hi gh pressure (PH)
fl ows to the movabl e face of the dri ven pul l ey vi a the shi ft val ve, and turns i nto l ow
pressure (PL)
at the PL regul ator val ve. The l ow pressure (PL)
fl ows to the movabl e face of the dri ve pul l ey vi a the shi ft
val ve. At thi s ti me, the
pul l ey
rati o remai ns l ow.
The hi gh pressure (PH)
becomes the cl utch reduci ng pressure
{CR) at the cl utch reduci ng val ve. The cl utch reduci ng pres_
sure {CR) fl ows to the start cl utch contfol val ve, the manual val ve, the PH-PL control val ve, and the shi ft control val ve, and
i s i ntercepted by those val ves.
Under thi s condi ti on, hydraul i c pressure i s not appl i ed to the cl utches and reverse brake.
14- 17A
E
position, at low speed range
The fl ow of fl ui d up to the dri ve
pul l ey. the dri ven
pul l ey, and the cl utch reduci ng val ve i s the same as i n
E
posi ti on. The
pul l ey rati o i s l ow because the dri ven pul l ey recei ves hi gh pressure
(PH),
and the dri ve pul i ey recei ves l ow pressure {PL).
i n" "tut"t reduci ng pressure
(CR)
fl ows through the manual val ve to the forward cl utch, then forward cl utch i s engaged.
The forward cl utch then dri ves the dri ve
pul l ey shaft, whi ch dri ves the dri ven
pul l ey shaft'
Al so, cl utch reduci ng
pressure
(CB)
fl ows to the start cl utch control val ve, and becomes cl utch control
pressure
(CC).
Cl utch control
pressure
(CC)
becomes start cl utch
pressure
(SC)
at the shi ft i nhi bi tor val ve. Start cl utch
pressure
(SC)
i s
aool i ed to the start cl utch to engage the start cl utch
(cont
d
14-179
Description
Hydraul i c Fl ow
(cont' dl
lll
position,
at middle sped range
As the speed of the vehi cl e reaches the prescri bed val ue. the shi ft control l i near sol enoi d i s acti vated by the TCM. The shi ft
control l i near sol enoi d control s the shi ft control val ve to acti vate shi ft val ve pressure (SV).
Cl utch reduci ng pressure (CR)
from the cl utch reduci ng val ve becomes shi ft val ve pressure (SV)
at the shi ft cont.ol val ve. Shi ft val ve pressure (SV)
fl ows
to the l eft end of the shi ft val ve, the shi ft val ve to the ri ght si de and posi ti oni ng i t i n the mi ddl e of i ts travel . The shi ft val ve
covers the port to stop hi gh pressure (PH)
to the pul l eys.
and uncovers the port l eadi ng l ow pressure (PL)
to the
pul l eys.
The dri ve pul l ey and the dri ven pul l ey recei ve l ow pressure (PL).
At thi s ti me, the
pul l ey
rati o i s i n the mi ddl e.
Pressure remai ns to appl y the forward cl utch and the stan cl utch.
NOTE: When used,
"l eft"
or
"ri ght"
$
14- 180
E
position, at high speed range
As the speed of the vehi cl e reaches the prescri bed val ue, the shi ft control l i near sol enoi d moves the shi ft control val ve to
i ncrease shi ft val ve pressure (SVl
at the l eft end of the shi ft val ve. The shi ft val ve moves to the ri ght si de compared to i ts
posi ti on at the mi ddl e pul tey rati o. The shi ft val ve uncovers the port l eadi ng hi gh pressure (PH)
to the dri ve pul l ey and
uncovers the
pon l eadi ng l ow pressure (PLl to
the dri ven
pul l ey. The dri ve pul l ey recei ves hi gh pressure (PH)
and the dri v-
en
pul l ey recei ves l ow
pressure (PL).
The pul l ey rati o i s hi gh
Pressure remai ns to appl y the forward cl utch and the start cl utch.
NOTE: When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t
(cont' d)
14-181
Description
Hydraulic Flow
(cont'dl
lll
position
The fl ow of fl ui d up to the dri ve pul l ey, the dri ven pul l ey, and the cl utch reduci ng val ve i s the same as i n
E
posi ti on. The
pul l ey rati o i s l ow because the dri ven pul l ey recei ves hi gh pressure (pH)
and the dri ve pul l ey recei ves l ow
pressure (pL).
The manual val ve i s shi fted i nto the
E
posi ti on,
and i t uncovers the port that l eads reverse brake pressure (RVS)
to the
reverse i nhi bi tor val ve. The i nhi bi tor sol enoi d turns off by means of the TCM, and reverse i nhi bi tor pressure (Rl )
i s appl i ed
to the ri ght end of the reverse i nhi bi tor val ve. The reverse i nhi bi tor val ve moves to the l eft si de, and uncovers the pon that
l eads reverse brake pressure (RVS)
to the reverse brake. Cl utch reduci ng pressure (CR)
becomes reverse brake pressure
{RVS) at the manual val ve, and fl ows to the reverse brake. The reverse brake i s engaged, and i t l ocks the ri ng gear.
NOTE: When used,
"1eft"
or
"ri ght"
i ndi cates di recti on on the hvdraul i c ci rcui t.
\
14-182
Lll
position
FeveBe lnhibitor Control
l f the
E
posi ti on i s sel ected whi l e the vehi cl e i s movi ng forward at speeds over 6 mph
(10 kml h), the i nhi bi tor sol enoi d
doesn,t turn off by means of the TCM. Reverse i nhi bi tor pressure
(Rl )
i s not appl i ed to the reverse i nhi bi tor val ve as the
reverse i nhi bi tor sol enoi d turns on. The reverse i nhi bi tor val ve i s kept on the ri ght si de, and covers the port to stop
reverse brake
pressure
(RVS)
to the reverse brake from the manual val ve. Reverse brake
pressure
(RVS)
i s not appl i ed to
the reverse brake, and Dower i s not transmj tted to the reverse di recti on.
NOTE: When used,
"l eft"
or
"ri ght"
(cont' d)
14-183
Description
Hydraul i c Fl ow
(cont' dl
El
position
The fl ow of fl ui d up to the dri ve pul l ey, the dri ven pul l ey, and the cl utch reduci ng val ve i s the same as i n
E
posi ti on.
Cl utch reduci ng pressure (CR)
fl ows to the stan cl utch control val ve, th manual val ve, and the shi ft control val ve. and i s
i ntercepted by those val ves.
Under thi s condi ti on, hydraul i c pressure i s not appl i ed to the cl utches and reverse brake.
14-144
E
po3ition. when the electronic control system is taulty.
When the el ectroni c control system
(l i near
sol enoi ds and sensors) i s faul ty, the transmi ssi on uses the pi tot pi pe pressure
(PP)
to al l ow the vehi cl e to dri ve.
When al l l i near sol enoi ds and sensors are off because of a faul ty el ectroni c control system, cl utch reduci ng pressure
{CR)
fl ows to the start cl utch control val ve, the manual val ve, the PH-PL control val ve, and the shi ft control val ve. Cl utch reduc-
i ng pressure (CR)
becomes shi ft val ve pressure (SV)
at the shi ft control val ve, and shi ft val ve pressure (SV)
i s appl i ed to
the l eft end of the shi ft val ve and the ri ght end of the shi ft i nhi bi tor val ve. The shi ft val ve moves to the ri ght si de, and
uncovers the port that l eads hi gh pressure (PH)
to the dri ve pul l ey and uncovers the
port that l eads l ow pressure (PL)
to
the dri ven
pul l ey. At thi s ti me, the pul l ey rati o i s hi gh. The shi ft i nhi bi tor val ve moves to the l eft si de, and uncovers the
port
that l eads shi ft i nhi bi tor pressure (Sl )
to the pi tot l ubri cati on pi pe and the pi tot regul ator val ve. The pi tot l ubri cati on
pi pe di scharges fl ui d i nsi de of the pi tot fl ange, and di scharged fl ui d enters i nto the pi tot pi pe and i t i s appl i ed to the l eft
end of the pi tot regul ator val ve. The pi tot regul ator val ve moves to the ri ght si de, and uncovers the pon that l eads pi tot
regul ator pressure (PR)
to the shi ft i nhi bi tor val ve. Pi tot regul ator pressure
{PR) becomes start cl utch pressure (SC)
at the
shi ft i nhi bi tor val ve. and i s appl i ed to the start cl utch. The start cl utch i s engaged. The forward cl utch pressure (FWD)
i s
appl i ed to the forward cl utch, and the forward cl utch i s engaged. Thi s al l ows the vehi cl e to dri ve.
NOTE: When used,
"l eft"
or
"ri ght"
(cont' d)
14- 185
Description
Hydraul i c Fl ow
(cont' dl
E
position,
when the electronic control system is faulty.
The fl ow offl ui d up to the dri ve pul l ey, the dri ven pul l ey, and the start cl utch i s the same as i n
E
posi ti on.
The manual val ve i s shi fted i nto the
E
posi ti on,
and i t uncovers the port that l eads reverse brake pressure (RVS)
to the
reverse i nhi bi tor val ve. Reverse i nhi bi tor pressure (Rl )
i s appl i ed to the ri ght end of the reverse i nhi bi tor val ve because of
a faul ty i nhi bi tor sol enoi d. The reverse i nhi bi tor val ve moves to the l eft si de, and uncovers the port
that l eads reverse
brake pressure (RVS)
to the reverse brake. Cl utch reduci ng pressure (CR)
becomes reverse brake pressure (RVS)
at the
manual val ve, and fl ows to the reverse brake. The reverse brake i s engaged and l ocks the ri ng gear. Thi s al l ows the vehi -
cl e to dri ve i n reverse.
NOTE: When used,
"l eft"
or
"ri ght"
14-186
Parki ng Brake Mechani sm
The parki ng brake mechani sm l ocks the transmi ssi on by engagi ng the
parki ng brake
pawl wi th the
parki ng gear whi ch i s
i ntegral wi th the secondary dri ve
gear. The secondary dri ve gear engages wi th the secondary dri ven gear whi ch engages
wi th the fi nal dri ven gear.
Shi fti ng to E
posi ti on causes the parki ng cone
(i nstal l ed
at the end of the parki ng brake rod) to press the
parki ng brake
pawl onto the parki ng gear. Even i t the end of the
parki ng brake
pawl ri des on the top of the
parki ng gear teeth, sl i ght
movement of the vehi cl e wi l l cause the
parki ng brake pawl and the parki ng gear to mesh wi th each other compl etel y
because the parki ng brake cone recei ves the tensi on from the parki ng brake rod spri ng. The parki ng brake pawl recei ves
the tensi on
(whi ch
acts to separate the
parkj ng brake
pawl from the parki ng gear) from the parki ng pawl spri ng.
ART CLUTCH
PARKING GEAR
PARKING BRAKE ROD
PARKING BRAKE
PAWL
PARKING BRAKE
ROD SPRING
14-187
a
BRAKE SWITCH
INHIBITOR SOLENOID
START CLUTCH CONTROL
SECONOARY GEAR SHAFT
SPEED SENSOR
AUTOMATIC TRANSAXLE {A/T)
GEAR POSITION SWITCH
MANIFOLD ABSOLUTE
PRESSURE {MAP) SENSOR
SENSOR
SHIFT CONTROL
LI NEAR SOLENOI D
PH-PL CONTROL
LI NEAR SOLENOI D
LI NEAR SOLENOI D
14. 1A9
TCM Ci rcui t Di agram
UNDER-HOOD FUSE/RELAY BOX
UNDER-DASH
FUSE/RELAY BOX
No. 41 l 80A) No. 47
( 7. 5A)
To 12v
l Gl
5V
REGULATOS
\
I GNI TI ON COI L
V
I
I
I
I
BLU
oul
PARKING
BRAKE
SWITCH
Y
I
I
I
I
\
\
BLK
I
I
I
:
G401
G404
[ ,
14- 190
GAUGE ASSEMBLY
LT GRN
8LK/8LU
_
RED
GRN/8LK
- Gf l N-
_
BLU
A/I GEAR POSITION
I NDI CATOR
l A4 l A17
l A13
l A26
BRN/BL(
|
8l,K
I
I
BRN/BLK
I
BLK
L--.1 L---l
t l
? T
t - t a
'lFr 'i
Fl
1P 1ts
8RN/BLK BLK
,rr,r,.o,
I i
s0LEN0r0
| L
t l
_o _o_
: - :
G101 G101
I J ,
RED/BLU
I
T T
t l
LOJ
DNNE PULLEY
SPEEO SENSOR
DRIVEN PUI-LEY SECONDARY PH_PT START SHIFT
SPEED SENSOR GEAR SHAFT CONTROL CLUTCH CONTROT
SPEED SENSOR LINEAR CONIROL I.INEAR
SOLENOI D LI NEAR SOLENOI D
SOLENOI D
T
*t*
I
*-I*
T
*^,T,*
T
;i,
T
,,t,,.
T
wHT I WHT/RED I PNK/8LK I
PNK/BLU
I
GRNTYEL
I
GRN/BLK
- - l +- - ++
T T T T T. , ^T, , T
; I .
T". T"T
I I I I P K/BLK I
PNK/8LU
I
GRNIYEL
I
G8N/BLK
I I | | | | I I I t . l -
L C @ @ @ @ l F l
TCM Terminal Locations
X
1
,,
4
E
7 8 I 1 0 1 1
,l t,
I 2 6 7 8 9 1 0
1 4 1 5 l 6 1 7 20 23 25 26 1 3 1 4 t 5 1 6 1 8 20
TCM
- A
{ 26P) Connct or
TCM- B l 22P) Connecl or
14-191
TGM Termi nal Vol tage/Measuri ng
Gondi ti ons
1 2 3 4 1 I r 0 i 1 112
l a 15 16 11 20 2 3 , / 26
I 2 I 6 7 10
12 14 15 1 7 l 8 20
TCM Torminal Locations
--r-
a
L )
TCM-A
(26P1
Connoctor
TCM CONNECTOR A {26P}
Termi nal Numbor
A1 3
417
A1 8
424
4 1 0
4 1 1
TCM. B l 22Pl Connect or
Measuring Conditions/Terminal Voltage
Engi ne i dl i ng,
E
posi t i on:
Aoorox. 0. 4 V
Engi ne i dl i ng,
l l l
posi t i onl
Appr ox. 0. 7 V
Engi ne i dl i ng,
El
posi t i onl
i ne r unni ng: Pul si ng si gnal
I n
i ! . 1
posi t i on: 0 V
I n ot her t han
E
posi t i on:
I n
EJ
posi t i on: 0 V
l n other than
E
posi ti on: Approx. 1O V
I n
Ll l
posi t i on: 0 V
In other than
E
posi ti on: Approx. 1O V
I nEor Epos i t i onr oV
I n ot her t han
N
or
E
posi t i on:
Approx. 1O V
I n
LEI
posi t i on: 0 V
I n ot her t han
E
posi t i on: Appr ox. 1O V
Wi t h i gni t i on swi t ch ON 1l l ): Bat t ery vol t age
wi rh swi t ch OFF| 0 V
Engi ne i dl i ng,
Engi ne i dl i ng,
Aopr ox. 5. 0 V
Engi ne i dl i ng,
ADor ox. 6. 0 V
posati on:
\
A1 5
A1 6
A19
i ndi cat or l i ght comes on: Approx. 10 V
i ndi cat or l i ght OFF: 0 V
Al ways banery vol t age
(l l ):
Bat t ery vol t age
Wi t h i gni t i on swi t ch OFF| 0 V
14-192
426
St art cl ut ch cont rol l i near sol enoi d
PH PL cont rol l i near sol enoi d power
Shi f t cont rol l i near sol enoi d power
Ay' T gear posi t i on swi t ch
L!
posi t i on
A/T gear posi ti on swi tch
l g
posi ti on
si gnal i nput
A,/T gear posi ti on swi tch
E
posi ti on
Ay'T gear position switch
E or
E
A, , / T gear posi t i on
swi t ch
E
posi t i on
St art cl ut ch cont rol l i near sol enoi d
PH-PL cont rol l i near sol enoi d Dower
Shi f t cont rol l i near sol enoi d power
E
i ndi cat or l i ghr cont rol
{
TCM CONNECTOR B
(22P)
Terminal Number
813
8 1 4
816
817
8 1 8
8 1 9
822
B1
82
B3
B4
B5
B6
B7
B8
8 1 0
Bt l
812
Me6suring Conditions/Terminal Voltag
Wi t h i nhi bi t or sol enoi d ONr Bat t ery vol t age
Wi t h i nhi bi t or sol enoi d OFF: 0 V
( l l ) : Appr ox. 2. 5 V
Wi t h engi ne i dl i ng: Approx. 1. 0 V
(dependi ng on
engi ne speed)
(l l )
and t hrot t l e f ul l y open:
4. 14
-
4. 42 V
(l l )
and t hrot t l e f ul l y
cl osed: 0. 44
-
0. 56 V
(l l )
and rot at i ng f ront
wh e e l s i 0 - SVc y c l e
(l l ): Pul si ng si gnal
(l l )r Pul si ng si gnal
I n ot her t han E
and E
posi t i on: Pul si ng si gnal
l n ot her t han
posi t i on; Pul si ng si gnal
Wi t h brake
pedal
depressedr Bat t ery vol t age
Wi t h brake r el eased: 0 V
wi th i gni ti on swi tch oN
(l l ): Approx.5.0 v
(l l )
and servi ce check con
nect or open: Approx. S V
(l l )
and servi ce check con-
nect or connect ed wi t h speci al t ool : 0 V
Dependi ng on vehi cl e speed: Pul si ng sagnal
When vehi cl e i s st opped: 0 V
par ki ng br ake l ever pul l ed: 0 V
rki nq brake l ever rel eased: vol t age
( l l ) :
Appr ox. 5 .
8 1 5
820
821
Mani l ol d Absol ut e Pressure
(MAP)
sensor si gnal i nput
Throt t l e Posi t i on l TP)
sensor si gnal
i nput
Dat a communi cat i on wi t h ECMI
Transmi ssi on cont rol dat a oLl t put
Dat a communi cat i on wi t h EcM:
PGI M-Fl cont rol dat a i nput
Dri ven
pul l ey speed sensor si gnal
Dri ve pul l ey speed sensor si gnal
Brake swi t ch si gnal i nput
SCS
I
Servi ce check si gnal
Secondary gear shaf t speed sensor
si gnal i nput
Secondary
gear shaf t speed sensor
Parki ng brake swi t ch si gnal i nput
14-193
l. How To Begin Troubleshooting
When the
E
i ndi cator l i ght has been reported on, use the appropri ate procedure bel ow to di agnose and repai r the
proorem.
A. When the
E
i ndi cator l i ght has come onl
1. Connect the Honda PGM Tester or an OBD l l Scan Tool to the 16P Data Li nk Connecl or
(DLC)
l ocated near the l eft
ki ck panel .
(l l ).
3. Check the DTC and note i t. Al so check and note
the freeze trame data.
Refer to the Di agnosti c Troubl e Code Chan and
begi n troubl eshooti ng.
INOICATOR
LIGXT
NOTE: SeetheOBDl l ScanTool or Honda PGM Tester user' s ma n ua l s for speci fi c operati ng i nstructi ons.
Some PGM-Fl probl ems wi l l al so make the
E
i ndi cator l i ght come on. After repai ri ng the PGM-Fl system, di sconnect the
BACK UP fuse
(7.5
A) i n the under-hood fuse/rel ay box for more than 10 seconds to reset the TCM memory, then recheck.
NOTE: Di sconnecti ng the BACK UP tuse al so cancel s the radi o preset stati ons and the cl ock setti ng, Make note of the
radi o presets before removi ng the fuse so you can reset them.
OBD tl SCAN TOoL or
HONDA PGM TESTER
o0\-/oo
OATA LINK CONNECTOR I16PI
14-194
B. DTCS wi l l be i ndi cated by the bl i nki ng of the
E
i ndi cator l i ght wi th the SCS servi ce connect or connected. Connect
the SCS servi ce connector to Servi ce Check Connector as shown.
(The
Servi ce Check Connector
(2P)
i s l ocated
under the dash on the passenger' s si de of the vehi cl e.) Turn the i gni ti on swi tch ON
(l l )
CONNECTOR
07PAZ
-
@101tX)
Codes l through 9 are i ndi cated by i ndi vi dual short bl i nks. Codes 10 and above are i ndi cated by a seri es of l ong and shon
bl i nks. One l ong bl i nk equal s 10 short bl i nks. Add the l ong and shon bl i nks together to determi ne the code. After deter-
mi ni ng the code, refer to the el ectri cal system Symptom-to-Component Chart on pages 14-198 and 14-199.
S.. DYCI
S.c DlC2
Long blink Sho.t blinkt {fiv. tim6l
S.c DTC15
Some PGM-Fl probl ems wi l l al so make the
E
i ndi cator l i ght come on. After repai ri ng the PGN4-Fl system, di sconnect the
BACK UP fuse
(7.5
A) i n the under-hood fuse/rel av box for more than 10 seconds to reset the TCM memory, then recheck.
(cont' d)
CONNECTOR I2PI
Shon blink {onc.l
14-195
(cont'd)
C. l f the i nspecti on for a parti cul ar code requi res vol tage or resi stance checks at the TCM connectors, remove the
dri ver' s si de ki ck panel .
Unbol t the TCM. Turn the i gni ti on swi tch OFF, and connect the backprobe sets and a di gi tal
mul ti meter as descri bed bel ow. Check the system accordi ng to the procedure
descri bed for the appropri ate code(s)
l i sted on the fol l owi ng pages.
How to use the Backprobe Set
Connect the backprobe adapters to the stacki ng patch cords, and connect the cords to a mul ti meter. Usi ng the wi re
i nsul ati on as a gui de for the contoured ti p of the backprobe adapter, gentl y
sl i de the ti p i nto the connector from the
wi re si de unti l comes i n contact wi th the termi nal end of the wi re.
BACKPROBE SET
07sAz
- (x)1000A
(two
roquiredl
DIGITAL MULTIMETER
lCommcrcirlly rv.ilablol
KS- AHM- 32- 003,
or equivalent
ADAPTER
CORD
14- 196
ll. TCM Reset Procedure
2. Remove t he BACK UP f use
( 7. 5
A) f r omt he under hood f use/ r el ay boxf or l 0secondst o r eset t heTCM.
NOTEI
. Di sconnecti ng the BACK UP fuse al so cancel s the radi o preset stati ons and the cl ock setti ng. Make note of the radi o
presets before removi ng the fuse so you can reset them
BACK UP
(7.5
A) FUSE
. The TCM can al so be cl eared by usi ng the OBD l l Scan Tool or Honda PGM Tester.
DATA LINK CONNECTOB I16P)
l l l . Fi nal Procedure
NOTE: Thi s procedure must be done after any troubl eshooti ng.
2. Reset the TCM.
3. Di sconnect the OBD l l Scan Tool or Honda PGM Tester from the Data Li nk Connector
(16P),
or remove the speci al tool
from the Servi ce Check Connector.
(l l ),
and set the radi o presets and cl ock setti ng.
OBO ll SCAN TOOL ol
PGM TESTER
14-197
Di agnosti c
Troubl e Code
(DTC)*
E
Indi caror
Li g ht
Symptom Possi bl e Cause
Refer to
Page
P1790
( 3)
Bl i nks
Engi ne r pm does not i ncr ease.
Transmi ssi on does not ki ck-
Transmi ssi on does not change
t o hi gher rat i o.
Di sconnected throttl e posi ti on (TP)
sensor connecl or
Short or open i n TP sensor wi re
Faul ty TP sensor
14-200
P1791
( 4)
Bl i nks
.
No speci fi c symptom appears. Di sconnected vehi cl e speed sensor
(VSS)
connector
Short or open i n VSS wi re
Faul ty VSS
14 201
P' 1705
15)
Bl i nks
.
Transmi ssi on shi fts same as
E
posi ti on
i n any posi ti ons.
Short i n A/T gear posi ti on
swi tch wi re
Faul ty A"/T gear posi ti on
swi tch
14 202
P' 1706
( 6)
OFF
.
Transmi ssi on shi fts same as
@
posi ti on i n any posi ti ons.
Di sconnected A/T gear posi ti on
swi tch
connector
Open i n A,/T gear posi ti on swi tch wi re
Faul ty Aft gear posi ti on
swi tch
14-204
P0725
( 1
1 )
Bl i nks
Poor accel erati on, fl ares on
starting off.
Di sconnected i gni ti on coi l connector
Short or open i n i gni ti on coi l wi re
Faul t y i gni t i on coi l
14-206
P1793
\ 121
Bl i nks
No speci ti c symptom appears. Di sconnected mani tol d absol ute pres,
sure
(I/AP)
sensor connector
Shon or open i n MAP sensor wi re
Faul ty MAP sensor
14-207
P1870
(30)
Bl i nks
.
starti ng oft.
Di sconnected sol enoi d harness con-
necror
Short or open i n shi ft control l i near
sol enoi d wi re
Faul ty shi ft control l i near sol enoi d
14-208
P1873
( 31
)
Bl i nks
stani ng off.
Di sconnected sol enoi d harness con-
nector
Shon or open i n PH- PL cont r ol l i near
sol enoi d wi re
Faul ty PH-PL control l i near sol enoi d
't4-209
P 1879
(32)
Bl i nks
starti ng off.
Di sconnected sol enoi d harness con
nector
Short or open i n start cl utch control
l i near sol enoi d wi re
Faul ty start cl utch control l i near
sol enoi d
't4-210
P1882
(33)
Bl i nks
No speci fi c symptom appears. Di sconnected sol enoi d harness con-
nector
Shon or open i n i nhi bi tor sol enoi d wtre
Faul t y i nhi bi t or sol enoi d
' t4-2' t
1
Electrical System
{DTC)*: The DTCS i n parentheses
are the number of the
E
i ndi cator l i ght bl i nks when the servi ce check connector i s con-
(SCS
Servi ce Connector).
14-198
\
Di agnosti c
Troubl e Code
(DTCT
E
Indi cator
Li ght
Symptom
Possi bl e Cause
Refer to
Page
P1885
(34)
Bl i nks
starti ng off.
Di sconnected dri ve pul l ey speed sen-
sor connector
Shon or open i n dri ve
Pul l eY
speed
sensot wi re
Faul ty dri ve
pul l ey speed sensor
14-212
P1886
( 35)
Bl i nks
.
starting off.
Di sconnected dri ven pul l ey speed sen-
sor connecror
Shon or open i n dri ven
PUl l ey
speed
sensor wi re
Faul ty dri ven
14-213
P1888
(36)
Bl i nks
.
Poor accel erat i on, f l ares on
st art i ng of f .
Di sconnected secondarY gear shaft
speecl sensor connecror
Short or open i n secondary
gear shaft
speed sensor wtre
Faul ty secondary
gear shaft speed
sensor
14-214
P1655
l 31l
Bl i nks
.
Poor creepi ng
power wi th brake
pedal rel eased.
Short or open i n TMA wi re between
87 termi nal and ECIVI
Shon or open i n TMB wi re between 86
t er mi nal and ECM
Faul ty ECM
Faul ry TCM
14-215
P1890
\421
Bl i nks
starti ng off.
.
Faul ty shi ft control system
14-217
P1891
(43)
Bl i nks
Poor accel erat i on, f l ares on st art -
i ng ot f .
Faul ty start cl utch control system
14-214
(DTC)*:
The DTCS i n
parentheses are the number ol the
E
i ndi cator l i ght bl i nks when the servi ce check
(SCS
Servi ce Connector).
l f the sel f-di agnosti c E
i ndi cator l i ghr does not bl i nk,
perform an i nspecti on accordi ng to the tabl e bel ow
connecl or rs con-
SymPtom
E
i ndi caror l i ght does not come on l or two seconds after i gni ti on swi tch
i s fi rst turn on {l l ).
Inspecti on
Ref . page
14-220
@
i ndi cator l i ght i s on constantl y
(not
bl i nki ng) whenever the i gni ti on
swi tch i s on
(l l ).
14-222
NOTE:
. It a customer descri bed the symptom for code P1706
(5),
i t wi l l be necessary to recreate l he symptom by test dri vi ng,
then recheck the DTC.
. Someti me the E
i ndi cator l i ght and the Mal functi on Indi cator l amp
(Ml L) may come on si mul taneousl y. l f so, repai r the
pGM- Fl
syst em accor di ng t o t he DTc, t hen r eset t he memor y by r emovi ng t he BACK UP f use i n t he under - hood
fuse/rel ay box for more than 10 seconds. Dri ve the vehi cl e for several mi nutes at a speed over 30 mph
(50
km/h), then
recheck the DTC.
)
14- 199
Troubleshooting
Flowchart
-
Throttle Position
(Tp)
Sensor
Possible Cause
.
Disconnoctd throttle Dosition
(TP)
sensor connecior
.
Short or open in TP sensor wire
.
Faultv TP sonsor
TCM CONNECTORS
WHT/ RED
.
OBD ll Scan Tool indic.les Code
P1790.
.
Sef-diagnosis
E indicaior light
blinks threo times.
Check I or Anot he. Code or MI L
Bl i nki ng:
' 1.
(l l ).
2. Check whether the OBD

scan
t ool i ndi cat es anot her code or
the Malfunction Indicator Lamp
l Ml L) bl i nks
(see
sect i on 11).
Does the OBD llscan tool indicate
anot hercode or i st he MI L bl i nk
i ng?
Repai r t he PGM-Fl syst em
l se
sect i on 111.
Measure VREF Vohage:
' L
2. Di sconnect t he A
(26P)
and B
122 P) connect or s f r om l he
TCM.
3. Tur n t he i gni t ; on swi t ch ON
f l r).
t he 820 and A13 or 426 t ermi -
nal s,
Repair op6n or short in the wir6
between the 820 terminal and the
ECM.
Measu.e TPS Voltagel
Measur e t he vol t age bet ween t he
B4 and A13 or A26 t er mi nal s.
Repair open in the whe betwoen
the 84terminal and the TP sensor.
l s t here 0. 4
-0. 6V?
Chock lor loos6 TCM connectoB.
ff necossary, substitute a known-
good TCM and recheck.
l26Pl
RED/BLK
WIRE SIDE OF FEMAI-E TERMINALS
Troubleshooting
Flowchart
-
Vehicle Speed Sensor
(VSSI
Possible Cause
.
Di 3connect ed vehi cl s sPeed
ienaor
(VSSI connectol
.
Short or ooan in VSS wile
.
Faulty VSS
.
Mak6 3ure lifts, iacks,
and salety stands aro
plsced properly
lseo
section 1l
.
Set tho
pa*ing brake socurgly, and block the rear wh6el3.
.
Jack up the front of the vehicl, and supPort it with salety 3tands'
TCM CONNECTORS
.
OBD ll Scan Tool indicare. Codo
P1791.
.
Sor-di.gnotb E
indhttor light
blink3lour tim.i
Refol to s.ction 23 tor vehicle
spood 3ensor {VSSI t6t.
check rh. vss voh.go:
1. Rai so t he vehi cl e.
2. Shi f t t he t ransmi ssi on t o E
posrt|on.
3. Disconnect the A 126P) and B
( 22P) connect or s f r om t he
TCM.
4. Turn t he i gni t i on swi t ch ON l l l )
5. Rot at e t he t ront wheel and
check for the voltage between
nal s. Bl ock t he ot her wheel so
it does not turn.
Check l or open i n t he wi r o
botwean tho 85 torminal and the
vehi cl o speod sen30r
(vSSl .
l f
wire is OK, chock the VSS
(see
3ction 23).
Chack for loo3o TCM connoctoG.
ll nacaaarry, aubltituto t known'
good TcM rnd rechock.
14-201
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Shortl
Possible Cause
. Shor t
i n A/ T gear posi t i on
switch wire
.
Feutty A/T gear pGition
switch
NOTE: Code 5 i s caused when t he TCM
recerves t wo gear posi l i on
i nput s at t he
TCM CONNECTOR A I26P}
WIRE SIOE OF FEMALE TERMINALS
.
OBD ll Scan Tool indicates Codo
P1705.
.
Selt-diagnosis
@
indicator tight
blinks five timos.
Observe t he A/ T
9. r
posi t i on
indicator:
1. Tur n t he i gni t i on swi t ch ON
(
) .
2. Observe t he A/ T gear posi t i on
andi cat or , and shi f t t o each
posi t i on
separat el y.
The sysl em i s OK at t hi s t i m.
Check the wire harness tor dem-
age.
Do any indicators stay on when the
shift lever is not in that position?
Mersure ATP R Voltagel
1. Shi t t t o al l posi t i ons
ot he. t han
tr.
t he Al 1 and A13 or 426 t ermi -
nal s.
Check f or shor t i n l he wi . e
betwoen the A11 terminal and tho
A/T gear position
switch or A/T
gear position
indicator. ll wire is
OK, check for loose TCM connoc-
t ors. l f nocessary, subst i t ut e a
known-good TCM and .echeck.
Measure ATP NP Voltagei
1. Shi f t t o al l pos i t i ons
ot her
t han
E or
E.
t he 410 and A13 or 426 t ermi ,
nal s,
Check f or shor t i n t h6 wi r o
bet ween l he A10 t ermi nal and
the A/T gar position
indicator.
or a short in tho wires botween
t h A/ T gear posi t i on
i ndi cat or
and t he A/ T gear posi t i on
switch. lI wires are OK, check for
loose TCM connectors. ll neces-
sary, subst i l ut e a known-good
TCM and rochck.
l s t here approx. l 0 V?
Measure ATP D Vohago:
ot her t han
E,
t he A9 and A13 or 426 rermi -
nal s.
Check f or short i n t he wi re
bstwoon the Ag terminal and the
A/T gear position switch. ll wiro
is OK, check lor loose TCM con-
nectoG. lf neces3ary, substitute a
known-good TCM and rcheck.
To page 14' 203
14-202
From page 14-202
M.ssur6 ATP S Vohage:
1. Shj f t t o al l
posi t i ons ot her t han
ts.
t he Ag and A13 or A26 t ermi
nal s.
Check l or sho* i n t he wi re
between tho A8 tolminal and the
A/T
9o.r
po3ilion switch or the
A/T goar position indicrtor. lf wirc
is OK, check for loose TCM con-
nctors. ll necessery, substitute a
known-good TcM and rochck
Moasure ATP L voltager
1. Shi t t t o al l
posi t i ons ot her t han
E.
t he A7 and A13 or A26 t ermi -
nat s,
Check f or short i n t he wi l e
betwoen the A? terminal and the
A/T gear po3ition switch or the
A/f gear pGition indicttor. lf wile
is OK, check for loo3o TCM con-
nectors. lf nocasi.ry. subditute a
known-good TCM and rc.ch.ck.
Check tor looso TCM connoctors.
It neco$ary, substitute a known_
good TCM and rechock.
TCM CONNECTOR A
(26P}
14-203
El ectri cal Troubl eshooti ng
Troubfeshooti ng
Fl owchart- AIT Gear
posi ti on
Swi tch
(Open)
\
Possible Cause
.
Oisconnected A/T geer position
switch connector
.
Open in A/T gear position
switch
.
Faulty A/T gear position
switch
Measure ATP R Voltage:
(l l ).
2. Shi f t t o
E
posi t i on.
t he A11 and A13 or 426 t er mi
nal s,
Ii
14-204
.
P1706.
.
Self-diagnosis
E indicator tight
blinks six times.
Repair open in the wire botween
l he A11 t er mi nal and t he A/ T
gear position switch.
1. Shi f t t o
E or
E
posi t i on.
t he A10 and A13 or 426 t er mi -
nal s.
Bepair op6n in the wire between
t he A10 t er mi nel and t he A/ T
gea. position
switch.
Measure ATP D Voltage:
1. Shi f t t o
E
posi t i on.
t he Ag and Al 3 or 426 t ermi
nal s.
Repair open in tho wire between
the Ag torminal and the A/T gea.
Dosition switch,
To page
14 205
Frcm page 14-204
Measuro ATP S Voltage:
1. Shi t t t o
E
posi t i on.
t he Ag and A13 or A26 t ermi _
nal s.
Repair open in lhe wire between
the A8 terminal and the A/T
gear
oo3iiion swilch.
Meesure ATP L Voltage:
1. Shi f t t o E
posi t i on.
t he A7 and A13 or A26 t ermi _
nal s.
the A7 termin.l and th A/T
goar
oosition switch.
Check for loose TCM connectors.
lf necessary, sub3titute a known'
TCM CONNECTOR A {26P}
14-205
Troubleshooting
Flowchart
-
lgnition Goil
PosFibls Cause
.
Oisconnected ignition coil con-
ngctor
.
Short or op6n ignition coil wire
.
Faulty ignition coil
.
OBD ll Scan Tool indicats Code
P0725.
'
Selt-diagn6is
E
indicaior tight
indicat6s Cod6
'l
1.
Maasu.o NE Voltag6:
1. Di sconnect t he A l 26p) con-
nect or f rom t he TCM.
2. Start the engine.
t he A5 and A13 or 426 t ermi ,
nal s.
Repair open or short in the wiro
between the A5 torminal and ths
ignition coil. f wire is OK, chsck
the ignhion coil tost {see section
23l..
Chock tor loose TCM connector.
It nec$sary, sub3titute a known-
Ii
14-206
-
(MAP)
Sensor
Po$iblo Causo
.
Dilconnoctod manitold absolute
prG3u.a
{MAP} sensor connoc_
lol
.
Short or opan i n MAP 3on3o.
MAP snsol
TCM CONNECTORS
.
OBO ll Scan Tool indicat$ Code
P1793.
.
Self.diagno.i3 E
indicator light
indicat* Cods 12.
Check tor Anolhor Coda or MIL
Blinking:
(l l ).
2. Check whether the OBO ll scan
tool indicates another code or
the Malfr.rnction Indicator LamP
(Ml L) bl i nks
(see
sect i on 11).
Doest he OBD l l scan t ool i ndi cat e
anot her code ori st he MI L bl i nk-
i ng?
Repair PGM-Fl syltem 1366 3ec'
t i on 111.
Mca3uro VREF Vohtge:
l . Turn t he i gni t i on swi t ch OFF
(26P) and B
( 22P)
connect or s Jr om t he
TCM,
(ll).
nal s.
R6pai. opon ot short in ths wire
botw.on the 820 tolminal and
rhe ECM.
Moasur. MAP
(PBl voltago:
Measure the voltage between the
82 and A13 or 426 t ermi nal s.
Repair open or shon in the wire
botween tho 82 terminal and tho
MAP snsor.
Chck tor loo3e TCM connectors.
lf n6ce$ary, 3ubstitut6 a known'
good TCM and rech6ck.
WHT/REO
WIRE SIOE OF FMALE TERMINALS
14-207
-
Shift Control Linear Solenoid
Possibl Cau3e
.
Disconnected solenoid harness
connector
.
Short or op6n i n shi f t cont . ol
linear solonoid wire
.
Faulty shift control linear solc-
noi d
SOLENOI D HABNESS
8P CONNECTOR
TERMI NAL SI DE OF MALE TERMI NALS
WI BE SI DE OF FEMALE TERMI NALS
.
P1870.
.
Selt-diagnosis
E
indicator light
indicetes Cod 30.
Measure Shift Control Line.r Sole-
noi d Resi st ance at l he Sol enoi d
Harness Connector:
f rom t he sol enoi d harness con-
nector.
2, Measu r e t he r esi st ance
beNveen the No. 3 and the No.
7 t ermi nal s of t he sol enoi d har
ness connector.
l s t he resi st ance 3. 8 6. 8 O?
Check Shift Control Linear Sole-
noid for a Shon Circuit:
( 26P)
con
body ground
and t he 43 t er-
mi n a l a n d t h e A1 6 t e r mi n a l
i ndi vi dual l y.
Repair shorl in the wi.es be'tween
the A3 and A16 terminals and the
body ground.
l s t here conl i nui t y?
Maasur e Shi f t Cont r ol Li near
Solenoid R6istance:
1. Connect t he 8P connect or t o
t he sol enoi d harness connec
t or.
2 . Me a s u r e t h e r e s i s t a n c e
rJet ween t he A3 and A16 t er-
m t nal s.
Repair loose terminal or open in
t he wi res bet ween t he A3 and
A16 t ermi nal s and t he sol enoi d
harness connector.
l s t he resi st ance 3. 8
-
6. 8
g?
Check lor loose TCM connectors.
ll nece$ary, substitute a known-
8LU/WHT
GRN/ YEL
TCM CONNECTOR A I26PI
o
GRN/ YEL
I 3 a 7 8 9 l 0 1 1 12
11 l 5 16 1 7 20 23 26
BLU/ YEL
o
GRN/ YEL
1 1
2
' '
t'Ft
4 5 I I 10 1 t 12 13
1 7 m 23 25 26
BLU/ YEL
14-208
,--
Troubteshooting
Flowchart
-
PH-PL Control Linear Solenoid
Po$ib16 Cau3e
.
Disconnected solonoid hatn8s
connectol
.
Short or opon in PH_PL contol
linear 3olenoid wire
.
Faulty PH-PL control linear sole_
noid
SOLENOID HARNESS
8P CONNECTOR
GRN/WHT
TCM CONNECTOR A
(26P)
OBD ll Scan Tool indicats Codo
P1873.
Self-diagnosis E
indicrtor light
indicats Codo 31.
Mgasure PH-PL Cont rol Li neet
Solenoid Rgsistanca al th6 Sole-
noid Harne3s Conn6ctor:
from the solenoid harness con-
nector.
2. Measu r e t he r esi st ance
between the No. 2 and the No.
6 t ermi nal s of t he sol enoi d ha.
ness connector.
ls the resistance 3.8
-
6.8 0?
Check PH- PL Cont r ol Li noar
Sol.noid tor a Short Circuit:
(26P)
con-
nector from the TCNI.
body
ground and t he A2 t er_
mi nal and t he A15 t er mi nal
i odi vi dual l y.
R6pai r 3hor t i n t he wi r es
between the A2 and 415 tormi-
nals and the body ground.
Mea3ure PH-PL Cont rol Li near
Solsnoid Ro3istance:
t he sol enoi d harness connec-
t or.
2. Measur e t he r esast ance
bet ween t he A2 and A15 t er-
manal s,
Ropair loosa terminel or opon in
i he wi res bet ween t he A2 and
A' 15 t ormi nal s and t he sol onoi d
haJness conn6ctor.
-
6. 8 0?
Ch.ck for loosa TCM connectors.
It nece$ary, substhuto a known_
good ICM and rechck.
PNK/ BLK
o
PNK/ BLK
1 1 5 8 I 10 1 1 12 1 3
11 15 11
20 23 25 26
LGRN/WHr
o
_J( ) l -
- l
t , t .
u1l]
PNK/ BLK
3 a 8 9 t 0 11 12 13
16 1 7 20 23 25 26
GRN/WHT
14-209
.
OBO ll Sc.n Tool indicst$ Code
P1879.
.
Selt-diagnosis
E
indicator light
indicates Code 32.
Measuro Sl an Cl ut ch Cont rol
Linar Solenoid Rosistance at the
Solenoid Harness Connoqtor:
from the solenoid harness con-
nector,
between the No. 4 and the No.
8 t ermi nal s of t he sol enoi d har-
ness connector.
-
6.8 O?
Check Start Clutch Control Lin-
ear Solonoid tor a Shori Circuitr
(26P)
con-
body ground
and t he A1 t er-
mi nal and t he A14 t er mi nal
i ndi vi dual l y.
R6pai r shor t i n t he wi r 6s
betwoen th6 Al and A1{ lermi-
nals and the body grcund.
Measu. 6 51. n Cl ut ch Cont . ol
Linoar Solenoid Ro3istance:
t he sol enoi d harness connec-
t or.
bet ween t he A1 and 414 t er-
mrnal s.
Repair looae tormin.l o. open in
i h. wi r6s bot woen t h Al snd
414 t ermi nal s and t ho sol enoi d
htanos3 connectot.
-
6.8 O?
Check for loos TCM connsctors.
lf necossary, substitute a known-
good TCM and rechock.
-
Start Clutch Control Linear Solenoid
Possible Crule
.
Disconnectod sol.noid harno33
connoctot
' Sho. l
or opan i n 6t art cl ut ch
control lineff solonoid wire
.
Faulty 3tart clutch control lineat
solenoid
SOLENOID HARNESS
8P CONNECTOR
YEL
PNK/BLU
TCM CONNECTOR A I26P)
o
PNK/ BLU
1 2 3 I 5 7 E 9 10 1 1 12 13
1a t5 16 20 23 25 26
I YEL
0)
F
J r
I
PNK/BLU
2 3
il
5 7 8 9 10 12 13
a 15 16 17 20 23 25 26
YEL
14-210
-
lnhibitor Solenoid
Po$ible Cause
.
Disconnected solenoid harn6s3
connectol
.
Short or open in inhibitor sol.'
noid wi.e
.
F.ultv inhibhor solenoid
SOLENOID HARNESS
8P CONNECTOR
.
P1882.
.
Self-diagnosis E
indicator light
indicates Code 33.
Masure Inhibitor Solenoid Re3ist'
ance at l he Sol enoi d Har ness
Connector:
1. o; sconnect t he 8P connect or
f r om t he sol enoi d har ness
connect or.
2. Measu r e t he r esl st ance
bet ween t he No. 5 t ermi nal of
t he sol enoi d harness connec_
t or and body
ground-
l st he resi st ance 11. 7
-
21. 0 A?
Check I nhi bi t or Sol enoi d f or a
Short Circuit:
1. Di sconnect t he I
( 22P) con-
t h e B' 1 t e r mi n a l a n d b o d y
ground.
Repair 3hort in the wire between
the B1 and the body ground.
Measure lnhibhor Solenoid Resisl'
ance:
t he sol enoi d harness connec_
I Or.
bet ween t he B1 and body
gr ound.
ReDair loose terminal or open in
the wire between the Bl and the
solenoid harness connectoa.
-21. 0{l ?
Check tor loose TCM connectors.
lI necessarv, substitute a known-
TCM CoNNECTOR B l22p)
WIRE S|OE OF FEMALE TERMINALS
14-211
.
P18a5.
.
Selt-diagnosis
El indicator tight
indicat$ Codo 3{.
l s t he dri ve pul l ey
speed sen-
sor i nst al l ed properl y?
Measurc D.iv6 Pulloy Sped Sen-
sor Rasistlnce st the SorBor Con-
nctoJ:
f rom t he dri ve pul l ey
speed
sensor connect or,
dri ve pul l ey
speed sensor.
-
600 O?
Check Dri v6 Pul l Gy Spood S. n-
sor for s Short Ci.cuit:
1. Disconnect the B
(22p)
connec-
t orf rom t he TCM.
2. Check for continlity between
body ground
and t he Bl 0 t r,
mi nal and 817 t er mi nal i ndi -
vi dual l y.
nepair shon in th. wiags botween
t he B10. nd 817 t ormi nal s 6nd
the driv6 pulley
spd 3onso..
Measuro Drivo Pulloy Spood Sen-
sor R6ktanco;
1. Connect the drive pulley
speed
sensor 2P connector,
bet ween t he 810 and 817 t er-
mi nal s.
RepaL looro toiminal or open in
tha wiro3 betw6on tho Bto rnd
817 t.rminak .nd the driv6 oul-
lay !p6od an3or.
-
600 0?
Chock lor looso TCM connestor.
lf necessary. sub3titute e known-
good
TCM and rechock.
Troubleshooting
Flowchart
-
Drive
pulley
Speed Sensor
Po$iblo Cause
.
Dbconnectod drivo pulloy
lpocd
30n301 connectot
.
Shon or op. n i n di i v. pul l ey
tpasd sonaor wire
.
Faulty drivr pull.y
sp..d ron-
soa
TERMINAL
\
ORIVE PULEY SPEED
SENSOR 2P CO NECTOR
t|;Trl
*r-r
t 9
LJ
SIDE OF MALE TERMINALS
\
TCM CONNECTOR B
(22P}
RED/BLU
REO/BLU
2 4 5 6 , E 9 t 0
12 t3 11 t5 16 1' 18 m
GRN
t,
I 2 a 5 iTiT;f;Fdz
12 131a t5 16 ,I,ElVdVV
GRN
14-212
Troubleshooting
Flowchart
-
Driven Pulley Speed Sensor
Possible Cause
.
Di sconnect ed dt i ven
PUl l ey
3pegd sensor connec'tor
.
Short or open in driv6n PulleY
so6d son3or wire
.
Faulty driven
pulley speed sen_
TERMINAL
DRIVEN PULLEY SPEED
SENSOR 2P CONNECTOR
t- r-_- l
l t 1 | 2 |
lL+
-T-r
l @
t l
t_.1
TCM CONNECTOR
B
(22P)
WHT
'
OBD ll Scan Tool indicats Code
P1846.
.
Solt-diagnosis E
indicator light
indicates Code 35.
Chec k t he dr i v en
Pul l ey
s Peed
sensor i n st a l l at i o n,
l s t he dri ven
pul l ey speed sen-
sor i nst al l ed
properl y?
Measure Driven Pulloy Speed Sen-
sor Resistance at the Sensor Con-
nector:
1. Di sconnect t he 2P connect ol
f rom l he dri ven
PUl l eY
speed
sensor connect or-
dri ven pul l ey speed sensor,
l s t he resi st ance 350 600 0?
Check Driven Pulley Speed Sn-
sor for a Short Citcuit:
(22P)
connec'
t orf rom t he TCM.
body
ground and t he 88 t er
mi nal and 89 t ermi nal i ndi vi d-
uaI y.
Reoair short in the wirs bgtween
th 88 .nd 89 terminals and the
driven
pulley spoed sensor.
Measule Driven Pulloy Speod Son-
sor Resistance:
1 . Co n n e c t t h e d r i v e n
PUl l e Y
speed sensor 2P connect or.
bet ween t he 88 and Bg t ermi
nal s,
Eepair loose trminal or opon in
th wires botween the 88 and Bg
l ermi nal s and t he dri ven
Pul l ey
soeed sensoJ,
l s t he resi st ance 350 600 O?
Check lor loose TCM connector.
lf necessarv, substitute a known'
good TcM and recheck.
0 o
a 5 6 8 10
12 13 14 15 1 6 1 7 1 8 20
RED/BLUI
Al
\j/
WHT
1 2 a 6 8 10
12 13 14 15 16 17 1 8 20
14-213
Troubleshooting
Flowchart
-
Secondary Gear Shaft Speed Sensor
.
OBD ll Scan Tool indicates Cod
P1884.
.
Self-diagnosis
E
indicalor light
indicates Code 36.
Possible Cause
.
Di sconnecl ed 3econdary gea.
shaft speed sonsor connctot
.
Short or open in scondary gear
shaft speed sonsor wire
.
Faul t y secondary
9ea1
3haf t
TERMI NAL
SECONDARY GEAR SHAFT SPEED
SENSOR 2P CONNECTOR
lT- T---1
t l l 2 l
-T--T-
t a
t l
L__l
TCM CONNECTOR B
(22PI
Check t he secondar y gear shat t
speed sensor i nst al l at i on.
l s t he secondary gear
shat t speed
sensor i nst al l ed properl y?
Measur Secondary Gear Shaf t
Speed Sonsor Resistance at the
Sensor Connectoa:
f rom t he secondary gear
shaf t
speeo sensor connect or.
secondary gear
shaf t speed
-
600 O?
Ch6ck Countrsheft Speed Sen-
sor for a Short Circuitl
1. Disconnect the B
(22P)
connec,
tor from the TcM.
body ground
and t he 815 t er-
mi nal and 816 t er mi nal i ndi
vi dual l y.
Ropair short in the wires betwoen
t he 815 end 816 t ermi nal s and
the socondary g6ar 3haft speed
sensor.
l s t her e cont i nui t y?
Measure Secondery Goar Shaf t
Sped Sensor Resistance:
1. Connect t he secondar y gear
shaf t speed sensor 2P connec-
t or,
bet ween t he 815 and 816 t er-
mt nal s.
Bepair loose terminal or oDen in
the wires btween the 815 and
816 terminals and the secondery
gear
shaft speed sensor.
-
600 O?
Check tor loose TCM connector.
It nocessary, substitute a known-
1 a 5 6 8 9 10
12 13
' 14
15 16 17 18 20
WHT/REDT
' 1
ORN/BLU
o) (o
2 1
8 10
12 13 14 15 16 1 7 l 8 20
WHT/ REI
A
I
ORN/ BLU
14-214
Troubl eshooti ng Fl owchart
-
TMA and TMB Si gnal s
Po$ible Csuse
.
Shor t or open i n TMA wi r e
between B? terminal and ECM
.
Shor t or oDen i n TMB wi r e
beiwoen 86 terminal and ECM
.
Faultv ECM
'
F.ultv TCM
TCM CONNECTOR B I22P)
GRY
WIRE SIDE OF FMALE TERMINALS
GRY
GRY
{ cont ' d)
o
I 2 a 6 t 7 8 I 10
12
't3
1a 15 16 17 18 20
ECM CONNECTOB C 131P)
GRY
2 3 1 s J s ; l I I
1 112 t 3 t 4 16 17l l e
/t./
22
/ / / / l 2s
I
1 1 5 7 8 I 10
12 13 14 1 6 1 7 18 20
ECM CONNECTOR C {31P)
1 2 I 5 6 7 8 10
11 12 131 4 t 5 1 7r 8
t/
4r 30
.
OBO ll Scan Tool indicate3 Code
P1665.
.
Seff-dirgnosis E
indicator light
indicstos Cod 37.
Check TMA Wire ContinuitY:
(22P) con-
3. Di sconnect t he C
( 31P)
con
nect or f rom t he ECM.
t he 87 t er mi nal of t he TcM
and t he Cg t er mi nal of t he
ECM.
Rpair open in the wiro between
the TCM and the ECM.
Chock TMA wite lor a Shorl Ci.-
cuiti
Check l or cont i nui t y bet ween t he
87 t ermi nal of t he TCM or t he Cg
t er mi nal of t he ECM and body
ground.
Check the ECM:
1. Reconnect t he C { 31P) con
nect or t o t he ECM, and t he B
{22P) connect or t o t he TCM.
(l l ).
t he c9 t er mi nal of t he EcM
and body
ground.
Check fo. loose ECM connectors.
ll necessary, substitute a known'
good ECM and rcheck.
To page 14-216
14-215
-
TMA and TMB Signals
(cont'dl
TCM CONNECTOR B I22P}
WIRE SIDE OF FEMALE TRMINALS
PNK
PNK
f t om page 14 215
Check TMB Wire Continuity:
2. Di sconnect t he C 13' 1P) connec
t or f rom t he ECM. and t he B
{22P) con neclor from the TCM.
t he 86 t er mi nal of t he TCM
and t he C30 t er mi nal of t he
ECM.
Repeir open in the wi.o between
the TCM and th6 ECM.
Check TMB Wire tor a Short Cir-
cuit:
86 t er mi nal of t he TCM or t he
C3 0 t e r mi n a l o f t h e ECM a n d
body ground.
check th6 TcM:
1. Reconnect t he B
( 22P)
con-
nect or t o t he TCM, and t he C
(31P)
connect or t o t he ECM.
2. Turn t he i gni t i on swi t ch ON {l l }.
t he 86 t er mi nal of t he TCM
and body ground.
Check Ior loose TCM connectors.
lf nece3sery, substituto a known-
good TCM and rcheck.
o
I 2 4 I | 9 1 0
12 1314 l 5 1 7 1 8 20
ECM CONNECTOR C {31P}
1 2 4 s l 6 7 I 9 10
1 12 t 3 l 4 16 1 181/r,/)/
LA WU 14+
PNK I
o
2 4 5 7 8 10
12 131a 15 16 17 18 20
PNK
1 2 4 6 1 8 9
' t0
12 1 3 11
' 15
1 6 1 7 l 8 20
14-216
Troubleshooting
Flowchart
-
Shift Control System
Poasibla C.uta
.
Faulty shitt control rystom
.
OgD ll Sc.n Tool indiclt6 Codo
P1890.
.
S.lt diagno.b E
indicator ligl|t
indic.tG Codo 42.
Ch6ck for Anoth.r Cod.:
check wht her t he E]
i ndi cat or
light indicates snother code.
Parl orm l ha Troubl 63hoot i ng
Fl owch. rt t or t hc i ndi ct t cd
Codolrl.
l st he
E
i ndi cat or l i ght i ndi -
cato another cod6?
Ch.ck Stlll Spo.d RPM:
Meagur e t he st al l speed RPM
(see pag6 14-230).
ls the stall speed over 3,500 rpm?
lsthe stall soeed blow 2,000 rPm?
T. ! l -dri vo . nd Ch. ok Engi na
Spa!d:
t . Dri v t he vehi cl e at 30 mPh
(50 km/h) constantly for sev-
eral minutes,
2. Check t he engi ne sps6d.
ls th6 engino speed within tho
spocification
(se6 page 14-228
and 1+229)?
14-217
Troubleshooting
Flowchart
-
Start Clutch Gontrol System
.
P1891.
.
Selt-diagnb
E
indicator tight
indicates Code 43.
Check for Another Code:
Check whet her t he
E
i ndi cat or
l i ght i ndi cat es anot her code.
PossiblG Cause
.
Feulty start clutch control sys-
tem
Per l or m t he Tr oubl eshoot i ng
Fl owchar t f or t he i ndi cat od
Code(sl .
l s t he
E
i ndi cat or t i ght i ndi
cat e anot her code?
Test Start Clutch Operationl
2. oi sconnect t he 8P connect or
f rom t he sol enoi d harness con-
3. St art t he engi ne, and shi f t t o
E
posi t i on.
4. Check whet her t he vehi cl e
moves,
ooes t he vehi cl e moveT
Replaco the stan clutch, assemblv.
Check Creeping Speed:
2. Reconnect t he 8P connect or t o
t he sol enoi d harness connec,
t or.
3. St an t he engi ne, and shi f t t o
E
posi t i on.
4. Check whet her t he vehi ci e
creeps, and check t he creep,
i ng speed.
Does t he vehi cl e move and i s
t he cr eepi ng speed appr ox. 3
mph ( 5
km/ h) ?
To page 14- 219
14-218
From page 14-218
Chock Stall Speed RPM:
Measure t he st al l sooed RPM
(see
page 14-230).
ls the stall sDeed over 3,500 rpm?
Warm Up Eogi ne and Rochck
F.ilure:
1. War m up t he engi ne t o nor
mal oper at i ng' aemper at ur e
l t he radi at or f an comes on).
2. Check whet her t he st art cl ut ch
probl em appears agai n.
The syst6m k OK rt this time.
a
14-219
Troubleshooting
Flowchart
-
E]
Indicator Light Does Not Come On
TCM CONNECTOR A
(26P)
BLI i r ( [ ,
l-
1 a 8 9 10 t 1 12
a
14 15 16 1 7 20 23 25
a
BLK
(
o
The
E
I ndi cat or t i ght does not
come on whon lhe ignition switch
is first turned ON
(lll. (lt
should
come on tor about two seconds.l
Check the Service Chock Connec-
tot:
Make sure t he speci al t ool 1SCS
Ser vi ce Connect or ) i s not con
nect ed t o t he servi ce check con-
nect or,
l s t he speci al t ool
(SCS
Servi ce
Connect or) connect ed t o t he ser-
vi ce check connect or?
Disconnsct th6 sDecial tool trom
the sgrvice chgck connector and
recheck.
Check th
E
Indicator Light:
Shi f t t o
E
posi t i on.
Chock tor loosc TCM connector3.
ff n6cess6ry, 3ubstituta e known-
good TCM and rachock.
Does t he
E
i ndi cat or l i ght
Check the Ground Circuit:
( 26p)
con-
t he A13 t er mi nal and body
ground
and t he 426 t ermi nal
and body ground.
.
Repai r opan i n t he wi . s
botwean lho A13 or A26 termi-
nal s and G101.
.
Repair poor ground
ic101).
Io page
14 221
Fr om page 14 220
Measure Power SuPPI Y Ci rcui l
Voltege:
(l l ).
t e r mi n a l s A1 2 a n d A1 3 a n d
bet ween t er mi nal s A25 and
426.
Repair open or short in the wiro
between the Al2 and/or A25 ter-
mi nal s and t he undeFdash f use
box.
l s I her e baner y vol t age?
Measure O IND Voltag6:
2. Connect t he A 126P)
connec'
t or t o t he TCM.
3. Connect a di gi t al mul t i l est er
10 t he A20 and A13 or A26 t er
mr nal s.
(l l ),
and make sure that the voltage
i s avai l abl e f ort wo seconds
Check t or oDen i n t he wi r e
bt ween t he A20 t ermi nal and
lhc gauge assembly. lf the wire
is OK, check for a faulty
El
indi-
cator lighl bulb or a faulty
gauge
assombly
printed circuit boa.d
Check D IND lor an Short Ci.ctlit:
1. TLrrn t he i gni t i on swi t ch OFF.
( 26P)
con
t he A20 t ermi nal and t he No. I
t ermi nal of t he
gauge assem-
bl y connect or l see sect i on 23).
the A20 terminal and the gauge
essemblY,
Check tor loose TCM connectors.
Check t he A/ T
ge. r posi t i on
switch. lf necessary. substitute a
known-good TCM and recheck.
BLK/WHT I
( v)
Y
I
1 2 I 5 I 9
' 10
l t 12
t a 15 16 1 7 20 23 25 26
BLK/WHT
)
TCM CONNECTOR A
(26PI
TCM CONNECTOR A
(26P}
WIEE SIDE OF FEMALE TERMINALS
BLK
BLK
GRN/ BLK
14-221
Tho
llj indicator light b on con-
st ant l y {not bl i nki ng} whenev. r
the ignition switch b ON
(ll).
Mea3ure D IND Voltag6:
2. Di sconnect t he A ( 26P)
con-
3. Turn the ignition switch ON {ll).
t he 420 t er mi nal and body
ground.
Repair short to
powsr
in the wir.
bot woon t ha A20 t 6rmi nal . nd
lhs gaug essombly.
Me.3ur6 ATP OVohage:
2. Connect t he A
(26P)
connec-
t or t o t he TCM.
(ll).
4. Shi f t t o any posi t i on ot her t han
E.
t h e AS t e r mi n a l a n d b o d y
ground.
Chock tor a short lo ground
on
t he wi re. I t wi ro i 3 OK, ropl aco
the A/T goar pGition
indic.tor.
-
El
Indicator Light On Constantly
TCM CONNECTOR A I26PI
\
1 2 3 { 7 8 9 10 t l 12 13
t 4 15 1 5 1 7 20 23 25 26
GRN/ 8LK
1 2 3 I 5 E 9 l 0 I t 12 13
t a l 5 16 11 20 23 E 26
rd
14-222
Li near Sol enoi ds/l nhi bi tor Sol enoi d
Test
2.
'L
Di sconnect the 8P connector from the sol enoi d har-
ness connecl or.
Measur e t he r esi st ance of t he shi f t cont r ol l i near
sol enoi d between the No. 3 and No. 7 termi nal s of
the sol enoi d harness connector.
l Measure the resi stance of the PH-PL control l i near
sol enoi d between the No. 2 and No. 6 termi nal s.
Measure the resi stance of the start cl utch control
l i near sol enoi d between the No. 4 and No. 8 termi -
nal s.
STANDARD: 3.8
-
6.8 o
Measur e t he r esi st ance of t he i nhi bi t or sol enoi d
between the No. 5 termi nal and body ground.
STANDARD: 11.7
-
21.0 0
3.
SOLENOI D HARNESS
CONNECTOR
ATF DIPSTICK
6. Repl ace the l ower val ve body assembl y i f any of the
sol enoi ds resi stance i s beyond the standard.
14-223
7. l f al l of the resi stances are wi thi n the standard, a
cl i cki ng sound shoul d be hear d when connect i ng
the battery termi nal s to the sol enoi d harness con
nector termi nal s bel ow:
. Shift control linear solenoid
No.3: Batterv
posi ti ve
termi nal
No.7: Battery negati ve termi nal
. PH-PL control linear solenoid
No.2: Bafterv oosi ti ve termi nal
No.6: Battery negati ve termi nal
. Start clutch control linear solenoid
No. 4: Batterv oosi ti ve termi nal
No. 8: Battery negati ve termi nal
. l nhi bi tor sol enoi d
No. 5: Battery
posi ti ve
termi nal
Body ground: Battery negati ve termi nal
SOLENOID HARNESS CONNECTOR
l f no cl i cki ng sound i s hear d, r epl ace t he l ower
val ve body assembl y.
NOTE| l f t he l ower val ve body assembl y r epl ace-
ment i s requi red, see Lower Val ve Body Assembl y
Repl acement {page' 1 4-234).
8.
Drive Pulley/Driven Pulley/Secondary Gear Shaft Speed
Sensors
Replacement
CAUTION: While replacing the speed sensor, be sure not to allow dust and other loreign particles
to enter into the ttans-
mi ssi on.
1. Di sconnect the dri ve pul l ey,
the dri ven pul l ey, or the secondary gear shaft speed sensor connector.
2. Remove the 6 mm bol t from the transmi ssi on housi ng, and remove the dri ve pul l ey. the dri ven pul l ey, or the sec-
ondary gear shaft speed sensol .
3. Repl ace the O-ri ng wi th a new one before rei nstal l i ng the dri ve pul l ey, the dri ven pul l ey, or the secondary gear shaft
sDeed sensor.
6 x 1 . 0 mm
12 N.m {1.2 kgf.m, 8.7 lbl.ftl
6 x 1 . 0 mm
12 N. m (1. 2
kgf . m,
8.7 tbf fr)
\ ,
DRI VEN PULLEY SPEEO SENSOR
14-224
\
Start Clutch Control
Start Clutch Calibration Procedure
NOTE: When the fol l owi ng parts are repl aced, the TCM
must memori ze the teedback si gnal for the start cl utch
control .
o TCM
. Transmi ssi on assembl y
. Start cl utch assembl y
. Lower val ve body assembl y
. Engi ne assembl y or overhaul
'96
Modl Only
CAUTION: Do not use thi s procedure
on' 97
-' 98
mod.
el s or you wi l l damage the transmi ssi on. On' 97
-' 98
models, the TCM memorizes the feedback signals when
you drive the vehicle.
1. Engage t he par k i ng br ak e, and bl oc k t he f r ont
wheel s securel y.
2. Connect the SCS servi ce connector to the Servi ce
Check Connect or as shown.
( The
Ser vi ce Check
Connect or
( 2P)
i s l ocat ed under t he dash on t he
passenger' s si de of the vehi cl e.)
CONNECTOR
07PAZ
-
0010100
Start the engi ne, and warm i t up to normal operat
i ng temperature
(the
radi ator fan comes on twi ce).
Ful l y depress the brake pedal and accel erator for 20
seconds i n the
E
posi ti on.
4.
CONNECTOR
(2PI
14-225
7.
8.
Shi f t i nt o
E
or
E
posi t i on. To st or e t he engi ne
negat i ve pressure i n memory, l et t he engi ne i dl e i n
E
or
E
posi t i on f or one mi nut e under t he f ol l ow-
i ng condi t i onsl
. Wi t h t he brake pedal depressed.
. Wi t h t he A, / C swi t ch OFF.
. Wi l h t he combi nat i on l i ght swi t ch OFF.
. Wi t h t he heat er f an swi t ch OFF.
. Turn OFF al l ot her el ect ri cal syst ems.
NOTE: St art st ep 5 w; t hi n 60 seconds af t er t he radi -
at or I an goes of f .
Shi f t i nt o
E
posi t i on, and l et t he engi ne i dl e l or t wo
mi nut es t o st or e t he f eedback si gnal i n memor y
under t he same condi t i ons as i n st ep 5.
Connect t he Honda PGM Test er. Check t hat t he TCM
has compl et ed t he st art cl ut ch cal i brat i on.
NOTE:
o The TCM wi l l not store the feedback si gnal when
the CVT fl ui d temperature i s bel ow 40' C
(104' F)
even i l the engi ne cool ant temperature reaches
the normal operati ng temperature.
a Repeat t hese pr ocedur es unt i l t he st ar t cl ut ch
cal i brati on i s compl eted.
Di sconnect t he SCS ser vi ce connect or f r om t he
Servi ce Check Connector.
'97
-
'98
Models
The TCM memori zes the feedback si gnal when you
dri ve the vehi cl e as fol l ows:
Af t er war ni ng up t he engi ne
( t he
r adi at or f an
comes on) .
Shi ft i nto
E
posi ti on.
Turn OFF al l el ectri cal systems.
Dr i ve t he vehi cl e up t o t he speed 37 mph { 60
km/h).
Af t er t he s peed r eac hes 37 mph
( 60
k m/ h) ,
rel ease the accel erator for 5 seconds.
a
a
Symptom-to-Gomponent
Chart
Hydraulic System
SYMPTOM Check these i tems on the PROBABLE CAUSE Li st
Engi ne runs, but vehi cl e does not move i n anv
posi ti on.
1, 2, 3, 4, 5, 6, 1, 8, 9, 10, 20, 34, 35, 36, 38, 41
@, [, S
posi ti ons.
10, 11, 12, 20, 41
B
posi ti on.
5, 10, 11, 12, 11
, 1a, 19, 20, 39, 41
No shi ft to hi gher rati o.
9, 13, 14, 15, 16, 35, 37, 40
Poor accel erat i on.
9, 13, 14, 1s, 16, 20, 35, 37, 3a, 40
Fl ar es on movi ng.
9, 10, 20, 21, 35, 36, 38, 40, 42
Excessi ve shock when depressi ng and rel easi ng
accel erator pedal .
9, 10, 20, 21, 35, 36, 38, 42
No engi ne br aki ng.
9, 20, 21, 35, 36,3A
Vehi cl e does not accel erate i n
E
posi ti on.
9, 17, 18, 19, 20, 35, 36, 38
Vehi cl e moves i n
N
posi ti on.
(Shi ft
cabl e adj ustment i s proper).
10, 22, 23
Late shi ft from
@
posi ti on
to
D
posi ti on,
and from
@
posi ti on
to
E
posi ti on.
10, 11, 12, 22, 41
Late shi ft from
N
posi ti on to
E
posi ti on,
and from
E
posi ti on to
@
posi ti on.
' t 1,
12, 17, 1A, 22, 41
Engi ne stops when shi fted to
@
posi tl on from
N
posi ti on.
9, 10, 20, 35, 37, 3A, 42
Engi ne stops when shi fted to
E
posi ti on from
E
posi ti on.
9, 18, 19, 20, 25, 26. 35, 31, 38, 42
Noi se from transmi ssi on i n
E
posi ti on.*1
5, 11
,
18, 19, 25, 26
Excessi ve i dl e vi brati on.
2, 3, 8, 21
, 28
Noi se from transmi ssi on i n
E
and
E
posi ti ons.
2, 3, 19, 24, 25, 2A
Hunt i ng engi ne speed.
16, 35, 37, 38
Vi brat i on i n al l posi t i on.
a, 2a
Shi ft l ever does not operate smoothty. 11, 29, 4' l
Transmi ssi on wi l l not shi ft i nto
E
posi ti on
or transmi s-
si on cannot be removed from
p
posi ti on.
11
,
29, 30, 31, 32, 33
Vehi cl e does not accel erate to more than a certai n sDeed. 9, 10, 14, 15, 16, 20, 35, 31
Excessi ve shock on stani ng off.
38, 42
Fl ares on accel erat i ng at l ow speed.
20, 21, 34, 42
Excessi ve vi brati on i n
@,
p, p,
@
posi ri ons.
20, 21, 3A, 42
Low engi ne speed i n
[, [,
p,
@
posi ti ons.
20, 21, 38, 42
St al l speed hi gh.
10, 20, 38
Stal l speed l ow.
9, 20, 21
, 37 , 3a
Judder on st art i ng of f .
20,43
*1:
Some gear noi se i s normal i n the
E
posi ti on due to pl anetary gear actton.
I
4-226
a
PROBABLE CAUSE LIST
1 Low CVT fl ui dt evel
2 ATF pump worn. AT gears worn or damaged. Forei gn materi al i n ATF pump.
3 ATF
pump
chai n/ATF
pump sprocket worn or damaged.
4 I nput shaf t wor n or damaged.
5 Sun gear wor n or damaged.
Fi nal dr i ven gear wor n or damaged.
1 Secondary dri ve gear/secondary dri ven gear worn or damaged.
8 Fl ywheel /dri ve pl ate worn or damaged.
9 Intermedi ate housi ng assembl y worn or damaged.
1 0 Forward cl ut ch def ect i ve.
1 1 Shi f t cabl e broken/ out of adi ust ment .
1 2 Manual l ever pi n wor n.
t 5 ATF feed pi pe (pul l ey pressure) worn or damaged.
14 Dri ve pul l ey speed sensor/dri ven
pul l ey speed sensor defecti ve.
Vehi cl e speed sensor defecti ve.
TCM defecti ve.
1 7 Reverse brake def ect i ve.
1 8 Reverse brake pi ston and rel ated parts worn or damaged.
1 9 Pl anet ar y
gear wor n or damaged.
20 Sta rt cl utch defecti ve.
21 ATF teed
pi pe
l start
cl utch pressure) worn or damaged.
22 Cl ut ch cl earance/ reverse brake cl earance i ncorrect .
23 Reverse brake ret urn spri ng/ ret ai ner worn or damaged-
24 Needl e beari ng on i nput shaft worn or damaged.
25 Thr ust needl e bear i ng on car r i er wor n or damaged.
Thrust washer on carri er worn or damaged.
, 1
Engi ne out put l ow.
2a Fl ywheel assembl y def ect i ve.
29 Cont r ol l ever wor n or damaged.
30 Parki ng brake pawl /parki ng brake pawl shaft worn or damaged.
Detent l ever/parki ng brake rod assembl y worn or damaged.
32 Parki ng gear worn or damaged.
Parki ng brake pawl spri ng worn or damaged.
34 ATF strai ner/ATF fi l ter cl ogged.
35 Lower val ve bodv assembl v def ect i ve.
36 Lower val ve body assembl y defecti ve
(PL
regul ator val ve body assembl y defecti ve).
37 Lower val ve bodv assembl v defecl i ve l shi ft val ve body assembl y defecti ve).
38 Lower val ve bodv assembl V detecti ve
(start
cl utch control val ve body assembl y defecti ve).
Lower val ve bodv assembl v defecti ve l i nhi bi tor
sol enoi d defecti ve).
40 Sol enoi d harness worn or damaged.
4 1 Manual val ve body wor n or damaged.
42 PB feedback system del ecti ve,
43 CVT fl ui d deteri orated.
Road Test
NOTE: Warm up the engi ne to normal operati ng temperature {the radi ator fan comes on).
1, Appl y the parki ng
brake and bl ock the wheel s. Start the engi ne, then shi ft to the
E
posi ti on whi l e depressi ng the
brake pedal . Depress the accel erator pedal and rel ease i t suddenl y. The engi ne shoul d not stal l .
2. Test i n
E
posi t i on
Park the vehi cl e i n a sl ope
(approx.
16"), appl y the parki ng
brake, and shi ft i nto
E
posi ti on. Rel ease the brake; the
vehi cl e shoul d not move.
3. Test-dri ve the vehj cl e on a fl at road i n the posi ti on shown i n the tabl e, Check that the engi ne speeds meet the approx-
i mate vehi cl e speeds shown i n the tabl e.
NOTET Throttl e posi ti on sensor vol tage represents the throttl e openi ng, To moni tor the throttl e posi ti on sensor vol t-
age, use one of the fol l owi ng methods:
A. Connect the Honda PGM Tester, and go to the PGM-FI Data Li st.
B.' !. Remove the ki ck panel to expose the TCM for road testi ng; refer to page 14-194.
2. Setthedi gi tal mul ti tester to check vol tage betl veen the 84
(+)termi nal
andA4(-) or A17
(-)termi nal
ol theTCM
for throttl e posi ti on sensor.
TCM
84 T6rmin.l
I
I
I
I
l
[' '
I
BACKPROBE SET
07sAz
-
001000A
{two raquirad}
DIGITAL MULTIMETER
lCommelcielly .v.ilabl.)
KS- AHM- 32- 003
or oquivilont
BACKPROBE AOAPTER
STACKING PATCH
CORD
TCM CONNECTORS
OBo ll SCAN TOOL oI
HONOA PGM TESTEB
14-228
.
E
position: Engine Speed rpm
Throttl e Openi ng
Vehicle Soeed
25 mph
(40
km/h) 37 mph
(60
km/hl 62 mph 1100 km/hl
Throttl e posi ti on sensor vol tage: 0.75 V 1, 250 1, 650
Throttl e posi ti on sensor vol tage: 2.25 V 2,500 3, r 00 2,6s0 3,250 2,700 3,300
Throttl e posi ti on sensor vol tager 4.5 V
Ful l throttl e posi ti on
3,950 4,550 4,650 5,250 5,200 5,800
.
E
posi ti on: Engi ne Speed.pm
Throttle Opening
Vehicle Speed
2s mph
(40
km/h) 37 mph 160 km/hl 62 mph
(100
km/hl
Throttl e posi ti on sensor vol tage: 0.75 V 1
,800
-
2,200 2,200
-
2,AOO 3,550
-
4.150
Throttl e posi ti on sensor vol tage: 2.25 V 2,950
-
3,550 3,250
-
3,850 4,050
-
4,650
Throttl e posi ti on sensor vol tage: 4.5 V
Ful l t hr ol t l e posi t aon
4, 100
-
4, 700 5,100
-
5,700 5,900
-
6,500
.
E
posi ti on: Engi ne Speed rpm
Throttle Opening
Vehicle SDeed
25 mph
(40
km/hl 37 moh 160 km/h) 62 mph
(100
km/hl
Throttl e posi ti on sensor vol tage: 0.75 V 3,' l 00
-
3,700 3,650
-
4,250 4,450
-
5,050
Throt t l e posi t i on sensor vol t age: 2. 25 V 3.500
-
4,100 4,050
-
4,650 4,800 5,400
Throttl e posi ti on sensor vol tage: 4.5
Ful l throttl e posi ti on
4,100 4,700 5, 100
-
5, 700 5,900
-
6.500
14-229
Stall Speed
Test
CAUTION:
. To prevent transmi ssi on damage, do notteststal l speed for more than 10 seconds at a ti me.
. Do not shift the lever while raising the engine speed,
. Be sure to remove the pressure gauge before testing stall speed.
. Stall speed tests should be used for diagnostic purposes
only.
1. Engage t he par ki ng br ake, and bl ock t he f r ont wheel s.
2. Connect a tachometer to the engi ne, and start the engi ne.
3. Make sure the IVC swi tch i s OFF
4. After the engi ne has warmed up to normal operati ng temperature (the
radi ator fan comes on), shi ft i nto
E
posi ti on.
5. Ful l y depress the brake pedal and accel erator for 6 to 8 seconds, and note engi ne speed.
6. Al l ow two mi nutes for cool i ng, then repeat the test i n
E, E,
and
E
posi ti ons.
Stal l Speed RPM i n
@
posi ti on:
Specilication: 2,500 rpm
Service Limit: 2,350
-
2,650 rpm
Stal l Speed RPM i n
p.
I
and
@
posi ti ons:
Speci fi cati on: 3,000 rpm
Servi ce Li mi t: 2,800
-
3,100 l Dm
TROUBLE
PROBABLE CAUSE
St al l r pm hi gh i n
E, E, E, and
E
posi t i ons
Low fl ui d l evel or ATF pump
output
Cl ogged ATF strai ner
PH regul ator val ve stuck cl osed
Sl i ppage of forward cl utch
Faul ty stan cl utch
St al l r pm hi gh i n
@
posi t i on
Sl i ppage of reverse brake
Faul ty sta rt cl utch
Stal l rpm l ow i n
Dl ,
p,
[,
and
@
posi ti ons Engi ne out put l ow
Faul ty sta rt cl utch
Stuck shi ft val ve
14-230
Fl ui d Level
Checki ng/Changi ng
CAUTION: whi l e checki ng and changi ng, be sure not to
allow dust and other foreign particles to enter into the
transmi ssi on,
Checking
NOTEr Check the fl ui d l evel wi th the engi ne at normal
operati ng temperature
(the radi ator tan comes on
i ust
1. Par k t he vehi cl e on t he l evel gr ound. Tur n of f t he
engi ne.
2. Remove the di psri ck
(yel l ow
l oop) from the trans-
mi ssi on, and wi pe i t wi th a cl ean cl oth.
NOTE: Check t he t r ansmi ssi on f l ui d 60 t o 90 sec-
onds after shutti ng off the engi ne.
3. Insen the di psti ck i nto the transmi ssi on.
DIPSTICK {YELLOW LOOPI
l
4. Remove t he di pst i ck and check t he f l ui d l evel . l t
shoul d be between the upper and l ower mark.
5. l f the l evel i s bel ow the l ower mark. add fl ui d
t he f i l l er hol e t o br i ng i t t o t he upper mar k.
Genui ne Honda CVT Fl ui d onl y.
Insen the di psti ck i nto the transmi ssi on.
rnto
Use
Changing
1. Bri ng the transmi ssi on up to normal operati ng tem-
perature (the
radi ator fan comes on) by dri vi ng the
vehi cl e. Par k t he vehi cl e on t he l evel gr ound, and
turn oi f the engi ne.
2. Remove the drai n pl ug, and drai n the CVT fl ui d.
NOTE: l l a cool er fl usher i s to be used, see page 14-
284 and
'14-285.
3. Rei nstal l the drai n
pl ug wi th a new seal i ng washer,
t hen r ef i l l t he t r ansmi ssi on wi t h Genui ne Honda
CVT Fl ui d to the upper mark on the di psti ck.
Automati c Transmi ssi on Fl ui d Capaci ty:
3.9 ? 14.1 US
qt, 3.4 l mp qtl at changi ng
6.4 {
(6.8
US
qt,5.5l mp qtl at overhaul
Recommended Automati c Transmi ssi on Fl ui d:
Genui ne Honda CVT Fl ui d.
Use Genui ne Honda CVT f l ui d onl y. Usi ng ot her t l u-
i ds can af f ect t r ansmi ssi on oper at i on and may
reduce transmi ssi on l i fe.
Change Interval :
Normal Condi ti on: 30,000 mi l es
(48,000
kml
Severe Condi ti on: 30,000 mi l es {48,000
kml , but i f
you dri ve at hi gh speeds i n hi gh
t90"F {32"C1 and abovel temper'
at ur es, t he t r ansmi ssi on f l ui d
should be changed every 15'000
mi l es {24,000 km).
DRAIN PLUG
18 x 1. 5 mm
49 N. m 15. 0 kgI m, 36l bf t t l
SEALING WASHER
Repl ace.
14-231
Pressure Testing
L
3.
. While testing, be careful of the rotating tront wheels.
. Make sure lifts,
iacks,
and safety stands are placed properly
{see section 11.
CAUTION:
. Belore testing, be sure the transmission fluid is lilled to the proper level.
. Warm up the engine to normal operating temperature before testing.
. While testing, be sure not to allow dust and other foreign particles
to enter into the transmission.
1. Rai se the front of the vehi cl e, and support i twi th safety stands
(see
secti on I).
2. Set the parki ng brake, and bl ock both rear wheel s securel v.
Al l ow the front wheel s to rotate freel y.
Warm up the engi ne
(the
radi ator fan comes on), then stop and connect a tachometer.
Connect the speci al tool to each i nspecti on hol e.
TOROUE: 18 N.m
(1.8
kgf.m, 13 tbf.ft)
CAUTION:
'
Connect the oil pressure g.uge
securely, be sure not to allow dust and other toreign particles
to enter the inspec-
tion hole.
. When troubleshooting by the
E
indicator light indicates a problem, you must use an oil pressure gauge that mea
sures 4,900 kPa
{4.90 MPa, 50.0 kgflcnf, 711 psil or more when measuring drive pulley pressure
and driven pulley
Dressure.
NOTE:
. Dri ve pul l ey pressure
may be above 3,430 kPa
(3.43
MPa,35.0 kgf/cmr,498 psi ) when there i s a transmi ssi on prob-
l em that causes the TCM to go i nto the fai l safe mode.
. Use a commer ci al l y avai l abl e oi l pr essur e gauge
t hat measur es 4, 900 kpa ( 4. 90
Mpa, 50. 0 kgt cmr , 711 psi ) or
more, and the A,/T Oi l Pressure Hose, 22
j 0
mm
(071\i tAJ - py40 j
1A).
5.
FORWARD CLUTCH PRESSURE
INSPECTION
( Mar k ed
wi t h
" F" )
REVERSE BRAKE PRESSURE
INSPECTION HOLE
A/T OIL PRESSURE
GAUGE
SET w/PANEL
07406
-
0020400
LUBRICATION PRESSUBE
INSPECTION HOLE
( Mar ked
wi t h
" LUB" )
A/T LOW PRESSURE
GAUGE W/ PANEL
07406
-
0070300
DRIVE PULLEY PRESSURE
INSPECTION HOLE
l Marked wi t h
"DR")
A/T PRESSURE HOSE
ADAPTER
07MAJ
-
PY40120
(4
Requirad)
A/T PRESSURE HOSE
2210 rnfi
OTMAJ
-
PY4O11A
(4
Bequired)
oJ..
DBI VEN PULLEY PRESSURE
INSPECTION HOLE
(Ma. ked
wi t h
"DN ")
START CLUTCH PRESSURE
INSPECTION HOLE
(Marked
wi t h
"SC")
14-232
ATF OIPSTICK
7.
Stan the engi ne.
shi ft to the respecti ve shi ft l ever posi ti on as i n the tabl e, and measure the fol l owi ng
pressures at 1,500 rpm.
. Forward Cl utch Pressure
. Reverse Brake Pressure
. Dri ve Pul l ey Pressure
. Dri ven Pul l ey Pressure
Shi ft to E
posi ti on, and measure the l ubri cati on
pressure. at 3.000 rpm
Di sconnect the speci al tool after
pressure testi ng.
Instal l the seal i ng bol t wi th a new seal i ng washer i n the i nspecti on hol e, and ti ghten to the speci fi ed l orque
TOROUE: 18 N.m
(1.8
kgf'm. 13 lbt'ft)
CAUTION: Koep all ol the foroign
particles out of the transmission.
8.
a
)a
q
10.
)
PRESSURE
SHIFT LEVER
POStTtON
SYMPTOM PROBABLE CAUSE
FLUID PRESSURE
Standard/Service Limit
Forward
Cl utch
E No or l ow for-
ward cl utch
pressure
Forward Cl ut ch
' 1.4
-
1.75 MPa
(14.3 -
17.8 kgtcm' , 203
-
253 psi )
Reverse
Brake
E
No or l ow
reverse brake
pressure
Reverse Brake 1. 4
-
1. 75 MPa
(14.3
-
17.8 kgf/cm' , 203
-
253 psi )
Dri ve
Pul l ey
E
No or l ow
dri ve pul l ey
pressure
ATF pump, PH reg-
ul ator val ve, PL
regul ator val ve,
Shi ft val ve
0.2
-
0.7 MPa
(2
-
7.1 kgfl cm' ,28
-
101 psi )
Dri ve
pul l ey
pressure too
hi g h
PH regul ator val ve,
PL regul al or val ve,
Shi ft val ve, Shi ft
control l i near
sol enoi d
Dri ven
Pul l ey
No or l ow
dri ven
pul l ey
pressure
ATF pump, PH reg'
ul ator val ve, Shi ft
val ve. Shi ft control
l i near sol enoi d
1. 5
-
2. 3 MPa
(15.3
-
23.5 kgfi cm' , 218
-
334
Psi )
Dri ven pul l ey
pressure too
hi g h
PH regul ator val ve
Lubri cati on No or l ow
l ubri cati on
pressure
ATF pump,
Lubri cati on val ve
Above 0.2 MPa
(Above
2 kgf/cm' , 30 psi )
14-2?:t
Lower Valve Body Assembly
Repl acement
!@
Make sure l i fts,
j acks,
and safety stands
are placed properly
{see section 11.
CAUTI ON: Whi l e r emovi ng and i nst al l i ng t he l ower
val ve body assembl y. be sure not to al l ow dust and
other toreign particles
to enter into the transmission.
1. Rai se the front of the vehi cl e, and suoDort i t wi th
safety stands
{see secti on 1}.
3.
4.
Set the parki ng
brake, and bl ock both rear wheel s
securel y.
Remove t he dr ai n pl ug, and dr ai n t he CVT f l ui d.
Rei nst al l t he dr ai n pl ug wi t h a new seal i ng washer
(see page 14-231).
CAUTION: Keep all ol other foreign particles
out of
the transmi ssi on.
Di sconnect the 8P connector from the sol enoi d har
ness connector.
pi pes, Turn the ends of the ATF cool er hoses up to
prevent ATF from fl owi ng out, then pl ug
the ATF
cooter noses.
CAUTION: Keep all of other foreign particles
out ot
the transmission.
Remove the ri ght front mounvbracket.
' 10
x 1. 25 mm
44 N.m
(,1.5
kgtm, 33 lbnftl
6.
/
RI GHT FRONT
MOUNT/BRACKET
ATF COOLER PIPE
' 10
x 1. 25 mm
54 N.m
(5.5
kgt.m,
40 tbt.ft)
l-
C
14-234
ATF COOLER HOSE
7. Remove the ATF cool er outl et pi pe.
8. Remove the ATF cool er
Di pe bracket bol t.
9. Remove the ATF pan (fourteen
bol ts).
10. Remove the ATF strai ner
(two
bol ts).
11. Remove t he one bol t secur i ng t he sol enoi d har ness
connector.
' 12.
Remove t he l ower val ve
bol ts).
SEALI NG
Repl ace.
ATF COOLEE
OUTLET PIPE
body assembl y ( ei g
ht
JOINT BOLT
28 N.m
(2.9
kgtm, 2l lbf.ft)
O.RING
Repl ace
SOLENOI D HARNESS
CONNECTOR
DOWEL PIN
ATF
STRAINER
6 x 1 . 0 mm
12 N. m {1. 2 kgl . m,
8.7 tbf.tt)
LOWER VALVE
BODY ASSEMBLY
6 x 1 . 0 mm
12 N. m 11. 2 kgf . m,
8.7 tbtft)
ATF PAN GASKET
Repl ace.
O-RI NG
Repl ace.
6 x 1 . 0 mm
12 N. m 11. 2 kgt m,
8.7 rbtftl
DOWEL PIN
ATF COOLER INLET
PIPE BRACKET BOLT
I x 1. 25 mm
26 N. m
(2. 7
kgt . m,
20 tbl.ft)
ATF PAN
13. I nst al l t he new l ower val ve body i n t he r ever se
order of the removal procedure
CAUTION: Keep all of other toreign particles
out of
the transmi ssi on.
NOTE:
. Repl ace the fol l owi ng parts:
-
O- r i ngs on t he sol enoi d har ness connect or
and the ATF strai ner
-
ATF pan gasket
Seal i ng washer s
. l f t he ATF cool er i nl et pi pe br acket i s bent or
warped, put i t back to the ori gi nal posi ti on.
14. Per f or m t he st ar t cl ut ch cal i br at i on pr ocedur e
on
page 14 225.
6 x 1 . 0 mm
12 N. m (1. 2
kgf . m, 8. 7 l bl . f t )
ATF Filter
@@
Make sure lifts,
iacks,
and safety stands
are placed properly
lsee section 11.
CAUTION: While removing and installing the ATF filter,
be sure not to allow dust and other foreign particles to
enter into the transmission.
1. Rai se the front of the vehi cl e, and support i t wi th
sal ety stands
(see
secti on 1).
2. Ser the parki ng brake, and bl ock both rear wheel s
secu rel y.
3. Remove t he dr ai n
pl ug, and dr ai n t he CVT f l ui d.
Rei nstal l the drai n
pl ug wi th a new seal i ng washer
(see page
' 14
231).
CAUTION: Keep all of other foreign particles out of
the transmission.
Di 9es. Turn the ends of the ATF cool er hoses up to
prevent
ATF from fl owi ng out, then pl ug the ATF
cool er hoses.
CAUTION: Keep all of othet loreign
particles out ot
the transmission.
Remove the ri ght front mounvbracket.
10 x 1. 25 mm
44 N. m
(4. 5 kgt ' m, 33 l bf f t l
RIGHT FRONT
MOUNT/BRACKET
10 x 1. 25 mm
54 N.m
(5.5 kgf'm,
40 rb{ft1
5.
ATF COOLER HOSE
14-235
6. Remove the ATF cool er outl et pi pe
7. Remove the ATF cool er
pi pe bracket bol t.
8. Remove the ATF
pan (founeen
bol ts).
9. Remove the ATF cool er i nl et
pi pe from the ATF pan
{three bol ts).
10. Remove the ATF fi l ter, and cl ean i t.
11. Check that the ATF fi l ter i s i n good condi ti on
12. Repl ace the ATF ti l ter i f i t i s cl ogged.
JOINT BOLT
28 N.m 12.9
kgl m, 2'l lblftl
SEALING
Repl ace.
ATF COOLER OUTLET
6 x
' l . 0
mm
ATF COOLER INLET
PIPE BRACKET BOLT
I x 1. 25 mm
26 N.m
(2.7
kgt m,
12 N. m
(1, 2 kgf m,
8.7 tbtft)
DOWEL
ATF P
GASKET
Repl ace.
O. RI NG
Repl ace.
't
3.
ATF PAN
6 x 1 . 0 mm
12 N'm {1.2 kgl m, 8 7 lbf'ft}
l nst al l t he ATF f i l t er i n t he r ever se or der of t he
removal procedure.
CAUTI ON: Keep al l f orei gn
part i cl es out of t he
transmission.
NOTEI
. Repl ace t he O- r i ngs, t he ATF pan gasket and
seal i ng washers.
. l f t he ATF cool er i nl et pi pe br acket i s bent or
warped, put i t back t o t he ori gi nal posi t i on.
Transmi ssi on
Removal
@@
2.
Make sure lifts,
iacks,
and safety stands are placed
pfoperly,
and hoist bracket are attached to the cor-
rect position
on the engine
(see
seqtion 1).
Appl y parki ng
brake and bl ock rear wheel s, so the
vehicle will not roll off stands and fall on
vou while
working under it.
CAUTION: Use fender covers to avoid damaging painted
surfaces.
'L
Di sconnect the battery negati ve (-)
termi nal from
l he battery. then remove the posi ti ve
{+) termi nal .
Remove t he i nt ake ai r duct and ai r cl eaner housi ng
assemDty.
3. Remove t he st ar t er cabl es and cabl e hol der f r om
the starter motor.
STARTER CABLE
Ft
STARTER MOTON
14-236
4. Di sconnect the sol enoi d harness connector, the dri ve
pul l ey
speed sensor connector, and the ground
cabl e
termi nal s.
GROUND CABLE
TERMI NAL
DRIVE PULLEY
SPEED SENSOR
CONNECIOR
5.
SOLENOIO HARNESS
CONNECTOR
Remove the cl i p, then separate the shi ft cabl e from
the control l ever.
GAUTION: Take care not to bend the shift cable.
WASHER
WASHER
GROUND CABLE
CONTROL LEVER
SHI FI CABLE
(VSS)
connec-
tor, the dri ven
pul l eY speed sensor connector, and
the secondary
gear shaft speed sensor connector.
SECONDAFY GEAR
SHAFT SPEED
DRIVEN PULLEY
SPEED SENSOR
CONNECTOR
SENSOR
F(A
--
. . ,
, f i
.
' - 1
-
SENSOR
(VSSt
CONNECTOR
7. Remove the transmi ssi on housi ng mounti ng bol ts.
8. Remove t he dr ai n
pl ug, and dr ai n t he CVT f l ui d.
Rei nstal l the drai n
pl ug wi th a new seal i ng washer'
CAUTION: whi l e i nstal l i ng the drai n
pl ug, be sure
not to al l ow dust and other fotei gn parti cl es to
enter into the transmission
DRAIN PLUG
18 x 1. 5 mm
irg N.m {5.0 kgl m.36lbt'ft)
9. Remove t he spl ash shi el d.
SEALING WASHER
Repl ace.
( cont ' d)
14-237
Transmi ssi on
Removal (cont' dl
10. Remove the cotter pi ns
and castl e nuts, then separate
the bal l
j oi nts
trom the l ower arm
(see
secti on 18).
't
4.
1 t .
12.
Remove the ri ght damper fork bol t, then separate
r i ght damper f or k and damper .
Pry the ri ght and l eft dri veshafts out of the di fferen-
t i al .
Pul l on the i nboard
j oi nt
and the ri ght and l eft dri ve,
shafts (see
secti on 16).
Tj e pl asti c
bags over the dri veshaft ends.
NOTE: Coat al l preci si on
fi ni shed surfaces wi th cl ean
engi ne oi l .
Remove the exhaust pi pe A.
SELF-LOCKING NUT
Repl ace.
t 5 ,
r")
SELF-LOCKING
NUT
Bepl ace.
14-238
EXHAUST PIPE A
r9.
16. Remove t he ri ght f ront mount / bracket .
TF COOLER PIPE
ATF COOLER HOSE
pi pes. Turn the ends of the ATF cool er hoses up to
prevent
CVT fl ui d from fl owj ng out, then pl ug the
ATF cool er hoses and pi pes.
NOTE: Check for any si gn of l eakage at the hose
j oi nts.
Remove the engi ne sti ffeners and the fl ywheel cover.
11.
Remove t he ei ght dri ve pl at e bol t s one at t i me whi l e
rot at i ng t he crankshaf t pul l ey.
ENGI NE STI FFENER
20. Remove the di stri butor.
Attach a hoi sti ng bracket to the engi ne, then l i ft the
engi ne sl i ght l y.
t 1
22. Pl ace a
j ack
under the transmi ssi on, and rai se the
transmi ssi on
j ust
enough to take wei ght off of the
mounts, then remove the transmi ssi on mount bracket
TRANSMISSION MOUNT
23. Remove t he t r ansmi ssi on housi ng mount i ng bol t
and rear engi ne mounti ng bol ts.
MOUNTING BOI-T
REAR ENGI NE MOUNTI NG
BOLT
24. Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the 14 mm dowel
pi ns, then l ower i t on the
transmi ssi on i ack.
lP.-
WASHER
14-239
lllustrated Index
Transmi ssi on/Lower Val ve Body Assembl y
\
\
\
14-240
O)
ATF DIPSTICK
@
o-RI NG Repl ace.
O SOI-ENOID HARNESS CONNECTOR
O
LowER vALvE BODY ASSEMBI-Y
O DowEL PIN
O
JoINT aoLT
)
ATF COOLER INLET PIPE BRACKET SOLT
@ A'F COOLER INLET PIPE ASSEMBLY
o SEALING WASHER Replace.
G,
ATF COOI-ER OUTLET PIPE
@
o-RING Replace.
Ci)
ATF FILTER
@ o-RI NG Repl ace.
G)
ATF PAN
(9
DOWEL PtN
@ O-RI NG Repl ace.
)
ATF STRAINER
G}
ATF MAGNET
@ ATF PAN GASKET Replace.
)
ATF MAGNET
@
DRAIN PLUG
@
SEALING WASHER BepIace,
Boh/Nut No. Torque Value Sizs Remarks
6A
8F
12J
18D
12 N m
(1.2
kgf.m,8.7 l bf' ft)
26 N.m
(2.7
kgf.m,20 l bf.ft)
28 N.m
(2.9
kgf.m,21 l bi ' ft)
49 N.m
(5.0
kgnm, 36 lbf.ft)
6 x 1 . 0 mm
8 x 1. 25 mm
' 12
x 1.25 mm
18 x 1. 5 mm
Joi nt bol t
Drai n pl ug
14-241
lllustrated Index
Transmi ssi on
Housi ng/Fl ywheel
Housi ng
8G
I
P
\
\
\
14-242
af O-RI NG Repl ace.
le oll sEAl- Replace.
:O FLYWHEEL HOUSING
i 4l FLYWHEEL HOUSI NG GASKET Repl ace.
.1'- DIFFERENTIAL ASSEMBLY
G,I
ATF PASSAGE PIPE ASSEMBLY
?l o-RI NG Repl ace.
i8') DOWEL PIN
.' ATF PUMP ASSEMBLY
iio DOWEL PlN, 18 x 10 mm
l l O-RI NG Repl ace.
a1a OOWEL PlN, 22 x 10 mm
O
ATF PUMP oRIvE CHAIN
.iO SNAP RING
i 9 THRUST sHl M, 22 x 28 mm Sel ect i ve
pan
(10)
ATF PUMP DRIVE SPROCKET
.1I PITOT FLANGE
.O ATF PUMP DRIVE SPROCKET HUB
i!i) THRUST WASHERS
6i
PIToT PIPE BRACKET
iz:i, PITOT LUBRICATION PIPE
.,
PITOT PIPE
ag
OI L SEAL Repl ace.
ari SET BING, 80 mm Selective
part
29 ATF PASSAGE PIPE HOLDER ASSEMBLY
! d O-RI NG Repl ace.
LA START CLUTCH ATF FEED PIPE
e3 o-RING Feplace.
8
FEED PIPE FLANGE
.O SNAP RING
@
CONNECTOR BRACKET
A BALI BEARING
@ SNAP RI NG
@
COTTER RETAINER
@ COTTERS, 25.5 mm Selective part
@
START CLUTCH ASSEMBLY
6I SECONDARY DRIVE GEAR ASSEMBLY
@
o-RI NGS Repl ace.
@
DIFFERENTIAL COVER
@
THRUST sHlM, 25 x 35 mm selecrive
part
.4i SECONDARY GEAB SHAFT
6D PABKING BRAKE PAWL SHAFT
@
PARKING BRAKE PAWL SPRING
'O
PARKING BRAKE PAWL
@
TONGUED WASHER RepIace.
{3
PARKING BRAKE ROD HOLDER
I
BALL BEARING
i o o-RI NG Repl ace.
.4!) VEHICLE SPED SENSOB
60 OI L SEAL Repl ace.
Bol t/Nut No. Torque Val ue Si ze Remarks
6A
8A
8F
8G
12 N.m
(' 1.2
kgi m,8.7 l bf' ft)
22 N.m 12.2 kgf.m, 16l bf.ft)
26 N.m
(2.7
kgf.m,20 l bnft)
29 N.m
(3.0
kgtm,22 l bf.ft)
6 x 1 . 0 mm
8 x
' l . 25
mm
8 x 1. 25 mm
8 x 1. 25 mm
14-243
lllustrated Index
Ri ght Si de Cover/l ntermedi ate
Housi ng
8B
I
tr
g
.i) RIGHT SIDE COVER
(.]
ATF FEED PIPE
i3. DOWEL PIN
O
O-RING Replace.
i5) FEED PIPE FLANGE
]
FEED PIPE FLANG PLATE
Ol'
RoLLER
iq,] INTERMEOIATE HOUSING ASSEMBLY
O CONTROL SHAFT ASSEMBLY
1_oI
TRANSMISSION HouSlNG
.11) SHIFT CABI-E BRACKET
iO BREATHER CAP
O ol L SEAL Repl ace.
(4
CONTROI- LEVER
(3
LOCK WASHER Replace.
ii6-i SECONDARY GEAB SHAFT SPEED SENSOR
Ji DRIVEN PULLEY SPEED SENSOR
(8_'
O-RING Replace.
t!9 SNAP R|NG
.9 TBANSMISSION HOUSING DRIVEN PULLEY
SHAFT ROLLER BEABING
2i RI GHT SI DE COVER GASKET FEPI ACE.
(2?j
O-RING Replace.
PO MANUAL VALVE BODY LINE A
.]i MANUAL VALVE BODY LINE 8
a3 o-RI NG Repl ace.
,! DETENT SPRING
!]) ATF FEED PIPE
Q0 O-RI NG Repl ace.
EI
MANUAL VALVE BODY
13o]
DOWEL PIN
51)
MANUAL VALVE BODY SEPARATOB PLATE
34 SNAP RING
$) FORWARD CLUTCH ASSEMBLY
gl
o-RI NG Fepl ace.
69 SNAP BING
(30
SPRING RETAINEB/RETURN SPRING ASSEMBLY
O REVERSE BRAKE PISTON
(381
O-RING Replace.
r SNAP RING RETAINER
.4!) ATF FEED PIPE
(t TRANSMISSION HOUSING GASKET Replace
@}
DOWEL PIN
@
ATF FEED PIPE
@ O-RI NG Repl ace.
6t
o-RING Replace.
.45) DRIVE PULLEY SPEED SENSOR
(?
TRANSMISSION HANGER
(O
SNAP RING
e0
THRUST SHI M, 25 x 31 mm Sel ect i ve
pa(
6i
BALL BEARING
O
RI NG GEAR
69 SNAP RING
6l
REVERSE BRAKE END PLATE Selective
pan
@I
REVERSE BRAKE DISC
69
REVERSE BRAKE PLATE
6! D|SC SPRTNG
@
THRUST WASHER
6J' THRUST NEEDLE BEARING
63 THRUST WASHER
@
CARRIER ASSEMBLY
6)
THRUST WASHER
@
@
SUN GEAR
@ SEALING RING Replace.
69 NEEDLE BEARING
@
INPUT SHAFT
@
NEEDLE BEARING
@ SEALI NG RI NG Repl ace.
69 SEALING RING IRUBBER)
Replace.
@
ATF FEED PIPE
Bol t / Nut No. Torque Val ue Si ze
Remarks
6A
6B
8B
8F
8G
12 N.m
(1.2 kgf.m,8.7 l bf' ft)
14 N. m
( 1. 4
kgnm, 10l bi f t )
37 N.m
(3.8
kgi m,27 l bf' fti
26 N.m 12.7
kgf.m,20 l bf.ft)
29 N.m
(3.0
kgf.m,22 l bnft)
6 x 1 . 0 mm
6 x 1 . 0 mm
8 x 1. 25 mm
8 x 1. 25 mm
8 x 1. 25 mm
14-245
Transmission
Housing/Lower
Valve Body Assembly
Removal
NOTE:
o Cl ean al l parts
thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r.
. When removi ng the l ower val ve body, repl ace the fol l owi ng:
-
O-ri ngs
-
ATF pan gasket
-
Seal i ng washers
OOWEL PIN
O.BING
Repl ace.
SOLENOID HARNESS CONNECTOR
6 x 1. 0 mm BOLT
LOWER VALVE BODY ASSEMBLY
6 x 1. 0 mm EOLT
ATF STRAINER
6 x 1. 0 mm BOLT
ATF PAN GASKET
Fepl ace.
ATF COOLER INLET PIPE
BRACKET BOLT
8 x 1. 25 mm
ATF COOLER INLET PIPE
14-246
ATF PAN
6 x 1. 0 mm EOLT
1. Remove the ATF cool er i nl et pi pe bracket bol t.
2. Remove the ATF cool er outl et pi pe.
3. Remove the ATF pan (founeen
bol ts).
4. Remove the ATF strai ner
(two
bol ts).
5. Remove the one bol t securi ng the sol enoi d harness
connector, then push the connector,
6. Remove the l ower val ve body
(ei ght
bol ts).
7. Cl ean the i nl et openi ng of the ATF strai ner thoroughl y
wi th compressed ai r, then check that i t i s i n good
condi ti on, and the i nl et openi ng i s not cl ogged.
ATF STRAINES
Repl ace the ATF strai ner i f i t i s cl ogged or damaged.
NOTE: The ATF strai ner can be reused i f i t i s not
cl ogged.
2
14-247
Transmi ssi on Housi ng/Fl ywheel Housi ng
Removal
NOTE:
. Cl ean al l
parts thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r.
. When removi ng the transmi ssi on housi ngfl ywheel housi ng, repl ace the fol l owi ngl
-
O-ri ngs
-
Secondary dri ve gear assembl ,
-
Stan cl utch assembl y
-
Fl ywheel housi ng gasket
ATF PASSAGE PIPE
HOLOER ASSEMBLY
8 x 1. 25 mm BOLT
CONNECTOR BRACKET
O.RING
Repl ace.
COTTERS, 25.5 mm
Selective part
DOWEL PIN
OIFFERENTIAL ASSEMBLY
SNAP RING
COTTER RETAINER
FLYWHEEL HOUSING GASKET
Reol ace,
FLYWHEEL HOUSING
INPUT SHAFT
g
fl
fl
B
START CLUTCH
ASSEMBLY
Repl ace.
ATF PASSAGE
PIPE ASSEMBLY
6 x 1.0 mm BOLT
O-RING
Repl ace.
ATF PUMP DRIVE CHAIN
SNAP RING
THRUST SHIM, 22 x 28 mm
Selective
part
6 x 1. 0 mm BOLT
ATF PUMP DRIVE
SPROCKET
PITOT FLANGE
ATF PUMP DRIVE
SPROCKET HUB
THRUST WASHERS
O-RING
Repl ace.
THRUST SHIM,
2 5 x 3 5 mm
Selective part
SECONDARY
GEAR SHAFT
SECONDARY DRIVE
GEAR ASSEMBLY
Repl ace.
PARKING BRAKE
PAWL SI{AFT
PARKING BRAKE PAWL
SPRING
PARKING BRAKE PAWL
14-248
ORIVEN PULLEY SHAFT
1 . Remove the ATF passage pi pe hol der assembl y.
Remove the fl ywheel housi ng
(twenty
bol ts).
Remove the ATF passage pi pe assembl y
(one
bol t).
Remove the ATF pump dri ve sprocket
(three
bol ts),
then remove the ATF pump dri ve charn.
Move the
pitot flange toward its cutout, then remove
the pitot flange.
Remove the snap ri ng securi ng the ATF pump dri ve
sprocket hub, then remove the 22 x,28 mm thrust
shim, the ATF pump drive sprocket hub and the thrust
washers.
Remove the di fterenti al assembl y.
Remove the parki ng brake pawl shaft, the parki ng
brake pawl spri ng, and the parki ng brake pawl .
Remove the snap ri ng securi ng the start cl utch, then
remove the cotter retainer and the cotters.
7.
PITOT PIPE
)
14-249
10. Set the speci al tool on the start cl utch, and attach the
pawl of the speci al tool to the parki ng gear securel y
as snown.
CAUTION:
. Do not place the pawl ol the special tool on the
start clutch guide. lf the pawl of the special tool
contacts the slart clutch guide. the start clutch
guide may be damaged.
. Be sure not to allow dust and other toreign par-
ticles to enter into the driven pulley shaft.
START CLUTCH
REMOVER
07TAE
-
P4V0120
START CLUTCH
ASSEMBLY
Repl ace.
1 1 . Remove t he st ar t cl ut ch and t he secondar y dr i ve
gear assembl y usi ng the speci al tool , then remove
the secondary
gear shaft.
START CLUTCH
REMOVER
07TAE
-
P4V01 20
PARKING GEAR
Ri ght Si de Gover/l ntermedi ate
Housi ng
Removal
NOTE:
. Cl ean al l parts i n sol vent or carburetor cl eaner, and dry wi th compressed ai r.
. El ow out al l
passages.
. When removi ng the ri ght si de cover/i ntermedi ate housi ng. repl ace the fol l owi ng parts:
-
O r i ngs
-
Ri ght si de cover gasket
-
Transmi ssi on housi ng gasket
-
Seal i ng r i ngs
-
Seal i ng washer s
8 x 1. 25 mm BOLT
REVERSE BRAKE
{u
END PLATE
6 x 1. 0 mm BOLT
Dtsc
PLATE
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLE
SEARING
SUN GEAR
INPUT SHAFT
SNAP RING
CLUTCH END
PLATE
Sel ect i ve pan
RING GEAR
THBUST WASHER
THRUST NEEOLE
BEARING
DISC SPRING
SNAP
THRUST SHIM.
2 5 x 3 1 mm
SNAP RING
RIGHT SIDE COVER
GASKET
Repl ace.
DOWEL PIN
8 x 1. 25 mm BOLT
TRANSMISSION
HOUSING GASKET
Repl ace,
FORWARD CLUTCH
ASSEMBLY
SEALING RING
(BUBBER}
Bepl ace.
DOWEL PIN
SPRING RETAINER/
RETURN SPRINGS
SNAP RING
14-250
1. Remove t he r i ght si de cover
( t hr ee
6 mm bol t s,
el even 8 mm bol ts).
2. Remove the manual val ve body l i nes A and B.
Remove the snap ri ng securi ng the ri ng gear, then
remove the thrust shi m and the rang gear.
Remove t he snap r i ng secur i ng t he r ever se br ake
di scs and pl ates, then remove the reverse brake end
pl ate, brake di scs, brake pl ates, and di sc spri ng.
Remove the carri er wi th the thrust washers and the
thrust needl e beari ng, from the forward cl utch.
Remove the sun gear and the i nput shaft as a sub
assembl y by pul l i ng i r.
The sun gear i s press fi tted ti ghtl y i nto i nput shaft.
Remove the snap ri ng securi ng the forward cl utch,
and remove the snap ri ng securi ng the forward cl utch
end pl ate, then remove the forward cl utch end pl ate.
Rei nst al l t he car r i er on t he f or war d cl ut ch, t hen
secure the carri er wi th the snap ri ng on the forward
ci utch end pl ate.
3.
6.
7.
8.
9. Remove t he f or war d cl ut ch and car r i er assembl y
together.
10. I nst al l t he speci al t ool t o r emove t he snap r i ng
securi ng the reverse brake return spri ng retai ner as
snown.
REVERSE BRAXE
SPRING COMPRESSOR
07TAE
-
P4V01r0
11. Compress the return spri ngs. then remove the snap
r i ng.
CAUTI ON: l f t he spr i ng l et ai ner t ab i s on t he
l everse brake
pi ston, the spri ng retai ner may be
damaged. Be sure the spri ng retai ner tab i s not on
the pi ston.
SPRING RETAIiIER
TAA
Remove t he speci al t ool , t hen r emove t he spr i ng
retai ner/return spri ng assembl y.
Remove the seal i ng bol t securi ng the reverse brake
pressure i nspecti on hol e.
Appl y ai r pressure to the i nspecti on hol e to remove
the reverse brake pi ston.
12.
14.
SPRNG RETAINER/
RETURN SPRING
ASSEMBLY
REVERSE BRAKE
PISTON
o-Rt Gs
Replace.
REVERSE BRAXE
PRESSUR INSPECNON
HOIT
SEALING
WASHER
Replace.
8 x 1 .25 mm
18 N.m {1.E kgl.m, 13 lbf.ftl
15. Remove the snap ri ng retai ner from the dri ve pul l ey
shaft.
16. Remove the manual val ve body
(fi ve
bol ts).
' 17
Remove the rol l er, and Dush the control shaft assem-
bl y toward the outsi de of the transmi ssi on housi ng,
then remove the i ntermedi ate housi ng
(four
bol ts).
SPECIAL TOOL
14-251
Manual Val ve Body
NOTEI
. Cl eanal l
parts thoroughl y i n sol vent or carburetor cl eaner, and drywi th compressed ai r. Bl owoutal l
passages,
o Coat al l
parts wi th CVT Fl ui d duri ng assembl y,
SPRING SEAT
RVERSE INHIBITOR
VALVE SPRING
REVERSE INHIBITOR
VALVE
N'
MANUAL VALVE BODY
and scori ng.
MANUAL VALVE
14-252
I
Forward Glutch
lllustrated Index
CLUTCH
PISTON
CLUTCHORUM
\
\
\ _
RETURN
SPRING
RETAINER
SNAP RING
CLUTCH PLATES
2. 00 mm
(0. 079
i n)
CLUTCH END PLATE
clurcH
Dlscs
St andar d
t hi ckness;
1. 94 mm
( 0
076 i n)
DISC SPRING
SNAP RING
14-253
Forward Clutch
Disassembly
1. Remove t he snap ri ng, t hen remove t he cl ut ch end
pl at e,
cl ut ch di scs, and pl at es.
SNAP RING
2. Remove the di sc spri ng.
DISC SPRING
14-254
SPRING RETAINER
3. Instal l the speci al tool s as shown.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
OTHAE PLsO, I OO
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
oTGAE
-PG40200
CAUTION: lf either end ot the special tool is set over
an area ol the spring retainor which is unsupported
by the return spring, the retainer may be damaged,
Be sure the special tool is adiusted to have full con-
tact with the spring retsiner.
SPECIAL TOOL
Do not st hre.
Remove the snap ri ng. Then remove the speci al tool s,
spri ng retai ner, and return spri ng.
5.
SPRI NG RETAI NER
6. Wrap a shop rag around the cl utch drum, and appl y
ai r pressure to the fl ui d passage to remove the pi ston.
Pl ace a fi nger ti p on the other end whi l e appl yi ng ai r
pressure.
OSHA.APPROVED
30 p3i NOZZLE
14-255
Forward
Clutch
ReassemblY
NOTE:
. Cl ean al l
parts thoroughl y
i n sol vent
or carburetor
cl eaner,
and dry them wi th compressed
al r'
. Bl ow out al l
Passages.
. Lubri cate
al l parts wi th CVT Fl ui d
before reassemDl y'
1. Inspect the check
val ve; i { i t' s l oose' repl ace the
prs-
t on.
O. RI NGS
CHECK VALVE
2. Instal l new O-ri ngs on the cl utch
pi ston'
PI STON
14-256
3. l nstal l the
pi ston i n the cl utch drum Appl y
pressure
and rotate to ensure
proper seatl ng'
NOTE:
Lubri cate the
pi ston O-ri ng
wi th CVT Fl ui d
before i nstal l i ng
CAUTION:
Do not
pinch the O-ring by installing
the
piston with too much lorce
PISTON
l nst al l t he r et ur n spr i ng and spr i ng
r et ai ner ' and
posi ti on the snap ri ng on the retai ner'
SNAP RI NG
SPRING RETAINER
RETURN SPRI NG
CLUTCH
DRUM
5. Instal l the speci al tool s as shown,
CLUTCH SPRI NG
COMPBESSOR
ATTACHMENT
OTLAE PX4Ol OO
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
oTHAE-P150100
CLUTCH SPRI NG
COMPRESSOR
EOLT ASSEMBLY
07GAE-PG40200
CAUTION: lf either end ot the special tool is set over
an area ol the spring retainor which is unsupported
by the return spring, the retainer may be damaged.
Be sure the special tool is adlusted to have full con-
tact with the spring retainer.
Sot here.
SPECIAL TOOL
/
Do not set hre.
7. I nst al l t he snap r i ng.
8. Remove the speci al tool s.
(cont' d)
SNAP RI NG
RETAINER
14-257
Forward Clutch
Reassembl y
(cont' dl
9. I nst al l t he di sc spr i ng.
NOTE: Instal l the di sc spri ng i n the di recti on shown.
DI SC SPRI NG
10.
\
".urr* o.r*
Soak the cl utch di scs thoroughl y i n CVT Fl ui d for a
mi ni mum of 30 mi nut es.
Starti ng wi th a cl utch
pl ate, al ternatel y i nstal l the
cl utch pl ates and di scs. Instal l the cl utch end pl ate
wi th fl at si de toward the di sc.
NOTE: Before i nstal l i ng the pl ates and di scs, make
sure the i nsi de of the cl utch drum i s free of di rt or
other forei gn matter.
1
' ].
CLUTCH END PLATE
14-254
12. I nst al l t he snap r i ng.
SNAP RI NG
13, Veri fy that the snap ri ng end gap i s correct.
CLUTCH
DRUM
Mi ni mum 7. 9 mm { 0. 31
i n)
I
i
I
14. Measu.e the cl earanc between the cl utch end pl ate
and top di sc wi th a di al i ndi cator. Zero the di al i ndi ca-
tor with the clutch end
plate lowered, and lift it up to
the snap ri ng. The di stance that the cl utch end pl ate
moves is the clearance between the clutch end Dlate
and top di sc.
Clutch End Plate-to-Top Disc Clearance:
STANDARD: 0.6
-
0.8 mm
(0.024 -
0.031 in)
r'
15. l f the cl earance i s out of tol erance, sel ect a new cl utch
end pl ate from the fol l owi ng tabl e. then recheck.
NOTE: It the thi ckest cl utch end pl ate i s i nstal l ed but
the cl earance i s sti l l over the standard, repl ace the
cl utch di scs and cl utch pl ates.
PLATE I{UM8ER
Thicknoss
FORWARD CLUTCH END PLATE
After repl aci ng the cl utch end pl ate, make sure that
the cl earance i s wi thi n tol erance.
CLUTCH END PI-ATE
Pl al e No. Part Numbel Thi ckness
1 o r 1 5 22561
-
P4V
-
003 3. 5 mm
( 0. 138
i n)
2 o t 1 6 22562-P4V-003 3. 6 mm
( 0. 142
i n)
3 o r 1 7 22563- P4V- 0033. 7 mm
( 0. 146
i n)
4 o t 1 8 22564- P4V- OO33. 8 mm
( 0. 150
i n)
5 or
' 19
22565- P4V- 0033. 9 mm
( 0. 154
i n)
6 o r 2 0 22566- P4V- 003 4. 0 mm ( 0. 157 i n)
7 o t 2 1 22561
-P4V
OO3 4. 1 mm
( 0. 161
i n)
8 o t 2 2 22568- P4V- 0034. 2 mm
( 0. 165
i n)
9 o r 2 3 22569- P4V- 003 4. 3 mm
( 0. 169
i n)
' 10
or 24 22510 P4V OO3 4. 4 mm
( 0. 173
i n)
11 or 25 225't1 P4V
,
OO3 4. 5 mm
( 0. 177
i n)
or 225- 72- PAV- OO34. 6 mm
( 0. 181
i n)
or 22573
-
P4V
-
OO3 4. 7 mm
( 0. 185
i n)
14-259
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection
1. Measure the di stance between the fl ywheel housi ng
surface and the bal l beari ng as shown, then note
the measurement
(Measurement
A).
FLYWHEEL
HOUSI NG
--"i<t=''
BALL
BEARING
FLYWHEEL
HOUSING
Instal l the secondary gear shaft i n the transmi ssi on
housrng.
Measur e t he di st ance bet ween t he t r ansmi ssi on
housi ng sur f ace and t he t hr ust washer mount i ng
surface of the secondary gear shaft as shown, then
note the measurement
{Measurement B).
SECONDARY
GEAR SHAFT
fi-i"r*,.g oi.r".." \
I
4. Cal cul ate 25 x 35 mm thrust shi m thi ckness bv fol -
l owi ng formul a.
FORMULA:
25 x 35 mm Thrust Shim Thickness
= Measurement A
-
Measurement B + Fl ywheel
Housi ng Gasket Thi ckness: 0.5 mm
(0.020
i n)
ExamDle:
Measurement A:32.7 mm
(1.287
i n)
Measurement B:30.1 mm
(1.185
i n)
25 x 35 mm Thrust Shim Thicknss
= 32.7 mm 11.287 i nl
-30.1
mm {1.185 i n}
+ 0.5 mm
(0.020
i n)
= 3.1 mm 10.122 i n)
Select 25 x 35 mm Thrust Shim D.
5. Sel ect the 25 x 35 mm thrust shi m from the fol l ow-
i ng the tabl e.
9055' 1
- P4V- 000
2. 8 mm
( 0. 110
i n)
B 90552- P4V- 000 2. 9 mm { 0, 114 i n)
c 90553- P4V- 000 3. 0 mm
( 0. 118
i n)
90s 54- P4V- 0003. 1 mm
( 0. 122
i n)
E 90555- P4V- 000 3. 2 mm { 0. 126 i n)
F 90556- P4V- 000 3. 3 mm
( 0, 130
i n)
905s7- P4V- 0003. 4 mm
( 0, 134
i n)
H 90558- P4V- 000 3. 5 mm
( 0. 138
i n)
90559- P4V- 000 3. 6 mm ( 0. 142
i nl
J 90560- P4V- 000 3. 7 mm
( 0. 146
i n)
K 90561
-
P4V
-
000 3. 8 mm { 0. 150 i n)
14-260
Differential
l l l ustrated l ndex
AOLTS
10 r 1. 0 mm
101 N.m {10.3 kgf.m.
74.5 |bfit)
Left'hand threads
FINAL ORIVEN GEAR
BALL BEARING
14-261
Backlash Inspection
1. Pl ace the di fferenti al assembl y on V-bl ocks, and i nstal l
both axles.
2. Check the backl ash of both pi ni on gears.
Standard
(Newl :
0.05
-
0.15 mm {0.002
-
0.006 i nl
PINION GEARS
l f the backl ash i s out of tol erance, repl ace the di ffer-
enti al carri er.
Differential
I
Beari ng Repl acement
NOTE: Check the beari ngs for wear and rough rotati on.
l f the beari ngs are OK, removal i s not necessary.
1. Remove the bal l beari ngs usi ng a beari ng pul l er,
BALL BEARING
Instal l the new bal l beari ngs usi ng the speci al tool
wi th a press as shown.
p
14-262
BALL BEARI NG
Differential Carrier Replacement
1. Remove the fi nal dri ven gear from the di fferenti al
carri er.
NOTE: The fi nal dri ven gear bol ts have l eft-hand
threads.
BOLTS
10 x 1. 0 mm
98 N.m {10.0 kg{.m,
72 tbf.ft)
Lef t -hand t hreads
2.
DIFFERENTIAL
CARRIEN
Instal l the fi nal dri ven gear wi th i ts chamfered si de
on the i nner bore faci ng the di fferenti al carri er.
Torque the bolts to the specified torque in a crisscross
panern.
TOROUE: 98 N.m {10.0 kgf.m, 72 lbf.ftl
Oi l Seal Removal
1. Remove the di fferenti al assembl y.
2. Remove the oi l seal from the transmi ssi on housi ng.
TRANSMISSION
HOUSING
Replace.
3. Remove t he oi l seal f rom t he f l ywheel housi ng.
,l
OIL SEAL
Oi l Seal Instal l ati on/Si de Cl earance
1. I nst al l a 2. 50 mm { 0. 098
i n) t hi ck 80 mm wi de set
r i ng i n t he t r ansmi ssi on housi ng.
NOTE: Do not i nstal l the oi l seal yet.
SET RING,
80 mm
Seleclive part
TRANSIflSStON
HOUSING
Instal l the di fterenti al assembl y i nto the transmi s-
si on housi ng usi ng the speci al tool as shown.
( cont ' d)
HOUSING
14-263
Differential
Oi l Seal Instal l ati on/Si de
Cl earance
3. l nst al l t he f l ywheel housi ng, and t i ght en t he bol t s.
DIFFERENTIAL
ASSEMBLY
FLYWTIEEL
HOUSING GASKET
1. 25 mm
N m
(3. 0
kgt m, 22 l b{f t }
8 x
29
u f
H s
FLYWHEEL
HOUSING
h
14-264
(cont' d)
\
4. Measure the cl earance between the 80 mm set ri ng
and out er r ace of t he bal l bear i ng i n t he t r ansmi s-
si on housi ng.
STANDARD: 0
-
015 mm
(0 -
0 006 i nl
TRANSMISSION
HOUSING
l f t he cl earance i s more t han t he st andard, sel ect a
new set ri ng f rom t he t abl e, and i nst al l i t .
SET RI NG, 80 mm
NOTE| l f the cl earance measured i n step 4 i s stan
dard. i t i s not necessary to perform steps 7 and 8
Remove the fl ywheel housi ng.
Repl ace the 2.50 mm
(0.098 i n) set ri ng, 80 mm wi th
the one of the correct thi ckness sel ected i n step 5
6.
1.
Part Number
Thi ckness
90414- 689- 000
90415
-
689 000
90416- 689- 000
90417- 689- 000
90418- 689- 000
90419- PH8- 000
2. 50 mm
( 0. 098 i n)
2. 60 mm
( 0. 102 i n)
2. 70 mm 10. 106 i n)
2. 80 mm
( 0. 110 i n)
2. 90 mm
( 0. 114
i n)
3. 00 mm 10. 118
i n)
Fl ywheel Housi ng
Input Shaft Oi l Seal
8. Instal l the oi l seal i n the transmi ssi on housi ng usi ng
DRIVER
07749
-
0010000
Instal l the oi l seal i n the fl ywheel housi ng usi ng the
soeci al tool s as shown.
q
PILOT,
2 6 r 3 0 mm
07JAD
-
PH80200
DRIVER
ATTACHMENT,5E
x 72 mm
079{?
-
6340201
Replacement
1. Remove the i nput shaft oi l
houst ng.
seal from the fl ywheel
Instal l rhe oi l seal i n the fl ywheel housi ng usi ng the
speci al tool s as shown.
FLYWHEEL
Installed depth:
2. 5
-
3. 5 mm
fo"rrr'l,i.ttl, ,"rf
t @
ATTACHMENT,
3 2 x 3 5 mm
07746
-
0010100
14-265
Transmi ssi on Housi ng Beari ngs
Driven Pulley Shaft Bearing Replacement
' 1.
To remove the dri ven pul l ey shaft beari ng from the
t r ansmi ssi on housi ng, expand t he snap r i ng wi t h
snap r i ng pl i er s, t hen push t he bear i ng out usi ng
the speci al tool s and a press
as shown.
NOTE: Do not remove the snap ri ng unl ess i t' s nec-
essary to cl ean the groove i n the housi ng.
07749
-
0010000
ATTACHMENT.
7 2 x 7 5 mm
07746
-
0010600
BEARI NG
14-266
HOUSI NG
SNAP RI NG
\
Expand the snap ri ng wi th snap ri ng pl i ers. i nsert
the new beari ng part-way i nto the housi ng usi ng
the speci al tool s and a press
as shown. Instal l the
beari ng wi th the groove
faci ng outsi de the housi ng.
NOTE: Coat al l pans wi t h CVT Fl ui d.
Rel ease the pl i ers. then push
the beari ng down i nto
the housi ng unti l the ri ng snaps i n pl ace around i t,
usi ng t he speci al t ool s as shown.
BEARING
ATTACHMENT,
7 2 x 7 5 mm
07746
-
001 0600
4.
GBOOVE
SNAP RING
After i nstal l i ng the beari ng veri fy the fol l owi ng:
. The snap ri ng i s seated i n the beari ng and hous-
Ing gfooves.
. The snap ri ng operates properl y.
. The ri ng end gap i s correct.
ENDGAP: 0 - 9 mm
(0-
0. 35 i n)
Fl ywheel Housi ng
Beari ng
Secondary Gear Shaft Bearing
Replacement
1. Remove the secondary
gear shaft beari ng usi ng the
speci al t ool s as shown.
3/ 8"
-
16 SLI DE HAMMER
lCommercially
availablel
SECONDARY GEAR
ADJUSTABLE BEARING SHAFT BEARING
PULLER,25
- ,10
mm
07?36
-
4010004
Instal l the new secondary
gear shaft beari ng unti l i t
bottoms i n the transmi ssi on housi ng, usi ng the spe-
ci al t ool s as shown.
ATTACHMENT,
72 x 75 mrn
07746
-
0010600
Secondary Gear Shaft Bearing
Replacement
1. Remove the secondary gear shaft beari ng usi ng the
soeci al tool as shown,
ADJUSTABLE BEARING
PULLER. 26
-
40 mm
07736
-
A01000A
l nstal l the new secondary
gear shaft beari ng unti l i t
bottoms i n the fl ywheel housi ng, usi ng the speci al
tool s as shown.
DRIVER
07749
-
0010000
ATTACHMENT.
6 2 x 6 8 mm
07746
-
0010500
14-267
Ri ng Gear Beari ng
Control Shaft Assembly
Repl acement
1. Remove t he r i ng gear bear i ng.
RI NG GEAR
Instal l the new ri ng gear beari ng unti l i l bottoms i n
the ri ng gear, usi ng the speci al tool s as snown.
0?749
-
0010000
RING
DRIVER
b
14-268
RemovaUl nstal l ati on
1. Remove t he bol t and l ock washer.
CONTROL SHAFT
ASSEMBLY
6 x 1 . 0 mm
14 N. m (1. 4
kgf . m,
10 tbf.ttl
TRANSMISSION
CONTROL
LEVER
LOCK WASHER
Repl ace.
3.
5.
6.
Remove the control l ever from the control shaft.
Remove the control shaft assembl y.
Instal l the control shaft assembl y i n the transmi ssi on
nousrng.
Instal l the control l ever to the control shaft.
Instal l and ti ghten the bol t wi th a new l ock washer.
Transmi ssi on
Reassembly
CAUTION: Whi l e reassembl i ng, be sure not to al l ow dust and other forei gn parti cl es to enter i nto the transmi ssi on.
NOTE:
. Coat al l parts wi th CVT Fl ui d.
. Repl ace the fol l owi ng parts:
-
O-ri ngs
-
Seal i ng r i ngs
-
Seal i ng washer s
-
Gaskets
-
Stan cl utch assembl y and Secondary dri ve gear assembl y
8 x 1. 25 mm
37 N.m {3.8 kgl.in, 27 lbt.ft)
6 x 1 . 0 mm
12 N. m l I . 2 kgf . m, 8. 7 l bnf t l
\
REVERSE ERAKE
END PLATE
RIGHT SIDE COVER
DOWEL
PIN
olsc
PLATE
DISC SPRING
O.RINGS
RIGHT SIDE COVEB GASKET
6 x 1 . 0 mm
12 N m
(1. 2
kgf . m. 8. 7 l bf . f t l THRUST SHl M. 25 x 31 mm
Sel ect i ve part
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEOLE
BEARING
8 x 1. 25 mm
29 N. m 13. 0 kgt l n. 22l bt f t l
INTERMEDIATE
HOUSING ASSEMBLY
ROLLER
THRUST WASHER
THRUST NEEOLE
BEABING
RING GEAR
SUN GEAR
INPUT SHAFT
SNAP
RING
MANUAL
VALVE
BODY
O. RI NGS
ATF FEED PIPE
DOWEL PIN
TRANSMISSION
HOUSING GASKET
SNAP RI NG
FORWARD CLUTCH
CONTROL SHAFT
ASSEMBLY
SNAP AING
SPRING RETAINER/
RETURN SPRI NG
ASSEMBLY
REVERSE BRAKE PISTON
O. RI NGS
SNAP RING
MANUAL VALVE
ATF FEED PIPES
14-270
SNAP RING RETAINER
HOUSI NG
2.
?
1 .
7.
Instal l the ATF feed pi pe i n the transmi ssi on hous-
i ng, and i nstal l the three ATF feed pi pes wi th new
O- r i ngs i n t he t r ansmi ssi on housi ng.
Instal l the two dowel
pi ns and new transmi ssi on hous-
i ng gasket on the transmi ssi on housi ng.
Push the control shaft assembl y toward the outsi de
of the transmi ssi on housi ng, then i nstal l the i nter-
medi ate housi ng assembl y
(four
bol ts).
l nstal l the manual val ve body separator
pl ate and
the two dowel
pi ns on the i ntermedi ate housi ng.
then i nstal l the manual val ve body wi th the detent
spri ng
(fi ve
bol ts).
Put the control shaft assembl y back, then i nstal l the
rol l er i n the i ntermedi ate housi ng.
Instal l the reverse brake
pi ston i n the i ntermedi ate
housi ng.
l nstal l the spri ng retai ner/retu.n spri ng assembl y on
the reverse brake
Paston.
NOTE: Instal l the return spri ngs on the spri ng gui des
oJ the reverse brake piston securelY
Instal l the speci al tool to compress the return sprl ng
as shown.
REVERSE BRAKE
SPRING COMPRESSOE
o?TAE
-
P4V0110
CAUTION: lf the spring letainer tab is on the reverse
brake
piston, the spring retainer may be damaged.
Be sure the spring retainer tab is not on the piston.
SPECIAL TOOL REVERSE BRAKE
10.
Compress the return spri ngs. then i nstal l the snap
ri ng i n the i ntermedi ate housi ng above the spri ng
retarner.
Veri fy that the snap ri ng end
gap i s correct
Mi ni mum 15 mm
( 0. 59
i n)
,a7
"-,,,,.
/,.' \.,
i r
'
i r ' ,
/ / /
,'t
.
:''
SNAP RING
Soak t he r ever se br ake di scs t hor oughl y i n CVT
Fl ui d f or mi ni mum 30 mi nut es
Instal l the di sc spri ng on the reverse brake
pi ston.
Sl ar t i ng wi t h a r ever se br ake pl at e, al t er nat el y
i nstal l the reverse brake
pl ates and di scs l nstal l the
reverse brake end
pi ate, and the snap ri ng
Measure the cl earance between the reverse brake
end
pl ate and the top di sc wi th a di al i ndi cator. Zero
t he di al i ndi cat or wi t h a r ever se br ake end
pl at e
l owered, and l i ft i t up to the snap ri ng. The di stance
that the reverse brake and
pl ate moves i s the cl ear-
ance between the reverse end pl ate, and the top
di sc.
NOTE: Take measurements i n at l east three
pl aces,
and use the average as the actual cl earance
STANDARD: 0.45
-
0.75 mm
(0.018 -
0.030 i n)
(cont ' di
1 1 .
t 5 .
14.
14-271
Transmi ssi on
Reassembly
(cont'd)
l f the cl earance i s not wi thi n the standard, remove the
reverse brake end pl ate and measure i ts thi ckness.
Sel ect and i nst al l a new r ever se br ake end pl at e,
then recheck.
NOTE: l f t he t hi ckest r ever se br ake end pl at e
j s
i nstal l ed, but the cl earance i s sti l l over the standard,
repl ace the reverse brake di scs and pl ates.
REVERSE BRAKE END PLATE
After repl aci ng the reverse brake end pl ate,
make
sur e t hat t he cl ear ance i s wi t hi n t he st andar d.
Remove t he snap r i ng, r ever se br ake end pl at e,
dascs, pl ates,
and di sc spri ng.
l nst al l t he snap r i ng r et ai ner on t he dr i ve pul l ey
shaft.
Wrap the dri ve pul l ey shaft spl i nes wi th tape to pre-
vent damage t o t he O- r i ngs, t hen i nst al l new O-
fl ngs.
Instal l the forward cl utch assembl y on the dri ve pul
l ey shaft, then i nstal l the snap ri ng.
SNAP BIT{G
O.RINGS
SNAP RING
RETAINER
18.
17.
19.
20.
Pl ate No. Part Number Thickness
22551
-
P4V 003 3. 6 mm
( 0. 142
i n)
2 22552
-
P4V 003 3. 8 mm ( 0. 150
i n)
3 22553-P4V OO3 4. 0 mm
( 0. 157
i n)
22554
-
P4V 003 4. 2 mm 10. 165 i n)
5 22555- P4V- 003 4. 4 mm
( 0. 173
i n)
6 22556- P4V- 0034. 6 mm ( 0. 181
i n)
7 22551
-P4V -OO3
4. 8 mm
( 0. 189
i n)
8 22558- P4V- 0035. 0 mm ( 0. 200
i n)
14- 272
\
22. Veri l y t hat t he out si de di amet er of t he snap ri ng i s
correct .
Maxi mum 4l 4 mm 11. 63 i n)
23. I nst al l t he i nput shaf t and t he sun gear as a sub
assembl y.
2 4 . I n s t a l l t h e t h r u s t n e e d l e b e a r i n g a n d t h e t h r u s t
washer on t he sun gear.
CARRIER ASSEMBLY
""^rr,""()
THBUST NEEDLE
BEARING
25. Instal l the carri er assembl y on the forward cl utch.
THRUST
26. Instal l the thrust washer, the thrust needl e bearang,
and the thrust washer on the carri er assembl y.
SNAP BI NG
THRUST SHI M,
2 5 x 3 1 mm
Sel ect i ve
pa rt
27.
RING GEAR
THRUST NEEDLE
THRUST WASHERS
BEANING
Instal l the ri ng gear and the 25 x 31 mm thrust shi m.
then i nstal l the snap ri ng.
Veri fy that the outsi de di ameter of the snap ri ng i s
correct.
Maxi mum 30. 7 mm
( 1
21 i n)
F - 1
't'":' \
/./ \\
/ l r l
i l r '
\ \ ,
, / _
SruEP RING,
Measur e t he cl ear ance bet ween t he 25 x 31 mm
thrust shi m and the snap ri ng.
STANDARD: 0.05
-
0.11 mm 10.0020
-
0.00/B inl
pl aces,
28.
29.
,*"ua{t",",
' ! ttl .
RI NG GEAB
14-273
30.
3'| .
l f the cl earance i s out of tol erance, remove the 25 x
31 mm thrust shi m and measure i ts thi ckness.
Sel ect and i nstal l a new 25 x 3' l mm thrust shi m,
then recheck.
THRUST SHIM. 25 x 31 mm
After repl aci ng the 25 x 31 mm thrust shi m, make
sure that the cl earance i s wi thi n tol erance and the
snap ri ng outsi de di ameter i s correct
Instal l the di sc spri ng i n the di recti on shown.
St ar t i ng wi t h a r ever se br ake pl at e, al t er nat el y
i nst al l t he r ever se br ake Dl at es and di scs. l nst al l
sel ected reverse brake end
pl ate.
then i nstal l the
snap f l ng.
32.
34.
REVERSE BRAKE
END PLATE
REVERSE BRAKE
PLATES
Dtscs
OISC SPRING
l nst al l i n t hi s di rect i on
(cont' d)
90451
-
P4V
-
000 1. 05 mm
(0. 011
i n)
B 90452 P4V
-
000 1. 12 mm
( 0. 044
i n)
c 90453 P4V
-
000 1. 19 mm
( 0. 047
i n)
D 90454- P4V- 000 1. 26 mm
(0. 050 i nl
E 90455- P4V- 000 1. 33 mm {0. 052 i n)
F 90456- P4V- 000 1. 40 mm
(0. 055 i n)
G 90457- P4V- 000
' 1. 47
mm
(0. 058
i n)
H 90458- P4V- 000 1. 54 mm
(0. 061
i n)
90459- P4V- 000 1. 61 mm {0. 063 i n)
J 90460- P4V- 000 1. 68 mm
(0. 066 i n)
K 90461
-
P4V 000 1. 75 rnm {0. 069 i n}
L 90462 P4V
-
000 1. 82 mm
(0. 072
i n)
M 90480- P4V- 000 1. 085 mm
(0. 0427 i n)
N 90481- P4V- 000 1. 155 mm 10. 0454
i n)
o 90482- P4V- 000 1. 225 mm
(0. 0482 i n)
P 90483- P4V- 000 1. 295 mm
(0. 0510 i n)
o 90484- P4V- 000 1. 365 mm {0. 0537 i n)
R 90485 P4V
-
000 1. 435 mm
(0. 0565 i n)
90486- P4V- 000 1. 505 mm
(0. 0593
i n)
T 90487- P4V- 000 1. 575 mm
(0. 0620 i n)
90488- P4V- 000 1. 645 mm
(0. 0648 i n)
90489- P4V- 000 1. 715 mm
(0. 0675 i n)
90490- P4V- 000
' 1. 785
mm {0. 0703 i n)
Transmi ssi on
Reassembly
(cont'dl
35. Veri fy that the snap ri ng end gap i s correct.
Mi ni mum 18 mm
( 0. 71
i n)
--
I'J
t\
.,..
.\i
1 r
' t ,
sruapntruc-/ \ ,/
. : :
8 x 1. 25 mm
37 N.m
(3.8
kgI.m, 27 lbt.ft)
I nst al l t he manual val ve body pi pes A and B wi t h
new O-ri ngs on the manual val ve body and the i nter-
medi ate housi ng.
36.
6 x 1 . 0 mm
1 2 Nm( 1 . 2 k g f . m.
8.7 tbt.ftl
f,
t'tl\
E J \
"
E P
9>- E
RI GHT SI DE
COVER GASKET
DOWEL PI NS
O. RI NGS
MANUAL VALVE
BODY PIPE A
ATF FEEO
PI PES
MANUAL VALVE
BODY
Instal l the two dowel pi ns and new ri ght si de cover
gasket on t he i nt er medi at e housi ng, t hen i nst al l
new O-ri ngs on the ATF l eed pi pes.
Instal l the ri ght si de cover
(three
6 mm bol ts, el even
8 mm bol ts).
NOTE: I nst al l t he ni ne 8 mm bol t s i n t he r i ght si de
cover
( t wo
8 mm bol t s r emai n i n t he r i ght si de
cover) then ti ghten the el even 8 mm bol ts.
37.
38.
14- 274
39. Instal l the
parki ng brake pawl , spri ng, and shaft on
t he t r ansmi ssi on housi ng, t hen move t he cont r ol
l ever to any
gear other than
E
posi ti on.
SNAP RI NG
THRUST SHI M,
SECONDARY
GEAB SHAFT
COTTER
RETAI NER
COTTERS,
25. 5 mm
Sel ect i ve pan
PABKING BRAKE
PAWL SHAFT
START CLUTCH
ASSEMBLY
SECONDARY
DRIVE GEAR
ASSEMBLY
O-RI NGS
PARKING BRAKE
PAWL SPRING
40.
4 1 .
42.
43.
PARKING
ORIVEN PULLEY
SHAFT
Instal l the secondary gear shaft wi th sel ected 25 x
35 mm t hr ust shi m
( see page 14- 100) .
Wr ap t he dr i ven pul l ey shaf t spl i nes wi t h t ape t o
prevent damage to the O-ri ngs, then i nstal l new O-
nngs.
Assembl e the secondary dri ve gear assembl y i n the
start cl utch assembl v. then i nstal l them on the dri ven
oul l ev shaft.
Pul l t he handl e of t he speci al t ool up, t hen i nst al l
the ti p of i t i nto the dri ven pul l ey shaft hol e, and set
the soeci al tool on the start cl utch-
CAUTION: While installing the start clutch and the
secondary dri v gear assembl y usi ng the speci al
tool , be sure not to al l ow dust and other torei gn
particles to enter into the transmission.
START CLUTCH
INSTALLER
07TAE
-
P4V0130
I
t r , , nuna' " .
44. Push the handl e of the speci al tool , then ti ghten the
nut to seat the secondary dri ve gear assembl y on
the dri ven pul l ey shaft securel y.
S?ART CLUTCH INSTALLER
HANOLE
Pul l the handl e of the speci al tool up, and remove
the speci al tool -
Installthe cotters, then measure the clearance between
the cotters and the sl art cl utch gui de.
STANDARD: 0
-
0.13 mm {0
-
0.005 i n)
NOTE| Take measurements an at l east thfee pl aces,
45.
46.
GAUGE
l)
li
l f
START CLUTCH
GAUGE
,l
COTTERS, 25.5 mm
4't .
48.
50.
It the cl earance i s not wi thi n the standard. remove
the cotters and measure th ei r thi ckness.
Sel ect and i nstal l new cotters, then recheck.
coTTERS, 25.5 mm
49. After repl aci ng the 25.5 mm cotters, make sure thal
the the cl earance i s the standard.
I nst al l t he cot t er r et ai ner and t he snap r i ng.
Veri fy rhat the outsi de di ameter of the snap ri ng i s
correcI.
Mi ni mum 33. 9 mm 11. 33 i n)
n
"no"*,/\--/
I ns t al l t he t hr us t was her s , t he ATF
pump
dr i v e
sprocket hub and the 22 x 28 mm thrust shi m on the
i nput shaft, then i nstal l the snap ri ng.
SNAPRI NG\
Selective oan
52.
ATF PUMP DRIVE
SPNOCXET HUA
THRUST WASHENS
( cont
d)
No. Part Numbel Thickness
90429- P4V- 0002. 9mm { 0. 114 i n)
B 90430- P4V- 000 3. 0 mm
( 0. 118
i n)
c 90431
-
P4V
-
000 3. 1 mm { 0. 122
i n)
D 90432- P4V- 0003. 2 mm { 0. 126 i n)
START CLUTCH
14-275
Transmission
Reassembly
(cont'dl
53. Veri fy that the outsi de di ameter of the snap ri ng i s
correct.
Maxi mum 26. 3 mm { 1. 04 i n)
r5
54. Measure the cl earance between the 22 x 28 mm
thrust shi m and the snap ri ng.
STANDARD; 0.37
-
0.65 mm
10.015
-
0.026 in)
pl aces,
THFUST SHIM,
22x28 mm
l f the cl earance i s out of tol erance, remove the 22 x
28 mm thrust shi m and measure i ts thl ckness.
Sel ect and i nstal l a new 22 x 28 mm thrust shi m,
then recheck.
THRUST SHIM. 22 x 28 mm
56.
c 90573- P4V- 000 1. ' 15 mm
{ 0. 045 i n)
D 90574- P4V- 000 1.40 mm
(0.055
i n)
E 90575- P4V- 000 1.65 mm
(0.065
i n)
F 90s76- P4V- 0001. 90 mm
( 0. 075
i n)
90577- P4V- 000 2. 15 mm
( 0. 085
i n)
H 90578- P4V- 000 2.40 mm
(0.095
i n)
14-276
INPUT SHAFT
51.
58.
After repl aci ng the 22 x 28 mm thrust shi m, make
sure that the cl earance i s wi thi n tol erance and the
snap ri ng outsi de di ameter i s correct
Instal l the pi tot fl ange usi ng i ts cutout as shown to
cl ear the pi tot pi pes.
INPUT SHAFT
l nstal l the ATF pump dri ve sprocket. and put the
ATF pump dri ve chai n on the ATF
pump
dri ve and
dri ven sprockets. then l nstal l and ti ghten the bol ts
(three
bol ts),
Eq
PUMP ORIVE CHAIN
6 x
' l . 0
mm
12 N. m
(1. 2
kgf . m, 8. 7 l bt f t )
ATF PUMP DRIVE
SPROCKET
PITOT FLANGE
ATF PUMP
I
60. Instal l the di fferenti al assembl y.
61. Instal l the ATF passage pi pe assembl y wi th new O-ri ngs
(one
bol t).
62. Instal l the three dowel pi ns and new fl ywheel housi ng gasket on the transmi ssi on housi ng
63. Instal l the fl ywheel housi ng and connector bracket
(twenty
bol ts).
64. Instal l the ATF passage pi pe hol der assembl y
(two
bol ts).
8 x 1 .25 mm
29 N.m
(3.0 k91.m,22lbl'ftl
I
arF PAssAGE PIPE
I
HOLDER ASSEMBLY
I
\
\n
f - {
\ A
[tr1
o-RrNG-___\S/
FLYWHEEL HOUSING
GASKET
6 x 1 . 0 mm
12 N. m {1. 2 kgf . m,
8.7 tbI.ft)
E
{u
R
FLYWHEEL HOUSING
ATF PASSAGE PIPE
CONNECTOR ERACKET
DOWEI. PIN
DOWEL PIN
6 x 1 . 0 mm
12 N. m 11. 2
kgf . m,
8.7 tbtftl
at":
,):/;[
ri-{e
DOWEL PIN
( co
nt ' d )
14- 277
Transmission
Reassembly
(cont'dl
65. Instal l the sol enoi d harness connector wi th a new O-ri ng {one bol t}, then i nstal l the l ower val ve body assembl y wi th
three dowel pi ns (ei ght
bol tsl .
66. Instal l the ATF strai ner wi th a new O-ri ng
(two
bol ts).
67. l f necessary, assembl e the ATF pan, ATF fi l ter, and the ATF cool er i nl et pi pe (see page
' 14-235).
68. Instal l the ATF pan wi th the two dowel pi ns and a new ATF pan gasket (fourteen
bol ts).
69. Instal l the ATF cool er i nl et pi pe bracket bol t.
70. l nstal l the ATF cool er outl et
pi pe wi th the
j oi nt
bol t and new seal i ng washers.
6 x 1 . 0 mm
12 N. m 11. 2 kgf m,
8.7 tbt.ftl
DOWEL PINS
ATF STRAINER
OOWEL PINS
O-RI NG
ATF COOLEF INLET
ATF COOLER OUTLET PIPE
ATF PAN/ATF FILTER/
ATF COOLER INLET
PIPE ASSEMEI-Y
6 x 1 . 0 mm
12 N. m 11. 2 kgf . m,
8.7 tbf.ttl
SEALING
WASHERS
O-RING
JOTNT BOLT
CONNECTOR
5 x 1 . 0 mm
28 N.m {2.9 ksf.m, 21 lbf.ft)
HARNESS
12 N. m {1. 2 kgt . m,
8.7 tbf.ftl
LOWER VALVE BODY
ASSEMBLY
6 x 1 . 0 mm
12 N. m 11. 2 kgt m,
8.7 tbf.ft)
PIPE ERACKET BOLT
8 x 1. 25 mm
26 N.m
(2.7
kgf.m, 20 lbf.ftl
14-278
Flywheel/Drive Plate
DRIVE PLATE
6nKn,
WASHER
t eet h ot t he ri ng gear f or excessi ve wear.
a
12 x 1, 0 mm
74 N.m {7.5 kgI.m, 54lbl.ftl
Torque in 6 crisscross
pattern.
14-279
Transmission
l
Instal l ati on
Fl ush the ATF cool er as descri bed on pages
' 14-284
and 14' 285.
Remove t he used gr ease i n t he f l ywheel hub cap
and fl ywheel spl i nes.
Fi l l the i nsi de of the fl ywheel hub cap, and coat the fl y
wheel hub spl i nes wi th Super Hi gh Temp Urea Grease
(P/N
08798
-
9002) as shown.
2.
3.
SUPER HIGH TEMP
UREA GNEASE
{P/N 08798
-
90021
1.5
-
2.5 g (0.05 -
0.og ozl
4. I ns t al l a new s eal i ng r i ng
( r ubber )
on t he i nput
shaft, and i nstal l two 14 x 20 mm dowel pi ns i n the
l l ywheel housi ng.
l nstal l the fl ywheel securel y on the i nput shaft, then
i nstal l the starter motor on the fl ywheel housi ng.
44 N. m
(4.5
kgf.m.33 lbf.ft)
I NPUT SHAFT
STARTER
r t l
I
1 4 x 2 0 mm
DOWEI- PIN
SEALI NG RI NG
{ RUBBER)
14 x 20 mm DOWEL PI N
SPLI NES
Apply SUPER HIGH TEMP
UREA GREASE
{P/N 08798
-
90021
14-280
FLYWHEEL
MOUNT
6. Pl ace the transmi ssi on on a
j ack,
and rai se i t to the
engi ne assembl y l evel .
7. Attach the transmi ssi on on the engi ne, then i nstal l
t he t r ansmi ssi on housi ng mount i ng bol t and r ear
engi ne mount i ng bol t s.
MOUNTI NG BOLT
64 N.m
(6.5
kgt.m,
REAR ENGINE MOUNTING
BOLT
Repl ace.
' 12
x 1, 25 mm
59 N.m
(6.0
kgf.m, 43 lbtftl
WASHER
41
.:_11
12 x L25 mm
74 N. m {7. 5 kgl . m, 54l bt f t }
8. l nstal l the transmi ssi on mount bracket Ti ghten the
l ong bol t l oosel y, and ti ghten the nuts and bol t on
t he mount br acket t o t he speci f i ed t or que. Then
ti ghten the l ong bol t to the speci fi ed torque.
12 x 1. 25 mm
64 N.m {6.5 kgl.m, 47 lbl.ft)
9. Instal l the remai ni ng transmi ssi on housi ng mount-
i ng bol ts.
PRIMARY OXYGEN SENSOR
Remove the transmi ssi on
j ack
and the hoi st, then
remove the hoi st bracket from the engi ne.
Attach the fl ywheel to the dri ve pl ate wi th ei ght
bol ts and torque as fol l ows:
Rotate the crankshaft
pul l ey as necessary to ti ghten
the bol ts to hal f of the speci fi ed torque, then to the
fi nal torque, i n a cri sscross
pattern.
Af t er t i ght eni ng t he l as t bol t , c hec k t hat t he
crankshaft rotates freel y.
Instal l the fl ywheel cover and the engi ne sti ffeners.
6 x 1 . 0 mm
12 N. m
11. 2 kot m.
TE
e.z ruittt
10.
1 1 .
12.
DRIVE
ENGI NE
STIFFENER
10 x
'l
.25 mm
,14
N.m
(4.5
kgf.m,
33 tbt.ftl
8 x 1. 25 mm
2 4 N m
(2.6
kgf.m,
17 tbf.ftl
8 x 1. 25 mm
26 N.m
12.7 kgl..n.
20 rbf.ft)
DRIVE PLATE BOLT
6 x 1 . 0 x 1 4 mm
12 N. m {1. 2 kgt m,
8.7 tbl.ft|
FLYWHEEL
ENGINE STIFFENER
8 x 1. 25 mm
10 x 1. 25 mm
44 N.m
(4.5
kgf.m,
33 rbtft)
24 N.m
(2.4 kgf'm, 17 lbt ft)
22 N m {2. 2 kgf . m, 16l bt f t l
14-281
14.
13. Ti ghten the crankshaft
pul l ey bol t, i f necessary
(see
secti on 6).
Connect the ATF cooler hoses to the ATF cooler
pipes
(see page 14-2891.
CAUTION: While connecting the ATF cooler hoses,
be sure not to allow dust and other loreign parti-
cles to enter ioto the transmission.
Instal l the ri ght front mounvbracket.
10 x 1. 25 mm
4{ N.m
(,1.5
kgl m, 33 lbf ftl
RIGHT FRONT
MOUNT/EFACKET
ATF COOI.IR PIPE
' 10
x 1. 25 mm
54 N.m 15.5 kgt m,
{0 rbf.ft)
ATF COOI.ER HOSE
16. I nst al l t he exhaust
pi pe A.
EXHAUST PIPE A
GASKET
Repl ace.
@
\
SELF.LOCKING NUT
Repl ace.
10 x 1. 25 mm
54 N.m
(5.5
kgf m,
4r) tbt.ftt
(cont' d)
oo"*ar-@
Repl ace.
SELF.LOCKING
Bepl ace.
8 x 1. 25 mm
SELF.LOCKING NUT
Repl ace.
8 r 1 .25 mm
16 N. m 11. 6 kgf m,
12 tbf.ft)
Transmission
1 7 .
18.
Instal l ati on
(cont' d)
Instal l a new set ri ng on the end of each dri veshaft.
Instal l the ri ght and l eft dri veshafts
(see
secti on 16).
CAUTION: Whi l e i nstal l i ng the dri vcshal ts i n the
diflerential, be sure not to allow dust and other for-
eign particles to enter into the transmission.
NOTE:
I Cl ean the areas where the dri veshafts contact the
t r ansmi ssi on
( di f f er ent i al )
t hor oughl y wi t h sol -
vent or car bur et or cl eaner , and dr y wi t h com
pressed
arr.
. Turn the ri ght and l eft steeri ng knuckl e ful l y out-
ward, and sl i de each dri veshaft i nto the di fferen-
ti al unti l you {eel i ts set ri ng cl i p engage the si de
gear .
Instal l the damper fork, then i nstal l the ri ght and l eft
bal l
j oi nt s
t o each l ower ar m wj t h t he cast l e nut s
and new cotter prns.
10 x 1, 25 mm
43 N.m
(4,4
kgf.m, 32 lbf.ftl
19.
SELF-LOCKING NUT
Repl ace.
12x 1. 25 nm
64 N.m
{6.5 ks{.m, 47 lbf.ftl
./*:,
./ cbr-rER PtN
CASTLE NUT
12 x 1. 25 mm
Bepl ace.
49- 59 Nm 15. 0- 6. 0kgf . m,
36
-
43 tbf.ftl
14-282
\
20. Instal l the spl ash shi el d.
6 x
' l . O
mm SPLASH SHI ELD
9. 8 N. m { 1. 0 kgf . m,
7 .2 tbl'ttl
21. Connect t he vehi cl e speed sensor connect or , t he
dri ven pul l ey speed sensor connector and the sec-
ondary
gear
shaft speed sensor connector.
VEHICLE SPEEO
SENSOR
CONNECTOR
SECONDARY GEAR
SHAFT SPEED
SENSOR CONNECTOR
6 x 1 . 0 mm
'12
N.m {1.2 kgf.m, 8.7 lbl.ft}
DRIVEN PULLEY
SPEEO SENSOR
CONNECTOR
6 x 1 . 0 mm
12 N. m 11. 2 kgl m, 8. 7 l bf . f t l
a ' .
22. Instal l the shi ft cabl e end on the control l ever, and
i nstal l the shi ft cabl e on the shi ft cabl e bracket.
CAUTIONT Take care not to bend the shi ft cabl e.
23. I nst al l t he cl i p i n t he di r ect i on shown.
LOCKNUT
SHIFT CABLE 29 N.m
(3.0
kgl.m, 22 lbfftl
SHI FT CABLE
BRACKET
WASHER
IPLASTIC}
CONTBOL LEVER
24. Connect the sol enoi d harness connector, the dri ve
pul l ey speed sensor connect or , and t he gr ound
cabl e t er mi nal s.
6 x 1 . 0 mm
12 N. m {1. 2 kgl m,
8.7 tbt.f0
GROUND CABLE
TERMTNAL
6x1. 0mm
12 N. m
11. 2 kgl . m,
8.7 rbf.ftl
DRIVE PULLEY
SPEED SENSOR
CONNECTOR
25. Connect the starter motor cabl e on the starter motor,
and i nstal l the cabl e hol der.
NOTEr When i nstal l i ng the starter motor cabl e, make
sur e t hat t he cr i mped si de of t he r i ng t er mi nal i s
faci ng out
(see
secti on 23).
STARTER
26. Instal l al l removed connectors and cl amps.
27. Insl al l the di stri butor.
28. I nst al l t he i nt ake ai r duct and ai r cl eaner housi ng
assemDty.
29. Ref i l l t he t r ansmi ssi on wi t h t he r ecommended
Genui ne Honda CW Fl ui d
( see page l 4- 231) ,
CAUTION: While lilling the CVT Fluid, be sure not to
allow dust and other toreign particles to enter into
the transmi ssi on.
B TERMI NAL MOUNTI NG NUT
I N.m 10.9 kgt.m, 7 lbtft)
Connect the batterv
posi ti ve (+)
termi nal fi rst, then
the negati ve {-) termi nal to the battery.
Check the i gni ti on ti mi ng
(see
secti on 231.
Start the engi ne. Set the parki ng brake, and shi ft the
t r ansmi ssi on t hr ough al l gear s t hr ee t i mes. Check
shi ft cabl e adj ustment
(see page 14-287).
33. Check the front wheel al i gnment
(see
secti on 18).
34. Let t he engi ne r each oper at i ng t emper at ur e
( t he
r adi at or f an comes on) wi t h t he t r ansmi ssi on i n
E
or
E
posi ti on, then turn i t of{ and check fl ui d l evel .
35. Per f or m t he st ar t cl ut ch cal i br at i on
pr ocedur e on
page 14-225.
36. Road test as described on pages 14 228 and 14-229.
30.
a)
STARTER MOTOR
14-283
Transmission
1 .
Cool er Fl ushi ng
!@
To prevent iniury to face and eyes, always
wear satety gl asses or a face shi el d when usi ng the
transmission flusher,
NOTE: Thi s procedure
shoul d be performed before rei n-
stal l i nq the transmi ssi on.
Check t ool and hoses f or wear and cr acks bef or e
usi ng. l f wear or cracks are found, repl ace the hoses
be{ore usi ng.
Usi ng the measuri ng cup, fi l l the tank wi th 21 ounces
(approxi matel y
213 tul l l ot bi odegradabl e fl ushi ng
fl ui d
(J35944 -
20). Do not substi tute wi th any other
f l ui d. Fol l ow t he handl i ng pr ocedur e on t he f l ui d
contai ner.
Secure the fl usher fi l l er cap, and pressuri ze the tank
wi th compressed ai r to between 550
-
829 kpa
(5.6 -
8.45 kgf/cm,,80
-
120 psi ).
NOTE: The ai r l i ne shoul d be equi pped wi th a water
trap to ensure a dry ai r system.
Hang the tool under the vehi cl e.
Attach the tank' s di scharge hose to the return l i ne
of the transmi ssi on cool er usi ng a cl amp.
Connect the drai n hose to the i nl et l i ne on the trans-
mi ssi on cool er usi ng a cl amp.
IMPORTANT:
Securely clamp the opposite end ol the drain hose to a
bucket or fl oor drai n.
2.
3.
4.
5.
6.
{Commercially availablel
Kent-Moore J384O5-A
or equivalent
14-284
16.
\
7. With the water and air valves off, attach the water and
ai r suppl i es t o t he f l usher.
(Hot
wat er i f avai l abl e. )
8. Turn on the fl usher water val ve so water wi l l fl ow
through the cool er for 10 seconds.
NOTE: l f water does not fl ow through the cool er, i t
i s compl etel y pl ugged, cannot be fl ushed, and must
be repl aced.
9. Depress the tri gger to mi x the fl ushi ng fl ui d i nto the
water fl ow. Use the wi re cl i p to hol d the tri gger down.
10. Whi l e fl ushi ng wi th the water and fl ushi ng fl ui d for
two mi nutes, turn the ai r val ve on for fi ve seconds
every
' 15
-
20 seconds to create a surgi ng acti on.
AIR PRESSURE: MAX 845 kpa
(8.45
kgtcm,, 120 psi )
11. Turn the water val ve off. Rel ease the tri gger, then
reverse the hoses to the cool er so you can l l ush i n
the opposi te di recti on. Repeat steps 8 through 10.
Rel ease the tri gger, and ri nse the cool er wi th water
onl y f or one mi nut e.
Turn the water valve off, and turn off the water supply.
Turn the ai r val ve on to dry the system out wi th ai r
for two ful l mi nutes or unti l no moi sture i s vi si bl e
l eavi ng the drai n hose.
CAUTION: Residual moisture in the cooler or lines
can damage the transmission.
Remove the fl usher from the cool er l i ne. Attach the
drai n hose to a contai ner.
I nst al l t he t r ansmi ssi on, and l eave t he dr ai n hose
attached to the cool er l i ne.
1 4 .
15.
' t1
. Make sure the transmi ssi on i s i n the E
posi ti on.
Fi l l t he t r ansmi ssi on wi t h CVT Fl ui d, and r un t he
engi ne for 30 seconds or unti l approxi matel y 0.95 /
( 1. 0
US qt . , 0. 8 l mp qt . ) i s di schar ged.
Remove t he dr ai n hose, and r econnect t he cool er
return hose to the transmi ssi on
(see page l 4 287).
Refi l l the transmi ssi on wi th CVT Fl ui d to the proper
l evel
( see page' 14 231) .
' 18.
19.
TOOL MAINTENANCE
' 1.
Empty and ri nse after each use. Fi l l the can wi th water
and pressuri ze the can. Fl ush the di scharge l i ne to
ensur e t hat t he uni t i s cl ean.
2. l f di scharge l i qui d does not foam, the ori fi ce may be
bl ocked.
3. To cl ean, di sconnect t he pl umbi ng f r om t he t ank at
t he l ar ge coupl i ng nut .
couPLlf{G
NUT
I
I
-@q
\
ORIFICE
Remove the i n-l i ne fi l ter from the di scharge si de and
cl ean i f necessary.
The t l ui d ori f i ce i s l ocat ed behi nd t he f i l t er. Cl ean i t
wi t h t he pi ck st ored i n t he bot t om of t he t ank han
dl e, or bl ow i t cl ean wi t h ai r. Securel y reassembl e
al l part s.
FILLER CAP
14-285
Shift Cable
!
!@
Make sure lifts,
iacks
and salety stands ale
placed properly (see
section 1).
(see
secti on 20).
2. Shi ft to
ffi
the adi uster.
( 0. 7
kgf . m, 5l bf . f t l
ADJUSTER
14-286
\
3. Remove the ai r cl eaner housi ng assembl y.
Remove the cl i p from the control l ever, and l oosen
the l ocknut.
CLIP SHIFT CABLE LOCKNUT
Tr
WASHER
(>
29 N.m {3.0 ksf.m, 22 lbtft)
SHIFI CABLE
BRACKET
Remove the shi ft cabl e from the control l ever, the
shi ft cabl e bracket, and the cl amp.
Remove the shi ft cabl e bracket bol ts and nuts, then
remove the shi ft cabl e. Take care not to bend the
shi ft cabl e when removi ng/i nstal l i ng i t,
SHIFT CABLE BRACKET
Instal l the shi ft cabl e i n the reverse order of removal .
Check the cabl e adj ustment (see page 14-2871.
\
1.
8.
CONTROL LEVER
{1.2 kgt.m, 8.7 lbl.ft)
Adjustment
@
Make sure lifts,lacks and safety stands are
placed properly
{see sestion 11,
(see
secti on 20).
2. Shi ft to
E
the adj uster.
SHI FT CABLE
10. 7 kgf ' m, 5 l bf ' f t l
3. Check that the hol e i n the adi uster i s perfectl y al i gned
wi th the hol e i n the shi ft cabl e. There are two hol es i n
the adj uster. They are
posi ti oned 90" apart to al l ow
cabl e adi ustment i n 1/4 turn i ncrements.
l f the hol e i s not perfectl y al i gned, l oosen the l ock-
nut on the adj uster and adj ust as requi red.
Ti ghten the l ocknut to 7 N.m {0.7 kgf.m, 5 l bnft}.
Instal l the l ock pi n on the adj uster. l f you feel the
l ock pi n bi ndi ng as you rei nstal l i t. the cabl e i s sti l l
out of adj ustment and must be readj usted.
q
7. Make sur e t he l ock pi n i s seat ed i n t he adj ust er
securel y.
Move the shi ft l ever to each
posi ti on, and veri fy that
the shi ft posi ti on i ndi cator fol l ows the automati c
transaxl e
gear posi ti on swi tch.
St ar t t he engi ne, and check t he shi f t l ever i n al l
posi ti ons. If any
gear does not work properl y. rei er
to troubl eshooti ng
(see page 14-226 and l 4-227J.
Insen the i gni ti on key i nto the key cyl i nder on the
A//T gear posi ti on i ndi cator panel , and veri fy that the
shi ft l ock l ever i s rel eased.
14-287
Shift Lever
LEVER COVER
SCREW
3 N.m {0.3 kgt m, 2 lbtft)
3 N.m {0.3 kgf.m,
2 tbf.ftl
SHIFT LEVER BRACKET
BASE COLLAR
PUSH KNOB SPRI NG
PUSH KNOB
SHIFT INOICATOR LAMP
,l
-6r
SILICONE GREASE
SHIFT LOCK
SOLENOID
6 x l . 0 mm
9. 8 N. m {1. 0
kgl m,
1 .2 tbt.ltl
@'""'-rccretn
ADJUSTER
6 x 1 . 0 mm
9. 8 N. m
(1. 0 kgf m, 7 2l bt f t )
LEVER COVER
BUSHI NG
..@]
SILICONE GREASE
SHIFT LEVER ASSEMBLY
EJ
-6.,1
SILICONE GREASE
A/T GEAR POSITION
PLATE
SHIFT LEVER BRACKET BASE
14-288
Shi ft Indi cator Panel ATF Cooler/Hoses
Adjustment
1. Check t hat t he i ndex mar k on t he i ndi cat or al i gns
wi th the E
mark on the shi ft i ndi cator panel when
t he t r ansmi ssi on i s i n NEUTRAL.
MOUNTI NG SCREW
TANEL
3 Nm {0. 3 kgt . rn. 2 l bt f t }
l f not al i gned, remove t he f ront consol e
(see
sect i on
20).
Remove t he shi f t i ndi cat or panel mount i ng screws
and adj ust by movi ng t he panel .
NOTE: Whenever t he shi f t i ndi cat or panel i s removed,
rei nst al l t he
panel as descri bed above,
I
I
l nstal l ati on
1. I nst al l t he ATF cool er , ATF cool er pi pe assembl y
and the ATF cool er hoses.
6 x 1 . 0 mm
ATF COOLER PIPE ASSEMBLY
ATF COOLER HOSE
(0. 2 -
0. 3 i n)
6 - 8 mm
(0. 2 -
0. 3 i n)
3 3 - 3 5 mm
( 1. 3
-
1. 4 i nl
/,/'
RADtAfoR
6 x l . 0 mm
9. 8 N. m
(1. 0
t gl m, 7. 8 l bf f t l
ATF COOLER HOSES
Connect t he ATF cool er hoses t o t he ATF cool er
l i nes and ATF cool er, and secure them wi th the cl i ps
as shown.
RADIATOR
/
&)
\ - 6 - g mm
2 - 4 mm
10. 1
-
0. 2 i nl
14-289
Differential
Manual Transmi ssi on ...................... seeti on 1 3
Automati c Transmi ssi on ................. secti on 1 4
d
Driveshafts
Speci al
Tool s ..........
""".."' 16-2
Driveshafts
I nspect i on
. . . ". . . ' . ' . . ' . . . . ' . . .
16-3
Removal
.... 16-3
Di sassembl y
. . ". ' . . . . ". . . . . "
16-5
Reassembl y
. . . . . . . ". . . ' . ". . . . 16-7
l nst al l at i on
. . ' . . . . . . . . ' . . ' . ' . . ' .
16-11
Special Tools
I
Ref. No. I Tool Number
Bal l Joi nt Remover, 28 mm
o
16-2
Driveshafts
Inspection
Drivoshafi Boot
Check the boots on the dri veshaft for cracks, damage,
l eaki ng
grease and l oose boot bands. l f any damage i s
found, repl ace the boot and boot bands
Loose Splines
Turn the dri veshaft by hand and make sure the spl i nes
and i oi nt
are not excessi vel y l oose l f any damage as
found. repl ace the i nboard
j oi nt.
Twisted or Cracked
Make sure the dri veshaft i s not twi sted or cracked.
ReDl ace i t i f necessary.
a
BOOT BANDS
1 .
Removal
Loosen the wheel nuts sl i ghtl Y.
Rai se the tront of the vehi cl e, and support i t wi th
safety stands i n the
proper l ocati ons
(see
secti on 1).
Remove the wheel nuts and front wheel s.
7.
Drai n the transmi ssi on fl ui d
(see
secti on 13 or 14).
Rai s e t he l oc k i ng t ab on t he s pi ndl e nut , t hen
remove the nut,
Remove the sel f-l ocki ng nut and fl ange bol ts.
FLANGE EOLT
10 x 1. 25 mm
12 x 1. 25 mm
Repl ace.
Remove t he damper f ork.
(cont' d)
16-7
Driveshafts
Removal
{cont'd)
8. Remove the cotter pi n from the l ower arm bal l
j oi nt
castl e nut, and remove the nut.
I nst al l a 12 mm hex nut on t he bal l
j oi nt .
Be sur e
that the hex nut i s fl ush wi th the bal l
j oi nt pi n end,
or the threaded secti on of the bal l
j oi nt pi n mi ght be
damaged by the speci al tool .
Use the speci al tool as shown i n secti on 18, to sepa-
rate the bal l
i oi nt
and l ower arm. Be careful not to
damage the bal l
j oi nt
boot,
NOTE: l f nece' ssary, appl y penetrati ng type l ubri -
cant to l oosen the bsl l
j oi nt.
Pry the dri veshaft assembl y wi th a screwdri ver, as
shown, to force the set ri ng at the dri veshaft end
past the groove.
9.
10.
1 1 .
3. 5 mm
07MAC
-
St_00200
SCREWDRIVER
16-4
12. Pul l t he i nboar d
j oi nt ,
and r emove t he dr i veshaf t
from the di fferenti al case as an assembl y. Do not
pul l on the dri veshaft; the i nboard
j oi nt
may come
apart. Use care when pryi ng out the assembl y, and
pul l i t strai ght to avoi d damagi ng the di fferenti al oi l
seal .
13. Pul l the knuckl e outward. and remove the dri veshaft
out boar d
j oi nt
f r om t he f r ont wheel hub usi ng a
ol asti c hammer.
SCREWDRIVER
ORIVESHAFT
Disassembly
1 . Caretul l y cl amp the dri veshaft i n a vi se wi th soft
j aws,
then remove the set ri ng from the i nboard
j oi nt.
To remove the boot band,
pry up the l ocki ng tabs
wi th a screwdri ver and rai se the end of the band.
Take care not to damage the boot.
SET RING
Replace.
-
l f the boot band i s the wel ded type, cut i t off as
snown.
BOOT BAND
Repl ace.
-
l f the boot band i s the cri mpi ng type,
pry up the
end of the band wi th a screwdri ver.
BOOT BAND
Repl ace.
-
It the boot band i s doubl e l oop type, rai se the
band bend as shown.
DOUB1I I.OOP BAND
R6pl ace.
Mark each rol l er and i nboard
i oi nt
t o i dent i f y t he
l ocat i ons of rol l ers and
grooves i n t he i nboard
j oi nt .
Then remove t he i nboard
j oi nt
on t he shop t owel .
Be caref ul not t o drop t he rol l ers when separat ang
t hem f rom t he i nboard
j oi nt .
INBOARD JOINT
Check spl i nes l or wear or damage
Check i nsi de bore f or wear'
Inspect {or cracks.
Mark3
{cont' d)
16- 5
Driveshafts
Disassembly
(cont'dl
4. Mark the rol l ers and spi der to i denti fy the l ocati ons
of rol l ers on the sDi der, then remove the rol l ers.
Remove the ci rcl i p.
Mark the spi der and dri veshaft to i denti ty the posi -
ti on of the spi der on the shaft.
Remove the spi der usi ng a beari ng remover.
Remove the stop ri ng
(except
Japan
produced).
7.
16- 6
\
9. Wrap the spl i nes on the dri veshaft wi th vi nyl tape to
prevent damage to the boots and dynami c damper.
INBOARD BOOT
Inspect for cracki ng,
spl i tti ng and wear.
BOOT BAND
Repl ace.
DYNAMIC OAMPER
BAND
Repl ace.
10.
1 1 .
12.
13.
OYNAMIC DAMPER
Check f or damage.
Remove the boot band and i nboard boot. Take care
not to damage the boot.
Remove t he dynami c damper band and dynami c
damper, i f equi pped. Take care not to damage the
dynami c damper.
Remove the boot bsnds and outboard boot, then
remove the vi nyl tape.
Inspect the outboard
j oi nt
for faul ty movement and
wear. l f any roughness or excess
pl ay i s fel t, repl ace
the outboard
j oi nt.
OUTBOARD BOOT
I nspect f or cracki ng,
spl i t t i ng and wear.
OUTBOARD JOINT
Reassembly
Note these i tems duri ng reassembl yl
. Cl ean the di sassembl ed
parts wi th sol vent, and dry them throughl y wi th compressed ai r. Do not wash the rubber
parts
wi th sol vent.
. -,.6l : Thoroughl y
pack the i nboard
j oi nt
and both
j oi nt
boots wi th the
i oi nt
grease i ncl uded i n the new dri veshaft
Grease
quantity:
l nboard Joi nt
Japan Produced
' 110
-
120 g
{ 3. 9
-
4. 2 oz)
Except Japan Produced
' 120
-
130 g
{4.2
-
4.6 ozl
Outboard Joi nt
Japan Produced 70
-
80
g (2.5 -
2.8 oz)
Except Japan Produced 115
-
135
g ( 4. 0 -
4. 8 oz)
INBOARD JOINT
STOP RING {Except Japan
producod}
SCT RING
Repl ace.
\zn
Pack cavi t y wi t h grease.
DYNAMIC DAMPER
OUTBOARD BOOT
BOOT BANDS
Repl ace.
ROLLER
INBOARD B(rcT
- - -
--" &l
Pack cavity with groase.
DRIVESHAFT
OYNAMIC DAMPER BAND
Repl ace.
-611
Pack cavity
(cont' d)
wrt n grease.
16-7
Driveshafts
Reassembly
(cont'dl
1 . Wrap the spl i nes wi th vi nyl tape to prevent damage
to the boots and dvnami c damoer.
APE
OUTBOARO BOOT
2.
V;
Pack the outboard
j oi nt
wi th the
j oi nt grease i ncl uded
in the new driveshaft set,
Grease quantity:
Japan Producd: 7o
-
80 g (2.5 -
2.a ozl
Except Japan Produced: 115
-
135
9
(i1.0 -
4.8 ozl
DYNAMIC DAMPER
I nst al l t he out boar d
i nboar d boot t o t he
vi nyl tape. Take care
dynami c damper.
INAOARD BOOT
boot , dyna mi c damper and
dr i veshaf t . t hen r emove t he
not to damage the boots and
16- 8
4. I nst al l t he st op r i ng i nt o t he dr i veshaf t gr oove
{except Japan produced),
Al ways rotate the stop
ri ng i n i ts groove
to be sure i t i s ful l y seated.
\zr|<-C|RCL|P
Instal l the spi der on the dri veshaft by al i gni ng the
marks on the spi der and end of the dri veshaft.
Fi t the ci rcl i p i nto the dri veshaft groove.
Al ways
rotate the ci rcl i p i n i ts groove to be sure i t i s ful l y
seated.
Fi t the rol l ers to the spi der wi th thei r hi gh shoul ders
7.
faci ng outward, and note these i tems:
. Rei nstal l the rol l ers i n thei r ori gi nal
the spi der by al i gni ng the marks.
. Hol d t he dr i veshaf t poi nt ed
uD t o
rol l ers from tal l i ng off.
posi ti ons
on
prevent the
8. Pack the i nboard i oi nt
wi th the
j oi nt grease i ncl uded
i n the new dri veshaft set.
Grease
quanti ty:
Jaoan Produced: 110
-
120 g
(3.9 -
4.2 ozl
Except Japan Produced: 120
-
130
g (4.2 -
4.6 ozl
Fi t the i nboard
j oi nt
onto the dri veshaft, and note
these rtems:
. Rei nstal l the i nboard
j oi nt
onto the dri veshaft by
al i gni ng t he mar ks on t he i nboar d
j oi nr
wi t h t he
marks on the rol l ers.
. Hol d the dri veshaft so the i nboard
j oi nt poi nts up
to prevent i t from fal l i ng off.
INBOARD
JOINT
10. Adj ust the l ength of the dri veshafts to the fi gure
bel ow, then adi ust the boots to hal fway between
f ul l compr essi on and f ul l ext ensi on The ends of
boots seat i n the groove of the dri veshaft and
j oi nt.
Left driveshaft: 774
-
779 mm 130.5
-
30.7 in)
Right driveshaft: 501
-
506 mm 119.7
-
19.9 in)
1L Posi ti on the dynami c damper as shown bel ow.
Left:
Wi thout
"SRl "
mark: 94 :t 2 mm 13.7
t 0.1 i n)
Wi th
"SR1"
mark: 75 t 2 mm 12.9
i 0.1 i n)
Ri ght : 5512 mm
( 2. 2
t 0. 1 i nl
DYNAMIC DAMPER BAND
{cont' d)
16- 9
Driveshafts
Reassembly
(cont'd)
12. Set the doubl e l oop band onto the boot and dynam-
i c damper wi th the band end toward to front of the
vehi cl e.
Pul l up the sl ack i n the band by hand.
Mark a posi ti on
on the band 10
-
14 mm
(0.4 -
0.6
i n) from the cl i p.
14.
cuP
1 6 - 1 0
\
Thread the free end of the band through the nose
secti on oJ the boot band tool and i nto the sl ot on
the wi ndi ng mandrel .
Pl ace a wrench on the wi ndi ng mandrsl of the boot
band tool , and ti ghten the band unti l the mark you
made on the band meets the edge of the cl i p,
AOOT BAND
TOOL
(KD-3191
or equi val ent)
Mark on band.
17. Rai se up the boot band tool to bend the free end of
the band 90 degrees, then center-punch the cl i p,
HAiIMER
' 19.
18, Unwi nd the boot band tool , and cut oft the excess 5
-
l 0 mm 10.2
-
0.4 i n) from the cl i P.
5 - 1 0 mm
(0.2 -
0.4 in)
Secure the end of the boot band by tappi ng i t down
wi th a hammer,
Note these i tems after reassembl y:
. Make sure the band and cl i p does not i nterfere wi th
anythi ng and the band does not move.
! Remove any
gr ease r emai ni ng on t he sur r oundi ng
surtaces.
lnstallation
1. Instal l the new set ri ng onto the dri veshaft
groove.
Al ways use a new set ri ng whenever the dri veshaft
i s bei ng i nstal l ed.
2. Instal l the outboard
j oi nt
i nto the knuckl e.
(cont' d)
INBOARD JOINT
SET RING GROOVE
KNUCKLE
OUTBOARD JOINT
16- 1 1
Driveshafts
Instal l ati on
(cont' d)
Cl ean the areas where the dri veshaft contact the
transmi ssi on
(di fferenti al )
thoroughl y wi th sol vent
or carburetor cl eaner. and dry wi th compressed ai r.
Insert the i nboard end of the dri veshaft i nto the di f-
ferenti al unti l the set ri ng l ocks i n the groove.
INAOARD JOINT
DIFFERENNAL
Instal l the knuckl e on the l ower arm. Be careful not
damege t he bal l
j oi nt
boot . Wi pe of f t he gr ease
before ti ghteni ng the nut at the bal l
j oi nt.
Torque
the castl e nut to the l ower torque speci fi cati on. then
ti ghten i t onl y far enough to al i gn the sl ot wi th the
pi n hol e. Do not al i gn the nut by l ooseni ng.
CASTLE
12 x 1 .25 mm
alt
-
59 N.m 15.0
-
6.0 kg{.m, 36
-
ail lbl.ftl
COTTER PIN
Replace.
On reassembl y,
bend the cotter pin
f,
16- 12
5. Instal l the damper fork over the dri veshaft and onto
t he l ower ar m. I nst al l t he damper i n t he damper
f or k so t he al i gni ng t ab i s al i gned wi t h t he st ot i n
the damoer fork.
FLANGE BOLT
10 x 1.25 mm
(3
N.m la.a kgf.m. 32 lbf.trl
aLtGNtNG TAB
6.
7.
SELF.LOCKING NUI
12 x 1. 25 mm
fl N.m
(6.5
kgf.m, it7 lbf'ltl
Repi ace.
Loosel y i nst al l t he f l ange bol t s and t he new sel f -
l ocki ng nut .
Appl y oi l t o t he seat i ng surf ace of t he new spi ndl e
nur .
stake the spi ndl e nut shoul der agai nst the dri veshaft.
8. Instal l a new spi ndl e nut, then ti ghten the nut.
9. Cl ean the mati ng surfaces of the brake di sc and the
wheel , then i nstal l the front wheel wi th the wheel
nutS,
10. Ti ghten the fl ange bol ts and the new setf-l ocki ng
nut wi th the vehi cl e' s wei ght on the damper.
11. Refi l l the transmi ssi on wi th recommended fl ui d
(see
secti on 13 or 14).
' 12.
Check the front wh;el tl bnment and adj ust i f nec-
essarv
(see
secti on 18).
' i l
FRONT WHEEL
WHEEL NUT 12 x 1. 5 mm
108 N.m {11.0 kgt m, 80lbt ftl
SPINDLE NUT 22 x 1.5 mm
181 N.m 118.5 kg{.m, 134lbf.tt)
NOTE: After tightening, use a drift to
Steering
Speci af Tool s . . . . . . . . . . . . . 17-2
Manual Steeri ng
Component Locations
f ndex . . . . . . . . . . . . . . . . . . . . . . . 17' 3
Inspection and Adiustment
St eeri ng Operat i on . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Rack Gui de Adj ust ment . . . . . . . . . . . . . . . . . . . 17-5
' Steering
Wheel
(See power steering sec'tion)
*Steering
Column
(See power steering sectionl
Steering Gearbox
Removal . . . . . . . . . . . . . . . . . 17-5
Disassembly ........... 17' 7
Reassembly ............ 17-9
l nst al l at i on . . . . . . . . . . . . . 17-13
Power Steering
Component Locations
l ndex . . . . . . . . . . . . . . . . . . . . . . . 17-15
System Description
Fl ui d Fl ow Di agram . . . . . . . . . . . . . . . . . . . . . . . . . . 17-16
St eeri ng Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
-17
St eeri ng Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
Troubleshooting
Generaf Troubleshooting ................ 17
-22
Noi se and Vi brat i on . . . . . . . . . . . . . . . . . . . . . . . . . 17-26
Ff ui d Leaks . . . . . . . . . . . . . 17-28
Inspestion and Adiustment
St eeri ng Operat i on . . . . . . . . . . . . . . . . . . . . . . . . . . 17-30
Power Assist Check
With Vehicle Parked .................... 17-30
Steering Linkage and Gearbox ....... 17-31
Pump Beft .............. 17-32
Rack Guide Adjustment ................... 17-33
Fl ui d Rep| acement . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-33
Pump Pressure Check . . . . . . . . . . . . . . . . . . . . . . 17-34
*Steering
Wheel
Removal . . . . . . . . . . . . . . . . . 17-35
l nst al l at i on . . . . . . . . . . . . . 17-35
Disassembly/Reassembly ............... I 7-36
' Steering
Column
Removal/lnstallation ....................... 17
-37
I nspect i on . . . . . . . . . . . . . . 17. 38
Power Steering Hoses, Lines
Fluid Leakage Inspection ................. 17-39
Replacement .......... 17-39
Power Steering Pump
Removal/lnstallation ....................... 17-tlo
Disassembly ........... 17-41
f nspect i on . . . . . . . . . . . . . . 17-42
Reassembl y . . . . . . . . . . . . 17-44
Steering Gearbox
Removaf , , , , . , . . . . . . . . . . . 17
-47
Disassembly ........... 17-lt!l
Reassembl y . . . . . . . . . . . . 17-55
l nst al l at i on . . . . . . . . . . . . . 17-65
Ball Joint Boot Replacement .......... 17-68
Special Tools
\
Ref. No
I
Tool Number
Description
Oty
I
Page Referenco
a
aal
@
o
@
ao'r
07GAF
-
PH70100
07GAG
-
SD40l 0A or
07GAG
-
SD40100
07GAG
-
SD40204 or
07GAG
-
SD40200
* 07JGG
-
001010A
07MAC
-
S100200
OTNAD
-
SR3O2OA
07NAG
-
SR3090A or
07NAG
-
SR30900
07RAK
-
5040110
07RAK
-
5040121 or
07RAK
-
5040120
07406
-
0010004 or
07406
-
00' 10001
07725
-
0030000
07746
-
0010100
07746
-
0020' 100
07746
-
0030300
07749
-
0010000
07916
-
SA50001
07965
-
SA50500
07974
-
SA5020A or
07974
-
SA50200
07974
-
SA50800
@
o
@
@
@
@
@
@
@
@
Pi l ot Col l ar
Pi ston Seal Ri ng
Pi ston Seal Ri ng Si zi ng Tool
Bel t Tensi on Gauge
Bal l Joi nt Remover , 2S mm
Cyl i nder End Seal Remover Attachment
Pi ston Seal Ri ng Si zi ng Tool
P/S Joi nt Adaptor (Pump)
P/S Joi nt Adaptor (Hose)
P/S Pressure Gauge
Uni versal Hol der
Attachment,32 x 35 mm
Dri ver, 22 mm l .D.
Attachment, 30 mm l .D.
Dri ver
Locknut Wrench, 40 mm
Front Hub Di s/Assembl y Tool
Sl eeve Seal Ri ng Si zi ng Tool
Eal l Joi nt Boot Cl i p Gui de
11-54
17-59
17- 59
17- 6, 47
17
-51
17-56
17
-34
't]-34
17
-34
17
-42,
46
17-57,58
l 7- 10
't7
-44
17
-57
17-68
17
-51
17-57, 68
1
'l
I
1
*
Incl uded i n the Bel t Tensi on Gauge Set, 07TGG
-
001OOOA.
g/
@
o
,g
=fu*
( o )
l:1
@
@
o
0 (D
@
7-2
l ndex
Manual Steeri ng
NOTE:
. l f an i ntact ai rbag assembl y has been removed from a scrapped vehi cl e or has been found defecti ve or damaged dur-
i ng transi t, storage or servi ce, i t shoul d be depl oyed {see secti on 24)'
. Before removi ng the gearbox, remove the dri ver' s ai rbag assembl y and steeri ng wheel
. After i nstal l i ng the gearbox, check the wheel al i gnment and adj ust i f necessary.
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and
procedures i n the SRS
secti on {24} before performi ng repai rs or servi ce
STEERI NG WHEEL
Removal / l nst al l ai i on,
page 17-35
Di sassembl y/ Reassembl y,
page 17' 36
DRIVER'S AIRBAG ASSEMBLY
Bemoval / l nst al l at i on, see sect i on 24
STEEBING COLUMN
Removal / l nst al l at i on, Page
17 37
I nspect i on,
page' 17-38
CABLE REEL
Femoval / l nst al l at i on, see sect i on 24
IGNITION SWITCH
See sect i on 23
STEERING GEARBOX
Rack Gui de Adj ust ment ,
Page
17-5
Removal ,
page' 17- 5
Di sassembl y,
page 17-7
Beassembl y, page
' 17
9
I nst al l at i on, page 17 13
TIE.ROD ENO BALL JOINT
Bal l Joi nt Boot Fepl acement ,
page 17-68
17-3
Inspection and Adjustment
Steeri ng Operati on
Steering Wheel Rotational Play
Pl ace the front wheel s i n a strai ght ahead posi ti on and
measure the di stance the steeri ng wheel can be turned
wi thout movi ng the front wheel s.
ROTATIONAL PLAY: 0
-
10 mm
(0 -
0.4 i n)
l f the
pl ay
exceeds the servi ce l i mi t, perform rack gui de
adj ustment
(see page 17' 5).
l f the
pl ay i s sti l l excessi ve after rack gui de adj ustment,
i nspect the steeri ng l i nkage and gearbox as descri bed
TIE.ROD LOCKNUT
Check f or l oose l ocknut .
\
I
BOOT
I nspect f or damage and det er i or at r on
STEERING JOINTS
Check f or l oose
i oi nt
bol t s.
Steering Eftort Check
Rai se the front wheel s off the ground.
Turn the steeri ng wheel wi th a spri ng scal e and check i ts
reao Ing.
Standard: 15 N {1.5 kgf,3.3 l bfl maxi mum
l f i t r eads mor e, per f or m r ack gui de adj ust ment
( see
page 17-5).
I nsPect f or l oose col umn
mount i ng bol t s and nut s
PINION SHAFT GROMMET
f or damage and det eri orat i on
BALL JOINT BOOT
I nspect f or damage and det eri orat i on.
See page 17-68 f or repl acement .
COLUMN
END BALL JOINT
I nspect f or f aul t y movement
ano oamage.
GEARBOX
MOUNTI NG
l nspect f or det er r or at l on
GEARBOX
ASSEMBLY
BOTATIONAL PLAY
-
\ - J
TJ
17- 4
I nspect f or l oose mount i ng bol t s.
\
Steering Gearbox
Rack Guide Adjustment
NOTE: Per f or m t he r ack gui de adj ust ment wi t h t he
wheel s i n the strai ght ahead posi ti on.
1. Loosen the rack gui de screw l ocknut wi th the spe-
ci al tool , then l oosen the rack gui de screw.
Ti ghten the rack gui de screw unti l i t compresses the
spri ng and seats agai nst the rack gui de, then l oosen
i t.
Reti ghten the rack gui de screw to 4 N.m
(0.4
kgf' m,
2.9 l btft), then back i t off to speci fi ed angl e.
Specitied Return Angle: 30' max.
Ti ght en t he l ocknut whi l e hol di ng t he r ack gui de
screw.
Check for ti ght or l oose steeri ng through the com-
pi ete turni ng travel .
Recheck steeri ng effort
(see page 17-4).
07916
-
SA5000l
Removal
NOTE: Usi ng sol vent and a brush. to wash any oi l and
di rt off the gearbox. Bl ow dry wi th compressed ai r.
1. Rai se the front of vehi cl e, and support i t on safety
stands i n the
proper l ocati ons
(see
secti on 1).
2. Remove the front wheel s.
3. Remove the steeri ng wheel
(see page 17-35).
4. Remove the steeri ng
i oi nt
cover
Remove the steeri ng
j oi nt
l ower bol t, and di scon-
nect the steeri ng
j oi nt
by movi ng the
j oi nt
toward
t he col umn.
5.
STEEBING JOINT COVER
STEERING JOINT
{cont' d)
Steering Gearbox
Removal
(cont'dl
Remove the cotter pi n from the castl e nut
(' 96 -' 97
model ) or nut
(' 98
model ) and remove the nut.
COTTER PINS
Repl ace.
7.
10.
1 1 .
12.
Instal l the 10 mm hex nut on the bal l
j oi nt.
Be sure that the 10 mm hex nut i s fl ush wi th the bal l
j oi nt pi n end, or the threaded secti on of the bal l
j oi nt
pi n mi ght be damaged by the bal l
j oi nt
remover.
NOTE: Remove the bal l
j oi nt
usi ng the speci al tool .
Ref er t o sect i on 18 f or how t o use t he bal l
j oi nt
remover.
Separate the ti e-rod bal l
j oi nt
and knuckl e usi ng the
speci al t ool .
CAUTION: Avoid damaging lhe ball
ioint
boot.
Remove the l eft ti e-rod end, then sl i de the rack al l
the way to the ri ght,
Separate the exhaust pi pe A or TWC
(see
secti on
_9).
Di sconnect the shi ft l i nkage
(see
secti on 13 or sec-
t i on 14) .
Remove the sti ffener pl ate,
17- 6
13, Remove the mounti ng bracket.
Pul l the steeri ng gearbox
al l the way down to cl ear
the pi ni on shaft from the bul khead, then remove the
pi ni on shaft grommet.
Move the steeri ng gearbox to ri ght so the l eft rack
end cl ears the rear beam, then ti l t the l el t si de down
to remove i t from the car.
14.
STEERING GEARBOX
PI NI ON SHAFT GROMMET
Disassembly
Pl ace the gearbox i n a vi se wi th a soft
j aws,
then
cl amp t he gear box at t he mount br acket or gear
noust ng.
CAUTION: Be carful not to distort the gear hous-
ing by clamping it too tight in the vise incorrectly.
Remove the ti e-rod end and l ocknut.
Remove the boot bands and ti e rod cl i ps. Pul l the
boots away from the ends of the gearbox.
BOOT
Repl ace.
4. Hol d t he s t eer i ng r ac k wi t h one wr enc h, and
unscrew the rack end wi th another wrench.
CAUTION: Be caretul not to damage the rack sur-
face with the wrench.
l .
2.
3.
CLI P E-ROD
I
I
@
STEENING RACK ENO
5. Push the ri ght end of the rack back i nto the cyl i nder
housi ng so the smooth surface that ri des agai nst
the seal won' t be damaged.
6. Loosen t he l ocknut , and r emove t he r ack gui de
screw.
Remove t he di sc washer , spr i ng and r ack gui de
7 .
8.
9.
from the gear housi ng.
SPRING
OISC WASHER
LOCKNUT FACK GUIDE SCREW
Remove t he pi ni on dust seal and t he 35 mm snap
r i ng.
Hol d the pi ni on shaft wi th a vi se securel y.
Remove t he pi ni on by t appi ng evenl y ar ound l he
fl anged secti on of the gearbox wi th a pl asti c ham
me r .
CAUTION: Do not tap on the steering rack.
NOTE: Do not reuse the removed pi naon.
PINION OUST SEAL
Repl 6ce.
SNAP RING, 35 mm
STEERING PINION
Fepl ace.
17- 7
Steering Gearbox
Di sassembl y
(cont' dl
10. Sl i de the steeri ng rack out of the cyl i nder housi ng.
CAUTION: Be caretul not to damage the bushing in
the cyl i nder housi ng.
11. Remove t he r ack end bushi ng.
RACK ENO BUSHING
I nspect i nner wal l f or wear or damage
GEARBOX MOUNTI NG CUSHI ON
17- A
12. Repl ace the gearbox mounti ng cushi on i f necessary:
To remove the cushi on, use a sharp kni fe and make
a cut down the l ength of the cushi on. Be careful not
to damage the pai nt on the outsi de of the cyl i nder
housi ng. Remove the ol d cushi on.
Appl y weatherstri p adhesi ve to the i nsi de of the
new cushi on. Instal l the cushi on onto the cyl i nder
housi ng and posi ti on i t 20
-
22 mm
(0.79 -
0.87 i n)
from the end of the cyl i nder housi ng as shown.
NOTE: Af t er i nst al l i ng t he cushi on, wi pe of f any
excess adhesi ve t hat may have dr i pped i nt o t he
i nsi de of t he cyl i nder housi ng.
20
-
22 mm 10. 79
-
0. 87 i n)
Reassembl y
NOTE:
parts wi th sol vent, and dry them wi th compressed ai r. Do not di p the rubber parts i n sol vent.
. Al ways repl ace the non-reuseabl e
parts wi th new ones before assembl y.
. Do not al l ow dust, di rt, or other forei gn materi al s to enter the steeri ng
gearbox.
RACK ENO BUSHING
\
t_
r @
-R4
-6r
PINION DUST SEAL
Repl ace.
GEARBOX MOUNTING CUSHIONS
M."^pR,NG.3smm
-$d
\ \
RACKGUTDESCREW
DISC WASHER
RACK GUIDE
( cont ' d)
17-9
Steering Gearbox
Reassembl y
(cont' d)
' t.
3.
4.
2.
Appl y a thi n coat of grease to the i nsi de surface ot
the rack end bushi ng.
Grease quanti ty: 1
-
3 g (0.04-0.1
oz)
CAUTION: Do not fi l l the sl ots wi th greas;
they
must remain open to serve as air passages.
I nst al l t he r ack end bushi ng by al i gni ng t he r ound
proj ecti on on the bushi ng wi th the hol e i n the cyl i n-
der housi ng
Grease the steeri ng rack teeth.
I nst al l t he st eer i ng r ack i nt o t he cyl i nder housi ng
car ef ul l y t o avoi d damagi ng t he r ack end bushi ng.
17- 10
CYLINDER HOUSING
' 11.
Adj ust the rack gui de screw
(see page 17-5).
5. Dri ve i n the steeri ng pi ni on i n the gear housi ng wi th
t he speci al t ool s.
DRIVER,
22 .rlml.D.
07146
-
0020 t00
SNAP RI NG, 35 mm
PI NI ON DUST
SEAL
Repl ace.
Vi nyl t ape
STEERING
PINION
6.
1.
I nst al l t he 35 mm snap r i ng secur el y i n t he gear
nousrng groove.
Appl y vi nyl tape to the pi ni on shaft, then coat the
vi nyl t ape wi t h gr ease.
8. Instal l the pi ni on
dust seal on the gear housi ng unti l
i t seats properl y, then remove the tape.
9. Gr ease t he sl i di ng sur f ace of t he r ack gui de, and
i nst al l i t on t o t he gear housi ng.
' 10.
Instal l the spri ng, di sc washer and rack gui de screw
on t he gear housi ng.
NOTE: Instal l the di sc washer wi th i ts convex si de
f aci ng i n.
DISC WASHER
SPRING
RACK GUIDE SCREW
LOCKNUT
12. I nst al l t he new l ock washer i n t he gr oove i n t he
steeri ng rack.
Instal l the steeri ng rack end i nto the rack.
LOCK WASHER
RACK END 54 N.m 15.5 kgif m, 40 lbtftl
I J .
RACK END
Hol d the steeri ng rack wi th a wrench and ti ghten
the rack end wi th another.
CAUTION: Be carelul not to damage the rack sur-
tace with the wrench.
After ti ghteni ng the rack ends, stake the four sec-
ti ons of the l ock washer wi th a rol l pi n dri ft and a
ma l l et.
. Pl ace the wood bl ock on the
press tabl e, then set
the l ock washer secti on of the rack end on the
wood bl ock securel y.
. Be sure the tool i s al i gned wi th the fl at secti ons
of the steeri ng rack end before
pressi ng
. St ake t he l ock washer i n t he cent er of t he f l at
secti on of the steeri ng rack end.
1 4
t 5 ,
Repi ace.
TAB
NOTE: Thi s dri t t has a f l at
t i p, t o prevent punct unng
srrenrruc nncxl
ROLL PIN ORIFT:
(Commorcially
availablel
Snap-On No. PPR8 or equivalent
Press
woooEN ELocK
TI E. ROD CLI P
16. Appl y
grease around the outsi de of the rack end
houst ng.
Appl y a l i ght coat of si l i cone gr ease t o t he boot
grooves on the rack ends,
I nst al l t he boot s i n t he r ack end wi t h t he t i e- r od
cl r ps.
NOTE: Instal l the boot band wi th the rack i n the
strai ght ahead
posi ti on (ri ght
and l eft ti e-rods are
equal i n l engt h) .
t;J"' "
.=-!!!r9i!l
SILICONE GREASE
1 7 .
18.
(cont' d)
17- 11
NOTE: Wi pe
grease of f
t he t hread sect i on.
Steering Gearbox
19.
Reassembly
(cont'd)
Instal l the boot band so that the l ocki ng tabs of the
band
(stake poi nts)
are i n the range shown bel ow.
(Tabs
shoul d face up and sl i ghtl y forwaro.J
Bend both sets of l ocki ng tabs.
Li ghtl y tap on the doubl ed-over porti ons to reduce
t hei r hei ght .
CAUTION: Stake the band l ocki ng tabs fi rml y.
22. Sl i de the rack ri ght and l eft to be certai n that the
boots are not deformed or twi sted.
St ake poi nt s
+
Front
Right Boot Band
(Vi ewed
f rom t he ri ght si dei
20.
2 1 .
L6ft Boot Band
( Vi ewed
f r om t he l ef t si de)
1 7 - 1 2
1 .
l nstal l ati on
Sl i de the rack al l the way to the ri ght.
Instal l the
pi ni on shaft grommet, and i nsert the
pi n-
i on shaft up through the bul khead.
NOTE: Al i gn the notch i n the pi ni on shaft grommet
wi th the tab on the gear housi ng.
2
3. Instal l the mounti ng brackets wi th the two gearbox
mounti ng bol ts on the cushi on.
PINION SHAFT GROMMET
STEERING GEARBOX
14. 0 kgl . m, 29l bt f t l
NOTE: The arrow on t he bracket
poi nt t oward t he f ront .
STIFFENER PLATE
4. I nst al l t he st i f f ener
pl at e wi t h t he t wo gear box
mounti ng bol ts and sti ffener
pl ate attachi ng bol ts.
NOTEr I nst al l t he bol t s l oosel y f i r st , t hen t i ght en
them securel v.
GEARBOX MOUNTING BOLTS
43 N.m
(4.{
kgf.m, 32 lbf.ft)
5. Center the steeri ng rack wi thi n i ts stroke,
6. Sl i p the l ower end of the steeri ng
j oi nt
onto the
pi n-
i on shaf t { l i ne up t he bol t hol e wi t h t he gr oove
around the shaft), and ti ghten the l ower bol t.
NOTE:
. Connect the steeri ng shaft and pi ni on wi th the
steeri ng wheel and steeri ng rack centered.
Be s ur e t hat t he l ower s t eer i ng
j oi nt
bol t i s
securel y i n the groove i n the steeri ng gearbox
pr n r on.
l f the steeri ng wheel and rack are not centered,
r eposi t i on t he ser r at i ons at l ower end of t he
steeri ng
j oi nt.
STEERING JOINT
STEERING JOINT
LOWER BOLT
22 N. m
12.2 kgt m, 16 lbf.ftl
(cont' d)
17- 13
Steering Gearbox
Installation
(cont'dl
Center the cabl e reel by fi rst rotati ng i t cl ockwi se
unt i l i t st ops, Then r ot at e i t count er cl ockwi se
(approxi matel y two turns) unti l the arrow mark on
the l abel poi nts strai ght up. Rei nstal l the steeri ng
wheel
(see page 17-35).
Instal l the steeri ng
i oi nt
cover wi th the cl amps and
cl ros.
' 1.
STEERING JOINT COVER
17- 14
9. Reconnect the ti e-rod ends to the steeri ng knuckl es,
then ti ghten the castl e nut
(' 96
-' 97
model ) or nut
{' 98 model ) to the speci fi ed torque, and i nstal l new
cotter Dins.
NOTE: Betore connecti ng the ti e-rod ends, wi pe off
any
gr eas e c ont ami nat i on f r om t he bal l
l oi nt
taoered secti on and threads.
CAUTION: Torque the csstle nut to the lower torque
spoci fi cati on, thn ti ghtsn i t onl y fsr enough to
El i gn th sl ot wi th the
pi n hol 6. Do not al i gn the
nut by loosoning {'96
-'97
modol only}.
TIE-ROD
COTTER PINS
Repl ace.
On reassembl y, bend
t he cot t er
Pl n
as shown.
'95
-
'97
model:
38 model:
!=-
,10 -
48 N'm
(ir.o -
4.8 kgt m.
29
-
35 rbl.ftl
NUT
4,1N.m
(4.5
kgf'm,
33 lbf.frl
1 1 .
Instal l the exhaust
pi pe A or TWC
(see
secti on 9)'
Connect the shi ft l i nkage
(see secti on 13 or secti on
14) .
Instal l the front wheel s.
After i nstal l ati on,
perform the fol l owi ng checks'
. Adj ust the front toe
(see secti on 18).
. Check the steeri ng wheel spoke angl e' Adj ust by
turni ng the ri ght and l eft ti e-rods, i t necessary'
NOTE: Turn the ri ght and l eft ti e-rods equal l y'
12.
Component Locations
l ndex
Power Steering:
NOTE:
. l f an i ntact ai rbag assembl y has been removed from a scrapped vehi cl e or has been found detecti ve or dsmaged dur-
i ng transi t, storage or servi ce, i t shoul d be depl oyed
(see
secti on 24).
a Betore removi ng the gearbox, remove the dri ver' s ai rbag assembl y and steeri ng wheel .
. After i nstal l i ng the gearbox, check the wheel al i gnment and adj ust i f necessary.
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and procedures i n the SRS
secti on
(24)
before performi ng repai rs or servi ce.
STEERING WHEEL
page 17-35
Di sassembl y/ Reassembl y,
page 17 36
DRIVER'S AIRBAG ASSEMBLY
Removal / l nst al l at i on, see sect i on 24
STEERI NG GEARBOX
Rack Gui de Adj ust ment ,
page 17 33
Removal , page 17-47
Di sassembl y, page 17-49
Reassembl y, page 17-55
I nst al l at i on, page 17' 65
VALVE BODY UNIT
Overhaul ,
page 17 52
COLUMN
Removal / l nst al l at i on, page 17-37
CABLE REEL
Removal / l nst al l at i on, see sect i on 24
IGNITION SWITCH
See sect i on 23
POWER STEERING PUMP
Pump Bel t I nspect i on, page 17' 32
Pump Bel t Adi ust ment , page 17-32
Pump Pressure Check, page 17 34
Bemoval / l nst al l at i on, page 17-40
Di sassembl y/ Reassembl y, page 17 41
TIE.ROD END BALLJOINT
Bal l Joi nt Boot Repl acement ,
page 17-68
17- 15
System
Description
Fl ui d Fl ow Di agram
The system i s a compact rotary-val ve,type
power steeri ng, connected to the steeri ng
gearbox. The fl ui d pressure i s pro-
vi ded by a vane-type pump whi ch i s dri ven by the engi ne crank pul l ey. The amount of fl ui d and
pressure i s regul ated by
the fl ow control val ve bui l t i nto the
pump. The fl ui d pressure from the pump i s del i vered to the val ve body uni t around the
pi nj on of the steeri ng gearbox. The val ve i nsi de the val ve body uni t control s the hydraul i c
pressure and changes the di rec-
ti on of the fl ow. The fl ui d then fl ows to the
power
cyl i nder, where rack thrust i s generated. Fl ui d returni ng from the power
cyl i nder fl ows back to the reservoi r, where the fl ui d i s
"fi l tered"
and suppl i ed to the pump agai n'
RESERVOIB
FLOW CONTROL VALVE
VALVE BODY UNIT
SUB.VALVE
STEERI NG GEANBOX POWER CYLINDER
17- 16
Steeri ng Pump
Construction
The pump i s a vane-type i ncorporati ng a fl ow control val ve
(wi th
an i ntegrated rel i ef val ve) and i s dri ven by a POLY-V-bel t
from the crank pul l ey, The pump features 10 vanes. Each vane performs two i ntake/di scharge operati ons for every rota-
ti on of the rotor. Thi s means that the hydraul i c fl ui d pressure pul se becomes extremel y smal l duri ng di scharge.
ROTOR VANE CAM RING
Operation
The bel t,dri ven pul l ey rotates the rotor through the dri ve shaft. As the rotor rotates, the hydraul i c pressure i s appl i ed to
the vane chamber of the rotor and the vanes wi l l rotate whi l e bei ng pushed onto the i nner ci rcumference of the cam ri ng.
The i nner ci rcumference of the cam ri ng has an extended porti on wi th respect to the center of the shaft, so the vanes
move downward i n the axi al di recti on as the rotor rotates. As a resul t of thi s rol l er movement. the i nternal vol ume of the
vane chamber wi l l change, r esul t i ng i n f l ui d i nt ake and di schar ge.
START OF FLUID INTAKE: FLUID INTAKE: FLUID MOVEMENT:
FLUID OISCHARGE:
The vanes ar e pushed ont o
t he i nner ci rcumf erence of t he
cam r i ng.
The vol ume of t he vane cham
ber i ncreases so t hat f l ui d i s
sucked i n.
Th e s u c k e d - i n f l u i d mo v e s
t oward t he dascharge
pon.
As t he vanes r et ur n t o t he
t hei r or i gi nal
posi t i on on t he
i nner si de, t he vol ume of t he
vane chamber decr eases so
t he f l ui d i s di schar ged f r om
t he di scharge
port .
(cont' d)
17- 17
FLOW CONTROL VALVE
System Description
Steering Pump
(cont'dl
The fl ow control val ve and sub-val ve i n the pump per-
forms the fol l owi ng steps
O
through
@
to control the
fl ow of fl ui d, that i s to i ncrease the di scharge vol ume
when engi ne speed i s l ow. and to decrease i t when the
engi ne speed i ncr eases, The assi st ance t hr ust of t he
s t eer i ng gear box c hanges i n c ompl i anc e wi t h t he
change i n the di scharge vol ume.
When the engi ne starts, fl ui d di scharged from the
di scharge port stans to fl ow through oi l passage A,
the fi xed ori fi ce and the vari abl e ori fi ce to the steer-
i ng gearbox, When the engi ne speed i s extremel y
l ow, the return port i s cl osed by the fl ow control
val ve.
Fl ui d pressure di scharged from the di scharge port
i s appl i ed to the top of the sub-val ve, and the fl ui d
pressure that passed through oi l passage A i s appl i ed
to the bottom of the sub-val ve. When thi s happens,
the pressure
difference between the ends of oil pas-
sage A, which is caused by the resistance oil passage
A when t he f l ui d f l ows t hr ough t he
passage,
i s
appl i ed to the sub-val ve. However, the pressure di f-
ference appl i ed to the sub-val ve. that i s the force
t hat pushes t he sub- val ve down, i s t oo smal l t o
overcome the spri ng force, and the vari abl e ori fi ce i s
ful l y open when the engi ne speed i s e)dremel y l ow,
Because the fl ui d vol ume fl owi ng through the fi xed
ori ti ce and vari abl e ori fi ce i ncreases, a
pressure
di f-
ference i s created between the ends of these ori -
fi ces, and i t i ncreases i n proporti on to the engi ne
speed. As the l l ui d pressure that passed the fi xed
ori fi ce and vari abl e ori fi ce i s di rected to the bottom
of the fl ow control val ve, a pressure di fference i s
created between the top and bottom of the val ve,
whi ch Dushes down t he f l ow cont r ol val ve and
opens the return port.
As a resul t, part
of the fl ui d
di scharged from the di scharge port returns to the
pump sucti on port, keepi ng the di scharge vol ume
consl anl ,
In thi s condi ti on, the sub-val ve does not move, and
the vari abl e ori fi ce stays ful l y open.
L
l "
I J
t r r
;
o
-..}
PUMP R. P. M.
To STEERING GEARBOx
SUB-VALVE
To STEERING GEARBOX
FLOW CURVE
Bottom
//l'.zRx
\
=K.Aq
o'.io"l^LKq;OY
11\ t / . /
FLOW CONTROL VALVE
SUB-VALVE
1 ) l
v r -
ORIFICE
17- 18
FLOW CONTROL VALVE
O
The fl ui d vol ume that fl ows thorough oi l passage A
and the
pressure
di fference appl i ed to the sub-val ve
i ncr ease i n
pr opor t i on t o t he engi ne speed. The
sub-val ve l owers overcomi ng the spri ng force, and
i t starts to cl ose the vari abl e ori fi ce to regul ate the
di scharge vol ume, When thi s happens, the fl ui d vol -
ume fl owi ng to the steeri ng gearbox decreases as
the engi ne speed i ncreases. At the same ti me. the
fl ow control val ve conti nues to control the fl ui d vol -
ume to the return Dort.
@
As the engi ne speed i ncreases further, the
pressure
di fference at the sub-val ve i ncreases further as wel l .
The sub-val ve then cl oses the vari abl e ori fi ce com-
pl et el y, r egul at i ng t he di schar ge vol ume f ur t her .
When t hi s happens. t he f l ui d vol ume di schar ged
from the
pump to the steeri ng
gearbox i s regul ated
and mai nt ai ned at a gi ven l evel unt i l t he engi ne
speed reaches the hi gh speed range. The fl ow con-
trol val ve functi ons conti nues to control the fl ui d
vol ume to the return Dort.
Pressure Relief
Pr essur e at t he di schar ge si de of t he f i xed or i f i ce i s
di rected to the bottom of the fl ow control val ve. When
the pressure bui l ds up, the rel i ef val ve i n the fl ow con-
trol val ve opens to rel ease the
pressure at the bottom ot
t he val ve. Thi s al l ows t he f l ow cont r ol val ve t o be
pushed
back by the pressure di fference. and the fl ui d
vol ume to the
pump return port i ncreases.
As expl ai ned above, the system keeps the pump di s-
charge
pressure (rel i ef pressure) from exceedi ng the
gi ven l evel by control l i ng the vol ume of the fl ui d to the
pump return pon.
To STEERING GEARBOX
To STEERING GEARBOX
DAMPING ORIFICE
(Decreases excessive
vibration in the valve.l
/z/ffi\\
+/A<Y?il
o',-lorlo[5o zit)Y
\ \
-et27
FLOW CONTROL VALVE
SUB.VALVE
FLOW CONTROL VALVE
/X
TI-p..\
LTJ6("4")il
o"'ro"iio't?2ia)f
11"QJtYl
FLOW CONTBOL VALVE
RELIEF VALVE
(Openl
17- 19
System Description
Steering Gearbox
The rack and-pi ni on type steeri ng gearbox has a val ve body uni t i ncorporated wi th the pi ni on l o control the steeri ng fl ui d
pressure. Steeri ng fl ui d from the pump i s regul ated by a rotary val ve i n the val ve body uni t and i s sent through the cyl i n
der l i ne to the
power cyl i nder, where hydraul i c pressure i s appl i ed. The steeri ng fl ui d i n the other si de of the
power cyl i n-
der returns through the cyl i nder l i ne and val ve body uni t to the reservoi r.
VALVE BODY UNIT
CYLI NDER LI NE
To RESERVOIR
+
From PUMP
ri
POWER CYLI NDER
Valve Body Unit
Insi de the val ve body uni t i s the val ve. whi ch i s coaxi al wi th the pi ni on shaft, and control s the steeri ng fl ui d pressure. The
val ve housi ng i s connected wi th the fl ui d l i ne from the pump, the return l i ne to the reservoi r, and the two cyl i nder l i nes
from the respecti ve
power cyl i nder. The pi ni on shaft i s doubl e
-
structured wi th the i nput shatt connected to the pi ni on
gear, both of whi ch are i nterconnected wl th the torsi on bar.
The pi n i nserted i n the val ve and the pi ni on shaft groove engage; thi s al l ows the
pi ni on shaft to rotate together wi th the
val ve. Because of thi s constructi on, the di fference i n angl e i n the ci rcumferenti al di recti on between the i nput sh8ft and the
val ve becomes l arger accordi ng to the torsi onal strength of the pi ni on or steeri ng resi stance. However. maxi mum torsi on
betl veen the shafts i s regul ated by the engaged spl i nes of the shafts at the pi n engagement secti on to hol d the torsi on bar
wi thi n the set val ue.
Thi s al l ows the steeri ng system to functi on as an ordi nary rack-and-pi ni on type steeri ng i f the steeri ng fl ui d i s not pressur-
i zed because of a faul ty pump.
VALVE
Diflerence in angle between the
input shaft and pinion shaft
PINION SHAFT
l a
INPUT SHAFT
-l
B
17-20
INPUT SHAFT
Pressure Control
Low assi st at hi gher speeds:
When steeri ng resi stance i s l ow, such as when dri vi ng at hi gh speeds, or when dri vi ng strai ght ahead, the i nput shaft i s
near or i n the neutral
posi ti on,
so there i s l i ttl e or no fl ow to any of the power cyl i nder ori fi ces. N4ost of the feed pressure
from the
pump i s bypassed to the reservoi r. Because of thi s, the pressure stays the same i n both si des of the power cyl i n-
der, resul ti ng i n l ow or no assi st.
VALVE From PUMP
RETURN PASSAGE
lTo RESERVOIR)
VALVE BODY
UNI T
SECTION A.A
FLUID PASSAGE TO
POWEB CYLI NDER
. A
J
POWER CYLINDER
GEAREOX
Hi gh assi st at l ower speeds:
When steeri ng resi stance i s hi gh, such as when dri vi ng at l ow speeds, or when turni ng the wheel wi th the vehi cl e
stopped, the di fference i n angl e created between the i nput shaft and the val ve opens the fl ui d passage on one si de, and
cl oses the fl ui d passage on the other si de. at each pai r of ori fi ces, The fl ui d pressure i ncreases i n the si de of the power
cyl i nder fed by the l arger fl ui d passage. Thi s i ncreased pressure pushes on the rack pi ston, al l owi ng the steeri ng wheel to
be turned wi th l i ght effort. On the other si de of the
power cyl i nder, the return passage opens al l owi ng the steeri ng fl ui d to
return through the i nput shaft to the reservoi r. The fl ui d
passages
to the power cyl i nder automati cal l y change i n si ze,
i ncreasi ng as the steeri ng resi stance i ncreases. In other words. the passages become l arger and power assi st i ncreases
when the steeri ng effort woul d normal l y be hi gh,
(for
exampl e, when parki ng or maki ng l ow speed turns), and the
pas-
sages become smal l er and
power assi st decreases when the steeri ng effort woul d normal l y be l ow,
(for
exampl e, when
dri vi ng at hi gh speeds or strai ght ahead).
From PUMP
---------\\
r
- /
SECTION A-A
(High lluid pressurl
17-21
Troubl eshooti ng
General Troubleshooting
Check the fol l owi ng before you begi n:
. Has the suspensi on been modi fi ed i n a way that woul d affect steeri ng?
. Are ti re si zes, ti re vari ety and ai r
pressure
correct?
. l s the steeri ng wheel ori gi nal equi pment orequi val ent?
. l s the power steeri ng pump bel t properl y adj usted?
. l s steeri ng fl ui d reservoi rfi l l ed to proper l evel ?
. l s the engi ne i dl e speed correct and steady?
Hard Steering
(Check
the power assist, see page
'17-30.
lflhe force is over 29 N 13.0 kgf,6.6 lbf), Precede with this troubleshooting.)
Abnormal
I l ui d pressure
{f l ui d
pressure
i s t oo hi gh)
Faul t y val ve body uni t
Relief pres-
Abnormal
Faulty flow control valve
(Repl ace
t he
pump
as an
assembl y)
Check t he l eed and r et ur n ci r cui t l i nes and hose
bet ween t he gear box and pump f or cl oggi ng and
del ormat i on.
Nor mal l i ne and hose
Check t he pump f l ui d pressure
(see page 17-34).
Measure st eady st at e f l ui d pres
sure whi l e i dl i ng wi t h t he bot h
val ves f ul l y open.
I t shoul d be 1, 500 kPa
(15
kgvcm, ,
213 psi ) or bel ow.
Normal
Check the tlow control valve
(see page 17-42).
.
Check t he val ve f or smoot h movement i n t he hous-
i ng.
'
Check t he rel i ef val ve f or l eaks.
Check t he
pump { l ui d pr essur e
{see
page 17-34).
Measur e pum p r el i ef pr essur e
while idling with the pressure con-
trol valve Iully closed.
It should be 6,400
-
7,400 kPa 165
-
75 kgflcm', 920
-
1,070 psi)
Normal rel i ef pressure
17
- 22
Go t o
page 17 23 Faul t y pump assembl y
Check t he l orce requi red l o t urn
t he wheol
(see page 17-30).
St art t he engi ne and measure t he
force required to turn the wheel
to the right and left. Difference of
t he f or ce r equi r ed t o t ur n t he
wheel to the right and to the left
shoul d be 2. 9 N
(0. 3 kgl , 0. 7 l bt )
Normal Check for bent rack shaft.
Check r ack
gui de adj ust mgnt
( see
page 17' 33) .
Check
pump t l ui d
pressure (see
page 17-34).
Turn the steering wheelfully to the
right and left while idling wirh the
pressure control valvg Iully open,
and measurethe fruid
pressure.
lr should be 6,400
-7,400
kPa
(65 -
75 kgflcm,, 920
-
1,070 psi).
Adj ust ment OK
Faul t y val ve body uni t
Abnormal
-
Faul t y gearbox
Check the
parts othor than the gearbox-related parts lor
Drooer rotation.
.
l mproper rot at i on of t he st eedng col umn-rel at sd
part (s)
.
Faul t y st eeri ng
j oi nt
.
Faul t y rack end i e-rod end bal l
i oi nt s
.
Interference in the steering system
Normal
- l mproperl y adi ust ed rack gui de
(cont' d)
17
-23
Check t he
gearbox.
Remove t he gearbox and mea-
sure t he pi ni on t orque.
The t orque shoul d be;
*
0. 7
-
1. 2 N. m
(7 -
12 kgf ' cm, 6
-
10 lbl.in) with the steering rack
i n t h6 st rai ght dri vi ng
posi t i on.
11. 3
N. m
( 13
kgf . cm, 11. 3 l bf i n)
wi t h t he st eeri ng rack i n any
other position.
Abnormal
Adj ust t he rack gui de (see
Page
17- 33) , and r echock t he pi ni on
torque.
Abnormal
Faulty gearbox
Troubleshooting
f''
General Troubleshooting
(cont'd)
Assist
(excossively
light steering) at
hi gh speed.
Shock or vi brat i on when wheel i s
t urned t o f ul l l ock.
St eeri ng wheel wi l l not rot urn
smoot hl y.
lf the
problem
is not corrected by
adj ust i ng t he rack gui de, adj ust
t he l ront whel al i gnment
(see
soct i on 18).
Check t he rack gui de f or proper
adi ust ment
(see page 17-33).
Check t he rack gui de t or proper
adj ust ment
(see page 17-33).
Adj ust t he rack gui de.
Rack gui de i s adi ust ed
properl y.
lf the problom is not corrected by
adi ust i ng t he rack gui de, repl ace
t he gearbox.
Check t he bel t t or sl i ppage and
adj ust as necessary
(see page
17
-321.
A and I cyl i nder l i nes ar e nor -
mal . check wheel al i gnment
(see
soct i on l 8).
Wheel a l ; gnment i s abnor mal ,
adjust as needed.
' l t
shoul d be 0. 7
-
1. 2 N. m
( 7 -
1 2 k g f . c m, 6
-
1 0 l b t . i n ) o r
bel ow wi t h t he st eeri ng rack i n
t he st rai ght ahead dri vi ng
posi -
t i on.
.
1. 3 N. m
(13
kgf . cm, 11. 3 l bf . i nl
wi t h t he st eer i ng r ack i n any
ot her posi t i on.
Wheel al i gnment i s normal .
Remove t he gear box f r om t he
f r ame and measur e t he pi ni on
t orque on t he gearbox.
l f t he measurement s are out of
speci f i cat i ons, adj ust t he r ack
gurde.
l f t he probl em i s not correct ed by
adj l st i ng t he rack gui de, repl ace
t he gearbox.
17- 24
I
Uneven or rough st eeri ng,
Mjust the rack guide (see page 17-33).
lf the problom is not coftected bY
adj ust i ng t he rack gui de, ropl ace
t he gearbox.
Adiust the belt tension. Replace the
belt, if necessary
(see page 17-321.
lfthe engine stalls when the wheel
i s t urnd whi l e car i s st oppod or
movi ng at l ow speed, adj ust t he
idle speed
(see
seclion 11).
ldle speed low or erratic.
Check power stoering fluid level. lf
the level is excessively low, chock
tor leaks in the system. Add fluid
to the spcified level.
Ai r i n resgrvoi r, or check powor
st eeri ng f l ui d l evel .
lf lluid level is OK, check O-rings
8nd seal s on bot h onds of t he
pump i nl t hose, and t he P/ S
pump housi ng mat i ng surf aces
and t he
pump shaf t oi l seal f or
suct i on l eaks. Repl ace part s as
St oeri ng wheel ki cks back
duri ng wi d t urns.
Adl ust t he bel t t ensi on {see Page
17-32)or replace beh.
P! mp bel t sl i ppi ng on
pul l ey
{pump st ops moment ari l y).
Check it pump prssure is normal
and the gauge needle travel is 500
kPa
( 5
kgf l cm' , 71 psi ) or l ess.
Check the flow control valve if the
needle travel exceeds 500 kPa 15
kgt/cm,, 71 psi). lf the flow control
valve is normal, replace the pump
as an assembly,
Install the power steering
pressure
gauge. Close the pressuro control
val ve l ul l y and measure t he pump
pressure (see page 17-34).
17
-25
Troubleshooting
Noi se and Vi brati on
NOTE: Pump noi se i n fi rst 2
-
3 mi nutes after stani ng i n col d weather i s normal .
Humm
j ng
Rat t l e or chat t eri ng
f' '
Hummi ng due t o pul sat i on
of f l ui d i s normal , part i cul arl y
when t he wheel i s
t urned wi t h t he vehi cl e st oooed.
l f equi pped wi t h aut omat i c t rans-
r ni ssi on, t he h! m coul d be t he
t orque convert er or pump noi se.
Confirm by temporarily removing
the
pump
belt.
Hi gh-pressure l i ne t ouchi ng t he
f rame.
Repositjon the line.
Loose st eeri ng shaf t connect or,
t i e-rod, or bal l i oi nt .
Check and t i ght en, or r epl ace
parts
as necessary.
Col umn shaf t wobbl i ng. Replace the column assembly.
Check t he rack gui de l or proper
adj ust ment
(see page 17-33).
Adjust, if necessary.
Rat t l i ng sound and f eel i ng when t urni ng t he st eeri ng wheel ri ght and l ef t wi t h t he
engi ne OFF i s a sound when t he val ve body uni t cont act s t he st oo. Thi s i s normal .
Pump noi se, t hough not l oud, f rom t he val ve body uni t can be heard when t urn-
i ng t he st eeri ng wheel ri ght or l ef t . Thi s i s normal .
CAUTION: When inspecting, do not hold the steering wheel 8ll the way to
the right or the left.
17-26
Pump noi se
Grat i ng noi se
f rom pump
Pump
gear noi se
,Ou"u,,nn
Rat t l e or chat t eri ng
,l
Check the fluid lev1.
l f l ow, f i l l t he r eser voi r t o t he
propor level, and chock for leaks.
Tighten or rplace as necessary.
Cavi t at i on caused by ai r bubbl es
i n t he f l ui d.
Check f or a crushed suct i on hose
or a l oose hose cl amp al l owi ng
ai r i nl o t he suct i on si de ol t ho
system.
Tightgn or replace 8s necessary.
NOTE: Pump noi se uP t o 2
-
3
mi nut es af t er st ar t i ng i n col d
weat her i s normal .
Compare
pump noiso at operating
t emperat ure t o si mul ar vehi cl e.
l l pump noi se i s abnormal l y l oud,
remove and i nspect t he pump t or
wear and damage
(see page 17-
41t .
Tighten or roplace the pully.
l f shsf t i s l ooso, r ePl ace l he
pump.
17- 27
Troubleshooting
Fluid Leaks
. Check the gearbox assembl y for oi l l eaks careful l y. Oi l can l eak out of vari ous poi nts, dependi ng on l ocati on of the
faul ty oi l seal s/seal ri ngs. Check the fol l owi ng before removi ng l he
gearbox from the frame.
St eeri ng Gearbox
Leaki ng f rom t he oi l seal on t he
t op of t he val ve housi ng.
Repl ace t he val ve oi l seal f rom
t he val ve housi ng.
Repl aco t he val ve oi l seal f rom
t he pi ni on shaf t .
Leaki ng l rom cyl i nder end i nt o
left tie rod boot.
Repl ace t he cyl i nder end seal on
t he gar housi ng si de.
Leaki ng f rom cyl i nder end i nt o
right tie-rod boot.
Repl ace t he cyl i nder end seal on
the cylinder end side.
Leaki ng f rom t he shaf t upper end
sect i on or pi n engagemenl sec-
t i on of t he pi ni on shaf t .
Replace the valve body unit.
Tighton th6 connector. lI it's still
l eaki ng, repl ace t h l i no, cyl i nder
or val ve housi ng uni t .
Leaki ng l rom cyl i nder l i ne A or B
connect i ons
(at
f l are nut ).
Leaki ng caused by a damaged
cyl i nder l i ne A or L
Repl ace cyl i nder l i ne A or B.
Leaki ng f rom f eed l i ne and ret urn
l i ne
j oi nt
f i t t i ng on t he val ve body
uni t
(at
f l are nut ).
Ti ght en t he connect or. l f i t ' s st i l l
l eaki ng, repl ace t he l i ne,
j oi nt
f i t -
t i ng or val ve housi ng.
17
-28
Repl ace t he housi ng O-ri ngs.
l f t he housi ng st i l l l eaks, repl ace
t he
pump.
Reservoir is ov6rfilled.
Pul l of f t he hose and drai n t he
reservoir to the
proper lev1.
Air leak in suction side ot the sys-
l em {resrvoi r,
i nl et hose, {ront
pump seal ).
af
Pump out l et l i ne
(hi gh-pressure)
Pump i nl et l i ne
(low-pressure)
Tighten the fining. It it's still leak-
in9, replaco the O-ring or feed line.
Leaking at the lhreaded litting.
Leaki ng at t he swsgged
j oi nt .
Leaking because of damage. dete-
rioration, or improper assombly.
Replace or ropair as necessary.
Steering Operation
Pl ace the front wheel s i n the strai ght ahead posi ti on,
and measur e t he di st ance t he st eer i ng wheel can be
turned wi thout movi ng the front wheel s.
ROTATIONAL PLAY: 0
-
10 mm l0
-
0.39 inl
l f the pl ay exceeds the servi ce l i mi t, perform rack gui de
adj ustment
(see page 17-33).
l f the pl ay i s sti l l excessi ve after rack gui de adj ustment,
i nspect the steeri ng l i nkage and gearbox as descri bed
on the next page.
ROTATIONAL PLAY
17-30
Power Assist Check with
Vehi cl e Parked
1. Check the power steeri ng fl ui d l evel
(see page l 7-
33) and pump bel t tensi on
(see page 17-32).
2. Start the engi ne, al l ow i t to i dl e, and turn the steer-
i ng wheel from l ock-to-l ock several ti mes to warm
up the fl ui d.
3. Attach a spri ng scal e to the steeri ng wheel . Wi th the
engi ne i dl i ng and the vehi cl e on a cl ean, dry fl oor,
Dul l the scal e as shown and read i t as soon as the
ti res begi n to turn.
The scal e shoul d read no more than 29 N
(3,0
kgf,
6. 6 l bf ) . l f i t r eads mor e, check t he gear box and
oumo.
7 t l
Steeri ng Li nkage and Gearbox
TIE.ROD END BALL JOINT
I nsoect f or f aul t v movement
and damage.
damage and det er i or at i on.
BOOT
I nspect
a
TIE.ROD LOCKNUT
f or l oose l ocknut .
3ALL JOINT BOOT
See
p49e 17-68 for replacement.
JOINTS
Check f or l oose
j oi nt
bol t s.
SHAFT GROMMET
STEERING GEARBOX
I nspect f or l oose mount i ng bol t s.
GEABBOX MOUNTING CUSHIONS
l nsoect t or det eri orat i on.
17-31
Pump Bel t
NOTE: When usi ng a new bel t, fi rst adj ust the defl ecti on
or tensi on to the val ues for the new bel t, then readj ust
the defl ecti on or tensi on to the val ues for the used bel t
af t er r unni ng engi ne f or l i ve mi nut es.
Inspection
Attach the speci al tool to the bel t and measure the ten
si on of the bel t.
Tensi onr
used Bel r: 340
-
490 N
{35
-
50 kgf. 77
-
110 tbt)
New Belt: 640
-
780 N {65
-
80 kgl, 143
-
176 tbfl
NOTE:
. l f there are cracks or any damage evi dent on the bel t,
repl ace i t wi th a new one.
. Fol l ow the manufacturer' s i nstructi ons for the tensi on
ga uge.
BELT TENSION GAUGE
07JGG
_
001010A
Inspect the pump bel t for cracks or any damage.
Repl ace the bel t wi th a new one i f necessary.
Measurement wi thout Bel t Tensi on Gauge:
Appl y a force of 98 N (10
kgl ,22 l bt) and measure
def l ect i on bet ween t he power
st eer i ng pump and
cr ankshaf t pul l eys.
Detlection:
Used Bel t: 10.5
-
14.0 mm
(0.41 -
0.55 i n)
New Bel t: 7.5
-
10.0 mm
(0.30 -
0.39 i nl
t he
t he
17-32
Adiustment
1. Loosen the power
steeri ng pump mounti ng bol ts.
PUMP MOUNTI NG BOLT
24 N m 12.4 kgt m, 17 lbffrl
POWER
PUMP
PUMP MOUNTING BOLT
24 N.m {2.4 kgf.m, 17 lbr.ft)
3.
2. Adj ust the bel t tensi on by movi ng the power
steer-
i ng pump wi th a 1/2" dri ve breaker bar to obtai n the
pr oper bel t t ensi on, t hen r et i ght en t he mount i ng
bol ts.
Start the engi ne and turn the steeri ng wheel from
l ock-to-l ock several ti mes, then stop the engi ne and
recheck the defl ecti on of the bel t.
t l
Rack Guide Adjustment
NOTE: Perform rack
gui de adj ustment wi th the wheel s
i n the strai ght ahead
posi ti on.
1.
'96
-
97 model:
Loosen the rack gui de screw l ocknut wi th the spe-
ci al tool , then l oosen the rack gui da screw.
'98
modol:
Remove the ol d seal ant off of the threaded secti on,
then appl y new seal ant to the fi rst three threads.
Loosel y i nstal l the rack gui de screw.
Ti ghten the rack gui de screw to 25 N' m
(2.5 kgf m,
18 l bf.ft), then l oosen i t.
Reti ghten the rack gui de screw to 3.9 N.m
(0.4
kgf' m,
2.9 lbf.ft), then back it off to specified angle.
Specified Retuh Angle: 20" max.
Ti ght en t he l ocknut whi l e hol di ng t he r ack gui de
screw.
Check for ti ght or l oose steeri ng through the com-
pl ete
turni ng travel .
Perform fol l owi ng i nspecti ons:
. Steeri ng operati on
(see page 17-30).
. Power assi st wi th vehi cl e
parked.
Fluid Replacement
Check the reservoi r at regul ar i nterval s, and add fl ui d as
necessary.
CAUTION: Always use Gonuin Honda Powsr Steering
Fluid-V or S. Using any oth.r type ot pow 3toering
f l ui d or sut omat i c l r snsmi s3i on f l ui d can cause
increased wear and
poor steoring in cold woather.
SYSTEM CAPACITY:
0.85 litor 10.90
US.
qt,
0.75 lmp.qtl
at dkassembly
RESERVOIR CAPACITY:
0.4 liter {0.42 US.
qt, 0.35 lmp.qt)
UPPER LEVEL LINE
LOWER LEVEL LINE
1 .
a
Rai se the reservoi r, then di sconnect the return hose
Connect a hose of sui tabl e di ameter to the di scon-
nected return hose, and
put
the hose end i n a sui t-
abl e contai ner.
CAUTION: Taks car. not to spi l l tho l l ui d on tho
body and parts. Wipe off any spilled fluid at once.
Start the engi ne, l et i t run at i dl e, and turn the steer-
i ng wheel f r om l ock- t o- l ock sever al t i ms. When
f l ui d st ops r unni ng out of t he hose, shut of f t he
engi ne. Di scard the fl ui d.
Rei nstal l the return hose on the reservoi r.
Fi l l the reservoi r to the uoDer l evel l i ne.
Start the engi ne and run i t at fast i dl e, then turn the
steeri ng from l ock-to-l ock several ti mes to bl eed ai r
from the system.
Recheck the fl ui d l evel and add some i f necessary.
CAUTION: Do not fi l l the reservoi r beYond the
upper lovel line.
4.
7 .
HOSE
17-33
Pump Pressure Check
Chec k t he f l ui d
pr es s ur e
as f ol l ows t o det er mi ne
whether the troubl e i s i n the pump or gearbox.
NOTE: Fi rst check the
power steeri ng fl ui d l evel and
pump bel t tensi on.
CAUTION: Disconnect the high pressure hose with care
so as not to spill the power steering fluid on the ftame
and other parts.
1. Di sconnect the outl et l i ne from the
pump outl et fi t-
ti ng, then
j nstal l
the P/S
j oi nt
adaptor {pump) on the
pump outl et.
2. Connect the P/S
j oi nt
adaptor
(hose)
to the power
steeri ng
pressure gauge, then connect the outl et
hose to the adaptor.
3. Instal l the power steeri ng
pressure gauge to the P/S
j oi nt
adaptor {pump) as shown.
6 x 1. 0 mm BOLT
OUTLET HOSE FTTNNG
P/S JOINT ADAPTOR IHOSE)
07MK
-
5040121
oa
07RAK
-
S040r20
P/S PRESSURE GAUGE
07405
-
001 000A
ol
07,106
- q)l0001
lPart of tooll
11 N. m
(1.1 ksf.m, I lbt'ft)
PRESSURE
CONTROL VALVE
.OFF
VALVE
PUMP OUTLET
FITTING
6 x 1. 0 mm BOLT
(Part
ot tooll
1 1 N m
(1. 1
ksf . m, 8l bt f t )
5.
Open the shut-off val ve ful l y.
Open the pressure control val ve ful l y.
17-34
6. Start the engi ne and l et i t i dl e.
7. Turn the steeri ng wheel from l ock-to-l ock several
ti mes to warm the fl ui d to operati ng temperature.
8. Measure steady-state fl ui d pressure whi l e i dl i ng. l f
t he
pump i s i n good condi t i on, t he gauge shoul d
read l ess than 1500 kPa
(15
kgfl cm' , 213 psi ).
l f i t reads hi gh, check the outl et l i ne or val ve body
uni t
(see
General Troubl eshooti ng 17-22).
9. Cl ose t he pr essur e cont r ol val ve, t hen cl ose t he
shut-off val ve gradual l y unti l the pressure gauge
needl e i s stabl e. Read the pressure.
10. l mmedi atel y open the
pressure control val ve ful l y.
CAUTION: Do not kp the
pressure conlrol valve
closed more then 5 seconds or the
pump could be
damaged by over-heating.
l f the pump i s i n good condi ti on, the gauge shoul d
read at least 6.400
-
7,400 kPa
(65 -
75 kgflcn',920
-
1.070 psi ). A l ow readi ng means pump output i s too
l ow for ful l assi st. Repai r or repl ace the
pump.
P/S PRESSURE GAUGE
07{06
-
00'llD0A
ot
SHUT.OFF VALVE
Steering Wheel
I
Removal
SRS component s ar e l ocat ed i n t hi s ar ea. Revi ew t he
SRS component l ocati ons,
precauti ons, and procedures
i n the SRS secti on
(24)
before
performi ng repai rs or ser-
vi ce.
NOTE: Bef or e r emovi ng t he st eer i ng wheel , al i gn t he
front wheel s strai ght ahead.
' 1.
Remov e t he dr i v er ' s ai r bag as s embl y f r om t he
steeri ng wheel
(see
secti on 24).
2. Di sconnect t he hor n connect or and cr ui se cont r ol
swi tches connector.
3. Remove t he st eeri ng wheel nut .
STEERI NG WHEEL NUT
Repl ace.
4. Remove t he st eeri ng wheel by rocki ng i t sl i ght l y f rom
si de t o si de as
you pul l st eadi l y wi t h bot h hands.
l nstal l ati on
CAUTION: Do not tap on the steering wheel or steering
col umn shaft when i nstal l i ng the steeri ng wheel .
NOTE: Bef or e i nst al l i ng t he st eer i ng wheel , al i gn t he
front wheel s strai ght ahead.
1. Bef or e i nst al l i ng t he st eer i ng wheel , cent er t he
cabl e reel . Do thi s by fi rst rotati ng the cabl e reel
cl ockwi se unti l i t stops. Then rotate i t countercl ock-
wi se approxi matel y two turns. The arrow mark on
the cabl e reel l abel shoul d
poi nts strai ght up.
l nstal l the steeri ng wheel wi th the steeri ng wheel
nut.
NOTE: Be sur e t he st eer i ng wheel shaf t engages
the cabl e reel and cancel i ng sl eeve.
2.
4.
5.
6.
3. Attach the crui se control swi tches connector to the
st eer i ng wheel cl i P.
Connect the horn connector.
I nst al l t he dr i ver ' s ai r bag assembl y, and conf i r m
proper system operati on l see secti on 24).
Check t he hor n and cr ui se cont r ol swi t ches f or
proper operati ons.
CABLE REEL
17-35
Steering
Wheel
Disassembly/Reassembly \
*@*&*W
-:<z<z
%
17-36
Steeri ng Col umn
SRS component l ocati ons, precauti ons, and
procedures
(24)
before performi ng repai rs or ser-
vi ce.
NOTE: Before removi ng the steeri ng col umn for SRS,
remove the dri ver' s ai rbag assembl y and cabl e reel
(see
secti on 24).
1. Remove the steeri ng wheel
(see page 17-35).
2. Remove t he dr i ver ' s dashboar d l ower cover and
dri ver' s knee bol ster
(see
secti on 20).
3. Remove the combi nati on swi tch assembl v from the
steeri ng col umn shaft by di sconnecti ng the connec-
rors.
4. Di sconnect the i gni ti on swi tch connectors.
j oi nt
cover
j oi nt
bol ts.
7. Di sconnect t he st eer i ng
i oi nt
by movi ng t he
j oi nt
toward the col umn, and remove i t from the col umn
shaft.
8. Remov e t he s t eer i ng c ol umn by r emov i ng t he
attachi ng nuts and bol t.
UPPER
RETAINING COLLAR
NOTE: Take care not t o l et t he
ret ai ni ng col l ar f al l out of
posi t i on duri ng i nst al l at i on.
STEERING JOINT BOLTS
22 N.m {2.2 kgt m, 16 lbl.ftl
FLANGE BOLTS
22 N.m 12.2 kgl'rn,
9. Instal l ati on i s the reverse of the removal procedure.
NOTE:
. Make sure the steeri ng
j oi nt
i s connected as fol l ows:
a. Insert the upper end of the steeri ng
j oi nt
onto the
steeri ng shaft
(l i ne
up the bol t hol e wi th the fl at on
the shaft), and l oosel y i nstal l the upper
j oi nt
bol t.
b. Sl i p the l ower end of the steeri ng
j oi nt
onto the
pi ni on shaft
(l i ne
up the bol t hol e wi th the groove
ar ound t he shaf t ) . and l oosel y i nst al l t he l ower
j oi nt
bol t.
Be sure that the l ower
j oi nt
bol t i s securel y i n the
groove i n the pi ni on shaft.
c. Pul l on t he st eer i ng
j oi nt
t o make sur e t hat t he
steeri ng
j oi nt
i s ful l y seated. Then ti ghten the
j oi nt
bol ts.
. Be sure the wi res are not caught or pi nched by any
parts when i nstal l i ng the col umn.
. Make sure the wi re harness i s routed and fastened
properl y,
. Make sure the connectors are
properl y connected.
STEERING COLUMN
COMBINATION SWITCH
ASSEMBLY
t
UPPER JOINT BOLT
Bol t must l i ne up
on shaf t .
15 lbl tr)
JOINT BOLT
COLUMN COVER
Groove.
Bol t must l i ne up wi t h
g. oove ar ound on shaf t .
CLI P
JOINT COVER
17-37
Steeri ng Col umn
Inspection
NOTE: The ti l t steeri ng col umn type i s shown; the con-
vent i onal st eer i ng col umn i s si mi l ar except f or t he t i l t
mechani sm.
Check the steeri ng col umn bal l beari ng and the steer-
i ng
j oi nt
beari ngs for pl ay and proper movement. l f
there i s noi se or i f there i s excessi ve pl ay, repl ace the
steeri ng col umn as an assembl y.
Check t he r et ai ni ng col l ar f or damage. l f i t i s dam-
aged, repl ace the retai ni ng col l ar.
Check the absorbi ng pl ates, absorbi ng pl ate gui des
and sl i di ng capsul es for di stoni on or breakage.
Repl ace the steeri ng col umn as an assembl y i f they
are di storted or broken.
COLUMN BALL BEARI NG
IGNITION
ABSORBING PLATES
Thi s par t i s at t ached
t o t he col umn br acket
wi t h t he
pl ast i c i nj ect i ons.
ABSORBING PLATE GUIDES
RETAINING COLLAR
BEARI NGS
\
SLI DI NG
See sect i on 23.
' 1.
l Move the ti l t l ever from the l oose posi ti on to l ock
posi t i on 3 t o 5 t i mes; t hen measur e t he t i l t l ever
pr el oad 10 mm
( 0. 4 i n) f r om t he end of t he t i l t l ever .
Prel oad: 70
-
90 N {7
-
I kgl . 15-20 l bf)
2. l f t he meas ur ement i s out of t he s pec i f i c at i on,
adj ust t he pr el oad usi ng t he f ol l owi ng pr ocedur es.
a. Loosen the ti l t l ever, and set the steeri ng col umn
i n the neutral posi ti on.
b. Remove the 6 mm l ock bol t and remove the stop.
c. Adj ust the prel oad by turni ng the ti l t l ock bol t l eft
or ngnr .
d. Pul l up the ti l t l ever to the uppermost posi ti on and
i nst al l t he st op. Check t he pr el oad agai n. l f t he
measurement i s sti l l out of speci ti cati on, repeat
the above procedures
"a"
through
"c"
to adi ust.
CAUTI ON: Be cal el ul not t o l oosen t he t i l t l evel
when i nst al l i ng t he st op or t i ght eni ng t he 6 mm
l ock bol t .
TILT LOCK BOLT
Ti ght en t he l ock bol t
t he t i l t l ever rai sed.
17- 38
9. 8 N. m { 1. 0
kgl m, 7l bl f t )
Power Steering Hoses, Lines
Fl ui d Leakage Inspecti on
HOSES and LINES
. I nspect hoses f or damage, l eaks, i nt er f er ence or
rwrsI| ng.
. Inspect fl ui d l i nes for damage, rusti ng and l eakage.
. Inspect for l eaks at hose and l i ne
j oi nts
and connec
trons.
POWER STEERING PRESSURE SWITCH
12 N. m
(1. 2
ksf . m, 9 l bt hl
CYLINDER HOUSING-to-CYLINDER LINES
28 N.m {2.7 kg{.m, 20 lbf.ft)
BOOT
Check for l eaks.
OUTLET HOSE
11 N. m
(1. 1
kgf . m, 8
Check f or l eaks at t he pump
seal , i nl et and oudet f i t t i ngs.
Replacement
NOTE:
. Connect each hose to the correspondi ng pi pe securel y
unti l i t contacts the stop on the l i ne. Instal l the cl amp
or adj ustabl e cl amp at the speci fi ed di stance from the
hose end as shown.
. Add the power steeri ng fl ui d to the speci fi ed l evel on
the reservoi r and check for l eaks.
ADJUSTABLE HOSE CLAMP:
. Posi t i on t he adj ust abl e hose cl amps at t he poi nt s
i ndi cated
(a)
i n the drawi ng above.
. Sl i de the hose over the l i ne unti l i t contacts the stop.
12 tbf ft,
vALVE BODY UNIT-to-FEED/RETURN LINES
Feed line: 14 x 1.5 mm flare nut
37 N.rn 13.8 kgf.m, 27 lbl.ft)
Rdurn Line Joint: 16 x 1.5 mm flare nui
28 N.m
(2.7
kgt m, 20lbf.ftl
GEARBOX and VALVE BODY UNIT
Check f or l eaks at t he mat i ng surf ace
and f l a re nut connecl i ons.
--!-t__1 /Z\\\
tqtT-f*r-
g-
@- f f i
_t r _ll
2. 5
-
5. 5 mm
(0. 01 -
0. 22 i nl
2. 0- 4. 0 mm
10. 08
-
0. ' 16 i nl
VALVE BODY UNIT-Io-CYLINoER LINES
17 N. m 11. 7
(Doubl e
Ri ng Type)
CAUTION: Check all clamps for deterioration or defor-
mation; leplace with the clamps new ones it necessary.
HOSE CLAMP:
. Posi t i ont he hose cl amps at t he poi nt s i ndi cat ed { b) i n
the drawi ng above.
. Sl i de the hose over the l i ne unti l i t contacts the stop.
2. 5- 5. 5 mm
{0. 01
-
0. 22 i n}
17-39
Power Steering Pump
RemovaUlnstallation
NOTE: Before di sconnecti ng the hoses f.om the pump,
pl ace a sui tabl e contai ner under the car.
1. Remove the bel t by l ooseni ng the pump mounti ng
bolts.
PUMP MOUNTING EOLT
2il N.m {2.4 kgf.m, 1? lbt.ft)
Cover the A,/C compressor wi th several shop towel s
to protect i t from spi l l ed power steeri ng fl ui d.
Di sconnect the i nl et hose and the outl et l i ne from
t he pump, and pl ug t hem.
NOTE: Take care not to spi l l the fl ui d on the body
or parts. Wi pe off any spi l l ed fl ui d at once.
Remove the pump mounti ng bol ts, then remove the
pump.
NOTE:
. Do not turn the steeri ng wheel wi th the pump
removed.
. Wrap the openi ng of the pump wi th a pi ece of
tape to prevent forei gn materi al from enteri ng
I ne pump.
11 N. m {1. 1 kgt . m,
PUMP MOUNTING BOLT
2{ N.m {2.4 kgf.m, 17 lbf ft)
17-40
7.
Connect the i nl et hose and the outl et l i ne. Ti ghten
the pump fi tti ngs securel y.
Loosel y i nstal l the pump i n the pump
bracket wi th
mounti ng bol ts.
Instal l the oump bel t.
CAUTION:
. Mako suro that the
power
3teering belt is prop-
erly
positioned on the pulleys.
. Do not get power siesring fluid or
gresse in the
power steering belt or pulley fac$. Clean ofl any
fluid or grcase before installation.
Adj ust the pump bel t
(see page 17-32).
Fi l l the reservoi r to the upper l evel l i ne
(see page
11- 33t .
8.
Disassembly
CAUTION: The power steering components are made of aluminum. Avoid damaging the componsnG during assembly.
NOTE:
parts wi th a sol vent, and dry them wi th compressed ai r. Do not di p the rubber parts i n a sol -
vent.
a Al ways repl ace the O-ri ngs and rubber seal s wi th new ones before assembl y,
. Appl y recommended power steeri ng fl ui d to the parts i ndi cated i n the assembl y procedures.
. Do not al l ow dust, di rt, or other forei gn materi al s to enter the powe. steeri ng system.
. Repl ace the pump as an assembl y i fthe pans i ndi cated wi th asteri sk
(+)
are worn or damaged.
FLANGE EOLTS
20 N.m
(2.0
kgf.m.
14 tbtft)
PUMP COVER
5 mm ROLLER
. PUMP
HOUSI NG
4. 5 mm ROLLEB
PUMP COVER SEAL
Repl ace.
3 t
*OUTER
SIDE PLATE
,SUB-VALVE
.SIDE
PLATE
SNAP RI NG 13 x 1. 9 mm O-RI NG
Repl ace.
15. 2 x 2. 4 mm O-RI NG
Bepl ace.
INLET JOINT
51 x 2. { mm O-RI NG
Repl ace.
FLANGE BOLTS
11 N, m {1. 1 kgf . m,
8 rbf.ft)
PUMP SEAL
Repl ace.
PUMP SEAL SPACER
BALL BEARING
I nspect i on and Repl acement ,
see page 17-43
a0 mm CIRCLIP
*FLOW
CONTROL VALVE
I nsoect i on and Overhaul .
seePasel T"
fi ' -tl u"i :3;' n^ô' ^' ' o
spnrruc/
d
PULLEY
PULLEY NUT
64 N.m {6.5 kgt.m,
47l bt.ft)
FLOW CONTROL VALVE
4It N.m {5.0 kgf.m,
36 tbtft)
(cont' d)
*PUMP
FOTOR
CAP
17-41
Power Steering Pump
D
Disassembly
(cont'd)
1 .
7.
10.
Drai n the fl ui d from the pump.
Hol d the steeri ng pump i n a vi se wi th soft
j aws,
hol d the
pul l ey
wi th the speci al tool , and remove
the pul l ey
nut and pul l ey.
CAUTION: Be carel ul not to damage th6 pump
housing with thc
iaws
ot the viso and extension bar.
Loosen the fl ow control val ve cap wi th a hex wrench
and remove i t.
Remove the O-ri ng, fl ow control val ve and spri ng.
Remove the i nl et
j oi nt
and O-ri ng.
Remove the pump cover and pump cover seal .
Remove the outer si de pl ate, pump cam ri ng, pump
rotor, pump vanes, si de pl ate and O-ri ngs,
Remove the snap ri ng, then remove the sub-val ve
from the pump housi ng.
Remove the ci rcl i p, then remove the pump dri ve
shaft by tappi ng the shaft end wi th the pl asti c ham-
mer.
Remove the pump seal spacer and pump seal .
UNIVERSAL HOLDER
17
- 42
Inspection
Flow Control Valve:
1. Check the fl ow control val ve for wear, burrs, and
other damage to the edges of the
grooves
i n the
val ve.
FLOW
CONTROL VALVE
Check f or
damage t o edges.
Inspect the bore the flow control valve for scratches
or wear.
Sl i p the val ve back i n the pump, and check that i t
moves i n and out smoothl y.
l f OK, go
on step 4; i f not, repl ace the pump as an
assembl y, The fl ow control val ve i s not avai l abl e
separatel y.
Attach a hose to the end of the val ve as shown.
FLOW CONTFOL VALVE HOSE
\
5. Submerge the val ve i n a contai ner of power steer-
i ng tl ui d or sol vent. and bl ow i n the hose. l f ai r bub-
bl es l eak t hr ough t he val ve at l ess t han 98 kPa
{1.0 kgfl cm,, 14.2 psi ), repai r i t as fol l ows.
<-- POWER STEERING
FLUID or SOLVENT
Hol d the bottom end of the val ve wi th a open end
wrench.
Unscrew the seat i n the top end of the val ve, and
remove any shi ms. the rel i ef check bal l , rel i ef val ve
and rel i ef val ve spri ng.
7.
.{
D
RELIEF CHECK BALL
SEAT
9 N. m
{ 0. 9 kgl . m. 6. 5l bt f t )
Cl amp t hi s end i n
a open eno wt encn.
FLOW CONTROL VALVE
8. Cl ean al l t he par t s i n sol vent , dr y t hem of f , t hen
reassembl e and retest the val ve. l f the fl ow control
val ve tests OK, rei nstal l i t i n the
pump. l f the fl ow
control val ve sti l l l eaks ai r, repl ace the
pump as an
assembl y. The fl ow control val ve i s not avai l abl e
separatel y.
NOTE: It necessary, rel i ef pressure i s adj usted at
the factory by addi ng shi ms under the check bal l
seat. l f
you found shi ms i n your val ve, be sure you
rei nstal l as manv as vou took out.
RELIEF VALVE
Bal l Beari ng:
1. Inspect the bal l beari ng by rotati ng the outer race
sl owl y. l f any pl ay or roughness i s fel t, repl ace the
bal l beari ng.
Remove and di scard the bal l beari ng usi ng a press
as snown.
Instal l the new bal l beari ng usi ng a
press as shown.
Ball Bearing Replacement:
2.
l nst al l wi t h t he
r ed shi el ded si de
f aci ng down.
NOTE: Suppon t he i nner race
wi t h t he t ool securel y-
BALL BEARING
17-43
Power Steering Pump
Reassembly
1 . Al i gn the pi n of the sub-val ve wi th the oi l passage
i n pump housi ng, and push down the sub-val ve.
Instal l the snap ri ng properl y.
OIL PASSAGE
Al i gn t he pi n
of
sub val ve wi t h
t he oi l passage.
2.
PUMP HOUSI NG
SNAP FI NG
Instal l the new pump seal i n the pump housi ng by
hand, then i nstal l the pump seal spacer.
NOTE: Insert the pump seal wi th i ts grooved
si de
f aci ng i n.
Posi ti on the pump dri ve shaft i n the pump housi ng,
then dri ve i t i n usi ng a speci al tool as shown.
BALL EEARI NG
PUMP DRIVE SHAFT
PUMP SEAL SPACER
I
Instal l the 40 mm ci rcl i p wi th i ts radi used si de fac-
Ing out.
40 mm CtRCLtp
ATTACHMENT,30mm
H
ozzls
-
oososob q:D
17-44
ROLIIRS
\
Coat the pump cover seal and the cover bushi ng
wi th the power steeri ng fl ui d, then i nstal l the pump
cover seal i nto the
groove
i n the pump cover.
Instal l the outer si de ol ate over the two rol l ers.
OUTER SIDE PLATE
4.5 mm ROLLER
5 mm ROLLER
,rr","oE \
7.
PUMP COVER
Set the pump
cam ri ng over the two rol l ers wi th the
" " "
mark on the cam ri ng upward.
ROLI.IR SET HO|'.CS
ROLLER SET HOLES
PUMP CAM RING
9.
Assembl e pump rotor to the pump cover wi th the
" o "
marks on the rotor faci ng down.
Set the 10 vanes i n the grooves i n the rotor.
NOTE: Be sure that the round ends of the vanes are
i n contact wi th the sl i di ng surface of the cam ri ng.
PUi'P VANES
(10 plrt
.)
PUMP ROTOR
Coat t he O- r i ng wi t h power st eer i ng l l ui d. and
i nstal l i t i nto the grooves i n the si de pl ate.
Instal l the si de pl ate on the cam ri ng by al i gni ng the
rol l er set hol es i n the si de pl ate wi th the rol l ers.
mm O-RING
ROU.R SET HOll
SET HOIf
a E
nn
D
10.
1 l .
I
E
15-2 | 2.1
Repl ace.
SIDE PLATE
ROU"EBS
17-45
13.
Coat the O-ri ng wi th power steeri ng fl ui d, and posi -
ti on i t i nto the pump housi ng.
Instal l the pump cover assembl y i n the pump hous-
I ng.
FLANGE BOLTS
20 N.m {2.0 kgl.m,
r4 tbf.ftl
Coat the fl ow control val ve wi th power steeri ng
f l ui d.
I nst al l t he f l ow cont r ol val ve and spr i ng on t he
pump housi ng.
Coat t he O- r i ng wi t h power st eer i ng t l ui d. and
i nstal l i t on the fl ow control val ve cap.
Instal l the fl ow cont.ol val ve cap on the
pump hous-
i ng, and ti ghten i t.
't
4.
15.
16.
' t]
.
SPRING
M
r
E
15. 2 x 2. 4 rnm O-RI NG
Replace.
v (64
\ t br y
\
FLOW CONTROL
VALVE CAP
49 N.m
(5,0
kgl.m,
36 rbtft)
(cont' d)
Power Steering
Pump
18.
1 9 .
Reassembly
(cont'dl
Coat t he O- r i ng wi t h power st eer i ng f l ui d, and
i nstal l i t i nto the grooves i n the i nl et
j oi nt
I nst al l t he i nl et
j oi nt
on t he pump housi ng
11 N. m
(1. 1 kgl . m,
8 tbtfr)
20. l nst al l t he Dul l ev as shown bel ow, t hen l oosel y
I nst al l t he
pul l ey nut . Hol d t he st eer i ng
pump i n a
vi se wi th soft
j aws.
CAUTION: Be carelul not to damage the pump hous-
ing with the
iaws
of the vise.
15. 2 x 2. 4
Bepl ace.
E
17-46
21. Hol d the pul l ey wi th the speci al tool , and ti ghten the
pul l ey nut .
UNIVERSAL HOLDER
PULLEY NUT
64 N.m {6.5 kgtm,
Check that the pump turns smoothl y by turnrng
pul l ey by hand.
rne
Steering Gearbox
Removal
NOTE: Usi ng sol vent and a brush, wash any oi l and di rt
off the val ve body uni t i ts l i nes, and the end i f the gear-
box. Bl ow dry wi th compressed ai r.
1, Drai n the power steeri ng fl ui d as descri bed on page
17
- 33.
Rai se the front of vehi cl e, and support i t on satety
stands i n the proper l ocati ons
(see
secti on l ).
Remove the front wheel s.
Remove the dri ver' s ai rbag assembl y, and steeri ng
wheel
(see page 17-35).
Bemove the steeri ng
j oi nt
cover.
D
j oi nt
l ower bol t, and di scon-
nect the steeri ng
j oi nt
by movi ng the
j oi nt
toward
t he col umn.
,l
7. Remove the cotter pi n from the castl e nut
(' 96 -' 97
model ) or nut
(' 98
model ) and remove the nut.
TIE.ROD END
Instal l the 10 mm hex nut on the bal l j oi nt.
Be sure that the 10 mm hex nut i s fl ush wi th the bal l
j oi nt pi n end, or t he t hr eaded sect i on of t he bal l
j oi nt pi n mi ght be damaged by the speci al tool .
NOTE: Remove the bal l
j oi nt
usi ng the speci al tool .
Ref er t o sect i on l 8 f or how t o use t he bal l
j oi nt
remover.
Separate the ti e-rod bal l
j oi nt
and knuckl e usi ng the
speci al tool .
CAUTION: Avoid damaging tho ball
ioint
boot.
Remove the l eft ti e-rod end, then sl i de the rack al l the
way to the right.
Separate the exhaust
pi pe A or TWC
(see
secti on 9).
Di sconnectthe shi ft l i nkage
(see
secti on 13 or secti on
141.
(cont' d)
10.
1 1 .
17- 47
Steering Gearbox
14.
Removal
(cont' dl
Loosen the 14 mm fl are nut and di sconnect the feed
l ne,
Loosen the adj ustabl e hose cl amp and di sconnect
the return hose.
Loosen the 16 mm fl are nut and remove the return
hose i oi nt from the val ve bodv uni t.
CAUTION: After disconnecting the hose and line,
plug or seal the hose and line with a piece of tape
or equi val snt to prevent forei gn materi al s from
entering the valve body unit.
NOTE: Do not l oosen t he cyl i nder l i ne A and B
between the val ve body uni t and cyl i nder.
ADJUSTABI.E HOSE
CLAMP
Remove the sti ffener pl ate.
NOTE: Some sti ffener pl ate attachi ng bol ts are al so
used as gearbox mounti ng bol ts. The gearbox wi l l
ti l t to si de when these bol ts are removed.
14 mm FLARE NUT
STIFFENER PLATE
ATIACHING BOLTS
17
-48
17. Remove the mounti ng brackets.
Pul l the steeri ng
gearbox al l the way down to cl ear
the
pi ni on shaft from the bul khead, then remove the
pi ni on shaft grommet.
Move the steeri ng gearbox to ri ght so the l eft rack
end cl ears the rear beam, then ti l t the l eft si de down
to remove i t from the vehi cl e.
CAUTION: Be careful not to bend or damage the
l eed l i ne and cyl i nder l i nss whn rmovi ng th6
gearbox.
18.
19.
STEERING GEARBOX
.l
Disassembly
Steoring Rack Disassombly
NOTE:
. Before di sassembl e the
gearbox, wash i t off wi th sol -
vent and a brush.
. Do not di p seal s and O-ri ngs i n sol vent.
1. Remove the steri ng gearbox (see page l 7-47).
2. Remove the ti e-rod end and l ocknut.
3. Remove ai rtube and cl i ps.
Remove the boot bands and ti e-rod cl i ps, Pul l
boots away from the ends of the gearbox.
BOOT
TIE-ROO CLIP
17-49
5. Hol d the steeri ng rack wi th a wrench {' 98 model : l eft
end onl v), and unscrew the rack end wi th another
wrench.
CAUTION: Bo caroful not to damage tho rack sur-
fac with tho wrench.
NOTE:
' 96
-' 97
model i s shown.
STEERING RACK
Loosen the l ocknut, then remove the rack gui de
screw
(' 98
model ) and O-ri ng {' 96
-' 97
model onl y).
Remove the spri ng and the rack
gui de from the
gear
housr ng.
7.
RACK GUIDE
scREws
(cont' d)
STEERING RACK END
Steeri ng Gearbox
Disassembly
(cont'dl
8. Remove cyl i nder l i nes A and B f rom t he
gearbox
CYLI NDER LI NE B CYLINDER LINE A
9. Drai n t he f l ui d f rom t he cyl i nder f i t t i ngs by sl owl y
movi ng t he st eeri ng rack back and f ort h
10. Remove t he t wo f l ange bol t s, t hen remove t he val ve
body uni t f r om t he
gear box.
( See page 17 52 f or
val ve body uni t di sassembl Y. )
BOLT FLANGE
,
I
'96
-
'97
model:
32 mm SHIMS
'98
modol:
WAVE WASHER
VALVE BODY UNIT
17- 50
13. Loosen and remove the cyl i nder end.
11. Dr i l l a 3 mm { 0. 12
i n) di amet er hol e appr oxi mat el y
2. 5
-
3. 0 mm
( 0. 10 -
0. 12 i n) i n dept h i n t he st aked
poi nt on t he cyl i nder .
CAUTION:
. Do not allow metal shavings to enter the cylin'
der housi ng.
. After removi ng the cyl i nder end, remove any
burrs at the staked
Point.
Deprhr 2. 5
-
3. 0 mm {0. 10
-
0. 12 i n)
CYLI NDER
12. Hol d t he s t eer i ng
gear box us i ng a C- c l amp as
shown.
14. Assembl e a
' 12
x 1.25 mm fl ange nut onto a 12 x 175
mm grade 10 fl ange bol t as shown.
NOTE: Wr ap t he f l ange por t i on of t he bol t wi t h
vi nyl tape to protect the cyl i nder.
I nst al l t he f l ange bol t i nt o t he end of t he st eer i ng
r ack unt i l i t bot t oms i n t he hol e, t hen back t he
f l ange bol t out 1/ 4 t ur n. Hol d t he f l ange bol t , and
ti ghten the fl ange nut agai nst the rack by hand.
Instal l the beari ng separator on the gearbox housi ng
as shown.
'12
x 1t5 mm Press
FLANGE BOLT
r-,,'
BEARING SEPARATOR
o
-
4112" I
(commerciallv
availablel
STEERING RACK
CYLINOER END SEAL
17. Set the gearbox i n a press so the gear housi ng poi nt
upward, then
press the cyl i nder end seal and steer-
i ng rack out of the gearbox.
NOTE: Hol d the steeri ng rack to keep i t from fal l i ng
when pressed cl ear.
CAUTION:
. Be carel ul not damage to i nner surtace of the
cyl i nder housi ng wi th the tl ange bol t.
. Do not pl ace your l i ngers under the steeri ng
rack.
tP/N 90177
-
SLo
-
0001
CYLI NDER END SEAL
Repi ace,
l " r
|
\s-,'
t " . .
I
t ^
I o-tfl
Q ) *
20. Insert a 24" l ol
ci al tool i nto th
NOTE: Make s
posi ti oned on t
' 18.
Remove the l 2 mm bol t and nut from the steeri ng
rack.
19. Remove t he cyl i nder end seal f r om t he st eer i ng
rack.
CYLINDER HOUSING
CAUTION: Be careful not damage to inner surtace
of the cyl i nder housi ng wi th the speci al tool .
21. Set the gearbox i n a press, then press out the cyl i n-
der end seal and backup ri ng from the
gearbox.
CAUTION:
. Keep the tool straight to avoid damaging the cylin'
der wall. Check the tool angle, and correct it if nec-
essary, when removing the cylinder end seal.
. Use a press to rcmove the cylinder end seal. Do
not try to remove the seal by striking the tool. h
will break the backup ring, and the cylinder end
sealwill remain in the gearbox.
24
"LONG
3/8" DRIVE EXTENSIONI
{Commercially available)
BACKUP RING
CYLINDER ENO SEAL
the spe-
sr de.
securel y
l ong, 3/8" dri ve extensi on and
the cyl i nder from the gearbox
) sure that the speci al tool i s
n the backup ri ng edges.
CYLINDER ENO SEAL
REMOVER ATTACHMENT
07NAO
-
SB3020A
(cont' d)
17-51
Press
Steering Gearbox
l
Di sassembl y
(cont' dl
22. Carctul l y pry the pi ston seal ri ng and O-ri ng off the
prsl on racK.
CAUTION: Be careful not to damage the i nsi de ot
seal ri ng groove and pi ston edges when temovi ng
the seal ri ng.
L
t ,
Repl ace.
17-52
Valve Body Unit Disassembly
23. Bef or e r emovi ngt he val ve housi ng, appl yvi nyl t ape
to spl i nes of the pi ni on shaft.
24. Separate the val ve housi ng from the pi ni on
shaft/
val ve usrn9 a press.
VALVE HOUSING
Vinyl tape
PINION SHAFT
Check the i nner wal l of the val ve housi ng where the
seal ri ng sl i des wi th your fi nger. l f there i s a step i n
t he wal l , t he val ve housi ng i s wor n. Repl ace t he
val ve housi ng.
NOTE;
Ther e may be t he sl i di ng mar ks f r om t he seal
r i ng on t he wal l of t he val ve housi ng. Repl ace
the val ve housi ng onl y i f the wal l i s stepped.
When the val ve housi ng i s repl aced, i nstal l new
shi m(s) on the beari ng surface of the housi ng to
adi ust the thi ckness.
25
Check t he i nsi de of val ve housi ng
whet her t he wal l i s st epped.
3 f
26. Check f or wear , bur r s and ot her damage t o t he
edges of the
grooves i n the sl eeve.
NOTE: The pi ni on shaft and sl eeve are a
preci si on
mat ched set . l f ei t her t he
pi ni on
shaf t or sl eeve
must be replaced, replace both
parts as a set.
SLEEVE SEAL RINGS
Checkl or
peel of f or
damage.
27. Remove the ci rcl i p and
pi ni on shaft sl eeve from the
pi ni on shaft.
)
28. Usi ng a cutter or an equi val ent tool , cut and remove
the four seal ri ngs from the sl eeve.
CAUTIONT Be careful not to damage the edges of
the sleeve
groovos and out6r sufaca whon romov-
ing the 3eal rings.
Usi ng a cutter or an equi val ent tool . cut the val ve
seal ri ng and O-ri ng at the groove the
pi ni on shaft.
Remove the val ve seal ri ng and O-ri ng.
CAUTION: Be caretul not to damage the odges of
the
pi ni on shaft
groove and outor 3urfac when
rmoving ths valve seal ring 8nd O-ring.
VALVE SEAL RING
Repl ace.
(cont' d)
SLEEVE
Cuf t i ng sl ot
Posi t i on.
17-53
Steering Gearbox
Disassembly
(cont'd)
30, Remove the val ve oi l seal and backup ri ng
(' 96 -' 97
model ) or wave washer
(' 98
model ) from the pi ni on
shaft.
NOTE:
Inspect the bal l beari ng by rotati ng the outer race
sl owl y. l f there i s any excessi ve pl ay, repl ace the
pi ni on shaft and sl eeve as an assembl y.
The pi ni on shaft and sl eeve are a
preci se
fi u do
not i nt er mi x ol d and new
pi ni on
shaf t s and
sl eeves.
'96
-
'97
model:
BACKUP RING
Repl ace.
Press the val ve oi l seal and rol l er beari ng
{' 96
-' 97
model ) or bushi ng
( ' 98
model l out of t he val ve
housi ng usi ng a hydr aul i c pr ess
and speci al t ool
shown bel ow.
NOTE: Do not use a hammer ; i t wi l l damage t he
speci al tool .
'96
-
'97
model:
PILOT COLLAR
07GAF
-
PH70100
31.
VALVE OIL SEAI-
Repl ace.
ROLLER BEARING
Bepl ace.
PILOT COLLAR
07GAF
-
PH701(x)
VALVE OIL SEAL
Repl ace.
BUSHING
Repl ace.
BALL BEARING
t , ,
17-54
Reassembly
NOTE:
. Cl ean the di sassembl ed parts wi th a sol vent, and dry them wi th compressed ai r. Do not di p the rubber parts i n a sol -
vent.
. Al ways repl ace the O-ri ngs and rubber seal s wi th new ones before assembl y,
. Appl y the recommended power steeri ng fl ui d to the pans.i ndi cated i n the assembl y procedures.
. Do not al l ow dust, di rt, or other forei gn materi al s to enter the power steeri ng system.
. Use the appropri ate speci al tool s where necessary.
CYLINDER LINE B
VALVE HOUSING
VALVE OIL SEAL
Replace.
FLARE NUTS
17 N m 11.7 kgt.m, 12 lbt.ft)
CYLINOER END SEAL
Replace.
CYLINDER END
63 N'm {7.0 kqf.m, 51 lbftll
BACKUP
Repl ace.
I
CYLINDER
Replace
-S-.-
BEARING
SLEEVE SEAL RINGS
.-.--------..--
S
--=-..--
",r"a,,
.o'S
RePIace
VALVE OIL SEAL .
Replace.
\
$<-----sueve
-.$}-S:"_------;T;i,',Tl"t',
- " - v >
itoilJoril."." ***t.----..--..-
valvE SEAL RING
wAvE wASHER
p
-_____
-;;oi;"*.
HouslNG
ll
----_
GEAR HOUSING
\ \ - - - - . - W - - - P t . t t o ' r s " n n
S, ----' 96-' 97
modol onl y:
S-- 32 mm SHIMS
'96
-
'97
mod6l only:
O.RING
Replace.
{cont' d)
17-55
CYLINDER LINE A
'98
modol:
Steering Gearbox
Reassembly
(cont'd)
Valvs Body Unit Rsassembly
1. Appl y vi nyl tape to the stepped porti on
of the pi n-
i on shaft, and coat the surface of the vi nvl taDe wi th
the power steeri ng fl ui d.
2. I nst al l t he backup r i ng
( ' 96 - ' 97
model ) or wave
washer
(' 98
model ) wi th i ts tapered si de as shown
3. Coat t he i nsi de sur f ace ot t he new val ve oi l seal
wi th power steeri ng fl ui d.
4. Sl i de the val ve oi l seal over the pi ni on
shaft, bei ng
careful not to damage the seal i ng l i p.
Vinyl tape
lStepped
ponion)
Tapered posi t i on.
EACKUP RING
Groove si de.
sure t he spri ng i s
seat ed i n t he oi l seal .
PINION SHAFT
mvewAsHERt
CAUTION: Instsllthe valve oit sealwhh its grooved
side facing opposite the bearing.
Appl y vi nyl tape to the spl i nes and stepped porti on
of the shaft, and coat the surface of the vi nyl tape
wi th the power
steeri ng fl ui d.
Fi t the new O-ri ng i n the groove of the pi ni on
shaft.
Then sl i de the new val ve seal ri ng over the shaft
and the groove i n on the pi ni on
shaft.
Remove the vi nyl tape from the pi ni on shaft.
'96
-
'97
modal:
S6aling
E
lip
t
7.
VALVE SEAL RING
Repl ace
Do not over-expand.
17- 56
8. Appl y power steeri ng fl ui d to the surface of the
val ve seal r i ng t hat was i nst al l ed on t he
pi ni on
shaft.
9. Appl y power
steeri ng fl ui d to the i nsi de of the spe-
ci al tool . Set th l arger di ameter end of the speci al
tool over the val ve seal ri ng.
10. Move the speci al tool up and down several ti mes to
make the val ve seal ri ng fi t i n the pi ni on
shaft.
11. Remove the speci al tool ,
12. Turn the speci al tool over, and setthe smal l erdi am-
eter end of the speci al tool over the val ve seal ri ng.
Move the speci al tool up and down several ti mes to
make t he val ve seal r i ng f i t snugl y i n t he pi ni on
shaft.
PISTON SEAL RING
SIZING TOOL
OTNAG
-
SR3G'OA
or
07NAG
-
SR3o900
(w(ffi
Use t he l ar ger di amet er
end of t he speci al
t ool f i r st t o make
t he val ve seal r i ng
f i t i n t he pi ni on
shaft.
Make t he val ve seal ri ng
f i t snugl y i n t he pi ni on
shaf t usi ng t he ot her end
(smal l er
di amet er end) of
t he speci al t ool .
Appl y power steeri ng fl ui d to the surface of the spe-
ci al tool . Set the new seal ri ngs over the speci al tool
f r om t he smal l er di amet er end of t he t ool . and
expand the seal ri ngs. Do two ri ngs at a ti me from
each end of the sl eeve.
NOTE:
. Do not over-expand the seal ri ng. Instal l the resi n
seal ri ngs wi th care so as not to damage them.
After i nstal l ati on. be sure to contract the seal
ri ngs usi ng the speci al tool
(si zi ng
tool ).
. There are two types of sl eeve seal ri ngs: bl ack
and brown. Do not mi x the di fferent types of
sl eeve seal ri ngs as they are not compati bl e.
Set the speci al tool i n the grooves i n the sl eeve, and
set each ri ng i n each groove securel y.
NOTE: After i nstal l ati on, compress the seal ri ngs
wi th your fi ngers temporari l y.
15. Appl y power steeri ng fl ui d ro the seal ri ngs on the
sl eeve, and to the enti re i nsi de surface of the spe-
ci al t ool .
16. Insert the sl eeve i nto the speci al tool sl owl y.
17, Move t he sl eeve each di r ect i on sever al t i mes t o
make the seal ri ngs snugl y fi t i n the sl eeve.
NOTE: Be sure ri ngs are not t urned up.
SLEEVE SEAL RING
SIZING TOOL
14.
)
t hat t he seal
fr
07974
-
SA5020A or
07974
-
SA50200
18, Appl y power steeri ng fl ui d to the surface of the pi n-
i on shaft. Assembl e the sl eeve over the
pi ni on shaft
by al i gni ng t he l ocat i ng pi n on t he i nsi de of t he
sl eeve wi th the cutout i n the shaft. Then i nstal l the
new ci rcl i p securel y i n the pi ni on shaft
groove.
NOTE:
o Be car ef ul not t o damage t he val ve seal r i ng
when i nserti ng the sl eeve.
.Instal l the ci rcl i p wi th i ts radi used si de toward the
sl eeve.
Appl y power steeri ng fl ui d to the seal ri ng l i p of the
val ve oi l seal , then i nstal l the seal i n the val ve hous-
i ng usi ng a hydr aul i c pr ess and speci al t ool s as
shown.
CAUTION: l nstal l the val ve oi l soal wi th i ts grooved
side facing the tool.
19.
ATTACHMENT,
3 2 x 3 5 mm
07746
-
0010100
VALVE OIL SEAL
Repl ace.
spr i ng i s i n t he
oi t seat .
{ cont . d)
17-57
Steering Gearbox
20.
Reassembly
(cont'd)
DRIVER
07749-0010000
Pr ess t he new bear i ng 1' 96
- ' 97
model ) or new
bushi ng
(' 98
model ) i nto the val ve housi ng usi ng a
hydraul i c press
and speci al tool as shown.
NOTE: Pl ace the rol l er beari ng
(' 96 -' 97
model ) or
bushi ng
(' 98
model ) on the val ve housi ng wi th the
st amped l et t er f aci ng
( ' 96 - ' 97
model onl y) up
towards the val ve si de.
Pres3
+
ATTACHMENT.
3 2 x 3 5 mm
077i16
-
0010100
'96
-
'97
model:
ROLLER BEARING
Letter stamped face
upward,
21. Appl y vi nyl tape to the pi ni on
shaft, then coat the
vi nyl tape wi th power
steeri ng fl ui d.
Sealing lip lace.
VALVE OIL SEAL
VALVE HOUSING
PINION
r
E
SLEEVE SEAL RI NGS
Repl ace.
Be sure t hat t he
sear f i ngs are not
t urned up, t hen
anst al l .
22. Insert the pi ni on shaft i nto the val ve housi ng.
CAUTION: Bo carotul not to damage the valve seal
ri n9s.
23. Remove the vi nyl tape from the
pi ni on shaft.
17- 58
24. Pr ess t he pi ni on
shaf t / sl eeve usi ng a hydr aul i c
press
as shown.
NOTE: Check t hat t he pi ni on
shaf t / sl eeve t ur ns
smoothl y by turni ng the pi ni on
shaft,
Steering Rack Roassembly
25. Coat the
pi ston seal ri ng
gui de wi th power steeri ng
fl ui d, then sl i de i t onto the rack, bi g end fi rst
26. Posi ti on the new O-ri ng and new pi ston seal ri ng on
the speci al tool , then sl i de them down toward the
bi g end of t he t ool .
NOTE:
. Do not over expand the resi n seal ri ngs. Instal l
the resi n seal ri ngs wi th care so as not to dam-
age them. After i nstal l ati on, be sure to contract
t he seal r i ng usi ng t he speci al t ool
( si zi ng
t ool )
. Repl ace the pi ston' s O-ri ng and seal ri ng as a set.
27. Pul l the O ri ng off i nto the pi ston groove, then pul l
the
pi ston seal ri ng off i nto the pi ston groove on top
of the O-ri ng.
I
PISTON SEAL RING
GUIDE
07GAG
-
SD,OloA or
07GAG
-
SDIO100
28.
29.
30.
O.RING
Replace
PISTON SEAL RING
Replace-
Coat the pi ston seal ri ng and the i nsi de of the spe-
ci al tool wi th
power steeri ng fl ui d
Careful l y sl i de the tool onto the rack and over the
pi ston seal ri ng.
Move the speci al tool back and forth several ti mes
to make the pi ston seal ri ng fi t snugl y i n the
pi ston.
PISTON
Repl ace.
r
E
PISTON
32.
33.
31. Wrap vi nyl tape around the rack teeth and rack end
edges. then coat the surface of the tape wi th the
power steeri ng fl ui d.
NOTE: Make sur e t hat t he vi nyl t ape i s wr apped
careful l v so that there i s no stepped
porti on.
Coat the i nsi de surface of the new cyl i nder end seal
Instal l the cyl i nder end seal onto the steeri ng rack
wi th i ts grooved si de toward the pi ston.
CAUTION: when i nsl al l i ng the cyl i nder ond seal .
be careful nol damago the seal i ng l i p face of the
seal with th edges or teeth of the steering rack.
Make sure t he
sPri ng i s i n t he cyl i nder
eno seal
Remove t he vi nyl t ape f rom t he st eeri ng rack
NOTE| Remove any resi due of t ape adhesi ve
(cont ' d)
CYLINDER END SEAL
Grooved srde.
34.
17-59
Steering Gearbox
Reassembly
(cont'd)
35. Instal l the new backup ri ng on the steeri ng rack.
then pl ace the cyl i nder end seal to pi ston.
Grease the steering rack teeth, then insert the steer-
i ng rack i nto the gear housi ng.
CAUTION: Be careful not to damage to inner sur-
faco ot tho cylinder housing with tho rack edgB.
36.
BACKUP RING
CYLINDER HOUSING
17-60
Pre33
Instal l the fl ange bol t i nto the end of the steeri ng
r ack unt i l i t bot t oms i n t he hol e. t hen back t he
f l ange bol t out 1/ 4 t ur n. Hol d t he f l ange bol t and
ti ghten the fl ange nut agai nst the rack by hand.
Instal l the cyl i nder end seal i nto the bottom of the
cyl i nder by pr essi ng on t he bol t wi t h a
pr ess
as
shown.
CAUTION: Do not push on the boft with sxcessive
lorca as it may damage tha cylinder nd seal.
12 x 175 mm FLANGE BOLT
(P/N
90177
-
SLo
-
0001
12 mm FLANGE NUT
40.
Remove t he f l ange bol t , and cent er t he st eer i ng
rack.
Wr ap vi nyl t ape ar ound t he r ack end edges. and
coat the surface of the tape wi th the power steeri ng
f l ui d.
NOTE: Make sur e t hat t he vi nyl t ape i s wr apped
carel ul l y so that there i s no stepped porti on.
41. Coat the i nsi de surface of the new cyl i nder end seal
Instal l the cyl i nder end seal onto the steeri ng rack
with its grooved side toward the
piston,
Push i n the cvl i nder end seal wi th
your fi nger.
CAUTION: Wh.n i rstal l i ng the cyl i ndsr ond 3eal ,
b6 csreful not damage the sealing face ol th seal
with the threads and burrs at the stakad
position of
the cylinder housing.
E
43.
CYLI NOER ENO SEAL
Repl ace.
Make sure t he spri ng
i s i n t he cyl i nder end seal
Staked
posr! on,
Grooved si de
CYLI NOER END
SEAL
44.
45.
Remove the vi nyl tape from the steeri ng rack.
NOTE: Remove any resi due of tape adhesi ve.
Hol d the steeri ng
gearbox usi ng a C-cl amp as shown.
GEARBOX
46. Coat t he i nsi de sur f ace of t he cyl i nder end wi t h
power steeri ng fl ui d, then i nstal l the cyl i nder end by
screwi ng i t i nto the cyl i nder housi ng
Remove the C-cl 8mp from the steeri ng
gearbox.
After ti ghteni ng the cyl i nder end, stake the poi nt of
t he cyl i nder housi ng shown bel ow. For ' 98 model
go to step 51.
NOTE: Stake the cyl i nder i n the
posi ti on opposi te
from where the stake was removed duri ng di sas-
sembl Y.
Stake poi nt. Depl h: 1.0 mm 10.0{ i nl
mm {0. 16 i n}
CYLINDEE END
CYLINDEB END
69 N.m {7.0 kgt m, 5l lbf.ft)
Be car ef ul not t o damage
t he bushi ng when i nseni ng
t he cyl i nder end.
49. Sel ect the 32 mm shi m(s)
(' 96 -' 97
model onl y).
NOTE: Onl y r ei nst al l t he or i gi nal 32 mm shi m( s)
when the steeri ng
gearbox i s reassembl ed wi thout
repl aci ng the
pi ni on shaft, val ve housi ng, and gear-
box housi ng wi th new ones.
l f t he
pi ni on shaf t , val ve housi ng, and gear box
housi ng are repl aced, sel ect the new shi ml s) as fol -
l ows.
Shim selestion:
a. Set the four 32 mm shi ms on the beari ng surface of
t he gear box housi ng. Tot al t hi ckness of t he t our
shi ms shoul d equal no more than 0,70 mm.
Shi m set: four 32 mm shi ms
(Thi ckness:
0,10 mm,
0.15 mm, 0,20 mm, 0.25 mm respecti vel y)
CAUTION; Tho four 32 mm shi ms do not havo
thickness identification ma1k3. Measuro iho thick-
nass of each shi m usi ng a mi cromster, and mark
the shim for identitication.
47.
48.
(cont' d)
17-61
Steering Gearbox
Reassembly
(cont'dl
l nst al l t he val ve body uni t on t he gear box, and
ti ghten the fl ange bol ts to the speci fi ed torque.
FLANGE BOLT
20 N. m {2. 0 kgt m, l 4l bf f t }
VALVE BODY UNI T
Measur e t he cl ear ance bet ween t he gear box and
val ve body uni t usi ng a feel er gauge as shown.
NOTE: Measure the cl earance at the
poi nt
mi dway
between the two mounti ng bol ts.
d. Det er mi ne t he r equi r ed t hi ckness of t he 32 mm
shi ms by subt r act i ng t he cl ear ance obt ai ned i n t he
step
"c"
from the total thi ckness of the four shi ms
( Tot al
t hi ckness of t he 4 shi ms)
- ( cl ear ance) =
Requi r ed t hi ckness of t he shi ms
NOTE: Sel ect the shi ms so that the total thi ckness
i s cl ose to, but l ess than, the requi red thi ckness.
g
[ ,
17-62
\
Exampl e:
l vl easurement i s 0.28 mm
(0.011
i n):
0. 70
- 0. 28
=
0. 42 mm
( 0. 028- 0. 011=0. 017 i n)
The sel ect ed shi ms shoul d be 0. 25 mm
( 0. 010
i n) and
0. 15 mm { 0. 006
i n} i n t hi ckness.
l f t he r equi r ed shi m t hi ckness i s 0. 10 mm or l ess, no
snrms are necessary.
50. Set the sel ected 32 mm shi ms on the beari ng sur-
face of the gearbox housi ng.
VE EODY UNIT
32 mm SHI MS
Coat the new O-ri ng wi th grease, and careful l y fi t i t
on the val ve housi ng.
Appl y grease to the needl e beari ng i n the
gearbox
housr ng.
Instal l the val ve body uni t on the gearbox housi ng
by engagi ng the gears.
NOTE: Note the val ve body uni t i nstal l ati on posi -
ti on
(di recti on
of l i ne connecti on).
Ti ghten rhe fl ange bol ts to the speci fi ed torque
O. RI NG
Repl ace.
-61
NEEDLE BEARI NG
--6'
56.
57.
59.
55. Instal l the cyl i nder l i nes A and B.
NOTE:
. Cl ean t he
j oi nt s
of t he cyl i nder l i nes A and B
thoroughl y. The
j oi nts
must be free of forei gn
materi al .
. Instal t the cvl i nder l i nes A and I by ti ghti ng the
fl are nuts by hand fi rst, then ti ghten the fl a.e
nuts to the speci fi ed torque.
Grease the sl i di ng surface of the rack
gui de, and
i nstal l i t onto the
gear housi ng.
'95
-
'97
model:
Appl y a thi n coat of
grease to the new O-ri ng, and
i nstal l i t on the rack gui de screw.
'98
model:
Remove the old sealant off of the threaded section,
then appl y new seal ant to the fi rct three threads.
Instal l the spri ng, rack gui de screw and l ocknut on
the gear housi ng.
Adj ust the rack gui de screw
(see page 17-33).
NOTE: After adj usti ng, check that the rack moves
smoothl y by sl i di ng the rack ri ght and l eft.
'96
-
.97
model:
RACK GUIDE
scREws
..-6ll
O.RING
Replace.
17 N. m {1. 7 kgl . m, 12l bt f t )
28 N.m {2.? kgf.m, 20 lbl.ft}
CYLINOER LINE B CYLINDER LINE A
LOCKNUTS
STEERING RACK
60. l nst al l t he new l ockwasher i n t he gr oove i n t he
steeri ng rack.
61. Screw each rack ends i nto the rack.
62. Hol d the steeri ng rack wi th a wrench
(' 98
model : l eft
end onl y), and ti ghten the rack ends.
CAUTION: Be careful not to damags tho rack sur-
facr whh the wrench,
NOTE:
' 96
-' 97
model i s shown
STEERING RACK END
5il N.m 15.5 kgf.m, 40 lbf'ft)
STEERING RACK
After ti ghteni ng the rack ends, stake the four sec-
ti ons of l ock washer wi th a dri ft and a mal l et.
Pl ace the wood bl ock on the
press
tabl e, then set
the l ock washer secti on of the rack end on the
wood bl ock securel y.
Be sure the tool i s al i gned wi th the fl at secti ons
of the steering rack end before
pressing.
Stake the l ock washer i n the centet of the fl at
secti on of the steeri ng rack end.
63.
NOTE: Thi s dri f t has a f l at ,
t o
prevent punct uri ng
{cont' d)
17-63
LOCK WASHER
WOODEN ELOCK
Steering Gearbox
Reassembly
(cont'd)
64. Appl y grease to the ci rcumference ot the rack end
housi ng.
Appl y a l i ght coat of si l i cone
gr ease t o t he boot
grooves on the rack ends.
l nst al l t he boot s i n t he r ack end wi t h t he t i e- r od
cl r ps.
NOTE: Instal l the boots wi th the rack i n the strai ght
ahead posi ti on (ri ght
and l eft ti e-rods are equal i n
l ength).
=_.
:!4AEn
SILICONE GREASE
65.
a-.
.:!!!!t!H
SILICONE GREASE
@
\
\
TIE-ROO
RACK END
17-64
69.
!'
67. Adj ust the ai r hose fi tti ng
posi ti on of the boots by
turni ng i t as shown bel ow.
LEFT BOOT
(Viewed from the
l ef t si de)
RIGHT BOOT
{Vi ewed
f rom t he
ri ght si de)
68.
AI8 HOSE FITTING
Instal l new boot bands on the boot, and bend both
sets of l ocki ng tabs.
CAUTION: Stake the band locking tabs firmly.
Li ghtl y tap on the doubl ed-over porti ons to reduce
t hei r hei ght .
Sl i de the rack ri ght and l eft to be certai n that the
boots are not deformed or twi sted.
71, Connect t he ai r t ube bet ween t he r i ght and l ef t
boot.
72. Instal l the cl i pspn the cyl i nder l i nes, then cl amp the
ai r tube wi th the cl i ps.
CYLINDER LINE A
CLIP
lnstallation
CAUTION: Be caletul not to bend or damag ths tood
line and cylinder linos when insialling tha
gearbox.
1. Before i nstal l i ng the
gearbox, sl i de the rack al l the
way to ri ght.
2. Instal l the mounti ng cushi on on the steeri ng gear-
oox.
3. Instal l the pi ni on shaft grommet, then i nsert the pi n-
i on shaft up through the bul khead.
NOTE: Al i gn the notch i n the
pi ni on shaft grommet
wi th the tab on l he val ve housi ng.
I nst al l t he mount i ng br acket over t he mount i ng
cushi on, then i nstal l two gearbox mounti ng bol ts.
MOUNTING BRACKET
{4.0 kgf.m, 29 lbl ft)
NOTE: I nst al l t he br acket
wi t h t he ar r ow poi nt i ng
(cont' d)
17-65
Steering Gearbox
Installation (cont'd)
l nst al l t he st i f t ener pl at e wi t h t he t wo gear box
mounti ng bol ts and sti ffener pl ate
attachi ng bol ts.
CAUTION: Be sure the ai r tube i s not caught ol
pinched by stiftener plate.
NOTE: I nst al l t he bol t s l oosel y f i r st , t hen t i ght en
them securel y.
STIFFENER PLATE
ATTACHING EOLTS
38 N.m
(3.9
kg,f.m.28 lbl.ftl
GEARBOX MOUNTING BOLTS
,
N.m
({.4
ksl.m, 32 lbl.fr}
Instal l the return hose
j oi nt
by ti ghteni ng the l 6 mm
fl are nut.
Connect the return hose securel y, and ti ghten the
adj ust abl e hose cl amp f r om t he engi ne compar t -
ment.
Connect the feed l j ne and ti ghten the 14 mm fl are
nut.
NOTE: Make sur e t hat t her e i s no i nt er f er ence
between the fl ui d l i nes, the rear beam or any other
pans.
8.
1.
ADJUSTAELE HOSE
CLAMP
(see page 17-39i
15 mm FLARE NUT
28 N.m {2.7 kgf.m. 20 lbtft)
FETURN HOSE
1{ mm FLARE NUT
37 N.m
(3.8
kgtm,27 lbf.tt)
17-66
9.
10.
Center the steeri ng rack wi thi n i ts stroke.
Sl i p the l ower end of the steeri ng j oi nt
onto the pi n-
i on shaf t
( l i ne
up t he bol t hol e wi t h t he gr oove
around the shaft), and ti ghten the l ower bol t.
NOTE:
.
Connect the steeri ng shaft and pi ni on wi th the
cabl e reel and steeri ng rack centered.
Be sure that the l ower steeri ng
j oi nt
bol t i s securel y
i n the groove
i n the steeri ng gearbox pi ni on.
l f the steeri ng wheel and rack are not centered.
r eposi t i on t he ser r at i ons at l ower end of t he
steeri ng
j oi nt.
\
STEERING JOINT
LOWER BOLT
22 N.m
(2.2
kgf.m, 16 lbl.ft)
' I
1. Center the cabl e reel by fi rst rotati ng i t cl ockwi se
unt i l i t st ops. Then r ot at e i t count er cl ockwi se
(approxi matel y
two turns) unti l the arrow mark on
the l abel poi nts
strai ght up. Rei nstal l the steeri ng
wheel (see page 17-35).
STEERING JOINT
12. Instal l the steeri ng
j oi nt
cover wi th the cl amps and a
cl i p.
Reconnect the ti e-rod ends to the steeri ng knuckl es,
ti ghten the castl e nut
(' 96
-' 97
model ) or nut {' 98
model ) to the speci fi ed torque, and i nstal l new cotter
prns.
NOTE: Before connecting the tie-rod ends, wipe off
any grease contami nati on from the bal l
j oi nt
tapered
secti on and threads.
CAUTION: Torque the castle nut to the lower torque
specification, thn tighten it only far enough to align
the slot whh the
pin hole. Do not align the nut by
looeening
('96 -
,97
modd onlyl.
COTTER PINS
Repl ace.
On reassembl y, bend
t he cot t er
pi n
as shown.
CASTLE NUT
,+0 - ,18
N'm
14.0
-
4.8 kgt'm,
29
-
35 lbf.fr)
NUT
il,l N.m
( 4. 5
kgl ' m, 33 l bf f r l
NE.ROD ENO
14.
17.
15.
Instal l the exhaust
pi pe A or TWC
(see
secti on 9).
Connect the shi ft l i nkage {see secti on l 3 or secti on
14) .
l nstal l the front wheel s.
Fi l l the system wi th power steeri ng fl ui d. and bl eed
ai r from the system
(see page 17-33).
After i nstal l ati on.
perform the fol l owi ng checks,
. St ar t t he engi ne, al l ow i t t o i dl e, and t ur n t he
steeri ng wheel from l ock-tol ock several ti mes to
warm up the tl ui d. Chck the
gearbox for l esks
(see page 17-39).
. Adj ust the tront toe
(see
secti on 18),
. Check the steeri ng wheel spoke angl e. Adj ust by
turni ng the ri ght and l eft ti e-rods, i f necessary.
NOTE: Turn the ri ght and l eft ti e-rods equsl l y.
18.
17-67
Bal l
j oi nt
Boot Repl acement
'96
-
'97
modol:
L Remove the boot set ri ng and the boot.
GAUTION: Do not contami nate the boot i nstal l a-
tion section with gtease.
Pack the i nteri or of the boot and l i p wi th grease.
Wi pe the grease
off the sl i di ng surface of the bal l
pi n,
then pack the l ower area wi th fresh grease.
CAUTION:
. Keep grsase
off th6 boot installation section and
the tapered s6stion ot the ball pin.
. Do nol allow dust. dirt, or othar foteign matori-
2.
3.
als to enter the boot.
LIP BALL PIN TAPERED
SECTION
Wi pe of f t he grease.
BOOT INSTALLATION
SECTION
Wi pe of f t he grease.
SECTION
Wi pe of f t he
grease-
Instal l the boot i n the groove of the boot i nstal l ati on
secti on securel v, then bl eed the ai r from the boot.
i
f '
r
4.
ADJUSTING BOLT
Adj ust t he dept h
by t urni ng t he bol t .
SET RING
Adj ust the speci al tool wi th the adj usti ng bol r unti l
the end of the tool al i gns wi th the groove
on the
boot. Sl i de the set ri ng over the tool and i nto posi -
I r on.
CAUTION: After installing tho boot, chock the batt
pin taprod section tor gtsase contamination and
wipo il if necess8ry.
17-68
'98
modol:
CAUTION: Do not contaminate tho boot instsllation sec.
tion with grease.
1. Remove the boot from the ti e-rod end, and wi oe the
ol d grease off the bal l pi n,
2. Pack the l ower area ofthe bal l pi n wi th fresh grease.
3. Pack the i nteri or of the new boot and l i D wi th fresh
grease.
GAUTION:
. Kep grgase offtha boot installation soction and
lhe tapered soction if the batl pin.
. Do not allow dust, dirt. or othor foroign materials
to enter ths boot,
BOOT INSTALI."A
sEcnoN
Wipe offthe grease.
Instal l the new boot usi ng the speci al tool as shown
oerow,
NOTE: The boot must not be a gap at the boot instaf
lation sections.
\
CAUTION: Aftr installing the
pin taperod sgction for grase
wipo it il nocessary.
FRONT HUB
DIS/ASSEMBLY IOOL
0796s
-
SA5o500
, . . , '
^'
, ; i
.
-,.-.:.-
boot, chock the ball
contamination, and
Suspensi on
Speci af Toof s . . . . . . . . . . . . . 18-2
Component Locations
l ndex . . . . . . . . . . . . . . . . . . . . . . 18' 3
Wheel Alignment
Cast er , . . . . . . . . . . . . . .
. . . , , , 18' 4
Camber
. . . . . . . . . . . . . . . . . . 18-4
Front Toe Inspection/
Adi ust ment
. . . . . . ' . 18-5
Rear Toe Inspection/
Adiustment ........ 18-5
Turni ng Angl e I nspect i on . . . . . . . . . . . . . . . ' 18-6
Wheel/Hub Inspection
Beari ng End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . "" 1a' 7
Wheel Runout
....... 18-7
Front Suspension
Suspension Arms Replacement ..... 18-8
Knuckl e/ Hub Repl acement . . ' . . . . . . . ' . ' 18-9
Lower Ball Joint Replacement ....... 18-15
Ball Joint Boot Replacement .......... 18-16
Front Damper
Removal
. . . . . . . . . . . . . . . . . 18-16
Disassembly/lnspection
........' .... "..' 1A-17
Reassembl y
. . . . . . . . . . . 18-18
I nst al l at i on . . . . . . . . . . . . . 18-18
Rear Suspension
Suspension Arms Replacement ..... 18-20
Hub Bearing Unit Replacement ...... 18-21
Upper Arm Bushing Replacement . 18-22
Rear Damper
Removal
. . . . . . . . . . . . . . . . . t 8-23
Disassembf
y/lnspection .............. ".' 18' 24
Reassembly
........... 18' 25
Installation ............. 18-26
1
Speci al Tool s
Ref. No. Tool Number Description Oty Page Reterence
o
@
at\
@
!o,
o
@
6l
@
o
@
@
@
07GAF
-
SE00200
07GAF
-
SE00401
07GAG
-
SD40700
07JAF
-
SH20110
OTJAF SH2O120
07JAF
-
SH20200
0TiilAC
-
S100200
07746
-
0010500
07749
-
0010000
07947
-
6340201
07965
-
S800100
07965
-
S800200
07965
-
SD90100
07974
-
SA50700
Hub Assembl y Gui de Attachment
Hub Di s/Assembl y Base
Bal l Joi nt Boot Cl i p Gui de
Hub Di s/Assembl y Pi l ot, 38 mm
Hub Di s/Assembl y Shatr,22.4 x25.4 mm
Bal l Joi nt Remover Base
Bal l Joi nt Remover , 28 mm
Dri ver
Dri ver Attachment
Bal l Joi nt Remover/l nstal l er
Bal l Joi nt l nst al l er Base
Support Base
Bal l Joi nt Boot Cl i p G ui de
1
'I
1
I
1
1
1
1
I
1
1
1
1
1
18- 14
18- 13
18- 16
' 18-
13
18- 13
18- 15
18- 1
' 1,
18- 13
18- 13
18- 14
18- 15
18- 14
1 e 1 R
1 2
1 6
o o.(} o
@, @
@ @
8-2
Component Locations
Index
Wheel Al i gnment , page 18-4
FRONT DAMPER
'
Removal ,
page 18-16
.
Di sassembl y/ l nspect i on,
page' 18' 17
.
Reassembl y, page 18 18
.
l nst al l at i on, page 18' 18
KNUCKLE/ HUB
.
Repl acement ,
page 18 9
Front SusDension:
Rear Suspensi on:
TRAILING ARM
.
UPPER ARM
.
Repl acement ,
page 18-8
.
Wheel Beari ng Repl acement ,
page 18. 13
.
Lower Eal l Joi nt Repl acement , page 18- ' 15
STABILIZER BAR
.
Repl acement ,
page 18-8
LOWER ARM
.
Repl acement ,
page 18-8
UPPER ARM
'
LOWER ARM
.
REAB DAMPER
'
Removal , page 18 23
.
Di sassembl y/ l nspect i on,
page 18-24
.
Reassembl y,
page 18-25
.
I nst al l at i on,
page 18-26
.
Repl acement , page 18 20
18- 3
Wheel Al i gnment
Caster
NOTE| For proper i nspecti on/adj ustment of the wheel
al i gnment check and adj ust the fol l owi ng before check-
i ng the al i gnment.
. Check that the suspensi on i s not modi fi ed.
. Check the ti re si ze and ti re pressure.
. Check the runout of the wheel s and ti res.
. Check the suspensi on bal l
j oi nts. (Hol d
a wheel wi th
your hands and move i t up and down and ri ght and
l eft to check for wobbl i ng.)
Inspection
NOTE: Use commer ci al l y- avai l abl e comput er i zed f our
wheel al i gnment equi pment t o measur e wheel al i gn-
ment
( cast er ,
camber , t oe, and t ur ni ng angl e) . Fol l ow
the equi pment manufacturer' s i nstructi ons,
1. Check the caster angl e.
Caster angl e: 1"40' t 1"
2. l f out of speci fi cati on, check for bent or damaged
suspensron componenrs.
D=r$*
18-4
Camber
Inspection
ment
( cast er ,
the equi pment manufacturer' s i nstructi ons.
1. Check the camber angl e.
Camb6r angl e:
Front: 0'00' I 1'
Rear :
-
1" 11'
2. l f out of speci fi cati on, check for bent or damaged
suspensi on components.
Front Toe Inspection/Adjustment
ment
( cast er ,
' 1.
Check the ti re pressure.
2. Center steeri ng wheel spokes.
3, Check t he t oe wi t h t he wheel s poi nt ed st r ai ght
ahead.
Front toe: l N 1 t 2 mm
(l N
1/16l : 1/16 i n)
-
l f adj ustment i s requi red, go on to step 4.
-
l f no adj ustment i s requi red. remove al i gnment
equi pment .
4. Loosen the ti e-rod l ocknuts, and turn both ti e-rods
i n the same di recti on unti l the front wheel s are i n
strai ght ahead
posi ti on.
TIE.ROD LOCKNUT
14 x 1. 5 mm
Turn both ti e-rods equal l y unti l the toe readi ng on
the turni ng radi us gauge i s correct.
After adj usti ng, ti ghten the ti e-rod l ocknuts.
NOTE: Reposi ti on the ti e-rod boot i f i t i s twi sted or
di spl aced.
{,1 N.m
(,1.5
kgt m, 33 lbtftl
Rear Toe Inspection/Adjustment
ment
( cast er ,
1. Rel ease parki ng brake.
NOTE:
. Measur e di f f er ence i n t oe measur ement s wi t h
the wheel s poi nted strai ght ahead.
. l f the
parki ng brake i s engaged. you may get an
i ncorrect readi ng.
Rear toe-i n: 2 1i mm ttl te:l j l 8 i nt
-
l f adj ustment i s requi red, go to step 2.
-
l f no adj ustment i s requi red, remove al i gnment
equi pment .
Before adj ustment, note the l ocati ons of adj usti ng
bol ts on the ri ght and l eft compensator arms.
Loosen the adj usti ng bol ts. and sl i de the compen-
sator arm i n or out, as shown, to adj ust the toe.
ADJUSTING BOLT
10 x 1. 25 mm
IN
COMPENSATOR
ARM
4. Ti ghten the adj usti ng bol ts.
. Exampl e:
Af t er t he r ear t oe i nspect i on, t he wheel i s 2 mm
(0.08
i n) out of the speci fi cati on.
-
Move t he ar m so t he adj ust i ng bol t moves 2 mm
(0.08
i n) i nward from the posi ti on recorded before the
adj ustment.
-
The di stance the adj usti ng bol t i s moved shoul d be
equal to the amount out-of-speci fi cati on.
64 N.m {6.5 kgt.m. 47 lbtftl
18- 5
Wheel Al i gnment
Turni ng Angl e Inspecti on
ment
( cast er ,
the eoui Dment manufacturer' s i nstructi ons.
1. Tur n t he wheel r i ght and l ef t whi l e appl yi ng t he
b r a k e , a n d me a s u r e t h e t u r n i n g a n g l e o f b o t h
wheel s.
Turni ng angl e:
lnward wheel: 39"50'
Outward wheol lreferencel: 33"10'
2. l f t he t ur ni ng angl e
check f or bent or
nenrs.
i s not wi thi n the speci fi cati ons,
damaged suspensi on compo-
18- 6
Wheel /Hub Inspecti on
Beari ng End Pl ay
1. Rai se the vehi cl e off the ground. and support i t wi th
safety stands i n the proper l ocati ons
(see
secti on 1).
2. Remove the wheel s, then rei nstal l the wheel nuts.
3. Aftach the di al gauge as shown.
4. l Measure the beari ng end pl ay by movi ng the di sc i n
or outward.
Front/Rear:
Standsrd:0
-
0.05 mm {0
-
0.002 i nl
i
Measure end pl ay at cent er o{
t he hub cap.
l f t he beari ng end pl ay measurement i s
t he st andar d, r epl ace t he wheel bear i ng.
mor e t han
I
1 .
Wheel Runout
Rai se the vehi cl e off the ground, and suppon i t wj th
safety stands i n the proper l ocati ons
(see
secti on 1).
Check for bent or deformed wheel s.
Attach the di al gauge as shown.
Measure the wheel runout by turni ng the wheel .
Front and Rar wheel Axial Runout:
Stand8rd:
Steel Wheel: 0
-
1.0 mm
(0 -
0.0/t inl
Al umi num wheel : 0
-
0.7 mm {0
-
0.03 i n)
3.
Service Limit: 2.0 mm 10.08 i nl
Front and Rear Wheel Radial Runout'
Standard:
Steel Wheel : 0
-
1.0 mm
(0 -
0.0/t i nl
Al umi num Wheel : 0
-
0.7 mm
(0 -
0.03 i n)
(0.06
i nl
more than the servi ce l i mi t,
5. l f the wheel runout i s
repl ace the wheel .
18-7
Front Suspensi on
Suspensi on Arms Repl acement
CAUTION:
. Replace tho selt-locking nuts after removal.
. The vehicle should be on the ground betore any bolts or nuts connected to rubber mounts or bushings are tightened.
NOTE:
. Wi pe off any di rt, oi l from grease on the threads before ti ghteni ng the fasteners.
. The ri ght and l eft damper forks are not i nterchangeabl e. The l eft damper fork i s marked wi th
"AL"
whi l e the ri ght
damper tork i s marked wi th
"AR
.
. The ri ght and l eft upper arms are not i nterchangeabl e. The l eft upper arm i s marked wi th
"SO1-L"
whi l e the ri ght arm
i s mar ked wi t h
" SO1- R" .
. Before ti ghteni ng the upper and l ower mounti ng nuts on the stabi l i zer l i nk, adj ust the l ocati on of the l i nk wi th the sus-
pensi on under vehi cl e l oad.
. When i nstal l i ng the radi us arm washers, the
"FR"
mark faces the front of the vehi cl e.
. After i nstal l i ng the suspensi on arm, check the front wheel al i gnment, and adj ust i f necessary
(see page 18 4).
STABILIZER
BUSHI NG
UPPER ARM
Check t he bushi ng f or det eri orat i on and damage.
FLANGE BOLTS
10 x 1. 25 mm
54 N.m {5.5 kgl.m,
40 tbf.ft)
STABILIZER BAR
Al i gn t he st abi l i zer mark
wi t h end of st abi l i zer bushi
STABILIZER END
BALL JOINT BOOT
.
Check f or det er i or at i on and damage.
.
See page 18 16 f or boot r epl acement .
RUBBER BUSHI NG
Check f or det eri orat i on
ano oamage,
FLANGE BOLT
l i l x' 1. 5 mm
103 N. m 110. 5 kgt m,
\
76l bf f t l
\
STABILIZER BAR
Check f or bendi ng and damage.
FLANGE BOLT
8 x 1. 25 mm
22 N.m 12.2 kgt.m,
16 tbf.ftl
LOWER ARM
RUBBER BUSHI NG
.
ano oamage.
14 x 1. 5 mm
Repl ace-
83 N.m 18.5 kg{.m, 61 lbtft}
14 x 1. 5 mm
89 N. m
(9. 1
kgf . m, 66 l bf f t )
SILICONE GREASE
RUBBER BUSHI NGS
SELF-LOCKING NUT 8 x 1.25 mm
22 N.m
(2.2
kgl.m, 16 lbf.ft)
Repl ace.
SILICONE GREASE
SELF-LOCKING NUT
12 x' 1. 25 mm
Repl ace.
64 N.m
(6.5
kgf.m, {7 lbnft}
FLANGE BOLT
10 x 1. 25 mm
i|i} N'm 14.4 kgl'm.
32 rbf ft)
RUBBER BUSHI NG
.
Check f or det eri orat i on and damage
STABI LI ZER END RUBBER BUSHI NGS
Not e t he di rect i on
ot t he bushi ngs.
18- 8
Knuckl e/Hub Repl acement
CAUTION:
. Replace the selt-locking nuts after removal.
. The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened.
. Torque the castle nut to the lower torque specification, then tighten it only far enough to slign the slot with the pin
hol e. Do not al i gn the nut by l ooseni ng.
NOTE:
. Use onl y genui ne Honda wheel wei ghts for al umi num wheel s. Non-genui ne wheel wei ghts may corrode and damage
t he al umi num wheel s.
. On the al umi num wheel s, remove the center cap from the i nsi de of the wheel after removi ng thewheel .
o Before i nstal l i ng the brake di sc, cl ean the mati ng surfaces of the front hub and brake di sc.
. Before i nstal l i ng the wheel , cl ean the mati ng surfaces of the brake di sc and wheel .
. Wi pe off the grease before ti ghteni ng the nut at the bal l j oi nt.
CALIPER MOUNTING BOLT
12x 1. 25 mm
108 N. m
(11. 0
kgt m, 80 l bnf t l
CASTLE NUT
10 x 1. 25 mm
39
-
47 N.m 14.0
-
4.8 kgf.m, 29
-
35 lbtft)
COTTER PIN
Repl ace.
WI{EEL BEARING
Repl ace.
GUARO
CIRCLIP
I nspect f or f aul t y
movement and wear.
Repl acement ,
page 18 15
LOWER BALL
BALL JOINT BOOT
ERAKE DISC
SCREW
5 x 0 . 8 mm
4. 9 N. m {0. 5 kgt m. 3. 6l b{. f t l
SET
COTTER PIN
Repl ace.
FRONT HU8
Check f or damage 6nd
Repl acement ,
page l 8- 10
ano oamage.
CASTLE NUT
12 x 1. 25 mm
49
-
59 N m 15.0
-
6.0 kgf m, 36
- iB lbf.ft)
SPINDLE NUT
22 x 1. 5 mm
181 N.m 118.5 kgt.m, 134lbf.tt)
Repl ace.
NOTE:
.
Bet ore i nst al l i ng t he spi ndl e nut , appl y
engi ne oi l t o t he seat i ng surf ace of t he nut .
.
Af t ert i ght eni ng, use a dri f t t o st aket he
spi ndl e nut shoul der agai nst t he dri veshaf t .
Check f or wear and
rust.
Repl acement , page' 18' 10
I nspect aon, sect i on 19,
WHEEL NUT
12 x 1. 5 mm
't08
N.m
{11. 0 ksf . m, 80 l bf . f t )
6 mm BRAKE DISC RETAINING SCREW
9. 8 N. m 11. 0 ksf m, 7 l bt f t )
{cont' d)
18- 9
Front Suspension
Knuckle/Hub Replacement
{cont'd}
1 . Loosen the wheel nuts sl i ghtl y.
Raise the front of vehicle, and support it with safety
stands in the proper locations
(see
section 1).
Remove the wheel nuts and wheel .
WHEEL NUT
108 N. m
{11 kgt m. 80 l bf . f t l
2.
3.
5.
181 N. m {r8. 5 kgf . m, 134l bt f t )
Repl ace.
NOTE: Bef ore i nst al l i ng t he spi ndl e nut , appl y
engi ne oi l t o t he seat i ng surf ace of t he nut . At t er
t i ght eni ng, use a dri t t t o st ake t he spi ndl e nut
shoul der agai nst t he dri veshaf t
Rai se t he l ocki ng t ab on t he spi ndl e nut , t hen remove
t he nut .
Remove t he brake hose mount i ng bol t s.
BMKE HOSE MOUNNNG BOLT
8 x 1. 25 mm
Remove t he cal i per mount i ng bol t s and hang t he
cal i per assembl v to one si de.
CAUTION; To prevent acci dental damage to th
caliper assembly or brake hose, use a short piece ot
wire to hang the caliper from the undercarriage.
6.
'+
SPINDI.f NUT
12 N.m 11.2 ksI.m,8.7 lbtftl
CAI-IPER MOUNTING BOLTS
12 x 1. 25 mm
108 N. m
(11. 0
kgf . m, 80 l bl . f t )
1 8 - 1 0
7. Remove the 6 mm brake di sc retai ni ng screws.
8 x 1.25 mm BOLTS
8. Screw two 8 x 1.25 mm bol ts i nto the di sc to push i t
away from the hub.
NOTE: Turn each bol t two turns at a ti me to prevent
cocki ng the di sc excessi vel y.
Remove the brake di sc from the knuckl e.
Check the front hub for damage and cracks.
Remove the wheel sensor from the knuckl e
(for
cars
wi th ABS).
9.
10.
6 mm BRAKE DISC
RETAINING SCREWS
9.8 N.m ll.0 kgl.m, 7 lbf.ft)
9. 8 N. m
{1. 0 kgf . m,
7 rbr.ft)
' t1.
NOTE: Do not di sconnect the wheel sensor connec-
ror.
MOUNTI NG
BOLTS
9. 8 N. m
11. 0 kgf . m, 7 l bf . f t l
NOTE: Use the speci al tool to separate the bal l
i oi nts
from the suspensi on or steeri ng arm
CAUTION: Be careful not to damage the ball
ioint
boot.
13.
12.
14.
CASTLE NUT
10 x 1. 25 mm
39
-
47 N.m
(4.0 -
4.8 kgf.m,
COTTER.PIN
Repl ace.
On reassembl y,
bend t he cot t er pi n
';"
.
CASTLE NUT
Cl ean any di rt or grease off the bal l
j oi nt.
Remove the cotter pi n from the steeri ng arm and
remove the nut.
Appl y grease to the speci al tool on the areas shown.
Thi s wi l l ease i nst al l at i on of t he t ool and pr event
damage to the pressure bol t threads.
PRESSURE BOLT
j oi nt .
Be sur e
j oi nt pi n end to
pr event damage t o t he t hr eaded end of t he bal l
Jornt.
I nst al l t he speci al t ool as shown. I nser t t he
j aws
careful l y, maki ng sure you do not damage the bal l
j oi nt
boot . Adj ust t he
j aw
spaci ng by t ur ni ng t he
pressure bol t.
NOTE: l f necessar y, appl y penet r at i ng t ype l ubr i -
cant to l oosen the bal l
j oi nt.
xei ruur
BALL JOINT REMOVER, 28 mm
07MAC
-
SL00200
Repl ace.
18- 1 1
17. Once the speci al tool i s i n pl ace, turn the adj usti ng
bol t as necessary to make the
j aws paral l el . Then
hand- t i ght en t he pr essur e bol t , and r echeck t he
j aws
to make sure they are sti l l
paral l el .
ADJUSTING BOLT
NOTE: After maki ng the adj ustment to the adj ust-
i ng bol t, be sure the head of the adj usti ng bol t i s i n
thi s posi ti on to the al l ow the
j aw
to
pi vot.
18. Wi th a wrench, ti ghten the pressure bol t unti l the
bal l j oi nt shaft pops l oose from the steeri ng arm.
@
wear eye protecti on. The bal l
i oi nt
can break loose suddenly and scatter dirt or other
deblis in your eyes,
19. Remove the tool , then remove the nut {rom the end
of t he bal l
j oi nt
and pul l t he bal l
j oi nt
out of t he
steeri ng/suspensi on arm. Inspect the bal l
j oi nt
boot
and repl ace i t i f damaged.
{cont' d)
Front Suspension
{cont' dl
20. Remove the cotter pi n from the l ower arm bal l
j oi nt
castl e nut, and remove the nut.
COTTER.PIN
Repl ace.
On reassembl y,
bend t he cot t er
pi n
CASTLE NUT
12 x 1. 25 mn
49
-
59 N.m {5.0
-
6.0 kgf.m, 36
- /H
lbtftl
CASTI-E NUT
12 x 1. 8 mm
BALL JOINT REMOVER, 28 mm
07MAC
-
5100200
21.
22.
j oi nt .
Be sur e
j oi nt pi n end,
or the threaded secti on of the bal l
j oi nt pi n mi ght be
damaged by the bal l
j oi nt
remover.
Use the speci al tool as shown on page 18- 11 to sep-
arate the bal l
j oi nt
and l ower arm.
NOTE: l f necessar y, appl y penet r at i ng t ype l ubr i -
cant t o l oosen t he bal l j oi nt .
I
18-12
23. Remove the cotter pi n from the upper bal l
j oi nt
cas-
tl e nut. and remove the nut.
12 mm HEX NUT
Instal l the 12 mm hex nut on the bal l
j oi nt.
Be sure that the hex nut i s fl ush wi th the bal l
j oi nt
pi n end, or the threaded secti on of the bal l
j oi nt pi n
mi ght be damaged by the bal l
j oi nt
remover.
Use the speci al tool as shown on page 18-11 to sep-
arate the bal l
j oi nt
and knuckl e.
NOTE: l f necessary. appl y penetrati ng type l ubri -
cant to l oosen the bal l
j oi nt.
Pul l the knuckl e outward and remove the dri veshaft
outboard
j oi nt
from the knuckl e by tappi ng the dri ve-
shaft end wi th a pl asti c hammer, then remove the
knuckl e.
KNUCKLE
Check for damage.
24.
26.
12 x 1. 25 mm
39
-
47 N.m
{4.0
-
4.8 kgt m,
29
-
35 tbtft)
NOTE: Replace the bearing with a new one after removal.
27. Separate the hub from the knuckl e usi ng the speci al
tool s and a hvdraul i c
press.
CAUTION:
. Take care not lo disto.t the splash guard.
. Hold onto lhe hub to keep it from falling when
preised clear.
a To prevenl damage to the tool. make Sure ihe
threads are fully engaged before
pressing.
KNUCKLE
Remove the ci rcl i p and the
knuckl e.
HUB DI S/ ASSEMBLY
PILOT, 38 mm
07JAF
-
SH20r 10
HU8 DI S/ ASSEMELY
SHAFT. 22. 4 x 25. 4 mm
07JAF
-
SH20120
spl ash
guard from the
29. Pr esst hewheel bear i ng out of t he knuckl e usi ngt he
soeci al tool s and a
press
as shown.
DRIVER
07749
-
00'10000
Press
+
KNUCKLE
ATTACHMENT,
6 2 x 6 8 mm
07746
-
0010500
l
I
HUB DIS/ASSEMBLY BASE
07GAF
-
SE0040r
30. Pr ess t he wheel bear i ng
usi ng the speci al tool s, a
press as shown,
WHEEL BEARING
Repl ace.
i nner r ace f r om t he hub
beari ng separat or, and a
BEABING
SEPARATOR
0
-
1112 i n.
(Commerci al l y avai l abl e)
HUB DIS/ASSEMBLY
PILOT, 38 mm
07JAF
-
SH20110
Pres3
I
HUB DI S/ ASSEMBLY
SHAFT, 22. 4 x 25. 4 mm
07JAF
-
SH20120
(cont' d)
j
l
l
18- 13
Front Suspension
(cont' d)
NOTE: Wash t he knuckl e and hub t hor oughl y i n
hi gh fl ash poi nt sol vent before reassembl y.
Press a new wheel beari ng i nto the knuckl e usi ng
the speci al tool s and a
press
as shown.
NOTE: Pl ace the wheel beari ng on the knuckl e wi th
the Dack seal
(metal
col or) toward the i nsi de. Be
careful not to damage the sl eeve of the pack seal .
Press
ATTACHMENT
5 8 x 7 2 mm
07947
-
6340201
HANDLE
o7749
-
DRIVER
WHEEL
BEARING
.,
OOUBLE LIP SEAL
IBLACK COLOR)
I
I
I
KNUCKLE
SUPPORT BASE
07965
-
SO90100
32. Instal l the ci rcl i p securel y i n the knuckl e groove.
33. Instal l the spl ash guard and ti ghten the screws.
scREws
4.9 N.m
(0.5
kgf.m, 4l btft)
*_l
18-14
,:1S
34. Instal l the hub on the knuckl e usi ng the speci al tool s
shown and a hvdraul i c Dress as shown.
CAUTION: Take care not to distort the splash
guard.
HUB/ASSEMBLY
GUIDE ATTACHMET'rT
07cAF
-
SEqt200
35.
FRONT HUB
SPLASH GUARD
l nstal l the knuckl e i n the reverse order of removal ,
and pay parti cul ar attenti on to the fol l owi ng i tems:
Be car ef ul not t o damage t he bal l
j oi nt
boot s
when i nstal l i ng the knuckl e.
Torque al l mounti ng hardware to the speci fi ed
t or que val ues.
Torque the castl e nuts to the l ower torque speci -
fi cati ons. then ti ghten them onl y far enough to
al i gn the sl ot wi th the pi n hol e, Do not al i gn the
castl e nut by l ooseni ng,
Instal l new cotter pi ns on the castl e nuts after
t or qui ng.
Avoi d twi sti ng the sensor wi res when i nstal l i ng
the wheel sensor.
Before i nstal l i ng the brake di sc, cl ean the mati ng
surfaces of the front hub and the i nsi de of the
brake di sc.
Before i nstal l i ng the wheel , cl ean the mati ng sur-
face of the brake di sc and the i nsi de of the wheel .
Check the l ront wheql i al i gnment, and adj ust i t i f
necessary {see
page {S0.
2.
3.
Lower Bal l Joi nt Repl acement
1 . Remove the knuckl e
(see page 18 10).
Remove the boot by
pryi ng the set ri ng off.
Chec k t he boot f or det er i or at i on and damage,
repl ace i f necessary.
I nst al l t he speci al t ool s on t he bal l
i oi nt
and t i ght en
the castl e nut.
Posi t i on t he speci al t ool s over
shown, then set the assembl y an
bal l
j oi nt
out of the knuckl e.
SALL JOINT REMOVER/INSTALLER
t he bal l
j oi nt
as
a vi se. Press the
07965
-
5800100
CASTLE NUT
5.
(
- -
6.
7.
BALL JOINT REMOVER BASE
07JAF
-
SH20200
Pl ace t he bal l
j oi nt
i n posi t i on by hand.
I nst al l t he speci al t ool s over t he bal l
j oi nt
as shown,
t hen
pr ess t he bal l
j oi nt
i n.
BALL JOINT INSTALLER BASE
BALL JOINT REMOVER/
INSTALLER
07965
-
5800100
BALL JOINT HOUSING SURFACE
8. Instal l the bal l
j oi nt
boot and set ri ng usi ng the spe
ci al t ool
( see page 18- 16) .
ADJUSTING BOLT
Adj ! st t he dept h by
t urni ng t he bol t .
9. Instal l the knuckl e i n the reverse order of removal ,
and pay parti cul ar aftenti on to the fol l owi ng i tems:
. Be car ef ul not t o damage t he bal l
i oi nt
boot s
when i nst al l i ng t he knuckl e.
r Torque al l mounti ng hardware to the speci fi ed
torque val ues.
. Torque the castl e nuts to the l ower torque speci -
f i cat i ons, t hen t i ght en t hem onl y f ar enough t o
al i gn t he sl ot wi t h t he pi n hol e. Do not al i gn t he
castl e nut by l ooseni ng.
. Instal l new cotter
pi ns on the castl e nuts after
t or qui ng.
. Avoi d twi sti ng the sensor wi res when i nstal l i ng
the wheel sensor.
. Before i nstal l i ng the brake di sc, cl ean the mati ng
surfaces of the front hub and the i nsi de of the
brake di sc.
Before i nstal l i ng the wheel , cl ean the matang sur-
face of the brake di sc and the i nsi de of the wheel .
Check the front wheel al i gnment, and adj ust i t i f
necessary
(see page 18-4).
1 8 - 1 5
Front Suspensi on Front Damper
Bal l Joi nt Boot Repl acement
Remove the set ri ng and the boot.
CAUTION: Do not contami nate the boot i nstal l a-
tion section with grease.
Pack the i nteri or of the boot and l i p wi th grease.
LtP
BALL PtN TAPRED SECTTON
Wipe ofl the grease.
3. Wi pe the grease off the sl i di ng surface of the bal l
pi n and pack wi th fresh grease.
GAUTION:
. Keep grease
off the boot installation section and
the taperd section of the ball pin.
. Do not allow dust, dirt, or other loreign matcri-
als to enter the boot.
l nstal l the boot i n the groove of the boot i nstal l ati on
secti on securel y, then bl eed ai r.
l nstal l the upper and l ower bal l
j oi nt
boot set rl ngs
usi ng the speci al tool s as fol l ows:
Lower bal l
j oi nt :
Adj ust t he speci al t ool wi t h t he
adj usti ng bol t unti l the end of the tool al i gns wi th
the groove on the boot. Sl i de the set ri ng over the
tool and i nto posi ti on.
BOOT INSTALLANON SECTION
Wi pe ot f t he grease.
5.
BALL JOINT
ADJUSNNG BOLT
Adiust the depth by
t urni ng t he boh.
aooT cLrP
GUI OE
UPPER BALL
JOINT BOOT:
07GAG
-
SDr0700
LOWER BALL
JOINT BOOT:
07974
-
SA50700
CAUTION: Aftei installing the boot, check rhe batl
pi n tapered secti on for grease contami nati on and
wipe it il necessary.
1 8 - 1 6
' 1.
Removal
Remove the front wheel s
(see page 18-10).
Remove t he damper pi nch bol t f r om t he t op of
damper fork,
OAMPER FORK
DAMPER
FORK
BOLT
DAMPER
PINCH
BOLT
10 x 1. 25 mm
SELF.LOCKING NUT
12 x 1. 25 mm
Repl ace.
Remove the damper fork bol t and sel f-l ocki ng nut
from the bottom of the damper fork, then remove
damper fork.
Remove the damper by removi ng the two nuts.
OAMPER
Di sassembl y/l nspecti on
Disassembly
1. Compress the damper spri ng wi th the spri ng com-
pr essor accor di ng t o t he manuf act ur er ' s l i nst r uc-
ti ons, then remove the sel f l ocki ng nut.
CAUTION: Do not compress the spring more than
neceaaery to remove the nut.
10 mm SELF-
LOCKING NUT
Repl ace.
STRUT SPRING
COMPRESSOR:
lCommercially availablel
ERANICKo T/N MST.58OA, T/N 7200,
or eouivalent
Rel ease the
pressure
from the spri ng compressor,
then di sassembl e the damper as shown i n the next
col umn.
Inspection
1. Reassembl e al l
parts, except the spri ng.
2. Push on t he damper assembl y as shown.
Check f or smoot h oper at i on t hr ough a
both compressi on and extensi on.
stroke,
3.
NoTEr The damper shoul d move smoot hl y l f i t
does not
(no
compressi on or no extensi on), the gas
i s l eaki ng, and t he damper shoul d be r epl aced.
4. Check f or oi l l eaks, abnor mal noi ses or bi ndi ng dur -
i ng these tests.
io'i'i'"?Tllo
" "----------------g
29 N m 13.0 kg{.m, 22 lbtftl
Repl ace.
DAMPER MOUNTING WASHEB
BASE
DAMPER MOUNTI NG
RUBBEB
Check f or det er i or at i on
and oamage,
OAMPER SPBING
Check f or weakened compressi on
ano oamage.
SPRING MOUNTING RUBBER
ano oamage,
BUMP STOP
Check f or weakness and
DUST COVER
BUMP STOP PLATE
damage.
DUST COVER
PLATE
DAMPEB UNIT
18-17
Front Damper
Reassembly
2.
1 . l nstal l the damper uni t on a spri ng compressor.
Assembl e the damper i n reverse order of removal
except the damper mounti ng washer and sel f l ock-
i ng nut .
NOTE: Al i gn t he bot t om of damper s pr i ng and
spnng tower seat as shown.
STRUTSPRI NG COMPRESSOR:
(Commarcially
availablol
BRANICKO T/N MST.58OA, T/N 7200,
or equi val ent
SPRING LOWER SEAT
Posi ti on the damper mounti ng base on the damper
unr t as snown.
Compress the damper spri ng.
Instal l the damper mounti ng rubber, damper mount-
i ng washer and a new 10 mm sel f-l ocki ng nut.
Hol d the damper shaft and ti ghten the 10 mm sel f-
l ocki ng nut.
SELF.LOCKING NUT
10 x 1.25 mm
MOUNTING WASHER
5.
29 N.m
{3.0 kgf.m, 22 lbf.ft)
1 8 - 1 8
L
Installation
Loosel y i nstal l the damper on the frame wi th
al i gni ng t ab f aci ng i nsi de, t hen l oosel y i nst al l
two fl ange nuts.
FLANGE NUTS
10 x 1.25 mm
49 N.m
(5.0
kgf.m, 36 lbf.ft)
DAMPER ASSEMBLY
t he
t he
2. Instal l the damper fork over the dri veshaft and onto
t he l ower ar m. l ns t al l t he f r ont damper i n t he
damper fork so the al i gni ng tab i s al i gned wi th the
sl ot i n the damDer tork.
ALIGNING TAB
DAMPER
FORK
BOLT
SELF.LOCKING NUT
12 x 1. 25 mm
64 N.m {6.5 kgt m, 47 lbf,ft)
Repl ace.
DAMPER
PINCH
BOLT
10 r 1. 25 mm
N.m 14.4 kgf m, 32 lbf.ft)
?
5.
6.
7.
Loosel y i nstal l the damper
pi nch bol t on the top of
the damper fork.
Loosel y i nstal l the damper fork bol t and a new sel f-
l ocki ng nut on the bottom of the damper fork.
Rai se the knuckl e wi th a fl oor
j ack
unti l the vehi cl e
j ust
l i fts oft the safety stand.
@
The floor
iack
must be securely
posi'
tioned or
personal iniury may rsuli.
Ti ghten the damper
Pi nch
bol t.
Ti ghten the damper fork bol t and sel f-l ocki ng nut.
Ti ghten the fl ange nuts on top of the damper.
9. l nstal l the brake hose mounts wi th the brake hose
mounti ng bol ts.
8.
10. l nstal l the front wheel .
1 8 - 1 9
Rear Suspensi on
Suspensi on Arms Repl acement
@
when the suspension arms are to be removed, place additional weight in the trunk before hoisting. when
substantial weight is removed from the rear of the vehicle, the center of gravity
may change causing the car to tip for-
ward.
CAUTION:
. Replace the self-locking nuts after removal.
. The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightgn.
NOTEI
a Make sure the toe adj usti ng bol ts on the compensator arm are i nstal l ed i n the same di recti on.
.
" t
UP L" or
" i
UP LH G" or
" l
UP LK" or
" t
Up LS. , i s st amped on t he l ef t upper ar m and
, , t
Up R, , or , , t Up RH G, , or
" t
UP RK" or
" t
UP RS" on t he r i ght upper ar m.
. The ri ght and l eft compensator arm are symmetri cal . l nstal l so the
"l
UP" mark stamped si de faces forward.
. After i nstal l i ng the suspensi on arm,checkthe rearwheel al i gn ment, a nd ad
j ust
i f necessa
ry
(see page
.18-4).
FLANGE BOLT
10 x 1. 25 mm
54 N.m
ADJUSTING EOLT
(FLANGE
BOLT)
10 x 1. 25 mm
BUSHI NG
Check f or det er i or at i on
ano oamage,
-.- SILICONE
.d@l cREAsE
15.5 kgt.m, 40 lbl.ft)
UPPER ARM I NNER
47 tbf.ft)
COMPENSATOR
ARM
Check f or bendi ng
ano oamage.
10 mm FLANGE BOLT
N.m 14.0 kgf.m,29 lbt.ft)
UPPER ARM
Check f or bendi ng
damage.
TBAILING ARM
DAMPER MOUNTING BOLT
{FLANGE BOLT)
10 x 1. 25 mm
sil N.m
{5.5 kgt m, 40 lbt.ft)
FI-ANGE BOLT
10 x 1. 25 mm
54 N. m
{5.5 kgt m, 40 lbtftl
i
FLANGE BOL
' 10
x 1. 25 mm
54 N. m
FLANGE BOLT
12 x 1. 25 mm
64 N.m 16.5 kgl m,
rl7
lbf.ft)
I
(5.5
kgf m, 40 lbtft)
COMPENSATOR ARM
I NNER BUSHI NG
,--
S|L|CONE
*@l cnense
and damage.
FLANGE BOLT
10 x 1. 25 mm
64 N. m {6. 5 kgf . m.
47 tbf.ftl
LOWER ARM
Check f or cracks
ano oamage.
LOWER ARM EUSHING
...-
SILICONE
,4@] GREASE
ano oamage.
18-20
Hub Beari ng Uni t Repl acement
NOTE:
. Use onl y genui ne Honda wheel wei ghts for al umi num wheel s. Non-genui ne wheel wei ghts may corrode and damage
t he al umi num wheel s.
. Onthe al umi num wheel s, remove the center cap f rom the i nsi de ofthewheel after removi ng thewheel .
. Before i nstal l i ng the brake drum, cl ean the mati ng surfaces of the rear hub and the brake drum.
. Before i nstal l i ng the wheel , cl ean the mati ng surfaces of the brake drum and wheel .
TRAILING ARM
Check f or cracki ng
ano oamage. BNAKE SHOE
SPINOLE NUT
22 x 1.5 rnm
181 N. m 118. 5 kgf . m, 134l bt . f t )
Repl ace.
NOTE: Af t er t i ght eni ng, use a dri f t
punch t o l ock t he spi ndl e nut shoul der
i nt o t he spi ndl e.
SPI NDLE WASHER
BACKING PLATE
FLANGE BOLT
10 x 1. 25 mm
5,1 N.m
(5.5
kgtm,,l0 lbtft)
REAR WHEEL
HUB BEABI NG UNI T
Check t or cracki ng
and oamage.
BRAKE DRUM
Check f or wear
ano oamage.
WHEEL NUT
12 x 1. 5 mm
108 N. m
(11. 0
kgf ' m, 80l bt f t )
(cont' dl
18-21
Rear Suspensi on
Hub Beari ng Uni t Repl acement
(cont' dl
1. Loosen the wheel nuts sl i ghtl y.
2. Rai se the rear of vehi cl e, and support i t wi th safety
stands i n the proper
l ocati ons
(see
secti on 1).
3. Remove the wheel nuts and rear wneel .
SPI NOLE NUT
22 x 1. 5 mm
181 N. m {18. 5 ksf . m, 134l bt h)
Repl ace.
NOTE: Af t er t i ght eni ng, use a dri f t t o
st ake t he spi ndl e nut shoul der agai nst
t he spi ndl e.
HUB CAP
Repl ace.
NOTE: Take care not t o damage t he hub beari ng uni t
on di sassembl y.
WHEEL NUT
12 x 1. 5 mm
108 N.m
fi1.0 kgf.m,
g0
tM.ftl
4. Pul l the parki ng
brake l ever up.
5. Remove the hub cap.
6. Rai se the l ocki ng tab on the spi ndl e nut, then remove
the nut.
7. Rel ease the parki ng
brake l ever.
8. Remove the brake drum, hub beari ng uni t and spi n
dl e washer .
REAR WHEEL
HUB BEARING UNIT
Check t or cr acks and damage
BRAKE ORUM
SPINDLE WASHER
9. Instal l i n the reverse order of removal .
18-22
Upper Arm Bushi ng Repl acement
1. Remove t he upper ar m
as shown.
UPPER ARM INNER BUSHING
bushi ng and i nner bushi ng
N4ar k a scr i be l i ne on t he upper ar m i nner bushi ng
so that i t i s i n l i ne wi th the bol t mounti no surface.
Mark on the upper arm at two poi nts so that they
ar e i n l i ne and make a r i ght angl e wi t h t he ar m as
2.
3.
5.
shown.
MARK
BOLT MOUNTING
SURFACE
Dri ve i n the upper arm i nner bushi ng wi th the marks
al i gned.
Dr i ve t he upper ar m bushi ng i nt o t he upper ar m.
NOTEr Dr i ve i n t he upper ar m bushi ng and i nner
bushi ng unti l thei r l eadi ng edges are fl ush wi th the
REAR UPPER ARM
Rear Damper
Removal
1 . Rem ove the rear wheel s
(see page 18-22).
2. Remove the speaker cover and speaker
(Hatchbackl .
Sedan and Coupe: Remove the trunk si de
panel (see
secti on 20).
3. Remove the two fl ange nuts.
FLANGE NUTS
10 x 1. 25 mm
4. Remove the fl ange bol t from the damper.
FLANGE BOLT
10 x 1. 25 mm
Remove the fl ange bol t that connects the l ower arm
to the trai l i ng arm.
FLANGE BOLT
10 x 1. 25 mm
6. Lowerthe rear suspensi on, and remove the damper.
OAMPER
18-23
Rear Damper
I
Disassembly/l nspection
Disassembly
L Compress the damper spri ng wi th the spri ng com-
pr essor accor di ng t o t he manuf act ur er ' s i nst r uc,
ti ons, then remove the sel f-l ocki ng nut.
CAUTION: Do not compress the spring more than
necessary to remove the selflocking nut.
STRUT SPRING COMPRESSOR:
(Commercially
availablel
BRANICI(@ T/N MST-580A, T/N 7200, or equivatent
Rel ease t he pressure
f rom t he spri ng compressor,
t hen di sassembl e t he damper as shown on page 18-
18-24
lnspection
1. Reassembl e al l parts,
except the spri ng.
2. Push on the damper as shown.
WOODEN BLOCK
Check for smooth operati on through a ful l stroke.
both compressi on and extensi on.
NOTE: The damper shoul d move smoot hl y. l f i t
does not
(no
compressi on or no extensi on), the gas
as l eaki ng, and the damper shoul d be repl aced.
Check for oi l l eaks. abnormal noi ses and bi ndi ng dur-
ing these tests.
SELF-LOCKINGNUT--------------- gr
10 x 1. 25 mm Y
29 N.m
(3.0
kgt.m, 22 lbl.ft)
DAMPER
MOUNTI NG
WASHER
OAMPER MOUNTING
RUBBER
Check f or
det eri orat i on
ano oamage.
DAMPER MOUNTING
COLLAR
DAMPER
MOUNTING BASE
DAMPER MOUNTI NG
RUBBER
Check f or
det eri orat i on
ano oamage,
Check f or weakness,
compressi on and damage.
SPRING
RUBBER
DAMPER SPRING
ano oamage.
BUMP STOP
Check f or weakness
ano oamage.
DUST COVER BOOT
ano oamage,
DUST COVER PLATE
DUST COVER
Check f or bendi ng
DAMPER UNIT
18-25
Reassembl y
1. I nst al l t he damper uni t on a spr i ng compr essor '
NOTE: Fol l owthe manufacturer' s i nstructi ons.
2. Assembl e the rear damper i n reverse order of di sas
sembl y except t he damper mount i ng washer and
sel f l ocki ng nut .
NOTEr Al i gn t he bot t om of damper s pr i ng and
spri ng l ower seat as shown.
3. Posi ti on the damper
uni t as shown.
DAMPER MOUNTING
mount i ng base on t he damper
STRUT SPRING COMPRESSOR:
(Commercially available)
BRANICKO T/N MST-580A. T/N 7200,
or equivalent
SPRING LOWER SEAT
t he damper spri ng wi t h t he spri ng com-
5.
Compress
pressor.
I nst al l t he damper mount i ng washer , and l oosel y
i nstal l a new sel f-l ocki ng nut.
6. Hol d the damper shaft wi th a
the sel f-l ocki ng nut.
SELF-LOCKING NUT
' 10
x 1. 25 mm
29 N. m {3. 0 kgf . m, 22l bf f t }
Repl ace.
hex wrench and t i ght en
DAMPER
MOUNTING
WASHER
Rear Damper
Installation
L Lower t he r ear s us pens i on, and pos i t i on
t he
damper wi th the spri ng stop poi nted
toward the l eft
si de of the vehi cl e.
:..
,i
2. Loosel y i nstal l the two fl ange
Loosel y i nstal l the fl ange bol t.
FLANGE BoLT
10 x 1.25 mm
'
54 N.m {5.5 kgl.m,40 lbf.ftl
i ' a - - a I
as'.(
r'
: I
FLANGE BOLT
10 x 1. 25 mm
54 N,m 15.5 kgt.m,
40 rbf.ft)
7.
SPRING STOP
NUI s.
FLANGE NUTS
10 x 1. 25 mm
49 N.m {5 kgl.m, 35 lbf.ftl
Ti ght en t hese nut s i n
St ep 7.
5.
Rai se the rear suspensi on wi th a fl oor
j ack
unti l the
vehi cl e
i ust
l i fts off the safetv stand.
@
The floo.
iack
must be securely posi-
tioned or personal iniury may result
Ti ghten the fl ange bol t.
Ti ghten the two fl ange nuts on top of the damper to
the speci fi ed torque.
Check the rear wheel al i gnment and adj ust i t neces-
sary
(see page
18-41.
18-26
Brakes
Conventi onal Brakes ........ 19-1
Anti -l ock Brake System
(ABS)
............. 19-31
Gonventional Brake
Speci al Tool s . . . . . . . . . . . . . 19-2
Component Locations
l ndex . . . . . . . . . . . . . . . . . . . . . . 19-3
Brake System Rubber Parts
and Brake Boost er . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-4
Brake Pedal . . . . . . . . . . . . 19-5
Parki ng Brake . . . . . . . . 19-6
Bl eedi ng . . . . . . . . . . . . . . . . . 19-7
Front Brake Pads
Inspection and Replacement .......... 19-8
Front Brake Disc
Di sc Runout I nspect i on . . . . . . . . . . . . . . . . . . . 19-12
Disc Thickness and Parallelism
f nspect i on . . . . . . . . . . 19-12
Front Brake Caliper
Di sassembl y . . . . . . . . . . 19-13
Reassembl y . . . . . . . . . . . 19-16
Master Cylinder/Brake Booster
Removal/lnstallation ....................... 19-21
Pushrod Clearance Adiustment ...... 19-22
Brake Booster Inspection ..............,, 1 9-23
Rear Drum Brake
f ndex/f nspection .............................. 19-21
Inspection .............. 19-25
Brake Shoe Disassembly ................. f 9-26
Erake Shoe Reassembly .................. 19-26
Brake Hoses/Lines
Inspection/Torque Specffications ..... 19-28
Hose Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-29
Parking Brake Cable
Inspection and Replacement .......... 19.30
Special Tools
Ret. No. I Tool Number Description Oty
I
Pag Retorencs
o
07JAG
-
SD40100 Pushrod Adj ustment Gauge
'l 't9-22
o
9-2
Component
Locati ons
l ndex
BRAKE PEDAI-
Inspecti on and
Adj ustment, page 19-5
BRAKE HOSES LINES
Inspection/Torque specifications, page 19-28
Hose Repl acement , page' 19-29
MASTER CYLINDER/ARAKE BOOSTER
page 19-21
Pushrod Cl earance Adi ust ment , page 19_22
Brake Boost er I nspect i on,
page 19' 23
PARKING BRAKE CABLE
I nspect i on and RePl acement ,
page 19-36
PARKING BRAKE
Adj ust ment , page 19 6
REAR ORUM ERAKES
I nspect i on,
page 19-25
Erake Shoe Repl acement , Page
19 26
FRONT
NOTE: There are two types of front brake calipers:
The cal i per t ypes can be i dent i t i ed by t he
"5410"
or
"2056"
st ampd on t he cal i per body. Check t he
type ol the brake caliper belore servicing
Front Brake Pads
5410 Type:
page 19-8
2056 Type: page 19-10
Front Brake Di sc,
page' 19-12
Front Brake Cal i per
5410 Type: page 19' 13
2056 Type: page 19-14
19- 3
@
o
Brake System Rubber Parts and Brake Booster
Brake Boostel
Check brake operati on by appl yi ng the brakes.
l f the brakes do not work
properl y, check the brake
booster. Repl ace the brake booster as an assembl y
i f i t does not work properl y or i f there are si gns of
l eakage.
Piston Cup and Pressure Cup Inspeqtion
. Check brake operati on by appl yi ng the brakes.
Vi sual l y check for damage or si gns of fl ui d l eak-
age.
Repl ace t he mast er cyl i nder as an assembl y i f
the
pedal
does not work properl y or i f there i s
damage or si gns of fl ui d l eakage.
. Check f or a di f f er ence i n br ake pedal st r oke
bet ween
qui ck and sl ow br ake appl i cat i ons.
Repl ace the master cyl i nder i f there i s a di ffer-
ence i n oedal stroke.
Brake Hoses
Vi sual l y check for damage or si gns of fl ui d l eakage.
Repl ace the brake hose wi th a new one i f i t i s dam-
aged or l eaki ng.
Caliper Piston Seal and Piston Boots
Check brake operati on by appl yi ng the brakes,
l f the
pedal
does not operate properl y, the brakes
drag. or there i s damage or si gns of fl ui d l eakage,
di sassembl e and i nspect the brake cal i per. Repl sce
the boots and seal s wi th new ones whenever the
brake cal i per i s di sassembl ed,
Wheel Cylinder Piston Cup and Du3t Cover
Check brake operati on by appl yi ng the brakes.
It the
pedal
does not operate
properl y, the brakes
drag, or there i s damage or si gns of fl ui d l eakage,
di sassembl e and i nspect the wheel cyl i nder. l f nec-
essary, repl ace the wheel cyl i nder as an assembl y.
)
@
19-4
I
Brake Pedal
Pedal Height
L Di sconnect the brake swi tch connector, l oosen the
brake switch locknut, and back off the brake switch
unti l i t i s no l onger touchi ng the brake pedal .
2. At the carpet cutout, measure the pedal hei ght from
the ri ght si de center of the pedal pad.
PUSHROD
LOCKNUT
BRAKE SWITCH
MEASURI NG
POINT {CUTOUT}
Standsrd Pedal Height
(with
carpet removedl:
M/T: 156.5 mm
(5.15
i nl
A/T, CW: 161 mm 16 5/16 i nl
3. Loosen the
pushrod l ocknut, and screw the pushrod
i n or out wi th pl i ers unti l the standard pedal hei ght
from the fl oor i s reached. After adj ustment, ti ghten
the l ocknut fi rml y.
NOTE: Do not adj ust t he pedal hei ght wi t h t he
oushrod deoressed.
PUSHROD LOCKNUT
15 N. m
11. 5 kg{. m. 11 l bf . f t l
4. Screw i n the brake swi tch unti l i ts pl unger i s ful l y
depressed
(threaded
end touchi ng the
pad on the
oedal arm). Then back off the swi tch 1/4 turn to
make 0. 3 mm
( 0. 01
i n) of cl ear ance bet ween t he
threaded end and pad. Ti ghten the l ocknut fi rmi y.
Connect the brake swi tch connector.
CAUTION: Make sure that the brake lights go off
when th pdal is relea3ed.
LOCKNUT
5. Check the brake
pedal free pl ay as descri bed bel ow.
Pedal Free Play
1. Wi th the engi ne off, i nspect the pl ay on the
pedal
pad by pushi ng the pedal by hand.
Free Pl ay: 1
-
5 mm
(l /16 -
3/16 i n)
2. l f the pedal free pl ay i s out of speci fi cati on, adj ust
the brake swi tch.
CAUTION: lf the pedal froe play i3 insufficient, it
may result in brake drag.
BRAKE PEDAL PAO
I
0. 3 mm
{0.0'l in)
19- 5
i-
Parki ng Brake
Inspection
1. Pul l the parki ng brake l ever wi th 196 N
(20
kgf. 44 l bf)
force to ful l y appl y the parki ng brake. The parki ng
brake l ever shoul d be l ocked wi thi n the sDeci fi ed
notches.
Levsr Locked Notches: 6
-
I
Pul l ed up 96 N
(20 kgf , 44 l bf )
2. Adj ust the parki ng brake i f the l ever notches are out
of speci fi cati on.
Adiustment
NOTE: After rear brake shoe servi ci ng, l oosen the
park-
i ng brake adj usti ng nut, $tart the engi ne, and depress
the brake pedal several ti mes to set the sel f-adj usti ng
brake before adj usti ng the
parki ng brake.
1. Rai se the fear wheel s off the ground, and support
the vehi cl e on safety stands.
@
Block th tront wheers before
iacking
up the rear ol the vehicle.
wi t h 1
\
9-6
7.
Remove the rear consol e {see secti on 20),
Pul l the parki ng brake l ever up one notch.
Ti ghten the adi usti ng nut unti l the rear wheel s drag
sl i ghtl y when turned.
Rel ease the parki ng brake l ever i ul l y, and check that
the rear wheel s do not drag when turned. Readj ust
i f necessary.
Make sure that the parki ng brakes are ful l y appl i ed
when the parki ng brake l ever i s pul l ed up ful l y.
Rei nstal l the rear consol e.
AOJUSTING NUT
Bl eedi ng
CAUTION:
. Always use Gonuino Honda DOT 3 Brake Fuid. Using a
non-Honda brake tl ui d can cause corro3i on and
dcr.ase th. liis ot tho 3wtam.
. Mako suro no dirt or other foroign matter is allowd
to contaminato tho brake tluid.
. Do not spill brako tluid on the vohicle. it may damage
the paint; if brake tluid does contact tho paint. wash
it off immediatoly with wator.
NOTE: The reservoi r' on the master cyl i nder must be at
the MAX
(upper)
l evel mark at the start of the bl eedi ng
pr ocedur e and checked af t er bl eedi ng each br ake
cal i per. Add fl ui d as requi red.
1. Make sure the brake fl ui d l evel i n the reservoi r i s at
the MAX
(upperl
l evel l i ne.
MAX {UPPERI LEVEL
LINE
RESERVOIR
MASTER CYLINDER
Have someone sl owl y pump the brake pedal several
ti mes, then appl y steady
pressure.
Loosen the brake bl eed screw to al l ow ai r to escape
f r om t he syst em. Then t i ght en t he bl eed scr ew
scuretv.
Repeat the procedure for each wheel in the sequence
shown bel ow unti l ai r bubbl es no l onger appear i n
the fl ui d.
Refi l l the master cvl i nder reservoi r to the MAX
(up-
oer) l evel l i ne.
BLEEDING SEOUENCE:
O
F ont Risht
O
Rear Right
4.
O
Front Left O
Re.r Left
1et
*
BLEED SCREW
I N.m 10.9 kgl m, 6.5 lbf.ftl
FRONT:
REAR:
/
/ i
BLEED SCREW
7 N.m 10.7 kgl.m, 5 lbf.ftl
Front Brake Pads
,
Inspection and Replacement
NOTE: There are two tvpes of front brake cal i pers:
The cal i per t ypes can be i dent l f i ed by t he
" 5410"
or
"2056"
stamped on the cal i per body 8s shown bel ow.
Check the type of the brake cal i per before servi ci ng.
5410 Typo:
NOTE: For 2056 type di sassembl y
procedures, see
page
19- 10.
@
. Nver use an air ho3e or dry brush to clean brako
assemblies.
1 .
Use 8n OSHA approved vacuum cl aner i o avoi d
breathing brake dust.
Loosen the front wheel nuts sl i ghtl y, then rai se the
vehi cl e. and support i t on safety stands. Remove
the front wheel s.
Remove the brake hose bracket from the knuckl e.
Remove the cal i per bol t, and
pi vot the cal i per up
out of the wav.
f i
P
NOTE: Check the hoses and
pi n boots for damage
and deteri orati on.
CALIPER BOLT
19- 8
4. Remove the pad shi m.
pad retai ners and pads.
NOTE: When the cal i per i s equi pped wi th on outer
pad
shi m, repl ace the shi m together wi th the
pads
as a ser.
Usi ng ver ni er cal i per s. measur e t he t hi ckness of
each brake
pad l i ni ng.
Brake Pad Thicknss:
Standard: 9.5
-
10.5 mm
(0.37 -
0.,t1 inl
Servico Limit: 1.6 mm
(0.06
in)
NOTE: Measurement does not i ncl ude pad backi ng
pl ate thi ckness.
l f the brake pad thi ckness i s l ess than servi ce l i mi t,
repl ace the front pads as a set.
7. Cl ean the cal i per thoroughl y; remove any rust. and
check for grooves and cracks,
Check the brake di sc for damage and cracks.
Instal l the pad retai ners.
10. Appl y grease to the
poi nts i ndi cated by the arrows
i n the foi l owi ng i l l ustrati on:
NOTE: Use the pad grease i ncl uded i n the pad set
or Mol ykote M77 grease, and appl y a thi n coat of
grease evenl y to the desi gnated poi nts.
. Pi ston end and i nner pad contact surface
. Pad and cal i per bracket contact surface
. Outer
pad
and cal i per body contact surface
. Outer Dad shi m and outer oad contact surface
. Outer
pad
shi m and cal i per body contact surface
WEAR INDICAIOS
I NNER PAO
OUTER PAD
11. Instal l the brake
pads and pad shi m correctl y.
Whon reusi ng the
pads,
al ways rei nstal l the
brake pads in thoir original
positions
to
prevent
loss of braking efficiency.
Contaminatd brake disca or
pads reduce stop-
ping ability, Keop grease off the discs snd pads.
NOTE: l nstal l the
pad wi th the wear i ndi cator on
the i nsi de.
o.
OUTER
PAO SHIM
]
A
5...1
ur
12. Push i n the pi ston so that the cal i per wi l l fi t over the
pads. Make sure that the pi ston boot i s i n posi ti on
to prevent damagi ng i t when pi voti ng
the cal i per
down.
Pi vot t he cal i per down l nt o
posi t i on,
t hen i nst al l
cal i per bol t and ti ghten i t.
CAUTION: Be careful noi damage tho pi n boot
when pivoting tho caliper down.
Instal l the brake hose bracket on the knuckl e.
NOTE: Inspect the brake hose for i nterference or
twi sti ng.
DeDress the brake Dedal several ti mes to make sure
the brakes work, then test-dri ve.
NOTE: Engagement of t he br ske may r equi r e a
greater pedal
stroke i mmedi atel y after the brake
pads have been repl aced as a set. Several appl i ca-
t i ons of t he br ake pedal wi l l r est or e t he nor mal
pedal stroke.
After i nstal l ati on, check for l eaks at hose and l i ne
j oi nts
or connecti ons, and reti ghten i f necessary,
rl
ii;
i
13.
14.
15.
15.
(cont' d)
19- 9
CALIPER BOLT
N.m {3.3 ksl.m, 24 lbnftl
Front Brake Pads
2056 Type:
@
(cont'dl
t
Nev6r usg an air ho3e or dry brush to cloan brakg
sssembligs.
Usg an OSHA approved vacuum cl eanor to avoi d
breathing brako dust.
vehi cl e, and support i t on safety stands. Remove
the front wheel s.
Remove the brake hose bracket from the knuckle.
Remove the cal i per bol t B, and pi vot the cal i per up
out of the wav.
1 .
BRAKE HOSE ARACKET
CALIPER
BOLT B
NOTE; Check the hoses and
pi n
boots for damage
and deteri orati on.
Remove the
pad
shi m,
pad retai ners and pads,
NOTE: When repl aci ng the pads. repl ace the shi m
together wi th the as a set.
OUTER
PAD SHIM
Check for wear.
INNER PAD
PAO RETAINERS
Check f or weakness and
damage.
OUTER PAD
1 9 - 1 0
5, Usi ng verni er cal i pers, measure the thi ckness of
each brake
pad l i ni ng.
Brake P8d Thickness:
Standard: 8.5
-
9.5 mm
(0.33 -
0.37 in)
(0.06
in)
NOTE: Measurement does not i ncl ude
pad
backi ng
ol ate thi ckness.
6. l f the brake
pad
thi ckness i s l ess than servi ce l i mi t.
replace the front pads as a set.
7. Cl ean the cal i per thoroughl y; remove any rust, and
check for grooves and crscks.
8. Check the brake di sc for damage and cracks.
9. l nstal l the oad retai ners.
BACKING PLATE
10. Appl y grease to the poi nts i ndi cated by the arrows
i n the fol l owi ng i l l ustrati on:
NOTE: Use the pad grease i ncl uded i n the pad set
or l vol ykote M77 grease, and appl y a thi n coat of
grease evenl y to the desi gnated poi nts.
. Pi ston end and i nner oad contact surface
. Pad and cal i per bracket contact surface
. Outer
pad and cal i per body contact surface
. Outer
pad
shi m and outer
pad contact surface
. Outer
pad shi m and cal i per body contact surface
OUTER PAD
OUTER
PAD SHIM
11. I nst al l t he brake
pads
and
pad shi m correct l y.
o When reusi ng the pads, al ways rei nstal l the
brake
pads in their original positions to prevent
loss of braking efficiency.
. Contaminatd brake discs or pads reduca stop-
ping ability. Keep grea3 off the discs and pads.
NOTE: I nst al l t he pad wi t h t he wear i ndi cat or on
the i nsi de,
WEAR INDICATOR
12. Push i n the pi ston so that the cal i per wi l l fi t over the
pads. Make sure that the pi ston boot i s i n posi ti on
to prevent damagi ng i t when pi voti ng the cal i per
oown.
CALIPER BOLT B
26 N.m {2.7 kgl.m,
20 tbt.ftt
13,
14.
Pi vot t he cal i per down i nt o posi t i on, t hen i nst al l
cal i per bol t B and ti ghten i t.
l nstal l the brake hose bracket on the knuckl e.
NOTE: l nspect the brake hose for i nterference and
twi strng.
Depress the brake
pedal
several ti mes to make sure
the brakes work, then road-test.
NOTE: Engagement of t he br ake may r equi r e a
greater pedal stroke i mmedi atel y after the brake
pads have been repl aced as a set. Several appl i ca-
t i ons of t he br ake pedal wi l l r est or e t he nor mal
pedal stroke.
After i nstal l ati on, check for l eaks at hose and l i ne
j oi nts
and connecti ons. and reti ghten i f necessary.
15.
PISTON
19- 1 1
Front Brake Disc
Disc Runout Inspection
t .
4,
vehi cl e, and support i t on safety stands. Remove
the front wheel s.
Remove the brake pads (see page 19-8).
I nspect t he di sc sur f ace f or damage and cr acks.
Cl ean the di sc thoroughl y and remove al l rust.
Use wheel nuts and sui tabl e pl ai n washers to hol d
the di sc securel y agai nst the hub, then mount a di al
i ndi cat or as shown, and measur e t he r unout at
' 10
mm
(0.4
i n) from the outer edge of the di sc.
Brake Disc Runout:
Service Limit 0.10 mm {0.00,1 in)
W{EEL NUT AND
PLAIN WASHER
108 N.m
(11 kgf . m, 80l bt f t )
l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc wi th an on-car brake l athe. The Kwi k-
Lathe
produced
by Kwi k-way manufacturi ng Co.
and the
"Front
Brake Di sc Lathe" offered by Snap-
on Tool s Co. are approved for thi s operati on.
M8x. Reti ni sh Li mi t 19.0 mm
(0.75
i nl
NOTE: A new di sc shoul d be refi ni shed i f i ts runout
i s greater than 0.10 mm
(0.004
i n)
19- 12
Disc Thickness and Parallelism
Inspection
1 . Loosen the front wheel nuts sl i ghtl y. then rsi se the
vehi cl e. and support i t on safety stands, Remove
the front wheel s.
Remove the brake pads (see page 19-8).
Usi ng a mi cr omet er , measur e di sc t hi ckness at
ei ght poi nts, approxi matel y 45" apart and 10 mm
(0.4
i n) i n from the outer edge of the di sc.
Brake Disc Thicknsss:
Standard: 20.9
-
21.8 mm {0.82
-
0.86 in)
Max. Refi ni shi ng Li mi l : 19.0 mm
(0.75
i n)
NOTE: ReDl ace the brake di sc i f the smal l est mea-
surement i s l ess than the max. refi ni shi ng l i mi t.
Erake Di3c Parallelism: 0.015 mm 10.0006 inl max.
NOTE: Thi s i s the maxi mum al l owabl e di fference
between the thickness measurements.
l f the di sc i s beyond the servi ce l i mi t for paral l el i sm,
refi ni sh the brake di sc wi th an on-car brake l athe.
The Kwi k-Lathe
produced by Kwi k-Way Manufac-
turi ng Co. and the
"Front
Erake Di sc Lathe" offered
by Snap-on Tool s Co. are approved for thi s opera-
t r on.
NOTE: See secti on 18 for brake di sc repl acement.
Front Brake Galiper
Disassembly
NOTE: There are two types of front brake cal i pers:
The cal i per t ypes can be i dent i f i ed by t he
" 5410"
or
"2056"
stamped on the cal i per body as shown bel ow.
Check the type of the brake cal i per before servi ci ng.
5410 Type:
NOTE: For 2056 type di sassembl y
procedures, see page
' 19-13.
Nsvr use an ai r hose or dry brush to cl ean brake
assemblics.
Use an OSHA approved vacuum cl ganer to avoi d
breathing brake dust.
CAUTION:
. Do not spill brske tluid on the vehicle; il may damage
the
paint; if braka fluid does contact the paint. wssh
it off immediately with water.
. To prcvent spills, cover the hose
ioints
with rsgs or
shop towels.
. Clesn all
parts in brake fluid and air dry; blow out all
passages with compressed air.
L Remove the banj o bol t, and di sconnect the brake
hose from the cal i per.
CALIPER
EANJO SOLT
SEALING
Repl ace.
CALIPER BOLTS
Remove the cal i per bol ts, then remove the cal i per
from the bracket.
L
3. Remove t he cal i per pi ns and pi n boot s f r om t he
cal i oer bracket.
CALIPER PIN B
CALIPER BRACKET
CALIPER PIN A
l f necessary, appl y compressed ai r to the cal i per
fl ui d i nl et to
get the pi ston out. Pl ace a shop rag or
wooden bl ock as shown to cushi on the
pi ston when
i t i s expel l ed. Use l ow pressure ai r i n short spurts,
. Do not
place your fingrs in froni ot tho piston.
. Do not use hi gh ai r
pr essur e; usG an OSHA
approved 30 PSI nozzle.
Remove the pi ston from the cal i per, and check the
pi ston for scori ng.
Remove the boot cl i p,
pi ston boot and pi ston seal .
CAUTION: Take care not to damage the cyl i nder
bore.
PISTON SEAL
Repl ace.
BOOT CLIP
Bepl ace.
\ ,
t l
( \
U
PISTON BOOT
Repl ace.
CALIPER BODY
Check f or scori ng
{cont ' d)
1 9 - 1 3
Front Brake Caliper
2056 Type:
@
Disassembly
(cont'dl
. Never use an ai r hose or dry brush to cl ean brake
assemblis.
. Use an OSHA approved vacuum cl eaner to avoi d
breathing brak dust,
CAUTION:
. Do not spill brake fluid on tha vohicle; it may dsmage
the paint; if brake tluid dos contaqt the
paint.
wash
it otf immdiately with water.
. To prevent spills, cov6r tho hose
ioints
with iag3 or
shop towels,
. Clean all parts in brake tluid and air dry; blow out all
pasragos with compressed air.
1. Remove the bani o bol t, and di sconnect the brake
hose from the cal i oer.
SEALING WASHERS
Repl ace.
Remove cal i per bol t B, pi vot the cal i per up out ol
the way, then remove the cal i per from the bracket.
Remove the gui de pi n
boot from sl eeve A on the
cal i per bracket.
!
GUIDE PIN BOOT
Repl ace.
CALIPER BRACKET
Check I or cracks.
Check f or damage.
19- 14
4. Remove t he pi n boot , sl eeve B and sl eeve
from the cal i per body.
CALIPER SODY
Check for scori ng
on cyt i nder wal l .
/
SLEEVE I
Repl ace.
a
a
boot
Remove the pi ston
from the cal i per, and check the
piston for scoling.
d
st EEVE I
Check l or damage.
l f necessary, appl y compressed ai r to the cal i per
fl ui d i nl et to get the pi ston out. Pl ace a shop rag or
wooden bl ock as shown to cushi on the pi ston when
i t i s expel l ed. Use l ow pressure
ai r i n short spurts.
Do not plac your tingers in front of the piston.
Do not us hi gh 8i r prossur;
usc an OSHA
approved 30 PSI nozzle.
7. Remove the boot cl i p,
pi ston boot and pi ston seal .
CAUTION: Take care not to damage the cyl i nder
bore.
800T cLtP
Repl ace.
PISTON EOOT
Repl ace.
SEAL
Front Brake Galiper
Reassembly
5,110 Type:
NOTE; For 2056 type reassembl y procedures. see page
19-18,
o Never use an air hose or dry brush lo clan brske t$embliss.
. Use on OSHA approvsd vacuum cleaner to avoid breathing brako dust,
. Contaminated braks discs or pads reduce stopping ability.
. when teusing the pads,
always reinstall the brake pads in their original positions
to prevent loss ot braking cfficiancy.
CAUTION:
. Do not spill brak lluid on the vehicle; it may damage tho
paint;
if brrke lluid does contact the
paint,
wash it off imme-
diately with water.
. Clean all parts in brake fluid 8nd air dry; blow out all pa$ages
with compr63sed air.
. Bofore rea$embling, check thai all parts a.o froo of dust and other lorsign particlog.
. Roplace part3 with nw onss whenever spscified to do so.
. Make sure no dirt or othe. foreign mattor is allowed to contaminste tha brake fluid.
. Alway3 us Genuine Honda DOT 3 Brrke Fluid. Using a non-Honda brako fluid c8n caus corrosion and decroase the
lifs of the system.
NOTE:
. Coat the
pi ston, pi ston
seal . and cal i per bore wi th cl ean brake fl ui d.
. Repl ace al l rubber parts wi th new ones whenever di sassembl ed.
#r-anrrsr-H:
Use recommended rubber grease i n the csl i per seal set.
-61' Use recommended seal
grease
i n the cal i per seal set.
PIN BOOTS
Repl ace.
_41
oUTER PAD SH|M
ta,
R
---+-s'
caupeaet Na/
-
@
BLEED SCREW
9 N m
(0.9
kgr.m, 6.5 lbf.ft)
WEAB INDICATOR
BEAKE PAOS
rMA
|trf,
(l
n
t \ '
\ \ J q l c A
T O R \ \ r l i
CALIPER BRACKET MOUNTING BOLT
BRACKET
PAD RETAINERS
=..
.H!!q9ril
PISTON SEAL
Repl ace.
PISTON BOOT
Repl ace.
-6r
/
eoor cue
f
Replace.
A ]
wo
1 9 - 1 6
CALIPEB BOOY
1 . Cl ean the pi ston and cal i per bore wi th brake fl ui d,
and i nspect for wear and damage.
Coat the new Di ston seal wi th the recommended
rubber grease i n the cal i per seal set. and i nstal l the
seal i n the cyl i nder
groove,
Appl y the recommended seal
grease i n the cal i per
seal set to the seal i ng l i ps and i nsi de of a new pi s-
ton boot. and secure i nstal l i t i n the cal i per wi th the
new boot cl i o.
CAUTION: 8o carel ul not to damage the cal i per
cylinder wall.
Lubr i cat e t he cal i Der and
pi st on
wi t h br ake f l ui d.
then i nstal l the
pi ston i n the cyl i nder wi th the di shed
end faci ng i n.
PISTON SEAL
Repl ace.
=^.
,->---!!!!!Lil
RUBBER GREASE
PISTON BOOT
Repl ace.
.,'.{@l
SILICONE GREASE
PIN BOOT
\
Repl ace.
- \
Appl y the recommended seal grease i n the cal i per
seal set to the sl i di ng surface of the
pi ns and the
i nsi de of the new Di n boots,
Instal l the
pi n boots i nto the grooves i n the cal i per
bracket properl y.
CALIPER BRACKET
CALIPER
.@]
CALIPER PIN B
-6,l
CALIPEF PIN
PIN BOOTS
Repl ace.
7. Insert
pi n
A and
pi n B i nto the cal i per bracket.
8. Instal l the pi n boots i nto the
grooves i n the pi ns
properl y.
9. Instal l the brake pads i n thei r ori gi nal
posi ti ons (see
page 19-9).
10- Push i n the pi ston so that the cal i per wi l l fi t over the
pads, and i nstal l the cal i per.
11. Ti ghten the cal i per bol ts.
12. Connect the brake hose to the cal i per wi th new seal -
i ng washers, and ti ghten the banj o bol t.
BANJO BOLT
34 N. m
(3. 5
kgl . m. 25 l bf f t )
SEALING WASHERS
Repl ace.
13.
CALIPER BOLT
32 N. m {3. 3 ksf . m, 24 l bf . f t }
Fi l l the brake reservoi r and bl eed the brake svstem
{see
page 19-7).
Perform the fol l owi ng checks.
. Check tor l eaks at hose and l i ne
j oi nts
and con-
necti ons, and reti ghten i f necessary.
. Check for brake hoses for interference and twisting.
(cont' dl
14.
Front Brake Caliper
Reassembly
(cont'd)
2056 Type:
. Ngver uso an air hose or dry brush to clean brake assemblies.
. Uss an OSHA approved vacuum cleaner to avoid breathing brake dust.
. Contaminated brake discs or pads reduce stopping ability.
. When reusing the pads. always reinstall ths brake pads in their original positions to prevent loss of braking efticisncy.
CAUTION:
. Do not spill brake fluid on the vehicle; it may dsmage th paint; if brak fluid does contact the paint, wash it off imme.
diately with water.
. Clan all parts in brake fluid and air dry; blow out all
passages
with compre$d air.
. Betore reassembling, check th8t all parts
are free of dust and other toreign particles.
. Rplace parts with new ones whenever specified to do so.
. Make sure no dirt or othsr forgign mattsr is allowed to contaminate the brake tluid.
. Always use Genuine Honda DOT 3 Erake Fluid. Using a non-Honda brakc fluid can cause corrosion and decrease the
lite ot the system.
NOTE:
. Coat the
pi ston. pi ston
seal . and cal i per bore wi th cl ean brake fl ui d.
o Reol ace al l rubber Darts wi th new ones whenever di sassembl ed.
c' ' -"{@: Use recommended rubber grease i n the cal i per seal set.
-Gr, use recommended sear grease in the caliper sear set.
_.-cALrpER ERACKET MoUNTTNG BoLT
@f
toe ru'- {tt.o kg{.m. 80 rbtft)
BRAKE PADS
"\
N
\
A-t -- .ALTPER BRA.KET
OUTER PAO
WEAR INDICATOR
ir*l;r**t,;;ll;-fn
h \
*6ry--
'ADRETA,NER'
M lll
' l
r) Pl
culoEP,NBoor \\ / H, I ll I l' I
%.
" o. , " , " *
\ l l t l d6
u. . ( b
-t'.---.-
""-,t"oo*tJ*, "'*nW
\l
**-y
BLEED SCREW
--\_^
\
SLEEVE A
s N.m ro.s ksr.m,6.s tbr.ft)
tr. _ \ 6"1
'-b
#\S"^.(*r1
/\ I YffA"
,o,,,,"o,,"
/ W \Uf->" -,P,sroNBoor
Tffi
l.'
26N.m{2.7ksf.m.2orbftt}
^/-^^.. mFZ\
-
| l (// )A{
Reorace.
;i f;rqq
80()T cLtP
Repl ace.
BNAKE PADS
1 9 - 1 8
' 1.
Cl ean the pi ston and cal i per bore wi th brake fl ui d,
and i nspect for wear and damage.
Coat a new pi ston seal wi th the recommended rub-
ber grease i n the cal i per seal set, and i nstal l the seal
i n the cyl i nder groove.
Appl y the recommended seal grease i n the cal i per
seal set to the seal i ng l i ps and i nsi de of a new pi s-
ton boot, and secure i nstal l i t i n the cal i per wi th a
new boot cl i p.
CAUTION: Be caretul not to damage the cal i pel
cylinder wall.
BOOT CLIP
Repl ace.
Repl ace.
-e1
SILICONE GREAS
Repl ace.
re---.
- :-!!!r!ail
RUBBER GREASE
4. Lubri cate the cal i per and
pi ston
wi th brake fl ui d,
t hen i nst al l t he pi st on i n t he cyl i nder wi t h t he
di shed end faci ng i n.
Appl y the recommended seal
grease i n the cal i per
seal set to the sl i di ng surface of sl eeve B and the
i nsi de of the new pi n and sl eeve boots.
Instal l the new sl eeve and
pi n boots and sl eeve B
on the cal i per.
NOTE: Be sure to i nstal l the boots i nto the
grooves
i n the cal i per and sl eeve B properl y.
SLEEVE BOOT
5.
6.
Y
PIN BOOT
Repl ace,
(cont' d)
1 9 - 1 9
SLEEVE B
Front Brake Caliper
Reassembly
(cont'd)
7 . Appl y the recommended seal grease i n the cal i per
seal set to the sl i di ng surface of sl eeve A and the
i nsi de of a new gui de pi n boot.
I nst al l t he gui de pi n boot i nt o t he gr oove i n t he
sl eeve A.
Make sure that the brake pad retai ners and brake
pads are i n thei r ori gi nal posi ti ons
{see
page 19-10).
10. Instal l the cal i per onto sl eeve A, and pi vot i t down
i nto posi ti on.
NOTE: Instal l the gui de pi n boot i nto the groove i n
the cal i per properl y.
SLEEVE A
19-20
1 1 .
12.
Connect the brake hose to the caliper with n"w a6al-
i ng washers. and ti ghten the banj o bol t,
Ti ghten the cal i per bol t B.
BANJO BOLT
34 N.m {3.5 kgf.m,25 lbt.ftl
Fi l l the brake reservoi r and bl eed the brake system
(see page 19-7).
o Check for l eaks at hose and l i ne
j oi nts
and con-
necti ons, and reti ghten i f necessary.
. Check for brake hoses for interference and twist-
I ng.
13.
14.
_ 1
26 N.m
(2.7
kgf.m, 20 lbt.frl
Master Cylinder/Brake
Booster
I
RemovaUlnstallation
CAUTION:
. 86 careful not to bend or damage the brake lines when
removing the master cylinder.
. Do not spill brake fluid on tho vehicle; it maY damage
the
paint; if brake tluid doas contaqt the paint, wash
. To
prevent spill3, cover thg hose
ioints
whh rags or
shop towels.
9. Remove the four booster mounti ng nuts
10. Pul l the brake booster forward unti l the cl evi s i s
cl ear of the bul khead.
11. Remove the brake booster from the engi ne com-
panmenr.
12. l nstal l the brake booster and master cyl i nder i n the
CAUTION:
. When connecti ng the brake l i nes, make sure
that lhere is no intrterence between the brake
lines and other
Parts.
. Be caretul not to bend or damage the brake lines
when installing the master cylinder.
NOTE: l f r epl aci ng t he mast er cyl i nder or br ake
boost er , check and adi ust t he
pushr od cl ear ance
before installing the master cylinder
(see page 19-22\.
Fi l l t he mast er cvl i nder r eser voi r , and bl eed t he
brake system
(see
Page
19-7).
After i nstal l ati on, check the brake
pedal hei ght and
brake
pedal free pl ay (see page 19-5) and adj ust i f
necessary.
BRAKE BOOSTER
(Wi th ABS: 7"
.
S" tandem brake boosi er)
BRAKE FLUID LEVEL
SWITCH CONNECTORS
1 .
2.
?
5.
Di sconnect the brake fl ui d l evel swi tch connectors.
Remove the reservoi r cap trom the master cyl i nder.
The brake fl ui d may be sucked out through the top
of the master cyl i nder reservoi r wi th a syri nge.
Di sconnect the brake l i nes from the master cyl i nder'
Remove t he mast er cyl i nder mount i ng nut s and
wasners.
6. Remove the master cylinder from the brake booster'
7. Disconnect the vacuum hose from the brake booster'
8. Remove the cofter
pi n and cl evi s
pi n from the cl evi s'
CAUTION: Do noi disconnect the clovis by remov'
ing it from ths operating rod of the brake booster' lf
the clevis is loosenod, adiust the pushrod length
before installing the brake booster
(see page 19-221
13 N. m {1. 3 kst m, 9 l bt f t )
13.
14.
-6ll
CLEVIS PIN
MASTEF CYLINDER
VACUUM HOSE
To Front Cal i per
(Wi t hout
ABS)
PROPORTIONING CONTROL VALVE
.---
15 N. m
(1. 5 kgf . m,
11 tbt.ft)
15 N. m
(1. 5
ksf ' m, 11 l bf f t )
(Wi t h
ABSTTo modul at or uni t )
To Rear Wheel Cyl i nders
19-21
Master Gylinder/Brake Booster
Pushrod Clearance Adjustment
NOTE:
. Master cyl i nder pushrod-to pi ston cl earance must be
checked and adj ustments made, i f necessary, before
l .
i nstal l i ng master cyl i nder.
ABS type i s shown, conventi onal brake tvpe i s si mi l ar.
Set the special tool on the master cylinder body; push
in the center shaft until the top of it contacts the end
of the secondary pi ston
by turni ng the adj usti ng nut.
PUSHROD ADJUSTMENT GAUGE
07JAG
-
SD'(}l00
SECONDARY
PISTON
ADJUSTING
NUT
CENTER
SHAFT
MASTER CYLINDER
Wi thout di sturbi ng the center shaft' s posi ti on,
i nstal l
the speci al tool upsi de down on the booster.
Instal l the master cyl i nder nuts and ti ghten to the
sDeci fi ed toroue.
Connect the booster i nl i ne wi th a vacuum gauge
O
-
101 kPa (0 -
760 mmHg, 30 i n.Hg) to the booster' s
engane vacuum suppl y, and mai nt ai n an engi ne
speed that wi l l del i ver 66 kPa
(500
mmHg, 20 i n.Hg)
vacuum.
Wi th a feel er gauge, measure the cl earance between
the gauge
body and the adj usti ng nut as shown.
Clearance: 0
-
0.4 mm
(0 -
0.02 in)
VACUUM GAUGE
{Commercially aveilable)
0
-
101 kPe
{0
-
760 mm Hg, 30 i n. Hgl
AOJUSTING NUT
2.
HOSE
Connect a hose of
sui t abl e di amet er.
FEELER GAUGE
CYLI NDEB NUT
19-22
15 N. m 11. 5 kgf . m, 11 l bf f i )
10.
NOTE: l f t he cl ear ance bet ween t he gauge
body
8nd adj usti ng nut i s 0.4 mm
10.02 i n), the pushrod-
to-pi ston cl earance i s 0 mm. However, i f the cl ear-
ance between the gauge
body and adj usti ng nut i s
0 mm, the pushrod-to-pi ston
cl earance i s 0.4 mm
(0.02
i n) or more. Therefore i t must be adj usted and
rechecked.
6. l f cl earance i s i ncorrect, l oosen the star l ocknut and
turn the adi uster i n or out to adj ust.
NOTE:
Adj ust the cl earance whi l e the speci fi ed vacuum
i s appl i ed to the booster.
Hol d the cl evi s whi l e adi usti ng.
Ti ghten the star l ocknut securel y.
Remove the speci al tool .
0
- 0. 4
mm { 0- 0. 02 i nl
7.
8.
STAR LOCKNUT
22 N.m
12.2 kgt m, 16 lbf.ft)
CLEVIS
PUSHROD
ADJUSTMENT GAUGE
07JAG
-
SD40100
9. Adj ust the pushrod
l ength as
ts removed.
' 11610. 5
mm
(4. 5710. 02
i n)
PUSHROD
LOCKNUT
15 N. m
(1. 5
kgl . m, 11 l bf . f t )
l nst al l t he mast er cyl i nder (see page l 9-21).
Brake Booster Inspection
FunctionalTest
' 1.
Wi th the engi ne stopped. depress the brake
pedal
several ti mes to depl ete the vacuum reservoi r, then
depress the pedal hard and hol d i t for 15 seconds. l f
t he
pedal
s i nk s , ei t her t he mas t er c y l i nder l s
bypassi ng i nternal l y, or the brake system
(master
cyl i nder , l i nes, modul at or , pr opor t i oni ng cont r ol
val ve. or cal i per) i s l eaki ng.
2. St an t he engi ne wi t h t he pedal depr essed. l f t he
pedal si nks sl i ghtl y, the vacuum booster i s operati ng
nor mal l y. l f t he
pedal hei ght does not var y, t he
booster or check valve is faulty.
3. Wi th the engi ne runni ng, depress the brake pedal
l i ght l y. Appl y
j ust
enough pr essur e t o hol d back
aut omat i c t r ansmi ssi on cr eep. l f t he br ake pedal
si nks mor e t han 25 mm { 1. 0 i n. ) i n t hr ee mi nut es,
t he mast er cyl i nder i s f aul t y. A sl i ght change i n
pedal hei ght when the A/C compressor cycl es on
and of f i f nor mal .
( The
A/ C c ompr es s or l oad
changes the vacuum avai l abl e to the booster.)
Leak Test
1. Depress the brake
pedal wi th the engi ne runni ng,
then stop the engi ne. l f the pedal hei ght does not
varv whi l e depressed for 30 seconds, the vacuum
boost er i s OK. l f t he
pedal r i ses. t he boost er i s
faul tv.
2. Wi th the engi ne stopped, depress the brake pedal
sever al t i mes usi ng nor mal pr essur e. When t he
pedal i s fi rst depressed, i t shoul d be l ow. On con-
secuti ve appl i cati ons, the pedal hei ght shoul d grad-
ual l y ri se. l f the pedal posi ti on does not vary, check
the booster check val ve.
Booster Check Valve Test
1. Di sconnect the brake booster vacuum hose at the
booster.
2. Start the engi ne and l et i t i dl e. There shoul d be vac-
uum. l f no vacuum i s avai l abl e, the check val ve i s
not worki ng properl y. Repl ace the brake booster
vacuum hose and check val ve, and retest.
BRAKE BOOSTER
VACUUM HOSE
( Check
val ve
bui l t - i n)
19-23
Rear Drum Brakes
Index/lnspection
a
a
a
a
' 1.
N6vr use an air hos or dry brush to clean brako assemblies.
Use an OSHA approved vacuum cleaner to avoid brealhing brake dust.
Contaminated brake linings or drums reduce siopping ability.
Block thc front wheels before
iacking
up the rear of ihe vehicle.
Bl ock the front wheel s, l oosen the rear wheel nuts sl i ghtl y, support the rear of vehi cl e on safety stands, then remove
the rear wheel s.
2. Rel ease the parki ng brake, and remove the rear brake drum.
I N.m {0.9 kgt m, 6.5 lbf.ftl
WHEEL CYLINOER
I nspect f or l eakage.
It necessary, replace as an assembly.
u-cLtP
Repl ace.
UPPER RETURN SPRING
I
@
PIVOT PIN
Check f or weakness
ano oamage.
TENSION PIN
10 mm BOLT
64 N.m {6.5 kgf.m,
47 rbf.ft)
BRAKE SHOE
AOJUSTER EOLT
Check ratchet teeth
{or wear and damage.
/
{-l
^
I
I
"*'"i
cLEV' sB
/
(
r
/
,.to,n.*.r*,"n
/ ,
Install securely on
| /
t ensi on pi n.
& /
- d/
ts
LOWER RETURN
SPRING
Check l or weakness
and damage-
l nspect i on, see
page 19 30
l f brake shoes are t o be
reused, mark and reassembl e
i n same posi t i on.
SELF.ADJUSTER
SPRING
Check f or weakness
ano oamage,
19-24
Inspection
1 .
2.
3.
Check the wheel cyl i nder Jor l eakage.
Check the brake l i ni ngs for cracki ng,
gl azi ng, wear
and contami nati on,
Measure the brake l i ni ng thi ckness.
Brake Lining Thicknoss:
Sisndard:
/1.0
mm
(0.157
in)
(0.08
in)
NOTE: Measurement does not i ncl ude brake shoe
thi ckness,
\
l f t he br ake l i ni ng t hi ckness r s l ess t han ser vi ce
l i mi t, repl ace the brake shoes as a set
Check the beari ngs i n the hub uni t for smooth oper-
ati on. l f defecti ve, refer to secti on 18.
5.
WHEEL CYLINDER
6. Measur e t he i nsi de di amet er of t he br ake dr um
usi ng the i nsi de verni er cal i pers,
Drum lnside Diametr:
Standard: 199.9
-
200.0 mm
(7.870 -
7.874 in)
Servi cs Li mh: 201.0 mm
(7.913
i n)
l f the i nsi de di ameter of the brake drum i s more
than servi ce l i mi t, repl ace the brake drum.
Check t he br ake dr um f or scor i ng,
gr ooves and
cracks.
7 .
8.
INSIDE VERNIER CALIPERS
Rear Drum Brake
Brake Shoe Disassembly
1. Remove t he t ensi on pi ns by pushi ng
t he r et ai ner
spri ngs and turni ng them.
RETAINER SPRINGS
Lower the brake shoe assembl y, and remove the
l ower return spri ng.
NOTE: Be careful not to damage the dust cover on
the wheel cyl i nder.
Remove the brake shoe assembl y.
Di sconnect the parki ng
brake cabl e from the parki ng
brake l ever.
Remove the upper return spri ng, sel f-adj uster l ever
and sel f - adj ust er spr i ng. and separ at e t he br ake
shoes.
ADJUSTER BOLT
Check ratchet toeth tor
wear ano damage.
UPPER RETURN SPRING
Check f or weakness
ano oamage.
I'
io
I
. : l
\'
r\
r
//
SPRING
19-26
6, Remove the wave washer, parki ng
brake l ever and
pi vot pi n from the brake shoe by.emovi ng the U-
cl i D.
PARKING ERAKE
LVER
WAVE WASHER
/
@G
I
u'cLrP
Repl ace.
1 .
Brake Shoe Reassembly
Apply brake cylinder grease (P/N:
08733
-
8020E) or
equi val ent rubber grease
to the sl i di ng surface of
the pi vot pi n,
and i nsert the pi n i nto the brake shoe.
Instal l the psrki ng
brake l ever and wave wasner on
the pi vot pi n
and secure wi th U-cl i p,
NOTE: Pinch the U-clip securely to prevent
the pivot
pin from coming out ofthe brake shoe.
Connect t he
par ki ng br ake cabl e t o t he par ki ng
brake l ever.
Appl y grease on each sl i di ng surface.
@
contami nated brake l i ni ngs reduce
stopping ability. Keep grease or oil off the brake lin'
ings. Wipe any excess
grase oft the parts.
. Appl y brake cyl i nder
grease (P/N:
08733
-
8020E)
or equi val ent rubber grease to the sl i di ng sur-
faces as shown.
-| a
Sl i di ng surf ace
. Appl y Mol ykote 44MA to the brake shoe ends and
opposite edges of the shoes as shown.
+a
Opposi t e edge of t he shoe
- ) o
Br ake shoe ends
6.
1.
Cl ean the threaded
poni ons of cl evi ses A and B.
Coat the threads of the cl evi ses wi th
grease. To
shorten the cl evi ses, turn the adj uster bol t.
Hook the sel f-adj uster spri ng to the sel f-adj uster
l ever fi rst, then to the brake shoe.
Instal l the cl evi ses and upper return spri ng noti ng
the i nstal l ati on di recti on,
NOTE; Be careful not to damage the wheel cyl i nder
dust covers.
Instal l the l ower return sPri ng.
Instal l the tensi on
pi ns and retai ni ng spri ngs.
UPPER RETURN SPRING
CLEVIS B
CLEVI S A
8.
9.
SELF-ADJUSTER
SPRING
10.
1 1 .
12.
Instal l the brake drum.
l f the wh6el cyl i nder has been removed. bl eed the
brakc system
(see page l9-6), and check for leaks at
brake l i ne connecti ons, and reti ghten i f necessary.
Depress the brake pedal several ti mes to set the
self-adjusting brake.
Adj ustthe
parki ng brake
(see page l 9-6). 13.
19-27
Brake Hoses/Lines
Inspection/Torque
Specif ications
1. Inspect the brake hoses for damage, deteri orati on, l eaks, i nterference and twi sti ng.
2. Check the brake l i nes for damage, rusti ng and l eakage. Al so check for bent brake l i nes.
3. Check for l eaks at hose and l i ne
j oi nts
and connecti ons, and reti ghten i f necessary.
4. Check the master cyl i nder and ABS modul ator uni t for damage and l eakage.
CAUTION: Replace the brake hose clip whenever thc brake hose is serviced.
ABS MODULATOR UNIT-Io-BRAKE L|NE
19 N.m 11.9 kgt m. 1a lbtftl
PROPORTIONING CONTBOL VALVE.
Io.BRAKE LINE
15 N.m
(1.5
kgf.m, 11 lbf.ft)
MASTER CYLINDER.TO.ARAKE LINE
15 N.m {1.5 ksf.m, 11 lbf.ft}
aRAKE LINE-Io-WHEEL CYLTNDER
15 N.m
11.5 kgf.m, 11 lbtft)
BLEED SCREW
7 N.m {0.7 kgt m, 5 lbl.frl
SRAKE LINE-Io-BMKE HOSE
15 N.m (1.5
kgf.m, 1r lbnftl
BRAKE LINE-IO.BRAKE HOSE
15 N' m
{1. 5 kgf . m, 11 l bf f t l
BRAKE HOSE-io-CALIPEB
IBAIUJO BOLT}
3l N.ln
(3.5
ksf.m,25 lbf'ft}
19-28
Hose Replacement
CAUTION:
o Before reas3embling, check that all
parts are free ol
dust and other toreign
particles.
. Replace
parts with new ones whenever spcified to
do so.
. Do not 3pill brak fluid on the vehicle; it may damage
the
paint; il brake fluid does contact the paint, wash
1. ReDl ace the brake hose i f the hose i s twi sted, cracked,
or i f i t l eaks,
Di sconnect the brake hose from the
a 10 mm fl are nut wrench.
brake l i ne usi ng
FLARE NUT
( Commer ci al l y
avai l abl e)
BRAKE LINE
Remove and di scard
brake hose.
the brake hose cl i p from the
4. Remove the banj o bol t, and di sconnect the brake
hose from the cal i per.
5. Remove the brake hose bracket from the knuckl e.
6, lnstall the brake hose bracket and brake hose on the
knuckl e fi rst, then connect the brake hose to the
cal i per wi th the bani o bol t and new seal i ng washers
6 mm HOSE ERACKET
7. lnstallthe brake hose on the upper brake hose bracket
with a new brake hose clip.
BOLTS
9. 8 N. m
{1.0 ksf.m, 7 lbf'ft)
9.
BANJO BOLT
3,1 N.m
(3.5
kgf.m.25 lbf.ft)
1 5 N m
{1.5 kgf.m, 11 lbf.ft)
Connect the brake l i ne to the brake hose.
After i nstal l i ng the brake hose, bl eed the brake sys-
t em
( see page' 19- 7) .
. Check the brake hose and
ti ghten i f necessary.
. Check the brake hoses for
I ng.
l i ne
j oi nt
for l eaks, and
interference and twist-
10.
19-29
Parking Brake Cable
CAUTION: The parking
brake cables must not be bent or distortad. Thi3 will lad to stiff operation and premature
cable
failure.
PARKING BRAKE CABLE
Check f or f aul t y movement .
PARKING BRAKE SWITCH
Remove the parki ng
brake cabl e from the backi ng pl ate
usi ng a 12 mm offset wrench as shown,
BACKING PLATE
19- 30
Anti-lock Brake System
(ABS)
Special Tools ...' ......... 19-32
Component Locat i ons . . . . . ". . . . . . . . . . . . . . ' . . . 19-33
(ABSI
Features/Construction
.....' ...' .......... 1 9-34
Operat i on
' . . . . . . . . . . . . . . 19-35
Gircuit Diagram
......... 19-38
ABS Control Unit Terminal
Arrangement
......... 19-40
Troubfeshooting Precautions ....,.. " " " 19-42
(DTG)
.. Diaonostic Trouble Gode
(DTCI
a l nai cat i on . . . . . . . . . . . 19-44
DTC Erasure
........... 19-45
Symptom-to System Chart .....' ....... 19-46
Troubleshooting
ABS Indicator Light Does Not
Come On . . . . . . . . . . . . 19-48
ABS Indicator Light Does Not
Go Of f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19-50
Wheel Sensor
........ 19-52
Sol enoi d
. . . . . . . . . . . . . . . . . 19-54
ABS Pump Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-56
Mai n Rel ay
. . . . . . . . . . . " 19-59
lgnition Voltage
.... 19-60
Central Processing Unit
(CPU)
........ 19-61
Modulator Unit
Removal/lnstallation
....................... 1 9-62
ABS Control Unit
Replacement
.....' ... 19-6:l
Pulsers/Wheel Sensors
Inspection
..........."' 19-63
Wheel Sensor Replacement .......' .... 19-64
Speci al Tool s
Rsl. No. Tool Number Description Oty Page Retorence
o
07PAZ
-
0010100 SCS Servi ce connector
1 19-44
I
19- 32
SERVICE CHECK CONNECTOE I2PI
RI GHT-REAR WHEEL
SENSOR CONNECTOR
MODULATOB UNIT
ABS CONTROL UNIT
RIGHT.REAR WHEEL SENSOR
UNOER. HOOO ABS
FUSE/RELAY BOX
LEFT.REAR WHEEL
SENSOF CONNECTOR
LEFT.FRONT WHEEL
SENSOR CONNECTOR
UNOER.OASH FUSE/RELAY BOX
LEFT-FRONT WHEEL SENSOR
ABS +B {20 A} FUSE
HORN/ STOP
(15
A) FUSE
UNDER-HOOD ABS FUSE/RELAY BOX
UNDER-HOOO FUSE/RELAY BOX
rcl
(40
A' FUSE
PUMP MOTOR I40 A) FUSE
ABS INDICATOR LIGHT
UNDER. DASH FUSE/ RELAY BOX
PUMP MOTOR BEI-AY
n n n
-r n -fl
LIJ n rr rr fl
'-
LJ LJ I]
f l f l n I
t t t l t -
Q ! !
,
METER {7, 5 A} FUSE
[ 0000
[ 0000
0000
n
0000
u
0000[ [
RR DEF RLY {7. 5 A) FUSE MTR CHECK {7, 5 AI FUSE
19- 33
(ABS)
Features/Construction
when the brake pedal
i s depressed duri ng dri vi ng, the wheel s can l ock before the vehi cl e comes to a stop. In such a case.
the maneuverabi l i ty of the vehi cl e i s reduced i f the front wheel s are l ocked, and the stabi l i ty of the vehi cl e i s reduced i f the
rear wheel s are l ocked. creati ng an extremel y unstabl e condi ti on. The ABS preci sel y
control s the sl i p rate ot the wheel s to
ensure the gri p
force of the ti res, and i t thereby ensures the maneuverbi l i ty and stabi l i tv of the vehi cl e.
Judgi ng the vehi cl e speed, the ABS cal cul ates the sl i p rate of the wheel s based on the vehi cl e speed and the wheet speed.
then i t control s the brake fl ui d pressure
to attai n the target sl i p rate.
Grip Force ol Tire and Road Surface
COEFFICIENT OF
FRICTION
A: Distance without slio
B: Slipped distance
C: Actual distance to stoo
sr.re nnre =
f
TARGET SLIP RATE
SLIP RATE
STOP POINT
19- 34
Operati on
ABS Control Unit
Mai n Control
The ABS control uni t detects the wheel speed based on the wheel sensor si gnal i t recei ved, then i t cal cul ates the vehi cl e
speed based on the detected wheel speed. The control uni t detects the vehi cl e speed duri ng decel erati on based on the
rate of decel erati on.
The ABS cont r ol uni t cal cul at es t he sl i p r at e of each wheel , and i t t r ansmi t s t he cont r ol si gnal t o t he modul at or uni t
sol enoi d val ve when t he sl i p r at e i s hi gh.
The pressure reducti on control i s a three mode system, that i s pressure reducti on, pressure retai ni ng and pressure i ntensi
fvi no modes.
Sel l -di agnosi s Functi on
The ABS control uni t i s equi pped wi th a mai n CPU and a sub CPU, and the CPUS check each other.
The CPUS check the ci rcui t of the system.
When the CPUs detect fai l ure, they shi ft to the
"system
down mode" or the
"control
i nhi bi ti on mode".
The sel f-di agnosi s can be cl assi fi el d i nto these four categori es.
Or
I ni t i al di agnosi s
@:
Except ABS control
O:
Du r i ng ABS cont r ol
( D:
Du r i ng war ni ng
On-board Diagnosis Funstion
The ABS control uni t i s connected to the data l i nk connector
(16P)
The ABS system can be di agnosed wi th the Honda PGM Tester'
( cont ' d)
19- 35
ABS CONIFOL UN T
MODE ABS I NDI CATOR LI GHT
MAI N
RELAY
SOLENOI D
VALVE
CPU Rest art condi t i on DTC
SYSTEM
DOWN
ON
No
operati on
Dri ve
i nhi bi t i on
Oper at i on' l
l gni t i on
swi tch
OFF
-
ON Memory
CONTROL
I NHI BI TI ON
ON
No
oper at i on
Dri ve
i nhi bi t i on
Oper at i on Automati c l Memory
+1:
Except CPU f ai l ur e
(ABS)
Operation
{cont'd)
ABS Modulator
The ABS modul ator consi sts of the i nl et sol enoi d val ve, outl et sol enoi d val ve, reservoi r, pump, pump motor and the
dampi ng chamber .
The modul ator reduces the cal i per fl ui d pressure di rectl y. and i t i s al so referred to as a ci rcul ati ng type because the brake fl ui d
ci rcul ates through the cal i per, reservoi r and the master cyl i nder.
The hydraul i c control has three modes: pressure reducti on, pressure retai ni ng and pressure i ntensi fyi ng.
The hydraul i c ci rcui t i s the i ndependent four channel type, one channel for each wheel .
SOLENOID VALVE
PUMP MOTOR
RF
Pressure i ntensi i yi ng model
Pressure retai ni ng mode:
Pressure reducti on mode:
Motor operati on mode:
L F
l N: I NLETVALVE ( NOFMALLY
OPEN)
OUT: OUTLET VALVE (NOF
l\,4ALLY CLoSED)
Inl et val ve open, outl et val ve cl osed
l vl aster cyl i nder fl ui d i s pumped out to the cal i per.
Inl et val ve cl osed, outl et val ve cl osed
Cal i per fl ui d i s retai ned bv the i nl et val ve and outl et val ve.
Inl et val ve cl osed, outl et val ve open
Cal i per fl ui d fl ows through the outl et val ve to the reservoi r.
When stani ng the pressure reducti on mode, the pump motor i s ON.
When stoppi ng ABS operati on, the pump motor i s OFF.
The reservoi r fl ui d i s pumped out by the pump, through the dampi ng chamber, to the master
cyl i nder .
19- 36
Wheel Soeed and Modul at or Cont rol
VEHI CLE SPEED
REFERENCE VEHICLE SPEED
WHEEL SPEED
OUTLET
VALVE
ON
OFF
INLET
VALVE
ON
OFF
MOTOR
ON
OFF
When the wheel speed drops sharpl y bel ow l he vehi cl e speed, the i nl et val ve cl oses to retai n the cal i per fl ui d pressure.
When the wheel soeed drops further, the outl et val ve opens momentari l y to reduce the cal i per fl ui d pressure The pump
motor starts at thi s ti me.
As the wheel speed i s restored, the i nl et val ve opens momentari l y to i ncrease the cal i per fl ui d pressure.
Wheel Sensol
The wheel sensors are the magneti c contactl ess type.
As the gear pul ser teeth rotate past the wheel sensor' s magneti c coi l , AC current i s generated. The AC frequency changes
i n accordance wi th the wheel speed. The ABS control uni t detects the wheel sensor s;gnal frequency and thereby detects
the wheel speed.
There are four wheel sensors, one for each wheel .
The gear pul ser has 50 teeth.
at LOW SPEED
o
GEAR PULSER
19- 37
Ci rcui t Di agram
UNDEF.OASH
YE!8IK-1
UNDER.HOOD ABS FUSE/RELAY BOX
3P CONNECTOR
(a)
number)
I 2 3 l
UNDER.HOOD ABS FUSE/RELAY BOX
2P CONNECTOR i ! number)
a 1 , f
UNOEF DASH FUSE,/BELAY BOX
20P CONNECTOR
(C
number)
l 2 5 6
t 0 1 1 l l 1 5 18 19 20
UNDEB.DASH FUSE/RELAY BOX
18P CONNECTOR
( f
nl mber )
1 2 3 a l r , : 1 5 6
9 t 0 I l 2 1 3 1 4 / 1 6 t 7
, /
GAUGE ASSEMBLY 5P CONNECTOR
(O
numbsr)
f l "
l 1 l /
3 5 l
MODULATOR UNI T 1OP CONNECTOR
( C
number )
PUMP MOTOR 2P CONNECTOR
( f l
n! mber )
LEFI.FBONT SOLE N OIO
-Fm-Feiu
.-..@u*
F GHi.FRONT SOLENOID
REDDTU
YELTLU
- FO -
- YTL -
BtKa
19- 38
fi
I
l
l
GF|//vvHI--GR^L&Hr
ECM I PCMI SCS)
V
r B
V
8t K
rL
cor, coz
n , _ l n A ^ n I o a TAL NK
' - '
l a 3
I ? l 3l coNNEcr oF
r r 6P)
t'-
BTK
4
cot , ct oz
wln/GFN---E
-"**d
RIDE!I]
YtlrBlll
DATA LINK
coNNECTOB (16P)
Tep*'
cnoic.oz cnoicloz
TERMI NAL SI OE OF
MALE TERMINALS
B!!/YEt
GNDl
;--l
*l:,1.
J
WHEEL SENSOR
2P CONNECTOF]
FRONT
llllrh
REAR
l T,
tTl
l - r l
I
SERVICE CHECK
coNNECTOF (2P)
ABS CONTROL UNIT22P CONNECTOR
(l
number)
4
/",/l t /),
l 0 t t
12 1 i / 1 9 / 21 22
ABS CONTROL UNIT 26P CONNECTOR
( C
number )
2 3 6 / : a 9 1 0 t 2 t l
1 5 1 1 t 9 ./ zt / 123 25 2E
19- 39
ABS Gontrol Uni t Termi nal Arrangement
-
7-rt-Il:
I
;:,
I
.li
WIRE SIDE OF FEMALE TERM
VB: Battery Voltage
Terminal
numbel
Wire
color
Tormind sign
ITermin.l namol
Description
Voltago
tafininlb
Condition3
(lgnition
Switch ON
(lll)
Output voltagg
1 GRN^r'VHI
PCOt\4
(Pri mary
common)
Power source tor the sol enoi d
val ve and pump motor. 1-GND ON
6
ON O V
OFF AC: 3-6 V
2 BLIqWHT
scoM
(Secondary
common)
Power source l or t he sol enoi d
2.GND
OFF
lConnect
the SCS service]
\ connector l
Approx. 3 V
3 BLK/BLU
(l gni t i on
2)
Detects ignition switch 2
si gnal . {Syst em act i vat e si gnal )
3-GND VB
BLU//EL
RRO
(Rear-ri ght
0)
Detects right-rear wheel
sonsor srgnal .
When the wheel i s
turned at 1 turn/second.
53 mV or above on
digitaltester {AC
range)
(Referance)
150 mvtrp or above
on oscilloscope
GRY
RLO
(Rear-l eft
0)
Detects left-rear wheel sensor
sr gna l .
8 GRN
FRO
(Front -ri ght
0)
Detects right-front wheel
sensor srgnal .
8-21
Stops ADprox. 2. 5V
I GRNA/VHT
STOP
(Stop)
Detects brake switch signal.
{Prevents unnecessaryABS operation)
9-GND
Erake pedal
depressed. VB
Erake pedal rel eased. O V
10 BRN^/vHT
FLO
(Front-l eft
0)
Detects left-front wheel sensor
si gnal .
10-23
When the wheel i s
turned at 1 turn/
secono.
53 mV or above on
digitsl tester {AC
rangel (ffeferance)
150 mvpp or above
on oscilloscope
Stops Approx. 2. 5 V
12 YEL
RL-OUT
(Rear-left
outlet)
Dri ves l ef t -rear out l et sol enoi d
12-GND
uJ
ON
' 5
-9
ON O V
AC: 3-6 V
REO/vVHT
RR-IN
(Rearri ght
i nl et)
Dri ves ri ght -rear i nl et sol enoi d
I 3- GND
OFF
lConnectthe
SCS service]
\
connector I
Appr ox. 3 V
1 4
B1
(Battery
1)
Power source for the sol enoi d
val ve and pump motor.
14-GND
VB
r'VHT/GRN
(Battery
2)
Power source f or t he sol enoi d
val ve and pump mot or.
15, GND
1 6 BLK
GND2
(Ground
2)
Ground f or t he ABS cont rol
uni t .
16. GND
Bel ow 0.3 V
1 7 GRN/YEL
RR1
(Rear-ri ght
1)
Detects right-rear wheel
sensor si gnal .
When t he wheel i s t urned
at
'l
turn/second.
53 mV or above
on di gi t al t est er
(AC
range)
(Ref erance)
150
mVp-p or above
on osci l l oscope
1 9 LT BLU
RLl
(Rear-left
'l
)
Det ect s l ef t -rear wheel sensor
si gnal .
19,6
) 1
GRN/BLK
FR1
(Front -ri ghr
1)
Detects right-front wheel
sensor si gnal .
21-A
23
FLI
(Front -l ef t
1)
Detects left-front wheel sensor
si gnal .
23- 10
Stops Appr ox. 2. 5 V
RED
RL-IN
(Rear-l eft
i nl et)
Dri ves l eft-rear i nl et sol enoi d
val ve.
25. GND
ON
' 6
ON O V
OFF AC: 3- 6 V
OFF
lconnect
the SCS seNicel
I Connector
l
Approx. 3 V
26 BLK
GND3
(Ground
3)
uni t .
26-GND Bel ow 0.3 V
19- 40
VB: Battery Voltage
Tsiminal
numb6r
WiJe
cot ol
Terminal sign
lTo]minal nomsl
Doscription
Voltage
Conditions
(lgnition
Switch ON lll)l
Output voltago
tef|ninak
I RED/BLU
FR.IN
(Front-ri ght
i nl et)
Dri ves ri ght -f ront i nl et
sol enoi d val ve.
1- GND o
ON
'6
ON O V
OFF AC: 3-6 V
OFF
lconnsct
the SCS servicel
\ connedor I
Approx. 3 V
BRN
(Service
check
si gnal )
Det ect s servi ce check si gnal
(Di agnost i c
t roubl e code
i ndi cat i onl
4-GND
SCS service connector
connecl eo.
O V
SCS service connector
disconn6cted,
Approx. 5 V
7 BLU/RED
(Warni ng
ramp,
Dri ves ABS l ndi cator Ii ght {The
i ndi cator l i ght goes off when
ABS control unit outputs bat-
tery voltage).
7- GND
Indi cator l i ght oN Approx. 2 V
I ndi cat or l i ght OFF VB
10 YEUSLK
FL-OUT
(Front-l eft
outl et)
Drives left-tront outlet
sol enoi d val ve. 1O- GND
uJ
ON
ON O V
OFF AC: 3' 6 V
11 RED/BLK
FL-IN
(Front-let
inletl
Dri ves l ef t -f ront i nl et sol enoi d
11. GND
OFF
/Connect
the SCS seruiceJ
\ conneclor I
Approx. 3 V
YEUBLU
FR-OUT
(Front-ri ght
outl et)
Dri ves ri ght -f ront out l et
sol enoi d val ve. 12- GND
l 4 LT BLU
DLC
(Dat a
l i nk
connector)
Communi cat es wi t h Honda
PGM Test er. 14- GND Approx. 5 V
17 BR N/VE L
MCK
(l l otor
check)
Detects pump motor dri ve
sr gnal . 17 GND
Pump
motor
relay
ON VB
OFF O V
1 9 YEVRED
PMR
(Pump
mot or
ret ay,
Dri ves pump motor rel ay.
I 9- GND
ON
ON O V
OFF AC: 3-6 V
OFF
lconnect
the SCS servicq
\
connefior
l
Approx, 3 V
BLU
RR-OUT
{Rear-ri ght
outl et)
Dri ves ri ght-rear outl et
sol enoi d val ve.
21- GND
ON
Pump
motor
reray
ON O V
OFF AC: 3-6 V
OFF
lconnect
the SCS seNicq
\ connedor I
Appr ox. 3 V
BLK
GND2
(Ground
2)
uni t .
22-GND Bel ow 0.3 V
19-41
Troubleshooting Precautions
ABS Indicato. Light
1. The ABS i ndi cator l i ght comes on when the ABS control uni t detects a probl em i n the system. However, even though
the system i s normal . the ABS i ndi cator l i ght can come on. too, under the fol l owi ng condi ti ons. To determi ne the
actual cause of probl em, questi on
the customer about the
probl em,
taki ng the fol l owi ng condi ti ons i nto consi dera-
I | on.
. Si gnal di sturbance
. Wheel spi n
.
Onl y dri ve wheel s rotate
. Battery voltage Iluctuates
2. When a probl em i s detected and the ABS i ndi cator l i ght comes on, the i ndi cator l i ght can stay on unti l the i gni ti on
swi tch i s turned off, or i t can automati cal l y go
off, dependi ng on the mode.
. Li ghtstayson unti l the i gni ti on swi tch i sturned off: Whenthesystem i s i nthesystem down mode.
. Li ght automati cal l y goes
off: When the system i s i n the control i nhi bi ti on mode.
(refer
to symptom-to-system chart)
3. The ABS i ndi cator l i ght stays on when the system i s reacti vated wi thout erasi ng the DTC, but i t goes off after starti ng
the car.
When the wheel sensor system is faulty and the ABS indicator light comes on, the algorithm of the system automatically
turns off the ABS indicator light after the wheel speed signal returns to the normal speed. While, when the DTC is erased.
the CPU is reset and the ABS indicator light goes
off when the system checked out normal by the initial dlagnosis.
Therefore, test-dri ve the car after servi ci ng the wheel sensor system, and be sure that the ABS i ndi cator l i ght does not
come on.
4. When the ABS control uni t outputs battery vol tage to gauge assembl y. the ABS i ndi cator l i ght goes
off,
Diagnostic Troublo Code
(DTCI
1. The di agnosti c troubl e code
(DTC)
i s memori zed when a probl em i s detected and the ABS i ndi cator l i ght does not go
off, or when the ABS i ndi cator l i ght comes on.
The DTC i s not memori ?ed when the ABS i ndi cator l i ght comes on unl ess the CPU i s acti vated.
2. The memory can hol d any number of DTCs. However, when the same DTC i s detected twi ce or more, the l ater one i s
wri tten over the ol d one.
Therefore, when the same
probl em
i s detected repeatedl y, i t i s recorded as one DTC.
3. The DTCS are i ndi cated i n the order of ascendi ng number, not i n the order they occur.
4. The DTC$ are memori zed i n the EEPROM
(non-vol ati l e
memory).
Therefore, the memori zed DTCS cannot be cancel ed by di sconnecti ng the battery. Perform the speci fi ed procedures
to
erase.
Self-diagnosis
1. The sel f-di agnosi s can be cl assi fi el d i nto these four catego.i es.
. Ini ti al di agnosi s: Performed ri g ht after the engi ne sta rts and unti l the ABS i nd i cator l i ght goes ofJ
. Except ABS control : Performed when the ABS i s not functi oni ng.
. Duri ng ABS control : Performed when the ABS i s functi oni ng.
. Duri ng warni ng; Performed when the ABS i ndi cator l i ght i s ON.
2. The system performs the fol l owi ng control s when a probl em i s detected by the sel f-di agnosi s.
! ABS i ndi cator l i ght ON
. Memory of DTC
. Mode change to the
"system
down mode" or the
"control
i nhi bi ti on mode".
MODE ABS INDICATOR LIGHT
MAI N
RELAY
SOLENOI D
VALVE
CPU Restart condi ti on DTC
SYSTEM
DOWN
ON
No
operatron
Dri ve
i nhi bi t i on
Operati on*1
l gni ti on
swatch
OFF
*
ON Memory
CONTROL
I NHI BI TI ON
ON
No
opera on
Dri ve
i nhi bi ti on
Operati on Automati c Memory
*1:
Except CPU fai l ure
19-42
Kickbsck
1. The motor operates when the ABS i s functi oni ng, and the fl ui d i n the reservoi r i s forced out to the master cyl i nder
causi ng ki ckback at the brake pedal .
2. The ABS control uni t operates the sol enoi d val ve when the brake
pedal i s rel eased after the i ni ti al di agnosi s. You may
hear the fai nt sol enoi d val ve operati on sound at thi s ti me, but i t i s normal .
Pump Motor
1. The pump motor operates when the ABS i s functi oni ng.
2. The ABS control uni t checks the pump motor operati on duri ng accel erati on. You may hear the fai nt operati on sound
at thi s ti me, but i t i s normal .
Brake Fluid Replacment/Air Bleeding
1. Brake fl ui d repl acement and ai r bl eedi ng
procedures are same as conventi onal brakes.
Troubleshooting
1. The troubl eshooti ng fl owcharts expl ai n the
procedures on the assumpti on that the cause of the probl em i s sti l l pre-
sent and the ABS i ndi cator l i ght i s sti l l on.
Note that troubl eshooti ng fol l owi ng the fl owchart when the ABS i ndi cator l i ght does not come on can resul t i n
j ncor-
rect
j udgment.
Ouesti on the customer about the condi ti ons when the probl em occurred, and try to reproduce the same condi ti ons
for troubl eshooti ng.
Sel f-di agnosi s i s made at vari ous ti mes such as the i ni ti al di agnosi s, except ABS control , duri ng ABS control , duri ng
accel erati on, duri ng the speci fi ed vehi cl e speed, etc. Therefore. the symptom cannot be checked unl ess the check
condi ti ons match wi th the probl em condi ti ons.
When the ABS i ndi cator l i ght does not come on duri ng the test-dri ve, but the troubl eshooti ng i s performed based on
the DTC, check for the l oose connectors, poor contact of the termi nal s, etc, before troubl eshooti ng.
After troubl eshooti ng, erase the DTC and test-dri ve the car. Be sure that the ABS i ndi cator l i ght does not come on.
The connector i l l ustrati ons show the femal e connectors wi th a si ngl e outl i ne and the mal e connectors wi th a doubl e
ouI | t ne.
The connector termi nal cavi ti es contai ni ng femal e termi nal s are al ways numbered by l ooki ng at the connector from
the wi re si de, and the cavi ti es contai ni ng mal e termi nal s are al ways numbered by l ooki ng at the connector from the
termi nal si de.
19-{f
{DTC}
Diagnostic Trouble Code {DTG)
Indication
NOTE: Thi s operati on can al so be carri ed out wi th Honda PGM Tester.
1. Connect the SCS servi ce connector to the servi ce check connector i nsi de the
passenger' s si de ki ck
panel
2, Turn the i gni ti on swi tch ON
(l l ),
but do not start the engi ne
NOTE: Do not depress the brake
pedal when turni ng the i gni ti on swi tch.
3. Record the bl i nki ng frequency of the ABs i ndi cator l i ght. The bl i nki ng frequency i ndi cates the DTc.
4. Turn the i gni ti on swi tch OFF, and remove the SCS servi ce connector.
NOTE; The Mal functi on Indi cator Lamp
(Ml L)
wi l l stay on after the engi ne i s started i f the SCS servi ce connector i s
connected.
5. Erase the DTC.
condiiions for DTC indication
. The car i s stoDDed.
. The SCS servi ce connector i s connected before the i gni ti on swi tch i s turned ON
(l l ).
. The brake pedal i s rel eased.
. The SCS servi ce connector remai ns connected duri ng thi s
procedure
The DTC indication stops and the ABS control unh executes the software tunction if at least ono of the tollowing condi'
tions is satisfied,
. The car i s not stopped.
. TheABScontrol uni trecei vesthe normal si gnal
(whi ch
i sfortheABS control uni t)from a Honda PGM Tester.
. The SCS servi ce connector i s di sconnected duri ng thi s
procedure.
ABS INDICATOR LIGHT
u.s.A.
@
CANADA
@
A8S INDICATOR LIGHT
or c | 12
. 3 sec.
0. 3 sc.
8ff'?,1i'*"n
x : Eulb chck mc'd
Sscond
. When i gni ti on swi tch i s turned ON
(l l ),
the ABS i ndi cator l i ght comes on to check the bul b. Do not count i t as a DTC.
. The ABS control uni t can memori ze any number of DTCs.
. The new DTC i s not memori zed when the ABS control uni t has al ready memori zed the same DTC.
. l f t heDTCi s not memor i z ed, t heABSi ndi c at or l i ght s t ay s ONaf t er i t goes of t f or 36s ec onds '
19-44
,t
DTC Erasure
1. Connect the SCS servi ce connector to the servi ce check connector i nsi de the passenger' s si de ki ck panel .
2. Depress the brake
pedal .
(l l )
whi l e hol di ng the brake pedsl , but do not start the engi ne. The ABS i ndi cator l i ght
goes off after two seconds.
4. After the i ndi cator l i ght goes oft, rol ease the brake pedal . The i ndi cator l i ght comes on after four seconds.
5. After the i ndi cator l i ght comes on. depress the brake pedal agai n. The i ndi cator l i ght
goes
off agai n after four sec-
onds.
(the
brake
pedal i s sti l l depressed.)
6. After the i ndi cator l i ght goes off, rel ease the brake
pedal agai n,
7. After four seconds, the i ndi cator l i ght bl i nks twi ce for 0.3 second and the DTC i s erased.
8. Confi rm the DTC i ndi cati on, and check that the DTC was erased.
NOTE; Always maintain these steps. lf you disconnect the SCS service connector and/or fail to operate the brake
pedal
accordi ng to the i ndi cator l i ght i ndi cati on, the DTC wi l l not be erased.
Conditions tor DTC orasuro
. The car i s stopped.
o The SCS servi ce connector i s connected before the i gni ti on swi tch i s turned ON
(l l ).
. Thebrakepedal i s depressed before the i gni ti on swi tch i s turned ON {l l ).
. The SCS servi ce connector remai ns connected duri ng thi s procedure.
The DTC erasurs stops and ABS control unit xacutos tho software tunction if 8t least ons of the following conditions is
satislid.
. The car i s not stopped.
. The SCS servi ce connector i s di sconnected duri ng thi s servi ce,
. The ABS control uni t recei ves the normal si gnal
(whi ch
i sfortheABS control uni t) from a Honda PGM Tester.
. The brake pedal i s not operated accordi ng to the i ndi cator l i ght i ndi cati on,
. The DTC erasure i s fi ni shed.
ABS INDICATOR LIGHT
OFF
DEPRESS
BRAKE PEDAL
RELEASE
)
0. 3sec.
lqnilion switch
oN
(
)
19- 45
Diagnostic Trouble Gode
(DTCI
Symptom-to-System Chart
orc
s k =
< x Y
oTAGNOSTS/
SYMPTOM
OETECIION TIMING
> 7
i : Y
PROBAELE CAUSE
EXts
1 6 >
2
xE
Z E
e P 8
z z
48"
6 a z
NO
Drc
ABS indicEto. lisht do6s
nor come on whon ignirion
swirch is turnod on (ll)
Open in the power source circuitfo.the ABS indacator light
Elown ABS indicator lightbulb
Op6n in the ABS andicato.light drive circuit.
Shorrio
powo. in th6 WALP ci.cuit
F6ultv ABS codtfol unit
ON
ABS indacator light doos
not go ofi aftsrngine is
Opsn in th lG2 cncuit
Opsn in lh +B circuit
Opsn and/or shon to body
srcund
in rhe WALP circuit
FaultY aBS controluoil
1 l
oNr
Whe6l s6nsor
(op6r' /shon
O o o
o
Op6n, shonto body
sround
and/orshonto pow6r inrhe whel
Faulty aBS contrclunit
15
11 RL
12
oN'
(chipp6d pulssr ga/noise)
o o
o
Shon io who6l sonsor
(0)circuit inth whol scnsor
(1)circuit
Faulty wheel sensor inst8ll6tion
Faulty AgS controlunit
1 6
1E RL
ON
Sol6noid {op6 sho.tio
o o o
FR IN opn, shonto body ground and/or shonlo powr inthe
Opsn in lhe COM circuit
Faulty AaS contrclunit
32 F8.OUT
33 FL I N
3,r FL.OUT
35 FA I N
RR-OUT
37 RT-IN
3a RI.OUT
5 1 ON o o
Op.n in th6 motor poworsourco ci.cuit
Op6n in rh motor GNDcarcuit
Fautty AAS oontrol u.it
52 ON o o
Open in lh COM, PMF and/or MCK circuit
Op6n.nd/or blown fus6 in th undeFhood ABS fus6/r6l6y box
Faulty pump motor rBlay
Fault ABS cont.ol unil
53 ON o
Shonto body ground in the PMB circuii
Shortto power in the
pump motor power sou@ circuit
Faulty pump motor rcl.y
Faultv ABS cont.olunit
54 ON o o o
Opon, shorito body
sround
dncyor blown fuss in the B1 or 82
Shonro body g.ound andlorshonto
powor in rh COM circuit
Fsulty modulalor unit
Fa! l t vABS cont r ol uni t
6'I ON
lgoilion voltago ilow voh'
o o o o
Conoction oltho 24v battery for engine start
Faulrycharuinq sy8tem
Opn in th6lG2 circuit
FaultvABS controlunit
81 ON CPU o o o o
Exteml feto sj can b lho c!u!(s) ol the preblem
Faul t yABS cont r ol uni t
r:
It DTCS t 1 18 (whool
ssnsor codos) wsre detocred th6 last time th6 ca, w.s drav6n, the ABS indicator light will 3ray on unril the ignilion switch is tLrrnod oN
(ll),
6nd the
conlrol unit confirms that th wheel sensoF arc OK,
19- 46
CONDITION FOR DETECTION
MANAGEMENT
FFER
TO
PAGE
DURI NG
A8S CONTROL
EXCEPT
ASS CONTROL
1 9
19-50
Th ABS indicalor light comes on when vehicl is stopped and wheelsensora givn voltag does not
19 52
The ABS indjcalorcomes on underrhe following conditions.
.
When more than one ol wheels ar at a srandstill and the velocitY ofth. fasrsi wheel reaches a
.
When the vl@ity ol the faste$ wheel reaches or erc@ds a givsn sp*d, and ifthere a.e som whels
whos vlo.ity is slowerthan a ce.lain parcnlaqe ol the fastel wheelspd tor a given period.
.
Whsn there aretempor.ry open orshort ctcuits of lhe wheel sensor, chippod pulsof gear, o. signal
19,52
The main relay repeats ON/OFF switching aialltimes.
.
When the main relav is ON, a shorttest
pulse is sentto each valve.lfthere is some discrepancy, the
ABS indicalo. liqht comes on.
.
Whn ti main r6lav is OFF, a shontest
puls is soni ro each valve.lt lhe solenoid drive voltage is
oul of a given range, the ABS indicator light comes on.
19 54
.
Th pump motor is aclivated once or twice afterevery ignition switch ON
(ll)operation while lhe
vehicle accelerals, thon lhe moror drive vollag ischocked. Whan lhe voltags is abnormal,lhoABS
indi@ror light comes on.
.AfterABS
conrrol comglerion, lhe motorswirchgd is ofiand the main CPU chects the motor drivo
voltaqe. Whn rhe voltaqe is abno.msl,tho ABS indicator lightcomas on
' 19,56
During an active mororresl or AaS cont.ol, the main CPU checksthe supply voltaqe to lhe motor.
When t he vol t ag i s abnor mal , l heABS i ndi car or l i ght comes on.
19- 56
lf the moro. driv voltage indicates motor operarion when lhe main CPU does notswilch the motor
oN, rh ABS indicalorcomes on.
19-56
.
When a solenoid valve failure is detected, rhe CPU checks rhe vottag ofrhe main relay output lfth
vottage is lowe.than a given vohage, the AgS indicator lighl comoson.
.
The main relay rpeats ON/oFF switching atalltims- whon the main relay is oft, a shon test pulse
is sent lo each valve. The CPU monito.s tho relerence voltage, lflh vollage is out ot 3 given rang.
the aBs indicator liohr comes on.
t 9 59
Whenrhe isnition voltaoe is lower or higherthan a given voltage, the CPU inhibirs ABS contoland
swirches offrhe main relay, and the ABS indicator lighr comes on. when the ignition vollage recovers
lo no.mal r.nge, ABS inhibition is canceled.
l9-60
The main CPU.nd sub CPU check each other under certsin condirions. when the CPUS detectthe lol_
lowing d iscrepansies, lhe ABS indicaror light comes on.
' When
there is discrepancy in thecalculaled wheelspeed velocitylhatconiinuesfo. morethan a given
.
Whnrh6re is discrepancy in the phase informarion thatcontinues for morethan a givon priod
.
When thors is discreoancy in the calculsted connolparameter.
' when
the warch dos control
pulse is faals lor a given period.. whsn rho checksum ofthe ROM is tails
.When
there is discrepancy in ths dara radins and wrilins procadu.e of FAM.
1 9 6 1
19-47
Troubleshooting
ABS Indicator Light Does Not Come On
The ABS indicator light does not come on when ignhion switch is turned ON {ll)
NOTE: Al l i ndi cat or l i ght s except t he charg-
i ng syst em l i ght wi l l not come on when t he
METER 17. 5 A) f use i s bl own.
YES
NOTE:
Rei nst al l t he
fuse it it is OK.
I G1 I YEL)
Th ABS indicator light doos not
come on whn ignhion switch is
turned ON llll.
check t he MEI ER
(7. 5
A) l use i n
t he under-dash f use/ rel ay box.
Boplaco the tu3e and recheck.
Chock lor .n open in tho lcl cir-
cuit:
1. Di sconnect t he
gauge
assem-
bl y 5P connect or.
(l l ).
t he
gauge
assembl y 5P con-
nect or t er mi n6l No. 5 and
body ground.
.
Repai r opcn i n t he wi r a
bet ween t he METER 17. 5 Al
tus and gauga aitombly,
.
Rookca l he undor-dr3h f u3. /
rolay box.
(Opcn
circuit insido
tho box.
check t he ABs i ndi cat or l i ght
bul b i n t he
gauge
assembl y.
Check lor a shon to oower in tho
WALP circuit:
Measure t he vol t age beNveen t he
gauge assembl y 5P con nect or
t ermi nal No. 1 and body ground.
Ropair short to powo. in the wiro
bet ween t he gaugo
a33ombl v
and ABS comrol unit.
ls there battery vohage?
(To page 19-49|
19- 48
(From page 19-48)
Check tho gaugo .$smbly:
2. Connct t he gauge assembl y
5P connect or,
3. Connect t he t ermi nal No. 3 t o
body gr ound wi t h a
j umper
(l l ).
Roplace the ABS indic.tor light
drive cilcuit in tha
grugg
a33em-
blv.
Does t he ABS i nd; cat or
l i ght come on?
. Ropai r
opon i n t ho wi r e
bot waen t he g. uge ei 3ambl y
and body ground.
.
Ropai r pool gr ound
l c, l o1.
cl{)2t.
GAUGE ASSEMBLY 5P CONNECTOF
19- 49
Troubleshooting
Thc ABS indicator light does not
90
off after the 6ngine is slarted.
YES NOTE:Rei nst al l t he f use i t i t i s OK.
YES NOTE: Roi nst al l t he f use i f i t i s oK.
ABS Indicator Light Does Not Go Off
WIRE SID OF FEMAI-E TERMINALS
81 IWHT/GRNI
IG2 {BLK/BLU}
WIR SIDE OF FEMALE TERMINALS
-
Wi t h engi ne. unni ng, ABS
indic.tor light is ON.
-
With the SCS srvice connec-
tor connocted
(s6o pago 194,11,
no DTC is indicrted.
check the RR DEF RLY
(7.5
A) luse
in the under-dash fuse/relay box.
Raolaco tho fuso and Jachock.
Check t he ABS +B
(20
A) f use i n
the under-hood fuse/relay box.
Replace tho tuse and rech6ck.
Check for an opcn in the lG2 cir-
cuh:
(l l ).
t he ABS cont rol uni t 26P con-
n e c t o r t e r mi n a l No . 3 a n d
body ground.
Ropair opon in tha wira bstwaan
the RR DEF RLY 17.5 Al tu30 rnd
ABS contrcl unh,
Check for .n open in the Bl and
82 ci.cuit:
Measur e t he vol t age bet ween
body ground and t ermi nal s No. 14
and No. 15 i ndi vi dual l y.
Reprir opon in the wir6 brtwaan
the ABS +B 120 Al furo snd ABS
control unh.
{To
page 19-51)
19- 50
(From page 19 50)
Check for a short to bodY
ground
in the WALP circuit:
2. Di sconnect t he ABS cont r ol
uni t 22P and gauge assembl Y
5P connect ors.
body
ground.
Repai r shor! l o body
ground i n
the wire botween th ABS con'
trol unit and
gauge assemblY.
Check the ABS control unat:
1. Connect t he ABS cont r ol uni t
22P connect or .
2. Tur n t he i gni t aon swi t ch ON
( l l )
3. Measur e t he vol t age bet ween
t he ABS cont r ol uni t 22P con
body
gr ound.
Check l or an open i n t h GND2
ci rcui t :
1. Connect t he ABS cont rol uni t
26P connect or t ermi nal No 16
t o body
ground wi t h a
j umper
t he ABS cont rol uni t 22P con
n e c t o r t e r mi n a l No 7 a n d
body
ground.
Chck f or an open i n t he WALP
circuit;
Measure t he vol t age bet ween t he
ga uge assembl y 5P connect or
t ermi nal No. 1 and body
ground.
Repair open in th wire betwoen
the ABS control unit and
gauge
assemblv.
ABS CONTROL UNIT 22P CONNECTOB
JUMPER
WIRE
Replace the ABS indicator light
driv6 ci.cuit in the gauge assem'
bl v.
WALP I BLU/ REOI
WALP
(BLU/REO)
t 2 3 4 6 , / 8 I r 0 12113
1 4 t 5 1 6 1 7 / ' , 1s
./
21 26
GND2
(8LK)
.
the ABS control unit and bodY
ground.
.
Repai r poor gr ound
{ Gi l o1,
G402).
l s t her e bat t er y vol t ageT
Check for loose ABS control unit
connectors, It necessary. substi-
tute a known-good ABS control
unit and recheck.
GAUGE ASSEMELY 5P CONNECTOR
19- 51
Troubleshooting
Wheel Sensor
(DTCI
11-18: Wheel Sensor Di agnosi s
NOTE: The ABS i ndi cator l i ght comes on when onl y the dri ve wheel s are turni ng. si gnal di sturbance i s detected. etc. Therefore,
test-drive the car at a speed of 12 mph
(20
km/h) or more after turning the ignition switch from OFF to ON 0l). and if the ABS
indicator light does not come on, the system is OK.
RL1 I LT 8LU) FRl {GRN/ BLKI
RRO
I ELU/ YELI
RRl {GRN/YELI FLl {GRN/ORNI
DTC
Appropri at e Termi nal
(O)
SI DE
( 1) SI DE
11, l 2 ( Ri ghr - l r ont )
No. 8: FRo No. 21: FRl
13, 14
(Left-front)
No 10: FLo No. 23: FLl
15, 16
( Ri sht - r eaf )
No. 4: RBo No. 17: RR1
'17,
18 {Left-rear) No. 6: RLo No. 19: RL' l
NOTE: Judgement val ue t or short t o
NO
NOTE
.
Normal vol t age: Approx. 2 V
.
0 V: Repl ace t he ABS cont rol uni t .
.
4 V or more i ndi cat es a short t o power.
-
With tho ignition switch ON
llll, ABS indicltor lisht does
not go
off.
-
Af t er dl i vi ng, ABS i ndi cat or
light comes on.
-
With the SCS service connec-
tor connocted
ls
page
1$501,
DTCa 11-18 ar indicated.
Check the wh6ol sensor circuit:
l Di sconnect t he ABS cont rol
uni t 26P connect or.
between the appropriate wheel
sensor 10) and
(1)
ci rcui t t ermi -
.
Roplir opcn in the l0l or
('l)
cir-
cuit wire, or ahort to tho
(0,
cir-
cuit wir. in thc
(1)
circuit wire
betwoon tha ABS control unit
and appropriata wheal son3or.
'
Roplace tho approprirto wh.el
3an30r,
ls the resistance OK?
/Front:
750
-
1050 o/20.c, 68"F\
l Rear.
850
-
1150 020' C, 68"F/
Check tor a shon to body ground
in the wheel sensor circuit:
ABS cont rol uni t 26P connect or
appropri at e wheel sensor
(0)
ci r
cui t t ermi nal * and body ground.
'
Rspair 3hort to body ground
in
t he l 0) or { 11 ci r cui t wi r e
between the ABS control unit
and appropriato wheel snsor,
.
Replace the appropiiate wheel
Check tor a short to
power
in the
wheel sensor circuitl
1. Reconnect t he ABS cont rol uni t
26P connector.
nect or appropri at e wheel sen
sor
( 0)
ci r cui t t er mi nal and
body ground.
Repair shon to powor
in the
(01
or {l ) ci rcui t wi ro bt ween t he
ABS control unit and appropriate
l s t here 4 V or more?
(To page 19-53)
19-52
(From page 19-52)
Check f or chi pped
pul ser gear.
Ropl . ce t he dri verhrf t or hub
unit.
(Chipped pulst goerl
DTC 11. 13. 15, 17: Ropl sco t he
ABS control unit,
DTC 12, 1ir, 16,
't8:
The ABS con-
trol unit may have dotected sig'
nil dbturbanco.
19- 53
Troubleshooting
Sol enoi d
Di agnosti c Troubl e Code {DTC) 31-38: Sol enoi d Di agnosi s ABS CONTROL UNIT 22P CONNECTOR
-
With the ignition switch ON
(l l ).
ABS i ndi cat or l i ght does
not
go
off, or ABS ifldicator
l i ght comes on whi l e ABS i s
t unct i oni ng.
-
With the SCS sewice connec-
tor connoctod lsoe
page 1$50).
DTCS 31
-38
are indicated.
wlRE SIDE OF FEMALE TERMINALS
FL-OUT {YEL/BLK}
DTC
Ter mi nal
3 1 : F R l N 22P No . 1
32: FR-OUT 22P No. 12
33r FL l N 22P No. 11
34i FL-OUT 22P No . 1 0
35: RR- l N 26P No. 13
36: RR-OUT 22P No. 21
37i RL' I N 26P No. 25
38: RL-OUT 26P No . 1 2
Chock tor a short to powr in the
solenoid circuit:
uni t 22P and 26P connect ors.
t he ABS cont rol uni t connect or
appr opr i at e sol enoi d ci r cui t
t ermi nal * and body ground.
R6pai r shor t l o power i n t he
appropriate solenoid circuit wire
bet ween t he ABS cont rol uni t
and modulator unh,
check lor a 3hort to bodY ground
in the solenoid circuili
Check {or continuity betlveen the
appropriate solenoid circuit termi
nal * and body gr oLr nd.
.
Repair shon to body ground in
the appropriato solenoid circuit
wire between tho ABS control
unit end modulator unit.
.
Replace the inodulator unit.
Check the ABS control unit:
2. Connect t he ABS cont rol unh
22P and 26P connect ors.
nect or,
(l l ).
nect or appropri at e COM ci rcui t
t ermi nal ** and body ground.
Chock lor loose ABS control unit
conneclors. lf oecessary, substi-
tule a known-good ABS control
unit and recheck.
RL. OUT I YEL}
oTc
Ter mi nal
31: FR I N No. 2: SCOM
32: FR-OUT No. 2: SCOM
33: FL- l N No. 1: PCO[,
34: FL-OUT No. l : PCOM
35i RR l N No. 1: PCOM
36: RR'OUT No. 1: PCO[,
37: RL I N No. 2: SCOM
38: RL-OUT No. 2: SCOM
RL. OUT {YELI
YES
PCOM
19- 54
(To page l 9-55)
(GRN/WHTI
{From
page 19-54)
Check for an open in th. solenoid
circuit:
ABS control unit connedor aPPro_
pri at e sol enoi d ci rcui t t ermi nal *
and body
ground.
.
Repair open in the appropriate
COM circuit wire betwen the
ABS cortrol unit and modulator
unit.
.
Repair open in the applopriate
sol enoi d ci rcui l wi t e bst ween
the ABS control unit rnd modu-
lator unit.
.
ReDlace the modulato. unit.
l s t here spprox. 3 V?
Check for looso ABS control unit
connostors, lf nocGaary, sub3ti'
tute 6 known-good ABS control
unit and recheck.
FL.OUT IYEL/BLK)
DTC
Appr opnal e
Connector
Appropriate
Termi nal
3 l : F R l N 22P No. l
32: FR OUT 22P No. 12
33: FL]N 22P No. 1' l
34i FL-OUT 22P No . 1 0
35: RR lN 26P No. 13
36: RR OUT 22P No. 21
37: RLI N 26P No. 25
38: RL. OUT 26P No. 12
RL.OUT
(YEL)
19- 55
Troubleshooting
ABS Pump Motor
Diagnoetic Trouble Cod6
(DTC)
51-53: ABS Pump Motor Diagnosis
yES NOTE: Shor t t he PMR t er manat t o body
NOTE: Rei nst al l
ground f or a moment , and recheck t he f use.
the fuse it it is OK.
lf the fuse is blown, check for a short to body
ground i n t he MCK ci rcui t .
l 1 8 / 1 0t l
l 4 , / 117
191, / 21
PMR IYEL/RED} I JUMPER
I wrRE
YES
NOTE: Rei nstal l
the fuse if it is OK.
NOTE: Shor t t he PMR t er mi nal t o body
ground t or a moment , and recheck t he t use.
lf the fuse is blown, check for a shon to body
ground i n t he wi re be&veen t he under hood
ABS tuse/relay box and pump motor.
-
With rhe ignition 3wilch ON
{lll, ABS indic.tor light do..
not
9o
ott.
-
With the SCS srvice conn.c-
tor connoc{d 13
pegg 19-50},
DTCa 5l-53 .rc indlstod.
check the MTR cHEcK 0.5 A) tuse.
Rcplaco the tus6 and r6ch6ck.
Repl.co the fuso and .scheck.
Replacc tho pump motor .alay.
Check t h pump
mot or powet
source circuit:
(l l ).
Check tor a short to
powoJ
in tho
pump
motot
powar
sourco circ{it:
Remove the
pump
motor relay.
Does the
pump
motor operate?
Repair 3hort to
powar
in tha wile
bot woon t he under-hood ABS
t u3o/ rol ay box and ABS pump
motot.
Does the pump motor operate?
Chock tor loose ABS control unit
connector!. lf nece$sry, subsli-
tute a known-good A8S control
unit and recheck.
(To page
19-57)
19- 56
T
I
{From
page 19-56)
UNDER-HOOD ABS
FUSE/RELAY BOX
TERMINAL TERMINA.
PUMP MOTOR 2P CONNECTOR
MOTOR +B
(WHTl , S
rv)
-
Y
MOTOR +B i RED)
MOTOR GND I BLKI
(cont' d)
19-57
JUMPER WI RE
WIRE SIDE OF FEMALE TEFMINALS
Check the pump motor circ!it:
1. Remove t he
pump mot or rel ay
(l l )
3. Connect t he
PUmP
mot or rel ay
connector +B and MOTOR ter_
mi nal s wi t h a
j umper wi re f or
a momenl .
Check f or an open i n t he
PumP
motor +B circuit:
1. Turn t he i Oni t i on swi t ch OFF.
2. Di sconnect t he
pump mot or
2P connect or.
(l l ).
4. Connect t he pump mot or rel ay
connect or +B and MOTOR t et '
mi nal s wi t h a
i umPer
wi re.
t he
pump mot or 2P connect or
t e r mi n a l No . l a n d b o d Y
ground.
Does t he pump mot or operat e?
Repair open in the wire betwoen
t he under-hood ABS f us/ rel av
box and
pump motor.
Check t he
pump mol or opera'
tion:
Connect the battery
(+)
termanal to
the
pump motor 2P connector ter
mi nal No. ' 1, and t he
(
) t er mi nal t o
t he t ermi nal No. 2 f or a moment .
Beolace the modulator unit.
{Fallty
pump motorl
Does t he pump mot or oPerat e?
Repah open in the wita between
the pump motor rnd bodY
ground,
or
poor ground (G/o31.
Check for a short to body
ground
in the PMR circuit:
t e r mi n a l No . 1 9 a n d b o d y
ground.
Repai r short t o body
ground i n
t h6 wi r e bet ween l he undr -
hood ABS t use/ r el ay box and
ABS control unit.
l s l her e cont i nui t y?
(To page 19-58)
Troubl eshooti ng
ABS Pump Motor
(cont' dl
(From page 19-57)
ABS CONTROI- UNIT 22P CONNECTOR
7 8 10 t l
12 / 1 4 1 1 21 22
PMR {YEL/ RED)
WIRE SIDE OF FEMALE IERMINALS
Check loi .n open in the PCOM
ci rcui t :
1. Turn t he agni t i on swi t ch OFF.
2. Reconnect t he ABS cont r ol
nect or,
(l l ).
5. Measure t he vokage bet ween
t he pump
mot or r el ay con-
nect or PCO M t er mi nal and
body ground.
Bopair open in the wire betwoen
t ha under-hood ABS t use/ rel ey
box and ABS cont.ol unit.
l s t here approx. 3 V2
Chock tor an open in ihe PMR cir-
cuit:
Ropair open in the wire betwaen
t he under-hood ABS f use/ rel ay
box and ABS control unit.
Check t or an open i n t he MCK
circuit:
2. Di sconnect t he SCS ser vi ce
connect or.
(l l ).
4. Measure the voltage betlveen
t he ABS cont rol uni t 22P con
nect or t er mi nal No. 17 and
body ground
whi l e connect -
i n g t h e p u mp
mo t o r r e l a y
connect or +B and MOTOR t er
mi nal wi t h a
j umper
wi re f or
moment .
Repair open in the wire betwoen
t he under-hood ABS f uso/ rl . y
box and ABS control unit.
Check tor loose ABS control unit
connectors, It necessary, substi-
tuto a known-good ABS control
un;t and recheck.
tr
) t-1E
r . l
Main Relay
(DTC)
54: Main Rlay Disgnosis
YES
NOTE: Rei nst al l
t he f use i f i t i s OK.
B1
(WHT/GRNI
PCOM
{GRN/WIIT)
SCOM
{BLK/WHTI
( cont ' d)
t 6 1 7
-
{ll}, ABs indicator light do.s
not go off.
-
With the SCS 3oruics connec-
tor conn.ctod h6e Psgc
19601,
DTC
g
b indcst d.
check the ABs +B
(20
A) fuse.
Raplac! lha fuso snd lachock.
Ch6ck for .n open in thc 81, 82
circuh:
Measur e t he vol t age bet ween
body ground and the ABS control
unit 26P connector terminal No. 14
Ropair open in th. wi.o bdtw.en
tho ABS control unit and under'
hood ABS tuse/rol.y box.
Check lor a ihon to body
Itound
in the PMR citcuit:
2, Removethe
pump motor relay.
3. Di sconnect t he ABS cont rol
unit 22P connector.
ground.
Ropair short to bodY
ground in
t ho wi ro bot wean t h. undel '
hood ABS f u3e/ . ehY box t nd
ABS control unil.
Check for a short lo bodY
ground
in the PCOM, SCOM cilcuit:
body
ground and the ABS con-
t rol uni t 26P t ermi nal s No l
.
Repair short to bodY
ground in
the PCOM circuit wirs bctween
tho ABS control unit and undor_
hood ABS t6o/r.lay box.
.
Rpair 3hon lo bodY
ground in
th6 PCOM oJ SCOM cilcuit wiro
botwoen the ABS control unit
end modulator unit.
' Ropl ace
t he modul t t or uni t .
(Short
circuh in3ide th6 unitl
(To page 19-60)
19- 59
Troubleshooting
Main Relay
(cont'd)
(From page
19, 59)
\
PCOM
{GRN/WHT}
NOTE: 8 V or more indicates a short to
Check lor a rhort to power
in the
PCOM, SCOM circuit:
body ground
and ABS cont rol
uni t 26P connect or t ermi nal s
No. l and No. 2 i ndi vi dual t y.
.
Rcp. i . 3hort t o powor
i n t he
PCOM circuh wirc bqtwaen tho
ABS cont rol uni t and undoa-
hood ABS fuso/relay bor.
.
Ropai J shorl t o
powor
i n t h6
PCOM or SCOM ci rcui t wi r.
botwoen tha ABS control unit
and modulato. unit.
.
Repl . co t he modul at or uni t .
lshorl to powol
inside tho unitl
l s t here 8 V or more?
Turn the ignhion switch OFF and
conn.ct thc SGS sorvics connoc-
lo.. Then tuJn the ignition rwitch
ON lll) rnd m.rsuro th. voltago
betwcen the PCOM and SCOM
t t . mi nal s and body ground.
l f
there i3 0 V, rephco the ABS| con-
trol unit.
19- 60
l gni ti on Vol tage
Diagnostic Trouble Code {DTC)
61: lgnition Voltage Diagnosis
I G2I BLK/ BLU}
-
With the engine running, ABS
indic.lor light is ON.
-
With the SCS service connoc-
tor connected
(sae page 19-501,
OTC 61 is indicded.
Problem ve.ification:
1. Erase t he DTC.
3. Make sure t hat t he ABS i ndi
cat or l i ght comes on and DTC
61 i s i ndi cat ed.
The swlern is OK at this time.
l s DTC 61 i ndi cat ed?
Chcck the lG2 circuit:
Me6sure t he vol t age bet ween t he
l s t here 18 V or above?
ff the vohage is 0 V, check tor an
ooen in the lG2 circuit.
lf there h 12
-
17 V, substitute a
known-good ABS control unit rnd
rchck.
9- 61
Troubleshooting
Central Processing Unit
(CPU)
Diagnostic Troubl Code {DTC} 81: CPU Diagnosis
19-62
-
(ll),
ABS indicato. light doos
not go off.
-
Wrth the SCS srvice connec-
tor connoctod
lsee
page 19601,
DTC 81 i! indieted.
Ploblem v6dtication:
1. Erase the DTC.
2. Test-drive tho vehicle.
3. M6ke sure t hat t he ABS i ndi -
cator light comes on and DTC
81 i s i ndi cat ed.
RopbcG tho ABS control unil.
The syitom b OK rt this time.
Modul ator Uni t
Removal/lnstallation
CAUTION:
. Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the
paint, wash it off immedi-
ately with water.
. Take care not to damage or deform the brake lines during lemoval and installation.
. To Drevent the brake fluid from flowing, plug and cover the hose ends and
ioints
with . shop towal or equivalent
materi al .
NOTE: Ti ghten the fl are nuts to 15 N.m
(
1.5 kgf m, 1 1 l bf' ft).
Removal
1. Di sconnect the modul ator uni t 10P and
pump
motor 2P connectors
2. Di sconnect the brake l i nes, then remove the modul ator uni t
l nstal l ati on
1. Instal l the modul ator uni t, then connect the brake l i nes.
2. Connect the modul ator uni t
' l 0P
and
pump
motor 2P connectors
3. Bl eed the brake system.
4. Start the engi ne, and check that the ABS i ndi cator l i ght goes off.
PUMP MOTOR
2P CONNECTOR
ffi
t '
TOR UNIT
'%
19- 63
ABS Control Unit
Pulsers/Wheel
Sensors
Repl acement
Remove the ri ght si de ki ck panel .
Di sconnect the ABS control uni t connectors.
Remove the ABS control uni t.
Instal l the ABS control uni t i n the reverse order of
removal .
1 .
2.
3.
4.
CONNECTORS
19-64
Inspection
1. Check the front and rear pul ser for chi pped or dam-
aged teeth.
2. Measure the ai r gap
between the wheel sensor and
pul ser
al l the way around whi i e rotati ng the pul ser.
Standard:0.4
-
1.0 mm
(0.02 -
0,04 i nl
NOTE: l f t he gap
exceeds 1. 0 mm
( 0. 04
i n) , t he
pr obabi l i t y
i s a di st or t ed suspensi on ar m whi ch
shoul d be repl aced.
Front
0. 4
-
1. 0 mm
{0. 02
-
0. 04 i nl
0. 4
-
1. 0 mm
(0. 02 -
0. 04 i n)
Pulsers/Wheel Sensor
Wheel Sensor Replacement
NOTE:
. Be careful when i nstal l i ng the sensors to avoi d twi sti ng the wi res.
. The torque val ue of the bol ts i s at 9.8 N' m
(1.0
kgf m, 7 l bi ft)
Front
WHEEL SENSOR
Remove the hub beari ng uni t
(see
secti on 18).
Remove the four backi ng
pl ate bol ts
pul l
the backi ng pl ate away from the trai l i ng arm, then remove the wheel sensor. l t i s not necessary to di sconnect the
br ake l i ne.
1 .
2.
''-----_l'-
19- 65
I
Body
(' 96
model )
Doors
Front Door Index
(4D) .-' 2O-2
Rear Door Index
(4D) ..' .. 20-8
Door fndex l zDl 3Dl
."""20' 14
Embl ems
f nstallation
20'118
Exterior
Gomponent
Locat i on I ndex' . . . . . . . ". . . . .
20- 93
*Frame
Repai r Ghart ........,.
2O' 12O
*lnterior
Component
Locati on Index .... ".' .....' . 20-58
Mi rrors
Mi rror Repl acement
.... "...' . "...' . . ". " "' 20-24
Mi rror Hofder Repl acement
""' .' .""..'
20-25
Mi rror Cover Repl acement
"."""' ."".
20-25
Rearvi ew Mi rror Repl acement
' ..-""" 20' 25
Moonroof
l ndex , . . . . . . . . .
. . ' . . . . . . ' . ' . . . . . ' . ' . 20' 50
Opener Cable/Opener
and Latch/
Wi per and Washer
Component
Locati on Index ..' .......' . ". 20-1oj
Seats and Seat Belts
Component
Locati on Index ..' ..' .... "".20' 73
Sub-frame
."' 20-119
Wi ndshi el d,
Rear Wi ndow and Ouarter Gl ass
f ndex . . . . . . ' . ' .
' . . ' . ". ' . """' . ' . '
20' 26
Body
(' 97
model l ............. ...""."20-123
Body
(' 98
model ) . . . . . . . . .
. . . . . ' . . . . 20-131
Doors
OETENT
ROO
SASH TRIM
Adjustment, page
20-23
Front Door Index
ilD:
WEATHERSTRIP
POWER WINDOW
SWITCH
fu-P
'aer7a
[q-/
DOOR
PROTECTOR
c
\f
R--2''
7t'<
DOOB POCKET
GRI P
r - \
-."v
"rrd*r, ef'
COVER
DOOR
GRI P
COVER
o
o b n
DOOR
DOOR
20-2
GLASS
Repl acement ,
page 20'6
Adjustment,
page 20-20
CENTER LOWER
CHANNEL
CYLINOER
PROTECTOR
REGULATOR
Repl acement ,
pa9e
20-6
LOCK ROO
PROTECTOR
LATCH
Repl acement ,
20-6
RETAINER
CLIP
.^@
\lzl
dD
STRIKER
Adjustment,
page 20-23
I
\ t l
\ (
A ( *
V*#a
/
CYLINDER
ROD
LOCK
CYLI NDEB
Repl acement , page 20- 5
INNER HANOLE ROD
-wfi6*
$ @
ô
e'
\".ou.oro,
HANOLE
POWER DOOR
LOCK SWITCH
(dri ver' s
onl y)
LATCH
PROTECTOR
I NNER
HANDLE
20-3
Doors
Door Panel RePl acement
NOTE: Take care not to scratch the door
panel and other
pans.
1. Remove:
. Inner handl e
(see
Page
20-3)
. Mi rror mount cover
panel (see page 20' 24l '
l l appl i cabl e,
remove t he regul at or handl e by pul l i ng
t he cl i p out wi t h a wi re hook
TOR HANDLE
WIRE HOOK
3. Remove the door
gri p cover and speaker cover, then
remove the screws.
>: Sctew locations,
5
POWER WINDOW
swlTcH
20-4
4. Rel ease the cl i ps that hol d the door
panel Remove
the door
panel by pul l i ng i t upward
NOTE: Remove the door
panel wi th as l i tti e bendi ng
as possi bl e to avoi d creasi ng or breaki ng i t
.L
12 mm
{0.47
in}
T-
TRIM PAD
REMOVER
(Commerci al l y
avai l abl e)
Snap-on
#4171, or
equivalent
95 mm 13. 74
i nl
/t4-
, ./zn
nu"
1mm
L, -- |
10. 04 i n)
45 mm
{1. 77 i nl
>: Cl i p l ocat i ons, 5
i
J [ i
:lt{
ltN i
cL,P
l\
i
REMoVERi
I i
-E/
Di sconnect t he
speaker connecl or '
5. Instal l ati on i s the reverse of the removal
procedure'
Outer Handle Replacement
NOTE: Rai se the gl ass ful l y.
1. Remove:
a Door panel
. Plastic cover {see
page 20-21
2. Pul l out the retai ner cl i p.
CYLINDER PROTECTOR
LOCK CYLINDER
RETAINER
CLIP
Remove the bol ts, then remove the cyl i nder
protec-
tor, l ock cyl i nder and outer handl e.
>: Bolt locations,2
I
r$\'* 6 x 1.0 mm i
\Af@ g.a
N.m tr.o tsr.m, I
?.2 tbI.ft) )
-_-_--/
CYLINDER
LOCK CYLINDER
CYLI NOER ROD
20-5
4. Pul l out the outer handl e. Pry the outer handl e rod
out of i ts
j oi nt
usi ng di agonal cutters.
NOTE:
. To ease reassembl y, note l ocati on
@
ofthe outer
handl e rod on the
j oi nt
before di sconnecti ng i t.
. Take care not to bend the outer handl e rod.
. Use a shop towel to protect the openi ng i n the
door.
OUTER HANDLE
ROD
DIAGONAL
CUTTERS
5,
SHOP
TOWEL
l nstal l ati on i s the reverse of the removal
procedure,
NOTEj Make sure the door l ocks and opens properl y.
BUSHI NG
Repl ace.
\
,1rl'.
l
Doors
1 .
Latch Replacement
Remove:
. Door panel (see page 20-4)
. Pl asti c cover
(see page 20-21
. Outer handl e
(see page 20-5)
Remove the bolt, then move the center lower channel
forward.
3. Di sconnect the connector, and detach the harness
cl i p f r om t he door . Remove t he l at ch t hr ough t he
hol e i n the door.
NOTE: Take care not to bend the i nner handl e rod,
outer handl e rod, cyl i nder rod and l ock rod.
>: Screw l ocati ons,3
2.
6 x 1 . 0 mm
I N.m {0.8 kgf.m,
6 tbf.ft)
NOTE:
. Make sur e t he i nner handl e
are connected properl y.
. l vl ake sure the door l ocks and
20-6
procedure.
rod and connect or
opens properl y.
LOCK ROD
' t .
Glass/Regulator Replacement
Remove:
. Pl asti c cover
(see page 20-2)
Careful l y move the gl ass unti l you can see the bol ts,
t hen r emov e t hem. Car et ul l y pul l t he gl as s out
through the wi ndow sl ot.
NOTE: Take care not to drop the gl ass i nsi de the door.
>: Bolt locations. 2
GLASS
REGULATOR
cl i p, t hen r emove t he r egul at or t hr ough t he hol e i n
t he door .
>: Bol t l ocat i ons
a > , 4 8 > , 3
6 x 1 . 0 mm
6 x 1 . 0 mm
I
a: Nut l ocat i ons, 3
l
AR 6 x 1 . 0 mm
@ e ru.- 1o.a
rgt -,
i 6rbf f t )
L- r
REGULATOR
( Manual t ype)
REGULATOR
4. Grease al l the sl i di ng surfaces of the regul ator where
shown.
REGULATOR
MOTOR
Instal l ati on i s the reverse of the removal
procedure
NOTE: Rol l the
gl ass up and down to see i f i t moves
freel y wi thout bi ndi ng. Al so make sure that there i s
no cl earance between the gl ass and gl ass run chan-
nel when the
gl ass i s cl osed. Adj ust the
posi ti on of
the
gl ass as necessary
(see page 20-20).
5.
20-7
Doors
Rear Door Index
4D:
OUTER
WEATHERSTRIP
I NNER
WEATHERSTRIP
DOOR
Adj ustment,
page 20-23
S"'P
Y-*^
HI NGE
...-\\\
iD\\
\b\
\ \
fu4
R'r"'
oooR
PROTECTOR
20-8
n
(2
REARCHANNEL\
\4\
\ \ \
\ \ \
t \
Ql l
a @ l l l
"ro."*o""..*
I
jl
coLLAB
\ J I
*-@\l'
OUTER HANOLE
Repl acement ,
page 20-1 1
REGULATOR
HANDLE
\
>-9
\n'
POWER WINDOW
MOTOR
LOCK ROD
PROTECTOR
Repl acement ,
page 20-12
POWER DOOR
LOCK ACTUATOR
I NNER
HANDLE
ROD
20-9
Doors
Door Panel Replacement
NOTEj Take care not to scratch the door panel and other
pa rts.
' 1.
Remove:
. Inner handl e
{see
page 20-9)
. Regul ator handl e
(see page 20-4)
2. Remove the door grip cover, then remove the screws.
\ 20- 10
e - - '
3. Rel ease the cl i ps that hol d the door
panel .
Remove
the door panel by pul l i ng i t upward,
NOTE: Remove the door panel wi th as l i ttl e bend-
i ng as possi bl e to avoi d creasi ng or breaki ng i t.
.L
12 mm
{0.47 in)
T-
TRIM PAD
REMOVER
(Commerci al l y
avai l abl e)
Snap-on
44177, ol
6qui val ent
/={
t ./t , cs"
1fim
-i-,.--t
'
I
10. 04 i nl I L ,
45 mm
{1. 77 i nl
>: Cl i p l ocal i ons, 7
4. Instal l ati on i s the reverse of the removal orocedure.
Outer Handl e Repl acement
' 1.
Remove:
. Door panel
. Pl asti c cover
(see page 20-8)
2. Remove the screws.
>r Screw locations, 3
6 x 1 . 0 mm
6 N.m
(0.6
kgt m,
4 rbf.ft)
3. Move t he l at ch down, and remove t he bol t s.
>: Bol t l ocat i ons, 2
|
I
6@.1
s' t.o--
i ----,!Sl/
g.a
N.m
)
11.o kd m,7 .2 tbt'ft|
/
I
)
ft_-..p
^\ r
r - - - t - - J-
4 t---\---
pS\..
\]
\ \ - V
out of i ts
j oi nt
NOTE:
@
of the outer
handl e rod on the
j oi nt
ooor.
BUSHI NG
Repl ace.
OUTER
HANDLE
ROD
.41
DIAGONAL
\
:'"*'
,Yt:
5. Instal l ati on i s the reverse of the removal Drocedure.
NOTE: Make sure the door l ocks and opens
properl y.
SHOP TOWEL
20-11
Doors
Latch Replacement
NOTE: Rai se the
gl ass ful l y.
1. Remove:
r Door panel
(see page 20-10)
. Pl asti c cover {see Page
20-8)
. Outer handl e
(see page 20-11)
2. Remove the i ock crank and cl i P.
>: Screw l ocat i on, 1 >: Cl i p l ocat i on, 1
Remove the rear channel col l ar.
NOTE: Take care not to bend the l ock rod and i nner
handl e rod.
REAR CI{ANNEL
LATCH
\i
6 x 1 . 0 mm
I Nm( 0. 8kgf . m,
6 tbf.ft)
Remove the l atch through the hol e i n the door.
Instal l ati on i s the reverse of the removal procedure.
NOTE: Make sure the door l ocks and opens
properl y.
Di sconnect t he
connect or .
4.
5.
20-12
, , <\
I N. m 10. 8 kgt m, 6l bf f t l
'
t Fllt--n]nTl
"<1'
)
,/
2.
Glass/Regulator
RePlacement
1 . Remove:
. Door
panel (see page 20-10)
. Pl asti c cover {see
page 20-8)
Careful l y move the gl ass unti l you can see the bol ts,
then remove them.
NOTE: Take care not to drop the gl ass i nsi de the door.
>: Bolt locations, 2
f i
s' r . o- -
|
@
9.8 N m tl .o kgtm,
J
-
L2 tbl.tlt
, ,,-----/,/
3. Car ef ul l y l ower t he gl ass. Remove t he bol t s and
screw trom the rear channel , then remove the gl ass
trom the rear channel .
NOTE: Take care not to drop the
gl ass i nsi de the door.
>: Bolt. screw locations
A' 1
i
t ' t
@@!iT,--,,-, ,J
@
6w.ftt
_-,/./ _
\
I
I
B, 1
6 r 1 . 0 mm
4. Caret ul l y remove t he
REAR
t he wi ndow sl ot .
outer mol di ng, then remove the quar-
gl ass f rom
I
CHANNEL
COLLAR
5.
B
Remove the
ter gl ass.
6. Di sconnect the connector, and detach the
cl i p, then remove the regul ator through the
the door.
>: Boli locations
a > , 2
6 x
' l .0
mm
I
B > . 2
| 6 x 1 . 0 mm
har ness
hol e i n
I
OUARTER
El
sN- { o. a* gr . m, 8Nml o. 8ksf m,
ff
o rrr.rt 6 tbtftt
)
20-13
CLIP
Grease al l the sl i di ng surtaces of the regul ator where
shown.
NOTE:
a l f necessary, remove the power wi ndow motor
from the regul ator.
. Before removi ng the power wi ndow motor, scri be
a l i ne across the sector gear and regul ator.
SECTOR GEAR
wtNDow
POWER
wtNDow
MOTOR
6 x 1 . 0 mm
7 N.ml0.7 kgf.m,
5 tbf.ft)
8.
REGULATOR
l nstal l ati on i s the reverse of the removal orocedure.
NOTE: Rol l the gl ass up and down to see i f i t moves
freel y wi thout bi ndi ng. Al so make sure that there i s
no cl earance between the gl ass and gl ass run chan-
nel when the gl ass i s cl osed. Adj ust the posi ti on of
the gl ass as necessary
(see page 20-20).
REGULATOF
Doors
Door Index
2Dl3Dl
\
GLASS GUIDE
CLIP
I
sAsH
S 1 1
\
6P\ \
\ T \
a_\
OUTER
WEATHERSTRIP
INNER HANDLE
TRIM
(wi t h power door l ocks)
\
:
",Ro,--"ou",
\.l+--
covER PANEL
<an
ffi*'"o'
ft{351'"'
{h
tuf
@
".o.*.r\
-re
\
eowen ooon INNER HANDLE
\
LOCK SWTTCH tRtM
\ \
{wi t hout
power
ts1.,h.* |
-\Q'-Qh.\\-*<y
tls!^
\J'
(t!5t
\\
ARMRE'T
\R]
POCKET
- |
oooR
Cf- I
Adjustment,
-.
,.JL
Pase
20'23
W
+..-ooon
PROTECTOR
ARMREST
POCKET
1-O-14
h\>l\\
r\J
-,-'\
9,,
i i
[-\r
\i
, \
S
GLASS
Repl acement ,
page 20-19
Adi ust ment ,
page 20-20
GLASS RUN
CHANNEL
3ill,'î,i"**\N
\
\\
\\\\
REGULATOR
\ \ \ \
Rept acement , pas
20. 19
l\\\\
\ z
trq\\\t v.
CYLINDER
PROTECTOR
,6@
POWER
MOTOR
LOCK
CYLI NDER
RETAINER
CLIP
Repl acement , page
20-17
ROD PROTECTOR
w
HANDLE BOD
FRONT LOCK
ROD
REAR LOCK
ROD
LATCH
PROTECTOR
e'
\".or.oro*
HANDLE
20-15
Doors
Door Panel Repl acement
NOTE: Take car e not t o scr at ch t he door panel and
other parts.
1. Remove:
! Inner handl e tri m
(see page 20-14)
. Mi rror mount cover panel
{see
page20-241
2. l f appl i c abl e. r emov e l he r egul at or handl e by
pul l i ng the cl i p out wi th a wi re hook.
REGULATOR HANDLE
WIRE HOOK
Remove t he ar mr est pocket , t hen di sconnect t he
oower wi ndow swi t ch connect or.
ARMREST
POCKET
4. Remove the soeaker cover. then remove the screws.
|
>i Screw localions, 3
6hD:"
L"
COVER
20-16
6. Instal l ati on i s the reverse of the removal Drocedure.
TRIM PAD
REMOVER
(Commerci al l y
avai l abl e)
Snap-on
*4177, or
equivalnt
5. Rel ease the cl i ps that hol d the door panel . Remove
the door
panel by pul l i ng i t upward. Di sconnect the
soeaker connector.
NOTE: Remove the door panel wi th as l i ttl e bendi ng
as
possi bl e
to avoi d creasi ng or breaki ng i t.
95 mm 13. 74 i nl
12 mm
-L
10.47
in)
1-
>: Clip location3,
i l _
JF
=l$
INOS
t\
cr_rp
-------l
I
REMoVER
F?
r I
/t1-
1mm
L---'"t/lf'
to.o4 inl I :
-]
45 mm
I
(1. 77
i n)
.i CONNECTOR
\
DOOR PANEL
Outer Handl e Repl acement
l . Remove:
. Door panel
. Pl asti c cover
(see page 20-14)
2. Pul l out t he r et ai ner cl i p.
3.
CYLI NDER PROTECTOR
LOCK CYLINDER
Remove the bol ts, then remove the cyl i nder protec
tor, l ock cyl i nder and outer handl e.
>: Eol t l ocat i ons. 2
CLIP
LOCK CYLI NDER
CYLINDER ROD
20-17
out of i ts
j oi nt
NOTE:
@
of the outer
handl e rod on the
j oi nt
door.
OI AGONAL
CUTTERS
SHOP
TOWEL
I nst al l at i on i s t he reverse of t he removal procedure.
NOTE: Make sure t he door l ocks and opens properl y.
BUSHI NG
Repl ace.
\
,w,
5.
Doors
Latch Replacement
l .
Remove:
. Pl asti c cover
(see page 20-14)
. Outer handl e
(see page 20-17)
Remove the rod protector. 2.
PROTECTOR
b
20-18
3. Remove the bol ts and move the center l ower channel .
NOTE: Take care not to bend the i nner handl e rod
and l ock rods.
>: Screw locataons
A > , 3 8 > , 3
@
l
_ )
CENTER LOWER
CHANNEL
CBANK
HOLDER
6 x l . 0 mm
8 N.m
{0.8 kgf.m,
6 rbr.ftl
Remove t he i nner handl e, t hen r emove t he l at ch
through the hol e i n the door.
l nstal l ati on i s the reverse ol the removal procedure.
NOTE: Make sure the door l ocks and opens properl y.
5 x 1 . o mm
i
[ ) ) 4p6Nm{ 0. 6kef m, i
v
4 tbt.h)
)
2.
Glass/Regulator
Replacement
1 . Remove:
. Door panel
(see page 20-16)
. Pl asti c cover {see
page 20-14)
Caretul l y move the gl ass unti l
you can see the bol ts,
then l oosen them. Sl i de the gui de rearward. remove
t he gl ass f r om t he
gui de, and car ef ul l y
pul l t he
gl ass out through the wi ndow sl ot.
NOTE: Take care not to drop the
gl ass i nsi de the door.
>: Bol t l ocal i ons, 2
6 x 1 . 0 mm
E
9.8 N.m 11.0 kg{.m,
I
,*
7.2 tbrft)
|
l Loosen.
/
GUI DE
cl i p, then remove the regul ator through the hol e i n
the door.
NOTE: Scri be a l i ne around the rear rol l er gui de bol t
to show the ori gi nal adl ustment
>: Bolt locations
A > , 4 B > , 2
6 x 1 . 0 mm 6 x 1 . 0 mm
I N.m 10.8 ksl.m,
I
6|lofttt
)
8 N m {0.8 kst.m,
I
6 rbrft
|
LOOSen.
ROLLER BEGULATOR
BOLTS
(cont' d)
20-19
Doors
Glass/Regulator
Replacement
(cont'dl
Grease al l the sl i di ng surfaces of the regul ator where
shown.
NOTE:
a l f necessary, remove the power
wi ndow motor
from the regul ator.
. Before removi ng the power
wi ndow motor, scri be
a l i ne across the sector gear and regul ator.
REGULATOR
q(] )
6x r . om; - ]
POWER WINDOW
5. Instal l ati on i s the reverse ofthe removal procedure.
NOTE: Rol l the gl ass
up and down to see i f i t moves
freel y wi thout bi ndi ng. Al so make sure that there
j s
no cl earance between the gl ass and gl ass run chan
nel when the gl ass i s cl osed. Adj ust the posi ti on
of
the gl ass as necessary.
SECTOR GEAR
20-20
Glass Adjustment
NOTE:
. Pl ace the vehi cl e on a fi rm, l evel surface when adj ust-
i ng the gl ass.
. Check the weatherstri ps and gl ass run channel for dam-
age or deterioration, and replace them if necessary.
1. Remove:
. Door panel (see pages
20-4, 10, 16)
. Pl asti c cover
(see pages
20-2,8, 14)
2. Adj ust the gl ass.
4D:
Rai se t he gl ass f ul l y.
Loosen t he gl ass
mount i ng bol t s
( f r ont
door )
and regul ator mounti ng bol ts.
c. Push t he gl ass r ear war d ( f r ont
door gl ass)
or
f orward (rear
door gl ass).
d. Ti ght en t he gl ass mount i ng bol t s (f ront
door)
and regul at or mount i ng bol t s.
A >: Gl ass mount i ng bol t
locations.
B >: Rgulato. mouting
bolt locations.
Front:
a ,
o.
REGULATOR
; l L- ^ \
//
->
GLASS
REGULATOR
A
u +
e. Loosen the front channel mounti ng bol ts
(tront
door ) or r ear c hannel mount i ng bol t
( r ear
door).
f. Lower the gl ass.
g. Push t he f r ont or r ear channel s agai nst t he
gl ass, then ti ghten the mounti ng bol ts.
>r Fi ont and rear
channel mounti ng
bolt locations
Front:
Rear:
2DI3D:
o.
Rai se the
gl ass as far up as possi bl e, and hol d
i t agai nst the gl ass run channel .
Loosen t he r ol l er gui de bol t s, and adj ust t he
gl ass so i t i s paral l el wi th the gl ass run channel .
GLASS RUN
CHANNEL
ROLLER GUIDE BOLTS
(cont' d)
20-21
Doors
Glass Adjustment
(cont'dl
c. Ti ghten the rol l er gui de
bol ts.
d. Loosen the front channel bol ts.
e. Lower the gl ass.
f. Push the front channel agai nst the gl ass, then
ti ghten the mounti ng bol ts.
MOUNTING
BOLT
3. Check that the gl ass
moves smoothl y.
4. Rai se the gl ass
ful l y and check for gaps.
5. Check the gl ass operati on,
NOTE: Check that the gl ass contacts the gl ass run
channel evenl y.
WEATHERSTFIP
GLASS
20-22
g
Forward
6. Check for water l eaks.
Spray water over the roof and on the seal i ng area
as shown.
NOTE:
. Adj ust the water pressure
as shown.
. Do not squeeze the ti p of the hose.
12 mm {0. 47 i nl
hd
Y
HOSE
7. Attach the pl asti c cover, then i nstal l the door panel
(see pages 20-4, 10, 16).
l nstal l the regul ator handl e so i t poi nts forward and
up at a 45 degree angl e wi th the gl ass
cl osed.
300 mm
(11. 8
i n)
Position Adjustment
NOTE: Pl ace the vehi cl e on a fi rm. l evel surtace when
adj usti ng the doors.
After i nstal l i ng the door, check for a fl ush fi t wi th the
body. then check for equal gaps between the front, rear,
and bot t om door edges and t he body. The door and
body edges shoul d al so be paral l el . Adj ust at the hi nges
as shown.
CAUTION: Pl ace a shop towel on the
l ack
to prevent
damage to the door when l ooseni ng the door and hi nge
mounting bolts lor adiustment.
DOOR MOUNTING BOLTS
8 x' 1. 25 mm
28 N.m {2.9 kgt.m, 21 lbf.ftl
Loosen t he door mount i ng bol t s sl i ght l y
t o move t he door l N or OUT unt i l
i t ' s f l ush wi t h t he body. l f necessary,
you can i nst al l a shi m behi nd one
hi nge t o make t he door edges
PARALLEL wi t h t he body.
HINGE MOUNTING BOLTS
8 x 1. 25 mm
28 N m {2.9 kgf.m,21 lbf.ft)
Remove t he i nner f ender,
l oosen t he hi nge mount i ng
bol t s, and move t he door
BACKWARD or FORWARD,
UP or DOWN as necessary
t o equal i ze t he gaps.
Lower t he gl ass.
The door and body edges shoul d be
paral l el .
,lJl:ril:x;T9#
NOTE: Check for water l eaks.
20-23
Striker Adiustment
Make sure the door l atches securel y wi thout sl ammi ng.
l f i t needs adj ustment:
NOTEr The st r i ker nut s ar e f i xed. The st r i ker can be
adj usted 1.5 mm
(0.059
i n) up or down, and 3 mm
(0.1 i n)
tn or out.
1. Loosen the screws, then i nsert a shop towel between
the body and stri ker.
1. 5 mm
(0. 059
i n)
1. 5 mm
{o. 059 i n}
I nser t a shop t owel
bet ween t he body and
PLASTIC
HAMMER
8 x 1. 25 mm
l 8 N. m {1. 8 kgl m,
r3 tbf ft)
TOWEL
2.
3.
Li ghtl y ti ghten the screws.
Wrap the stri ker wi th a shop towel , then adi ust the
stri ker by tappi ng i t wi th a
pl asti c hammer.
CAUTION: Do not sttike the striker too hard.
NOTE: Hol d the outer handl e out, and
push the door
agai nst the body to be sure the stri ker al l ows a fl ush
fi t.
l f the door l atches properl y, l oosen the screws, then
remove a shop towel. Tighten the screws and recheck
4.
Mi rrors
Mirror Replacement
NOTE: Take care not to scratch the mi rror, mi rror base
cover ano ooor.
I Lower t he door gl ass.
2. Careful l y pry out the mi rror mount cover panel by
nano.
Power milror:
MIRROR MOUNT
COVER PANEL
Manual mi rror:
Remove the cap, screw and knob, then remove the
mi rror mount cover panel .
MI RROR MOUNT
KNOB
20-24
\
3. Remove the mi rror mounti ng nuts whi l e supporti ng
the mrrror.
a: Nut locations, 3
)coNNEcToR
(Mi rror
si de)
MIRROR
{Door harness
si de)
CONNECTOR
Instal l ati on i s the reverse ot the removal procedure.
NOTE: Make sure the connector i s connected prop-
erly.
Mirror Holder Replacement
CAUTION: Wear gloves to remove and install the mir-
ror holder.
' 1.
Car ef ul l y
pr y out t he mi r r or hol der wi t h a f l at t i p
screwdri ver as shown.
PIVOT
-6r
JOI NT PI N
--Gl
JOINT PIN
-6,l
MIRROR HOLDER
2. l nstal l ati on i s the reverse of the removal
procedure
NOTE: Appl y grease to the l ocati ons i ndi cated by
tne arrows.
Mi rror Cover Repl acement
>: Screw locations
A > . 3
d\.nri''i.'.'i.i-. ]
':::_)
d\.,.,',r.,+. I
\{ P#'/u2 I
)
s > , 2
To remove the screws,
pul l t he seal away.
SHOP TOWEL
MIRROR BASE
20-25
l .
2.
Rearview Mirror Replacement
3.
Remove the rubber damper.
Pry the cover off usi ng the end of a fl at ti p screw-
dnver.
CAUTION: When prying with a flat tip screwdriver,
wrap it wilh a shop towel to prevent damage.
Remove the screws, then remove the rearvi ew mi r-
ror.
l nstal l ati on i s the reverse of the removal procedure
SCREW
5 x 0 . 8 mm
4 N,m {0.{ kgf.m,
3 tbf.ftt
REARVIEW
MIRROR
SHOP TOWEL
RUBBER DAMPER
-ln=T-
VIf. U
.ll)
|
. _ . [ _ _
Windshield, Rear Window and Ouarter Glass
Index
NOTE: The numbers after the part names show the
quanti ti es of the parts used.
Wi ndshi el d
(2Dl 3D/4D):
MOLDING
Rear Window {2Dl4D}:
UPPER RUBEEF
REAR WINDOW
Removal,
page
20-32
FASTENER, 4
(Sel t -adhesi ve-t ype, gl ass si de)
I
/
FASTENER,4
/
{Sel f -adhesi ve. rype, body si de}
* . /
d
SPACER,
w
g
@
i.
20-26
Rear Wi ndow {3D):
FASTENER,
,T
l Sel f -adhesi ve-t ype,
gl ass si de)
SPACER,
I
|
,o.r.".*, n
Iff'".*-.Y'e'bod'side)
RUBBER DAM, 2
Removal,
page 20-36
t
I
\
SEAL
\
SEAL
A, 1
8 , 2
Ouarter Glassi
3D:
OUARTER GLASS
Removal , Page
20-40
l nst al l at i on, Page
20_41
LOWER RUBBER
DAM
OUARTER
GLASS TRIM
LOWER CLIP
(Sel f -adhesi ve t ype)
OUATER GLASS
I nsral l at i on,
page 20 46
( Sel t
adhesi ve- t ype,
body si de)
\
n
2Di
UPPER CLIP
(Self-adhesive-type)
h\f
\il
FASTENER
{Sel l -adhesi ve t ype,
gl ass si de)
LOWER CLIP
(Sel I -adhesi ve t ype)
rr-il
(--/ /:=
20-27
Wi ndshi el d
Removal
CAUTION:
. Wear gl oves
to remove and i nstal l the wi ndshi el d.
. Use seat covers to avoid damaging any surfaces,
1. To remove the wi ndshi el d, fi rst remove the:
. Rearvi ew mi rror
(see
page 20 25)
. Sunvi sors and hol ders (see page
20 64)
. Fr ont pi l l ar
t r i m
( see pages 20- 59, 60, 61)
. Wi ndshi el d wi per arms and cowl cover
(see page
20 113\
2. Peel ol l the mol di ng, and remove the gl ass
brack
ets.
NOTE: When mol di ng removal i s di ffi cul t, cut the
mol di ng wi th a kni fe.
wl NDSHI ELD
3. Pul l down the front of the headl i ner
{see
page 20-
64).
CAUTION: Take care not to bend the headl i ner
excessively.
MOLDING
20-28
6. Caref ul l y remove t he wi ndshi el d.
\
4. Appl y protecti ve
tape al ong the edge of the dash-
boar d and body as shown. Usi ng an awl , make a
hol e t hr ough t he r ubber dam and adhesi ve f r om
i ns i de t he c ar . Pus h t he pi ano wi r e t hr ough t he
hol e, and wrap each end around a pi ece of wood.
PIANO WIRE
PROTECTIVE
I
tit'
DAM
WI NDSHI ELD
ADHESI VE
UPPER
RUBBER
PROTECTIVE
TAPE
DASHBOARD
5.
aoxesrir lowEB
DEFOGGEB
SEAL BUBBER
OAM
Wi t h a hel per on t he out si de, pul l t he pi ano
wi r e
back and forth i n a sawi ng moti on, and careful l y cut
t hr ough t he r ubber dam and adhesi ve ar ound t he
enti re wi ndshi el d.
CAUTION: Hold the piano wire as close to the wind-
shield as possible
to prevent
damage to the body
and dashboard,
1 .
3.
2.
l nstal l ati on
Usi ng a kni fe, scrape the ol d adhesi ve smooth to a
thi ckness of about 2 mm
(0.08
i n) on the bondi ng sur
Iace around the enti re wi ndshi el d openi ng tl ange
NOTE:
. Do not scrape down to the pai nted surface of the
body; damaged
pai nt wi l l i nterfere wi th proper
bondi ng.
. Remove the rubber dams and tasteners from the
body.
. Mask off surroundi ng surfaces before pai nti ng.
Cl ean the body bondi ng surface wi th a sponge damp-
ened i n al cohol .
NOTE: Af t er cl eani ng, keep oi l , gr ease and wat er
from getti ng on the surface.
l f the ol d wi ndshi el d i s to be rei nstal l ed, use a putty
kni fe to scrape off al l traces of ol d adhesi ve, then
cl ean t he wi ndshi el d sur f ace wi t h al cohol wher e
new adhesi ve i s to be appl i ed.
NOTE: Make sure the bondi ng surl ace i s kept free
of water, oi l and grease.
CAUTION: Avoid setting the windshield on its edges;
small chips may later develop into cracks.
NOTE:
. Cl ean the shadowed area.
o Cl ean area
@
as shown.
l nsi de
JL
WI NDSHI ELD
WI NDSHI ELD
20-29
4. Gl ue t he r ubber dam and f ast ener s t o t he i nsi de
face of the wi ndshi el d as shown.
NOTE: Be careful not to touch the wi ndshi el d where
adhesi ve wi l l be appl i ed.
{0. 53 i nl ALI GNMENT
\._-
- !41Ks _
ALIGNMENT
MARK
' 13. s
mm
10. 53 i n)
LOWER RUBBER
DAM
WINDSHIELD
5. Al i gn and gl ue t he mol di ng t o t he edge of t he wi nd
shi el d.
NOTE: Be caref ul not t o t ouch t he wi ndshi el d where
Appl y
pri mer (3M
N 200, or equi val ent ) t o edge (cont ' d)
of t he wi ndshi el d.
Wi ndshi el d
7.
SCREW
8. Remove t he wi ndshi el d.
20-30
Installation
(cont'dl
Instal l the gl ass brackets and fasteners as shown.
NOTE: The numbers after the
part names show the
quanti ti es
ot the parts used.
GLASS BRACKETS, 2
Set the wi ndshi el d on the gl ass brackets, then cen
ter i t i n the openi ng. Make al i gnment marks across
the wi ndshi el d and body wi th a grease penci l at the
four poi nts shown.
NOTE: Be careful not to touch the wi ndshi el d where
BRACKETS
NOTE: Adj ust t he gl ass
brack-
et s t o cent er t he wi ndshi el d i n
t he openi ng, t hen t i ght en t he
\
9. Wi th a sponge, appl y a l i ght coat of gl ass pri mer
around the edge of the wi ndshi el d as shown, then
l i ghtl y wi pe i t off wi th gauze
or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the wi ndshi el d, and
do not get body and gl ass pri mer sponges mi xed
up.
. Never touch the pri med surfaces wi th your hands.
l f you do, the adhesi ve may not bond to the wi nd-
shi el d properl y, causi ng a l eak after the wi ndshi el d
i s i nstal l ed.
. Keep water, dust, and abrasi ve
from the pri med surface.
/fu
, appty gt .. primer here.
materi al s away
Appl y gl ass pri mer
9. 5 mm
{0. 37 i n)
RUBBER DAM
FASTENER
WINDSHIELD
WINDSHIELD
10. Wi th a sponge, appl y a l i ght coat of body pri mer to
t he or i gi nal adhesi ve r emai ni ng ar ound t he wi nd-
shi el d openi ng fl ange. Let the body pri mer dry for
at l east 10 mi nutes.
NOTE:
. Do not appl y gl ass pri mer to the body. and be care-
ful not l o mi x up gl ass and body pri mer sponges.
. Never touch the pri med
surfaces wi th your hands.
. Mask off the dashboard before pai nti ng the fl ange.
)./////
///////
: Applr bodv
wime.
here.
16 mm
I n)
6 mm
(0. 2{
i n)
1 6 mm 5 mm
{0. 63 i n} 10. 2 i n)
MOLDING
1 1 . Thoroughl y mi x the adhesi ve and hardener together
on a gl ass or metal pl ate wi th a putty kni fe.
NOTE:
. Cl ean the pl ate wi th a sponge and al cohol before
mr xr ng.
. Fol l ow the i nstructi ons that come wi th the adhe-
si ve.
Before l i l l i ng a cartri dge, cut the end of the nozzl e
as shown.
Cut nozzl e end
10 mm
(0. 39 i n)
7 mm
(0.27 i nl
Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nuous del i very. Put the cartri dge i n a
caul ki ng
gun, and r un a bead of adhesi ve ar ound
the edge of the wi ndshi el d as shown.
NOTE| Appl y the adhesi ve wi thi n 30 mi nutes after
appl yi ng the gl ass pri mer.
12 mm
(0.47
i n)
12.
1
-tl
i .,1
aouestvr
,T"Irr,,,",
MOLDING
Make a sl i ght l y t hi cker
bead at each cor ner .
5 mm
(0. 2
i n)
FASTENER
LOWER
RUBBER
DAM
-_r
r
-/lr:.-,j.'o'.uo
/
\--..
\
/ w
WI NDSHI ELD
LOWER
RUBBER
OAM
10. 04 i nl
WI NDSHI ELD
20-31
14. Use sucti on cups to hol d the wi ndshi el d over the
openi ng, al i gn i t wi th the al i gnment marks made i n
st ep 7, and set i t down on t he adhesi ve. Li ght l y
push
on the wi ndshi el d unti l i ts edge i s ful l y seated
on the adhesi ve al l the waY around.
NOTEI
i s dry.
Do not open or cl ose the doors unti l adhesi ve
ALIGNMENT MARK
Scrape or wi pe the excess adhesi ve off wi th a putty
kni fe or towel .
NOTE: To remove adhesi ve from a pai nted surface or
the wi ndshi el d, wi pe wi th a soft shop towel dampened
wi th al cohol .
Let the adhesi ve dry for at l east one hour, then spray
water over the wi ndshi el d and check for l eaks. Mark
the l eaki ng areas, l et the wi ndshi el d dry, then seal
wi th seal ant.
NOTE:
. Let the car stand for at l east four hours after wi nd
shi el d i nstal l ati on. l f the car has to be used wi thi n
the fi rst four hours. i t must be dri ven sl owl y.
. Keep the wi ndshi el d dry for the fi rst hour after
i nstal l ati on.
. Check that the ends of the si de mol di ng are set
under the ai r scoop.
Rei nstal l al l remai ni ng removed parts.
NOTE:
. Instal l the rearvi ew mi rror rubber damper after
the adhesi ve has dri ed thoroughl y.
. Advise the customer not to do the following things
for two to three days:
-
Sl am t he door s wi t h al l t he wi ndows r ol l ed
up.
-
Twi st t he body excessi vel y
( such
as when
goi ng i n and out of dri veways at an angl e or
dri vi ng over rough, uneven roads).
15.
16.
1 7 .
Rear Window
Removal
2DI1D:
CAUTION:
a Wgar gloves to remove and install the rear window.
. Use seat covers to avoid damaging any surfacss.
. Do not damage the rear window defogger grid lines,
window antenna grid lines, and terminals.
1. To remove the rear wi ndow, fi rst remove the:
. Trunk l i d
. Rear seat cushi on
(see pages
20-79.81)
. Rear seat si de bol sters
(4D,
see page 20-791
. Rear seat-back
(2D,
see page 20-81)
. Rear shel f
(see pages
20-59,61)
. Rear pi l l ar tri m (4D,
see page 20-59)
. Si de tri m panel (2D,
see page 20-61)
. Ouarter trj m panel (2D,
see page 20-61)
.
Rear roof tri m
(see page
20-65)
2. Di sconnect t he r ear wi ndow def ogger connect or
from each si de.
3. Peel off the mol di ng.
NOTE: When mol di ng removal i s di ffi cul t. cut the
mol di ng wi th a kni fe.
il"*t,
^D.HE:tyE
._ --,///
MOLOING
REAR WINOOW
S
MOLOI NG
20-32
6. Careful l y remove the rear wi ndow.
4. Appl y protecti ve tape al ong the edge of the body as
shown. Usi ng an awl , make a hol e t hr ough t he
adhesi ve from i nsi de the car. Push the pi ano wi re
t hr ough t he hol e, and wr ap eac h end ar ound a
pi ece of wood.
ADHESIVE
REAR WINDOW
PEOTECTIVE
TAPE
PIANO WIRE
PROTECTIVE
TAPE
Wi th a hel per on the outsi de, pul l
the pi ano wi re
back and forth i n a sawi ng moti on, and careful l y cut
t hr ough t he adhesi ve ar ound t he ent i r e r ear wi n-
dow.
CAUTION: Hold the pisno wire as close to the rear
window as possible to prevent
damage to the body.
PIANO WIRE
ADHESIVE
1 .
3.
l nstal l ati on
t hi ckness of about 2 mm
( 0. 08
i n) on t he bondi ng
sur f ace ar ound t he ent i r e r ear wi ndow openi ng
fl ange.
NOTE:
body; damaged
bon d i ng
. Mask otf surroundi ng surfaces before pai nti ng.
. Remove t he f ast ener s and spacer s f r om t he
DOOy.
Cl ean t he body bondi ng sur f ace wi t h a sponge
dampened i n al cohol .
NOTE: Af t er cl eani ng, keep oi l , gr ease and wat er
l f the ol d rear wi ndow i s to be rei nstal l ed, use a putty
kni fe to scrape off al l traces of ol d adhesi ve and the
rubber dam, then cl ean the rear wi ndow surface wi th
al cohol where new adhesi ve i s to be appl i ed.
NOTE: Make sure the bondi ng surface i s kept free
CAUTION: Avoi d setti ng the rear wi ndow on i ts
edges; small chips may later develop into cracks.
NOTE: Cl ean the shadowed area.
4. Appl y the doubl e faced adhesi ve tape
(NITTO
501,
or equi val ent) to the edge of the rear wi ndow, then
i nstal l the mol di ng around the edge of the rear wi n
dow as shown.
NOTE: Be car ef ul not t o t ouch t he r ear wi ndow
wher e adhesi ve wi l l be appl i ed.
ALI GNMENT MARK
ADHESIVE TAPE
867 mm {34. 1 i n)
5 mm
(0. 2
i nl
ADHESIVE
TAPE
Thickness:
0. ' 16 mm {0. 006 i nl
MOLOI NG
WlNDOW
Gl ue the fasteners and spacers to the i nsi de face of
the rear wi ndow as shown.
NOTE: Be car ef ul not t o t ouch t he r ear wi ndow
wher e adhesi ve wi l l be appl i ed.
5.
ALI GNMENT
MARK
>: Fastener, spacer
loc6tions
A >. 4 FASTENER
MOLDI NG
GNMENT
I
ALI
\ M A
MARKS
(cont' dl
20- 33
MOLDI NG
REAR WI NDOW
B > , 2
Outside
--=,
Rear Wi ndow
Instal l ati on
(cont' d)
6. Gl ue the fasteners to the body as shown.
Fastener locations, 4
FASTENER
\ e l
4i< )
l Y l
F_L^NGE NycH,/,/
Set the rear wi ndow, then center i t i n the openi ng.
Make al i gnment marks across the rear wi ndow and
body wi th a grease penci l
at the four poi nts
shown.
8. Remove the rear wi ndow.
1.
ALI GNMENT MABK
S
20-34
I n,
9. Wi t h a sponge, appl y a l i ght coat of gl ass pr i mer
around the edge of the rear wi ndow as shown, then
l i ghtl y wi pe i t off wi th gauze or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the rear wi ndow,
and do not get body and gl ass pri mer sponges
mi xed up.
l f you do, the adhesi ve may not bond to the rear
wi ndow properl y, causi ng a l eak after the rear
wi ndow i s i nstal l ed.
. Keep water, dust, and abrasi ve materi al s away
'//f
, appty gtass primer hera.
10 mm 10. 39 i n)
GLASS Al l around.
FASTENER
REAR WINDOW
t he or i gi nal adhesi ve r emai ni ng ar ound t he r ear
wi ndow openi ng fl ange. Let the body pri mer dry for
NOTE:
. Do not appl y gl ass pri mer to the body, and be care-
ful not to mi x up gl ass and body pri mer sponges.
''/fu7.
, oort, Aoa,
orimer
here.
16 mm
{0. 63 i nl
16 mm 7 m m
10.28 in)
t
I
MOLDING
1
' t.
Thoroughl y mi x the adhesi ve and hardener together
on a gl ass or metal pl ate wi th a pufty kni fe
NOTE:
mr xr ng.
. Fol l ow the i nstructi ons that came wi th the adhe
si ve.
Before fi l l i ng a cartri dge, cut the end of the nozzl e
as snown.
10 mm 10. 39 i nl
7 mm {0.27 i nl
Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nous del i very. Put the canri dge i n a
caul ki ng gun, and r un a bead ot adhesi ve ar ound
the edge of the rear wi ndow as shown.
NOTE: Appl y the adhesi ve wi thi n 30 mi nutes after
12.
13.
12 mm 10. 47
i nl
[/
oo"r'u.
-+-
8 mm
(0. 31 i n)
Make a sl i ght l y t hi cker
bead at each cor ner .
GLASS
' 14.
Use sucti on cups to hol d the rear wi ndow over the
openi ng, al i gn i t wi th the al i gnment marks made i n
st ep 7, and set i t down on t he adhesi ve. Li ght l y
push on t he r ear wi ndow unt i l i t s edges ar e f ul l y
seated on the adhesi ve al l the way around
NOTE: Do not open or cl ose the doors unti l the adhe-
si ve i s dry.
SUCTION ALIGNMENT
CUPS MARK
1' t .
kni fe or towel .
NOTE: To remove adhesi ve from a
pai nted surface
or the rear wi ndow, use a soft shop l owel damp-
ened wi th al cohol .
Let t he adhesi ve dr y f or at l east one hour , t hen
spr ay wat er over t he r ear wi ndow and check f or
l eaks. Mark the l eaki ng areas, l et the rear wi ndow
dry, then seal wi th seal ant.
NOTE: Let the car sl and for at l east four hours after
re4wi ndow i nstal l ati on. l f the car has to be used
wi thi n the fi rst four hours, i t must be dri ven sl owl y.
Rei nstal l al l remai ni ng removed
parts.
NOTE: Advi se the customer not to do the fol l owi ng
thi ngs for two to three days:
. Sl am the doors wi th al l the wi ndows rol l ed up.
. Twi st the body excessi vel y
(such
as when goi ng
i n and out of dr i veways at an angl e or dr i vi ng
over rough, uneven roads).
15.
16.
20- 35
Rear Wi ndow
Removal
3D:
CAUTION:
. Wear gloves
to remove and install the rear window.
. Use seat covers to avoid damaging any surlaces.
. Do not damage the real wi ndow defogger gri d l i nes.
. Take care not scratch the rear window molding.
t . t o
a
a
4.
3.
remove the rear wi ndow, fi rst remove thel
Rear center shel f
(see page 20-60)
Hat ch upper t r i m, hat ch t r i m panel and hat ch
si de tri m
(see page
20-63)
Rear wi ndow wi per arm {see
page 20-1 15)
Hatch spoi l er
(see page 20- 101)
Di sconnect t he r ear wi ndow def ogger connect or
from each si de.
Appl y protecti ve
tape to the i nner edge of the tai l
gare.
From i nsi de the hatch, use a kni fe to cut through the
rear wi ndow adhesi ve al l the way around.
NOTE:
. l f the rear wi ndow i s to be rei nstal l ed, take care
not to damage the mol di ng.
. l f the mol di ng i s damaged, repl ace the rear wi n
dow and mol di ng as an assembl y
HATCH
x
G^Yb\
's>
BEAR WINDOW
20-36
Upper porti on:
TAPE
Side portion:
Lower Dortion:
MOLDING
Careful l y remove the rear wi ndow.
NOTE: Check the mol di ng for damage, and repl ace
the rear wi ndow i f necessary.
GLASS
ADHESI VE
' 1.
2.
l nstal l ati on
( 0. 08 i n) on t he bondi ng
sur f ace ar ound t he ent i r e r ear wi ndow openi ng
fl ange.
NOTE:
body; damaged
bondi ng.
. Remove the rubber dams, spacers and fasteners
from the hatch.
. Mask off surroundi ng surfaces before appl yi ng
pri mer.
Cl ean t he hat ch bondi ng sur f ace wi t h a sponge
dampened i n al cohol .
NOTE: Af t er cl eani ng, keep oi l , gr ease or wat er
l f t he ol d r ear wi ndow i s t o be r ei nst al l ed, use a
putty kni fe to scrape off al l traces of ol d adhesi ve,
t hen cl ean t he r ear wi ndow sur f ace wi t h al cohol
where new adhesi ve i s to be appl i ed.
NOTE: Make sure the bondi ng surface i s kept free of
water, oi l and grease.
CAUTION: Avoi d setti ng the rear wi ndow on i ts
edges; the molding can be psrmanently deformed.
NOTEr Cl ean the shadowed area.
REAR WINOOW
4. Gl ue the rubber dams to the i nsi de tace of the rear
wi ndow, as shown, to contai n the adhesi ve duri ng
i nstal l ati on, and gl ue the fasteners, spacer and seal s
as shown.
NOTE:
. Gl ue the rubber dams usi ng the pri nted dots as a
gu l de.
. Be careful not to touch the rear wi ndow where
>: Fastener, spacer 6nd seal
locations
a > , 4
RUBBER
-d
'
-f--At
FASTENER PRINTED DOTS
FASTENER
REAR WINDOW
B> , 1
D > , 2
Insid.
SPACER
RUBBER
DAM
MOLDING
(cont ' d)
20-37
Rear Window
lnstallation
{cont'd)
Instal l the fasteners to the hatch as shown.
>: Fastener locations, 4
Set the rear wi ndow upri ght on the hatch, then cen-
ter i t i n the openi ng. Make al i gnment marks across
the rear wi ndow and body wi th a grease penci l
at
the four poi nts
shown.
NOTE: Be careful not to touch the rear window where
7. Remove the rear wi ndow.
20-38
8. Wi th a sponge, appl y a l i ght coat of gl ass pri mer
around the edge of the rear wi ndow, then l i ghtl y
wi pe i t oi f wi rh gauze
or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the rear wi ndow,
mi xed up.
Never touch the pri med surfaces wi th your hands.
l f you do, the adhesi ve may not bond to the rear
wi ndow properl y,
causi ng a l eak after the rear
wi ndow i s i nstal l ed.
Keep water, dust. and abrasi ve materi al s away
from the pri med
surface.
V//////7, , eppv
stass c,im6,
h6r6.
\
Insido I
V , l l s mm
I W-- ]10.59
inl
N r t
A I \
/ N \
cr-l'ss
*
\
SPACER
REAR wlNOOW
t he or i gi nal adhesi ve r emai ni ng ar ound t he r ear
wi ndow openi ng fl ange. Let the body pri mer dry for
NOTE:
. Do not appl y gl ass pri mer to the body, and be care-
tul not to mi x up gl ass and body pri mer sponges.
///////l ' aooV roay primer here.
NOTE:
mr xr ng.
. Fol l ow the i nstructi ons that came wi th the adhe-
si ve,
10.
11. Before fi l l i ng a cartri dge, cut the end of the nozzl e
as shown.
Cut nozzl e
' 10
mm {0. 3S i n)
l 6 mm
{0. 63 i n)
22 Jnm
7 mm {0. 27 i n)
12. Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nuos del i very. Put the canri dge i n a
caul ki ng
gun, and r un a bead of adhesi ve ar ound
the edge of the rear wi ndow as shown.
NOTE: Appl y the adhesi ve wi thi n 30 mi nutes after
i:EI^,T_/:
aDHEs,vE
8 mm
{ 0. 31 i nl
- - _Jr - -
DZT
ro.ornr
tEt
J I \
, / N \
SPACER
GLASS
REAR WINDOW
MOLDI NG
GLASS
-----ll
f \ -L, --
ffi-f
to.oe int
,,.17
MOLDI NG, -
\
(cont' d)
20-39
Rear Window
Ouarter Glass
Installation
(cont'd)
13. Use sucti on cups to hol d the rear wi ndow over the
openi ng, al i gn i t wi t h t he al i gnment mar ks made i n
step 6, and set i t down on the adhesi ve. Li ghtl y push
on the rear wi ndow unti l i ts edges are ful l y seated
on t he adhesi ve al l t he way ar ound.
NOTE: Do not open or cl ose the doors unti l the adhe-
si ve i s dry.
SUCTION
cuPs
kni fe or towel .
NOTE: To remove adhesi ve from a pai nted surface
or the rear wi ndow, use a soft shop towel damp-
ened wi th al cohol .
spr ay wat er over t he r ear wi ndow and check f or
l eaks. Mark the l eaki ng areas, l et the rear wi ndow
NOTE: Let the car stand for at l east four hours after
rear wi ndow i nstal l ati on. l f the car has to be used
Rei nstal l al l remai ni ng removed pans.
.
Sl am the doors wi th al l the wi ndows rol l ed up.
(such
as when goi ng
i n and out ot dr i veways at an angl e or dr i vi ng
l
.J
1 4 .
16.
20-40
Removal
3D:
CAUTION:
a Wear gloves
to remove and install the quarter glass.
a Use seat covers to avoid damaging any surfaces.
1. To remove the quarter gl ass, fi rst remove the:
. Rear seat-back and rear seat cushi on
(see page
20_80)
. Rear center shel f and rear si de shel f
(see page
20-60)
Rear t r i m panel
and si de t r i m panel ( see page
20-60)
Upper anchor bol ts from the front and rear seat
bel ts {see
pages 20 86, 89)
Ouaner tri m panel (see page 20-60)
2. From i nsi de the car, use a kni fe to cut through the
quarter gl ass adhesi ve al l the way around.
NOTE:
. l f the cl i p on the rear edge i s broken, the quarter
gl ass can be rei nstal l ed usi ng butyl tape (see page
20-421.
. Appl y protecti ve
tape al ong the edge ofthe enti re
quarter gl ass
openi ng fl ange.
\
GLASS
Upper portion:
Lower
portion:
Pi l l ar port i on:
OUARTER
GLASS TRI M
PROTECTIVE
TAPE
ADHESI VE
ADHESIVE
RUABER
DAM
PROTECTIVE
TAPE
3.
ADHESI VE
Careful l y remove the quarter gl ass.
NOTE: Check t he quar t er gl ass t r i m and cl i ps f or
damage, and repl ace them i f necessary.
CLI P
Instal l ati on
( 0. 08
i n) on t he bondi ng
sur f ace ar ound t he ent i r e quar t er gl ass cpeni ng
t l ange.
NOTE:
body; damaged pai nt wi l l i nterfere wi th proper
bondi ng.
. Remove the rubber dams from the body.
. l f any of the cl i ps are broken, remove them from
the body.
. Mask off surroundi ng surfaces before appl yi ng
pnmer .
ened i n al cohol .
NOTE: Af t er cl eani ng. keep oi l , gr ease and wat er
l f the quaner gl ass i s to be rei nstal l ed, use a putty
cl ean the quarter gl ass surface wi th al cohol where
adhesi ve i s to be appl i ed.
NOTE: Make sure the bondi ng surface i s kept free
CAUTION: Avoi d setti ng the quarter gl ass on i ts
2.
3.
(cont' d)
20-41
Ouarter Glass
Installation
{cont'dl
Gl ue the upper and l ower rubber dams to the i nsi de
face of the quarter gl ass, as shown, to contai n the
adhesi ve duri ng i nstal l ati on.
NOTE: Be car ef ul not t o t ouch t he quar t er gl ass
where adhesi ve wi l l be appl i ed.
>: Al i gnment mark
'o""tton"
oao""
UPPER
RUBBER DAM
t l
--f-_1_-
r - ' J - - . i . .
13.5
mml
tT-
i l 0. 14 i nl
I
I
\
RUBEER
\
DAM
LOWER
BUBBER DAM
Instal l the quarter gl ass tri m on the quarter gl ass,
then gl ue the upper and l ower cl i ps as shown.
OUARTER
NOTE: Cont act t he cl i ps agai nst t he
quart er
9l ass
t ri m at t he areas
i ndi cat ed by t he arrows.
OUARTER
GLASS
UPPER
GLASS TRIM
20-42
6. l f the ol d quarter gl ass i s to be rei nstal l ed
(and
the
cl i p on t he r ear edge i s br oken of f ) , appl y a l i ght
coat of pri mer (3M
C-100, or equi val ent), then appl y
butyl tape to the quarter gl ass.
as shown. and seal
the body hol e wi th pi ece of urethane tape.
NOTE:
o Be careful not to touch the quarter gl ass where
. Do not peel the separator off the butyl tape.
'//////7r,
: eug tape tocstions
(3M
8628, or equivelent)
Thi ckn*s:3.2 mm 10.13 i nl
Width: 6.4 mm 10.25 inl
\
7. Wi th a sponge, appl y a l i ght coat of gl ass pri mer to
the i nsi de face of the
quarter gl ass, as shown, then
l i ghtl y wi pe i t off wi th gauze or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the quarter gl ass,
mi xed up.
It you do, the adhesi ve may not bond to the quar-
ter gl ass properl y, causi ng a l eak after the quar
ter
gl ass i s i nstal l ed.
////////
' eooV
st.,.
primer here.
21 mm 15 mm
lo.tB io) {0.59 inl
OUARTER
GLASS TRIM
15 mm
30 mm
{0. 59 i n)
l r. 2 i n)
the ori gi nal adhesi ve remai ni ng around the quarter
gl ass openi ng fl ange. Let the body pri mer dry for at
l east 10 mi nutes.
NOTE:
. Do not appl y gl ass pri mer to the body, and be
car ef ul not t o mi x up gl ass and body pr i mer
sponges.
. Mask off the rear si de tri m panel before
pai nti ng
t he f l ange.
////////7 : aootv bodv
odmer
here.
16 mm
(0.63
inl
NOTE:
m r xr ng.
. Fol l ow the i nstructi ons that came wi th the adhe-
stve.
10. Before fi l l i ng a cartri dge. cut the end of the nozzl e
as shown.
Cut nozzl e end
10 mm 10. 39
i n)
(cont ' d)
7 mm 10. 27 i n)
20-43
Ouarter Glass
Installation
{cont'd)
11. Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nuous del i very. Put the cartri dge i n a
caul ki ng gun, and r un a bead of adhesi ve ar ound
the edge of the quarter gl ass as shown.
NOTEI
. l f the ol d quarter gl ass i s to be rei nstal l ed, peel
the separator off the butyl tape after appl yi ng the
adhesi ve.
. Appl y the adhesi ve wi thi n 30 mi nutes after appl y-
i ng the
gl ass pri mer.
l i .;l ,l /:ADHE' ,' E
8 mm
{0 3' l i nl
OUARTER
GLASS TRIM
22. 5 nm
{0. 89 i n)
UPPER
RUBBER
DAM
BUTYL
TAPE
LOWER
RUBBER
DAM
RUBBER
DAM
20-44
12. Use sucti on cups to hol d the quarter gl ass over the
openi ng. al i gn the cl i ps, and set i t down on the adhe
si ve. Li ghtl y push on the quarter gl ass unti l i ts edges
are ful l y seated on the adhesi ve al l the way around.
NOTE: Do not open or cl ose t he door s unt i l t he
adhesi ve i s drv.
kni fe or towel .
NOTE: To remove adhesi ve from a pai nted surface
or the
quarter gl ass, wi pe wi th a soft shop towel
dampened wi th al cohol .
spray water over the quarter gl ass and check for
l eaks. Mark the l eaki ng areas, l et the quarter gl ass
NOTE: Let the car stand l or at l east four hours after
quarter gl ass i nstal l ati on. l f the car has to be used
Rei nstal l al l remai ni ng removed parts.
(such
as when goi ng
14.
15.
CLIP
Removal
2Di
CAUTION:
. Wear gloves to remove and install th quarter glass.
. Use seat covers to avoid damaging any surfaces,
1. To remove the quaner gl ass, fi rst remove the:
(see page
20-81)
.
Si de tri m panel (see page 20-61)
. Rear shel f
(see page 20-61)
o Upper anchor bol t from the front seat bel t
(see
page 20 86)
. Ouaner tri m panel (see page 20-61)
2. Ftom i nsi de the car, use a kni fe to cut through the
quarter gl ass adhesi ve al l the way around-
NOTE:
. l f the quarter gl ass i s to be rei nstal l ed, take care
not to damage the mol di ng.
. Appl y protecti ve tape al ong the edge ofthe enti re
quarter gl ass openi ng fl ange.
a
GLASS
Upper portion:
ADHESIVE
PROTECTIVE
TAPE
Rear edge portion:
Pillar portion:
Careful l y remove the quaner gl ass.
NOTE: Check the mol di ng for damag, and repl ace
i t i f necessary.
TAPE
20-45
Ouarter Glass
' t .
Instal l ati on
( 0. 08
l n) on t he bondi ng
sur f ace ar ound t he ent i r e quar t er gl ass openi ng
f l ange.
NOTE:
. Do not scrape down to the
pai nted
surface of the
body; damaged pai nt wi l l i nterfere wi th proper
bondi ng.
. Remove the fastener from the body.
. l f any ot the cl i ps are broken, remove them from
the body.
o Mask off surroundi ng surfaces before appl yi ng
pri mer.
ened i n al cohol .
NOTE: After cl eani ng, keep oi l , grease and water
l f the quaner gl ass i s to be rei nstal l ed, use a putty
cl ean the quarter gl ass surface wi th al cohol where
adhesi ve i s to be appl i ed.
NOTE: Make sure the bondi ng surface i s kept tree
CAUTION: Avoi d setti ng the quarter gl ass on i ts
20-46
\
4. Instal l the mol di ng around the edge of the quarter
gl ass as shown.
NOTE:
. It the ol d mol di ng i s to be rei nstal l ed, scrape off
t he ol d adhesi ve t ape f r om t he mol di ng, and
cl ean t he mol di ng sur f ace wi t h al cohol wher e
new adhesi ve tape i s to be appl i ed. Appl y the
doubl e-faced adhesi ve tape to the mol di ng and
quarter gl ass as shown.
. Be carel ul not to touch the quarter gl ass where
adhesi ve wi l l be aDDl i ed.
Adhesive tape A {3M 4215, or equivalentl
Thickness: 0.4 mm
(0.02
inl
Wi dth: 5 mm 10.2 i n)
Length:440 mm
(17.3
i n)
Adhesive tape B
(NITTO
501, or equivalontl
Thickness: 0.16 mm
(0.006
inl
Wi dth: 8 mm 10.3 i nl
Length:
' 140
mm
(17.3
i n)
Adhesive tape C {3M
'1213,
or equivalentl
Thi ckness:0.8 mm
(0.03
i nl
Wi dth: 5 mm
(0.2
i n)
Length: 30 mm
(1.2
i n)
ADHESIVE
5. l f the ol d quarter gl ass i s to be rei nstal l ed, gl ue the
upper and l ower cl i ps and fastener as shown.
>: Clip, tastener loc.tions
a > , 2 B > , 1
2. 5 mm
6. Gl ue the fastener to the body as shown.
>: Fastener locstion. 1
ALIGNMENT
ALIGNMENT
7. Wi th a sponge, appl y a l i ght coat of gl ass pri mer to
the i nsi de face of the quarter gl ass, as shown, then
l i ghtl y wi pe i t off wj th gauze or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the quarter gl ass,
mi xed up.
l f you do, the adhesi ve may not bond to the quar-
ter gl ass properl y, causi ng a l eak after the quar-
ter gl ass i s i nstal l ed.
t///////1
' aooV wav
orime,
hero.
MOLDI NG
15. 5 mm 10 mm
{0.61 in)
(0.39
in)
(cont' d)
20-47
Ouarter Glass
Installation
(cont'd)
Wi th a sponge. appl y a l i ght coat ol body pri mer
to
the ori gi nal adhesi ve remai ni ng around the quarter
gl ass openi ng fl ange. Let the body pri mer
dry for at
l east 10 mi nutes.
NOTE:
. Do not appl y gl ass pri mer to the body, and be
car ef ul not t o mi x up gl ass and body pr i mer
sponges.
. Mask off the rear si de tri m panel
before pai nti ng
the fl ange.
t///////7,
, eppty roay
erimer
here.
1. 5 mm
9. Thoroughl y mi x the adhesi ve and hardener togeth,
er on a gl ass or metal pl ate wi th a putty kni fe.
NOTE:
mi xi ng.
. Fol l ow the i nstructi ons that came wi th the adhe
si ve.
10. Before fi l l i ng a cartri dge, cut the end of the nozzl e
as shown.
Cut nozzl e end
20-48
10 mm {0.39 in)
1 1. Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nuous del i very. Put the cartri ge i n a
caul ki ng gun, and r un a bead of adhesi ve ar ound
the edge of the quarter gl ass
as shown.
NOTE:
. l f the ol d quarter gl ass i s to be rei nstal l ed. peel
the separator off the butyl tape after appl yi ng the
adhesi ve.
. Peel the separator off the adhesi ve tape after
appl yi ng the adhesi ve.
. Appl y the adhesi ve wi thi n 30 mi nutes after appl y-
i ng the gl ass pri mer.
i ; . I i ^, / :
ADHE' T' E
8 mm
(0. 31
i n)
CLIP
12. Use sucti on cups to hol d the
quarter gl ass over the
openi ng, al i gn t he cl i ps, and set i t down on t he
adhesi ve. Li ghtl y
push on the
quaner gl ass unti l i ts
edges are ful l y seated on the adhesi ve al l the way
ar ound.
NOTE: Do not open or cl ose t he door s unt i l t he
adhesi ve i s dry.
Scrape or wi pe the excess adhesi ve off wi th a puny
kni fe or towel .
NOTE: To remove adhesi ve from a
pai nted surface
or the quarter gl ass, wi pe wi th a soft shop towel
dampened wi th al cohol .
spr ay wat er over t he quar t er gl ass and check f or
l eaks. Mark the l eaki ng areas, l et the quarter gl ass
NOTE: Let the car stand for at l east four hours after
quarter gl ass i nstal l ati on. l f the car has to be used
Rei nstal l al l remai ni ng removed
parts.
thi ngs for tl vo to three days:
. Twi st the body excessi vel y l such
as when goi ng
13.
1 4 .
CLIP
20-49
Moonroof
SWTTCH PLATE
Adi ust ment , page 20-56
l ndex
CABLE ASSEMBLY
Repl acement , page
20-55
INNER CABLE
SUNSHADE
RAIL HOI-DER B
RAIL HOLDER A
REAR DFAIN
TUBE
, /
?<^
/ \ ?'''
UBE
l l /
L f P
l l ,
U 6
a"w
REAR DRAIN
VALVE
=-.
SLIDER
FRONT DRAI N TUBE
20- 50
Troubl eshooti ng
Symptom
Probable Cause
' 1.
Cl ogged drai n tube.
2. Gap between
gl ass weatherstri p and roof panel
3. Defecti ve or i mproperl y i nstal l ed
gl ass weatherstri p
4. Gap between drai n seal and roof panel .
Water l eaks
Wi nd noi se
1. Excessi ve cl earance between
gl ass weatherstri p and roof panel .
1. Loose motor.
2. Worn gear or beari ng.
3. Cabl e assembl y deformed.
Motor noi se
Gl ass does not move. but motor turns
' 1.
Cl utch out of adj ustment.
2. Forei gn matter stuck between gui de rai l and sl i der.
3. Inner cabl e l oose.
4. Cabl e assembl y not attached properl y.
Gl ass does not move and motor does not turn
(gl ass
can be moved wi th moonroof wrench)
1. Bl own fuse.
2. Faul ty swi tch.
3. Battery run down.
4. Defecti ve motor.
5. Faul ty rel ay.
Gl ass Hei ght Adj ustment
The roof
panel
shoul d be even wi th the gl ass weather
st r i p, t o wi t hi n 1. 7 l l t f mm
( 0. 07
l 3&' i n) al l t he way
around. l f not, open the gl ass ful l y, and:
1. Remove the bracket cover.
Loosen the nuts, and i nstal l the shi ms between the
gl ass frame and gl ass bracket as shown.
Shi m thi ckness: Front max.3 mm {0.12 i nl
Rear max. 2 mm
(0.08
i nl
Repeat on opposi te si de i f necessary
6 x l . 0 mm
9. 8 N m
(1. 0 kgl m,
7.2lbl.ltl
BRACKET
COVER
6 x 1 . 0 mm
9. 8 N. m {' 1. 0 kgI . m.
7. 2l bt f t )
1.7 rl .3 mm
{0.07 13:3i in)
20-51
Moonroof
Gl ass, Gl ass Bracket and Sunshade Repl acement
1. Cl ose t he gl ass I ul l y.
2. Sl i de the sunshade al l the way back.
3. Remove both bracket covers.
SCREW
Forward
4. Remove t he nut s t rom bot h gl ass bracket s.
6 x
' l .0
mm
9.8 N.m {1.0 kst m,7.2l bf ft)
Remove the gl ass by l i fti ng up and pul l i ng forward
as shown.
NOTE| Do not damage the roof panel .
BRACKET COVER
GLASS BRACKET
GLASS
20-52
\
6. Remove t he dr ai n channel .
DRAI N CHANNEL
RAIL HOLDER B
Usi ng the moonroof wrench, move the gl ass bracket
to the posi ti on where the moonroof normal l y pi vots
down, and remove the screws.
7. Remove t he hol der cover , t hen r emove t he
hol der B.
NUT
6 x 1 . 0 mm
9 N.m {0.9 kgf.m,
7 rbf.frl
{itt'za
scREws
NUT
6 x 1 . 0 mm
9 N.m {0.9 kgf m,
9. Remove the rai l hol der A.
DRAIN CHANNEL ROO STOP
Rotate as shown to remove i t from the gui de rai l .
10, Remove the drai n channel rod sl i der by movi ng the
cabl e sl i der forward usi ng the moonroof wrench.
' 11.
Detach the drai n channel rod stop from the cutout
of the gui de rai l as shown,
I
I
13.
14.
12. Sl i de the sunshade forward, then remove i t.
NOTE: Check the gl ass hei ght
(see page 20-51).
Check for water l eaks.
NOTE: Do not use hi gh-pressure water'
20-53
Moonroof
Motor, Drain Tube and Frame Replacement
GAUTION:
.
Wear gloves
to remove and install the ftame.
. Be careful not to damage the seats, dashboard and other interior trim.
1. Remove the headl i ner (see page 20-64).
2. Di sconnect the motor connector and gl ass posi ti on
swi l ch connector.
NOTE: when removi ng the motor, detach the connector from the frame, remove the bol ts and nuts. then remove tne
motor.
3. Remove the gl ass
{see
page 20-52).
4. Di sconnect the drai n tubes, and detach the cei l i ng l i ght harness.
5. Remove the frame mounti ng bol ts.
NOTE:
. An assi stant i s hel pful when removi ng the bol ts.
. Remove the front bol ts l ast.
6. Detach the rear hooks by movi ng the frame forward, then remove the frame.
Remove l ast ,
BOLT
6 x 1 . 0 mm
9. 8Nm( 1. 0kgl . m,
7.2 tbl.tll
6 x 1. 0 mni
9. 8 N. m 11. 0 kgf . m, 7. 2 t bt f o
20-54
7. Pul l the drai n tubes out the front and rear pi l l ars
NOTE: Before
pul l i ng out the drai n tube, ti e a stri ng
to the end ot i t so i t can be rei nstal l ed.
REAR DBAIN
VALVE
procedure'
NOTE:
. Before i nstal l i ng the frame, cl ear the drai n tubes
and drai n val ves by usi ng compressed
al r.
. Check the frame seal .
. Cl ean the surface of the frame.
. When i nstal l i ng the trame, fi rst attach the rear
hooks i nto the body hol es.
. When connecti ng the drai n tube, sl i de i t over the
frame nozzl e at l east 10 mm
(0.39 i n)
. I nst al l t he t ube cl i P as shown.
Upward
I
I
I
TUBE CLIP
9. Check for water l eaks.
NOTE: Do not use hi gh-pressure water.
I
f
DRAI N TUBE
Gui de Rai l s/Cabl e
Assembl Y
Replacement
CAUTION: Wear
gloves to remove and install the
guide
rai l s and cabl e assembl y.
1. Remove the frame.
2. Remove the motor and glass bracket
(see page 20 52)'
3. Remove the nuts, and l i i t off each gui de rai l , then
remove the cabl e assembl y wi th sl i ders attached'
NOTE: Take care not to bend the cabl e tubes and
gui de r ai l s.
GROMMET
procedure'
NOTE:
. Damaged
parts shoul d be repl aced
. Grease the sl i di ng
porti on wi th Super Hi gh Temp
Urea Grease, P/N 08758
-
9002.
. Fi l l the groove i n each
grommet wi th seal ant.
a
a
l nstal l the frame seal securel Y
Before i nstal l i ng the motor, make sure both sl i d-
ers are
paral l el .
Before i nstal l i ng the motor, i nstal l the trame and
gl ass, then check the openi ng drag
(see page 20-
57).
20-55
Moonroof
Switch Plate Adjustment
(Fully
Closed Positionl
GUI OE
PLATE
\
1 .
2.
Remove the headl i ner
{see
page 20-64).
Usi ng the moonroof wrench, cl ose the gl ass
ful l y.
NOTE: Check the gl ass fi t to the roof panel .
3. Usi ng an open-end wrench, l oosen the swi tch pl ate mounti ng bol ts.
4. Adj ust posi ti on of the swi tch pl ate (swi tch
cam) as shown.
5. Check the operati on of the gl ass (from
ti l t-up posi ti on
to ful l y cl osed posi ti on, from the ful l y open posi ti on to the ful l y
cl osed posi tj on) by operati ng the moonroof swi tch.
NOTE: Check the gl ass hei ght {see page 20-51}.
SWITCH PLATE
Check t he swi t ch pl at e
cont act s t he
cabl e bracket .
CABLE ERACKET
Cl ose the gl ass ful l y, and check tor water l eaks.
NOTE: Do not use hi gh-pressure water.
Vt, ,
SWITCH CAM INNER CAELE END
Whi l e movi ng t he swi t ch pl at e l i t t l e by l i t t l e, secure t he swi t ch
pl at e
at t he posi t i on
where t he swi t ch cam cont act s t he swi t ch
A
(a
f ai nt cl i ck i s heard).
I
cnecl rr
I
ca or e or
l c ,
20- 56
Openi ng Drag Check
(Motor
Removed)
Before i nstal l i ng the motor, measure the effort requi red
to open the gl ass usi ng a spri ng scal e as shown.
CAUTION: When using a spring scale. plotest the lad-
ing dge of the glass with a shop towel.
l f l oad i s over 40 N
(4
kgf,9 l bf), check the si de cl earance
and gl ass hei ght
( see page 20- 51) .
SHOP TOWEL
Closing Force Check
(Motor
Instal l ed)
1. Af t er i nst al l i ng al l r emoved par t s, have a hel per
hol d the swi tch to cl ose the gl ass whi l e you mea-
sure the force requi red to stop i t. Attach a spri ng
scal e as shown. Read the force as soon as the gl ass
stops movi ng, then i mmedi atel y rel ease the swi tch
and spri ng scal e.
CAUTION: When using a spring scale,
protect the
leading edge ol the
glass with a shop towel.
Closing Force: 200
-
290 N
(20 -
30 ksf,
/14 -
66 lbf)
l f the force i n not wi thi n speci fi cati on, i nstal l a new
l ock washer, adj ust the tensi on by turni ng the motor
cl ut ch adj ust i ng nut , and bend t he l ock washer
agai nst the motor cl utch adj usti ng nur.
LOCK
WASHEB
Repl ace.
a
I
COUNTER-
cLocKwtsE
To decr ease
SCALE
20-57
lnterior
Component Location Index
SRS components are l ocated i n the pans
areas marked wi th an asteri sk
(*).
Revi ew the SRS component l ocauons, precau-
ti ons, and procedures i n the SRS secti on
(24)
before pertormi ng repai rs or servi ce.
2D l3D llDl
CENTER PILLAR
UPPER TRIM
{see
page 20 59)
FRONT PILLAR
TRIM
(see pages
20' 59, 60, 61i
CENTER PILLAR
LOWER TRIM PANEL
(see page
20 59)
REAR PILLAR
TRIM
(see page 20-59)
(see page 20-59)
TRUNK
TRIM
(see page 20-62)
SEAT
SIDE TRIM
(see page 20-59)
REAR
REAR
PANEL
(see page 20-60)
Component Removal / l nst al l at i on,
page 20-68
Removal , page
20-70
TCARPET
Fepl acement , page
20-66
PANEL
Replacement. page 20-67
3D:
OUARTER
TRIM PANEL
(see page 20 60)
OUARTER
TRIM PANEL
2Dl
REAR ROOF TRIM
(see page
20 65)
REAR ROOF
TRIM
{see
page
20, 65}
HATCH
UPPER
TRIM
(see page 20 63)
REAR CENTER
SHELF
(see page
20-60)
SIDE TRIM
{see
page
20-60}
REAB
PANEL
(see page
20-62)
REAF
TRIM PANEL
(see page
20'63)
SIDE TRIM
PANEL
(see page 20-60)
20- 58
(see page 20-6' 1)
l nteri or Tri m
Replacement
CAUTION:
. Wear gloves to remove and install the trim and
panels.
. When prying with a tlat tip screwdriver, wrap it wilh
protective tape to prevent damage.
NOTE: Take care not to bend or scratch the tri m and panel s
4D:
>: Clip locations
a > , 2
o > , 2 E > , 2
c > , 2 1
CLIP
LOCK CYLINDER TRIM
CENTER PILLAR
+
SEAT
T SIOE TRIM
Di sconnect t he
hi gh mount brake
l i ght connect or.
LOWER TRIM
PANEL
BELT UPPER
ANCHOR
(see page 20 85)
Remove t he rear seat cushi on and rear
seat si de bol st er
(see page 20 79i .
procedure.
NOTE:
. l f necessary, repl ace any damaged cl i ps.
. Before i nstal l i ng the front seat bel t upper anchor
and rear shel t, make sure there are no twi sts or
ki nks i n the seat bel ts.
(cont,d)
retu
n>( |
\Zl\ J
^f
FRONT PILLAR
TRIM
RIGHT KICK
PANEL
8 > , 6
CLI P
REAR SHELF
20- 59
Interi or Tri m
Repl acement
(cont' dl
3D:
>: Cl i p l ocat i ons
a > , 2
CLIP
n l-,
rr,\\F\
i
,\\ l\ l
\ \ u /
_ _ - /
F > , 1 { G> , 2
I N ' .,. ] rci g
N i 4 )
i @ i
|_) _t),t )_w/
FRONT SEAT
EELT UPPER
ANCHOR
B > . 3
CLIP
c > , 8 D > , 3
E > , 8
>: Screw, bolt locations
a > , 3 B > , 6
c > . 1
,r+n
\ - -
D > , 2
H > , 2
l @@
\ - -
(see page 20-86)
REAR SIDE
SHELF
SIDE TRIM
PANEL
Remove t he rear seat -back and
rear seat cushi on
(see page
20-80)
Di sconnect t he rear speaker
connect or
(bot h
si des,
f or some model s).
REAR TRIM
PANEL
SIDE TRIM PANEL
PROTECTOB
SIDE TRIM
FRONT SEAT BELT
LOWER ANCHOR
( see page 20 86)
H
REAR CENTER
SHELF
SPABE TIRE
LID
A i f , n \ l e
##
s
qHP
Y
l*@
_ _ - / _ 7 /
\
REAR SEAT BELT
UPPER ANCHOR
{see
page 20-89)
NOTE:
. Before i nstal l i ng the anchor bol ts, make sure there
are no twi sts or ki nks i n the seat bel ts.
20-60
,
2D:
>: Clip locations
a > , 2
>: Screw locations,4
B > , 3 c >, 14
SEAT BELT
LOWER ANCHOR
(see page 20-86)
D > , 3 E > , 2
F > , 8 H > , 2
,. I r$H
N,tU
ffi
{see
page 20-86)
SIDE TRIM PANEL
SIDE TRIM PANEL
Remove t he rear seat -back and
rear seat cushi on
(see page
20 81) .
LOCK CYLINDER
TRIM
Di sconnect t he hi gh
mount brake l i ght
connect or.
PIVOT BRACKET
(see page 20-81)
NOTE:
. l f necessary. repl ace any damaged cl i ps.
. Before i nstal l i ng the anchor bol ts and rear shel f,
make sure there are no tvvi sts or ki nks i n the seat
bel ts
SIDE TRIM
TRIM
G> , 4
FRONT PILLAR
FRONT SEAT
EELT UPPER
ANCHOR
A
w'
, \ .
/ " c
a
ntoir rrcx
@
LEFT KICK
PANEL
20-61
Trunk Tri m
Replacement
CAUTION:
. Wear gloves
to remove and install the trim and panels.
. Whon prying with a flat tip screwdriver, wrap it with protective
tape to prevent damage.
NOTE:
. Take care not to bend or scratch the tri m and panel s.
. When removi ng the trunk si de tri m or trunk tri m
panel ,
fol d the seat-back torward.
Japan-produced:
4D:
RI GHT TRUNK
SIDE TRIM
TRUNK MAT
REAR TRIM
PANEL
>: Clip locations
a > , 6
I
B
I
s
CLI P
R -.--\ra
I l' 3{aQ' F-
I
s : ' \
|
"
| NNER
\\- cll
B > , 6
NOTE: Do not push
t he i nner cl i p i n t oo f ar.
B t -' )
, 2
i J
!l
i
) :Hook locations
Ai -), t
2D:
TRUNK TRIM
NOTE:
. l f necessary, repl ace any damaged cl ;ps.
. To i nstal l the A cl i ps, pul l
the i nner cl i p up, i nstal l
the cl i p, then push the i nner cl i p unti l i t' s fl ush.
(
, -
t -
/ t t
\ - -
20-62
Hatch Trim
Repl acement
CAUTION:
. Wear gloves to remove and install the trim.
. When prying with a flat tip screwdriver, wrap it with protective tape to
prevent damage.
NOTE: Take care not to bend or scratch the tri m and panel .
B > , 7
r r
-
vr:
/
Y , /
a > ' 2
I
NOTE: Do not push t he
I
i nner cl i p i n t oo f ar.
I
M cr-rp. I
54@-, 1
g * - \
|
:?-
INNER ]
ct!,/
c > , 1 3
i
I S ]
-N-l
" , /
a
c l
.rt-ATa-a-a
; - - ' " [ 1 "
c c
LEFT HATCH
SIDE TRIM
HATCH
UPPER TRI M
NOTE:
. To i nst al l t he A cl i ps, pul l t he i nner cl i p up. i nst al l
t he cl i p, t hen push t he i nner cl i p unt i l i t ' s f l ush.
'Pr-u
20-63
Headl i ner
Replacement
CAUTION: When pryi ng wi th a fl at ti p screwdri ver.
wlap it with protective tape to prevent damage.
NOTE:
. Take care not to bend and scratch the headl i ner.
. Be careful not to damage the dashboard and other
i nteri or tri m.
' 1.
Remove:
4D:
Front pi l l ar tri m
(both
si des, see page 20-59)
Center pi l l ar l ower tri m panel (both
si des, see page
20-59)
Upper anchor bol t from the front seat bel t
(both
Center pi l l ar outer tri m and center pi l l ar upper tri m
(both
Cei l i ng l i ght
(see
secti on 23)
Rearvi ew mi rror
(see page 20-25)
a
a
a
3D:
. Front pi l l ar tri m
(both
. Ri ght rear seat-back and rear seat cushi on
(see
page 20-80)
. Rear center shel f
(see page 20-60)
o Rear si de shel f and si de t r i m panel ( r i ght
si de,
see page 20 60)
. Upper anchor bol ts from the front and rear seat
belts {right side, see pages 20-86, 89)
. Ouarter tri m panel (ri ghtsi de,
see page 20-50)
. Cei l i ng l i ght
(see
secti on 23)
. Rearvi ew mi rror
(see page 20-25)
2Dl
. Front pi l l ar tri m
(both
. Ri ght rear seat-back and rear seat cushi on
(see
page 20-81)
. Si de trl m panel (ri ght
si de, see page20-61)
. Upper anchor bol t from the front seat bel t
(rl ght
si de, see page 20-86)
. Ouarter tri m panel (ri ght
si de, see page 20 61)
. Cei l i ng l i ght
(see
secti on 23)
. Rearvi ew mi rror
(see page 20-25)
20-64
2. Remove t he sunvi sor and hol der f rom each si de.
3. Remove the grab handl es and coat hanger.
ACCESS
LID scREws
ACCESS
LID
COAT HANGER
BRACKET
4. Remove t he r ear r oot t r i m and cl i ps, and r emove
t he roof t ri m and socket pl ug
(moonroof model )
>: Clip locations
A> 20l 40, 7 B > Wi t h moonrool , 1
3D, 5 Wi t hout moonrool , 3
l
)At
EE
% ) & )
2D l3D l4Dl
HEAOLI NEB
REAR BOOF
REAR
PILLAR
TRIM
3D:
2Dl
5.
7.
OUARTER
TRIM PANEL
4D: Lower the rear pi l l ar tri m on both si des.
3D: Remove the upper anchor bol ts from the front
and rear seat bel ts
(see pages 20-86.89i , then l ower
the quaner tri m
panel on l eft si de.
2D: Remove t he upper anchor bol t t r om t he f r ont
seat bel t
(see page 20-86), then l ower the quarter
tri m
panel on l eft si de.
Lower t he headl i ner .
Careful l y remove the headl i ner through the passen-
ger' s door openi ng
(2Dl 4D)
or hatch openi ng
(3D)
Instal l ati on i s the reverse oI the removal procecl ure.
NOTE:
. When i nser t i ng t he headl i ner t hr ough t he open-
i ng, be careful not to fol d or bend i t. Al so, be care-
tul not to scratch the body.
. Chec k t hat bot h s i des of t he headl i ner ar e
securel y attached to the tri m.
. When i nst al l i ng t he r oof t r i m, i nst al l t he
j oi nt
toward the ri ght si de
(moonroof
model )
6.
8.
20-65
Carpet
Replacement
SRS components are l ocated i n thi s area. Revi ew the SRS
component l ocati ons, precauti ons, and procedures i n the
SRS secti on
(24)
1. Remove:
. Front seat
(see page 20-7 4l
. Rear seat cushi on (see pages 20-79, 80, 81)
Ki ck panel (see pages 20-59, 60, 61)
Center pi l l ar l ower tri m panel (4D.
see page 20,59)
Front seat bel t l ower anchor
(2Dl 3D,
see page 20-
86)
Si de tri m {see
pages 20-59, 60, 61)
Front and rear consol es
Consol e panel
a
a
a
a
3.
Remove the SRS uni t covers.
Cut areas
@
and
@
i n the carpet, then pul l i t back as
snown.
>: Cl i p l oceti ons, 2
--.ils - I
l@l
-llp
-
|
LEFT SRS
UNIT COVER
20- 66
4. Remove the footrest and parki ng brake l ever mount-
i ng bol ts, and detach the cl i ps, then remove the car-
pet.
A > , 2 B > . 2
>: Clip locations,
rft
\ t l
2Dl3Dl4D:
I
9 l
s /
O
6 x ' l . 0 m m
tf I
e.s N.m t1.o ksrm,
E
/
7 2 tbrftl
5.
2D l3Dl
NOTE:
. Take care not to damage, wri nkl e or twi st the car
pet.
. Make sure the wire harnesses are routed correctly.
. Sl i p the carpet under the seat si de tri m
(4D)
or
si de tri m panel (2Dl 3D)
on each si de properl y.
. Reattach the cut areas
@
and
@
i n the carpet
wi th wi re ti es.
FOOTREST
SIDE TRIM
Consol es/Consol e Panel
Repl acement
NOTE: Take care not to scratch the front and rear consol es, front seat and rel ated parts.
Di sassembl e i n numbered sequence.
>: Screw locations
A> , 8 A> . / t
>: Clip localions
A> , 2 B> , 2
D7777777v-r
0F* @@'
-f
i
: ) " ) _ : )
o
REAR CONSOLE
l wi t h armrest )
('
FRONT CONSOLE
Remove t he shi f ! l ever knob { M, / T) .
^\
NOTE:
. Make sure the wi re harnesses are not pi nched.
. Make sure the connector i s connected properl y.
20-67
Dashboard
Component Removal /l nstal l ati on
CAUTION: when plying with a flat tip screwdriver, wrap
it with
protective tape, and apply
protective tape around
the related
parts, to prevent damage.
NOTE: Take care not to scratch the dashboard and rel ated
parts.
Instrument panel removal:
2.
1 . Lower the steeri ng col umn.
Remove the screws, and detach the cl i ps, then care-
ful l y remove the i nstrument panel .
>: Screw locations, 2
3. l nstal l ati on i s the reverse of the removal Drocedure.
>: Cl i p l ocat i ons. 2
"[ ] I
p 1
l J
PANEL
Driver's dashboard lower cover and knee bolster removal:
SRS components are l ocated i n thi s area. Revi ew the SRS
component l ocati ons, precauti ons, and procedures i n the
SRS secti on {24} before
performi ng repai rs or servi ce.
1. Remove t he scr ews, and det ach t he cl i ps, t hen
r emov e t he dr i v er ' s das hboar d l ower c ov er . l f
equi pped wi th power mi rrors and moonroof, di scon-
nect the connectors.
>: Screw, bolt locations
a > , 3 B> , 2
--' 4.i /D,-
ox l omm
***\Y
((n1lfl
)e.8
N m
(l.o
kgt m,
\)- 7.2 tbf.ftl
>: Clip locations
a > . 2 B > , 1
d
F-,,
POWER MIRROR
SWITCH CONNECTOR
(f or
some model s)
MU(,NTIUUI-
swtTcH
CONNECTOR
model s)
3.
2.
DRIVER' S DASHBOARD
LOWER COVER
Remove the bol ts, then remove the knee bol ster.
Glove box removal:
Remove the bol ts, then remove the
gl ove
box.
5xo. 8mm I
9 N m lO.9 ksf.m,
I
'::"
)
SIDE AIR VENT
Remove t he dri ver' s dashboard l ower
cover, or open t he gl ove box,
t hen push t he cl i ps t rom each
openi ng by hand, and pul l i t
out. Disconnect the connedors
l nstal l ati on i s the reverse ot the removal orocedure.
Side air vent/Side defogger trim removal:
SI DE DEFOGGER TRI M
Car ef ul l y pr y r t at t he si de edge.
HOOKS
CLIP
HOOKS
(dri ver' s
si de).
DASH LIGHTS
BRIGHTNESS
CONTROLLER
l- [3LT'-""'31r",.,
CRUISE CONTROL
MASTER SWITCH
CONNECTOR
(f or
some model s)
' 1.
Center dashboard lower covsr:
Remove:
. Dri ver' s dashboard l ower cover
. Gl ove box
Remove t he screws and bol t . t hen remove t he cen
t er dashboard l ower cover. Di sconnect t he accesso-
ry socket connect or.
>: 8olt, scrsw locations
A > , I B > , 5
2.
A , r o. r - - A
6:u;q
9 Q,
CENTER DASHBOARO
LOWER COVER
3. I nst gl l at i on i s t he reverse of t he removal procedure
(cont' d)
20- 69
Dashboard
Component
(cont'd)
Center panel removal:
' 1.
Remove:
. Center dashboard l ower cover
(see page 20-69)
. Radi o
(see
secti on 23)
2. Remove the rear wi ndow defogger swi tch and haz
ard warni ng swi tch, then di sconnect the connectors.
>: Screw locations,5 >: Clip locations
A > , 4
B > , 3
6tr'
CENTER
N<4
w
I
REAR
WINDOW
/w4,
ew
I
I
HAZARD
WARNING
swrTcH
4.
i'Y
@-Y-r
Mtx
CONTROL
CABLE
DEFOGGER CONTROL
SWITCH UNIT
Di sconnect the ai r mi x control cabl e, and remove the
screws, then pul l out the center panel .
Di sconnect the connectors from the heater control
unr t .
NOTE:
a Make sure the connectors are connected properl y.
. Adj ust the ai r mi x control cabl e
(see
secti on 21).
20-70
Removal
SRS component l ocatl ons, precauti ons, and procedures
(24) before preformi ng repai rs or ser-
vtce.
NOTE:
. An assi stanl i s hel pful when removi ng and i nstal l i ng
t he dashboar d.
. Take car e not t o scr at ch t he dashboar d, body and
rel ated parts.
1. Remove:
. Front and rear consol es
(see page 20-67)
. Consol e panel
(see page 20-67)
. Dri ver' s dashboard l ower cover and knee bol ster
(see page 20-68)
. Gl ove box {see
page 20-69)
. Center dashboard l ower cover
(see page 20-69)
2. Lower the steeri ng col umn
(see
secti on 17)
@@
To avoi d acci dental depl oyment and
possi bl o i ni ury, al ways di sconnsct the dri ver' s
airbag connector before lowering the steering col-
umn lsee section 2,1).
NOTE: To prevent damage to the steeri ng col umn,
wrap i t wi th a shop towel .
3. Di sconnect the dashboard wi re harness connectors,
remove the nuts, then move the under-dash fuse/
rel ay box. Di sconnect the antenna l ead and moon-
roof rel ay connectors.
oasHeolno 9LlPs
CONNECTORS
(f or
some model s)
FRAME
DASHBOARO
MOONROOF
RELAY
SRS MAIN
HARNESS
UNDER.DASH
FUSE/RELAY
BOX
6 x 1 . 0 mm
9. 8 N. m 11. 0 kg{. m,
7.2 tbt.tll
ANTENNA
LEAD
OATA
CONNECTOR WIRE HARNESS
Detach. CONNECTORS
4. Remove the fol l owi ng parts l rom the dashboard.
. Dri ver' s dashboard si de cover
. Passenger' s dashboard l ower cover
. Dashboard center l i d
5. Di sconnect the connectors and ai r mi x control cabl e.
D > , 1
@
OASHBOARD
, J i i l l I . l l I v t )
ft,ffits M,i
M
"ffi
j
/ffi)
WT
' | . 1 , / - - t t / - - - J
AIR MIX CONTROL
UNOER.OASH
FUSE/BELAY
PROTECTIVE
BOX
PLATE
Loosen t he bol t .
Remove the bol ts, then l i ft and remove the dashboard.
CAUTION: Use protective platss on the bottom ol the front pillar trim.
B
r
I
PASSENGER'S
DASHBOARD
LOWER COVER
6.
!!!@
To avoid accidental deployment and possible inlury, always disconnect the flont passenger's ai.bag
connector when the SRS main harness is disconnested
(see
section 241
>: Bolt, screw localions
A > , 7
>: Clip locations
A > , 1 B > , 1
B > , 1
,,{\
I x 1.25 mm
I
l[!,P
22 N.m {2.2 ksrm,
I
:
,"--
_,J
c > , 5
DASHBOARD
c > , 1
l \ - 6 x 1 . 0 mm I
LBJIP
e.6 N rn 11.s 1s1m,
I
_:_'_"o'nt ___ L
(cont' d)
20-71
8x1. 25mm
I
22 N-m 12.2 kgl.m,
)
16 tbt ftl
/
Dashboard
Removal
(cont'dl
7. l f necessary, remove the dashboard
frame from the dashboard
>: Screw locations
] r 45
s' r . o- -
\Gt"/ s.8 N.m_11.0 ksf.m,
a > , 2 1
I Fu'
( . - -
B> , 4
.4\
l f t ) ) @
! v
\ -
r1, b, f t
>: Clio locations
INSTRUMENT
PANEL
DASHBOARD
DASHBOARD
FRAME
DASHBOARD
WIRE HARNESS
DASHBOABD
BRACKET
SIDE COVER
8. I nst al l at i on i s t he reverse of t he removal
procedure.
NOTEi
. Bef ore t i ght eni ng t he bol t s, make sure t he dashboard wi re harnesses are not pi nched
. Make sure t he connect ors, ant enna l ead and ai r mi x cont rol cabl e are connect ed
properl y'
STRIKEB
20-72
Seats and Seat Belts
Component Locati on Index
2Dl3Dl1D:
SHOULDER ANCHOR
ADJUSTER I4DI
l see
page 20-85)
REAn SEAT BELT 12Dl,lDl
Repl acement,
page 20-88
Inspecti on,
page 20-91
REAR SEAT BELT BUCKLE/
CENTER BELT TONGUE
{2DI4DI
(see page
20' 90)
FRONT SEAT BELT
Repl acement , pages 20 85, 86
FRONT SEATS
Harness Wi ri ng and Becl i ne
Cabl e Locat i ons,
page 20 77
Seat Cover Fepl acement ,
page 20 77
3D:
REAB SEAT
(2Dl4D)
Removal , pages 20-79, 81
Seat-back Latch Replacement,
page 20 82
Seat Cover Repl acement ,
page 20-83
BELT BUCKLES
(see page 20-87)
REAR SEAT BELT BUCKLE/
CENTER BELT TONGUE
(see page 20 90)
REAR SEAT BELT
I nspect i on, page 20 91
REAR SEAT
Removal , page 20 80
Seat back Lal ch Bepl acement , page 20 82
Seat Cover Repl acement , page 20 83
20-73
Front Seat
Removal
CAUTION: when prying with a flat tip screwdrivol, wrap
it with proteqtive tape to prevent damage.
NOTE: Take care not to scratch the seat covers and body.
' 1.
Remove the seat track end cover, then remove the
bol ts.
FRONT SEAT
BOLT
)
10 x 1 ,25 mm
39 N.m
(4.0
kgf.m,
29
BOLT
I x 1. 25 mm
22 N.m 12.2 kgl.m,
16 rbf.ftl
8 x 1. 25 mm
22 N.m 12.2 kgl.m,
16 tbt.ftt
20-74
2. Li ft the dri ver' s front seat, then di sconnect the seat
belt switch connector.
Remove the headrest.
Careful l y remove the front seat through the door
openr ng.
NOTE: Make sure the connector i s connected prop-
erl y.
Replacement
CAUnON: When prying with a flat tip screwdriver, wrap it with protective tape to provent damage.
NOTE:
a Take care not to scratch the seat covers and body.
. Remove the front seat through the door openang.
Drivel's:
NOTE: Refer to page 20-77 for the seat bel t swi tch harness wi ri ng l ocati on.
HEADREST
SEAT.BACK
SEAT CUSHION
CENTER
PIVOT NUT
8 x 1. 25 mm
22 N.n i'2,2
16 lbf.ft)
v
I
10 x 1. 25 mm
,17
N.m {4.8 kgt m,
10 x 1. 25 mm
47 N.m
(4.8
kgt.m,
35 tbt.fr)
RECLINE AOJUSTER
LOW
&
ER CAP
t
RECLINE
CONNECTING WIRE
To connect , t wi st 180' .
OUTER SEAT
TRACK
i s the reverse of the removal procedure,
Instal l ati on
NOTE:
8 x 1. 25 mm
20 N.m
(2.0
kgf.m,
1/r lbf.ft)
washer ar e . Make sur e t he bushi ng and pi vot
i nstal l ed properl y.
. To
pr event
wr i nkl es when i nst al l i ng t he seat -
back cover. make sure the materi al i s stretched
evenl y over the pad.
. Grease the sl i di ng
porti on.
(cont' d)
10 x 1. 25 mm
20-75
Front Seat
Replacement
(cont'dl
Passenger's
lwith
recline cablel:
NOTE: Refer to page 20-77 for the recl i ne cabl e l ocati on.
HEADREST
PIVOT
WASHER
LOWER
CAP
PIVOT NUT
I x 1.25 mm
22 N.m
(2.2
kgf.m,
rbr.ftl
SEAT CUSHI ON
10 x 1. 25 mm
47 N.m {4.8 kgf.m,
l 0 x 1. 25 mm
47 N.m
(4.8
kgf.m,
35 tbnfr)
INNER SEAT
35 tbf.ftl
RECLINE
i
rowER CAP
b
10 x 1. 25 mm
47 N.m
({.7
kgf.m,
35 tbf.ft)
OUTER SEAT
TRACK
WIRE
To connect , t wr st 180 .
8 x 1. 25 mm
20 N.m
(2.0
kgf.m,
14 tbtft)
NOTE:
. Make sur e t he bushi ng and pi vot washer ar e
i nstal l ed properl y.
. To prevent wri nkl es when i nstal l i ng the seat-back
cover, make sure the materi al i s stretched evenl y
over the pad.
. Adj ust the recl i ne cabl e.
. Grease the sl i di ng porti on.
SEAT.BACK
20-76
Harness Wi ri ng and Recl i ne
Cabl e Locati ons
NOTE: When i nstal l i ng the seat cushi on, make sure the
seat bel t swi tch harness, connector and recl i ne cabl e are
fastened correctl y on the seat cushi on frame.
Driver's: >: Clip locations
Passenger' s
(wi th
recl i ne cabl el :
TRACK
2.
Seat Cover Replacement
CAUTION: Wear gloves to remove and install the seat
GOVetS.
NOTE: Take care not to tear the seams or damage the
seat covers.
Seat-back cover removal:
1. Rel ease the hook. and fol d back the seat-back cover.
Rel ease al l i nsi de spri ngs, then foi d back the seat-
DacK cover.
Remove the headrest.
Remove the headrest gui de, then remove the seat-
DacK cover.
procedure.
NOTE: To prevent wri nkl es when i nstal l i ng a seat-
back cover. make sure the mateial is stretched evenly
over the pad before securi ng the i nsi de spri ngs and
hook.
3.
(cont' d)
20- 77
HEADREST
Front Seat
Seat Cover Replacement
(cont'dl
Seat cushion cover removal:
(see pages 20-75,76).
2. Remove the cl i ps from under the seat cushi on, then
l oosen the seat cushi on cover.
>: Clip locations
Pul l back the edge of the seat cushi on cover al l the
way around, then rel ease the cl i ps, and remove the
seat cushion cover.
>: Clip locations
20-78
\
NOTE:
. To prevent wri nkl es when i nstal l i ng a seat cush-
i on cover, make sure the materi al i s stretched
evenl y over the pad before securi ng the cl i ps.
. Repl ace the rel eased cl i ps wi th new ones.
NEW CLI P
SEAT FFAME
COVER
Rear Seat
Removal
NOTE: Take care not to scratch the seat covers and body.
4D:
: : -): Hook l ocat i ons, 2
c > , 1 D > , 1
>: Cl i p l ocat i oG, 14
I
@
---------8tr--
Fq
E U )
- w
, /
B
r>t
RIGHT SEAT-BACK
V
CENTER
PIVOT
BRACKET
r - - r
SEAT CUSHION
NOTE:
a Before aftachi ng the seat-back and seat cushi on, make sure there
center bel t.
. When i nstal l i ng the seat cushi on, sl i p the seat bel t buckl es through
. N4ake sure the seat-back l ocks securel y.
PIVOT BOLT ERACKET
8 x 1. 25 mm
22 N.m {2.2 kgtm, 15 lbf.ftl
Appl y l i qui d t hread l ock.
are no t wi st s or ki nks i n t he rear seat bel t s and
t he sl i t s i n t he seat cushi on.
SEAT.BACK
Pivot bolt construction:
TOOTHED
LOCK
WASHER
BUSHI NG
(cont' d)
20-79
o l f necessary, adj ust the seat-back l atch
(see page 20-82) and seat-back.
Rear Seat
(:) : Hook locations, 2 >: Clip locations, 14
SEAT CUSHION
STRIKER
v@n
FE
E E )
e e /
PIVOT
BRACKET
BUSHING
PtvoT BoLT
BRACKET
8 x 1.25 mm
NOTE:
22 N. m {2. 2 kgf . m, 16l bt f t )
. Before attachi ng the seat-back and seat cushi on, make sure there are no twi sts or ki nks i n the rear seat bel ts and
center bel t.
. When i nstal l i ng the seat cushi on, sl i p the seat bel t buckl es through the sl i ts i n the seat cushi on.
. Make sure the seat-back l ocks securel y.
. l f necessary, adj ust the stri ker and seat-back.
20- 80
Removal
(cont'd)
3D:
>: Bolt locations
A > , 6
STRIKER
Remove t he si de t ri m
panel (see page 20 60).
c > , 1
6 x 1 . 0 mm
TRUNK
STRIKER
T
A
B
CENTER
PIVOT
A
BRACKET
LEFT
SEAT.BACK
TOOTHED
LOCK
WASHER
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kst m, l
6 x 1 . 0 mm
22 N.m |.2.2
kgl.m)
':*2
16tbt'-ft')
- -J)
8 > , 1
ffi
I
It
6 x 1. 0 mrn
SEAT CUSHION
9. 8Nm( 1. 0kgf . m,
1.2 tbt.ftl
2Di
A > , 6
i )
: Hook l ocat i ons, 2
>: Cl i p l ocat i ons, l i l
c > , 1
l
6 x 1 . Omm
9. 8Nm11. 0ksf . m, ;
':*'
)
v
v
PIVOT BRACKET
RIGHT SEAT-BACK
TOOTHD
LOCK
WASHER
PIVOT
'..'
6x 1. omm
I , 8, u" , , 0- -
22 N m t2.2 kgtm,'
\ff
S.e N m tr.O ksf -,
16tbfi tt
) E
7.2rbr.tt)
V
|\
BUSI{ING
SEAT CUSHI ON
PIVOT BOLT BRACKET
8 x 1. 25 mm
22 N m
(2.2
kgI.m, 16 lbf.ft)
NOTE:
center bel t.
. Make sure the seat back l ocks securel y.
. l f necessary, adt' ust the seat-back l atch (see page 20-82) and seat-back.
B > , 1
R
I
,r@?r,
FF
E E )
CENTER
PIVOT BRACKET
SEAT CUSHI ON
--v-.
SEAT-8ACK MAT
20-81
Rear Seat
Seat-back Latch Replacement
2Dl1.D:
Remove t he l ock cyl i nder t r i m. t hen r emove t he r ear
shel f
(see pages 20-59, 61).
NOTE: Take care not to bend each l ock rod.
>: Boh, scrow locrtions
A > , 4
B > , 2
r g l
: l
LOCK CYLINDER
TRIM
G
or t . o- -
Ei
g.s
w m tt.o tot.-.
E
7.2 tbr.ft,
-
)
c 7 /
Instal l ati on i s the reverse of the removal procedure,
NOTE:
a Make sure each l ock rod i s connected securel y.
. Make sur e each seat - back l ocks secur el y and
opens properl y.
. l f necessary. adj ust the seat-back l atch.
BACK LATCH
20-82
\
3D:
Pul l the trunk mat away from the seat-back
(see page 20-
80) .
i
>: Bolt. screw locations
a > , 2
/ - \
6 x 1 . 0 mm
ffifu
s.a N.. tt.o r,sf.-.
Y 11'11 )
B > , 1
@
SEAT-BACK
nstal l ati on i s the reverse of the removal procedure.
NOTE:
. Make sure the seat-back l ocks securel y and opens
propeny.
Seat Gover Replacement
CAUTION: Wear glovs to remove and install the seat
covels.
NOTE; Take care not to tear the seams or damage the seat
covers.
Soat-back cover removal:
2DI4D:
L Remove the seat-back
(see pages 20-79,81).
2. Loosen t he seat - back cover by r el easi ng al l t he
cl r ps.
>: Cl i p l ocati ons
LEFT SEAT.BACK
COVER
RIGHT SEAT.BACK
COVER
3. Pul l back t he edge of t he seat -back cover al l t he way
around. t hen rel ease t he cl i ps.
RI GHT
2.
4. Instal l ati on i s the reverse ot the removal procedure.
NOTE:
i on cover, make sure the materi al i s stretched
3D:
' 1.
Remove the seat-back
(see page 20-80).
Loosen the seat-back cover by rel easi ng al l the cl i ps.
NOTE: Remove the l ock knob, l ock col l ar and l atch
cover.
>: Clip locations
SEAT.BACK
COVER
3. Pul l back the edge of the seat-back cover al l the way
around, then rel ease the cl i ps.
>: Clip locations
SEAT.BACK
COVER
NOTE:
. To prevent wri nkl es when i nstal l i ng a seat-back
cover, make sure the materi al i s stretched evenl y
over the pad before securi ng the cl i ps.
(cont' d)
20-83
Rear Seat
Seat Gover Replacement
(cont'dl
Seat side bolster cover rmoval l,lDl:
2.
1 . Remove the seat si de bol ster
(see page 20-79).
Loosen the seat si de bol ster cover by rel easi ng al l
the cl i ps, then remove i t.
SEAT SIDE
BOLSTER
COVER
NOTE:
a To prevent wri nkl es when i nstal l i ng a seat si de
bol ster cover, make sure the materi al i s stretched
Seat cushion cover removal:
1. Remove t he seat cushi on
( see pages 20- 79, 80, 81) .
2. Loosen the seat cushi on cover by rel easi ng al l the
cl r ps.
>: Cl i p l ocati ons
4D:
+
_ - / -
v, l a
/ . )
-.lL J lL--Jl
' .n
20-84
SEAT FRAME
2Dl3Dl
COVER
Pul l back t he edge of t he seat cushi on cover al l t he
way around, rel ease t he cl i ps, and remove t he seat
cushron cover.
4D:
COVER
NOTE:
aon cover , make sur e t he mat er i al i s st r et ched
UPHOLSTERY RING PLIERS
l Commerci al l v avai l abl e)
V
-
EF*aa-bF-E<
\
f . I --l f
,
l m n
r
- r _I - - t
rt=r/
{ lr
(!, .t=!l
20 l3Dl
Front Seat Belt
1 .
2.
Replacement
CAUTION: Check the tront seat belts for damage, and
replace then if nacessary. B9 careful not to damage then
during removal and installation,
Fronl seat belt removal {,[D):
Sl i de the front seat forward ful l y.
Remove the center pi l l ar l ower tri m panel (see page
20-59).
Remove the upper anchor cover and l ower anchor
cap.
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N,m
(3.3
kgf.m,
24 rbf.ftl
UPPER ANCHOR
COVER
FRONT SEA
BELT
RETRACTOR
MOUNTING BOLT
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf.m,
7.2 tbf.ftl
RETRACTOR
RETRACTOR BOLT
7/ 1&20 UNF
32 N.m
(3.3
kgt.m,
2a tbtft)
LOWEN ANCHOR BOLT
7,/16-20 UNF
32 N.m
(3.3
kgf.m, 24 lbf ftl
+
I
I
I
I
LOW
CAP
ER ANCHOR
Remove al l the anchor bol ts and the retractor bol t,
remove the retractor mounti ng bol t. then remove
the front seat bel t and retractor.
6.
Remove the center
pi l l ar upper tri m
(see page 20-59).
Remove the shoul der anchor adj uster.
I x 1. 25 mm
23 N.m
(2.3
kgf m,
17 tbf.ft)
ANCHOR
ADJUSTER
NOTE:
. Check that the retractor l ocki ng mechani sm func-
ti ons as descri bed on page 20-91.
. Make sure
you
assembl e the washers and col l ars
on the uoDer and l ower anchor bol ts as shown.
are no twists or kinks in the front seat belt.
Upper anchor boh construqtion:
UPPER
ANCHOR
UPPER ANCHOR
BOLT
Appl y l i qui d t hread
COLLAR
(cont' d)
BEARI NG
20-85
Front Seat Belt
Replacement
(cont'dl
Lower anchor bolt construction:
SPRING
WASHEF
COLLARS WASHERS
Rtractor bolt construction:
LOWER
ANCHOR
BEARING
RETRACTOR
BOLT
I
ll rrtnn-ffi\
\Y
**rss,t
I
RETRACTOR
WASHERS
20- 86
\
FRONT SEAT
BELT
Front seat belt romoval
(2Dl3D):
1. Sl i de the front seat forward ful l y.
2. Remove:
(see pages
20 80, 81)
. Rear cent er shel f and r ear si de shel t
( 3D,
see
page 20-60)
. Reartri m panel (3D,
see page 20-60)
. Si de tri m panel (see pages 20-60,61)
3. Remove the upper anchor cover and l ower anchor cap.
LOWER
ANCHOR
CAP
I
I
t
o
UPPER ANCHOR BOLT
7/ r6-20 UNF
32 N.m 13.3 kgt.m,
24 rbf.ft)
RETRACTOR
MOUNTING BOLT
6 x 1 . 0 mm
9.8 N.m {'t.0 kgt.m,
7.2 tbf.ftl
LOWER ANCHOR BOLT
7/ 16-20 UNF
32 N. m {3. 3 kgt m, 24 l bf . f t l
remove the retractor mounti ng bol t, then remove the
front seat belt and retractor.
RETRACTOR BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgl.m,
24 tbI.ft)
4.
NOTE:
Make sure you assembl e the washers and col l ars
on the uoDer and l ower anchor bol ts as shown.
Before i nstal l i ng the anchor bol ts, make sure there
are no twists or kinks in the front seat beit.
Upper anchor bolt construclion:
SPRI NG
WASHER
SPRI NG
WASHER
BEARI NG
COLLARS
WASHERS
LowER
LOCK WASHER
Retractor bolt construction:
BEARING
ANCHOR
LOWER ANCHOR
BOLT
RETBACTOR TOOTHEO
LOCK WASHER
b
WASHERS
RETRACTOB
20-87
Seat beh buckle removal:
1 .
2.
Remove t he f r ont seat t hr ough t he door openi ng
(see page 20 74).
Remove the center cover
(see pages 20-75, 76).
Remove the center anchor bolt, then remove the seat
bel t buckl e.
SEAT BELT
BUCKLE
CLIP 32 N'm {3.3 kgf m, 2't lbfft)
4. Dri ver' s: Detach the seat bel t swi tch connector and
harness cl i p from the seat cushi on
(see page 20-77).
Remove the seat cushi on mounti ng bol ts from the
i nner seat track {see
page 20-751, and move the i nner
seat track, then pul l the seat bel t swi tch harness out.
NOTE: Take care not to damage the hi nge bracket.
Center anchor bolt construction:
CENTER ANCHOR
BOLT
SPRI NG
WASHER
WASHER
NOTE: Make sure you assembl e the washers and
beari ng on the center anchor bol t as shown.
ANCHOR BOLT
Rear Seat Belt
Replacement
GAUTION: Check the rear seat bel ts for damage, and
replace then if necessary, Be careful not to damage then
during removal and installation.
Rear seat belt removal l2DllDl:.
1. Remove:
(see pages 20-79, 81)
. Rear seat-back {2D, see page 20-81)
. Si de tri m panel (2D,
see page 20 61)
r Rear shel f
(see pages 20-59, 61)
. Rear tri m panel (see page 20-62)
. Trunk si de tri m, Japan-produced
(see
page 20-62)
. Trunk tri m panel , USA-produced
(see
page 20-62)
2. Remove al l the anchor bol ts and retractor bol t, then
remove the rear seat bel t and retractor.
UPPER ANCHOR BOLT
7/16-20 UNF
7/ 1S20 UNF
32 N.m 13.3 kgI.m,24lbl.ftl
RETRACTOR BOLT
7/ 16-20 UNF
32 N.m {3.3 kgf.m,
24 rbf.ft)
20-88
RETRACTOR
NOTE:
. Make sure you assembl e the washers and col l ar
on the upper anchor bol t as shown.
. Before i nstal l i ng the anchor bol t, make sure there
are no twists or kinks in the rear seat belt.
Upper anchor boh construction:
TOOTHED
LOCK WASHER
LOWER ANCI{OR
BOLT
LOWER ANCHOR
Retrastor bolt construqtion:
RETRACTOR
BOLT
/7-'\ 177--7,
, / Rr / i \ n t z l l l \
trv-*q
/ \ \
TOOTHED
LOCK WASHER
Rear seat belt removal l3Dl:
1. Remove:
(see page
20_80)
. Rear center shel f and rear si de shel t
(see page
20-601
. Rear tri m
panel and si de tri m
panel (see page 20-
60)
2. Remove the upper anchor cover
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N. m {3. 3
kgl m. 24l bf f t l
3.
7/ 15-20 UNF
32 N. m
(3. 3
kg{. m, 24l bf f t )
Remove al l the anchor bol ts and retractor bol t. then
remove the rear seat bel t and retractor'
RETRACTOB BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgf.m,
NOTE:
ti ons as descri bed on
Page
20-91
. Make sure
you assembl e the washers and col l ars
on the upper anchor bol t as shown
. Betore i nstal l i ng the anchor bol t, make sure there
are no twi sts or ki nks i n the rear seat bel t.
Upper anchor boh construqtion:
SPRING
UPPER ANCHOR
BOLT
WASHER TOOTHEO
LOCK
WASHER
LOWEB ANCHOB
TOOTHED
LOCK WASHER
Retraqtor boh conslruction:
TOOTHED
LOCK WASHER
(cont ' d)
BOLT
20-89
Rear Seat Belt
Replacement
(cont'd)
Soat belt buckle/Canter belt tongue removal:
1. Remove the rear seat cushi on
(see pages 20-79,80,
81) .
2. Remove the center anchor bol ts, then remove the
seat bel t buckl es and center bel t tongue.
2DI4'D:
CENTER BELT
BUCKLE
7/ 16-20 UNF
CENTER BELT TONGUE
3D:
CENTER ANCHOR BOLTS
7/16-20 UNF
32 N.m {3.3 kgf.m,
24 tbtftt
20-90
CENTER BELT
\
Centel anchor bolt construction:
CENTER ANCHOR
TOOTHEO
LOCK WASHER
Instal l ati on i s the reverse of the removal Drocedure.
NOTE: Before attaching the seat-back and seat cush-
ion, make sure there are no twists or kinks in the cen-
ter belts.
Seat Belts
Retractor Inspection
Before i nstal l i ng the retractor, check that the seat bel t
can be
pul l ed out freel y.
lvake sure that the seat belt does not lock when the
retractor i s l eaned sl owl v up to 15' from the mounted
posi ti on. The seat bel t shoul d l ock when the retrador
i s l eaned over 40".
CAUTION: Do not attempt to disassemble the retrac-
tor.
Inspection
' 1.
Front:
4D:
*:
Mounted Posilion
Forward lnside
2DI3D:
Rear:
2D l
lDl
lnside
Forward l nsi de
J
7 .
20-91
3D:
2.
RETRACTOR
3. Repl ace the seat bel t wi th a new one i f there i s any
abnormal i ty.
On-the-Car Seat Belt Inspection
1. Check that the seat bel t i s not twi sted or caught on
anyrnrng,
After i nstal l i ng the anchors, check for free move-
ment on the anchor bol ts. l f necessary. remove the
anchor bol ts and check that the washers and other
parts are not damaged or i mproperl y i nstal l ed.
Check the seat bel ts for damage or di scol orati on.
Cl ean wi th a shop towel i f necessary.
CAUTION: Use only soap and water to clean.
NOTE: Di rt bui l d-up i n the metal l oops of the upper
anchors can cause the seat bel ts to retract sl owl y.
Wi pe the i nsi de of the l oops wi th a cl ean cl oth damP
ened i n i sopropyl al cohol .
Check that the seat bel t does not l ock when pul l ed
out sl owl y. The seat bel t i s desi gned to l ock onl y
duri ng a sudden stop or i mpact.
Make sure that the seat bel t wi l l retract automati cal l y
when rel eased.
For each passenger' s seat bel t, make sure that the
l ocki ng mechani sm i n t he seat bel t r et r act or wi l l
engage when the seat bel t i s pul l ed al l the way out.
Repl ace the seat bel t wi th a new one i f there i s any
abnormal i ty.
3.
Forward
Seat Belts
Ghi l d Seat Anchor Pl ate
Attachment poi nts
are provi ded for a rear seat mounted
chi l d restrai nt system whi ch uses a top tether. The attach-
ment poi nts
are l ocated on the rear shel f or rear tri m
panel , j ust
behi nd the rear seat-back. When usi ng a chi l d
seat wi th a top tether, i nstal l the chj l d seat anchor pl ates
securel y.
2Dl4Dl
NOTE: Remove t he pl ug
cover s f r om t he at t achment
points
of the rear shelf.
3D:
NOTE: The reartri m panel has perforati ons
ateach attach-
ment point,
Cut the rea. trim panel
along the perforations
to make a hol e.
REAR TRIM
PANEL
PLUG COVERS
REAR SHELF
a
20-92
8 x 1. 25 mm
22 N. m
(2. 2
kgf . m. 16l bf . f t l
CHILD SEAT
ANCHOR
PLATE
NOTE:
WASHER
. Do not remove the toothed washer from the chi l d seat
anchor pl ate.
Use the chi l d seat anchor pl ate
wi th the
toothed washer attached to i t.
.
When i nstal l i ng a chi l d seat on the rear seat, fol l ow
the i nstructi ons of the manufacturer ot the chi l d seat.
. Addi ti onal anchor pl ates
are avai l abl e.
Do noi use the child seat anchor plate for any other
purpose;
it is designed exclusively tor installation of a
child seat.
Make sure the rear seat-back is locked tirmlv when
installing a child seat.
Exterior
NOTE: Ref er t o t he Ci vi c Body Repai r Manual , 1996 Model Ser i es, P/ N. 6150330, f or t he hood, t r unk l i d and hat ch r emoval
2D t3D tlD:
LICENSE PLATE
TRIM
TRUNK LID
ROOF MOLDING
Repl acement ,
SIDE WINDOW
MOLOINGS
Repl acement ,
page 20-102
Repl acement ,
page 20
' t
00
Adj ust ment , page 20 97
Torsi on Bar Removal ,
page 20 1O2
20 99
HOOD
Adj ust ment ,
Page
20-96
Hood Edge
Prot ect or
page 20-99
TRUNK LI D
WEATHERSTRIP
Repl acement ,
page 20-100
REAR BUMPER
Repl acement ,
page 20' 95
REAR AIR OUTLET
Fepl acement ,
page 20-106
PIPE
PROTECTOR
Repl acement ,
page 20-106
FRONT GRILLE
(see page 20 99) DOOR and SIDE MOLDINGS
Repl acement ,
page 20 103
FENDERWELL TRIM
Repl acement ,
page 20 106
SI LL PANEL
Repl acement , page 20- 105
I NNER
Repl acement ,
page 20- 106
3D:
HATCH SPOILER
HATCH
HATCH
Adi ust ment ,
page 20 98
LICENSE PLATE TRIM
Repl acement ,
page 20 100
REAR AIR OUTLET
Repl acement ,
page 20' 106
WEATHERSTRIP
20-93
Front Bumper
Replacement
CAUTION: Wsa. gloves
to remove and install the front bumper.
NOTE:
. An assi stant i s hel pful when removi ng the front bumper.
. Take care not to scratch the front bumper and bodv.
FRONT BUMPER BEAM
NOTE:
. Make sure the front bumper engages the front
bumper si de sti ffener on each si de securel y.
. lf necessary, adjust the front bumper side stiffener
to obtai n the proper gap.
>: 8olt, screw locations
a > , 2
>: Cl i p
locations, 7
B > , 2
c > , 4
ldb
!J,J:ff,ry-"_.
t165
\I/ _r6rbrftl
_g
D > , 4
6 x 1 . 0 mm
9. 8 N. m {' 1. 0 kgf . m,
7.2 tbf.ft)
ABSOREER
I
A
FRONT EUMPER
SIOE STIFFENER
20-94
Rear Bumper
Replacement
CAUTION: Wear gloves to remove and install the rear bumpet.
NOTE:
. An assi stant i s hel pful when removi ng the rear bumper'
. Take care not to scratch the rear bumper and body.
. 2D and 4D shown here;3D removal procedures are the same as 4D.
>: Screw, bolt locaiions
A > , 2
A
R
i , , A
\r9{
B >, 4
>: Clip locations, 7
,9iiffiF=*-..ffi
REAR BUMPER BEAM
REAR BUMPER
Instal l ati on i s the reverse of the removal
procedure.
NOTE:
. Make sure the rear bumper engages the si de cl i p on each si de securel y.
20-95
Hood
Adjustment
NOTE: Before adj usti ng the hood, l oosen each bol t sl i ghtl y.
1. Adj ust the hood hi nges ri ght and l efr, as wel l as fore and aft, by usi ng the el ongated hol es.
2. Turn the hood edge cushi ons, as necessary, to make the hood fi t fl ush wi th the body at front and si de edges.
3. Adj ust the hood l atch to obtai n the proper hei ght at the forward edge.
4. After adi ustment, ti ghten each bol t securel y.
9. 8 N. m {1. 0 kgf , m,
1.2lbl.ttl
NOTE: Move the hood l atch
i s centered i n the hood l atch
\ \ " '
)
,/
_ _ _ , /
ri ght or l eft unti l the stri ker
as shown.
6 x 1 . 0 mm
CUSHION
6 x 1 , 0 mm
9.8 N.m 11.0 kgf.m,
7.2 tblfrl
HOOD
20- 96
Trunk Li d
Adjustment
NOTE: Before adj usti ng the trunk l i d, l oosen each bol t sl i ghtl y
1. Adj ust the trunk l i d hi nges rl ght and l eft, as wel l as fore and aft, by usi ng the el ongated hol es.
2. Turn the trunk l i d edge cushi ons, as necessary, to make the trunk l i d fi t fl ush wi th the body at the rear and si de edges
3. Adj ust the fi t between the trunk l i d and the trunk l i d openi ng by movi ng the stri ker'
4. After adj ustment, ti ghten each bol t securel y.
TRUNK LI D EDGE
CUSHI ON
21"
(
i r/-\\
\ V,,'' /
TBUNK LID
\
rY
. / srrucrs
\ - 2/ \
NOTE: Take car e not
t o hi t t he r ear wi ndow
when l oosen ng t he
bol t s.
NOTE: Move the stri ker ri ght or l eft unti l i t' s centered
the trunk l i d l atch as shown.
tn
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
:> ---
-
-)
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgl . m, 7. 2 l bf . f t l
/
NOTE: Remove the rear shel f l see
pases 20-59,61).
//
STRI KEB
20-97
Hatch
Adjustment
NOTE:
. Before adj usti ng the hatch, l oosen each bol t and nut sl i ghtl y.
o The support struts shoul d be removed.
. To adj ust, remove both hatch si de tri m {see
page 20-63) and the rear roof tri m
(see
page 20-65).
1. Adj ust the hatch hi nges ri ght and l eft, as wel l as fore and aft, by usi ng the el ongated hol es.
2. Turn the hatch edge cushi ons, as necessary, to make the hatch fi t fl ush wi th the body at each si de.
3. Adj ust the hatch fi t to the hatch openi ng by movi ng the stri ker.
4. After adj ustment, ti ghten each bol t and nut securel y.
HATCH
EDGE CUSHI ON
9. 8 N. m
(1. 0
kgt . m,
HATCH
HI NGE
6 x 1 . 0 mm
Rearward
HA
EDGE
CUSHION
@
\
co
38 N.m {3.9 kgl.m,
2.8 rbf.ft)
NOTE: Move the stri ker ri ght or l eft unti l i t' s centered
the hatch l atch, as shown.
HATCH
HI NGE
STRIKER
10 x 1. 25 VER
HATCH
EDGE
CUSHION
tn
9. 8 N. m {1. 0 kgf . m,
7.2 tbl.ttl
6 x 1 . 0 mm
Front Gri l l e/Hood Edge
Protector
Trunk Li d Torsi on
Bars
Repl acement
Fronl gri l l e:
NOTE: Take care not to scratch the front bumper.
Remove the front bumper
(see page 20-94). Remove the
cl i ps and screws. then sl i de the front gri l l e forward by
detachi ng the hooks.
>: Screw l ocati ons,4
j
A I
A l
:Y/
Hood edge
prolector:
NOTE:
. When removi ng t he cl i ps, use a cl i p remover.
>: Cl i p l ocari ons, l S
HOOO EDGE
Removal
CAUTION: Wear gloves to remove and installthe torsion
bars.
NOTE: Take care not to damage the body.
Remove the torsi on bars wi th the torsi on bar assembl y
t ool whi l e hol di ng t he t r unk l i d as shown.
CENTER CLIP
NOTE:
. Adj ust the torsi on bars fore or aft wi th the
si on bar assembl y tool as shown.
a = Normal posi t i on
a
=
Hi gher t ensi on
Make sure t he t runk l i d opens properl y.
tor
20- 99
Trunk Li d/Hatch
Weatherstrip License Plate Trim
Repl acement
When i nstal l i ng the trunk l i d/hatch weatherstri p, al i gn i t
wi th the al i gnment mark on the trunk l i d/hatch openi ng.
NOTE:
. Make sure there are no wri nkl es i n the weatherstri p.
. Check for water l eaks.
2D l 4Dl
STEEL
CORE
ALI GNMENT
MARK
(2Dl4D)
ALIGNMENT MARK
WEATHERSTRIP
ALI GNMENT MARK
BODY
20- 100
Repl acement
CAUTION: Wear gloves to remove and install the license
plate trim.
NOTE: Take care not to scratch the trunk l i d/hatch.
1. Remove the l j cense pl ate.
2. 3D: Remove the hatch tri m panel (see page 20-63).
3. Remove the nuts and cl i ps, and detach the cl i p, then
remove the l i cense pl ate tri m.
NOTE: Take care not to drop the nuts i nsi de the trunk
l i d/hatch.
f f i sxo. amm I
\Y9l ,/ 1.8 N.m {0.18 kstm.l
-
13 tbtfr)
,/
I
n A L
I E L
@t a9@
4. Instal l ati on i s the reverse ofthe removal procedure.
NOTE: l f necessary, repl ace any damaged cl i ps.
Hatch Spoiler
Removal
NOTE: Take care not to scratch the hatch and body.
1. Remove the hatch upper tri m
(see page 20-63).
2. Remove the nuts, and detach the cl i p, then Ii ft the
hatch spoi l er up.
a: Nut localions, 4
6 x 1 . 0 mm
l
9.8 N m 11.0 ksf.m. I
7 .2
\t.to - _J/
GROMMET
HIGH MOUNT BRAKE
LIGHT CONNECTOR
3.
ACCESS CAP
Di sconnect the hi gh mount brake l i ght connector and
r ear wi ndow washer t ube, t hen r emove t he hat ch
spoIer.
4. l f necessary, remove the spoi l er tri m from the spoi l er
frame.
NOTE: The hatch spoi l er tri m for Canada produced
cars cannot be di sassembl ed.
>: Clip locations
>: Screw
locations, 4
l
6 \ l
"ig
i
v /
SPOILER
SIDE TRI
SPOILER
CENTER
TRIM
A
NOTE:
a Make sur e t he connect or and washer t ube ar e
connected properl y.
20-101
Si de Wi ndow Mol di ngs Roof Mol di ng
Replacement
CAUTION: Wear gloves to remove and install the side
window moldings.
NOTE:
. Take care not to scratch the body.
. Remove the screw, and pul l the si de wi ndow mol di ng
by hand.
>: Clip locetions
A> , 1 3
l nstal l ati on i s the reverse of the removal procedure.
I
)
Screw locations,
*@
MOLDI NG
20-102
Replacement
CAUTION; Whsn prying with a flat tip sc.ewdriver, wrap
it with protective tape to prevent damage, and use pro-
tective tape on the body.
NOTE: Take care not to scratch the bodv,
WINDSHIELO
MOLDING
NOTEi
. Take care not to damage the wi ndshi el d mol di ng.
. Make sure the roof mol di ng i s i nstal l ed securel y.
ROOF MOLDI NG
K
(Body
si de)
I
)
ARACKET
Door and Si de Mol di ngs
Replacement
CAUTION: When prying with a tlat tip screwdriver, wrap it with protective tape to prevent damage.
NOTE:
. To remove the front si de mol di ng, remove the i nner fender
(see page 20-106).
. To remove the door mol di ng, remove the door
panel (see pages 20 4, 10, l 6) and pl asti c cover.
. To remove the rear si de mol di ng, remove the si de tri m panel (see pages 20-60,61).
. Take care not to bend the door mol di ngs.
. Before .eassembl i ng, cl ean the door bondi ng surface wi th a sponge dampened i n al cohol .
. After cl eani ng, keep oi l , grease and water from getti ng on the surface
4D:
2Dl3Dl
c > . 2
REAR SIDE
MOLDING
a: Plastic nut location, 1
@)
(cont' d)
20-103
A >:
, l O,
11
2013r),7
B > , 3
_/
Door and Si de Mol di ngs
Replacement
(cont'dl
Door mol di ng removal :
The fol l owi ng materi al s and tool s are requi red to repai r
t he door mol di ngs.
NOTE: Fol l owthe manufacturer' s i nstructi ons-
Materi al s: {Reference}
. Stri pe remover
3M 08907
.
Stri pe adhesi ve remover
3M 08908
. Adhesi ve tape
3M Super Automoti ve Attachment Tape
Tool s:
. Protective tape
. Kni fe or Cutter
. Sponge or Shop towel
. Infrared dryer
. Fi l m
. Putty kni fe
. Al cohol
CAUTION: Wear gloves to remove and install the dool
mol di ngs.
1. Remove t he door panel , and pul l back t he pl ast i c
cover.
2. Appl y protecti ve tape on and around the mol di ng.
Rel ease the cl i ps from i nsi de of the door. Careful l y
cut the adhesi ve tape wi th a kni fe or cutter whi l e
pul l i ng the edge of the mol di ng away from the door
as shown.
NOTE: Take care not to scratch or bend the mol d-
I ng
KNTFE
3.
OOOB MOLDI NG
20-104
Door mol di ng i nstal l ati on:
L Gl ue t he new adhesi ve t ape t o t he mol di ngs as
shown.
N\\N\l
: Adhesive tape locations
60 mm
t 2. 1
820 mm 132. 3 i nl
Forward
L
MOLDING
Forward L
CLIP
HOLDER
40 mm
(1. 6
i n)
2Dl3Dl
1, 050 mm {41. 31 i nl
2.
2
5 mm {0. 2 i n)
ADHESIVE TAPE
Thickness: 1.2 mm 10.05 inl
I nst al l t he cl i ps on t he mol di ng.
Heat t he bondi ng sur f ace of t he door and door
mol di ng wi th an i nfrared dryer.
Door: 104
-
140' F
(40 -
60' C)
Mol di ng: 68
-
86' F
(20 -
30' C)
NOTE: Use care when heati ng to prevent deforma-
t i on ot t he mol di ng.
Al i gn the mol di ng wi th the cl i p l ocati ons, and set
the mol di ng. Li ghtl y push on the mol di ng unti l i ts
edge i s ful l y seated on the adhesi ve tape.
NOTE: Do not spray water on the mol di ng wi thi n
the fi rst 24 hours after i nstal l ati on.
Reassembl e al l removed parts.
4.
Si de Si l l Panel
Repl acement
NOTEI
. Take care not to scratch the body.
. 4D shown here;2D and 3D removal procedure i s the same as 4D.
A > , 3
>: Scr ew l ocat i ons, 4
B > , 7
NOTE: Loosen t he screw,
t hen remove t he l ower cl i p
usi ng a cl i p remover.
SI DE CLI P
Remove t he si de cl i ps f rom t he body
by t urni ng t hem 45'
I
I
)
SIDE SILL PANEL
Remove t he l ower cl i ps,
t hen r emove t he si de si l l
panel
by sl i di ng i t f or war d.
NOTE: When removi ng t he si de
si l l panel , t he si de cl i ps wi l l
st ay i n t he body.
To i nstal l the si de si l l
panel , remove the si de cl i ps from the body, i nstal l them on the si de si l l panel , then i nstal l the si de si l l
oanel on t he car .
NOTE:
. Take care not to twi st the si de si l l panel .
. l f necessary, repl ace any damaged si de and l ower cl i ps.
\
20-105
Inner Fender, Fenderwell Trim, Fuel Pipe Protector and Rear
Air Outlet
Replacement
lnner fender:
>: Screw locations, 4
6h* l
: , /
Fenderwell trim/Fuel pipe protector/Rear air outlet:
NOTE:
. Take care not to bend the tenderwel l tri m.
. Betore i nstal l i ng the fenderwel l tri m, cl ean the body
bondi ng surface wi th a sponge dampened i n al cohol .
. After cleaning, keep oil, grease or water from getting on
the surface.
. To remove the fuel pipe protector, first remove the rear
wheel
(see
secti on 18).
. To remove the rear ai r outl et, fi rst remove the rear
bumper
(see page 20-95).
STEEL FENDERWELL
>: Clip locations
a > , 4 B > , 4
d
c > . 2
'@
+
CLIP
20- 106
Opener Cable/Opener and Latch/Wiper and Washer
zDl3Dl4Dt
*TNDSHTELD wrPER aRMs
Repl acement, page 20-1 13
Adi ustment,
page 20-1 17
WINDSHIELD
WASHER NOZZLES
Adj ust ment ,
page 20-117
REAR WINDOW wlPER
ARM rnd MOTOR
Eepl acement,
page 20-' l 15
Adjustment, page 20-'l 17
LID OPENER
{see
page 20-111)
REI."EAS HANDLE
TNUNK LID OPENER
CABLE
(see page
20 108)
LI D/ FUEL
FUEL LID OPENER
CABLE
(see page 20-108)
(see p6ge 20-110)
3D:
REAR WINDOW
WASHER NOZZLE
Adi ust ment , page 20-1 17
REAR WINDOW
WASHER TUBE
(see page 20 1161
HATCH/
FUEL LID OPENER
{see
page 20-111)
FUEL LI D OPENER
CABLE
{se
page
20-' 110)
HATCI{ OPENER
CABLE
(see page
20-110)
J
(see page 20 111)
20-107
Opener Cables
Replacement
NOTE:
. When removi ng the cl i ps, use a cl i p remover.
. Take care not to bend the opener cabl es.
Hood openr cable:
NOTE: Remove the front bumper
(see page 20-94) and
i nner fender
(see page 20-106).
A > , 5
B
@
D, 1
#l
HOOD RELEASE
HANDLE
{see
page
20-110)
Rout e t he opener
cabl e t hr ough t he
hol e i n t he body.
NOTE:
. Make sure the hood opener cabl e i s routed and
connected properl y.
. Make sure the hood opens properl y.
20- 108
\
Trunk l i d/Fuel l i d opener cabl e
(2Dl i [D):
NOTE: Remove the fol l owi ng parts from the l eft si de of
the vehi cl e. then
pul l the carpet back, as necessary {see
page 20-66).
(see pages 20-79, 81)
. Rear seat si de bol ster
(4D,
see page 20-79)
. Rear seat-back {2D, see page 20-81)
. Center pi l l ar l owertri m panel (4D,
see page 20-59)
. Lower anchor bol t from the front seat bel t
(2D,
page 20-86)
. Si de tri m
(see pages 20-59, 61)
o Seat si de tri m
(4D.
see page 20-59)
. Si de tri m panel (2D.
see page 20-61)
. Trunk mat and spare ti re l i d
. Trunk si de tri m, Japan-produced
(see page 20-62)
. Trunk tri m panel , UsA-produced
(see page 20-62)
>: Cl i D. cabl e cushi on l ocati ons
a > , 4
# l
_L)
D > , 3
I > , 4 D, r
B
_-__l \ _,)
c >, 1 {4D)
ffi
E >, 4D, 1
2D,2
TRUNK LID LATCH
(see page 20 112)
4D:
To t runk l i d
l at ch,
To t runk l i d
l at ch.
TRUNK LI D/ FUEL
LIO OPENER
( see page 20' 111)
TRUNK LID
OPENER CABLE
a
A \
FUEL LIO
OPENER CABLE
TRUNK LI O/ FUEL
LID OPENER
( see page 20- 111)
(cont' d)
20- 109
Opener Cables Opener and Latch
Replacement
(cont'dl
Hatch/Fuel lid opener cable
(3D):
NOTE: Bemove the fol l owi ng parts, then pul l the carpet
back as necessary
(see page 20-66).
. Rear seat cushi on and rear seat-back {see
page 20-80}
. Lower anchor bol t from the tront seat bel t
(see page
20-86)
. Si de tri m
(see page 20-60)
. Spare ti re l i d
. Rear center shel f and rear si de shel f
(see page 20-60)
. Si de tri m panel (see page 20-60)
>: Clip, c.ble cushion locations
A> , 9 D> , 5 B > , 1 c > , 1
* i
l
FUEL LID LATCH
(see page 20-112)
d o o
FUEL LID
OPENER
CABLE
--\,"
o / l
#)
Rout e t he opener
cabl e t hrough t he
hol e i n t he body.
STRIKER
HATCH
OPENER CABLE
HATCH/FUEL LID
OPENER
Instal l ati on i s the reverse of the removai procedure.
NOTE:
. N4ake sure each opener cabl e i s routed and con
nected properly,
. Make sure the hatch and fuel l i d open properl y.
20-110
Replacement
NOTE: Take care not to bend the opener cabl es.
Hood release handle:
NOTE: Remove t he ki ck panel ( see pages 20- 59. 60, 61) .
>: Bol l l ocat i ons, 2 |
I
6 x 1 . 0 mm
i
9. 8 N. m
I
HOOO OPENER
CABLE
{see
page
20-108)
HOOD RELEASE
HANDLE
Hood latch:
NOTE: Remove the front bumper
(see page 20-94).
NOTE:
. Make sure the opener cabl e i s connected
properl y.
. Make sur e t he hood opens pr oper l y and l ocks
securel y.
Trunk lid or Hatch/Fuel lid opener:
NOTE: Remove the si de tri m
(see pages 20-59,60.61).
>: Bol t l ocrti ons, 2
OPENER LOCK
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt . m,
7.2 tbl.ftt
a@-\
CYUNDER
la//tzDt4Dl
L-.-^
TRUNK LID,/HATCH
OPENER CABLE
{see 20- 108, 110)
To t runk l i d l at ch
or st ri ker.
To f uel l i d l at ch.
\
FUEL LID
OPENER CABLE
(see pages 20-108, 110)
NOTE:
. Make sure the opener cabl e i s connected
properl y.
. Make sure the trunk l i d or hatch and fuel l i d open
properl y.
Striker l3D):
NOTE: Remove the rear tri m
panel (see page 20-601.
6 x 1 . 0 mm
HATCH
OPENER CABLE
(see page 20-110)
l nst al l at i on i s t he reverse of t he removal procedure.
NOTEi
a Make sure
erl Y.
. Make sur e
securel y.
each opener cabl e i s connected
prop'
the hatch opens
properl y and l ocks
(cont' d)
20-111
9. 8 N. m
(1. 0
kgf . m,
I
' :-!,
J
Opener and Latch
Repl acement
(cont' dl
Fuel lid latch:
NOTE: Remove the fol l owi ng parts.
2Dl4Di
. Rear t r i m panel
{ seepage2062)
. Rear edge of the trunk si de tri m or trunk tri m
(l eft
si de, see page 20-62)
3D:
. Access panel on the si de tri m panel
5 x 1. 0 mrn
FUEL LID LATCH
FUEL LI D
Af t er i nst al l i ng check f or
a f l ush f i t wi t h t he body.
panel
I
I
FUEL LI D OPENER
CABLE
(see pages 20' 108, 1' 10i
FUEI- LID LATCH
Remove t he f uel l i d l at ch
by t urni ng i t 90'
Instal l ati on i s the reverse ot the removal procedure.
NOTE:
. Make sure each opener cabl e i s connected prop-
erl y.
. Make sure the fuel l i d opens properl y and l ocks
securei y.
,-*Y:EiI::Y
20-112
Trunk lid latch/Lock cylinder:
>: Bolt locations
A > , 3 B> , 1
TRUNK LID
LATCH
CYLINDER
ROD
LOCK
CYLINDER
CONNECTOR
Di sconnect .
LOCK
CYLINDER
NOTE:
. Grease the trunk l i d l atch.
. Make sure the trunk l i d opens
properl y and l ocks
securel y.
. Make sur e t he connect or and cyl i nder r od ar e
a-
@
Windshield Wiper Arms
and Li nkage
Hatch latch/Lock cylinder:
NOTE: Remove t he hat ch t ri m
panel (see page 20-63).
A > , 3
8 > , 1
6 x 1 . 0 mm
9. 8 N. m 11. 0
7.2 tbt.ft)
kgf.m,
6 x 1 . 0 mm
9. 8 N m
(1. 0 kgf . m, j
1.2tbttij
/
HATCH
LATCH
{
NOTE:
. Grease the hatch l atch.
. Make sur e t he hat ch opens pr oper l y and l ocks
securel y.
. Make sure the cyl i nder rod i s connected
properl y.
Repl acement
CAUTION: Wear gloves to remove and inslall the wind-
shi el d wi per l i nkage.
NOTE: Take care not to scratch the hood and body.
l Remove t he wi ndshi el d wi per ar ms, t hen r emove
the hood seal and cowl cover.
>: Clip locations
a > , 9 I > , 9
COWL COVER
Di sconnect the connector, then
shi el d wi per l i nkage assembl y.
Japan/Canada-produced:
remove the wi nd-
I t L
.-.-=-
i ? Lat r
(lb
\--:.-
t)
10 x' 1. 25 mm
l 8 N. m
(1. 8
kgf . m.
(cont ' d)
20-113
Wi ndshi el d Wi per Arms and Li nkage
Repl acement
(cont' dl
USA-produced:
WINDSHIELD
WIPER LINKAGE
ASSEMBLY
>: Bol l l ocat i ons, 3
l @. ' , , . 0- -
E
9.8 N.m n.o ksf.m,
\_q.
7 2 rbr'ftl
Separ at e t he wi ndshi el d wi per l i nkage and wi nd-
shi el d wi per motor.
Japan/Canada-produced:
NOTE: Scri be a l i ne across the l i nk and wi ndshi el d
wi per l i nkage to show the ori gi nal adj ustment.
' 10
x 1. 25 mm
18 N. m (1. 8
kgt . m,
rbrftl
SPRI NG
WASHER
WIPER LINKAGE
20-114
WIPER MOTOR
USA-produced:
NOTE: Scri be a l i ne across the l i nk and wi ndshi el d
wi per motor to show the o.i gi nal adj ustment.
NUT
10 x 1. 25 mm
18 N. m 11. 8 kgf . m,
13 rbf.ft)
WIPER MOTOR
WIPER MOTOR
NOTE:
. Make sure the connector i s connected properl y.
. l i necessary, repl ace any damaged cl i ps.
. I nst al l t he wj ndshi el d wi per ar ms as descr i bed
on page 20- 117.
. Check the wi ndshi el d wi per motor operati on.
. Grease the movi ng parts.
R
6 x 1 . 0 mm
I
tf
I N.m to.s kstm, I
P,:!-Y )
Rear Window wiper
Arm and Motor
Washer Reservoir
Replacement
1. Remove the hatch tri m
2, Remov e t he r ear wi ndow wi per ar m and wl per
motor as shown.
l nstal l ati on i s the reverse of the removal procedure.
NOTE:
a Make sure the connector i s connected
properl y.
a Instal l the rear wi ndow wi per arm as descri bed on
page 20-117 .
. Check the rear wi ndow wi per motor operati on.
. Grease the movi ng
parts.
3.
5 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 tbf.ft)
WIPER MOTOR
Replacement
1 . Remove the front bumper
(see page 20 94).
Di sconnect the connectors and washer tubes from
the washer motors,
>: Boll locations, 3
/)^ Gxl .o mm
Ql (S)
s. eNmt t . orsr' m.
\-/ 7.2 tbf.f

)
- - '/
H*?H"[*
3.
MOTOR
WASHER MOTOR
(3D,
for some model s)
Remove the bol ts, then remove the washer reser-
voi r.
procedure
NOTE:
. Make sur e t he washer mot or connect or s and
washer tubes are connected
properl y.
. Check the washer motor operataon.
Rout e t he washer t ubes
t o t he washer reservoi r
20-115
Washer Tube
Repl acement
NOTE:
. To remove the wi ndshi el d washer tube, remove the
l eft i nner fender (see page 20-' 106).
. To remove the rear wi ndow washer tube
(3D).
remove
the fol l owi ng parts from the l eft si de of the vehi cl e.
-
I nner f ender
( see page 20- 106)
-
Ki ck panel and si de tri m
(see page 20-60)
-
Rear seat back and rear seat cushi on
(see page 20
80)
Spare ti re l i d
-
Rear cenl er shel f and rear si de shel f l see
page 20-
60)
-
Rear tri m panel and si de tri m panel (see page 20-
60)
Ouarter tri m panel
{see
page 20 60)
-
Rear roof tri m {see
page 20-65)
*
Hatch spoi l er
(see page 20 101)
>: Washer nozzle, clip and cushion locations
A > , 2 B> , 3 c > . 1
c
wtwosptel o I
wrsren
=--S1
lNozzLE
CE
i @
\-
\f
-f7!
] \ N
\ \ \
|
-,J:n
<:/1+-
,
-+3
|g"
D > , 1 E > , 1 F> , 1 1
WINDSHIELD
TUBE
A
t o t he washer reservoi r
REAR WINDOW
WASHER TUBE
(f or
some model s)
REAR WINDOW
WASHER TUBE
under t he wi re harness.
a
I
(see page 20-101).
NOTE:
. Take care not to pi nch the washer tubes.
. After i nstal l i ng, adj ust the ai m of the washer noz
zl es (see page 20-117).
20-116
Wiper Arms/Washer
Nozzles
Adjustment
Windshield Wiper/washer:
1. Adj ust the wi per arms so that thei r
park posi ti ons
match the i l l ustrati on.
View from front to rear
WINDSHIELD
WIPER ARMS
2. By i nser t i ng a t ack and movl ng r t as necessar y,
adj ust the washer nozzl es so that they ai m at posi -
t l ons A. A' , B, and B' shown i n t he i l l ust r at i on.
NOTE: The tl ui d
j ets
shoul d hi t wi thi n a 50 mm
(2
0
i n) radi us around each of
poi nts A, A' , B, and B'
Center line
Di stance
Nozzl e ai m
\
from center
I I ne
f rom bl ack
cerami c edge
A and A' 400 mm
( 15. 7
i n) 255 mm
(10.0
i n)
B and B' 1 15 mm
( 4. 5
i n) 322 mm 112.1
inl
Rear Window Wiper/Washer
(3D):
l . Adj ust the rear wi ndow wi per arm so that i ts park
posi ti on matches the i l l ustrati on.
View from rear to front
REAR WI NDOW
WIPEF ARM
BLACK
CERAMIC
EDGE
By i nser t i ng a t ack and movi ng i t as necessar y,
adj ust the washer nozzl e so that i t ai ms at posi ti on
C as shown i n the i l l ustrati on.
NOTE: The fl ui d
j et
shoul d hi t wi thi n a 50 mm
(2.0
i n) r adi us ar ound
poi nt C.
20-117
Embl ems
Instal l ati on
Appl y the embl ems where shown.
NOTE:
o Before appl yi ng, cl ean the body surface wi th a sponge dampened i n al cohol .
. After cl eani ng, keep oi l , grease and water from getti ng
on the surface.
Attachment Points
{Relerencel:
Uni t : mm ( i n)
CIVIC emblem
TRUNK LID
VBion emblem
Version emblem Version emblm
20-118
Sub-frame
Sub-flame Torque Sequence:
CAUTION: Aftel loosening the sub-frame mounting bolts, be sure to replace them with new ones'
BOLTS
10 x 1. 25 mm
38 N.m 13.9
kgf.m;
14 x 1. 5 mm
90 N.m {9.1 kgf.m,
66 rb{.ft)
Repl ace-
28 tbf.ft)
20-119
Frame Repair Chart
Uni t : mm
(i n)
6: I nner di amet er
oETATL AREA :ll
i
> =
POINT d3
o15 {0. 591
Transmisaion
Mount Point
20-120
I l : 3D
SECTION AA
o12 10. 471
Upper Arm
POINT
Upper
a12l o. 0l
a25
o 8 (
otN'
LOCA
Hol e
Tank
St rap
Poi nt
-o20
{0r8) Locate
Hole
POINT w
o20 10.8) Locate Hole
SECTION 8B
Damoer Lower Bush Center
20-121
Body
{' 97
model}
Front Seat Belt
....20-128
Rear Seat
.".20-126
Washer Tube
Repfacement ..................
20-129
Wi ndshi el d
l ndex ..........
20' 124
I
I
i
i
Outline of
' 97
Model Changes
The mol di ng si de seal was added.
The method of i nstal l i ng the rear seat cushi on was changed.
(2Dl 3D)
A mi ddl e fl oor gusset was added and the method of detachi ng the seat bel t retractor was changed.
(2Dl 3D)
The i nstal l ati on posi ti on of the washer tube was changed.
Wi ndshi el d
Index
NOTE: The numbers after the part names show the quanti ti es
of the pans used.
WINDSHIELO
MOLDING
UPPER RUEBER
DAM
FASTENER, 2
(Sel t -adhesi ve-t ype, gl ass si de)
FASTENER, 2
WINDSHIELD
20-124
Mol di ng Si de Seal
lnstallation
Gl ue the mol di ng si de seal to the wi ndshi el d mol di ng on
each si de.
20-125
Rear Seat
3D:
>: Boll locations
A > . 6
i
t Q6 ' t . o - - |
ps.a ru'- {r.o rgr.-,
E 7.2 tbf.ftt
,/
STRI KER
Bemove t he si de t ri m
panel (see page 20 60).
6 x 1 . 0 mm
22N-m 12.2 k
16 tbf.ft)
B > , 1 c > , 1
I
I
gf -,]
,)
9. 8 N. m {1. 0 kgt m, i
1.2tbt-ltl !
6 x l . 0 mm
PIVOT
BRACKET
STRIKER
>: Cl i p l ocat i ons. 14
I
; ,-------\
l Mwm
I F E
I F F
\_
!t
V
v
V v
Yvt
RIGHT
SEAT
PIVOT
BRACKET
--\--------
Pivot bolt construclion:
WASHER
SEAT.BACK
NOTE:
. Before attachi ng the seat back and seat cushi on, make sure there are
center bel t.
. When i nstal l i ng the seat cushi on. sl i p the seat bel t buckl es through the
. l f necessary, adj ust the stri ker and seat-back.
20-126
PIVOT BOLT
BRACKET
8 x 1. 25 mm
22 N.m
(2.2
kgf.m, 16 lbnftl
no t wi st s or ki nks i n t he rear seat bel t s and
sl i t s i n t he seat cushi on.
i
I
-!
SEAT CUSHION
HOOK
A
I
8 ( - ) . t
2D:
>: Bolt locations
A > , 6
93;mr,
g
7.2 tbrftt
B > , 1
@
v
i
i
ksf.m,'
)
c > , 1
SEAT-BACK MAT
PIVOT BOLT
MIDDLE FLOOR
CENTER GUSSET
BUSHING
BRACKET
>: Clip locations, 14
I
@ n i
- - - - - - i r l | H- - |
E E )
qr
,/
PIVOT ERACKET
RIGHT SEAT-8ACK
SEAT CUSHION
i i l
TOOTHED
LOCK
WASHER
8 x 1. 25 mm
22 N.m
(2.2
kgtm. 16 lbf.ft)
NOTE:
center bel t.
. l f necessarV, adi ust the seat-back l atch and seat-back.
20-127
Front Seat Belt
RemovaUlnstallation
2D l3Dt
1. Sl i de the front seat forward ful l y.
2. Remove:
(see pages
20-126,1271
. Rear cent er shel f and r ear si de shel f
( 3D.
see
page 20 60)
. Rear trim panel (3D,
see page 20-60)
.
Side trim panel (see pages 2G60,61)
3. Pul l back the carpet as necessary, and remove the
bolts. then remove the middle floor gusset.
>: Boh locations,8
10 x 1. 25 mm
38 N.m
(3.9
kgf.m.
28 tbt f0
20-128
4. Remove the upper anchor cover and l ower anchor
cap.
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N.m {3.3 kgf..n,
24 tbtftl
RETRACTOR BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgf.m,
24 rbnft)
l-owER
ANCHOR
CAP
I
I
+
o
@'a--- 'PPER ANcHoR
RETRACTOB
MOUNTING AOLT
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt m,
7.2 tbl.ftl
LOWER ANCHOR BOLT
7/ 16-20 UNF
32 N.m 13.3 kgl.m, 24lbl.ftl
remove the retractor mounting bolt, then remove the
tront seat belt and retractor.
Instal l ati on i s the reverse of the removal orocedure.
NOTE:
. Make sure you assembl e the washers and col l ars
on the upper and l ower anchor bol ts as shown.
are no twists or kinks in the front seat belt.
Washer Tube
Repl acement
NOTE: To remove the wi ndshi el d washer tube, remove the l eft i nner fender
(see page 20 106).
>: Washer nozzl e. cl i p and cushi on l ocat i ons
C t ' , 1 D > , 1 E > , 1
F > , 1 G> , 1
a > , 2 B> , ' l
I
9)
-r'v!
| ,, 1 |
\ T i W, ' i . <a>t ,
\\\ J
',',,4
|
'*V
l
E -/ _' ' _-/ _ _J
REAR WINDOW
REAB WINDOW
I wasHER TUBE
WASHER TUBE I \
_*)
wtNDSHtELD
.--7 l
ffi,"td-<g
*.\
|
@ t " (
\3t
/
-----J
behi nd t he EcM/ PcM br acket .
WI NDSHI ELD
TUBE
A
\ ;
Rout e i he washer t ubes
t o t he washer reservoar
NOTE:
. Take care not to pi nch the washer tubes.
. After i nstal l i ng, adj ust the ai m of the washer nozzl es
(see page 20-117).
(cont' d)
20-129
REAR WINDOW
WASHER TUBE
Washer Tube
Replacement
(cont'd)
NOTE: To remove the rear wi ndow washer tube
(3D),
remove the fol l owi ng parts from the l eft si de of the vehi cl e.
-
Inner fender
(see page 20-106)
-
Ki ck panel and si de tri m
(see page 20-60)
-
Rear seat-back and rear seat cushi on
(see
page 20-80)
-
Spare ti re l i d
-
Rear center shel f and rear si de shel f
(see page 20-60)
-
Rear tri m panel and si de tri m panel (see page 20-50)
-
Ouarter tri m panel (see page 20-60)
-
Rear rooftri m
(see page 20-65)
-
Hatch spoi l er
(see page 20-101)
>: Washer nozzle, clip and cushion locations
A > , 9 B> , 2
To rear window
washer nozzl e
(see page
20-101).
c > , 1
. / ' - : . 1
a / j
_____J K) -?)
Installation is the reverse of the removal Drocedure.
NOTE:
a Take care not to Dinch the washer tubes.
. l f necessary, repl ace anydamaged cl i ps.
. After i nstal l i ng. adj ust the ai m of the washer nozzl es (see page 20-1j 7).
mot or.
20-130
Y
Body
(' 98
modell
Opener and Latch
Repl acement ..................
20' 132
Outline of
' 98
Model Ghanges
.
The hood l at ch cover was added.
.
The hat ch handl e was added.
(3D)
Opener and Latch
Repl acement
HOOD LATCH COVER
NOTE: Take care not to the hood l atch cover and body.
HOOD LATCH COVER
i
HOOD LATCH
20-132
Hatch Handl e
1. Remove the hatch tri m panel (see page 20 63).
2. Remove the hatch handl e bol ts.
>: Boh l ocati ons,2
I
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
I
"'o::___,/
HANDLE ROD
4. Note the posi ti on of the
j oi nt
on the handl e rod
(A).
Pry the handl e rod of the
j oi nt
usi ng di agonal cut-
t er s; t ake car e not t o bend t he r od. Remove t he
hatch handl e.
EUSHING
Replace.
l nst al l i n t he r ever se or der of r emoval , and not e
these i tems:
. Make sure the handl e rod i s connected properl y.
. Before i nstal l i ng the hatch tri m panel , make sure
the hatch opens
properl y.
Hatch Latch/Lock Gylinder
1 .
LOCK
ROO
{'
Remove the hatch tri m panel (see page 20-53).
Remove the hatch l atch screws.
>: Screw locations. 3
6 x 1 . 0 mm
9,8 N.m {1.0 kg{.m.
7,2 tbtttl
Di sconnect t he l ock r od, t he handl e r od, t he l ock
cyl i nder rod, and the connector, then remove the
hatch l atch,
LOCK CYLINDER
RoD
I
...Ly';
/)<
/
CONNECTOR
{cont' d)
20-133
Opener and Latch
Replacement
(cont'dl
Pul l the l ock rod out.
LOCK
I
6 x 1 . 0 mm I
9. 8 N. m 11. 0 kgf . m, l
!!,b,!)__J
5. It necessary, remove the l ock cyl i nder.
>: Boh location, 1
l nst al l i n t he r ever se or der of r emoval , and not e
these rtems:
. Appl y grease to the hatch l atch.
. Make sure the connector i s connected
properl y.
. Before i nstal l i ng the hatch tri m panel , make sure
the hatch opens
properl y and l ocks securel y.
20-134
Heater and Ai r Condi ti oni ng
Heat er
"""""' 21- 1
Ai r Condi t i oni ng
' . ' . . . . . . . . .
"' 22- 1
SUPPLEMENTAL
RESTRAINT SYSTEM
(SRS}
The ci vi c sRS i ncl udes a dri ver' s ai rbag l ocated i n the steeri ng wheel hub. l n addi ti on, al l model s
(except
some
model s for Canada) have a
passenger' s ai rbag l ocated i n the dashboard above the gl ove box'
l nformati on necessary to safel y servi ce the sRS i s i ncl uded i n thi s servi ce Manual . ttems marked wi th an asteri sk
(*)
on the contents
page i ncl ude, or are l ocated near, SRS components. servi ci ng, di sassembl i ng
or repl aci ng these
i tems wi l l requi re speci al
precauti ons and tool s, and shoul d therefore be done by an authori zed Honda deal er.
@
-;;Gia rendsring the SRS inoperative, which could lead to petsonal iniury or death in the event ol severs
flontal collision, all SRS service work must be
pertormed by an authorized Honda dealer'
. lmproper service
procsdures, including incolrect removal 8nd installation of the sRs, could lesd to
personal
injury caused by unintentional activation ol the airbags.
o Do not bump the sRS unit. otherwise, the system may tail in case of a collision, or the airbags maY dsploy
when the ignition switch is ON
(lll
. All sRs electrical wiring harnesses are covered with yellow insulation. Related components are locatod in thg
steeling column, tront console, dashboald, dashboard lower panel, and in the dashboard above the
glove box.
Do not use elstricaltst equipment on these circuits.
T
t
I
Heater
f f f ust rat ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2
Ci rcui t Di agram , , , , , . . . . 21-3
Troubleshooting
Sympt om Chan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-4
Heater Control Panel Input/Output
Si gnal s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5
Flowcharts
Bl ower Mot or Speed . . . . . . . . . . . . . . . . . . . 21-6
Bl ower Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-8
Mode Cont rol Mot or . . . . . . . . . . . . . . . . . . . . 21-11
Recirculation Control Motor ,,,.... 21-14
Blower Unit
Repl acement . . . . . . . . . 21-16
Overhaul . . . . . . . . . . . . . . . . 21-17
*
Heater Unit
Repl acement . . . . . . . . . 21-18
Overhauf . . . . . . . . . . . . . . . . 21-20
Heater Control Panel
Repfacement .........21-21
Overhauf . . . . . . . . . . . . . . . . 21-22
Temperature Control
Adiustment ............21-23
Mode Control Motol
Test . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Repf acement .........21-24
Recirculation Gontrol Motor
Test . . . . . . . . . . . . . . . . . . . . . . . . 21' 25
Repfacement ,.,,,.,,.21-25
Relay
Test . . . . . . . . . . . . . . . . . . . . . . . . 21-26
Heater Fan Switch
Test . . . . . . . . . . . . . . . . . . . . . . . . 21-26
Mode Control Switch
Test . . . . . . . . . . . . . . . . . . . , . , . . 21-27
*
Read SBS
precautions before working in
this area.
lllustrated Index
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons.
and
procedures
i n the SRS
secti on {24) before performi ng repai rs or servi ce.
BLOWER UNIT
Repl acement , page 21' 16
Overhaul , page 21 17
HEATEB UNIT
Fepl acement , page 21, 18
Overhaul , page
21-20
BLOWER
RESISTOR
Test,
page 21-7
HEATER VALVE CABLE
Adj ust ment , page
21-23
CONTROL MOTOR
Test , page
21-25
A/C SWTTCH
{with A/c)
TER FAN
swrTcH
Test , page
21-26
MODE CONTROL
MOTOR
Test , page 21-24
AIR MIX CONTROL CABLE
Adi ust ment , page 21' 23
MODE CONTROL
swtTcHEs
lest, page 21-27
HEAIER CONTROL
PANEL
Ovethaul, page 21-22
TEMPERATURE CONTROL
LEVER
Adj ustment, page 21 23
Def roster-aqtivated A/C System
Turni ng the defroster on acti vates the A,/C and sets the ai r fl ow mode to FRESH. It i s possi bl e
to turn the Ay' C off or to
change the ai r fl ow to RECIRCULATE by pressi ng
the Ay' C button or the FRESH/RECTRCULATE button.
21- 2
Ci rcui t Di agram
a
UNDEN'HOOD FUSE/RETAY BOX
UNDEs OASH
FECIRCULATION
17
I
I
I
BLU/RED
a
DASH LIGHTS
SRIGHTNESS
CONTNOLLEF
21-3
BLOWEF
I
G401
G' 102
eil+ji'^*'l-fl Lf:} Lr_l il:Y i,fi*r.,{ | | Ieff{+jir*'It-} ?r,l
-tr'-?
?r
{
a
HEATERCONTROL PANL
Troubl eshooti ng
Symptom Ghart
NOTE:
. Check the engi ne cool ant l evel , and al l ow the engi ne to warm up before troubl eshooti ng.
. Any abnormal i ty must be corrected before conti nui ng the test.
. Because of the preci se measurements needed, use a mul ti meter when testi ng.
. Before performi ng
any troubl eshooti ng procedures checkl
._
Fuses
*1No.
47 \1 .5 A),
*1No.
55 {40 A},
*,No.
17
(7.5
A)
-
Gr ounds No. G401, c402
-
Cl eanl i ness and ti ghtness of al l connectors
*rr
In the under-hood fuse/rel ay box
*' :
In the under-dash fuse/rel ay box
Symptom Remedy
Hot ai r f l ow i s l ow. Bl ower motor runs, but one or more
speeds are i noperati ve.
Perform the procedures i n the fl owchan (see page 21 6).
Bl ower runs properl y.
Check for the fol l owi ng:
.
Cl ogged heater duct
.
Cl ogged heater outl et
.
l ncorrect door posi ti on
No hot ai r f l ow. Bl ower motor does not run at al l . Perform the procedures i n the fl owchart
(see page 21-8).
Bl ower motor runs. Check for the fol l owi ng:
.
Cl ogged heater duct
.
Cl ogged bl ower outl et
.
Cl ogged heater val ve
.
Faul t y ai r mi x door
.
Heater valve cable adjustment
(see page 21-23l,
'
Ai r mi x control cabl e adj ustment
(see page 21-23)
.
Faul ty cool i ng system thermostat
(see
secti on 10)
'
Cl ogged evaporator
(wi th
ai r condi ti oni ng)
.
Frozen evaporator
(wi th
ai r condi ti oni ng)
Mode control motor does not run, or one or more modes
are i noperati ve.
Perform the procedures i n the fl owchart
(see page 21-l 1).
Reci rcul ati on control door does not chanqe between
FRESH and RECIRCULATE.
Perform the procedures i n the fl owchart
(see page 2' l -14).
I
I
I
r-
21-4
Heater Control Panel Input/Output Signals
HEATER CONTNOL PANEL 14P CONNECTOR
Terminal
No.
Wire
color
Si gnal
Termi nal
No.
Wire
color
Si gnal
YEL HEAT/OEF I NPUT 8 YEURED VENT I NPUT
BLVYEL tG2 I NPUT GRN/YEL HEATA/ENT I NPUT
WHT/BLU +B I NPUT
' 10
BLK GROUND OUTPUT
YEUBLU DEF I NPUT BLU/RED A.i C THERMOSTAT I NPUT
RED
DASH LIGHTS
BRIGHTNESS CONTROLLER
OUTPUT 12 GRN/WHT FRESH I NPUT
6 RED/BLK
COMBINATION LIGHT
SWITCH
INPUT 13 GRN/ RED RECIRCULATE I NPUT
7 BLU^r'r'HT HEAT INPUT 1 4 GRN HEATER FAN SWITCH OUTPUT
21-5
Troubl eshooti ng
Blower Motor Speed
6 A t l \
z t -r,
- .
HEATER FAN SWITCII 6P CONNECTOR
Bl ower mot or runs. but one or
more speds are inoperalive.
Check f or a 3hor t or an open i n
t he wi r e( s) :
Tur n t he i gni t i on s wi t c h ON
( l l ) ,
and t he heat er f an swi t ch OFF.
Does t he bl ower mot or run?
Check for a shon in the wi.e{s}:
' 1.
2, Di sconnect t he bl ower mot or
2P connect or,
3. Remove t he cent er dashboard
l ower cover
(see
sect i on 20),
and di sconnect t he heat er f an
switch 6P connector,
4. Di sconnect t he bl ower resi s
t or 4P connect or,
the No. 2, 3, 4 and 5 terminals
of t he heat er f an swi t ch 6P
connect or and body gr ound
i ndi vi dual l y.
Replace the heater f'n switch.
Repai r shor t i n t he wi r el s)
between the blower resbtor, the
heater fan switch and the blower
From
page 2' l
-6
Check th6 blower rsistor:
' 1.
Turn t he i gni t i on swi t ch OFF
2. Di sconnect t he bl ower resi s
t or 4P connect or,
3. Measur e t he r esr st ance
bet ween t he No. 2 and No. 4
t ermi nal s of t he bl ower resi s'
t or.
l s t here approx. 2
-
3 ohms?
Does t he bl ower mot or r un at
pr ogr essi vel y hi gher speeds?
Beolaco the heator fan switch.
Repair open or cause of excessive
r esi st ance i n i hG appr oP. i at e
wirels) between the blower resis-
tor and tho heaterlan switch.
BLOWEB RESISTOR
HEATER FAN SWITCH 6P CONNECTOR
Check tor an open in thg witelslr
1. Reconnect t he bl ower . esi st or
4P connect or.
l ower cover
(see
sect i on 20i ,
and di sconnect t he heat er f n
(l l i .
4. Ground each of t hese t ermi -
nal s i ndi vi dual l y i n t he f ol l ow-
i ng order; No. 4, 2, 5 and 3.
BLU/WHT
2
1 6
BLU I IBLU/Y
BLU/BLK
JUMPER
WIRE
21- 7
Troubleshooting
Blower Motor
21-8
BLOWER MOTOR 2P CONNECTOR
WIRE SIDE OF FEMA1T TERMINALS
F
l l l
l-,1
ruueeif6rureu
wrRE
1
F
glulwxr
L'--r'|--]
L1J
d)
I
Blower motor does not run al ell.
Check t he No. 55 {40 A)t use i n t he
undeFhood f use/ rel ay box, and
t he No. 17
( 7. 5
A) f use i n t he
under-dash fuse/relay box.
Roplaco the lu3o(!1, rnd rochock.
Check tho blowcr motor:
1. Connect t he No. 2 t ermi nal oI
t he bl ower mot or 2P connec-
t or t o body gr ound wi t h a
(ll).
Does t he bl ower mot or run?
Check tor an open in the wire:
1. Di sconnect t he
j umper
wi r e
and t he bl ower mot or 2P con-
nector.
t he No. l t ermi nal and body
ground,
Chack the blower motor relay:
2. Remove t he bl ower mot or
r ol ay f f om t he under - hood
fuse/relay box, and test it
(see
page
21-26).
Rcpltc tho blowo. motol r.l!y.
To page 21' 9
To page
21-10
From page 21-8
Check lor an open in the wite:
1. Turn t he i gni t i on swi t ch OFF,
a n d d i s c o n n e c t t h e
j u mPe r
2, Remove t he cent er dashboard
l ower cover
(see
sect i on 20),
and di sconnect t he heat er f an
(l l )
t he No. 3 t er mi nal and body
ground.
the blower motor and the heatol
lan switch.
Check for an open in the wire:
t he No. l t ermi nal of t he heat er
f an swi t ch 6P connect or and
body
ground.
Replace the heaier fan switch.
Check l or an oDen i n t he wi re
between the h6ater tan switch
and body ground. It the wir is OK,
check lor
poor ground at G401 and
G&2.
HEATER FAN SWITCH 6P CONNECTOR
(cont ' d)
21-9
Troubl eshooti ng
Blower Motor
(cont'dl
Check the under-hood fuse/relay
box:
Measure the voltage beNveen the
No . 3 t e r mi n a l o f t h e b l o we r
mot or r el ay 4P socket and body
gr ound.
BLOWER MOTOR RELAY 4P SOCKET
rD
{
rl-
,
l 2 1 1 l
r r -
l r l 3 |
IBLK/YEL
o)
Y
From page 21 8
Chock for an open in the wi.e:
' 1.
(l l ).
2, Me6sure the voltage between
t he No. 4 t er mi nal of t he bl ow
er mot or rel ay 4P socket and
body ground.
Repair opcn in the wire between
t he No. 17 l use and t he bl owe.
motor reley.
Check tor an opon in the wire:
2. Check for continuity betlveen
the No. 2 terminal of the blow-
er mot or rel ay 4P socket and
body ground.
Check t o. an oDen i n t he wi i e
between lhe blowor motor relev
and body glound. lf the wire is
OK. check f or poor ground
at
G{01 .nd G{02.
Repai r opon i n t he BLU/ WHT
wiae bolwean the blower motor
relav snd the blower motor,
21- 10
Mode Control Motor
Mode control motoa does nol run,
or one or more modes are inoPen_
tive.
check t he No. 17
(7. 5
A) f use i n
the under'dash fuse/relay box.
ReDlace the lus, and rechck.
Chsck toJ an open in the wire:
1. Di sconnect t he mode cont rol
mot or 7P connect or,
(ll).
t he No. l t ermi nal and body
grou no.
Repair open in the wi.e between
t he No. 17 f use and t he mode
control motor,
ls lhere battery voltage?
Check tor an open in the wite:
t he No. 7 t ermi nal of t he mode
cont rol mot or 7P connect or
and body ground.
Check f or an opon i n t he wi re
h$ro6n the modc control motor
and body
ground.lllho wire is OK,
check lor poor gaound tl G,Ol and
G402.
Test the mode control motor
(soe
page 21-24).
Check the mode control linkage
and doors:
1 . Re mo v e t h e mo d e c o n t r o l
mot or
(see page 21 24).
2. Check the mode control linkage
and doors f or smoot h move-
ment.
l st he mode cont rol mot or OK?
Do the mode control iinkage
and doors move smoothly?
Roolace the mode control motor.
MODE CONTROL MOTOR 7P CONNECTOR
To
page21- 12
f
3 I 5
BLK/ YEL
_ l T
1 I 6 7
BLK
{ l
(cont' d)
21- 11
Troubl eshooti ng
Mode Control Motor
(cont'd)
21- 12
HEATER CONTROL PANEL 1{P CONNECTOR
Fr om page
21- 11
Check for a short in the wire{sl:
1. Remove t he cent er dashboar d
To page 21- 13
Repei r any short i n t he wi re(sl
between the mode control motol
and the heater control panel.
Check for a short to Dower:
Check t he same wi res f or vol t aoe.
Repair short to power in the wir6
betweon the mode control motor
rnd t he heat er cont rol oanel .
(This
short damages the heatel
control oanel.l
l s t here any vol t age?
Ch6ck for an open in tho wirolsl:
f ol l owi ng t ermi nal s of t he mode
cont rol mot or 7P connect or and
t he heat er cont rol
panel 14P con'
nector,
7P: 14P:
N o . 2 - N o . 4
No . 3 - No . 1
No. 4- No. 7
No . 5 - No . I
No . 6 - No . 8
Ropei r l ny opn i n t ha wi l ol sl
biwe6n tho modo conlrol motor
and th6 haaie. contol
P.nal.
Ch6ck l o. l ooso wi ro3 ot Pool
connoc'tion3 at iha haatcr conttol
prn6l l/aP conncctot. ll tho con-
nactions !.o
good, rcplace tho
hgelr control
pancl.
Frcm
page 21-12
HEATER CONTROL PANEL 14P CONNECTOR
MODE CONTROL MOTOR 7P CONNECTOR
21-13
Troubleshooting
Recirculation Control Motor
Recirculation control door does
not change btween FRESH and
RECIRCULATE.
RECISCULATION CONTROL MOTOR
4P CONNECTOR
1
BLK/YEL
Check t he No. 17 (7. 5
Al {use i n
the under-dash fuse/relay box.
Roplace the lus6, aod rscheck.
Check for an open in th6 wi.e:
1. Di sconnect t he r eci r cul at i on
control motor 4P connector.
(ll).
3. Messure t he vol t age bet ween
t he No. ' 1 t er mi nal and body
grou nd.
Repair open in tho wirc botweon
the No. 17 tuse and lhe recircula-
tion control motor.
Check t he reci rcul at i on cont rol
motor:
2. Test t he reci rcul at i on cont rol
mot or (see page 2l 25).
Check the rccirculation control
linkago and door:
1. Remove t he reci rcul at i on con-
t rol mot or
(see page 2l -25).
2. Check the recirculation control
l i nkage and door f or smoot h
Oo t he reci rcul at i on cont rol l i nk-
age and door move smoot hl y?
Repai r t he reci rcul at i on cont rol
linkage or door.
To page 21
' l 5
21-14
Check Ior a short in the wite(s):
l ower cover
(see
sect i on 20),
and disconned the heater con
trol
panel 14P connector'
2. Check f or conl i nui t y bet ween
t he No. 12 and No 13 t ermi -
nal s and body
ground i ndi vi d
R6air short in the wilo(a) bstween
the rdrculaiion conttol motor rnd
tfte heater control Panel.
Check for a short io powar:
Check t he same wi res f or vol t age
Repair short to
Powsr
in the wir
between the recirculstion control
mot or and t ho heat or cont rol
penel .
l Thi s
short damages t he
h6ater control
pan6l'l
Check lor an opon in tho wire{s}:
tollowing terminals of the recircu
lation control motor 4P connector
and t he heat er cont rol Panel
14P
4P: 14P:
No . 2 - No . l 2
No . 4
-
No . 1 3
Repai r open i n t he wi re(sl
between the recitculation comrol
mot or and l he heet er cont t ol
oanel.
Check f or l oose wi l es or
Poor
connections at the heater control
oanel l,lP connector. ll tha con-
nect i ons are
good, repl ace t he
heater control
Panel.
Fr om page 21- 14
HEATEF CONTROL PANEL 14P CONNECTOR
1 2
;-?
4
7 8 9 'o
lx
1 1 1 2 r3 1 4
GRN/wHr
| |
oo
GRN/ REO
1 2
t ?
4
1 8 10
|
11 12 13 1 4
GRN/WHT
v) ( v
GRN/RED
GRN/RED
I
I ,
RECTRCULATION CONTROL MOTOR
4P CONNECTOR
1 2 ''l
1 5 6
7 8 9 10
I
1 1 12
' t3
1 1
GRN/WHT
GRN/W
t-
I
o
I_
\ r -
-tl
A
I
iRN/RTiD
, l r \ / 4
21-15
Blower
Unit
2.
Replacement
NOTE: The bl ower motor, reci rcul ati on control motor
and bl ower resi stor can be repl aced wi thout removi nq
the bl ower uni t
(see
next page).
1 . Remove t he gl ove box
{see sect i on 20).
Remove t he sel f -t appi ng screw and t he passenger, s
dashboar d l ower cover . Remove t he bol t , t he nut
and t he knee bol st er, t hen remove t he f i ve bol t s and
t he gl ove
box f rame.
GLOVE BOX FRAME
Without Air Conditioning
3-a. Remove the wi re harness from the heater duct, then
remove the two sel f-tappi ng screws and the heater
quct.
tr
tr
6 a ^ t \
z a - t r ,
KNEE
HEATER DUCT
With Air Conditioning
3-b. Remove the evaporator (see page
22-25).
6 x 1 . 0 mm
9.8 N.m
7.2 tbt tll
6 x 1 . 0 mm
9,8 N.m
(1.0
kgf.m,7.2 tbtf
Di sconnect the connectors from the bl ower motor,
bl ower resi stor and reci rcul ati on
control motor.
Remove the wi re harness cl i p from the reci rcul ati on
control motor, and rel ease the wi re harness from the
cl amp on the bl ower uni t. Remove the two mount-
i ng bol ts, the mounti ng nut and the bl ower uni t.
9.8 N.m (1.0
kgf.m,
7.2 tbl.ttl
Instal l i n the reverse order of removal . Make sure
that there i s no ai r l eakage.
I
: r -
iCIi1,
6 x 1 . 0 mm
9.8 N.m {1.0 kgf m,
7.2 tbf.tr)
6 x l . 0 mm
Overhaul
NOTE:
. Before reassembl y, make sure that the reci rcul ati on control door and l i nkage move smoothl y wi thout bi ndi ng'
. when attachi ng the reci rcul ati on control motor, make sure i ts posi ti oni ng wi l l not al l ow the reci rcul ati on control door
to be
pul l ed too far.
. After attachi ng the reci rcul ati on control motor, connect
power and ground, and watch the movement of the reci rcul a-
ti on control door.
m
21-17
Heater Unit
1 .
Repl acement
SRS component l ocati ons. precauti ons, and procedures
i n the SRS secti on 124) before performi ng repai rs or ser-
vi ce,
Di sconnect the negati ve cabl e from the battery.
When the engi ne i s cool , set the temperature con-
trol l ever to MAX. HOT
(open
the heater val ve), then
drai n the engi ne cool ant from the radi ator
{see sec-
t i on 10) .
!@
Do not remove the radiator cap when
the engine is hot; the engins coolant is under pres-
sure and could severely scald you.
2.
3. Open the cl amp, then di sconnect the heater val ve
cabl e from the heater val ve arm
CLAMP
HEATER VALVE ARM
HEATER VALVE CABLE
21-14
4. Di sconnect the heater hoses from the heater uni t.
CAUTI ON: Engi ne cool ant wi l l damage pai nt .
Ouickly rinse any spilled sngine coolant ftom painted
surtaces.
NOTE| Engi ne cool ant wi l l run out when the hoses
are di sconnected; drai n i t i nto a cl ean dri p
pan.
HEATER HOSE
{OUTLET SIOEI
5. Remove the mounti ng nut from the heater uni t.
NOTE: When removi ng the mounti ng nut, take care
not t o damage or bend t he f uel pi pes, t he br ake
pi pes, etc.
8 x 1. 25 mm
22 N.m
(2.2
kgl.m, 16lbf.ft)
7.
Remove the dashboard
(see
secti on 20).
Remove the heater duct
(see page 21-16) or evapo-
rator
(see page 22-251.
Di sconnect the connector from the mode control
motor, and remove the wi re harness cl i ps and wi re
harness Jrom the heater uni t. Remove the cl i p from
the heater duct, then remove the two mounti ng
nuts and the heater uni t.
6 x 1 . 0 mm
9.8 N m 11.0 kgf'm, 7.2 lblft)
TER DUCT
HEATER UN]T
l nstal l i n the reverse order of removal . Make note oi
the fol l owi ng i tems.
Appl y seal ant to the grommets.
Do not i nterchange the i nl et and outl et heater
hoses. Make sure that the cl amps are secure.
Ref i l l t he cool i ng syst em wi t h engi ne cool ant
(see
secti on 101.
Connect al l cabl es, and make sure they are
prop-
erl y adj usted
(see page 21-23).
Make sure that there i s no ai r l eakage.
8.
9.
a
a
21-19
Heater Unit
1 .
Overhaul
Remove the two sel f-tappi ng screws and the heater
core cover.
Pul l out the grommet from the heater core pi pes.
Remove the sel f-tappi ng screw and the cl amp.
Pul l out the heater core from the heater uni t.
NOTE: Be careful not to bend the i nl et and outl et
pi pes duri ng heater core removal .
Assembl e i n the reverse order of di sassembl y.
HEATER CONE COVER
21-20
Heater Control Panel
Replacement
Remove the dri ver' s dashboard l ower cover, the
gl ove box and the center dashboard l ower cover
(see
secti on 20).
Di sconnect the ai r mi x control cabl e from the heater
uni t
(see page 21-23).
Remove the rear window defogger switch, the hazard
warni ng swi tch and the audi o uni t
(see
secti on 23).
Di sconnect the connectors i rom the heater control
panel .
Remove the fi ve sel f-tappi ng screws and the
center
panel together wi th the heater control
panel .
NOTE: The l ocki ng tabs are on the bottom of the
con nectors,
AIR MIX CONTROL
CABLE
5. Remove t he f our sel f -t appi ng screws and t he heat er
control
panel ,
HEATER CONTROI. PANEL
Instal l i n the reverse order of removal . Adj ust the 8i r
mi x control cabl e and the heater val ve cabl e
(see
page 21-231.
' 1.
21-21
Heater Gontrol Panel
Overhaul
Adi ust ment ,
page 21' 23
HEATER FAN SWITCH
Test , page 21-27
Air Mix Control Cable Replacement
1. Cut the i nner cabl e on the l ever si de ofthe cabl e hol der, then remove both pi eces ofthe i nner cabl e.
2. Usi ng a sharp kni fe, cut compl etel y l hrough the end of the cabl e housi ng at the two l ocati ons.
3. Sl i dethe l arge secti on ofthecabl e housi ng outofthecabl e hol der, bei ng careful not to da mage the cabl e stops.
4. Careful l y remove the cut pi eces of the cabl e housi ng wi th a smal l fl at ti p screwdri ver.
5. Hook the ti p of the new ai r mi x control cabl e to the temperature control l ever, then push the cabl e housi ng i nto the
cabl e hol der unti l i t l ocks i nto pl ace.
g
\ n4. - - -
^Jj- 6:B
ffi
^gvry
f f i \
CAALE HOLDER
TEMPERATURE
CONTFOL LEVER
NOTE: After assem bl y, check that the temperatu re control l ever sl i des smoothl y through the ful l stroke from ri ghtto l eft.
21- 22
Temperature Control
Adjustment
1. Under the hood, di sconnect the
from the heater val ve.
HEATER VALVE A8M
heat er val ve cabl e
TER
VALVE
CABLE
2.
3.
Under t he dash, di sconnect t he ai r mi x cont rol cabl e
housi ng f rom t he cabl e cl amP.
Set the temperature control l ever to MAX. COOL
Wi th the ai r mi x control cabl e attached to the ai r
mi x cont r ol ar m,
gent l y pul l on t he out er cabl e
housi ng to ful l y cl ose the door and to remove any
sl ack i n the cabl e. Don' t
pul l to hard, or the temper-
ature control l ever wi l l move.
Hol d the ai r mi x control arm agai nst the stop, then
snap t he ai r mi x cont r ol cabl e housi ng i nt o t he
cabl e cl amp.
6. Under the hood, move the heater val ve arm to the
f ul l v cl osed
posi t i on,
t hen anach t he heat er val ve
cabl e to the heater val ve arm.
CLAMP
HEATER
VALVE
CABLE
7. Hol d t he heat er val ve ar m i n t he cl osed
posi t i on,
and
gentl y pul l on the heater cabl e outer housi ng to
take up any sl ack, then i nstal l the heater val ve cabl e
housi ng i nt o t he cabl e cl amp.
HEATER VALVE ARM
21-23
Mode Control Motor
Test
1 .
2.
Di sconnect the 7P connector trom the mode control
motor.
Connect battery power to the No. 1 termi nal , and
gr ound t he No, 7 t er mi nal .
CAUTION: Never connect the battery in the oppo-
site direction.
Usi ng a
j umper wi r e, connect t he No. 7 t er mi nal
i ndi vi dual l y to the No. 2, 3, 4, 5 and 6 termi nal s i n
that order. Each ti me the connecti on i s made' the
mode control motor shoul d run smoothl y and stop.
NOTE: It the mode control motor does not run when
j umpi ng the fi rst termi nal ,
j ump
that termi nal agai n
after
j umpi ng
the other termi nal s. The mode control
motor i s OK i t i t runs when
j umpi ng
the fi rst termi -
nal agai n.
MOOE CONTROL MOTOR
4. l f the mode control motor does not run i n step 3,
remove i t, then check the mode control l i nkage and
doors Ior smooth movement. l f they move smoothl y,
repl ace the mode control motor.
21-24
Replacement
1 . Disconnect the 7P connector from the mode control
motor.
Remove the rod from the arm of the mode control
motor.
Bemove the two sel f-tappi ng screws and the mode
control motor.
Instal l i n the reverse order of removal . After i nstal l a-
t i on, mak e s ur e t he mode c ont r ol mot or r uns
smoothl v.
7P CONNECTOR
I
I
Recirculation Control Motor
Test
1 .
2.
4.
Di sconnect the 4P connector from the reci rcul ati on
control motor.
Connect battery power to the No. 1 termi nal . and
ground the No. 2 and No. 4 termi nal s; the reci rcul a-
ti on control motor shoul d run smoothl y.
CAUTION: Never connect the battety in the oppo-
site direction.
Di sconnect the No. 2 or No. 4 termi nal s from ground;
the reci rcul ati on control motor shoul d stop at FRESH
or RECIRCULATE.
NOTE: Don' t cycl e the reci rcul ati on control motor
for a l ong ti me.
RECIRCULATION CONTROL MOTOR
l f the reci rcul ati on control motor does not run i n step
2. remove i t, then check the reci rcul ati on control l i nk-
age and door l or smooth movement. l f they move
smoothl y, repl ace the reci rcul ati on control motor.
Repl acement
1 . Di sconnect the 4P connector from the reci rcul ati on
cont r ol mot or , and r emove t he wi r e har ness cl i p
from i t.
Remove the two sel f-tappi ng screws and the reci r-
cul ati on control motor.
Instal l i n the reverse order of removal . After i nstal l a-
ti on, make sure the reci rcul ati on control motor runs
smoothl y.
j
CONTFOL MOTOR
21-25
Relay Heater Fan Switch
Test
There shoul d be conti nui ty between the No. I and No. 3
termi nal s when power
and ground are connected to the
No. 2 and No. 4 termi nal s, and there shoul d be no conti -
nui ty when power i s di sconnected.
r [ a
H F
' r t
1 2 -
ffi
IF.=qI
"++
l l
21-26
Test
Check for conti nui ty btween the termi nal s accordi ng to
the tabl e bel ow.
\
Termi nal
Posi ti on
,1
o 4
a
3
OFF
o o
o-
-o
o-
--o
o- o
\
Mode Control Switch
Test
Check for conti nui ty between the termi nal s accordi ng to
the tabl e bel ow.
Termi nal
Posi ti on
1 0 7 1 8 I
Heat o-
-o
HeaVDef o
-c
Def
o-
-o
Vent o-
-o
Heawent o-
-o
;l
t
a
7 8 9
l
21- 27
T
I
;
Ai r Condi ti oni ng
Speciaf Tools
"' .......".22' 2
lf f ustrated Index .........................' ---...".
22-3
Wiring/Connector Locations' .............'
22-4
Description
outfine ............
"""' 22' 5
Circuit Diagram
....' ....22' 6
Tloubleshooting
Sympt om Chart . . . . . . . . . . . . . . . . . . . . ". . ' ---. . '
22' 7
Condenser Fan ....."......' .".........., " ". 22-8
Compressor
."' ...-' .' 22' 11
A/C System
..---.."' .22-15
A/C Thermostat
Test . . . . . . . . . . . . "' . .
. . ""' 22' 14
Relay
Test . . . ' . . . . . . . . . . . . .
. . . . . . . 22-14
A/C Service Tips and Precautions ....' . 22-19
A/C System Torque Specifications
...- 22-2O
A/C System Service
Recovery
...".' ...-."" 22' 21
Performance Test .....................' ..' ,,' .
22-22
Pressure Test Chart ..' ......."".... ...."' 22' 24
Evaporator
Replacement
.-."....22-25
Overhaul
. . . . . . . . . . . . . . . . 22-26
Gompressor
Repfacement
-......-.22-27
ff f ustrated f ndex "........' .....' ..."..' .."..
22-29
Clutch Inspection ...............' .....' .' .'
--- 22' 30
Cf ut ch Overhaul ' . . . . . ' . . ' . . . . . . . . ". . . .
. . . ". . 22-31
Thermal Protector Replacement
.... 22'33
Refief Valve Replacement .....-......". 22' 33
A/C Gompressor Belt
Adiustment
.-."' ..--..22-34
Condenser
Repfacement
-......' .22-35
A/G System Service
Evacuation
........,....22' 36
Chargi ng
"' . . . . . . ". . . . . 22-37
Leak Test
....' ..........22-37
Special Tools
\
Ret. No. Tool Numbor Description Oty
I
Page Reference
o
o
Ar
@
*07JGG
-
001010A
07sAz
-
0010004
07947
-
6340300
07965
-
6920500
Backprobe Set
Dri ver Attachment
Hub Assembl y Gui de Attachment
1
2
'I
't
22-34
22- 12, 14
22-3'l
*
Incl uded i n the Bel t Tensi on Gauge Set, 07TGG-001000A.
e @
,a
o
I
22-2
lllustrated Index
EVAPORATOR
Repl acement ,
page 22-25
Overhaul ,
page 22-26
A/C PRESSURE SWITCH
When t he ref ri gerant
pressure i s bel ow 200 kPa
(2. 0
kgt cm' ,
28
psi)
due to refrigerant leakage or above 3200 kPa 132 kgflcm',
455 psi) due to refrigerant blockage, the A,/C pressure switch
opens t he ci rcuh t o t he A/ C swi t ch and st ops t he ai r condi t i oni ng
to protect the compressor.
RECEIVER,/DRYER
SERVICE VALVE
ILOW.PRESSURE SIOE}
CONDENSER
Repl acement ,
page 22-35
Test , page 22 18
Repl acement ,
page 22' 27
22-3
Wiring/Connector
Locations
DI ODE,
CONOENSER FAN RELAY,
COMPRESSOF CLUTCH RELAY
{Locat ed i n t he underhood f use/ rel av box}
CONDENSER FAN
CONNECTOR
COMPARTMENT
WIRE HARNESS
CONNECTOR
22-4
Description
Outl i ne
The ai r condi ti oner system removes heat from the passenger compartment by ci rcul ati ng refri gerant through the system
as shown bel ow.
Hi gh-temperature/ Hi gh-temperature/
hi gh- pr essu r e gas hi gh- pr essur e l i qui d
Sucti on and compressi on Radi ati on of heat
Hi gh-temperature/
hi gh- pr essur e l i qui d
t r aps oeDf l s,
ano removes
motstu re
Mor e l i qui di f i ed
l ow-pressure vapor
Absorpti on of heat
E VAT\ JhA I UN \
a
a
coMpREssoR
- CoNDENSER-
RECEI VER/ DRYER
Less moi sturi zed
l ow-pressure vapor
EVAPORATOR
RECEIVER LINE
DISCHARGE LINE
SUCTION LINE
RECEIVER/DRYER
COMPRESSOR
Thi s car uses HFC-134a {R-' 134a)
refri gerant whi ch does not contai n chl orofl uorocarbons, Pay attenti on to the fol l owi ng
servtce rtems:
Do not mi x refri gerants CFC-12
(R-12)
and HFC-134a
(R-134a)
They are not compati bl e.
Use onl y the recommended
pol yal kyl enegl ycol
(PAG) refri gerant oi l
(SP-10)
desi gned for the R-134a compressor.
Intermi xi ng the recommended {PAG)
refri gerant oi l wi th any other refri gerant oi l wi l l resul t i n compressor fai l ure.
Al l Ay' C system
parts (compressor, di scharge l i ne, sucti on l i ne, evaporator, condenser, recei ver/dryer, expans' on val ve.
O-ri ngs for
j oi nts)
have to be proper for refri gerant R-134a. Do not confuse wi th R-12 parts.
Use a hal ogen gas l eak detector desi gned for refri gerant R-134a.
R-12 and R,134a refri gerant servi ci ng equi pment are not i nterchangeabl e, Use onl y a Recovery/Recycl i ng/Chargi ng System
that i s U.L.,l i sted and i s certi fi ed to meet the requi rements ot SAE J2210 to servi ce R-134a ai r condi ti oni ng systems.
Al ways recover the refri gerant R-' 134a wi th an approved Recovery/Recycl i ng/Chargi ng System before di sconnecti ng any
A,/C fitting.
22-5
Ci rcui t Di agram
UNDER- HOOD FUSE/ BELAY BOX
UNDER DASH
FUSE/RELAY 8OX
No. 17
( 7. 541
N0. 41 i 80A) N0. 42
( 40A)
No. 56l 20A)
I
j
COMPRESSOR
CLUTCH
RELAY
4
1
BLU/ryVHT
I
iS. rc
(, r
)
PRESSURE
\.:J./
SWITCH
CONDENSER
FAN MOTOR
BIK
I
COMPRESSOR
cLUTcH
REsrsToR
22-6
. N. . i . . _-)
Troubl eshooti ng
Symptom Ghart
NOTE:
. Any abnormal i ty must be corrected before conti nui ng the test.
. Because of the preci se measurements needed, use a mul ti meter when testi ng.
o Before performi ng any troubl eshooti ng
procedures check;
_
Fuses
* 1No.
47
( 7. 5
A) ,
* 1No. 56
( 20
A) ,
* , No.
17
( 7. 5
Al
-
Grounds No. G401, G402, G751
-
Cl eanl i ness and ti ghtness ot al l connectors
*r:
In the under-hood fuse/rel ay box
*2:
In the under-dash fuse/rel av box
I
I
I
!
s
Symptom
Remedy
Condenser tan does not run at al l . Perform the
procedures i n the fl owchart
(see page 22-8).
Compressor cl utch does not engage Perform the
procedures i n the fl owchart
(see page 22-11)
A,/C system does not come on
(compressor and tan). Perform the
procedures i n the fl owchan
(see page 22-15).
22-7
Troubleshooting
Condenser Fan
CONDENSER FAN RELAY 4P SOCKET
Condensa lan does noi run at ell.
Remove t he condenser f an rel ay,
and t est i t {see
page 22-18).
Replace the condenser trn relay.
Check the unde.-hood Iuse/rlsy
box:
No. 3 t ermi nal of t he condenser
f an r el ay 4P socket and body
grou nd.
Check tho conden3e. tan:
Connect t he No.
' l
and No. 3 t er
minafs of the condenset lan rclay
4P socket with a
jumper
wire.
Does t he condenser f an run?
To page 22' 9
To page
22-10
22-8
From page 22 8
Check for an open in the wire:
1. Di sconnect t he
i umper
wi re.
2. Di sconnect t he condenser f an
2P connect or.
t he No. 1 t ermi nal ol t he con-
denser f an rel ay 4P socket and
t he No. 1 t ermi nal of t he con-
denser f an 2P connect or.
Repair opn in the wire betwoen
tho condenser fan relay and the
condenser tan.
Check for an op.n in the wire:
Check for continuity beNveen the
No. 2 t ermi nal ol t he condenser
f an 2P connect or and body
ground.
RsDlace the condenser fan motor, l s t here cont i nui t y?
Chock I or an ooen i n l he wi l e
between the condenser tan and
body
ground. ll the wire i3 OK,
chsck for poor ground at G751.
CONDENSER FAN RELAY 'P SOCKET
wHT a------l
1 l
I r--------------1
l t 3 l
l f f i
I l n l ' l
6 \ -
\:/
I
I r - r
L-r,T;l
wHT t-----l-----J
CONDENSER FAN 2P CONNECTOR
(cont' d)
22-9
Troubleshooting
Condenser Fan
(cont' dl
Check the diode:
1. Di sconnect t he
j umper
wi re.
2. Remove t he di ode f r om t he
under-hood f use/ rel ay box.
3. Check f or current f l ow i n bot h
di rect i ons bet ween t he A and
B t ermi nal s.
a o--J(-----o n
From page 22-8
l s t here current f l ow i n onl y
one di rect i on?
22-10
Compressor
COMPRESSOR CLUTCH BELAY 4P SOCKET
JUMPER
WIRE
COMPRESSOR CLUTCH 1P CONNECTOR
WIRE SIDE OF FEMALE TERMINAL
(cont' d)
22-11
Remove t he compressor cl ut ch
relay, and test it
(see page 22-18)-
Check the under-hood fuse/relay
box:
No. 3 t ermi nal of t he compressor
cl ut ch rel ay 4P socket and body
ground.
Check tho compr*sor clutchl
Connect the No. 1 and No. 3 termi'
nals otthe compressor clutch relay
4P socket with a iumoer wire.
Does t he comoressor cl ut ch cl i ck?
Check l or. n opon i n t he wi r:
1. Di sconnect t he
j l mper wi re.
2. Di sconnect t he compr essor
cl ut ch 1P connect or.
t he No. 1 t ermi nal of t he com-
pressor clutch relay 4P socket
and t he t ermi nal of t he com
pressor cl ut ch 1P connect or,
Rapair open in tho wite botwoen
tha compa6sor clutch aelay ,nd
tho compressor clutch.
I nspct t ho compressor cl ut ch
(se pago 22-301.
f o page 22-12
Troubl eshooti ng
Compressor
(cont'dl
f o page 22-13
COMPRESSOR CLUICH RELAY 4P SOCKET
ECM/PCM CONNECTOR A
(32PI
*How
t o use t he backorobe set s
Connect t he backprobe adapt ers t o t he st acki ng pat ch
cords, and
connect t he cords t o a mul t i met or, Usi ng t he wi re i nsul at i on as a
gul de f or t he cont oured t i p ot t he backprobe adapt er, gent l v
sl i de
t he t i p i nt o t he connect or f rom t he wi re si de unt al i t comes i n con-
t act wi t h t het ermi nal end of t he wi re l see sect i on 11).
t uom page22- 11
Check for an open in the wi.e:
1. Di sconnect t he
j umper
wi re,
t he No. 4 t ermi nal of t he com
pressor
clutch relay 4P socket
and body ground.
I s t her e bat t er y vol t age?
Chock tor an open in thg wira:
t hen rei nst al l t he compressor
clutch relay.
2. Nlake sure the A/C and heater
tan switches are OFF, then turn
t he i gni t i on swi t ch ON l l l ).
3. Usi ng a
*Backprobe
Set
(T/ N
07SAZ
-
001000A), measure
the voltage betweon the No. 17
terminal of the ECWPCM con,
nect or A { 32P) and body
ground
with the ECM/PCM con-
n6ctors connected.
Repair open in the wiro between
the compressor clutch .elay snd
rhe ECM/PCM.
l s t here bat t ery vol t age?
22- 12
Frcm page 22-12
To page 22-14
Chock lor an opon in tha wira;
2. Di sconnoct t he Ay' C
pressure
switch 2P conneclor.
(ll).
t h No. l t ermi nal and body
grouno.
Rsprir open in the wire between
lh6 condanser fan relav and th6
A/C oro$ure switch.
Ch6ck thc A/C
pressuJo rwitch:
2. Check for continuity betwesn
t h No. 1 and No. 2 t ermi nal s
of th NC Dressure switch.
Check tor Ay'C system
pressure.
Rop.ir the A/C
pr.3suro ploblem.
Replacc th. A/C
pr4sute swhch.
A/C PRESSURE SWITCH 2P CONNECTOR
A/C PRESSURE SWITCH
(cont' d)
22-13
Troubl eshooti ng
Compressor {cont'd)
Connect t he backprobe adapt ers t o t he st 6cki ng
pat ch cords, and
connect t he cords t o a mul t i met er. Usi ng t he wi re i nsul at i on as a
gui de t or t he cont oured t i p of t he backprobe adapt er, gent l y sl i de
t he t i p i nt o t he connect or f rom t he wi re si de unt i l i t comes i n con-
t act wi t h t he t ermi nal end of t he wi re {see sect i on 11).
Check for an op6n in the wire:
1. Reconnect t he , a/ C pressure
swilch 2P connector, then turn
t he i gni t i on swi t ch ON {l l ).
2. Usi ng a
*Backprobe
Set {T/ N
07SAZ
-
001000A), measure
the voltage between the No. 5
terminal ol the EcM,rrPcM con-
nect or C { 31P) and body
ground with the ECM,PCM con-
nectors connected.
Ropair opon in the wire between
the A/C oresure switch and the
ECM/PCM.
Check l or l oos6 wi res or poor
connect i ons at t he ECM/ PCM
connectors A {32P} and C 131Pl. It
the connec,tions are good, substi-
t ut e a known-good ECM/ PCM,
and recheck. l f t he sympt om/
i ndi cat i on
goes
away, repl ace
the oriqinal ECM/PCM.
Frcm page 22 13
*How
t o uset he backprobe set s
ECM/PCM CONNECTOR C 131P)
22-14
I
l
A/C System
CONDENSER FAN RELAY 'P SOCKET
A/C THERMOSTAT 3P CONNECTOR
WIRE SIDE OF FEMALE TEBMINALS
(cont' d)
22-15
A/ C aYst em does not come on
(compressot and fanl.
Ch e c k t h e No . 5 6 f u s e i n t h e
under-hood f use/ rel aY box and
t he No. 17 f use i n t he under-dash
Iuse/relay box.
Replace the tuse(sl, and recheck.
Check for an open in the wi.e:
1, Bemove t he condenser f an
r el ay f r om t he under - hood
fuse/relay box.
(l l ).
3. i/leasure the voltage between
t he No. 4 t ermi nal of t he con-
denser f an r el ay 4P socket
and body
ground.
Ropair opgn in the wile botween
t he No. 17 t uso and t he con'
donssr lan relay.
Check th under-hood fuso/relaY
box:
No. 3 t ermi nal of t he condenser
f an r el ay 4P socket and body
grouno,
Check toJ an opon in lhe wire:
and r ei nst al l t he condenser
I an rel ay.
2. Disconnect the NC thermostat
3P connector.
(ll)
4. Measure the voltage betlveen
t he No. 3 t ermi nal and body
grou nd.
Repair open in the wite betwen
the No. l? fuse and tho A/C thet-
mostal.
To page 22 16
Troubl eshooti ng
A/C System
{cont'dl
Ftom page
22-15
. -t-
l 1 l 2 l 3 l
u----r---u
JUMPER
I
BLU/RED
wrRE
l
I
HEATER CONTROL PANEL,I4P CONNECTOR
1 2 3 ''|
f
a 5
8 9 l o l I t 12 13 14
WIRE SIDE OF FEMAI,T TERMINAU;
Ch6ck for an open in the wirsi
No. 1 t ermi nal of t he A"/ C t hermo,
st at 3P connect or and body
grouno,
Repai. open in the wire botwaen
the condonser fan rolay and th6
A/C thermGt.t.
Chck lhe A/C thermostat:
2. Reconnect the Py'C thermostat
3P connect or,
3. Connect t he No. 2 t ermi nal t o
ground
wi t h a
i umper
wi re.
Do bot h f ans run and does t he
compressor cl ut ch engage?
Check lor an open in the wire:
r , r ur n r ne r gnr t r on swnch ut - t - ,
t hen di sconnect t he
j umper
2. Fl emove t he cent er dashboard
l ower cover
(see
sect i on 20),
and di sconnect t he heat er con
t rol panel 14P connect or.
(l l ).
4, Measure t he vol t age bet ween
t he No. l 1 t ermi nal and body
ground.
Ropair open in tho wire bttt oon
the A/C th.rmGt.t.nd th. hertor
conlrol panol.
To page 22-17
22-16
From page 22-16
Chock tor en opon in the wire:
2. Di sconnect t he heat er f an
3. Check for continuity beNveen
t he No. 14 t er mi nal of t he
heat er cont rol
panel 14P con-
nect or and t he No. 6 t ermi nal
ofthe heater fan switch 6P con-
nector,
Rpair open in tho wire bstwoon
tho hoater control
panl
and the
hoater f.n switch.
Chock lor an op6n in the wir6:
No. 1 t ermi nal of t he heat er f an
swi t ch 6P connect or and body
ground.
Ch6ck f or an opon i n t he wi rs
botwecn tho hsator fan switch
and body ground. lf the wire is OK,
check lor
poor ground .t Gl01 and
G102.
Test t he heat er f an swi t ch l see
page 21-26).
Replace the hedter fan swiich.
ls the heater fan switch OK?
Chgck l or l oo! wi res or
Poor
connections at thg ho.ler coBtrol
panol 14P connecto.. It the con_
noct i on3 arg good, repl ace t he
herler contlol Danol.
HEATER CONTROL PANEL 1'P CONNECTOR
HEATER FAN SW]TCH 6P CONNECTOR
1 2
;--?
I 5 5
8 9 10
X
11 12 13 14
GRN
2
4 5 6
GRN
22- 17
A/C Thermostat
Rel ay
Test
Connect battery power
to the No. 3 termi nal , ground the
No. 2 termi nal , and connect a test l i ght between the No. 1
and No. 3 termi nal s.
NOTE: Use a 12 V, 3 W
-
18 W test ti ght.
Dip the !y'C thermostat into a cup filled with ice water, and
check the test light.
Serpentine type evaporator
The l i ght shoul d go
off at 36
-
39' F {2
-
4"C) or l ess, and
shoul d come on at 39
-
41"F
(4 -
5"C) or more.
Laminate type evaporator
The l i ght shoul d go off at 39
-
43.F
{4
-
6.C) or l ess, and
shoul d come on at 43
-
45"F (6 -
7"Cl or more.
l f t he l i ght doesn' t come on and go
of f as speci f i ed,
repl ace the Ay' C thermostat.
1 2 v , 3 w- 1 8 W
\ 1 \
Test
There shoul d be conti nui ty between the No. 1 and No.3
termi nal s when power
and ground
are connected to the
No. 2 and No. 4 termi nal s, and there shoul d be no conti -
nui ty when power
i s di sconnected.
, I I
t Y t >
l n l o
. I
I
1. ,
rE-],,'
I A
L l t i |
.,,fl--$-....
a
A/C Service Tips and Precautions
E I
The ai r condi ti oner system uses HFC-134a
(R-134a)
refri gerant and pol yal kyl enegl ycol
(PAG)
refri gerant oi l *' whi ch are not
compati bl e wi th 6p6-12 1n-tZ)
refri gerant and mi neral oi l . Do not use R-12 refri gerant or mi neral oi l i n thi s system, and do
not attempt to use R-12 servi ci ng equi pment; damage to the ai r condi ti oner system or your servi ci ng equi pment wi l l resul t.
*Sanden
SP-10:
. P/N 38897
-
Pl 3
-
A01AH: 120 mf
(4
fl ' oz. 4.2 l mp' oz)
. P/N 38899
-
P13
-
A01: 40 ml 11 l BIl ' oz, 1.4 l mp' oz)
Use onl y servi ce equi pment that i s U.L. l i sted and i s certi fi ed to meet the requi rements of SAE J2210 to remove R-134a
from the ai r condi ti oner system.
CAUTION: Exposure to air conditioner rftigerant and lublicant vapor or mist can irritatg eyes, nose and lhroat. Avoid
breathing the air conditioner refrigerant and lubticant vapor or mist.
l f acci dental system di scharge occurs, venti l ate work area before resumi ng servi ce'
R-134a servi ce equi pment or vehi cl e ai r condi ti oner systems shoul d not be pressure tested or Ieak tested wi th compressed
ai r .
@
Some mixtures ol air and R.i34a havs been shown to b9 combusiible at elevated
pressures and can resuh
iiTiiffiiplo"ion causing iniury or property damage. Nevet use compresscd air to pressure test R-13/+a servica equip-
ment or vehicle air conditionor systems.
Addi ti onal heal th and safetY i nformati on may be obtai ned from the refri gerant and l ubri cant manufacturers'
t. Al ways di sconnect the negati ve cabl e from the battery whenever repl aci ng ai r condi ti oni ng
parts.
2. Keep moi sture and dust out of the system. When di sconnecti ng any l i nes, pl ug or cap the fi tti ngs i mmedi atel y; don' t
remove the caps or
pl ugs unti l
j ust
before
you reconnect each l i ne.
3. Before connecti ng any hose or l i ne, appl y a few drops of refri gerant oi l to the O-ri ng'
4. When ti ghteni ng or l ooseni ng a ti tti ng, use a second wrench to support the matchi ng fi tti ng'
5. When di schargi ng the system, use a R-134a refri gerant Recovery/Recycl i ng/chargi ng
system; don' t rel ease refri ger-
ant i nto the atmosphere
6. Add refri gerant oi l after repl aci ng the fol l owi ng
parts:
NOTE:
. To avoi d contami nati on, do not return the oi l to the contai ner once di spensed, and never mi x i t wi th other refri ger-
ant oi l s.
. l mmedi atel y after usi ng the oi l , repl ace the cap on the contai ner, and seal i t to avoi d moi sture absorpti on
. Do not spi l l the refri gerant oi l on the vehi cl e; i t may damage the pai nt; i fthe refri gerant oi l contacts the pai nt, wash
i t off i mmedi atel Y.
Condenser
.......20 m/
(2/3
fl ' oz' 0.7 l mp' ozl
Evaporator ........................................
i l s
m I 11
213 tl ' oz' 1.6 l mp' ozl
Li ne or hose...........
10 ml
(1/3
fl ' oz. 0.4 l mp' oz)
Receiver/Dryer
10 ml
(1/3
fl'oz, 0.4 lmp'oz)
Leakage repair
25 m/
(5/6
ll'o2, 0.9 lmp'ozl
compressor
.., For compressot tepl acement, subtract the vol ume of oi l drai ned {rom the
rmoved comDressor from 130 m/
(4
1/3 fl'oz,
'1.6
tmpoz), and drain the calculated
volum of oil from the new compressor: 130 m0
l'l
l/3 floz, 4'6 lmp'oz)
-
volume
of removed comprgssot = Volume to drain from new compressor'
NOTE: Even i f no oi l i s drai ned from the removed compressor, don t dral n more
than 50 m/ \1
2/3 tl ' o2,1.8 l mp' oz) from the new compressor.
REMOVED
NEW
COMPRESSOR
COMPRESSOR
6(C re
w
w
f f i f f i
I I l6_d r
omrr,rrruc
l
h['-saue
uver
-.ffir
volunae
]
130 m{ t4 1/3 rr'oz' 16 rmP ozr
22-19
A/C System Torque Specifications
O
Di scharge hose to the compressor (6
x i .0 mm) ...............
........................ 9.S N.m
0.0 kgf.m, 7.2 l bf.ft)
@
Di schargo hose to the condenser (6
x 1.0 mm)...................
....................... 9.8 N.m
0.0 kgf.m, 7.2 tbf.ft)
@ Condenser pi pe to the condenser
{6 x 1.0 mm| ...................
...................... 9.8 N.m
fl .0 ksf.m, 7.2 l bf.ft)
@
Condenser pi pe to tho recei ver/dryer
{6 x i ,0 mm).........
.......................... 9,g N.m (1.0
kgt.m, 7.2 l br.ft}
@
Recei ver pi pe
A to the rocei ver/dryer (6
x 1.0 mm)...,.....
.....................,.... 9.8 N.m 0.0 kgf.m, 7.2 tbf.ft)
@
Receiver pipe B to the receiver pipe A
t3 N.m
{1.3 kgt.m, 9.4 tbf.ft)
O
Receiver pipe
Cto the receiver pipe B
t3 N.m
(1.3
kgf.m,9.it lbf.ft)
@
Recei ver pi pe
C to the evaporator
(6
x 1.0 mm) ...............
.........................
9.8 N.m 0.0 kgf.m, 7.2 l bf.ft)
O
Sucti on pi pe
B to the evaporatol
(6
x 1.0 mm)................
.......................... 9.8 N.m
{1.0 kgf.m, 7.2 tbf.ft)
@ Sucti on pi pe A to the sucti on pi pe B
........................... 31 N.m
{3.2 kgf.m, 23 tbf.ftl
@
Sucti on hose to tho susti on pi pe A...
........................... 3t N.m
{3.2 kgt.m, 23 l bf.ft)
@)
Sucti on hose to the compressor (6
x 1.0 mm),..............,...
........,,.............. 9.8 N.m
{i .0 kSf.m, 7.2 l bf,ft}
@
Compressor i o the comp.essor bracket
(8
x 1.25 mm)..,
.......,..,.......-....,,..- 24 N.m {2.4 kgl .m, 17 l bf.ft}
@
Compressor bracket to the cyl i ndor bl ock
{10 x 1.25 mm} ..................................................._...... /14
N.m
(4.S
kgr.m, 33 tbf.ft)
@
Compressor bracket i o the l eft front engi ne mount
{12 x t.2S mm) ..........................................
59 N.m
(6.0
kgf.m, 43 tbr.ft)
22-20
ru
A/C System Service
Recovery
Use onl y servi ce equi pment that i s U.L
-l i sted
and i s cer-
ti fi ed to meet the requi rements of SAE J2210 to remove
HFC-134a
(R-134a)
from the ai r condi ti oner system
CAUTION: Exposure to air conditioner rfrigersnt and
l ubri cant vapol or mi st c8n i rri tate syes, nose and
ihroat. Avoid breathing the air conditioner lgfrigerant
and lubricant vapol or mist.
l f acci dental system di scharge occurs, venti l ate work
area before resumi ng servi ce.
R-134a servi ce equi pment or vehi cl e ai r condi ti oner sys-
tems shoul d not be pressure tested or l eak tested wi th
comDressed atr.
!@
some mixtures of air and R-134a have been
strown to be combustible at elovated
pressures and can
resull in fire or explosion causing inlury or
prope y
dam'
age. Nver use compressed air to
pressure test R'i34a
srvice equipment ot vehicle air conditionsr systems.
Addi ti onal heal th and safety i nformati on may be obtai ned
from the refrigerant and iubricant manuJacturers.
Connect a R-134a refri gerant Recovery/Recycl i ng/
Chargi ng System to the vehi cl e, as shown, fol l owi ng
Measure the amount of refri gerant oi l removed from
the A,/C system after the recovery
process i s com-
pl eted.
NOTE: Be sure to i nstal l the same amount of new
refrigerant oil back into the ly'C system before charg-
I ng.
Recovery/Recyclin
g/Charging system
1 .
22-21
A/G System Service
Performance Test
The Derformance test wi l l hel o determi ne i f the ai r con-
di ti oner system i s operati ng wi thi n speci fi cati ons.
Use onl y servi ce equi pment that i s U.L.-l i sted and i s cer-
HFC-134a
(R-134a)
from the ai r condi ti oner svstem.
CAUTION: Exposure to air conditioner relrigerant and
l ubri cant vapor ol mi st can i rti tate eyes, nose and
throat. Avoid broathing the air conditioner retrigerant
and lubricant vapor or mist.
area before .esumi ng servi ce,
tems shoul d not be
pressure
tested or l eak tested wi th
compressed ai r.
!@
som mixtures of air 8nd R-134a have been
shown to b combustible at elevated p.essures
and can
resul t i n fi re or expl osi on causi ng i ni ury or property
damage. Nev6r uss compressed air to pressure
togt R.
134a sarvice equipment or vohicl air conditioner sy3-
tems.
from the refrigerant and lubricant manufacturers.
1. Connect a R- 134a r ef r i ger ant Recover / Recycl i ng/
Chargi ng System to the vehi cl e. as shown, fol l ow-
i ng the equi pment manufacturer' s i nstructi ons.
2. l nser t a t her momet er i n t he cent er vent out l et .
Determi ne the rel ati ve humi di tv and ai r temDera-
ture.
Test condi ti ons:
. Avoi d di rect sunl i ght,
o Open hood.
. Open front doors.
.
Set the temperature control l ever to MAX. COOL,
the mode control swi tch on VENT and the reci r-
cul ati on control swi tch on RECIRCULATE.
. Turn the IVC swi tch on, and the heater fan swi tch
on MAX.
. Run the engi ne at 1,500 rpm.
. No dri ver or passengers
i n vehi cl e
After runni ng the ai r condi ti oni ng for 10 mi nutes
under the above test condi ti ons, read the del i very
temperature from the thermometer i n the dash vent
and the hi gh and l ow system pressure from the !y' C
gauges.
Recovory/Recycling/charging Systom
5. To compl ete the charts:
. Markthe del i very temperature al ong the verti cal l i ne.
o Markthe i ntake temperature
(ambi ent
ai r temperature) al ongthe bottom l i ne.
. Draw a l i ne strai ght up from the ai r temperature to the humi di ty
. Mark a Doi nt one l i ne above and one l i ne bel ow the humi di ty l evel
(10%aboveand
10% bel owthe humi di ty l evel ).
. From each poi nt, draw a hori zontal l i ne across the del i very temperature.
. The del i verv temoerature shoul d fal l between the two l i nes
. Compl ete the l ow si de
pressure test and hi gh si de pressure test i n the same way.
. Anv measurements outsi de the l i ne maY i ndi cate the need for further i nspecti on
kPa
lkgf/cm'l
lpsil
80/o
307o
2900
-
(30t
t0t
2500
-
t25)
t3601
2000
-
t20)
1280t
1500
-
t15t
t2101
980
-
{ 10)
11lol
INTAKE
PRESSURE
DELIVERY
PRESSURE
80vo
kPa
{kgt/cmz)
tpsil
"F
{"c}
l
I
l
l
l
ri
68
(20t
59
t l st
DELIVERY
PRESSURE
400
-
l,ll
t57l
85
{30t
77
l25l
50
{ 10}
11
(5t
300
-
t3)
li(}l
INTAKE
PRESSURE
200
-
tzl
I2Al
100
{ 11
l t
4l
0 -
DELIVERY
TEMPERATURE
DELIVERY
TEMPERATURE
95
104
"F
(35)
(,r01
fC)
6 a n a 6
l20l
(251
t30)
INTAKE TEMPERATUFE
22-23
A/C System Service
Pressure Test Chart
NOTE: Performance Test i s on page 22-22.
\
Test results Related symptoms Probable cause Remedy
Di schar ge
( hi gh)
pressure
abnor,
mal l y hi gh
After stoppi ng compressor, pres-
sure drops to about 200 kPa
{2.0 kgfl cm,,28 psi ) qui ckl y.
and
t hen f al l s gr adual l y.
Ai r i n system Recover, evacuate, and
recharge with specified amount.
Evacuati on: see page 22-36
Chargi ng: see page 22-37
Reduced or no ai r f l ow t hr ough
condenser
.
Cl ogged condenser fi ns
.
Condenser fan not work-
i ng properl y
Cl ean.
Check vol tage and fan rpm.
Check fan di recti on.
Li ne to condenser i s excessi vel y
hot.
Restri cted fl ow of refri ger
ant i n system
Restri cted l i nes
Di scharge pres-
sur e abnor mal l y
Hi gh and l ow pressures
are bal
anced soon after stopping compres-
sor. Low si de i s hi gherthan normal .
.
Faul ty compressor di s-
charge val ve
.
Faul ty compressor seal
Repl ace the compressor.
Outl et of expansi on val ve i s not
frosted, l ow pressure gauge i ndi -
cates vacuum.
.
Faul ty expansi on val ve
.
Moi sture i n system
.
Repl ace.
.
Recover, evacuate. and
recharge wi th speci fi ed
amount.
Sucti on (l ow)
pressure
abnor-
mal l y l ow
Sucti on pres-
sur e abnor mal l y
hi gh
S""tl"" ""d d' ;
l
cnarge pres-
sures abnormal l y
nr gn
Expansi on val ve i s not frosted, and
l ow pressure
l i ne i s not col d. Low
pressure gauge i ndi cates vacuum.
Frozen expansi on val ve
Faul ty expansi on val ve
Repl ace t he expansi on val ve.
Di scharge temperature i s l ow, and
the ai r fl ow from vents i s restri cted.
Frozen evaporator Run the fan wi th compressor
off, then check A,/C thermostat.
Expansi on val ve i s frosted.
Recei ver/dryer outl et i s cool , and
i nl et i s warm (shoul d
be warm
11lr9i!99!:!.
_
Low pressure hose and check
j oi nt
are cool er than the tempera
tu re around evaporator.
l -l ,gh ""d l "* pr""sure
are equal -
i zed as soon as the compressor i s
stopped, and both gauges
fl uctu
]
at e whi l e r unni ng.
Reduced ai r fl ow through con-
I
denser.
Sucti on pressure
i s l owered when
condenser i s cool ed by water.
Cl ogged expansi on val ve
Cl ogged recei ver/dryer
.
Expansi on val ve open too
l o ng
.
Loose expansi on capi l l ary
t ube
Excessi ve refri gerant i n sys-
tem
.
Faul ty gasket
.
Faul ty hi gh pressure val ve
.
Forei gn parti cl e stuck i n
hi gh pressure val ve
Cl ean or repl ace.
Repl ace.
Repai r or repl ace.
Recover, evacuate, and
recharge wi th speci fi ed amount.
Repl ace the compressor.
.
Cl ogged condenser fi ns
.
Condenser fan not work-
i ng properl y
Cl ean condenser.
Check vol tage and fan rpm.
Check fan di recti on.
Sucti on and di s-
charge pressure
abnormal l y l ow
Low pressure hose and metal end
areas are cool er than evaporator.
Temperature around expansi on
val ve i s too l ow compared wi th
that around recei ver/dryer.
Cl ogged or ki nked l ow pres-
sure hose parts
Repai r or repl ace.
Cl ogged hi gh pressure
l i ne Repai r or repl ace.
Ref ri gerant l eaks Compressor cl utch i s di rty. Compressor shaft seal leaking Repl ace the compressor.
Compressor bol t{s) are di rty. Leaki ng around bol t(s) Ti ghten bol t(s) or repl ace com-
pressor.
Compressor gasket i s wet wi th oi l . Gasket l eaki ng Repl ace the compressor.
22-24
Evaporator
Replacement
' ]
Remove the battery.
Recover the refri gerant wi th a Recovery/Recycl i ng/
Chargi ng System
(see page 22 21).
3, Remove the bol ts, then di sconnect the sucti on and
recei ver l i nes from the evaporator.
NOTE: Pl ug or cap the l i nes i mmedi atel y after di s-
connecti ng them to avoi d moi sture and dust con-
tami natron.
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgl . m,
7.2 tbt.ftt
Remove the gl ove box
(see
secti on 20).
Remove the sel f-tappi ng screw and the passenger' s
dashboar d l ower cover . Remove t he bol t , t he nut
and the knee bol ster, then remove the fi ve bol ts and
the gl ove box frame.
2.
SUCTION LINE
RECEIVER LINE
. 1. . .
,;1
,,
i1:-.....
-;1
t'i
i',
r'l--.;:,i,,
,. i
6. Di sconnect the connector from the A,,/C thermostat,
and remove the wi re harness from the evaporator'
Remove the four sel f-tappi ng screws, the mounti ng
boi t and t he mount i ng nut . Di sconnect t he dr ai n
hose. then remove the evaPorator.
1. 0 mm
N. m {1. 0 kgl . m. 7. 2 l bt f t }
: 1
i
. , i , I
\
7.
THERMOSTAT
CONNECTOR
EVAPORATOR
Instal l i n the reverse order of removal . Make note of
l f you' re i nstal l i ng a new evaporator, add refri ger-
ant oi l
(SP-10) (see page 22-191.
Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them.
NOTE: Be sure to use the ri ght O-ri ngs for HFC-
134a {R-134a)
to avoi d l eakage.
Appl y seal ant to the grommets.
Make sure that there i s no ai r l eakage.
Charge the system
(see page 22-311, and test its
performance
(see page 22-22J.
a
a
a
ORAIN HOSE
22-25
Evaporator
1 .
1201 5 mm
{4. 7 10. 2 i n)
2.
3.
Overhaul
Pul l out the Ay' C thermostat sensor from the evapo-
rator fi ns.
Remove the sel f-tappi ng screws and cl amps from
the housi ngs.
Careful l y separate the housi ngs, then remove the
evaporator.
l f necessary, remove the expansi on val ve.
NOTE: When l ooseni ng the expansi on val ve nuts, use
a second wrench to hol d the expansi on val ve or the
evaporator pipe. Otherwise, they can be damaged.
5. Assembl e i n the reverse order of di sassembl v. Make
note of fol l owj ng i tems.
Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a t hi n coat of r ef r i ger ant oi l bef or e
i nstal l i ng them,
NOTE: Be sure to use the ri ght O-ri ngs for HFC
134a
(R-134a)
to avoi d l eakage.
Instal l the expansi on val ve capi l l ary tube so that
i t i s i n di rect contact wi th the sucti on l i ne. Then
wrap wrth tape.
Rei nstal l the Iy' C thermostat sensor to i ts ori gi nal
l ocati on.
6th fin trom inlet side
Serpentine type:
TAPE
Repl ace.
Make sure t here i s no f orei gn mat t er st uck bet ween
t he capi l l ary t ube and out l et l i ne.
UPPER HOUSING
N.m {0.8 kgl.m,
rbr.ftl
CAPILLARY TUBE
EXPANSION VALVE
a
Laminate type:
6 0 1 5 mm
12.1 ! 0,2 inl
EVAPOBATOR
bl ow di rt out of t i ns
wi t h compressed ai r.
6th fin from outlet side
N.m {2.it kg{.m,
A/C THERMOSTAT
Test page
22 18
22-26
LOWER HOUSING
Compressor
Replacement
' 1.
2.
5.
6.
I t t he compr essor i s mar gi nal l y oper abl e, r un t he
engi ne at i dl e speed, and l et t he ai r condi t i oner
work tor a few mi nutes, then shut the engi ne off.
Di sconnect the negati ve cabl e from the battery.
Recover the refri gerant wi th a Recovery/Recycl i ng/
Chargi ng System l see
page 22-211.
Remove the bol ts, then di sconnect the sucti on and
di scharge l i nes from the compressor.
t ami nat i on.
6 x 1 . 0 mm
DISCHARGE LINE
Remove the condenser
(see page 22-35).
NOTE: Do not di sconnect the di scharge hose from
l he condenser-
Remove the power steeri ng pump bel t {see secti on
171.
SUCTION LINE
7. Loosen t he cent er nut of t he i dl er
pul l ey and t he
adj usti ng bol t, then remove the Ay' C compressor bel t
from the
pul l eys, Remove the two mounti ng bol ts
from the l eft front engi ne mount, then remove the
A,/C compressor bel t by passi ng i t through the gap
between the body and the l eft front engi ne mount.
ADJUSTING BOLT
1 . 0 x 1 2 5 mm
a4 N.m {4.5 kg{.m,33 lbtftl
8. Remove t he f our mount i ng bol t s and t he compressor.
(cont' d)
J
I
I
CENTER NUT
LEFT FRONT
COMPRESSOR
2il N m 12.4 kg[.m, 17 lbf.ftl
22-27
Compressor
Replacement
(cont'd)
9. l f necessary, remove the compressor bracket as fol -
tows.
-
Remove the nut and the washer.
NOTE: When ti ghteni ng the nut of the l eft front
engi ne mount, make sure the washer i s set prop-
erl y on the l eft front engi ne mount as shown.
-
Remove the four mounti ng bol ts and the com-
pressor
bracket.
12 r 1. 25 mm
59 N.m {6.0 kgl.m,
43 tbf.ftl
COMPRESSOR
BRACKET
1. 0 x 1. 25 mm
a{ N.m 14.5 kgt m.33 tbf.ft)
LEFT FRONT
ENGINE MOUNT
WASHER
22-28
10. l nstal l i n the reverse order of removal . Make note of
l f you' re i nstal l i ng a new compressor, drai n al l
the refri gerant oi l from the removed compressor,
and measure i ts vol ume. Subtract the vol ume of
drai ned oi l l rom 130mf 14 1B fl .oz,4.6 l mp.oz);
the resul t i s the amount of oi l you shoul d drai n
from the new compressor
(through
the sucti on
fitting).
Repl ace the O-ri ngs wi th new ones at each fi t-
t i ng, and appl y a t hi n coat of r ef r i ger ant oi l
NOTE: Be sure to use the ri ght O-ri ngs for HFC-
134a
(R-134al to
avoi d l eakage.
Use refri gerant oi l
(SP-10l for
R-134a Sanden and
Hadsys spi ral type compressors onl y.
To avoi d contami nati on, do not return the oi l to
the contai ner once di spensed, and never mi x i t
wi th other refri gerant oi l s.
l mmedi atel y after usi ng the oi l , repl ace the cap
on the contai ner. and seal i t to avoi d moi sture
absorpti on.
Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the pai nt; i f the refri gerant oi l con-
tacts the
pai nt, wash i t off l mmedi atel y.
Adjust the Ay'C compressor belt
(see page
22-341
and the
power
steering
pump
belt {see section 17).
Charge the system
(see page 22-371, and test its
performance (see page 22-22' ).
lllustrated Index
CENTER NUT
Repl ace.
ARMATURE PLATE
sHrM{s)
Repl ace.
Repl ace.
ROTOR PULLEY
SNAP RING A
Repl ace.
FIELD COIL
COMPRESSOR
{Do not disassemble.)
----"-}l
q\
q \
_-2
RELTEF vALvE
a-
Repl acement, page 22-33
THERMAL PROTECTOR
Repl ace.
I nspect i on,
page 22-30
Repl acement ,
page 22 33
a
22-29
Compressor
Clutch Inspection
Check the pl ated parts of the armature pl ate for col or
changes, peel i ng
or ot her damage. l f t her e i s dam-
age, repl ace the cl utch set.
Check the rotor pul l ey beari ng pl ay
and drag by rotat-
i ng the rotor pul l ey by hand. Repl ace the cl utch set
wi th a new one i t i t i s noi sy or has excessi ve pl ay/drag.
Measure the cl earance between the rotor pul l ey
and
the armature pl ate
al l the way around. l f the cl ear-
ance i s not wi thi n speci fi ed l i mi ts, the armature pl ate
must be removed and shi ms added or removed as
requi red, fol l owi ng the procedure
on page
22-31.
Cl earanca: 0.5 t 0.15 mm {0.0201 0.006 i n}
NOTE: The shi ms are avai l abl e i n four thi cknesses:
0. 1 mm, 0. 2 mm. 0. 4 mm and 0. 5 mm
22-30
. Rel ease the fi el d coi l connector from the hol der, then
di sconnect i t. Check the thermal protector for conti -
nui t y. l I t her e i s no cont i nui t y. r epl ace t he t her mal
Drotector.
Check resi stance of the fi el d coi l .
Fi el d Coi l Resi stance:3.2 t 0.15 ohms at 68"F {20"C1
l f resi stance i s not wi thi n speci fi cati ons, repl ace the
fi el d coi l .
I
I
i
Clutch Overhaul
1. Remove the center nut whi l e hol di nq the armature
ol ate wi th the tool .
CENTER NUT
17.6 N.m {1.8 kg{.m, 13 lbf.ft}
2. Remove the armature pl ate by pul l i ng i t up by hand.
ARMATURE PLATE
. l
. ) '
t
A/C CI-UTCH HOLDER
(Commercially
available)
Robinai.: P/N 10204
Kent-Moore: P/N J37872
/ t ,
. \ \
3. Remove snap ri ng B wi th snap ri ng pl i ers.
NOTE:
a Be car ef ul not t o damage t he r ot or pul l ey and
compressor duri ng removal /i nstal l ati on.
. Once snap ri ng B i s removed, repl ace i t wi th a
new one,
o
-..::::.:...-
4. Remove t he rot or pul l ey f rom t he shaf t wi t h a pul l er
and t he speci al t ool .
NOTE: Put t he cl aws of t he pul l er on t he back of t he
r ot or pul l ey, not on t he bel t ar ea; ot her wi se t he
rot or pul l ey can be damaged.
(cont' d)
22-31
Compressor
Cl utch Overhaul
(cont' d)
5. Remove the screw from the fi el d coi l ground termi -
nal , t hen di s c onnec t t he f i el d c oi l c onnec t or .
Remove snap r i ng A wi t h snap r i ng pl i er s, t hen
remove the fi el d coi l ,
NOTE:
. Be careful not to damage the fi el d coi l and com-
pressor duri ng remove/i nstal l ati on.
. Once snap ri ng A i s removed, repl ace i t wi th a
new one.
. When i nstal l i ng the fi el d coi l , al i gn the boss on
the fi el d coi l wi th the hol e i n the compressor.
SNAP RING A
Repl ace.
6. Posi ti on the rotor pul l ey squarel y over the fi el d coi l .
Press the rotor
pul l ey
onto the compressor boss
wi t h t he speci al t ool . l f t he r ot or pul l ey does not
press
on strai ght, remove i t, and check the rotor
pul l ey and compressor boss for burrs or damage.
CAUTI ON: Maxi mum
pr ess l oad: 39, 200 kPa
(400
kgt/cm', 5,690
psil
Preit
T
HUB ASSEMBLY
GUIDE ATTACHMENT
07965
-
6920500
FOTOR
PULLEY
-
22-32
7. Assembl e i n t he r ever se or der of di sassembl y.
Make note of the fol l owi ng i tems.
. Instal l the fi el d coi l wi th the wi re si de faci ng down.
. Cl ean t he r ot or
pul l ey
and compr essor sl i di ng
surfaces wi th non-pet.ol eum sol vent,
. Make sure the snap ri ngs are ful l y seated i n the
groove.
. Make sure that the rotor
pul l ey turns smoothl y
after it's reassembled.
. Route and cl amp the wi res
properl y or they can
be damaged by the rotor pul l ey.
Thermal Protector Replacement
1. Bemove the bol t. the ground termi nal and the hol d-
er. Di sconnect the fi el d coi l connector. then remove
the thermal protector.
7.{ N.m {0.75 kgl.m, 5,4lbf.ftl
THERMAL
PROTECTOR
Repl ace the thermal
protector
wi th a new one, and
appl y si l i cone seal ant to the top of the thermal pro-
tector.
SILICONE SEALANT
3. l nst al l i n t he reverse order of removal .
Relief Valve Replacement
1 .
5.
Remove the rel i ef val ve and the O-ri ng,
NOTE:
. Do not l et the compressor oi l run out.
. Make sure that no forei gn matter enters the sys-
tem.
RELIEF
VALVE
9. 8 N. m
(1. 0
kgt m,
7.2 rbnft)
O.RING
Repl ace.
Cl ean the mati ng surfaces.
Repl ace the O-ri ng wi th a new one at the rel i ef val ve,
and appl y a t hi n coat of r ef r i ger ant oi l bef or e
i nstal l i ng i t.
NOTE:
. To avoi d contami nati on, do not return the oi l to
the contai ner once di spensed, and never mi x i t
wi th other refri gerant oi l s.
. l mmedi atel y after usi ng the oi l , repl ace the cap
on the contai ner, and seal i t to avoi d moi sture
absorpti on.
. Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the
pai nt; i f the refri gerant oi l con-
tacts the pai nt, wash i t off i mmedi atel y.
Instal l and ti ghten the rel i ef val ve.
Charge the system
(see page 22-311, and test i ts
performance (see page 22-221.
Qt )
.Y,/
,
22-33
A/C Compressor Belt
Adjustment
Deflection Method
1. Appl y a force of 98 N
(10
kgf, 22 l bf), and measure
the defl ecti on between the A,/C compressor and the
crankshaft pul l ey.
A/C Compressor Belt
Used Bel t:7.5
-
9.5 mm
10.30
-
0.37 i n)
New Bel t: 5.0
-
6.5 mm
(0.20 -
0.26 i n)
NOTE:
. l f there are cracks or any damage evi dent on the
bel t, repl ace i t wi th a new one.
.
"Used
bel t" means a bel t whi ch has been used
for fi ve mi nutes or more.
.
"New
for l ess than fi ve mi nutes.
2. Loosen the center nut ofthe i dl er pul l ey,
3. Turn the adj usti ng bol t to get proper bel t tensi on.
4. Reti ghten the center nut ofthe i dl er pul l ey.
5. Recheck the defl ecti on of the Ay' C compressor bel t.
22-34
\
Tension Gauge Method
' 1.
Attach the speci al tool to the Ay' C compressor bel t as
shown bel ow, and measure the tensi on of the bel t.
A/C Comprossor Belt
Used Belt: 340
- it90
N
(35 -
50 ksf, 77
-
110 lbfl
New Belt: 690
-
830 N
(70 -
85 kgf, 150
-
190 lbf)
NOTE:
o Fol l ow the manufacturer' s i nstructi ons tor the
bel t tensi on gauge.
. l f there are cracks or any damage evi dent on the
bel t, repl ace i t wi th a new one.
.
"Used
for i i ve mi nutes or more.
.
"New
for l ess than fi ve mi nutes.
2. Loosen the center nut ofthe i dl er pul l ey.
3. Turn the adj usti ng bol t to get proper bel t tensi on,
4. Reti ghten the center nut ofthe i dl er pul l ey.
5. Recheck the tensi on of the Ay' C compressor bel t.
Condenser
Replacement
1 . Recover the refri gerant wi th a Recovery/Recycl i ng/
Chargi ng System
(see page 22 21).
Di sconnect the condenser fan connector from the
A/C wi re harness, then remove the Ay' C wi re harness
from the condenser fan shroud.
2.
CONDENSER
FAN
CONNECTOR
3. Remove t he bol t s, t hen di sconnect t he di schar ge
and condenser l i nes from the condenser.
raml naton.
A/C WIRE HARNESS
6 x 1 . O m m
DTSCHARGE L| NE
9. 8 N. m 11. 0
CONDENSER
9.8 N.m {1.0 kgf.m, 7.2 lbf ft)
6 x 1 . 0
22-35
4. Remove the bol t from the sucti on hose bracket, and
remove the two bol ts and the upper mount bracket.
Remove the condenser assembl y by l i fti ng i t up
NOTE: Be carefui not to damage the condenser fi ns
when removi ng the condenser assembl y.
UPPER MOUNT BRACKET
5. l nstal l i n the reverse order of removal . Make note of
. l f you' re i nstal l i ng a new condenser, add refri ger-
ant oi l
(SP-10) (see
Page
22-19).
. Repl ace the O-ri ngs wi th new ones at each fi t-
t i ng, and appl y a t hi n coat of r ef r i ger ant oi l
NOTE: Be sure to use the ri ght O-ri ngs for HFc-
1344
(R-' 134a) to avoi d l eakage.
a Be car ef ul not t o damage t he condenser f i ns
when i nstal l i ng the condenser assembl y.
. Charge the system {see
page 22-37). and test i ts
performance {see Page
22-221
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m. 7. 2l bf f t l
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgl . m, 7. 2l bI . f t l
A/C System Service
Evacuati on
Use onl y servi ce equi pment that i s U.L.-l i sted and i s cer
HFC-134a {R 134a) trom the ai r condi ti oner system.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irrilate eyes, nose and throat.
Avoid breathing the air conditioner refrigerant and lubri-
cant vapor or mist.
tems shoul d not be Dressure tested or l eak tested wi th
compressed arr.
@
some mixtures ot air and R-134a have bn
shown to be combustible at elevatd ptessures and can
resul t i n ti re or expl osi on causi ng i ni ury or
property
damage. Never use compressed air to pressure
test R-
134a service equipment or vehicle air conditioner sys-
Iems.
from the refri gerant and l ubri cant manufacturers.
' 1.
When an Ay' C System has been opened to the atmo-
sphere, such as duri ng i nstal l ati on or repai r, i t must
be evacuated usi ng a R-134a refri gerant Recovery/
Recycl i ng/Chargi ng System.
(l f
the system has been
open for several days, the recei ver/dryer shoul d be
repl aced, and the system shoul d be evacuated for
several hours.)
2. Connect a R-134a refri gerant Recove ryl Recycl i ng/
Chargi ng System to the vehi cl e, as shown, fol l ow-
i ng the equi pment manufacturer' s i nstructi ons,
NOTE: l f l ow pressure does not reach more than 93.3
kPa
( 700
mmHg, 27. 6 i n. Hg) i n 15 mi nut es, t her e i s
probabl y a l eak i n the system. Parti al l y charge the
system, and check for l eaks
(see
Leak Test).
Recovery/Recyclin g/Chargin g System
\
22-36
Chargi ng
Use onl y servi ce equi pment that i s U.L.-l i sted and i s cer-
ti ti ed to meet the reoui rements of SAE J22,!0 to remove
HFC-' 134a
(R-134a)
CAUTION: Exposure to ai r condi ti oner refri gerant and
l ubri cant vapor or mi st can i rri tate eyes, nose and
thl oat. Avoi d breathi ng the ai r condi ti oner retri gerant
and l ubri cant vaoor or mi st.
l f acci dent al syst em di schar ge occur s, vent i l at e wor k
ar ea bef or e r esumi ng ser vi ce. Addi t i onal heal t h and
safety i nformati on may be obtai ned from the refri gerant
and l ubri cant manufacturers.
Refrigerant capacity: 550:go
I
{22.9:q s oz)
CAUnON: Do not overcharge the system; the compressor
will be damaged.
Connect a R-134a refri gerant Recovery/Recycl i ng/Chargi ng
System to the vehi cl e, as shown, fol l owi ng the equj pment
manufacturer' s i nstructi ons.
Recovery/Recycling/Charging System
LOW. PRESSURE
SI DE
Leak Test
Use onl y servi ce equi pment that i s U.L. l i sted and i s cer-
HFC-' 134a
(R-134a)
CAUTION: Exposure to ai r condi ti oner refri gerant and
lubricant vapor or mist can irritate eyes, nose and throat.
Avoid breathing the air conditioner retrigerant and lubri-
cant vapor or mist.
l f acci dent al syst em di schar ge occur s, vent i l at e wor k
R l 34a servi ce equi Dment or vehi cl e ai r condi ti oner sys-
tems shoul d not be pressure tested or l eak tested wi th
compressed ai r.
![@
some mi xtures ot ai r and R-13,1a have
been shown to be combusti bl e at el evated
pressures
and can resul t i n fi re or expl osi on causi ng i ni ury or
property damage. Never use compressed ail to pressure
test R-134a service equipment or vehicle air conditioner
systems.
from the refri gerant and l ubri cant manufacturers.
1. Connect a R-134a refri gerant Recove ryl Recyc l i n g/
Char gi ng Syst em t o t he vehi cl e, as shown i n t he
previ ous col umn fol l owi ng the equi pment manufac-
turer' s i nstructi ons.
NOTEr Be sure to i nstal l the same amount of new
refri gerant oi l back i nto the A,/C system before charg-
I ng.
Open hi gh pressure val ve to charge the system to
the speci fi ed capaci ty, then cl ose the suppl y val ve,
and remove the chargi ng system coupl ers.
Refrigerant capacity: 650130
O 122.9:1a
ozl
Check the system for l eaks usi ng a R-134a refri ger-
ant l eak detector wi th an accuracy of l 4 g (0.5
oz)
per year or better.
l f you fi nd l eaks that requi re the system to be opened
(to
repai r or repl ace hoses, fi tti ngs, etc.), recover the
system accordi ng to the Recovery Procedure on page
22- 21.
After checki ng and repai ri ng l eaks, the system must
be evacuated l see System Evacuati on on page 22 36)
3.
4.
5.
22- 37
Electrical
Speci af Toof s
. . " " " " " " ' 23- 2
Troubleshooting
Ti os and Precauti ons ..............' .
" " "" 23-3
Fi ve-step Troubl eshooti ng
........" """" """ 23-5
wire color codes
"" 23-5
Schemati c
SYmbol s ..... ....' .' ......' . "" " 23-6
Relay and Control Unit Locations
Engi ne Compartment
..' .............' . . " """" 23-7
Dashboard
" " 23-8
Door ......................
""""' 23-12
,Ai rbags
...,........,...
........ Sesti on 24
Air Conditioning
. " Section 2l
Atternator
.......,........,........,..23-98
Anti-lock Brake Svstem IABSI
... .." " " Section 19
System .. . "" Sestion 14
Bat t el y . . . . . . . . . . . . . . . . . .
" " " " " " " 23- 77
Blower Controls
Section 21
Chargi ng System
" """"""23' 72
Connestor ldentification and Wire Harness
Rout i ng . . . . . . . . . . . . . . . . .
" " " " ' 23- 11
crui se contl of
" """""""' 23-2oa
Dash Lights Brightness Controller . " " "" 23'160
Fan Control s
....... """ " 23-111
Fuel Pump
........."""
Secti on 11
Fuses , . . . . . . . . . . . . . . . . . . . .
" " " " " " 23- 52
PGM-FI Control System ... .................
"" Seqti on 11
*G.uges
Ci rcui t Di .gram
" "" "23-116
FuefGauge
"" " """"' 23-126
Speedometer
........'
" " 23-114
cround Di stri buti on
...........23-65
Heatet controls
"""" section 21
* Hor n
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . - . . 23- 173
,fgni ti on
Swi tch
.......-.-..........23-75
lgnition System
" 23-88
*A/T
Gear Posi ti on Indi cator ..... .... ... ........ . "" 23-133
i l ntegrated
Control Uni t ........,.........-.-...............,..
23-140
fnterlock System
""""""""' 23-124
Lighting System
- """ " 23-146
Lights, Exteriol
Bsck-up Lights
""""23-151
Brake Lights
"" " "" 23-158
Davti me Runni ng Li ghts
(Canadal ...' . " "' 23-150
Front Parki ng Li ghts ....... .... ............ . "" 23-151
Front Turn Si gnal Li ghts......' .........
" " 23-151
Headl i ghts
.. " "" " 23-151
Hi gh Mount Brake Li ght ... .......... "" "" 23-159
" "" 23-156
Tai l l i ght s. . . . . . . . . . . . . . .
" " 23- 153
fnteri or Li ghts
.... """"""23-162
Moonrool
.................,...........
23-203
Powel Distribution
""""""'23-57
Power Door Locks
""""""23-219
Power Mi rrors
"" """ " 23' 180
Power Retays.........
"""""""23-72
Power Wi ndows
" "" "' 23-191
RearWi ndow
Detogger .....' ..........' ......
"""""23-176
Spark Pl ugs
.... . "" " "' 23' 97
Starti ng System
..... "" " 23-79
*Stereo
Sound System ........,......,........................'
23-167
'supplemental
Restraint Systom
(SRSI ..... Section 24
Turn Signal/Hazard
Flasher System
"" " "' 23-154
+Under-dash
Fuse/Rel ay
Box ...............................
23-71
(VSS)
...... . " " """"23"124
rwipers/Washers " "" 23-186
NOTE: Unl ess otherwi se speci fi ed. references to auto-
mati c transmi ssi on
(A,/T)
i n thi s secti on i ncl ude the CVT'
- +
Special Tools
Rel. No. I Tool Number Description Oty
i
Page Reterence
o
{t*
o
o
A973X 041
_
XXXXX
07JGG
-
0010104
OTLAJ
_
PT3O2OA
07NAC
-
SR20100
07PM
-
0010100
Vacuum Pump Gauge, 0
-
30 i n. Hg.
Test Harness
Fuel Sender Wrench
23-215
23-' t 10
23-124,125
23-126
23-9' l
*:
Incl uded i n Bel t Tensi on Gauge Set 07TGG
-
0010004
o
ri an
@
\
\
\
I
23-2
Troubleshooting
Tips and Precautions
Bofore Troubleshootin
g
. Check agpl i cabl e fuses i n the appropri ate fuse/rel ay
oox.
. Check the battery for damage, state of charge, and
cl ean and ti ght connecti ons.
. Check the al ternator bel t tensi on.
CAUTION:
. Do not
qui ck-chafge a battety unl ess the battery
ground cable has been disconnected, otherwise
you
will damage the alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connected or you will severely
damage the wi ri ng.
Handling Connectols
. Make sure the connectors are cl ean and have no l oose
wi re termi nal s.
. Make sure mul ti pl e cavi ty connectors are packed wi th
grease (except
waterti ght connectors).
. Al l connectors have
push-down rel ease type l ocks.
Some connectors have a cl i p on thei r si de used to
attach them to a mount bracket on the body or on
another component. Thi s cl i p has a pul l type l ock
Some mounted connectors cannot be di sconnected
unl ess
you fi rst rel ease the l ock and remove the con-
nector from i ts mount bracket.
LOCKING
PAWL ON
OTHER
HALF OF
CONNECTOR
Pul l t o
dr sengage
LOCKI NG TAB
BRACKET
Never t r y t o di sconnect connect or s by pul l i ng on
thei r wi res; pul l on the connector hal ves i nstead.
Al ways rei nstal l
pl asti c covers.
Before connecti ng connectors, make sure the termi -
nal s are i n
pl ace
and not bent.
. Check for l oose retai ner and rubber seal s.
RETAI NER
The backs of some connect or s ar e
packed wi t h
grease- Add grease i t necessary. l f the
grease i s con-
tami nated, repl ace i t.
(cont' d)
23-3
Troubl eshooti ng
Fsce
opon end
Handling Wires and Harnesses
. Secure wi res and wi re harnesses to the frame wi th
thei r respecti ve wi re ti es at the desi gnated l ocati ons.
. Remove cl i ps careful l y; don' t damage thei r l ocks.
Sl i p pl i ers under the cl i p base and through the hol e at
an angl e, then squeeze the expansi on tabs to rel ease the
cl l
P.
Tips and Precautions
(cont'd)
Insert the connector al l the way and make sure i t i s
securel y l ocked.
Posi ti on wi res so that the open end of the cover faces
down.
After i nstal l l ng harness cl i ps, make sure the harness
doesn' t i nterfere wi th any movi ng parts.
Keep wi re harnesses away from exhaust pi pes and
other hot parts. from sharp edges of brackets and
hol es. and from exDosed screws and bol ts.
SNAP.RING PLIERS
23-4
NOT GOOO
A & - /
-w--_w\\
l l
I
Testing and Repairs
. Do not use wi res or harnesses wi th broken i nsul ati on.
Repl ace them or repai r them by wrappi ng the break
wi th el ectri cal taDe.
a Af t er i nst al l i ng par t s, make sur e t hat no wi r es ar e
oi nched under them.
. When usi ng el ect r i cal t est equi pment , f ol l ow t he
manufacturer' s i nstructi ons and those descri bed i n
t hi s manual .
. l f
possi bl e,
i nser t t he
pr obe
of t he t est er f r om t he
wi re si de
(exceDt
waterDroof connector).
. Seat grommet s i n t hei r grooves properl y.
. Use a probe wi th a tapered ti p.
Refer to the i nstructi ons i n the Honda Termi nal Ki t for
i dent i f i cat i on and r epl acement of connect or t er mi -
nal s.
Five-step Troubleshooting
1 .
2.
J .
Veri fy The Compl ai nt
Turn on al l the components i n the
probl em ci rcui t to
veri fy the customer compl ai nt. Note the symptoms
Do not begi n di sassembl y or testi ng unti l you have
narrowed down the
probl em area.
Anal yze The Schemati c
Look up t he schemat i c f or t he pr obl em ci r cui t .
Determi ne how the ci rcui t i s supposed to work by
t r aci ng t he cur r ent
pat hs f r om t he power f eed
through the ci rcui t components to
ground. l f several
ci rcui ts fai l at the same ti me, the fuse or
ground i s a
l i kel y cause.
Based on the symptoms and your understandi ng of
the ci rcui t operati on, i denti fy one or more possi bl e
causes of the probl em.
l sol ate The Probl em By Testi ng The Ci rcui t
Make ci rcui t tests to check the di agnosi s
you made
i n step 2. Keep i n mi nd that a l ogi cal , si mpl e
proce-
dure i s the key to effi ci ent troubl eshooti ng. Test for
the most l i kel y cause of fai l ure fi rst. Try to make
tests at poi nts that are easi l y accessi bl e.
Fi x The Probl em
Once the speci fi c
probl em i s i denti fi ed, make the
repai r. Be sure to use
proper tool s and sal e proce-
oures.
Make Sure The Ci rcui t Works
Turn on al l components i n the repai red ci rcui t i n al l
modes to make sure you' ve fi xed the enti re prob-
l em. l f the probl em was a bl own fuse, be sure to
test al l of the ci rcui ts on the fuse. Make sure no new
probl ems turn up and the ori gi nal
probl em does not
recur,
Wire Color Codes
The fol l owi ng abbrevi ati ons are used to i denti fy wi re
col ors i n the ci rcui t schemati cs:
WHT . . . . . . . . . . . . . . . . . . . . . . , . . . . . . Whi t e
YEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yel l ow
BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl ack
BLU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81ue
GRN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr een
RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
ORN . . . . . . . . . . . . , . , . . . . . . . . . . . . . . Or ange
PNK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pi nk
BRN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Br own
GRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr ay
PUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pur pl e
LT BLU . , . . . . . . . . . . . . . . . . . . . . , . . Li ght Bl ue
LT GRN . . . . . . . . . . . . . . , . . . . . . . . . Li ght Gr een
The wi r e i nsul at i on has one col or or one col or wi t h
another col or stri pe. The second col or i s the stri pe.
WHT/ALK
23-5
Troubleshooting
\
Schematic Symbols
\
EATTERY
l,r ril
t " " l
r
GRO
Ground t ermi nal
I
I
_d_
.:
UND
Componenl ground
I
I
_1
-
FUSE
<'r.-e
COIL, SOLENOID
rh
l a t
+
CIGARETTE LIGHTER
A
l T l
i7
RESISTOR
I
I
VARIABLE RESISTOR
i l H
THERMI STOR
/+'
q.r
IGNITION SWITCH
Jl-
BULB
+
HEATER
A
t = l
+
MOTOR
Q
PUMP
c
CIRCUIT
gREAKER
I
t
T
I
HORN
+
DIODE
+
SPEAKER, BUZZER
D
Mast
Y
ANTI:NNA
I
t t l
TRANSISTOR
(Trl
I 4
SWITCH lln n
Normally open
swi t ch
I
l'0\
v
I
o.mal
politionl
I
Normally closed
'*i'"n
/c\
|
\h/
i l
LIGHT EMITTING
DIODE {LED)
A+,
Y T
RELAY {ln no
Normal l y open rel ay
t--.--' l
fT' t
t i l
t i l
trf
rmal
positionl
Normal l y cl osed rel ay
G
t - l - |
l r l
l-*'+
CONDENSER
I
T
CONNI
l nput
V
I
icTtoN
Out put
J-
CONNECTOR
--+>-
-r-l-
!
REED SWITCH
A
I t ' r l
Y
\
23-6
Engi ne Gompartment
UNDER.HOOD
ABS
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY BOX
CONDENSER FAN
RELAY
BLOWER
MOTOR
RELAY
A/C COMPRESSOR
CLUTCH RELAY
RADIATOR
FAN RELAY
ELD UNI T
t :
n
tr
tl
-fr@
D
T ' l r r r l
r--
--1
23-7
Dashboard: 96, 97 model s
CRUISE CONTROL UNIT
DAYTIME
RUNNING LIGHTS
CONTROL UNIT
(Canad.)
[Wi]e
colors: GRN/ORN, GRN/YEL,l
I WHT,
GRN/ RED, and BLK
I
DASH LIGI{TS BRIGHTNESS CONTROLLER
(Has
bui l t -i n cont rol uni t )
STARTER CUT RELAY
Iwir6 colo]s: BLK/wHf, au/wxf,l
I
BLU/aLK, and BLK/RED l
.
MOONROOF OPEN RELAY
[wire colors: GRN/ORw. CAru/Ae O,l
[WHT,
YEL, and BLK
I
.
MOONROOF CLOSE RELAY
23-8
b-
.:
Coupe
23-9
INTEGRATED
CONTROL UNIT
UNDER.DASH
FUSE/RELAY BOX
POWER WINDOW RELAY
TURN SIGNAL/
HAZARO RELAY
INTERLOCK CONTROL UNIT
lTcM
tcw)
il-trral a\{\ fi |
F n n r - 1 n n n n n - r
Fr J r J r J u u L l u L r L J U| l J
F- nnr r ' - 1nn| - 1nr l
p! r r r Lr Lr r r uLr ' . uLJ | P
u_:;_:_:_l:_:_l_;E::
Dashboard:98 model
CRUISE CONTROL UNIT
DAYTIME
RUNNING LIGHTS
CONTROL UNIT
{Cenada}
DASH LIGHTS BRIGHTNESS CONTROLLER
(Has
lwilo
colo]s: cRN/ORru, Cnn/Yel,l
IWHT,
GRN/RED, and BLK
I
[Wi]e
colols: BLK/WHT, etX/WXf,l
IBLU/BI-K,
and BLK/RED
J
Wire colors: WHT/GRN, BLU/RED,
GRY and WHT/GRN
23-10
I\JJJ'IJJJIJJJ LI
POWER WINDOW FELAY
INTERLOCK CONTROL UNIT
':
Coupc
.TCM (CvT)
23-11
Rel ay and Control Uni t Locati ons
Dashboard/Door
POWER OOOR LOCK
CONTROL UNIT
MASTER SWITCH
(Has
AUDIO UNIT
(Has
bui l t i n keyl ess recei ver ci rcui t )
PGM.FI MAIN RELAY
ABS CONTROL UNIT
23-12
Connector
ldentification
and Wire Harness Routing
How to ldentily Connectols:
l denti fi cati on numbers have been assi gned to al l connectors. The number i s preceded by the l efter
"C"
for connectors'
" G"
f or
gr ound t er mi nal s or
" T"
f or non
gr ound t er mi nal s
Location
Harness
Engine Compartment
Dashboard
Others lFloor. Door,
Trunk/Hatch, and Root)
Starter cabl es
T1, T2 and @
Battery ground cabl e
Gl and O
Engi ne
gr ound cabl e A
Engi ne gr ound cabl e B T4
G3
Under-hood ABS fuse/rel ay box wi re
harness
(wi th ABS)
t 5 ano
( ?
Engi ne wi re harness
C101 t hr u C147
T10l and T102
G' r 01
Engi ne compartment
wl re narness C20l t hr u C214
G201 and G202
Mai n wi re harness
C301 t hr u C310
C351 thru C360
C401 thru C446
G401 and G402
Dashboard wi re harness
C501 thru C520
Fl oor wi re harness
C551 thru C573 {C574)
G551 and G552
Rear wi re harness
C601 t hr u C617
G601
Dri ver' s door wi re harness
C631 thru C639
Passenger' s door wi re harness
C651 thru C656
Left rear door wi re harness
(Sedan)
C661 thru C664
Ri ght rear door wi re harness
(Sedan)
C671 thru C674
Roof wi re harness {Wi thout
moonroof)
C701 thru C703
Moonroof wi re harness
(Wi th moon'
roof)
C711 t hr u C718
Heater sub-harness A
C721 thru C727
Heater sub-harness B
C741 thru C743
A,/C wi re harness
C751 t hr u C754
Hatch wi re harness
(Hatchback) C76l thru C768
G761
Rear wi ndow defogger
ground wi re
c771
G77' l
Secondary heated oxygen sensor sub-
harness
C781 and C782
Fuel tank pressure sensor sub-harness
C791 thru C793
SRSmar n har ness
C801 thru C807
G801
O: 97, 98
model
23-13
Connector ldentification and Wire Harness Routing
Starter Cables
Connector or
Termi nal
Number ol
Cavities
Locati on
Connects to Notes
T,1
T2
Ri ght si de of engi ne companment
Ri ght si de of engi ne compartment
Under-hood fuse/rel ay box
Starter motor
o Battery
Battery posi ti ve
termi nal
Battery Ground Cable
Connector or
Termi nal
Number of
Cavities
Locati on
Connects to Notes
Ri ght f ront shock t ower Body ground, vi a battery ground
cabl e
o
Baftery
Battery negati ve termi nal
Engi ne Ground Cabl e A
Connector or
Tgrminal
Number of
Cavities
Locati on
Connects to Notes
T3 Left si de of engi ne Power steeri ng pump bracket
Left si de of engi ne compartment Body ground, vi a engi ne ground
cabl e A
Engi ne Ground Cabl e B
Connector ot
Terminal
Number of
Cavities
Location
Connects to Notes
T4 Ri ght si de of engi ne compartment Transmi ssi on
Ri ght si de of front frame Body ground, vi a engi ne ground
cabl e B
Under-hood ABS Fuse/Relay Box Wire Harness
Connoctor or
Terminal
Number of
Cavities
Location
Connaqts to Notes
T5 Ri ght si de of engi ne compartment Under-hood fuse/rel ay box
@
Battery
Battery posi ti ve
termi nal
A/C Wire Harness
Connestor or
Terminal
Number of
Cavities
Location
ConnecG to Notes
c751
c754
1
2
Engi ne compartment wi re harness
(c209)
Compressor cl utch
Condenser fan motor
Ay' C pressure
swi tch
G751 Left si de of engi ne companment Body ground, vi a Ay' C wi re harness
23-14
BATTERY
GROUND
CABLE
UNDER-HOOD
ABS FUSE/RELAY
BOX WIRE
HABNESS
GROUNO
CASLE B
A/C WIRE
HARNESS
23-15
Connector
ldentification and Wire Harness Routing
Engi ne Wi re Harness
(Dl 6Y5,
D16Yg engi nesl
-,(Arr)
Ay'T:
96 model
'1
(Avn:
97. 98
model s
AlT..
97, 98
model s
-,{A,/T)
-1
(Arr)
.,
(A/r)
* 1
{r\,riT)
-' (A/T)
*1
(CVT)
.,(A/T)
Mai n wi re harness {C303)
Crankshaf t speed f l uct uat i on
(CKF) sensor
Engi ne oi l pressure swi t ch
Alternator
Al t ernat or
No. l f uel i nj ect or
No. 2 t uel i nj ect or
No. 3l uel i nj ect or
No. 4 f uel i nj ect or
I AC val ve
Throt t l e
posi t i on (TP)
sensor
Manilold absolute
pressure (MAP)
sensor
I nt ake ai r t emperat ure
(l AT)
sensor
Power steering
pressure (PSP)
switch
EVAP purge cont rol sol enoi d val ve
Junct i on connect or
Vehi cl e speed sensor {VSSI
Count ershaf t sPeed sensor
Engine coolant temperature
(ECT)
switch A
Di st ri but or
Engine coolant tefiperature
(ECT)
sending
unii
Engine coolanttemperature
(ECT)
sensor
Pri mary HO2S {sensor
1)
Primary HO2S
(sensor 1)
Back-up light switch
Lock-up control solenoid valve
Secondary
HO2S
(sensor 2)
Mai nshaf t speed sensor
Li nar sol enoi d val ve
Shi f t cont rol sol enoi d val ve
St art er sol enoi d
Mai n wi re harness
(C446)
ECM/ PCM
PCM
ECM/ PCM
ECM/ PCM
Mai n wi re harness
(C305)
Mai n wi re harness {c305)
Mai n wi re harness
(C305)
Knock sensor
(KS)
IAC valve
VTEC sol enoi d val ve
VTEC
pressure switch
EGR cont rol sol enoi d val ve
Secondary
gear shaf t speed sensor
EGR val ve
EGR val ve
Dri ve pul l ey speed sensor
Sol enoi d connect or
(CVT)
Dri ven
Lef t si de of engi ne compart ment
Mi ddl e of engi ne
Ni l i ddl e ot engi ne
Lef t si de of engi ne comPart ment
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
I rl i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e oI engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Left side of engine comPartment
Mi ddl e ot engi ne
Mi ddl e ot engi ne
Mi ddl e ol engi ne
Mi ddl e of engi ne
Mi ddl e ol engi ne
Mi ddl e ol engi ne
Middle ol engine
Middle o'f engine
Middle ot engine
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
Ri ght si de ol engi ne comPart ment
Eehi nd ri ght ki ck
Panel
Under ri ght si de ot dash
Under ri ght si de of dash
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Lef t si de of engi ne comPart ment
Mi ddl e of engi ne
Mi ddl e of engi ne
Right side ol engine compartment
Ri ght si de of engi ne comPart menl
side of engine comPaftment
10
3
1
3
2
2
2
2
3
3
3
2
2
2
14
1 4
3
2
2
10
1
2
8
2
2
2
2
2
1
20
22
32
25
1 4
' 14
2
2
1
2
2
2
2
2
8
2
c 101
c102
c103
c104
c104
c105
c106
c 107
c 108
c109
c 110
c 1 1 l
cl 12
c 113
c114
c 1 1 5
c 1 1 6
cl17
c 118
c 119
c120
c121
c122
c123
c123
c124
c124
c125
cl26
c127
c128
c129
c130
c] 31
cl32
c136
c 137
c138
c139
c140
c141
c142
c143
c144
c144
c145
c146
c147
Lef t si de oI engi ne comPart ment
ground, vi a engi ne wi re harness
*1:
D16Y5 engi ne
' 2:
D16Y8 engi ne
*3:
D16Y5
(A,,/T), D16YA engi nes
23-16
c132
am crog
c138 c113 T101
c110
1 2
c141
T102.
c117-
c143
c' t 17
c144
c140
c l 18
c139
c120
c129
c146
c145
ENGINE WINE
HARNESS
cl ' r 5
c116
c137
c102
23-17
Connector ldentification
\
Engi ne Wi re Harness
{D16Y7 engi ne):96 model
Connector ot
Termi nal
c 10' 1
c102
c103
c104
c 104
c105
c106
c' 107
c 108
c 109
c 1 1 0
c 1 1 1
cl 12
C' 1 13
c 1 1 4
c l 1 5
c l 1 6
c117
c l 1 8
c119
cl20
c121
Cavities
1 0
3
Location
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
[ / i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
f vl i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Ri ght si de of engi ne compart ment
Behi nd ri ght ki ck panel
Under r i ght si de of dash
Under r i ght si de of dash
Connects to
Mai n wi re harness (C303)
Crankshaft speed fl uctuati on (CKF)
sensor
Engi ne oi l pressure
swi tch
Al ternator
Al ternator
No. I fuel i nj ector
No. 2 fuel i nj ector
IAC val ve
Throttl e posi ti on (TP)
sensor
Manifold absolute pressure (MAp)
sensor
l ntake ai r temperature
(l AT)
sensor
Power steeri ng pressure (PSP)
swi tcn
EVAP purge
Junctaon connector
Junctron connector
Vehi cl e speed sensor (VSS)
Countershaft speed sensor
Engi ne cool ant temperature (ECT)
swi tch A
Di stri butor
Engi ne cool ant temperature (ECT)
sendi ng uni t
{ECT) sensor
Pri mary HO2S (sensor
1)
Back-up l i ght swi tch
Lock up control sol enoi d val ve
Secondary HO2S
(sensor
2)
Mai nshaft speed sensor
Li near sol enoi d val ve
Shi ft control sol enoi d val ve
Starter sol enoi d
Juncti on Connector
NIai n wi re harness (C446)
ECM/PCM
PCM
ECM/PCM
ECM/PCM
USA
Canada
Lef t si de of engi ne compart menl
Ri ght si de of engi ne compart ment
Mi ddl e of engi ne
Engi ne ground, vi a engi ne wi re harness
23-18
96 model :
c135 C134
ENGINE WIRE HARNESS
c106
cr 07 c103
c133 cl 32
t't,
c"'
c108
c130
T102
c1' r7
c119
c120
c118
c129
23-19
Engi ne Wi re Harness (D16Y7
engi ne):97 model
Connector or
Termi nal
Number of
Cavities
Locati on
Conneqts to Notes
c 101
c102
cr 03
c104
c104
c105
cr 06
cl 07
cl 08
c109
c 1 1 0
c 1 1 1
cl 12
c113
c 1 1 4
c 1 1 7
c l 1 8
c l 1 9
c120
c121
c122
c124
c124
c' t21
cl 2A
c129
c130
c 13' r
c' t32
c133
c 134
c136
c137
1 0
1
4
3
2
2
2
2
3
3
2
)
2
1 4
1 4
3
,
2
1 0
'l
2
2
2
2
2
2
1
20
22
25
1 6
8
2
Left si de of engi ne compartment
Mi ddl e of engi ne
N4i ddl e of engi ne
l vl i ddl e of engi ne
Mi ddl e of engi ne
l vl i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Behi nd ri ght ki ck panel
Mi ddl e of engi ne
Crankshaft speed fl uctuati on (CKF)
sensor
Engi ne oi l pressure
swi tch
Al ternator
Al ternator
IAC val ve
Throttl e posi ti on (TP)
sensor
Manifold absolute pressure (MAP)
sensor
Intake ai r temperature
(l AT)
sensor
Power steeri ng pressure (PSP)
swi tch
EVAP purge
Juncti on connector
Junc on connector
Vehi cl e speed sensor (VSS)
Countershaft speed sensor
Engi ne cool ant temperature
(ECT)
switch A
Di stri butor
Engi ne cool ant temperature
(ECT)
sendi ng uni t
(ECT)
sensor
Pr i mar y HO2S ( sensor
1)
Back-up l i ght swi tch
Lock-up control sol enoi d val ve
Secondary HO2S
(sensor
2)
Mai nshaft speed sensor
Li near sol enoi d val ve
Shi ft control sol enoi d val ve
Staner sol enoi d
Juncti on connector
Mai n wi re harness
(C446)
ECM/PCM
PCM
ECM/PCM
ECM/PCM
Mai n wi re harness
(C305)
EVAP control cani ster vent shut val ve
USA
Canada
USA
NT
Alr
NT
Alr
Alr
A/r
T 101
r102
Left si de o{ engi ne compartment
Al ternator
G 101 Mi ddl e of engi ne Engi ne ground, vi a engi ne wi re harness
23-20
97 model :
WIRE HARNESS
ct t o
" ' , ' '
23-21
Engine Compartment Wire Harnesg
Connector or
Te.mi nal
Number ol
Cavities
Location Conncts to Notes
c201
c202
c202
c203
c204
c205
c206
c207
c20a
c209
c210
c210
c211
c212
c213
c214
1 0
6
2
4
2
1
2
1
2
3
8
Lel t si de of engi ne compartment
Behi nd tront bumper
Behi nd front bumper
Behi nd tront bumper
Left si de of engi ne companment
Mai n wi re harness
(C308)
Mai n wi re harness
(C309)
Mai n wi re harness {C309}
Crui se actuator
Wi ndshi el d washer motor
Rear wi ndow washer motor
Left front turn si gnaUparki ng l i ght
Front fog l i ght
Left headl i ght
A,/C wi re harness
(C751)
Horn
Horn
Radi ator fan motor
Ri ght headl i ght
Ri ght front turn si gnal /parki ng l i ght
Mai n wi re harness
(C355)
Opti onal
model s
98 model
G201
G202
Body ground. vi a engi ne compartment
wi re harness
Body ground. vi a engi ne compartment
wi re harness
*' l :
Wi th crui se control
*2:
Wi thout crui se control
| 23-22
I
I
ENGINE COMPABTMENT
WIRE HARNESS
23-23
Main Wire Harness
lLeft side ol engine compartment branch)
Connector or
Termi nal
Number of
Cavities
Location
Connects to Notes
c301
c302
c303
c304
c305
c305
c306
c307
c308
c309
c309
c310
5
1 0
1 4
8
I
1
10
2
Wi ndshi el d wj per motor
Test tachometer connector
Engi ne wi r e har ness ( C101)
Dayti me runni ng l i ghts resi stor
(C136)
(C136)
Brake fl ui d l evel swi tch
(+)
Brake fl ui d l evel swi tch
(-)
Engi ne companment wi re harness
(C2011
Engi ne compartment wi re harness (C202)
Engine compartment wire harness (C202)
Left front ABS wheel sensor
Canada
A8S
* 1:
D16Y5 engi ne
*2:
D16YB engi ne
*3:
Wi th crui se control
*4:
Wi thout crui se control
Main Wire Ha.ness
(Right
3ide of engine compartment branch)
23-24
Connqtor or
Termi nal
Number of
Cavities
Location
Connects to Notes
c351
c354
c355
c357
c358
c3s9
c360
1' l
9
5
I
3
2
2
10
Ri ght si de of engi ne compaTtment
(C9081
(C906)
(C905)
Under-hood fuse/rel ay box (C907)
Engi ne compartment wi re harness
(C214)
Under-hood ABS fuse/rel ay box
{C927)
Under-hood ABS fuse/rel ay box
(C926)
Ri ght front ABS wheel sensor
ABS sol enoi d
ABS pump motor
USA
ABS
ABS
ABS
ABS
ABS
G403 Ri ght si de of engi ne companment Body ground, vi a mai n wi re harness
UNDER-HOOD
FUSE/RELAY BOX
MAIN WIRE HARNESS
(l ef t
branch)
23-25
Main Wire Harness
(Left
side of dash and floor branchl
*2:
Wi thout moonroof
*4:
Wi th moonroof
*5:
M//T
(wi th
crui se control or for Dl 6Y5 engi ne)
*6:
Wi th secondary heated oxygen sensor
(H025)
Connector ol
Termi nal
Nurnber of
Cavities
Location Connects to Notes
c401
c402
c403
c404
c405
c406
c401
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c419
c420
c421
c422
c423
c424
c425
c426
c421
c42A
c429
c430
c431
c432
c433
c434
c435
c437
c438
c439
1 4
4
4
1 4
4
8
2
2
1
1 0
24
?
l 6
4
7
6
2
2
18
20
18
7
6
8
6
7
3
8
1 4
2
26
22
1
Above underdash fuse/rel ay box
Under l eft si de of dash
Behi nd under-dash fuse/rel ay box
Above under-dash fuse/rel ay box
Behi nd under' dash fuse/rel ay box
Behi nd underdash fuse/rel ay box
l n the steeri ng col umn cover
In the steeri ng col umn cover
Under mi ddl e of dash
Under ml ddl e of dash
(C555)
(C554)
Securi ty system
Crui se control uni t
Dayti me runni ng l i ghts control uni t
Roof wi re harness
(C701)
(C7' 1
1)
Front fog l i ght connector
l ntegrated control uni t
Dashboard wi re harness {C504}
{C502)
SRS mai n harness
(C802)
Data l i nk connector
Starter cut rel ay
l gni ti on swi tch
Securi ty system
Cl utch swi tch
Cl utch i nterl ock swi tch
Under-dash fuse/rel ay box
(C919)
(C920)
Underdash fuse/rel ay box {C922)
Underdash fuse/rel ay box
(C914)
Under' dash fuse/rel ay box
(C915)
Horn rel ay
Brake switch
Wi ndshi el d wi per/washer swi tch
Rear wi ndow wi per/washer swi tch
Turn si gnal swi tch
Combi nati on l i ghtûrn si gnal swi tch
Cabl e reel
Interl ock control uni t
harness (C781)
A,/T gear position switch
Shi ft l ock sol enoi d
Parki ng pi n
swi tch and IVT gear
posi ti on consol e l i ght
Transmi ssi on control modul e
(TCM)
(TCM)
(C925)
ABS
Opti onal
Canada
Canada
Opti onal
Atr
Mtr
Opti onal
M/T
A/r
CVT
cw
Opti onal
G401 Lef t ki ck panel Body ground, vi a mai n wi re harness
23-26
1 C410
- n - - r - - n r - n - r n n
U U U U U U U U U U U U q I U
23-27
Gonnector ldentification and Wire Harness Routing
Main Wile Harness
(Left
side of dash and floor branchl: 98 model
Connector or
Terminal
Number of
Cavities
Location Conneqts to Notes
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c41
'1
c412
c413
c414
c415
c416
c417
c418
c419
c420
c42' l
c422
c423
c424
c425
c426
c421
c428
c429
c430
c431
c432
c433
c434
c435
c431
c438
1 4
1 4
8
2
2
1
1 0
24
3
1 6
7
6
2
1 8
20
18
7
6
I
6
4
7
3
8
1 4
2
Above under-dash tuse/rel ay box
Under l ei t si de of dash
Under-dash rel ay box
Under-dash rel ay box
l n the steeri ng col umn cover
(C555)
(C554)
Security system
Crui se control uni t
Roof wi re harness
(C701)
(C711)
Front fog l i ght connector
Integrated control uni t
(C504)
(C502)
SRS mai n harness
(C802)
Data l i nk connector
Starter cut rel ay
l gni ti on swi tch
Securi ty system
Cl utch swi tch
Cl utch i nterl ock swi tch
(C919)
(C920)
(C922)
(C914)
(C915)
Horn rel ay
Brake swi tch
Wi ndshi el d wi per/washer swi tch
Rear wi ndow wi per/washer swi tch
Turn si gnal swi tch
Combi nati on l i ghtnurn si gnal swi tch
Cabl e reel
l nterl ock control uni t
harness
(C781)
Ay' T gear posi ti on swi tch
Shi ft l ock sol enoi d
Parki ng pi n swi tch and A,/T gear
posi ti on consol e l i ght
(TCM)
(TCM)
ABS
Opti onal
Canada
Canada
Opti onal
Mfi
Opti onal
M/T
Atr
CVr
CVT
G 401 Left ki ck panel Body ground, vi a mai n wi re harness
*2:
Wi thout moonroof
*4:
Wi th moonroof
*5:
M/T
(wi th
crui se control or for D16Y5 engi ne)
*6:
Wi th secondary heated oxygen sensor
(H02S)
23-28
98 model : "n ,
ctza
c,81
c42A c/(}0
I clzs
MAIN WIRE
HARNESS
c412 C411 C410
UNDEB. DASH
FUSE/RELAY BOX
23-29
Main Wire Harnsss
(Bight
side of dash branchl
Conneclor or
Trminal
Number of
Cavities
c440
c441
c442
c443
c444
c445
c446
20
7
22
26
(C721)
Servi ce check connector
Juncti on connector
PGM-Fl mai n rel ay
ABS control uni t
ABS control uni t
Engi ne wi r e har ness
( C131)
G402 Ri ght ki ck panel Body ground. vi a mai n wi re harness
MAIN WIRE HARNESS
23-30
Dashboard Wire Harness
Connector or
Termi nal
Number of
Cavities
c501
c502
c503
c504
c505
c506
c507
c508
c509
c510
c512
L 5 t 5
c5l 4
c515
c517
c5' t 8
c519
c520
20
24
1 6
1 2
5
3
20
5
5
1 4
' 10
5
1 6
5
2
5
Behi nd dashboard l ower panel
Left si de of steeri ng wheel
Bel ow gauges
Behi nd gauges
Behi nd gauges
Behi nd gauges
Behi nd gauges
Behi nd gauges
Ri ght si de of gauges
Ri ght si de of
gauges
Behi nd mi ddl e of dash
Behl nd mi ddl e of dash
Behi nd gauges
(C912)
Mai n wi r e har ness
( c41
1)
(C553)
( C410)
Crui se mai n swi tch
Dash l i ghts bri ghtness control l er
Juncti on connector
Gauge assembl y
Gauge assembl y
Gauge assembl y
Gauge assembl y
Gauge assembl y
Hazard warni ng swi tch
Rear wi ndow defogger swi tch
Audi o uni t {Keyl ess recei ver ci rcui t)
Securi ty control uni t
Audi o uni t
Securi ty system
Ci garette l i ghter
Gauge assembl y
SRS
Opti onal
Opti onal
ABS
G501 Under mi ddl e of dash Body ground, vi a dashboard wi re harness
*1:
Wi th shi ft-up i ndi cator or crui se control system
(96,97
model s)
Wi th crui se control system
(98
model )
cs09 c511 cs10 c515
13 I C517
c520
c502 c504 c501
23-31
Connector
ldentification
and
Wire
Harness
Routing
Floor Wire Harnsss {Coupe/Hatchback)
Undetdash
fuse/rel aY
box {C923)
Under-dash
fuse/rel aY
box
(C921)
Dashboard
wi re harness
(C503)
Mai n wi re harness
(C402)
Mai n wi re harness
(C401)
Dri ver' s
door wi re harness
(C631)
Dri ver' s
door wi re harness
(C63' l )
Passenger' s
door wi re harness
(C651)
Passenger' s
door
wi re harness {C651)
Parki ng
brake swi tch
Dri ver' s seat bel t swi tch
Passenger' s
door swi tch
Left rear ABS wheel sensor
Rear wi re harness {C60' l )
Rear wi re harness
(C602)
Fuel
gauge sendi ng
uni t
Fuel
PumP
Ri ght rear ABS wheel sensor
Dri ver' s
door swi tch
Fuel tank
pressure sensor
sub-harness
{ c791)
Power
mi rror swi tch
Behi nd
under-dash
fuse/rel aY
box
Behi nd
under-dash
fuse/rel aY
box
Above
under-dash
fuse/rel aY
box
Under
l eft si de of dash
Above under-dash
Juse/rel aY
box
Dri ver' s
door
Dri ver' s
door
Passenger' s
door
Passenger' s
door
Mi ddl e
of fl oor
Left si de of fl oor
Left B-pi l l er
l nsi de
of l eft rear wheel
Left C-Pi l l er
Left C-pi l l er
Fuel tank
Fuel tank
l nsi de
of ri ght rear wheel
Left B-Pi l l er
Fuel tank
' 16
8
4
25
2
25
2
1
2
1
2
2
2
2
1
1 0
c553
c554
Lb55
c556
c556
cs57
LSCO
c559
L50 r
c563
c564
c565
c566
cs67
c568
c569
Body
ground. vi a fl oor wi re harness
Body
ground, vi a fl oor wi re harness
Left kick Panel
I
*1:
Wi th
Power
wi ndows
*2:
Wi thout Power
wi ndows
' 3:
97 model :
D16Y3 engi ne
( Coupe)
98 model :
D16Y8 engi ne
(Coupe/Hatchback'
23-32
FLOOR WIRE HARNESS
c552
23-33
I
I
Floor Wire Harness {Sedanl: 96 model
*1:
Wi th power wi ndows
*2:
Wi thout power wi ndows
Connector or
Termi nal
Number ol
Cavities
c55' l
c553
c554
L CCC
c556
ucco
c557
c558
c559
c560
c561
c563
c564
c565
c567
c569
c570
c571
c572
c573
8
1 4
25
2
2
1
2
1
2
1 4
2
2
2
1
1 0
6
6
1
1
Dri ver' s door
Dri ver' s door
Passenger' s door
Passenger' s door
Mi ddl e of fl oor
Ri ght B pi l l er
l nsi de of l eft rear wheel
Left C-pi l l er
Left C-pi l l er
Fuel tank
Fuel t ank
Insi de of ri ght rear wheel
Left B-pi l l er
Ri ght B- pi l l er
Left B-pi l l er
Left quarter panel
Ri ght quarter panel
Under-dash fuse/rel ay box {C923)
(C921)
(C503)
Mai n wi re harness
(C402)
( C401)
Dri ver' s door wi re harness {C631)
(C63' l )
Front passenger' s door wi re harness
(C651)
Front passenger' s door wi re harness
(C651)
Parki ng brake swi tch
Front passenger' s door swi tch
Rear wi re harness
(C601)
Rear wi re harness
(C602)
Fuel gauge sendi ng uni t
Fuel pump ( FP)
Dri ver' s door swi tch
Power mi rror swi tch
(C671)
(C661)
Left rear door switch
Ri ght rear door swi tch
ABS
ABS
ABS
G551
G552
Left ki ck panel
Body ground, vi a fl oor wi re harness
Body ground. vi a fl oor wi re harness
23-34
96 model:
c573 c566 C564
c558
FLOOR WIRE HARNESS c570
c560
23-35
Gonnector ldentification and Wire Harness Routing
Floor Wire Harness
(Sedanl:
97. 98 models
Connector ol
Terminal
Number of
Cavilies
c553
c554
L555
LC50
L55b
c557
c558
c560
c562
c564
c57r
c512
c573
c514
l 6
8
1 6
1 4
1
2
1
2
16
t
2
2
'I
l 0
6
,l
1
Behi nd underdash fuse/rel ay box
Dri ver' s door
Dri ver' s door
Passenger' s door
Passenger' s door
Mi ddl e of fl oor
Left side ot floor
Ri ght B-pi l l er
l nsi de of l eft rear wheel
Left C-pi l l er
Left C-pi l l er
Fuel tank
Fuel t ank
Insi de of ri ght rear wheel
Left B-pi l l er
Ri ght B-pi l l er
Left B-pi l l er
Left quarter panel
Fuel tank
Under-dash fuse/rel ay box {C923)
Under-dash tuse/rel ay box
(C921)
(C503)
Mai n wi re harness
(C402)
Mai n wi re harness
(C401)
(C631)
(C631)
Front passenger's door wire harness
(C651)
Front passenger's doorwire harness
(C651)
Parki ng brake swi tch
Front passenger' s door swi tch
Rear wi re harness
(C601)
Rear wi re harness
(C602)
Fuel gauge sendi ng uni t
Fuel pump
{ FP)
Dri ver' s door swi tch
Power mi rror swi tch
(C671)
(C661)
Left rear door switch
Ri ght rear door swi tch
Fuel tank pressure sensor sub-harness
{ c791)
ABS
ABS
ABS
Left ki ck panel
Left side of floor
Body ground, vi a fl oor wi re harness
Bodv ground, vi a fl oor wi re harness
*1:
*2:
97.98 model s:
HARNESS
23-37
Raar Wire Harnoss
{Hatchback)
Conneclor or
Tsrminal
Number ot
Cavities
Location
Connects to Notos
c601
c602
c603
c604
c606
c607
c608
1 4
2
2
2
Left quarter panel
Left quarter panel
Left quarter panel
Left side of cargo area
Ri ght si de of cargo area
(C562)
Fl oor wi re harness (C563)
Left rear speaker
Left outer tai l l i ght
Ri ght outer tai l l i ght
Ri ght rear speaker
Hatch wi re harness
(C761)
Hatch wi re harness
(C762)
Opti onal
Opti onal
G601 Mi ddl e of cargo area Body ground, vi a rear wi re harness
REAR wlRE HARNESS
I
J--
23- 39
Rear wire Harness
(CouPe/Sedan)
Connector or
Terminal
Number of
Cavities
Location
Connects to
Notes
c601
c602
c603
c604
c605
c606
c609
c6'r 0
c611
c612
c614
c615
c617
1 6
2
2
2
1
2
2
1
2
2
2
4
Left
quarter panel
Left quarter panel
Left quarter panel
Left si de of trunk
Ri ght si de of trunk
Left si de of rear wi ndow
Mi ddl e of rear shel f
Mi ddl e of rear shel l
Ri ght si de of rear wi ndow
Left si de of trunk
Mi ddl e of t r unk
Mi ddl e of t r unk
l Mi ddl e of trunk
Ri ght si de of trunk
(C562)
(C563)
Left rear speaker
Left outer tai l l i ght
Ri ght out er t ai l l i ght
Ri ght rear speaker
(+)
Hi gh mount br ake l i ght
Tr unk l i ght
(-)
Left i nner tai l l i ght
Left l i cense pl ate l i ght
Trunk l atch swi tch
Ri ght l i cense
pl ate l i ght
Ri ght i nner t ai l l i ght
G601
Mi ddl e of t r unk
Body ground, vi a rear wi re harness
REAR WIRE HARNESS
c617
c615
Driver's Door Wire Harness
(Couoe/Hatchbackl
Connector ol
Termi nal
Number of
Cavities
Location
Connects to Notes
c634
c63s
c636
c638
c639
c640
25
2
2
2
1 2
5
8
1 2
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Insi de of l eft power
mi rror
Dri ver' s door
(C556)
Left front door speaker
Dri ver' s power wi ndow motor
Dri ver' s door l ock actuator
Tweeter
Power wi ndow master swi tch
Dri ver' s door l ock swi tch
Left power mi rror
Power door l ock control uni t
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
*' l :
*2:
Passenger's Door Wire Harness
(Coupe/Hatchback)
*1:
Wi th power
wi ndows
*2:
23-40
.
Connector or
Termi nal
Number of
Cavilies
Location
Connects to Notes
c651
c653
c654
c655
c656
25
2
2
2
2
8
2
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Insi de of ri ght power mi rror
Passenger' s door
Ri ght front door speaker
Front passenger' s power
wi ndow motor
Front passenger' s
door l ock actuato.
Front passenger' s power wi ndow swi tch
Ri ght power mi rror
Tweeter
Coupe
Coupe
Coupe
Coupe
Coupe
DRIVER'S OOOR WIRE HARNESS
PASSENGER'S DOOR WIRE HARNESS
23-41
Driver's Door Wire Harness
{Sedanl
*1:
*2:
Front Passenger's Door Wire Harness
lSedanl
*1:
Wi t h power
wi ndows
i 2:
Wi t hout power wi ndows
Connector or
Termi nal
Number of
Cavities
Locati on
Connects to Notes
c632
c633
c634
c636
c638
c639
c640
25
2
2
1
3
8
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Insi de of l eft power mi rror
Dri ver' s door
Left front door speaker
Dri ver' s power wi ndow motor
Dri ver' s door l ock actuator
Dri ver' s door l ock swi tch
Left power mi rror
Power door l ock control uni t
Connector ol
Termi nal
Number of
Cavities
Locati on
Connects to Notes
c65l
c653
c654
25
2
2
2
2
5
I
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Insi de of ri ght power mi rror
(C557)
Ri ght front door speaker
wi ndow motor
Front passenger' s
door l ock actuator
wi ndow swi tch
Ri ght power mi rror
23-42
DNNEB'S DOOR
WIRE HARNESS
c6:|7 c636 C633
23-43
Left Rea. Door Wire Harness {Sedanl
Right Rear Door Wire Harness {Sedan}
Connestor ot
Termi nal
Number ol
Cavities
location
Connects to Notes
c662
c663
c664
6
2
Left B pi l l er
Left rear door
Left rear door
Left rear door
(C571)
Left rear power window motor
Left rear power window switch
Left rear door l ock actuator
Conneclor or
Termi nal
Number of
Cavities
Location
Connects to Notes
c671
c672
c673
c674
6
2
5
2
Ri ght B-pi l l er
Ri ght rear door
Ri ght rear door
Ri ght rear door
(C570)
Ri ght rear power wi ndow motor
Ri ght rear power
wi ndow swl tch
Ri ght rear door l ock actuator
Left Rear Door:
LEFT REAR DOOR
WIRE HARNESS
RIGHT REAR DOOR
WIRE HARNESS
Fi ght Rear Door:
*
23-44
Heater Sub-harness A
Connector or
Termi nal
Number of
Cavities
Location
Connecis to
Notes
c721
c722
c723
c724
c125
c726
c727
r 6
7
20
3
2
4
Behi nd gl ove box
Behi nd gl ove box
Behi nd gl ove box
Behi nd
gl ove box
Behi nd gl ove box
Behi nd
gl ove box
Mai n wi re harness
(C437)
Mode control motor
Heater sub-harness B
(C741)
AVC thermostat
Bl ower motor
Bl ower resi ster
Reci rcul ati on control motor
Heater Sub-halness B
Connector or
Termi nal
Number ol
Cavities
Location
Connects to
Notes
cl 4' l
c142
c7 43
20
6
1 4
Behi nd
gl ove box
(C723)
Heater fan swi tch
Heater control
Panel
HEATER SUB.HARNESS B
2345
Hatch Wire Harness
(Hatchbackl
Connestor or
Termi nal
Number ol
Cavities
Location
Connects to Notos
c761
c764
c766
c767
6
2
2
1
2
2
2
Ri ght quaner panel
Rear of roof
Ri ght si de of tai l gate
Mi ddl e of tai l gate
Rear wi re harness
(C607)
Rear wi re harness
(C608)
Hi gh mount brake l i ght
(+)
Ri ght l i cense l i ght
Left l i cense l i ght
Rear wi ndow wi per motor
Tai l gate l atch swi tch
G761 Mi ddl e of t ai l gat e Body ground, vi a tai l gate wi re harness
Rear Window Detogger Ground Wire lHatchback)
Connectot or
Terminal
Number of
Cavities
Location
Connects to
Notes
c711 1 Left si de of tai l gate
(-)
G771 Left si de of tai l gate Body ground. vi a rear wi ndow def ogger
ground wrre
23-46
96, 97 models:
REAF WINDOW DEFOGGEB
GROUNO WI RE
c768
TCH WIRE HARNESS
TCH WIBE HARNESS
c766
c767
REAR WINDOW OEFOGGER
GROUND WIRE
2347
Gonnector l denti fi cati on and Wi re Harness Routi ng
Roof Wire Harness
(Coupe/Hatchbackl
Connestor or
Termi nal
Number of
Csvities
Location
Connects to Notes
c701
c702
2
2
Center of roof
Cei l i ng l i ght
Root Wire Harness
{Sedan}
Connector or
Termi nal
Number ot
Cavities
Location
Connects to Notes
c701
c702
c703
2
I
1
Center of roof
Center of roof
Cei l i ng l i ght
(Power)
Cei l i ng l i ght
( Gr ound)
Moonroof Wire Harness
lCoupe/Sedanl
Connector or
Termi nal
Number ot
Cavities
Locati on
Connests to Notes
c711
c712
c7 t 3
c714
c715
c716
c' t 17
c718
c719
2
3
6
6
3
2
1
Behi nd dashboard l ower panel
Left si de of dashboard bracket
Left si de of dashboard bracket
Center of roof
Rear of roof
Rear of roof
Front of roof
(C910)
Moonroof open rel ay
Moonroof cl ose rel ay
Moonroof swi tch
Cei l i ng l i ght
Moonroof motor
Moonroof motor
(Ti l t
swi tch)
Spot l i ght
Opti onal
98 model
WIRE HARNESS
23-49
Rear Heated Oxygen Sensor Sub-harness
Connector or Number of
Terminal Cavities
c7al
c7a2
4
4
Location
Connects to
U nder mi ddl e of dash
Secondary heated oxygen sensor
(Secondary
HO25)
Notes
Fuel Tank Pressure Sensor Sub-harness
Connector or
Termi nal
Number ol
Cavities
Location
Connects to Notes
c79' 1
c192
c793
6
3
2
Mi ddl e of f l oor
Lef t si de of f uel t ank
Lef t si de of f uel t ank
Fl oor wi re harness (C568:
Coupe/
Hatchback, C574: Sedan)
Fuel tank pressure sensor
EVAP two way val ve
23- 50
a
SRS Main Harness
Connector or
Termi nal
Numbcr ol
Cavities
Location
Connests to
Notes
c801
c802
c803
c804
c805
c806
c807
2
3
2
2
2
2
18
Above u nder - dash f use/ r el aY
DOX
Ri ght si de of under - dash
f use/
relay box
Under left side of dash
Under ri ght si de ot dash
Mi ddl e of fl oor
Middle of floor
Under-dash fuse/rel aY box
(c911)
( C412)
Memory erase si gnal
(MES) connector
Cabl e reel
Passenger' s ai rbag assembl Y
Dummy resi stor connector
SRS uni t
USA
Canada
G801
Mi ddl e of f l oor
Body ground, vi a SRS mai n harness
SRS MAIN HARNESS
23-51
Fuses
Under-hood Fuse/Rel ay Box
ALTERNATOR
ITo engine wire harness (T101)l
c901
ITo condenser tan relayl
*:
Not used
NOTEr Vi ew from the backsi de of the under-hood fuse/rel ay box.
BATTERY
lTo starter cables
(Tlll
c903
ITo radiator tan relayl
c904
lTo blower motor relayl
cr06
lTo main wire hsrness (C352ll
c905
lTo main wire harness {C353}l
t E
tr
tr
tr
r-'l
IJ
r'1
47
LI
r'1
51
LI
n
56
IJ
r'1
LI
23-52
lTo main wire harness {C354)l lTo main wire harness {C351)l
Fuse Number
Amps
Wire Colol
Component(s)
or Circuit(s) Protectod
Power di stri buti on
To i gni ti on swi tch
(BAT)
Cei l i ng l i ght, data l i nk connector,
trunk l i ght
PGM-Fl mai n rel ay
Not used
Power wi ndow motors
(vi a power wi ndow rel ay)
Audi o uni t, cl ock, TCM {CVT).
ECM/PCM
(VBU)
41 8 0 A
40A
WHT/BLK
43
7. 5 A
WHT/RED
44 1 5 A
WHT/BLK
45
46 40A
WHT/BLU
47 7. 5 A WHT/BLU
No. 33
(7.5
A) fuse, To combi nati on
l i ght swi tch
(headl i ght)
Not used
Rear wi ndow detogger
(vi a
rear wi ndow defogger rel ay)
Power door l ock control uni t, moonroof motor
48 30A
WHT
49
50 3 0 A
WHT/GRN
5l
204
WHT/GRN
Horn svstem, brake l i ghts, brake si gnal
Hazard warni ng l i ght, turn si gnal /hazard
rel ay
Opti on {+B)
Bl ower motor
(vi a bl ower motor rel ay)
52
1 5 A WHT/GRN
53
1 0 A WHT/BLK
54 40A
WHT/RED
5 C 40A
BLU,4/VHT
Condenser fan motor
(via condenser fan relaYl
56
2 0 A
WHT
RED
A/C compressor cl utch
(vi a A\/C compressor
cl utch rel ay)
57
2 0 A
BLIqRED
Radi ator fan motor
(vi a radi ator fan rel ay)
,a
23-53
Fuses
Under-dash Fuse/Relay Box
c912
[To dashboard wir6 harness lC501ll
c913
lTo ignition swhchl
llo main wire h.rno.s
lciP2)l
c915
lTo main wiro harn$3 1C423)l
lTo
powar
window relayj
a: Canada
r:
Not used
O:
Cg26loption
l+Bll
@: C!t2? Ioption
(drsh
lightsll
G)r Gt28 loption lACCll
@:
Cg2g loption llc2ll
NOTE: Vi ew from the backsi de of the under-dash fuse/rel av box.
c!'17
lTo turn signal/he2ard rolayl
dotogger relayl
C925
(96,
97 modebl
lTo msin wiro h.rncss (C/('g)l
- r-t r-'l - T-l Ft n El rl Fl Tt r'l
23 2a aa 26 27 2A 29 30 31 32 33
I-J LI tJ LI LI LJ LI L.J tJ TJ LI LI
r-r r"t T1 n r'r r't n |-l rt r.1 T1 r-1
12 13 r a 15 16 17 1a 19 20 21 22
LI IJ I.J LI LJ LI L-J IJ LI LI I.J I.J
r'l r;l El r't r-r r'l |;l r-l r't I;l T1 T1
1 2 3 1 5 6 r 8 9 1 0 1 1
TI IJ LJ LI TJ IJ LI LI IJ LI TJ LI
23-54
lTo main wire harn*31C419)l
Fus6 Numbel Amps
Wire Color
Componsnt{s) or Circuit(s) Protscted
Not used
Not used
Rear wi ndow wi per motor, rear wi ndow washer motor
1 0 A GRN
1 0 A RED/BLU Ri ght headl i ght
(hi gh beam)
Lef t headl i ght t hi gh beam), hi gh beam i ndi cat or l i ght
5
1 0 A RED/GRN
6
Not used
Left rear
power window motor
Ri ght rear
power wi ndow motor
Not used
(96,
97 model s)
Di stri butor
(i gni ti on control modul e)
(98
model )
1 2 0 A RED/WHT
8
204 YEUBLK
9
1 5 A
RED
10 2 0 A
GRN/ BLK Front
passenger' s power wi ndow motor
l ' l 204 BLU/BLK
Dri ver' s
power wi ndow motor
Turn si gnal /hazard
rel ay
(vi a
turn si gnal /hazard swi tch)
12
YEUBLK
13
1 5 A
YEUGRN PGM-Fl mai n rel ay
SRS uni t {VA)
Crui se control system. audi o uni t
cRY or BLKI/EL
1 4
BLKI/EL
1 5 7. 5 A 8LK/WHT
Al ternator, VSS. ELD uni t {USA),
EVAP
purge control sol enoi d val ve,
oxygen sensors, TCM
(CVT)
ABS
pump motor, rear wi ndow defogger
t o 7. 5 A BLI</8LU
1 7
BLK/YEL
l ' l c system,
power mi rror, opti on
(l G2)
18 7. 5 A YEUBLK Dayti me runni ng l i ghts rel ay
(Canada)
1 9 7. 5 A YEURED Back-up l i ghts
(Canada)
20
1 0 A BLK/WHT
1 0 A REO,4ryHT Ri ght headl i ght
(l ow
beam)
Left headl i ght {l ow
beam)
SRS uni t
(VB)
Moonroof rel ays
Gauge and i ndi cator l i ghts, i nterl ock control uni t
22 1 0 A
RED|YE L
1 0 A GRY or PNK
24
7. 5 A GRN/ORN
7. 5 A YEL
20A. GRN/BLK
Wi ndshi el d wi per motor, wi ndshi el d washer motor.
i nteqrated control uni t {Canada)
Accessorv socket
(ACC)
Audi o uni t, opti on
(ACC)
Not used
Dash l i ghts, opti on
(dash l i ghts)
ECM/PCM, PGM-Fl mai n rel ay. i ntegrated control uni t
1 5 A YEUGRN
28 10A,/15A'
YEURED
29
30 7. 5 A RED/BLK
31 7. 5 A BLU/IVHT
7. 5 A RED/BLK
Front
parki ng l i ghts, tai l l i ghts, l i cense
pl ate l i ghts
WHT/GRN Interl ock control uni t, key i nterl ock sol enoi d
*(' 98
Model Onl y)
23- 55
Fuses
Under-hood ABS Fuse/Relay Box
lTo undor-hood ABS tuse/relav box wire harnssl
c926
l To mai n wi re harness l C357l l
Wi re Col or
c928
lTo ABS pump
motor relayl
cs27
lTo main wire ha.ness {C350ll
Component(s) or Circuitls) Proiected Fuse Number
23- 56
61 4 0 A WHT ABS pump motor
(vi a
ABS pump motor rel ay)
7, 5 A BRN//EL ABS control uni t l motor check)
63 2 0 A WHT/GRN ABS cont r ol uni t
( +81)
F'
Power Di stri buti on
Ci rcui t l denti fi cati on
CONTFOL
V
I
GRNiWHT
wHT GFN
-] l Bs. onuo' rn, t
WHT ABS pump molof
BFN/ YEL
YEURED
I
ABS conlrol unrt
BLK-
sl ader mol or
UNDER-HOOD
FUSE/FELAY BOX
wHTBL K-
GRN/ RED
-
Hazard wan ng lighl
Turn sional,hazatd relav
(vra s ilch)
Horn
Horn re ay
ABS conl rol unrl
ECMi PCM
TCM (CVr)
Cruise conlrolwil
Brake ights
ECMi PCM
I-*^
G401
G402
TCM (CW)
ECM/PCM
UNDER HOOD ABS
FUSEi RELAY BOX
ALTERNATOR
V
t#i',33),5i3i
L
l--'- cl'. t Ot'r Sw
-C-
:.-
NHr ts-/
-2>.=""1i ")i i s
WHT/FED
WHI/BLK
-
Ce ling lighl
Trunklighl
Dala link conneclor
lD-:
InleEaled conlroluni:
PGM FLmai n r eLay
UNDER DAS-
FL.JSEIRELAV i:
'
(To page 2: a'
23-57
Power Distribution
(cont' d)
F\ , , . , ^ - ^ ^ " - ,
t4,-T GF\
-.,i .>
UNo-EF DaSH F-Sl
ql
I AY BoX
>/
t
apagF zrb \
V'/-- Gi\
-
Powe. door lo(l (ortro
u t r
-
Moonr ool mol or
, "--. . .
h\ -\ DEq DAS-
EUsE
FE-A' Box
1,.'
llo oag" 2
j-6n
BLUMHT
-
Bower molor
No. 17 ( 7. 54) FUSE
(From page 23 59)
BLK/ REO
-
ECMi PCM (Va ArC pressure
swilch)
,nClhermoslal
Condenser lan moloa
llo compressor c ulch
ECMi PCM
oot
G402
UNDEF HOOD FUSE]RELAY BOX
" *- ]
BLU/1flHT
ELUA&HT
UNDER.OASI,] FUSEiRELAY BOX
(To page 23-62)
COMBINATION LIGHT SWLTCH
(Io page
23.63. 64)
IJNDER.DASH FUSE/FELAY BOX
(To page 23-64)
23- 58
BLK/RED
-
Fadiatorlan motor
UNDEF DASH FUSAFELAY BOX
No 17 (7.5A)
N0. 12 ( 7 sA)
N0. 14 ( 7. sA)
N0. 15 ( 7. 5A)
N0.42 (40A) FUSE
(From page 23'57)
BLKELU
-
ABsConlrol unit
(Fuse/relay box socket)
Oplonal conneclor (lG2)
F\
qEAR
WI \ DOW DEFOGGER FELAV
+-l', >
(V,a rear srldo$, deloqger swilcF
I
l,z (To page 23.51)
I
l-
Rear wrndow delogger swilcll
indicalor ighl
.
BLOWER MOTOR RELAY
.CONDENSER
FAN FELAY
'
,vc coMPREssoR
CLUTCH RELAY
.
RADIATON FAN RELAY
{Io
page 23 58)
Healer conlrolpanel
A/C thermoslat
Mode conlrol molor
Fecirculalion conllol molor
lefl
.|
mwe, m,r,or actualor
GRN
GRN
YEUGRN
_
Rear wndow washer molor
Re windowwipel motor
Turn sional/hazard relaY
(Via switdr)
PGM-F firain relay
SRS lnil (VA)
BLK/VEL
-l-
CrJse co"lroturl rvra ma,ns\rilch)
l-
C'LEe marr swilch lrdrcalor I'gtl
l-
Auoio J1,r
t(ey'e9s'ece'ver
ctcuil)
vss
HO2S
EVAP conlrol canisler venl shut valve
BL</w--
+
F-"t :J"!i'.rT
BLXMHT
--
f TcM
(cvTj
BLKtr/HT
-
chaGing syslem lighl
I
(cont' d '
23- 59
IGNITION SWITCH
eN i ,,
I
- . ,
ACC
|'\ DAvllME RLNN'NG L GH_S
YELBL(
-l j
>
CO\TFO_ UN
-
(Caladd)
V'
llo
page 23-64)
.
8L(YEL
+
lgnilon coil
YEUBLK
-
Power Distribution
Circuit ldentification
(cont'd)
tGNtTtoN sw TcH (ACC)
(From page 23.59)
Back-up lighls
GFY i o' PN<i
-
SFS Lr i l ( va)
Gauge assenb y
SRS ndlcalor lighl
ABS indicalor light
Mqear Dos ron ndcatof J
Crurie nd cator I
ormmrng crrc!l
Inlegraled conlrctunil
Opl onal conneclor (ACC)
Audio unil
UNDER,DASH FUSE/RELAY BOX
POWEH WINOOW RELAY
(To page
23-61)
No 25 (7.5A)
GF\.CF\
-
Moonroor open reay
-
Moolrool ctose
.etay
(Fuserelay bor sockel)
nlegfalpd conlro Llnil
. ; . - -
S' l | r t oo( sor enoo (
, , - .
l -
I nt er l oc^cont ol Lnt l I
l r yr l
{Fusgrelay
box socke0
GRN/8LK
-
Windshleldwper molor
Inlegraled conlrol !nil
(VE windshield wlprswlch)
W ndshield u/asher motor
(Vasrvitch)
YEUGRN
-
Accessory power
sockel (ACC)
N0.54 (40A)FUSE
(From page 23 58)
ft
I
WHT/ RED
UNDER.DASH FUSEIRELAY BOX
(Fuse/f elay box sockel)
N0.46 (40A)FUSE
(From page 23'57)
f-;-7
\7
I
I
Wl.lTiELLJ
No 16 (7. sA)FUSE
(Va swilch)
(From paqe 23'59)
f,7
I
BLll/YEL
Oplional conneclor (+B)
tr*a
d-J ts-^
+
'oitFr
wrnJo{ n'o;le $ .1
l-
Powef w nOOw COntO Lnrl
(via power wrndow master sw lcn)
GRN/BL(
-
]
Fronl
Passengers Power
GRN/ BLK
- J wn00wm0l 0r
/via
powerwrndow masler sw ch
\
land
lronl
Passengels Power l
\wndow swilch I
'::
::- i Le'l
rear
oowe, wrdow
-olor
'/Vla
Powr
$r.oow mdsle swdch
\
\and ell rear Power
w ndow swilclr /
:":"1 i Riohreal oowe wndow
-olor
'/v'a
power wlndow mas el swllcl
l
\ ar o
ngl t ' edl powe' w dow sw l cl /
G401
G402
No 50
(From
(30A)FUSE
paqe 23'58)
v
I
WHT]GRN
Rear window delogqer
"n-f,-
G40t
G402
( cont ' d)
23-61
No24( 75A) FUSE
(From page 23 60)
Power Distribution
(cont' dl
(M T)
GN|T 0N SW TCH
{ST)
(From page 23.59)
I
ELKi RED
L-
NUTRAL POSLT]ON
SWITCH
(Flse/relay box sockel)
In1egraled conlrol un t
BLUI/VHI
-
PGM-F|main retay
BTUMHT
_
ECi?VPCM
WI-]T/GRN
..............--
Inle ock conrrotun
I
(Via intedoct swrlch)
r-
Key inleiock sotenord
[l;'i f'"od)
i,Y ",5
F-
**
BLKMHI
i "'
cu
qELA"
cLU c- swl rcH
t-
"n*n'
-fff
,,,,,,*
@**-f_
l l i l
BLK4THT
--Tl-
BLK/RED
T
BLK,vHT
_
srarrer sotenoid G401
23-62
*-, [\
covB NATToN LicH- swtrci
'
V
I'o
Page
23 63 6',
UNDER'DASH FUSE]RELAY BOX
N0. 5110A)
l n
I
PASSTNG
t o
USA:
COMB NATION
LIGHT SWITCH
No 48 (30A)
FUSE
\ 23 58 /
w
I
REDi BLU
-
REDTGRN
-
REDTGRN
-
REDIWHT
-
REOI YEL
-
Frghl headlghl
lHrgh
beam)
Hgh bear n i d cal or ! ghl
Lell headlighl(H
glr beam)
RLght headl g
{ Low
beam)
Lell head ghllLow beam)
No 48130A)
FUSE
/ Fr om
page
\
\ 23 62 /
(Fuse/reay box soc(el)
(Fuseirelay boxsockel)
RED/BLK
-t
Opl onal conneclor (Dash ghls)
nieoraled conlro !n
Hazard warnrn! sw tch lghl
Gauge Lght s
Feaf wndow deloggr swtch
$h]
Cfurse ma n sw(ch
11
cr Lt se nd cat or
) c mm nq c, r , r
A qear posr 0n no cdr or r
Dash ighls bnglrlness conlro er
A'T gear poslon consoie lghl
Healer conlro pane lghl
l ef , | i , ont oa' t no l oht
Hq n t l
Hqnr r
r ' t r h1J
i nn"' l u' ' gl t t
- - - :
l cense oal e l ohl s
Hq NI J
REDlBLK
FEDIELK
-
( cont ' d)
23-63
Power Distribution
(cont' dl
\23.59
-
/
REDMHT
No 48 (30A)
FUSE
/ Fr om
page\
\ 23 62 l
\7
I
WHT
RED/ BLU
-
Rght headi ght ( Hi gh beam)
BEDiBtU
--<
REs sToF (Canada)
RED/GFN
-
Nigh beam indiclor ighl
FEDTGRN
T
Len headlghl (H,qh bearn)
<
REs sroR
l canada)
BEOMHT
-
Fighl headlighl (Low beam)
Lell headl ght (Lowbeam)
{Flserelay
box sockel)
(Fuse/reay bor sockel)
RED/BLK
No l 8 ( 7 5A)
FUSE
/From
page\
\23.59 J
RED/GBN
N0.48 (40A)
FUSE
\23 58 J
Oplional connector (Dash I ghls)
Inlegraled conlrclunrl
Hazard warning swilch lighl
Galge I ghls
Audio un1
Rear window delogger sw lch lghl
Crlise nan swllch lght
Cruise nd cator
I
dlmmtng
lVT gear posil on indicalorJ crc!i1
Dash
hts
brlghhess conlro ler
t+
FED,BLU
---D
RGHT HEADLGHT (Hshbeanr)
wHr/RED........+?
|
I
f-llrr-t-
REo/GFN
-->
LEFT HEADL cHT (Hish beam)
t l
F,i6,'.E"
I
Y I
l-.,-;
' |
.*o^,
I T I I F L U D
I , J I LEVEL
I'*'" l-
BLK REDI GRN
I A
I Y
.
G401
G402
REDTBLK
-
Mgear pos on consote rght
-
Healer contro pane tqhl
RED/BLK
-t
l"'l'n' )
uon'
ou"'"n
'nn'
l"fn,]
o''.' ''"'nn"
h,'fn, )
'-" ''' "n*'
lt'j" )
'*n."
o'"'"
'nn,,
8LK
I
G40l
G402
UNDER.DASH FUSEiRELAY BOX
l o
I
PASS NG
t o
YELIBLK
RES STOF
Ground
Di stri buti on
I
I
)
Ballery
Power sleer ng pump brackel
i
BRN/BLK
I
V
page 23 66)
Transnissron nous ng
BLK
BLK
BLK
BLK
BLK
Primary HO2S (M/T)
I
EGR val ve ( M/ T)
| l Or svS
"ng, n. )
so enoid vave (AiT) l
ECTswl ch
VSS
PSP sw ch
( PG1)
I
f EoMTPCM
{PG2)
l
t r l
s, r.
-l FI pLh
-
PGMF menl eay
'
E1t t "' t u-'
WEC
pressure swilcfl
( D16Y5 016Y8 engne r 98 mode
)
Ballery ground cab e
Engine ground cable A
E
: Engineground cable B
B
Engnlvire harness
( cont ' d)
23-65
o,
i'
@
t',la n wre turness
Ground Di stri buti on
(cont' dl
page 23 65)
w
A
|l]
BRN/ BLK
f
_{r
I enNierx
L^F Sensor
1
L
-E={ll
Erui RED
Knock sensor ( KS) +i :
FED/ BLU
LG1
I
l Ect,t PcM
roz J
l
,."
PrmaryH02S*' - WHT
Manshallspeed sensor
-
RED
Counlershall speed se.sor
-1Fl
BtU
y:1=.":*:-]
Dl6Ygengrne
Dl6Y5, 016Y7 engine
--:'--l
BRN/BLK
-
I
BRN/ BLK
_
reo[[,]-
f
tcvrc*1
wrr
--+
|
WHT/RED.+ J
[--;'*:+il;
Drive puleyspeed sensor
.-!l
RED/BLU
Driven puley speed sefsor
=.j
WHT
Secondar ygear shal l speed sensor
- - - - 1Fl
WHTTRED
E
:
Engi newre harness
E
:
Manwre harness
23-66
Shlelding * 1 : D]6Y5, 016Y8 engine
* 2: Excepl D16Y5 engine (M/T)
*3: 016Y5
eng ne (M/ I )
r-
Fiqhl headliqhr
BL ^
-
; g n ' r u , .
Pc , " ' ' e ' s n
l-
Riqhllronl lurn signal llghl
o L ^ - - - - - ! -
l-
Lerllronl
Parking
lighl
l-
Leit lront lun
gqnal
ight
8L <
?
!',/ ndshield wasrrr malo'
l-
Fearwndowwashef molor
-
cruisocontroltclualor
E
, Engine cotpanmentwre hatn"ss
( conl ' d
23-67
(cont' dl
oit
@
:
Englne companmenlwre harness
@
Main wre haness
Cru se conlrolunil
Daylime runnng ighls conlrolunll (Canada)
Clllch switch
([,]/T wlh crrise conlrolor lor D]6Y5 engine)
Fear w ndow delogger relay
Inlegraled conlrcllnil
Torn signal/hazard relay
o_^
----
Yll nosr,eE wtcEr moro,
t_
Bra{e llLto eve swilci
6_^
----
g1' or rev sw,lcrL
f i
oata t.. co-.ecro, o-c,
W ndsh e d wiper/washer swilch
,r*
-fi-f6
B,L,oc^
- ud^ |
s6' s7 m.dels
:-'"
-
"-
I
Re wlfdow wiper/waslrer swilch
oL^
- -
l e1och conr r o Jr
! i a/ r ,
l-
oaaiT
on swilc,r J
'
-
ctJlci irreroc\ swrtcLt lM-l
8rK
8LK
I_
(Fuse/relay box sockel)
(Fuse/relay box sockl)
(Fuse/relay box socket)
(Fuse/relay bor socket)
BLK
J
\u/
402
To Faqe
23 69-
G
(
Crulse nrain swrlch lighl
Clu se indicalor dimming circut
Re windowdslogger swlch lght
l/T gsal pos ton indicator dlmm ng cncuit
ACCeSSOTy power
sockel
SRS indicalor lighr circuil
Gauges and ind caloas
ABS nd cator ighl circu[
Gauge lighls
E
: Dashboard wre haness
E
: Moonroolwire harness
;L^
------
1roon.oor.wrcr
l-
voon.oot oper
'etay
-
Mool , ool ct ose, et ay
a-1
----
lasr r'gnls or qrrress co'ro rer
l-
Key/ess doo' ock corro, u'r
.....-
tsL^
--F
Seculry conlto, Jflr
BLK
BLK
BLK
BLK
-+
Dashboard wre harness
: Drivers door wire harness
: Healer sub harness B
(w rh A8s)
r wi h. , I ARsr
BLK
-<
caol (Fom
ease
2,.6s)-
l
BLK-
l/Tiear
Position
swlch
BLK Servrce check conneclor
UNDER. HOOD
FUSE/RELAY BOX
ABS
plmp molor
Audio un1
l a
oro,
G501
tr
Lr - ! l
ttt
f i t
trn
BLK
+
Po{e! doot \od\ !oi\o\ uh\
l-
Drveis door loch aclualof
r-
Dfiver s door tock swilch
I i Pow window rraLn sw ci
tt4
)
l-
Dfper s
powerwrndow molor
Fuel unl
BLK
-
5ii.?i1!"f1,.,,'"n
23- 69
(cont' d)
l-L!
J--.
-t:JEL^
I - l
t l
l l
r - ' l -
-
-d
3-{
-1_t-L:
;_K
G601
-l "r.,l n"' nno
I
1t
l"$$,)',r"n,"ou'.,,n'''.
I
Hgh moonl brake lighl
I
G76l
Rear windowwiper motor
(Halcnback r96 97 models)
t - . 1- . . . - - ! " . .
t - l
l l
- l l l - l -
< a_K
-iJ-1:
ts-h
G60l
L.
t-iin1J
tt't,ignt'
Leil ) .
RrghtJ
rrcene
Prale
rqn$
High mounl brake lighl
Rear window wiper motor
Trunk lalch swilch
L
I
I
_l
m00u
G761
(Halchback:98
c
:
G601
h"'$,)
o*t""'u'nn"
L e f i l .
Rrghl J
Innel larl||gn$
Let l l .
R qhtJ
lrcense
Prae {ms
Trunk lalch switch
High mounl take lighl
Rearwindow delogger
(Coupe/Sedan)
Condenser lan rnolor
oir,
G77l
out
] , , , , . '
Hatclr wire hamess
U
: Rear window delogger ground wire
El
: sns main harness
Rear window delogger (Nalchbach)
:
96 97 models
:
98 model
* GRY
GRN
B
rdl
E
23-70
Under-dash
Fuse/Relay
Box
SRS componeol s' rl e l ocated i n thi s area Revi ew the
(24)
before
vi ce.
Removal :
t. Di sconnect the battery negati ve cabl e, then di scon-
nect the
posi ti ve cabl e, and wai t at l east three mi n-
utes.
2. Di sconnect the ai rbag connectors {see secti on 24)
knee bol ster
(see
secti on 20).
4. Remove the t\rvo mounti ng nuts, and
pul l the under-
dash fuse/rel ay box out from under the dash.
UNOER. OASH
FUSE/RELAY BOX
Di sconnect t he connect or s f r om t he under - dash
fuse/rel ay box, and take out the under-dash fuse/
rel ay box
(see
secti on 24).
lnstallalion:
1. Connect t he connect or s t o t he under - dash f use/
rel ay box, then i nstal l the under-dash fuse/rel ay box
i n the reverse order of removal {see secti on 24).
2. l nstal l the dri ver' s dashboard l ower cover
(see
sec-
ti on 20).
3. Connect the ai rbag connectors
(see
secti on 24).
4. Connect the battery
posi ti ve cabl e, then connect the
negati ve cabl e.
5. Conl i rm that al l systems work
properl y.
2?- 71
Power Relays
Relay Test
NOTE: See page 23-155 for turn si gnal /hazard rel al i nput
Le5t .
Normally-open type:
' 1.
Check for conti nui ty between the termi nal s.
. There shoul d be conti nui ty between the No. 1 and
No. 3 termi nal s when power and ground are con-
nected to the No. 2 and No. 4 termi nal s.
. There shoul d be no conti nui ty between the No. 1
and No.3 termi nal s when power
i s di sconnected.
\
Ter mi nal
ao*o o,o. = *o.if'
3
Di sconnected
Connected o o
l(-l-
h- - 5
l n P
' I
I
. Bl ower motor rel ay
. ABS pump motor rel ay
\
o Rear wi ndow defogger rel ay
Starter cut rel ay:96,97 model s
Horn rel ay: 96, 97 model s
a
Normally-open type:
1. Check tor conti nui ty between the termi nal s
. There shoul d be conti nui ty between the No. 1 and
No. 2 termi nal s when power and ground are con
nected to the No. 3 and No. 4 termi nal s
. There shoul d be no conti nui ty between the No. 1
and No. 2 termi nal s when power i s di sconnected'
\
| ermrnal
Power
(N0. 3
-
No. 4) \
2
Disconnected
Connectd o
-----o
2
a
a
a
Power wi ndow rel ay
Radi ator fan rel ay
Condenser fan rel ay
IVC compressor cl utch rel aY
Starter cut rel aY:98 model
Hor n r el ay: 98 model
Five-lerminal tyPe:
1. Check for conti nui ty between the termi nal s.
. There shoul d be conti nui ty between the No l and
No. 2 termi nal s when power and
ground are con
nect ed t o t he No. 3 and No. 5 t er mi nal s.
. There shoul d be conti nui ty between the No.2 and
No. 4 termi nal s when power i s di sconnected
\
Termi nal
t"i* r*"-,
-
t". u\
1 2 4
Di sconnected
o-
---o
Connected
o- O
(
9
I
r. l
{
a
Moonroof open rel aY; 96, 97 model s
Moonroof cl ose rel ay: 96, 97 model s
23-73
Power Relay
Relay Test
Five-terminal type:
l . Check for conti nui ty between the termi nal s.
. There shoul d be conti nui ty between the No. 1
and No. 2 t er mi nal s when power
and gr ound
ar e
connected to the No. 5 and No. 3 termi nal s.
. There shoul d be conti nui ty between the No.
.l
and No. 4 termi nal s when power
i s di sconnected.
5
Moonroof open rel ay: 98 model
Moonroof cl ose rel ay: 98 model
a
a
I
|
23-74
L
\
Termi nal
Power
(No.
5
-
No. 3) \
1 2
Di sconnected o-
----o
Connected o-
--o
\
lgnition Switch
Test
SRS components are l ocated i n thi s area. Revi ew the
precautl ons, and
proceoures
i n the SRS secti on {24) before
performi ng repaars or ser-
vtce.
1. Di sconnect the battery negati ve cabl e.
2. Remove the dri ver' s dashboard l ower cover and
knee bolster
(see
section 20).
3, Di sconnect the 5P connector from the under-dash
fuse/rel ay box and the 7P connector from the mai n
wi re harness.
4. Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e.
[ ] :7P connector
Wi r e si de of l emal e t er mi nal s
BLK/WHT
(ST}
WHT
(BAT}
7P CONNECTOR
WHT/ 8LK
YEL {I G2)
BLK/ YEL
(I Gl I
l f the conti nui ty checks do not agree wi th the tabl e,
reol ace the el ectri cal swi tch
\
Termi nal
,olirton-__\
1
(ACC)
(3)
{ BAT)
E
0G1) I l \ r Z,
( 1 )
{ST)
o {LocK)
|
(ACC) o-
---o
l r
(oN)
o-
--o
III
(START) o-
---o
Electrical Switch RePlacement
SRS components are l ocatd i n thi s area Revi ew the
(24)
before
vi ce,
2. Remove the dri ver' s dashboard l ower cover
(see
secti on 20).
3. Di sconnect the 5P connector from the under-dash
fuse/rel ay box and the 7P connector from the mai n
wi re harness
(see
l eft col umn).
4. Remove the steeri ng col umn covers
(see secti on
171.
5. Insen the i gni ti on key, and turn i t to
"0
(LOCK)".
6. Remove the two screws and the el ectri cal swi tch
from the steeri ng l ock.
7. l nstal l i n the reverse order of removal
23-75
lgnition Switch
5.
6.
Steering Lock Replacement
SRS component l ocati ons, precauti ons,
and procedures
(24)
before performi ng repai rs or ser-
vi ce.
Remove:
knee bol ster
(see
secti on 20).
3. Di sconnect the 5P connector from the under-dash
fuse/rel ay box and the 7P connector trom the mai n
wi re harness
(see previ ous page).
4. Remove the steeri ng col umn covers, then remove
the mounti ng bol ts and nuts from the steeri ng col -
umn
(see
secti on 17).
Lower the steerl ng col umn assembl y.
Center-punch each of the two shear bol ts, then dri l l
thei r heads off wi th a 5 mm
(3/16
i n) dri l l bi t.
CAUTION: Do not damage the steering lock body.
Remove the shear bol ts and the steeri ng l ock
ory.
7.
Insiallation:
1. Instal l the new steeri ng l ock assembl y wi thout the
key i nserted.
2. Loosel y ti ghten the new shear bol ts.
3. l nsert the i gni ti on key, and check for proper
opera-
ti on of the steeri ng wheel l ock and that the i gni ti on
key turns freel y.
4. Ti ghten the shear bol ts unti l the hex heads twi st off.
TWIST-OFF PORTION
5. Instal l i n the reverse order of removal .
SHEAR BOLT
Battery
Test
@
a Battery fluid
(electrolytel Gontatns sulfuric acid. lt may cause sevele burns if it gets on your skin or in youl eyos weal
protective clothing and a face shield.
-
lf electrolyte
gets on
youl skin or clothes, rinse it off with water immediately'
- | | e| eqt r o| yt eget si nyour eyes, | | ushi t out bysp| ashi ngwat er i nyour eyes| or at | sast 15mi nut es; c8| | aphysi ci an
i mmedi atel Y.
. Abaf t er ygi vesof ' hydl ogengas. | f i gni t gd, t hghydr ogenwi l | exp| odandcou| dcr ackt hebat t er ycaseandsp| at t er
acid on you. Keep sparkg. flames, and cigarottes away lrom ths battery'
. overcharging
will raise the temperatur; ths electrolyte, This may force electrolyte to spray out of the battery vents.
Fol | owthechargel manufactul er,si nstructi ons,andchal gethebatteryatapl oper]ate.
Use ei ther a JCI or Bear ARBST tester, and fol l ow the manufacturer' s
procedures. l f you don' t have one of these comput-
eri zed testers, fol l ow thi s conventi onal test
procedure:
Toqet accur at er esu| t s, t het emper at ur eof t hee| ect r oI yt emust bebet weenTo. F( 21. c) and100. F( 38" c) .
l f the case i s cracked or the
posts are l oose, repl ace
the battery.
Check Indi cator EYE Col or
l f t he i ndi cat or shows l ow el ect rol yt e, add di st i l l ed
Test Load Capaci ty
(#1)
.
Appl y 300 amp l oad f or
' 15
seconds t o r emove
surface charge.
.
Al l ow 15 seconds recovery
Perl oo.
.
Appl y test l oad
(see
Test Load Chart)
.
Record vol tage at the end of 15 seconds.
Stays above 9.6 vol ts;
battery i s OK.
{ c o' : :
23- 77
Battery
Test
(cont'd)
Charge on Hi gh Seni ng {40 amps}
Charge unti l EYE shows charge i s OK;
pl us
an
addi ti onal 30 mi nutes to assure ful l charge.
NOTE: lf the battery charge is very low, it may
be necessary to bypass the charger' s pol ari ty
protection
circuitry.
l f the EYE does not show charge i s OK wi thi n
three hours, the battery i s no-good; repl ace i t.
Wr i t e down how l ong t he bat t er y was
charged.
Test Load Capacity
(#2)
Appl y 300 amp l oad for 15 seconds to remove surface charoe.
Al l ow l 5 seconds recovery peri od.
Apply test load
(se
Test Load Chart,.
Record vol tage at the end of 15 seconds.
Stays above 9.6 volts; batterv is OK. Drops be]ow 9,6 volts; battery is no-good,
5582{L
-
MF ot
558241
(St -
MF
fr,
TEST LOAD CHART
Use the test l oad or 1/2 the col d cranki ng amps (CCA) pri nted
on the
l abel on the top of the battery, l f nei ther i s i ndi cated, use the
i nformati on bel ow:
BATTE RY
CODE
COLD CRANKING
AMPS
(CCA)
LOAD
tamps,
405
( * 410)
200
*:
5sB24L (S) -
MF
23-78
Starting
System
Component
Location
lndex
Test, page 23-138
Repl acement ,
page 23 139
STARTER CUT RELAY
(M/T)
les\,
page za t z, t r
CLUTCH INTEBLOCK
swrTcH
BATTERY
Test,
page 23-77
STARTER
Test ,
page 23-81
Sol enoi d Test ,
Page
23-82
Repl acement , Page
23 86
Performance Test,
Page
23-87
23-79
Starting System
IGNITION
SW TCH
WHT]BLK {-WHT
SLKA/VHT
I
t l
BLKWHT BLKMHT
A,TTGEAR
POS TI ON SWTCH
( Cl osed: l n pos
on
N
or
E)
STARTER
CUT RELAY
CLUTCN
swiTcll
Closed :Clulclr pedal)
lully depressed /
BLI]/8LK
I
BLK
1
G40l
G4A2
STARTEF
( Per manenl magnel l ype)
23- 80
UNDER.HOOD FUSETRELAY BOX
No 41 (80A) No 42 (40A)
Starting System
Starter Test
(cont'd)
Check lor Wear and Damage
The s t ar t er s houl d c r ank t he engi ne s moot hl y and
st eadi l y, l f t he st ar t er engages, but cr anks t he engi ne
errati cal l y, remove i t, and i nspect the starter dri ve gear
and torque converter or fl ywheel ri ng gear for damage.
. Check the dri ve gear overrunni ng cl utch for bi ndi ng
or sl i ppi ng when t he ar mat ur e i s r ot at ed wi t h t he
dr i ve gear hel d.
-
l f damaged, repl ace the gears.
Check Cranking Voltage and Current Draw
Cr anki ng vol t age shoul d be no l ess t han 8. 5 vol t s.
Current draw shoul d be no more than 350 amperes.
l f cranki ng vol tage i s too l ow, or current draw too hi gh,
check for:
. dead or l ow battery.
. open ci r cui t i n st ar t er ar mat ur e commut at or seg,
menrs.
. staner armature draggtng.
. shoned armature wi ndi ng.
o excessi ve drag i n engi ne.
Check Cranki ng rpm
Engi ne speed dur i ng cr anki ng shoul d be above 100 r pm.
l f speed i s too l ow, check for:
a l oose banery or starter termi nal s.
a excessi vel y worn starter brushes.
. open ci rcui t i n commutator segments.
. di ny or damaged hel i cal spl i ne or dr i ve gear .
. defecti ve dri ve gear overrunni ng cl utch.
Check Starter Disengagement
Wi th the shi ft l ever i n
S
or
E
posi ti on (A,/T)
or wi th the
cl utch pedal depressed
(Mff),
rurn the i gni ti on swi tch to
START
( l l l ) ,
and r el ease t o ON
( l l ) .
The starter dri ve gear shoul d di sengage from the torque
converter or fl ywheel ri ng gear when you rel ease the
key.
l f the dri ve gear hangs up on the torque convener or fl y
wheel ri ng gear, check for:
. sol enoi d pl unger and swi tch mal functi on.
. di r t y dr i ve gear assembl y or damaged over r unni ng
cl ut ch.
23-82
Starter Solenoid Test
1. Check the hol d-i n coi l for conti nui ty between the S
t er mi nal and t he ar mat ur e housi ng
( gr ound) .
The
col l i s OK i f there i s contj nui ty.
ARMATURE
HOUSI NG
(GROUND)
S TERMI NAL
M TERMI NAL
B TERMI NAL
STARTER
CABLE B TERMI NAL
MOUNTI NG NUT
9 Nm( 0 . 9 k g t m,
7 tbtft)
2. Check the pul l -i n coi l tor conti nui ty between the S
and M termi nal s. The coi l i s OK i f there i s conti nui tv.
Armature InsPection and Test
1 . Inspect the armature for wear or damage due to con-
tact wi th the
permanent magnet or fi el d wi ndi ng.
a l f there i s wear or damage, repl ace the armature.
Inspect for damage.
2. Check commutator surface and di ameter.
. lf the surface is dirty or burnt, resurface with emery
cloth or a lathe within the following specifications,
or recondition with #500 or #600 sandpaper.
. l f commutator di ameter i s bel ow the servi ce l i mi t,
repl ace the armature
Commutator Diamate.
Standard
(NEW) Servi ce Li mi t
28.0
-
28.1 mm
( 1. 102
-
1. 106 i n)
27.5 mm
( 1. 083 i n)
VERNI ER CALI PEB
3. Measure the commutator runout.
. l f the commutator runout i s wi thi n the servi ce
l i mi t. check the commutator for carbon dust or
brass chi ps between the segments.
. l f the commutator runout i s not wi thi n the ser
vi ce l i mi t, repl ace the armature.
Commutator Runout
Standard
0
-
0.02 mm
(0 -
0.0008 i n)
0.05 mm
(0.002
i n)
COMMUTATOR
(cont ' d)
23-83
Starting System
Armature Inspection and Test
(cont'dl
4. Check tor mi ca depth. l f necessary, undercut mi ca
wi th a hacksaw bl ade to achi eve
proper depth. l f ser-
vi ce l i mi t cannot be mai ntai ned, repl ace the armature.
MICA DEPTH
Commulator Mica DeDth
5. Check for conti nui ty between the segments of the
commutator, l f an open ci rcui t exi sts between any
segments, repl ace the armature.
NOT GOOD
Standard
(NEW)
Servi ce Li mi t
0. 4
-
0. 5 mm
( 0. 016 -
0. 02 i n)
0. 15 mm
( 0. 006
i n)
23-84
COMMUTATOR
6. Pl ace the armature on an armature tester. Hol d a
hacksaw bl ade on the armature core.
ARMATURE TESTER
. l f the bl ade i s attracted to the core or vi brates
whi l e the core i s turned. the armature i s shorted.
Repl ace the armature.
7. Check wi th an ohmmeter that no conti nui ty exi sts
between the commutator and armature coi l core,
and between the commutator and armature shaft. l f
there i s conti nui ty, repl ace the armature.
ARMATURE
corl coRE
2.
Brush Holder Test
' t.
Check that there i s no conti nui ty between the O and
O brush hol ders.
l f t her e i s c ont i nui t y ,
r epl ac e t he br us h hol der
assemDry.
O BRUSH HOLDER
O BRUSH HOLDER O ERUSH HOLDER
l nsen the brush i nto the brush hol der, and bri ng the
brush i nto contact wi th the commutator, then attach
a spri ng scal e to the spri ng. Measure the sprl ng ten-
si on at the moment the spri ng l i fts off the brush.
SPRI NG SCALE
Spri ng Tensi on
15.7
-
17 .7 N
(1.60
-
1.80 kgf, 3 5
-
4.0 l bf)
I
BRUSH
Brush Inspection
Measure the brush l ength. l f not wi thi n the servi ce l i mi t,
repl ace the brush
(or
brush hol der assembl y)
Brush Length
NOTE: To seat new brushes after i nstal l i ng them i n thei r
hol ders, sl i p a stri p of #500 or #600 sandpaper, wi th the
gri t si de up. over the commutator and smoothl y rotate
the armature. The contact surface of the brushes wi l l be
sanded to the same contour as the commutator.
Overrunni ng
Cl utch InsPecti on
1 . Sl i de the overrunni ng cl utch al ong the shaft. Does i t
move freel y? l f not, rePl ace i t.
Rotate the overrunni ng cl utch both ways. Does i t
l oc k i n one di r ec t i on and r ot at e s moot hl y i n
reverse? l f i t dces not l ock i n ei ther di recti on or i t
l ocks i n both di recti ons, repl ace i t.
Standard
15. 8
-
15. 2 mm
(0.62
-
0.64 i n)
11. 0 mm
( 0. 43
i n)
CLUTCH GEAR
23-85
Starting System
Starter Reassembly
' t.
Di sconnect the battery negati ve cabl e.
Di sconnect the starter cabl e from the B termi nal on
t he sol enoi d, t hen di sconnect t he BLKATVHT wi r e
from the S termi nal .
MOUNTING BOLT
44 N.m {4.5 kgf.m,32 lbf.ft)
S TERMINAL
BLK/WHT
WIRE
STARTER
CABLE
MOUNTING BOLT
44 N.m {4.5 kgl.m, 32 lbtftl
B TERMINAL
B TERMINAL
MOUNTING NUT
9 N. m {0. 9 kgt m,
6.5 tbtfr)
Remove t he t wo bol t s hol di ng t he st ar t er , t hen
remove the starter.
Instal l i n the reverse order of removal .
NOTE: When i nstal l i ng the staner cabl e. make sure
thatthe cri mped si de ofthe ri ng termi nal i sfaci ng out.
Cri mped si de ol ri ng
t ermt nal
TERMINAL
Connect the battery positive cable and negative cable
to the battery.
23-86
Starter Reassembly
1. Pry back each brush spri ng wi th a screwdri ver, then
posi ti on
the brush about hal fway out of i ts hol der,
and rel ease the spri ng to hol d i t there.
2. Instal l the armature i n the housi ng. Next. pry
back
each brush spri ng agai n, and push the brush down
unti l i t seats agai nst the commutator, then rel ease
the spri ng agai nst the end of the orusn.
aw
brush hol der.
s
Instal l the end cover on the
Performance Test
NOTE: Betore stani ng the fol l owi ng checks, di sconnect
t he wi r e f r om t er mi nal M, and make a connect i on as
descri bed bel ow usi ng as heavy a wi re as
possi bl e (prefer-
abl y equi val ent to the wi re used for the car).
Pull-in Coil Test:
Connect the battery as shown. l f the starter pi ni on pops
out, i t i s worki ng properl y.
CAUTION: Do not leave the battery connected for more
than 10 seconds.
Hold-in Coil Test:
Di sconnect the battery from the M termi nal . l f the pi ni on
does not retract, the hol d i n coi l i s worki ng properl y.
CAUTION: Do not leave the batterv connected for more
than l 0 seconds,
Relracting Test:
Di sconnect the battery al so from the body. It the pi ni on
retracts i mmedi atel y, i t i s worki ng properl y.
CAUTION: Do not leave the battery connected for more
than 10 seconds.
Starter No-load Test:
Cl amp the starter fi rml y i n a vi se.
Connect the starter to the battery as descri bed i n
t he di agr am bel ow, and conf i r m t hat t he mot or
starts and keeps rotati ng.
L
/ ' 4 N
"p
cr"
F4
L
/ J
Y
, t - \
STARTER
BATTERY
l f t he el ect r i c cur r ent and mot or speed meet t he
speci fi cati ons when the battery vol tage i s at 1 1.5 V,
the starter i s worki ng proPerl y,
80 A or l ess
( El ect r i c
cur r ent ) , 2. 600 r pm or mor e
{Motor-speed)
Specifications:
23-87
lgnition System
IGNITION TIMING CONTROL SYSTEM
. Troubl eshooti ng, secti on 11
. l dl e speed Inspecti on/Adj ustment, secti on 11
. l nspecti on and Setti ng, page 23-91
SERVICE CHECK CONNECTOR {2PI
lwire colors: BRN and BLKI
TEST TACHOMETER CONNECTOR
IGNITION WIRES
I nspect i on and Test , page 23-96
PLUGS
DISTRIBUTOR
Repl acement , page
23' 92
Overhaul , page 23-93
l gni t i on Coi l Test , page 23-96
l gni t i on Cont rol Modul e
(l CM)
I nput Test , page 23-95
23-88
l gni ti on System
i I
BLKYEL YELiGRN
Ci rcui t Di agram : 96,97 model s
GN TION
SWI TCH
UNDER DASH
FUSE/RELAY BOX
BLU'
I
n
BLU' BLU
I A
Ji[3î''l=
TACHOMETER
TCt\4 {CWr
.lJ
l-
++
J
* 1 HITACH]
*2 TEC
UNDEF HOOD FUSE/FELAY BOX
BLI(YEL
^ l
BLK/YEL YEL/GRN
GN T]ON
col L
TDC: Top dead cenl er
CKP : Craf kshalt posilion
CYP CyLnder posilron
TDC/CKPiCYP SENSOR
-
+ i wlteLu
IGN TION CONTROL
MODULE ( CM)
/
Has bu l l . n
\
I
noEe
l
TDC
CKP
CYP
23- 89
lgnition System
Ci r cui t Di agr am : 98 model
I GNI TON
SWITCH
UNDER. OASH
FUSE/RELAY BOX
/-1\, I-*',il] EcMipcM
u''"'.-* -un*'{_:z BLx'EL-E_,}I,
Y
t l
YELiGRN
1
++
23- 90
liIl]'_r
i+++
|
-MFCM-
I
BLU'
I
t l
BLUl BLU
J
t l
l n
I
TEST
I
TACHOMETER
\__7 CONNECTOR
TACHOMETER
TCM
(CW)
X 1 HI TACHI
+2 TEC
UNDER HOOD FUSE]RELAY BOX
TDCr Top dead cenl er
CKP: Crankshalt posilion
CYPTCy i nder posl i on
TDC/ CKPi CYP SENSOF
"
+ l B L U _
lgnition Timing Inspection and Setting
2.
1 .
3.
Check the i dl e speed, and adj ust i t i f necessary
(see
sect i on 11) .
Pul l out the servi ce check connector 2P
(BRN
and BLK
wi res) from the connector hol der l ocated under the
dash on the front passenger si de, then connect the
SCS servi ce connector
(T/N
07PM
-
0010100)to i t
no l oad
(AfI
i n
N
or
E,
M/f i n neutral ) unti l the
radiator {an comes on, then let it idle
Connect the ti mi ng l i ght to the No.
' l
i gni ti on wi re,
then poi nt the l i ght toward the
poi nter on the ti mi ng
bel t cover.
Check t he i gni t i on t i mi ng i n no l oad condi t i ons:
headl i ghts, bl ower fan, rear wi ndow defogger, and
ai r condi ti oner are not operatl ng.
l gni ti on Ti mi ng:
12' t 2" BTDC
( RED)
dur i ng i dl i ng i n
neutral
M
12" 12" BTDC
( RED)
dur i ng i dl i ng i n
@
or E
POINTER
RED MARK
23-91
To ADVANCE
.r<,
6. Adj ust the i gni ti on ti mi ng i f necessary, as fol l ows.
Loosen the di stri butor mounti ng bol ts, and turn the
di stri butor i gni ti on {Dl ) housi ng countercl ockwi se to
advance the ti mi ng, or cl ockwi se to retard the ti m-
I ng.
MOUNTING BOLTS
18 N' m 11.8 kgt' m, 13 l bf ft)
Ti ghten the di stri butor mounti ng bol ts, and recheck
r he i gni t i on t i mi ng.
Di sconnect the SCS servi ce connector from the ser
vi ce check connector.
7.
lgnition System
Distributor Replacement
Removal :
1. Di sconnect the connector from the di stri butor.
2- Di sconnect t he i gni t i on wi r es f r om t he di st r i but or
i gni t i on ( Dl )
cap.
3. Remove t he mount i ng bol t s f r om t he di st r i but or ,
then remove the di stri butor from the cyl i nder head.
DISTRIBUTOR END CAMSHAFI END
MOUNTING BOLT
18 N.m {1.8 kgt.m, 13 lbtft}
l nsl al l ati on:
NOTE: Before you i nstal l the di stri butor, bri ng the No. 1
pi ston to compressi on stroke TDC.
1. Coat a new O-ri ng wi th engi ne oi l , then i nstal l i t.
2. Sl i p the di stri butor i nto posi ti of
NOTE; The Iug on the end of the di stri butor and i ts
mati ng grooves i n the camshaft end are both offset
to el i mi nate the possi bi l i ty of i nstal l i ng the di stri bu'
tor 180" out of ti me.
3. l nst al l t he mount i ng bol t s, and t i ght en t hem l i ght l y.
23-92
4. Connect the i gni ti on wi res to the di stri butor i gni ti on
( Dl )
cap as shown.
HITACHI:
No. 1
CYLINDER
MARK
TEC:
No. 1
CYLINOER
No . 2
No.
il
5. Connect the connector to the di stri butor.
6. Set the i gni ti on ti mi ng
(see previ ous page).
7. After setti ng the i gni ti on ti mi ng, ti ghten the mount-
i ng bol ts.
Distributor Overhaul
HITACHI:
DI STRI BUTOR I GNI TI ON {DO HOUSI NG
Check f or cracks and damaqe.
IGNITION COIL
Test, page 23-96
)
Troubl eshoot i ng, sect i on 1 1
Do not di sassembl e.
IGNTTION CONTROL MODULE {ICMI
l nput Test , page 23' 95
CAP SEAL
Check f or damage.
OISTBIBUTOR IGNITION
(DII
CAP
Check f or cracks, wear,
damage, and f oul i ng.
Cl ean or repl ace.
( cont ' d)
23-93
lgnition System
Distributor Overhaul
(cont'd)
TEC:
LEAK COVER
DI STBI BUTOR I GNI TI ON {DI } HOUSI NG
Check f or cr acks and damage.
DISTRIBUTOR IGNITION
(DI)
ROTOB
CAP SEAL
Check f or damage
DISTRIBUTOR IGNITION {DII CAP
Check f or cracks, wear,
damage, and f oul i ng.
Cl ean or repl ace.
IGNITION COIL
Test, page 23-96
O-RI NG
Repl ace
\
A
v
TDC/CKP/CYP SENSOR
Troubl eshoot i ng, sect i on 1 1
Do not di sassembl e.
WHT/ BLU
23-94
l gni ti on Gontrol Modul e
(l CM)
Input Test
NOTE:
. See secti on 11 when the mal l uncti on i ndi cator l amp
(Ml L)
turned on.
. Perform an i nput test for the i gni ti on control modul e
( l CM)
af t er f i ni shi ng t he f undament al t est s f or t he
i gni ti on system and the fuel and emi ssi ons systems.
1. Remove the di stri butor i gni ti on {Dl ) cap, the di stri b
utor i gni ti on
(Dl )
rotor and the l eak cover
(TECl .
2. Di sconnect the wi res from the l CM.
HITACHI:
BLK/YEL
BLU' WI RE YEL/GRN WIRE
TEC:
BLK/ YEL WI RE
23- 95
(l l ).
Check for vol tage
between the BLK//EL wi re and body ground.
There shoul d be battery vol tage.
. l f there i s no battery vol tage, check the BLK/YEL
wi re between the under-dash fuse/rel ay box and
t he I CM.
. l I there i s battery vol tage, go to step 4.
(l l ).
Check tor vol tage
between the wi re*r and body ground.
. l f there i s no batteryvol tage, check:
-
t he i gni t i on coi l .
-
t he
* r wi r e
bet ween t he i gni t i on coi l and t he
t cM.
. l f there i s battery vol tage,
go to step 5.
* 1:
BLU' wi r e
( HI TACHI )
WHT/BLU wi re
(TEc)
Di sconnect the ECM/PCM connector A 132P). Chec.
f or cont i nui t y on t he YEL/ GRN wi r e bet ween t l " .
ECI\I/PCM and the l CM.
There shoul d be contanui ty.
Check for conti nui ty on the YEL/GRN wi re to boc,
gr ound.
There shoul d be no conti nui ty.
Check f or cont i nui t y on t he BLUr wi r e bet ween t he
test tachometer connector and the l cM.
There shoul d be conti nui ty.
Check for conti nui ty on the BLU' wi re to body ground
There shoul d be no conti nui ty.
l f al l the tests are normal , repl ace the l CM.
6.
7.
9.
lgnition System
lgnition Coil Test
Usi ng an ohmmeter, measure resi stance between the
termi nal s. l f the resi stance i s not wi thi n soeci fi cati ons,
repl ace the i gni ti on coi l .
NOTE: Resi stance wi l l vary wi th the coi l temperature;
speci fi cati ons are at 68' F
(20' C).
HITACHI:
Primary Winding Resistance
(Between
the A and B termi nal sl :
0.45
-
0.55 0
Secondary Winding Resistance
(Eetween
the A and secondary winding terminalsl:
22.4
-
33.6 k{r
TERMINAL B {-I
TERMINAL A
(+
TEC:
{Between the A and B terminalsl:
0.63
-
0.77 0
(Between
the A and secondary winding terminals):
12.8
-
19.2 kO
SECONDARY
WINDING
TERMINAL
TERMINAL A {+
@ O
23- 96
TERMINAL B
(_)
lgnition Wire Inspection and Test
CAUTI ON: Car ef ul l y r emove t he i gni t i on wi r es by
pulling on the rubber boots. Do not bend the wires; you
might break them inside.
1. Check the condi ti on of the i gni ti on wi re termi nal s. l f
anv termi nal i s corroded, cl ean i t. and i f i t i s broken
or di storted, repl ace the i gni ti on wrre.
Check f or broken,
corroded, and benl
t ermi nal s.
IGNITION WIRE
2. Connect ohmmeter probes and measure resi stance.
lgnition Wire Resistance:
25 kO max. at 68'F
(20"C)
I GNI TI ON WI RE
3. l f resi st ance exceeds 25 kO, repl ace t he i gni t i on wi re.
lgnition System
lgnition Coil Test
Usi ng an ohmmeter, measure resi stance between the
termi nal s. l f the resi stance i s not wi thi n soeci fi cati ons,
repl ace the i gni ti on coi l .
NOTE: Resi stance wi l l vary wi th the coi l temperature;
speci fi cati ons are at 68' F
(20' C).
HITACHI:
(Between
the A and B termi nal sl :
0.45
-
0.55 0
(Eetween
the A and secondary winding terminalsl:
22.4
-
33.6 k{r
TERMINAL B {-I
TERMINAL A
(+
TEC:
{Between the A and B terminalsl:
0.63
-
0.77 0
(Between
the A and secondary winding terminals):
12.8
-
19.2 kO
SECONDARY
WINDING
TERMINAL
TERMINAL A {+
@ O
23- 96
TERMINAL B
(_)
lgnition Wire Inspection and Test
CAUTI ON: Car ef ul l y r emove t he i gni t i on wi r es by
pulling on the rubber boots. Do not bend the wires; you
might break them inside.
1. Check the condi ti on of the i gni ti on wi re termi nal s. l f
anv termi nal i s corroded, cl ean i t. and i f i t i s broken
or di storted, repl ace the i gni ti on wrre.
Check f or broken,
corroded, and benl
t ermi nal s.
IGNITION WIRE
2. Connect ohmmeter probes and measure resi stance.
lgnition Wire Resistance:
25 kO max. at 68'F
(20"C)
I GNI TI ON WI RE
3. l f resi st ance exceeds 25 kO, repl ace t he i gni t i on wi re.
Spark Plug Inspection
1. Inspect the el ectrodes and cerami c i nsul ator for:
.
l mproper
gap
.
Oi l -f oul i ng
.
Carbon deposi t s
.
Cracked cent er
el ect rode i nsul at or Damaged
gasket
Burned or worn electrodes may be caused by:
. Advanced i gni ti on ti mi ng
. Loose spark
pl ug
. Pl ug heat range too l ow
. Insuffi ci ent cool i ng
Fouled plugs may be caused by:
. Retarded i gni ti on ti mi ng
. Oi l i n combusti on chamber
. l ncorrect spark pl ug gap
. Pl ug heat range too hi gh
. Excessi ve i dl i ng/l ow speed runni ng
. cl ogged ai r cl eaner el ement
. Deteri orated i gni ti on coi l or i gni ti on wi res
worn or deformod
2. Check the el ectrode gap.
! Adj ust the
gap wi th a sui tabl e
gappi ng tool .
Electrode Gap
St andar d I
t . t 8 mm
( 0. 043
8oo, i n)
' l . l
mm
(0. 043
i n)
Repl ace the pl ug i f the center el ectrode i s rounded
as shown bel ow:
3. Appl y a smal l
quanti ty of anti -sei ze compound to
the pl ug threads, and screw the pl ugs i nto the cyl i n-
der head fi nger-ti ght. Then torque them to 18 N m
(1.8 kgf.m, 13l bf.ft).
ROUNDED
ELECTRODE
I r----a
l l Fq-
Engine Types Spark Pl ugs
D16Y5 ZFR4F. 11 { NGK)
KJ l 4CR- 111
( DENSO)
D16Y7,
D16Y8
ZFR5F- 11
( NGK)
KJ16CR- 111
( DENSO)
23-97
Gharging System
UNDER.HOOD FUSE/RELAY BOX
i *Has
repl aceabl e ELECTRICAL LOAD
j
I DETECToR
(ELD)
UNIT 1
CHARGING SYSTEM LIGHT
(l n
t he gauge assembl y)
BATTERY
lest, page 23-77
Troubl eshoot i ng, page 23-100
Repl acement , page
23-105
Rect i f i er Removal , page 23-106
Rect i f i er Test , page 23-107
Rear Beari ng Bepl acement , page 23-109
ALTERNAIOR BELT
I nspect i on and Adj ust ment , page
23-110
E]
t rrl
Ci rcui t Di agram
UNDER HOOD FUSEiRELAY BOX
ON]TION
SWTCH
I
,/T\
I
BAT
I
\ tcl ,t
\3-l
I
BLKiYEL
WHT/GFN BLK/YEL
UNDER,DASH
FUSE/BELAY
BOX
1,,*'
T"*
WHT/BLU
No 41 (8OA)
,.4\
No 42 (40A)
VOLTAGE REGULATOR
GRN]RED
I
ALTERNATOR
23- 99
Charging System
Troubleshooting
l f the chargi ng system l i ght does not come on or does not go off, or the battery i s dead or l ow, test the fol l owi ng i tems i n
the order l i sted bel ow:
1. Battery
(see page 23 771
2. Chargj ng system l i ght
3. Vol tage
4. Al ternator control system
(USA)
5. Al ternator/regul ator
Charging System Light Test
ALTERNATOR 4P CONNECTOR
{usAt
Wi re si de of
IG
{BLK/YEL)
{Canadal
I G
IBLK/YELI
[ ] : Canada
23-100
. - l
1
l
2 l
I l-T;l
t -
I
(v)
T
Charging System Light Chck-1:
Make sure t he chargi ng syst em
l i ght comes on.
Ch.ck lor a blown No. 15 {7.5 Al
f use and a bl own chargi ng sys-
t em l i ght bul b. l f t he f u3e and
bul b are OK, ropai r t ho opon i n
the wHT/BLU wila.
Does t he chargi ng syst em
l i ght come on?
Charging Systcm Light Ch6ck-2:
St art t he enoi ne.
Does the charging system
l i ght go off?
Vollage Chock:
Measure t he vol t age at t he No. 1
l No. 2l t ermi nal
of t he 4P I 3Pl con-
nector with the ignition switch ON
f l r).
Ropair the opon in the BLK/YEL
wire bstwogn tho dternrtor and
under{a3h f uio/relay box.
(To
next
page)
)
(From previ ous
Page)
Chgck for an open in the L cir-
cui t -1:
2. Di sconnect t he 4P [ 3Pl con-
nector from the alternator.
3. Ground t he No. 3 t ermi nsl of
t he 4P [ 3Pl connect or.
(ll).
Turn the ignition switch OFF, and
r epai r t ho opon i n t ho wHT/
gLU
wile.
Does the charging system
l i ght come on?
Chock for an op6n in the L cir'
cuit.2:
Di sconnect t he No. 3 t ermi nal ot
t he 4P t 3Pl
connect or t r om t he
ground.
Does t he chargi ng syst gm
l i ght
go of i ?
Turn the ignition 3witch OFF, and
rgpair tha 3hon to ground in the
WHT,/BLU wiro.
ALTERNATOR'P CONNEGTOR
{usAt
.-r
l l l 2 l
t-T;t
-r-
L
L
IWHT/BLU)
-+.t
1 1
2 l
l .T;l
-r-
'w"l".ur
l)
Wi re si de of
f emal e t ermrnal s
L
IWHT/BLUI
{Crnadal
Wi re si de of
t emal e t ermi nal s
(WHT/8LUI
(conl ' d)
23-10
[ ] : Canada
Charging System
Troubleshootin g
{cont'dl
Alte.nator Control System Tost
IUSAI
NOTE: Before testi ng, check proper
operati on of the ELD by confi rmi ng wi th the MIL
(see
secti on 11).
BATTERY
CAUTION: Be sure to use a voltmetr
with its
plus
terminal conncted to bat,
tery plus and i$ minus torminal to the
4P connector temrinal No. 2.
c
{WHT/GRNI
Wi re si de of
ALTERNATOR
ilP
CONNECTOR
Chock f or a short i n t ha ci rcui t
(Al-TC
linel:
1, Reconnect t he 4P connect or
to the alternator.
2. St art t he engi ne, and t urn t he
headl i ght s
(hi gh
beam) ON.
4P connect or t ermi nal No. 2
and t he posi t i ve
t ermi nal of
the baftery.
l s t here 1 V or l ess?
IALTC linel:
1. Tur n t he headl aght and i gni -
t aon swi t ch OFF.
f rom t he ECM/ PCM.
t he ECM/ PCM 32P connect or
t ermi nal No. 19 and al t ernat or
4P connect or t ermi nal No, 2.
Rep.i. open in tho wi.e bolwocn
the.lternator.nd ECM/PCM.
Check for short in the wire {ALTC
l i ne):
1. Tur n t he headl i ght and i gni
t i on swi t ch OFF.
f rom t he ECl vl / PcM.
t he ECM/ PCM 32P connect or
grouno,
PCM, and recheck.
ll prescribd
voltage is now avail"
abl e, repl ace t he ori gi nal ECM/
PCM,
Repair short in th wi.e betwen
th alte.nator and ECM/PCM.
ECM/PCM CONNECTOR A I32PI
1 2 3 1 5 8 9
, 1 0
11
12 13 14 1 5 16 1 7 1 8 19 20 21 22 23 2a
25 26 21 30
Wi re si de of
t emal e t ermi nal s
( [ ,
_f
ATLC
IWHT/GRN)
IWHT/GRN)
ALTERNATOR
Wi re si de of
1 2
3 4
. I ' UUNNEUI ( , K
ECM/PCM CONNECTOR A {32P}
1 2 3 I 6 1 7 8 I 1 0 1 1
12 13 l i l l 5 1 5 11 1 8 t 1 9 20' 21 2212321
25 26 30
Wire side of I ATLC
I WXf / CnXl
[ ]
23-102
i-_*_lffi*
Alternator/Regulator lest_'l :
1. Connect a Sun vAT- 40
( or
equi val ent t est er), ano l urn
the selector switch to
Posilion
1( st anang) .
2. Shi f t t o neut ral
(A, / T
i n
E
or
E)
posi t i on, and st ar t t he
engi ne. Hol d t he engi ne at
3, 000 rpm wi t h no l oad unt i l
t he r adi at or f an comes on,
t hen l et i t i dl e.
3 . Ra i s e t h e e n g i n e s Pe e d t o
2, 000 rpm, and hol d i t t here.
l s t he vol t age ovor 15. 1 V?
Ahernator/negulator Tesl-2i
1. Fel ease t he accel erat or Pedal ,
and l et t he engi ne i dl e.
2. Make sure al l accessori es are
t urned of f . Turn t he sel ect or
swi t ch t o posi t i on 2
(chargi ng).
3. Remove t he i nduct i ve
Pi ck-uP,
and zero t he ammet er,
4. Pl ace t he i nduct i ve
Pi ck- uP
over the battery
groLrnd cable
so that the arrow
points to the
baftery negative terminal.
5. Rai se t he engi ne speed t o
2, 000 rpm, and hol d i t t here
l s t he vol t age l ess t han 13. 5 V?
Alternator/Regulator Test-3:
Appl y a l oad wi t h a VAT-40 unt i l
t he bat t er y vol t age dr oPs t o
between 12
-
'13.5
V.
Alternator/Begulator
Test
NOTE: Make sure the battery i s suffi ci entl y charged
(see pa
9e
23-77]-
FULL FIELO
TESTER
LEAD IBLU}
VOLTMETER
NEGATIVE
LOAD ADJUSTER
ICARBON
PILE)
(BLK}
FIELD
SELECTOR
VOLTMETER
POS|TIVE
LEAD IREDI
NEGATIVE TESTER
CABLE IBLKI
POSITIVE TESTEi
CABLE
(REDI
swtTcH
INDUCTIVE
PICK-UP
{GRN)
INDUCTIVE
PICK.UP
TIVE
TERMINAL
)
(cont' d)
23-103
lrffil @
r[@*.:
.gdi
To next page
Gharging System
Troubl eshooti ng
(cont' dl
From previ ous page
l s t he amperage 50 A or more?
CAUTION: The voltago will rise quickly
when the alteinato. is tull-fielded. Do not.llow
the voltage to exceed 18 V; it may damage the electrical system.
NOTE: Af t ach a probe t o a VAT 40 f ul l f i el d t est l ead, and i nsert t he probe i nt o t he f ul j f i el d
access hol e at t he back of t he al t ernat or. Swi t ch t he I i el d sel ect or t o t he
"A
(Ground), . posi -
t i on moment ari l y, and check t he amperage readi ng.
The charging system is OK.
Alternator/Regulator Test-4:
Wi t h t he engi ne speed st i l l at
2, 000 rom, f ul l -f i el d t he al t ernat or.
23-104
)
Alternator
RePlacement
NOTE: Remove the alternator from below the vehicle
1. Remove the battery negati ve cabl e, then di sconnect
the
Positive
cable.
2. Di sconnect the 4P
(or
3P) connector from the al ter-
naI0r.
TERMINAL NUT
7.85 N.m
(0.8
kgf m, 5 79 lbtft)
4P lor 3P)
CONNECTOR
| ) : Canada
3. Remove the termi nal
the B termi nal .
nut and the WHT wi re from
4. Remove t he adi ust i ng bol t and t hr ough bol t nut ,
then remove the al ternator bel t from the
pul l ey'
UPPER MOUNT
BRACKET EOLT
44 N. m {4. 5 kgl . m, 33l bl f t l
ALTERNATOR
ADJUSTING BOLT
24 N.m {2.4 kgf'm, 17 lbf ft)
44 N. m
(4. 5
ksf m. 33 l bI f t l
5.
LOWER MOUNT
BRACKET BOLTS
44 N.m {4.5
kgf m.33 lbf ftl
Pul l out t he al t er nat or t hr ough bol t , t hen r emove
the al ternator.
l f necessary, remove the mount bracket bol ts, and
the upper and l ower mount brackets
Adj ust the al ternator
bel t tensi on
after i nstal l ati on
( see page 23- 110) .
b.
1 .
23-105
Charging System
Rectifier Removal
1. Remove the four through bol ts.
Heat the rear beari ng seat wi th a
' 1,000
W hai r dri er
for about fi ve mi nutes
(120 -
140"F, 50
-
60"C),
HAIR DRIER
REAR EEARING
SEAT
23-106
3. Sepa.ate the rear housi ng from the dri ve-end hous-
i ng by i nserti ng a fl at ti p screwdri ver i nto the open-
i ngs and pryi ng
them a
part.
Be careful not to dam-
age the stator wi th the ti p of the scfewdri ver,
Separ at e t he r ear housi ng and dr i ve- end housi ng
wi th the stator attached to the rear housi nq.
REAR HOUSI NG
DRIVE-END HOUSING
5. Separate the rear housi ng from the stator/recti fi er
assembl y by removi ng the four screws and the ter-
mi nal nut.
Unsol der the recti {i er from the stator l eads
. To avoi d damagi ng the di odes wi th heat,
pi nch
the stator leads between
pliers to carry heat off,
and appl y the sol deri ng
i ron onl y l ong enough to
separate the l eads from the recti l l er.
. Use a 100 W sol deri ng i ron.
7. lnstallthe new rectifier in the reverse order of removal
. Appl y t he sol der i ng i r on onl y l ong enough t o
ensure a good connecti on so the heat wi l l not
damage the di odes
. Use onl y a rosi n core type sol der or sol der
j oi nts
wi l l corrode.
Rectifier
Test
NOTE: The di odes are desi gned to al l ow current to
pass
i n one di recti on whi l e bl ocki ng i t i n the opposi te di rec-
ti on. Si nce the al ternator
recti fi er i s made up of ni ne
di odes, each di ode must be tested for conti nui ty i n both
di r ect i ons wi t h an ohmmet er t hat has di ode checki ng
capabi l i ty; a total of 18 checks
1. Check for conti nui ty i n each di recti on between
-
the B and P termi nal s.
-
the B' and P termi nal s.
-
E
(ground) and the P termi nal s.
Al l di odes shoul d have conti nui ty i n onl y one di rec-
ti on.
l f anv of the di odes fai l s, repl ace the recti fi er assem-
bl y.
(Di odes
are not avai l abl e separatel y.l
23-107
Charging System
Rotor Slip Ring Test
1. Check the resi stance between the sl i p ri ngs.
There shoul d be 1.8
-
3.0 ohms.
. lf resistance meets the specification, go
to step 2.
. l f r esi st ance does not meet t he sDeci f i cat i on.
repl ace the al ternator.
Check that there i s no conti nui ty between the sl i p
ri ngs and the rotor or rotor shaft.
l f the rotor fai l s ei ther conti nui ty check, repl ace the
a l ternato r.
Stator Test
1. Check that there i s conti nui ty between each pai r
of
l eads.
cotL
CORE
Check that there i s no conti nui ty between each l ead
and the coi l core.
l f the coi l fai l s ei ther conti nui ty check, repl ace the
al ternator.
FOTOR SHAFT
23- 108
Alternator Brush Inspection
Separate the dri ve-end housi ng from the rear hous-
i ng as descri bed on page
23-106.
Separate the rear housi ng from the stator/recti fi er
assembl y by removi ng the four scrsws and the ter-
mi nal nut from the rear housi ng
(see page
23-,| 06).
Measur e t he l engt h of t he br ushes wi t h ver ni er
cal i pers.
Alternator Brush Longth:
O Standard
(NEW)
O
Servi ce Li mi t
19.0 mm
(0.75
i n) 5.0 mm
(0.20
i n)
l f the brushes are l ess than the servi ce l i mi t, repl ace
t hem.
\
1 .
)
Rear Beari ng RePl acement
1. Pul l off the rear beari ng.
. Make sure the ti ps ot the beari ng
pul l er j aws are
thi n enough to fi t between the beari ng and the
sl i p ri ngs.
. Do not reuse the beari ng.
SLIP RINGS
BEARING PULLER
Use a hand press to i nstal l the new beari ng. Appl y
pressure onl y on the i nner race to avoi d damagi ng
the beari ng.
REAR BEARING
SLIP RING
REAR BEARING
Alternator ReassemblY
1. Push t he br ushes i n, t hen i nser t a
pi n or dr i l l bi t
(about 1.8 mm di ameter) to hol d them there
BRUSHES
Heat t he r ear bear i ng seat i n t he r ear housi ng as
descri bed on page 23-106. After heati ng, conti nue
i mmedi atel y wi th assembl i ng before the rear bear-
i ng seat cool s compl etel y.
Put the rear housi ng/stator assembl y and dri ve-end
housi ng/rotor assembl y together, ti ghten the four
through bol ts and pul l out the
Pi n.
BRUSH ACCESS
REAR
STATOB ASSMBLY
After assembl i ng the al ternator, turn the pul l ey by
hand to make sure the rotor rotates smoothl y and
wi thout noi se.
THROUGH BOI,T
* ,
23- 109
Charging System
Alternator Belt Inspection and Adjustment
Detloction M6thod:
Appl y a force of 98 N
(10
kgt,22 l bf), and measure the
defl ecti on between the al ternator and the crankshaft oul -
Defl ecti on
|
8.0
-
10.5 mm
{0.31
-
0.41 i n}
NOTE: On a brand-new belt {one that has been run for less
than fi ve mi nutes), the defl ecti on shoul d be 6,0
-
9.5 mm
(0.26 -
0.33 i n) when fi rst measured. l f the bel t i s worn or
damaged. repl ace i t,
Measure here.
24Nm12. 4kgf . m,
CRANKSHAFT
PULLEY
lf adiustment is ncessary:
l . Loosen the l ower mounti ng nut and the upper mount-
i ng bol t.
2. Move the al ternator to obtai n the proper
bel t tensi on,
then reti ghten the upper mounti ng bol t and the l ower
mounti ng nut to the speci fi ed torques.
3. Recheck the defl ecti on of the bel r.
23-110
Belt Tension Gaug Method:
Fol l owi ng the gauge
manutacturer,s i nstructi ons. attach
the speci al tool to the bel t, and measure the tensi on.
Tens i on
I
340- 490N( 35- 50k gf , 77- j 10t bf )
NOTE: On a brand-new belt
(one
that has been run for less
than fi ve mi nutes), the tensi on shoul d be S4O
-740
N
(55 -
75 kgt 121
-
165 l bf) when fi rsr measured. l f the bel t
as worn or damaged, repl ace i t.
BELT TENSION GAUGE
07JGG
-
0010'l0A
lf adiuslment is ncossary:
' L
Loosen the l ower mounti ng nut and the upper mount-
ing bolt.
2. Move the al ternator to obtai n the proper
bel t tensi on,
then reti ghten the upper mounti ng bol t and the l ower
mounti ng nut to the speci fi ed torques.
3. Recheck the tensi on ot the bel t.
Fan Controls
Component
Location
Index
RAOIATOR FAN RELAY
Test ,
page 23 73
CONDENSER FAN RELAY
Test ,
page 23 73
UNOER-HOOD
CONOENSER
FAN MOTOR
FAN MOTOR
Removal , sect i on 10
ENGINE COOLANT
TEMPERATURE
(ECTI
swlTcH
Removal , sect i on 10
Test, section 10
.
- r i - r T _ t F - 1 t r ' l
t I r-r T-t T-l
,-, LJ L_J L_J I___I
t Qr _ -
-l
U LJ L-Jrr
23-111
Fan Control s
IGNITION SW TCH
Ci rcui t Di agram
UNDER.DASI-1
FUSEi RELAY BOX
l-'"----E l
-YEL-.].--o.\-F-h
- l
BrK
yEL -J
1,,**,
,J"
f
twl.i-:;"
BLK
I
I
t
G101
BLKi RED
I
I
l,^,^,",
T*'
I
BLK
I
I
-:
G20l
23- 112
UNDEF.HOOD FUSEi RELAY BOX
No 4r
i80A)
No 42 (40A)
Gauge Assembl y
Component
Locati on Index
sRS components are l ocated i n thi s area. Revi ew the sRS component l ocati ons,
precauti ons' and procedures i n the sRS
secti on {24} before
6 x 1 . 0 mm
9.8 N.m
(1.0 kg{.m,
22 tbt.ftl
VEHICLE SPEED SENSOR IVSS)
Troubl eshoot i ng, Page
23 124
FUEL GAUGE SENDI NG UNI T
Test ,
page 23' 126
GAUGE ASSEMBLY
Gauge/ l ndi cat or/ Termi nal
Locat i on I ndex,
Page
23_114
Removal ,
page 23-119
Bul b Locat i on,
Page
23 120
Di sassembl y,
page 23-122
)
BRAKE SWITCH
FLUID LEVEL SWITCH
ENGINE COOLANT TEMPERATURE IECT) GAUGE
SENDING UNIT
23-113
Gauge Assembl y
Gauge/l ndi cator/Termi nal
Locati on Index
With tachometer:
CONNECTOR
"A"
(A/ T
GEAR POSI TI ON I NDI CATOR)
CONNECTOR
"8"
{GAUGE and INDICATOR}
CONNECTOR
"C"
CONNECTOR
"O"
{ABS INDICATOB}
CONNECTOR
"E"
I
sHrFr-up or cRU|sE
I
lrNDrcAToR I
CONNECTOR
"F"
(SRS
INDICATOB}
SPEEDOMETER:
Indicates 60 km/h at 637 rpm or
60 mph at 1, 025 r pm of t he
vehi cl e speed sensor
( VSS) .
A/T GEAR POSITION
INDICATOR
See page
23-133
TACHOMETER:
I ndi cat es 100 rpm at
200 pul ses per mi nut e
of t he i gni t i on cont rol
modul e
( l CM) .
FUEL GAUGE
A1-
- --+A6
l rl . . : : . f i |
t.t
_..-ts|
----
47
- ->A14
B 1 - - - - - - - - - - { - B t 6
Jililil{ililt1
c 1
- - - - - - - - - > c 1 3
JililtHililL
o
o
.'
"3{\
D1-
- - - >D5
Fl-
- -->
F5
oa/
\ oo
23- 114
Gauge/ Sendi ng LJni t Test , page 23 126
EI ' I
Without tachometer:
CONNECTOR
"A"
tA/T GEAR POSITION INOICATOR}
CONNECTOR
"B"
IcAUGE and lNDlcAToRl
CONNECTOR
"C"
IcAUGE and INDICATORI
C 1 - - - - - . - - - . - - - > C 1 3
lilillllllL
81.
- - - - - - - - - - . - - - - - - +816
Innrruttttttl
---->414
\J (Ju gr
-
A a-)
, 6
s :
Fl --) F5
Dl - - - >05
CONNECTOR
"D"
IABS
INDICATOR)
SPEEDOMETER:
l ndi cat es 60 km/ h at 637 rpm or
60 mph at 1, 025 rpm of t he
vehi cl e speed sensor
(VSS).
(ECT) GAUGE
See sect i on 5
FUEL GAUGE
Gauge/ Sendi ng Uni t Test ,
page 23 126
oo/ \ oo
23-115
Gauge Assembl y
l " l '
BLK BLU
IJ
1",,-'
I
I
G401
G402
i
I
i
I
I
I
ol sysl em)
T l "
t t
I
*i"'
t l
t l
i I
l v
I
cRUl sE
I
CONTROL
' UNI T
Ci rcui t Di agram
(Wilh shill up ndicalor tighl)
I
l "
I RED/GRN
l f
I
WHT/RED
r l
t +
L'*'-
N0. 30 ( 7 5A)
FUSE
V
I
RED/BLK RED/BLK
FED
I
I
I
I
+
DASH LIGHTS
ERi GHTNESS
CONTFOLLEF
BLK
G401
l"'
WHTIBLU
v
TEFNATOF
UNDER. HOOD FUSEi FELAY BOX
UNDER DASH
FUSEi RELAY BOX
CHAFGING
SYSTEM
LI GHT
GAUGE
LI GHTS
l 3wx4 |
23- 116
l_"'f"'
BLK
I
G552
ECM/PCM
RIGHT
TURN
SI GNAL
INDICATOR
L GHT
ENGI NE
COOLANT
TEMPERATUFE
{ECT)
GAUGE
BLKAVHT +
(With lachomele0
:
rc-,w'oi-_l
I CoNTROL I
I
MODULE
I
|
( cM)
i
t v I
i , l , l
l l " i
No. 5l l 0A)
V
I
TUFN S]GNAL'
HAZARD WARNI NG
SWITCH
LEFT F]GHT
r-7 f-7
t l
t l
GRN/ RED CRN/ YEL
GAUGE ASSEMBLY
To
NEXT
PAGE
LOW FIJEL
IND CATOF
LI GHT
(3w)
ENGI NE
COOLANT
TEMPERATURE
(ECT)
SEND NG I]N T
BLK
o,1o,
G4A2
BtUtRED
L
V
ABS
CONTROL
IJNlT
8LK
G401
G402
{ cont ' d)
23-117
Gauge Assembl y
GAUGE ASSEMBLY
Ci rcui t Di agram
(cont' dl
PARKING
BFAKE
SW TCH
fclosed
Lever up )
(Opn
Leverdown J
folosed
:Unbuckled
l
lopen :Euckled
.l
(
YEUFED GRN/ORN
v l I
_i
|
,.y."
rRUNK
| , "", .
i'iiifl ,,,,,,,**,
r
p
rlt*i'!l*, *.","n,
t
:
ERAKE
FLUI O
TEVEL
swiTcH
lolosed
: Floal down
(Open
FloalLrp
23-118
PREVOUS
PAGE
ERAKE
SYSTEM
L GHT
(1. 4w)
)
./
SEAT
BELT
REMINDER
LIGHT
( 1. 4W)
\
C
't
I
TRUNK
INDICATOS
LIGHT
0. 4w)
\
'./
(
LOW OtL
PRESSURE
INOICATOR
LiGHT
(1. 4W)
\ / -
MALFUNCTION
INDICATOS
(MrL)
0.4w)
B6 83
BLK
T
G552
BLK
I
c401
G402
1 .
2.
3.
Removal
Remove the two screws from the i nstrument
panel .
Remove the i nstrument
Panel .
CAUTION: Carelully remove the instrument
panel without damaging the clips'
Ti l t the steeri ng wheel down wi th the ti l t adj ustment l ever.
Spread a protecti ve cl oth over the steeri ng col umn
5. Remove the four mounti ng screws from the
gauge assembl y.
6. Pry the
gauge assembl y out, and di sconnect al l connectors from i t'
7. Take out the gauge assembl y.
GAUGE ASSEMBLY
I NSTBUMENT PANEL
23-119
Gauge Assembly
Bulb Locations
(With
Tachometerl
TRUNK INDICATOR
LTGHT (1. 4
W)
GAUGE LI GHT {1. 4 wl
BRAKE SYSTEM
{1. 4 Wl
SEAT BELT
CHARGING SYSTEM LIGHT I1.4 WI
\
REMI NOER LI GHT {1. 4 W}
LOW FUEL INOICATOR
LIGHT
13 W}
HIGH BEAM
INDICATOR LIGHT
LTGHT
(1. 4
W)
LOW ENGINE OIL PRESSURE
INOICATOR LIGHT {1,4 WI
MALFUNCTION
INDICATOR
LAMP
IMIL}
{ 1. 4 W)
t 1. 4 Wl
RIGHT TURN SIGNAL
INDICATOR LIGHT
I1.4 WI
A/T GEAR POSITION
I NDI CATOR
11. 12 x 6l
{On t he pri nt ed
ci rcui t board)
LEFT TURN SIGNAL
INDICATOR LIGHT {T.4 WI
GAUGE LIGHTS {3 WI
SRS INDICATOR
(1.4
wl
{On t he pri nt ed
ci rcui t board)
GAUGE LI GHT I 3. 4 W}
aBs tNDtcAToR t1.4 Wt
{On the pri nted
ci rcui t board)
CRUISE or SHIFT-UP INOICATOR (1.12
Wl
{On t he pri nt ed
ci rcui t board)
23-120
E' |
Bulb Locations
(Without
Tachometerl
TRUNK INOICATOR
LTGHT t l . 4 W)
GAUGE LI GHT {1. , 1W)
BRAKE SYSTEM
LI GHT
(1. {
W)
SEAT BELT
REMI NDER LI GHT I 1. 4 WI
LOW FUEL INOICATOR
LIGHT
(3
W)
RIGHT TURN SIGNAL
CHARGING SYSTEM LIGHT
(1.4
WI
GAUGE LI GHT I 1. { W)
LOW ENGINE OIL PRESSURE
TOR LI GHT I 1. 4 W)
MALFUNCTION
INOICATOR
LAMP {MILI
BULB
(1. 4
W}
INDICATOR LIGHT
{1. 4 W}
sRs tNDtcAToR t1.4 W)
{On t he
pri nt ed ci rcui t board)
LEFT TURN SIGNAL
INDICATOR LIGHT {1.,r wl
A/T GEAR POSITION
I NDI CATOR {1, 12 x 6)
{On t he pri nt ed
ci rcLri t board)
GAUGE LIGHTS 13 W)
GAUGE LIGHT
13. 4
Wt
ABS tND|CATOR t1.4 Wt
{On the Dri nted ci rcui t board)
o / o
V @
J
23-121
Gauge Assembl y
Disassembly
{With
Tachometer)
NOTE: Handl e t he t ermi nal s and
pri nt ed
ci rcui t boards
car ef ul l y t o avoi d damagi ng t hem.
CRUISE or SHIFT-UP INDICATOR
PRINTEO CIRCUIT BOARD
TACHOMETER
Speci f i cat i on, page
23-1 14
METER PANEL
\
PRINTED CIRCUIT
d,@
ABS INDICATOR
PRINTED CIRCUIT BOARD
@
FUEL and ENGINE COOLANT TEMPERATURE {ECTI
,-@
ob,
.,- Il $
ts*u" El
| ""i l \ r
A/T GEAR POSITION INDICA
PRINTEO CIRCUIT BOARD
GAUGE AUGE
I
@ * l
l 6$-
\ \,/
@' ,
I
o 1
o, , o.
e F- - ^ ^ i ' \
g -.-
e\J !=r
c)
./
\\
o \ sê' - - - - - " ' )
I u , ' @
\\.Q
t/@
.,:
;=1 @ /+i
" . , , Yu
7
23-122
Disassembly
(Without
Tachometer)
NOTE: Handl e the termi nal s and
pri nted ci rcui t boards
careful l y to avoi d damagi ng them.
FUEL GAUGE
MOUNTING SCREWS {x 3}
METER PANEL
ENGINE COOLANT TEMPEMTURE
GAUGE MOUNTING SCREWS lx 3l
' o @
,"o
"
ôo
rmhiffi
rugF5w
.w- \\''$f ,a._d\
-r?ft
\
A \
A/T GEAR PoslrloN lNolcara
V
\ PRINTED CIRCUIT BOARO
ABS INDICATOR
@
PRINTED CIRCUTT BOARD
SPEEDoMETER .nd
ODO/TRIP METER
Speci fi cati on,
page 23' 115
ri\-
\,.j
4
D,l
\.{
FUEL
Tost,
GAUGE
page 23-126
oOOo
-z\\
' . oo. . - - - - - . . \
'.o.,'
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i ; o \
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ID
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23-123
Vehicle Speed Sensor
(VSSI
Troubl eshooti ng
Before testi ng, i nspect the No. l 5
(7.5
A) fuse i n the under-dash fuse/rel ay box.
Test ths 8LK wire:
t rom t he vehi cl e speed sensor
(vss).
2. Connect t he t est har ness
107LAJ
-
PT30200) only to the
engi ne wi re harness.
3. Connect t he RED t est harness
clip to the positive probe
of a
ohmmet er.
t he RED t est harness cl i p and
body ground.
\
(To
next page)
23-124
-
Repai r open i n t h. BLK wi r e
botwoen the VSS and G101.
Tesi tho BLK/YEL Wir:
1. Connect the WHT test harness
clip to the positive probe
of a
voltmeter, and connect the RED
test harness clip to the negative
probe.
(ll).
Repair open in the BLISYEL wire
betwoon tho VSS and tho under-
dash tuso/.slay box.
vss
I
(From previous page)
WHT TEST HARNESS
CLIP
TEST HARNESS
O7LAJ. PT3O2OA
RED TEST HASNSS
CLIP
"8"
PROTECTIVE
TAPE
GRN TESI HARNESS CLIP
Test rhe BLU/WHT wirer
Connect t he GRN t est har ness
cl i p t o t he
posi t i ve
Pr obe
of a
vol t met er, and connect t he RED
t est harness cl i p t o t he ngat i ve
probe.
Repair open in ihe BLUMHT wire
bctween lh6 VSS and ECM/FCM,
TCM {CWl, snd ctui3 control unit
l s t here about 5 V or more ?
T6st the vSS:
2. Connect t he ot her t est har-
ness connect or t o t he VSS
3. Rai se t he f ront of t he vehi cl e,
and suppor t i t wi t h sat et y
st ands,
4. Put t he vehi cl e i n neut ral wi t h
t he i gni t i on swi t ch ON
(l l )
5. Sl owl y rot at e one wheel wi t h
t he ot her wheel bl ocked
Does voltage pulse from 0 to
approx, 5 V or more ?
Speodometel Tost:
" B"
f r om t he
gauge assem_
2. Touch a probe to the BLU,ryVHT
wi re, and connect i t t o body
ground t hrough a vol t met er.
3. Slowly rotate one wheel with
t he ot her wheel bl ocked.
Ropair opsn in th BLU/WHT wire
between tho VSS and the spo.d'
meter.
Dos t he met er i ndi cat e
pul s-
i ng vol t age?
23-125
Fuel Gauge
4.
Gauge/Sendi ng Uni t Test
!@s@
Do nor smoKe wnre worxrng on tne ruet
system, Keep open flame away from yout work area.
NOTE: Refer to page
23-117 for the fuel gauge
system
crrcutl .
1. Check the No. 25
(7.5
A) fuse i n the under-dash fuse/
rel ay box before testi ng.
2. Remove the access panel from the fl oor.
ACCESS PANEL
Di sconnect t he 3P connect or f r om t he f uel gauge
sendi ng uni t .
Connect the vol tmeter posi ti ve probe
to the No. 2
termi nal and the negati ve probe
to the No. 1 termi -
nal , t hen t ur n t he i gni t i on swi t ch ON
( l l ) .
There shoul d be between 5 and 8 V.
. l f the vol tage i s as speci fi ed, go to step 5.
. l f the vol tage i s not as speci fi ed, check for:
-
an open i n the YEL/BLK or BLK wi re.
-
poor gr ound ( G552) .
Attach a
j umper
wi re between the No. 1 and No. 2
t er mi nal s, t hen t ur n t he i gni t i on swi t ch ON ( l l ) .
5.
6.
23-126
7. Check that the poi nter
of the fuel gauge
starts mov-
i ng toward the
"F"
mark.
CAUTION: Turn the ignition switch OFF betore the
poi nter reaches
"F"
on the gauge di al . Fai l ure to do
so may damage the tuel gauge.
NOTE| The fuel gauge i s a bobbi n
(cross-coi l )
type,
hence the fuel l evel i s conti nuousl y i ndi cated even
when t he i gni t i on swi t ch i s OFF, and t he poi nt er
moves more slowly than that of a bimetal type.
. l f the poi nter of the tuel gauge
does not move at
al l , r epl ace t he gauge.
. l f the gauge i s OK, i nspect the fuel gauge send
i ng uni t .
Remove the fuel gauge
sendi ng uni t as shown.
Japan-produced
FUEL GAUGE
SENDING UNIT
IJSA. Canada-Droduced
FUEL GAUGE
SENDING UNIT
8.
9. Measure the resi stance between the No 1 and No. 2
t er mi nal s at E
( EMPTY) , 1/ 2
( HALF
FULL) and F
(FULL)
by movi ng the fl oat.
USA, Canada-produced
(Cerami c
board typel :
Top ot t he wor kbench l Bot t om of t he f Ll el t ank)
l f the resi stance readi ngs are beyond the range, repl ace
t he f uel gauge sendl ng uni t .
E 1
FI oat Posi t i on
1/2 F
Resi stance
(O) 105 108 29.5
-
35.5 3 . 5 - 5
Japan-Produced {Wire-wound
type)'
Fl oat Posi ti on E
F
Resi stance
(O) 105
-
110 25. 5
-
39. 5
4 __r.*_
23-127
Interlock System
UNI T
I nput Test , page 23 130
KEY INTERLOCK SOLENOID
and KEY INTERLOCK SWITCH
(l n
t he st eeri ng l ock assembl y)
Test , page 23 131
PARKING PIN SWITCH
Test , page 23-132
SHIFT LOCK SOLENOID
6'm
,
\-/ \-!J
INTERLOCK
Test , page 23-131
23-128
UNDER.HOOD FUSE]RELAY BOX
No 41 (80A) N0.42 (40A)
L{Eu'flil'
+
YEL
fto
t f l
r'lTGEAR
POS TION
INDICATOR
17
I
BLK/BLU
feurrr
nro
l
sl eer n0
[o*
-
-]
GRN] WHT
I
t l
GRN/WHT GRN'1flHT
.
BRAKE LIGHTS
'CRUISE
CONTROT UNIT
.
ABS CONTROL UN]T
.
TCi,4 (CW)
J
YELTBLK
3 NTERLOCK CONTFOL UN1T
PARK NG
PLN SW TCH
A,TT GEAR
POSITLON
SWITCH
( C osed I n posr l on
E )
WHT/BLK
I
Yr
BLK
I
G401
G402
l '
BLK
I
G401
KEY INTERIOCK C RCUIT
BLK/BLU
23-129
G401
J
lnterlock System
2.
Control Uni t Input Test
t . Di sconnect the 8P connector from the i nterl ock con-
t r ol unr t .
I nspect t he connect or and socket t er mi nal s t o be
sure they are al l maki ng good contact.
. l f the termi nal s are bent, l oose or corroded, repai r
them as necessary, and recheck the system.
. l f t he t er mi nal s l ook OK, mak e t he f ol l owi ng
i nput tests at the connector.
l f a test i ndi cates a probl em, fi nd and correct
the cause, then recheck the system.
-
l f al l t he i nput t est s pr ove OK, subst i t ut e a
known-good control uni t, and recheck the sys-
tem. l f the check i s OK, the control uni t must
be faul ty; repl ace i t.
NOTE: l f t he shi f t l ock sol enoi d cl i cks when t he
i gni ti on swi tch i s turned ON
(l l )
and you step on the
brake pedal (wi th
the shi ft l ever i n
E),
the shi ft l ock
syst em i s el ect r oni cal l y nor mal ; i f t he shi f t l ever
cannot be shi fted from
E,
test the A//T gear posi ti on
swi tch. parki ng pi n swi tch, and see secti on 14.
Key Interlock System:
Cavi ty Wire Test condition Test: Desired result
Test: Desired result
Wi re si de of
Possible cause if result is not obtained
INTERI-OCK
CONTROL UNIT
Reconnect the 8P connector to the i nterl ock control uni t.
Shift Lock System:
Cavity Test condi ti on Wi re Possible cause if result is not obtained
WHT/BLU
1
4 5 1 I
wHT
sLr/glu wHrlneo
1 WHT/BLU
l gni t i on swi t ch t urned t o
ACC
( l l and
key pushed; n
Check f or vol t age t o gr oundl
Ther e shoul d be bat t er y vol t age.
Bl own No. 48
(30
A) f use i n t he under-
hood f use/ rel ay box
Bl own No. 33
(7. 5
Ai f use i n t he under
dash f use/ rel ay box
Faul t y st eeri ng l ock assembl y
(key
i nt erl ock sol enoi d)
An open i n t he wi re
5
4 BLK
Under al l c ondi t i ons Check f or cont i nui t y t o ground:
There sho(, l d be cont i nuat y.
.
Poor ground (G401,
G402)
.
BLI (BLU
Shi f t l ever i n
E Check l or cont i nui t y t o ground:
There shoul d be cont i nui t y.
Poor ground
{G401, G402)
Faul t y M
gear posi t i on swi t ch
2 YEL
l gni t i on swi t ch ON
(l l )
Check f or vol t age t o
ground:
There shoul d be bat t ery vol t age.
'
Bl own No. 25
(7. 5
A) f use i n t he under
dash f use/ rel ay box
.
3 YEUBLK
( l l )
Check f or vol t age t o gr ound:
Bl own No. 25
( 7. 5
A) f use i n t he under -
dash fuse/relay box
Faul t y shi f t l ock sol enoi d
An open an t he wi r e
6 BLK/8LU
Shi f t l ever I n
E
Ther e shoul d be 1 V or l ess.
Poor ground (G401,
G402)
Faul t y A, / T gear posi t i on swi t ch
I WHT/ RED
(l l )
Brake pedal depressed
Bl own No. 52
(15
Al f use i n t he under
hood f userel ay box
Faul t y PCM
Faul t y brake swi t ch
(see
sect i on 11)
Faul t y t hrot t l e
posi t i on
{TP} sensor
{see sect i on l 1)
( l l )
Br ake pedal and
accelerator depressed at
t he same t r me
23- 130
Key Interlock Solenoid Test
' 1.
2.
Remove t he dr i ver ' s dashboar d l ower cover and
knee bol ster {see secti on 20).
Di sconnect t he 7P connect or f r om t he mai n wi r e
harness.
t
)
key
4. Check that the key cannot be removed wi th
power
and ground connected to the No. 7 and No. 5 termi
na l s.
. l f the key cannot be removed, the key i nterl ock
sol enoi d i s OK.
. l f the key can be removed, repl ace the steeri ng
l ock assembl y
(the
i nterl ock sol enoi d i s not avai l -
abl e separatel y).
I
\
Ter mi nal
;il;
-- --\
7
l gni ti on
switch
ACC {r)
Key pushed i n o--
--' o
Key rel eased o- o
1 .
Shift Lock Solenoid Test
Remove the tront consol e
(see
secti on 201.
Di sconnect the shi ft l ock sol enoi d 2P connector.
Connect battery
power to the No. 1 termi nal and
ground to the No. 2 termi nal of the sol enoi d momen-
rarIy,
NOTE: Do not connect
power to the No. 2
(-)
termi -
nal
(reverse pol ari ty) or you wi l l damage the di ode
i nsi de the sol enoi d.
Check that the shi ft l ock rel eases when the rel ease
l ever i s pushed. and check that i t l ocks when the
rel ease l ever i s rel eased.
l f the sol enoi d does not work, repl ace the sol enoi d
23-131
Interlock System
Parking Pin Switch Test
1 . Remove the front consol e
(see
secti on 20).
Di sconnect the 4P connector from the
parki ng pi n
swi tch.
Check for conti nui ty between the No. 3 and No. 4
termi nal s wi th:
-
the shi ft l ever any posi ti on other than
E.
or
-
the push button pushed i n
E.
There shoul d be conti nui ty,
Check for conti nui ty between the No. 3 and No. 4
termi nal s wi th the shi ft l ever i n
E
and the push but-
ton rel eased. There shoul d be no conti nui ty. It nec-
essary, repl ace the parki ng pi n swi tch.
NOTE: Parki ng pi n swi tch 4P connector No. 1 and
No, 2 termi nal s are for A,/T gear posi ti on consol e
l i ght, refer to the ci rcui t di agram on page 23-134.
2.
23-132
A/T Gear
Posi ti on Indi cator
J
Component
Location Index
sRs components are l ocated i n thi s area. Revi ew the sRs component l ocati ons,
precauti ons, and procedures i n the sRs
secti on
(24)
before
performi ng repai rs or servi ce
A/T GEAR POSITION INDICATOR
I nput Test ,
Page
23-136
Test ,
page 23-138
Repl acement , Page
23-139
t
E
N
E
E
B
E
N
E
E
E
(cvr)
23-133
A/T Gear Position Indicator
N0.30 {7.54)
FUSE
\-/
I
RED/BLK
UNDER-DASH
FUSEi FELAY 8OX
t'*','uorl
f..*fl
I t l
I
YEL
\
Ci rcui t Di agram
CW:
.
ECM
.
TCM
V
I
LTGRN
A,4 GEAR PoSlTloN NDICATOR (n the gauge assenrbly)
No30 (7 5A)
V
I
NED/8LK
t ,
| ,,-k
g'qen
I
l l q l c o N s o L E l
I Y./ LGHT I
| |
"' *'
I
t l l
t '
RED
I
I
V
OASH LI GHTS
BRI GHTNESS
CONTROLLER
23-134
IGNITION
SWTCH
A"/T GEAR POSITION NDICATOR DIMMING CIFCUIT
BLK
G401
G402
VYVY
t t l t
T/TGEAR
POSTTl0N
SWTCH
UNDEF- OASH
FUSE/RELAY BOX
Ci rcui t Di agram
Except CVT:
. \ OEP HOOD
LUSE
RELAY BOX
PCM
V
I
GRN]BL(
I
YEL
I
BLK
I
I
I
-:
G401
G402
( COnt
d
23- 135
No30
0.54)
V
I
REDi BLK
t ,
| ,L e;"'lgn I
l { d l c o N s o t E l
l Yi t ei l |
t t l
t '
I
FED
I
I
DASH LIGHTS
BR] GHTNESS
CONTROLLEF
I
A,TGEAR POSIT ON NDICATOR D]MI!,IING CIRCU]T
\ \ l t /
-
/
RED/BLK
l./TGEAR POS T ON INDICATOR
(h thegalge assemby)
A2
YYYY
RED
I
I
I
DASH LIGHTS
BR GHTNESS
CONTNOLLER
,t^j
I
A"|t GEAR
POS TON
SWITCH
A/T Gear Position Indicator
Indi cator Input Test
1 . Remove the gauge
assembl y from the dashboard
(see page 23-1' 19), and di sconnect the t4p connector from rne gauge
assembl y.
Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
. l f the termi nal s are bent, l oose or co rroded, repa i r l hem as necessary, a nd recheck the system.
. l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the 14p connector.
-
l f a test i ndi cates a probl em, fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests prove OK, but the i ndi cator i s faul ty, repl ace the pri nted ci rcui t board.
14P CONNECTOR
"A"
YEL RED/ BLK RED
BLU BRN
(*1I
A1 A2 A3 A6
A8 A9 A10 A1 1 412 413 414
BLK
WHT LT
GAUGE ASSEMBLY
*1i
Not used
'2:
Excepr CVT
*3:
CvT
23-136
\
I
Cavity Wire
Test condition
Test: Desiled result
Possible cause il result is not obtained
*1:
Except CVT
*2:
CVT
A'I
YEL
l gni ti on swi tch ON {l l )
Check for vol tage to ground:
.
Bl own No.25
(7.5
A) fuse i n the
under-dash fuse/rel aY box
.
An open i n the wi re
A2 RED/BLK
Combi nat i on l i ght
swi t ch ON and dash
l i ght s bri ght ness
cont rol di al on f ul l
bri ght
Check for vol tage between
RED/BLK and RED termi nal s:
There shoul d be battery vol tage
Bl own No. 30
( 7. 5
A) f use i n t he
Faul ty combi nati on l i ght swi tch
Faul ty dash l i ghts bri ghtness
control l er
A3 RED
A4 BLU Shi ft l ever i n
E
or
E
Check Ior conti nui ty to groundl
There shoul d be conti nui ty
NOTE: There shoul d be no
conti nui ty i n anY other
Posi ti on
.
Faul ty A//T gear posi ti on swi tch
.
410 GRN Shi ft l ever i n [q] or E
RED
Shi ft l ever i n
E
A.12 WHT Shi ft l ever i n
@
413 BLVBLU
Shi ft l ever i n
E
NOTE: Don' t depress
the brake
pedal .
A9
YEL* 1
l gni ti on swi tch ON
(l l )
and shi ft l ever i n anY
posi ti on except El
There shoul d be battery vol tage for
tl vo seconds after the i gni ti on
swi tch i s turned ON
(l l ), and then
l ess than 1 V.
Faul ty TCM*'
Faul ty PCM*'
GRN/BLK*'
(l l )
and shi ft l ever i n any
posi ton except @
A8 BLK
Under al l condi t i ons
Check for conti nui ty to ground:
There shoul d be conti nui tY.
.
Poor
ground
(G401,
G402)
.
A14 LT GRN
(l l ) Check for vol tage to ground:
.
There shoul d be battery vol tage*'
.
There shoul d be about 5 V*r
Faul ty TCM*'
Faul ty PCM*i
23-137
A/T Gear Posi ti on Indi cator
A/T Gear Position Switch Test
1. Remove the front consol e l see secti on 20).
2. Di sconnect the 14P connector from the Ay' T gear posi ti on
swi tch.
3. Check for conti nui ty between the termi nal s i n each swi tch posi ti on accordi ng to the tabl e.
. Move the shi ft l ever back and fonh wi thout pushi ng the shi ft l ever at each swi tch posi ti on, and check for conti nui ty
wi thi n the range of free pl ay of the shi ft l ever.
. l f there i s no conti nui ty wi thi n the range of free pl ay. adj ust the posi ti on of the swi tch as descri bed on the next
page.
Back
-
up Neutral
Light Switch Position Switch
* 1 : With cruise controlsystem
23- 138
Ter mi nal si de o{ mal e t er mi nal s
\
Termi nal
t**"\
2 5 6 7
* 1
I
1 '
l 3 1 4 3 l 0 1 1
(Not
used) G-
--o
a tr CF
-_o
E E o-
--o
E E o-
-o
N N o-
--o
o-
--o
tr tr o-
--o
o-
--o
E tr o-
-_o
CF
--o
n
Replacement
4.
' t.
Remove the l ront consol e, then di sconnect the
connector from the A' /T gear posi ti on swi tch
Remove the two mountang nuts
swrTcH
SLIDER
6 xl .0 mm
98Nm( 1 0 kgf ' m, 7l bnf t )
Posi t i on t he swi t ch sl i der t o
" Neut r al "
as shown
above.
Move the shi ft l ever to
"Neutral ",
then sl i p the swi tch
i nto
posati on.
Attach the swi tch wi th the two mounti ng nuts'
Test the swi tch i n the E
and N
posi ti on of the shi ft
l ever. The engi ne shoul d start when the shi ft l ever
i s i n posi ti on
E
anywhere
i n the range of free pl ay
Connect the 14P connector, cl amp the harness, and
i nstal l the front consol e.
14P
1 .
Adjustment
1. Shi ft to the
E
posi ti on, and l oosen the nuts'
2. Sl i de the swi tch i n the di recti on of El
or
E
posi ti on
Iwi thi n
2.0 mm
(0.079 i n.)l so that there i s conti nu' ty
between the No. 1 and No.7 termi nal s i n the range
of free
pl ay of the shi ft l ever'
3. Recheck for conti nui ty between each of the termi -
nal s.
NOTE:
. It adj ustment i s not possi bl e, check for damage
t o t he shi f t l ever det ent and/ or t he br acket l f
there i s no damage, repl ace the consol e swi tch'
. The engi ne shoul d sl art when the shi l t l ever i s i n
posi ti on
S
i n the range of free pl ay
Fre play
Di rect i on o{
I DI
or E Posi t i on
I wi t hi n
2. 0 mm
(0. 079 i n)l
LOCK PI N
23-139
Integrated Control Unit
\
Ci rcui t Di agram
WHT/8LK +WH'I
W NDSHIELD WIPERi
WASHER
9WTTCH
.
OFF/INT INT
f7 f7
t l
t l
t l
t l
8LU/BLK YEL/BLU
WHT/RED
\
BLK
G40l
G402
ELU,JWHT
I
I
I
r7
WINDSH ELD
WI PER
MOTOR
l un^r,r-r
--1--
l$'lli3fl*"'
I
i v
I
|
|
wHnBLK
|
*'f--J
i l
| ,,^v.,,
I WASHER
|
__
"oto*
_
UNDER,HOOD FUSE/RELAY BOX
g
*
COMBINED
WIPER WASHEH
CI RCUI T
INTERMITTENT
W PER BELAY
CI RCUI T
* With combrned wiper washer opeGl on
(ffr)
A/T GEAR
POSITION SWITCH - -
( Cl osed: npos| on l g
or
[ N] )
t
6
gr_r<rqrl
BLKI\lvHl
-
10 \--l11
BLU,BLK+[:'##"
I
COMBINATION
LIGHT SW]TCH
f7
I
REDiGRN
STARTER
CUI FELAY
UNDER DASH FUSE/BELAY BOX
I
YEL
A
SEAT BELT
FEII,I NDER
LIGHT
INTEGRATED CONTROL UNIT
GRN
LI
I
A L T
I,if;',"",",.. ,
foeen
Doorcrosed ,
-:
|
''o
[t
BLUi RED
9]
l u '
I
I
ttu,.'
BLU/BED
A
Y
lf#,]"J
' )
l(3ix' ;
BLK
T
G401
G402
I
GRNi RED
BLK
T
c552
23-141
, l = - _
Integrated Control Unit
Input Test
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons,
and procedures
an the SRS
secti on
(24)
before performi ng
repai rs or servi ce.
1. Remove the dri ver' s dashboard l ower cover and knee bol ster
(see
secti on 20).
2. Di sconnect the 10P connector from the i ntegrated control uni t.
3. Remove the i ntegrated control uni t from the under-dash fuse/rel av box.
4. Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
. l f the termi nal s are bent, l oose or corroded, repai r them as necessary, and recheck the system.
. l f t het er mi nal sl ookoK, maket hef ol l owi ngi nput t est sat t heconnect or andt hef use/ r el ayboxsocket .
-
l f any test i ndi cates a probl em, fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests prove OK, the control uni t must be faul ty; repl ace i t.
INTEGRATEO CONTROL UNIT
1OP CONNECTOR
Wi re si de of
23-142
\
All Systems:
Cavity Wire
Test condition
Intermittent Wiper SYstem:
Cavity Wire
Test condition
Test: Desired rssult
(cont' d)
A14 BLK
Under al l condi ti ons Check for conti nui ty to
ground:
There shoul d be conti nui ty
.
Poor
ground
(G401,
G402)
.
A9
Under al l condi ti ons
Check f or vol t age t o
ground:
There shoul d be bat t ery vol t age
Bl own No. 43
(7.5 A) fuse i n the
under-hood fuse/rel aY box
A6
(l l ) Check for vol tage to
ground:
There shoul d be batterY vol tage.
.
Bl own No. 25
(7.5
A) fuse i n the
under-dash fuse/rel ay box
.
B1
82
BLU/BLK
and
BLU,AiVHT
(l l ),
and wi ndshi el d wi Per
swi tch at OFF or INT
Check for conti nui tY between the
BLU/BLK and BLU/WHT termi nal s:
There shoul d be conti nui tY.
Bl own No. 26
( 20
A) f use i n t he
underdash fuse/rel ay box
Faul ty wi ndshi el d wi Per swi tch
Faul ty wi ndshi el d wi Per motor
B3 YEUBLU
(l l ),
and wi ndshi el d wi Per
swi tch at INT
Check for vol tage to
ground:
Bl own No. 26
( 20
A) f use i n t he
Faul ty wi ndshi el d wi Per swi tch
*A5
(l l )
Bl own No. 26
( 20
A) f use i n t he
* 84
WHT/BLK
(l l ),
and wi ndshi el d washer
swi tch ON
.
Faul t y wi ndshi el d washer swi t ch
.
*:
Wi th combi ned wi per-washer operati on
rre-
23-143
Integrated
Control Unit
Input Test
(cont' dl
a l
- - - - - - - - - - - > A 7
A 8 - - - - - - - - . - > A 1 4
Key-in/Seat Belt Reminder, Lights-on Reminder System:
Cavity Wire Test condition
Bulb Check System
(Brake
System Light):
BLU/ RED
Possible cause it result is not obtaineo
A8
swi t ch ON
Check f or vol t age t o groundl
There shoul d be bat t ery vol t age.
Bl own No. 30
( 7. 5
Al f use i n t he
under-dash f use/ rel ay box
Faul t y combi nat i on l i ght swi t ch
81 RED/BLU
( l l ) ,
and dri ver' s seat bel t
swi tch unbuckl ed
Poor gr ound ( c552)
Faul ty seat bel t swi tch
B9 GRN
Dri ver' s door open Check for vol tage to ground:
There shoul d be i V or l ess.
.
Faul ty dri ver' s door swi tch
'
810 BLU/RE D
l gni ti on key i nserted
i nto the i gni ti on key
swrtcn
Ther e shoul d be' l V or l ess.
Poor gr ound ( G401,
c402)
Faul ty i gni ti on key swi tch
A4 GRN/ RED
l gni t i on swi t ch oN (
) ,
brake fl ui d reservoi r
f ul l , and par ki ng
br ake
l ever down
Connect to ground:
Brake system
l i ght shoul d come on.
Bl own No. 25 (7.5
A) fuse i n the
under dash fuse/rel ay box
Bl own brake system l i ght bul b
A1 3 B tU/^/VHT
l gni ti on swi tch at
START
0 )
Bl own No. 31
(7.5
A) fuse i n the
Faul ty starter cut rel ay
An open i n t he wi r e
23-144
l.r
^
Lighting System
DAYTIME RUNNING LIGHTS
RESISTOR
(canadal
Test , page 23-151
DAYNME RUNNING LIGHTS
CONTROL UNIT
(Canadal
I nput Test ,
page 23-150
.HEADLIGHT
Adj ust ment ,
Page
23
' 152
Repl acement ,
page 23 151
SIGNAL LIGHT
Repl acement ,
Page
23-151
HIGH MOUNT BRAKE LIGHT
Repl acement ,
page 23 159
LICENSE PLATE
Repl acement ,
page 23-156
INNER TAILLIGHT
OUTER TAILLIGHT
RePl acement ,
Page
23 153
*:
Headl i ght and f ront parki ng/ f ront t urn si gnal l i ght cannot be separat ed
( cont ' d)
23-145
Li ghti ng
System
(cont' dl
DASH LIGHTS BRIGHTNESS
CONTROLLER
Cont rol l er l nput Test ,
page
23-161
TURN SIGNAL/HAZARD RELAY
I nput Test , page 23-155
HIGH BEAM INDICATOR LIGHT
23-146
TURN SI GNAL I NDI CATOR LI GHT
COMBINATION LIGHT SWITCH
Test , page
23 149
r- rll l......--,.'...-1F''------4 | l \
q L__.r
L__Jt
'
-;----
)
--:fft,1al
flfl 11 f-
---l
L_J
{_
O
n n n n n n n n n n ; n
r _ _ r f l
O
_
Lr u r,J rJ rJ [J LJ LJ rJ LJ LJ rJ
|
|
I - n n n n r r - n n r r n n L J
! J
a -
IJ I-] IJ LI tJ IJ LJ t,J U T-J U LI
r'r n rr n it rr r't rl - n r.t 11 it r'l
ut Jl J| ' JLl | JLJLI LI | . JLj | ' Jt JLl
trtt
Ci rcui t Di agram
(USA)
RED/BLK
I
I
I
r?
PARKING LIGHTS
TA]tL]GHTS
LICENSE PLATE LIGHTS
FEDi BLK
I
I
I
Y'
DASH LIGHTS
DASH LIGHTS
BRIGHTNESS
CONTROLLER
REDiGRN
I
BLK
I
G401
G402
H]GI-] BEAM
NDICATOR
LIGHT
( 1. 4w)
UNDEB,HOOD FUSEi RELAY BOX
. \ - -
- - - - - - - ' r \ - - - - '
-T
\-"
T,g,?..
T
o
I,JNDER.DASH FUSE/FELAY BOX
)
J
No. 5
?
00A)
I
No 30
(7. 5A)
I
i
u',';
I
N0.22
( 104)
l , l
Zltl
(
I I
N0. 4
00A)
BLK
I
G201
BLK
I
oio,
23-147
Lighting System
EBAKE SYSTEM
L GHT
I NTEGFATED
CONTBOL UNIT
\-7
I
I
RED/GRN
Ci rcui t Di agram
(Canadal
23-14A
REDi GFN
I
I
A
| ) l
I BRAKE FLI JI D
I
LEVEL SW TCH
)l
I
Ic
osd . Floar downl
BLK
I
-L
-
G401
G402
T
:
BLK
n
:
G40l
G402
BLK
I
G2A1
BL(
I
G2A2
FED' GRN
I
I
( ei
Y*,0
t N c
I L G
l ( r a
8LK
I
I
G401
G402
UNDEF HOOD FUSE/ RELAY 8OX
REDI WHT
RED
L
UNDER.DASH FUSE/FELAY BOX
RED/GNN ]T : L
N0.20
(r 0A)
,
N0. 18
)
(7.54)
L_l
qbiNo.4
( 10A)
I I
)No
30
)t o. : z
L
{7.sA)
'r
t7 5A)
T I
FLD GF\ cLD
vF.
RFo W- FFD 8LU
qro
e. , ( neo a_x
| | |
|
,^,f,-,,,^,."f:",
t t l
| | |
|
Eiffifg.'':trio.'''0-',
I | | r*.",-lT1F*,,._
""t*
l)tJ-;-,
3t:'r{"is-t}6}"
t&Jdt&JsJ
)
liE;;-""' lt*.'
ru$i'%H
I I
ftHT YEL
'BLK
OAYTIME
FUNN NG LIGHTS
CONTROL UNI T
REDi 3RN
PARKING
BRAKE
swrTcH
lclosed
Lever upl
COMBINATION LIGHT SWITCH
Headlight/Dimmel/Passing
Switch :
*
: Canada
Turn Si gnal Swi tch :
Combination
Light Switch Test
1 . Remove the dri ver,s dashboard l ower cover and steeri ng col umn covers
(see
secti on 20).
Di sconnect the 4P and 7P connectors from the swi tch.
I nsoect t heconnect or andsocket t er mi nal st obesur et heyar ea| | maki nggoodcont act '
. l l the termi nal s are bent, l oose. orcorroded, repai rthem as necessary, and recheck the system'
. l f the termi nal s l ook OK, check for conti nui ty between them i n each swi tch
posi ti on accordi ng to the tabl es l f there
i s no conti nui ty between any of them, check for conti nui ty i n the swi tch harness
-
l f there i s conti nui ty i n the swi tch harness' repl ace the combi nati on l i ght swi tch'
-
l f there i s no conti nui ty i n the swi tch harness, repl ace l t'
rffi]
t t Al t A2 ! l
-l :
f l -
l ar
mJl
7P CONNECTOB
\
Tetmi nal
Position \
B1 82
B3
* 8 4 B5 B6
Headlight switch
OFF
:m: o--
- o
=D
LOW cF-
--o
o-
--o
HIGH o-
----o
o-
----o
Passing switch
OFF
ON
O-
---{
Terminal
Position
A1 A2 A4
RIGHT o-
o
NEUTRAL
LEFT o o
23-149
Lighting System
Dayti me Runni ng Li ghts Gontrol Uni t Input Test
(Canadal
2.
3.
1 . Remove t he dr i ver ' s dashboar d l ower cover and
knee bol ster
(see
secti on 20).
Di sconnect t he connect or s f r om t he dayt i me r un-
ni ng l i ght s cont r ol uni t .
I nspect t he connect or and socket t er mi nal s t o be
sure they are al l maki ng good contact.
l f the termi nal s are bent. l oose or corroded, repai r
them as necessary, and recheck the system.
l f t he t er mi nal s l ook OK, make t he f ol l owi ng
i nput tests at the connector.
-
l f any test i ndi cates a probl em, fi nd and correct
the cause, then recheck the system.
-
l { al l the i nput tests prove OK, the control uni t
must be faul ty; repl ace i t.
Cavity Test condition Test: Desired rgsult
Wi re
B1 BLK
U nder al l condi t i ons Check f or cont i nui t y t o gr ound:
Ther e shoul d be cont i nui t y.
.
Poor ground (G401.
G402)
.
A2 BLK /VHT
Under al l condi t i ons Check for vol tage to groundl
.
El own No. 20
(10
A) fuse i n the
under-dash fuse/relay box
.
82 YEUBLK
Igni ti on swi tch ON
(l l )
Bl own No.
' 18
(7.5
A) fuse i n the
Faul ty i gni ti on swi tch
RED
swi t ch i n
"=d'
posi t i on
Bl own No. 48
(30
Al fuse i n the
under-hood fuse/rel ay box
Faul ty combi nati on l i ght swi tch
A1 WHT/RED
swi tch OFF; connect a
j umper
wi re between
t he YEUBLK and
WHT/RED termi nal s,
t hen t ur n t he i gni t i on
swi t ch ON
( l l )
Headl i ght s ( hi gh
beam) shoul d
come on,
( and
hi gh beam
i ndi cat or shoul d come on) .
Poor gr ound ( G201,
G202. G401,
G402)
Bl own bul bs
Faul ty dayti me runni ng l i ghts
resi stor
B3 GRN/ RED
( l l ) ,
brake f l ui d reservoi r
f ul l , and parki ng
brake
l ever down
Connect to ground: The brake
system l i ght shoul d come on.
Bl own No. 25 {7.5 A) fuse i n the
Bl own brake system l i ght
B6 RED/GRN
Parki ng brake l ever up Check for conti nui ty to ground:
.
Faul ty parki ng
brake swi tch
.
23- 150
Headlights/Front
Turn
Signal/Parking
Lights
I
Dayti me Runni ng Li ghts Resi stor
Test
(Canada)
CAUTION: The davtime running lights resistor becomes
very hot when the daytime running lights are on; do not
touch i t or the attachi ng hardware i mmedi atel y aftel
the lights have been turned oft.
1. Di sconnect the 3P connector from the resi stor'
termi nal s
Measure the resi stance between the resi stor termi _
nal s
(No.
' l
and No. 2) and the power termi nal No 3
Resistance: 1,6 o i 0 08 o
Repl ace the resi stor wi th a new one i t any of the
resi stances are beyond speci l i cati on.
DAYTIME RUNNING
. ^
23-15'
Repl acement
CAUTION: Halogen headlights become very hot in uss;
do not touch them 01 the attaching hardware immedi-
atelv after they have been turned oft.
1. Remove t he l ront bumper
(see
sect i on 20).
2. Remove t he mount i ng bol t s
3. Di sconnect each connect or, t hen remove t he head
l i ght / f ront t urn si gnal / parki ng
l i ght assembl y.
MOUNTING
BOLT
HEADLIGHT,/FRONT TURN SIGNAL/
PARKING LIGHT ASSEMBLY
HEADLIGHT: 60/55 W
FRONT TURN SIGNAL/PARKING LIGHT: 2115 W
Headl i ghts
Adjustment
Before adj usti ng the headl i ghts:
. Park the vehi cl e on l evel ground.
. l vl ake sure the fuel tank i s ful l .
. The dri ver or someone who wei ghs the same shoul d
si t i n the dri ver' s seat.
. Load the trunk wi th the i tems you usual l y carry.
. Push down on the front and rear bumoeG several ti mes
to make sure the car i s si tti ng normal l y.
CAUTION: Halogen headlights become very hot in use;
do not touch them or the attaching hardware immedi-
ately after they have been turned off,
1. Open t he hood.
2. Check the hori zontal adj ustment i ndi cator.
The
"0"
mark on the hori zontal i ndi cator gear shoul d
be al i gned wi th the mark on the hori zontal i ndi cator.
3. l f t he i ndi cat or i s not al i gned wi t h i t s
" 0"
mar k as
descri bed above, an adj ustment can be made by usi ng
a Phi l l i Ds screwdri ver.
23-152
HORIZONTAL INDICATOR
HORIZONTAL INDICATOR
Adj ust the headl i ghts to l ocal requi rements by turn,
i ng the adj usters.
After headl i ght repl acement, i t may be necessary to
readj ust the hori zontal i ndi cator gear.
. Fi rst i nstal l the headl i ght, and adj ust i ts hori zontal
and ver t i cal ai mi ngs accor di ng t o l ocal r equi r e-
menIs.
. Then check that the arrow on the hori zontal i ndi -
cator gear i s al i gned wi th the mark on the hori -
zontal i ndi cator.
-
l f they are not al i gned, remove the screw, adj ust
the indicator gear, and retighten the screw.
NOTE: As the outer l enses a.e made of an acryl i -
coated, pol ycarbonated
materi al , do not cover the
headl i ghts when they are turned on.
Tai l l i ghts
Repl acement
NOTE:
. tnspect the gaskeU repl ace i t i f i t i s di storted or stays
compressed.
. After
j nstal l i ng
the tai l l i ghts, run water over them to
make sure they do not l eak
Outer Tai l l i ghts:
1. Open t he t r unk l i d/ hat ch.
2. Di sconnect the 4P or 6P connector from the outer
t ai l l i ght .
3. Remove t he f our mount i ng nut s, t hen
pul l out t he
out er t ai l l i ght .
Hatchback:
BRAKE/TAILLIGHT:
2115W
TURN SIGNAL LIGHT: 21 W
BACK-UPLIGHT:
21W
Coupe/Sedan:
BRAKE/TAILLIGHT:
2115w
TURN SIGNAL LIGHT: 21 W
,lP
or 6P CONNECTOR
23- 153
Inner Tai l l i ghts
(Coupe/Sedan):
1. Open t he t r unk l i d, t hen r emove t he access
panel
2. Di sconnect the 4P connector from the i nner tai l l i ght
3. Remove t he I our l t hr ee]
mount i ng nut s. t hen pul l
out t he i nner t ai l l i ght .
I l : Sedan
Coupe:
I NNER TAI LLI GHT
Sedan:
BRAKE/TAILLIGHT:
2115W
BACK-UP LIGHT: 21W
INNER TAILLIGHT
4P CONNECTOR
Turn SignaUHazard Flasher System
No 30
(7.541
V
" l
RED/BLK
I
t l
r l
I
DASH LIGHTS
BRI GHTNESS
CONTROLLER
GRN/YEL
Ci rcui t Di agram
G601. G76t Hatchback
G601 CouperSedan
(Nol used) 2
TUFN S GNAL SWITCH
FRONT
(2rw)
ND CATOR
( 1. 4W)
BLK BL(
G2A2
BLK
G40l
G4A2
CoOt, GZOt tlrt.nlr.t
G601 : Coupe/ Sedan
G201
UNDER. OASH
FIJSEiRELAY BOX
GRNMHT
3
RIGHT TURN SIGNAL LIGHTS
INDlCATOR
N0. 12 ( 7. 5A)
UNOER HOOD FUSEi RELAY BOX
GN T] ON SWI CH
23-154
trI\
.t Turn Signal/Hazard
Relay Input Test
precauti ons, and
procedures
(24)
betore
vrce.
1. Remove the turn si gnal /hazard rel ay from the under-
dash fuse/rel ay box.
2. Inspect the rel ay and fuse/rel ay box socket termi nal s
to be sure they are al l maki ng
good contact.
. l f t he t er mi nal s ar e bent , l oose or cor r oded,
repair them as necessary, and recheck the system.
. l f t he t er mi nal s l ook OK, make t he f ol l owi ng
inDut tests at the fuse/relay box socket.
-
l f any test i ndi cates a probl em' fi nd and cor-
rect the cause, then recheck the system.
-
l f al l the i nput tests
prove OK, the turn si gnal /
hazard rel av must be faul ty; repl ace i t
{
{
J
FUSE/RELAY BOX
SOCKET
Possible caus if lesult is not obtained
Cavity Tesi condition
Ted: Desired results
r=\-:=
t - l
iln nE-
..ll
,\l
' l L l l
........r------
'l
Hazard warni ng swi tch
ON; connect the No. 1
termi nal to the No. 3
termi nal .
Hazard l i ghts shoul d come on.
Poor gr ound
( G201,
G202, G401,
G402, G551. G552, G60' 1, G76' 1)
Faul ty hazard warni ng swi tch
(l l )
and
turn si gnal swi tch i n ri ght
or l eft; connect the No. 1
termi nal to the No, 3
te.mi nal .
Ri ght or l eft turn si gnal l i ghts shoul d
come on,
.
Faul ty turn si gnal swi tch
2
Check for conti nui ty to ground:
'
Poor ground
(G401,
G402)
.
(l l l Connect for vol tage to ground:
Bl own No. 12
( 7. 5
A) f use i n t he
Hazard warni ng swi tch ON Connect for vol tage to ground:
Bl own No. 53
(10
A) fuse i n the under-
hood fuse/rel ay box
23- 155
Turn Sign al
I
Hazard Flasher
System
Hazard Warning Switch Test
CAUTION: Be careful not to damage the hazard warn-
ing switch or the center outlet panel when prying
the
switch out.
1. Pry the hazard warni ng swi tch out of the center out
l et oanel .
2. Di sconnect the 10P connector from the hazard warn-
i ng swi tch.
swi tch posi ti on
accordi ng to the tabl e.
Termi nal No. 4 i s not used
23- 156
I
l OP CONNECTOR
\
Termi nal
_ -
. - \
rost l t on
\
2 3 4 5 6 8 I 10
. OFF
o
o
o
@ o
ON
o o o o
o
o
o
(9
o
Replacement
Sedan/Coupe:
1. Remove the two screws from the l i cense pl ate l i ght.
and pul l
the l i ght out part of the way.
2. Di sconnect the 2P connector from the l i ght.
3. Take the l ens off, then repl ace the bul b.
Halchback:
1. Careful l y pry the l i cence pl ate
l i ght out ofthe l i cense
pl ate tri m.
2. Di sconnect the 2P connector from the Ii ght.
2P CONNECTOR
2P CONNECTOR
LENS
Back-up Li ghts
Ci rcui t Di agram
IGN]TION
swtTcH
wnreLx..*wHr6-I
eLx/YeL
""' --""\ 9r-
-l
f[,,*.iliuit*t**
YELiRED
I
l r AT GEAR
/K
PosrTloN
Vt[{,[H.,.
r
I
l cLored
n
eosrrcn El l
GFN/ BLK
)
I
UNDER.HOOD FI.JSE/RELAY BOX
23-15i
Brake Lights
\
Ci rcui t Di agram
UNDER.HOOD
FUSE/RELAY BOX
'61
F!_*,.
\ ,
|
* l wj c PN_ l
I V
fi--
H.BNSYSTEM
I,t' "t
Pedardeoressedl
GRNA'VHT
..,F.,,*,,r
ffi; I
I t*i
i r i
Li ;
GRN,ryVHT
I
,l.
ffi,!,.,
I P } BRAKE
Y
r,:"'
I
BLK
* 2lW Coupe/Sedan
18W Hatchback
[ ]
Wilh c.uise contro
G601, G761 Halchback
G601 :Coupe/Sedan
.
ABS CONTROL UNIT
'
ECi,I/PC[I
' TCM (CW)
.]NTEHLOCK
coNTRot UN T
' CRUI SE
CONTNOL UNI T
23- 158
Hi gh Mount Brake Li ght Repl acement
Hatchback:
1. Loos en t he t wo s c r ews , t hen r emov e t he hi gh
mount br ake l i ght . Be car ef ul not t o damage t he
hatch spoi l er.
2. Remove the bul b socket from the l i ght.
)
BULB SOCKET
Coupe/Sedan:
1. Remove the rear shel f {see
secti on 20)
2 Remove t he t wo scr ews, t hen r emove t he hi gh
mount brake l i ght from the rear shel f.
TWO SCREWS
23- 159
Dash Li ghts Bri ghtness Control l er
Ci rcui t Di agram
G401
c402
23-160
\,
\
\
a Controller
Input test
NOTE: The control uni t i s bui l t i nto the dash l i ghts bri ght-
ness control l er.
1. Careful l y
pry the control l er out of the dashboard
2. Di sconnect the 3P connector from the control l er'
3. Inspect the connector termi nal s to be sure they are
al l maki ng
good contact.
. l f the termi nal s are bent, l oose, or corroded, repai r
l hem as necessary, and recheck the system
. l f the termi nal s l ook OK, make the l ol l owi ng i nput
tests al the connector.
-
l f any test i ndi cates a probl em, fi nd and cor
rect the cause, then recheck the system'
-
If al l the i nput tests
prove OK, the control l er
must be faul tyj repl ace i i .
Cavity
Test condition
Test: Desired lesults
RED/BLK
swi tch ON
Bl own No. 30
( 7. 5 A) f use i n t he
under-dash f use/rel aY box
Faul ty combi nati on l i ght swatch
2 BLK
Under al l condi t i ons
Check f or cont i nui t y t o ground:
Ther e shoul d be cont i nui t y
.
Poor gr ound
( G401, G402)
.
An open i n t he war e
3 RED
swi tch ON
Connect to groundl
Dash l i ght s shoul d come on f ul l
bri ght.
'
23-161
Interior Lights
SPOT LIGHTS
Test , page 23-166
LEFT REAR DOOR SwlTCH
\
CEILING LIGHT
Test, page 23-165
FRONT PASSENGER'S
oooR swtTcH
RIGHT REAR DOOR SWITCH
TRUNK LIGHT {Coup6/Sodan)
Test. page 23-166
IRUNK LATCH SWITCH
23-162
t Ci rcui t Di agram
(Wi thout
Spotl i ghts)
T GRN/ RED
|
*tecroreo
l coNTBot UNLT
rf--l
I T-'.- )
6NN
LT G
A (
ftm'
\
I Tcosed
Doo' open
I
| [OPen Door closed -]
I
I
:
BLU/BLK
I
I
I
I
&i*J,"'
I V
|
,,J,,,
!
I
BLUi BLK
A
Tn':ii
l[3'&'i'
Tt*:r.:, )
8LK
I
G60l G761 :Halchbac(
G601 : Coupe/Sedai
.
*1 3 4w: l l sA, Canada
Pr oduceo
5W lJapan'Produced
* 2 8W r Wl h moonr ool
5W :Wilhoul moonroo{
CEILING
LIGHT
R] GHT
REAR
DOOR
swtTcH
fcbsed
iDoor open
)
(open :Doorclosed ,
FRONT
PASSENGERS
DOOR
swtrcH
fcbsed
Door open
'l
(Open :0oor closed J
LEFT
REAR
DOOR
SWITCH
folosed
:Door open
I
(Open Doorclosed J
UNDER-HOOD FUSE/FELAY BOX
W].]T/RED
ON
\
OFF
23- 163
lnterior Lights
t"
Ci rcui t Di agram
(Wi th
Spotl i ghts|
UNDER-HOOD FUSEi BELAY BOX
WHT/REO
r h r
I I. l'-,-1
T !
I
BLU/ BLK
I
I
|
**,,",
I ' V
|
.,J,,-
I
BLU/BLK
A
[niH,,,,,,*,,
Bt K
I
CeOt CZOI
ga"f,O""k
G601 :Coupe/Sedan
x I 3.4W :USA, Canada-pfoduced
5W: Japan prodl ced
*2 8W Wl h moonrool
5W Wlhoul moonrool
23-164
t
A
Y""
I
REAR
I DOOF
t;:ff
ll3;:1"'
I(ooo
ao
GRN LTGRN/ REO
A A
Y*,urr" Yoo*
l3$?rt" IPASSENGEFS
ItfuTi::.Ll li*r*.r
I
-
lDoorcrosed.J
- : :
T
]NTEGRATEO
CONTFOL UNIT
L
J Ceiling Light Test
1. Turn the l i ght swi tch OFF.
2. Pry off the l ens.
3. Remove the two mounti ng nuts
(or
a bol t) from the
housi ng, then remove the housi ng
4. Di sconnect the connector(s) from the housi ng.
swi tch
With moonroof:
3P CONNECTOR
\
rermrnar
Position \
I
2
or
2'
3
ot
3'
4
OFF
o-
/a\
--o
\:/
MIDDLE
o-
/:\ --o
\:./
ON G_
/A -_o
\./
l'
23- 165
Without moonrool:
Coupe/Hatchback:
BULB {5 WI
1
4
2'
Interior Lights
Spotlights Test
1. Turn the spotl i ght swi tch OFF.
2. Pry off the l ens.
3. Remove the two screws and the housi ng.
4. Di sconnect the 1P connector from the housi ng.
swi tch posi ti on
\
Terminal
*"t*
_\
1 2 3
o-t
(9
/a\
--o
--o
\-.7
ON
o- oJ
(9
/^
--o
--o
\,/
23-166
\.
Trunk Light Test
1. Open the trunk l i ght cover from the housi ng.
2. Pry out the l i ght assembl y.
3. Di sconnect the 2P connector from the housi ng.
4. Make sure that the bul b i s OK. Check for conti nui ty
between the No. 1
(+)
and No.2
(-l termi nats.
BULB I TT
rl
3.4 W: USA, Canad!-producod
5 W: Japan-produced
t
Stereo Sound System
Component
Locati on Index
sRS components are l ocated i n thi s area. Revi ew the sRS component l ocati ons, precauti ons, and procedures i n the sRS
secti on
(24)
before
AUDIO UNIT
(SfEREO RADIO TUNER)
Repl acement , Page
23 169
Termi nal s,
page 23 170
ANTENNA MAST
Repl acement ,
LEF1 TWEETER
Repl acement ,
page 23-171
LEFT FRONT SPEAKER
Repl acement ,
page 23_171
RIGHT TWEETER
Repl acement ,
page 23 171
RIGHT FRONT SPEAKER
Repl acement ,
page 23-171
it
)
suB
LEAD
CASSETTE PLAYER
Repl acement , Page
23-169
REAR SPEAKERS
Repl acement ,
page 23-171
23-167
Stereo Sound System
Ci rcui t Di agram
UNDEF DASH
FUSEi RELAY SOX
t' *' fdl
-t-'---ll
I
I
I
I
I
I
YEURED
No.30 (7.5A)
V
I
FED/BLK
RED
I
I
I
I
J
DASH LIGHTS
BRIGHTNESS
CONTROLLER
I REDTEr
H
Rl GHT NEAR
SPEAKER
GNIT ON SW TCH
UNDER, HOOD FUSE/ FELAY BOX
WHT/BLU
ANTENNA
LEAD
,,I;J,
LEFT FRONI
DOOR SPEAKER
LEFT REAR
SPEAKER
23-168
J
Removal
Stereo Radio Tuner:
1. Remove the center dashboard
l ower cover
(see sec-
ti on 20).
2. Remove the two mounti ng bol ts, and
pul l the stereo
r adi o t uner out
3. Di sconnect t he 16P connect or s,
sub ant enna l ead
and DIN cord
(wi th cassette
pl ayer)' then remove
the stereo radi o tuner.
t
16P CONNECTORS
STEREO RADIO TUNER
{t
23- 169
Cassette Playel:
L Remove the front consol e
panel
(see
secti on 20).
2. Remove the DIN cord from the stereo radi o tuner'
3. Remove the l our mounti ng bol ts, then remove the
cassette Pl ayer'
MOUNTING BOLTS
Stereo Sound System
Stereo Radi o Tuner Termi nal s
For kevl ess ent r v
To OIN CORD
To DIN CORD
(f or
securi t y
syst em)
Cavity Wire
A1 RED/GRN
Ri ght front door speaker @,
ri ght tweeter O
A2 BLU
Left front door speaker O,
left tweeter @
A3 RE D/B LK Li ghts-on si gnal
A4 WHT/BLU
Constant power (tuni ng
memory)
YEURED
ACC
(mai n
stereo power
suppl y)
A7 BLUI/EL Left rear door speaker @
A8 R EDI/E L Ri ght rear door speaker O
A9 BR N/BLK
Ri ght front door speaker O,
ri ght tweeter O
4 1 0 GRY/BLK
Left front door speaker O,
left tweeter O
412 RED
Dash l i ghts bri ghtness con-
t r ol l er
414 BLK Gr ound
( G50' 1)
4 1 5 GRYA/r'HT Left rear door speaker O
4 1 6 BRN,^/VHT Ri ght rear door speaker O
Ter mi nal s A6, 411
Mast Antenna Repl acement
1. Di sconnect the connector between the antenna l ead
and sub ant enna l ead.
2. Remove the two mounti ng screws, then remove the
mast antenna.
MAST ANTENNA
MOUNTING SCREWS
J
Speaker Replacement
Front speaker:
1. Remove the speaker cover'
2. Remove the three screws from the speaker'
3. Di sconnect the 2P connector, and remove the door
speaker.
g
FRONT SPEAKER
Tweeter:
1. Remove the door
panel
{see secti on 20)
2. Di sconnect the 2P connector from the tweeter'
3, Remove the mi rror
garni sh.
4. Remove the two screws, then remove the tweeter'
TWEETER
|'
23-171
Rgar spaker:
1. Remove the rear si de shel f or rear shel f
(see
secti on
20).
2. Di sconnect the 2P connector from the speaker.
3. Remove the four screws, then remove the speaker.
Hatchback:
Coupe/Sedan:
2P CONNECTOR
2P CONNECTOR
REAR
Horn
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons. precauti ons.
and
procedures
i n the SRS
secti on
(24)
before performi ng
HORN ASSEMBLY
Test, page 23-173
\
HORN RELAY: 98 modot
lWire
colors: WHT/GRN, cRy.l
IWHT/GRN, BLU/RED
I
Test, page
23-73
a \
\ )
\-'/"''\
\ rap
/ i
L - l | | I
- l
hJrrfl a\ a\ fl f- - L--l
n F F r n n - r - r F r l ' 1 l l r -
---t | |
Lr ur r Lr ! Lr r r r . r Lr Ur r r r
i | |
r ' r Fr n n r ' r Fr - n Fr Fr r r r l
Ll
LJ J
J: : : : : : : : : t J: -
t l
HORN RELAY: 96, 97 modots
lWiro
color3: WHT/GRN, GRy,l
lwHT/cRN, BLU/RED
I
Test, psge
23-72
UNDER.DASH FUSE/BELAY BOX
h-
23-172
BATTERY
g
Ci rcui t Di agram: 96,97 model s
HORN
RELAY
rt
I
Y--
BLU/RED
I
BLK
I
G401
G4o2
{
23-173
Horn Test: 96,97 model s
' L
Remove the tront bumper
(see
secti on 20).
2. Di sconnect the 2P connector from the horn'
Remove the horn.
Test the horn by connecti ng
battery
power to one
termi nal and
groundi ng the other. l f the horn fai l s to
sound, repl ace i t.
LOW HORN
Horn
Circuit Diagram: 98 model
WHT/GRN
4,",,
I
t
I
':
BATTERY
BRAKE
SWITCH
Wl h l , eyessenry
"; ,
svsm
i r - ?
l J ! - - oA"
t v i I
23-174
1 .
Horn Test 98 model
Remove the front bumper
(see
secti on 20).
Oi sconnect the 1P connector from the horn.
3. Test the horn by connecti ng battery
power to the
t er mi nal and
gr oundi ng t he mount i ng bol t l f t he
horn fai l s to sound, repl ace i t.
\
TERMINAL
g
Switch Test
1. Di sconnect the battery negati ve cabl e, then di sconnect
the posi ti ve cabl e, and wai t at l east three mi nutes'
2. Di sconnect the dri ver' s ai rbag connector
(see
sec-
ti on 24).
3. Remove t he dr i ver ' s dashboar d l ower cover { see
secti on 20).
4. Di sconnect the cabl e reel sub-harness
3P connector
from the mai n wi re harness.
REEL
SUB.HARNESS
3P CONNECTOR
Termi nal si de of
mal e t ermi nal s
5. Check for conti nui ty between the No. 2 termi nal of
t he cabl e r eel sub- har ness and body
gr ound wi t h
the horn swi tch
Pressed.
Termi nal si de ol
mal e t ermi nal s
a
a
l f there i s conti nui ty, the horn swi tch i s OK.
l f there i s no conti nui ty,
go to step 6.
-
MAIN WIRE
HARNESS
3P CONNECTOR
)
7 .
Remove t he dr i ver ' s ai r bag assembl y
( see
sect i on
24) , t hen di sconnect t he hor n connect or f r om t he
steeri ng wheel .
Check for conti nui ty between the No 2 termi nal of
the cabl e reel sub-harness
3P connector and horn
posi t i ve t er mi nal .
HORN POSITIVE TERMINAL
HORN CONNECTOR
. l f t her e i s no cont i nui t y, r epl ace t he cabl e r eel
(see
secti on 24).
. l f there i s conti nui ty, repai r or repl ace the horn
swi tch.
l f al l t est s
pr ove OK, r ei nst al l t he dr i ver ' s ai r bag
assembl y
(see secti on 24), and reconnect the cabl e
reel sub harness connector'
Reconnect the dri ver' s ai rbag connector, and rel n-
stal l the access
panel on the steeri ng wheel .
Reconnect the battery positive cable, then the negative
termi nal .
After i nstal l i ng the ai rbag assembl y, confi rm
proper
system oPeratl on:
(l l );
the SRS i ndi ca-
tor l i ght shoul d come on for about si x seconds
and then go off.
Make sure both horn buttons work.
1 1 .
9.
10.
23-175
CABLE REEL
Rear Wi ndow Defogger
UNDER-DASH FUSE/RELAY BOX
REAR WINDOW DEFOGGEF SWITCH
I nput Test , page
23-179
t l t t l . - :
- :--=-=-=;----------.l
: uuu u !
!
o
- n- - nhnn- n; n
. - 1 f l
_
u u u u u u ! u l u u u
| | l
u u ! u u ! u u ! u ! u
/ - - - - t
REAR WINOOW DEFOGGER
FLrnction Test, page
23-178
Defogger Wjre Repair, page
23-1j8
23-176
U
trt\
IGNITION
SWTCH
-
Ci rcui t Di agram
**"-*9
N0.30 (7 sA)
FUSE
v
I
RED/BLK
I
I
I
V
DASH LIGHTS
ERI GHTNESS
CONTROLLER
BLK
G401
G402
BLK]BLU
t
I
+
I - I
REAR
| -r]] |
wrNDow
I ;- I
DEFOGGER
T
I
BLK
I
I
I
I
--
G6ol :Coupe/Sedan
G771 HalchbacK
\t
UNDER DASH FUSE/RELAY BOX
UNDER HOOD FUSE/FELAY BOX
No 41 (80A) No 42 (404)
G40l
G402
ZLITT
rt
Rear Wi ndow Defogger
Functi on Test
CAUTION: Be careful not to scratch or damage the detog-
ger wires with the tester probe.
1. Check for vol tage between the posi ti ve termi nal and
body ground wi th the i gni ti on swi tch and defogger
swi tch ON.
Ther e shoul d be baner y vol l age.
. l f there i s no vol tage, check for:
-
fau l ty defogger rel ay.
-
faul ty defogger swi tch.
-
an open i n t he ELI VBLU wr r e.
. l f there i s battery vol tage, go to step 2.
NEGATI VE TERMI NAL
POSITIVE TERMINAL
Check for conti nui ty between the negati ve termi nal
and body gr ound.
l f t her e i s no cont i nui t y, check f or an open i n t he
defogger g round wi re.
Touch the vol tmeter posi ti ve probe to the hal fway
poi nt of each defogger wi re, and the negati ve probe
t o t he negat i ve t er mi nal .
There shoul d be approxi matel y 6 V wi th the i gni ti on
switch and the deiogger switch ON.
l J the vol tage i s as speci fi ed, the defogger wi re i s
oK.
l f t he vol t age i s not as speci f i ed, repai r t he def og
ger wi r e.
l f i t i s more t han 6 V, t here i s a break i n t he
negat i ve hal f of t he wi re.
-
l f i t i s l ess t han 6 V, t her e i s a br eak i n t he
posi t i ve
hal l ot t he wi re.
23-178
Defogger Wire Repair
NOTE: To make an ef f ect i ve repai r, t he broken sect i on
must be no l onger t han one i nch.
1. Li ght l y rub t he area around t he broken sect i on wi t h
f i ne st eel wool , t hen cl ean i t wi t h al cohol .
2. Carcl ul l y mask above and bel ow t he broken port i on
of t he def ogger wi re wi t h cel l ophane t ape.
3.
CELLOPHANE
TAPE
Usi ng a smal l br ush, appl y a heavy coat of si l ver
c o n d u c t i v e p a i n t
e x t e n d i n g a b o u t 1 / g , , o n b o t h
si des of t he break. Al l ow 30 mi nut es t o dry.
NOTE: Thoroughl y mi x t he pai nt
bef ore use.
4. Check for conti nui ty i n the repai red wi re.
Appl y a second coat of pai nt i n the same way. Let i t
dry three hours before removi ng the tape.
5.
OPEN
J
Switch Input Test
CAUTION: Be careful not to damage the rear window
defogger swi tch or the center
panel when pl yi ng the
switch out,
NOTE: Bef or e t est i ng, check f or bl own No 16
( 7
5 A)
fuse i n the under dash fuse/rel ay box
1. Pry the swi tch out of the center
panel (see
secti on 20)'
2. Di sconnect the 5P connector from the swi tch.
3. Turn the i gni ti on swi tch ON {l l ), and check the vol tage
between the BLVBLU
(+)
and the BLK {-)
termi nal s
. l l there i s no vol tage, check for an open i n the
BLVBLU wi re
. l f there i s battery vol tage,
go to step 4.
Wi re si de of famal e termi nal s
Connect a
j umper wi re between the BLK/BLU and
the BLU/YEL termi nal s.
(l l ).
and check that the
rear wi ndow defogger works; i f i t does, repl ace the
defogger swi tch.
t
4.
RED
rt
23-179
Power Mirrors
Power Mi rror
Functi on Test, page 23-182
Power Mi rror Test, page
23-183
Repl acement, secti on 20
Actuator Repl acement, page 23-184
POWER MIRROR SWITCH
Test , page 23, 183
23- 180
hr-
Ci rcui t Di agram
a
GN TION
swrTcH
YEL
I lu"; I
I
BLK/YEL
-
UNDER.OASH
FUSE/RELAY
BOX
lt
G551
23-181
f#'-_'":1:
*
3 5
BLUi BLK GRN/WHT
-...
Power Mirrors
Function Test
CAUTION: Be caretul not to damage the mirror switch
or the dashboard driver's lower cover when prying
the
switch out.
1. Pry the swi tch out of the dri ver,s dashboard l ower
cover.
lOP CONNECTOR
BLU/WHT
YEL/REO
BLK/YEL BLK
2 4
6
/ 1 8
YEL/BLK
POWR MIRROR
swtTcH
Mirror Test
Both inoperative:
2.
' 1.
Check for vol tage between the No. 2
(BLK,/YEL)
ter-
mi nal and body ground
wi th the i gni ti on swi tch ON
(

) .
. l f there i s no vol tage, check for:
-
bl own No. 17 ( 7. 5
A) f use i n t he under dash
fuse/rel ay box.
-
an open i n the BLVYEL wi re.
. l f there i s batteryvol tage, goto
step 2.
Check for conti nui ty between the No. 4
(BLK)
termi -
nal and body gr ound.
. l f there i s no conti nui ty, check for:
-
an open i n t he BLK wi r e.
-
poor gr ound ( G551) .
!.\-
23-182
Left mirror inoperative:
Connect the No. 2
(BLK/YEL)
termi nal of the 1Op connec-
tor to the No. 3
(YEURED)
termi nat and the No. 5
(or
No.
6) termi nal to body ground
wi th
j umper
wi res. The l eft
mi rror shoul d ti l t down (or
swi ng l eft) when the i gni ti on
swi tch i s turned ON l ).
l f the mi rror does not ti l t down
(or
does not swi ng l eft),
remove the l eft door panel ,
and check for an open i n
t he BLU/ WHT ( or
BLU/ BLK) wi r e bet ween t he l ef t
power
mi rror and the swi tch.
-
l f the wi re i s OK, check the l eft power
mrrror acrua_
tor.
l f the mi rror nei ther ti l ts down nor swi ngs l eft, repai r
the YEVRED wi re.
l f the mi rror operates properl y,
check the mi rror swi tch.
Right mirror inoperative:
Connect the No. 2
(BLVYEL)
te.mi nal of the 1Op connector
to the No. 3
(YEURED)
termi nat and the No. 9
(or
No. 8)
termi nal to body ground
wi th
j umper
wi res. The ri ght mi r-
r or shoul d t i l t down ( or
swi ng l ef t ) when t he i gni t i on
swi tch i s turned ON {l l ).
l f the mi rror does not ti l t down
(or
does not swi no
l eft), remove the ri ght door panel ,
and check for ai
open i n the GRN,Ar' /HT (or
YEUBLK) wi re between the
ri ght power
mi .ror and the swi tch.
-
l f the wi re i s OK, check the ri ght power
mi rror actu-
ator.
l f the mi f ror nei ther ti l ts down nor swi ngs l eft. repai r
the YEVRED wi re.
l f t he mi r r or oper at es pr oper l y,
check t he mi r r or
swi tch.
J
Switch Test
1. Remove the swi tch as descri bed i n Functi on Test
(see page 23-182).
swi tch
Mirror Switch:
POWER
MIRROR
swlTcH
g
)
rt
I
\
rermrnal
Position \
2 3 4 5 6 8 9
L
UP
o-
-o
o-
-o
DOWN o-
-o
o-
-o
LEFT G
-o
G
-o
RIGHT
o-
-o
G
-o
UP
o-
-o
o-
_o
DOWN o-
_o
o-
_o
LEFT o-
-o
o-
RIGHT
o-
-o
o-
-o
NH. t I ,
Power Mirror Test
1. Prv out the cover
panei
{see secti on 20}
covR
Termi nal si de of
mal e t ermi nal s
Di sconnect the 8P connector from the power mi trrt
Check actuator operati on by connecti ng
power
-l
ground accordi ng to the tabl es.
\
Termi nal
P*t,i""--
-_\
6 1 t
TILT UP
o
TILT DOWN
o
SWING LEFT
o @
SWI NG RI GHT
@
23- 183
Power Mirrors
Mirror Actuator Replacement
(Donnelly
Typel
1. Remove the power mi rror from the door
(see
sec-
t,on 20), and di sconnect the 8P connector,
2. Remove t he mi r r or base cover f r om t he mi r r or
housi ng.
MIRROR HOLDER
Remove the mi rror hol der from the mi rror housi ng.
Gentl y pul l
i t out by hand.
Remove the three screws from the actuator and the
t wo scr ews f r om t he br acket at t he base of t he
assembl y.
5. Remove the bracket from the housi no.
MIRROR HOUSING
23-184
\r-
9. Pass the connector boot over the wi re harness.
7.
8.
6. Remove the two screws, cut the wi re harness, and
remove the actuator.
ACTUATOR BRACKET
Record the termi nal l ocati ons and wi re col ors.
Route the wi re harness of the new actuator through
t he hol e i n t he br acket . Be sur e t o pass
t he wi r e
under the bracket clip.
BRACKET
a
rt
10. l nsert the termi nal s i nto the connector i n the ori gi -
nal ar r angement
( r ecor ded i n st ep 7) , as shown
Del ow.
Appl y tape to seal the i ntersecti on of the connector
boot and the wi re harness.
Reassembl e i n the reverse order of di sassembl y. Be
careful not to break the mi rror when rei nstal l i ng i t
to the actuator.
Rei nstal l the mi rror assembl y to the door.
Operate the
power mi rror to check that the actuator
works smoothl y.
Ri ght :
Left:
1
' ] .
13.
14.
PNK
PNK
rt
23- 185
Wipers/Washers
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons,
and procedures
i n the SRS
secti on
(24)
before performi ng
WIPER/WASHER SWITCH
Test , page 23-189
REAR WINDOW WIPER
MOTOR lHatchbackl
Test, page
23,190
WINDSHIELD WIPER MOTOR
Test, page
23-189
WINDSHIELO WIPER ARMS/BLAOES
FLUI D
RESERVOIR
WINOSHIELD
WASHER
MOTOR
Test , page
23' 190
REAR WINDOW
WASHER MOTOR {Hatchb.ck)
Tesl, page 23-190
23-186
\
nf-___]
l.,...--.--_
I l f r
{ - J l l l
[
]_ll-l
UNDEF.HOOD FUSEi FELAY BOX
UNDR-DASH
FUSE/REtAY 8OX
Ci rcui t Di agram
(Wi ndshi el d)
WINDSHIELD
WASHER
MOTOR
WHTiBLK
I
Y
BLK
I
G2A2
rt
BLK
I
G401
G402
BLK
G401
G402
23-187
-fsu
]NTEGRATED
CONTROL
UNT
/
Has buiLl'in
\
I
intem lenl
I
I
wper reray
I
\t
,I
:W]lh COMBINED OPERATION WIPERMASHER
Wipers/Washers
Ci rcui t Di agram
(Rear
Wi ndow)
UNDER.HOOD FUSE/RELAY 8OX
REAR WINDOW
WIPER MOTOR
REAF WINDOW
W]PERA/VASHER
SWITCH
8LK BLK
G401
23-188
\ _
, ' / - \ \ : - - - -
- - - - l
BLK
n\
tY Wiper/Washer Switch Test
Remove the dri ver' s dashboard l ower cover
(see
secti on 20).
Remove the steeri ng col umn covers.
Di sconnect t he 8P and 6P connect or s f r om t he
swi tch, remove the two screws. and
pul l out the
swi tch.
\t
swi tch
posi ti on
Windshield Wiper/Wssher Swiich:
\
| ermrnsl
rost r| on \
1 2 3 4 5 1
OFF
o
.o
INT
o o
o o
LO
o o
HI
o o
l \4i st swi tch"0N"
o o
Washer swi tch
"0N "
o o
' 1.
2.
3.
Rear Window Wiper/Washer Switch:
\
Terminal
t*t*---__\
1 2 3 6
Washer swi tch
"0N"
{Wi per swi tch
"0FF"}
o-
-o
o-
-o
OFF o-
-o
ON o-
-o
Washer swi tch
"
0N'
(Wi per
swi tch
"0N")
o-
-o
G
-o
WIPER/WASHER SWITCH
wi ndshi el d:
1 1 2
3 4 l
| t 1_- a T t |
l 5
6
j 7
8
|
Rear Window:
i l
2 3 l
li;i7-',611
rt
23- 189
1 .
Windshield Wiper Motor Test
Open the hood, and remove the cap nuts. Careful l y
remove the wi per arms so that they do not touch
the hood.
Remove the cowl cover by pryi ng out the tri m cl i ps
(see
secti on 20).
Di sconnect the 5P connector from the wi ndshi el d
wi per motor.
Test the motor by connecti ng battery
power
ground accordi ng to the tabl e.
l f the motor does not run or fai l s to run smoothl y.
repl ace i t.
5. Connect an anal og vol tmeter between the No. 5
(+)
and No. 3
(-)
termi nal s, and run the motor at l ow or
hi gh speed.
The vol tmeter shoul d i ndi cate 0 V and 4 V or l ess
al ternatel y.
ano
Termi nal si de of
mal e t ermi nal s
\
Ter mi nal
;;il-
-\
1 2
LOW SPEED
o o
HI GH SPEED o @
Wipers/Washers
Rear Wiper Motor Test
(Hatchbackl
Remove the hatch l ower tri m panel (see
secti on 20).
Di sconnect the 4P connector from the wi per motor
assemDty.
Test the motor by connecting battery power to the
No. 1 termi nal and ground to the No. 3 termi nal .
l f the motor does not run or fai l s to run smoothl y,
replace [.
Reconnect the 4P connector to the wiper motor.
Connect an anal og vol tmeter between the No. 4
(+)
and No. 2
( - ) t er mi nal s.
Run the motor by turni ng the wi per swi tch ON.
The vol tmeter shoul d i ndi cate 0 V and 4 V or l ess
al ternatel y.
23- 190
\
t .
2.
1 .
2.
Washer Motor Test
Remove the front bumper {see secti on 20).
Di sconnect the 2P connectors from the washer.
3. Test the washer motor by connecti ng battery power
and ground
. l fthe motor fai l s to run smoothl y, repl ace i t.
. l f the motor runs smoothl y, but l i ttl e or no washer
f l ui d i s
pumped.
check f or a di sconnect ed or
bl ocked washer hose, or a cl ogged pump
outl et i n
the motor.
Termi nal
Battery
1 2
Di sconnected
Connect ed @ o
Power Windows
v
Component Locati on l ndex
FUSE/ RELAY BOX
POWER WNDOW
MASTER SWITCH
(Has
I nput Test ,
page 23-196
Test ,
page 23-194
\t
DRtVER'S WINOOW
Test,
page 23-201
LEFT REAR WINDOW SWITCH lS.-
Test, page 23-200
I
I
POWER WINDOW RELAY
Test ,
page 23 73
FRONT PASSENGEB'S WINDOW SWITCH
Test , page 23-200
FRONT PASSENGER'S WINDOW MOTOR
Test, page 23_202
LEFT REAR WINOOW MOTOR
(Sedanl
Iest.
page 23-202
RIGHT REAR WINDOW SWITCH
(SEdAN)
Test , page 23-200
RIGHT REAR WINDOW MOTOB
{Sedanl
Test,
page 23'202
23-191
P - ( ) ( ) ( )
( )
I
\t
Power Wi ndows
UNDER.HOOD FUSEi FELAY BOX
Ci rcui t Di agram
(Coupe/Hatchback)
23-192
\
.
\
BLK
t
G551
UNDER.DASH FUSE/BELAY BOX
BLK
G55l
PASSENGERS
WiNDOW I'IOTOR
G401
G402
EfI
J
Ci rcui t Di agram
(Sedan)
UNDER.HOOD FUSEi FELAY 8OX
WINDOW
SWI TCH
BLUI YEL BLU] oRN RED/YEL
UNDER, DASH FUSE/ RELAY 8OX
MASTER SWTCH
PASSENGER' S
lt
c 1 1 8 4 B5
8LK
4 3 I LEFT REAF 3 I FI GHT REAR 4 I 3 I F R O N T
RED YEL RED/YEL 8ru;FED I
SW TCH
^ |
':i"'
rffi-r
l u l
FIGHT FEAR W NDOW
MOTOR
W NDOW
SW TCH
PASSENGERS
WI NDOW
RED]BLU
2 I
LEFT REAR WINDOW
MOTOR
GN T]ON SWITCH
BLK
t
G551
DRI VEF S W NDOW MOTOR I 4
BLK
I
G551 G40l
G402 FRONT PASSENGER S
WINDOW MOTOR
\I'
2s- 193
Power Windows
Master Switch Test
(Coupe/Hatchback)
1 . Remove the master swi tch from the dri ver' s door
Di sconnect t he 12P connect or f r om t he mast er
swi tch.
MAI N
swtTcH
Termi nal si de ol mal e termi nal s
switch position
acco{ding to the table.
Driver's Switch:
The dri ver' s swi tch i s combi ned wi th the control uni t so
you cannot i sol ate the swi tch to test i t. Instead, run the
master switch input test procedures at termrnals A1, A3,
44, A8 and A12 on page 23-196. l f the tests are normal .
the dri ver' s swi tch must be faul ty.
AI A2 A3 A4 A5
A6 A7 A8 412
Passenger's Switch:
\
Terminal
P",ir"'-T-mil\
A2 A5 A6 A7
OFF
ON
o-
--o
OFF
o-
--o
UP
ON
o-
--o
o-
--o
OFF
o-
-o
DOWN
ON
G-
*-o
--o
G_
OFF
G_
--o
v
Master Switch Test
(Sedanl
1. Remove the armrest from the dri ver' s door panel
(see page 23-198).
2. Di sconnect t he 16P and 1P connect or s f r om t he
master swi tch.
oRtvER'S SWITCH
POWER WINDOW
MASTER SWITCH
FRONT
PASSENGB'S
swlTcH
v
Check f or cont i nui t v bet ween t he t ermi nal s i n each
swi t ch
posi t i on accordi ng t o t he t abl es.
Driver's Switch:
The dri ver' s swi tch i s combi ned wi th the control uni t so
you cannot i sol ate the swi tch to test i t. Instead, run the
master swi tch i nput test procedures at termi nal s 83, 84'
85, 86 and 87 on
page 23-198 | f the tests are normal ,
v
the dri ver' s swi tch must be faul ty
MAIN SWITCH
B1 B3 B4 B5 B7
B8 B9 810Br 1
,/1,/
814815
Termi nal si de of
mal e t ermi nal s
J=\
H
Iti [:], i fl {m
F ont Passenger's Switch:
\
Termi nal
t".-*Tm;\
B1 82 Bl 1 cl
OFF
ON
o-
--o
OFF
CF
--.o
UP
ON
o-
--o
o-
--o
OFF
G-
--o
DOWN
ON
G-
o-
--o
--o
OFF
o-
--o
Left Rear Switch:
\
Terminal
r".-*-f-m}
814 815 Bl 6
OFF
ON G
-_o
OFF CF
--o
UP
ON
o-
--o
CF
--o
OFF o-
--o
00wN
ON
o-
c)-
--o
OFF o-
--o
\
Terminal
P."-b"Tmm\
B8 B9 810 c1
OFF
ON G_ o
-o
OFF o-
--o
UP
ON
o-
-_o
o-
--o
OFF
G-
--o
DOWN
ON
o-
--o
--o
o-
OFF
o-
-o
Right Rear Swhch:
23- 195
Power Windows
Master Switch Input Test
(Coupe/Hatchback)
NOTE: The control uni t i s bui l t i ntothe power wi ndow master swi tch, and onl y control s d ri ver' s door w
j ndow
operati ons.
1 . Remove the dri ver' s door pa nel , a nd di sconnect the I2p con nector from the master swi tch.
2. l nspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
a l f the termi nal s are bent, l oose or corroded, repai r them as necessary, and recheck the svstem.
. l f the termi nal s l ook OK, make the {ol l owi ng i nput tests al the connector.
-
-
l f al l the i nput tests prove OK, the power wi ndow master swj tch must be faul ty; repl ace i t.
L-
23- 196
Wire side of female t6rminals
\
! - t \
I ' I \
l-l
v
v
Csvrty Wire Ta3t condition
To3t Desirod result Possible cause if result is not obttined
A5
BLK
Under al l condi ti ons Check for conti nui ty to ground:
.
Poor
ground (G551)
.
A8
A1 BLU/BLK
(l l ) Check for vol tage to ground:
There should be battery voltage.
Bl own No. 10 or 11
(20 A) fuse i n
the under-dash fuse/rel aY box
Faulty
power window relaY
A6 GRN/BLK
A4 RE D/BLU
connect the BLU/BLK
terminal to the RED/YEL
termi nal . and the RED/
BLU termi nal to the
BLK termi nal , then turn
the i gni ti on swi tch ON
fl r).
Check the dri ver' s wi ndow motor:
It shoul d run
(the
wi ndow moves
down).
.
Faul ty dri ver' s wi ndow motor
.
A3 RED/YEL
A7 BLUI/EL
Connect the GRN/BLK
termi nal ro the BLUI/EL
termi nal , and the BLU/
ORN termi nal to the
fl r).
Check the passenger' s wi ndow
motor: l t shoul d run
(the
wi ndow
moves downl .
Faul ty
passenger' s wi ndow motor
Faul ty passenger' s wi ndow swi tch
BLU/ORN
A't2 BLU
Connect the BLU/BLK
terminal to the RED//EL
termi nal , and the BLK
termi nal to the RED/
BLU termi nal , then
turn the i gni ti on swi tch
oN 0r).
Check for voltage between the
BLU and BLK termi nal s: APProx. 6
V shoul d be i ndi cated as the dri v-
er' s wi ndow motor runs.
Faul ty
pul ser
A8 BLK
23-197
,futi,rs*g
\y
Power Windows
Master Switch Input Test
(Sedan)
NOTE: The control un i t i s bu i l t i nto the power wi ndow master swi tch, and on l y control s dri ver' s door wi ndow opera!ons.
l Remove the dri ver' s armrest, and di sconnect the 16P and 1p connectors from the master swi tch.
2. Inspect the connector and socket termi nal s to be sure they are al l maki ng good
contact.
. l f the termi nal s are bent, l oose orcorroded, repai r them as necessary, and recheck the system.
. l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the connecror.
-
-
l f al l the i nput tests prove OK, the power wi ndow maser swi tch must be faul ty; repl ace i t.
POWER WTNOOW swtTcH
ABMREST
\
Wi re si de ot
L.
23-198
ry
Cavity
Test condition
Test: Desired result Possible causc il resuh is not obtained
v
{Y
23-199
!'{*flf
Wire
B4
BLK
Under al l condi ti ons Check for conti nui ty to ground:
.
Poor gr ound
( G551)
.
c1
B3 BLU/BLK
(l l )
There shoul d be batterY vol tage
Bl own No. 7, 8, 10 or 11
( 20 A)
fuse i n the under-dash fuse/rel aY
box
Faul ty
power wi ndow rel aY
82 GRN/ BLK
B8 YEUBLK
815 RDAr'VHT
B7 RED/BLU
Connecr the BLU/BLK
terminalto the RED/YEL
termi nal , and the RED/
BLU termi nal to the
BLK termi nal . then turn
0 r ) .
Check the dri ver' s wi ndow motor:
It shoul d run {the
wi ndow moves
down).
B5 RED/YEL
B1 BLU//EL
Connect the GRN/BLK
termi nal to the BLU/YEL
termi nal , and the BLU/
ORN termi nal to the
fl r).
Check the front passenger' s
wi ndow motor:
It shoul d run
(the
wi ndow moves
oown).
Faul ty front passenger' s wi ndow
motor
Faul ty front passenger' s wi ndow
switch
8 1 1 BLU/ORN
B9 YEL
connect the YEUBLK
termi nal to the YEL ter-
mi nal , and t he YEU
GRN termi nal to the
fl r).
Check the ri ght rear motor:
It shoul d run
(the
wi ndow moves
oown).
Faul ty ri ght rear wi ndow motor
Faul ty ri ght wi ndow swi tch
810 YEUGRN
814 GRNfYEL
Connect the REDny'VHT
termi nal to the GRN/
YEL termi nal , and the
GRN termi nal to the
0l ) .
Check the l eft rear motor:
It shoul d run {the
wi ndow moves
oown,.
Faul t y l ef t rear wi ndow mot or
Faul t y l ef t rear wi ndow swi t ch
816 GRN
BLU
Connect the BLU/BLK
termi nal to the RED/
YEL termi nal , and the
BLK termi nal to the
RED/8LU termi nal ,
then turn the i gni ti on
swi tch ON
(l l ).
Check for vol tage between the
BLU and BLK termi nal s:
Approx, 6 V shoul d be i ndi cated as
the dri ver' s wi ndow motor runs.
Faul ty pul ser
B4 BLK
Power Windows
Passenger's Window Switch Test
Coupe/Hatchback:
1. Remove t he ar mr est pocket f r om t he door panel
(see
secti on 20).
5P CONNECTOR
2. Di sconnect the 5P connector from the passenger' s
wi ndow swi tch.
Sedan:
1. Remove the armrest
(see
secti on 20).
ARMREST
wtNDow
swtTcH
2. Di sconnect the 5P connector, then remove the mount-
i ng screw f rom t he passenger' s swi t ch.
23-200
L{ -
PASSENGER'S WINDOW SWITCH
5P CONNECTOR
Switch side ot 5P terminal:
Ter mi nal si de of
mal e t er mi nal s
Check for conti nui ty between the termi nal s i n each
swi tch posi ti on accordi ng to the tabl e.
\
Termi nal
ilil----t
1 2 3 5
UP
o-
-o
o-
-o
OFF
o-
-o
o-
-o
DOWN
o-
-o
o-
-o
E\
I
v
v
Driver's Window
Motor Test
Motol Test:
1. Remove the dri ver' s door
panel
(see
secti on 20)'
Termi nal si de ot mal e t ermi nal s
Disconnect the 4P connector from the motor'
Test the motor i n each di recti on by connecti ng bat-
tery power and
ground accordi ng to the tabl e.
CAUTION: When the motor stops running' discon-
nect one lead immedistelY.
4. l f the motor does not run or fai l s to run smoothl y,
repl ace i t.
2.
3.
\
Termi nal
;;;;--_l\
2
UP
o @
DOWN
@
o
ly
rlNMfl
Pulser Test:
5. Connect the test l eads of an anal og ohmmeter to the
No. 3 and No. 4 termi nal s.
6. Run the motor by connecti ng
power and ground to
the No. 1 and No. 2 termi nal s The ohmmeter needl e
shoul d move back and forth al ternatel y.
23-201
Power Windows
Passenger's
Window Motor Test
Front:
' 1.
Remove t he passenger ' s
door panel ( see
sect i on
20t.
2. Di s c onnec t t he 2P c onnec t or f r om t he wi ndow
motor.
2P CONNECTOB
t ermi nal s
3. Check wi ndow motor operati on by connecti ng power
and ground
CAUTION: When the motor stops runni ng, di scon-
nect one l ead i mmedi atel y.
4. l f the motor does not run or fai l s to run smoothl v.
repl ace i t.
23-202
f,.!*
,
\
Ter mi nal
il;;
-_-l
2
UP
@ o
DOWN
o
o
Rear:
1. Remove t he passenger ' s
door panel ( see
sect i on
20).
2. Di sconnect t he 2P connect or f r om t he wi ndow
mol or.
NOTE: The i l l ustrati on shows the ri ght rear wi ndow
motor; the l eft rear wi ndow motor i s symmetri cal .
2P CONNECTOR
t ermi nal s
3. Check wi ndow motor operati on by connecti ng power
and ground
accordi ng to the tabre.
CAUTION: When the motor stops running, discon_
nect ons lead immediately.
4. l f the motor does not run or fai l s to run smoothl v.
repl ace i t.
\
Ter mi nal
Di recti on \
1 t
UP o
@
DOWN @
I
I
Moonroof
Gomponent
Location Index
MOONROOF SwrTCH
Test,
page 23-206
v
.
IWirr colo]s: w T, GRN/YEL, I
IGRN/ORN,
BLK, lNd GNN/REDJ
Test, page 23-73,74
.
MOONROOF OPEN RELAY
IWir. color.: WHT, GRN/REO,l
LGRN/ORN,
BLK.nd YEL
I
Te6l.
gage 23-7 3, 7 4
MOTOR
Test,
page 23-206
\y
23-203
Moonroof
Ci rcui t Di agram
UNDEq. - OOD FUSE RELAY BOX
MOONFOOF
OPEN
BETAY
*1 : 96, 97 model s
x2 : 98 model
OPEN/CLOSE SWITCH:
.
DLrrinq the llino ooeraUon
(:lr[ !-p
-
Filticlosed)
A and C lorminals ate @nnected.
'
Durm the slidno ooeraton
(Fullyilosed
i
Fullv opn)
A and Elermrna s are cbnnecied
TILT/CLOSE SWITCH:
.
Du nq the lillinO OOeratron
(-Iill ui
-
Fulticlosed)
D and F terminalsare corinpded
'
DufirE lhe slidno ooeratron
(Fully closed
-;
Fltv oDen)
D arld E lermrnals are conhecied
BLK
I
-1r
'
G401
G402
23-204
b.,1
IGNITION SWITCH
No 4l (80A) N0.42 (40A)
WHT/BLK +_ WHT
UNDER.DASH FUSURELAY 8OX
MOONROOF SWITCH
nl
ry
v
Function Test
CAUTION: 8e carsftil not to damage the moonroof swhch
or the driver's dashboard lowet cover when
prying the
switch out.
NOTE: Check the No. 51 {20 A) fuse i n the under-hood
fuse/rel ay box and No. 24
(7
5 A) fuse i n the under-dash
fuse/rel ay box, before testang
1. Pry the swi tch out of the dri ver' s dashboard l ower
cover.
Wi re si de oI f emal e t ermi nal s
4P CONNECTOR
\y
23-205
7.
Connect the No. 1
(YEL)
termi nal to body ground
wi th a
j umper wi re, then turn the i gni ti on swi tch ON
(l l ),
The moonroof shoul d open.
. l f the moonrooi opens, check the swi tch.
. l f the moonroof does not open, checkfor:
-
an open i n t he YEL wi r e
-
faul ty moonroof open rel ay.
-
faul ty moonroof cl ose rel aY.
-
poor gr ound
( G401,
G402) .
Connect the No. 3
(YEURED)
termi nal to body
ground
wi th a
(l l ).
The moonroof shoul d cl ose.
. l f the moonroof cl oses, check the swi tch
a l f the moonroof does not cl ose, check for:
-
an open i n the YEURED or GRN/RED wi re.
-
faul ty moonroof cl ose rel aY.
-
faul ty moonroof open rel ay.
-
faul ty ti l vcl ose swi tch.
Connect the No. 2
(BLU) termi nal to body ground wi th
a
(l l )
The moonroof shoul d ti l t uP.
. l f the moonroof ti l ts up, checkthe swi tch.
. l l the moonroof does notti l t up, checkfor:
-
an open i n the BLU wi re.
-
faul ty ti l vcl ose swi tch.
Connect the No. 3
(YEURED)
termi nal to body
ground
wi th a
(l l ).
The moonroof shoul d ti l t down.
l f the moonroof does not ti l t down, the open/cl ose
relay must be faultY.
Check for conti nui ty to body ground on the No 4
( BLK) t er mi nal .
. l f there i s conti nui ty. check the swi tch
. l f there i s no conti nui ty, check for:
-
an open i n t he BLK wi r e
-
poor ground
(G401,
G402)
Moonroof
Switch Test
1. Careful l y remove the swi tch from the dri ver,s dash,
board l ower cover
(see page
23-205).
swi tch posi ti on
\
Termi nal
t*,*--_\
l 2 3
OFF
OPEN
o-
--o
CLOSE
o-
--o
TILT
o-
--o
\
23-206
Motor Test
1, Remove the headl i ner
{see secti on 20}.
2. Di sconnect t he 2P connect or f r om t he moonr oof
motor.
Check the motor by connecti ng power
and ground
4. l fthe motor does not run, repl ace i t
(see
secti on 2O).
NOTE: See Cl osi ng Force Check i n secti on 20 for
motor cl utch test.
\
\
\_ __lg.-rq
Posi ti on
I
OPEN o @
CLOSE @ o
Open/Glose-Tilt/Close
Switch
Test
1. Remove the headl i ner
(see
secti on 20).
2. Di sconnect the 2P and 4P connectors trom the moon-
roo{ motor and the switch.
3. Check for conti nui tY between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e
v
\!y
Position
Terminal
1 2 3
CLoSE
-
Tl tT o--
--o
o-
-_o
CLoSE
-
oPEN G-
-_o
4. l l there i s no conti nui ty, adj ust or repl ace the swi tch'
23-207
Crui se Control
MAIN SWIICH
TesVRepl acement ,
page
23 212
CABLE REEL
Repl acement , sect i on 24
CRUISE CONTROL UNIT
I nput Test , page
23-210
.
Test , page
23-214
.
Pedal Hi ght Adi ust ment ,
sect i on 19
swtTctl tM/T)
.
Test , page
23 214
.
cl ut ch Pedal Adj ust ment ,
sect i on 12
A/T GEAR POSMON
swtTcH
.
Test, page 23-138
.
Repl acement , page
23 139
ACTUATOR CABLE
Adj ust ment , page
23-216
VACUUM TANK
TOR ASSEMBLY
.
Test , page
23-215
.
Repl acement , page
23-216
.
Sot enoi d Test , page
23_217
.
Di sassembt y, page
23-218
23-20a
\ -
-.
UNDER,DASH FUSEi RELAY BOX
CRUI SE
CONTROL
ACTUATOR
ND CATOF
LGHT
(0 84W)
5 2 6
9 1 l
7
1 0
CRU SE CONTFOL UNI T
l 3
3
Ci rcui t Di agram
UNDER. HOOD
FUSE] FELAY BOX
No 30
{7.sA)
FUSE
f7
I
REDJBLK
WHT/ 8LK
+WHT
GAUGE
ASSEMBLY
ELL.JMHT BLK BLK
+
r--l
:;i ", I
i"$L:H;JF ) |
I oN: Pedareeasedl /
T
l
G40l
G402
PNK
A
Yr",
I'
:
G40l
G402
l '
BLK
A
G202
CRNIWHT
J
BRAKE
TIGHTS
v
23-209
'ry
GN]TION
SWTCH
No 41 (80A) No 42 (40A)
WHTi GRN
\v
Crui se Control
Control Unit Input Test
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and
procedu.es i n the SRS
secti on
(24)
1. Remove the dri ver' s dashboard l ower cover and knee bol ster
(see
secti on 20).
2. Di sconnect the 14P connector from the control uni t.
3. l nspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
l f the termi nal s are bent, l oose, or corroded, repai r them as necessary, and recheck the system.
l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the connector.
-
l f any test i ndi cates a
probl em, fi nd and correct the cause, then recheck the system.
-
prove OK, the control uni t must be faul ty; repl ace i t.
CONNECTOR
CRUISE CONTROL UNIT
[ -
" - " 0
Wi re si de ol f emal e t ermi nal s
;--?\
I 2 6 7
I 10 1 l 1 2 1 3 l 4
GRN/WHT LTGRN/RED LT GRN/BLK
BRN/BLK BLU/WHT LT GRN
v
ly
Test: Desired tesult Possible cau3e it result is not obtained
9 BRN/VVHT
Under al l condi ti ons Check for resi stance to ground:
Ther e shoul d be 80
-
120 O
Faul ty actuator sol enoi d
Poor ground
(G202)
1 BRN
Under al l condi ti ons Check for resi stance to ground:
There shoul d be 40
-
60 O'
1 1 BRN/BLK
Under al l condi ti ons Check for resi stance to grouno:
Ther e shoul d be 70
-
110 O'
l oni ti on swi tch ON
(l l ),
Check tor vol tage to
ground:
ri ai n swi tch oN and There shoul d be 0 V wi th the
pedal
brake
pedal pushed, pushed and battery vol tage wi th
then rel eased
the
Pedal
rel eased.
2 GRY
.
Faul ty brake swi tch
.
BLK
Under al l condrt i ons
,
Check f or cont i nui t y t o ground:
There shoul d be cont i nu' t Y'
.
Poor ground
(G401,
G402)
.
5 GRN/!VHT
Brake
pedal
Pushed,
then rel eased
There shoul d be batterY vol tage
wi th the
pedal pushed, and 0 V
wi th the
pedal rel eased.
Bl own No. 52
( 15
A) f use i n t he
under-hood fuse/rel aY box
Faul ty brake swi tch
LT GRN/
RED
Set button
Pushed
ground:
Bl own No. 52
(15
A) tuse i n the
Faul ty horn rel aY
Faul ty sevresume swi tch
Faul ty cabl e reel
7
LT GRN/
BLK
Resume button
PUshed
10 RED/BLU
(l l )
Attach to
ground:
Crui se i ndi cator l i ght i n the
gauge
assembl y shoul d come on.
Bl own bul b
Bl own No. 25
(7.5
A) fuse i n the
Faul ty di mmi ng ci rcui t i n the
gauge assemDl y
An open i n the w,re
't2
BLU/VVHT
l gni ti on swi tch ON {l l )
and mai n swi tch ON;
rai se the front of the
car, and rotate one
wheel sl owl y wi th the
other wheel bl ocked.
Check for vol tage between the
BLUMHT O and BLK O termi nal s:
Ther e shoul d be 0- 5 V or mor e
-0 -
5 V or more rePeatedl y.
.
Faul ty vehi cl e speed sensor
(VSS)
.
1 3 LT GRN
(l l )
and mai n swi tch ON
Bl own No. 14
(7.5
A) fuse i n the
Faul ty mai n swi tch
1 4 PNK
A/f:
Shi ft l ever i n
E,
b'l or
[f
M/ T: Cl ut ch
pedal
rel eased
Check for conti nui ty to
ground:
NOTE: There shoul d be no conti -
nui ty when the cl utch
Pedal
i s
depressed or when the shi ft l ever
i s i n other
posi ti ons.
Faulty A,rr
gear
Position
switch
Faul ty or mi sadj usted cl utch
swi tch
(M/T)
Poor ground
(G401, G402)
'\ty
23-211
Cruise Control
Main Switch Test/Replacement
Remove the dri ver' s dashboard l ower cover
(see
sec-
ti on 20).
Careful l y push out the swi l ch from behi nd the dash_
ooar q.
3. Di sconnect t he connect or f rom t he swi t ch.
MAIN SWITCH
BULBS
{0. 84 W)
swi tch posi ti on
l f there i s no conti nui ty, reOl ace the swi tch.
23-212
llL *
'
\
Terminal
t*t*-\
1
3 5
OFF
o-
/:\
-o
G-
/5
-o
\-/
\-/
ON
o
/:\
o o-
/5
-o
\:,,
\:./
4.
Set/Resume Switch
Test/Replacement
l . Dl sconnect the battery negatj ve cabl e, then di scon-
nect the posi ti ve
cabl e, and wai t at l east three mi n_
UI ES.
Di sconnect
the dri ver' s ai rbag connector (see
sec-
ri on 24).
Remove the dashboard dri ver' s l ower cover
(see
sec-
ti on 20).
Di sconnect the cabl e reel sub-harness 3p connector
from the mai n wi re harness.
MAIN WIRE
HARNESS
3P CONNECTOR
Termi nal si de of
mal e t ermi nal s
Check for conti nui ty between the termi nal s of the
cabl e reel sub-harness 3p connector i n each swi tch
posi ti on
\
Termi nal
t^,*
__\
I 2 3
SET
(ON}
o-
-o
RESUME (ON}
o-
---o
l f t her e i s cont i nui t y, and
j t
mat ches t he t abl e,
the swi tch i s OK.
l f there i s no conti nui ty i n one or both posi ti ons,
go to step 6.
a
a
6. Remove the two screws, then remove the swi tch
Check for conti nui ty betl veen the termi nal s i n swi tch
7.
{y
\
l erml nal
Position \
2 3
SET
(ON)
o-
---o
RESUME
(ON}
o--
-o
l f t here i s cont i nui t y, and i t mat ches t he t abl e,
repl ace t he cabl e reel .
l f t here i s no cont i nui t y i n one or bot h
posi t i ons,
repl ace t he swi t ch.
SET/RESUME
'st
-5
9.
10.
l f al l tests
prove OK, reconnect the cabl e reel and
cabl e reel sub-harness connector. then rei nstal l the
steeri ng col umn covers.
Reconnect the dri ver' s ai rbag connector, and rei n-
stal l the access
panel on the steeri ng wheel '
Reconnect the battery
posi ti ve cabl e, then the nega-
ti ve cabl e.
Af t er connect i ng t he ai r bag connect or s,
conf i r m
proper system operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS i ndi cator l i ght shoul d come on for about
six seconds and then
go off
23-213
1
' ].
Cruise Control
l - N7- r l ] ] l l

1
l x 2 |
l f f l
| 3 . l l
| ,
,
I
Brake Switch Test
4P CONNECTOR
BRAKE
PEOAL
Check for conti nui ty between the termi nal s accord-
i ng to the tabl e.
\
Terminal
tr**On----\
2 3 4
RELEASED
o-
--o
DEPRESSED
o-
--o
3. l f necessary, repl ace the swi tch or adi ust Dedal
hei ght (see
secti onl 9).
23-214
\ ^
Glutch Switch Test
(M/T)
1. Di sconnect the 2P con nector from the swi tch.
CLUTCH SWITCH
2. Check for conti nui ty between the termi nal s accord-
i ng to the tabl e.
\
\
Terminal
at**",
-\
2
RELEASED
DEPRESSED
o o
3. l f necessar y, r epl ace t he swi t ch or adj ust pedal
hei ght (see
sesti on 12).
\
Y
iy
Actuator Test
1. Di sconnect the actuator cabl e from the actuator rod
and the 4P connector'
2. Connect battery
power to the No. 4 termi nal and
ground to the No. 1, No. 2 and No. 3 termi nal s
3. Connect a vacuum pump to the vacuum hose Then
appl y vacuum to the actuator.
VACUUM PUMP
GAUGE, 0
-
30 i n. Hq.
(A973X -
041
-
xxxxxt
ACTUATOR
.P CONNECTOR
4. The actuator rod shoul d
pul l i n compl etel y. l fthe rod
pul l s i n onl y part-way or not at al l , check for a l eak-
i ng vacuum l i ne or defecti ve sol enoi d.
ACTUATOR ROD
v
23-215
5. Wi th vol tage and vacuum sti l l appl i ed, try to
pul l the
actuator rod out by hand. You shoul d not be abl e to
pul l
i t out. l f you can, i t i s defecti ve.
7.
8.
Di sconnect
ground from the No. 3 termi nal The actu-
ator rod should return. lf it does not return, but the
vent hose and fi l ter are not pl ugged. the sol enoi d
valve assembly is defective.
Repeat steps 2 through 5, and di sconnect
ground
from the No. 1 termi nal The actuator rod shoul d
return. l f i t does not return, but the vent hose and
fi l ter are not pl ugged, the sol enoi d val ve assembl y
is detective.
l f vou reDl ace the sol enoi d val ve assembl y, be sure
to use new O-ri ngs on each sol enoi d.
Disconnect
power and
ground from the 4P connector'
Disconnect the vent hose from the actuator. Connect
a vacuum pump to the actuator vent hose pon, and
appl y vacuum. The actuator rod shoul d
pul l i n com-
pl et el y. l f not , t he vacuum val ve i s st uck open.
Reolace the aduator.
Cruise Control
Actuator Replacement
t .
2.
Pul l back the boot, and l oosen the l ocknut. Then di s-
connect the cabl e from the bracket.
Di sconnect the cabl e end from the actuator rod.
Di sconnect the 4P connector from the actuator.
Di sconnect the vacuum hose from the vacuum tank.
Pul l out the vent hose.
Remove the three mounti ng bol ts and the actuator
wi th the bracket.
CABLE 4P CONNECTOR
l f necessary, di sconnect the cabl e end from the l i nk-
age over the accel erator pedal , then turn the grom-
met 90' i n the bul khead, and remove the cabl e.
Instal l i n the reverse order of removal , and adj ust
tree pl ay at the actuator rod after connecti ng the
cabl e
(see
next col umn).
5.
7.
6.
LOCKNUT
VACUUM HOSE
23-216
r L -
Actuator Gable Adjustment
1 .
5.
Check that the actuator cabl e operates smoothl y
wi th no bi ndi ng or sti cki ng.
Stan the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(Aff
i n
N
or
E .
MfI i n neutral ) unti l the
radi ator fan comes on. then l et i t i dl e.
Measure the amount of movement of the actuator
r od unt i l t he cabl e pul l s
on t he accel er at or l ever
(engi ne
speed starts to i ncrease). Free pl ay
shoul d
be 11 i 1. 0 mm
( 0. 43
t 0. 04 i n) .
ACTUATOR
CABLE
LOCKNUT FREE PLAY: 11 t 1.0 mm
{0.43 t 0.0i1 in}
l f free pl ay i s not wi thi n specs, l oosen the l ocknut.
and turn the adj usti ng nut as requi red.
NOTE: l f necessary, check the throttl e cabl e free
pl ay (see
secti on 1 I ), then recheck the actuator rod
free pl ay.
Reti ghten the l ocknut, and recheck the free pl ay.
ACTUATOR ROD
t r l l
{y
Actuator Solenoid Test
1. Di sconnect the 4P connector from the actuator.
2.
From VENT
HOSE
Check for resi stance between the termi nal s accord-
i ng to the tabl e.
NOTE: Resi stance wi l l varv sl i ghtl y wi th tempera-
ture; speci fi ed resi stance i s at 70' F
(20' C).
SAFETY VALVE
VACUUM VALVE
+
To VACUUM
ACTUATOR
\
Termi nal
;rb"*"Q)---\
1 2 3 4
VENT SOLENOID
40
-
60()
o--
--o
VACUUIVI SOLENOIO
30
-
50()
o-
-o
SAFETY SOLENOID
40
-
60c)
o-
--o
{y
TANK
23-217
Cruise Control
Actuator Disassembly
CHECK
VALVE
@,
ACTUATOR CABLE
\9
o
ACTUATOR BRACKET
WIRE SUPPORT ERACKET
ACTUATOR
Test, page
23-215
SOI.ENOID VALVES
Tesr. page
23-217
I
elR
YAJ
e
FILTER COVER
E
23-218
Power Door Locks
Y
Component
Location Index
NOTE
(With
keYless entry system):
. l f the doors unl ock or l ock wi th the transmi tter. but the
RIGHT REAR DOOR LOCK ACTUATOR
Test,
page 23-229
Replacemnt, section 20
FRONT PASSENGER'S DOOR LOCK ACTUATOR
v
Test,
page 23-229
Replacemnt, section 20
AUDIO UNIT
repl ace the transmatter.
. when you unl ockthe doors wi th the transmi tter, the cei l i ng l i ght
(mi ddl e posi ti on) comes on tor 30 seconds.
(However,
i f the audi o uni t i s not i nstal l ed, the l i ght does not come on l
a l f any door i s open,
you cannot l ock or unl ock the doors wi th the transm' tter'
. The horn sounds onl y the fi rst ti me you press a transmi tter button.
(Pressi ng repeatedl y does not acti vate the horn
agat n. l
. l f vou unl ocked the doors wi th the trsnsmi tter, but do not open any of the doors wi thi n 30 seconds, the doors rel ock
automati csl l v.
. The doors do not l ock or unl ock wi th the transmi tter i f the i gni ti on key i s i nserted i n the i gni ti on swi tch.
. l f you press the PANIC button for more than two seconds, the horn sounds for about 30 seconds, and the transmi tter
LED comes on.
(The pani c mode wi l l not be acti vated i f the i gni ti on key i s i n the i gni ti on swi tch.) The
pani c mode i s
cancel l ed by pressi ng any of the transmi tter buttons.
o After repl aci ng the t;nsmi tter battery.
press the l ock and unl ock buttons fi ve or si x ti mes to acti vate the transml tter'
LED on the transmi tter does not come on, the LED i s faul ty;
LEFT REAR OOOR LOCK ACTUATOR
Test,
page 23-229
LOCK ACTUATOR
Test,
page 23 229
{STEREO
RADIO TUNER)
/ Hasbui h-i n
keyl ossl
\tecorvor
qrcu|l
I
Replacemont.
page 23-169
Input Test,
page 23-226
Termi nal s,
page 23-228
KEYLESS TRANSMITTER
Storing oI Transmitter Codes,
page 23-231
TesvReplacement, Page
23 230
DRIVER'S DOOR LOCK SWITCH
Test, page 23'228
POWEB OOOR LOCK
CONTROL UNTT
l nput Test ,
page 23-224
t-.a
@
\ql
F , ,
{y
23-219
Power Door Locks
Circuit Diagram (With
Keyless Entry System)
WHT/BLK
WHT/RED
WNT/BLU
LOCK KNOB
n
]
xev
I
r--1--n1
i-H__!J
BLK
G551
WHT/FED
I
l , l
i-A-r I
LIJ
I
FEAR
l l ro*
L
LOCK I PASSENGER' S
io'
lRsi^"s'
YEUFED gLK
G551
I
UNDEF HOOD FUSE/RELAY BOX
No41 (804) N0.42 (40A)
POWER DOOR LOCK CONTHOL UN T
unLocx@ rocx
@
GRN,4VHT
GRN/ORN
DOOF LOCK KNOB
BLK
G551
23-220
v
]GNITION
swrTcl.l
WHT/REC
v
TRUNK
LI GHT
HORN
RELAY
T
GFY
T GRN/ BED
|
*rrurorro
I
CONTRoT UN|T
t'---l-----"--------'7
t r (
I L,.- )
GRN LT
I
d\
v - ,
l::;=:-'
|
:,.s!. lccf opn
| | loe. loor c osed
UNDEF-DASH
FUSE/ RELAY
BOX
WHT/BLK BLK/YEL
|-+-_-+-l
|
' J
r' ro.zg ) Norq I
|
(
(roA)
f,
(7.5A)
|
t l
YEURED BLK/YEL
BLU/RED
l *recnereo
I
coNTRoL UN| T
I Y
| ,,u'rro
r
BLU/FED
I
i l t )
f*,o"
liff.ii
I'r,t*rt* ;
I
BLK
I
t_
oio,
G402
LTGRN/RED
l
GRN/RED
I
A
Y,,,
I REAR
I
DoOF
l:xH
I
to*"
I
I
-l
GRN/ FED
A
Il$'.i')""'
i
lt3'tri'
8silsr.:, l
I
FIGHT
REAR
DOOR
SWITCH
ubseo : uooropen
I
(Open :0oor closed
,l
KEYLESS RECEIVER CIRCUlT
(ln lhe audio un()
23-221
G401
G402
v
Power Door Locks
Ci rcui t Di agram
(Wi thout
Keyl ess Entry System)
23- 222
\
DOOR LOCK KNOB
t l
I
BLU/WI-17
WHT/FED
BLUi NED
UNDEF.HOOD FUSEi RELAY 8OX
DEI VER' S
DOOH LOCK
SWTCH
BLK
I
I
I
G551
POWER
DOOR LOCK
CONTROL UNIT
BLK
G55l
ry
!y
Troubl eshooti ng
NOTE: The numbers i n the tabl e show the troubl eshooti ng sequence
*:
wi th keyl ess entry system
NOTE:
. When the remote transmi tter button i s
pressed the fi rst ti me, onl y the dri ver' s door wi l l unl ock. When the button i s
Dressed the second ti me, al l the doors wi l l unl ock.
. Thedoorswi l l rel ock automati cal l y after 30 seconds i fa door i s notopened, orthe key i sout ofthe i gni ti on swi tch
. The keyl ess entry system wi l l not l ock or unl ock the doors when the key i s i n the i gni ti on swi tch.
Item to be i nspected
Symptom
o
_9
{ p
e c
3
9 c
t 3
; o
E 5
o
(J
)
o
:
o
f
-o
o
9 - )
3 n '
O Y
3
:
. z
o
F
. g
=
E
F
. z
: ;
< :
o
IL
E
o
Power door l ock system does not work at al l . 1 2 G551 WHT/GRN
Doors don' t l ock wi th dri ver' s
door l ock knob swi tch.
Al l doors 1 2 3
B LU,ryVHT
One or mor e
doors
1 2
YEURED or
WHT/RED
Doors don' t l ock or unl ock
wi th dri ver' s door l ock swi tch.
Al l doors
1 3 2
GRN,ryVHT,
GRN/ ORN,
YEURED or
WHT/RED
One or mor e
doors
2
YEURED or
WHT/RED
*
The power door l ock system works
properl y but
the keyless entry system doesn't.
1 2
G401
G402
GRNAVHT or
GRN/ORN
Power Door Locks
Control Uni t Input Test
Remove the dri ver' s door panel (see
secti on 20).
Di sconnect the 12P connector from the control uni t.
l nspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
a l f the termi nal s are bent, l oose or corroded, repai r them as necessary, and recheck the system.
. l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the connector.
-
l f any test i ndi cates a probl em, fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests prove OK, the control uni t must be faul ty; repl ace i t.
12P CONNECTOR
*r
With keyless entry system
\
' t .
2.
\
\
t-
YEL/ RED
GRN/WHT
1 2 1 5
1 I 1 2
BLU/ WHT
23-224
v
ry
Di sconnect the l 2P connector from the
power
door l ock control uni t.
CAUTION: To prevent damage to the actuator, apply battery voltage only momentarily.
Cavily Wire Test condition Test: Degired result
*:
With keyless entry system
Reconnect the 12P connector to the power door l ock control uni t.
Cavity Wire Test condition Test: Desired result
BLK
Under al l condi t i ons Check for conti nui ty to ground:
.
Poor gr ound ( G551)
.
't2
WHT/GRN
Under al l condi t i ons Check for vol tage to
ground:
.
Bl own No. 51 {20 A) fuse i n the
.
YEURED
Connect the YEURED
termi nal to the WHT/
GRN termi nal , and the
WHT/REO termi nal to
the BLK termi nal
momentari l y.
Check door l ock operati on:
Al l passenger' s doors shoul d
unt ocK.
Bl own No. 51
(20
A) fuse i n the
Faul ty actuator
BLU/RED
connect the BLU/RED
GRN termi nal . and the
WHT/RED termi nal to
the BLK termi nal
momentari l y.
Dri ver' s door shoul d unl ock.
5 WHT/RED
Connect the WHT/RED
GBN t er mi nal , and t he
YEURED termi nal to
the BLK termi nal
momenranry.
Al l passenger doors shoul d Iock.
BLUI/EL
Under al l condi ti ons. Check for conti nui ty between the
power door l ock control uni t 12P
connector No.6 termi nal and audi o
uni t 16P connector No.3 termi nal :
.
GRN/WHT
Dri ver' s door l ock
swi tch i n LOCK
ground:
There shoul d be 1 V or l ess.
Faul ty dri ver' s door l ock swi tch
r oor
gr ouno
t ( l 55 r ,
6 GRN/ORN
swi tch i n UNLOCK
7 BLU,Mr'HT
Dri ver' s door l ock knob
i n LOCK
Faul ty dri ver' s door l ock actuator
Poor gr ound
{ G551)
ty
23-225
Power Door Locks
Audio Unit
(Keyless
Receiver Circuitl Input Test
(with
keyless entry systeml
Remove the audi o uni t, then di sconnect the A and B connecto.s
(see page 23-169).
Inspect the connector and socket termi nal s to be sure they are al l maki ng
good contact.
. l f the termi nal s are bent. l oose or corroded, repai r them as necessary, and recheck the system.
. l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the connector'
-
l f anv test i ndi cates a
probl em, fi nd and correct the cause, then recheck the system.
-
prove
OK, the control uni t must be faul ty; repl ace at.
A CONNECTOR B CONNECTOR
AUDIO UNIT
\
{KEYLESS RECEIVER CIRCUIT)
\.
23-226
v
v
Di sconnect the A and B connectors from the audi o uni t
Reconnect the B connector onl y to the audi o uni t.
Cavity wire Tsst condition
Possible cause if result is not obtaind
Possibls cause if r93ult is not obtaingd
A4 WHTi BLU
Under al l condi ti ons Check for vol tage to ground:
.
Bl own No. 47
(7.5
A) fuse i n the
under-hood {use/rel ay box
.
YEURED
l gni t i on swi t ch ACC {l } Check for vol tage to ground:
Bl own No. 28
(10
A) fuse i n the
B6 BLfi EL
(l l )
.
Bl own No. 14
(7.5
A) fuse i n the
.
BLK
Under atl condi ti ons Check for conti nui ty to ground:
There should be continuitv.
Poor ground (G401,
G402)
An open in the wire
BI BLU/RED
l gni ti on key i nserted
i nto the i gni ti on keY
switch
ground:
Poor ground
{G401.
G402)
Faul ty i gni ti on key swi tch
Short i n the wi re
lgnition key removed
from the i gni ti on key
switch
There shoul d be 4 V or more.
B3 BLU//EL
Check tor continuity between the
audi o uni t 16P connector No. 3 ter-
mi nal and
power door l ock control
uni t 12P connector No. 6 termi nal :
.
B8
LT GRN/
BLK
Cei l i ng l i ght swi t ch i n
"mi ddl e
posi t i on"
Connect to ground:
The cei l i ng l i ght shoul d come on.
Bl own No. 43
(7.5
A) fuse i n the
under-hood tuse/rel ay box
Bl own cei l i ng l i ght bul b
Faul ty cei l i ng l i ght
814
LT GRN/
RED
Each door open, one at
a Irme
ground:
.
Faulty door switch
.
B16 GRY
Connect to ground:
Horn shoul d sound.
Bl own No.52
(15 A) fuse i n the
Faul ty horn
Faul ty horn rel ay
B9 GRN/ORN
swi tch i n UNLOCK
Poor ground
(G551)
Shon i n the wi re
swi tch i n LOCK
ground:
810 GRN/WHT
swi tch i n UNLOCK
ground:
Poor ground
(G551)
Short i n the wi re
swi tch i n LOCK
Check fo. vol tage to ground:
v
23-227
Power Door Locks
Audio Unit
(keyless
receiver
ci rcui tl Termi nal s
Cavity Dsstination Wire
16P CONNECTOR
B1 BLU/RE D l gni ti on key swi tch
'B2
LT GRN Trunk l atch swi tch
B3 BLU/YEL Unl ock
(Dri ver' s
door)
B4 BLU Val et swi tch
* 85
LT BLU Securi ty
(l N)
BLK/YE L No. 14
( 7. 5
A) f use
* 87
ORN Securi ty
(D2)
88 LT GRN/BLKCei l i ng l i ght
B9 GRN/ ORN Unl ock
( Al l
door )
810 GRN^r'r'HTLock
(Output)
* B1 1
BLU^ll/HT LED O
*812
WHT/BLK Secufi ty
(D0)
* Bl 3
YEUBLU Securi ty
(D1)
Bl 4 LT GRN/RED Door switch
815 BLK Gr ou nd
( G401,
G402)
GRY HOrn
*i
For securi ty system
(opti on)
Driver's Door Lock Switch Test
1. Remove the i nner handl e
(see
secti on 20).
2. Di sconnect t he 3P connect or f r om t he door l ock
Check for conti nui ty between the termi nal s i n each
swi tch posi ti on accordi ng to the tabl e.
DRIVER'S
DOOR
LOCK
swtTcH
\
Terminal
I 2
Position
LOCK
o
----o
OFF
UNLOCK
o o
\
Y
v
Driver's Door Lock Actuator Test
1. Remove the dri ver' s door
panel
{see secti on 20).
2. Di sconnect the 4P connector from the actuator.
Termin.l srdc ol
mele l.rminals
3. Check for continuity between the terminals in each
knob swi tch
posi ti on accordi ng ro the tabl e
4. Check actuator operation by con.!ct'ng
power ano
ground accordi ng to the tabl e. To p.went damage
to the actuator, apply battery voltage only momen-
tari l v.
\
Termi nal
Posi ti on \
LOCK
o--l
UNLOCK
\
Termi nal
;".ltfi
-\
1 2
LOCK
@
UNLOCK
{y
5. lf the actuator fails to work properly, .eplace it.
23-229
' 1.
Passenger's Door Lock Actuator Test
Remove the passenger' s door
panel
{see secti on
20t.
Di sconnect the 2P connector from the actuator.
NOTE: The front passenger' s door l ock actuator i s
shown; the l eft rear and ri ght rear door l ock actua-
tors are si mi l ar.
3. Check actuator operati on by connecti ng
power and
ground accordi ng to the tabl e. To prevent damage
to the actuator, appl y battery vol tage onl y momen-
tari l y.
4. l f the actuator fai l s to work
properl y, repl ace i t
Termi nal si de oI mal e t ormi nal s
\
Termi nal
r-*r,r""----_\
LOCK
o
o
UNLOCK
@
Power Door Locks
Transmitter Inspection/Replacement
NOTE:
. l f the doors unl ock or l ock wi th the transmi tter, but the LED on the transmi tter does not come on, the LED i s faul ty;
repl ace the transmi tter.
. l f any door i s open, you
cannot l ock or unl ock the doors wi th the transmi tter.
. l f you unl ocked wi th the transmi tter, but do not open any of the doors wi thi n 30 seconds. the doors rel ock automati -
cal l y.
. The doors do not l ock or unl ock wi th the transmi tter i f the i gni ti on key i s i nserted i n the i gni ti on swi tch.
BATTERY
CQ
o
\
\*
23-230
Door3 cannot bo locked o.
unlocked with the transmittor.
Press t he l ock or
(rnl ock
but t on
f i ve or si x t i mes t o r 6sot t he
transmtter.
Repl ace t he t ransmi t t er bat t ery
with a new one, and try to lock/
unl ock t he doors wi t h t he t rans,
mi t t er. Press t he l ock or unl ock
button fiv6 or six times.
Rewrite and register the transmit-
ter cod, then try to lock/unlock
t he doors
(see page
23-231).
v
ry
Storing of Transmitter
Codes
NOTE:
. The codes of up to four transmi tters can be stored i n the control uni t
(l f
a fi fth code i s stored' the code whi ch was
stored ti rst wi l l be erased.l
. When the system enters the regi strati on mode, al l previ ousl y stored codes wi l l be erased'
. The system l eaves the regi strati on mode and returns to the normal mode i f you
-
turn the val et swi tch OFF. or
-
turn the i gni ti on swi tch OFF, or
-
do not Dress the transmi tter button for more than 10 seconds'
Procedure:
NOTE: l f t he t uner i s t urned ON, i t wi l l
go of f and come on agai n when t he reg-
i st rat i on
procedure i s compl et ed
NOTE: lf you want to register the codes
of more than one transmitter, repeat step
4 wi t hi n 10 seconds wi t h t he ne)d t rans-
mitter,
NOTE: Af t er st ori ng i t s code, make sure
t he t r ansmi t t er
wor ks
pr oper l y oy
repeat edl y
pressi ng one of i t s but t ons.
(The syst em st art s t o work when
You
press any transmitter button six times )
1. l nsert t he i gni t i on kev i nt o t he
i gni t i on swi t ch.
f l r).
Wi t hi n 1O seconds,
go t o st ep 3.
3. Press and hold the valet switch
lor at least five seconds.
(You will hear the sound of the
actuators t! rning to UNLOCK.)
VALET SWITCH
r-r
.
l-r l-l
I t ' t t t l
Within 10 seconds,
go to steP 4.
4. Press one of t he t ransmrt t er
buttons.
(You wi l l hear t he sound of t he
act uat ors t urni ng t o UNLOCK. )
Y
TRANSMITTER
23-231
v
Supplemental
Restraint System
(SRSI
Speci af Tool s. . .
. . . . . . . . . . ' 21' 2
Component/Wiring
Locations
f ndex . ' . . . . . . . . . . . . . .
"""21' 3
Description
................ 2/t-5
Gircuit Diagram
..' .,,,..2+6
Precautions/Procedures
Generaf Precaut i ons . . . . ". . . . . . . . . . . . . . . . . . 21' 7
Airbag Handling and Storage ......". 21-7
SRS Unit Precautions ....' ................. 2/t-8
lnspection After Deployment ' ......' . 24-8
Wi ri ng Precaut i ons ". . . . . ", . . . . . . . . ". . . . . .
2t t -9
Backprobing SPring-loaded
Lock
Connectors
.-.,....2+S
Spring-loaded
Lock Connector ......' 2+10
Spring-loaded
Lock Connector with
Bui l t -i n Short Cont act ' . . . . . . ' . . . . . . . . .
2i t -1 0
Disconnecting the Airbag
Connector(s)
......21-11
Steering-related
Precautions .. -..--... 2+12
\y
Troubleshooting
Seff-diagnostic
Procedures
....... -....' 24' 13
Readi ng t he DTC . . . . . . . . ' . . ". . . . . . . . . . . . . . . ' .
24-13
Erasing the DTG Memory ...."......" ' 24-15
Troubleshooting
Intermittent
Faifures
.' --..........24-15
SRS Unit ldentification ....' ..."...' ..' ...
24-16
(DTCI
Chart
-
' 96
-
97 Mode| s. . . . . . . . . . . . ' . . .
24-17
(DTCI
chart
-
' 98
Model .....""""" """"" 24-19
SRS Indicator Light Wire
Connections
......24' 25
Flowcharts
.............24-26
Airbag
Repf acement
....",..24-67
Di sposaf
. . . . . . . . . . . . . . . . . 24-70
Cable Reel
Repf acement
..."....24' 72
SRS Unit
Repf acement
.' .......24-76
'c
Speci al Tool s
Ref. No. Tool Numbel Description Oty Page Referencs
o
6,
@-
07HAZ
-
SG00400
07PAZ
-
0010100
071 AZ
-
5250200
07TAZ
-
0010204
Depl oyment Tool
SRS Servi ce Connector {2 0)
Backprobe Adapter, 17 mm
1
1
1
24-70
24-' t4
24-42
24-30
*:
Use wi th the stacki ng patch cords from T/N 07SAZ- 0010004, Backprobe Set.
o
SRS INFLATOR
SIMULATOR
07sAz
-
TB4011A
@
SNS SMULATOR
LEAO C
07TAZ-525011A
NOTE: The SRS Ser vi ce Connect or { 2 O) , T/ N 07TAZ
-
5250200, i s not avai l abl e. I nst ead, use t he SRS I nf l at or
Si mul ator, T/N 07SAZ
-
T8401' l A, and the SRS Si mul ator Lead C, T/N 07TAZ
-525011A.
When the SRS Servi ce
Connector {2 O), T/N 07TAZ
-
5250200, i s cal l ed for, connect the l ead to one of the si mul ator' s
"2
0" i acks.
\
t
L
Gomponent/Wiring
Locations
v
lndex: With Front Passenger's
Airbag
SRS INDICATOB
LIGHT {ln the
gauge assemblv)
Troubleshooting, Page
24-13
Gauge sssembl Y, sect i on 23
CABLE REEL
Replacement,
page 24-72
To HORN
MAIN
HARNESS
To ORIVER'S AIRBAG
DASHBOABD
WIRE HARNESS
ro SRS INDICATOR UGHT in
GAUGE ASSEMBLY
5P CONNECTOR
ORIVER'S AIRBAG
ASSEMBLY
Replacement,
page 24-67
Disposal,
page 24-70
FRONT PASSENGER'S
AIRBAG
ASSEMBLY
Replacement, Page
24-67
Disposal, Page
24-70
ry
SBS MAIN
sRS MAIN HARNESS
ro CABII EEEL
2P OONNECTOR
SERVICE CHECK
coNNECTOn {2Pl
IBRN,
BLKI
to UNDER.DASH
FUSE/RELAY BOX
2P COT{NECTOR
SRS MAIN HABNESS
to FRONT PASSENGER'S
AIREAG
2P CONNECTOR
SRS MAIN HARNESS
to sRS UttlT
18P CONNECTOR
SRS MAIN I{ARNESS
to MAIN
WME HANNESS
3P OONNECTOR
MEMORY EMSE SIGNAL
IMES) CONNECTOR EPI
IGRY,
GRYI ot [GRN,
GRNI
MAIN WIRE HABNESS
to DASHBOARD
WIRE HARNESS
24P CONNESTOR
SRS UNTT
{lncluding
saling
snsor
and imPact sensor)
Repl acement , Page
24-76
Y
24-3
Component/Wiring Locations
Index: Without Front Passenger's Airbag
(Part
of CANADA Model)
SRS I NDI CATOR UGHT
(l n
t he gauge assembl y)
24-13
Gauge assembl y, sect i on 23
DRIVER'S AIREAG
ASSEMBLY
Replacement.
page 2+67
Disposal, page 24-70
CABLE REEL
Replacement,
page 24-72
swtTcH
To CRUISE CONTROL
sEt swtTcH
To DRIVER'S AIRBAG
\
DASHEOARD WIRE HARNESS
tO SRS INOICATOR LIGHT iN
GAUGE ASSEMBLY
5P CONNECTOR
SERVICE CHECK
CONNECTOR {2PI
IBRN, BLK]
SRS MAIN
SRS MAIN HARNESS
SRS UNIT
{l ncl udi ng saf i ng sensor
and i mpact sensor)
Replacement, page 24-76
to UNOER-DASH
FUSE/RELAY BOX
2P CONNECTOR
SRS MAIN HARNESS
to SRS UNIT
18P CONNECIOR
SRS MAIN HARNESS
io MAIN
WIRE
HARNESS
3P CONNECTOR
MEMORY ERASE SIGNAL
{MESI CONNECTOR I2PI
IGRY, GRYI o. [GRN, GRNI
I
24-4
DUMMY RESISTOR
{
Description
v
v
The sRS i s a sal ety devi ce whi ch, when used i n conj uncti on
wi th the seat bel t, i s desi gned to hel p
protect the dri ver
(and
l r ont passenger ) i naf r ont a| l mpact exceedi ngacer t ai nset | i mi t ' Thesyst emconsi st sof t hesRSuni t ( i nc| udi ngsaf i ng
sensor and i mpact sensor), the cabl e reel , the dri ver' s ai rbag
(and
l ront
passenger' s ai rbag)'
ORIVER'S AIBBAG
CABLE REEL
Operation
Themai nci r cui t i nt heSRsuni t sensesandj udgest hef or ceof i mpact and, i f necessar y, i gni t est hei n' | at or char ge( s) . | f
bat t er yvo| t agei st ool owor power i sdi sconnect edduet ot hei mpact , t hevol t ager egu| at or andt heback. uppower ci r cui t
respecti vel y wi l l keep vol tage at a constant
l evel '
Fol the SRS to operate:
{1)
The i mpact sensor must acti vate, and send el ectri c si gnal s to the mi croprocessor'
(2)
The mi croprocessor
mu$ compute the si gnal s, and must send si gnal s to the ai rbag i nfl ator(s)'
{3) The i nfl ator(s) must i gni te and depl oy the ai rbag(s)'
f f * :
*;_--l
+
I
i * w -
i
t t l
gsIF'-'"
Self-diagnosis Sysiem
A sel f-di agnosi s ci rcui t i s bui l t i nto the sRs uni u when the i gni ti on swi tch i s turned oN
(l l )'
the sRS i ndi cator l i ght comes
on and
gol es off after about si x seconds i f the system i s operati ng normal l y
l f the l i ght does not "o." on, o. do""-i ot
go ofi "ft", "i " ""condi , or i f i t comes on whi l e dri vi ng, i t i ndi cates an abnormal -
itv in tn'" "y"t".. fne system must be inspected and repaired as soon as
possible'
For bet t er ser vi ceabi | i t y, t hememor ywi l I st or et hecauseof t hema| f unct i on. andt hedat aI i nkci r cui t passesont hei nf or -
mat i onf r omt hememor yt ot hedat a| i nkconnect or ( DLc) ' Thi si nf or mat i oncanber eadwi t ht heHondaPGMTest er con.
nected to the DLC
(16P).
{y
24-5
Circuit Diagram
I GNI TI ON
SWITCH
L
UNDER- OASH
FUSE/RELAY
BOX
GRY
IGRN}
GRY
(GRN}
D
G80t
BLK
G401
G402
t l
t . r Tl
t " " t
MEMORY ERASE
SI GNAL
(MES)
CONNECTOR
I2PI
GRY
I GRN)
t
BRN 8RN
t l
t l
f7
V V
ECM/ PCM SERVI CE
CHECK
CONNECTOR
GRY
IGBN)
I
LT 8LU
I
I
DATA TINK
CONNECTOR
{ DLC) ( 16P)
SRS UNITTERMINALS
24-6
UNOER HOOD FUSE/NETAY 80X
WHT/BIK +-WHT
BLKffEL
J
PGM- FI
SRS INDICATOR CIBCUIT
{ln the gauge
assmblyl
Bfake systm light
DRIVER'S
AIRBAG
INFLATOR
p8ssnger's
aib8g
[**-*i-l
I
lfrsEsATGE*s
I
I
rNFr.AroR
I
i / - \ i
passenge/s
airbag
t l
t l
!
sytru%,
I
SRS INOICATOR
t-tGHT t1.4W)
10 14 1 13 6 TI VA) 3{ VB)
SRS UNI T
1 6 1 7 1 5 9 t 8 I
Teminal side of lnale ierminals
ti
\
Precautions/Procedu
res
v
v
General Precautions
. Carefully inspect any SRS
part before
you install it Do
not install any part that shows signs of being dropped
or improperly handled, such as dents, cracks or defor-
maI| on:
-
Ai rbag assembl i es
-
Cabl e reel
-
SRS uni t
r Use onl y a di gi tal mul ti meter to check the system l f
i t' s not a Honda mul ti meter, make sure i ts output i s
1O mA
(0.01
A) or l ess when swi tched to the smal l est
val ue i n the ohmmeter range. A tester wi th a hi gher
output coul d damage the ai rbag crrcul t or cause accl -
dental depl oyment and
possi bl e i ni ury.
) Do not i nstal l used SRS
parts l rom another vehi cl e
When maki ng SRS repai rs, use onl y new pans'
r Ex c ept when
per f or mi ng el ec l r i c al
i ns pec t i ons ,
al ways di sconnect both the negati ve cabl e and
posi -
ti ve cabl e from the battery, and wai t at l east three
mi nutes before begi nni ng work.
. Repl acement
of t he combi nat i on l i ght and wi per /
washer swi t ches and cr ui se cont r ol swi t ch can be
done wi thout removi ng the steeri ng wheel :
-
For combi nat i on
l i ght and wi per washer swi t ch
repl acement, see secti on 23
-
For crui se control sevresume swi tch repl acement,
see secti on 23.
. Whenever the i gni ti on swi tch i s ON tl l r, or has been
turned OFF for l ess than three mi nutes be careful not
t o bump t he SRS uni U t he ai r bag( sl coul d acci dent al -
l y depl oy and cause damage or i nj ury'
. Whenever the ai rbag(s) has(havel ben acti vated,
reol ace the SRS uni t.
{y
24-7
Ai rbag Handl i ng and Storage
Do not try to di sassembl e the ai rbag assembl y l t has no
servi ceabl e
parts.
Once an ai rbag has been operated
(depl oyed), i t cannot be repai red or reused.
For temporary storage of the ai rbag assembl y duri ng ser
vi ce, pl ease observe the fol l owi ng
precauti ons:
. Store the removed ai rbag assembl y wi th the
pad sur-
face up. The dri ver' s {and
front passenger' s) ai rbag
connector(s) has
(have) a bui l t-i n short contact {see
page24-11J.
!!@
r the airbag is improprlY stored face down,
i6ilEftil?eptoyment
could
propel the unit with enough
Iorce to cause serious iniurY.
AIRBAG CONNECTORS
{Wi t h bui l t ' i n short cont act )
. Store the removed ai rbag assembl y on a secure fl at
surface awav from any hi gh heat source
(exceedi ng
212' Ft1OO"CI and free of any oi l ,
grease, detergent or
water,
CAUTION: lmproper handling ot storage can internally
damage the airbag assembly, making it inoperative'
lf
you suspeqt the airbag assembly has been damagGd,
install a new unit, and refer to the Deployment/Disposal
procedures for disposing of the damaged airbag.
Precautions/Procedu res
SRS Unit Precautions
Take extra care when pai nti ng or doi ng body work i n
the area bel ow the dashboard. Avoi d di rect exposure
of t he SRS uni t or wi r i ng t o heat guns, wel di ng, or
sprayi ng equi pment.
Di sconnect t he ai r bag connect or ( s) bef or e di scon-
necti ng SRS harness connectors
(see page 24-11l ,.
After any degree of frontal body damage, or after a
col l i si on wi thout ai rbag depl oyment, i nspect the SRS
uni t for physi cal damage. l f i t i s dented, cracked, or
deformed, reDl ace i t.
Be sure the SRS uni t i s i nstal l ed securel y.
Do not di sassembl e the SRS uni t.
Store the SRS uni t i n a cool
(l ess
than about
' 104.F/
40' C) and dry
(l ess
than 80% humi di ty, no moi sture)
pl ace. Do not spi l l water or oi l on the SRS uni t, and
keep i t away from dust.
Duri ng i nstal l ati on or repl acement, be careful not to
bump
(i mpact
wrench, hammer, etc.) the area around
the SRS uni t. The ai rbag(s) coul d acci dental l y depl oy
and cause damage or i nj ury.
\
24-8
lnspection After Deployment
Af t er a col l i si on i n whi ch t he ai r bag( s) was
( wer e)
depl oyed, repl ace the SRS uni t, and i nspect the fol l owi ng:
l . Inspect al l the SRS wi re harnesses. ReDl ace, don' t
repai r, any damaged harnesses.
2. Inspect the cabl e reel for heat damage. l f there i s any
damage, repl ace the cabl e reel .
3. Af t er t he vehi cl e i s compl et el y r epai r ed, t ur n t he
i gni ti on swi tch on, l f the SRS i ndi cator l i ght comes
on for about si x seconds and then goes off. the SRS
system i s OK. l f the i ndi cator l i ght does not functi on
properl y, go
to SRS Troubl eshooti ng.
I
v
Wiring Precautions
. Never attempt to modi fy, spl i ce or repai r SRS wi ri ng
NOTE: SRS wi ri ng can be i denti fi ed by speci al
yel l ow
outer
Protecti ve
coveri ng.
Be sure to i nstal l the harness wi res so that they are not
Di nched or i nterferi ng wi th other
parts.
v
Make sur e al l SRS
gr ound l ocat i ons ar e cl ean and
grounds are securel y fastened for opti mum
metal -to-
metal contact. Poor
groundi ng can cause i ntermi ttent
Drobl ems that are di ffi cul t to di agnose.
v
24-9
Backprobi ng
SPri ng-l oaded
Lock
Connectors
. When checki ng vol tage or resi stance on thi s type of
connector the fi rst ti me, i t i s necessary to remove the
retai ner to i nsert tester
probes from the wi re si de
NOTE: l t i s not necessary to rei nstal l the removed
retai ner; the termi nal s wi l l stay l ocked i n the connec
tor housang.
To remove the retai ner, i nsert a fl at ti p screwdrtver
between connector body and retai ner, and careful l y
pry out the retai ner'
NOTE; Take care not to break the connector'
FLAT TIP
SCREWDRIVER
RETAINER
*
Di scard af t er removal .
RETAINER
RETAINER
Preca utions/Procedu
res
Spri ng-l oaded Lock Connector
Some SRS system connectors have a spri ng-l oaded l ock.
Disconnecting
To rel ease the l ock, pul l
the spri ng-l oaded sl eeve toward
the stop whi l e hol di ng the opposi te hal f of the connector.
Then pul l
the connector hal ves apart.
NOTE: Be sur e t o pul l
on t he sl eeve and not on t he
connector hal f.
SPRING.LOADED
SLEEVE
Do not pul l on
t hi s
hal f ot t he connect or.
Connecti ng
1. Hol d the pawl -si de
connector hal f, and press on the
back of the sl eeve,si de connector hal f i n the di recti on
shown. As the two connector hal ves are pressed
together, the sl eeve i s pushed
back by the pawl .
NOTE: Do not touch the sl eeve.
When the connector hal ves are compl etel y connected.
the pawl
i s rel eased, and the spri ng l oaded sl eeve
locks the connector.
SPRING-LOAOED
SLEVE
|
24- 1O
It
Spring-loaded Lock Connector with
Built-in Short Contact
The dri ver' s ai rbag
(and
front passenger.s)
ai rbag has
( have)
a spr i ng- l oaded l ock connect or wi t h a bui l t - i n
short contact. When thi s connector i s di sconnected. the
power t er mi nal and t he gr ound
t er mi nal i n t he ai r bag
connector are automati cal l y shorted.
Conneqtot halves disconnected:
SHORT CONTACT
Connegtor halves connected:
GROUNO TERMINAL
CASLE REEL CONNECTOR
GROUND TERMINAL
v
Disconnecting
the Airbag Gonnector(s)
!u@
To
provant accidenlal ai.bag dsploymsnl,
turn the ignition switch oFF' disconnect the nogltiv! blttrty
..lt-.. and wait th,ee minutes before disconnecting
any sRs connostors'
. Before di sconnecti ng
the SRS mai n harness
(A)
from the SRS uni t' di sconnect both ai rbaqs
(C'
D)'
. Before di sconnecti ng
the cabl e reel 2P con nector
(B),
di sconnect the dri ver' s ai rbag 2P connector
(C)'
v
1. Di sconnect the negati ve battery cabl e, and wai t at
l east thrse mi nutes.
2. Di sconnect the ai rbag connector(sl .
Driver's Side:
. Remove the access
panel from the steeri ng wheel ,
then di sconnect
the dri ver' s ai rbag 2P connector and
cabl e reel 2P connector.
AOCESS PANEL
Front Passonger's Sids:
. Remove the
gl ove box. then di sconnect the front
pas-
senger' s ai rbag 2P connector and SRS mai n harness
2P connector.
t
{y
Precautions/Procedu res
Steering-related Precautions
Steoring Wheel and Cable Reol Alignment
NOTE: To avoi d mi sal i gnment of the steeri ng wheel on
reassembl y, make sure the wheel s are turned strai ght
ahead before removi ng the steeri ng wheel .
Rotate the cabl e reel cl ockwi se unti l i t stops.
Then rotate i t countercl ockwi se (approxi matel y
two and
a hal f turns) unti l the arrow mark on the cabl e reel l abel
poi nts strai ght up.
ARROW MARK
\)
24-12
-
SteeringColumn Romoval
GAUTION:
. Betoro rmoving the steering column. first discon-
nect tho connector between ihe cable 1a9l and tho
SRS main harness.
. lf the steering column is going to be removed with-
out dismounting the stering wheel, lock the stecr.
ing by turning the ignition key to o-LOCK position.
or
remove the key from the ignition so thal lhe steering
whed will not turn.
NOTE:
When the ai rbag assembl y and cabl e reel are di scon-
nected. and the battery i s reconnected and the i gni -
ti on swi tch i s turned ON
(l l ),
the SRS uni t wi l l store
thi s as an open i n the dri ver' s ai rbag i nfl ator, and the
SRS i ndi cat or l i ght wi l l come on, I n such a case.
make sure to confi rm the DTC, then cl ear the SRS
uni t memorv.
For di sconnecti ng the spri ng-l oaded l ock type con-
nector, refer to page 24-10.
SRS MAIN HARNESS
2P CONNECTOR
Do not repl ace the ori gi nal steeri ng wheel wi th any other
desi gn because i t wi l l make i t i mpossi bl e t o pr oper l y
i nstal l the ai rbag
(onl y
use genui ne Honda repl acement
parts).
After reassembl y, confi rm the wheel s are sti l l turned
strai ght ahead and that the steeri ng wheel spoke angl e
i s correct. l f mi nor spoke angl e adj ustment i s necessary,
do so onl y by adj usti ng the ti e-rods, not by removi ng
and reposi ti oni ng the steeri ng whee..
Troubleshooting
Y
Self-diagnostic
Procedures
The sel f-di agnosti c
functi on of the sRs system al l ows i t to l ocate the causes ot system
probl ems and to store thi s i ntorma-
ti on i n mem-ory. For easi er troubl eshooti ng,
thi s data can be retri eved vi a a data l i nk ci rcui t'
. wheny out ur nt hei gni t | ons w| t c hoN( | | } , t hes Rs i ndi c at or wi | | c omeon. | f i t goes of f at t er s i x s ec onds , t hes y s t emi s
normar.
. l f there i s an abnormal i ty, the system l ocates and defi nes the
probl em, stores thi s i nformati on i n memory. and turns
t hes Rs i ndi c at or | i ght on. Thedat awi | | r emai ni nt hememor y ev enwhent hei gni t i ons wi t c hi s t ur nedof ' or i f t hebat .
tery i s di sconnected.
. when
you connect the scs servi ce connector to the sewi ce check connector
(2P),
and turn the i gni ti on swi tch oN
(l l )'
the SR3 i ndi cator l i ght wi l l i ndi cate the di agnosti c troubl e code
(DTC) by the number ol bl i nks'
. After readi ng and recordi ng the DTC,
proceed wi th the troubl eshooti ng
for thi s code'
Precautions
. Use on| y a di gi ta| mu| t| meter to check the system. | f i t,s not a Honda mul ti meter, make sure i ts output i s 10 mA
(0.01
A)
or l ess when swi tched to the smal l est val ue i n the ohmmeter range. A tester wi th a hi gher output coul d damage the
ai rbag ci rcui t or cause acci dental ai rbag depl oyment and
possi bl e i ni ury'
r Whenever the i gni ti on swi tch i s oN
(l l ),
or has been turned oFF for l ess than three mi nutes, be caretul not to bump the
SRS uni t; the ai rbags coul d acci dental l y depl oy and cause damage or i nj uri es'
. Before vou remove the sRS mai n harness, di sconnect the dri ver' s ai rbag connector
(and
the front
passenger' s ai rbag
connector).
. Make sure the battery i s suffi ci entl y charged
(see
secti on 23). l f the battery i s dead or l ow, measuri ng val ues won' t be
correct.
. Do not touch a tester
probe to the termi nal s i n the sRS uni t or harness connectors, and do not connect the termi nal s
wi th a
j umper wi re. Use onl y the backprobe set and the SCS servi ce
connector'
For backprobi ng spri ng-l osded l ock type connectors, refer to
page 24-9'
v
Readi ng the DTC
When the SRS i ndi cator l i ght i s on, read the DTC usi ng one of these methods:
A. Connect the Honda PGM Tester to the 16P Data Li nk Connector
(DLC),
and fol l ow the tester' s
prompts' l f the tester
i ndi c at es noDTc , doub| e- c hec k by j umpi ngt hes er v i c ec hec k c onnec t or andwat c hi ngt hes Rs i ndi c at or I i ght ( s ee
next page).
I
HONDA PGM TESTER
DATA LINK CONNECTOR {16P)
v
2+1'
Troubleshooting
B. The SRS i ndi cator l i ght can al so i ndi cate the DTC by the number of bl i nks when the SCS servi ce connector i s connect-
ed to the servi ce check connector {2P}.
Turn the i gni ti on swi tch OFF, and wai t for ten seconds. Then connect the SCS servi ce connector to the servi ce check
connector
(2P).
l f you
do not wai t ten seconds, the SRS uni t wi l l not be compl etel y reset and wi l l not output DTCS.
SERVICE CHECK
CONNECTOR
(2PI
IGRY, GRYI or [GRN, GRNI
SCS SERVICE CONNECTOR
07PAZ
- (x)101(xt
(l l ).
The SRS i ndi cator l i ght comes on for about si x seconds and goes off. Then i t wi l l i ndi -
cate the DTC:
-
The DTC consi sts of a mai n code and a sub-code.
-
Incl udi ng the most recent probl em,
up to three di fferent mal functi ons can be i ndi cated.
-
In case of a conti nuous fai l ure. the DTC wi l l be i ndi cated repeatedl y
(see
exampl e 1 bel ow).
-
l n case of an i ntermi ttent fai l ure, the SRS i ndi cator l i ght wi l l i ndi cate the DTC one ti me, then i t wi l l stay on
(see
exarn-
pl e
2 bel ow).
-
l f both a conti nuous and an i ntermi ttent fai l ure occur, both DTCs wi l l be i ndi cated as conti nuous fai l ures.
*
In case the system is normal
{no DTC}, the SRS indicator light will stay on
(see
example 3}.
Read the DTC.
Turn the i gni ti on swi tch OFF, and wai t for ten seconds. Then di sconnect the SCS servi ce connector from the servi ce
check connector {2P).
1 .
Ex8molos of DTC Indications:
1. Conti nuous fai l ure, SRS Indi cator Li ght i s:
[.- , s
--]
-
l1'"*0"
DTC 2.1
Mosr rocnt p.obt.m
Intermi ttent fai l ure, SRS Indi cator Li ght i s:
f - . f -
- l F -
t
M.in.ods
ll) Sub,code l2l
oTc r.2
-4
t-
--t
F
Main cod. (l)
Sub.cod. (1)
!._.--!-
DTC r . 1
Thnd moll r66.t
l-ight 3rry3 on in e$ ot
3. Normal
(no
fai l ure), SRS Indi cator Li ght i s:
oTc 5.1
-
\
\"
Y
MES
connactoi
to.minal!
Erasing the DTC MemorY
To erase the DTC(s) from the SRS uni t, use a Honda
PGM Test er { see
t he Honda PGM Test er SRS vehi cl e
System Suppl ement)
or the fol l owi ng
procedure'
1. Make sure the i gni ti on swi tch i s OFF
2. Connect the SCS servi ce connector to the MES con-
nector
(2P).
Do not use a
i umper
wi re
I L
&
MEMORY EMSE
SIGNAL {MESI
CONNECTOR {2PI
IGRY,
GRYI or [GRN,
GRNI
(l l ).
The SRS i ndi cator l i ght comes on for about si x sec-
onds and
goes off. Remove the SCS service connec-
tor from the tat "onn"61or {2P)
wi thi n four seconds
after the SRS indicator light went off.
Troubleshootin
g Intermittent
Fai l ures
l f there was a mal functi on, but i t doesn' t
recur, i t wi l l be
stored i n the memory as an i ntermi ttent
fai l ure. and the
SRS i ndi cator l i ght comes on.
After checking the DTC, troubleshoot
as tollows:
1. Read the DTC
(see
"Readi ng
the DTc")
2. Er ase t he DTC memor y
( see
" Er asi ng
t he DTC
Memory").
3. Wi th the shi ft l ever i n neutral , turn the i gni ti on swi tch
ON
(l l ),
and l et the engi ne i dl e.
4. The SRS i ndi cator l i ght comes on for about si x sec-
onds and
goes off.
I
6.oc
l<-
ON
t t
--
-J
Shake the wire harness and the connector, take a test
dri ve
(qui ck accel erati on,
qui ck braki ng, corneri ng),
and turn the steeri ng wheel ful l y l eft and ri ght, and
hold it there for five to ten seconds to find the cause
of the intermittent failure
l f t he
pr obl em r ecur s, t he SRS i ndi cat or l i ght wi l l
stay on.
--l
**
F
::ff
Problem recurs, light staYs on'
l f you can' t dupl i cate the i ntermi ttent
fai l ure. the sYs-
tem i s OK at thi s ti me.
ics senvtce coruruscron
07PAZ
-
0010100
3.
5. The SRS i ndi cator l i ght comes on agai n Reconnect
the SCS servi ce connector to the MES connector
{2P) wi thi n the four seconds after the SRS i ndi cator
7.
l i ght comes on.
The SRS i ndi cator l i ght
goes off. Remove the SCS
ser vi ce connect or
f r om t he MES connect o'
( 2P)
wi thi n four seconds
The SRS i ndi cator l i ght i ndi cates that the memory l s
erased bY bl i nki ng two ti mes.
8. Turn the i gni ti on swi tch oFF, and wai t for ten sec-
onds.
Bl i nki og
SRS indic.tor
figlrr
L
.--
l t | I l
CONNECTED
4 sec or less
v
DISCONNECTED
24-15
Troubleshooting
SRS Unit ldentification
*:
On
' 98
model s, the troubl eshooti ng procedures
are di fferent for each type of SBS uni t. l denti fy the SRS uni t i n the vehi -
cl e usi ng the chart bel ow, then fol l ow the proper fl owchart i n the fol l owi ng pages.
'98
Model SRS units
'96
-
97 Models SRS units
MAKER PARTS NUMBER
IDENTIFICATION
MARK*
Remark
NEC
77960- S04- A91
[/41 Dri ver' s si de SRS ai rbag onl y
77960, S04
-
N91
M1
Dri ver' s & Passenger' s si de
SRS ai rbag
KEIHIN 77960- S04- N91
M2
SRS ai rbag
SI EMENS 77960- S02- A82
M3
SRS ai rbag
MAKER PARTS NUMBER
Remark
NEC
77960- S04- C81
Dri ver' s si de SRS ai rbag onl y
77960- S04- N8l
SRS ai rbag
TAKATA
77960- S04- N82
SRS ai rbag
SI EMENS 77960- S02- A81
SRS ai rbag,
' 97
Model onty
24-16
Di agnosti c
Troubl e Code
(DTC)
Chart
-' 96 -
97 Model s
v
v
Faul ty SRS i ndi cator l i ght ci rcui t
Troubl eshooti ng
Faul t y SRS i ndi cat or l i ght ci rcui t , i nt ernal
f ai l ure of SRS uni t . I aul t y SRS
power suppl y
1-1 ODen i n the dri ver' s ai rbag i nfl ator
l ncreased
resi stance i n the dri ver' s ai rbag
i nfl ator
Short to another wi re i n the dri ver' s al rbag
i nfl ator or decreased
resi stance
Short to Dower
i n the dri ver' s ai rbag i nfl ator
Short to
ground i n the dri ver' s ai rbag i nfl ator
Wi th front
passenger' s ai rbag:
Open i n the
passenger' s ai rbag i nfl ator
Wi thout front
Passenger' s
ai rbag:
Open i n the dummy resl stor
Wi th front
l ncreased resi stance i n the passenger' s ai rbag
i nfl ator
Wi thout front
Passenger' s
ai rbag:
l ncreased resi stance i n the dummy resl stor
Wi th front passenger' s ai rbag:
Short to another wi re i n the
passenger' s
ai rbag i nfl ator or decreased
resi stance
Wi thout front Passenger' s
ai rbag:
Short to another wi re i n the dummy
resl stor
or decreased
resi stance
Wi th front
Short to power i n the
i nfl ator
Wi thout front
Passenger' s
ai rbag:
Short to power i n the dummy resi stor
Wi th front
Passenger' s
ai rbag:
Short to
ground i n the
i nfl ator
Wi thout front
Passenger' s
ai rbag:
Shon to
ground i n the dummy resi stor
(cont' d)
24-17
v
Troubleshooting
SRS i ndi cator l i ght DTC Possible cause Corrective action See page
comes on
5-1*'
I nt ernal f ai l ure of t he SRS uni t
SRS uni t
repracement
24 16
5 4
6-1
l nternal fai l ure of the SRS uni t
SRS uni t
reptacemenl
24-16
6-2
6-4
Internal fai l ure of the SRS uni t
SRS uni t
repl acement
24-7 6
7-2
8- 1
SRS uni t
repl acement
24-7 6
8-2
8-3
8-4
8-5
8-6
Internal fai l ure of the SRS uni t or two fai l u.es at a
ti me
Troubl eshooti ng 24-62
8-6*3 Internal fai l ure ofthe SRS uni t
SRS uni t
repl acement
24-7 6
SRS uni t
repracement
24-16
Faul ty SRS power suppl y
(VB
l i ne) Troubl eshooti ng 24-64
10- 1
SRS uni t repl acement code
(SRS
uni t must not
be used any l onger)
SRS uni t
repl acement
24 76
(DTCI
Chart
-' 96 -' 97
Model s
(cont' dl
NOTE:
*11
In case of an i ntermi ttent fai l ure DTC 9-1, i t means there was an i nternal fai l ure of the SRS uni t or a
tor l i ght ci rcui t. Do the troubl eshooti ng for i ntermi ttent fai l ures
(see page
24-15).
*2:
l t both DTC 9-2 and DTC 5-1 are i ndi cated, do the troubl eshooti ng for DTC 9-2.
*3:
Appl y to the
' 97
model coupe HX and DX.
*4:
DTC cannot be read wi th a Honda PGM Tester; check by
j umpi ng
the SCS servi ce connector.
\
faul ty SRS i ndi ca-
,-
v
v
Diagnostic
Trouble
Code
(DTC)
Ghart
-'98
Model
NEC SRS Unh
none*. I
Faul ty SRS i ndi cator l i ght ci rcui t, i nternal
(doesn' t
I
fal l ureol sRs
uni t.Jaul tvSRS
powersuppl y
Troubl eshooti ng
No DTC' r
{l i 9ht
comes on Faul t y SRS
power suppl y
(VA
l i ne)
Troubl eshooti ng
Open i n the dri ver' s ai rbag i nfl ator
l ncreased resi stance i n the dri ver' s ai rbag
i nfl ator
Short to another wi re i n the dri ver' s ai rbag
i nfl ator or decreased
tesi stance
Short to power i n the dri ver' s ai rbag i nfl ator
Short to
Troubl eshooti ng
Wi th front
Open i n the
Wi thout front
Passenger' s
ai rbag:
Open i n the dummy resi stor
Wi th front passenger' s ai rbag:
l ncreased resi stance i n the
passonger' s ai rbag
i nfl ator
Wi thout front Passenger' s
ai rbag:
l ncreased resi stanc i n the dummy resi stor
24-52
24-59
Wi th front
Shon to another wi re i n the
passenger s
ai rbag i nfl ator or decreased
resi stance
Wi thout front
Short to another wi re i n the dummy resl sl or
or decreased resi stance
I
Wi th front
Passenger' s
ai rbag:
I
St o.t to power i n the
2-4 i nfl ator
Wi thout front
Short to power i n the dummy resi stor
Wi th front
Passenger' s
ai rbag:
Shon to ground i n the passenger' s ai rbag
2-5
Inialor
tvnhout front
Passenger' s
ai rbag:
Short to ground i n the dummy resi stor
(cont' d)
24-19
v
Troubleshooting
(DTC)
Chart
-,9g
Model
(cont,dl
NOTE:
r1:
In case of an i ntermi ttent fai l ure DTC 9-1, i t means there was an i nternal tai l ure of the SRS uni t or a faul ty SRS i ndi ca-
tor l i ght ci rcui t. Do the troubl eshooti ng for i ntermi ttent fai l ures (page
24-15).
+2:
In case of an i ni ermi ttent fai l u.e DTc 9-2, i t means there was an i nternal fai l ure of the power suppl y
(vB
l i ne). Do the
troubl eshooti ng for i ntermi ttent fai l ures.
*3:
DTC cannot be read wi th a Honda PGM Tester; check by
j umpi ng
the SCS servi ce connector,
SRS indicator light DTC
Possible cause
Corrective action Ses pago
comes on
5-1
SRS uni t
repracement
24-16
5-4
6-1
SRS uni t
repl acement
24-7 6
o-J
6-4
5l | 5 Unr t
repl acement
24-76
7-2
8-1
SRS uni t
repracement
24-76
a-2
8-6
Internal fai l ure of the SRS uni t or two fai l ures
at a ti me
Troubl eshooti ng
24-62
SRS uni t
reptacement
24-16
9-2*'
*1
Internal fai l ure of the SRS uni r
SRS unit
reptacement
24-7 6
l 0- 1
SRS ai rbags depl oyed (SRS
uni t must be
repl aced)
SRS uni t
reptacement
24-76
\
ry
KEIHIN SRS Unit
Possible cause
Corrective sction Ses
page
doesn' t come on
none
(doesn' t
come on)
Troubl eshooti ng
24-26
comes on
none* 3
(doesn' t
go off)
Faul tv SRS i ndi cator l i ght ci rcui t, i nternal
fai l ure oJ SRS uni t, taul ty SRS
power suppl y
(VB
l i ne)
Troubl eshooti ng
24-34
1-1 Open i n the dri ver' s ai rbag i nfl ator
Troubl eshooti ng
24-42
l ncreased resi stance i n the dri ver' s ai rbag
i nfl ator
24-12
1-3
Short t o anot her wi re i n t he dri ver' s ai rbag
i nf l at or or decreased resi st ance
24-44
1- 4 Short to
power i n the dri ver' s ai rbag i nfl ator
24-46
1, 5 Short to
24-48
Open i n the
Troubl eshooti ng
24-50
l ncreased resi stance i n the
i nfl ator
24-50
2-3
Shon to another wi re i n the
passenger' s
ai rbag i nfl ator or decreased resi stance
24-52
Short to
power i n the
i nfl ator
24-54
2-5
Short to ground i n the passenger' s ai rbag
i nfl ator
24-56
(cont' d)
v
24-21
'...-'--.
Troubleshooting
Diagnostic Trouble Gode
(DTG)
Ghan
-'98
Model
{cont,d}
NOTE:
*l :
In case of an i ntermi ttent fai l ure DTC
g-1,
i t means there was an i nternal fai l ure of the SRS uni t or a faul ty SRS i ndi ca-
(page
24_15).
*2:
In case of an i ntermi ttent fai rure DTc 9-2, i t means there was an i nternar fai rure of the power
suppry
(vB
ri ne). Do the
*3;
DTC cannot be read wi th a Honda
pGM
Tester; check by
j umpi ng
24-22
-'-'.-
sRs indicaror tighr
I
DTc
Possiblo cause
Correstive action See page
comes on
5-1
l nternal fai l ure of the SRS uni t
SRS uni t
repl acement
24-76
5-3
5-4
SRS uni t
repl acement
24-76
6-2
6-3
6-4
SRS uni t
repl acement
24-76
1-3
8-' l
SRS uni t
repl acement
24-76
8-2
8-6
9- 1+1
* 3
-rI 5 unt r
repl acement
24-76
9-2*,
*3
10- 1
SRS uni t
repl acement
24-76
SRS ai rbags depl oyed
(SRS
uni t must be
reol aced)
SRS uni t
repl acement
24-76
.J
)
SIEMENS SRS Uni t
Possible cause
Corrective action SeL
page
doesn t come on
none
(doesn' t
come on)
Troubl eshooti ng
Troubl eshooti ng
24-26
24-34
comes on
Short to ground i n the passenger' s al rbag
i nfl ator
none*,
I
Faul ty SRS i ndi cator l i ght ci rcui t, i nternal
(doesn' t fai l ure of SRS uni t, faul ty SRS
power suppl y
go off)
(VB
l i ne)
Short to another wi re i n the
passenger' s
z r
ai rbag i nfl ator or decreased resi stance
Short to
power i n the
t - 4
r nl t ar or
1 , 1 Open i n the dri ver' s ai rbag i nfl ator
Short to another wi re i n the dri ver' s ai rbag
i nfl ator or decreased resi stance
1-4 Short to oower
i n the dri ver' s ai rbag i nfl ator
1' 5 Short to
2-1 Open i n the
2-5
Troubl eshooti ng
24 42
24-44
24 46
24-44
Troubl eshooti ng
24-50
24-52
24-54
24-56
(cont' d)
24-23
l/
Troubleshooting
{DTC) Chart
-' 98
Model
(cont' dl
NOTE:
"1:
l n case of an i ntermi ttent fai l ure DTC 9-1, i t means there was an i nternal fai l ure of the SRS uni t or a faul ty SFS i ndi ca-
{page 24-15).
*2:
In case of an i ntermi ttent fai rure DTc
g-2,
i t means there was an i nternar fai rure of the power
suppry
(vB
ri ne). Do the
*3:
DTC cannot be read wi th a Honda
pGN4
Tester; check by
j umpi ng
SRS i ndi cator l i ght DTC
Possible cause
Correstive aqtion See pago
comes on
5- l
SRS uni t
repl acement
24-76
5-4
Internal fai l ure of the SRS uni r
SRS uni t
repl acement
24-76
6-4
SRS uni t
repl acement
24-76
7_?
8- 1
I nt ernal f ai l ure of t he SRS uni t
SRS uni t
reptacement
24-7 6
a-2
g_l * r * 3
SRS uni t
reptacement
24-76
9-2*2
*3
l nt er nal f ai l ur e of t he SRS uni t
SRS uni r
repl acement
24-7 6
10- 1
SRS ai rbags depl oyed (SRS
uni t must be
repl aced)
SRS uni t
repl acement
24-76
24-24
-
SRS Indi cator Li ght Wi re Connecti ons
SRS Indicator Light Power Circuit
OASHBOARO WI RE HARNESS
To UNOER- DASH
FUSE/RELAY BOX
<_
2OP CONNECTOR
SRS Indicator Light Control Cilcuit
To SRS UNIT
t
I
SRS MAIN HARNESS
GRY
I GRN)
C411, C412 : Torminal side of mslo trminsls
csor. csoz, csog. c801, c802, c8o7 : wi re si do ot f . mal e t o' mi nal s
MAIN WIRE HARNESS
8LU
C508
-+
To GAUGE ASSEMBLY
c411
To GAUGE ASSEMBLY
a.j
GRY
I
| GRN)
|
I
_ _ - l l
+f;I?
csol
t--qt
I
To UNDER-DASH
FUSE/RELAY BOX
2P CONNECTOR
CsO1 : DASHAOARD WI RE HARNESS 2OP CONNECTOR
CSO8 : DASHBOABD WIRE HARNESS 5P CONNECTOR
C8O'l : SRS MAIN HARNESS 2P CONNECTOR
C8O7 : SRS MAI N HARNESS
' l 8P
CONNECTOR
C8O2 : SRS MAIN HARNESS 3P CONNECTOR
C412 : MAI N WI RE HARNESS 3P CONNECTOR
c411 : MAI N WI RE HARNESS 24P CONNECTOR
C5O2 : DASHBOARD wlRE HARNESS 2rtP CONNECTOR
v
24-25
Troubleshooting
The SRS Indicator Light Doesn't Gome On
CAUTION: Whenever the i gni ti on swi tch i s ON
(l l l .
or
has been turned OFF tor l ess than three mi nutes, be
caretul not to bump the SRS uni t; the ai rbag(s) coul d
acci dental l y depl oy and cause damage or i ni uri es,
Check the
power
supply llu3e):
(l l ),
and check whet her t he ot her
i ndi cat or l i ght s come on or not {brake syst em, et c. ).
Do the other indicator lights como on?
YES NO
Check ihe fuse:
Check t he No. 25
(7. 5
Al f use i n t he undeFdash f use/ rel av
box.
ls th6 fuse OK?
NO YES
Check tho bulb:
Repl ace t he No. 25
(7. 5
A) I use, and check t hat t he
SRS i ndi cat or l i ght comes on.
Does the SRS indicalor liqht come on?
I
YES No
END
Check the wir harness between fuse and gauge assemblyl
Check f or an open i n t he wi re harness bet ween f use
No. 25 {7. 5 A) and t he gauge assembl y, and repai r. Check
t hat t he sRs i ndi cat or l aght comes on.
Doe3 the SRS indicator liqhl come on?
I
yEs
No
I
END
Check t h SRS i ndi cat o. l i ght but b:
2, Remove t he gauge
assembl y,
3. Check f or bl own SRS i ndi cat or l i oht but b.
ls the SRS indicator light butb OK?
YES
NO
Check the SRS indicator light circuit:
Repl ace t he bul b, and r econnect t he gauge
assembl y
connect ors. Then t urn t he i gni l i on swi t ch ON
(t l ).
Does the SRS indicator light come on?
YES
No
:ND
l Al ro page
24-27
l Bl 10
page
24-27
, 24-26
I
$
) )
No. 25
(7.s
Al FUSE
T
I
J
v
From page 24-26
(A)
From page 24-26
( B) DASHBOARD
WIBE HARNESS
MAIN WIRE HANNESS
Chock the SRS indicator light circuit:
1. Di sconnect t he dashboard wi re harness 5P connoct or
f rom t he
gauge assembl y
2. Connect a vol t met er bet ween t he No l t ermi nal
(+)
of
t he 5P connect or and
ground
(l l ).
and measure
l s t here 8. 5 V or l gsi t or si x soconds af t or t he i gni t i on
switch has beon tumed ON
F ulty SRS indicitor light circuit in th6 gauge a$embly;
rpl ace t he SRS pl i nt ed ci rcui t board i n t he
93uge
Chsck th. wir6 harness ot the SRS indicator light circuit ll l:
2, Di sconnect t he mai n wi re harness 24P connect or f rom
t he dashboard wi re harness
3. Connect a vol t met er bet ween t he No 5 t ermi nal {+) of
t he mai n wi re harness 24P connect or and
ground
4. Turn t he i gni t i on ON {l l ), and measure vol t age
l s t here 8. 5 V or l ess f or si x seconds af t er t he i gni t i on
switch has been tumed oN llll?
Short to Dowor in the BLU wire ot the dashboard wire
To page 24-28
DASHBOARD WIRE
HARNESS 2iIP
CONNECTOR
c41 1
(cont' d)
24-27
Troubl eshooti ng
Frcm page 24-27
Check th wire harness otthe SRS indicator light circuit
(2):
2. Di sconnect t he SRS mai n harness 3P connoct or f rorn t he
mai n wi re harness,
3. Connect a vol t met er bet ween t he No. 1 t ermi nal
(+)
of
t he SRS mai n harness 3P connect or and ground.
(l l ),
and measure vol t age.
l s t here 8. 5 V or l ess t or si x seconds . t t er t he i gni t i on
switch has ben turnod ON llll?
Shori lo powq
in the BLU wire of lhe main wirs hrnolis:
Check the wire harnoss ofthe SRS indicator circuit 13)i
' L
2. Disconnect the battery nagative cable, then the positive
cabl e. and wai t t hree mi nut es.
3. Disconnect the drivor's
(and
front passenger'sl
airbag con-
nect o(s) (s6e page
2+11).
4. Di sconnect t he SRS mai n harness 18p connect or f rom
t he SRS uni t .
5. Connect a vol t mel er bet ween t he No. 6 t ermi nal
(+)
ol
t he SRS mai n harness 18P connect or and ground.
(ll),
and measu.e voltage. There
should be 0.5 V or less.
SRS unit; roplaco tho unit
(see paq6
2+
Short to power
in the BLU wire of the SRS main harne$:
The SRS Indicator Light Doesn't Come On
(cont'dl
SRS MAIN HARNESS
16P CONNECTOR
\
SRS MAIN HARNESS
3P CONNECTOR
c802
SRS MAI N HARNESS 18P CONNECTOR
SRS UN]T
24-28
J
The SRS Indi cator
Li ght Doesn' t Go Off
-' 96 -' 97
Model s
CAUT| oN: whengve' t hei gni t i onswi t chi soN( l | } , ol hasbeent ur nedoFFf or | osst hant hr eemi nut es, becar ol u| not t o
bump the SRS unit; the airbag(sl could accidentally deploy and cause damage or iniuries'
No. 13
(15 Al FUS
v'
SBS UNIT
SRS MAIN HARNESS
Try to reproduco tho SRS indicator light:
1. Erase the DTC memory
(see page 24'15)
2. Turn the ignition switch OFF, and wait for ten seconds'
3. Turn th ianition switch ON lll), and check that the SRS indi-
cator lighicomes on for about slx seconds and
goes otf
Does the SRS indicator light stay on?
l nt el mi t t ent l ai l ur6, sYst em i s OK at l hi s t i me See
Intormittent Failuros on
Page
2{_15.
ch6ck th6 No. 13 115 Al .nd No. 23
(10 Al tuses:
2. Checkf or t l own No. 13
( 15 A) and No. 23
( 10
A) f uses i n
t he under-dash f usekel aY box.
Replaca the fuses, and erase the memory
L Replace the luses.
2. Connect t he SCS servi ce connect or t o t he MES con-
nector,
3. Erase t he DTC memory
(see page 24-15)
4. Turn t he i gni t i on swi t ch OFF, t hen di sconnect t he SCS
seryice connector from the MES connector'
5. Turn t he i gni t i on swi t ch ON l l l )
Does th. SRS indicator light
go ofl aftol six soconds?
Confirm tho OTC, snd continuo
7. Turn t he i gni t i on swi t ch on
Check lo. an open in the SRS main harnoss {vA lino}:
2. Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he
posi t i ve cabl e, and wai t f or t hree mi nut es
3. Di sconnect t he dri ver' s
(and I ront
passenger' s) ai rbag
connect or(s)
(see
Page
24_11).
4. Di sconnect t he SRS mai n harness 18P connect or
f rom
t he sRs uni t .
5. Reconnect the battery
positive cable, then reconnect the
negat i ve cabl e.
6. Co-nnect a vol t met er bet ween t he No 7 t ermi nal
(+)
of
t he SRS mai n harnoss 18P connect or and
groLl no
ODon in th6 SRS main harne3s lvA
linol; roplace the SRS
YES
To page 24-30
(cont' d)
v
24-29
,_
Troubleshooting
The SRS Indicator Light Doesn't Go Off
-'96 -
97 Models
(cont'd)
From page 24-29
(A)
SRS MAIN HABNESS
18P CONNECTOR
\
SRS UNIT
Check the SRS unit:
Connect t he SRS mai n harness
' l 8P
connect or t ermi nal s No.
6 and No. 7 wi t h a i umoer wi re and
Faulty SRS unit or
pool
contact at tho SRS main harness
18P connector; chock the connoctor.
lfth connector is OK, replace the SRS unit.
07TAZ
-
@1020A
JUMPER WI RE
Wire side ot fsmale terminals
t
From
page 24-30
{ B)
OASHBOARD WIRE HARNESS
y;T7f;V4csoe
Llr.-L_v)fr
I
BLU
IYEL
wi re. si de of f emal e
JUMPER WI RE
t erml nal s
Wi r e si de of f emal e
I er mt nat s
SRS MAIN HARNESS
, I 8P
CONNECTOR
DASHBOARD WIRE HARNESS
5P CONNECTOR
Chock the SRS indicator circuit:
2. Remove t he
gauge assembl Y
NOTE: Do not di sconnect t he dashboard wi re harness 5P
connector from the
gauge assembly
(l l ).
4. Connect t he dashboard wi re harness 5P connect or t ermi -
nal s No. 1 and No 5 wi t h a
j umper wi re.
Do.s the SRS indicator light go otff
Fsulty SRS indic.tor light circuit in the
g.uge ts3embly;
repl ace t he SRS
pri nt ed ci rcui l board i n t he
gauge
Check to. a short to
ground in rhe SRS indicator light cir-
cuit:
2. Di sconnect t he dashboard wi re harness 5P connect or
f rom t he
gauge assembl y
3. Check resistance between the No. 1 terminal ot the dash-
board wire harness 5P connector and
ground. There should
be 1 Mo or more.
Check for an oDen in th6 SRS indicttor light circuit:
1. Check resi st ance bet ween t he No 6 t ermi nal of t he SRS
mai n harness 18P connect or and No 1 t ermi nal of t he
dashboard wi re harness 5P connect or; t here shoul d be
0 - 1 . 0 0 .
7o page 24-32
(D)
To page 24-33
( E)
To page 24-33
{cont' d}
a.t
24-31
Troubleshooting
The SRS Indicator
Light Doesn,t Go Off
-
,96
-
97 Models
(cont'd)
From page
24 3l
{c)
Check for a shon to ground
in the main wir6 harness:
1. Di sconnect t he dashboard wi re harness 24p connect or
f rom t he mai n wi re harness,
2. Check resi st ance bet ween t he No. 5 t ermi nal of t he mai n
wrre harness 24P connect or and ground.
There shoul d be
1 N40 or more.
Short to ground
in the dashboard wire harness; reoai.
the dashboerd wire harn6ss.
Short t o ground
i n t he mai n wi re ha. ness; r6pei r t he
main wire harnoss,
Short to ground
in the SnS main harness; replace the SRS
main harness.
MAIN WIRE HARNESS
HARNESS
MAIN WIRE HARNESS
3P CONNECTOR
Check tor a short to ground
in the SRS main harness:
' 1.
Di sconnect t he SRS mai n harness 3p connect or f rom t he
maan wi re harness,
2. Check resi st ance bet ween t he No. i t ermi nal of t he SRS
mai n harness 3P Connect or and ground,
There shoul d be
1 MO or more.
SRS MAIN HARNESS
3P CONNECTOR
t er mi nal s
Check the SRS indic.to. circuit input voltag:
1. Reconnect t he SRS mai n harness 18P connect or t o t he
SRS uni t .
2. Connect a vol t met er bet ween t he No 1 l ermi nal l +)
o{f
t he dashboard 5P connect or and
ground'
3. rurn the isnition switch ol!!!!jl!lg!:ylly9!j399-
ls thorc 8.5 V or more lix seconds after the ignhion swhch
has ben lurned ON
(fll7
-
NO
YES
The
problom ha3 dirappcared due to ditconnecting
and
conncqting the connactor3. Bo sure all tgrminal3 makc
oood c ont ac t , and r ac hec k t he s y s t em { s c o
iroubleshooting Intermittent
Failuros on
pago 24'151
Poor contect at tha SRS m.in harncss 18P connoctor; chock
thc connectot.
.
It tho conn6ctor i3 OK, substitulc a known-good SRS unit'
and rochock.
.
lf th.
probl6m is 3till
p.esnt, tepltco the SRS m'in har'
ncss.
\,1
From
page 24-31
(D)
5P CONNECTOR
From page 24-31
( E)
SRS MAIN HARNESS
18P CONNECTOR
c807
c41 1
MAI N WI RE HARNESS Termi nal si de of mal e t ermi nal s
24P CONNECTOR
SRS MAIN HARNESS
18P CONNECTOB
SRS MAIN HARNESS
3P CONNECTOR
)
Check for an opsn in tha drshbo.rd
wi.o harnos:
1. Oi sconnect t he dashboard
wi re harness 24P connect or
l rom t he mai n wi re harness
2. Check resistance between the No O terminal of the SRS
mai n harness 18P connect or and No 5 t ermi nal of t he
mai n wi r e har ness 24P connect or ; t her e shoul d be
Opon in tho BLU wir. ot the dGhboard
wire harngis;
thc daahborrd wit6 ha]n.it.
Chock tor an opon in tho main wire harness:
1. Di sconnect t he SRS mai n harness 3P connect or f rom t he
mai n wi re harness.
2. Check resistance between the No. 6 terminal oI the SRS
mai n harness 18P connect or and No l t ermi nal of t he
SRS main harn6ss 3P connector; there should be 0
-
1 0 O
Oocn in th BLU wi.o of tho mein wire hamess; repalr
thc msin wire haness.
Oo6n in tho SRS main ham6r; ropl.ce the SRS main har'
24-33
Troubl eshooti ng
-
,9g
Model
fl l ), or
has been turned OFF for l ess than three mi nutes, be
careful not to bump the SRS uni t; the ai rbags coul d
accidentally deploy and cause damage or iniuries.
SRS MAI N HARNESS
18P CONNECTOF
No. 23 {10 A} FUSE
FUSE/ RELAY BOX
Try to reproduce the SRS indicator light:
1. Erase t he DTC memory (see page 24-15).
(l l ),
and check t hat t he SRS
i ndi cat or l i ght comes on f or about si x seconos ano ooes
off.
Does the SRS indicator lioht stav on?
Inte.mitlent failure, systom b OK at thi3 tim6. See Trouble-
Intrmittent Failur3 on page
2+lS.
check t he No. 23 {10 Al f use:
2. Check t or bl own No. 23
(10
A) t use i n t he under-dash
Replace the fuse, and erass the memory
1. Repl ace t he No. 23
( 10
A) t use.
(see page 24, 1S).
(l l ).
Does th6 SRS indicstor light qo off after six seconds?
Check lor an oDen in the SRS main h.rn6ss [vB line):
1. Di sconnect t he bat t erv negat i ve cabl e, t hen di sconnect
t he posi t i ve cabl e, and wai t f or t hree mi nut es.
(and
f ront passenger' s) ai rbag
connect orl s)
(see page 24' 11).
3. Di sconnect t he SRS mai n harness 18P connect or l rom
t he sRS uni r.
4. Reconnect the batterv
positive
cable, then reconnect the
negat i ve cabl e.
5. Connect a vol t met er bet ween t he No. 3 t ermi nal
(+)
of
t he SRS mai n harness
' 18P
connect or and oround.
6. Turn t he i sni t i on swi t ch ON
(i l ).
Open i n r he SRS mai n har n63s
( VB
l i ne) ; r epl ace t he
To page 24-35
24-34
T
From
page 24_34
(A)
SBS MAIN HARNESS 18P CONNECTOR
c50a
l of f emal e
DASHBOARD
WIRE HARNESS
5P CONNECTOR
DASHBOARD
WIRE HARNESS
5P CONNECTOR
(cont' d)
sBsUNI T
Check the SRS unit:
Connect t he SRS mai n harness 18P connect or t ermi nal s No
6 and No. 3 wi t h a
j umper wi re and backprobe adapt
Does the SRS indicato.light
go oll?
YES
NO
Faultv SRS unit or
poor contact al the SRS main harnass
18P connector; check the connector.
lf the connector is OK, replaco the SRS unit
Did fuse No. 23
(10 A) blow?
YES
NO
( I
f o
page24 ?
l )
6
Check for a short to ground in the SRS indicator light cir'
cuit:
f rom t he gauge assembl y
3. Check resi st ance bet ween t he No 1t ermi nal of t hedash
boar d wi r e har ness 5P connect or and gr ound Ther e
shoul d be 1 MO or more.
ls the resistance as specitied?
-
YES
NO
(c)
Io page 24'37
Short to
ground in the gtuge assembly; replace the gauge
JUMPER WI RE
Wire side ot lemale termanals
24-35
Troubl eshooti ng
-'98
Model
(cont'dl
From page 24 35 OASHEOARO W|RE HARNESS
(B)
5P CONNECTOR
Check the SRS indicator circuit:
2. Remove t he gauge
assembl y. Do not di sconnect t he
dashboard wi re harness 5P connect or f rom t he gauge
(l l ).
4. Connect t he dashboard wi re harness 5P connect or t ermi -
nal s No. 1 and No. 5 wi t h a i umDer wi re.
Do6s th6 SRS indicator liqht go
oftT
YES
NO
Faultv SRS indicator light circuit in the gauge assembly;
ropl aca t he SRS pri nt ed
ci rcui t board i n t he gauge
assombly.
Check for an open in the SRS indicator light circuit:
f rom t he gauge
assembl y.
3. Check resistance between the No. 6 termanal of the SRS
mai n harness 18P connect or and No. 1 t ermi nal of t he
dashboard wi re harness 5P connect ori t here shoul d be
0 - 1 . 0 0 .
ls the resistanco as 3pecified?
YES
NO
(D)
To page
24-38
( E)
To page
24-38
OASHBOARD WIRE HARNESS
5P CONNECTOR
l;rfr-zr-cuo"
\J#
I
Bru
IYEL
JUMPER Wt RE
t or manat s
SRS MAI[{ HARNESS
18P CONNECTOR
DASHBOARD WIRE HANNESS
5P CONNECTOR
, 24-36
Wi re si de ot t emal e t ermi nal s
[r.
\
Chock for a short to
ground in the main wiro harness:
f rom t he mai n wi re harness
2. Check resi st ance beNveen t he No 5t ermi nal of t hedash_
bosrd wi re harness 24P connect or and ground There
shoul d be 1 MO or more.
Short to
glound in the dashboard wire hamoss; repail
Check for a short to ground in lhe SBS main hamess:
mai n wi re harness
2. Check resi st ance bet ween t he No. I t ermi nal of t he SRS
mai n harness 3P connect or and
ground There shoul d be
1 MO or more,
Short t o
ground i n t ho mai n wi re herness; rspai r i he
Short to glound in the SRS main harness; repl.ce the SRS
From
page 24-35
(c)
OASHBOARD
WI RE HARNESS
24P CONNECTOR
DASHEOARD WIRE
HARNESS 24P CONNECTOR
BLU
l ermrnal s
MAIN WIRE HANNESS
3P CONNECTOR
SRS MAIN HARNESS
3P CONNECTOR
SRS MAIN HARNESS
3P CONNECTOR
c802
(cont' d)
24-37
--
Troubleshooting
The SRS Indi cator Li ght Doesn' t
Go Off
-' 98
Model
(cont,d)
From page 24-36
r D)
Check the SRS indicato. circuit input voltago:
' 1.
Reconnect t he SRS mai n harness 1gP connect or t o t he
SRS uni t .
2. Connect a vol t met er bet ween t he No. I t ermi nal {+) of
t he dashboard 5P connect or and ground.
(l l i ,
wai t f or si x seconds,
t hen measure
From page 24 36
5P CONNECTOR
DASHBOARD Wt RE HARNESS
5P CONNECTOR
c508
c802
SRS MAI N HARNESS
l AP CONNECTOB
c807
c411
SRS MAI N HARNESS
18P CONNECTOR
SRS MAI N HARNESS
3P CONNECTOR
\
ls there 8.5 V or moreT
The problem
has disappeared due to disconnecting and
connecting the connoctors. Be sure all terminals make
good cont act , and recheck t he sy3t em l s6e Troubl e-
Intermittent Failules on
paqe
24-
Poor contact ai the SRS main h.rness 18p connector; check
the connoctor.
.
lf ihe connector is OK, subslituto a known-good SRS unit,
and recheck.
.
It the problem is still presont,
repbce the SRS main har-
ness.
Check lor an open in th dashboa.d wire narness:
1, Di sconnect t he mai n wi r e har ness 24P connect or f r om
t he dashboar d wi r e har ness.
2. Check r esi st ance bet ween t he No. 6 t er mi nal of t he SRS
main harness 18P connector and No. 5 terminal ofthe main
wire harness 24P connector; there should be 0
-
1.0 0.
ls the resistance as sDecifiedT
YES
NO
Open in the BLU wire of the dashboard wire harness;
repair the dashboard wire ha.noss.
Check tor an open in the main wire harnsss:
1. Di sconnect t he SRS mai n harness 3p connect or f rom t he
mai n wi re harness,
2. Check resi st ance bet ween t he No_ 6 t erm; nal of t he SRS
mai n harness 18P connect or and No. 1 t ermi nal ot t he SRS
mai n harness 3P connect or; t here shoul d be 0
_
1. 0 O.
ls the resistance as soecified?
YES
NO
Open in the BLU wire of the main wire harness; reDair
the main wire harn6ss.
Open in the SRS main harnoss; replace the SRS main har-
243A
\
No DTC
-' 98
Model
(l l ),
or
acci dental l y depl oy and cause damage or i ni uri es'
(A)
To
page 24-40
Check for short to
ground between the undet-dash fuse/
relay box and the SRS unit.
t he posi t i ve cabl e, and wai t f or t hree mi nut es
3, Di sconnect t he dri ver' s
(and f ront passenger' s ai rbag)
connect o(s)
(see
Page
24' 11)
Di sconnect t he SRS mai n harness 18P connect or l rom
t he sRS uni t .
Check resi st ance bet ween t he No 7 t ermi nal of t he SRS
ground
There shoul d be 1 MO or more
ls the resistance as specified?
4.
5.
sRs
18P CONNECTOR
J
{ B)
To page 24-40
(cont' d)
Check the fu3e:
Check f or bl own No. 13
( 15
A) { use i n t he under - dash f use/
Repl ace t he f use. Tur n t he i gni t i on swi t ch ON { l l ) , and check
t hat t he l use doesn' t bl ow.
The problom has disappeared Test'drive th vehiclo and
se Troubleshooting Intermittent Failures on
Page
2+15'
Faufty SRS unit; replace the SRS unit {see
page21'761'
No. 13
(15 A) FUSE
24-39
Troubleshooting
No DTC
-'98
Model
(cont'd)
trom page
24-39
1B)
Chack tor short to ground in the SRS main harness:
under-dash luse/relay box.
2. Check resistance between the No. 7 terminal of the SRS
mai n harness 18P connect or and ground. There shoul d
be 1. 0 MO or more.
SRS MAIN HARNESS
2P CONNECTOR
SRS MAIN HARNESS
18P CONNECTOR
Short t o ground i n t ho unde. -dash f use/ r6l ay box;
Short to ground
in the SRS main harnoss; .eplace thc SRS
mein halno3s.
24-40
SRS MAIN HARNESS
18P CONNECTOR
FUSE/RELAY BOX
c807
caoT
Check lor an opgn in the SRS main hrlness:
2. Di sconnect t he bat t ory negat i ve cabl e, t hn di sconnect
t he
posi t i ve
cabl e, and wai t f or t hree mi nut es.
3. Di sconnect t h6 dri ver' s l and f ront passenger' s)
ai rbag
connecl or(s)
(see page
24-11).
4. Di sconnect t he SRS mai n harness 18P connect or f rom
5. Reconnect the battery positive
negat i ve cabl e.
6. Connect a voltmeter btween the No. 7 terminal oI the
SRS mai n harness 18P connect or and oround.
(l l ),
and measure
Poor conlact at ths SRS main harnoss 18P connoctor;
check the connoctoa,
.
lf the connector is OK, sub3tituta a known-good SRS
unit. and rschack.
'
lf the p.oblem is still
prosent,
raplaca lhe SRS main
harness.
(A)From page 24-39
To page
24 41
\
From page 24'40
Check for an oDen in the SRS main ha.ness:
2, Di sconnect t he SRS mai n harness 2P connect or f rom t he
undeFdash f use/ rel ay box.
3. Check resi st ance bet ween t he No. 1 t ermi nal of t he SRS
SRS mai n harness 18P connect or.
There shoul d be 0 0. 5 o.
Poor cont act at t he SRS mai n harness 2P connect or;
check the connector.
.
lf the connector is OK, substitute a known-good under'
dash fu3e/relay box, and recheck.
.
It lhe problem is still
present, replace the SnS main
harness.
Open in the SRS main harness; replace the SRS main har'
ness,
SRS MAI N HARNESS
18P CONNECTOR
FUSE/RELAY BOX
caoT
SRS MAI N HARNESS
2P CONNECTOR
24-41
Troubl eshooti ng
DTC 1-1 and DTC 1-2
(tt),
or
has besn tul ned OFF l or l ess than three mi nuts, be
carel ul not to bump the SRS uni ti the ai rbag(sl coul d
accidentally deploy and cause damage or iniuries.
DRIVER'S AIRBAG
2P CONNECTOR
SRS MAIN HARNESS
2P CONNECTOR
SRS SERVICE
CONNECTOR {2 O'
07TAZ
-
5250200
Try to reproduce the SRS indicator lighti
1. Erase t he DTC memory {see
page 24, 15i .
2. Turn t he i gni t i on swi t ch ON {l l ), and checkt hat t he SRS i ndi -
cator light comes on for about six seconds and goes
off.
Doe3 the SRS indicaror light stay on?
YES
NO
Intrmittem tailure, svstem is OK ai thb time. S6e Troublr
shooting Intermittent Failuros on page
2G15.
Chck tor an opon in the driver's airbag inflator
2. Disconnect the battery negative cable, then disconnect the
posi t i ve
3. Di sconnect t he dri ver' s ai rbag 2P connect or f rom t he cabl e
reel 2P connector,
CAUTION: Do not disconnect the psssenger's
airbag con-
nec{or,
4. Connect t he speci al t ool
(2
O) t o t he cabl e reel 2P connec
t or.
5. Beconnect the battery positive
negat i ve cabl e.
6. Erase t he DTC memory (see page
24-15).
7. Read the DTC
(see page 24 13i.
ls DTC 1-1 or DTC 1-2 indicatod?
NO
YES
Opon or increased aesidance in the driver's airbag infla-
tor;.eplace th driver's airbag essemblv (see pase 2+671.
Chock lor sn open in the cable reel:
l - Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he posi t i ve
2. Di sconnect t he speci al t ool
(2
0) I rom t he cabl e reel 2P
connect or.
3. Remove t he dashboard l ower cover, and di sconnect t he
cabl e reel 2P connect or f rom t he SBS mai n harness.
4. Connect t he speci al t ool (2
0) t o t he SRS mai n harness
2P connect or.
{cont , d}
f o page 24' 43
24-42
SRS SERVICE
CoNNECTOR
(2
0l
07TAZ
-
5250200
CABLE
REEL
2P CONNECTOR
DRIVER'S AIRBAG
ASSEMBLY
CABLE REEL
2P CONNECTOR
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
{2 0 JACK)
07sAz
-
TB401rA
SRS SIMULATOR
LEAD C
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
t2 0 JACK)
07sM
-
T84011A
1
Frcm page 24-42
Check for an opon in the cable loel
(cont'd)
5. Reconnect the batterv
negative cable.
6. Erase t he DTC memory l see
page 24-15).
7. Read t he DTC {see
page 24-13).
ls DTC 1-1 or DTC 1-2 indicated?
NO
YES
Ooen or increased rcsisttnce in the cable reel; replace
the cable reel
(see paq 24-721.
Check tor an oDen in ths SRS main hamo3s:
t he
posi t i ve cabl e, and wai t f or t hree mi nut es.
2. Disconnoct the front
passenger's airbag connector ftom
(wi t h
f ront
passenger' s ai rbag)
t he SRS uni t . Do not di sconnect t he speci al t ool
(2
O)
f rom t he SRS mal n harness 2P connect or'
4. Check resi st ance bet ween t ermi nal s No 1 and No 13 of
t he SRS mai n harness 18P connect or.
There shoul d be approx. 2. 0
-
3. 0 o.
ls the residance as specitied?
YES
NO
Poor contac't at the SRS main harnoss 18P connoctor;
chock the connector.
.
lf the connodor is OK. substitute a known_good SRS
unh. and recheck.
. l l
l he
probl em b st i l l
prel enl , repl ace t ho SRS mai n
haaness.
Op6n or i ncreased resi 3t snco i n t he SRS mai n harness;
replace the hlmess,
24-43
Troubl eshooti ng
DTC 1-3
(l l l ,
ol
has been tu.ned OFF for l ess than three mi nutes, be
caretul not to bump the SRS uni t; the ai rbag{s) coul d
acci dental l y depl oy and cause damage or i ni uri es.
DRIVER'S AIRBAG
2P CONNECTOR
DRIVER'S
AIRBAG
ASSEMBLY
CABLE REEL
2P CONNECTOR
a
5(\
\ \
sRs sERvtcE
\,/' coNNECToR 12 ol
07TAZ
-
5250200
S8S MAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
or
,^F--.-
SRS SERVICE
coNNECTOR {2 0)
07TAZ
-
5250200
24-44
Tryto rproduce tha SRS indicator light:
(see page 24-15).
(l l ),
and checkt hat t he SRS i ndi
cator light comes on for about six seconds and
goes
off.
Does ihe SRS indicator light stay on?
YES NO
lr e.mittent failure, systom is OK at this limo. S6e Trouble-
shooting Intermittent Feilures on
page 2il-15.
Check lor a short to another wire in the driver's airbao infla-
lor:
t he posi t i ve
3. Di sconnect t he dri ver' s ai rbag 2P connect or l rom t he
cabl e reel 2P connect or,
CAUTI ON: Do not di sconnect t he passenger' s ai rbag
connector.
(2
0) t o t he cabl e reel 2P connec-
t or.
5. Reconnect t he baf t erv
posi t i ve
cabl e, t hen reconnect t he
negat i ve cabl e.
(see page 24 15).
7. Bead t he DTC l see
page 24 13).
ls DTC 1.3 indicatod?
YES NO
Short in the driver's airbag inflator; replace lhe driv-
er's airbag assembly
(see paqe
24-67).
Check tor a short in the cable reel:
t he posi t i ve cabl e, and wai t f or t hree mi nut es.
(2
0) f rom t he cabl e reel 2P
3. Remove t he dashboard l ower cover, and di sconnect t he
cabl e reel 2P connect or f rom t he SRS mai n harness,
4. Connect t he spaci al t ool
(2
0i t o t he SRS mai n harness
2P connect or,
(cont ' d)
To
page 24 45
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
12 0 JACK)
07saz
-
T8401'tA
SRS SIMULATOR
LEAD C
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
12 0 JACK)
07sAz
-
TB4011A
\
From page 24-44
Check for a shon in the c.ble tool lcont'd):
negat i ve cabl e.
6. Erase t he DTC memorv
(see page 24-15).
7. Read the DTC {see
page 24-13).
Short in lhe cablo rool; replac the cable re6l
(see
Chock tor a short in tho SRS mtin harn$s:
1. Di sconnoct t he baf t ery negat i ve cabl e, t hen di sconnect
t he Dosi t i ve cabl e, and wai t f or t hree mi nut es
2. Di sconnect t he f ront
passenger' s ai rbag connect or f rom
the SRS main harness
(with
front
passengor's airbag)
t he SRS uni t . Do not di sconnect t he speci al t ool
(2
0)
l rom t he SRS mai n harness 2P connect or'
4. Check resi st ance bet ween t ermi nai s No. 1 and No 13 of
t he SRS mai n harness 18P connect or.
There shoul d be aPDrox. 2. 0
-
3. 0 0.
SRS uniu replac. th. SRS unit lse6
pagG2+
Short in the SRS main hamo3s; roplace tho SRS mtin har-
SRS UNI T
24-45
Troubl eshooti ng
DTC 1-4
CAUTION: Whenever the i gni ti on swi tch i s ON fl l ), or
careful not to bump the SRS uni t; the ai rbag{s) coul d
acci dental l y depl oy and cause damage or i ni uri es.
Intormittent failure, sydem is OK atthis time. Se Trouble-
Inlermittent Failures on
page
24-15.
NO
SRS MAIN HARNESS
2P CONNECTOR
---
"*" ,a"u,"a
GoNNECTOR
{2 O)
07f az
-
s250200
24-46
L
SRS SERVICE
CoNNECTOR
{2 0}
07TAZ
-
S250200
CABLE
REEL
2P CONNECTOR
DRIVER'S AIRBAG
ASSEMBLY
CAELE REEL
2P CONNECTOR
SRS SIMULATOR
LEAD C
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
{2 0 JACKI
07sAz
-
TB401lA
SRS SIMULATOR
LEAD C
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
{2 0 JACK)
07sAz
-
TB4011A
Try to reproduce the SRS indicator light:
1. Eraset he DTC memory (see page 24 15).
(l l ),
and checkt hat t he SRS i ndi
cator light comes on for about six seconds and aoes off,
Does the SRS indicrtor liqht stav on?
Check for a shon to power in the driver's airbag inflator:
2. Di sconnect t he bat t ery negat ave cabl e, t hen di sconnect
t he posi t i ve
cabl e, and wai t l or t hree mi nut es.
3. Di sconnect t he dri ver' s ai rbag 2P connect or f rom t he
cabl e reel 2P connect or.
CAUTION: Do not disconnect the passongr,s
airbag
connactor.
4. Connect t he SRS servi ce connect or
(2
O) t o t he cabl e reel
2P connect or.
5. Reconnect the battery posiitive
negat i ve cabl e.
(see page
24-15).
7. Read t he DTC
(see pase
24 t 3).
Short to power in the driver's airbag intlator; replace
Check lor a short to
power
in the cable rel:
1. Di sconnect t he bat t er y negat i ve cabl e, t hen di sconnect
t he posi t i ve
cabl e, and wai t f or t hr ee mi nut es.
( 2
0) f r om t he cabl e r eel 2p
3. Remove t he dashboar d l ower cover , and di sconnect t he
cabl e r eel 2P connect or f r om t he SRS mai n har ness.
4. Connect t he specj al t ool
( 2
O) t o t he SRS mai n har ness
2P connect or, (cont ,
fo page 24-41
\
From
page 24-46
Check for a short lo power in tho cable reel {cont'dl:
5. Reconnect t he bat t er y
posi t i ve cabl e, t hen r econnect t he
negat i ve cabl e,
6. Er ase t he DTC memor y
( see page 24- 15)
7. Read t he DTC
(see
Page
24' 13)
ls DTC 1nl indicated?
Short to
power in the cable reel; replace the cable reel
Check for a short to
power in th SRS main hatness:
t he posi t i ve cabl e, and wai t f or t hree mi nut es'
2. Di sconnect t he f ront
passenger' s ai rbag connect or f rom
(wi t h l ront
passenger' s ai rbagi
3. Remove t he speci al t ool
(2
0i f rom t he SRS mai n harness
2P connect or.
4. Di sconnect t he SRS mai n harness
' l 8P
connect or l rom
t he sRS uni t .
5. Reconnect t he bat t erY
posi t i ve cabl e, t hen reconnect t he
negative cable.
6. Co-nnect a vol t met er bet ween t he No 1
(+)
t ermi nal of
t he SRS mai n hat ness 18P connect or and bodv
ground'
7. Turn t he i gni l i on swi t ch ON
(l l r,
and measure vol t age'
There shoul d be 0. 5 V or l ess
L Turn t he i gni t i on swi t ch OFF.
9. connect ; vol t met er bet ween t he No 13
(+)
t ermi nal of
t he SRS mai n harness 18P connect or and body
ground
l O. Turn t he i gni t i on swi t ch ON
(l l ),
and measure vol t age
There shoul d be 0. 5 V or I ess
Short lo
power in lhe SRS main harness; leplace the SRS
SRS UNIT
24-47
Troubl eshooti ng
DTC 1-5
(l l l ,
or
has been turned OFF l or l ess than three mi nutes, be
caretul not to bump the SRS uni t; the ai rbag(s) coul d
accidentally deploy and cause damagc or iniuries.
DRIVER'S AIRAAG
2P CONNECTOR
DRIVER'S AIRBAG
ASSEMBLY
a
%..
\ \
sRs sERvrcE
\,/ CoNNECTOR t2 0l
07TAZ
-
5250200
SRS MAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
^P*---.-
(
-,
sRs sERvrcE
coNNECTOR t2 0t
07TAZ
-
5250200
SRS SIMULATOR
LEAD C
07TAZ
-
SZ5011A
and SRS INFLATOR
SIMULATOR
{2 0 JACK)
07sAz
-
TB4o11A
TrV to reproduce tho SRS indicator lightl
1. Erase t he DTC memory (See page 24 15).
2. Turn t he i gni t i on swi t ch ON {l l ), and check t hat t he SRS i ndi ,
cator light comes on for about six seconds and goes off.
Do6s the SRS indicator liqht 3tev on?
lmehittent tailure, svstem is OK at tfiis timc. See lrouble-
Intermittent Failures on Daqe 24-15.
Check for a short to ground in the driver's airbag intlator:
t he posi t i ve
cabl e reel 2P connect or.
CAUTI ON: Do not di sconnocl t he passangei ' 3
ai rbag
connoctot,
(2
0) t o t he cabl e reel 2P connec,
t or.
negat i ve cabl e.
(see page
24-15).
7. Read t he DTC {see
page 24, 13).
Short lo ground in the ddvo.'s airbag inflator; replace the
Ch6ck for a short to ground in the cable reet:
L Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he posi t i ve
(2
0) f rom t he cabl e reel 2P
connect or,
3. Bemove t he dashboard l ower cover, and di sconnect t he
cabl e reel 2P connect or f rom t he SRS mai n harness.
4. Connect t he Speci al t ool
(2
O) t o t he SRS mai n harness
2P connect or
(cont ' d).
To page 24-49
24-48
\__
\
From pag 24-48
Ch.ck for ! Bhort to
gtound in tho clble rool
(cont'dl:
5. Reconnect the battry
negative cabl.
6. Erase t he OTC memory
(see page 24-15).
7. Read t h6 DTC {see
page 24-13).
ls OIC 1-5 indicrtodT
YES
NO
Short to
ground in the ctble r.cl; t.Placo thc cable teol
{3o.
psse
24-721.
Chcck for a lhort to
ground in tho SRS main hlrn.ss:
the
positive cable, and wait for three minutes'
2. Di sconnect t he l ront
passenger' s ai rbag 2P connect or
f r om t he SRS mai n har ness i wi t h t r ont
passenger ' s
ai rbag).
3 Removo t he speci al t ool
(2
0)I rom t h6 SRS mai n harness
2P connector.
4. Check resistance between the No- 1 terminal of th SRS
ground, and bet ween
t he No. 13 t ermi nal of t he SRS mai n harness 18P connec-
t or and ground.
There shoul d be 1 Mo or more.
b th. r$bt.nc6 13 spocifiod?
YES
SRS unit;6pl.ce th. SRS unit l3eo
page 2&
Shon to
ground in tho SRS m.in harne3s; iopl.co the SRS
main hrrn.3s.
SRS UNIT
o
24-49
Troubleshooting
DTC 2-1 and DTC 2-2
-Wath
Front Passenger's Airbag
CAUTION: Whenever tho ignition switch is ON { }, or
has been turned OFF for l ess th8n thre mi nute3, be
accidentally doploy and cause damage or iniuries.
Trv to reproduce the SRS indicstor light:
1. Erase t he DTC memory (see page 24, 15).
(ll),
and checkrhatthe SRS indi-
cator light comes on for about six seconds and goes
off.
NO
YES
Intermiftcm tailure, 3ystem is OK at thb lime. S6e Trouble
shooting Intermittent Failures on pag6
2+15.
Check lor an open in the passenger's
airbag inllator:
2. Oi sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he posi t i ve
3. Disconnect the front passenger's
airbag connector from
t he SRS mai n harness (see page
24-11).
(2
O) t o t he SRS mai n harness
2P connector.
CAUTION: Do not disconnoct tho driver's airbag connec-
tor.
negative cable.
6. Erase t he DTC memory (see page
24-15).
7. Read t he DTC
(see pag 24-13).
ls DTC 2-1 or DTC 2-2 indic.t6d?
YES
NO
Open or increasd resiitance in lhe prssenger's
airbag
intlator; replec6 the pa3sgnger's
airbag e3sombly
lsee
page 24-67).
To page 24' 51
SRS SERVICE
CoNNECTOR t2 0l
07TAZ
-
SZ5m00
24-50
\
E\
From page 24-50
Chack for rn ooen in ths SRS main hatnossi
' 1.
Di sconnect t hs baf t ery ngat i ve cabl e, t hen di sconnect
t he posi t i ve cabl e, and wai t t or t hree mi nut es.
2. Di sconnect t he dri ver' s ai rbag 2P connect or l rom t he
csbl e reel 2P connect or {see
page 24-11).
t he SRS uni t . Do not di sconnect t he speci al t ool {2 0)
from the SRS main harness 2P connector'
4. Check @sistance be8voen the No. 10 terminal and No. 14
t ermi nal of t he SRS mai n harness 18P connect or. There
shoul d be aDorox. 2. 0
-3. 0
o.
ls tho r4irtance a3 3pecifiad?
NO
YES
Poor conlact at lhe SRS mtin ha]ngss
'l8P
connector;
ch.ck tho connctor.
.
lf the connoctol is OK, subitituta . known-good SRS
unit, .nd rochcck.
.ll
lh. probl6m is still
ptesont, replsce the SRS main
hatnas!!.
Opcn or incrarsad re3ist!nc6 in tha SRS m.in harnoss;
rcplac! tho harnots.
SRS UNIT
SRS MAIN
18P CONNECTOR
24-51
Troubleshooting
DTC 2-3
-
With Front Passenger's Airbag
CAUTION: Whsnevor the ignition switch is ON
([),
or
has been turned OFF for l 6ss than th.6 mi nut6s. be
caretul not to bump tho SRS uni t; the ai rbags coul d
accidsntally daploy and caus6 damage or iniuries.
t
FRONT PASSENGER'S
AIRBAG 2P CONNECTOR
SRS SERVICE
CoNNECTOR t2 0)
07TAZ
-
5250200
Tryto roproduc tho SRS indic.to.light:
1. Erase the DTC memory (sse page
2+15).
2. Turn the ignition switch ON { ), and check that the SRS indi-
c6tor light comes on for about six seconds ahd goes
off.
Oo.3 tho SRS indic.tor light ltrv on7
Into.mitt.nt tailurc, rwtam b OK st thb tim6, S.e Troublo-
Intermittont Friluraa on
gaqe
24-15.
Chack to. . Bhon to another wir. or docroasod r$irtanca in
tho pr3sgngor'r
airbag intlator:
2. Di sconnect t he bat t ery negat i ve cabl e. t hen di sconnect
the positive
cable. and wait for three minutes.
3. Di sconnct t he t ront passenggr' s
ai rbag 2P connect or
t rom t he SRS mai n harnss {see
page 24-11).
(2
2P connector,
CAUTION: Do not dbconnect tho driver'r airbag connoc-
tor.
positive
negative cable.
6. Erase t he DTC memory (see pase
24-15).
7. R6ad the DTC
(see pag'e
24-131.
Short to anothoi wi.e or docrgagod r63btanco in the par-
sangg/s airbf,g inflator; roplaco thg passongor,r
ai.b6g
To page 24-53
24-52
\ _
\
From
page 24-52
Chock for a lhort to anothor wiro or dacrcatad lotittancc in
th. SRS fi.in hamo3s:
1. Di sconnect t h6 bat t ery negat i ve cabl e, t hen di sconnect
the
positive cable. and wait for three minutas'
cabl e reel 2P conngct or.
3. Di sconnect t he SRS mai n harn6ss
' l 8P
conngct or f rom
the SRS unit. Do not disconnect the special tool
(2 O)from
the SRS main hsrness 2P connedor'
4. Check resi st ance bet ween t he No. 10 t ermi nal and No 14
terminal of the SRS main harness 18P connector' Thsre
shoul d bg approx 2. 0
b thc .eai3tlnca ss aPacifiad?
YES
F.ultv SRS unit; r.pl.c. th. SRS unh l3.e
prge 2il'761
NO
Short lo anolhar wiro or docrgatod rasist'nc' in th' SRS
mlin ha.n.!3; rcpllco th! SBq!q!L!g!9!a--
SRS MAIN HARNES9
18P CONNECTOR
24-53
r-
Troubleshooting
DTC 2-4
-
With Front Passenger's Airbag
CAUTION: Whenever tho i gni ti on swi tch i s ON
(l l ),
or
has been turned OFF for l ess thar thrse mi nutes. be
careful not to bump the SRS uni t; the ai rbsgs coul d
accidentally deploy and caus damag or iniu.ies,
24-54
FRONT PASSENGER'S
AIRBAG 2P CONNECTON
HARNESS
2P CONNECTOR
/,4\
sRs SERV|CE
(
/,/
GoNNECTOR
t2 0l
-
07TAZ
-
SZso200
Try to reproduco tho SRS indicator light:
(se page 24-15).
(ll),
and check thatthe SRS indi-
YES NO
lrtermittont fsilure, 3ystom is O|( at this time. Se Trouble-
shooting Intormittent Failuros on
pago
2{-15.
Ch6ck for a shon to powsr in the psssengor's
airbag infla-
lor:
2. Di sconnoct t he baf t ery negat i ve cabl e, t hen di sconnect
the
positive
cable, and wait tor three minutes.
3. Di sconnect t he t ront passenger' s ai rbag 2P connect or
f rom t he SRS mai n harness l see
page 24' 11)-
(2
2P connector.
CAUIION: Oo not disconnest the d.iver's airbag connoc-
tor.
5. Reconnect t he bat t ery
posi t i ve
cabl e, t hen reconnect t he
negat i ve cabl e.
(see page 24 15).
7. Read t he DTC
(see page 24 13).
ls DTC 2-4 indicat.d?
NO YES
Short to pow.r in the p.$eng6r's airbag inflator; .cplace
thg
pa$enger's
airbag a$ombly {s.e
p.ge
24-67).
To page 24-55
SBS SIMULATOR
LEAD C
07TAZ
-
SZ5011A
.nd SRS INFLATOR
SIMULATOR
(2
0 JACK)
07sAz
-
TBa011A
N-_
a
From page 24 54
main harness; replace tha SRS
Chock lor a short to oower in tho SRS main harnss:
t he posi t i ve cabl e, and wai t l or t hree mi nut es.
2. Di sconnect t he dri vr' s ai rbag 2P connect or f rom t he
cable reel 2P connector.
t he SRS uni t .
4. Remove t he speci al t ool
(2
O) f rom t he SRS mai n harness
2P connect or,
5. Reconnect the battery oositive cable, then reconnect the
negat i ve cabl e.
6. Connect a vol t met er bet ween t he No. 10
(+)
t ermi nal ol
SRS mai n harness 18P connect or and
ground.
(l l ),
and measure vol t age.
There shoul d be 0. 5 V or l ess.
L Connect a vol t met er bet ween t he No. 14
(+)
t ermi nal of
t he SRS mai n harness 18P connect or and ground, and
measure vohage. There shoul d be 0. 5 V or l ess.
SRS unit; rsDlace tho SRS unit
(so page 24'76)
SRS UNIT
24-55
Troubleshooting
DTC 2-5
-
With Front Passenger's
Airbag
CAUTION: Whenever the ignition switch is ON
0ll. o.
has been turned OFF for l ess than thros mi nutos, be
aqcidentally deploy and cause damage or iniuries.
Try to roproduce tho SRS indicator light:
1. Erase the DTC memory (see page
24-1S).
2. Turn the ignition switch ON 0t), and check that the SRS indi_
cator light comes on for about six seconds and aoes otf.
Doos tho SRS indicator light stsy on7
YES
NO
Intermittent feilurc, syrtem is OK at this timo, See Troubl.-
shooting Intormittont Failurea on
page
24-lS.
Chock to. a short to ground
in tho passongs/s
airbag ir ator:
t he posi t i ve
cabl o, and wai t f or t hree mi nut es.
3. Di sconnect t he t ront passengsr' s
ai rbag 2p connoct or
f rom t he SRS mai n harness (see page 24, 11).
(2
0) t o t he SRS mai n harnass
2P connect or,
CAUTTON: Do not disconnect the drivor.s airbrg connec-
loa,
negat i ve cabl e.
{see
page
24,15).
7. Read t he DTC
(see page
24-13).
b DTC 2-5 indicatod?
YES
NO
Shon to ground
in the pa*lengart
airbrg inflator; raplac6
the pa3r6nge/i
ailb.g '3.ombly
lsoo
pago 2+67),
To page 24-57
24-56
N-
SRS SERVICE
CoNNECTOR
(2
0l
07TAZ
-
5250200
\ I
From page 24-56
\
Cha.t to. a ahon to ground in th. SRS mrin harnda:
1. Oi sconneci t he banery negat i ve cabl e, t hen di sconnect
t he posi t i ve cabl e, and wai l t or t hree mi nul es.
2. Di sconnect t he dri ver' s ai rbag 2P connect or t rom t he
cable reel 2P connector.
3. Oisconnccl tha SRS main harnass 18P connector from
!\. s s u^n
a Rarnoyr thc sp6itl tool {2 O) from the SRS main harness
2P @nnctor.
b tha l.aaat|nc! !3
YES
SRS UNIT
Shon lo
ground in th. SRS mein h.m6s; replaco the SRS
mlin ham6a.
5 Checl resi st ance bet ween t he No 10t ermi nal of t heSRS
maan harness 18P connect or and
ground, and bet ween
rhe No. l 4 t ermi nal ol t he SRS mai n harness 18P connec'
l or and
qr ound. Ther e shoul d be 1 MO or mor e.
24-57
- /
1.3T
Troubleshooting
DTC 2-1 and DTC 2-2
-
Without Front
passenger,s
Airbag
CAUTION: Whenever rhe i gni ti on swi tch i s ON
(
), or
hrs been turned OFF for l ess than three mi nui es. be
cr.etul not to bump the SRS unit; the ailbag could acci.
dentally deploy and cause damage or injuries.
Try to reproduco the SRS indicstor light:
{see
page
2+15).
2. Turn the agnition switch ON 0), and checkthatthe SRS indi_
cator light comes on tor aboot six seconds and goes
off.
SRS UNIT
DUMMY RESISTOR
DUMMY
REStSTOn
SRS MAIN HARNESS
18P CONNECTOR
Open or i ncre. sed re3i st ance i n t ho SRS mai n harness;
th harness.
SRS MAIN HARNESS
2P CONNECTOR
Does the SRS indicator lisht stav on?
lntormittent failu.e, system is OK at this time. See Trouble.
Inte.mittent F ilures on
paq
24-15.
Check for .n open or increased rosistance in th dummy
lesistori
2. Remove t he dummy resi st or t rom t he SRS mai n harness
2P connect or.
3. Check t he resi st ance bet ween t he A and
g
t ermi nal s of
t he dummy resi st or. There shoul d be 1. 5 2. 5 0.
ls the rsistanc as sDecifiod?
Check for an open or increased rcsistance in the SRS main
harness:
1- Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he posi t i ve
cabl e, and wai t f or t hree mt nut es.
2. Di sconnect t he dri ver, s ai rbag 2p connect or f rom t he
cabl e reel 2P connect or
{see
page
24-11).
3. Di sconnect t he SRS mai n harness 1gp connect or f rom
t he sRs uni t .
4. Connect t he dummy resj st or t o t he SRS mai n harness 2p
connector.
5. Check resi st ance bet ween t he No. l 0t ermi nal andNo. 14
t ermi nal of t he SFS mai n harness 1gp connect or. There
shoul d be approx. 1. 5
-
2. 5 0.
Poor cont ect at t he SRS m. i n hamess l Bp connect or;
chck the connector,
.
It lhe connector is OK, substituto a known-good
SRS
unit. and recheck.
.
It lhe problem
is stilt present.
replaco the SRS main
haaness.
24-58
ffi
DTC 2-3
-
Without Front Passenger's Airbag
CAUTION: whensver ths ignition switch is ON
(ll),
or
has been turned OFF tor l 3s than three mi nutes, be
careful nol to bump th SRS unit; lhe airbag could acci-
dntally daploy and caus damag or iniuries.
SRS UNIT
DUMMY RESISTOR
SRS MAIN HARNESS
2P CONNECTOR
SRS UNIT
SRS MAIN I.IARNESS
18P CONNECTOR
Try to rep.oduc. th. SRS indicatot ligM:
1. Erase th DTC memory {see
page 24-15).
(ll),
and check that the SRS indi-
com6s on lor about six seconds and gogs off
Doo! th. SRS indicltor light stey on?
l nt armi t t ont l ei l ure, 3yst am i 3 OK at t hi s t i me. See
Intormittgnt Failutos on
page 2+15.
Chack for a rhort to anothar wits or d6ctcarod ]$btance in
the dummy la5i3tor:
2. Remov6 t he dummy resi st or f rom t he SBS mai n harness
2P connsctor.
3. Check tho resistance between the A and B tsrminals of
t he dummv resi st or. There shoul d be 1 5
-
2 5 0.
13 tho rgsistancg as 3pocified?
Chack lor a ahort to rnothd wile or dccreased relbtance in
the SRS main harn6s:
t he Dosi t i ve cabl e, and wai t f or t hree manut es
2. Di sconnect t he dri ver' s ai rbsg 2P connect or f rom t he
(see page 24-111
t he SRS uni t .
NOTE: Do not connoct t he dummy resi st or t o t he SRS
msin harness 2P connector,
4. Check resistance betwon the No. 10 terminal and No. 14
t ermi nal of t he SRS mai n harness 18P connect or' There
shoul d be 1 M0 or more.
F.ulty SRS unit; lepl.co the SRS unit lso6
pege 24'76).
Short to anothar wirc ot decro.sed resbtence in the SRS
mrin hsrnoaa; taplaco ths SRS main harness.
24-59
- t
Troubleshooting
DTC 2-4
-
Without Front Passenger,s
Airbag
CAUTION: Whenever the ignition switch is ON llll, or
has be6n turned OFF for less than ihreo minutes, be
careful not bump tha SRS unit; the sirbag could acci_
dentally doploy and cau3 damago or iniuries.
Try to rep.oduco the SRS indicator light:
1. Erae the DTC memory
{s6e
page
24-15).
2. Turn the ignition switch ON 0t), and check thatthe SRS indi_
Do.i the SRS indic.tor light stly on?
NO
YES
Intormltlont failur., 3yrtom b OK !t thb tim.. S.e Troubl6.
thooting Int.rmittent Failuros on p.g.2+tS.
Chock for a short to power
in th. SRS mjn h.rno3ii
1. Disconnect the battery negativd cable, then disconnect
the positive
cable, and wait for three minutes.
2. Di sconnect t he dri ver. s ai rbag 2p connect or f rom t he
cable reel 2P connector (see psge
2+1.1).
3. Di sconnect t hg SRS mai n harness l gp connect or f rom
t he SRS uni t .
4. Feconnect the battery positive
cable, thn reconnect the
negative cable.
5. Connect a voltmeter between th No. 10 (+)
terminal ot
t he SRS mai n harness 18p connect or ano grouno.
l l , and moasure vol t age.
There should be 0.5 V or less.
7. Connect a vol t met er bet ween t he No. 14
(+)
t ermi nal of
t he SRS mai n harness 18p connect or and ground,
and
measure vol t age. There shoul d b6 0. 5 V or l ess.
Aro vohtgos as rpocili.d?
YES
NO
F.ufty SRS unit; replace the SRS unit l.oo
p
ago 2+761.
I
Sho to power
in tha SRS main harno!3 or tha dummy
rsi3tor; chcck tor contact betwoen tho dummy rosistor and
another wiro. It tharo is no contact. ,oplace tho SRS mrin
natnoss.
I
SRS UNIT
24-60
\
-
SBS MAIN HARNESS
18P CONNECTOR
\
DTC 2-5
-
Without
Front Passenger's
Airbag
CAUTION: whenver the ignition switch i3 ON
(ll),
ot
has been tutned OFF fot l ess than thres mi nutos, be
careful not to bump the SRS unit; the sirbag could acci'
dentally deploy and cause damago or iniuries.
Try to reproduce tho SRS indicator lightl
l . Erase t he DTC memorv t see
psge 24_15).
(ll),
and check thal lhe SRS indi-
cator liqht comes on for about six seconds and
gos off
Chock for e short to ground in tho SBS main halne3si
the Dositive cable, and wait for three minutes'
2. Di s; onnect t he dri ver' s ai rbag 2P connect or f rom t he
(see page 24-11)
3. Di sconnect t he SRS mai n harness 18P connect or l rom
t he sRS uni t .
4. Check resi st ance bel ween No l O t ermi nal of t he SFS
ground, and bel ween
t he No. 14 t ermi nal of t he SFS mai n harness 18P connec_
SRS UN]T
SRS MAIN HARNESS
18P CONNECTOR
tor and
ground. There should be 1 l\/to or more
Oo.3 tho SRS indicator light .t!Y on?
Faulty SRS unit; replaco the SRS unit {36e
pag.21-761
Short to
ground in tho SRS main harnosi or the dummy
resistor; check lor conttc{ between the dummy rcablor and
ground. ll lhero b no contact, roplsco the SRS main har'
24-61
,tl
rr-
Troubleshooting
DTC 8-6
CAUTION: Whenever the i gni ti on swi tch i s ON l ), or
hss been turnod OFF for l ss than thre mi nul es, bs
carsful nol to bump the SRS uni t; the ai rbags coul d
sccidentally deploy and causo damage or iniulies.
Besi des i ndi cati ng an abnormal i ty i n the SRS uni t, DTC
8-6 may al so i ndi cate that two probl ems
equi val ent to
DTC
' f-l
and 2-4, 1-4 and 2-1, ot 1-4 and 2-4 occurred at
the same ti me, Proceed i n the order shown bel ow.
sRs
18P CONNECTOR
Check the SRS main harn$s:
t he posi t i ve
cabl e, and wai t f or t hrce mi nut es.
2. Di sconnect t he dri ver' s ai rbag (and
t ront passenger, s
airbag) connecto(s) (see page
24-111.
t he SRS uni t .
negat i ve cabl e.
(l l ).
6. Connect a voltmeter and measure voltage betlveen the
No. 10 t ermi nal of t he SRS mai n harness l 8p connect or
and ground,
and bt ween t he No.
' 14
t ermi nal and ground.
There should be approx. 0
-
0.5 V.
Aro voltag.3 as spocifi.d?
YES
NO
Short to powsr in tho SRS main h6rnoss; roplace the SRS
msin hamesl.
Check the SRS mein hr]ne3s rnd the csble recli
Connect a voltmoter and moasure voltage between the
No. 1 t ermi nal of t he SRS mai n harness 18p connect or
and gr ound,
and bet ween t he No. 13 t er mi nal and
ground. There shoul d be aDprox. 0-0. 5 V.
Aro voltag$ a3 apecifiod?
YES
NO
Faufty SRS unit; replace the SRS unit {3ce
page
2+761,
To page 24-63 (A)
24-62
\_
E1
From page 24' 62
(Al
Chock tho ceble ro.l:
2. Di sconnei t t he cabl e reel 2P conn6cl ot
f ' om t he SRS
mat n harness.
(l l )
4, Connect a voltmeter and measure vohaga btreen the
No. 1 t ermi nal of t he sRS mai n harness 18P connodt or
I
)
)
24-63
-/
and
qr ound,
and bet ween t he No. 13 t er mi nal and
. , o' n' d- There shoul d be aoprox. O
-
O 5 V.
Short to power in the crbl6 toel; roplsco th' c'ble 16ol
Short to
pow.l
in tho SRS m.in hamoss; lopltc' th SRS
Troubleshooting
DTC 9-2
CAUTION: Whedover tho ignition switch is ON
([).
o,
h!3 bsen turned OFF for l ess than thre mi nutes, bo
clrctul not to bump tho SRS unit; the airbag(sl could
lccidontally deploy and cau3e demage or iniuries.
Check th6 tu3ei
2. Check f or bl own No. 23 (10
A) f use i n t he underdash
(A)
To page
24-65
No. 23 110 A) FUSE
FUSE/RELAY BOX
24-64
SRS UNIT
SRS MAIIII HARNESS
,I8P
CONNECTOB
Repl ace t he f use. Turn t he i gni t i on swi t ch ON
(l l )
, and check
that the fuse doesn't blow.
Thc problorn
hr3 dblppoa.ed. Tcat-drive the vehicla ,nd
3ee Troubl*hooting
Int.rmiftant F ilu..s on page
2+15.
Chock tor 3hort to g.ound
betwoan tho undgr-dash fus6/
reby box and tho SRS unii.
the positivo
cable, and wait lor three minutes.
3. Di sconnect t he dri ver, s (and
t ront passengsr, s)
ai rbag
connect or{s) (see page 2/ t -1' l ).
4. Di sconnect t he SRS mai n harness l gp connect or l rom
t he SRS uni t .
5. Check resistance botween the No. 3 terminal of the SRS
Oround.
There shoul d be 1 M0 or more.
SRS unh; replacs th. SRS unir {3oo
page 2+761.
1B)
To page
24-65
fl
(B)f rom page 24-64
ChaFk tor lhort to ground in th. SRS m'in h'mo3t:
1. Di sconnect t he SRS mai n harness 2P connect or
{rom t he
underdash fuse/rlaY box.
2. aheck resistance between the No 3 terminal ot the SRS
ground There shoul d
be 1. 0 Mo or mor
ls tho l.3itt nco .. 3P.cifi.4l-
NO
YES
Short t o
gt ound i n t ha undor' dt t h f u3' / t ol f , Y box;
r.of.ca th. und.rdssh
rusolrelaV box.
-sho.t
m ground in th. sRs m.in htrnes;; r'plrct th' sRs
fiain h!mo$.
0t'@r
FUSE/RELAY
BOX
(cont' d)
24-65
SRS MAIN HARI{ESS
18P CONNECTOR
Chack loa an opcn in lha SRS main harne3s:
1. Turn t he i qni t i on swi t ch OFF
2. Di sconne; t t he bat t ery negat i ve cabl e, t hen di sconnect
t he
posi t i ve cabl e, and wai t t or t hree mrnut es'
(and l ront
passenger' s) ai rbag
connect or
(see
Page
24-11).
/ t . Di sconnect t he SRS mai n harness l 8P connect or f rom
t he sRs uni t .
positivo cabl, then reconnect the
neoat i ve cabl e.
S. Co-nnect a voltmeter betlveon the No 3 terminal of the
SRS mai n harness 18P connct or ancl
grouno'
7. Turn t h i oni t i on swi t ch ON {l l }, and measure
Poor contact st th SRS main harnasa 18P connoctor;
chrck tho conn6ctor'
.
ll tha connactot b OK, 3ubltituta a known-good SRS
unit, and tschgck.
.
It th. Droblem
i. still
pJcrent, ].pt.ce tho SRS mtin
(A) From
page 24-64
To page 24-66
SRS MAIN HARNESS
18P CONNECTOR
."
froubleshooting
DTC 9-2
(cont'd)
Chock for an open in tho SRS main harness:
2. oi sconnect t he SRS mai n harness 2pconnect orl romt he
under-dash fuse/relay box.
3. Check resistance botween the No. 2 terminal of the SRS
SRS mai n harness 18P connect or.
There shoul d be 0
-
0. 5 0.
UNDER.DASI{
FUSE/RELAY
8OX
SRS MAI N HARNESS
18P CONNECTOR
Wire side of female
CaOl
t ermi nal s
SRS MAIN HARNESS
2P CONNECTOR
24-66
i\
"L
From page 24-65
Poor cont sct at t he SRS mai n harness 2p connecl or:
chack the connector.
.
lf the connoctor is OK, 3ubstitute a known-good under_
d.sh tuse/rlay box, and r6chgck,
.lt
the problem
is still pro3ont,
replace the SRS mrin
hamess.
Open in tho SRS main harncs3; replaco the SRS main har-
nosli,
Airbag
Replacement
After a col ti si on i n whi ch the ai rbags
were depl oyed, the
ai rbag assembl i ss and the SRS uni t must be repl aced'
!@
sb'! r'..-eycd
l*bag
whh the oad sur'
iiFup. r tm ri6r9 b improPorly
storod lac down'
accidcnti d.plovnanl Gaald
proprl lht unit with
nough to.6 to Glr !-iqt f{u.V.
CAUTION:
. Always disconnoct thc airblg connoctol(s)
when the
harness is disconnactad.
. Oo not disa3semblo or ttmper with ths airbag'
NOTE:
. Do not i nstal l used SRS
p8rts from another vehi cl e'
when repai ri ng, usa onty new SRS
parts'
. CareJul l y i nspect the ai rbag before
you i nstal l i t Do
not i nsi al l 8n ai r bag t hat shows si gns of bei ng
droooed
or i mproperl y
handl ed, such as dents' cracKs
or deformati on.
1. Disconnect the battery negative cable' then discon-
nect the
positive cable from the battery'
and wa't at
l east thtee mi nutes.
2. Di sconnect
the ai rbag connector(sl :
Driver's Side:
. Remove the access
panel from the steeri ng
wheel '
then di sconnect
the 2P connector
between the dri v-
er' s ai rbag and cabl e reel '
NOTE: When di sconnected,
the ai rbag connector
i s
automati cal l Y
shorted
DRIVER S
AIRBAG
)
DRIVER'S
AIRBAG
2P CONNECTOR
.
F ont P[.Jrga/t
Sld.:
. Disconnect the 2P connec'tor
between the tront
p88-
sengr' s ai tbag and SRS msi n harnsss'
NOTE: When disconnected,
the airb8g connoctor ls
automati cal l y
shoned. FRONT PASEltlGER's
AIRBAG
2P @NNECIOR
4. Remove the si rbag(s):
Diivar's Side:
o Remove the two Torx bolts using a Torx T30 bit' then
remove the dri ver s ai rbag'
TORX BOI-TS
U.. . Torr
F0
bit.
(cont'd)
24-67
Airbag
Replacement
(cont'd)
Front Passenger's Side:
. Remove the three mounti ng nuts from the bracket,
then remove the harness cl i D.
. Li ft the front passenger' s
ai rbag out of the dashboard
by coveri ng the l i d and dashboard \ /i th
a cl oth, and
pryi ng careful l y wi th a fl at-ti p screwdri ver,
NOTE: The l i d of t he ai r bag has pawl s
on i t s si de
whi ch attach i t to the dashboard.
2+68
CAUTION: B sure to instsl the SRS wiring so that it is
not pinched
or intertsring with othr parts.
4. Instal l the new ai rbag(s):
Dri ver' s Si de: Pl ace the dri ver' s ai rbag i nto the steeri ng
wheel . and secure i t wi th new Torx botrs.
TORX BOLTS
9. 8 N. m
l l . 0 kgf . m, 7. 2 l bt f rl
Repl ace.
Front Passenge.'s Side:
. Pl ace t he f r ont passenger , s
ai r bag i nt o t he d6sh_
board.
. Ti ghten the front passenger,s
ai rbag mounti ng nuts.
AIRBAG MOUNTING NUTS
9. 8 N. m 11. 0 kgf . m, 7. 2l bf . f t )
Reol ace.
DRIVER'S AIRBAG
)
5. Reconnect the airbag connector(s).
Frod P.ss.nga/s Sidc:
. Aftach ths ai.bag connector to the connector
holder'
then rinstall ths
glove box.
CONNECTOB
KOTDR
RT'T ?ASSE'{GER'S
AIRBAG
Driver's Side:
. Connect the dri ver' s ai rbag 2P connector to the cabl e
reel 2P connector, then i nstal l the access
panel on the
steeri ng wheel .
1.
DRIVEN'S AIRBAG
2P CONNECTOR
Connect the battery
posi ti ve cabl e, then connect the
negati ve cabl e.
After i nstal l i ng the ai rbag, confi rm
proper system
operatl on:
. Turn the i gni ti on swi tch ON
(l l );
the SRS i ndi ca-
tor l i ght shoul d come on for about si x seconds
and then
go off.
. Make sure both horn buttons work'
24-69
1T
Airbag
Disposal
Before scrappi ng any ai rbags
(i ncl udi ng
those i n a whol e
vehi cl e to be scrapped), the ai rbags must be depl oyed. l f
the vehi cl e i s sti l l wi thi n the warranty
peri od,
before you
depl oy the ai .bags, the Honda Di stri ct Servi ce Manager
must gi ve
approval and/or speci al i nstructi ons, Onl y after
the ai rbags have been depl oyed {as the resul t of vehi cl e
col l i si on, tor exampl e), can they be scrapped.
l f the ai rbags appear i ntact {not depl oyed), treat them
wi th extreme cauti on.
Fol l ow thi s
procedure:
Deploying the Airbags: In-vohicl
NOTE: It an SRS vehi cl e i s to be enti rel y scrspped, i ts
ai rbags shoul d be depl oyed whi l e sti l l i n the vehi cl e. The
ai rbags shoul d not be consi dered as sal vageabl e pans
and shoul d never be i nstal l ed i n another vehi cl e.
! @
conf i r m t hat esch ai r bag assembl y i s
3.cursly mounted; otherwisg, soverg ptsonal iniury
could result from doploymont.
l . Di sconnect the baftery negati ve cabl e, then di scon-
nect the posi ti ve cabl e.
2. Confi rm that the speci al tool i s tuncti oni ng properl y
by fol l owi ng the check procedure
on the tool l abel
ot on page 24-7'l .
Driver's Airbag:
3. Remove the access Danel , then di sconnect the 2P
connecto. between the driver's airbag and the cable
reel .
DRIVER'S
AIRBAG
2P CONNECTOR
t'4-70
BATTERY
Front Passngsr's Airbag:
4, Remove the
gl ove
box, then di sconnect the 2P con-
nector between the front passenger' s
ai rbag and
sRS main harness
FR.NT
pAssENGER's
AIRBAG
SRS MAIN HARNESS
5. Cut off the ai rbag connector, stri p the ends of the
ai rbag wi res, and connect the depl oyment tool al l i -
gator
cl i ps to the ai rbag. Pl ace the depl oyment tool
at l east thi rty teet
(10
meters) away from the ai rbag,
DRIVER'S
AIRBAG
FRONT PASSENGER'S
AIRBAG
I
7.
Connect a 12 vol t battery to the tool :
. l f the
green l i ght on the tool comes on' the ai r-
bag i gni ter ci rcui t i s defecti ve
and cannot depl ov
t he ai r bag. Go t o Damaged Ai r bag Spec i al
Procedure.
. l f the red l i ght on the tool comes on, the ai rbag i s
readY to be dePl oYed.
Push t he t ool ' s depl oyment
swi t ch The ai r bag
shoul d depl ov
(depl oyment i s both hi ghl y audi bl e
and vi si bl e; a l oud noi se and rapi d i nfl al i on of the
bag, fol l owed bY sl ow defl ati on).
. l f the ai rbags depl oy and the
green l i ght on the
tool comes on, conti nue wi th thi s
procedure
. l f an ai rbag doesn' t depl oy,
yet the
green l i ght
comes ON. i ts i gni ter i s del ecti ve
Go to Dam
aged Airbag Specia\ Procedure'
=E
ri.,-.d .l.nlovment the airbag assem-
F".n u"co-.
hot enough to burn
you wait thir-
w' mi nut.s
after depl oyment
before touchi ng
the
assemulY.
8. Di spose of the compl ete
ai rbag assembl y
No
part
of i t can be reused Pl ace i t i n a sturdy
pl asti c bag'
and seal i t securel y,
CAUTION:
. wear a lace shigtd and
gloves when handling a
deploYed airbag.
r Wash
your hands and r i nse t hem wel l wi t h
water after handling a deploYed
ailbag'
)
O
AIRBAG
Deploying
the Airbag: Out-ot-vehicle
NOTE: l f an i nt act ai r bag has been r emoved f r om a
scraooed
vehi cl e, or has been found defecti ve or dam-
aged dur i ng t r ansi t , st or age or ser vi ce, i t shoul d be
depl oyed as fol l ows:
tffi Posilion the airbag face up, outdoors
on
iiffiat
l"ast thirtv feet
(10 ml trom anv obstacles
or
people.
1. Confi rm
that the speci al tool i s functi oni ng
properl Y
by fol l owi ng the check
procedure on thrs
page or on
the tool l abel .
2. Fol l ow steps 5, 6, 7, and 8 of the i n-vehi cl e depl oY
ment
Procedure.
Damaged Aitbag Special
Procedure
!!@
r an ailbag cannot be deployed'
it should
not be treatgd as normal scrap; rt should still be consid-
ered a potentiallY explosive
device
that can cause serl-
ous iniury.
1. l f i nstal l ed
i n a vehi cl e,
fol l ow the removal
proce
dure on
Page
24-67'
2. l n al l cases. make a short ci rcui t by twi sti ng together
the two ai rbag i nfl ator wl res
3. Package the ai rbag i n exactl y the same
packagi ng
that the new repl acement
part came In
4. Mark the outsi de
of the box
"DAMAGED
AIRBAG
NOT DEPLOYED"
sQ i t does not get confused
wi th
your
Parts
stock.
5. Cont act
your Honda Di st r i ct Ser vi ce Manager
f or
how and where to return i t for di sposal
Deployment
Tool: Check Procedure
1. Connect the
yel l ow cl i ps to both swi tch
protector
handl es on the tool ; connect the tool to a battery'
2. Push the operati on
swi tch:
green means the tool i s
OK; red means the tool i s faul tY
3. Di sconnect
the battery and the yel l ow cl i ps'
24-71
T:
Gable Reel
Replacement
@
sto.e a remove airbag assembly with the
pad surface up. lf the 8irbag is improperly stored face
down, accidontal deployment could propl the unit with
enough torce to cause serious iniury,
CAUTION:
. Always dkconnest th6 airbag conneqtor(s) when the
harnsss is disconnected.
. Do not disassemble or tampor with the airbag.
NOTE: Car ef ul l y i nspect t he ai r bag assembl y bef or e
i nstal l i ng i t. Do not i nstal l an ai rbag that shows si gns of
bei ng dr opped or i mpr oper l y handl ed, such as dent s,
cracks or deformati on,
1 . Di sconnect the battery negati ve cabl , then di scon-
nect the posi ti ve
cabl e from the battery, and wai t at
l east three mi nutes.
Remove the access panel from the steeri ng wheel ,
then di sconnect the 2P connector between the dri v-
er' s ai rbag and cabl e reel .
NOTE: When di sconnected, the ai rbag connecror ts
automati cal l y shorted.
DRIVER'S
AIRBAG
DRIVER'S AIRBAG
2P CONNECTOR
4.
Make sure the wheel s are al i gned strai ght ahead.
Remove the dri ver' s dashboard l ower cover.
DRIVER'S AIRBAG
5. Remove the two Torx bol ts from the steeri ng wheel .
and di sconnect the horn connector. Then remove
the dri ver' s ai rbag.
TORX BOLTS
Use a Torx T30 bh.
DRIVER'S DASHBOARD LOWER COVER
-El
i ng wheel nut,
STEERING WHEEL
6. Di sconnect the connectors from the horn and crui se
cont.ol sevresume switches, then remove the steer-
Remove the steeri ng
pul l er.
CABLE REEL
2P CONNECTOR
wheel usi ng a st eeri ng wheel 1.
STEERING WHEEL PULLER
(Commerci al l y-avai l abl e)
24-73
8. Romove tho column rdverq
Di sconnect the 3P connector between the mai n wi re
harness and cabl e reel sub-harness, and the 2P con-
nector betl veen the cabl e reel and SRS mai n harness.
I
9.
CABLE REEL SUB
HARNESS
3P CONNECTOR
SRS MAIN HARNESS
2P CONNECTOR
10. Remove t he cabl e r eel f r omt hecol umn.
( cont ' d)
CABLE REEL
f
Gable Reel
Replacement
(cont'd)
NOTE:
. Bef or e i nst al l i ng t he st eer i ng wheel , t he f r ont
wheel s shoul d be al i gned strai ght ahead.
. Be sure to l nstal l the harness wi res so that they
are not pi nched
or i nterferi ng wi th other parts.
. After reassembl y, confi rm that the wheel s are
sti l l turned strai ght ahead and that the steeri ng
wheel spoke angl e i s correct
(road
test). l f mi nor
spoke angl e adj ustment i s necessary, do so onl y
by adj usti ng the ti e-rods, not by removi ng and
reposi ti oni ng the steeri ng wheel .
11. Set t he cancel sl eeve so t hat t he
pr oi ect i ons
ar e
al i gned veni cal l y.
CANCEL
SLEEVE
PROJECTIONS
12. Careful l y i nstal l the cabl e reel on the steeri ng col
umn shaf t . Then connect t he 3p connect or t o t he
cabl e reel sub-harness, and connect the 2p connec-
tor to the SRS mai n harness.
SRS MAI N HARNESS
o' 1
: _ - - - - - - - - - - - - - <
r 3,
14.
Instal l the steeri ng col umn covers.
lf necessary, center the cable reel.
(New
replacement
cable reels come centered.) Do this by first rotating the
cable reel clockwise until it stops. Then rotate it coun-
terclockwise
(approximately
two and a half turns) until
the arrow mark on the cabl e reel l abel poi nts
strai ght
uD.
ARROW MARK
15. I nst al l t he st eer i ng wheel , t hen connect t he hor n
connector and crui se control sevresume swi tch con_
necl or.
STEERING WHEEL
CRUISE CONTROL
SET/RESUME
SRS Uni t
Replacement
CAUNON:
. Beforo disconnesting any part of the SRS wire har-
ness, disconneet the ailbag connector(s).
. Duri ng i nstal l ati on or rspl acement, do not bump
(impact
wronch, hammor etc.) the aroa near tho SRS
unit.
NOTE:
. Do not damage the SRS uni t termi nal s or connectors.
. Do not di sassembl e the SRS uni t; i t has no servi ce-
abl e oarts.
.
Store the SRS uni t i n a cl ean, dry area.
. Do not use any SRS uni t whi ch has been subj ected to
water or shows si gns of bei ng dropped or i mproperl y
handl ed, such as dents, cracks or deformati on.
l . Di sconnect the battery negati ve cabl e, then di scon-
nect the posi ti ve
cabl e from the battery, andwai tat
l east three mi nutes.
2. Di sconnect the ai rbag connector{s}:
NOTE: When di sconnected, the ai rbag connector i s
automati cal l y shorted.
Driver's Side:
o
Remove the access panel
from the steeri ng wheel .
then di sconnect the 2P connector between the dri v-
er' s ai rbag and cabl e reel
(see page
24-11).
Front Passenggr's Sidg:
. Di sconnect the 2P connector between the front pas-
senger' s ai rbag and SRS mai n harness
(see page
24-
11) .
I
3. Remove the ri ght si de cover from the SRS uni t.
SRS UNlT
TORX
BOL?S
U3a r Torx
T30 bit.
RIGHT SIDE
Remove the l eft si de cover from the SRS uni t. then
di sconnect t he SRS mai n har ness 18P connect or
from the SRS uni t,
SRS UNIT
Remove the four Torx bol ts from the SRS uni t, then
pul l
out the SRS uni t from the dri ver' s si de,
l,---,
$'
\-./ tt
COVER
r, i
I
6. l nstal l the new SRS uni t.
TORX BOLTS
9.8 N.m 11.0 kgf.m, 7.2 lbfft)
Uso a Torx T30 bh.
Repl ace.
SRS MAIN HARNESS
18P CONNECTOR
7.
9.8 N.m
(1.0
kgtm.7.2l btftl
Uso a Torx T30 bit.
Repl ace.
Connect the SRS mai n harness 18P connector to the
SRS uni t;
push i t i nto posi ti on unti l i t cl i cks
I nst al l t he SRS uni t cover s
( r i ght and l ef t ) . Make
sure the covers snap together i n the mi ddl e
8.
TORX BOLTS
10.
9. Reconnect tho drivgr's airbr 2P :onnector lo the
cabl e reel 2P connctor, than rernstal l the access
panel on the steeri ng r*reel -
Reconnect the front passenger' s ai .bag connecl or
to the SRS mai n harness.
Reconnect the battery
posi ti ve
cabl e, thn l ho n6ga-
ti ve cabl e.
After i nstal l i ng the SRS uni t, confi rm
proper system
operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS
i ndi cator l i ght shoul d come on for about si x seconds
and then
go off.
1 1 .

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7. Instal l the back cover, then i nstal l the camshaft pul -

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