I NT RO DUCT ION I

G e n e ra l n fo

How to Use This Manual This manualis dividedinto 23 sect

tion is markedwith a blacktab that linsup with its co.responding
thumb indextab on this paqeand the back cover. you can auicklv
tind the tirst pageof each sectionwithout lookingthrougha full table of contents.The symbolsprintedat the top cornerof each page
can also be used as a quick referencesystem.
Each section includes:
1. A table of contents,or an explodedview index showing:
a Partsdisassemblvsequence.
a Bolt torquesand thread sizes.
a Pagereterencesto descriptionsin text.
2. Disassembly/assembly
proceduresand tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.

Specifications

f,|tr

Maintenance

Engine

ll=

SpecialInformation
tnai""tes a strong possibility ot sevoro prsonal injury
@@
or losa of lite it instluctions ar not tollowed.

Cooling

It

ri!

CAUTION: Indicates a possibility of poBonal iniury ol oquipmont

damage if instructions aro not tollowed.
NOTE: Gives helpful information.
CAUTfON: Detaifoddescriptionsol st ndard wo*shop procedures,
satety p nciplesand servicopalationsaro not includod.pleasonot6
that this manualcontainswamings and cautionsagainstsoms spocitic srvice methods which could cause PERSONALlNJURy, d8mag6
a vahicl or mako it unsafe. Pleaaaundratandthat thos6 warnings
cannot cover all concivableways in which sorvice, whethgr 01 not
recommended by HONDA might b6 dono, or of tho possible
hazardous consequences of evely conceivablo way, no. could
HONDA invostigateallsuch ways. Anyono using sorvics proceduros
01toofs. whether or not rocommendedby HONDA,must satjslyhimsel, thoroughly that ngithor pr3onal aatety nor vohicl s8fety will
be jsopardized.
All informationcontainedin this manualis basedon the latest Droduct
info.mationavailableat the time of printing.We reservethe right
to makechangesat any time without notice.No part of this publication may be reproduced,storedin retrievalsystem.or transmitted,
in any form by any means,electronic.mechanical,photocopying,
recording,or otherwise,without the prior written permissionoJ the
publisher.This includestext, figures and tables.

First Edition9/92
1516 pages
HONDA MOTORCO..LTD.
All Rights Reserved
Seruic Publication Offics
Specilicationsapply to U.S.A. and Canada

Fueland Emissions
ZZ
*Transaxle

*Steering

If." r

* Brakes
(lncludin
* Bo d y
* H e a te ra n d
Ai r C o n d i ti o n i n

L'___

As soctions with * includ6 SRS comDononrs.

spcial piocautions aro roquirad whoit so.vicing.

* Electrical
(lncluding

GeneralInformation
Chassis
and PaintCodes.................
1-2
ldentification
NumberLocations....... 1-4
Warning/Caution
Labels..................
1-s
Lift and SupportPoints
Lift ...........
. . . . . . . . . . . . .1. .-.9
F l o o Jr a c k
. . . . . . . . . . . . . .1. -. .1 0
S a f e t yS t a n d s
. . . . . . . . . . .1. - 1 1
Towing
.......1-12
ServicePrecautions
Handlingof SpecialNuts

and Bolts

1-13

'!.
7t

Chassisand Paint Codes

U.S. Model
EngineNumber
F22A1-9200001

JHMBA814'PCOOOOol

Type of Vehicle
J H M : H O N D AM O T O RC O . , L T D .
HONDA, PassengerCar
BA8: Prelude2.2 /
BBl : Prelude2.2 t VfEC
BB2: Prelude2.3 /
Body and TransmissionTYPe
1: 2-door s-sDeedManual
2t 2-doot 4-speedAutomatic
Vehicle Grade
4: PreludeS
5: PreludeSi
6: PreludeSi 4WS
7: PreludeSi VTEC
Chock Digit
Model Yoat
'1993
P:,

Engine Type
F22A1; 2.2 / SOHC SequentialMultiport Fuel-injectedengine
H22A1t 2-2, DOHCVTEC Sequential
engane
Multiport Fuel-iniected
H23A1t 2.3, DOHC SequentialMultiport Ful-injectedengine
EmiesionGroup
lOO: Califolniawith H22A1 engine
130: 49ST with H22A1 engine
2OO:Californiawith H23A1 engine
23O: 49ST with H23A1 engine
920: Calilorniawith F22A1 engine
923: 49ST with F22A1 engine
Serial Numbel

M2F4-1000001

M2F4: Manualwith H22A1 engine

M2L5: Manualwith F22Al engine
M2S4: Manual with H23A1 engine
M2F4: l OOOOO1
Exceot M2F4: 20OOOO1

Vehicle ldentificationNumbel
and FederalMotor Vehicle
Safety Standard Certification'

ii

ir
i[i

Paint Code

COLOR
B-64P

Fresco Blue Pearl

Brittany Blue Metallic
GranadaBlsck Peatl
SeablingSilver Metallic
Frost White
Mirano Red

CanadaModel
Vehicle ldentificationNumber
J H M B A 8 1 4 *P C 8 0 0 0 0 1

F22A1: 2.2 / SOHC SequentialMulti

port Fuef injected engine
H22A'l:2.2 / DOHC VTEC Seouential
Multiport Fuel-injected
engine
H23A1: 2.3 / DOHC SequentialMultipon Fuel-injected
engine

J H M : H O N D AM O T O RC O . . L T D .
HONDA, PassengerCa.
BA8: Prelude2.2 /
B B 1 :P r e l u d2e. 2 . l E C
BB2: Ptelude 2.3 I
Body and T.ansmission Type
1: 2-door s-sDeedManual
2', 2-doot 4-speedAutomatic

F22A1 engine; 928OOO1

H22A1 engine: l TOOOO
lH23A1 engine: 27OOOO1

Vehicle Glade
4: Prelude

5: PreludeSR
6: PreludeSR 4WS
7: PreludeSR-V
Check Digit
Model Y6at
P: 1993

M2F4-1000001
M2F4: Manual with H22A1 engine
M2L5: Manualwith F22Al engine
M2S4: Manual with H23A 1 engine

C: SaitamaFactoryin Japan

M2F4: l OOOOO
l ExceptM2F4: 2OOOO01

Vehicle ldentificationNumbe]
and CanadianMotor Vohicle
Safety Standard Certification.

Paint Code

COLOR
8,64P

F esco Blue Pearl

Brittany Blue Met8llic
Granada Black Pearl
SeablingSilverMetallic
Frost White
Mirano Red

1-3

ldentificationNumberLocations
Vehicle ldentif ication
Number

V.hicl ldontitication
Numbo.

TransmissionNumber
(Automaticl
t

'l i,
,l

Tiansmission Number
lManual)

Warning/CautionLabelLocations

A: CABLE REELCAUTION A
CAUTION: ISRSI
BEFOREINSTA-I.IINGCABLE REEL:
. CENTERTHE FRONTWHEELS.
. ALIGN THE MARKS.
. READ SERVICEMANUAL.
B: CABL REELCAUTION B

cAUTtOt{:
NO SERVICEABLE
PARTSINSIDE;DO NOT DISASSEMBLE
OR TAMPER.
C: DRIVERMODULE DANGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATEROR HEAVYMETALSSUCH
AS COPPER.LEAD OR MEFCURYMAY PRODUCEHARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGETEMPERATURES
MUST I{OT EXCEED
2OO"F{1OOOCI.FORPROPERHANDLII{G,STORAGEAND
DISPOSALPROCEDURESREFERTO SERVICEMANUAL,
SRS SUPPI.EMENT.
POTSON
COI{TAINSPOISONOUSSODIUMAZIDEAND POTASSIUM
NITRATE,
FIRSTAIO
IF CONTENTSARESWALLOWED.II{DUCEVOMITING.FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR 15
MINUTES.IF GASES (FROMACID OR WATER CONTACT)
ABE INHALED, SEEI( FRESHAIR. IN EVERY CASE, GET
PROMPTMEDICAL ATTENTION.
KEEPOUT OF REACHOF CHILDREN.

D: DRIVERMODULEWARI{|]{G
A WARI{ING
THEAIRBAGI'{FLATOR
IS EXPLOSIVE
AND,IF ACCIDEN.
TALLYDEPLOYED,
CAt{ SERIOUSLY
HURTOF KILLYOU.
. DOI{OI USEELECTRICAL
TESTEOUIPMENT
ORPNOBII{G DEVICES.THEY CAN CAUSE ACCIDENTAL
DEPTOYI'EI{T.
. NO SERVICEABLE
PARTSINSIDE,DO OT DISAS.
SEMBLE.
. PLACEAIRBAGUPf,IGHTWHEI{BEMOVED.
a Fou.ow sERvtcE MAI{UAL |]{STRUCT|O]{S
CAREFULLY.
E: I FLATOR WARNING TAG
A WARNING
ACCIDENIAL AIRBAG DEPLOYMEI{I CA]T SERIOUSLY
HURTOR KILLYOU. II{STALLTHE REDSERVICECONNECIOB WHENTHE INFLATORHARITESSIS DISCONNECTED.
F: STEERINGWHEEL t{OllCE
NOTICE
IMPROPERSTEERINGVYHEELREMOVAL OR II{STALLATION
CAN DAMAGE SRS COMPOT{EI{TS.
FOLLOWSERVICEMA UA! INSTRUCTIONCAREFULLY.

(cont'd)

1-5

Warning/CautionLabelLocations
(cont'dl

'E: Inflatorwarning tag (Reterto page l-5).

G: SRSWARNING{ENGINEHOOOI
SUPPLEMENTALRESTRAIIIITSYSTEM ISRS)
THIS VEHICLE IS EOUIPPEDWITH DRIVERAND FRONT
SEAT PASSENGEB
AIRBAGSAND FRONTSEAT BELTTEN.
SIONERSYSTEMS.
ALL SRS ELECTRICALWIRING AND CONNECTORSARE
COLOREOYELLOW.
TAMPERINGWITH, DISCONNECTING
OR USINGELECTRICAL TEST EOUIPMENTON THE SRS WIRING CAN MAKE
THE SYSTEMINOPERATIVEOR CAUSEACCIDENTALFIRING OF THE INFLATOR.
A WARNING
THE AIRBAG INFLATORIS EXPLOSIVEAND. IF ACCIDE .
TALLY OEPLOYED.CAN SERIOUSLYHURTYOU. FOLLOW
SERVICEMANUAL INSTRUCTIONSCAREFULLY.
H: STEERING
COLUMNCAUTION

CAUTION ISRS
To AvotD DAMAGIIGrHE sRs CABLEoB REE|-.
wHtcH
COULDMAKETHESYSTEMINOPERATIVE,
REMOVETHE
STEERING
WHEELBFOREREMOVING
THE STEERING
SHAFTCONNECTOR
BOLT.
l: FRONTSEAT PASSENGER
AIRBAGMODULEDANGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATEROR HEAVY METALSSUCH
AS COPPER,LEAD OR MERCURYMAY PRODUCEHARM.
FUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGETEMPERATURES
MUST NOT EXCEED
2OOOF(lOOOC}FORPROPEB
HANDLING,STORAGEANO
DISPOSAL PROCEDURESREFERTO SERVICEMANUAL,
SRS SUPPLEMEI\'T.
POISON
CONTAINSPOISONOUSSOOIUMAZIDEAND POTASSIUM
NITRATE.
FIRSTAID
IF CONTENTSARESWALLOWED,INOUCEVOMITING.FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR T5
MINUTES.IF GASESIFROMACID OR WATERCONTACTI
ABE INHALED, SEEK FRESHAIR. IN EVERY CASE, GET
PROMPTMEDICAL ATTENTION.
KEEPOUT OF REACHOF CHILDREI\'.
A WARNING
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN.
TALLY DEPLOYED,CAN SEBIOUSLYHURT OR KILL YOU.
. DO NOT USEELECTRICAL
TESTOUIPMENTOR PROBING DEVICES. THEY CAN CAUSE ACCIDENTAL
DEPLOYMENT.
. NO SERVICEABLEPARTS INSIDE. DO NOT DISASSEMBLE.
. PLACEAIRBAG UPRIGHTWHEN BEMOVED.
. FOLLOW SERVICEMANUAI- INSTRUCTIONS
CAREFULLY.

K: DRIVERINFORMATION
ISUNVISOB)

ALWAY WEARYOURSEATBELT
CAR IS EOUIPPEDWITH A DRIVERAIRBAG AS A
SUPPLEMENTALRESTRAINTSYSTEM {SRSI.
. IT IS OESIGNEDTO SUPPLEMENTTHE SEAT BELT.
. BEFORE
ORIVINGREADLABELINSIDETHEGLOVEBOX.
'K: DRIVERINFORMATION

ALWAY WEARYOURSEATBELT
CAR IS EOUIPPEOWITH A DBIVERAIRBAG AND
A FRONTSEAT PASSENGER
AIRBAGAS A SUPPIEMENTAL RESTRAINTSYSTEM ISRS).
. IT IS DESIGNEDTO SUPPLEMENTTHE SEAT BELT.
. BEFOREDRIVINGREAOLABELINSIDETHEGLOVEBOX.
L: GLOVEBOX INFORMATION
DRIVER'SAIREAG INFORMATION
. SUPPLEMENTAL
RESTRAINTSYSTEMISRSICAN PROVIDE AOOITIONALPROTECTIONFORTHE DRIVERIN A
FRONTALCOLLISION.A FUNCTIONALDESCRIPTION
OF
THE SRS IS IN YOUR OWNER'S MANUAL.
. THE SYSTEMMUST BEINSPECTEDTEN YEARSAFTER
DATE OF MANUFACTURE,AS NOTEDON THE CERTIFICATION PLATE.
. ANY REPAIR,INSPECTION
OR NEARBYACCESSORYII{.
STALLATIONSHOULD8E DONE BY AN AUTHORIzED
HONDA DEALER.
. IF YOUR SRS INDICATOR:
. LIGHTSWHILE DRIVINGOR FLASHES;
. FAILSTO LIGHTOR STAYS ON AFTERTHE IGNITION
IS FIRSTTURNEDON:
SEE YOUR AUTHORIZEDHONDA DEALER.
'L: GLOVEBOX INFORMATION
DRIVER'SAND FRONTSEAT PASSENGER'SAIRBAG INFORMATION
. SUPPLEMENTAL
RESTRAINTSYSTEM{SRSICAN PRO.
VIDEADDITIONALPROTECTION
FORTHE DN|VERAND
FRONTSEAT PASSENGERIN A FRONTALCOLLISION.
A FUNCTIONALDESCRIPTION
OF THE SRS IS IN YOUR
OWNER'S MANUAI..
. THE SYSTEMMUST BE INSPECTEO
TENYEARSAFTER
DATE OF MANUFACTURE,AS NOTEDON THE CERTIFICATION PLATE.
. ANY REPAIR,INSPECTION
ORNEARBYACCESSORYINSTALLATIONSHOULD BE DONE BY AN AUTHORIZEO
HONDA DEALER.
. IF YOURSRS INDICATOR:
. LIGHTS WHII-E DRIVINGOR FLASHES;
. FAII.STO LIGHTOR STAYS ON AFTERTHE IGNITION
rs FrRsTTUBNEDON;
I
. SEEYOUR AUTHORIZED
HONDA OEALER.
M: SRS UNIT CAUTION
CAUTIONi
. NO SERVICEABLEPARTS INSIOE.
. DO NOT OISASSEMELE
OR TAMPER.
. DO NOT DROP.
. STOREIN A CLEAN,DRY AREA,

*This versionof the label is used on cars with lront passengerairbag.

(cont'd)

1-7

Warning/CautionLabelLocations

AIR CLEAI{ERELEMEI{T,
OIL FILTEB,RECOMMENDATIOI{
ENGINEOll- and SPARK PLUG

tl i-l atl

;DZ"N

t:
RAOIATORCAP
CAUTION

I
I

I
.

\..

1-8

Lift and Support Points

wnen heavy real components such as suspension, fuel tank. spare tile and trunk lid are to be removed,
@Q
plac additional weight in tha trunk betole hoisting. When substantial weight is removed trom the lear of th6 cal, the
center of gravity may change and can causs the car to tip forward on tho hoist.
NOTE: Sinceeach tire/wheelassemblyweighs approximately30 lbs { 14 kg), placingthe front wheels in the trunk can
assist with weight dist.ibution.
1. Placethe lift blocks as shown.
2.

Raisethe hoist a few inches (centimeters)and .ock the car to be sure it is firmly supponed.

3.

Raisethe hoist to tull height and inspect lift points for solid support.

DH
REARSUPPORTPOINT

(cont'd)

1-9

Lift and SuPPortPoints

Floor Jack

@
o Always uso salty stands when wolking on or

Set the parkingbrakeand blockthe wheelsthat are

not being lifted.

undor any vehiclo that is supponed only by a

jack.
a Nver attmpt to use a bumpel iack for lifting ol
supporting tho cat.

When liJtingthe rear of the car, put the gearshift

lever in reverse{Automatictransmissionin @ position).
Raisethe ca. high enoughto insertthe safety stands'
Adjust and placethe satety standsas shown on page
1-1 1 so the car will be approximatelylevel,then lower the car onto them.

CENTERBEAM

Centerthe iacking
bracket in the middle
of the jack lilt Platform.

Centerthejacking
bracketin the middle
ol the iack lift Platform

1-10

PLATFORM

LIFT PLATFORM

Safety Stands

DH
FRONTSUPPORTPOINT

SAFEW STANDS

REARSUPPORTPOINT

1-11
j

Towing
towing
ll the car needsto be towed. call a proJessional
service.Nevertow the car behindanothercar with just
a roDeor chain. lt is verY dangerous
Emelgency Towing
There are three popularmethodsof towing a car:

TtEDOWIIHOOKS

Flat-bedEquipment- The operatorloadsthe car on the

back ol a truck. This is the best way of transponingthe
car.
Wheel Litt Equipmont - The tow truck uses two plvoring arms that go underthe tires {tront or rear)and lifts
them otf the ground. The other two wheels remainon
the ground.
Sling-type Equipmont - The two truck uses metal cables with hooks on the ends. These hooks go around
Dartsof the trame or suspensionand the cableslift that
end of the car oft the ground.The car's suspensionand
body can be seriouslydamagedif this methodof towing
is attempted.
lf the car cannotbe transportedby flst-bed,it shouldbe
towed with the front wheels off the ground. lf due to
damage,the car must be towed with the front wheels
on the ground, do the following:
5-spe6d Manual Tlansmission
a Releasethe Parkingbrake.
a Shift the transmissionto Neutral.
Automatic Tlansmission
a Releasethe Parkingbrake.
a Start the engine.
a Shift to @ position,then @ position.
a Turn off the engine.
NOTICE:lmpropertowing preparationwill damagethe
Followthe aboveprocedureexactly.It you
transmission.
transmissionor start the engine(autothe
shift
cannot
your car must be transponedon a
matic transmission),
flat-bed.

.-)
t:

f
'l

\.

a lt is best to tow the car no farther than 50 miles

(8okm),and keepthe speedbelow 35 mph (55 km/hl'
NOTICE:Tryingto lift or tow the car by the bumperswill
causeseriousdamage.The bumpersare not designedto
suooortthe car's weight.

1-1 2

TOWINGHOOK

Service Precautions
Handlingof SpecialNuts and Bolts
Becausethe tront sub frame sectionson this car a.e constructed with aluminum alloys. use only the special
"Dacro" type nuts and bolts recommendedby Honda.
NOTE:
a Dacro finish can be identitiedby gray plating.
a Some Dacro tinish bolts have a green coating on
the th.ead sectionof the bolt for easielapplication. This type ot bolt is calleda "Torqu6r" bolt,
a Use of other types ot nuts and bolts may cause
electrolvsisand corrosion,which in turn could
caus the bolt to loosen.

l.

When replacing nuts and bolts, use only the same

type.
Tighten the nuts and bolts with I torqua wrench to
ths specificationsprovidedin this manual.

J.

Clean all thread ridges with a non wire type bristle

brush. Foroignmatter in the threads may cause the
bolt to loosen.

4 . Sctions on this car requiringthe use of Dacro nuts

and bolts will be indicatedbv a l* I in this manual.

Gray

Grcon coating
on tha thraad!
of ao|lro bolta.

Gray plsting: "Dacro" type

Gray plating + Greencoating on the threads:
"Torquer" type

1-13

Specifications
Standards
and ServiceLimits ...........3-2
DesignSpecifications
......................
3-15
BodySpecifications
....... 3-18

Standardsand Service Limits

CytinderHead/ValveTrain {F22A1 engine} Section 6
TTaEASuREMENT

I
Compression

25O rpm and

wide open throttle

psi)
kPa{ks/cm2,
Cylindrhead
Camshaft

Valve stem O.D.

Stem-to-guide clearance
Valve seat

width
Stem installed height

Valve spring

Nominal
Minimum

r49l'm!Il9!919!

Warpage
Hoight
End play
oil clearance
Camshalt-to-holder
Total runout
Cam lobe height
Valve clearance

Freelength

IN
EX

IN

EX
IN

EX
IN

EX
IN
EX
IN

EX
lN

EX
Valve guide

t.D.
height
Installed

Bocksr arm

Arm-to-shaft clearance

''l: CHUO HATSUJOmanulacturedvalve sprrng.

'2: NIHONHATSUJOmanulactllredvalve spring

IN
EX
IN
EX

IN
EX

sraruolnotruewt

senvtceumtr

1.250 112.5,1781
9 5 0 { 9 . 5 ,1 3 5 )
200 12.0.2al
0.o5 (0.002)
9 9 . 9 5 - 1 0 0 . 0( 53 . 9 3 5 - 3 . 9 3 9 )
o.5 {0.02)
o.05-o.15 (0.002-0.006)
0.15 (0.006)
0.o50-0.089(o.oo20-o.oo35)
o.06 (0.002)
0.03 {0.0o1)max.
3 8 . 5 2 6( 1 . 5 1 6 8 )
3a.77a11.52671
1)
o.23-0.28(0.o09-0.o1
(0.01 '0.01
3)
0.27-0.30
oossro.:I oet
5 . 4 8 5 - 5 . 4 9150 . 2519 - 0 . 2613 )
5.4201o.21341
50)
5.450-5.460(0.2146-0.21
0.08(o.oo3)
0.o20-0.045{o.0008-o.oo20)
o.12 (0.oo5)
)
0.055,0.o80{0.0022-o.oo3'l
2.0 {0.08)
(
0
.
0
4
9
0
.
0
6
1
)
1.25-1.55
2.0 10.08)
1 . 2 5 - 1 . 5(5O . 0 4 9 - 0 . 0)6 1
4 8 . 9 6 5t 1 . 9 2 7 8 1
79)
15 (1.8994-1.91
48.245-48.7
( 1 . 9 8 0 9 - 1 , 9 9 9 4 ) 5 1 . 0 3 5( 2 . 0 0 9 2 1
5 0 . 3 15 - 5 0 . 7 8 5
5 4 . 8 11 2 . 1 5 8 )
54.82(2.r 58) 2
5 6 . 2 6{ 2 . 2 1 5 )
56.2A12.21612
5 . 5 3( 0 . 2 1 8 )
1-0.2177|
5.515,5.53010.217
5 . 5 3{ 0 . 2 1 8 1
1-O.21771
5.515-5.5301o.211
5-0.954)
23.75-24.25(O.91
2)
15.05-'5.55
1
{O.593-0.61
o.o17-o.050
l0.oo07'o.oo20) 0.08 (0.003)

)
o.o18-0.054(0.ooo7-o.0021

o.08{o.oo3)

Unit of tength:mm (in)

Cylinder Head/ValveTrain (H23A1 enginel - Section 6

MEASUREMENT
Compression

250 rpm and

wide open throttle
kPa lkg/cm2, psi)

Cylinderhead

Warpage
Heighr
End play
Camshaft-to-holder
oil clearance

Camshatt

Total runout
Cam lobe height

srAr{DARDtt{Ewl

Nominal
Minimum
Maximumvaiation

1 3 1 . 9 5 - 1 3 2 . 0 5( 5 . 1 9 5 , 5 . 91 9 )

Valve stem O.D.

Stem to-guide clearance
Valve seat

I.l

Widrh
Stem anstalledheight

Valvo spring

Freelength

Valve guide

t.D.

lN
EX

4 7 . 1 41 1 . 8 5 6 1
47.r4 (1.856)

IN

6.61-6.63(O.260-0.261
I
( 0 . 2 6 0 - 0 . 2)6 1
6.61,6.63
13.25-13.75 1O.522-0.541
|
13 . 75 - 14 . 2 5( O . 5 4-10 . 5 6 )1

IN

EX
' 1: ExhaustNo. 5 journal.
'2: ExceptexhaustNo. 5 journal.

0.o5{0.oo2)

IN
EX
IN
EX
IN
EX
IN
EX
IN
EX

IN

EX
Installed height

stnvtce urirr

0.05 0.15 (0.oo2-o.006)

o.5 {0.02}
*1
o.050-0.089(o.0020-o.oo35)
o . 1 5{ 0 . 0 0 6 ) . 1
0. 100,o.139 (o.0039-0.0055)*2 0.20 (o.oo8)*,
0 . O 3( 0 . O 0 1m1a x .
0.06 (0.oo2l
3 3 . 6 6 1{ 1 . 3 2 5 2 }
3 3. 72 5 t 1. 3 2 78 )
o.07-0.11 (0.003-0.004)
o . 15 - 0 . 1 9t 0 . o o 60 . 0 0 7 )
-0.2594)
6.580-6.590(O.2591
6 . 5 5( O . 2 5 8 )
6.550-6.560(O.2579-0.2583)
6.32 t0.257l
o.o2-o.05(o.oo1-0.002)
0.08 {o.oo3)
0.o5-o.08(o.oo2-0.o031
0 . 1 1( O . O O 4 )
1 . 2 5 - 1 . 5(50 . 0 4 9 - 0 . 0)6 1
2.0 (o.081
0 . 0 4 9 , O . 0)6 1
1 . 2 5 - ' 1 . 5( 5
2.0 (0.081
3 9 . 3 6 5 - 3 9 . 8 3t '51 . 5 4 9 8 - 1 . 5 6 8 3 )4 0 . 0 8 5{ 1 . 5 7 8 1 )
3 9 .19 5 , 3 9 . 6 3 (51 . 5 4 3-11 . 5 6 0 4 t 3 9 . 8 8 5{ 1 . 5 7 0 3 )

EX
Valve clearance

1,250 112.5,1181
9 5 0 { 9 , 5 ,1 3 5 }
200 12.o,2al

6.70 to.264l
6.70 {0.264)

{cont'd)

3-3

Standardsand Service Limits

CylinderHead/ValveTrain (H22A1 engine) Sectit)n 6

STANDARDtNEwl

MEASUREMENT
Nominal
Minimum
Maximum varlatron

Compression

250 rpm and

wide open throttle
kPa (kg/cm2,psi)

Cvlinderhead

Warpage
Heisht
End play
Camshalt-to_holderoil clearance
Total runout
lN
Cam lobe height

Camshaft

EX

Valve clearance
Valve stem O.D.
clearance
Stem-to-guide
Valve seat

Primary
Mid
Secondary
PrimarY
Mid
Secondary
lN
EX
lN
EX
lN
EX
IN
EX
IN
EX

lN

t.D.
height
Installed

Rockerarm

Arm-to-shaft clearance

CHUOHATSUJOmanufacturedvalve spr'ng'

, 2 | NIHONHATSUJOmanufacturedvalve spring'

ii

ii

3-4

0 . 0 3( O . 0 0|1m a x
34.04' 1{1.3402)
3 6 . 8 5 6( 1 . 4 5 1 0 )
3 4 . 9 7 1{ r . 3 7 6 8 }
3 3 . 7 4 5{ 1 . 3 2 8 5 )
3 6 . 3 2 3( 1 . 4 3 0 0 1
3 4 . 6 8 3( 1 . 3 6 5 5 )
9 (0.006-0.oo7)
0.15-O.1
o.17 0.21 (O.OO7-O.OO8|
59)
l
5.475-5.4851O.2'56'0.21
5.475-5.485(0.2156-0.2159)
o.025-0.055(0.0010-0.oo22)
)
o.o5o-0.080{0.0020-0.0031
(
0
.
0
4
9
0
.
0
6
1
)
1.25-1.55
1 . 2 5 - 1 . 5(50 . 0 4 9 - 0 . 0)6 1
(1.4750-' |.4935)
37.465-37.935
3 7 .16 5 - 3 7 . 6 3 (51 . 4 6 3 2 - 1 . 478)1

EX
IN
EX

0'0.0020)
0.025-0.052(O.OO1
0 0.oo20)
o.025-o.052(O.001

Outer
tnner

Valve guide

o.o5{0.002}

4 5 . 1 6( 1 . 7 7 8 )' r
4 5 . 7 6 ( 1 . 8 0 2 )' 2
4 1 . 7 8 { 1 . 6 4 5 ') 1
41 .75 11.6441 '2
-r
46.72 (1.839)
'2
46.74 11.8401
3 9 . 3 2 ( 1 . 5 4 8 )* r
'2
39.28 (1.546)
69-0.217 7 |
5.51o-5.530 1O.21
5 . 5 3 5 - 5 . 5 5 5( 0 . 2 17 9 ' 0 . 2 18 7 )
12 . 5 5 - 13 . O 5 ( O . 4 9 4 - 0 . 5 1 4 1
4)
12.55-13.O5 (O.494-0.51

Outer
lnner

EX

1 , 3 0 O( 1 3 . 0 ,1 8 5 )
950 {9.5, 135)
200 (2.o, 28)

0.5(0.02)
5 {O.OO2-0.006}
o.o5-o.1
o . 1 5( 0 . 0 0 6 )
(o.o020-o.oo35)
o.050-0.o89

widrh

Freelength

sERvlcELlMlr

1 4 1 . 9 51 4 2 . 0 5{ 5 . 5 8 9 - 5 . 5 9 3 )

Steminstalledheight
Valve spring

IN
EX
IN

0.06 {o.oo2)

i.oou to.z'tool

5.445{0.2144)
0.08 (0.003)
0.11 (0.oo4)

2.0 10.079)
2.0 t0.079)
3 8 . 1 8 5( 1 . 5 0 3 3 )
3 7 . 8 8 5{ 1 . 4 9 1 5 }

5 . 5 5( 0 . 2 1 9 )
5.60 {O.220)
1 3 . 3 0{ O . 5 2 4 }
1 3 . 3 0( 0 . 5 2 4 )

0.o8(o.003)
o.08i0.oo3)

_]]

EngineBlock

Unit of length:mm linl

Section
MEASUREMENT

Cylinder block

-']

Warpageof deck surtace

Bore diameterF22A1 engine
H23Al, H22A1engines

Piston

Pistonring

Piston Pin

Connecting rod

Crankshaft

Eearings

Bore taper
Reboringlimit F22A1 engine
H23A1, H22A1 engines
Skirt O.D.*1 F22At engine
No Letter (A)
Letter B
H2341, H22A1 enginesNo Letter {A}
Letter B
Cfoarancein cylinder
F22A1 engine
H 2 3 4 ' 1 ,H 2 2 A 1 e n g i n e s
Groovewidth F22A1 engine
Top
{for ring}
Second
oil
H 2 3 A 1 ,H 2 2 At e n g i n e s T o p
Second
oil
Ring-to-groove
clearance
Top
Second
Ring end gap F22Al engine
Top
Second
oil
H 2 3 A 1 ,H 2 2 A 1 e n g i n e s T o p
Second
oil

o.D.
Pin-to-pistonclearance F22A1 engine
H23Al, H22A1 engines
Pin-to-rodinterlerence
Small end bore diameter
Largeend bore diameter Nominal
nd play installedon crankshaft
Srhallend bore-tolargeend bore parallelism
Main journaldiameter
No. 1 and 2 journals
No. 3 journal
No. 4 journal
No. 5 journal
Rod journaldiameter
Taper
Out-of-round
End play
Total runoul
Main bearing-to-journal
oil clearance
No.1and2 journals
_
No. 3 journal
No. 4 iournal
No. 5 journal
Rod bearing-to-journal
oil clearance
F22A1 engine
H 2 3 A 1 ,H 2 2 A t e n g i n e s

STANDARD{NEW}

SERVICELIMIT

0.07 10.003)max.
0 . 1 01 0 . 0 0 4 1
8 5 . 0 10 8 5 . 0 2 0( 3 . 3 4 6 8 , 3 . 3 4 7 2 )
8 5 . 0 71 3 . 3 4 9 )
3 . 3 4 6 53 . 3 4 6 8 )
8 5 . 0 0 0 , 8 5 . 0 1( 0
87.O'f
0-87.020\3.4256-3.4260)
87.O7t3.4281
87.OOO
87.01013.42523.42561
0.o5 (0.002)
0 . 5 0( 0 . 0 2 0 )
0 . 2 51 0 . 0 1 0 )
8 4 . 9 8 0 - 8 4 . 9 9{ 30 . 3 4 5 7 - 3 . 3 4)6 1 8 4 . 9 7 0( 3 . 3 4 5 3 )
8 4 . 9 7 08 4 . 9 8 0{ 3 . 3 4 5 33 . 3 4 5 7 ) 84.960(3.3449)
86.990-87.003
13.424A-3.42531 87.980(3.4638)
86.980-86.993
42491 87.97013.4634)
13.4244-3.
0.020-0.o40(0.ooo8,0.001
6)
0 . 0 5{ 0 . 0 0 2 )
o.007-0.030(0.0003-0.001
2)
o . 0 4{ o . 0 0 2 )
1.220-1.230 {O.04800.0484)
1 . 2 5( 0 . 0 4 9 )
1.220-1.
230 {O.0480,0.0484)
1 . 2 5( 0 . 0 4 9 )
2.405-2.420(O.1104-0.11101
2
. 8 5( 0 . 112 )
'1.2301.245{0.0484-0.0490t
1 . 2 6 5{ 0 . 0 4 9 8 )
1.230-1.245t0.0484-O.0490)
1 . 2 6 5{ 0 . 0 4 9 8 )
2.405-2.820(0.1104-0.1110)
2 . 8 5t O . 1 1 2 l
0.035-0.060(o.0014-0.0024)
0 . 1 3( 0 . o o 5 )
0.030-0.055to.oo12-o.oo22l
0 . 1 3( 0 . 0 0 5 )
0.20-o.35(0.008-0.01
4)
0.60 {0.024)
0.40-o.ss(0.o16-0.022)
0,70 {0.028)
0.20-0.70(0.0080.028)
o . 8 0( 0 . 0 3 1 )
o . 2 5 - 0 . 3 {50 . 0 1
0-o.014)
o.60 (0.024)
0.60,0.75(o.0240.o30)
0 . 9 0( 0 . 0 3 5 )
*2
0.20-o.50{0.008-0.o20)
0.60 10.024)
*3
0.20-0.70(0.oo8-0.0281
0 , 8 0( o . 0 3 1 )

(0.8659-0.866
21.994-22.OOO
1)
o.o12-0.o24
{o.0005-o.ooo9}
0.012-0.026to.0005-0.0o10)
0.o13-o.o32(o.ooo5-o.001
3l

2 1 . 9 6 8 - 2 1 . 9 8 1( 0 . 8 6 4 9 - O . 8 6 5 4 )
5 1 . 0{ 2 . O 1 )
o. 15-0.30 (0.006-0.012)
0 ax.
0 . 1 2 ( 0 . O 0 5 ) / 1 0m
4 9 . 9 7 6 - 5 0 . 0 0 0( 1 . 9 6 7 6 - 1 . 9 6 8 5 )
4 9 . 9 7 24 9 . 9 9 6 ( 1 . 9 6 7 4 , 1 . 9 6 8 3 1
4 9 . 9 8 4 - 5 0 . 0 0 8( 1 . 9 6 7 9 - 1 . 9 6 8 8 )
4 9 . 9 8 8 - 5 0 . 021 ( 1 . 9 6 8 0 - 1 . 9 6 9 0 )
4 7 . 9 7 6 4 9 . 0 0 0 { 1 . 8 8 8 81- . 8 8 9 8 )
0.005 (0.0002) max.
0.OO5(O.0002)max.
o.10,o.35 (0.oo4,0.014l
O.03 {0.OOl) max.

0.006 (0.0002)
0.006 {0.0002)
0 . 4 5{ O . 0 1 8 )
o.04 {o.002)

0.021-0.045(o.00080.0018)
0.025-0.049(0.0o10-0.001
9)
0.013-0.037(0.ooo5-o.001
5)
0.009-0.033(0.0004,0.001
3)

0.050 (0.0020)
0.055 (0.0022)
0.050 {0.0020)
0 . 0 4 0{ o . 0 0 1 6 )

0.021-0.049{o.0008-0.oo20)
0.027-0.055(o.001'l-0.oo22)

0.055 (0.oo22)
0.060 (0.o024t

0 . 4 0( o . o 1 6 )
0 . 15 ( 0 . o o 6 y 1 0 0

'1: Measuredat 2l.O mm (O.83inl on F22A1

engineand 15.0 mm (0.59 in) on H23A1. H22A1 enginesborh from bottom o{ skirt.
'2: TEIKOKUPISTONRINGmanufacturedpisron
ring.
'3: RIKENmanufacturedpiston ring.

3-5

Standardsand Service Limits

Engine Block - Section 7 (cont'd)
STANOARD
INEW}

MEASUREMENT
Balancershatl

No. 1 iournal(lront)
No. 1 journal(rear)
No. 2 journals
No. 3 iournals

Journaldiameter

Journaltaper
End play

Balancershalt
beanng

Front
Rear

Total runout
Oil clearance No. 1 journallrear)
No. 1 (front)and No 3iournal
No. 2 iournals
No. 1 journal(frontl
LO.
No. 1 journal{rear)
No.2,ournals
No. 3 iournals

LIMIT
SERVICE

42.722-42.734(1.6820'1.68241 4 2 . 7 ' l{ 1 , 6 8 9 }
{O.8243-0.8248) 20.92 Q.A24l
20.938-20.950
3A.712-3A.724 11.5241-1.52461 3 8 . 7 0( 1 . 5 2 4 )
34 (1.3670-1.3675) 3 4 . 7 1{ 1 . 3 6 7 )
34.722-34.7
0.005 (0.0002)
0. 10,0.35(O.OO4-0.O14)
o.06-0.18 to.002-0.o07)
o.osro.oot
t
0 . 0 2( o . o o 1 )
o.09{o.oo4)
o.050-0.075to.oo20-0.0030)
0 . 1 2( O . 0 0 5 )
18 (0.0026-0.0046)
0.066-0.1
0 . 1 3{ 0 . 0 0 5 )
o.o76-0i 2a {o.oo30-0.0050)
42.AOO-42.820
{1.6850-1.6958) 4 2 . 8 3( 1 . 6 8 6 )
3 { 0 . 8 2 6 8 - 0 . 8 2 7 3 ) 21.O2@.A2Al
2 1 . 0 0 0 -12. 0 1
6-1.52431 3 8 . S 3( 1 . 5 2 9 )
11.527
38.800-38.820
(1.3701-1.3709) 3 4 . 8 3( 1 . 3 7 1 )
34.8OO-34.82O

EngineLubrication- Section 8
STAI{DARD(IIEW}

MEASUREMENT
Engineoil

Capacityt (US qt, Imp qt)

F22A1 engine
H23A1 engine
H22A 1 engine

Oil p'rmp

Fleliefvalve

? IUS qt, lmp qtl/min @rpm

Displacement
lnner-toouter rotor radialclearance
Pump body-toouter rotor radialclearance
Pump body-to-rotoraxialclearance
Pressuresettingat oil termperature176oF (80oC)
at idle
kPa (kg/cm2,psi)
at 3,0OOrpm

Cooling - Section

4.9 {5.2, 4.3} for engineoverhaul

3.8 14.0,3.3) for oil change,includinglilte.
5.4 (5,7, 4.81 for engineovrhaul
4.0 (4.2, 3.5) lor oil change,includinglilter
5.9 (6.2, 5.2) for engineoverhaul
4.A $i, 4.21 tor oil chnge,includingfilter
73.5 177.7,64.7) @6,000

-o.006)
o.02-0.16 10.001
0.10,0.19 (0.004-0.007)
o.02-0.07(o.oo1-0.003)

o
STAI{OARD(NEW}

Enginecoolantcapacity
includingengine,
heater,cooling
line and reservoir
{ (US qr, lmp qt)

F22A1 engine

H23A1 engine

H22A1 engine

i;

I!
Ir
I i
,l
't

Badiatorcap
Thermostat

Waler pump

Radialorfan

o.20 (0.008)
0.21 (O.OO8)
0 . 1 2( 0 . 0 0 5 )

70 {0.7, 1O}min.
350 (3.5, 50) min.

MEASUREMENT
Radiator

SERVICE
LIMIT

o . 6( o . 6o, . 5 )

ReservoircapacitY
OpeningpressurekPa {kg/cm2,Psi)
Start to open
F u l l yo p e n
Valve lifi at Iully open

oF {oc)
'F {oC)

F22A1 engine
H23Al engine
H22A1 engine
F 2 2 A 1 ,H 2 3 A 1 e n g i n e s
E C Ts w i t c h" O N "
H22A I engine
temperature
ECT switch "OFF" tempetatureoF (oC)
Displacement
f {US qt. lmp qt)hin @rpm

M/T: 7.1 (7.5, 6.2) for overhaul

3.5 (3.7, 3.1) for coolantchange
AlTt 7.O 17.4, 6.2) tor ovorhaul
3.4 (3.6, 3.0) for coolantchange
MlTt 7.4 17.9,6.5) for overhaul
3.8 (4.0, 3.3) for coolantchange
All: 7.3 17.7, 6.4) lor overhaul
3.7 (3.9, 3.3) lor coolantchange
M/T: 7.8 (8.2, 6.9) Ior overhaul
4.2 14.4,3.7) for coolantchange
9 5 - 1 2 5 ( 0 . 9 5 - 1 . 2 5 1, 3 . 5 ' 1 7 . 8 )
169-177 {76-80)
194 (90)
8 . O 1 O . 3 1m
) in.

1 6 5 ( 1 7 4 ,1 4 5 )@ 6 , 0 0 0
1 s 9 1 1 6 8 1, 4 0 )@ 6 , 0 0 0
1 6 3 ( 1 7 2 ,1 4 3 )@ 6 , 0 0 0
194,205(90,96)
198-208(92-98)
"ON" temperature
Subtruct4'13 {l-7} tfom actual

Unil ol lengthi mm (in

Fuel and Emission- Section 1 1

MEASUREMENT
Fuel pump
Pressureregulator

Fuel tank
Engine

STANDARD(NEW)

Displacement
cc {US oz, lmp oz} in 10 seconds
Pressurewith regulatorvacuumhose dtsconnected
k P a{ k g / c m 2p, s i }
F 2 2 A 1 ,H 2 3 A 1 e n g i n e s
H22A1 engine
Capacity{ {US gal, lmp gal)
Fast idle rpm
ldle speedrpm

with headlightand
cooling fan ott

ldle CO %

Clutch

0.1 max.

MEASUREMENT

Flywheel
Clutch disc

Clutch cover

Pedal height
Stroke
Pedalplay
Disengagement
height
Clutch surlacerunout
Rivet head depth
Surface runout
Thickness
Pressureplate warpage

Manual Transmission

ro ttoor
to floor

STANDARD
INEWI
2 0 8( 8 . 1 1 )
1 3 5 - 1 4(55 . 3 1 - 5 . 7 1 )
1 . 0 - 7 . 0( 0 . O 4 - O . 2 8 )
9 4 { 3 . 7 0m
) in.
0.05 {O.002}max.
'l.3 (0.O51)min.
O.8(0.03)max.
8 . 4 - 9 . 1( O . 3 3 1 - 0 . 3 s 8 )
0 . 0 3( O . 0 0 1m1a x .

STANDARo{NEw}

Transmissionoil

Capacityt (uS qt, lmp qt)

1 . 9 1 2 . O1
, . 7 1 f o ro i l c h a n g e
2.O 12.1, 1.Al tor overhaul

Mainshaft

End play
Diameter ot ball bearing contact area
Diameterof third gear contact ara
Diameter ol ball bearing contact area
Runout

0. 10-0.16 {0.0039-0.0063)
2 7 . 9 7 7- 2 7 . 9 9 0( 1 .1 0 15 1 .10 2 0 )
3 7 . 9 8 4 - 3 8 . O O1O1 . 4 9 5 41 . 4 9 6 1)
( 1 .10 18 - 1 .1 0 2 4 )
2 7 . 9 8 7- 2 8 . O O O
0.02 (0.0008) max.

Mainshatt3rd and
fourth gears

LD.
End play
Thickness

3rd gear M2L5, M2S4

M2F4
4th gear M2L5, M2S4
M2F4

Mainshaltsth gear

t.D.
Endplay
Thickness

Countershaft

End play
Oiameterof needlebearingcontact area
Diameterof ball bearingand needlebearing
conlact area
Diameterot low gear contact area
Runout

Countershaltlsl
gear
Countershatt 2nd
gea(

t.D.
Endplay
LD.
Endplay
Thickness

SERVICE
LIMIT

o.15 (0.006)
o . 2(0.008)
1 . O(0.04)
6 . O (0.2361
o . 1 5( 0 . 0 6 )

Section 1 3
MEASUREMENT

_]]]

255-305(2.55,3.05,36-43)
230-280{2.3-2.8.33-40)
6 0 ( 1 5 . 9 ,1 3 . 2 )
1,400
700 150 (M/T:neurral)
7OO150 {A/T:E o. E position)

Section 1 2

Clutch pedal

-]']

205 (6.93, 7 .221 tnin.

sERvIcELIMIT

Adjustwith a shim.
27.94 11.1001
3 7 . 9 3( 1 . 4 9 3 )
2 7 . 9 4( 1 . 1 0 0 )
0.o5 (0.0021
4 3 . O O 9 - 4 3 . 0(215. 6 9 3 3 , 1 . 6 9 3 9 ) 4 3 . 0 8 0{ 1 . 6 9 6 1 )
0.06,0.21(0.0024,O.0083)
o . 3 0( 0 . o 1 2 )
3 2 . 4 2 - 34
27
. t l . 2 76 -1 . 2 78 l
3 2 . 3( 1 . 2 7 2 1
34.92-34.9711.37
5-1.3771
3 4 . 81 1 . 3 7 0 1
3 0 . 9 2 - 3 0 . 9171 . 2 1-71 . 2 1 9 1
3 0 . 8( 1 . 2 1 3 )
31.42-31.4711.237-1.2391
3 1 . 3{ 1 . 2 3 2 )
4 3 . 0 0 94 3 . 0 2 5{ 1 . 6 9 3 31-. 6 9 3 9 } 4 3 . 0 8 0( 1 . 6 9 6 1 )
0.06-0.21(o.0024,0.oo83)
0 . 3 0{ 0 . 0 1 2 }
1l
3 0 . 9 2 - 3 0 . 9171 . 2 1-71 . 2 9
3 0 . 8( 1 . 2 1 3 )
0.05,0.40 (0.0019-0.0157)
3 8 . O O O - 3 8 . 5O {11 . 4 9 6 '-11 . 4 9 6 7 )

o . 5 0{ o . 0 2 )

24.947-25.OOO(O.9837-0.9845)

24.94lO.982l
3 9 . 9 3{ 1 . 5 7 2 }
o.05 (o.oo2)

39. 984-40.OOO11.5742-1.574al
O.02 {O.0OO8)
max.
4 6 . 0 0 9 - 4 6 . 0 2 5{ 1 . 8 114 - 1 . 8 12 0 }
0.04,0.10 (o.002 0.oo4)

4 7. O O 9 - 4
.O
7 2 5( 1 . 8 5 0 71 . 8 5 1 4 )
o.04-0.10 {0.002-o.004)
2 8 . 9 22 a . 9 7( 1 . '3t 9 , 1 . 1 4 1 )

3 7 . 9 5( 1 . 4 9 4 )

46.08 (1.8't4)
Adiust with a washer.
47.08 ('t.854)
Adjust with a collar.
2 8 . 8( 1 . 1 3 )

(cont'd)

3-7

Standardsand Service Limits

Manual Transmission- Section 13 (cont d l
STANOARD INEW)

MEASUREMENT
Spacercollar
lCountershaft
2nd gear)

LD.
o.D.

Spacecollar
(Mainshaft4th and
5th gear)

LD.

Reverseidlergear

LD.
Gear-loreversegearshalt clearance

Syncro ring

Ring-togear clearance(ringpushedagainst
gearl
Clearance(ringpushedagainstgear)
Outer synchroring to_gear
Innersynchroring-togear
Outersynchroring-tosynchrocone
M215, M2S4
Fingerthickness
M2F4
Forkto syncrosleeveclearance

Dual cone
sYncnronng

Shift fork

Reverseshitt fork

Length

B
-Jo
a-

o.D.
Length

la

width
,uu,
r i ' w , groove
Pawl
srouvc w
A
Fork'to reverse idle gear clearance I
Groove width
Fork-to-tifth/
reverseshift
shalt clearance

{r

atA
atB
atA
atB

SERVICELIMIT

3 6 . 5 0( 1 . 4 3 7 1
36.48-36.49{1.4362-1.4366)
4 1 . 9 8 9 - 4 2 . O {010. 6 5 3-11 . 6 5 3 5 ) 4 1 . 9 4( 1 . 6 5 2 )
( 14. 14 2 5 - 11. 4 3 3 )
29.O2-29.O
-29.09(' |.144-1.145)
29.O7
3 1 . 0 0 2 - 3 1 . 20 1( 1 . 2 2 0 5 - 1 . 2 2 0 9 ) 3 1 . 0 6( 1. 2 2 3 )
. 4 9 5 6 - 1 . 4 9)6 1 3 7 . 9 4( 1 . 4 9 4 )
3 7 . 9 8 9 - 3 8 . O (O1O
56.45,56.5512.222-2.2261
(1.0248-1.0268)
26-03-26.08
20.09(o.7909|
l
20.o16-20.O43(0.7880-0.7891
0.160 to.ooo6l
0.036-0.084{o.oo14-0.00331
o.85-1.10 (0.034-0.043)

0 . 4 0{ o . o 1 6 l

0.95-1.68(0.037-0.066)
o.5-1.O(0.02-0.04)
o.5-1.O(0.02-O.041

0.6 (0.024)
o . 3( 0 . o 1 1
0 . 3( 0 . 0 1 )

6.2,6.41O.244-0.2521
7 . 4 , 7 . 6( O . 2 9 1 - 0 . 2 9 9 )
o.35-0.65t0.014-0.026)
1 3 . 0 - 1 3 .(30 . 5 1 - 0 . 5 2 )
0 . 5 - 1 . 1( 0 . 0 2 - 0 . 4 3 1
7.O5-7.2510.27a-O.25541
.301
7.4-7.7 tO.29-O
o.o5-0.3510.002-o.o14)
0.4,o.8{o.02-0.03)

Shift arm

LD.
Shift arm-to-shaftclearance
Shift tork diameterat contact area
lork shaft clearance
Shift-arm-ro-shaft

6.000 {O.6289-0.6299)
15.973-1
o.005,0.059to.ooo2-o.oo23)
2)
12.9-13.O(0.508-0.51
0.2-o.5to.ol -o.02l

Selectlever

Pin sizeof contact area

Selectleverto-shitt peice clearance
Shaft outer diameler
Shift arm cover clearance

7.9,8.O (O.311-0.3' I5)

o.o5 0.25 10.002-o.o10)
15 . 4 1 -15 . 6 8 ( 0 . 6 0 7 - 0 . 6 1 7 )
3-0.0040)
0.032-o.102 (0.OO1

Shift arm lever

o.D.
Tlansmissionhousingclearance

15.941-15.968 {0.6276-0.62871
0.027-0.139 (O.0011-O.OO55)

lntedock

Eorediameter
Shitt arm lever clearance

16.00-16.O510.630'0.632)
0.032-0.109 (0.0013-o.oo43)

1 . O( 0 . 0 3 9 )

1 . 8( 0 . 0 7 )
o.5 to.02l
1 . 0{ o . 0 4 )

o.5 (0.o20)

Unit of length mm (in)

Automatic Transmission- Section 14

MEASUREMENT
Transmission
tluid

Capacityf (US qt, lmp qt)

Hydraulic
Line Dressureat 2.OO0rom
pressure
inEorEpositron
(F22A1 engine)
kPa lkg/cm2,
psr,

4th clutch oressureat 2.000 rom

in @ position

STANDARD {NEWI

8 0 0 t 8 . 0 ,1 1 4 1
throftleIully-closed
I
8 5 0 ( 8 . 5 ,1 2 1 )
lhrottlemorethan3/16 open

7 3 O1 1 . 5 1, O 7 l
throttlemorethan3/16
open

530 (5.3, 75)

throttle fully,closed

480 (4.8, 68) throttte

lully-closed

3rd and 2nd clutch pressureat 2,000 rpm

posrtion
in E

Throttle B pressure
Hydraulic
pressure
(H23A1 engine)
kPa {kg/cm2,
pst,

750 17.5,1071
throttlemorethan3/16
open

5 0 0{ 5 . 0 , 7 1 )
throttleIullv-closed

450 (4.5, 64)

throttle fully-closed

8 5 0 ( 8 . 5 ,1 2 1 )
throttlomorethan3/16 open

750 (7.5,107)
throttle more than 3/16
open

8 0 0 - 8 5 0( 8 . 0 - 8 . 51.1 4 - 1 2 1 1

7 5 0 1 7 . 5 1, O 7 l

800-850{8.0-8.5,114-121}

750 17.5,1071

0 (0.o)
8 0 0 - 8 5t08 . 0 - 8 . 511. 4 - 1 2 1 1

Throttle fully closed

Throttle fully open
Line pressureat 2.000 rom
in E or E]position

8 5 0 ( 8 . 5 ,1 2 1 )
thro le tully-closed

4rd clutch pressureat 2.OOOrDm

in @ positron

900 (9.o, 129)

throttlemorethan 3/16 open
5 3 0( 5 . 3 , 7 5 )
throttlefully-closed

900 (9.o, 128)

throttlemorethan3/16 open
3rd and 2nd clutch pressureat 2,0OOrpm
position
in E

2nll_glutch pressrue at 2,OOOrpm

in L2l position
1st and 1st-holddutch pressure
at 2,000 rpm in Lll posirion
Throttle I pressure
Throttle fully closed
Throtttefully open
Stalf speed rpm
F22A1 engine
{Checkwith car on level ground)
H23A1 engine

850 (8.5.'121)
throttle more than 3/16 open

2nd clutch pressureat 2,OOOrpm

in Lzl position
1st and 1st-holdclutch pressure
at 2.000 rpm in LLI position

SERVICELIMIT

6.0 (6.3, 5.3) Ior overhaul

2 A 1 2 . 5 ,2 . 1 1 t o rl l u i d c h a n g e

5 O O( 5 . 0 . 7 1 )
throtlle tullv-closed

7 5 0 1 7 . 5 ,1 0 7 )

8O0(8.0. t 14l
throttlemorothan 3/16
open
48O (4.8, 68) throtte
tully-closed

800 (8.0,114)
throttle more than 3/16
open
450 {4.5, 64)
rhrottle fully-closed

900 (9.o, 128)

throttlemorethan3/16 open

8 0 0 { 8 . 0 ,1 1 4 }
throttlemorethan3/16
open

8 5 0 , 9 0 0 1 8 . 5 - 9 . O1. 2 1 - 12 8 )

800 {8.0,114}

850-900{8.5-9.0,121-128)

800 {8.0,114)

o (o,o)

850-900(8.5-9.0,121-128)
2,350-2,650
2,600-2,900

8 0 0 ( 8 . 0 .1 1 4 )

{cont'd)

3-9

Standardsand Service Limits

Automatic Transmission-

Section 14 (cont'd)

MEASUREMENT
Clutch

Valve body

Shilting device,
parking brake
and throttle
control system
Seryo body
Regulatorvalve
body
Accumulator
DOOy
Stator shalt
Transmission

ii

i :

It

f 'ji
:t

lst-hold
1st, 2nd
3rd' 4th
Clutchreturnspringfree length 1sr, 2nd, 3rd' 4th
Clutch disc thickness
Clutch plate thickness 1st, 1st'hold
2nd, F22A1 engine
H234 1 engine
3rd,4th
Mark l
Clutch end plate thickness
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mark 8
Mark I

Clutch initialclearance

Stator shah needlebearingcontact l.D

Torque converter side
Oil pump side
Oil pump gear side clearance
Drive
Oil pump gear-to-bodyclearance
Diven
Oil pump drivengear I.D.
Oil pump shatt O.D.
Reverseshitt lork finger thickness
Parkingbrakeratchet Pawl
Parkingbrakegear
Throttle cam stopper height

SERVICELIMIT

STANDARD(I{EW)
0.80-1.00{0.031-0.039}
0.65-0.85{0.026'0.033}
0.4-o.6{o.016-0.024)
33.511.32)
1.88-2.00lO.O74-O.079)
(O.077-O.O81
)
1.95-2.O5
2.55-2.65(O.089-0.093)
(0.077-0.081
|
1.95-2.O5
2.25-2.35(O.089-0.0931
-O.083)
2.05-2.10 (O.081
2.15-2.20(O.085-0.O87)
2.25-2.30(0.089-0.091)
2.35-2.40(0.093-0.094)
2.45-2.50 t0.096-0.O98)
2.55-2.60(O.100-0.102)
106)
2.65-2.70{0.104-0.
2 . 7 5 - 2 . 8 10 0 . 1 0 8 -1o1. 0 1
14)
2.85-2.90(O.112-O.1

s1.g tr.zat

Untilgroovesworn out.
Discolorataon

tV

Discoloration
Discoloration

tI
I

Discoloration

(1.0630-1.
1638)
27.OOO-27.O21
3 11.1417-1.14221
29.OOO-29.O1
0.03-0.05{o.oo1-0.oo2l
041
o.210-0.265l0.OO83-0.01
0.070-0.125 {0.OO28-O.00491
84.5525)
14.01F14.034(0.551
13.980,13.990 (0.55040.55081
5.90,6.00(o.232-0.236)

wear ol damage

0.07to.oo3)
ie", o, d"."ge
wear or damag

\
t

5 . 4 0( O . 2 1 3 1
Wearor
otherdfect

Shitt fork shaft bore l.D.

Shift lork shatt valve bore l.DSealingring contact LD.

17.O-17.1{O.669-0,673)
6l
2-O.551
r 4.00G14.010(0.551
37.OOO-37.039
{1.4567-1.4582) 3 7 . 0 4 5t 1 . 4 5 8 5 )
(1.3780-1.3789) 3 5 . 0 5( 1 . 3 7 9 9 )
35.OOO-35.025

Sealingring contact l.D.

3 {1.2598-1.2604)
32.OOG32.O1

3 2 . 0 5 0( 1 . 2 6 1 8 1

29.0OG29.013
l'l.1417-1.14221

2 9 . 0 5 0( 1 . 1 4 3 7 1

Sealingring contact l.D.

Diameter ot needle bearing contact area
On mainshaft of stator shaft
On mainshaftot 3rd gear collar
gear collar
On mainshalt oI 4th'tst
gear collar
On countershattof
On countershaft of 4th gear
On countershaftof Parkinggear
On countershaftof reversegeat
On secondaryshaft ot 1st gear
On secondary shaft ol 2nd gear
On reverseidler gear shaft
lnsidediameter
Mainshaft3rd gear
Mainshaft4th gear
Counte.shaftlst gear
Countershaft 4th gear
Countershaftreversegear
Countershaftidler gear
Secondaryshatt lst gear
Secondaryshaft 2nd gear
Reverseidlergear shaft holder

Wear or damage
22.9A4-23.@O (0.9049-O:90551
45.984-46.000(1.8104-1.8110)
11.2592'1.2598)
31.984-32.OOO
(1.6135-1.6142)
40.984-41.OOO
31.975'31.991 (' |.2589-1.2595)
39.984-40.000 11.5742-1.57 4a'l
(' 1.4165'1.41
73)
35.979-36.OOO
3 1 . 9 7 5 - 3 1 . 9 9 (11 . 2 5 8 9 - 1 . 2 5 9 5 )
3 ' t . 9 7 5 - 3 1 . 9 9(11 . 2 5 8 9 - 1 . 2 5 9 5 )
2)
13.990-14.000 {0.5508-0.551
9 12.O472"2.O4aOl
52.OOO-52.O1
(1.4963-1.4969)
38.OOs-38.021
6 {1.8504-1.8510)
47.OOO-47.O1
6 (1.4961-1.4967)
38.000-38.O1
6 (1.6535-1.6542)
42.OOO-42.O1
48.000-48.016 {1.8898'1.8904)
37.00G37.016 (1.4567'' 1.4573)
37.000,37.o16 {1.4567'1.4573}
14.41 6-1.434 (O.5676-0.5683)

Wear or damage

Unlt ot lngthi mm (in)

Automati c Transmission- Section 14

MEASUREMENT
Transmission
{cont'd)

Mainshaft3rd gear collarlengrh

Mainshaft4th gear collarlength
Countershatt1st gear collar length
Thrust washerthickness
Countershaft1st gear
Countershaft idler gear
Countershaltparkinggear length
Secondaryshaft 1st gear distancecollar
length
Secondary shaft 2nd gear thrust washer
thickness
Secondaryshaft 2nd gear splinewasher
thickness

MEASUREMEI{T
Spring

Regultor
valvespringA F22A1 engine
H23A1engine
Regulatorvalve springB
Stator reaction spring
Torqueconve er check valve spring
Reliofvalve spring
Coolerreliefvalve spring
2nd orificecontrol valve spring
Oriticecontrol valve spring
Servo control valve spring
4th exhaust valve spring
Throttlevalve B adjustingsprang
Throttlevalve B spring
1-2 shilt valve spring
2-3l3-4 shift valve spring
1st-holdaccumulatorspring
lst accumulatorspring
4th accumulatorspring
2nd accumulatorspring
3rd accumulatorspring
Lock-up shitt valve spring
Lock-uptirningvalve spring
CPC valve spring
Modulatorvalve spring
Lock-up control valve spring
3rd kick-downvalve spring
3-2 kick down valve spring

STANDARD {NEWI

SERI/ICE LIMIT

1 9 . 5 01- 9 .s 5 ( 0 . 7 6 8 - 0 . 7 7 0 )
4 7 . 5 0 - 4.75 5 l t . 8 1 0 - 1 . 8 7 2 )
2 7 . 5 0 - 2 7 . 5(51 . 0 8 3 - 1 . 0 8 5 )

Wear or damage
wear or damage
Wear or damage

1 . 4 5 - 1 . 5(00 . 0 5 7 , O . 0 5 9 )
3.45-3.55(0.136-0.140)
(0.98544.9861
25.030-25.048
l

Weor or damage
Wear or damage
Wear or damage

4.95-5.00{O.195-0.197)

Wear or damage

4.35-4.45 tO.t 7 13-O.17 521

Wear or damage

4.O2-4.05(O.158-0.159)
4.07-4.'t0 (0.160-0.161 )
4 . 12 - 4 . 15 ( 0 . 1 6 2 - 0 . 1 6 3 )
4. 17-4.20 (0.164-0.165)
4.22-4.25 tO.166-0.167)
4.27,4.30 {O.168-0.169)
4.32-4.35 lO.17 0-O.17 1|
4.37 -4.40 lO.17 2-O.173l
4.42-4.45 tO.17 4-O.17 5l

STANDARDINEWI
Wir6 Dia.

1 . 8( O . 0 7 1 )
1 . 8( 0 . 0 7 1 )
' 1 . 8( 0 . 0 7 1 )
4.5 lO.177l
1. 1 ( O . 0 4 3 )
1 . 0{ 0 . 0 3 9 )
1 . 1( 0 . 0 4 3 )
0.6 10.o24)
0.8(0.031)
1 . 0( 0 . 0 3 9 )
0.9 (0.035)
o.8 (0.o31)
1 . 4( 0 . 0 5 5 )
1 . 41 0 . 0 5 5 1
1 . 4( O . O 5 5 )
1 . 0( 0 . 0 3 9 )
o.9 (0.035)
4.0(0.157)
1 . 81 0 . 0 7 1 )
2 . 9{ 0 . 1 1 4 t
3.3{0.130)
2.6t0.102)
0.910.035)
0.8{0.031)
'l.4
{o.055)
1 . 4( 0 . 0 s 5 )
0.7 (0.028)
1. 1 ( 0 . 0 4 3 )
1 . 2t O . O 4 1 l

o.D.

Frco Longth

1 4 . 7( 0 . 5 7 9 )
86.5 (3.406)
14.1 lO.579l
88.6 (3.488)
9.6(0.378t
44.Ot1.732t
3 5 . 4( 1 . 3 9 4 )
3 0 . 3t 1 . 1 9 3 1
8 . 4 ( 0 . 3 3 I1
3 6 . 4( 1 . 4 3 3 )
8.4(0.331)
3 9 . 1( 1 . 5 3 9 1
8.4 t0.331)
4 6 . 8( 1 . 8 4 3 )
6.6 (O.2601
58.3 (2.295)
6.6 (O.2601
52.5 t2.O61l
8.1{0.319)
52.6 (2.O711
7.1(0.280'
6 0 . 8( 2 . 3 9 4 1
6.2 lo.244l
s 0 . 0{ 1 . 1 8 1 }
8.5lO.335l
4 1 . 5{ 1 . 6 3 4 )
8.5{0.335t
4 1 . 5{ 1 . 6 3 4 )
8 . 5 ( O . 3 3 5 ) 4 1 . 6( 1 . 6 3 8 1
8.6 tO.339)
4 1 . 3{ 1. 6 2 6 )
7 . 6t O . 2 9 9 t
57.Ot2.2441
2 5 . 0( 0 . 9 8 4 )
64.7 12,547)
1 6 . 3( 0 . 6 4 2 t 11 5 . 4( 4 . 5 4 3 )
22.0 {0.866)
9 0 . 1( 3 . 5 4 7 )
22.0 (0.866)
8 4 . 9( 3 . 3 4 3 )
1 7 . 5( 0 . 6 8 9 ) 1 0 4 . 51 4 . 1 1 4 )
7.6 tO.229l
73.7 t2.9021
6.6 {0.260}
5 1 . 11 2 . 0 1 2 )
9.4{0.370)
3 3 . 0( 1 . 2 9 9 )
9.4 (0.370)
3 3 . O( 1 . 2 9 9 1
6.6 (0.260)
3 8 . 01 1 . 4 9 6 )
7 . 6 1 0 . 2 9 9 ) 4 8 . 3( 1 . 9 0 2 )
7 . 1{ 0 . 2 8 0 )
4 6 . 9( ' t . 8 4 6 )

No, ot Collr
to.5

1.92
12.0
15.1
1 7. O
15.8
33.0
22.4
28.9
8.0
10.5
11.2
12.4
16.9
7.3
18.6
10.9
11 . 1
18.0
14.7
10.5
10.5
14.1

3-11

Standardsand Service Limits

Differential (Manualtransmission)

Section 1 5
STANDARD INEW}

MEASUREMENT
Final driven
geal

Backlash

Dillerontial
carriet

Pinionshaft contact area l.D.

Carrier-to-pinionclearance
Driveshatt contact aroa LD.
Carrisr-to-driveshaftclearance

Dillerential

Taperroller
bearingpreload

Right
Left

Backlash
t.D.
Piniongearto-pinion
shaftclaarance
StartingTorqueN.m {kg-cm,lb-in)

Differential (Automatic tlansmission)

(NEW}
STANDARO

SERVICELIMIT

Backlash
LO.
Pinion gear-to-pinionshaft clearance
New bearing
Starting Torque
Reusedbearing
N.m lkg.cm, lb-inl

15 (o.oo2-o.oo6t
0.05,0.
(O.7103-0.71
13)
18.042,18.066
(o.oo23-o.oo37)
0.059-o.o95

Pump
Power steering
lluid

o.15 {0.006)
Adjust with a shim

Differcntial

Gearbox

AdjLrstwith a shim

o.o85-o.142 {O.0033-0.0056)
18.000-1
8.018 t0.7087-0.7094)
9}
0 . 1 0( 0 . 0 0 4 )
o.o17-o.o47 {0.0007-0.oo1
2 8 . 0 O 5 - 2 8 . 0{215.1 0 2 6 - 1 . 1 0 3 3 )
o . 1 2( 0 . 0 0 5 )
0.025-0.066to.oo10-o.oo26)

Stsring whsel

li

0 . 1 2t o . o o s t
0.15 (0.006I

0.20(o.oo8)

2.A-4.OQA-40, 24-3sl
2.5-3.7 t25-37, 22-321

Adjust with a shim

o.12 (O.OO5)
Adjust with I thim

Section1 7
STAI{DARDINEW}

MEASUREMEl{T

0.10{o.oo4t

Escklash
Pinionshaft contact area l.D.
Caftier-to-pinionclearance
Driveshaft contact area l.D.
CarrieFto-driveahaftclearanace

Ste6ring

!i

o.20(o.o08l

Finaldrivngar
Dlflerential
carnef

Taperroller
bearim preload

0.085-o.142 {O.OO33-0.0056)
'18.000,18.018 {0.7087-0.7094}
9l
0.013-0.047(0.0005-o.oo1
28.005-28.025
{' 1.1026-1.10331
0.025-o.066(0.0010-o.oo26l
0.o55-0.091{o.oo22-o.oo36l
o.05-0.'t5 to.o02-0.0061 ' l
3)
18.042-18.066
tO.7103-0.71
0.055-o.095(0.oo22-o.0037)
1.4-2.6( 4-26, 12-231

SERVICELIMIT

Section 1 5

MEASUREMENT

Play at steering wheel circumterence

Starting load at stoering wheel circumlronce N {kg, lbsl
Engine running
When the hydraulic system to the power steerang
soeed sensor is cut ofl
Angle ot rack-guide-screwloosengd trom locked position
Pump pressure with valve closed (oil temp./spoed: 1O5"F
{4OoCl min./idle. Do not run for more than 5 sconds}.
kPa {kg/cm2, psi}
Recommenddfluid
Fluid capacity
System
Reservoir
, (US qt. lmp qt)
'lOON (1o kg, 22 lbs) betweenpulleys
Deflectionwith

o-10(o-o.4)
30 {3.O,6.61
50 (5.0,11.Ol

(70-80,995-1,138t
7.O00-8,OOO
Hondapowersteoringfluid-V
1 . 7 { 1 . 8 0 ,1 . 5 0 1
0.5 {o.53,0.441

13.5-16.5 10.53-0.65)with used belt

9.5-11,5 {0.37-0.451with new belt
350-5OO{35-50. 77-1101with used bslt
Belt tension N (kg, lbsl
(7O-9O,154-198) with new blt
7OO-9OO
Mgasured with belt tension gauge
* When using a nsw belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.
Readiust deflsction or tension to used belt values.
Power stgring
belt'

Unit of lengthmm {in

Suspension- Section18
(NEWI
STANDARO

MEASUREMEIIT
Wheel
argnment
{2WS)

alrgnment
{4WS}

Wheel bearinq

Camber

Front
Rear
Caster
Front
Total toe
Front
Rear
Front whel turning angle Inward wheel
Outward wheel
Carhber
Front
Bear
Caster
Front
Total toe
Front
Rear
Whgel turning angl
Inward whoel
Front
Rear
Outward wheel Front
Rear
Rim runout {Aluminumwhel}
Axial
Radial
Rim runout (Steel wheell
Axial
Radial
End play
Front

Rear

Brakes

o" oo' i 10
-oo 45, 1300
2040'!1.
o t 2.o(0 10.08)
t N 2 . Ol 2 . O ( 0 . 0 8t O . O 8 l
3 6 02 0 ' ! 2 "
6 . O O '! 1 "
29" 20'
6" 20'
o-0.7 10-0.03)
o-o.7 (0-0.03)
o-1.0 (o-0.041
0-1.0 (o-0.041

2.OtO.08l
1 . 5( 0 . 0 6 )
2.0 (o.08)
r.5 to.o6)

0-0.05(o.oo2)
o-0.05(0.oo2l

STANDARD(NEWI

Parkingbrake
lever

Playin strokeat 2OON (20 kg, 44lbsl levrforce

F""r braL
pedal

Pedal height (with floor mat removod)

Oisc brake

-o" 45' 1 ' to

20 40' !10
0 r 2.0 (o !0.081
rN 2.0 ! 2.0 t0.08 10.08)
360 20' 12.
290 40'

Section
MEASUREMENT

M*t"|. "y["d*

SERVICELIMIT

o" oo' r 10

M/T
Atf

Free play
Piston'to-pushrod clearance Cars without ABS
Cars with ABS
Disc thickness
Front
Rear
Disc.unout
Front
Rear
Disc parsllslism
Front ano rear
Pad thickness
ftont H22A1, H23A1 engine
H22A 1 engine
Rear

SEFVICELIMIT

To be locked when pulled

6-10 notches
1 6 5 { 6 . 5 }m i n .
1 8 6 { 7 . 3 )m i n .
1-5(1/16-13/64)

o-o.4(o-0.02)
0 - 0 . 2t o , o . 0 1 )
23.O(0.09)
1 0 . 0( 0 . 3 9 )

t r.u to.ogt
1 1 . O{ 0 . 4 3 )
9.0 {o.35)

2 1 . O( 0 . 8 3 )
8.0(0.31t
0,10 {o.004)
o.10 (o.oo4)
0.015 (0.ooo6t
1 . 6( 0 . 0 6 )
1 . 6( 0 . 0 6 )
1 . 6( 0 . 0 6 )

3-13

Standardsand Service Limits

Air Conditioning

Section 22
STANDARD{NEW)

MEASUREMENT
Condenser
Evaporator
Line or hose
Rservoir

Air conditioning Lubricant capacity

cc (ll oz)
system

Compressor

Comprgasor
belt'

Lubricant capacity cc {tl oz}

Fieldcoil resistanceEt 68oF {2OoC)0
Pulley-to-pressureplate clearance
Dollectionwith lOO N (10 kg, 22 lbs)
between pulleys

10(1/3)
30(1)
10 {r/3)
10(1/3)
1 3 0 - 1 5 0( 4 1 / 3 - 5 )
3.05-3.35
0.35-0.65(0.014-0.026)
10.0-12.0{0.39-0.471with usedbelt
4.5-7.0{0.18-O.28} with new blt

450-600 (45-60, 99-132) with used bslt

Belt tsnsion N (kg. lbs)
950'1.150 (95'115, 209-254) with new bslt
Masured with belt tension gauge
. Wh* u"ing I new belt, adjust dellection or tension to now values. Run tho engine lor 5 minutes thsn turn it o{f
REdiustdflgction or tension to used belt values

Electlical - Section 23
STAI{DARDINEW)

MEASUREMENT
lgnitioncoil

Rated voltage V
Primarywinding resistanc8t 68 oF (2OoC)o
Scoodarvwinding resistanceat 68 oF (20ocl kO

12
0.6-0.8

Spark Plug

Type
Gap

S6e Sgction 23
1 . 0 - 1 . 1{ 0 . 3 9 - 0 . 4 3 )

lgnitiontiming

At idling

Alternator belt'

BTOC
(10
kg, 22 lbs)
Defloctionwith 1OON
between pulleys
Belt tension N (kg, lbsl
Mgasured with belt tnsion gauge

MEASUREMENT
Output 13.5 V at hot A
Alternator
(NIPPONDENSOCoil rsistance (rotor) O
SIip ring O.D.
Erush lngth
g {oz)
Brush spring tnsion
Tvpo
motor
Starter
(MITSUBA
Mica depth
Commutator runout
1.4 kW)
CommutatorO,O.
Brush length
N (kg, lbsl
Brush spring t6naion (new)
Starter motor
(MITSUBA
1.6 kW)

il

ii
:1
!I
I

Tvpe
Mic8 depth
Commutator runout
CommutatorO.D.
Brush length
Brushspringtensionlnw)

N lkg, lbs)

1 5 ol 2 o { R e d )STDC
10.5-12.5 (0.42-0.51) with used belt
8.O-10.0 {0.32-O.4Olwith new blt
3OO-45O{30-45, 66-99} with usod belt
550-750 {55-75, 121-165) with new belt

SERVICELIMIT
STANDARD{NEW)
80/90
2 . 7- 3 . 1
t r.e to.sot
1 4 . 2 - 1 4 .{40 . 5 6 - 0 . 5 7 }
1 . 5t 0 . 0 6 )
1 0 . 5( O . 4 1 )
300-360t10.6-12.7)
magnt
Spargearreduction,Permanent
0.15 t0.oo6)
0.4-0.5(0.016-0.o20)
o.o5(0.oo2)
o-0.02{o-0.ooo8)
2 7 . 5( 1 . 0 8 3 )
2 8 . 0 - 2 8 . (11 . 1 0 2 , 1 . 1 0 6 )
10.0(0.39)
15.8-16.2(0.62-O.64t
1 6 . 0 , 1 8 . (01 . 6 0 - 1 . 8 0 ,
3.53-3.93)
magnet
Spargearreduction,Permanent
0 . 1 5( 0 . 0 0 6 )
0.4-0.5(o.0'16-0.o20l
0.o5 t0.o02)
o-o.02{o-o.ooo8)
2 7 . 5{ 1 . 0 8 3 )
2 8 . 0 - 2 8 . (11 . 1 0 2 - 1 . 1 0 6 )
(0.62-0.64)
10.0 (0.39)
15 . 8 - 1 6 . 2
1 6 . 0 - 1 8 .(O1 . 6 0 - 1 . 8 0 ,
3.53-3.93)

* When usanga new belt, adjust detlection or tonsion to new valuos. Run the engine lor 5 minutes then turn it ofl.
Redjust detloction or tension to used bolt and values.

Design Specifications
Overall Length
Ov.all Width
OverallHeight
Wheelbase
Track F/R
GroundClearance

Type

4,440mm
1 , 7 6 5m m
1 , 2 9 0m m

2 . 5 5 0m m

H23A1 engine
H224l engine
CylinderA.rangement
Bore and
F22A1 engine
Stroke
H23A1 engine
H22A 1 enigne
OisplacementF22A1 engine
H23A1 ngine
H22A'l engine
Compression F22A1 engine
Ratio
H23A1 engine
H22At engine
Valve Train F22A1 engine
H2341 engine
H22A'l engine
Lubrication System
Ful Required F22A1 engine

l
l

H23A1, H22A1 engines

Makes/Type
Normal Output
NominalVoltage
Hour Rating
Directionof Rotation

M/T
TRANSMISSION

i
|

t O O . qi n

6 0 . 0 / 5 9 . 6j n
5.7 in

Water-cooled, 4,srroke SOHC

gasolineengjne
Water-cooled, 4-stroke DOHC
gasolineengine
Water-cooled, 4-stroke DOHC
VTECgasolineengine
Inline4-cyljnder,transverse
8 5 . 0 x 9 5 . Om m
3 . 3 5x 3 . 7 4 i n
8 7 . 0 x 9 5 . Om m
3 . 4 2x 3 . 7 4 i n
8 7 . Ox 9 0 . 7 m m
3.43 x 3 57 in
2 , 15 6 c m 3 ( c c )
132cu-in
2,259 cm3 {cc)
138 cu-in
2,157cm3 (cc)
132 cu-in
8.8 : 1
9.8:1
1 0 . 0: 1
Belt driven,SOHC4-vatveper cytinder
Belt driven.DOHC4-valveper cytinder
Belt drive,DOHC4,valveper cylinderVTEC
Forcedand wet sump, trochoidpump
UNLEADEDgradegasolinewith 86 pump
OctaneNumberor higher
PremiumUNLEADEDgradogasolinewith
91 Pump OctaneNumberor
MITSUBA/Spurgear reduction,
permanentmagnet
1.4 kW, 1.6 kW
12V
30 seconds
Counterclockwise
as viewedfrom gearend

3 . 7k s

MIT

GearRatio

1 , 5 2 5 / 1 , 5 1 5m m
145 mm

F22A1 engine

1 7 4 . 8j n
69.5 in
5 O . 8i n

I
I
|

8 . 2l b s

Singleplatesdry, diaphragmspring
Torque converter
203 cm2
31
|
Synchronized s-speed forward, 1 reverse
Electronically
controlled
-speed automatic, 1 reverse
Direct 1 : 1

lsr
2nd
3rd
4th
5th
Reverse

4.062

4.266

4.266

(cont'd)

3-15

Design Specifications
(cont'd)

TRANSMISSION
{conl'dl

Engine tYPe
lst
2nd
3rd
4th
5rh
Reverse
Gear tYPe
Gear ratio

Automatic
GearRatio

Final Rsduction
AIR CONDITIONING

Cooling Capacity
Conditions:
compressor Speed
Outsid Air Temparature
Outeide Air HumidilY
CondnserAir TemPerature
CondenserAir VelocitY
Blower Capacity
Typg/Mkes
Compressor
No. oI cylinder
CaPacitY
Max. Spsd
Lubric8nt CaPacitY
Condenser
Evaporator
Elower

TyPe
Type
Type
Motor Input
Speod Control
Max. CaPacity

Temp. Control
Comp, Clutch
Rotrigerant

Type
Power ConsumPtion
Type
Ouantity

STEERNG
SYSTEM

Type
Ovorgll Rtio
Turns, Lock-to-Lock
Steedng Whosl Di6.

SUSPENSION

Type. Front
Type, Rsar
Shock Absorber, Front and Rar

t,

l.,i

ENGLISTI

METRIC

ITEM

NOTES

H23A1

F2241

2.705

2.705
1.442
1.028
o.701

1.057
0.750

2.O47

2.O47

Singlhelicalgear
4.428
4.285
|
'14,682BTU/h
3,7O0Kcauh

1 , 8 0 ( rpm

81 0F

50 %

95.F
35 0C
8.2ltlsec
2.5 mlsec
16,247 ctt-ftlh
460 m3/h
ScrooltyP/SANDEN

5.23 cu-in/rev
85.7 cc/rev
|
10,000 rpm
4 1/3 tl oz
130 cc
I
Corrugatodlin type
Corrugated lin type
Sirocco lan
220 Wl12 V
4-spsod
16.247 cu-ft/h
460 m3/h
I
Air-mix type
Dry, single plat, poly-V'belt drive
42 W max.l12 V
F-l34a

osO-8os

t8.a-9.ao
oz

Power as8isted, rack and Pinion

2 W S : 1 5 . 8 6 , 4 W S :1 5 . 1
2wS: 2.91, 4WSt 2'77
15.0 in
380 mm
I
wishbone,
lndependent double
coil spring with stabilizer
lndeDendentdouble wishbone,
coil spring with stabilizer
Tolescopic, hydraulic nitrogen gas-filled

sP-10

Camber

Front
Rear

Caster
Front
Rear

BRAKESYSTEM

Type, Front
llear

Pad and LiningSurfaceArea: Front

Rear
ParkingErakeKind and Type
Size
'1:S
ELECTRICAL

Battery
Starter
Allernator
FusesIn UndeFdashFuse/Relay
Box
In UndeFhoodFuse/Flelay
Box

FrontTurn SignalLights
Front ParkingLights
RearTurn SignalLights
Brake/Taillights
High Mount BrakeLight
Side Marker Lights Front
Rear
Back{p Lights
LicensePlateLights
InteriorLights
Trunk Lights
GaugeLights
IndicatorLighrs
WarningLights
llluminationand Pilot Lights

Omm

oin

In 2.O mm

In 0.08 in
I
Power-assistedselt,adjusting
ventilated disc
Power-assistodselt-adjustingsotid disc
5 8 . O c m 2x 2
8.99sq-inx2
I
27.Ocmzx2
4 . 1 9 s q - i n x2
|
Mechanical actuating, rear two whsel
brakes

1 8 5 / 7 0R 1 4 8 7 H . 1
2 0 5 / 5 5R 1 5 8 7 V * 2
f125l7o O l5 {Sparetirel *r
T135/80D 15 {Sparerire)*2
12 V-55AH/5HR
1 2 V - 1 . 4k W , 1 2 V - . t . 6k W
1 2 V - 9 0A , 8 0 A
7 . 5 A . ' 1 0A , 1 5 A , 2 0 A , 3 0 A
7 . 5A , 1 0 A , 1 5 A , 2 0 A , 4 0 A ,
50 A. 60 A, 100 A
1 2 V - 6 5W
1 2 V - 5 5W
1 2 V - 3 2C P
1 2 V _ 5W
1 2 V - 4 5C P
12 V-43t3CP
12 V -21 CP
1 2 V - 3C P
'12v-3 cP
1 2 V - 3 2W
1 2 V - 8W
1 2V , 8W
1 2 V - 3 . 4W
1 2 V - 3 . 0W , 1 . 4W
'l2v-1.12W
,
1 . 4W , 3 . 0 W , 3 . 2 W
12V-1.4
W
1 2 V - 1 . 4W , 1 . 1 2W , 0 . 8 4W , L E O
1 2 V - 1 . 4W

3-17

Body Specifications
Unit: mm (in)

lr;i

Maintenance
Lubrication
Points
Maintenance
Schedule

..........4-z
... 4-4

{lI

LubricationPoints
Indexand variouswolk proFor detailsof lubricationpoints and types of lubricantsto be applied,referto the lllustrated
cedures(suchasAssemb|y/Reassemb|Y,RepIacement,overhau|,Insta||ation,etc.)containedineachsection.

"Energy ConservingII"
API ServiceGrade:Use
SG gradeoil.
F22A1, H23A1 engine:5 W-30 preferred.
H22A1 engine:1O W-30 Preferred.
SAE Viscosity:See chart below.
Transmission

Manual

Automatic

API ServiceGrade:SF or SG
SAE viscosity:
10W-30or1OW-40
HondaPremiumFormulaAulomaticTransmission
Fluidor an equivalentDEXRON@II Automatic
transmissionfluid
Brakefluid DOT3 or DOT4
Brakfluid DOT3 or DOT4
SteeringgreaseP/N 08733 - BOTOt

Shift lever pivots (Manualtransmission)

Releasefork {Manualtransmission)
Steeringboots
Steeringball joints
Selectlever (Automatictransmission)
Pedallinkage
lntermediateshaft
Brakemaster cylinderPushrod
Trunk hingesand latch
Door hingesupper/lowerand latches
Door openingdetents
Fuelfill lid
Enginehood hingesand enginehood latch
Clutch mastercYlinderPushrod
Throttle cable end
Pistonseal. Dust seal,
Caliperpin, Piston
cable ends
select
and
Shift

Caliper

Hondapower steeringfluid-V
Comoressoroil SPlO P/N 38899-P13-OO3
Selectthe oil for your car accordingto this chart:

F22A1,H23A1ongine
Amblent Temoeraturo

'l
!

An oil with a viscosityoJ 5 W-30 is preferredfor improvedtuel economyand year-roundprotectionin the

car. You may use a 1O W-30 oil il the climatein
your area is limitedto the temperaturerange snown
on the chart.

4-2

An oil with a viscosityof 1O W-30 is preferred

for improved{uel economYand year-roundprotection in the car. You may use a 5 W-30 oil if the
climatein your area is within the temperature
range shown on the chart

4-3

MaintenanceSchedule

3.e
e9

.g

E.9

P E
B E

z 6
dcicicidd
L l l

o o'-

+r+rE

;z ;z "- 1x

'=u

1!

a a96

stststdstst6

Oo
o ;

t :

l l l i
i ; 9
t_c

;!.

6:-:---

== *2
22-?=

.l c? ': ': ': ''l 6

q 6

; p
P.9

o . 9

3 *
E '

- E ;

];;.

.!:

F-..j.". B '
gci ai.+

:td:
P ; 4 P1
,i.ib9-

= c ; 6

t P . :E i; Eq -o
::r^H

E,i!,iE,i=i ; d

BETH-I
N N A : ;

u
J ; Ee
z 2 z z o

is.sd
e c . r c .;Y =s
.eE

o >

i i3FF
1 e : - -

3-E<3S

ie'Nll

'

ll

l.'i

;g

.::

< 9

a 9
Q !
c 6

6 5
9 o
b 6

;
'd

= :
i 6

6 3
z
.E

-:r

;:3

-x

^ F

!E! E! iE! ; !J: E E :

E<
F:

b i

6 E

,6 9,.oi o. )rdc, 99o o; ; :

I:-;-;-;E;-;i
; E 3 3 3 e F3 3 ;
; !r'.on.goo
-:

9 +
a E

aj + { 6 ci ai ;

H5**-*-E:*i

S:|t)6o:nF
(J:('l'!r<ooo

-o

9 o

-Ee
95

*iS
. , ii k

'st 5B
6 . >
q 3 5

: -5
d E
i S ee P P

i - ' . sb i.i 6, F
; P :

6P ; * g t
aisiis!
a
E
-g

E
I

':

l
i

4-5

MaintenanceSchedule(cont'd)
P
P " ;
E * 6 - b
g 6 : ( l .

t
(,)
3
o E

i i
o 6
6 i
c'6

<

s
*
E
E

:R E
Ee6- ts
EE! E
l3! s

\ i o

E e i EE
: E E:

t ;

>

9 E
- g

' 6 C

8ri n;;
;3 5

BE

'E

o
a

tEii:5

<

z
oo

;-E
5 o :

r;E;i
i

li

ai

5 . e3

; i ;

!;,i.8 !

EE R # ; : T

-;;;Eg;E

EE::i;EF
9i:!;srs

i$:EsiEi
.i;"qHE!.i

;
L 6

.9

li

;;igxB:E
;oEdds-:s
t t t I
; ,

a
P
E

ir

.4
8

ri
.

>

b
t

st : 6E E !E- ; !; E=

,e!EE tEE '9!ccE E

E
!*
r
I
!

.9

4-6

ciiFi:!i;
ri

3E8

<,iddci,ii,!

Engine
Constructionand Function
. . . . . . . . . .5 - 1
lH22Al engine)
E n g i n eR e m o v a l / l n s t a l l a t i.o. .n. . . . . . . . . . .5. - 1 7
C y l i n d eH
r e a d / V a l vTer a i n . . . . . . . . . . . . . . . .6. - 1
E n g i nB
e f o c k. . . . . . . .
.........7-1
E n g i n eL u b r i c a t i o n
. . . . . . . . .8 - 1
IntakeManifold/Exhaust
System ........ 9-1
Cooling
. . . . . .1 0 - 1

Construction
and Function
lH22A1 enginel
Outline
Description
................5-2
VTEC
Outline
.... 5-4
Mechanism
................5-6
Control
System
...........5-7
GylinderHead
Outline
.... 5-9
Camshafts
. . . . . . . . . . . . . .5. .-.1 0
ValvesandValveSprings...............
5-11
BeltTensioner
Outfine
....5-12
A u t o - T e n s i o n. .e. r. . . . . . . . . . . . . . . . . . . .5. .-1
. .3. .
C y l i n d e r B l o c. .k. . . . . .
......5
. -14
OilFlow
......5-15

Outline
Description
cooledand
ThenewH22A1 engineis an in-line4-cylinderDoHc designdisplacing2,157 cm31131.6 cu in) lt is water
and usesa
premium
unleaded
fuel
to
use
is
specified
lt
chamber.
pent-root
combustion
plug
type
with
a
center
equipped
Variable
Valve
Honda
called
pGM-Fl(SequentialMultipon FuelIniection)system.This engineincorporatesa mechanism
(VTEC)
System.
Timing and Valve Lift ElectronicControl
The enginealsoinThis ststem allowsthe timing and litt oJthe intakeand exhaustvalvesto be changedsimultaneously.
chamber.
the
intake
volume
of
varies
the
that
system
intake
manitold
cludesa electronically-controlled

I
il

L.

5-2

nd

tn-

ll!i)r

Specificstions

Type

Water cooled4-stroke,In-line4-cylindergasolineengine

Oisplacement

2 , 1 5 7 c m 3( 1 3 1 . 6 c u - i n )

Eore x Stroke

8 7 . Ox 9 0 . 7 m m t 3 . 4 3 x 3 . 5 7 i n l

CompressionRatio

1O.O:1

Cam, Valve Mechanism

Dual over-headcamshaft,VTEC

Valve Train

FuelSupply System

SequentialMultipon Fuel Injection{SFl)

Main Features:
a The cylinderhead ls made of aluminumalloy,a centerplug type, pentroof-shaped
combustionchamberis used, and
the 4-valvesystem uses 2 intakevalves and 2 exhaustvalves,
The camshaftsand the valvetrain are drivenwith the timing belt. andthe two balancershaftsare drivenby the timing
balancerbelt. Belt tension is automaticallyadjusted.
a The cylinderblock is made of aluminumalloy using fiber reinforcedmetal (FRM)sleves.
a The crankshaftis made by torging,the mainshsftis suppo.tedat tive points and has eight balancerweights.
a The balancershafts employ a gear-typereve,semechanismto reducesecondaryenginevibration.
a The intake manifoldis made ot aluminumalloy, and the heat riseris usedfor hatingthe airlfuelmixture.
a The exhaustmanifoldis made of stainlesssteel.
a The electronicfuel injectionsystem is of a sequentialmaltiport fuel injectiontype and injects fuel into all four
cylinders,the throttle body is of a one-barrelside-drafitype.
a The ignitionsystem is a fully-transistorized,
contactlesstype. The spark advanceis electronic.
a The air cleaneris equippedwith a resonator.
a The radiatoris of a corrugatedtype. and th coolingtan is elctricallypowered.

5-3

VTEC
Outline

T h e e n g i n e i s e q u i p p e d w i t h m u | t . p | e c a m I o b e s p e r c y | i n d e r , p r o v i d i n g o n e v a | v e t i m i n g a n d v a | vand
eIiftpro'i|eatIowspe
other is controlledelectronically' is selecied
and a differentproiileat haghspeed.switch-overfrom one profileto the
by monitoringcurrent enginespeed and load.

CAMSHAFT
CAM LOBESFOR LOW RPM
CAM LOBESFOR HIGH RPM
PRIMARYBOCKERARM
MID ROCKERARM
SECONDARYROCKERARM
HYDRAULICPISTON(A}
HYORAULICPISTOI{ {AI
STOPPERPISTON
LOST MOTION ASSEMBLY
EXHAUST VALVE
INTAKE VALVE

lr
r'l

il

5-4

rd
!d

In gnoral,it would be idealif the high rpm performanceof a racingengineand the low rpm pertormanceot a standard
passengercar enginecould be combinedin a singleengine.This would resultin a maximumperformancenginewith a
wid6 power band. Two of the major differencesbetweenracingenginesand standardenginesare the timing ot the intake/6xhaustvalvesand the degreeof valve lift. Racingengineshsve longerintake/exhaust
timing and a highervalvelift
than standardengines,The Honda VariableValve Timing and Valve Lift ElectronicControlSystemtakes this into account, Whn valve actuationis set for low rpm timing and lift, low rpm torque is betterthan in a standardengine.Whon
valve actuationis then switchedlor high rpm timing and lift, output improvesto the levelgiven by a racingengine.Until
now. tew variablevalvetiming systemshave beencommercialized,
In thosethat have,only the time that both vatves8re
open (intake/exhaust
overlap)could be changed.Honda'ssystem is the first in the world in which both the valvetiming
and the degreeof valve litt can be changedas needed,makingit the most advancedvalve train mechanismavailable.

RacingEngine

Valve Timing
(exhsust/intake)
Valve Lift

VTEC Engine

StandardEngine

Erh.u.t

lntrk

Erhrurt

lntlk

Exhlult

Intrko

Max. Power
Low rpm Torque
ldling stability
'TDC = Top Dead Center
*BDC = Bottom Dead Center
O = Ootimum Characteristic
The engineis equippedwith two valve timing and valve lift settingswhich changeaccordingto drivingconditions.

RPM switch ovgr

pornt

5-5

VTEC
Mechanism
At Low rpm:
Asshown,theprimaryandsecondaryrockelarmsalenotconnectedtothemidrockerarmbutaledrivenseparSte|yby
cam|obesAandBatdifferenttimrngandIift.A|thoughthemidrockera.misfo||owingthecentercam|obewiththe|ostvalvesin the low rpm range'
motion assembly,it has no effect on the openingand closingof the
At Low rpm:

CAM PROFILESFOR
LOW RPM

CAMSHAFT

*A and B cam lobes

ddve the rocker arma
sepsrot6lY
RETURNSPftNG

HYDRAULIC
PISTON(AI

PISTON
STOPPER

HYDRAULIC
PISTONIBI

PRIMARY
ROCKERARM

MID
ROCKERARM

SECONDARY
ROCKEBARM

At High rpm:
Whendrivingathighrpm,plstonlA)movesinthedirectionshownbYthearrowinthefigureba|ow.Asaresu|t,th
primary.secondary,andmidrockerarmsareIinkedby2hydrau|icpistons(|ikeaskewerlandthe3rockerarmsmoveas
and closingthe valvesat the valvetiming
a singleunit. In this state. a the rockerarmsare drivenby cam lobec, opening
and valve lift set fot high operation.
At High Dm:

CAM PNOFILEFOR
HIGHRPII

*The rockr arms ere linked

via the hydraulic Piston.
Cam lobe C drives the rocker
arms.

+
;

l,
il

STOPPR
PISTON
HYDRAULIC
PISTON (AI

5-6

HYDNAULIC
PISTON(B)

ControlSystem
The controlsystemfor this mechanism,as shown below, constantlymonitorsthe changesin enginestatussuch as load,
rpm and vehiclespeed.this intormationis transmittedto the EngineControlModule {ECM).
Valv Timing ChEngeConditions
Englne Speed: 4,9OO nm or higher
Vohicle Spood: 19 mph (3O km/hl 01 tastel
Engino Coolant Temperature: lrtooF {6OoC) or higher

ControlSystem

VTEC PRESSURESWITCH

VTECSOLENOIDVALVE

F.oft

OILPUMP +

Et{Gtt{E
CONTROL
MODULE
{ECM)

5-7

ControlSystem(cont'd)
I

Lost Motlon Machanbm

at low spsds' At low spoeds' th lost motion
The mid rockr arm is always driven by the high-spesd cam lobe' even
mechanismkeepsthemidrockerarmincontactwiththehigh.speedcam|obe'Athighsp6ds,the|ostmotion
mechanismscts as part of the valve spring load'

CAM PfiOFILE
SPRII{G
SPRIIIGA

RETAINEN

GUIDEHOLDER

LOSTMOTIONASSEMELY

Hydraulic Prg$ure Contlol Machanism

VTEC solenoidvalve/VTECpressuteswitch
the oil passagato the rocketarm at low speed'
The VTECsolenoid,ralve,in responseto a signalfrom the ECM,closes
a.ms ope]8t6 indopendent|y.At high sp66d, tho
This cuts oiI pressureto the hydrau|ic pistons in the rocker arms so the
EcMopsnstheVTEcso|enoidva|ve.Theincreasedoi|pressurecausesthehydrau|icpistonsto|ockthep'imary,sgcon
dary, and mid tocker arms together.
TheVTECpressureswitchsgrvesasasensortodetermineiftheswitch-overhastakenp|aceinlsponsetothEcM
signsl.

I's
t. l:

5-8

CylinderHead
Outline
The one-piececylinderhead is made of aluminumalloy to reducethe weight while increasingefficiency
The combustionchamberis a compactpent roof shape,centerplugtype. The cylinderheadusesa DOHC4-valvesystem
with 2 intakevalvesand 2 exhaustvalvesarrangedfor cross flow. Combustionis stabledue to the optimizationof the
ignitiontiming, compressionratio and valve timing.

EXHAUST
CAMSHAFT

INTAKE
CAMSXAFT

EXHAUST
ROCKERARM
II{TAKE
ROCKERARM
EXHAUSTPORT

INTAKE PORT

INTAKEVALVE
EXHAUSTVALVE

5-9

GylinderHead
Camshafts

T h e c a m s h a f t i s a c a s t p i e c e . B y i m p r o v i n g d i m e n s i o n a | a c c u r a c y , i t b e c a m e p o s s i b | e t o a c h i e v e mforcinimumspacg
on five bearingiournalswith
tween cams,thus a owing a more compactcylinderhead.Eachcamshaftis supported
intakecyctesrequireI totaloJ 24 cam
ed lubrication.on the left end of eachcamshaftis a drivenpulley.The exhaustand
lobesto oDenand closethe valves

A: PRIMARY
B: MID
C: SECONOARY

EXHAUST

CAMSHAFTJOURNALS

II{TAKE

CAMSHAFTJOURNALS

High-speod valve timing

Low-speedvalve timing

<F i Intok6 valva opon

: Exhau3t vslvg opon
-

INTAKEA

INTAKE B

XHAUSTB

INTAKE C

TDC: Top dead center

BDC: Bottomdead center

Valves and Valve Springs

t,c
lm

The valves are openedand closedby rocke. arms driven by the camshatt.
Light weight and large diametervalves made ot a high strength metal with small diameterstems are used. The air
resistanceis decreasedby the slenderstems and the intakeefticiencyis inc.easedby inlet ports that match with laroe
diametervalves,
Valve specitications
U n i t :m m ( i n )
VALVE

INTAKE

EXHAUST

HEAD DIAMETER

3 5 . O( 1 . 3 8 )

3 0 . o{ 1 . 1 8 )

STEMDIAMETER

5.5 tO.22l
r 0 6 . 7 5( 4 . 2 0 3 )

ITEM

OVERALLLENGTH
VALVE LIFT

Fr
|

Secondary:8.O (O.31)
Mid:
11 . 5 ( O . 4 5 ) *
Primary: 6.5 (O.26)

5.5 lO.22l

' 1 0 6 . 9(54 . 2 r
1)
S e c o n d a r y : 7 . 5( O . 3 O )
Mid:
1 O . 5( O . 4 1 1 *
P r i m a r y : 6 . O{ 0 . 2 4 )
* Indicateshigh-speed
valves

oVERALLLENGTH

,/|l

ffir

HEAD
DIAMETER

The valve spring wire uses a moditiedcross-sectionto valve lift in a limitedsoace.

EGG SHAPE

LEMON SHAPE

5-11

Belt Tensioner
Outline

ThetensionersforthebaIancersha'tdrivebe|tandthetimingbe|tarearrangedinpara||e|onasing|eaxisforamolecom
pact configuration,This tensionerallows easv belt maintenance'

TIMING BELT

WATER PUMP
PULLEY

TENSIOI{ERSPRINGfol
TIMING BALAIIICERBELT

AUTO.
for TIMING BELT

MAINTENANCEBOLT

TIMI G AELT
AOJUSTER

BALANCERBELT
TENSIONER

5-12

- Auto-tensioner
The auto-tensioner
usesa torsionspringto regulatethe timing belt tension.The maincomponentsare the torsionsp.ing,
. malescrew and a temalerod. The assemblyis filledwith oil and sealed.The springturnsthe malescrew. which pushes
lhe lemalerod out againstthe belt. The designis such that the rod cannot be pushedback into the housingby belt tens'on. To pull the female rod back into the assembly.the male screw must be turned with a screwdriver.

SCREWIMALEI

Machanbm:
8lt Ro6ctlon Fo.ce

male screw is
o The
rotated by the
lorsron spflng.

ri The lemale rod is

pushedout as lhe
rod rotates,

O The rod stops when the force

oI the torsion spring and
the timing belt equalize.

5-13

CylinderBlock
madeoJ FRM,a composite
The cylinderblock is a closeddeck designmadeof aluminumalloy . The cylindersleevesare
balancer
shaftsand the deep
for
the
block
cylinder
in
the
The
bores
iiber.
tiber
and
carbon
alumina
materialof aluminum,
skirt designimprovethe rigidityof the block.

Cylinder spocitications

Bore Pitch

8 7 . Ox 9 0 . 7 m m ( 3 . 4 3 x 3 . 5 7 i n )
9 4 . Om m ( 3 . 7 Oi n )

Block Height

2 1 9 . 5 2( 8 . 6 4 3i n )

Skirt Depth

5 0 . Om m ( 1. 9 7 i n )
2 . 1 5 7 c m 3( 1 3 1. 6 c u - i n )

Bore x Stroke

Displacement

7.0 mm {0.28 inl

-.-----\L----J-JJ
\7-J\^/\-

BALA'{CERSI{AFT
BORES

,.\

/zr

O O O

.\

iEff

Q O

Oil Flow
Lubricationof the c.ankshattand connectingrod bearingsis done by oil pumpedthroughthe main bearingcaps ano Inro
passagesin the crankshalt.The pistonsand cylinderwalls are lubricatedby oil spray nozzlesmountedon the cvlinder
block.

INTAKECAMSHAFT

OIL CONTROL
ORIFICE
VTEC SOLENOID
VALVE
CAMSHAFT HOLDER
PIPEOIL

VTEC
PRESSUBE

swtTcH

IHAUST CAMSHAFT
.XXJRI{AL

ENGINEOIL COOLER

ENGINEOIL FILTER

ENGINECOOI"ANT

FRONTBALANCER
ENGINEOIL PRESSURESWITCH

OIL JET
NOZZLE

REAR BALANCER

(cont'd)

5-15

Oil Flow
(cont'd)
oi|pumpedtothecy|inderheadservestwopurposes;to|ub'icatethecomponentsandtooperatetheVTEC.oi|is
pumpedintothecamshaftho|dertoIub'icatethejourna|s,anditsprayslfomorificesintheho|derto|ubricatetherocker
this valveopensand oil is pumpedat high
arms and valves.oil is alsosuppliedto the VTECsolenoidvalve.At high RPM.
Dressurethrough the rockerarm shatts to operatethe VTEC'

VTEC SOLEIIOIDVALVE

OIL CONTROL
ORIFICE
ENGINEOIL FILTER
ENGINEOIL COOLER
OIL JET
NOZZLE

EngineRemoval/lnstallation

EngineRemoval/lnstallation
@
frla-i6iwe

iacks and saletY stands 8re placod ploperly and hoist brackots are attachod to the corr'ct
positions on th 6ngin6.
a Mako suls tho car will not roll ofl stands 6nd lall
whlle you are working undal it.
CAUTION:
a Use tendl covers to svoid damaging paintd
surtacas.
a Unspocified itoma alo common
a Unplug th wiring connoctolE carstullY while holding
the connoctor portion to avoid damago.
a Mark all wiring and hosas to avoid miaconnection.
Also. bo 3u1that thoy do not contact othar witing ol
hosos or into.lernco with othar parts.

5. Loosenthe drain plug on the radaator.

6. Drainthe transmissionoil/lluid. Reinstallthe drain
plug using a new washer.
7 . Orainthe engineoil. Reinstallthe drainplug usinga
new wasnef.
CAUTION: Do not ovsrtighlan tho dlain plug'
8. Lower the hoist.
9. Removethe air cleanerhousingand intakeair duct'
6 x 1.O ]||m
10 .m {1.0 ks-m, 8 lb-ftl

NOTE: The radiomay hsve a codedthett protectioncircuit. Be sureto get the customer'scode numbrbelore
- Disconnecting the battery.
- Romovingthe No. 43 (10 A) Juse(ln the under-hood
tuse/relavboxl.
- Removingthe radio.
Atter service,reconnectpower to the radio and turn at
on.
"CODE" is displayed. enter the
When the word
customer's5-digit code to restoreradio operation.
1. Securethe hood as far open as possible.
2. Disconnectthe batterynegativeterminaltirst, then
the positivetetminal.
AIRCLEA'{EFHOUSI'{G
3. Removethe radiatorcap
use care vuhonremoving tho radiator
!@
cap lo avoid scalding by hot coolant ol atoam.
4. Raisethe hoist to full height.
Remove the Jront wheels and the engine splssh
shield.

1O. Removethe pulsed secondaryair iniectionIPAIR)

vacuum tank and bracket.
PAIR
VACUUMTANK

6x1.Omm
lO N.m 11.0kg-m,

I rb-trl

6 x 1 . Om m
'10t{.m (1.O kg-m,

a tb-ft|

BRACKET

6 x 1.0 mm
1O N.ln (1.0 kg-m,
7 lb-ftl

5-18

I
Front

11. Remove the battery, battery base, battery cable

and starter cable.
MANUALTRANSMISSION
tM/TI:
8 r 1,25rnm
22 tt.m 12.2kg-m,
16 tb-ft)

CAUTION:
a Bfore disconnocting any fu6l line, r6livs the
tuel prssur os dosc.ibod above.
a Place I shop towol ovel the tultilter to prevent
prossulizod tuol trom sprsying ovor tho ongine.
13. Removethe fuel feed hose from the fuel rail.
WASHER

STARTER
CABLE
AUTOMATIC
TRANSMISSION
{A/r}:
NOTE: When installingthe starter cable clamp.
make sure the tab is in the hole in the bracket,

14. Removethe injectorresistorconnectoron th8 left

side of enginecompartment.
6x1.0mm
10 N.m {1.0 kg-m,

INJECTOR
RESISTOR

INJECTOR

0 r 1.0 rnm
1 0 N . m( 1 . 0k g - m ,
7 tb-ftl

1 2 . Relievefuel pressureby slowly looseningthe service bolt on the fuel rail aboutone turn (seesection
11 ) .
Do not smoke while working on tul
@
systom. Keop opsn tlame or spark away ttom work
alaa. Drain tuol only into an apptoved containet.

(cont'd)

5-19

EngineRemoval/lnstallation
(cont'd)
15. Removethe throttlecableby looseningthe locknut'
then slip the cableend out of the throttle linkage'
NOTE;
a Take care not to bend the cablewhen removlng
it. Always replaceany kinked cable with a new
one.
a Adiust the throttle cable when installing(see
s e c t i o n1 1 ) .

emis18. Removethe brakeboostervacuum hoss and

intake
the
from
tubes
vacuum
sion control
manilold.
IEVAPICONTROL
EMISSION
EVAPORATIVE

BRAKEBOOSTER
VACUUMHOSE

1 9 .Disconnect the connector and vacuum tube' thn

remove th cruise control actuatol.

NUT
ADJUSYING

Ir

to.

Removethe engine wire harnessconnectors.rerminal snd clamps on the right side of engine
compartment.
Bemove the power cable from the under-hood
tuse/relaybox.
POWERCABLE

t l

Il'

UNDER.HOOD

CRUISECO'{TROL
ACTUATOR

8r1.Omm
10 .m (1.o kg-m,
7 tb-frl

20. Remove the engine g.ound cable from the body

side.
21. Removethe power steering (p/Sl pump belt and
pump.
a Do not disconnectthe p/S hoses.

23. Loosenthe alternatormounting bolt, nut and adjusting nut, then removethe alternatorbelt,
MOUNTING EOLT

8 x 1.25 rhm
22 .m (2.2 kg-m.

t8

ALTERNATOR
AELT

PI,MPBELT

LOCKI{UT

P/S PUMP

r 1 . 2 5m m
22 N.m {2.2 kg-m, 16 tb-frl

22. Rsmove the air conditioning{A/C} condenserlan

shroud. then install a protector Dlate on the
radiator.

24. Loosen the mounting bolt, then remove the A/C

compressof.Disconnectthe connector.
a Do not disconnectthe A/C noses.

6x1.Omm
10 N.m (1.0 kg-m,
7 tb-ft}

8 x '1.25mm
22 N.m 12.2 kl-m.
16 rb-ft}
. Do not remove
tho bohs

(conr'd)

5-21

EngineRemoval/lnstallation
(cont'd)
25, Removethe upperand lower radiatorhosesandthe
heaterhoses.

27. Removethe shift cable and selectcable (M/T)'

NOTE:
a Take care not to bend the cablewhen removing
it. Always replaceany kinkedcablewith a new
one.
a Adjust the shiJtcable and seleci cable when installing(seesection 13).
I x 1 . 2 5m m

WASHER

BRACKET

WASHER
\

COTTER
Roplace.

SELECT
CAELE

PI.ASTIC WASHCR

STEELWASHER
26. Remove the transmissionground cable and the
automatic transmissionfluid (ATF) cooler hoses
(A/T).

Removeth clutch slave cylinder and the pipe/hose

assembly(M/T).
NOTE:
a Do not ooerate the clutch pedal once the slave
cvlinderhas been lemoved.
a Take care not to bend the PiPe.
ASSEMBLY

SLAVECYLINDEB

t
I

8 r 1.25mm
22 N.m 12.2 kg-m,
16 rb-frl

5-22

29, Removethe clutch damperassembly.

NOTE: Take care not to bend the pipe.
tng

CLUTCHDAMPER

31. Raisethe hoist to ful hoight.

32. Removethe exhaust pipe A and bracket.
GASKET

SEI.F-LOCKIIIGNUT
18 N.m {1.8 ks-m, t3 tb-ft}
Replace.

rin-

@'

tHER

8 r 1 . 2 5m m
22 N.m 12.2kg-m,
t6 tb_ftl

nc
IER

I{UT

55 N.tn (5.5 kg-h, 40 b-trl

Replace.

30. Remove the vehicle speed sensor {VSS)/power

steeringlPlS) speedsensorassembly.
NOTE: Do not disconnectthe noses.
18 N.m (1.8 kg-m,
ilave

EXHAUSTPIPEA

33. Removethe A/T shift cable (A/T).

NOTE:
a Take ca.e not to bend the cable when removing
it. Always rplaceany kinkedcable with a new
one.
a Adiust the shift cable when installing (see section 14).

ISLY

P/S

6 x 1 . Om m
10 N.m (1.0 kg-m, 7 lb-ft)
tg N.m (1.8 kg-m,
13 tb-ftl

(cont'dl

5-23

EngineRemoval/lnstallation
(cont'd)
34. Bemove the damper fork.

36. Removethe driveshafts.

SELF-LOCKINGBOLT
10 r 1.25 mm
/+4 N.m (4.4 kg-m, 32 lb-frl

I
I

h
t

I
|l

DRIVESHAFT
1 2 x 1 . 2 5m m
65 N'm 185 kg-m,47 lb-ftI
RePlace.
35. Disconnectthe suspensionlower arm balljointwith
the special tool. Refer to section 18 tor the
procedure.

37. Swing the driveshaftunder the fender.

NOTE:
surfaceswith clean
a Coat all precision-finished
engineoil or grease'
a Tie plastic bags over the driveshaJtends'

PLASTICBAG

CASTLENUT
14 x 2,O mm
50-60 N.m

fl

36-43 tb-ft)

38. Lower the hoist.

39. Attach the chain hoist to the engine.

5-25

EngineRemoval/lnstallation
lcont'd)
40. Removethe rear mount bracket

42. Removethe lelt side enginemount.

BEAR STIFFENER

4 3 . Remove the transmrsslon

41. Removethe front mount bracket.

and mount

bracket.

44. Raisethe chain hoist to removeall slack from the

chain.

45. Checkthat the engineis completelyfree of vacuum

hoses, fuet and coolant hoses, and elect.ical
wiring.

i'

46, Slowly raisethe engineapproximately150 mm {6

an).
Check once again that all hoses and wires have
been disconnectedtrom the engane.
47. Raisethe engineallthe way and removeit Jromthe
car.

5-26

48. Installth8 enginein the reverseordr of removal.

a Check that the spring clip on the end ot each

driveshaftclicks in to olace.

NOTE: After the engineis in place:

a Torque the engine mounting bolts in the squence shown below.

CAUTION: lnstall now spring cllps

Eleed air from the cooling system at the bleed

bolt with the heatervalve open.
a Adjust the throttle cable tension.
a Checkthe clutch pedalfree play {M/T).
a Check thst the transmissionshifts into gear
smoothly.
l 2 x 1 . 2 6m m
1 0 r 1 . 2 5m m
@ es .m le.s tg-m,
REAR
MOUITIT
1s b-ft}
@2r 'm t2.1
47 b-trl
1 0 r 1 , 2 5m m
Rplace.
.m
39
{3.9 kg-m.28lb-ft}

CAUTION: Fallurto tlghton the bolts In the p?opor

aoquencccln cauae orcegtivo noiar and vlbrstion.
and rcduce bushing litc; check thst thc bushing!
aro not twirtrd or offsot.

TRAIISMISSIOT{
MOUI{T

10 r 1.25mm
@ 39 .ln t3.9 ks-m.

O Tightsnsnugonty.
1 2 r 1 . 2 5m m
@ 65 t{.h {6.5 kg-h, 47 b-trl

12 x 1.25mrn
O 55 .m 15.5ks-m, 40 tb-trl
ReDlace.

12 x 1.25mm
@ 65 .ln (6.5 kg-m, 47 tb".ft)
RgDlac6.

FROI{TMOUI{T
SIDEE'{GI E
IIOUNT
the
12| 7.29
@ 55

.m (5.5lg-ln, 40

tum
'acal

r {6
6Ve

the

@ Tighton snug onty.

l O x 1 . 2 5m m

@ 39 N.m (3.9 kg-m,28 tb.ft}

NOTE:
. Torque th mounting bolts/nuts in the
numbgred squenceas shown (O-@).
. After road t6sting, loosen and rtighten
the thre bolts on the front r'lount
brackoi.

@ Tighten

only.

1 2 r 1 . 2 5m m
O 65 t{.m lO.5 kg-m,47 tb-ftl (cont'dl

5-27

EngineRemoval/lnstallation
(cont'd)
a InsDectfor fuel leakage.
After connectingall tuel line parts. turn on the
ignition switch (do not operate the starterl so
that the fuel pump operatesfor approximately
two seconds and the fuel line is pressurized.
Repeatthis operationtwo or three times, then
check for fuel leakageat any point in the Juel
line.

a Adiust the tensionof the following drive belts:

Alternatorbelt (section23).
Power steeringpump belt (section17).
Air conditionercompressorbelt {section22).
a Clean battery posts and cable tetminals with
sandpaper,assemble,then apply greaseto prevent corrosron.
Mount and BracketBolts/NutsTorque Value Specifications:
MOUNT

TRANSMISSIONMOUNT

1 2 r 1 . 2 5m m
95 N'm {9.5 kg-m, 69 lb-ftl

REABMOUNT
10 r 1.25mm
39 N.m 13.9kg-m,
28 lb-tt)

TRANSMISSION
MOUNT '10 r '1.25mm
BRACKET 39 N.m (3.9 kg-m,

2a tb-ft|

(Standardfor
some tvpos)
SIDE ENGINE
MOUNTING BRACKET

'10x 1.25mrr
48 N.m (4.8 kg-m.
35 tb-ft|

I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ftl
H23A'1.H22Al ngine:
Et{GINEMOUNT
BRACKETA

!r
lO x 1.25mm
45 N.m {4.5 kg-m,
33 lb-tr)
12 x 1.25mm
95 N.m (9.5 kg-rn,69 lb-ftl

FRONTMOUNT

8 x 1 . 2 5m m
22 N.n 12.2ks-m,
16 rb-ft|
lO x '1.25mm
48 N.m (4.8 kg-m, 35 lb-ft)

5-28

AdditionalTorqueValue Specifications;

P/S BRACKET
{F22A1 onginol

TRANSMISSIONMOUNT BOLTS
65 N.m 16.5kg-m,47 lb-ftl

8 x 1,25mm
22 N.m 12,2 kg-m,
16 tb-ftt

.ft)
INTAKE MANIFOLO
x 1.25mm
50 N.m {5.O kg-m,
36 rb-ftt

8 x 1.25mm
N.m {2.2 kg-m, 16lb-ftt
EXHAUST MANIFOI.D
BRACKET

10 x 1.25mm
50 N.m {5.O kg-m, 36 lb-frl

P/SBRACKET
(H23A1,H22Al ongino)

tg-m,

10 r 1.25mm
45 N.m {4.5 kg-m, 33 lb-ftl

1 0 x 1 . 2 5m m
50 .m {5.Okg-m,36 lb-trl

I for
es)

10 x 1.25mm
50 N.m (5.O kg-m, 36 lb-ftl
Apply liquidgasket
to the bok threads,

1 0 x ' 1 . 2 5m m
50 N.m {5.O kg-m, 36 lb-ftl

ALTERNATORBRACKET

A/C BRACKET

5-29

Cylinder Head/ValveTrain
F22A-1engine
H 2 3 A 1e n g i n e
H22Al engine

...............
6-1
. . . . . . . . . . . .6. .- 3 7
..............
6-71

CylinderHeadA/alveTrain
lF22A1 enginel
SpeciafTools
.........6-2
Valve Seats
l l l u s t r a t oIdn d e x . . . . . . . . . . . . . . . . . . . . . . .6. .-.3.
Reconditioning
.... 6-17
Valve Seals
Valve Guides
(Gylinder
Replacement
head
V a l v eM o v e m e n.t. . . . . . . . . . . . . . . . . .6. -. .1. 8
removalnot rquiredl .............6-5
Replacement
.......6-19
CylinderHead
Reaming
.............6-20
Removal
. . . . . . . . . . . .6. - 7
Camshaft/Rocker
Arms and
Warpage
............6-18
CamshaftSeals/Pulley
Installation
.........6-23
fnstalfation
.........6-22
Camshaft Pulley
Timing Belt and Timing BalancerBelt
Removal
.............6-12
lllustrated
Indox ........................
6-25
Rocker Arm Assembly
Replacemont
.......6-29
Removal
. . . . . . . . . . . . . 6 - 1 2 Timing Belt
Rocker Arms
lnspection
..........6-26
Overhaul
. . . . . . . . . . .6. - 1 3
TensionAdjustment
...................
6-26
Clearance
...........6-15
PositioningCrankshaftBefore
lnstalling
TimingBelt ..............
Camshaft
6-28
Inspection
. . . . . . . . . . 6 - 1 4 Timing BalancerBelt
fnspection
..........6-27
Valves, Valve Springs and Valve Seals
Valve
Clearance
Removal
. . . . . . . . . . . .6. - 1 6
Adjustment
.........6-34
Valve Spring and Valve S6al
InstallationSequence..............6-21
Valve Installation.......................
6-2 1

SpecialTools

Ref. No. I

o
o

@
@
@

Tool [tlumber
07HAH-PJ701OAor
OTHAH_PJ701OB
OTNAF_PTOOlOA
OTNAF_PTOO20A
OA
OTNAG-PTOOl
o7742-OO10100

Valve Guide Reamer,5.5 mm

6-20

InstallerCUP
lnstaller Shalt
Seal Guide
Valve Guide Drivr, 5.5 mm

6-22
6-22
6-22
6 - 1 9 ,2 0

I
e:Gt'r----------E

fllustratedIndex
CAUTION:
a To avoid damaging the cyllnder head. wsit until th6 engine coolant tompe.aturo drops bolow loooF {38ocl bforo
romoving it.
a In handling a metal gaskot. tak6 caro not to fold it or damago the contacl surtaco ot tho gasket.
NOTE:
a Use new O-ringsand gasketswhen reassembling,
a Cleanthe oil control orifice before installino.
CAP NUT
6 r 1.0 rrn
10 N.m11.Okg-m.7lb-ftI

?
HEADCOVER
CYLII{OER

RUBEER
SEALS
Rplacowhon dEmagd
or dteriorstd.

Put longer bolt

CYUITDER
HEADBOLT
1 2 r 1 . 2 5m m
1OO ,m (lO.Okg{n, 72 lb-ft}
Tightening.page6-23
Apply sngineoil to the thrgadg.

CYLII{DERHEAD
8 x 1 . 2 5m m
la N.m11.8kg-m,13lb-ftl

DOWELPI'{
otl coilTRol oRtFtcE
Clean.
O.RING
Roplace.
8 r 1.25mrn
22 t{,m (2.2 kg-m, 16 lb-ftl

CYLINDERHEADGASKET
{METALGASKETI
Rolacg.

TIMINGBELT
Rsplacement,page 6-29
Inspoction/Adjustmont,
page 6-26

---

./--'77'---)

AD.'UST|IG ruT
10 r 1.25mm
45 [.m 14.5 kg-m, 33 lb-ft,
Loos6n, but do not r6movg.

(cont'd)

6-3

lllustratedIndex
(cont'd)
cleanall the partsin solvent,dry them.nd applylubricantto any contsctparts'
,rto, to teassembling,

nl

6 x 1 . Om m
12 N'm tl.2 ks-m, 9 lb-ft)

r 1.25mm
22 trl,m (2.2 kg-h, 16 lb-ft)

e
I

ROCKEBARM ASSEMBLY
Ovorhsul,pag 6-13
lnspoction, page 6-1 5

VALVE ADJUSTING SCREW

7 r 0.75 mm
20 .m (2.0 kg-m, 14 lb-ft,
Apply oil.
Adjustment, psge 6-34

oo*:..rn-y'

SEAL
lnstdflation, page 6-22
Rplace.

CAMSHAFTPULLEY
page6-12
Romovsl,
Installation,pago6-22

CAMSHAFT

8 x 1.25 mm

38 .m (3.8 kg-m.27 lb-ft)

VALVE KEEPERS-*_-_-\
---ro
--_
spRtl{GRETATNER

-'^"'-"-'-"-' -------Ib

;ili'
spRrNG...-_____la

vALvE
ExHAUsr

ExHAUsrvALvEsEAL

p8gs6-5 8nd 16
Replacment,
Reptace.

rgli
Fz-->.-

--"i

vALvE spntitc

I ExHAUsr
valvE

.Ve-une

w
VALVEIGEPERS
RETAII{ER
ITTAIG VALVE SPfiI C
II{TAKE VALVE SEAL
RDlace.

SEAT
VALVESPRING
II{TAKEVALVE GUIDE
EACr COVER
CYLINDERHEAD

6 x 1.Orm
12 N.mll.2 kg-m,9 lb-ftl
INTAKEV

B6movsl,pao 6-16
Installation, page 6-21

6-4

Valve Seals
Replacement(Gylinderhead removalnot requiredl
NOTE: Cylinder head removal is not required in this
orocedure.
Ths procdur6shown below applies when using the incar valve spring compressor. (Snapon YA8845 with
YA8845-2 A 7/8' attachmentl

@E

Intake V!lv. Soals:

6. Slgct the 7/8 in diameter long compressor attachmnt 8nd fasten the gttachment to th6 No. 5 hole
of th levor arm with the speed pin supplid.
Insrt an air adaptor into the spa.k plug hole. Pump
air into the cylinder to ke6p the valve closod whils
comprssing springs and rsmoving th valv
ke6o6rs.

Alway woar approv.d oyc prot.ctron

whon uslng th6 in-cel valvo spring compt!3!or.

1. Turn the crankshaftso that th6 No. I 8nd the No.
4 pistons are at top desd center (TDC).
2.

Removeth cvlinder head cover and the rocker arm

assembly.
NOTE;
a Rsfr to p8ge 6-12 for rocker arm assembly
removal.
I When removing or installing the rocker arm 8ssambly, do not r6mov6th camshaft holdorbolts,
Th6 bolts will keepthe holders,sprirs and rocksl
arms on th shaft,

3.

Remove the fuel injectors and the wire hsrnss.

4.

Using the 8 mm bolts supplied with the tool, mount

the two uprightsto the cylinderh6adatthe end camshaft holders. Th uprights tit ov8r the camshatt as
shown,

5.

Insertthe cross shaft through th6 top hola of th two

uprights.

6.

Position the levr arm und6r ths cross shaft so the

lover is porpondiculsrto th shaft and the compres8or sttachm6nt rests on top of the rgtsinsr tor the
spring being compressd.Us th tront position slot
on ths lvsr as shown.
NOTE: RJt shop towek over the oil passagesto prevent th6 valvo kepB from falling into the cylindsr
h6ad.

OII. PA&gAGES

trl

(cont'd)

6-5

Valve Seals

Replacement
lGylinderheadremovalnot required)(cont'dl

9. Using a downward motion on the lve, arm, compressthe valvespringand removethe keepersfrom
the valve stem. Slowly release pressureon the
sprlng.

'15. Using a downwatd motion on the levsr arm, compress the valve spring and remove the keepersfrom
the valve stem. Slowly release paessuleon the
sprlng.

1 O . R e m o v et h e v a l v es e a l s( p a g e6 - 1 6 ) .

16. Removethe valve seals(page6-16).

1 1 . Installthe valve seals (page6-21).

17. Installthe valv seals lpage 6-21).

12. Installthe springs,the retainersand the keepersin

reverseorder of removal.

18. Installthe springs,the rtainers8nd th koop.sin

rgvorso ordr of romovSl,

ExhaustValv6 Seals:

19. Repeatsteps 6 to 18 on the other cylinde,s.

attach13. Selectthe 7/8 in. diametershortcompressor

ment and lasten the attachmentto the No. 4 hole of
the lever arm with the speedpin supplied.
14. Positionthe lever arm under the cross shaft so the
leveris perpendicularto the shaft and the compressor
attachment rests on top of the retainerfor the spring
being compressed.Use the front position slot on the
lever as shown.
NOTE: Put shop towels over the oil passagesto prevent the valve keepersfrom falling into the cylinder
head.

6-6

CylinderHead
Removal
Engineremovalis not requiredtor this procedure.

1 . Disconnectthe negativeterminalfrom the battery.

2 . Drainthe enginecoolant{seesection101.
o Make sur6 iacks and sefsty stands are placed propsdy
and hoist bfackets are sttachod to co.roct @shions on
tho ongin,
o Maks sure the car will not roll off stfltds and tall whilo
you are working under it.

. Removethe radiatorcap to speeddraining

5.

@
Do not snoke whlc wo*rng on ftrc
sydem, krop oFn ffrnc or spark away trom wor*
s!. Drdn ft|ol ody into an approvrd contrlnor.

CAUTION:
a Us tndr covors to avoid damaging paintod surtacas.
a Unspecifiad hms arc common.
o Unplug tho wiring connec{ors carefully whil holding ths
connoctor Fprtion to avok ddylago.
. Mark a[ wMng and hosos to avokt miEconnection.Abo,
bo su.o that they do not contact oth6. widng or hosos ol
innerto?e with othq parts.
o To avoid damaging th cylinder hoad. wah untilthe sngine coolant temp.aturs drop6 blow 100oF (38oC)
botor loosoning tho ltaining boh.
o Inspect th timing beh bofore removing the cylnder
hoad.
. Tum the crankshaft pulley so that tho No. 1 dston is at
top doad center {pag6-281.
a Maks all emission hoss betore disconnocting thm.
NOTE; The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode numberbefore
Disconnectingthe battery.
- Removingthe No.43 (1OA)tuse (ln the under-hood
fuse/relavboxl.
Removingthe radio.
After service,reconnectpower to the radioand turn it on.
Whenthe word "CODE" is displayed.enterthe customer's
s-digit code to restoreradioope.ation.

Relievethe fuel pressure.

SHOPTOWEI-

SERVICE
EOLT
12 N.m {1.2 kg-m,9 tb-ft}

FUELRAIL

4.

Rmovethevacuumtube,breatherhoseand intskeair
duct.
Removethewater bypasshosefrom the cylinderhead
Removethe fuel feed hose and evaDorativeemission
(EVAP)controlcanisterhosefrom the intakemaniJold.

(cont'dl

6-7

CylinderHead
Removal(cont'd)
7.

Removethe brakeboostervacuum hose and vacuum hosemount (A/T only)fromthe intakemanitold.

8 . Removethe luel return hose and cruisecontrol vacu-

10. Removalthe ignitioncoil.

* 8x 1.25mm
22 N.m(2.2kg-m,16lb-ftl

um hose.

CRUISE

Removethe spark plug caps and the distributor,

9.

Removethe throttle cableand the throttle control ca

bl; (A/T only) from the throttle body.
NOTE:
o Take care not to bend the cablewhen removingit.
Always replaceany kinkedcable with a new one.
a Adjust the throttle cable when installing(seesection 1 I ).

6r10mm
1 2 N . m( 1 . 2k g - mI, l b - f t l

THROTTLECONTROL
CABLE (A/T onlyl

1 2 . Removethe connectorand the te.minalfrom the alternator, then removethe enginewire harnesstrom the
cylinderhead cover.

1 3 .Removethe followingenginewire harnessconnectors

and clamps f.om the cylinder head and the intake
manitold:
a Fourtuel injectorconnectors
o Intakeair temDerature{lAT) sensorconnector
o ldle air control (lAC) valve connector
. Throttle position (TP)sensorconnector
o Exhaustgas recirculation(EGR)valve lift sensor
connector
. Groundcableterminals
. Enginecoolant temperature(ECT)switch B connecror
o Heatedoxygen sensor (HO25)connector
a ECTsensorconnector
o ECTgaugesendingunit connector
. lgnition coil conneclor
. CKP/TDC/CYPsensorconnector
. Vehiclespeedsensor(VSS)connector
a ECTswitch A connector
BOLT
r!: CORROSION
RESISTANT

14. Removethe upper and lower radiatorhosesand heater noses.

18. Disconnectthe connectorandvacuumtube,then remove the cruisecontrol actuator

CNUISECONTROL
ACTUATOR
6 x '1.0rnm
10 N.m {'1.0kg-h, 7 tb-trl

UPPERRADIATOR
HOSE

VACUUMTUBE

HEATEROUTLET
HOSE
HEATERINLET
HOSE

cor{r{EcToR

,//

,4

15. Remove the emission vacuum hoses and water

bypasshosesfrom the intake manifoldassemblv.
'16.

erne

Removethe water bvoass hose from thermostat

housing.

17. Remove the thermostat assemblv from intake

manifold.

./
1 9 .Removethe enginegroundcablefrom the bodyside.
20. Removethe power steeringlP/S)pumpbelt and pump.
NOTE:
a Do not disconnect the P/S hoses.
. After installingsdiust the tension of the P/S pump
belt (seesection 17).

ke

P/S PUMP

THERMOSTATASSEMALY

LOCKNUT
1 5 N . m l t . 5 k g - m ,1 1 l b - f t )

I x 1.25mm
22 N-lm 12.2 kg-m,
16 tb-ftt

P/S PUMPBELT

(cont'd)

6-9

CylinderHead
Removal{cont'd)
21. Remove the intake manitold bracket and intake
mani{old.

MANtFoLo
TNTAKE

24. Removethe heat insulator(carsequippedwith air conditioningonlY).

25. Removethe self]ocking nuts and disconnectthe exhaust manifoldand exhaustPiPeA.

GASKET

26. Bemove the exhaust manifold bracket and exhaust

manifold.

BRACKET

22. Lift the tront of the car up andplaceit on safetystands'

Mako sure lifts, iacks and safaty stands aro dacsd

propsdy. and hoist brackts are attachd to the corrct position on the ongin (seo page 1-10 rhlu
1-121.
Apply pa*ing b.ake and block rear wheeb, so car
will not roll oft slands and lsll on you wh e workng
und91il.
23. Removethe front wheelsand the enginesplashshield
(page5-18).

EXHAUSTPIPA

HEAT INSULATOR
(Carsoquippedwith air conditioningl

2 7 . Remove the positive crankcase ventilation (PCV)

hose, then removethe cylinderhead cover.

24. Removethe upPercover.

29. Loosanthe adjuatingnut 27O - 3600.
30. Pushthe tensionerto releasetensionfrom the timing
blt, then retightenthe adiustingnut.

6-10

31 . Removethe timing belt from the camshaft pulley.

NOTE: Separatethe cylinderhead from ihe block with a

llat bladescrewdriveras shown.

ex

CAUTION: Do not crimp or bend

tho timing balt mor than 90o or
less than 25 mm (1 inl in diameter.

GA
No Good

32. Removethe cylinderhead bolts. then removethe

cylinderhead.
CAUTION: To prevont warpag. unscrow tho bolts
in soquonc 1/3 turn at a timo; ropat untllall bohs
ars loosonad.
CYLIT{OER
HEAOSOLTLOOSENING
SEOUENCE
ning)

>cv)

mrng

6-11

RockerArm AssemblY

CamshaftPulleY

Removal

Removal
1.

To easereassembly,turn the camshaftpulleyuntilthe

"UP" mark faces up, and the front timing mark is
alignedwith the cylinderhead upper surface.

,.UP"MARK

1.

Loosenthe sdjustingscrews, then remove the bolts

and the rockerarm assembly.
NOTE:
. Unscrsw the camshaft holderbolts two tums at a
time, in a crisscrosspsnern to pre\nt damaging
the valvesor rocker arm assmbly.
. When removingthe rocker arm assembly.do not
remove the camshaft holder bohs. The bolts will
keep the camshaft holders, the springs and the
rockerarms on the shafts.

b%
TDCGROOVES
Alignfronttimingmarkon
Pulleywith the cylinder
headuppersurfac,

Removethe timing belt.

J.

Removethe retaining bolt, the special washer, the

camshaft pulley and the key, then removethe back
cover.

CAMSHAFT
PULLEY

BACK COVER

6-12

6 mm BOLTS

RockerArms
r Overhaul
NOTE:
a ldentifypartsastheyareremovedto ensurereinstallation
in originallocations.
a Inspectrockershafts and rockerarms (page6-15).
. Rockerarms must be installedin the same positionif reused.
a When removingor installingrockerarm assembly,do not removethe camshaftholderbolts. The bolts will keepthe
holders,
springsand rockerarms on the shaft.
o when reassembling,fit the projectionof the intakerocker shaft to the notch in the camshaftholder.
'

Priorto reassembling.clean all the part in solvent, dry them and apply lubricantto any contact parts.

Letter "9" is stamped

on tocker atm.

IITITAKE
BOCKER

INTAKEROCKER

sHAFr@

ARMs

3 places)

lh,,tr"o.,
I liif.ro"
HoLDER
HoLDER

ll

INTAKEROCKER

sxmr @
(long,

lshon, 2 placesl

Lefter "A" is stampod

on tocker arm.

ti;or"or,
HoLDER

ll"t "o'
HoLDER

| .,nou.,,,or".^
|

(4 plsces)

l ' u " ' T I" '

| t . l^ l , l ^

#,dffifu,Lffi,#u/=m
LpC .ffig*ffir
|flry 16tr
-

' o

or.,t o

(short, 2 palces)

"

s '

U f "#
t [ U

"*,n('

ROCKERARM
(8 places)

(long, 3 places)

rc
/

EXIIAUST ROCTERSHAFT

6-13

Camshaft
Inspection
Removethe bolts, then removethe camshaftholders
lrom the cylinderhead.

Note:
. Do not rotate the camshaftduringinspection.
a Removethe rockerarms and rockershafts.
1.

- Lift camshaftout ot cylidnerhead,wipe clean,then

inspectlift ramps.Replacecamshaftif lobesarep'tted, scored,or excessivelyworn.

Rrt the camshaft and the camshaft holders on the

cylinder head, then tighten the bolts to the specilied
torque.

- Cleanthe camshaftbearingsurfscesin the cylinder

head,then set camshaft back in place'

Specified tolque:
8 mm bohs: 22 N m (2.2 kg-m, 16 lb-ft)
6 mm bohs: 12 N'm (1.2 kg-m,9 lbjt)

- Insertplastigagestrip acrosseach iournal'

lnstall the camshaft holders,the tighten the bohs to
the specijiedtorque as shown in the left column on
this page.

6 mm BOLTS

o.

Measurewidest portionof plastigageon eachjournal'

Camshatt-tolloldcr Oil Clearance:
standard (Newl: 0 050-0.O89 mm
(o.0020-o.0O35 in)
O.15 mm {0.000 in)
Servbe Limh:

8 mm BOLTS
PTASTIGAGE STNIP

Seatthe camshaftby pushingittoward distributorend

of cylinderhead.
Zerothe dial indicatoragainstend ol distributordrive.
then push the camshaft back and forth and read the
end play.
Camshaft End Play:
StandardlNow): 0.o5-o.1 5 mm
(O.0O2-O.0O6in)
O.5 mm {O.O2in)
SrviceUmh:

CAMSHAFT

6-14

RockerArms
Clearance
efs

!n

pit-

der

7.

lf camshaft-to-holderoil clearanceis out ot tolerance:

- And the camshaft has alreadybeen replaced,you
must replacethe cylinderhead.
- lt camshafthasnot beenreplaced,tirst checktotal
runout with the camshaft supportedon V-blocks.

Measureboth the intake rockershafts and exhaustrocker

shaft.
Measure diameter ot the shaft at the tirst rocker
location.

Canshaft Total Runout:

Standard(Nw): O.O3mm (0.0O1in) max.
Srvice Limit: 0.06 mm (0.002 in)

tto
on

nal.
Surfaceshouldbe smooth.

Zero the gaugeto the shaft diameter.

- lf the total runout of the camshaft is within tolerance, replacethe cylinderhead.

- lf the total runout is out of tolerance,reDlacethe
camshaftand recheck,lfthe oilclearanceis stillout
ol tolerance,replacethe cylinderhead.
Measurecam lobe height.
Cam Lob Height:
lntakeStanda.d: 38.526 mm (1.5168in)
Erhaust Standard: 38.778 mm { 1.5267 in)

Measurethe insidediameterof the.ocker arm and

check tor out-of-roundcondition.
Rockr Am-to-Shaft Cloarance:
Standdd(Nw)
lmak6:
O.O17-O.O5O
mm
(0.OOO7-O.OO2O
in)
Exhaust:
O.O18-O.054mm
{O.OOO7-O.0O21
in)
Ssrvico Linit: 0.O8 mm
(O.0O3in)

Inspectrocker arm
laca tor wear,
Inspectthis areator wear.

Repeatfor all rockers.lf over limit, replacethe rocker

shaft and all over-tolerancerockerarms.

6-15

Valves, Valve Springsand Valve Seals

Removal
NOTE: ldentify valvesand valve springsas they are removed so that each item can be reinstalledin its original
Dosition.
1.

Tap each valve stem with a plastic mallet to loosen

valvekeepersbeforeinstallingthe springcompressor'

2.

Install the spring compressor.Compressthe spring

and removethe valve keepers.

4.

Removethe valve seal.

COMMRCIALLYAVAILABLE

3.

Installthespecialtoolas shown.

VALVEGUIDESEALREMOVER
LISLEP/N57900or KD3350
AVAILABLE
COMMERCIALLY

lntako Valvo txrronsions

A Standtd(tlowl: 33.90-34.1O mm
(1.335- 1.343 in)
B Standtdocw): 1 1O.88-l 1 1.18 mm
(4.365-4.377 in)
C Strdard{ ow}: 5.485- 5.495 mm
{ O . 2 1 5 9 - O . 2 1 6 i3n )
5.455 mm (0.2148 in)
C SorviceLinit:
D Standard(t{ow}:0.85-1.1 5 mm
(0.033-O.045 in)
mm (0.026 inl
0.65
Linit:
D Srvbr
Exha.|3t Valvo Dlmonsions
A Sta.!dsd(t{ow): 28.90-29.10 mm
t 1 . 1 3 8 - 1 . 1 4 6i n )
8 Stard1*d(ltswl: 122 15 -122.45 mm
(4.809-4.821 in)
C Siandsdl ewl: 5.450- 5.460 mm
( 0 . 2 1 4 6 - O . 2 1 5 0i n l
5.420 mm (O.2134 in)
C SorvicoUmh:
D Standard(Now): I .O5- 1.35 mm
-O.O53 in)
(O.O41
0.95 mm {0.037 in)
D SrvicoLimit:

6-16

Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a
valve seat cutter.

5.

NOTE: lf guidesare worn (page6-18),replacethem

(page6-191beforecutting the valve sears.

After resurfacingthe sat, inspectforeven valveseating; Apply PrussianBluecompoundto the valve face,
and insertvalvein originallocationin the head,then lift
it and snap it closedagsinstthe seat severaltimes.

PRUSSIAI{

2.

Carefully cut a 45o seat, removing only enough

materialto ensurea smooth and concentricseat.

3.

Bvelthe upper edge ot the seat with the 3Oo cutter

and the lower edge of the seat with the 600 cutter.
Check width of seat and adjust accordingty.

4.

6.

The actualvslveseatingsurface,as shown bythe blue

compound,should be centeredon the seat.
. lf it is too high {closrto the valvestem), you must
make a secondcut with the 600 cutter to move it
doun,then one mor cut with the 45o cutter to restore sest width.
a lf it is too low (closerto the vslve edge),you must
make a secondcut with the 3Oo cutter to move it
up, then one more cut whh the 45o cutter to re_
store seat width.
NOTE:The final cut should alwavs be made with
the 45o cutter.

7.

Insertintakeandexhaustvalvesin the headand measure vatve stem installedheight.

Make one more very light passwith the 45o cutter to

removeany possibleburrscausedbv the other cutter.

Intako Valv6 Stam lnstalsd Hight:

Standnd (New): 48.245-48.]15 mm
(1.8994- 1.9179 inl
SsrviceLimh:
48.965 mm (1.9278in)
Exhaust Valve Stem I]rrtaH Hotght:
Standrd (t{ow}: 50.315-8O.785 mm

Valve Sat Width:

Stsdard (Nowl: 1.25-1.55 mm
(O.049-O.061in)
ServiceLimit:
2.OOmm (0.079 in)

Sorvice Linh:

1 1 . 9 8 0 91- . 9 9 9 4i n l
51.O35mm (2.OO92
in)

SEAI WIDTH

8.

lf valve stem installedheight is over the servicelimit,

replacethe valve and recheck.li still over the service
limit, replacethe cylindef head; the valve seat in the
head is too deep.

6-17

CylinderHead
Warpage
NOTE: lf camshaft-to-holderoil clesrance{page6-14) are
not within specitication, the cylinder head cannot be
resurfaced.
lf camshaft-to-holderoil clearancesare within specitications. check the cvlinderheadfor warpage.
. lf warpageis lessthan O.05 mm {0.OO2in)cylinderhead
resurfacingis not .equired.
. lf warpageis betweenO.O5mm (O.0O2in) and 0.2 mm
(0.008 in), resurtacecrinder head.
a Maximumresurfacelimit is 0.2 mm {0.008 in) basedon
a heightof 10Omm {3.94 in).

ValveGuides
Valve Movement
Measurethe guide-to-stemclearancewith a dial indicator
while rocking the stem in the direclion ol normal thrust
(wobblemethodl.
lntako Valve Stem-to4ulde Clearanca:
Standrd {New}: 0.04-O.O9 mm
(O.OO2-0.OO4
inl
0 16 mm (0.006 in)
ServiceLimh:
Exhaust Valve Stom'to4uite Clea.ance:
Standard(New): 0.1 1 -0.16 mm
{0.0O4-0.0O6in)
O.24 mm (0.OO9in)
SorvicoLimit:
Valve extended 1Omm out from seat

STRAIGHTEDGE
PRECISION

o --\-_z
\

'

a lf measurementexcedsthe servicelimit, recheck

using a new valve.
a l{ measurementis now within service limit, reassmbleusing a new valve,
a lf measurementstill exceedslimit, recheckusingalternate method below. then replace valve and
guide, it necessary.
NOTE: An ahemate method oJ checking guide to
stem clearanceis to subtract the O.D. ol the valve
stem, measuredwith a micrometer,from the l.D. of
the valve guide, measuredwith an insidemicrometer
or ball gauge.
Takethe measurementsinthree placesalongthe valve
stem and three placesinsidethe valve guide.
The difference between the largest gulde measurement and the smalleststem measurementshouldnot
exceedthe servicelimit.
Measurealong edges,and 3 ways acrosscenter.

lntako Valvo Stom-toukle Clearance:

Standqd (Newl: 0.020-0.045 mm

Cyfndr Hoad Hoight:

Strdard lNew): 99.95- 1o0.O5mm
(3.935- 3.939 in)

SrvicoLimit;

(0.ooo8-o.oo18
in)

O.Ogmm (O.OO3in)

Exhaust Valvo Stm-to-Guide Clearancr:

Standcd (Newl: o.055-o.08o mm
(O.OO22-O'OO31
in)
0.1 2 mm {O.OO5in}
SorvicaLimh:

6-18

- Replacement
1.

As illustratedin the removalst6ps of this procedure,

use a commercially-available air-impact ddver attachment modified to fit tho diameter of the valve
guides. ln most cases, tho same procedurecan be
done usingthe ValveGuideOriverand a convntional
nammer.

4.

Workingtrom the camshaftside.Usethe driverand an

air hammer to drive the guide about 2 mm {0.1 in)
towards the combustionchamber.This will knock off
some of the carbon and make removaleasier.

GAUTION:
o AlwEys woar satsty goggles or a face shiold when
uCng tha air hamnr6r.
. Hold th6 ak hdnmcf dkecdy in lina wlth iha valv
guue to prevni darnaglng th driv$.

VALVEGUIDEORIVER
COMMERCIALIY
AVAILABLE

5.

Turn the headover and drive the guideout toward the

camshaftside of head.

RcmovC.nd lrddlrtlon
VALVEGUIDEDR|VER.
8.5 mm
07742-0Or0100

Selectthe properreplacementguidossnd chillthem in

the treezersectionot a refrigeratorJor about an hour.
Usea hot plsteor ovento evenlyheattha cylinderhead
to 3OOoF(150oC). Monitor the temperaturewith a
cookingthermometer.
eck
)asJ aland

,to
alve
r. ol
eler
alve

c)o

iurenor

CAUTION:
. Oo mt uso a tordr; h may wrp thc hoad.
. Do not glt dro he.d hotter rhan 3{X)oF fi5oocl:
oxccsslvc hoat may looaan tl|c vdw rcat3.
a To avoid brrB. uco heavy gbves whon hsnding
tho hoad cyrer h.ad.

lf a valveguidestillwon't move, drillit out with a I mm

(5/16 inch)bh, then try again.
CAUTION: Ddd gridos only in xtrm6 casas; you
couH damago tho cytndcr hoad if ths guilo breaks.
6.

Removethe new guide(s)from the refrigerator,one at

8 time, as you needthem.
(cont'dl

6-19

Valve Guides
Reaming

(cont'dl
Replacement
7.

Slipa 6 mm (0.2 in)steelwashet andthe correctdriver

attachmert ovr the end of the driver(Thewasherwill
absorbsome ot the impact and xtend the life of the
driver).

F:-p-qo
t
t
DROER

6 mm (0.2In)
WASHER

NOTE: For new valve guidesonly.

1.

Coat both reamerand valve guide with cutting oil

2.

Rotatethe reamerclockwisethe full lengthol the valvs

guide bore.

3.

Continueto rotatethe reamerclockwisewhile removing it from the bore.

4.

Thoroughlywash the guide in detergentand water to

removeany cutting residue.

5.

Check clesrancewith a valve {page6-181.

- Verify that the valve slides in the intake and exhaust vslve guideswithout exertingpressure.

ATTACHMENT

Instsllthe new guide(s)trom the camshaftside of the

head;drive each one in until the attachmentbottoms
on the head.lf you have all sixteenguidesto do, you
mav have to reheatthe headone or two more times.

VALVEGUIDEREAMER,
5.5 mft

OTHAH-PJ7OlOA ot

oTHAH-PJ70l08

VALVEGUIDEDRIVER,
07742-OOlO100

Valve Gulde Insta{od H.iglrt:

fntak: 23.75-24.25 mm (O.915-O.947 inl
Exhaust: 15.o5- 15.55 mm (0'593-0.61 2 in)

6-20

Turn teamgrin
clockwise diroctiononlY.

HANDLE
REAMER

Valves,ValveSpringsand VatveSeals
ValveSpringand ValveSealInstallationSequence
NOTE: Exhsustand intakevalve salsare NOT intsrchangeable.

@A=----UO|-UEKEEPERS
NOTE: Pl6cs the snd ot valve
spring wilh closly wound coitg
towa.d tllo cvlinds. he6d.

VALVERETAIT{ER

INTA(EVALVESEAL
(WHTTE
SPRINGI
Replace.

ALVESPRII{G

VALVEGUIDESEAII STALTIR
KD-2899
COUMERCIAI,I.Y
AVAILABT"E
t{OlE: UsgsrnalllO endof tool.

EXHAUSTVALVESEAL
IBLACTSPRIITGI
Replace.

I{OTE: Installlhe vatve springcests

bofore installinothe vstvg seals.

ValveInstallation
When installingvalves in cylinderhead, coat valve stems
with oil before insertinginto vslve guides,and make sure
valvesmove up and down smoothlv,
Whenvalvesand springsare in place,lightlytap the end of
eachvalvestem two or th.ee times with a plasticmalletto
ensureproperseatingof valve and valve keepers.
NOTE: Tapthe valvestem only alongits axisso you do not
bend the stem.

6-21

Arms and CamshaftSeals/Pulley

Camshaft/Rocker
lnstallation
OIL SEAL

CAUTION:
. Mako suro that alltoc*rs aro in algffnnt vvith valvas
whn to(qukrg rockr assambly bohs'
. Vshrs tocknds shodd bo bosonad and 8di$t Ecrows
backed ofi beloro in3tal8don'
. To Fovont rocker arm as!6mbly trom coming apart'
leavo baring crp holding bohs h tho hobs'
1.

After wiping down the camshaft and journals in

cylinder heod. lubricate both sur(aces and install
camshaft.

aubrt""a"""m tobesafterreassembly.

SEAL GUTOE
o7t{AG - PT0010A
o.

Turn the camshaftuntil its keywsy is facing up.

(No.1cylinderTDC).

CUP
INSTALLEF
OTNAF_PIOOlOA

Tiohteneach bolt two turns at a time in the sequence

sh-ownbelowto ensurethatthe rockersdo not bind on
the valves.
Spcdffod torcuo:
8 mm bolts: 22 N'm (2'2 kg-m, 16 lb-ft)
6 mm bohs: 12 N'm ( l .2 kg-m, 9 lb-ft)

Apply liquidgasketto the headmating surfacesof the

No. 1 and No. 6 camshaftholders'
- Apply liquidgasketto the shadedareas.

6 mm BOLTS

No.1

-B
\J-

lt

v
Setthe rockerarm assemblyin place8nd looselyinstall
the bolts.
- Make sure that the rockerarms are propeflyposltioned on the valve stems.
lnstallthe camshaftoil s8al using the speci8ltools as
shown.
CAMSHAFT

SEAL GUIDE

8 mm BOLTS
7.

lnstallthe back cover.

8.

Installths key and the camshaftpulleyonto the camshaft, then tighten the retaining bolt to the torque
shown.
BACKCOVER

o7l{ac-PTOOl0A
Applyoil.

CAMSI{AFT
PULLEY

Mw
I

Sssl housing sudace

should b dry.
CAMSHAFT OIL SEAL
Apply a light coar oI oil
to camshaft and inner
lip of seal.

6-22

INSTALLER SHAFT
OTNAF_PTOO2OA

RETAININGBOLT
8 x 1.25 mm
1 2 N m ( ' 1 . 2 k g - m38
. N.rn{3.8 kg-m,
27 tb-ft)
I lb-ftl

CylinderHead
Installation
Installthe cylinderhead in the reverseorder of removal:
FT
,A

NOTE:
a Always use a new headgasket.
. Cylinderheadand engineblock surfacemust be clean.
a "UP" mark on camshaftpulleyshouldbe at the too.
. Tum the crankshaftso the No. 1 cylinderis at TDC (psge

6-28t.

o Cleanthe oil contrclorifice before installino.

\
nce
,on

1.

Cylinderhead dowel pins and oil control orifice must

be aligned.

DOWELPIN
CYLINDER
HEAD
GASKET
Replace.

Installthe bolts that securethe intake manifoldto its

bracketbut do not tighten them yet,
J.

Positionthe camshaftcorrectly (page6-29).

4. Tighten the cylinder head bolts sequentiallyin three

steps.

1rt stop to.que: 40 N.m (4.0 kg-m, 29 lb-ft)

2nd stop torque: 70 N.m (7.0 kg-m, 51 tb-ft)
3.d ctep to?quo: 10O N.m (10.Okg-m. 72 tb-ft)
NOTE:
a W recommendusinga beam-typetorque wrench.
When using a preset-typetorque wrench, be sure
to tighten slowly and not to overtighten.
a lf a boh makesany noisewhile you are torquingit,
loosenthe boh and retightenit from the I st steo.

ooml P {

a/

CYLI'{DERHEADBOLTSTOROUESEOUENCE

OILCONTROL
ORIFICE
Clean.
O-RING
Replace.

CYTJI{DER
12 r 1.25mm
lOO N.m ('lO.Okg-m, 72 tb-ftt
Apply clsan engineoil to bolt
threads and under bott heads,

(cont'd)

6-23

Cylinder Head

lnstallation(cont'd)

the nuts In-a

"5. Installthe intakemanifoldandtighten
with the
beginning
steps'
ot
3
2
in
"t't"""too p.orn
innernuts.
o Alwavsusea newintakemanifddgasket'

nuts n a
putt"a in 2 or 3 steps' beginning with the

the
7 . lnstall the exhaust mdtifold and tighten

"ri"""roo
innel nut'
a Always use 8 now exhaust manifoldgasket'

thn instsll the

8 . lnstall th exhaust manifold bracket'

pip",q and the bracket, and then install the

i"h"tt
covf.

GASXET
Replace.

GASKET
Replace.

8x l'25mm
32Nm13.2kg-m.
23 lb-ft)
Replace.

MANIFOLD

8 x 1 . 2 5m m
22 N.m {2.2 kg-m'
16 rb-ftl

I x 1.25mm
22 N.m(2 2 kg-m'
16 tb-ft)

1Ox 1.25mm
45 N.m(4.5kg-m,
33 tb-ft)
and the
lnstallthe heat insulatorto the cylinderhead
block.

GASKET
Rplaco.
6r1.Omm
1ON.m(1.0kg-m,
7 tb-ft)

6-24

10 x 1.25 mm
55 N.m {5.5 kg-m.
40 lb-ft)
Replace,

EXHAUSTPIPEA

TimingBelt and TimingBalancerBelt

lllustratedIndex
NOTE:
o Referto page 6-28 tor positioningcrankshaftand pulley beforeinstallingtiming belt.
o Beforeremoving,mark directionof rotation.

ADJUSTING
NUT
POWERSTEERING
BELT
45 N.m(4.5kg-m,
Adjustment,
section17
33 rb-ft)
6x l.Omm
12Nm(1.2kg-m,
I tb-ft)
\

UPPER
COVER
RUBBER
SEALS
Replace
whendamaged
or detsrioratod.

CAP NUT

LOWERCOVER 6 x l . O m m
Removethe five 1 0 N . m ( 1 . 0k g - m ,
7 tb-ft)
bolts.

CYLINDER
HEAD
COVER

6r l.Omm
12 N.m {1.2 kg-m,_,glb-tr)
,.'

::aNm(22.0ks-m,
:3 bft)
\:ot engineoil to the
:crr threads,but not
u '- surfacethat
r.--ts the washet.

ltrcnNartia

l-

Adjustment, section 23

SEALS
Replacewhen damaged
or dgtrioroled.

.uGAELT
.lo.ction, page 6-26
Sustmnt, Page6-26
:,.dacement, pago 6-29

BELT
TE SIOITERS

Remove
any oil.
SPRING

6r 1.Omm
r 2 N . m( 1 . 2k s - m .
I rb,ft)

CRAr{KSHAFT
.^
UAMSHAFT
WIIIV
PYLEY
aelr i"-*"
"n" oir.

SPRII{G
Installwith concave
surfacefacing in.
Femove any oil.

AELT
ADJUSTING
BOLT
68 N.m(6.8ks-m,
49lb-ft)

8 x 1.25 mm
38 N.m (3.8 kg-m,27 tb-ft)

TIMII{G AALA CEREELT

Inspection,page 6-27

6-25

TimingBelt
Inspection
Disconnectthe altelnatorterminaland the connector.
then removethe enginewire harnessfrom the cylinder
head cover.
Removethe cYlinderhead cover'
Removethe upper cover.
4.

Inspect the timing belt for cracks and oil or coolant

soaking.
NOTE:
. Replacethe belt if oil or coolant soaked.
a Removeany oil or solventthat gets on the belt'

TensionAdiustment
CAUTION: AhtvavsadFst timing boh tensbn with th6 ongin6 cold.
NOTE:
o The tensioneris springloadedto applypropertens'onto
the belt sutomaticsllYafter making the lollowing adjustment.
a Always rotate the crankshaftcounterclockwisewhen
viewed lrom the pulleyside. Rotatingit clockwisemay
result in improperadlustmentof the belt tension
. Inspectthe timing balancerbelt beforeadiustingthe belt
tension.
. Do not loosenthe adjustingnut morethan one full turn'
1.

Inspectthis arealor wear.

Disconnectthe alternatorterminaland the connector'

then removetheenginewire harnessflom the cylinder
headcover.
Removethe cylinderheadcover'

Set the No. 1 piston at TDC (page6-28).

4.

Loosenthe adiustingnut 2/3-1 turn, then tighten it'

ADJUSTINGNUT
45 N.m(4.5kg-m,33lb-ft)

Rotate the crankshaft counterclockwise3-teeth on

the camshaftpulley.then reloosenthe adiustingnutto
createtensionon the timing belt.

5,

to
After inspecting,retorquethe crankshaftpulleybolt
(22.O
lb-ftl'
1
59
ks-m,
N.m
220

6.

Tightenthe adjustingnut.
After sdiusting,retorquethe crankshaftpulleybolt to
22ON.m (22.0 ks-m, 159 lb-ft).

TimingBalancerBelt
Inspection
1.

Disconnectthe altematorterminaland the connector,

then removethe enginewire harnesstromthe cylinder
headcover.

2.

Removethe cylinderheadcover

3.

Removethe uppercover.

4.

Removethe crankshaftpulley.

5,

Removethe lower cover,

6.

Installthe crankshaftpulley.

7.

Inspectthe timing balancerbelt for c.acks and oil or

coolantsoaking.
NOTE:
o Replacethe belt if oil or coolant soaked.
a Removeany oil or solventthat gets on the belt.
Inspectthis areator wear.

Botatepulley
andrnspectbelt.
After inspecting,retorquethe crankshaftpulleybolt to
22O N'm (22.Oks-m, 159 tb-ftl.
NOTE: Refer to page 6-32 tor timing batancerbelt
tension adjustment.

6-27

Timing Belt
PositioningCrankshaftBeforeInstallingTimingBelt
NOTE:
. Installthe timing belt with the No. 1 piston at TDC.
. After installingretorquethe crankshaftpulley bolt to
220 N.m (22.0 kg-m, 159 lb-ft).

CAMSHAFTTDC POSITION:

,,UP"MARK

CRANKSHAFTTDC POSITIO]T:
MANUAL TRANSMISSION:
INSPECTIOI{HOLE

FLYWHEEL

AUTOMANC TRANSMISSION:

DRIVEPTATE

TOC MARK
(WHITEI

NOTE: When turning the crankshaft with a socket

wrench, installthe crankshaftpulleyand rhe pulleybolt'

6-28

INSPECNO HOLE

POINTERS

ot{ BLocK

TimingBeltand TimingBalancerBelt
Replacement.

CAUTION: Inspoct tho walor pump whon radachg th6

timing blt (Pag610-12)
NOTE: Turn the crankshaftso that the No. 1 piston is at
TDC (page6-28).
I . Removethe splashshield.

3.

Removethe mounting bolts, nuts and P/S pump belt

from the power steering(P/S)pump.
NOTE:
a Do not disconnectthe PiS pipe and hose.
. After installing,adiustthe tensionof the P/Spump
belt {seesection171.

POWEBSTEERING
PUMP
MOUNTINGBO(TS

LOCKNUT
1 5N . m{ 1 . 5k g - m ,
11 tb-ft)

8x1.25mm
SPLASH SHIELD

.,

Disconnectthe connector. then remove the cruise

control actuator.
NOTE:
a Do not disconnectthe control cable.
a Takecarenot to bendthe cablewhen removingthe
actuator.Always replacea kinkedcablewith a new
one.

CRUISE
ACTUATOR

6x1.Omm
10 t{.m {1.0 kg-m,
7 tb-ttl

22 N.m 12.2kg-m,
1E rb-ftl

P/SPUMPAELT

4 . Disconnectthe alternatorterminaland the connector,

then removetheenginewire harnessfrom the cvlinder
head cover.
Loosenthe alternatormountingbolt/nut and adjusting
bolt, then rernovethe altematorbelt.
NOTE: After installing,adjustthe tensionof the alternator bett lsee section 231.
MOUNTIM! EOLT
1 Ox 1 . 2 5m m
45Nm{4.5kg-m,
33 tb-fr)

ALTENNATOR
AELT

MOUI{TINGNUT
8 x 1.25 mm
22 N.m (2.2 kg-m, 16lFft)
(cont'd)

6-29

TimingBeltand TimingBalancerBelt
(cont'd)
Replacement
Removethe cylinderheadcover.
Removethe sideenginemount bracketB {standardfor
some typesl.

I 1. Removethe pulleybolt and the crankshaftpulley Remove the two rearboltsfrom the centerbeamto allow
the engineto drop down and give clearanceto remove
the lower cover.
12. Removethe rubbsr seal aound the adiustingnut. Do
not loosn the adiusting nut.

Removeth uppercover.
Removethe side enginemount.

13. Removethe lower cover'

'10.Removethe dipstick and the pipe.

6 r 'l,Omm
12 N m ('t.2 kg-m,
12 r, 1,25''un
9 rb-ft)
55 N.m (5.5kgfl, 40 lb-ft|

CYUNDERHEAD
COVER

DIPSTICK/PIPE

e
e

RUBEER
SEALS
l2 x 1,25 mm
65 N.m (6.5 kg-m, SIDE
47 tb-ft)
MOUNT

UPPR
COVER
6xl.Omft
1 2 N . m ( 1 . 2k g - m ,
I rb-ft)

Rplacewhn
damagdor
deterioratsd.

RUBBERSEALS
Replacewhen
damagedor
deterior6ted.

SEAL
RUEBER
Replacewhsn damaged
or detorioratod.
AOJUSTINGNUT
1 0 x 1 . 2 5m m
45 N.m (4.5 kg-m,
33 lb-ft)

PULTfYEOLT
14 x 1.25mm
220 N.m 122.0ksn, 159 lb-ftl
6xt.Omm
Apply 6n9ineoil to th boli ihraads,
n LLEY
12 N m (1.2kg-m,
but not to the sudace that
oil.
Removs
any
lb-ft)
I
contads the washer.

6-30

TIMING BALAITCEFBELT
Inspection,Page6-27

e-

)o

'1
4. Lockthe timing belt adjusterarm in placeby installing
one of the 6 x 1.0 mm lower cover mounting bolts,
15. Loosenthe timing belt adjusringnut. push on the pu!
ley to removetension trom the timing balancerbelt,
then tighten the adjustingnut.
16. Removethe timing balancerbelt.
NOTE: It you are removingonly the timing balancer
belt, goto step 22. lf you areremovingboth belts,con,
tinue with this procedure.

TIMINGBELT
ADJUSTERARM

aDJUsnNGNUT
45 N.m14.5kg-m,33lb-tt)

17. Loosenthe 6 x 1.0 mm lock bolt andthe adjustingnut.

Pushon the timing belt adjusterpulleyto removetension from the belt, then tighten the adiustingnut.
18. Removethe timing belt.
19, Installthe timing belt in the reverseorderof removal.
Adjust the valve clesrances(page6-34)
- Betoreinstallingthe riming blt, the crankshaftand
camshaft pulleysas shown on page 6-28.
2O. Perform the timing belt tension adjustment lpage
6-26).
21 . Tightenthe 6 x 1.0 mm bolr to tockthe timing belt adJusterarm'

DRIVEPULLEY

(cont'd)

6-31

Timing Belt and Timing BalancerBelt

Replacement(cont'dl
22. Make surethe crankshaftis positionedwith the No 1
piston at TDC.
23. Alignthe grooveon the front balancerafter pulleywith
the pointeron the oil pump housingas shown,
24. Align the rear balancershaft pulleyby using 6 x 1OO
mm bolt or equivalentas an alignmenttool.
Scribea line 74 mm (2.9 in) from the end ol the bolt.
Inserttheboh intothe maintenanceholeto the scribed
line.

27. Turn the crankshaft pullev about one turn counterclockwise,then tighten the adjustingnuit to the speci{ied torque.
NOTE: Both belt adiusters are spring-loaded to
properlytensionthe behs.Do not spply any extm pressure to the pulleysor tensionerswhile performingthe
adiustment,
REARBALANCERSHAFT

25. Loosenthe adjusting nut and verity that the timing

balancerbelt adjustermovesfreely.
Installthe timing balancerbelt. Removethe 6 x 1OO
mm bolt from the rear balancershaft.

74 mm 12.9in)

MAII{TENANCE
HOLE
6 x 10O mm BOLT

WASHER
Replace.
12 mm SEAU G BOLT
30 N.m(3.0 kq-tn,22 lb-ftl
NOTE:Tightenthe boltafter
installingthe belt.
AI'JUSTII{GNUT

Align the groove of the

front driven pulley with the
pointer on the oil pump housing.

TIMINGBALA'TCERBELT
DRIVEPULLEY
Set the crankshaftat TDC.

6-32

6 x 100 1'|mBOLT

24. Removethe 6 x 1.Omm bolt from the timing belt ad-

32. Installthe upper cover.

Justerarm.

33. Installthe crankshaftpulley.

29. Removethe crankshaftpultey.
34. Coat the threads and seatingtace oJ the putley bolt

30. Installthe lower cover.

with engine oil. Install and tighten to the specified

rorque.

3 1 .Installa rubberseal aroundthe adjustingnut. Do not

loosenthe nut.

Specifiodtorqus: 220 N.m {22.Okg-m. 159 tb-ft}

UPPERCOVER

6r1.0mm
12 N.m(1.2kg-m,I lb-ftl

SEAL

ADJUSTING
I{UT
1 0 x 1 . 2 5 rn

Replgcswhon damsged
or dsterioratsd.

45 N.m (4.5 kg-m,

33 rb-ft)

PULLEYBOLT
1 4x 1 . 2 5m m
22O N.m {22.0 kg-m, 159 lb-ft)
Apply engineoilto the
bolt threads.

6x1.0mm
12 N.m {1.2 kg-m,9 lb'ft}

6-33

Valve Clearance
Adiustment
Adjust valves on No. 1 cylinder.

NOTE:
. Valvesshouldbe adjustedcold when the cylinderhead
is lessthan loOoF {38oC).
temoerature
. After adiusting,retorquethe crankshaftpulley bolt to
22ON.m (22.0 kg-m, 159 lb-ft).
1.

in}1333fll13.ffi!lll
Intake:0.26mm{o.o1o
in)13.33ffi13ffi9ili
Exhaut:o.30mm{0.o12
Loosenlocknut and turn adjustmentscrew untilJeeler
gaugeslidesbackandforth with slightamountofdrag.

Removethe cvlinderheadcover.
INTAKE

N o . 4 N o . 3 N o , 2 N o .1

LOCKlrlUTTxO.T5mm
20 N.m(2.0kg-m,14lb-ft)
Applyengineoil.

N o . 4 N o . 3 N o . 2 N o .1

EXHAUST

GAUGE
FEELER

2.

"UP" mark on the camshaft

Set No. 1 piston at TDC.
pulleyshouldbe at top, and TDC grooveson the camshaft pulleyshould alignwith cylindrhad surface.

Numbor1 riston at TDC:

@-
\

Ut\-/

) l-24

6-34

5.

Tightenlocknut8nd checkclearanceagain.Repeatadjustment if necessary.

6.

Rotatecrankshaft180o counterclockwise(Camshaft
pulley turns 9Oo). The "UP" mark should be at exhaust side, Adjust valveson No. 3 cylinder.

Number 3 Piston at TDC:

8.

Rotatecrankshat180o counterclockwiseto bring

No. 2 pistonto TDC. The "UP" mark shoutdbe at
intske side. Adjust valves on No. 2 cylinder.

Number 2 Pbton at TDC:

,,UP" MARK

7,

Rotatecrankshaft180o counterclockwiseto bring

No.4 piston to TDC. Both TDC g.ooves are once
again visible.Adjust valves on No. 4 cylinder.

Numbor 4 Piston at TDC:

6-35

CylinderHead/ValveTrain

(H23A1engane)

SpecialTools
.........6-38
lllustratodlndex ...........................
6-39
Valve Seals
Replacement (Cylinder head
removalnot requiredl .............6-41
Cylinder Head
Romoval
.............6-43
Warpage
............6-52
Installation
.........6-56
Camshaft Pulleys
Removal
.............6-48
Camshafts
lnspection
..........6-48
Valves, Valve Springs and Valve Seala
Removal
.............6-50
Valve Spring and Valve Seal
InstallationSequence..............6-55
Valv Installation.......................
6-55
Valve Seats
Recondltioning
..... 6-51

Valve Guldes
ValveMovement.......................
6-52
Replacernent
.......6-53
Reaming
.............6-54
RockerArms/Camehafteand
Camrhaft Soals/Pulleys
lnstallation
.........6-57
Tlmlng Belt and Timing BalancerBelt
lllustratod
Index ........................
6-59
Replacement
.......6-63
Timing Belt
Inspoctlon
..........6-60
TensionAdjustment
...................
6-60
PositionlngCrankshaftBefore
Installing
TlmingBelt ..............
6-62
Timing BalancerBeh
Inspoction
..........6-61
Valve Clearance
Adjustment
.........6-68

SpecialTools

Ret.l{o.

@
@
@

Too\ l{urnbor
07GAD-PH70100
o7757-PJ1010A
07942-6570100
O 7 9 8 4 - 6 5 7 O 1 OoCr
07984-657010D

qq

O6r,cdgl0tr\
Valve Guide Sal lnstall6]
Valve Spring Compressor Attachment
Valve Guide Driver,6.6 mm
Valve Guide Reamer,6.6 mm

t
o

--fl'------------

6-38

1
I
1
1

Prq. Rd.r.nca
6-55
6-50
6-53,54
6-54

lllustratedIndex
CAUTION: To avoid darnaglngtho cylinder head, wait until tho engino coolant tomporature drop6 blow 100oF (38ocl
betoro romoving it.
NOTE: Use new O-ringsand gasketswhen reassembling.
6 r 1 0m m
10 N'm {1.0 kg-m,7 lb-ftl

6 r 1 . 0m m
10 N..n l1.O kg-m.7 lb-ft}

WASHER

8 x 1.25mrn
22 .m (2.2 lg-m, lE lb-ttl

RUBBEB
SEAIS
Replace wlrsn
or doterioratd.

6rlOmm
12 N.m (1.2 kg-m,9 lb-ttl

frI n-'-''
flEuflE

ui
ffiHnfl
,&V,
W#

DOWEL PIII

8 x 1 . 2 5m m
18N.ft11.a

6x10mm
lO N.m (1.2 kg-m,7 lb-ft}

/tt{TAKE CAMSHAFT
HOLDER

L!, e

13 lb-frl

8-

iih
qub
o

HEX

|l{TAKE CAMSHAFT
roction,pag66-48
SEALS
Instsllation,psge 6-57
Roplacs.
CAMSHAFT PULLEYS
Removal, pag6 6-48
Installation, page 6-57

DISTRIBUTOR
EXHAUST
CAMSHAFT
ROCKERARM
ADJUSTING SCREW
Adjustment, page 6-68
LOCKT{UT
27 N.n 12.7 kg-m, 20 lb-ft)

8 x 1.25mm
38 N.m (3.4 ks-m. 27 lb-ftl
tor ntanual
p.r-lllgnriant ot
caftah6tt

{cont'd)

6-39

lllustratedIndex
(cont'd)
CAUTION: In handllng a motal gasket. tako car6 not to lold it or damage tho contact surtaco of tho gsskt.
NOTE: Cleanthe oil control orifice beJoreinstalling.

'11

clean all the pans in solvent, dry them and apply lubricantto any contact parts,
Priorto reassembling,

HEADBOLT
12 x 1.26 mrn
lOO N.m (10.0 ks-m, 72 lb-ft)
Apply cleanongineoil to
threadsand underthg
bolt heads.

INTAKE VALVE GUIDE

Inspction, page 6-52
Replacement,page 6-53
Rsaming,pag 6-54

VALVE
SPRINGRET

EXHAUSTVALVE
EXHAUSTVALVESEAL
Rsplaca.
VALVESPRINGSEAT
EXHAUSTVALVE

nfl

VALVEKEEPERS
SPEINGRETAINER
A(E VAIV SPNI G
I]{TAXEVALVE SEAL
Replacamnt,
psgs 6-41 and 50

ALVESPRI G SEAT
EIID PIVOTEOLTS
64 N'm 16.4kg-m,46 lb-ftl

BACK COVER
ENGII{EMOUNT
B
BRACKET
1 0 r 1 . 2 5m m

CYLINDERHEAD GASKET
IMETAL GASKET}
Roplace.

45 N.m (4.5 kg-m,

33 rb-ft)
8 x 1 . 2 5m m
22 N.m
{2.2 kg-m, 16 lb-ftl

OOWEL PIN

INTAKEVALVE
Replacemont,
Dimonsions, pag 6-50
Reconditioningvslve
sat, pag 6-5'l
Adiustment. paga 6-68
TIMING BELT
Inspection/Adiristment,page
R6placoment.page 6-63

ADJUSTIT{G
10 x '1.25mm
45 N.m (4.5 kg-m,

33 tb-ft)
Loosen,but do not remove.

6-40

CYLINDERHEAD
Rmoval. page 6-43
Reconditioningvalve
seat, pago 6-51
Warpage, page 6-52
Installation, pag 6-56

OIL CONTROL
ORIFICE
Clean.
O-RING
Feplace.

Valve Seals
Replacement{Cylinderhead removalnot requiredl
NOTE: Cylinder head removal is not required in this
procdure.
Usethe procedureshown below applieswhen usingthe
in-car valve spring compressor(Snap-onYA8845).

Intako Valva Sorb:

8. Selectthe 1-1l18 in. diameterlongcompressorattachment and fasten the attachment to the hole of
the lever arm with the speed pin supplied.

9 . Insert an air sdaptor into the spark plug hole. Pump

Alway waar approved oye protcction
l@
when using tho in-car valvo spring compas{rr.
1. Turn the crankshaftso that the No. 1 and the No.
4 Distonsare at TDC.
2.

Removethe cvlinderhead cover.

3.

Loosen and remove timing belt from the camshaft

pulleys.

4.

Remove the distributor.

5.

Removethe camshsft holder bolts, then removethe

camshaft holders, the camshafts, and the rocker
arms.

air into the cylinder to keep the valve closed while

compressing springs and removing the valve
keeoers.

1 0 . Positionthe lever arm under the cross shalt so the

lever is perpendicularto the shaft and the compressor attachment rests on top of the retainer for the
spring boing comp.essed, Use the tront position
slot on the lever as shown.
NOTE: Put shop towels over the oil passagesto
prevent ths valve keepers from lalling into the
cvlinderhead.

OIL PASSAGES

Usingthe 6 mm boltssuppliedwith the tool, mount

the two uprights to the cylinder as shown.
Insert the cross shaft through the bottom holes ol
the two uprights.

OIL PASSAGES

(cont'd)

6-41

Valve Seals

Replacement(Cylinderhead removalnot required)(cont'dl

1 1.

Usinga downward motion on the leverarm, compressthe valve spling and removethe keepersfiom
ths valve stem. Slowly releasepressureon the
spnng.

1 8 . Using a downward motion on the lever arm, com-

12.

Repeatstep 1 1 for the other intakevalve in that

cvlinder.

1 9 . Repeatstep 18 tor the othor exhaust valve in that

13.

Removethe valve seals (page 6-50).

20. Removethe valve sals (page 6-50).

14.

Replacethe valve seals (page6-55).

2 1 . Replacethe valve ssals (page 6-55).

15.

Installthe springs,the retainers8nd the keepers

in reverse order of removal.

2 2 . Install the springs, the retainers and the keepers

Exhaust Valvo Soals:

16. Slectthe 7/8 in. diametercompressorattachmnt
8nd tasten the attachment to the No. 5 hole of the
lever arm with the speed pin.
17.

ll

Positionthe lever arm under the cross shaft so it

is perpendiculsrto the shaft and the compressor
attachment rests on top of the retainer for the
spring being comprcssed. Use the front position
slot on the lever as shown.
NOTE: Put shop towels over the oil passagesto
prevent the valve keepers from Jalling into the
cvlinderhead.

6-42

pressthe valve spring and removethe keepersfrom

the valve stem. Slowly release pressurs on the
spflng.

cylinder.

in reverse order of removal.

23. Repat stps 8 to 22 for the other cylinders.

CylinderHead
Removal
Enginer8movalis not requiredJor this procedure.

l.

Disconnect the negative terminal trom the battery.

2 . Drainthe enginecoolant (seesection 1O).

a Mako sure iscks and safoty stands ars placad
propedy and hoist bfacksG era attachod to corract positions on ths oingino.
a Mako suro tho car will not roll oft stands and fall
while you ar6 working undr it.
CAUTION:
a Uso fendor covors to avoid damaging paintod
surtaces.
a Unspocifiod items ara common.
a Unplug tlF widng connectoB caroft.fy while hol+
ing th6 connocto? ponion to avoid damags,
a Ma.k 8t wHng and hoss3 to rvdd rrisconncctlon.
Also, bo sur6 that thsy do not contact othor wiring oi hosos o. intorfats with other parts.
a To avoid damaging the cylindar herd, w8it untll
tho engine coolant tmporaturo &opr bclow
100oF (38ocl befoio loosanlng the rotllnlng
bohs.
NOTE:
a Inspect the timing belt befo.e removing the
cvlinder head.
a Turn the crankshaftpulleyso that tho No. 1 piston
is at top dead csnter (page 6-62).
a Mark 8ll emission hoses belore disconnecting
them.
a The radio may have a coded theft protection circuit. Be sure to get the customer's code number
before.
- Disconnecting the battery.
- Removingthe No. 43 (lOAl fuse.
(ln the under-hood fuse/relav boxl
- Removingthe radio.
After service. reconnect Dowe. to th radio and
turn it on. Whenthe word "COOE" is displayed,
enter the customer's 5-digit code to restore radio ooeration.

a Removethe radiatorcap to speed draining.

3 . Relievethe fuel pressure,

Do not smoko whilo workino on fuel
@
aystem, koop open flamo or spark arlay from work
area, Draln fuol only into an approved containar.
4.

Removethe intske air duct.

Removethe fuel teed hose and evaporativeemission

(EVAP) control canister hose from the intake
manifold.

6.

Removethe throttle control cabletrom the throttle

body (A/T onlyl.
NOTE:
a Take care not to bendthe cable when removing
it. Always replaceany kinkedcablewith a new
one.
a Adiust the throttle cable when installing(seesect i o n 11 1 .
6 x l.O mm
12 .ft 11.2kg-m, 9lb-ftl
THROTTLECAALE

THROTTLECONTROL
CABLE
LOCKNUT

(cont'd)

6-43

CylinderHead
Removal(cont'd)
7.

Removethe tuel feed hose,the tuel returnhoseand

the brake boostervacuum hose.
FUELFEEDHOSE

9.

Rmoveth engine ground cable Jtom th cylinder

head cover.

10, Disconnect the alternator terminal and connector,

then remove the engine wire harness from tho
cvlindsr head cover.
EI{GINEWIRE
HARNESS

WASHER
Replace.

6r

8 t{.m (0.8 kg-m, 6 lb-ftl

6x l.Orr|m
10 'm (1.0 kg-m,7 lb-ftl

11. Removothe powsr steeringlP/S)pump belt and

pump.
a Do not disconnectthe P/S hosos.
Removethe lollowingenginewire hsrnessconnectors and clamps ftom the cylindr head and the intake manifold:
o
a
a
a
a
a
a
o
a
a
a
a
a
a
a
a
a

Four fuel injectorconnectors

lntake air temDerature(lAT) sensorconnector
ldle air control (lACl valve connector
Throttle position (TP) sensor connector
Exhaust g8s recirculstion (EGR)valve lift sensor
connecror
Groundcableterminals
Enginecoolanttemperature(ECT)switch B connecror
Heatedoxygen sensor (HO2S)connectot
ECT sensor connector
ECT gauge sendingunit connector
lgnition control module llCMl connector
CKP/ToC/CYPsensorconnector
VehiclesDeedsensor (VSS)connector
lgnition coil connector
Intake air bypass solenoid valve connsctor
ECT switch A connector
Knock sensorconnector

6-44

8 x 1.25mm
22 .|n (2.2 kg-m,
16 tb-ft1

15 N.m ll.5 *g-m,

I I lb-ftl

12. Removethe ignitioncoil.

16. Remove the intake manifold bracket and intake

manitold.

IGNITIONCOIL

*8 x 1.25lnm
*6x LOmm
22 N.m 12.2 ke-m, CO ECTOR 12 rr| {1.2 kgn,
16 tb-trl
9 tb-ft1
13. Remove the emission vacuum hoses and water
bypass hoses from the intake manifold asemblv.
14. Removethe radiatorupper hose and heater hose
from the cvlinderhead.

17. Removethe selt-lockingnuts and disconnectthe ex_

haust manitold8nd exhaustpipe A.

1 5. Removethe water bypass hose and the thermostst

housing.

18. Removethe heat insulator(carsequippedwith A/Cl,

exhaustmanifoldbracketand exhau$ manifold.

6 x 1.0mm
12 tt.m 11.2 kg_m,9 tb-ft|
*:

CORNOSIONRESISTANTBOLT

EXHAUST PIPEA

HEAT INSULATOR
{carsoquippedwith A/C)
(cont'd)

6-45

CylinderHead
Removal{cont'd)
1 9 . Remove the PCV hose, then remove the cylinder
head cover.

20. Removethe middlecover.

2 1 . Loosenthe adjustingnut 180".

24.

Remove the camshatt Pullsys.

NOTE: To set the camshafts at TDC for No. 1
cylinder,alignthe holesin the camshaftswith thg
holesin the No. 1 camshaftholdersand insert 5.O
mm oin punches.

Pushthe tensionerto releasetension from the timing belt, then retightenthe adjustingnut.

8 r 1.25mm
38 .m 13.8kg{r,
27 tb-ft)
25. Loosen the rocker arm adiusting screws, then remove the camshaft holders and camshafts.
23,

Removethe timing belttrom the camshaJtpulleys.

ADJUSTING SCREWS

CAUTION: Do not crimp or bond

tho timing belt more than 90 o ol lsss
than 25 mm ( l inl in diametor.

G4z
No Good

ADJUSTING SCREWS

6-46

Removethe side engine mount bracket B and back

covea.

ENGII{EMOUI{T
SRACKET
B

NOTE: Separatethe cvlinderheadfrom the block with

a flat tip screwdriveras shown.

10 r 1.25mm
45 N.m (4,5 kg-m,
33 rb-ft}

BRACKET

8 x 1 . 2 5m m
22 N.m 12.2kg-m,
16 tb-ftl

27. Removethe cylinderhead bolts, then removethe

cylinderhead.
CAUTION: To prevont vvalpaga,unscrlw tho bohr
in sequenc 1/3 turn at a timo; rapaat until all bohr
arg loosaned,
CYLINOERHEAD BOLT LOOSEI{INGSEOUEI{CE

6-47

Camshafts

Gamshaft Pulleys

Inspection

Removal
"UP"
1. To easereassembly,turn the pulleyuntil the
marks face up, and the front timing marks are aligned
with the marks on the Dullevs.

NOTE: Do not totate camshaft during inspection'

1. Removethe rocker arms.
NOTE: Rockerarms musi be installedin the same
oosition if reused.

"UP" m6rks

2.

Put the camshaftsand the camshaftholderson the

cylinder head, then tighten the bolts to the specified
toroue.
Specifled torque:
Exc8pt Intake @, @. Exhaust @, @:
l0 N'm (1'0 kg'm, 7 lb'ft|
Intake @, @. Exhaust @' @:
12 N'm (1.2 kg-m, 9 lb-ft1
TIGHTEI{II{G
SEOUECE

Align the marks on the pulleys.

Removethe timing belt,

Removethepulleybolts,then removethe camshaft
pulleys.
NOTE: To set the camshafts at TDC for No. 1
cylinder,alignthe holesin the camshsftswith the
holes in the No. 1 camshaftholdersand insert 5 0
mm pin punches.

t ,

PULLEYBOLTS

6-48

@ @

I
?

Seatcamshaftsby pushingthem toward distributor

end of cylinderhead.

4.

Zero dial indicatoragainstend of camshsft, then

push camshaft back and forth, and readthe end play.

7.

lf camshaft-to-holderoilclearancsis out oftolerance:

a And th6 camshaft has alreadybeen replaced,you
must r6placgthe cylinderhead.
r lf camshaft has not been replaced,first check total runout with th6 camshaft supported on Vblocks.

Camshaft End Play:

Standard(New): 0.O5-O.15 mm
(0.0O2-O.006 in)
Sorvice Limit:
0.5 mm {0.02 in}

Crmrheft Total Runout:

Standard (Nowl: 0.03 mm (O.0Ol Inl max.
Sorvlce Llmh:
0.06 mm (0.002 Inl

Rotate camshaft
while msssuring

5.

Removethe camshaft holder bolts from the cylinder

head.
a LiJt camshaft out of cylinder head, wipe clean,
then inpsect lift ramps,/Replaccamshaft if lobes
are pitted, scored, ot excessively worn,
a Clean the camshaft beadng surfaces in the
cylinderhead.then set csmshaft back in place.
a Insert plastigagestrip acrosseach journsl.
a Install the camshaJt holders and torque bolts to
the valuesand in the sequenceshown on page
6-48.

6.

Measure widest portion ot plastigage on each

journal.

- lf the total runout of the camshsft is within tolerance, replace the cylinder head.
- lf the total runout is out ot tolerance, replacethe
camshaft and recheck. lf the oil clearanceis still
out of tolerance,replacethe cylinderhead.
8.

Measurecamshaft lobe height.

Intak. Standlrd:
33.661 mm (1.3252 inl
Exhlurt Stlnda.d: 33.725 mm (1.3278 Inl

Camshsfi-to-Holdor Oil Cloaiance:

Standard(Now): O.O5O-0.089 mm
(0.0020-O.OO35 inl
SorvicaLimit: O.15 mm (0.0O6inl
Exhaust No. 5 Jounal:
Standard(Newl: O.lOO-0.139 mm
{0.0039-0.OO55 inl
Servics Limit:
0.20 mm (O.OOBinl

Inspect this are for wear.

6-49

Valves,Valve Springsand Valve Seals

Removal
NOTE: ldentify valves and valve springs as they are remov6d so that ach item can be reinstalledin its original
position.
1.

Tap ach valve stem with a plastic mallet to loosen

valve keepers before installing the spring comDressor.

2.

Installthespling compressor.Compressspringand
remove valve keeper.

4.

Removeth valve se8l.

VALVESPFINGCOMPRESSOR
AVAILABLE
COMMERCALLY

VALVESPRING
COMPRESSOR
ATTACHMENT
07757-PJIOIOA

3.

Installthe sDecialtools as shown,

lntake Valvo Dlncndons
A Standard (Nowl: 33.90-34.10

VALVE GUIDESEALRETVIOVER
LISLEP/N57900 or KD335o
AVAILABLE
COMMERCIALLY

mm

(1.335- 1.343inl
mm
B Standard l]{.wl: 102.6O-1O2.8O
(4.035-4.047 lnl
C Standard {rw}: 6.58O-6.590 mm
10.2691-O.2594inl
6.55 mm 10.258Inl
C Sorvic. Llmh:
D StandErd ( !rv): O . 8 5 -1 . 1 5m m
(O.O33-o.o45Inl
0.65 mm (O.O26inl
D Servic Llmh:
Exhoust Valvo Dlmcnalonr
A Standsrd(Newl: 28.9o-29.10 mm

( 1. 1 3 8 - 1 . 1 6 1I n l

B stand.rd lt{cw}: 1 0 1 . 4 0 -1 O 1 . 7 0m m

(3.992-4.oO4inl

C StandErd lt{ewl: 6.550-6.560 mm

Inl
10.2579*O.2583
6.52 mm 10.257inl
C Servico Lknh:
D Standard (Nrw): 1 . 0 5 - ' 1 . 3 5m m
D Sorvico Lirit:

6-50

(O.O41-0.O53
In)
o.85 rnm (O.O33inl

Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a
valve seat cutter.

After resurfacing the seat, inspect Jor even valv

seating: Apply PrussianBlue compound to the valve
face, and insen valv in originallocation in the he8d,
then lift it and snapit closedagainstthe seatseveral times.

NOTE: lf guidesare worn (page6-52), replacethem

(page6-531betorecutting the valve seats.

ACTUAL
SEAN G
SURFACE

VALVE
SEAT
PRUSSIANBLUE COMPOUI{D

K@"8

The actualvslve seatingsudace, as shown by the

blue compound,should bo centeredon the seat.
a lf it is too high (closer to the valv6 stem), you
must make a second cut with the 600 cuttef to
move it down, then onB more cut with the 45o
cutter to rgstore saat width.
a ]f it is too low (closeto th6 valve edge), you must
make a second cut with the 30o cutter to move
it up, then one more cut with the 45o cutter to
restore seat width.

Carefully cut a 45o se8t. removing only enough

materialto ensurea smooth and concentricseat.

NOTE: The tinal cut shoutdalways be made wirh

the 45o cutter.

Bevelthe upper edge of the seat whh the 3Oo cutter

and the lowsr edg of the seat with the 600 cutter,
Check width of sest and adjustaccordingly.

Insen intake and exhaust valves in the head and

measurovalve stem installedheight.

Make one more very ligt|t pass whh tha 45o cutte, to
removeany possibleburrscaussdby the other cufters.

Intake Valve St.m Inliall.d Hright:

Standard (l{cwl: 39.365-39.835 mm
(1.5498- 1.5683 inl
Scrvlce Limlt:
4O.Oa5 (1.5781 tnl
Exhau* Valve Stom lnstallcd Hdght:
Standard(Now): 39.165-39.635 mm
1 1 . 5 4 1 9 -1 . 5 6 0 4i n l
S.rvlce Limit:
39.885 mm ('1.5703inl

VCv. Sct Wld$ (ht!k lnd.xhaltl:

Standlrd:
1.25- 1.55 mm
(O.O49-O.061int
Sendcellmh: 2.0O mm (0.079 in)

)
VALVESTEM
INSTALLEDHEIGHT

8.

It valve stem installedheight is over the servicelimit,

replacevalve and recheck.lf still ovef the service
limit, replacecylinderhead;the valve seat in the head
is too deeo.

6-51

CylinderHead
Warpage
NOTE: lf camshaft-to-holderoil clearances(page 649)
are not within specitication,the cylinder head cannot be
resurfaced.
lf camshaft-to-holderoil clearancesare within specifications, check the cylinderheadlor warpage
. lf warpageis lessthan0'05 mm (0.0O2in)cylinderhead
resurfacingis not requard
. lf wsrpage is btw6n O.05 mm {0.0O2 in) 8nd 0.2
mm (0.008 in), rosurfacecylinderhead.
. Maximumresurfacelimit is 0.2 mm (0.OO8in) basedon
a heightof 132.o mm (5.20 in)

Valve Guides
Valve Movement
Measurethe guide-to-stemclearancewith dial indicstor
while rocking the stem in the direction of normsl thrust
(wobblemethod).
lntsko Vdvo St.m-to{iukla Clearance:
Standard(New): 0.04-0' 10 mm
{0'002-0.0O4 in)
O.16 mm (0.006 in)
Sewlca Umh:
Exha6t Valve Stom-to4ulde Clearanca:
Standrd lNow): O.10-0.16 mm
(O'0O4-O.006 in)
0
22 mm (0.OO9in)
Limh:
Sowic.
1O mm out trom sat.

..

Mssuro along gdggg. and 3 ways across center'

.o

a lf measuremantexcedsthe servicelimit, r8check

using a new valvs.
a lf measurement is now within the servic limit.
reassembleusing a ngw valv.
a lf measurementstill excaads limit, recheck using
alternate mthod blow, then replace vslve snd
guide, if necessary,
NOTE: An altsrnate mthod of chcking guide to
stem clearanceis to subtract the O.D. of ths valve
stem, measurgdwith a micrometer. from the l.D. ot
the valve guide, measured with an inside micrometer o. ball gauge.
Take the measurements in three places along the
valve stem and three placesinsidethe valve guide.
The difference betwesn the largest guide measurement and the smalleststem measurementshouldnot
exceedthe servicelimit.

Cyllrdor H6ad Hight:

Stardard(Nowl: 131.95- 132.05mm
15.1955
- . 1 9 9i n l

Intake Valvo Stom-tecuida Closrsnca:

Stardtd lt{rw}: 0.02-0.05 mm
(O.OOl-O.OO2 in)
O.08 mm (O.0O3in)
Servba Limit:
Erhaust Valw Stom-to4uidc Cbarancs:
Stsrdrd (ltlew): O.05-O.O8 mm
(O.OO2-0.OO3
inl
O.11 mm (O.0O4in)
ServlccLimit:

6-52

Replacement
1.

As illustratedin the removalsteps of this procedure,

use a commercially-available air-impact driver attachment moditied to fit the diameter ot the valve
guides. In most cases, the same procedurecan be
done using Valve Guide Drivers and a conventional
hammer. Tool numbers are at the end of this
Drocedure.

4.

CATUION:
a Always wear salty goggles 01 a taco shield when
using th aL hamm6..
. Hold the ak hammer directly in lin with tho valve
$.rido to pr8vont damaging the driver.

VALVECUIDEDRIVER
Y AVAILAELE
6,4 mm
{O.25ln}

87 mm +tr+l3.rt:l In) I

57mln
l2-24h,tl

Workingfrom the camshaftside, usethe driverand an

air hammer to drive the guide about 2 mm (0.1 in)
towards the combustionchamber.This will knock off
some oJthe carbonand make removaleasier,

5,

l_l
lr_r

Turn the headover and drivethe guideout toward the

camshaftside of head.

1 1 . 3m m
O.44In)

Rmoval
andinstallation
VALVEGUIDEDRIVER.
6.6 mm
07942-6570100
Selectthe properreplacementguidesand chillthem in
the freezersectionof a refrigeratorfor about an hour.
Usea hotplate oroven to evenlyheatthecylinderhead
to 3OOoF{150oC). Monitor the temperarure\^iith a
cooking thermometer.

VALVEGUIDEDRIVER
COMMEBCIALLY
AVAILABLE

lo

-\

R@ig
CAUTION:
a Do not uss a lorch; h may wan rh had.
. Do not got ths head hotr6r than 3O0oF (1soocl;
oxcasaivo hsat may loosen tho valve seats.
a To avoid burns. uso hoavy glovas when handling
ths heatod cylinde. hoad.

lf a valve guide still won't move, drill it out with a

I mm (5/16 inch) bit, then try again.
CAUTION: Drill guides only in extremo casos; you
could damage tho cylinder head it th gukte breaks.
6.

Removethe new guide(slfrom the refrigerator,one at

a time, as you needthem.
{cont'd)

6-53

Valve Guides

Reaming

Replacement
{cont'd}
7.

SliDa 6.5 mm (0.26 in) steel washer and the correct

driver attachment over the end of the driver (The
washerwill absorbsome of the impact and extendthe
life of the driver).

T:-r-w
DRIVER

6.5 rm 10.26hl
WAHSER

NOTE: For new valve guidesonly.

1.

Coat both reamerand valve guide with cuning oil.

2.

Rotatethe reamerclockwisethe fulllengthofthe valve

guide bore.

3.

Continueto rotatethe teamerclockwisewhile removing it trom the bore.

4.

Thoroughlywash the guide in detergentand water to

removeany cutting residue.

ATTACHMET

5.
Insta,,thenew guidels)trom the camshaftside ot the
head:drive each one in until the attachmentbottoms
on the head.lf you have allsixteen guidesto do, you
mav have to rcheat the head one ot two more times

VALVEGUIDEDRIVER,
6.6 mm
07942-65701fi,

check clearance with a valve (page 6-52)

o Verify that the valve slides in the intake and exhaust valv gurUeswithoui exerting pressufe.

REAMER
HA'{DLE

07984-65701OC ol
07984-657010D

Vdvo Guide InstatredHoight:

Standard(Newl:
l m a k e : 1 3 . 2 5 - 1 3 . 7 5m m
(O.522-O.541
in)
Erhaust: 13.75- 14.25 mm
(O.541-O.561
in)
VALVEGUIDE

6-54

Valves,ValveSpringsand ValveSeals
ValveSpdngand ValveSealInstallationSequence
NOTE: Exhaustand intake valve sealsare NOT interchangeable.

@A.--.--.-uo..uEKEEPERS
NOTE: Placethe end ol valve
spring with closely wound coils
toward the cylinderhead.

VALVERETAINER

IIITAKEVALVESEAL
WHITESPRIIIGI
Beplace.

VALVESPNNO
VALVEGUIDESEAL
IITSTALLER
oTGAO-PH701(x)

EXHAUSTVALVESEAL
(BTACK
SPRING}
Replac.

SPRINGSEAT
NOTE:Installthe valve springseats before
installinothe valve seals.

ValveInstallation
When installingvalves in cylinderhead. coat valve stems
with oil before insening into valve guides,and make sure
valvesmove up and down smoothly.
When valvesand springsare in place,lightlytap the end of
each valvestem two or three times with a plasticmalletto
ensureproperseatingof valve and valve keeprs.
NOTE; T8p the valvestem only alongits axisso you do not
bendthe stem.

6-55

CylinderHead
lnstallation
Installthe cylinderheadin the reverseorderol removal:
NOTE:
a Always use a new head gasket
a Cylinderhead and engineblock surfacemust be clean
a "UP" marks on camshaft pulleysshouldbe at the top.
. Turn the crankshaftso the No. 1 piston is at TDC (page
6-62).
a Cleanthe oil control orifice beforeinstalling
1.

Cylinderhead dowel pins and oil control orifice must

be aliqned.

in three
2. Tightenthe cylinderheadboltssequentially
steps.
lst stoptorque: 40 N m (4.0 kg-m,29 lb-ft)
2ndsteptorque:70 N'm (7.0kg-m,51 lb-ft)
3rd stoptorquo: 10ON m {10.0kg-m,72 lb-ft)
NOTE:
torquewrench'
a We recommend
usinga beam-type
be sure
wrench,
preset-type
torque
a
using
When
to tightenslowlyandnot to overtighten'
. It a boltmakesanynoisewhileyou aretorquingit,
loosenthe bohandretightenit tromthe Ist step'
SEOUENCE
TONOUE
BOLTS
HEAD
CYLINOER

DOWEL

\
\
\

CYLINOER
HEADGASKET
Replace.

OIL CONTROL
ORIFICE
Clean.
O-RING
Replace.

HEADBOLTS
CYLII{OER
1 2 x 1 . 2 5m m
1OON.mllO.Okg-m.72lb-ft)
Applycleanengineoil bolt
threadsandunderboltheads

6-56

RockerArms/Camshafts
and Seals/Pulleys
Installation
lnslallthe intakemanifoldand tighten the nuts in a
criss-crosspaltern in 2 or 3 steps. beginningwith
the Inner nuts.
GASKET

. Mak6 sura drat the keyways on th camdrafts a] fackrg up. (No. 1 r* on TDCI.
a Valv locknuts should b loosonedand boforo scrsws
backed off botoio installation.
a Replacthe rocker arms in thsir origlnal positions,
1.

Placethe rockerarmson the pivotboltsandthe valve

srems.

2.

Installthe camshaftsand the camshalt sealswith

the open side (spring)facing in.

8 r 1 . 2 5m m
22 N.m(2.2kg-m,
16 tb-ft)
22 N.m(2.2kg-m,
16 tb_ft}
4.

ROCKERARM

Installthe exhaustmanifoldand bracket.Tightenthe

nuts in a criss-crosspatternin 2 or 3 steps, beginning with the inner nuts.

3.

Apply liquidgasketto the head mating surtacesof

the No.1 and No. 6 camshaft holders,then install
them, along with No. 2, 3. 4 and 5.
NOTE:
a "1" or "E' marks are stampedon the camshaft
holders.
a Do not apply oil to the holdermating surfaceof
camshaftseals.
a Apply liquid gasketto the shadedareas.
a The a.rows marked on the camshaft holders
should point toward the timing bett.

GASKET
I x 1.25mm
Replace.
32 N.m{3.2kg-m,
23 rb-ft)

No.2

l"'ln_m*ll
^/'""1"'"1*"
trBfr m ffi

/No.

1 0 x 1 . 2 5m m
45 N.m (4.5 kg-m,
I x 1 . 2 5m m
22 N.m (2.2 kg-m,
16 rb-ft)

GASKET
Replace.

33 rb ft)
6 x 1 . 0m m

1 ON . m ( 1 . Ok g m ,
7 tb-tr)
HEAT INSULATOR

1 0 x 1 . 2 5m m
55 N.m 15.5kg,m,40 lb,ft)
Replace.

K g H H F HWi

M H

Ili H

tru

6r
&{
pI
LOJ

16r
M
liT

tl

TNTAKE

ffi4.n**"
{cont'd)

6-57

RockerArms/Camshaftsand Seals/Pulleys
lnstallation(cont'd)
4.

Tightenthe camshaftholderstemporarily'
a Make sure that the rocker arms are properlyposltioned on the valve stems'

Torque:Exhaust
SDecifi6d
ExceotG), (O: 10 N m {1.0kg-m,7lb-ft)
, lb-ft)
1 2 N . m{ 1 . 2k s - m 9
@, @i

\
5.

Pressin the camshaftsealssecurely.

lnstallthe back cover.

8 . Installkeys into camshaftgrooves.

NOTE: To set the camshaftsat TDC positionfor No'
1 piston, align the holes in the cdnshafts with the
holesin llo. 1 camshaftholdersand insert 5'O mm pin
punchesin the holes.

Tighteneach bolt in two stepsto ensurethat the rockers do not bind on the valves.
Specified Torque: lntake
qceq@,O, 1ON.m (1.Okg'm, 7 lb-ft)
12 N.m (1.2 kg-m,I lb-ft)

(9,(r,

INTAKE

I x 1 . 2 5m m

9.

Push camshaft pulleys onto camshafts,then tighten

the retainingbolts to the torque specified'

1 0 . Adjust the valve cle316nes(page6-68).

1 1 .After installation,check that the all tubes, hosesand
connectorsare installedcorrectly.

6-58

Timing Belt and Timing BalancerBelt

lllustratedIndex
NOTE:
. Referto page 6-62 for posilioningcrankshaftand pulley beJoreinstallingtiming belt.
a BeJoreremoving,mark directiono{ rotationon each belt.

POWERSTEERING
IP/SI
PUMPBELT
Adiustment,section17

ALTERNATOR
BELT
Adjustment,
section23 ADJUSTTNG
NUT

LOWER
COVEB
COVER Removethe tive bolts.

45 N.m {4.5 kg-m,

33 rb-ft)

6x1.0mm

RUEBER
SEALS
ReDlace
when
damaged
or deto.iorated.

12Nm(1.2kg-m,

CAPt{UT
6 r 1 . 0] n m
'lON.m
l1.Okg-m,7 lb-ftl
CYLINDERHEAD
6x1.0mm
1 2 N . m ( 1 . 2k g - m ,
CRANKSHAFI I lb'ft)

R'LLEY

PULLEY8OL

WASHEB------+o

Removgany oil.
14 x 1.25 mm
RUEBER
SEALS
220 N.m (22.0 kg-m, 159 tb-ft)
Roplacewhen damaged
Apply engineoil to th6 bolt
or detoriorated.
thrcads, but not to the
surfacethat contacts the
8 r 1.25 mm
washer.
38 N.m(3.8ks-m,27lb-ft)
KEYS

TEI{SIO'{ER
SPAII{G

TE SIOI{ER
SPRII{G

BELT
tENStOa{ERS

CAMSI{AFT PULLEYS

I(EY
TIMINGBELT
ADJUSTING
BOLT
68 N.m(6.8kg-m,49lb'ft)
Remove
any ofl.
6 x 1,0 rhm
12 N.m (1.2 kg-m,I lb-ftl

TIMING BALANCERBELT
Inspectjon, page 6-61.

BELT
Inspection,pag6 6-60
Adjustment,page 6-60
Beplacement,page 6-63

surlacelacing in.
Bemoveany oil.

6-59

TimingBelt
Inspection
1.

Disconnectthe alternatorterminaland the connector,

then removetheenginewire harnessfrom the cylinder
head cover.

2.

Removethe cylinderheadcover.

3.

Removethe middlecover.

4.

lnspect the timing belt for cracks and oil or coolant

soaking.
NOTE:
a Replacethe belt if oil or coolant soaked.
. Removeany oil or solvent that gets on the belt.
Inspectthis
area{or wear.

TensionAdiustment
CAUTION: AtwaF adiust timing boh tension with thew
enginecold.
NOTE:
o The tensioneris springJoadedto applypropertensionto
the belt automaticallyafter making the following adjustment.
. Alwavs rotate the crankshaft counterclockwise when
viewed trom the pulleyside. Rotatingit clockwisemay
result in improperadiustmentot the belt tension.
. Inspectthe timing balancerbelt beforeadjustingthe belt
tension.
a Do not loosenthe adjustingnut morethan one full turn'
1.

Disconnectthe alternatorterminaland the connector,

then removetheenginewire harnesstrom the cylinder
head cover.

2.

Removethe cylinderheadcover.

3.

Set the No. 1 piston at TDC (page6-62).

4.

Loosenthe adiustingnut 2/3-1 turn, then tighten it'

Rotatepulley
ano rnspect
belt.

Rotatethe crankshaftcounteclockwise3-teethon the

camshafqpr.rlley,then reloosenthe adjusting nut to
createtensionon the timing belt.

After inspecting, retorque the crank*|aft pulley bolt to

22ON.m (22.Okg-m, 159 lb-ft).
o.

Tightenthe diustingnut.
After adiusting,ratorquethe crankshaftpulleybolt to
22O N.m {22.Okg-tn, 159 lb-ft).

6-60

TimingBalancerBelt
Inspection
1,

Disconnectthe alternatorterminaland the connector,

then removethe enginewire harnessfrom the cylinder
headcover.

2.

Removethe cylinderheadcover.

3.

Removethe middlecover.

4.

Removethe crankshaftpulley.

5.

Removethe lower cover.

6.

Installthe crankshaftpulley.

7.

Inspect the timing belt for cracks and oil or coolant

soaking.
NOTE:
a Replacethe belt if oil or coolant soaked.
o Removeany oil or solventthat gets on the belt.

Rotatepullgy
andinspectbglt.
After inspcting,retorquethecrankshaftpulleybolt to
22O N.m (22.Okg-m, 159 lb-ft).
NOTE: Refer to psge 6-66 for timing batancerbelt
tensionadiustmnt.

6-61

Timing Belt
PositioningCrankshaftBeforeInstallingTimingBelt.
NOTE:
. Installthe timing belt with the No. 1 piston at TDC.
. After installing,retorquethe crankshaftpulley bolt to
22ON.m (22.Oks-m, 159 lb-ft).

TDCFOSITION:
CAMSHAFT
,,UP''MARKS

CMN(SHAFTTDCFOSITION:

POINTERS
ON BLOCK

TDC MARKS
Align the marks
on the pullays.

FLYWHEEL

DRIVEPLATE
PI Pt CHES,5.0nm

CAUTIOI{: Romovc thr pln Frnchos attor installlng

th. tlming boh.

NOTE: When turning the crankshaft with a socket

wrench, installthe crankshaJtpulleyand the pully
bolt.

6-62

TimingBeltandTimingBalancer
Belt
Replacement
CAUTION: lmpoct tho water pump whon roplacing the
timing bh lpags 10-12).

3. Removethe
mountingbolts,nutsandpoly-V-blt
from
the powersteering(P/Slpump.

NOTE; Turn the crankshaftso that the No. I oiston is at

TDC (page6-62).

NOTE:
. Oonot disconnect
the P/SpiDeandhose.
. Afterinstalling,
adiustthetensionot the P/Spump

1. Removethe sDlashshield,

belt (seesection 171.

LOCKI{UT
' 1 5N . m( 1 . 5k g - m ,
11 tb-ft)

P/S PUMP

BOLTS/T{UTS
8 r 1.25rfn
22 N.m 12.2kg-m,
16 rb-ftt

SPLASHSrmU)
Disconnectthe connector, then remove the cruise
control actuator.
NOTE:
a Do not disconnectthe control cabte.
. Takecarenot to bendthe cablewhen removingthe
actuator.Always replacea kinkedcablewith a new
one.
CNU|sECONTROL
ACTUATOR

6r1.0mm
1oNm(1.okg-m,
7 tb-ft)

4.

Disconnectthe alternatorterminaland the connector,

then removethe enginewire hamessfrom the cylinder
headcover.
Loosen the altemator mounting bolt, nd rnd the adiusting boh, then removethe ahernatorbeh.
NOTE: After installing,adiustthe tensionof the alternator beh {seesection 23).

J:aLIERNlton
ool{]{ECTOR

ADJUSTING
BOLT

MOUI{TIXGBOLT
tO x 1.25mrn
45 N.m(4.5kg{, 33 lb-ft)

MOUNTI{G NUT
8xt.25mm
22 N.m {2.2 kg-m,
16lb_ft}

ALTERI{ATOR
BELT
(cont'd)

6-63

TimingBeltandTimingBalancerBelt
(cont'd)
Replacement
1 0 . Removethe pulleybolt and the crankshaftpulley.Re-

6. Removethe cylinderheadcover.

move the two rearboltsJromthe centerbeamto allow

the engineto drop down and give clearancetoremove
the lower cover,

7. Removethe middlecover.
8. Removethe side enginemount.

1 1 .Removeth rubberseal aroundthe adiustingnut. Do

not loosnthe adjustingnut.

9. Removethe dipstick and the pipe.

12. Removethe lower cover.

6x1.0mm
1 2 N . m( 1 . 2k g ' m ,9 rb-ftt
12 x 1.25 mft
55 N.m (5.5 kg-r(,
40 tb-ft)

O-RING
Replace.

1 2 x 1 . 2 5m m
65 N.m {6.5 kg-m,
47 tb,ft)
RUBBERSEALS
Replacewhsn
damagedor
deterio.ated.

RUBBERSEAL
Replacewhen
damagedor
detaiorated.

RUBBER
SEALS
Replace
when
ol
MIDDLE COVER oamageo
Semove any
o .

6x1.0mm
12 N.m (1.2 kg-m.9 lb-ft)

PULLEYBOLT
1 4 x 1 . 2 5m m
220N.m(22.Okg-m,159lb-ft)
Apply engineoil to the
bolt threads, but not
to the surfacthat
contacts the washer.
CRAI{KSHAFT
PUI.LEY
Removeany oil.

6-64

TIMII{G BELT
Inspoction, pago 6-60
Adiusting, page 6-60
ADJUSTIf{GNUT 6 x 1 . O m m
1 2 N . m { 1 . 2k g - m ,
10 r 1.25 mm
45 N.m {4.5 kg-m, 9lb-ft)
33lb-ft)

13. Lockthe timing belt adlusterarm in placeby installing one of the 6 x 1 .O mm lower cover mounting
bolts,

16. Loosen6 x 1.O mm lock bolt and the adjustingnut.

Pushon the timing belt adjusterpulleyto removetension trom the belt, then tighten the adjustingnut.

14. Loosenthe timing belt adjustingnut. Pushon the pulleyto removetensionfrom the timing balancerbelt,
then tighten the adjustingnut.

17. Removethe timing blt.

'15.

Removethe timing balancerbelt.

18. lnstallthe timing beh in the reverseorderof removal.

- Beforeinstallingthe timing belt, positionthe crankshaft and camshaft pulleys as shown on page
6-62.

NOTE: lf you are removingonly the timing balancer

belt, go to step 21 . li you are removingboth belts,
continuewith this procedure.

19. Per{orm the timing belt tension adiustment {page

TIMINGBELT
ADJUSTERARM

6-60t.

20. Tightenthe 6 x 1.Omm bolt to lock the timing belt adrusterarm.

ADJUSTING
t{UT
45 N.m(4.5 kg-m,33 lb-ft)

(cont'd)

6-65

Timing Belt and Timing BalancerBelt

(cont'd)
Replacement
21 , Make surethe crankshaftis positionedwith the No. 1
piston at TDC.
22, Alignthe grooveon the front balancershaft pulleYwith
the pointeron the oil pump housingas shown.
23. Align the rearbalancershaft pulleyby usinga 6 x 1OO
mm bolt or equivalentas an alignmenttool.
Scribea line 74 mm (2.9 in) Irom the end of the bolt.
lnsertthe boh into the maintenanceholeto the scribed
line.

26. Tu(n the crankshaft pulleYabout one turn counterclockwise. then tighten the adiusting nut to the specltied torque.
NOTE: Both belt adiusters are spring-loaded to
properlytensionthe belts.Do not applyanyextra pressure to the pulleYsor tensionerswhile performingthe
adjustment.
REARBATANCER

24. Loosenthe adjusting nut and verifY that the timing

balancerbelt adiustermoves freely.
25. Installthe timing balancerbelt. Removethe 6 x 1OO
mm bolt from the rear balancershaft.
74 mm (2.9 in)

6 r 1OOmm BOLT
Rplace.
12 mm SEALI G AOLT
30 N.m (3.0 kg-m, 22lb-ft)
NOTE: Tighten the bolt after
installingthe belt.

6 x 100 rm BoLT

ADJUSTING]{UT

Align the g.oove oI the

front driven pulley with
the pointer on the oil
pump housing

TIMII{GBALAT{CER
EELT
DN|VEIT
PULI..EY

BALAI{CER BELT
ORIVEPULLEY
Set the crankshaft
at TDC.

6-66

27. Removethe 6 x 1,Omm bolt from the timing belt adjuster arm.

31. Installthe middlecover.

32. Installthe crankshaftputley.

28. Removethe crankshaftpulley.

33. Coat the throads 8nd seating face of the pulley bolt
with engine oil. Install and tighten to the specified
toroue.

29, Installthe lowercover.

30. Installa rubberseal aroundthe adiustingnut. Do not
loosenthe nut.

RUBBERSEAL
Replacewhen
damagedor
deterioratd.

MIODLECOVER

Spocifiedto|ql|3: 220 N.m {22.0 kg-m, 159 tb-ft)

RUBEERSEAL
Replacwhen
damagedot
deteriorated.

RUEBERSEALS
Repl6c6when
damagdor
dsteriorated.

6 x 'l.Omm
1 2 N m ( 1 . 2 k s - mI,l b , f t )

PULLEYEOLT
1 4 r 1 . 2 5m m

22ON.m 122.0ks-tn
159lb-ft)
CRANKSHAFT
PUI.LEY
Bemoveanyoil.

6 x 1.Orrn
12 N.m ll.2 kg-m,I lb-ftl

10 x 1.25rm
45 N.m(4.5 kg-rn,33 lb-ftl

6-67

Valve Clearance
Adjustment
Adjust valves on No. 1 cylinder.

NOTE:
. Valvesshouldbe adjustedcold when the cylinderhead
is lessthan 1oOoF(38oC).
temperature
. After adjusting,retorquethe crankshaftpulley bolt to
220 N.m (22.0 ks-m, 159 lb-ft)
1.

Removethe cylinderheadcover

Valve Cl6a?anca:
lntak: 0.07-O.11 mm (O.0O3-0.0O4in)
Exhaust:0.15-0.19 mm (0.006-0.007 in)
4,

Loosenlocknut and turn adjustingscrew until feeler

gaugeslidesback andJonhwith slightamountofdrag.

INTAKE

27 N.m{2.7kg-m.20 lb-ftl
Applyongine
oil.

2.

"UP" markson the camshaft

Set No. 1 pistonat TDC.
pulleysshouldbe attop. andTDC Arooveson the camshaft pulleysshould align with cylinderheadsurface.

Number 1 fiston at TDC:

,,UP" MARKS

TDC MARKS
Align the marks
on the pulleys.

6-68

Tightenthe locknut andcheckclearanceag8in.Repeat

adjustmentif necessary.

6.

Rotatecrankshsft 18Oocounterclockwis(C8mshaft
pulleystums 9Oo).The "UP" marks should b6 at xhaust side. Adjust valveson No. 3 cylindor.

filumber 3 Diston at TDC:

8.

RotatecrankshaftI8Oo counterclockwiseto bring

No.2 Distonto TDC. The "UP" marks shouldbe at
intake side. Adjust valveson No. 2 cylinder.

Number 2 dston at TDC:

,,UP" MARKS

7.

Rotatecrankshaft18Oocounterclockwiseto bring
No. 4 piston to TDC. the TDC groovesare onc agsin
aligned.Adjust valves on No. 4 cylinder,

Numbor 4 piston 8t TDC:

6-69

GylinderHeadA/alveTrain
lHz2!-l engine)
Special
Tools
...........6-72
lllustrated
lndex..............................
&73

Camshafts
Inspectbn
............6-93
wEc
Vdves, VafueSpringsand ValveSeals
Troubleshooting Flowc*rart Removal
..............
6-95
WEC Solenoid
Vdve ................6-75
Vdve Springand Vdve Seal
lrutalationSequence.................
WEC PressureSwitch... . . ....... . .. 6-77
6-101
Vdve lnstallation
VTEC SolnoidValve Inspoction...... 60
... 6-102
Vaho Seats
Rocker Arms
Reconditioning
......6-97
ManualInspection. . . . . . . . . . . . . .. . . . . . . . . . 61
Vdve
Gukles
Inspeabn UsingSpecialToo|s........61
Valve
Movernent
........................,
Inspectbn
6-98
. .... .... . .. 6-92
Replacemst.....
..,.6-99
Cylinder llead
Reaming
.........,....
Removal
6-t0O
..............6:l
TimingBdt and nming BalancerBat
Warpage.........
.....6-98
ltusratodlndex....................,.....
Instalhtion
. 6-107
...........6-103
Feplacemem.....
Rocker Armg and Shafts
....6-109
TimingBlt
Removal
..............6g
Inspection
Locations. . . . . . . . .
............6-108
....6-90
TimlngBdancerBeh
Clearance
...... ..
.....6-91
Inspoction
Installation
............6-10g
...........6-102
Vaho Cbarance
Lost motion AssemHies
Adfu3rnora
Inspection
..........6-1tE
............ 6-92

Ref. No.

o
@
@
@
\!,

Tool Number

OTHAH_PJ701OA
or O'?HAH-Pl'lO1OB
OTLAJ_PR3O2OA
oTMAA-PR70t10
07MAA-PR70120
OTMAF_PR90IOA
07NAG-P130100
07742-O010100
o7757-PJ10l0A

Descfption

Oty

vaNe Gu\de Reame(, 5.5 mm

Air Stopper
Tappet Adiuster
Tappet Locknut Wrench
Valve SpringComprssorAttachment
Extension
Timing Belt Slider
Valve Guide Driver, 5.5 mm
Valve Spring Compressor Attachment

1
1
1
1

Page Rotorcncr

6-100
6 - 8 1 ,8 2
6 - 11 5
6-115
6-95
6-106
6-99, 100
6-95

P
--!_rr--_--__---b

il
o

U
@

:r------------

r-blrrrlllsaf

6-72

A---J
\9

q:\
"_-___e.dD/
@

lllustratedIndex
CAUTION: To avokl damaging the cylinder h6ad, wait until the engine coolant tmporatur dlope below IOOoF (38oC) before
removing h.
NOTE:
a Use new O-ringsand gasketswhen reassembling.
. Use liquidgasket, Pan No. 08740-OOO1.
a Clesnthe oil controlorifice betoreinstalling.
Prio,to r"""sembling, clean all the parts in solvent.dry them, and apply lubricantto any contact pans.

x 1 . 0m m
1 0 N . m ( 1 . 0k g - m ,7 l b - t t )

PLUGWINE
COVER

CLAMP

CYLINDERHEAD
COVER
6 x 1 . 0m m
1 ON m ( 1 . 0k g - m , 7 l b ' f t )
WASHER
Apply liquid gaskt
to these pornts.

RUBBEB
SEALS
Replacewhn
or deteriorated.

I r 1 . 2 5m m
26Nm{k2.6kg-m,
't lb,ftl
9

6r t.Omm
1 2N . m( 1. 2 k g , m )

6x1.Omm
1 2 N . m { 1 . 2k g - m ,
9tbft)

RUBBERCAP
Replacewhen
damagedor
dete orated.

CAMSHAFTHOLOER

AKE CAMSHAFT
page 6-93

8 x 1.25 mm
18Nm(1.8kg-m
13 tb-ft)

page6-105
Installation,
Replace.
CAMSHAFTPULLEYS
Removal,page 6-86
page6-105
Installation.

DISTBIBUTOR

KEYS

wEc
SOLENOID
VALVE

5 x kl.0 mm
12 N . m ( 1 . 2k g - m
I tb-ft)
VTEC SOLENOID
VALVE FILTER
Replace.

1 0 x 1 . 2 5m m
5 1 N . m ( 5 . 1k g - m ,
37 tb-ft)
'lO
x 1.25 mm
45 N m (4.5 kg m, 33 tb ftl

EXHAUST
CAMSHAFT
O-RING
Replace.
OIL CONTROL
ORIFICE
Clean.
BACKCOVER

6x1.0mm
1 2 N . m ( 1. 2 k g m

I lb{tl

8 x 1.25 |nrl
22Nm(2.2koJn-

qo.'

enctrue
uourur

r o ru--ttt

{cont'd)

BRACKETB

6-73

lllustratedIndex
(cont'd)
NOTE: Cleanthe rocksr shaft orificeswhen installing.

EXHAUSTVALVE
SPRIG NI{ER

ROCIGRABM ASSEMBLY
IPRIMARY,MIO, SECOI{DARY)

CYLINDERHEAD
BOLTS
1 2 x 1 . 2 5m m
100 N.m {10.0 kg-m,72 lb-ft)
Apply clean engineoil
to threads and
underthe bolt heads.

VALVEKEEPERS

VALVE KEEPRS

,f,"*'*o"'o'n"
INTAKEVALVE
INNER
SPRING

EXHAUSTVAL
SPRINGOUTER
SEALINGBOLTS20 mm
60 N.m (6.0 kg-m,43lb-ftl

INTAKEVALVE
SPNINGOUTER

O.RINGS
Replace.

WASHEB
Replace.

Replacement,pags6-95
ROCKERSHAFTS

I
VALVESEAL

INTAKEBOCKER
SHAFTORIFICE
Clean.

VALVE

LOSTMOTION
ASSEMBLY
EXHAUSTROCKER
SHAFTORIFICE
Clean.
i
HEADGASKET
CYLINDER
{METALGASKETI
Replace.
DOWEL
PINS

NOTE: Do not installthe oil control orifice.

6-74

SPRINGSEAT
ALVE GUIDE
Inspection,page 6-98
Replacement,page 6-99
Roaming,page6-10O
LOSTMOTION
ASSEMBLY

HEAD
CYI"INOER
Removal,page 6-83
Roconditioningvslve
sst, page 6-97
Warpage,page 6-98
Installation,page 6-103
EXHAUST VALVE
INTAKE VALVE
Rplacement,
Oimension,pag 6-95
Reconditioningvalve
seal, pago 6-97
Adiustment, page 6-1 '15

VTEC
TroubleshootingFlowchart - VTEC SolenoidValve
-f6il

lttll

Maffunction
Indicato.Lamp(MlL)indicatesCliagnostic
TroubleCode(DTC)21:A problemin the \rrEC
Solenoid
ValvecircNJit,

-r-'
---.1116l -l
21l-----i-

MIL hr! bon ,aoon6d on.

With srvlc chock connoctor
Fmpod lp.go 11-42), cod6 2 1
i8 indhatod.

Do tho onglno c-ontrol modole

(ECMI Rosot Plocoduro (p.go
11-43).

Wann up ongino to normd oprating tompo.ature lradiator t6n

como! onr.

Do thg RoadTest.r

ls MIL on and does it indicate

code 21?

*Road Test:
Acceleratein 2nd gear to an onginespgedover 6000 rpm.
Hold that enginespedfor at least two seconds.
Ropeatthis test at least threo times.
Intorrnlttaot lailuro, 3y8tom ir OK
at thi! tim6.
Ch6ck tor poo. connoctiona o.
10036 wiro. at VTEC aolonoid
valve and ECM,

Dbconnoc-t tho 1P connoctd from

tho VTEC aolonold vdv6.

Ch6d( lor cootinuitv betwoon lP

connoctoa torminal and body

ls there 14-300?

lTo page6-761

(cont'd)

I
VTEC

Flowchart-VTEC SolenoidValve(cont'd)
Troubleshooting
{Frompage 6-75}

Reconnoct 1P connoctof to VTEC

solonoidvalv6. Conngct tho ECM
tost hamds lo the moin ha.n$t

Measuro the rosfutanco botween

A4 trmlnaland 426 t6rminal.

ls there14-30 0?

substituts a known{ood ECM

and rccheck. ll symplom/indlc'tion goos away toplaco thc odginal
ECM.

6-76

Chd( lor ogdt or !ho.l In wlto batw.on ECM lnd VTEC lohnold
vdvg.

TroubleshootingFlowchart@'l

r.-l
!r{=r j-

VTECPressureSwitch

l2rl I Uafun"tionIndicatorLsmp{MlLlindicatesDiagnostic
TroubteCodelDfcl 221 A Droblem in the
VTECPressureSwitch circuit.
- f-;;r
ta I

MIL h6 baan rcponod on.

Wlth ..wlca chccl corn.cior
Fmp.d {p.gr I 142). Cod. 22
l! Indlcltrd.

Do the ongine control moduls

(ECMI Bgset Procedure lpags
11-43).

Warmup engineto normaloperating tempmturlradiEtorfan

comesonr.

*Ro6d Test:
Accelorgte in 2nd 96.r to on gngine spoed ovfl 6000 rpm.
Hold that engino speod for at loast two sconds.
Repsat this test 6t lgagt thr6 timos.

Do the RoodTest.'
lr tmltt nt dura, !y!t!m b OK
rt lhl! tlmc.
Chlck td poor conn.ctlionr ot
loota wklr rt VTEC prct.or.
rwltch lnd EM,

VTECPRESSURE

Tu.n the ignition switch OFF.

Digconnoct the 2P connoctor from

th VTEC oressuro switch.

Chsckfor continuivbstwoentho
2 terminalson the VTECpreasurs
switch.

Turn the ignition switch ON.

Mga6urcthe voltags betw66n the

8LU/BLK wire 6nd body grolnd.

{To pags 6-78)

(cont'd)

VTEC

TroubleshootingFlowchart(Frompage 6-77)

ls there approx. 10 V?

Measurs the voltage across the

8LU/BLKand BLK wires in 2P connector.

ls ther6 approx. 10 V?

VTECPressureSwitch (cont'dl
Inspoct lor an opon oa thort to
ground ln th. BLU/BLKwiro b.tw6n tho 2P connccto. tnd D6
t.rmlnll ol th. EcM. It wko b oK,
rub.iltuto r known-good ECM
and ictort.

VTECPRESSURE

swtYcH

Rgpolropon d.ori In BLK wko botwcn lha 2P connoctor gnd body

ground.

Turn the ignitionswitch OFF.

1 0v ?

Reftove 10 mm soaling bolt nd

connect oil prgss!re gauge.

GAUGE
OIL PRESSURE
COMMERCIALLY
AVAILABLE

Connoct a tachomster {se section 1'1).

Start the ngine and warm it uP

to normsl operatingtemperature.
WASHER
Replaco.
Check oil prossure at engine
'l,OOO,3,0OOand 5,0OO
speedof
rpm.
NOTE: Keepmeasutingtimo as shon
as Dossiblebecausgengineis running
with no load (lessthan one minutel.

ri
ls pressurebelow 50 kPa (O.5
kg/cm', 7 psi)7
'l
Disconnectth P connectorfrom
the VTEC solenoid valve,

F.
iiri
;i

Aftach the battory positive terminal to the GRN/VVHTtermin6l

{To pge 6-79)

6-78

SEALINGEOLT
GAUGE JONT ADAPTOR
20 N.m (2.Okg-ln, SNAP.ON MT26-17
t 4 tb-ftt
10 x l.O mm

In3pocl tho VfEc tol.nold v.lv!.

. Use new washr when

installing the sealing bolt.

(From page 6-78)

Start th6 engine nd check oil

p.essure at 5,OOOrpm.
PRESSUREGAUGE
COMMERCIAI.IYAVAILAALE

WASHER
R6place.

NOTE: Keep rl|ossuring timg as short

as poasiblebgcauseenginis running
with no losd (l6ssthan one minute).

SEALIIIGBOLT
20 N.ln l2.O kg-ln,
14 tb-frl

ls p.essure above 4OO kPa

(4 kg/cm', 57 psi)?

S]{AP-ONMT26-17
10 r 1.0 rnm
. Usonew washgrwhen
installingthe sealingbolt.

Inrpoct tho VTEC rol.nold vCv..

Turn the ignition switch OFF.

Reconnect the 2P connctor to

the VTEC Dressureswitch.

Install the tgst hamess (page

11-251.

Stsrt the engins and run above

5,OOOrpm. Measurethe voltage
between D6 l+l and O22 l-l
terminal ol the ECM.

Subrlhute a known,good ECM

.nd r.chock, It rymptoh/lndic.tlon gooa lwsy rcplsce tha o.iginll ECM.

6-79

t-

WEC
WEG SolenoidValve InsPection
Disconnectthe 1P connectorfrom the VTECsolenoid
valve.
2. Measureresistancebetween the terminal and body
grouno.
Resistance: approx 14-30 ohms
1.

4.

lf the filter is not clogged, push the VTEC solenoid

valve with your finger and check its movement'
o lf VTECsolenoidvalve is normal,checkthe engine
oil oressure.

6x1.0mm
12 N.m 11.2kg-m,9lb-ft)

lf the resistanceis within specifications,removethe

VTEC solenoid valve from the cylinder head, and
check the VTECsolenoidvalve filter for clogging.
o lf there is clogging,replacethe engineoil filter and
the engineoil.
;.1

Fl

VTEC SOLENOIDVALVE

' Il
r t

VTEC SOLENOIDVALVE
FILTER
Replace.

6-80

6x1.0mm
l 2 N . m ( 1 . 2k g - m ,g l b ' f t )

RockerArms
ManualInspection

InspectionUsingSpecialTools

Removethe cylinderheadcover.
o

Btoro using the spodd tool (Valv! lmpction Tooll,

mak6 sure that tho aL pnesaurogauga on th6 air com_
pressor indkrat.s ovor 250 kpa (2.S kg/cmr, 36 p3l).
Inspect th valv clearance before rockr arm inspoctbn.
Covcr thc dming bah with a lhop towol to fotoct thc
beh frcm o0 roakhg,
Check th. mH rocksr e]m of 6sch xilton Et TDC.

1.

Removethe cylinderhead cover.

2.

Plugthe relief hole with th speciattool.

Push the mid rocker a.m on the No, 1 cylinder

manually.
o
Checkthatthe mid rockerarm movesindependentlyof
the primaryand secondaryintake rockerarms.
MID ROCKER
ARM

EXHAUST

4.

Checkthe mid rockerarm of each cylinderat TDC.

a lf the mid rocker arm does not move, rmovethe
mid, primaryand secondaryrocker arms as an assembly and check that the pistons in the mid and
pfimary rockerarms move smoothly.
o lf any rocker arm needs .eplacing, replace the
primary,mid, and secondaryrockerarms as an as_
semblv.

(cont'dl

6-81

RockerArms

InspectionUsingSpecialTools(cont'd)

3.

Removethe bolt and w8sherfrom the inspectionhole

and connectthe valve inspectiontool.

4.

Loosenthe regulatorvalveon the valveinspectiontool

. and applythe specifiedair pressureto the rockerarm
pistons.
Sp6dfied A Pr$sui:
250 kPa (2.5 kg/cm', 36 psil
- 5Oo kPa (5.0 kg/cm', 71 Fil
Makesurethat the intakeprimaryand secondaryrocker armsaremechanicallyconnectedby the pistonsand
that the mid rocker arms do not move when pushed
manuallv.

VALVE
REGULATOR
Pullthe leverand
turn to adiust.

MID ROCKER
ARM

LOSTMOTION
ASSEMBLY

SEAUNGBOLT
1 Ox 1 . 0m m
20 N.m(2.0kg-m,
14 lb-ft)

1 0x 1 . Om m
ADAPTER
S]{APONMT26-17
o. EOUIVAEI{T

o lt any mid rockerarm independentlyof the primary

and secondary rocker 8rms, replace the rocker
arms, as a ser,
Removethe tools.

,,1
'f

Checkfor smooth operationoI the lost motion assembly. lt is compressedslightlywhen the mid rockerarm
is lightlypushedand compresseddeeplywhen the mid
rockerarm is stronglyPushed.
. ReDlacethe lost motion assembly iJ it does not
move smoothly.
After insDection,check that the malfunctionindicator
lamo lMlL) does not come on.

6-42

CylinderHead
Removal
Engineremovalis not requiredlor this procedure.

1 . Disconnect the negative terminal from the battery.

@E

. MalG surs Fcks and salaty stands re dac.d p(opody

ard hoist brack6is ar attachod to co.roct positions on
ths engln6.
. Mako sur the car wlll not loll off stards and fall while
you aro working undor it.

CAUTION:
. Uss tender covors to avokl damaglng paintad surfaces,
o Undug rhe wiing connoctoB ceefuf,y whte holdlng th
connctor ponion to avokt damage,
a Ma.k aI wiing and hosos to avoH misconnectbn. Also,
bo sur that they do not contact othor widng or hosa3 01
interfere whh othr DarB.
. To avokl dsmaging the cytrder hrad. wait until tho
coolanttempraturedropobelow IOOoF(38oC)engine
bforo bosening the rotaining bolts,

Drainthe enoinecoolant(seesection 1Ol.

a Removethe radiator cap to speed draining
J.

Relievefuel pressure.
@
Do not moke whllo wor{ng on ft,"l
sFtm, k3p opan f!|m or rFrt away from work
Eroa. Drain fr.rCor{y lnto an apFovd contakrr.

4.

Removethe intak air duct,

Removeth fud feed hose and evaDorativeemission
(EVAP)controlcanistor
hosfrom the intakemanifold.

NOTE:
. Inspect the timing belt belore removing the cylinder
head.
a Turn the crankshaftpulleyso that the No, 1 piston is at
top dead center (page6-1061.
a Mark allemissionhosesbeforedisconnectingthem.
NOTE: The radiomay have a coded theft protectioncircuit. Be sure to get the customer'scode numberbefore
- Disconnectingthe b8ttery.
- Removingthe No. 43 (1O A) tuse (ln the under-hood
fuse/relavboxl.
- Removingthe radio.
After service,reconnectpower to the radio and turn it
on.
When the word "CODE" is displayed.enrerthe customer's s{igit code to restoreradiooperation.

POSITIVECRANKCASE

o.

Removethe throttle cable from the throttle body,

NOTE:
a Take care not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
a Adjust the throttle cable when installing(see
s e c l i o n1 1 ) .

ADJUSNNGNUT

{cont'd)

6-83

"t.

CylinderHead
Removal(cont'dl
7.

Removethe fuel teed hose, the tuel return hose and

the brakeboostervacuum hose.
FUELFEEOHOSE

9.

Remove the engine ground cable lrom the cylinder

head cover.

10. Disconnect the alternator terminal and connector,

, thsn removetheenginewire harnessflom the cylinder
h9d cover.

6 x 1 . 0m m
8 N.m(O8 kg-m,5.8lb-ft)

6 x 1 . 0m m

10 N.m (1.0 kg-m.7 lb-ft)

l ,}

1 1. Rdmovethe power stsering (P/S)pump bolt and pump.

a Do not disconnecl the P/S hoses.

a
a
a
a
a
a

fo

a
a
o
o
o
o
a
a
o
a
a
a

Removethe Jollowingenginewire harnessconnectors

and clamps from the cylindet head and the intake
manifold:
Fourfuel injectorconnectors
lntake air temperature{lAT) sensolconnector
ldle air control (lAC) valve connector
Throttle position {TP)sensorconnector
Exhaustgas recirculation(EGR)valve lift sensorconnector
Groundcableterminals
Enginecoolanttemperature(ECTIswitch B connector
Heatedoxygen sensor(Ho2S)connector
ECTsensorconnector
ECTgaugesendingunit connector
lgnition control module (lCMl connector
CKP/TDC/CYPsensorconnector
VehiclesDeedsensor {VSS}connector
lgnitioncoil connector
VTECsolenoidvalve connector
VTECpresserswitch connector
Intake 8ir bypasssolenoidvalve connector
ECTswitch A connector
Knock sensorconnector

6-84

u'o-n,
li,l.3u,ll*n-..'

LOCKNUT
1 5N . m( 1 . 5k g - m ,
1't rb-ft)

8 x 1.25 mm
22 N.m (2.2 kg-m.
16 rb-ftl

P/SPUMPBELT

I
I

I
1 2 .Bemovethe ignitioncoil.

16, Femove the bracket and intake manifold.

RESISTANT
BOLT
*: CORROTION
* 8x1.25mm
22 N.m (2.2 kg-m, 16 lb-ft)

* 8x 1.25mm
22N,n 12.2kg-r'|,,
16 tb_ft)

1 3 . Remove the emission vacuum hoses and water

'17.

bypasshosesfrom the intakemanifoldassembly.

1 4 . Removethe radiStorupperhose and heaterhosetrom
the cylinderhead.
15. Removethe water bypass hose and the thermostat
housing.

'18.

Removethe selflocking nuts and disconnectthe ex,

haust manitoldand exhaustpipe A.
Remove the heat insulator, brackets and exhaust
manifold.

BBACKETS

o-Rt]{G
Replace.

6-85

CylinderHead
Removal(cont'd)
1 9 . Rmovethe cylinderheadcover.

23, Removethe belt from the camshaftpulleys.

20. Removethe middlecover.

Use a wrench to loosen the maintenancebolt lf it
cannot be loosenedwilh an open-endwrench, a box
wrench can be used after pullingout the lock pin

CAUTION: Do not caimp oi b.nd

tho tlr$ng bdt mors fran 9Oo or
bss thtn 25 mm | 1 in) h damcter'

NOTE: Useof a tool shotildbe limhedto initialloosening only.

22, Loosen the maintenanceboh by hand until it stops'
The auto-tonsionerbracketis now tixed.
NOTE:
a Neverusea tool to loosenthe maintenancebolt after initisl loosening.
a ll tha auto-tensioner has been extendsd 8nd the
timing beh cannot b installd,remove the autotensionsr,@mpressit and lainstsllh (page6-1 12).

G4?
No Good

24. Removethe camshaftPulleYs'

CAMSHAFTPULLEYS

MAINTENANCE

AOLT

Auto-tonsioner
funstistl.
;*,6r*;i*

MAINTENAI{CE
BOLT

Auto-tensaoner
fixed in plac6.

6-86

25. Loosenthe rockerarm adjustingscrews,then remove

the camshaft holdersand camshafts

ADJUSTINGSCREWS

27, Rmove ihe cylinder head bolts, then remove the

cylinderhead.
CAUTION: To p.event warpag, unscrw the bolts in
soqunce 1/3 tutn at a time; rspeat the sequonce until
all bohs aro loossned.
CYLINDER
HEADSOLTLOOSENING
SEOUENCE

ADJUSTINGSCREWS

24. Rsmovethe side enginernount bracket B and timing

bh back cover.
NOTE: Separatethe cylinderheadfrom the block with a
flat tip screwdriveras shown.

'lO

x 1,25 mm
45 N.m (4.5 kg-m,
33 rb-ft)

8 x 1 . 2 5m m
22Nm12.2kg-n',
16 tb ft)

6-87

RockerArms and Shafts

Removal
Loosenthe adjustingscrews, then remove the bolts
and the rockerarm assemblY
NOTE:
a Unscrew the camshaft holderbolts two turns at a
time, in a crisscrosspattem, to preventdamag'ng
the valvesor rocker arm assembly.
a when removingthe rocker arm assembly,do not
remove the camshaft holder bolts. The bolts will
keep the camshaft holders, the springs and the
rockerarms on the shafts.

INTAKE
No.4

No.3

No.2

i t

No.1

2.

No.4

No.3

No.2

Removethe VTECsolenoidvalve 8nd fiher.

wEc solEflolD
VALVE

EXHAUST

,i"
VTECSOLENOID
VALVEFILTER
Replace.

6-88

6 x k 1 . Om m
1 2 N . m { 1 . 2k g - m ,
I tb-ft)

3.

Hold the rocker arms together with a rubber band to

preventthem trom separating.

Screw 12 mm bolts into the rocker arm shafts. Remove each rockerarm while slowly pullingout the inlake and exhaustrockerarm shafts.

RUBBER
BAND

BOCKER
ARMS

12 mm EOLTS

4.

Removethe intake and exhaustrockershaft orifice.

ROCKERSHAFT

NOTE: The shapesof the rockershaft ori{icesof the

intakeand exhaustare difterent. ldentify the parts as
they areremovedto ensurereinstallationin the original
locations.

6-89

RockerArms and Shafts

Locations
h8s ban imrtod
CAUTION: Attd hstafling the ]ockor shrtt odfic.. try to tum ihe locker shaft to mak sura that iho oriffco
plsce'
tum'
it ehorld not
in th6 holo ot rodcr shaft conectlY. lf th. odfica b in
NOTE:
a ldentify parts as they are removedto ensurereinstallationin originallocations'
. Inspectrockershafts and rockerarms (pages6-93 and 941.
a Rockerarms must be installedin the same positionit reused.
o Cleanthe intakeand exhausttocket shaft orificesbetoreinstalling.
I

erior to reinstalling,clean all the parts in sopent, dry thern and apply lubricantto any contact surfaces,

ARMASSEMBLIES
ROCKER
TNTAKE

m
, |/
I

|
No.2

No.3

cyLtNoERNUMBEB

t /
No.1

BOLTS20 mm
SEALING
TNTAKE
ROCKER
60 N.m{6.0ks-m,43lb-ft} SHAFT

ri
i

II

ll
I

rli

No.4

No.3

No.2

*oi,

t
EXHAUSTROCKERARM ASSEMBLIES

6-90

RUBBER
BAND
\

\
\
CYLINDERNUMBER

RockerArms and Shafts

Clearance
Measure both the intake rocker shaft and exhaust rocker
shaft.

3.

1,

Rocksr Arm-to-Shatt Clearance:

l sko and Erhaust
Standard{Nw}: 0.025-0.052 mm
(O.OO1O0.OO2Oin)
Swice Limit:
O.08 mm (0.003 in.)

2.

Measurediameterof shaft at first rockerlocation.

Measureinsidediameterof rocker arm and check tor

out-of-roundcondition.

Zero gaugeto shaft diameter.

Surfaceshould be smooth.

Repeatfor all rockers.

- lf over limit, replace rocker shaft and all ove.tolerancerockerarms.
NOTE: lf any rocker arm needsreplacement,replace
all three rocker arms in that set (primary.mid. and
secondarvl.

MICROMETER

6-91

RockerArms
Inspection
NOTE: When reassemblingthe primaryrocker arm, carefully applyair pressureto the oil passageol the rockerarm.
1.

Inspectthe rockerarm piston.Pushit manually.

- ll it does not move smoothly, replacethe rocker
arm assemblY.

il

PRIMARYROCKENARM

Check piston movement

a Apply oil to the pistonswhen reassembling.

a Bundlethe rocker arms with a rubberband to pre-

vent them from separatlng.

6-92

Lost MotionAssemblies
Inspection
Removethe lost motion assemblyfrom the cylinder
head and inspect it. Pushingit gently with the linger
will causeit to sink slightly.Increasingthe force on it
will causeit to sink deeper.
- lf the lost motion assemblydoesnot move smoothly, replaceit.

LOSTMOTIONASSEMBLY

Camshafts
Inspection
NOTE: Oo not rotate camshaftduring inspection.
1.

Seat camshafts by pushingthem toward distributor

end ot cylinderhead.

Removethe .ocker arms and rockershafts,

4.
NOTE; Rockerarmsmust be installedin the sameposition if reused.

2,

fut the camshafts,camshaftholdersand holderpipes

on the cylinder head, then tighten the bolts to the
specitiedtorque.

Zero dialindicatoragainstend of camshaft.then push

camshaft back and torth and readthe end play.
CamshaftEnd Play:
Standa.d{New): O.O5-O.'1
5 mm
{O.OO2-O.006
in)
SrvicoLimh:
O.5 mm lO.O2in)

Specified tolque:
@-@: 8x 1.25mm
26 N.m (2.6 kg-m, 19 tb-ft)
@-@: 6x 1.Omm
1 2 N . m ( 1 . 2k g - m ,I t b - f t )

Removethe camshaft holdersand holderoiDes

trom the cylinderhead.
. Lift camshaftout of cylinderhead.wipeclean,then
inspect lift ramps. Replacecamshaft if lobes are
pitted, scored,or excessivelyworn.
. Cleanthe camshaftholdersurfacesin the cylinder
head,then set camshaft back in olace.
a Insertplastigagestrip acrosseach journal.
o Installthe camshaft holdersand holder oiees and
torque bolts to the values and in the sequence
shown in left column.

(cont'd)

6-93

Gamshafts
Inspection(cont'd)
Measurecam lobe height.

Measure widest portion ot plastigage on each

journal.
Camshaft-to-Holder Oil CNearance:
StandardlNowl: 0.050-O.089 mm
(0.0020-0'0035 in)
ServiceLimh: O.15 mm (0.006 in)

lnsooct this arca tor wear.

EXHAUST

INTAKE
Pf,I

7.
it

lf camshaft-to-holderoil clearanceis out of tolerance:

a And the camshaft has alreadybeen replaced,you
must replacethe cylinderhead.
o lf camshsft has not been replaced,first check total runout with the camshaft supported on Vblocks.
Camshatt Total Runout:
Standad {Newl: O.O3mm {O.OOIin} max.
Servica Limit:
O.O6 mm (0.0O2 Inl

Rotate camshaft
while measuring

- lf thetotalrunout ot the camshaftis within tolerance, replacethe cylinderhead,

- lf the total runoutis out of tolerance,replacethe
camshaftand recheck.It the beanangclearance
is still out of tolerance. replacethe cylinder head.

6-94

MID SEC

\
T/B
T/B

t,

SEC MID

PBI

T/8

Pql: PRIMARY
MID: MID
T/8: Tlill G BELT

SEC:SECO DARY

Cam l-obe Holght Standrd (Ncwl:

II\ITAKE

EXHAUST

PRIMARY

34.041 mm
( 1 . 3 4 0 2i n )

33.745 mm
( 1 . 3 2 8 5i n l

MID

36.856 mm
(1.451O
in)

SECONDARY

34.971 mm
( 1 . 3 7 6 8i n )

36.323mm
inl
{1.43OO
34.683mm
{ 1 . 3 6 5 5i n }

Valves, Valve Springs and Valve Seals

Removal
NOTE: ldentify valves and valve sprinos as they are removed so that each item can be reinstalledin its original
position.
1.

Using an appropriately-sized
socket and Dlastic
mallet. lightly tap the valve retalner to loosen the
valve keepersbefore installingthe valve spring compressor.

2.

Install spring compressor. Compress spring and remove valve keeDef.

VALVESPNI G
COMPRESSOR
ATTACHMENT
EXTENSION
OTMAF_PR90lOA

VALVESPRING
COMPRESSOR
ATTACHMENT
07757-PJ1010A

PLASTICMALLET

SOCKET

{cont'd)

6-95

Valves, Valve Springs and Valve Seals

Removal (cont'd)
3.

lnstallthe specialtool as shown.

Valve Dimemions:

VALVE GUIDESEALREMOVER
LISLEP/t{ 579oo or KD 3350
AVAILABLE
COMMERCIALLY

lntako Valvo
A Stsndrrd (Now): 34.9O-35.10mm

(1.374- 1.382 In)

mm
B Standard (Ncwl: 105.rO- 1O5.7O
1 4 . 1 5 0 - 4 . 1 6 1l n l
4.

Removethe valve seal.

C StEndard {t{ew}: 5.475-5.483 mm

(O.2156-0.2159lnl

5.W 10.2144lnl
C Ssrvlco Limit:
D Standard (Newl: 1 . 0 5 - 1 . 3 5m m

;r

D Scruico Limit:

(O.O41-0.O53
In)
0.86 mm (O.O34Inl

ExhaGt vllvc
A Standard {Nsw}: 29.90-3O.1Omm

( 1 . 1 7 -7 1 . 1 8 5i n l

B Standard (t{ow,: 105.OO-105.30mm

(4.134-4.1116inl
C Standard (Ncw): 5.475-5.485 mm

(O,2156-0.2159In)

C Service Llnh:
5.rt45 (O.21.14Inl
(Ncwl:
D Stand8rd
1 . 6 5 - 1 . 9 5m m

iri

D Srvico Limit;

6-96

(O.O05-O.o78
In)
1.45 mm (O.O57inl

Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a
valve seat cutter.

VALVE
SEAT
PRUSSIANBLUE COMPOUI{D
o.

NOTE: lf guidesare worn (page6-98), replacethem

(page 6-991 before cutting the valve seats.

The sctual valve seating surface, as shown by the

blue compound, should be centered on the seat.
a lf it is too high (closer to the valve stem), vou
must make a second cut with the 600 cutter to
move it down, then one more cut with the 45o
cutter to restoreseat width.
a lf it is too low (closeto the valve edge),you must
make a second cut with the 3Oo cutter to move
it up, then one more cut with the 45o cutter to
restore seat width,
NOTE: The final cut shouldalways be made with
the 45o cutter.

Carefullycut a 45o seat, removing only enough

material to ensure a smooth and concentric seat.

Insert intake and exhaust valves in the head and

measure valve stem installed height.

Bevel the upper edge of the seat with the 30" cutter and the lower edgeof the seatwith the 60o cutter. Check width of seat and adjust accordingly.

Intak Valv. Stsm lmtallod Height:

Standa.d {Now}: 37.465-37.935 mm
(1.4750- 1.4935 int
So.vic Limit: 38.185 mm {1.5033 inl

Mak one mor very light pass with the 45o cutter
to remove any possible burrs caused bv the other
cutters.

Exhalst Valve Stom Installad Height:

Standard(Newl: 37.165-37.635 mm
(1 .rt632- 1.rt817 in)
Servicol-imit: 37.885 mm (1.4915 inl

Valvo Soat Width (lntake and exhaustl:

Standard(N6w): 1.25- 1.55 mm
(0.0r1!l-0.061 inl
Sorvice Llmit:
2.0O mm 10.079 in)

SEATWIDTH

VALVESTEM
INSTALLEDHEIGHT

5.

After resurfacing the seat, inspect for even valve

seating; Apply PrussianBluecompound to th valve
fEce, and insert valve in originallocation in the head,
then lift it and snap it closed against the seat several tames.

8.

lf valve stem installedheight is ove. the servicelimit,

replace valve and recheck. lf still over th service
limit, replacecylinderhead;the valve seat in the head
is too deeD.

6-97

Cylinder Head
Warpage
oil clearances(page6-93)
NOTE: lf camshaft-to-holder
are not within speci{ication,the head cannot be
resurfaced.

Valve Guides
Valve Movement
Measure the guide-to-stem clearance with I di6l indicator while rocking the stem in the dirsction of normal thrust (wobblemethodl.
lntako valvo Stsm-to-Guldo Clearancc:
Standard(Now): 0.05-O.11 mm
tO.O02-0.OO4in)
0.16 mm (O.OO6Inl
Servic6 Limit:

oil clearancesare within specificalf camshaft-to-holder

tions, check the head tor warpsge
. lf warpageis lessthan O.05 mm (0.OO2in) cylinder
head resurlacing is not required
o lf warpageis between O.O5mm (0.OO2in) and O.2
mm (O.OO8in), resurlacecylinderhead.
a Maximumresurfacelimit is 0.2 mm (o.oo8 in) based
'132.0
mm (5.20 in).
on a height of

Exhaust Valvo Stem-to-Guldc Cloarancc:

standard (Now): 0.1O-0.16 mm
(O.oO4-o'006 inl
0.22 mm (O'OO9Inl
Sarvice Limh:
vrlvs anondcd 10 mm out trom t!|t'

PRECISIONSTRAIGHTEDGE

.rl
.,il

Measurealong edges, and 3 ways acrosscente..

a lf measursmentexceedsthe servicelimit, recheck

using a new valv6.
a lf measurement is now within th service limit,
reassemble using a new valve.
a lf measurementstill exceeds limit, rechack using
altrnate method below, then replsce valve and
guide, if necssary.
NOTE: An ahernate method of chcking guide to
stem clearanceis to subtract the O.D. ol the vslve
stem, measuredwith a micrometer, from the I'D of
the valvs guide, measuredwith an inside micromter or ball gauge
Take the measuromentsin three plsces along th
valve stem and three placas inside the vslve guide.
The difference between the largest guids measursment and the smalleststem measuremntshouldnot
exceed the service limit.
lntako Valvo Stam-to-Gddo Clcalanco:
Standard{Now): O.O25-O'055 mm
t0.O01O-O.0O22in)
0.O8 mm lO.0O3 inl
Sorvlce Limit:

Cylindol Head Hoight:

Standard(New): 141.95-142.05 mm
(5.589-5.593 in)

6-98

Exhaust valvo Stom-to-Guida Cbarlncai

Standard (New): O.O50-O.080 mm
(0.o020-0.0O31 inl
0.1 1 mm (0'0O4 Inl
Sorvice Limit:

Replacement
l.

As illust.ated in the removalsteps o{ this procedu.e,

use a commercially-available
air-impactdriver attachment modifiedto tit the diameterof the valve guides.
In most cases,the same procedurecan be done using Valve GuideDriversand a conventionalhammer.
Tool numbersare at the end of this procedure.

VAI.VE GUIDEDBIVER
Y AVAIIAALE

4.

Workingfrom the camshaftside,use the driverand

an air hammer to driver the guide about 2 mm
(O.1in) towa.dsthe combustionchamber.This will
knock off some of the csrbon and make removal
easier.
CAUTION:
a Always wear satoty goggles or a tace shield whon
using th ai. hammot.
a Holdthe air hamnrerdhectly in line with th valvo
guide to prevnt damaging the driver.

5.3 mm
lO.2'l in)

Turn the head over and drive the guide out toward
the camshaftside of head.

l r

tl_rl
10.8 mm
10.42 Inl

Removaland Installation
VALVEGUIDEDR|VER,5.S ftm
07742-d)10100

2 . Select the proper replacementguides and chill them

in the freezer section of a retrigerator for about an
hour.
Use a hot plate or oven to evenly heat the cylinder
head to 3OOoF(150oC). Monitor the temoerature
with a cookingthermometer.

VALVEGUIDEDRIVER,
COMMERCIAIIY
AVAILABTI

<reDi-k

lf a valve guide still won't move, d,ill it out with a

8 mm (5/16 inchl bit, then try again.
CAUTION:
a Do not us6 a torch; lt may warp th6 hoad.
a Do not get tho h6ad hotter rhan 3OOoF(150"C);
xcesslvo heat may looron tho valvo soats,
a To avoid burns, uso hoavy glovos whon handling
tho hEted cylindsr head.

CAUTION: Drill guidos only in extrcmo cass; you

could damagotho cyllndr head lftho guide breaks,
6.

Removeth new guide(sltrom ths refrigerator.one

at a time, as vou need them.
{cont'd}

6-99

Valve Guides
(cont'd)
Replacement
7.

Slip a 6 mm (0,2 in) steel washer and the correct

driver attachment over the end ol the driver (the
washerwill absorbsome ot the impact and extend
the lite ot the driver).

/--Tr-1-l--l-

DRIVEB

Reaming

al;\
Y

6 mm 10.2in)
WASHER

-r

NOTE: Fo. nw valve guidesonly.

1.

Rotate the reamer clockwise the full length of th

valve guide bore.
Continue to rotate the reamer clockwise whil
removing it from the bore.

rnr
\---jY

ATTACHMENT

8 . tnstallthe new guide(s)Jromthe camshaftside oJ

the head;driveeachone in untilthe attachmentbottoms on the head.It you have 8ll sixteenguidesto
do, you may have to reheatthe head one or two
more times.

Coat both reamerand valve guide with cutting oil.

4.

Thoroughly wash the guide in dstergent and water

to removeany cutting residue.
Check clealancewith a valve (page 6-98).
a Verify that the vslve slides in the intake and exhaust valve guides without exerting pressure.

VALVE GUIDEDRIVER,
5 . 5m m
07742-@10100

9*6W
)/>-A()
5.5 mm
OTHAH-PJTOIOA
oTHAH-PJ70108

Valvo Guid6 Installd Hoight:

Standard {New):
lnrak: 12.55-13.O5 mm (O.494-0'514 in)
Exhaust:12.55- 13.O5 mm (O.494-O.514Inl

VALVEGUIDE

6-100

Valves, Valve Springsand Valve Seals

ValveSping andValveSealInstallationSequence
NOTE: Exhaustand intakevalve sealsare NOT interchangeable,
VALVEKEEPERS
e{t'
A\---.'-

---.,-VALVE SPRING
RETAINER

VALVE SPRING
OUTER

NOTE: Pt.c. the ond ot valvo

.prlng whh clo3.ly wound coll!
row..d tho cyllndor herd.

VALVE SPNNG
INNER

II{TAKEVALVE SEAL
{WHITESPRING}
Replace.

:,.^,7
NOTE: In6tallthe valve spring seats
before installingth6 valv seals.

VALVE GUIDESEALINSTALLER
KD-2899

NOTE:Usesmalllo
ndol tool.

wre
6-101

Valves,Valve Springsand
Valve Seals
Valve Installation
When installing valves in cylinder head, coat valve
stems with oil bejore insertinginto valve guides, and
make sure valvesmove up and down smoothly.
Whenvalvesand springsare in place.lightly1apthe end
ol each valve stem two or three times to ensureproper
seating of valve and valve keepers (use hammer.grip
bottom).

RockerArms
lnstallation
1 . lnstallthe rockerarms in the reverseorderof removal:
o Valve adjustinglocknuts should be loosenedand
adjustingscrew backedoff betore installation.
o The comDonentDans must be reinstalledin the
originallocations.
Installthe lost motion assembly.

3 . Installthe rocker arms while passingthe rocker arm

NOTE: Tap the valvestem only alongits axisso you do
not bend the stem.

shaft through the cylinderhead.

NOTE: Removedthe rubber band after installingthe
rockerarms.

Il
I

4.

ri

lnstallthe rockershaft orifices.lf the holesin the rocker 8rm shaft and cvlinderheadare not in line with each
other, threadsa 12 mm boh into the rockerarm shaft
and rotate the shaft.
NOTE:
a The shapesof the rockershaft orificeslor the intale
and exhaustare different.The oriticesmust be installedin the originallocations.
o Cleanand installthe rockershaft oriticeswith new
O-rings.
EXHAUSTROCKER
SHAFTORIFICE

6-102

CylinderHead
lnstallation
Install the cylindr head in the reverse ord6r ol
removal:
a Always use new hadand manifoldgaske$.
. The cylinder head gaskt is a m6tal gasket. Take
care not to bend it.
. Rotate the crsnkshaft, s6t the No. 1 piston at TDC
(pase&106).
Installthe cylinderhesd gasketand dowd pins on the
cvlindrhead.

3.

Tighten the cylinder head bolts sequentiallvin thr6e

steps.
lst stop torquo: 40 N.m (4.0 kg-m, 29 lb-ft)
2nd stop torquo: 70 N.m {7.Okg-m, 51 lb-ftl
&d stp torque: 10O N.m {10.Okg-m, 72 lb-ftl
NOTE:
o We recommendusinga beam-typetorque wrench,
When using a preset-typetorque wrgnch, be sure
to tighten slowly and not to overtighten.
. lf a bolt makesany noisewhile you 8re torquingit,
loosenthe bolt and retightenit from the lst step.

CYLINOERHEAO

CYUNDERHEADBOLTSTOROUESEOUENCE

DOWELPIN

oowEl n

CYUI{DERHEADBOLTS
12 x 1,25mm
1OO
N.m(10.0kg-m.72 lb-ftl
Applycleannginooilto bolt
thrsads8ndunderboltheads.

{cont'd)

6-103

CylinderHead
Installation(cont'd)
4.

lnstall the intke manifold and tighten the nuts in a

crisscrosspattern in 2 or 3 steps, beginningwith the
Innernuls.

lnstallthe camshaftsand camshaft oil seals.

6.

NOTE:
o Installthe camshaftswilh keyway facing up.
. Installth oil s8al with the springside fscing in.
. The dl seal housingsurfaceshouldbe dry.

INTAKEMANIFOLD
GASKET

7 . Cleanand installthe oil controlorificewith new O-ring

in the oil passageof the No. 3 camshaft holde..

I x 1 . 2 5m m
22Nm{2.2kg-m,
16 lb-ft)

I x 1.25 mm
2 2 N . m1 2 . 2 l . g - m ,
16 tb-ft)

ERACKET

o-RrNG

;;;--

Instsllthe exhaustmanifoldand brackets.Tightenthe

nuta in a crisscrosspattern in 2 or 3 steps, binning
with th innernuts,

8 x f.-$.mm
ks-m,
32 N.m-|C.2
23 tb-ir)

ReDlac.

Apply liquidgasketto the headmating surtaceof the

No. 1 and No. 5 camshaftholderson both the intake
and exhaustside. Confirmthat the csmshaft kvway
are face up, then plscethe holders,togetherwith the
No. 2. No. 3 and No.4 camshaftholders,on the
cylinderhead.

EXHAUSTMANIFOLD
GASKET
Replace.

NOTE; The arrows markedon the camshaft holders

shouldpoint to the timing blt.

8xL25mm
22 N.m12.2kg-m,
16 tb-ft)

CAMSHAFTHOLDERS
No.5

6x1.Omm
10N.m
( 1 . 0k g - m ,
7 tb-ft)
' 1 0x 1 . 2 5m m
45Nm14.5kg-m,
33 tb-ft)

SEI.f,-LOCKING
NUT
l O x 1 . 2 5m m
55 N.m (5.5 kg-m,
40 tb-ft)
Replace.

6-104

8 x 1.25 mm
22Nm(2.2kg-m,
16 lb-fr)

FA
t t l
We)

n A

ffil"t

K-

o.4

No.3

No.2

t{o.l

Ifr Ai ,:)t Bqt

IITTAKE

M H S

BFl f'q ffiTn

\t

APPIvliquid gasket
to tne shadedareas.

\t

ta/\el

EXHAUST

9.

Temporarilytighten the bolts ot the camshaft holders

and the camshaftholderoioes.

1 0 . fush the camshaftoilseal securelyagainstthebaseof

the camshaft holder.

1 1. Tightenthe bolts in the sequenceshown below.

O-@:8x1.25mm
26 N.m (2.6 kg-m, 19 lb-ft)
@-@:6x1.Omm
12 N.m (1.2 kg-m,9 lb-ft}
12. Installthebackcoverot the timingbelt.
13. Installthecamshaftpulleys.

..

,7*,

KEY

W&

CAMSHAFTPULLEY

1 0 r 1 . 2 5m m
5 1 N m 1 5 . ' k1 g - m , 3 7 l b - f t )

6-105

CylinderHead
Installation(cont'd)
1 4 . Installthe timing belt in the reverseorder of removal.
Adjust the valve clearanceslpage 6-1 151
- Beforeinstallingthe timing belt, positionthe crankshaft and camshaft pulleysas shown
TDCPOSITION:
CAMSHAFT
,,I" MARKS

16. Installthe timing belt.

NOTE:
a It the autotensioner has been extended and the
timing belt cannot be installed.remove the autotensioner.@mpressit ard reinstallit {page6-1 12}.
. Take care not to damagethe timing belt when installingit.

TDC MARKS
:
CRANKSHAFTTDG POSITION

17. Tighten the maintenance bolt to make the autotensionertunctional.

NOTE: Turn the maintenancebolt bv hand until it
stoos.

TDC MARK ON

THEFI.YWHEEL
1 E

lnstallthe specialtool on the intake camshaftpulley.

Auto-tensioner
tixd in ploce.

EXHAUST
CAMSHAFT
PtJLLEY

Auto-tensioner
lunctional.

6-106

Timing Belt and Timing BalancerBelt

lllustratedIndex
NOTE:
a Reterto page 6-1OOtor positioningcrankshaftand pulley beforeinstallingtiming belt.
o Beforeremoving,mark directionof rotationon each belt.
ADJUSTING
NUT
'lOt 1.25mm
MIDOLE

45 N.m (4.5 kg-m,33lbJt)

RUBEERSEAL
Replacewhen damaged
or deteriorated.

RUBBERSEALS
Replacewhen
damagedor deteriorated.

CRANKSHAFT
PULLEY
Removeany ojl.
CAP NUT
6xl.Omm
10Nm{1.0kg-m,7lb-ft)

PULLEYEOLT
1 4 r 1 . 2 5m m
220 N.m {22.Okg m, 159 lb-tt}
Applyengineoilto the bolt
threads, but not to the
surtacethat contacts the

WASHER

LOWERCOVER

POWER
STEERING
BELT
Adiushent, sction17

Romovethe five bolts.

RUBBERSEALS
Replacewhen damaged
or deteriorated.
6x1.Omm
'l2
N.m (1.2 kg,m, 9 lb-ft)
CAMSHAFTPULLEYS
1 Ox 1 . 2 5m m
5 1 N . m ( 5 . 1k g - m ,
37lb-ftl

ALTEBNATOR
Adjustment,section 23

TIMINGEELT
page6-108
Inspectaon,
Installation,page 6 109

AUTO.TEI{SIONER
AI'JUSTING BOLT
68 N.m (6.8 kg-m,49 tb-ftl
Apply liquid gasker
to the bolt lhreads
installedin the
blockside.

TIMING BALANCERBELT
page6-'l08.
Inspectaon,

lnstall with concave

surtacefacing in.
Removeany oil.

6-107

Timing BalancerBelt

Timing Beft

Inspection

lnspection
1.

Disconnectthe alternatorterminaland the connector'

then removethe enginewire harnessfromthe cylinder
head cover.

1.

Disconnectthe alternatorterminaland the connector,

then.emovethe enginewire harnessfromthe cylinder
headcover.

2.

Removethe cylinderheadcover

2.

Removethe cylinderheadcover

3.

Removethe middlecover.

3.

Removethe middlecover.

4.

Inspect the timing belt for cracks and oil or coolant

soakang.

4.

Removethe crankshaftpulley.

5.

Removethe lower cover.

6.

Installthe crankshaftpulleY.

7.

Inspect the timing belt for cracks and oil or coolant

soaking.

NOTE:
a Replacethe belt if oil or coolant soaked.
. Removeany oil or solventthat gets onthe belt.

Inspectthis
areafor wear,

NOTE:
. Replacethe belt if oil or coolant soaked.
a Removeany oil or solventthat gets on the belt.

Inspectthis
areator wear,

Rotatepulloy
and inspect belt.

pulleyboltto
crankshaft
retorquethe
Afterinspecting,
220 N.m(22.Oks-m,159lb-ft).
.{d.,

6-108

After inspecting,retolquethe ctankshaftpulleybolt to

220 N.m (22.Oks-m, 159 lb-ft).
NOTE: Reterto page 6-1 l3 for timing balancerbelt
tension adiustment.

TimingBelt and TimingBalancerBelt

Replacement
CAUTION: Inspct th wstr Frmp whon roplacing tho
timhg boh (pag61O-121.

Removethe mounting bolts, nuts and belt from the

power steering(P/S)pump.

NOTE: Turn the crankshaftso that the No. 1 Distonis at

TDC {page6-106}.

NOTE:
o Do not disconnectthe P/S pipe and hose.
o After installing,adjustthe tensionof the P/Spump
belt (seesection 171.

1,

Removethe splashshield.

MOUNTINGEOLTS

LOCKNUT
15Nm(1.5kg-m,
l l

SPLASH
SHIELD
2.

8 x 1 , 2 5m m
22N,m 12.2kg-m,

Disconnectthe connector, then remove the cruise

control actuator,
NOTE:
a Oo not disconnectthe control cable.
a Takecarenot to bendthe cablewhen removingthe
actuator,Always replacea kinkedcablewith a new
one.

CBUISECONTROL
ACTUATOR

6x1.0mm
10 N.m ('l.Okg-m,
7 tb-fr)

16 tb-ft|
Disconnectthe ahetnatorterminaland the connector.
then removethe engine wire ha.nessfrom the body
srde.
Loosenthe ahernatormounting bolt, nut and th adjusting nut, then removethe alternatorbelt.
NOTE: After installin,adjustthe tensionof the atternstor belt (seesection 23).
ALTERNATOR
COI{NECTOR

CONNECTOR

P/SPUMPBELT

TERMINAL

MOUNTNG AOLT
1Ox 1.25 mm
45 N.m (4.5 kg-m,
33 tb-ft)

AL
MOUNTINGNUT
BELI
8 x 1.25 mm
22N m 12.2kg-m,
16 tb-ft)
(cont'dl

6-109

Timing Belt and Timing BalancerBelt

Replacement(cont'dl
1 0 .Removethe crankshaftbolt and the pulley.

Bemovethe cylinderhead cover.

Removethe two rear bolts lrom the center beam to

allow the engineto drop down and give clearanceto
removethe lower cover.

Removethe middlecover.
Removethe side enginemount.

1 1 .Removethe adiusterrubber seal. Do not loosenthe

adjustingnut.

1 2x 1 . 2 5m m
5 5 N . m{ 5 . 5k g m ,
40 rb-ft)

1 2 . Removethe lower cover.

1 3 . Loosenthe adjustingnut. Pushon the pulleyto remove
tensiontrom the timing balancerbelt, then tightenthe
adjustingnut.

il

il
t ,
l l

1 4 . Removethe timing balancerbelt.

12 x 1.25 fifi
65Nm(6.5kg-m,
47 tb-fr)

9.

tD.

1 6 . Removethe auto-tensioner.

Removethe dipstick and the PiPe

6x1.0mm
1 2 N . m( 1 . 2k g - m ,9 tb ft)

Replace.

6-110

Removethe timing belt.

CYLINOERHEAD
COVER

TIMING BELT
Inspection,page 6-108

6x1.Omm
12 N.m(1.2kg-m,9 lb-ft)

MIDOLECOVER

TIMINGBALANCERBELT
page6-108
Inspection,
ADJUSTIT{GNUT
l 0 x 1 , 2 5m m
45 N.m {4.5 kg-m,
33lb-tt)

RUBBER
SEAL
Replace
whendamaged
or deleriorated.
AUTO.TENSIONER

rullEY BOLT
1 4 x 1 . 2 5m m
220 N m (22.0 kg-m, 159 lb-ft)

RUBBER
Replacewhen
damagedor
deteriorated.
6t1.0mm
12Nm(1.2kg-m,
9 tb-ft)

PULLEY
Remove any oil.

6-111

Timing Belt and Timing BalancerBelt

Replacement{cont'd}
1 7 . Installthe timing belt in the reverseorder ol removal.
- Beforeinstallingthe timing belt, positionthe crankshaft and camshaft pullevsas shown
,,T" MARKS

NOTE: Take care not to damagethe threads or the

gasketcontacl surfacewith the sctewdriver'

FLAT BLADE
SCREWDRIVER

MAINTENANCE
BOLT

STOPFER
P/N 14540-Pl3-003

2 1 . Removethe screwdriverand reinstallthemaintenance

bolt.
NOTE: Be sureto ube a new gasket.

i
MAINTENANCE
BOLT
I N.m(0.8kg-m,
6lb{r)

Replace.

TDC
MARK
the auto-tensionerwith the maintenancebolt
.l , pointingup. Loosenand removethe maintenancebolt.

t
'

I
;

NOTE: Handlethe auto-tensionercarefullyso the

oil insidedoes not spill or leak. Replenishthe autotensionerwith oil if any spills or leaks. The total
capacityis 8 cc {1/4 ii oz).

Make sure no oil is leakingaround the maintsnance

bolt. Installthe auto-tensioneron the engine.
NOTE: Make sure the stopperstays in place.
STOPPER
P/N

19. Clamp the boss oJ the auto-tensionerin a vise. Use

DiecesoJ wood or a cloth to protect the boss,
NOTE: Do not grip the housingot the auto-tensioner.
20. lnsert a flat blade screwdriverinto the maintenance
hole. Placethe stopper {P/N 1454O-P13-OO3)on the
auto-tensionerwhile turning the screwdriver clockwise to comDressthe bottom.
8 x 1 . 2 5m m
22 N.m (2.2 kg-m,
16 rb-ft)

6-112

23. Removethe stopper.

26. Align the rearbalancershsft pulleyby usinga 6 x 10O

mm bolt or equivlentas an alignmenttool.
Scribea line 74 mm (2.9 in) trom the end of th boh.
Insertthe bolt into the maintenancholeto the scribsd
line.

ADJUSTER

27. Loosen the adjusting nut and verify that the timing
balancerbelt adiustermoves freely.
28. Instsll the timing balancerbelt. Removethe 6 x 10O
mm bolt trom the rear balsncershsft.
29. Turnthe crankshaftpulleyaboutoneturn, then tighten
the adjustingnut to the specifiedtorque.
P/N 14540-P't3-OO3

24. Make surethe crankshaftis positionedwith the No. 1

cylinderat TDC.

25. Align the grooveon the front balancershaft pulleywith

the pointeron the oil pump housingas shown.

NOTE: Both belt adjusters are spring-loaded to

properlytensionthe belts.Do not applyany extra prossureto the pulleysor tsnsionerswhile performingtha
adjustmenl.
REARBALANCERSHAFT

74 mm 12.9in)

6 r 100 mm BOLT

12 mm SEALINGBOLT
30 N.m {3.0 kg-m, 22lb-ft}
NOTE:Tighten the bolt after
installingthe belt.

Align the groove of the

tront driven pulley with
the pointer on the oil
pump housing.

REARTIMING BALANCEREELT
DRIVENPULLEY

BALANCERBELT

DRIVEPULLEY
Setthe crsnkshaftat TDC.

(cont'dl

6-113

Timing Belt and Timing BalancerBeh

(cont'dl
Replacement
30. lnstallthe lower cover.

32. Installthe middlecover.

3 ' 1 Install
.
a rubberseal aroundthe adjustingnut. Do not

33. Installthecrankshaftpulley.

loosenthe nut.

34. Coat the threads and seating face of the pulley bolt
with engine oil. Install and tighten to the specified
torque.
Spocifiedtorquo: 22O N'm (22.Okg-m. 159 lb-ft)

6x1.Omm
12 N.m (1.2 kg-m,9 lb-ft1

MIDDLECOVER

I
i

AD.'USTINGt{UT
1Ox 1.25tnm
45 N.m(4.5kg-m,33lb-ft)

SEALS
RUBBER
when
Roplace
or deteriorated.
damaged

RUBBER
SEAL
Roplace
whgndarnged
or deteriorated.
A'LLEY EOLT
1 4 r 1 . 2 5m m
220 N.m {22.0 kg-m, 159lb-ft)
Apply engineoil to the
bolt thrsads, but not
to the surfacethat
contacts the washer.

-ldl

6x1.Omm
'12N.m(1.2kg-m,I lb-ft}

iili
I

f,

PULLEY

6-114

ALTEN ATORBELT
Adiustmnt,soction23

ValveClearance
Adjustment
NOTE:
. Valvesshouldbe adjustedcold when the cylinderhead
temperatureis lessthan 1oOoF(38oC).
. After adjusting,retorquethe crankshaftpu ey bolt to
22ON.m (22.Okg-m, 159 lb-ft).

3.

1.

4.

Removethe cvlinderheadcover.

INTAKE

2.

Set No.l pistonat TDC. "f" markson the pulleys

should be at top. and TDC grooves on the pulleys
shouldalign with cylinderheadssurface.

Number1 pistonat TDC:

Adjustvalveson No.1cylinder.
Valve Cloalance:
Intaks: O.15-0.19 mm {0.0O6-0.O07in}
Exhaust:O.17-0.21 mm (O.O07-O.OO8
in)
Loosenlocknut and turn adjustingscrew until feeler
gaugeslidesbackandfonh with slightamountof drag.
TAPPET
ADJUSTER
o7MAA-PR70'110

20 N.m(2.Okg'm,
14 tb-ft)

WRENCH
oTMAA-PR70120

Tightenthe locknutandcheckclearanceagain.Repeat
adjustmentit necessary.

FEELENGAUGE

TDC MARKS
Alignthe marks
on the pulleys

(cont'dl

6-115

Valve Clearance
Adjustmentlcont'd)
6.

Rotate crankshaft 180o counterclockwise(camshaft

pullevsturns 9Oo). The "f" marks should be at exhaust side. Adjust valves on No.3 cylinder'

Numbd 3 glstonat TDc:

,,I,, MARKS

1
I

7.

Rotate crankshaft 1800 counterclockwiseto bring

No. 4 pistonto TDC, The TDC groovesare once again
aligned.Adjust valves on No. 4 cylinder.

Number4 Dl.tonat TDC:

li
I

ld
l
I

6-116

8.

Rotate crankshaft 18Oo counterclockwiseto bring

"i" marks shouldbe at inNo. 2 piston to TDC. The
take side. Adjust valves on No. 2 cylinder.

Numbrr2 Di.tonat TOC:

EngineBlock
SpeciafToofs
..................................7-2
lllustratedIndex................
.............
7-3
Flywheeland DrivePlate
Replacement
,.........,,..................7-7
ConnectingRod and Crankshaft
EndPlay
..........7-7
Main Bearings
Clearance
....,,..7-g
Selection
.........7-9
ConnectingRod Bearings
Cfearance
....,,..7-10
Sefection
.........7-11
Crankshaft, BalancerShafts and Pistons
Removal
........,,7-12
Crankshaft
Inspection
.......7-15
Pistons
Inspection
.......7-16
fnstallation
......7-25
CylinderBlock
fnspection
..,....7-17
Bore Honing lH23A1,H22Al enginesl ................7-18
BoreHoning(F22A1engine)...............................
7-19
Piston Pins
Removal
..........7-19
fnstallation
......7-20
fnspection
.......7-21
ConnectingRods
Sefection
.,.,,,,..7-2O
Piston Rings
EndGap
...........7-22
Repfacement
,.............,.,........,,...7-23
Ring-to-GrooveClearance
........7-23
Afignment
.......7-24
CrankshaftOil Seal
fnstaflation
......7-25
Crankshaftand BalancerShaft Oil Seal
Installation(engineremoval is not requiredl ....7-30
Crankshaft and balancershafts
fnstration
,.......,7-26
BalancerShafts
fnspection
.......l-91

SpecialTools

R.l. No.

O
o

O
@
@
@

O
@
O
@
@
@
@

I
|
I
|
|
|
I
|
|
|
|
I

oTcAF- PH6o3oo
- PH7ol00
07GAF

orcar-seoozoo

oTHAF-PL2o1o2
oTLAD- PT3oloA
o;Lnr - lvootooor
07924- PD20oo3
07746- oo3o3oo
07749- ooloooo
07948-sBoo101
- PEoo3lo
07973
07s73- PEoo32o
07s73- 6570500
07973- 6570600

Oty

D6cripiion

Tool Number

Pag6Rdorence

PistonPin BaseInsert
PilotCollar
Hub AssemblyGuideAttachment
PistonBaseHead
Se8lOriver
RingGearHolder

1-19,20
7 -19,20
7-30
7 -19,20
7-30

Attachment,30 mm l.D.
Driver
Driver Attachment
PistonPin DriverShaft
PistonPin DriverHead
Piston Ease
Piston BaseSpring

7-30
1-25,30
7- 2 5 , 3 0
7-19,20
7-'t9,20
7 -19,20
1-19,20

i
1
l

!1

ti

t
I

.'

(0

7-2

lllustratedIndex
I

Lroric"t" "tl inrernalpartswith engineoil during reassembly.

6x1.0mm
12 N.m 11.2

OIL SCAEEN
6x1.Omm
12 t{.m 11.2kg-m.

GASKET
Roplace.

6x1.0mm
12 N.rnlt.2 kg-m,9lb'ftI

BAFFLEPLATE

AEARINGCAP
BRIOGE

11 x 1.5mm
75 N.rn {7.5 lg-m,
54 tb-ttl
Applyengineoilto the bolt
throada.
NOTEr
Aftor torquing o6chcap.
turn crankshaftto check
Ior binding.

DOWEL PIN

-rx
TOROUECONVERTER
COVERIA/T)

12 x 1.0mm
75 N.m 17.5kg-m,
5t tb-ftl
Torquesequence,
page7-7

DOWEL PINS

WASHER
DRIVEPLAIE {A/T)
Checkfor cracks.
CLUTCH COVER
(M/T)
6 t 1 . Om m
12 N.m (1.2 kg-m,
9 rb-ftl

FLYWHEEL

12 x 1.0mm
105N{n (10.5kg-m, 76lb-ft,
page7-7
Torquesequence,

(cont'd)

7-3

lllustrated Index
(cont'dl
Luuri"ut""tl internalpartswith engineoil duringreassembly.

NOTE:
Apply liquid gasketto the mating surfacesot the right
side coverand oil pump casebetoreinstallingthem
Useliquidgasket,part No. 08718- 0001

CRANI}IAFT
Endplay,Page7'7
Runout.Tapor 6nd
Out-of-Round,Page7-15
Installation,Page7-26

MAIN BEARINGS
page7-8
Oilclearance,
page7-9
Slection,
NOTE:New main boaringsmust
be selectedby matchingcrank and
markings.
blockidentification

:l

Groovedsidestac outward.
NOTE: Thrust washerthicknoss
is lixed and must not be changed
by grindingor shimming.

ll

8 x 1.25mm
25 N{n {2.5 kg-m,
18 tb-frl

CRAI{KSHAFTOIL SEAL
Install6tion,pag* 7-25and 30

O.RINGS
Replace.

OIL SEAL
CRANKSHAFT
psges7-308nd 8-'11
Installation,
Replace.
THRUSTWASHER

RIGHTSIDE @VEB
Apply liquid g88ktto
block mating surface.

AALANCERDRIVEN
GEAR

PIN

'Il

6x1.0mm
12 l$m 11.2kg-m,9 lb"ftl
Apply liq!id gasketto
the bolt threads.

il

il

BALANCERSHAFTOIL SEAL
pages7-30and 8-11
Installation,
Reolace.
TIMINGBALANCERBELT
DRIVENPULEY

7-4

OIL PUMP
Se page8-9
Apply liquid gssk6t
to block mating surtace.

Gr1.0mm
12Nrn (1.2
9IEftI
Apply liquid g8skstto
the boft threads.

OII-JET BOLT
ito N.rn {a.0tg-m, 29 lb-ftl
Inspection,page 8-8

OIL JET
Handlethe nozzlewith
care.Do not damage or
detormed.
Inspection,page 8-8

H22Al engincl

REARBALANCERSHAFT
End play, p6ge 7-31
Runout.Tapor and
Out-of-Round,psges 7-31,32
Inst6llation,pag 7,26

BALANCR
SHAFT
BEARINGS
page7-31
Inspction,

BETAINER
NOTE: Retainerthicknossis tixed
and must not bs changedby
Orindingor shimming.

BALANCER

(cont'd)

7-5

lllustratedIndex
lcont'd)
lruri""t" "tl internalpartswithengineoil orr'nn,"u""".b'J;ron

INSTALLATIONDIRECTION

NOTE; New rod bearingsmust be selectedby matching

markings
connectingrod and crankshaftidentification
( p a g e s7 - 1 0 1
l
)
.
,

1r;--..l@
ft##**if{*{"}H

EXHAUST

A ?/ A Ae-l
A

-/ (3
\3
\7
\7

\9,-//
\Eo.J
'\r'
'\7

INTAKE
PISTON
Removal,page7-12
page7-16
M6asurement,
NOTE:To maintainproperclearance,
matchthe lefter on the piston top with
the lettor for eachcylinder stamped on
the block.
On the block
On the pistontop
A or I
No letter <Bor'l

PISTONPIN
Removal,page7-19
page7-20
Installation
page7'21
lnspection,

CONNECNNGROO
Endplay,page7-7
Selection,page 7-20
Smallend measurement,
Page7-21

ENGINEBL(rcK
p6oo7'17
Cylinderboreinspection,
Warpageinspection,Page7-17
Cylinderborehoning,pag667-18,19
Inspecttop of each cylinder bore
tor carbon build-up or ridge before
removing Pigton.
Removeridge if n6cessary,pagB7.14

ROD
CONNECTING
BEARINGS
page7-10
Clearance,
page7 11
Selection,

CONNECNNGRODBEARINGCAP
Installation,page7-26
NOTE:Installcap so the bearingrocessis
on the samesideasthe recessin the rod

RODNUT..-_.-....-__-.}
CONNECTING
9 x 0.75 mm
47 N{n (i1.7kg-m, 34 lb-ft,
After torquing each bearingcaP,
rotate crankshaftto checklor
binding.

7-6

CYUNDERBORESIZES
(A or l, B or rl)
NOTE: To maintain proper piston
clearance,rnatchthese lefterswith
the letterson the pistons.The letters
on the block readfrom left to right,
No. 1 throughNo. 4 cylinders.
On the block
On the pistontop
A or | --------------- > No letter
B or,l --------------- > B

e
No.4

Flywheel and Drive Plate

GonnectingRodand
Crankshaft

Replacement

End Play

ManualTransmission:

ConnectingRod End Plsy:

Standard (Newl: 0.15- 0.30 mm
{0.006- 0.012in)
SorviceLimit
0.40 mm 10.016inl

Remove the eight flywheel bolts, then separatethe flyw h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n ,

tightenthe bolts in the sequenceshown.

CONNECTING
ROO

RINGGEAi

07LAB- PVtDl(x)

or 0792it - PO20O03

BINGGEARHOLDER
07LAB- Pv(xrltx)
or 07924- PD2qr03

.
.

aoo

\o;

lf out-of-tolerance,install a new connecting rod.

lf still out-of-tolerance,replacethe crankshaftlpages
7-11and7-26]..

Pushthe crankshaftfirmly away from the dial indicstor.

and zerothe dial againstthe end of the crsnkshaft.Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimit.
Inspgctring gear
teoth for w6ar or damage.

12x 1.0mm
105 N.rn 110.5kg-m, tG lb-ft,

AutomaticTransmission:
Removethe ight drive plate bolts, thon separatethe
drive platefrom the crankshaftflange.After installation.
tightenthe bolts in the sequenceshown.

SCREWDRIVER

/ AXid-*a\Ao

CrankshaftEnd Phy:
Standard lNqwl: 0.10- 0.35 mm
(0.004- 0.014in)
Ssrvice Limit
0.45 mm {0.018inl
.

lf end play is excessivethan the servicelimit, inspect

the thrust washersand thrust surfaceon the crank,
shaft.Replacepartsas necessary.

NOTE:Thrustwasherthicknessis fixed and must not be

changedeitherby grindingor shimming.
Thrust washersare installedwith groovedsidesfacing
outwaad.

7-7

Main Bearings
Clearance
L

T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves

C l e a ne a c h m a i n i o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshoptowel.

l.

STRIP
PLASTIGAGE

Placeone strip of plastigageacrosseach main journal.

NOTE:lf the engineis still in the car when you bolt
the main cap down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plastF
gage further than just the torque on the cap bolt.
and give you an incorrectreading.For an accurate
r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e
c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r , n ga t a
time.

4.

R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
bolts.
75 N.m {7.5kg-m,54lb-ft)
NOTE:Do not rotatethe crankshaftduring inspectron.

5.

Removethe cap and bearingsagain,and measure

the widest part ot the Plastigage.
Main Bearing-to-JournalOil Clearance:
Siandard {Newl:
No. 1. 2:
0.021- 0.0i15mm
{0.(xn8 - 0.0018in)
SqrviceLimit 0.050mm (0.0020inl
0.025- 0.0,19mm
No. 3
{0.0010- 0.0019in}
ServiceLimii: 0.055mm 10.0022inl
0.013- 0.037mm
No. 4
10.0005- 0.d115in)
in)
ServiceLimit: 0.050mm {0.1X120
o.(xlg- 0.033mm
No. 5
(0.0004- 0.0013in)
ServicaLimii: 0.040mm (0.0015inl

7-8

lf the plastigagemeasurestoo wide or too narrow,

(removethe engine if it's still in the car). remove
the crankshaft,and remove the upper half of the
bearing.Install a new, complete bearingwith the
same color code (selectthe color as shown on the
next pags),and recheckthe clearance.
CAUTION: Do not fi16,3him, or 3crapoth b.arings
or the caps to adiu3t clearance.
7 . lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(the color
listedaboveor belowthat one),and checkagain.
NOTE: lf the groper clearancscannot be obtained
by usingthe appropriatelargeror smallerbearings,
reDlacethe crankshaftand startover.

Selection
CAUTION: lf the codes ars indecipherabls bcauso of
an accumulationof dirt and dust, do not scrub them
with a wiro brush or scraper,Cleanthgm onlv wiih sol.
vent or .totrgont.
CrankshaftBors Code Location
{Numbers,Lettgrs or Bars}

Main Journal Code Locations

(Numbers or Bars)
H22Al engine:

Main JoumalCodeLocationslNumbersor Ba'sl

Numbersor Lettersor Bars have been stampedon the

end of the blockas a code for the size of each of the 5
main journalbores.
Use them, and the numbersstampedon the crankshaft
(codesfor main journalsize),to choosethe correctbearIngs.

H23A1.F22Al engines:
The Main Journal Codesare stampedin one of the following locations.
Main Jou.nalCodoLocations(Numbalsor Bar3)

IPULI.TYEND}
BcaringDosign

No. 5 JOURNAL
{FLYWHEEL
ENDI

PROJECTION

LOWER
Berring ldentitication

----------------

Largercrankbore

Colorcodeis on the
edgeofthe bearing.
----------> Smaller bearing (Thicker)

Main Journrl Coda Locationi {Numbersor Br.!}

No. 5 JOURNAL
IFLY WHEELENDI

No. 1 CRANK WEB

Smaller
main
iournal

Smaller
bearing
(Thicker)

NOTE:When usingbearinghalvesof
different colors, it does not matter
whichcolor is usedin the top or bottom.

No. 1 JOURNAL
(PULLEY
ENDI

GonnectingRod Bearings
Clearance
lf the plastigagemeasursstoo wide or too narrow,
removethe upper half ot the bearing,installa new,
complete bearing with the same color code (select
the color as shown on the next page),and recheck
the clearance.

Removethe connectingrod cap and bearinghalf.

Cleanthe crankshaftrod journal and bearing half
with a cleanshoptowel.
Placeplastigageacrossthe rod journal.

CAUTION: Do not file, shim, or scrapothc boaring3

or tha cap3to adiust cloaranc.

Reinstallthe bearing half and cap, and torque the

nutsto:
1.
47 N.m (4.7 kg-m, 34 lb-ft)
NOTE:Do not rotatethe crankshaftduring inspection.
5.

Removethe rod cap and bearinghalf and meassure

the widestpart of the plastigage.
ConnectingRod Bearing.to.Journll Oil Clearsnce:
P'AAI ngin6:
Standard (Newl: 0.021- 0.049mm
10.0008- 0.0019in)
0.05 mm (0.002in)
ServicLimh:
H23A1,ll22Ai enginos:
Standald {Newl: 0.027- 0.055mm
(0.0011- 0.0022inl
0.06 mm (0.002in)
Ssrvice Limh:

PLASTIGAGESTRIP

iI
H
t;,
ili
tit
il

it;
'll
:'l

I!:

7-10

lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(thecolor
listed above or below that one), and check clearanceagarn.
NOTE: lf the proper clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
reolacethe crankshaftand startover.

Selection
CAUTION: lf th6 cod6s aro indscipherable because of
an accumulationof dirt and dust, do not scrub them
with a wirg brush or licrapor.Clsan them only with sol
v6nt or detergent.
ConnectingRod Journal Code Locations
{Numbersor Bars)

ConnqtingRod Journal Code Locations

(Lettersor Barsl
H22A1engine:
ConnectingRod Journal Code Locliion! lLstterr or BrBl

N u m b e r so r B a r s h a v e b e e n s t a m p e do n t h e s i d e o f
each connectingrod as a code for the size of the big
end. Use it, and the lettersor barsstampedon the crank
lcodsfor rod journal size),to choosethe correctbearings,

Halfot numberor bar

is stampedon bearingcap
and the otherhalf is
stampedon rod

H23Al, F22Al cngincs:

The ConnectingRod Journal Codesare stampedin one
ol the followinglocations.
..,:-.

ConnoctingRod Journrl Codo Locltion3 {Latta'3 or B!1!}

BoaringD6i9n

PBOJECTION
ConnectingRod Journd Coda Location3llatta.3 or B.rrl

No. 5 JOURNAL
Eoaring ldantif ication
Colorcodeis on the
edgeol the bearing.

.---..-----+

Largerbig end bore

Smallerbearing(Thicker)

Elue

Smaller
rod
journal

Smaller
bearing
lThicker)

No. I CRANKWEB

No. 1 JOURNAL
IPULTIY END}

Grankshaft,BalancerShaftsand Pistons
Removal
1.

Removethe right side cover.

DOWELPIN

3.

Removethe front balancordrivenpulleyas thown.

BALANCER
DF]VENPULEY

MANTE'{ANCEHOI

I
I
)

SCREWT'RIVER

I
t1

Align the bolt hole and the bslancershaft hole.thon

insert a 6 x 100 mm bolt to hold the rear balsncsr
shaft.

il
;l
Ii

2.

Removethe balancergearcase.

DOU'ELPIN

Removeth6 bolt and the balancordrivengs8r.

REARBALA]IIGEB
SHAFT

8 x 1.25mm
25 N.m 12.5kg-m, 18lb-ft)

6 x lm .nm BOLT

va mm {2.9inl
BALANCER
GEARCASE

DOWELPIN

REARBALANCERSHAFT

7-12

Rmovethe oil screenand the oil pump.

7.

Rsmovthe baffle plate.

8.

Removethe bolts and the bearingcap bridge,then

removethe bearingcaps.
CAUTION: To provent wsrpago. un3crew tha bolts
in loqucnc 1/3 turn at a timc; ropcst tho srqucnco
until rll bolt3 are loosGnod.

o|LscaEE

BAFFLEPLATE

MAIN BEARINGCAP BOLTSLOOSENINGSEOUENCE

7-13

Grankshaft,BalancerShaftsand Pistons
Removal(cont'dl
9. Turn the crankshaftso No. 2 and 3 crankpinsare at
the top.
and main caps/bear1 0 . Removethe rod caps/bearings
in order.
ings.Keepall caps/bearings
1 1 . Lift the crankshaftout of the engine,being careful
not to damagejournals.

15. lf you can teel a ridge of metal or hard carbon

around the top of each cylinder,remove it with a
ridge reamer. Follow the reamer manufactursr's
instructions.
CAUTION: lf the ridgo k not rcmoved, h mly dtmag6 the pistons a! thcy lrc purhod out.

Use the wooden handle of a hammer to drivo the

pastons
out.
CRANKSHAFT

'12. Removethe bolts and the retainer.then removethe

front balancershaftand the rearbalancershaft.

RETAINER

CAUTION:
. Tako caro not to dtmago thc contlct turflcc of
tho motal g.!kot.
. Whan romoving thc pirton/connactlng rod trka
cara not to hit thr oil irt (H22Al cngine onlyl.
. It th. oil ict nozzlo is drmlg.d or d.formld, rrplaco the oil iet .srombly {H22Al .ngin. only,
page 8-81.

't1. Reinstalltheconnectingrod bearingsand capsaftor

removing each piston/connectingrod assombly.

1 3 . Removethe upperbearinghalvesfrom the connecting rods and set them aside with their respective
caps.

1 8 . Mark each piston/connectingrod 8ssmbly with its

cylindernumberto avoid mixup on .eassembly.

1 4 . Reinstallthe main caps and bearingson the engine

in properorder,

NOTE:The existingnumbsr on the connsctingrod

does not indicateits positionin the engine,it indicatesthe rod bore size.

Crankshaft
Inspection
C l e a n t h e c r a n k s h a f to i l p a s s a g e sw i t h p i p e
cleanersor a suitablebrush.
Checkthe keywayand threads,

Alignment
a M e a s u r er u n o u t o n a l l m a i n i o u r n a l st o m a k e
surethe crankis not bent,
. The difference between measurementson each
journalmust not be more than the servicelimit.

Out-of-Roundand Taper
o Measure out-of-round at the middle of each rod
and main journalin two places.
. The differgncebetyveenmeasurementson each
journalmust not be more than th serviclimit,
Journal Oui-ot.Round:
Standa.d (Ncw): o.qE mm {0.0002in}
SorvicoLimit: O.q)6mm (0.0002inl

CrsnkehaftTotal lndicatod Runouti

Standard (Nw): 0.03 mm (0.001in)
Ssrvico Limit: 0.04 mm (0.002in)

DIALINDICATOR
Rotatecrankshafttwo
compteterovolutions.
M6asursin two
pl6cesat middl.

Suppon with lathetype tool or V-blocks.

Measu16
taper
near edgs.

Measuretaper at the edge of each rod and main

journal.
The difference between measurementson each
journalmust not be more than the servicelimit.
Journal Taper:
St.ndrrd (Now): 0.005mm (O.(xXr2
int m!x.
Scrvicc Limit
0.006mm (0.(xn2 in)

Pistons
Inspection
C a l c u l a t et h e d i f f e r e n c eb e t w e e nc y l i n d 6 r b o r e
diameteron (page7-17)and pistondiamet6r.

Checkthe Distonfor distonionor cracks.

NOTE:lf the cylinderis bored,an oversizedpiston
must be used.
Measurethe piston diameterat a point F22A1:21 mm
(0.8in),H23A1,H22A1:15mm (0.6in)from the bottom
of the skirt.

Pbton-to-CvlinderClsrranco:
F22Al engine:
Standard (Nw): 0.020- 0.0/(, mm
l0.00oB- 0.0016in)
0.05 mm {0.002in)
ServiceLimil:

e i s t o n s( N o
N O T E :T h e r ea r e t w o s t a n d a r d - s i zp
Letter(A) or B). The letteris stampedon the top of
the piston. There letters are also stamped on the
blockas cylinderbore sizes.

H2341,H22A1engines:
Standard (Newl: 0.007- 0.030mm
(0.0003- 0.0012in)
SorviceLimit: 0.04 mm (0.002inl

Piston Diameter:
F22Al engine:
Standard lNewl:
No Letter lA): 8i[.980- 8i1.990mm
(3.3457- 3.3451inl
84.970- 84.980mm
B:
13.3453- 3.3,157in)
ServiceLimit:
No Letter {A}: 8i0.970mm (3.3453in}
84.950mm (3.3449in)
B:
H23A1,H22A1enginss:
Standard lNewl:
No Letter (A): 86.990- 87.003mm
- 3.4253inl
(3./1248
86.980- 86.993mm
B:
- 3.42,19inl
{3.,[2/14
ServiceLimit:
inl
No Lettor {A}: 86.980mm {3.,12,14
B:
F22Al sngino:
21 mm 10.8inl

lf the clearanceis near or excesdsthe servicelimit,

inspectthe piston and cylinderblockfor excessive
wear.

86.970 mm (3.,[2'10in]
SKIRT
DIAMETER

OvorsizePiston Diamoter:
F22A1engine:
0.25:85.230- 85.2/0 mm {3.3555- 3.3559in}
0.50:85.,180- 85.tlln mm {3.3653- 3.3657in}
H23A1.H22Al rngin.3:
O.25t87.230- 87.2,(l mm (3./8/02- 3.,13{8in)
4.

Checkthe piston pin-to-pistonclearance.Coat ths

piston pin with engineoil. lt should then be possible to push the piston pin into the piston hole with
thumb Dressure,
Piston Pin-to Piston Clctrtnco:
F22Al engine:
Standard (Newl: 0.012- 0.02amm
(0.fi)05- 0.qt0o in)
H23Al, H22Al ongines:
Standard {Nw}: 0.012- 0.026mm
10.000t- o.(XllOin)

7-16

CylinderBlock
Inspection
1 . M e a s u r ew e a r a n d t a p e r i n d i r e c t i o nX a n d Y a t
three levelsin eachcvlinderas shown.

Boro Taprr:
Limil: {Diftorcncabotw.on lirst snd third
maasuromcntl 0.05 mm {0.002inl

6 mm 10.2in)

Firrt
Ma!!urcmant
S.cond
Mar!uramcnt

Third
Mer3uramant

l f m e a s u r e m e n t si n a n y c y l i n d e r a r e b e y o n d
OversizeBore ServiceLimit, replacethe block.
l f t h e b l o c k i s t o b e r 6 b o r e d ,r e f e r t o P i s t o n
Clearance
Inspection(page7-16)afterreboring.

NOTE: Scored or scratchdcylinder bores must be

honed.

6 mm 10.2inl

F22Al engine: 0.50 mm (0.020inl

H2341,H2/IA1rngincr: 0.25 mm (0.010inl
2,

Checkthe top of the block for warpage.

Measurealong the edgesand acrossthe centeras
snown.

SUNFACES
TO BEMEASUBED
CYLINDERBORESIZES
lA or I, B or rll
Readth ltterstrom lelt-to'right
for No. 1 throughNo.4 cylinders.

CYLINDER
BONE

Cylindcr Boro Size:

F22Al engino:
Stendlrd (Ncw):
A or l: 85.010- 85.020mm {3.3458B ot ll: 85.000- 85.010mm (3.3i165
Sorvicr Limit: 85.070mm (3.3492in)
H23A1,HPAI ongines:
Stlndffd {Now,:
A or l: 87.010- 87.020mm {3.4256I or ll: 87.000- 87.010mm (3.'1252Srrvicc Limit: 87.070mm {3.i|:l79inl

Enginc Block W..prge:

Stlndlrd {Ncw): bclow 0.07 mm (0.003in}
S.rvico Limit: 0.10 mm (0.(Xt4inl
PRECISIONSIRAIGHT EDGE

3.3/t?2in)
3.3i168in)

3.4260in)
3.i1256in)

OvoEizo:
F22Al cngino:
0.25:85.250- 85.260mm (3.356:t- 3.3569inl
0.50:85.500- 85.510mm {3.3661- 3.3665in)
H2341, H22Al 6nginsr:
0.25:87.260mm 13.4:l5i[inl

7-1

CylinderBlock
BoreHoning(H2341,H2241engines)
l.

rbv^

,,

CAUTION: Thir cylinder linor ussr FRM (Fiber

ReinlorccdMatall. Hono only !s diroctod below.
1.

2.

3.

Masurecylinderboresas shown on page7-16.

It the block is to be reused,hone the cylindersand
remeasurethe bores,
To honecylinderbores;
. Useonly a rigid hone.
. Honingstone:
GC- 600- J or finer stone
(for nonf6rrousmetals)
. Pressure:
2OO- 3OOkP;
(2-3 kg-cm', 28 - 43 psi)
. Honingrpm:
45 - 50 rpm
. Honingthickness;Lessthan 0.02mm (0.0008in)
Do not hone mote than
20 cvcls
. Honinglubricant Oil type
. Roughnessof
finishedsurfaces:VVV or 1.2S
. Honingpattern: 60 degrecross-hatch
CAUTION: Cloantho honing stono oyory 5 cyclos.

W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a nt h e
cylinderblockof all metal particles.Washthe cylinder bores with hot soapy water. then dry and oil
immediatelyto preventrusting.
NOTE: Never use solvent, it will only redistribute
the grit on the cylinderwalls.

4.

lf scoring or scratchgsare still presentin cylinder

boresafter horningto servicelimit, reborethe cylinder block.
NOTE:Some light verticalscoringand scratchingis
acceptableif it is not deepenoughto catchyour fingernailand does not run the full lengthof the bore.

PistonPins
BoreHoninglF22A1enginel
Measurecylinderboresas shown on page7-16.
lf the block is to be reused,hone the cvlindersand
remasurethe bores.

Removal
Assemblethe PistonPin Toolsas shown.
PISTONSASEHEAD
OTHAF-PUM102

Honecylinderboreswith honing oil and a fine (400

grit) stone in a 60 degree cross-hatchpattern,

PISTON PIN BASE INSENT

OTGAF- PHq'3U'

NOTE:
. Use only a rigid honewith 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
. Do not use stonesthat are worn or broksn.

tl
PFTONBASE
0tt3 - 65t0500
Adjust the length A of the piston pin driv8r.
A: 51.5 mm (2.G1inl
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
engine block of all metsl particles.Wash the cylinder bores with hot soapy water, then dry and oil
immediatelyto preventrusting.
NOTE; Never use solvent, it will only .edistribute
the grit on the cylinderwalls.
lf scoring or scratchesare still presentin cylinder
bores after honing to the servicelimit, rgbore the
cvlinderblock.
NOTE:Some light vsrticalscoringand scratchingis
acceptableit it is not deep enough to catch your fingrnailand does not run the full lengthof the bore.

PISTON PIN DRIVERHEAD

0t9t3 - PE|D320

l l

H
trl-

PISTOI{PII{ DRlvENSHAFT

or9r3- Fdto3ro

m--.--

PILOTOOLLAN
o'GAF- PHt0100
Emboesed
marklacingup.

CYLINDEBHONE

NOTEiUEea hydraulicpro6s.
When prossingpin in or out,
make sure that th rgco$ad
ponionofthe pistonoligns
with tho liD3on th collar.

NOTE:
.

After honing,cleanthe cylinderthoroughlywith

soapy water.
o Only a scored or scratchedcylindr bore must be
honed.

Placeths piston on the piston base and pressthe

pin out with a hydraulicpress.

7-19

PistonPins

ConnectingRods

lnstallation

Selection
Each rod falls into one of four toleranceranges(from 0
to 0.024mm {0.0009in), in 0.006mm (0.0002in) increments) dependingon the size of its big end bore. lt's
then stampedwith a numberor bar \'1,2,3, ot 4ll, t, ttl,
or Irl) indicatingthe range.
'1,2,3, ot 4/1,t, ttl,o(
You may find any combinationoI
Irl in any engine.
Normal Boro Sizr: 51.0 mm (2.01in)
NOTE:
Referncnumbersor bars are for big end bore
sizeand do not indicatethe positionof th rod in
the engine.
Inspectconnectingrod for cracksand heat damage.

Usea hydraulicprossfor installation.

1.

Wh6n pressingthe pin, in or out, bo sureto position ths recessodtlat on the piston againstthe
lugs on the base8ft8chment.

The arrow must laco the

timing belt side of the
6nOine.

Tho ma* must faco

the timing beltsid6
ol th6 engin6.

RODBORE
CONNECTING
NUMBERoi BAR
BEFEBEITCE
Half ot number is sttmpsd on
bearingcap, ths other half on
connectingrod.

2.

Adjust the length B of the piston pin driver.

B: 51.5mm (2.G1in)
HEAO
PISTONPINDRTVER
- PEqB2o
0797:1

PISTONPIIIIDBIVERSHAFT
07973- PE00310
Embossdmark

I
ffi*r,"ron'n
PILOTCOLLAR
07GAF- PH701d)

Inspgctbolts
and nuts for
strogscracks.
PISTONPIN BASE NSEBT
07GAF- PH6o3q)
PISTONBASE HEAD
07HAF- P120102
PISTONBASE
07973 - 6705{X'

NOTE: Installthe assembledpiston and rod with

t h e o i l h o l e f a c i n g t h e i n t a k em a n i f o l d ( E r ( c e p t
H22A1enginel.

7-20

PistonPins
Inspection
Measurethe diameterof the pistonpin.

Measurethe pistonpin-to-piston
clearance.

Pbton Pin Diamoter:

Standard (Nawl: 21.994(0.86s9Ov6rsizg:
21.997{0.8560-

NOTE:Checkthe pistonfor distortionor cracKs.

22.(XX'mm
0.8561inl
22.003mm
0.866:linl

l f t h e p i s t o n p i n c l e a r a n c ei s g r e a t e rt h a n F 2 2 A 1
e n g i n e : 0 . 0 2 4 m m { 0 . 0 0 0 9i n ) H 2 3 A 1 ,H 2 2 A 1
engines:0,026mm (0.0010in), remeasureusing an
oversizepistonpin.

NOTE:All replacementpistonpins are oversize.

Piston Pin-to.PistonClearanco:
F22A1engine:
Standird (Ncw): 0.012- 0.024mm
{0.0005- 0.q)(xt in,
H2341, H22Al ongines:
Stlndsrd lNewl: 0.012- 0.026mm

2.

Zerothe dial indicstorto the DistonDindiameter.

4.

Checkthe diferrencebetweenpiston pin diameter

and connectingrod smallend diameter.
Pbton pin-to ConnoctingRod Interfa.oncs:
Standa.d (Ncwl: 0.013- 0.032mm
- 0.0013in)
{0.00OS

7-21

PistonRings
EndGap
1.

Using a piston, push a new ring into th cylindor

'15
bore - 20 mm {0.6- 0.8 in) from the bottom.
M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l r
gauge:
lf the gap is too small,checkto see if you have
the properringsfor your engine.
lf the gap is too large,recheckthe cylinderbore
diameteragainstthe wear limitson page7-17.
lf the bore is over the servicelimit, the cylinder
blockmust be rebored.
Pistoo Ring End-Gap:
F22Al ongio:
Top Ring
Standard (Newlr 0.20- 0.35 mm
(0.008- 0.014in)
SorvicoLimil:
0.60 mm 10.024in)
ScondRing
Slandard {N6wl: o.i(t - 0.55 mm
(0.015- 0.022inl
SorviceLimh: 0.70 mm (0.028inl
Oil Ring
Standard (Newl: 0.20- 0.70 mm
{0.008- 0.028in}
0.80 mm (0.03'linl
ServicLimit
H23A1,H22Al engine3:
Top Ring
Standard {New): 0.25- 0.35 mm
- 0.014in)
10.010
SorvicaLimit: 0.61tmm (0.02'lin)
Socond Ring
Standard (N6w): 0.60- 0.75 mm
10.02,t- 0.030in)
ServiceLimit: 0.90 mm {0.035inl
Oil Ring
Stsndard (Newl:
TEIKOKUPISTONRINGmanufacturs:
0.20- 0.50 mm (0.fi)8 - 0.020inl
RIKENmanufacture:
0.20- 0.70 mm (0.008- 0.028inl
Srvics Limit:
TEIKOKUPISTONRINGmanutactur:
0.60 mm (0.02i1in)
RIKENmanutaqture:
0.80mm (0.031in)

7-22

PISTONRING

iiii

r.---iLi.i----

ENDGAP

Ovg6izo:
F22Al lnginel
0.25185.25mm (3.356inl
0.50:85.50mm (3.366inl
H23A1. H22Al .nginc:
0.25:87.25mm (3.i|il5inl

Replacement
1.

Usinga ring expander,removethe old pistonrings,

2.

Cleanall ring groovesthoroughly.

NOTE:
. U s e a s q u a r e d - o fbf r o k e nr i n g o r r i n g groove
cleanerwith bladeto fit pistongrooves.
. Top and 2nd ring groovesare 1.2 mm ( 0 . 0 5i n )
wide and the oil ring groove is 2.8 mm ( 0 . ll i n )
wide.
. Filedown bladeif necessarv.
CAUTION: Dq not uss a wire brush to clean the ring
groovgs, or cut ring groove3 d9per with cloaning
tools.
NOTE:lfthe pistonis to be separatedfrom the connectingrod, do not installnew ringsyet.
Installnew rings in the proper sequenceand position (page7-24).
NOTE:Do not useold pistonrings.

RINGEXPANDER

Ring-to-Groove
Clearance
After installinga new set of rings. measurethe ring-togrooveclearances:
Top Ring Clarlnc6
Standard (New): 0.035- 0.060mm
{0.0014- 0.002,tinl
SorvicoLimit: 0.13 mm (0.005in)
Second Ring Clsaranco
Standard (Now): 0.030- 0.055mm
(0.fl)12- 0.fl122inl
SorvicoLimit: 0.13 mm (0.005inl

PistonRings
Alignment
1 , lnstalltheringsas shown.

Rotatethe rings in their groovesto make sure they

do not bind.

ldentifyrop and secondrings by the chamferon the

edge.Makesurethey are in their propergrooveson
the paston.

MARK

TOP RING

NOTE: The manufacturingmarks must be facing

upwaro.
SECONDRING

3.

Positionthe ring end gsps 8s shown:

SECONDRINGGAP

DO NOT position any rinOgap

at piston thrust surfaces.

H23A1,H22Al onginos:
Approx.90'

Appiox.
90"

OIL RING
GAP

TOPRINGGAP
DO NOT posilion any ring gap
in linewith the oistonoin hole.

GAP
OIL RINGGAP

CrankshaftOil Seal

Pistons

;I Installatio
|
|

.11
'E

l.

lnstallation

The sealsurfaceon the blockshouldbe dry.

Apply a light coat of oit to the crankshaftand to
the lip of the s6al.

Drivein crankshaftoil sealagainstright sidecover.

B e f o r e i n s t a l l i n gt h e p i s t o n , a p p l y a c o a t o f
engine oil to the ring groovesand cylinder
bores.
1.

NOTE:Drivethe crankshaftoil sealin squarely.

DRIVER
07749- 0or(xDo

2.
Installsealwith the
part number sid6
facingout.

ll the crankshaftis alreadyinstalled:

. Setthe crankshaftto BDCfor eachcvlinder.
o Removethe connectingrod caps and slip short
sectionsof rubber hose over the threadedends
of the connectingrod bolts.
. Installthe ring compressor,checkthat the bearing is securelyin place,then position-thepiston
in the cylinder and tap it in using the wooden
handleof a hammer.
a Stop after the ring compressor pops free and
checkthe connectingrod-to-crankjournal alignment beforepushingpistoninto place.
. Installthe rod capswith bearings,and torquethe
nutsto:
47 N.m {4.7kg-m.34lb-ft)
lf the crankshaftis not installed:
. Removethe rod caps and bearings,install the
nng compressor,then positionthe piston in the
cylinderand tap it in usingthe wooden handleof
a nammer.
. Positionall pistonsat toD deadcenter,

DRIVEBATTACHMCNT
079ir8- SBlXtl01
C o n f i r m t h a t t h e c l e a r a n c ei s e q u a l a l l t h e w a y
aroundwith a feelergauge.

The arrow must tace the

timing beltsideot the
engine.

Cloarancc:0.5 - 0.8 mm (0.02- 0.03 inl

RIGHTSIDE
COVER

0.5 - 0.8 mm

The mark muBttace

the timing beltside
of the engine.

NOTE:Maintaindownward force on the ring comp r e s s o rt o p r e v e n tr i n g s f r o m e x p a n d i n gb e t o r e

enteringthe cylinderbore,
Usethe woodnhandle
of a hammorto push,or

NOTE:Referto pages7-30and 8-11for installation

of the oil pump sidecrankshaftoil sear.

Grankshaftand BalancerShafts
lnstallation
Betoreinstallingthe crankshaft,apply a coat of
e n g i n eo i l t o t h e m a i n b e a r i n g s .r o d b e a r i n g s
and balancershaft bearings.

6.

Insertbearinghalvesin the cylinderblockand connectingrods.

Holdthe crankshaftso rod journaisfor cylindersNo.
2 and No,3 are straightup.

Installthe thrust washers,main bearingcaps and

bearingcap bridge.
Check clearancewith plastigage(page 7-8), then
tightenthe bearingcap boltsin 2 steps.
ln the first step tighten all bolts in sequence,to
about 30 N.m (3.0 kg-m, 22 lb-ft);in the finsl step
tighten in same sequenc,to 75 N.m {7,5 kg-m.54
tb-ft).
NOTE:Coatthe bolt threadswith engineoil.

Lowerthe crankshaftinto the block,seatingthe rod

journalsinto connectingrods No. 1 and No. 4.
lnstallthe rod capsand nutsfingertight.

RODNo. 2

WASHERS

CAUTION: Whlnovor any crankshaft or connccting

rod baaring i3 roplacad, it ir nocosarY lftcr lc!sscmbly to lun tho cngin. Ei idling tpoed until it
rcacho! normal opcrrting iamporltula. thcn Gon.
tinue to run it lor approximataly 15 minut6.

RODNo. a

7.

I
\
'l

Rotatethe crankshaftclockwise,seat journals into

connectingrods No, 2 and No.3, and installthe rod
capsand nuts fingertiqht.
NOTE:Installcaps so the bearingrecessis on the
sameside as the recessin the rod.
Checkrod bearingclearancewith plastigage(page
7-10),then torquothe capnuts.
47 N.m (4.7kg-m.34lb-ft)
NOTE: Referencenumbers on connectingrod are
for big-endbore toleranceand do not indicatethe
positionof pistonin the engine.

7-26

Insenthe balancershaftsinto the block,then install

the retainerto the front balancershaftand block.

NOTE:
. Useliquidgasket,parrNo.087t8-0001.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
. Apply liquidgasketevenly,beingcarefulto cover
allthe matingsurface.
. To preventleakagof oil. apply liquid gasketto
the innerthr6adsof th6 bolt holes,
. Do not install the parts if 20 minutes or more
haveelapsedsinceapplyingthe liquidgasket.
Insteadreapplyliquid gasketafter removingthe
old residue,
. After assembly, wait at least 30 minutes before
filling th6 enginewith oit.
8.

Apply liquid gasket to the block mating surfaee of

the right side cover, then install it on the cylinder
block.

Apply liquidgasket
to block mating surface.

6 x 1,0 rnm
12 N.m (1.2 kg'm, 9 lb-ft)
Apply liquid gasket
to the bolt threads.

RIGHTSIDECOVER

BIGHTSIDECOVER:
9.

Apply liquid gaskstto the oil pump mating surfac

of the block,then installthe oil pump on the cylinder block.
.

Apply greaseto the lips of the oil seals.

T h e n , i n s t a l lt h e o i l p u m p w h i t e a l i g n i n gt h e
inner rotor with the crankshaft.When the pump
i s i n p l a c e , c l e a n a n y e x c e s sg r e a s e o f f t h e
crankshaftand the balancer shaft, then check
that the oil se8llips are not distorted.

OIL PUMP:

Apply liquid gaskst along

the broken line.

{cont'd)

7 -27

Crankshaftand BalancerShafts
Installation (cont'd)
12. Holdthe rearbalancershaftwith a 6 x 100mm bolt,
then installthebalancerdrivengear.
6x1.0mm
12 N.m (1.2kg-m,9lb-ftl

OIL SCREEN

REAFBALANCERSHAFT:
8 x 1.25mm
25 N'm {2.5 kg-m, 18 lb-trl

O.RINGS
Applyengineoil.
Replace.

6 r lOOmm BOIT
74 mm 12.9inl

DOWELPIN
6x1.0mm
OIL PUMP
12 N.m 11.2kg-m,
Applyliquidgasketto
9 tb-ft)
block mating surface.
Applyliquidgasket
to the bolt threads. Applygreaseto the seallips.

10. Installthebaifleplate,then installtheoil screen.

'11. Apply molybdenumdisulfideto the thrust surfaces
of the balancergears as shown, before installing
t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
case.
Applymolybdenum
EALANCER
SHAFT
disutfide.
DRIVEN

BALANCERBELT
DRIVENPULLEY

7-28

BALANCERDRIVEGEAR
AALANCERGEAR CASE

REARBALANCERSHAFT

'13. Hold the front balancershaft with a screwdriver,

then installthetiming balancerbelt drivenpulley.
FRONTBALANCERSHAFT:

14. lnstallthebalancargea|.caseto the oil pump.

NOTE:Align the groovo on the pulley sdg to the
pointoron the gear casswhile holdingths rear balancer with 6 x 100 mm bolt, then install the gear
casg.

16. Install the oil pan.

OIL PAN GASKET

Replace.

Apply liquid
gasketto here.

DOWELPIN
E x 1.25mm
25 N.rn 12.5lg.m.
18 rb-ft|

BALAI{CER DOWELPIN
GEAR$SE
POINTEB

O.RING
Applyengineoil,
Roplace.

Alignthe groov
to pornter.

WASHER
Replace.

6xl,0mm
12 N.m {1.2kg.h,
9 rb-ft}

45N.m(4.5kg.m.
33tb-ftt
Donot overtighten,
1 1 . Tightenthe boltsand nuts as shown below,
Torqu.: 12 N.m (1.2 kg-m, 9 lb.ft)

GROOVE

Checkalignmentof pointersafter installingthe gear

case.
POINTER
ONTHEPUL1TY

NOTE:Tightenthe bolts and nuts in two stoosand

torquethem in a criss-cross
pattern.

7-29

Crankshaftand BalancerShaft Oil Seals

Installation{engineremovalnot requiredl
NOTE:The crankshaftand front balancershaft
oil sealhousingsurfaceshouldbe dry.
the
Apply a light coat oJgreaseto the crankshaft,
seals.
the
lips
ot
the
balancershaftand to
Using the specialtool, drive in the crankshaftoil
sealuntil the driverbottomsagainstthe oil pump.
When thg seal is in place.clean any excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.

3.

Using the specialtool, drive in the crankshaftoil

seal into ths right side coverto the point where the
clearancebetween the bottom of the crankshsft oil
seal and right side cover is 0.5 - 0.8 mm (0.020.03in) lpage7-251.
NOTE:Align the hole in the driver attachmentwith
the pin on the crankshaft.

- (x)1|xno
07749

SEALDRIVER
O'LAD - PI':IOIOA
lnslall se6l with the
part number sido
facing out.

2,

Using the specialtool, d.ive in the front balancer

shaft oil seal until the driver bottomsagainstthe oil
pump. When the seal is in pl8ce,clean any excess
greaseoff the balancershaft 8nd checkthst the oil
sealliDis not distorted.

GUIDE
HUBASSEMBLY
ATTACHMENT
OTGAF_

7-30

ATTACHMEITT,
30 mm l.D.
077t6 - @30300

DRIVERATTACHMEMT
079a8- SB@r01
lnstollsealwiththe
part number side
facing out.

BalancerShafts
Inspection
NOTE: Inspectthe balancershaft before removingthe
right sidecoverand the balancergearcase{page7-12).

Removethe balancershafts(page7-12).

'1.

NOTE:Cleanthe balancershsfts,

Push the balancershaft firmly away from the dial

indicator,and zerothe dial againstthe front end of
the balancershaft,then pull the balancershaftfirmly backtoward the indicator.

Inspectthe surfaceof the balancershaftjournaland

balancerbearing.

Froni BalancorShaft End Play

Standard (Nsw): 0.10- 0.35 mm
l0.00il- 0.014in)

Replaceif there is wear,damageor discolorationon

the surfaceof the bearingor the balsncershaftjournal. When replacingthe rear No. 1 bearingbe sure
to replacethe oil pump housingwith a new one.
NOTE;A mirro.-likesurfaceis normat.
Measuretaperat the edgesof eachjournal.
.

The differencebetweenmeasurementson each

lournal.
Journal Tapor
Standard (Newl: 0.005mm (0.0002in)

lf end play is excessive,inspectthe retainerand

thrustsurfaceson the balancershaft.

Rsar BalancorShrft End Play

Stsndard(Nw):0.06- 0.18mm
10.002- 0.007inl

lf end play is excessiv,inspectthe thrust washer and thrust surfaceson the driven qear and oil
pump Dody.

N O T E :T h e t h i c k n e s so f t h e r e t a i n e r( f r o n t ) a n d
t h r u s t w a s h e r ( r e a r )a r e f i x e d a n d m u s t n o t b e
changedeitherby grindingor shimming.

{cont'd)

7-31

BalancerShafts
Inspection(cont'd)
6.

Measurerunout on the No. 2 journal of each balancershaftto makesurethe balancershaltsare not

bent,
Ealanc6rShaft Total IndicatodRunout
Standrrd (Now): 0.02 mm (0.001inl
Sewice Limit: 0.03 mm 10'001inl

Journal Diamotr
Stlndard (New)
No, 1 ioutnal:
Front:
12-722- 12..731mm
11.6820- 1.6824inl
20.938- 20.950mm
Rear:
{0.824:l- 0.82'18in}
No. 2 iourn.l: 38.712- 38.724mm
l1.52al- 1.5245inl
No. 3 iourn.f : 31.722- 31.731mm
(1.3670- 1.3675inl
Limit:
Scrvica
No. I iournal:
42.71mm {1.681in)
Front:
inl
20.92mm 10.82,1
Rcar:
No. 2 iouinll: 38.70mm (1.524inl
No. 3 iournal:34.71mm (1.367in)

Measurethe diametersof the balancershaft journ al s .

:
I

MEASURINGPOINTS

i
I

Removethe crankshaft,the pistons and the other

oartsfrom the block,then cleanthe balancershaft
i o u r n a l b e a r i n g so f t h e b l o c k a n d t h e o i l p u m p
housingwith a cleanshoptowel.

9.
i

7 -32

Checkthe surfaceof the bearings,if there is wear.

damage or discoloration,replacethe bearingsor
the oil pump housing.

1 0 . Measurethe inner diametersof the balancer shaft

journalbearings.
MEASUREPOINTS
No. 2 BEARING
IBLOCKI

Bearing Inner Diametor

Standard {Nswl:
No. I iournals:
Fronl:
12.8OO- 12-82Omm
(1.6850- 1.6858in)
Rear:
21.flD - 21.013mm
{0.8268- 0.8273inl
No. 2 iournals: 38.800- 38.820mm
- 1.5283in)
(1.5276
No. 3 iournals: 34.800- 3,1.820mm
{1.3701- 1.3709inl
ServicoLimit:
No. l iournals:
Front:
42.8:lmm 11.686inl
R6ar:
21.02mm (0.828in)
No. 2 iournals: 38.tIl mm (1.529in)
No.3 iournsls:3i1.83
mm (1.371in)
11. Calculatethe shaft-to-bearings
oil clearances.
BEARINGl.D. - JOURNALO.D. = OtL CLEARANCE

No. 2 BEARING
IBLOCK)
BLOCK

Boaring-to-shaftOil Cl.aranc
Standard (Newl
No. I iournal front and No. 3 iournsls:
0.066- 0.118mm {0.0026- 0.0046inl
No. 2 iournab:
0.076- 0.128mm (0.0030- 0.0050in)
No. 1 iournal rar:
0.050- 0.075mm (0.0020- 0.0030in)
S6rviceLimit:
No. I iournal tront and No. 3 iournats:
0.12mm (0.005inl
No. 2 tournsls: 0.13mm {0.005inl
No. I iournal roar: 0.09 mm (0.004in)

DIALGAUGE

No. 1 REARBEARING
IOIL PUMP HOUSINGI

7-33

EngineLubrication
Speciaf
Tools..........
...........9-2
lllustratedlndex...........
.....8-3
EngineOil
Inspection
......................
8-5
Replacement
.......................................
8-5
Oil Filter
Rep|acement
.......................................
8-6
Oil Pressure
Testing
......8-8
OilJet
fnspectionlHz2Al engineonly) ........8-8
Oil Pump
Overhaul
.........................
8-9
RemovaUlnspection/lnstallation
......8-10

SpecialTools

Rs{. No.

@
Ar

OTLAD07746077490 7 9 1 2-

Oty

Drtcription

Tool Numbel
PT3O1OA
0010300
0010000
6110001

8-2

PEg. Rctercnc.
8-11
8-1 1
8-1' I
a-7

SealDriver
Attachment,42 x 47 mm
Driver
Oil Filterwrench

lllustratedIndex
NOTE:
a Us new O-ringswhen reassembling.
. Apply oilto O-ringsbeforeinstallation.
. Useliquidgasket,PartNo. 08718- OOO1.
. Cleanthe oil controlorificewhen installing.
8 x 1.25mm

CAUTION: Do not overtighten the drain plug.

OILPUMP
Overhaul,pageI 9
Inspection,
page8-10
Apply liquidgasketto
blockmatingsurface.
O-RINGS
Replace. F22A1,H23At enginesj
OIL CONTROLORIFICE
Do not installit on the H22A1engine.
Clean.

8 x 1.25mm
30 N.m (3.0 kg-m,
22tb-ft1

O.RING
Replace.

F22Al engin:
ENGINEOIL PRESSURE
SWITCH
18 N.m (1.8 kg.m, t3 tb-ft)
1/8in. BSP{British
standardpipetaper)
28 threads/inch.Use
properliquidsealant.

BALANCEN
GEARCASE

H23A1,H22At engin.s:
KNOCKSENSOR
32 N.m 13.3kg-m, 23 tb-ftl

O.RING
Replace.

8 x 1.25mm
25 N'm 12.5kg-m, i8 tb-ft}

DOWEL
PIN

ENGINEOIL COOI..ER
{H23A1,H22Al ongin6)

DOWELPIN
GASKET
Replace.

OIL PAN GASKET

Roplace.

OIL FILTER
7/8 turn or
22 N.m l2.2lg-m, i6 tb-ft|
Replacemg6lp6gs g 6
Replaceevery 7,500miles
{12,000km) or 6 months.
H23A1,H22At engin$:
ENGINEOIL PRESSURE
SWITCH
18 N.m {1.8 kg-m, t3 tb-ftl

OIL SCREEN

6x1.0mm
12 N.m 11.2kg-m,9 tb-ft|

6x1.0mm
12 N.rn(1.2kg-m.9 tb-ft)
WASHER
Replace.

OIL PAN

DRAINBOLT
1 4x 1 . 5m m
45 N.m 14.5kg-m,33 lb-ttl
Do not overtighten.

(cont'd)

8-3

lllustratedIndex
lcont'd)
NOTE:
a Usenew O-ringswhen reassembling.
. Apply oilto O-ringsbeforeinstallation
. Use liquidgasket,PartNo. 08718- 0001.
1 1x 1 , 5m m
75 N.m (7.5kg-m,
54 tb-ft}
Applyengineoiltolhe bolt
threads and th washers
NOTE:
Alter torquing each cap,
turn crankshaftto chock
for binding.

5x1.0mm
12 N.m 11.2kg-m,9lb-ft|

BAFF1TPLATE

EEARINGCAP
BRIDGE

OIL JET BOLT

40 N.m {a.0 kg-m,
29 tb-ft)
OIL JET
Handlethe nozzlewith
care.Replaceil any pan
is damagedor detormed.
6x1.0mm
12 N.m {1.2lg-m,9lb-ft}

CRANKSHAFT

THRUSTWASHERS
Groovedsidesface outward.

a-4

EngineOil
Inspection

Replacement

Checkengine oil with the engine off and the car

parkedon levelground.

CAUTION:Removs the drain bolt carofullywhile th6

ongine is hot oil m8y caus6scalding.

Makecertainthat the oil level indicatedon the diostickis betweenthe upoerand lowe. marks.

W a r mu p t h e e n g i n e .

2.

Drainthe engineoil.

lf the level has dropped close to the lower mark.

add oil until it reachesthe upDermarK.
CAUTION: In36rt thc dipstick cardully to avoid
bonding it.

45 N.m{a.5kg-m,33 tb-ft|

WASHER
R6placo.

R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r , a n d
refillwith the recommendedoil.
CAUTION: Do not ov6rtight6n the drain bolt.
Requirement API ServiceGrade:Use "Energy Conserving
ll" SG gradeoil.
F22A1,H23A1engines:5 W- 30 preferred.
H22Al engine:10W - 30 preferred.
Capacity

F22A1enginel
3.8f (4.0US qt,3.3 tmp qt)
change,includingfilter.
4 . 9 1( 5 . 2U S q t , 4 . 3 l m pq t )
atter engine overhaul.
H23A1engine:
4.3f (4.5US qt, 3.8tmp qt)
chang,includingfilt6r.
5.4f (5.7US qt, 4.8lmp qt)
afterengineoverhaul.
H22A1engino:
4.8f (5.1US qt, 4.2 lmp qO
change,includingfitter.
5.9f (6.2US qt, 5.2lmp qt)
aflerengineoverhaul,

Change

Every7,500miles {12.OOO
krn) or 6 months

{cont'd)

8-5

Oil Filter

Engi n eOi l
Replacement(cont'd)
The numbersin the middle of the API Servicelabeltell
you the oil's SAE viscosityor weight. Selectthe oil for
your car accordingto this chart:
F22A1.H23A1engines:

Ambint Temperaturo

Replacement
o Ltter tte engine has been run. the exhaurt pipo will
be hot; be caroful when working around the axhau3t
pipo.
Be careful when loo3oning the drain bolt while tho
engino i3 hot, Burns can rosult becausothG oil lgm'
peraturc is very high.
R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r
wrench.
Inspectthe threadsand rubber seal on the new filter.
Wipe off seat on engine block,then apply a light
coat of oil to the filter rubberseal.

A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r
improved fuel economy and year-roundprotection in
the car. You may use a 10 W - 30 oil if the climate in
your area is limitedto the temperaturerangeshown on
the chart.
H22A1engine:

Ambiont Temo6raturs

-20

An oil with a viscosity of 10 W - 30 is preferredfor

improved tuel economy and year-roundprotectionin
the car. You may use a 5 W - 30 oil if the climate in
your area is within the temperaturerangeshown on the
chan.
N O T E : T h e o i l f i l t e r s h o u l d b e r e p l a c e da t e a c h o i l
change.

8-6

NOTE: Use only filters with a built-in bypasssysrem.

Applyengineoilto rubbr
sealbeforeinstalling.

Installtheoil filter by hand.

A f t e r t h e r u b b e rs e a l s e a t s .t i g h t e n t h e o i l f i l t e r
clockwisewith the specialtool.
Tighten: 7/8 turn clockwise
Tightoning torque: 22 N.m (2.2 kg-m, 16 lb-ftl
CAUTION: lnstallation other than the abov procsdur6 could result in sgrious ongine damage due to
oil l6ak.go.

eight numbers(1 to 8l are printedon the surfaceof the

filter.
The following explainsthe procedurefor tighteningfil,
ters usingthesenumbers.
1) Make a mark on the cylinderblock under the number that shows at the bottom of the filter when the
rubbersealis seated.
2)

OIL FILTERWRENCH
07912- 611t)00r

Tightenthe filter by turning it clockwisesevennumbersfrom the markedpoint. For example,if a mark

is made under the number 2 when the rubberseal
i s s e a t e d t, h e f i l t e r s h o u l d b e t i g h t e n e du n t i t t h e
number1 comesup to the markedpoint.

Numberwhen rubber
sealis seated.

Numberaftertightening.

Numberwhen rubber
sealis seated
ENGINEOIL COOLER
(H23Al, H22A1engine3l

Numberaftertightening

5.

4
8

8
1

After installation,fill the engine with oil up to the

specifiedlevel,run the enginefor more than 3 min
utes,then checkfor oil leakage.

a-7

Oil Pressure

Oil Jet
fnspectionlH22A1engineonlyl

lf the oil pressurewarning light stayson with the engine

running.checkthe engineoil level.lf the oil level is correct:
'1.

Connecta tachometer.
Removethe engine oil pressureswitch and install
an oil pressuregauge.
S t a r t t h e e n g i n e . S h u t i t o f f i m m e d i a t e l yi f t h e
gauge registersno oil pressure.Repairthe problem
beforecontinuing.
Allow the engine to reach operatingtemperature
(radiatorlan comeson at leasttwice).The pressure
shouldbe:

Removethe oil jet (page8-4) and inspectit as folrows.

Make sure that a 1.1 mm {0.04in} diameterdrill
will go throughthe nozzlehole {1.2mm t0.05in)
diameter).
Insertthe other end of the same 1.1mm {0,04in}
drill into the oil intake(1.2 mm (0.05in) diameter). Make sure the check ball moves smoothlv
and has a strokeof approximately4.0 mm (0.16
In,.

Checkthe oil jet operationwith an air nozzle.lt

should take at least200 kPa (2.0 kg/cm,,28 psi)
to unseatthe checkball.
NOTE:Replacethe oil jet assemblyif the nozzl
is damagedor bent,

Engine Oil Tamp6rrture: 176'F {80'C)

EngineOil Pressure:
At ldle:
70 kP8 (9.7 kg/cm,, 10.0psi)
minimum
At 3,flt0 rpm: 350 kPa (3.5kg/cm,, 50 p3il
minimum
1!

lf oil pressureis within specifications,

replacethe
oil pressureswitch and recheck.
l f o i l p r e s s u r ei s N O T w i t h i n s p e c i f i c a t i o n s ,
inspectthe oil pump (pages8-10,11|.

I
:.
'

ENGINEOIL PRESSURE
SWITCHMOUNTINGHOLE
{F22A1engino}

OIL PRESSURE
GAUGE

I
i

I
I

ENGINEOIL PRESSURE
SWiTCH
MOUNTINGHOLE
lH23A1,H22Al cneinos)
lH23A1,H22A1.ngin.!l

8-8

Mounting torque is critical.Be very precisewhen

installing.
Torquo: 40 N.m (4.0 kg-m, 29 lb-ft)

Oil Pump
Overhaul
NOTE:
Usenew O-ringswhen reassembling,
Apply oilto O-ringsbeforeinstallation.
Use liquidgasket,PartNo.08718- 0001.

6x1.0mm
7 N.m {0.7 kg-m, 5.1 lb-ftl
PUMPCOVER

OOWELPIN

6x1.0mm
12 N.m {1.2kg-m,9lb-ft}.
Apply liquid gasker
to the bolt threads,

OIL SEALS
Replace.

OUTER
ROTOR
page8-10,11
Inspection,

INNERROTOR
page8-10,t 1
Inspection,

PUMPHOUSING
pageI 10.11
Inspction,

8-9

Oil Pump
Removal/lnspection/lnstallation
9. Removethe screwsfrom the pump housing,then
separatethe housingand cover.

1 . D r a i nt h e e n g i n eo i l .
2.

Turn the crankshaftso that the No. 1 pistonis at top

d e a d c e n t e r( F 2 2 A 1e n g i n e :p a g e 6 - 2 8 ,H 2 3 A 1
engine:page6-62,H2241engine:page6-106).
Removethe timing belt and the timing balancerbelt
(F22A1engine:page6-29,H23A1engine:page6-63,
H22A1engine:page6-'l07).

'10.

Checkthe inner-to-outerrotor radial clearanceon

the oumo rotor.
lnner Rotor-to-OuterRotor RsdialClea.anc
Sland8ld (Newl: 0.02- 0.16 mm (0.001- 0.006in)
ServiceLimit: 0.20 mm 10.008inl

R e m o v et h e t i m i n g b e l t t e n s i o n e ra n d t h e t i m i n g
balancerbelttensioner.
Bemovethe timing belt drive pulleyand the timing
balancerbelt drivenpulley(page7-12).
6.

R e m o v et h e b a l a n c e .g e a r c a s ea n d t h e b a l a n c e r
drivengear(page7-121.
Removethe oil pan and the oil screen.
R e m o v et h e m o u n t i n gb o l t s a n d t h e o i l p u m p
assemory.

ii
I
DOWELPIN

OIL PUMP

lf the inner-to-outerrotor clearanceexceedsthe

servicelimit, replacethe innerand outer rotors.

1'1. Checkthe housing-to-rotoraxial clearancson the

oumo rotor.

O.RINGS
Replace-

Housing-to-RotorAxial Clcaranco
Standard lNewl: 0.02- 0.07 mm (0.001- 0.003in)
SorvicoLimit
0.12 mm 10.005inl

Replace.

PUMPHOUSING

OUTER
ROTOR
ROTOR
OUTER

OIL SCREEN

8-10

lf the housing-to-rotoraxial clearancexceeds

t h e s e r v i c el i m i t , r e p l a c et h e s e t o f i n n e r a n d
outer rotorsand/orthe pump housing.

12. Chckthe housing-to-outer

rotor radialclearance,
Housing.to-OuterRolor RadialClrarsnc
Stlnda.d {Nsw}: 0.10- 0.19 mm (0.004- 0.007in}
SorvicaLimit: 0.21 mm (0.fi)8 in)

,rJ:|xaTmm

077a6_ 00,t0300

Rsassemblethe oil pump, applying liquid thrcad

lockto the pump housingscrews.
1 7 . Checkthat the oil pump turnsfreely,
?8. Installa dowel pin and the new O-ringon the pump,
NOTE:
a Useliquidgasket,Pan No. 08718- 0001.
a Checkthat the matingsurfacesare cleanand dry

l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e
exceedsthe service limit, replacethe set of inner
and outer roto.sand/orthe pump housing.

1 3 . Inspect both rotors and the pump housing for scoring or other damage.Replaceparts if necessary.
Removethe old oil sealsfrom the oil pump.
t5.

Gentlytap in the new oil sealsuntil the specialtool

bottomson the pump.
NOTE:The oil sealsalon can be reolacedwithout
romovingth oil pump usingthe specialtool.

beforeapplyingliquidgasket.
Apply liquidgasketevenly,in a narrowbeadcenteredon the matingsurface.
. To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes,
. Do not install the parts if 20 minutes or more
haveelapsedsinceapplyingliquidgasket.
Insteadreapplyliquid gasketafter removingthe
old residue.
. After assembly, wait at least 30 minutes before
filling the enginewith oil.
19. Apply liquidgasketto the oit pump and insta it.
.

Apply greaseto the lips of the crankshaftoil seal

and the balancershaft seal.Then, installthe oil
pump Inner rotor onto the crankshaft.When the
pump is in place,cleanany excessgreaseoff the
crankshaftand the balancer shaft, then check
that the oil seal liDsare not distorted.

Apply iiquidgasket
alongthe brokenline.

(cont'd)

8-11

Oil Pump
Removal/lnspection/lnstallation
{cont'd}
23, Hold the rear balaocorshaft with the 6 x 100 mm
bolt,then installthe balancerdrivengear.
Apply grease
to the seallips. 6 x 10 mm
12 N.m 11.2kg-m, 9 lb-ft|
OIL PUMP
Apply liquidgasketto the
Applyliquidgasket
bolt threads.
to block mating surface.

REARBALANCER:

I x 1.25mm
25 N.m {2.5 kg-m, 18lb-ft}

O.RINGS
Applyengineoil.
Replace.

6 x 100mm EOLT

OIL SCREEN

6x1.0mm
12 N.m (1.2kg"m,
9 tb-ttl

t4 mm 12.9inl

Installthe baffleplate.
2 1 . Installthe oil screen.
Apply molybdenumdisultideto the thrust surfaces
of the balancergears.as shown, before installing
t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
case.
Apply molybdonum
disulfide.

BALANCERDBIVEN
GEAR

REANBALAI{CERSHAFT

24. Hold the front balancershaft with a screwdrivr,

then installthe timing balsnce.blt drivnpull6y.
FRONTBALANCER:

BALANCERDRIVE
GEAR

8-12

25, lnstallthebalancergear caseon the oil pump.

NOTE;Align the groove on the pulley edge to the
pointeron the gear casewhile holdingthe rear balancerwith the 6 x 100mm bolt,then installthe gear
case.

27. Install the oil pan.

Apply liquid
gaskthere.

OIL PAN GASKET

Replace.

DOWELPIN
8 x 1.25mm
25 N.m 12.5kg-m, 18 lb-ftl

BALANCER
GEARCASE

DOWELPIN

O.FING
Apply6nginoil.
Replace.

WASHER
Replac6.

6x1.0mm

DRAINEOLT
ils .m 14.5ks-m, 33 tb_ft)
Donotovertightsn.

POINTER
Alignthe O.ooveto
pornter,

24. Tightenthe boltsand nuts as shown below.

Torquo: 12 Nfl (1.2tg-m,9 lb-ft)

GROOVE

26. Checkalignmentof pointersafter installingthe gear

case.
POINTER
ONTHEPULLEY

a -------_

POINTERON
THEOIL PUMP

NOTE:Tightenthe bolts and nuts in two stepsand

torquethem in a crisscrosspattern.

8-13

Intake Manifold/Exhaust
System
Intake Manifold
Replacemen
. .t. . . . . . . . . . . . . . . . . . . . . . .9. .- .2. . .
ExhaustManifold
R e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . . . . . . . .9. .- .4. . .
ExhaustPipe and Muffler
R e p | a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . 9
. .-.7. .

Intake Manifold
Replacement
NOTE: Use new O-ringsand gasketswhen reassembling.

a Chock tof folds or scratchos on ths surlace of th6 gaskot.

a Replaco with a new gasket it dsmaged.
8 r 1,25mm

H2341, H2241 engines: 22 N.m (2.2 ks-m, 16 lb-tll

INTAKE MANIFOLD
CHAMBER
Replacoif cracked or
if mating surfaces are
damaged.

STARTINGAIR VALVE
6xl.0mm
12 N.m 11.2 kg-m, 9 lb-ft|
IDLE AIR CONTROL

{tAc}val-vE
8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft}

THROITLEBODY

d
O-RINGS
Replace.

GASKET
Replsce.
FAST IDLE TXERMO VALVE

INTAKE AIR BYPASS

IIAB}VALVEBODYASSEMELY
Replaceif crackedor
if mating surlaces are
oamageo.

GASKET
Replace.

|l['sJ!'J[*%''
(fAT) SE[{SOR

6 x 1 . 0m m
12 N.m ('1.2kg-m,I lb-ttl

8 r 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

Y"Sft

EXHAUSTGAS
NECIBCULATIOI{
IEGR}VALVE

./
O.RING
Replace.

INTAKE
Replaceit crackedor
if mating su aces are
damaged.

8r1.25mm
22 N.m
(2.2 ks-m,l6 lb-tt)
GASKET
Replace.
8x1.25mm
22 N.tn 12,2 kg-m, 16 lb-ftI

8 x 1.25mm
22 N.m 12.2 kg-m, '16 lb-ftl

9-2

INTAKE MANIFOLD BRACKET

NOTE: Use new O-ringsand gasketswhen reassembling.

CAUTION:
a Check fol tolds or scfatchos on tho surfac6 ot the gaskst.
a Roplsco with a nw gasket if damaged.
F2241 engino:
FAST IDI-ETHERMOVALVE

8 x 1.25mm

22 N'm 12.2ks-m, 16 lb-ftl

I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ftl
STARTINGAIR VALVE

IAC VALVE

O-RINGS
Replace.

6 x 1.0 mm
12 N.m 11.2 kg'm, 9 lb-ft}
6 x 1.0 mm
12 N.m 11.2 kg-m, 9 lb-ttt

O.RINGS
Replace.

THROTTLEBODY

INTAKE MANIFOLD
CHAMBER
Replaceif cracked or
if mating surfaces are
damaged.

GASKETS
Replace.

8 x 1 . 2 5m m
22 N.m 12.2kg-m,
16 tb-ftl

8 x '1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)
EGR VALVE

GASKETS
Replace.

8 r 1.25mm
22 N.rn 12,2 kg-m, 16 lb-ft)

8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

INTAKE MANIFOLD
BRACKET

9-3

Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when reassembling'
CAUTION:
a Check for folds or scratchas on the sutfaca of tho gasket'
a Rsplace with 6 new gaskot il damagod.
H23A1 engine:

SELF-LOCKINGNUT
I x 1.25mm
32 N.rn (3.2 kg-m, 23 lb-ft)
Replace.

GASKET
R6place.

8 r 1.25mm
22 N.n 12.2 kg-m, 16 lb-ft)

EXHAUSTMA IFOID
BRACKET

lO x 1.25mm
45 t{.m (4.5 kg-m. 33 lb-ft}
r 1.25mm
22 N.m 12.2 kg-m, l6 lb-ftl

GASKETS
Roplace.

1 0 r 1 . 2 5m m
45 N.m t4.5 kg-m.33 lb-ft)
6 x 1.0 m]n
12 N.m ll.2 kg-m. 9 lb-ft)
T INSULATOR

NUT
SELF-LOCKING
10 x 'l,25 mm
55 N.m t5.5 kg-m,40 lb-ftl

9-4

6 x 1.0 mm
10 N.m (1.0 kg-m, 7 lb-ft)

NOTE: Use new gasketsand selflocking nuts when reassembling.

GAUTION:
a Check tor folds or sclatches on th surfacs of the gaskt.
a Replacewith a new gaskot if damaged.
F2241 ongine:

GASI(ET
Replace.

EXHAUST

SELF.I.OCKING
1{UT
8 x 1 . 2 5m m

32 'm 13.2 kg-m, 23 lb-ft|

Replace.

,.(

HEATEDOXYGEI!
SENSOR
{HO2Sl
45 N.m 14.5 kg-m, 33 lb-ft)
Be carelul not to

EXHAUSTMANIFOI.D
BRACI(ET

8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

GASKET
Replace.
10 x 1.25mm
45 N.m {4.5 ks-m, 33 lb-ft}

SELF.I-OCKIl{GNUT
10 x 1.25mm
55 N'm 15.5 kg-m. 40 lb-fi)
Replace.

HO23
CONNECTOR

COVER

HEAT INSULATOR
lCars equippedwith air conditioningl

6 x 1 . Om m
10 N.m (1.O kg-m, 7 lb-fil

9-5

Exhaust Manifold
Replacement
NOTE: Use new gasketsand self-lockingnuts when reassembling.
CAUTION:
a Chock tor folds or scratchoa on tho surface of the gasket.
a Replaco with a now gaskot it damaged.
H22A'l ongino:

lr
I

SELF.LOCKINGt{UT
8 r 1.25mm
32 N.m {3.2 kg-m, 23 lb-ft)
Replace.

GASKET
Replace.
EXHAUST MAf{IFOLD

COVER

1 0 r 1 . 2 5m | n

.m 14.5 lg.|n,

33 lb-tt)

GASKETS
R6place.

8 x '1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

HEATINSULATOR
SELF-LOCKII{GNUT
10 x 1.25mm
55 N.m (5.5 kg-m, il.O lb-ft)

8 x 1.25mm
22 N.m 12.2 ks-m, 16 lb-ft1
EXHAUST PIPEA

9-6

6 x 1.0 mm
10 N.m (1.0 ks-m, 7 lb-ft|

Exhaust Pipe and Muffler

Replacement
NOTE: Use new gasketsand self-lockingnuts when reassemblino.

6 x 1 . 0m m
10 N.m {1.Okg-m.7 lb-ftl
HEAT SHIELD
SELF-LOCKINGNUT
1 2 x 1 , 2 5m m
55 N.m {5.5 kg-m,4O lb-ft|
Replace.

\
EXHAUST PIPETIP

THREEWAY
CATALYTIC
COI{VERTR
TTWCI
TOROUESEOUENCE

MUFFLER

\
GASKET
Replace.

EXHAUSTPIPEB

SEI.F.LOCKINGNUT
10 x 1.25mm
34 N.m {3.4 kg-m, 25 tb-ftl
Replace.

45 N.ln 14.5 kg-m, 33 lb-ft|

Be carefulnot to damage.

oor*rrr\

Replace.
V

GASKET

SELF-LOCKINGNUT
10 x 1.25mm
55 N.m (5.5 kg-m,40 lb-ttl
Replace.

SELF-LOCKINGNUTS
I x 1,25mm
18 N.m (1.8 kg-m, 13 tb-ftl
Replace.

SELF-LOCKINGNUT
10 x 1-25mm
34 N.m (3,4 kg-m, 25 lb-ttl
R6place.

I
9-7

Cooling
Radiator
fffustrated
Index.........
. 1O-2
R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1
. .O. .-.5.
EngineCoolantRefilling
a n dB l e e d i n g
. . . . . . . . . . .1. 0 - 6
C a pT e s t i n g
. . . . . . . . . . . . .1. .0 - 7
Testing
..... 1O-7
Thermostat
R e p | a c e m e.n. .t . . . . . . . . . . . . . . . . . . . . . . 1
. .O. .-.8.
Testing
..... 10-9
Water Pump
lllustrated
Index.........
. 1O-1O
fnspection
. 10-12
Repfacement
..............
1O-12

Radiator
lllustratedIndex
sy"t". is under high pressurewhon engino
@
is hot, To avoid dangel ot releasingscaldingcoolant, remove cap only when engine is cool.

CAUTION: Whn poudng ongino coolant, be suts

to shut the relay box lid and not to spill coolant on
the electlical parts or tha paintsd po ion. lf 8ny
coolant spills, rinse it off immdiately.

Total Cooling System capacity {lncluding hoater and

resrvoir)
F2241 engin:
",
.1 | l7 .5 US qt,
Manuaf:
Automatic: 7 .O | (7 .4 US qt,
H23A1 sngin:
Manuaf:
7 ,4 (. 0,A US qt,
Automatic: 7 .3 I 17.7 US qt.
H2241 engin:
Manual: 7.6 | (8.O US qt,

NOTE:
a Checkallcoolingsystemhosesfor damsge,leaks
or deteriorationand replaceif necessSry.
a Check all hoss clamps and retightenif necessary.
a Use new O-ringswhen reassembling.

6.2 lmp qt)

6.2 lmp qt)

RADIATOR
Engine
coolant

6.5 lmp qtl

6.4 lmp qt)

Refillingand bleoding.p6ge 'l0-6

Leak test, page 1O-7
Inspect soldered joints and
seamsfor leaks.
Blow out dirt from between
core fins with compregsedair.
l{ insects,etc., are clogging
radiator, wash them off with
low oressule water.

6.7 lmp qt)

Reselvoircapacity:O.6 t {0.6 US qt, O.5 lmp qt)

RADIATOB
CAP
Pressure
testing,pago 1O-7

6 x 1.0 mm
1 0 N . m { ' l . Ok g - m ,
7 tb-ft)

FLUID (ATF) COOLER

FAN MOTOR

6 r 1 . 0m m
' l ON . m( 1 . 0rg-m,
7 tb-ttl

o.

O-RING
DRATNPLUG Replace.

;t'i.*:l:XS[YJ,,,
Replace.

COOLINGFAN

FAN SHROUD

10-2

Engino Ho86 Connoctions:

IOLEAIR CONTROL
{IACI VALVE

F22A1 engine:
FAST IDLE
THERMO V

THERMOSTAT
HOUSING

\
HEATEROUTLET

LOWERHOSE

CONI{ECTINGPIPE
BYPASS HOSE

HEATERINLET
HOSE

Replace.

H23Al engine:

POSITIVECRANKCASE
VENTILATION(PCV} PIPE
IAC VALVE

EYPASS HOSES
O.RING
Replace.
OIL COOLER
BYPASS HOSE

O-RING
Replace.

HEATER

* 8 x 1 . 2 5m m
CONNECTINGPIPE
22 N'm
kg-rn,
OIL COOLER
12.2
16 tb-ft)
BYPASS HOSE COOLER
r:: CORFOSIONRESTSTANT
BOLT

(cont'd)

10-3

Radiator
lllustratedIndex (cont'd)

Engin Hose Connections:

H22A'l ngin:

THERMOSTAT
HOUSING

HEATERINLET
HOSE
HEATEROUTLET
HOSE
PIPE
CONNECTING

O-RING COOLER
Replaco.

* 8 x 1 . 2 5m m
22 N.m 12.2kg-m,
16 tb-ft}

RESISTANTBOLT
*: CORROSION

10 -4

Replacement
1 . Drinenginecoolant.
Romovethe upper and
coolor hoses.

5.

Removethe fan shroudassembliesand other parts

from radiator.

radiatorhoses,and ATF
Instsllthe radiatorin the reverseorder of removal:

Disconnect the fan motor connectors.

4.

Rmovethe radiatorupper brackets,then pull up the

radiator.

NOTE:
a Set the upper and lower cushionssecurly.
a Fillthe radistorwith enginecoolantand bleedthe
ai''.

6 x 1.0 mm
10 N.m (1.0 kg-n, 7lb-ft1

RADIATOR
page 1O-7
BADIATOR CAP
Testing,page 'lO-7

6x1.0mm
10 N.m ll.O kg-m,7 lb-ft}

UPPERBRACKET
ANDCUSHION

UPPERI{OSE

:tt'l13l3l=.--_g
I x 1.0 mm
lO N.in (t.O kg-m.7 tb-frt

F/o
"l

sng
7.r.

d
FAN MOTOR
CON'VECTOR

1\ RESERVOIRHOSE

owER CUSHTON
ATF COOLER
HOSE$

DRAIN PLUG

O-RING
Replace.
LOWERHOSE

RESERVOIR

10-5

Radiator
EngineCoolantnefill\ and Bleeding
CAUTlOttl: When pouting enginocoolaisQgsuro to shut
th6 ralay box lid and not to lst coolanl spill on tho electrical part6 or lh paint. lf any coolant spills, rinse it off
immodiat6ly.
1. Set the heatertemperaturelever or conttol dial to
maxamumheat.
2.

Removethe engine splashshield.

3.

When the radiatoris cool, removethe radiatorcap.

Loosenthe drain plug, and drain the coolant.

4.

Removethe drain bolt trom the rear side of the

cylinderblock to drain the block and heater,

5.

Apply liquidgasketto the drain bolt threads,then

reinstall the bolt with a new washer and tighten it
securely.

6.

Tightenthe radiatordrain plug securely.

7,

Remove,drainand reinstallthereservoir.Fillthetank
haltway to the MAX mark with water, then up to the
MAX mark with anti-freeze.

8.

Mix the recommendedanti-freezewith an equal

amount ol water in a clean container.

H23Al engine:
Manual: 3.8 X (4'O US qt, 3.3 lmp qrl
Automatic: 3.7 t {3.9 US qt, 3.3 lmp qt}
H22Al engino:
4.O f 9.2 US qt, 3'5 lmp qt)
Manuaf:

9 . Loosenthe air bleed bolt in the thetmostat housing,

then fillthe radiatorto the bottom of the tiller neck
with the coolantmixtu.e. Tightenthe bleedbolt as
soon as coolant stans to run out in a steadv stream
without bubbles.
BLEEDBOLT

NOTE:
a Use only genuineHonda anti-Jreeze/coolant.
a Fof best corrosionDrotection,the coolant concentration must be maintainedyear-roundat 50
lessthan 50%
minimum.Coolantconcentrations
may not provide sutficient protection againstcorrosion or treezing.
a Coolantconcentrationsgreaterthan 60% will impaif cooling efficiency and are not recommended.
CAUTION:
a Do not mix dilferent brands of anti-freoze/
coolants.
a Do not uso additional rust inhibitors or anti-rust
products; they may not be compatible with tho
gnuine coolant.
Engine Coolant Refill Capacity: including reservoir
{0.6 t {0.6 US qt, 0.5 lmp qt}l and heatar{0.6 f (o.6
US qt, 0.5 lmp qt)|.
F22Al engine:
Manual: 3.5 I (3.7 US qt,3.1 lmp qt)
Automatic: 3.4 f {3.6 US qt, 3.0 lmp qtl

10 -6

DRAII{ BOLT

60 N.m {6.0 kg-m,43 lb-ft}

Applvliquidgasketto the
boltthreadswheninstalling.
1O. With the radiatorcap oft, start the engineand let it
run until warmed up (Radiatorfan goes on at least
twice). Then,if necessary,add more coolantmix to
bring the level back up to the bottom ot the filler
neck.
11. Put the radiatorcap on tightly, then run the engine
again and check tor leaks.

Cap Testing
Removethe radiatorcap, wet its seal with engine
coolant,then insmll it on the pressuretester.
A p p l y a p r e s s u r eo f 9 5 - 1 2 5
k g / c m , ,1 4 - 1 8 p s i ) .

kpa (0.9b-1.25

Check for a drop in pressure.

4.

lf the pressuredrops, replacethe cap.

RADIATORPRESSUBE
TESTER
COMMERCIALLY
AVAILABLE

ADAPTOR
{for smallcap)

Testing
1. Wait until the engineis cool. then carefullyremove
the radiator cap and fill the radiator with engine
coolant to the toD of the filler neck.
2,

Attach the pressuretesterto the radistorand apply

a p r e s s u r eo f 9 5 - 1 2 5 k P a ( 0 . 9 5 - 1 . 2 5 k g / c m r ,
14. 18 psi).

3.

Inspect for enngine coolanl leaks and a drop in

pressure,

4,

Removethe tester and reinstallthe radiatorcao.

RADIATOR
PBESSURE
TESTER
COMMERCIALLYAVAILABLE

NOTE; Check for engineoil in the coolant and/or

coolant in engineoil.

10-7

Thermostat
Replacement
NOTE: Use new O-ringswhen reassembling.
F22A1, H23Al engin6s:
ELEED
BOLT
10 N.m lt.0 kg-m,7 lb-ftl

6 x 1.0mm
'12 N.m (1.2 kg-m, 9 lb-ft)

ENGIfTE
COOLANT
(ECT}
TEMPERATURE
SWITCHA
28 t{.m (2.8 ks-m, 20 lb-ft|

CONNECTING
PIPE

6 x ' l . Om m
12 N.m l'1.2kg-m,9 lb-ft}
RUBBERSEAL
Replace.
THERMOSTAT
Installwith pin up.
AT COVER

H22Al enginor
BLEEDBOLT
10 N.m (1.0 kg-m.7 lb-ftl

ECTSWITCHA
28 N.m {2.8 kg-m,20 lb-ft|

6x1.0mm
'12 N'm
11.2 kg-m, 9 lb-ttl

10-8

THENMOSTAT
Instaliwith pin up.

AT COVER

Testing
Replacethe thermostat if it is open at room temperature,
To test a closed thermostat;
1. Suspendthe the.mostatin a containerof wate. as
snown.
2.

Heat the water and check the temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens.and at which it is fully open.
CAUTION: Do not l6t the thelmometor touch tho
bottom of hot containor.

3.

Measurelift height ot the thermostat when fullv

ooen.
STANDARD THERMOSTAT
Lift h.ight: above 8.0 mm {O.31 in.}
Stans oponing: 169 - 176oF {76-8OoCl
Fully open: 194oF (9OoC)

THEBMOSTAT

10-9

Water Pump
lllustrated Index
NOTE: Use new O-ringswhen reassembling.
F22A1, H23Al onginsE:
WATER OUTI.ET
HOUSING
Apply liquidgasketto
cylindrhead mating
surface.

ENGINECOOLANT
TEMPERATURE{ECT)
SENSOR
'13lb-ft)
18 t{.m (1.a kg-m'

ECTGAUGE
SEI{DINGUNIT

9 N.m lO.9 kg-m,6.5 lb-ft|

t{Gtl{EOILCOOLER
(H234l engine)

x 'l,O mm
12 N.m (1.2 kg-m,
9 tb-fr)

B
28 N.m {2.8 kg-m, 20 tb-ft|
ECT SWITCH A
2a .m (2.8 kg-m, 20 lb-ft)
BLEEDBOI.T
10 x 1.25mm
1 O N . m 1 1 . 0k g - m ,
7 tb-trl

6 x l.O mm
12 N.m (1.2kg-m,
I rb-ft)

O-RINGS
Replace.

*8 x 1.25mm
22 N.m 12.2 kg-n,
16 tb-fr)

6 x 1 . 0m m
1 2 N . m( 1 . 2k g - m ,
9 rb-ft)
DRAIN BOLT
60 N.m 16.0 kg-m,
43 rb-frl
Apply liquid gasket to bolt
threadswhen installing.

O-BING
Repl6ce.

CONI{ECTINGPIPE
(F22A1 enginel

RSISTANTBOLT
*: CORROSION

10-10

H22A1 cnglne:
ECT SEI{SOR
18 N.m (1.8 kg-m, 13lb-ft}

6 x 1.0 mm
12 N.m {1.2kg-m,
9 rb-ttl

ECTGAUGE
UNIT
SENDIT{G
9 N.m lO,9kg-m,
6.5 rb-ft|
ECTSWITCHB
28 N.m (2.a kg-m,20 lb-ftl
6 r 1.0 ir|m
1 2 . m 1 1 . 2k g - m ,
glb.ft)

BLEEDBOLT
10 x 'l.25 mm
lO N.m {l.O kg-m,
7 tb-ftl

E GINE OIL COOLER

28 N.m 12.8kg-m,
20 rb-frl
WATEFR,MP

o-Rtt{Gs
Replace.

*8 x 1.25mm
22 N'm 12.2 kg-m, 16 lb-fr)

CONNECTINGPIPE

6 x l.O mm
12 .ln lt.2 kg-m. 9 lb-ft}

*: CORROSION
RES|STANT
BOLT

1 0 - 11

Water Pump
Replacement

Inspection
Removethe timing balancerbelt and timing belt
(F22A1 engine: page 6-29, H23Al engine: page
6-63, H22A1 engine:page 6-109)

Removethe timing balsncerbelt and timing blt

(F22A1 engine: page 6-29, H23A1 engine: page
6-63, H22A1 engine:Page6-1091

check that the water pump pulleY turns freely.

Unscrew the bolts, then remove the water pump'

Check for signs ol seal leakage.

NOTE: Smsllamountof
is normal.

"weeping" Irom bleedhole

6x1.Omm
12 N.m {1.2kg-m.
9 tb-ft|

O.RING
R6place.

I
,

3.
BLEEDHOLES

BLEEDHOLE

10-12

RUBBERSEAL
Apply liquid gaskst
to the water pump
mating surtace.

Install the water pump in the reverse order of

removal.

Fuel and Emissions

S p e c i aTl o o l s
. . . . . . . . . . . - . . .1. ' l - 2
ComoonentLocations
I n d e x. . . . . . . . . . . . . . . . .
. . . . . .1 1 - 3
System Description
V a c u u mC o n n e c t i o n. .s, . . . . . . . . . . . . . , . . . . . .1.1.-. 8, .
E l e c t r i c aCl o n n e c t i o n.s. . . . . . . . . . . . . . . . . . . , . . .1. .1.- 12
S y s t e mC o n n e c t o r s. . , . . . . . . . . . . , . . . , . . . . . . . . .1.l.-. 2 O
Troubleshooting
T r o u b l e s h o o t i nGgu i d e . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 4 0
S e l f - d i a g n o s tPi cr o c e d u r e s , , , . . . . . . . . , . , . . .1. '. l.- 4 2
H o w t o R e a dF l o w c h a r t s. . . . , . , . . . . . . . . . . , , . ,1. 1
. -47

PGM-FISystem
System Description
....... 1 1-48
Troubleshooting Flowchans
Engine
W i l l N o t S t a r t. . . . . . . . . . . . . . . . . . . . . . .1.1.-. S
. .0
E n g i n eC o n t r o lM o d u t e. . . . . . . . . . . . . . . . . . . . . . .1. .1.- 5 1
H e a t e dO x y g e nS e n s o r , , . . . . . . . . . . , . . . . . . 1
. .1.-. 5. .6
H e a t e dO x y g e nS e n s o rH e a t e r. . . , . . . . . . . . . ,1. 1 - 5 8
F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . . . . . . . . . . .1. 1
. .- .6. 2
.
ManifoldAbsolute PressureSensor .,...... l1-64
Top Dead Center/Crankshsft position/
C y l i n d eP
r o s i t i o nS e n s o r . . . . . . . , . . . . ....., . ' l 1- 7 O
EngineCoolantTemperatureSensor ....... 11-72
T h r o t t l eP o s i t i o nS e n s o r. . . . . . . . . . . . . ...... .- . .- 1 ' l- 74
I n t a k eA i r T e m p e r a t u rS
e e n s o r. . . . . . . . . . . . . .1. 1 - 7 6
B a r o m e t r iP
c ressurS
e e n s o r. . . . . . . . . . . . . . . . . 1
. .l - 7 8
l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .I. .1.- 8 0
V e h i c l eS p e e dS e n s o r. . . . . . . . . . . . ...... . . . . . . . . 1
. 1- a 2
E l e c t r i c aLlo a dD e t e c t o r. . . . . . . . . . . . . . . . . . . . . .1.1. - 8 4
Knock Sensor
l E x c e p tF 2 2 A 1 e n g i n e { S ).l . . . . . . . . . . . . . . .I .1- 8 8
A / T F l S i g n aAt / B . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. .9.0.

ldle Control System

S y s t e mT r o u b l e s h o o t i nGgu i d e . . . . . . . . . . . . . . . . I. .1- 9 2
System Description
....... 1 1-93
TroubleshootingFlowcharts
l d l eA i r C o n t r o V
l a l v e . . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 9 6
A i r C o n d i t i o n i nS
g i 9 n a 1. . . . . . . . . . . . . . . . . . . . . .I. .1.- 9 8
A l t e r n a t oF
r RSignal
.. I1-1OO
AutomSticTransaxle
G e a rP o s i t i o S
n i g n a l. . . . . . . . . . . . . . . . . . . . 1. 1- 1 0 2
S t a r t e .S w i t c h S i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .- 10 4
B r a k eS w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . 1. .1.-.1.0. 6
Power SteeringPressufeSwitch Signal ... 1l-108
F a s tl d l eT h e r m oV a l v e. . . . . . . . . . . . . . . . . . . . . . . I. .1. -. .1.0 9
S t a r t i nA
g i r V a l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1.-.1. 1
. .O.
l d l eS p e e dS e t t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.l.j .1.

Fuel Injectors
Iniector Resistor
Fuel PressureRegulator
Fuel Filter

1-113
' t- ' l 1 4
1 - 11 4
1 - 11 6
1-'t21
't-122
1-123
1-124
t-tzo
1 -1 3 0

Intake Air System

System T.oubleshootingGuide
11-13r
System Description
11-132
Air Cleaner
11-133
Intake Control Svstem
lExcept F22A't engine(Sll
1-134
Throttle Cable
1-138
Throttle Bodv
1 - 13 9
Intake Air Bypass Control System
lExcepr F22A'l engine(Sll
1-143
I n t a k eM a n i f o l dI F 2 2 4 1 e n g i n e ( S l .] . . . . . . . . . . . . 1 - 14 8

EmissionControl System
System TroubleshootingGuide ....
1-149
System Description
1 - 15 0
TailpipeEmission
1-150
T h r e eW a y C a t a l y t i cC o n v e n e r. . . . . . . - . . . . . . . . . .1 - 1 5 1
E x h a u sG
t a s R e c i r c u l a t i oSnv s t e m . . . . . . . . . . . . . 1 - 1 5 3
PositiveCrankcaseVentilationSystem .,.,.,.. 1 - 15 9
EvaporativeEmissionControls
1-160

Special Tools

Dascription

Rel. No.

Tool Number

A973X_041_XXXXX

Vacuum Pump/Gauge

KS-AHM_32 OO3
OTLAJ PT30l OA
07JAZ-OO1000B
07406-OO40001

DigitalMultimeter
Test Harness
Vacuum/Pressure
Gauge0-4
Fuel PressureGauge

,ar

@
/A

\a)

11-2

in. Hg

I O'ty I

Pag Roforence

1 1 - 6 8 ,1 3 5 , 1 3 9 ,
144, 154, 162, 165
11 - 4 5 ,5 8 , 6 3
11 - 4 5
1 1 - 1 6 4 1, 6 5
1 ' l - 1 1 5 ,1 2 2

\9

ComponentLocations
Index
H23A1 engine (USA: Si/Canada:SRI:
ELECTRICAL
LOADDETECTONIELOI
(TPISENSORMANIFOLO
THROTTTE
POSITIOI{
ABSOLUTE

Troubleshooting,
page 1 1-84
EXHAUST GAS RECIRCULATION{EGR)
VALVE LIFT

sEr{son

Troubleshooting,
p a g et l - 1 5 3

page 1 I-74
Troubleshooting,
FAST IDLE
THERMO
VALVE
Inspection
p a g e1 1 - 1 O g

PRESSURE
IMAPI SENSOR
Troubleshooting,
page 1 1-64, 68
IDLE AIR CONTROL(IACI VALVE
Troubleshooting,
page 1 1-96

IGNITIONCONTBOLMODULE (ICM)
page |'l -80
Troubleshooting,

EVAPORATIVEEMISSION
(EVAP} PURGECONTROL
SOLENOIDVALVE
page 1 1-162
Troubleshooting,

INTAKE CONTROL
SOLENOIDVALVE
Troubleshooting,

\
\ . o a q e1 1 1 3 5
TOPDEADCEITTER/
}
CRANKSHAFT
POSITION/\. //'

STABTING AIR VALVE

Description,
p a g e1 1 - 1 1 0

CYLII{DERPOS]TION

ITDC/CKP/CYP'
Troubleshooting,
page11-70

IIIIJECTOBRESISTER
Testing,page 11-'121

'trt
?,{oL
AKE AIR
IIATI SENSOR
Troubleshooting,
p a g e1 1 - 7 6

ENGINECOOLANT
TEMPERATUBE{CT) SENSOR
Troub16shooling,
page 11-72

TURE

EXHAUST GAS RECIRCULATION{EGR}

VACUUM CONTBOLVALVE
Troubleshooting,
p a g e1 1 - 1 5 3

KNOCK SENSOR{t(Sl
page 1 1-88
Troubleshooting,

HEATEDOXYGEN
SENSOR
tHO25)
Troubleshooting,

INTAKE AIR BYPASS {IAB} VALVE

Testing.page 1 1-146

p a g e 11 - 5 6

EXHAUST GAS RECIRCULATION{EGR)CONTBOL

SOLENOIDVALVE
page 1 1-153
Troubleshooting,

POWER
PRESSURE(PSP}SWITCH
page 1 1-108
Troubleshooting,
INTAKE AIR BYPASS IIAEI CONTBOLSOLENOIOVALVE
page 11-144
Troubleshooting,

11-3

Component Locations
lndex
H22Al ongino {USA: Si VTEC/Canada:sB-v)

EI-ECTRICALLOAD DETECTOB{ELD)
Troubleshooting,
IDLE AIR CONTROL{IAC) VALVE
p a g e1 1 - 8 4
Troubleshooting,
11 - 9 6
XHAUST GAS RECIRCULATIONIEGRI
POSITION
ITPISENSOR
THBOTTLE
VALVE LIFT SENSOR
11-74
Troubleshooting,
Page
page 1 1-153
Troubleshooting,
FAST IDLE
MANIFOLOABSOLUTE
THERMO
INTAKECONTROL
PFESSUNEIMAP} SENSOR
VALVE
VALVE
SOLENOID
Troubleshooting,
lnspection
Troubleshooting,
page '11-64,68
p a g o1 1 - 1 O g
p a g eI 1 - 1 3 5

IGNITIONCONTROLMODULE (|CM}
page 1 1-80
Troubleshooting,

EVAPOBATIVEEMISSION
(EVAP} PUFGECONTROL
SOLET{OIDVALVE
page 1 1-162
Troubleshooting,

ToP DEAOCENTER/ ..
\
CR} .KSHAFT^POSITION/
\

AIR VALVE
STARTII{G
Description,
p a g e11 - 11 0
INJECTOR
RESISTER
T e s t i n gp,a g e1 1 - 1 2 1

CYLINDERPOSITIOl{
{TDC/CI(P/CYP}SENSOR
Troubleshooting,
page 'l 1-70

INTAKEAIR TEMPERATURE
0AT) SEI{SOB
Troubleshooting,
p a g e1 1 - 7 6

GAS

(EGRI
RECIRCULATIOT{
VALVE
VACUUMCOI{TROL
page11-l53
Troubleshooting,

ENGIf{ECOOLANT

(ECTISENSOR
TEMPERATURE
Troubleshooting,
page 11-72

EXHAUST GAS RECIRCULATIONIEGRI

CONTROLSOLENOIDVALVE
page 1 1-153
Troubleshooting,

KNOCK SEI{SOB {KS}

Troubleshooting, page 11'88

HEATEDOXYGEN
SENSOR
tHO2S)
Troubleshooting,
p a g e1 1 - 5 6
INTAKE AIR BYPASS (IAB) VALVE
'l1-146
Testing.page

11-4

POWERSTEERINGPRESSURE(PSPI SWITCH
p89e 1 1-1OB
Troublshooting,

INTAKE AIR BYPASS {IABI CONTROLSOLENOIDVALVE

page 1 1-144
Troubleshooting,

F22Al ongins (S):

IDLE AIR CONTROL{IAC} VALVE
Troubleshooting.
p a g e1 1 - 9 6
MANIFOLD
ABSOLUTE
THROTTLEPOSITIOT{
PRESSURE
ITP) SEITISOR
{MAPI SENSON
EXHAUST GAS BECIRCULATION{EGRI Troubfeshooting.page 1 1-74
Troublsshooting.
VALVELIFTSEI{SOR
page 11-64, 68

ELECTRICAL
LOAD DETECTOR
{ELDI
Troubleshooting.
psge11-84

pago11-,|53
Troubleshooting.
IGNITIONCO TBOLMODULEIICM}
pag611-80\\
Troubleshooting.
TOPDEADCENTER/
CRAN(SHAFTPOSITIOI{/
CYLINDER
POSITION
{TDC/CKP/CYP}

(EVAP)
EVAFORATIVE
EMISSION
PURGECONTROL
SOLENOID
VALVE
Troubleshooting.
page11-,|62
FASTIDLE
THERMOVALVE
page11-110
Inspoction,

Troubleshooting.
p a g e1 1 - 7 O

II{JECTOR
RESISTER
Testing,

11-121

STARTII{G
AIR VALVE
Description,
p a g e1 1 - 1 1 0
I TAKE AIR
TEMPERATUR:
(IAT} SENSOR
Troubleshooting.
page 1'l-76

ENGINECOOLANT
TEMPRATURE(ECT) SENSOR
Troublshooting,
page 11-72

HEATEOOXYGEI{

EXHAUSTGASRECIRCULATION
IEGR)
VACUUiI CO TROLVALVE
page11-153
Troubleahooting,
.
,-/ /
'-''./
(EGRICONTROL
EXHAUSTGAS RECIRCULATIOI{
SOLEiIo|DVALVE
page11-'l53
Troubleshooting,
POWER STEERII{G PNESSUREIPSPI SWITCH
Troubleshooting, pago 1 1-1OB

(Ho2st
sEr{soR
Troubleshooting,
page 1 1-56

11-5

ComponentLocations
Index

EMISSIOI{
EVAPORATIVE
{EVAPITWO WAY VALVE
Testing,page11-165

FUEL
ruMP

Tosting,p6ge 'l t -125

paoo 11-125
Roplacemgnl,
FUELFILL
CAP I

FUEL
FUEL FIITER
page 1 1-123
Replacoment,

EVAPORATIVE
EMISSION
CAI{ISTEB
IEVAP)CONTROL
page11-'162
Troubleshooting,

TAI{K
Replacemgnt,
p s g 11 - 1 3 0

FUEL
REGULATOR
PNESSURE
Testing,page11-122
p.g6 11-123
Rphcomont,

FUEL VAPOR
HOSE

FUEL RAIL

I]{JECTORS
Troubleshooting,
ptgo11-116
page 11-1 19
Replacomedt,

11-6

AIR CLEANER{ACL)
Oisass6mbly.
p a g e1 1 - 1 3 3

II'ITAKE
cot{TRoL

THROTTLE
BOOY
page11,139
Inspection,
pagel l -141
Disassembly,

II{TAKEAIB

DIAPfIRAGM
(Exclpt F22A1
.ngin.l
Troubloshooting
p a g 1 1 - 1 3 5

lnspection/Adjustment,
page 1 1- l38
Installation, page 1 1-'l 38

POSITIVECRAI{KCASEVENTILATIOI{ (FCV) VALVE

Inspction.pago 1 1-159

PGM-FI MAII{ RELAY

RolayT6sting,page 'l 1-126
page 1 1-128
Troubloshooting,

ENGINECO TROL MODULE {ECMI

Sell-diagnostic Procedures.page 1 1-42
Troubleshooting.page 1 1-50
Romoval,page 11-45

SEBVICECHECK CONNECTOR(2PI
Sff-diagnosticProcedures,page 1 1-42

11-7

System Description
Vacuum Connections
H23Al engine{USA: Si/Csnada:SR}
SR-V}
H22Al engine{USA: Si VTEC/Canada:
EMISSIOI{IEVAPI
EVAPORATIVE
PURGE
COI{TROL
VALVE
SOLEI{OID
EMISSION
EVAPORATIVE
VALVE
DIAPI.IRAGM
{EVAP)R'IRGECONTROL
EVAPORATIVEEMISSIOI{
{EVAPI COI{TROLCANISTER

TO
EVAPORATIVE
EMISSION
{EVAPITWO WAY VALVE
EXHAUSTGAS RECIRCULATION
IEGR)
VALVELIFTSENSOB
EXHAUSTGAS RECIRCULATION
IGR)
VALVE
MAI{IFOLDAESOLUTE
PREESURE
I API 8E1{8OR
STARTII{GAIR VALVE
I TAKE AIR BYPASS
IIABI CHECTVALVE
INTAKE
CONTROL
SOLENOID
VALVE

:?'

FRONTOF VEHICLE FUEL

REGULATOR

INTAKEAIR BYPASS
IIABI CO TROL
VALVE
SOLEI{OID
TO

INTAKE AIR BYPASS IIAB} COI{TROL

OIAPHRAGM

CRUISECOI{TROL
ACTUATOR

EXHAUST GAS
CONTROL
DIAPHRAGM

11-8

SOLEI{OID
VAIVE
CONTROL

EXHAUSTGAS
RCCIRCULATIO
IEGR)VACUUM
CO TROLVALVE
(EGR)

F22Al ongine (S):

EVAPORATIVEEMISSION
IEVAPI CONTROI.CANISTER

EVAPORATIVE
EMISSION
{EVAP}
ruBGE COTITROL
SOLENOID
VALVE

EVAPORATIVEEMISSION
(EVAPI PUBGECONTROLDIAPHRAGMVALVE

TO
EVAPORATIVE
EMISSION
{EVAPITWO WAY VALVE

EXHAUST GAS
RECIRCULATIONIEGR}
VALVE LIFT SENSOR

MANIFOLD AESOLUTEPNESSURE
(MAP} SENSOR

EXHAUSTGAS
RECIBCULATION
IEGR}VALVE

STARTII{G AIR VALVE

(EGR}
EXHAUSTGAS NECIFCULATION
VALVE
VACUUMCOI{TROL

FUEL PRESSURE
REGULATOR

TO
CRUISECONTROL
ACTUATOR
EXHAUST GAS BECIRCULATIOI{(EGR}
CONTROLSOLEI{OIDVALVE

11-9

System Description
Vacuum Connections
H23A1 ongino (USA: Si/Canada:SR)
SR-V}
H22A1 ongine{USA: Si VTEC/Canada:

(Ho2s) \--J@
oxycENsENsoR
o) HEATED

ABSOLUTE
PRESSURE
{MAPISENSOR
O MANIFOLD
(ECT)SENSOR
COOLANTTEMPERATURE
O ENGINE
(IAT}SEI{SOR
AIR TEMPERATURE
@ TNTAKE
@ KNocK sENsoR(Ksl
@ |DLEAtR co rRoL flact vALvE
SCREW
O IDLEADJUSTING
@ FASTIDLETHERMOVALVE
AIR VALVE
@ STABTING
@ FUEL[rtJEcToR
@ FUELFILTEB
REGULATOF
@ FUELPRESSURE
@ FUELPUMP
@ FUELTANK
@ AIRCLEANER
@ RESONATOR
DIAPHRAGM
@ INTAKEAIR BYPASS(IAB}COIIITROL
@ TNTAKEAtR BYPASSflABl CONTROLSOLENOIDVALVE

11-10

@ II{TAKEAIR BYPASSIIABIVACUUMTANK
ArRBYPASS0AB)CHECI(VALVE
@ ra{TAKE
DIAPHRAGM
@ II{TAKECOI{TROL
SOLENOTD
VALVE
@ tt{TAKECOIT|TROL
VACUUMTANK
@ I TAKECONTROL
CHECKVALVE
@ INTAKECONTROL
(TWCI
CONVERTEn
@ THREEWAY CATALYTTC
VENTILATTON
{FCV)VALVE
@ postT|vE CRANKCASE
(EGRIVALVE
@ EXHAUSTGASBECTRCULAIION
(EGR}VALVELIFT
@ EXHAUSTGASRECIRCULATION
SENSOR
(EGRIVACUUM
@ EXHAUSTGAS REC|RCULAT|OII
VALVE
CONTBOL
{EGR}CONTROL
@ EXHAUSTGAS RECTRCULATTON
VALVE
SOLENOID
(EVAP}CONTROL
CAt{ISTER
EM|SS|OT{
@ EVAPORATTVE
(EVAP)PURGE
COI{TROL
EMTSSION
@ EVAPORATTVE
VALVE
SOLENOID
CONTROL
EMTSSTON
{EVAP}PURGE
@ EVAPORATTVE
VALVE
DIAPHRAGM
@ EvapoRATtvEEMtsstoN{EvaPl rwo wAY vALvE

F22A1 ongine

O HEATEDoxYGEr{sEr{soR(Ho2sl
pREssuREtMApt sENsoR
O MAr{rFoLDABSOLUTE
coolA T TEMPERATUBE
@ ENGINE
tEcTI sEI{soR
(IAT)sEI{soR
@ II{TAKEAIR TEMPERATURE
O |DLEAtR co rRoL 0Acl valvE
@ IDLEADJUSTI G scREw
@ FASTIDLETHERMOVALVE
ArRvALv
@ START|NG
@ FUELI JEcToR
@ FUELFILTER
REGULAToR
O FUEI.PRESSURE
@ FUELPUMP
@ FUELTANK
@ AIR CLEANEn
@ RESOI{ATOR

way caTALyTrccoNvERTEn
fiwcl
@ THREE
(PcvtvalvE
vEr{TrLATror{
c) posrTlvEcRAl{KcasE
(EGR}
GAsREcrRcuLATtOr{
valvE
@ EXHAUST
(EGR}
GAsREcrRcuLATror{
valvE L|FT
@ EXHAUST
SENSOR

(EGRI
vAcuuM
@ ExHAUsrGAsREctRcuLATtot{
COI{TROL
VALVE
(EGR}
GAsBEcrRcuLATror{
coNTRoL
@ EXHAUST

SOLEIIOID
VALVE
(EVAPIcO TRoL CAI{ISTER
EMISSION
@ EVAPORATIVE
EMTSSION
PUnGECOI{TROL
TEVAP)
@ EVAPORATTVE
SOLENOID
VALVE
conrRol
@ EvApoRATrvEEMrssroN(EvAp)PURGE
DIAPHRAGM
VALVE
@ EvapoRATrvEEMtsstoN(EvApl Two wAy vALvE

11-11

System Description

ElectricalConnections

FUEL
PUMP

'1_

CYP
SEI{SOR
TDC

sEf{soR
CKP

sEitsoR

wEc
PfiESSURE

swtTcH
SERVICE
CHEGX

cot{t{EcroR
col{DEl{SOR
FAl{
RELAY

A/C

swtTcH

GAUCE ASSEMSIY

i FUsEs

A/T GEAR
POStTtOt{

swtrcH

c) clocx RADrot10al.
tlOOAt.
@ SATTERY
@ rGsw tso A).
@ sToPHORir(15Al.
BOXtr$ Alr
@ FUSE

o. 4 BACKUP(10 A)
ECUGcill (15 Al
t{o. 13 ttlETER{1OAl
cot{oEI{sERFAt{ t15 At.
REIAY110At
o. 11 nEARDEFROSTER
SIG AL 17.5Al
l{o.2 ATARTER

L _ _ _ _ _ _ _ _ _ _ _ _

': in the UI{OER-HOOOFUSE/RELAYBOX

at-tz

TIAP

sE son
TP
8EI{SOR
EGR
vAt-vE
LIFT
SEI{sOR

SOLEOIDVALVE r--=-l
H22Al .nglnc)

Gn co TnoL solEftolo valvE

EVAP PUNGECO TNOLSOLEI{OIDVAIVE
IAB CO[{TROLSOlEtrtOtOVALVE
INTAXE COITROL AOLETTOID
VALVE

o o o o o o o o o o o o o

o o o o o o o o

o o o o o o o o o o o

o o o o o o o o o o o o o

o o o o o o o o

o o o o o o o o o o o

TERMI AL LOCATIONS

(cont'dl

11-13

System Description
ElectricalConnections(cont'd)

Cttt

HO23

YEIiTLK

oR /wlft

nco/Btu-

w,si

WHT/GRt{
WHT/RED-

1l

,arn*"rfl

q101

cl13

---J------'l
vrr.rvyxr
---l lrP sE SoR I
RD,srx
GRx/wHTr _!l________J

---------.r-T------------'l

__jl.:l*r1l

tto prg. 1I -16l

11-14

lTo p.gp t1-151

lTo p.!. 11-15)

11-141

( F r o r np . g . 1 l - 1 4 1 l F r o m p . g . 1 1 - j 4 )

c425

TDC/CXP/CYP
SEI{SOR

c 133
:-:wHT---_----

c102

nroisrxl-[dfiiiJidi5il
BRn---l-[I:jl__l
clo3

c1(x

nronu---1-f
iiliifididil
BLU-

]lltro. 3l

c105

--j-liiiiili6i5i-l
n:omx
-l
YEL

lr o. a)

cl11

srr'---1-ffii----l
RED/GR'{
]-E!lf9r-___l
ct 09

sLxryel ---- iid--]

ox{

I| lsolCtoro
I
| vatvE
I
lErccpt F22A1 .ngin.)

cl22

Hiiii;l I."' ".n"o*

|
c10g

$ffiElfl | ,"r senson

I
BED^^rHrlJ-----l
wxrierr I I EGRVALVE I
cRil/wHr,l I tlFr sEI{soRI

System Description
ElectricalConnections(cont'dl
c31O-..._at-K/YEt---l lci co liol
----llj95:g:i1:l

RED,

sa".;-l
ffi#ffll
TO COi{DEiISER FAI{
Bt-u/RED_____'

-----i Toa/cHcRoMPnEssoR
RED/8LU
-----> TO A/C SYVITCH

-l I r^ra co|rnol I
I lsor.Er{oro
I
llJ !!E-J
lErc.Dl F2241 f,{arl

J I6ERVTCE
llcHEct(

ll-99!!!9r98--J
t-Jl
r

C43LT GFI{/RED_Il DATA Lt K I

BLI(/RED-l I cO ECTORI

T GRX/RED

[E+_

REDiErx

E<-YEL/BLU
TCil lA/Tl
ORIIl
PI{K
[T GN[{/BLX

11-16

I
|

UI{DED.HOOO
FUSE/RELAYBOX

Ut{DED-HOOD

BATTERY
{1(x)A)
tG sw l5o Al
FUSE8OX liro Ar
CLOCKRADIO{10 A)
sToP HOR[{t15 Al

FUSE/RELAY
c421
c422
WHT/RED

WHTA'EL

WHT/YEL
c424
WHT/YEL
c420
ATKATEL

BIK

Grl03
BATTERY

PGM.FI

YE|-/SL(

YEL/BLK
GRI/BLKt

E<--BLK
FUEL

fl_

-C537

v:l- _-____j-1

(PJ

Eszzaer-x ll
G52r

pUMp

____h

tc tTtON

swrTcH

UI{DER.DASH
FUSE/REI.AY
BOX
c) ECUiECMItls At
stcilAl
@ Ito. 2 STAKTER
t7.5Al
@ o.4 BACKUPt10 Al
tlo A)
O o. 13 METER

TO
M/T: STARTER
CUTRELAY
A/T: A/T GEAR
POStTtot{
SYVITCH
c466
c471

BLU/RED

GRiUwHT'

GRt{/WHTI
GRI{MIHT

FUSE/RELAYBOX

c479..-........................"-.".-.rHrljl
GRr{^
BRAKE I

wnrrrer-ll_llcH
lTo p!96 11-18,

l
(cont'd)

11-17

System Description
ElectricalConnections(cont'dl

l F . o mp ! g ! 1 1 . 1 7 1

GAUGE ASSEi'BLY

N |-'FFGEF_I
I I HPOSmOI{

ll ltrlswmcx

c4a4 - cr39

c13a
cRr/YEL--

wEc solEl{olD
VALVE
lH22A'l.n!rn.l

swrTcH
tH22.A1

ri

11-18

System Description
System Connectols lEngine Compartment]
SR-V}
H22Al engine{USA: Si VTEC/Canada:
H23A1 ongine{USA: Si/Canada:SR)

ENGINE
WIRE HARTTESS
MAIN WIR
HARNESS

11-20

c114

c117

cll5

c122

rF|-r
l l l 2 1 |3

IO) IGRN^^/HTZ

lEilwlr-O loRt,M/Hr
ldlYE BLK

I
i

C137 lH22Al onglnql

l-6''I"*t----.',
lO IBL(,"/eL

l6F'it------1

C138 (H22Al .nginol

c420

lrJ

tr
l-6'l6iNrEi-----'l

c422

r-FF-r

l l j 2 1 3 l

2
7

r'-T"*----l

9 10 1 1

REO/6LU

I
-- ---1

2IBLX/GRI

f5-lwxr

3
FEOr'GFN

LX tASSt
LKI''EL IA65)

NOTE: Diflerent wi,es with the same color have been given a number suffix to distinguish them {for example YEL/BLK1
and YEL/BLKzare not the samel.
l: Relatedto Fuel and EmissionsSvstem.

System Description
SystemConnectors[EngineCompartment](cont'd]
H22Al engine (USA: Si VTEC/Canada:SR-V)
H23A1 engine (USA: Si/Canada:SRI

6'

!,,-

.lv

c432
c135
MAIN WIRE
HARNESS

c4a4
c139

ENGINEWIRE
HARNESS

11-22

c426

c/*12 (M/Tl

c429

C484 (H22Ai onglnrl

{,t(
IBLUI"'EL

'It,,YEL

IT

lO--lCiNrEL

--l

RED/II.U

\oTE:

Diffotent wirs with the same color hsve baen given a number suffix to distinguish them (for example YEL/BLK1
and YEL/BLK, are not the same).
O: Rlated to Fuel and Emissions Svstm.

(cont'd)

11-23

System Description
SystemConnectorslEngineCompartment](cont'd]
H22A1 engine (USA: Si VTEc/Canada: sR-vl
H23Al ongina (USA: Si/Canads:SRI

LEFTE GIT{E
COIIPARTIIIENT
WIREHARI{ESS

HARNESS

11-24

ct 02

tr-r-rl
2tl

c106

tl

c103

c 104

c105

tr---T---ll
ti 2tl tl

tr---r---rl
ll 2 I 1 ll

t--T----rl
ll 2 | 1 ll

---|6'TREo/BIK - - - j@ leRN

to) tRED/Blx

lZiTREp-l

l6TnED/aLi--------f6-lilu

-'l
lSTiED/ELr ---]
l6ltrL

c107

c108

cl 09

clt1.

c310

c320

c321

r+

l l l 2 l

NOTE: Difterentwi.es with the samecolor have beengiven a numbersuffix to distinguishthem (tor exsmpleyEL/BLKI
and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSvstem.

System Description
SystemGonnectors[EngineCompartment](cont'd]
F22Al ongino{Sl:

ti

MAIN WIRE
HARNESS

HART{ESS

11-26

clr3

cl14

c 11 5

c117

c122

rf:lr

l 1 l 2 1 3 l

16loRNi------l
lO IBLK/YEL
---l I

loFii'c420

c421

r--Fl_____1

lrl2l3l

FT-,--__l
2
l

l8r(/GFN

16lwii-.

c424
1

4
8

1
2

REO/6LU

10 tt

10

ALK/YELIAAS)

NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (for
exampteyEL/BLKr
and YEL/BLK2are not the samel.
O: Relatedto Fuel and EmissionsSvstem.

System Description

SystemGonnectors[EngineCompartment](cont'd]

F22A1anginolsl:

MAIN
WIBE
HARNESS
ENGI'{E WIRE
HARI{ESS

11-28

c426

c432 (Mtf I

ALK/BIU
RED/6LK
LU'EL
ALK/iED
FEO'
8LU
YEL

BLI.I/GiN

c432 lA/Tl

'LU/GRIiI

BfiI'I/6LK

a
HT

NOTE: Different wires with tho same color have been given a number suffix to distinguish them (for example yEL/BLK1
and YEL/BLK2are not the sam).
O: Related to Fuel and Emissions Svstem.

System Description

SystemConnectors[EngineCompartment](cont'd)

F22A1 engine{S):

'j

11-30

ct ol

cl02

c103

J r-----r1I I----T-----rI

-J r-----rl-

c104

c105

Il2 | 1 ll

tffJl

tErll

ll 2 | 1 ll

c106

c107

c108

c111

c3lo

c320

l 1 l 2 l

NOTE: Oifferent wires with the same color have been given a numbe. sulfix to distinguish them (tor exampte YEL/BLKi
and YEL/BLK,are not the same).
.-r:Relatedto Fuel and EmissionsSvstem.

System Description
System Connectors [Dash and Floor] lcont'd)

DASHBOARDWIRE
HARNESS
MAIN WIRE
HARNESS

I-EFTENGINE
COMPARTMENT
WIRE

LEFT SIDE
WIRE HARNESS

11-32

c442

c443

| 1 1 2|

1 l / 1 3|
|r------y.____J__l

c445 (A/Tl

r-EFr

c451

4
2 3
8 9 llol11

r-----.-t

ll;Tvrtl

I r_____lz_____r_J
I

I(, ]LTGRN/RED I
lO lBLx/Ro

2
3 GRNTYEL

ALK

t o YL

lElwH------l
t 2 t

| 3

BLKIVHT

5
12

c461

c463

c466

l1l2l3l

2
3

BLX/GFN"

12
l 3 RIO/SLK

BLU/REO
q) RED/ALU
3 YEL/BLK

7
8
I

@ BIU/BLK
15
16

YL

aLu
BCU,IYEL

1o

1A
1 9 RED/YEL
20

BLK/ryEI
FED/GRN

c469

BIU/REO
YEL/BLU

10

6LU
8L(
YEL

12
1 3 BLU
BLK/tEL

ALK
L&'YEL
BLK,YEI
BLK/YEL

8
YEL/BCO

12
1 3 ALK

BLK/REO
1A
1 9 BLK,YEL
20

YL/8LK

NOTE: Differentwi.es with the samecolor have beengiven a numbersuftix to dastinguish

them (for exampleYEL/BLK1
and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSvstem.
* : Canada
* *: Canada(with heatedseatsl

11-33

System Description
SystemConnectors[Dashand Floor](cont'd

OASHBOARDWIFE
HARNESS

MAIN
WIRE
HARI{ESS

11-34

c479

c601

c612
I
4 X
,/t7
I 9 t 0 1 1 l2lxh3 1 4 1 5 1

RED/BLK

2
3

AtK'/EL
YEL
LIJ/FEO

GiN/ALU

12

GRA/YEL
1t
12
GFN

BLK
ALU
r 6 ALK/RED

6
l 6 BLK

c614

2 BLK/ryEL
3
ALU'

1
17
YEL'
t9
20 GFN/BLK
21 GhN/REO

22
a

YEL
REO

1 2 YEL/iED
13
15

BLU/FEO
26
2 7 RED/BLK

3(

NOTE: Ditferentwires with the same color have beengiven a numbersuffix to distinguishthem (for exampleYEL/BLK1
and YEL/BLK,a.e not the same).
O: Relatedto Fuel and EmissionsSvstem.
*: Canada

System Description
System Connectors [Dash and Floorl (cont'dl

OASHBOARD
WIBE
HARNESS

MAIN WIRE
HARNESS

11-36

c411 (A/Tt

c404

1t

c415 {ECM-A}

12
2

YEL
RED
H?2rlri?rul I
GRNTYI!

3
giN/BLK

r5

15

YEL/BLU
RED/gL(

ta

AED/BLU

LI GFN]BLK
19
20

22

20

YEL/GFN
LK/8!U
BLK'

c4t6 (ECM-BI

c417 tECM-D)

311'r9 7 5 3 1
ldl/rfl 210 8
4 2
YEL/BLK

BLU/FED

WHI/YEL
GRN/IYHT'

(}

AEo/BLlr"'

l@

BRN,IVHT

I(' a0//EL
i1a
l{il

BLU/ALK

@ LT3{urtr22lrmnr
8LU/GAN
BLU/^rlt

['

REO/ALK

NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem {for exampleYEL/BLK1
and YEL/BLKrare not the same).
O: Relatedto Fuel and EmissionsSvstem.
* * * : E x c e p tF 2 2 A 1 e n g i n e

System Description
SystemConnectorslFuel Pump](cont'd)

11-38

c537

E
NOTE: Ditfe.ent witos with the same color have been given I number suffix to distinguish them (for example YEL/BLKr
and YEL/BLKzare not the same).
O: Related to Fuel 8nd EmissionsSvstem.

11-39

Troubleshooting
TroubleshootingGuide
NOTE: Across each row in the chart, the systems that could be sourcesof a symptom are ranked in the o.der they should
be inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likely source,then refer
to the pagelistedat the top of that column,It inspectionshows the systemis OK, try the next most liklysystemO, etc,
SYSTTM
at'iclNE
CONTROI
MOOULE
50
MALFUNCTIONINDICAIOR
LAMP IMIII" TURNS ON

MAIFUNCTION INOICATOB
LAMP IMILl" BLIN(S

EorEl

or-Ll

ENGINEWON'T STAFT

OIFFICUITTO STAFT
ENGINEWHEN COID

IBU)

WHEN COLO
FAST IDLE
OUT OF SPEC.

ROUGHIOLE

HEAIEO
OXYGEN
SENSOR
56, 54, 62

.o:

TOPDEADCENIER/ TNGINC
THNOTTLE
EANOMEIRIC IGNITON
COOTANT
TEM.
ABSOLUTE
PO9TtOtl
PitssuSE OUTPUT
FCi^TURE
PNESSUfiE POSITON/CYUNDES
sc soR
sfNsoR stcNA!
SENSOR
SENSOR POSftOt'tsE|so8 fuiE sEt{sof

64, 6a

:i6):
lll

or Lll

70

-mi
O or-8.o.:ft

76

-r.tr-

:r6t:
:r6t1
/---\
/---\
-mi rg: lrm.t:

- --i-t r t - \.--l- t r t / - - t__i-r t l - - t t l t .

\

---'_-\

/'_-i-

\.--r-r

-t---i-15l- \.--1-,
-l_--l-\
t? t\
/
/

@
@

sE[son
a2

80

7A

vtHtclE
SPfED

o
@

IDTING
HIGH

@
a9

'

IBU)

:l

FREOUENT
STALLING

'lr

ANCE

ROUGH
RUNNING

EMTSSTON
TEST

LOSS OF

@
@

@
@

lf codesother then those listedaboveare indicated,count the numberof blinksagain. It the MIL is in fact blinking
these codes, reDlacethe ECM.
@ tt ttr" MIL is on while the engineis running,jump the servicecheck connector.lf no code is displayed(MlL stays
on steady),the back-upsystem is in operation.
Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM.
**

USA:
Canada:
'6+rr-trMALFUNCTTON -[tgltCHECK
;ND;CATOR
ENGTNE ;t-\+:
,
LAMP {MILI
LIGHT
'**
E x c e p tF 2 2 A 1 e n g i n e( s )
SR-V)
engine (USA: Si VTEC/Canada:

11-40

IOLECONTFOL
ELECTRICAL
LOAO
uFrE|lcTnoMc LIFTELECNOMC
DETCCTOR
:o{TnoLsoLENoto
:OIITROL
PiESS!iI
84

tf

6-75

-q.

SIGNALA

SIGNAL
8

90

90

8a

rg-

/ - \

t 2 2|
/-....-.

-t 23I 11361,lrt-

D E

IOIEAIF
CON'FOL

96

OTH'i
IDL'
c0NTROTS

FUEI
INJECTOF

92

116

o
o
o

r13

INIAKT

131

nEcncu.

OTHER
EMtSS|ON

c0[TioL
sYstE

coNTiots

153

149

-r6t-

- ' .

/_l-\

\.--.1-

- l r 6I

o
o

OTHER
FUEL

-r6t-

ffil
/---\

EMISSIONCONTFOL
ETH USI GAS

677

\.--r-l

-t 201 -t-_-i--2r I
/---,_-. ,
\

XNOCK
SENSOF

FUELSUPPTY

| | 2t\ -

z --"i--

@
@

@
@

o
@

11-41

Troubleshooting
Self-diagnosticProcedures
When the MaltunctionIndicatorLamp (MlL) has been reponed on, do the following:
1. Connectthe servicecheckconnectorterminalswith a jumperwire as shown (the servicecheck connectoris located behindthe center console).Turn the ignitionswitch on.

OATA LINK

co itcToR{3Pl
Do not attach
the jumperwire.

CHECK
SERVICE
(2P)
CONNECTOR

JUMPERWIRE

2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesa code by the lengthand numberof blinks.The MIL
can indicstesimultaneouscomponentproblemsby blinkinqseparatecodes,one atter another.Codes 1 through
I are indicatedby individualshon blinks.Codes10 through43 are indicatedby a seriesof long and shon blinks.
The numberof long blinks equalsthe first digit, the numberoJ short blinks equalsthe seconddigit.
USA:
MALFUNCTION
INDICATOR
LAMP
{MIL}

CANADA:
CHECK
ENGINE
LIGHT

S6pa1.t. Ptobl.mr:
Shon
l-1 -jl-rLtU-X-r- r]r1.f1--JlrrL

X{ILong sho.l
SimuhanoouaProbloms:
J rJTxrL-----n
l'lr]rL
Jltll-r-r]f1J-1l-LnnrL
--n-trxrrl_
J-lt-x-L-J

11-42

= Soe DTC 1
= Seo OTC 3

= scoDTC13

= 566 DTc 1 and 3

= 566 OTC 3 and 4
= Soo DTC 3 and 14

ll.

EngineControl Module {ECM}ResetProcedure

1. Turn the ignitionswitch off.
2. Removethe the CLOCKRADlO ( 1O A) f use f rom the under-hoodtuse/relavbox for 1O secondsto resetthe ECM.
NOTE:
a Disconnectingthe CLOCKRADIO(10 A ) fuse also cancelsthe radio preset stationsand the clock setting.
Make note of the radio presetsbefore removingthe fuse so you can.eset them.
a The radio may have a coded theft protectioncircuit. Be sure you get the customer's code numberbefore removing
the CLOCKRADIO{10 A) fuse.

t . FinalProcedure(this proceduremust be done sfter any troubleshooting)

1. Removethe jumper wire.
NOTE: lf the servicecheck connectoris jumped, the MIL will stay on.
2, Do the ECM ResetProcedure.
3, Set the radio presetstationsand the clock.

11-43

Troubleshooting
Self-diagnosticProcedures(cont'dl
DIAGONOSTIC
TROUBLE
coDE (DTC)

SYSTEMINDICATED

Page

ENGINECONTROLMODULE(ECMI

11 - 5 0

(HO23)
HEATED
OXYGEN
SENSOR

I t-50

(MAP SENSOR)
MANIFOLDABSOLUTEPRESSURE

11 - 6 4 ,
68

CRANKSHAFTPOSITION(CKPSENSOR}

11-70

6
7

(ECTSENSORI
ENGINECOOLANTTEMPERATURE
THROTTLEPOSITION(TP SENSOR}

11-74

TOP DEAD CENTERPOSITION(TDC SENSOR}

11-70

N o , 1 CYLINDERPOSITION{CYP SENSOR)

11-70

10
't2

(IATSENSOR}
INTAKEAIRTEMPERATURE
EXHAUST
GASRECIRCULATION
IEGRVALVELIFTSENSOR)

11-76

13

(8ARO SENSOR)
EAROMETRIC
PRESSURE

11-79

14

IDLEAIR CONTROL(IAC VALVE)

11 - 9 6

tc

IGNITION
O U T P U TS I G N A L

11 - 8 0

to

FUELINJECTOR

11-116

11 - ' l5 3

VEHICLESPEEDSENSORIVSS)

1' 1-82

20

(ELD)
ELECTRICAL
LOADDETECTOR

'I

21

VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC

CONTROL{VTEC}
SOLENOIDVALVE*'

6-75

22

VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC

CONTROL{VTECI
PRESSURE
SWITCH**

6-77

23

K N O C KS E N S O R( K S } I

11 - 8 8

4'l

(HO2S)HEATER
HEATED
OXYGEN
SENSOR
FUELSUPPLY
SYSTEM

11 - 5 8

1-84

'.1

'tJ

43

11-62
*: ExceptF22A1 engine(Sl
": H22A'l engine{USA: Si VTEC/Canada:SR-V)

a lf codesotherthan those listedaboveare indicated,verify the code. It the code indicatedis not listedabove,replace
the EcM.
a The MalfunctionIndicatorLamp (MlL) may come on, indicstinga system problemwhen, in fact, there is a poor or
intermittentelectricalconnection.First,check the electricalconnections,clean or repairconnectionsif necessary.
a The MIL and D4 indicatorlight may light simultaneouslywhen the code blinks 6, 7 and 17.
Checkthe PGM-FIsystem accordingto the PGM-FIsystem troubleshooting,then recheckthe D4 indicatorlight. lf
it lights, see page l4-36.
a The MIL does not come on when there is a maltunction in the A/T Fl signalor slectricsl losd detector circuits. However,
it will indicatethe codes when the servicecheck connectoris iumDed.

11-44

lf the inspctionfor a panicularfailurscode requiresthe test harness,removethe right door sill moldingand the small
coveron the right kick panel8nd pull the carpetbsck to exposethe ECM.Unboltthe ECMcover.With the ignitionswitch
off, connectthe test harnss.Checkthe system accordingto the proceduredescribedtor the appropriatecode(s)listed
on the following pages.

DIGITALMULTIMETER
KS-AHM-32-003

o o o o o o o o o o o o o

o o o o o o o o

o o o o o o o o o o o

o o o o o o o o o o o o o

o o o o o o o o

o o o o o o o o o o o

TERMII{AL LOCATIOI{S

{cont'd)

11-45

Troubleshooting
Self-diagnosticProcedures(cont'd)
a Punctudng th6 insulation on a wile can causa poor or Intermittent eloctdcal connectlona,
a For lasling at connectora othor than ths test harness, brlng tho taster probo into contact wltlr tho telmlnll tlom tho
connoctor side of wiro harnoaaconnoctors in th engin companmont. For temelo connectoB,lust touch llghtly whh
tho tostsr probe and do not insort th probe.

TERMII{AL

t,-l

l-rI
,i,1i
-it1

11-46

How to Read Flowcharts

A flowchart is designedto be used from start to final repair.lt's like a map showing you the shortestdistance.But beware: it you qo off the "map" anywherebut a "stop" symbol, you can easilyget lost.

TSTAR-T]
Eotaivpet

Fdfibxl
@

trroFl

(bold typel

Describesthe conditionsor situationto start a troubleshootingflowchart.

Asks you to do something;perform a test, set up a conditionetc,
Asks you about the resultof an action,then sendsyou in the appropriatetroubleshootingdirection.
The end of a seriesof actionsand decisions.describesa tinal repairaction and sometimesdirects
you to an earlierpart of the flowchart to confirm your repair.

NOTE:
a The term " lntermittentFailure"is usedin thesecharts.lt simplymeansa systemmay havehad a tailure.but it checks
out OK at this time. It the MaltunctionIndicatorLamp(MlL)on the dashdoesnot come on, checkfor poorconnections
or loose wires at all connectorsrelatedto the circuit that you are troubleshooting(see illustrationbelow,.
a Most of the troubleshooting
flowchartshaveyou resetthe EngineControlModule(ECM)and try to duplicatethe diagnostic troublecode (DTC).lf the problemis intermittentand you can't duplicatethe code, do not continuethrough
the tlowchart. To do so will only result in confusionand, possibly,a needlesslyreplacedECM.
a "Open" and "Short" are common electricalterms. An open is a break in a wire or at a connection.A short is an
accidentalconnectionof a wire to groundor to anotherwire. In simpleelectronics,this usuallymeanssomethingwon't
work at all. In complexelectronics{likeECM's),this can sometimesmeansomethingworks, but not the way it's supposeoro.
a It the electricalreadingsare not as specifiedwhen usingthe test harness,checkthe test ha.nessconnectionsbefore
proceeding.

11-47

PGM-FISystem
System Description
ENGINECONTROLMODULE{ECM)
Sensor
TDC/CKP/CYP
MAP Sensor
ECT Sensor
IAT Sensor
TP Sensor
HO2S

vss

BAROSensor
StarterSignal
ALT FR Signal
Air ConditioningSignal
A/T Gear PositionSignal
BatteryVoltage(lGN. 1)
BrakeSwitch Signal
PSP Switch Signal
EGR Valve Lift Sensor
Knock Sensor*
VTEC PressureSwitch* *

OUTPUTS
Fuel Injectors
PGM-FlMain Relay(FuelPump)
MIL
IAC Valve
A/C CompressorClutch Relay

rcM

F"*li"",---fl-ni-l-".M;l

EVAP Purge Control Solenoid Valve

HO25 Heater
VTEC Solenoid Valve"
@;bbc-t.d
ALT
EGR Control Solenoid Valve
Fit"rJ,,"o,,"-',....-,,,"o.*-,,cont,ot,,cont.trr".**-_-l
IAB ControlSolenoidValve'
lntake Control Solenoid Valve*

--_]l

Eil,*"s c-,'d

fEcMB*k',p F;tb";-ll]]l

': ExcptF22A1 enqine

": H22A'l engine

't,

i:r
fii

PGM-FISvst.m
The PGM-FIsystem on this model is a sequentialmultipon fuel injectionsystem
Fuel Inlector Timing and Duration
The ECM containsmemo.iesfor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The
basicdischargeduration,after beingreadout from the memory,is further moditiedby signalssent from varioussansors
to obtain the final dischargeduration,
ldle Air Control
ldle Air ControlValve (lAC Valve)
When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) or the alternatoris charging,
the ECM controlscurrent to the IAC Valve to maintsincorrect idle speed.
lgnition Timing Control
o The ECMcontainsmemoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming
is also adjustedtor enginecoolanttemperature.
a A KnockControlSystemisalsoused.When detonationis dotectedbythe knocksensor,the igntiontiming is retarded
(ExceptF22A1 engine).
Other Control Functions
1. Starting Control
When the engineis started,the ECM providesa rich mixture by increasing{uel iniectorduration.
2. Fuel Pump Control
a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-FImain relay that supplies
current to the fuel pump fo. two secondsto pressurizethe fuel system.
a When the engineis running.the ECMsuppliesgroundto the PGM-Flmain relaythat suppliescurrentto the fuel pump.
a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relaywhich cuts
currentto the fuel pump.
3. Fuel Cut-off Control
a Duringdecelerationwith the th.ottle valveclosed.currentto the fuel injectorsis cutoff toimprove fuel economy
'l
at speedsover ,1OOrpm.
a Fuel cut-otf action also takes place when engine speed exceeds, F22A1 (S): 6,6O0 rpm. H23A1 (USA: Si/
Canada:SR): 6,8O0 rpm. H2241 (USA: Si VTEC/Canada:SR-VI: 7,7OOrpm, regardlessof the positionof the
throttle valve. to protect the enginetrom over-revving.

11-48

4.

A/C CompressorClutch Relay

When the ECMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorJrombeing
energized,and enrichesthe mixture to assuresmooth transitionto the A/C mode.

5.

EvaporativeEmission(EVAP)purge ControlSolenoidValve
when the enginecoolanttemperatureis betow 167 oF (75 "Cl IH22A'| engine(USA:Si VTEC/Canada:
SR-V):1bg oF
(70oC)1,the ECMsuppliesa groundto the EVAPpurgecontrolsolenoidvalvewhich
cuts vacuumto the EVAp purge
control diaphragmvalve.

6.

IntakeAir Bypass(lAB) ControlSolenoidValve

When the enginespeed is below 4,8OOrpm IH22A1 engine(USA: Si VTEC/Canada:
SR-V):4,600 rpml, the IAB
controlsolenoidvalveis activatedby a signalfrom the ECM,intakeair tlows throughthe long intakepath, then high
torque is deliveredAt speedshigherthan 4,8OO(or 4,600) rpm, the solenoidvalve is deactivatedby the ECM.
and
intake air flows through the short intake path in order to reducethe resistancein airflow.

7.

Intake Control SolenoidValve

When the enginespeedis below 4,000 rpm, the ECM suppliesa groundto the intakecontrol solenoidvalve. This
opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.

8.

ExhaustGas Recirculation{EGR)Control SolenoidValve

when the EGRis requiredtor control of oxidesof nitrogen(NOx)emission,the ECM suppliesground to the EGR
control solenoidvalve which suppliesfegulatedvacuum to the EGRvalve.

9.

Alternator(ALT) Control
The system controlsthe voltagegeneratedat the altematorin accordancewith the electricalload and drive mode,
and reducesthe engineload to improvethe fuel economv.

ECM tail-safe/back-upFunctions
1. Fsil-safeFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM ignoresthat signaland assumesa pre-programmed
value fof that sensot that allows the engineto continueto run.
2.

Back-uDFunction
When an abnormalityoccursin the ECM itself,the fuel injectorsare controlledby a back-upcircuit indeDendent
ot
the system in order to permit minimaldriving.

3.

Self-diagnosis
FunctionIMalfunctionIndicatorLamp (MlL]1
When an abnotmalityoccurs in a signalfrom a sensor,the ECM lights the MIL and stores the code in erasablememory.
When the ignitionis initiallyturned on, the ECMsuppliesgroundtor the MIL for two secondsto check the MIL bulb
condition.

11-49

PGM-FISystem
Flowchart- EngineWill Not Stan
Troubleshooting

Watch the Mallunction Indicator

Lamp (MlL)and turn th ignition
swirch ON.

Did the MIL come on at all?

Porfo.m tioubleshooting on pago

11-51.

Portorm t.oubloshootingon pago

11-52.

Turn the ignitionswitch OFF.

Connectthe test harnessb6tw96n

the ECM and connectors (see
page 1 1-45).

1 . OV ?
Turn the ignitionswitch ON.

Measure voltage between body

ground and the tollowing terminafs individually:A23, A24.

ls there less than 1.O V?

R6psir op6n in wir6(61 botwoon

ECM 6nd GlOl llocstd at thermoltat houringl that had mo.6
thsn 1.0 V.

Inspect tuel pressure (see page

1 1 - 11 5 ) .

Popair as nocoaaa.y {ago pag6

11 - t t 5 ) .

Portorm ignition systom chock

{3o6 Baction 231.

11-50

TroubleshootingFlowchart - EngineControl Module (ECM)

Tho Maltunction Indlc.tor Lamp
(MlLl nover com6! on l6vcn tor
two sgcondsl aftei ignition i3
tuhgd on.

ls the low oil p.essurelight on?

Inspect No. 13 METER110 A)

fuse (in the under-dashfuse/relay
oox,.

Turn the ignitionswitch OFF.

Connectthe test harnessbetween

the ECM and connectors (se
page 1 1-45).

R6palropan in YEL wir6 botwoon

No. 13 METER(1O A) ture.nd
gaugo alrombly.

o o o o o o o o o o o o o ooooo ooo I o@#qPt}| ooooooooooo

ooooo odooo ooo I oooooo oo

ooooooooooo

Turn the ignition switch ON.

ls the MIL on?

- RaDlocoth6 MIL bulb.

- Ropairop6n in 8LU/WHT wire
botwoon ECM lA13l and
gaugs a88ombly.

|
t-.-----+-

423

II LoooooooooooQo

|---T-

L Le.. than 1 .0 V? --{

I ooooo999l1!9!t!1!!lg{ ooooooooooo I

a,

+Measure voltage between body

ground and the tollowing terminals individuallv: A23, A24.

ls thsre less than 1.0 V?

Ropalr opon in wiro(sl botwson

ECM and GlO1 {locatod at thormostat housing) that had moro
than 1.0 V.

G101

Subrtituto a known-good ECM

6nd rechock, lf symptom/lndicatlon gooa away, raplaco tho origi
nal ECM.

11-51

PGM-FISystem
TroubleshootingFlowchart - Engine Control Module IECM)
The Mallunction Indicator L6mP
(MlL) 3tays on or com63 on allo.
two soconoS.

NOTE: When there is no code stored,the MIL will stay

on if the servicecheck connectoris jumped.

Connect the service check connector terminalswith a jumper

wire {see page 11-42).

Turn the ignitionswitch ON.

Does the MIL indicate

any Diagnostic Trouble
code (DTc)?

Go to rslf-diagnoatic ptocodutos
lso6 pags 11401.
o oooooooo oooo I oooooooom
ooooo ooooo oo ol oooooooo

Rmovethe iumper wire from the

service check connoctor.
Turn the ignition switch OFF.

oooooooooo

D 4l + l
r_S V?
{A/T:

Try to start the engine.

Connectthe test harnessbetween
the ECM and conneclors {see
p a g e1 1 - 4 5 ) .
Turn the ignitionswitch ON.
Measurevoltage between D4 (+)
terminaland D21 l-) terminal.

ls thereapprox.5V (A/T: 11 V)?

Bopair shorl to body ground in

BRN/ WHT wiro botwon tt|o ECM
{t}4}, lrsnsmission Control Modulo lTCMl, ABS contrcl unit or
4WS control unit and seryico
chock connoqtor.

Removeand inspectthe NO. 4

BACKUP(10 Altuse in the underdash fuse/relaybox.

ls the fuse OK7

YES
{ T o p a g e1 1 - 5 3 )

11-52

- Repairopen in BRN/WHTwite
botwoon ECM (O4l and sorvico chock connoctor.
- Repairop6n in BLU/WHTwite
botwoon sorvico check connoctor and ECM {O211.

Connect the service

check connector termanalswith a jumper ware.

Mgasure voltage between D4 (.t ) terminal

and D21 {-) terminal.

ls there spprox. 5 V
( A / T :1 1 V l ?

Remove the ,umper

wire from the service
check connector.

page 11-53)
'NorE: After reDair,disconnectrhe servicecheck con- lro
nector iumper wire, test drive the car, and recheck the
MIL for code.

11-52)
Insp6ctthe ECU (ECM) (15 A)
Iuse anthe underdash tuse/relay
box.

Disconnect"A" con,
nectorlrom the EcM.

Turn the ignitionswitch ON.

Disconn6ct the 3P connector of

each sengor one at a time:
. MAP sensor
. EGRvalve litt snsor
. Throttle Position (TP) sensor

Doesthe MIL romainON?

Substituto . known{ood ECM

and rochock. lt lymptom/indication gooa awsy, roplaca the origin8l ECM.

ls the MIL ON?

Rprir rhort to body

ground in BLU/WHT
wlro betwoontho ECM
{A131rnd th6 MlL.
RoDlacatho aenaor that causod
thc light to 9o our.

Turn the ignition switch OFF.

"l;_-l
Connect the test harness.
Oisconnoct the "O" connector
Irom the ECMonlv, not the m6in
wire hamess(seepage | 1-451.

I o o o o o o o o o o o o o I o o o o o o o o f , S & l * * * * No o o o o o o o o o o |

I
|

D20
-l-

\:-----:J
Continuitv?

Check tor continuity between

body groundterminalsD'l9, D2O.

ls thre continuityT

NO
Reconnect all the sensor connectors.
Reconnectthe "D" connector to
the ECM.

- Bopair .hort to body ground in

RED/WHTwiro bctwe.n ECM
{Dl9} ond MAP 3onso.or EGR
valve lift sonror.
- Bopair shon to body g.ound in
YEL/WHT wlre botw66n ECM
lD2Ol and TP !on3or.

Turn th ignirionswitch ON.

(To page 1 1-54)

(cont'd)

11-53

PGM-FlSystem
TroubleshootingFlowchart - Enginecontrol Module IECMI (cont'd)
(Frompage 1 '!-53)

Measurevoltage between body

groundandthe tollowingterminal
individually:A26, B2.
A26 82
l
l

]L

ls rhere lessthan 1.0 V?

Less than

'1.0 v?

Repai.op6nin BLK/REDlA26) or
BRN/BLK(B2l.nd G101 llocatod
6t thormoslat housingl.

A 2 5( . r ) 8 1 { + )
Measurevoltage between A26
I - ) andthe following:81 {+ ) and
A25 (+).

BATTERY
VOLTAGE?

BATTERY
VOLTAGE?

- Repair opon in YEL/BLK wir6

betweon ECM (425, 81) and
PGM-Fl main iolay.
- Check PGM-FImain tolaY .nd
wiring connoctors at PGM-FI
main r6lav.
Substitute a known-good ECM
and recheck. lf symptom/indication goes avray, replacethe otiginal ECM.

11-54
Y

PGM-FISystem
TroubleshootingFlowchart - Heated Oxygen Sensor (HO2S)
The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTroublecode {DTC)1: A problemin th
mrri--ri
_.-i- _ HeatedOxygen Sensor(HO2S)circuit.
ff'_
The HeatedOxygen Sensor(HO2S)detectsthe oxygen content in the exhaustgas and signalsthe ECM. In opration,
the ECM receivesthe signalsfrom the sensorand variesthe durationduring which fuel is injected.The HO25 has an
(H2341 engine
internalheater,The heaterstabilizesthe sensor'soutput. The HO2S is installedin the exhaustmanifold
pipe
A)'
(USA: Si/Canada:SR). H22A1 engine(USA: Si VTEC/Csnada:SR-VI:in the exhaust
HEATER
TEBMINALS
VOLTAGEIVI

SENSOR
TERMINALS

lm;rl lrirl
-Y-

-.-i-

- Tha MIL hsa becn roDortodon.

- Yvlth sorvico chack connoclor
iumpod l.60 page I 142), codo
1 i3 indicatod.

Do the ECMResetProcedure{see
p a g e1 1 - 4 3 ) .

Warm up engine to normal oPeF

atingtmperature(the radiatorfan
comeson),

Run enginetor 60 seconds.

Roadtest with the manualtrqlsmission in 4th geat I AfIt lA

position).
Starting st 1,600 rpm, accelerate
using wide open throttl for at
least 5 seconds.Then docelerte
tor at least 5 seconds with the
throttle completoly closed.

ls the MIL on and does it indicate code 1?

Go !o pagl. and prtorm tcat for

p.fo 11-62).
.-.3
l-

11-56

Intormittont lrllur., systom l. OK

al thb time. Ch.ck to,. poot connoctlons o. loorc wiror at C432
{locatod al tight shock towcr),
C114 (HO2S)and ECM.

- LEAI{
RICH- AIR.
FUEL
RATIO

PGM-FISystem
Flowchart- HeatedOxygenSensor(HO2SlHeater
Troubleshooting
:ml1:f,f-f
-*-Y-

The MattunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)41: A problemin

the HeatedOxygen Sensor(HO2S)Heatercircuit.

-[6]- ]l-rTll
/

-]-\

7.---:-

- Engino ia running,
- Tho MIL hsr bcon roportodon.
With rervica chock connoctol
iumpod (soopage 11421, codo
41 ir indicalod.

Do the ECM RssetProcedure(see

p a g e1 1 - 4 3 ) .

ls the MIL on and does it indicate code 41?

H23Al ongino {USA: Si/Clnada: SR)

H22Al engin. {uSA: Si vTEc/Canada: SR-VI:

lrrtd$frqrttS$6,3ystom 13OK at thi! tlmo

Itost drlvo maY bo
nacrsrsryl.
Chock lor poot connoctionr or 10036wirot rt
C432 llocat.d at right
shock toworl, C114
lHO2Sl and EcM.

10-r|o
o?

Turn the ignition switch OFF.

DIGITAL
MULTIMETER
KS-AHM-32-003

Disconnectthe 4P connectorfrom
the HO25.

Me6sute tesistance betweon terminsls C and D on the HO2S.

ls there 1O-4O 0?

( T o p a g e1 1 - 5 9 )

11-58

DIGITAL
MULTIMETEB
KS-AHM-32-003

11-58)

H23A1 engino
IUSA: Si/Canada:SRl.
H22Al ongino
(USA: Si VTEC/Canada:SB-V):

Check lor continuity to body

ground on telminalsC and D ot
the HO2S.

Check foi continuity between terminalD and terminalsA and B individually.

F22A1 ongine (S):

HO2S
45 N.m
(4.5 kg-m,

Turn the ignitionswitch ON.

At HO25 harness,measurevol,
tage between YEL/BLK{+ I terminal and ORNMHT {- ) terminat.

ls there battery voltage?

Meosure voltage bstween YEL/

BLK (+l re.minal and body
ground.

YES

Disconnectthe "A"
from the ECM.

connector

HO2S
45 N.m
{4,5 kg-m, 33 tb-ftl

At HO25 harness, measure voltage between YEL/BLK(+ )termi

nal and ORN/WHT(- ) teiminal.

ls there battery voltage?

Repair 3hon in ORf{/

WHT wire botwoen
ECM (A6l and HO2S.

Ropairopon in YEL/BLK
wiro botwoon HO2S
and PGM-FImsin rolav.
Turn the ignirionswitch OFF.

Reconnectthe HO25 connector.

{To page 1 1-60}

{To page 1 1-60)

{cont'd}

11-59

PGM-FI
iM-Fl System
TroubleshootingFlowchart - HeatedOxygen Sensor(HO2S)Heater {cont'd)
(Frompsge 11-59)

"A"
Connoct the tesl harness
connector to the main wile haF
ness only. not the ECM (seepage
11-45).

Connect an ammetet btween telminalsA6 { + ) and A26 (- )

' Monitor over a 5 minutes period.
ls the curront less than
0.1A?'

Subrtltut. a knownSood ECM

lnd rochock. ll .ymptom/indication 9o6a away, roplaco tha origi_
nal ECM,

I
Reconnect the 4P connector to
the Ho2s.

"A"
Connect the test hahess
connector to the main wi.e haF
ness onlv, not the ECM (s.e page
11-45).

BATTERY o o o o o o o o o o o o o
oo ooooooooooo
VOLT

oooooooo
oooooooo

ooooooooooo
ooooooooooo

Turn th6 ignitionswitch ON.

Measurevoltage between A6 {+}

terminsland A23 {- } terrninal.

ls there battery voltage?

Rep.lr opn in OR /WHl wir. bctwcrn ECM lA6) .nd HO2S.

Subllltuto 6 known-good ECM

and$chock. ll symptomlindicat'roril'golr ay{ay, rsplaco tho otigil_
nal ECM.

11-60
F

PGM-FISystem
TroubleshootingFlowchart - Fuel Supply System

:r,*n-- \r-r-l
-t 13l
/

- - - | t

The MatfunctionIndicatorLamp (MlL) indicatesDiagnosticTroublecode (DTC)43: A problemin

the HeatedOxygen Sensor{HO25) circuit or a problemin the Fuel Supply System

l@r rE.
Fiom cod. 1 troubb'l
3hootlng lpag. I -561.

- Tho MtL hc! b.cn roportod on .

- Wlth rorvico chock connoctoi
iurDod t!.3 p.Oe 1 142), codo
43 l. indicatod.
ls the codo 43 accompaniod by
the MIL and poor driveabilitY?

Go to Fu.l Supply Systam (3.o

p!9. l1-'1131.

Do the ECM Reset Procedure

lse6 page 1 1-43).
warm up engineto normSloper'
ating tompgrature{the radiatorfan
comes on).
Hold engineat 3,OOOrpm lor two
mtnutes.
(A/T:NorEposition.)

,,ti

i,l

ls the MIL on and doss it

indicate code 43?

Intlrmlttdrt t ilurc, ly.tom is OK

at thir dm (t6st drlv. may ba
nocoalarYl.
Chock tor ooor connactiona o.
loor. wirst at C432 lloclt.d !t
rtght rhock low.tl, C1f4IHO2S) and ECM.

Turn the ignition switch OFF.

Connect the test hamess bgtween

the ECM and connoctors {see
page 1'l-45).

With the ignitionswhch OFF,wait

tor st least two minutes.

NOTE:
. Use DIGITALMULTIMETER
(KS-AHM-32-OO3)or equival6nt.
. Use 2 Volt range.

A26
JUMPERWIRE

Install a iumper wire on the test

harnessbotween A6 and A26.

Turn the ignition switch ON.

Measure voltage between Dl4
A26 {- ) termil+) terminaland
nal as soon as the ignition switch
is turned on,
lTo page 11-63)

11-62

A26{-t

Voltaga .hould ttan tl

0.4-0.5 v wh.n thc
ignltion .whch i. fit8t
tunad oo, and dactaaso
to b.low O.l V In L.t
than two mlnut6a.

D 1 4( + l

lFrom page 11-62)

ls there 0.1 V or lss when the

ignition switch is tirsr turned
on?

Measurevoltage belween D14

{ + ) t e r m i n a la n d A 2 6 ( - )
telminal.

ls there more than 0.1 V?

Disconnect the "D" connector

trom the main wire harness.

Measurevoltage between D14

l nd A26 {-) rer
{+} terminaa
minal.

Bop.ir rhon in WHT

wlro b.tw.on ECM
(Dl4l andHO2S.

ls there more than 0.1 V?

Measu.e voltage at the engine

wi.e harness side ot the HO2S
connector between GRNMHT
( - ) a n d W H T( + ) .

Substitute a known{ood ECM

and r6.hock. lf symptom/indlcation goos away, roplact the orlglnal ECM.

ls thre mor than 0.1 V?

Chock for oDcn in IIVHTwiro betw..n ECM (D141 and HO2S. lf

wlrs ir OK, r6poir opcn in
GBN/WHT wiro berw66n ECM
(D221and HO2S.

H23A1 ongin6 (USA: Si/CanadarSR),

H22Al ongino (USA: Si VTEC/Conada:SR-V);

GRl{/
WHT

W H T( + )

F2241 sngino {S):

GRI{/

IVHT - l

WHT

(+l

moro than

o.'t v?
DIGITAL MULTIMETER
KS-AHM-32-OO3

HO25
45 .m
(4.5 kg-m,33 lb-ft|

HO2S
45 N.m
14.5 kg-m, 33 lb-ft)

DIGITAL MULTIMETER
KS-AHM-32-OO3

11-63

PGM-FISystem

TroubleshootingFlowchart -Manifold Absolute Pressure(MAP) $gn5s1

- -l--

- ---1- -

t 1 6 l - /- l 3, l \/--l-\
\

/-

/-

\ /---i-

The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 3: An electricsl

oroblemin the ManifoldAbsolutePressure{MAP) Sensorsystem.

MalfunctionIndicatorLamp {MlL) indicatesDiagnosticTroublecode (DTC) 5: A mechanical

{-61--fr-r- The
problem(vacuumleak) in the ManifoldAbsolutePressure(MAP) SensorSystem'
\

The MAP sensorconvertsmanifoldabsolutepressureinto electricalsignalsand inputs the EcM.

CAVITY

OUTPUT
VOLTAGE
(vl3.5
3.0
2.5
2.0
1.5

-16l-

0.5

/-\/

- Engin6 is watm ond running.

- Tho MIL has b6nloPortodon
- With soryico ch6ck connoctot
jumpod (so pago 1'142), codo
3 is indicalod.
I

r',i
i , l'

Do the ECM ResetProcedure{see

p a g e1 1 - 4 3 ) .

I'iI
l

ls the MIL on and does it indicate code 3?

Turn the ignitionswitch OFF.

Disconnectthe 3P connectorfrom
the MAP sonsor.

Turn the ignitionswitch ON.

(To psge l1-65)

11-64

Intgrmittont failuro, 3yltam is OK

at this time ltort ddve may D6
noc{r!ry}.
Chock tor Poor connoction! ol
loose wiror at O163 (locatod undor loft 3ideol drshl, C32O IMAP
3.n3otl and ECM.

lar. Hll OAUOE

N: DING

l F r o mp s g e 1 1 - 6 4 )

Measure voltage between RED/

WHT (+) terminal and body
ground.

ls there approx. 5 V?

ft

D 1 9t r l D 2 1( _ l
ooooooooooooo
ovooooooooooo

I o oooo ooo
I oooooooo

Measure voltage between RED/

WHT (+ ) terminaland BLUMHT
{ - ) terminal.

Turn the ignirionswirch OFF.

ls there approx. 5 V?

Ropai. op6n in BLU/

WHT wiro betwoon
ECM {D21} and MAP
s6n8l't.

Connect the test harness "D"

connecto.to the ECMonly, notto
the main wire harness (see page
1145).

Turn the ignitionswitch ON.

Measurevollage between D19

l + ) t e r m i n a la n d D 2 1 ( - )
terminal.

ls there approx. 5 V?

Measure voltage betweon WHT/

BLU {+ ) terminaland ELUMHT
{ - ) terminal.

Ropairopon in RED/WHTwiro botwcon ECM (D191 and MAP

son3()r.

Sub3tituto a known-good ECM

and rochock. lf 3ymptom/indication 9003away, .eplacotho original ECM.

ls there approx. 5 V?

Turn the ignitionswitch OFF.

Reconnect the 3P connector to
the MAP sensor.
Connectthe test harnessbetween
the EC|VIand connectorlsee page
11-45).
Turn the ignitionswitch ON.

{To page 1 1-66)

{ T o p a g e1 1 - 6 6 }

(cont'd)

11-65

PGM-FISystem
(MAPISensorlcont'dl
Flowchart- ManifoldAbsolutePressure
Troubleshooting
{Frompsge 11-65)

(Frompage 1 1-65)
MeasuG voltage bstween D'l7
(+l terminaland D21 (-)
terminal.

Turn the ignitionswitch OFF.

"D"
Connect the test harnss
not
to
connectorto the ECMonly,
the main wire harness {see page
11-45).

Turn the ignitionswitch ON.

ls there approx. 3 V?

Sub.tituls . known{ood ECM

rnd r.chock. lf 3ymptom/lndication goo! 6w!y, r.plact th. odgi
nal ECM.

Measurevoltage betweon D17

( + l t e r m i n a la n d D 2 1 { - )
tetmlnal.

ls there approx. 5 V7

Substltuto a known{ood ECM

and rochock. lf aymptorn/indicrtion goo3 away, taplace tho original ECM.

11-66

- Roplir rhort In WHT/BLU wiro

botworn ECf,l {D17) rnd MAP
loflto],
- R.prir opon in WHT/BLU wlrc
botwo.n ECM (Dl7l.nd MAP
36nao..

PGM-FISystem

{MAP}Sensorlcont'dlFlowchart- ManifoldAbsolutePressure
Troubleshooting

-g-

,g:

- The MIL has boon reponod on.

- With sorvic chock connector
jumpod ls6opago 1 142), code
5 is indicatod.

Do the ECM ResetProcedure{see

p a g e1 1 - 4 3 ) .

Start the engine and keep engine

speed at 2,000 rpm tor one
minutewith the manualtransmas
sion in neutral {A/T: @ or S position).

ls the MIL on and does it indicate code 5?

- Intgrmitl6nt lailuro, 3y3tom is

OK al this tlm6 lt$t ddvo mav
bo nocoasaryl.
- Chock vacuun ho3or, PiPo3
ond connoctionS.
- Mako turo all conn9ctota ar6
30cu16,
MAP SENSOR

l l

'1i

Turn the ignitionswitch OFF.

r:ttl

Hrl
Disconnect#21 hose lrom the
throtle body, connect vacuum
pump to the hose and apply

VACUUMPUMP/
GAUGE
A973X-041-XXXXX
#21 HOSE
Connect a vacuum pump to the
MAP sensorand apply vacuum.

Does it hold vacuuml

Connecta T-titling from a vacuum gauge between the throttle

body and #21 hose.

{ T o p a g e1 1 - 6 9 }

11-68

Repairvscuum lsak in hoa routing betwaon MAP asn3or lnd

rhrottlo body .

{Frompag6 1 1-68)

Start the engine.

ls there manifoldvacuum?

Turn the ignitionswitch OFF.

Connectths test harnessbetween

the ECM and connectors (see
p a g e1 1 - 4 5 ) .

Turn the ignitionswitch ON.

T-FITTING

3V?

D l 7 t + l D 2 1{ - }
Measurevoltage between D17
(.t ) terminal and 021 ( - )
lermrnal,

ls there approx.3 V?

Start the engineand allow it to

idle.

ls there approx. 1 V?

Subltitute a known-good ECM

and rocheck. ll symptom/indication 9063away, ropl6cotho o.iginal ECM.

11-69

PGM-FISystem
Sensor
Flowchart- TDC/CKP/CYP
Troubleshooting
-

Tr-l-

The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)4: A problemin the

CrankshaftPosition(CKP)Sensorci,cuit.

- l r G./l - --_-1_/
l 8l-

The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTtoubleCode{DTC)8: A problemin rhe

Top Dead Center (TDC)Sensorcircuit.

16l-

-Yt-._r-\

/-i-\

\_

j_'-,2

\_

_/

- 1--t-\
16l--l e l/---- \
/

IndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)9: A problemin the

The fiilalfunction
CvlinderPosition(CYP)Sensorcircuit.

The CKP Sensordeterminestiming fo. fuel injectionand ignitionof each cylinderand also detects enginespeed.The
TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects
the position of No. I cylinder for sequential fuel injection to each cYlindet.

-@Jtrl:;m:-;F;

.ir

l,l

- Tho MIL ha. bn Jooortod on.

- lilfith loruice chck conn.ctol
iumpd (3ooprgo 1142), codc
4. 8 rnd/or 9 aro indicstgd.

Do the ECM Resetprocedurelsee

pago 1 1-43).

ls lhe MIL on and does it indi

cate code 4. 8 and/or 9?

l ormittont l.ilur., syltom b OK

at this timo ltelt driv6 may bo
neco$aryl.
Chock for Door connoctiona or
loos6 wir.s at Al25 (locatod at
dght shock towo.), Cl25 (TDC/
CKP/CYPionsorl .nd ECM.

Turn the ignition switch OFF.

H23A'l ongino{USA: Si/Canada:SRl, .,.

vrew rrom
H22a1 engino

sa-vt,
iiisr, si vlicrca"aaa

Disconnectthe 8P connctorfrom
the TDC/CKP/CYPsensor.

( T op a g e1 1 - 7 1 )

11 -7 0

$jT'"'

1 1-70)

Measurerosistancebetween terminals of the indicnted senso..

'9oo tsblg

oTc

SENSOR

SENSOF

COLOF
815

cxP
ls there 350- 700 O?

Roplacathe di.Mbuto.
houalng {16o soction
231.

ECM

TOC

c
G

ALU/GRN

416

SLUTYEL

al3
at4

OFN/aLU

Bll

OFN

Bt2

Chck lor continuitv to bodv

ground on both terminals of the
indicatgd sensor.
RoDlrc. th. di.trlbutor
houling (soo aocdon
231.

Connect the test harness to the

main whe harnossonlv, nottothe
ECM (seepag 1 1-45).

Measurerosistancebetween trminals of the indicated sensoron

test harness.
'see tablg

350-7OOO?

8:16

o oooooooooooo I oooooo
ooooo oooooooo I oooooo

o l:1E$iq#Cittl o o o oo o oo oo o
o ooooo oo oo o

B1l-

350-7ooo?

o o o o o o o o o o o o o I o o o o o o o o r . s E t $ d i 6 d qo o o o o o o o o o o

ooooo oooooooo I ooooo0oo lfrlE#lls*llooooooooooo

350-7000?

ls there 35O-7OO 0?

812

R9pai.op.n In tho indicatad alnlor wi10a.

'!oo trble

Check tor continuity to body

groundon Bl 5, 813 or 81 1 termtnals,

Subltltuto a known-good ECM

lnd r6chock. lt aymptom/indicrtion goor away, rcphca tho origin.l ECM.

11-71

PGM-FISystem
TroubleshootingFlowchart - Engine Goolant Temperature(ECTI Sensot -

lri-tl
f'at, - ---;--

The MalfunctionIndicatorLamp (MlL) indicstesDiagnosticTroubleCode (DTC)6: A problemin

the EngineCoolantTemperature(ECT)Sensorcircuit.

The ECTSensoris a temperaturedependantresistor(thermistor).The resistanceof the thermistordecreasesas the engine coolanttemperatureincreasesas shown below.
RESISTANCE
(KO)

-!/
-r - -l---i5l-

-- h- l 6
l-

/----,

0 ,ro ao ao r roo 12o (rc,

. 12 aa r0. !.ro 1ta 2r2 2.r r.fl

-20

- The MIL has b6onroDongdon.

- With sorvica ch6ck connoctol
'l
,ump6d l.oo pag 1421, c!d6
6 is indicatsd.

COOLANTTEMPERATURE
ENGIT{E

Do the ECM ResetProcedure{see

page 1 1-43).

Turn the ignition switch ON,

j

ls the MIL on and does it indi

cate code 6?

Warm up engine to normal operating temperature(th radiatorfan

comeson).

Turn the ignitionswitch OFF.

Disconnectthe 2P connectorfrom
the ECT sensor.

Measureresistancebetween the
2 terminals on the ECT sensor.

ls there 2OO-4OO0?

{To pagc 1 1-73)

11-72

Intermittnt failure, systgm i3 OK

at thir timo lt6st d.ivr m.y b.
n6ce!l|'yl.
Chock tor poor connootions or
looro wir6 at 9125, 9126 (locrtod at righl shock toworl, Cl22
IECT lenrotl, AIf: C411 (TcMl
and ECM.

( F r o mp a g e 1 1 - 7 2 )

Turn the ignitionswitch ON.

Measure voltage between YEL/

BLU and body ground.

GBN/
wHT

YEL/BLU
Measure voltage between YEL/
BLU (+ ) torminaland GRNA/VHT
(- ) terminal.

ls there approx. 5 V?

Repair opn in GRN/

WHT wlra brtw.on
EGM (D22) and ECT
tonaoa.

Turn the ignitionswitch OFF.

ls there approx. 5 V?
A/T only
Subrrituto r known{ood ECM
and iocheck. lf lymptom/lndlcrtion goaa aw!y, rol aco tha original ECM.

Disconnect the 22P connector

trom the TCM.

Turn the ignitionswitch ON.

ls there approx. 5 V?

YES

NO
I

Turn the ignitionswitch OFF.

I
I

Connect the test harness "D"

connectorto the ECMonly, notto
the main wire harnsss lse page
11 - 4 5 ) .

v?
T-5
O13l+l

Turn the ignitionswitch ON.

D22 t-l
Measurevoltage belween D13
( + l t e r m j n a la n d D 2 2 ( - )
rermtnat.

ls there approx. 5 V?

NO

Ropairopen or rhon in YEL/BLU

wir. betwoon ECM lDl3l snd
ECT sensor.

Subatituto a known-good ECM

and rechock. lt symptom/indication goos away, r6pl6cothe original ECM.

11-73

PGM-FISystem
TroubleshootingFlowchart - Throttle Position (TP) Sensor
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode IDTC) 7: A problemin
the Throttle Position{TP) Sensorcircuit.

lf1=lllfifl
.:.
:

The TP Sensoris a potentiometer.lt is connectedto the throttle valve shaft. As the throftle positionchanges,the TP
Sensorvariesthe voltage signalto the ECM.
ERUSH
HOLDER

OUTPUTVOLTAGENI
BRUSH

5
4
3

RESISTOR

:.t1

lr6t1

1
o.5
0

-t-

-Yr

- Engino b running.
- Tho MlLhas beonreDortedon.
- With sorvico check connoctot
iumpsd ls6opage 1 142), codo
7 is indicatod.

TERMINAL

ls the MIL on and does it

indicatecode 7?

INNER
BRUSH

Inlormittont Iailure, systom b OK

at this timo lt6st d.ivs m6y b6
nocossaryl.
Chock tor Dooi connections or
loos wiros at O125, g*13 llocatod at right shock rowerl, C113
(TP sonsorl, A/T: C4'l l ITCMI
and ECM.

Turn the ignitionswitch OFF.

Disconnectthe 3P connectorfrom
the TP sensor.

Turn the ignitionswitch ON.

Measure voltage between YEL/

WHT (+ ) terminaland GRNMHT
(- ) terminal.

ls there approx. 5 V?

Measure voltage between YEL/

WHT (+) rorminal and body
grouno,
YEL/ RED/ GNN/
WI{T BLK WHT

YES
{ T o p a g e1 1 - 7 5 }

11-7 4

(To page 'l1-75)

;;ii-

oPEt{rNG

THROTTLE

Do the ECM ResetProcedure(see

p a g e1 1 - 4 3 ) .

THROTTLE

(F om p8O11-741

(Frompage 1 1-74)

ls there 6pprox. 5 V?
Turn the ignition switch OFF.

Repaii opon in GBN/

WHT wiro botwo6n
ECM (D221 End TP
30n3('t.

Turn th6 ignition switch OFF.

Connoct
thtestharness
btween
tho ECM snd connectors{see
p8ge11-451.

Connoct the test hamess b9tw6n

the ECM and connoctors lse
p a g e1 1 ' 4 5 1 .

Turn the ignition switch ON.

Measure voltage betwgen D2O

( + ) t e r m i n a la n d D 2 2 { - )
terminal.
Turn the ignhion switch ON.
ls there aoo.ox. 5 V?

Measurevoltago btween Dll

{+) trminaland D22 (-,
terminal.

Rop.ir op.n in YEL/

WHT wlra bolwoon
ECM {D2O} a.|d TP
aonlot,

Subltltut. . known{ood ECM

.nd r.ch.ck. It piclcribcd voltage
i! now lvoilabl., rrphco tho orlgin.l ECM.

o o o o o o o o o o o o o I o o o o o o o o E f f n f f i n S HoFol o o o o o o o o o
o o o o o o o o o oo o o I o o o o o o o o
ooooooooo
D 2 0t + l D 2 2 l - l

tsv,J
0.5 V at tull close throttle?
4.5 V at lull open throttle?
ls voltago 0.5 V at full clos
throttle, and approx.4.5 V 8t
full open throttls?
NOIE: There should be a
smooth transition from O.5 V
to approx.4.5 V as the throttle
is depressgd.

Sub.litulc ! known-good ECM

.nd rochsck. lf symptom/lndic.tlon goat rway, ropl.c. the odginll ECM.

Diaconngct the 22P connecto.

from th6 TCM.

ls voltageO.5 V at full clos6

throftls, and 4.5 V at full
open throttl?
NOTE: Thero should be a
smooth transition from 0.5 V
to 4.5 V 8s the throftlo is
dpressed.

- Roplac6 the TP
lonaoa.
- Rapairoponoarhon
in RED/BLKwiro betw.n ECM {Dl 11,
TCM and TP r.n!or.

11-75

PGM-FISystem
Troubleshooting
Flowchart- IntakeAir Temperature(lAT) Sensor
f6l

F
---:- l-

The MaltunctionIndicatorLamp(MtL)indicatesDiagnosticTroubleCode(DTC)1O:A problemin the

Intake Air TemDerature(lATl Sensorcircuit.

The IAT Sensofis a temperaturedependantresistor(thermistor).The resistanceofthe thermistordecreasesas the intake

air temoeratureincreasesas shown below.
RESISTANCE(KO}

THERMISTOR
. 12 aa ro4 1aolta :12 t a |.Fr

INTAKEAIR TEMPERATURE
IA7 SENSOR

:[611:frnl
--i/ --T/

i:

- Tho MIL har b6onropon6d on.

- Wlth s6rvico chock connoctol
iumpod {3opago 1142}. cod6
10 is indicsrod.

Do the ECM ResetProcedur(see

p a g e1 1 - 4 3 ) .

Turn the ignitionswitch ON.

ls the MIL on and dos it

indicatecod6 10?

Turn the ignitionswitch OFF.

Disconnectthe 2P connectortrom
the iAT sensor.

Measureresistanc6between the
2 terminalson the IAT sensor,

ls there 0.4 -4.0 k0?

lro page 11-771

11 -7 6

Intermitl.nt tailu.o, sydom iB OK

at thir tims (tost ddvo may bo
noc6ssttyl.
Chock for poor connoction! ol
loo!. wircr .t O+25, 9126lloclled ot right .hock towor), CiOS
llAT sonsorl and ECM.

GR N'VHT

(Frompag 1 1-76)

Turn the ignitionswitch ON.

Measurevoltage between RED/

YEL (+) terminal and body
ground.

ls th6re approx. 5 V?

Turn the ignitionswitch OFF.

Connect the test hamess "D"

connectorto the EcM only, notto
the main wire harness lsee page
11-45).

Mgasure voltage betweon BED/

YEL (+ ) terminaland GRNMHT
{- ) terminal.

li there approx. 5 V?

Ropair opcn in GRN/

WHT wlr6 botwoon
ECM (D221 and IAT
lon301.

Subrtitut. . known-good ECM

and rochock. ll lymptom/indicatioh goe! aw!y, r6pl.ce th. orlglnel ECM.

Turn the ignitionswitch ON.

Measurevoltage between Dl5

{+} terminafand D22 l-)
terminal.

ls ther6 approx.5 V?

Ropairoponor lhort in REOrYEL

wirebotweenECM{D15}.ndIAT
aona{tr.

Substilute a known-good ECM

and .ochock. lI symptom/indication go6s awsy, roplac6tha original ECM,

11-77

PGM-FISystem

Troubleshooting
Flowchart- BarometricPressure(BARO)Sensor

lmil
.(--

frrf:
.+.

ThsMalluncrionIndicatorLamp{MlLlindicstsDiagnosticTroubleCode(DTC)13: A problemin the

B a r o m e t rPi cr e s s u r(eB A R OS) e n s o r .

The BAROSensoris builtinto the ECM.

-\ 13\/--i- Tho MIL hsr boon r.ponod on.

- With sr|.ico chack connacto.
iumpcd l!.o p.06 I 142), cod
13l! Indlcstod.

Do the ECM RsotProc6dlre (se6

page 'l1-43).

Turn the ignitionswitch ON.

ls the MIL on and do6s it

indicatecode 13?

Int.rmltt.nt f.llut . lyltgm Ir OK

at thlr tlm. lt6!t drlv. mly b.
nacoar!ry1.

Subrtituto a known{ood ECM

.nd rcchock. lf symptom/indlc!tion goo! away, r6phca tha odolnsl ECM.

11^78
i

PGM-FISystem
TroubleshootingFlowchart - lgnition Output Signal
i151
:

:16:

The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)15: A problemin the

lgnitionOutput Signalcircuit.
H23Al ongine IUSA: Si/Caneda:SRl,
H22A1 ongino IUSA: Si VTEC/ Clnada

sR-v):
- Tho MIL ha5 beenroponod on.
- With sorvice chock connoctot
iumpod {! p.g 1142), code
15 is indic.ted.

Do the ECM ResetProcedure(see

p a g e1 1 - 4 3 1 .

NOTE: lf the engino won't stari. it

mav take 20 seconds of cranking to
set the code.

ls the MIL on and doos it

indicatecode 15?

lntrmittant failute. tYllam i! OK

.t this timo (t.!l drive may bo
nac6slary).
Chcck for poot connactions or
looso wi.or ot C433 {locrtod at
.ight shock towet). Ct2S llgntdon
Conlrol Modulo llCMl) and ECM.

Turn the ignitionswitch OFF.

Turn the ignitionswitch ON.

Measure voltage betwegn YEL

(+ ) terminland body ground.

YES
{ T o p a g e1 1 - 8 1 }

1 1 -8 0

(To page 1 1-81)

Turn the igniitionswitch OFF.

Reconnectthe 2P connector.
ls the ignirioncoil OK?
Connectthe test harnessbetween
the ECMand connector(seepage
11-45).

Turn the ignition switch ON.

- Repsii opon in YEL wiro botwoon tho 2P oonngcto. and

ignition coil,
- Ropaii opon in BLK|'EL wi.o
botwoon tho ignition coil ond
ignition $witch.

Measurevoltage individually bet w e e nA 2 1 ( + ) , A 2 2 { + l t 6 r m i nals and A26 t-) terminal.

1OV? ---r
A 2 1{ + }
oooooooooooo

oooooooooooo
A 22l+t 426 l-l

t-J

1 0v ?

ls th6ro approx. 10 V?

Substituto . known-good ECM

and roch.ck. lf symptom/lndic.tlon goos awsy, .oplacoth6 original ECM.

- Roolocs lho lCM.

- Repair opon oi lhon in YEL/
GRN wir. botwon ICM lnd
ECM {A2l or A221.
NOTE:lf the YEL/GRNwire was shorted.
the ICM may be damag6d.

11 - 8 1

PGM-FISystem
Troubleshooting
Flowchart- VehicleSpeedSensor(VSSI
- -

-c+l
--lKgll-

:'; rI r'' l-

The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCod(DTC)17: A problemin the

vehicle speed sensor {vss) circuit.

The VSS generatesa pulsingsignalwhen the front wheels turn.

- Th6 MIL has bo6n rportodon.
- With sorvico ch6ck connoctor
ls6opage I 142), cod
iumped
'17 is indicatod.

Do the ECM RestProcedure(see

p a g e1 1 - 4 3 ) .

Road test necessary.

With manualtransmission
in 2nd
gear (A/T: E position)accelerate
to 4,000 rpm, thn decelerateto
1,5OO rpm with throttle tully
croseo.

ls the MIL on and does it

indicatecode 17?

rl

Block rear wheels and set the

parkingbrake.Jack up the front
oI the car and support with salety stands.

Intormlttont lallurc, 3ystcm ls OK

at this tim.
Chock tor Door connoctiona ol
loose wir6s at C433 {locrtod at
.ight shock tow6.). Cl15 {VSSI
and ECM,

@emr
ro.l wheel

beloro
jacking up front ot
cat,

Turn the ignitionswilch OFF.

Connectthetest harnessbetween
the ECM and connectors (see
p a g e1 1 - 4 5 ) .

Turn the ignitionswitch ON.

Block the right front wheel and

slowly rotate left lront wheel and
measurevoltage between B1O
{ + } t e r m i n a la n d A 2 6 { - )
Iermrnat.

Does voltage pulse 0 V and

'12 V
lH22A1 engine{USA: Si
VTC/Canada:
SR'V)5.0 V)?

Substituto a known-good ECM

and rochock, lf symptom/indication gooaaway, roplacoth6 original ECM.

11-82

o oooooo ooo ooo I oooooooo &ruffi

ooooooooooooo I oooooooo EEwryl
A 2 6l - )

8 1 0( + )

O - 1 2v
ot O *5.o v?

NOTE: Transmissionin @ position{A/T).

Turn the ignition switch OFF.

( T o p a g e1 1 - 8 3 )

ooooooooooo
oooooooo ooo

(From page 1 'l-82)

Disconnoctthe B connector trom

the ECM only, not the main wire
harngss.

Turn the ignition switch ON.

Block the right front wheel and

slowly rotate left front wheel and
masurevoltage between 810
(+) terminaland A26 (-)
tefmrnal.

Does voltage pulse O V 8nd

12 V lH22A1 engine (USA:
Si VTEC/Canada:
SR-V):5.0
VI?

Sub.tituto r known{ood ECM

.nd r.ch.ck. lf lymptom/indication goar rway. roplace tho original ECM.

- Reprir 3hort in ORN

wi.e b6twoon ECM
(8101and tho VSS,
Tianlmission Control Modulc, spo6domotor, 4WS control unit, or cruiso
contrcl unit.
- Ropoiropon in ORN
wire b6two6n ECl,
{8101and VSS.
- lf wlr i8 OK. tort th
VSS {!oo .oction
23t.

11-83

PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad gs1s61q1(ELD)

tf

- --r--'
I 20 l-

The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)20: A problemin the

EtectricalLoad Detector(ELD)circuit.

With sorvice chock connoctor

jumpcd (3oepago 1142), code
20 is indicatod.

Do the ECM Resetprocedure{see

page 1 1-43).

Start engineand keep enginerpm

at idle.
Turn on headlighls.

Doesthe MIL indicatecode 20?

Intormitlgnl lalluro, system is OK

at this timo {to.t ddv m.Y bo
nocoa!4ry1.
Chock tor ooor connociion3 ot
looso wlr6s at C420 IELD) 8nd
ECM.

Turn the ignitionswilch OFF.

,i

Remove the undeFhood tuse/

relay box and remove the fuse/
relay box lower cover,

it
(+ }
SLKTYEL

Turn the ignitionswitch ON.

Measure voltage between BLK/

l nd BLK (-l
Y E L ( + ) t e r m i n aa
terminal.

LOWERCOVER
Measure voltage between BLK/
YEL {+) terminal and body
ground.

ls there battery vollage?

Ropairopon in BLK/YELwlto botweon ECU IECMI {'15Al fu3o {in

tho undor-dash tuso/rolay boxl
and lho 3P connector.
(To page 1 1-85)

11-84

Roplir opon In BLK rvk.

batwcan tha 3P conn ctor and erc3 llocatcd undor middlo ol
dashl.

{Frompsge 1 1-84}

Measure voltage between GRN/

8LK terminl and body ground.

ls there 4.5- 5.0 V?

Rep.ir opon or short in GRN/BLK

rvi. brtwoon ECM lDlO) and tho
3P connoctoa.
It wiro is OK, aubstitut6a knowngood ECM and ..chock.

GRI{/BLK
I+ )

Turn the ignition switch OFF.

LOWERCOVER

Connectth6 tst hsmossbetween

the ECM and conneclors (see
p a g e1 1 - 4 5 ) .

{To poge 1 1-86}

(cont'd)

11-85

PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad Detectol (ELDI (cont'd)

Underthe conditions listd in the

chart to the right, measure vol_
tage between D1O {+ } terminal
and A26 (- l terrninal.

'

it

Substituto a known{ood ECM

and recheck, ll symptom/indication goos away. 6phco tha otiginel ECM.

11-86

Condition

Voltage

Headlightswitch, first position (.)

1 . 5 - 3 . OV

Headlightswitch, second position( a)

1 . 0 - 2 . OV

PGM-FISystem

Flowchan- KnockSensor(KSl [ExceptF22A1 engine(S]lTroubleshooting

t-7=.l_lltlllll-

-r#-l .l l-

The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)23: A problemin

the Knock Sensor(KS) circuit.

-e-tm- Thc MlLhas boenroponed on.

- With !6wico chack connoctol
lumpd l..o pago I 1421, codo
23 is indicatod.

Do tho ECM RestProcedurslse

p a g e1 1 - 4 3 ) .

Warm up the sngine to normsl

opgratingtempotature (tho radiator lan comgs on).

Hold engine8t 3,OOo- 4,0OOrpm

tor 1Osecondswith manualtransmiesion in neutral {A/T: lll or lq
position).

ls the MIL on and does it

indicats code 23?

Int.mittonl l.llur., sy.t.m b OK

at thir tim. (tod driv. maY bo
nocolaorYl.
Chack for poot conncctlon! ot
loolq wlro3 al O+32 (loortrd rt
right shod( tow.r), Cl l2lKS) and
ECM,

Turn the ignition swirch OFF.

Connect the test harness to the

engine wire harneasonly, not to
the ECM (seepage 1 1-45),

o3

t_
Continuity?

Ch6ck lor continuity between D3

trminal and body ground.

Rop6ir.hon in RED/BLUwite bctrY.en ECM lD3l snd th. KS.

(To page 11-89)

1 1-88

Check tor continuity on RED/BLU

wire betweenD3 terminaland2p
connectorof enginewhe harness.

lContinuity?
Ropairopon in RED/BLUwiro botwoon ECM lD3) and tho KS.

Warm up tho engineto normal

operatingtemperature{theradia,
tor fan comgs on).

Hold engineat 3,OOO-4,OOOrpm

lor 1Osgcondswith manualtransmissionin noutral (A,rf: @ or @
oosr!onl.

ls the MIL on and does it

indicatecode 23?

Subslituto a known-good ECM

and rsch6ck. lt symptom/indic!tion goos aw6y, .oplacothe original ECM.

32 N.m 13.2ks-m.23 lb-ftl

11-89

PGM-FISystem
Flowchart- A/T Fl SignalA/B (A/T only)
Troubleshooting
---l-The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)30: A problemin
-l 30 ltne A/T Fl Signsl A circuit between TransmissionControl Module {TCM) and ECM.
-

(MlLl indicatesDiagnosticTroubleCode {DTCI 31: A problemin

r;;--] The MaltunctionIndicatorLamp
I Jr l- the A/T Fl SignalB circuit between Transmissioncontrol Module {TCM) and ECM.

\.----_/\r---:-/

- l 3 0l - o , - l 3 l l
------ ---j\

With 3orvico chock connactor

jumpod, (ra. pagc 1142), codo
30 .nd/or 31 arc indicatod.

Do the ECMR6setProcedure{see
p a g e1 1 - 4 3 ) .

Test drive necessarv.

Drive th3 car for severalmiles so
that the transmissionupshiftsand
downshifts soveral times.

l
I
I

Does th MIL indicat code

30 and/or 31?

lhtdmittont failurs, gylt.m i. OK

ai thir tlmo.
Chock for poot connoction! or
loo.. wiro. at C4ll (TCMI snd
ECM,

r'l
Turn the ignition switch OFF.

Connect the test harnssg to the

msin hrnessonly, nottothe ECM
'l1-45).
{see page

Disconnect the 22P connector

from rhe TCIV.

+
Conlinuity?

Check for continuity between 93

and/or 84' terminal and body
grouno.

Continuity

*r codo 31 {A/T Fl signal B)

RoDairrhort in ORN or Pf{Kr wilo
botw.n ECM {B3 or B4r I .nd rh.
TCM.

NO
( T op a g e1 1 - 9 1 )

11-90

(Frompsge 11-9O)

Check lor continuity on ORN or

PNK'wire between 83 or 84*
and 22P connectorot rhe TCM.

Ropsiiopon in ORI{ or P{lK. wir6

botween ECM {8:} o?84. I and rhc
TCM.
Subltitute a known{ood ECM
and rochack. lt lymptorh/indication gogs rway, roplaca tha original ECM.

11-91

ldle Control System

System TroubleshootingGuide
NOTE:
a Acrosseachrow in the chart,the sub-systemsthat couldbe sourcesof a symptomare rankedin the orderthey should
then refer
be inspected,startingwith @. Findthe symptomin the left column,read aclossto the most likelysource.
next
system
try
the
is
OK'
@' etc'
the
system
to ths page listed at the top ot that column. lf inspectionshows
Trouble
(MlLl
Diagnostic
not
blink
does
Lsmp
Indicator
Malfunction
a lf the idle sDeedis out ot specificstionand the
page
11-95.
go
on
described
to inspection
Code {DTC) 14,

PAGE
SYMPTOM

ALIER,
IOLE
coNDr- NATOs
ADJUST I D I E A I R
CONTROL
l s u s - s Y s T M ING
FR
TIONING
SIGNAL S I G N A I
SCREW
-'\
100
96
98
ttl

STARTER ERAKE STEERING FAST IDLE STAFTING

swtTcH swtTcH PFESSUNE THERMO

srGt'rALSIGNAL SIGNAL

102

l04

106

104

ROUGHIDLE

WHENWARMRPiNTOOHIGH

load)

@
@

T00 Low

liomr in ON

11-92

o
\,

WHII,EWARMING
UP

AFTERWARMING

TEST
FAILSEMISSION

o
o
@

WHEN

FREOUENT
STALLING

110

TO START
DIFFICULT
ENGINEWHENCOLO
WHEI.{COLDFASI IDLEOUTOF
SPEC.(1
,000- 2,000rpm)

l09

HOSES
AND
CONNEC.
TIONS

System Description
The idle speed of the engine is contro ed by the ldte Air Control ACI Vatve.
The vElve chsnges th smount of air bypassing into the intake manifold in responseto
electric current contro ed by the
ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle
speed.

TO PGM.FI
MAIN RELAY

.,\
\r-

STARTITIG
AIB VALVE

vARtous
SENSORS

FAST
IOLE
THERMO
VALVE

11-93

ldle Gontrol System

System Description(cont'd)
1. After the enginestarts,the IAC valveopensfor a certaintime. The amountof air is increasedto raisethe idle sp6d
'l
about 50- 3OOrPm.
2.

When the engine coolant temperatureis low, the IAC valve is openedto obtain the prope. fast idle speed. The amount
of bvoassedair is thus controlledin relationto the enginecoolanttemperature'

IDLE SPEEO
{rpml

11-94

104

140

&

60

l.

When the idlespeedis out of specificationand the MalfunctionIndicatorLamp(MlL)does not blinkDiagnosticTrouble Code lDTC) 14, check the following items:
. Adjust the idte speed (page I 1- l 1 I
)
. Air conditioningsignal (page 11-99)
. A L T F R s i g n a t{ p a g e1 1 - 1 0 0 )
. A/T gear positionsignat{page 11-1O21
. Starterswitch signal (p8ge 1j-1O41
. Brakeswitch signal(page 11-106)
. PSPswitch signat(page t 1-108)
. Fast idle thermo valve (page l.l_109)
. Starting air valve
. Hosesand connections
. IAC valve and its mountingO-fings

2.

It the above items are normal,substitutea known-goodIAC valve and readiustthe idle speed
{page 11-l1l).
. lf the idle speed still cannot be adjustedto specification(and the MtL does not blink
code 14) sfter IAC valve
replacement,substitutea known-goodECM and recheck.ll symptom goes away, replscethe originalECM.

11-95

ldle Control System

TroubleshootingFlowchart - ldle Air Gontrol (lAC) Valve
-r---i
-tgll

- - -;lr
l_
I

The MaltunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 14: A problemin

the ldte Air controt {tAc) vatve circuit.

The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in
order to maintainthe proper idle speed.
TO INTAKE
MANIFOLD

VALVE

FROM AIR
CLEANER

SPRING

--t6t:Frl
---r-l-

- Tho MIL has boen r6portodon.

- With sgrvico check connoctor
jumped lsopago 1 1421, codo
l4 is indicatod.

Do the ECMResetProcedure(see
p a g e1 1 - 4 3 1 .

ls the MIL on and does it indicale code 14?

Remove the 2P connector ttom

the IAC valve.

With lhe engine running and the

accelerator pedal released, disconnect the 2P connector lrom
the IAC valve.

ls there a reduction
in enginerpm?

Substhute a known-good IAC

valve and retost.

( T op a g e1 1 9 7 )

11-96

Intormitlant lafluro, ay8tom is OK dt this timo

{to3t d.iving may bo
nocassa,yl.
Chock tor ooor connoction or looso wiros at
c+25, C433 (locarod at
right ahock towoil.
C106 llAC valvo) and
ECM.

(Frompage 1 1-96)

Measure voltage between the

YEL/BLKwire 8nd body ground.

Rop6iropen in YEL/BLKwiro botwoon ths IAC valvc.nd PGM-FI

main relay.
Turn the ignition switch ott and
reconnectthe 2P connectorto the
IAC valve.

Connect the test hamess "A"

connector to the main wire harness only. not the ECM lsee page
11 - 4 5 ) .

Turn the ignition switch ON.

Mofientarily connect Ag terminal

to A26 terminsl several times.

Doosthe IAC valve click?

Ropairopon or .hort in BLX/aLU

wirc b.tw.on IAC v.lvo and ECM
(A9l . It tho wlr. i! OK, r6pl.co th6
IAC valv6.

Subrtitut . known{ood ECM

.nd r.to.t. lt rymptom/ktdicrtkrn
gooa away, raplaca tho original
ECM.

ldle Control System

Troubleshooting Flowchart -

Air Conditioning Signal

This signalsthe ECM when there is a demandfor coolingfrom the ai. conditioningsystem.

Connectthe test hatnessbetween

the ECM and connectors.
Disconnect"B" connectorfrom
the main wire harness only, not
the ECM (seepage 11-45)

Turn lhe ignitionswitch ON.

A26 t-t
Measurevoltage between 85 (+)
terminaland A26 (-) terminal.

ls there approx. 5 V?

Substituto a knowngood ECM and ]e fieck.

It prssc bod voltago i3
now availablo, rapl6c6
th6 origln.l ECM.

Reconnect "8" connector to the

main wirc harness.

Momentarily connect A15 terminal to /q26 trminal several

times.
ls thsre a clicking nob ftom the
A/C comprc$or clulch?

Clicklng?

Connecrrho RED/BLU torminrl ot

ihe 4P conneclor on tho A,/C
clutch rolty to body g.ound.

Vigw from wire harness side

13thorc I clicking noiaetrom the

A/C comore6sor clutch ?

Ropairopen in RED/BLUwlr6 borwo.n ECM {A 15} rrd A/C drnc*l

relay.
{ T o p a g e1 1 - 9 9 }

11-98

S6a alr condltlonat inrpaetlon lrac toction

22t.

(Fromp8g6 1 1-98)

r-

Lo!! rhan 1.0 v? --------.1

es t*t

| ooooooo ooooo o looooc

looooooooooooQ I ooooc
r---------------A26 t_l
I

|
I

Measure voltage between 85 (+)

terminaland A26 {-) terminal.

ls voltagelessthan 1.O V?
Air conditioning iignal i3 OK.

Ropairopen in BLU/BLK
wiro botwoon ECM lB5l
and A/C awitch.

Substituto a known-good ECM

and rodrock. ll proscribod voltago
is .row availoblo, rsplacg tho original ECM.

11-99

ldle Control System

TroubleshootingFlowchart- Altelnator (ALT) FR Signal
This signalsthe ECM when the alternatoris charging.

Inspoction ol ALT FR sign.l.

Connectthe test harnessbetween

the ECM and connectors.
Oisconnect"D" connectorfrom
the main wire harnessonly, not
the ECM (see page 11-45).
4.5 V? Turn the ignirionswitch ON.

A26 t-l
Measure voltage between D9
(+) rerminal and 426 (-) termrnat,

ls thereapprox.4.5 V?

'l

li

Subltitut. a khown{ood ECM

and r..hock. lf pr.rcribed voltlgo
ir now availabl., rophce lh. ottginel ECM.

Turn the ignitionswrtchOFF.

"D"
Reconnect
connector to the
main wire harness.

Warm up engineto normaloPer

ating temperatu (the radiatortan
comes onl.

Vohfo

D 9l + l

ooooooooooo

Measure voltage between Dg

l+) terminal and A26 {-) terminal.

Does the vohage decreasewhen

heedlighls and rear dfogggr 8re
turnedon ?

Do the ECM ResetProcedure(see

p a g e11 - 4 3 ) .

ALT FR sign.l is OK.

(To page 'l 1-10'l)

ooooooooooo

Turn the ignition switch OFF.

(Frompage 1 1-1OO)
Disconnect"O" connectortrom
ECM only, not the main wire
harness.

NOTE: The radio may have a coded theft protection

circuit. Be sure you get the customer'scode number before disconnectingthe battery cable.

Disconnecl the negative banery

cable trom the battery.

Check tor continuity between D9

trmanaland body ground.

DisconnectGRNconnectorfrom
the ALT.

Check tor continuity between D9

trmin.l and body g.ound.

Check for continuity betwoon Dg

terminaland body ground.

Ropair3hon in WHT/REDwiro botwoon ECM (Dgl snd ALT.

Ropoi.opn in WHT/REDwiro b6twon ECM lDgl and ALT.

11 - 1 0 1

ldle Control System

TroubleshootingFlowchart - AutomaticTransaxle(A/Tl Geat Position-

Signal(A/T only)

This signalsthe ECM when the automatictransmissionis in @ or@] position.

Tum the ignition switch ON.

Observethe A/T gear position indicator and select gach Position

separately.

Ooesrhs indicatorlight ProPrlY?

S6e A/T goar position indicatoi inspecdon (soction 141.

Turn the ignitiongwitch OFF.

Connectthe test harnessbetween

the ECM and connectors.
"B" connector trom
Disconnect
the main wire hamess only, not
the ECM (see page 11-451

5V?

87(+)

Turn the ignitionswilch ON.

A26 (-l
Measure voltage between 87
{+} terminal and A26 (-} terminal.

ls there approx. 5 V?

Turn the ignition 3wilch OFF.

Reconnect"8" connectorto the

main wire harness.

(To page 1 1-1031

11-102

Subltituto a known-good ECM

and rech.ck. ll prsc.ibod voltago
b now avriloblo, taplaco the original ECM.

( F r o mp a g e1 ' l - 1 0 2 )
L6s8 than 1.O V7 --.-87 l+l

ooooooooooooo

oooooooooooo
A26 t-l
Measurevoltago botween 87 (+ )
terminal and A26 (-) tellninal
gith the trsnsmission in LNI and
lll position individually.

ls there lessthan 1.0 V?

Ropair opon in LT GBN wir. betwoon ECM lB7) .nd gaug6 aelombly.

12V7Measure voltage btween 87

{+l terminal and A26 (-) ter,
minal with the transmission in
gear.

ls ther approx. 12 V7

Ropalr rhort ir| LT GRN wir6 b.tw.cn ECM {87} and gaugo .rlombly.

A/T gear poritlon .lgn.l i. OK.

11-103

ldle Control System

Troubleshooting Flowchart -Starter

Switch Signal

This signalsthe ECM when the engineis cranking.

BATTERY

Connectthe test harnessbetween

the ECM and connectors {see
p a g e1 1 - 4 5 )

Measurevoltage between Bg (+)

terminal and ,426 (-) terminal
when the ignitionswitch in the
start posrton.

ls there battery vollage ?

ooooooooooooo
oooooooooooo
A26 (-t
NOTE:
a M/T: Cluich pedal must be
deoressed.
o Ait: Transmission in @] or @
posltlon.

SIGNAL
InsoectNo. 2 STARTER
(7.5 A) fus (in the undr-dash
fusefielavboxl.

Rap.i. opon In BLU/REDwlr. b.tw.sn ECM (B9l rnd t{o. 2

SIGNAL17.5Al lur!'
STARTER

Startr switch signol i3 OK.

ldle Control System

TroubleshootingFlowchart - Brake Switch Signal
This signalsthe ECM when the brake pedal is depressed.

Inspoclion ol Brak6 Srvhdi Signal.

Are the brake lights on without

depressingthe brake pedal?

Inapoct th6 br!k6 3wltch (!o aoction 19).

Oo the brake lighB come on7

InspectSTOPHORN('l5 A) luse
(in th under-hood Iuse/rel8y
boxl.

Connect the t6st harnoss to the

main wire harnssonlv, nottothe
ECM (see page 11-45).

( T op a g e1 1 - 1 0 7 1

- Roprir op.n In WHT^'EL wlrc

b.twoon bruks lwitch lnd
STOP HOR[{ 115 A} tu!o.
- Inrpgcl tho b'r6ko rwltch l!o.
lection l9l.

( F r o mp a g e 1 1 - 1 0 6 )

MeasurevoltagebetweenD2 (+)
lerminal and A26 (-) terminal
with the brake oedal deDressed.

ls there bane.y voltage t

BAI-TERY
VOLTAGE?

02 t+l

Roplir opon in GRII/WHT wlro betwoon th. brakq lwltch rnd ECM
{D2t.

Br.k. .wilch lional i. OK.

11-107

ldle Control System

I Troubleshooting
l ,uurEJl
l ! ! t l , r l I I l g Flowchart
flt.,Yvvrrql

Pressure(PSP)Switch Signal
rvYYtEI
Power
r
Steering

This signalsthe ECM when the power steeringload is high.

Inrp.clion ol PSP twltch Signal

ooooooooooooo
Connectthe tst harnes6between
the ECM and connectors (see
p a g e1 1 - 4 5 ) .

oooooooo

oooooooooooo oooQoooo

ooooooooooo
oooooooooo

Tu.n tho ignilion swilch ON.

Moasurevoltage btween 88 {+}

torminsland A26 (-l terminsl.
Disconnectthe 2P connectorfrom
the PSPswitch.
ls rhere more than 1.0 V?

Tum rtaaring whool slowly.

ls ther6 more than 1.0 V?

M66sure voltage betw66n BB (+)

t6rminal and A26 {-} torminsl
whilo stggring wheel is turning.

Repairopon in RED/GRNwir6 b6tw6on ECM (88) snd PSPswitch

or BLK wir. bolwog.i PSP.wilch
a n dG l O l .

ls there battery voltage?

PSP 3wirch slgnal i! OK.

Disconnectthe 2P conneclorfrom
the PSPswitch.

Measurevoltage between 88 {+ )
terminaland 426 l- l terminal.

ls there battery voltage?

Rooairshon in RED/GRNwilo botwoon ECM {88) and P1SP

switch.
lI wire is OK, substituto a knowngood ECM and rochock. lf
proscdbodvoltege ir now availabl6, roplace tho original ECM.

11-108

swtTcH

Fast ldle Thermo Valve

Description

lnspection

To preventerraticrunningwhen the engineis warming

up, it is necessaryto raisethe idls speed.The fast idle
thermo valve is controlledby a thermowax plunger.
When the engineis cold, the enginecoolant surrounding the thermowax contractsthe plungef,allowingadditionalair to be bypassedinto the intake manifoldso thst
the engineidlesfaster.When the enginereachesope.ating temperature,the valve closes.reducingthe amount
of air bypassinginto the manitold.

H23A1 engino(USA: Si/Canada:SR),

H22Al 6ngin (USA: Si VTEC/Canada:SR-V)
NOT: The fast idle thermo valve is factory adiusted;
it should not be disassembled.
1. Removethe intakeair duct from the throttle bodv.
2.

Stan the engine.

3.

Put your finger over the lower port in throttle body

and makesurethat there is air flow with the engine
cold {engine coolant temperature below 860F,

300c).

FAST
IDLE
THERMO
VAIVE
thermo valve and

12 .m
(1.2 kg-m, 9 lb-ttl

4.

Warm up the engine (the radiatorfan comes on).

Check that the valve is completelyclosed. lf not,
air suctioncan be telt at the lower gort in the throttle body.
a lf any suclion is felt, the valve is leaking.Check
enginecoolantlevelandforair in the enginecooling system (seesection 1O).
lf OK, reDlacethe tast idle thermo vslve and
recheck.

11-109

ldle Control System

Fast ldle Thermo Valve (cont'd)
F22A'l onginelS):
NOTE: The tast idle thermo valve is factory adjusted;
it should not be disassembled.
1.

Removethe cover of the fast idle thermo valve.

2.

Start the engine.

3.

Put your fingeron the valveseat areaand makesure

thst ther is 8ir flow with the enginecold {engine
coolanttemperaturebelow 86oF, 30oCl and idling.

Starting Air Valve

Description
Whencrankingthe engine,the startingair valvesuppliss
additionalair to the intake maniJoldto ease engine
starting.

DIAPHRAGM

iI
i

I
TO INTAKE
MANIFOLD
lf not, replacethe tast idle thermo valve and
retest.
't2 N.m
(1.2 ks-m.I lb-ttl

4.

radaatorfan
tan comes on).
Warm up the engine (the radiator

5.

Checkthat the valveis completelyclosed.lf not, air

suction can be {elt in the valve seat area.
a It any suction is felt, the valve is leaking.
Checkenginecoolantleveland for air in the engine coolingsystem (see section 'lO).
It OK, replacethe fast idle thermo valve and
recheck.

1 1 - 11 0

ADDITIONAL
AIR FROM
AIR CLEANER

ldle Speed Setting

lnspection/Adjustment
NOTE: (Canada)Pull the parkingbrake lever up.
Start the engine,then checkthat the headlightsare olf.
1.

Startthe engineand warm it up to normaloperating

temperature(the radiatorfan comes on).

2.

Turn the ignitionswitch OFF.

3.

Connecta tachometer.

4.

Disconnectthe 2P connectorfrom the ldle Air Con-

Adjust the idle speed, if necessary,by turning

the idle adjustingscrew.
IOLEADJUSTING
SCREW

7 . Turn the ignirionswitch OFF.

Reconnectthe 2P connectoron the IAC valve.then
removeCLOCKRADIO(1OA) Iuse in the under-hood
fuse/relaybox tor 1O secondsto reset the ECM.
Restartand idle the enginewith no-loadconditions
for one minute, then check the idle speed.
NOTE: {Canada)Pull the parking brake lever up.
Start the engine,the checkthat the headlightsare
off.
Start the enginewith the acceleratorpedalslightly
depressed.Stabilizethe rpm at 10O0,then slowly
releasethe pedal until the engineidles.
Checkidlingin no-loadconditions:headlights,
blower
fan, reardefogger,radiatorfan, and air conditioner
are not operating.

H23A1 engine (USA: Si/Canada:SRI:

A/T

H23A1 engine(USA: Si/Canada:SRI:

M/T

7OO 1 50 rpm
7OO I

50 rpm {in @ or @ position)

H22Al engine (USA: Si VTEG/Canada:

SR-V):

ldle speed should be;

M/T

ldle speed shoul.dbe;

55O t 50 rpm
55O + 50 rpm {in S

or @ position}

7OO 1 50 rpm
F22Al engine {S}:
Mfi
AlT

7O0 1 50 rpm
7OO t

50 rpm (in S

or @ position)

H22A1 engine {USA: Si VTEC/Canada:

SR-V):
55O 1 50 rpm
F22Al engine (Sl:
M/T

55O I

NT

50 rpm (in I

550 t

50 rpm
or @ position)

(cont'd)

11-111

ldle Control System

ldle Speed Setting (cont'dl
1O. ldle the enginefor one minute with headlights{Hi}
and rear defoggerON and check the idle speed,
ldl speod should be;
H23A1 engine {USA: Si/Canada:SR}:

M/T
A/T

78O t

50 rpm

78O 1 50 rpm {in S

or @ posirionl

H22A1 ongino (USA: Si VTEC/Canada:SR-V):

79O t 50 rpm
F22Al engine {S):
77O t

l\illT
Afi

50 rpm

770 I 50 rpm (in S or E position)

1 1 .Turn the headlightsand rear defoggeroff.

ldle the enginefor one minute with heatertan switch
at Hl and air conditioneron, then check the idle
speeo.
ldlo speod should be;
I
I

:
ri ,

H23Al engin (USA: Si/Canads:SRI:

M/T
NT

78O t 50 rpm

78O t 50 rpm (inI

or E position)

H22A1 engin (USA: Si VTEC/Canada:SR-VI:

79O 1 50 rpm
F22A1 engina (S):
M/T

NT

77O i

50 rpm

770 t 50 rpm lin S or @ Fosition)

NOTE: lf the idle speedis not within specification,

Guideon page 1'l-92.
see SystemTroubleshooting

11-112
t

FuelSupply System
System TroubleshootingGuide
NOTE; Across each row in the chart,the sub-systemsthat could be sourcesof a symptom are rankedin the orderthey
shouldbe inspectedstartingwith O. Findthe symptom in the left column,read acrossto the most likelysource,then
referto the page listedat the top of that column.It inspectionshows the systemis OK, try the next most likelysystem
!), etc.

PAGE

SU8-SYSTEM

------SYMPTOM

FUEL
FUEL
FUEI.
PRESSURE
INJECTOF
FILTER
REGULATOR
116

122

FUEL
PUI\4P

PGM-FI
MAIN
RELAY

123

124

126

ENGINEWON'T START

OIFFICULT
TO STARTENGINE
WHENCOLDORHOT

ROUGH
IDL
MISFIFEOR
ROUGH
RUNNING
FAILS
POOR
PERFORMANCE EMTSStON

Loss0F
POWER

FREOUNT
STALLING

WHILE
WARMING
UP
AFTEF
WARMING
UP

coNTAtrl
NATED
FUEL

o
e

Fuel with din, water or a high percentageof atcoholis consideredcontaminated.

11-113

Fuel Supply System

System Description
The tuel supplysystem consistsof a Jueltank, in-tank
high pressurefuel pump, PGM-Flmain relay,fuel filter,
fuel pressureregulator,fuel injectors,injectorresistor,
and Juel deliveryand return pipes and hoses.
fuel to the fuel
This systemdeliverspressure-regulated
iniectorsand cuts the fuel deliverywhen the engineis
not running.

FuelPressure
Relieving

@
a

Do not smoke while working on the fu6l systm.

Keep open llames or sparks away ftom your work
alea.
a Be sure to relieveluel pressulewhile the ngins is off.

NOTE: Beforedisconnectingluel pipes or hoses,release

pressurefrom the system by looseningthe 6 mm service bolt on top of the fuel rail.
1.

Disconnectthe batterynegativecablefrom the battery negativeterminal.

NOTE: The radiomay havea codedthett protection
circuit. Be sure you get the customer'scode number before disconnectingthe battery cable.

2.

Removethe fuel fill caD.

3.

Use a box end wrench on the 6 mm servicebolt at

the fuel rail,while holdingthe specialbanjobolt with
anotherwrench.

4.

Placea rag or shop towel over the 6 mm servicebolt.

5.

Slowly loosenthe 6 mm servicebolt one complete

turn.
12 N.m {1.2 kg-m, 9 lb-ft)

NOTE:
a A fuel pressuregaugecan be attachedat the 6
mm servicebolt hole.
a Always replacethe washerbetweenthe service
bolt and the specialbanjobolt, wheneverthe service bolt is loosened.
a Replace all washers whenever the bolts are
removed.

11-114

Inspection
1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e 1 1 - 1 1 4 1 .

a lf the fuel pressureis not as specified.first checkthe

fuel pump(seepage1 1-125).lf the pumpis OK, check
the following:

2.

Removethe servicebolt on the fuel rail while holding the banjobolt with anotherwrench. Attach the
tuel pressuregauge.

3.

Start the engine. *Measurethe fuel pressurewith

the engineidlingand vacuumhose ot the fuel pressure regulatordisconnectedfrom the fuel pressure
regulatorand pinched.

lf the fuel pressureis higherthan specified.inspect

loti
a Pinchedor cloggedJuel return hose or pipe.
a Faultyfuel pressureregulstor{seepage 11-1221,
lf the fuel pressureis lower than specifiedinspect,
for:
a Cloggedfuel filter.
a Faultyfuel pressureregulator{seep age 11-1221,
a Leakagein the tuel pipes or hoses.

Plessur should be;

H23A1 ongine (USA: Si/Canada:SR),
F22Al engine (S):
2 5 5 - 3 O 5 k P a( 2 . 5 5 - 3 . O 5 k g / c m 2 , 3 6 - 4 3 p s i )
H22A1 engine (USA: Si VTEC/Canada:
SR_V):
23O-2AO kPa 12.3-2.8 kg/cmr. 33-4O psi)
4.

Reconnect vacuum hose to the fuel Dressure

regulator.
Prssureshould b:
H23Al engine (USA: Si/Canada:SR).
F22A1 ongine (S):
195-245 kPa (1.95-2.45 kg/cm2,28-35

psi)

H22A1 engine (USA: Si VTEC/Canada:SR-V):

17O-22O kPs 11.7-2.2 kg/cmr. 24-31 psi)

PRESSURE
REGULATOR
': lf the enginewill not stan, turn the ignitionswitch
on, wait for two seconds,turn it otf then back
on again and read the iuel pressure.

11-115

Fuel Supply System

Fuel lnjectors
TroubleshootingFlowchart
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroublecode (DTc) 16: A problemin
the Fuel Injectorcircuit.
The Fuel Iniectors are a solenoid-actuatedconstant-stroke pintle type consisting ol a solenoid, plunger needle valve and
tuel is injected.Becausethe neehousing.When currentis appliedto the solenoidcoil, the valve lifts up and pressurized
the lengthof time that the valvo
quantity
by
pressure
is
determined
injection
are constant,the
dle valve liJtand the fuel
is open (i.e.,the durationthe current is suppliedto the solenoidcoil).The FuelIniectoris sealedby an O-ting and seal
ring at the top and bottom. These sealsalso reduceoperatingnoise.

SEAL
BII{G

PLUNGER

- __l=-

\.__.,:_

FUEL
INJECTOR
INSULATOR

-tFJ- ;ull:
- Th6 MIL has boonrooortodon.
- With sorvice chock conncctor
{s6pago 11421, codo
iumpod
'l6 is indicatod.

Do the ECM ResetProcedure(see

p a g e1 1 - 4 3 ) .

NOTE:lf enginewill not start, it may take

10 secondsof crankingto set the code.

ls the MIL on and does it indi

cate code 16?

Into.mittent lailuro, 3yst6m ir OK

at this tim (to3t drivo moy bs
nocossary).
Chock fo. Door connoctiona ot
looso wires at C433, C425 llocatod ar right shock towotl, C1O2,
ClO3, ClO4, C1O5 (tuel ini.ctoBl, Cl07 {iniocto. risto.), and
ECM.

(To page '1'1-1171

11-116
r

2P CONNECTOR
Starl engingand lislenai 6ach luel
injectorror a clickingsound.

Turn the ignitionswitch OFF.

Disconnectthe 2P connectorfrom
the fuel injector that dogs not
click.

Measure rgsistancebetween the

2 terminals of luol injector.

l s t h e r e1 . 5 - 2 . 5 O ?

Ropl.c. th6 tu.l inictor/inioctor!

thlt aro not 1.5-2.5 O.

FUEL
IITJECTOB

Turn the ignition switch ON.

MeasurovoltaoebetweenREO/
8LK { + } terminalin rhe 2P conngctorand body ground.

Tu.n tho ignition switch OFF.

Turn the ignitionswitch ON.

Measure voltsge between YEL/

BLK {+) terminal and body
ground.

(To page 1 1-118)

{To page 1 1-l 18)

11-117

Fuel Supply System

Fuel Injectors(cont'dl
{Frompage 1 1-'l17}

( F r o mp a g e 1 1 - 11 7 )
Rgpair op6n in tho
YEL/BLKwire botws6n
the inioctor resistot and
tho PGM-FImain ,olaY.
Testthe injectorresistor(seepage
11-1211.

Reconnect the 2P connector to

the tuel iniector.

Turn the ignitionswitch OFF.

Bpair op6n RED/BLK wiro botwen lhe 2P connocto. end inioctor roaistor.

Connectthe test harnessbetwoen

the ECM and connectors (see
p a g e1 1 - 4 5 ) .

Turn the ignitionswitch ON.

Measure voltage between A23

{-) terminal and following
termrnal:
. No. 1 tuel iniector:
A1 {+) terminal.
. No. 2 fuel iniector:
A3 (t)terminal.
. No. 3 fuel injector:
A5 {+ | terminal.
. No. 4 tuel injector:
42 {+) terminal.

13. rott.*t

$Li6iiitl'--

A 1 { + } lA 5 l + )

oooooooooo

oooooooo

oooooooooooo oooooooo

ls there battery voltage?

Substilute a known-good ECM

and rechock. ll symptom/indication goos away, roplacetho origi
nal ECM.

11-118

Ropairop6n in tha wire batwoon

the ECM(A1, A3, A5 or A2) and
tho luol inioctor.

ooo ooo ooooo

ooooooooooo

Replacoment
@@
l

oo not smoke when working on tha fuel system. Keep open llam6s away from your wolk a.sa,

Relievefuel pressure(see page 11-114).

2 . Disconnectthe connectorsfrom the fuel injectorsand IAC valve.

Disconnectthe vacuumhose trom the fuel pressureregulatorand EGRvalve,and the luel returnhosefrom the fuel
pressureregulator.
NOTE: Placea rag or shop towel over the hoses before disconnectingthem.
4.

Disconnectthe tuel hose from the fuel rail.

5.

Loosenthe retainernuts on the fuel rail and harnessholder.

6.

Disconnectthe PCV valve and fuel rail.

7.

Removethe fuel injectorstrom the intake manifold.

SEALING
WASHER
Replsc6.

00
00

CUSHION
RING
Replace.

8.

Slidenew cushionrings onto the fuel injectors.

9.

Coat new O-ringswith clean engineoil and put them on the fuel injectors.

1O. Insertthe fuel iniectorsinto the fuel rail first.

'I

1. Coat new seal rings with clean engineoil and press them into the intake maniforo.

(cont'd)

11-119

Fuel Supply System

Fuel Injectors lcont'dl
12. lnstallthe tuel injectorsand fuel rail assemblyin the manifold'
CAUTION:
a To prevent damag to ths O{ings, install the lul inioctors In th fuol rall first. then inslall thm in tho intaks manifold.

FUEL RAIL

13. Align the center line on the connectorwith the mark on the Juel rail.
'14, Install
and tighten the retainernuts.
15. Connectthe Juel hose to the fuel rail with new washers.
16. Connectthe vacuumhoseto the tuel pressureregulatorand EGRvalve,and the fuel returnhoseto the tuel pressure
regulator.
17. Installthe connectorson the fuel injectorsand IAC valve.
18. Replacethe 6 mm servicebolt washer and tighten the bolt.
two seconds,
19. Turnthe ignitionswitch ON. but do not operatethe starter.After the fuel pump runsfor approximately
the luel pressurein the fuel line rises.Repeatthis two or three times, then check whetherthere is any tuel leakage.

11-120

InjectorResistor
Description
The resistorlowersthe currentsuppliedto the fuel
injectorsto preventdamageto the fuel injectorcoils.
This allows a faster responsetime of the fuel inrectors,

Testing
1.

Disconnectthe injectorresistorconnector.

2.

Check for resistance between each of the inisctor

resistorterminals{E, D, C 8nd B) and the power trminal (A).
Resistanceshould be: 5-7 O

LLLLL

FUEL
a Replacethe injectorresistorwith a new one if any
of the resistancesare outsideof the sDecification.

11-121

Fuel Supply System

Fuel PressureRegulatol
Testing

Description
The fuel pressureregulatormaintainsa constant fuel
pressureto the fuel injectors.When the differencebetween the luel pressureand manifoldpressureexceeds
300 kpa (3.0 kg/cm' , 43 psi), the diaphragmis pushed
uDward,and the excessfuel is fed back into the fuel tank
through the return line.
CLOSE

Do not smokdurlngtho test. Kap

Iry
opan flamesaway lrom your work area.
1 . Attach a fuel pressuregaugeto the serviceport of

t h e f u e l r a i l ( s e ep a g e 1 1 - 1 1 5 ) .
Pressurs should be;
H23A1 engino (USA: Si/Canada:SR),
F22A1 engino (S):
255-3O5 kPa (2.55-3.05 kg/cm2,36-43 psi)

INTAKEMANIFOLD
VACUUM

H22Al engino (USA: Si WEC/Canada:SR-VI:

23o-2ao kPa (2.3-2.8 kg/cm2.33-4o psil
{with the fu6l pressuro logulator vacuum hose disconnectod and pinchedl

INTAKE MANIFOLD
VACUUM

DIAPHRAGM

REGULATOR
PRESSURE

ar
t FUEL
\INLET

2.

Reconnectthe vacuum hose to the fuel ptessure

regulator.

3.

Check that the fuel Dressurerises when the vacuum hose from the tuel pressureregulatoris disconnected again.
lf the fuel pressuredid not rise, replacethe fuel pressure regulalor.

FUELRETURN

11-122

Fuel Filter
Replacement
E@

Replacement

oo not smok6whilewolkingon fuelsys-

tm. Keep open flame arvay from yout work area.

1. Placea shop towel unde. the tuel pressureregulator, then relievefuel pressure(see page 1l-114).

2.

Disconnectthe vacuum hose and fuel returnhose.

3.

Removethe two 6 mm mounting bolts.

VACUUM HOSE

O,RING
Replace

oo not amoko whib working on fuol sys@

tem. Kesp open flame away ftom yout wolk atea.
The fuel filter should be replacedevery 4 yea.s or 60.OOO
miles(96,000 kml, whichevercomesfirst or whenever
the fuel pressuredrops below the specifiedvalue IH23A1
e n g i n e ,F 2 2 4 1 e n g i n e :2 5 5 - 3 O 5 k P a , 2 . S 5 - 3 . 0 s
kg/cm' , 36-43 psi (H22A1 engine: 23O-280 kpa,
2.3-2.8 kg/cm2,33-40 psi) with the fuel pressure
regulato.vacuumhosedisconnectedand pinchedlafter
making sure that the fuel pump and the fuel pressure
regulatorare OK.
1.

Placea shop towel under and aroundthe fuel rail.

2,

R e l i e v ef u e l p r e s s u r e( s e ep a g e 1 1 - 1 ' 1 4 ) .

3.

Removethe 12 mm banjobolt and the fuel feed pipe

trom the fuel filter.

4.

Removethe fuel Jilterclamp and fuel filter.

5.

When assembling,use new washers,as shown.

28 N.m (2.8 ks-m,20 lb-ft)

FUEL
PRESSURE
REGULATOR

NOTE:
a Replacethe O-ring.
a Whenassemblingthe fuel pressureregulator,apply clean engineoil to the O-ringand assemble
it into its proper position, taking care not to
damagethe O-ring.

NOTE; Cleanthe flaredjoint of high pressurehoses

thoroughlybefore reconnectingthem.

11-123

Fuel Supply System

Fuel Pump
Description

Becauseof its compactimpellerdesign,the iuel pump is installedinsidethe tuel tank. therebYsavingspaceand simplifying the fuel line system.

FUEL pUMp CROSS SECTION(ToD viowl

FUEL PUMP CROSS SECTION(Side vtew)

rFrrFFVALVE
var vF
RELIEF

DISCHARGEPORT

FUEL
PUMPCOVER

rNrETPOBr

IMPEI.LER

CASING

GROOVES

CHECKVALVE
ARMATUBECOIL

FUEL PUWIPCASING

IMPELLER

protectingthe fuel linesystems,

The fuel pumpis comprisedof a DC motor, a circumterenceflow pump,a telietvalvetor
port. The fuel pump assemblyconsistsof
port,
discharge
and
a
pressure,
inlet
an
residual
retaining
for
valve
check
a
pumpingchamber),and the fuel pump cove,.
the imoeller(drivenby the motorl, the fuel pump casing{which forms the
OPERATION
"o PGM-FImain telaY
relav actuates
actrratesthe fuel pump' and the motor turns tlle impeller'
(1) When the engineis stsrted, the
Differentialpressureis generatedby the numerousgroovesaroundthe impeller'
(2) Fuetenteringthe inlet port flows insidethe motor from the pumpingchambefand is torced throlgh the dischargo
valve will open
oort via the check valve. lf fuel Jlow is obstructedat the dischargesside of the fuel line, the relief
pressure'
fuel
prevent
port
excessive
and
inlet
fuel
to
the
the
to bypass
(3) Whe; the enginestops,the fueipump stops automatically.However,a checkvalveclosesby springactionto retain
the residualpressurein the line. helpingthe engineto restart more easily'

11-124

Testing

Replacement

Do not smokeduringthe test. Kepopon

E@E
flame away from your work area,

@@l

lf you suspecta problemwith the fuel pump,checkthat

the tuel pump actuallyruns;when it is ON, you will hear
somenoiseif you holdyour ea. nearthe tuel till port with
the fuel fill cap removed.The fuel pump shouldrun for
two secondswhen the ignitionswitch is first turnedon.
lf there is no noiseat the fuel fill port, check as follows;

1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e 1 1 - 1 1 4 ) .

Donot smokewhilowolkingon fuetsys-

tam. Kep open flsmes away ttom yout wotk area.

2.

Removethe accesspanel in t.unk.

3.

Disconnectthe 2P connectorJrom the tuel pump.

4.

Removethe fuel pump mountingnuts.

5.

Removethe tuel pump from the fuel tank.

1. Removethe accessDanelin trunK,

CAUTION: B sure to turn tha ignition switch OFF
betore disconnecting tho wiles.
2.

Disconnectthe 2P connector-

Disconnectthe PGM-Ftmain relay conneclor and

connect the BLK/YEL@ wire and yEL @ wirc with
a jumper wire.

\<
\ ..-\

6 N.m
(O.6 kg-m,
4 tb-ftl

FUELPUMPUNIT

pcm-H
MA|N

I
28 N.m (2.8 kg-m,
20 tb-ftI

BLK/
YELG)

JUMPER
'WIRE

YEL)

Check that battery voltage is availableat the fuel

pump connectorwhen the ignitionswitch is turned
ON (positiveprobeto the yEL wire, negativeprobe
to the BLK wire).

Y E L{ + }
lf battery voltage is available,replacethe fuel
DUMO.

lf there is no voltage, check the fuel pump grouno

and wire harness(see page 1j- 128).

11-125

Fuel Supply System

PGM-FIMain Relay
Relay Testing

Descdption
The PGM-Flmain relayactuallycontainstwo individual
retavs.
The relay is located at the left side of the cowl.
One relayis energizedwheneverthe ignitionis on which
supplies the battery voltage to the ECM, power to the
fuel injectors,and power for the secondrelay.
The second rlay is energizedlor 2 seconds when the
ignitionis switched on, and when the engineis running
which suppliespowet to the fuel pump.

NOTE: lf the car starts and continues to run, the

PGM-FImain relay is OK
1.

Removethe PGM-Flmain relay.

2.

Attach the b8ttery positivete.minalto the No' 6 terminal and the batt8ry negativeterminalto the No.
I terminalof ths PGM-Flmain relay.Then checktot
continuity between the No. 5 terminal 8nd No' 7 tetminal of the PGM-FImain rlaY.
a It there is continuity.go on to step 3.
a ll there is no continuity, replacethe relay and

FGM.FI
MAIN RELAY

TO IGN.1

TO GROUND

TO 8AT C)

to EcM (A25,Btl

TO ST. SWTTCH

TO ECM{A7, 8}
3.

TO FUELPUMP

Attach the battery positive terminal to the No' 5 tsrminal and the battery negative terminal to the No.
2 terminslof the PGM-Flmain relav.Then check that
there is continuitybetweenthe No. 1 terminal8nd
No. 3 terminalot the PGM-FImain relay.
a lf there is continuity, go on to step 4.
a lf there is no continuity, replacethe relay and
relesl.

4.

Aftach the baftery positive terminal to the No. 3 terminal and the batterY negative terminsl to the No.
8 terminalof the PGM-Flmain relav. Then check that
there is continuitv between the No. 5 terminsl and
No. 7 terminalof the PGM-Flmain relay'
a lf there is continuity,the relay is OK.
a lf there is no continuity, replacethe relay and
retesl
(cont'dl

11-126
!

FuelSupplySystem
PGM-FlMain Relay(cont'd
TroubleshootingFlowchart
- Engino will not 3tan.
- InlDcction ot PGM-FI
rclay.

Check for continuitY between

BLK terminal @ and bodY
ground.
Ropairopon in 8LK wirc b6tw.en
PGM-FImain relay and GlOl {locatod at th6amostot housing).

Measure the voltage between

YEL/BLU terminal O and bodv
gtouno.

ls there battery voltage?

- Roplace tho No. 4 BACK UP

{10 Al tu36 {in tho undordash
fu3o/rolay borl.
- Ropoir op6n in rho YEL/BLU
wire btweon tho NiM-Fl rnain
relay and ths No. 4 BACK uP
{10 Al lu8o.

Turn the ignitionswitch ON.

PGM-FI
MAIN
RELAY

Measure the voltago between

BLK/YEL terminal @ and body
glouno,

ls there battery voltage?

Turn the ignition swilch to the

START position.

Measure the voltage betwen

BLU/REDterrninal@ and body
ground.

ls there baltery voltage?

- Roolacoth. ECUIECMI {15 A}

tuis {in tho und6r{eh tut /rolay boxl.
- R6pai opgn In tho BLK/YEK
wiro btween d|o FGM-FI tnein
r6laYand tho Ecu (ECM) {15
Al fu3e.

NOTE:
. M/T: Clutch pedal must
be depressed.
a A/T: transmissionin I n I
or [E position.

- Replaco lhc No. 2 STARTER

SIGNAL {7.5 A} furo lin tho
undor-dashf uso/ralay borl.
- B.p.ir op.n in tho BLU/RED
wiro b.twoon th6 FGM-FI rtain
r6lay .nd lh. ignition twitch

(sr).

( T op s g e I ' l - 1 2 9 )

11-128

BLK @

BLK)

YEL)

11.12Al
Turn the ignitionswitch OFF.

Connectthe test harnessbetwgen

the ECM and connectors.
Disconnoct "A" connector from
the ECMonlv, not the main wire
harness(see page 11-451.

Check tor continuity between

GRN/BLK terminal @ and rhe
followingterminals;A7. A8.

R6palropen in GRN/BLKwlr. btwoon ECM lA7, A8l and PGM-FI

main rohy.

Turn the ignitionswirch ON.

Measure the voltage between

423 1-) terminaland the tollowing terminals:A25 (+) 81 lf).

ls there battery vokage?

R.pair opon in tho YEL/BLKO

rvi 6 botwoon th. ECM (A25,
811 lnd PGM-FIh.in iohy.
R.pl.c. PGM-FImain r6lay.

Turn lhe ignilion switch OFF.

o o o o o o o o o o o o o o ooooooo lfitoHruffs{sl
ooo ooo ooooo
o oooo ooooo ooo I oo oooo oo
ooooooooooo
Connect a voltmeter between A7
l+l te.minal and A23 l-) rer
mtnat.

ls there battry voltage tor lwo

seconds when the ignition
switch is first tu.ned on?

Subrtltulc 6 known-good ECM

and raatrock. ll p.eacriH voltago
b now svail.Hg, rgf aco tho original ECM.

Chock th. PGM-FI mlin r.l6y (.eo

pag. l1-126).

1 - 129

FuelSupplySystem

Ir

FuelTank
Replacement
@
1.
2.
3.
4.

Do not smoke while working on fuel systm. Keep open llame away from your work area.

Block front wheels. Jack up the rear of the car and supportwith jackstands.
Removethe drain bolt and drain the fuel into an aoorovedcontainer,
Removethe accesspanel.
Disconnectthe connectorsfrom the fuel gaugesendingunit and the fuel pump,then removethe fuel feed line and
return hose.
CAUTION: Be sur to turn the ignition switch OFF before disconnecting the wires.

5. Removethe fuel hose protectors.

6. Oisconnectthe hoses.
CAUTION: Whon disconnocting the hos6s. slide back ths clamps, then twist hosos as you pull to avoid damaglng
them.
7. Placea iack, or other support,underthe tank.
8. Removethe strap bolts and nuts. and let the strapsfall free.
9. Removethe fuel tank,
NOTE: The tank may stick on the undercoatappliedto its mount. To remove,caretullypry it off the mount.
1O. lnstalla new washer on the drain bolt and the fuel pump line, thn installpans in the reverseorderol removal.

38 N m 13.8ks-m.28 lb-ft|
CAUTION: Cloanthe flared ioint of high prossu.oho8e3
thloughly botoro .oconnecting thom.

FUEL PUMP
GAUGE
SENOINGUNIT
FUELTANK
WASHER
Rplace
DRAII{ BOLT
50 N.m (5.o kg-m, 36 lb-tt)

3a N.m (3.8 ks-m. 28 lb-ft|

11-130

Intake Air System

System TroubleshootingGuide
NOTE: Acrosseach row in the chan, the sub-systemsthat could be sourcesof a symptomare rankedin the orderthev
shouldbe inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likelysource,then
refer to the page listed at the top of the column. lf inspectionshows the system is OK, try the next system @, etc.

SYMPTOM
WHEN COLD FAST IDLEOUT OF SPEC
W H E NW A R M I D L ET O O H I G H
LOSSOF POWER
*: Except F224 1-engine{S)

11-131

Intake Air System

System Description
The systemsuppliesair lor all engineneeds.lt consistsof the Air Cleaner(ACL).intakeair pipe, intakeair duct, Throttle
*intakecontrol
Bodv {TB},ldle Air Control(lAC)Valve,tast idlethermo valve, *lntake Air Bypass(lAB)ControlSystem,
system,and intakemanifold.A resonatorin the intakeair pipeprovidesadditionalsilencingas air is drawn intothe system.
*: Except F22A1 engine (S)

.IAB
CONTROL
SOLENOID
VALVE

.tA8
VACUUM
TANK

?!t'----_'o

ECU|ECM){'r5 A' FUSE

Xll'----'oPGM.FIMAINRELAY
VARIOUS
SENSORS
INTAKEAIR DUCT

r|AB CONTROL
DIAPHRAGM

BODY
:II{TAKE
CONTROL
SOLENOID
VALVE

.If{TAKE
CONTROL
CHECK
VALVE

-1 32

SLK/
YEL
WHT

FAST
IOLE
THERMO
VALVE

.- TO ECU{ECM}(15 AI
FUSE
RESOI{ATOR

INTAKE
AIR
PIPE

Air Cleaner{ACL}
Air Cl6anel (ACL) Element Raplacemont

ACL HOUSINGCOVER

ACL HOUSING

ACL ELMENT
Roplacvery 3O,OOOmiles (48,OO0 kml
or 24 months.
'l5.OOO
Cleanair cleanerelementeverv
(24,OOO
mil6s
kml or 12 months under
conditions, rough or muddv roads.

INTAKE AIR DUCT

11-133

Intake Air System

Intake Control System [Except F22A1 engine (S)l
Description
The intake control svstem decreasesair intake noise.

INTAKE CONTROISOLENOIDVALVE

BLK/ ------? - TO ECU (ECMIll5 Al

FusE
YEL

II{TAKE CONTROL

VACUUMT
INTAKE CONTROL
CHECKVALVE

BLK

I
=

RESONATOR

When the engine speed is below 4,OO0rpm, the ECM provides ground for the intako control solenoid valv6. This opens
the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.

11-134

Troubleshooting Flowchart

VACUUMPUMP/GAUGE
A973X-O41-XXXXX

AKE
CONTROL
SoLENOTO
VALVE

St.n onginernd allow to idle.

Remove the #8 vacuum hos6

from the hose joint and connect
a vacuum gaug to the solenoid

Oisconnect lhe lower vacuum

hosofthe solonoidvalv6from the
air chamb6r and connecl a vacuum gau96 to th hos6.
Chcck tho v.cuum
lina tor profEr conn6ctlon, crack!,
blockrg! or dtr;onn*tod ho!o.
Closn manltold m.t.
Disconnect th 2P connector
from the intake control solehoid

Measurs votiag botwson BLK/

YEL (+ l terminaland WHT (- )
tornanal.

INTAKE
CONTROL
SOLENOID
VALVE

ls there battery vollag?

R.pl.co th. Intlko

control aobndd volve.

Measure voltage betwen BLK/

YEL {+l torminal and body
ground.

{To page 11-136)

(To page 1 1-136)

(cont'dl

11-135

Intake Air System

Intake Control System lExcept F22A1 engine (S)l {cont'd}
{ F r o mp a g o1 1 - 1 3 5 }

lFrom psge 1 1 - 1 3 5 )

ls there battery voltage?

Ropairopoo in BLK|/EL
wi.o botwoon tho 2P
connoctor and ECU
(ECMI (15 Al tuso lin
tho undo.-dsshfus/r6l6y box).

Turn the ignirionswitch OFF.

Connectthe test harnessbetween

the ECM and connectors (see
page 1 1-45).
Turn the ionition switch ON.
Connect a jumper wire between
A19 terminaland A26 terminal.

Ropair opon in WHT

wiro betwoon ECM
lA19) and tho 2P connectot.

Substituto s known-good ECM

and .ochock. lf symptom/indication goos away, replgceth6 odginal ECM.

Turn the ignilion swilch OFF.

Check for continuity to ground

(To pago 1 1 - ' t 3 7 )

{ T o p a g e1 1 ' 1 3 7 )

11-136

(Frompage 11-136)

lFrom psge 1 1-136)

R6pai. ahort lo ground

in WHT wira b6twen
ECM {A19).nd rhe 2P
connoctot.

Subltitute a known-good ECM

and rechock. lf symptom goaa
away, .oplaco tho originsl ECM.

Connect a vacuum pump to the

#8 vacuum hose.

Does it hold vacuumT

Chack dr vecuum line for propor

connaction oa diaconnected
noaa.
lf OK. '.plac6 tho inllk. control
dl.phrlgm.

l aha contol ayatam b OK,

11-137

Intake Air System

Throttle Cable
Inspection/Adjustment

lnstallation

1. Warm up the engineto normaloperatingtemperature (the radiatorfan comes on).

1.

Fully open the throttle valve,then installthe throttle cablein the throttle linkageand installthe cable
housingin the cable bracket.

2.

Warm up the engine10 normaloperatinqtemprature (the radiatortan comes on).

Hold the cable sheath. removingall slack from the

cable.

2.

3.

Check that the throttle cable operates smoothly

with no bindingor sticking.Repairas necessary.
Checkcablefree play at the throttle linkage.Cable
d e f l e c t i o ns h o u l db e 1 O - 1 2 m m ( O . 3 9 - 0 . 4 7 i n . )

DEFLECTION
10- 12 mm
1O.39-O.47 in.)

It deflectionis not within specs,loosenthe locknut.

turn the adjustingnut untilthe deflectionis as specified, then retightenthe locknut,
5 . With the cableproperlyadjusted,checkthe throttle
valve to be sure it opens fully when you push the
acceleratorDedalto the tloor. Also checkthe throttle valve to be sure it returnsto the idle position
wheneveryou releasethe acceleratorpedal.

38

Turnthe adiustingnut untilit is 3 mm (0.12 in.)away

from the cable bracket.
Tightenthe locknut. The csbledetlectionshouldnow
b e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . ) .l f n o t ,s e ei n s p e c tion/adjustment.
CABLE
ARACKET

Throttle Body
Description

Inspection

The throttls body is ot the single-barrel

side-dratttype.
The lower portion oJ the throttle valve is heated by engine coolant which is fed from the cylinder head.The idle
bypass 8ir
adjustingscrew which increases/decreases
and the EvaDorativeEmission{EVAP)ControlCsnister
port are locatedon the top ot the throttle body.

CAUTION: Do not adiust the throttls stop screw,

It i3 presot at tho tactory.
1. Stan the engineand allow it to reachnormaloper
ating temperature(the radiatorfan comes on).
2.

IDLEADJUSTING
SCREW

ontrol
Disconnectthe vacuum hose (to the EVAP' ccontro
canister)trom the top of the throttle body; connect
connec
I vacuum gaugeto the throttle body.

VACUUMPUMP/GAUGE
A973X-04t -XXXXX

3 . Allow the engineto idle and check that the gauge

indicatesno vacuum.
a lf there is vacuum,check the throttle cable (see
p a g e11 - 1 3 8 ) .
4.

Checkthat vacuumis indicatedon the gaugewhen

the throttle is opnedslightlyfrom idle.
a lf the gauge indicates no vacuum, check the
throttle body port. ll the throttle body port is
clogged,cloan it with carburetorcleaner.
Stop the engine and check that the throttle cable
operatessmoothly without bindingor sticking.
a It there are any abnormalities
in the abovesteps,
check for:
- Excessivewear or play in the throttle valve
sh8tt.
- Sticky or binding throttle lever at full close
position.
- Clearance between throttle stop screw and
throttle levr at full close oosition,

11 - 1 3 9

Intake Air System

Throttle Body (cont'd)
THROTTLELEVER

There should be
no clearance.

THROTTLE
STOPSCREW
(Non-adiustable)

Replacethe throttlebody if there is excessiveplay in the

throttle valve shatt or if the shatt is bindingor sticking.

11-140

Throttle Body
Disassembly

GASKET
Rgplaco

THROTTLECABLE

(2.2 kg-m, 16 lb-ft}

A/T THROTTLE
CONTROL
CABLE

11-141

r
Intake Air System
Throttle Body (cont'd)
a The throttle stop scrw is non-adiustable,
a Aftd rrllrombly. adiust tho throftle cabl {seo pag6 'l 1-138}. and A/T throttlo control cable (s66 section 141tor cars l
whh A/T.
F22A1 angine (S):

IDLEADJUSTING
SCREW

H23Al ngino (USAr Si/Can8d8:SR),

H22Al engine (USA: Si VTEC/Csnada:SR-VI:

FAST
IDLETHEBMOVAVLE
pago1'l-110
Inspection,

('1.2kg-m, 9 lb-lt)

11-142

lntake Air Bypass (lABl Control System fExcept F22A1 engi,ne(Sll

Description
Two air intake paths are providedin the intake manifoldto allow the selectionof the intake path most tavorablefor a
given enginespeed.
Optimum perlormance at any RPM is achieved by c\osing and opening the \ntake Air ByDass(tA,Bl\ratves. High torque
at low RPM is acheivedwhen the IAB valves are closed, whereashigh powe, at high RPM is achievedwhn the IAB
valves are ooened.

tA8
CHECK
VALVE

IAB CONTROL
DIAPHRAGM

9i['-_------->
I$.i"u

tA8
CONTROL
SOLENOID
VALVE

(15A]
tEcM]

IAB VACUUMTANK
VARIOUS
SENSORS

IAB CONTROLSOLENOIDVALVE OFF

ET{GINERPM IS ABOVE
4,800 rpm (H23A1 onginel
or 4,600 .pm (ll22Al nginol

(cont'd)

11-143

IntakeAir System
lntakeAir Bypass(lABlGontrolSystem[ExceptF2241engine{S}](cont'd)Troubleshooting Flowchart

#13 VACUUM
HOSE

COI{TROLDIAP}IRAGM

In.poction ot IAB Control Sy.t.m

Stan ongino lnd allow to idl.

'l3

Remove #
vacuum hose trom
the lAg control diaphragm hd
connecl vacuum gauge to th6
nose,

/f

VACUUM
PUMP/GAUGE
A973X-O4t-XXXXX

Disconnectthe 2P connectorfrom
the IAB control solnoid valve.

Measure voltagg between BLK/

YEL (+) terminaland PNK (-)
terminal.

IAB COI{TROL
SoLENO|O
VATVE

'
t
I

II
II
I
I

Pl{K

ls tho.o banory vohrgo ?

Rcp.lr th. block.g. or

vlcuu|n lark bltwaan
lh. intlk m.ntlold .nd
d!ph.!gm, it vrqrxn l!
OK, r.pl.c. the IAB
contrcl lolcnold vllva.

Matturu voh.ge btwen BLK/

YEL (+) t.rmin.l and bodv
gaouno,

13there bancry vohage ?

Turn the nrtion swilch OFF.

(To page 1 1-145)

11-144

(To page 1 'l-145)

R.p.lr op.r| in BLK|rEL

wlre bctwaon th! 2P
connaclor lnd ECU
IECMI (15 Al tur. {ln
tha undardrah lura/.chy boxl.

(Frompage 1 1-1441

{Ffom page 1 1-144)

Reconnect the 2P connector to

the IAB control solenoid valve.

Connect the tost harness to the

mainwire harnessonly {seepage
11 - 4 5 ) .

Turn the ignitionswitch ON and

connect a jumper wiro between
A17 terminaland A26 torminal.

Does the solenoid valve click

Rop.ir opon in P K wlro

botwoon ECM {A17)
ond tho 2P connctor. lf
tho wiie i. OK, ,oDlac6.
th6 IAB cootol 8olongid

Substhuto a known-good ECM

and .echack. lf proacriH vohlgo
i3 now sveilabloroplacetho originll ECM.

Disconnectthe 2P connectorfrom
the IAB controisolnoidvalve.

Turn the ignilion swatchOFF.

Check for continuity to ground on

rhe PNK wire.
IAB control syrtom i! OK.

Ropair short to giound

rt PNK wir6 b6twoen
ECM {A17) and tho 2P
conneclol.
Substituts a known-good ECM
and rachock. lt symptom goos
away, rcplaco the original ECM.

11-145

Intake Air System

IntakeAir Bypass(lABlControlSystem
lExceptF22Al engine{S}l(cont'd}
IAB Valve Testing
CAUTION: Do not adjust the IAB valve full-close5c1w.
It was preset 8t the factory.
1.

Check the IAB valve shaft for bindingor sticking,

2.

Check the IAB valve for smooth movement.

3.

With the engineOFF,ctreckthat @ of the bypass

valve is in close contact with the stoDper.

4.

With the engine at idle, check that (9of the IAB

valve is in close contact with the full-closescrew.

a ll sny fautt is found, clanthe linkagoand shafts

with calbuistor clssner.
lf the Droblemstill exists after cleaning,disassemble the intakemanifoldand check the IAB valve
( s e ep a g e 1 1 - 1 4 7 )

11-1 4 6

fntake Air Bypass (lAB) Control System lExcept F22A1 engine (S)l

22 N.m
12.2kg-m, 16

e s
H
e
s
ll

22 N.m
(2.2 kg-m,16 lb-ttl

IA8 VALVE

@ ^ ^
IAB tCONTROL

SOLENOIDVAI-VE

@-,rrn.^
{2.2 kg-m, 16 tb-frl

11-147

Intake Air System

fntake Manifold 1F22A1engine (S)l

e
22 N.m (2.2 kg-m.

16 rb.ftl

-l9

HEn

@
*
^\,,^^

EmissionControl System
System TroubleshootingGuide
NOTE: Acrosseach row in the chan, the sub-systemsthat could be sourcesof a symptom a.e rankedin the orderthey
should be inspectedstartingwith O. Find the symptom in the left column,read acrossto the most likelysource,then
referto the pagelistedat the top of that column.It inspectionshows the system is OK, try the next most likelysystem
@. etc.

PAGE

SUB-SYSTEM THREEWAY
CATALYTIC
CONVERTER

SYMPTOM

t 5 l

ROUGHIDLE

FREOUENT
STALLING

POOR
PERFORMANCE

POSITIVE
EXHAUSTGAS
CRANKCASE
RECIRCULATION VENTILATION
SYSTEM
SYSTEM
t55

159

WARMINGUP

MISFIREOR
ROUGH
RUNNING

FAILS
EMTSSTON
TEST

LOSSOF
POWER

EVAPORATIVE
EMISSION
CONTROLS
160

11-149

EmissionGontrol System
SystemDescription
The emissioncontrol system includesa Three Way Catalytic Converter(TWC),ExhaustGasRecirculation
IEGR)
system, Postitive CrankcaseVentilation (PCV) system
and EvaporativeEmission(EVAP)control system. The
emissioncontrolsystemis designedto meet federaland
state emissionstandards,

Tailpipe Emission
lnspection
Do not smoke during this procedure.Keep
@
any open flame away ltom your wotk alea.
1.

Start the engineand warm up to normaloperating

temperatureby driving on the road.
Connect a tachometer.
Check and adjustthe idle speed,if necessary(see
p a g e1 1 - 1 1 1 ) .
Warm up and calibratethe CO meter accordingto
the meter manufacturer'sinstructions.
Check idle CO with lhe headlights,heaterblower,
rea. window defogger,coolingfan. and air conditioner oft.
CO meter should indicateO.1 % maximum,-

11-150

ThreeWay CatalyticConverter(TWC)
Description
The ThreeW8y CatalyticConverter(TWC) is used to convert hydrocarbons(HC),carbon monoxide(CO),and oxides
of nitrogen(Nox) in the exhaustgas to carbon dioxide {co2), dinitrogen(N2)and water vapor.

HOUSING

THREEWAY
CATALYST

FROI{TOF VEHICLE

11 - 1 5 1

EmissionControl System
Three Way Catalytic Converter (TWC) (cont'd)
Inspection
lf sxcessiveexhaust systgm back-pressureis suspected, .emove the TWC from the car and make a visual check for plugging, meltingor crackingof the cstalyst. Replacethe TWC if any of the visiblearea is damagedor plugged.

34 N.m
13,4 kg-m,

SD
SN
HEAT SHIELD

34 N.m
13.4 kg-m, 25 lb-ft)

ia"\

IJ

FRONTOF
VEHICLE

11-15,2

10 N.m 11.Okg-m, 7 lb-ft)

(EGRISystem
ExhaustGasRecirculation
TroubleshootingFlowchart
\
l
/
-lra-ll-

l
lf;-f
\ . L-l!J _

The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 12: A problemin

the ExhaustGas Recirculation(EGR)system.

The EGRsystem is designedto reduceoxidesof nitrogenemissions{NOx)by recirculatingexhaustgas throughthe EGR

valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve.EGRvcuum cont.olvalve.
EGRcontrol solenoidvalve, ECM and varioussensors.
The ECM memorycontainsidealEGRvalve lifts tor varyingoperatingconditions.The EGRvslve lilt sensordetectsthe
amount of EGRvalve lift and sendsthe informationto the ECM. The ECM then comparesit with the jdeal EGRvalve
lift which is determinedby signslssent from the other sensors.lf there is any di{ferencebetween the two, the ECM
variescurrent to the EGRcontrol solenoidvalve to further regulatevacuum appliedto the EGRvalve.

EGR
CONTROL
sol-Et{otD
VALVE

---l>
BLK/YEL

ECUIECMI{15 A}

EGB
VACUUM
CONTROL
VALVE
RED/
EGRVALVE 5-J WHT
LIFTSENSoR I.+-WHT/BLK
BLK

{cont'd)

11 - 1 5 3

EmissionControl System
ExhaustGasRecirculation
{EGR)System{cont'd)
-

- h--J-6 l -.-_:-

\ ---r-l

-l12l/--\

- lho MIL has boon roportedon.

' With rsNico chcck connoctot
iumpedlsoopa06 1142), cod.
12 is indicatod.

Do the FCM ResetProcedure{see

p a g e1 1 - 4 3 1 .

Roadtost necessary:Warm upthe

engine to normal operating temperature {the radiator fan comes
on).
Drive the car on lhe road for approx. 10 minutes.Keep th6 engine speedin the 1.700-2.500
rpm.

ls the MIL on and does it

indicatecode 12?

With the engineat idle, disconnect the # 16 hosefrom the EGR

valve and connect a vacuum
pump/gauge to the hose.

ls there any vacuum?

VACUUMPUMP/
GAUGE
4973X-04't -XXXXX

II
|
Intormitlrnt t llur6, .yltom ir OK
at thi! tlm..
Chock for poor connaction! ot
loo.. wlr.s at Ot25, gl28llocatod at rlght ihock towqr), C463
(locatod at loft .ida und.r dashl,
C1 17 (EGR vllvo lift $n.or),
C31O GGB comrol .olonoid vrlv.l
and ECM.

Disconnoct2P connoctorfrom the

EGR control solgnoid valve and
checkthe # 16 hosgfor vacuum
again.

Move the vacuum pump/gaugeto

# 16 HOSE

{To page

1 1 -1 5 4

#16 HOSE

EGRVALVE
LIFTSENSOR

EGR VALVE
l T o p a g e1 1 - 1 5 5 1

EGRVALVE

{Frompage 1 1-154}

With the engineat idle, apply 2O0

mm Hg (8 in Hglof vacuumto the
EGRvalve.

(Frompage t 1-154)

ls there any vacuum?

Check vacuum hoso

rouling of the ontiro
EGR system. It hoss
routing ir OK, roplac.
EGR control 3olenoid

Turn the ignitionswitch OFFand

disconnect the "A" conngctor
from the ECM.

Checktor continuity to ground on

REDwire of the 2P connector.
Ropairsho.t in REDwir6
botween EGR control
solonoid valvo ard ECM
{A11t.
Substitut. a knownood ECM
and rot$t. It symptom/indication
goos away, roploco tho odginol
ECM.
EGR
CONTROL
SOLENOID
VALVE
Ooesthe enginestall or run
rough and does the EGR
valve hold vacuum?

Disconnectthe 2P connectorfrom
the EGRcontrol solenoidvalve.

Measurevoltage between BLK/

YEL(+lterminalon the mainwire
harness and body ground.

ls there battery voltage?

Repairopon in BLKrYELwir6 botween th6 EGR contrcl iolenoid

v6lv. .nd ECU (ECM)(15 Al fuso
(in tho und6r{a.h turo/,olay borl.

Reconnectthe vacuum pump/

gaugeto the # |6 hose.

( T op a g e11 - 1 5 6 )

{cont'd)

11 - 1 5 5

EmissionGontrolSystem
(EGRISystem(cont'dl
ExhaustGas Recirculation
{ F r o mp a g e

'11-1551

Connect battery oower lerminal

to the A terminal of the 2P connector. While watching the vacuum gauge, ground the B terminal.

ls there approx.2OOmm Hg
(8 in.Hg)within 1 second?

Turn the ignitionswitch OFFand

inspectthe # 16 and #24 hoses
for leaks, restrictions, or misrouting.

Turn the ignition swith OFF and

reconnectthe 2P connector,

Are the hoses OK?

EGRVALVE
LIFT

EGRVACUUM
CONTROLVALVE

EGRCOI{TROL
VALVE
SOLENOID

(
Disconnect the lower hose on
EGR control solenoid valve and
connect a vacuum gaugeto the
hose.

VACUUMPUMP/
GAUGE
A973X-O4t -XXXXX

Disconnect3P connectorfrom the

EGR valve lift sensor.

Turn the ignitionswitch ON.

ls there 150-250 mrn Hg

16- 1o in.Hg) ol vacuum?

Measure voltage between RED/

wHT (t ) terminaland GFN^dHT
{- ) terminal.

ls there approx. 5 V?

( T op a g eI l - 1 5 7 )

11-156

Measure voltage betwen RED/

WHT {+} terminal and bodv
ground.

l T o p a g e1 1 - ' l 5 7 1

Roobca the EGB vacuum control valvg.

{Frompage 1 1-156}

't
{Frompage 1 - 1 5 6 )
Ropair open in GRN/
WHT wii. botweon
EGR vrlv6 lift sonsor
ond ECM (D22).
Connect the test harness "D"
connectorto the ECMonly. not to
th6 main wire harness (see pags
11 - 4 5 ) .

Turn the ignitionswitch ON.

Measure voltage botween D19

(+) terminaf and O22 l-l
terminal.
Rgpair opon in RED/
WHT wir. batwoon
EGR valv. litt !.n3or
.nd ECM (Dl91.
Subrtituto a known{ood ECM
and .ech6ck, lf symptom/lndiction go6i away, ,ophc6 rha original ECM.

Turn the ignition switch OFF.

Reconnoct the 3P connector to

the EGRvalve lift sensor.

D 1 2t + t D 2 2 t - l

Connectthe test hmessbelween

the ECM and connectors (see
p a g e1 1 - 4 5 ) .

1.2 V wirh no vacuum appli.d?

4.3 V rvith 2OO mm Hg (8 in.Hol
of vacuum appliod?

Turn the ignition switch ON.

Measure voltage between O'l2

f+) terminaf and D22 l-)
terminal.

ls the voltageapprox. 1.2 V

with no vacuum applied and
approx.4.3 V with 2OOmm
Hg {8 in Hg) of vacuum applied to the EGR valve?

(To page 1 1-158)

Ropair opon or lhort in WHT/

BLK wir. botwo.n EGR valvo
lift !.n.or and ECM {D12}.
ll YYi.ob OK, r.Dlac. th. EGR

(cont'd)

11-157

EmissionControl System
ExhaustGas Recirculation(EGR)System (cont'd)
( F r o mp a g e 1 1 - 1 5 8 )

,:

Does the voltageconsistenly

increase/decreaseas the
vacuum increases/decreases?

Connecl 41 1 terminalto 426 teF

minal with a jumper wire.

Did the enginestall

or run rough?

Substitute a known-good ECM

and rechck. ll symptom/indication goes away, replacthe original ECM.

11-158

Ropair open in RED uviro botwoon

ECM lAl ll and EGRconlrol3donoid valv6.

Positive CrankcaseVentilation (PCVI System

Description

Inspection

The Positive CrankcaseVentilation (PCV) system is

designedto preventblow-by gas from escapingto the
atmosphere.The PCV valve contains a springjoaded
plunger.When the enginestarts.the plungerin the PCV
valve is lifted in proportionto intake manifoldvacuum
and the blow-by gas is drawn directly into the intake
manifold.

1. Checkthe PCVhosesand connectionsfor leaksand

clogging.

PCV
HOSE

BREATHER
PIPE

VALVE

- : BLOW-BYVAPOR
Cf I FRESHAIR

At idle,makesurethere is a clickingsoundfrom the

PCV valve when the hose betweenPCV valve and
intakemanifoldin lighttypincfiedwirh your fingers
or olrers.

Ll\l

.t

Gently pinch here

lf thereis no clickingsound.checkthe pCV valve

grommetfor cracks or damage.ll the grommet
is OK, replacethe PCV valve and recheck.

11 - 1 5 9

EmissionControl SYstem
EvaporativeEmission(EVAPI Controls
Description
vapor escapingto the atmosphere'The
The evaporativeemissioncontrotsare designedto minimizethe amountof fuel
system consistsof the following components:
A.

Evaporative Emission (EVAPI Control Caniatot

be purgedfrom
An EVAPcontrol canisteris used tor the temporarystorageof fuel vapor until the fuel vapor can
burned
the EVAP control canisterinto the engineand

Vapor Putgo Control System

EVAPcontro|canisterpurg|ngisaccomp|ishedbydrawingfreshairthroughtheEVAPcontro|canisterandintoa
portonthethrott|ebody.Thepurgingvacuumiscontro||edbytheEVAPpurgecontro|diaphragmva|veandthe
EVAP putge control solenoidvalve
EVAP PURGECONTROLSOLENOIDVALVE OFF AFTER
STARTINGENGINE

ABOVE I67OF (75OC)

ENGINECOOLANTTEMPERATURE
(
U
S
A
:
S:R - V ) :1 5 8 " F ( 7 O o C ) 1
S
i
V
T
E
C
/
C
a
nada
e
n
g
i
n
e
[H22A1

Fuel Tank Vapor Conttol SYstem

When fuel vapor pressurein the fuel tank is higherthan the set value of the EVAPtwo way valve,the valve opens
and regulatesthe flow of fuel vapor to lhe EVAPcontrol canister.

11-160

EVAP
PURGE

cot{TRoL
SOLENOID
VALVE

TO ECU(ECM)
{15 A} FUSE

FUEL FILL CAP

FUELTANK

EVAP CONTROL
CANISTER

FRESH

11-161

EmissionControl System
EvaporativeEmission{EVAP) Controls (cont'd
TroubleshootingFLowchart

EVAP
PURGECONTROL
OIAPHRAGMVALVE

# 3 VACUUMHOSE

Disconnect #3 vacuum hose

from the EVAP purge control diaphragmvalve (on the EVAPcontrol canister) 6nd connect a
vacuum gaugelo lhe hose.

VACUUMPUMP/GAUGE
A973X-041-XXXXX

Start the ongine and allow it to

idle.
NOTE: Enginecoolant temperature mustbe below 158oF{70oC}

EVAP CONTROL
CANISTER

Measure voltage between BLK/

YEL (+ ) terminaland REO/GRN
(- ) terminal.

ls there battery vollage ?

Measure voltage betwgon BLK/

YEL (+) terminal and body
ground.

(Topage11-163)

11-162

{To page 1 1-'163)

Inspoct vacuum hoso

routin9.
lf OK, .oplaco EVAP
purge control solenoid

( F r o mp a g e 1 1 - 1 6 2 )

Warm up the engine to normal

operatingtemperature{th6radiator fan comes on).

l F r o mp a g e1 1 - 1 6 2 )

ls there battery vohage ?

Ropairopon in BLK/YEL
wir6 betwoon ECU
(ECM) (15 Al lus6 lin
tho undordash fuso/rolay boxl 6nd ths 2P
connoclor.

lBpoct RED/GRNwlro tor an opn

beiwen ECM (4201 end tho connocrot.
lf wir6 is OK. substitut6 a knowngood ECM and rcchock. lf symptom gos away, ioplaco tho
original ECM.
Hold engineat 2,OO0rpm.

Check for vacuum at rF3 vacuum

hose after starting the engine.

ls theremanifoldvacuum?

ls there manifoldvacuumT

InSD6ct vocuum hose

routing.
It OK. r6placo EVAP
purge control 3olenoid

Insp6ct lor . short in RED/GRN

wiro b6tw6on ECM lA2O) and tho
conn6ctol,
ll wir6 is OK, sub3titutoa knowngood ECM and rech6ck. lt 3ymptom goo3 away, r6placo tho
original ECM.

(To page 'l 'l - 164)

( c o n t ' dI

11-163

EmissionControl System
EvaporativeEmission(EVAP) Controls {cont'd)
{Frompage 1 1-1631

VACUUM PRESSUNE
GAUGE0-4 in. Hg
o7JA2 -OO10008

Connect a vacuum gauge to

EVAP control canister purge air
nose,

Does vacuum appgar on gauge

'l
within minute?

Connect a vacuum gauge to the

purge hose and raise lhe ngine
sDeedto 3,5OOrpm.

Inlpacl tho purgo hoas

..d throt r body po.t
tor pinch or blockag..

Soo EVAP two way valvo tost to

comoloto.
Evaoorativo ombsion control! aro

oK.

Rsol6c6 th6 EVAP conttol caniator.

11-1 6 4

EVAP Two Way Valve Test

1.

Removethe fuel fill cap.

2.

Removevapor line lrom the fuel tank and connect

to T-tittinglrom vacuumgaugeand vacuum pump
as snown.
VACUUM/PRESSURE
GAUGE
0-4 in. Hg
07JAZ-0010008
VACUUM PUMP/
GAUGE
A973Xo4'l -

xxxxx

F
T-FITTING

3.

Applyvacuumslowly and continuouslywhile walching

the gauge.
Vacuumshouldstabilizemomentarilyat 5 to 15 mm
H g ( O . 2t o 0 . 6 i n . H g ) .
a lf vacuum stabilizes(valveopens)below 5 mm
H s ( 0 . 2 i n . H g )o r a b o v el 5 m m H g { o . 6 i n . H g l ,
installa new valve and retest.

4.

Move vacuum pump hose from vacuum to pressure

tifiing, and move vacuumgaugehosefrom vacuum
to oressureside as shown.

the vaporline while watchingthe

Slowly pressuraze
gauge.
Pressureshould stabilizeat 1O to 35 mm Hg {O.4
to 1.4 in. Hg).
a It pressuremomentarilystabilizes(valveopens)
a t 1 Ot o 3 5 m m H g ( O . 4t o 1. 4 i n . H g ) .t h e v a l v e
is OK.
a lt pressurestabilizes
below 1Omm Hg (O.4in. Hg)
l new
o r a b o v e3 5 m m H g ( 1 . 4 i n . H g ) , i n s t a l a
valve and retest.

11-165

Transaxle
Clutch
...........12-1
ManualTransmission
............................
13-1
AutomaticTransmission
..................
.....14-1
Differential
ManualTransmission
.........................
15-1
AutomaticTransmission...................
15-10
Driveshafts
... 16-1

Clutch
Special
Tools..........
...........12-2
fffustrated
Index...........
.....12-3
ClutchPedal
Adjustment
....................
12-4
ClutchMasterGylinder
RemovaUlnstallation
....12-5
SlaveGylinder
Removal
.... 12-6
Installation
.....................
12-6
ReleaseBearing
Disassembly/f
nspection....................
12-7
fnstaflation................;....
.....................
12-7
PressurePlate
RemovaUlnspection
......12-8
GlutchDisc
Inspection
......................
12-9
Flywheel
fnspection/Removal
......12-10
Flywheeland ClutchDisc
lnstaflation
.....................
12-10

SpecialTools
Re{.No

Tool Numbqt
O T J A -F
07LAB0792407LAF07936-

PM7011A
PV00100
or
PD20003
PT00110
3710100

ClutchAlignmentDisc
RingGearHolder

12-8
1 2 - 89, , r 0

ClutchAlignmentShaft
Handle

12-4,10
1 2 - 8 t. 0

g
o

B
@

12-2

6,

lllustratedIndex
NOTE:
a Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface.
a When partsmarked"*" are removed,the clutchhydraulicsystemmust be bled.
. Bleedthe clutchhydraulicsystem(seepage 12-6).
. Inspectthe hosesfor damage,leaks,interference,
and twisting.
PEDAL
PIN
r19 N.m lt.g kg.m, la lb-fil

6x1.0mm
10 N.m {1.0lg.m,

8 x 1.25mm
22 N{n 12.2kg-m, 16 lb-ft)

7 rb.ftl

.rg runrfl.g tg-m, 14lb-ft1

'15 N{n l'1.5kg-m,

11 tb-ft|

8 x 1.25mm
22 N.ln {2.2 kg-m,
16 |b-ft)

.CLUTCHMASTERCYLINDER
R6moval/lnstall6tion.
pag6 12-5

.RESERVOIF

.OIL BOLT
30 t&n {3.0kg-m,
z2tb-ftI

WASHER
R.pl|c..

'REsERvolR
HosE

l/A+,

Y*
\_-/

Pro

'Fr

(fr&..]{{r+--->
| \\l
t \\

I x1,25 mm ..-

virh.

IJUz tt.r"tz.zrg.m,

CLUTCHDAMPER

r15 N{n 11.5kg-ft,

11 tb.ftl

^*i!-

tW

r15 N{n {1.5rg-.,

lt tb-ft|

7 ^r*V
" lJYr-'
n x r.o mm
10N.m{1.0ls-m, 7 tb.ft}

RET-EASE
SEANING
p8gol2-7
Romoval,
pago12-7
Inspoction,
page12-7
Installation,

DOU'ELPIN

FLYWHEEL
page12-10
Inspection/Removal,
page12-10
Installation,
CLUTCHDISC
page12-9
Inspection,
psge 12-10
Installation,
PRESSURE
PLATE
Femoval/lnspection,pa96 12-8
page12-10
Installation,

TRANSMISSION
See section 13

RELEASEFORK
Removal.page12-7
page12-7
Installation,
*CLUTCH
15 N{n (1.5kg-m,
11 tb-ft}

TSLAVE CYLINOER
R e m o v a l / l n s t a l l a t i o np
, a g e 12 ' 6

12-3

GlutchPedal
Adjustment
NOTE
. To checkthe clutchpedalswitchA and B, seesection

Threadthe clutchpedalswitchA in until it contacts

the clutchpedal.

Turn the clutchswitchA in 114- '12lurn further.

The clutchis self-adjusting

to compensatefor wear.

CAUTION: ll thro is no cl6aranc6betwon tho mastel

qylindor piston and push rod, the releasebearing is held
lgainrt tho diaphrrgm spring, which can result in clutch
slippago or other clutch problms.
1,

L o o s e nl o c k n u tA , a n d b a c k o f f t h e c l u t c h p e d a l
switchA or bolt until it no longertouchesthe clutch
peoal.

2.

LoosenlocknutC, and turn the push rod in or out to

g e t t h e s p e c i f i e ds t r o k ea n d h e i g h t a t t h e c l u t c h
Deoat.

3.

TightenlocknutC,

TightenlocknutA.
7.

LoosenlocknutB and clutchpedalswitchB.

8 . Measursthe clsarancebetweenthe floor board and

clutchpedal.lviththe clutchpedalfully depressed,
q

Releasethe clutchpedal '15- 20 mm (0.59- 0.79

i n ) f r o m t h e f u l l y d e p r e s s e dp o s i t i o na n d h o l d i t
there.
Adjust the positionof clutch pedalswitch B so that
the engine will start with the clutch pedal in this
position.

10. Thread the clutch pedal switch B in 114further,

112-tu'n

11. TightenlocknutB.
LOCKNUTC
15 N.m 11.5

tl tb-ft}

LOCKNUT
B
10N.m{1.0kg-m,7 lb.ftl
CLUTCHPEDALSWITCHB

CLUTCIIPEDALSwlTCHA
PUSHROD

L(rcKNUTA
10 l,I.|n(1.0kg.m, 7 lb.ft)

CLUTCHMASTERCYLINOER

Padrl in contld

whh awhch

CLUTCHASSISTSPRING

-6El

@
@
@
@

(STROKE8t PEDALI:135- 1ir5mm (5.31- 5.71 in)

(TOTALCLUTCHPEDALFREEPLAY):9.0 - 15.0mm 10.35- 0.59 in) includo ths psdal plsy 1 - 7 mm t0.0t - 0.28 in).
190mm (7.48in)
ICLUTCHPEDALHEIGHT):
PEDAL
DISENGAGEMENT
HEIGHT):9,[ mm (3.70in) minimum to the ftoor.
ICLUTCH

2-4

ClutchMasterCylinder
Removal/lnstallation
CAUTION:Avoid spilling brake fluid on paint.d surtacos,as it may damagoths tinish.

5.

Removethe clutchmastrcvlinder.

NOTE:Plug the end of the resrvoirhose,and cap the

end of the clutchpipe,with a plug and cap suchas those
discardedfrom an A/C kit.
1.

Removethe reservoirhose from the clutch master

c v l i n d e ra n d d r a i n t h e b r a k ef l u i d i n t o a s u i t a b l e
contarner,
NOTE:The brakefluid csn be suckedout through
the top ot the reservoirwith a syringe.

2.

Removethe reservoirfrom the enginecompartment

bulkhead.

3.

Disconnectthe clutch pipe from the clutch mastsr

cylinder.
CLUTCH
PIPE
19 N.m 11.9kg-m, la lb-ttl

CLUTCHMASIER
CYLINDER

6x1.0mm

10ll.rn 11.0ke-m,
7 tb-ft)

6.

Install the clutch mastor cylinder in the revrse

order of removal.
NOTE: Blsed the clutch hydraulic systom (see psge
12-6t.

RESERVOIR
CLUTCH
RESEBVOIR
HOSE
MASTER
CYLINDER
Pry out the cotterpin, and pull the pedal pin out of
the voke.Removethe nuts.
PEDALPIN

COTTERPIN
Replac.

-6rl

NUTS
13 N{n (1.3kg.m,9lb-ft|

2-5

SlaveCylinder
lnstallation

Removal
Disconnect
the clutchpipefrom th slavecylinder.

-6ll,

CAUTION: Avoid spilling braks tluid on the paintod

3u.facos,as it may damagoth tinish.
NOTE:Plug the end of the resrvoirhose,and cap
the end of the clutchpipe,with a plug and cap such
as those discardedfrom an IVC kit.

SuperHighTemp LJreaGrease(P/N087989002).
: BrakeAssemblyLubeor equivalentrubber
grease.

1 . Install the slave cylinder on the clutch housing.

Connect the clutch pipe.

Removethe slavecylinderfrom the clutchhousing.

CLUTCHPIPE
15 N'm {1.5kg-m.

SLAVE CYUNDER

CLUTCHPIPE

BLEEOER
SCREW
10 N{n (1,0kg-m,

l,

7 tb-ft|

8 x 1,25mm
22 N.m {2.2 kg-m,
16 tb-ft|

-#,1

(P/N08798-

BOOT
Relhovand chocktor signs of leaking
and deterioration.

(BraksAssembly
Lub6)

3.

Bleed the ciutch hydraulic system:

Attacha hoseto the bleederscrewand suspend

the hosein a containerof brakefluid.
Makesurethere is an adequatesupplyof fluid at
the mastercylinder,then slowly pump the clutch
pedaluntil no more bubblesappearat the bleeder hose.
a Refillthe mastercvlinderfluid when done.
a Useonlv DOT3 or 4 brakefluid.

12-6

ReleaseBearing
Disassembly/lnspection
Removethe boot trom the clutchhousing.
Removethe releasefork from the clutchhousingby
squeezingthe releasefork set spring with pliers.
Removethe releasebearing.

lnstallation
N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e( P / N
08798- 9002).
Installthe releasefork set springon the releasetork.
RELEASE
FORK

RELEASE
FORKSETSPBING

-#l

{P/N08798-

RELEASEFOBK

-6El

{P/N08798*

With the releasefork slid betweenthe releasebearing pawls, installthe releasebearingon the mainshaft while insening the releasefork through the
hole in clutchhousing.
Align the detentof the releasefork with tlle release
f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e
releasefork bolt souarelv.
RELEAS
BEARING

RELEASEFoRK
SETSPRING

RELEASEFOBK

(P/N08798- 9002t

RELEASE
FORKSET
SPRING

CLUTCHHOUSING

Checkthe releasebaringfor play by spinningit by

h an d .
CAUTION: Tho reloass besring is packed with
groas.Do not wa3h it in solvsnt.

BELEASEFORKBOLT
30 N.rn {3.0 kg-m, 22 lb-ftl

f-

Installthe boot, being sure that there is no clearance:releasefork-to-boot,and boot-to,clutchhousing,

.Move the releasefork right and left to make sure
that the releasefork fits properlyagainstthe release
bearing,and that the releasebearingslidessmoothRCLEASE
BEARING

lf there is excessiveplay, replacethe releasebear

ing with a new one.
RELEASEFORK

12-7

PressurePlate
RemovaUlnspection
To prevent warping. unscrew the pressure plate
mounting bolts in a crisscrosspattern in several
steps.then remove the pressureplate.

Inspectthe fingersof the diaphragmspringfor wear

at the releasebearingcontactarea.
Assemblethe specialtoolsas shown.
N O T E :A s s e m b l et h e C l u t c hA l i g n m e n tD i s cw i t h
side "A" facingthe diaphragmspringas shown.
Checkthe diaphragmspringfingersfor heightusrrg
the specialtoolsand a feelergauge.
Standard(New): 0.6 mm {0.02in) max.
0,8 mm {0.03in)
ServiceLimit:

PRESSUREPLATE

Inspectthe pressureplate surfacefor wear, cracks,

a n db u r n i n g .

CLUTCH
ALIGNMENT

Dtsc

FEELERGAUGE

OTJAFPM7O11A

1.

NOTE:Measureacrossthe pressureplate at three

pornts.

CLUTCHALIGNMENTSHAFT
07LAF- PTOo110
HANDLE
07936- 3710100

4.

Inspectfor warpage using a straight edge and a

feelergauge.

Standard (lrl6wl: 0.03 mm (O.0Olin) max.

0.15 mm (0.006in)
Sorvicc Limit

Install the special tools as shown.

FEELERGAUGE

45 N.m
(4.5kg-m,
33 tb-ft)

HANDLE
07936- 3710100

/
/

'

CLUTCH
I ALIGNMENT
SHAFT
07LAF- PT00110
RINGGEARHOLDER ENGINEBLOCK
07LAB- PV00100
07924- PD20003

RINGGEARHOLDER
ADJUSTERNUT
AOJUSTEBBOLT
BOLT

WASHER

12-8

STRAIGHTEDGE

ClutchDisc
Inspection
L

Removethe clutchdisc.

2.

lnspectthe lining of the clutchdiscfor signsof slipp i n g o r o i l . R e p l a c ei t i f i t i s b u r n e d b l a c ko r o i l

soaked.

Measurethe depth from the lining surfaceto the

rivets,on both sides,
Rivt Dspth:
StandardlNewl: 1.3mm {0.05in) min.
SrvicoLimit:
0.2 mm (0.01in)

xi (

@
CLUTCHOISC

CLUTCHDISC
3.

Measurethe clutchdiscthickness.
Clutch Disc Thicknss.
Standard(New|: 8.4- 9.1 mm {0.33- 0.36in}
ServiceLimit:
6.0 mm 10.24inl

12-9

Flywheeland ClutchDisc

Flywheel
Inspection/Removal
1,

Inspectthe ring gearteethfor wear and damage,

2.

Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks,Sndburning.

Measurethe flywheel runout using a disl indicator
through at least two full turns. Push the flywheel
towardsthe engineto take up the crankshaftthrust
washerclearance.
N O T E :T h e r u n o u t c a n b e m e a s u r e dw i t h e n g i n e
installed.

lnstallation
.-Alignthe hole in the flywheel with the crankshsft
dowel pin and assemble.Installthe mountingbolts
only tingertight.
Installthe specialtool. then torque the mounting
b o l t s i n d c r i s s c r o s sp a t t e r n i n s e v e r a ls t e p s a s
shown.

FLYWHEEL

Standard lNowl: 0.05 mm {0.002in) mrx.

0.15 mm {0.(X)6in)
ServiceLimit
lf the runout exceedsthe servicelirnit, reDlacethe
flywheel.
(}

rLvwxeel

07LAB- PV00100
or MOUNTTNG
BOLTS
07924- PD2fi)O3 tO5N.rntj9.5 k,-m, ?Gtb-ft1

l "
4.

I n s t a l lt h e c l u t c h d i s c u s i n g t h e s p e c i a lt o o l s a s
shown.

R e m o v et h e e i g h t f l y w h e e l m o u n t i n g b o l t s i n a
crisscrosspattern in ssveral steps, and remove the
flywheel.

FLY\AIHEEL

FLYWHEEL

HANDI.I
07936- 3710100

CLUTCHDISC

RII{GGEARHOLDER
o?LAB- PVO010O
ol
0?924 - PD2o003

CLUTCHALIGNMENT
SHAFT
07LAF- PT|X)I10

(P/N08798- 9002)

4.

Installthe DressureDlate.

Pf,ESSUREPLAIC

Torquethe mountingbolts in a crisscrosspatternas

shown.Tightenthem severalstepsto preventwarping the diaphragmspring.

MOUNTINGBOLTS
26 N.m (2.6kg-m, 19 lb-ft|

6.

Removethe soecialtools.

12-11

ManualTransmission
SpeciafTools...
...........
13-2
Maintenance
Transmission
Oil ..............................
13-3
Back-up Llght Switch
Replacement
.,.,,....13-3
Transmission Assembly
Removal
.................
13-4
Gearshift Mechanism
Overhaul
................
13-9
lllustratedIndex ...................................
13-10
Shift Arm Assembly
fndex ................
......13-12
Disassembly/Reassembly
...............
13-13
TransmissionHousing
Removal
.................
13-15
ReverseShift Fork
Glearance
Inspection,,,....,..............,
13-16
Reverseldler Gear
Removal
.................
13-17
Mainshaft, Countershaft
Removal
.................
13-17
Mainshaft
lndex ...............
.......13-18
Clearance
Inspection......,................
13-19
Disassembly
..........13-20
Inspection
..............
13-21
Reassembly
...........13-22

Countershaft
fndex ................
......13-23
Cfearancefnspection.......................
13-24
Disassembly
..........13-25
Inspection
..............
13-26
Reassembly
...........
13-25
Shift Fork Assembly
Disassembly/Reassembly
...............
13-28
Clearance
Inspection.......................
13-29
SynchroSleeve,SynchroHub
Inspection
Installation
.............
13-30
SynchroRing,Gear
Inspection
..............
13-31
MainshaftBearing/OilSeal
Replacement
.....,.,,13-32
CountershaftBearing
Replacement
.........13-33
MainshaftThrust Shim
Adiustment
............
13-34
Transmission
Reassembly
...........
13-37
TransmissionAssembly
Installation
.............
13-40

NOTE:The radio may havea codedtheft protectioncircuit.Be sureto get the customer'scode numberbefore
- Disconnecting
the battery.
- Removingthe No. 43 {10A)fuse in the under-hoodfuse/relaybox.
- Removingthe radio.
After service,reconnectpowerto the radioand turn it on.
Whenthe word "CODE"is displayed,enterthe customer's5-digitcodeto restoreradiooperation.

SpecialTools

R{.No.

Tool Number
07GAJ07GAJ*07736077460774607746077460774907947-

@
/a\

@
@
@

o
@
o

Pc2o' r'r0
PG20130
A010004
0010300
0010500
0030100
0030400
0010000
6890100

Oty

Description
MainshaftHolder
MainshaftBase
AdjustableBearingPuller,25- 40 mm
Attachment,42 x 47 mm
Attachment.62 x 68 mm
Driver,40 mm l.D.
Attachment35 mm LD.
Driver
SealDriver

1
1
,l
1
,|
1
1
1
1

PagReferonc
tJ-JO, J/

13-32.33
't3-22,21
,32
13-32.33
't3-22
13-22
13-22,21
,32,33
't3-21

* Must be usedwith commerciallvavailable3/8 in x 16 thread/inSlideHammer.

13-2

TransmissionAssembly
Removal

@Makr 3uro

iacks and safoty 3tlnds aro placed proper'

ly, rnd hoi3t brlckot! aro sftached to corroqt posi'
lion on tho cngins.
Apply parking brako and block roar whool3 30 car
will not roll off stand3 lnd fdl on you whilo working
uodor it.

4.

Removethe intakeair duct and air cleanerassemDtv.

CAUTION: U3o lcndrr coveB to 8void dEmlging print'

ed surfaces.

fti

NOTE: The radio may have a coded theft protection circuit.Bo sureto get tha customer'scode numberbefore
- Disconnectingthe battery.
- Removingthe No. 43 (]0 A) fuse.
{Under-hoodfuse/relaybox)
- Removingthe radio.
After service,reconnectpower to the radio and turn it
on.
" C O D E "i s d i s p l a y e de
, n t e rt h s c u s When the word
tomer's5-digitcodeto restoreradiooperation.
1.

Disconnectthe negative(-) and positive(+) cabls

from the b8ttery,then remove the battery.

2.

Drainthe transmissionoil (seepage13-3).

3.

Removethe battery base and bsse stay,

Removethe intakecontrol vacuumtank and brackt,

NOTE:Do not disconnectthe hoses,
INTAKEOONTROL

13-4

6. Disconnectthe starter motor cables,then remove

the startermotor.

1 1 .Disconnectthe vehiclespeedsensor(VSS)connector and removethe VSS/powersteeringspeedsensor, but leaveits hosesconnected.

7. Disconnectthe back-uplight switchconnectorsand

transmissiongroundcable.
vss coNNEc?oR

8. Removethe wire harnessclamp.

WIRE

LIGHTSWITCH
BACK.UP

HARNESS

POWER
STEERING
SPEED
SENSOR

STARTEB
MOTOR
STARTER
MOTOR
CABLES

O-RING
Replace.
TRANSMISSION
GROUNDCABI.T

12. Removethe slavecylinder.

9 . Shiftthe transmissioninto reverse.
1 0 . Firstremovethe cablebracket,then disconnectthe
cablesfrom the top housingof the transmission.
NOTE:Removeboth cablesand the brackettogether.

NOTE:
. Do not operatethe clutch pedal once the slave
cylinderhas beenremoved.
. Takecarenot to bendthe clutchpipe.
CLUTCHHOSE

CAUTION: Take crre not to bond ths cables.

Do not aamovo.

WASI{EB
WASHER
Inspectfor
and

'}{FT CAALE

Replace.
STEEL
PLASTIC
WASHERI WASHER
Inspectfor
wear and
oamage.

SLAVECYLINDEB

(cont'd)

13-5

TransmissionAssembly
Removal(cont'd)
1 3 . R e m o v t h e c l u t c h d a m p e r m o u n t i n g b o l t s , a n d
raisethe clutchdamDer.

Removethe cotterpins and ball joint nuts,then separate the ball joints and lower arms on both sides
(seesection'18).
1 6 . Removethe right damperfork bolt.

CLUTCHOAMPER

't1. Remove the right radius rod.

BOLTS
SELF.LOCKING
Replace.

SELF.LOCKING
NUT
Replace.

I,
l '

36i'J'--*
NUr
MOUNTINGBOLTS

COTTERPIN
Replace.

a.

14. Removethe rearenginemount bracketstay.

DAMPER
NUT
SELF.LOCKING
Replace.

18. Removethe driveshaftsand intermediateshaft (see

section16).
N O T E : C o a t a l l D r e c i s i o nf i n i s h e ds u r f a c e sw i t h
cleanengineoil or grease.Tie plasticbags over the
driveshaftends.

REAR
ENGINE
MOUNT
BRACKET
S?AY

SHAFT
INTERMEDIATE

13-6

19. Removethe centerbeam.

21. Removethe intakemanifoldstav.

INTAKEMANIFOLOSTAY

20. Removethe front enginestiffenerand clutchcover.

22. Removethe rear beam stiffener.

REARBEAMSTIFFENER

13-7

TransmissionAssembly

Removal(cont'dl
23. Removethe three rearenginemount bracketmounting bolts.

Removethe two uppertransmissionhousingmounting bolts.

UPPERMOUNTING BOLTS

!
:
Placea floor jack under the transmissionand raise
the transmissionjust enoughto take weight oft of
the mounts.

27. R e m o v et h e t h r e e l o w e r t r a n s m i s s i o nh o u s i n g
mountingbolts.

Removethe transmissionmount and mount bracket.

LOWERMOUNNNG BOLTS

MOUNT BRACKET

13-8

28. Pull the transmissionaway ftom the engine until it

clearsthe mainshaft.

GearshiftMechanism
Overhaul
NOTE:
. Inspect
rubberpartsfor wearanddamagewhendisassembling.
. Checkthatthe newcotterpin is seated
firmly.

6x1.0mm
10 N.rn (1.0 kg-m,
7 tb-ft)

CHANGEWIREPLATE
Replace.

SELECTCABLE

tr

COTTERPIN
Replace.

l',

6x1.0mm
l0 N.m {1,0kg-m,
7 tb-ftt

@---=.-

6x1.0n
'10N.m
kg-m,7 lb-ft}
11.0kg-n

IL

sELF-LocKrNG
NUT

damsge.

Replace.
'10N.m (1.0
kg-m, 7 lb-ft|

CHANGE
LEVER
LINKAGE

\
\ - -

\-ry
\
\\\ N
\

PLASTIC
WASHER
Inspectfor

CHANGEI,.EVER
CHANGE
LEVER

CHANGEBALL

O-RINGS
Feplace.

&

*ou.)@o\
WAVE
WASHER
WASH
SELF.LOCKING
SELF.LO
NUT
Replace.
CHANGEBALL
HOLOER

CHANGELEVER

Ptvot
CHANGEPIVOT
GUIDE
6x1.0mm
10 N.m 11.0kg-m,
7 tb-ft)
SHIFTLEVERBRACKET

FLOATINGCOLLAR

13-9

lllustratedIndex
Referto the drawingbelowfor the transmissiondisassembly
Cleanall pans thoroughlyin solventand dry with compressedair.

Luuri""t""tl partswithoil beforereassembly.

This transmissionusesno gasketsbetweenthe major housings;use liquidgasket(P/N08718- 0001)

(seepage 13-14.39).
Alwayscleanthe magnetO wheneverthe transmissionhousingis disassembled.

t
.>_._------.\\
_._i---.---'l
__----.--

.-.-_.-.-_---

/---ry
o CLUTCHHOUSING

oll SEALReplace.
. Seesection15
an 14 x 20 mm DOWELPIN
OIL GUIDEPLATE
NEEDLEBEARING
. Inspectfor wear and oporation.
0 RETAININGPLATE
7 MAGNET

13-10

@ REVERSEIDI.IR GEARSHAFT
@ REVERSEIDLERGEAR
@ OIL SEALReplace.
BEARING
o BALL
'

Inspectfor wear and operation.

@ SPRINGWASHER
@ WASHER
@ REVERSESHIFI FORK

G' SHIFTFORKASSEMBLY
. Index,page 13-28
G' MAINSHAFTASSEMBLY
. lndex,page13-18
ASSEMBLY
E) COUNTERSHAFT
' Index,pago13-23
ASSEMBLY
CD DIFFERENTIAI. Seesection15

0n

_l
I
'ei
,w

'

l_

I
I

E9 SHIFTARM ASSEMELY
. Index,page13-12
E4 OIL GUTTERPLATE

@ THnusrsHrM

. S e l e c t i o n ,p a g e 1 3 - 3 4

@
@
@
@
@
Ql
@

oIL GUIDEPLATE
WASHER
Replace.
BACK-UP
LTGHT
swITcH
sErflNG scREw
WASHER
Reptace.
SPRTNG
lL.30 mmt
srEELEALL{D.s/16inl

9 TRANSMISSIONHANGER
@ 28 mm SEALINGBOLT
60 32 mm SEALINGBOLT
6D waSHER Reptace.
' BEVERSEIDIEN GEAR
SHAFTBOLT
T8]OIL SEAL
. Seesection15
.'9 OIL DRAINPLUG
a{o)WASHERReplace.

('
@
Q}
@

OIL FILIfR BOLT

WASHERReplace.
TRANSMISSION
HANGER
TRANSMISSIoNHoUSING

1 3 - 11

Shift Arm Assembly

lndex
NOTE:
. The shift arm covercan be removedand installedwith the transmissionin the car.
. Lubricateall movingand slidingsurfaceswith grease.
. Turn the boot so the hole is facingdown
SELEGTLEVER

-G1

08798 - 9lD2l

OIL SEAL
Replac.

6x1.0mm
12 N.m {1.2kg-m,
9 rb-ftt

SHIFTARM COVER

SHIFTARM
. Inspoction,page 13_29
8x1.0mm
29 N.m 12.9kg-m,
2'l tb-ftl

SELECTRETURNPIN
6x1.0mm
'12N.m 11.2kg-m,
9 tb-ft}

6xl.0mm
15 N.m 11.5kg-m,

LOCKWASHEB
Replace.

11tb-ftI

5TH/REVERSE
SELECTSPRING

INTERLOCX

BOLT

sE[rcT
RETURNSPRING
SELECTARM

-6ll

/N 08798-

OIL SEAL
Replace.

13-12

4xBmm
DOWELPINS

Disassembly/Reassembly
NOTE:Duringreassembly,
greaseall slidingparts.
1.

4.

Removethe shift arm coverassembly.

Removethe reverselockcam.
6x1.0mm
15 N.m (1.5kg-m,11 lb-ftl

6x1.0mm
12N.m(1.2kg-m,9lb-ft|
SHIFTARM COVER
ASSEMALY

{x8mm
DOWEI-PINS

R e m o v et h e s p r i n g p i n , t h e n r e m o v e t h e s e l e c t
lever,selectarm and springs.
Removethe selectreturnpin.

5x22mm
SPRINGPIN

-'

5.

Removethe oil seal.

OIL SEAL
Rplace.

SELECTARM
,/

SELECTRETURNSPRIMi
SELECTRETURNPIN
6x l.0mm
12 N.m 11.2kg-m,9lb-ft|

5TH/REVERSE
SELECTSPRING

SELECT
LEVER

.JG

(cont'dl

13-13

Shift Arm Assembly

(cont'dl
Disassembly/Reassembly
gend the tab of the lock washer,then remove the
bolt.
Removethe interlockbolt.
NOTE: Apply liquid gasket(P/N 08718the threadsbeforereassembly.

0001)to

8x1.0mm
29 N.m {2.9kg-m,
21 tb-ft)

9.

Installthe shift arm assemblyin the reverseorderof

removal.
NOTE:
. Use liquidgasket(P/N08718- 0001).
o Removethe din oilfrom the sealingsurface.
of the bolt hole to
. Sealthe entirecircumference
preventoil leakage.
. lf 20 minutes have passedafter applying liquid
g a s k e t ,r e a p p l yi t a n d a s s e m b l et h e h o u s i n g s
a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t a sa f t e r
assemblybeforefillingtransmissionwith oil.

o
\ .oi* *os".^
Replace.

8.

Removethe shift lever,shift arm. and interlock.

NOTE:Turn the boot so the hole is facingdown,

13-14

--: LIOUID
GASKET

Transmission
Housing
Removal
NOTE:
. lf the transmissionhousing or clutch housingwere
replaced,the bearingpreloadmust be adjusted.
o Placethe clutchhousingon two piecesof wood thick
enough to keep the mainshaftfrom the hitting the
workbench.

Removethe 32 mm sealingbolt.
7.

Expandthe snap ring on the countershaftball bearing and remove it from the groove using a pair of
snap ring pliers.
Separatethe transmissionhousingfrom the clutch
housingand wipe it cleanof the sealant.

'1. Removethe shift

arm coverassembly(seepage 13131.

SNAPRING

Removethe reverseidlergear shaftbolt.

Removethe settingscrews,then removethe washers,springs.and steelballs.
STEELBALLlD.5/16 in)

-/

r-^

WASHERReplace.
SETTINGSCREW

9.

4.

Removethe back-uplight switch.

Removethe l0 mm bolts and 8 mm bolts in a crisscross pattern in severalsteps.

Removethe 28 mm sealing bolt, then removethe

oil gutterplate.
NOTE:The transmissionhousingcan be removed
with the oil gutter plate in the transmissionhousing.
28mm SEALTNG
BOLI
OIL GUTTERPLATE

OIL GUTTERPLATE

BACK.UPLIGHT

swlTcH

1 3 - 15

ReverseShift Fork
ClearanceInspection
1.

Measurethe clearancebetween the reverseshift

fork and 5th/reverse
shift piecepin.

l.

0.5 - 1.1 mm (0.020- 0.043in)

Standard:
Srrvico Limit: 1.8 mm (0.071inl

A: 0.05- 0.35 mm 10.002- 0.01i|in)

B: 0.,1- 0.8 mm {0.016- 0.031in)
ServicoLimit; A: 0.5 mm (0.020inl
B: 1.0mm {0.039in)
Standard:

lf the clearanceexceedthe service limit, measure

the width of the groovein the reverseshiftfork.
Stand8rd:A: 7.05- 7.25 mm (0.278- 0.285inl
8: 7.4- 7.7 mm (0.291-0.303 inl

REVERSE
SHIFTFONK

lf the width of the groove exceedsthe standard,

replacethe reverseshiftfork with a new one.
It the width of the groove is within the standard,
reolacethe sth/reverse
shift Diecewith a new one.

13-16

Measurethe clearancebetween the reverseidler

gear and reverseshiftfork.

4.

lf the clearanceexceedsthe servicelimit, measure

the width of the reverseshift tork.
Standard: 13.0- 13.3mm {0.512- 0.52'l in)

REVERSE
SHIFTFORK

l f t h e w i d t h e x c e e d st h e s t a n d a r d ,r e D l a c et h e
reverseshiftfork with a new one.
l f t h e w i d t h i s w i t h i n t h e s t a n d a r d ,r e o l a c et h e
reverseidlergearwith a new one.

Reverseldler Gear

Removal

Removal
1.

Mainshaft,
Countershaft

Removethe reverseshift fork.

1.

Removethe mainshaftand countershaftassemblies

with the shift forksfrom the clutchhousinq.
NOTE:Tape the mainshaftspline before removing
the mainshaftand countershaitassemblies.

REVERSE
SHIFT
MAINSHAFTASSEMBLY

COUNTERSHAFT
ASSEMBLY

Tapethe mai
shattspline.
SPRINGWASHER

Removethe reverseidler gear shaftand the reverse

idlergear.
CLUICH
HOUSING

2.

Removethe differentialassembly.

DIFFERENNAL
ASSEMBLY

REVERSE
IDLER
GEARSHAFT

13-17

Mainshaft
lndex
I

B"for" """"mbling. cleanall partsin solvent,dry them with compressedair,then coatthem with cleanoil.

RING
STOPPER

1,.

3RD/irTH
SYNCHROHUB
3RD/4TH
SYNCHRO
SLEEVE

TAPERRING

3RD/irTHSYNCHROHUB
page'1330
Inspection,

SYNCHRO
SPRING
SYNCHRO
RING

" o oro /

SYNCHROSPRING

SYNCHNORING
page13-31
Inspection,
3ROGEAR
Inspec!on,page
13,19,31
NEEDLEBEARING
Checkwear and operation.
MAINSHAFT
page13?1
Inspection,

13-18

NEEOLEBEARING
Checkwear and ooeiation.
SPACERCOLLAS
SYNCHRORING
page13 31
lnspection,
SYNCHROSPRING
sTH SYNCHROHUB
page13-30
Inspection,
sTH SYNCHROSLEEVE
page13-30
Inspection,
SYNCHROSPRING
SYNCHRORING
page13-31
Inspection,

NOTE:lf replacementis required,always replacethe

synchrosleeveand hub as a set.

Measurethe clearancebetween 4th gear and the

soacercollar.

1 . Support the bearing inner race with a socketand

push down on the mainshaft.

Standard:
0.06- 0.21 mm {0.002- 0.fl18 in}
ServiceLimit: 0.3 mm {0.012in}

Measurethe clearancebetween2nd and 3rd gears.

0.06- 0.21 mm
{0.002- 0.008in)
ServiceLimit:0.3mm 10.012
inl
I
Stands.d:

5.

lf the clearanceexceedsthe servicelimit, measure

distance@ on the spacercollar.
26.03- 26.08mm (1.025- 1.027in)
Standard:
ServiceLimit:26.01mm {1.024inl

lf the clearanceexceedsthe servicelimit. measure

the thicknessof 3rd gear.
Transmission
Type
Standard
ServiceLimit

M215.M254

M2F4

32.42-32.41 mm 34.92- 34.97mm

- 1.2'18inl { 1 . 3 7 -5 1 . 3 7 7i n )
1'1.276
32.3mm
11.272 inl

6J-l-l
L+

34.8mm
( 1 . 3 7 0i n )

3RD GEAR

1,

.nrcean
S|DE

SPACER
coLLAR ----+l_J
6.

lf distanceO is lessthan the servicelimit, roplace

the spacercollarwith a new one.
tf distance@ is within the service limit, measure
the thicknessot 4th gear.

Transmission
Type
Standard
ServiceLimit

M215,M254

M2F4

30.92- 30.97mm 3 1 . 4 2- 3 1 . 4 7m m
- 1.219inl ( 1 . 2 3 7- 1 . 2 3 9i n )
11.217
30.8mm
( 1 . 2 1 i3n )

3 1 . 3m m
l'1.232inl

t,A

El
r| ^J-_-6
lf the thicknessof 3rd gear is lessthan the service
limit,replace3rd gearwith a new one.
l f t h e t h i c k n e s so f 3 r d g e a r i s w i t h i n t h e s e r v i c e
limit, replacethe 3rd/4thsynchro hub with a new
one.

\--t
1
I

. .THGEAn

l
lf the thicknessof 4th gear is lessthan the service
limit, replace4th gearwith a new one.
l f t h e t h i c k n e s so f 4 t h g e a r i s w i t h i n t h e s e r v i c e
limit, replacethe 3rd/4thsynchro hub with a new
one.
(cont'd)

Mainshaft
GlearanceInspection{cont'dl
Measurethe clearancebetweenthe spacer collar
and 5th gear.
0.06- 0.21mm
(0.002- 0.008in)
inl
SsrviceLimit: 0.3 mm 10.012

Disassembly
CAUTION: Removethe synchro hubs using a press and
steel blocks as shown. Use of a iaw.typ puller can
damagethe gsar teeth,

Standsrd:

Removethe ball bearingusing a bearingpuller as

shown.

BEARINGPULLER

BALLBEARING

lf the clearanceexceedsthe servicelimit, measure

distance@ on the spacercollar.
26.03- 26.08mm
{1.025- 1.027in)
SorviceLimit: 26.01mm {1.02'lin)
Standard:

SPACER
COLLAR

STOPPER
RING

sTHGEAR
SIDE
lf distance) is lesathan servicelimit, replacethe
spacercollarwith a new one.
lf distance@ is within the service limit, measure
thicknessof sth gear.
Standard: 30.92- 30.97mm (1.211-1.219inl
inl
ServiceLimit: 30.8mm 11.213
5TH GEAR

lf the thicknessof sth gear is lessthan the service

limit, replace5th gearwith a new one.
l I t h e t h i c k n e s so f 5 t h g e a r i s w i t h i n t h e s e r v i c e
limit, replacethe sth synchrohub with a new one.

13-20

BAI-L
BEARING

MAINSHAFT

lnspection
S u p p o r t s t h g e a r o n s t e e l b l o c k sa s s h o w n a n d
Drsssthe shaftout of the sth synchrohub.

'1. Inspectthe gear surtace and bearing surface for

wear and damage,then measurethe mainshaftat
pointsA, B, and C.
Standard:
A {88ll bearing surlacol:
B (Needlebearing surfaco):
C (Ball bearing 3urface):
Ssrvico Limit A: 27.940mm
B: .37.930mm
C: 27.940mm

27.987- 28.000mm
( 1 . 1 0 1-8 1 . 1 0 2 'i ln )
37.98'l- 38.000mm
(1.irgsit- 1.,t961in)
27.977- 27.99Omm
( 1 . 1 0 1-5 1 . 1 0 2 0
in)
(1.1000in)
(1.4933in)
(1.1000in)

I n s p e c t o i l p a s s a g e sf o r c l o g g i n g .

In the same manneras above,supportthe 3rd gear

on stel blocks and pressthe shaft out of the
3rd/4th svnchro hub as shown.

lf any part of the mainshaftis lessthan the service

limit, replaceit with a new one.
Inspectfor runout.
Standard:
0.02 mm (0.001in) max.
Seivico Limit: 0.05 mm 10.002in)
N O T E : S u p p o r t t h e m a i n s h a f ta t b o t h e n d s a s
snown.

lf the runout exceedsthe servicelimit, reolacethe

mainshaftwith a new one,

13-21

Mainshaft
Reassembly
NOTE:Referto page13-18for reassemblysequence.
1.

Installthe sth synchro hub using the spocialtools

ano a pressas snown.

Support 2nd gar on steel blocks as shown, then

i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n gt h e s p e c i a l
tools and a pressas shown.

ORIVER.,40mm l.D.
07746- (x)30100

NOTE:After installing,inspectthe operationof the

3rd/ 4th synchrohub set.
M2L5,M2S4(T..nsmi$ionTypol:

HUB
sTHSYNCHRO

PRESS

1
3RD/4TH
SYNCHRO
HU8
3.

lnstallthe ball bearingusingthe specialtools and a

pressas snown.

M2F4 {Transmis3ionTypel:

BCARING
ATTACHMENT,35mm l.D.
07745 - (x}301o0

2ND GEAR

13-22

ATTACHMENT,
a2xaTmm
07?46- 0010300

Countershaft
lndex
I

B"for" """"mbling. cleanall partsin solvent,dry them with compressdair,then coatthem with cleanoil.

LOCKNUTReplsce.
130 + 0 + 130N.m
+ 0 + 13kg-m,
113
r 9a + 0 + 9a lb-ft

GEAB
REVERSE

lSI/2ND SYNCHROHUB
Inspction,page 13-30

SPRINGWASHER
BALLBEARING
Checkwear and oporation.

NEEDLEBEARING
Checkwear and operation.
FRICTIONDAMPER
Checkwar and d6mag.

5TH GEAR

SYNCHROSPRING
ilTH GEAR
SYNCHRORING
Inspection,pa96 13-31

lST GEAR

3RD GEAR

page13-24,
3'l
Inspection,
BEARING
NEEDLE
Checkwearsndoporation
THRUSTWASHER
page13-?4
Solection,

2ND GEAR
pag13-24,31
Inspoction,

NEEDI..E
BEARING
Chsckwear and operation.
SPACERCOLLAB
pag13-24
Sel6ction,

OOUNTERSHAFT
InsDection,p8g 13-26

FRICTIONOAMPER
Checkwear and damage.
Removal,page13-25
page13-27
Installation,
INNERSYNCHRORING
page13-31
Inspection,
SYNCHROCONE
OUTERSYNCHRORING
page'13-31
Inspction,
SYNCHROSPRING

13-23

Gountershaft
ClearanceInspection
l,

Measurethe clearancebetweenthe 1st gear and

thrustwasher.

3.

Measurethe clearancebetwoenthe 2nd gear and

3rd gear.

0.04- 0.10mm
{0.002- 0.0O'lin}
ServicaLimit: 0.18 mm 10.007inl
Standard:

Strndlrd:

0.0,1- 0.10mm
{0.002- 0.00il in)
SorvicoLimil:0.18mm (0.007in)

THBUSTWASHER

2.

lf the clearanceexceedsthe servicelimit. selectthe

appropriatethrust washerfor the correctclearance
from the chartbelow,

THRUSTWASHER

1 . 9 6m m ( 0 . 0 7 7 i1n )

23923-PG1-000

2.02mm (0.0795in)

23924-PG1-000
23925- PGl -000

2.05mm (0.0807in)

13-24

lf the clearanceexcesdathe service limit, selectthe

appropriatespace.collar for the correctclearance
from the chart below.

SPACERCOLLAR

Part Number
23921- PG1- 000
2 3 9 2 2 - P G 1- 0 0 0

4.

Thicknaes
1.99mm (0.0783in)

2.08mm 10.0819
inl

Prrt Numbcr

Thickn..s

23917-P21-O10

29.02- 29.04mm
( 1 . 1 4 2- 51 . 1 4 3i 3
n)

23918-P2'r-010

29.07- 29.09mm
( 1 . 1 4 4-5 1 . 1 4 5 i3n )

'1.

S e c u . e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n I
benchvisewith wood blocks.
Raisethe locknuttab from the groove ot the shaft
and removethe locknutand the springwasher,

4.

Remove the friction damper trom the spacer collar

using a prgss and a socket as shown.
PRESS

CHISEL

SPRINGWASHER
BENCH

vtsE

WOODBLOCKS

3.

Replac.

Removethe ball bearingusinga pressas shown.

PRESS

ATTACHMENT

4TH GEAR

COUNTERSHAFT

STEELBLOCKS

3-25

Countershaft
Inspection

Reassembly

'1. lnspect the gear surface and bearing surface for

wear and damage,then measurethe countershaft
at pointsA, B, and C.
StandErd:

A:38.fi10l1.i(t61 B: 39.984{1.5742C: 24.987{0.98:17

NOTE:Referto page13-23for reassemblysequence.

1,

38.015mm
f.il967 inl
/{1.000mm
1.57'18
inl
25.000mm
0.9843in)

Installthe thrustshim, needlebearing,lst gear,friction damper,synchroring,and synchrospring.

NOTE:Reassemble
th lst gear and frictiondamper
beforeinstallation.
SYNCHROSPRING

Limit:A:37.950
Sorvico
mm (t.t*t41in)
B:39.930
mm (1.5729
inl
C:2il.9il0mm (0.9819
inl

SYNCHRORING
FBICTIONDAMPER
lST GEAR
NEEDI.EBEARING
THRUSTSHIM

COUNTERSHAFT

Inspectfor wearand damage.

lf any part ot the countershaftis lessthan the service limit. replaceit with a new one.
Inspectfor runout.
St.ndard:
0.02 mm 10.001in)
SrvicoLimh: 0.05 mm (0.002in)
2.
NOTE:Support th6 countershaftat both ends as
snown.

Installthe 1sv2ndsynchrohub by aligningthe frict i o n d a m p e r f i n g e r s w i t h 1 s t / 2 n ds y n c h r o h u b

grooves.
lST/2ND
SYNCHROHUB

Rotatetwo complelerevolutions,

It the runout exceedsthe servicelimit, reDlacethe

countershaft
with a new one.

13-26

Installthe Jrictiondamperon the spacercollarusing

the soecialtoolsand a Dressas shown.

Installthe needlebearing,
Installthe ball bearing using a specialtool and a
pressas shown.
PRESS

PRESS

DRIVER
077 - 0010000

+
ATTACHMENT,42 x 47 mm
07746- (X)103q)

SPACERCOLLAR

ffi!--;.+a'-,
1.

Installthe springwasher.

8.

S e c u r e l yc l a m p t h c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.

Tightenthe new locknutto the correcttorque,thn

stakethe locknuttab into the groove

I n s t a l tl h e 2 n d g e a r b y a l i g n i n gt h e s y n c h r oc o n e
fingerswith 2nd geargrooves.

Torqus:130+ 0 + 130N.m (13.0- 13.0kg-m,

9 4 + 0 + 9 al b - f t )
LOCKNUT
Replace.

GROOVE

FINGER
BENCH

vtsE

wooD Bl-ocKs

13-27

Shift ForkAssembly
Disassembly/Reassembly
I

e,ior.,o reassembling,
cleanall the partsin solvent,dry them and apply lubricantto any contactparts.

5 mm PIN PUNCH

1ST/2NDSHIFTFORK

13-24

NOTE:The synchrosleeveand synchrohub should be

replacedas a set.
1.

Measurethe clearancebetweeneach shift fork and

its matchingsynchrosleeve.

3.

Measurethe clearancebetweenthe shift fork and

the shift arm.
Standard:
0.2 - 0.5 mm l0.fi)8-0.019in)
SorvicLimit 0.6 mm (0.02i1inl

Standard:
0.35- 0.65mm {0.014- 0.026in}
ServiceLimit: 1.0{ mm {0.039in)
sTH/REVERSE
SHIFTPIECE

SYNCHROSIfEVE

3ND/'TH
SHIFTFORK

SHIFTFORK
SHIFTARM

lf the clearanceexceedsthe servicelimit, measure

the width of the shift arm.
2.

lf the clearanceexceedsthe servicelimit, measure

the thicknessof the shiftfork fingers.

Stlndard: 12.9- 13.0mm (0.508- 0.5f2 inl

Standard:
M2F4(Transmission
Type)
3rd/4th shift fork
M2L5/M2S4(Transmission
Type)
3rd/4th shift fork

7 . 4- 7 . 6m m
(0.291- 0.299in)
6.2- 6.4 mm
|'0.244- 0.252inl

iy

SHIFTARM

SHFTFORK

lf the thicknessof the shift fork finger is less than

the standard,replacethe shjftfork with a new one.
lf the thicknessof the shift fork finger is within the
standard, replacethe synchro sleeve with a new
one.

lf the width of the shift fork finger is less than the

standard,replacethe shiftarm with a new one.
lf the width of the shiftfork finger is within the standard, feplacethe shift fork or shift piecewith a new
ones.

SynchroSleeve,SynchroHub
lnstallation

Inspection
1.

Inspectgear teeth on all synchrohubs and synchro

sleevesfor rounded off corners. which indicates

Eachsynchrosleevehas three sets of longerteeth (120

degreesapan)that must be matchedwith the three sets
of deepergroovesin the synchrohub when assembled.

I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o
sleeveand checkfor freedomof movement.

NOTE:Installingthe synchrosleevewith its longer

teeth in the 1sV2ndsynchrohub slots will damage
the spring ring.

NOTE:lf replacementis required,always replace

ths synchrosleeveand synchrohub as a set.

LONGERTEETH
SYNCHRO
HUB SLOT

SYNCHRO
HUB

13-30

SynchroRing,Gear
Inspection
1.

SYNCHBO

Inspectthe synchroring and gear.

A: Inspectthe insideof the synchroring for wear.
B: Inspectthe synchrosleeveteeth and matching
t e e t h o n t h e s y n c h r or i n g f o r w e a r { r o u n d e d
off).

SYNCHRO

GOODWORN
C: Inspect the synchro sleeve teeth and matching

teethon the gearfor wear (rounde;$).

GOOO WORN

D: Inspectthe gear hub thrustsurfacefor wear.

E: Inspectthe cone surfacefor wear and roughness.

F: Inspectthe teeth on all gearsfor unevenwear.
scoring,galling,and cracks.
2.

C o a t t h e c o n e s u r f a c eo f t h e g e a r w i t h o i l a n d
p l a c et h e s y n c h r o r i n g o n t h e m a t c h i n gg e a r .
Rotatethe rjng, makingsurethat it does not slip.
Measurethe clearancebetweenthe synchro ring
and gear all the way around.
N O T E : H o l d t h e s y n c h r o r i n g a g a i n s tt h e g e a r
evenlywhile measuringthe clearance.
Synchro Ring-to-GearClearance
Standard: 0.85- 1.10mm
(0.033- 0.0,|:|inl
ServicoLimit: 0.4 mm {0.015in)
Doubl Cone Synchro-to-GearClearance
Standard:
@:(Outer Synchro Ring to Synchro Con)
0.5- 1.0mm (0.020-0.039 inl
@: (synchro Cone to Gear)
0.5- 1.0mm (0.020- 0.039in)
@:lOuter Synchro Ring to Gear)
0.95- 1.68mm (0.037- 0.066in)

SYNCI{FORING

Ssrvice Limit:
@:0.3mm (0.012in)
@:0.3mm (0.012in)
@:0.6mm (0.024in)

SYNCHRORING

l f t h e c l e a r a n c ei s I e s s t h a n t h e s e r v i c e l i m i t ,
replacethe synchroring and synchrocone.
INNEN
SYNCHRO
RING

13-31

MainshaftBearing/OilSeal
Replacement
1.

Removethe differentialassembly.

4.

Drivethe new oil seal in from the transmissionside

usingthe specialtoolsas shown.

R e m o v et h e b a l l b e a . i n gw i t h t h e s p e c i a tl o o l a s
snown.
3.

DRIVER
07749- 001(x)00

Removethe oil sealfrom the clutchside.

ATTACHMEN?,
U 2 x 1 7m m
07746 - (x)l0300

3/8 in r( 16 thr.rd/in SLIDEHAMMER

{Comm.rci.lly .v.il.blc)

Aq,USTABLEBEARING
PULER, 25 - 40 mm
07736- A01rDoA
OIL SEAL
Replacs.

Drivethe new ball besringin from the transmission

side usingthe specialtoolsas shown.

BALLBEABING

AALLBEARING

ATTACHMENT,
62x68mm
077a6 - (X)105(x)

AALLAEARING

13-32

CountershaftBearing
Replacement
1.

Removethe retainingplatefrom the clutchhousing.

Positionthe oil guide plateand new needlebearing

in the bore of the clutchhousing.
NOTE:Positionthe needlebearingwith the oil hole
facingup.
OIL HOLES
NEEDLEBEARING

Removethe needle bearing with the specialtool,

then removethe oil guide plate.

Drive the needlebearingin using the specialtools

as shown.

3/8 in x 16 throad/in SLIDEHAMMER

(Commc.ciallyrvailrblel

DRIVER
07749- (xll(xx)O

ADJUSTAB1IBEARING
PULLER,25 - i(, mm
0t736 - A01@0A

NEEDl-E
NEEDLEBEARING

(cont'd)

13-33

CountershaftBearing
Replacement(cont'dl
lnstallthe retainingplsteand stakethe bolt headsin
the groovein the retainingplate.
6x1.0mm
12 N'm {1.2kg-m,9lb-ftl
Replaco.

MainshaftThrustShim
Adjustment
1.

Removethe thrust shim and oil guide plate from

the transmissionhousing.
otl GUIDEPLATE

rHnr rcr qHlM

RETAININGPLATE

Installthe 3rd/4thsynchrohub, spacercollars,sth

synchro hub, and ball bearing on the mainshaft,
then installthe aboveassemblyin the transmission
housrng.
lnstallthewasheron the mainshaft.
Measuredistance@ betweenthe end of the transmissionhousingand washer.
NOTE:
a Usea straightedgeand verniercaliper.
a Measureat three locationsand averagethe readIng.

ENDot
TRANSMISSION
HOUSING

MAINSHAFT

WASHER

3RD/4THSYNCHROHUA
SPACERCOLLAR
sTH SYNCHROHUB
SPACER
BALLBEARING

1 3 -3 4

5.

Measure distance @ between the end of th clutch

housingand bearinginnerrace.
NOTE:
. Usea straightedgand depthgauge.
! Measureat three locationsand averagsthe readings.

ENDof CLUTCHHOUSING

78 mm THRUSTSHIM
Part Numbor
23941- PK5- 000

'1.20mm (0.0472
in)

23942-PKs-000

1.23mm (0.0484in)

23943-PKs-000

1 . 2 6m m ( 0 . 0 4 9 i6n )

23944-PK5-000

1.29mm (0.0508in)

23945-PKs-000

1.32mm (0.0520in)

23946-PKs-000

1.35mm (0.0531in)

23947-PKs-000

1.38mm (0.0543in)

23948-PKs-000
23949-PKs-000

1.41mm (0.0555in)

BEARING

6.

S e l e c tt h e p r o p e rt h r u s t s h i m f r o m t h e c h a r t b y
usingthe formulabelow.
NOTE:Useonly one thrustshim.

you made in steps4 8nd 5:

Fromthe measurements
-1. Add distance@ {step5) to distsnce@ (step4).
-2. Ftom this number,subtract0.93 (which is the midpoint of the flex rangeof the clutchhousingbearing
springwasher).
-3. Take this number and compare it to the available
shim sizesin the chart.
(Forexample)
B: 2.39
+ C: O.22
=
.

,.tr/

,
/,/

2.61
0.93

= t*

Try the 1.68mm (0.0661in) shim.

1.44mm (0.0567in)
1.47mm {0.0579in)

23950-PKs-000
- PKs- 000
23951

23952-PKs-000

1.53mm (0.0602
in)

23953*PKs-000

1.56mm (0.0614in)

23954-PK5-000

1.59mm (0.0626in)

23955-PKs-000

23956-PKs-000

1.62mm (0.0638in)
'1.65mm (0.0650in)

23957-PKs-000

1.68mm (0.0661in)

23958-PKs-000

1.71mm (0.0673in)

23959-PKs-000

1.74mm (0.0685in)

23960-PKs-000
23961- PKs- 000

1.77mm (0.0697in)

23962-PKs-000

1.83mm (0.0720in)

23963-PKs-000
23964-PK5-000

1.86mm (0.0732in)
'1.89mm (0.0744
in)

23965-PK5-000

1.92mm (0.0756in

23966-PKs-000

1.95mm (0.0768in

23967-PKs-000

L98 mm (0.0780in

AB

23968-PKs-000

2.01mm (0.0791in

AC

23969-PKs-000

2.04mm {0.0803in

AD
AE

23970-PKs-000
- PK5- 000
23971

2.07mm {0.0815in
2 . 1 0m m ( 0 . 0 8 2 i7n

AF

23972-PKs-000

2.13mm (0.0839in

23973-PK5-000

Shim SoleqtionFormula:

Thiqkno!!

1.50mm (0.0591in)

1.80mm (0.0709in)

AH

23974-PKs-000

2.16mm (0.0850in
2.19mm (0.0862in)

AI

23975-PKs-000

2.22mm (0.0874
in)

AJ

23976-PKs-000

2.25mm {0.0886in}

AK

23977-PK5-000

2.28mm (0.0898in)

AL

23978-PKs-000
23979-PKs-000

2.31mm (0.0909in)

23980-PKs-000

2.37mm (0.0933in)

AM
AN

2.34mm (0.0921in)
{cont'd)

13-35

MainshaftThrustShim
Adiustment(cont'd)
Checkthe thrust clearancein the mannerdescribed
below,

-7. Slidethe mainshaftbaseover the mainshaft.

MAINSHAFT

NOTE:Carryout the measuremsntat normal room

temperature.

TRANSMISSION

-1. Installthe thrust shim selectedand oil guide

platein the transmissionhousing.
OIL GUIDEPLAYE

-2. Install the spring w a s h e ra n d w a s h e ro n t h e

ball bearing.
NOTE:
. Cleanthe springwasher,washerand thrustshim
throughlybeforeinstallation.
. l n s t a l l t h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t
shim properly.

WASHER

aSttRrNGwasHER
Installthemainshaftin the clutchhousing.
-4. Placethe transmissionhousingover the mainshaftand onto the clutchhousing.
Tighten the clutch 8nd transmissionhousings
with several8 mm and l0 mm bolts
Tap the mainshaftwith a plastichammer.

-8, Attachthe mainshaftholderto the mainshaftas

follows:
NOTE:
o B a c k - o u tt h e m a i n s h a f t h o l d e r b o l t a n d
loosenthe two hex bolts.
. Fit the holderover the mainshaftso its liD is
towardsthe transmission.
. Align the mainshaftholder'slip around the
groove at the insideof the mainshaft
splines,then tightenthe hex bolts.
MAINSHAFT
HOLDER
EOLT

lla-F.

l:vli ffir"
MAINSHAFT
HOLDER
O?GAJ- PG2O11O

BASE
MAINSHAFT
07GAJ- PG20130
-9. Seatthe mainshaftfully by tappingits end with
a plastichammer.
-10. Threadthe mainshaftholderbolt in until it just
c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t
Dase.
-1 1.Zero a dial gaugeon the end of the mainshaft.

13-36

Transmission
Reassembly
-12, Turn the mainshaftholder bolt clockwise;stop
t u r n i n g w h e n t h e d i a l g a u g e h a s r e a c h e di t s
maximum movement.The readingon the dial
gaugeis the amountof mainshaftend play.

Installthe differentialassemblyin the clutch housing.

OIFFERENTIAL
ASSEMBLY

CAUTION: Turning iho mainshaft holder bolt

mor than 60 dogrecs after tho noodle of ths
d i a l g l u g a 3 t o p s m o v i n g m a y d a m a g ot h e
transmission.
DIALGAUGE

MAINSHAFT
HOLDER
07GAJ- FG20110
-13. lf the readingis within the standard.the clearance is correct.
lf the reading is not within the standard. recheckthe shim thickness.
Strndard:0.10-

0.16mm (0.00i1- 0.006in)

CLUTCH
HOUSING
Installthe springwasherand washerwith the angle
againstthe clutchhousingas shown
lnsertthe mainshaftand countershaftinto the shift
forks 8nd installthemas an assemblv.
NOTE: Beforeinstallingthe mainshaftand countershaft assemblies,
tape the mainshaftsplinesto protectthem.
MAINSHAFT
ASSEMBLY

Tapethe mainshaft
splrn6.

(cont'd)

13-37

Transmission
(cont'dl
Reassembly
4.

Installthe reverseidler gear and reverseidler gear

shaft in the clutchhousing.

NOTE:Selectthe thrust shim accordingto the measurmentsmadeon page13-34.

6.

Installthe oil guide plate and thrust shim into the

transmissionhousing.

CLUTCH
TRANSMISSION
HOUSING

5.

Installthe reverseshift fork in the clutch housing

with th sth/reverse
shift piecepin positionedin the
slot of the reverseshift fork,
NOTE:Checkthat the steelball is in the properposiIlon.

7.

Installthe oil gutter plate in the transmissionhousing.

NOTE:Bendthe hook of the oil gutter plateinto the
holeon the transmissionhousing.
Installthe28 mm sealingbolt.

REVERSE
SHIFTFORK

6x1.0mm
15 N'm 11.5kg-m.11lb-ft,

NOTE:Apply liquid gasket(P/N 08718the threads.

28 mm SEALINGBOLT
15 N.m 14.5kg-m, 33 lb-ftl
OIL GUTTERPLATE

TNANSMISSIONHOUSING

13-38

0001)to

Apply liquid gasketto the clutch housing mating

surfaceas shown.
NOTE:
. Useliquidgasket(P/N08718- 0001).
. Removethe dirt oil fromthe sealingsurface.
. Seal the entirecircumference
of the bolt hole to
preventoil leakage.
. lf 20 minutes have passedafter applying liquid
g a s k e t ,r e a p p l yi t a n d a s s e m b l et h e h o u s i n g s
a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r
assemblybeforefillingtransmissionwith oil.

12. Lower the transmissionhousingwith the snap ring

p l i e r sa n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e
countershaftbearing.
SNAPRING

---: Liquid g6k.t

*: Dow6l pin

1 0 . Installthe14 x 20 mm dowel pins.

1 1 . Set the stopperring as shown. Placethe transmission housingover the clutchhousing,being careful
to line up the shafts.
NOTE:Align the long arm of sth shift fork with the
hook on the stopperring.

1 3 . Checkthat the snap ring is securelyseated in the

grooveof the countershaftbearing.
DimensionA as installed: 3.60 - 6.32 mm
l0.i,r2_ 0.249inl
1 4 . Installthe 32 mm sealingbolt.

NOTE:Apply liquid gasket(PiN 08718the threads.

32mm SEAI-ING
BOLT
25 N.m12.5kg-m,18lb-ftl

0001)to

sNAperN.:

{ c o n t ' )d

13-39

Assembly
Transmission

Transmission

lnstallation

Reassembly(cont'dl
tc,

Torque the bolts in a crisscrosspattern in several

stepsas shown.

1.

Installthe dowel pins.

I x 1.25mm bolts: 28 N'm (2.8 kg"m, 20 lb-ft)

10 x 1.25mm bolts: ,15N.m (4.5 kg-m, 33 lb-ft|
1O mm BOLTS

O Or 8 x 50 mm bolts
Other:8 x /U'mm bolts

Apply greaseto the pans as shown,then installthe

releasebearingand releasefork (seepage 12-7).

16. Installthe reverseidlergearshaft bolt.

N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e
(P/N08798- 9002).

17. Installthe steel balls,springs,washersand settlng

screws.
BALLlD.5/16in)
STEEL
WASHER
Beplace.
G SCREW
22 N.m {2.2kg-m, 16lb-ft)

RELEASEFORK

RELEASEFORK
SETSPRING

I
I

RELEASE
FORK
BOOT
FORKBOLT
30 N.m 13.0kg-m, 22 lb-Itl

3.
BOLT
55 N.m 15.5kg'm. 40 lb'ttl
shift arm cover assembly (see page 13-

18
13).

19. Shift the transmissionthrough all the gears before

installingit.

1 3 -4 0

lnstallthereleasefork boot.

P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o ni a c k ,
and raiseit to the enginelevel.

7.

Installthe three lowertfansmissionmountinqbolts.

R a i s et h e t r a n s m i s s i o n ,t h e n i n s t a l l t h e m o u n t
bracketand transmissionmount.
NOTE:
. T o r q u e m o u n t i n gb o l t s a n d n u t s i n s e q u e n c e
snown.
. Makesurethe bushingsare not twistedor offset.

12 x 1.25mm
65 N.m 16.5kg-m.

TBANSMISSION
MOUNT

O Tighren
10x 1.25mm

O Tighten
10 x 1.25mm
39 N.m 13.9kg-]n,
tb-ft)

BRACKET
66 N.m (6.5kg-m, ia1lb-ft)

O tidhron

6.

Installthe two uppertransmissionmountingbolts.

O Tighton
10x 1.25mm
10 x 1.25mm
39 N.m (3.9kg-m, 39 N.rn 13,9kg-m,
28 tb-ft)
28 rb-ft)
O Tight.n t.mpor..ily
@ Tighron
12x 1.25mm
65 N{n (6.5 kg-m, a7 lb"ftl
8.

Install the th.ee rear engjne mount bracketmounting bolts.

MOUNTINGBOLTS
Replace.
12 x 1.25mm
55 N.m 15.5kg-m, 40 lb-ft)

12 x 1,25mm
65 N.m (6.5kg-m, 4t lb-ft}

(cont'd)

TransmissionAssembly
Installation(cont'dl
9. lnstalltherearbeamstiftener.

11. Installthe front enginestiffenerand clutchcover.

NOTE:Torque the front engine stiftenermounting
boltsfollowingthe numberedsequenca.
Torque: 39 N.m 13.9kg-m. 28 lb-ft)

3!, N.m {3.9 kg-rn, 28 tb-ft)

'10. Install the intake manifold staY.

INTAKEMANIFOLDSTAY

12. lnstallthe centerbeam,

10 x 1.25mm
60 N.m 16.0kg-m, 43 lb-ftl

13-42

Installthe intermediateshaft and driveshafts{see

section161.

1 7 . Installthe rearenginemount bracketstay.

NOTE: Loosely installthe stay mounting bolt and
nut, then torque in the sequenceshown.

10x 1.25mm
39 N.m13.9kg-m,28lb-ft|

10x 1.25mm
21 N.m {2.'l kg-m,
15 tb-ft|

SPECIALBOLT
10 x 1.25mm
39 N.m (3.9tg-m,
28 tb-ft,

1 4 . Installtheradiusrod.
NOTE: Check for deteriorationor damage of the
radiusrod rubberbushings.
1 5 . Connectthe ball joint to the lower arm, then install
t h e b a l l j o i n tn u t .

10x 1.25mm
39 N.m 13.9kg-m, 28 lb-ft)

16. Installthe damper fork bolt,

SELF.LOCKING
BOLTS
Replac.
12 r 1,25mm
105 N{n (10.5kg-m, ?6lb-ft|

SELF.LOCKING
NUT
Replace.
12 x 1.25mm
55 N{r| (5.5 kg-m,

18. Installtheclutchdamoer.

40 tb-ft|

ROD

/1*-

corrERPrN

Replace.
/
AALLJOINT NUT
14xZtmm
55 N.m 15.5kg-m. 40 lb-ltl

SELF.LOCKING
NUT
Replace.
12x 1.25mm
65 N.m {6.5 kg-m, a7 lb-ft|
I x 1.25mm
22 N.m 12.2kg-m, 16 lb-ft|

(cont'd)

13-43

TransmissionAssembly
lnstallation (cont'dl
19. Installthe slavecylinder,then installthe clutch pipe
joint and stay.
CAUTION: Take care not to bend the clutch pipe.

21. Installthe shift cable and selectcable to the shift

leverand to selectleverrespectavely.
CAUTION: Tako care not to bsnd the cabls.
NOTE:
! Checkthat the new cotterpin is seatedfirmly.
. Turn the boot of the shift leverso the hole is facIng down.
I x 1.25mm

I x 1.25 mm
22 N.m 12.2kg-m, 16 lb'ft}

{P/N 08798- 90021

COTTERPIN
ReplaceSTEEL
WASHER
PLASTIC
WASHER
SELECT
CABLE

6x1.0mm
10 N.m {1.0kg-m,
7 rb-ft}

CABLE

)
tP/N 08798- 9002)

8 x 1.25mm
22 N.m
{2.2kg-m, 16lb-ft}

PIN
COTTEB
Replace.

BOOT
SHIFTLEVER
WASHER

WASHER

22. Connectthe transmissiongroundcableand back-up

light switchconnectors.
20. Installthe vehiclespeedsensor(VSS)/powersteering speedsensor,then connectthe VSSconnector'

23. Installthewire harnessclamp.

24. Installthe starter motor, then connect the starter
motor cables.

I x 1.25mm
kg-m,14lb-ft)
19N.m11.9
S CONNECTOR

Mr"'

POWERSTEERING
SPEEDSENSOR

N O T E : W h e n i n s t a l l i n gt h e s t a r t e r m o t o r c a b l e ,
makesurethat the crimpedside of the ring terminal
is facingout (seesection23).
6x1.0mm

l0 x 1.25mm

t 'o-ft1 45N'm(il5 ks-m,33lb-ft|

io r'i'"'ii.i 11n--,

fnt$rtt ,"o""",..to"
GROUND
CABLE

WIRE
HARNESS- ,
CLAMP
STARTER
MOTOB
CABLES

8 x 1.25mm
22 N.m (2.2kg-m,
16 tb-ft)

13-44

12 x 1.25mm
75 N.m (7.5kg-m,
54 tb'ft)
6x1.0mm
't0 N.m 11.0kg-m,7 rb-ft)

25. Installthe bracketand intakecontrolvacuumtank.

27. Installthebasestayand batterybase.

INTAKECONTROL

x 1,0mm
10 N.m 11.0kg-m,
7 tb-ft|

BASE
STAY

6x1.0mm
10 N.rn (1.0kg-m,
7 tb.ftl

BRACKET

8 x 1,25mm
22 N.m (2.2 kg-m,
16 rb-ft}

Front

26. Installthe air cleanerassemblvand intakeair duct.

6x1.0mm
10 N.m {1.0kg-m,7 lb-ft|

24. Refillthetransmissionwith oil (seepage13-2).

29. Install the battery. then connect the battery positive
(+) and negative(-) cablesto the battery.
30. Checkthe clutchoperation.
3 1 . Shift the transmissionand checkfor smooth operatron.
32. Checkthe front wheel alignment{seesection18).

{cont'd)

13-45

TransmissionAssembly
Installation (cont'd)
33. Loosenthe three mountingbolts of the front engine
m o u n t b r a c k e t ,t h e n t o r q u e t h e t h r e e m o u n t i n g
bolts.
NOTE:Make sure the bushingsare not twisted or
offset.
ENGINE
MOUNTBRACKET
FRONT

13 -4 6

Automatic Transmission
Tools.....
Speciaf
........14-2
OilPump
Description
........
........14-3
Inspection..........
....14-101
C1utches.............................................1
4-6
MainValve Bodv
PowerF|ow.......................................1
4-9
Disassembly/lnspection/Reassembly.
.....'l4-102
Electrical
ControlSvstem................1
4-10
SecondaryValveBody
Hydraulic
Flow.................................,1
4-13
Disassembly/lnspection/Reassembly.
.....14-104
Lock-upSystem...............................1
4-22
RegulatorValve Body
Hydraufic
Contro1..............................1
4-28
14- 106
Disassembly/lnspection/Reassembly......
ThrottleValveBody
EloctricalSystom
Disassembly/lnspection/Reassembly.
.....14'107
Component
Location.......,...................1
4-31
Servo Body
CircuitDiagram.
........14-32
1+ 108
Disassembly/lnspection/Reassembly......
* Troubleshooting
Procedures...,,,,.,,,,,,,1
4-g
1st/2ndAccumulatorBody
Symptom-to-Component
Charr
14- 109
Disassembly/lnspection/Reassembly......
Electrical
Svstem..............................1
4-36
Mainshaft
ElectricalTroubleshooting
+1 1O
Disassembly/lnspection/Reassembly.
.....1
Troubleshooting
F|owchart...............,....
14-38
Countershaft
Mainshaft/Countershaft
SoeedSensors
Disassembly/lnspection/Reassembly.
.....14-11 1
Replacement
.........14-61
Remova1.............
....14-112
Lock-upControlSolenoidValveA/B
13
lnstallation
.,...........14-1
Test..........,.........
....14-62
One-wavClutch
Repfacement
.........14-62
+1 14
Disassembly/lnspection/Reassembly.
.....1
Shift ControlSolenoidValveA/B
SecondarvShaft
Test....................
....14-63
15
Disassembly/lnspection/Reassembly......14-1
Replacement
.........14-63
Insoection..........
....14-116
Clutch
HydraulicSystom
+1 17
flfustrated
fndex...................
..............1
Symptom-to-Component
Chart
Hydraulic
System.............................1
+64
* RoadTest.......
...........14-68
StallSoeed
Test....................................................1
4-71
FluidLevel
+1 28
Countershaft
Bearing
Replacement...,.,..1
Checking/Changin9.......................
....1
+72
4-128
Secondary
ShaftBearing
Replacemen1...1
Pressure
Testin9.................,,..,,..,...,.....1
4-73
Transmission
HousingBearings
Removal/lnstallation
.....................
....14-129
Transmission
Transmission
Transmission
Reassembly
.......
....1+130
Remova1.............
....14-80
RightSideCover
lllustratedlndex
+1 36
FeedPipeInsta;;ation......................,.1
RightSideCover...............................1
4-86
ParkingBrakeStopper
Transmission
Housin9......................1
4-88
4-1s?6
Inspection/Adlustment
....................1
TorqueConverterHousin9...........,,.1
4-90
ToroueConverter
RightSideCover
Disassemblv
..........1+'137
Remova1.............
....14-92
Transmission
Transmission
Housing
Installation
.............1+138
Remova|.............
....14-94
CooferFlushing..
..,.14-142
TorqueConverter
Housing/Vafue
Body
shifr cable
*Removal/lnstallation
Remova|.............
....14-96
4-144
..............,...
.,,,,,.1
*Adjustment......
ValveBodv
......14'146
* Gearshift
Repair.................
....14-98
4'147
Selector.............,,..,,.,,,,,.,...,.1
Valve
A/T GearPositionIndicatorPanel
*Adjustment......
Assembly...........
....14-99
.,'.1+148
ValveCaos
ThrottleControlCable
Description
...,....
....14-100
Insoection..........
....14-149
Adiustment........
....14-150

'i45"Hgffi
*i:|i'',i',

SpecialTools

Rot. t{o.

o
ri

o
o

@
@

@
@
'@
@
@
@

@
@

07GAB-PF5010Oor
07GAB-PF50101
oTGAE-PG40200
oTHAC-PK4010A
07HAE-PL50100
07LAE-PX40100
OTLAJ-PT3O1OA
07406-@20201
07406-@20@3
07106-0070@0
07730-A010@A
07746-@10400
07746-OO10500
07746-0010600
07749-OO10000
07947-63zto5@
J38405-A

otv

Dolcrlptlon

Tool Numbar

PagoRoferanca

MainshsttHoHer

1+92,1U

ClutchSprinoCompressor
BoltAssmbv
HousingPullor
Clutch SpringCompressorAttachment
Clutch SpringCompresaorAttachm6nt
Test Harnass
Hoss}
A/T oilPressure
Hose{ReDlacement
A/T OilPressureGsugeSt
A/T Low PressureGauge
AdjustableBesringPuller,25-40 mm
Attschment, 52 x 55 mm
Attachment, 62 x 68 mm
Attachment, 72 x 75 mm
Oriver
Attachment
TransmissionCoolrFlushor

1
1
I
I
I
I
1
1
1
1
1
1
1
1
'I

1+121,124
1+93
1+121,124
1+121,124
1+35,68
1+73
1+73
1+73
1+1n
1+18
1+127,'128
1+'127
1+127,14
1+127
1+142

6,rmr--

\!,

0
'0

14-2

Must be used with commerciallyavailable3/8 in, x 16 throads/in.slid6nammer.

Description
The Automatic Transmissionis a combination of a 3-element torque converter 8nd tripls-shaft electronicaly controllod
sutom8tic transmissionwhich provides 4 speedsforward and 1 speed reverse.The entire unit is poshionedin line with the
engrne.
Torqug Convarter, G6arsand Clutches
The torque converter consistsof a pump,turbine and stator Sssembledin a singlsunh,
Thsy are connectedto the enginecrankshsJtso they turn togethr as a unh as the engineturns. Around th outside of the
torque convrter is a ring gear which meshes with the stsrtel pinion wh6n the engin ig bing st8rt6d. The antir torque
converter assemblyservesas a flywheel while transmittingpower to the transmissionmainshaft.
The transmissionhas three psrsllelshatts: the mainshatt,the countershaft, and ths secondaryshaft. The mainshaftis in line
with the enginecrankshsJt.
The mainshaftincludesthe clutchestor 3rd. snd 4th, and gearsfor 3rd, 4th, R6vsrseand ldlor (Rsversegesr is intogralwith 4th
gear).
The countershaftincludesthe lst-hold clutch and gearsfor 2nd, 3rd, 4th, Reverse,lst EndHler.
Th6 secondaryshaft includesthe 1st and 2nd clutches,andgesrstor 2nd, 1st and Hler.
The 4th 8nd reverse garscan be lockedto the countershaft 8t its center, providing4th gear or Reverse,dependingon which
w8v the selectoris moved.
Ths gears on the msinshaJtare in constsnt msh with thosa on ths countershatt and the secondaryshaft. When certain
combinationsof gears illbe lMsDl9giol lre etglged by the clutches, power is tr8nsmitted from the mainshalt to the
countershaftto pro"ia" O.-l,f-O"-l,f , T and@oosirions.
EleqtronicControl
The electroniccontrol system consistsof the TransmissionControl Module{TCM),sensors,and 4 solonoidvalves.Shifting 8nd
lock-upare l6ctronicsllycontrolledfor comtonable drivingunder allconditions,
The TCM is locatedb8low the dsshboard,behindthe right sido kick panolon the psss6ng6r'ssids.
Hydr8ullcConilol
The vslve bodiesincludethe main valve body. secondaryvafue body, servo body, regulatorvafue body, throttl vsve body and
lst/2nd accumulatofbody.They 8re bohedto the torque converter housingas an assembly,
The main vslve body containsthe msnualvalve, 1-2 shift valvs, 2-3 shift valvs, coolel relief valve, lock-up shift vafue, lock-up
control valve, 3-2 kick-down valve, modul8torvatue.CPCvalve and oil pump gears,
The secondaryvalvo body includesthe 4th exhaust valve, 3rd kick-down v8lve,3-4 shift vafu, servo control vslve, orific
controlvalveandthe 2ndotificecontrolvalv6.
The servo body contains the accumulator pistons 8nd servo valve. The rogulEtorvafus body contains the roguhtor valve,
torque converter check valve, and lock-uptiming v8lve. The throttle valve body contains ths throttle valve B and relief valve.
Fluidfrom the regulatorpassesthroughthe manuslvatveto the variouscontrol valves.
The clutchesreceiveoiltrom their respectivefeed pip6sor internalhydrauliccircuit,
Shlft Control Mechanism
Input from various sensors located throughout the car determinswhich shift control solsnoidvalve the TCM will activate.
Activating 8 shiJt control solenoidvalve chsngesmodulator pressure,causingI shtft valve to move. This pressurizesa line to
one of the clutches,engagingthat clutch and its correspondinggear,
Lock-up Machanlsm
InL91l position,in 2nd, 3rd and 4th. andI D3 | positionin 3rd, pressurizedfluid is drainedfrom the back of the torque converter
througir an oil pass8ge,csusing the lock-up piston to be heH agsinst the torqus converter cover. As this takes phcs, th
mainshaftrotates 8t the samespeedas the enginecrankshaft.Togetherwith hydrsuliccontrol, the TCM optimizesthe timingof
the lock-upmechanism.
The lock-upvatuescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalves A and B, andthrottle valve B.
When lock-up controlsolsnoid vslves A and B activate, modulatorpressurechanges.Lock-up controlsolenoidvslvs A and B
are mountedon the torque converter housing.and are controlledby the TCM,
lcont'dl

14-3

Description
(cont'd)
Gaar Sobction

gear,"n0"", @
Thesetectorteverhassevenpositions:@PARKt,
Fl REVERSe,
@ rueurnef-,1o. 11stthroush4th
1stthrough
3rdgearrangss,
| 2l2ndgearandl1 llstge8r.
Position

@ernr
I nl nevensr
I n-]r.reurnnroo-l
onve
I(1st
through

4th)

Dolcrlptlon
Front wheelslocked;p8rkingpswlengsgsdwith parkinggesr on countershaft.Allclutches released.
Reve.se;reverseselectorengagedwith countershaftreversegear8nd 4th gearclutch locked.
Allclutches released.
Generaldriving;starts oft in lst, shifts automaticallyto 2nd, 3rd, thsn 4th, dependingon vehiclespeed
and throttle poshion. Downshift tEglgh 3rd, 2nd and 1st on decelerationto stop. The lock-up
mechanismcomes into operstionin LP1Jpositionin 2nd, 3rd and 4th speed.

I o.lonve
Flst throush
3rdl

For rapidaccelerationat highwayspeedsand genersldrivlng;up-hillanddown-hilldriving;starts otf in

lst, shifts automsticslly to 2nd, then 3rd, dspsnding on vehicle speed and throttl position.
DownshiJtsthrough 2nd to 1st on dscelertionto stop. The lock-up mechsnismcomes into operation
in 3rd sDeed.

@secor.ro

For enginebrskingor better traction starting off on looseor slipporysurfaces;stsys in 2nd gsar,doos
not shitt up or down.

f rrnsr

For enginebrsking;stays in lst ge8r,does not shift up.

St8rting is possibleonly in Ll,l andL!_.1positionsthrough th use ol 8 slide-type,nutral-ssfetyswitch.

Automatlc TransaxlolA/Tl GoEl PoshlonIndlcatol
A/T gear position indicator in the instrument panelshows what gear has been selectedwithout hsving to look down at the
consore.

14-4

VA\

,IST CLUTCH

RINGGEAR

TOBOUECOT{VERTER

2I{D CLUTCH

COU TEASHAFT
SPEEDSE SOR

lST-HOLD
CLUTCH

PARKINGGEAR

4TH CLUTCH

3RD CLUTCH

14-5

Description
Clutches
The four-speed automatic transmissionuses hydraulicallyactuated clutches to engageor disengagethe transmissiongears.
When clutch pressureis introducedinto the clutch drum, the clutch piston is Epplied.This presssthe friction discs and stsl
plstes together. locking them so they don't slip. Power is then transmitted the through the engagedclutch psck to its hubmountedgear.
Likewise,when clutch pressureis bledlrom the clutch pack, the piston releasesthe triction discs and stsel plstes,snd thy are
tree to slidepast each other while disengaged.
This allowsthe gearto spin independentlyof its shaft, trsnsmittingno power.
13t Clutch
lst gear,and is locatedat the center of the secondaryshaft.
The lst clutch engges/disengages
The lst clutch is joinedback-to-b8ckto the 2nd clutch.
The 1st clutch is suppliedclutch pressureby its oilfeed pipe within the secondsryshaft,
1st-hoH Clutch
'l
The 1st-holdclutch engages/disengages
st-holdor 1 1 i position,and is locatedat the end of the countershaft,just behind
the torque converter housing.The I st-holdclutch is-suppliedclutch pressureby its oil teed pipe within the countershsft.
2nd Clutch
The 2id clutch engages/disengages
2nd gear,and is locatedat the center of th6 secondaryshaft, The hd clutch is ioined backto-back to the 1st clutch. The 2nd clutch is suppliedclutch pressurethrough th socondaryshsft by a circuit connectedto th6
internalhydraulic
circuit.
3rd Clutch
The 3rd clutch engages/disengages
3rd geaf,and is locatedat the center of the msinshsft.
The 3rd clutch is joinedback-to-backto the 4th clutch.
The 3rd clutch is suppliedclutch pressurethroughthe mainshaftby a circuit connoctodto ths regulatorvalve body,
4th Clutch
The 4th clutch engages/disengages
4th gear, as well as reverse gear, and is located at the c6nt6r of the msinshaft.The4th
clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied clutch proasuraby its oil feed pipe within the
mainshaft.
One-way Clutch
The one-wayclutch is positionedbetweenthe countershaft lst gear and 3rd 968r,with the 3rd gsar splinedto th countsrshsft.
The 1st gear providesthe outer racs surface, and the 3rd gear providesthe inner race surfacs, The on-way clutch locks up
when power istransmitted from the mainshaft1st gearto the countershEft1st gear.
_
The lst clutch and gearsremainengagedin the 1st. 2nd, 3rd, and 4th gsr rangssin the ll1l, fQg,lor l ll oosition.
position.
However, the one-wayclutch disengageswhen the 2nd, 3rd, or 4th clutches/gsErsare aooliedin th@
, I olorl2l
This is becausethe increasedrotationalspeedof the gesrson the countershstt overridesths locking"spe6d range" of th6 onsway clutch,Thereafter,the one-way clutch freewheelswith the 1st clutch still6ngaged.

COUNTERSHAFT1ST GEAA
LOCKS

FREE

NOTE:
Viewlrom rightsidcovorsid.

14-6

COUNTERSHAFT
3RDGEAR
MANSHAFT
COUI{TERSHAFT
1ST GEAB

3RD CLUTCH
4TH CLUTCH
MAII{SHAFT
4TH GEAR
MAIITSHAFT
REVERSEGEAR

MAII{SHAFT
IDLERGEAR
COUNTERSHAFT
4TH GEAR

REVERSE
SELECTOR

MAIl{SHAFT

SEI.ECTOR
HUB
COUTTERSHAFT
IDLER
GEAR

FII{ALDRIVE
lST.HOLD

ARKINGGEAR

SECOI{DARY
SHAFT

COUNTERSHAFT
2NDGEAR
COUiITERSHAFT
REVERSE
GEAR
SECONDARYSHAFT
IDLERGEAN

SECOI{DARYSHAFT
2NO GEAR
2ND CLUTCH

FI AL DRIVEI{GEAR

14-7

Description
Clutches(cont'd)
Lock-up Clutch
1. Operation{clutchon)
With th lock-up clutch on, ths oil in the chsmbor between the converter cover and lock-up piston is drsined otf, snd the
converter oil exerts prssurethroughthe piston againstthe convertsr cover. As a resuh,the converter turbine is lockedto the
converter cover. The effect is to bypassthe converter, thereby placingthe car in direct drive.

tF"*"'ffil

PISTON
LOCK.UP

DAMPERSPRING

The power flows by way of:

Engine

Driv plat

Torqueconverter cover

Lock-up piston

Dsmperspring

Turbine

Msinshalt

MAINSHAFT

2. Operation(clutchotf)
With the lock-upclutch off, the oil flows in the revers of CLUTCHON.As s resutt,the lock-up piston moves away from the
converter cover andth torouo converter lock-uDis relasd,
TURBINE

Engine
tirive plate
J
Torqueconvrtercover
J
Pump
J
Turbine
J
Mainshaft

MAINSHAFT

14-8

PowerFlow

}K
tr

t^-l

tr'|

4TH

t5l

2ND
3RD

f;t

tr

o
o
o
o
o

o
-o
-o
X

3RD

2ND

Lil

o
o
o

sT

TOROUE1STGEAR lST GEAF 1 S TG E A F2NDGEAF3RDGEAR

4TH
REVERSEPARKING
coN- 'IST-HOLD l S T ONE-WAY 2ND
3RD
GEAR
GEAR
VERTER CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH

.o

o
.o
X

.o

.o
o

O: Operates, x: Doesn't operate, *: Akhough the 1st clutch engsges,driving pow6r in not transmittsd as the one-wav clutch
sliDs.
COUNTERSMFT MAINSHAFT
1STGEAR
3RD GEAR 3RDCLUTCH

MANSHAFT

GEAR
4THCLUTCH REVERSE
COUt'ITERSHAFT
3RDGEAR

MAII{SHAFT /

4TH GEAR

REVERSEIDLERGEAR

MAINSHAFTIDLERGEAR
MAINSHAFT
COUiITERSHAFT
2I{D GEAR
COUNTERSHAFT
IDLERGEAR
PARKI G GEAR

<-

coul{TERSHAFT
PARKI]'IGPAWL
SECONOARYSHAFT

OIL PUMP

TOROUECONVEBTER

SECONDARYSHAFT
IDLERGEAR

FINAL
GEAR
lST.TIOLDCLUTCH

SHAFT 1ST
GEAR
lST CLUTCH

2NDCLUTCHI

SECODARYSH/TFT
2NDGEAR
COUI{TRSHAFT
REVERSE
OEAR
REVERSE
SELECTOR
COUI{TERSHAFT
4TH GEAR

SERVOVALVE

14-9

Description
ElectronicControlSystem
Eloctror c Contlol Systom
The sloctroniccontrol system consistsot the TransmissionControl Module{TCM},sensors,and 4 solnoidvalves. Shitting8nd
lock-upars sloctronicsllycontrollsdfor comfortabledrivingundersllconditions,
The TCM is locatedbslow the dsshboard,behindthe right side kick panelonthe passengar'ssida,
Shlft Control
Gstting a signslfrom each sensor,the TCM determinesthe appropriategearand activatesshift controlsolenoidvavos A and/or
The combinationof drivingsignalsto shift controlsolenoidvafuesA and B is shown in the tsble below.
\Shitt control solenoidvalve

ON

OFF

@a'at
1o.-llos-ltrstt

ON

ON

OFF

ON

I o.-llo.-lrznar
15.-llo.-lts,ar

ON

ON

ON

OFF

OFF

OFF

ON

OFF

Position(gesr)

trstt

(4th)

tr

Lock-up Contlol
From sensor input signals,the TCM determineswhether to turn the lock-up ON or OFFand activates lock-up control solenoid
valve A and/or B accordingly.
The combinationot drivingsignalsto lock-upcontrolsolenoidvalves A and B is shown in th6 table below.

Solenoidvalve
A

t*"*"-*----\
Lock-up OFF

urr

Lock-up,slight

ON

Duty operstion
OFF1) ON

Lock-up,hstf

ON

ON

Lock-up,full

ON

ON

LOCI(-Up
during dec6leration

ON

Duty operation
OFF<J ON

14-10

OFF

I
U

Throttlo Position
SonsorSignal

Shlft Conlrol
SolenoidValve A

Shift Control
Shift Control
Sobnoid Valve B

EnginoCoolam
Senso. Sienal
ENGINE

cot{TRoL
MODULE
IECM}

Sorylco Check
Connector

Lock.up Control
SoLnoid V.tue A
Lock-up
Control
Lock-upControl
Solonoid Valv6 B

EngineSpood

Alr Conditioning
Signal

BrakoSwitch
Signal
Main!haft/Countor$haft
Spo6dSsnso. Signal

Vohlclo SpedSeNor Slgnal

not"ao,Lretr

'

I]]]

II{TERLOCK
CONTROLUNIT

D.

Dr

Solt-Diagnosi3
Signol

14-11

Description
ElectronicControl System (cont'd)
Clrcuh Diagramand Terminal Locstion

;
-:.'

nr
r 1 r9 : n{FoTrt! 9osllroN
r 2 ECT: ENGIIE
COOLiTTTIMPIiATLJRI

'/;scs

ms|rtFlcoiTior

rocx utco{nol

A13lA1!
A1

TCM TERMINALLOCATION

14-12

HydraulicFlow
No,
1

4
L'

DESCRIPTION
OF PRESSURE
LINE
LINE
LINE
LINE
LINE
LINE
LINE
LINE

MODULATE

No.

DESCRIPTION
OF PRESSURE

No.

No,

6'

MODULATE
(DUTYCONTROL)

DESCRIPTION
OF PRESSURE

30

3RDCLUTCH

93

31
l ST CLUTCH
lST.HOLDCLUTCH
lST.HOLDCLUTCH
LINE
2NDCLUTCH
2NDCLUTCH
LINE

4A

3RD CLUTCH
4TH CLUTCH
4TH CLUTCH

10
15
18

21
zc

41

THROTTLEB
90
9l

qA

s9

THROTTLEB
X
TOROUECONVERTER

DESCRIPTION
OF PRESSTIRF
OILCOOLER
LUBRICATION

TOROUECONVERTER
SUCTION

BLEED

TOROUECONVERTER
92 TOROUECONVERTER

I N I Position
As the enginetufns, the oil pump alsostarts to operate.Automatic transmissionfluid (ATFI is drawn from (g9l and dischsrged
into (1).Then, ATF pressureis controlledby the regulatorvalve and becomesthe line pressure{1).The torque converter intet
pressure(921enters (94)of torque converter throughthe orifice and dischargesjnto (90).
The torque conve,ter check valve preventsthe torque converter pressurefrom rising.
Underthis condition,the hydraulicpressureis not appliedto the clutchesas the manualvalv6 stoDsline oressure{l ).
NOTE:
When used,"lett" or "right" indicatesdirectionon the flowchart.

(cont'd)

14-13

Description
HydraulicFlow (cont'dl
I 1 lPositlon
Th6 linepressure(1)becomeslinepressure{4)at the manualvalveandpassesto the lst clutchand lst accumulator.
Then line pressure(4) flows throughthe 1st-holdclutch and 1st-holdaccumulator.The power is transmittedonly during
deceleration
throughthe lst-holdclutch,
Fluidflows bv wav of :
- LinePressurel4)+ 1-2 Shift Vatve+ 2-3 Shift Valve- 3rd ClutchPressure(31)+ 3-4 Shift Vslve-4th ClutchPressure
(41)r ManualValve- I st-holdClutchPressure(16)J 1st-holdClutch
to the 1-2and2-3 shift valves.
The modulatorpressure(6)is supplied
The line pressure(1)alsotlows to throttle valve B.
NOTE;
"left" or "right" indicatesdirectionon the flowchart.
When used,

14-14

I 2 lPosition
The linepressure(1)becomeslinepressure{4) as it passesthroughthe manualvslve.h then goesthroughline (2O)to the 2nd
clutch.Also.linepressure(1)goesto the modulatorvalvethroughthe fiher andbecomesthe modulatorpressure(6l,Modulator
pressure{6)is not supplledto the l-2, 2-3 and3-4 shift valves.
Linpressure(1)alsoflows to throttlevalveB.
NOTE:
When used,"lett" or "right" indicatesdirectionon the flowchart,

{cont'd)

'14-15

Description
HydraulicFlow {cont'd}
I oglo.lEl Positio"
1.

1st Spod
The f low of f luidthroughthe torqueconvertercircuitis the sameas inI N lposition.
The line pressure (1) becomesline pressure{4} and it becomesthe 1-stclutch pressure{10).The lst clutch prossureis
aooliedto the 1st clutch and 1st accumulator;consequently,the vehiclewill move as the enginepower is transmitted.
The line Dressure(1) becomesthe modulatorpressure(6) by the modulatorvalve snd travsls to 1-2 8nd 3-4 shift v8lvs.
The 1-2 shitt vave is moved to the right side becausethe shift control solenoidvalve A is turned ofJ 8nd B is turned on by
the TCM, This valve stops 2nd clutch pressureand the power is not transmittedto the 2nd clutch.
Lins pressure{4)alsoflows to the servo valve and line pressure{1)slso tlows to throttle valve B
NOTE:
"left" or "right" indicatesdirectionon the flowchart.
When used,

1 4 - 16

2nd Speed
The flow of fluid up the 1-2 and 2-g shift valves ls the same as in the lst sped. As the speed of th6 car reachesthe
prescribedvlue,the solenoidvalve A is turnad on by meansof the TCM. As a resuh, the 1-2 shift vav is moved to the
left and uncoversthe port leadingto the 2nd clutch; the 2nd clutch is engaged.
Fluidflows by way of ;
-Line pressure{4) + 1-2 Shift Valve+ 2-3 Shift Valve-2nd ClutchPressure
{21)J Orifice-2nd ClutchPressure
(20)-r 2nd Clutch
The hydraulicptessurealsoflows to the 1st clutch. However, no power is transmittedbecauseof the one-wavctutch.
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchart.

(cont'dl

14-17

Description
HydraulicFlow (cont'd)
3rd Spoed
The flow of tluid up to the 1-2, 2-3 and 3-4 shift valves is the sameas in the 2nd speed.As the speedof the car roachesthe
prescribedvalue,the shift control solenoidvalve B is turned oft (shift control solenoidvalve A remainson). The 2-3 shift
valve is then moved to the laft, uncoveringthe oil port leadingto the 3rd clutch. Sincethe 3-4 shitt valve is moved to the
right to cover the oil port to the 4th clutch, the 3rd clutch is turned on.
Fluidtlows by w8y of :
-Line Pressure(41J 1-2Shift ValveJ 2-3 Shift Valve- 3rd ClutchPressure(31)J 3-4 Shift Valve (not controlled)
-3rd Clutch Pressure(30)-r 3rd Clutch

E
aFt

Thc
prrt
Asd
shift

Fbn

The hydraulicpressurealsotlows to the 1st clutch, However, no power is transmitted becauseof the one-wayclutch as in
the 2nd sDeed.
NOTE:
When used, "left" or "right" indicatesdirectionon the tlowchart.

Tho
M
NO

wh

14-18

!he
hft
the

I Da lPoshion
Fth Speed
The flow of fluid up to ths 1-2, 2-3 and 34 shift vslves is the same as in the 3rd speed.As th sped of tho car reachesthe
prscribedvalu,the shitt control sol8noidvatueA is turned olt (shitt control solnoidvalv B remsinsoff).
As this takos place,3-4 shift valve is moved to th left and uncoverstho oil port leadingto ths 4th clutch, Sincathe 1-2and 2-3
shift vslves are kept on the lft side,the fluid flows th.ough the 4th clutch; the power is trsnsmitted throughthe 4th clutch.

Ed)

tin

Fluidflows by way of :
-Line Pressure(4) J1-2 Shift Vslvo J 2-3 Shift Vslve-3rd Clutch Pressure(31) + 3-4 Shift Vslvs-4th Clutch pressuro
(41)+ ManualVslve-4th Clutch Pressure(4O)J 4th Clutch
Ths hydraulicprossurealsoflows to th8 1st clutch, However, no power is transmittedbecsuseof ths one-wsy clutch 8s in
2nd and 3rd sDeed.
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchan.

(cont'd)

14-19

Description
HydraulicFlow (cont'd)
I R lPolhlon
Th; tlow of fluid through th6 torque converter circuit is the same ss in the I N I position.The fluid {1)trom the oil pump flows
throughth manualvatveand becomesline prsssure(3). lt then flows throug-hthe 1-2 shift valv to the servo valve {3),causing
the shift tork shsft to be moved in the rovorsedirection,
Undeqthis condition,the shift controlsolenoidvalve A is turned on whereasthe valve B is turned off 8s in 3rd speedinLqllor
I D3 I position.As a resuh, tho 1-2 shift valve is also moved to th8 lsft. The Jluid (3') will flow through the seryo valve and
m:Ei[alvalve to the 4th clutch; power is transmittedthroughthe 4th clutch,
Rev6rsoInhibito!-.lE=ontrol
When the I R I positionis selectedwhile the vehicleis movingforward at a speed over 6 mph (10 km/h), the TCM
outputslst;i6;al (A: OFF,B; ON),and the 1-2shift valve is moved to the right side.Th6 line pressure(3)is interceptedby
th 1.2 shift vave; consequntly,pow6r ia not transmittedas the 4th clutch and servo vatueare not operated.
NOTE:
"right" indicstesdirectionon the tlowchart.
When used,"left" or

14-20

tr

The
prst
End
Hot\

NOI
Wix

ins
,J

I P I Poshlon
The flow of fluid th.ough the torque converter circuit is the same as in
fTl position.Tho line prsssuro {11bscomes the tine
prsssure{31as it passesthrough the manualvatue.Then line pressure(3)*flows
through the l-2 shitlgrvs to the sarvo v8vs
and the servo control valve,causingthe shift tork shatt to be movedto rhe reversepositionas in th R position.
I I
However,the hyd.auilcpressureis not supptiedto the crutches.The power is not trsnsmittod.

rrd
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchart,
CM

E
a

14-21

Description
Lock-upSystem
h l5r-l positionin 2nd, 3rd and 4th, andI 03 | position in 3rd, pressurizedfluid is drainedjrom the back oJ the torque convsrtsr
th;o6h an oil passage,causingthe lock-up piston to be held against the torquo converter cover. As this takes pl8cs, th
mainshsttrotates at the samespedas the enginecrankshaft.Togetherwhh hydrauliccontrol, th TCM optimizosthe timing of
the lock-upsystem. Undercenain conditions,the lock-upclutch is appliedduringdecsleration,in 3rd 8nd 4th sp66d.
The lock-up systam controls the rangeof lock-up accordingto lock-up control solenoidvavs A and B,8nd throttle valve B'
When lock-up control solenoidvslves A and B activate. modulstor pressurechanges.Lock-up controlsolenoidvalvos A 8nd B
are mountedon the torque converter housing,and are controlledby the TCM,
NOTE:
When used, "left" or "right" indicatesdirectlonon the flowchart,

LOCKUP II
coNrRoL ll
S O L E N O I IDl
V A L V E :A l l

1
L O C K u pC O N T R O L
S O L E N O TVOA L V E :

FEGULATOF

14-22

l,lo Lock-up
The pressurizedfluid regulstedby the modulatorworks on both ends of the lock-up shift vsfue and on the left side
of the lockup controlvslvo. Underthis condition,the pressuresworking on both ends of the lock-upshift valveireequat. ttre stritt vatve
is
movsd to the right side bv the tensionof the v8tuespringalone.The fluid trom the oil pump willflow throught;e bft side of
the
lock-upclutch to the torque converter; i,e.,the lock-upclutch is in OFFcondition.
NOTE;
When used,"left" or "right" indicatesdirectionon the flowchart,

!BRi?'",
I

v 1

;9ii?9P! !B:i,VBS",jffi?f"

I\4ODULATOR
PRESSURE

T O R O U C O N V E R T E R
C H E C KV A L V

(cont'd)

14-23

Description
Lock-upSystem (cont'd)
PartialLoqk-up
VslveB: OFF
Lock-upControl SolenoidValve A: ON Lock-upControlSolenoid
Tho
The TCM switches the solenoidvalve A on to releasethe modulatorpressurein the lett cavity of the lock-up shift valve'
valve
is
shitt
the
lock-up
thus
forc8,
the
spring
overcomes
valve
pressure
lock-up
shilt
ot
the
right
cavity
in the
modulator
movedto the left side,
The modulatorpressureis separatedto the two passages:
Torque Converter InnerPressure:enters into right side-toengagelock-upclutch
Torque ConverterBack Pressure:enters into left side-todisengagelock-upclutch
The bici pressure(FA is regulatedby the lock-upcontrol vave whereasthe positionot the lock-uptiming valve is doterminad
positionoJ the lock-up
by the throttle B pressure,tension ot the valve springand pressureregulatedby the modulator.Also the
p.essurergulatedby the
converter
and
torque
pressuie
controlvalve
lock-up
oithe
the
back
by
is
determinded
controlvalve
end of th lockcheck valve.With the lock-upcontrolsolenoidvalve B kept oJf, ihe modulatorpressureis maintainedin the left
in other woios, the tock-upcontrol vave is moved slightlyto the leJtside.This slightmovement of the lock-up
,p--nt-iu"V";
controlvalve causesthe back pressureto be lowered slightly,resuttingin partiallock-up'
NOTE:
"left" or "right" indicatesdirectionon the tlowchart.
When used,

IOCKUP
CONTfiOL
SOLENOID

LOC(UP CONTFOL
V A L v E :B
SOLENOID

PRESSURE
MODULATOR

TOROIJE CONVERTA

14-24

Half Lock-up
Lock-upControlSolenoid
VafueA: ON Lock-upControlsolenoid
ValveB:ON
The modulator pressureis releasedby the solenoidvalve B, causingthe modulator pressurein the lft cavity of ths
lock-up
controlvalve to lower.
Also the modulator pressurein the leJtcavity ot the lock-uptiming v8lve is low. However the throttle B pressurois still low
at
thjs.time;consequently,the lock-uptimingvalve is kept on the righi side by the springforce.
With the lock-upcontrolsolenoidvalve B turned on, the lock-up controlvalve is moved somewhat to tho lelt side,causing
ths
back pressure(F2)to lower. This allows a greater amount of the fluid (Fi ) to work on the lock-u; ;bich ;; 8s ro engage
the
clutch. The back pressure(Fa which stillexists preventsthe clutch from engagingfully.
NOTE:
When used,"left" or "right" indicatesdirectionon the flowchart.

ixi"iivflL

!3:i",3,3"J:'&?."

MODULATOR
PRESSURE

VALVE

T O F O U EC O N V E R T E R
C H E C KV A L V E

(cont'd)

14-25

Description
Lock-upSystem (cont'd)
Ful Lock-up
Lock-uDControlSolenoidVaVe A: ON Lock-up ControlSolenoidVaMe B: ON
When the vohiclespeedfurther increases,the throttle B pressureis increasedin accordancewith the throttl opening.
The lock-upttmingvalve overcomssthe springforca and movesto the left side.Also, this vslve closesthe oil port leadingto the
torou convrter chsck vave.
Underthis condition,the throttle B pressuraworking on the right end ol the lock-upcontrolvalve becomesgleatsr than that on
the left end (modulatorpressurein the lelt end has alreadybeen relessedby the solenoidvatue B); i.e.,the lock-upcontrolvalve
is mov6d to ths l6ft. As this happ6ns,the torque convertar back pressureis releasedtully, causingthe lock-up clutch to bs
ng8gedJully.
NOTE:
"left" or "right" indicatesdirctionon the flowchart.
When used,

coNlROL ll
SOLENOIDII
VALVE: A ll

X
LOCKUPCONTROI
SOIENOIDVALVE: A

THROTTLE
B PRESSURE

MODULATOR
PRESSURE

T O R O U EC O N V E R T E R
C X E C KV A L V E

orr cooLEA

14-26

DacoleratlonLock-up
Lock-upcontrolsorenoid
VatveA; oN Lock-upcontrorsoronoid
vatueB:Dutyoperation(oNoFF)
TheTCMswitchessolsnoidvslveB on andotf iapidlyunderceitainconCitions.
Tfreslightlock-upandhalflock-upregions8re
msintEined
so 8sto lockthe torqueconverterproperV.
NOTE:
Whenused,"left" or "right" indicatos
directionon the flowchan.

rocr(uP JI

33i,'^i":i
I
LOCXIJ

MOOULATOR
PRESSURE

T O R O U EC O N V E R T E R
C H E C KV A L V E

F E L I E FV A L V E

14-27

Description
HydraulicControl
TheValvebodyinc|udesthemainva|Vebody,the'egulatorVa|vebody,thethrott|evalvebody,thesecondaryvslvbody,the
servo body and the 1st/2ndaccumulatorbody.
oilllows throughthe
The oil pump is driven by splineson the right snd of the tolqus convener which is attachedto the engine'
through the main valve body to the manualvalv and the servo bodv, dirocting
,"si,[i;, rriv" t" mainiiin specitieJ pies--sure
oressureto eachof the clutches.

THROTTLEVALVE
BODY

SERVOBOOY

VALVE
REGULATOR
BODY

VALVEB
THROTTLE

VALVE
SECONDANY
BODY

SHIFTCONTROL
VALVE
SOLE]TOID
ASSEMBLY

MAINVALVEB(X'Y

THROTTLELO[{G
VALVE

l ST/2ltD
ACCUIUIULATOR
BODY

RELIEFVALVE

COrTROL
LOCK.UP
VAI.VE
SOLENOID
Ot purip
ASSEMBLY

OILPUMPDRIVEGEAR

ORIVEiIGEAR

4TH ACCUMULATOR
3RD
ACCUMULATOR
lST-HOLD
ACCUMULATOR

sEnvo
VALVE

REGULATOR
VALVE

LOCK.UPTIMING
VALVE

TOROUECONVERTER
CHECKVALVE

1STACCUMULATOR
3RDKICK-DOWI{
VALVE
CPC VALVE

VALVE
VAL
MODULATOR

1-2 SHTFT
VALVE

COOLER
VALVE

34 SHIFT
VALVE

4THEXHAUST
VALVE

LOCK.UP
SHIFT
VALVE

MANUAL VALVE

VALVE
2-3 SHTFT

14-28

2]IDACCUMULATOR
2 D ORIFICE
VALVE
COT{TBOL

co TnoL
oRrFrcE

VALVE

SERVO
cot{TRoL
VALVE

RogulatorValve
The regulstorvalv8 maintainsa constant hydraulicpressuresent trom the oil pump to th hydrsuliccontrol svstem, while also
turnishingoilto the lubricstingsystem and torque convarter.
Oil flows through B and B', The oilwhich enters through B flows through ths vslve orifice to A, pushingtho regulatorvalve to
the right. Accordingto the level ot hydraulicpressurethrough B, the poshion ot the valve changes,and the smount of th oil
through B'from D alsochanges.This operationis conttnued,maintainingline prossure.

I{OT RUN II{G)

IENGI]TE

GiIGI]TE RUN ING)

To TOROUECOIWERTER

To RELIEF
VALVE

Stator RoactionHydtaulc P1!ssur6Control

Hydraulicprossuroincreaseaccordingto torque is performod by the regulatorvalve using stator torqus reaction.The stator
shEft is spllnedin the ststor, and hs arm end contacts the ragulatorspringcap. whn the car is acclerEtingor climbing(Torque
Converter Range),stator to.que reaction acts on the stator shaft, snd the stator arm pushesthe rgulsto; springcap in the -)
direction in proportion to the reaction.The stator roaction spring compressos,and the regulatorvalve movss to increasethe
regulatedcontrol pressureor line prssure.Line prgssureis maximumwhen the stStor reactionis maximum.

REGULATOR
VALVE

STATOR REACTIONSPRII{G

REGULATOf,SPRINGCAP
STATOR SHAFTARM

STATON SHAFT

{cont'd}

14-29

Description
HydraulicControl (cont'd)
Thlottle V8tuo B
Throttle vave B converts changesin the throttle openingto changesin transmissionhydraulic pressute.The end ot throttle
vave B contscts the throttle cam which is connectedby a cable to the throttle body. The cable pullsthe cam which, in turn,
moves the throttle valve B. The throttle valve B-to-camengagementis adiustablefor shitt smoothnessand lock-up.Throttle
valve B controlsthe accumulators,to make smooth changesfrom one gearto snother.An assist tunction is used to lessenthe
throttle load.
ModulEtor Valv6
The modulstorvalve maintainsline pressureJrom the regulator,to the pressureshitt control solnoidvatuesA/B and lock-up
control solenoidvalves A/8, thus maintainingaccurateshi{t and lock-upcharacteristics.
2nd Ollflce Contiol Vslvo
For smooth shifting between 2nd and 3rd. the 2nd orifice controlvalve relievesthe 2nd clutch pressure.
As 3rd clutch Dressureis incressed,the 2nd orilice controlvalve movesto uncover the oil port relievingthe 2nd clutch pressure.

14-30

ComponentLocation

TRAl'ISMISSION
CO]\ITROL
(TCMI
MODULE

BRAKESWITCH
ENGINE
CONTROI.
MODULE(ECM}

LOCK.UPCONTROL
SOLENOID
VALVE
ASSEMBLY

VEHICLESPEEDSENSOR{VSS}

COUNTERSHAFT
SPEEDSENSOR

AUTOMATIC TRANSAXLE(A/TI
GEARPOSITIONSWITCH

THROTTLE
POSITION
{TPISENSOR

ENGINECOOLANT
TEMPERATURE
{ECT}SENSOR
MAINSHAFTSPEEDSENSOR

SHIFTCONTROLSOLENOID
VALVE ASSEMBLY

14-31

Circuit Diagram

HOOD
FUSE/FELAY
UNDER8OX
t l o . 4 t( 1 5 4 i

tlo.32l100Al

No.43ll0A|

423 424

A2O
D2
IRAI{SMISSION
CONTROL
MODULE
{TCM}
A19
A7
Ar8
A21

AIO A8

A17

A/T GEARPOSITIOI'I
I DtCAT0R
8LK

G40r

8U(

4
G40l

14-32

A15

At3

All

SERVICE
CHECX I
CONNECTOR I

THROTTTE
ENGINT
POSInON CoOtANr

I sENsoR
+iHr*_
SENSOR

REO/BIX

Dl8

A22

D9 013 Otl

Dt6

D6

D7

D5

A25

A26

TRANSMISSION
CONTEOL
MOOUIE
IICM}
017

Dt5

D19

012

A6

A4

A5

A3

wHT/EU(

8LU,^TEL

GRN/BL(

r,oct(- uPcoNTRot-sHtFrcorTRolSO[TNODVALVESOI-EI\OIDVAI.VE

COUTIIERSHAFI
SPEEDSENSOR

A3 A 5

MAINSHAFI
SPIEDSENSOR

A9 A11 A13A l 5 A 1 7Ar9 421

A4 A6 A8 A ! C

atr

A18 ^ tttta t'ltt ) aa, t

TCMT.nnin.lLocnbns

14-33

TroubleshootingProcedures
When the TCM sensesan abnormslityin the input or output systems, th | D4 lindicator light in the gsugeasseEUlLwillblink.
Whn the Service Check Connector (locatedbehindthe center console)is-E6nnectodwith I jumper wire, the I Da lindicator
light will blinkthe DiagnosticTroubleCode (DTC)when the ignitionswitch is turned on'
When the I D;l indicatorlight has beenreported on, connect the two terminalsof the ServiceCheck Connectortogether whh a
iumperwire,
Thon turn on the ignitionswitch and observethel Da lindicator light.

DATA LI'{K

coNiEcToRt3Pt
cAUTlOir:

GAUOEASSEMELY

Do not attadr tha

lumper wlre,
JUiIPER

3'S,Y,!"3reJl'ii['
Codes1 throuqh 9 are indicatedby individualshort blinks,codes 10 throught 15 8re indicatedby a soriesof longand short blinks.
Onlong blink equals10 short blinks.Add the long and short blinkstogether to determinethe code. After dsterminingthe code,
refer to the electricalsystem Symptom-to-ComponentChart on pages1+36 8nd 37.
rhort

n
S.. DTC I

Soo DTC 2

L]

s.. DTC '14

rhort

Some PGM-FIproblemswill also make the I D4 lindicator light com on. After repairingthe PGM-FIsyatem, disconnectth
CLOCKRADIOfuse (1OA)in th6 under-hoodtuse/relavbox for more thsn 1Osecondsto reset the TCM memory.
NOTE;
. PGM-Flsystem
The PGM-Flsystsmon this modelis I sequenti8lmuhipon tuel iniectionsystem.
. Disconnectingthe CLOCK RADIOfuse also cancelsthe radio antFthett code, preset stations 8nd the clock setting. Get the
customr'scode numbe. and make note oJ the radio presetsbefore removingthe Juseso you can .eset thm.

14-34

CAUTION:
. Al SRS electrlcal whlng haro6sres are covorod with
yelow outor insuhtlon.
. Before dsconnoctlng the SRS wila harnoss, install th
lhort connoclor(s)on tho ailbag(s)(so6soction 23 I.
. Roplaceiho snllro affectod SRS harness assombly if it
ha! sn opon circuit or damagodwlring.

. TCM Roset Procodure

1. Turnthe ignitionswitchoft.
2.

Remove the No. 43 CLOCK RADIO fuse (10A) lrom

the under-hoodtuse/relaybox tor 10 secondsto reset
the TCM.
NOTE:
Disconnecting
the No.43 CLOCK RADIOluse aho
cancelsthe radio anti-theft code, Drsetstations and
the clock setting. Get the customer's code number
8nd mske note of the rsdio presets befors romoving
the fuse so vou can resat them.

CLOCKRADIOFUSE

lf the inspctionfor a particularfailure code requiresthe

usa ot Test Harnesa(07LAJ-PT3010A);
1,

Removethe right door sill molding,door trim and right

side kick psnel(seesection 20).

2.

Pullthecsrpetbackto exposethe TCM.

3,

Connectthe wire harnessto the Test Harness.and/or

connect ths Test Harnessto the TCM accordingto the
troublshootingf lowchart.
NOTE:
. OnV the A and D terminalsof the Test Harnessare
usedfor A/T troubleshooting.
. Unloss otherwise noted, use only the Digital
Muhimeter,KS-AHM-32-003, tor testing.
DIGITALMULTIMETER
KS-AHM-32-O03

UI{DER-HOOD
FUSE/RELAY
BOX
. FinalProcodure
NOTE:
This proceduremust be done after any troubleshooting.
l.

Remove the iumper wire from the Ssrvice Chsck

Connector.
Resetthe TCM.
Sst the rsdio preset stations and clock setting.

, o o o o o o o o o o o olio o o o o oo qo o o o o 6to o o o o r o o o ) c

14-35

Chart
Symptom-to-Component
ElectricalSyst
NumbsroI Da
indicatorlight
blinkswhile
Ssrvice Check
Connectoris
jumped.

Da indicator
light

PossibleCause

Symptom

Referto
page

Blinks

Disconnectedlock-up controi solenoidvafue

A connector
Shon or open in lock-up control solenoid
vafueA wire
Faultvlock-uocontrolsolenoidvalve A

Lock-up clutch does not

engage.
Lock-up clutch does not
disengage.
Unstableidlespeed.

14-38

Blinks

Disconnectedlock-up control solenoidvafue

B connector
Short or open in lock-up control solenoid
valve B wire
Faultylock-upcontrolsolenoidvalve B

Lock-up clutch does not

engage.

1+39

Blinks
or OFF

Disconnectsd throttle position (TP) sensor

connector
Short or oDenin TP sensorwire
FauhvTP sensor

Lock-up clutch does not

engage.

1440

Blinks

Disconnected vehicle speed sensor {VSS)

connector
Shortor openin VSS wire
FauftyVSS

Lock-up clutch does not

engage.

1441

Blinks

Short in A/T 9e8r positionswitch wire

FauhyA/T gear poshionswitch

' Failsto shi{t other than

zrde4th gears.
' Lock-up clutch does not
engage,

1442

OFF

geat position switch

Diconnected Nf
connector
Open in A/T gear positionswitch wire
FaultyA/T gear positionswitch

Blinks

Disconnectedshift control solenoidvalve A

connector
Short or open in shift control solenoidvalve
A wire
valveA
Fauhyshift controlsolenoid

' Failsto shitt (between 1

ste4th, 2nde4th or 2
nde3rd gesrsonly).
' Failsto shift (stuck in 4
th gear)

1446

Blinks

Disconnectedshift control solenoidvalve B

connecror
Short or oDBnin shitt control solenoidvalve B

' Failsto shift (stuck in I

st or 4th gears).

14-47

Lock-up clutch does not

engage.

1+44

Failsto shift other than

2ndo4th ge8rs,
Lock-up clutch does not
engage.
Lock-up clutch sngages
and disengagesahernate-

1444

Fsuhv shift controlsolenoidvalve B

9

14-36

Blinks

Disconnected countershaft speed sensor

connector
Short or opon in the countershaft speed
sensorwir
Fauhycountershaftspeedsensor

Numberof Dr
indicslor light
blinkswhile
ServiceCheck
Connsctoris
iumped.

Da indicator
light

PossibleCsuse

Symptom

Referto
pa9e

10

Blinks

Disconnected engine coolsnt temperature

(ECT)sensorconnector
Short or open in ECTsensorwire
FauhvECTsensor

Lock-up clutch does not

engage.

14-50

11

OFF

Disconnectedignitioncoil connector
Short or open in ignitioncoil wire
Fauhyignitioncoil

Lock-up clutch does not

engage.

1+51

't4

OFF

OFF

'Short or open in FAS

wire be- ' Transmissionjerks hard
{ORIVRED}
tween the D16 terminalandECM
when shifting.
' Troublein ECM
Disconnectedmainsh8ft speed sensor connector
Shon or openin mainshattspeedsensorwire
Faulty mainshaftsDeedsensor

Transmissionjerks hard
when shifting.

14-52

1+U

f the setf-diasnois
L91l indicatoflight does not blink,perform an inspectionaccordingto the tabtebelow.
Symptom

ProbableCause

Da indicator light does not come on for 2 seconds atter ignhion is first
turndon.

14-56

D4 indicstorlight is on steady,not blinkingwheneverthe ignitionis on.

Lock-upclutch does not have duty operation{ON-OFF).
Lock-upclutch does not engage.
Shift lever cannot be moved from
doressed.

RBf. page

1+58
Check A/C signal
with A/C on.

Dosition with the brake oedal Checkbrakeswitchsignal.

1+59

14-60

. It a customer describesthe symptoms f or codes 3, 6, or t t ,

inaicatorlight is not blinking,it wilt be necessaryto
Jeqn" I Oo--l
rcrsglg1lie symptom by tost driving,andthen checkingthe I D4 | indic8torlightwith the ignitionstill ON.
o lf the
ElJindic$gllight displsyscodesother than those liste-daboveor stays lit continuously,the TCM is tauhy.
. Sometimesthe
Lgllind;cator light and the MalfunctionIndicatorLamp (MlL)/CheckEnginelight may come on simuhaneously.
It so, chsck the PGM-FIsystm accordingto the number ot blinkson the MIL/CheckEnginelight. then reset the memorv bv
removingthe CLOCK RADIOfuse in the under-hoodfuse/relaybox tor more than 10 seconds.Drive the vehicle for several
minutesat speedover 30 mph (50 km/h).rhen recheckthe MIL/CheckEnginetight.
NOTE:
. PGM-FIsvstem
The PGM-Flsystem on this modelis a sequentiatmuhiport fuel iniectionsystem.
' Disconnectingth CLOCK RADIOfuse also cancelsthe radio anti-thett code. preset stations and the clock
setting. Get the
cuatomer'scode numberand make note of the radiopresetsbefore removingthe fuse so you can reset them.

14-37

ElectricalTroubleshooting
TroubleshootingFlowchart
Soff-dirgnosis I I,a I indicstor
lght blink. onc.--

Disconnect the 26 P connector trom the TCM,

Possib16
Caus6
. Oisconn6ctdlock-up control
solnoidvalv6 A connector
' Short or open in bck-up controlsolnoidvslv6 A wire
' Fauhylock-upcontrol solenoid

Turn the ignitionswhch ON.

Msasure the vohago betw6n

th6 AO (RED/WHT)and A25
(BLK/RED)
or A26 (BRN/BLK)
terminals.
Ropairthorl to power rouaca
in REDMHT wlro botwo6n
tho AO tormln l and the lockuDconlrol lolonold valvo A.
Turn the ignitionswitch OFF.

Measure the resistance b6tw6n th A6 (RED/WHT)and

A25 (BLK/RED)or A26 (BRtl/
BLKlterminals.

ls th6 resistanco
12-24 O ?

Chcck for bo.o TCM cor|r|octorg. It nacollgry, lubrtftute

a known-good aolenoid vtlvo
assombly o. TCM ond
rochock.

Diconn6ct th6 2P connector

i.om the lock-up control sob.
noidvalve assembv.

Check tor continuity betwon

the A6 (BED/WHT)snd A25
GLKiRED)or A26 (BRIVBLK)
tgrminsls.
Bopah lhort to ground In RED
/wHT wire betwoon tho AB
tormlml and tho bck-uD control 3olonoldvrlva A.
Mgasureth6 resistanceot the
solenoid at the 2P connsctor
(1+62).

fs the resistanc12-24 A?

Rophce the bck-up cofirol

aolonoid vafuo a$ombly.

14- 3 8

Chock for opon In RED/WHT

wire between thc A6 tarmlnal
and the lock-up control roLnold valve A.

NOTE: Vi6w f rom terminalsid6.

PossiblsC6use

Diocomect the 26 P conn6cto. f.om the TCM.

' Disconn6ctod lock-up control

aolono'xtvafu6 B connoctor
. Short or oD6n in bck-uD coft
trolsolenoidvafueB wko
' Fauhybck-up controlsolonoil
vafueB

Vi6w f rom terminalside.

Turn th6 ignitionswitch ON.

Meaaur6tho vohago btwoon

th6 A4 {WHT/BLK) and A25
(BLK/RED)or A26 {BRIVSLK)
terminab.

6.\ 12-24 Q7
BRN/BLK-r-Y-WHT/BLK
I V,, Voh.sa?
Rapllr ahort to Dowar aolrca
In WHT/BLK wlr. b.twoon
ths A4 t.rmlnal lnd th. loct.
up control roLnold vrlva B.

Turn tho ignitionswitch OFF.

Mrsua th6 resistanc6 btweon th A4 {WHT/BLK)and

A25 (BLK/REDIor A26 lBFl!
BLKltormingls.

ls th rsistance12-24 Q ?

Chad( tor loota TCM connoctoaa. ll nacaltary, tubttltuta

r known-good toLnold vllva
.t!.mbly
or TCM !nd
rachack.

Disconnctth6 ? connector
lrom th lock-up cootrol solonoidvafueassernbv.

Ch6ck for continuity betw6en

the A4 (WHT/BLKI 8nd A25
(BLK/RED)o. A26 {BRI,I/BLK)
tsrminsb.
Rapalr rhort lo ground In
WHT/BLX wh. brtw.on thr
A4 t.ri| ml rnd lha lock-uo
control aoLnold valva B.
Me63uretho rosistanceof th6
aolonoidat th6 2P connector
t1+6,4.

ls tho rosbtance 12-24 O ?

Ch.ck tor oD.n In WHT/BLK

wlra baiwaon tho A4 tarmlnal
ard th. lock-up control aob"
nold v.lv.8.

R.pbc. th. bck-up control

rcLnold vtlva r'!an|blv.

(cont'd)

14-39

ElectricalTroubleshooting
Flowchart(cont'd)
Troubleshooting
S.ltdlomrl!
{ Xr4| lndlc.tor
leht bl|rb thr..-i6.r.

Turn the ignitiooswitch ON.

Possibh Csus
' Disconnected throttl position
{TP}sonsorconnoctor
' Shon or opn in TP sonsor
' FEulty TP sonsor

Chock whothor tho Malfunction Indicato. Lamp (MlL)

blinkslsse soction 111.

ls th6 MIL blinking?

Disconnoct th6 26P and 22P

connectorstrom th TCM.
C o n n o c tt h 6 T 6 s t H a r n e s s
"4" arfr "D" connoctora to
the wire harno$ onv, not to
the TCM 114-3$.

R.p.h th. PGM.FI Sy.t.m

{r....ctlon l1}.

oooooooooooo
oooooooooooo

ooooooooooo
ooooooooooo

Turn the ignhionswitch ON.

4 . 7 5 - 5 . 2 5V ?
Mosgursths vohsg btwe6n
the D1I ard A29A26 torm'F
na|s.

ls the vohago4.75-5.25 V?

R.plli op.n or rhort In LT

ORiUBLKwl.. b.tw..n th.
D I I tcrmlnll aid thc ECM.

Turn the ignitionswitch OFF.

Appror.0.5V?
C o n n e c tt h 6 T e s t H a r n e s s
"A" snd "0" conn6ctors to
tho TCM.

oooooooooooo
oooooooooooo
A26

Turn th ignitionswitch ON,

Moasurotho voltago btwen

th6 D7 snd A2tA26 torminal.

ls tho vohagbapprox.O.5V?

YES
Chack tor boao TCM connacto.a. ll nacoraary, aubrlhula
a known-good TCM lnd
mclract.

14-40

R.pdr op.n or thon In RED/

BLK wlrr b.twarn lh. D7
tcrmlnd lnd lha TP $naor.

ooooooooooo
ooooooooooo

Selt-diagnosl. I 04 | Indlcator
llght blnk! four tm.,

PossibloCaus
' Disconnoctod vhicl spood
snsor{VSS)congctor
. Short or opn in VSS wir6
' FauhyVSS

R.l.J to S.ctlon 23 tor v.Hcle speed s.nlor (VSSI l.{.

. Mak. ru16 lft!,lrckr,

end lrloty stends are plac.d properly
(!oo sactlon 11,
. Sot tho parklng blaks r.cul.ly lnd block lhc rcer whccb.
. Jeck up tho troni ol the clr .nd ruppoit whh srtcty .t!rdr.
Disconnect the 26P and 22
connoctorg trom th6 TCM.
C o n n e c tt h s T 6 s t H a r n e s s
"4" and "D" connectors to
th6 wire harnessonv, not to
tho TCM {1+35).

oooooooooooo
oooooooooooo

ooooooooooo
ooooooooooo

Turn th6 ignhionswitch ON.

Botate the f.ont wh61 snd

check for voltagbotweonthe
Dg and A2ryA26 terminats.
Block th6 other whe6l so it
dos not tum,

Doesth vohageO-12 V
spp6arshrnteV?

Chock for lhort or oDon ln

ORI{ wh! bglwaln th. Dg tcrmlnll .nd th. VSS. It wl.a lr
OK, check rh. VSS (rc.
lecllon 23).

Chack to. bosa TCM conrEclor3. lf nceaaary,aubatftuto

a known-good TCM tnd
.echock.

(cont'd)

1441

ElectricalTroubleshooting
Troubleshooting
Flowchart(cont'd)
s.fil|lno.lt
I D4 | Indcliot
|!t'n b&*! tlv!-m.t.

Turn th6 ignhionswhch ON.

Obsrvetho A/T 906r position

indbator, 6nd saloct oach posF
tion sopr6aat6ly.

Do ony irdicalors tail to

lightwhn shiftdthrough
sll positionsT

PossibloCauE6
' Sho.t in A/T g6sr position
switch wir6
' Faulty A/T gsr positioh
switch

NOTE:
Codg 5 is causod wh6n th
TCM rsc6iv6s two gpar position inputs at tho 3ametim6,

So. A/T g.r po.hlon Indlior l.Epactlon (raa aactlon

23).

Turn tho ignitionswhch OFF.

Connoct the Tost Hamoss

btwoon th6 TCM and connoctors {'l+3$.

Turn the ignhionswhch ON.

Bsnery vohaoo?
r@l
a21 A25
o o ooooooooOo O I O:66irOO:fto:lG6{ticie,Olooo ooooooo o
ooooooooooooo I oogsgooc,l'g ottgoo I oooooooo ooo
426

Mo.surc tho vohago botwoen

tho A21 and A2gA28 termi
nals.

ls thre battory voltag?

Chock to. .ho.l ln GRI{/RED wl.. b.tween tho A2l to.irjnrl |nd
th. A/T o.!r po.hlon lwhch or A/T gelr po.ltlon Indhlto.. It wlr.
l! OK, chack fof bolo TCM connoctorr. ll nacallary. aubtthula a
known.goodTCM and rochock.

.-@r
A19 A25
Msssure th6 vohag btwoen
tho A19 ard A2tA26 tormina|s.

YES
To paga1+43

14-42

oooooooooooo
oooooooooooo

Esttrv voftaoo?

ooooooooooo
ooooooooooo

Chock loJ .hort ln LT GRN wlr. belw..n tho A19 tormlnll rnd th.
A/T gelr po.ltlon Indlcltor or . lhort In GRN/IVHT o. GRI{ wlrer
b.tw..n th. A/T glr po.ltio.r Indlcltor lnd tho A/T golt pothlon
awhch. lf wlia b OK. c$acl tor loora TCM c$nactot!. lf nacoatlry,
.ubrtltut. t known-good TCM .nd r.chock.

Frcm. page 1442

r-@-r

Battery vohag6?

Moasurothe vohsge betwosn

the Af7 and A2gA
tetminals.
A26

ls thore battery vohag?

Masurthe vohage between

the A15 and A2tA26 termin6ls.

ls ther6 battory vohago?

Moasurethe vohago btwogn

trho A13 and 429A26 t6rminals.

Chock fo. lhon In GRN/8LKwire betwoon th. Al7 t.rmln.l rnd tho
A/T g.ar polition luyitch. lf wiro is OK, chock fo. loolo TCM connoctor!.It noco$ary, 3ubstllutc a known-goodTCM and.ochock.

A26

Check tor.hort in GRN/BIUwlro botwoon ths A'15 torminal rnd tho

A/T gear position switch or A/T g6ai po.hlon indlcator.lf wira ls OK,
chock for looso TCM connesto''. It necersa.y, lubatliuto a knowngood TCM and rochock.

oooooooooooo
oooooooooooo

ooooooooooo
ooooooooooo

426

ls th6r battery vohage?

Chock tor short in GRN/YELwire betwoon tho A13 t.rmlnal and the
A/T goor posltlon swltch or A/T g.ar porition indlc.tor. lf wl.o b OK,
check lo. loor6 TCM connociors, It n6cas3!rv, subatitute a knowngood TCM and recheck.

oooooooooooo
oooooooooooo
Moasurethe voltage botwen
th6 A11 and A2tA26 termina|s.

ooooooooooo
ooooooooooo

a26

Check for short in LT GRN/W}|T wiro botw.on the A11 torminrl and
the A/T opar polition lwitch or A/T go.i po.hion indicator. lf wi.e i!
OK, chack for loose TCM connoctora. lf nocorsa.y. rubrtltuto a
known-goodICM and rachock.
Ched( tor bo36 TCM connactor!. It necolsa.y, substilute
a known-good TCM and
rochock.

lcont'd)

1443

ElectricalTroubleshooting
TroubleshootingFlowchart (cont'd)
Solf-dlrgno.lr I D4 I Indlcrtor
Ight bll.I(. !h tma.

Connoct tho Tgst Hamess

btweon th TCM and conn6ctors {1+35}.

PossiblC.uso
. Disconnctod A/T gpa. posF
tion sw?tchconnector
' Op6n in A/T g6ar position
switch wirs
' Faulty A/T 066r position
switch

Turn th6 ignitionswitch ON.

Mesurstho vohage btwoen

th6 A21 6nd A29A26 terminab.

o o oooo o oo o o o o t:ltoooojs9$:*:occD.gol ooo oo o oo ooo

o oo oo o oo o o oo o l,(to.ooogrri6:{lifxl{lotllt:lo oo oooo o oo o

R.pdr opn In GR /RED wlr.

batwaan th. A21 tarmlnal
lnd th. Al g.!r po.ltlon
rwhch.

Mssuroth6 vohag btwo6n

the A19 and A2tA26 te.minals.

Rcprlr opln In LT GB wl..

b.two.n th. A19 tormlnC
and th. A/T g.!r po.lllon
hdlclto..

To psg1+45

14-44

From p.g6 1/+-44

Voh6g.?
Measur6ths vohago botwaon
tho A17 dld A2dA26 r6rmF
nab.

ooooooooOooo
oooooooooooo

ooooooooooo
ooooooooooo

R.p!h op.n ln GRN/8L|( wiro b.tw.cn th

A17 t.rmln l .nd tho A/T g6a. polhlon
.wltch,

Volt.go?

Mo!8urotho vohagbotweon
th6 415 ard A2gA26 tsrminab.

oooooooooooo
oooooooooooo

ooooooooooo
ooooooooooo

Ropll op.n In GRT BLU wlro betw..n thr

Al5 t.rmlnll ..rd th. A/Y 96r. l|orhlon
!wltch.
Vollrg.?

Moasuro the vohago t atweon

th A13 sd A2dA28 t6.tr*
n6b.

oooooooooooo
oooooooooooo

ooooooooooo
ooooooooooo

R.pllr op.n In GRT YEL wl.. b.tw.en tno

413 t.rmlnll rnd lh. A/T gar polhlon
twltch.
Voh!96?

oooooooooooo
oooooooooooo

ooooooooooo
ooooooooooo

Meaguretho vohago bgtwoon

th6 A11 and A2ryA28 terminab.

R.pllr op.n In LT GRN/WHT wlra

b.tw..n tho All t.rmln.l .nd tho A/T
gclr poohlon lwhch.

Chact lo. loo.. YCM codr.ctora. lt nacaaaary. lr$atltuta

t known-good TCM .nd
rochodr.

{cont'dl

1445

ElectricalTroubleshooting
Flowchart(cont'd)
Troubleshooting
PossiblCaus

Disconnoctths 26P connsctor

trom th6 TCM.

. Disconngctod shilt control

solonoidvafu6A connector
' Short or opon in shift control
solsnoft,valve A wire
' Fauhy thift control solnoid

12-24 A?
{rslK-l
6\
_
___r_5_
BLU/YEL
BLK/RED

Turn th6 ignitionswitch ON.

Moasureth6 vohag btwson

tho A5 {BLU/YEL} ANd A25
GLK/REo) or A26 (BRII/BLK)
t6rminals.
Roplir ahon to powai loulca
ln BLU/YELwh. botw.en tho
A5 tordml ard thc lhlft control loLnold valvc A.
Turn tho ignitionswhch OFF,

M6aure the resistanco btws6n th AS (BLU/YEL)snd

A25 (BLK/RED)or A26 (BRiU
BLK)t6rminals.

ls tho resistanc612-24 Q ?

Chock fo. loo.. TCM codr.ctor!. lf naceaaary, rubltlistc

! known-gpod lolonold vllvo
lrtambly or TCM rnd
iechack.

Disconnctth6 3P connoctor
trom the shift control solonoid
valvs assombv.

Chgck for continuity bstwon

th A5 (BLU/YEL}8Nd A25
(BLK/RED)or A26 (BR|I/BLK)
t6rminals.
Ropllr rhort to g.ound in BLU
/YEL wlro botwen tho A5 totrnlnll and th6 lhllt corttol
aolenold vllvo A.
Measurth resistanc6of tho
solgnoid at the 3P connsctor
{1+63).

fs the rsistsnce12-24 Q7

Roolace lho !hlft control

sobnoid valvo a!!mblY.

14-46

Ch.ck tor opon In BLU/YEL

wlre botwoon the A5 tormlnal
.nd tho rhlfl comrol lolenold
valva A.

NOTE:

View from terminals'Nls.

Self-diagnoli3 | D4 Indlcator
light btnkr oight tlm.s,

Disconnectth 26P connctor

trom the TCM.

PossibhCause
. Disconnctod shitt control
solenoidvalv6 g connoctor
' Short or opsn in shift control
solnoidvalvo B wire
' Fauhy shift control solonoid
vslv B

Turn th6 ignitionswitch ON.

Measurethe vohag btween

th6 43 (GRN/YEL)snd A25
(BLK/RED)
or A26 (BRN/BLK)
lermanals.
Ropllr rhort to powar tource
In GRIIUYEIwlro botw..r th.
A3 termln.l and rhlfl coDtrol
lolenold vrlvo B.

NOTE:

View from trminalsid6.

Turn the ignitionswitch OFF.

Measure th resistance be^

tween the 43 (GRN/YEL)and
A25 (BLK/BEO)or A26 (BRll/
BLK)terminals.

ls th resistsnc612-24 O ?

Chack for bolo TCM conn.cto.r. It noco$ary. lubrtltuto

a known-good roLnold valvo
!rrembly or TCM ond
rachack.

Disconnsct the 3P connoctor

lrom the shift control solonoid
vave assembv.

Chsck tor continuity bstwen

the 43 (GRi.i/YEL)and 425
(BLK/RED)or 426 {BRN/BLK)
t6rmrnals.
Rcpalr rhort to g.ound In GRN
/YEL wlr. b.twe.n lhe A3 termlnal and the lhift control
lolonold valvo B,
Measureth6 resistanceof the
solenoidat th6 3P connctor
(1+63).

ls the rosistance12-24 O ?

Chock to. oD.n ln GFTUYEL

wl.g botwoon tho A3 tormlnal
and the lhlfl conlrol lolonold
vllvo B.

Replaca the 3hilt control

lolonold valvo a$amblv.

(cont'd)

14-47

ElectricalTroubleshooting
TroubleshootingFlowchart (cont'd)
S.ltdl.g|lorl!
| Da I lrdlcltor
lghtbtr*.nln.-il-m...

PossiblCause
' Loose or falhy connoction
btweon th TCM and car har_
ness.
' Disconnct6d count6rshatt
gpoedsonsoaconnoctoa
' Shon or opn in tho count6t_
shaft spedsenaorwire
' Fauhy countorshaft spd sonsot

ls tho coumsGhaft sposd

snsorinstalledproporv?

Disconnsct th 2P connoctor
Irom tho countrshaft spood
sensorconnector,

Moasureth6 rosistancoof th6

countsrshaftsPeeds6nsor.

lsthe rsistance
400- 6@ o ?
(at7OoF.
2OoC)
Cootl
Disconnecttho 22P connoctor
from th TCM. Connoct the
"O" connoctoa
Tost Hsrn6ss
to th wir6 harnossonlY, not
to tho TcM {14-3$.

Check for cottinuitY betwoon

body ground8nd D17 torminsl
and D15 terminalindividuslly.
R.o.l. rhort In BLU/GRN or
BLU/YEL wlr. b.tw..n D17
lnd Dl5 tcrmlnaL and lh.
coumorrhaft apead tdrtor.
Roconnct th6 countershoft
sp6edsensorconnector.

To pdss1+/{)

14-48

lty?

From pag 14-/18

400 -600 0?

l\teaaurc thg roaisttnco botw6n Dl7 E ld Dl5torminah.

b th6 a6!iat6nc6

4@-8(D O?
2OoC)
lar 7OoF,

Rapllr boaa tarmlnrl or opan

In BLU/GR o. BLU/YELwlr.
b.tw...r D17 did D16 farrtnala |r|d tha coumarlhnft
apaad lanror.

Chad( for loa. TC co.rrcior. lf r|.c...Jy,

rubathul. .
lnown-good TCM lnd
rachad(.

1449

ElectricalTroubleshooting
TroubleshootingFlowchart (cont'd)
Solt-diagnoslsI D4 | indicatoi
lghl blinks tont-ime..

Turn the ignitionswitch ON.

Chock whethor the Malfunc_

tion Indicator Lamp (MlL)
blinkslse6 section 11).

PossiblCause
' Disconnacted engine coolant
t6mperature (ECT) sensor
connector
' Short or op6n in th ECT
sensorwire
' FauhyECTsensor

Booah lho PGM-FI Syttem

l!.o 3oction 111.

Turn the ignitionswhh OFF

Disconnect the 26P and W

connectors lrom the TCM.
C o n n e c tt h e T e s t H a r n e s s
"A" and "O" connoctors lo
th wire harnessonly, not to
the TCM(14-35).

Turn tho ignitionswitch ON.

A?5

oooooooooooo
oooooooooooo

ooooooooooo
oooooooo

Measurethe vohage betwoen

the 018 ard A2tA26 termina|s.

ls the vohag64.75-5.25V?

Ropair opon or rhort in LT

GRN/BLKwir. botween the O
18 t.rmin6l and tho ECM,

Turn the ignitionswitch OFF.

C o n n 6 c tt h e T 6 s t H a r n e s s
..A,. and ,,D,, connectols to
tho TCM.

oooooooooooo
oooooooooooo

Start th engino and warm it

up to normalopratingtemperature (the radiator fan comes
on).

Measurethe voha96 betwoen

the D5snd A2ryA26 terminals

ls the vohagelssthan

'lV?

check for loolo TCM connoc_

tor!. ll noce!.s.Y, subatitut6
a lnown-good TCM snd
aactEck.

14-50

Ropoil opon or short in YEL/

BLU wiro botvvsenthe D5 tor_
mlnrl and th6 ECT!on3or.

ooooooooooo
ooooooooooo

PorrlbL Caula
. Disconn6cted ignition coil
connocror
. Short o. opon in ionhioncoil
Oiaconngct the 26P connector
from tho TCM.

. F6uhyignhioncoil

Turn ths ignitionswhch ON.

Moasurotho vohago botwoon

tho A9 IBLU and A25 (BLK/
RED) or A26 {BRN/BLK)
torminab.
Viw trom lrminal6id6.

Raprl? opon or .hort ln BLU

wh. b.tw.on tho A9te.mlnal
lnd tho lgnhloncoll.
Chod. fof l@q. YCM conlracto.a. lf naca$lry, tubttltqt. a known.good TCM lnd
aachad(.

14-51

ElectricalTroubleshooting
Flowchart(cont'd)
Troubleshooting
s.||d.enodt I D4 | Indlcato.
leht bld.. to|rtTi'tlmrt.

15ths Maltunction hdicator

L.mp (MlL)on ?

PorrlbL cluto

Shortor openin FAS{OBiY

RED)wi.
Troublin ECM

r Make sure llfts, iacks and satety stands 416

placed propsrly, and hoisl blackots aro
attachad to the corl6c-t position on tho ongino
(seosection 1).
. Whlle testing, bo caroful of the lotatlng flont
wheels.

n.o!L th. PGM.FI SYltem

(r.. !.ctlon 111.

Start th ongin and wtrm it

up to normal operrlino
temp6ratuao{tho rsdiator fan
comesonl.

Approx.5 v?

Turn tho ignitfttnswhch OFF.

oooooooooooo
oooooooooooo

Connoct th6 Tolt Harnoss

botwon th6 TCM tr|d coonector3 (1+351.

Turn the hnition swhch ON

a.d wait Ior at l6aat two
ggcotxt5.

l\reaaurethe voh.go tgtweon

the 016 {+) rnd A2gA26(-l
torminab.

Ch.d( to. l@a TcM conrrcto.r, ll nacortxy, !t bttitul. ! known-good TCM and
rcch.ck.
Turn th6 ignitionswitch OFF.

Dkconnoct ths ToEt Haangss

from tho TCM.
L66ve conn6ct6d lo car
n6anoa8.

switch ON.
Turn th6 i{tnit'ron

To prg61+lB

14-52

ooooooooooo
oooooooQooo

From pag14-52

Msasurgth6 vohago botwoon

the D16(+) and A2gA26(-)
torminab.

Ch.ck tor bola TCM corr

nacto[. lt ]raca$ary, rubtdtut. ! known-good TCM ard
rachack.
Disconnoctthe 26P connector
from th ECM.

Check for continuity btwsn

the D18 and A25lA26
torminalsot th Test Harn6ss.

R.o.h .hort ln OR /RED

Tcltl
{FAS} wh. b.tw..n
lnd ECM.

Ch6ck for continuity on tho

OR^I/REOwire botween the D
18 t.min8l on ths TCM snd
tho AlStorminalontho ECM.

Ch.d( tor loot! TCtt oo.r

nactora. It nacattary. tubttltuto r known-gogd TCM and
rcchack.
R.p!|. lhoit In OR /REO
(FASI wlr. b.tw..n TCM ..d
ECM,

(cont'd)

14-53

ElectricalTroubleshooting
TroubleshootingFlowchart (cont'd)
NOTE:

Po.rlblo C!u!.
. Disconnectodmainshaft
9pe6dsonsorconnector
. Shon or op6n in mainahaft
spdSonsorwilo
. F6uhymainshaftsp66d
0nsoa

A cod 15 on th TCM doesn't th/vay6msan th6re'e an

sl6ctricsl problm in ths main8h.ft or countorahatt
sp6d sonsor circlh; code 15 may 8bo indicato 6
mochanicalproblmin th transmbsion.

Ars th mainshstt and

count6rshaft sPsed senaors
installdproperly?

Disconnectthe 2P connector
trom th6 mainshaft spood
s6nsor.

Masur6th resistanceof the

mainshrft spoodsengor.

ls th rssistanc4OO600 O 7 (6t7OoF,2OoCl

Disconnectth 22P conn6ctor

trom th6 TCM.
C o n n 6 c tt h e T o s t H a r n o s s
"0" connctor to ths wire
harnoss only, not to thg TCM

(1+35).

ooooooooooooo
ooooooooooooo

Ch6ck th continuity botwoen

D19 and D12 torminalsand
body ground.
Ropllr lhort In O8N/8LU or
WHT/BLU w1..3 b.tw..n D
19 and Dl2 t.lmlnab lnd lhc
rmlmhlfl apaed tanaoa.
Roconnsct the 2P connoctor
to th rnsinshdftapeodsonaor'

To psg 1+55

14-54

ooooooooooo
ooooooooooo

From p6ge1+54

D' l I

Measure th resistance
between D19 and O12
trminals.

ooooooooooooo
ooooooooooooo

ooooooooooo
ooooo9ooooo

400-600 0?
ls th resistance4OO600 Q ? lat 70oF.2OoCl

Chgck tor corninuity between

D19 terminal and the
mainshaft sp6edsensor.

R.palr op.n in ORN/BLUwi.e

batwaan D19 t..min!l and
tha malnlhatt spcad r.n!or.
Ch6ck fo. continuity btw66n
O12 terminal and th6
mainshaft spg6dsensor.

Rep.ir opon In WHT/BLU wlro

botwaan D12 tormlnal and
tho malnahlft rDoodlanror.
Run El.clricsl Troublcrhooting to. codc 9.
Ch.ck tor looro TCM cfinecto.. It necsrrlry. rubatltuta ! known-good TCM lnd
rochock,

Ch.ck tor loor. TCM cor!

nacto6. It nacalatry, aubrtltute t known-good TCM and
rachack.

(cont'dl

14-55

ElectricalTroubleshooting
TroubleshootingFlowchart {cont'd)
I or I tndicator llght do.t not
6-m. oo with the lgnition
3vYttchON. lh thouH c!m. on
lor gbout 2 aocond!.)

Does tne @

indicator lhhl

Ch.ck lo. bot. TCM connac_

tola, lf nacoraary, aubllltut.
r known-good TCM lnd
Echrck,

Turn the ignitionswitch OFF

Disconngctthe 26P connector

{rom the TCM.
connect th6 Tst Harn6ss
"A" connector to tho wire
harnsss only, not to the TCM
(1+35).
Cor ollty?

Check for continuity btweon

rhe A25 lorminal and bodY
ground and 426 and body
ground.
R.Drl, opon BLK/REDo. BR /
BLK wirc. b.tw.!n A25 ot A
20 t.rrnln.lt .nd GI 01 .

Turn tho ignitionswitch ON.

[P oattc,vvatecr
A23A25

Measurethe vohage betwon

th A23 or A24 and A25 or A
26 trmlnals.

ls thers batterYvohag?
YES
Turn the ignitionswitch OFF.
To psge 1+57

14-56

R.prlr opon o. lhon In BLK/

YEL wlr. botwoon tho A23
andloJ A24 taamlnala and
undo?-hoodf uaa/r.ltY box.

From page1+56

C o n n 6 c tt h e T 6 s t H a r n e s s
"A" connsctor
to the TCM.

Turn the ignition switch ON.

Be sure th6t voltago is
availabl6 tor 2 seconds
b6tween the Ag terminal and
A2gA26 trminal.

oooooooooooo
oooQoooooooo
A8
Lo-.._----J

ooooooooooo
ooooooooooo

A25

Voh!ge?

Chack lor opan or ahort In

GRN/OR wlro betwe.n tho
AB tormlnsl ond tha gaugo
a!!omblv.
Turn ths ignitionswhch OFF.

Oisconngct the Tst Hsrness

"A" connector
from the TCM.

Check ior cominuhy between

th6 A8 trminal and rhe GRI/
ORN wiro at the gauge
assemDry.

Ropairop.n In GRwOnN wh.

betwon the A8 tormlnll .nd
tho gaugllrombly.

Chod( for loo6o TCM connoctor!.

Ch.ck tho A/T gear po!ftlon
awftdr. lf noco3aary, aubstltut. I known-good TCM and
rechock.

(cont'd)

14-57

ElectricalTroubleshooting
TroubleshootingFlowchart (cont'd)
I D4 I Indlc.tor llght It on
;i--adY {not bllnllng}
whon.vd th. lgnltlon twttch
b oN.

Turn tho ignitionswitch OFF.

oisconhoctths 26P connoctor

trom the TCM.
C o n n o c tt h o T 6 s t H a r n e s s
"A" coonectoa to the wiro
harngssonv, not to the TCM.
(1+35).

Iurn the ignitiooswitch ON.

Measuroth voltago betwoen

th6 A8 torminal and bodY
ground.

C o n n 6 c tt h o T o s t H a r n 6 s s
"A" connectorto the TCM.

Moasureth vohag6 b6tw69n

the GR[{/ORN wir6 at th6
gaug6 assembt and to bodY
gaouno.

RaDllr rhort to powot toutco

oo G8N/ORNwlr. brtweon A
8 tarml[l and lEugp a!!em_
blv.

14-58

A8

Volt.gc?

l.Ep.ctlon ot rh. A/C tlgnll.

Symptom
. Lockrp chnch doos not havo
duty opo.dtion(ONe OFFI.
. Lock-up chjtch dos not
eng6g6.

Tu.n tho bbwer switch ON.

Pu3htho A,/Cswitch ON.

8c. Alr Condhlonlng Inrp.ctlon

(... r.cilon 22).

NOTE:

trom torminalsid.

Disconnoctth6 26P connector

from th6 TCM.

Measuroths vohag botweon

the A22 IRED/BLU)6nd A25
IBLK/RED)or A26 {BRwBLKI
tsrminals. {A/C comDaealror
OFF)

RED/BLU
Eanaryvoltage?

Rcpah open lo RED/BLU wlr.

b.tw..n th. A22 t.rmln.l and
A/C compr.$or clutch rcLy.
'A/C.ler|llbOK.
' CH( lo. loor. TCM corF
.racto.a, It nacaaatay, ar5.
.inul. a Lnown-good TCM
and rachack.
' lnlD.ct th. .lr cor|dtlonftt
(!.. r.ctlon 22,.

(cont'd)

14-59

ElectricalTroubleshooting
Svmptom
Shift hv6r camot bo mov6d
irom E position with tho
brako pd6ld6prsssed.
Ch6ck that the brak lights
come on with the brake Pdal
dopressod.

Disconnect the 26P and 22P

connectorsfrom the TCM.
C o n n e c tt h e T o s t H a r n e s s
"A" and "O" connoctors to
th6 wil6 harnssonly, not to
the TCM (1+35).

ooooooooooo

oooooooooooo
oooooooooooo
Moasuroth6 vohagg betwoon
th6 02 and A2tA26 termin3k
with the br6ko Podal
depresssd.

oooooooooo

ris

t_----{}-

14-60

D2
Baitery voh.g.?

Rrplh op.n In GRN/WHT

wlrc b.lw..n lh. D2 t rmlnd
and b]ak. lwhci.

' Br.ko rrvhch tlgnal OK.

. Chod( for loot TCM connacto.r. lf nocoltary, tub_
rtltuto a known-good TCM
and rcchack.
. lnrDoct the brgka twhch
circuh {!.a aociion 23}.

Mainshaft/Gountershaf
t
SpeedSensors
Replacement
1.

Removthe 6 mm bolt f.om th transmissionhousing

and remove the mainshaft and countershaft soesd
sensors.

COUNTERSHAFT
SPEEDSENSOB

o-R[{GS
Rplsc6.

6 x 1 . 0m m
12 N.m {1.2 ks-m , g b-tt}

6x1.Omm
12 N.m (1.2 ks-m , I lb-ft)

MAINSHAFTSPEEDSE SOR

Replacthe O-ringswith a new one before reassemblingthe mainshaftand countershaftspeedsensors.

14-61

Lock-upControlsolenoidValveA/B
Test

Replacement

NOTE:
Lock-up control solenoidvaves A and B must be removed/
reDlacedas an assembly.

1.

1.

Disconnect the connector trom the lock-up control

solenoidvave A/8.

2.

Measure the resistsnce between the No, 1 terminal

(solenoldvalve. A) of the lock-up control solenoid
valve connector and body ground, and between the
No. 2 terminsl (solenoidvalve B) and body ground.

Remove the mounting bolts and lock-up control

solenoidvalve assembly.
NOTE:
Be sure to rmove or replsce the lock-up control
solenoidvakes A and B 8s an assembly.

2,

Check the tock-up control solenoidvalv oil passages

for dust ot din, 8nd replscs 8s sn sssembv, if
necessarv.
LOCK-UPCONTROL
VALVE
SOLENOID
ASSEMBLY

6r1.0mm
12 N.m {1.2 kem , 9 lb-ft)

STANDARD: 12- 24Q

LOCK-UPCONTROL
VALVE
SOLENOID
ASSEMBLY

ReDlacethe lock-uDcontrol solanoidvatue assemblyil

the resistanceis out of specification.
lf the resistanceis within the standard, connect the
No. 1 terminal of the lock-up control solenoid valve
connector to the batterv positive terminsl' A clicking
sound shouldbe he8rd. Connect th No. 2 terminsl to
the battery positive terminsl. A clicking sound should
be heard. Replacethe lock-up control solenoidvave
assemblyif no clickingsound is heard'

14-62

Cloanth mountingaurface
andoil passag68.

FILTER/GASKET
Roplac6.

Clean the mounting surface and oil psssgesof the

klck-up control solenoidvslve assembly,8nd install I
new tilter/gasket.
Check the connector for rust, dirt or oil, and raconnect it securely.

Shift ControlSolenoidValve A/B

Replacement
NOTE:
Shift control solenoidvalves A and B must be removd/
reolacedas an assemblv.
1.

Disconnect the connector from the shiJt control

solenoidvave A/8.

2.

Masurethe resistance between the No. 1 terminal

(solenoidvalve A) of the shitt control solenoidvalve
connactor and body ground, snd between the No. 2
terminal(solenoidvalve B) and body ground.

1.

Removethe mounting bohs and shift control solenoid

vafueassamblv.
NOTE:
Be sure to remove or replacethe shift control solenoid
valvesA and B as an assembly.

2.

Check the shift control solenoidvatue oil passagesfor

dust or dirt, and replaceas an assembly,if necesssry.

6x1.Omm
12 N.m11.2kg"m, 9 lb-ft)

STANDARD: 12- 24Q

Cl6anthe mountingsurfac6
and oilpassgBs.
FILTER/GASKET
sHtFTCOI{fROL
R6placs.

SOLENOID
VALVE
ASSEMBLY

3.

Clean the mounting su ace and oil passagesof the

shift control solenoidvalve assembly,and installa new
fiher/gasket,

4.

Chsck the connector for rust, dirt or oil, and reconnect it securely.

Replacethe shfft control solenoid valve assembtyif

th rsistanceis out of soecification.
lf the resistsnce is within the standard, connsct the
No. 1 terminal of the shift control solenoid valve
connector to the battery positive terminsl. A clicking
sound shouldbe heard.Connect the No, 2 terminalto
the battery poshive terminsl. A clicking sound should
be he8rd. Replace the shiJt control solenoid valve
assemblyif no clickingsound is hesrd,

14-63

Chart
Symptom-to-Component
HydraulicSystem
SYMPTOM
Emine runs, but.car oasnot move m anYgaar."D+"
"8" and "2" but not in "Dg"
or "1"
Car movos in
,
,
oosition.
"Ds" "D1" "1" "R" but not in "2"
Car moves n
,
,
,
,
Dosition.
"'1" but not in "R"
"Ds" "Dt" "2'
Car moves in
.
,
,
,
Dosition.
''Dosition.
C8r moves in "N
Excessiveidlevi )rauon.
liosin 8 oaars.
"1"
No enqinebrakinqin
Dosition.
os in 1st oe8r,
rs in 2nd qear.
rs in 3rd gear,
lios in 4t n oear
SliDsin reversegsar.
Flsreson
uos
Flareson 2-3 uDs t .
Flareson 3- uos
No upshift; transmissionstays in 1st gear.
No downsh ift to lst qeat
Late upshift.
Erraticshittins.
Harshshi t {uDand down s
tnHar

Checktheso items on ths

PROBABLECAUSEList

K, , . R , S

a,8,44,4a

c,M,o

9, 30,49

C,L

,22, 34,34,39,&
.4

14-64

i.H

t 12Har
t(3
Harshkick-dowr
h kick-down shi
8t closedtl
Harshdowns
ngto "1" Dosition.
Har h shift when manuallvs
Axle s) slipsout of transmissionon turns.
Axle sl stuck in transmission.
"R" position.
ns noisewhn shifting into
Ratc
"R posrtion.
Loud ooooinono sewhen takins off in
"R" to "P" positionor
noise
wh8n
shifting
from
Ratcheting
from "R" to "N" oosition.
Noisefrom transmissionin all selectorlver positions,
Noise{rom transmissionon v when wheeF are rollrnq.
Gesr whine, rom relsted (Ditchchanseswith shi
tangeswnn spee(
Goarwhine.sDeed16
"D4"
to 4th qesr in
Dosition,
Transmissionw nor s
lock-up
smool
.ock-uoclutch does not
.ock-uDclutc r does not oDerateDroDel
Transmissionhas multitudeof problemsshifting.
At disassmbly,large particlss ot metsl are found on
maqnet.

Check these items on th8

NOTESList

38,39,40, 45

L,O

.4i
,41
7

43

L,O

PROBABLE
CAUSE
2.
4.

5.
7.
e

Shift cablebroken/out of adiustment

Throttls cabletoo short.
Throttls cabletoo lono.
Wronq tvoe ATF.
e rDmtoo low/hish.
il oumDworn or bindino.
ressurerequlatorstuck,
st clutch defective.
nd clutch defective,
3rd clutch defective.
clutch defective.
st-holdclutch d6fectivs.
Mainshatt,countsrshatt,and scondarvshatt idlsrq6arsworrvdsmaosd.
Modulatorvalve stuck.
e vafueB stuc
TF strainercloqoed.
oroue converter defective.
oroue convgrter check valvs stuck,
- 2 shift vefue stuck-

shift valve stuck.

shift valve stuck.
orvo control vSlvestuck.
ftch oressurecontrol (CPC)valve stuck.
2nd oritice controlvalve stuck.
Ori{icecontrol valve stuck,

2i

3-2

3i
35.
2A

37.
38.
39.
4
4
4i
4
47.
t.

kickdown velve stuck.

3rd kick-down valve stuck.

4th exhaustvalve stuck.
st accumulatordafectivs.
nd accumulatordefective.
3rd accumulatordefective.
4th accumuletordefective,
st-holdaccumulatordetective.
ervo vave stuck.
ock-uo timinq valve stuck.
ock-uo shit'tvalve stuck
ock-uo control valvs stuck.
Shift tork bent.
Reveraeqearsworn/damaoed{3 qsars}.
versesebctot worn.
rd q6arsworn/damaqed(2qesrs).
inaloearsworn/damaqed(2 osars).
DitferentialDinionshaft worn.
esdoiDeO-rinqbroken,
r searsworn/damased(2ssars).
eat claranceincorgct.
Clutch clssranceincorrect.
ne-way (soraq)clutch dsJective.
ealinqrinqs/quideworn.
Axl-inboardioint clip missino.

14-65

Ghart
Symptom-to-Gomponent
HydraulicSystem (cont'dl
Checkthssitemson th6
PROBABLE
CAUSE
DUE
To IMPROPER
REPAIRList

The followingsymptoms can be caused

by improperrpairor assembly.
)ar creeosin N Dosition.
"D3" or "D4" position.
)ar dos not move in
ransmissionlocks uD in "R" position.
(cgssivedraqin transmission,
ve vibration,rom r
Noisewith wheels movinoor

n aeal DoDsout.

ariousshiftins problems.
HarshuDshifts.

PROBABLE
REPAIR
CAUSEDUETO IMPROPER

14-66

hsms on th6
NOTESList

NOTES
A.
R

D,

Seeflushinqprocedure,Daqe1+142snd 143.
Sst idle rpm in gear to specitiedidle speed.lf stillno good, adjust rnotor mounta as outlinsd in enginesection
ol service manuel.
lf th l8roeclutch oiston O-rinois broken,insoactthe Distonqroovefor rouqh machininq.
It the cfutch psck is seizedor is exceasivelyworn, inspect the othr clutchgstor wear, and chsck th6 orifice
controlvefuesand throttle valves for free movemnt.
lf throttle valve B is stuck. insoectthe clutchesfor wear.
lf the I - 2 shift v8lve is stuck closed,th6 transmissionwill not upshift. lf stuck open, the transmissionhas no
lst oaer.

K.

th 2nd orifice controlvalve is stuck, insDectthe 2nd and 3rd clutch oscks tor wear.
th oaificecontrol valve is stuck. insDecttho 3rd 8nd 4th clutch Dscksfor wear.
the clutch oressurecontrolvalve is stuck closed.th trsnsmissionwill not shift out of lst qe8r.
lmpropor alignmentor main vav body snd torqus convrtr ho$ing may causo oil pump seizure.The
svmbtoms

M.
N.

o.

R.

s.
r.
U.

er6 mostlv en rom-rdletgd

tickino noise or d hioh-Ditchod

sdueek-

tf the ATF strainer is clogedwith particlesol steelor aluminum,inspoct the oil pump 8nd diff6rentialpinion
sheft- lf both 616OK snd no caus6lor the conteminetionis {ound. roolecethe tordua convertor.
lf th lst clutch feedpipe guide in the right sida cover i8 scorod by the secondaryshaft, inspct tho ball
be8ringlor xc6ssiv6mov6m6ntin tho transmissionhousing,lf OK, roplacoth6 right sid6cov6r as it is dsntad.
Th O-rinoundrtho ouideis Drobablvwo.n.
Replacothe mainshaftiJ the bushingfor th 4th feedpipeis looseor dsmagd.
lf th6 4th {eedpipeis dsmsgedor out of round, roplacsit.
Bsplsceth countershaftif the bushingfor the 1st-hoHfgedpipeis loossor dsmsged.
lf th 1si-hoHfeedpipeis damagedor out of round,replach.
Rsplacethe secondaryshaft it the bushingfor the 1st feodpipeis looseor damgod.
lf the 1st f66doiDeis damaoddor out of round.rsDlacsh.
A worn or damagadspragclutch is mostly a result oJ shitting the transmissionin "D3" or "D4" posrtionwhile
the wheels rotato in aoverse.such as rockinothe caain snow.
nsDectthe frame tor collisiondamase.
Inspectlor damageor wear:
1. Reverseselectorgearteeth chamfers,
2. Engsgementteeth chamfersof countershatt4th snd revsrsegar,
3. Shift fork for scuff marks in center.
4. Differentialpinionshatt lor wear under piniongears.
5. Bottomof 1st-holdclutchfor swirlmsrks.
Replaceitems 1, 2, 3 and 4 it worn or damaged.lf transmissionmskes clicking,grindingor whirring noise,also
replacemsinshaft4th gear and reverseidlergear andcountershsft 4th gear in additionto 1, 2, 3 or 4,
lf differential pinion shaft is worn, overhaul differentialssembly,and replsceATF strain6r,and thoroughly
cleantransmission,flush torque convartsr, cooler and lines.
lf bottom oJ 1st-holdclutch is swirled and transmissionmakes gear noise, replaceth countershaft and tinal
driven oeer86 very careful not to damagethe torque converter housingwhen replaclngth main bsll besring.You may
also damagethe oil pump when you torque down the main valve body. This will resuh in oil pump seizureif
not detected.[Jseorooertools.
Installthe main s6alflush with the torque converter housing.lf you push it into the torqus converter housing
until it bottoms out. h willblock the oil return Dassaoeand resuftin damaoe.
Harsh downshifts when coasting to a stop with zero throttle may be cauaed by a bent-in throttlo valve
retainer/camstooDer.Throttle cablesdiustmentmav clearthis Droblm.
Check if servo vatue stopper cap is installed.lf it was not installod,th check vave may have been pushed
out bv hvdraulicoressurecausinoa leak (internal)atfectinq sllforward qears.
Throttle cable adjustmentis essentialfor proper operation of the transmission.Not only does it sffect the
shift points if misadjusted,but alsothe shift qualityand lock-upclutch operation.
A cable adjustedtoo long will resuh in th.ottle pressureb6ingtoo low for th6 amount of enginetorque input
into the trsnsmissionand m8y causeclutch slippage.A cablesdjustedtoo short will resuttin too highthrottle
oressurewhich mav causeharshshitts, erratic shitts andtorque conveter hunting,

14-67

RoadTest
NOTE:
Warm up the enginsto normsloporatingtemperature(the radiatortsn comes on).
position while
1. AppV parking brake 8nd block th wheels. Start the engine, thon mov the selector lever to @]
depressingth brak6 pedal.Dopressthe accelaratorpedaland releaseit suddenly.Engineshouldnot stall.
2. Repeetsametest in I D3 l poshion
3. ShiJtthe selectorlev-ertol Dn-lpositionand check that the shiJ'tpoints occur at approximatsspeedsshown. Also check
for abnormalnoiseand clut-chslippage.
NOTE:
Throttle positionsnsorvoltagBtepresentsth throttls opening.
- 1.
-2.

Connectthe Test Harnessbetween the ECMand connector (seesection 11l'

Set the digital multimstr to check voltage betwen Dl1 (+) terminal and D22 {-) trminal for the throttle
posiiionaenaor.

CAUTION:
. Al SRS oloctrlcal wldng harnot3as aro covolad whh yelow
outor Inrulatlon.
. Bololo dsconnecllng tho SRSwlro herna$, Installtho short
connoctor{ll on tho !lrb.g(!}.
. Replac6tho or|tlle sffocted SRS hlrnoss ass.mblY if h has
an opon chcuh or damrgod wlring.

SRS MAI'{ HARI{ESS

DIGITALMULTIMETER
KS_AHM_32

14-68

F22Al Engln.:l Da I Polhlor

1st+2nd

2ndJ3rd

Lock"up
Cinchof'l

Throttlo polhlon lorEor voltago:

mph

13- 15

26-24

36-40

l4-17

Coaatlngdown-hll from a stop

km/h

21-24

42-45

58- 64

23-27

Throttlcporhlonlomor vohago:
2.'t8V
Accobratlon from a stop

mph

17- 2'l

37 -4'l

57-63

6 1- 6 7

km/h

27-34

60-66

92-101

98- 108

Fu[throttlo

mph

E-34

60-65

88- 94

8t -86

AcceLrltlon from a stop

km/h

47 -55

97- 105

142-'151

130-138

4thJ3rd

3rdJ2nd

2nd-+ l st

o.83V

Dowruhltt

Lock-up
Clutch
oFF

Throftlo porhlon sg]lor voltego:

o.83V
Corstlng
or braklng
to ! stop

Throttb po3ltlon lsmor Yoftago:

2.18V
When car is sbwed by increr3od
grldo, wlnd, oic.
Fd-throttlo
When car lr tbwed
grada,wlnd, etc.

mph

13- 16

18-22l4tHld)

6- 10

km/h

2't-26

E-35{4thrhdl

10-16

mph

53- 59

km/h

&5-95

mph

77-82

76-42

km/h

124-132

123-132

by Increased

52-

al

u-92

2'l -26
34- 42

{cont'd)

14-69

RoadTest
(cont'd)
H23Al Engine:I Da I Position
'Upshift

Throttlepositionsonsolvohago:
o.83V
Coastingdown-hlllfrom a stop

lst-2nd
mph

13-15

km/h

3rd -,4th

Lock-up
Clutch
0N

26-A

36-40

14-'17

42*45

58- 64

23-27

2nd--r3rd

Thlottls positionsensorvohago:
2.18V
from I stop
Accaloration

mph

1A-22

36-40

54-60

58- 64

km/h

29-35

58- 64

87 -97

93- 103

Full-throttle

mph

E-34

57-62

&l-88

s-85

Accelerationtrom a stop

km/h

47-55

92- 100

134-142

l?9-137

4th-J3rd

3rdJ2nd

2nd+lst

.Downshift

Lock-uD
Clutch
oFF

Thlottlepositionsensolvoltago:
0.83V

mph

13- 16

18- 22(4thJzd)

6- 10

Coasling 01 blaking to a stop

km/h

21-26

29-35{4th+hd}

10-16

Throttle position 3onsorvohage:

2.18V
wh6n car is slowed by incleased
grado,wind. otc.

mph

48-5/.

km/h

77-47

mph

73-&

km/h

117-lE

Full-throttlo
When car is slowed by Incroased
grade,wind, etc.
4.

73-79
1 1 7- 1 2 7

51-56

24-A

82- 90

39- 47

Accelersteto about 35 mph(57km/h) so the transmisionis in 4th, then shift lE+-Jpositionto f Z-l position.The car should
immediatelyboginslowingdown from enginebraking,
GAUTION:

to E-lor F-l posltlon

at sposdsover63 mph(1ookm/h];youmeydamaso
Donotshifrtrom-Ioi lor lE-l position

the transmission.

5.

Check lor abnormalnoiseand clutch slippagein the following positions.

L! ] {lst Gear)Position
-1. Acceleratetrom a stop t lullthrottle.Checkthat theris no abnormalnoise
or clutchslippago.
- 2. Upshiftsshouldnot occur with the selectorin this position.
[7 (2ndcear) Position
- 1. Acceleratefrom I stop at tull throttle. Checkthat there is no abnormalnoiseor clutch slippage.
- 2. Upshiftsand downshifts shouldnot occur with the selectorin this position,
T-:-1,tl |lr|everselrostuon
A.ccelerstefrom 8 stop at fullthrottle, and check to. abnormslnoiseand clutch slipp8ge.

6.

Test in I P I lParkino)Position
the brake;the car should
Parkcar on slope(approx.16o),sppv the parkingbrake,and shift intoI P I position.Release
not move.

14-70

StallSpeed
Test
CAUTION:
. To provont tlansmissiondamago,do not t6st stall spoodfor mors than 1Olocond! at r tlma,
. Do not shlft tho lovel whlle lalsing tha enginespeed.
. 86 suro lo romovo the prossuregaugobefolo testlng stal spood.
1.
2,
3.
4.

Enggeparkingbrakeand block the front wheels.

Connecttachometer.and sta.t the engine.
Makesurethe A/C switchis OFF.
After the enginehas warmed up to normaloperatingtempersture (the rad;8tortan comeson), shift into @ Ooshion.

for 6 to 8 seconds,
andnoteenginssped,
5. Fullydepressthe brakepedalandaccelerator
6. Allow2 minutesfor coolins,thenrepeatthe test inloil, [Tl , ana[_] oositions.
NOTE:
. St8llspeed
restsshouldbe usedlor diasfEtiplqrpossonly.
. Stallspeedshouldbethe samein
L91l , L?l , L1l andL!_l positions.

Stall SoeedRPM:
F22Al Engin
Spoclficatlon:
Sarvice Limit:
H23Al Engino
Spcification:
Service Limit:

2,500rpm
23&-2,6fu

rpm

2,7@rpm
2,60O-2,90O rpm

PROBAELE
CAUSE

TROUBLE

starlrpm
hishi" F;] ,E .E -o E
posruons

Low fluidleveloroil pumpoutput

CloggedATF strsiner
Pressurergulstolvafuestuck clossd
Slippingclutch

Stallrom hiohin @ nosition

Slippageol 4th clutch

Stallrom hiehin@ and@ oositions

StallrpmhishinE position

Slippageof 2nd clutch

stallrpmlowi" [D;l .E

Engineoutput low
Torque converter one-way clutch slipping

positions

,f

a.a@

Slippageof 1st clutch or lst gesr one-wayclutch

14-71

FluidLevel
Checking/Changing
Chocklng

ChEnglng

NOTE:
Chsck ths fluid lvsl with th6 6ngin6 at normal
opsrstingtemperaturs (th rsdistorf8n comes on).
1.

Psrk the car on lv6lground,Turn oft th 6ngin6.

2.

Remov6 ths dipstick {yellow loop) from th

transmission,and wipe it with a cls8ncloth.

3.

Insertths diDstickinto th trsnsmission,

1. Bring the trsnsmission up to normal oprating

tampsrature lths radistorf8n coms on) by drivingthe
car. P6rk ths car on l6vel ground,turn the 6ngin6olf,
andthn romovothe drain plug.
NOTE:
lf 8 coolr flushar is to be usad, sa6 paee 14-142 and
143.
2

DIPSTICK{YELLOWLOOPI

Roinstsllths drain plug with a nsw saling wsshr;

thon rsfill ths tranamisaionto the uDDermark on th
dipstick.
Automatlc Tranlmllllon FhrldCapachy:
at chsngins
2.4 t (2.5 US qt , 2.1 lmp qt)
at ovsrhaul
6.0 e (6.3 US $ , 5.3 lmp qt)

Romoveths dipstick and ch6ck ths fluid bvel. lt shouH

be bstw66n th6 uDDerand lowgr marks.

DIPSTICK

IA
Ell-

UPPER
LOWER

lf the lvel is below the lower mark, add lluid into tho
tub to bringh to the upper mark. Use HondsPremium
Formula Automstic Transmission Fluid or an
equivalentDEXROIIall Automstic TrsnsmissionFluid
(ATF)only.
hsert th dipstick bsck into th6 transmission.

14-72

DRAI'{PLT'G
18r 1.5rnm
50 N.m(5O ks-m , 36 lb-tt)

4.

Stsrt the engins, and msasurs ths rospoctivs

Drssuroas follows:
' LinePr6ssuro
. Throttl B Prossur
. Clutch Pr6ssur6
' Clutch Low/High Prassurs

Instsll a new waahsr and the sesling boh in th6

inspectionhols, andtighton to th6 sp6cifi6dtorqus.

. Whlle t$tlng, bs careful of ths rotallng tront whoob,

. Mak6 suro tfts, lackr. End safoiy stands aro phccd
proparly(3oosoctlon 1l.
CAUTION:
. Botora toltlng, bo surc tho tra]lmirlion fluld lr flled
to tho plopol loval.
. Wsrm up tha onglnebtoro toltlng.

TOROUE:
1.

Raisethe car.{seesection1).

2.

Warm up the engine, thon stop ths sngine End

connect a tachometer.

3.

Connect the oil pressuregaugeto esch insp6ction

hole.
TOROUE:

18 N.m (1.8 kgm , 13 lb-ft)

NOTE:
Do not rsuse old aluminumwashers.

18 N.m (1.8 kg-m, 13 lb-ft)

CAUTION:
Connect tho oll prssuragaugo 3ecuroly;be rure noi
to allow dust and other folelgn partlcl$ to ent.l th
lmpoctlon hol.

A/T OILPRESSURE
GAUGESET
07406- 0020003

A/T OILPRESSURE
HOSE
07406- 0020201

A/f LOW PRESSURE

GAUGE

07408-OO7o(xXr

(cont'd)

14-73

PressureTesting
(cont'd)
. Llno Prcrluro Maalurcmcnt
- 1.

Set the psrkingbrake 8nd block both rear wheels securely.

-2.

RunthE 6ngineat 2,000 rpm.

- 3.

Shift ths s6l6ct l6v6r to N

or E

position.

NOTE:
Highsrprossures
msyboindicEted
it measurements
armadein solctorpositionsothrthanLryl orLll position,
-4,

M8sursline pressur.

LINEPRESSURE
I SPECTION
HOLE
F22A1 Engin
PRESSURE

SELECTOR
POSITtON

FLUIDPRESSURE
SYMPTOM

PROEABLE
CAUSE
Standard

Line

E*E

No (or low)
line pressure

Torqu6conv6rt6r,
oil pump, prossurs
regulator,torque
converter check
valve

Scrvlcc Llmh

&O- 85O kP8

750 kPa(7.5 ks/cm,,
(8.O-8.5 ks/cm' , 107 psi)
1 1 4 - 1 2 1p s i )

H23A1 Englno

PRESSURE

SELECTOR
POST|oN

FLUIDPRESSURE

SYMPTOM

PROBAELE
CAUSE
Stand!rd

Ltne

14-74

Eo'E

No (or low)
line pressu,e

Torqueconverter,
oil pump, pressure
regulator,torqug
convertr check
vatve

Scrvlco Llmh

85O-9OOkPa
&O kPa(8.Oks/cm,,
(8.5-9.O ks/cm, , '114psi)
1 2 1 - 1 2 8p s i )

. Thlotllo I ProssulMoasurement
- 1. Set the parkingbrakesecurelyand block the wheels.
-2,

Runthe ongine8t 1,00Orpm.

-3.

Disconnectthe throttle control cable lrom the throttle control lev6r and set the throttle control lver in full throttle
position.
THROTTLE
B PRESSURC
INSPECTIOI{
HOLE

THROTTLE
COiTTROL
CABLE

THROTTLE
COiITROL
LEVER
F22Al Englno

PRESSURE

SELECTOR
POStTtot{

FLUIDPRESSURE

SYMPTOM

PROBABLE
CAUSE
Standard

Throttle B

Prssure
too
hish

Throttls VElveB

0 kP8 (O kgy'cm',
0.0 psi)
throttle lver tullyclosod
kPa
&0-850
18.0-8.5 ke/cnt' ,
114-121 psi)
throttl lever fullyopensd

No or low
pressure

SorvlceLlmlt

75O kPa (7.5 kg/cm, ,

1O7 psi)
throttle lever fullyopeneo

H23A1 Engine
PRESSURE

SELECTOR
POSITtON

FLUIDPRESSURE

SYMPTOM

CAUSE
PROBABLE
Standard

Throttle B

Pressuretoo
high

No or low
pressure

Throttl Vslve B

SorvlcoLimh

0 kP8 (0 ks/cm' ,
O.O psi)
throttle lever fulvclosd
85O- 9OO k P8
(8.5-9.0 kdcnP .
121- 128 psi)
throttle leve. fullyopen6d

SO kPa {8.0 ksr'crn,.

114 psi)
throttle lever fullyopened
{cont'dl

14-75.

PressureTesting
(cont'dl
. Clutch PressuloMeaaurmant

@
Whila t$ting, bo ca.fulof tho totatlng front wheals.
-'1.

Set the parkingbrskeandblockboth rearwheelssecurely.

-2.

Raisethe front of the car and support h whh salety stands.

-3.

Allow the Jront wheelsto rotate freely,

-4,

Runthe engineat 2,0OOrpm.

-5.

Measureeachclutchpressure.

PRESSURE
lST CLUTCH
INSPECTION
HOLE

lST-HOLD CLUTCHPRESSURE
INSPECTION
HOLE

14-76

2NDCLUTCHPRESSURE
II{SPECTION
HOLE

4TH CLUTCHPRESSURE
II{SPECTK)]T
HOLE

3RDCLUTCHPFESSUBE
INSPECTIOI{
HOLE

CENNEB
BEAM

F22Al Englno

SELECTOR
PRESSURE POSITtON

SYMPTOM

PROBABLE
CAUSE

FLUIDPRESSUBE
Standard

1st Clutch

E",F;]

No or low
lst pressure

lst Clutch

No or low lsthold pressure

1st-holdClutch

No or low
2nd pressure

2nd Clutch

No or low
2nd pressure

2nd Clutch

3rd Clutch

No or low
3rd pressure

3rd Clutch

4th Clutch

llo or low
4th pressur

4th Clutch

1st-hold
Clutch

tr

2nd Clutch

tr;-]
L1l

2nd Clutch

Servo Vslve or
4th Clutch

tr

Servic6 Limit

SO-85O kPa
{8.0-8.5 kgy'cm',
114-121 psi)

75O kPa (7.5 ks/cm, .

1O7 psil

5OOkPa (5.0 kg/cm, ,

71 psi)
(Throttlelsvr fully closedl
85O kPa (8.5 kg/cm, ,
121 psi)
{Throttlelever more
than 3/16 oDened)
53O kPa {5.3 kg,icm,,
75 psi)
(Throttlelever fully closd)
85O kPa (8.5 ks/cm, ,
'121psi)
(Throttlelever more
than 3/16 ooen6d)

450 kPa (4.5 kg/cm, ,

64 psi)
(Throttlelver fully closedl
75O kPa (7.5 ks/cm' .
107 psil
(Throttlelsver more
than 3/16 oDenedl
4$ kPa 14.8 kg/cm, ,
68 psi)
(Throttle levor fully closed)
75O kPa {7.5 kg/cm, ,
107 psil
(Throttle lever more
thsn 3/16 oDnedl
75O kP8 (7.5 kg,/cm',
107 psi)

gJO-a5O kP8 lE.O-8.5

kg/cm, , 114-121 psi)

H23Al Englne
SELECTOR
PRESSURE POSITrON

SYMPTOM

PROBABLE
CAUSE

FLUIDPBESSURE
Standrrd

lst Clutch

E-[5.']

No or low
1st pressure

1st Clutch

No or low lsthold pressure

1st-holdCluich

No or low
2nd prsssure

2nd Clutch

No or low
Zrd pressure

2nd Clutch

3rd Clutch

No or low
3rd prssure

3rd Clutch

4th Clutch

No or low
4th pressure

4th Clutch

1st-hold
Clutch

tr

2nd Clutch

tr;-l

2nd Clutch

r=---l
l u 4I

IA

SrvoValve or
4th Clutch

Sorvico Limlt

85O- 9OO k Pa
(8.5-9.0 ks/cmz,
1 2 1 - 1 2 8p s i )

&O kPa{8.0 ks/cm' ,

l14 psi)

50O kPa (5.O kslcm, ,

71 psil
(Throttle lever fully closed)
90O kPa (9.0 kg/cm' .
128 psil
(Throttle lover more than
3/16 oDencdl
53O kPa (5.3 ks/cm, ,
75 psi)
(Throttlelever fully closed)
9OO kPa (9.O kg/cm, ,
128 psi)
(Th.ottle lever more than
3/16 ooened)
8S-9OO kPa (8.5-9.0
ks/cm' , 121-128 psi)

45O kP8 (4.5 ks,/cm' ,

64 psi)
(Throttlelever tully closed)
800 kPa (8.0 kgy'cm,,
114 psi)
{Throttlo lever more than
3/16 ooened)
4m kPa (4.8 ks,/cm' ,
68 psi)
(Throttle lever fully closed)
80O kPa (8.0 kg/cm, ,
114 psi)
(Throttlelever more than
3/16 ooened)
DO kPa (8O ks/cm' ,
1'14 psi)

14-77

PressureTesting
(cont'd)
-8.

. Low/Hlgh ProssuroTost
-1,

Set the psrkingbrake and block the rear wheels

securety.

-2.

Raisethe car and support with satety stands.

-3.

Attach the gaugeset to the approp.iatepressure

inspectionholes.

-4.

Remove the throttle control cable end of the

throttle control lever,

With the enginidling,lift the throttle control l6vr

up approximately 1/2 of its possible travel and
increasethe engine.pm until pressureis indicated
on the appropriate gaug. Record th8 highest
pressurereadingobtained.

NOTE:
Do not loosen the locknuts; simply unhook the
throttle control cableend.
THROTTLE
CO TROL
CABLE
LOCKNUT

THROTTLE
CONTROL
LEVER
THROTTLE
COIVTNOL
LEVER
-9.
-5.

Warm up the engine to normal operating

temperature(the radiatorfan comeson).

with the engineidling,move the slector leverto

E
-7.

position.

Slowly move the throttle linkageto increasesngin

rpm until pressure is indicated on the appropriate
gauge.Then releasethe throttle linksge,sllowingthe
engineto return to an idle. and record the pressure
reading.

THROTTLELINKAGE

14-78

Repe8tsteps -7. and -8. tor each clutch pressure

beinginspectd.

CE TERBEA]II

Englno

PRESSURE

SELECTOR
POSITtON

FLUIDPRESSURE
SYMPTOM

DD'IEADI

E 'TA I ICE

Standard
2nd Clutch

L9!

No or low
2nd pressure

2nd Clutch

3rd Clutch

No or low
3rd pressure

3rd Clutch

4th Clutch

No or low
4th pressure

4th Clutch

SorYiceLlmlt

5OO- 85O kPa

lc.u-5,9 Kg/cm' ,
71-121 psi)
vsries with throttle
lever opning

45O kPa {4.5 ks/cm, ,

64 psil
{Throftleleverfullycbsed)
75O kPa (7.5 kg/cm, ,
107 psi)
(Throttlelever more
than 3/16 opend)

53O-850 kPa
(5.3-8.5 ksy'cm,,
75-121 psi)
varies with throttle
lever opening

4& kP8 {4.8 ks/cm, ,

68 psi)
{Throttleleverfulv closed}
75O kPa (7.5 ks/cm, ,
107 psil
(Throttle lever more
than 3/16 opened)

Engino
PRESSURE

SELECTOR
POSITtON

FLUIDPRESSURE
SYMPTOM

PROBABLE
CAUSE
StEndard

2nd Clutch

No or low
2nd pressure

2nd Clutch

3rd Clutch

No or low
3rd pressure

3rd Clutch

4th Clutch

No or low
4th pressure

4th Clutch

Sorvlce Llmit

50O- 9OO kPa

(5.0-9.O ksy'cm,,
71- 128 ps')
varieswith throttle
leveropening

45O kPa (4.5 ks/cm, ,

64 psil
{Throttleleverfullycbsed)
&O kPa (8.O kg/cm, ,
114 psi)
(Thfottle lever more
than 3/16 opened)

53O- 90O kPa

(5.3-9.O ksy'cm',
75-128 psi)
varieswith throttle
lever opening

48O kPa {4.8 kg/cm, ,

68 psil
{Throftleleverfulv cbsd)
8OO kPa (8.O kg/cm2,
114 psi)
(Throttle lever more
than 3/16 opened)

14-79

Transmission
Removal
t.

. Make Eu16ltfts. iacks and safoty stands aro placed

properv, 8nd hoist brackots ato attachod to the
corroct positlon on th6 6n9lne(360soctlon 1).
. Apply psrklng brak6 and Hock roar wheols, so car will
not roll otf stands and ta[ on you while worklng
und6r h.

Disconnectthe battery negative (-) 8nd positive {+)

cablesfrom the battery.
Remov the battery set pl8te, then remove the
battery.
Remove the drsin plug, and drain the automatic
transmissionlluid (ATFl. Reinstallthe drsin plugwith a
new sealingwasher.

5.

CAUTION:
Uso fnder covols to avold damagingpaintodsurfacs.

TOROUE:

50 N'm (5.O kem , 36 lb-ft)

CAUTION:
. A[ SRS olsctrical wi]ing halnossas are covetd whh
yellow outor insulation.
. Bofore dlsconncting the SRS wlro harnoss, install
tho short connoclor (3)on the slrbag ls).
. Reolacotho entlre affocted SRS ham$s assemHy if
it has an open circuit or damagedwirlng.
NOTE:
The radio mav have I codd theft protection circuit. Be
sure to get the customer'scode numberbefole.
- Disconnectingthe battery.
- Removing
the No.43 (10 Alfuse.
{ln the under-hoodfuse/relayboxl
- Removingthe radio,
AJter service, reconnect power to the r8dio and turn it
on.
"CODE" is displsyed, enter the
When th word
customer's Sdigh code to restore radiooperation.

DRAINPLUG
18x 1.5 rrm
50 N.m (5.0 ks-m ,
36 b-ft)

4.

Removethe resonator,intaks air duct and air clesnet

housing.
Disconnect the connectot from the intak conttol
vacuum tank, then removs the intake control vacuum
tank 8ndtank bracket.
NOTE:
Do not remove the vacuum tube from the intsko
controlvacuumtank.

HOUSIM!
AIRCLEAI{ER

I]YfAKECOi{TROLVACUUMTANK

14-80

6.

Disconnect the glound cabsl from the transmission

and body.
Removethe bEttery basewhh th groundcable.

6.

1 3 . Removethe starter rnotor cables.

1 4 . Disconnectthe countershattspeedsensorconnector.
COUNTERSHAFT
SPEED
SENSOR
CONNECTOR

Removsthe battery bassstay.

GROUNDCABLE

BATTERY
BASESTAY
q

Disconnectthe lock-upcontrol solenoidvalve and shift

control solenoidvalve connectors.

1 0 . Disconnectthe throttle control cablefrom the throttle

STARTSER
MOTOR
15. Disconnect the vehicle speed sensor connecter.
Remove the rear stiffener, then remove the vehicle
speedsensor/powersteeringspaedsensor.

controllever.

1 1 . Disconnectthe mainshaftspeedsensorconnector.
12. Removeths ATF cooler hosesat the joint pipes.
Turn the ends of the ATF cooler hoses uo to Drevent
ATF from flowing out, then plugthe ioint pipes.
NOTE:
Check for any signsof leakageat tha hose joints.
MAI]TSHAFT SPEED
SE SOR COI{NECTOR

NOTE:
Do not disconnectthe power steeringpressurehoses
from the vehicls speed sensor/powr steering speed
s9nsor,
POWERSTECRING
VEHICLESPEED
PRESSURE
HOSES
SENSOR
REAREI{GINE
MOUI{T

SOLENOID
VALVE
coNf{EcToRs

TRANSMISSK)N

GROUD
CABLE

REARSTIFFENER

POU'ER
STEERIT{G
SENSOR
\SPEED

O-RING
Replac6.

(cont'dl

14-81

Transmission
Removal(cont'd)
16. Removethe transmissionhousingmountingbohs.

1& Removsthe transmissionmount.

TRAl{SMlsSOt{MOUI{T

TRANSMISSIONHOUSING
MOUI{TINGBOLTS

17. Loosenthe Jront enginemount brscket bolts.

-

19. Rsmovethe splsshshield.

FROiIT E]{GII{E MOUNTT

BRACKETBOLTS

SHIELD
SPLASH

FRONTENGINE
MOUiTT

14-82

20. Rmovethe center beam8nd r6ar beamstifJener.

B.

Pry the drivshaftsout ot ths differentisl.

24. Pullon the inboardjoint and remove the right and left
drivshafts(s6ssction 16).

Tie plasticbagsov6r the drivsh8ftenos.

NOTE:
Coat 8ll precisionfinished 9urf8c6s with clean ongine
oilor groass.

DRIVESHAFT
E D

21. Romovsths cottr pins and castls nuts, thsn sep8r8t6

26. Removethe right dsmpsr pinch boh, then separatetho

damoerfork and dsmoor,

22 Remove the damper tork bohs. then separste tha

27. Remove the self-locking bolts and self-locking nut,

then romoveths right radiusrod.

the ballioints from the low6r arm (seesection 18),

dampertork and lower arm.

r
SELF.LOCKING
UT
Roploco.

rY

P6*ii53., cAsrLENur

DAMPERPII{CH
EOLT
R6plac.

sELF-L(rcKhIG
BOLT

DAMPERFORK

SELF.LOCKIIIG
NUT
ReDhco.

RADIUSROD

R6place,

(cont'd)

14-83

Transmission
Removal(cont'd)
n.

Rmovo ths torque convorter covr and shift csbb

covgt.

31. Plsce 8 jack undr the transmission, and raise th

transmissionjust enough to take weight oft of the
mount.

E.

R6moveths lock bott sscuringthe control lver, then

rsmovo the shift cablswith the controllsvsr.

32. Romovethe intake manitoHbracket.

CAUTION:
Tlks care nol to b.nd tha lhlft cable whllo removlng
h.

33, Removethe trsnsmissionhousingmountingbolts 8nd

rear anginemountingbolts,
34. Pull the transmissionaway trom the ngine until it
clesrs the 14 mm dowel pins, then lower it on the
transmissionjack.

SHIFTCABLE
TRANSMISSIONHOUSING
MOUiTTI'{G EOLTS

TOROT,E
COI{VERTER
COVER

30. Rsmovoths eight drive plate bolts one at a tims whils

rotatingth cr8nkshEftpulby.

DN|VEPLATCBOLT
6x1.Omm

DRIVEPLATE

14-84

TRANSMISSION
JACK

INTAKETIAI{IFOLD
ERACKET

lllustratedIndex
Right Side Cov

14-86

SIDECOVERPROTECTOR
SPEEDSENSOR
Replace,

SIDECOVER
Replace.
TH CLUTCHFEEDPIPE
SIDECOVERGASKETReDlsce.
Replace.
PIPEGUIDE
RING
ST CLUTCHFEEDPIPE
Replace.
PIPEGUIDE
RING
Replace.
SPEEDSENSOR
lST.HOLDCLUTCHFEEDPIPE
PIN

@O-RlMisReDtsce.
P|PEGUTDE
@FEED
OSNAPR|NG
@CouITERSHAFT
LocKNUT,24 x 1.2s mm
(Flange
nutlReplsce.
SPRINGWASHERReDlace.
ARKINGGEAR
NEEDLEBEARING
IDLERGEAR
EEARING

NEEDLE
BEARIMi
WASHER
LOCKNUT,24 x 1.25 mm

(Flange
nut)Replace.
NOTE:Left-handthreads
WASHERReptace.
OCONICALSPRTNG
@)MAIN!|HAFTIDLERGEAR

SHAFTLOCKNUT,24 x 1.25 mm
@SECONDARY
{Flangenut) Rplace.
@CONICALSPRINGWASHERReptace.
CISECONDARYSHAFT IDLERGEAR
@LOCKWASHERReplace.
@THROTTLECONTROLLEVER
@THROTTLECONTROLLEVERSPRING
HANGER
@'TRANSMISSION
@ATF LEVELGAUGE
@DRAINPLUG
@SEALINGWASHERReplace.
E)PARKINGBRAKEPAWL
@)PARKINGBRAKEPAWL SPRING
@PARKINGBRAKEPAWL SHAFT
@PARKINGBRAKEPAWL STOPPER
@LOCK BOLT
@LOCK WASHERReplace.
@PARKINGBRAKELEVER
OPARKINGBRAKESPRING
g) PARKII{GBRAKESTOPPER
HOUSTNG
6)TRANSMTSSTON
6)TRANSMISSIONHOUSINGGASKETReDtace.
@)DOWEL P[rl
6)ATF COOLEFPIPES

BOLT
@tJorNT

@ SEALINGWASHERSReplace.
6)JOTNTBOLT
@SEALINGWASHERSReplace.
STEERINGSPEED
@VEHIGLESPEEDSENSOR/POWER
SENSOR
@ O-Rll,lGReplace.
G)REVERSEIDLERGEARSHAFT HOLDER
@ NEEDLEBEARING

TOROUE
SPECIFICATIONS
Ref No.
A
B
E
H

TorqueValue
1 2 N . m( 1 . 2 k g - m , I l b - t t )
14 N.m (1.4 ks-m, 10 lb-ft)
18 N'm (1.8 ks-m, 13 lb-ft)
55 N.m (5.5 ks-m ,4O lb-ftl
29 N.m (2.9 kg-m,21 lb-ft)
50 N.m (5.0 kg-m,36 lb-ftl
23O N.m (23.0 ks-m, 166 lb-ft)
170 N.m (17.0 kgrm, 123 lb-ft)
230 N'm (23.0 ksFm,166 lb-ft)
1 7 0 N . m( 1 7 . 0k s - m , 1 2 3 l b - f t )
23O N.m (23.0 ks-m , 166 lb-ft)
170 N.m (17.0 kg-m, 123 tb-ft)
8 N'm (0.8 ks-m , 5.8 lbjtl

Bolt Size
6x1.Omm
6x1.Omm
I x 1 . 2 5m m
1 0 x 1 . 2 5m m
1 2 x 1 . 2 5m m
1 8x 1 . 5m m
z+x t.zcmm
24 x 1.25mm
z4 x t.zc mm

Remarks

Joint Boft
DrainPlug
MainshartLocknut
Left-handthreads
SecondarySh8tt
Locknut
Countershaft
Locknut

5x0.8mm

14-87

lllustratedIndex
Housing
Transmission

@ B
@
@

@
@

@
{}

(t

14-88

OTHRUSTWASHER
OTHRUSTNEEDLE
BEARING
OSEcoNDARYSHAFT2NDGEAR
BEARINGS
@NEEDLE
NEEDLE
@THRUST
BEARING
WASHERStectiveosrt
@SPLINED
@1ST/2ND
CLUTcHASSEMBLY
Reptace.
@o-RlNGs
(9)SECONDARY
SHAFT
@THRUST
NEEDLE
BEARING
BEARING
ONEEDLE
@SECoNDARY
SHAFTlsr GEAR
@DtsrANcEcoLLAR.s.o mm
@corrERs, 29 mm
RETAINER
RING
RINGS,32 mm

Replace.

NEEDLE
EEARING
4TH/REVERSEGEAR
BEARII{GS
I{EEDLEBEARING
GEARCOLLAR
TH CLUTCHASSEMBLY
GEARCOLLAR

THRUST]TEEDLE
BEARIITIG
BEARING
3RD GEAR

NEEDLE
8EARI]{G
Rephce.

BOLT
WASHERReplace.
FORK
2ND GEAR
REVERSEGEAR
BEARING

SELECTOR
HUB
SELECTOR

RINGS,35mm
RING,29 mm
BEARING

RII{G
IDLERGEARSHAFf HOLDER
BEARING
SEAL Reolace.
HOUSINGOIL SEAL Reolace.
SHIM SelectiveDart
OUTERRACE
HOUSINGGASKETReplsce.

4TH GEAR
BEARING
RING

32 mm
TERS,
29 mm
ANCECOLLAR
3RD GEAR
NEEDLEBEARING
@oNE-WAY CLUTCH
}COUMIERSHAFT1ST GEAR
)NEEDLEBEARING
@THRUSTWASHER
lST GEARCOLLAR
@COUNTERSHAFT
@tlsT-HoLD cLuTcH ASSEMBLY

HOUSII{GMAINSHAFTEEARII{G
HOUSIMI SECOI{DARYSHAFT

EEARI'{G
HOUS|NG
COUI\TTERSHAFT
BEARTNG
@)TRANSM|SS|OI{
IDLERGEAR
@NEVERSE
ASSEMBLY
GDIFFERET\ITIAL
OUTERRACE
G)EEARIIIIG
COI{VERTER
HOUSING
OILSEALReDtace.
@)TOROUE
COI{VERTER
HOUStitc
@TOROUE

TOROUESPECIFICATIONS
Ret No.

TorqueValu
1 2 N . m( 1 . 2k g - m , 9 l b - f t )
14 N.m (1.4 kg-m, 10 lb-ftl

Boh Size

Rsmsrks

6x1.Omm
6x l.Omm

14-89

lllustratedIndex
TorqueConverterHousing

\l

il

IU

@.-.

lL? a

@
' @

&P

14-90

OATF STRATNER
@MAGNET
@OILFEEDPIPE
@otl FEEDP|PE
covER
@4THACGUMULAToR
@o-Rlltc Reohce.
OLOCKwAsHERReotace.
BASE
@sERvoDETENT
@sERvoBoDY
SEPARAToR
@SERVO
PLATE
@cHEcKBALL
vALvE BoDY
@SECoI{DARY
PIN
@DOWEL
@SECoNDARY
SEPARAToR
PLATE
@AccuMULAToRBoDy covER
@lsT AccuMUrAToRcHoKE
@cHEcKBALL
@1sT/2 D ACGUMULAToR
BoDY
vALvE BoDY
@THROTTLE
pt-arE
SEPARAToR
@THRoTTLE
PrN
@oowEtCOTTROL
SHAFT
!THROTTLE
@ERINGReplace.
Replace.
@FILTER
VALVEBODY
@REGULATOR
Replace.
@O-RllJG
SHAFT
@STATOR
SHAFT
@STOPPEB
COiTVERTER
CHECKVALVE
@TOROUE
CONVERTER
CHECKVALVESPRING
@TOROUE

1 2 N . m ( 1 . 2k g . m , I l b - f t )
18 N.m (1.8 ksFm, 13 ltsft)

FEEDPIPE
BALL
TERReplace.
PIN

FEEDPIPE
VALVEBODY
PUMPDRIVENGEARSHAFT
PUMP DRIVEGEAR
PUMP DRIVENGEAR
SHAFT
SPRIiIG
ARM
ARM SHAFT
PIN
SEPARATORPLATE

NEEDLE
BEARIM!
GUIDEPLATE
SHAFT BALL EEARING

GUIDEPLATE
SEAL
COiITROL
SOLEI{OID
FILTER/GASKET
Replace.
COiITROLSOLEI{OID
VALVEA$SEMBLY
-UPCONTROLSOLENOID
VALVEASSEMBLY
HOLDER

-UPCOTIITROL
SOLENOID
FILTER/GASKET
Replacs.
@TOROUECONVERTERHOUStt{c
6)II'AINSHAFTBALL BEARING
@OlLSEAL Replace.

6x1.0mm
8 x 1.25mm

14-91

RightSide Cover
Removal
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleanersnd dry with complssedair.
. Blow out allpasssges.
. When removing the transmission right side cover,
replacethe following:
, Rightsidecover gasket
. Lock washers
. Transmissionhousinggasket
. O-rings
. Eachshatt locknut and conicalspringw8sher
. Sealingwsshers

Removethe elevnbolts scuringthe right sido covet,

then removethe right sidecover.
NOTE:
h is not necessarv to remove ths right side covsl
protector.
Slipthe specialtoolonto th mainshsft.
MAII{SHAFTHOLDER
or
07GAB-PF5010O
07GAB-PF50lOl

LOCKNUT

cott|cAl sPRlltG
WASHER
R6phc.

PARKIT{GGCAN
IDLERGEAR
COUNTERAHAFT

RIGHTSIDECOVER

IDLERGEAR
REVERSE
SHAFTHOLDR

ERAKEPAWL

W-

n
\

LEVER
"o rNGBBAKE

V-TRA]{SM|SS0i{HOlrSlNo
BOLTS

RIGHTSIDE

COVERGASKET
Rplace.
TRANSMISSION
HANGER

TRANSMISSO HOUANG

ATF LEVELGAUGE

IDLERGEAR
REVERSE

E x 1 . 0m m
BOLT

HOUSII{G
TRA SMISSIO|{
GASKET
R6Dlsco.

ATF COOLER
PIPES

JOINTBOL

14-92

}IOUSII{G
CO VERTER
TOROUE
SEALII{GWASHERS
Rophc6.

J.

4.

Engagethe parkingbrake pawl with the parkinggear.

12. Removethe reverseidlergear shaft holder.

Cut the lock tabs of each shaft locknut usinga chisel

as shown. Then remove the locknuts and conical
springwashersfrom esch shaft,

NOTE;
The steel ball does not pop out becsuseit is stsked in
the shaft.

NOTE:
. Mainshaftlocknut has left-handthreads.
. Cleanthe old locknuts; they are used to installthe
press fit idler gearson the mianshaftand secondary
shaft andthe parkinggearon the countershaft.
. Always wear safety glasses,

13. Move the reverse idler gear to disengageit trom the

countershaftand mainshsftreversegarsas shown.

CAUTION:
Keep all of ths chiselod particlos out ot tho
tranamission.

NOTE:
The transmissionhousingwill not separate from the
torque converter housing if the reverse idlsr gesr is
not removed.

MAINSHAFT

REVERSE
IDLERGEAR
Moveinthisdirsction.

LOCKTAB

,! o_ -:.-.:{>,
a

Rsmove the special tool from the mainshaft after

removingthe locknuts.
o.

Remove the parkinggear using a puller f.om the

countershaft as shown. Then remove the idler gesrs
usinga pullerfrom the mainshaftand secondaryshaft.

\!r'
l

COUNTERSHAFT
14. Align the spring pin of the control shstt with the
transmission housing groove by turning the control
shaft.
15. Install the speci8l tool on the transmission housing,
then removethe housingas shown.
HOUSINGPULLER

Remove the countershaft idler gear, needle besring.

thrust needle bearing. and thrust washer from the
countershaft.
8.

Removethe parkingbrake pawl, spring,shaft. and

stopperfrom the housing.

GROOVE

9 . Removethe throttlecontrolleverand springfrom the

throttle control shaft.

1 0 . Removethe ATF coolerpipe mountingboh from the

transmissionhanger.
1 1 .Removethe transmissionhousingmountingbotts.

SPRINGPIl{
CONTROLSHAFT

14-93

TransmissionHousing
Removal

TRANSMISSIONHOUSI G
Removal 14-92

2ND GEAR
COUNTTERSHAFT
COUiITERSHAFTREVERSEGEAR

I{EEDLEBEARII{G
TRANSMISSO

HOUSlttc
GASKET
Replace.

HUB
REVERSE
SELECTOR
SHIFTFORK

SELECTOR
BEVERSE
MAII{SHAFT
SUB.ASSEMBLY

COUITTERSHAFT
4TH GEAR
THRUSTWAS}GB
BEARIiIG
THRUSTI{EEDLE
COUTYTERSHAFT
SUB.ASSEMBLY

SECONDARYSHAFT
2'{D GEAR

BEANI GS
NEEDLE
THRUST]{EEDLEBEARIiIG
SPLII{EDWASHER
SECOI{DARY
SHAFT
SUB-ASSEMBLY

DIFFEREICTI,AL
ASSEMBIY

HOUSING
TOROUECOIWERTER

14-94

NOTE:
. Cl8n 8ll parts thoroughly in solvent or carburetor
cleansrand dry wilh comDressedair.
. Blow out all passsges.
. Whsn rmoving the transmissionhousing, roplace the
following:
. Trsnsmissionhousinggaskst
. Lock w8sh6r
1.

Removethe trsnsmissionhousing(seepage14-94.

2,

Rsmove the reverse idler gar from the transmission

housing.

3.

Removs ths countrahaft 2nd go8r, reverse gear,

socondaryshaft 2nd gear, thrust washr, and thrust
nsdl besring togsther from the countershaft and
secondaryshaft.

4.

Remove the lock bott socuring the shift fork, then

romovs ths fork with tho ravrse slector from the
countershaft.

5.

Rmove tho n66dle besrings,thrust nesdle besring,

8nd splinedwasher from the socondaryshaft.

6.

Romovethe secondsryshaft sub-Ess8mbly,

7.

Removethe msinshaftsub-assmbly.

8.

Removethe countershaftsub-assembv.

9.

Removethe differentialass6mbv.

14-95

Torque ConverterHousing/ValveBody
Removal

O.RING
Roplace,

THROTTLE
COI.ITROL
SHAFT.

^3a

E-R.NG fl
Replace.
-

P'PE
\

fi nllltn
\s ll llUlfllle
i l r i l , H |t J i l _
1
II

.
\

o r FEED
F

ll
u

s' 1!1
U I

ff

STOPPERSHAFT

TOROUECONVERTER
CHECK
VALVE
CHECKVALVE
SPRING
OIL FEEDPIPE

ATF STRAINER

;HROTTLE
VALVE
BODY

rHRorrLGsEpARAroR

S1
-

f,

4TH ACCUMULATOR
COVER

PLATE

>[nN
* /

LOCKWASHER
Replac6.

REGUtAroBvAtvE

SEBVODETENT
BASE

O-RING
Rephce.

STATORSHAFT

SERVOBODY

OETENTARMSHAFT
DETENTARM

colvrRoL
SHAFT

SEBVOSEPARATOR
PLATE
CHECKBALLS

VALVE
SECONDARY
BODY
DOWELPIN
MAIN VALVE
BODY

SECONDABY
SEPARATOR

OILPUMPDRIVEN
GEARSHAFT
OILPUMPDRIVEN
GEAR

OILPUMP
DRIVEGEAR

MAIN SEPARATOR
PLATE
DOWELPIN

TOROUECONVERTERHOUSING

14-96

ACCUMUI.ATOR
BODY
COVER
IST/2NDACCMULATOR
BODY

NOTE:
. Clsn all parts thoroughly in sotuent or carburtor
cle8nrand dry with compressedair.
. Blow out all p8ss8g8,
. Whsn removingthe vslve body, replscethe following;
. O-rings
. Lock w88h6rs
1.

Removsthe two bohs securingthe servo detent base,

thn rsmovs ths aervo detent bass.

9 . Romovethe ststor shsft snd stopper shaft.

1 0 . Romovthe dstsnt spring from ths dstsnt arm, thsn
remove the control shaft trom the toroue converter
housing.
1 1 .Rsmovthe detent arm snd detent srm shalt from the
m8inv8fus body.

12. Removoth four bohs securingtho main valve body,

th6n rmoveth mainvalve body.

2.

Removsthe two bohs sgcuringth6 ATF strsiner,then

removs th ATF strainsr.

1 3 . Remove the six bofts securing the lst/2nd accumulstor body, thn rsmovs the 1st/2ndaccumulatorbody.

3.

Remove the oil fe6d pipes from the srvo body and
mainvalve body.

4.

Rmovethe three bofts securingthe 4th accumulator

covsr, thsn removethe 4th accumulatorcovr.

1 4 . Remove the oil pump drivon 968r shatt, then remove

the oil pump gears.
1 5 . Rgmov th6 main seDarator Dlat6 with three dow6l
Dins.

NOTE;
Ths 4th accumulator covsr is spring loaded, to
prsvsnt strippingthe threads in the srvo body, press
down on tha accumulstorcover while unscrewingthe
bohs in a crisscrossDsttern.
5.

R6movethe seven bohs securingth8 servo body, then

removs the sarvo body snd s6parstor plats.

6.

Removethe secondsryvalve body and soparstorpl8te.

7.

Rsmove the seven bohs securing th throttle valve

body, then remove the throttle valve body and
soparatorplata.

8.

Rsmove the boh securing the regulator vslve body,

then removethe rsgulatorvElvebody.

14-97

Valve Body
Repair
NOTE:
This repair is only necessary if one or more of the
valves in a valve body do not slide smoothly in their
bores.You may use this ptocedule to free the vaves
in the valve bodies.

Removthe #600 paper.Thoroughlywash the entire

vavs body in solvent,then dry with compressedair.

6. Cost the vslv whh ATF, then drop it into its bor8. h
shouH droD to thg bottom of the bore under its own
weight. ll not, ropeat step 4, then retest.

Soak a shet of $600 abrasive paper in ATF for

about 30 minutes,
Carefully tap the vatve body so the sticking vslve
droDsout of its bore.

VALVE

CAUTION:
h may bo necossaryto us a 3mal3crewd vor to plY
tho valve fioo. Be carsful not io scratch the bot
whh ths sclowdrlvor.
InsDectthe vave tor any scutf marks. Use the ATFsoaked #60O paperto polishotf any burrs that are on
the valve, then wash the vatue in solvent 8nd dry it
with compressed8ir.
Rotl up hlf a sheet of ATF-soaked f60O paper and
insert it in the valve bore ot the stickingvalve.
Twist ths paper slightly,so that it unrollsand fits the
boretightly,then polishthe boreby twistingthe paper
as you push it tn and out.
CAUTION:
Th6 valve My is aluminum and doosn't roquito
much polshing to remove any bulls.

VALVE
BODY

ffi
t

7. Romovs tho vslve 8nd thoroughv clean it 8nd the

valve body wilh solvent. DrY 8ll parts with

comDroasedair, then reassemble using ATF 8s a
lubricant.

snl
[ssYi
vV/fJ
,.llJ'"-Q)

14-98

Valve
Assembly
NOTE:
Cost all psns with ATF before assembly.
.

Sst the springin the valv6 and installth6m in tha valvs

body. Push th spring in with 8 scrowdrivor, th6n
instsllthe springssat.

lnstallthovalvs, valve springandcap in the vavo body,

and securwith ths rollsr.

VALVEBODY

ROLLER

14-9!)

Valve Caps
Description
Caps with one projocted tip and one flat end are
installedwith the flat end towsrd the inside ot the
valve body.
Caps with a projectod tip on ach end are instslled
with th6 smsller tip toward th8 inside ot the valve
body. The smslltip is I springguide.

TOWARDOUTSIDEOFVALVEBODY

Caos with hollow ends ar6 installedwith the hollow

awav trom the insideof the valve body.
CaDswith notched ends are instslledwith the notch
toward the insideot the valve body,
Caps with flat gnds and a hole through the center are
installsdwith the smallerhole towsrd the insideof the
vave body.

TOWARDOUTSIDEOFVALVEBODY

EEEA
TOWARDII{SIDEOFVALVESODY

Caps with one projected tip snd hollow end sre

instslledwith the tip toward tho inside oJ the valve
body. Th6 tip is I springguide.

TOWARDOUTSIDEOFVALVEEODY

TOWARD INSIDEOF VALVE BODY

14-100

TOWAROI SIT'EOFVALVEBODY

Oi l Pu mp
lnspection
1.

Measurethe side clearsnceof the oil pumDdrive and

driven gars.

Install the oil pump gears 8nd oil pump driven gear
shsft in the mainvslve bodv.

OilPump Ga.lE Side (Radial)Cloalance:

Standard(New)l
Oil Pump Ddva goal
0.210-0.265 mm (0.0083-0.0104 inl
Oll Pump Drlvan g6al
0.035-0.063 mm (O.OO14-O.0O25in)

OILPUMP
ORIVE
GEAR
Inspecttethlor
wearor damage.
3.

Remove the oil pump driven gesr shaft, Measurethe

thrust clearanceof the oil pump driven gear-to-valv
body.
OllPump Drlvo/DrivonG6sr Thrust (Axiall Clearance:
Standard(Now): 0.03-0.05 mm (0.001-0.002 in)
Selvico Limit:
0.07 mm (O.0O3in)

STRAIGHTEDGE

MAIN VALVE BODY

14-101

MainValve Body
Disassembly/lnspection/Reassembly
NOTE:
. Clean8ll parts thoroughlyin solvent or carburetorcleaner,and dry with compressd8ir. Blow out all psssages.
. Replacevalve body as an assemblyif any parts are worn or damaged'
. Check allvavs tor free movement.lf any fail to slidefreely, seeVafueBody Repairon page1+98.
CAUTION:
Do not use a magnotto tomovo tho ctrock balb; it may magnotizotho bak.

MODULATOR
VAIVE

CPCVALVE

3-2 K|CK-DOWN
FILTER
VALVE

OIL FEEDPIPE

R6phc6.
lnstsll in this diroction-

SEAT

\n
U
SHIFT
CHECK
BALLS
3pcs.

DETENTARM

1_2 SHIFTVALVE

VALVECAP

R
u
2_3 SHIFTVALVE
ROLLER
MAIN VALVE BODY
Inspectlor scoring
or domag.
MANUAL VALVE

14-102

FILTER
Rephce.

E
E

CHECKBALLS

MAIN VALVE BODY

(SctionalView)

DETEN|T
ARMSHAFT

SPRINGSPECIFICATIONS

Unit:mm (in)
Standard(New)

No.

Spring
Wire Di8.

@
@

o
o
@
o
@

Lock-up control valve spring

Lock-up shift valve spring
Coolerrelist valve spring
Modulatorvalve spring
CPCvatuespring
3-2 kick-downvatuespring
1-2 shitt valvspring
2-3 shift valve spring

o.70(0.028)
o.90 {0.035)
1.10(0.043)
1.40(O.O55)
1.40(0.055)
1.20(O.O47t
1.00(0.039)
o.90(0.035)

o.D.
6.60(0.260)
7.60(0.299)
8.40(0.331)
9.40{0.370)
9.40(0.370)
7.10{O.2m)
8.60(0.339)
7.60(0.299)

Free Length

38.00(1.496)
73.70 .2.9021
46.80(1.8431
(1.299)
33.OO
33.00{1.299)
46.90{1.846)
41.30(1.626)
57.@t2.2441

No. ot Coils
14.1
32.O
't7.o
10.5
10.5
20.6
16.9
26.8

14-103

SecondaryValve Body
Disassembly/lnspection/Reassembly
NOTE:
. Clesnall parts thoroughlyin solvnt or carburetorcleansr,and dry with compressod8ir. Blow out all passages.
. Check allvalvesfor lree movsment.lf sny fail to slidefreely, seeVave Body Rep8iron page1+98.
. Coat all parts with ATF befor assembling.
. Replacethe vave body as 8n assemblyif any pans 8re worn or damaged.
CAUTION:
Do not uso a mrgnoi to romova th chock balls;h may magnatizotho bak'

3_4 SHIFTVALVE

0 l

,n4u %

CHECKBALLS
7 pcs.

SECONOARY

VALVEBODY
Inspectfor scoring
or damag6.

-p^

'cqtcrco21{DOR|F|CECOI{TROL
VALVE

/"%

SLEEVE
@

14-104
L

CHECKBALLS

CHECKSALLS

n
LJ

CHECKBALLS

rV1 nU nl-l- l-_\)v,

r.,f7

SECO DARYVALVEBODY
(SoctionslVisw)

SPRITIIG
SPECIFICATIONS

Unh:mm(in)
Stsndard(llew)

No,

Springs
Wir Dia.

O
@
@

@
@

4th sxhsust valve spring

3-4 shift vatuespring
3rd kickdown vslve spring
Sarvo controlvalva spring
Orifice control vslve spring
2nd orifice controlvalve spring

0.90(o.o35t
0.90(o.o35)
1.10(0.043)
1.@(0.039)
0.s to.031)
0.60(0.024)

o.D.
7.10(0.2&)
7.@ (0.299)
7.60{0.299)
8.10(0.319)
6.60(0.260)
6.@ (0.260)

Free Lngth

60.e (2.394)
57.@ l.2.244l.
48.30(1.902)
52.60l2.O71l
52.&12,06,7l
5A30 (2.295)

No, of Coils

4.9
26.8
4.3
22.4
33.O
15.8

14-105

RegulatorValve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cleanatlparts thoroughlyin solvent or carburetorcleaner,and dry with comprsssadair. Blow out all p8ssages.
. Replacevalve body 8s an assemblyif any parts are worn or dsmaged.
. Ch6ck 8llvalvesfor tree movement.lf 8ny tailto slidefreely, see Valve Body Repairon page1+98.
Holdthe regulatorspringcap in plscewhile removingthe stopper boh. Oncethe stopper bolt is removed,releasethe spring
c8p slowty.

1.

CAUTION:
Th rogulatorspllng cap can pop oui whon tho lock boh is romovod.
R8assemblyis the reversordgr of disassembly.

2.

NOTE:
. co8t 8ll parts with ATF.
. AliSnthe hole in the rogulatorspringcap with the hole in th valve body; thsn pressthe spring c8p into the valve body
and tightn the stoppor boh.
REGULATOR
SPRINGCAP

BOLT
STOPPER
6x1.0mm
12 N.m(1.2ks-m,9 lb-ft)
VALVE
REGULATOB

FILTER
Rophce.
LOCX.UPTIMINGVALVE
E BOOY
Inapgctfor w6ar. scratchos
or scorng.

TOROUECONVERYER
CHECK
VALVE

ROLLER
SPRINGSPECIFICATIOTSS

Unit:mm (in)
Standard(New)

No.

Springs
Wire Di8.

Regulatorvalve springA

Regulatorvalve springB
Stator reactionspring
Lock-uptlming vaVe spring
Torque converter check valve spring

3
ra

14-106

F22A1 engine
H23A1 engine

o.D.

FreeLength

1.O (0.O71) 14.70(O.579) 86.50(3.406)

1.80(0.071) 14.70 (0.579) 88.60{3.488)
r.s (0.071) 9.60 (0.378) rr4.oo(1.732)
4.50(0.177) 35.40(1.394) 30.30(1.193)
o.s {o.o31) 6.60 (0.260) 51.10(2.012)
1.10(0.043) 8.40(0.331) 36.rto(1.433)

No. of Coils
16.5
16.5
12.7
1.92
't4.7

't2.o

Throttle Valve Body

Disassembly/lnspection/Rassembly
NOTE:
. Cleanall parts thoroughlyin solvent or carburetorcleaner,anddry with comprossdair. Blow out all passagas.
. Check allvalvesfor free movement,It any failto slidefreely, see Valve Body Repairon page14-98.
. Coatallpartswith ATF beloreassembling.
. Replacethe valve body as an assemblyif any parts are worn or damaged.
AOLT
5r0.8
8 N m(0.8k s m , 5 . 8 l b - f i )

\
\
\
THROTTLE
SHORTVAIVE B

THROTTLE
LOI{GVALVE

THROTTLE
CAM
STOPPER

THROTTLE
ADJUSTING
BOLT
CAUTION: Do not loosen or remove.
RELIEF
VALVE

THROTTLE
VALVEBOOY
InsDect
lor wear,
scratches
or scoring.

SPRINGSEAT

SPRINGSPECIFICATIONS
Unit:mm (in)
Stsndard{New)
No.

Springs
Wire Dia.

ThrottlevalveB spring

Throttle vaVe I adjustingspring

Relietvalve spring

1.40{O.O55)
1.40{O.O55)
1./tO(O.Oss)
0.& (0.o311
1.OO(O.O39)

o.o.

FreeLength

8.so(0.335) 41.50(1.634)
8.50(0.335) 41.50(1.6341
8.50(0.335) 4 1 . 6 0( 1 . 6 3 8 )
6.20tO.2Ml 3 0 . 0 0( 1 . 1 8 1 )
8.40(O.331) 39.10(1.539)

No. of Coils
10.5
11.2
't2.4
8.O
'15.1

14-107

Servo Body
Disassembly/lnspection/Reassembly
NOTE:
. iiel"n attp"rts t6oroughlyin sofuentor carburetorcl6aner,anddty whh compt6ssdEir.Blow out all passag.s.
. n"ptt"" itt" ""*o body as an assemblyil anYparts are worn or damsgd'
. ReplaceATF strainet if its inlet openingis clogged.
. Cost all Dartswith ATF before assembly.
TORCOVER

MAG[{ET
Clean.

(<
\j

ATF STRAINER
Cleanor roplac.

4TH ACCUMULATOR
PISTON

BASE
SERVODETET{T

OILFEEDPIPE

SERVOBODY

Inspoctlor woar
scratchg8or scoing.
O.RING
Replace,

VALVE
SHIFTFONKSHAFT/SERVO
Inspoctfor sco ngor dama|o.
3RD ACCUMULATOR
PISTON

SPRINGSPECIFICATIONS

Unit: mm (in)
Stsndard(New)
Springs

No.

ot\

4th accumulatorsPring
1st-holdaccumulatorspring
3rd accumulatorspring

14-108

Wire Di8.

o.D.

FreeLengrth

2.90(O.114) 22.@ (0.866) 90.10(3.547)

4.OO(0.157) 25.@ (0.984) 64.702.5/.71
(4.114)
2.60 (O.102) 17.50(0.69) 104.50

No. of Coils

10.9
7.3
18.O

1st/2nd AccumulatorBody
Disassembly/lnspection/Reassembly
NOTE:
. Cleanall parts thoroughlyin solvont or carburto.claaner,and dry with comprsssadair, Blow out all passsges.
. Cost sll psns with ATF bfore sssembly.
CAUTIO : Do not usa r mrgnot to temoya the cfiack bal!; h may megnotlzo tho bals.
ACCUMULATOR
EODYCOVER

CHECKBALL

lST ACCUMULATOR

PrsTot{

2I{DACCUMULATOR
PISTON

sPRtt{GSPEC|F|CAT|O
S
Unit:mm (in)
No.

Standard(Nsw)
Springs
Wire Di8.

lst accumulatorsprim
zrd accumulatorspring

o.D.

FreeLength

1.e (o.o71) 16.30to.64a 115.40 (4.543)

3.30to.130) 22.@ (0.866) 84.90 (3.343)

No. ol Coils
18.6
11 . 1

14-109

Mainshaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricateallpartswith ATF duringreassembly.
.Instellthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher.
. Inspectthrust needle and needlebearingsforgallingand roughmovement.
. Before instsllingthe O-rings,wrap the shaft splineswith tape to prevent damageto the O-rings.
LOCKNUT{FLANGENUT}
Replace.
NOTE: Lotr-handthr6ads
23O N m (23O ks-m , 166 lb-ft}
+O )
170 N.m (17.0 ks-m.123 lb-ft)
CONICALSPRINGWASHER
R6place.
IOLERGEAR
TRANSMISSION
HOUSINGBEARING

SNAPRING
COLLAR
BEARING
THRUSTNEEDLE
4TH/REVERSE
GEAR

NEEDLEBEARINGS

O-RINGS
Replaco.

THRUSTNEEDLEEEARIiIG
4THE GEARCOLI.AR

3RO/4THCLUTCH
ASSEMBLY
MAINSHAFT
Chck splinesfor excessive
w6ar or oamage,
Check beadngsurtacetor
scorang,
scratchesor

3RD GEARCOLLAR

?I{RUST EEDLEBEARING
NEEDLEBEARING

3RDGEAR

SEALINGRINGS.35 mm
RING,29 mm
NEEDLEBEARING
SET RING,23 mm

14-110

THBUSTNEEDLEBEARING

Countershaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricateallparts with ATF duringreassembly.
.Installthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher,
. Inspectthrust needle and needlebesringstor gallingand rough movement.
. Before installingthe O-rings,wrap the shaft splineswith tape to prevent damageto the O-rings.

2ND GEAR
LOCKNUT(FLA'IIGENUTI
Replace.
230 N.m (23.0 ks"m , 166 lFft)
--r O -)
1 7 0 N . m( 1 7 O k s - m , 1 2 3h - t t l

REVERSE
SELECTOR

NEEOLEBEARING
CONICALSPRINGWASHER
RsDhca.

REVERSE
SELECTOR
4TH GEAR

NEEDLE
BEARING

PARKII{G
GEAB
THRUSTNEEDLE
BEARII{G
IDLER
GEAR

COLLAR.
32 mm
COTTERS,
29 mm
DISTANCECOLLAR
3RO GEAR

EEDLE
BEARING
THRUST EEDLE
BEARhIG
THRUST
WASHER
TRAl{SMtSStot{
HOUSII{GBEARING

ONE-WAYCLUTCH

1STGEAR

COUI'ITERSHAFT
Ch6ck splinsfor excessive
war or damage.
Check baringsurtacetor
scoring.scratchesor

1ST GEARCOLLAR

lST-HOLD CLUTCH
ASSEMgLY

14-111

Countershaft
Removal
1.

Using a press, press out the countershEft while

supponingth lst-hold clutch.
NOTE:
Place an attachment betwoen the press 8nd
countershaftto prevent dsmagsto the shalt.

14-112

lnstallation
NOTE:
Lubricateall parts with ATF duringEssembv.
1,

Align the shaft splins with thoso of 3rd gaar, then

pressthe countershaftinto 3rd gearwith a press.

Instslltwo new O-ringson the countershaft,

NOTE;
Before installingthe O-ring6,wrap ths shaft splines
with tape to prsvent dsmagsto the O-rings.

2.

4.

Assemblsthe 1st-holdclutch assembly,lst gearcollar,

thrust washer, needl bearing, lst gaar, one-way
clutch, thrust needlebearingand 3rd gear.

3RDGEAR

NOTE:
. Also align the shaft splines with those of th lsthoH clutch when pressingthe countershaft into the
3rd gear.
. Use 8n attachment between the shaft and a press
to provant damageto the countershatt.
. Stop pressingthe countershaJtwhen the 1st-hold
clutch contacts the finaldrive gear.

PRESS

THRUST'{EEDLE
BEARIl{G

O]TE-WAY
CLUTCH
lnstallinthisdirection.

1ST-HOLDCLUTCH

lST GEAR

I{EEDLEBEARING

THRUSTWASHER

lST GEANCOLLAR

1ST-HOLDCLUYCH
ASAEMBLY

3.

Installth8 above assemblvon the countershaft.

14-113

One-wayClutch
Disassembly/lnspection/Reassombly
1.

Separatecountorshstt 3rd gar from countershaft 1st

gear by turning3rd garin the directionshown,

3.

Inspectthe parts as follows:

COU]YTERSHAFT
3RDGEAR
Inspsct3rd gear
for wear oascoring-

Inspoct the thaust

noodls bearing tor
damage or faulty
movmgm.

COUNTEBSHAFTIST GEAR

ffi.-

Remove the one-way clutch by prying h up with the

end of a screwdriver,

Inspectth ono-way
clutch for damagoor
fauhy movement.

Inspect lst gear

tor war or scoring.

ONE.WAYCLUTCH

After the Dartsare sssembled,holdcountershatt

1st gesr and turn countershatt 3rd gear in
directionshown to be sure it turns Ireelv.
3RDGEAR
COUI{TERSHAFT

1ST GEAR
COUT{TERSHAFT

14-114

SecondaryShaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricstesll parts with ATF duringreassembly,
o lnstalltho thrust needlebesringswith unrollededgeof bearingretaineffacingwasher.
. Inspctthrust needle and needlebesringstor galling8nd rough movement.
. BsJoreinstallingthe O-rings,wrap the shatt splineswith t8pe to pravent damageto ths O-rings.

LOCKNUT{FLANGENUT}
Roplsc6.

23ON.m(23,0kg-m, 166 |tsft)

-JO-)
170 N.m(17.0ks-m.123lb-ft)
CONICALSPRING
WASHER
Replsco.
GEAR
IDLER
TRAI{SM|SS|OI{
HOUSTG
BEARII{G
THRUST
WASIGN
THRUSTNEEDLE
BEARING
2NDGEAR

SECONDARYSHAFT
Check splinsfor oxcossive
w6ar or d6magE.
Chgck bearingsurfacofor
scoring,scrotchesor
excosstvowoat.

NEEDLE
BEARI]IIGS

THRUSTNEEDLE
BEABII{G
SPLIT{ED
WASHER
prt
Sol6ctiv

THRUSTNEEDLEBEARII{G
I{EEDLEBEARIMi

1STGEAR

DISTANCECOLLAR.5 mm
COTTERS,
29 mm
COTTER
RETAINER
SNAPRING
SEALING
RINGS,
32 mm

14-115

SecondaryShaft
Inspection
Messure2ndgearsaxialclearancewhile moving2nd
gear,

4.

. CbarancaMaasurement
NOTE:
Lubricstall parts with ATF duringsssemblv.

0.07-0.15 mm(0.003-O.0O6in)
STANDARD:

1. Rmove the secondsry shaft bearing trom the

transmissionhousing(seepsgo 1+129).

NOTE:
in at loastthlee plscos,anduse
Takemeasurements
the averageasthe actuslclearance.

2.

Assomble the s6condsry shEft sssembly without

O-rings.Instsllth6 idler gear usinga press,then to.qu
the 36cond8rythaft locknut to
30 N.m (3.0 ksFm, 22 lb-tt)
NOTE:
Do not instsllthe O-ringsduringinspection.

LOCKITUT

It the clearanceis out of tolerance,removethe splinsd

washer and measurethe thickness.

5.

3.

Attach the disl indicatorto 2nd gearas shown.

SPLINEDWASHER
Pari l{umbol

fhbknols

90406- PX4- 700

4.05 mm 1O.159in)

90407-PX4-7@

4.10 mm(0.161in)

90408- PX4- 700

4.15 mm(0.163in)

90rto9- PX4- 700

4.20 mm(0.165in)

90410-PX4-7@

4.25 mm (0.167 in)

90411-PX4-7m

4.30 mm {0.169 in)

90412-?X4-70o

4.35 mm 10.171in)

90413-PX4-700

4.2!Omm {0.173 inl

90414-PX4-700

4.45 mm {0.175in)

No.
DAL INOICATOR

2ND GEAR

14-116

6.

After r8plscingthe splinedwashsr, make sur that the

clearanceis within tolgrance.

Clutch
lllustratedIndex
3RD/4TH CLUTCHASSEMBLY

SI{AP RII{G

CLUTCHEI{DPLATE

ct uTcHDrscs
Stshdardthickness:
1.94 mm {0.076 inl

CLUTCH
PLATES
Standard
thicknoss:
2.30 mm(0.091in)

nEruRNsPuu'rc---'--@
SNAP RII{G

srRrnc
aeurnea.-(C)
SPRI]TGRETAINER

s APRTNG--o

RETURNSPRII{G

PISTON

CLUTCHDISCS
Standardthickn6ss:
'l
.94 mm (0.076 inl

O.RINGS
Rsplacs.

CLUTCHDRUM

(cont'd)

14-117

Clutch
lllustratedIndex (cont'd)
1ST/2NDCLUTCHASSEMBLY:H23A1 Ensino

CLUTCHENDPLATE

SPRINGRETAINER

SPRINGRETAINER

CLUTCHENDPLATE

SNAP RING
2ND CLUTCHDRUM

lST CLUTCHDRUM

14-118
L

1ST/2NDCLUTCHASSEMBLY:
F22A1Enstn

O-RINGS
Replace.

----.....-__----l/
PrsroN
Xtt

CLUTCH
PLATES
Standard
thicknoss:
2.60 mm(0.102in)

qfluansrnrNcre
Y)

-=...._<>
SPRTNG
RErarr{ER

smr nnc--..-...-

-l-,,

sPRr
GRETATNEB----__.._<>

SNAPRtNG--___..v-)

&

RETURNSPRING
DISCSPRING

2ND CLUTCH
DBUM

1ST CLUTCHDBUM

{cont'd}

14-119

Clutch
lllustratedIndex (cont'd)
1ST-HOLDCLUTCHASSEMBLY

CLUTCHE O PLATE

CLUTCHPLATES
thicknsss:
Standard
2.00 mm(0.079inl

-----------....
sr{APR|NG

13

------..-..-<>
RETATNER
SPRTNG
RETURN
DISCSPBING

PISTON

O-RllrlcS
B6placs.

CLUTCHDRUM

14-120

Disassembly
1.

Remove the snap ring, then remove the clutch end

plate,clutch discs and plates.

Installthe specialtoolsas shown.

NOTE: For lst-hold clutch

NOTE: For a clutches

CLUTCHSPBING
COMPRESSOR
ATTACHMENT
oTLAE-PX40100

SNAP RING

CLUTCHSPRING
COMPRESSOR
ATTACHMEI{T
07HAE-P150100

SCBEWDRIVER

Removethe discspring.
NOTE: For 1st-holdnd 2nd clutches
NOTE: For 1st,2nd,3rdand4th clutches.
DISCSPRING

CLUTCHSPRING
COMPRESSOR
ATTACHMEiIT
OTLAE-PX/[O1OO

CLUTCHSPNNG
COMPRESSOR
ATTACHMEIYT
07HAE-P150100

CLUTCHSPRING
COMPRESSOR
AOLT ASSEMBLY
07GAE-PG40200
{cont'dl

14-121

Clutch
(cont'd)
Disassembly
CAUTION:
It olthor ond of tho comproraor attachmont i! 3ot ovel an
aroa ol the sprlng rotalner which ls unsuppo od bY the
rsturn sprlng.the rotalnor may be d8magod.

Removethe snap ring.Then remove the spscialtools,

springretainer8ndretrunspring.

Do not s6t hore.

NOTE: SteDs4 thru 6 are for allclutches.

Comprssthe returnspring.

14-122

Wrap a shop rag aroundthe clutchdrum and apply8ir

pressureto the oil passageto removethe piston.Plsco
a tingertip on the other nd while appving air pres6ure.

Reassembly
NOTE:
. Clean sll parts thoroughly in solvnt ot carburetor
cleangr,and dry with compressedarr.
. Blow out all psssages,
. Lubricateall parts with ATF beJoreassembv.
1.

Inspectthe piston for a loosecheck vslve, if the check

valve is loose,replaceth p;ston.
CHECKVALVE

4.

Installthe piston in the clutch drum. Apply pressure

and rotate to ensureproper seating.
NOTE:
. Forallclutches
. Lubricate the piston O-ring with ATF before
installing.
CAUfION:
Do not dnch O-ringby instaling the ],iston whh force.
PISTON

PISTON

Be sure that the disc springis securelystaked.

NOTE:
For 1st, 3rd and 4th clutches
Installnew O-ringson the piston.
O-RINGS

CLUTCHDRUM

Installthe return springand springretainerand position

the snapringon the retainer.
NOTE: For allclutches

(cont'd)

14-123

Clutch
Reassembly(cont'd)
6.

CAUTION:
lf otthor end of lho comprslsol attachmcnt b 8ct
ovor an lroa of the sp ng lelalnor whlcft k
unrupportod by tha toturn sprlng.tha rctalnel may b
dam!god.

as shown.
Installthespecialtools
NOTE: For 1st-holdclutch

CLUTCHSPRIiIG
COMPRESSOR
ATTACHMEiTT
07LAE- PX40100

CLUTCHSPRI G
COMPRESSOR
ATTACHMENT
oTHAE- Pl601 00
Do not set h6ro.
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE-PG402q)

NOT: Steps 7 thru I 8re for allclutches.

7.

NOTE: For 1st, 2nd, 3rd and 4th clutches

SPRING
CLUTCH
COMPRESSOR
ATTACHMEITT
07LAE- PX40lOO

CLUTCHSPRI G
COMPRESSOR
ATTACHMET{T
oTHAE-P150100

CLUTCHSPRING
COMPRESSOR
SOLTASSEMALY
OTGAE PG4O2OO

14-124

ComDresathe retuln sPring.

8.

Installthe snap ring.

NOTE: Steps11 thru 15 aretor allclutchos.

11. Soak the ctutch discs thoroughv in ATF tor I minimum ot 30 minutes.
12. Starting with I clutch plats, ahernately instsll ths
clutch platesand discs,Installthe clutch end platewith
flat sidetoward the disc.
NOTE:
Before installingthe platss snd discs, mske sure the
insideof the clutch drum is free of dirt or other forsign
mattot.
CLUTCHENDPLATE

CLUTCH

Dtsc
9 . Removethe specialtools.
1 0 . Installthe disc spring.
NOTE:
. For 1st-holdand 2nd clutches
. Installthe disc springin the directionsnown.
13. Installthsnspring.
Dtsc SPRI{G

SCREWDBIVEB

(cont'dl

14-125

Clutch
Reassembly(cont'd)
14. Measurethe clearancebetween th clutch snd plate
8ndtop discwith a dislindicator.
Zero the dial indicstor with the clutch end plste
lowered and lift it up to the snap ring. The distancs
that the clutch end plate moves is the cleatance
botween th clutch end plate8nd top disc.
NOTE:
Measureat three locations.

1st
2nd
3rd
4th
1st-Hold

It the clearanceis not within th service limits,select a

new clutch nd platefrom the followingtable'
NOTE:
It the thickest clutch nd plst is installsd but the
clearanceis still over the st8ndatd,roplacethe clutch
discs 8nd clutch plstes.
CLUTCHENDPLATE

Clutcfi End Plato-to-TopDisc Glearance:

Clutch

1E

Seryico Llmh

0.65-0.85 mm(0.o26-O'033in)
0.65-0.85 mm(0.026-0.033 in)
0.40-0.60 mm(0.016-0.024 in)
0.40-0.60 mm(0.016-0.024 in)
O.&-1.0O mm(0.031-0.039in)

Phte
t{o.

Part Number

22551-PX4-@3
2,562-PX4-m3
22553-PX4-OO3
22554-PX4-0o3
22555-PX4-@3
22556-PX4-@3
22557-PX4-@3
22558-PX4-003
22569-PX4-003

3
4
5
o

I
9

TOPDISC

CLUTCHENDPLATE

14-126

Thlckncrs
mm (lnl

2.10(0.o&')
2.n lo.oaTl
2.30(0.091)
2.40 to.og4l
2.50(0.098)
2.60(0.102
2.70(0.106)
2.& (0.110)
2.90(0.114)

TorqueConverterHousingBearings
MainshaftBearing/Oil
SealReplacement
1.

Driv out th mainshaftbearingand oil seal, usingthe

sDecisltools
as shown,

DRIVER
07749-OOTOOOO

3.

Installthe nw oils6alflush with the housing,usingthe

as shown.
sDscialtools

DRIVER
07749-001o(xro

ATTACHMEIYT
07947- 6340500

ATTACHMEI\IT.
72x75mm
07740-(x)lo6{x,
TOROUE
COI{VERTER
HOUSIT{G

Orive in the new mainshaftbsaringuntil it bottoms in

the housing,usingthe specialtoolsas shown.

DRIVER
07749-OOl(xXX'

ATTACHMENT,
62x68mm

07746-(xrlos(x,

14-127

TorqueGonverterHousingBearings
CountershaftBearingReplacement
1.

Remove the countershaft bearing using the special

toolas shown.

Replacement
Secondary
ShaftBearing
1.

Remove the secondary shaJt bearingby heating the

torque converter housing to 212oF {10O"C) with a
heat gun, then tap the housinguntil the bearinglalls
our.
CAUTION:
Do not hoat tho case in excsss of 212oF (1OOoCl.

Comrnarclaly
AvoiLbL
3/8 ln, r 16 throad./ln.
![de hammai

ADJUSTAELE
BEARII{G
PULLER,
25-4O mm
07736-AO1000A

COUTttTERSHAFT
NEEDLEBEARII{G

/-\.=\-\
\, _-,/-_--_\,

Installthe oil guideplate.

2. Installthe oil guideplate,

Drive th6 new bearing into th housing, using the

specialtoolsas shown.

5.

DRIVER
07749-(x)lOqro

Drive the new bea.ing into the housing, using the

specialtoolsas shown.

DRIVER
07749-OO10000

ATTACHMEifT,
62x88mm
07746-0010500

BEARING

0 -0.03
l0 0.01inl

BEARING

O-0.03 mm
(0-0.01 In)
HOUS[{G

OII GUIDEPLATE

14-128

OIL GUIDEPLATE

HOUSING

HousingBearings
Transmission
Removal/lnstallation
1.

To rrnovsths mainshait,countershsft and secondary

shaft bearingslrom the tranamissionhousing,expand
each snap ring with snap ring plisrs, thon push th
bearingout.

ins the
Expsndach snap ring with snap ring pliers,insert
:he pliors.
new baringpart-way into it. then releasethe
I until
Push the bearingdown into the transmission
u
the
ringsnapsin placaaroundit,

NOTE:
Do not remove th snap rings unlessit's necesaaryto
clanthe groovesin the housing.

NOTE:
ins the
Inst8llwith groove side o{ the housingfacing inside
transmissionhousing.

lnstali

Remov

After installingth6 bosringverify the following:

. The snap ring ls se8tedin the bearingand housing
hol
groovas.
. Th6 snap ring operatesproperly.
. Ths ring6nd gap is correct.
P: 0-7mm
(O-o.28 in)
SNAP RING

14-129

Transmission
Reassembly
NOTE:
. Coat all parts with ATF.
. Replace
the partsbelow:
.O-rings
. Lock washers
. Gaskets
. Locknutsandconicalspring
washers
. Sealingwasher
. Torquethe 6 x 1.Omm Bohs:
1 2 N . m( ' 1 . 2k s m , 9 l b - f t )

THROTTLE
CONTROL
SHAFT

Tluffir
e:'1

Iw

F;flilf":-.
STOPPER

TOROUECOIWERTER
CHECKVALVE
CHECKVALVE SPRING

6xl,Omm
2 Bohs

ATF STRAINER

4TH ACCUMULATOR
COVER
8x1.Omm
2 Bohs

1 Boh

LOCKWASHR
Reolace.

VALVE
REGULATOR
BODY
O-Rlf{G
Replace.

SERVODETET{T
BASE

SERVOSODY

STATORSHAFT
DETEI{T ARM S}IAFT
DETENf ARiI

OIL FEEDPIPE

cot{TRoL
SHAFT

6x 1.0
1 Boh

SECONDARYSEPAFATOR
PLATE

MAINVALVEBODY
OIL PUMPDRIVEN
GEARSHAFT

6 x l.O inm
6 Eohs

OILPUMPDRIVEGEAR

ACCUMULATOR
BODYCOVER

MAIN SEPARATORPLATE

lST/2ND
ACCUMULATOB
EODY

DOWELPIN

TOROUECO VERTERHOUSIT{G

14-130

CHECKBALLS
VALVE
SECOI{DARY
BODY

8 x 1.25mm
'18N m (1.8ks-m
'13lb-ftl

OIL PUMP DRIVENGEAR

SERVOSEPABATOR
PLATE

Installthe main sepa.ator plate with three dowel pins

on the torque converter housing.Then install the oil
pumpgearsandoil pumpdrivengearshaft.

NOTE:
Installthe oil pump driven gear with its grooved and
chamteredsidefacingdown,

8. Installtho scondarysaparator plate with two dowol

pins on the mainvalve body.

Installth control shali in the housingwith the control

shaft and msnualvafuetogether.

1 0 . Installthe dtent arm and alm shatt in the main valve

body, then hook the detent springto tho detent arm.

OIL PUMP DRIVEN

GEARSHAFT

\
orl PUMP

DRIVEGEAR

SERVOSEPARATOR
PLATE

rr-'rr
\

11 ll
II

\U

II

GRoovE
SECO DARYVALVEBOOY
OII PUMP
DRIVEN CHAMFER
GEAB

Groovednd chamfer6d
aidefacs separatorplats.

COIVTBOL
SHAFT

Installthe main vafue bodv whh tour bohs. Maks sure

the oil pump drive gear rotates smoothly in the normal
operating direction and oil pump driven gsar shaft
movss smoothly in the axial and normal operating
directions.

DETEI{TSPRING

lf the oil pump drive gear and oil pump driven gear
shatt do not move treely, loosenthe main valve body
bohs, realignthe oil pump driven gear shatt, and th8n
retightento the specifiedtorque.
CAUTION:
Failuro to align tho oll pump drlvan goEr shaft
correctly wlll rosuh In a seizadoll pump drlva getl 01
oil pump driven gear shalt.

MANUALVALVE
1 1 . Installthe secondaryvslve body, servo separatorplate
and servo body with seven bohs.

't2. Installth6 oil fosd pipe in tho servo body, then install
the 4th 8ccumulatorcover whh three bohs.
OIL PUMPORIVEN
GEARSHAFT

:/
)
OIL PUMP
DRIVEGEAR

OIL PUMP
DRIVENGEAR

4.

Installthe stator shaft and stoDDershaft.

5.

Install the two dowel pins, torque converter check

vafue and torque converter check valve spring in the
mainvalve body.

12

Installth6ATF strainerwith two bohs.

14. Installthe servo dotont base with two bohs and new
lock w8shers.

1 5 . Inst8llthe lst/2nd sccumulstorbody with six bohs.

1 6 . Installtwo oil ts6d pipes in the main valv body and
th pipe in the servo body,

Installthe.egulator valve body with the bolt on the

mainvalve body.
7.

Installthe two dowel pins and separator plate on the

regulator vatue body, then install the throttle vave
bodv with seven bohs.

(conr'd)

14-131

Transmission
Reassembly(cont'd)
17. Install the differential assembly, countershaft subassembly, mainshatt sub-sssembly, and secondary
shaft sub-assemblvin the torque converter housing.
MAINSHAFT
SUB-ASSEMBLY

20. Turn the shitt tofk shaft so the largechamferedhole is

facingthe fork bott hole.Thn installthe shift fork and
the lock boh with a new lock washer, and torque
Bendthe lock tab againstthe boh head

COUNTERSHAFT
SUB-ASSEMBLY
SH|T FORKBOLTHOLE

SCCONDARYSHAFT
SUB.ASSEMBLY

LOCKWASHER
Rplac6.

LOCKBOLT
6x1.Omm
14 N.m{1.4 kg-m,
10 rb-ft)
SHIFTFOBKSHAFT
BOLTHOLE
hole
Largechsmtred
facssthisway.

TOROUE
COi|vERTER
HOUSING
1 8 . Installthe splined washer, thrust needle besring 8nd
needlebearingson the secondaryshaft.

1 9 . lnstall the needle bearings. countershaft 4th gear,

2 1 . lnstsll the secondary shaft 2nd gear, thrust needle

boaring and thrust washer on the socondary shalt.
Installthe countershaft reverse gear and 2nd gear on
the countershaftas shown.

reverse selector hub, and reverse selector with the

shift fork on the countershaft.
THRUSTWASHER

NEEDLE
BEARING
REVERSE
SELECTOR

COU TERSHAFT
21{DGEAR

SHIFTFORI(
THRUST
NEEDLE
BEARIMi

REVERSE
lnsta in this direction.

COUUTERSHAFT
REVEBSE
GEAR
SECONDARY
SHAFT
2NDGEAR

EEDLE
BEARINGS

COUNTERSHAFT

THRUST
NEEDLE
BEARING

COUNTERSHAFT
4TH GEAR

NEEDLE
BEARIiIG
COUNTERSHAFT

SECOI|I'ARY SHAFT

14-132

SECONDARY
SHAFT

22. Slipthe rverseidlsr gearinto the transmissonhousing

s snown.

m. hstall the trsnsmissionhousingbolts and t.ansmission

hanger,then torque the bolts to 55 N.m (5.5 kg-m, rlo
lb-ft) in two or more steps in the pattern shown.

,Adlafu

v|>=l

R@P
23. Align the spring pin of the control shaft with the
transmission housing g.oove by turning the control
shaft.
24. Install thr6 dowel pins and a new gasket on thg
torqus converter housing,
25. Plscs ths transmission housing on the torque
convertr housing.
CONTROL
SHAFT

27. Engagethe reverse idler gear to the countershaft and

mainshattreverse gesrs, then installthe reverse idler
gesr shaft holderon the transmissionhousing,

6x1.0mm
12 N.m (1.2 ks-m ,
I lb-ft)

1 0r 1 2 5 m m
55 N'm (5.5 kg-m ,
40 b-ftt

DOWELPI

hE
28. Install the parking brske lever on the control shaft,
then torque the lock bolt loosely with a naw lock
wasner.
NOTE:
Do not tighten the lock boh to the specifiedtorque and
bendthe lock t8b in this steD.

DOWELPIN

14-133

Transmission
Reassembly(cont'dl
the mainshaft.
29. Sliothe sDecialtoolonto
MAINSHAFTHOLDER
OTGAB-PF50100ol
07GAB-PF50101

35. Placea 24 mm socket on the parkinggeEr,and instslla

10 x 1.25 mm boh in the count8rshaft. Then engage
the parking brake pawl with the parking gesr by
movingup the parkingbrake pawl.
CAUTlOltl:
Kap anof tho particlosout of tho transmissionwhon
insialllng a bolt.
36. Tightenthe boh and lightlyseat the parkinggear.
NOTE:
Do not drive the parkinggearon whh a hammer.
37. Removethe boh and socket.
38. Use the old locknut to tighten the press fit parking
gearto the specifledtorque, then loosenit.
TOROUE:230 N'm {23.Oks-m,166 lb-ft)

30. Installthe mainshaftidlergear.

21

Installthe old locknut on the mainshaftto seat the idler

gear.
NOTE:
. The mainshaftlocknut has left-handthresds,
. Do not drive the idlergearon with a hammer.

SOCKET.24mm
PARI(INGGEAR

TOROUE:230 N m (23.Oks-m, 166 lb-ft)

32. Installthe secondaryshaft idlergear on the secondsry

10 x 1.25 mm
BOLT

shaft.

33. Installthe thrust washr, thrust needlebearing,needle

bearing,countershatt idler gear and parking gear on
the countershatt.

34. Installthe old locknut on the secondaryshaft. Tighten

the old locknut to seat the secondaryshaft idler ge81

while holdingthe countershsJtidlergear.
NOTE:
Do not drive the idlergearon with a hammer.

PARKINGBRAKE

PAWL

39. Remove th old locknuts, th8n install new conical

springwashers8nd new locknutson each shstt'
CAUTION:
Insts[ th conical spfng washora In tho di]octlon
shown,
MAINSHAFTLOCKNUT
Left-h8ndthrads

T O R O U E :2 3 0 N m ( 2 3 . 0 k s - m , 1 6 6 l b - t t )

COUMTERSHAFT
LOCK'{UT

PARKII{GGEAR

Stmp siJs

CONICALSPRING
WASHERS
hstall in this
diroction.

SECONDARYSHAFT
IOLERGEAR

14-134

40, Tightenthe locknutsto spcifiedtorque.

TOROUE:
Mainrhaft

170 N'm {17.Okg-m, 123 lb-Jt)

Countorshaft

170 N.m (17.0 ks-m , 123 lb-ftl

Secondaryshaft

't70

N.m (17.0 ks-m, 123 lb-ft)

NOTE:
Themainshsftlocknuthaslelt-handthreads

42. St rhe psrking brake lever in tne lT-l position, thon

verity that the parkingbrake pswl ei-gagesthe parking

9ear.

4i,. lf th pswl doss not engagefully, check the psrking

brake pawl stopper clearanceas describedon page
1+136.
44. Tightenthe lock boh, and bendthe lock tab againstthe
bolt head.
PARKIMiBRAKE
ROLLER
LEVER

TOROUEWRENCH

PARKINGBRAKE
PAWLSHAFT

SECONDARYSHAFT
IOLERGEAR

PAWL

45. lnstallthe right sidecover.

41. Stake each locknut into its shsJt using a 3,5 mm puncn.

0.7-1.2 mln
10.o3-0.05Inl

TOROUE: 12 N'm {1.2 kg-m, 9 lb-ftl

46. InstalltheATF cooler pipeswith new sealingwashers.

TOROUE:29 N'm (2.9 ks-m , 21 lb-ft)
47. Installthe ATF levelOauge.

14-135

RightSideCover
FeedPipeInstallation
Installthe feed pipes in the right side cover with new
O-,ings,aligningthe lugs with the grooves in the right
side over.
Installthe snap rings,

ParkingBrakeStopper
Inspection/Adjustment
1.

Set the parkingbrakeleverin thel P lposition.

2.

Measurethe distancebetween the psrkingblake pawl

shaJtand the parkingbr8ke lever roller pin as shown.
STANDARD:64.5-65.5 mm {2.54-2 58 in)
PARKINGBRAKE
LEVERROLLERPIN

PARKINGGEAR

LOCK BOLT
6xl.0mm
14 N.m (1.4 kg-m ,
10 tb-ft)

Distanc6

PARKINGBRAKE
STOPPER
PARKINGBRAKELEVER

NGHTSIDECOVER

Fififtflllf*

PARKTNGBRAKE

ff the measuremant is out oJ tolerance, select and

installthe sppropriateparkingbrakestopperfrom the
tablebelow.

,- '.l r - - f f i - T , , .
--Tr

I r lr \ , l\ ,l , / |
\ \t-l

,/r>

PARKINGBRAKESTOPPER

BRAKESTOPPER
PARKING
Mark

Part Numbor

Ll

Lz

24537-PA9-OO3 11.0Omm
(0.433 in)

11.00mm
(o.433in)

24538-PAg-m3

1O.8Omm
(0.425 in)

10.65 mm
(0.419 in)

24539-PAg-OO3 10.60mm

(0.417in)

10.30mm
(0.400in)

After replacingthe parkingbrakestoppor,make sure

the distanceis within tolerance.

14-13 6

TorqueConverter
Disassembly

ErlOm.r|
75 N.m{7.5kem , 54 b-ftl

DRIVEPLATE
lnsDct
for crackg.

TOROUE
CO VERTER
GEAR
ASSEMBLY/RI'{G

1 2x 1 . 0m m
75 N.m(7.5kgtsm
, 54 b-ft)
Torquoin crisscrogs
Dattgrn.

14-137

Transmission
lnstallation
1 . Flush ths ATF cooler as describedon psges 14-142
and 143.

5.

Installthtransmissionhousingmountingbolts.

2. lnstall the stsrter motor on the torque converter

housing,and inst8llthetwo 14 x 20 mm dowel pinsin
the torque converter housing,

45 N.m 14.5 kg-m ,

ATARTERMOTOR

33 tuft)

DOWEL
'14x 20 PIN
mm

HOUSIG
TRAI{SMISSION
MOUiITING
BOLTS
12 r '1.25mm
65 N.m(6.5 kgtsm
,47 lb-ft)
DOWELPIN
14r20mm
TOROUECONVERTER
ASSEMBLY

Roplaca.

Place the transmission on I jack, and raise to th

engine8ssmblylevel.
4.

Attach the transmissionon the engine,then installthe

transmission housing mounting bolts, raar engine
mountingbohs and intake maniJoldbracket botts.

I1{TAKEMANIFOLD

BRACKET

o.

Tighten the front engine mount bracket bolts to

sp6cifiedtorque.

FROT{TEI{GII{EMOUNf
BRACKETBOLTS
10 x 1.25 mm
39 N.m (3.9 ksFm, 28 lb-ft)

INTAKEMANIFOLD
ERACKETBOLTS
I x 1.25 mm
2. N.rn 12,2 kg-m ,
16 tb-ft)

TRANSMlsSION
HOUSING
MOUNTINGBOLTS
12 r 1.25 mm
65 N.m (6.5 kg-m ,
47 tb-ft}
FNOI{T E GINE
MOUNTBRACKET

FROI{TE'{GINE
MOUl{f

TRAfISMISSK)NJACK

14-138

REARENGINEMOUNfiNG
BOLTS
12 x 1.25 mm
Rplac.
55 N.m (5.5 ks-m ,40 lb-ft)

Installthe transmissionmount. Tighten the bott then

tighten the nuts to specifiedtorque, and retightenthe
boh to specifiedtorque.
NUTS
1Ox 1.25mm
39 N'm(3.9kem,28 b-ft)

10. lnstafi the control lsvsr with the shift cable on the
control shaft,
CAUTION:
Tak6 cara not to bondtho shlft cEHo.
11. lnstallthe lock boh with a new lock washer,then bend
ths lock tab.
12. Instsll the toroue converter cover and shift cable
covar.
SHIFTCABEL

cot{TRoL
LEVER

LOCK
WASHER
R6plsc.

CONTROL
SHAFT
SHIFTCABLE
COVER

1 2 r 1 , 2 5m m
65 N.m {6.5 kgim , 47 h-ft)

8.

Removethe transmissionjack.

Attach the torque converter to the drive plats with

eight bolts, snd torque to 12 N.m (1.2kg-m, 9lb-ft).
Rotate the crankshsJt 8s necessary to tighten th
'll2
botts to
of the specifiedtorque, then linaltorque,
in I crisscrossDattern.
After tightening the last bolt, check thst the
crankshaft rotstes freslv.

LOCI(BOLT
6x1.Omm
14 N'm (1.4ks-m,
10 b-ft)

TOROUE
COI{VERTER
COVER

8 x 1.25 mm
18 N.m (1.8 kg-m ,
13 lb-ftl

0 x 1.0 nvn
12 N.m (1.2 kg-m,9 lb-ft)

13. Installthe rightradiusrodanddamperfork.

NOTE:
Checkfor dotsriorationor damageof the radiusrod
rubberbushings.
SELF.LOCKING
NUT
1 2 x 1 . 2 5m m
55 N.m {5.5 kg-m ,40 b-ft}

DAMPEBPINCHBOLT
1Ox 1.25 ftm
6x1.Omm
75 N'm (7.5 kgtsm. 54 h-ft)

R6place.

44 N.m(4.4kem,32 b-tr)
Roplace.

RUBBER
BUS}IINGS
RADIUSROD
l2 x 1.25 mm
105 N.m (10.5 kgFm.76 lb-ft)
Roplaco.
{cont'dl

14-139

Transmission
lnstallation(cont'd)
1 4 . Instsllnew set ringson th end of th drivsshsfts'

19, Installthe vehicle speed sensor/powersteeringspeed

ssnsor and roar stiffoner. Conngcl the vehiclo spe6d

sensorconnecror.

1 5 . Installthe right snd left driveshafts.

BOLT
SPECIAL
6x1.Omm
12 N'm(1.2kgFm.9b-ft)

NOTE:
Turn the right 8nd lelt steeringknucklesfully outward,
and axisllv into th difterential until you f8sl th set
ring engageth sidegear.
to.

lnstallths damDerfork to the lower arm. Thsn instsll

the bslljoint to the lower arm. Usethe castls nuts whh
new cotter olns.

POWER
STEERIl{G
SPEED
SE\lsqR
O-RING
R6pbc6.

10x 1.25mm
21 N'm (2.'lks-m,
15 tb-ft)

REARSTIFFENER

1 O r 1 , 2 5m m
39 N.m(3.9 ks-m, 28 lb-ft)
NUT
SELF-LOCKING
12 r 1.25 mm
65 N.m {6.5 kem , 47 b-ft}
R6phco.

n.
COTTERPI
Replaca.

CASTLEIUT
l2 x 1.25mm
65 N.m16.5ks-m, 47 h-ft)

Connoctth ATF cooler hosesto the ioint pip6s.

21. Connect the lock-up control solenoid, shift control

solsnoid vslve connectors, 8nd the throttle control
cabls.

22. Connectths msinshaftsp66dsenaorconnector.

17. Installth rear beamstiffner 8nd center be8m.

SOLEM)IDVALVE
col{t{EcToRS

CEI{TERBEAM
1 0x 1 . 2 5m m
39 N.m{3.9 ks-m.
28 b-ft)
18. hstat the solashshield.

,t

14-140

10 x 1.25mm
60 N.m{6.0 krm ,
43 tb-ft)

Installthe ground
cablein step 26.

B . Connectthe countershaitsoeedsensorconnector.
24. Connectth starter motor cables.
NOTE:
When installingthe starter cable, mak sur6 that the
crimped side ot the ring terminal is facing out (see
section 23).

27. Install the intske control vacuum tank and intake

control vacuum tank brscket, then connect the
connecror.
28. lnstallthe air cleanerhousingand intake air duct.
29. Refillthetransmissionwith ATF (see page14-74.
30. Connect the battery positive (+) and negative (-)
cablesto the battery.

COUI{TERSHAFT
SPEED
SEITISOR
CONNECTOR

31. Start the engine.Set the parkingbrake,and shitt the

trsnsmissionthrough all gears three times. Check tor
proper shift cablesdjustment.
32. Check 8nd adjust the front wheel alignment (see
section 18).

33, Let the enginereach operatingtemperatur!_lthe

ralie-torf8ncomson)with the transmission
inI N I or
I P I position,thenturn it off andch6cktluidl8vel.
34. Roadtest as describedon pages1+68 thru 14-7O.
35, R8setths radiostations.

CABLS

36. Loosenthe tront enginemount bracket botts after the

road test, and retightenthem to specitiedtorque.

25. lnstallthe bsttery bsseand basestay.

26. Connect the ground cable to the body and the
transmission.
GROUND
CABLE

FRONTENGINE
MOUNTERACKET
BOLTS
1Ox 1.25 mm

39 N.m(3.9 ks-m, 28 lb-ft)

FROl{f ENGINE
MOUiff
BATTERYBASESTAY

14-141
I

Transmission
CoolerFlushing
7.
To prcvent iniury to faco and eyes, always woar salety
glasses 01 a laco shleld when using tho lransmlssion
tlusher,
NOTE:
This procedureshouldbe performedbefore reinstallingthe
transmission.
1.

Checktool andhosesfor wear or cracksbeforeusing.

It wear or cracks are found, replacethe hoses betore
using.

2.

Usingthe measuringcup, fillthe tank with 21 ounces

(approximately
tlushingfluid
23 full)of biodegradable
(J35S44-20). Do not substitute with any other tluid.
Followthe handlingprocedureon the tluid container.

3.

Securethe flusherfiller cap and pressurizethe tank

w i t h c o m p r e s sa i r t o b e t w e e n5 6 0 - 8 4 5 k p a { 5 . 6 8.45ks/cm,,80- 120 psi).
NOTE:
The air line should be equippedwith a water trap to
ensureI drYair system.

With ths water and air valves oft, attach the watr
8nd air suDDlies
to the Jlusher,(Hot water it svailsbl8.)

OFF

Turn on the flusher water vave so water will flow

throughthe oilcoolerfor 10 seconds
NOTE:
lf wster doos not flow through the oil cooler it is
completoly plugged.cannot be flushed, and must be
reolaced.

4.

Hsngthe tool underthe vehicle.

5.

Attach the dischsrgehose of the tank to the return

lineot the transmissioncooler usinga clamp,

9. Depressthe trigger to mix the flushing fluid into thg

6.

Connect the drain hose to the inlet line of the

transmissioncooler usinga clamp.

1 0 . While flushing with the wat6r and flushing fluid {or 2

IMPORTANT:
Securelyclampthe oppositeend of the drain hose to a
bucketor floordrain,

water flow. Usethe wire clip to holdthe triggerdown.

minutes,turn the sir valveon for 5 secondsevery 1S
20 secondsto create a surgingaction.
AIR PRESSURE;
MAX 845 kp8 (8.45kg/cm', 120 psi)
11. Turn the water vave off. Releasethe trigqer,then
reversethe hosesto the cooler so you can tlush in the
oppositedirection.Repeatsteps I through 1O.
12, Releasethe trigger and allow wster only to rinss the
coolr with water tor one minule
13. Turn the water vslve ofl 8ndturn off the water supply.
14. Turnthe air vslveon to dry the systemout with airJor
two Jull minutes or until no moisture is visible leaving
the drainhose.
CAUTION:
Rosldual moisturo In the oil coolor or plpo3 can
damagethe tiansmlssion.
15. Removethe flusherfrom the coolerline.Attach the
drainhose to a oil container,
16. Install the transmission and leave the drain hose
attachedto the coolor line.

TRANSMISSIONCOOLER
FLUSHER
J38405-A

14-142
L

1 7 . Make sure the transmissionis inl P lposition.

Then tillthe trsnsmissionwith ATF and run the engine
for 30 secondsor until approximately0.95 0 (1.0 US
qt.,O.8lmpqt.l is discharged.

TOOL MAINTENANCE
1.

Emotyandrinseatter eachuse.Fillthecan with watsr

and pressurizethe can, Flush the discharge lino to
ensurethat the unit is clean.

1 8 . Remove the drain hose and reconnect the cooler

2.

lf dischargeliquiddoes not foam. the orifice may be

blocked.

3.

To clean,disconnectthe plumbingtrom the tank at the

largecouplingnut.

4.

Remove the inline tiher from the dischargeside and

cleanif necessary.

5.

The Jluidorifice is locatedbehindthe fiher.

Cleanit with the pick stored in the bottom of the tank
handleor blow it cleanwith air. Securelyreassembleall

return hose to the transmission.

tcl

Refillthe transmissionwith ATF to the orooer level

(seep89e 1+74.

DArtS.

FILLERCAP

14-143

shift cable
Removal/lnstallation

. Make suro llfts, lacks and satty stands aro dacod

plopelly, and hobt brackots ars attachod to the corroct
positlon on the englne{se6sectlon 1).
. Apply parklng brake and block roar whoob, so car wlll
not lol olf stands and fal on you whllo working undorh.
CAUTION:
. A SRS olectllcal wiring harnorsos aro coverod whh
ydbw oui61 imulaiion.
. Boforo dlsconnectingthe SRS who harness, Instal tho
short connctor(s)on the aiftag(sl.
. Roelacetho 6nthe aftctod SRS harn63sa$cmbly lf h
has an opon circuh or damagdwiring.

1.

Removethe front console{seesection 2O}'

Z.

Stritt to I tttl position, then remove the lock pin from

the cabte-adiuster.

3.

Removethe bohs securingthe bracket.

LOCK PI
6 x 'l.Omm
10 N.m (1.0 kg.m , 7 luft)

BRACKET
ADJUSTER

4.

SRSMAIN HARI{ES8

Removethe shitt cablecover.

Remove the lock boh securingthe control lever,
removethe control lever with the shift cable'

COt{TROLLEVER
6x1.Omm
1 2 N . m( 1 kem , I lb-lt)

SHIFTCABLE

sHtFT
CABLE
COVER
8 x 1.25 mm
18 N.m (1.8 ks-m, 13 b-ft)

14-144

LOCKBOLT
6x1,0mm
'10lb-ftl
14 N'm 11.4kem ,

6.

Removeth exhaust pipeB and heat shiell.

8.

Removethe cotter pin and lock pin, then separatetho

control lver from the shift cable.

SELF.LOCKING
NUT
34 N'm(3.4 kem . 25 b-ft)
R6pl8c.
SHIFTCABLE
SELF.LOCKING
NUT
56 N.m (5.5 k$m ,40 b-ft)
HEAT SHIELD

COTTERPIN
Rspbca.
EXHAUSTPIPEB
9. lnstallth8 shift cablin the reverseorder of removal,

GASKET
R6phc.

7,

10. Check the cable adiustment after instsllingthe shift

cable (seepage1+146).

Romovethe cablsguideand grommet.

Exl.Omm
12 N.m (1.2 ksFm,I b-ft)

14-145

Shift Cable
Adjustment
CAUTION:
. All SRS oloctlical wirlng harno3sos alo covorod whh
ydbw ouier insulation.
. Befolo disconneclingtho SRS who harn6ss, lnllall tho
short connoctor (s) on tho ai6ag (s).
. Replscsthe sr iro 8fiect6d SRs halno$ Esrembly lf h
has an open circuit or damagdwiring.

4.

Check that the hole in the adiusteris pertectv sligned

with the holein the shift cable.

AIT'USTER

Cabh
Too Shon

Stan the engine.Shift to reverseto see il the reverse

gear engages.lf not, reJerto Troubleshootingon page
1+64 thru 67.

Exact
Alignmnt

NOTE:
There are two holesin the end of the shift cable.They
are Dositionad9Ooapart to allow cable adiustmentsin
1/4turn increments.

With the engine off, remove the tront console (sae

section 20).
Snit to I tt l position, then remove ths lock pin from
the cable-adjuster,

Cabl
Too Long

lf not pertectly alignod,loosenthe locknut on the shift

cable,and sdiust as required.

6. Tightenthe locknut.
Installtho lock pin on the adiuster.lf you tesl the lock
pin bindingas you reinstall it, the cable is still out of
adjustmentand must be readiusted.
Move the shift lever to eachgearand verify that the
A/T gear position indicator follows the A/T gear
positionswitch.
l'.

Start the engineand check the shift lever in allgears.lf

any gear does not work properV, reler to troubleshootingon page14-64 thtu 67,

1 0 . Insertthe ignitionky into the key cylinderon the A/T

gar indicatot panel,8nd verify that the shift lock lever

is released.

SHIFTCABLE

LOCKNUT
7 N'm lO.7kg-m
5.1 tb-it)

AOI'STEN

14-146
E.

GearshiftSelector
CAUTIOI{:
. A[ SRS olectrlcal wlrlng hamossos alo cove]ad with
yellolYouter inlulation.
. Baloro dlsconnectlng tho SRS who harn6ss, Instsll
the short connector (s) on the alrbsg (sl.
. Raplacotho entilo affectsd SRS harnoss assombly lf
it h!3 an opon circuit or damagedrylrlng.

SRS MAIN HARI{EAS

SELECTLEVERKNOB

,,J:::$

3 N.m(0.3 ks-m, 2.2 b-ft)

AppV non-hardening
thre8d
locksoalsnt.

A/T GEARPOSITION
INDICATOR
PANEL

-Gl
ICONEGREASE

LEVERCOVER

10 N.m ('1.0kgFm, 7 h-ft)

MOUNTBRACKET
SELECTOR

14-147

A/T GearPositionIndicatorPanel
Adiustment
CAUTIO :
r Al sRS clectrlcd wl ng h!m.rsc! ar. covoled wlth
yalow outcr lmuhlon.
. Bcforo dtconncctlng th. SRS wlr. harn33s, lmtal tha
rhort comoctor bl on tha ahbrg lsl.
. Replrct th..ntlrc eff.ct.d SRS harn.3. assombly lf h
ha! an opan drcuh or damagpdwlrlng.

1 . With the transmissionin I N I position, chsck that the

index msrk on the indicst-oralignswith ths N mark on
the A/T gosr plgtion indicator panel when th
t.ansmissionis in Lll position.
lf not sligned,rsmovs the front conaole (sso section

2ol.
3. Remove the A/T gear position indicstor pansl
mountingscrews, and adiustby movingth8 pansl'

NOTE:
Whenever the A/T g8r position indicstor panel is
removed,.sinstallths psnelas d6scribedabovo.
A/T OEARPOSITIOI{
II{IXCATORPAI{EL

14-148,

ThrottleControlCable
Inspection
NOTE:
Before inspecting the throttle control cable, make sure
that:

3.

Check that there is plsy in the throttle control levsr

while depressingth accGlerator pedal to the fulF
throttle oosition.

. Throttle cablefree Dlayis correct {seesection 11),

. ldlespeedis correct(seesection11).
. You warm up the engineto normal operating temperature{theradiatortan comeson),
1. Verify that the throttle control lever is synchronizsd
with the th.ottle linkagewhile depressinoand releasing
the acceleratoroedal.
2.

ff the throttle control lever is not synchronizedwhh

the throttle linkage.ad.iustthe throttle controlcable.

THROTTLELINKAGE

Remove the cable end oJ the throttle control cablo

trom tho throttls controllavsr.
5.

Check that the throttle control lsv6r moves smoothly.

THROTTLECABLE

THROTTLECONTROLLEVER

THROTTLECOI\ITROLLEVER

1 4 -14 9

Throttle ControlCable
Adiustment
NOTE:
Beforeadjustingthe throttle controlcable,make sure that:

4.

Tightenthe locknuts.

. Throttle cablefree play is correct (seesection 11).

. ldlespeedis correct(sesection11).
. You warm up the engine to normal operatingtemperature(theradiatorfan comeson l,
1. Verify thst the throttle linksge is in the fully-closed
oosition.

LEVER
THROTTLE
CONTROL

LINKAGE
THROTTLE

Loosenthe locknut on the throttle control cableat the

throttle control lever.
Removethe free play in the throttle control cablewith
the locknut, whil6 pushingthe throttle control lavt to
the tullv-closedDoshionas shown.

THROTTLECOI{TROLLEVEB
Pushin this direction.

t-

14-150

5.

A{ter tightening the locknuts, inspect the synchronization8ndthrottle control lever movemsnt.

NOTE:
To tailor the shift/lock-up characteristicsto 8 particular
customer's driving expct8tions, you can adiust the
throttle control cablup to 2mm {0.078inl shorter thsn tho
"synchronized" point.

Differential
ManualTransmission
............................
15-t
AutomaticTransmission
.......................
15-10

Differential(ManualTransmissionl
Special
Tools..........
...........15-2
Differential
lllustrated
Index.................................
15-3
Backlash
Inspection
......15-4
FinalDrivenGearReplacement
........15-4
TaperedRollerBearing
Replacement
.......................................
15-5
Oil SealRemoval
...........
15-5
BearingOuterRace
Replacement
.......................................
15-6
TaperedRollerBearingPreload
Adjustment
....................
15-7
OilSeallnstallation
.......15-9

SpecialTools

Re{.No.

o
@
o
@
@

@
@

Tool Numblr
07GAD07HAJ 07JAD07JAD07LAD07746077460774607749-

PG40'100
PK40201
PH80101
PH80400
PW50601
0010400
0010500
0010600
0010000

15-9
15-7

Driver Attachment
PreloadInspectionTool
Driver Attachment
Pilot.28 x 30 mm
Attachment,40 x 50 mm l.D.
Attachment,52 x 55 mm
Attachment.62 x 68 mm
Attachment,72 x 75 mm
Driver

15-9
15-5
15-6
'|5-6
15-6
15-6,I

@
a

,6

15-2

Differential(ManualTransmissionl
lllustratedlndex
NOTE:lf the ' mark partswere replaced,the taperedrollerbearingpreloadmust be adjusted(seepage15-9).

OIL SEAL
Removal,page 15-5
Installation,p8ge 15-9

.BEARIT{GOUTERRACE
Replacsment,page 15-6
Inspecttor wear and damage,
.TAPEREDROLLER
BEARING
Replacement,page 15-5
Inspgctfor wear and damag.
'TAPERED ROL1IR BEARING
Replacement,page 15-5
Inspoctfor wear and damagg.
TBEABINGOUTEB RACE
Replgcement,page 15-6
Inspectfor wear and dam6ge.

.THRUST
Sel6ct,Adjustment,page 15-7
10 x 1.25lnm
103 N.m 110,3kg-m,7a lb-ftl
Left-handthreads.

DRIVENGEAR
Replacementpage 15-4
Inspectfor wear and damage.

(@o..._
r;-

ITHRUSTSHIM
CAFBIER
Inspectfor cracks.

Remov1,page 15,5
lnstallation,
pag15-9

15-3

Differential(ManualTransmissionl
FinalDrivenGearRePlacement

BacklashInspection
1.

Placedifferentialassemblyon V-blocksand inst8ll

both driveshafts.

2.

Measurethe backlashof both piniongears.

Standard {Newl: 0.05- O.'15mm
10.002- 0.006in)

1,

Remove the bolts in a crisscrosspattern in several

steps,and removethe final drivengearfrom the ditferentialcarrier.
NOTE: The final driven gar bolts have left-hand
threads,

Chamferon inside diametor

of final driven goar facoscarraer'
DIAL INDICATOR

PINIONGEARS

10 mm EOLT
103 N.m (10.3kg-m, 74lb-ft|

Installthe final driven gear by tighteningthe bolts

in a crisscrossDatternin severalsteps.

lf the backlashis not within the standard,replace

the differentialcarrier.

15-4

TaperedRollerBearing

Oil SealRemoval

Replacement
NOTE:
. T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e
shouldbe replacedas a set.
. Inspectand adjustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced.
. Checkthe taperedrollerbearingsfor wear and rough
rotation.lf taperedrollerbearingsare OK, removalis
not necessary.
1.

1.

Removethe differentialassembly.

2.

Removethe oil sealfrom the transmissionhousing.

OIL SEAL
Replace.

Removethe taperedroller bearingsusinga bearing

puller.
BEARINGPULLER

3.

Installnew taperedroller bearingsusingthe special

tool as shown.

Removethe oil sealfromthe clutchhousinq.

CLUTCHHOUSING

N O T E ;D r i v et h e t a p e r e dr o l l e r b e a r i n g so n u n t i l
they bottomagainstthe differentialcarrier.

ATTACHMENT,
40 x 50 mm l.D.
07LAD - PWSool

otl sEAt_
Replace.

15-5

Differential(ManualTransmissionl
BearingOuterRaceRePlacement
NOTE:
. T h e b e a r i n go u t e r r a c e a n d t a p e r e dr o l l e r b e a r i n g
shouldbe replacedas a set.
. Inspectand adlustthe taperedroller bearingpreload
wheneverthe taperedrollerbearingis replaced.
1.

Removethe oil sealsfrom the transmissionhousing

a n dc l u t c hh o u s i n g( s e eP a g e ' 1 5
5)

2.

Drivethe bearingouter raceand thrust shim out of

t h e t r a n s m i s s i o nh o u s i n g ,o r r e m o v et h e b e a r i n g
outer race and thrust shim from the transmission
h o u s i n gb y h e a t i n gt h e t r a n s m i s s i o nh o u s i n gt o
) i t h a h e a tg u n .
a b o u t2 1 2 " F( 1 0 0 ' Cw
CAUTION: Do not reus the thrust shim if the
outer racGwas driven out.
N O T E : D o n o t h e a t t h e t r a n s m i s s i o nh o u s i n gi n
excessof 212'F(100'C).

After installingthe thrust shim. install 8n bearing

outer race in the transmissionhousing and clutch
housingusingthe specialtools as shown.

3.

NOTE:
. Installthebearingouter racesquarely.
. Check that there is no clearancebetween the
bearing outer race,thrust shim, and transmission housin9.
TRANSMISSION
HOUSING:
DRIVER
077a9- (xn(xx)o

ATTACHMENT,
fi:l x 68 mm
077i16- (x)los(x)

ORIVER
07749- OOl(Xno

TRANSMISSION
HOUSING:

THNUSTSHIM

ATTACHMENT,
52x55mm
07715- (X)10400
THRUSTSHIM

CLUTCH
HOUSING:

BEARING
OUTEFRACE

DRIVER
- 00tqx)0

:'----J)-4
ATTACHMENT.
72xt5mm
07746 - 0011}600

EEARING

OUTER
THRUST

4.
THRUSTSHIM

15-6

OUTERRACE

Installthe oil seal{seepage15-9).

TaperedRollerBearingPreloadAdjustment
After installingthe thrust shim, installthe bearing
bea
outer race in the transmissionhousing (see
re page
t
15-6).

NOTE: lf any of the items listed below were replaced,

the taperedrollerbearingpreloadmust be adjusted.
.
o
.
o
.
1.

Trsnsmissionhousing
Clutchhousing
Differentialcarrier
Taperedrollerbearingand bearingouter race
Thrustshim

R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m
from the transmissionhousing(seepage 15-6).

NOTE:
. Installthe bearingouter racesquarely.
. C h e c kt h a t t h e r e i s n o c l e a r a n c eb
between
e t w e e nthe
transmission
bearingouter race,thrust shim and transmis
nousrng.
4.

NOTE:Installthe thrust shim onlv on the transmission housingside.

2.

W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e moov' e d ,
i n s t a l lt h e d i f f e r e n t i a al s s e m b l y ,a n d t o r q uee t h e
clutchhousingand transmissionhousing,

CAUTION: Do not reusothe thru3t shim it the boaring outer rrco wls drivcn out,

TOROUE:10 x 1.25mm:45 N.m

('1.5kg-m, 33 lb-ft|
8 x 1.25mm: 28 N.m
(2.8 kg-m, 20 lb-ft1

NOTE:Let the transmissioncool to the room temperature if the bearing outer race was removed by
heatingthe transmissionhousing befo.e adjusting
the taperedfoller bearingpreload.

N O T E : l t i s n o t n e c e s s a r yt o u s e s e a lI inngg a g( e n t
betlveenthe housings.
5.

Rotatethe differentialassemblyin both directions

direct
to seatthe taperedrollerbearings.

6.

Measurethe startingtorque of the differential

rent|al assemblywith the specialtool and a torquewrench.
wrenc

F i r s tt r y t h e s a m e s i z et h r u s t s h i m t h a t w a s r e moved.
CAUTION: Use only ono thrust rhim.

STANDARD:1.4- 2.6 N.m

114- 26 kg-cm,12 - 23 lb-inl
THRUSTSHIM

NOTE:
. M e a s u r et h e t a p e r e dr o l l e r b e a r i n gp r e rl ooaa oA I
normSlroom temperature.
a M e a s u r et h e t a p e r e dr o l l e r b e a r i n gp r e l o a oi n
both directions.

C
WRENCH
TRANSMISSIONHOUSING

TOOL
PRELOADINSPECTION
07HAJ- PK40201

{ c o n td I

15-7

Differential{ManualTransmission)
Tapered Roller BearingPreloadAdiustment {cont'dl
ll the tapered roller bearing preload is not within
the standard,selectthe thrust shim which will give
the correcttaperedroller bearingpreloadfrom the
followingtable.

7.

NOTE: Changingtho thrust shim to the next size

w i l l i n c r e a s eo r d e c r e a s et a p e r e d r o l l e r b e a r i n g
preloadabout3 - 4 kg-cm(2.60- 3.47lb-in).
THRUSTSHIM
Thickneee

Part Numbr
41381- PXs- 000

1.90mm (0.075in)

41382-PX5-000

1 . 9 3m m ( 0 . 0 7 6i n )

41383-PX5-000

41384-PXs-000

1.96mm {0.077in)
'1.99mm (0.078in)

41385-PX5-000

2.02mm (0.079inl

41386-PXs-000

2.05mm (0.081in)

41387-PXs-000

2.08mm (0.082in)

41388-PXs-000

2 . 1 1m m ( 0 . 0 8 3i n )

41389-PX5-000

2 . 1 4m m ( 0 . 0 8 4i n )

41390-PXs-000

2 . 1 7m m { 0 . 0 8 5i n }

4 1 3 9 1- P X 5 - 0 0 0

2.20mm (0.087in)

41392-PXs-000

2.23mm (0.088in)

41393-PXs-000

2.26mm (0.089in)

41394-PX5-000

41395-PXs-000

2.29mm {0.090in)
2.32mm (0.091in)

41396-PXs-000

2.35mm (0.092in)

41397-PX5-000

2.38mm (0.094in)

41398-PXs-000

2 . 4 1m m ( 0 . 0 9 5i n )

41399-PX5-000

2.44mm (0.096in)

4' 1400-PX5-000

2.47mm (0.097in)

T
8.

Recheck
the taperedrollerbearingprload.

9. How to selectthe correctthrustshim:

- 1 ) C o m p a r et h e t a p e r e d r o l l e r b e a r i n gp r e l o a d
you get with the thrust shim that was removed,
with the specifiedpreloadof l4 - 26 kg cm ('12
- 23lb-in).
-2) lf your measuredtaperedrollerbearingpreload
is lessthan specified.subtractyours irom the
specified.
l f y o u r s i s m o r e t h a n s p e c l f i e ds, u b t r a c t h e
specitiedfrom your measuremenl.
For examplewith a 2.17mm thrustshim:
26 kg-cm(23 lb-in)
@ specified
you measure 6 kg-cm(5 lb-in)
2 0 k g - c m{ 1 8 l b - i nl)e s s
@ you measure 34 kg-cm(30 lb'in)
- specified
26 kq-cm(23 lb-in)
8 kg-cm(7 lb-in)more
-3) Eachshim size up or down from standard
makesabout 3 - 4 kg-cm (2.60- 3.47 lb-in)
differencein taperedrollerbearingpreload.
In exampleA, your measuredtaperedroller
b e a r i n g p r e l o a dw a s 2 0 k g - c m l e s s t h a n
s t a n d a r ds o y o u n e e d a t h r u s t s h i m f i v e
sizesthickerthan standard(try the 2.32mm
thrustshim,and recheck)
. In exampleB, yours was 8 kg-cm more than
s t a n d a r d ,s o y o u n e e d a t h r u s t s h i m t w o
s i z e st h i n n e r( t r y t h e 2 . 1 1m m t h r u s ts h i m ,
and recheck).

'10.After adjustingthe tapered roller bearingpreload,

assemblethe transmissionand installthe transmission housing(seepage'13-3'l).
TOROUE:10 x 1.25mm: 45 N'm
{,[.5kg-m, 33 lb-ftl
8 x 1.25mm: 28 N'm
(2.8kg-m, 20 lb-ft|
1 1 . Rotatethe differentialassemblvin both directions
to seatthe taperedrollerbearings.

15-8

Oil Seallnstallation
lnstallthe new oil seal flush with the transmission
housingusingthe specialtools as shown.

2.

Installthenew oil sealinto the clutchhousingusing

the sogcialtoolsas shown,

CLUTCH
HOUSING

TRANSMISSloN
HOUSING

DRIVER
077a9- 001o{xlo

DRIVER
077it9- 001qxto
OIL SEAL
Replace.

OR]VERATTACHMENT
otGAD - FG('lrX)
PILOT,2E x 30 mm
07JAD - PHE0/00

OIL SEAL
Roplace.

DRIVERATT
07JAD- PHgtl01

PILOT,28 x 30 mm
07JAD - PH8o4{r0

15-9

Differential(AutomaticTransmissionl
15-12
Tools..........
...........
Special
Differential(AutomaticTransmission)
.. 15-13
lllustratedlndex ..........
Backlash
Inspection
......15-14
.........................
15-14
BearingReplacement
....................
15-15
Inspection/Disassembly
Reassembly
....................
15-16
15-17
Oil SealRemoval
........,..
TaperRollerBearingPreload
....................
15-18
Adjustment
BearingOuterRaceReplacement.....15-20
.......15-20
Oil SealInstallation

SpecialTools

R{.No.

07GAD07GAD07HAJ 07HAD07JAD07JAD07LAD0774907947-

o
@
o
@
o

SD40101or
SD40100
PK40201
SF10r00
PH80101
PH80400
PW50601
0010000
SD90200

oty

Do3cription

Tool Number

15-20

PreloadInspectionTool
Driver Attachment
Driver Attachment
P i l o t , 2 8x 3 0 m m
Attachment,40 x 50 mm
Oriver
DriverAttachment

,l

1E_14

1
I
1
I
1
1

15-19
15-20
15-20
1 5 -1 4
15-19,20
15-20

t9

cro)
o

15-12

Poge Refercncc

DriverAttachment

@ @ > a @

IT @

@
@

Differential(AutomaticTransmission)
lllustratedIndex

THRUSTSHIM
page15-18
Selection,

OUTERRACE

eg
9"

10 mm BOLT
103 N.m 110.3kg-m,7a lb-ft1
Left-handthreads

ROLLEB
BEARING
TAPER
lnspectfor f6ultymovement.

FII{ALORIVENGEAR
Disa6s6mbly,page 15-15
psge 15-15
Inspgctaon,
Insp6ctfor exc6ssive

lnstall in this direction.

DIFFERENNALCARBIER
lnsoocttor cracks.

THRUSTWASHEB

PINIONWASHER

TAPERROLI..ER

SPRINGPIN
PINIONGEAR
page15-14
inspection,
Backlash

BEARIiIG OUTERRACE

PINIONSHAFT
Inspgct{or wear or
damage.

15-13

Differential(AutomaticTransmissionl
BearingReplacement

BacklashInspection
' t . P l a c et h e d i f f e r e n t i a a
l s s e m b l yo n V - b l o c k s
installboth axles.
Checkbacklashof both side gears.
StandardlNowl: 0.05- 0.15mm
10.002- 0.006in.l

NOTE:Checkthe bearingsfor wear and rough rotation.

lf the bearingsare OK, removalis not necessary.
Removethe taper r o l l e rb e a r i n g su s i n ga b e a r i n g
puIer.
BEARING
PULI.IR

DIALINDICATOR SIDEGEARS

BEARING
TAPER
ROLLER
Installthe new taper roller bearings.usingthe specialtool and a pressas shown,
3.

lf out of tolerance,disassemble
the differentialand
selectnew pinionwashersfrom the table below.

PINIONWASHEB
Part Numbcr
4 1 3 5 -1P G I - 0 0 0
4 1 3 5 2- P G 1- 0 0 0
4 1 3 5 3- P G 1- 0 0 0
4 1 3 5 4* P G 1- 0 0 0
4 1 3 5 5- P G 1- 0 0 0
41356-PGl-000
4 1 3 5 7- P G 1- 0 0 0
4 1 3 5 8- P G 1- 0 0 0

Thickness
0.70mm (0.028n )
0.75mm (0.029n )
0.80mm (0.031n )
0.85mm (0.032n )
0.90mm (0.035n )
0.95mm (0.036n )
1.00mm (0.039n )
1.05mm (0.041n )

NOTE:
. Drivethe bearingson until they bottom.
. Usethe specialtool:
. large end for torque converterhousing side
bearing.
small end for transmissionhousingside bearIng.
ATTACHMENT,
,(t x 50 mm
07LAD- PW5o601

NOTE:
. The bearingand outer race should be replaced
as a set.
. lnspectand adjustthe bearingpreloadwhenever
a bearingis replaced.
. Drivein the bearingssecurelyso that there is no
clearancebetweenthe bearingsand differential
carner.

15-14

Inspection/Disassembly
Removethe final driven gear and inspectteeth for
wear or oamage.

3,

Remove the pinion shaft, pinion gears, washers,

thrustwashers,and side gears.

NOTE: The final driven gear bolts have left-hand

threads,

FINAL DRIVENGEAR
PINIONGEARS

SIDEGEAR
CARRIER
DIFFERENTIAL

Driveout the springpin with a pin punch.

Wash the pans thoroughlyin solventand dry them

with compressedair. Inspoctall pans for wear or
damageand replaceany that are defective.

5.0 mm PIN PUiICH

15-15

Differential(AutomaticTransmissionl
Reassembly
'1. Installthe side gears,with thrustwashersin tho differentialcarrier.

Rotatethe gears until the shaft holes in the pinion

gearsIine up with the shaft holesin carrier.

NOTE: Coat all gears with molybdenum disulfide

greaseon all sides.

Insertthe pinionshaftand alignthe spring pin holes

in one end with the matchinghole in the carrier.
Alignthe holes.

THRUSTWASHER

5.

Drivein the springpin with a pin punch.

Set the pinion gears in the place exactlyopposite

each other in mesh with side gears,then install a
pinion washer behind each one. Wsshersmust be
of equalthickness.
NOTE: Selectthe correct Dinion washer from the
tableon page15-14.

Checkbacklashof both piniongearsagain.

Standard {New}: 0.05- 0.15 mm
{0.lxt2- 0.006in}
It still out of tolerance,replacboth thrustwashers.
lf still out of tolerance.replacethe side and pinion gears,and recheckbacklash.
lf still out of tolerance,replacethe carrierassemory.

15-16

Oil SealRemoval
7.

Installthe final drivn gear.Torquethe boltsto 103

N.m (10.3kg-m,74 lb-ftl.

1 . Removeth differentialass6mbly.
Removethe oil sealfromthe transmissionhousing.

NOTE:The final driven gear bolts have left-hand

th.eads.

FINAL DRIVENGEAR

Chamf6ron innsr side

ot final driven gear fac6s
cSrner.

10 mft EOLT
103 N,m 110.3kg.rn, 74 lb-ftl
Lett-h8ndthreads

OIL SEAL

TRANS|tsstotrl
HOUSI G

Remove th oil seal from the toroue convrter

housing.

TOROUECONVERTER
HOUSING

OIL SEAL
Replace.

15-17

Differential{AutomaticTransmissionl
TaperRollerBearingPreloadAdjustment
Selectthe thrust shim from the table below so that
theirtotal thicknessis 2.60mm (0.102in).

NOTE: lf the transmissionhousing, torque converter

housing,differentialcarrier,taper roller bearing.outer
raceor thrust shim were replaced,the bearingpreload
must be adjusted.
1.

CAUTION: Do not use mor than two shims to

adiust tho bearing prelosd.

R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m
from the transmissionhousingby heatingthe housing to about212"F(100'C)with a heatgun.

BEARINGOUTER
RACE

CAUTION;
. Do not h6at tha houling in oxcass ol 212'F
{100"c1.
. Roplacothc tapsr rollor bearing when tho outer
race is to bs rgplacad.
. Do not uso a ghim on the torqug convsrt9r hou3ing sid6.
N O T E :L e t t h e t r a n s m i s s i o nh o u s i n gc o o l t o t h e
r o o m t e m p e r a t u r eb e f o r e a d j u s t i n gt h e b e a r i n g
preroao.

HEATGUN

THRUSTSHIM
Part Numb6r
41441- PK4- 000

2.20mm (0.087in)

41442-PK4-000

2.25mm (0.089in)

41443-PK4-000

2.30mm (0.091in)

41444-PK4-000

2.35mm (0.093in)

41445-PK4-000

2 . 4 0m m ( 0 . 0 9 4i n )

41446-PK4-000

2.45mm (0.096in)

41447-PK4-000

2.50mm (0.098in)

41448-PK4-000

in)
2 . 5 5m m ( 0 . 1 0 0

41449-PK4-000

in)
2 . 6 0m m ( 0 . 1 0 2
2 . 6 5m m ( 0 . 1 0 1i n l

41450-PK4-000
4 1 4 5 1- P K 4 - 0 0 0

41452-PK4-000

2 . 7 5m m ( 0 . 1 0 8i n )

41453-PK4-000

2 . 8 0m m ( 0 . 1 1 0i n )

41454-PK4-000

2 . 8 5m m { 0 . 1 1 2i n )

41455-PK4-000

2 . 9 0m m ( 0 . 1 1 4
inl

41456-PK4-000

2 . 9 5m m ( 0 . 1 1 6i n )

41457-PK4-000

3 . 0 0m m ( 0 . 1 ' 1i8n )

41458-PK4-000

3 . 0 5m m ( 0 . 1 2 0i n )

No.

Thickncss

2 . 7 0m m ( 0 . 1 0 6i n )

* Standard shim

15-18

3.

After instaliingthe thrustshim, installthe outer race

in the transmissionhousing,usingthe specialtools
as snown.
CAUTION:
. Install the outsr .ace squaraly in tho trsnsmi!.
sion housing.
. Check that thero is no cloaranco bciwocn th,
outsr race,shim and t ansmissionhousing.
. Install tho gasket whon chocking pr6lo6d.

6,

M e a s u r et h e s t a r t i n g t o r q u e o f t h e d i f f e r e n t i a l
assemblywith the specialtool and a to.que wrench.
STANDARD:
Now bosrings:

2.8 -,[.0 N'm

128- ,l|) kg-cm, 2,1- 35 lb-inl
Rculod bslrings: 2.5 - 3.7 N.m
(25 - 37 kg-cm, 22 - 32 lb-in)

07?49- qlrqtoo

,'l
PRELOADINSPECTIONTOOL
07HAJ - PKIO201

NOTE:
! Measu.e
thestarting
torqueat normalroomtemp6.ature
in bothdirections.

With the mainshaft,countershaftand secondarv

shaft removed,installthe differentialassemblyand
torquethe transmissionhousing.

lf out of spec,selecttwo thrust shimswhich will

give the correct preload,and repeatsteps 1 - 6.
Changingone of the shims to the next sizewill
increaseor decreasestaningtorque about3 - 4
kg-cm(2.60- 3.,17lb-ln).
T o i n c r e a s et h e s t a r t i n gt o r q u e , i n c r e a s et h e
t h i c k n e s so f s h i m s . T o d e c r e a s et h e s t a r t i n g
torque,decreasethe thicknessof shims.

TOROUE:55 N.m 15.5kg-m. /r0 lb-ft|

Rotatethe differentialassemblyin both directions
to seatthe bearings.

15-19

Differential(AutomaticTransmission)
BearingOuterRaceReplacement
Removethe bearingouter racefrom the torqueconv e r t r h o u s i n g b y h e a t i n gt h e h o u s i n gt o a b o u t
212"F(100"C)with a heatgun.

Oil SealInstallation
1.

CAUTION: Do not hcat the hou3ing in excassof

212"F(100"c).

I n s t a l lt h e o i l s e a l i n t h e t r a n s m i s s i o nh o u s i n g ,
u s i n gt h e s p c i a tl o o l s a s s h o w n .

DRTVER
07749- 00ltXXtO

NOTE:
. Replacethe bearingwith a new one whenever
the outer raceis to be replaced.
. Do not use shims on the torque converterhousing side.
. Adjust preloadafter replacingthe bearingouter
raceand bearing.
TAPERROLLER

HEATGUN

OIL SEAL

2.

I n s t a l lt h e n e w b e a r i n go u t e r r a c ef l u s h w i t h t h e
housingusingthe specialtools.

07749 - 001(xXlO

DRIVERATTACHMENT
07GAD- SO|O101or
o]GAD - SD.O100

15-20

Drivethe oil seal into the torqueconverterhousing,

usingthe specialtools as shown.

Driveshafts
S p e c i aTl o o l s . . . . . . . .
Driveshafts
Removal
Disassembly
Disassembly/lnspection
Reassembly
Installation
IntermediateShaft
R e p l a c e m e n. t. . . . . . . . . . . . . .
Disassembly
Disassembly/lnspection
Reassembly

16-2
16-3
16-5
16-6
16-7
16-9
16-11
16-12
16-13
16-14

SpecialTools

Rel. No.

o
6\

/?\

@
rA
\of

Tool Numbel

oTGAD-PH70201
oTGAF-SD40700
oTMAC-SLOO100
o7746-OO10200
07746-O010400
07746-OO30400
o7749-OO'OOOO
l

re

tll

16-2

I o-J

1 6 - 12
16-14
16-14
1 6 - 1 2 ,1 4

,;A

l---:z-----.1

16 - 1 4
1 6 - 1 2 ,1 4

Oil Seal Driver

Hub Dis/AssemblyBase
BallJoint Remover,32 mm
Attachment,37 x 40 mm
Attachment,52 x 55 mm
Attachment,35 mm LD.
Driver

ct_@
o

Driveshafts
Removal
INSPECTION

5. Remove the damper tork nut, bolt and damper

pinch bolt.

Drivoshaft Boot
Check the boots on the driveshaftfor cracks,damage,
leakinggreaseor loose boot bands.
It any damageis found. replacethe boot.

6. Removethe damperfork.
OAMPERPINCH BOLT
(SELF.LOCKINGBOLT)
10 r 1.25mm

Spline Looseness
Turn the driveshaftby hand and make sure the spline
and joint are not excessivelyloose.
It damageis found, replacethe inboardjoint.
Twisted or Crscksd
Make sure the driveshaftis not twisted or cracked.
Replaceif necessary.
l.

Raisethe car and placesatety standsin the proper

locations(seesection 1).
Removethe tront wheels.
Dralnthe transmissionoil or fluid.

4.

Raisethe lockingtab on the spindlenut and remove

rt,

OAMPEB

NUTI
ISELF.LOCKING
1 2 x 1 . 2 5m m
Replace.

DAMPERFORK BOLT

7, Removethe cotter pin from the lower arm balljoint

castle nut and removethe nut.
8. Installa 14 mm hex nut on the ball joint, Be sure
that the 14 mm hex nut is flush with the ball joint
pin end. or the threadedsectionot the balljoint pin
might be damagedby the ball joint remover.

FRONTWHEEL

9. Use the ball ioint remover, 32 mm as shown on

page 18-13 to separatethe ball joint and lower
arm.
1O, Positionthe specialtool between the knuckleand
lower arm as shown, then separdtethe lower arm.
CAUTION: B careful not to damag the ball ioinr
boot.

CASTLEXUT

SPINOLENUT
24 r 1.5 mm
Replace.
14 mm HX NUT

Replace.

(cont'd)

16-3

Driveshafts
Removal(cont'd)
11. Pry the driveshaftassemblywith a screwdriveras
shown to force the set ring at the driveshaftend
past the groove,

with lntermediateShaft:
Removethe left driveshaftfrom the bearingsuppon by tapping the inboardjoint of the driveshaJt
with a Dlastichammer.
CAUTION:
a Do not oull on the driveshaft. as the CV joint
may come apan.
a Use care whsn prying out the assembly and pull
it stlaight to avoid damaging the diffelsntial oil
sal.

12. Pullthe inboardioint and removethe driveshaftand

CV joint Jromthe ditferentialcase as an assembly.

13, Pulltheknuckleoutward and removethe driveshaft

outboard ioint from the front wheel hub using a
olastichammer.

KNUCKLE

OUTBOARDJOINT
INBOARDJOINT

16 -4

Disassembly
CAUTION: Do not try to disassmble the outboard
joint.
1. To rmovethe boot band, pry up the lockingtabs
with a screwdriverand raisethe end of the band.
CAUTION: Tak care not to damage the boots.

Removethe inboardjoint and rollers.

Removethe circlip.then removethe spiderusinga
commerciallyavailablebearingremover.
NOTE: Before disassembly,mark the spider and
driveshaftso they can be reinstalledin their original
positions.

NOTE: Carelullv clamp the driveshaft in a vise

with solf jaws.

BEARINGREMOVER

STOPPERRING

INBOAROJOII{T

16-5

Driveshafts
Disassembly/lnsPection
NOTE:
a Mark the rollersand rollergroovesduringdisassemblyto ensureproperpositioningduting reassembly.
a Beforedisassembly,mark the spiderand driveshaftso they can be reinstalledin their originalposilions.
a The inboardjoint must be removedto .eplacethe boots.
a lf the boot band is the welded type, cut off as shown.
CAUTION: Take care not to damag tho boots.

DRIVESHAFT

INAOARDJOINT
Checksplinestor wear or damage.
Check insideborelor wear.
Inspectfor cracks,

SPIOEB

SET R|NG __571

Replace.

ROLLER

LEFT
INBOARDJOINT
lYvith int6rmodlato
Checksplineslor wear or damage.
Check insidebore for wear.
Inspect for cracks.

STOPPERRING

BOOT
INBOARD
lor cracking,
Inspect
splittingand wear.

CIRCLIP
DYI{AMIC OAMPERBAND
(A/T mod.b, loft ddvosh.ft onlYl
Replace.

BOOTBAND
Replace.
AOOTBAND
Replace.

------.,
OUTBOAROJOINT
Inspect Ior faulty movement and wear.
Inspect ball bearings whilo rotaiang
Do not try to disassemble

BOOTBANO
Replace.
OUTBOARD
EOOT
Inspectfor cracking,
splittingandwear.

16 -6

OUTAOARORING
Checkfor damage.
DRIVESHAFT

Reassembly
Cleanthe driveshattsbeforereassemblv.
Wrap the splineswith vinyl tape to preventdamage
to the boots and dynamicdamper(A/T models,ltt
driveshaftonly).

6.

Pack the outboard joint with the joint grase

cluded in the new driveshaftset.
crease Ouantity. 130-140 9 (4.6-4.9 ozl

Installthe outboardboot, dynamicdamperand inboard boot to the driveshaft,then removethe vinyl

IADE.

BOOT
OUTBOARO

VIf{YL TAPE

DYNAMICDAMPER
lA/T modob,
loft ddvGhaft onlvl

INBOARD
BOOT
Installthe stopperring into the driveshaftgroove,
Rotatethe stopperring in its grooveto be sure it is
fully seated.
4.

Installthe spider on the driveshaftby aligningthe

marks on the spiderand end of the driveshaft.

Fit the rollersto the spiderwith their high shoulders

facing outward.
CAUTION:
a Rainstalltho rollor3 in their o ginal posilions on
the sDidel.
a To prsvnt it from talling off, hold tho drlveshatt
assembly so th spidor and lollor point up.

Fit the circlipinto the driveshaftgroove.Rotatethe

circlip in its grooveto be sure it is fully seated,
CIRCLIP

b
"""@

SPIDER

STOPPERRING

1S7

Driveshafts
Reassemblylcont'd)
8.

9.

Packthe inboardioint with the ioint greaseincluded

in the new driveshaftset.

1 1 .lnstall new boot bands on the boot and bend both

sets ot locking tabs

GroasoOuantity: 130-140 g (4.6-4.9 oz)

A/T modls, Laft ddveshaft
120- 130 g 14.2-4.6 ozl

1 2 . Lightlytap on the doubled-overportionsto reduce

their height.

Fit the inboardioint onto the driveshaft.

CAUTION: To provant it from falling oft, hold tho
drivoshaft assomblYso tho inboard joint points up.

INBOARDJOINT

OnlY:
ManualTransmission
Align the holder direction of the rollers
toward the slot of inboard joint as

HOLOER

1 0 .Adjust the length of the driveshafts to the tigure

below. then adjust the boots to halfway between
full compressionand Iull extension.

13. Positionthe dynamicdamperas shown below.

a Install a new dynamic damper band and bend
down both sets of lockingtabs.
a Lightly tap on the doubled-over portion of the
band to reduceits height.

NOTE: The ends oJ boots seat in the grooveof the

driveshaftand joint.
R i g h r :5 0 7 . 9 - 5 1 2 . 9 m m ( 2 O . O O - 2 0 . 1 9i n )
Left:
. A/T modelg
8 6 2 . 9 - 8 6 7 . 9 m m ( 3 3 . 9 7- 3 4 . 1 7 i n l

16 -8

M/T models
52O.9- 525.9 mm (2O.50-20.7O inl

DYNAMIC OAMPEB

175 r 2 mm 16.9a O.l In)

DAMPERBAND

lnstallation
1 . Installtheoutboardjoint in the knuckle,then loose-

ly installthe spindlenut.
Apply 1 .O- 1 .5 g (O.O4-O.O5 oz) of specified
grease to the whole spline surface of the intermediateshatt,
NOTE: Atter applyinggrease,remove the grease
from the splinegroovesat intervalsof 2-3 splines
and Jromthe set ring grooveso air can bleedfrom
the inboardjoint.
J.

Installthe new set ring onto the driveshaftor intermediateshaft groove.

NOTE: Atter applying grease, rcmove
)ve the
grease from the spline grooves at tntervats
int(
g groove,
g
ot 2-3 splines and trom the set ring

CAUTION: Always use a new set dng whon6va?

th6 drivoshatt is being installod.
4.

Installthe inboardend of the driveshaftinto the ditferentialor intermediateshaft.

NEWSETRIIIG
INTERMEDIATE
SHAFT

SETRINGGROOVE

INBOARDJOINT

SET RING
RIGHT
Make sure the right driveshaft locks in the dit{erential side gesr groove, and the CV ioint sub-axle
bottoms in the ditterential.

LEFTDRIVESHAFT
Insert the le{t driveshaft CV joint sub-axle anto
(cont dI
the intermediate shaft until the intermediate shaft
set ring locks in the groove in the lelt driveshaft.

16-9

Driveshafts
Installation(cont'd)
5.

6.

Installthe damperfork overthe driveshaJtand onto

the lower arm. Install the damper in the damper
tork so the aligningtab is alignedwith the slot in
the damperfork.
Looselyinstallthe damperpinch bolt, and the new
damoerfork nut and bolt.
NOTE: The bolts and nut shouldbe tightenedwith
the vehicle'sweight on the damPer.

8. Tightenthe new spindlenut

9, lnstsll the wheels with the wheel lug nuts.
NOTE: Before installing the wheel, clean the
mating surtaceof the brakedisc and insideof the
wheel.

FRONTWHEEL

DAMPERPINCH BOLT
BOLTI
{SELF-LOCKING
10 x 1.25mm
44 N'm 14.4 kg-m, 32 lb-ft)

DAMPERFORK
NUTI
TSELF-LOCKING
1 2 x 1. 2 5 m m

65 N.m 16.5kg-m,47lb-ft|
l. t",i"tbtrf,+r"knuckle on the lower arm, then tighten
the castlenut and installnew cotter pln.
CAUTION:
a 8e calotul not to damago tho ballioint boot.
a Torque the castle nut to the lowol torque
specitication, thon tightsn it only far snough to
align tho slot with ths pin hol. Do not 8li9n tho
nut by loosening.

WHEELLUG NUT
1 2 x 1 . 5m m
1 1 ON ' m
(11 kg-m,
80 tb-ft)

NUT24 x 1.5 mm
SPINDLE
25o N.m 125kg'm, 'l8l lb-ft}
usea dritl
NOTE:Aftertightening,
to stakespindlenut shoulder
the d veshatt.
against

1 0 .Tightenthe damperpinch bolt and the new damper

tork nut with the vehicle'sweight on the damper.
1 1 .ReJillthe transmissionwith recommendedoil or
tluid.

1 2 .Check the tront wheel alignment and adjust if

necassary(seepage 18-4).

COTTERPIN
On reassembly,
bendthe cotter pin

16-10

CASTLENUT
14 x 2.0 mm
5 0 - 6 0 N ' m ( 5 0 - 6 . 0 k9_m'
36-43 tb-ftI

IntermediateShaft
Replacement
1 . Drainthe transmissionoil or fluid.
2.

5.

Remove the left driveshstt assembly (see page

16-4).
Removethe flange bolt and hex bolts.

Installin the reverseorder of removal.

FLANGEBOLT
39 N.m 13.9kg-m,
2a |b-fr)
\

\
t

HEX BOLTS

HEXBOLTS
39 N.m 13,9kg-m,
28 tb-ftl

,a\,

Removethe intermediateshaft assemblyfrom the

differential.
CAUTION: To prevent damage to th diftersntial
oil s81,hold ths intormediate shaft horizontal until
it is clear ot tho diffsrontial.

rrrrnme6lhrrsxlrr

16-11

lntermediateShaft
Disassembly
NOTE: Be carefulnot to damagethe metal ringson the
intermediateshaft during disassembly
1.

Removethe set ring.

2.

Removethe intermediateshaft outer seal from the

bearingsupport.

3.

Removethe externalcirclip.

5.

Removethe internalcirclip.

EXTERNALCIRCLIP

{)
\J
l
OUTERSEAL
Replace.
4.

SET RII{G
Rplace.

6.

Press the intermediate shaft bearing out oJ the

bearingsuppon usingthe specialtoolsand a press.

Press the intermediate shatt out to the shaft bearing using the specialtools and a press.
NOTE: Positionthe specialtools so they do not
damagethe metal ring on the shafr.

Pres!

I
INTERMEOIATESHAFT BEARING

HUB DIS/
ASSEMBLYBASE
07GAF-SD40700

16-12

Disassembly/lnspection

INTERMEDIATESHAFT RING
Checkfor damageor distonion.
INTERMEDIATESHAFT
Checkfor damage.

BEARINGSUPPORTRING
Check tor damage or distortion.

HEXBOLTS

FLANGEBOLT

INTERITALCIRCLIP

BEARINGSUPPORT
Checktor damage.

d^

@,, @
I

INTERMEDIA
ATE !SHAFT
EEARING
Replace.

EXTERNAL
CIRCLIP

0\
SET RING
Replace.

OUTERSEAL
Repl.ce.

16-13

IntermediateShaft
Reassembly
Seat the external circlip in the groove of the in
termediateshaft.

NOTE: Be carefulnot to damagethe metal ringson the

intermediateshalt during reassembly
1.

CAUTION: Installthe circlip with the taperedend

tacing out,

Pressthe intermediateshaft bearinginto the bearing supportusing the specialtools and a press

5 , Pressthe outer seal into the bearingsupportusing

the specialtools and a Press.

Pre3s
DRIVER
o7749-OO10000

CAUTION: Do not damage the lip on outer seal

duringinstallation.
NOTE: Press the seal flush with the bearing
support.

ATTACHMENT
52x55mm
07746-OO10400

Packthe interiorand
lip of the outer seal.
2 . O - 3 . 5 g ( O . 0 7- 0 . 1 2 o z l

HUB DIS/

oTGAF-SD40700
2.

Seatthe internalcirclipin the grooveof the bearing

supPort.

3.

Pressthe intermediateshaft into the shaft bearing

using the specialtool and a Press.
Pr6ss

F-t
F4

n
+*:-+
F

6,

| .,-.t

ATTACIlMENT,
35 mm l.O.

46-0030400

HUB DIS/
07GAF-SD40700

16-14

Installthe new set ring in the intermediateshaft

groove.

Steering
. . . . . . . . . . . . . . . .1. 7 - 2
SpecialToofs
General lnformation
4 W S S e r v i c eI n f o r m a t i o n. . . . . . . . . . . . . . . . . . , . .1,7. - 3
Component Location
I n d e xl 2 W S i 4 W S )
. . . . . . .1 7 - 5
Component Location
. . . . . . . . . . . . .1. 7 - 6
I n d e x( 4 w s l
System Descliption
FluidFlow Diagram
1 7- 7
1 7- 8
Steering Pump
F l u i dR e s e r v o i r / F i l t.e.... . , , ., .- . . . . .-. . . . . . . . .... . ' t 7- 9
1 7- 1 0
4-way Valve
F u l l - l o cU
k n l o a d eSr y s t e m . . . . . . . . . . . . . . . . . . .1. .7- 1 2
PowerSteeringSpeedSensor
1 7- 1 2
ElectronicallvControlled
P o w e rA s s i s t e d4 W S . . . . . . . . . . . . . . . . . . . . . . 1. .7. - 15
Troubleshooting (Power Steering
System)
. .7- - 2 5
G e n e r aTl r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . . . . - 1
..,.. 17-24
Noissand Vibration
F f u i dL e a k s
. . . . . . . . . . . . . . .1. 7 - 2 9
Troubleshooting l4WS)
. .0
C o m p o n e nL to c a t i o n. . . . . . . . . . . . . . . . . . . . . . . 1. .7. -. 3
C o n n e c t oLr o c a t i o n s. , . . , . . , . . , . , . . . . . . . . . . . . .17-31
...
Cilcuit Diagram
17-32
4WS CONTROLUNIT Terminal
17-34
Arrangement
DiagnosticTroubleCode(DTCI
17-36
Precautions
17-37
S y m p t o m - t o - S y s t sCmh a r t. . . , . . . , . . . . . . . . . . .1. .7 - 3 8
..
4 W S I n d i c a t oLr i g h tC i r c u i t. . . . . . . . . . . . . . . . . . .17-42
DiagnosticTroubleCodes {DTCS):
17-45
1 0 , 1 2 ,r 6
DiagnosticTlouble Codes (DTCsl:
1 1 , 1 3 ,1 7
17-50
DiagnosticTiouble Codes (DTCsl:
2 0 ,2 2 ,2 4 , 2 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .7. .- .5.5.
Diagnostic Trouble Codes (DTCsl:
2 1, 2 3 . 2 5 , 2 9
17-59
DiagnosticTroubleCodes (DTCsl:
17-63
30,34 ...............
DiagnosticTlouble Codes (DTCSl:
17-64
3 1 .3 5 . . . . . . . . . . . . . . .
Diagnostic Troubls Codes (DTCs):
32,36 ...............
17-66
DiagnosticTroubleCode(DTCI:33 .......... 1 7 - 6 8
DiagnosticTroubleCode(DTC):50 .......... 1 7- 7 0
D i a g n o s t iTcr o u b l eC o d e{ D T C } 5
: 1 . . . . . . . . . .1 7- 7 1
DiagnosticTroubleCodes {DTCS}:
1 7- 7 1
6 0 , 6 1, 6 2 , 6 3
Maintenance
P u m pB e l tA d i u s t m e n t. . . . . . . . . . . . . . . . ........ . . .17 - 74
On-Car Checks
R a c kG u i d eA d i u s t m e n t. . . . . . . . . . . . . . . . . . . . . . 1. .7.- 75
FluidReplacement
,..,.. 17-77
P u m pP r e s s u rCeh e c k. . . . . , . . . . . . . . . , . . , , . . ,1.7, -. 7
.4
.
S t e s r i n gW h e e fS o t a t i o n aPl l a y. . - . . . . . . - . . - . 1. .7 - 7 9

Power Assist Chsck

w i t h C a rP a r k e d
. . . . . .1 7 - 7 9
A s s i s tC h e c ka t R o a dS D e e d. . . . . . . . . . , . . . . . . 1. .7 - 8 O
Power Steering Speed Sensor
Replacement
. . . . . . . . . .1 7 - 8 0
Steering Wheel
R e m o v a, l. . . . . . . . . , . .
. . , . . . .1 7 - 8 1
D i s a s s e m b l y / R e a s s e m. .b.l.y. , . . . . . . . . . . . . . . .1.7. - 8 3
Installation
2 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .7. -. 8
. .4. . . .
4 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 7
. .-.8. .6. . . .
SteeringColumn
R e m o v a.l. . . . . . . . . . . .
. . . . . . .1 7 - 8 9
. . . . . . . . . . . . . . . .1. 7 - 9 2
fnsoection
Installation
. . . . . . . . . . . . . . .1. 7 - 9 3
SteeringPump
17-96
Beolacement
P u l l eR
y e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . .1. 7
. .-.9. .6
Flow Control Valve Insoection
17 -97
and Rsplacement
17-99
Disassemblv
lllustratedIndex
17-102
17 - 1 0 3
Ass6mblv
Steering Gearbox
l n d e x. . . . . . . . . . . . . . . . .
. . . . . . .1 7 - 1 0 5
. . . . . . . . . .1 7 - 1 0 6
V a l v eB o d yU n i r
. . . . . . .1 7 - 1 1 4
G e a r b o xR e m o v a l
. . . . . . . . . .1 7- 1 1 7
l l f u s t r a t sfdn d e x
O v e r h a u.l. . . . . . . . . . .
. . . . . . .1 7 - 1 1 8
. . . . . . . . . . . . . . .1. 7- 1 3 4
fnstallation
Rear Steering Actuator (4WS)
f f f u s t r a t efdn d e x
. . . . . . . . . .1 7 - 1 3 7
R e m o v a. l. . . . . . . , . . . .
. . . . . . ,1 7 - 1 3 8
Disassembly
. . . . . . . . . . . . .1. 7 - ' l 4 O
. . . . . . . . . . . . . . .1. .7. - 1 4 1
Asssmbfv
fnstallation
. . . . . . . . . . . . . . .1. 7- 1 4 4
4WS Control Unit
R e m o v aal n dl n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . . ' l7 - 14 5
Tie-rod End Boot
. . . . . . . . . . . . .1. 7 - 1 4 5
Replacement
4WS System Inspection
E l e c t r o n iN
c e u t r aC
l h e c k . - . . - - . . . . . - . . - . . - . . -1.7. .- 1 4 6
4WS System Adiustment
4 W S S y s t e mA d j u s t m e n t. . . . . . . . , . . . . . , , . . , . . .7. '-l 15 1
Sub SteeringAngle Sensor
. . . . . . . . . . .1 7 - 1 5 3
Adjustment

S p e ci a l To ols

Ref. No.

o
(;\

DoscriDtion

Tool Numbel

Oty

Page Relerence
17 - 1 0 8
17-74
1 7- 1 2 5
1 7- 1 2 5
1 7- 1 2 6
17 15,76, 132
1 7- ' t1 4 , 1 3 4
17-74
1778
1 7- 1 4 0 , 1 4 2
17-4,144, 150,
15 6 . 1 5 7
17-80

Hub Dis/AssemblyBase
Belt TensionGauge
PistonSeal Ring Guide
PistonSeal RingSizingTool
CylinderEnd Seal Slider
LocknutWrench, 43 mm
BallJoint Remover,28 mm
P/S Joint Adapter {Pump)
P/S Joint Adapter(Hose)
Rack Holdr
RearSteeringCenterLock Pin

1
'I

OTGAF SD40TOO
oTJGG-OO10100
OTLAG_SM401OA
OTLAG SM402OA
OTLAG SM403OA
o7t\4AA-SLOo20A
oTMAC-SLOO200
'IA
O T N A K S R 3 O1
OTNAK_SR3012A
oTNAB-SSOO100
OTNAJ_SSOO2OA

07406-OO10101

BypassTube Joint
( l n c l u d e dw i t h 0 7 4 0 6 - 0 0 1 O O 0 1l
P/S PressureGauge
PressureControlValve
PressureGauge
UniversalHolder
Attachment,37 x 40 mm
Attachment,42 x 47 mm
Driver
DriverAttachment
Hub AssemblyGuideAttachment

aa)
@
Lcf

@
,G)

@
@-1
@-2
@

(t

@
@
@
@

o7406-OO10001
o7406-oo10300
07406-OO10400
o7725-OO30000
o7746-0010200
07746 0010300
07749-OO l OOOO
o7947-6340500
o7974-6920500

o
/g)

\Z'cfp
@

/t-\

i=
@@

7-2

1
1
1
I
I
1
1
I
1

1
1
1
1
1
1
I
1
1

17-78
1 7- 7 I
1 7- 7 4
'17-96
17-103
1 7- 1 2 0 , 1 2 3
1 7- ' t2 3
17-103
17,145

GeneralInformation
4WS ServiceInformation
On modelsequippedwith the electronicallycontrolledpower assisted4WS (4-wheelsteeringsystemi, note the foliowing specialprecautionsbefo.e service.
a After performingthe following operations,check and adiustthe 4WS systemto be sure that it is electronicallyand
mechanicallyin neutral(all 4 wheels in properalignment).

Operation

Check for
mechanical
neutral

Rack guide adjustment

Steeringwheel replacement

o
o

Steeringcolumn removal/installation

or
Front steeringgarboxremoval/installation
dissssemblv

Rearactuatorremoval/installation

Steeringwheel removal/installation

Ffont/rearsub steeringangle sensor

removal/installation
Front msin steeringangle sensor
removal/installation
Rearmain steeringanglesensor
removal/installation

Checkfor
electronic
neutral

Relerence
page
1 77 6

1 7 - 8 ' ,l 8 6

o
o
o
o

17-86
17 89, 93
17 - 11 8 , 13 1
17 137

1 7 - 1 1 7 1, 3 7

1-t -92

17 137

in neutralfor Woperoperation.Performthe following

a Th6 4WS Systemmust be ( l ) mechanicallyand (2) electronically
mechanicalneutralcheck on the system and adjustas necessaryfirst, then performthe followingelectronicneutral
check and adjust as necessary.(4WS system adiustmeni:see page 17-151 )
(l) Mechanicallyneutrsl:
Be surethat the front and rearwheelsalignpfoperlywith the steeringwheel in the straightdrivingposition(i.e.dif
ferencein computerizedfour wheel alignmentequipmentreadingbetweenthe right and left wheels is within 0.5
mm/O.02 inl.
{2) Elctronicneutral:
in neutralwith the steeringwheelin the straightdrivingposition.
Be surethat the tollowingsensorsare electronically
Electronicneutralpositionis indicatedby blinkingor lightingof the 4WS indicatorlight.
Front Main SteeringAngle Sensor
Front Sub SteeringAngle Sensor
Rear Main SteeringAngle Sensor
RearSub SteeringAngle Sensor

4ws tNDtcaToRLtcHT
I
.

,..

I
at{rt4-

( c o n t ' d)

7-3

Generallnformation
4WS Service lnformation (cont'd)
o It the spokesngleof steeringwheel is not atthe designatedanglewhiledrivingstraight,checkwhetherit was caused
simply by an improperlyinstalledsteeringwheel or by the misalignmentof the lront and rear wheels. Check the
wheels for properalignmentbefore adjustingthe steeringwheel spoke angle.
Installtherearsteeringlock pin in the rearactuatorand. with the steeringwheelin the straightdrivingposition,check
the wheelsfor properalignment(i,e.differencein computerizedfour wheelalignmentequipmentreadingbetweenthe
right and left wheels is within 0.5 mm/0.02 in).
Checkthe sensorsfor electronicneutralto be sure that the rearwheels are in correctsteeringanglewhile driving.
a Do not contaminatethe front and rea. sub steeringanglesensors,front and rearmain steeringanglesensors,and the
rear steeringactuatormotor terminalswith mud, oil, and grease.
a Thephrase"the steeringwheel in the straightdrivingposition" meansthat the front wheels are in the straightdriving
positionwith the steeringwheel spokesat a horizontalangle.
a lf the power to the 4WS controlunit was shut down for the followingoperations,start the engineand turn the steering wheel tully right and left before checkingand adjustingthe 4WS system.
- Battery removal/installation
- 4WS control unit removal/installation
- No,43 fuse CLOCKRADIOremoval(in the under-hoodfuse/relaybox)
CAUTION;
a The roar whoel steoring angle is not controlled when the engine is OFF. When the engine is staned, the rear
whaels aro ste6r6d to an angle in accordancewith the front whoelangle. We recommendthat the steering system
b6 sorviced wilh the steering whoel set in th6 straight driving position,
a Do not st8n the engino with the lock pin sot in the rear acluator. The rear actuator might be damaged whsn the
rear whools aro steorod. Bo surs to removs ths lock Din after service.

CAPBOLT
22 N.rn
12.2kg-m.16 tb-ftt

17-4

SEALINGWASHER
Replace.

ComponentLocation
Index (2WS/4WS)
NOTE: lf an intact driver's airbag assemblyhas been removedfrom a scrappedcar or has been found defectiveor
damagedduringtransit, storageor service,it shouldbe deployed{seesection23}.

STEERINGWHEEL
Removall2WS/4WS).page 17'81
page 17-83
Disassembly/Reassembly,
Installation{2WS}, page 17-84
Installation{4wS}, page 17-86
STEERINGCOLUMN
Removal,page 17-89
Inspection,p6ge 17-92
Installation,page'l7-93
FRONTMAIN STEERING
ANGLE SENSOR{4WSI
Adiustment,page 17-15'l
IGNITIONSWITCH
Steering Lock Replacomentand
Swirch Test, see ElectricalSection
STEENI G GEARBOX
RackGuideAdiustment(2WS/4WS),pago 17-75
Removal,pge 17-114
Index,page 17-1 17
Ovrhaul,page 17-118

POWERSTEERINGSPEEDSENSOR
Rgplscement,pag 17-8O
TIE.RODENO
BallJoinr Eoot
Replacement,
p g a e1 7 - 1 4 5

VALVEBODYUNIT
Ovsrhaul,page 17-106
FROI{T SUB STEERING
ANGLE SENSORI4WS)
Adiustment,
p a g e1 7 - 1 5 3
FLUIORESERVOIR
FluidReplacement,
page 17 77

STEERINGPUMP
Pump Belt Adjustmenr,page 17 74
page 17-77
FluidRepfacement,
PumpPressureCheck,page 17-78
page 17-96
Pump Replacement,
page 17-97
ControlValve Inspectionand Replacement,
page 17-99
Disassembly,
page 17-103
Reassembly,

17-5

GomponentLocation
Index (4WSl
4WS COTTROL UI{IT
page | 7-145
Removal/lnstallation,
4WS SYSTEM I SPECTION.nd ADJUSTMET{T
Inspction,page 17-15'l

RACK EI{O
Removal,page 17-138
page 17-144
Installation,

REARSUB STEERINGANGLE SENSOR

Adjustmenl,page 17 155
Romoval,page 17 138
page 17-141
Installation,

REARMAIN STEERINGANGLE SENSOR

R e m o v a lp, a g e1 7 1 4 1
fnstaflation,page 17'1 42
TIE-RODEND
Boot Replacement,
p a g e1 7 | 4 5

REARSTEERINGACTUATOR
lllustratedIndex,page 17-137
ActuatorRemoval,page 17-138
Actuator Dissssembly, Page 17-140

17-6

SystemDescription
FluidFlow Diagram
the fluid and deliversit through a high
The reservoirsuppliespower steeringtluid to the pump; the pump pressurizes
pressurehose to the valve body unit on the gearbox.
The 4-way valve {in the valve body unit) controlsthe directionof the turn by shiftingfluid to the left or right side of the
piston on the rack {in the power cylinder).
The gain control valve jn the valve body unit controlsthe amount ot the assistby regulatingthe stroke of the 4 way
valve.The operationot the gain controlvalveis atlectedby the fluid pressure,which is regulatedby the pressurecontrol
valve, sensororifice and power steeringspeed sensor.
Constant pressureis generatedby the pressurecontrol valve. This pressureis used as a referencepressuretor the
responseto the car speed.By introducingthis pressureto the power steeringspeedsensorthroughthe sensororilice,
the pressuredownstreamol the orificeis changedaccordingto the speedof car. This pressureis then used to operate
the gain control valve.Two orificesare pfovidedaroundthe circumferenceof the gain controlvalve.Theseorificesprovide th steplessreductionof the pressuretrom the pump accordingto the changesin the car speed.The reduced
pressu.eis then sent to the reactionchambers.Theretorethe assistvariesby regulatingthe lluid pressurein the valve
body unit accordingto the speedot car.
FIuidretrrrninglrom the power cylinderflows back throughthe 4-way valveand out to the reservoirthroughthe cooler.

VALVE EODY UNIT

tr---------SENSORORIFICE

------l
PRESSURE
CONTROL
VALVE

RESERVOIR

GAIN CONTROLVATVE
REACTIONPLUNGER

a-say y4s-ys{

GEARBOX
I
I

CYLINDER
FLOW CONTROLVALVE
lhas s built-in reliel valvel

WHEEL
STEERING

7-7

System Description
Construction
The pump is a vane-typeincorporatinga tlow controlvalve(with an integratedreliefvalve)and is drivenby a V-beltfrom
operationslor every rotationof
the crank pulley.The pump features1Ovanes.Eachvane performstwo intake/discharge
th rotor. This meansthat the hydraulicfluid pressurepulse becomesextremelysmall duringdischarge.

FLOW CONTROLVALVE

DRIVESHAFT

Operation
pressureis appliedto
The belt-drivenpullevrotatesthe rotor throughthe drjve shaft. As the rotor rotates,the hydraulic
of the cam rlng'
circumference
pushed
inner
onto
the
being
the vane chamberof the rotor and the vaneswill rotatewhile
so the rollers
the
shaft,
of
the
center
portion
respect
to
with
extended
The inner circumterenceof the cam ring has an
volume
of the
the
internal
roller
movement,
this
result
of
As
a
carrier
rotates.
the
direction
as
move downward in the axial
vane chamberwill change,resultingin fluid intake and discharge

START OF FLUID INTAKE

FLUID INTAKE

FLUIDMOVEMENT

FLUIDDISCHARGE

The volume of the

chamber increases so t h a t
tluid is suckedin.

The sucked-in fluid moves

toward the discharge port,

As the vanes return to the

their original position on the
inner side, the volume of the
vane ch6mber decreases so
the fluid is discharged from
the discharge pon.

INLET
POBT

The vanes are pushed onto

the inner circumferenceof
the cam ring.

17-8

Fluid Reservoir/Filter
Flow Control
Fluidtrom the pump runs through a meteringorificeto
the valve body unit. This createsa pressurediJference
between the pump and valve body unit sides of the
orifice.When pressurein the pump side is higherthan
the force ot the spring holdingthe flow control valve
closed, it pushesthe valve down (openl, and excess
fluid returnsto the Dumoinlet. The combinedetiect ot
the metsringoriJiceand the flow controlvalve provides
a relativelyconstantflow of Jluidto the valvebody unit.

A one-piecereservoirand filter is attachedto the tender

apron on the left side of the enginecompartment.The
fluid and the filter/reservoirshould be replacedif the
system is openedfor repairs,or if the fluid gets water or
dirt in it.
CAUTION: Use only Honda Powsr sleering
Fluid-V,The use ot othel fluid such as A.T.F., or
othor manufacturor's power stsering fluid. will
cause damago to the system.

METERING
ORIFICE

<To Valve bodv Unit

Steering
SpeedSensor

ProssureRelief
As prssureon the valve body unit side builds up, it
pushes the relief valve ball (inside the tlow control
valve)up againstits spring,and excessfluid returnsto
the pump inlet. As the pressureunderthe flow control
valve drops,the reliefvalve ball is closedby its spring,
and the flow control valve is forced down again.allowing excesslluid from the pump side to returnto the inlet. This tlow control valve-reliefvalve cylinder keeps
pump output pressure between TOOO-8OOO kPa
( 7 O - 8 0 k g i c m ' .9 9 5 - 1 , 13 8 p s i ) .

From Valve body Unit

<r
To Steering Pump

RELIEFVALVE OPEN

RELIEFVALVE EALL

1 7- 9

System Description
4-Way Valve
Mountedon ihe lower sideof the gearboxis a 4-way valvethat is movedhorizontallyby a pin on the pinionholderto shift
tluid pressureto the right or left side of the power cylinderwhen the steeringwheel is turned.
reactionchambers,one on each side.
It has thrust pins at both ends, and two inter-connected
plungersthat rise againstright and lelt thrust pins.
Eachreactionchambercontainsa pair of spring-loaded
The valve body fluid passagesare controlledby the 4-way valve.
Fluidpressurein the reactionchambersis reducedby the gaincontrolvalvein orderto changethe amountof the assistin
accordancewith the changein the car's speed

VALVE BODY UNIT

SENSORORIFICE

RESERVOIR

GAIN CONTROLVALVE

4-WAYVALVE+

l r >

matl ontrtce

i ----------JJ-l-

L________
FLOW CONTROLVALVE
lha! I built-ln toliot valvo)

+WAY VALVE

17-10

POWERCYLINDER

In the power steeringunit, the methodusedto directa singlesourceot fluid pressurein eitherof two directions(for left or
"message" oJ directionto the tluid in the 4-way valve
right turns) involvesthe piniongear transferringa
pair
pinion
in
a
ot
bearings,which are in turn mountedin a pinionholdercylinderthat
is mountedslightlyoff-center
The
rotates,centeredin its own outer bearings.At the bottom ol the PinionHolderis a pin, which fits in a slot in the 4-way
valve.
As the pinionis turned (to turn lett or right),becauseit is off-center.it alsomovesslightlyalongthe rack.This movement
is transferredto the holder.The pin in the holderthen movesthe 4-way valve,to directfluid pressureto eithersideof the
rack in th power cylinder.
The bsck edgesot the pinionholder(facingaway lrom the rack)hit the stopscast into both sidesof the gearhousingto
avoidpushingthe 4-way valvetoo far in eitherdirsction,The tront edgeof the pinionholdercuts off assistat full lock as
describedon the next page.

POWERCYLINDERS

NEEDLEROLLER
BEARIG

STEERINGRACK

BALL BEARING
Plt{

+WAY VALV
HOLOEB

4.WAYVALVE

RACK

1 7- 1 1

System Description
Full-lockUnloaderSystem
The 4-way valveshifts the directionof fluid flow when
the steeringwheel is turned right or left.
However,when the wheel is turned to the right or left
lock at parking speed, the edge of the pinion holder
ridesup on the end of the rack, movingthe pin in the opposite directionwhich pulls the 4-way valve back to
nsutral.
This keeps pump pressure from building up (which
could cause idl speedto drop), and improvessteering
leel by increasingresistanceat left and right lock.

Power SteeringSpeedSensor
The power steering speed sensor is a trochoid-rotor,
hydraulicpump combinedwith a reliefvalveand a oneway valve. lt is driven by the speedometergear shatt
which in turn is driven by a helical gear on the
differential.

INNERROTOR
OUTERROTOR

ONE-WAYVALVE
Controlin "assist" position

SPEEDOMETER
GEAR
The power steeringspeed sensorturns only when the
car is moving.controllingthe gain control valve.
The constant pressureis generatedby the pressure
conlrol valve.

4-way valve moves back to "neutral" position

This pressureis used as a relerencepressurefor the

response to the car's speed. Bv introducing this
pressureto the power steeringspeed sensor through
the sensor oritice, the pressuredownstream of the
orifice is changedaccordingto the speedof the car.
PRESSURECONTROLVALVE
To power steeringspeedsensor

Pressurein response
to vehiclespeed
FEEOSIDEORIFICE

17-12

With the engine running at idle in a parked car, fluid

flow through the sensor rotors is blockedbecausethe
rotors are not turning.Theretorethe gain control valve
movesto the left. On the gain controlvalve.the oritice
resistanceis high on pump side, while it is low on the
reservoirside, with the resultthat pressurein the reaction chambe,is loweredand steeringassist is high.

When the car is moving at high speed, the sensor

reducesthe pressureturther and the gain control valve
moves furthsr to the right. The orifice pressureon the
pump side is low and the pressureon the reservoirside
is high,the fluid pressurein the reactionchamberis also
high giving the steeringwheel less assist.
Hydraulic prossurein response
to the car's speed(Lowl

FEEDSIOEORIFICE
RESERVOIRSIDE OiIFICE

Hydraulic pressurein
responseto thg car's
speed{High}

RETURl{
RETURN

GAr{ CO|{TRO|VALVE
Pressurein reaction
chamber(Low)

As th car is driven.the rotorsstart turningand the fluid

returns to the reservoir, reducing the fluid pressure at
the gaincontrolvalve.Theretore,the gain controlvalve
bsginsto move to the right. The orifice resistanceon
the pump and reservoirsidesis appropriatelybalanced,
with the result that the reaction chamber is in the
mediumrangeand the steeringresistanceis moderate.

in reaponse
HvdraulicPressure
ro the car'ssDeed(Mdium)
SIDEORIFICE FEED
RESERVOIR

REACTIONCHAMBER

(cont'd)

17-13

System Description
PowerSteeringSpeedSensor(cont'd)
One-wayValve(ln PowerSteeringSpeed
Sonsorl
Wh6n the car is moving at high speed, negative
pressure develops at the sensor inlet because the
power steeringspeedsensoris pumpingfasterthan the
fluid can be supplied.To compensatefor this, the outlet
and inlet ports are connectedinternsllyby a passage
containinga one-way valve that lets output tluid recir
culate to the inlt pon to equalizepressure.

ReliefValve (ln PowerSteeringSpeedSensorl

When the car is moving in reverse,the power steering
speed sensor also turns backward and pumps tluid in
the oppositedirection.To avoid buildingup pressurein
the reactionchambersthat would increasesteeringefton while driving in reverse,the inlet and outlet-ports
are connectedby a secondinternalpassagecontaining
a relief valve that allows the tluid to recarculate.

Driving in Reve.se:

Driving at Hlgh Speed:

ONE.WAYVALVE

ROTORS
RELIEFVALVE

17-1 4

ElectronicallyControlledPower Assasted4WS
Outline
The electronicallycontrolledpower assisted4WS (4-wheelsteeringsystem)consistsof the hydraulicpower steering
systemthat steersthe front wheels,the rearactuatorthat steersthe rearwheels,the 4WS controlunit, and the sensors
that detectthe car's speedand othersteeringconditions,The front steeringgearboxandthe rearactuatorare connected
by a wire harness.The rearsteeringangleis controlledelectrically,allowingthe rearwheelsto be set at any desigrated
steeringangle.

FRONTMAIN STEENINGANGLE SENSOR

VEHICLESPEED

17-15

System Description
ElectronicallyControlledPower Assisted 4WS (cont'd)
System Operation
The 4WS control unit receivesinput from the VehicleSpeedSensor(VSS),front main steeringanglesensor,and the
f.ont sub steeringanglesensor.The 4WS controlunit calculatesthe vehiclespeed,steeringturningangle,steeringspeed
and steeringdijectionto determinethe best angleto steer the rear wheels.

(System opration flow)

VSS ggrves the soeedmeter as

well.

Front main st66dng angle sgnsol

Front gub stooring angl sonaol

C.lculation ot steoring rotation speed

Calculation of the
car's apggd

Calculation ot stooring angle lor toar whgels

4WS Control unit

17-16

The rear wheels are turned by a motor built into the rearsteeringactuator.The motor is activedby the power circuit in
the 4WS controlunit. The actualsteeringangleof the rearwheelsis detectedby the rearmainsteeringanglesensor,and
the rearsub steeringanglesensor.The 4WS controlunit adjuststhe angleaccordingto the differencebetweenthe sensed steeringangle of the rear wheels and the targetedsteeringangleof the rear wheels.

FRONTMAIN STEERING
ANGLESENSOR
SENSOR

REARSUB STEERING
ANGLESENSOR

REARSTEERINGACTUATOR
FRONTSUB STEENING
ANGLE SENSOR

4WS CONTROLUNIT

REARMAIN
STEERINGANGLE
SENSOR

( c o n t ' d)

1 7- 1 7

System Description
ElectronicallyControlledPower Assisted 4WS {cont'd)
System Operation
Featuresol rear wheol steering:
The electronicsllvcontrolledpower assisted4WS sets the rear wheels at the best steeringanglelor the car's speed,
steeringrotationspeed,steeringwheel angle,etc.
a Car speed
When the car is travelingat low speed,the 4WS systemturns the rearwheelsin the reversedirectionof the front wheels
in proportionto the rotationangleof the steeringwheei. When the car is travelinga higherspeed,the system increases
the steeringangle of the rear wheels in the same directionas the front wheels.
Changingthe steeringangleperformanceof the rearwheelsin relationto the car's speedgivesthe car improvedhandling
characteristics.
a Steeringspeed 18 mph (3O km/h) or above
The rear wheel steeringanglevarieswith how rapidlythe steeringwheel is rotated.See graph

lSto6ring angl/sped
portoamancocuwol

Slow st6.ing

Rapid stooring

0. 5
200
0
-0. 5

17-18

100

300

400

Component Function & Operation

Roa?actuator:
The rearactuatoris mountedat the rearoI the car to steerthe rearwheels.The motor, built into the actuator,is madeup
of a stato. with a permanentmagnet. a rotor. and brushesthat pass electricjtyto the commutators.The motor is
mountedon the sameaxis as the steeringshaft screw, makingthe rearactuatorcompactand light in weight. The rearactuato. also containsthe rear main steeringanglesensorand the rear sub steeringanglesensor.
The 4WS control unit drivesthe electricmotor with DC current.lt switchesthe currentpolarityto changethe motor's
direction.Two strong return springs,one at each end ot the actuator,providea centeringaction.They returnthe rear
wheelsto the straight-aheadpositionwhenevercurrent is cut to the motor.
REARSUB STEERING
ANGLESENSOR

ACTUATORHOUSING

STATOR
REARMAIN STERING
ANGLESENSOB

RETURNSPRING

COMMUTATOR

STEERII{GSHAFT SCREW

BRUSHES
ROTOR

RECIRCULATING
BALL SCREW
<RETURN SPRINGOPERATION>
Mov6s to lft:

Moves to right:

The return spring compresseswhen the steeringshaft

screw moves to right or left. When the motor is OFF,
the stesring shaft screw is held in the straight ahead
(neutral)positionby the force oJ the return spring.
{cont'd)

17-19

Maintenance

Back-upLight Switch

Transmission
Oil

Replacement

NOTE:Checkthe oil with the engineOFF,and the car on

levelground.
1.

NOTE:Checkthe switchseesection23.
1.

Disconnectthe back-uplight switch wire connecrors.

2.

Removethe back-uplight switch,

3.

Installthenew washerand back-uplight switch,

Removethe oil tiller plug, then checkthe level and

conditionof the oil.
WASHEN
Replace.

ProperLevel.

OILFILI.IRPLUG
45 N.m(4.5kg-m,33lb-ftl
2.

The oil levelmust be up to the fill hote.lf it is below

the hole, add oil until it runs out. then reinstallthe
o i l f i l l e rp l u g .

3.

l f t h e t r a n s m i s s i o no i l i s d i r t y , r e m o v et h e d r a i n
p l u ga n dd r a i nt h e o i l .

4.

R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d
refillthe transmissionoil to the properlevel.
NOTE:The drain plug washershouldbe replacedat
everyoil change.

5.

Reinstallthe oil filler plug with a new washer.

Oil Capacity
1.9/ 12.0US qt, 1.7lmp qtl ar oil chango.
2.0 / {2.1 US qt, 1.8 lmp qtl at overhaul.

Useonly SAE 10 W - 30 or 10 W - 40,SF or SG grade.

OIL FILLERPLUG
'15N.m (4.5kg-m. 33 lb-ft)
WASHER
Feplace.

13-3

System Description
ElectronicallyGontrolledPower Assisted 4WS (cont'd)
Component Function & OPeration
Front main stso.ing anglg sensor:
The front main steeringanglesensoris mountedin the
stee,ing column. lt senssthe directionand angle of
steering wheel {otation and converts it to electrical
signalsthat are sent to the 4WS control unit.

CIRCUIT

Roal main stedng angle 9en9o1:

The rear main steeringanglesensoris mountedon the
rear actuator. lt sensesthe directionand angle of the
rear wheels and sendssignalsto the 4WS control unit.
The 4WS controlunit usesthis informationas feedback
to determineif the actual rear wheel positionmatches
the desiredDosition.

17-20

HALL IC

MR ELEMENT

MR ELEMENT

HALL IC

Front tub stoering angl snsor:

The front sub steeringangle sensoris mountedon the
front stgering gearbox. lts purpose is to detect the posi
tion of the front wheels and convert this inJormationto
an slectrical signal for the 4WS control unit.
The front sub steering angle sensor uses a springloadedplungerthat ridesin a slopedgroovein the rack.
As ths rack turns the tront wheels,the plungerridesup
the slope and is pushed into the differential transformer
assembly.The plunge.'spositionis used to determine
how tar the rack is turned.

FROI{T SUB STEERINGANGLE SENSOR

STEERINGRACK

Rgar sub gtoodng anglg aensor:

Th6 r6a. sub steeringangle sensor is mounted on the
rear actuator spring cover. lts detects the position oI
the rear wheels as a feedbacksignalfor the 4wS contrcl unit. lt ogerates in exactlv the same wav as the
front sub steering angle sensor.

11-21

System Descripton
ElectronicallyControlled Power Assisted 4WS {cont'd)
Componont Function & Operation (cont'dl
a Average moving curent control
The 4WS controlunit monitorsthe averagemovingcurrentol the motor to protectthe system.Whenthe averagemoving currentexceedsa given value,the 4WS control unii lowers the currentto changesteeringangleof the rear wheels
graduslly(approximately6 degrees/3osecondsl.When the averagemoving currentto the motor is below the given
value,the rear wheels returnto the designatedsteeringangle slowly {approximately6 degrees/2minutes).
a Over-voltage control
An increasein battery voltage (due to a voltageregulatorfailure,for example)could causeexcessiveactuationof the
motor and grraticcontrolof the rarwheels.To preventthis, the 4WS controlunjt monitorsthe voltage.lI it exceedsa
givenvalue,the 4WS controlunit slowly returnsthe rearwheelsto the straightaheadpositionby reducingvoltageto the
motor and turns the 4WS indicatorlight ON.

17-2 2

Fail-satFunction:
When the 4WS controlunit sensesa tailurein the system,it switchesto fail-safemode. In this mode, it powersthe tailsafe and damper relays.The fail-salerelay cuts power to the rear steeringmotor, while the damper relay slows the
motor's returnto neutral.As a result,the rearwheelsreturnslowly to the straightaheadpositionand then remainthere.
The car then drives like conventional2WS.
When the 4WS control unit switchesto fail-safemode, it storesa DiagnosticTroubleCode(DTC)and turns on the 4WS
indicatorlight to notify the driver of a problem.This code can be read by connectingthe servicecheck connectorter
minals with a iumoerwire under the dash. The code is read as blinksof the 4WS indicatorliqht.

4WS INDICATORLIGHT

..

;=;

=' i

-:-

="1

Flr,\-n-'Puf

:a.

JUMPERWIRE

Damper Control:
When the system goesinto fail-safemode,it cuts power to the motor by poweringthe fail-saferelay.Without sometype
positiontoo rapidly,adverselyatlecting
of damping,the returnsspringswould turn the rearwheelsto the straight-ahead
the car's handling.
To counteractthis, the 4WS control unit also powersthe damperrelay.The armatureo{ the now deactivatedmotor is
spun by the movementof the steeringshaft. This causesthe motor to act as a generator.The voltagegeneratedby this
action is appliedback to the motor throughthe damperrelay.This causesthe motor to resistthe force ot the returnsprings. allowingthe rear wheels to go back to the straightaheadpositionslowly.

1 7- 2 3

System Descripton
ControlledPowerAssisted4WS (cont'dl
Electronically
Componont Function & Operation (cont'dl
a Elctronic neutral Position
ln other
For the 4WS system to work correctly,it must be in elctronicalignmentas well as mechanicalalignment
w o r d s , t h e s Y s t e m , s ' r o n t a n d r e a l s e n s o r s m u s t S i g n a | t h a t t"electronic
hewhee|sarepointedstraightaheadwhenthewhee|sare
straightahead" by connectingthe service
mgchsnicallypointedstraightahead.The techniciancan test tor
rear
wheels'
front
and
turning
the
wire
and
with
a
terminals
ch6ck connector
iumper

17-24

Troubleshooting(PowerSteeringSystem)
GeneralTroubleshooting
Check the following betoreyou begin:
a
a
a
a
a
a

Has the suspensionbeen modifiedin a way that would affect steering?

Are tire sizesand air Dressurecorrect?
ls the steeringwheel originalequipmentor equivalent?
ls the power steeringpump belt properlyadjusted?
ls steeringfluid reservoirfilledto properlevel?
ls the engineidle speedcorrect and steady?
HardSteering

Littleor no assistin both directions

with car parked.

Assislin one directiononly, littleor

no assistin the olher.

Check for bubbles in power steering fluid.

Remove the valve body unrt and

check the pinion pin for free movement. lf OK, check lhe 4 way valve
for free movement (see page
1/,107|.
Repair as necessary.

l{ there are no bubbles, check i{

assist improveswhen engine speed
is increasedlC| 3,O00 rpm.

lf assistimproves,checkthe pump
flow control volve lor internal leak'
ing, and clean or replace as
necgssary(seepage 17-98). lf the
valve is OK, replacethe steering

It there are bubbles, check the

reservoir inpul side hoses and
pump front seallor air leaks.
Repairas necessary.

lI assist does nol improve,check

tluid pressure,using power steering pressure gauge with shut off
valve closed(seepage 17-78).

Fluid pressurebelow 7,000 kPa

(7O kglcm2, 995 psi).

Fluid pressure7,00O 8.O00 kPa

l 7 o - 8 0 k s l c n ' . 9 9 5 - 1 .1 3 8 p s i ) .

Checkthe pump flow controlvalve

Ior internal leaking,and clean or
replace 6s necessary {see page
17-98). lf the valve is OK, replace
the pumP.

The pump is OK. Measurethe force

requiredto turn the wheel with the
speed sensor hose plugged and the
car parked (see page 17 79).

Steeringeffort above30 N (3.0 kg,

6.6 lbs)- Check the pressurecon'
trol valve for stickingor a clogged
orifice; clean or replacethe valve
as necessary(seepage 17'107). lf
the pressurecontrol valve is OK,
checkthe pinionpin for free move_
ment. lf seizedor bindingoverhaul
the steeringgearbox,

Steeringeffon below 30 N (3.o kg,

6.6 lbs).The power steeringspeed
sensoris leakinginternallyireplace
the power steeringspeed snsor
( s e ep a g e1 7 B 0 ) .

(cont'd

17-25

Troubleshooting(PowerSteeringSystem)
GeneralTroubleshooting(cont'd)
Beltslippingon the pulley.

Adiustthe belttension.Replace
the belt,iJ necessary(seepage
17-141.

Checkgaincontrolvalve;clean
or replacethe gaincontrolvalve
or valvebodyunit.

ldle speed low or erratic.

lI the enginestallswhen wheel

is turnedwhilecar is stoppedor
movingat low speed,adjustidle
speed(seefuel section).

rough ataering.

Air in reservoirtank, o. low

powersteeringlluid level.

Check power steeringfuid level,

lf levelis excessivelylow. check
for leaks in the system. Add
tluid to the soecitiedlevel.

It fluid levelis OK, check O-rings

and sealson both ends ot the
pump inlet hose, and the oil
pump housingmatingsurfaces
tor suctionleaks.ReDlace
Darts
as necessarv.

Adjustthe rackguide(seepage
1 7 75 r ' .

lf the rack guide adjustmentis

OK, check the pinion bearings
for wear or damage. Replace
them as necessary.

7-26

Shock or vibrationwhen wheel

turned to tull lock.

Assist (excessivelylight steering)at

high speed:

Pump belt slipping on pulley

(pump stops momenlarily).

Adiustthe belttension(seepage
17-74)or replacebelt.

Set the powersteeringpressure

gauge.Closethe shut-offvalve
fully and measurethe pump
p.essure(seepage17 781.

The pump pressureshould be

7,000 8,000 kPa (70 80
k g / c m ,9, 9 5 - 1 , 1 3 8p s i )w i t h
needle fluctuation of t 5OO
k P a ( t 5 k g / c m , ,a 7 0 p s i )o r
l e s s .l l t h e n e e d l ef l u c t u a t i o n
exceeds :t 5O0 kPa (t 5
kg/cm' ,:t 70 psii checkthe
f l o w c o n t r o vl a l v e ,o f t h e J l o w
controlvalve is OK, replace
the pump.

Measureforce requiredto turn

wheel with bypass tube joint
installed, and car parked on
dry paved surface (see page
17-80).

lf below, check gain con

trol/pressure control valves
and valve body unit and
replace parts as necessary.

Adjust the belt tension (see

page 17 74l' or replacebelt.

Steering kicks back during wide

turns.

Wheel will not return shoothlv.

Sticking gain control valve or

valve body unit.

Replace the gain control valve

or valve body unit.

Rackguideadjustedtoo loose.

Adjust the rack guide (see

page 17 751.

Readjustthe front wheel align,

ment or replace parts as
necessary.

1 7- 2 7

Troubleshooting(PowerSteeringSystem)
Noiseand Vibration
NOTE:PumDnoise in first 2-3 minutesafter starting in cold weather (-2o'c,

-4oF or colder)is normal

Hummingdue to pulsationof fluid is normal,particularlywhen wheel is turned

wilh car stopped.
lf equipped with autolnalic
the hum couldbe tortransmission,
que converter or pump noise,

Confirm by temporafily removrng

pump bert.

High p.ssure
lrame.

R e p o s i l r o nl h e f i n e .

line touching

lhe

Pinion shaft seal nol lubricatod

Horn contact nol lubricaled, or

Grease the conlacl, or bend rl to

reduce tne pres3ure.

"clunk" maY bo e notmal amount of linkageclearance'To

NOTE: A sangte
this
lyp
ol clunk, turn th wl|el back and lorth with lhe engineOFi
distinguish

Loosc pump pully.

Tighten or replace pulley

ll sh6lt is loose, raplacelh pump.

Rattle or chr(e.ing
Loos6 sleerinO shtfl conn6ctor, ti6_
rod, or ball pant.

Check and tighlen, or teplace gans

Columnshaft wobbling.

Replacethe columnassemblY.

Lines or hoses from the valve bodY

unit louching each other.
Noise from valve body unil.

Pump gea. norse

NOT: Pump noise up to 2-3

mrnutes afler starting in cold
weather (-2OoC, -4oF or colde.)
Compere pump norse at ope.atrng
lemperalure to another car

Gratrngdorselrofi pump

lf pump noise is abnormallyloud,

check the pump ball bearingand
any parts.(seepage 17-102).
Check llurd level
l l l o w , f r l l r e s e r v o r rl o p r o p e r l e v e l .
and check for leaks
Trghten or replace as necessatY

Check lo. crushed suclron hose o.

a loose hose clamp allowrng ar Inio
Trghten of replace as necessary

17-28

Fluid Leaks
NOTE: When tluid leaks lrom one
side of the rack the balance tube
transfers the fluid to the other
side, giving the appearance that
both sides are leaking. To
troubleshoot, remove both boots,
clean the rack and locate the leak.

Resealgearbox and inspect the

rack sealingsurfacebetweenthe
steeringrack piston and the righl

Bemove the 4 way valve and inspect the 11 mm O-ring and rhe
port housing bore for pits, burrs or
s c r a t c h e s( s e e p a g e 1 7 1 0 7 ) .
Repair as necessary.

lf no abnormalrty is found, replace

the O ring, reseal the gearbox and
Inspect the steeflng rack seaiing
surface lor burrs or scratches be
tween the steenng rack gear teelh
and the piston. Inspect the seal re
tainer bore in the gearbox housing
for proper chamfer and sharp
e d g e s ( s e ep a g e 1 / 1 1 7 1 .

e n d { s e ep a q e 1 7 1 1 7 ) .

Trghten attachrng bolls or replace

valve body or port housrng.
Sreeflng gearbo'(
Leaking

l.om

erlher side of

valve

Replace all valve body unit seals

and O-rings.

Replacethe valve body.

Replace the front seal.

Pump housrng leaks et ither end

Leaking from around cap,

Replace housing O rngs.

ll lhe housrng st|ll leaks, replace
the pump

R e s e r v o i ro v e r l i l l e d
Pullolt the hose and drarnto proper

Air leak in
s4r,.

lhrgh pressure)

LO\/vpfessure hoses

Lealrng because ol damage,

delefioralron, or rmproper as.

Replacor repar as necessary

Tighten connector. lf still leaking.

the prpeor vaive bodv unrt.

Leaking at gearbox connection

{at O ring jojnt).

1 7- 2 9

Troubleshooting(4WS)
ComponentLocation
NOTE:
The radio may have a coded theft protectioncircuit.
Be sure to get the customer'scode number betore
- Disconnectingthe battery.
- Removingthe No. 43 CLOCK.RADIO (1O Al fuse.
- Removingthe radio.
After service,reconnectDowerto the radioand turn it on.
When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation.

CLOCK,RADIO(10 AI FUSE

ANGLE
REABMAIN STEERING
SENSOR

UNDER'HOOD
FUSE/RELAYBOX

ABS CONTROLUNIT

REARSUB STEERING
ANGLESENSOR
FRONT MAIN STEERING
ANGLE SENSOR

REARACTUATOB
UNDER,DASH
BOX
FUSE/RELAY
VEHICLESPEEOSENSOR

{vss)

ANGLE
FRONTSUB STEERING
SENSOR
SERVICECHECK CONNECTORI2P}
Behindthe cenler console

No. 22 4WS tto Al FUSE

17 -3 0

ConnectorLocations

ABS CONTROLUNIT CONNECTOR

4WS CONTROLUNIT POWERTERMINAL
G 503

4WS CONTROLUN|T CONNECTOR{4p)

4WS CONTROLUNIT
CONNECTOR
{18P)
VEHICLESPEEDSENSOB
CONNECTOR
I3P)

CONTROLUNIT CONNECIORI12PI

SERVICECHECKCONNECTOR
{2P}
Behind the conler console.

1 7- 3 1

Troubleshooting(4WS)
CircuitDiagram
UNOR.HOOD
FUSENELAY
BOX

wffi--------*-No.
FUSE
23

FUSELABELNAME

ECU
F/CMIRNOR

METER
1WS

UNDER-OASH
80X
FUSEiRELAY

LIGHT
SYSTEM
CI'IARGING

IGNITION
SWITCH
l|G1l

VEHICI.E
SPEEDSENSOR

GRNETD

,ro*
41.,
\ ll^ ,/ LEVEL

*1- swrcr

STEERING
REAR
SUBSTEERING FRONTSUB
ANGLE
SENSOR
ANGLE
SENSOR

A
-=

G301
-+YELtsLU
V'/HTALUBLK+YEUBI(
B[K/r{HI------O-

ANGTE
SENSOR
SITIRING
FRONTMAIN

WHTELU-.+GRYmt
BLK---.-

*l
SENSOR
MAINSIIERINGAMNGLE
REAR

cIr

GO2
G101

17-32

GRY

GRY/BLK

SERVICE
CHECK
CONNECTOR
IGNITION
SW]TCH
l|G2)
ABSCONNOL
UNII
IGRt{nED

l--':*ln'"-Io'j

rr\

(lL ,
PARKTNG

anlxeY'

91,v116gJ-

IWSCONTROL
UNIT
POWER
TERMINAT

I8PCONNECTOR
1

10

't2

12PCONNECTOR
7

1 4 1 5 16 1 7 1 8

1 9 20

21

23

27 28

IWSCONTIOL
UNIT
CONNECTOR

interiorside

17-33

Troubleshooting(4WS)
UNITTerminalArrangement
4WS CONTROL

13 14 1 5 16 17 18

10

(C)
4P CONNECTOR

(B)
12P CONNECTOR

(AI
18P CONNECTOB

22 2 3

192 0
24 2 5

POWERTERMINALID}

26 1 , /

2 8

View from controlunit terminalside

concon_
necror
necror
No.

Check
W i r ec o l o r

Termanalname

G R Y / R E D R e a rr i g h tp u l s e

Measurement
condition

Normal
voltage

While the wheel is

being rotated slowly

5V-OV
Batteryvoltage.

Engine ON

WHT/BLU

Charge

GRY/WHT

Rear left pulse

BLK/YEL

lgnition 2

Measuremt
termimals
1- 2 4
2-24

O V

EngineOFF
While the wheel is
being rotated slowly

5 V-O
Battery voltage

IG SW ON

3-24
4-24

IG SW
OFF, ACC, START

O V

Rearmain steering
angle sensorground

IG SW ON

O V

5 -ground

Rearmain steerang
angle sensorA phase

While actuatormotor
is runningslowly

5V-OV

6-24

RED

WHT/GRN

PNK

Warning 1

GRN

Front main steering

angle sensorA phase

O V

Light ON

Battery voltage

Lisht OFF
While steeringwheel
is being rotated slowlY

5V-OV

8-24

I
10

B R N / W H T Service check signal

OV

Short

10-24

5V(AT:1lV)

Open

1 1
1')

BLU

Front main steerlng

angle sensorZ phase

While steeringwheel
is being rotated slowlY

5V-0V

Rearmain steerrng
angle sensorB phase

While actuatormotor
is runningslowly

5VOV

13

BLU/GRN

14

G R N / R E D Parking brake

I D

YEL/RED
BLK

ON

O V

OFF

Battery voltage

Front main steerlng

angle sensorB phase

While steeringwheel
is being rotated slowlY

Ground2

IG SW ON

Rearsub steering
anble sensorcenter

Analogtester DC
range

17

GRY/YEL

18

WHT/YEL I Back up Power source

At all times

5 V-0

12,24

1 4- 2 4
15,24

O V

16-ground

approx.
2 . 5V

1 7- 2 4

Battery voltage

18- 24

s w i t c h ,A C C :accessory{'l position)

17 -34

18P CONNECTOR
IAI

t0

12 1 3

1 4 l 5

12P CONNECTOR
IB}

t9 20

21 2 2

24 25 26

2 829

16 17 18

CONNECTOR
{c)

ffi
Eqql

interior side

View from control unit terminalside

connector

connector
No.

Ch e c k

Wire color

Terminalname

Measurement
condition

Normal
voltage

Measuremt
rermtmats

'19

ORN

Vehiclespeed sensor

While front wheel is

being rotated slowly

5 V*O

19-24

20

GRN

Rearmain steering
angle sensorZ phase

While actuator motor

asrunningslowly

5 V.,O

20

21

YEL/BLK

Front sub steering

angle sensor left

Analog tester AC
range

YEL/BLU

Front sub steering

angle sensorright

Analog tester AC
range

23

PNK

Warning 2

24

BLK

Ground 1

25

YEL/RED

lgnition 1

Left CenterrRight

Right

O V

Light OFF

Battery voltage

IG SW ON

O V

IGSW ON

Baltery voltage

O V
approx.
2.5 V

Analog tester DC
range

2S

GRY/BLK

Rearsub steering
angle sensorleft

Analog tester AC
range

29

GRY

Rearsub steering
angle sensorright

Analog tester AC
range

YEL

Damper

23

24
gtound

24

I G S W O F F ,A C C

Front sub steering

angle sensorcenter

22 26

2 . OV 2 . 5 V 3 . 0 v

Light ON

YEL/GRN

21 26

s.ovT2svb.o v
Left

24

25 24
)6

?4

27
Left Cen!

Right

2 . OV 2 . 5 V

3 . 0v

Left

2A 17

Right

29 17

3 . 0v 2 . 5V 2 . OV

31
32

34

FI

BLU

Damper

Resistancerange
Disconnect4P
connector.
Start the engine

WHT

Motor power source

At all times

Battery voltage

ground

BRN

power (motorl ground

IG SW ON

O V

ground

RED

Motor terminal

ground

BLK

Motor terminal

Momentarilyopen,
no conI|nutry

O V
Start the engine

Continuity

Battery voltage

33- 34
control untt
Iermtnal

D -- ground

The normalvoltage is the value when the system is working properly.

17-35

Troubleshooting(4WS)
I rOUOle UOOe
Code(DTC)
Diagnostic
agnOSIlC Trouble
tu I l-f -

To display the DiagnosticTrouble Code (DTC)

( 1 ) Pullout the servicecheck connector(2P) locatedbehindthe centerconsoleand connectthe two terminalsof the
connectorwith a iumper wire.
(3 P)
DATA LINK CONNECTOR

NOTE:
Do not attach
the jumper wire.

,-->,/
' _ \

JUMPR

SERVICECHECK
coNNECIOR (2Pt

(2) Turn the ignitionswitch ON. but do not start the engrne.

( 3 ) Watch as the 4WS indicatorlight blinksto displaythe code

{4) Recordthe codes.
NOTE:
a Be sure to recordthe code. lf you do any oI the following, the code will be erased.
- Disconnectthe battery terminals
- RemoveNo. 43 CLOCKRADIO (10 A) fuse from the under-hoodfuse/relaybox
- Disconnectthe 4WS control unit connector.
IndicatorLamp (MlL) will stay on
a It the engineis started with the serviceconnectorjumped, the N,lalfunction
pattern
DTCindication
Main - sub
V.fv6
chock

t+ #12,
o.g 0.4

t--0.8

--,

#22
o.g o.4

--+'
l'.""i11,n"i""
signsl
3.0

sub *

5'u" --"

F-#22=,

t<-#

Main
12

0.8 0.4
0.8 0.4
The 4WS indicatorlight displaysa code by a seriesof long and short blinks.This indicatorlight can displaymultiplecomponent problemsby blinkingseparatecodes,one after another.The numberof long blinksequalsthe lirst d;git of the
code. the numberof short blinksequalsthe seconddigit. When there are multiplecodes,there is a two secondpause
betweenthe codes.
System problemscan be detectedby both the main and sub centralprocessingunits (CPUS)in the 4WS control unit
Each CPU can memorizeup to 1O codes. lf both CPUshave stored codes, the 4WS indicatorlight will:
a Blink quickly once as an indicatorlignt check, (this happensonly when the ignitionswitch is first turned on).
a Pausetor three seconds.
a DisDlavthe codes stored in the main CPU.
a Pausefor 1.6 seconds.
a Blink rapidlytor three secondsto indicatethe switch betweenthe main and sub CPU.
a Pausefor 1.6 seconds.
a Displaythe codes stored in the sub CPU.
a Pausefor three seconds,then repeatthe cycle.
This cycle will continueuntil the ignitionis turned OFF.
NOTE:
a Be su.e to check both CPUsfor at least 10 codes betoreturning OFF the ignitionswitch
a lf the main and sub CPUSdisplaythe same codes,those codes need only be checkedonce.

7-36

Precautions
DiagnosticTrouble Code (DTC):
The DTC is memo.izedwhen the 4WS control unit detects an abnormality,even if it was a temporarycondition.To
troubleshoot,ask the customerin detailaboutthe conditionswhen the 4WS indicatorlight cameon, and try to duplicate
those conditionsduringthe test drive.lt the 4WS indicatorlight does not come on duringthe test drive,do not continue
to troubleshoot;the system is OK at this time, The troubleshootingproceduresassumethat the symptom is occuning.
Check for loose connectionsor poor contacts at the connectorsby wigglingthe harness.etc.

The 4WS indicatorlightcomeson when the 4WS controlunit detectsa problemin the system.Dependingon the problem,
the 4WS indicatorlight may be canceledby turningthe ignitionswitch ofl, or it might requireremovingthe CLOCK,RADIO (10 A) tuse in the under-hoodfuse/relaybox. It a problemis detectedin the main steeringangle sensorsystem,
you must removethe CLOCK,RADIO{1O A) fuse to cancelthe 4WS indicatorlight. lI a problemis detectedin any other
part of the system, turningthe ignitionswitch off will canceithe 4WS indicatorlight.
NOTE: It the 4WS light comes on becauseof a temporaryproblemin the main steeringanglesensorsystem, it cannot
be canceledby simply removingthe causeof the problemand cyclingthe ignitionswitch; the CLOCK,RADIO (10 A)
fuse must be removed.
The 4WS indicatorlight does not come on when the DTC is 71 , 72, ot 73. However.the 4WS indicatorlight will flash
these codes when the servicecheck connectoris iumoed.

TemporaryDriving conditions:
Whenthe vehicleis operatedunderextremelyharshor abnormalconditions,the 4WS controlunit interpretsit as a problem
and memorizesthe DTC.

DTC

Operation

70

The ignitionis turned from OFF to ON while driving.

71

The car is driven aggressivelywith the driver and three passengerson

board. or the steeringwheel is turned with a rear wheel blocked by
the curb, etc.

4WS IndicarorLight
ON

The engine is started while quick-charging the battery.

74

Drivingthe car with the parkingbrake ON.

ON 5 minutes
after detection

Fail-safecontrol:
When the fail-safe conditions are met, the 4WS control unit stops the 4WS control and returns the rear wheels to the
straight driving position slowly.

17-37

Troubleshooting(4WSl
Symptom-to-SystemChart
FAIL SAFE(F/S)ITEM

AFFECTED
l5

z a

-LE
o t

& z

tr9
o:l
z ,,,

36

z
-

O O

NO
code

z
F X

z i

3;

6 =

F14

;E

c
4

It

z =
i z i z
tr< t <

a=

> 6
Eul
[ <

.rr nr T
zz.
A H
> ;
riz

2=,

t-z
crii'i

I
> o

= z

o l(l. < D < i

aa
E t1) t a

z
f

(r
o
F

c
F

E
F

t-

C)

(J

<(r

z
o

c0

< A
3 #
5

t
F

IE
F

nfr

2e
R+

z
lr
F

2
o

18
25

Go to
trouble
shoo!ng

10

FRONT

22

ACTION

(,
=

7 +23

No
code

; o

t--

-'z
) a

t
z

Go to
trouDte
snoorng

1 74 2

Go to

1 14 5
snoorng
Go to

REAR

1t

17

o
v,

a)

1750
snoorng

FRONT

REAR

11

c)

2a

Go to
trouole
snooflng

1 74 5

Go to
trouble
snooflng

1750

Replace

14

(,
z

FRONT

REAR

(9

z
tr

Replace
trolunrt

at)
l

16

17

FRONT

REAR

22
26
21

17

2a

18

17-38

Go to

1t 45
shootrng

,-l

Go to
trouble
snoorng

Repiace
4WScon

17 50

FAIL-SAFE(F/S)ITEM
(9

4
(E
lDz
F q

z )
i z

tr<

rroLrble- 17 59

Go to

1 7- 3 9

Troubleshooting(4WS)
Symptom-to-SystemChart (cont'dl
AFFECTED

FAIL-SAFE{F/S)ITEM
(9
F

z i
l o
-.lE
o l
E Z

l
E
F
F p
tD F^

z,,,
<5

o(J

33

34

2
a
x z
;fr

REAR
R/L

FRONT

19

REAR L

REAR R

o
=

(9
2

Ful
Z:!
i z

-'z

t z
= z.z
) <1, <
= 6

tr< aa<E

<

s:

;o

t;i
@ z

t
z

z i
O ltr
. TL

; o
t z

<tr

o
- z

t
z
)

l5

l
F

z
o

la
iE

E
d)
(9

z
2
o

E"'

z
o

*E

co

3 <E ; 5^ P $

'l

o
o

o
< E

ACTION

cc
i

Go to
trouble- 1 7 - 6 8
snoorng

Go to

17-63

17-64

VEHICLE
SPEED

40

CONTROL
UNIT

41

CONTBOL
UNIT

42

L
z
:)

43

o
F
z
o
o

UNIT

UNIT

44

45

46

z o
5 t 6

17-40

17-66
shooting

Replace
4WS con-

REARL

37

Replace
4WS con
trol unrt

o
o

CONTROL
UNIT

o
o
o

UNI-T
4WS
CONTROL
UNIT

o
C +

C +
D _

Go to

1770
1 7- 7 1

Go to
trouble'
shooting

11-11

1 77 1

1 7- 4 1

Troubleshooting (4WSl
4WS IndicatorLight Circuit
4WS CONTROLUNIT 18P/12PCONNECTORS
The 4WS indicarorlight does noi
como on whon ignition switch is
first turned ON.

Connect

View from terminal side.

Turn the ignition switch ON and
pull the parking brake.

Does the brake indicator light

c h e c k t h e N o . 1 3 M E T E Rf u s e
1 1 0A ) i n t h e u n d e rd a s hf u s e k e '

ls the luse OK?

Connectthe 4WScontrolunitNo.
7 terminal(PNK)and No. 23 terminal(PNK)wire to body ground.

ReDairopen in the YEL wire b

twn rhe No. 13 METERtuso 110
Al .nd the 4WS indicator light.

Does the 4WS indicator light

Reolacerhe 4WS control unft.

The 4WS indicator light does not

go oft alier stariing ngineand no
DTC is shown.

Start the engine and check the

charging system light.

Does the light go off?

Turn the rgnrlronswitch OFF.

Checkthe No. 43 CLOCK,RADIO

fuse (10 A) in the under_hood

ls the fuse OK?

{ T op a g e1 7 4 3 )

17-42

Reolace the fuse and recheck,

Reolaceth fuso and rocheck.

lFrom page 17-42)

Checkthe No. 22 4WS luse (10

A) in the undeFdashluse/rel8y
box.

ls the fuse OK?

Replacoth. lulc 6nd rochock.

checktheNo.I R/c MlRRoRluse

(15 Alin theunder-d8sh
fuse/retayDox.

Roolacotha fula and rochock.

Disconnectthg 4WS controlunit

'l8P connector and 12P connector.

Repalrihort in tho Pf{K wlrc! b6tw6en tho 4WS cont.ol unit and
tho indicrtor light.

4WS CONTROLUNIT 18P CONNECTOR

Connect lhe 4WS contiol unit

18P connoctor and 12P con'
nector,

8aft6ry Voltsgo?
Measure voltage between the
4WS controlunitNo. 18 terminal
(WHTrYL)and body ground.

ls there bsttery vollage?

{To page 17-44}

Ropalrop.n in WHT|'EL wlro botwcon tho 4WS control unit .nd

undor-hood fuaa/rolay bor.

(4WS)
Troubleshooting
4WS IndicatorLight Circuit (cont'd)
(Frompage 17-43)

4WS CONTROLUNIT CONNECTOR

12?

Measure voltage between the

4WS control unit terminals:No.
'|8 (WHTryEL)and No. 16 (BLK),
and botwenNo. 18 (WHT,ryEL)
and No. 24 (BLK).

View lrom terminalside

Ropairtho poor ground lcso'l) o.
oDon in BLK wir6 bolwesn tho
4WS control unit and body
ground.

Turn the ignitionswitch ON.

Measure voltag between the

4WS controlunit No. 25 terminal
(YEL/RED)
and body ground,

ls there battery voltageT

Reprir op6n in tho YEL/REOwlr6

btw6n the 4WS conlrol unh and
undr-d6ahfuse/rolav box.

4WS CONTROLUNIT CONNECTOR

18P

Measure voltage betwen the

4WS control unit No. 4 terminal
and body ground,
{BLK/YEL)

ls there battery voltage?

v
Ropairopen in tho 8LK/YELwir6
botwoon tho 4WS control unit and
tho under-dashtusoholay box.

Measure voltage between the

4WS controlunit No. 2 terminal
{WHT/BLU)and body ground.
Ropairopnin th6 WHT/BLUwir6
btwoon tho 4wS conttol unit and
tho undor-dashfuso/rolav box.
Roplacoth6 4WS control unit.

12P

V ) Bsttory
View from terminal side.

DiagnosticTroubleCodes(DTCs):10, 12, 16
-Thc 4WS indicoro. light has
boan roDortodon.
-With sorvico ch6ck conn6ctor
irmpod codos 10. 12, 16 610indlc.tcd.

Disconnectthe front sub steering

anglesensorconnector,

Measurresistancebetween the
No. 1 terminal {BLK)and No. 2
terminal{WHT/BLU}ot the sensor
side connector.

l s t h e r e8 . 4 - 1 2 . 2 O ?

Measureresistancebgtween the
No. 2 terminal {WHT/BLU)and
No. 3 terminal(BLKMHTI ot rhe
senaor side connector.

ls rhere8.4- 12.2O?

Checkfor continuity between the

sensor side connsctor No. I te.minal (8LK)and body ground.

ANGLESENSOR
FNONTSUB STEERING
SENSONAIDE CONNECTOR

Continyity?
8.4-12.2 A?
View from terminalside.

Turn the ignitionswitch ON.

(To page '17-46)

1 7- 4 5

(4WSl
Troubleshooting
DiagnosticTroubleCodes {DTCs): 10, 12,16 {cont'd)
lFrom page 17-45)

ANGLESENSOR
FRONTSUB STEERING
4WS CONTROLUNIT SIDECONNECTOR

Measurethe voltsge betweenthe

4WS control unit side of the ssnsor connector No. 1 torminal
(YEL/BLK)and body ground.

i+_I-}
/J\ z.svr
Y
View from terminalside.

ls there approximatly2.5 V?

Disconnectthe 4WS controlunit

12P connector.
4WS CONTROLUNIT 12P SENSORSIDECONNECTOR

Checktor continuity between the

4WS controlunitNo.21 terminal
{YEL/8LK)and body ground.
Viw from terminalside.
R.o.li short in the YEL/BLKwire
botwoontho 4WS controlunil and
tho front sub steering angle
sonsor.

Connect the 4WS control unit

12P connector.
4WS CONTROLUNIT 12P CONNECTOR
Measurevoltagbetween the No.
21 terminal{YEL/BLKIol the 4WS
control unit and body ground.

ls there approximarely2.5 V?

lfo page 17-471

17 -46

Ropairop6n in tho YEL/BLKwiro

botwoon tho 4WS control unit and
th tront sub stooring anglo
30nsot.

R6plac6 the 4WS conlrol unit.

(Frompage 17-46)

ANGLESENSOR
FRONTSUB STEERING
4WS CONTROLUNIT SIOECONNECTOR

Measurethe voltage belween the

4WS control unit side of the sensor connector No. 2 terminal
and body ground.
IYEL/GRN)

rlTf-\
w
(V) 1 25 v?

Y
View from terminalside.

ls there app.oximately1.25 V?

Disconnectthe 4WS control unit

12P connector.
4WS COI{TROLUNIT 12P SENSORSIDECONNECTOR

Checktor continuity between lhe

4WS controlunit No. 26 terminal
and body ground.
{YEL/GRN)

Continuity?
View trom terminalside.

Ropairshort in the YEL/GRNwire

botw66n the 4WS control unit and
tho sub steeJingangle sensor.

Connect the 4WS control unit

12P connector.
4WS CONTROLUNIT 12P CONNECTOR

Measur6 voltage betwoen the

4WS controlunitNo. 26 terminal
and bodv ground.
{YEL/GRN)
View from terminalside.

ls there approximatoly1.25 V?

{To page 17-481

Rool6c6the 4ws control unit.

R6pai opon in tho YEL/GRNwire

borwoon tho 4ws contol unit and
tho front rub staering anglo
aonaot.

17 -47

Troubleshooting(4WS)
DiagnosticTroubleCodes (DTCs):10, 12, 16 (cont'd)
lFrcnr,page 17'471
ANGLESENSOR
FRONTSUB STEERING
4WS CONTROLUNIT SIDE CONNECTOR

Messurethe voltage betweenthe

4WS control unit side ol the sensor connector No, 3 terminsl(YEL/BLU)
and body ground.

( v )2 . 5 V l

:r

View from terminalside.

ls lhere approximately2.5 V?

Disconnectthe 4WS control !nit

12P connector,
4WS CONTROLUNIT 12P SENSORSIDECONNECTOR

Checkfor continuity between the

4WS controlunit No. 22lerminal
(YEL/8LU)and body ground.
View from terminalside.
Ropai.shorl in the YEL/BLUwiro
b,6two6nth6 4WS contiol unh 6nd
3ub stooring 6n9lo sonsor.

Connect the 4WS control unit

12P connector.
4WS CONTROLUNIT 12P CONNECTOR

Measure voltage between the

4WS controlunitNo. 22 terminal
(YEL/BLU)
and body ground.

View trom terminalside.

ls there approximately2.5 V?

(To page 17 49)

Rop6iropon in tho YEL/BLUwiro
botrYoontho 4WS control unh ald
the front sub 3t66ring angl6
sonsor.

17 -48

Raolac6tho 4wS control unit.

(Frompage 17-48)
4WS CONTROLUNIT 12P CONNECTOR

Conneclthe front sub steeringangle sensorconnector.

List6d Voltage?
View from terminalsideFRONTSUB STEERINGANGLESENSORTERMINALVOLTAGE
IREFEBENCE}

STEERING
WHEEL
P0stTt0N
Whileturningthe steeringwheel,
measurevoltagebetweenNo. 22
(YEL/BL|)and No. 26 (YEL/GRN)
terminalsol the 4WS control unit
usingAC rangeof analogtester.

LEFT
approx
2 . OV

Voltage

CENTER
approx
2 . 5V

RIGHT
approx

3 . 0v

Analog tester AC range

Does voltage change as

shown in the table?

Check the neutral point of the

front sub steeringanglesensor.
{ s e ep a g e1 7 1 4 6 ) .

ls the neutralpoint OK?

Adtust the noul.al point ot tho

troni 3!b steering sensor.

ReDlacoth6 4WS control unit

17-49

Troubleshooting(4WS}
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7

-Th6 4WS indicator light has

boon toDorled on.
-With sorvic6 chock connoctor
'l7 are iniumpod cod6s 1l, 13,
dicatod.

ANGLESENSOR
REARSUB STEERING
SENSORSIDECONNECTOR
l|l
/-\rFP

Disconnectthe rear sub steerang

anglesensorconnector.

Measure resistancebetween the

No. 1 terminal {BLKMHT), and
the No. 2 terminal{WHT/BLU}oI
th sensorsadeconnector'

l s r h e r e8 . 4 - 1 2 . 2 0 7

Measure rosistancebetween the

and
No. 2 terminal (BLK,ryVHT),
th6 No. 3 terminal (BLK)of the
sensor sadeconnector,

l s t h e r e8 . 4

1 2 . 20 ?

Chock for continuity between the

sensorside connectorNo. 3 ter
minal (BLK)and ground.

Turn the ignitionswitch ON.

llo page r /-5l l

17-50

ur\u
\"/

12.3L/z\

-r_

ua\ lr /^\
Ir,/ Continuitv?
\"/
\ ..r/

a . 4 - 1 2 . 2A ? +
View from terminal side.

lFrom page 17-5Ol

REAR SUB STEERINGANGLE SENSOR
4WS CONTROLUNIT SIDECONNECTON

r-Ffi-r
Measurethe voltage bGtweenthe
4WS control unit side of the sensor connector No, 1 terminat
(GRYI and body ground.

(V) z.svz
Y
View from terminalside.

ls there approximately2.5 V?

Disconnectthe 4WS conlrolunit

12P connector.
4WS CONTROLUNIT 12P SENSORSIDECONNECTOR

fl-ll

wrl

Check for continuity between the

4WS controlunit No. 29 terminal
(GRY)and body ground.

rarfT l

continuiry

View from terminal side.

YES

RoDairshort in the GRY wiro between the 4WS control unit and
the rearsub steeringanglesonsor.

Connect the 4WS control unit

12P connector.
4WS CONTROLUNIT 12P CONNECTOR

Measure voltage between the

4WS controlunit No.29terminal
(GRYIand body ground.
View from terminalsrde,

ls there approximately2.5 V?

fio page 17-52l,

R6pairopon in tho GRY wir6 b6twoon the 4WS control unit and
tho roar sub stooring anglo aonsor.

17 - 5 1

Troubleshooting(4WSl
D i a g n o s t i cT r o u b l eG o d e s( D T C s ) :1 1 , 1 3 ' 1 7 ( c o n t ' d l
( F r o mp a g e 1 7 - 5 1 )

ANGLESENSOR
REARSUB STEERING
4WS CONTROLUNIT SIDECONNECTOR

Meas!re the voltage betweenthe

4wS control unit side of the sensor connector No, 2 terminal
{GRY|YL)wire and body ground.

'1.25V?
ls there approximately

1.25V?

View lrom terminalside.

Disconnectthe 4WS control unit

18P connector.
4WS CONTROLUNIT 18P SENSOBSIDECONNECTOB

Check for continuitv between lhe

4WS controiunit No. 17 terminal
and bodv ground.
{GRY/YEL)
View from terminal side.

Reoahshort in the GRY/YELwire

betwoontho 4WS conttol unit and
the rearsub stGringanglesensor.

Connect the 4WS control unit

18P connector.
4WS CONTROLUNIT 18P CONNECTOR

Measure voltage between the

4WS controlunitNo. lTterminal
(GRY/YEL)
and body ground.
View from terminalside.
'1.25V?
ls there approximatelv

(To page 17-53)

17-52

Ropairopen in the GRYI/EL tYire

b6lwo6n tho 4WS control unit and
tho roar sub steoring englo sonsor.

Roolaceth6 4WS control unit.

(Frompage 17-52)

REARSU8 STEERING
ANGLESENSOR
4WS CONTROLUNIT SIDECONNECTOR
(3.1 I !

Masurethe voltage betwoen the

4WS control !nit sido of the sensor connector No. 3 terminal
(GRY/BLK)
and body ground.

(V) z.svz
Y
View trom terminalside

ls there approximately2.5 V?

Disconnectthe 4WS controlunit

12P connector,
4WS CONTROLUNIT 12P SENSORSIDECONNECTOR

Checklor continuity between the

4WS controlunir No. 28 terminal
and body ground.
{GRY/BLK)

Repai.shon in the GRY/8LKwiro

hw6n the 4WS controlunitsnd
tho rotr sub storinganglosonsor.

Connect the 4WS control unit

12P connector,

4WS CONTROLUNIT ,I2P CONNECTOR

Measure voltage between the
4WS controlunit No. 28 terminal
and body ground.
{GRY/BLK)

View from terminalside.

ls there approximatelv2.5 V?

{To page 17-54)

Reolace4WS control unit.

Ropairop.n in tho GRY/BLKwire

between $ 4WS control unit and
th roaasub Stseaingangle sensor.

17-53

Troubleshooting(4WSt
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7 { c o n t ' d )
(Frompage 17-531
4WS CONTROLUNIT'I8Pi12P
CONNECTOR
Connectthe rear sub steeringangle sensor connector-

ANGLESENSORTERMINALVOLTAGE
REARSUB STEERING
(REFEREI{CE)

While turning the steering whool

and measurevoltagebetweenNo.
and No. 29 (GRY)
17 lGRY,ryELl
terminalsof the 4WS controlunit
using AC range ot an analog
tester.

WHEEL
STEERING
P0stTt0N
Voltage

Checkthe neutralpoint ot the rear

sub steering angle sensor (sse
page 17-1461.

Replacotha 4WS control unit

17 -54

CENTER

RIGHT

approx

approx
2.5V

approx
2 . OV

3 . 0v

Analog tester AC

Doos voltage change as

shown in the table?

ls the neutral point OK?

LEFT

Aqu3t dre iratural point of tt| tolr

aub ltoailng aanlor.

DiagnosticTroubleCodes (DTCsl: 20, 22, 24,28

-Th6 4WS indicator light has
bggn reDortodon.
With service chock conngctot
iumpod codes 20. 22, 24. 28
are indicated.

ANGLESENSOR
FRONTMAIN STEEBING
4WS CONTROLUNIT SIDECONNECTOR

BsnoryVoltago?

Disconnectthe front main steerIng anglesensorconnector,

View from terminalside.

Turn the ignitionswilch ON.

Measure voltage between the
4WS controlunit sideconnector
No. 1 terminal {BLK/YEL}and
body ground.

ANGLESENSOR
FRONTMAIN STEEBING
4WS CONTROLUNIT SIDE CONNECTOR

fT-fFlt
-XRopair op6n in th6 harnoss wiro
betwoen tho No. 22 4WS tuso
and tho tront main stoering angle
sonsor.

Measurethe voltage between the

4WS controlunit sideof the sensor connectorNo. 4 terminal(LT
GRN)and body ground.

ls there approximately4.5 V7

( V.)c.svr

:r

View from ierminalside.

4WS CONTROLUNIT 18P

SENSONSIDECONNECTOR
Disconnectthe 4WS controll unit
18P connector.

Checkfor continuity between the

4WS control unit No. 8 terminal
(GRN)and body ground.

View from terminalside.

Rooairshort in tho GRN wiro betwoon tho 4WS control unit and
th6 main stedng angle aonsor.
Connect the 4WS control unit
18P connector.

4WS CONTROLUNIT 18P CONNECTOR

Measure voltage between the

4WS controlunit No. 8 terminal
(GRN)and body ground.
View from terminalside.
ls there approximately4.5 V?

( T op a g e1 7 - 5 6 )

Roolaceth6 4WS cont.ol unit.

Ropah open in the GRN wiro betweon the 4WS control unit and
the front main sloo.ing anglo

17-55

Troubleshooting(4WSl
DiagnosticTroubleCodes (DTCs):20, 22, 24, 28 (cont'd)
{Frompage 17-55)
ANGLESENSOR
FRONTMAIN STEERING
4WS CONTROLUNIT SIDE CONNECTOR

Measurgthevoltage between the

4WS control unit side of the senaor connoctorNo.3 terminal(BLU)
and body ground.
View from terminalside.

ls there approximately4.5 V?

Disconnectthe 4WS control unit

18P connector.

4WS CONTROLUNIT 1AP

SENSORSIDECONNECTOR

Check tor continuity between the

4WS controlunit No. 3 terminal
{BLU}and body ground.
View lrom terminalside.
R.Dair short in tha BLU wire b6twoon tho 4WS cont.ol unit and
the main stooring angl aonsor.

Conn6cl the 4WS control unit

18P connector.

4WS CONTROLUNIT 18P CONNECTOR

Moasure voltage between the

4WS controlunitNo. 12 terminal
(BLU)and body ground.
View from terminalside.

ls there pproximatoly4.5 V?

(To psge 17-57)

Repair opon in tho BLU wiro betwoon th6 4WS control unit 6nd
th6 front main stoodng anglo
30n3('t.

17-56

Roplsce the 4WS control unit.

{Frompage 17-56}

ANGLESENSOR
FRONTMAIN STEERING
4WS CONTROLUNIT SIDECONNECTOR

Megsureth voltago between the

4WS control unit side of the sensor connectol No. 2 trminal
(YEL/REDI
wire and bodyground.
View from terminalside.

ls th6re approximat6ly4.5 V?

Disconnectthe 4WS controlunit

18P connector.

4WS CONTROLUNIT 18P

SENSORSIDECONNECTOR

Checkfor continuity between the

4WS controlunit No. 15 terminal
and body ground.
{YEL/RED)
View from terminalside,

Ropairshon in tho YEL/REDwire

botweon lhe 4WS control unit and
tho main stering sngle snsor.
Connect the 4WS control unit
18P connector.
4WS CONTROLUNIT 18P CONNECTOR
Measure voltage between the
4WS controlunit No. 15 terminal
and body ground.
{YEL/BEO)

View from terminalside.

ls there approximately4.5 V?

lTo page 17-58)

Reolacethe 4WS control unit.

Ropairopon in th6 YEL/REDwire

botwo6n tho 4WS control unit and
th6 front main sto6.ing angle
aon30r.

1 7- 5 7

Troubleshooting(4WS)
Diagnostic Trouble Codes IDTCs):20, 22, 24, 2A (cont'd)
(Frompage 17-57)

FRONTMAIN STEBINGANGLESENSOR
4WS CONTROLUNIT SIDE CONNECTOR

Check for voltage between the

and the
No.2 terminalIYEL/RED)
No. 5 terminalIELK)of the 4WS
control unit side connectorof the
front main steeringanglesensor.

ls there approximately4.5 V?

[T'T-TT;I
l

\:/

4.5 V?

View from terminalside

Rcpair tho poor ground lG 4Ol,

402, 4041or oDenin rhe BLKwiro
botwon th6 front main atooring
anglo 3onsor and body ground.

Reconnectth front main steering

anglesensor5P connector,

While turning the steeringwheel,

check for the signalsbetweenthe
following 4WS control unit termi'
nals and the body ground with an
analogvoltmoteron the DC range.
A-phase:
Betwsentho No. 8 terminal(GRN)
and body ground: should pulse
O-4.5 V rspidly {every2o)
B-phas6:
Between th No. 15 terminal
(YEL/RED)and body ground:
shouldpulse0e4.5 V rapidly(ev
ry 2o)
Z-ph8se:
Bgtween the No. 12 terminal
IBLU) and body ground: should
pulse0*4.5 V onceper steoring
wheel revolution

4WS CONTROLUNIT 18P CONNECTOR

0-4 . 5 v ? ( V ) ( V )

(V

View from terminalside

Are the signalsavailablebetween the respctive terminal

and the body ground?

Checkthe Z-phaseneutralposi'
t i o n ( s e ep a g e1 7 - 1 4 6 ) .

ls the Z'phasein the straight

drivingposition?

adjust the front main stooringanglo sonsor noutral poaition

{soo pago 17-15)

YES

Podormtroublgshootinglor OTCa
1 0 . ' 1 2 1. 6 .
{3e6pag6'17451.

Srraight
l revolustion
A-phase
o
B-phase
Z-phase

4.5
0
4.5

---------------- Time

L-

17 -58

DiagnosticTroubleCodes (DTCs):21 , 23, 25,29

REARMAIN STEERING
ANGLESENSOR
4WS CONTROLUNIT SIDECONNECTOR

-Th6 4WS indicalor light hss

b6on rooorlod on,
-V\fth sorvica check connecto.
.iumpodcod6s 21 , 23. 25, 29
ato indicatod.

\\.)
t..t

tlt

\:/

Battery voltaqo?

Disconnectthe rear main steering

angresensorconnector.

JJ

View from terminalside

Turn the ignitionswitch ON.

REARMAIN STEERING
ANGLESENSOR
4WS CONTBOLUNIT SIDECONNECTOR
Measure voltage between the
4WS conlrol unit side connector
No. 1 terminal (RED)and body
grouno.

ls there battery voltage?

YES

Ropair open in thg hahoss wire

bolweon tho No.22 4WS fuse
and the reaamain gtoering tngla
sensot.

Measurethe voltage between the

4WS control unit side No.3 termi
nal {WHT/GRN}and body ground.

ls there approximately4.5 V?

View from terminalside

4WS CONTROLUNIT 18P
SENSORSIDECONNECTOR

Disconnecl the 4WS control unit

18P connector.

YES
Checktor continuity belwoen the
4WS controlunit No. 6 terminal
(WHI/GRN)and body ground.

ls there continuity?
NO
Connect the 4WS control unit
18P connector.

View from terminalside

Repairshort in the WHT/GRNwire

betwecn tho 4WS controlunit and
the main steering angle sensor,
4WS CONTROLUNIT 18P CONNECTOR

Measure voltage between the

4WS controlunit No. 6 terminal
{WHT/GRN}and body ground.

ls there approximately4.5 V?

lTo page I7-60)

ReDlacothe 4WS control unir.

Repairopon in th6 WHT/GRN wi.o

botwoon the 4WS contol unit and
the aoaa main stooring angle
sensot.

17-59

Troubleshooting(4WS)
DiagnosticTroubleCodes (DTCs):21, 23, 25, 29 lcont'd)
{Frompag6 17-59)
REAR MAIN STEERINGANGLE SENSOR
4WS CONTROLUNIT SIDE CONNECTOR
Measurthe voltage betwen the
4WS controlunit side No 4lerminal (ORN) wire and body
9rouno.

View from lerminalside

ls ther pproximately4.5 V?

Disconnectth 4wS control unit

12P conneclor.

4WS CONTROLUNIT 12P

SENSORSIDECONNECTOR

l--T--fl nr lEf-l

ffiwx)
Checklor continuity between the
4WS controlunit No. 20 terminal
{ORN)snd body ground.

(p
Continuitv?
View trom terminalside
RoDairshon in ths ORN wiro botweon tho 4WS control unit 6nd
tho .oar main stoering anglo
80n8('t.

Connoct the 4WS control unit

12P connector.
12P CONNECTOR
CONTROL,UNIT

Measure voltage belwoen the

4WS controlunitNo. 20terminal
{ORN)snd body ground

r'.l-H-tD
ff
(V) +.svr

:r

View trom terminalside

ls there approximately4.5 V?

{ T o p a g 61 7 - 6 1 )

1 7 -6 0

Ropairopon In tho OBN wi.c bo_

twoon tho 4WS conttol unit and
the roar main 3loaring angle
30nlot.

Roplacotho 4WS conttol unit

{Frompage 17 601

REARMAIN STEERING
ANGLESENSOR
4WS CONTROLUNIT SIDECONNECTOR
.-rnfla
/
F
vl5,l,/t )

Measurethe voltage betweon the

4WS control unit side No. 6 ter
m i n a l ( B L U / G R N )a n d b o d y
gtouno,

( V ) a . sv r
Y
View trom terminalside

ls there approximately4.5 V?

Disconnectthe 4WS controlunit

18P connector.

4WS CONTROLUNIT 18P

SENSORSIDECONNECTOR

Checktor continuity between the

4WS controlunit No 13 terminal
and body ground.
{BLU/GRN)
View from terminal side

YES

Connect the 4WS control unit

l8P connector.

ReDai.short in the BLU/GRNwire

betweenthe 4WS controlunit and
the rear main stgoring angle
sensor.

4WS CONTROLUNIT 1AP CONNECTOR

Measure voltage between the

4WS controlunit No. 13 terminal
(BLU/GRN)
and body ground.
View from terminal side

ls there approximately4.5 V?

{To page 17-62)

Raolace the 4WS control unit.

R6pai.op.n in the BLU/GRNwire

botween tho 4WS control unit and
tho ioaa main Stoaring anglg
sensor.

1 7- 6 1

Troubleshooting(4WSl
DiagnosticTroubleCodes(DTCs):21' 23, 25, 29 lcont'dl
(Frompage 17-611

REAR MAIN STEERINGANGLE SENSOR

4WS CONTROLUNIT SIDECONNECTOR

Masure voltsge betwson the

No,6 terminsl {BLU/GRNIand the
No. I terminal (RED)of the 4WS
contrcl unit aide connector ot the
reat main steedng angle sensor.

ls there pproximately4.5 V?

View from terminalside

R.p.l opcn In th. RED wir. botwocn tho 4WS cont?ol unit and
tha ra.] maln ltooting anglo
Itn!o1,

Rsconngctthe rear main ateering

sngle sonsot 8P connector.

While turning th steering whe|,

check for the signalsbetwenthe
following 4WS conttol unit termin6ls and the body ground with an
analogvoltmeteron the DC range.
A-phase:
Eetween the No. 6 terminal
(WHT/GRN)ahd body ground:
shouldpulseO-4.5 V rapidlylevery 2o)
B-phase:
Between thc No. 13 terminal
(BLU/GRN) and body ground:
shouldpulseO-4.5 V rapidly(ov'
ery 2ol
Z-phaae:
Betwesn the No. 20 terminal
IORN) and body ground: should
pulsoO4.5 V once per ste6ring
wheel revolution

4WS CONTROLUNIT 18P/12P

CONNECTOR
I

O-4

. 5v ? ( V

l2oHl

ri+ffi M

Check the Z-phase neutral Position {seo page 17-'146).

ls the Z-phase in the straighi

driving position?

A-phase
B-phase
Z-pha86

4.5

4.5
0
4.5
0

---------------- Time

17-62

View from terminalside

Are the signals availablebetween lhe resDectiveterminal

and the body ground?

Porform trouble.hooting of
the DTCs 11, 13, 17. (.o6 psgo
t7-501

(v)

DiagnosticTroubleCodes (DTCsl: 30, 34

vehicle speed sensor (VSS)
NOTE: DTC 34 may have been memorizedon 4WS control unit after the using ALB checker.
It so, disconnectNo. 43 CLOCK,RADIO(10 A) fuse in under-hoodtuse/relavbox to reset the 4WS control unit.
-Tho 4WS indicator light has
boon roDortedon.
-With aervice check connector
iumpod codos 30 and 34 are
indicated.

Disconnectlhe
No.43 fuse{'l0 A)
in the undeFhoodfuse/relaybox.

Tesl drive the car.

Do codes 30 and 34 appear?

Does the speedometer

operate properly?

Disconnectthe 4WS controlunit

12P connector,

Sy3tom is OK at trrb tims. Inlpoct

tho vohicle spoed sonso. tominal
connecrots.

(Go to pago 23-1181

4WS CONTROLUI{IT 12P SENSORSIOECONNECTOR

Turn the ignitionswitch ON.

Measurevoltage betweenthe No.

l9 terminal(ORN)of sensorside
connector ot 4WS control unit
and body ground.

ls there more than 5 V?

View from terminalside

Rool6c6 the 4WS control unit

lwhon tho symplom rocurrod.)

Repaii opon or short in the ORN

wh to body ground betwoen the
vehiclospeedsensorand rhe 4WS
contol unil.

17-63

(4WS)
Troubleshooting
DiagnosticTroubleCodes(DTCs):31, 35 (cont'd)

4WS CONTROLUNIT 18P CONNECTOR

-Tho 4WS indicator light ha6

boon ropott6d on.
-With asivico chock connoctol
jumpod codos 31 and 35 oro
indicatod.

View trom terminalside

Does the ABS indicator light
stay ON?

Go to pago 19-54
Problem in ABS rystom

Stop the engine.Then turn the ignition switch back ON.

With the loft rear wheel raisedoll

ground, slowly rotate the wheel
while checking {or voltage be
tween the 4WS control unit No.
3 terminal{GRYMHT) and body
ground.

Does the voltage alternate from

zero to approximately 5 V?

(Topage1 7 - 6 5 )

7-64

Record lhc DTC rnd clear the

4WS contiol unit. Tost drive th6
car, if th6 DTC doo3 not roaPpear,
chock tho to.minal connoctions ol
th 4WS co.rtrol unii 18P connc'l4P
tor and tho A8s contiol unit
connoctor.

l F r o mp a g e1 7 - 6 4 )

Turn the ignitionswitch OFF.

4WS CONTROLUNIT 18P SENSORSIDECONNECTOR

Disconnectthe 4WS control unit

connectorand the ABS control
unil connector,
View from terminalside
Checklor continuitybetweenthe
4WS control unit No. 3 terminal
(GRY/WHT)and body ground.
Repeirshon in tho GBY,^/HT wire
bctwoon tho 4WS control unh and
tho ABS control unit.

4WS CONTROLUNIT lAP CONNECTOR

Turn the ignitionswitch ON.

Measurevoltagebetween the No.

3 terminalof the 4WS control unit
connectorand body ground.

ls there approximately5 V?

View from terminal sade

Rophco tho 4WS control unit.

ABS CONTROLUNIT 14P SENSORSIDECONNECTOR

Measure voltage betweon the No.

3 terminal (GRY/WHT) of sensor
side connector oI ABS control unit
14P connector and body ground.

Rsp.ir opsn in tho GRY/WHTrYiro

botwoon tha 4WS control unh snd
th ABS control unit.
R6olacothe ABS control unit.

View from terminalside

(4WSI
Troubleshooting
DiagnosticTroubleCodes(DTCs):32, 36

-Th. 4WS indlcator light h$

baan ropo.tgd on.
-Yvlth lowica chack connoctor
iumpod code. 32 and 36 sro
indiclt.d.

4WS COI{TROLUNIT IAP CONNECTOR

View trom terminalside

YES

co to p!9.'19-54
ftoblem in ABS .y.t.m

Stop the engine.Then turn the ignition switch back ON.

With the right rear whol .aised

off the ground. slowly rotate the
wheel while checking for voltag
betweenth 4WS contrclunit No.
1 terminal IGRY/RED)and bodv
grouno.

Does the voltage alte.nate trom

zero to approximstely 5 V?

NO
{To page 17-67}

17-6 6

Rocord tha DTC .nd cl..t th.

4l rS control unll. l.al driv. tho
c.r, it tha DTC dodc not ro.ppaat,
afFck tra tarmind connacdonr ot
d|. 4WS cont ol unit 18P cofir.c_
toi and th. ABS control unit l4P
connoqtoi.

(Frompage 17-66)

Turn the ignitionswitch OFF.

4WS CONTROLUNIT

'I8P SENSORSIDE CONNECTOR

Disconnectthe 4WS control unit

connector and the ABS control
unit connoctor,
Viw from terminalside
Check tor continuity between the
4WS control unit No. 1 terminal
and body ground.
{GRY/REO}
Rap.i. .hon In th. GRY/REDwi?o
bltwa.n th.4WS conltol onh and
th. ABS conlrol unit.

4WS CONTFOLUNIT 18P CONNECTOR

Turn the ignitionswitch ON.

Moasurevoltagebetweenthe No.
1 terminal (GRY/REDlotth 4wS
conlrol unit conneclor and body
ground.

ls there approximately 5 V?

View trom terminalside

Rcplscr lh. 4WS control unii

ABS CONTROLUNIT 14P SENSORSIOECONNECTOR

Measurevoltagbetween the No.

1 terminsl IGRY/RED)of sensor
sideconnectorof ABS controlunit
14Pconnectorand body ground.
Rcplli opcn in th! GBY/REDwite
b.twran th.4WS coiltol unh lnd
th. ABS control unit.
Roplacalhc ABS conttol unit.

17-67

Troubleshooting(4WS)
DiagnosticTroubleCode(DTCI:33
NOTE: Problemcode 33 is memorizedwhen the front wheelsare turned at a speedot 30 km/h for 2 minuteswith the
lront wheels raisedoff the ground and the rear wheels blocked.(Parkingbrake must be off to test this code.)

-The 4WS indicator light has

boon roDortodon.
-Whh sorvic6 chack connoctor
iumpod codo 33 ir indicsted.

4WS CONTROLUNIT 18P CONNECTOR

3

Does the ABS light stay ON?

Rotate the rear left wheel slowly

and check for voltage btween
the 4WS unit control No. 1 terminal IGRY/RED)
and body ground,
and betweenthe No. 3 terminal
(GRYA HT) and body ground.

(To page 17-69)

17-68

0-5 V?

View from terminalside

Perfo.m troubleshooting ol tho ABS system
(pag6 '19-541

Stop the engino.Then turn the ignition switch back ON.

Doesthe voltage from both rear

wheel sensorsalternatefrom
zero to approximately5 V?

Record tho DTC and clear th6

4WS control unit. T6st driv th
car, if th6 DTC doos not rsappoar,
chock tho torminal3 connoctions
ot tho 4WS control unit 18P connector and tho ABS control unlt
14P connoctor.

(Frompage 17-68)
4WS CONTROLUNIT

'I8P SENSORSIDECONNECTOR

Disconnoctthe 4WS control unit

connector and the ABS control
untl connectol,

Chockfor continuity between the

4WS control unit No. 1 terminsl
(GRY/RED)
and body ground.

View from terminalside

Ropai.shorl in tho GRY/REDwire

botwoen 4WS control unit and the
ABS control unit.
4WS CONTROLUNIT 18P SENSORSIDECONNECTOR
Check for continuity between the
4WS controlunit No. 3 terminal
{GRY/WHT)and body ground.
Ropairlhon in th6 GRY/WHT wiro
between tho 4WS control unit snd
tho ABS control unit.

View from terminal side

4WS CONTROL UNIT 18P CONNECTOF

Measure voltage between the

4WS control unit No. 1 terminal
(GRY/RED)
and body ground.
View from terminalside
ls there approximately5 V?

Roplac6ths 4WS control unit.

YES
{To page 17'70)

17-69

(4WSl
Troubleshooting
Diagnostic
TroubleCode(DTCI:33 (cont'dl-DiagnosticTroubleCode{DTC}:50
{Frompage 17-691

4WS CONTROLUNIT 18P CONNECTOR

Measure voltage between thg

4WS control unit No. 3 terminal
IGRYMHTI and body ground.
View from terminalside
ls there approximately 5 V?

Beolaco tho 4WS control unit.

ABS CONTROLUNIT 14P CONNECTOR

Measure vollage between the

ot the
No. 7 terminal{GRY/RED}
14Pconnectorof the ABS control
unit and body ground.

9;;;

TERMINAL

View from terminalside

ls there approximstely 5 V?

Ropairopn in th6 GBY/REDwiro.

ABS CONTROLUNIT

'I4P CONNECTOR

Measure voltage between the

No. 8 tgrminalof the 14Pconn6ctor of the ABS control unit and
body Oround.
View from interiorside
ls there approxinately 5 V?

REARACTUATOR MOTOR TERMINAL

Baplaco the ABS control unit.

Diogno.tic Trouble Cod6 (DTCI: 50

-The 4WS indicato. light hes

boon rcooned on.
-with
aoavico Ghock connectol
iumped codo 50 is indicolod.

Start the engine. Turn the stoeF

ing wheel and check the rear
stering motor lor function,

Does it operate properly?

4WS CONTROLUNIT POWERTERMINAL

Cloa. tho 4WS control unit and
rotort, if tho DTC roccouB, then
.6placo tho contlol unit.

8LK MOT _

l
Roplacotho r6aaactuator motot.

R E DM O T +

BRN GND

l
WHT+B

View from terminalside

17-70

60, 61, 62, 63

Trouble
Codes(DTCsl:
Trouble
Code(DTCI:51-Diagnostic
Diagnostic
Diagnostic Trouble Codo {DTC}: 51

-Tho 4WS indicstor light ha8

boon rgportod on.
-Wlth s6rvico chock connoctoi
iump6d codo 51 is indicatod.

Start the engine. Turn the steer

ing wheel and check the rear
steeringmotor for function.

Does it operate properly?

Th6 DTC 51 blinkt whon lhg roar

whoals cannot bo atoerod bgcause th6y aia blockad wfth tho
cuab, otc.
ll tho DTc 51 blink! aftor rhr rg3t
drivo, tho control unit i. taultY.

Rolacoth6 roar actuatoamolor.

4WS CONTROLUNIT POWERTERMINAL

Diagnostic Troubl Codes {DTCS):60, 61, 62, 63

-Th6 4WS indicator light h.s
boen roportod on.
-With sorvico chock connoctor
iumpod codos 60, 61,62, 63
aro indicatad.

B.tt.ry Voltago?
Batt.ry Voltage?

check the No.38 4ws fuse

(60 AI in the under-hoodfuse/re-

Battory Volrage?
View from interiorside

Roplaco th turo lnd rccheck

Measure voltage between the A

rarminal(WHTI of the 4WS con
trol unit powerterminalandbody
grouno.
Ropairopon in th6 WHT wi.a botwo.n thq undo,-hood fute/tol.y
box and tho 4WS control unlt.
Measure voltage between the B
terminallBRN)of the 4WS control
unit power torminal and body
grouno.
Rop.lr tho poor gtound lG5O2l or
opon in ths ERltl wiro balw.dr lh6
4WS cont.ol unlt and bodY
ground lG5O2l.
Startthe engineand immediately
(withinapproximately
2 seconds
after starting the engine) check
for voltage between the C termi
nal {RED)of the 4WS controlunit
powrterminaland bodyground.

Roplsco th6 4WS control unit.

7-7

Troubleshooting(4WS)
DiagnosticTroubleCodes(DTCs):60, 61, 62, 63 (cont'd)
4WS CONTROLUNIT POWERTERMINAL

l F r o mp a g 1 7 - 7 1 )

Stop the engineand turn the ig_

nition switch ON.

Measure voltage between the D

terminal (BLK)ot rhe 4WS control
unit power terminal and body
groundimmediatelyafter {wilhin
approximately2 seconds)starting
the engrne.

Roplacolh 4WS control unit

Measure voltage between the C

terminal(BED)of the rear actu
ator motor and body ground
after{withinapproximmediately
imately 2 seconds)startingthe
engine.

ls there battery voltage?

Repair opsn in the RED wi.o betwoen tho 4WS control unit and
tho roar actuator motor.

Measurevoltagebetweenthe D
rerminal{BLK}of the rearactua
tor motor and body ground
alter {withinapprox'
immediately
imately 2 seconds)startingthe
engine.

ls there battery voltage?

Measure voltage between the

No. 33 terminal{YEL}of the rear
actuatormotor and body ground
immediatelyafter lwithin approximalely 2 secondslstartingthe
engine.

Ropair opon in the BLK wir6 between tho 4WS control unit and
the rcar actuator motor.

ACTUATORMOTORTERMINAL

D U P + N O .3 3 I Y E T I

(To page 17 73)

Battery Voltag6?

17-72

lftonl. page 17-721

ls there battery voltage?

Raolacotho rsar actuato. motor.

ACTUTOR MOTOR TERMINAL

Measure voltage between the

No. 34terminal(8LU)of the rear
actustor motor and body ground
immodiatelyafter (within approximately 2 secondsl slarting the
engrn9.

ls there battery voltage?

Roplacotho roar actuator motor.

Meaaure voltsge between the

controlunitNo. 33 terminal(YEL)
and body ground immediatelvafter (within spproximately 2
seconds) starting the engine.
Ropair op.n in tho YEL wir6 botwo6n the 4WS cont.ol unit and
tho roar actuator motot.
4WS CONTROLUNIT 4P CONNECTOR

Measure voltage between the

control unit No. 34 terminal (8LU)
and body ground immediatelyatter (within approximstely 2
seconds) starting the ngine.

ls there baftery voltage?

Roplacs lhc 4wS control unit.

'rT\

ffi

( v ) ( vBattory
) Voltago?
Repaii opon in the BLU wir6 b6twoon th6 4ws control unil and
the ioai actuator motoi.

Y:T

View from terminalside

Maintenance
Pump Belt Adjustment
NOTE: When using a new belt, first adiustthe deflection or tensionto the valuesfor the new belt.then read
just the deflectionor tensionto the valuesfor the used
belt after runningenginefor tive mjnutes.
1 . A p p l ya l o r c eo f 1 0 ON ( 1 Ok g , 2 2 l b s )a n d m e a s u r e
the deflectionbetween the power steeringpump
and the crankshaftPulleys.
Doflection:
U s 6 db e l t : 1 3 . 5 - 1 6 . 5 m m { 0 . 5 3 - 0 . 6 5 i n l
New belt: 9.5-11.5 mm (0.37-0.45 in)
NOTE: lf there are cracks or any damageevident
on the belt, replaceit with a new one.
PULLEY
POWERSTEERING

2,

Loosen the power steering pump mounting bolt,

nuts and adjustingbolt locknut.

3.

Turn the adjustingbolt to get the properbelt ten

sion, then retightenthe adiustingbolt locknut and
mountingbolts.

4.

Start the engineand turn the steeringwheel lrom

lock-to-lockseveraltimes,then stop the engineand
recheckthe deflectionof the belt

POWERSTEERING
BOLT
MOUNTING
22 N.m 12.2kg-m,16lb-ftl

AOJUSTING BOLT LOCKNUT

15 N.m 11.5 kg-m, 1 1 lb-tt)

Measurewith Belt TensionGaugel

Attach the belt tension gauge to the belt and
measurethe tension of the belt.
T6nsion:
U s db o l t : 3 5 0 - 5 O O N ( 3 5 - 7 0 k g , 7 7 - 1 1 Ol b s l
Now belt: 7oo-9oo N {70-90 kg, 154-198 lbs}
NOTE: lf there are cracks or any damageevident
on the belt, replaceit wilh a new one.
Follow the manufacturer'sinstructionslor the tensrongauge.
PULLEY
POWERSTEERING

CRANKSHAFTPULLEY

17-74

ADJUSTING
POWERSTEERING
MOUNTINGNUTS
2 2 N ' m ( 2 . 2k s ' m , 1 6 l b - t t )

On-CarChecks
RackGuideAdjustment
CAUTIONTwhen servicing,be careful not to damage
the power steering fluid linss with the special tool.
RACK GUIOESCREW

NOTE: Adjust the rack guide at the center ol the rack

stroke.
2WS:
'1.
Removethe gearboxshield.
2.

Loosen the rack guide screw locknut with the

specialtool.

3.

Tighten,loosenand retightenthe rack guide screw

two times to 4 N.m (O.4kg-m, 2.9 lb-ft) then back
*
it oft 20 3".

4.

T i g h t e nt h e l o c k n u tt o a b o u t 2 5 N . m ( 2 . 5 k g - m ,
18 lb-ft) while holdingthe guide screw.

5.

Checkfor tight or loosesteeringthrough the complete turning travel.

6.

R e c h e c ks t e e r i n ga s s i s t( s e ep a g e1 7 7 9 ) .

1 7- 7 5

On-CarChecks
Rack Guide Adjustment {cont'd)
4WS:
'1. Removethe gearboxshield.
2.

Cut wire tie trom the cover, then removethe cover

from the front sub steeringangle sensor,
CAUTION: Cut the wire tie with carefullv,so as
not to damago the harness.

SENSORWIREHARNESS

cot{t{EcToR

4. Loosen the rack guide screw locknut with the

specialtool.
5. Tlghten.loosenand retightenthe rack guidescrew
two times to 4 N.m (O.4kg-m, 2,9 ib-ft) then back
*
it olf 20 !'.
6. Tighten the locknut to about 25 N.m (2.5 kg-m,
18 lb-ft) while holdingthe rack guide screw.
7. Check for tight or loosesteeringthrough the complete turningtravel.
8. Rechecksteeringassist (seepage l7-79i.

COVER

zo.3'
ANGLESENSOR
FRONTSUBSTEERING

3. Removethe sub steeringanglesensorwire harness

from the clamDand disconnectthe connector.
RACKGUIDESCREW
LOCKNUT

LOCKNUTWRENCH,43 mm
07MAA-S10020A
RACKGUIDESCRW

9. Reconnectthe connector and secure the sensor

wire harnesswith the clamp and installthe cover.
NOTE:
a Be sure the sensor wire harness dois not interfere with the stabilizer and other moving
parts.
a Be certain that the sensor wire harnessis not
twisted before connectingit.
1O. Set the cover on the tront sub steerangangle sensor. Securethe cover with the new wire tie.
NOTE: After rack guide adjustment,perform the
electrical check on the 4WS system (see page
17-146).

17-76

On-CarChecks
Fluid Replacement
Fluid Level Inspection

FluidReplacement

Check the power steeringfluid level with the engine

cold and the car parkedon levelground.Make surethe
fluid levelis betweenthe UPPERand LOWERlevellines
on the reservoir.lf the level is near or below the lower
level line, check the system for leaks.lf the system is
not leking.and fluid levelis low, add fluid to the upper
level line.

1.

Raisethe reservoirand disconnectthe hose that

goes to the oil cooler.

2.

Connecta hose of suitablediameterto the disconnected hose that goes to the oil coolerand put the
hose end in a suitablecontainer.

3.

Startthe engine,let it run at idle,andturn the steering wheel from lock-to-lockseveraltimes When
tluid stops running out ol the hose, shut off the
engine.
Discardthe fluid.

RESERVOIR

4.

Reconnectthe return hose to the reservotr.

Fill the reservoirto the upoer levelline.
NOTE: Take care not to spill the fluid on the body
and parts. Wipe oll the spilledat once,
CAUTION: Uso only Honda Power Stsering
Fluid-V. Using other fluids such as ATF or othor
manufactuer's pow6r steering fluid will damagethe
systm.
System Capacity:
1 . 7 l i t e r( 1 . 8 0 U S q t , 1 . 5 o l m p q t l 8 t c h a n g o
RosorvoirCapacity:
O.5 liter 10.53 US qt, 0.44 lmp qt)
Start the engine and run it at idle, then turn the
steeringfrom lock-to-lockseveraltimesto bleedair
from the system.

7.

Recheckthe fluid leveland add some if necessary.

CAUTION: Do not fill the reservoirbeyondthe upoer lovgl line.

1 7- 7 7

On-GarChecks
Pump PressureCheck

Check the fluid Dressureas follows to determine

whether the trouble is in the pump or gearbox.
NOTE: First check the power steeringtluid level
and pump belt tension.
CAUTION: Dlsconnct tho high plossule hosa
carofully, so as not to spill tho power steering tluid
on thg trame and other parts.

O p e nt h e s h u t o f f v a l v ef u l l y .
5 . Open the pressurecontrol valve fully.
6 . Start the engineand let it idle.
'1.

8.

Close the shut oft valve, then close the pressure

control valve gradually until the pressuregauge
needleis stable.Readthe pressLrre.

9.

l m m e d i a t e loyp e nt h e s h u t o l f v a l v ef u l l y .

1. Disconnectthe outlet hose from the pump outlet

Jifting, and install the pump joint adaptor on the
pump outlet.
2.

Connectthe hoseioint adaptorto the power steering pressuregauge,then connectthe outlet hoseto
the adaotor.

3.

Install the power steering pressuregauge to the

pump joint adaptoras shown.

P/S JOII{T ADAPTOR{PUMPI

oTNAK-SR30l1A

Turn the steeringwheel from lock-to-lockseveral

times to warm the fluid to operatingtemperature.

CAUTION: Do not keep the shut-oft valve closed

mol than 5 secondsor the pump could be damaged by over-heating.
l l t h e p u m p i s i n g o o dc o n d i t i o nt,h e g a u g es h o u l d
r e a d a t l e a s t7 , O 0 O - 8 , O O 0k P a ( 7 0 8 0 k g / c m ' ,
9 9 5 1 , 1 3 8 p s i ) .A l o w r e a d i n gm e a n sp u m p o u t put is too low for full assist. Repairor replacethe
pump.

P/S JOINT AOAPTORIHOSE)

07NAK-SR3012A

VALVE

SHUT-OFFVALVE

17-78

SteeringWheel RotationalPlay
1 . Placethe lront wheels in the straight ahead position and measurethe distancethe steeringwheel
can be turned without movingthe front wheels.

Power Assist Check with Car

Parked
'1.

Check the power steering fluid level and pump beil

Iensron.

2,

Start the engine.allow it to idle, and turn steering

wheel from lock-to-lockseveraltimes to warm up
the Jluid.

3.

Attach a spring scaleto the steeringwheel. With

the engineidling and the car on a clean.dry floor,
pull the scale as shown and read it as soon as the
tires begin to turn.

2 . lf the play exceedsthe servicelimit.checkall steering components.

0- 10 mm (O-0.4 inl

SPRING
SCALE
The scaleshouldread no more than 30 N (3.O kg,
6.6 lbs).
lf it readsmore or less,go on step 5.
Stop the engine. Disconnectthe hose from the
power steeringspeedsensorand plugthe hoseand
the sensorfitting as shown.

POWERSTEERING
SPEEDSENSOR

o.

Start the engineand let it idle.

a I t t h e r e a d i n gi s n o w 3 0 N ( 3 . 0 k g , 6 . 6 l b s ) o r
less. replacethe power steeringspeed s e n s or ,
see page 1 7-8O.
a lf the readingis still more than 30 N
6 . 6 l b s ) ,c h e c kt h e g e a r b o xa n d p u m p

17-79

On-CarChecks
Assist Check at Road Speed
'1.

Check the power steering fluid level lsee page

17-771and pump belt tension (see page 17 74).

P o w e r S t e e r i n gS p e e d S e n s o r
Replacement
1.

Removethe rear mountingbracketstay.

2.

Disconnectthe sensor wire connector trom the

power steenngspeeo sensor.

2 . Sta.t the engine,let it warm up to normaloperating

temperature(the cooling fan comes on), and turn
the steering wheel lock-to lock a few times to
warm up the fluid.
Stop the engine.To simulatespeedsabove 50 mph
(80 km/h), disconnectthe hoses from the power
steering speed sensor and connect them to the
bypasstube joint. PIugthe end of the bypasstube
joint.
BYPASSTUBEJOINT
07406-0010101
(lncluded with

07406-0010001)

3 . Remove the sensor mounting bolt and pull the

power steeringspeed sensorlrom the diflerential
nousrng.
4.

Disconnectthe sensorhosesand plug the tittings.

SENSORMOUNTINGBOLT
6 x 1 . Om m
19 N.m
(1.9 kg-m, 14 lb-ft)
NEARMOUNTING

POWERSTEERING
SPEEDSENSOR

HOSES

BRACKETSTAY

Plugs.

4.

Attach the springscaleto the steeringwheel.With

the engineidling and the car on a clean,dry floor,
pull the scale as shown and read it as soon as the
tires beginto turn.

10 x 1.25mm
21 N.m
( 2 . 1k s - m ,1 5 l b - f t I

O-RING
Replace.
'l
10 r .25 mm
N.m
39

(3 9 kg-m' 28 lb-ftl

Alter installinga new power steeringspeedsensor,

turn the steeringwheellock to lock with the engine
idlingto bleed air lrom the system.
6 . Checkthe reservoirand add fluid if necessary(see
p a g e1 7- 7 7 1 .
lf the scalereadsa normal50 N (5.o kg, 1 1 lbs),
or more the assistproblemat high speedsis being caused by reduced power steering speed
sensoroutput.
Replacethe power steeringspeed sensor.
l f t h e s c a l er e a d sl e s st h a n 5 0 N ( 5 , Ok g , I 1 l b s ) ,
the power steeringspeed sensoris OK and the
problemis in the sensorleed line, the pump, or
lhe valve body unit.
Seeif the feed line is pinchedor bent then check
pumpSee GeneralTroubleshooting(seepage 17-25).

17-80

SteeringWheel
- Removal
Disconnectthe negative and positive cable from
the battery.

with sRs:
store a removed driver's airbag
!@
assemblywith the pad surlace up, i{ lhe airbaqis
impropelly stored face down, accidentaldeployment could propel tho unit with enough lorc to
cause sedous injury.
CAUTION:
a Eefore removing the steering wheel, align the
front wheels straight ahead.
a Do not installused SRS parts Jrom anolhercar.
When repairing,use only new SRS parts.
a Caretully inspecl the airbag assmbly belore installing. Do not install an airbagassemblythat
shows signs of being dropped or imp.oparly
handled,such as dents, cracks or deformation.
a Always keep the shon connector(s)on the airbag(s)when the harnessis disconnected.
a Do not disassembleor tamper with the airbag
assembly.
NOTE:
The radio may have a coded theft protectioncircuit. Be sure to get the customer's code number
betore
- Disconnectingthe battery.
- Removing
t h e N o . 4 3 ( 1 OA ) t u s e l i n t h e u n d e r hood fuse/relaybox).
- Removingthe radao.
After service, reconnect power to the radio and
"CODE" is displayed,
turn it on. Whenthe word
enter the customer's s-digit code to restoreradio
ooeration.

Removethe accesspanel from the steeringwheel

lower cover, then remove the short connector
(RED).
Disconnectthe connectorbetweenthe airbagand
c a b l er e e l .

4.

Connect the short connector (RED)to the airbag

side ot the connector.

ACCESSPANEL

Removethe covers.
Remove the two TORXo T3O bit bolts, then
removethe driver's airbagassembly.
DRIVER'SAIREAGASSEMBL

1..-\

&

I\T
TORXO
Replace.

SRSMAIN HARNESS

(cont a

17-81

SteeringWheel

t-

Removal(cont'd)
7.

Disconnect the connectors from the horn and

cruisecontrol set/resumeswitches connector'

CRUISECONTROL
SET/RSUMESWITCHES

Without SRS:
- Removethe emblemand steeringwheel nut'
NOTE: Be carefulnot to damagethe emblemand steering wheel.
- Remove the steering wheel by rocking it slightly
from side-toside as you pull steadily with both
hands.
STEERINGWHEEL
EMBLEM
NUT
Replace.

II

bo

STEERINGWHEEI.

- Removethe steeringwheel nut

- Remove the steering wheel by rocking it slightly
Irom side-to-sideas you pull steadily with both
hands,

17-82

Disassembly/Reassembly
CAUTION:
a Carelullyinspectths driver'sairbagass6mblybetore
installing.Do not installthe driver'sairbagassembly
that shows signs ol being dropped o. impropo.ly
handled,such as dents, cracks or deformation.
a Always keep the short connector{s}on the airbag(s}
when the halnessis dioconnected.
o Do not disassembleor temper, with the d.ivsr's airbag assembly.

store a rsmoved driver's airbag assombly

@
with the pad su.face up. ll the airbsg is improperly
stored faco down. accidental deploymont could propol
th unit with 6nough forc6 to cause serious inlury.
NOTE: lf an intact driver's airbag assemblyhas been
removedfrom a scrapoedcar or has beenfound defective or damaged during transit, storage or service, it
shouldbe deploved(seesection 23).
<With SRS:>
WHEELNUT
STEERING
5ON'm
(5.Oks-m, 36 lb-ft)

\
roRx@
BoLr \

WHEEL
STEERING

-Rg

ii#I'i" b
\*.R=

p^

$q>
I

DRIVER'SAIRBAG
ACCESSPANEL

<Without SRS:>

Qlt

I
I

EMBLEM

7 -83

SteeringWheel
lnstallation
2WS/With SRS:
CAUTION:
a Bfore installing the stearing wheel, align the
front wheels straight ahead.
a Be suro to install the ha.ness wires so that they
are not pinched or interfering with other ca.
pans.
a Do not replace the original steering wheel with
any othor dsign, since it will make it impossible
to properly install the airbag. lOnly use gsnuine
HONDA replacement pans)
a Aftel ieassembly, contirm that the wheels are
still straight ahead and that steering wheel
spoke angle is co ect. lf minor spokeangle adiustmnt is necessary, do so only by adiustment
of tho ti rods, not by lemoving and lspositioning the stesring wheel.

2.

Installthe steeringwheel and tighten the steerang

wheel nut.
NOTE: Be sure the steeringwheel shaft engages
the pins of the cable reel.
CABLEREEL
PIN

WHEEI
STEERING
NUT
50 N.m
l5.O kg-m, 36 lb-ft)

conlirm that ths driver's airbag

l@
assembly is socutely attached to lhe steering
whe6l; othorwise, sgvgie personal iniury could
result during airbag dgploYment
1.

Before installing the steering wheel, center the

cable reel,
Do this by first rotatingthe cablereelclockwiseuntil it stops.
Then rotate it counterclockwise(approximately
two turns) until:
- The yellow gear tooth lines up with the alignment mark on the cover.
- The arrow mark on the cable reel label points
straight uP.

ALIGNMENTMARK

17-84

WHEEL
lnsert the cruise control set/resume swltches connector to the steering wheel clips.
Connect the horn connector.

5,

Install the driver's airbag assembly with new

TOBXo bolts.
DRIVER'SAIRBAGASSEMBLY

TORX@ BOLT
lO N.m {'l.O kg-m, 7 lb-ft|

9. Connect the battery positive terminal and then

connectthe negativeterminal.
'10. After installingthe driver's airbagassembly,con
firm propersystem operation:
a Turn the ignition to ll position:the instrument
p a n e l S R S i n d i c a t o rl i g h t s h o u l dc o m e o n f o r
about six secondsand then go off.
a Confirmoperationof horn buttons.
a Confirm operationof cruise control set/resume
S\/!r'rrcns.
a Turn the steeringwheel counterclockwiseand
m a k e s u r e t h e y e l l o w g e a r t o o t h s t i l l I i n e su p
with the alignmentmark.

TORX@ BOLT

10 N.m 11.0kg-m, 7 lb-ftl

6.

Disconnectthe short connector(RED)from the airbag connector.

7,

Connect the airbag connector and cable reel

connector.

8.

Attach the short connector {BED) to the access

panel, and installthe accesspanelon the steering
lower cover.

YELLOWGEAR TOOTH
CAELE REEL
CONNECTOR

SHORTCONNECTOR

17-85

SteeringWheel
Installation(cont'd)
2ws/without SRS:
1. Installthe steeringwheel and tighten the steering
wheel nut.

4WS/With SRS:
CAUTION:
a The tront main steeringangle sensor with the
neutrallock mechanismis mounted on the column shall ot the car. When the steeringwheelis
removed,the rotationpart oJ the sensoris locked at the electricallyneutral position,and it is
unlockdwhen the steelingwheel is inserted to
the specifiedinstallationposition.
a lf the spokeangleis not at the designatedangle
while driving straight, check the front and rear
wheelsfor properalignmentbeforeadjustingthe
spokg angle.
Pertorm the electronic n6utral check ot the 4WS
systemto be surethat the rearwheelsare at the
correct steedng angle while driving {see page
17-146).
a B6fore installingthe steering wheel. align the
f.ont whsels straight ahead.
a B su.e to installthe harnesswiles so that they
aie not pinched or interfering with other car
oarts.
a Do not replacethe originalsteeringwheel with
any other design,sinceit will make it impossible
to properlyinstallthe airbag.lOnly use genuine
HONDA replacementparts)

NOTE: Align the slots on the steeringwheel and

tabs on the turn signalcancellingsleeve.
2.

Installthe emblem.
WHEEL
STEERING
SIGNAL

STEERINGWHEEL

EMBLEM

STEERING
WHEELNUT
50 N.m
{5.Oks-m, 36 lb-ft|

confirm that the airbag assemblyis

!@
securelyattachedto the steedngwheel;otherwise,
sevorepersonalinjury could tesult during later airbag dsployment.
1.

Beforeinstallingthe steeringwheel, centerthe ca

ble reel.
Do this by first rotating the cable reel clockwise
until it stops.
w ise (approximatelv
Then rotate it counterclock
two turns) until:
- The yellow gear tooth lines up with the align
ment mark on the cover.
The arrow mark on the cable reel label points
strarghtuP.
ARROWMARK

ii.

fr.
l

CABLEREEL

ALIGNMENTMARK

17-86

2 . Temporarilyinstall the steering wheel aligning it

6.

with the column shaft serration.

Turn the steeringwheel fully to the right and left
and set the steering wheel in the center of the
rangewhere the front wheels move (i.e.centerthe
steeringrack).

Reinstall the steering wheel in the straight ahead

d r i v i n g p o s i t i o n ,b e i n g c a r e f u ln o t t o m a k e i t o f f t o
either side from the position set in step 3.
NOTE:
a A l i g n t h e h o l e i n t h e s l e e r i n gw h e e l w i t h t h e p i n
of the cable reel.
a Align the steering wheel with the sefiations
which makes the spoke angle closest to
horizontal.

NOTE:
a Be sure that the tront wheels are in the straight
aheaddrivingposition.
a Be sure the steering wheel shaft engagesthe
Dinsof the cable reel.

\,'
CABLEREEL

tE#

ffi

7.

\rD,,

i rj

/^\

4.

Removethe steeringwheel.
Check whether the yellow paint mark of the tront
main steering angle sensor rotor is facing down
(i.e. in neutral lock position where the rotor does
not turn).

lf the spoke angle is not horizontal, adjust the steer

ing wheel slightly right or left, without pushing in
the steering wheel too deep.

WHEELNUT
STEERING
50 N'm
{5.0 kg-m, 36

NOTE: lf the paint mark is not facingdown, adjust

as tollows.
1) Temporarilyinstallthe steeringwheel with the
spokesat a horizontalangle.
2) Turn the steeringwheel until the mark is facing
down.
3) Returnthe steeringwheel spokesto the horizontal angle set in the step 1, being carefulnot to
push in the steeringwheel. Removethe steering

With the spoke angle set at the horizontal, then

push the steering wheel in fully. Tighten the steer
ing wheel nut while pushing the steering wheel
NOTE: Do not turn the steering wheel when
pushing the steering wheel.

wneet.
8.
FRONTSTEERINGANGLE

Check the four front and rearwheelsfor alignment

and perform the electronic neutral check on the
4 W S s y s t e m ( s e e p a g e 17 1 4 6 ) .

sEilsoR
ICOn: -

17-87

SteeringWheel
lnstallation{cont'd)
9. Insertthe cruisecontrol set/resumeswitches connector to the steeringwheel clips.
Connectthe horn connector'

SWITCHES
SET/RESUME

1 1 . D i s c o n n e ct th e s h o r tc o n n e c t o(rR E D f)r o m t h e a i r
bag connecror.
'12.

Connect the airbag connector and cable reel

connector.

13. Attach the short connector (RED)on the access

panel,and installthe accesspanel on the steering
lower cover.

IREDI

10. Install the driver's airbag assembly with new

TORX@bolts.

ORIVER'SAIREAGASSEMBLY

BOLT
10 N.m {1.O kg-m
7 rb-ft1

17-88

TORXO EOLT
10 N.m 11.0kg-m, 7 lb-ftl

14. Connectthe batterypositiveterminalandthen con

nect the negativeterminal,
15. After installingthe driver's airbag assemblY,con
lirm ProPersYstemoPeration:
a Turn the ignition to ll positionl the instrument
panel SRS indicator light should come on for
about six secondsand then go off.
a Confirm operationof horn buttons.
a Contirm operationot cruise control set/resume
switches.
a Turn the steeringwheel counterclockwiseand
make sure the yellow gear tooth still lines up
with the alignmentmark.

SteeringColumn
Removal
1 . Removethe driver's airbagassemblyand steering
w h e e l( s e ep a g e 1 7 - 8 1 ) .

Wirh 4WS:
CAUTION: Th6 front main steering angle sonso.
with the neutral lock machanism is mounted on the
column shaft ol the car. When the steering wheelis
removed, the rotation part ol the ssnsof is locked
at tho olectrically nautral position, and it is unlockd whgn the stooring whoel is inserted to th
spociliod installation position.

Remove the steeringjoint bolt and toothed lock

washer (from the enginecompartment).

TOOTHEDLOCK WASHER

with sRs:
CAUTION:
a All SRS glsctrical wiring hamossas are coversd
with yellow outer insulation.
a Before disconnocting thg SRS wire harness install th6 $hort connector(s) on the airbag(s)(s6e
page 23-290|.
a Rplace tho entire affected SRS harnass
assembly it has an open circuit or damagsd
wiring.
NOTE:
The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode number
betore
- Disconnectingthe battery.
- Removingthe No. 43 (1O A) fuse lin the underhood Juse/relaybox).
Removingthe radio.
After service, reconnect power to the radio and
"CODE" is disolayed,
turn it on. When the word
enter the customer's s-digit code to restoreradio
oDeratlon.

SRSMAIN HARNESS

Remove the dashboard lower cover and driver's

knee bolster.

DRIVER'SKNEEBOLSTER

OASH BOARD
LOWERCOVER

(cont'd)

17-89

SteeringColumn
Removal(cont'd)
4.

Removethe upper and lower column covers.

6.

Removethe cable reel assembly(SRSonly).

CABLEREELASSEMBLY

Removethe cable reel harnesslrom the underside

oJ the column bracket by removingthe clip (SRS
onlv).

7.

Removethe turn signalcancelingsleeve,combination switch assemblyand front main steeringangle

sensor(4wS only) by removingthe circlip
NOTE: After removingthe combinationswitch assembly, place it on the floor gently so that it does
not hinderyou in service.Do not disconnectthe cables from the combinationswitch assembly.

CIRCLIP

@!
\
TURNSIGNAL
CANCELING
SLEEVE

CLIP
SRS WIRE HARNESS
FRONTMAIN STEERING
ANGLESENSOR
(4WS Only)

17-90

8.

Removethe air duct.

1O. Disconnectthe ignitionswitch wtre connecror.

1 1 . Removethe steeringcolumnassemblyby removing
the attachingnuts. bolts and column holder.

AIR OUCT

9.

COI-UMNHOLDER

Removethe steeringjoint cover.

STEERINGJOINT
COVER

1 7- 9 1

SteeringGolumn
Inspection
NOTE: Checkthe tilt mechanism,steeringioint bearingsand steeringshaft for propermovementand damage
as an assemblyif damagedor faulty.

Replace

CAUTION: Do not apply an impact load to the column shaft in the axial direction
Front Main Stooring Angle Sensor (4WS):
Checkwhether the Yellowpaint mark of the front main
steering angle sensor rotor is facing down {i.e in
neutral lock position where the rotor does not turn).
This indicatesthat the front main steeringanglesensor
is electronicallyin neutral.

FRONTMAIN STEERING
ANGLESENSORI4WS ONLY}

YELLOWPAINTMARK

CAUTION: It th tront main steering angle sensor is

unlocked onca, turn it to tho locking position and lock
sgcu16ly.

RETAINING
COLLAR
Checkfor damage.

STEERINGCOLUMN

rN-\

qt

FRONTMAIN STEERING
ANGLE SENSOR

t4ws oNLY)

FLANGENUT
I x 1 . 2 5m m
't6 t{.m
('1.6kg-m, 12lb-ft)

tr
,,,\
colur'rr ttot-DER
,{g

FLANGEBOLT
39 N.m (3.9 kg-m, 28 lb-fil

a Check the tilt mechanismfor propermovement

and damage.
- Attach a springscaleto the knob of the tilt lever.
Measurethe preloadrequiredto move the lever.
Prsload:7O-9O N U-9

(2.2 kg-m, 16 lb-tl)

SPRINGSCALE
TILT LOCKBOLT

-6.1
STOPPER

kg, 15-20 lbs)

- lJ the preload measured is not within the

specification.removethe 6 mm bolt and stopper. Then adjust the preload by tightening or
looseningthe tilt lockboltat the lever pulledup.
- Reinstall the stopper and 6 mm bolt, then
recheckthe preloadagain.
CAUTION: Do not loosen the tilt lover when setthg dp ltoppor and when iightening the bolt.

17-92

6 mm EOLT
1 0 N . m { 1 . 0 k g - m ,7 l b - f t l

lnstallation
NOTE:
a Be sure the pinion shaft and the steeringshaft are
aligned;the joint should sllp on freely.
lf not, repositionthe steering rack to correct the
misalignment.
a Coat the interiorof the steeringjoint grommet with
grease.
1.

4.

Installthe steeringjoint cover with the clampsand

cliP.

Guidethe steeringshaft through the enginecompartmentbulkhead.Align the bolt hole in the steering joint with the slot in the steeringshaft, and insert the shaft into the steeringjoint.
STEERINGJOINT BOLI
Bolt rnust line up with lhe
tlat on shaft22 N.m
STEERINGSHAFT (2.2 kg-m, 16 lb-fi)
JoINT
COVER
5.

SREERIITG
JOINT
Slip the upperend of the steeringjoint onto the steering
shafi (lineup the bolt hole with the groovearoundthe shaft)
and inslallthe steeringioint bolt.

Installthesteeringcolumnassemblywith the nuts,

bolts and column holder.

CLIP

Install the front main steering angle sensor (4WS

o n l y ) , c o m b i n a t i o ns w i t c h a s s e m b l ya n d t u r n s i g n a l
c a n c e l i n gs l e e v e w i t h a c i r c l i p .
NOTE:
a Be sure the wires are not caught or pinched by
any parts when connecting the combination
switch and the cable reel.
a A l i g n t h e s l o t s I n t h e t u r n s i g n a lc a n c e l i n gs l e e v e
w i t h t h e t a b s o n t h e f r o n t m a i n s t e e r ; n ga n g l e

sensor,
TURNSIGNALCANCELING
MAIN STEERING SLEEVE

FRONT

Connectthe ignitionswitch connector.

COMBINATION
SWITCH

16 N.m
11.6kg-m, 12 lb-ft)
HOLDER

39 N.m
13.9kg-m,28 lb-ftl
FRONTMAIN STEERING
ANGLESENSOR
l4WS Onlyl
tconl c

17-93

SteeringGolumn
Installation(cont'd)
6.

Installthe cable reel assemblY(SBSonlv).

8.

Installthe upper and lower column covers

NOTE: Align the slot in the cancelingsleevewith

the projectionon the cable reel (2wS only).
UPPERCOLUMNCOVER

2WS:
PROJECTION

FROI{T MAII{ STEERINGANGLE SENSOR

9.

Installthe air duct.

Connect the cable reel harness and SRS wire

harness,then attach the cable reel harnesson the
undersideot the column bracket with the clip.

AIR DUCT

SRS WIRE HARNESS

17-94

1O. Install the driver's knee bolster and dashboard

tower cover.

DRIVER'S
BOLSTER
6 mm BOLT
WASHER
1 ON . m
(1.O kg-m, 7 lb-ltl
DASH BOAND
LOWERCOVER

1 1 . I n s t a l l t h e s t e e r i n gw h e e l a n d d r i v e r ' s a i r b a g
a s s e m b l y( s e ep a g e 1 7 8 4 o r 8 6 ) .

17-95

SteeringPump
PulleyReplacement

Replacement
NOTE: Beforedisconnectingthe hosesfrom the pump,
place a suitablecontainerunder the car.
1.

Orainthe tluid from the system (seepage 17-77).

2.

Removethe belt by looseningthe power steering

mountingbolt, nut and adjustingbolt

3.

Disconnectthe inlet and outlet hoses from the

pump and plug them.

Hold the steeringpump in a vise with soft jaws, and

hold the pulleYwith the specialtool, and remove the
p u l l e yn u t a n d P u l l e Y
N O T E : P u l l e yn u t h a s l e l t - h a n dt h r e a d s .

HOLDER
UNIVERSAL
07725-O030000

NOTE: Take care not to spill the fluid on the body

and parts. Wipe oft the spilledat once
4.

Removethe power steeringmountingbolt and nut,

then removethe pumP.
ADJUSTING

o9llEr eolr

BOLT

't 't N.m

11.1kg-m, 8 lb-ft)
PUMP ASSEMBLY

O.RING
Replace.

HOSECLAMP
PULLEYNUT
Left-handthread
STEERING
MOUNTINGNUTS
22 N.m
12.2kg-m, 16 lb-ftl

Reinstallthe pulleyin the reverseorder ol removal

INLET HOSE

NOTE: Installthe pulleyas shown

POWERSTEERINGBELT
PULLEY
POWR

NUT
PULLEY
65 N'm (6.5 kg-m,47 lb-ft)

MOUNTINGBOLT
22 N.m
(2.2 ks-m. 16 lb'ft)

NOTE: Do not turn the steeringwheel while the

pump removeo.
5.

Looselyinstalla new pump on the bracket.

6.

Connectthe inlet and outlet hosesto the pump.

7.

lnstalland adiust the belt (seepage 17-741.

CAUTION:
a Mak sure that the powel steering belt is
securoly on the groove of tho pulleys
a Do not get powor stering fluid or groase in the
powsr steeiing belt or pulley {aces.
Clan ofl any fluid or gloase bsforo installation.

8.

Fill rhe reservoirwith new fluid to the UPPERlevel

fine on the reservoir{see page 17 -771

17-9 6

Check that the pump turns smoothly by turning the

pulley.

Flow Control Valve Inspectionand Replacement

Removethe controlvalve cap by removingthe two
tlange bolts.

4.

Slip the flow control valve back in the pump and

check that it moves in and out smoothly.

Removethe flow controlvalve,springand O-rings.

FLOWCONTROLVALVE

FLOWCONTROLVALVE

SPRING

"o"r*o,- uo.u. "o,

@-'@h,
,q/@

lf OK. go on to step 5; if not. replacethe flow control

vatve:
a The originalvalvewas selectedfor a precise{it in the
pump housingbore, so make sure the new one has
the same identificationmark.
IDENTIFICATION

Check lor wear, burrs, and other damageto the

edges of the groovesin the flow control valve,

Mark

FLOW CONTROL
VALVE A

S i z em m ( i n )
1 7 . 9 9 1- 1 7 . 9 9 6
(o.7083-O.7085)

FLOW CONTROL
VALVE B

17.996-18.OO1
(o.7085-O.7087)

Part Name

lconl dI

17-97

SteeringPump
Flow Control Valve Inspectionand Replacement(cont'd)
Attach a hose to the end of the flow control valve
as shown.

7. ClamDthe bottom end of the {low controlvalvein a

vise with sott jaws.
8. Unscrewthe seal in the top end of the tlow control
valve, and removeanv shims,the reliefcheck ball,
relief valve and relief valve spring.
RELIEF
CHECKBALL

'%

RELIEFVALVE

"*,",.,

11.3kg-m, 9 lb-ft)
FLOW CONTROLVALVE
Clamp this end in
a visg with sott jaws.

SPPING

9. Clean all the parts in solvent, dry them olf then

reassembleand retest the flow control valve.

Submergethe llow control valve in a containetof

power steering fluid or solvent. and blow in the
hose. lf air bubblesleak through the relief valve.
reDlaceor repairit as Jollows.

AIR PRESSURE
No mor6 than 20 kPa
{0.2 kg/cm2, 0.3 plll

NOTE: lf necessary.relief pressureis adjustedat

the factory by adding shims under the check ball
seat. It you found shims in your valve, be sureyou
reinstallas many as You took out.
'lO. lnstallthetlow controlvalve in the reverseorderof
removal.
NOTE:
a Coat the tlow control valve with power steering
fluid, then installit and sPring.
a When replacingthe flow control valve, be sur
the replacementflow controlvalvehasthe same
identificalionletter as the originalflow control
VALVE

a-fuh,
J

contnoL vlle

clp

**@'.

FLANGEBOLT
11N.m
(l .1 kg-m, a lb-ft|

22.1 x 1.9 mm O-RING

17-9 8

5.8 x 1.9 mm O'RING

Disassembly
CAUTION: The pump components are made ot aluminum. Be careful not to damago thm wh6n sorvicing.
1.

Removethe pump from car (seepage 17-96).

2.

Removethe pulley (seepage 17-96).

3.

Removethe flow control valve (see page 17-971.

4.

Removethe inlet joint and 13 x 1 .9 mm O-ring.

6 . Remove the pump cam ring from the

housing.

PUMP CAM RING

HOUSING

INLETJOINT

1 3 x ' 1 . 9m m
O-RING
Replace.

5.

Remove the pump cover and O-ring.

7.

Removethe pump rotor and pump vanes.

PUMP VANES

"d

68.5 x 1
O-BING
Replace.

f..!

PUMP COVER

(cont'dt

7-99

SteeringPump
Disassembly(cont'd)
8 . Removethe two rollersfrom the side plate.
9 . Removethe side plate and preloadspring.

11. Remove the circlip. then remove the drive shaft

from the pump housingusing a plastic hammer.
12. Removethe pump seal spacerand oil seal.

ROLLER
x 26.8 mm
CIRCLIP
SIOE PLATE

- : . ' ' - . . ., -OAtVe

U,se) / sHAFf

ff
t-\v1t

\a__-/
Il

U -.ryv:jjAr

A1/sP^cER
\:/
PUMPHOUSING

orr
sFA
OIL SEAL
Replace.

1O. Removethe O-ringsfrom the side plate.

1 3 .Inspectthe bearingby rotatingthe outer raceslowly. lf any play or roughnessis felt, it must be replaced. Performstep 14 and 1 5

1 6 . 8x 1 . 9 m m
O-RING
Replace.
Sx1.9mm
O.RING
Replace.

SIOE PLATE

BEARING

17-100

14. Remove the bearing using the special tool and

pressas shown.
Pross

HUB OIS/ASSEMBLYBASE
OTGAF-SDi+O7OO

15. Installthe new bearingusingthe pressand special

tool as shown.

Plo!!

+
Blacksealside.

Red seal side.

HUB DIS/ASSEMBLYBASE
oTGAF-SD40700
NOTE:Hold the innerrace
with the tool securely.

17-101

SteeringPump
lllustlated Index
CAUTION: Pump components aro made ot aluminum, Be careful not to damago lhem when servicing'
NOTE:
a Cleanall of the disassembledparts thoroughly.
a Replaceall O-ringsand seals.Do not dip new O-ringsand sealsin solvent; coat O-ringswith power steeringfluid
before installation,and make sure they stay in placeduring reassembly.
a lf any part denotedwith an asterisk(*) is worn or damaged,replacethe completepump.

NEEDLEROLLEREEARING
FLANGEBOLT

20 N.m
(2.0kg-m,14

iPUMP CAM RIf{G

Check lor damage
and wear,
'PUMP VANES
(10 platBl
Checkfor damage

PUMP COVER
Check for damage to
sealingface.
ROLLER
4.5 x 49.8 rnm

88.5x 1.9 mm
O.RING
Rplace.

.PUMP HOUSING
Chock {or damage to
salingfaces.

1 3x 1 . 9
o-Rtt{G
Rgplace.

16.8x 1.9 mm
O.RING
Replace.

-6.l

OIL SEA
Replace.
PUMP SEAL
SPACER
ORIVE
SHAFT
Checkfor damage
and wear.

--(cL
FLANGEBOLT
11 N.m (1.1 kg-m, 8 lb-ft}
IT{LETJOINT
FLOW CONTROLVALVE
Check lor pressure
leak.
22.1 x 1.9 mm O-Rl 6 -'>Q

17-102

and cracks.

*{@

B1.2'""'-"

BEARING
Checklor

excessive
ptay.

FLANGEAOLT
11 N.m (1.1 kg-m, 8 lb-lt)

PULLEY
Checkfor distortion

CONTROLVALVE CAP

f^@'
PULLEYNUT
65 .m
16.5 ks-m, 47 lb-ft)

Assembly
'I .

Coat the lip of the new oil sealwith steeringgrease

{ H o n d aP / N0 8 7 3 3 - B o 7 o E ) .

2.

Install the new oil seal in the pump housing by

o.

Installthe preloadspringin the pump housing.

7 . Set the 4.5 x 49.8 mm rollerin the 4.5 mm hole in

the pump housing.

hand.

Installthe pump seal spacer,then installthe drive

shaft in the pump housingusingthe specialtools.

8 . Set the side plateover the rollerand installit on the

pump housrng,
o Set the 5 x 26.8 mm rollerin the 5 mm hole in the

Installthe circlipwith its taperedside facing out.

side plate.
5 x 26.8 mm
ROLLER

CIRCLIP

)
DRIVERATTACHMENT
07947 -6340500

4.5 x 49.8 mm
ROLLER

9=-o*,ve

ruI\
ATTACHMENT, 37 x 40 mm
07746*0010200

sHAFr

senl
FI purrrp
SPAGER
Jl

\v

HOUST G

PRELOAD
SPRING

4.5 mm HOLE

10. Assemblethe pump rotor to the drive shaft with

the "O" mark on the.otor facing upward.
5 . Coat the side plate grooves with power steering
fluid, then positionthe 16.8 x 1 .9 mm and 54 x 1.9
mm O-ringson the side plate.

1 1 . Set the 1O vanes in each groove in the rotor.

NOTE: Be sure that the round end of the vanes is
in contact with the slidingsurfaceol the cam ring.

16.8x 1.9 mm
O-RING

/E

,,O" MARK
54 x 1.9 mm
O.BING

Round 6nd

PUMP ROTOR

4o

VANE

{cont d

17-103

SteeringPump
Assembly{cont'dl
1 2 .Set the pump cam ring over the two rollerswith the
" : " m a r ko n t h e c a m r i n g u p w a r d .

'17
. S e t t h e 1 3 x 1 . 9 m m O - r i n go n t h e i n l e tj o i n t ,ano
installthe inlet joint on the pump housing,

1 3 . Apply clean power steeringfluid to the vanes and

pump cam flng.
PUMPCAM RING

INLETJOINT

FLANGEBOLT
11 N'm
(1.1 kg-m, 8 lb-ftl

18. Installthe flow control valve (seepage 17-98).

1 4 . I n s t a l lt h e 6 8 . 5 x 1 . 9 m m O - r i n go n t h e p u m p
cover.
1 5 .Align the rollerset holesin the pump cover with the
rollers.
Align the projectionon the pump housingand the
projectionon the pump cover,then tightenthe tour
bolts.
FLANGEBOLT
20 N.m
(2.O kg-m, 14 lb-ft)

68.5 x 1 . 9 m m
O-RING

ROLLEBS

17-104

19. Installthe pulley (see page 17-96) and check that

the pump turns smoothly by turning the pulley.

SteeringGearbox
Index
CAUTION: Betore diEassamblingthe gsarbor, wash it oll with solvent and a brush.

--=.-

ss t.13.9 kg-m, 28 lb-ft)

VALVEBODYUNIT
page17'106
Overhaul,

GEARBOXSHIELD

lr.O tg-m, 7 lb-ftl

RIGHTMOUNTING
BRACKET
AIR

RACKEND
BOOTBAND 65 N.m 16,5kg-m,47 lb-ft)
neptace.
\

CLAMP
TIE.ROD
LOCKNUY
45 N.m
(4.5 kg-m, 33 lb-ftl
TIE.RODEND

8o,or
\s
\ =K\
\)

MdNNry:

TUBE CI-AMP
TRANSFERHOSE

9-a

50-60 N.m
(5.0-6.0 kg-m,
36-43 tb-ft)

Ss'..t

TRANSFERHOSE
CLAMP

-ArR HOSE BAND RUBBER

/-

AIR HOSE BAND

COTTER-PIN
Replace.

17- 105

SteeringGearbox
Valve Body Unit
Romoval
1.

Drsin the power steeringfluid (seepage 17-77).

2.

Removethe gearboxshield.

Removethe two I mm flangebolts and removethe

valve body unit from the gearbox.
6.

Remove the O-rings and port orifices trom the

gearbox.

9.8 x 1.9 mm
O.RING
Replace.
PORT
ORIFICE
45.5 x 2 mm
O.RING
Replace.

GEARBOXSHIELD

Usingsolventand a brush.wash any oil and dirt off

the valve body unit, its lines, and that end of the
gearbox.Blow dry them with compressedair.
UsingJlarenut wrenches,disconnectthe four lines
Jrom the valve body unit.
A: To oil cooler: 17 mm wrench
8: To power stqring spsed sensor: 12 mm wrench
C: To reservoir:12 mm wrench
D: From pump: 14 mm wronch

17-106

8 mm FLANGEEOLT

UNIT

Valve Body Unit

Disassembly

4.

1.

Removethe three 6 mm flange bolts, then remove

the valve body cap trom the valve body.

2.

Removethe cap seal trom the valve body cap.

Checkthe Dressurecontrol valve:

Inspectits surfacefor scoringor scratchss.
Slip it back into the valvebody. and makesure it
slides smoothly without drag and without slde
play.

VALVEBODY
VALVE
CONTROL
PRESSURE
Checkfor scoringor
scratches,and rough
opgration.

6 mm FLANGEBOLT

NOTE: lf the valve body is damaged,replacethe

valvebody unit (valvebody, pressurecontrolvalve.
gain control valve,4-way valve)as an assembly.
Removethe pressurecontrolvalveand valvespflng
from the valve body.

5 . Remove the gain control valve and valve spring

irom the valve bodv.

VALVE BODY

VALVE BODY

\, .la

\(C

4*
VALVESPRING
VALVE SPRING

(conl ct

17-107

SteeringGearbox
Valve Body Unit (cont'd)
6.

Checkthe gain control valve:

a Inspectits surJaceJor scoringor scratches.
a Slip it back into the valve body and make sure it
slides smoothly without drag and without side
pray.

9. Remove the rollers from the 4-wav valve bv

pushingthe valve out one side of the valve body,
and then the other.
NOTE: When removing the rollers, hold the
plungerswith your linge.s to keep them ffom popprng our.

GAIN CONTROLVALVE
Checkfor scoring,
scratches,or rough
operation.

PLUNGERS

NOTE: lf the valve body is damaged,replacethe

valvebody unit (valvebody, pressurecontrolvalve,
gain control valve, 4-way valve) as an assembly.

1O. Remove the plungers, return springs and 4-way

valve from the valve body.
11. Removethe 11 mm O-ringt.om the 4-way valve.

Separatethe valve body and port housing.

12. Check the plungers.
Removethe port seal and dowel pins trom the port
housing.

a Inspecttheir surfacefor scoringor scratches.

a Slip each plungerinto the valve body, and make
sure it slides smoothly, without drag or side
play.
lf any plungeris damaged.replaceit.
VALVEBOOY
PLUNGERS
Check for scoring or
scratches, and rough
sliding.

DOWEL PIN

17-108

PLUNGERS
Check lor scoring or
scratches, and rough
sliding.

'13.

Checkthe 4-way valve.

Inspectits surfacefor scoringor scratches.
Slip it into the valve body, and make sure
slidessmoothly.without drag or side play,

4.WAY VALVE
Checkfor scoring,
scratches, or rough
operation,

NOTE: lf the valve body is damsged,replacethe

valvebody unit (valvebody, pressurecontrolvalve,
gain control valve,4-way valve)as an assembly.
1 4 . Using a 3 mm (1/64") drill bit, removethe sensor
oriJiceand 3.4 m O-ring,

gh

PORTHOUSING

17-109

SteeringGearbox
Valve Body Unit
Assembly
lllustratd lndx
1, Throughlycleanthe disassembledparts shown below.
2.

Coat the plungers,pressurecontrol valve, gain control valve and 4-way valve surfaceswith power steeringfluid.

3,

Beassemblethe pans in the reverseorder of disassembly.

CAUTION:
a Replacothe O-rings and ssals with nw onos,
a Do not dip tho O-dngs and saals in solvent.
a Apply tb power stedng fluid in the eal groovos to keep tho leals in pl8cs,
. -6f
: STEERING
GREASE(Pa.t NumbrO8733-BO?OE|

PORTHOUSING

45.5 x 2 mm
O.RING
Replace.

1l mm O-RING

DOWELPII{S

PRESSURE

cof{TRoL
VALVE

uo.u."r*nol trN
VALVE EODY
PLUNGERS
6 mm FLANGEBOLT
I N.m lO.9 kg-m, 7 lb-ft)

S*"MS^"..'.
.' \ / l i l
"/)H

--

^qq
d

+ w r vv t v e

\\

oo,n"onrro.
vALvE

1 \sENsoR

oRtFtcE

SPRINGS
ROLLER

3.4 m]n O-RING

R6place.

NOTE: lf the valve body is damaged,replacethe valve body unit (valvebody. pressurecontrolvalve,gain control
valve, 4-way valve)as an assembly.

17-1 1 0

4.

Coat the surface of the 4-way valve with power

steeringfluid, and installinto the valve body.

5 . Coat the surfaceo{ the plungerswith power steering tluid, and install the plungers,return springs
and rollerson the valve body.

7. Coat the pressurecontrol valve and gain conttol

valvewith power steeringfluid, and installtheminto the valve body,
8. Installthe valve springs.

VALVEBODY
1 1 mm
SPRINGS

r0

VALVE SPRINGS

PRESSURECONTROLVALVE

PLUNGERS

E
6.

9. Coatthe cap sealwith power steeringfluid, and install it in the groove ot the valve body cap.

Coatthe port sealwith power steeringfluid, and install it the grooveof the port housing.Then install
the valve body and port housing.

1O. Installthe valve body cap on the valve body with

6 mm flange bolts.
CAUTION: Maka sure the mating surface ot th6
valve body and cap are flush at the uppor sid6.
VALVE BODY

PORT HOUSING
6 mm FLAIIGE BOLT
9 N.m (0.9 kg-m, 7 lb-ft)

VALVEBODYCAP

rol
{cont 6

17-111

SteeringGearbox
Valve Body Unit (cont'd)
'I 1. Make sure the 4-way valve moves smoothly,and
returnsto neutrSlDosition.

lnstallation
1.

Coatthe 9,8 x 1.9 mm O-ringswith power steering

fluid, and installthem togetherwith the orifices.

2.

Installthevalvebody unit on the gear housingwith

the two 8 mm bolts.
CAUTION;
a When installing, be caleful not to hil th pinion
holderpin.
a Mak sure the O-rings are in place and not
pinchad,

PINIONHOLDERPIN

-6l

9.8 x 1.9 mm
O-RINGS

E
PORTORIFICES
45.5 x 2 mm
O.RING

BODYUI{IT

22 N'm 12.2ks-m' 16 lb-lil

Connectthe four linesto the valve body unit, using
flare nut wrenches.
17 mm wrench
29 N.m {2.9 kg-m, 21 lb-ftl
B: To power stering spoed aensor:
12 mm wrench
13 N.m (1.3 kg-m, 9 lb-lt)
12 mm wrench
C: To rgsorvoir:
13N.m (1.3 kg-m, 9 lb-ft)
14 mm wrench
D: From pump:
38 N.m (3.8 kg-m, 28 lb-tt)

A: To oil coolor:

17-1 1 2

Fillthe reservoirwith power steeringfluid and bleed

air from the system by turning the steeringwheel
from lock to lock severaltimes with the engine
warm lsee page 17-771.
Make sure there are no fluid leaks,then installthe
gearboxshield.
o.

Recheckthe fluid level in the reservorr.

GEARBOXSHIELO

1 ON . m
(1.0 kg-m, 7 lb-ftl

17-113

SteeringGearbox
GearboxRemoval
NOTE: Beforeremovingthe steeringgearbox,alignthe
front wheels straightahead.
1.

Drainthe power steeringfluid as describedon page

17-77.

2.

Raisethe front o{ car and supporton safety stands

in the properlocations(see sectjon 1).

3.

Removethe front wheels.

4.

Remove the cotter pin lrom the castel nut and

removethe nut.

7 . Removethe selfJockingnuts that connectthe exhaust pipe A to the three way catalyticconverter,
and the exhaustoiDeA to the exhaustmanitold.
8.

Disconnectthe heated oxygen sensor connector

(H23A1 and H22A1 engine)and remove the exhaust pipe A,
CAUTION: Replac tho oxhaust gaskot and salflocking nuts when you loinstall ths pipe.

Installa 12 mm hex nut on the ball joint. Be sure

that the 12 mm hex nut is tlush with the ball joint
pin end, or the threadedsectionof the ballioint pin
might be damagedby the ball joint remover.
NOTE: Removethe ball joint using the Ball Joint
Remover.Referto page 18-13 tor how to use the
ball joint remover.
Separatethe tie-rodballjoint and knuckleusingthe
s p e c i atl o o l .
CAUTION: Avoid damagingthe ballioint boot.

EXHAUST PIPEA

Automatic transmissiononly.
a Removethe shift cable holder and disconnect
ihe shift cablefrom the shift control shaft.

SHIFT CONTROLSHAFT

12 mm HEX NUT

SHIFTCABLEHOLDER

17-114

1 0 .Removethe center beam.

NOTE: Replacethe self-lockingbolts if you
easilythread them in.

1 2 .Usingsolventand a brush,wash any oil and dirt ofl

the valve body unit, its lines, and the end ot the
gea.box. Blow dry them with compressedair.
CAUTION: Aftel disconnecting the hoses and
pipes,plug or sealthe hosesand pipeswith a piece
of tape o. equivalent to paevent foreign material
lrom entering the valve body unit.

1 3 .Usingtlare nut wrenches,disconnectthe four lines

trom the valve body unit.
A: To oil cooler: 17 mm wrench
B: To power stssring speed sensor: 12 mm wrench
C: To reservoir:12 mm wrench
D; From pump: 14 mm wrench

11. Removethe gearboxshield.

4WS:
14. Cur the wire tie from the cover, then removethe
cover from the front sub steeringanglesensor,
CAUTION: Use care when cutting the wire tie so
as not to cut into the wire harness,
15. Removethe sensor wire harnessfrom the clamp
and disconnectthe connector.
CONNECTOR
COVER

GEARBOXSHIELD

WIRETIE
Replace. FRONTSUB STEERING
ANGLESENSOR

17-115

SteeringGearbox
q,
gearDox
Removallcont
Gearbo llemoval
lcont'd)
16. Lock the steeringshaft with ignition key to keep
the steeringshaft position.

1 9 . Removethe left-tie rod end, then slidethe rack all

the way to the right.

17. Removethe steeringjoint bolt, and move the joint

toward the column.

20. Pull the steering gearbox assembly all the way

down to clear the Dinionshaft lrom the bulkhead.

STEERINGJOINT

21 . Move the steeringgearboxassemblyto the right so

the left rack end clearsthe rear beamHold the steeringgearboxassemblyand slide the
rack all the way to the left. Placethe left rack end
below the rear beam.
Move the steeringgearboxassemblyto the left and
tilt the left side down to removeit from the car.

LOCKWASHER
TOOTHED
18. Remove the left mounting bracket first, then
removethe right mountingbrackets.

RAq
In6ta
innoa

STEERINGGEARBOXASSEMBLY

35.

o{
R.!

CAUTION: Bo calsful not to bond or damage the

four power aleedng lines when lomoving the gearbox aasemblv.

AIR HOSE CLAMP

17-1 1 6

z<

lllustratedIndex
a
a
a
a

Thoroughlyclean all disassembledparts.

Always replaceo-rings and seals.
Replaceparts with damagedslidingsurtaces.
Do not dip sealsand O-ringsin solvent;coat O-ringswith power steeringfluid or steeringgrease,makesurethey stay
in positionduring reassembly,and use the appropriatespecialtools to installlhem where necessary.
: STEERING
GREASE{P/N08733 BoToEl
-!56{

FRONTSUB STEERING
ANGLESENSOR

l4wsl
Adjustment
page 17-132
RACKGUIDESCREW
(2WSl
SEAL RETAI'{ER

SPRING
CYLINDERCAP

BUSHINGSTOPPER

AALL
BEARING

RACK
cutDE

..@]

RETAIT{ING
WASHER
9.8 x 1.9 mm _-.,t
o-RTNGS--J

Beplsce.

""'!kr
ser.
ersron
35.5 x 2.4 mm

-GEAR

-:

AE5<-- PrNtoNHoLDER
\-+-pr roNHoLDER

ffi"k

#.'=....-#

PORTORIFICES

BING
Feplace

&--(nlr-

)d'ffi"o
CYLINDER
;rd$;t

HousrNG

ffi

BALLBEARTNG
SAf{P R|NG

R'.
iJillitt.l"l3T-0"-","
i:11T,""*,
SNAP RING

Inspect lor damage to

inner surface

CYLIIIIDER
,sPRlNG

-";tJilhre$m''L,NDER
--=.:=\/V\\-\

-5ffiq

O-RING
Replace.

fiI.;!,?,T
\

I::X'"T:U:'*""
/'e-

'-

CYLINDERBOLT
22 N.m
12.2 kg-m, 16 lb-trl

17-117

SteeringGearbox
Overhaul
1.

Removethe two 8 mm flangebolts and removethe

valve body unit trom the gearbox.

2.

Remove the O-rings and port orifices from the

gearbox.

4WS:
5. Loosen the locknut and remove the rack guide
screw/front sub steeringangle sensorassembly.
6.

Removethe spring and rack guide from the gear

housing.

8 m m FLANGEBOLT

45.5 x 2 mm
O-RING
Replace.

9.8 x 1.9 mm
O-RINGS
Replace.

Loosen the locknut and remove the rSck guide

5Crew.

RACK GUIDE

7,

Removethe rack guide screw, O-ringand locknut

from the front sub steeringangle sensor.

Removethe spring and rack guide trom the gear

housing.

LOCKNUT

RACKGUIDE

17-118

8 . Csretully clamp the gearbox in I vise with soft

jaws.

1 1 .Hold th steeringrack with I wrench and unscrew

the rack end with a wrench.

9 . Removethe tie-rod end.

RACK END

LOCK WASHER

TIE.RODLOCKNUT

,^@
@-=-47'
1- r_------_1,

\
TIE.RODEND

1 0 . Bemovethe boot bands and tube clamps. Pull the

1 2 . Removethe dust cover.

dust sealsaway from the ends of the gearbox.

1 3 .Removethe gear housingcap from the gear housing by removingthe four 6 mm flange bolts.
1 4 . Remove the steering pinion seal from the gear
housingcap.

DUST COVER

STEERINGPINIONSEAL
Replace.
GEAR HOUSINGCAP
46 r 1.5mm
O.RING
Replace.

TUBE CLAMP

(cont'd)

17-119

SteeringGearbox
Overhaul(cont'd)
15. Pushthe right end ot the rack back into the cYlinder
housing so the smooth surtace that rides agsinst
the seal won't be damaged.

a Removethe ball bearingusing a commercially

availablebearingpuller.

Install the ball bearing on the pinion using a

p.ess and the specialtools.
to.

Checkthe ball bearingot the pinionfor play; if it is

good, go on step 17,
lf the bearingis noisyor hasexcessiveplay,replace
the bearing.
a Removethe snap ring.

BALL BEARING

17-120

a Installthe snap.ing on the pinion.

19. Remove the cylinder end seal from the cylindel

housing.
NOTE: Useyour tingersor a woodenstick to avoid
damagingthe housing.

PINION

II

END

CYLINDER
ENDSEAL CYLTNDER
HOUStt{G

17. Removethe four cylinderbolts from the end of the

cylinder housing, then slide the housing off the
tacK.

20. Removethe cylinder,sealretainer,cylindercap and

steeringrack from the gear housing.

18. Remove the O-ring. back-up ring, steering rack

bushingA and cylinderspring.

CYI-INDER
GEARHOUSING

17-121

SteeringGearbox
Overhaul(cont'd)

21. Removethe retainerwasherJromthe gearhousing.

a Removethe pinionholdertrom the gearhousing.

a Check the needle roller bearingsin the pinion
holderand gear housingfor damage;if oK, pack
the needlerollerbearingwith grease.lf the bearings are damaged.replacethem as a set.
PINIONHOLDER

GEAR I{OUSING

22, Check the pinion holder for tree movement, excessiveplay and rough movement;if it is good 90
on steD 23.
lf it is damaged,or if dirt has gone past the sealinto
the grease,replacethe bearing.
a Removethe circlipfrom the pinion holder.

a Checkthe ball bearingfor damage;it it is good.

go on step 23.
a Remove the pinion ball bearingfrom the gear
housing.

BALL BEARING
PINIONHOLOER

17-122

I
t

a Drivethe new ball bearinginto the gear housing

using the specialtools.

a Reinstallthe circlip with its taperedside facing

ouI.
NOTE: Circlip ends must be alignedwith the flat
area.

ORIVER
07749-OO10000
47 mm
CIRCLIP

a Installthe pinion holderin the gear housing.

PINIONHOLDER

23, Removethe cylindercap and sealretainerfrom the

steeringrack.

CYLINDERCAP/
SEAL RETAINER
NEEDLEROI-LER
BEARINGS

STEERINGRACK
GEARHOUSING

{cont d,

17-123

SteeringGearbox
Overhaul(cont'd)
24. Removethe O-ringand snap ring ftom the seal retainer.then removethe cylindercap from the seal
retalner.

28. Carefullypry the piston sealting and O-ringoff the

olsron,

25. Removethe O-ringstrom the cylindercap.

29.7x 1.9 mm
O.RING
Replace.

43.3 x 1,5 mm
O.RINGS
Replace.

II

(\s
CI

SEAL RETAINER

SNAP RING

PtSTON
SEALRI[{G
RPlace.

CYLINOERCAP

Remove the bushing stopper ring lrom the seal

retainer.

2 7 . Removethe cylinderend seal and rack bushingB.

BUSHINGSTOPPER

SEAL RETAINER

RACK BUSHINGB

SEAL

17-124

NOTE: Befo.e reassemblingany parts, inspect

them as describedon page 17-'l17 and mak sure
they are clean. Replaceworn or damagedparts

29. Install a new O-ring on the piston with Its narrow

dge facing out.

32. Coat the piston seal ring and insideof the special
tool with power steeringfluid.
33. Carefullyslidethe tool onto the rack and ove. the
pistonsealring, then rotatethe tool as you move it
up and down to seat the piston seal ring.

30. Coat the pistonseal ring guide with power steering

fluid. then slide it onto the rack, big end fifst.
31. Positionthe new piston seal ring on the special
tool, slideit down onto the big end of the tool, then
pull it otf into the piston groove on top of the Oring.

34. Coat new O-ringswith powe. steeringfluid and install them on the cylindercaD.

43.3 x 1.5 mm O-RINGS

STEERINGRACK

(cont'dr

17-125

SteeringGearbox
Overhaul(cont'd)
35. Slidethe cvlindercap onto the seal retainer.
36. Installthe snap ring on the seal retainerand coat
new O-ringwith power steeringfluid and installit
on the seal reta,ner.
29.7 x 1,9 mm
O-R|NG

S[{AP RII{G

38. Grasethe slidingsurfacesot the new cylinderend

sealand the specialtool.then placethe sealon the
specialtool with its grooved side facing opposite
the slider.

BACK.UPRING
Make sure the back-up
ring is seated in the
cylinde.end seal.

\.-6
^@"\
* \ !

@'f

cYtlt{DERcAP

CYLINOERENO SEAL
lnstall end soal with its grooved
side facing opPosite
seal slider.

SEALRETAINER
END
CYLINDER
SEALSLIDER
07LAG-SM/tO30A
37. Greasethe sliding surface of the rack bushingB.
and installthe bushingon the steeringrack.

-Gl

RACK BUSHING

17-126

39, lnstallthe specialtool and cylinderend seal.

40. Separatethe cylinder end seal from the special

tool, then removethe specialtool from the fack.

4 2 . Push the rack bushing B toward the seal retainer by

hand until the cylinderend seal is seatedin the retainer.Fit the bushingstopperring in the grooveot
the sealretainersecurely.Then greasethe steerinq
racK.

CYLINDEREND
SEAL SLIDER
07LAG-SM4030A
AUSHINGSTOPPERRING
SEAL RETAINER

RACK SUSHINGB

RAC( BUSHINGB

41. Fit the seal retaineron the steeringrack.

43. Installthe retainerwasher on the gea. housing.

SEAL RETAIT{ER
GEAR HOUSING

{cont'dl

17-127

SteeringGearbox
Overhaul(cont'd)
44, Placsthe gea. housingon the work bench and insert the sealretainerand steeringrack into the gear
housing.
45. Coat the insidesurfaceof the cylinderwith powet
steeringfluid, slideit overthe rack and into the gear
housing;press it into the housinguntill il seats'

48. Coat the insidesurfaceof the cylinderwith power

steeringfluid and installthe cYlinderend seal with
its groovedside Jacingout.

GROOVES

STEERINGRACK
CYLINDEREND SEAL
SEAL RETAIITER

CYLINDER
ENO SEAL

49. Coatthe new O-ringwith grease.then installtheOring and back-upring into the gear housing.

HOUSING

50. Carefullypositionthe cylinderon the gear housing

and looselyinstallwith four cylinderbolts.
CAUTION: Bo cartul not to damagetho 6nd sel in
the cylinder housing.

46. Installthe cylinderspringover the rack, then coat

the rack bushingA with greaseand installit on the
sp.ing.

CYLINDERHOUSING

4 7 . Wrap the end of the steeringrack with vinyl tape.

Coat the tape with grease.

-6q

,6Q

A_e2
RACKBUSHTNG

CYLINDERSPRING

A)
-.9

--F\
d

STEERINGRACK

59 x 2.4 mm
O.RING
Vinyl tape

-Gl

17-128

-6ll

51. Removethe vinyl tape from the steeringrack.

55. Greasethe sealinglip ot the steeringpinion seal.

and installit on the gear housingcap.

52. Tightenthe four cylinderbolts.

NOTE: Beforetighteningthe bolts, make sure the
mating surfacesof the cylinderand gearhousingfit
properly by pushing them together; hold them
togetherwhile tighteningthe bolts.

56. Wrap the spline area of the steering pinion with

vinyl tape and greasethe surfaceoi the tape.
57. Greasethe new O-ring and install it in the gear
housing.
58. Slidethe gear housingcap over the steeringpinion,
being carefulnot to damagesealinglip or dislodge
the springof the steeringpinionseal.
59. Removethe vinyl tape.

CYLINDERHOUSING

6mm
FLANGEBOLT
1'l N'ln {1.1 kg-m, 8 lb-ft}

DUST

/
:ERINGPINION

-6i

CYLINDENBOLT
22 N.m
12.2kg-m, 16 lb-Ill

HOUSINGCAP

-61

Make sure the O-ring

is in placeand not
pinched.

Vinyl tape

'
46 x 1.5 mm O-RING

HOUSING

53. Insert the steeringrack into the cylinderhousing,

being caretul not to damage the steering rack
slidingsurface.
54. Installthe pinion in the pinionholder.
Install the circlip securely in the pinion holder
groove.
NOTE: Installthe circlip with its taperedside facIng our.

6 0 . Screw each rack end into the steeringrack while

holdingthe lock washer so its tabs are in the slots
in the steeringrack.
Hold the steeringrack with a wrench and tighten
t h e r a c ke n d t o 6 5 N . m ( 6 . 5 k g - m , 4 7 l b - f t ) .
RACK ENO

PINIONHOLDER

STEERINGRACK

{conl d

17-129

SteeringGearbox
Overhaul{cont'd)
62. After tighteningthe rack end, stske the four sections of lock washer with a dritt,

6 3 . Apply greaseto the circumlerenceof the rack end.

6 4 . Coat the tie-rodgrooveand insideoJ the boot with
siliconegrease.

AVAILABLEDRIFT
COMMERCIALLY
(Roll Pln Ddft, SnsPOn No. PPfi8l

SILICONEGREASE
Cost the sliding
surface ot the rack
end.

-6,1
RACK END

GROOVE
NOTE: This drift has a tlat,
to prevent punctunng
the metal washer.

6 5 . lnstall the boots on the rack end with the tube

qamps.
NOTE: Checkthat the boot joint piece(i.e.air hose
ioint) is not clogged with grease.
LOCK WASHER

Wood
block

1.0- 1.3mm
(0.04-O.05 inl
Check the lock wssher
diameter aftr staking.

I'
I
TUBE
CLAMP

17-130

66. Installthe right and lft tie-rod6nds.

70. Adiust the rack guide at the center of the rack

stroke.
71. Tighten the rack guide screw until it compresses
the spring and seats againstthe rack guide, then
loosenrt.

TIE-ROOLOCKNUT
Final to.que: 45 N.m {4.5 kg-m, 33 lb-ft|

72. Retightenit to 4 N.m (O.4kg-m, 2.9 lb-ft), back it

off about 20 + 5; then installthe locknuton the rack
guide screw.
73. Tightenthe locknut with the specialtool to about
25 N.m (2.5 kg-m, 18 lb-ft) while holdingthe rack
guide screw.
RACKGUIDESCREW
mm
WRENCH,43
LOCKNUT
oTMAA-SLOO20A

NE.RODEND

6 7 . Greasea new O-ringand instsll it in ths groovs in

the rack guide sctew.

6 8 . Coat the rack guide slidingsurfacewith grease,.

6 9 . Installthe rack guide, spring and rack guide screw
on the gear housing.
GEAR HOUSII{G

4WS:
74. Installthe locknut on the front sub steeringangle
sensor.
75. Greasea new O-ringand installit in the groove in
the front sub steeringanglesensor.Installthe rack
guide screw.

SPRING

RACK GUIDESCREW

GUIDE
LOCKNUT

t*F
Loosolyinslall.

(cont d

SteeringGearbox
Overhaul{cont'd}
76. Coat the rack guide slidingsurfacewith grease.

81 . Coat the 9.8 x 1 .9 mm O-ringswith power steering

Jluid.and installthem togetherwith the orifices.

77. Installthe rack guide, spring, O-ringand the .ack

guide screw/frontsub steeringanglesensoron the
gear housing. Then adjust the rack guide at the
center of the rack stroke.

82. Coat the 45.5 x 2 mm O-ringand pinionholderpin

with grease,then installit in the valve body unit.
83. Installthe valve body unit on the gear housingwith
the two 8 mm bolts.
CAUTION:
a Whon installing. b carolul not to hit the pinion
holderpin.
a Make sute the O-rings ale in place and not
pinched.

LOCKNUT

RACK GUIOE
O.RING

-6,1

8 mm BOLT
22 N.m '16
(2.2 kg-m, lb-ftl

RACKGUIDESCREW
ANGLE
FRONTSUBSTEERING
SENSOR

78. Tighten the rack guide screw until it compresses

the spring and seats againstthe rack guide. then
loosenit.
79. Retightenit to 4 N.m (O.4kg-m, 3lb-ft). back it otf
+
about 20 3' and install the locknut on the rack
guide screw with the specialtool.
80, Tightenthe locknut to with the specialtool about
25 N.m (2.5 kg-m, 18 lb-tt) while holdingthe guide
screw.

17-132

Ee?H",.

45,5 x 2 mm
O.RING
9.8 x 1.9 mm
O.RINGS

NOTE: Install the boot band with the rack in the

straight ahead position (i.e. right and left tie-rodsare
equal in length).
84. lnstallthe boot bandso that the lockingtabs of the
band (stakepointsl are in the rangeshown below.
(Lockingtabs shouldtace up and slightlyforward.)

8 7 . lnstallthe air hose cliDas shown.

8 8 . lnstallthe bandcushionand air hoss band;Dosition
the band as shown then tighten it. Installthe air
hose,

8 9 . After assembling,slidethe rack right and left to be

cenain that the boots are not deformedor twisted.

85. Installnew boot bandson the boot and bend both

sets of lockingtabs.

NOTE: After installation, perform the electrical

check on the 4wS system (seepage 17-146).

86. Lightlytap on the doubled-overponions to reduce

their height.
CAUTION:
a Stako the band locking tabs firmly.
a When staking. be cartul not to damag the
boot.

AIR HOSECLIP
(Viewedlrom the right side)

AIR HOSE BAf{O

(Viewed lrom the right side)
6mm

Clamp
AIR HOSE
CLIP

atRHosE
NOTE: Connect with the
protector side toward
th6 gearbox,

AIN HOSE BAND

45i5o

LOCKINGTA&S
The locking tabs (stake
points) should be in this
range.

TUBE
JOINT

Front +

Bandwinding
direction.

OFFSET
SHAFT
LINE
CENTER
LEFTBOOTBAND
(Viewedfrom the lelt side)

10a50

RIGHT BOOT BAND

(Viewed from the right side)

17-133

SteeringGearbox
lnstallation
Slidethe rack all the way to the right.

7 . Positionthe steeringrack centerof its strokes.

Make sure that the cable reel of the driver'sairbag
system is centeredas follows:

Pass the right side of the steering gearbox

assemblyabove and through the right side of the
rear Deam,

a Turn the steering wheel left approx. l50

degrees,to check the cable reel position with
indicator.
a lf the cable reel is centered,the yellow gear
tooth lines up with the aljgnmentmark on the
cover.
a Return the steering wheel right approx. 150
degreesto position the steering wheel to the
straightaheadposition.

Hold the steeringgearboxassembly8nd slide the

rack all the way to the right.
4.

Raisethe left sideot the steeringgearboxassembly

above and th.ough the left side ot the rear beam.

Looselyinstallthe left and right mountingbrackets

with the six mountingbolts,
Tighten the mounting bolts on the left mounting
bracket ti.st, then tighten the mounting bolts on
the right mountingbrackets.
\

<L6tt

\
LEFTMOU NNG
BRACKET

YELLOW

GEAR

9.

39 N.m

(3.9 kg-m, 28 lb-ftl

<Bight Sido:> 44 N.m
{4.4 kg-m, 32 lb-ft|

Slip the lower of the steeringjoint onto the pinion

shaft (line up the bolt hole with the groovearound
the shaftl and looselyinstallthe steeringjoint bolt.
NOTE:
a Connectthe steeringshatt and pinionwhen the
cable reel and steeringrack are centered.
a Be sure that the steeringjoint bolt is securelyin
the groove in the pinionshatt.

BOLTHOLE

STEERINGJOINT BOLT
22 N.m 12.2 kg-m, 16lb-ft)
STEERINGJOINT

MOUNTIT{G

BRACKET
FGHT MOUNTING
TNACKET
AIR HO
CLAMP

17-134

NOTE: The arrow on the

brscket points toward
the front.
39 l{.m
13.9 ks-m, 28 lb-ft)

1 0 .Connectthe four linesto the valvebody unit, using

flare nut wrenches.
17 mm wrench
29 N.m (2.9 kg-m, 21 lb-ftl
B: To powgr stoedng speod sen3of:
12 mm wranch
13 N.m {1.3 kg-m, 9 lb-ft}
12 mm wrench
C: To rsseryoir:
1 3 N . m ( 1 . 3 k g - m ,9 l b - t t )
pump:
14 mm wronch
D: From
38 N.m {3.8 kg-m, 28 lb-ft)

A: To oil cooler:

Fill the reservoir with power steering fluid and bleod

air from the system by tufning the stesring whesl
from lock to lock several times with the engine
warm (see page 17-77l..
1 4 . Make sure there afe no tluid leaks,then installthe
gearboxshield,
Recheckthe fluid level in the reservoir.

1 1 .Reconnectthe connector and secure the sensor

wire harnesswith the clamp and installthe cover.
NOTE:
a -Be sure the sensor wire harnessdoes not interferewith the stabilizeror other moving parts.
a Be certain that the sensor wire harnessis not
twisted betore connectingit.

GEARBOXSHIELD

{1.0 kg-m, 7 lb-ft}

15. Install the center beam.

Set the cover on the front sub steeringangle sensor. Securethe sensorwire harnessand cover with
a new wire tie.
CONNECTOR

SENSORWIRE

60 N'm

WIRETIE

CI-AMP

SUB STEERING

NOTE: After rack guide adjustment,perlorm the

electrical check on the 4WS system (see page
17-146],.

60 N'm
{6.0 kg-]n,4.:lb-ft1

{cont d

17-135

SteeringGearbox
lnstallation(cont'd)
16. Automatictransmissionmodel only.
a Connectthe shift cable end to the shift control
shaft. and installthe cable holder.

SHIFT CABLE

18. Reconnect the tie-rod ends to the steering

knuckles.tightenthe castlenut to the specifiedtorque, and instailnew cotter pins.
CAUTION: Torque the castle nut to the lower tolqu sp6citication, th6n tighton it onlY tar nough to
atign the slot wilh the pin hol6. Do not align the nut
by loosening.

CASTLENUT
50-60 N.m
(5.0-6.O kg-m.
36-/13lb-ft)

tl.4 kg-ln, 10 lb-ftl

CABLE

1 8N ' m
1 1 . 8k g - m ,1 3 l b ' f t |

17. Installthe exhaustpipe A with a new gasket.then

tighten the new self-lockingnuts. Connect the
heated oxygen sensor connector (H23A1 and
H22A1engine).

COTTER PIN
On reassembly,bond
the cottgr pin as shown.

'19.

Adiust the front toe (seesection 18).

NOTE: lf the steeringwheel and rack are notaligned centered,reDositionthe serrationsat lower end
of the steeringjoint.

20. Fillthe system:

a Fill the reservoirwith new Honda Power Steeri n g F l u i d - V{ s e ep a g e 1 7 - 7 7 ) .

55 N.m 15.5kg-m,40 lb-ftl

7 -136

EXHAUST PIPEA

21. After installation,perform the following chcks

a Stan the engineand let it run at idle, then turn
the steering wheel trom lock-to-lock several
times to bleed air from the system (see page
1 7- 7 7 t .
a Check the fluid again, and add more if
necessary.
a Check the gearboxfor leaks.
a Check the tront toe (seesection 181.
a Check the steeringwheel spoke angle.
a Checkthe 4WS system {4WS only).

RearSteeringActuator
lllustrated Index
CAUTION:
a Do not strlks tho rack end and shaft scrow.
a Us the spocial tool when removing the rear stee ng actuator. Tho special tool should remain installed excopt whon
tha aciuator ia inspected tor tunction, stc.
a Do not try to disasEambletho rear stoering actuator. lf the actuator is taulty, roplace it a3 an assembly.
a Whon disassemblingand sorvicing. do not let dust, din. and forign matelials snter tho rgar atsring actuator.
a Whn eithor th roar sub stoering anglo sonsor or th6 roar main st6o.ing angle sensor are removsd, pertorm Inspgction
and adiustmont ot the raar sub stee ng angle sensor aftr installing ths rear steering actuator.
a Lock th shatt scrow using th6 r6ar steoring lock pin special tool betole removal/installstion and
dlsassembly/rassemblyof tho real steering actuator assembly.

5O-60 N.m
15.0-6.0 kg-n, 36-43 lb-ft)

\
t

LOCKNUT
45 .m
14.5kg-m,33 lb-lrl

RACK
55 N.m
(5.5 kg-m, 40 lb-ftl

BOOTBAI{D
Replace.

TORX@ BOLT
'10t{.m (1.O
kg-m, 7 tb-ft|

d%
w

O.RING
Replace.
NOTE: Do not let dust, dirt,
and {oreign materials enter
the actuator.

Replace.
REARSUB
ANLGE SENSOR
Adjustmenl. page 1 7 - 15 5

LOCKNUT
25 N'm (2.5 kg-m, 18 lb-ft)

REAB STEERING
ACTUATOR

SHAFT SCREW

17-137

RearSteeringActuator
Removal
1.

Raisethe rear of car and supporton safety stands

in the properlocations(seesection 1).

5.

Removethe rear steeringactuatorcover.

NOTE: When the engineis OFF,the shaft screw of

the rearsteeringactuatoris held in the neutralposition (straightaheaddriving position)by the return
springtension.
CAUTION: Do not start the ngin with the real
stering lock pin set in lhe roal stoering actuator. lf
the stering whsal is tumed with the engina running, the rear 6teringactuator will oporate, damaging th rear stoering actuator.

2 . Remove the cotter pin from the castel nut and

removethe nut.
Installa 12 mm hex nut on the ball joint. Be sure
that the 12 mm hex nut is tlush with the ball joint
pin end. or the threadedsectionot the balljoint pin
might be damagedby the ball joint remover.
NOTE: Removethe ball joint using the Ball Joint
Remover.Referto page 18-13 for how to use the
ball joint .emover.
Separatethe tie-rodballjoint and knuckleusingthe
specialtool.

REARSTEERING
ACTUATOR
COVER
6.

Disconnectthe ground cable connectorsand terminalsfrom the rear steeringactuator.

CAUTION: Avoid damaging th6 ball ioint boot.

12 mm HEXNUT
3.P CONNECTOR

TERMINALNUTS

NOTE: Do not contaminatethe terminal bolt and

nut with grease.Cleanthem if necessary.

17-138

7.

Removethe rearsteeringactuatorby removingthe

four mountingbolts and bracket.

REARSTEERINGACTUATOR

MOUNTINGERACKET
MOUNNNG AOLTS

17-13!l

RearSteeringActuator
Disassembly
1.

Removethe tie-rod ends,

3.

Using a soft hammer,drive in th spcialtool between the actuator housing and stopper washer
with the flat side of the specialtool toward the
housing.

4.

Straightenthe tie-rod lock washer.

TIE.RODEND
RACKHOLDER
O7NA8-SSOo1OO

Removethe boot bands and tube clamDs.Pullthe

boots awav trom the ends ot the rack end.

5.

LOCKWASHER
Reolace.

Hold the shaft screw end with the spscialtool and

unscrewthe rack end with a wrench,

RACKEND
TUBE CLAMP

6.

17-140

Removethe specialtool.

Assembly
7 . Removethe rearsub steetinganglesensorfrom the
actuatorhousing.

REARSUB STEERING
ANGLE SENSOR

1 . Installthe locknut on the rear sub steeringangle

sensor,then greasea new O-ringand installit.
Screw the rear sub steeringangle sensorinto the
actuator housingfully by hand, back it off about
1/2 turn, and looselytighten the locknut.

REARSUBSTEERIITG
AI{GLESENSOR
Screw in the resr sub stgering
angle sonsor until se6ted, thgn
back it oft about 1/2 turn.

LOCKNUT

ACTUATOR HOUSING
LOCKl{UT

8.

Removethe rear main steeringangle sensorfrom

the actuatorhousing.
ACTUATOR HOUSII{G
REARMAIN STEERING

NOTE: Adiust the rear sub steeringangle sensor

(seepage 1 7-155) after instsllingthe rear steering
actuatoron the car.

CAUTION: Aftor disassembly, attach a pioco of

tape or equivalent materialon each port andioint ot
tho r6ar stooring actuator to protoct it trom dust.
dirt, and foraign matoriala.

{coltl c

17-117

RearSteeringActuator
Assembly(cont'd)
3.

Greasea new O-ringand installit in the .ear main

steering angl sensor, then install the rear main
steeringangle sensor.
REARMAIN STEERING
ANGLE SENSOR

5 . Using a soft hammer, drive the special tool between the housing and stopper washer with the
tlat side of the specialtool toward the housing.
o.

TORXO EOLT
1O lt'm
{1.Oks-m, 7 lb-ttl

Tightonthe rack end securely,then bend the lock

washer back against the tlat on the flange as
snown.
ACTUATOR HOUSING

-611
o-Rrr{G

DOWEL PINS

55 N.m
15.5kg-m,rto lb-ftl
CAUTION:
a Tako exfiomo car6 not to apply axisl impact and
fotational tolc on the shaft screw.
a St th projoction ot the lock washer in the
groove in the lack securely. After tightoning the
rack ond, bend th6 tabs of ths washer sgainst
the tlats securly.

Screw each rack end into the shaft screw while

holdingthe lock washerso lts tabs are in the slots
the shaft screw end.
NOTE: Install the stopDer washer with the
chamferedside tacing out.

7 . Removethe specialtool,

8 . Apply greaseto the circumferenceof the rack end

housing.

STOPPERWASHER
o

Coat the rack end groove and insideot the boot

with siliconegrease.

:GREASE
Coar the sliding
surtace of the rack
end.
BOOT
TUBE CLAMP

17-142

11. Installthe right and left tie-rod ends on the right

and lsft rack ends.

1O. lnstallnew boot bands,

- Installthe boot band so that th lockingtabs oJ
the band (stake points) are in the range shown
below.
{Tabsshouldface up and slightlyforward.)
LOCKING
TABS
RIGHT SOOT BAI{D
Front lr

LEFTBOOT
Th locking tsbs
(stake points)
should bs in this
range.
The locking tsbs (stske
points) should be in this
ran9e.
-

Install new boot bands on the boot and bend

both sets of locking tabs.

- Lightly tap on the doubled-overponions

reducetheir height,
CAUTION:
a Siako tho band locking tabs firmly.
a Whan staking, bo careful not to damago the
boot.

LOCKINGTAB{i

17-14:l

RearSteeringActuator
lnstallation
Installthe rear steeringactuator with four mounting bolts and bracket.

NOTE: Do not contaminatethe terminal bolt 8nd

nut with grease.Cleanthem iJ necessary.

NOTE: Installthe bolts looselyfirst, then tighten

them.

Connect the ground cable, connectots and ler'

minalsto the rear steeringactuator.
NOTE: Be surethe wires are not caughto. pinched
by any parts.

MOUNTINGCUSHION
REARSTEERINGACTUATOR

,-9

II
44 N.m
(4.4 kg-m, 32 lb-ft)

MOUNTINGSRACKET
The arrow on the
bracketpoint up.

39 N.m (3.9 kg-m,28 lb-ft|

2.

Reconnectthe tie-rod ends to the rear steering

knuckles,tightenthe castlenut to the specifiedtor
que, and installnew cotter Pins.
CAUTION: Torquethe castls nut to the lower tolque specitication, then tighten it only tar enough to
align the slot with the pin hole. Do not align the nut
by loosening.
4.
CASTLENUT
50-60 N'm
l5.O-6.0 kg-m,
36-43 lb-ft}

COTTERPIN
On reassembly,bend
lhe cotter pin as shown,

TIE-RODEND

17-144;

Adjustthe rearsub steeringanglesensor(seepage

1 7 - 15 5 1 .
NOTE:
a Be sure that the tront sub steeringanglesensor
and front main steering angle sensor are in
neutral8nd the steeringwheel is in the sttaight
aheaddrivingposition,
a Bs sur that the rear steeringlock pin {special
tool) is set in the rear actuator.
lnstalltheterminalcover and rearsteerlngactuator
cover,

4WS ControlUnit

Tie-rod End Boot

Removaland Installation

Replacement
Removethe boot.

1 . Removethe rear seat back {seesection 20}.

,

Disconnectthe terminalwires and connectorsf.om

the 4WS control unit.

2 . Packthe interiorof the boot and lip with grease.

Wipe the greaseoff the slidingsurfaceof the ball
pin, then pack the lower area with lresh grease.

Removethe 4WS control unit.

CAUTION:
a Koep groase otl the boot installation sction and
th6 tapersd section of the ball pin.
a Do not sllow dust, din, or othar foreign
matrials to onter the boot.

UNIT
4WS CONTROL

-\P

BOOT INSTALLATTON
SECTION
and
BALL PIN TAPERED
SECTION

4.

BLK wire.

Installthe new balljolnt boot usingthe specialtool

as shown below.

7 N.m lO.7 kg-m, 5 lb-lt)

NOTE: After driving the boot onto the ball joint,

apply sealantbetweenthe tie-rod end and boot.
REDwire.

BRNwire.

TIE.RODEND

4.

Installin the reverseorderof removal.

NOTE: Turn the ignitionswitch ON and check the
4WS indicatorlight operation.

CAUTION: After installing the boot, check the ball

pin tapered section fol grease contamination and
wipe it if necossary.

17-145

4WS System Inspection

ElectronicNeutral Gheck
NOTE: The sDecificationsare the measurements
on the outer circumferenceof the steeringwheel.

Preparation
NOTE:
a lf the power of the 4WS control unit was shut
down tor the following operations,start the
engine and turn the steering wheel lully right
and left.
- Batteryremoval/installation
- 4WS control unit removal/installation
- N o . 4 3 f u s e C L O C KR A D I Or e m o v a l{ i n t h e
under-hoodfuse/relaybox)
a Before performingthe electronicneutralcheck
on the 4WS system check the following items.
Be surethat the steeringwheelspokeangleis
at the designatedanglewhile drivingstraight
aneao.
- Be sure that the rear wheels are not steered
to the right or left, but in the straight ahead
drivingposition,

a18 mm l!0.7 inl Florn

MARK
CENTER

a9 mm 110.4inl From

MARK
CENTER

Jack up the car and placethe tour wheelsslowly in

the ceriterof the lurning radiusgaugeturn tables.
Placea pieceof maskingtape or equivalentapproximately 3OOmm {12.O in) long on the top edge of
the steering wheel. Place a mark on the tape at
each of the following measurements:
a Center (highestpoint of the steeringwheel).
a 9 mm {O.4 in) right and lell oI center (Forfront
main steeringanglesensor).
a 18 mm {O.7in) right and left of center(Fortront
sub steeringangle sensoradjustment).
a 55 mm (2.2 in) right and left of center(Forfront
sub steeringangle sensorinspection).

Fashiona pieceof stift wire (coathanger)and place

it on top of the dashboard.Positionthe wire so the
indicatingtip is closeto the marks on the steering
wheel and tape the wire down securely.
4.

17-146

Set the steeringwheel in the straightaheaddriving

positionand set the wire at the centermark on the
steeringwheel.

5.

Take out the service check connector (BLU 2P)

trom behind the center console.Connect the terminals with a piece ot jumper wire.
NOTE:
a The 4WS indicator light will not indicate that
sensorsare in the neutralpositionwhen displaying stored problemcodes.
a Check and verify any problemcodes displayed
beforecheckingthe neutralposition.

Front sonsors insoection:

7. Checkthe front main steeringanglesensorwith the
ignitionswitch on (engineoff),
- From the straight ahead driving position, turn
the steering wheel to the left, then turn the
steering wheel slowly to the right beyond the
straight aheaddriving position.Do not turn the
steeringwheel inversely.
- Turn the steeringwheel to the left, then turn to
the right beyondthe straightaheaddrivingposition. Repeatthis operation severaltimes until
vou tind the position where the 4WS indicator
light starts to come on steady.

4WS INDICATOR
LIGHT
t

'
,r9 mm (t0.4 in/:!3of
F.omCENTER
MARK

-: --=- rll

-Br
'11\
!

JUMPERWIRE SERVICECHECK
CONNECTONIBLU 2P}
!1i

o-

Pullup the parkingbrakeleverfully and turn the ignition switch on (engineoff) to turn the parking
brske indicatorlight on. This sets the front sensors
in the insoectionmode.

The 4WS indicatorlight should start to come on

within the rangeof i9 mm (1O,4 in/a3") from the
center mark on the steeringwheel.
NOTE;
a The 4WS indicator light might look as if it is
blinkingat a point nearthe ends of the specilied
range.
a To determinethat the 4WS indicatorlight is oo
and not blinking,be surethat the 4WS indicator
light stays on for more than 2 seconds.
- Adjust the 4WS system if the indicatorlight
startsto come on at a ooint outsidethe marked range on the steering wheel (see page
17-151l.

(cont'd)

17-147

4WS System Inspection

ElectronicNeutral Check (cont'd)
8.

Checkthe front sub steeringanglesensorwith the

ignitionswitch on {engineoff),
- From the slraight ahead driving position. turn
the steeringwheelto the right,then turn it slowly to the left beyond the straight aheaddriving
position. Do not turn the steering wheel
inversely.
- Turn the steeringwheelto the right,then turn to
the left beyondthe straightaheaddriving position. Repeatthis operationseveraltimes until
you find the centerpoint of the rangewhere the
4WS indicatorlight blinks(at the intervalsof O.2
seconds).

Rsal sgnsols insDection:

9. Releasethe parkingbrakeleverfully to turn off the
parkingbrakeindicatorlight. This sets the rearsensors in the insDectionmode.

4WS INDICATORLIGHT

'I

O. Turn the ignitionswitch off.

1 1 .Removethe cap bolt and sealingwasher from the

rear steeringactuator.and screw the specialtool
into the rear steeringactuatoras far as it will go.
NOTE: Do not start the engine with the special
tool set in the rear steeringactuator.

The centerpoint shouldbe within the rangeof t55

mm l!2.2 ini11 6,50 ) from the centermark on the
steeringwheel. After adjustingthe front sub steering anglesensor,however,the centerpoint should
b e w i t h i n t h e r a n g eo f 1 1 8 m m ( 1 0 . 7 i n / 1 5 . 5 " )
from the center mark.
- It the center point is outsidethe markedrange
on the steeringwheel. adjustthe front sub steering anglesensor(see page 17-153).

17-148

'12.

Set the steeringwheel in the straightaheaddriving

positionto preventthe rearwheelsfrom steeringif
the engineis started in error.

14. Set the steeringwheel in the straightahesddriving

positionto preventthe rearwheelsfrom steeringit
the engineis startedin error.

13. Turn the ignition switch on (engineoff) to check

the rear sub steeringanglesensor.
- Push the rea. left wheel fully to the .ight by
hand, then push it slowlv to the lett.
- The 4WS indicatorlight shouldblink at intervals
of O.2 secondswhen the rearwheel is oushedto
the lett.

15. Turn the ignitionswitch on (engineoff) and check

the rear main steeringanglesensor.
- Pushthe rearleft wheel fully to the left by hand,
then push it slowly to the right.
- The 4WS indicatorlight should turn ON when
the rear wheel is pushedto the right.

4WS If{DICATORLIGHT

ra,.!?.' " """""ffi--1_.-1)

TURNTO LEFT

Froni

NOTE: The 4WS indicatorlight blinks in a narrow

range.Take care not to overlookit
- lf the 4WS indicatorlight does not blink, adjust
the rear sub steering angle sensor (see page
1 7 - l5 5 ) .

4WS INDICATOR

uear

1
REARLEFTWHEEL

TURN TO RIGHT

Front

NOTE:
a The 4WS indicator light turns on in a narrow
range.Take care not to overlookit.
o The 4WS indicator light might look as it it is
blinking at a point near the ends oI the range
where the light is on.
a To determinethat the 4WS indicatorljght is nor
blinking. be sure that the 4WS indicator lighr
stays on tor more than 2 seconds.
a lf the 4WS indicator light does not turn on,
removethe rear main steeringanglesensorand
check it for damage.

17-149

4WS System Inspection

ElectronicNeutral Check {cont'd)
16. Turn the ignitionswitch oJt.
17. Removethe specialtool from the lear steeringactuator, and installthe cap bolt and the new sealang
washer on the rear steering actuator'

REARSTEERII{G
ACTUATOR
18. Removethe jumper wire from th ssrvice check
connectorterminals{BLU 2P).
19. Returnthe connectorbehindthe center console.
20. Reinstallthe removedparts.

17-150

4WS System Adjustment

4WS System Adjustment
Adjust the 4WS system usingthe followingprocedure,
NOTE;
a lf the Dower ot the 4WS control unit was shut
down for the Jollowing operations,start the
engine and turn the steeringwheel tully right
and left.
- Battery removal/installation
- 4WS control unit removal/installation
- N o . 4 3 f u s e C L O C KR A D I Or e m o v s l{ i n t h e
under-hoodfuse/relavbox)

a Check whether the yellow paint mark ot the

tront main stseringangle sensorrotor is facing
down (i.e. in neutral lock position where the
rotor does not turnl. This indicatesthat the front
main steering angle sensor is electronicallyin
neutral.
NOTE: lf the paint mark is not facing down, adjust
as instructedin step 5, (1) through (3) on page
't7 -87
.
FRONTMAIN STEERING

1,

Jack up the car and placethe wheelin the centerof

the turning radiusgaugeturn tables.

RADIUS
GAUGE
TURNING
TURNTABLE
Set the steeringwheelso that it is positionedin the
centerof the rangewhere the steeringwheelturns
fully to the right and left. (This centers the tront
steeringrack.l

a Installthe steeringwheel, aligningit with the

serrationwhich makes the spoke angle closest
to horizontal.
- lf the spokeangleis not horizontal,adjustthe
steering wheel slightly right or left. being
careful not to push in on the steeringwheel.
WHEELNUT
STEERING
5ON.m
{5.0 ks-m, 36 lb-ft)

lf the steering wheel spoke angle is not at the

designatedanglewith the steeringwheel set in the
positionexplainedin step 2. adjustthe tront main
steeringanglesensorand spoke angleas follows.
a Set the steeringwheelin the straightaheaddriving position,then removeit.
STEERINGWHEEL

a With the spoke angle set at horizontal,then

push the steeringwheel in fully.
Tighten the steefing wheel nut while pushing
the steeringwheel in.
NOTE:
a Do not removethe steeringwheel until adjustment is completed.
a Do not turn the steeringwheel when pushing
the steeringwheel.
tcont c

17-151

4WS System Adjustment

4WS System Adjustment (cont'd)
4.

Be sure that the rear wheels are not steeredto the

right or left, but in the straight ahead driving
Dosition,

Take out the service check connector (BLU 2P)

trom behind the center console.Connectthe terminalswith a pieceof jumper wire.

Checkthe sub and main steeringanglesensorsusing the table shown below (seepage 17-146).
NOTE:
a Turn the ignition switch on (engine off ) to
check.
a The 4WS indicatorlight does not indicatethe
electronicneutralpositionwhen it is indicating
problemcodes.
a Check the sensors by turning the specified
wheel in the specifieddirection shown in the
table below, The sensorsare adiustedproperlyif
the 4wS indicatorlight turns on in the specilied
range on the steeringwheel, or if the center ot
the rangewhere the 4WS indicatorlight blinksis
within the specifiedrangeon the steeringwheel.
Sensor
type

Check

Frontmain
steering
angre
sensor

Turn front
wheelsto right

Front sub
steering
angle
sensor

Turn front
wheels to left

Rearsub
steering
angle
sensor

'4 Turn rear

wheelsto
lefl

Parkingbrake lever
*2 Release
l Pull

.2 0N

*3 Blinks

'3 Blinks

Flearmain
*4 Turn rear
steering
*2 Blinks
wheelsto
angle
ngnt
sensor
*'1:Be sure that the parking brake indicatorlight operates
properly.
'2: The 4WS indicatorlight might look as if it is blinkingat a
point near the ends oI the range where the light is ON.
*3: The 4WS indicator lighl blinks in the intervalsof O.2
seconds.When the indicatorlight is indicatingthe main
steeringanglesensorcondition{lightON),indicationot the
sub steeringanglesensorcondilionby blinkingis canceled.
*4: Turn the rear wheel slowly by hand with the specialtool
(rear steering center lock pin) sel in the rear steering
actuator,

17-152

Sub Steering Angle Sensor

Adjustment
7 . lf the sensors are not sdiusted properly. adjust
eacn sensof.
a It the front main steeringanglesensoris not adiusted properly, start with the step 2.
a Front sub stee,ing angle sensor adiustment: see
psge17-153.
a Rear sub steerlng angle sensor: see page
17-155.
NOTE: The rsar main steeringanglesensorcannot
be adjustsd.lf the rear main steeringangle sensor
is sbnormal,removeit and check it tor damage.

Front Sub SteeringAngle Sensor

NOTE: Before adjusting the sub steering angle
sensor. check that the front main steeringangle
senso. is adjustedproperly(see page 17-146).
1. Jack up the ca. and raise all four wheels off the
ground.Placethe salety stands in the properlocations to supportthe car (seesection 1).
2.

Set the steeringwheel in the straightaheaddriving

oosttton.

3.

Take out the service check connector (BLU 2P)

from behind the center console.Connect the terminals with a piece of iumper wrre.
NOTE:
. The 4WS indicatorlight will not indicatethat the
sensors are in the electronic neutral oosition
when displaying stored Diagnostic Trouble
C o d e s( D T C ) .
a Check and verify problem codes displayed
betorecheckingthe electronicneutralposition.

4.

Set the parking brake lever and turn the ignition

switch on {engineofl). Be sure that the parking
brakeindicatorlight turns on,
Turn the ignitionswitch oJf.

17-1!i :l

4WS System Adjustment

Sub SteeringAngle Sensol Adjustment (cont'd)
6.

Cut the wi.e tie from the cover, then remove the
cover Jromthe front sub steeringanglesensor.
CAUTION: Uso car6 whon cutting lhe wire tie so
as not to cut into the wiro harnsss.

7,

Removethe sensor wire harnessfrom the clamp

and disconnectthe connector.

9, Turn the ignitionswitch on {engineoff).

10. Set the steeringwheel in the straightaheaddriving
position.Set the front main steeringangle sensor
electronicallyin neutral (4WS indicator light is
blinking)this time.
NOTE: Hold the steeringwheel in this positionuntil adjustmentis completed,lJ the steeringwheel is
moved in effor. repeat the adjustment procedure
starting with step 10.

CONI{ECTOR

COVER

/w
"

\ '

WIRETIE
R6place.

11. Turn the front sub steering angle sensor slowly

clockwise. and check the range Jrom where the
4WS indicatorlight startsto blinkto where it stops.

Loosenthe locknut. Tighten the locknut fully by

hand, back it off about 3/4 turns and connectthe
connector.

LOCKf{UT

FRONTSUB STEERING
ANGLE SEIISOR

12. Loosenthe front sub steeringanglesensor.Repeat

the step 11 severaltimes to set the sub steering
anglesensorin the centerof the rangefrom where
the 4WS indicatorlight starts to blink to where it
srops.
] CENTER
LIGHT STABTS
TO BLINK

LIGHT OFF

TURNINGDIRECTIOI{

NOTE:
a Turn the front sub steering angle sensor
clockwiseto makethe 4wS indicatorlight blink.
a lf the sub steeringangle sensorwire is twisted
excessively,turn the ignitionswitch ott, disconnect the connector,and straightenthe wire.

17-154

13. Tighten the locknut while holding the front sub

steefingangle sensorwith a wrencn.
NOTE: Take carenot to turn the tront sub steerino
angle sensor.
LOCKNUT
25 N'm 12.5 kg-m,
18 tb-ftl

FRONTSUB STEERING
ANGLE SENSOR

RearSub SteeringAngle Sensor

1. Jack up the car and raise all four wheels off the
ground.Placethe safety slands in the properlocations to supportthe car (see section 1).
2.

Take out the service check connector (BLU 2Pl

from behind the center console.Connect the terminalswith a pieceof jumper wire.
NOTE:
a The 4WS indicatorlight will not indicatethat the
sensor is in electronic neutral oosition, when
displaying stored Diagnostic Trouble Codes
(DTC).
a Check and verify problem codes displaved
beforecheckingthe electricallyneutralposition.

SENSOR
WIREHARNESS

'I
4. Disconnectthe front sub steeringanglesensorconnector to straightenthe sensorwire harness.
Reconnectthe connecior.
NOTE: Do not contaminatethe front sub steering
angle sensor connector terminals with mud, oil,
and grease.
'15.

Check that each sensoris electronicallvin neutral

{ s e ep a g e 1 7 - 1 4 6 ) .
NOTE: Be sure that the centerof the rangewhere
the 4WS indicatortighr btinks (indicatingthat the
front sub steeringangle sensoris electronicaltyin
n e u t r a l l ,i s i n t h e r a n g e : t 1 8 m m ( a 0 . 7 i n / r s . 5 0 )
from the center mark on the steeringwheel.
t(rir'

i18 mm lao.7 in) Frorn

CENTERMARK

'

'

///{\
.
.

JUMPERWIRE

3 . Releasethe parkingbrakeleverfully and turn the ignition switch on (engineotf). Be surethat the parking brake indicatorlight goes olt.
4.

Turn the ignitionswitch off.

PARKINGBLAKE LEVER

16, Reconnectthe connectorand securethe sub steering angle sensorwire harnesswith the clamp and
installthe cover.
NOTE:
a Be sure the sensor wire harnessdoes not interferewith the stabilizeror other movingparts.
a Be certain that the wire is not twisted before
connectingit.
17. Securethe cover with a new wire tie.

(cont'd)

17-155

4WS System Adjustment

Sub SteeringAngle SensorAdjustment lcont'dl
Removethe fear steeringactuatorcover
Remove the cap bolt and sealing washer from the
rear steeringactuator.Sc.ew the specialtool in as
far as it will go.

o.

9. Set the steering wheel in the strsight ahead driving

position to prevent the rear wheels trom steering if
the engineis startedin error.
1O. Turn the ignitionswitch on (engineotf).
11. Push the rear left wheel tully to the left by hand,
then push it slowly to the right to turn the 4WS indicatorlight on (i.e..ear main stee.inganglesensor
is electronicallvin neutral).

SEALIT{GWASHER

REARLEFTWHEEL

TURNTO

STEERING

LOCKPIN
CENTER
REAi STEERING
07NAJ-SSOO20A

Frcnt

7.

Remove the rear sub steering angle sensor wire

from the clamp and disconnectthe connector'

8.

Loosen the locknut. Tighten the locknut tully by

'l12 turn and connect
hand, then bsck it oft about
the connector'
LOCKNUT

17-156

NOTE:
a The 4WS indicator light turns on in a natrow
range.Do not ovetlookit.
a Work with ca.e so as not to move the real
wheels from this neuttal position.

12. Turn the ignitionswitch on {engineoff}.

13. Turn the .ear sub steering angle sensor slowly
counterclockwise,
and checkthe rangelrom where
the 4WS indicstorlight starts to blink. to where it
srops.
14. Tightenthe rear sub steeringangle sensora little.
Repeatthe step l3 severaltimes to set the sub
steering angle sensor in the center of the range
from where the 4WS indicatorlight starts to blink,
to where it stops. I
CEIITER
LrcHToFF
I
LIGHT STARTS
TO BLII{K

16. Disconnectthe rear sub steeringanglesensorconnecto. to straighten the wire. Reconnect the
connector.
NOTE: Do not contaminatethe rear sub steering
angle sensor connector terminals with mud, oil,
ano grease.
17. Checkthat each sensoris electronicin neutral(see
p a g e1 7 - 1 4 6 ) .
18. Turn the igntion switch olf. Removethe special
tool from the rear steeringactuator,and installthe
cap bolt and the new sealingwasher on the reat
steeringactuator.
19, Installthe rear steeringactuatorcover.

TURI{ING
DIRECTION

CAPBOLT
22 N.m
{2.2 kg-m,16 lb-ft)

NOTE:
a Turn the rear sub steering angle sensor
counterclockwiseto make the 4WS indicator
light blink.
a lf the rear sub steering angle sensor wire is
twistd excessively,turn the ignitionswitch off,
disconnectthe connector, and straightenthe
15. Tighten the locknut while holding the rear sub
steeringangle sensorwith a wrench.
NOTE: Take care not to turn the rearsub steering
angle sensor.
REARSUB STEERING
ANGLESEI{SOR

SEALINGWASHER

REARSTEERING
ACTUATOR
REARSTEERINGCENTERLOCK PIN
07NAJ-SSOO20A

Suspension
......... 18-2
SpecialTools
ComponentLocation
.... 18-3
l n d e x. . . . . . . . . . . . .
Alignment
Wheel
S e r v i c e1 n f o r m a t i o n , , , . . . . . . . . . . .1. .8.-, 4,
Camber
. . . . . . . . . . . . .1. 8 - 5
.... 18-5
C a s t o r. . . . . . . . . . . .
Front Toe Inspection/
Adjustment
..... 18-6
RearToe Inspection/
Adjustment
..... 18-7
Turning Angle Inspection/
..... 18-8
Adjustment
Wheel Measurements
B e a r i n gE n d P l a y. . . . . . . . . . . . . . . . . . . .1. .8. - 9
R u n o u t. . . . . . . . . . .
.... 18-9
Front Suspension
................18-10
Torque Specifications
Knuckle/Hub
I n d e x. . . . . . . . . . . . . . . . . . 1
. .8. - 11
lllustrated
. . . . . . . . .1 8 - 1 2
Removal
Hub Unit and Wheel Bearing
Replacement
... 18-15
...... 18-17
lnstallation
Arms
Suspension
Removal/lnspection
................18-19
...... 18-20
lnstallation
Ball Joint Boot Replacement....... 18-21
Lowerarm BushingReplacement
.... 18-21

Front Damper
Removaf
.............18-22
Disassembly/lnspection
.............. 1A-22
........ 18-24
Reassembly
......... 18-25
lnstallation
Rear Suspension
Torque Specifications
................ 18-26
Knuckle/Hub
llfustratedIndex ..................... 1A-27
......... 18-28
Removal
...... 18-31
lnstallation
Suspension Arms
Removal/lnspection
................18-33
Installation
...... 18-34
BallJointBootReplacement
......... 18-35
LowerArm BushingReplacement
.... 18-35
Rear Damper
Removal
.......... 18'36
.... 18-37
Disassembly
....... 18-37
Inspection
..... 18-39
Reassembly
...... 18-40
lnstallation
D a m p e rD i s p o s a.l. . . . . . . . . . . . . . . . . . .1. .8. - 4 1

SpecialTools

Rcf. No.

Desc ption

Tool Number

oTGAF-SD40700
oTGAF-SEOo100
oTGAF-SEOO200
07GAG-SD40700
oTHAD-SG00100
07MAC-5100100
oTMAC-S100200
oTNAD-SS00100
07746-OO10500
07749-0010000
07965-SD90100
07974-SA50800

@
@
@
@
@
@
@
@

O'ty

Hub Dis/AssmblyBase
Hub Dis/AssemblyTool
Hub Assembly Guide Attachment
Ball Joint Boot CliDGuide
Driver Attachment
Ball Joint Remover,32 mm
Ball Joint Remover,28 mm
BushingDriver
Attachment, 62 x 68 mm
Driver
support Base
BallJoint Boot Clio Guide

H
| l

{--ru

tr

:,.--l

/-]
l , r a l

---G-1

@o

H
l_,

hJ

8-2

Pag. Refcrcnce

2
r
1
1

1A-'t5
1 8 - 1 5 1, 6 , 1 7
L18-17
| 1 8 - 2 13, 5

| 18-14,30

r
r

r
1
1

I ra-ro

I ra-ra,14,so,36
| 1 8 - 2 1 .3 5

I rg-rs

Jr1 8e- -1 r6 ,sr1 7e,

I 1 8 - 2 1 ,3 5

I(J
@

N
W
@

F1

v
/

@@

@
@

Component Location
lndex
The tront and real dampe.s contain nitrogon gas and oil undor presauro,The prsssuro must be raliovd
@
betore disposal to provent oxplosion and possiblo iniury whon scrapping.
Wheel Alignment,page 18-4
Front Suspension:
FRONTDAMPER
. Removal, page 18-22
. Disassembly/lnspection,
page 18 22
. Reassembly,page 18-24
. Installstion,page 18-25
. Disposal,page 'l8-41

FRONTLOWERARM
. Removal/lnspection,
page 18-19
. Installation,page 18-20

FROI{T UPPERARM
. Removal/lnspection,
page 'l8-19
. Installation,page 18-2O

STABIUZER
BAR
. Removal/lnspection,
page18-19
. Installation,
page18-20
FBOI{T KNUCKLE/HUB
. Removal,page 18-12
. BearingReplacement,
Page 18-15
. lnstallation,page 18-17

t l /

RADIUSROD
,/
. Removal/lnspection.
p6ge18-19
. Installation,
page18-20

Roar Suspension:

REAR OAMPER
. Removal,page 18-36
. Disassembly,page 18-37
. Inspection,pago 18-37
. Reassembly,
page 18-39
. Installation,page 18-40
. Oisposal,page 18-41

BEAR UPPERARM
. Removal/lnspection,page 18-33
. Installation.page 18-34

REARKNUCKLE/HUB
. Removal,
page18-28
. Installation,
pago18-31

REAR LOWEA ARM

. Removal/lnspection,
Page 18-33
. Installation,page 18-34

TRAILINGARM
. Removal/lnspection,page '18-33
. Installation,page 18-34

1&3

Wheel Alignment
Service Information
NOTE: For proper inspection/adjustment of the wheel
alignment, check and adiust the following before checking the alignment.
a
a
a
a

Check that the suspension is not modified.

Check the tire size and tire pressure
Check the runout oJ the wheels and tires.
Checkthe suspensionballjoints. (Holda wheel with
your hands and move it up and down and right and
left to check for wobbling.)

wheel alignment adjustment procedure

Each of the wheel alignment elements relates to the
other, Theretore, the total adjustment of the lront/rea.
wheel alignmentis requiredwhenevereitherone of lements (i.e.camber.caster.toe, snd/orturningangle)is
adiusted.

Adiust cambet

Adiust caster

Adiust toe

Adiust turning angle

Radjust camber

Read,ustcaster

Roadiusttoe

Readjustturning angle

18 -4

Caster

Camber
lnsp6ction

Inspection

NOTE: Use commerciallyavailablecomputerizedfour

wheel alignmentequipmentto measurewheel alignment
(i.e. caster, camber,toe, and/orturning anolel. Follow
the equipment manufacturer's instructions.

NOTE: Use commercially

;ommerciallyavsilablecomputerizedfour
wheel alignment
ent equipmer
equipmentto measurewheel alignment
(i.e. caster, camber,
ramber,toe, and/orturning angle).Follow
rt manufact!
manufacturer'sinstructions.
the equipment

1. Check the tire pressure.

1.

Turn the front wheels to the straight aheadposition.

2.

Turn the Jront wheels to the straight ahead position.

te caster angle.
Check the

3.

Check the camber angle.

ngl: 20,
2o4O' 1 1"
Caster angl:

Cambel angle, Front: 0oO0' t 10

10 (2WSl
Roar: -Oo45't

ll adjustment
nent is r
required,recordthe casterreading,
4, lf adjustment is not required, rethen go too step 4
gnment(equipment.
move alignment

Front: lf out of specitication.check for damagedsuspensroncomponents.

:aster an
NOTE: Caster
angle can be adjusted by increasing/decreasing
lasingth
the numberol the sdjustingshims.
Remove and inst
install the radius rod each time the
rgle is a(
adjusted.
caster angle

-oo45' r 30' (4ws)

4.

Rear (2wsl: lJ out oJ specification, chck for

damagedsuspensioncomponents.
4.

Raisethe front en(

end of the car and placesafety stands
in the proper
oper locr
locations(see section 1).

5.

Removethe
the selfi(
selfiocking nut on the end of the radius
rod.

b.

Removethe radiu
radiusrod attachingbolts at the lower
n remov{
removethe radiusrod (page 18-19).
arm, then

(4WSl: - lf adiustment is requared,go to step

- i no adjustmentis required,remove
alignmentequipment.

Rear Camber Adjustment (4WSl

5,

Hold the adiustingbolt and loosenthe self-locking

nut.

o.

Adjust the rear camber by turning the adjusting bolt

until camberis co.rect.

7.

Installthe new self-lockingnut and tighten while

holdingthe adjustingbolt.

Adiust the
the
e caster angle by increasing/decreasing
adjustingI shims.
shims.
- One adjusting
djustingshim changesthe casterangle by
40' and
d the cas
caster anglecan be adjustedby I o20'
maxtmum.
- One adjusting s h i m i s 3 . 2 m m ( O . 13 i n l i n
thickness.

ADJUSTING SHIM

SELF.LOCKIIIGNUT
12 x 1.25mm
Rgplace.
65 N.m 16.5 kg-m,
47 tb-ft}

SELF.LOCKING
NUT
55 N'm {5.5 kg-m,!
Replac.

ADJUSThIG BOLT

BADIUS ROO

NOTE:
a Do not ul
use more than two adjustingshims.
a After the
re adjustment. tighten the self-lockingnur
to the sD
speci{ied torque.

18

Wheel Alignment
Front Toe Inspection/Adiustment
Loosenthe tie-rod locknutsand turn both tie-rods
in the same directionuntil the lront wheels are in
straightaheadposition.

NOTE: Use commerciallyavailablecomputerizedfour

wheelalignmentequipmentto measurewheelalignment
{i.e. caster,camber,toe. 8nd/or turning angle),Follow
the equipmentmanufacturer'sinstructions.

Turn both tie-rodsequallyuntil the toe is correct.

1. Check the tire pressure.
6.
2.

2WS: Set the tront wheels to the straight ahead

posation.
4WS: Set the front main steering angle sensor in
the neutral position and jump the service check connector to turn the 4WS indicator ON (see page
1 7 - 15 6 ) .
NOTE:Maintainthis conditionduringinspectionand
adjustment.
4WS INDICATOR

Check the lront toe.

Front toe: 0 t 2.O mm lO a O'O8in)
- lt adjustment is required, go on to step 5. ,
- lf no adjustment is required. remove alignment
equipment.

8-6

After adjusting,tighten the tie-rod locknuts.

NOTE: Repositionthe tie-rod boot if it is twisted or
displaced.

TIE-RODLOCKNUT
14 r 1.5 mm
45 lrl'm {4.5 kg-m, 33 lb-ft)

TIE.ROD

RearToe Inspection/Adjustment
NOTE: Use commercially available computerized tour
wheel alignmentequipmentto measurewhe6l alignment
(i.e. caster,camber,toe, and/or turning angle).Follow
the equipmentmanufacturr'sinstructions.
1.

4WS only: Checkthe rear main steeringanglesensor is in the neutralpositionand jump the service
checkconnectorto turn the 4WS indicatorON (see
psge17-156).

4.

2WS:
a Hold the sdjusting bolt on the rear lower arm B
and loosen the self-locking nut.
a Adjust the rear toe by turning the adjusting bolt
until toe is correct.
a Installthe nw self-lockingnut andtighten while
holdingthe adjustingbolt.

NOTE:Maintainthis conditionduring inspection.

4WS INDICATOR

4WS:
a Loosenthe tie-rod locknuts and turn both tie-rods
in the samedirectionuntil the rearwheelsare in
the straight ahead position.
NOTE: Make sure the 4WS indicatoris ON
Releaseparkingbrake.

a Turn both tie-rods equally until the toe is cortect.

Check the rear toe.

a After adjusting.tighten the tie-rod locknuts.

NOTE:
a Measureditferencein toe measurementswith the
wheels pointed st.aight ahead.
o lf the parkingbrakeis engaged,you may get an
incorrectreading.

NOTE:Rspositionthe tie-rodboot it it is twisted

or disDlaced,
45 N.m (4.5 kg-m, 33 lb-ft|

Reartoeln: 2.O ! 2.O mm (O.08r O.OBin)

- lf adjustment is required, go to step 4,
- lf no adjustmentis required,removealignment
equrpmenr.

TIE.ROD

1*7

Wheel Alignment
TurningAngle Inspection/Adjustment
NOTE: Use commercially available computerized four
wheel alignmentequipmentto masurewheel alignment
(i.e. caster,camber,toa, and/orturning angle).Follow
the equipmentmanufacturer'sinstructions.
1, Jack up the tront of the car. Set the turningradius
gaugesbeneaththe front wheels. then lower the car.
2,

2WSt Jack up the rearof the car. Placeboardsthat

are the same thicknessas the turningradius
gaugesunderthe rearwheels,then lower the
car.
4WS: Jack up the rear of the car. Set the turning
radiusgaugesbeneaththe reat wheels,then
lower the car.
NOTE:Foraccuratereadings.the car must be level.

3.

Turn the wheel right and left while applying the

brake. Measure the tutning angle oJ both front
wheels, and both rear wheels (4WS models).

Front turning angl:

lnwa.d whsol: 36o20' ! 2o
Outward whaol: 29o4O' (roloronca)
Raar tuming anglo (4WSlr
lnward wheel: 6000' 1 10
Outward whcsl: 6020' (.otoronce)

18-8

4.

It the measurementsare not within the specifications, adiust as required by turning the tie-rods.
NOTE:After adiusting, recheck the front wheel toe
and readiustif necessary.Repositionthe tie-rod boot
it twisted or displscad.
TIE-ROD
LOCKNUT
1 4 x 1 . 5m m
45 N.m (4.5 kg-m,33lb-ft) llE-ROD

Wheel Measurements
Bearing End Play

Runout

1.

Raisethe car and support it with safety stands in the

proper locations(seesection 1,.

1.

Raisethe car and support it with safety stands in the

proper locations(see section I l.

2.

Removethe wheels, then reinstallthe lug nuts.

2.

Check tor bnt or deformedwheels.

3.

Attach the dial gauge as shown.

3.

Attach the dial gauge as shown.

4.

Masurethe bearingend play by movingthe disc in

and out.

4.

Measurethe wheel runout by tuming the wheel.

Front and Raar Wheel Axial Runout:

front wheol End Play:

Standard:0-O.O5 mm {O-O.002 inl

Rear Who6l End PlsY:

Standard:
0- 1 .O mm (O-O.O4 in)
St6ol l|haol:
AluminumWhool: O-O.7 mm {0-0.03 in}
2.O mm {0.O8 inl
Se.vlce Limitr

Front and Rear Wheel Radial Runout:

Standard:0-0.05 mm (0-0.002 in)

St.ndard;
0-1.0 mm (O-O'O4 inl
Stoel Whool:
Aluminum Wh.ol: O-O'7 mm (O-O.O3 inl
1.5 mm (0.06 inl
Scrvico Limlt:

lf the bearingend play measurementis more than

the standard,replacethe wheel bearing.

lf the wheel runout is more than the servicelimn

reolacethe wheel.

1&9

Front Suspension
TorqueSpecifications
CAiJ-fN,
a Reiface the slf-lockingnuts after rsmoval.
a Beplacotho solt-lockingbolts it you can aasily thlaad a non-soll-lockingnut past th6ir nylon locking lnsotts.
{lt shoub requir 1 N'm (0.1 kg-m. O.7 lb'ft) ot torqus to tuln thc nut on tho bolt}'
a The vehtg|es-houldb on th groundbeloreany bolts or nuta connoctedto rubbermountsor bushingaro tighten6d.
a Torqueihe castlenut to th low6r torquespocification.thon tighton lt only far onoughto aligntho slot with tho dn
holo. Do not align the nut by loosening.
NOTE:Wipe off the greasebloretighteningthe nut at the balljoint.

INSERT

NUT
SELF.LOCKIT{G
1 0 x 1 . 2 5m m
30 N'm (3.0 kg-m,22 lb-ftl
Replace.
SELF-LOCKII{G
1{UT
12 r 1.25 ]nm
65 ltl.m 16,5kg-m, 47 tb-ttl
Replace.

SELF.LOCKII{G
NUT
1 0 x 1 . 2 5m m
30 t{.m {3.0 ks-m, 22 lb-ftl

NUT
1 0 x 1 . 2 5m m
39 N'm 13.9kg-n. 28 lb-tt)
CASTLENUT
lO r 1.25mm
4O-48 N'm
l4.O-4.8 kg-tn,29-35 lb-ft}

Reolace.

DAMPERNNC'.IEOLT
(SELF.LOCKII{G
EOLTI
1 0 x 1 . 2 5m m
44 N.m 14.4kg-m,32 lb-ft}
SELF.LOCKII{G
BOLT
1 2 x 1 . 2 5m m

55 N'm (5.5 kg-m,

40 tb-ftl

CASTLENUT
12 , 1,25rnft
50-6{, ]t.m 15.O-6.0 kg-m,
36-43 tb-frl

t{ur
sPtt{Dt"E

SELF-LOCKING
t{UT
1 2 r 1 . 2 5m m
55 N.m(5.5kg-m,
40 tb-ft)
Replace.

24 x 1.5 mm
25ON'm (25 kg-m,
r81 tb-ft|
Raplacs.
NOTE:Aftsr tightoning,usoI drift to
nut ahouldsrag6rnst
stakgths apindlG
tho spindle.

BOLT
SELF.LOCKI]TG
1 2 x 1 . 2 5m m
105 N.m(10,5 kg-m,
76 lb-ft

NUT
SELF-LOCKING
'1.25
mm
12 x
55 N'm 15.5kg-m,40 lb-ttl
Replace.

18-10

CALIPER
BRACKET
MOUNTING
BOLT
1 2 x 1 . 2 5m m
11ON.m(11 ks-m,80 lb-ft|

DAMPB FORKt{UY
NUTI
{SELF.LOCKII{G
1 2 r 1 . 2 5m m
65 'm (6.5 kg-m,47 lb-ft)
Beolace.
CASTLCNUT

14 r 2.o mm
50-60 I{'m{5.0-6.0 ks-m,
36-43 tb-ftt

Knuckle/Hub
lllustrated lnd6x
NOTE:
a Use only genuineHondawheel weights for aluminumwheels.Non-genuinewheel weights may corrode8nd damsge
the aluminumwheels.
a Before installing the brake disc, cleen the mating surfacas of the front hub and inside ot tbe brake disc.
a Beforeinstallingthe wheel, clean the mating surfacesof the brake disc and insideof the wheel.

K1{UCKIE
Checkfor dam8ge.

KNUCKLEPROTECTOR
Ch6cktor damage.
BOLT-WASHER
6 x 1 . Om m
10 N.m (1.Okg-m, 7 lb-ft)

K UCKLERING
Checkfor damag,

COTTERPIl{
Roplace.
WHEEL AEARING
Replace.
psge 18-15
Replacament,
CIRCLIP
SPLASH GUARD
Check tor bending
or damage.

BALLJUNT EOOT
Checkfor doteiorstion
or damago.
CIRCLIP----"""i)

:3J.'ff*.--.......

SCREW
10 'm (1.0 kg-ft, 7lb-fil

FROI{THUB
Chckfor d6mag6or
cracKs.

BRAKEDISC
Chsck for w6ar or rust.
Inspoction,soction 19

LUG UT
1 2 x 1 . 5m m
1 10 N.m 111 kg-rn, 80 b-trl

I lnm EnAKEDISC
SCREW
RETAII{ING
10 'm (1.0 ks-m,7 lb-ft|

atl

1&t I

Front Suspension
Knuckle/Hub(cont'd)
Removal
Loosenthe wheel nuts slightly.
Raisethe Jrontof car and supporton safety stands
in properlocations{seesection 1).
Removethe wheel lug nuts and front wheel.
4.

7.

Removethe 6 mm brake disc retainingscrews.

8.

Screwtwo 8 x 1 .25 mm bolts into the disc to push

it away from the hub.
NOTE:Turn each bolt two turns at a time to prevent
cockingthe disc excessively.

9 . Removethe b.ake disc from the knuckle.

Raisethe lockingtab on the spindlenut. then remove

the nut.

x 1.25 mm BOLTS

6 mm SRAKEDISC
SCREWS
RETAINING

1 0 .Removethe wheel sensorwire bracket,then remove

the wheel sensorfrom the knuckle.
Removethe brake hose mounting bolts.

6 . Removethe caliperbracket mounting bolts and hang

the csliperassemblyto one side.
CAUTION: To provont accidantal damago to the
calipr assomblyor brako hos. us a short piece ol
wire to hang lhe calipel sgombly from lhe undrcariago.

CAIIPR ARAO(ET MOUNTING BOLTS

12 r 1.25mm

18-12

NOTE:Do not disconnectthe wheel sensor wire.

NOTE:Use ballioint remover,to separatethe balljoints

from the suspensionor steeringarm.
CAUTION: B calotul not to damEgothe ball ioint boot'

1 6 .Once the tool is in place,turn the sdiustingbolt as

necessaryto make the jaws parallel.Then handtighten the pressurebolt and recheckthe iaws to
make sure they are still parallel.

1 1. Cleanany dirt or greaseotf the ball joint.

12. Apply greaseto the specialtoolon the areasshown.
This will esse installationot the tool and prevent
damageto the pressurebolt threads.
Apply greasehere.

PRESSURE
BOLT

BoLT
ADJUSTING
13. Removethe cotter pin Jromthe steering arm and remove the nut.
14. lnstalla 12 mm hex nut on the balljoint. Besurethat
the hex nut is flush with the balljointpin end to prevent damageto the threadedend of the ball joint.
15. Use the ball ioint removeras shown.
Insert the jaws carefully,making sure you do not
damagethe ball joint boot. Adjust the iaw spacing
by turning the pressurebolt.
NOTE:It necessary,apply penetratingtype lub.icant
to loosenthe ball joint.

;i

1 7 . With a w.ench, tighten the pressurebolt until the

ball joint shaft pops loose from the steeringarm.
w6ar eye protsction. The ball ioint
l!@
can brsak loose suddenly and scatto. dirt or othgl
debris in your oyos.
1 8 . Removethe tool. then removethe nut lrom the end
of the ballioint and pullthe balljoint out ol the steerjng/suspension
arm. Inspectthe ball ioint boot and
replaceit if damaged.

)
12 mm HEX

{cont c

1&13

Front Suspension
(cont'dl
Knuckle/Hub
19. Rmovethe cotter pin and lowef arm balljoint nut.

22. Remove the knuckle protector,

20. Installa 14 mm hex nut on the balljoint.Be surethat

the hex nut is flush with the ballioint pin end, or the
thresded section of the ball joint pin might be
damagedby the ball joint remover.

23. Removethe cotter pin and the upper balljoint nut.

21. Use the balljoint .emoveras shown on page 18-13

to separatethe ball ioint and lower armNOTE:lf necess8ry,apply penetrtingtype lubricant
to loosenthe ball ioint.

24. Installa 1O mm hex nut on the ball joint.

Be sure that the hex nut is tlush with the ballioint
pin end, or the threadedsectionot the balljoint pin
might be damagedby the ball joint.emover.
25. Use the balljoint removeras shown on page 18-13
to separatethe ball joint and knuckle.
NOTE:lJ necessary,apply penetrstingtype lubricant
to loosenthe ball joint.
BA1I JOIITT

oTMAC-StOO200

1..
\
r',

10 mm HEx NUT

BAI.I JOINT
REMOVER,32 mm
07MAC-SLOOTO0

CASTLE
10 x 1.25 ]nln

COTTER PII{
Rplace,

26. Pulltheknuckleoutwa,d and removethe driveshaft

outboardjoint Jromthe knuckleusinga plastichammer. then removethe knuckle.

KNUCKLE

18-14

Hub Unit and Wheel BearingReplacement

29. Remove the circlip and tho splash guErd from tho
knuckle.

NOTE:Replacethe bearingwith a new one after removal.

27. Separatethe hub from the knuckleusing the special tools and a press.

cAuT|O:
a Take cars not to distort th6 splash guard,
a Hold onlo the hub to k6ep it trom talling whon
pressod clear.

30. Pressthe wheel bearingout ofthe knuckls using tn

special tools and a Press.
HUBDIS/ASSEMBLY
TOOL
oTGAF-SE00tOO
28. Removethe knucklering trom the knuckle.

ho!t

ORIVEB
07749-OOIOOOO
KNUCTLE

ATTACHME'{T.
82 x 88 mtt

07744-(xr1oBm

@
BASE
HUBDIS/ASSEMBLY
07GAF-SD/()7OO

(cont'dl

18-15

Front Suspension
Knuckle/Hub {cont'dl
31. Pressthe wheelbearinginnerracef rom the hub using the specialtools and a commerciallyavailable
bea.ingseparalor.

NOTE: Wash the knuckle and hub thoroughly in high

tlash-point solvent bfore reassembly.
32. Pressa new wheel besringinto the hub using the
specialtools shown and a press,

HU8 DIS/ASSEMELY
TOOL
07GAF-SEOOIOO
BEARII{G
SEPARATOR

praaa

DRNE'
INNERBACE

ATTACHMET{T
oTHAD-SGOO100
WHEEL
BEARII{G

BASE
SUPPORT
07965-SD90100
33. Install the circlip securly in th knuckle groove.
34. Install the splash guard and tighten the screws.

18-16

3 5 . Installthehub on the knuckleusingthe specialtools

lnstallation

shown and a Dress.

CAUTION:Tak car6 not lo diston tho splarh guard.
HUBASSEMBLY
GUIDEATTACHMENT
07cAF-SEOO200

CAUTIOIII:
a B csrotul not to damage ths ball irint boot.
a Torquo tho castlo nut to th lowor torquo specitication, thon tlghton it only lar enough lo align the slot
with tho pin holo, Do not allgn the nut bY loo8cning37. Installthe knuckleon the driveshaft.
38. Installtheknuckleon the lower arm and the tie-rod,
then tightsn the castle nuts and install new cotter
Dtns.

COTTER PII{
On reassembly,
bond the cofte. pin

BASE

36, lnstallthe knucklering on the knuckle.

RING
KNUCKLE

CASTLEI{UT
1 2 t 1 . 2 5m m
50-60 N'm
{5.o-6.o ks-m,
36 - 43 tb-frl
CASTLENUT
14 x 2.0 mm
50-60 N'm (5.0-6.0 kg-m,36-43 lb-ft|
39. Installthe knuckleon the upper arm, then tighten
the castle nut and install a new cotter pln.
40. lnstall the knuckle protector with the 6 mm bolt.

@
K UCI(LE
PNOTECTON
COTTENPIN
On reassembly.
bgnd the cotter pin

10 N.m (1.Okg-m' 7lb'frl

CASTLENUT
10 x 1.25mm

(cont'd)

rlo-rt8 N'm (4.0-4.8 kgn, 29-35 lb-ft)

18-17

Front Suspension
Knuckle/Hub (cont'd)
41. Installthe wheel sensorwith the sensormounting
bolts.
NOTE:8e careful when installingthe sensorsto
avoid lwisting wires.

42. lnstall the sensorwire with the two bolts.

10 N.m
(1.O

7 tb-fr)

44. Install the brake caliper with the calipel bracket

mounting bolts.
45. Installthe brakehose with the brakehosemounting
bolts.
BRAKEHOSE
BOLTS
MOUNTING
lo N'm (t.o kg-m,7 lb-ft1

SENSORMOUNTING
BOLTS
22 N.Jn
12.2 ks-m, 16 lb-ft)

'l '10N.m (11 kg-m.80 lb-ftl

46. Tightenthe new spindlenut.
WHEEL SENSOR

NOT:Betoreinstallingthe wheel,cleanthe mating

surlace of the brake disc and inside ot the wheel.

43. lnstallthe brakedisc with the 6 mm brakedisc retaining screws.

47. Installthe wheel with the wheel lug nuts.

WHEEL LUG NUT

12 x 1.5 mm
t10.in
{11 kg-m. 80 lb-fr}

6 mm BRAKEDISC
RETAII{II{G
SCREWS
10 N.mll.0 kg-m,7 tb-fr)

24 x 1.5 mm
250 'm {25 kg-m, 181 lb'ftl
NOTE: After tightening, use a drift
to stake sDindlenut shoulder
againstthe spindle.

44. Check the front wheel alignment and adjust if necessary (see page 18-41.

8 -18

SuspensionArms
Removal/lnspection
GAUTION:
a Roplacetho salt-lockingnuts aftor removal.
nut past thoir nylon lockingins6n8.
a Rplacothe salf-lockingbolts it you can oasilythiead a non-selt-locking
(lt shouldrquire1 N'm (0.1 kg-m, O.7 lb-ft) of to.qus to turn lho nut on th bolt).
a Bo carfulnot to damagethe ballioint boots.
SELF.LOCKINGNUT
12 x 1.25mm
Replace.
UPPERARM ASSEMBLY
Checkfor bendingor damage.
NOTE:Do not disassemble.

BALLJOINTBOOT
Checklor detorioration
or damage.
SELF-LOCKINGBOLT
12 x '1.25 rn''rjf

STABIUZER
BAR
Checkfor bendingor
damage.
RADIUS ROD WASHERS
SELF-LOCKINGNUT
12 x 1.25mm
Replace.
STABILIZERLINK
RUBBERBUSHING
Check Ior delerioration
or damage.
LOWERARM
Checktor damage.
OAMPERPINCH BOLT
ISELF.LOCKINGBOLT)
t0 x 1.25mm
SELF.LOCKINGNUT
12 x 1.25mm
Replace.

DAMPERFORK NUT
NUTI
{SELF-LOCKING
12 x 1.25 rnm
Replace.

RADIUS ROD

DAMPERFORK
CheckIor damage.
SELF-LOCKINGNUT
8 x '1.25mm
Replace.
ADJUSTING SHIM

NOTE:Adjustthe casterangleby increasing/decreasing

the adjustingshims (seepage 18-4).
'aqa a

1&19

Front Suspension
SuspensionArms {cont'd)
Installation
CAUTION: Th6 vehicle should bs on th glound bstoro any bolts or nuts connctd to rubbol mounts or bushing are
tightened.
NOTE:
a Wipe off the greasebefore tighteningthe nut at the ball joint.
a The right and left dampertorks 8re not symmetrical.The left damperfork is markedwith "SL" while the right damper
tork is markedwith "SR". Do not inte.changethem.
a The right and left upper arms are not symmetrical,The left upper arm is markedwith "SL" while the right arm is
markedwith "SR". Do not interchangethem.
a AJter installingthe suspensionarm. check the wheel alignmentand adjust it necessary.
a When installingthe radius rod washers,the "FR" mark faces the front of the car.
SELF"LOCKINGNUT
'12 x 1.25
mm
65 N'm (6.5 kg-m, 47 lb-ft)

UPPERARM ASSEMBLY
SELF.LOCKINGBOLT
1 2 x 1 . 2 5m m
55 N.m (5.5 kg-m, /rc lb-fr)

SELF-LOCI(INGNUT
12 x 1.25mm
55 N.m (5.5 ks-m,40 tb-ft)
STABILIZEBBAR
BOLT
I x 1.25mm
22 N.m 12.2 kg-m, l6 lb-ftl
SELF-LOCKIG NUT
12 x 1.25 fi.n
55 .m (5.5 kg-m, tlo lb-ft)
RUBAER

RUBBERAUSHING

stLrcoNE

.@]

GREASE

stLtcoNE
GREASE

DAMPER PINCH BOLT

ISELF.LOCKINGBOLTI
10 x 1.25mm
tt4 N.m (4.4 kg-m, 32 lb-ftl

BOLT
SELF-TOCKING
12 x 1.25mm
105 N'm {10.5kg'm,
76 rb-ftl

DAMPER FORKNUT
(SELF-LOCKING
NUT)
12 x 1.25mm
65 N.m {6.5 ks-m, 47 lb-ft}
DAMPERFORK
SELF-LOCKINGNUT
8 x 1.25mm
18 N'm {1.8 kg-m, 13lb-ftl

FRONT:GD,

Align the marKs.

CAUTIOII: Do not interchange the radius lod rubbor bushings.

1a-20

Ball Joint Boot Replacement

'1.

Removethe set ring and the boot.

CAUTION: Do not contaminate the boot installation
section with gf6as6.
Pack the interiorof the boot and lip with grease.

Lower Arm BushingReplacementAdjust the bushingdriverso that it matchesthe outside

dimensionof the lower arm bushing,Pressthe lowerarm
bushingusing the specialtool and a press.
NOTE:When installingthe lower arm bushing,press it
so that its leadingedges are llush with the lower arm.

BALL PIN TAPEREDSECTION

'l

SOCKETBOL

BOOT INSTALLATIONSECTION

BOOT INSTALLATION
SECTION

Wipe the greaseoff the slidingsurfaceof the ball

pin and pack with fresh grease.
CAUTION:
a Koep gloase oll the boot installation sction and
tho tapored soction of tho ball pin.
a Do not allow dust. dirt, or othor toreign mata.ials to enter tho boot.
4.

<+

Installtheboot in the grooveot the boot installation

section securely,then bleed air.
Installthe upperand lower balljointboot clipsusing
the specialtools as follows:
Lower balljoint: Adjust the specialtool with the adiusting bolt until the end ol the tool alignswith the
grooveon the boot. Slidethe set ring over the tool
and into position.
Upper ball joint: Hold the tool over the ball joint,
then slidethe clip over the tool and into position.
BALL JOINT
BOOT CLIP
GUIDE

ADJUSTING BOLT
Adjust the depth by
turning the bolt.

ARM BUSHING

UPPER
BALL
JOINTBOOT:
o7974-SA50aOO
LOWERBALL
JOINTBOOT:
OTGAG-SO/rO7O0

6ET RING

40 mm CIRCLIP
CAUTION: Afler installing tho boot, chock the ball
gin tapeld sction tol greas contaminalion and
wipo it if necossary,

1&21

Front Damper
Disassembly/lnsPection

Removal
1 . Removethe brake hose mounting bolts from the
oamper.

2 . Removethe damper pinch bolt.

Disassembly
1. compressthe damperspring with the spring compressoraccordingto the manufacturer'sinstructions,
then removethe self-lockingnut.
CAUTION: Do not compress th spling more than
necessary to remove tho nut.

Removethe damperfork nut, bolt and removethe

damperfork.

OAMPERPINCHBOLT
BOLT)
ISELF-LOCKING

BRAKEHOSEMOUI{TINGBOLT
(8x 16

SELF-LOCKINGNUT
1 0 x 1 . 2 5m m
Replace.

BRAKE HOSE
MOUNTING BOLT
(8 x 20 mml

STRUT SPRING
COMPRESSOR:
Cornmordally Avallablo
BRANICKOT/N MST-sAOA
o. oouivalont

2.

DAMPERFORK

Removethe springcompressorthen disassemblethe

damperas shown on the next page.

Inspection
DAMPERFORK NUT
NUTI
{SELF-LOCKING
Replac6.

4.

DAMPEn

1.

Reassembleall parts. except the spring.

2.

Push on the damperassemblvu" "hi-n.

3.

Check for smooth operationthrough a full stroke.

both compressionand extension.

Removethe damperby removingthe three nuts.

NUTS

NOTE:The dampershould move smoothly. lf it does

not (no compressionor no extension),the gas is leaking. and the damper should be replaced.

1 0 x 1 . 2 5m m

4.

Checkfor oil leaks,abnormalnoisesor bindingduring these tests.

NOTE:See page 18-41 for damperdisposal.

8-22

Inspection
SELF.L(rcKING
]{UT
1 0 x 1 . 2 5m m
30 N'm (3.0 kg-m,22 lb-ft|
ReDlacs.

\ , /

@z
a@\,/

*{

DAMPERMOUNTINGWASHER
Checkfor wgakness.
DAMPERMOUNTII{G
RUBEEB
DAMPERMOUNTING
COLLAR

DAMPERMOUNTI'{G

Rueeei
(92'

BUMP STOP PLATE

BUMP STOP
Check tor weakness o,

damage.

_\

,/
,/

-.-..t.@@

vH

\J

SPRINGMOUNTING BUBBER
Check for damag.

-----@

DUSTCOVERPLATE

l l

lY l

OUSTCOVER
Checkfor bendingor damage.

OAMPERUNIT
. Check tor leaks and
faulty operation.
. Check tor rust.

1a-23

Front Damper
Reassembly
Installthe damper unit on a spring compressor.

4.

Compressthe damperspringwith the spring comDressor.

NOTE:Follow the manufacturer'sinstructions.

CAUTlOltl: Do nol comptess tho spring more than
necosaary to install lhe nut.

Assemblethe damDerin reverseorderof disassembly except the dampermounting washer and selflocking nut.
NOTE: Align the bottom of the dsmperspringwith
the spring lower seat as shown,

Installthedampermountingwasher.then looselyinstall the new seltlocking nut.

6.

Hold the damper shatt and tighten the new selflockingnut.

Positionthe dampermountingbase on the damper

unit as shown.
SELF.LOCKINGNUT
10 x 1.25mm
30 N.m 13.0 kg-m, 22lb-l1l

<LEFT:>

STUDBOLT

STRUT SPRII{GCOMPRESSOR:
CommorciollyAvail.blo
BRANICKOT/N MST-sAOA

SPRINGLOWERSEAT

18-24

Installation
1 . Loosely install ths damper on thg trame with the
sligningtab tacing inside.

NUT
1 0 x 1 . 2 5m m
39 N.m 13.9kg-n, 28 lb-ftl

2 . Installthe damperfork over the driveshaftand onto

the lower arm. Installthedamperin the damperfork
so the aligningtab is alignedwith the slot in the
dampertork.
a

Hand-tightenthe bolts and nuts.

4.

Raisethe knucklewith a tloor jack until the car just

litls otJ the salety stand.
NOTE:The bolts and nuts shouldbe tightenedwith
the vehicle'sweight on the damper.

5 . Tightenthe damperpinch bolt.

Securethe dampertork bolt with I new selflocking
nut.
Securethe damperassemblyto the frame with the
flange nuts.
8.

lnstall the brske hose mounting bolts.

BRAKE HOSE MOUNTII{G EOLT

{8 x 16 rml
22 N.m 12.2kg-m. 16 lb-ft)

BRAKEHOSE
MOUNTING
BOLT
(8 x 20 mm)
22 N.m
16 tb-frt
12.2

DAMPER
BOLT
(SELF-LOCKING
BOLT)
10 x 1.25mm
44 N.m (4,4 kg-m,
32 rb-ftt

DAMPER FOBK AOLT

DAMPERFORK NUT
NUT}
{SELF-LOCKING
12 x 1.25mm
65 N'm (6.5 kg-m, 47 lb-ft)

18-25

RearSuspension
Torque Specifications
CAUTIOIT:
a R.C.cr tho 3olt-locking nuts aftor removal.
a RaDLc. tho rett-locklng bohs It you can easily throad a non-salf-locking nut past thair nylon locklng in3.rls.
{h.houH r.quko 1 N'm (0.'l kg-m, 0.7 lb-ft) of torque to tuln tho nut on tho bolt}'
a lta vhlcla should bo on th6 ground botore any bolts or nuts connoctedto rubbor mounls or bushings 8re tightenod,
a Torquc th! casdo nut to tha lower torquo epoqlllcatlon, then tight6n lt only far enough to align tho llot wfth the dn
hole. Do not allgn thc nut by loosoning.
NOTE:Wipe off th greasebetore tighteningthe nut at the ball joint.

SEIF.LOCKINGNUT
10 r 1.25mm
30 N.m l3.O kg-m, 22 lb-frl
Rgolace.

NUT
1 0 x 1 . 2 5m m
39 N'm {3.9 ks-m. 28 lb-ft)

SELF.LOCKINGNUT
12 x 1.25mm
OE .m 16.5 kg-m, 47 lb-ft|
Roploce.
CASTLEttIUT
1 0 x 1 . 2 5m m
40-48 N.m {4.0-4.8
29-35 tb-ft|

kg-m,

BOLT
8 x 1,25 lnm
22 N.m {2.2 kg-m. 16 tb-ft)

'l

l
NUT
sELF-LocKtt{c
10 x 1.25mm

45 N.m (4.5 ks-m, 33 lb-ft)

Replace.
/
]{UT
SELF.LOCKII{G
1 2 x 1 . 2 6m m
65 t{.m (5.5 kg-m,40 lb-ftl
Rgoloce.

CASTLENUT
12 x 1.25mm
50-60 tl.m 15.0-6.0 ks-rn,
36-43 tb-ftl

SPI]TDLEfIUT
22 x 1.5 fim
185 N.m
{18.5 kgn, 134 lb-tt}
Replac6.
NOTE: After tightoning, use I drift to
stske the spindlo nut shouldor against
the spindle.
CASTLE NUT
14 x 2.0 mm
50-60 N.m {5.0-6.0 ke-m,
36-43 tb-ft|
SELF.LOCKINGBOLT
12 x 1.25 mrn
CALIPERBRACKETMOUNTII{G BOLT
65 N.m 16.5 kg-m, 47 lb-ftl 12 x '1.25lrxn
39 N'm (3.9 ks-m, 28 lb-ftl

18-26

Knuckle/Hub
lllustrated lndex
NOTE:
a Use only genuineHondawheel weightsfor aluminumwheels. Non-genuinewheel weights may corrode8nd dsmsge
the aluminumwheels.
a Beforeinstallingthe brake disc, cleanthe mating surfacesot the rear hub and insideof the brakedisc.
a Beforeinstallingthe wheel, cleanthe mating surtacesof the brake disc and insideof the wheel.

SELF-LOCKINGBOLT
10 x 1.25mm
44 N.m 14.4 kg-m, 32 lb-tll

COTTERPIN
Replace.

\--q,

KNUCKLEPROTECTOR
Ch6ckfor damago.
BOLT
6 x 1 . 0m m
10 N.m ll.O kg-m, 7 lb-frl

b
REAR
SPINDLEASSEMBLY
Check for damage.

SPLASHGUARD
Checkfor bending
or damago.
10 N'm l1.O kg-m, 7 lb-ft)

s-

\ COTTERPIN
Replace.

REARWHEEL
HUB UNIT
Check for cracking
or damags.

WASHER
SPINDI..E

tan^l
BRAKE OISC
Check for wear or rust.
Inspection, section 19
6 mm BRAKEDISC
RETAININGSCREWS
10 N.m (1.0 kg-m, 7lb-ft|

ae

WHEELLUG NUT
12 x 1,5 mm
110 N'm 111 kg-m,80 lb-frl
(cont'dl

18-27

RearSuspension
Knuckle/Hub(cont'dl
Removal

8 . Removethe 6 mm brake disc retainingscrews

1. Loosenthe wheel nuts slightly.

9 . Screw two 8 x 1.25 mm bolts into the disc to push

it away from the hub.

2.

Raisethe rearof car and support it with safety stands

in properlocations(seesectjon 1).

3.

Bemovethe wheel lug nuts and rear wheel.

4.

Pull the parking brake lever up.

5.

Removethe hub cap, then raisethe lockingtab on

the spindlenut, then removethe nut.
HUBCAP
Replace.

NOTE:Turn each bolt two turns at time to prevent

cocking the disc excessively.

1 0 .Removethe brake disc.

I x 1.25 mm BOLTS

NOTE| Take care not to damagethe hub

BRAKEOISC

6 mm
5
MM ERAKE
EBAKE DISC
S
RETAINIT{GSCREWS

1 1. Remove the hub unit from the knuckle,

o.

Removethe brake hose mounting bolts.

7.

Removethe caliperbracketmountingboltsand hang

the caliperassemblyto one side.
CAUTION: To prevent accidental damage to the
caliper assemblyor brake hoss, use a shon pisce ot
wir to hang th calipr as$mbly lrom th6 und6.cardag6.
BRAKEHOUSEMOUNTING
BOLT

TRAILINGARM

CALIPERASSEMBLY
CAUPERARACKETMOUNTING BOLT

18-28

12. Removethe splssh guard from the knuckle.

1 5. Removethe rear spindleassemblyfrom the knuckle.

SELF-LOCKINGNUT
10 x 1.25mm
Replace.

ASSEMBLY
13. Removethe parkingbrakecabletrom the knuckle.
14. Removethe wheel sensorwire bracket.then remove
the wheel sensorfrom the knuckle.
NOTE:Do not disconnectthe wheel sensorwire.

1 6 .Hold the ball pin of the stabilizertink with a hex

wfench and loosenthe self-lockingnut.
Removethe selflocking nut, then disconnectthe
slabilizerlink from the stabilizerbar.

WHEELSENSOR

PARKINGBRAKE CABLE

1 2 r 1 . 2 5m m
Replace.

{cont'd)

18-29
l'-

Rear Suspension
Knuckle/Hub {cont'd)
18. Remove the cotter pin from the tie-rod end (4WS)
or lower arm B (2WS) 8nd removethe castle nut.
19. lnstalla 12 mm hex nut on the ballioint. Besurethat
the hex nut is flush with the balljointpin end. or the
threaded section of the bsll joint pin might be
damagedby the ball joint remover.
20. Usethe balljoint removeras shown on page | 8-13
to separate the ball ioint and knuckle.
NOTE:lf necessary,apply penetratingtype lubricant
to loosenthe ball joint.
COTTERPIN
Replace.

24. Removethe knuckleProtector.

25. Removethe cotter pin and the upperbsll joint nut.
26. lnstall a 1O mm hex nut on the ball joint.
Be sure that the hex nut is flush with the bsll ioint
Dinend, or the threadedsectionot the balljoint pin
might be damagedby the ball joint removar.
27. Usethe balljoint remove.as shown on page 18-13
to separatethe balljoint and knuckle,then remove
the knuckle.
NOTE:lf necessary,apply penetratingtype lubricant
to loosenthe ball joint,
BALLJ()|NT
28 mm
REMOVER.
oTMAC-SLOO200

BALL JOINT
REMOVER,28 mm
oTMAC-SLOO200

21 . Removethe cotter pin and lower arm balljoint nut.

K UCKLEPROTECTOR

22. Installa 14 mm hex nut on the balljoint.Be sutethat

the hex nut is flush with the balljoint pin end, or the
threaded section of the ball joint pin might be
damagedby the ball joint remover.
23. Usethe balljoint removeras shown on page 18-13
to separatethe ball joint and lower arm.
NOTE:lf necessary,apply penetratingtype lubricant
to loosenthe ball joint.

,a,-,",
mm HEX NUT

CASTI.ENUT
14 x 2.0 mm
EALLJOINT
32 mm
REmOVER,

-slooro0
oTmac

18-30

Rplace.

lnstallation

33. Installthe whel sensor, wheel sensor wire bracket

and parkingbrake cable on the knuckle.

28. Connectthe lowe. arm, lower arm B (2WSl or tierod end (4WS) 8nd upper arm with the knuckle, then
tighten the castle nuts,

NOTE:Be careful when installingthe sensorto avoid

twisting the wire.
22

.m {2.2 kg-m, 16lb-ftl

29. Installthe naw cotter oins.

30. Installthe knuckleDrotectorwith the bolt.
31. Connect the knuckle and the stabilizerbar, then
tighten the new selflocking nut.
CASTLENUT
1 0 x 1 . 2 5m m
40-/t8 N.m 14.0-4.8 kg-ir,
29 - 35 tb-tr)

COTTERPIT{
On roa$ombly,
bondth cottr pin

22 N.m 12.2kg-m, 16 lb-ft)

I{UT
SELF.LOCKING
1 2 x 1 . 2 5m m
55

.m 15.5 ks-m,40 lb-ttl

34. Installthe splashguard with the bolts.

CASTLEITUT
14 x 2.0 mm
50-60 N.m(5.0-6.0 kg-m,
36-43 tb-ft|
COTTERPIN
CASTLE NUT
1 2 x 1 . 2 5m m

50-60 .m (5.0_6.0 kg.h,

36_43 tb-ttt
32. Installthe rearspindleassemblyon the knuckle,then
tighten the new self-locking nuts.
SEI.F.LOq(NGIIUTS
lO r 1.25mm
45 N.m (4.5 kg{n, 33 lb-ftl

10 N.m(1.0 kg{, 7 |tsft}

18-31

RearSuspension
Knuckle/Hub (cont'dl
35. Install the hub unit and spindle washer on the
knuckle.

37. Installthe caliperassemblywith the caliperbracket

mounting bolts.
38. Installthebfakehosewith the brakohosemounting
bolts,
BRAI(EHOSEMOUI{TINGBOLT
16 tb-ft|
22 N.m 12.2

ASSEMBLY
CALIPER

MOUNTII{GBOLTS
39 N'm 13.9kg-m,2a lb-ft)
SPi DLE WASHER

39. Installthe new spindlenut, then tighten the nut'

40. Installthe new hub cap.

ito.

lnstallthe brakedisc with the 6 mm brakedisc retaining screws.

41. Installthe rear wheel with the wheel lug nuts.

NOTE:BeJoreinstsllingthe wheel,cleanthe mating
surfaceof the brakedisc and insideo{ the wheel.

REANWHEEL

SPI DLE ]{UT

22 x 1.5 mm
185 N,m (18.5 kg-m. 134 lb-ft|
NOTE: After tightening, uss a drift to
stake the spindle nut shouldgr against

WHEELLUGNUT
1 1 0N . m
(l I kg-rn,80 lb-ft}

the spindl6.

6 mm BRAKE DISC
RETAII{INGSCNEWS
10 N.m (l.o kg-m, 7 lb-ft|

18-32

42. Checktherearwheelalignmentand adjustif necessary (seepage 18-4).

SuspensionArms
Removal/lnspection
GAUTION:
a Rplacetho selllocking nuts afte.;emoval.
a Roplacethe self-locking bolts it you can oasily thread a non-solt-locking nut past thoir nylon locking insons,
(lt should roquire 1 N.m (O.1 kg-m, O.7 lb-ft) of torque to turn the nul on tho bolt).
a B caroful not to damage the balljoint boots.
SELF.LOCKINGNUT
12 x 1.25mm
Replace.

UPPER
ARM ASSEMBLY
Checklor bending
or damage.
NOTE:Do not disassemble.

SELF-LOCKINGNUT
10 x 'l.25 mm
Replace.
l2wS only)
SELF.LOCKINGNUT
12 x 1.25mm
Roplace.
{4wS only)

bo
SELF.LOCKINGBOLT
14 x 1.5 mm
(2wS only)

SELF-LOCKIf{G
12 x 1.25mm
Replace.

""\;\^.J

,aar-ao"*,no"oa\

STAAILEER BUSHII{G
Check lor deterioration
or damag6.
LOWERARM B
Check tor bnding
or damage.
(2WS only)

RUBBER
BUSHING
Checktor deterioration
or damage.
SELF-LOCKINGBOLT
12 x 1.25mm

TRAILINGARM
BUSHING
Check for deterioration
or damage.

{cont'd)

18-33

Rear Suspension
SuspensionArms (cont'dl
Installation
CAUTION: Tho vohiclo ehould be on the ground bofor any bolts or nuts connectod to rubb3r mounls or bu3hlng arc
tlghtcnod.
NOTE;
a Wipe ofJ the grease before tightening the nut at the ball joint.
a The right lower arm B is identiJiedby white paint.
"L" while the right 8rm is markod
a The right and left upper arms are not symmetrical. The left upper arm is marked with
"R".
Do not interchangethem.
with
a After installing the suspension arm, check the wheel alignment and adiust if necesssry.
SELF.LOCKINGNUT
12 x 1.25mm
65 N.|n (6.5 ks-m, 47 lb-ft1

-\

_rrat

UPPERARM ASSEMBLY

SELF.LOCKINGT{UT
10 x 1.25mm
55 N.m 15.5 kg-m,
4{' tb'ft|
(2WS onlyl

NUT
SELF-LOCKIT{G
12 x 1.25mm
65 N.m (6.5 kg-m, 47 lb-ft|
(4wS only)

SELF-LOCKINGBOLT
14 x 1.5 mm

BOLT
10 x 1.25 rn.n
44 .m {4.4 kg-rn, 32 lb-ftl

85 N'.n 18.5ks-m, 61 lb-ft)

(2WSonlyl
BOLT
8 r 1.25mm
22 N.m 12.2kg-m, 16 lb-ft|

22 N.m 12.2kg-m,
16 tb-ft}

SELF-LOCKINGNUT
12 x 1.25 tnm
55 N'm {5.5 kg-m.
/to lb-ft)

LOWERARM B
onlyl

LOWERARM

SELF-LOCKINGBOLT
12 x 1.25mm
65 i.in 16.5 kg-m, 47 lb-ft}
TRAILIT{GARM

18-34

BOLT
SELF-LOCKI]TG
1 2 | 1 . 2 5m m
65 N.m 16.5kg-m,47 lb-ftl

Ball Joint Boot Replacement

Removethe set ring and the boot.
CAUTION: Do not contaminate ths boot installation
soctlon with giease.
Pack the interiorof the boot and lip with grease.

Lower Arm Bushing Replacement

Adjust lhe bushing driver so that it matches the outside
dimensionof the lower arm bushing.Pressthe lower arm
bushingusing the specialtool and a press.
NOTE:When instsllingthe lower arm bushing,press it
so that its leadingedges are tlush with the lower arm.

BALL PIN TAPEREDSECTION

Pr9!a

BOOT INSTALLATIOI{SECTION

BUSHITIG
DRIVER
o7t{AD-SSq)lOO

BOOTINSTALLATIOT{
SECTION
3.

Wipe the greaseotf the slidingsurfaceof the ball

pin and pack with tresh grease.

a Keep g.oas off the boot inatallationssction and

ths tapered soction of tho ball pin.
a Oo not allow dust, dirt, or other foroign mat6dals to ontJ the boot.
4.

Installthe boot in the grooveof the boot installation

section securely.then bleed air.

5.

Installthe upperand lower balljointboot clipsusing

the sDecialtools as Jollows:
Lower balljoint:Adjust the specialtool with the adjusting bolt until the end of the tool alignswith the
grooveon the boot. Slidethe set ring over the tool
and into position.
Upper ball ,oint: Hold the tool over the ball joint.
then slidethe clip over the tool and into position.

BALL JOINT
BOOT CLIP
GUIDE

AOJUSTII{G BOLT
Adjust the depth bV
turning the bolt.

UPPERBALL
JOINTBOOT:
07974-SA50800
LOWERBALL
JOINTBOOT:
07GAG-SD/rO700

SET RING

40 mm CIRCLIP
CAUTION: Attor installing the boot, chck tho ball
pin tapered soction tor greaso contaminatlon and
wipe it it nscossary.

18-3s

Rear Damper
Removal
1 . Jack up the rear of car and support on satety stands
in properlocationslsee section 1).

9 . Remove the damper mounting bolt.

1 0 . Lower th8 raar suspnsionand remov the dampgr

Remove the rear wheel.

t

Removethe trunk side trim.

4.

Removethe two nuts,

assemblv.

NUTS
10 x 1.25rfn

Removethe knuckleprotector.
6.

Remove the cotter pin and the upper ball ioint nut.

7.

lnstalla 1O mm hex nut on the ball ioint.

Be sure that the hex nut is flush with the ball joint
Dinend, or the threadedsectionof the ballioint pin
might be damaged by the ball joint remover.

8 . Usethe balljoint .emoveras shown on page 18-13

to separatethe ball joint 8nd knuckle.
NOTE:lf necessary,apply psnetratingtype lubricant
1o loosenthe ball joint.

10 mm HX

UT

BALL JOINT
BEMOVER,28 mm
oTMAC-SLOO200

KNUCKLEPROTECTOR
CASTLEl{UT
1 0 x 1 . 2 5m m

COTTEBPIIT
Replaco.

18 -3 6
'b'--

BOLT
6x t.Omm

MOU TINGBOLY
(SELF.LOCKIl{G
BOLT)
1 2x t . 2 6 m m

Disassembly

Inspection
Reassembleall parts, except the spring.

1 . Compress th damper spring with the spring compressoraccordingto the manufacturer'sinstructions,

Push on the damper assemblyas shown.

CAUTIO : Do not compr.rs th6 sprlDg mora than
noceaaaryto ramovo tho sclt-locking nut.

J.

Remove the selflocking nut trom the damper assmbly,

Check for smooth operation through a full stroke.

both comoression and extension.
NOTE:The damper should move smoothly. lf it does
not (no compressionor no extensionl,the gas is leakin9, and the dampershould be replaced.

STRUT SPRINGCOMPfiESSOR:
Commo.d.lly Av.illbl.
BRANICKOT/t{ MST.5g)A
or oquivrlant

3.

Remove the spring compressor and disassembly the

damper as shown on the next page.

4.

Checkfor oil leaks.abnormalnoisesor bindingduring these tests.

NOTE:See page 18-41 for damperdisposal.

(cont'dl

18-37

RearDamper
Inspection (cont'd)
SELF-LOCKINGNUT
10 x 1.25mm
Reolace.
30 N.m (3.0 kg-m, 22 lb-ft|

DAMPER
MOUTTTTNG
^r'
WASHER -_ --.f.:, g
Ch6cktor
woakness.

./
DAMPER MOUT{TING
RUBBER

\Y

DAMPER
MOUI'IN G BASE

DAMPERMOUl{TrirG

iUBBER

DAMPCRSPRII{G
Check for weakened
compresspnor oamage.

ll l*----.-

t---^6

ooio" "ornr,ro

--

\r'

BUMPSTOPPLATE

w
,ffi,

*r'

',/
SPf,INGMOUNTING
RUBBER
Check lor damago
or cracKs.

DUSTCOVERPLATE

DUSTCOVER
Chocklor bending
or damage.

DUSTCOVERAOOT
Ch6ckfor detorioration
or damage.

DAMPER UITIT
. Check tor leaks and
faulty operation.
. Check tor rust.

18-3 8

Reassembly
1 . Install th dampel unit on 8 spring compressor.

4.

Compress the damper spring with the spring compressor.

NOTE: Follow the manutacturer's instructions.

AssemHe the damper in revsrse order of disassembly except the damper mounting washr and sel{locking nut.
NOTE:Align the bottom ot the damperspringwith
th6 spring lower seat as shown,

GAUTION: Do not compross ihe spring more than

necesaary to Install tho nut.
Installthe dampermounting washer, then loosely install the new selflocking nut.

6 . Hold the dampershaft and tighten the self-locking

nut.

Position the damper mounting base on the dsmpr

unit as shown.

<RIGHT:
>

<LEFT:>

SELF-LOCKII{G
lrluT
1 0 x 1 , 2 5m m
30 tl.m l3.Oks-m, 22 ltFftl
OAMPM

WELDED UT

WASHER

STRUTSPRII{GCOMPRESSOR:
Commrrd.lly Avdllbl.
BRAt{lCKoT/1{MST-580A

SPfiING LOWERSEAT

18-39

Rear Damper
Installation
I
1 . Lower the rear suspensionand set the damperas,
semblv.

4.

Connectthe upper arm and knuckle,then tighten the

castle nut.

2 . Connectthe damperassemblyand the lowe. arm,

5.

Installthe knuckleprotectorwith the bolt.

then looselyinstallthe dampermounting bolt.

NOTE:The damp. mountingbolt should be tightened with the damDerunder vehicleload.

KNUCKLEPROTECTOR
COTTERPIN
On reassembly,
bend the cotter pin

..:-.'l"t'
DAMPER
MOUNTING
BOLT
(SEI"F-LOCKING
BOtTI
1 2 r 1 . 2 5m m

- { 4

I
CASTLE NUT
1 2 x 1 . 2 5m m
40-48 N'm
{4.O-4.8 kg-m,
29 - 35 rb-frl

WELDEDNUT

COTTERPIN
l0

. m { 1 . Ok g - m , 7 l b - f t l

Raisethe rearsuspensionwith a tloor jack until the

weight ot the car is on the dampe,.

Tightenthe two nuts.

7 . Tightenthe dampermounting bolt

NUTS
l O x 1 . 2 5m m
39 N'm (3.9 kg-m,2a lb-trl

DAMPEB
MOU]IINNG AOLT
{SELF.LOCKING

BOr-Tl

12 x 1.25mm
65 N.m 16.5 kg-m,
47 tb-ftl

8.

18-40

Checkthe rearwheelalignmentand adjustif necessary (seepage 18-4).

Damper Disposal

a Ths dampors contain nitrogn gas and oil under p(3sur6. Tha prossur6must b6 roliovod boforo disposal
to provent explosion and possible hiuly whon
scrapping.
a Always wear oye protsction to avoid getting motal
shavings in your eyes whon the gas dampel prssuro
is rolieved.
Placethe damperon a levelsur{acewith its rod extende d a n d d r i l la h o l eo t 2 . 0 - 3 . 0 m m { 0 . O 8 - 0 . 1 2 i n l d i ameter in the body to release the gas.

( Front Damper:>

Drill here.

( Rear Damper:>

Drill here.

18-41

Brakes
Conventional
Brakes......
19-1
A n t i - L o c kB r a k eS y s t e m( A B S I . . . . . . . . . . .1 9 - 3 1

ConventionalBrakes
.......... 19-2
SpeciafToofs
l l l u s t r a t eIdn d e x . . . . . . . . . . . . . . . . . . . . . , . .1. 9
. .-. 3
PedalHeight
......... 19-4
Adjustment
ParkingBrake
......... 19-5
Adjustment
Flont Brakes
T o r q u e / l n s p e c t i .o. n. . . , . . . . . . . . . . . . .1. .9. - 6
Front Brake Pads
..............19-7
Inspection/Replacement
Front Caliper
....... 19-9
Disassembly
. . . . . . . .1 9 - 1 0
Reassembly
Front BrakeDisc
R u n o u It n s p e c t i o .n. . . . . . . . . . . . . . . , , . 1. .9. - 11
Thicknessand Parallelism
....... 19-11
Inspection
. . . . . . . . . . . . . . 1. .9 - 1 2
Bleeding
Master Cylinderand Brake Booster
...................19-13
Removal/lnstallation
Master Cylinder
.........1
. 9-14
Inspection
Brake Boostel
.....19-15
Tests............
Adjustment..... 19-15
PushrodClearance

RearDisc Brakes
T o r q u e / l n s p e c t i .o. n. . . . . . . . . . . . . . . . . 1 9 - 1 7
RearBrake Pads
..............19-18
Inspection/Replacement
RearBrake Disc
R u n o u It n s p e c t i o n , . . , , . . . . . . , , . . . . ,1,9. .-.2 0
Thicknessand Parallelism
Inspection
....... 19-20
RearCaliper
....... 19-21
Disassembly
Reassembly
........ 19-24
BrakeHoses/Pipes
fnspection
...,,,,,.. 19-27
.............19-28
BrakeHoseReplacement
ParkingBrake
Disassembly
and Reassembly...... 19-29

SpecialTools

Rol. No.

Tool Number

oTHAE-SGOO100
oTJAG-SD40100
o7914-SA50000
o7916-6390001

BrakeSpringCompressor
Pushrod Adjustmenl Gauge
Snap RingPliers
LocknutWrench

19-2

19-22, 19-25
19-l5
19-22, 19-25
19-21, 19-26

an

lllustratedlndex

FRONTBRAKES
Torque/lnspection,page 19-6
Front Brsk Pads. page 19-7
Front Csliper, pag6 19-9
FrontSrakeDisc,page 19-11

PARKINGBFAKE
Adjustmont, pago | 9-5
Diaa$embly 6nd Reassombly,
p6go 19-29

REARDISC BRAKES
Torqu6/lnspsction,p8g 19- l7
R6arBrak6P8ds,psgs 19-18
R6ar Brak Disc, page 19-20
R6ar Calipr, page 'l9-2'l

ERAKEPEDAL
Adjustmont,psg l9-4
MASTER CYLIT{DER
AND BRAKEBOOSTER
Rgmoval/lnstallation,psge 19-13
MastsrCylinder,page 19-14
BrakgBooster19-15

BRAKEHOSES/PIPES
Inspoclion,pag 19-27
Brake Hoso Replacmnt.p6g 'l 9-24

19-3

PedalHeight
Adjustment
'I

Disconnectthe brakeswitch connector,loosenthe

brakeswitch locknutand back off the brakeswitch
until it is no longertouchingthe brake pedal.

2 . Measurethe pedalheight from the left side center

of the Dedalsurface.
BRAKE

swtrcH

4.

Screw in the brake switch until its plungeris fully

depressed(threadedend touching the pad on the
pedal arm). Then back otf the switch 1/4 turn to
make O.3 mm {0.O1 in} of clearancebetween the
threadedend and pad. Tightenthe locknut tirmly.
Connectthe brake switch connector.
CAUTION: Ch6ck that the brak lights go oft
whon ths psdsl is lleased.

PAD

A: Podal Freo Play

1-5 mm (1/16- 13/64in)
B: Standard Pdal Height (with floor mat
removed)
MT: 165 mm (6.5 inl minimum
AT: 186 mm (7.3 in) minimum

3 . Loosenthe pushrodlocknutand screw the pushrod

in or out with pliersuntil the standardpedalheight
from the floor is reached.After adjustment.tighten
the locknut firmlv,

PUSHRODLOCKNUT
l5 N.m 11.5kg-m, 11lb-fll tor cai. without ABS
19 .m {1.9 kg-m, 14 lb-ftl for cars with ABS

19-4
bsnmrr

BrEke Podal Froe Play Inspection:

Stop the engine and inspect the play by pushingthe
pedalby hand.
BrakePdalFreePlay: 1-5 mm {1/16-13/64 inl
CAUTION: It tho pedal freo play is insufficient, it
may ro3ult in brak drag.

ParkingBrake
Adjustment
NOTE: After rear brake caliper servicing,loosen the
parking brake adiusting nut, start the engine and
depressthe brake pedal severaltimes to set the selfadjustingbrake beforeadjustingthe parkingbrake.

Tighten the adjusting nut until the rear wheels drag

slightly when turned.

o.

Relasethe parkingb,ake lever and check that the

rar wheels do not drag whn turned. Readjustit
nScessarv.

Bbck the flont wheots beforo iacking up

@
the loar of the car1.

Raisethe rear wheels off the ground.

2.

Make sure the lever of the rear brake calipercontacts the pin ot the brake caliper.

With the equalizer properly adjusted, the rear

brakes should be tully applied when the parking
brake lever is pulledup 6 to 1O clicks.

3 . Pull rhe parkingbrake lever up one notch.

Removethe tront consoleand centerconsole(see
p a g e2 O - 5 1 ) .

19-5

Front Brakes
Torque/lnspectaon
a Nevgl us an air hos6 or dry brush to clan braks assamblies.
a Use an OsHA-spproved vacuum cl6aner, to avoid breathing brake dust,
a Contaminated brake discs or pads reduce stopping ability.
CAUTION:
a Do not spill brake tluid on tho car; it may damagethe paint; it brakefluid does contact tho paint, wash it ott immediately with water.
a To prevont spills, cover the hose loints with rags or shop towels.
a Cl8n all pans in brake lluid and air dry; blow out all passageswith comprossdail.
a Btore reassembling.chcck that all parts ar free of dust and othr toreign particlas.
a Replaceparts with new ones whcnvel specitisd to do so.
a Make sure no dirt or othor lorign mattr is allowed to contaminato th6 brako fluid.
a Do not mir different brands of braks fluid as thy may not b6 compatible.
a Do not reuse the drained tluid. Us6 onlv clean DOT 3 or 4 brake fluid.
NOTE:
a Coat piston, piston seal, and caliperbore with clean brakefluid.
a Reolaceall rubberoarts with new ones wheneverdisassembled.
-ffi:

Brakecyrindergrease(P/N:08733-Bo2oE) or equivalentrubbergrease.

WEAR INDICATOR
INNERPAD SHIM B
lnstallinnerpad with
Checklor wear or
wear indicatorupward.
ats
oamage.
Apply Molykoteo M77
to shim A sadeol shim.

\/L
,.
I r t \
{ ( /?

OUTERPAD SHIM
Check tor wear or
oamage.
Apply Molykoteo N477ptt{ B
to pad side of shim.
Checkfor bendingor
damage.

tI

INNERPAD SHIM A /
CheckIor wear or
damage.
Apply Molykoreo M77
to both sidesof shim.

,/
BUSHING

-6,l

10 x 'l.O mm
50 N'm {5.0 kg-m,
36 tb-ftl

BRAKEPADS

rinins
check
thicknes.
q{

BLEEDSCBEW
I N.m
(0.9 kg-m, 6.5lb-fr)

CALIPERBODY
CheckIor scoring
on cylinderwall-

yN
P t o . /

<
'iN.-_

Check for bending or

u afl

_G1

damase.

naEih
ffi,.--Nv Yl(o,6
-N/ffiL
/

PrsroNSEAL

RETAIl{ER
Checkfor

I \V--\.-_
I

."o,,nn
8'n"i"?nfo,
on srlrface.

19-6

1 2 x 1 . 2 5m
1 1 0 N . l n ( 1 1 . 0k g - m ,
80 lb-ftl

4-

siliconegrease.

Ptt{BooT

-41

\"--'--\
^t t

..6|t,

damage.

PISTONBOOT
Replace.

Replace.

-6l

Front BrakePads
Inspection/Replacement
4.
a Nevar us an air hoss or dry brush to clan blake
assemblies.
a Use an OsHA-approved vacuum cleanet, to avoid
broathing brako dust.
1.

Loosenthe front wheel lug nuts slightly,then raise

the car and supporton safety stands,
Removethe front wheels.

2.

Removethe caliperbolt and pivot the caliperup out

of the way.

Using vernier calipers,measurethe thickness of

each brakepad lining.
Brako Pad Thickness:
Standard:
F22A1 and H23Al sngine: 12.5 mm (O.49in)
H22A1 engin: 1 1.O mm {0.43 in)
Servic Limit:
1.6 mm {0.06 inl

CALIPERSOLT

CALIPER
BODY
3.

lf the brake pad thicknessis lessthan servicelimit

at step 5, replacethe front pads as a set.

Removethe pad shims, pad retainersand pads.

NOTE: Measurementdoesnot includepad backing

plate thickness.
6.

Cleanthe caliperthoroughly;removeany rust, and

check for groovesor cracks.
Installthe pad retainers.

Front BrakePads
(cont'd)
Inspection/Replacement
8 . Apply Molykote@ M77 compound to the pad
shims and the back of the pads. Wipe off excess.
9 . lnstallthe brake pads and pad shims correctly.

@
a Wh6n

1 1 .P ivotthe caliperdown into position,then installthe

caliperbolt (flangebolt).
NOTE: Make sure the pin is clean before installation, then applya cleansiliconegreaseto the inside
ot the boot and the Din.

reusing th pads, always leinstall tho

brake pads in their original positions to pravent
loss ot braking efticiency.
a Contaminated brake discs or pads reduce stopping sbility, Kep greas oll the discs and p8ds.

NOTE: Installthe pad with the wear indicatoron

the inside.

CALIPER
50 N.m

{5.Okg-m,
36 rb-ft|
PISTON

INNERPAD SHIM A
Apply Molykote@
M77 to borh
sidesof shim.

Apply Molykoteo
M77 to inner
side of shim.

t ' \

INNERPAD SHIM B
Apply Molykote@
M77 to inner
INNERBRAKEPAD
sadeof shim.

indicator)

t l

E i
V

OUTERBRAKEPADS

1O. Pushin the pistonso that the caliperwilltit overthe

pads. Keepthe boot in positionto preventdamaging the boot when pivotingthe caliperdown.

19-8

12. Depressthe brakepedalseveraltimesto make sure

the brakeswork. then road-test.

NOTE: Engagementof the brake may requi.e a

greater pedal stroke immediatelyafter the brake
pads have been replacedas a set. Severalapplications of the brake Dedalwill restore the normal
oedal stroke.

FrontCaliper
Disassembly
lf necessary,apply compressedair to the caliper
fluid inlet to get the piston out. Placea shop rag or
wooden block as shown to cushion the oiston
when it is exoelled.
Use low pressureair in short spurts.
Removethe piston from the caliDer.

a N6vor uso an air hose or dry brush to clean brake

assmbli9s.
a Use an OSHA-approved vacuum clganr to avoid
broathing brake dust.
CAUTION:
a Do not spill brak fluid on the ca1;it may d8magthe
paint; il brake fluid dos contact the paint, wash it
ofl immediatoly with wat6r.
a To plevent spills, cover the hose ioints with rags or
shop towels.
a Clean all parts in brak6 tluid and air dry; blow out all
passages with comprossed air.
1.

Removethe banjo bolt and disconnectthe brake

hose from the calioer.

2.

Removethe caliperbolts, then removethe caliper.

a Do not placo your fingsrs in front of th piston.

a Do not use high air pressuls; use an OSHAapprovsd 30 PSI nozzle.

4.

SEALING
WASHERS
Replace.

Removethe piston boot and piston seat.

CAUTION: Take care not to damago the cylindel
bore,

CALIPERBOLT

19-9

Front Caliper
Reassembly
CAUTIOt{l
a Do not spill brako fluid on the ca.; it may damagethe
paint; if brake fluid do6s contact th paint, wash it
off immediately with water.
a Bofore reassgmbling,chock that all parts are troe ot
dust and othol toreign pa.ticles.
a Raplacepans with new ones whgn6vo. spocitied to
do so.
a Make suls no di.t or othor loroign mattor is allowod
to contaminate the brak tluid.
a Do not mix different brands ot brake tluid as they
may not be compatible,
a Do not reus tho draindfluid. Use onlv cloan DOT 3
or 4 brakefluid.
1.

Cleanthe piston and caliperbore with braketluid

and inspectfor wear or damage.

2.

Coal a new piston sealwith siliconegreaseand install it in the cylindergroove.

3.

4.

Lubricatethe calipercylinderand pistonwith brake

fluid, then installthe piston in the cylinderwith the
dishedend facing in,

5.

Install the brake pad retainersand brake pads in

their originalpositions(seepage 19-8).

Apply brakecylindergrease(P/N:08733-BO2OE)
or equivalentrubbergreaseto the sealinglips and
insideof a new piston boot, and installthe boot in
the cylindergroove.

Always rinstall the brake pads in

@
their o.iginal positions to prevent loss ol braking
ofliciancy.
6.

Installthecaliperon the caliperbracketand tighten

the caliperbolts.

7 . Connect the brake hose to the calipe. with new

sealingwashersand tighten the banio bolt.

BANJO BOLT
35 t{.m {3.5 kg-m,

25 tb-ftt

,:^"
#-i!!r9ul
RUBBERGREASE

PISTONSEAL

-611
SILICONEGREASE

SEALING
WASHERS

CALIPER
BOLT
50 .m (5.0 kg-m,
36 tb_trl
8.

19-10

Fill the brake reservoir up and bleed the brake

s y s t e m{ s e ep a g e1 9 1 2 ) .

Front BrakeDisc
Runout lnspection

Thicknessand Parallelism
Inspection

Loosenthe front wheel lug nuts slightly,then raise

the car and supporton safety stands.
Removethe front wheels.
2.

Removethe brake pads (seepage 19-7).

3.

Inspectthe disc surfacefor cracks,and rust. Clean

the disc thoroughlyand removeall rust.

4.

Use lug nuts and suitableplainwashefsto holdthe

disc secu.elyagainstthe hub, then mount a dial indicatoras shown and measurethe runoutat IO mm
(O.4 inl from the outer edge oJ the disc,

Loosenthe front wheel lug nuts slightly,then raise

the car and support on safety stands.
Removethe front wheels.

2 . Removethe brake pads (see page 19-7).

Using a micrometer, measure disc thickness at
eight points, approximately45o apartand 1O mm
(O.4 in) in trom the outer edge of the disc.

Brak6 Disc Runout:

Scrvlc. Limlt: O.10 mm (0.004 in)
5.

lf the disc is beyond the servicelimit, refinishthe

rotor with an on-car brake lathe. The Kwik-Lathe
producedby Kwik-WayManufacturingCo. and the
"Front Brake Disc Lathe" offered by Snap-onTools
Co. are appfovedfor this operation.
MEx. RefinishingLimit: 21.0 mm (0.83 in)

Brako disc thickness:

Standard:23.O mm {0.91 inl
BrakoDisc Parallelism:
O.O15mm (0.00OOin) mar.
NOTE; This is the maximum allowabledifference
between any thicknessmeasurements.
4.

NOTE: A new disc should be retinished if its

runout is greaterthat O.l O mm {O.OO4in}.

lf the disc is beyondthe servicelimit for parallelism,

refinishthe rgtor with an on-car brake lathe. The
Kwik-Larheproducedby Kwik-Way Manufacturing
Co. and the "Front BrakeDisc Lathe" offered by
Snap-onTools Co. are approvedfor this operation.
Max. RfinishingLimit: 21.O mm (0.83 in)

19-11

Bleeding
cAUTtOt{:
o Uso only clsan DOT 3 or 4 brake fluid,
a Mako suro no dirt 01 othl toreign mattor i5 allowod
to contaminate ths brake tluid.
a Do not mix diflorent brands of brako fluid as they
may not be compatible.
a Do not spill brake fluid on tho car; lt may damags the
paint; it brake tluid does contact the paint, wash it
ofl immadiately with wator.

FRONT:

NOTE: The reservoiron the master cvlinder must be

full at the stan ot bleedingprocedure,and checked
after bleedingeach brakecaliper.Add fluid as required.
Use only clean DOT 3 or 4 brakefluid.
BLEEDING
SEOUENCE:

REAR:
O Fronr Right

O Roar Rlght

BI-EEDSCREW

a Front Loft

a R..r L.fi

1 . Have someone slowly pump the brake pedal

severaltimes, then apply steady pressure.
Loosenthe brake bleed screw to allow air to escape
from the system. Then tighten the bleed screw
securelv.
3.

Repeatthe procedurefor each wheel in the sequence shown above, until air bubblesno longer
appearin the fluid,

4.

Check brake performanceby road testing.

19-12

Master Cylinderand BrakeBooster

Removal/lnstallation
CAUTION:
a Be calelul not to bend or damago tho brake pips whsn removing tho mast6r cylindor and boostef.
a Do not spill brako fluid on the cai; it may damagthe paint; if brake fluid dos contact th paint. wash it oft immediately with watr.
o To prevsnt spllls, cover the hose ioinis wiih rags or shop tow6ls.
a Before lesssembling, check that all parts als tree ol dust and othr toreign particlos.
a Mako sur6 no din or oth6r foroign matter is allowod to contaminat th brake tluid.
a Do not mir dift6r6nt brands ot brak tluid as they may not bo compatibls.
a Do not raus th6 draind fluid. Us only closn DOT 3 oi 4 brake fluid.
a Whon connecting the b18kpipes, msko suro that thor6 is no intoderenco botwoan tho brake pipos and othor parts.
a Do not disassmbletho mastor cylindor or boost6r, Roplacothm as complots assomblies.
Drainthe brakefluid from the mastercylinder.
Disconnectthe brakefluid level switch connectors.
Disconnectthe brake pipesJromthe mastercylinder.
Removethe mastef cylindermountingnuts and the mastercylinder.
Disconnectthe vacuum hose from the boosterand removethe vacuum hose bracket.
Removethe thfottle/cruisecontrolcableb.acket,then.emovethe throttlecableg.ommetfrom the enginecompartment bulkhead,
7 . Removethe intake air temperaturesensorfrom the intakemanifold. PUSHBOD
LOCKNUT
8 . Loosenthe pushrodlocknut. and removethe cotter pin and joint pin. 15 N.m ll.5 kg-m,11 lb-ftltor carswithoutABS
q
19 N.m 11,9kg-m, 14lb-ftl tor cars with ABS
Removethe boostermountingnuts and clevis,
COTTER.PIN
1 0 . Removethe brak booster(seenext page).
BRAKEBOOSTER
1.
2.
3.
4.
5.
6.

Do not disassemble.

8 x 1.25mm
13 N.m
11.3kg-m, 9 lb-ft|

JOII{T PIN

-6l
To rightrcar blako

DUALPROPORTIONING
VALVE
Oonot disassemble.
x 1,25
l5 N.m
( 1 . 5 k g - m ,1 1 l b - f t )

To left-.e6r b.ako

---

l O r 1 . Om m
19 N.m
{1.9 kg-m, t4 lb-ftl

19 N.m
{1.9 kg-m, 14lb-ft)

,/
To .ight-tront brako

11. Installthe brake boosterand mastercvlinderin the reverseorder oI removal.

NOTE: Beforeinstallingthe mastercylinder,check and adjustthe pushrodclearance(seepage 19-15).
12. After installation,check and adjustthe brakepedal height (seepage
- 19-4).
1 3. Fill and bleedthe brake system {see page 19-12).

(cont'd)

19-13

Master Cvlinder and Brake

Booster
(cont'dl
Removal/lnstallation
Boorter Replacement
1.

Pull th8 brak6 booster torward. then turn it to th6

right until the oporating rod is clear of the bulkhead
as shown below.

2.

Move the ope.sting rod beyond the left dampe.

bas6 by turningthe brake booster.
ROD
OPERATII{G

EFAKEBOOSTER

Master Cylinder
Inspection
CAUTION:
a Do not splll brak6 tluid on the car; it may damagc the
palnt; il brak fluid doos contact th paint, wash lt
ofl immediately with vvater.
a Bforo roassambling,check thst all parts ar treo ot
dust and other fo?olgn particles,
a Do not try to disasssmblo th6 maEtar cylindef
assembly, Beplaco tho ma3tr cylindor assombly
with a now part it necessary.
a Make sura no dirt or othof toloign matter is allowed
to contaminate tho blako tluld.

Frcnt
/
LEFTDAMPERBASE

Continue to turn the brak8 booster until the

ope.ating rod points forward,
Rmove the brake booster from the engin compartmont with the front cylinder shell sid8 of the
b18kboosteruDw8rd.

FRONTCYLII{DERSHELL

SILICONEGREASE

OPERATINGROD

19-14

CYLINDER
Checkfor loaksor damags.

BrakeBooster
Tests

PushrodClearanceAdjustment

Functlonal Test
1, With the enginestopped.depressthe brake pedal
severaltimes,then depressthe pedalhardand hold
that pressurefo. 15 seconds.lf the pedalsinks,the
master cylinder, brake line or a brake caliper is
taulty.
2.

NOTE: Master cylinder pushrod-to-pistonclearance

must be checkedand adjustmentsmade, if necessary.
bfore installingmastercylinder.
1.

Start the engine with the pedal depressed.lf the

pedal sinks slightly,the vacuum booster is working. lf the pedalheightdoes not va,y, the boosteror
check valve is faulty.

PUSHBOD
ADJUSTMENT
GAUGE
0TJAG-SD40100

Lesk T6st
1. Deprsssthe b,ake pedal with the enginerunning,
then stop the engine.It the pedal height does not
vary while depressedfor 30 seconds,the vacuum
booster is OK, lf the pedal rises, the booster is
taulty.
CAUTION: Do not try to disa$ombl th boosto..
Replacthe boostor assembly with a new ono.
2.

With the enginestopped,depressthe brake pedal

several times using normal prssure.When the
pedal is first depressed,it should be low. On consecutiveapplications,pedalheight shouldgradually rise. lf the pedal positiondoes not va,y, check
the boostercheck valve.

Check Valve Tost

1. Disconnectthe brake boostervacuum hose at the
booster.
2.

Stsrt the engine and let it idle. There should be

vacuum available.lf no vacuum is available.the
check valve is not working correctly.
Replacethe check valve and retest.

CHECKVALVE

Set the specialtool on the master cylinderbody;

push in the center shaft until the top ot it contacts
with the end of the secondarypistonby turningthe
sdjustingnut.

ADJUS?ING NUT

MASTER CYLINOER
SECONDARYPISTON
CENTERSHAFT

Without disturbingthe center shaft's position,install the specialtool upsidedown on the booster.
Install the master cylinder nuts and tighten to the
specified torque.
4.

Connectthe booster in-linewith a vacuum gauge

0-760 mm HS (O-30 in Hg) to the booster's
engine vacuum supply, and maintain a engine
speed that will deliver 500 mm Hg (2O in Hg)
vacuum.

5 . With a feeler gauge. measurethe clearancebetween the gauge body and the adjusting nut as
snown.
Cloaranc6:
C81swithout ABS: O-0.4 mm {O-0.O2 in}
Car8 with ABS:
O-O.2 mm (O-O.01 inl
VACUUM GAUGE
0-760 mm Hg lO-3O in Hgl
(Commercially
Available)

15 N.m 11.5kg-rn,
1 1 tb-ft}

]{UT
ADJUSTING

(cont'd)

1 9 - 15

BrakeBooster
PushrodClearanceAdjustment (cont'd)
NOTE: lf the clearancebetween the gauge body and
adjustingnut is 0.4 mm (0.02 in) [cars with ABS: 0.2
mm (0.01 inll, the pushrod-to-pistonclearanceis 0
mm. However,the clearancebetweenthe gauge body
and adjusting nut is O mm, the pushrod-to-piston
clearanceis O.4 mm (O.O2inl lcars with ABS: O.2 mm
(O.O1in)l or MOBE.Therefore,it must be adjustedand
rechecked.
6.

7 . Adjust the pushrodlength as shown ii the booster

is removed.

1 1 6r 0 . 5 m m
(4.6 t 0.02 in)

lf the clearanceis incorrect:

- Cars without ABS: loosenthe star locknut and
adjustthe clearanceby turningthe adjusterin or
out while holdingthe pushrod.
Tightenthe star locknut to the specifiedtorque
and removethe sPecialtool.
NOTE:
a Adjustthe clearancewhile the specifiedvacuum
is appliedto the booster,
a Hold the cleviswhile adjusting,
O-O.4 mm (0-0.02 inl

STARLOCKNUT
22 N.m
12.2kg-m,l6lb-ft|

- Cars with ABS: removethe specialtool and adjust the clearanceby turning the adjusterin or
out while holdingthe output rod.
O - O . 2m m 1 0 - 0 . 0 1i n l

19-16

PUSHROD

LOCKNUT
15 N.m
(1.5 kg-m,
11 tb-ftt

8.

lnstallthe mastercylinder(seepage 19-13).

After installation,perform the following inspections and adjustil necessary.

a Brakepedal height {seepage 19-4}
. Brakepedalfree play (seepage 19-4)

RearDisc Brakes
Torque/lnspection
a Ngver use an air hose or dry brush to clean btake assemblies.
a Use an OSHA-approvedvacuum cleaner,to avoid breathingbrakedust.
a Contaminated brake discs or pads reduce stopping ability.
CAUTION:
a Do not spill blake tluid on the car; it may damagethe paint; il brske fluid does contact the paint, wash it oft immediatoly with watsr.
a To prevent spills, cover the hose ioints with rags or shop towels,
a Clean all parts in brako fluid and air dry; blow out all passagewith comprssdair.
a Batore reassembling,check that all parts ar6 free of dust and other toreign panicles.
a Replacs parts with new ones whenevei sDeciliedto do so,
a Make sure no dirt o? other loreign mattet is allowgd to contaminate the blake fluid,
a Do not mix different brands of brake fluid as they may not be compatiblo.
a Do not reuse the drained lluid. Use onlv clean DOT 3 or 4 brake fluid.
NOTE:
a Coat piston, piston seal, and caliperbore with cleanbrakefluid.
a Replaceall rubberparts with new ones wheneverdiassembled.
-{Z-aiiif-{ : Brakecylindergrease(P/N:08733-Bo2oE) or equivalentrubbergrease.
BRAKEPADS
CheckliningthickINNERPAD SHIM
Checktor wear.
Apply Molykoreo M77 ro
pad side of shim.

, Siliconegrease.

.-6f

RETAINER
OUTERPAD SHIM
Checkfor weakness Checkfor wear.
or oamage,
Apply Molykoteo M77 to
pad side of shim.

'10x 1.25 mrn

39 N.m
(3.9 kg-m, 28 lb-ftl

CALIPER
BRACKET
CheckIor
cracks.

PARKINGNUT
10x1.25mm
28 N.m (2.8 kg-m.
20 tb-frl
SPRING
CAM BOOT
Replace.
PAD SPRING
cr,."t r". *.*
or
damage,

I
I

D S^

=^"

CALIPERBODY
Checkfor scoring
on cylinderwall.
8 mm FLANGEBOLT
23 N.m (2.3 kg-m, 17lb-ftl

check ror wearor

d"maqe.

'''ry9

O-RING'Reolace.
c:_9!!a!$l

Replace.

or damaoe.

KX(
lniir-

.,,-

PINBOOTS

PlsroN
SLEEVE
Checkfor wear

I
I
',.''
1

-.'j@Ell

cuP ./

Replace.
A-^
._=i!!l!iil

PISTONASSEMBLY
Checktor scoringon
the surface,

'y"P"M
cfRcLrP

(nl,--/

BEARTNGA
Check for damage
ADJUSTING
Replace.
SPRINGB
SPBING
tor
Check
Checkfor damage.

/r,"ron

"oo,

Replace.

4..

19-17

RearBrakePads
Inspection/Replacement
lf liningthicknessis lessthan servicelimit at step 5,
.eplace the rear pads as a set.

@
a iloyor uae an alr hose 01 dry blush to cloan brake
assamblies.
a Us6 an OsHA-approvod vacuum cloanor, to avoid
breathing brake dust.
1.

Block the front wheels, loosenthe rear wheel luq.

nuts slightly, support the rear of car on satety
stands.then removethe rear wheels.
Releasethe parkingbrake.

2,

Removethe calioershield.

CALIPER
SHIELD
Remove the two caliper mounting bolts and the
calipertrom the bracket.
CAUTION:
a Thoroughly cloan ths outsido ot tho calipsr to
prevont dust and dirt ttom ontodng insid6.
a Support the calipel with a pleco ot wilo 5o that it
does not hang trom tho brako hose.

4.

Removethe pad shims, pads and pad retainers.

Using vernier calipers,measurethe thickness of
each brakepad lining,
B.ako Pad Thicknass:
9.O mm (O.35 in)
Standard:
ServicoLimii: 1.6 mm (0.06 inl

CALIPERMOUNTING

NOTE: Measurementdoesnot includepad backing

Dlatethickness.

19-18

o.

Cle6nthe caliperthoroughly;removeany rust, and

check lor groovesor cracks.

7.

Make surethat the pad retainersare installedin the

correct Dositions.

9. Rotatethe caliperpistonclockwiseinto placein the

cylinder,then alignthe cutout in the pistonwith the
tab on the inner pad by turningthe piston back.
CAUTION: Lubricats the boot with silicone groaso
to avoid twisting the piston boot. lf piston boot is
twisted, back it out so it sits proporly,
1O. Installthe caliperon the caliperbracketand tighten
the calipermountingbolts.

BRACKET

8.

Install the brake pads and pad shims on caliDer

bracket.

a Whon rousing tho pads, always reinstall the

blake pads in their original poaitions to prevent
loss ot braking sfficioncy.
a Contaminated brako discs or pads reduco stopping abillty. Kop greaseoft tho disca and pads.

CALIPERMOUNTING
BOLTS
23 .m (2.3 kg-m,
t 7 lb-ft1

PISTONBOOT

11. Installthe calipershield.

=^"
#.!!!4t!x

NOTE:
a Apply Molykote@ M77 to the pad side of the
shims. Wipe excessgreaseoff the shims.
a Install the inne. pad with its war indicator facing upwa.d.

12. Depressthe brakepedalseveraltimes to make sure

the b.akeswork, then road-tesr.

REARBRAKEPADS

NOTE; Engagementof the brake may require a

grater pedal stroke immediatelyatter the brake
pads have been replacedas a set. Seve.alapplications ot the brake pedal will restore the normal
pedal stroke.

19-19

RearBrakeDisc
Thicknessand Parallelism
Inspection

Runout Inspection
Loosenthe rear wheel lug nuts slightly,then raise
the car and supporton safety stands.
Removethe rear wheels.

1.

Removethe brake pads (seepage 19-18).

2 . Removethe brake pads (see page 19-181.

Using a micrometeJ.measure disc thickness at

eight points, approximately45o apart 8nd 1O mm
(0.4 in) in from the outer edge of the disc.

InsDectthe disc surlace tor grooves,cracks, and

rust, Cleanthe disc thoroughlyand removeall rust.
4.

Loosenthe rear wheel lug nuts slightly,then raise

the car and supporton safety stands.
Removethe rear wheels.

Use lug nuts and suitableplainwashersto hold the

disc securelyagainstthe hub. then mount a dial indicatoras shown and measurethe runoutat 1Omm
(O.4 inl from the outer edge of the disc.
Brake Disc Runout:
Selvics Limit: 0.1O mm (0.O04in)
lf the disc is beyondthe servicelimit, refinishthe
rotor,
Max. RslinishingLimit: 8.O mm lO'32 in)

Blake Disc Thickness:

Standard:1O.Omm (O.39in)
O.O15mm (O.O006inl max.
BrakeDisc Parallelism:

WHEELNUT
1 1 ON ' m
tl1 kg-m'80 lb-ft|
NOTE: A new disc should be refinished if its
runout is greatetthan O.1Omm (O OO4in).

19-20

NOTE: This is the maximum allowablediJference

between any thicknessmeasurements.
4.

It the disc is bevondthe servicelimit tor parallelism,

.efinishthe totor.
Max. Refinishing Limit: LO mm {0.32 in)

ren

RearCaliper
Disassembly
a Never use an air hose or dly brush to clean brake
assemblies.
a Use an OsHA-apprgved vacuum clganer to avoid
bleathingbrake dust.

5 . Removethe pad springfrom the caliperbody.

6.

CAUTION:
a Do not spill brake fluid on the car; it may damago th
paint; it brake fluid does contact the paint, wash it
off immediately with water.
a To prevent spills, cover the hose ioints with rags or
shoo towels.
a Clean all parts in brake tluid and air dry; blow out all
passages with complessed air.
1.

R e m o v et h e c a l i p e sr h i e l d( s e ep a g e1 9 - 1 8 ) .

2.

R e m o v et h e l o c k p i n a n d c l e v i sp i n .
Removethe cable clip and disconnectthe parking
brake cable trom the arm.

Remove the piston by rotating the piston

counterclockwisewith the specialtool and remove
the Distonboot.
CAUTION: Avoid damaging the piston.
PISTONBOOT

LOCK PIN

WRENCH
LOCKNUT
07916-6390001

7.

Removethe piston seal.

CAUTION: Take cars not to damage th6 cylinde.
bole.

3.

Removethe banjo bolt and two sealingwashers.

4.

Removethe two calipermountingbolts and caliper

body from the bracket.

MOUNTING
EOLT
CALIPER

Replace.

SEALING
WASHERS
Replace.

(cont'd)

19-21

RearCaliper
Disassembly(cont'd)
8. Install the specialtool between the calipet body
and spflng cover.

1 1. Lower the locknutslully and tighten the locknuts

securely.

CAUTION: Be careful not to damag th inside of

tho calipor cylinder du ng calipGrdisa$mbly.

NOTE: Keepthe locknutsin this positionuntil you

reinstallthe citcliD.

9. Positionthe locknutsas shown, then turn the shaft

until the plate just contactsthe caliperbody,
NOTE: Do not compress the spring under the
spring cover.

LOCKNUTS
PLATE

BRAKESPRING
COMPRESSOR
oTHAE-SGOOIOO

12. Removethe circlipwith snap ring pliers.

SNAP RING
PLIERS

07914-SAs(Xxro
1O. Turn the shaft clockwise 1/4-112 turn to compressthe adiustingspring B in the caliperbody.
CAUTION: To plsvnt damags to ths innr compononts, do not turn thg shaft more than 1/2 tutn.

19-22

13. Hold the plate with your fingersand turn the shatt
counterclockwise.Remove the sDecialtool from
the caliper.

1 6 . Removethe sleevepiston,and removethe pin from

the cam.

SLEEVE
PISTON
17. Removethe return spring.
18. Removethe parkingleverand cam as an assembly
from the caliperbody.
1 4 . Removethe adjustingbolt.
Remove the spring cover, adjusting spring B,
spacer,bearingA and cup trom the adjustingbolt.

CAUTION: Do not loosn the parking nut with tho

cam installod in tho calipar body. It the lever and
shaft must b6 sopa.ated, hold the levsr in a viso
and looson tho parking nut.
19. Removethe cam boot.
RETURN
SPRIlTG
PARKINGLEVER/
CAM ASSEMBLY
PARKI G NUT

19-23

RearCaliper
Reassembly
CAUTION:
a Do not spillbrakotluidonthe car; it may damagothe
paint; if blake fluid does contact the paint, wash it
oft immsdiatoly with water.
a Botore reassembling,check thst all pa.ts aro floa ol
dust and othr forsign panicles.
a Roplaceparts with new ones whenve. spcifisd to
do ao.
a Make sure no din or other forign matter is allowed
to contaminato the brak tluid.
a Oo not mix different brands of brske fluid as thoy
may not be compatibl.
a Do not reuse th drained tluid, Uso only cloan DOT 3
or 4 brakefluid.
'I .

Pack all cavitiesof the needle bearingwith commerciallyavailableassemblylube.

2.

Coat the new cam boot with commercially

availableassemblylube and installit in the caliper

Z^"
#jlqqil

: Commarcially.vailabl
..'embtv tube

RETURN

DOOy.

3.

Apply commerciallyavailableassemblylube to the

pin contactingarea of the cam and installthe cam
and lever assemblyinto the caliperbody.

4.

Installthe return spring.

CAUTION:
a When the cam and leve? wa.e separatgd, bo
sure to assemblothsm betoro installing the cam
in th caliper body. Install tho lvsr and 3p ng
washer, apply locking agnt to ths threads, and
tighten the parking nut whib holding lhe lovor
with a viso.
a Avoid damaging the cam boot since it must be
installed botore the cam.
a When installing the cam, do not allow the cam
boot liDs to tu]n outsid in.

lnstsllthe pin in the cam.

Installa new O-ringon the sleevepiston.
lnstallthe sleeveDistonso the holein the bottom of
the piston is alignedwith the pin in the cam, and
two pins on the pistonare alignedwith the holesin
the caliDer.

HOLES

SLEEVnSTOf{

19-24

8. Cost a new cup with brake cylindergrease (P/N:

08733-BO2OE) or equivalentrubber grease,and
instaltit with its groovefacingthe bearingA sideof
the adiusting bolt.
9. Fit the bearingA, spacer, adjustingspring B and
springcover on the adjustingbolt. and installthem
in the calipercylinder.

11. Check that the tlared end of the spring cover is

below the circlipgroove.
12. Installthe circlip in the groove, then remove the
specialtool.
NOTE: Check that the circlip is seated in the
groove properly.
SI{AP RING
PLIERS

SPRING
COVER

@-S";X""'Y"
@+SPACER
+__EEARINGA

l<ro'lusrnc

/15

\=z

{=="r"
=^^

r:4i!!l!!,il

'lo. Installthe specialtool on the springcover and tu.n

the shaft until the locknut contactsthe olate.

13. Coat a new pistonseal with siliconegreaseand install it in the caliper.

14. Apply brakecylindergrease(P/N:08733-BO2OE)
or equivalentrubber greaseto the sealinglips and
inside of a new piston boot, and install it in the
calioer.
PISTONSEAL

-Gr

PISTONBOOT
tzt=-1"=-- "

.4-$q!!n
RUBBER
GREASE (cont,d)

19-25

RearCaliper
Reassembly(cont'd)
15. Coat the outsideof the Distonwith brakefluid and
install it on the adjusting bolt while rotating it
clockwisewith the sDecialtool
CAUTION: Avoid damaging the piston and piston
boot.

19. Installthe caliperon the caliperbracketand tighten

the calipermountingbolts.
20. Connect the brake hose to the caliper with new
sealingwashersand tighten the banjo bolt.

CALIPERMOUNTINGBOLTS
23 .m (2.3 kg-m, l7 lb-ft)
CALIPERBRACKET

BAI{JO
BOLT
35 N.m 13.5kg-m.
25 rb-ft|

EXTENSION
8AR
Commercially
available

16. Installthe pad spring on the caliper.

CALIPER

21. Insen the parkingbrakecablethroughthe arm and

connect the parkingbrake cable to the lever with
the clevis pin and lock pin.
Installthe cable clip securely.

PAD SPRING
LOCK PIN

PARKINGBRAKE

CABLECLIP

17. Installthe brake pad retainersand brake pads.

22. Fill the brake reservoir up and bleed the brake

s y s t e m( s e ep a g e1 9 - 1 2 ) .

18. Align the cutout in the pistonwith the tab on the tnn e r p a d { s e ep a g e 1 9 - 1 9 ) .

23, Operatethe brakepedalseveraltimes, then adiust

the parkingbrake (seepage 19-51.

19-26

BrakeHoses/Pipes
Inspection
1.

Inspectthe brake hosesfor damage,leaks,interferenceor twisting.

2.

Chckthe brakelines tor damage,tipping, rustingor leakage.Also check ior bent brakelines.

3.

Check fo. leaksat hose and line joints or connections.and retightenif necessary.
CAUTION: Roplacotho brako hose clip whonever the blake hos6 is servicod.

BBAKE LINE.TO.ARAKEHOSE
15 N.m {1.5 lg-m, 1l lFftl

BRAKELII{E.TO.BBAKE
HOSE
15 N.m 11.5kg-m,11 lb-ftl
LINE
MASTER CYLIT{DER-TO.BRAKE
19 .m {1.9 ks-m. 14 lb-ft)

BLEEDSCREW
9 N.m (0.9kg-m,6.5lb-ftl
BRAKEHOSE.TO.CALIPER
IBANJOBOLTI
35 .m {3.5 kg-m.25 lb-ft|

BLEEDSCREW
9 N.m lO.9 kg-m,6.5 lb-ftl
BRAKEHOSE.TO.CALIPER
IBANJO BOLT)
35 N.m {3.5 kg-m,25 lb-ft}

19-27

BrakeHoses/Pipes
Brake Hose Replacement
cAuTro :
a Bofo.. reassembling,chck that all parts are free ol
dust and othel toraign particles.
Roplaceparts with new ones whenevl spocitiod to
do so.
a Uss only clan DOT 3 oi DOT 4 braks fluid.
a Mako suro no dirt or otho. toroign mattar is allowod
to contaminate th blake tluid.
a Do not mix diffrnt brands of brako fluid 8s thoy
may not be compatibl.
a Do not spill brake fluid on the car; it may damagethe
paint; it brake tluid doos contact the paint, wash it
oft immediately with wator.
1.

2.

Replacethe brake hose if the hose is twisted,

crackedor if it leaks.
Disconnectthe brakehose from the brakeoioe using a 1O mm flare nut wrench.

BNAKEHOSE CLIP
Roplace.
BRAK HOSE MOUNTING
SOLT
(8 x 16 mml
22 N.m 12.2 kg-m,
16 tb-frl

BRAKEHOSE
MOUNTING BOLT
1 8x 2 0 m m ) l

22 N.m 12.2
16 lb-fr)

BRAKE P'PE
BANJO BOLT
1 0 x 1 . Om m
35 N.m
13,5kg-m, 25 lb-tt)

6.

HOSE
MOUNTINGBOLT
10 N.m (1.0kg-m,
7 tb-ftl

Installa new brakehose with the brakehoseclamo

bolts.

7 . Connectthe brakehoseto the caliperwith the banjo bolt and new sealingwashers.
8.

Installa new brake hose clip on the brakehose.

9 . Connectthe b.ake hose to the brakepipe.

Removeand discardthe brake hose clip from the

brake hose.
4.

Removethe banjo bolt and disconnectthe brake

hose from the caliper.
Removethe brakehose clamp bolts and the brake
hose.

BRAKEHOSECLIP

1 0 .After installingthe brake hose, bleed the brake

system (see page 19-121,check the hose and line
joints for leaks.and tighten if necessary.

19-28

ParkingBrake
Disassembly
and Reassembly
CAUTION: Tho parking brak cables must not be bont or distorted. This will load to stift operation and prematurr cablo
tailure,

PARKINGBRAKECABLES
Check for laulty movomont.

"

ds
/
/
/

CLEVISPIN

\
\
\

LOCK PIN
Replace.

EOUALIZER
(Sliding
surface)

Disconnectthe pa,king brake cable from the lever on

the caliperby removingthe lock pin and clevispin, and
removethe cable from the arm by removingthe clip.

cLEVtSnN

19-29

Anti-lockBrakeSystem(ABSI
.......... 19-32
SpecialTools
. .-. 3 3
l l l u s t l a t oIdn d e x . . . . . . . . . . . . . . . . . . . . . . . .1. 9
(ABSI
Anti-lock Brake System
Featules/Construction/
........ 19-34
Operation
....... 19-46
CircuitDiagram
Wiring/ConnoctolLocations ............ 19-5O
ALB Checker
...... 19-51
FunctionTest
Wheel Sensor Signal
... 19-53
Gonfirmation
Troubleshooting
Anti-lock Brake System (ABSI
.. 19-54
IndicatorLight
Symptom-to-SystemChart .......... 19-56
......... 19-57
Flowcharts
Hydraulic System
Index HydraulicConnections........ 19-80
Relieving Accumulator/
... 19-81
LinePressure

Modulator Unit
.... 19-8.2
...............
Removal/lnstallation
19-83
.......
lndex/Torque
Solenoids
............19-84
LeakTost
Pump
PressureSwitch Replacement...... 19-84
Accumulator
..............19-85
Disposal
. . . . . . . . . . . . . . .1. .9 - 8 6
Bleeding
Electronic Components
ABS ControlUnit Replacemont..... 19-87
... 19-87
RelayInspection
Puleers/WheelSensors
...........19-88
Inspection
..........19-89
WheelSensorReplacement

Sp e ci a l To ols

Ref. No.

Tool Numbel

Description

OTHAA-SGOO101
or
oTHAA SG00r O0
O T H A J - S G O OOl A o r
OTHAJ_SGOOlOB
oTHAJ-SGOO200

,a\

Oty

BleederT-wrench

19 - 5 7 . 1 9 - 6 4 ,
't9-81.19-86

ALB Checker

1q_ql

r 9-86
ALB Checker(Canada)

ffi?n

tr
+{

-Ti-l
E

ll

II

tl
u
U
o

I
19-32
"

Page Reference

i.?,,

1q_A?

lllustratedIndex
The accumlator contains high-pressure nitrogon gas, do not puncture, expose to tlame or altempt to
@
the
accumlator or it may explode; severe personal injury may.osuh.
disassernble

HYDRAULICSYSTEM
RelievingAccumulator/Line
Pressure,page | 9-81
Bleeding,page 19-86

BRAKEHOSES/PIPES
fnspection, page 19-27
BrakeHose Replacement,
page 19-28

REARWHEEL SENSOR
Inspection,page 19-88
page 19-89
Replacement,

MODULATORUNIT
HydraulicConnection,page 19-80
page 19-82
Removal/lnstallalion,
page 19-83
Index/Torque,
Accumulator,page 19-85

ABS CONTROLUNIT
page 19-87
Replacement,

FRONTERAKES
page 19-6
Torque/lnspection,
Front BrakePads,page 19-7
Front Caliper,page 19-9
Fronl BrakeDisc,page 19_11

MASTERCYLINDERAND BRAKEBOOSTER
HydraulicConneclion,page 19_8O
MasterCylinder,page 19 14
BrakeBooster,page 19 15

PARKINGBBAKE
Adjustment,page 19-5
Disassemblyand
page 19-29
Roassembly,

REARDISC
page 19-17
Torque/lnspection,
RearBrakePads,page 19-18
RearBrakeDisc, page 19-20
RearCaliper,page 19-2't
WHEELSENSOR
Inspeclion,page 19-88
paqe 19-89
Replacement,

19-33

Anti-lockBrakeSystem (ABSI
Features/Construction/Operation
In a conventionalbrakesystem, iJ the brakepedalis depressedvery hard,the wheelscan lock beforethe vehiclecomes
to a stop. In such a case,the stabilityof the vehicleis reducedif the rearwheelsare locked,and maneuverability
of the
vehicleis reducedif the front wheels are locked,creatingan ext.emelyunstablecondition.
The Anti-lock BrakeSystem (ABS)modulatesthe pressureof the braketluid appliedto each front caliperor both rear
caliperstherebypreventingthe lockingof the wheels,wheneverthe wheelsare likelyto be lockeddue to hardbfaking.lt
then restoresnormalhydraulicpressurewhen there is no longerany possibilityof wheel locking.

F6atures
a
a
a
a

Increasedbrakingstabilitycan be achievedregardlessof changingd.ivingconditions.

The maneuverabilityot the vehicleis improvedas the system preventsthe front wheels from locking.
When the anti-lockb.ake system goes into action, a kickbackis felt on the brakepedal.
The system is equippedwith a self-diagnosis
function.When an abnormalityis detected.the ABS indicatorlight
comeson. The locationoi the system'stroublecan be diagnosedfrom the frequencyof the systemindicatorlight
blinks.
This sYstemhas individualcontrolot the lront wheels and commoncontrol ("Select Low") lor the rear wheels.
"Select Low"
means that the rear wheel that would lock first (the one with the lowest resistanceto lock-uo)
determinesanti-lockbrake system activationtor both rear wheels.
The system has a fail-safefunction that allows normal braking if there's a problemwith the anti-lockbrake
svstem.

Construction
In additionto the conventionalb.aking system, the anti-lockbrake system consistsof: gear pulsersattachedto the
rotating part of individualwheels; wheel sensors,which generatepulsesignalscorresponding
to the revolutionof the
gear pulsers;ABS controlunit, which controlsthe workingof the anti-lockbrakesystemby performingcalculationsbased on the signalsfrom the individualwheel sensorsand the individualswitches; modulatorunit, which adjuststhe
hydtaulicpressureappliedto each caliperon the basisot the signalsreceivedfrom the ABS controlunit; an accumulator,
in which high-pressurebrake lluid is stored, a pressureswitch, which detects the pressurein the accumulatorand
transmits signalsto the ABS control unit; a power unit, which suppliesthe high-pressureworking fluid to the accumulatorby meansof a pump; a motor relayIor drivingthe power unit; {ail-saierelays.which cut off the solenoidvalve
ground circuit when the fail-safedevice is at work; and, an ABS indicatorlight.
ABSCONTROL

MASTER CYLINDER
WHEEL SENSOR

PULSER SENSOR

19-34

Master Cylinder
1. Construction
A tandemmastercylinderis usedto improveth safety of the brakingsystem.In addition,centervalvesara usodso
as to match the anti-lockbrakesvstem oDeration.
The mastercylinderhas one reservoirtank which is connectedto the cylindersectionsby two smallholes.lt hastwo
pistons:primaryand secondary,which are crisscrossconnectedwith the cslipersso that the fluid pressureworks
separatelyon each system (front right wheel & rear left wheel, and front left wheel & resr right wheell.
A stop bolt for controllingmovementof the primarypistonis providedat the sideof the mastercylindetbody. A rd
switch for detectingthe braketluid volume is also providedin the cap of the reservoi,tank.
2.

Ooeration
When the brakepedalis depressed,the secondarypistonis pushedthroughthe brakeboosterand the contervalveB
is closedso that fluid pressureis generatedon the secondaryside.At the sametime, the p,imarypistonis push6dby
the sscondaryfluid pressureand the centervalveA is closedso that brakingfluid pressureis generatedboth on th
primaryand secondarysides.
When the brake pedal is released,the primaryand secondarypistonsare returnedto the originalpositionby the
brakefluid pressureand piston spring.

CENTERVALVEB

(cont'dl

19-35

Anti-lockBrakeSystem (ABSI
(cont'd)
Features/Construction/Operation
3.

Responseswhen fluid is leaking

(1) In case of leakingtrom the primarysysteml
Sincethe fluid pressureon the primaryside does not rise,the primarypiston is pushedby the fluid pressureof
the secondarypiston and the tensionof the pistonspringuntil the end hits on the cylinder.The brakingis performed bv the fluid oressureon the secondarvside.

FRONT-LEFT

t 2 l In case of leakingfrom the secondarysystem:

The secondarypiston does not producefluid pressure,keeps moving ahead,hits on the end surlace of the
primarypistonso that the primarypiston is pushedunderthe sameconditionas an ordinaryrod. Theretore,the
brakingis conductedby the fluid pressureon the primaryside.

1 9 -3 6

Wheel Sensor
The wheel sensoris a contactlesstype that detectsthe rotatingspeedof a wheel.lt is comprisedof a permanentmagnet
and coil. When the gear pulsersattached to the rotating parts of each wheel (front wheel: outboard toint of the
driveshaft,rear: hub bearingunit) turn, the magneticllux aroundthe coil in the wheel sensoralternates.generaling
voltageswith frequencyin proportionto wheel rotatingspeed.Thesepulsesare sentto the ABS controlunit and the ABS
control unit identifiesthe wheel speeds.
PERMANENT
MAGNET

\lrrral

/ JJ"-'-c-- ou*ur
, f t
GEAR PULSER
at HIGHSPEED
"-',

at LOW SPEED

VOLTAGE

ABS ControlUnit
The ABS controlunit consistsof a main functionsection,which controlsthe operationof the anti-lockbrakesystem,and
"self-diagnosis"
subfunction,which controlsthe pump motor and
'1. Main Function
The main lunction sectionof the ABS controlunit performscalculationson the basisof the signalslrom each wheel
sensor and controlsthe operationof the anti-lockbrake system by putting into action the solenoidvalves in the
modulatorunit for each front brakeand lor the two rear brakes.
2. Sub-tunction
"selt-diagnosis"signals,necessary
The sub-functionsectiongivesdrivingsignalsto the pump motor and alsogives
for backingup the anti-lockbrakesystem.

soLEf{orD

ABS CONTROLUNIT

VALVES
WHEEL
SENSORS

MAIN FUNCTION

SWITCH
PRESSURE
PUMPMOTOR
PARKINGBRAKE

SUB-FUNCTION
. FAIL-SAFE
. PUMPMOTORCONTROL
. SELF-DIAGNOSIS

swtrcH

MAIN FUNCTION

SUB.FUNCTION
. FAIL-SAFE
. PUMP MOTOR CONTROL
. SELF.DIAGNOSIS

19-37

Anti-lock BrakeSystem (ABS)

(cont'dl
Features/Construction/Operation
1.

Sell-diagnosticFunction
Sincethe anti-lockbrakesystem modulatesthe brakingpressurewhen a wheel is about to lock, .egardlessol the
driver's intention,the system operationand the braking power will be impairediJ thsre is a malfunctionin th
function,p.ovidedin the
system. To preventthis possibility,at speedsabove 6 mph (1O km/h). the selt-diagnosis
sub-tunctionof the ABS control unit. monitorsthe main system functions.When an abnormalityis detected,tho
systemitself;when the ignitionswitch
ABS indicatorlight goes on. Thereis alsoa check modeof the self-diagnosis
is tirst turned on, the ABS indicatorlight comeson and stays on for a Jew secondssfter the enginestarts,to signify
system is functional.
that the self-diagnosis

2.

Fail-safeFunction
the solenoidoperationsare suspendedby
When abnormalityis detectedin the controlsystem by the self-diagnosis,
turningoft the relaysItail-saterelays)which disconnectthe groundlinesof all the solenoidvalvesto inhibitanti-lock
brakesvstem operations,Underthese conditions,the brakingsystemfunctionsjust as an ordinaryone, msintaining
the necessarybrakingfunction. When the ABS indicatorlight is turned on, it meansthe tail-safeis Junctioning.

ModulatorUnit
Modulatorsfor each wheel and solenoidvalvesare integratedin the modulatorunit.
The modulatorsfor front and rearbrakesare ot independentconstructionand are positionedverticallyfor improvedmainControlValve)in ordelto pretainability.The modulatorsfor rearbrakesare providedwith a PCVfunction(Proportioning
vent the rear wheel from locking when the anti-lock brake system is malfunctioning or the anti-lock brake system is not
actrvated.
The solenoidvalve featuresquick response(5 ms or less).
The inlet and outlet valves are integrated in the solenoid valve unit. There are three solenoid valves provided, on fol
each front wheel, and one for the rear wheels.

SoLENOtO

To Pump
Aas6mbly
F.om M..t

r Cylnd.r
Pl.tor

M..l.r CyLd.t
Prlrnary Plrto|r

From
Pump
Ar36mbly

19 -3 8

To Lcft-f.ont
Brakc Cdllpol
To Rlght-rea.
B]rk. Callpr

Accumulator
brakefluid fed from the pump incorporatedin the
The accumulatoris a pneumatictype which accumulateshigh-pressure
power unit. When the anti-lockbrakesystem operates,the accumulatorand the power unit supplyhigh-pressure
brake
Jluidto the modulatorvalve via the inlet side ot the solenoidvalve.

ACCUMULATOR

ALADDER

PressureSwitch
The pressureswitch monito,sthe pressureaccumulation(pressurelrom the pump)in the accumulatorand is turnedoff
when the pressurebecomeslower than a prescribedlevel.Whenthe pressureswitch is turnedoft, the switchingsignalis
sent to the ABS control unit. Upon receivingthe signal,the ABS controlunit activatesthe pump motor relayto operate
the motor. lf the pressuredoesn't reachthe prescribedvalue,the ABS indicatorlight comes on.
ODeration
When the pressurein the accumulatorrises,the Bourdontube in the pressureswitch deformsoutwards.When the
free end of the Bourdontube movesmore than the prescribedamount,the micro-switchis activatedby the force of
the spring attachedto the sensinglever. When the pressurein the accumulatordecreasesdue to anti-lockbrake
system operations.the Bourdontube moves in the directionopposileto the one describedabove, and the microswitch is eventuallyturned off. Upon receivingthis signal,the ABS controlunit activatesthe motor relayto operate
the motor.

SENSINGLEVER

(cont'd

19-39

Anti-lockBrakeSystem (ABS)
(cont'd)
Features/Construction/Operation
Power Unit
The power unit consistsof a motor, filter, guide, piston rod and cylinderbody. Sincea guide is positionedoftset to the
centerof the motor shalt, the rotationof the motor and cylinderbody providesthe reciprocating
motionto the piston,od,
The brakefluid is thus pressurizedand fed to the relief valve. accumulatorand modulator,
As the pressurein the accumulatorexceedsthe prescribedlevel,the pressureswitch is turnedon. Approx.O.5 sconds
after receivingthe ON-signal.the ABS control unit stops the motor relayoperation.In this state, the pressurein the accumulatorreaches23000 kPa (23Okg/cm' , 327O psi).
lf the pressuredoesn't reachthe prescribedvalueafter the motor has operatedcontinuouslytor a specitiedperiod,the
ABS control unit stoDsthe motor and activatesthe ABS indicatorliqht.

ACCUMULATOR

PRESSUBE

swlTcH

To Modulator

Roliot V.lvo

valv6 Rod
cylindor Eody
lRotationl

Pisron Rod
(ReciptocaringMotionl

Anti-lock BrakeSystem (ABSI IndicatorLight

This warningsystemturns on the ABS indicatorlight when one or moreof the belowdescribedabnormalities
is detected.
This is onlv a oartiallist.
a When the operatingtime of the motor in the power unil exceedsthe specitiedperiod.
a When vehiclerunningtime exceeds30 secondswithout releasingthe parkingbrakelever.
a When one of the rear wheels is lockedduring running,
a When absenceot speedsignalsfrom any of the tour wheel sensorsis detected.
a When the activationtime of all solenoidsexceedsa given time or an open or short circuit is detectedin the
solenoidsystem.
a When solenoidoutput is not detectedin the simulatedanti-lockbrakesystemoperationcarriedout duringrunning
at speedsof 6 mph (1O km/h) or more.
To checkthe ABS indicatorlight bulb.the light is activatedwhen the ignitionswitch is turnedon. lt is turnedoff after the
engrneis startedif there is no abnormalityin the system,

19-40

Operation
1.

OrdinaryBrakingFunction
In ordinsrybrakeoperations,the cut-off valvein the modulatoris open,transmittingthe hydraulicpressurefrom the
maste. cylinderto the brake calipersvia chamberA and chamberB.
ChamberC is connectedto the reservoirthroughthe outlet valve,which is normallyopen.lt is alsoconnectedto the
hydraulicpressuresource (pump,accumulator,pressureswitch, etc.)via the inlet valve.which is normallyclosed.
ChamberD servesas an air chamber.Underthese conditions,the pressuresol chambersC and D are maintainedat
about atmosphericpfessure,permittingregularbrakingoperations.

CHAMBERO
RESENVOIR

SLIOE
PISTON
CUT.OFF

CHAMBERB

VALVE

CHAMBERA
CALIPER

ACCUMULATOR
CHAMBERC

19-41

Anti-lockBrakeSystem (ABS)
(cont'd)
Features/Construction/Operation
It brake inputs (torceexened on brake pedal)are excessivelylargeand a possibilityof wheel lockingoccu,s, the ABS
control unit operatesthe solenoidvalve, closing the outlet valve and openjngthe inlet valve. As a result, the high
pressureis di.ectedinto chamberC, the piston is pushedupward,causingthe slidepistonto move upward and the cutoff valveto close.As the cut-oft valvecloses,the tlow from the mastercylinderto the calipetis interrupted,the volume
ol chamberB. which is connectedto the caliper,increases.and the fluid pressurein the caliperdeclines,
When both of the valves,inletand outlet, are closed(whenonly the outletvalveis activated)the pressurein the caliperis
maintainedconstant.
When the possibilityof wheel lockingceases,it is necessaryto restorethe pressurein the caliper.The solenoidvalve is
thereforeturned off (outletvalve: open, inlet valve: closed).

Process

InletValve

Outlet Valve

CaliperPressure

Electric
Power

Hydraulic
Circuit

Electric
Power

Hydraulic
Circuit

Caliperpressuredeclining

ON

Close

ON

Open

Caliperoressureconstant

ON

Close

OFF

Close

OFF

Open

OFF

Close

Caliperpressureincreasing

MASTER
CHAMBERD

RESERVOIR

CHAMBER8

CHAMBERA

CALIPER

ACCUMULATOR

19-42

CHAMBERC

2.

SlidePistonFunction
When the car is used on roughroadswhere the tires sometimesloseadhesion,the antilock brakesystemmay function excessively,causinga very largevolumeof brakefluid to flow into chamberC. When this occurs,the piston is
moved excessively,resultingin an abnormalloss of pressurein chamberB. In orderto overcomethis problem.the
slidepiston is kept in properpositionby springforce to preventthe pressurein chamberB from becomingnegative.

CHAMBERC

(cont'dl

19-43

Anti-lockBrakeSystem (ABSI
(cont'dl
Features/Gonstruction/Operation
3.

Kickback
When the anti-lockbrakesystem is functioning.the pistonmovesupward.the volumeof chamberB increases,and
the fluid pressureon the caliperside is reduced.At the sametime. the volumeof chamberA is reducedandthe brake
fluid is returnedto the mastercylinder.Whenthe braketluid is pushedbackto the mastercylinder,the drivercanfeel
the functioningof the anti-lockbrakesystem becausethe brakepedalis kickedback.

4.

ControlValve) Function
PCV {Proportioning
ln the modulatorfo. the rearwheels.the diametersof the pistonandthe slidepistonare distinctlydifterent.This proControlValve) function to preventthe rear wheelsfrom lockingduringan emergency
vides a PCV (Proportioning
stop.
{ 1 ) B e f o r et h e T u r n i n gP o i n t :
1)When the fluid pressurelrom the master cylinderis below the turning point. the cut off valve is always
pusheddownward by the force of the slidepiston and its spring,
Underthese conditjons,there is a gap betweenthe cut-off valve shoulderand the sleeve.ChamberA and
chamberB are theretoreconnectedthrough the gap. The pressurefrom the mastercylinderflows into the
rear calipersthrough chamberA and chamberB.

MASTER

CHAMBERC

19-4tr;

2) When the fluid pressuretrom the mastercylindefreachesthe turningpoint,the force on the slidepistonovercomes the torce ot the spring,causingthe slidepislon to travel upward.
The cut-ofI valve,previouslybeingin contactwith the bottom of the slidepiston,then movesupwardandthe
cut-otl valveshoulderhits the sleeve,blockingthe fluid passages(the fluid pressureat this point is calledthe
turning point).

E3
6E
Hi

CHAMBERC

(2) After the turning point:

As the lluid pressurefrom the mastercylinderincreases,the pressurein chamberA becomeshigher,causinga
the slide piston comesdown. the
force to push down the largediamelerportionot the piston. Consequently,
cut-off valve is pusheddownward by the bottom of the slide piston, allowingchambersA and B to connect
momentarily.As this occurs, pressurein chamberB increases,the slide piston is pushedupward, the cut-off
valve goes up. and the connectionbetweenchamberA and chamberB is blockedagain.As describedabove,
when the pressurein the mastercylinderis abovethe lurning point,the slidepistonreducesthe pressurein the
rear caliperto the prescribedamount by repeatingihis process.

1945

CircuitDiagram(2WSl

BATTERY

FUS
No. FUSE
TAEELNAME
ECU
't3
MElrR

RrcMIRROR

sumL-f

UNOR.HOOD
FUSENEIAY
8OX

UNDEfiOASH
FUSENELAY
8OX

A
GL*,,,n,.uf
UGHT
CHASGING
SYSIEM

tGs:w(50Al
88ATE
SYSIEM
UGHT

sTotHoRN
lr5A)

A \ I
.-.1U'-

II

UGI{T
A8SINDICATOR

88AIG
$,$fCH

YE$c+
A8Si,lOT0R
Al
150

YEUGRT{-ar-

A8SUr{rI05 A}
WHTETU

sLuau(*l

REOAVHT

PUMP
l r u I ABS
MOTON

GRN

BU(

8U(

+
G|03

19-46

-o-=
Gr0l
Gt02
GOl

ECM

,\o
,rrtrr lSERVICE
CHECK
CONNECTOR

IGR{NEO

,A
ttl-t,-l{,F_YEL+sLK-a

GRMED

ERAKE
FI.UID
EVrI

PREssuRE

srvrrin

3i3;

swtTcH

Gl01
t9 WASN
2

ABSINSPECTION

5 WARtir

WHIELj(

s0[rNolDs
FRONT.R

3 fl-ot T
RLW{+l
11 R.tN
6 ROW

12P CONNECTOR

18P CO[{NECTOR

30 29 28

21

21 2 0 1 9 1 8 1 7 1 6 1 5 1 4 1 3
ABS CONTROLUNIT COIINECTOR
View t.om terminal side.

't0

l1

,/

8
1

ABS CONTROLUNIT CONNECTOR

CASE
View trom terminalside.
GSOUND

1947

Circuit Diagram(4WS)
FUSE
No. FUSE
LABET
NAIVE
SAMRY

13

MFTEfi

R/CMIFROR

UNDER.HOOD
FUSENEIAY
BOX

UNDEROASH
FUSENEIAY
BOX

rGsw{50a)

STOP
HORN
{15A}

wHr-{
EvnED_f-

>_

ABSMOTOR
{50A}

r-

JJm
A8SUNIT{?.54)
WHI,ATU
I
8TD/WHT

sLu,sLX_reL

A8SPUMP
MOTOR
GRN

SLK

BtK

G103

19-48

J-=
G101
G102
GOI

BEAR
FAII--SAFE
RELAY

A8SCONTROT
' TC|V(SCS)
. ECMISCS)

ECM

x,a

4
glgl,rrgf-l

s8vtcE
cHEcK
CONNECTOR

IGRMEO

^A
nL*t,i[9-YEL+8LK-a

GRMTD

BRAK
FTUID
LEVEL

Tt::$E
swrlcH

swtTcH

.*

b*,

Gt0l
18WARN
2
ABSINSPECIION

-J

s0tEN0tDs
IRONT-R

R L W ( +1) 7
8RP 7
RLP 8

2OPCONNECTOR

34 33

30

28

2 6

25 24 2322 212 0 19 1 8 17

15

ABS CONTROLUNIT CONNECTOR

View from terminalside.

CASE
ABS CONTROLUNIT CONNECTOR
GROUND View from terminalside.

19-49

Wiring/ConnectorLocations

ABS 82 II5 A}

UNDER.HOOD
BOX
FUSE/RELAY

ABS UNIT
(7.5 A} FUSE

FUSE
ABS
MOTOR
RELAY

STOP/HORN
{'l 5 A}
FUSE

ABS 81 (20 A} FUSE

EATTERY
{1(x' A}
FUSE
ABS MOTOR
(50 A) FUSE

ABS COI{TROL

iTGHT.BEAB
WHEELSEI{SOR

rG sw {50 Al FUSE UNIT

U1{IT
MODULATOR

LEFT-REAR
WHEELSENSOR

RIGHT.FRONT
WHEELSENSOR

FAIL.SAFE
RELAYS

RIGHT.FRONT
WHEELSENSOR

WHEEL SENSOR
CONNECTOR

19-50
F.

LEFT-FROl{T
WHEELSENSOR

ALB Checker
FunctionTest
NOTE:
a The ALB checker is designed to confirm proper
operation of the anri-lockbrake system (ABS) by
simulatingeach system function and operatingcondition. Before using the checker, contirm that the
anti-lockbrakesystem (ABS)indicatorlight is not indicating some other problemwith the system. The
light shouldgo on when the ignitionis first turnedon
and then go off and stay off one second after the
engineis started.
a The checkershouldbe used through modes 1-5 to
confirm properoperationof the system in anv one of
the following situations:
- After replacingany ABS component.
- After replacingor bleedingthe system fluid {0
mode not necessaavl.
- After any body or suspensionrepair that may
have affectedthe sensorsor their wiring.
a The procedure{or modes 1-5 are on this page and
19-52, mode "O" {wheel sensorsignal)is on page
19 - 5 3 .

NOTE; Placethe vehicleon level ground with the

wheels blocked,out the transmissionin neutraltor
manualtransmissionmodels,and in @ positionfor
automatictransmissionmodels.
Stan the engineand releasethe parkingbrake,
5.

Operatethe ALB checkeras follows:

( l ) T u r n t h e M o d e S e l e c t o sr w i t c ht o " 1 " .
(2)Pushthe Start Test switch:
- The test in progresslight shouldcome ON.
- In one or two more seconds, all four monitor
lights should come on (lf not the checker is
faultv).
- The ABS indicatorlight shouldnot come ON.
NOTE: When the test in progressindicatorlight is
ON, don't turn the Mode Selectorswitch.

Disconnoct the ALB checker belore driv@

ing the car, A collision can rosult tlom a roduction, or
completo loss, of braking ability csusing aevo.o personal injury or doath.

Monlror Lights

4W ALB CHECKER
1.

With the ignitionswitch off , disconnectthe ABS inspectionconnector(6P) from the connectorcover
located on the cross-member under the passenger's seat and connect the ABS inspection
connector(6P) to the ALB checker.

Taal ln prog.art

)
o

Porval Ol{

4.

Start Tcat

Modo Slscro.

Turn the Mode SelectorSwitch ro "2"

A
oTHAJ-SGOO108
See poge 19-32 for othe. applicablecheckers.

{cont'd)

19-51

ALB Checker
FunctionTest (cont'd)
Depress the brake pedal firmly and push the Start
Test switch.
The ABS indicatorlight shouldnot go on while the
Test in P.ogress light is ON. There should be
kickbackon the brakePedal.

Inspection points:
'1. The ABS indicatotlight comes ON.
a Check the DiagnosticTrouble Code and go to
the troubleshooting,se8 page 19-55.
2.

NOTE: The operation sequence simulated by

Modes 2. 3, 4 and 5:

Aboul 30 racond3

6.

"3", "4" and

Turn the Mode Selectorswitch to
"5" .
Perform step 5 for each oJ the test mode positions.

Mode 1 :
S8ndsthe simulateddrivingsignalO mph (O km/h)
* 1 1 3 m p h ( 1 8 0 k m / h l - 0 m p h { Ok m / h )o f e a c h
wheel to the ABS control unit. Thereshouldbe NO
kickback.
Mode 2:
Sendsthe drivingsignalot each wheel, then sends
the lock signal of the left .ear wheel to the ABS
control unit. There should be kickback.
Mode 3:
Sndsthe drivingsignalof each wheel, then sends
the lock signal of the right rear wheel to the ABS
control unit. There should be kickback.
Mode 4:
Sendsthe drivingsignalof each wheel, then sends
the lock signal of the left front wheel to the ABS
control unit. There shouldbe kickback.
Mode 5:
Sendsthe drivingsignaloJ each wheel. then sends
the lock signalot the right ftont wheel to the ABS
control unit. There shouldbe kickback.
Mode 6:
Not used on this model.

The.e is no or liftle kickbackin modes 2 through 5

and the ABS indicatorlight does not come ON'
a Air in the high Pressu.eline
a Restricted high Pressureline.
a Faultvmodulatorunat.

WheelSensorSignalConfirmation
"O") to contirm
NOTE: Use the ALB checker (mode
properwheel sensoroperation.
1.

Disconnect the ABS inspection connector {6P)

from the connector cover located on the crossmember under the passenger'sseat and connect
the ABS insDectionconnector (6P) to the ALB
checker.

Monitor Lig}lt3

4W ALB CHECKER

Toat In Prog6ss

Powot ON

Start Te3t

Modo Scbctot

5 . With the transmissionin neutral.rotate

rota each wheel
briskly (one revolutionper secondl
ndl by hand, and
conJirm that its respectivemonitor
ritor light on the
checkerblinks as the wheel rotates.

07HAJ-SGOo10B
checkers.
Seepage19 32 for otherapplicable

NOTE:
a Rotatinga wheel too slowly will
p
ill produce
only a
weak blink of its monitor light that
thl may be difJicultto see.
a In bright sunlight.the monitor light
ligl may be difJicultto see. Performtests in ar shaded
st
area.
a In some instances,it may not be
p(
e possible
to spin
ge a monitorinthe tront wheelsfast enoughtoI get
dication.It necessary,stan the engine
en{
and slowly accelerate and decele.ate the
he front wheels.
The monitor lights should blink,
ink, indicating a
good wheel sensorsignal.
lf any monitor light fails to blink,
blin check the
susPected sensor, its air gap and its
wiring/connectors.

Raisethe car so that all lour wheels are ott the

ground and supporton safety stands.
Turn the ignitionswitch ON.
"O".
Turn the Mode Selectorswitch to

19-53

Troubleshooting
Anti-lock BrakeSystem (ABS) IndicatorLight
Tomporary Driving Conditions:
1. The ABS indicatorlight comeson and the ABS control unit memorizesthe diagnostictrouble code
(DTC)under certainconditions.
NOTE: The DTCSare explainedon page 19-56.

ABS Indicatol Light Circuir:

CAUTION: Us6 only the digital multimetr to chsck th.
syst6m.
1 . The ABS indicato.light does not go on when the ig-

nition switch is turned on.

a The tire(s)adhesionis lost due to excesslvecorneringspeed.
DTC: 5, 5-4, 5-8.
o The vehiclelosestraction when startingftom a
stuck condition on a muddy, snowY, or sandy
road.
DTC: 4-1 . 4-2, 4-4, 4-4.
a When the patkingbrakeis appliedfor mofe than
30 secondswhile the vehicleis being driven.
D T C :2 - 1 .
a The vehicle is driven on an extremely rough
road.
The ABS js OK. it the ABS indicatorlight goes off
atter the engineis testarted.

Check the following items. lf they are OK, check

the ABS control unit connectors.lf not loose or
disconnected,substitutea known-goodABS control unit and recheck:
. Blown ABS indicatorlight bulb.
a Open circuit in YEL wire between the No. 13
METER('lO A) fuse in the under-dashfuse/relay
box and gaugeassembly.
a Open circuit in BLU/REDwire between the
gauge assemblyand ABS cont.ol unit,
a Poot ground connection between the ABS control unit and the body.
The ABS indicatorlight remainsON after the engine
is started.howeverthe ABS indicatorlight does not
blink any DTC. Check the following items:

ABS INDICATORLIGHT

lf you receivea customer'sreportthat the ABS indicator light sometimes comes on, check the
system using the ALB checkerto contirm whether
there is any trouble in the system.
S e e p a g e1 9 - 5 1 .
The ABS indicatorlight will come on and the ABS
control unit will memorizea DTC when there is insulficient battery voltageto the ABS control unit.
An examplewould be when the batteryis so weak
that the car must be iump-started Aftet the battery
is sufficiently recharged,the ABS indicator light
will work normallyafter the engineis stoppedand
restarted.
However, after rechargingthe battety, the DTC
must be cleared from the ABS control unit's
memory by disconnectingthe ABS 82 {15 A) luse
in the under-hoodfuse/relaybox ior at least three
seconds.

1 9 -5 4

a Looseor poor connectionof the wire harnessat

the ABS control unit.
. Faulty ABS 82 (15 Al Juse in the under-hood
fuse/relaybox.
a Open circuit in WHT wire betweenthe ABS 82
(15 A) fuse in the undet-hoodfuse/telaybox and
ABS control unit.
a ODencircuitin BLK/YELwire betweenthe No. 9
R/C MIRROR (15 A) fuse in the under-dash
fuse/relaybox and ABS control unit.
a Short circuit in BLU/REDwire between gauge
assemblyand ABS control unil
a ODen circuit in WHT/BLU wire between alternator and ABS control unit.
lf the Droblemis not found, substitute a knowngood ABS control unit and techeck whether the
ABS indicatorlight remainsON.

Oiagnostic Troubl Cod {DTCI:

1. Disconnectthe servicecheck connectorfrom the connectorcover locatedbehindthe tront of the centerconsole.
Connectthe two terminalsof the servicecheck connectorwith a jumper wire.
2. Turn the ignitionswitch on. but do not start the engine.
3, Recordthe blinkingfrequencyof the ABS indicatorlight.
The blinkingfrequencyindicatesthe diagnostictroublecode (DTC).
CAUTION: Bforo starting the engine, disconnact the lumper wire from tho sorvico ch6ck connoctor, o. els the
MalfunctionIndicatorLamp (MlL) will stay on with tho engine.unning.

DTC indication oatto.n

A8S
Indicator -,
light on

DTC.4-2
MainCode:4
Sub-Codo:2

Tum the lgnition

switch on
-.

DTC: 1
Main Cod6: 1
Sub-Cods: none

Dfc| 7 -2
Mlin Code:7
Sub-Cod!:2

ABS
lndicator
light oft
Conngct tho
iumpor wi.e

1
Second Socond
pauso p6u30
1 Socond

5 Socond
pau30

5 Sacond
pauro

Socond
paulo

NOTE:
a The ABS control unit can indicatethree DTCS(one,two or three problems).
a lf the ABS indicatorlight does not light, see Troubleshooting
of ABS IndicatorLight Circuitpage 19-54.
a lf you miscountthe blinkingtrequsncy,turn the ignitionswitch off then on to cyclethe ABS indicatorlight again.
a After the repairis completed.disconnsctthe ABS 82 {15 A) fuse in the under-hoodfuse/relaybox for at least
three secondsto erasethe ABS control unit's memory.Then turn the ignitionkey on agsin and recheck.
a The memoryis erasedit the connectoris disconnectedfrom the ABS controlunit or the ABS controlunit is removed from the bodv.
a AJter recordingthe DTC (if applicable),referto the Symptom-to-System
Chart.

SERVICECHECX
CONNECTOR
I2PI

DATA LINK CONNECTOR(3PI

NOTE: Do not attach
the jumperwire.

ABS INDICATORLIGHT

19-55

Troubleshooting
Symptom-to-SystemChart
DIAGNOSTIC
AFFECTED
TROUELECODE PROBLEMATIC
(DTC)
COMPONENT/
SYSTEM
FRONT FRONT REAR REAR
MAIN SUB.
RIGHT LEFT RIGHT LEFT
CODE CODE

{3}

OTHER
COMPONENT

PAGE

Solenoid

ABS pump motor

over-tun

1 9 - 5 7 ABS pump motor

ABS pump motot

circuit problem

19-59

Pressureswitch

.tt!

High pressure
leakage

1 9 - 6 2 Solenoid{s)

it)

Pressure
switch

19-63

Accumulator
I
| gas teakage

x,.

{i}

Pulser(sl

\9r

Wheel sensor

Wheel sensorls)

r:\

v..

{u

rt
!)

19-56

Solenoid related
problem

Wheel sensor
installation

19-65

o
19-67

o
o

Fail-salerelay

{1}

o
o

rD

19-88

J.;\

tqt
\:l

19-84

I
I BrakeJluidlevel
19-64
I
I switch,
I
I BrakesYstemlight

tu

o
o
o
o

19-87

19-64

Parkingbrake
switch-related
problem

/*\

{3}

ABS motor relay

ABS unit tuse
ABS motor fuse

\7

{t}
'.'-

PAGE

Modulator
Rear brake drag
19-87
(Function
Test)

19-69

o
o

19-75

ABS 81 fuse
Front Jail-saferelaY

19-78

Rear tail-safe relay

Flowcharts
Diagnostic Trouble Code (DTC) 1: ABS Pump Motol Over-run (2O seconds)
CAUTION: Uso only tho digitsl multimetor to chock tho systom'
Pro-lat st6p:
a Check tor tluid leaksfrom the tunctionalparts and teplacethe faulty pans it there is a leak'
Functional pans:
a Modulatorunit
a ABS Pump assembly
a High pressurehose/pipe
-

View lrom underhood lusekelav box

terminal side.

FmnffiffirflFTr;l
IUffilluffillE:l

With onglno running, ABS indicotor llght ls Oil.

\ tith Bewicchsck connocto.
iumpod lsoe pago 19-55),
DTC 1 b lndlcat6d.

Bleed high pressure fluid from

the maintenance bleeder with
the EleederT-wrench {see p6go
19-81).

Connect the No. 29 and 30 terminals using a jumpe. wire lor

about eighl seconds.

Doesthe ABS pump motor run

loud,
with an increasingly
raspy sound?

UNDER-HOOD
FUSE/BELAYBOX
Pump runr with a conatant 3oft
touno:
Blo.d sl. trom anil-lock b.ako
lyttam uling the procoduto on
p6go 19-86 and chock the pump
round again.

Check the accumulator fluid

quantity by bleeding the high
pressureline with the BleederT'
UNOER.HOODFUSE/RELAYBOX CIRCUITDIAGRAM

ls there40-70 cc?

(To page 19-59)

70 cc (UPPERuMlTl
40 cc {LOWERLlMlTl

(To page 19-58)

T-WRENCH
BLEEOER
oTHAA-SGOO101

{cont ct

19-57

Troubleshooting
Flowcharts (cont'dl
(Frompage 19-57)

{Frompage 19.571

Connectthe No. 29 and No. 30

terminalsusinga jumperwire for
about 1O seconds.

Check if there is any changein

the fluid level in the reservoir
tank.
ls there anV change?

Faulty ABS pump motor {Rell6t

velve i3 dofective and ooenl.
Replace tha ABS pump a$emblv.

F.uhy.olonoid (loak.g6l.
R6plac6lho modulator unit.

Connect the No. 29 and No. 30

terminalsusinga iumperwire for
about 1O seconds.

Disconnect the pressure switch

2P connectorand checkthe continuity betweenthe No. 1 (YEL)
and No. 2 {YEL)terminals.

TIE v.r|.ch b OK at thb timo.

19-5 8

Continuity?
View from terminalside.

DiagnosticTroubleCode (DTCI l-2: ABS Pump Motor CircuitProblem

CAUTION: Use only the digital multimeterto check the system.
NOTE: l{ a malfunctionis detected,this code appearsand the fail-safelunction is activated.The ABS indicatorlight
the ABS 82 (15 A) fuse in the under hood
comesON after restartingthe engineuntil the DTC is erased{by disconnecting
fuse/relaybox for three seconds).
Pre-test stgps:
a Check ABS MOTOR \5O A) iuse in the under-hood luselle\aY box
a Check ABS UNIT {7.5 A) fuse in the under hood {use/relaybox.
a Check for loose under-hoodfuse/relaybox connectors.
-

Wirh engine running, ABS indicator light is ON.

- With sruicecheck connector
iumped lsee Pago 19'551,
DTC 1-2 is indicated.

Checkthe ABS pumPmotor relaY

(seepage 'l9-87).

Does it work Proporly?

View from underhood luse/relaybox

terminalside.

Connectthe No. 29 and No. 30

terminals using a iumPer wlre.

Doesthe ABS oumpmotor run?

( T op a g e1 9 - 6 1 )

ffilffilffil
_ ll
l _?9lgl91l-l
l___q1_1_

Removerhe ABS UNIT (7.5 A)

Iuse in the underhoodfuse/relaY
box.

Turn the ignitionswitch ON.

(To page 19-60)

JUMPERWIRE

UNDER.HOODFUSE/RELAYBOX CIRCUITDIAGRAM

19-59

Troubleshooting
Flowcharts (cont'd
19-59t

Check tor voltage belween lhe

underhood fuse/relavbox ABS
UNIT fuse No. 31 terminal and
body groLrnd.

ls there battery vollage?

Repairopen in WHT/BLK wire between the ABS UNIT (7.5 Al luse

in ihe undr-hoodluse/rlaYbox
and ABS contaolunit.

Reinstallthe fuse in the under'

hood fuse/relaybox.

Disconnect the 2P connector

lrom the ABS pump molor-

Check for voltage between the

ABS pump molor relay No. 30
terminaland body ground.

UNDER-HOOD Batteryvoltago?
FUSE/RELAY
AOX
ls therebatteryvoltage?

Check for voltage between the

No. 32 termjnal and body
ground.

ls therebatteryvoltage?

Rpair opon in BI-K/YELwire betwsen the No. S R/C MIRROR

(15 Al fuso in the undeFdash
fusa/relav box and ABS PumP
motor alav.

'l8P
{4wS: 2OP)
Disconneclthe
connectorfrom the ABS control
unit.

l2WSl
18P CONNECTOR
2 5 2 4 23
30 29 2a 27 t!J
14 13
22 21 20 1 9 1 8 1 7 1 6

B.ttery

uon"n",
)r,-,r.o
Qf
I
IPMR}

View from ABS controlunit terminalside

Check {or voltage between the
ABS control unit connectorNo
ter
18 {4WS: No. 21 ) (YEL/RED)
minal and body ground.

20P CONNECTORl4WSl

32 3 1

34
24

ls there battery voltageT

YES

lul

30

2A 21

2 1 20 1 9 1 8 1'1

't5

Ropairopsn in YEL/REOwire be'

tween iho ABS pump motor relay
and ABS control unit.
Battery vorr"e"z$)

\tu"o

t'"t'

View from ABS conlrolunit terminalside

trcl rrir

19-60

dd

recheck

lFrompag619 59)

Cheek tor vollago bgtwoon the

No.29 terminal and body
ground.

HARt{ESS-SIDECONNECTOR
BLK (GROUNDI

WHT/BLU IMOTOR RELAYI

Disconnect the 2P connector

Irom the ABS pump motor.

Check for voltagg btween the

No, 1 (WHT/BLUItrminal and
body ground.

ls thro battry voltage?

Rogah opn in WHT/BLU wiro

bctwaan th6 ABS pump motor
rohy and ABS pump molor.
HARNESS-SIDECOI{NECTOR

Ch6ck for voltage betwen the

'l (WHT/BLU) terminal and
No.
No. 2l8LKl tsrminal.

BLK {GROUNDI

WHT/ALU IMOTOB

86ftery Voh.g?

View from terminalside.

ls there battery voltago?

Rpairopen in BLK wlro botwoon

tho AgS pump moto. and g.ound
or pool ground 1c403).

Fauhy ABS pump motor.

Roplac tho ABS pump a.tom'
blv.

191

Troubleshooting
Flowcharts (cont'd)
Diagnosric Troubl Code (DTC) 1-3: High Pr6$ur Leakag6
CAUTIOI{: Uso only th digital multimetor to check tho syEtam.
Pre-test steps:
a Check reservoirfluid level. and if necessa.y,fill to the MAX level line.
a Check for tluid leaksfrom the lunctionalparts and replacethe faulty parts if there is a leak.
Functional parts:
a Modulatorunit
a ABS Pump assembly
a High pressurehose/pipe
-

Whh 6ngino running, ABS indicator light is ON.

With soryice chock conngctor
jumpod (s6o pag6 19-55),
DTC 'l-3 is indicatod,

View trom undeFhood fuse/relay box

terminalside.

il-fnntrT-ll ll-Tl-f-Tlll

IUffil[Iml|[[_trl

I l'.ll

Bleed high pressure lluid lrom

the maintenance bleeder with
the BleederT-wrenchlsee p6ge
19-81).

Connectthe No. 29 and No. 30

terminals using a iumper wire lor
about 10 seconds.

Disconnect the 2P connector

from the pressureswitch.

Alter 30 minutes, check for continuiry belween the No.1 {YEL)

and No.2 {YELIterminalson the
switch side of connector.

AAS PUMP AAg UiIIT I7.5AI

UI{OER-HOODFUSE/RELAYBOX CIRCUITDIAGRAM
SWITCH SIDE CONNECTOR

The v.hicL l. OK rt thb tlmo.

Continulty?
Frrty .oLnoid (leakago).
Ragaac. tha modulator unit.

View from terminal side.

19-62
J

! ' . r t

i t . d .

Dlagnostic Trouble Code (DTC) 1-4: PressurSwitch Circuit

CAUTION: Uso only tho digit8l multim6tor to chock tho systom.

Wlth.nglno iunnlng, ABS indlcator llghi 18ON.

- With solvico check connoctor
iumped (3e p.go 19-551,
DTC t-4 k indicatod.

8led high pressure fluid trom

the maintenance bleeder with
the Bleeder T-wrench {soe page
19-81).
SWITCH.SIOECONNECTOR
Oisconnect the 2P connector
from the pressureswilch.

Continuity?

Chock ths continuiiy ol prssur

switch b6twe6n the No.l (YEL)
and No.2 (YEL)terminals.

View trom terminalside.

HARNESS.SIOCONNECTOR

Check for continuity between

the No. 1 (YEL) terminal and
body ground on lh harness sade
connsclor.

Ropairlhort In YEL wl.o ttotwoen

tho ABS control unit and P]taur6 lwitch.

View from terminal side.

Chock for looao ABS control unii

connactor!. lf noc6ara.y, lubatituto a known-good ABS control
unlt and r6chock.

(conl d,

19-63

Troubleshooting
Flowcharts (cont'd)
Diagnostic Troublo Codo {DTC) 1-8: Accumulator Gas Leakage
Chock tho tollowing itoms:
a The relief plug is loose.
a The reliet plug O-ringis out ol place.
a Bleedthe high pressureline with the BleederT-wrench.Operatethe ABS pump motor for 10 secondsand bleedthe
high pressureline againwith the BleederT-wrench.lf no tluid or more than 70 cc of lluid come out, replacethe ABS
pump assembly.
BLEEDERT.WRENCH
07HAA-SGOOIO'l or
07t{AA-SG00100
RESERVOIR

ABS PUMP ASSEMELY

Diagnostic Trouble Code {DTC) 2-1: Parking Brake Stvitch Related Problom
lf the parkingbrakehasbeenreleased.the followingitemsare possiblecauses.lf they are OK, checkthe ABS controlunit
connectorsfor good connection.lf not looseor disconnected,substitutea known-goodABS control unit and recheck.
NOTE: BeforetroubleshootingDTC 2-1, removethe ABS 82 {15 A) fuse in the under-hoodfuse/relaybox for three
secondsto clearthe ABS control unit's memory,then test drive the car.
lf the ABS indicatorlight stays otf, the probabilityis that the car was drivenwith the parkingbrakeapplied.
a
a
a
a
a
a

The parkingbrake is appliedfor more than 30 secondswhile driving.

The brakefluid level in the mastercylinderis too low.
GRN/REDwire is shortedbetweenthe brakesystem light and parkingbrakeswitch.
GRN/REDwire is shoned betweenthe brake system light and brakefluid levelswitch.
The brakesystem light is blown
GRNiREDwire has an open betweenthe brakesystem light and the ABS control unit.

'

Diagnostic Troublo Code {DTC} 4-1 to 4-8: Wh6el Sensor

CAUTION: Us only th6 digital multimeter to chck ths systsm.
NOTE: lf a malfunctionis detected,this code sppearsand the fail-safefunctionis activated.The ABS indicatorlight may
the ABS 82 (15 A) fuse in the under-hood
come ON after restartingthe engineuntil the DTC is erased(by disconnecting
fuse/relavbox for three seconds).
-

With ongine running, ABS indicator light is oN.

With servico chgck conneclor
ju.npod (s66 pag. l9-551,
DTCa 4-1, 4-2, 4-4 andlol
4-8 a.e indicaled.

Disconnectthe 18P 14WS:20P)

connectorfrom the ABS control
unil.

18PCONNECTOR
{2WSl
GRN:FRO GRN/BLU:
FL @

BRN:FL O

GRN/BLK:FR @

cRy: RL O BLU/YEL:RR O

GRN/YEL:RR @
LT/BLU: BL @

Vi6w from ABS control unit terminal side.

20P CONNECTORl4WSl

Check the rcsistance of each

sensor between the positive and
negatave:
. GRN/BLK:Front Right Positive
GRN: Front Right Negative
. GRN/BLU:Front LeIt Positive
BRN:Front Left Negative
. GFN/YEL:RearRightPositive
BLU/YEL:RearRight Negative
. LT ELIJ: Rear Left Positive
GRY: Rear LeIt Negative

BRN:FL O

GRN:FR O GRN/BLU:FL O

34 33 32 3 1

Lq
21

24 23

30

2A 27

19 1 8 17 1 6 1 5

GBY: RL O BLU/YEL:RR O

GRN/YEL:
LT/BLU: RL O

View lrom ABS control unit terminal side

ls there
Front: 70O-11OO O,
Rear r 10OO 1600 o?
Rpsir short in Senaor wire ol
Roplacotho whool ren3or.

Disconnoct the 2P connector of

the wheel sensor.

CONNECTOR
SENSOR-SIOE
Check for loose ABS conttol unit
connoctors. Chock thai th6 son3o. is installod p.operly. ll
nocoslary. substitulo g knowngood ABS control unit and
rschck.

ls there
'1000,
Front:7O0- 1
Rear: 1OO0- 1600 0?

FRONT

(l zTI'|)
r-t

\+#
@

REAR

I|Ell

_/r-l\//---\\

tl

5--/

rFSb
.LOr
-

1000-1600 0?
700- l too o?
Viewfromterminal
side.

(To page 19-66)

19-65

Troubleshooting
Flowchart {cont'd)
(Frompage19-65)
HARNESS.SIDECONNECTOR

'l8P (4WS: 2OP)

Roconnectth
connector to the ABS control
unit.

FRONTLEFT

FRONTRIGHT

ffi"U""'os4ffiffin's

Check each wire for continuity

belween the whoel sensor
terminalsand body
harness-side
ground.

@
+

l\-/l

o
+

@
+

I6

Contlnuity?
REARLEFT
REARRIGHT
cRY: /=\ _LT8LU: BLU/YEL:_
GRN/YEL:

Rapalr opan lo wlr! hrmaaa.

Chock tor looao whool 3onaot

connoctoE. It nocolltry, tubatiiuto a known-good ABlt control
unit and rochock.

o-tFlfl-gf
@
-t-

0
I

Positivs:3.3 k0 a 15% is OK.

Nggrtivo:Lessthon 1 O i6 OK.

0L

lHgf o

-tF'tl_-

0I

Contlnulty?
Visw from terminal side.

19-6 6
""hi

r r! $Hl L,lllft&trrt,

Dbgnctic Troublo Code (DTC) 5 to 5-8: Wheol Snsor(s)

CAUTlOttl: Use only th digltal multimotor to chock tho syEtm.
NOTE: lt I malfunctionis detected,this code appearsand the iail-safefunctionis activated.The ABS indicatorlight may
the ABS B2 (15 A} fuse in the under-hood
come ON sfter restartingthe engineuntilthe DTC is erased{by disconnecting
box tor three seconds.)
(2WS)
18PCONNECTOR
-

Wlth onglnc running, ABS in'

dc or llght l! ON.
Wlih lowlco chock connoctor
iump.d {roe paga t9-55),
DTC. 5, 54 or 5-8 l! indlcrtod.

30

2a 27
21 20 1 9

t!!J
'18

26 25 24

1 1 16 1 5 1 4

LTBLU:RLE
:RLO \
RRO
BLU/YEL:
the 18P(4ws: 2OP)
Disconnect
connoctorlrom the ABS control
un|t.

Viw {rom ABS control unit t6rminal sido'

20P CONNECTOR
{4WSl
34

Chock th .esistance ot each

sonsor between th positive and
n6gativo:
. GRN/YEL:Rsar Right Positive
SLU/YEL: Rssr Right Negarive
. LT BLU: Rear Left Positive
GRY: Rear Left Ngative

32

25 24 23

uJl
21 20

GRY: R L O \

BLU/YEL:
RRO

30

26
1 8 't7 1 6

LYELU:RL@
RRO
GRN/YEL:

Vigw from ABScontrolLrnittsrminalside.

ls thero 1OO0- 1600 07

Rcprlr rhort In lonlor wiro ot
Rapbco tha whaol lonaor.

Disconngct lhe wire

trom wheel sensor.

hamgss

Rconnect the l8P (4WS: 2OP)

connsctor to the ABS control
unit.

Connoct the ALB checker to tho

ABS insDeclionconnector.
Chock Ior resistance botween
ths sensor terminals.

Chck for ABS lunction in mode

2 and 3.
Dos it work prop.ly?

Check to, rctr bt.k6 dr.g. ll OK,

sub.ftut6 a known-good ABS
control unlt and .ochgck.

SENSOR.SIOE
CONNECTOR
REAB

ls there 1OO0- 1600 O?

YES
(To pag 19-681

1000- 16000?
Viewfromterminalside. (conl.d)

19-67

Troubleshooting
Flowcharts {cont'd)

HARNESS.SIDE
CONNECTOR
REARLEFT
REARRIGHT

Reconnecrthe 18P l4WS: 2OP)

connoclor to th ABS control
unit.

GRY:\ /=\ lT BLU: BLU/YEL:^ GRN/YEL:

e_HE{_e
l:l

Check each wire for continuity

between the wheel sensor
harness-sidetorminals and body
ground.

9
+

+9

o_r$Lo
l,*,I
+9

Contlnulty?
Rrpdr op.r| lo whr h.rnaar,

Chock lor looig whool lenaoi

conn6ctorE.It nocoraary, aubatitut6 a known-good ABS control
unlt and rochock.

1 9 -6 8

Positivs: 3.3 k0 a 15% is OK.

Nogative: Less th6n 1 O is OK.

Vi6w trom torminal sido.

+0

Diagnostic Trouble Code (DTCI 6-1 : Front Fail-SafeRelay Cilcuit

CAUTION: Use only the digital multimtel to check tho systom.
Ple-test steDs:
a Check ABS B1 (2O A) tuse in the under-hoodfuse/relaybox.
a Check for loose under-hoodfuse/relavbox connectors.
-

FAIL.SAFERELAYS

With engine running, ABS indicator light is ON.

With so.vic6 chock connector
iumped lsee pags'19-551.
DTC 6-1 is indicated.

Removethe lronl faifsale relay

from under the gauge assembly.

Wire colors oI the laifsate relay conneclor

FTONT:
BRN/BLK,BLK/YEL,YEL/GRN,BLK
Rear: BLU/8LK,BLK/YEL,YEL/GRN,8LK

Check relay function lsee page

19-87).

Doesrt work properly?

R6plac. thc tront f.ll-..f.

r.hy.

Turn the ignition switch ON.

HARNESS-SIDECONNECTOR

Check for voltage between the

fail-saferelay connector No. 1
(BLK/YEL)termanal and body
ground,

ls there batte.y voltage?

Repiropen In 8LK/YEL wlre between the No. 9 R/C MIRROR

{15 A} fuso In the unde.-da.h
tuao/rolay box and lront tald-ato
reley.

Turn the ignitionswitch OFF.

Disconnectthe 10P connector

from the solenoids.
B.ttoryVoltago?
Check for continuity between
the fail safe relayconnectorNo.
2 (BRN/BLK)terminal and bodv
ground.

Continuity?

View trom terminalside.

{ T op a g e1 9 7 0 )
{cont'd)

19-69

Troubleshooting
Flowcharts (cont'd)
(Frompage19-691
R.pai. rhon In BRN/BLK wlro
botwoon thg aolenold and lront
tlilal. rolry.

Check each wire {or continuity

between the solenoid terminals
and body ground
Front Right
No.4 {BRN/BLK):
Front LeIt
No. 6 (BRN/BLU):
View from trminal sid6.
F.uhy lol.nold llhortl.
RapLca tha modulator unh.
12P CONNECTOR(2WS)
REO/8LU RED/BLK
tFL-r )
tFR-rN)

YEUBLK
IFR.OUTI

YEUBLU

{Ft-our}
Continuity?
Viw trom ABS control unit terminal sid6.
14P CONNECTOR(4WSl
RED/BLU
RED/BLK
(FUINI
{FR.IN)

Disconnct the connectors lrom

the ABS control unit.

YEUBIT(
(FR.OUTI

Check each wire for conlinuitY

between the ABS control unit
connectot and body ground.
RED/BLK:Front Rightlnlet
YEUBLK:Front RightOutlet
RED/BLU:Front LeIt Inlel
YEL/BLU:Fronl Left Outlet

YEL/BLU
(FL.OUT)

F.p.h lhon In wi . b.twgln tho

roLoold lnd A&S cont.ol unh:
RED/BLK:Froot Right InLl
YEUELK: Front Rlglrt Outht
RED/8LU: Front L.ft Inlot
YEUBLU: Froot L.ft Outlct

Contlnulty?
Viw from ABS control unit terminal side.

{ T op a g e1 9 - 7 1 )

. ",r-,.:,i .:dt til{ril

(Frompage19-7O)

'l8P CONNECTOR(2WS)
30 29 2A 27

llJ

26 25 24

21 20 1 9 1 8 1 1

14

c o n t i n u i t v r( C l ) ' Y E U G R N
Check tor continuity between
the No. 17 (4WS: No. 19)
(YEL/GRNIterminal and body
ground.

View {rom ABS control unit terminal side.

20P CONNECTORt4WSl

34 33
25 24

Rcoair rhon in YEUGRN wire

bctwaon tho ABS control unit
rnd tront l.ll-.afo rol6y,

31

tlJ

30
2a 27
21 20 't9 1 8 1 7 1 6 1 5

r'3*:::,,
I
View from ABS controlunit terminalside.

'l8P CONNECTORl2WSl

30 E 2a 27 tlJt 26 25 2 1
14 13
22 2 1 20 1 9 1 8 1 7 1 6

Reinstallthe tront lail-sale rolay.

Turn th ignition switch ON.

Batteiy
Check lor voltafe btween the
ABS control unit connector No.
17 l4WS: No. 19) {YEL/GBN)terminaland body ground.

"o,,un"r
(V)',tt"t{f*n

View from ABS controlunit terminalside.

20P CONNECTOR{4WSt

34
25

uJl

30

2A 27

21 20 1 9 1 8 11

15

,""ili*' (V
ls there batlery voltage?

Roplir op.o in YEUGR wi o

bot$,6on tha front lall-aalo rolay
and ABS control unlt.

8att6.y Voltago?
View from ABS controlunit terminalside.

Chock to. looso ABS cont.ol unit

connoctor3. ll n6c63sary, substituto a known-good ABS control unit snd .ochock.

19-71

Troubleshooting
Flowcharts (cont'd)
Diagnostic Troublo Codo (DTC) 6-4: Re81Fail-SafoRolay Cilcuit
CAUTION: Use only digital multimetar to chock tho system.
FAIL.SAFERELAYS
-

Whh engine running, ABS indicator light ie ON.

- With sorvice chock connoctol
iumpod lsee pago 19-55).
DTC 6-4 is indlcated.

Remove the rear lailsafe relay

from underthe gaugeassembly.

Wire colors of the tsil-s9te relay connector

Front:BRN/BLK,BLK/YEL,YELiGRN,BLK
Rear: 8LU/BLK,BLK/YEL,YEL/GRN,BLK

Check relay function (see Page

19,87).
Does ir work proprly?

Rplacethc r6at fall_3aferolaY.

HARI{ESS.SIDECONNECTOR
Turn th6 ignition switch ON.

Check for voltage between the

fail-saferelay connector No. 1
(BLK/YEL) terminal and body
ground.
R.plir opon In BLK/YEL wlro botwon th. No. 9 B/C MIRRoR
(15 Al fute In th! und.i-dalh
lu$/roby bor and ttont f.ll-lafo
lollY.
BlttoryVoh.go?

Turn tho ignition switch OFF.

Cootinuity?

Vi6w from trmin6l side.

Disconnectthe lOP connector
from the solenoids.

Check Ior continuity between

the fail-safe rclay connector No.
2 {BLU/BLK)terminal and boclv
ground.

Ropai. 3hon in BLU/BLK wlro b.twoon tho iolonold and torr failaalo rglav.
NO
( T op a g e1 9 7 3 )

19-72
:i

(Frompage19-72)

CONNECTOR
SOLENOID-SIDE

Chcck to. continuity bslwoon

th solenoidNo. 5 IERN/WHT)
terminalsnd body ground.

Faulty lolondd {rhortl.

Roolacctha modulalor unit.

Disconnect the connectors from

the ABS control unit.

Check each wire tor continuity

betwegn the ABS control unit
connector and body ground,
RED/WHT:Rearlnlet
YEUWHT; Rear Outlet

RED/WHT
IR.IN)

View from ABS controlunit terminalside.

14P CONNECTOR
l4WSl
RED/WHT{R.INI

12
8 7 6.

[]t

1 l 10 9
1

413

YEL/WHT I

Continuity?

View from ABS controlunit terminalside.

Repairrhort in wlre b.twoon tho
aolanoidond ABS control unit:
RED/WHT:Rear Inlot
YEI/WHT: Roar Outlot

lTo page19-74)

(cont'dl

19-73

Troubleshooting
Flowcharts (cont'd)
(Frompage19-73)

laP CONNECTORl2WS)

[Jl 26 25 24 23
30 29 2A
15 14
22 21 20 1 9 1 8 1 1

Continuity?

Check for continuity between

rhe No. l7 (4WS: No. 191
(YEL/GRN)terminal and bodv
ground.

tFsR)

View lrom ABS control unit terminal side.

20P CONNECTORt4WS)
34 33

3l

22

24

tllj

28

30

26

20 1 9 1 8 1 7 '16 1 5

,'.:1;"'
e

Fop.lr lhort In YEL/GRN wito

btwon tho ABS contlol unit
and '.ar lail3ata rclay.

Continuity? =L.

View from ABS control unit terminal side.

Reinstallthe rear laifsate relay.
18P CONNECTOR{2WS}
25 2 1
30 29 2A 27 uJ
't9 1 8 't7 1 6 1 5 1 1
21
20
22

Turn the ignitionswilch ON.

Check for vollage between the

ABS control unat connector No.
ter17 (4wS: No. 19) (YEL/GRN)
minal and body ground.

(V)
vorr"e"z

;:;;

View from ABS control unit terminal side

20P CONNECTORl4WS)
34 33
25 24

3l

tlJl

30

2A 27 26

2'l 20 1 9 1 8 1 7 1 6 1 5

YEL/GHN t \l
tFsRt
\-rganeryVoltage?E
Repair op6n in YEL/GRN wito
b6twcan thc toar fail-3at6 rel6Y
and ABS cont.ol unil.

ls there battory vollage?

chck lor looso ABS cont.ol unlt

connoctors, It necesaary, subrtituts a known-good ABS con_
trol wrh snd rocheck.

19-74
,

.d.'{Fi.FFn-.r-,,q.iiillilnryl&_

View from ABS controlunit terminalside.

Diagnostic Trouble Code {DTC) 7-1 and 7-21 Front Solonoid RolatedProblom
CAUTION: Uso only tha digital mullimeter lo chsck tho systom.
Pr6-test steps:
. Check ABS B1 (20 A) fuse in the under-hoodtuse/relaybox.
a Check for loose under-hoodluse/relaybox connectors.

wlth ongino running, ABS inlcator light is ON.

- Wlth sorvico ch6ck connocto.
,umpd lloo pa96 t9-551,
DTCa 7-1 6nd/or 7-2 ir indic.tod,

CONNECTOR
SOLENOID-SIDE
RED/BLK(FR-INI

RED/BLU{FLIN)

oisconnect the lOP connoctor

from the solenoids.

Check for resistance between

the solenoidterminal:
N o . 1 ( R E D / B L Ka) n d N o . 4
FrontRight Inlet
{ARN/BLK):
N o . 3 { R E D / B L Ua) n d N o . 6
(aRN/BLU):Front LeIt Inlet

1-3 0?

ls there 1 -3 0?

Check lor resistance between

the solenoid terminals:
N o . 8 ( Y E L / B L K a) n d N o . 4
(8RN/BLK):Fronr Right Outlel
No. 1O (YEL/BLU)and No. 6
IBRN/BLU):Front Left Outlet

'l
ls there -3 O?

{Topage19-761

t-30?
Viewfromterminal
side.

(cont dI

19-75

Troubleshooting
Flowcharts (cont'dl
(From page 19-75)

Disconnectthe 12P (4WSr 14Pl

connector from the ABS control
unit,

(2WSI
HARNESS-SIOE
CONNECTOR

RED/BLU
IFL,IN)
View from terminalside.
YEL/BLU
IFL,OUTI

YEL/BLK
(FR-OUTI
Check each wire lor continuity
belween lhe ABS cont.ol unit
and front solenoid.
RED/BLK:Front Righr Inlet
YEL/BLK:Front Right Outlet
RED/BLU:Front Lelt Inlet
YEL/BLU:Front Left Ourlet

Continuiiy?
RED/ALUIFI--IN)

tFR-OUtl
View lrom ABS controlunit terminalside.
HARNESS-SrOE
CONr{ECTORt4WS}
REOiBLU
IFL{NI

REO/SLK
{FR-INI
View lrom lermanalside.

YEL/BLU
(FL,OUT)

YEUALK
(FR-OUTI
Contlnuhy?
RED/8IU (FL.II{}

YEL/8LK
IFR-OUTI
View from ABS conirolunil terminalside.

Rapdr opan h vri a batwaan tha

|oldrold ..d ABS coitrol unh:
REDrSL|(: Froit Rlght lnbt
YEUBLK: F oni Rlght OutLt
REO/8LU: Front L.ft InLt
YEUBLU: F or L.ft OutLt

12P CONNECTOR
t2WS)
REDiBLK
{FR{NI

REO/8LU
{FL-IN)
Check each wire tor continuity
between the ABS control unit
and body ground.
RED/BLK:Front Right Inlet
YEL/BLK:Fronl Right Ourlet
RED/BLU:Fronl LeIt Inler
YEL/BLU:Front Lelr Ourlet

11
1

llJ

10 I

1n

;l:tt$

YEL/BLK
IFR-OUTI

.o) (o.

Continuity?
(To page19-77)

View lrom ABS controlunit terminalside.

1 9 -7 6
"

-ffit4!{r"{?flFqrr+*'

"'frf,!ffiru..

(Frompage19-76)

14P COI{NECTOR{4WS)
RED/BLU(FL-IiI} RED/BLKIFR.INI

12 tlJ 1 1 1 0 I )
I 7 6 5 4 3. 2

YEL/BLK
IFR-OUTI

Conrlnulrv?
/

6 oXo
c)| ['.:-6'r'Y'
View from ABS controlunit terminalside.
View from controlunit terminalside.
Ropalrrhort In wlre baiwaen th
lolonold and ABS contrcl unlt:
RED/BLK:Fronl Rlght Inlot
YEL/BLK:F.oot Rlght Outht
RED/BLU:Front Lolt lnlor
YEUBLU: F ont L6ft Outl.t

Remove the lront foil-sate ilav

from under the gauge assembly.

FAIL.SAFERELAYS

Wiro colors of the tail-saIe rlav connecror

FTONT:
BRN/BLK,BLK/YEL,YEL/GRN,BLK
Rear: BLU/8LK. 8LK/YEL, YEL/cRN, BLK

Check for relay function (se

pago 19-87).

Ooes it work propedy?

R.placc thc fronl tall-..fo .elay.

HARNESS-SIDECONNECTOR

Chck for continuity betwoen

th fail-sato rglsy connectoi No.
4 terminal and body ground.

Roprli opcn In BLK wire betwen

tho fall-aafo l6lay and g.ound or
poo. ground lG4O1, G4O2,
G/rO4l.
View from terminalside.
Check BRN/BLK wirs for continuity bgtwoonthe aolonoid3and
front failsate relay.

HARNESS.SIDECONNECTOR

BRN/BLK

Rcpair opon In BRN/BLKwl.o b.twean tho rolanolda and f.ont

lall{ol. relay,

Chack tor looae ABS control unh

connactota. lf nocolaaty.
.ublthuto . known-good ABS
contrcl unh ond rechock.
View Irom terminalside.

19-77

Troubleshooting
Flowcharts(cont'd)
Dllgnostic Troublo Code (DTCI 7-4: Roar Solenoid Problem
CAUTION: Uso only tha digltal multimolol to chck the systm'

YVhh.nglno runnlng, ABS Indcator fight ir ON.

- Whh raNico chqck conneclol
jurnp.d (te6 pag 19-551,
DTC 74 l. indlc.lod.

REDAAIHT

tR-rNl
BRN/WHT
YEL/WHT
{R-OUT}

Oisconnect the lOP connector

from the solenoids.

1-3 0?
View from tsrminal 9ido.

Check for registance between

the solenoid terminals:
N o . 2 ( R E D / W H TaI n d N o . 5
(BRN/WHI: RearInlet
N o . I ( Y E L f l V H TaI n d N o . 5
(BRN/WHT):Rear Outlst

HARNESS.SIOECOI{NECTORI2WSI

tgrminal 3ide.
ls thete 1 -3 O?

YEL/WHT
(R-OUTI
Co lnuhy?

(R.IIU
RED/WHT

Disconnectthe 12P (4WS: 14P)

connector trom ABS control unit.

Check each wt {or continuity

botween the ABS control unit
and r6ar solenoid:
RED/WHT: Rear Inl6t
YEL/WHT: Rear Outlet

View Irom ABS control unit terminal gide

HARNESS-SIDECONNECTOBI4WSI

Raprlr opan In wlra botwaan tho

rolonold .nd ABS cont.ol unlt:
REO/WHT:R.at Inl.t
YEL/WHT: Redr Outlot
Condnuity?

(R.INI
REDAATHT

YEL/WHT{R-OUTI
(To page19-79)

1 9 -7 8

View from ABS control unit terminal side'

{Frompage19-781

(2WSl
12PCONNECTOR
RED/WHT{R.INI

14P CONNECTORt4WSl
REON/HT IR-INI

Check each wi.e tor continuity

between the ABS control unit
and body ground:
RED/WHT:RoarInl6t
YEUWHT: Roar Outlet

IR-OUTI

View trom ABS control unit terminal side.

Roolir lhort ln wlre btwocn iho
lolgnold and ABS cont.ol unlt:
REO/WHT:Roar Inlot
YEL/WHT: R6or Outlct
Remove the rear lail-safe relav
Irom under the gauge sssembly.

View from ABS controlunit terminalside.

FAIL-SAFEBELAYS

Wire colors ot tho fail-safe relay connector

F.ONI:BRN/BLK.BLK/YEL,YEL/GRN,BLK
Rear: BLU/8LK,BLK/YEL,YEL/GRN,8LK

Check for rglay lunction {se

page 19-87).

Does it work properly?

RapLco tho rorr tril-lafo

roaly.
HARNESS.SIDECONNECTOB

Check for continuity betweon

the tail-safe rclav connector No.
4 (BLK) terminal and bodY
grouno.
Raprlr opon in BLK wl.o botw66n
tho hll-refe rcl.y and ground o.
poo. ground lc4o1, G402,

G/ro4l.

View from terminalside.

Check BLU/BLK wire tor continuity betwsen th solenoidand

rar tail-safe rlay.

HARNESS.SIDECONNECTOR

Ropalrop6n In BLU/BLKwi.o b.twaen lhe 3oLnold rnd roar faillrtc rohy.

Chock for loote ABS cont.ol unlt

connecioaa. lf nccoraary, aubBtitute a known-good ABS cont.ol unh and rochock.

BLU/BLK

Continuity?

19-79

HydraulicSystem
Index/HydraulicConnections
CAUTIOI{: Do not spill brsks tluid on tho car; it may damage the paint; if brake fluid does contact the paint, wash it oft
im.nadillcly tYith water.

TANK
RESERVOIR
BrakeFluidDraining,
page19-81

' 1 0x 1 . 0 m m
1 9 N . m 1 1 . 9k g - m ,
't 4 tb-ft)

To right-l.onl
brako

To lolt-tiont

to agnr+eat,// 7'
br.ke
,/
To loft-roar brake

MODULATORUNIT
page 19'82
Removal/lnstallation,
page 19-83
Index/Torque,

19-80

10 x 1.0 mm
1 9 N . m ( 1 . 9k g - m ,
14 tb-ft}

RelievingAccumulator/LinePressure
@

Use the BloederT-wrench before disassemblingthe parts shaded in th illustration,

1.

Ooen the hood.

2.

Rmovethe red cap from the bleederon the modulatorbody.

3.

Installthe specialtool on the maintenancebleederand turn it out slowly 90" to collecthigh-pressure

fluid into the
reservoir.Turn the specialtool out one completeturn to drainthe brakefluid thoroughly.

4.

Retightonthe maintenancebleederand discardthe fluid.

5.

Reinstsllthe red cao.

ReservoirBrake Fluid Draining

1.

Drainingbrakefluid from modulatortank:

The brake fluid may be sucked out through the top of the modulatortank with a syringe.lt may also be drained
through the pump joint after disconnectingthe pump hose.

2.

Drainingbrakefluid from mastercylinder:

Loosenthe bleed screw and pump the brake pedalto drainthe brakefluid from the mastercylinder.

a High-p.ossul tluid u,ill squirt out if th6 shadod hoso and pip are removod.
a To drain high-prossursbrake tluid. follow the procodure on this page.

19-81

ModulatorUnit
Removal/lnstallation
CAUTION:
a Ba carsful not to bond 01 damage tho brako pipos when romoving tho modulator unit'
a Do not spill brake lluid on th car; it may damagthe paint; if brak fluid dos contact the paint, w88h it ofl immodiately rYilh tYatel,
a To pravont spills, covol tho hose ioints with lags or shop towels'
a Bofore reassembling,ch6ck that all pans are free of duEt and othr fo?sign particlss'
a Do not mix diffarsnt brands ot brako tluid as thoy may not b compatibl'
a Do not reus6 the dtaind fluid. Uso only clean DOT 3 01 4 brake fluid'
a Whan connocting tho brak pipos, mako sula that thelo is no intorflonce betwaon th braka pipos and othor panE'
Drainthe brakeJluidIrom the mastercylinder.
2. Relievethe high pressurefluid (seepage 19-81) when the high pressurehose is to be disconnected,

1.

3,

Removethe intake air duct

Disconnectthe solenoid,pump motor and pressureswitch connectors'

5. Disconnectthe six brakepipesJromthe modulatorunit.

4.

6.Loosenthetwo|owermount|ngbo|ts,andremovetheuppermountingbo|tsndthemodu|atorunitlromtheframe.
7.
8.

lnstallthe modulatorunit in the reverseorder ot removal.

After installation, till and bleed the hydraulic system.

SOLENOIDCOI{NECTOR

UPPERMOUI{TII{G BOLT
8 x 1.25 mm
22 N.m 12.2kg-m, 16 lb-tt)

MODULATORUNIT

PRESSURE
swlTcH
CONNECTOR

10 x 1.0 mm
19 N.m 11,9 kg-m,
14 tb-ft)

LOWERMOU'{TING BOLTS
I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)
Loosn.

1 2 x 1 . Om m
'19 N.m ll.9 kg-m,
14 tb-ft)

19-A2
slrrr{EriE.a..

Index/Torque
Before removing tho modulatol-to-pump high-pressurelino, bo sur to reliove ths tluid ptossure trom th.
@
maintenancbloeder{se page 19-81).
CAUTION:
a Do not spill brake tluid on th6 car; it may damagetho paint; it brake fluid does contact the paint, wash it oft immodiatoly with watel.
a To prvent spills, cover the hose ioints with rags or shop towols'
a Befora roaassmbling.chock that all parts are freo ol dust and othor foreign particlos.
a Do not mix diffsront brands of brato fluid as thoy may not b compatible.
a Do not rous the drainod tluid. Use only cl6an DOT 3 or 4 brako fluid.
a Do not dissssembltho modulator unit, Replacotho modulator unit as an asssmbly if it is defectiv.
a Do not disassomblsthe pump (oxcept plsssuro switchl,
6 r 1.0mm
1O N'm (1.O kg-m.
7 lb-ft|
MODULATORASSEMBLY
Do not disassemble.

CONNECTOR
BRACKET
SEALINGWASHERS
Replace.

SOLENOIDS
LeakTest,page19-84

BANJO BOLT
35 N.m {3.5 kg-m.
25 tb-ft)

I x 1.25rnm
1 5 N . ml l . 5 k g - m ,
lt tb-frl

PUMPEBACKET
6x1.Omm
1 0 N . m 1 1 . 0k g - m ,
7 tb-tt)

MODULA
ARACKET

6 r 1 . Om m
1O N.m {1.O kg-m,
7 tb-ft)

ACCUMULATOR
Disposal,psgo 19-85

EANJOBOLT
35 N.m 13.5kg-m,
rb-ft)

HOSE CLAMP

Str.O^,'/
1 0 N . m 1 1 . 0k g - m ,
7 tb-til

SEALINGWASHERS
Replace.

PRESSURE
SWITCH PUMP ASSEMELY
Do not disassemble.

19-83

Solenoids
LeakTest
NOTE: lf a solnoidleaks excessively,the brake fluid
level in the modulator reservoirtank will rise when
operatingthe ABS pump motor. The modulatorreservoir may also overtlow.
1.

Disconnctthe pump motor and ptessureswitch

connectors.

2.

Connsct an ohmmeter between the YEL and YEL

terminalsof the pressurswitch connector.

3.

Attach the positive(+) leadoJ a fully charged12 V

battery to the RED/WHTterminal ot the motor connector and negative(-) lead to the GRN trminal,
and install a switch between negative lead 8nd
GRNterminalas shown.

4.

Pump
PressureSwitch Replacement
Removal
'1.

Securethe pump assemblyin a vise.

2.

Rmovethe banjo bolt, then removethe pressure

switch from the pump housing

BANJOBOLT
35 N.m 13.5kg-m,25 lb-ft)

/@

o@

/1

Turn the switch on to allow sutficient grssure to

build uo within the accumulatorand checkfor continuity. lf ths ohmmete.shows continuity(pressure
switch turned on), run the motor for 1O seconds
mors, then turn the switch off

lnstallation
lnstall the pressure switch with the banjo bolt and
sealingwashers,then tighten the bolt.

a CheckiJ the solenoidhissesor squeaks.Replsce

the modulatorif the solenoidhissesor squeaks.
a Check the pressure switch for continuity within
30 minutes,lt is normalif there is continuity' ll
there is no continuitv, a solenoid is taulty or
line leaks.
high-pressure

19-84

reL

Accumulator
Disposal
The accumulatol containa high prssur
@
nltrogen gas. Do not puncturo. oxpose lo the flamo, or
attomot to disassomblotho accumulatol or it may xplode and avar6 porsonal injury may lsult.
1.

Securethe pump assemblyin a vise and remove

the accumulator by turning it counterclockwise
with a 19 mm oDen-endwrench.
ACCUMULATOR

Securethe accumulatorin a vise so that the reliet

plug points straightup.
Slowly turn the plug 3-112 turns and then wait
three minutestor all pressureto escape.
4.

Remove the plug completely and dispose ot the

accumulator.

19-8s

Bleeding
CAUTION:
a Do not spill brake fluid on the car; it may damagetho
paint; it brako fluid does contact the paint, wash it
off immdiataly with water.
a Make sure no dirt or other loreign mattsr is allowed
to contaminato tho brake fluid.
a Do not mix dilferent brands of brake fluid as they
may not be compatible.
a Do not rous ths drained tluid. Use only clean DOT 3
or 4 blake fluid.
1.

Placethe vehicleon level ground with the wheels

blocked.Put the transmissionin neutralior manual
transmission models, and in @ position for
automatictransmissionmodels. Releasethe parking brake.

2,

Disconnect the ABS inspection connector (6P)

irom the cross-memberunderthe passenger'sseat
and connectthe ABS inspectionconnector(6P) to
the ALB checker.

Start the engine and allow it to idle for a iew

minutes,then stop it. Check the fluid level in the
modulatorreservoirand refillto the MAX levelline
if necessarv.

4.

Bleed high-pressurefluid from the maintenance

bleederwith the specialtool.
T.WRENCH
BLEEDER
oTHAA-SG00101

CONNECTOR

o.

Seepage19-32lor other
applicablo
chockers.

3.

Turn the Mode Selectorswitch of the checkerto 2.

8 . While dpressingthe brake pedal fitmly, push the

Start Test switch to operatethe modulator.There
should be kickback on the brake pedal. lf not.
fepest steps 5 to 8.

Fill the modulator reservoirto the MAX level ltne

and installthe reservoircap.

MAX LEVELLINE

Start the engine and allow it to idle lor a few

minutes,then stop it. Check the fluid level in the
modulatorreservoirand refillto the MAX levelline
if necessary,

NOTE: Continueto depressthe brakepedalfirmly

when operatingthe checker'
9.

Turn the Mode Selectorto 3, 4. and 5

Performstep 8 for each oJthe test mode positions.

1O. Refillthe modulatorreservoirto the MAX levelline

snd installthe reselvoircaP.
Disconnect the ALB checker botors driv@
ing tho car. A collision can result tlom a teduction ol
complt6 loss ol braking ability, causing sevsrs prsonal iniury or death.

19 -8 6

ElectronicComponents
ABS Control Unit Replacement
1 . Removethe right quartertrim panel.

Relay Inspection
1. Removethe fail-saferelaysand motor relay (locat i o n : p a g e1 9 - 5 0 1 .

2 . Disconnectthe ABS control unit connectors.

J.

Removethe ABS control unit attachingbolts, then

removethe ABS control unit.
ABS CONTROLUNIT

2. Check for continuity betweenthe terminalsC and

D.
Thereshouldbe continuity.
3. Check for continuitybetweenthe terminalsA and
B.
There should be continuity when the battery is connected betweenthe terminalsC and D.
There should be no continuity when the baftery is
disconnected,
<Fail-sate Relay:>

lnstallthe ABS control unit in the reverseorder of

rmovar.

<Motor Rlay:>

19-87

Pulsers/Wheel
Sensors
Inspection
Front

Rear

1. Checkthe pulserfor chippedor damagedteeth and

replaceif necessary.

1 . Removethe rear caliDerassemblY.

2 . Removethe rear brakedisc.

2.

Measurethe air gsp betweenthe sensorand pulser

all the way aroundwhile rotatingthe driveshaftby
hand.
Standard:o.4- 1 .0 mm (0.02-0.04 in)
NOTE: lf the gap oxceeds1.Omm (0.04 in) 8t any
point, the probabilityis a distortedknuckle,which
should be replaced.

FRONTWHEELSENSOR

Checkthe rearpulserfor chippedor damagedteeth

and replaceif necessary.
4.

Measurethe air gap betweenthe sensorand pulser

all the way around while rotatingthe hub bearing
unit by hand.
Standard:O.4- 1.O mm {O.O2-O.O4in}
NOTE: It the gsp exceeds1 .O mm (O.O4in) at any
point, the probabilityis a distortedknuckle.which
should be reolaced.

REARWHEELSENSOR

19-88

Wheel SensorReplacement
Front
NOTE:
a Be carefulwhen installingthe sensorsto avoid
twistingthe wires.
a After sensorreplacement,contirm properoperation
( s e ep a g e 1 9 - 5 3 1 .

ftI

6r1.Omm
'10N.m ll.0 kg-m,
7 tb-fr)

fr

6 r 1 . Om m
10 N.m (1.0 kg-m,
7 tb-ftI

8 x 1 . 2 5m m
22 N.m 12.2 kg-m,
't6 tb-frl

6 r 1.0mm
lO N.m (1.0 kg-m,
7 tb-ft)

Rear
NOTE:
a Be carefulwhen installingthe sensorsto avoid
twistingthe wires.
a After sensorreplacement,
confirmproperoperation
( s e ep a g e1 9 - 5 3 ) .

* )

l\h
"Y

8 r 1.25 mm
,/
22 N.m 12.2 kg-m, 16 lb-ft)

6 x 1.0 mm
1 0 . r n ( 1 . Okg-m, 7 lb-trl

19-89

Body
SillPanel
Roof Molding/Side

Bumpers

...............,.,,....,.
2G58
FrontReolacement
...............,,.,,..,,,.
2G60
FrontDisassembly
2G61
.............,............
RearReplacement
....20-62
RearDisassembly.......................

*Carpet
Reolacement

.......2G 48

*Consoles
Replacement

.......2G68

Reolacement

Seats

.....2G38
FrontRemoval
2G38
..,.,.,..................
FrontReplacement
FrontSeatCoverReplacement...,2G4O
2G41
RearReo|acement,.........................

Seat Belts
.......2G5O

*Dashboard
.........2O-5'l
Removal/lnstallation
ComDonent
.......2G55
Replacement

Doors

20-43
.........................
FrontReplacement
..................,,.,,...
2045
RearReolacement
............2G46
lnsoection
....fu47
ChifdSeatAnchor Plate.............

.......20-71

Sub-frame

Sunroof
fuz
1ndex
.................................................

DoorPanel/Plastic
2Gg
CoverReolacement,...............
OuterHandleReplacement........2G5
.....................
20-6
LatchRep|acement
Replacement...2G7
Glass/Regulator
OuterMoldingReplacement......2Gg
WeatherstripsReplacement.....2G9
.2G10
GlassAdjustment.................,........
2Gl 1
Adjustment.......................
Position
*12
StrikerAdiustment.........................

*FrameRepairChart...............
n-72
FuelLid
Ooenerand FuelLid
2C167
.....................
Latch Reolacement
2G66
OpenerCableReplacement...........

Headliners
Replacement

.......2G36

Hood

..............
2G63
Replacement/Adjustment
....2G63
Openerand Latch Replacement
......2G69
Replacement
HoodEdge
Protector

lnteriorTrims
Reofacement

,...,,.n'37

Mirrors

Power DoorMirrorReplacement..2G12
............
2G13
MirrorHolderReplacement
RearviewMirrorReolacement.....,2G13

RearEmblem
lnstaflation

...........2G7O

...2$ 28
lndex..................
..............................Tn
Troubfeshootin9
SlidingPanelHeightAdiustment ...2G29
RearEdgeClosingAdjustment......2G3O
SunroofLinerand SlidingPanel
...2G30
ReDlacement
............
2G31
SunroofRepair/lnstallation
Motor, DrainTube,and Frame
... fu32
ReDlacement
PanelStay/Slider.Lifter and
............
2G33
GuideRailsReplacement
OpeningDragCheck
(MotorRemovedl........................
20-34
ClosingForceCheck
(MotorInstalledl
2G35
..........................

TrunkLid

.....,,.,,,,,.
2G64
Repfacement/Adjustment
2G67
......................
OpenerReplacement
Trunk Lid LatchReolacement.......2G65
2G66
OpenerCableReplacement...........
OpeningWeatherstrip/License
2G69
PlateTrim Replacement.............
Trunk SpoilerReplacement...........2G7O

Window/
Windshield/Rear
OuarterGlass
fndex......,............
Windshield
Removal
lnstallation
RearWindow
Removal
lnstaffation
OuarterGlass
Removal
fnstallation

...20-14
...........
2G15
........2G16
...........2O-2O
........2G21
...........2G25
.'.....2G25

Doors
lndex
CENTER
SASHGUIDE
Rphcofirom,sopags2O7
GLASS
Roplacofirorlt, s6g pr6 2G7
Adjustnrsnt, soo pago 20l0

RBOTTATOR
R.pboe.v|6m,ss p.g 2OB

OUTER]IIOLDING
Replacemont,
so6psB2G9

GLAsSRUN
CHAiT{EL

r(D

a
(U

CEI{TERCHAI{]{EL
R6placomat,
sse pagp2Og

TXX)R
Adjustm,n,
s6epa2G11

-$

POWEAWNDOWMOTOR
LocK cYLr DR------&
Rophcemont,
sso p6gE2G5

*^r.r3:

ftto

CJfs t ba

OUTERH/\I{DLE
Rsplaceinent,
Ee6p.!B 2Gs

@RJ
o \

DETEiITROD

Adjuatmont,
s'6psfle n-12c

HIiIGE
PLASTICCOVER

I]U{ER HA DLE
ARMREATPOCKET

POWERDOOR
MIRRORSwlTCH

I I{ER HA DLE
TRIM PA EL

I'OOR PAI{EL
Rplacmnt,
s66 psc|e2G3

FOWERDOOR
LOCKSWTTCH
POWERWNDOW
swtTcH
SPEAKER
COVER

20-2
._-

CoverReplacement
DoorPanel/Plastic
Pry the cap, thon rmovethe scrow.
Removsth6 clips 8nd disconnoctth connectors,thon
remov6tha innerhandletrim oan8l.

NOTE;
to
Romovethe doorpanslwith aslittleb6nding8s possibl
or breakingit.
svoidcroasing

NOTE:
. Remove ths hook by slidingthe innsr hsndle trim
panel bsckward whil6 pulling the handle, then
ramoveths innerhandletrim panel.
. Tak6 care not to scrachthe innerhsndlotrim psnel'
N ENHA DLE
TRIMPA EL

12 hm

CLIP
REiIOVER
sltAPO
*a177

>: Clp bcttlon

HOOK

. 95 mm(3.74In)
|
-1
'\ l - - -

io-;;7;1''-L---tu

---frr * n l

Il{l{ERHANDLE

{o.oahl I l____l

, F

45 mm

irr.-F-

{1.77In}

5.

Rsmove the screws and clips bee clip tetnover)

attachingthg door pansl,
Rsmovethe door panslby pullingh upward.
Disconnoctthe oowsr door mitror awitch conn6ctor.

SCREW
> : Clp bc.tloru l9l
POWERDOOR
LOCKSW]TCH
CONiECTOR
POWERWtl{DOW
slvrTcH coi[{EcToR
DOORPAI{EL

\__ F{

Pry the c8p and ramovo the acrew, then rsmovo tha
armrst Docket.
SCREW

1".,,
F
l*"Yl
Pry th6 cap.

Pry tho cap.

SCREW

SCREW
POWEFTXX'F
MIRROFSWITCH

Pushher.

COT{NECTOR
(cont'd)

Doors
(cont'd)
GoverReplacement
DoorPanel/Plastic
4.

Remove th grommats, bracket and door lock unit,

thsn carefuly removethe plasticcover.

Apply sdhesivoalongthe edge where necessaryto

maintain8 continuousaealand DrsvsntwEtsr l6aks.

GROMMETS
GROMMETS

BRACKET

DOORLOCK
UMT

lnstallth6 door Daneland olastic covr in th revarae

ordel ol removal.
NOTE:
. Maka sure the door harnsssssand connoctors are
lastenedcorrsctly on the door.
(D: tlarno$ ctp locltloo!

. Before tighteningth6 door psnel mounting screwa,

mako sur6 tho door harnesaesare not pinchod,

.flEl-..

OuterHandleReplacement
NOTE:
Raisth glassfully.

Prv the lock cvlinderrod out, then removetho out6r

handle,

1. R6movs;
o Door panel(seepage2G3)
. Plasticcover (ses page2G4)

NOTE:
Takecarenot to bendthe lockcvlindrrod,

P66loff ths accesshol soal.

3 . Removs ths mounting bohs and clip, then pull the

outr handlsout.
CAUTION:
Uro protac{lve tapo lround tho outll
prevrnt damage.

handlo to

NOTE:
Do not drop th rnountingbohs 8nd clip insideth door.
OUTERHA]IDLE

PROTECTME
TAPE
MOUI{TING
BOLTS
6r1.Omm
5 N.m(0.5kem . 3.6 b-ft)
OUTER
HAI{DLE
6.

Pu[ out the ret8inerclip,then removethe lock cylinde].

LOCKCYLINDER
ROD

4.

Pry the outer hsndlerod out ot its ioint usingI flat tip
screwdriver.
CAUTIOI{:
Whon prylng whh a llat tip lcrawd vsr, wrap h whh
protctlvo tapo to pravont damlge,
L(rcKCYLII{DER
NOTE:
. To eas6 rosssembly,note the location @ of the
outer handlerod on the joint before disconnectingit.
. Tske ca.e not to damagethe joint.
7.

Installationis the reverseof the removalprocedure.

Doors
Latch Rephcement
Disconnectthe connector and harness clip from the
door, Removethe mountingscrews, then remove the
latch throughthe hole in the door.

NOTE:
R8iseths glassfu[y.
1.

Removs:
r Door panel(seepage2G3)
. Plasticcovor (seepage2G4)
. Center sssh (8page2G7)
. Outr handls{seepage2G5)

2.

Disconnoctthe inner handlerod and lock rod from the

inner handleand lock crank.
Rsmovethe scrsws, then removethe innerhandleand
lock crank,

NOTE;
Take care not to bendthe lods.
OUTERHAM'LE
ROD

NOTE:
Tak6 care not to bendthe rods.
FASTEI{ER

iloul{Tllrlc SCREWS
6 r 1 . Om m
5 N.m (0.5 kg-m ,

3,8 b-frl
HARNESSCLIP

4. lnstallation
is the reverseof the removalDrocedur.
NOTE:
Make sure the rods and connectorare fastend
correctly.

20-6

Replacement
Glass/Regulator
5.

Rmove:
. Door psnel(soepage2G3)
. Plasticcover (sse page2G4)

Csrefullypullthe 9l8ssout throughtheI window slot.

NOTE:
I door,
Take csre not to drop tho glassinsidethe

Lowr th glassf ully.

GUIDEPIf{

Peeloff the sssh guidecovsr and remove the gcrewa,

then .emove the centr sashguidfrom the door.

\ \ LI

GLASS

CEI'IIERSASHGUIDE

BOLTS
GLASSMOU]\ITI[{G
6r1.0mm
6 N'm10.6ks-m, 4.3 b-ftl
. Check th guide pin for damag, and replaco it
necssary.

SASH GUIDE
COVER
NOTE:
Whon inataling,
appv tho doublo-faced
adh$ivo tapo to the
sashguid6covor.

4,

NOTE:
s
th6 original
Sclib E line aroundth guide pin to show
location,
PIN
GUIDE

Caretulv movs the glasauntil you can 8oe th thss

mountingbolts,then looanthe glasamountingbohs.
Slidtho guidto the rear.then ramovtho glaaa.
R..r.ldo:

From aHa:

GUIDEPI

l___@.)l +

GUII'EPIN
MOU TI[{GBOLT
c[
6rl.0mm
3 N'm(0.3 ks.m, 2.2 lb-ft)

SEAL

{cont'd}

20-7

Doors
(cont'd)
Glass/Regulator
Replacement
P66lth glassrun channolout of the front chsnnel.
Rmove the mounting bolts, then remove the front
channol8nd center chsnnel.

BEGULATOB

NOTE:
After instslling,mak sur6 th ghss run chsnnolis not
twisted.
FROl{I
CHANNEL

MOU]TTING
BOI-TS
8r1,Omm
8 N.m(0.8ks<n, 5.8 b-ftI
Loosenthe bohs.

BOLLER

OLASSRUN
8x1.0mm
I N.m {O.8kg-m , 5.8 lb-ft)
q

MOUNTINGBOLTS
Sxl.Omm
I N.m (0.8 ko-m . 5.8 lb-ft)

Greaseall th6 slidingsurtaces oJ th6 regulatorwhere

snown.

1 0 . Before removingthe powar window motor, mark tho

MOU TII{G BOLTS
6r1.Omm
I N.m (0.9 ks-m ,6.5 lb-ft)

NOTE:
To install.fit the glassrunchannelintothe front andcsnter

location by scribingI line across th6 sctor gear and

rgulator.
Install using th6 motor mounting bohs. Move th
regulatorto tho originsl position by conecting I 12 V
battsry to tho power window motor {seos6ction 23).
SECTONGEAR

channlsas shown.
CEl{TER
CHA NEL

GLASS RUI{
CHANNEL

FROI{T
CHANNEL

NOTE:
Apply tho adhssivoto th6
shadowodar6s.

Removothe two mountingbolts, two rollrguidebolts

and loosn the two mounting bolts. Disconnect the
conector. Remove th regulator through the center
holein the door.
NOTE:
Scrib a line around the roller guide boh to show the
originsladjustment,
ROLLER
GUIDEBOLT

POWERwlI{DOW
MOTOR
l l . lnstEllEtion
is thg rovorss of ths removalorocsdurs.

12. Roll the glass up and down to so6 il it moves frsev

without binding. Also make sur that there is no
clearance between the glass 8nd glass run channol
when the glass is closed. Adjust the position of th6
glassas necesssry(seepage2Ol0).
Attach the door hsrness to th6 door correctly (see
psgs 2G4).
1 4 . When reinstallingthe plastic covr, apply adhesive
8long the edge wh6r6 noccssary to msintain a
continuousssal and prevsnt watsr lgaks{seepag2G
4t.

20-8
{'!ficarfr-

OuterMoldingReplacsmont

WeatherstripsReplacement

Remove;
. Door pansl(s66pass 2O3l
. Plasticcover (ss page2G4)
. Door mirror (seepagea,Aj-.lA
. Glass(se6pase2G7)

> : Clp bc.rlon

> : Clp locrilon.

WEAY}ERSTRIP

WEATHERSTRIP

cLtP16l

NOTE:
Takecarenot to twist or scratchthe outsrmoHing.

rnside f

MOLDIG
OUTER
Staningst tho reEr,prythe outormoHingup .rd
detachthe clps.thon.6movotho out6rmolding.
CI.ASsRUl{CHA EL

lnstsllationis the reversaof ths removalprocodure.

NOTE:
. ll nsces,sary,rsplscs any dsmagodclips.
. When instslling,slign ths r88r dgs of tho outsr
moldingwith the resr edgoof the door,

WEATHERSTRIPS
NOTE:
. Before instEllingth6 w68th6rstrip, sppv cle8r s68l8ntto
ths @ arasof th door as shown.
e lf necessary,replac6any damagdclips.
S!.hm: Comcdlnc # 85OO

20-9

Doors
GlassAdjustment
NOTE:
. Placsthe vshiclo on I tirm, lval surtsco when sdiusting
tha dass.
. Check th6 weathorstrip 8nd glEss run channel for
dsnrsgaor doteriorstion8nd rpl8ceil nsccoasary.

Maks surs tho glassgoss up anddown smoothv.

6. lf ncsssaly, sdjust the front channgl and c6ntor

channel,

1. R6movsth6 door p8nl8ndps6loff the plasticcovsr

(sa6pagss2G3,4).
2.

Conn6ct th powor window switch connoctor to the

door harna9aconngctor.

3.

Loosenth rollor guide bolts and sdju$ the glassso h

is p8rall6lwith ths glassrun chann6l.

FROIIITCHAiTIEL

NOTE:
Mak6 sure the guid6pin i9 in ths centst sashguide.

CE]|TERCXAiT{EL

GUE'EPIl{
7.

Rsisath giasstully snd check for g6ps.

OLASS RUl{ CHAi'IEL

WEAT}fRSTN|P

S"\
ROLLER
GUDEAOLTS
Loos6n,

R8issth glassas far up 8s possiblaEndhold it sgainst

th gbss run chann|,
Thon tbhten the rollerguid6bolts.

& Chockgbssoporstion,
NOTE:
Chockthst tho ghss contactsthe ghss run channel
evsnlv.

20-10
'F1rfrtryl-.

PositionAdjustment
9. Checklor watorl6aks.
NOTE:
water.
Donot usshighprossure

NOTE:
Place the vehicle on I tirm, level surface when adiustine
the doors.
Aft6r instsllingthe door, check tor a flush fh with the body,
thgn check for equalgapsbstween the front and rear, and
top 8nd bottom door edgssand the body,
Th door and body edgesshouldalso b p8rall8l,Adjust 8t
the hings8s shown.
GAUTION:
Plec6a shop towol on tho ieck to prevent damagoto lho
door whcn the mountig bohs are bosend for adiuttmem.
DOONMOUI{TINGBOLTS
I x 1.25mm
30 N'm(3.0 lg-m , 22 lb-ft)
Loosonthe door moumingbohs slkthtv to
movotho door lN or OUT until it's tlush
youcaninstall
with tho body.tf nocoasry,
a shim bhindoo hingEto m6k6the doo.
whh tho body,
odgssPARALLEL

y"i-6,

1 0 . Routg the door harnossssand connectors and faston

them to ths door (ss6 pag82G4).

1 1 . Attsch ths plastic cover, rhen install the door p8n6l

(soepEgss2G3.4),

HINGE
Low6r the gla8s.

HINGEMOUNTII'IG
BOLTS
8 x 1.25mm
30 N.ml3.Oks-m. 22 lb-ft)
Loos6n th hing mounting
bohs, 6nd move tho door
BACKWARDor FORWARD.
UP or DOWNos n6cossaryto
eqraliz6
th gaps.

SHOP TOWEL
Tho door and body 6dg6sshouHb6 pralle..

NOTE:
Chsckfor waterleaks.

20-',1

Mirrors

Doors
Striker Adjustment

PowerDoorMirrorReplacement

Make su.e the door latchessecurelywithout slsmming.

lf it needs adjustment:

1 . Pry out the covr panol with I flat tip scrswdrivor,

then removethe covGrpanel.
Disconnectthe connector.

1.

Drawa linearoudthe strikertor reference.

2.

Loosenthe mountingscrews and move the striker lN

or OUT to make the latch fit tighter or looser. Move
the striker UP or DOWN to align it with the latch
opening,Then lightlytighten the mountingscrews and
recheck.

2. Rernovethe mounting scrows while holdingtho door

mirror.

DOORMIRROR

STRIKER

MOUrrnG SCReWS
I x I.25mm
1 8 N.m {1.8 kg-m .
1 3 b-ft)

COVER PAI{EL

Installationis the reversof ths removalprocedure.

4.

Checkfor water leaks.

NOTE:
Do not use high pressurwat6r.

NOTE:
. Holdthe outer handleout and push the door against
the body to be sure the striker allowsa tlush Jit.
. Do not tap the striker with a metal hammer to
adiustthe position.
lf the door lstches properly, tighten the mounting
screwsandrecheck.
NOTE:
Rplacethe strikor it it is cracked.

20-12

Mirror HolderRoplacement
1,

Pry the mirror hoher from the bottom until you can
seethe actuator,thn detachth hooks usinga flat tip
screwdrivras shown.

RearviewMirrorReplacement
1.

Carstullyremoveths cover with a flat tip screwdrivr.

2.

Loosen the lock boh, then slide the mirror stay from
th lug.

NOTE:
Tak6 care not to scratchth mirror housing.
ADIfSIVE TAPE

REARVIEW
MIRROR

ffirSr

MIRRORSTAY

FJ

COVER
ACTUATOR

Removethe lock boft, thn rmove th toothed lock

washsr 8nd hoH springfrom the mirror stay.

Disconnectthe hooks and connector,then removth

mirror hoHer from the actuator.

ACTUATOR
LOCKBOLT
Loft-h6nd th16ads

TOOTHED
LOCKWASHEN
HOLDSPRING

-ld
.:I;)

HOOKPLATE

,"i
MIRRORSTAY

MIRRORHOLI'ER

3.

Installationis the reverseof ths rsmovalprocedure.

4.

lnstallationis the revarseof the .ernovalDrocedure.

20-13

Windshield,RearWindow, O,uarterGlass
lndex
( ):Ouanthyof part usd.

(1)
FASTE]TER
CENTER
(Clip-typ)

ffndd{dd:

I2I
UPPERFASTENER
(Clip-typ)
CORNEBCLIP{2}

cLrP{6)
(8I
RETANER

WINDSHIELD
s66p8g2G'15
Removsl,
s66pago2G16
Instolltion,

DAMS
RUBBER

(2}
FASTEiIER
UPPER
(solf-adhosive.typo)

FASTEER(1}
CENTER
(Solf-adh68iv6-tYP6)

GLASS
BRACKET12}

--=-Tr"-;;

MOLDIMi

R.ar Wlndow:

RUBBER
DAMS
REARWINDOW
Romovsl,roo pag62O2O
Instslldtion,sopag62G21

Ouortor GLrr:

\*r
I

OUARTERGLASS
Romovsl,soe p8g2G25
Installation,soe pagE2G25

20-14

DAM
nuesen

q.
\

SV-p\
s

\
\

BRACKET{2)
GLAss'
GLASS

\
LOWERMOLDtitG

MOLDII{G HOLOER(7)

Windshield
Removal
CAUTION:
. Woar glov63to remove and Instal the windlhiald.
. Use aeat covols to avoid damagingany surfaces.
1.

2.

To removethe windshield,first removethe:

r Rearviewmirror (seepsge2G13)
. Sunvlsors(seepage2G36)
. Front pillartrim (seepage2G37)
. Front wipers snd air scoop {seesection 23)

4.

CAUTION:
Take caro not to bond the h6adln6r oxcosrivev.
5.

Remove the other retainers and Jastnersfrom the

body.

6,

Apply p.otctiva tape alongthe edgoof the dashboard

and body as shown.
Usingan awl, mske a holethroughthe rubberdam and
sdhesive from inside the car. Push the oiano wire
throught the hole and wrap each end aroundI pieceof
wood.
PROTECTIVE
TAPE

Detach the clips from the retainers,then remove the

side sectionof the windshieldmoldingas shown.
NOTE:
lf necessary,replsce8ny dsmagedclips.

3,

Pulldown the front ot the front headlinr(seepsgG

2G36).

Peeloff the upper section ol the windshieHrnolding.

NOTE:
Wh6n the upper section of the windshield molding
removalis difficutt, cut oll the windshieldmolding.

WINDSHIELD
MOLDING

WINDSHIELD
MOLDING

l\..n'

\)v/

@Y

TAPE
PROTECTIVE

CORNERCLIP

7.

With helpe. on the outside, pull the piano wire back

and forth in a sawing motion and careJullycut through
the adhesive around the entire windshield, then
carefullyremovethe windshield.
CAUTION:
HoH tho plano wlre as closo to tho wlndshioH as
possiblo to pr6vent damago to tho body 8nd
dashboard.
PI,ANOWIRE

/Zh ;Erl
(

WINOSHIELD

/ / '
RETAINER
GLASSBRACKET

NOTE:
It necessary,
removethe screw,thenreplacethe ghss
bracket.

20-15

Windshield
lnstallation
1.

Scrape the old sdhssiv smooth with a knile, to I

thicknsss of sbout 2 mm (0.O8 in) on tho bonding
surlaca aroundthe entir windshieHoponingtlangs.
NOTE;
. Do not scrape down to the p8intsd surface of the
body; damsged psint will interfere with prop8r
bonding.
. Remove the rubber dsm and fsstners from the
bodv.
o Mask of{ surroundingsurfacesbstore p8inting.

2.

4.

Glue the rubber dams to the inside faca of th

windshieldas shown, to contain the sdhssiv durim
installation,
NOTE;
Be careful not to touch th windshieldwhsro adhssivg
willbe aeplied.
65 mm
326.5 mm
12.56In) {12.a5In}

RUEBER
DAMS

95 mm(3.74hl

Clean tho body bonding surfscs with a sponge

damDenedin slcohol.
9mm
10.35Inl

NOTE:
After cleaning,keep oil, greaseor water from gatting
on the sulfaca.
3.

]f ths old windshieH is to be reinstslled,use I putty

knife to scraDs off all trscss of oH 8dhesiv8, thon
clean the wlndshisldsurfac with slcohol wh6re new
sdhesiveis to be appliad.
NOTE:
Mak sure the bondingsutfecs ia kept 1166ot watsr,
oilandgre8se.

WIiDSHIELD

CAUTION:
Avoid stilng tho wlrdshl.H on h3 edlps; tmd.filpE
may hsr dovobp Into clrckt.
NOTE:
Cleanthe shadowed8reE.

WI DSHIELD

5.

Glu6the csntor and uppr fastsnrs to the insidetaco

ol tho windshislJas shown,
326.5mm
66 mm
(2.56Inl h2.85 Inl
I,,PPR
FASTEiER
(2)

95 mm 13.74lnl

CE TER
FASTET{ER

WhIDSHELD

WINDSHIELD

FASTEI{ERS

WINDSHIELD

20-16

With 8 sponge, apply a light coat of glass primer

around the edge of the windshield as shown, then
lightlywipe it off with gauzeor cheesecloth.

6, Inst8llthe glEssbrackets,retainersand fastenersto

the bodyasshown,
NOTE:
Donottightenthe glassbracketmountingsclews.

NOTE:
. Do not apply body primer to the windshield,and do
not get body and glassprimerspongesmixed up.
. Nevertouch the primedsurfaceswith your hands.lf
vou do, the adhesive may not bond to the
windshield properly, causing a leak atter the
windshieldis installed.
. Keepwster, dust. and abrasivematerislsaway from
the primedsurface.

FASTENER

l;-\
I

lfiftm?

L\_r=

\_.:

/////f

UPPERFASTE ER

: Agply slast$lmd

CENITER
FASTENER{1}

CENTER
FASTEI{ER

h6ro.

I mm 10.35in)

326.5mm
11285Inl

RUBEERDAM

WINDSHIELD

UPPERFASTENER

RETAII{ER
{8I
(2}
GLASSBBACKET
WINDSHIELD

7.

Set the windshieldupright on the glassbrackets,then

center it in the windshieH opening. Mske slignment
marks across the windshieldand body with I grease
Dncilat the four points shown.
11 mm 10.43Inl
ALIGNMENTMARKS

9.

With a sponge,apply a light coat of body p.imer to tho

origin8l adhesive remaining around the windshield
openingflsnge. Th windshieldshould be installed10
minutesafter you applythe body primer,
NOTE:
. Do not appv glass primer to the body. and be
carefulnotto mix up glssandbody primersponges.
. Nevertouch the primedsurfaceswlth your hands.
. Mask off the dashboardbefore paintingthe flange.
'//Z

I Apd,t bod,t Nlmor horo.

WII{DSHIELD
30 mm ('1.18inl

WINDSHIELD
GLASS BRACKETS

NOTE:
until
Adjust th6 glsss brackts
'l
th6ro is 6 sap ol 1 mm (0.4 in)
botwesn ths uppgr sdge ot the
windshieh snd the ladingedgs of
th rool, th6n tightn the
mountingsct6ws.

(conl d\

20-17

Windshield
lnstallation(cont'd)
1 0 . Thoroughv mix the adhssiveand hardenartogether on
a glassor rnetalplatewhh a putty knife.

NOTE:
. Clesn 8 glass or metal plate with a sponge and
slcoholbefore mixing.
. Folow the instructionsthat come with the adhesive.
1 1 . Before filling a carttidge,cut the nd ot the nozzlas
shown.

13. Uso suction cup8 to hold tho windshiold over tho

opening,alignh with the slignrnontmarks madin stsp
7 and sst it down on the sdhssive.LightlYpush on th
windshiHuntil h8 edg6is fullv seatedon the sdhosiv6
sllths wav around.
NOTE:
. Do not closs or opgntho doors until adhesivois dry.
. Mako surothe fastonela are fastensd correctlY.
WII{DSHELD

cut nozzleend

ALIG MEiT il|ARK8

10 mm (0.39ln}

7 mm10.27In)

12. Pack adhssiveinto the cartridg without air pockots

to ensure continuous delivery' Put the csnridge in a
calking gun and run a bead of adhesivo around the
edgeof the windshieldas shown.

NOTE:
AppW the sdhesivewithin 30 minutes alter sppving
the glassplimer.

2 mm (o.OgInl

-Tr

Make s slghtly thickor bo.d

at 6ach cornr d uppr.

Fffi,I\:AD}IESNE
t

8mm
10.31in)

lmm
Emm
(o.31 lnl (0.04

'l
CET{TER
FASTEIIER

RUBBER
OAM
WI DSHELD

WII{DSHIELD

20-18

At +cslvE

14. Installtho clips on tho windshioldmolding.

Scrape or wips ths 6xc63s 8dh68iveoff whh a putty

knife or tow6l,
NOTE:
To r6mov6 adhssivs from I Daintedsurface or the
windshieH, wipo with 8 solt shop towel damp6nd
whh alcohol.

1 6 . Installth6 windshioHmoHing.
NOTE:
. Wh6n instslling,make surs th6ra aro no twists in the
molding.
. Install th windshield molding by starting Et th6
upper corn9r.
. Gluethe upper soction with the Edh83iv8.

> : Clp, r.l!h.r

1 7 . Let ths adh6siv6dry for 8t l68st one hour, than sprsy

watr over the windshisH and ch6ck for laks,Mark
loakingErsassnd l6t th6 windshielddry, then sesl with
saalant.
NOTE:
. Lot th car stand for at last four hours aftsr
windshisH install6iton,ll th6 c81 h8s to bs ussd
within th first four hours,it muat b6 drivn slowly.
. K66p ths windshiH dry for th6 first hour sttol
installstion.
. check rhst the snds ol tho windshieldmoHing are
sat underths air scoop.
1 8 . Reassembls8ll r6mov6dp8rts.
NOTE:
lnstallth6 r6srvi6w mirror after the adh6siv6has dri6d
throughly.

bcltlonr

WIl{DSHIELD e
- WINDS]iELD
MOLDIT{G
MOLDIT{G

\k

<'.fr

#
4

R ETAIT{ER
{4}

I
cLrP(31

20-19

RearWindow
Removal
cAuTto :

4.

. War llovaa !o lamovo rnd ln3td thc loal wlndow.

. Do not drmrgc tho dctrortcr grld lnos.
1.

2.

To rorbvo the rsar window, first romove:

. Trunk lid (seepage2G64)
o Rearshelf (seepage2G37)
. Resr pillartrim panel{seepags2G37)

NOTE:
o When th6 rosr window moldingremovslis difficuh,
cut the 168rwindow mold:ngwhh 8 knife.
. lf ngcossary,remov6the screw, th6n replacetho
glas.sbrsckets'

REARwlMrcW

Disconnoct ths dofrosler l8ads, and rmove thil

holdars.
NOTE:
Avoid scrstching the r8r window whh ths cutter
blade.

3.

Peeloff th6 roar window molding.

Remove the moldinghoHers, thon rorrove the lowel

molding.

REARWINDOW
MOLDIIIG

l^ 1"7'*

(W
"-\-

I ,L

ADHESIVE

Ronrovoth6 r6ar hosdlinerls6o p8g2G36).

CAUTIO :
Td(. cr?c not io b.nd thc h3l

ml .rcosllvclY'

Apply protectiv8 tap6 to slom the odgeof ths bodYas

shown.
Usim En awl, mak a holethrough the rubbr d8m and
adh6siv6from insidothe car. Push pisno wira thlough
tha hole Endwrsp each and s;ound a pi6coof wood.

V*

Moldng hoHot rcmovel:

1) Removeor loo8snthe screw.
a

3)

Plscothe screw in tho screw

grommst agEinldo not screw
it in) and Drsssit down.
Pull the screw with th8
molding hoHer o|'n of tns
bodY.

HAM)WNE

Affi***S\ts,ro.or*

'

\r

HoLDER

10 ,,.,

,R{s

riigEb--

lnstallation
With a helpl on ths outside, pullthe piano wire back
8nd torth in a sawing motion Endcarefullycut through
the adhesivesroundthe ontire rear window.

Scrape the oH adhesiv smooth whh s knil6, to !

thickness of about 2 mm (0.08 in) on the bondim
surfsc aroundthe ntir rear window oponingfhnga.

CAUTION:
Hold the pl8no who ar dolo to tho rlar wlndow ss
posslbb to provc damagoto tha body.

NOTE:
. Do not scrape down to the painted sur{ace of tho
body; dsmased paint will intsriers whh proper
bonding.
. Remove the rubbsr dam and fastenars from the
body.
. Mask otf surrounding surfaces before applying
orimer.

PIANOWIRE

REARWINDOW

Clean the body bonding surfacs with a aponge

damponedin alcohol.
NOTE:
After clesning.keep oil, greaseor wat6r from gEtting
on th6 surface.
It the old rear window is to bs rsinstallsd,use I putty
knile to scrape oft all tracs of oH adhesive,thn
clgan the resr window aurtaca with alcohol whsre
new adhesivis to be appli6d.
NOTE:
Make sure the bondingsurface is kept fre of wst6r,
oil andgrssse.
CAUTION:
Avold sottlng the resr wlndow on h3 edgas; smal
chip may h
davalopinio cracks.
8.

Carefullvremovoths rsar window.

NOTE:
Cleanthe shsdowedarss.

REARWI DOW

(cont'd)

20-21

RearWindow
(cont'd)
Installation
4.

Gbo rha rubber dams to the inside lsce of ths roar

window as ahown, to contain th adhssive during
instalrtion.

6. Installthglassbracktsandfastenrsto the body8s

snown,
NOTE:
Donot tightenthe glsssbrscketmounting8crews.

NOTE:
Bs careful not to touch the roar window whra
sdh6sivewill b6 sDolid.

REABWINDOW

Glu6th side and uppar tastenersto the insid6fsce oJ

r6ar window as shown.

GLA88BRACKETS
{2}
FAETENER
BUBBER
DAM

7.

ALIGNMENTMARKS
UPPERFASTEI{ER(2}

DAM
RUBBER

Set the rear window upright on the ghss brsckots,

than centr it in the opening.Make alignrnontmarks
acroaathe roar window 8nd body with E greasepncil
at the tour ooints shown.
ALIGNMEIfTMARKS

10 lnm (039 Inl

Nft

. - I

FASTENER
{4)

SIDEFASTENER(2}

REARWII{DOW

20-22

NOTE:
Adiustths brscktsto centerthe rsar windowin the
screws.
thentightenth mounting
opening,

With a spongo, apply a light coat ot glass primer

around the edge of the rear window as shown, then
lightlywipe it off with gauzeor cheesecloth.

8.

NOTE:
. Do not apply body primer to the rear window, and
do not get body andglassprimerspongesmixed up.
. Nevertouch the primedsurfaceswith your hands.lf
you do, the adhesive may not bond to the r6ar
wlndow properly, causing a leak after the rear
window is instslled.
. Keep w8ter, dust, and abrasivematerialsaway trom
the primedsurface.
'////z

1 0 . Thoroughlymix the 8dhesiveand hardenertogother on

a glass or mtal plate with a putty knife. Follow th8
instructionsthst came with the adhesive.
NOTE:
CleanI glassor metal plste with s spongeand alcohol
before mixing.
1 1 . Before filling I cartridge,cut the end of the nozzleas
snown,

Cut nozzle end

as snown.
mm {0.39 In)

t apply snrt wl^", hcr..

9 mm(0.35inl

LJ

I
f-l

I
|

Ndffi-/
IDAM
RUBEER

GLAss

7 mm(O,27In)

,/

12. Pack adhesiveinto the csrtridge without 8i. pockets

to ansure continuous delivery. Put the canridge in a
calking gun and run a bead of adhesive around the
edgeof the rear window as shown.
NOTE:
Apply the sdhesive within 30 minutes after applying
ths glassprimr.

9 . With a sponoe,apply a light coat oJ body primer to the

original adhesive remalningaround the rear window
openingflange.The rear window shouldbe installed1O
minutessfter you appV the body primer.
NOTE:
. Do not apply glass primer to the body, snd be
carefulnot to mix up glassand body primersponges.
. Nevertouch the primedsurtaceswith you. hands.
/////t

; Appiv body pdmor horo.

tG mm 10.63lnl

20 mm
{0.79 in}

2 mm10.08in)
Mak I slightly thicksr
corner

.'f.ffi,T\

bead at each
:ADHESIVE
ano upp9r,

8mm
(0.31 In)

UPPER
FASTEI{ER

8mm
1031 In)

7.4 mm{o.29in}
ADHESIVE

RUAEEBDAM

(cont'd\

20-23

RearWindow
Installation(cont'd)
13. Us suction cups to hold the reat window over the
it with the alignmentmarks madein step
oponing,align
7 and st it down on the adhesiv.Lighttypush on the
raar window until its edges are fully sested on the
sdhosiveallthewaV around.

16, Installthe moldingholderon the lowr molding.

NOTE:
I Do not closeor open the doots until adhesiveis dry.
. Mske sure the fastenersare Jastenedcorrectly'
REAR

ALIGNMENTMARKS

wtt{oow

CUPS
1 4 . Scrapeor wipe excess adhesiveotf with a puttY knile
or tow|.
NOTE:
To removeadhesivefrom I paintedsurfsce or the rear
window, use a sott shop toweldampsnedwith alcohol'
ta.

lnstsllthe rear window molding.

NOTE:
. When installing,make sure thsre are no twists in the
rear window molding.
. First instaltthe upper section, thn install the each
side.
. Gluethe upper sectionwith the adhesive'

1 7 . lnstsll the lower moHing, then tighten the mounting

screws,

l1

REARWII{DOW
MOLDNI{G
18. Let th adhosivedry for at lesst one hour, then sprsy
wate. ovst the tear window 8nd check for leaks Mrk
l8king areas and let the rear window dry, than seal
with s68l8nt.
NOTE:
Let the csr stsnd for 8t least fout houts after lar
;indow installation ff the cat has to be used whhin
the first four hours,it must be driven slowv
19. Rssssomble8ll removedParts.

20-24

OuarterGlass
Removal

lnstallation

CAUTION:
. Woar 9bv63 to lomovo and In3ial th gbar.
. U3osoat covors to lvold damaglngany aurlecor.

l.

NOTE:
. Do not scrape down to the painted surface of th
body; damagod paint will interfero whh proper
bonding.
. Msk ofJ surrounding surtacas before applying
onmar.

NOTE:
Replacethe qu8rterglasswith new one when removingit.
1.

To rrnovethe quartergl8ss,first removeth6:

. Rearpillartrim panllsoe pago2G37)
. Ousrter t.im (s6epage2G37)
. Ousrter trim panellsee pag2G37)
2.

UseI knite to cut thloughth Edhssivefrom inside

thoc8r,allthewayaround.

Clean ths body bonding surtace with a sponge

dampsnedin alcohol.
NOTE:
After cleantng,keep oil, greaseor water from gatting
on the surface,

NOTE:
Takcarenotto damage
the quarte,grassandbody,
OUARTERGLASAMOLDI G

Scrape the old adhosive smooth with a knife, to s

thicknoss ot about 2 mm (O.O8in) on the bonding
aurfacearoundthe entire quarterglassopeningflango.

3.

Clean the new quarter glass surface with slcohol

where adhesiveis to be applied.
Make sure the bondingsurtace is kept free of watr,
oilandgrease.

CLIP

it /
Clan tho shadowd sr6s all
the way around.

3.

Removethe qus.ter glass.

20-25

OuarterGlass
lnstallation(cont'd)
',

with E spong3, sppv a light coat of glass prirnr to the

insilo tEco ot tho qusrtsr glass 8s shown, then lightly
wipe it off with gauzeor chaesecbth'
NOTE:
. Do mt sppv body prinrel to ths quarter ghss, and
do not gpt body 8nd glass primer sponga mixed up.
. l{ovr touch ths primodsurtacoswith your hsnds.ll
you do, the adhesivsmay not bond to the quErter
glssproperly,causinga leak sfter ths quartsr glas
is instsllod.
. Kegp w8ter, dust, and sbrasivomsteriab away from
the Drimedsurfaco.

r'///////, : Af,y fit

5.

With a sponge,apply 8 light coat oI bodv primerto the

o.iginal adhesive remainingaround the quarter 91888
openingfl8nge.Ths quarter glassshouldbe installed10
minutesafter you spply the bodYprimr.
NOTE:
. Oo not apply glass primer to the body, and be
careful not to mix up glsss8nd body primersponges.
. Nevertouch the primedsurfaceswith your hands'

'/f

; Applybody prlmethte'
38 mm {1.49In}

stmr hen.

11 |fxn
lo4:l hl

38 mm (1.49In)

OUARTEBGTASA
6.

Throughv mix the adhesiveand hardenertogether on

a gbss or metal plste with I puttY knife.
NOTE:
o Clean a glass or metsl plate with a sponge and
alcoholbefore mixing.
. Folbw the instructionsthat came with the adhesive.

7.

Befor6 tiling a cartridge,cut the end ot the nozzle8s

shown.
cut nozzb end
63 gttown.

10 lnm (0.39Inl

7 mm {0.27 In}

20-26

8.

Pack adhesiveinto the cartridge without air pockets

to ensure continuous delivery. Put th cartridge in a
calking gun and run a bead of adhssive around the
edgs of the quarterglassas shown.
NOTE:
Apply the adhesivewhhin 30 minutes after applying
the glassprimer,

9.

Use suction cups to hold the quarter glsss over tt|

opening,alignit with the clip setting points and st it
down on the adheisive,Lightly push on the quaner
glassuntil its edgesare fully seatedon the adhesivea[
the way around.
NOTE:
Do not oDen or close the doors until the adhosivois
drv.
CLIP

2 mm (0,08Inl

-Tr

13 mm
{O.51Inl

n:ADHEsrvE

Msk a slghtv thicker

boadat 6ach coln6r.

8mm
{0.31 Inl

H
fz_)

6 mm (O23 In)

i i ,L=_** r_ - _

SUCTK)N
CUPS

CLIP

1 0 . Scrspe or wipe the excess adhesiveoff wlth a putty

knifeor towel,
NOTE:
Use a soft shoD towel damDenedwith alcohol to
remove adhesive from a painted surlace or quaner
gEss.
OUARTERGLASSMOLDI G

1 1 . After the adhesive is dry, spray water over the

quarter glassand check for leaks. Mark leakingareas
and let the quaner glassdry, then sealwith sealant.
NOTE:
Let the car stand for at least four hours after ouarter
glassinstallation.It the car has to be used within the
first four hours,it must be driven slowly.
removedparts.
allremaining
12. Reinstall

20-27

Sunroof
lndex

SUNROOFPANEL
Adiustmont, s6e paE2G29
Rsplacmofi,seepagpan31

SUI'IROOFSEAL
REARSEAL HOLDER

FRONTSEAL HOLDER

SIDESEALTOLDER
SUNROOFLINER
Roplacemont.s6e pag20.30

CABLEASSEMBLY
OUTER
sse pag2G33
Rsplscomnt.
MOTOR
Repl6coment, se p6g6 2G32

PANELBBACKET

",,,or --#

.^*--,^,e
]
ttottt*

llniRt

b'=-n*o""r,

on",.o"

,*ER--& Y^*J"\

REARDRAIN
CHAI{NEL

ggygtr-4

FROTTDRAIN
CHANNEL
FAONT
STOPPER
FRAMESEAL

REARDRAII{TUBE

FRAiIE
Roplacamont, soe psB2G32

20-24
dtrr..-.

Troubleshooting

ProbablaCauso

Symptom
Water leaks

1 . Cloggeddraintube.
GapbetweensunroofsealandrooJpanel.
J . Defectiveor improperlyinstalledsunroof seal.
4 . GaDbetwan frame sealandroof Danel,

Wind noise

1. ExcessivecleSrancebetwaen sunroof sealand roof Danel,

Motor noise

1, Loosemotor.
2. Worn gearor besring.
3. Outer cabledeformed,

Sunroof Danal does not move, but

motor turns

1 . Clutch out of adjustment.

Sunroof Danel dos not move and

motor does not turn lsunroof panel
can be moved with sunroot wrench)

Foreignmatter stuck btwoen guiderailand slider,

a lnnercableloos.
4. Outer cablenot attached properly.

1.
2.
3.
4.
5.

Blowntuse.
Fauhyswitch.
Battery run down,
Dtective motor,
Fsulty relay.

Sunroof PanelHeight Adjustment

Boot panel should be even with the sunroof seal to
within 1.9 t 0.5 mm (0.o7 + 0.02 in) 8ll the w8y
around.lf not, tih the sunloot panelfully,and:

ROOFpA EL

1.9t o.5mm
{0.07t O.02Inl

SUNROOFSEAL

SHIMS
PANELBRACKET

1.

Removeths sunroof liner (seepage2G3O).

Loosen the sunroof panel mounting nuts and
instsll shims between sunroof panel and panel
bracket as shown.
1.O mm (O.O4in)
Shlm thlcknos!:
Adlustmont: max. 2.0 mm (0.O8in)
Repeaton oppositesids if necessary.

20-29

Sunroof
RearEdgeClosingAdjustment
ODenthe sunroof Danslabout a foot, then closeit to check
where rear edgbeginsto rise. lf it risestoo soon and sats
too tightty agEinstthe roof panel.or too late and does not
sest tithtv enough,adjust it.
1.
2.

SunroofLinerandSunroofPanelReplacement
l.

Removethe front of the root trim.

Align the locstion @ position ot tho fram6 to the
mountingscrew.

Remove the sunroof liner, then remove the sunroof

panel.

sut{RooF

MOUI{TINGSCREW

LINER

Chock that the position ot the litter is the same on

eachside.
NOTE:
It the position difters from sids to side, remove tha
motor (seepage2G32),then adjustthe positionof the
lifter on each side.

3.

Loosenthe mountingscrews. Align the panelbracket

to the same positionon each side.
l.

Removsthe mountingscrews 8nd clips. then slideths

sunroot linerslightlytorward.
NOTE:
Take care not to scratchtho sunroof liner.

> | CIp bcltlott!

AU ROOF
LINER

lnstall the sunrool panel. ClosBthe sunroot panol, then

check the alignment between the rool panel and
sunroot panel.
NOTE:
Adjust the sunrool panel right 8nd lft bY using the
oanelbracket mountingholes
With the sunroof panel closed fully, check for water
leaks.

4.

Slidethe sunroof linerbackward,thn romovoit'

SU ROOFPAI{EL

NOTE:
Do not use high Pressurawater.

SUNROOFLINER

20-30

Sunroof SealRepair
5. Rsmovethe mountingnutsfromthe panelbrackatson
bothsides,thenrernovethe sunroofpanelby liftingup.
NOTE:
the roof panel.
Donot damage

ff a sunroof sealis leaking,or if it is to be replaced,proceod

as follows:
1.

Removethe sunroof liner (seepage2G30).

2.

Removethe sunroof panel.

3.

Removethe sealholder,Carefullypeelthesealoff the

sunroof panel.

SUNROOF
PANEL

SUNROOF
SEAL

> : Scrow,nut locttlon!

r ' 9
c

t, 6
c,A

SU R(X)F SEAL

I N'm (0.9 ksFm,6.5 h-tt)

Fillwirh adhesive.
o.

lnstallationis the reverseof the removalprocedure.

NOTE;
. Before installingthe sunroof liner,close the sunrool
panel fully, then check fo. closing slignment, lf
necessary,adjust the sunroot panel alignment{see
page2G3Ol.
o When instllingthe sunroof linar, make sure the
sunroot liner is fastned correctly with the clips and
holder.

PANEL
SUNROOF
4.

NOTE:
After cleaning,keep oil, greaseor wster from getting
on the surface.
5.

Fill the sunroot seal groove with adhesive.Coat the

sunroof seal attching surfaces of the sunrool panel
with the sam adhesive.

6.

Fit the sunroot seal onto the sunrool panel evenly all
the way around.

7.

Wlpe off excess sdhesive with a clean cloth

dampenedwith alcohol.

8.

Allow the sdhesiveto cure tor st leastfour hours atter

sunroot seal installation 8nd before operating the
sunroof panel.

9.

Checkfor water leaks.

Check tor water leaks.

NOTE:
Do not us highpressurwater,

Cleanthe sunroof sealattachingsurfaceswith a clean

cloth dampenedin alcohol.

NOTE:
Do not use highpressurewater.

20-31

Sunroof
Motor, DrainTube, and Flame Replacement
cAuTto :
Be c'rfirl

]pl to damagoth soats or oth6l intorlor trim.

1.

Rornovethe headliner(seepage2G36).

2.

Disconnectthe motor connector;removathe clips securingthe ceilinglight wire harness'

NOTE:
When removingthe motor, removethe two mountingbohs andthree nuts.

3.

Removethe sunroolpanel(seepage2G31).

4.

Disconnectthe draintubes.

5.

Removethe 10 mountingbolts and rear hooks,then removethe frame from the car'
NOTE:
You mav requireassistancewhen removingthe lrame.
DRAhITUBE
To instsl,sid6ths drsintubs ovorth
trsrnsnozzlst loast10 mm (0.4in).
DRAI TUBE

GUIDEPIiI

REART()OK (2}

FRAMCSEAL

I x 1.On||n
10 N'm (1o kgFm.
7 b-ft)

NOTE:

lf you n6ed to remov6 a drain

tubo, tie a string to th6 ond ot
it so h can bs roinstalld.
REARDRAINTUBE

\g
/-:\

FRAME

MOTOR
M6ko su.o th lft6.s 6re
pal.l6l when instarng th6
motor.

@
FRONTDRAINTUBE

To install,insrt ths Jrama'sfear hooks into th body hols,then installparts in the reverseorder of removal.
NOTE:
. Installrhe tube clips with the 6ndsfacingto the sideto esse instsllstionof the headliner.
. Cleanthe surfaceol frame.
. Checkthe frame seal.
. Check tor wster leaks.

20-32

Lifter and Guide

Panel
Stay/Slider
v.etrv
errvr
RailsReplacement
r

1.

Rsmovothe frame (seepage2G32).

2.

Removethe front drainchannel,

Removsthe motor (page2G32).

o.

6r1,Omm
10 N.m(t.Oks-m,7 lb-ft)

Remove the mounting screws @, then remove the

guide rail. Remove the mounting screw @, then
removthe outer cableassemblv.
NOTE:
Tske care not to bendthe cableDiDos.

GROMMET
NOTE;
MOUiITING
SCREW

To install,fill the groove in 6ach

grommotwhh seahnt,
CABLE
PIPE

FROI{TDRAIN
CHANNEL
PANEL
STAY

OUTER
CABLE
ASSEMSLY

GUIDERAII.
Slide the p8n6l stay backwsrd, than remove it from
the guiderail.

Romovethe rear drainchannel.

8.

Romovethe resr railholder.

Remove the liftr Jrom the inner cable end, then

separats the panel stsy, lifter, slide stoppet link 8nd
slider.
NOTE:
To install,apply muhi-purposegreaseto the lifter and
slidestopper link.

6x1.Omm
10 N.m (1.0 kg-m ,
7 b-ft)

SLIDESTOPPER
LINK
{co.rt d

Sunroof
Panel Stay/Slider, Lifter and Guide
RailsReplacement(cont'd)
9.

OpeningDrag Gheck
(Motor Removed)

Tu,n the hook ol the snchor rod with I flat tip

screwdriver, then remove the anchor rod and anchor
springfrom the guidersilby slidingit backward.

Betor inEtallingthe motor, measure stfon required to

open sunroof panelusinga springscaleas shown

NOTE:
To install,apply muhi-purposegreaseto the hook.

wh.n rFlng a cp ng scals. proiect the loadingodgo ot tho

sunroof panelwhh a lhop towol.

cAuflo :

lf load is over 1O kg (22 lbs), check side clearanceand

sunroot panelhoightadiustment{spage2G29).

ANCIIORSPRING

ltooK

At{cHoRROD

is tha revetseot the rmovalprocedure.

10. Installation
NOTE:
. Beforeinstalling
the guiderail,appv the calkingto
guiderailmountfacesof the frame.

GUIDERAIL

FRAME

. Damagedparts shouldbe replaced'

. Apply greaseto the slidingportion.
. Belore installingthe motor, adiust the litter to the
samepositionon each side.

20-34

SHOPTOWEL

GlosingForceCheck
(Motor Installedl
1.

After installingall removed parts, hav a helper hold

the switch to close the sunroof panel while you
measure force required to stop it. Attsch a spring
scaleas shown. Readthe torce as soon as the sunroof
panel stops moving, then immedistely releasa the
switch and springscale.
CAUTION:
When udng a spring scale. protest th badng adgo
of tha 3unroof panelwhh a 3hoptowel.
ClosingForce: 20-30

ks {/t4-66 lbs)

SPRINGSCALE

SHOPTOWEL

lf force is not within sDociJication,install I new bck

washer,sdjust the tension by turningthe motor clutch
adjusting nut, and bend th lock washer agsinst the
motor clutch adjustingnut.

t ocK

WASHER

20-35

Headliners
Replacement
> : Clp b.rtlo.!

'

wwzz

-w(:

t6l

lr.#IlE

) - )

'_-

-lN-

*_)

@)

CAUTION:
When prying whh a flat tip scrowdrlvor, wrap it whh protcctlve tapo to pravent damago.
NOTE:
. Removthe front se8ts (seepage2G38).
. Tako care not to bendor scratch the flont and rear hoadliners.
o Keep water away Jromths front 8nd rsar headlinets.
. Be caretul not to dsmagethe dsshbosrdand other interiortrim'
JOtitT
OROOFTRIM
OFRONT
IEADLII{ER

@REARHEADLII'IER

)HOLDER

t
Looaoh th6 bohs.

O}iGH-MOUT{T
BRAKELIGHT

@suNvtsoR

(DCEILIIIG
LIGHT
Dbconnoct tho
connoctol.

OLE S

OHIGH.MOUiII
BRAKELIG+IT
COVER

REARPILLAR
TRIM PA EL

NOTE:
Removethe headlinerfrom the passenger'ssids dool opening'
l|stallationis the reverseol the removslprocdure.
NOTE:
. V,lt\en \nsta\\ng the lront and tsar head\nsrs, be csrstu\ r\ot to lo\d or bsnd R' A\so, be cqrelu\ not to scrstch ths bodY'
. Chckthat boih sidesof the tront and rearheadlinersare sscurelyattschadto the body and rear pillartrlm panol'
. Whon installingthe root trim, installthejoint towards the rear.
. It nocessary, replaceany damagedclips.

20-36

lnteriorTrims
Replacement

" 1 "

> : Clp bcltlon.

I B

t N t |

-r-)rv_trj

#l M\ryi

ffii

H I

Disassemblein numberdsquence.

- )

_:)_

CAUTION:
Whan prylng whh a tlrt tlp 3crcwdrlvel, wrap h with protoctivo tapo to prevont damago.

l, (#"" @'

NOTE:
Takecarenot to bndor scratchthe trimsandpanels.

ldB.t

OREARPILLAR
TRIMPAI{EL
Firstromovthe roar
(s6spsg62G36).
headlinor

\\--""-T

C)qUARTER TRIii

OSEATLOCKCOVER
(soepa62G42

@DOORTRIM

@REARSHELF
Fhst rsmov th spoakors
(s6sction23) and 166lsoat
upprtrim panellse psf|eMA.

u
OOOORSILL
MOLDING

OTRUNKTRIM

:z

@RIGHTTRUNKFRO]'IT
PANEL
First rgmovthe r6ar
s6at {soepags2G41).
@RIGHI TRUNKSIDE

OiIGTITKICKPA EL

oSPARETIRELID

C)REARTRIM PANEL

is the revelseof the removalprocedure.

lnstallation
NOTE:
clips.
replace8nydamaged
lf nocessary,

REARUPPERPANEL

20-37

Seats
Front Removal

Front Replacement

NOTE:
TSkecare not to scrStchthe sest covers and body.

NOTE:
Take care not to scratch the seal covers and bodv.

1.

Removethe mountingbolts covers.

1.

Removethe front s6at, then take it out from the doot

oPening.

2.

Remove the mounting bohs and disconnect the

connector.then removethe tront seat.

2.

Remove the screws and knobs, then removo the

reclinecover,

RECLII{E
COVER
FRONTSEAT

@scREw

r(

MOUiTTNGAOLTS
1Ox 1.25 mm
ito N.m l4.O ks:m .
29 tb-tt)
Disconnct th6 aeat
hgAtorconnoctor
(canadaI SR 4WS/

@<

xroa

\oulmonv
KNOB
ORECLII'E

3.

Removeth screws, then removethe center coval.

sR-v).

a.
\,

Disconnectths
connector
(drivor'sonly).

a
iV*

i,OUI{TI G
BOLT
COVER

MOUI{TING
BOLTS
10x 1.25mm
/O N'ml4.OkgFm,29 b-ft)

Rmovethe lower clips and Jastenerslrom the asatback, then Joldthe sest cover back.
> : Clp locltlont

3.

Instalhtionis the reverseof tho rsmoval procedure.

SEA-AACK

Foldthe s6at-b8ckcover 8nd pad back until you can

see the seat-backmountingbolts.

> | Cllp locltlom

NOTE:
Tsks care not to damagethe pad.
Rmove the seat-back and s68t cushion mounting
bolts and pivot nut, thon remove the soat-backEnd
seat cushionfrom the innrand outsr ssat tracks.

PlvorNur Pvor wAsHER

b4;;-

SEAT-BACK

,/'wqP

w^sHER
il

O: Clp loo.tloB

SEATHEATERUNIT

BUSH

REAR
SEAT

PIVOTI{UT
I x 1.25mm
2 N'mlz2 ks-m, 16 b-ft)

accEas
CABLE

To 86at bolt
buckh.

lo rast-back.

SEAT
cusHtof{

MOUNTIiIGBOLTS
SEATCUSHK)]T
10 x 1.25mm
43 N.m(4.3 kg-m,31 b-ft)

To so6t-back.
Diaconnoct th6 r6ar
366t aCCgSll

RECLIiE
AII'USTER

cabb.

SEAT CUSHION

HoatedSoat {C6nada:SR 4wS/SR-V)

SEAT.BACK MOUNIT|NGBOLTS
1Ox l,26 mm
43 N.m (4.3 kem .31 b-ft)

INNERAEAT
TBACK

SEATCUSHIONMOUI{TINGBOLTS
1Ox 1.25mm
43 N.m{4.3 kg-m.31 b-ft}

JOINT
ROD
NOTE:
Take c6re not to
b6ndth rod.

7.

OUTERSCATTRACK

lnstallstionis the rsverse of the romovalprocodule.

NOTE:
. To prevent wrinkles when installing8 seat-backcover, makg aurs tho materialis stlgtched evsnly ovel ths frame bsfore
securingsllthe clips.
. Apply gteaseto the movingsurfaces.

20-39

Seats
FrontSeatCoverReplacomnt
t

CAUTION:
Wora gbv! to lomov and iNtal the sgat-backand seat cushion covols.

I;f.:fo:Sffi*.

or. crp'rmovlr:

NOTE:
Take cars not to tear the ssamsor damsgethe seat-backand ssat cushioncovers.
Soat-backcover romoval:
1. Removethe sat-b8ckfrom the innerand out6r seat trscks.
2.

Removethe rea. seat accsstrim and lumbarsupport knob (6xcept S modsl:Driver's).

3.

Removthe ssat-backcovsr by releasingallth insidesprings,

SEAT-BACKCOVER

\\

^n- I

"OU

il#ss\\K;,i-l

'w,

Seal curhlon covar ramovsl:

1. Removeth6 s6at cushionfrom ths inn6r andouter s6at tracks,
2.

Removsall clipsfrom undsrths ssat cushion,thsn loossnthe ssat cushioncovar,

3.

Pullback th6 6dgoof the seat cushioncov6r allthe way around,th6n rsloasoth6 pad clips and insidssprings.
SEAT

custto

COVER

FRAME
SEAT CUStflOil COVER
Clp Inrtllrtlon:
RING
UPK)LSTERY
PLIERS
Commgrciatry
sv.ilablo.

hstsllstion is the reverseof the removalorocedure,

NOTE:
. To prevent wrinkles, mak sure ths matrialis stretched
6venv over the lrsme b6tor securingallthe clips and insidesprings.
. ll necsssary,replaceany damagedinsidesprings.
. RoDlacethe cliDs.

EW CLIP

WIRE.
lCovors kl6l

PAD

WIRE(P.dsidsl

20-40
..

RearReplacement
Disassomblein numboredssquencs.

G)HOOKt2l

OLEFTSEAT-8ACK

@10x 1.25mm
/tO N.m14.0ksFm, 29 b-ft|

)
(_

6l
----v

Push the roat cushion.

Pull th knob. th6n dirconnoct th6 hook.
PulluDsnd fomovo tho 3aat cu3hion.

CARPET

)N|GHTSEATCUAH|oN

OLEFTSEATCUSHION

2041

Seats
(cont'd)
RearReplacement
Dbsssofi$b in numboredsequsnce.

Rrlr aeat btch/Lock cylndor rgmoval:

SEAT LOCK COVER

SEATLOCK
COVER

REAR
AHELF

OG r 1.0mm
10 Nm 11.0ks.m,7 b-ft)

Pry h6re.
6x1.0mm
10 N'm (1.0 kgFm
7 b-ftl
NGHT PNOT
BRACKET

LOCKCYLI]'IDER
tho rear
R6movo
shotf{seepag62G32.

ORIGHTsEAT.
BACK

6x1.Omm
10 N'm (1O ksm ,7 tr-ft)

RIGHTPIVOTBRACKET
Removo
ths ouanortrim
pansl(so. psa2G37).

t ocK RoD
NOTE:

LEfT PIVOT
BRACKET

Hq)KS

Tak car not to

bsndtho bck rod.

I t 1.0 rnm
10 N'm (1O kg|.m. 7 b-ft)

LEFTPIVOTBRACKET
R6movotho soatcorltea
pd(sepsgo92.

hstEllationis the revsrs6of the rmovalprocodur.

NOTE:
. Bolore sttsching the sest-back and sgat cuahion,
,n8ke surathere ar no twists in th6 seat bh.
. Whon instsllinsthe ssat cushion, poshion the seat
behs correctly.

20-42

> : Clp bcltlonr

A

l
TN\\\\\\\$

N i

_-__)

B
I

+ i
\)

l
]

Seat Belts
Front Replacement
CAUTIOITI:
Chock tho 5o!t bohs for damago and roplaco thom ll necossary. B carelul not to dsmago thom durlng removd and
inslalation.
1.

Remove:
o Front seat (seepage2G38)
o Rearseat (seepage2G41)
. Door trim (seep8g2G37)
o Rearshelf (seepage2G37)
. Rishttrunk front panellsee page2G371
. ouarter trim panel(seepag2G37)

2. Removethe sest boh quideand centor cover.

Remov th all three anchor bohs, retractor bolt and ret.actor mounting bolt, then remove the segt belt 8nd seat belt
buckle.
NOTE:
Whn removingth anchorbohs and retlactor boh, use a 17 mm socket or box-andwrench.
TUPPERANCHORBOLT
7/16-20 UNF
33 N.m (3.3 kg-m , 24 b-ftl

SEATBELTGUIDE
SEATBELTGUIDE
MOU Tllrlc BOITS
6xl.0mm

SEATBELT

10 N.m (1.0 kem. 7 b-ft)

RETRACTOR
BOLT
6x1.Omm

RETRACTOR

10 N m (1.0 ksm .7 lb-ft)

REiRACTORBOLT
7/16-20 UNF
33 N.m (3.3 ks-m . 24 b-ft)

SEATBELT
EUCKLE
COVER
CEI{TER
(seepag620-38)

LOWERAI{CHORBOLT
7/16-20 UNF
33 N'm (3.3 ks-m , 24 lb-.ft)

ANCTIORCAP

LOCK
TOOTHED
WASHER
Disconnctthe connoctor
ldriv6r'sonlyl.

\\\
ICE TEB ANCHORBOLT
7/16-20 Uf{F
33 N m (3.3 ksFm.24 b-ft)

(cont'd)

2043

Seat Belts
(cont'd)
FrontReplacement
Aarchoabolt coft.lructlon :

LOCK
WASHER

WAVEWASHEF
LOCK
WASIER

BEARING
LOWERAITICHOR \
BOLT

J'Jil
WASHER

TOOTHED
LOCK
WASHER

*/

EEARNG

4.

ChBckthat the retractor lockingmechanismtunctions as describedon pago2G46.

5.

lnstallationis the revorsof the removalproceduro'

PLAII{
WASHERS

NOTE:
. Make sure you assemblethe washers8nd collsls on the uppr and low6l dnchorbolta aa ahown.
. Before attschingthe quartertrim pan6l,maks sure thra are no twists or kinks in the ssEtb6lts.
. On reassembly,rpl8cethe upper anchorboh and center anchorbolt {') and u86liquidthr68d lock'

20-44

TOOTIIED
LOCK
WASHER

RearReplacement
CAUTION:
Chsck tho roat bolts tol damago and roplaco them ll necesrary. 8o careful nol to damage tham du ng lemoval and
in3talation,
1.

Remove:
. Front s6st (seepage2G381
. Rearseat (8epagp2G41)
. sest center pad (s,epage*42!.
r Rearshetf (seepage2G37)
. Center console(seepsg82G51)
. Door trim (Esepsse 2G37)
. Righttrunk front panel(seepage2G37)
. Ouarter trim panellsee pags 2G37)
. Hsdliner(ses psge2G361
. Rarpillartrimpanel{seepage2G37}
Detschth seat belt guids.
Remov th6 all thrss anchor bohs, retractor bolt and retractor mounting bolt, thsn remove the sat belt snd se8t beh
buckle.

J.

NOTE:
When removingthe snchor bohs and retractor boft, us a 17 mm socket or box-endwrench.
TUPPER
AI{CHOR
BOLT
7/16-20 U]{F
33 N.m(3.3 kg-m, 24 b-ft)

n ,-,.' SEATBELT
curDE
f;l,?-

-)I,lb
'llll
It6\

IW

.U\

BOLT
RETRACTOR
7/16-20 UNF
33 N.m(3.3 kem .24 h-ftl
AI{CHOBBOLT
LOWER
7/ta-20 UNF
33 N.m(3.3 ks-m. 24 lb-fr)

RETRACTORMOUNTING
BOLT
Exl.Omm
10 N'm (1O kg-m, 7 b-tt)

TcENTER
Ar{cHoRBotr ---------9.

3l'i-?:Tn-.ro,"n,
"*r"b
BUCKLE
4.

Anchor bolt conrtructlon:

UPPER
ANCHOR

Checkthat the retrsctor lockingmschanismfunctionaas

describsdon psge 2G46.
lnstsllationis the rverseof the removalprocedul.
NOTE;
. Belore attachingthg rear pillartrim paneland .ear seat,
make sure thsre are no twists in the seat bett.
. On raassembly,replacethe upper and centr anchor
bofts (') snd use liquidthroad lock.

.CE TERA CHOR

BOLT

2045

Seat Behs
Inspection
RciEcto? hapoctlon
1. Btor6 installingtho retractor, check thst ths ssat bh
can be pulledout fr66ly.

On-tho-CarSost Beh Inlpoction

1. Check thst the s6st belt is not twisted or caught on
anything.

Mko sur that ths ssat beh does not lock when th
retractor is l6andalowly up to 15" flom the mountod
oosilion.Th seat beh shouldlock when ths ratractor
is leanedovr 4.0o.

2. After installingthe anchors.check for Jree movement

2.

on the anchor bohs. lf necessary,remove the anchor

bohs and check thst the washers and other Dartsare
not damsgador improperlyinst8lled.
Check the sest behs for damage or discoloration.
Cl68nwith a shop towel if necessary

GAUTlOlt:
Do not attempt io dls$romble tho lotraclor.
r: Mountld Poitloti

CAUTION:
Uso only 3oap and wator to clean.
NOTE:
Dirt build-upin ths metal loops of the upper anchors
can causetha seat behs to retract slowly.
WiDs the inside of the loops with 8 cl8n cloth
dampondin isopropvlalcohol.
Check that the seat belt does not lock when pulledout
slowv. The 88t beh is designedto lock only during a
suddenstop or impact.

t,

Make sur that the seat belt will tetract sutomaticslly

wh6n rlgasad.
6.

I
Forwlrd

hrld.

RETBACTOR
Forw!.d

h.ld.

Replaceth s6at belt with 8 now ons if thers is anY

abnormality,

20-46

ReDlscsthe seat beh with 8 new one if there is any

abnormality.

ChildSeat Anchor Plate

Attachment points are provided for a rear seat mounted
childrestraintsystem which usesa top tethe.,
The attachment points are located on the rear sholf, iust
behindthe rear sest-b8ck.
When usinga childsest with a top tether, use a razor blade
or sharp knife to carefully cut 8 1 inch diamster circle at
tho location ot the attachment points and installthe child
seat ancho. Dlatesecurelv,
15Omm {5.9Inl

ATTACHMET{TPOItYfS

8 x 1.25 mm
22 N.m 12.2ks-m , 16 lb-ft}

CHILDSEAT
PLATE
ANCHOR

TOOTHED
WASHER

NOTE:
. Do not remove the toothed washor from the child seat
anchor plate, Use the child sest anchor plste with the
toothd wssher attachedto it.
. When installinga child seat on the rear seat, follow the
instructionsof the manutacturorof the childseat,
. Additionslsnchor Dlatesare avsilable.

r So not \3q i\q t*{\d sst\ a\{i\sr $Er\c ls\ N\ tl\\6\

purpos6;it ls dosignadexchsivolY for Instanatbn ol a
child so8t.
. Mako eurs tha lear soat-back ie locksd fhmlY whon
Insta$ng a chlld seat.

2047

Carpet
Replacement
SRSwire harnessesare routod neat the carpet.
CAUTION:
. Al SRS cloctlical whing halnosses ale covorad whh
yolow outer iNubtlon.
. Bofor! disconnocting the SRS wiro halnos3, Inltal
thc short connoctol(s)on tho airbag(s).
. Reg|lco the entiro affocted SRS hrrnoss alscmblY if
ll has an opon chcuft or damagedwitlng.
NOTE:
The radio may hsve a coded thft protection circuh. Bo
sureto get the customer'scode numberbefore
- Disconnectingthe battery.
-Removing the l,lo.43 (1OA) fuse
(inthe under-hoodfuse/relaybox).
- Removingthe radio.
Atter service, reconnect power to the radio and turn it
"CODE" is displayed,enter the
on. When the word
customer's Sdigit code to restore radiooperation.
1.
'

Remove:
. Front se8ts (seepage2G381
. Consols(seepage2G50)
. Centerpanel{seepage2G51}
. Dashboardlower cover, knee bolster
(seepago2GtB)
. Glovs box (seepsge2GS)
. Rearseat {seepage2G41)
. Seat center pad (seepage&2)

opener cover (seepsge 2G67)

Front seat beh lower anchor(seepage2G43)
Door sill moldingand door trim (seepage2G37)
Kick panel(spsse 2G37)
RMt trunk front panaland quartrtrim panel
(seepage2G37)
. Footrest

o
.
.
.
.

2. Pry out the clips and removethe retainorfrom the door silltlange.
Detachthe fsstnar in the driver's side carpet,thsn pull back ths carpot at ths bottom of heatr.

4 . Removethe carpst by slidingh rsrward.

NOTE:
Take care not to damage,wrinkle or twist th carpet,

20-44

>:Cllpbcationr

Fq)TREST

FASTEI{ERS

OUARTERTRIM
PAI{EL
{se6psgp2G37)

DOORSILL MOLDING
(s6e page 2G37)

SEAT HARI{ESSES

SEAT HARI{ESS

DOORSILLMOLDING
(s6epage2G37)

DOOR A|LL
MOLDII{G

5,

Installationis the reverseoJ the removalprocedure.

NOTE:
. Take care not to damage, wrinkle or twist the
carDet.
. Make sure the seat harnessesare routed correctlY.

DOOR SILL FLAI{GE

2049

Consoles
Replacement
areroutednearthe tront console.
SRSwire hsrnesss
CAUTlo :
. Al SRSlrctrbal whlng harnessosare covotadwfth
yclow outorlmuhion.

8.fo.o dsconnoctlng the SRS who halno3s, Install

th. 3hort connoctorb) on the alrbag(sl.
Rcpbc. tho entir affoctod SRS harness assomHy lf
h hrs an opon chcuh 01damagodwl ng.

il""ll!'S

sF

SRS UNIT

CAUTIO :
. To plevenl damageto tho 3hlfl bvot knob ard shlft Indicatort m rlng, wrap thom whh a shop towol'
. When prying whh a th tip sclowdllver, wlaP h whh plotostlvo tape to prevent dEmago.
NOTE:
. Take ca.e not to scrgtchthe front and center consolesand dashboard.
. Slidethe front sest fully to the rear.
> r Clp locltlon!

Auiomlllc trantmllllor

SHFT II{DICATOR
TRIM RING

modal:
SHIFT II{DICATOR
TRIM RII{G

FROiIT
COI{SOLE
r
Manual t]antr

alloo mod.l:

SHIFTLEVER
KI{OB
FROi'T CONSOLE

hstElation is the reverseof the removalplocedure.

20-50
.L

Dashboard
ComponentRemoval/lnstallation
SRS wire hsrnesses8r routed near the dashboardand
steeringcolumn.
CAUTION:
o AI SRS oloctrlcal tyhlng harnossea!rc covord whh
yolow outor insulatlon.
. Botole dkconnectlng th SRS wlro hamesr, Inrtafi
tho rhort connoctor(s)on the alrbag(sl,
. Roplscotho ontlre alfeaed SRS harnols astombly lf
h has an opon drcuh or damlged whlng.
. Aftor Inrtalrtlon ol ths gauge a$ombly. iochock the
oFrEtlon of tho SRSIndcator lght.

NOTE:
. The radiomay h8v a codedthett protectioncircuit. Be sure to gat ths customer'scode numbarbofore
- Disconnectingthe battery.
- Rsmovingthe No. 43 (10 A) tuso {inths under-hoodfuse/rhy box).
- Romovingthe radio.
"CODE" is displaysd,entr tha customsr'a Sdigit
After service,reconnect power to the radioand turn it on, Whn th6 word
code to restora radiooDeration.
. Tak care not to scratchthe dsshboardand rslsted p8rts.
. Do not drop the screws insidethe dashbosrd.
cAUTrOil:
Whon prylng whh a flat tlp screwdrlvel, wlap h wlth protoctiv6 tape to pravolrt damlgo,
ATEREO
RADK)/
CASSETTE

Looaenths bolts.

Disconnoctthe
conn6ctols.

scREws

CENTERPANEL
Removoth front
coneole (see palp 2G5O).

(cont'd)

20-51

ClutchOverhaul
Removethe centernut while holdingthe armature
plate.

A,/CCLUTCHHOLDER
Commorcirlly av6ihble
Robin.ir: P/N 10204
Kent-Moore:P/N J3?872

CENTER
NUT
18N.m11.8
kg-m,13lb-ft1

3.

Removethe snap ring B with a snap ring pliers.

NOTE:
. Oncethe snap rjng B is removed,replaceit with
a new one.
a Be caretulnot to damagethe compressorbody
and rotor pulleyduring removal/installation.

A
\/
:

ROTOR
PULLEY

@)
Removethe armatureplateby pullingit up by hand.
lf you can not remove it by hand, attach the flywheel pullerto the armatureplate,screwthe bolt in
the centerand removethe armatureplate.

Removethe rotor pulleyfrom the shaftwith a puller

and the specialtool.
NOTE:Putthe clawsofthe pulleron the backofthe
r o t o r p u l l e y ,n o t o n t h e b e l t a r e a ;o t h e r w i s et h e
rotor pulleycan be damaged.

PULLER
FLYWHEEL
07935-8050003

SEAL DRIVER
07945-4150200

(cont'd)

22-37

Compressor
ClutchOverhaul(cont'dl
5.

Removethe snap ring A with a snap ring pliers.

Releasethe field coil connector from the connector
holder,and disconnectthe connectorand field coil
groundterminal.
Removethe field coil from the comDresso..
NOTE:
. Oncethe snap ring A is removed.replaceit with
a new one.
. When installingthe field coil. align the boss on
the tield coil with the hole in the comDressor.

6.

Positionthe rotor pulleysquarelyoverthe field coil.

Pressthe rotor pulley onto the compressorboss
with the soecialtool.
lf the rotor pulley does not presson straight,
remove it and checkthe rotor pulleyand compressor bossfor burrsor damage,
CAUTION: Maximum press load: il00 kg (882lbsl
SHAFTRING
REMOVEROTJAC_ SH2O3OO

Vv

22-38

7.

lnstall in the reverseorder of removal, and:

. Clsan the rotor pulley and compressorsliding
surfacaswith non-Detroleumsolvent.
. Installth6 snap rings with the chamferedside
facing out and make sure the snap rings are in
the groov complgtoly.
. After installing,mak sure that the rotor pulley
turns smoothly.
. Routeand clamp the wirs properlyor they can
be damag6d by the rotor pulley.

ThermalProtestorReplacement
1 . Removeth6 bolt,tield coil terminal,and retsiner,
Removethe thermal protector.
Removethe rssidueof siliconsssalantfrom the top
of thermal orotector.

Removal
NOTE: Make sure the suction and dischargeports are
pluggedwith caps.
1.

Removethe three bolts,heat insulator.reliefvalve,

and O-ring.
NOTE:Be sure to use the right O-ringsfor R-l34a
to avoid leakage.
CAUTION: Be caretul not to spill comprGssor oil,
lnd mlb gura there is no foreign matter in the 3y3t.|n.
HEAT
II{SULATOfi

!2 N.m {1.2ks-m,I lb-ftl

RELIEF
VALVE
New p.rt (R-134.1
10 N.m (1.0kg-m,
7 tb-ftl
O.RING
NGwp.rt (R-134.)
Replace.

to the top of the thermalproApply siliconesea18nt

tector.

lnstrllation
1'

Cleanoff the reliefvalvematingsurface,

ReplaceO-ringwith new one at the reliefvalve,and
a p p l y a t h i n c o a t o f r e f r i g e r a n to i l ( S P - 1 0 : P / N
38899-Pl3-0031beforeinstallingit.

SILICOI{ESEALAN'

NOTE:
. Oo not return the oil to the containeronce dispensedand nevermix with other refrigerantoils
to avoidcontamination.
. lmmediatelyafter using the oil, replacethe cap
o n t h e c o n t a i n e ra n d s e a l i t t o a v o i d m o i s t u r e
absorption.
. Do not spill the refrigerantoil on the car; it may
damagethe paint; if the refrigerantoil contacts
th paint,wash it off immediately,
Tightenthe reliefvalve.

4,

lnstallin the reverseorderof removal.

Checkthe relief valve for leaksand cap the relief

valvewith the valveseal.

Belt Adjustment
1.

Apply a torce of 100 N (10 kg, 22 lbs) and measure

rhe deflection betweenthe alternator and crankshaft
DUIeY.

Measurewith BeltTensionGauge:
Attachthe belt tensiongaugeto the belt and measurethe tensionof the belt.

Comp.6so. Beh
Moction:
U.cd Eolt: 10.0- 12.0mm 10.39- 0.,17in)
N.w Bh: 4.5 - 7.0 mm (0.18- 0.28 in)

CompresgorBglt
Tension:
Used Bsh: 450 - 600 N {i[5 - 60 kg,99 - 132 lbs]
New Belt: 950 - 1t5O N
{95 - 115 kg, 2Og- 254 lbs)

P/S Pump Belt

Usod Bolt: 13.5- 16.5mm (0.53- 0.65 in)
Now Bslt: 9.5 - 11.5mm (0.37- 0.,15in)

P/S Blt
Used Beh: 350 - 500 N {35 - 50 kg, 77 - 110 lbs}
Nsw Eolt: 700 - 900 N (70 - 90 kg, t5'l - 198 lbs)

NOTE:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
for lessthan five minutes.

NOTE:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
a Seethe instructionsfor the tensiongauge.

BELTTENSIONGAUGE
07JGG- (x)l010A
THBOUGHAOLT
il5 N.m {i1.5kg-m, 33 lb-ft)

THROUGHBOLT
45 N.m 1,1.5
kg-m, 33 lb-ft)

\
ADJUSTMENT
LOCKNUT
22 N.m {2.2kg-m, 16lb-ft|

A/C COMPRESSOR

CRANKSHAFT
PULI-EY

2.

Loosenthe through bolt and alternatorn"t.

3.

Turn the adjustingbolt to obtainthe properbelttens i o n , t h e n r e t i g h t e nt h e a d j u s t m e n tl o c k n u ta n d

through bolt.
Recheck
the deflectionof the belt.

Condenser
Replacement
1.

Recoverthe refrigerant(see page 22-251.

2.

Disconnectthe Ay'Cpressureswitch 2P connector,

then removethe receiverline A.

3.

o.

Removethe two mounting bolts, then lift out the

condenseras shown.
CAUTION:Do not damage tho radiator and condenserfins when removing the condenser.

the dischargeIinefrom the condenser.

Disconnect
CAUTION:Cap the opon fittings immediatcly to
keop moi3ture 8nd dirt out ot tho sy3l6m.
LINE
DISCHARGE
Now prrt (R-134.1

O.RING
Now pa.t {R-13,lal
R6place.
CONOENSEB

MOUNT

CONDENSER
MOUNT
CUSHION

RECEIVERLINE A
O.RING
N.w p.rt lR-134r1

SWITCH
A/C PRESSURE
2 P CONNECTOR

6x1.0mm

10N'm{1.0kg'm,7lb-ft|
Removethe two bolts and Ay'Chose bracket
'l.O mm
6 r
10 N.m {1.Okg-m, 7 lb-ftl

Removethe four bolts and radiator upper mount

brackets.
6x1.0mm
10N.m11.0kg-m,7 lb-ft)
6x1.0mm
RADIATORUPPEF 10 N.m 11.0kg-m, 7 lb-ft)
MOUNT BRACKET

Iil

,"".t
I f *oo,oto*
MO,UNTBRACKET
]

7.

Installin the reverseorderof removal.and:

. lf you're installinga new condenser,add refrigera n t o i l ( S P - 1 0 :P / N 3 8 8 9 9 P 1 3 - 0 0 3 )( s e ep a g e
22-21).
o ReplaceO-rings with new ones at each fitting,
a n d a p p l ya t h i n c o a t o f r e f r i g e r a not i l ( S P - 1 0 :
beforeinstallingthem.
P/N38899-P13-003)
N O T E : B e s u r e t o u s e t h e r i g h t O - r i n g sf o r
R-134ato avoid leakage.

6x1.0mm
10 N.m 11.0kg-m,7 lb-ttl

Be sureto installthe condensermount cushions

securelyinto the holes.
Charge the system (see page 22-431and test its
performance(seepage 22-261.

22-41

A/C System Service

Evacuation
Onry !se service equipmentthat is U.L.-listedand is
ce(ttd to meet the requirements
ol SAE J2210 to remove
e '34a trom the air conditionersystem.
C A U T I O N :E r p o g u r e l o a i r c o n d l t i o n a r
.etrigeranl and lubricant vapot ot mlgl can
irrilale eyes, nose end throat. Avold broathlng
the ai1 conditioner relrlgeranl and lubrlcanl
vapor or migt.
ll accidentalsystem dischargeoccurs,ventilatework area
beloreresumingservice.
B - 1 3 4 a s e r v i c ee e u i D m e not r v e h i c l ea i r c o n d i t i o n e r
systemsshouldnol be pressuretested or leak lsted with
compressedarr.
some mixture of atr and
E@
R-134ahave been shown to ba combustlble8l
elevaied pressures and can rslull in flre or
exploslon causing iniury or property damags.
Never use compressed alr lo pre3sura trlt
R.134a servlce equlpmsnt or vchlclo alr
condilloner gyslama.
Additionalhealth and salety inlormationmay be obtained
from lhe refrigerantand lubaicantmanufaclurers.
When an Ay'CSvstem has been opened to the atmosphere,such as during installationor repair,it must
be evacuatedusing a R-134arefrigerantRecovery/
Recycling/Charging
System.(lf the systemhas baan
open for severaldays,the receiver/dryer
should be
replaced.)
Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystemto the car as shown followingthe
equiomentmanutacturer's
instructions.
NOTE: lf low pressuredoes not reach more than
700 mm H9 (27 in-Hg)in 15 minuts,there is probably a leakin the system.Partiallychargethe system
and checkfor leaks{seeLeakTest).

22-42

R.cov.rylR.cycling/Ghrrging

Sptcm

Gharging
Only use service equipmenlthat is U.L.-listedand is
of SAE J2210 lo remove
certiliedto meet the requirements
R-134atrgm lhe air conditionersystem.

R.coyrry/Rlcyclin g/Charging Systm

C A U T I O N :E x p o 3 u r c t o e i 1 c o n d l l l o n e r
rofrlgcrant and lubricanl vapor or mlll can
lrltalo ye!, no3e and thloat. Avold bruathlng
lhc alr condllloner ratllgoranl and lubrlcanl
vapor or ml3t.
It accidentalsystem dischargeoccurs,ventilatework area
blore resumingservice. Additionalhealth and salely in'
lormationmay b obtainedkom the relrigrantand lubricant manulacturers.
Rctriglrlnt crpacity: 650* g 1231oz)
CAUTTON:Oo not ovrrchrrgc tha tYstcm; th! comp.t!'
3or will ba drm!g!d.
C o n n e c t a R - 1 3 4 8r s f r i g e r a n t R e c o v e r y / R e c y c l i n g /
C h s r g i n gS y s t e mt o t h e c a r a s s h o w n f o l l o w i n g t h e
instructions
aquipmentmanufacturer's

22-43

A/C SystemService
LeakTest
Only use service equipmentthat is U.L.-lisledand is
ol SAE J2210 to remove
cenrliedto meet the requirements
R'l34a lrom the air conditioner
syslem.

Rccov.rylRrcycling/Chrrging Syltlm

C A U T I O N :E x o o s u r e t o e i . c o n d i l i o n e r
,etrigerant and lubricant vapor or mist can
irdtale eyes, nose and throgt. Avoid breathing
lh air condltloner retrlgerani and lubrlcant
vapqr or migl.
It accidentalsystem dischargeoccurs,ventilatework area
beforeresumingsetuice.
R - 1 3 4 as e r v i c ee o u i o m e n o
t r v e h i c l ea i r c o n d i l i o n e r
syslemsshouldnot be pressuretested or leak tested with
compressedarr.
E@
some mixture ol air and
R.134ahave been shown to be combustibleat
glevated pressureg and qan resull In fire or
explosion causing injury or property damags.
Never use compressed air to pressure lgsl
R.134a servlce equipment or vehicle ail
conditionersystems.
Additionalheallh and salely informationmay be obtained
from the relrigerantand lubricantmanufacturers.
l.

Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystemto the car as shown followingthe
instructions.
eouiomenlmanufacturer's
NOTE:Be sure to installthe same amount ot new
r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e
c h a r gI n g .
Open high pressurevalve to chargethe system to
about 100 kPa (1.0 kg/cm?.14 psi), then close the
suppryvarve.
Checkthe systemtor leaksusing a R-134arefrigerant leak detector with an accuracvof 0.5/oz.per
vear or better.
l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e
opened (to repair or replacehouses.fittings, etc.).
r e c o v e rt h e s y s t e m a c c o r d i n gt o t h e R e c o v e r
Procedureon page22-25.

5.

After checkingand repairingleaks,the systemmust

be evacuatedlsee SystemEvacuationon page 2242t.

22-4

HIGHPRESSURE
SIDE

Electrical
Troubleshooting
T i p s a n d P r e c a u t i o n .s. . . . . . . . . . . . . . . . ...... . . . . . . , 2
. 3-3
Five-step
T r o u b l e s h o o t i n.g, . . . , . . , . . . . . . . . . . . . .2. ,3. - 5

How to Use This Section

Schematic Symbols
Wire Color Codes

Relayand Control Unit Locations

E n g i n eC o m p a r t m o n .t . . . . . . . . . . . . . . . . , ,....,,, , . , . . ,2 3 - 7
. . . . . . . . . . . . . . . . . .2. .3 - 8
Dashboard
............ 23-11
Dashboard/Seat
. . . . . . . . . .2. 3 - 1 2
F l o o r. . . . . . . . . . . . . . . . . .

Index to Circuits and Systems

. . . . . . . . . . .2 3 - 2 4 7
Airbag ...............
....... Section22
Air Conditioner
Anti-lock BrakeSystem {ABS) .............Ssction 19
Automatic TransmissionSystem ......... Section 14
..........2
. 3-66
Battery..............
...... Section21
Blowl Controls
...........23-102
C h a r g i n gS y s t s m
* C i g s r e t t eL i g h t o l . . . . . . . . . . . . . . . . . . . - . . . . . . . - . . . - 2
. .3- .-.2- 2 4
*Clock................
- . . . - . . - . .2- 3 - 2 1 8
C o n t r o lU n i t L o c a t i o n s. - . . . - . . - - . - - . . . - . . - . . . . .2. -3. -. .7
' C r u i s eC o n t r o f
. . . . . . . . . . , . , ,2. 3 - 2 7 2
DaytimeRunningLights (Canada)...............23-180
. . . . . . . . . . . .S. c c t i o n1 1
F u s lP u m p
Fuses
U n d r - d a sF
h u s e / R l aByo x . . . . . . . . . . . . . . . . .2. .3 - 4 8
U n d e r - h o oF
d u s e / R e l aByo x . . . . . . . . . . . . , . . . .2. .3 - 4 6
+Gauges
.........23-126
C i r c u i tD i a g r a m
Engine Coolant Temperature {ECT)
...23-123
G a u g e. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .2. 3 - 1 2 3
F u e lG a u g e
. . . . . , . . . . . ,2. 3 - 1 2 4
Spoedometer
- . . . - . . - . . - .2
. .3 - 1 2 4
Tachometer
Ground
. . . . . . . . . . . . . . . . . . . .2. 3. - 5 9
Distribution
. . . . . . . . . . . . . . .2
. .3 - 1 3
Locations
...... Section21
HeaterControls
*Horns ...............
,.,..,,..,2
. 3-220
r l g n i t i o nS w i t c h
. . . . . . . . . . . .2. 3 - 7 3
r l g n i t i o nS y s t e m
. . . . . . . . . . . .2. 3 - 9 0
. .3. .- 9 3
l g n i t i o nT i m i n gC o n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . 2
Indicators
* A / T G e a rP o s i t i o nl n d i c a t o r. . . . . , , , . . . . , . . . ,2. .3 - 14 4
H i g hE e a mfn d i c a t o r. . . . . . . . . . . . . . . . . . . . . . . . . 2
. .3. .- 1 3 2
* S a f e t yI n d i c a t o l
. . . . . . . .2 3 - 1 5 1
T u r n S i g n a fn d i c a t o r . . . . . . . . . . , . , , . . . . . . . . . . .2.3. .- 13 2
*fntsgratedControl Unit
,..23-164
t l n t e d o c kS y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3.-. 1
.5 8

Lights, Exterior
Back-upLights
........... 23-192
Brake/HighMount Blake Lights ..............23-194
. . . . . . . . . . . . . . .2
. .3 - 1 8 3
Hoadlights
L i c e n s eP l a t eL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. .- 1 4 8
P a l k i n gL i g h t s
. . . . . . . . . . .2. 3 - 1 8 6
23-185,188
SideMa*erLights................
T a i f f i g h t s. . . . . . . . . . . .
.......23-147
T u r n S i g n s lL i g h t s . . . . . . . . . . . . . . . . . . . . . . . . . . - .2. 3
. .-.1 8 5
Lights, Interiol
. . . . . . . . . . . . .2. 3 - 1 9 0
C e i l i n gL i g h t
' Dash Lights BlightnessControl ...............23-201
E n r l yL i g h r
................23-173
. .-. 17 3
l g n i t i o nK e y L i g h t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3
TlunkLighr
. . . . . . . . . . . . . . .2.3 - 1 8 9
*Lighting System
-.--..--...-.23-174
PGM-FISystom
Soction 11
..,..,,...,..,23-213
Powel Antenna
Power Distribution
.......... 23-51
+ P o w s rD o o r L o c k s. . . . . . . . . . . . . . . . . . . , . . , . . , . . . . .2. .3. .-.2 5 5
*Powsr Mirors
-,..-...,,.,,..,23-242
Power Windows
...--..-...-.23-248
Radiatorand CondanserFan Controls .,,...,., 23-'115
+ R e a rW i n d o w D e f o g g o r. . . . . . . . . . . . . . . . . . . . . . . . . .2.3. .- 2 2 7
,..,..,,..,..,23-7
RefayLocations
S e a tH e a t s r s{ C a n a d s }. . . . . . . . . . . . . . . . . . . . . . . . - -2. -3--. 2 3 2
*Side Markr/Turn Signal/Hazard
.......... 23-196
FlasherSystem
. . . . . . . . . . . . . . . . .2. .3 - 1 0 1
S p s r kP l u g s
.............23-76
StartingSystem
* S t e r e oS o u n dS y s t e m . , . . . . . . , . . . , . . , . . , . . , . . , . .2. .3. -, 2 0 6
* S u n r o o f. . . . . . . . . . . . .
. . . . . . . . . . . 2. 3 - 2 3 7
SupplementalRostrainlSystem (SRS)......... 23-287
V e h i c l eS D e e dS e n s o r( V S S I. . . . . . . . . . . . . . . . . . . .2. 3. - 1 3 8
. . . . . . . . . . . . . . .2.3 - 2 6 3
Wiper/Washer
wires, Harness. and Connectors
Connector ldontitications and
. .3. - 1 3
W i r e H a r n e s sR o u t i n g. . . . , . . , . . . . , . . . . . . . 2
.......... 23-332
Wi ng Diagram
rRead SRSprecautionson page 23-294, than installlh6
short connecior on the airbag before wolking in these
areas.

SpecialTools

Rcl.

o.

.lr

'2,

o
o@-'

o.
@'
@

Tool Numbol

Doscription

DigitalMultimete.
KS-AHM-32-003
Eelt TensionGauge
oTJGG-001010A
Antenna Wiench
07JAA*OO10008
OeploymentTool
oTHAZ-SGOO400
Test Harness A
07MAZ-SLOO500
Test HarnessB
oTMAZ-SPOO500
Test HarnessC
oTLAZ-S140300
Test Ha.nessD
oTLAZ-SL40400
A 9 7 3 X _ 0 4 1 _ X X X X XVacuum Pump Gauge

Oty
I
I
1
1
I
I
1
,l

I Pago Roloronco

23-99,293
23-1' 13,1't4
23-214
23-322
23-303
23-306
23-222, 274, 30'l
23-309
23-243

': lncludedin SRS Tool Set OTMAZ-SMSOOOA

* *: lncludedin SRSTool Set OTMAZ-SLoOlOA

@
@

(,

@
@

23-2

Troubleshooting
Tips and Precautions
Betol Troubloshooting
a Checkapplicabletuses in the appropriatefuse/relay
DOX.

Nevertry to disconnectconnectorsby pulling on their

wires; pull on the connectorhalvesinstead.
Always reinstallPlasticcovers.

a Check the battery for damsge, state ot chsrge, and

clean and tight connections.
a Check the alternatorbelt lension.
CAUTION:
a Do not quick-chargoa battory unlosslhe banory
ground cable has bs6n disconnoctod.
Otherwiseyou will damagath6 ahomator diod63.
a Do not attmpt to crank the ongino with the batt6ry ground cable loosely conncted or you will
seveloly damag tho widng.
Handling Connectors
a Make sure the connectorsare cleanand have no loose
wire terminals.
a Mske sure multiple cavity connectors8re pscked with
grease(exceptwatertight connectorsl.
a All connectorshave push-downreleasetype locks.

Befoaeconnectingconnectors,make sure the terminalsare in olace and not bent.

a Check lor looseretainerand rubberseals.

Some connectors have a clip on their side used to 8ttach them to a bracketon the bodv or on anothercomponent.This clip has a pull type lock.
RTAINER

Some mounted connecto.s cannot be disconnected

unlessyou first releasethe lock and remove the connecto. from its bracket.

The backs of some connectors are packed with

grease.Add greaseif necessary.lf the gresseis contaminated,replaceit.

ERACKET
{cont'd}

23-3

Troubleshooting
Tips and Precautions(cont'dl
a Insertthe connectorall the way and make sure it is
securelylocked.
a Position wires so that the open end ol the cover
f a c e sd o w n .

Fac6
open ond

a Seat grommetsIn lheir groovesproperlv.

A
-Yl

Hsndling Wilos and Halnossos

a Securewires and wire harnessesto the frame with
their respectivewire ties at the designatedlocations.
a Removeclips caretully;don't damagetheir locks.

Slippliersunderthe clip baseand throughthe hole at an

angle,then squeezethe expansiontabs to releasethe
cxp.

-M/
--P\
l

NOT GOOO

Testing and Repairs

a Do not usewiresor harnesses
with brokeninsulation.
Replacethem or repairthem by wrappingthe break
with electricaltape.
a After installingparts, make sure that no wires are
pinchedunder them.
a When using electricaltest equipment, follow the
manufacturer'sinstructionsand those describedin
this manual.
a lf possible.insert the probe of the tester from the wire
side (exceptwaterproofconnector).

a Use a probe with a tapered tio.

SNAP.RINGPI-IER

After installing harness clips, make sure the harness

doesn't inter{ere with any moving parts.
Keep wire harnesses away from exhaust pipes and
other hot parts, lrom sharp edges of brackets and
holes. and from exposed screws and bolts.

23-4

ReIerto the instructionsin the HondaTerminalKit for

identification
andreDlacement
of connectorterminals.

Five-StepTroubleshooting
1 . Vofly Tho Complaint
Turn on allthe componentsin the problemcircuitto
verifythe customercomplaint.Notethe symptoms.
Do not begindisassemblyor testing until you have
narowed down the oroblemarea,
Analyze The Schomatic
Look up the schematicfor the problemcircuit. Determine how the circuit is supposedto work by tracing the currentpaths from the power feed through
the circuitcomponentsto ground.lf severalcircuits
fail at the same time, the fuse or ground is a likely
cause.

4.

Fix Tho Problom

Once the speciticproblemis identiJied.make the
repair. Be sure to use proper tools and safe
proceoures.

5.

Make Suro Tho Ci.cuit Works

Turn on all componentsin the repairedcircuit in all
modesto make sure you've Jixedthe entire problem.
It the problemwas a blown fuse, be sure to test all
of the circuits on the fuse. Make sure no new
problemsturn up and the originalproblemdoes not
recur,

BSssdon the symptomsand your understandingof

the circuitoperation,identifyone or more possible
causesof the Droblem.

3 . lsolate Tho Problom By Tosring Th6 Circuir

Makecircuittests to checkth diagnosisyou made
in step 2. Keep in mind that a logical,simple procedure is the key to efficient troubleshooting. Test
for the most likelycauseof failurefirst. Try to make
tests at points that 8re easilvaccessible.

23-5

How to Use This Section

Schematic Symbols
AATTERY

GROUND
Componentground
Groundterminal

II

II

RESISTOR

VARIABLE
RESISTOR

THERMISTOR

CIGARETTELIGHTER

At

t+J

t-Al
+

S.-O-

I.:

cotl, soLE otD

FUSE

BULB

IGNITIONSWITCH

HEATER

fr
+ ilHH
+
+ + D
$ H
Y II
J)-

MOTOR

PUMP

CIRCUITBREAKER

T-

DIODE

HORN

SPEAKER.EUZZER

TRANSISTOR(TI)

ANTI:NNA

Mast

RELAY lln no rmal po.itlon)

Normallyopon rlay Normally closed relay

CONDENSER

GI - T - I
t i l

I
T

l-t^f

SWITCH {ln nrrrm6l positionl

Normallyopen
Normally closed
switch
switch

I
/f'[\
$/I

/rn\
\Y./

CONNECTION
Input
I Output

vY lJ rI

CONNECTOR

+>tt
!

TIGHTEMTTNITG
DIODE
ITEDI

00 tti

T T

Wire Color Codes

The following abbreviationsare used to identify wire

colors in the circuit schematics:
W H T . . . . . . . . . . .W
. hite
Y E L . . . . . . . . . . . . .Y. e l l o w
B L K . . . . . . . . . . . . .B. l a c k
B L U . . . . . . . . . . . .B. .l u e
. reen
G R N . . . . . . . . . . . .G
R E D . . . . . . . . . . .R
. . e. d
. range
O R N . . . . . . . . . . . .O
P N K. . . . . . . . . . . .P. .i n k
B R N. . . . . . , . . . . .B. ,r o w n
. ray
G R Y . . . . . . . . . . . .G
P U R. . . . . . . . . . . . .P. u r p l e
L T B L U . . . . . . . . .L i g h tB l u e
L T G R N . . . . . . . . .L i g h tG r e e n

The wire insulationhas one color or one color with

anothercolor stripe. The secondcolor is the stripe.

I
t

REEDSWITCH

A
ttit
Y

-___----{

9--wHr/BLK

.
-

Relay and Control Unit Locations

EngineCompartment

WII{DSHIELDWIPERINTERMITTEI{T
RELAYtB-rypo)
I Wir. colorr: BLK,BLU^/HT,
I
I BLU/nED,GR /aLK,snd cR /REDI

CONDENSER
FAN NELAY
I Wirocolo.s:YEIA tHT, WHT/GRN,I
and BLU|'EL
I BLU/RED,
I
Wirc
color3:
YEL/WHT,WHl, r
r
'l
BLU,and BLUrYEL
I

ABS MOTOR RELAY {A-typo)

RAOIATORFAN RELAY
lA-typo)

DIMMER RELAY
(a-typol

FUSE/RELAY
BOX
RELAY
A/C COMPRESSOR
CLUTCH NELAY

I Wiro colorr: YEL/BLK,YEL/BLK,

I RED/BLU.
and RED
*Ii Wire coloc: BLK|'EL,BLK^/EL,
NED/BLU.
6nd RED

IEST TACHOMETER
COl{NECTOR

r: Wlrh OFflONAL A/C

23-7

Relay and Control Unit Locations

Dashboard
CIGARETTELIGHTER
RELAY lA-typ.)
Wir6 colors: YEL/RED,,
WHT/BLU,BLK,
I
and WHT/BED
I
HOBN RELAY IA-Typo}
Wir. colors: WHT/YEL,

SUNROOFCLOSERELAY (B-typol

;ii,[iic
I ;tir/Rl=d
and BLK

-'

I
I

TURN SIGNAL/
HAZARD RELAY

OPENRELAY
SUI{BOOF

wrNDow

{i ' 'rl

r"'tE

CONTROLUNIT
INTEGRATED

RELAY (A-typel

wtNDow
DEFOGGER
RELAY(A-typcl

BLOWERMOTORRELAY
tA-typ6l

FUSE/RELAY
BOX

ABS FRONTFAIL.SAFE
nELAYlA-typol
, Wir. colo.3:BRN/BLK,,
YEL/GRN, I
I BLK/YEL,
I ond BLK
I

23-A

PGM-FI MAII{ RELAY

ABS REAR FAIL.SAFE

RELAY (A-typ.)
, Wire colors: 8LU/BLK, ,
IBLK/YEL,YEL/GBN, I
I and BLK
I

DASH LIGHTS BRIGHTNESS

CONTROLUNIT

DAYTIME
RUNNINGLIGHTS
CONTROL
UNIT
(Canada)

RADIATORFAN
COI{TROLMODULE

23-9

Relay and Control Unit Locations

Dashboard(cont'dl

TRA SMISSIOT{CONTROL
MODULE (TCMI

23-10

Dashboard/Seat

ORIVER'SSEAT HEATERRELAY (Ctntda)

SEAT HEATERMAI]II
RELAY {C.n!dal
, Wir. color.: WHT/BLK,'

BLK/GnN,I
IYEL/BLK,
l6nd BLK

PASSENGER'SSEAT HEATERRELAY (Can.d.l

COiJTROL
UNITIA/T)
II{TERLOCK

23-1

Relayand ControlUnit Locations

Floor

23-12

Connector ldentificationand Wire HarnessRouting

How to ldentify Connectors:
"C" for connectors,
ldentiticationnumbershave beenassignedto all connectors.The numberis precededby the letter
"G" for ground terminalsor "T" for non-groundterminals.
Location
Harnsss

Engine Companment

Starter cables

f1, T2, and +

Batteryground cable

T3
G l a n d-

Engineground cable

T4 and T5

Enginewire harness

C1 0 1t h r uC 1 3 9
T'l O1 thru T'l 03
G1 0 1

Right enginecompartmentwire
harness

C201thru C2l I
G201

Left enginecompartmentwire
harness

C301thru C326
G301

Main wire harness

C420 thru C435

and C484

Dashboard

OthoB (Floor. Dool,

Trunk, and Roof)

C401thru C419
C436 thru C483
G 4 0 1 ,G 4 0 2 . G 4 0 3 ,
and G4O4

Right side wire harness

C501 thru C514

T5O1 thru T5O9
G501,G502,G503,
G504, G505

Lefl side wire harness

C521 thru C543

G521 G522

Rear wire harness

C551 th.u C559

G5 5 1
C6O1 thru C622

Dashboardwire harness
Roof wire harness

C651 thru C655

SRS main harness

C701 thru C7O7

G701

Driver'sdoor wire harness

C721 thru C731

Passenger'sdoor wire harness

C741 thru C748

Rear window defoggerground wire

c801 G801

A/C wire harness

C381 thru C386

G381

23-1

Connector ldentificationand Wire HarnessRouting

Startor Cablos
Connector or
Terminal

Numborot
Cavitias

T1

Location

ConnoctEto

r2

Right side ot engine compartment

Right side of engine compartment

Unde.-hoodfuse/relaybox
Starter motol

Battery

Battery positive terminal

Notes

Battery GroundCables
Connector ot
Torminal

Numbor ot
Cavities

T?

Location

Connocts to

Middle of engine compartment

T16nsmissionhousing

Right side of engine compartment

Body ground, via battery gfound

cables

Battery

Battery negativ terminal

Notes

EngineGround Cables
Connoctor or
Torminal

Number of
Cavitios

Location

Connects to

T4
T5

Middle ot engine compartmnt

Middl of engine compartmant

Engine mount bracket

Valve cover

G2

Left side of engine companment

Body glound, via engineground

cables

23-14

Notos

BATTERY
POStTtVE
TERMINAL
BATTERY
t{EGATIVE
TEBMINAL

BATTERYGROU]TDCABLES

ENGINEMOUNTBBACKET

EI{GINEGROUT{DCABLES

( )

23-15

Connector ldentification and Wire Harness Routing

Errq\ne \Nne Rursess \AZZAI' Errg\rre. 2.2 t SSRQ.\
Connector or
Tlminal

Numbor of
Cavitios

c101
c 102
c103
c l04
c105
c106
c107
c 108
c110
c111
c113
c114
c115
c116
c117
c118

c119
cl20
c121
c122

I
1
4

6
,l
4

c123
cl24
c125
c126
c't 27
c128
c129
c130
c131
L I S J

c134
LtSC
LIJC
Lt50

Location

Connects to

Left side of engine compartment

Middle of engine
Middleof engine
Middleof engine
Middle of engine
Middle of enginecompartment
Left side of enginecompartment
Middle of enginecompartment
Middle of enginecompartment
Middle ot engine
Middle of enginecompartment
Middleof engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine

Alternator
No. 'l fuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
Idle air control (lAC) valve
Injectorresistor
Intake air temperature(lAT) sensor
Power steeringpressure(PSP)switch
Enqineoil pressureswitch
Throttle position (TP)sensor
Heatedoxygen sensor{HO2S)
Vehiclespeed sensor (VSS)
Countershaftspeed sensor
EGRvalve litt sensor
Enginecoolanttemperature(ECT)
switch A
Back-uplight swirch (-)
Back-uplight switch ( + )
lgnition coil
Enginecoolanttemperature{ECT)
sensor
Enginecoolanttemperature(ECTI
sendingunit
Staner solenoid
TDC/CKP/CYP
sensor
lgnition control module {lCM)
Enginecoolant temperature(ECT)
switch B
Mainshaftspeed sensor
Lock-upcontrol solenoidvalve
Shift control solenoidvalve
Junction connector
Main wire harness(C428)
Main wire harness{C425)
Main wire harness{C426)
Main wire harness{C432)
Main wire harness(C432)
Main wire harness(C433)

Middle of
Middle of
Middle of
Middle of

engine
engine
engine
engine

Middleof engine

I
I
2

Middle of
Middle of
Middle of
Middle of

engine
engine
engine
engine

10
2
14
10
10
4
14

Middle of engine
Middle of engine
Middle of engine
Right side of enginecompartment
Right side of enginecompanment
Right side of enginecompartment
Right side of enginecompartment
Right side of enginecompartment
Right side of enginecompartment
Right side of enginecompartment

Tl01
r't02

Right side of enginecompartment Under-hoodJuse/relaybox

Left side of enginecompartment
Alternator

G1 0 1

Middle of engine

23-16

Engineground,via enginewire
harness

Notos

Aft

Mrf
M/T

Arf
A/T
NT

NT
M/T

THEBMOSTAT
HOUSING

c104 c108

cl
cl35 C136

26

cl13

.t

9 r /" r o .

c r z rI c 1 J 7

23-17

Connector ldentificationand Wire HarnessRouting

EngineWire Harness(H22A1Engine:2.2 I VTECI

c101
cl02
c 103
c104
c105
c106
c107
c108
c109
c110
c 11 2
c 11 3
c114
c 1l 5
c117
c 11 8
c119
c'120
c121
c122
c123
c't24
c125
c126
c131
c132
c133
c134
Lt55

c136
c137
c138
c139
T1 0 1
T102
Tl 03

23-1A

6
2

3
4
3
2

Left side ot enginecompartment

Middle of engine
Middle of engine
Middle of engine
Middleof engine
Middle of enginecompartment
Left side of enginecompartment
Middle of enginecompartment
Middle of enginecompartment

Alternator
No. 1 fuel iniector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
ldle air control (lAC) valve
Injectorresistor
Intakeair temperature{lAT) sensor
Intake air bypass (lAB) control solenoid valve
Middle of engine compartment
Power steering pressure (PSPI switch
Middle ol engine
Knock sensor (KS)
Middle of enginecompartment
Throttle position (TP) sensor
Middleof engine
Hested oxygen sensor (HO25)
Middle of engine
Vehiclespeed sensor(VSS)
Middleof engine
EGRvalve lift sensor
Middle of engine
Enginecoolant temperature{ECTI
switch A
Middleof engine
Back-uplight switch ( - )
Middleof engine
Back-uplight switch { + )
Middleof engine
lgnitioncoil
Middle of engine
Enginecoolant tempersture(ECT)
sensor
Middle of engine
Engine coolant temperature (ECT)
sendingunit
Middleof engine
Starter solenoid
TDC/CKP/CYPsensor
Middleof engine
Middle oJ engine
lgnitioncontrol module (lCM)
Middle ol engine
Enginecoolanttemperature(ECT)
switch B
Right side ol enginecompanment Junction connector
Right side of enginecompartment Main wire harness(C429)
Right side of enginecompartment Main wire harness(C425)
Right side ot enginecompanment Main wire harness(C426)
Right side of enginecompartment Main wire harness(C432)
Right side of enginecompartment Main wire harness(C4331
VTEC pressure switch
Middleof engine
VTEC valve
Middle oJ engine
Right side of enginecompartment Main wire hsrness(C484)
Right side of enginecompartment Under-hood fuse/relay box
Alternator
Left side of enginecompartment
Engineoil pressufeswitch
Middle ot engine

c113

ct31
cl32
ct 33
c1
c139
cl
ct
c123

c1

23-19

Connector ldentificationand Wire HarnessRouting

EngineWire Hamess (H23A1 Engine:2.3 f DOHCI
Connoctor 01
T.rminal

Number ol
Cavities

c101
c102
c103
c104
c105
c106
cl07
c108
c109

c110
c112
c113
c114
c115
c 11 6
c117
c118

2
2
2
o

4
3
3
2
1
1
4

cl23

cl24
c'125
c126
c127

1
I
2

LIJI

c135
Lt5t'

Connects to

2
10
2
't4
10
10
4
14

Alternator
No- 1 fuel injector
No. 2 fuel injector
No. 3 tuel injector
No. 4 tuel iniector
ldle air control {lAC) valve
Injector resistor
Intakeair temperature{lAT) sensor
lntake air bypass (lAB) control solenoid valve
Middle of engine compartment
Power steering prssure (PSPI switch
Middle of engine
Knock sensor(KS)
Middle of engine compartment
Throttle position {TP) sensor
Middle of engine
Heatod oxygen sensor (HO25)
Middle of engine
Vehicle sped sensor (VSS)
Middle ol engine
Countershaft sped aonaor
Middle of engine
EGR valve lift sensor
Middle ol engine
Engine coolant temperature {ECT}
switch A
Middle ot engine
Back-up light switch ( - )
Middle of engine
Back-up light switch { + )
Middl of engine
lgnitioncoil
Middle of engine
Engine coolant temperature (ECT)
sensor
Middle of engine
Engine coolant temperature (ECT)
sending unit
Middle of engine
Starter solenoid
Middle ot engin
TDC/CKP/CYPsensor
Middle of engine
lgnitioncontrol module (lCM)
Middle of engine
Engine coolant temperature {ECTI
switch B
Middle of engine
Mainshaft soeed sensor
Middle of engine
Lock-uo control solenoid valve
Middleof engine
Shift control solenoid valve
Right side of engine compartment Junction connector
Right side of sngine compartment Main wire harness(C428)
Right side of enginecompartment Main wire harness1C425)
Right side of engine compartment Main wire larness (C426)
Right side of enginecompanment Main wire harness1C432)
Right side of engine compartment Main wire harness1C432)
Right side ot engine compa.tment Main wire harness{C433}

T101
r102
T103

Right side ot engine compartment

Lft sids of engine compartment
Middle oJ engine

Undr-hood fuse/relay box

Alternator
Engine oil pressure switch

G1 0 1

Middle of engine

Engineglound. via engine wire

nSrness

23-20

otes

Lett side of engine compartment

Middleof engine
lvliddleof engine
Middleof engine
Middleof engine
Middleof enginecompanment
Lett side of engine compartment
Middle ot engine compartment
Middleof enginecompartment

c119
cl20
c'121

c128
c129
cl30
c131
c132
c133
c134

Location

ATT

Mrr
M/T

A/T
A/T
A/T

ATT
M/T

THERMOSTATHOUSING

06

oa
cl15C118

El

WIRE HARI{ESS

:109cl
c1o3 /

c133
cl1

cl

cl1

cl22
c123
c1
c1

c1'14 T103
12
10

23-21

Connector ldentificationand Wire HarnessRouting

Right Engine Compartment Wire Harness
Conn6ctor ol
Torminal

Numborot
Cavities
2

c204
c205
c206
c207
c208
c209
c210
c211

23-22

2
2

22

Location

Connocts to

Middle ot enginecompartment
Middle oI enginecompartment
Middle oJ engine compartment
Behindright front side marker
light
Behind lront bumoer
Behindfront bumper
Behindright headlight
Middle ot engine compartment
Behindright headlight
Behindright headlight
Behindright kick panel

Right horn
Left horn
A/C pressure switch
Right front side markor light

Right side of enginecompanment

Body Oround,via main wire

harness

Right tront turn signal light

Right front fog light
Right headlight (High b6am)
Radiator fan motor
Right headlight (Low beam)
Right lront parking light
Main wire harnesslC4Ol )

l{ot6s

OPTION

9<P

23-23

Connector ldentificationand Wire HarnessRouting

Left Engine Compartment Wire Harness
Connoctor 01
Torminal

Numbsrof
Cavitlos

c301
c302

2
2
2

LSUJ

c304
c30s
c306
c307
c308
c309
c310
c311
c312
c313
c314
c315
c316
c317
c318
c319
c320

1
2
4
I

4
4
2
1
1

c322
c323

c324
c325
c326

20
22
20

G301

23-24

Location

Connocts to

BehindleJt front side marker light

Behindfront bumoer
Behindfront bumDer
Behindleft headlight
Middle of enginecompadment
Behindradistor
Behindleft headlight
Left side ot engine compartment
Lett side of engine compartment

Left front side markerlight

Left front turn signallight
Left front fog light
Left headlight(High beaml
A/C compressor clutch
Condenserfan motor
Left headlight(Low beam)
Cruisecontrol actuatot
A/C wire harness(C381)

Left side of engine compartment

Left side of enginecompartment
Left side of engine compartment
Left side of enginecompartment
Left side of sngine compartment
Behindfront bumpr
Behindleft headlight
Lett rear of engine companment
Left side ot engine compartment
Left side ot engine compartment
Middle of enginecompartment
Middle of enginecompartment

EGR control solenoid valve

Left front wheel sensor
A/C compressor clutch relay
Condenserfan relay
A/C diode
Windshield waaher motol
Left lront parkinglight
Windshieldwiper motor
Brake fluid level switch ( - |
Braketluid level switch (+ I
MAP sensor
Evaporative emission (EVAP) purge
control solenoid valve
Windshield wiper intermittnt relay
4WS front sub steering angle sensor

Left side of ngine compartment

Under middle of enginecompanment
Behind left kick panel
Behindlett kick Danel
Behindleft kick Danel
Left side ot engine companment

Main wire harness(C4621

Main wire harness(C463)
Junction connector
Body ground, via left enginecomoartment wire harnoss

Notas

OPTION
Alc
A/C
OPTIONAL

ABS

Atc
A/C
A/C

4WS

LEFT E GINE COMPARTMENTWIRE HARNESS

23-25

Connector ldentificationand Wire HarnessRouting

A/C Wire Harness {With optional A/Cl
Connoctor ol
Torminal

Numbr ol
Cavitios

Location

c381

Lelt side of engine compartment

c382
c383
c384
c385
c386

4
4
4
2

Under left
Und6r left
Under left
Under lft
Under lft

G381

23-26

Connocts to

side of dash
side of dash
side of dash
side oJ dash
side of dash

Left engine compartment wire harness (C3O9l

A/C diode
Condnser fan relsy
A/C compressor clutch relay
Condenser fan motor
A/C compressor clutch

Left front of engine compartment

Body ground, via A/C wire harness

Notos

23-27

Gonnectorldentificationand Wire HarnessRouting

Main Wire Harness(Right side of engine compartmentbranchl
Connector ol
Torminal

Number of
Cavitios

c420
a

c423
c424
c425
c426
c427
c42a
c429
c430
c431
c432
c433
c434
c4a4

23-28

I
14
10
2
10
10
4
14
I

Location
Right side of
Right side of
Right side of
Right side ot
Right side ot
Right side ot
Right side of
Right side of
Right side of
Right side of
Right side of
Right side ol
Right side of
Right side ol
Right side of
Right side of
Right side of
Right side ot

enginecompartment
enginecompartment
engine compartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
engine compartment
engine compartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment

Connects to
Under-hoodfuse/relavbox (C945)
Under-hoodfuse/relaybox (C946)
Under-hoodfuse/relavbox (C947)
Under-hoodfuse/relaybox (C948)
Underhood fuse/relaybox (C9491
Enginewire harness(C133)
Enginewire harness(C134)
Test tachometerconnector
Enginewire harness(C132)
Intakeair control solenoidvalve
Right front wheel sensor
ABS solenoids
Enginewire harness(C135)
Enginewire harness{C135)
Enginewire harness(C1361
ABS pressureswitch
ABS motor
Enginewire harness(139)

Not6s

DOHC
ABS
A/T
M/T

VTEC

lcontinuos on prgo 23-3'l l

FUS/RELAY
UNOER.HOOD
BOX
lviow lrom bolow)

MAII{ WIRE HARNESS

c427
c42A

c|+84
c429

(cont'd)

23-29

Connector ldentificationand Wire HarnessRouting

Main Wire Harness(Right side of dash and floor branch) (cont'dl

Under right side of dash

c401
c402
c403
c404
c405
c406
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c419
c436
c437
c438
c439
c440
c441
c442
c443
c444
c445
c446
c447
c448

to

20
20
6
10
2
4
26
22
20
20
16
22
14
20
I
3
4
to

16
2
2
12
3

Under right side of dash

Under right side of dash
Under right side of dash
Under right side of dash
Under right side ol dash
Under right side of dash
Under right side ot dash
Behind glove box
Behindright kick panel
Behindright kick panel
Behindright kick panel
Behind glove box
Bhindright kick panel
Under right side ot dash
Under right side ol da8h
Under right side ol dash
Under right side of dash
Under right side of dash
Under light side ot dash
Under middleof dash
Under middleoJ dash
Under middleot dash
Under middleof dash
Under middleot dash
Under middleof dash
Under middleof dash
Under middleoJ dash
Under middleol dash
Under middleot dash
Behind middle ol dash
Behind middle ol dash
Bhind right side ol dash
Under middleof dash
Under middleot dash
Under middleot dash

23-30

Right enginecompartmentwire harness

(c211)
Right side wire harness(CsO1)
Right side wire harness (C5O2l
Dashboardwire harness (C62O)
Passenger'sdoor wire harness (C742)
Passenger'sdoor wire harness(C741)
Blower resistor
Evaporatortemperatura sensor
Recirculationcontrol motor
Transmission control module (TCM)
Transmission control module (TCM)
Junction connector
Blower motot
Junction connector
ECM
ECM
ECM
Daytime running lights control unit
Junction connector
Radiator fan control module
Shift lock solenoid
Cigarefte lighter
Heater control panel
Blower fan switch
Stereo radio/cassette player
Servic check connector
Dsta link connector (DLC)
A/T gesr position console light
A/T gear position switch
A/T gear position switch (Back-up light
switch)
Junction connector
Mode control motor
Body ground, via main wire harness
Body ground, via main wir6 harnasa
Body ground,via main wire harness
Body ground, via main wirs harnss

Canada

MAIN WIREHARNESS

, Continuoa on I
Ipaee 23-33 |

I Continuo! on
I paso 23-29

c418

c413
c414

{cont'd)

23-31

Connector ldentificationand Wire HarnessRouting

Main Wire Harnesa(Left side of dash and floor branchl {cont'd}
Connac-tor or
TcrmlnEl

Numbol ot
Cavities

c449
c450
c451
c452
c453
c454
c455
c456
c457
c458
c459
c460
c461
c462

20
I

20
20
20

Under left side of dash

Under lett side of dash
Under left side ot dash
Under lett side ot dash
Under lett side oJ dash
Under left side of dash
Under left side of dash
Under left side of dash
Under left side of dash
Under left side of dash
Under lft side of dash
Under lett side ot dash
Under leli side oI dash
Under left side of dssh

c463

22

Under lett side ot dash

c464
c465
c466
c467
c468
c469
c470
c471
c472
c473
c47 4
c475
c476
c477
c478
c479
c479
c480
c481

c4a2
c483

23-32

5
8
14
10
I
J

Location

,:l
r
4

14
14

2 J
c
16

Under left side of dash

Under left side of dash
i Under left side of dssh
l Under left side of dash
Under left side of dash
1 Under left side of dash
| Under left side of dash
lUnder left side of dash
l Under left side of dash
I Undsr left side ot dash
Under left side ot dash
Under left side of dash
l Under left side of dash
| Under left side of dash
l Under left side of dash
l Under lett side ot dash
Under left side ol dash
Under left side of dash
Under left side ot dash
Under left side of dash
Under lelt side of dash

1
l
4

14

4
4

2
4
4
4

Conncts to
Junction connectof
lgnitionswitch
lgnitionswitch
Combinationlight switch
Driver'sdoo. wire harness(C7221
Driver'sdoor wire harness(C721)
Front main steeringangle sensor
Lights-onchime
lnterlock control unit
Clutch interlockswitch
Clutch switch
Junction connector
Lett side wire harness{C522}
Left engine compartment wire
harness(C324)
Left engine compartment wire
harness(C325)
Dashboardwire harness(C602l
Front tog light relay
Under-dashtuse/relaybox 1C918)
Under-dashtuse/relaybox {C922}
Under-dashJuse/relaybox {C920}
Under-dashJuse/relaybox (C915)
Underdashjuse/relaybox {C914}
Under-dashtuse/relaybox {C916)
Under-dashluse/relaybox {C919}
Integratedcontrol unit
Starter cut relay
Cigarette lighter relay
Horn relsy
Cruisecontrol unit
SRS main harness{C706l
Brake light switch
Brake light switch
ABS front fail-safe relay
ABS rear fail-safe relay
Seat heater main relay
PGM-Flmain relay

Notos

4WS
Afi
M/T
CRUISE

OPTION

M/T

sRs
sRs
cRulsE

Canada

(Continuoson page 23-31)

MAIN WIRE HARNESS

/ c453 c;54
c456
UNDER.DASH
FUSE/RELAY
BOX

c469

c46a
c467

INTEGRATEDCONTROL

23-33

Connector ldentificationand Wire HarnessRouting

Righr Side Wire Harness
Coonctor ol
Tcrminal

Numborof
Cavities

c501
c502
c503
c504

16
20

LCUS

c505
c506
c506
c507
c508
c509
c510
c51 1
c512

to

6
14
12
20
18
20
4
18
12
2

L5t5

c514
Tsol
Ts02
T503
T504
T505
T506
T507
T508
T509

Location
Jnderright side of dash
Jnder right side of dash
Jnder right side of dash
light side of tloor
iight quarter panel
light quaner panel
light quarter panel
light quaner panel
light quarter panel
-elt front of trunk
Left front of trunk
Left front o{ tiunk
lnside ol right rear wheel
Inside ot right rear wheel
Under middle oI trunk
Under middleoI trunk
Right side ot engine compartment
Let-tfront of trunk
Left lront oJ trunk
Lett front of trunk
Left front of trunk
Under middle ol trunk
Under middleof trunk
Under middleof trunk
Under middleof trunk

G501

Right side ol rear tloo.

G502

Middle tront of trunk

G503

Middle front ol trunk

G504

MiddleJ.ont of trunk

G505

Under middleof trunk

23-34

Connocts to
Main wire harness(C4O2)
Main wire harness(C403)
Dashboardwire harness(621)
ABS inspection connector
ABS control unit
ABS control unit
ABS control unit
ABS control unit
Junction connector
4WS control unit
4WS control unit
4WS control unit
Right rear wheel sensor
Le{t rear wheel sensor
4WS rear di{ferential trans{ormer
Rear main steering angle sensor
Under-hood fuse/relay
4WS control unit
4WS control unit
4WS control unit
4WS control unit
Rear steering motor
Rear steering moto.
Rear steering motor
Rear steering motor
Body ground, vi8 right side wire
harness
Body ground, via right side wire
narness
Body ground, via right side wire
nSrness
Body ground,via right side wire
narness
Body ground, via right side wire
harness

Not6s

ABS
4WS
4WS

4WS
4WS
4WS
ABS
ABS
4WS
4WS
4WS
4WS
4WS
4WS
4WS
4WS
4WS
4WS

II

T502
T503
T5()4
T505

Tsor

T5o8
REABSTEERING
MOTORI4WSI

lt,

FUSE/REI.AYBOX

RIGH?SIDE
WIRE HANNESS

ABS COI{TROL
U1{IT

(N
23-35

Connector ldentificationand Wire HarnessRouting

Left Side Wire Harness
Connoctor or
Trrminal

Number of
Cavities

c521
c522
c523
c524
c525
c526
c527
c52A
c529
c530
c531

14
20
16

c533
c534
c535
c536
c537
c538
c539
c540
c541
c542
c543
G521

1
6
6
18
2
'I
I

20
20
5
2

2
10
20

Location
Under left side of dash
Under left side of dash
Behindlett kick panel
Middle of center floor
Middle of center floor
Middle of center floo.
Middle of center floor
Left front ol trunk
Right side of floor
Left side oJ floor
Left side of floor
Right quarter panel
Left quarter panel
Lett quarter panel
Left side ol rear shelf
Fueltank
Fuel tank
Right side of rear shelf
Middle ot rear shelt
Left side of rear shelf
Behindrear consolepanel
Behind rear console panel
Let't side ot floor

Dashbosrd wire harness lC603)

Main wire harness(C461)
Under-dashfuse/relaybox 1C917)
Hazard wsrning switch
Parking brake switch
Passengor'sseat heater switch
Driver's seat heater switch
Rearwire harness{C5511
Passenger'sseat heatel
Driver'a seat hater
Driver's seat belt switch
Passenger'sdoor switch
Driver's door switch
Junction connectol
Roo{ wirs harness{C651}
Fuel gauge sending unit
Ful pump
Right rear spssker
Trunk light
Left rear apeaker
Wootsr sDeakel
Woofer amplifier
Junction connoctor

Lett side ot floor

Body ground, via left side wile

halnsss
Body ground, via left side wire
natneas

Right quarter panel

23-36

Connects to

Notss

Canada
Canada
Canada
Canada

VTEC
VTEC
VTEC

c535
c52a

E
4
' l rl

UNDER.OASHFUSE/RELAYBOX

Gonnectorldentificationand Wire HarnessRouting

RearWire Harness
Connoctor 01
Terminal

Number of
Cavitios

c551
c552

18
2

c554
c555
c556
c557
c558
c559

8
3
8

G551

Location

Connects to

Left front of trunk

Middle of trunk
Middle of trunk
Middle of trunk
Left side of trunk
Left side of trunk
Right side ot trunk
Right side of trunk
Right side ot trunk

Left side wire harness{C528}

Left license light
Trunk latch switch
Right licenselight
Left taillight
Left rear side markerlight
Right rear side marker light
Power antenna motor
Right taillight

Middle of trunk

Body ground, via rea. wire

narness

otos

Roof Wire Harness

Connector ol
Torminal
LO5

Numbor ot
Cavities

c652
c653
c654

1
2
5

Loction
Lft side oJ rear shelf
Rear of roof
Rear of roo{
Rear of roof
Rear of roof

Connocts to

Not6s

Left side wire harness (C535)

Rear window defogger
Sunroof motor
Ceilinglight
High mount brake light

Rear Window Defogger Ground Wire

Connector ot
Torminal

Number of
Cavhios

c801

G801

23-38

Location

Connocts to

Rear of roof

Rear window defogger

Rear of root

Body ground, via rear window

detogger ground wire

l{ot.!

BOOFWIREHAR ESS

REARWINDOW OEFOGGERGROUND

23-39

Connector ldentificationand Wire HarnessRouting

Dashboard Wire Harness
Connector ol
Tsrminal

c601
c602
c603
c604
c605
c606
c607
c608
c609
c610
c611
c612
c613
c614
c615
c616
c618
c619
c620
c621
c622

23-40

Numbel of
Cavitios

to
14
5
6
5
1
I
20
10
5
16
10
30
5
6
'I
1
20
20
16
10

Location
Bshindleft kick oanel
Under leJt side of dash
Under left side of dash
Under leJl side of dash
Under leJt side ot dash
Under leJ-tside ot dash
Under left side oJ dash
Under left side ot dash
Under left side ot dash
Behindmain gauge assembly
Behindmain gauge assembly
Behindmain gauge assembly
Behindsub gauge assembly
Behindsub gauge assembly
Behindsub gauge assembly
Behindmiddleot dash
Under right side ot dash
Under right side oJ dash
Under right side ot dash
Under right side of dash
Under right side of dash
Under left side ol dash

Connects to
Under-dashfuse/relay box (C9O7)
Main wire harness(C464)
Left side wire harness{C521)
Dash lights brightnesscontroller
Cruisecontrol main switch
Sunrool switch
Left front tweeter
Left front tweete.
Junction connector
Main gaug6 assembly
Main gauge assembly
Main gauge assembly
Sub gauge assembly
Sub gauge assembly
Clock
Dash lights brightnesscontrol unit
Right tront tweete.
Right tront tweeter
Junction connector
Main wire harness (C4O4)
Right side wir harness{C5O3)
Front fog light switch

Notog

CRUISE

sRs

OPTION

DASHBOARDWIRE HARNESS

' 19
C6i4 C615 C616

2'1

C602 C6O3

r--r e

BOX
UI{DER-DASHFUSE/NELAY

23-41

Gonnectorldentificationand Wire HarnessRouting

SRS Main Harness
Connoctor or
Tarminal

c701
c702
c703
c704
c705
c706
c707
G701

23-42

Number of
Csvities

2
18
4
o

Location

Connocts to

Behind left kick panel

Under left side of dash
Under right side ot dash
Middle ot floor
Under right side of dash
Under left side oJ dash
Under left side ot dash

Under-dashtuse/r8l8ybox (C931)
Lett dash sensor
Right dash sensor
SRS unit
Passenger'sairbag assembly
Main wire harness(C4781
Cable reel

Middle of floor

Body ground,via SRS main hsrness

t{otos

4WS, VTEC

-lnL
t--l-E
Fi-r
r-:-l
-EF

lE=

.ml

[ffiEHflHflHHil

23-43

Gonnectorldentificationand Wire HarnessRouting

Driver's Door Wire Harness
Cooncctor 01
Torminal

Numb.r ot
Caviti6s

c721
c722
c723
c724
c725
c726

14
8

c728
c729
c729
c730

4
6
18
2
10
6
10

Location
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoot
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor

Connocts to
Main wire hsrnsss (C454)
Main wire harness(C4531
Dfiver's door soeaker
Driver's Dower window motol
Driver'sdoor lock actuatot
Power door lock control unit
Power mirror defogger switch
Power mi.ror switch
Driver's Dower miror actuator
Driver's oower mirrot actuator
Driver'sdoor lock switch
Master oower window switch

otos

Canada
USA
Canada

Passenger's
DoorWire Hamess
Connector or
Terminal

l!umb6. of
Cavitios

c741
c7 42
c743
c744
c 74 5
c746
c7 47
c74A
c 74 8

10
o

5
5

Location
Passenger'sdoor
Passenger'sdoor
Passenger'sdoor
Passenger'sdoor
Passenger'sdoor
Passenger'sdool
Passenger'sdoor
Passenger'sdool
Passenger'sdoor

Connocts to
Main wire harness (C4O6)
Main wire harness (C4O5)
Passenger'sdoor speakel
Passenger'spowel window motor
Passenger'sdoor lock actuator
Passenger'spower window switch
Passsnger'sdoor lock switch
Passonger'spower mirror actuator
Passenger'spower mirror actuator

l{ote!

USA
Canada

c745

c744

PASSENGER'SOOOB WIRE HARNESS

23-45

Fuses
Under-hoodFuse/RelayBox

tr47f,E46fC45lE44 fE43 lC42fC41ftr4oftr3s l

tr4efC48f
E sllEsof
c941
lTo ABS motor rohyl
c942
[To ].di.tor tan r.llyl
4WS CONTROL
UNIT
I To right sld. wiro I
I hern63s ll5ol)

c943
lTo dimrn.rrCryl

BATTERY

cautes
[ [oretoncr
1

ALTERNATOR
I To onginowtr. I
r ha.n.r{T101},1

c945
I To mainwire I
t harne$ tC42O)|
c946
I To mainwlro
r harn$3(C4211

c947
I To mrin wir. h.m.s. I
. tc422l
I

23-46

lfo h.!d[ght

r.hyl

Fuse
Numbor Amps
al

32

Circuits and Components Ptotactd

Wlro Colol
ABS motor relav

50A

1 0 0A

Power distribution

33

50A

WHT

34

40A

BLK/GRN

Jb

40A

WHT

50

40A

WHT/RED Seat heaters(Canada),PGM-FImain relay

404

WHT/BLU Sunrootsystem, power window system, daytime runninglights control unit

lgnitionswitch {BAT)
Rearwindow deJoggerrelay
Blower motor relav

(Canadal

WHT

4WS control unit

38
39

60A

40

1 5A

41

1 5A

WHT/YEL Horns, horn relay, brake lights, brake light signal

42

20A'

REO/GRN Parkinglights, dash lights

43

1 0A

WHTA/EL Clock { + B), stereosound system, 4WS control unit, ECM, transmissioncontrol

44

1 5A

45

1 5A

WHT/GRN Condensertan motor, radiator tan control module

46

1 5A

WHT/BLU Ceilinglight, cigarettelighter rel8y,ttunk light, ignitionkey light

47

1 5A

4A

7.5 A

49

50

204
20A

c l

20A-

1 5A

WHTTYEL Turn signal/hazardrel8y, hazard warning lights

WHT

ABS control unit (82)

module ITCM)

WHT

Power door lock control unit

RadiatorJan motor

WHT/BLK ABS control unit

WHTi GRN

ABS control unit {B1l

RED/GRN

Right headlight

REDryEL Left headlight, high beam indicator light

23-47

Fuses
Under-dashFuse/RelayBox
Front Vi.w {... p!96 23-50 lor bsck viowli

C901 [To turn signal/hazardroloy]

C903 [To blower molor rolayl

C9O4 [To pow.r window rol6y]

c905
openI
Ir To aunroof
r

CgOGITo roar wlndow dologgor rolayl

rclay
c907
ITo da.hboard
I
t wir6 ham6s tC6Olll

CgOB tTo SRS luso block (C933)l

c931
lTo sRsm6ln I

I harno.r{C701}|

AUXILIARY
FUSE HOLDER
(4WSl

c932
lTo ignitionrwltchl

c909
I To combinrtionI
I light switch
I

F,

@@@q
- nnrjl
-I

n tnl
23
24
U IUI

| 1 a1 92 0

UUU

nr:In|:lnnnnn

91011121314'1516t

Sporo fuso

c933

UUIJIJUUUUT

l:lnnnr:rrj]nElr

lTo und.r{!.h
box (C9O8)l

1 2 3 4 5 6 7 8

UUIJUIJUIJIJ

SRSFUSEBLOCK
C910
C91 1
C912
C913

23-4a

loptionl
loptionl
loptionl
loptlonl

turc/rclly

Fuso
Number Amps

Circuit! and Compononts Prolocted

Wiro Colol
Not used

7.5 A

BLU/RED

1 5A

BLU/RED
YEL/BLU

1 0A

ECM, PGM-Flmain relay, sub gaug (brakecheck circuit)

Fronttog lights (option)
PGM-Flmain relay
Not used

1 5A

WHT/BLK Seat hester svstem (Canada)

30A

1 0A

Sunroof open relay, sunroof close relay

lnternal
connecI|on
RED/GRN Daytimerunninglights control unit {Can8d8)

1 5A

ODtion2 connector,blowr motor relay

lnternal
connect|on
BLKiYEL Heater control panel, power mirror systsm, ABS control unit, tadiator fan control
module, Mode/recirculation control motor

l1

1 0A

12

7.5 A

Rearwindow defoggerrsl8y, integratedcontrol unit,

lnternal
connection
YEL/BLK Seat heate. main relay (Canadal,A/C compressorclutch relay, ECM
YEL/RED Daytimerunninglights control unit (Csnada)

t 5

1 0A

14

7.5 A

t 5

17

20A.
20A
30A

18

1 0A

Not used

10

to

YEL

Gaugeand indicatorlights, clock, back-uplights

BLK/RED Cruise control system

WHT/BLK Driver's Dower window system
BLU/BLK

Passenger'spower window system

GBN/BLK

Windshieldwipr system

lnternal
connection

YEL/RED

Option 4 connector
Stereo radio/cassette plaYer, cigarette lighter
Not used

l o

Not used

20
*21
'22

1 0A

YEL/RED

4WS control unit

*23

1 5A

BLK/YEL

PGM-Flmain relay, transmissioncontrol module (TCM), radiatorfan control module

Not used

PNK

SRS unit

*24

RED
SRS unit
1 0A
' 2 1 . 2 2 : A U X I L I A R YF U S EH O L D E R( W i t h4 W S )
*23, 24: SRS FUSEBLOCK

(cont'dl

23-49

Fuses
Under-dashFuse/RelayBox
Brck Vhw {.!. p.gr 2348 to. tront vi.wl:

lTo m.ln wl.. h.ma$

lc470ll

c915
lTo mlin wlr! h!rno!. {C469)l

c916
lTo D.ln wlrc h.mct.

(C471ll

c917
[To l.tt rid. wl.. h.rn.r. (C523ll

c918
lTo m.ln who hlrnr.r

lc466ll

c920
lTo m.ln wiro ha]nor! {C468ll

c919
lTo mainwlr. hrrru.t (C472ll

c922
lTo inlin wlr. h.]no!. (c/t67)l

c921
lTo Intcgrr$d

23-50

control unltl

Power Distribution
Circuit ldentification
BATTEBY

r-F-q-*
I

BLK-

motor
Startor

wHT-

4WScontrolunit

SOX
FUSE/REI.AY
U DER-HOOO
No.38{60A)

i'

tlo.39l15A)
WHT,"YELNo,40{1541

Tumsional/fuiardrclay
Hazrrdwaminglighls
unitlB2)
ABScontrol

&akolightB,&Ekesigml
N0.49l20Al

wm/Gnl1

ABScontrolunit{BI }
ABScontrolunit183)

0.117.54)

ABSMOTOB
RELAY
ALTERNATOR

Y_,.GRN/8LK

ECM

-r"*
+l$l','13l!:ltlT

G4o'l
G4o2
G404

BLvcRN
+

*'n*

"*'
[Tl"['13-%P"ooo'^

"*'
h:o$5lJ59',0'i

wrrneo
$

*t
HloollAoltfrTu""'*t

WHT/BLU
+

t'
HtX'&-rol%i""tt*'

fro p.g23- 521

{cont'd}

23-51

PowerDistribution
Circuit ldentification (cont'dl

lFromp4o23- 51|

Sters rdio/clssottdayor
Pow6l6nt6nn6
motor
Clockl+ Sl
4WScontrclunh
Tra miaiioncontrolmodulITCM)
ECM

Powatdooabck control utit

WHT/GR-+

ndidor f.n conrolmodul

l.|r motorMatth,,/Cl
C.ndo|tgr
Clgrott.lQht6.
lgnilionkoylight
Keyintodock
lohndd la,/Tl
Intagratad
conttolunil
Trunkk t
Cih|ofght
oat! linkcortrroclor
{oLCl

RADIATON
FAN
MODUI.!
COI{TROL
BIUEU( -

Rrdiatorf8nmotor

YEL

raunm

{Top.g623- 53, 541

23-52

ENGTNE
cooLAt{T
TEMPMTURE
$

USA:
- HOOD
FUSE/NELAY
BOX
UNDR

. HIGH
BEAM
INDICA]OR
LIGHT
. RIGHT
HEADUGHT
(Hiohborml
. LEFT
HEADUGHT
{Highbo3ml
RED/GRN-

Right headlight{Lorvbem)
Risht hadlishtlHish beeml

No.51(20A1

coMEINAT|oN
UGHT
SWTCH

FOGUGI{T
st /tTcH
(Optionl

bft h6dlghl{Lowb6.rhl
Lrft h6ad[tt[ {Highboaml
Highb6mindicrtorhht
Foglightr6lry(oprionl

DIMMER

>GI

ORN

"-1
G401
G102
BIUiNED

_I
PASSING

Grc1

tot ^

G102
G404

i\3
i oFF
2
(;--r

RED/8t(
Riohttritight
F ont p.*ing lights
Roa aidemerkorlights
Lhons6pht6 fEhts
Int6grstadcontrol unit
Daehhhts
DEshlights brightnosscontrol unit
{Oplion O conrpclot)
Ljghts lin dim modoltor
clock, A,/Tg!. po*ion
indicrior rd cru&aaadic8lor
toft tdxght

Power Distribution
Circuit ldentification(cont'd
Canada:
-HOODFUSE/REI.AY
UNDEN
BOX

--..+
RED/GRN
, HIGH
BEAM
INDICATOR
LIGHT
. RIGHT
HEADUGHT
Hiohbehl
. LEF.IHEADTIGHT
{Highb66m)

Rightheadlighl
llow b.rm)

L+> 359g5115P^ouu*"

RED/YEL---F
F

Lrtl hoedli0htllow borml

Highbamindic3torlight
Foglight rchy loFion)

LD>36#S11"llf'*uo*
i8ilfl8sil3il

FOGLIGHT

swtTcH

I.OO

l0ption)

DIMMER

'"1_

onN

'"-l_
G401
G402
G404

II
I

REO/GRiI
REDTYEI
GRI.I/RED

GRI'I/RED
BLK

6301

23-54

DAYTIME
RUNI{ING
LIGHTS
{ORI.)
COMTROL
UNIT

YEURED
lf;l;'Jl?illtT,
<
REo/cRN
lH;'Jl3fliSE,,
<

Riohtrdffghr
Fmntprltin lightg
Rrrs&remafiorlights
Lic.ns.pletoliohs
kt grrtodcontrolunit
D.!h li$ts
D!,.hlightsbrighhGscor .ol udt
(OptionO connctorl
Light3{indimmodolfor
cbcl A'/Tgcsrposition
indicdorrM cruisiMicrtor
l.ft trtlghl

No.33{504)FUSE
pqo23- 511
{From

BLOC(
SRSFUSE

IGNITION
SWTTCH

Y
t

.,i-

l
I

r-----------------'l
No.24ll0A)
N0.23{15A1

,' ^lcz

PGM- Fl mainmlly
Radiltor fan control modulo

BLK/YEL
-

poc23- 571

8LK/YEL*
F
lBLKIYELBLK'YEL-

ch.rgino3y3t.mlightlsobo go)

|-,
F
F
F
I
I

tlo.l3{1041

Inraka.it comol .olsnoilv6tuo{DOHC}

vdv6
EGR
cnntol aolnoid
Evroorutivc
oinisioi IEVAPI
Putgscontrollolnoillv6fuo

a?
YEt ......-

] Trsnsmblion
conrlotmodur
FcMl
Vhiclospod!n3or{VSS)
Voh.gote! btorllcl)
lflata aitbypre!llA8lcontrcl
solnollv!tu. {DOHCI
ELouNlT
N-

fioPry2s-stt

GtugE36ndlMic3tor lghtt

llntomdconnoctionl

co(rtrolunit
Intagrsld
SWITCH
TURNSIGNAT

YEt ..+

l-

Brck- uPlight3
shift lockrohnoidlA/Tl

lF

Crui!6 cotttol mrn switch

Crubo contol unh

l-

Wndshiold wipd int.minont rcl6y

Windshioldwipr notot DleY

No.l417.5A)
B["f\iREDGRNiELK*

WIPE&WASHER
SWTCH
WINDSHIED
BLKryEL-

lgritioncrtl

Btt,ryEL
FUSE
AUXIUARY
HoL.DER
t4WS)

YEUREoF
L

4lVSfiont main.raing lngh 36[eot

4WScontrolurtt
/tWSr6srmeinslotingtngie$nsor

{cont'd)

23-55

Power Distribution
Circuitldentification(cont'd

DASHFUSE/RELAY
BOX
UNDER_

F-_..-/

-/---'-r

loption O connctorl
Cirlrfft hhtor r6ley
Sters ndio/crcaott!dryor
Wootd iinD[fr6r
Wrthlavan!0ak6rr)
No.gl15A)

0ntermlconnoctionl
lOptbn @ connectorl
lloltar conlroi p8nl
Powd mkror &lurtor!

BI.I(YL
BLK/YEL

i;'

powor
mlrord.io0e6r

Modacontrol motor

a8s fril- "f. trby

il;;' i
ABScontrclunh
ABSi|lpcti)n conn&lor
4WSconttolunh
Rldirtortln
lln controlnroduk
modllo
Rrcirdhtbn controlmolor

No.35lrcAlFUSE
p.9.23- 51I
lFrom
f-

' 'j- fif,HlSlBll'

_-i.-

:
G401
G402
G404

SluAvHr-

ilo.1217.5Al

8bw6.moior

r\

-{11)>
YEURED

DAYTIME
RUNMIGUGHIS
CoMTRoL
UN|T
(Top!0.23- 54,

ib.1l ll0Al
YEUBIX -

No.34140A,
A,SE
lFrcmpa!623-511

23-56

S..t h.tt.. mlin |!hy

,VC compllasof ctxdr ralty

l|l|tern.lcorlarcctionl
Irtogrltod conlrol u|t|:t
YEUGRN-

f,6lr wirdoyr drfo0[pr 3yritch

4I(GRX -

n !r window datogoar

tGNtTtoN
swrTcHlsll
- 551
p.ge23
lFrom

,a
6.[ -l
;!^,Girr
-jtTMTERLoCK
swrrcH
cLuTcH

BLX/RED
-

EU(/IVI{I-

++
G10l
G402
G404

strrrorsolnoid

__________r

BUoi/t{T -

strd6f solonoid

BOX
UNOEF-DASHFUSE/RELAY

BLUif,ED*

BtuiRED-

CM
FGM_ Flmainr6leY
Subgru!6 l&rk dck

No.36llOA)FUSE
lFrcmp.g23-51)

llntlmal connaclion)

loprionO conmctor)

BIUiRED

Foghht3 loptionl

YEUBLU

PGM- Flm3inroky

wm/Buf
i;'J

solth..!orlrLy

(cont'd)

23-57

Power Distribution
Circuit ldentification (cont'd)

_ DASHFUSSRETAY
UNDER
BOX

INTEGRATID
COMTROL
UNIT

Y
I

'"--f,_

No.37{404}FUSE
pag623-51}
{From

G4ot
G402
G104

tlo.15(20A1

WffT/BtX BtU/BLK -

--->
GRN/RED
GRiI/RED-

nrtnr, -$
GRNY|-

Bt(
A-:
G40l
G402
G404

23-s8

-p
',o,c"r

i
I

__i

Malter pow.. window lwhdl

orivo/t @war window motor
P!3!ng/! powar window motor

suilRooF
slyncH
glnmot moior

su nooF
slvrTcH
smrool r|oto,

', .o*'
liFlfl,#itT*f

GroundDistribution
Circuit ldentification

,l

T.':

r
-l

housing
Transmission

Valvscovor

G2

Main.hft sp6ed
snsorlA/T)

{#w"ttstu-1
l--l!l0RN/BLU

-r

I-rot-fiT/rilIl-t
liorr,r,u
|
|

Hostodoxygens6mor IHO2S)

-14

r_i!lBr-u,^YEL
+DIBIU/GRN

Co(litolshaft spd
.nsor lA/Tl

i|

ILTransmission
controlmodub
lfTCMl

-l
+j

| wHT-

Knocksnsor{KS)

Transmbsion
conlrolmodul(TCMI

r.* -{--.8rl*

ECM
Vohiclespds6nsorIVSS)
Engino
coola tomperature
IECTI

Cl'nk3haftposilion
{CKPIsonsor

1-i4lsLurenir
l-{ElarurrcL
l

TDCa6mor

1-i!JonNBLu
L+lOwrniBLU

po3rtion
Cylindor
ICYPI$nsor

<f-Elont
r
L-t!;lwHT

ORN
WHT

I
I

8LK/RED
Transmi$ion
contrclmoduloITCM)
DEta
linkconnoctor
{DLcl

"^-1,-.'E

BU(_

r*

WECpmssure
switch{VTECI

riX_o,."*r,

Bt-( *
I
l-

G10l

E i Battorygrcundcables
ground
cablss
tr :: Emine
E Enginowirohanesg

prossurcIPSPI
PowerstEring
switch
EngincoolanttBmperature
{ECTI
switchA

j
El Mdnnke hsmess
------S h i ew
l dh e

(cont'd)

23-59

Ground Distribution
Gircuit ldentification (cont'd)
8t-K

FIgt|rfrcnt parldng
light

BI.K

trghttronttumsignallight

BL(

ftglt fiont skJsmffkorlight

B|.l(

Radbtorfanmotor

8U(-

Right
lronltugrghtloption)

BU(elx -l
BU(+{olpjrx
|
|

l-lFl
F--lFlBU(su( -

Rightl
lLowbeam)
I h.dftgh
r!ft J
t-6rr

,u.J

Bu(

Crukacontrolactuator

8tx

Condonlor
f6nriotor

8u(

trft ftlnt foghht {optiml

Btx

L6ftlronrdd,.ma*6rlight

Btl(

bft trontrumlign.l kht

BU(-

&*o ffrkl lvslswhch

BIJ( -

L.ft fmnt prtjrE fght

BU(-

Wri$iald wipormotor

BU(-

Wri$bld wahd morot

BU(-

nlay
Wind$i.H rviporintonnittnt

CondeNorfln molor(Wth optionalA./Cl

: Right6ngin6comprt||rafit wira hdtL!.

: Lrft onginocompitrnant wira h!fiLd
i A/C wir6 hrm63afwrthot{ronrl A/Cl

23-60

P&!rneo/! doorbck Ectuatot

doorbck switch
Praagngar'!

l-;;;;;;;il;;;-l
Daytlma
runninglghrt contolunil

I
I L- - - - - - - - - - - - - - - - - I
I
tcr dr)
fhltar codrolpl|rl
F
pd; ff q6ncon1;6lmodug
l-

BKF
L

8tl( F
L
BLX-

Bt(

!t*
] A8st;t-r"f","r*
haar J
AESDreiijra lwitch

Cru|..contll unit
llnorlockcodrolunhlA/I)
lurloo poCtlon.witch
DimmrtlLv

EL! unh
l-

lightor
Cigerno
Homrby
Fro||tminltsring
{v/lrtt

d|gl saNot

odva/! porv6.minordotog[rlcantdal
Powotminorlwilch

Bt( F
l-

Masterpowe wlndowrwitdr
)
Ddvor',powarwindowmotor
Powddoorlockcontolunh
orlvor'sdoorlocl lwhch
Odvlr'adoorbcl rcturtor

B.*
+

"
Ht?'$"-rolUu,'n'*'

8LK-

St6roradio/ca8atl.plryar

G4o4

E .M6inwho hanoss

tr'

Ddver'sdoorwirhamoss

[ :
[]:

P!t!aar0a/t d@awi! htrs

RlghtCd. win hrrs

(cont'd)

23-61

GroundDistribution
Gircuit ldentification(cont'dl
UNDER-OASH
FUSE/REI-AY
80X

au

j Subgarg. !8!.muy
Maingatrg6allamtt
Slnrooflrvhdl

BLX

tug light3witchloptionl

8rI

ordr liohtshhttn rs comrclunh

'I
I Mdnga{ rlsembt

8Ll(
SunrcofclosorErry
Sunrcofopon l6l6y
'nrfrr*.ofttot

8r(
8t.K

Cruilomdnswitch
grb gmgoaslombv

8U(-

Clod

unfl

#Tum
Powarwindownlay
Blowarnotor rdrv
Combinalionligfrt lwhdl nd windCli.ld wiper/yra$or,witdr

s|.K-D

G521fio p!0.23- 61t

BI.K

Clu!$ swlth lwth cruL contol)

8tJ(

Clurdtlm.dod(rwirdl lM/Tl

#deu

G404{Frcmp.g23- 8l )

Bl-K ........b

Ljght -on chim.

Sart lbdar min lthy

lgrilionk y rwhch
Oo'rtl.lietn.. rllrt

:]---

BU( -

lhrt r ft|l .tyitdl

ABSrbtor

G403

wir6ham.ss
tr :: oashboerd
tr [!ft sidr,irhanost

23-62

PoworlmotorlgoundT504
l4WSco rclunitl

7-:i:
--^^
R6.rst .ing motor ffneO
{+l
Rear
lt.ring
motor ffarf
l-t

v-:::

G505

Raaritodnorrotor
fu;tion +}
{oamper
Radrlacrimmotor
funclion- I
lDempdl

rTl vFl

ffau

8tK

) lws comrorunir

El : Rightsidcwir6ham$3

(conl d)

23-63

GroundDist
Circuit

Drivor'ssoat hoatars
Ddvar'3s6tt h6atd roly
Ddvor's3ort hoatd 3witch
Paaaong6r'ssost hoatoa3
Paasangr'ss6!t hostor r6lay
P6ssongor'ssert hortor lwitch

FuolpumplFPl

Btx -#|

|
|

--!

s1x-]
su

l-{M-l
- eu(-

r.

lHlu

f -

t* -T
lL

HishmountblskoFght
cilim lisht

:Yt
] rc.NDrst6
rohtt
Lln r
frunk letchrwhclr
Driv..'r r6st b6h awitch
Woof.. lmplfir
fwith s.wn sDoako6)

Fuollandingunit

E
E
E

23-64

, L"ft slde,ire t'*ness

: Foofwit..
: Rear
wirahamcss

Rioht
- r
| tdltqhr
Lsft r
Rioht l
reea$o mncr ||gnt
L!-ft J
Poworantonnanrotor

tt*-I"'unn
I

Re.r window defogg6{

otot

E : Rearwnehmess
@ : sRsmainhanss
groundwir
dofoggor
E : R$windo\N

23-65

Battery
@
a

Baftery tluid (olectrolytl contains sulfuric acid. tt may causo aavolo burns if it gots on your skin ol In your 6yoa.
Wear protoclivo clothing and a face shiold.
- lf oloclrolyta g6ts on your skin or clothos. nae it off with watr immediatoly.
- It electrolyta gots in your yes, flush it out by splashingwatar in your oy63 tor at least 15 minutes; call a physician
immdiatoly.
a A batto.y gives off hydrogan gas. ll ignit6d, tho hydlogan will oxplode and could crsck tho battory caro and aplattol
acid on you. Keep sparks, tlames. snd cigatettes away flom tho battory.
a Overchargingwill raiso tha tamperature ot tho oloctrolyte. Thb may forco ol6ctroly'toto splay out of tho battory vontE'
Follow the chargor manufactulor's inatructions and chargo tho battory at a propol tato.

Use eithef a JCI or BearARBSTtester. and follow the manufacturer'sprocdures.l{ you don't have one oJ these computerizedtesters,follow this conventionaltest procedure:
To get accurateresults,the temperatureot the electrolytemust be between TOoF l21oCl and IOOoF (38oC).

lJ the case is cracked or the terminals are

loose, replace the baftery.

lf the indicator shows low electrolvte,

distilledwater it Dossible.

Test Load Capacity(# 1l

.
.
.
.

Apply 300 amp load for 15 secondsto remove

surfacecharge.
Allow 15 secondsrecovetyperiod.
Apply test load {see Test Load Chart).
Recordvoltage at the end oJ 15 seconds.

Voltage stays above 9.6

volts; battery is OK,

23-66

Chargeon High Setting (4O amps)

Chargsuntil EYEshows chargeis OK; plus an
additional30 minutesto assuretull charge.
NOTE:lf the battery cha,ge is very low, it
may be necessary to bypass the charger's
polarity protection circuitry.
lf the EYEdoes not show chargeis OK within
three hours, the baftery is no-good; replace it.
Write down how long the battery was
charged.

Test Load Capacity( # 2)

Apply 30O amp load lof 15 secondsto removesurfacecharge,
Allow 15 secondsrecoveryperiod.
Apply test load (see Test Load Chart).
Recordvoltage at the end of 15 seconds.

Voltage stays abov 9.6 volts; battery is OK.

Voltage drops below 9.6 volts; battery is

no-good.

80D26L-MF

TI

I_

BATTERYCODE

TEST LOAD CHART

Use the test load ot 112the cold crankingamps (CCA)printed on the labelon the top ot the baftery. lf neitheris indicated, use the informationbelow:

BATTERY
CODE
80
70

COLDCRANKING
AMPS (CCA)
I

55

LOAD
(amps)

550

270

440

220

405

200

23-67

Under-dashFuse/RelayBox
Removal/lnstallation
a All SRS elect cal wiling halnesses are covered with
yellow outer insulation.
a Belorodisconnectingthe SRSwirs harnoss,installthe
short connecto.(s) on the airbag(sl (see page 23-2941,
a Roplacth ontile aftected SRS harn$s assembly if
it has an opon ci.cuit or damaged wiring.

3.

Removethe dashboardlower cover, knee bolster,

and heaterduct,

NOTE: The radiomay havea codedtheJtprotectioncircuit. Be sureto get the customer'scode numberbeJore
- Disconnectingthe battery.
- Removingthe No. 43 (1O A) fuse.
(ln the under-hoodfuse/relavboxl
- Removingthe radio.
After service.reconnectpower to the radioand turn it on.
When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation.

DASHBOARDLOWERCOVER

4.

Removal:
1. Disconnectboth the negative cable and positive
cable from the battery.
2.

Removethe driver's foot rest.

23-68

Removthe door sill moldingand left kick panel

5.

Disconnectthe 16-Pconnectorfrom the integrated

control unit.

o.

Remove the mounting bolts and pull the fuse/relay

box away from the kick panel.
UNOER-DASH
FUSE/RELAYBOX

Installatioo:
1. Reconnectthe connectorsto the fuse/relaybox.
NOTE: To reinstallthe SRSmain harnessconnector,
push it into positionuntil it clicks, then closethe connector lid.
2.

Installthe under-dashfuse/relaybox.

3.

Reinstallthe kick panel and door sill molding.

4.

Reinstallthe knee bolster and dashboardlower

cover.
Connectboth the negativecableand positivecable
to the battery.

6.

Confirmthat all systems work properly.

Disconnectthe fuse/.elaybox connectorsand take

out the tuse/relaybox.
BOX
FUSE/RELAY
UNDER-DASH

SRS MAIN
HARNESS

NOTE: The SRSmain harnessconnecto.is doublelocked.To removeit, first lift the connectorlid,then
pressthe connectortab down and pull the connector out.

23-69

Power Relays
RelayTest {A-tYPe)
.eNOTE: See page 23-198 for the tu,n signal/haz8rd
lay input test and see page 23-236 for the seat heater
relav test,

a Seat heater main relaY

a ABS front fail-s8ferelay
a ABS rear fail-saferelay

1. Removethe power relay from its socket.

2.

Check continuitybetween relay terminals.

a Thereshouldbe continuitvbetweenthe C and D terminals.

a Thereshouldbe continuitybetweenthe A and B terminalswhen power and groundare connectedto the
C and D terminals.Thereshouldbe no continuitv when
oower is disconnected.

a
a
a
a
a
a

Starter cut relay

Horn relay
Cigarettelighter relay
Power window relay
Blower motor relay
Radiatorlan relay

23-70

a Condenserfan relay
a A/C comoressorclutch relav

a Hsadlightrelay
a R6ar window defogger r8lay
a ABS motor relav

23-71

Power Relays

l1

Relay Test (B-typel

Remove the power relay from its socket.

a Windshieldwiper intermittentrelay

Check continuity between relay terminals,

Thereshouldbe continuitvbetweenthe A and C terminalswhen power and groundare connectedto the
D and E terminals.
Thereshouldbe continuitybetweenthe B and C terminals when Dower is disconnected,

a Dimmerrelay

a Sunroof open .elay

a Sunroofclose .elav

E
A

E+,6
7"-'

23-72

lgnition Switch
Test
CAUTION:
a All SRS oloctrical wi ng harnassesar6 covorod wlth
yellow outl insulation.
a Boforedisconnectingtho SRSwira hsmess. instsll the
shon connsctor(s) on the airbag(s) {soe page 23-29a1.
a Roplacothe ontire affected SRS harne$ assembly it
it has an open cilcuit or damagad wiring,

3,

Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.

rernrnsl WHT/
Position

BLK WHT
tAcc) IBAI)

tl

-o
o-o-

Il

SRS MAIN HARNESS

BLK/
YEL
Gl)

YEL
flG2t

BLU/
WHT

{sT)

-o
--o

tE,

1 . Removethe dashboardlower cover, left kne bolste.. and left kick panel (see page 23-68).
Disconnectthe 5-P connectorfrom the under-dash
fuse/relavbox and disconnectthe 3-P connector
from the main wire harness.

3-P CONNECTOR
(Main wire harnessside)

ST IBLK/WHT}

3.P CONNECTOR

UNDER-DASH
BOX
FUSE/RELAY
SOCXET
5.P CONNECTOB

23-73

lgnition Switch
ElectricalSwitch Replacement
CAUTION:
a All SRS lectlical wiring harnossrr are covorod with
yollow outor insulation.
a Boforo disconnocting the SRS wir6 h.mo$, install th
shon connoctor on the airbag{sl (3oo pag6 23-2941.
a Replacethe entilo affactod SRS hEmossa$ombly it
it has an open circuit or damagsd wiring.

3.

Disconnectthe 5-P connectorJromthe under-dash

fuse/relav box and disconnect the 3-P connector
from the main wir harness.

3.P CONNECTOR
(Main wiro harness sid6l

NOTE: The radiomay havea codedthett protectioncircuit. Be sure to get the customer's code number before
- Disconnectingthe battery.
- Removingthe No. 43 (1O Al fuse.
{ln the under-hoodfuse/relaybox)
- Removingthe radio.
After se.vice,reconnectpower tOthe radioand turn it On.
When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation.

3-P COl{ ECTOR

4.

Insert the key and turn it to "O",

Removs thg cover screw and ths cover.

SRSMAIN HARNESS
'1. Remove
the dashboard lowsr cover and let't knee
bolster.
2.

Rmove the two mounting scrsws and replaco the

switch.

Removethe steeringcolumn covers.

UPPERCOLUMN COVER

MOUI{TING SCREWS

23-74

Steering Lock Replacement

CAUTION:
a All SRS eleclrical wiring hslnossos aro covated wlth
yollow outar insulation.
a Bololo disconnocting the SRS wile hamoss. install tho
short connoclor(slon tho airbag(sl(saopage 23-294).
a Roplacoth ontiro aftectd SRS harneasassembly lf
it has an open cilcuit or damagad wiring'

4.

Centerpunch each of the two shearbolts and drill

their hads off with a 5 mm (3/ 16 in.) drill bit
CAUTION: Do not damage tho switch body whon
romoving the shoar bolts.

NOTE: The radio mav have a coded thett protection circuit. Be sureto get the customer'scode numberbefore
- Disconnecting lhe battery.
- Removingthe No. 43 (1O Al fuse.
{ln th under-hoodfuse/relaybox)
- Removingthe radio.
After service,reconnectpower to the radioand turn it on.
"COOE" is displaved,enter the cusWhen the word
tomer's 5-digit code to restoreradio operation,

5.

Remov the shear bolts trom the switch body.

6.

Installth new steering lock without the key insened.

Loosely tighten the new shear bolts.

8 . Insert the ignition key and check for proper operation o{ the steeringwheel lock and that the ignition
key turns freely.
9 . Tighten the shear bolts until the hex headstwist oft.

Removethe dashboardlower cover, left knse bolster, and lett kick panel (see page 23-68).

SHEAR BOLT

Disconnectthe 5-P connectorfrom tho under-dash

fuse/relaybox and the 3-P connectorfrom the main
wire harness.
Remove the steering column covers {see page
23-74t.

lll
TWIST-OFFPORTION

23-75

StartingSystem
ComponentLocation Index

A/T GEAR POSITION

swtTcHtA/Tl

{!nd NEUTRALPOSITIONSW|TCHI
Test. page 23-148
Replacoment.
pago 23-149

BATTERY
Test. page23-66

rM/rl
i:T:i,Ii5i?* sw'rcH
Switch PositionAdjustment,sction 12

STARTER
T6st, page 23-79
Solenoid Test, pag 23-83
Replacement,page 23-81
Overhaul, page 23-82
Reassembly,page 23-87

_lEr_
STARTER
CUTRELAY(M/TI
Wir6 color': BLK/WHT,
BLKAA'I{T,BLK/GNN,
lnd 8LK/RED
Test, page 23-70

f-l-D

--f--r
r-:-r lFl
-L-----l

--:--rl
r-rr1

l|

rfltll'l

l]0mmm[[|l

|Jmm[0[D0lj

23-76

Description
Startsr Intorlock Syslom {M/T):
The starter interlock system prevents the engine trom starting unless the clutch pedal is fully depressed.
The clutch interlockswitch turns on at the positionwhere the clutch disengages:15-20 mm {O.59-0.79 in) from the
fully depressedpositionoJ the clutch pedal.
NOTE: A full stroke of the clutch pedal is 135-145 mm (5.3-5.7 in) from the fully releasedposition

CLUTCH INTERLOCKSWITCH

135- 145 mm
{5.3-5.7 inl

Fully D6pro$od
Posidon

23-77

StartingSystem
Circuit Diagram

- HOODFUSE/RELAY
UNOR
8OX

t6Nfir0N
swTcH
$/Hr-o

l;\
crj

\87
I

BLl(A,t/l{T

{A/n

r--------------------------r

NEUTMIPOStTtoN
swtTcH
/ InA/Tger
\
\ poitionBwilch /

BLXNEO

T-r--'l
| )u.z

luNoF-oAsH

k {7,5A)|RSEinELAYSOX

r I
I

8t-u/RED

f7
. ECM
' PGM- FIMAIiIREI.AY
. BSAKE
CHECK
CIRCUIT

STATTER

23-7a

StarterTest
NOTE: The air temperaturemust be between 59 "F and
10O oF (15 oC 8nd 38 oC) betoretesting.

'1.

Disconnectthe 4-P connector from the ignition

coil.

Rccommandod Procedure:
a Use a starter systsm tester
a Connect and oporate ths equipment in accordance with manutacturer's instluctions.
a Test and tloublshoot as dscribed.
Altornat Procedura:
Use the followingequipment:
- Ammeter,O-4O0 A
- Voltmeter, O-2O V {accurate within O.1
volt)
- Tachometer,0- 12OOrpm
Hook up voltmeterand ammeteras shown.

Check the starter engagement:

Pressthe clutch pedalall the way in (M/T).and turn
"START". The startershould
the ignitionswitch to
crank the engine.
NOTE: On carsequippedwith manualtransmission,
the enginewill not crank unlessthe clutch pedalis
fully depressed.
a lf the starter does not crank the engine,check the
battery, battery positive cable. ground, nd the
wire connections for looseness and corrosion.
a Test again.
lf the starter still does not crank the engine,
bypassthe ignitionswitch circuit as follows:
Unplug the BLK/wHT wire trom the solenoidterminal. Connecta iumper wire ttom the battery
Dositive(+ ) terminalto the solenoidterminal.The
starter should crank the engine.
NEGATIVETERMII{AL

NOTE: After this test, or any subsequent repair,

resetthe ECMto clearany codes (seesection 1 1).

{cont'd)

23-79

StartingSystem
StarterTest (cont'd)
- lf the staner still does not crank the engine, remove the starter and diagnose its internal
problems.

Check crsnkingrpm:
Enginespeedduringcrankingshouldbe above 1O0
rom.

- lf the starter cranksthe engine,check for an open

in the BLKMHT wire and connectorsbetweenthe
starter and ignitionswitch.
Check the ignitionswitch.
On cars with automatictransmission,check the
A/T gear positionswitch (neut.alpositionswitch).
and connectors.
On cars with manual transmission.check the
starter cut relay, clutch interlockswitch, and connecrors.

lf soeed is too low, check tor:

NOTE; Checkthe No. 33 (50 A) fuse in the underhood Juse/rel8ybox and the starter cut relay,
Check for wear or damage:
The startershould crank the enginesmoothly and
steadilv.
lf the starter engages, but cranks the engine erratically, removethe startermotor. Checkthe starter,
drive gear, and flywheel ring gear for damag.
Check the drive gear overrunning clutch for binding
or slippingwhen the armatureis rotated with the
drive gear held. Replscethe gears if damaged.
Check crankingvoltage and current draw:
Voltageshould be no less than 8.5 volts.
Currentshould be no more than 38O amoeres.
lf voltage is too low, or current draw too high, check
for;

a Low batterv.
a Open circuit in starter armature commutator
segments.

a Starterarmaturedragging,
a Shortedarmaturwinding.
o Excessivedrag in engine.

23-80

a
a
a
a
a
o.

Loose battery or starter terminals.

Excessivelyworn starter brushes.
Open circuit in commutatorsegments.
Dirty or damagedhelicalsplineo. drive ge8r.
Defectivedrive gesr overrunningclutch.

Check the starter disengagement:

Pressthe clutch pedalallthe way in {M/T},turn the
ignitionswitch to "lll" and releaseto "ll" position.
The starter drive gear should disengagefrom the
flywheel ring gear.
lJthe drivegearhangsup on the flywheelring ge8r,
check for:
a Solenoidplungerand switch malfunction.
a Dirty drive gear assembly or damaged overrunning clutch.

Clutch InterlockSwitch Test (M/Tl

Remove the dashboard lower cover and knee
bolster, then disconnectthe 2-P connectortrom
the switch.
Check for continuitv b6tween the terminals according to the table.

Terminsl

.*.n*o]---\

Starter Replacement
NOTE: The radiomay havea codedtheft protectioncircuit. Be sureto get the customer'scode numberbeJore
- Disconnectingthe battery.
- Removingthe No.43 (10A)fuse.
(ln the under-hoodfuse/relavbox)
- Removingthe radio.
Atter service,reconnectDowerto the radioand tu.n it on,
"CODE" is displsyed,enter the cusWhen the word
tomer's 5-digit code to restoreradio operation.
1. Disconnectthe negativecable trom the battery,

RELEASEO
PUSHEO

G-

2.

Removethe enginewire harnessfrom the harness

clip on the starter motor.

3,

Disconnectthe startercabletrom the B terminalon

the solenoid,8nd the BLKMHT wire trom the S
terminal.
NOTE: In case of an A/T model, the starter cable
slso has to be removed from the bracket on the
transmissionhousing.

4.

Removethe two mountingbolts holdingthe starter, then remove the starter molor.

lJ necessary, rpl8ce th switch or adjust the

switch Dosition{sse section 121.

fl
9 N.m lO.9 kg-m, 6.5 lb-ftl

23-41

StartingSystem
Starting Overhaul
CAUTION: Btoro lmoving th6 starta., disconnect tho
ground cable from the battory.

BRUSHHOLDER

ARMATURE
ENO COVER

\-s
>*'N-

with PERMANENT
MAGNET

GEARHOUSING

@
\
l
LABYRINTH
TUEE

NUT
9 N.m (0
GEARHOUSING
COVER

soLEt{otD
Test, page 23-83

Wq
m"r"

23-82

)o.*o'o

OVERRUNIIII{G
CLUTCH ASSEMBLY

Starter SolenoidTest
'|,

Removethe stsnr solenoid.

2.

Checktor continuitybetweenthe terminalsin each

solenoidplungerpositionsccordingto th table,

Terminal

PULL.INCOIL

COIL
HOLD.IN

GITUUNU

Position
RELEASED
PUSHED

o-

SOLENOIOHOUSI G IGROUT{D)

23-83

StartingSystem
Armature lnspectionand Test
1.

Inspectthe armaturesurfacefor wear or damage.

Commutator Runout
Standard{Now}; 0-0.02 mm {0-0.0008 in)
SsrvicsLimit : 0.O5 mm (0.002 inl

Inspecl tor
damage.

A dirty or burnt commutatorsuriacemay Deresurfaced with emerycloth or a lathewithin the tollowing specificstions.

COMMUTATOR

Commutator Diametot
Standard(Newl: 28.0-28.1 mm
{ 1 . 1 O 2 -1 . 1 O 6i n l
SoruiceLimit ;27.5 mm (1.O8inr

VEBNIERCALIPER

lf the commutatorrunout and diametrare within

limits,checkthe commutatorfor damageor tor carbon dust or brasschips betweenthe segments.
4.

It the suriaceis dirty, reconditionit with a #SOOor

#600 sandpapr. Then, check mica deDth. ll
necessary, undercut the mica with a hacksaw
blad6to achieveproperdepth.

Commutator Mica Dpth

S t a n d a r d( N e w l : 0 . 4 - O . 5 m m ( 0 . 0 1 6 - 0 . 0 2 0 i n )
ServiceLimit : 0.15 mm {0.006 in}

23-a4

5 . CheckJor continuitybetweenthe segmentsof the

commutator.lf an open circuitexists betweenany
segments.replacethe armature.

7 . With an ohmmete.,checkthat no continuityexists

between the commutatorand armaturecoil core,
and betweenthe commutatorand armatureshaJt.
lf continuitvexists, replacethe armature.

COMMUTATOR

COILCORE

6.

COMMUTATOR

Placethe armatureon an armaturelesler. Hold a

hacksawblade on the armaturecore.

ARMATURETESTER

HACKSAW BLADE

j
ARMATURE

It the bladeis attractedto the coreor vibrateswhile

the core is turned,the armatureis shorted.Replace
the armature.

23-85

StartingSystem
Starter Brush HolderTest
1. Check that there is no continuity betweenthe @
and O brushholders.
lf continuity exists, replace the brush holder
assembly.

O EBUSHHOLOER

O BRUSHHOLDER

@ BRUSHHOLDER

2.

Measurebrush length. It not within the service limit,

replace the armature housing and brush holde.
assemblv.
Brush Length
Standa.d(Newl: 15.8-16.2 mm (0.62-0.64 in)
Sarvice Limit : 1O.Omm {O.39 in}

@ ERUSHHOLOER

Insertthe brushinto the brushholder,and bringthe

brush into contact with the commutator,then attach
a springscaleto the spring.Measurethe springtension at the moment the spring lifts off the brush.

SpringTension
[/ itsuba
( 1. 4 K W )

16-18N
.
6
'
l
.
8
kg, 3.5-4.O lbs)
{1

Mitsuba
{1.6KW)

1 6 - 1 8N
{1 . 6 - 1 . 8k g , 3 . s - 4 . O l b s )

SPRINGSCALE

23-86

Starter BrushInspection

NOTE: To seat new brushes after installingthem in

their holders, slip a strip of #5OO or #600 sandpaper,
with the grit side up, over the commutator, and
smoothly rotate the armature, The contact surface of
the brusheswill be sandedto the same contouras the
commutator.

OverrunningClutch Check
1 . Check that the overrunning clutch moves along the
shaft frsely. lf not, replace it.
Checkthat the overrunningclutch locks in one direction and rotates smoothly in reverse. lf it does not
lock in eitherdirectionor it locks in both directions,
reDlaceit.

Startel Reassembly

trI

Reassemblethe starter in the reverse order of

disassembly.
l.

Pry back each brush spring with a screwdriver,

then position the brush about haltway out of its
holder,and releasethe springto hold it there.

2.

Installthe armaturein the housing.Next pry back

each brush spring againand push the brushdown
until it seats against the commutator, then release
the springagainstthe end ot the brush.

aw

Checkthe starterdriv gear for wear and damage.

lf the gear is worn or damaged, replacethe overrunning clutch assembly; the gear is not available
separately.
NOTE: Check the condition ot the flywheel or totque convrter ring gear if the starter drive gear teeth
are damaged.

3.

Installthe end cover on the brush holder.

BRUSHHOLDER

23-87

Starting System
PerformanceTest
NOTE: Beforestarting the following checks, disconnoct
the wire from terminal M,8nd make a connectionas
describedbelow usingas heaw a wire 8s possible(preferablv equivalentto the wire used tor the car).
Pull-in Coil Test:
Connect the baftery as shown. lf the pinion protrudes,
it is working properly.
NOTE: Do not leavethe battery connectedfor more than
1O seconds,

Hold-in Coil Tsl:

Disconnect the battery from the M torminal. lf the pinion does not retract, the hold-in coil is working proporly.
NOTE: Do ;ot bave the battry connctodfor moro than
1O seconds.

23-88

Retlactlng Test:
Also disconnect the battery from the body. lf the pinion
retracts immediately, it is working properly.
NOTE: Do not l6avethe battery connectedJor more than
10 seconds.

Start.l [tlo-loadTest:
1.

Clamp the stsrter firmly in a vise.

2.

Connect the starter to the battery as described in

the diagrambelow and confirm that the motor starts
and keeps rotating.

3.

lf the electric current and motor soeed meet the

specifications when the battery voltage is 8t 1 lV,
the staner is working proprly.
Spocitication6:
Mitruba: 80 A 01 los! (aloclric currsnt),
(1.4KW) 2600 rpm 01 mote (motor spoodl
Mitsuba: 80 A or less (elctric curont),
{1.6KW) 2600 lpm or mor. {moior spccd}

23-89

lgnition System
ComponentLocation Index
IGNITIONTIMIITGCONTROLSYSTEM
. Description,page 23-91
. Troubleshooting,section 11
.Inspection and Stting,page 23-93

TESTTACHOMETER
DISTRIBUTOR
Top End Inspection,page 23-95
page 23-95, 97
Removal/lnstallation,
Overhaul,page 23-96
Reassembly,page 23-99
lgnirioncontrol Modu16{lcM)
Troubleshooting, section 1 I
ICM Input Test, Page 23-98

IGNITIONWIRES
Inspection and Test, page 23-99

SPARK
Inspection,page 23- 1O1

23-90

IGNITIONCOIL
Test, psge 23-1O0
SERVICECHECK COT{NECTOR
{2.P)

Description
lgnllion Timing Control:
The programmedignition (PGM-|G)used in this engineprovidesoptimum control oJ ignitiontiming. A microcomputer
determinesthe timing in responseto engine speed and manifoldvacuum. The input signalsare transmittedby the
TDC/CKP/CYPsensor,throttle position (TPl sensor,enginecoolanttemperature(ECT)sensor,and MAP sensor.This system,
which is not dependenton a governoror vacuum diaphragm,is capableof sefting leadangleswith complicatedcharacteristicswhich cannot be providedby conventionalgovernorsor diaphragms.

Enginecoolanttemperature(ECT)compensation

Basic Control:
The controlunit has storedwithin it the optimumbasicignitiontiming for ope.atingconditionsbasedupon enginespeed
and intakemaniJoldpressure,With compensstingsignalsfrom sensors,the system determinesoptimum ignitiontiming
and durationfor ambientconditionsand sends vottagepulsesto the lCM.
Compensationof ignitiontiming:
Compensationltem
ldling

RelatedSensorand Information
sensor
TDC/CKP/CYP
MAP sensor

Comoensationat warm-up ECTsensor

ECT compensation

ECT sensor

Description
lgnitiontiming is controlledto the ta.get speed
with compensationaccordingto the idling speed.
Lag angle is adjustedaccordingto warm-up conditions to bring about a good balancebetween
operatingperformanceand exhaustgas level.
Compensationfor lead angle at low engine
coolant temperatureand lag angle at high engine
coolanttemDerature.

Control at Start:
lgnitiontiming is fixed at 7o BTDCJorcranking.The crankingis detectedby the TDC sensor(crankingrpm) and slarter signal.

23-91

lgnitionSystem
CircuitDiagram

- HOODFUSEiRELAY
UNOER
BOX

""7
rcNtTtof{
swfTcH

ECM
IGNITION
COIL

il:-,

DISTTIBUTOR
ASSEMELY

TDC/CKPrcYP
SENSOR

-.-:1_| *,*t1*u

++
23-92

. TACHOMFIER
. TnANSMISSION
CONTROL
MODULE
fICM)
' CRUISECOMTROT
UNIT

GaugeAssembly
CircuitDiagram
- HooD
u DER
FtSE^ELAY
Box

T'ffi;ffi*"l
( + )+.-c'\-o.<\o+wtn-to
\_/

ittilfl8'I

6),,
rco/-

BtK,YEt

UI{DER.DASH
FUSSRELAY
80x

r-

BUVYEI

-iet'-

I
I
I

No.6lt20a)
l2O
FUSE

TMNsMtsstoN
COMTRO|
MoDULE
{rCM)

lt w
l l

YEL

R EOTYEI

GRNiORN

YEr, I

-[r-]^'
ll:'
l t l

MAINGAUGE
ASSEMSIY

++++
=;;;-

HIGH
BEAM
INDICATOR
UGHT
l1.4Wt

RED/BLU

GAUGE
LIGHTS
{3Wx5l

l"

Btt(

l82

I
RED

II
I

D MEN
FELAY

DASHUGHTS
BRIGIITNESS

couTRot
UNIT

G10t
G40z
G404

23-126

INDICATOR
POSITION
DIMMING
CIRCUIT

t
I

tcn|T,oN
CONTROL
MOOULE

0cMl
\--7

BLU

'---l

183

snmn I
MOTOR

PNK

-r_ J_

. 4WSCONTBoLUNTT I
. TnANSMTSSTON
I
MOOULE
COMTROL
{TCMI ORN
. CRUISE
CONTROT
UNIT
. ECM

Y_",_

4WS
COMTROI
UNIT

23-127

GaugeAssembly
CircuitDiagram(cont'd)

No.2(7.5A)
FUSE
ISTsigml)

COMBINATION
LIGHT
SWITCH

Y
II

RED/BTK

BLU/REO

cRursE

CONTROL
UNIT

23-128
l

t - - - - - - - - l

LIGHTTUBE
FLUOBESCENT
;
L______________---____J

TEMPEMTURE
FUEUNGINE
COOIATIT
IECT]
COMTROI.CIRCUIT

D4

t-+
\---J

INTEGMTED

coNrRoLUNlT

8\ ENGINEo|L
!. , PiESSURE
:I/ SWTCH

I t

F+t
A8SCONTROL
UNIT

23-129

GaugeAssembly
Removal
CAUTION:
a All SRS elctrical wi ng harnossesar covered with
ysllow outor insulation.
o Before disconnecting th6 SRS wire harn6ss, install
the short connoctor(s) on th6 airbag(s) (see page
23-294t.
a Roplacothe entir affected SRS harnossassembly if
it has an open cilcuit or damaged wiring.
. After inst8lling tho gauge a$embly, rechock tho
opration ot the SRS indicator light.

NOTE: The radiomay havea codedtheft protectioncircuit. Be sureto get the customer'scode numberbefore
- Disconnectingthe battery,
- R e m o v i n gt h e N o . 4 3 ( 1 OA ) f u s e .
(ln the under-hoodfuse/relaybox)
Removingthe radio.
Aiter service,reconnectDowerto the radio and turn it
on. When the word "CODE" is displayed,enter the
customer's 5-digit code to restoreradio operation.

2.

Removethe screws and the instrumentpanelvisor.

Removo th screws and the black face pan6l, then

disconn6ct the 6-P connector fiom ths clock reset
switch.

cot{t{EcToR

BLACTFACEPANEL

1.

Removethe tweeter covers trom the dashboaad,

covERs

23-130

Main Gauge Assembly:

4.

Remove the four screws from the main gauge

assembly.

Sub Gaugs Assembly:

6,

Remove the four screws from the sub gauge

assemblv.

7.

Placea cloth over tho dsshboardto protect the sub

gauge assembly,then pull the assemblyout and
disconnect its connectors.

MAIN GAUGEASSEMBLY

Place a cloth over the dashboard to protct the

main gauge assembly,then pull the assemblyout
and disconnectits connectors.

23-131

GaugeAssemblY
BulbLocations
Main Gaugo Assmblyi

HIGH BEAM II{DICATORLIGHT II.4 W}

rl{DtcaToRLTGHT
t1.4 W)
RIGHTTURN SIGNAI-IT{DICATORLIGHT (1.4 W}

sRs tNDtcatoF UGHTtl.4 Wl

(1.4Wl
4WStNDtCATOn
LTGHT

GAUGEucltTs {3 w r 5l

23-132

Sub Gaugs Assombly:

LOW FUELINDICA?ORLIGIIT 13 WI
CRUISELIGHT I3.2 W)

ABSIT{DICATOR
LIGHT(3 WI

BNAKESYSTEMLIGHT13W}

INDICATOR
LIGHT13W)

SEATBELTREMII{DERLIGHT(3 WI

{Caogda)

CHARGIXGSYSTE'{ UGHT 13 WI

BRAKEBULB
tf{DtcAToRIIGHT 13Wl

Tnu x r{lxcAToR
LIGHi (3 Wl

INDICATORLIGHT {3 WI
LOW OIL PRESSURE

MALFUNCTIONINDICATOR
LAMP (MIL}
(3 Wl

23-133

GaugeAssembly
Disassembly
Main Gsug Assembly:

SRSINDICATOR
MOUNTING
SCREWS
(x2)

NOTE:
a Handle the terminals and Drinted circuit boards
carefullyto avoid damagingthem.
a lf either the speedometeror the tachometr is faulty,
reolacethem both as a unit.

ilil0iltltil
lt0tl||Tilil
[0ffi[
L0l
SPEEDOMETER
MOU TI c SCREWS
lx3l

PRINTEDCIRCUITBOARD C

HOUSTNG

G
6- sd

ODO/TRIPMETER
page23-136

ra

r{e)

SRS INDICATORPANEL

FACEPAITEL
TACHOMETEB
Specificstion, page 23-124

PNI TED CIRCUITBOARD B

{-'2\:.

PRINTEDCIRCUITAOAROA

Spcificstion,
page 23-124

vtsoR

23-134

Sub Gaugs Assembly:

NOTE: Handle the terminals and printed circuit
boardscarefullyto avoid damagingthem.

PRINTEOCIRCUITBOARD/REARCOVER
MOU TI[{G SCREWS(x 161

FUEL/ENGINECOOLANT
TEMPEBATUREIECTI
GAUGE
Test, pge 23-139, 142

PNI EO CIRCUIf BOARO BOX

PRII{TEDCIRCUIT

FROIIT HOUSING

23-135

Meter/Odometer
Speedometer/Trip
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item to be inspected

:
a

9>.

'i

{ o -

a 3
-

c
c

.c.

z E

: P
v x

'E

Symptom

(L

l/,

Odometerand trip meter work, but speedometerdoes

o:-

?i o)

3 f

; d

n01.

Speedometerworks, but odmeterand trip meter do

not.

Speedometer,odometer,and trip meter do not work.

3
2

N O T E : V S S g r o u n di s v i a E C M ( G 1 O 1 ) .
VSS Input Test (At hahess side of 3-P connGctorl
No.
Wire
Test condition
Tost: DosirEdlsult
BLK

Underall conditions

BLK/YEL lgnitionswitch ON

ORN

lgnitionswitch ON

Checkfor continuityto ground:

Thereshould be continuity.
Checkfor voltageto ground:
Thereshouldbe battery
voltage.
Check for voltageto ground:
There shouldbe about 5 V

Possiblecause il .esult is not obtained

. An open in the wire.
. P o o rg r o u n d( G 1 0 1 ) .
. B l o w nN o . 2 3 { 15 A ) f u s e
. Short to ground
. Short to ground
. An open in the wire.

NOTE: A short to ground in the ORN wire can be causedby a short in anv comDonentconnectedto it.
VSS Test
Speedometer does not woIk.

lnspect No. 23 (15 A) luse in

undeFdashfuse/relaybox before
testing.

Turn the ignitionswitch ON.

Measure voltage between the

BLK/YELwire terminal and the
BLK wire terminalin the harness
sadeol the 3 P conneclor.
(To next page)

23-136

View from terminal side

CONNECTOR

(FrompreviousPage)

ls there battery voltageT

Check for continuity between

the BLK terminal and body
ground.

Repair op6n between VSS and

ground G101 via ECM.

Measure voltage belween the

oRN and rhe BLK wire terminals.

ls thereabout5 V?

Ropairop6n in tho BLK/YELwiro,

botwoen tho VSS and th undord6sh lus6/relay box.

Raise the lront oI the car and

supportil with stands.

Repatuopon in ths ORN wi.s or

shon to body grcund.

Touch a probe to the ORN wire

and connect it to body ground
througha voltmeter.

Slowly rotateone wheelwith the

other wheel blocked.

DoesvoltagepulselromOto
about 12 V?

Roplaca the vss

23-138).

(soe Page

Disconnectthe 16-P connector

at the speedometer,

Touch a probe to the ORN wire

and connect it to body ground
through a voltmeter,

Slowly rotate one wheel with the

other wheel blocked.

Doesthe meterindicate
pulsingvoltage?

Repairop6n in tho ORN wir betw6n the VSS and the sp6odometer.

VehicleSpeedSensor(VSS)

EngineLow Oil Pressure

IndicatorSystem

Replacement

Switch Test

Disconnect the 3-P connector from the vehicle

speedsensor (VSS).

1.

Remove the YEL/REDwire from the engine oil

pressureswitch.

Removethe mountingbolts, then removethe VSS.

2.

Checkfor continuitybetweenthe positiveterminal

and the engine (groundl,

NOTE: The VSS drive link is a very small part, be

careful not to lose it.

a There should be continuity with the engine

stopped.
a There should be no continuitywhen the engine
runs.

3-P CONNECTOR

OIL FILTER

3.

ENGINEOIL PBESSURESWITCH
18 N.m (1.8 kg-m, 13.0 lb-ftl
1/8 in. BSP(EritishStandard
PipeTaper)28 threads/inch.
Use proper liquid sealant.

Installin the reverseorder of removal.

YEL/REDWIRE

3.

23-138

POSITIVETEBMINAL

lf the switch fails to operate,check the engineoil

level.lf the engineoil levelis OK, checkthe engine
oil pressureand, it necessary,inspectthe oil pump
(seesection 8).

FuelGauge
GaugeTest
NOTE: Reterto page 23- 129 for the circuitdiagramof
the fuel gauge.
1.

Check the No. 13 {1O A) fuse in the under-dash

tuse/relaybox beforetesting.

2.

Open the trunk,

3.

Removethe fuel tank accesspanel.

4.

Disconnectthe 5-P connectorfrom the fuel gauge

sendingunit.

Turn the ignition switch OFF. Connect a iumper

wire between the YEL/GRN and YEL/WHT
terminals.
CAUTION: Do not connect power and ground to
th lerminals; it will damage th6 luel gaugs.
7 . Turnthe ignitionswitch ON, and checkif the gauge
"F"
indicates
CAUTION: Disconnct the iumpor rYireas soon as
"F", or you will damags the
the gaugs r6aches
gau9e.
a ll the fuel gaugedoes not work at all, replaceit.
a lf the fuel gaugeis OK, inspectthe sendingunit

YEL/GR

CONNECTOB

-L

I r t,---t I
Fi!.-1---1
I'--'-r--l l t I
YEUWHT

5.

Connect the voltmeter positive probe to the

YEL/GRNterminaland the negativeprobeto body
ground,then tu.n the ignitionswitch ON.
There shouldbe between 5 and 8 V.
a
a
-

lf the voltage is as specitied,go to step 5.

lJ the voltageis not as specitied,check for:
An open in the YEL or YEL/GRNwire.
Looseor disconnectedterminals.
Faultytuel gauge.

23-139

FuelGauge
SendingUnit Test
Do not smok whils working on ths fuol
@
systom. Ko6p open flame away flom th work aroa.

b.

Check the resistancebetween the B and C terminals.lt shouldchangeevenlyas you changethe

positionof the tloat.

1. Open the lrunk.

2.

Removethe fuel tank accesspanel-

3.

With the ignition switch OFF. disconnectthe 5-P

connectorfrom the fuel gauge sendingunit.

4.

a lf it does not change evenly, replacethe fuel

sendingunit.
a lf it changesevenly, go to step 7.
7 . Support the sending unit on a workbench in the
positionshown.

Removethe five nuts. then take the sendingunit

assemblyout of the fuel tank,

Top ot tho wortb.nch

8.

Measurethe resistancebetween the B and C terminals by moving the float to the distanceslisted
Jor E (EMPTY),1/2 (HALF FULL).and F (FULLl.

Float Position
ResistancelO)

Measure the resistance between the A and B

terminals.
a It it is more than about 27O-33O O, reDlacethe
tuel sendingunit.
. lf it is within about 27O-33O O, go to step 6.

23-140

(Bottom ol tho tuel tank)

E
16-32

1t2

E
20.5 mm
( O . 8 0i n )
9.

1 1 6 - 1 8 8 2 3 9- 3 1 4

F
73.6 mm
(2.90in)

126mm
l'4.7 inl

lf unableto obtain the above readings,replacethe

fuel gauge sendingunit.

Low Fuel IndicatorSystem

Indicator Light Test
NOTE: Referto page23-127 for the diagramof the low
fuel indicatorcircuit.

4.

Parkthe car on level ground.

Removethe fuel tank accesspaneland disconnect

the 5-Pconnector{rom the fuel gaugesendingunit.
Connect the GRN/WHTterminal to the BLK terminal with a iumper ware.
It the light comeson, the problemis the sending
unlt.
lf the light does not come on, the problemis an
ooen in the GRN/WHT wire to the gsuge
assemblv,no power to the gauge,a bad bulb, or
poor ground.

Do not smoke whil working on the

E@
tusl system. Keep open flamo away lrom tho wolk
area. Drain tuel only into an apploved container.
Drainthe fuel tank into an approvedcontainer.
Then installthe drain bolt with a new washer.
A d d l e s st h a n 9 . Ot 1 2 . 4U . S .G a l ,2 . Ol m p . G a l )o f
fuel and turn the ignitionswitch ON.
The low luel indicatorlight shouldcome on within
four minutes.

til
LIGHT
LOWFUELINDICATOR
(ln the subgaugeassemblyl
a lf the light goes on within four minutes,go on to
step 5.
a lf the light does not go on within four minutes,
go on to step 4,

5.

Add one more gallonof fuel [approx.4 f ( 1.1 U S.

G a l ,O . 9 l m p . G a l ) 1 .
The light should go off within four minutes.

23-141

(ECTIGauge
EngineCoolantTemperature
GaugeTest

SendingUnit Test

NOTE: Reterto pag 23- 129 tor the circuitdiaglamof

the enginecoolanttemperature(ECTIg8ugs.
'1.

Check the No. 13 (10 A) tuse in the under-dash

tuse/relaybox beforetesting.

2.

Make sure the ignitionswitch is OFF,then disconnect the REDwire from the ECT sendingunit 8nd
ground it with a jumper wire.

1 . Disconnctthe REDwire from the sendingunit.

2 . With the snginecold, use an ohmmeterto measure
rsistancebtween the positive terminal and the
engine (ground),

--------.____/

REO
WIRE
POSITIVETERMINAL

REDWIRE

ECT SEI{DII{GUNIT

Checkthe temoeratureof the coolant.

4.

Turn the ignition switch ON. Check that the

segmentsof the ECT gauge light up.
CAUTION: Turn tho ignition switch OFF lmmdiately after the ssgmsnts light up. Failuroto do
so may damag the gaug6.
a lf the segmentsdo not light up, check for an
open in the YEL or REDwire. lf the wire is OK,
replacethe ECT gauge.
a lf the segmentslight up, checkthe sendingunit.

23-142

ECT SENDINGUNIT

Run the engine and measu.e the change in

resistancewith the engine at operatingtemperature (.adiatorfan comes on).

Coolant
Tempgrature
Resistance(O)
5.

1 3 3 0 F( 5 6 . C )
(Enginecold)
'l42

1 8 5 0 F { 8 5 0C ) 2't20F t1000cl

49-32

lf the readingsyou get are substantiallydifterent

from the speciticationsabove,replacethe ECTsending unit.

BrakeSystem Light
ParkingBrakeSwitch Test
Removethe floor consoleand disconnectthe connectof from the switch.
Checkcontinuitybetweenthe positiveterminaland
body ground.
a There should be continuitY with the brake lever
uo.
a There should be no continuity with the brske
lever down.

BrakeFluid Level Switch Test

Remove the reservoir cap. Check that the float
movesup and down freely;if it doesn't, replacethe
reservoircap assemblY.
Check Jor continuity between the terminalswith
the tloat uD and down,
a There should be continuity with the float down
a Thereshouldbe no continuitvwith the float up
Replacethe resetvoircap assemblyif necessary.
RESERVOIRCAP

BRAKELEVER

a blilt-in
lHas
]
\ magner
l
DOWN POSITION
contacts closed
when float drops.

UP POSIIION
Canads:

Switch contacts open, at

properfluid level.

NOTE: lf the parkingbrakeswitch is OK, but the brake

system light does not work, performthe input test for
the daytime running lights control unit {see page
23-180).

23-143

A/T GearPositionIndicator
Component
LocationIndex
CAUTION:
a All SRS olectdcal wi ng harnsssss are covorad with
yellow outer insulation.
a Betore disconnecting the SRS wile ham6ss, install
the short connector(sl on the airbag{sl (see page
23-2941.
a Roplacethe ntile atfocted SRS hamoss assembly it
it has an open ci.cuit or damaged wiring.
a Aftel installing tho gaugo assembly, recheck th
operation ol the SRS indicator light.

MAIN GAUGE ASSEMBLY

Removal,p6ge23-130
p6ge23-134
Disassembly,
INTERLOCKSYSTEM
See page 23 158
A/T GEAR POSITION
INDICATOR
Input Test, page23-146
Bulb Replacemenr,
page 23-1

TRANSMISSIONCONTROLMODULE (TCMI
See Automatic Transmission,
section 14

A/T GEAR POSITIONSWITCH

Test, page23-148
page 23-149
Replacement,

23-144

CircuitDiagram

*t-r"T
UNDER_DASH
80X
FUSE/REI.AY

BOX
HOOD
FUSE/RELAY
UNDER-

COMBIiIATION
LGHTSWlTCH

. ECM
. TMNSMISSION
CONTNOL
MODUIE
ITCMI

TRANSMISSION
COMTFOL
MODULE(TCM)

I-TGRN

llnthomalngruo.a$omblyl

OIMMING
CIRCUIT
INDICATOR
AITGEAR
POSITION

II
t

10

TNANSMISSION
CONTNOL
(TCM)
MODULE
INTERLOCK
UNIT
CONTROL

T(

VI

GRNAVIfi

COMBINATION
LIGHT
SWITCH

VI
AITGEAR
POStTT0N
CONSOLE
LIGI{T

{r.4w)

t
t

E-.'-1,i,,,,'---Jn
AITGEAR
PostloN swlrcH

G4o1
G402
G404

G401
G402
G(X

23-145

A/T GearPositionlndicator
IndicatorInput Test
CAUTION:
a All SRS lectrical wiring harnossesa.e coveled with
yllow outor insulation.
a Betoro disconncting the SRS wirs harnoss, install
the shon connectorls) on the airbag{s} {see page
23-294t.
a Feplace tho entire atfoctod SRS hamoss assembly if
it has an open circuit or damagd wiring.
a After installing the gauge ssssmbly, r6check tho
operation of tho SRS indicatol light.
1.

Removethe main gauge assemblyfrom the dashb o a r d{ s e ep a g e2 3 - 1 3 O ) .

2,

Disconnectthe 16-P and 1O-Pconnectorsfrom it.

3.

Inspectthe connectorand socket terminalsto be

sure they are all makinggood contact.

SRSMAIN HARNESS

a lf the terminals afe bent, loose, o. corroded,

repair them as necessary, and recheck the
sysrem.
a lf the terminalslook OK, make the loltowing input tests at the connector.
- lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests prove OK, the indicator
must be faulty; replacethe gaugeassembly.
NOTE: Different wires with the same color have
been given a number suflix to distingujshthem
{YELj and YEL2are not the same).
View from wire side

23-146

Test condition
1

Tost: Desiled result

Possiblocaus il rosult is not obtainod

BLK

Under all conditions.

CheckJor continuityto ground:

There shouldbe continuitY.

. Poorground{G401,G4o2,G404).
. An ooenin the wire.

YELI

lgnitionswitch ON.

Checktor voltageto ground:

There shouldbe bsttery
voltage.

. B l o w nN o . 1 ( 1 OA ) f u s e .
(ln ths under-dashfuse/relayboxl
. An open in the wi,8.

GRN/WHT Shift lever in E.

NOTE: Don't push the
brake pedal.
GRN/RED Shift lever in @.
Shift lever in [.
GRN

Check for continuity to ground;

Thereshould be continuity.
NOTE:Thereshouldbe no
continuityin any other
position,

Faulty An gear position switch.

Poor ground (G4O1,G4O2,G4041.
An ooen in tho wire.

GRN/BLU Shift lever in E.

GRN/YEL Shift lever in @.
LT GRN/
WHT
4

Shift lever in [.

REDand Combinationlight switch

RED/BLK ON and dash lights
brightnesscontrol dial or
full bright.

Check for voltagebetween

RED/BLKand REDterminals:
There shouldbe battery
voltage.

. Faultydash lights brightnesscontrol system.

. An open in the wire.

GBN/ORN lgnitionswitch ON and

shift lever in any Position except @.

Check for voltageto ground:

Thereshould be bsttery
voltage fof two seconds after
the ignitionswitch is tutned
ON, and less than 1 V two
secondslater.

. F8ultytransmissioncontrol module
(TCM).
. An open in the wire.

lgnitionswitch ON and
shift lever in any posation except E.

Check for voltageto ground:

Thereshouldbe lessthan 1 V
tor two secondsafter the ignition switch is turned ON, 8nd
more than 5 V two seconds
later.

. FsultyTCM.
. An open in the wire.

lgnitionswitch ON.

Check for voltageto ground:

There shouldbe more than
1 1V .

. FaultyECM or TCM.
. An open in the wire.

YEL'

LT GRN

23-147

A/T GearPositionIndicator
A/T GearPositionSwitch Test
CAUTION:
a All SRS ol6ctrical wiring harnessosare coverod with
yallow outor insulation.
a Botore disconnoctlng the SRS wiro halnass, install
tho short connoctor(s) on th6 airbag(sl (s6o pagg
23-2941.
a Roplacoth ontire Effoctod SRS halness assombly if
it has an opon circuit or damaged wiring,
a Aftr imtalling th gaug6 asEembly, rocheck tho
op.ration ot tho SRS indlcator lighr.
1.

Removeths console,then disconnectthe 12-Pand

3-P connectorsfrom the switch.

2.

Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.
a Move the lever back and forth at each oosition
without touchingthe push button, and checkfor
continuitywithin the rangeof tree play.
a lf there is no continuitywithin the rangeof free
play, adjust tho position ot th switch as
describedon the next page.

A/T Goar
Posltlon
Switch
\

Back-up
Light
Switch

l{eutral
Positlon
Switch

T6rminal

ffi;-------l

tr

oo-

tr

oo-

o-

23-148

ll

t0

t3

15

-o

a
lTl

--{}
--{}

--o
--o
--o
--o
--o
--o

o-

_O

o- *-o
o- --o

A/T GearPositionSwitch

Adiustment
1

3,

A/T Gear PositionSwitch

Replacement

Shift to the lll positionand loosenthe switch nuts.

Removethe console,then disconnectthe 12-Pand

3-P connectorstrom the switch.

Slidethe switch rearwardlup to 2.0 mm (0.O8in)l

until there is continuitybetween No. 8 and No. 11
terminalswithin the range of free play of the shift
lever.

Remove the two mounting nuts and remove the

switch.

SWITCH SLIDERlln po3ition LLI)

Recheck for continuity between each of the

termtnals.

SHIFT LEVER

NOTE:
a li adiustmentis not possible,check ior damage
to the shift lever detent and/or bracket,
lf there is no damage,replacethe A/T gear position switch.
a The engineshouldstart when the shift leveris in
position@ anywhere within the range of free
play.

Fre play

]tl
@t

ll\''-q---------.__-

GEAR POSITION

LOCK PIN

swtTcH

Positionthe slideron the new switch to positionE

as shown above.
Shift the leverto
to position,
5-

"Neutral". then slipthe switch in-

Attach the switch with the two mountingnuts.

6 . Test the switch in the @ and $

positions.

NOTE: The engine should start when the shift

leveris in positionfl anywherein the rangeof free
ptay.
Adjust rearward
lup to 2.0 mm (O.O8in)l

Connectthe 12-P and 3-P connectors,clamp the

harness.and installthe console.

23-149

A/T GearPositionIndicator
Bulb Replacement
CAUTION:
a All SRS oloctrical wiring hamesses are coverod with
yellow outor insulation.
a Before disconncting tho SRS wir6 ham6ss, install
the shon connector(s) on th 8i|bag(s) {see page
23-294t.
a Replacothe ntire affectod SRS harness assembly if
it has an opon ci.cuit or damaged wi.ing.
a Afior installing tho gaug assombly, roch6ck tho
opelation of th SRS indicator light.

1.

Remove the main gauge assembly (see page

23-130t.

2.

Disassemblethe main gauge assembly(see page

23-134!.

3.

Remove the bulb from the A/T gear position indicator circuit board.

B U L BI 1 . 1 2W I

4.

Installtheindicatorin the reverseorderof removal.

23-150
SSlisul&

Safety Indicator
ComponentLocationIndex
CAUTION:
a All SRS elctrical wiling hamossos aro covared with
yellow outof insulation.
a Botor disconnecting th6 SRS wite harness, install
the short connector(e) on tha airbag(s) (see page
23-2941.
a Replacoihe ntiro aftocted SRS harnossassombly il
it has an open cilcuit or damagod wiring.
a After installing tho gauge assembly. rocheck ths
operation of tho SRS indicator light.
SAFETYINDICATOR(ln the sub gauge sssemblyl
Troubleshooting.pag 23-1 56
Removal,page23-130
fnput Test, page 23-154
page23 133
Bulb Replacement,
CEILINGLIGHT
Test/Replacement.page 23-1 90
HIGH MOUNT BRAKELIGHT
p a g e2 3 - 1 9 5
PASSENGER'SDOOR SWITCH
Test. page 23-191

BRAKESWITCH
Test, page23-195

TNUNK LIGHT
est, page 23-199

RIGI{T BRAKELIGHT
AILURESENSOR
Test, page 23-157

DRIVER'SDOOR
Test, page 23- 191

LEFTBRAKELIGHT
SENSOR
FAILURE
Test,page23-157

LATCH SWITCH
Test/Replscement,page 23-189

Safsiy lndicator Systsm:

Bulbsare usedto indicatewhen the trunk lid or a door is not fully closed,or when a brakelight is faulty. The bulbswill remain ON Jor about two seconds after the ignition switch has been turned ON to show that the system circuit is
functioning.
Blako Light Bulb Fallule Indicatot:
lf all brakelight bulbs are OK, the indicatorlight stays off becausethe WHT/GRNwire is constantlybeinggroundedby
the two brakelight tailuresensorsconnectedin series.With the brakelight ott, the groundis providedthroughthe diode,
the failuresensorrelaycoil, and the bulb filaments.With the brakelight on, alltour relays(threein the leit sensor.one in
the right sensor),connectedin series,supplyground.lJ eitherof the two bulbsis not working.the chainis brokenand the
WHT/GRNwire is not being grounded.The indicatorlight comes on.

23-1

Safety Indicator
Circuit Diagram
-HOOD
UNDER
FUSE/RTAY
BOX
WHT/YEL

'Mreoncreo
,*rn*tro
|

00oRtocK I

|| .POWER
38lY*0'I| 8fi|l*o'
POWER
D00R
rocK

| 8fii[*'' |

8Rifl*'

|H .Y,| "Y,

q*,*,Q*,,,n.,,,
l8fi,?f., lDooRsw'TcH

1
:

23-15.2

-:-

*tt"r,J

+V

. ECM
, TRANSMISSION
CONTROL
(TCMI
MODULE
' CRUISE
UNIT
CONTROL
' ABSCONTROL
UNIT

+BNlwHT

GRt{/l

LEFT !-

T A I T L I G H T ,:

BRAKE
LIGHI
t43CPl

BLK

BLK

{
G521

23-153

Safety Indicator
IndicatorInputTest
a All SRS eloclricsl widng ha]nossesare coverod with
yollow outr insulation.
a Bofole disconnecting the SRS wira hamss, install
ths short connoctor(s) on the airbag(s) lsee page
23-294t.
a Replacothe sntir affectad SRS harness assembly il
it has an opon circuit or damagod wiring.
a Aftor installing th6 gaug a$ombly, lochock ths
operation of the SRS indicator light.
1.

I
I

Removethe sub gauge assemblyfrom the dashboard (seepage 23-130).

2 . Disconnectthe 30-P connectorfrom the sub gauge

assembly.
Inspectthe connectorand socket terminalsto be
sure they are all makinggood contact.
a lf the terminals are bent, loose, or corroded,
repair them as necessary, and recheck the
sysrem.
a lf the terminalslook OK. make the following input tests at the connector.
- It a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf allthe input tests prove OK, the printedcircuit board must be faulty; replaceit.
Viow lrom wire side

GRN/BED

SUBGAUGEASSEMBLY

23-154

Tosi condition
1

T6str Desired rssult

Possiblcause it result is not obtained

BLK

Under all conditions.

Checkfor continuityto ground:

Thereshould be continuitv.

. Poor ground {G4Ol, G4O2,G4O4l.

YEL

lgnition switch ON.

Check for voltageto ground:

There shouldbe battery
voltage.

. B l o w nN o . 1 3 ( 1 OA ) I u s e .
(ln the underdashfuse/relaybox)
. An open in the wire.

Check for continuityto ground:

Thereshouldbe lessthan 4 kO.

B l o w nN o . 4 1 ( 1 5 A ) f u s e .
Faultybrakeswitch.
Blown brakelight bulb.
Faultybrakelight failuresensor.
P o o rg r o u n d( G 5 2 1 .G 5 5 1 ) .
An open in the wire.

GRN/BLK Trunk lid open.

Check for continuityto ground:

There shouldbe continuity.
NOTE:Beforetesting, remove
N o . 4 6 ( 15 A ) f u s e i n t h e
under-hoodfuse/relaybox.

Faultytrunk latch switch.

P o o rg r o u n d( G 5 2 1 ) .
An open in the wire.

BLK/WHT Ceilinglight switch in

Connectto ground:Ceiling
light shouldcome on.

E l o w nN o . 4 6 ( 1 5 A l f u s e .
Faultyceilinglight.
An open in the wire.

WHT/GRNBrakepedal pushed.

MIDDLEposition.

GRN/BLU Driver'sdoor oDen.

GRN/RED Passenger'sdoor open.

Check for continuityto ground:

Thereshouldbe continuity.
NOTE: Beforetesting. remove
N o . 4 4 ( 15 A l a n d N o . 4 6 ( 15
A) fuses in the under-hood
fuse/relaybox.

. Faultydoor switch.
. An open in the wire.

23-155
_

Safety Indicator
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence
Item to be inspected

a;

< +
rr:

o f
{ d

o c
z 3 z a
c g ; G
I t
9 c

-9

- c

3
<t

Symptom

G401
G402 Y E L
G404

No indicatorsooerate.
Indicator lights do not come on when the
ignition switch is turned to ON.

Door indicatorlight does not come on with

ooors open.
Trunk indicatorlight does not come on with
trunk lid open.

Brakeindicatorlight does not come on with

blown brake light bulb.

Brakeindicatorlight remainson with good

brake light bulbs.

Ceilinglight does not come on with door open

(with switch in MIDDLEposition).

23-156
i,,,

GRN/BLK
GRN/RED

G521

G551

GRN/BLK

WHT/GRN
or GRN
BLKiWHT

raKeLight
I Gsr
Densor Test
Llgnr Failure
rallure Sensor
Brak

1 . Firstmake sure the brakelights come on when the

brake oedal is gressed.
a lf all the brake lights come on. go to step 2.
a lf one of the brake lights does not come on.
check whether the bulb is blown. lf the bulb is
OK. go to step 2.
a lf none oi the brake lights come on, check the
brake light circuit {see page 23-153).

4.

Open the taillightaccesspanelto the left taillight.

Remove the bulb socket housing. watch the
light when the ignition switch is
trTARnAMFl
turnedfrom OFFto ON with the B (GRN)wire ot the
6-P connectorgroundedand the brakepedalpresseo.
LEFTFAILURESENSOR

Open the trunk lid and the taillightaccesspanelto

the right taillight.Removethe bulb sockethousing.
Watch the TBRARE-IAMFI light in the safety indicat( , when the B {WHT/GRN)wire of the 4-P connectoris groundedand the ignitionswitch is turned
t r o m O F Ft o O N .

a It the BRAKELAMP I light comes on and stays

on, there is an open in the B (GRNIwire between
the le{t failure sensor and the right failure sensor.
r tt ttre lEnnfELAME light does not stay on, go
to step 5.
a lf the IBRAKELAMP light comes on and stays
on, check tor an open in the B (WHT/GRN)wire
between the safety indicator and the right
failuresensor.
r tf the i gnnre- LAtt,tpI tight does not sray on. go
to steD 3.
3,

watch ttre f aRAKaLAMt light when the ignition

switch is turned from OFFto ON with the D {GRN)
wire of the 4-P connectorgroundedand the brake
pedal pressed.

5 . Warch rhe trRAK-E LAMFI light when the ignition

switch is turned from OFF to ON with the F (BLK)
wire ot the 6-P connectorgroundedand the brake
pedal pressed.
r tt ttre I aR-AKaLAMPI light comes on and srays
on, replacethe left tailuresensor.
o tt tne IaRAKaLAMPI light does nor slay on,
check for an open in the F {BLK)wire between
the left failuresensorand ground,and checkJor
a p o o rg r o u n da t G 5 5 1 .

o It the [6nAre LAMpllight comes on and stays

on, replacethe right failuresensor.
o tt ttre IERAKELAMpllight does not stay on, go
to step 4.

23-157

InterlockSystem
ComponentLocationIndex
CAUTION:
a All SRS sloctrical wiring hamosses ar cove?edwith
yollow outer insulation.
a Botolo disconnectlng ths SRS wira hamoss, install
the short connector(sl on the airbag{sl, then dlsconnect the wire harnesa (soo page 23-294).
a Rsplacthe sntile affected SRS hamass assembly if
It has an opon clrcuit 01 damaged wiring.
a Aftor inEtalling ths gaugo assombly. rechock th6
opelation ol th SRS indicator light.

A/T GEAR POSITIONII{OICATOR

So page23-144

INTERLOCK
CONTROLUNIT
InputTest,page23-161

KEY INTERLOCKSOLEI{OID
and KEY INTERLOCKSWITCH
(ln thg steering lock assembly)
Test, pge 23-162

A/T

swtTcH

POStTtON

Tst, page23-148
Replcement,psg 23-149

23-158

SHIFT LOCK SOLENOID

Test, page 23-163
page 23'163
Replacement,

Description
The car is equippedwith the following devicesto preventinadvertentshifting:
a Shift lever with shift lock
a Key cylinderwith interlockedignitionkey
Shilt Lock Systom:
The shift tock system preventsthe shitt leverfrom movingto @ or p

from the @ unlessyou step on the brakepedal.

NOTE:
a The shift lever cannot be shifted when the brakepedaland the acceleratorare steppedon at the same time.
a In caseof svstem malfunction,the shift levercan be releasedby pushinga key into the releaseslot nearthe shift lever.

Key Intorlock System:

When the shift leveris in any
The ignitionkey cannot be removedtrom the ignitionswitch unlessthe shift leveris in L?.1.
untilthe leveris movedto
to
be
removed
positionother than @. a solenoidis activated,makingit impossiblefor the key
the lP l.
I ne sntn tever rs In Ll:l

INTERLOCKLEVER

SOLENOID
IOFFI

KEYCYLINDER
The shilt lever is in any position except l-P-l

SOLENOID
(oNt

23-159

InterlockSystem
GircuitDiagram
NOTE: Different wires with the same color have been given a number suffix to distinguish them (GRN/WHTl and
GRN/WHT' are not the same).

- HOODFUSEiRELAY
UNOER
8OX

WHT/YEI.

DASH
UNOERFUSEiRELAY

GRNMIfT I

HORN
CIRCUIT

8ox

SHIFT
LOCK
s0LE otD
loN:UNLoCK)

. ERAKE
UGHTS
. cRutsE
c0t{rRoL

{
G40l
G402
G404

23-160

ControlUnit InputTest
Oisconnectthe 8-P connectorfrom the interlockcontrol
untr.
Inspectthe connectorand socket terminalsto be sure
they are all makinggood contact.
a lJ the terminalsare bent, loose, or corroded,repair
them as necessary,and recheckthe system.
a lt the terminalslook OK, make the following input
tests at the connector.
- lf a test indicatesa Droblem,find and correctthe
cause,then recheckthe svstem.
- lf all the input tests prove OK. substitute a
known-goodcontrol unit and recheckthe system.
lf the check is OK, the controlunit must be faulty;
reDlaceit.

CONTROLUNIT
INTERLOCK

WHT/GRN

NOTE: lf the shift lock solenoidclickswhen the ignition

switch is turned ON and you step on the btake pedal
{with the shift leverin LLI),the shift lock system is electronically normal; if the shift lever cannot be shifted
from LBl, test the A/T gear position switch as desctibed
on page 23-148 and see section 14.

View from wire side

Shift Lock System:

No.
1

Test condilion

Wile

WHTiGRN lgnition switch ON.

Brakepedal pushed.
lgnition switch ON,
brake pedsl and acceleratorpushedat the
s a m et i m e .
GRN/WHT' Shift lever in @.

GRN

lgnitionswitch ON.

Test: Dosired result

Check for voltage to ground:
There shouldbe battery
voltage.
Checkfor voltageto ground:
Thereshouldbe lessthan battery voltage.

Possiblocause if result is not obtained

Blown No. 41 (15 A) tuse.
Faulty ECM.
Faulty brakeswitch.
Faultythrottle position (TP,sensor.
An open in the wire.

Checkfor continuityto ground:

Thereshouldbe continuity.

FaultyA/T gear positionswitch.

Poorground (G4O'1.G4O2,G4O4).
An open in the wire.

Checktor voltageto ground:

There shouldbe battery
voltage.

Blown No. 13 {10 A) fuse.

Faultyshift lock solenoid.
An open in the wire.

K6y Int6 ock System:

Tst: Desired result

Possiblecause it lesult is not obtained

Checkfor continuityto ground:

There shouldbe continuity.

. P o o rg r o u n d{ G 4 O 1 G
, 4 0 2 ,G 4 O 4 )
. An open in the wire.

GRN/WHT' Shift lever in E.

Check for continuityto ground:

There shouldbe continuity.

FaultyA/T gear positionswitch.

Poor ground (G4O1, G4O2,G4O4).
An open in the wire.

WHT/RED lgnitionswitch turned to

ACC (l) and the key
WHT/BLU pushedall the way in.

Check for voltageto ground:

There should be battery
voltage.

B l o w nN o . 4 6 ( 1 o A ) f u s e .
Faultysteeringlock assembly(key
interlocksolenoid).
An open in the wire.

No.

Wire

BLK

Test condition
Under all conditions.

23-161

InterlockSystem
' Key
I esl SolenoidTest
InterlockDolenolq
Kev IntenOCK
CAUTION:
a Alt SRS elactrical wiring harnessosare covord with
yollow outer insulation.
Bolore disconnecting ths SRS wira ham45, inatall
the shon connectorls) on tho airbag(s) lsee page
23-2941.
Replacothe ntiro aftoctod SRS hamess assembly if
it has an opon cilcuit or damaged wiring.

3.

Checkfor continuitvbetweenthe terminalsin each

switch position according to the table.

\___------1"-'"d
lonition
iwitch
ACCfl)

4.

SRSMAINHARNESS
'1.

Remove the dashboard lower cover and knee

bolster.

2.

Disconnectthe 8-P connectortrom the main wire

narness.

View trom wire side

23-162

Po8ition
Koypushd
in.
Koyrlossod.

o(J-

--o

Check that the kev cannot be removed with powe.

and ground connectedto the A and C terminsls.
a lf the key cannot be removsd, th ksy interlock
solonoidis OK.
a It the key can be removed, roplace the ste8ring
lock assemblv (the key intetlock solsnoid is not
availablseparstely).

Shift Lock SolenoidTest/Replacement

Test:
1. Removethe console,then disconnectthe 3-P connectorof the shift lock solenoidfrom the main wire
narness.

NUTS
Replace.
1Ot{'m

NOTE: Do not connectpower to the B l-) terminal

{reversepolarity}or you will damagethe diode inside the solenoid.
Connect batterv oower to the A terminal and
ground to the B terminal momentarily.Check the
solenoidto see if it works. lf it does not work,
replaceit.
NOTE:
a When the shift lock solenoidis ON, check that
there is a cleafanceol 2.9 ! O.5 mm {0.114 t
0.020 in) between the top corner of the shift
\ack\e\e\ andthe \ock p\n qroo\e \see c\earance
check on this paqe).
a When the shift lock solenoidis OFF, make sure
that the lock pin is blocked by the shitt lock
tever.
a lf it is not, adjust the positionof the shift lock
solenoid.

lnstall the new shift lock solenoid in the reverse

order of removaland adjust its position.
a when the shift lock solenoidis ON. check that
e J 2 . 9 t O . 5 m m ( O . 1 1 4a
t h e r ei s a c l e a r a n c o
0.O2O in) between the top corner of the shift
lock lever and the lock pin groove, and tighten
the self-lockingnuts.
NOTE: Use brand-newselflocking nuts.
2.9 r 0.5 mm
(0.'114r O.O2OInl
SHIFT LOCK
LEVER

LOCK PIN
GROOVE

when the shift lock solenoidis OFF,make sure

that the lock pin is blocked by the shift lock
tever.

Rsplacement:
1. Removethe solenoidpin.
2.

Remove the self-locking nuts and shift lock

solenoid.

23-163

IntegratedGontrolUnit
CircuitDiagram
Descdption
An integrated control unit, located in the left kick panel, integrates the tunctions of the key - in/seat beh reminder,
side marker light f lasher, wiper/washer, lights - on reminder, rear window defogger timer, entry light timer, power
window ky -off timer, and engineoil pressureindicatorflashercircuits.
NOTE: Different wirs with the same color have be6n given a number suffix to distinguish them (for example,
GRN/RED1
and GRN/RED'are not the samel.
UNDERHOOD
FUSE/RELAY
BOX
N0.32{1004) No.46ll5Al
IGNITION
SWITCH

WINOSHIELD
WIPER/
WASHER
SWITCH

WASHER
swftcH

BLKffEL

COMBINATION
UGHTSWTCH

IMT

Y
IMTEGRATED
CONTNOT
UNIT

II'ITERMITTENT
I
wrPER
RELAY I

*f
*Y,
'
BI-UiWHT

,'

23-164

POWER
o00RLocK

r,r,!"rt,8filI*o'

Prsft
I v"

++
FROI'IT
SIDE
MARKER
UGI{T
{3CPt

B LK
WINDSHIELD INTERMITTEMT
MOTOB WIPER
REI-AY
WIPER

I
I

. SAFETY
INDICATOR
CIRCUIT
. POWER
DOOR
LOCK
UNIT
CONTROI,
RED/B].U

iilF-*lJ
",.gFI

BI..K

@i'fl"* (
BLK

G301

G20t

G401
G402

DRIVER'S
SEATBELT
swtTcH
BLK

_l.L

G522

' TRUNK
UGHT
, CIGARETTE
LIGHTER
. CEILING
UGHT
, KEYINTERLOCK
SOTENOID

REAR
REAR
wtNDow wtNDow
OEFOGGER
DEFOGGER
RELAY INDICATOR
\--7

'Y
E I

;l_

YEUGRN

,.

I 812

fl

Bu(

G4ot
G402
G{Ol

EITGINE

,k4

0rL

PRESSURE
swtTcH

23-165

IntegratedControl Unit
Input Test
CAUTION:
a All SRS electrical wiring halnesses are covered with
yellow outer insulation.
a Before disconnecting the SRS wira harness, install
th shon connector(s) on the airbag{sl (see page
23-2941.
a Roplacethe entire affectsd SRS harnessassembly if
it has an open circuit or damaged wiring.
1.

Remove the left kick panel. then disconnectthe

16-P connectortrom the integratedcontrol unit.

2.

Remove the underdash fuse/relay box, then

removethe integratedcontrol unit.

3.

Inspectthe connectorand the socket terminalsto

be sure they are all makinggood contact.
a li the terminals are bent, loose, or corroded,
repair them as necessary, and recheck the
system.
a lf the terminalslook OK, make the followinginput tests at the connectorand the socket.
lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf allthe input tests proveOK, the controlunit
must be faulty; replaceit

NOTE:
a Different wires with the same color have been
given a number suffix to distinguishthem {Jor
and GRN/RED' arenot the
example,GRN/RED1
same).
a Do not disconnect any connectors from the
under-dashfuse/relavbox exceDtthe one fof the
integratedcontrol unit.

View from terminalside

It-..-t..|.-z\

REO/BLU

23-166

GRN/WHT
View trom terminal side of lhe
under-dashluse/relaybox socket

Wiper Systsm:
No. Terminal

BLU/WHT,

GRN/BLK

View from wire side of the harnessconnector

Possiblecause if result is not obtained

Tost condition

Test: Desirod result

B1

Under all conditions,

Check for continuityto ground:

Thereshouldbe continuity.

B2

lgnition switch ON.

Check for voltageto ground:

Thereshould be battery
voltage.

B l o w nN o . 1 7 ( 3 OA ) f u s e .
(ln the under dash fuse/relaybox)
Faulty intermittentwiper relay.
An open in the wire.

810

lgnitionswitch ON
and wiper switch at
INT position.

Checkfor voltageto ground:

Thereshould be battery
voltage.

B'l 1

lgnitionswitch ON
and washer switch

Check tor voltageto ground:

There shouldbe battery
voltage,

B l o w nN o . 1 7 { 3 0 A ) f u s e .
(ln the under-dashtuse/relaybox)
Faulty wiper switch.
An open in the wire.
B l o w nN o . 1 7 ( 3 OA ) f u s e .
(ln the under-dashfuse/relaybox)
Faultywiper switch.
An open in the wire.

oN.
B3

lgnition switch ON.

Check for voltageto ground:

Thereshouldbe battery
voltage.

Engine Oil PressuroIndicatol FlasherSystm:

Tsst condition
No, Trminal

Tost: Desired result

. Poor ground (G4Ol, G402. G4O4l

. An open in the wire.

Blown No. 17 (30 A) tuse.

(ln the under-dashfuse/relayboxl
Faultyintermittentwiper relay.
Faultywindshieldwiper motor.
An open in the wire.

Possiblecause il result is not obtaind

. Poor ground (G4O1, G4O2,G4o4).
. An open in the wire.
. B l o w nN o . 13 ( 10 A ) t u s e .
(ln the under-dashfuse/relayboxl
. An open in the wire.

B1

Underall conditions.

Check for continuityto ground:

There shouldbe continuity.

B9

lgnition switch ON.

Check for voltageto ground:

Thereshouldbe battery
voltage.

B6

Headlightswitch ON.

Checkfor voltageto ground:

Thereshould be battery
voltage.

B l o w nN o . 4 2 ( 2 0 A ) f u s e .
(ln the under-hoodfuse/relayboxl
Faultycombinationlight switch.
An open in the wire.

87

lgnitionswitch ON
and turn signalswitch
to "Left".

Checkfor voltageto ground:

It shouldchangefrom
O-12 O V repeatedly.

814

lgnitionswitch ON
and turn signalswitch
to "Right".

B l o w nN o . 1 3 ( 1 OA ) f u s e .
(ln the under-dashfuse/relayboxl
relay.
Faultyturn signal/hazard
An open in the wire.

Check front side markerlight

operation:Lett (or Right)front
side ma.ker light shouldcome
on as the battery is connected.

Blown bulb.
P o o rg r o u n dI G 3 O 1( o r G 2 O 1 ) l
An open in the wire.

GRN/WHT Connectthe 85 terminal to the GRN/

W
GRN/RED1 HT (orGRN/RED1)
terminal.

{cont'd}

23-167

IntegratedControlUnit
Input Test (cont'd)

813

811

89

GRN/WHT

View from terminalside of the

underdash fuse/relaybox socket

Ky-in/Seat Eelt Rsminder System:

No. Terminal
Test condition
1

Test: Desired result

Under all conditions.

Check tor continuityto groundl

There shouldbe continuity.

B8

Driver'sdoor open.

Checkfor continuityto ground:

Thereshouldbe continuity.
NOTE: Betoretesting, remove
No. 46 (15 A) fusein the
under-hoodfuse/relaybox.

key is inserted into the ignition switch.

RED/BLU lgnitionswitch ON
and driver's seat belt
unbuckled.
B9

lgnition switch ON.

Power Window Key-oft Time. System:

No, Terminal
Test condition

Checkfor voltageto ground:

It shouldbe 1 V or less.

Faultyseat belt switch.

P o o rg r o u n d( G 5 2 2 ) .
An open in the wire.

Check for voltageto ground:

Thereshould be battery
voltage.

Test: Desired tesult

Under all conditions.

Check for continuityto ground:

Thereshouldbe continuity.

B5

Underall conditions.

Check tor voltageto ground:

The.e should be battery
voltage.

B8

Driver'sdoor open.

Check for continuityto ground:

There shouldbe continuity.
NOTE: Beforetesting, remove
N o . 4 6 { 15 A ) t u s e i n t h e
under-hoodfuse/relaybox.
Check for continuityto ground:
There shouldbe continuity.
NOTE: Beforetesting. remove
No. 46 (15 A) fuse in the
under-hoodtuse/relaybox.

G R N / B L K Connectthe 85 ter
Check window operationl
minal to the GRN/BLK Power windows shouldwork
terminal.
with the key OFF.

23-168

. Poor ground (G4O1,c4O2, G4O4).

. An open in the wire.
. Faultydriver'sdoor switch.
. An open in the wire.

Faultyignitionkey switch.
Poorground (G4O1,c4O2, G4O4).
An open in the wire.

B1

Possiblecause if result is not obtained

Check for voltageto ground:

It shouldbe 1 V or less.

G R N / R E D ' Passenger'sdoor
open.

GRN/BLK

View from wire side oI the harnessconnector

B1

BLU/WHT' lgnition

BLU/WHT'

. B l o w nN o . 1 3 ( 1 OA ) f u s e .
(ln the under-dashfuse/relayboxl
. An open in the wire.

Possiblecause it .esult is not obtained

. P o o rg r o u n d{ G 4 O l , c 4 O 2 , G 4 O 4 } .
. An open in the wire,
. B l o w nN o . 4 6 ( 1 5 A ) f u s e .
{ln the underhood fuse/relaybox)
. An open in the wire.
' Faultydriver'sdoor switch.
. An open in the wire.

. Faultydoor switch.
. An open in the wire.

Faulty power window relay.

Poor ground lG4O1, c4O2, c4O4).
An open in the wire.

WHTiBLUJ
ORN

8ED/BLU
GRN/WHT
View from terminal side ot the
under'dash fuse/relay box socket

Entry Light Timer System:

Test condition
No. Terminal

BLUiWHT'

GRN/8LK

View from wire side of the harnessconnector

Test: Desired result

Possiblecaus i{ result is not obtained

B1

Under all conditions.

Check for continuityto ground:

There shouldbe continuity.

B5

Underall conditions.

Checkfor voltageto ground:

Thereshouldbe battery
voltage.

. P o o rg r o u n d{ G 4 O l , G 4 O 2 ,G 4 O 4 } .
. An open in the wire.
. B l o w nN o . 4 6 ( 15 A ) f u s e .
lln the under hood fuse/relaybox)
. A n o p e ni n t h e w i r e .

WHT/BLK Under all conditions.

Attach to ground: lgnition key

light should come on.

. Blown bulb.
. An open in the wire.

Check Ior continuityto ground:

There shouldbe continuity.
NOTE: Beloretesting, remove
N o . 4 6 { ' l5 A ) I u s e i n t h e
under-hoodfuse/relaybox.

. Faultydriver'sdoor switch.
. An open in the wire.

B8

Driver'sdoor open.

Lights-on ReminderSystem:
Test condition
No. Terminal

Test: Desired result

Possiblecause if result is not obtained

. P o o rg r o u n d{ G 4 O 1 G
. 4 O 2 ,G 4 O 4 ) ,
. A n o p e ni n t h e w i r e .

B1

U n d e ra l l c o n d i t i o n s .

Check Ior continuityto ground:

Thereshould be continuity.

B6

Headlight switch ON.

Check for voltageto ground:

Thereshould be battery
voltage.

B l o w nN o . 4 2 l 2 O A J f u s e .
(ln the under-hoodfuse/relaybox)
Faultycombinationlight switch.
An open in the wire.

B9

l g n i t i o ns w i t c h O N .

Check for voltageto ground:

There shouldbe battery
voltage.

B8

Drjver'sdoor open.

Check for continuityto ground:

There shouldbe continuity.
NOTE: Beforetesting, remove
N o . 4 6 ( 1 5 A ) f u s ei n t h e
under-hoodIuse/relaybox.

. B l o w nN o . 1 3 ( 1 OA ) f u s e .
(ln the underdash fuse/relaybox)
. A n o p e ni n t h e w i r e .
. Faultydriver'sdoor switch.
. A n o p e ni n t h e w i r e .

ORN

lgnition switch ON
and connect the 89
terminal to the ORN
termtnal,

Check chime operation:Chime

should activateeach time the
battery is connected.

. F a u l t yc h i m e .
. An open in the wire.

(cont'd)

IntegratedControl Unit
InputTest(cont'd)

View from terminalside of the

under-dashtuse/relay box socket

View from wire side o{ the harnessconnector

Rear Window Defogger Timer Circuit:

No,

Terminal

Test condition

B1

Underall conditions.

Checkfor continuityto ground:

Thereshouldbe continuity.

. Poorground (G40'1. G402. G4O4l.

. An open in the wire.

813

Defoggerswitch
pushed.

Check for continuityto ground:

There shouldbe continuityas
the switch is pushed.

Faultydefoggerswitch.
Poor ground {G4O1,c4O2, c404}.
An open in the wire.

812

lgnitionswitch ON.

Attach to ground:
Rearwindow defoggershould
work and the defoggerswitch
indicatorlight shouldcome on.

Blown No. 34 (40 A) fuse.

(ln the under-hoodfuse/relayboxl
Faultydefoggerrelay.
Blown LED.
An open in the wire.

B9

lgnitionswitch ON.

Check for voltageto ground:

Thereshould be battery
voltage.

Test: Desired result

Engins Oil P.assur Indicator FlashorSvstem:

No. Trminal
Tst condition
I

B1

Under all conditions.

Check lor continuityto ground:

There shouldbe continuity.

B9

lgnition switch ON.

Checkfor voltageto ground:

Thereshouldbe battery
voltage.

WHT/BLUl Enginerunning.

Tsst: Dosired tosult

YEL/RED lginition switch OFF.

23-170

Check for voltageto ground:

Thereshould be battery
voltage.
Check for continuityto ground:
Theie should be continuity.

lgnition switch ON.

Check indicarorlight. lf the

light does not come on, attach
the YEL/REDterminalto
ground:The light shouldcome
on as the ignitionswitch is
turned ON.

Start the engine.

Check tor voltageto ground:

Thereshould be battery
voltage.

Possiblecause if result is not obtainod

. B l o w nN o . 1 3 ( 1 OA ) f u s e .
(ln the unde.-dashfuse/relayboxI
. An open in the wire,

Possiblecause il result is not obtained

. Poor ground (G4O1. G4O2,G4O4t.
. An open in the wire.
. B l o w nN o . 1 3 ( 1 OA ) f u s e .
(ln the under-dashfuse/relaybox)
. An open in the wire.
. Faultychargingsystem.
. An open in the wire.
. Faultyengineoil pressureswitch.
. An open in the wire.
. B l o w nb u l b .
. An open in the wire.

Insulficientoil.
lmp.operlubrication.
Faultyengineoil pressureswitch.

Key-inReminderSystem
lgnition Key Switch Test
NOTE: Refer to page 23-164 tor the diagram oJ the
key-in beepr circuit, and page 23-168 for the input
test of the beepercircuit.
When the ignitionkey is not removed,the key-inbeeper
in the integratedcontrolunit sensesgroundthroughthe
closedignitionkey switch. when you open the driver's
door,the beepercircuitsensesgtoundthroughthe clos"BLU/WHT2" and
ed door switch. With ground at the
"88" terminals,the beepersounds.
1.

Remove the dashboard lower cover and knee

bolster (seepage 23-68).

2.

Disconnectthe 8-P connectorfrom the main wire

harness.

Liqhts-onReminder
Sy-stem
Chime Test
NOTE: Refer to page 23-165 tor the diagramof the
lights-onremindercircuit, and page 23-169 for the input test of the circuit.
"O" position and
When the ignition key is turned to
removed. with the lights on, voltage is appliedto the
remindercircuit on the integratedcontrol unit. When
you open the driver's door, the circuit sensesground
through the closeddoor switch.
"86" terminal,groundat the "88"
With voltageat the
"B9" terminal,the chime
terminaland no voltageat the
soundsto remindthe driverto turn off the lights.
1.

Bemove the dashboard lower cover and knee

bolster.

2.

Disconnectthe 2-P connectorfrom the main wire

harness.

8-P CONNECTOR

2-P CONNECTOR

Test the chime by connectingbatterypower to No.

1 terminal,groundingto No. 2 terminal,and cycling
the power on-off repeatedly.

Check continuitybetweenterminalsA and B

a Thereshouldbe continuitywith the key in the ignition switch.
a There should be no continuity with the key
removgd.

4.

lf the chime fails to sound every time power is cy

cled, replaceit.

23-17 1

Seat Belt ReminderSystem

Description
NOTE: Refer to page 23-164 for the diagramof the
seat belt beeper/timercircuit.
With the ignitionswitch in "Run" or "Start", voltageis
appliedto the beeper/timerof the integratedcontrol
unit. When you unbuckle the driver's seat belt, the
beeper/timercircuil sensesground.With voltageat the
"89" terminaland ground
at the "RED/BLU" terminal.
the seat belt beeper sounds and the timer contacts
closeand open.This causesthe seat belt reminderlight
to ilash on and off. After five secondsthe alarmstoos
and the contacts .emain oDen.

SeatBeltSwitch Test
Slide the f.ont seat all the wav forward then
disconnect the 2-P connector from the seat belt
switch.

Chck continuitv between terminals A and B.

a There should be continuity with the seat belt
unbuckled.
a Thereshouldbe no continuitywith the seat belt
is buckled.

23-172

! l

Entry Light Timer System

lgnition Key Light Test

lgnition Key Light Replacement

Remove the dashboard lower cover and knee

bolster (see page 23-68).

1,

Remove the steering column covers lsee page

23-741.

Disconnectthe 8-P connectorfrom the main wire

narness.

2.

Removethe bulb/socketfrom the key light housing

by turning the socket 45o counterclockwise.

There should be continuity between the A and B

termlnals.
It there is no continuity,replacethe light.

23-173

LightingSystem
ComponentLocationIndex
DRL INDICATORLIGHT lcanadol
(ln the sub gaugassembly)
Bulb Locations,page 23-133

HIGH BEAM INDICATORLIGHT

{ln the main galge assembly)
BufbLocations,page23-132

COMBINATION
LIGHT SWITCH
Test, page 23-178
Repfacement,page 23-182

DAYTIME RUNNINGLIGHTS
CONTROLUNIT (Canadal
Test, page23-180

BOX
FUSE/RELAY
UNDER.HOOD

FRONT
LIGHT
Beplacement,
Page23-186

tAt----TAt:-,
I4A4A4I4A4!=Y -|ililil[|aL_Jat--l

(f, t(:) (:) to k:i -

I|

(B-type)
Test, page 23-72

(A-typel
Test, page 23-71

23-174

HEADLIGHTS
Adjustment,page 23-184
page23-183
Replacement,
FRONTTURN
SIGf{AL LIGHT
page23-185
Replacement,
SIDE
MABKERLIGHT
page 23-185
Replacement,

PASSENGER'SDOOR SWITCH
Test, page 23-191
CEILINGLIGHT
Test, page 23-190
page23-190
Replacement,

TRUNK LIGHT
Test, page 23-189
page 23'189
Replacement,

LICENSEPLATELIGHTS
page23-188
Replacement,

DOOBSWITCH
DRIVER'S
Tsr,page23-'l91

REARSIOE MARKERLIGHT
page 23-188
Replacment,

TAILLIGHTS
Repalcement,Page 23'1 87
page 23-187
BulbReplacement,

23-175

LightingSystem
CircuitDiagram(USA)
- HOOO
UNDR
FUSE/RELAY
8OX

BLK

COMEINATION
UGIfTSWITCH
BLK

BU(

t
t

rr-.'
\ /

l
l

I
I

L.TAII.I]GHT I

I
. DASH
LIGHTS
BRIGHTNESS
CONTROLTER
. DASH
LIGHTS
, SIOE
MARKER
UGHTS
. R,TAILTIGHT
, TICENSE
PTATE
IIGHTS
. INTEGRATED
CONTROL
UNIT
. FRONT
PARKING
UGTTTS
' HEATER
CONTROL
PANET
LIGHTS

G201

23-176

G40l
G442
G40+

G401
G4o2
G40,1

GircuitDiagram(Canada)
No.42{20A}

No.32ll00Al

DNLINOICATOR
LrGHT{3.0W1
REDffVHT
{/o+

Btu

DAYTIME
RUI.INING

UGt{rs

CONTROL
UNIT

Ln**nroT.RN/RED
GRN/RED

BRAKE
FLUID
|.lVEL
SWTCH

23-177

LightingSystem
CombinationLightSwitch Test
CAUTION:
a All SRS electrical wiring halnessos ara covered with
yollow outr insulation.
a Bofore disconnocting tho SRS wilo harnoss, install
th sho.t connector on th6 ai1b8g{se paga 23-2941,
a Roplacetho entire aftected SRS harno$ assembly it
it has an opon circuit or damagod widng.
NOTE: The radiomay havea codedtheft Drotectioncircuit. Be sureto get the customer'scode numberbetore
- Oisconnectingthe battery.
- Removingthe No. 43 (1OA) fuse.
(ln the under-hoodtuse/relaybox)
- Removingthe radio.
After service,reconnectpower to the radio and turn it
on. When the word "CODE" is displayed,enter the
customer's5-digit code to restoreradio operation.
1.

Remove the dashboard lower cover and knee

bolster.

2.

Disconnect the connectors from the main wire

narness.

3.

Inspectthe connectorterminalsto be surethey are

all making good contact.

SRS MAIN HARNESS

a lf the terminals are bent, loose. or corroded,

repair them as necessary, and recheck the
sysrem.
a lf the terminalslook OK, check for continuity
betweenthem in eachswitch positionaccording
to the tabl6s.

2O-PCONNECTOR

5.P CONNECTOR
View from wire side

DAHSBOARDLOWERCOVEF

KNEEBOLSTER View trom wire side

23-178

Headllght/Dlmmor/Pa$ing Switch
23

11

Terminal

1l

l4

23

Position
OFF
\J
Headlight
sw|Icn

a'\
LOW

o--

HIGH
Passinq
switch
siitch "OFF")
{Headlisht
Passing
switch
switch"."}
{Hsdlight

OFF

-----o

ON

---o

ON

Tum Siqnal Swltch

{See pa-ge23 - 197 fol turn signal circuit dlagraml

Tsrminsl

Position

--o

RIGHT
Nut18l

LEFT

'12

ar

---o

23-179

LightingSystem
Daytime RunningLights Control Unit Input Test lCanada)
CAUTION:
a All SRS elsctrical wiring harnessesare covord with
ycllow outr insulation.
a Botors disconnocting the SRS wire harnoss, inatall
th short connoctor on th6 airbag lsoo page 23-2941.
a Rcplacetho ontire affected SRS halness assmbly it
It has an open circuit or damaged wiring.
1.

Pullthe front passenger'scarpetaway and remove

the kick Danel.

2.

Disconnectthe 14-P connectorfrom the davtime

runninglights control unit.

3.

Inspectthe connectorterminalsto be surethev are

all making good contact.

a lf the terminSls are bent. loose, or corroded,

rpair them as necessary, and recheck the
svstem.
a lf the terminalslook OK, make the following input tests at the connector.
- lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests proveOK, the controlunit
must be faulty; replaceit.
NOTE: Different wires with the same color have
been given a number suffix to distinguishthem
(RED/GRN1
and RED/GRN,are nor the same).

14.P CONNECTOR

RED/WHT

RED/GRNI
GRN/WHT
REO/YEL BLK

View from wire 3id

BLU I RED/ORN GRN/RED

RED/BLU
14-P CONNECTOR

23-180

RADIATORFAN
CONTNOLMODULE

No,

Wils

Test condition

Test: Desired result

BLK

Under all conditions.

Check for continuityto ground:

There shouldbe continuitY.

Check for voltageto ground:

Thereshould be battery
voltage.

BLU/RED Under all conditions.

Check for voltageto ground:

There should be batterY
voltage.

. FaultyheadlightrelaY.
. An open in the wire.

YEL/RED lgnitionswitch ON.

Check for voltageto ground:

Thereshould be batterY
votrage.

. B l o w nN o . 1 2 ( 7 . 5 A ) t u s e .
(ln the under-dashfuse/relaybox)
. An open in the wire.

RED/GRNl Passingswitch ON.

Check for voltageto ground:

Thereshould be battery
voltage.

Faulty passingswitch.
Faultydimmerrelay.
Fsulty headlightrelay.
Blown No. 50 (20 A) fuse.
(ln the under-hoodfuse/relaybox)
B l o w nN o . 5 1 ( 2 OA ) f u s e .
An open in the wire.

Check for continuityto

ground:Thereshouldbe continuity.

Faultycombinationlight switch.
Faultydimmerrelay.
An open in the wire.

RED/YEL

RED/BLU Passingswitch ON.

ORN

Combinationlight
switch OFF.

RED/WHT Combinationlight
' l o RED/ORN switch OFF.
1l

. Poor ground (G4O1, G4O2,G4O4).

. An open in the wire.
Blown No. 37 (4o A) fuse.
(ln the under-hoodfuse/relaybox)
B l o w nN o . 8 { 1 OA ) f u s e .
(ln the under-dashtuse/relaybox)
An open in the wire.

R E D / G R N ' Under all conditions.

Possiblecaus it result is not obtainod

BLU

lgnition switch ON.

1 2 G R N / R E D lgnitionswitch ON.
1 3 GRNiWHT

Parking brake lever

up.

Check for continuitYbetween

the terminals:
There shouldbe continuitY.

. Blown headlightbulb (high beam).

. An open in the wire.

DRL indicatorlight should

come on.

. Blown bulb.
. An open in the wire.

Brakesystem light should

come on,
Check lor continuityto ground:
Thereshouldbe continuitY.

. Blown bulb.
. An open in the wire.
. Faultyparkingbrakeswitch.
. An open in the wire.

23-141

LightingSystem
GombinationLight Switch Replacement
CAUTION:
a All SRS olectrical wiring harneasesaro covered with
yollow outr insulation.
a Botore disconnecting th SRS wir ham6ss, install
the short connector{s} on the ailbag{s} (see page
23-2941.
a R6placothe ntire aftectd SRS harnessassembly il
it haa an opon circuit or damagd wiring.

2.

Removethe steeringcolumn covers.

COLUMNUPPERCOVER

COLUMNLOWERCOVER

Remove the dashboard lower cover and knee

bolster.

Disconnectthe connector from the combination

light switch assembly, then remove the two
screws and the switch.

COMBINATION

OASHBOAROLOWERCOVEN

4.

23-182

Installin the reverseorder of removal.

Headlights
Replacement
CAUTION:
a Halogen hsadllghts can becomo vory hot In urc; do
not touch thom or tho attaching hardware immodiatsly alter thcy have boon tumad oft'
a Do not try to replacc or claan tho headlights tYith tha
lights on.
1.

Removea screw, then removethe tront turn signal

light (see page 23-185).

2.

Remove a scrw, th6n remove the flont side

markerlight (seepage 23-185).

3.

Disconnct the connectors from the tlont turn

signallights and frqnt sids ma.ker lights.

4.

Remove ths front bumper (see section 2Ol.

o.

Disconnect the 2-P connectots from the headlight

bulbs.
Remov the
assmbly.

mounting bolts and headlight

2-P CONNECTORS

8.

After installing the hsadlights, adiust them to local

requlremenls.

Disconnect the 2-P connector from the front parking light, and remove the light by removing the
mounlrngscrew.

23-183

Headlights
Bulb Replacement

Adjustment

a Halogen hoadlights can become very hot in use; do

not touch them or the attaching hardwaro immodiately aftr thoy have b6on turnd off.
a Do not try to roplace or clean the headlights with ths
lights on.
NOTE:
a Before disconnecting the left side connectors,
removethe washer reservoirfiller neck {one bolt).
a Before disconnecting the right side connectors,
removethe batteryand the enginecoolantreservoir.
Disconnect the
headlight.

2-P connector(s) from the

Turn the bulb holder(s) counterclockwiseand

removethe bulb{s}.

EULBHOLDERS

Do not touch the giass

auLB{65 W}

2.P CONNECTORS

23-184

BULEt55 Wt

CAUTION:
a Halogn headlights can become vry hot in us; do
not touch them or the attaching hardware immediately attsr they havs bsen tuhod otf,
a Do not try to replace or clean the headlights with ths
lights on.
1,

Adjust the headlightsto localrequirementsby turning the adjusters,

VERTICAL
ADJUSTER

HORIZONTAL
ADJUSTER

Front Side Marker Lights

FrontTurnSignalLights
Replacement

Replacement
Removethe screw and pull th front side marker
light assemblyout of the front bumper.

1,

Removethe screw and pull the front turn signal

light assemblyout ot the front bumper.

FRONTTURN SIGNAL LIGHT

Disconnectthe 2-P connectorfrom the light.

Disconnectthe 2-P connectorfrom the light.

To reDlacethe bulb, turn the bulb socket 45o

counterclockwiseand removeit trom the housing.

To reolace the bulb, turn the bulb socket 45o

counterclockwiseand removeit from the housing.

FRONTTURN SIGNAL LIGHT

FRONTSIDE MARKERLIGHT

BULB
t3 cPl

BULB
t32 CPI

23-185

Front ParkingLights
Replacement
1 . Rmove the screw and sparate the parking light
from the headlight assmbly.

Turn the bulb socket 45o counterclockwise and

remove it from the housing, then replace the bulb.

NOTE: Be carefulnot to damagethe hoadlightand

the tront fender.

2 . Disconnectthe 2-P connectorfrom the light.

@'1
I

\
BULB15WI
\
BULBSOCKET

FRONTPARKII{GLIGHT

23-186

Taillights
Bulb Replacement

Replacement
1,

Oon the trunk lid and removethe tear trim panel.

Open the trunk lid and removethe taillightaccess

panel.
Removethe screws and the bulb holderpanel.

ACCESSPANEL

BULBHOLDER
PANEL
Oisconnectthe 8-P connector from the taillight
assembly.
Remove the six mounting nuts and the taillight
assembly.

8-P COf{NECTOR

Removethe faulty bulb by pushingit in and then

turning it 45o counterclockwise.
BULB{43/3 CP)
O BRAKELIGHT/TAILLIGHT
(45 CP}
LIGHT
BULB
TURN
SIGNAL
@
(
3
2
C
P)
B
U
L
B
L
I
G
H
T
B
A
C
K
.
U
P
O

ASSEMBLY

NOTE:
a Inspect the gasket; replace it if it is distorted or
stays compresseo.
a After installingthem, run water over the lights
to make sure they do not leak.

23-147

LicensePlateLights

RearSide Marker Lights

Replacement

Replacement

Removethe two screwsfrom the licenseplatelight

assembly.

Removethe screw from the rear side marker lioht

assembly.

Pullthe light out and disconnectthe 2-P connector

f.om it.

Carefullypry the light out of the rear bumper and

disconnectthe 2-P connectorfrom the light.
NOTE: Be carefulnot to damagethe rear bumper.

LICENSEPLATE
LIGHT

3.

Take the lens off, then replace the bulb.

3,

23-1AA

Remove the bulb socket by turning ir 450

counterclockwise.

-t

Trunk Light and Latch Switch

LatchSwitch Test/Replacement

Trunk LightTest/Replacement

Open the trunk lid and disconnectthe 2-P connector from the trunk latch.

Pry ofl the trunk light lens from the housing.

Pry out the light.

CheckcontinuitybetweenterminslsA and B. There

should be continuity.

Disconnectthe 2-P connectorfrom the housing.

BULA(3.4Wl

LENS

4.

Make sure that the bulb is oK

Check for continuity between A (+) and B (-)
terminals.
NOTE: This light has a diode in it. To get an accurate reading,eithertest it with a volt-ohmmeter
that comDensatastor diodes, or make sure you
connect vour tst leads to match the polarity
snown.

lJ necessary,remove the three bolts and pull the

latch ou1ot the trunk lid, then disconnecttho lock
rod from the latch,

4.

Disconnectthe trunk openercable from the latch.

{3.4W1
From

rr*rffi
FUSE

23-189

CeilingLight
Replacement
Turn th6 ciling light switch OFF.

Test
Check for continuitv between the terminals in ea'ch
switch positionaccordingto the table.

Pry ofl th lens.

\

Torminal
AorA'

P""-

!ot6

o-

OFF

ON

/\
\:.,.

G-

MIDDLE

o-

\:/

From 0.46 (l5Al FUSE

A

t8w
t l

ON ,l

)
)'\

A'B'

Disconnect th6 3-P connsctor and rmov th

housing.

23-190

OFF

., Bb c

Remove the two acrews from the ciling light

housing.

--o
-o

DoorSwitch Test
1 . Removethe screw and pull the door switch out.

2 . Disconnect the 1-P connector and temove the

switch.
Checkfor continuitybetweenthe terminalsin sach
switch positionaccordingto the table.

rermnal

\
Poshion

O TERMINAL

BASEPLATE

CLOSE
OPEN

e) TERMINAL

SCREW

23-191

Back- up Lights
CircuitDiagram

- HOODFT'S/RELAY
UNDER
BOX

MAIiIWIRE

A,rTGEAR
POSTT|oN
- uplioht

ENGINE
WIRE

MAINWIR

IIFT SIDEWRHARNESS

)
)

*.*-r-l
ucr{Ts I
t32oh2t

23-192

REAR
WIRE
HARNESS

Back-upLights
Switch Test
Manual Transmission:
1. Turn the ignition switch ON and move the shift
lever to LBJ.The back-uplights shouldcome on.
a back-uplight does not go on, check for:
Blown bulb in the taillightassembly.
both back-uplights do not go on. check tor:
Blown No. 13 (10 A) fuse in the under-dash
fuse/relaybox.
lf the fuse and bulbs are OK, go to step 2.
It
lf
-

Disconnectthe connectorstrom the back-uplight

switch,

Automatic Tmnsmission:
1. Turnthe ignitionswitch on and move the shitt lever
to LB-1.
The back-uplights shouldcome on.
a back-uplight does not go on, check for:
Blown bulb in the taillightassembly.
both back-uplights do not go on. check for:
Blown No. 13 (1O A) fuse in the under-dash
fuse/.elaybox.
It the fuse and bulbs are OK, go to step 2.
lf
lf
-

2 . Disconnectthe '12-Pconnectorfrom the A/T gear

positionswitch (back-uplight switch).

A (YELI

swtTcH

25 .m {2.5 kg-m,
1E rb-ftl

This washermust
always be rplaced
for the switch to
lunction properly
and to preventoil
reaKs.

Check for continuity between the A and B

terminals.
a There should be continuity only with the shilt
lever in @.
a lf there is no continuity,replacethe switch (see
s e c t i o n1 3 ) .
a lf there is continuity.but the back-uplights do
not go on. check for:
- An open in the YEL or GRN/BLKwire.
- P o o rg r o u n d( G 5 5 1 ) .

View trom wire side

Move the shiit lever back and lorth in E without

touchingthe push button, and checkfor continuity
between No. 9 and No. 1O terminals.
Thereshouldbe continuitywithin the rangeof tree
play of the shift lever.
a lf there is no continuitywithin the rangeof free
play, adjustthe positionof the A/T gearposition
s w i t c h ( s e ep a g e2 3 - 1 4 9 ) .
a l{ there is continuity,but the back-uplights do
not go on, check tor:
- An open in the YEL or GRN/BLKwire.
P o o rg r o u n d( G 5 5 1 ) .

23-193

BrakeLightsand High Mount BrakeLight

CircuitDiagram

, ECM
. TRANSMISSION
COMTROT
MODUI.E
ITCM)

. crursE
coNTnoLuNn
. A8S
Coilrnot
UN|T

LFr !-'

TAII"TIGHTi F

I ",F*l, 1 ,
7 f ? njT
\ BRAXE
) I UGHI
/ ErcPI

L.
8u(

G551

23-194

High Mount Brake Light/Bulb

Replacement

BrakeSwitch Test
1 . lf one of the brakelightsdoes not go on. checkthe
bulb in the taillightor the high mount brake light.

1 . Removethe cover.
Inspectthe bulbsand replacethem if they are burned out.

2 . lf none of the brakelights go on, checkthe No. 41

(1 5 A) fuse in the under-hoodtuse/relaybox.

\,
lf the tuse and bulbs are OK, disconnectthe 4-P
connectorfrom the brakeswitch.

il+

"JE={"
l i
4-P CONNECTOR

COVER
2

ll the light is taulty, removeits two mountingbolts.

4.

Disconnectthe 3-P connectorand removethe light.

Check for continuity between the B and C terminals.There should be continuitvwith th brake
pedal pushed.
a lf there is no continuity,adjustthe pedal height
(seesection 19), and recheck.
a It there is still no continuity,replscethe switch.
a lf there is continuity,but the brakelightsdo not
go on, check for:
P o o rg r o u n d( G 5 5 1 ) .
- An ooen in the WHT/YELor GRN/WHTwire.
- Faulty brake light failure sensors (see page
23-157t.

HtGHttiouNT BRAKELrcHT
lnstallin the reverseorder of removal,
NOTE: Clean the rear window glass first. and
make sure the rubber seal on the light is touching
the glassall the way around.

23-195

SideMarker/TurnSignal/HazardFlasherSystem
ComponentLocationlndex
CAUTION:
a All SRS olctdcal widng hamsses aro covered with
ycllow outel insulation.
a Bfor dlsconnecting the SRS wire hamoss, install
the short connector on the 8i1b89{sl,thon diEconnoct the wke hamess (so page 23-2941o Replacotho ontiro aftocted SRS hamess assombly
il it has is an open ciicuit or damagod wiring.

SRS MAIN HARNESS

UI{DER.DASH
FUSE/RELAYBOX

TUNNSrcNAUHAZARD
BELAY
InputTest,page23-198

SIDE MARKERLIGHT FLASHERCIRCUIT

{ln the integrated control unit)
fnput Test, page 23-167

TURI{ SIGIIAL II{DICATOR

UGHTS
(ln the gauge assomblyl
Bulb Locations, page 23-132

coMBll{A
swtTcH

LIGHT/TURN SIGT{AL

Test, psge 23-178

Repfacoment, page 23-182

23-196

HAZARD WARI{II{G SWTTCH

Romoval, page 23-2OO
Tosr, page 23-2OO

CircuitDiagram

6;\
**n"
T 'u7coMBlNATror,{
.-..J^._.
whr/ttl

v l _

RD/BII(

l
WHTTYEI

lg

lo

connctionl
{lntornal

-l

UGHTSWITCH

No.13l10A)

-J"-l

tA

HAZARD
I
WARNING I

sw[cH

II

wtfl /YEL

L / l \

TURN
SIGNAL
swlTcH

frl

GRN/YEL

DASHIG}TTS
BRIGITTI{ESS
COMTROT
UNIT

COMBINATION
t-tcHtswtTcH

VI

TURNSIGMU
RI-AY
HAZARD
6

4
I
llm.md connoction

FI-ASHER
CIRCUIT
SIDEMARKER
contrclunit)
llntheintagdt6d

I
llntamelconnction

ALUGHTS
TTFI]URNSIGN

RI{/8[U GRN/BLUGRNIBIU

tt
\?-^"V-"

rs\

urtfim
liiTii' li5)lin I ll.{

t t

uo
HTS
ru*r'ono,
^,0*r
-1
GRN
MHT
GRN,"YEL GRN/YELGRN/ryEL

GRI{,frED

t t

l I

(
h,o'Y i* v
n.'9r*[/
:P)
I S|DE I SrDr

9*r*''%
l',lHls
t t

MABKER
I MAixea

l(45cP)

BLK

BLK

rl

I
BT.K
t

I I I

:
G201

G55l

{T
P)

8I.(
[.(

t
:
G301

Bl-K
BI.K

BLK

f , T
l

G201

G40

FlasherSystem
Side Marker/TurnSignal/Hazard
RelayInputTest
Turn Signal/Hazard
CAUTION:
a All SRS electrical wlring harnessosare covared with
yollow outor insulation,
a When disconnecting tho SRS wiro harness. inslall
th short connectol on tho airbag(s). lhsn disconnoct the wiro ha.ness (soo page 23-294).
a Replacthe ntiro aft6ct6d SRS hamess assmbly it
it has is an open circuit or damagod wlring,
Removethe driver's side kick panel.then remove
the turn signal/hazardrelay from the under-dash
fuse/relaybox.
Inspectthe socket terminalsto be sure they are all
makinggood contact.
a lJ the terminals are bent, loose, or corroded,
repair them as necessary, and recheck the
sysrem.
a lf the terminalslook OK, make the following input tests at the socket.
- lJ a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input tests provB OK, the turn
relay must be faulty; replaceit.
signal/hazard

1 2 3

9ee
aEo
4

5 6

lerminal side

23-198

Possibls cause if result is nol obtainod

No.

Trminal

Tost condition

Tost: Desirad rosull

Under all conditions.

Checktor continuityto ground:

There shouldbe continuitv.

. Poor ground {G4O1, G4O2,G4O4).

. An ooen in the wire.

Underall conditions.

Check for voltageto gtound:

There should be battery
voltage.

. B l o w nN o . 3 9 ( 1 5 A ) f u s e .
(ln the under-hoodfuse/relayboxi
. An open in wire,

Hazardwaring switch

CheckJor voltageto ground:

There should be battery
voftage.

. Faultyhazardwarning switch.
. An ooen in the wire.

Chck for voltageto ground:

There should be baftery
voltage.

. Faultyhazardwarningswitch.
. An oDenin the wire.
B l o w nN o . 1 3 ( 1 OA l f u s e .
(ln the under-dashfuse/relaybox)
Faultyturn signalswitch.
An ooen in th wire.

oN.
lgnitionswitch ON
and turn signalswitch
in Right position.
Hazardwarning
switch ON.

lgnitionswitch ON
and turn signalswitch
in Left position.

B l o w nN o . 1 3 { 1 OA l f u s e .
{ln the under-dashfuse/relaybox)
Faultyturn signalswitch.
An open in the wire.

3 . 2

Connectthe No. 3
terminalto the No. 2
terminal.

Rightturn signallights should

come on whgn the terminals
are connected.

Blown bulb.
, 551)
P o o rg . o u n d( G 2 O 1 G
An open in the wire.

3.6

Connectthe No. 3
terminalto the No. 6
terminal.

Left turn signallights should

come on when the terminals
are connectgd.

Blown bulb.
, 5 5 1l
P o o rg r o u n d( G 3 O 1 G
An open in the wire.

23-199

Side Marker/TurnSignal/HazardFlasherSystem
HazardWarningSwitchTest

HazardWarningSwitch Replacement
CAUTION: Be careful not to damage the console
panls.
1.

Removethe front consolepanel (seesection 20).

2.

Remove the screw and turn the hazard warning

switch slowly in the directionshown and removeit
from the center console.

1 . Removethe hazardwarningswitch from the center

consolepanel.

2 . Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table,

3.

Disconnectthe 6-P connectorfrom the switch.

Te.minal

ON
OFF
CENTERCONSOLE

6.P CONNECTOR

23-200

il----\

o-

/1

\:,/

-o
ot_r_
-o
-o

Dash Lights BrightnessControl

Component Location Index
a All SRS olect cal wiring harnessesare coveld with
yellow outor insulation.
a Betor disconnecting the SRS wire harnoss, install
the short connector{s) on the airbag(s) (see page
23-2941.
a Roplaccthe entiro atfected SRS harnessassmbly if
it has an open cilcuit or damaged wiring.
a Alter installing the gaugo assombly, rechock the
oDrationof tho SBS indicator light.

\
sRsMAIN HARNESS

DASH LIGHTS BRIGXTNESSCONTROLUNIT

Test, page 23-2O4

DASH LIGHTS
BRIGHTNESS
CONTROLLER
Test, page 23-203

23-201

Dash Lights BrightnessControl

CircuitDiagram

BATTERvrv!98:!999l99sEsr9
No.32ll00Al No.a2
t20A)
I

'\_./ r-r

23-202

'

g3ilfl$$H3il

\_--

I
I

ControllerTest
Carelully pry the switches out of the dashboatd,
then disconnectthe connectorsfrom them.

Measureresistancebetweenthe C and E terminals.

Resistanca:8- 12 kO
NOTE: Resistancewill va.y slightlywith temperaIUTE.

Measure resistance between the D and E terminals

while rotatingthe adjustingdial.
Resistanceshouldvary from O to 1O kO as the dial
is rotated.
4.

Turn the controlleroft (clickingsound) and check

continuity betwen the B and F terminsls.There
should be no continuity.
lJ the controller is faulty, remove the two screws
and reDlaceit.

t T i- "l(

\ ucrtr
)

t0.Bwtl

cANcEL\./

23-203

DashLightsBrightnessControl
Control Unit Input Test
CAUTION:
a All SRS electrical wiriog harnesssare covrd with
yellow outl insulation.
o Befora disconnecting tho SRS wire harness. install
the short connector{s) on the airbag(s) (see page
23-294t.
a Rplaceth entire aflectod SRS hahoss assombly if
it has an open circuit or damagod wiring.
a After installing tho gauge assembly, rocheck th6
opo.ation ot th SRS indicator light.
1 . R e m o v e t h e s u b gauge assembly {see page
23-131).
2.

Disconnect the 6-P connector trom the control

unit.

3.

Inspectthe connectorterminalsto be surethey are

all makinggood contact.
a lf the terminals are bent, loose. or corroded,
repair them as necessary. and recheck the
svstem.
a l{ the trminalslook OK. make the following inDut tests at the connector.
- It a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all input tests prove OK, the control unit
must be faulty; replaceit

RED/BLU

23-204

T6st condition

No.

BLK
2

Under all conditions.

Possiblocaus it r6sult is not obtainad

CheckJor continuityto ground:

There shouldbe continuitv.

. Poorground {G401. G402, G404).

. An oosn in the wire.

RED/BLK Combinationlight switch Check for voltageto ground:

oN.

Test: Dsiled rsult

RED

There should be battery

voltage.

Combinationlight switch Attach to ground:Dash lights

should come on full bright.
oN.

RED/GRNAdjustingdial rotating.
or
RED/WHT

Checktor resistancebetween
the REDiGRNand RED/WHT
terminals:Thereshouldbe
8- 12 kO at all times,

RED/BLU Adjustingdial rotating.

ano
RED/WHT

Check for resistancebetween

the RED/BLUand RED/WHT
terminals:lt shouldvary from
O- 10 k0 as the dial is rotated.

Blown No. 42 {2O A) fuse.

(ln the under-hoodtuse/relayboxl
Faultycombinationlight switch.
An ooen in the wire.
. An open in the wire.
. Faultycontroller.
. An open in the wires.

23-205

StereoSoundSystem
Component Location Index
CAUTION:
a All SRS oloctrical wiring hamssses ara cov6r6d with
yellow outof insulation,
a Blore disconnocting the SRS wire hamoss, install
th short connctor{s} on tho airbag(sl (soo pago
23-2941.
a Replacethe ontile aftoct6d SRS harne$ assombly it
it has an opn circuit or damagod wi.ing,
NOTE: The radio may have a coded theft protection circuit. Be sure to get the customer'scode numberbefore
- Disconnectingthe battery.
- Removingthe No. 43 {1O A) fuse.
(ln the under-hoodfuse/relaybox)
- Removingthe radio.
After service,reconnectDowerto the radio8nd tu.n it
on, When the word "CODE" is displayed,enter the
customer's5-digit code to.estore radio opration.

DRIVER'S
DOORSPEAKER
Rspfacament,
page23-215

TWEETERS
Replacement,
psge 23-216

DOORSPEAKER
Repfacement,gae 23-215

STEREO
Removal,page23-210
Termioals, page 23-21 1

WOOFERAMPLIFIER
Removal,pae 23-212
fetminal, page 23-212

23-206

PLAYER

Doscliption:
For the desc.iption of a factory-instslled stereo radio/cassette player, please see the owner's manual.
The oower antennais controlldby the .adio ON/OFFswitch. lt will extendfully wheneverthe radioswitch and the ignition switch are on at the same time. When the radioor the ignitionis shut off, the antennaretractsfully. The antenna
motor has a built-inrslay together with a limit switch for this function.

A]{TEI{NA
page23-214
Repfacment,

23-207

StereoSound System
CircuitDiagram(ExceptSevenSpeakersSystem)

UNOER-HOOD
FUSE/RELAY
BOX

UNDER_DASH
FUSE/RETAY
BOX

COMBINATION
LIGHT
swtTcH

j"ffi**i
I

I BI-U/GRN

L--------------_J

{Wrthsixsp.kaE)

o
srERo
RAoro/o
CASSTTE
PI.AYER

-_____-__l

I RED/GRN

l-t4
8RN/B].X
I

IIIRIGHT :
I I ITWEETER
i
I

ANTENNA
ITAD

l7sLu/yer
+fl,en

Al5
_ GRY&Hr_l_\l

AT'ITENNA
IIAD
GROUND
2

REOTYEI
416
BRNAVHT

A
6
YEL/{VXT

POWER
ANTENNA
MOIOR
(Withtheantonna
r6tlect6dfullvl

I
G401
G402
G404

23-204

lllnEAR
SPEA(ER

RIGHT
REAR
SPAKER

CircuitDiagram{WithSevenSpeakersSystem)

OASH
UNDER8OX
FUSEJREI,AY
DRIVER'SPASSENGER'S
DooR
000R
SPAKEFSPEAKER

YEUWTiT
AI{TNNA
tlA0

YEUWIfI

AMPLIFIER
WOOfER
IIAD

MOTOR
rcWERAi.ITENNA
{Wrthlhalnr6nnsctractodfully)

o @

StereoSound System
Unit Removal
CAUTION;
a All SRS oloctrical wiring hahsses al covrad with
yallow outor inEulation,
a Befors disconnecting th SRS wilo harness, install
the short connsctor(s) on th airbag(s) {s6o pag
23-294t.
a Replacotha entiro affected SRS harness sssembly if
it has an op6n circuit or damagsd wiring.

2.

Remove the four mounting screws and pull the

radio panel assemblyout part of the way.

NOTE: The radiomay have a codedtheft protectioncircuit, Be sureto get the customer'scode numbrbefore.
- Disconnectingthe battery,
Removingthe No. 43 (1O Al fuse.
(ln the under-hoodfuse/relayboxl
- Removingthe radio.
After service.reconnectpower to the radio and turn it
on. When the word "CODE" is displayed.enter the
customer's 5-digit code to restoreradiooperation.

RADIO PANELASSEMBLY

Disconnectthe connectorsand antennalead,then

removethe assembly.
4.

Removethe 1Omountingscrews,then removethe

tront console.

23-210

Removethe two mounting screws. then temove

the stero radio/cassette player from the panel
assamblv.

Stereo Radto/CassettePlayer
Terminals

A9 -

- - - ----> A16

Connectato

A2

RED/GRN Right tront speakr @

BLU/GRN Le{t lront speaker (E

A3

RED/BLK

A1

Lights-on signal

WHT/YEL Constant power {Tuning memoryl

A5

YEL/RED

ACC

A6

YEL/WHT

Radioswilched powr

A7

BLU/YEL

Left roar speaker @

A8

RED/YEL

Right rear speaker O

A9

BRN/BLK

Rightfront speakerO

A10

GRY/BLK

Left lront speaker O

A11

{Not used}

al2

(Not used)

A13

(Not usedl
Ground(G4O1,G402, G4O4)

A14

BLK

A15

GRY/WHT Le{t rear speaker O

A16

BRN/WHT Right rear speaker O

23-21

Stereo Sound System

Woofer Amplifier Removal

Woofer Amplifier Terminals

1 . Removethe rga. seat (seesction 20).

Removethe rear seat csnter pad (seesection 20).
Removethe three screws and disconnectthe 1O-p
connectorfrom the amplifier,then removelr.

WOOFERSPEAKER

Connocts lo
.81

82

BLU/YEL

Lett rearspeaker(E

GRY/WHT Left rearspoakere

BRNAA,/HT Right rear speaker O

84
WOOFERAMPLIFIER

10-P COI{NECIOR

RED/YEL

87

23-212

Right rear spoaker (E

YEUWHT Radio switched Dower

YEUEED ACC
{Not used)

B8

8LK

Ground(G522)

B9

RED

Wooterspeaker(D

810

WHT

Wooler spoaker O

PowerAntennaMotor Test
.

Removethe trunk right side trim panel.

l.

Disconnectthe 3-P connectorfrom the motor. and

removethe connectorfrom its clamp.

3.

First, check power to the motor at the connector

termrnals:

5.

lf the motor fails to operateproperly.replaceit.

ANTENNA MAST

a There should be battery voltage between the

WHT/YEL(+) and BLK {-) terminalsallthe time
a There should be battery voltage between the
YEL/WHT (+) and BLK {-) terminalsonly with
the ignitionand radio switched ON.
View from wire side

l_ 1*
ilT
I r t flr I
Sticking Antnna:
The antennasticks in eitherthe up or down position.
1.

Usingthe antannanut wrench. removethe special

nut, spacer,and bushing(see next pagel,

2.

Clean the antenna mast housing threads, then

reinstallthe spacerand bushing.

PLASTICSLEEVE

ANTENNA MAST

Viewfromwireside
4.

Tesl motor operation:

EXTEND: Connectbatterypower to the No. I and
No. 2 terminalsand groundto the No. 3
terminal.
RETRACT:Then disconnectpower trom the No. 2
terminal.

5.

Usethe antennanut wrench and torquethe special

nut to 2.3 N.m (0.23 kg-m. 1 .7 lb-tt). lf the special
nut is over-torqued,the antennamay stick. It sticking occurs. back the nut off until the antenna
moves freelv.

23-213

Stereo Sound System

AntennaMast Replacement
NOT: The antenna mast alone can be replaced
without havingto removethe power antennamotor.
1.

Removethe specialnut, spacer,and bushing.

2.

Carefullywithdraw the antennamast while extending it by turning the radio switch ON.

g.-

SPECIALtIUT

\,.-

SPACER

(3

Hold the new antenna so the teeth on the drive

cable face in the directionshown, and insen the
drive cable into the antennahousino.

BUSHII{G

ANTENNA MAST DRIVE CAELE

ANTENNAwRENcH
/ ,-/ oTJAA-OO10{)08

4.

Check for engagsment of the cable teeth to the

drive gear by carefully moving the cable up and
down,
Turnthe radioswitch "OFF", and let the motor pull
the drive cable insidethe antnnahousing.

o-

Cleanthe threadson the antennamast housing.

SPECIALNUT

2.3 N.m 10.23ks-m,1.7 lb-ftl

TEETH

Insert the antenna mast into the antenna housing,

install the bushing and spacer, and tighten the
spcialnut to 2.3 N.m (O.23kg-m. 1.7 lb-ft).
NOTE: It th specialnutis overtorqued,the antenn8 may stick, lf sticking occurs, back the nut off
until thg antonna moves lrselv.

8 . Check thst th6 sntenna mast retracts and extends

fully whn th radio switch is turned ON and OFF
repeatedly.

POWENANTENNA
MOTOR

23-214

DoorSpeakerRePlacement

PowerAntennaMotol
Replacement

Remov the door panel.

Remove the trunk right side trim panel.

Disconnect the 3-P connector and antenna lead
from the motor, thn remove the special nut and
mounting nut, and take out the motor with the
antennamast,

OTJAA-OOIOOOA

2 . Rmov6the tour screws, then disconnectthe 2-P

connoctor from the speakr, and remove the
soeaKer,

(0.23 kg-m, 1.7 lb-ft)

SPACER

ANTENT{A
LEAD

colrr{EcToR

DRAIN HOSE
MOUNTING
NUT

MOTOR
BRAC(ET

When installing the new antenna, tightsn the

special nut first, thon tighten the mounting nut on
the motor brackt.

23-215

StereoSoundSystem
RearSpeakerReplacement
1.

Removethe three nuts from insidethe trunk, then

disconnectthe connectorand removethe speaker
assembly.

Tweeter Replacement
1.

Carefully pry the tweeter cover out of the

dashboard.then disconnectthe connectorsfrom
the soeaker.

/
LEFTREARSpeeren lsseireLv

LEFTTWEETER
COVER

Removethe two screws and removethe tweeter

from the cover.

Removethe three screws from the adapter,then

removethe speakercover.
Removethe three screws,then removethe soeaker
f.om the adaDter,

23-216

Woofer Replacement
Removethe rearseat uppertrim panel(seesection
201.
REARCONSOLEPANEL

Remove the four screws and disconnectthe 2-P

connector from the speaker. then replace the
sDeaKer,
WOOFERSPEAKER

2-P CONNECTOR

23-217

Clock
GircuitDiagram

FUEIdd EilGlNE
CooLAi{T
TEIIIPMruNE
IECT1
COMTROL
CIRCUTT

COi'|EI{ATON
UGXTS1VITCH

VI
I

REO/Bt.K

8t'|(

G401
G402
G404

23-218

r vaa i llFla httd! on thd lwltdt do mt

tlLr to th. v*iclo loood lartsr.

Removal/Terminals
CAUTION:
a All SRS ol6ct cal widng hamosses are qovorod with
yollow outef insulation.
a Betor disconnecting tho SRS wire hahoss, inslall
the short connector(sl on th airbag(s) (see page
23-2941.
o Reolacotho entire affectod SRS harness assembly it
it has an open circuit or damagod wiring.
a Aft6r installing tho gauge assombly, rechock tho
oporation of th6 sRs indicator light.
Romoval:
I . Removethe right tweeter cover (seepage23-130).
2.

Remove the instrument panel visor (see page

23-130).

3.

Removethe black Jacepanel (seepage 23-130).

4.

Remove the sub gauge assembly (see page

23-131).

F5<- - -Fl

Yry

Terminals:
Tsrminal wira
F1

BLK

Connocts to

G3

Ground
.,OO" SET
, , H ' 'U P

Ground

F2

RED/BLK Combinationlight switch

F3

LT GRN

F4

YEL

F5

Trminal
Connectato

Displayconttol circuit
lG1 (Main clock power supplyl

G4
G5

__

___--__-.--,,M" UP

WHT/YEL Constantpower (Time memorY)

NOTE: Theseletters on the switch do not refer to the
VehicleSoeedSensor.

23-219

Horns
ComponentLocationIndex
a All SRS olectrical wiring hahsses aro coverod with
yollow outer insulation.
a Beforo disconnecting the SRS wire hamss, install
tha short connecto.{s} on the airbagls) {see page
23-2941.
a Roplacothe ontire afloctod SRS harnossassombly il
it has an open cilcuit or damagd wifng.

. HORNS
fesi, page 23-221

HORN SWITCHES
Tesr, page 23-222

I
t

REEL
fesr, page 23-222

23-220

Test

CircuitDiagram
BATTERY

I
tf*";l

1.

Disconnect ths 2-P connector and remove the

norn.

2.

Test the horn by connecting batte.y power to one

terminaland groundingthe othr. The horn should
sound.

WHT,^YEL

- WHT/YEL

HORN

2-PcOlrllrlECTOR

UGTIT

3,

lf it fails to sound; replaceit.

23-221

Horns
Switch Test
cAUTtOt{:
a All SRS oloct cal whlng hamosaeaa.o coyorod whh
yellow outer insulstion,
a Bloro disconnocting the SRS wlro h!me3s. insiall
iho shon connector(sl on tho alrbag(ll (rce page
23-2941.
a Replacothe ntirr aftectod SRS hamoss a$embly it
it has an open clrcuit or damagod widng,
NOTE: The radio may havo a coded theft protection circuit. Be sure to get the customer's code number before
- Disconnecting the battery.
- Removingthe No. 43 (1O Al tuse.
(ln the under-hoodfuse/r6laybox)
- Removingthe radio.
After servica, reconnect powr to the radio and turn it
on.
When the word "CODE" is displayed, ent6r the
customer's 5-digit cod to restore r8dio operation.

5.

Installthe short connectoron the airbagconnector.

AIR BAG
CONNECTOR

SHORT/

ACCESSPANEL

6 . Romove the dashboard lower cover.

7.

Disconnect the baftery negative cable, and then

positive cable.
Make sure the wheels are turned straight ahead.
Remove the two scrows and accoss panel, th6n
remove the short connector trom the acc6ss Danel,
4.

Disconnsct the airbag connctor and cabl reel

connector.

23-222

Disconnectthe cable reel 6-P connectorfrom the

SRS main harness, then connect Test HarnessC
onlv to the cable reel side of the 6-P connector.

8 . Checkfor continuitybetweenthe No 3 terminalof

the 8-P connector of Test Harness C and body
ground with the horn switch pressed.

1O. Remove the two TORXo bolts using a TORX@

T3O bit, then removethe driver'sairbagassembly.

TEST HARNESSC
OTLAZ- SL/O3oo

?
CONTINUITY

AIRAAG
ASSEMALY

U3o a TOBXo T30 blt

CRUISECONTROL
SET/RESUME

a lf there is continuity,the horn switch is OK

a lf there is no continuity,go to step 9.
9.

Carefullyremove the cruise control SET/RESUME

switch cover by prying between the cover and
switch in the sequenceshown.

cRutsE
cot{TRoL
SET/RESUME

swtTcH

swlrcl{ covER
11. Checktor continuitybetweenthe horn positiveterminal and steering shaft with the horn switch
pressed.

HORf{
TERMII{AL
POSITIVE

cRursE
CONTBOL
SET,/RESUME
swtTcx covER

STEERING
SHAFT
a lf there is continuity;
- Checkthe cable reel.
- check the SET/RESUME
switch.
a lf the.e is no continuity,replacethe horn switch
(seesection 17).

23-223

GigaretteLighter
ComponentLocationIndex

CIGARETTELIGHTER
Repfacement, page 23-226

CIGARETTELIGHTER
RELAY{A-tyDl

fwrc cotolt:Veuneo,wxrlglu)
IBLK,.nd WHT/RED
I
'2
\esr,

-rl
-D
r-:-r
- L - l f---l
----------rl

,__"_
* ccL___J
nllfl|.|

l1[0mm[[il]

ummmml

23-224

page 23-70

CircuitDiagram

FUSE/REI.AY
BOX
U DER-HOOD

tct{utoN
swtTcH

_ DASHFUSE/RELAY
UNOER
8OX

6i\\

adf**'*

YEURED

I
I

wHIiBLUTwHr/BLU

STEREO
RADIO/
PITYER
CASSETTE

Bu(

BI.K

G40t
G402
G404

G40r
G402
G404

23-225

GigaretteLighter
Replacement
CAUTIO :
a All SRS olsctdcal widng hamesses arc covsrsd with
y6llow outer insulation.
a Boloro disconnecting the SRS wire hamess. install
iha short connector(s) on tho airbag(s) (see page
23-2941.
a Replacatho ontira affoctod SRS harness arsombly if
it has an open circuh or damaged wiring.

3.

Disconnect the thermofuse housing flom the

socket.
CIGARETTE
LIGHTER

NOTE; The radio may have 8 coded theft protection circuit. Be sureto get the customer'scode numberbefore
- Disconnectingthe battery.
- Removingthe No. 43 (10 A) fuse.
(ln the under-hoodfuse/.elaybox)
- Removingthe radio.
After service, reconnect power to the radio and turn it
on.
When the word "CODE" is displayed, enter the
customer's 5-digit code to restoreradioopgration.

UGHT{1.4W

4.

SRS MAII{ HARI{ESS

Remove the ring nut and sparate the cigar6tta

lighter socket trom the thrmal protector.
Wh6n installing the cigarette lighter, align ach lug
on th face pansl, illuminstion ring, and cigarette
lighter socket with the groove in the hole, then
position the bulb housing on ths thermal protector
hw66n ths stops in the radio panel,

6 . Mak sure that the ground wire, bulb sock6t, and

l.

Removethe front console{seesection 2O}.

Remove the radio panel assembly (see page
23-210t.

23-226

thermofuse housing are sested against the

cigartte lightsr assembly.

RearWindow Defogger
Component Location Index
CAUTION:
a All SRS electdcal wi ng hahosses ale covared with
yellow outor insulation.
a Beforo disconnecttng the SBS wile harne$, install
the short connactor on tha airbag(3), then disconnect the wiro hamess (se page 23-294).
a Replacoth6 entira aft6ctd SRS harnessassembly il
k has an open circuii 01 damagod wi ng.

sRsMAII{ HAR]TESS

REARWINDOW
DEFOGGERSWITCH
Test, page 23-230
23-230
Replacement,

UNDER-DASHFUSE/RELAYBOX

wftDow
DEFOGGER
RELAY
(A-Typ6l
Test, psge 23-7'l
OEFOGGER
REAR
Function Test, page 23-231

CIRCUIT
{ln the integrated control unit}
fnput Test, pago 23'170

DEFOGGER

The rear window defoggeris controlledby the integratedcontrol unit. When the defoggerswitch in th heatercontrol
panelis pushed,it sendsa signalto the defoggertimer in the integratedcontrolunit and the defoggerstayson for about
25 minutes,or until the ignitionis switchedoff.
The indicatorlight in the switch comes on when the defoggeris ON.

RearWindow Defogger
Circuit Diagram

IGNITION

swncH

UTIDERIIOODFUSE/NELAY
8OX

UiIDER_
DASI{FUS]REI,AY
8OX

ll .m.lconrEtfunl
COMBINANON
UGHTS1ITTCH

HEANNCOiITROL
PAiIET

BTJqGRN

+
BU(

G801

23-228

G4o1
G402
G404

G401
G102
G10,1

DASHUGI{TS
ERIGTTT
ESS
COMTROL
UNIT

Troubleshooting
NOTE: The numbsrsin the table show tho troubleshootingsequence.

Item to be insDected

?
;
6

3;
{ a

o
(t

Symptom
Defogger works, but indicator
light dogs not go on.

3
o

Defogger-on time too long or

too short compared with the
normalON time (25 minutes).

<

o+ o+

T8

- 9

!l-

o,;
2 t
c 9
. !

z a
r 9
; i

z
c
3
9

1
q
i
c

l t o

5o-

a.: a e
i i E
--c

9 o
c

o c

z
c
3
9

a
g
i
c

g o
o x

3
o

o o

lo

.FE: a

.E

ot
o)

o c

co

5E

o-

BLK/YEL'
YEL/GRN
YEL

o E

Oefogger does not work and

indicator light does not go on.
Defoggor doas not work, but
indicatorlight goes on.

ID

9 E e !
G S ,:o

G401
BLK/GRNI,
G402
YEL/WHT
G404
BLK/GRN'
G801

G401
G402 YEL/WHT
G404

23-229

RearWindow Defogger
Switch Test

Switch Replacement
1.

Removethe front console(seesection 201.

Removs th heater control Danel.

2,

Remove the stereo radio/cassette player (s66 page

23-21Ol.

Check for continuitv between th terminals according to the table.

3.

Disconnectthe air mix cable from the heater.

\

Terminal

t1

14

l6

l2

t".*"__\
ON

-o

OFF

BEARYVITDOW
DEFOGGER
SWITCH

ASSEMBLY

Remove the two mounting screws and diaconnect

the connectors, then remove the hester control
paner.
Install in the reverse order of removal.
o.

After installing the control panel, connect the air

mix cable (see section 22), and mak sure the
temperature control function works correctly.

23-230

DefoggerWires Repair

FunctionTest
CAUTION: Be careful not to scratch or damago tho
defogger wires with ths toster p1ob6.
1.

Check for voltage between the positive te.minal

and body ground with the ignition switch and
deloggerswitches ON.
There should be battery voltage.
a lf
-

NOTE: To make an effective repair, the broken section

must be no longerthan one inch.
1.

Lightly rub the srea around the break with tine steel
wool, then clean it with alcohol.

2,

Carfully mask above and bslow the broken portion

ot the defogge. wire with cellophanetape.

there is no voltage,check for:

Faulty defogger relay.
Faultydefoggerswitch.
Faulty integrated control unit.
An ooen in the GRN/BLKwire.

a lf there is battery voltage, go to stp 2.

POSMVETERMIIIAL

TAPE

Using a small brush, apply a heavy coat of silver

conductivepaint extendingabout 1/8" (3 mm) on
both sidesof the break.Allow 30 minutesto dry.
NOTE: Thoroughlymix the paint before use.
Check for continuity between the negative terminal
and body ground.
It there is no continuity, check for an open in the
defoggerground wire.
Touch the voltmeter positive probe to the halfway
point of each defogger wire and negative probo to
the negativeterminal.
There should be app.oximately 6 V with the ignition switch and detogger switch ON.
a lf the voltage is as specified, the defogger wire
is OK.
a lf the voltage is not as specified, repair the
defogger.
- lf it is more than 6 V, ther is a break in the
negativehalf of th wire.
- lf it is lss than 6 V, there is a break in the
Dositivehalf of the wire.

4.

Check lor continuityin the repairedwire.

Apply a second coat of paint in the same way Let it
drv three hours before removing the tape.

23-231

SeatHeaters(Canadal
ComponentLocationIndex

SEATBACKHEATER
Test,page23-236
SEAT HEATERRELAY
Test, page 23-236

SEATHEATERMAIN RELAY
lA typ6l
Test,page23-70

SEATCUSHIOT{
HEATEN
Test, pago 23-236

SEAT HEATERSWITCH
Test, page 23-235
Replacement.page 23-235

Description
Two heatersare providedin each front seat; one in the seat cushion and another in the seat back. In normal use,
temperatureis automaticallycontrolledby the thermostat[OFFabove104oF {40oCl] built into eachseatcushionheater.
Breaker1 [OFF above 'l22oF (50oC)l and breaker2 IOFFabove 158"F (70"C)1cut ott the circuitto preventabnormal
temoeraturerise.

23-232

CircuitDiagram
IGNITION
SWITCH

BOX
FUSEfrELAY
UNDER.HOOD

BOX
OASHFUSE/RELAY
UNDER-

MAINRELAY
SEATHEATER

R.SEAT
HEATER
SWTCH

TI

-t

l 1
8LK

BLK

REI.AY
HEATER
C R,SEAT

8 LK
t

rr

i Ii
r
r

ii

lrt.----J

|
I

r >
r
<
r
l

i1

i|
l

ii 9l ! 8t 8 , I'
O l

f o**..IJ

L.SEAT
CUSHION

r i

CUSHION
R.SEAT

BACK
L,SEAT

R.SEATHEA]ER
BLK

_lr

BRI : BREAKER
I OFFdbove122'F lSOc)l
:
TH1 THERMOSTAT
IOFF above1O4oF{4Oc)]
BR2: EREAKER
I OFFabove158oF(7Oc)l

G521

23-233

SeatHeaters(Ganadal
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence,

Item to be insDected

!
9 <

so

<
^ O

3 6
o
f
(r)6

r 6
< E
< c v ;
F

- 7
CI

Symptom

z
c
3
9

t
q
i
c

6 =

Seat heaters work, but indicator light

does not go on.
Seat heaters do not work and indicator
light does not go on.

Seat heaters do not

wo.k, but indicator
light goes on.

z )
--c

i
Co o

o
ro
o
@

(D

'oE
o
<t

o*g
BLK

G401
G402 WHT/BLK,
BLK/GRN
G404 YEL/BLK,
WHT/RED
G521

Left or right seat

Seat cushion heater or seat back hearer

does not work, but indicator light goes
on.

23-234

3
(D

Z J

GRN/WHT,
WHT/GRN,
BLU,WHT/RED,
WHT/BLU
BLU, GRN

Switch Replacement
1 . Pry the switch out ol the center consolepanel.

Switch Test
1.

Remove the seat heater switch Jrom the

console.

2.

Check to, continuitybetweenthe terminalsaccording to the table.

Disconnectthe 6-P connectortrom the switch.

6-P CONNECTOR

Torminal

Position
ON
OFF

oo-

--o

a\
\7
Z\
\7

--o

6t

NOTE: Left and right seat heaterswitches are the

same.
6

INDICATOR
t|Gt{T
l0.84wl

23-235

Seat Heaters(Canada)
HeaterTest
1.

Seat Heater RelayTest

Disconnectthe 6-P and 4-P connectorsas shown

below.

Remove the soat, then rsmove the relav from the

bottom of ths seat.

NOTE: Left front seat is shown. Rightfront seat is

similar.

Check continuity between relav terminsls.

a Ther8 should be continuity between the F and A
terminals, and the C and D terminals when
power and ground are connected to th F 8nd E
terminals.
a Th6rs should be continuity between the F and D
t6rminals when power is disconnected.

wire side

6-P
CONNECTOR

SAT HEATER
RELAY

r!+41

F+P

To FLOOR
HARNESS

wire side

Soat cushion hoata.:

Check for continuitybetweenthe No, 2 and No. 3
terminals(R x 103scale).
Thsre shouldbe continuity.
Seat back hoatel:
Check for continuitybetweenthe D and No. 8 terminals(R x 103scale).
There shouldbe continuitv.

23-236

NOTE: Left and right ssat heater relavs are the

same.

Irr

( J

'T t_i ,y'

t-F---------to

rT

<f

Sunroof
ComponentLocationIndex
a All SRS olsctricsl wiring harnossesaro coveled wlth
yollow outer insulation.
a Botob disconnecting tho SRS wire ha;noss, install
ths short connector(s) on tho airbag(s) (soe pag6
23-294t.
a Replacetho entiro affsctod SRS harnessassembly if
h has an op6n circuit or damaged widng.

SUNROOFMOTOR
Test, page 23-241

SUNROOF
CLOSE RELAY
{B typo}
Test, Pag

sut{RooF
OPEI{RELAY

(B-typ.)
Tost, page 23-72

JD

r:-l I

CC

r llfll-l

m[[[[I]
|lm[

llm[mmm|]

23-237

Sunroof
CircuitDiagram

COMEINATION
UGHTSWTCH

V
II

nED/Bu(

I
I

l.

I A
I
RqD

OASHUGHTS
ERIGHTNESS
CONTROL
UNIT

23-23A

Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence'
Item to be insocted

sE>
;,d Q
bg o-

g
o!D

6 8 9 5 b
E o o
= ! o < E
b= 6t'
o o - l 9
2
2
v xF !. Y

9i b
d 6 6

Symptom
Sunroof does not move,
tuns.
Sunroot does not
move and motor does
not run (sunroof can
be moved with
sunrootwrench).

but motor
With either
switch.

5 8
.o . 65

@
ID

gE

6 >
( a
(t;
e

F.6

aeg
Y 6

r.. !

I
3

;
z a z ) z )
c!P 6
=-c ; !
i !
;
-9c 9 c

E 3

ID

- c

0)

rL

(L

WHT/BLU,

G401
BLK/YEL,
G402
GRN/YELor
G404
GRN/RED

With OPEN
switch.

with cLosE
switch.

GRN/YELor
GRN/REO

1
1

or
GRN/RED
GRN/YEL

23-239

Sunroof
Switch Test/Removal
'1.

Caretullypry the switches out of the dashboard,

then disconnectthe connectorsfrom them.

3.

Ch6ck for continuity between the terminals in each

switch position sccording to the table.

rormrnal
Position

OFF

OPEN

G" @

ctosE

-o

-o
-o

A
B

c
2.

Removethe sunrool switch from the switch o8n6l.

D
E

)t) ucHT
t1.1wl

23-240

Motor Test
Removethe high mount brake light cover'
Remove the headliner,then disconnect the 2-P
connectotfrom the sunrooJmotor.
Test the moto. by connectingpower and groundto
the 1 and 2 terminalsaccordingto the table. The
motor shouldrun smoothlY.
NOTE: Motor clutch test is in section20

OPEN

No. 1 terminalto ground

No. 2 terminalto Power

CLOSE

No. 1 terminalto Power

No, 2 terminalto the ground

2.P CONNECTOR

wire sid6

2.P CONNECTOR

lf the motor does not run smoothly,replaceat

23-241

PowerMirrors
ComponentLocationIndex
CAUTIOT{:
a All SRS olectrical wi ng harnsssos a.e coverod with
y6llow outol insulation.
a When disconnecting th SRS wiro harness, install
the short connector on th8 Eirbag(s)then disconnect
tho wire hamess lso pago 23-2941.
a Replacthe ontirs affected SRS hamess assembly if
it has an open circuit or damaged wiring.

POWER
T'IRRORSW|TCH
Test, psge23-245

POWERMIRRORS
Test,page23-247
Repfacement, page23-247

23-242

CircuitDiagram(USA)
UNDER.HOOO
8OX
FUSSRELAY

ryIl' fffi,'' ffi,'oo;l --*-{$S,lfSl

eF["*lT

-f

- OASH
UNDEN
FUSgREtAY
BOX

SWTCH
POWEN
MIRNOR

r l

l i

__________Jr

/tt-----_---_-------:tl\

R.rcWER
MIRROR

Grc1
G,to2
G1o4

23-243

PowerMirrors
CircuitDiagram(Canada)
- r.tooD
uriDER
R,SE/REIAY
BOX

*rrr

|.*-;i^oJ;l
tr00A) t50At

tt)-flo<\!twdT-l
r/ aXr \ rcnrlor
\

lG2 , sl{lrcH

\l-/
I

/EL

I lm lili,tf,"e$"
BIJ(/YEL
POWER
MIRRON
SWTCH

OErcGGER

DOWN

23-244

SwitchTest
1. Remove the switch as described under
,,FUNCTIONTEST".
Checkfor continuitybetweenthe terminalsin each
switch Dositionaccordingto the table.

2.

Mirror SrYitch
lermlnal

Position

10

o-

OFF

UP

DOWN

tEFI

RIGHT

o-

-o
-o

oG-

-{.}

o-

oooo-

LEFT

o-

RIGHT

NIGHT

LEFT T
I

-o
-o

o-

-o

G-

DOWN

UP

----

o-

UP

_o
_o

o- -o

OFF

-o
-o

o-

-{.}

r l
l l
LL__-___IJ

=o
L l

o- -o

o-

L l

I R

-o
-o
_o

o-

l R

-o
UP

oeroccen
( \y' swrTcH

Il

Dofoggor Switch(Canada)
\

lermlnal
Position
ON
OFF

l0

o-

o-

-o
--o

,{l

"'i

RIGHT

i
I

z \ l -

lv
I OEFOGGER
I rNDlCAloR
| (rED)

I
I
L

;}T l*-T-;-f
E
;f,

i
J

, ? ' 1 ,. ? ' 1 ,
23-245

Power Mirrors
FunctionTest
Carefullypry the switch out ot the door panel.
Oisconnectthe connectorsfrom the switch,

a lf the mirrorneithertilts down nor swings left, repair

thE YEL/BLU\,virE.
a lf the mirrorworks properly,checkthe mirrorswitch.
Right mirlol inopemtiv:
Connectthe BLK/YELterminalot the 1O-pconnectorto
the GRN/BLUterminal and the BLU/ORN{or BLU/BLK}
terminalto body ground with jumper wires.
The right mir.orshouldtilt down (or swing left) with the
ignitionswitch ON.
a It the mirror does not tilt down (or does not swing
left), removethe right door panel and check for an
open in the BLU/ORN(or BLU/BLK)wire betweenth
right door mirror and the switch
ll the wire is OK, check the right door mirror motor,
a lf the mirrorneithertilts down nor swings lsft, repair
the GRN/BLUwire.
a lf the mirrorworks properly,checkthe mirrorswitch.

---)

Defogger test (Canadsl

viw trom wire side.

lcansda)

NOTE: Checkthe No. 9 {15 A) Iuse in the under-dash

Juse/relaybox betore testing.
1.

Check for voltage between the BLK/YELterminal of

the 2-P connectorand body ground with the ignition switch ON.
There should be battery voltage.
a It the.e is no voltage, check for an open in the
BLK/YELwire between the under-d8shJuse/
felay box and the detoggerswitch.
a lf there is bsttery voltage, go to step 2.

2.

Connectthe BLK/YELterminalof the 2-p connector

to the ORN terminalwith a jumper wire.
Both the right and left mirro.s should g.adually
warm up with the ignitionswitch ON.
a It neitherwaJms up, repairthe ORN wire.
a It only one fails to wa.m up, check its mirror
defogger efment lsee page 23-2471.
a lf both warm up, check the switch,

MirrorTest
One or both inoporative:
1. Check for voltage between the BLK/YELterminal
and body ground with the ignitionswitch ON.
The.e should be battery voltage.
a lf there is no voltage,check for;
- Blown No. 9 (15 A) tuse in the under-dash
fuse/relaybox.
- An open in the BLK/YELwire.
a lf there is baftery voltage, go to step 2.
2.

Checkfor continuitybetweenthe BLKte,minaland

body ground.
There shouldbe continuity.
a lf there is no continuity,check for;
- An open in the BLK wire.
- Poor ground (G4O1.c402, G404).

Loft mirror inoDorativ:

Connectthe BLK/YELterminalot the 1O-pconnectorto
the YEL/BLUterminat.and the BLU/ORN(or YEL/GRNI
terminalto body ground with jumper wrres.
The left mirrorshouldtilt down (or swing leftl with the
ignitionswitch ON.
a lf the mirror does not tilt down (or does not swing
left), remove the left door panel and check tor an
open in the BLU/ORN{or YEL/GRN)wire betweenthe
left door mirror and the switch.
lf the wire is OK. check the left door mirrormotor.

23-246

PowerMirrorMotor Test
C8rfullypry out the window corneJpanel with a
flat tip screwdriver.

1.

2 . Removethe door panel.

Disconnect the 3-P or 6-P connector from the
mirrot.

PowerMirrorReplacement
NOTE: Be{ore removing the mirror, lower the window
tully.
1.

Carefully pry out the window corner panel with a

flat tip screwdriver.

2.

Removethe door Panel.

3.

Disconnect the 3-P or 6-P connctor from the

mirlor.

4.

While holdingthe mirrorwith one hand,removethe

three mountingscrews with the other.

@-

3-PCONNECTOR 6-P CONI{ECTOR

(Canadal
tusAl

4.

Test actuato. operation:

TILT UP

TILT DOWN

SWINGLEFT

SWING
RIGHT

5.

Connect batterv power to the No.

3 terminaland groundto the No.
4 terminal.
Connect battery powel to the No.
4 terminaland groundto the No.
3 terminal.
Connect batterv power to the No,
4 terminaland groundto the No.
5 terminal.
Connect battery Power to the No.
5 terminaland groundto the No.
4 terminal.

Checktor continuitybetweenthe No. 1 and No. 2

terminals{RX 103scale).
There shouldbe continuity.

23-247

Power Windows
Component Location Index
PASSENGER'SWINDOW SWITCI{
Test, page 23-252
Repfacement,page 23-253

PASSENGER'SWINDOW MOTOR
Tost, page23-254
Replacement,section 20

ORIVER'S
WINDOWMOTOR
Test,pago23-254
Replacement,
section20

POWERWIITDOWSWITCH

InputTest,page23-251
Tosr,pag23-252
page23-253
Repfacement,

E=E
!

E1El
UI{OER.DASHFUSE/RELAYBOX

KEY.OFFTIMER CIRCUIT
{ln th integratod control !nit)
Inputtest, p8ge 23-168

Description
Power Window Key-olf Timr Oporation:
The power windows can still be operatedtor aboul 1Ominutesafter the ignitionswitch is turnedfrom the " " to the ,,1,,
or "O" positionas long as neitherdoor has been opened.This providesa convenienceto parkedoccupanrs.

23-248

CircuitDiagram
BOX
FUSE/RELAY
UNDER_HOOD

ernenv
llffif-ffifl
@wnolu
\:_/

wtNDow

PASSNGER'S
WINDOWMOTOR

23-249

Power Windows
Troubleshooting
NOTE: The numbe.sin the table show the troubleshootingsequence.
Item to be insoctod
! !

E !
9:.\

! ! g

3E

ae
s 6
..
( 9 I6

Symptom

c g

ID

El=

c\

o
(\

z )
3 !
9 c

3
!
o

'
o

C;

3 '
(D .o

3
i
;

.E

,
E

ID

E
3

'

'

.=
i

(D

.z

e E
! i :
9 0

- c

Y =

3 4

Drivr's window does not work in

AUTO,
Passenger'swindow do6s not
work.
One or both windows do not work
within 1O minuresaftr the ignition
switch is OFF.

23-250

2
1

o-

{ , o
oc'

G401
G402 GRN/BLK
G404
WHT/BLK

Driver'swindow does not work.

g 8

9 i

Neither window works.

1

ttt a

P !

't

'P 3Oo

BLU

BLU/BLK
J

NOTE: The control unit is built into the master power

window switch, and onlv controlsthe driver'swindow.
'1.

1O-PCONNECTOR
3-P CONNECTOR

Removethe driver'sdoor handlepaneland disconnect th 1O-P8nd 3-P connectorsfrom it.

lnsoectthe connectorterminalsto be surethey are
all makinggood contact.
a lf the terminals are bent, loose, or corroded,
reDair them as necessary, and recheck the
sYstem.
a It the terminalslook OK, make the tollowinginout tests at the 1O-Pconnectol
- lf a test indicatesa ptoblem,{ind and correct
the cause,then recheckthe system.
- lf all input tests prove OK, the control unit
must be faulty; replace the master power
window switch.

ELKI BLK' BLU/BLK

lrom
wire side
RED/YEL
WHT/BLK

No.

Terminal

Test condition

Test: Desirsd rssult

BLKl

Under all conditions.

Check for continuityto ground:

There shouldbe continuity.

WHT/BLK lgnitionswitch ON.

BLU/BLK
RED/BLU connect the wHT/
and
RED/YEL

BLK terminalto the

RED/BLUterminal,
and the RED/YELterminalto the BLKI terminal,then turn the
ignitionswitch ON.

Check for voltageto ground:

There shouldbe battery
voltage.
Checkthe driver'swindow
motor: lt shouldrun.

BLU/YEL Connectthe BLU/BLK Checkthe passenger'swindow

ano
BLU/GRN

terminalto the BLU/

GRNterminal,and the
BLU/YLterminalto
the BLK terminal,
then turn the ignition
switch ON.

motor: lt shouldrun.

BLU

connect the wHT/

BLK terminalto the
RED/YELterminal,
and the BLK2terminal
to the RED/8LUterminal,then turn the
ignitionswitch ON.

Connectan analogohmmeter
to the BLU and BLK2terminals:
The meter needleshouldmove
back and forth as the driver's
window motor runs.

ano

BLK'

BLU/YEL

Possiblecause if rosult is not obtained

. Poor ground (G4O1, G4O2,G4O4)
' A n o p e ni n t h e w i r e .
'16
{2O A) fuse.
Blown No. 1 5 or
(ln the underdash fuse/relaYboxl
Faultypower window relaY.
An open in the wire.
. Faultydriver'swindow motor.
. An open in the wire.

Faulty passenger'swindow motor.

Faultypassenger'swindow switch.
An open in the wire.

Faultypulser.
Faultydriver'swindow motor.
An open in the wire.

Power Windows
MasterPowerWindowSwitch Test
1 . Removethe driver'sdoor handlepaneland discon-

Passenger'sWindow Switch Test

'1.

nect the 1O-Pand 3-P connectorsfrom it.

Check{or continuitvbetweenthe terminalsin each

switch positionaccordingto the table.

DRIVEB'SSWITCH

2.

Carefully remove the passenger's door handle

panel from the door, then disconnect the 5-p
conneclor.
Checkfor continuitybetweenthe terminalsin each
switch positionaccordingto the table.

WINDOW
oooR HANDLEPANEL PASSENGER'S

OOORHANDLE PANEL

MASTER POWER

MAIN SWITCH

wtNDowswtTcH

E F G H I J

Ddvo?'s Switch
Terminal

T""ryl
\_____

Position

--o
o- --o

OFF

UP
DOWN
DowN(AUTo)

oo-

-o

Passong6r'sSrvltch
rermrnal

PositlonI Mainswitch\
ON
OFF

OFF

UP

ON
OFF

DOWN

ON
OFF

23-252

--o
o- -_o
o- --o
--o
o-o- --o
-o
--o
o--o
o-

Position

UP
OFF

00wN

--o
o- --o o- --o
-o
oo-

Switch Replacement
Maslcr powor window swilch:
1. Removethe mounting screw and pry the driver's
door handlepanelout of th door panel,
2.

Disconnctthe 10-P and 3-P connectorsfrom it'

Passangor'awindow Swhch:
1. Remove the mounting screw and pry th passenger's door handls panelout ot the door pan8l'
2.

3.P CONNECTOR

5.P CONNECTOR

DOOR
DRIVER'S
HANDLEPANEL

3.

Disconnectthe 5-P and 3-P connectorsfrom it.

Removethe master power window switch from the

door handle panel by removingthe four mounting
screws.

DOOR
PASSENGER'S
HANDLEPANEL

3.

Removethe passenger'swindow switch from tha

door handle panel by removingthe two mounting
screws.

MASTER POWER

wtNDowswlTcH
PASSEI{GER'SWINDOW SWITCH

DOOR HANDLE PANEL

23-253

Power Windows
Driver'sWindow Motor Test

Passenger's
Window Motor Test

Motor Tast:
1. Rmovethe door panel (seesction 20).

Romove the door panel (see sction 20).

Disconnect the 2-P connector from the motor.

2.

Disconnect the 4-P connctor from th6 motor.

3.

Tst motor operstion by connecting battery power

to the No. 3 terminaland g.oundingthe No. 4 terminal. T6st the motor in each direction bv switching the lesds.

4.

Tsst motor operation by connecting power and

ground to the No. 1 and No. 2 tsrminals.Test the
motor in each dirctionby switchingthe leads.
4.

lf the motor dos not run, rDlaceit.

lf the motor does not run, reolaco it.

View lrom wire sido

Pul3.r Tcst:
Connoct the test leads of an analog ohmmtor to ths
No. 1 8nd No. 2 terminals. Run the motor by connecting
power and groundto th6 No. 3 8nd No. 4 terminals.The
ohmmeter needl should move back and forth Es the
motor runs.

PASSoIGERS

wtN00w
Irl0TOR

23-254

Power Door Locks

ComponentLocationIndex
CAUTION:
a All SRS aloctdcal wiring harnsssare covrd with
yellow outer insulation.
a Bofore disconnectitrg tho SRS wire harness. install
tha short connoctor on th6 airb8g(s)th6n disconnoct
tho wir harnoss (s8e pags 23-2941.
a Replacethe ontiro aftscted SRS hamess assembly it
it has an opsn circuit or damaged witing.

DOOR LOCK SWlTCtl

Test, page 23-262

PASSENGER'SKEY CYLINOERSWITCH
Test, page 23-26'l
PASSEI{GER'SDOOR LOCK ACTUATOR
Test. page 23-261
RDlacement,section 20

U'{IT
CONTROL
Test, page23-258
tcl{lTrol{ KEYSWITCH
Test,page23-171

DRIVER'SOOOR LOCK ACTUATOR

and LOCKKNOBSWITCH
Test, paee23-260
section20
Replacement,

23-255

PowerDoorLocks
CircuitDiagram

- HOODFUSE/BEIAY
UNOER
8OX

PoIYER
000RtocKcoNlrot u n

lGNlTlot'l
KEY

swtTcH
8LK

8l PASSENGER'S
3 lpAssENGR.s
5
N
l,,
I 000RKEY
| 00oRtocK
'
I SWITCH
I CYUNDER
PASSNGER'S
I
I SWITCH

3fi'f;.'.|

Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item to be insoected

d q
!
o, !n o,

i 3

* R
t 5

<
o l

r o

3
{ 6

3
I

o >

2 )

- f

Symptom

9 c

Power door lock system

doesn't work at all.
Doorsdon't lock or
unlock with the
driver's power door
lock switch.

Ooorsdont't lock or
uFlockwith the
passngers power
door lock switch.
Doorsdon't lock
with th driver's
door lock knob.
{lgnitionkey not
insertdand doors
closed.l
Doors donit lock or
unlock with the
passenger'sdoor
key cylinderswitch.

8
O Y

5 5

o-

YEL/REO
or WHT/RED

G401
BLU/RED
or
G402
BLUiWHTI
G404

YEL/RED
or WHT/RED

Both
doors

Doors will lock when the kev is

still in the ignitionswitch and
the driver's door is ooen.

G401
BLK/WHTor
G402
BLK/RED
G404

Both
doors

One
door

YEL/RED
or WHT/RED

Both
doors

One
ooor

G401
GRN/WHT
G402
or GRN/RED1
G404

One
ooor

o
G401
G402 W H T
G404

Both
doors

One
door

(L

IL

2
3

G401
BLK/REDor
G402
BLK/WHT
G404
YEL/RED
or WHT/RED

G 4 0 1 BLU/WHT'
G402 G R N / R E D '
G404 or GRN/BLU

23-257

Power Door Locks

ControlUnit InputTest
Removetha driver's door panel {see section 20)
and disconnect the 18-P connector trom the power
door lock control unit.
Inspectthe connectorterminalsto be surethey are
all makinggood contact.
a It the terminals are bent, loose, or corroded,
repair them as necessary, and recheck the
svstem.
a lf the terminalslook OK, make the following inout test at the connectorterminals.
- lf a test indicatesa problem,Jindand correct
the cause.then recheckthe system.
- lf all ingut tests DroveOK, the control unit
must be taulty; replaceit.
NOTE: Different wires with the same color have
beengiven a numbersuffix to distinguishthem {tor
examole, GRN/RED1and GRN/RED,are not the
same).

POWERDOORLOCK

1A.P CONNECTOR

View from wi.e side

BLU/WHTI

BLK/WHT

23-258

GRlII/wXT

BLU/WHT'

Disconnect the 1

connecto?from the control unit.

No.

Wile

Test condition

Test: Dosi?adresult

BLK

Under all conditions.

Checktor continuityto ground:

There shouldbe continuitv.

WHT/RED connect the YEL/RED Check door lock operation:

All doors shouldunlock.
ancl
terminalto the WHT
YEL/RED terminal,and the
WHT/REDterminalto
the BLK termlnal
momentarily.
Connectthe wHT/
REDterminalto the
WHT terminal,and
the YEL/REDterminal
to the BLK terminal
momentarily.

Possibli caus6 it rosult is not obtainod

. Poor ground (G401, G4O2,G4O4).
. An ooen in the wire.
. Fauly actuator.
. An open in the wire.

Check door lock ooeration:

All doors shouldlock.

Reconnect the 18-P connector to the control unit.

No.

wiro

Test condition

WHT

Under all conditions.

GRN/WHT Driver'sdoor lock

switch in LOCK.

Tost: Dosirod te8ult

Chsck tor voltageto ground:
There should be battery
vo|tage.

PosEiblocauss if result is not obtainsd

. Blown No. 44 (15 Al fuse.
(ln the under-hoodtuse/felayboxl
. An open in the wire.

Check for voltageto ground:

Thereshouldbe 1 V or less.

Faultydriver'sdoor lock switch.

Poor ground (G4O1,G402, G404).
An ooen in the wire.

Checkfor voltageto gfound:

Thereshouldbe 1 V or less.

Faultypassenger'sdoor lock switch.

Poor ground (G4O1,G402, G4O4).
An open in the wire.

CheckJor voltageto ground:

There shouldbe 1 V or less.

Faultydriver'sdoor lock actuator.

Poorground (G4O1, G402, G4O4).
An oDenin the wire.

Check for voltageto ground:

Thereshouldbe 1 V or less.
NOTE: Beforetesting, remove
No. 46 (15 A) tuse in the
under-hoodfuse/relavbox.

Faultydoor switch.
Poorground.
An open in the wire.

Checkfor voltageto ground:

Thereshould be 1 V or less.

Faulty ignitionkey switch.

Poor ground (G4O1, G4O2,G4O4).
An open in the wire.

Checktor voltageto ground:

There shouldbe I V or less as
the switch is turned.

Faulty passenger'sdoor cylinder.

Poorground (G4O1, G402, G404).
An oDenin the wire.

G R N / R E D T Driver'sdoor lock

switch in UNLOCK.
BLKi RED

Passenger'sdoor lock
switch in LOCK.

BLK/WHT Passenger'sdoor lock

switch in UNLOCK.
6

BLU/WHTI Driver'sdoor lock

knob in LOCK.
BLUi RED

Driver'sdoor lock
k n o bi n U N L O C K .

GRN/BLU Driver'sdoor open.

G R N / R E D ' Passenger'sdoor
open.

BLU/WHT' lgnitionkey is in the

ignitionswitch.

BLKi RED

Passenger'sdoor key
cylinderin LOCK.

BLK/WHT Passenger'sdoor key

cylinderin UNLOCK.

To prevent damago to the motol, apply battefy voltago only momntarily.

23-259

PowerDoorLocks
Driver'sDoorLockActuator Test
t _

Remove the door panel (see soction 2O),

Check for continuity betw66n ths tsrminals in each

switch positionaccordingto the table.

2 . Disconnect the 6-P connctor from ths actuator,

\------ ry'"d

Position

r0cK
UNLOCK

DOORLOC|(X[O8

View trom wire Sids

Test actuator operation:

LOCK: With battery pow6r connected to the No. 4
terminal,groundthe No. 5 terminalmomntarily,
UNLOCK:With baftry power conncted to th6 No.
5 terminal,groundth No. 4 tarminalmomentarily.
CAUTION: To provont damago to thc motor, only
connocl powor momontarlly.

4.

lf the actuator doea not work properly, rplaco it.

23-260

o-

oo

-o

DoorLock
Passenger's
Tost
Actuator
1.

Removethe door panel (seesection 201.

2.

Disconnect the 6-P connector from the actuator.

KeyCylinderSwitch Test
1 . Removethe door Danel(seesection 20),
Disconnectthe 6-P connectorJromthe actuator,

6-P CONI{ECTOR
View from wire side

6.P CONNECTOR
View from wire side

T6st actuator operation:

LOCK: With battery power connected to th No, 4
terminal,groundthe No. 5 terminalmomentarily,
UNLOCK:With batterv power connected to ths No,
5 trminal,groundthe No. 4 terminalmomntarily.

3.

Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.

CAUTION: To provont dmag to ths motor. connsct power only momontadly,

4.

It the actuator does not work properly, replsce it.

\_____jy"'l

Position
LOCK
UNLOCK

o-

o- ---o
--o

23-261

Power Door Locks

Door Lock Switch Test
1.

Removethe door handleoanel.

3.P CONNECTOR

DOORIOCK SWTTCH

Disconnectthe 3-P connectorJromthe switch.

Check for continuity between the telminals in sch
switch positionaccordingto the table.

Terminal
A

Poshion
LOCK

o-

OFF
UNLOCK

23-262

o-

Wiper/Washer
ComponentLocationIndex

WINDSHIELD
WIPER/WASHER

swtTcH
Test, page 23-266
Repfacement, page 23-267
WINOSHIELDWIPER
ARMS/BLADES
Replacement,

WINOSHIELDINTERMITTENT
WIPERPELAY l8-typo)
Test, page 23-72

WINDSHIELDWIPER
MOTOR ASSEMBLY
Test, page 23-268
Repfacement. psge 23-27 O

Ut{DER.DAS}I
FUSE/RELAYBOX

MOTOR
Test, page 23-269

WIPER/WASHERCIRCUIT
{ln the integrated control unit}
fnput Test, page 23-167

23-263

WiperMasher
CircuitDiagram
- HOOD
UNDER
FUSE/RELAY
8OX

DASHFUSE/RELAY
UI{DER_
BOX

INTERMITTENT
WIPERCIRCUIT
flntlF intoEnod \

BLK

BLK

Btx

BI.J(

G30l

G30r

G4o1
G402
m4

G30l

23-264

G101

Grc2
G40/t

Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.

Item to be
inspected

6
P 9
3 E

l!

a;

c 9
t i
9 c

Symptom
Wipers
do not

ln all
positions
ln INT
In LOor Hl
ln MIST

Bladesdo not returnto

park positionwhen
wipers are turned OFF,

.2

E
;

Wipers and washer do

not work at the same
ttme.

g E!

X !

i5;

.2
o

6 E

o:?

a)

E E

6 :
Z Y

o-

o o
O E

GRN/BLK

G301
G401 G R No r
G402 BLU/WHT
G404 BLU/YELor BLU

1
t

')

BLU/YEL

BLU/WHT

ErraticintermittentcYcle or wipers do not

work in lNT.
Little or no washer fluid
is pumped.

-vii

E E o)

5 6

E!'

r'. f
z )

G R N / B L KG, R N .
BLU/WHTor
GRN/RED

G 3 0 1 BLK/YEL
BLK/YEL

23-265

Wiper/Washer
Wiper/Washer
Switch Test
1 . Remove the dashboard lower cover and knee
bolster.
2.

Disconnectthe 5-P and 20-P connectorstrom the

main wire harness.
Checkfor continuitybetweenthe terminalsin each
positionaccordingto the table.

20-P COI{NECTOR

DASHAOARD
LOWERCOVER

KIEE EOLSTEF

l4
Position

15

16

OFF

INT

t0

o-

HI

G_

o-

Mistswitch'0N'
WEsher
switch'0N'

23-266

o- ---o

11

24

ooo
--o

Switch RePlacement
Wiper/Washer
CAUTION:
a Atl SRS clectrical wlring harno!343 ato covarcd whh
yollow outct Inrulatlon.
a Bators dbconnocting tha SRS wito hlmcss, lnstell
th6 rhort connoctor(sl on tha sitbag(sl (sae pago
23-2941.
a Roplaco thr cnllro Effectad SRS hamcls asr.mbly lf
It has an opn circult or dsmlgod whlng'

1.

Remova the dashboard lower cover and l(nee

bolster.

Removethe steeringcolumncovers,

COLUMNCOVR
UPPER

Disconnectthe 8-P connector, then remove the

wip6r/washerswitch.

CONNECTOR

LOWERCOVER
DASHBOARD

23-267

Wiper/Washer
WindshieldWiper Motor Test
Open the hood and removethe cap nuts and the
wipef arms. Be caretulnot to damagethe hood.
Disconnect the 5-P connector from the wiDer
motor assemblv.

lfl (BLU/YEL}
B lGif{/BLt(}

5.

LO(BLU}

Rgconn6ct the 5-P connactor to the wior motor

assembly.

6 . Connsct an analog voltmter between the As

(BLUA /HT) 8nd the E IBLK) terminals. Fun the
motor by turning the wipr switch ON (LO or Hl
position). Th6 voltmete. should altrnately indicate
O V and mors than 4 V.
5.P CONNECIOR
termanalside.

Test motor ooeration;

LOW SPEED:Connect battery power to the B
(GRN/BLKIterminal and ground to
the LO {BLU)te.mins..
HIGH SPEED:Connect battery power to the B
(GRN/BLK)terminal and ground to
the Hl (BLU/YEL)termtnsl.

4.

lf the motor does not run. or Jailsto run smoothlv,

reolace it.

23-268

Windshield Washer Motor Test

Rsmovs the 18ft inner fendor.
Disconnect the 2-P connector from the washer
motor.
Tst the washsr motor by connecting battty
oowel to the @ terminal and grounding the O
terminsl.
a lf the motor does not run, or fails to run
smoothly, replsce it.
a lf the motor runs smoothly, but little or no washer tluid is pumped, check for a disconnscted or
blockedwasherhose,or I cloggedpump outlet.

2-P

cot{r{EcToR

23-269

Wiper/Washer
WindshieldWiper Motor Replacement
Open the hood and remove the caD nuts and the
wiper arms. Be carefulnot to damagethe hood.
Removethe windshieldlower molding,hood seal,
and air scoop by prying the trim clips out and
removingthe sctews.

Removethe three mountingbolts and one nut from

the wiper linkage,then removethe wiper motor.

NUT
22 N.m {2.2 kg-m,16 lb-ftl

CAPNUT

MOUI{TIIIIG
BOLTS
10 .m {1.O kg-m, 8 lb-ft|

3,

Disconnectthe 5-P connectorfrom the wiDermotor, then remove the wiper harnessfrom the wiDer
linkage.
VNPERMOTOR
WIPERLII{KAGEASSEMBLY

Removethe wiper linkageassemblyby removing

the three mountingbolts.

23-270

WasherMotor RePlacement
1.

Removethe washer filler neck.

2.

Rmoveth innerfender.

3.

Disconnectthe hose and the 2-P connectortrom

the washer motor'

4.

Romove the thre mounting bolts 8nd pull out the

washer .esetvoil.

5.

Romove the washer motor from the washer

reservolr.

6.

Removeths washel nozzlesand washer hose as

necessary.

7.

During installationtake care not to pinch 8ny

hoses, Instsllthe hose clips tirmly.

8.

After installingwasher nozzlss,check/adiusttheir

aim.

23-271

GruiseControl
ComponentLocationIndex
CAUTION:
a All SRS elect cal wiring harnesaosalo coverd wiih
yallow outr insulation.
a 8ofo.e di6connecting ths SRS wire harn6ss, install
the short connector{sl on tho ai.bag{s) (see page
23-2941.
a Roplacethe entiro affectod SRS harnoss assmbly if
it has an open circuit or damaged wiring.

CRUISECONTROLMAIN SWITCH
Test, page23,280
Replacement,page 23-280

COI{TROL
UNIT
fnputTesr,page23-276
CAALE REET
Test, page 23-278
Repfacement.pag6 23-276, 318

SET/RESUMESWITCH
Test, psge 23-278
Repf6cement. pdga 23-27 I

A/T GEAR POSINON

swtTcH

Test, page 23-149, 281

Replacoment,page 23-149

CLUTCH SWITCH
Test, page 23-281
Pedal Height Adiustmnt, section

swtTcH

Tst, pag 23-282

Pedal Hoight Adjustmenr, section 'l I

23-272

CABLE
ACTUATOR
Adjustment, Page23-294

ACUUII,IRESERVOIR

SofenoidTest, page 23'282

Test, page 23-283
Replacement,Page 23-284
Disa$embfy, page 23'285

23-273

CruiseControl
CircuitDiagram
- HOOO
UNDER
FUSE/RELTAY
8OX

UNOEROASHFUSSRE!{Y
8OX

c0MEtNAnoir
UGHT
SWITCH

INDICATOR
UGHT
t0.84wl

IP
Il

IOSET

IP
tb8h,
- rcNrnoN
cot{TRot

lL

MODUI.I
{rcMl

\7

REEL

t
I

ErlJ

P(

CRUISE
c0l{TRot
ACIUATOR

VEHICI.T
SPED

sNsoR
{vsst

l^

PosrTloir
swrTcH
I
t
12,ft, D.l

8u(

81-K

G301

23-274

M,/T: CLUICHSWTTCH\
,,/T: MGAn
I

G401
G402
G404

G40t
G4!2
G(X

Troubleshooting
a The numbe.sin the table show the troubleshootingsequonca.
a Beforetroubleshooting.
- Check the No. 14 (7.5 Al fuse in the undsr-dashfuse/relaybox End ths No' 41 (15 A) fuse in the undr-hood
fuse/relaybox.
- Checkthat th ho,ns sound.
- Check the tachometer for propor operation.

Items to be inspscted

o
o o

F
@

o
'P-

'P-

!l
6

Symptom

(!

ut
o
,E

o
o

o
o

<t
u,

'

F
ut
a

o
o
E

;:

o 6

T6;
E
-g I
q o

3 E

E 6 9

E'g5

o
o
o

o
o

E;
3 ;

P
; E
= E >

o = >

gg !

BRNMHT,
LT GRN/BLK,
G401 BRN/BLK,
BRN/RED,
G402
ORN,LT GRN
G404
BLU
LT GRN/RED,

Cruisecontrol cannot be set'

Cruise control can be set, but

indicatorlight does not go on.

Excessive overshooting and/or

undershootingwhen trYingto
set speeo.
Steady speed not held, even on
a flat road with cruisecontrol
set.

Set speed not cancelledwhon

shift lever is moved to 1 (A/Tl.

Set soeed not cancelledwhen

brake pedal is pushed

'I

Set speednot cancelledwhen

main switch is DushedOFF.
1

Set speed not cancellsd when

clutch pedal is Pushed(M/T).

Set sosed not resumed when

RESUMEbutton is Pushed(with
main switch ON, but set speed
temporarilycancelled).

GrtO1
G402 YEL,RED,RED/BLK
G404

Cruise speed noticeably highsl

or lower than what was set.

Car does not decelerateor accelsrateaccordinglYwhen SET

or RESUMEbutton is Pushed.

o o
-q .9

o
o

PNK

PNK

GRY, GRN/WHT

LT GRN

23-275

CruiseControl
ControlUnit Input Test
CAUTION:
a All SRS aloctfical widng harnessosare cov6rd with
yollow outo. insulation.
a Brtoro di3connoctlng the SRS wira hamoss, install
tho short conn6ctor(s) on the airbag(s) (see page
23-2941.
a Replacethe entiro affoctod SnS harn6ssa$ombly it
it has an opon clrcuit or damagod wiring,
1.

Disconnectthe 14-P connector from the control

untr.
Inspectthe connectorand socket terminalsto be
sure they ars all makinggood contact.
a lf the terminsls are bent, loose, or corrodsd.
fepair them as necessary, and rechsck the
system,
a It the terminalslook OK, make the following input tsts at the connector,
- lf a test indicatesa p.oblem,find and correct
th caus,then recheckthe svstem.
- lf allthe inputtests proveOK, the controlunit
must be faulty; replaceit.

cRUrsE
coNrRoLuwr /
r4-P CON|{ECTOR

View from wire side

23-276

't

Possiblocause if result is not obtain6d

Test condition

Test: Dosird result

BLK

Under all conditions.

Check for continuityto ground:

Thereshouldbe continuity,

LT GRN

lgnitionswitch ON
and main switch ON.

Checkfor voltageto ground:

There shouldbe battery
voltage.

B l o w nN o . 1 4 { 7 . 5 A ) f u s e .
(ln the under-dashtuse/relaybox)
Faultymain switch.
An open in the wire.

LT GRN/
BLK

RESUMEbutton pusheo.

LT GRN/
REO

SET button pushed.

Check tor voltageto ground:

Thereshouldbe battery
voltage.

B l o w nN o . 4 1 ( 1 5 A ) f u s e .
{ln the under-hoodfuse/relaybox)
Faulty SETiRESUMEswitch.
Faultycablereel.
An open in the wire.

Check for continuityto ground:

Thereshouldbe continuity.
NOTE: Thereshouldbe no
continuitywhen the clutch
pedal is releasedor when the
A/T shift lever is in other positions.

Faultyor misadjustedclutch switch

(M/T).
Faultyor misadjustedA/T gear position switch.
Poor ground{G4O1,G4O2,G404).
An open in the wire.

PNK

M/T: Clutch pedal

pusneo.
A/T: Shift lever in

E,E.o,E

. Poorground {G4Ol, G4O2,G404)

. An open in the wire.

. Faultyignitionsystem or ECM.
. An open in the wire.

BLU

Start the engine.

Check for voltageto ground:

There should be baftery
vortage.

ORN

lgnitionswitch ON
and main switch ON.
Raisethe front ot the
car, rotate one wheel

CheckJor voltagebetweenthe
ORN @ and BLK O terminals:
I t s h o u l db e 0 - ' 1 2 - O - 1 2 V
repeatedly.

GRY

lgnitionswitch ON,
main switch ON and
brake pedal pushed,
then released,

Check for voltageto ground:

Thereshouldbe O V with the
pedal pushed, and battery
voltagewith the pedalreleased.

. Faultybrakeswitch.
. An open in the wire.

Checkfor voltageto ground:

There shouldbe battery
voltage with the pedalpushed,
and O V with the pedal released.

. Faultybrakeswitch.
. An open in the wire.

10

GRN/WHT Brakepedal pushed,

then released.

RED

lgnitionswitch ON.

Connectto ground:Cruiseindicator in the gaugeassemblY

comes on.

BRN/RED Underall conditions.

Check for resistanceto

ground:Thereshouldbe
80- 1200.

'12 BRN/BLK Under all conditions.

Check for resistanceto

ground:Thereshouldbe
' 1o
70- 1
0.

1 3 BRN/WHT Under all conditions.

Check for resistanceto

ground:Thereshouldbe
40-60 0.

1'l

Fauhyvehiclespeedsensor(VSS).
P o o rg r o u n d( G 1 0 1 ) .
An open in the wire.

Elown bulb.
Blown No. 13 { 10 A} fuse.
(ln the under-dashfuse/relaybox)
Faultydimmingcircuit in the gauge
assemory.
An open in the wire.
. Faultyactuatorsolenoid.
. An open in the wire.

23-277

CruiseControl
Set/ResumeSwitch Test/Replacement
CAUTION:
a All SRS lectrical wiring halnesses ar covorad wlth
yellow outer inaulation.
a Botoro disconnecting tho SRS wire harness, install
the 6hon connector(sl on th airbag(s) (sea page
23-2941.
a Replacothe ntire affected SRS harnass assembly if
it has an opn circuit or damaged wiring.
NOTE: The radiomay havea codedtheft protectioncircuit. Be sureto get the customer'scode numberbefore
- Disconnectingthe battery.
Removingthe No. 43 (1O A) fuse.
(ln the under-hoodfuse/relaybox)
- Removingthe radio.
After service,reconnectpower to the .adio and turn it
on.
When the word "CODE" is displayed. enter the
customer's 5-digit code to restoreradio oDeration.

5.

Installtheshort connectofon the airbagconnector.

CABLE REEL
CONNECTOR

AIR BAG
CONNECTOF

ACCESSPANEL
SHORT
CONNECTOR
(RED}

o.

Remove the dashboard lower cover and knee

bolster,
Disconnect the cable reel 6-p connector from the
SRS main harness,then connect Test HarnessC
only to the cable reel side ot the 6-p connector.

Disconnectthe battery negative cable. and then

positivecable.
Make sure the wheels are turned straightahead.
Remove the two screws and access Danel,then
removethe short connectorfrom the accessDanel.
4.

Disconnectthe airbag connector from the cable

reel connector.

23-278

I
Checklor continuitybetweenthe terminalsof Test
HarnessC in each switch positionaccordingto the
table.

1 0 . Remove the two screws and cruise control

switch.
SET/RESUME

SET/BESUMESWITCH
rofinrnal

Position

ELU/NEU

SETION)
RESUME(ON}

o-

1
L TG R N / LTGRNi
BLK
REO

---o

G-

---o

a lf there is continuity.and it matchesthe table.

the switch is OK.
a lf there is no continuityin one or both positions,
go to stsp 9.
A'
A

9.

Carelullyremove the cruise control SET/RESUME

switch cover by prying between the cover and
switch in the sequenceshown.

CRUISE
CONTROL
SET/RESUME

1 1 Checkfor continuitybetweenthe terminslsin each

switch positionaccordingto the table.

swtrcH

CRUISE
cot{TRoL
SET.RESUME
SWITCH COVER

Terminal

AorA'

Position
SET(ONI

G-

RESUME
ION)

o-

---o
---o

lf there is no continuityin one or both positions,

reolacethe switch.
a lf there is continuitYand it matchesthe table,
replacethe cable reel.

23-279

GruiseControl
Main Switch Test/Replacement
1. Carefullypry the switches out of the instrument
panel and disconnecttheir connecrors.

3.

Checkfor continuitybetweenthe terminalsin each

switch positionaccordingto the table.

termrnal
Position

o-

OFF

o-

ON

,/.\
\:.,/
/:\
\:.,/

-o o-o o-

/:\

-o

a\

INDICATOR
LIGHT

ti
5-P
CONNECTOR

CRUISECONTROL
MA|N SWtTCt{

t0.84w)
t l
7

\
2.

Removethe cruise controlmain switch from the

switch panel.

SWITCH PANEL

23-2AO

a lf there is no continuity,replacethe switch.

A/T Gear PositionSwitch Test

Clutch Switch Test

1.

Disconnect the 3-P connector from the clutch

switch.

2.

Check for continuitybetween the terminalsaccording to the table.

Terminal
'c*.hP;f-l

1.

Remove the tront console, then disconnectthe

12-P connectorfrom the switch.

2,

Checktor continuitybetweenthe terminalsin each

switch positionaccordingto the table.

PUSHED
BELEASED

o-

Terminal

Position

tr
tr
E

o- ------o
o_- ------o
--o
o

tr
E
lf necessary,replacethe switch or adjust pedal
height (seesection 12).

3,

lI necessary,replacethe switch {seepage23-149).

23-281

CruiseGontrol
r BrakeSwitch Test
1.

ActuatorSolenoidTest

Disconnectthe 4-P connectorfrom the switch.

1.

Disconnectthe 4-P connectorfrom the actuStor,

BRAKESWITCH

View trom terminalside

Measure resistance between the terminals,
2.

Checkfor continuitybetweenthe te.minalsaccording to the table.

Terminal

G-

PUSHED
RELEASED

3.

;**;---_\

--o

o-

lf necessary,replacethe switch of adjust pedal

height (seesection 191.

Resistance
VENT SOLENOID(betwon C and Dt:
80- 120 0
VACUUM SOLEI{OID(bstwoen I 8nd Dt:
70-t100
SAFEW SOLENOID{botwoen A and Dl:
40-60 0
NOTE: Resistance will vary slightty with
temperature; specified resistance is at 70oF
(200c).
VEI{T VALVE

VACUUMVALVE

23-2a2

ActuatorTest
1.

Disconnectthe actuator cable from the actuator

rod and disconnectthe 4-P connector.

2.

Connect batterv Dower to the D terminal and

ground to the A, B, and C terminals.

3.

Connecta vacuum pump to the check valve.

Then apply vacuum to the actuator.

With voltage and vacuum still applied,try to pull

the actuator rod out by hand. You should not be
able to pull out. lf you can. it is defective

CHECKVALVE

I/ -YF
\N7

ACTUATOR

/A@

/t:#r'.\

o_

VACUUMPUMPGAUGE
a973X-041-XXXXX

View from
terminalside

4.

The actuatorrod shouldpull in completely.

lf the rod pulls in only part-wayor not at all, check
for a leakingvacuum line or defectivesolenoid.

Disconnectground from the C terminal. The actuator rod should return. lf it does not return but
the vent hose and filter are not plugged, the
solenoidvalve assemblyis defective.
Repeatsteps 2 through 5, and disconnectground
trom the A terminal. The actuator rod should
return. It it does not retu.n but the vent hose and
tilter ar not plugged,the solenoidvalve assembly
is defective.

8 . lf you replacethe solenoidvalve assembly,be sure

to use new O-ringson each solenoid.

ACTUATOR ROD

23-283

CruiseGontrol
Actuator/CableReplacement

Actuator CableAdjustment

Pull the boot back and loosen the locknut. then

disconnectthe cable from the bracket.

Check that the actuator cable operatessmoothly

with no bindingor sticking.
Start the engine.

Measurethe amount of movementof the actuator

rod until the cable pulls on the acceleratorlever
(enginespeedstarts to increase).Freeplay should
b e 1 1 t 1 . 5 m m ( O . 4 3t 0 . 0 6 i n ) .

ACTUATORROD

Disconnectthe cable end from the actuatorrod.

LOCKNUT

Disconnectthe 4-P connectortrom the actuator.

VACUUM HOSE

LOCKNUT
FREE
PLAY:11 a 1.5 mm
(0.43r 0.06 inl
4.

lf Jreeplay is not within specs,loosenthe locknut

and turn the adjustingnut as required.

VENTHOSE
NOTE: lf necessary.check the throttle cable free
play {see section 11), then recheck the actuator
rod free play.

e
4-P
CONNECTOR

4.

Pullthe vent hose out of its grommet.

Removethe two mounting bolts and the actuator
with the bracket.
Disconnectthe vacuumhosefrom the checkvalve.
lf necessary,disconnectthe cable end from the
linkage over the acceleratorpedal, then turn the
grommet 9Oo in the bulkhead and remove the
caDle.

8.

Installin the reverseorder of removal,and adjust

tree play at the actuator rod after connectingthe
cable (seenext column),

23-284

Retightenthe locknut and recheckthe free play.

I
Actuator Disassembly

FILTERCOVER

b
SOLENOIOVALVES
Test, pge 23-282

--)@r
GROMMET

VACUUMHOSE
CHECKVALVE

6-

VACUUMHOSE

ACTUATORBBACKET

ACTUATOR
Test, page23-283
DRAIN HOSE

ACTUATORBRACKET

23-285

..

SupplementalRestraintSYstem

(sRsl

Index'..."'.. '..'.'. 23-288

Location
Component
' 23-2Ag
Description
23-290
CircuitDiagram
23-292
WiringLocations
.' 23-293
Precautions/Procedures
'.23-294
..........
Troubleshooting
AirbagAssembly
23-318
Replacement
23-322
Disposal
CableReel
23-324
Repfacement
DashSensor
23-324
Replacement
SRSUnit
23-330
Replacement

SupplementalRestraintSystem (SRS)
ComponentLocationIndex

CABLEREEL
page23-324
Replacement,
SRS INDICATORLIGHT
{ln the gguge assembly}
Troubleshooting,page 23-298
Gsuge assembly, page 23-122

TO DRIVER'SAIREAG
ASSEMBLY

TO CRUISECOI{TROL
SET/RESUME
SWITCH

FRONTPASSEI{GER'SATRBAG

ASSEMBLY
Replacamont,
page23-318
Disposal.

UNOER.DASH
FUSE/RELAY8OX

BIGHT
DASH SEITSOR
Rplacement,
psge 23-328

DASH SE'{SOB
Replacernent,
page 23-328

23-288

ORIVER'SAIRBAG
{lnctudingcowr snsorlASSEMBLY
R6placement,
Replacement,
page 23-318
pag 23-330
Disposal,page 23-322

Description
The SRSis a safety devicewhich, when usedin conjunctionwith the seat belt.is designedto helpprotectthe driver{and
front passenger)in a frontal impact exceedinga certainset limit.
The system is composedof left and right dash sensors,the SRSunit (includescowl sensors),the cablereel,driver'sairbag and front passenger'sairbag(Si 4WS, Si VTEC: USA, SR 4WS,SR-V:Canadamodels).
SRS UNIT

AIRBAG
CABI-EREEL

OPERATION:
As shown in the diagrambelow, the left and right dash sensorsare connectedin parallel.The parallelset of sensotsis
connectedin seriesto each airbaginflatorcircuitand the car battery.In addition,a back-uppower circuitis connectedin
parallelwith the car battery.The back-uppower circuit and the cowl sensorsare locatedinsidethe SRSunit.
For the SRSto operate:
{1) One or both cowl sensorsand one or both dash sensorsmust activate.
(2) Electricalenergymust be suppliedto the airbaginftatorby the battery,or by the back-uppower circuitiJthe battery voltage is too low.
{3) The inflator chargemust ignite and deploythe airbag.
It takes about O.l secondfrom the beginningot the airbagdeploymentuntil it is completelydeflated(frontalcollision
againsta fixed wall at a speed of 30 mph t50 km/hl).

I l-r
t t

FRONT
PASSENGER'S
IA
AIRBAG
|RBAG ll
t L . - l

Selt-diagnosissystom
circuitis built into the SRSunit; when the ignitionswitch is turnedON. the SRSindicatorlight comeson
A seli-diagnosis
goes
after
about six secondsif the system is operatingnormally.It the light does not come on, or doesnot go oft
off
and
atter six seconds.or if it comeson while driving,it indicatesan abnormalityin the system.The systemmust be inspected
and repairedas soon as possible.

23-289

SupplementalRestraintSystem (SRSI
CircuitDiagram(WithoutFrontPassenger's
Airbag)
sRsrNorcAToRcrRcurT
sRs
tNotcAToR
ctRcurT

i1}358;,K%,

lln theg.u6a8!ombv)

A
Y

( ,o'ft ) 'on't'ot'*'ttt

wm

J---,
I Zlfoiil**'II

ti[*?

I i ir#i,
l*'

ORIVER'S
ANEAG
INFLATOR

o
o
o

@
@

l-1-,

\_-/

BATTERY

a
a
SAIrc
Btc

@
@
@

GNO@
tDc @
MI

SRSUI{ITI8 - PCONNECTOR

23-290

Airbagl
CircuitDiagram(WithFrontPassenger's
CIRCUIT
SRSINOICATOR
(lnthegaug
83smbiyl

BLKffEL

,k

( ,lYt ),.*'t'orr*,..*

G401
G4.02

WHT

J----,
rtr
|I |I

I,s,;
t#ff{,

I ln;'l-'

BATTERY

I
I

I n
I ll
I tl
r l l

CABLE
REEL
SAOH
DRIVER'S
AIRBAG
INFLATOR

o
@
a

FRONT
PASSNGER'S
AIRBAG
INFLATOR

@
@

SADC
BUC

a
a
@
a
@
o

@
@
MI @

GND
tDc

a
a

23-291

SupplementalRestraintSystem (SRS)
Widng Locations
CAUTION:Maksureall SRSgroundlocationsare cleanand groundsare socurelyattachd.
NOTE:
a All SRSelectrical
wiringharnesses
arecoveredwith yellowouterinsulation.
a Replace
the entireaftectedSRSharnessassembly
il it hasan opencircuitor dsmagedwiring.

OASHBOAFDWIRE HARNESS
ro SRS ItIDIcAToR LIGHT
in GAUGE ASSEMBLY
5.P CONNECTOR
SRS MAIN HARNESS
to FRONTPASSENGER,S
AIRAAG
3.P COITNECTOR
DASHBOARDWIREHARNESS

SRS MAIN HARNESS

Io UNDERDASH
FUSE/RELAYBOX
2-P

SRS MAIN
HARNESS
SRS UNIT
GROUNO
MAIN WIRE HARNESS
to DASHBOARDW|RE
HARNESS
2O-P CONNECTOR

SRSMAINHARITESS
ro RIGHTDASHsENsoR
2.P CONNECTOR

SRS MAIN HARNESSSOCKET

1A.PCONNECTOR

23-292

GeneralPrecautions
a Carefullyinspectany 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 detormation:
-

Airbagassembly(driver'sand front passenger's).

Dash sensors,
Cablereel.
SRSunit.

Airbag Handlingand Storage

the airbagassembly.lt has no
Do not try to disassemble
serviceableparts. Once an airbag has been operated
(deployed),it cannot be repairedor reused.
For temporary storage of the airbag assemblyduring
service,pleaseobservethe following precautions:
a Storethe removedairbagassemblywith the pad surface uD.

({,

lf the airbag is improgerly stored face

!!!@
d6ii, accidental deployment could propl the unit
with enough folce to cause serious iniuly.
. Use only a digitalmultimeter(KS-AHM-32-OO3)
to check the sYstem.Using an analogcircuit tester
may cause an accidentaldeploymentand possible
injury.

Storethe removedairbagassemblyon a secureJlat

surfaceaway from any high heat source (exceeding
212oF/'lOOoCland free oJ any oil, grease.detergent
or water.

a Do not install used SRS parts Jrom another car'

When makingSRS repairs,use only new parts'

CAUTTON: lmproper handling or storag can intsrnally damage ths airbag assambly, making it
inoperativs.
lf you suspect the airbag assembly has b6n damaged, install a new unit and refer to the Dsployment/Disposal Procdules lor disposing of the
damaged airbag

a Exceot when performing electrical inspections,

always disconnect both the negative cable and
positivecable at the battery beforebeginningwork'
a Replacement of the combination light and
wiDer/washerswitches and cruise control switch
can b done without removingthe steeringwheel:
- Combination light and wiper/washer switch
replacement(seePage23-182).
- C.uise control switch replacement (see page
23-2741.
a When rsinstallingthe SRS unit cover. be sure lt
snapstogetherProperlY.

23-293

SupplementalRestraintSystem (SRS)
WiringPrecautions
a Neverattemptto modity.spliceor repairSRSwiring.
NOTE: SRS wiring can be identified by special
yellow outer protectivecovering.

Instslling the short connector

To avoid accidenrat deployment 8nd
@
possible injury. always install ths protective short connector(s) on the driver's and passonget's airbag connector(s) belore working noar any SRS wiring.
NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code
numberbefo.e disconnectingthe battery.

Be sure to installthe harnesswires so that they are

not pinchedo. interferingwith other car parts.

l.

Disconnect the battery negative cable, then

disconnectthe positivecable.

2.

Installthe short connector{s)(RED):

Driver's Sido:
a Removethe access panel from the steeringwheel,
then remove the short connector (REDI from the
oanet.

Make sure all SRS ground locationsare clean and

groundsare securelyfastenedfor optimum metal-tometal contact. Poor groundingcan cause intermittent problemsthat are difficult to diagnose.

Disconnectthe 3-P connectorbetween the driver's

airbagand cablereel,then lnstalltheshort connector
(RED)on the airbagside of the connector.

23-294

Front Pass6nger'sSide:
a Remove the glove box, then remove the short connector (RED)from its holder.

FRONTPASSENGCR'S
AIRBAG
3.P CONNECTOR

Disconnecting the SRS Connector at the Fuse

Box
CAUTION: Avoid breEking tho connctor; it's doublelock6d.
1.

SHOR1 CONNECTOR{RED)

SRS MAI]II HARNESS

First lift the connectorlid with a thin screwdriver,

then press the connectortab down and pull the
connector out.

UI{DER.DASHFUSE/RELAYBOX

Q+

GLOVEBOX
Disconnect the 3-P connector between the front
passenger'sairbagand SRS main harness,then install the short connector (RED)on the airbag side of
the connector.

SRS MAIN HARNESS

To reinstalltheconnector.push it into positionuntil

it clicks.then close its lid.

23-295

SupplementalRestraintSystem (SRS)
Steering-relatedPrecautions
Steering Wheel and Cable Reel Alignment

SteeringColumnRemoval

NOTE: To avoid misalignmentof the steeringwheel or

airbagon reassembly,make surethe wheelsare turned
straightaheadbetore removingthe steeringwheel.

CAUTION:
a Eefors romoving the steering column, fitst disconnoct the connctor betwoen th cable reol and the
SRS main harnss.
a It tho steeling column is going to bo removed
withoul dismounting the stering wheel. lock ths
stesring by turning tho ignition key to O-LOCKposition 01 rsmova the key from ths ignition so that the
staering wh6al will not turn,

Rotatethe cable reel clockwiseuntil it stops.

Then rotate it counterclockwise(approximatelytwo
turns) until:
- The yellow gear tooth lines up with the alignment
mark on the cover.
- The arrow mark on the cablereellabelpointsstraight
up,

HARI{ESS

Do not replacethe originalsteeringwheel with any

other design,since it will m8ke it impossibleto properly install the ai.bag (only use genuine Honda
replacementpartsl.
After reassemblyconfirm that the wheels are still
turned straight ahead and that the steering wheel
spoke angle is correct. lf mino. spoke angle adjustment is necsssary,do so only by adjustmentof the
tie-rods, not by removing and repositioningthe
stee.ingwheel.
NOTE: Modelswith 4WS
Test and adiust the 4WS system (seesection 17).

23-296

I
InspectionAfter DePloYment

SensorInspection
CAUTION: Take extra care whan psinting ol doing
body work in the area bolow the dashboard. Avoid
dirct xposule of tho sensors ol wiring to hsat guns'
welding, or spraying equiPment.

@
-o
Disconnect both the negative and positivs battary
cables.
a Install the short connector(s) botore working blow
the dashboard ol near tho dash sensors.
a After any degree of frontal body damage, inspect
both dash sensors.Replacea sensorif it is dented.
cracked,or deformed.

After a collisionin which the airbagswere deployed,inspect the following:

1.

Inspect the dash sensorsfor physicaldamage. l{

the sensorsare damaged,replacethem.

2.

Inspectall the SRSwire harnesses.Replace,don't

repair,any damagedharnesses.

3.

Inspectthe cable reel tor heat damage lf there is

any damage,replacethe cable reel.

4.

AJter the car is completelyrepaired,turn the ignition switch on. It the SRSindicatorlight comeson
for about six secondsand then goes ofl, the SRS
system is OK. lf the indicatorlight does not function properly,go to SRSTroubleshooting.

DASI{ SENSOR

o Be sure the sensorsate installedsecurely'

DASH SENSOR

23-297

SupplementalRestraintSystem(SRS)
Troubleshooting
Self-diagnosisFunction
The SRSunit includesa selJ-diagnosis
function.lf there
is a failurein the snsors,SRSunit, inflator,or their circuits, the SRS indicator light in the gauge assembly
goes ON.
SRSINDICATOR
LIGHT

Short Connctor Installation

To avoid accidontat deploymont and
@
possible injury, always install the protective short con_
nectot on the drivel's ailbag connoctor and on cars
oquippod wlth flont paasengor,sairbag, install protac_
tivo short connctots on thg drlver.a airbag and front
paaaonger's airbag bofore working near any SRS
wiring.

f::=

NOTE: The radio may have a s-digit coded theJ't protection circuit. Be sure to get the customer's code
numberbetore disconnectingthe battery.
As a system check, the SRSindicatorlight also comes
on when the ignitionis iirst turned to the ll oosition.lJ
the light goes otf after approximatelysix seconds,the
system is OK.
lf the SRSindicatorlight remainson (or failsto come on
in the systemcheckmodel, one ot the SRScomDonents
(or the wiring/connectorsin bgtween)is faultv.
Troubloshooting Procautions
a AlwSys uso ths test hamess. Do not us tast probgs
dirsctly on component connoctot tatminala ot wiros;
you m8y damsgo them or th SRS unit.
a Wh6n connecting any of th6 tsst hamoasos to the
system. push the connectors straight-in; do not bend
tho connctot torminals.
a Boforo disconnacting any p8n ot tho SRS wire
ha.ness, install the short connector (RED) on the
driver's airbag. On csrs equippd with a front
passenger's airbag, instsll shon connoctols on the
driver's airbag and the front passngor,sairbag,
SRS Indicator Light Troubloshooting
Possibleconditions:
1. SRS indicatorlight does not come on at all _ see
page 23-3OO.
2. SRSindicatorlight stays on constantly- see page
23-304.
3. SRSindicatorlight comeson in combinationwith a
failure of another electricalsystem {brakesystem
light, malfunctionindicatorlamp (MlLl etc.). Check
for damage/corrosion
at the under-dashfuse/relav
box connector.
NOTE:
a Before starting the applicabletroubleshooting.
check the conditionof all SRS connectorsand
ground points,
a lf the fault is not found atter completingthe applicable troubleshooting,substitute a known_
good SRS unit and check whether the indicator
light goes off.

23-298

1.

Oisconnect the battery negative cabl, then

disconnectthe positivecable.

2.

Installthe short connector(sl:

Driver'sSide:
a Remove the access panel from the steering
wheel, th8n.emove the short connector(RED)
from the Danel.

DRIVER'SAIBBAG

3.P CONNECTOR

ACCESSPANEL

a Disconnectthe connecto.between the driver's

airbagand cable reel,then installthe short connctor {RED} on the airbag side of the
connector.
Front Passenger'sSide:
a Remove the glove box, then remove the short
connector(REDIfrom the holder.
a Disconnect the connector between the front
passenger'sairbagand SRSmain harness,then
installthe short connector (RED)on the airbag
side of the connector(seepage 23-295).

Test Harnessesand Attachment Points

Test HarnessA
DRIVER'SAIRBAG
ASSEMELY

TEST HABNESSA
07MAZ- SLOOSOo
2

DRIVER'S

't2

t 5 1

HARI{ESS C

o7LAz- s140300

FRONTPASSENGER'S
AIRBAG ASSEMBLY

Test Harness B

SRS MAIN HARNESS

1g.P CONNECTOR
3.P CONNECTOR

Test HarnessD
SRS MAIN HARNESS
2.P CONNECTOR

3
2

11 12 13
12 13

15

18

1 5 t6 1 1 18

ROW B {WIREHARNESSENDI

23-299

SupplementalRestraintSystem (SRS)
Troubleshooting
The SRS IndicatorDoes Not Light
CAUTION: Use only a digitatmulrimotel|KS-AHM-32_OO3)

Dbconnoct tho bottory nog8tivo

cablo 6nd thsn tho Dositivo
cable.
Install tho 3hort connocto.lsl on
the airbag{3|{.e page 23-294}.

to chock tha system.

NOTE: The radio may have a s-digir coded thelt protection circuit. Be sure to get the customer,s code
numberbefore disconnectingthe battery.

Reconnect the battery positive

cable and then the negative
cable.

Turn tho ignitionswitch ON.

Do any other indicator lights

(brake system light etc.)
come on {in tho gauge
ass6mbly)?

Turn the ignirionswitch OFF.

Disconnect the SRS main

hamess18-Pconnectorfrom the

Inspocttho No. 13 (10 A) tuse

{undeFdashfus/rclav box}

ls No. 13luse OK?

Replir opon In drlhborrd wiro

hsmoa! bqtwoon tho l{o. 13 tulo
and glugo raa.mbly.
SRS UNIT

Turn the ignitionswitch ON.

sRs MA[{
HARI{ESS
18-P CONl{ECTOR

Tho SRS unit is taultv.

Turn the ignitionswitch OFF.

{To page 23-301)

23-300

(From page 23-3OO)

Disconnect the SRS main

harness 4-P connector lrom the
main wire harness.

Turn the ignition switch ON.

SRS MAIN HARNESS

4-P CONNECTOR

ls SRSindicatorlightON?

The SRS main harnott is tauliY.

Turn the ignitionswitch OFF.

Remove the gauge assembly,

then inspect the SRS indicator
light b'.rlb.

Repl6cotho indicator light bulb.

DASHBOARDWIRE
HARNESS5.P CONNECTOR

Connct a voltmeler between

the No. 3 terminalofthe 5 P connector and body ground.

Turn the ignitionswitch ON.

Measure the voltage between

the No.3 terfiinal and body
ground.
{To psge 23-302}

e
BLU

Lo$ than 8.5V?

View from terminalside.

23-301
-

'

SupplementalRestraintSystem (SRS)
Troubleshooting(cont'dl
{Frompage 23-3OlI

ls therelessthan 8.5 V with

the ignitionswitch ON?

Sho.t in BLU wiio ot rhe

da3hboardwiro hamess. Reolace
tho dashboa.d wir6 harnoss.

Turn the ignitionswitch OFF.

HARNESS5-P CONNECTOR
Connect the voltmeter between
the No. 1 lerminal (+) and rhe
No. 5 terminal {-) oI the
dashboardwire harness 5-P con,
nector,

Turn the ignition switch ON.

Measure the voltage between

the No. 1 terminaland the No. 5
terminal.

rr--/#l

l : l r l 3 l 4 l l l
t
YEL

l
BLK

lL---(I0------r
^ l

Battary vohlga?
View lrom terminal side.

ls there battery voltage?

Chck tor continuity between

t h e N o . 5 t e r m i n a la n d b o d y
grouno.
Ropoi. oD6n in rh BLK
wire lNo. 5 tominall
Detwoen the gauge
a3sornbly and body
g.ound or look to. a
poor ground (c4O1,
4021.

Turn the ignitron switch OFF.

{To page 23-3031

Rep.ir opon in the YL wire lNo.
1 teminall ot the de3hboardwiro
hamo3s betwgen tho 9aug6
asaembly and the No. 13 luse.

23-302

{F.ompge 23-302}

Reconnecteach connctor to the

gauge assembly and SRS unit
then connect Test Harness A to
th sRs unit.

Measure the voltag between

tho No. 13 terminal and body
ground for six sconds after ignition is {irst tumed on.

TEST HARI{ESSA
07MAZ- S100500

lo

1 l 12 t3 1 4 1 5 16

Moro thon

ls theremorethan 8.5 V?

SRS Indlcatot cilcuit {in tho

gaugo 6!.mblyl 13taulty.

23-303

SupplementalRestraintSystem (SRSI
Troubleshooting{cont'd
SRS IndicatorLight Stays on Conrinuously
1.

Make a photoeopy of this page (without front

passenger'sairbag),or the next page (with tront
p a s s e n g e r 'asi r b a g ) .

2.

Connect Test HarnessA (O7MAZ-SLOOSOOI

to
the SRS unit as shown.

3,

Turn the ignitionswitch ON.

a Voltagesin the chart assumethe car,s,,battery
voltage" is about 12 volts. Less than 12 volts
will result in differentor possiblyfalse readings.
a Do not disconnectthe airbag from the circuit
when checkingSRS unit voltages.

4.

First,check for voltagebetweenTest HarnessTerm i n a lN o . 1 2 a n d g r o u n d .

a lf voltage is indicated,there is a poor ground
( s e ep a g e2 3 - 3 1 7 ) .
a lf no voltage is indicated,continuewith checking all the other terminals.

5.

Recordyour voltagereadings.tor each terminal,in

the row of blank boxes near the top of the chart.

6.

Compare each reading wilh the voltage ranges

listedin the columnbelow it. lf the readingis within
a range,circlethat range.
a lf you circledall the FailureMode rangesacross
any row, check the car for the probableFailure
Mode listedat the end of the row. (Referto the
letter for that Mode on the following pages).
a lf you did not circle all the ranges across any
row, replacethe SRS unit with a known-good
unit, and retest.
- lf all your voltage readingsare now Normal,
replacethe SRSunit.
- lf your voltage readingsare still not normal
but they don't tit within a completerow ot
FailureMode ranges,check the conditionoi
the terminalsin each of the SRS connectors
shown in the system diagram on page

Without Front Passonger'sAirbag:

NOTE: Do not disconnectthe airbagwhen checkingSRS unit voltages.
1
SADH

vcc

43
-56

2.8
-3.7

5
SV

8
SADC

10
BUC]

12 t3
GND rDc

4 . 5 12.O
- 5.5 14.3

5.6
- 7.3

11.5
- 14_5

8.5 8.4
- 13.6 10.9

4 5 12.O
5.5 14.3

3.7
4.9

11 . 5
- 14.5

2 0 8.4
8.5 - 10.9

P.obableFailureMode

A Open in one cowl sensor.

. Open in both cowl

4.5

r2.0
14.3

11 . 5
t4 5

2.O 8 . 4
- 8.5 10.9
. shon to drivf's atbag

86

12.O
- 14.3

5.7
-1.4

4 . 5 12.O
5 5 I4.3

8.6

4 . 5 12.0
5.5 14.3

43
-5 6
4.3
5.6

23-304

4.5

0
4.5
-5 5

0
12.4
I4.3

11.5
14.5

2.0 8 . 4
8 . 5 - r0.9

Short in cowl sensor of

C open in both dash sen

11 . 5
14.5

2 0 8.4
8.5 10.9

D Open in one dash sensof.

11 . 5
I4.5

2.O 4 . 4
8 5 -10 9

c' Open n driver's anbag

inllaror or .able recl

5.6
- 7.3

11.5
14.5

2 . 0 8.4
8.5 - to.9

Blown SRS luse {No. 24

H
''
1 0 A ) o r o p e ni n t h e w t e .

5.6
-73

- 14.5

0
(8.5 8 . 4
10.9
13.6

11.2
14.6

Shon (o' open) in SRS

In0rcalorwrre harness.

With Front Passenger'sAirbag:

NOTE: Do not disconnectthe airbagwhen checkingSRSunit voltages.
12 13
GND tDc

8
SADC

10
BUC]

4.5 12.0
- 5.5 14.3

5.6

11.5
-14.5

4 . 5 12.O
5.5 1 4 . 3

3.7
4.9

11.5
- 14.5

l
2
S A O H SAPH

vcc

4 . 3 4.3
-5.6

5
SV

14

8 . 5 8.4
- 13.6 10.9

FailurcMode
Probable

Reading

2.4 2.4
3.7 - 3.7

2.O 8 . 4

- 10.9

A openIn onecowlsenso..
. Openin bothcowl

4.5 12.0
5.5 ,14.3

11.5
- 14.5

2.0
-8.5

8.4
10.9

2.O 8 . 4
8.5 10.9

. Shon$ diver's or
passflger's
akbsginShod in cowl $nsor or
C open in both dssh sen'

4.5

12.O
- 14.3

11.2
14.6

11.5
- 14.5

4.5

12.O
14.3

7.4
9.7

.5
- 14.5

2.O E.4
-8.5 - 1 0 . 9

D Open in one dash sensor.

2.9
8.6
- 1 1 . 3 3.7

4.5 t2.o
- 5.5 14.3

3.7
-4.9

11 . 5
- 14.5

2.O 8 . 4
- 8.5- 10.9

Open in d'iver's anbog

E
,nllator or ceble reel.

2.9
-3.7

8.7

4.5 1 2 . 0
- 5.5 14.3

3.7
-4.9

1r.5
14.5

2.O 8 . 4
-8.5 - 10.9

in t.onl passengers
F Open

8.6
8.6
-11.3

- 5 . 5 - 14.3

12.0

11.5
14.5

2.0 8.4
8 . 5 - 10.9

5.6
-'t.3

|.5
14.5

2.O 8.4
8.5 - r0.9

BlownSRSruse(No.24
'|r'
1 0 A l o r o o e ni n l h e w i r c .

5.6

11.5
14.5

0
8.4
t8.5 1 0 . 9
13.6

short(oropen)in SBSin'I
dic.torwirchamess.

8.6 8.6
1 1 . 3- r 1 . 3
5.7
-7.4

5.7

4.3

4.3
-5.6

4.3

4.3
- 5.6

4.5 12.O
5.5 -14.3

Open in d.iver's and

23-305

SupplementalRestraintSystem (SRSI
Troubleshooting(cont'd)
Mod A: Open in ono cowl sn6or.

3.

Reconnect the driver's airbag connector, thsn

checkcontinuitybetweenthe B l terminalandbody
ground, and betwesn the 87 trminal and body
ground.

. The SRSunit is faulty. Substitutea known-goodSRS

unit and recheckthe voltagesaccordingto the chart
on page 23-304.

TESTHAR ESSB
07MAZ- SF005q'

Mode B:
. Shon to dfver's or passengor's ai.bag inflatol.
. Short in one dash sensor,
. Op6n in both cowl s6nsor.

A
B

NOTE: The radio may have a 5-digit coded theft protection circuit. Be sure to get the customer's code
number beforedisconnectingthe battery cables.
1.

Betore disconnectingany part ot the SRS wire

harness.installthe short connector(sl(RED)on the
airbag(sl (see page 23-2941.

2.

Connect Test HarnessB (O7MAZ-SP0O50O)between the SRS unit and SRS msin harness 18-P
conneclor.

a lf there is continuity at eithel terminal, go to

step 6.
a lf ther is no continuity at either torminal, go 10
steD 4.
4.

Reconnsct the front passenger'sairbag connector,

th6n check continuity betwen the B2 terminal and
body ground, and betwen the 88 terminal and
body ground.

TESTHARI{SSB
oTMAZ- SPdr6{X'

a lf there is continuity at either terminal, go to

step1O.
a lf there is no continuity at either terminal, go to
step 5.

23-306

- \ l

Check continuity between body ground and each

terminalof both dash sensors.

7 . Check continuity between the No, 4 terminaland

body ground. and between the No. 5 terminaland
body ground.

TESTHARNESS
B
07MAZ- SP00500

a lf there is continuityat any ol the terminals,go

to step12.
a lf there is no continuity at any terminal, go to
step13.
o.

Disconnectthe cable reel 6-P connectorfrom the

SRS main harness,then connect Test HarnessC
{O7LAZ-SL4O3OO)only to the cable reel side oI
the 6-P connector.

lf there is continuity at either terminal. go to

step 8.
lf there is no continuity at either terminsl,the
SRS main harness is faulty. Replace it and
recheckthe voltagesaccordingto the chart on
page 23-3O4.

{cont'd)

23-307
I

SupplementalRestraintSystem(SRS)
Troubleshooting(s6n1'd1
8.

Oisconnectthe driver's airbag3-P connectorfrom

the cable reel, then connect Test Harness C
(07LAZ-SL4O3OO) to the driver's airbag 3-P
connector.

1O. Disconnectthe front passenger'sairbag3-P connector from the SRS main harness,then connect
Test HarnessC {07LAZ-SL4O3O0)to the airbag
side of the connector.
FRONTPASSENGER'SAIRBAG

TESTHARNESS
C
07LAZ_S140300
1 1 .Check continuity between the No. 7 terminaland
body ground,and betweenthe No. 8 terminaland
body ground.
Check continuity betwsen the No. 7 terminaland
body ground, and betweenthe No. 8 terminal8nd
body ground.

TEST HARNESSC
oTLAZ - SL403qt

TEST HAR ESS C

oTLAZ - SL4og)O

lf there is continuityat eitherterminal,the front

passenger'sairbag inflator is faulty. Replaceit
and recheckthe voltagessccordingto ths chart
on page 23-304.
It there is continuity at either te.minal, the
dfiver's airbag intlator is laulty. Replaceit and
recheckthe voltagesaccordingto the chart on
page 23-3O4.
lf there is no continuity at either terminal,the
cable reel is faulty, Replaceit and recheckthe
voltagesaccordingto the chsrt on page23-304.

23-308

It there is no continuity at either terminal,the

SRS main harness is faulty. Replace it and
recheckthe voltagesaccordingto ths chart on
page 23-304.

' t 2 .Connect Test HarnessD (O7LAZ-S14O400) between the dash sensorand SRS main hatness2-P
connector.Checkcontinuitybetweenthe No.1 terminal and body ground,and betweenthe No.2 terminal and body ground.
SRS MAIN
HARNESS
2.P CONNECTOR

lf resistanceis 3.8-4.2 Ko for both sensors,

the SRS unit is taulty. Substitutea know-good
SRSunit and recheckthe voltagesaccordingto
the chart on page 23-304.
lf resistanceis less than 3.8 KO for either sensor, go to step 14,

't4. Connect Test HarnessD (07LAZ-SL4O4OO)between the dash sensor8nd SRS main harness2-P
connector.Checkthe resistancebetweenthe No.1
terminaland No. 2 terminal.

SENSOR

SRS MAIN
HARf{ESS
2-P COI{IIECTOR

TESTHART{ESS
D
07LAZ- SL/O4OO
TEST
HARNESSD
OTLAZ- SL/to4Oo

rffir

DASHSEf{SOR

a lf there is continuityat eitherterminal,the dash

sensor is faulty. Replace it and recheck the
voltagesaccordingto the chart on page23-304.
a It there is no continuity at either terminal,the
SRS main harness is faulty. Replace it and
recheckthe voltagesaccordingto the chart on
page 23-304.
13. Checkthe resistancebetweenthe left dash sensor
terminalsB12 and Bl6, and betweenthe right dash
sensorterminals84 and 86.

D
TESTHARNESS
- SL/IO4{X)
OTLAiZ
TEST
O
HARI{ESS
OTLAZ- SL4O/IOO

a It rssistance is 3.8-4.2 KO, the SRS main

harness is faultv. Replaceit and recheck the
voftagesaccordingto the chan on page23-304.
a lf resistanceis lessthan 3.8 KO,the dashsensor
is faulty. Replaceit and recheckthe voltagesaccordingto the chart on page 23-304.

B
TESTHAR]IIESS
07MAZ-SPOo50{'
A
I

(cont'd)

23-309
.4

SupplementalRestraintSystem (SRS)
Troubleshooting(cont'd)
Modo C: Short in cowl sgnsot. or oDn in both dash
snsors.
Mode D: Open in on dash sensor.
NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code
numberbeforedisconnectingthe bafte.y cables.
1.

Beiore disconnectingany pan ot the SRS wire

harness,installthe short connector(s)(RED)on the
airbag{sl(see page 23-294l..

2.

Connect Test HarnessB (07MAZ-SPoO5OO)between the SRS unit and SRS main harness 18-P
connector.

3.

Check the resistance between the left dash sensor

terminals812 and 816, and betweenthe right dash
sensorterminals84 and 86.

TEST HARI{ESS B
oTMA;Z - SPq)sd!

a lf resistance is more than 5 Kn for either set of

terminals,go to step 4.
a lf resistance is less than 5 KO for both sets of
terminal, the SRS unit is faultv. Substitute a
known-goodSRS unit and ,echeckthe voltages
accordingto the chart on page 23-304.

TESTHAR'{ESSB
oTMAZ-SP00500

23-310

'!

4.

Connect Test Harness D (07LAZ-SL404OO) between the dash sensorand SRS main harness2-P
connecror.
Check the resistancebetween the No' 1 terminal
and No. 2 terminal.

Mode E: Open in drivsr's airbag inflator or cable re6l.

NOTE: The radio may have a s-digit coded thelt protection circuit. Be sure to get the customer's code
number betoredisconnectingthe battery cables.
1.

Before disconnectingany part of the SRS wire

harness,the positive cable. Installthe short connector(s)(RED)on the airbsg(s)(seepage23-294).

2.

Connect Test HarnessB (O7MAZ-SP005OO)between the SRS unit and SRS main harness 18-P
connector.

TESTHARI{ESSD
07LAZ - 5140400

B
TEST}IARNESS
oTMAZ-SP00500

lf resistanceis more than 5 K0. the dash sensor

is faulty. Replaceit and recheckthe voltagesaccordingto the chart on page 23-304.
It resistanceis less than 5 KO, the SRS main
harnessis taulty. Replacethe SRSmain harness
and recheckthe voltagesaccordingto the chatt
on page 23-304.

Reconnect the driver's airbag connector, then

check the resistancebetween the B1 and the 87
terminals.
B
TESTHARI{ESS
oTMAZ- SmO500

a lf resistanceis more than O.2 KO, go to step 4.

a lf resistanceis lessthan O.2 KO.the SRSunit is
faulty. Substitute a known-goodSRS unit and
recheckthe voltagesaccordingto the chan on
page 23-3O4.

(cont'd)

23-311
-

'l

SupplementalRestraintSystem (SRS)
Troubleshooting(66n1'd1
4.

Disconnectthe cable reel 6-P connectorfrom the

SRS main harness.then connect Test HarnessC
(O7LAZ-SL4O300Ionly to the cable reel side of
the connector.

6,

Disconnectthe d.iver's airbag3-P connectortrom

the cable reel harness, then connect Test Harness
C {O7LAZ-SL4O30O)to the driver's airbag 3-P
connector.

7.

Measurethe .esistance between the No. 7 terminal

and the No. I terminal.

CABLE REEL

5.

Measurethe resistancebetweenthe No. 4 terminal

and the No. 5 terminal.

TESTHARI{ESSC
oTLAZ - S1403{tO

lf resistanceis more than 0.2 KO,9o to step 6.

lf resistanceis less than O.2 KO, the SRS main
harness is taulty. Replaceit and recheck the
voltages according to the chart on page 23-30'4,

TEST HAB'{ESS C

- st4{t3dt
oTr.Aiz

a lf resistanceis more than O.2 KO, the drive.'s

airbag intlator is faulty. Replace the airbag
assembly and recheck the voltages according to
the chart on page 23-304.
a lf resistance is less than 0.2 KO,the cable resl is
faulty. Replace it 8nd .echeck the voltages according to the chart on page 23-304.

23-312

Mode F: Open in lront passongot's airbag inflatol'

NOTE: The rsdio may have a s-digit coded theft protection circuit. Bs sure to get the customer's code
number before disconnecting the battery cables.
1.

Belore disconnectingany part of the SRS wire

harness,installthe short connector(s)(RED)on the
airbag(s) (see page 23-2941'

2.

Connect Test HarnessB (o7MAz-SPoOsoo) between the SRS unit and SRS main harness 18-P
connecror.

3.

Reconnectthe front passenger'sai.bagconnector,

then measure the resistance between the 82 terminal and 88 terminsl.

4.

Disconnectthe front passenger'sairbag 3-P connsctor from the SRS main harness,then connect
Test HarnessC (O7LAZ-S14030O) to the tront
passenger'sairbagside of the connector.

PASSENGER'SAIRBAG

TESTHABI{ESSB
oTMAZ- SPOO5d'
A

C
TESTHARNESS
07LAZ-S140300

Measurethe resistancebetweenthe No. 7 terminal

and the No. 8 terminal.
It resistanceis more than O.2 K0, go to step 4.
ll resistanceis lessthan O 2 KO,the SRSunit is
faulty. Substitute a known-good SRS unit and
recheckthe voltagesaccordingto the chart on
page 23-305.

TEST HABNESS C
07LAz - S[/rO3o,0

lf resistanceis more than O.2 K0, the front

passenger'sairbaginflatoris faulty. Replacethe
front passenger'sairbagassemblyand recheck
the voltages accordingto the chart on page
23-305.
lf resistanceis lessthan O.2 KO,the cablereelis
taultv. Replacethe cable reel and recheckthe
voltagesaccordingto the charton page23-305.

(cont'd)

23-313

SupplementalRestraintSystem(SRSI
Troubleshooting(cont'd)
Reconnectthe positiveand negativecablesto the
battery.

Modo G: Blown SRS No. 24 fuse. or opon in the wire.

4.

NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code
number beforedisconnectingthe battery cables.

5 . Measurethe voltagebetweenthe B13 te.minaland

body ground with the ignitionswitch ON.

Check the SRS No. 24 {10 A) Juse in the underdash fuse/relaybox. lf it's OK, go on to step 2.
lf it's blown, replaceit with a new 1OA tuse, then
turn the ignitionswitch ON:
a lf fuse doesn't blow, go on to step 2.

TESTHARNESS
B
07MAZ-SP00500
2

10 11 12

1 5 10

18

10 n 12

I6

18

a lf the Juseblows, troubleshootas necessarvto

find the short.

2 . Before disconnectingany part ot the SRS wire

harness.installtheshort connector(s)(RED)on the
airbag(s) (see page 23-2941.

lf there is batteryvoltage,the SRSunit is faulty.

Replaceit and recheckthe voltagesaccordingto
the chart on page 23-304.

Connect Test HarnessB (O7MAZ-SPOO5OO)

between the SRS unit and SRS main harness18-P
conneclor.

a lf less than battery voltage, the SRS main

ha.ness is faulty. Replaceit and .echeck the
voltagesaccordingto the chart on page23-304.

TEST HARNESSB
oTMAz-SPOO500

23-314

Modo H: Short or opsn SRs indicator wiro harnosa.

NOTE: The radio maY have a 5-digit coded theJl protection circuit. Be sure to get the customel's code
numberbeJoredisconnectingths battery cables.
1.

BeJoredisconnectingany pan of the SRS wire

harness,installthe short connector(s)(RED)on the
airbag(s) (see page 23-2941.

4.

beConnect Test HarnessB (O7MAZ-SPOO5OO)

tween the SRS unit and SRS main harness 18-P
connecror.

Disconnsctthe SRS main harness4-P connector

from the main wire harness.

oTMAZ_SP00500
Reconnectthe battery positivecable and negative
cable.
o.

Checkfor continuitybetweenthe B1 1 terminaland

body ground,

2 . Turn the ignition switch ON and wait for six

sconds.Measulethe voltage between the No' 1

terminal8nd body groundon the SRSmain harness
4-P connectorside.

TESTHARI{ESSB
oTMAZ- SP(xrs(x)

SRSMAII{ HARI{ESS
4 - P CONf{ECTOR
F-"-----F-i-rl

/JLILx
' l
BLU
-t

l-. ,\

ap
t_

View from terminslside.

a lf there is continuitv,the SRS main harnessis

shoned. Replacethe SRS main harness and
recheckths voltagesaccordingto the chart on
page 23-3O4.
a lf thre is no continuity,go to step 7.

a lf voltageis mote than 8.5 V, go to step 8'

a ll voltage is less than 8.5 V, go to step 3

23-315

SupplementalRestraintSystem (SRS)
Troubleshooting(cont'd)
7.

Check for continuitybetween the B1l terminalof

Test HarnessB (O7MAZ-SPOo5OO)
and the No. 1
terminalof the SRS main harness4-p connector.

Turn the ignition switch ON and wait tor six

seconds.
Measurethe voltage between the No. 5 terminal
and body ground.

TESTHARI{ESS
B
07MAZ-SPq)500
DASHBOARDWIRE
HARNES95-P CONNECTOR

A
B

View lrom terminalside

a lf there is continuity, the SRS unit is faultv.

Replaceit and recheckthe voltagesaccordingto
the chan on page 23-304.
a lf there is no continuity.there is an open in the
SRS main harness. Replace the SRS main
harnessand recheckthe voltagesaccordingto
the chart on page 23-304.
Reconnectthe SRSmain harness4-P connectorto
the main wire harness.Disconnectthe dashboard
wire harness 5-P connector from the gauge
assemblv.

HARNESS5.P CONNECTOB

23-316

a lf voltageis more than 8.5 V. the SRSindicator

circuitis faulty (in the gaugeassembly).Replace
the SRS indicator assembly and recheck the
voltagesaccordingto the chart on page23-304.
a lf voltageis lessthan 8.5 V. the dashboardwire
harness (or the main wire harness)is faulty.
Replaceil and recheckthe voltagesaccordingto
the chart on page 23-304.

Poor glound at SRS unit or unit mounting bolts

NOTE: The radio may have a s-digit coded theit protection circuit. Be sure to get the customer's code
numberbelore disconnectingthe battery cables.
1.

Betore disconnectingany part of the SRS wire

harness,installthe short connector(s)(RED)on the
airbag(s)(see page 23-294l,.

2.

Connect Test HarnessB (o7MAz-SP005oo) between the SRS unit and SRS main harness 18-P
conneclor.

a lf there is continuity at either terminal, the SRS

unit is Jaulty. Replace it and recheck the
voltages accordingto the chart on page 23-304
a lJ there is no continuity at either terminal,the
SRS unit ground, the SRS unit component
grounds, or the SRS main harness is faulty.
Check the grounds(checkthe SRS unit ground
wire and mounting bolts) and, if necessary,
rsplace the SRS main harness. Racheck the
voftagesaccordingto the chart on page23-304,

sRsur{tT
SRS MAIN HARNESS
18-P CONNECTOR

HARNESSB

07MAZ-SP00500

Check for continuitybetweenthe 85 terminaland

body ground. and the 815 terminal and body
ground.

TESTHARNESS8
07MAZ - SP005q)

23-317

SupplementalRestraintSystem(SRSI
Airbag Assembly Replacement
sro.e a rsmoved airbag assembtywith the
E@
pad surlace up. lf tho airbag is improprly stored face
down, accidental dployment could plopel th unit with
nough lotce to cause satious iniury.
CAUTION:
a Do not install used SRS parts f.om another cat.
Whn repailing as SRS, use only nw parts.
o Carelully inspect ths airbag assembly before you in_
stall it. Do not install an airbag assembly that shows
signs of being droppad or improperly handled, such
as dents, cracks or dolotmation.
a Always kep tho short connctor(sl (REDIon the air_
bag{s) whan th6 harness is disconnoctod.
a Do not disasaombls ()1 tamper with the airbag
assmbly.

Front Passenger'sSide:
a Removethe glove box, then remove the short
connector{RED)from its holder
a Disconnectthe 3-P connectorbetweenthe front
passenger'sairbagand SRSmain harness.then
installthe short connector (RED)on the airbag
side of the connector.

FRONTPASSENGER'S
AIRBAG
3.P CONNECTOR

NOTE: The radio may have a s-digit coded theft protection circuit, Be sure to get the customer's code
number beforedisconnectingthe battery cables.
l.

Disconnect the battery negative cable, then

disconnectthe positivecable.

2.

Installthe short connector(s)(REDIon the airbaq

side of the connector(s):
Oriver'sSide:
a Remove the access panel from the steering
wheel, then removethe shon connecto.{RED)
trom the panel.
a Disconnect the 3-P connector between the
driver's airbag and cable feel, then insta the
short connector(RED)on the airbagside of the
connector.
GLOVEBOX
CABLE REL3.P CONNECTOR

DRIVER'S
AIRBAG
3-P CONNECTOR
ACCESSPANEL
SHORT
CONNECTOR
{RED}

23-318

J.

Removethe ai.bag(s):
Driver'sSide:
a Remove the two TORXo bolts using a TORXo
T3O bit, then remove the driver's airbag
assembly,

Front Passenger'sSide:
a Removethe tweetet cover from the dashboard,
then removethe visor and blackface panel (see
p a g e2 3 - 1 3 0 ) .
a Remove the glove box, then remove the four
mountingnuts from the lront passenger'sairbag
assembly.

DRIVER'S
AIRBAGASSEMBLY
DASHBOABD

GLOVE BOX
TOBXO BOLT
U.. . TORX@ T3O bh

a Carefully lift the front passenger's airbag

assemblvout ot the dashboard.

(cont'd)

23-319

SupplementalRestraintSystem (SRSI
Airbag Assembly Replacement(cont,dl
CAUTIOI{: B sura to installthe SRS wi ng so thst it ie
nol pinchod or intorforing with oth6r car parts.
4.

Installthe new airbag(s).

Driver'sSide: Placethe driver'sairbagassemblyin
the steeringwheel. and secureit with new TORX@
bolts.
OBIVEB'S
AIRBAG

Front Passenger'sSide:
a Placethe front passenger'sairbagassemblyin
the dashboard.
a Loosenthe two mountingnuts on the L-bracket.
a P.essthe airbagassemblydownwardsand turn
the adjusting nuts until they touch the lower
part of the airbagassembly.
a Tighten the four airbag mounting nuts, then
tightenthe two mountingnuts on the L-bracket.
ADJUSTING
NUT

TORXO BOLT
10 N.m {1.Okg-m, 7.2 tb-ft)
Reolace.
U8o 6 TOBX@ T3O bit

23-320

L-BRACKET

L-BRACKET
MOUNTING NUT
10 N.m 11.0kg-m, 7.2 lb-ftl
Replace.

ASSEMBLY
MOUNTINGNUTS
10 N.m (1.0 kg-m, 7.2 tb-frl
Replace.

5.

Driver'sSide:
a Rmov the short connector {RED)from the
driver'sairbagconnector.then connectthe airbag 3-P connector to the cable reel 3-P
connector.

Rsmoveand ptoperlystore the short connsctor{s),

then reconnectthe airbagconnector{s).
Front passenger'sSide:
a Attach the short connector(REDltothe connecto, holder.
a Then reinst8llthe glove box, visor, and tweeter
covr on the dashboard.

a Attach the short connector(RED)to the access

panel. then reinstallthe panel on the steering
whel.

FRONTPASSENGER'S
AIRBAG3.P CONNECTOR

CABLEREEL3.P CONNECTOB

DRIVER'S
AIRBAG
3-PCO I{ECTOR

6 . Connsct th battery positive cable, then the

negstivecable.
Aft6r instaltingthe ai.ba(tassembly,conJirmproper
system operaflon:
a Turn the ignition ON {lll: The instrumentpanel
SRS indicatorlight should go on for about six
secondsand then go off.
a Make sure both horn buttons work.
a Take a test drivs and make sure the cruasecontrol set/resume switch works.

GLOVESOX

tt.

Enter the code number to restore radio operation

(see page 23-206).

23-321

SupplementalRestraintSystem (SRS)
Ai6ag AssemblyDisposal
Beforescrappingany airbag(s){includingone in a whole
car to be scrappedlthe airbagmust be doployed.lf the
car is still within the warrantyperiod,betoreyou deploy
the airbag.the Honda District Service Managermust
give approvaland/or specialinstruclons.
Only after an airbaghas beendeployed(asthe resultol
vehiclecollision.for example),it can be scrapped.
lf an airbag(s)appearsintact (not deployedltrestit with
extremecautaon.
Followthis Drocedure:

Front Passongef's Alrbag:

4.

Remove the glove box, then disconnectth6

3_p
connector between the front passengr,s airbag
and SRS main harness.
FBONT PASSEI{GER'SAIRBAG
3-P COt{t{EcToR

Dploying the Ai|bag(s): In-CE]

NOTE: lf an SRScar is to be entirelyscrapped,its 8ir_
bag(sl should be deployedwhile still in the ca..
The airbag(slshould not b consideredas salvageable
part and should never be installedin anothercar.
confirm that th6 airbag assombty i!
@E
secu.ely mountad; otherwiso sovoro porsonal injury
could rsult dudng doploymont,
1.
2.

Disconnectboth the negative cable and Dositiv8

cable from the batt8rv.
Confirmthat the specialtoolis functioningproporly
by following the check procedure on the label of
the tool set box, or on page 23-317

Drivor's Alrbag:
3.

Removethe accesspanel,then disconnctthe 3_p

connector between the d.iver,s airbSg and the
cable reel.

5.

Cut off the airbag connector, strip the ends of the

aibag. wires, and connsct the speci6l tool alligator
clips to ths bar6 wires. place the special tool approximatsly thirty fet away from the airbag.
DFIVER'SAIREAG

ALUGATOR
CLIPS
lY.lowl

ORIVER'S
AIRBAG
3.P CONNECTOB

23-322

ACCESS
PANEL

FRONTPASSEI{GER'S
AIRBAG

o,

Connct a 12 volt battery to the tool:

a lf ths g.een light on th tool goes on, tho airbag
ignit8r circuit is defective and csnnot deploy th
bag. Go to DamagedAirbag SpecialProcedure.
a It the red light on the tool goes on, the sirbagis
r8dy to be dployed.

7 . Push the tool's dployment switch. The airbag

should deploy (deploymentis both highly audible
and visible- a loud noisand rapidintlationof the
bag, tollowod by slow deflation).

D6ploying tho Ai6ag: Out-of-cal'

NOTE: lt 8n intact airbag assembly has b6n removed
from a scrapped car or has been found dotectivs or
damagedduringtransit,storage,or service,it shouldbe
deployedas follows:
Position tho ai6a9 aslembly faco up' out!@
tlat ground at loart thlrtY feet lrom any
E6EJn
obstacbs or Poople.

. ll audible/visibledeploymnt happensand the

gren light on the tool goes on, continue with
this procedure.
. It the airbagdoesn't deploy,yet the green light
goes ON, its igniter is dfective
Go to DamagedAitbag SpecialProcedure.
1.
Du?ing d.ployment, rho airbag
!@
assembly can bcomo hot gnough to burn you.
Wait thirty minutos aft6r doploymont before
touching the assmbly.

2.
3.

Disposeof the complste airb8gassembly.No pan

of it can be reused. Place it in a sturdy plsstic bag
and seal it securelv.
CAUTION:
a Wsar a taco shiold and glovos whn handling a
deploy6d Eirbag.
a Wash your hands and dns6 thom wall with
wat6r afior handling a doployed alrb8g.

Confirm that the specialtool is tunctioning properly

by following the check procadureon this page or on
the tool box l8bel.
Remove tho short connactor from the Eirbag
connector,
Follow steps 5, 6, 7 and I ot th in-car dploymnt
procodute.

Damagod Airbag Special Procedure'

lf an airbag cannot be dcployod' ir thould
!@
i6Fue tteatea aa normal scrap; it lhould stlll bo considorod a potontiallY explolivo dovico that can c.us
sarious lniury.
1.

It instslldin a car, tollow the rsmovsl procdure

o n p a g e2 3 - 3 1 9 .

2.

In allcases,make surea short connscto.is properly

installedon the airbagconngctor.

3.

Packagethe airbsg in exactly th same packaging

that the new replacamentpart came in.

4.

5.

"DAMAGED AIRBAG
Mark the outsideof th box
NoT DEPLOYED"so it does not get confused with
your parts stock.
Contact your Honda Oistrict Service Manager lor
how and where to return it for disposal.

Doploymant Tool: Chock Plocedulo.

1.

Connectthe vellow clips to both switch protoctor

handles on the tool; connact th tool to a baftary'
Pushthe operationswitch: greonmeanstool is OK;
red meanstool is Jsulty.

3 . Disconnect the bsttery and the yellow clips.

23-323

SupplementalRestraintSystem(SRSI
CableReelReplacement
storo a romovcd aiibag assombtywith tho
@
pld rurtrco up. lf tho airbag is lmpfoporly stored taco
down, eccldental dploymont could propol the unit with
lnough torc6 to cause sadous iniury.

4.

CAUTION:
r Carefully inspct the alrbag assembly botor6 installing h. Do not install an airbag asscmbly that shows
signs ot belng droppcd or lmprop. y handled, such
aa denta, cracks 01 dgtormation.
a AlwayE koop th. short connoctol(s) on tho airblg(sl
whn ths hames! is disconnectod.
a Do not disassomble or tampr with any ailbag
a8sambly.

CABLEREEL3.P COI{IECTOR

DNIVER'S
AIRBAG 3.P

cof{t{EcToR

NOTE: The radio may have a s-digit cod6d theft protection circuit. Be sure to gt the customer,s code
numberbetore disconnectingthe battery cable.
1.

Installths short connector{slon the airbag(s)(se

paga 23-2941.

SHORT

Disconnect the battery nogative cable 8nd then the

positivecabls.

cor{r{EcToR
(REDI

accEss
PAl{EL

2.

Make su,e ths wheels are facing straightahsad.

3.

Remove the dashboard lower cover, knee bolst6r,

and air duct.

Remove the driver,s airbag assembly trom

tho
steoring whel (two T30 TORXo bolts), then
ramov the steering whel nut.

S?EERII{GIYHEELITUT

TORXO BOLT
U.. . TOnXo T3O bh

23-324

Disconnect the connectors from the horn and

cruise control set/resume switches, then remove
the cable reel 3-P connectorJrom its clip.

HORN CONNECTOR

9. Disconnect the 6-P connector between the cable

reel 8nd SRS main harness,then removethe connctor holder from th staering column.

CRUISECONTROL
SET/RESUME
CABLEREEL

COI{NECTORHOLDER

7.

Removethe steeringwheel Jromthe column'

8.

Removethe upper and lower column covers'

1O. Removethe cable reel from the column.

UPPERCOLUMN COVER

23-325

SupplementalRestraintSystem (SRS)
Cable ReelReplacement(cont'd)
CAUTION:
a Bcforo Installingth steofng whool. th front whelg
should be alignod straight ahead.
a Bc aure to install the harnoss wires so that thoy ar
not pinch6d or intsrfering with other car parts.
a Aftor reassembly. contirm that the whoels aro still
straight ah6ad and that the rteerlng wheel spoke
angle is correct (road test), lf minor spoke angle adiustmont is ncesaary, do so only by adiustment ot
th ti-lods. not by removing and repositioning tho
stering whael.
11. 2WS: Align the cancel sleeve grooves with the
cable reel projections,

CANCELSLEEVE

13. Installthe steeringcolumnupperand lower covers,

14. Centerthe cable reel.
Do this by first rotatingthe cablereelclockwiseuntil it stoDs.
Then rotate it counterclockwise(approximately
two turns) until:
a The yellow geaf tooth lines up with the alignment mark on the cover.
a The arrow mark on the cable reel label Doints
straight up.
ARROW MARK

CABLE REL

ALIGNMENTMABK

15. Installthe steeringwheel and aftach the csble reel

connectorto the cliD.
HORI{ CONNECTOR

4WS: Be sure that the yellow make on the front

main steeringanglesensorrotorfacesdownwards.
It it doesn't,turn the rotortill it is in the neutrallock
position(seesection 17).

CRUISE
CONTROL
SET/RESUME
SWITCHCONNECTOR

Carefullyinstallthe cable reel on the steeringcolumn shaft. Then attach the connectorholderto the
steeringcolumn,

1 6 . Connect the horn connector and cruise control

set/resumeswitch connector.

23-326

1 7 . Installthe steeringwheel nut.

NOTE: Modelswith 4WS
Checkthat the 4WS system is neutral(seesection
17).
WHEELNUT
STEERING
50 N.m (5 kg-m,36 lb-It)

20. Removeand properlystore the short connector(s)

{RED),then reconnectthe airbagconnector(s}{and
reinstallthe glove box).
2'1. Reconnect the battery positive cable, then the
negativecable,
22. Atter installing the cable re|, conJirm proper
system operation:
a Turn the ignition ON (ll); the instrumentpanel
SRS indicatorlight should go on for about six
secondsand then go otf
a Make sure both horn buttons work.
a Make sure the headlight and wiper switches
work,
a Go for a test drive and make surethe cruisecontrol set/resumeswitch work.
a Rotate the steering wheel counterclockwise to
make sure the yellow gear tooth lines up with
the slot on the cover.

TORXO BOLTS
10 N'm (1.0 kg-m. 7.2 lb-ft)
BeDlace.
U3o a TORXo T30 blt
18. Install the driver's airbag assembly'
19. Connect the cable reel 6-P connector to the SRS
main harness, then installthe air duct, knee bolster'
and dashboard lower cover.

YELLOWGEARTOOTH

23. Enter the code number to resto.e radio operation

(see page 23-206).

DASHBOARDLOWERCOVER

23-327

SupplementalRestraintSystem(SRS)
DashSensorReplacement
CAUTION:
a Oo not damsgo tho sonsor wiring.
a Do not install ussd SRS parts trom anoth6. car.
Whn rpairing an SRS, use only new pans.
a Raplace a sansor il it is dented, c1ack6d, ol
dto1med.

3,

Left Dash Sensor:

Removethe footrestand left door sill molding,then
pull the carpet back.

4.

Right Dash Sensor:

Removethe right door sillmoldingand pull backthe
caroet. Removethe ECM.

NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code
numberbeforedisconnectingthe battery cable,
1.

Disconnectthe battery negative cable, thn the

positivecable.

2.

Installthe shorr connector{s}on the airbag{s}.

CAALE REEL
3-P CONt{ECTOR

SHORTCONNECTOR
(RED)
FRONTPASSENGER'S
AIRBAG

SRS MAIN

Remove the two mounting bolts, then remove thg

left or right dash sensor.

GLOVEBOX
BOLTS

23-328

CAUTION:
a Bg sure to install the harness wils go thoy ar
not Dinchd01 intorfering with oth6r cal parts.
a Carefully inspect the new dash sonsol(sl for
signs of being dropped or imploperly handl6d,
such as dents, cracks or deformation.
a Fol the SRS to function proporly, the dghl and
lett sansors must b installd on the propor
sidos.
o.

Installthe sensorsecurelY.

DASH SENSOR

8 . Removeand properlystore the short connector(sl

(RED),then reconnectto aitbag connector(s){and
reinstallthe glove boxl.
9 . Reconnectthe battery positive cable, then the
negativecable.

1 0 .After installingthe dash sensor, confirm proper

system operation:Turn the ignitionON (ll); the instrumentpanelsRS indicatotlight shouldgo on for
about six secondsand then go off

'l 'l . Enter the code number to restoreradio operation

(see page 23-206).

DASH SENSOR
MOUNTINGEOLTS
8 t 1 . 2 5m m
22 N'm t2.2 kg-m. 16 lb-ft)
RePlace

7.

Reinstall all other removed parts.

23-329

SupplementalRestraintSystem(SRSI
SRS Unit Replacement
4.
a Boloro disconnecting any pan ot the SRS wire
hamss. install the shon connctor(s) on th
airbag(s).
a Do not damage tho SRS unit terminals or
connectors,
a Oo not disassmble the SBS unit; it has no aorvicoable p8rts.
a Stor the SRS unit in a clean, dry arsa,
a Do not us any SRS unit which has ben subjcted
to watel damage or shows signs of bsing droppsd 01
improperly handled, such as dents, cracks or
doformation.
NOTE: The radio may have a s-digit coded theft protection circuit. Be sure to get the customer's code
number beforedisconnectingthe battery cable.
1.

Rmovethe left side cover trom the SRSunit, then

disconnectthe SRS main harnesslB-p connactor
from the SRS unit.
SRS UNIT

SBS MAIN
HARNESS
1a-P COI{NECTOR

Disconnectthe battery negative cable. then the

oositivecable.

TOBXO
BOLTS
Usc a TORXo
T30 btr

lnstallthe short connector{s)on the airbag(sllsee

page 23-2941.

3 . Removethe right side cover from the SRSunit.

5.

SRS UNIT

_--,/

TOBXo

8()tTs
Use ! TORXo
bir

23-330
t\

Removethe fou. SRSunit TORXo bolts, then oull

the SRS unit out from the driver'sside.

CAUTION: Ba sur to install tho SRSwidng so that

it is not pinch6d 01 intorfefng with othor cal pada'
lnstallthe new SBS unit.

Removeand properlystore the short connector{sl

{RED),then reconnectthe airbagconnector(s}(and
reinstallthe glove box).

1 0 .Reconnect the battety positive cable, then the

negativecable,
1 1 .After installing the SRS unit. confirm proper
systemoperation:Turn the ignitionto ll; the instrument panel SRS indicator light should go on for
about six secondsand then go otf

' 1 2 .Enter the code number to restore radio operation

(see page 23-206).

snsuNlr

ToRxo BOLTS 6 mm
10 N.m tl.O kg-m,7.2 lb-ft)
ReDlace.
U3e a TORxo T3O bit

SRS MAIN
HARNESS
18.P CONNECTOR

TORXo SOLTS6 mm
1ON'm 110 kg-m'7.2 lb-ft|
RePlace.
Ut. a TORXo T30 blt

Connectthe SRS main harness18-P connectorto

the SRS unit; push it into positionuntil it clicks.
8.

Installthe SRSunit covers (right and lett).

23-331