96-98 Service Manual Honda Civic

GeneralInformation
1-2
and PaintGodes.'.'..'.....'..'..'.."
Chassis
" 1-2O
NumberLocations'..'.'.
ldentification
Warning/CautionLabelLocations'..'..'1-21
Under-hoodEmissions
......1'25
ControlLabel..........
Lift and Support Points
1-21
Lift and SafetyStands.'..".'..'..'.'.'.".'
1'28
....,..................
FloorJack
'.'....'1-29
Towing
Chassisand PaintCodes
U.S.1996Model l2-door Hatchback)
2AG
2HG: HONDAOF CANADA
00001
D16Y7:1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
A4RA:4-speedAutomaticTransmission
S40 : s-speedManualTransmission
H: AllistonPlant,Ontario,Canada
Destin.iions
Vehicle ldentification Number

and FederalMotor Vehicle
Safety Standard Certification
t-z
GY-16P
NH-503P
NH.583M
R-97
Midori GreenPearl
GranadaBlackPearl
New VogueSilverMetallic
RomaRed
Paint Code
COLOR
GY.l6P
.\a
U.S. 1996Model {4-doorSedanl
J H ME J 65 2 * T S 0 0 0 0 0 1
D16Y7:1600SOHC16-valvesSequential
Engine
Multipon Fuel-injected
Sequential
D16Y8;1600SOHCVTEC16-valves
MultiportFuel-injected
Engine
JAPAN:D16Y7.D16Y8- 1300001U.S.A : D16Yt,D16Y8- 1500001-
Lino, Body 8nd EngineTyp

EJ6: CIVIC4-door/Dl6Y7
EJ8: CIVIC4-door/D'16Y8
Body Typo and TransmissionType
Manual
5: Sedan/s-speed
S4C : s-soeedManualTransmission
A4RA{U.S.A.) : 50000011000001S40.SaC(JAPAN):
3: DX with Ay'C
4: DX with ABS,EX
5: DX with ABS and A,/C
6: LX
7; LX with Ay'C
8: LX with ABS
9: LX with ABS and A,/C
ChckDigit
Model Year
T: 1996
L: EastLibertv.Ohio Plant,U.S.A.
Japan
S: SuzukaPlant.Mie Prefecture,

Safety Standard Cortification
B-73M
G-82P
NH-538
NH-503P
NH-583M
R-95P
CycloneBlueMetallic
CypressGreenPearl
FrostWhite
GranadaBlackPearl
lslandCoralPearl
PaintCode
COLOR
B.73M
1-i
U.S. 1996Model (2-doorCoupe)
l H G E J 61 2 * T L 0 0 0 0 0 1
Lino, Body and EnginaTypc

EJ6; ClvlCz-door/D16Y7
EJ7: ClVlC2-door/D16Y5
Body Type and Tranrmission Type
D16Y5:1600SOHCWEC-E16-valves
SequentialMultiport
Fuel-injected
Engine
Dl6Y7: 1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
D16Y8:1600SOHCVTEC16-valves
SequentialMultiport
Fuel-injected
Engine
JAPAN:D16Y5- 1300001U.S.A.: D16Y7.D16Y8- 15OOO01-
3; OX with ABS, HX with ABS

4: DX with Ay'C,HX with Ay'C,EX
5: DX with ABS and Ay'C,HX with ABS
and A"/CEX with ABS
ChockDigit
Modol Year
T: 1996
L: EastLiberty,Ohio Plant,U.S.A.
A4RA : 4-speodAutomaticTransmission
S40,S4C:s-speedManualTransmission
M4VA ; ContinuouslvVariable
Transmission(CVT)
A4RA:5000001-
s40,s4c
M4VA:1000001-

G-82P
NH.5O3P
NH-538
NH-583M
B-81
R.95P
CypressGreenPesrl
GranadaBlackPearl
FroslWhite
MilanoRed
lslandCoralPearl
PaintCode
COLOR
G-82P
1 -4
CANADA1996Modell2-doorHatchbackl
a
D16Y/- 1700001
2 H GE J 6 3 2 * T H0 0 0 0 0 1
Line, Body and EnginoTyps

Body Type and TransmissionType
A4RA:,t-speedAutomatic Transmission
S40 :s-soeedManualTransmission
CheckDigit
Modol Ysar
T: 1996

and CanadianMotor Vehicle
GY-T6P
NH-503P
NH.583M
R-97
Midori GreenPearl
GranadaBlackPearl
Roma Red
PaintCode
COLOR
GY.16P
1-5
CANADA 1996Model (4-doorSedan)
lHG EJ653*TL 800001
SequentialMultiport
Fuel-injected
Engine
Lino, Body and EnginoTyp6

Body Typo and TransmissionTypo
5; Sedan/s-soeed
Manual
4; LX with ABS
6: EX
7: EXwith ABS
CheckDigit
Model Year
T: 1996
L: EsstLiberty,Ohio Plant,U.S.A.
VehicleldentificationNumber
MotorVehicle
andCanadian
Safety StandardGertification
A4RA;4-speedAutomaticTransmission
S40 : 5-soeedManualTransmission
A4RA:5000001S40 :1000001-
B-73M
G-82P
NH-503P
NH-538
NH-583M
CycloneBlueMetallic
CypressGreenPearl
GranadaBlackPearl
Frost White
PaintCode
COLOR
8.73M
.'rr
F'.i!
1-6
CANADA 1996Model (2-doorCoupel
1 H GE J 61 2 * T L 0 0 0 0 0 1
1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
1600SOHCWEC 16-valves
SequentialMultipon
Fuel-injected
Engine
Lins, Body and EngineTypa

EJ6: ClVlC2-door/D16\'/
EJ8: ClVlC2-doo./D16Y8
Body Typ6 and Transmi3sionType
TransmissionNumber
A4RA- 5000001
3: Si with ABS
5: DX with ABS
ChockDigit
Model Yeat
T: 1996
Transmissionl
A4RA I 4-soeedAutomaticTransmission
s40,s4c:s-soeedManualTransmission
SerialNumbor
A4RA :
s40,s4c:
MotorVehicle
andCanadian
SafetyStandardCertification
G-82P
NH-503P
NH-538
NH-583M
R-81
R-95P
CypressGreen Pearl
GranadaBlackPearl
Frost White
MilanoRed
lsland Coral Pearl
PaintCode
COLOR
NH-538
1-7
U.S. 1997Model (2-door Hatchback)
2 H GE J 63 2 * V H 1 0 0 0 0 1
Type ol Vohicl
D16Y7i1600SOHC16-valves
SequentialMultipon
Fuel-injected
Engine
Lino, Body and EnginoTypr

Body Typo rnd Tranrmission Typc
3: CX with Ay'C
4: DX
5: DX with Ay'C
6: DX with ABS
7: DX with Ay'Cand ABS
Chcck Digit
Model Yoar
V; 1997
A4RA:4-sDeed
AutomaticTransmission
B4RA:4-speedAutomaticTransmission
A4RA: 600000'lB4RA:6000001S40 : 1000001-
H; AllistonPlant,Ontario,Canada
NH.503P
NH.583M
Pg-l 4P
R-97

GranadaBlackPearl
DarkAmethyst Pearl
RomaRed
Paint Code
COLOR
NH.583M
1-8
U.S. 1997Model l4-door Sedanl
J H ME J 6s 2 * V S 0 0 0 0 0 1
Dl6Y/: 1600SOHCl$valves Sequentisl
Engine
D16Y8:1600SOHCWEC 16-valvesSequential
Engine
JAPAN:D16Y7,D16Y8- 2300001U.S.A.: D16Yt,Dl6Y8 - 2500001-
Lino, Body snd EngineTypo

EJ6: ClVlC4-door/D16Y/
Body Typo and TrsnsmissionType
Manual
5: Sedan/s-sDeed
A4RA: 4-soesdAutomatic Transmission

B4RA: 4-spe6dAutomatic Transmission
M4RA:4-speedAutomaticTransmission
S40 :s-speedManualTransmission
A4RA(U.S.A.): 6000001B4RA{U.S.A.): 60000012000001M4RAUAPAN):

S40(JAPAN) : 10000013: DX with Ay'C
4: DX with ABS,EX
5: DX with ABS and Ay'C
7: LX with Ay'C
8: LX with ABS
9; LX with ABS and Ay'C
ChockDigit
Modol Ycsr
V: 1997
L: EastLibertv,Ohio Plant,U.S.A.
Japan
S: SuzukaPlant,Mie Prefecture.
H: AllistonPlant.Ontario,Canada

and FederalMotol Vehicle
CycloneBlueMetallic
CypressGreenPesrl
Frost White
GranadaBlackPearl
lnzaRed
B.73M
G-82P
NH-538
NH-503P
NH-583M
R.96P
Paint Code
COLOR
8.73M
1-9
EngineNumber
'tHG
E J 61 4 * V L 0 0 0 0 0 1
Manutaqturer,Make and
Type ol Vehicle
lHG: HONDAOFAMERICA
M F G , I, N C .
HONDAPassenger
vehicle
Line, Body and Engine Type
EJ6; ClVlC2-door/D16Y7
EJ8: ClvlC2'door/D16Ya
Body Typ and TransmissionType
1: Coupe/s-speed
M an u aI
2; Coupe/4-speedAutomatic, CVT
Vehicle Grade
2: DX, HX
3: DX with ABS,HX with ABS
4: DX with A,./C,
HX with A,./C.
EX
5: DX with ABS and A,iC,HX with ABS
and A'lC,EX with ABS
Chsck Digit
ModelYear
V: 1997
FactoryCode
Serial Number

D16Y5- 2300001
EngineType
D16Y5:1600SOHCWEC-E16-valves
SequentialMultiport
Fuel-injected
Engine
SequentialMultiport
Fuel-injected
Engine
D16Y8:1600SOHCVTEC16-valves
SequentialMultipon
Fuel-injected
Engine
Serial Numbr
JAPAN:Dl6Y5 - 2300001U.S.A.: D16Y7,D16Y8- 2500001-
TransmissionNumber
A4RA- 6000001
TransmissionType
A4RA: 4-speedAutomaticTransmission
B4RA: 4-speedAutomaticTransmission
M4VA:ContinuouslyVariable
Transmission
{CVT)
Serial Number
A4RA: 6000001B4RA: 6000001S40 :1000001M4VA:2000001-
G-82P
NH.5O3P
NH-538
NH.583M
R-81
CypressGreenPearl
GranadaBlackPearl
Frost White
N4ilano
Red
Paint Gode
COLOR
G.82P
1-10
CANADA 1997Model (2-door Hatchbackl
2 H GE J 63 2 * V H 0 0 0 0 0 1
D16fr: 1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
Line, Body lnd EnginTypo

EJ6; ClVlC3-door/D16Y7
B4RA:4-sDeedAutomaticTransmission
S40 : s-sDeedMsnualTransmission

and GanadianMotor Vehicle
NH-503P
NH.583M
PB-74P
R-97
G.anadaBlackPearl
DarkAmethyst Pearl
RomaRed
Paint Code
COLOR
NH-503P
1-11
Chassisand PaintGodes
1 H GE J 6 5 3 + V L 8 0 0 0 0 1
D16\.t: 1600SOHC16-valves
SequentialMultiport
FueliniectedEngine
Lino, Body and EngineTyps

EJ6: ClVlC4-door/Dl6Y7
Body Type and TEnlmLrion Type
5: Sedan/s-soeed
Manual
4: LX With ABS
5: LX with ABS and ly'C
7: EX with ABS
8: EX with ABS and !y'C
84RA:4-speedAutomaticTransmission
S40 : s-sDeedManualTransmission
L: EastLibertv,Ohio Plant,U.S.A.
andCanadian
MotorVehicle
SafetyStandardCertification
B-73M
G.82P
NH-503P
NH-538
NH-583M
Cyclone
BlueMetallic
CypressGreenPearl
Granada
BlackPearl
FrostWhite
NewVogueSilverMetallic
Paint Code
COLOR
B-73M
v-
1-12
CANADA 1997Model (2-doorCoupel
l H G E J 61 2 * V L 8 0 0 0 0 1
Lino. Eody and Engins Type

EJ6: CIVIC2-doorlD16W
EJ8: ClVlC2-door/D16Yg
Body Type lnd Tran3missionType
3: Si with ABS
5: DX with ABS
6: OX with ABS and Ay'C
7: Si with ABS and Ay'C
D16Y7:1600SOHC16-vslves
SequentialMultiport
Engine
Fuel-injected
D16Y8:1600SOHCWEC 16-valves
SequentialMultipon
Engine
Fuel-injected
44RA: 4-speedAutomatic Transmission

A4RA:6000001B4RA:6000001S40 :1000001-
L: East Liberty, Ohio Plant. U.S.A.
Vehicle ldentif ication Numbel

CypressGreenPearl
GranadaBlackPoarl
FrostWhite
MilanoRed
G-82P
NH-503P
NH-538
NH-583M
R-81
Paint Code
COLOR
NH-538
1-13
U.S. 1998Model (2-doorHatchbackl
2HGEJ632 *WH 1 00001
SequentialMultiport
Fuel-injected
Engine
Line, Body and EngineType
EJ6: ClvlC3-door/D16Y7
Body Type and TransmissionTyp
B4RA;4-speedAutomaticTransmission
3: CX with Ay'C
4: DX
5: DX with Ay'C
6: DX with ABS
7: DX with Ay'Cand ABS
CheckDigit
Modl Year
W: 1998
H: AllistonPlant.Ontario.Canada

Safety Standard Certificataon
B4RA:7000001S40 : 1000001-
NH.592P
NH-583M
PB-74P
R-97
FlamencoBlackPearl
DarkAmethystPearl
RomaRed
Paint Codo
COLOR
NH.583M
{i"
1-14
U.S. 1998Model (4-doorSedanl
J H M E J 65 2 * W S 0 0 0 0 0 1
EnginoTyp
D16Y/:'1600SOHC16-valves
Sequential
Engine
D16Y8;1600SOHCVTEC16-vslvesSquential
Engine
JAPAN:D16Y7.D16Y8- 3300001U.S.A : D16Y7,Dl6Y8 - 3500001-
Line, Body and EngineType

EJ6: CIVIC4-door/D16Y7
Manual
5: Sedan/5-speed
84RA: 4-soeedAutomaticTransmission
M4RA:4-sDeedAutomaticTransmission
S40 : s-soeedManuslTransmission
B4RA(U.S.A.): 7000001M4RA(JAPAN):
3000001'
S40(JAPAN) : 10000013: DX with A"/C
4: DX WithABS,EX
5: DX with ABS and Ay'C
7: LX with A,/C
8: LX with ABS
9: LX with ABS and Ay'C
Japan
S: SuzukaPlant,Mie Prefecture,
000001:JAPAN,U.S.A.
500001:CANADA
CycloneBlueMetallic
CypressGreen Pearl
TaffetaWhite
FlamencoBlackPearl
lnzaRedPearl
8.73M
NH-578
NH-592P
NH.583M
R.96P
Paint Code
COLOR
8.73M
VehicleldentificationNumbel
1-15
Ghassisand PaintCodes
EngineNumber
1 H GE J 6 1 2 + W L 0 0 0 0 0 1
Lin., Body and EnginaTypo

EJ6: ClVlC2-door/Dt6y7
EJ7: ClVlC2-door/D16y5
EJ8: ClVlC2-door/Dt6y8
Body Type and Transmbsion Type
1:Coupe/s-speed
Manual
2: Coupe/4-speed
Automatic.CVT
3: DX with ABS,HX with ABS
4: DX with !VC, HX with A,/C.EX
5; DX with ABS and Ay'C,HX with ABS
and Ay'C.EX with ABS
ChackDigit
Model Year
W: 1998
and FedoralMotor Vehicle
SafetyStsndardCertification
D16Y5- 3300001
Engins Typ
D16Y5:1600SOHCVTEC-Et6-vatves
SequentialMultipon
Fuel-injected
Engine
D16Yr:1600SoHC 16-valves
SequentialMultiport
Fuel-injected
Engine
D16Y8:1600SOHCWEC l6-vatves
SequentialMultipon
Fuel-injectd
Engine
Serial Numbor
- 3300001JAPAN:D16Y5
U.S.A.: D16Y7,
016Y8- 350OOO1-
B4RA: 4-speedAutomaticTransmissron
M4VA:ContinuouslyVariable
(CVT)
Transmission
B4RA;7000001S40 :1000001M4VA:4000001-
NH-592P
NH-578
NH.583M
R-81
CypressGreenPearl
FlamencoBlackPearl
TaffetaWhite
New VogueSilverMetsllic
MilanoRed
PaintCode
COLOR
G-82P
1-16
CANADA 1998Model l2-door Hatchbackl

2HGEJ632 *WH 000001
Manufacturr.M!ke and
Typ ot V6hicle
2HG: HONDAOF CANADA
MFG.,INC.
HONDAPassenger
vehicle
Lins, Body 8nd EnginoTypo
EJ6: ClVlC3-door/Dl6Yt
Body Typo and Transmi$ion Typ6
3: Hatchbacld5-speed
Manual
4: Hatchbacl(4-speed
Automatic
Vchiclo G18d.
2: CX
3: CX-G
Chock Digit
Modol Yoar
W;1998
FactoryCodo
Sarial Number
SequentialMultiport
Fuel-injected
Engine
B4RA:7000001S40 :1000001-
FlamencoBlackPeafl
DarkAmethyst Pearl
RomaRed
Vehicleldentification Numbsr
and CanadianMotor Vchicle
Srfoty StandardCertification
Paint Code
COLOR
NH.592P
1-17

,
\-
2HG EJ6 53 +W H 900001
Manutacturei. Make and
Type of Vehicle
2HG: HONDAOF CANADA

M F G . I, N C ,
HONDAPassenger
vehicle
JHM: HONDAMOTORCO..
LTD.
HONDAPassenger
vehicle
Line. Body and Engine Type
EJ6: ClVlC4-door/Dl6Y7
5: Sedan/s-speed
Manual
6: Sedan/4-speed
Automatic
VehicleGrade
0: EX
3: LX
4: LX with ABS
7: EX with ABS
8: EX with ABS and Ay'C
ChockDigit
Model Yoar
W: 1998
FactoryCode
S: SuzukaPlant,Mie Prefecture,
Jaoan
SerialNumb6r
800001-:JAPAN
900001-:CANADA
1-18
t
SequentialMultiport
FuelinjectedEngine
3750001-:
U.S.A.
3700001-:
JAPAN
TransmissionNumber
B4RA- 7000001
TransmissionType
B4RA: 4-speedAutomaticTransmissron
M4RA:4-speedAutomaticTransmission
Ssrial Number
B4RA(U.S.A.): 7000001M4RA(JAPAN):3000001S40(JAPAN) : 1000001-
B.73M
G.82P
NH.592P
NH-s78
NH.583M
CycloneBlueMetallic
CypressGreenPearl
FlamencoBlackPearl
TaffetaWhite
Paint Code
COLOR
B-73M
CANADA1998Model (2-doorGouPe)
a
1 H GE J 6 1 2 * W L 8 0 0 0 0 1
Line, Body and EnginType

EJ6: ClVlC2-door/D16Y/
EJ8: ClvlC2-door/D'16Y8
Body Type and TlansmissionTyPe
Vehicle Grade
2: DX, Si
3: Si with ABS
5: DX with ABS
6: DX with ABS and AVC
7: Siwith ABS and A,/C
CheckDigit
Modsl Yoar
W: 1998
SequentialMultiPort
Fuel-injected
Engine
D16Y8:1600SOHCWEC 16-valves
SequentialMultiport
Engine
Fuel-injected
D16Y7:3750001D16Y8:3780001-
l ransmission
S 4 0 : s - s p e e dM a n u aT
84RA:7000001S40 :1000001-
L: EastLibertv,Ohio Plant.U.S.A.
and CanadianMotor Vehlcle
Safety Standard Gertification
CypressGreenPearl
FlamencoBlackPearl
TaffetaWhite
M i l a n oR e d
G-82P
NH-592P
NH-578
NH.583M
R-81
PaintCode
COLOR
NH-578
1-19
ldentificationNumberLocations
V6hicl6 ldontification
NumborlVlN)
\_
Transmission
Numb6r
Numbl
1-20
*:.,
Y-
Warning/CautionLabelLocations
A: CABLEREELCAUTIONA
REFERTO SERVICEMANUAL FOR DETAILEDINSTRUC.
noNs.
a: DRIVERMODUTIWARNING
WARNING
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN.
HURTOR KILLYOU.
TALLYDEPLOYED,
CAN SERIOUSLY
TESTEOUIPMENTOR PROB'
. DO NOT USE ELECTRICAL
ING DEVICES,
DEPLOYMENT.
THEYCAN CAUSEACCIDENTAL
o NO SEnVICEABLEPARTSlNSlOE.DO NOT OISASSEM'
8tE.
. PLACEAIBBAGUPRIGHTWHENREMOVED.
CAREFULLY.
. FOIIOW SERVICEMANUAL INSTRUC'TIONS
C: DRIVERMOoULEDANGER
DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATER OR HEAVY METALSSUCH
LEADORMERCURYMAY PRODUCEHARMFUL
AS COPPER,
AND IRRITATINGGASES OR EXPLOSIVECOMPOUNDS.
MUST NOT EXCEED2OO"F
STORAGETEMPERATURES
{l(x}"CI, FORPROPERHANDLING,STORAGEAND DISPOS.
REFEi TO SERVICEMANUAI- SRS SUPAL PROCEDURES
PLEMENT.
POTSON
CONTAINSPOISONOUSSOOIUMAZIDEAND POTASSIUM
NITBATE.
FIRSTAID:
IF CONTENTSARE SWALLOWED,INDUCEVOMMNG, FOR
EYECOI{TACT.FLUSIJEYESw|TH WATERFOR15 MINUIES.
IF GASES(FROMACIO OR WATERCONTACI) ARE INHAI.ED,
SEEKFRESHAIR. IN EVERYCASE,GET PROMPTMEDICAL
ATTENNON.
KEEPOUT OF REACHOF CHILDREN.
{cont'd)
1-21
Warning/CautionLabelLocations
(cont'dl
(
E
o.E
l----_l
=-+:
D: DRIVERINFORMATION:
CANADAMODEI-
4!8q{Gt ALwAYsWEARyouR SEATBELT
THISCAR IS EOUIPPED
WITH A DRIVERAIRBAGAND A
FRONTSEATPASSENGER
AIFBAGTAS A SUPPLEMENTAL RESTRAINT
SYSTEMISRSI.
IT IS DESIGNEDTO SUPPLEMENT
THESEATBELT.
' Exc6mCANADACX
E: SRSINFORMATION:
U.S. modol {96,9? mod.l)
cAunoN
TO AVOID SERIOUSINJURY:
. FORMAXIMUM SAFEW PROTECNONIN ALL TYPESOF
CMSHES. YOU MUST ALWAYS WEAR YOUB SAFETY
BELT.
. DO NOT INSTALLREARWARD-FACING
CHILDSEATSIN
ANY FRONTPASSENGER
SEATPOSITION.
. DO NOT SIT OR LEAN UNNECESSARILY
CLOSETO THE
ANBAG.
. DO NOI PLACEANY OBJECTSOVEn THE AIRBAGOR
BETWEENTHEAIRBAGANO YOURSELF.
. SEETHE OWNER'SMANUAL FORFURTHERINFORMA.
TION AND EXPLANATIONS.
. THE SRS MUST BE INSPECTED
TEN YEARSAFTEN|l |s
INSTALLED.
. TTIEDATE OF INSTALLATIONIS SIIOWN OF THE DRIV.
ER'SDOORJAMB,
1-22
U.S. mod.l 198modell

WASNING
DEATHOR SERIOUSINJURYCAN (rcCUR.
. CHILDREN12 AND UNDERCAN BE KII-LEDBY THE
AIRBAG.
. THEBACKSEATlS THESAFESTPLACEFOBCHILDREN.
. N E V E RP U T A R E A R . F A C I N G
C H I L DS E A T I N T I I E
FRONT.
. SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG.
. ALWAYS USE SEAT BELTSAND CHILDRESTRAINIS.
. THESRS MUST BE INSPECTED
TEN YEARSAFTER1TIS
INSTALLED.
. THE OATEOF INSTALLANONIS SHOWNON THE DRIV.
ER'SDOORJAMB.
F: ASSISTANTINFORMATIONT
US MOOEL{96,97 modell
AIRBAGSEEOTHERSIDE.
U.S. model 198modell
AIRBAGWARNING
FLIPVISEROVER
G: STEERING
COLUMNNOTICE
NOTICE
TO PREVENTSRS DAMAGE, REMOVESTEERINGWHEEL
BEFOREREMOVING STEERINGSHAFT CONNECTING
BOLT.
H: MONITORCAUTION
NONCE
. NO SERVICEABLE
PAFTSINSIDE.
. REFERTO SERVICEMANUAL FOR DETAILEDINSTRUC.
TtoNs.
I: FRONTSEATPASSENGER
MODULEDANGER
J: SRSWARNINGIHOODI
SUPPLEMENTAIRESTRAINT
SYSTEMISRSI
THIS VEHICLEIS EOUIPPEDWITH DNIVERAND FBONT
SEATPASSENGER
AIRBAGS*.
ALL SRS ELECTRICAL
WIRINGAND CONNECTORS
ARE
COLOREDYELLOW.
TAMPERINGWITH, OISCONNECTING
OR USING ELECTRI.
CAL TEST EOUIPMENTON THE SRS WIRING CAN MAKE
THE SYSTEMINOPERATIVEOR CAUSEACCIDENTALFIR.
ING OF THEINFLATOR.
WARNING
THE AIRBAG INFLATORIS EXPLOSIVEANO. IF ACCIDENTALLY OEPI-OYED.
CAN SERIOUSLYHURT YOU. FOLLOW
SERVICEMANUAL INSTRUCTIONS
CAREFULLY.
' Exc.et CANADACX

f: PASSENGER
AIRBAG
CAUnON
U.S.rnodol198mod.l)
WARNING
CHILDRENCAN BE KILLEDOR INJURED 8Y PASSENGER
AIRBAG.
THE BACKSEAT IS THE SAFESTPLACEFORCHILDREN12
AND UNDER,MAKE SUREALL CHILDRNUSE SEATBELTS
OR CHILOSEATS.
DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATER OR HEAVY METALSSUCH
AS COPPER,LEAD OR MERCURYMAY PRODUCEHARM.
F U L A N D I F R I T A T I N GG A S E S O R E X P L O S I V EC O M POUNDS.STOBAGETEMPERATURES
MUST NOT EXCEED
2OO"FIlOO"CI.FOR PROPERHANDLING.STORAGEAND
DISPOSALPROCEDURES
REFERTO SERVICEMANUAL,
SRSSUPPLEMENT.
POTSON
CONTAINSPOISONOUSSODIUM AZIDEANO POTASSIUM
NITRATE.
FIRSTAID
IF CONTENTSARE SWALLOWED,INDUCEVOMITING.FOR
EYE CONTACT,FLUSH EYES WITH WATER FOR 15 MIN.
UTES,IF GASES IFROMACID OR WATER CONTACTIARE
INHALED,SEEKFRESHAIR IN EVERYCASE.GET PROMPT
MEDICALATTEiITION.
KEEPOUT OF REACI{OF CHILDREN.
WARNING
THE AIBBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN.
TALLYOEPLOYED,
CAN SERIOUSLY
HURTOR KILLYOU.
o DO NOT USE El-ECTRICAL
TESTEOUIPMENIOR PRO&
ING DEVICES.
THEYCAN CAUSEACCIDENTAL
DEPLOYMENT.
. NO SERVICEABLE
PARTSINSIDE.OO NOT DISASSEM.
BLE,
. PLACEAIRBAGUPRIGHTWHENREMOVEO.
. FOLLOWSERVICEMANUAL INSTRUCNONSCAREFULLY.
(cont'd)
1-23
Warning/CautionLabel Locations
(cont'd)
1-24
Under-hoodEmissionsControlLabel(19!16,
1997modell
EmissionGroupldentification
Engineand EvaporativeFamilies
Example:
EngineFamily:
tsF COOUNI, USE 'o'EO SOLUTION
VACUUMHOSEROUTINGDIAGRAM
VEHICLE
EMISSION
INFORMATION
CONTROL
FAM|LY
vHNl6vJcrcr
ls90.F}q?
ENGlrlE
D.SB-ACEME{T
O0 CIVIC
EvApoMtrvt
FAMrry
vHNroTTByMAc
p:9
rwcHo2s{2)sFl
CATALYST
'N.oRMA
Hrr.n u stcv'ct MA\uArro' aDoflror{A,

ro\.
ff-Tl
TUN!LPCO\DNOIIS:
ATNOFMAI
ENGIN!
OPFMTING
TTM'EqA-U8!.
I I|rf '
ALtACCESSoRTESTUq{Eo
FAN
oFf,CooUNG oFf,
TiANSMISSION
INNEUIML
N0 ollrEFaDJUSTT,TENTS
NE!DEo.
oBD CERTtftED
IOLESPEED
TMNSMISSION
12"l I3TDC
V H N1 . 6 V J G K G K
Model Ysar
T: 1996
V; 1997
Manufacturer
H N :H o n d a
Di3placomont
Clsss
V: Light Duty Vehicle/Passenger
Car
Fuol Systsm and Numbsr of Valvo3
J: ElectronicSequentialMultipon Injection
(threeor more valvesper cylinder)
Fuol Typ
G: Gasoline
Standard
F; 49 or 50 StatesTier 1
K: 49 or 50 StatesTier 1
1: CaliforniaTier 1
2: CaliforniaTLEV
3: CaliforniaLEV
4: CaliforniaULEV
Catalyst
E, F, G, H: Three Way Catalyst
OBD
K - T: OBDEquipped
T!
e+l rr _9.,.'
THISVTHICLE
CONFORMS
IO U.S.EPAANOSIAIE
OFCALIFO8NIA
REGULAIIO1TS
APPLICAELE
TO1997
MOOEL
YEAN
NEI1MOTON
VEHICIES.
CEBT]FICANON
IN.USE
112 nE-N2
ililulIl
NtR1
NEA1FUTL
H0N0AMOTO8
C0.,tTD.
50ST {50 States}:

THISVEHICLE
CONFORMS
TO U.S.EPAAND STATEOF
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 7
MODELYEARNEWMOTORVEHICLES.
49ST (49 States/Fodoral):
THISVEHICLE
CONFORMS
TO U.S.EPAREGULATIONS
APPLICABLE
TO 1997MODELYEARNEW MOTORVEHI-
CAL (Californis):
THISVEHICLE
CONFORMS
C A L I F O R N IR
M O D E LY E A R N E W P A S S E N G E C
R A R SP R O V I D E D
THATTHISVEHICLE
IS ONLYINTRODUCED
INTOCOM.
MERCEFORSALEIN THESTATEOF CALIFORNIA.
Evaporative Family:
V H N 1 0 7 7B Y M A C
ModetYsar
TT
T: 1996
|
V:1997
]
Manutaqturer
HN: Honda
Storage System
1:Canister
Canirtor Wolking Caprcity lgrEmsl
CanisterContigurstion
A: PlasticHousing(ClosedBottom)
B: PlasticHousing{OpenEottom)
Ful System
Y: FuelInjection
Fuel Tank
M: Metal
Standard
A: Current Evap
E: EnhancedEvap
Wild Card
(cont'd)
1-25
ControlLabel(1998modell
Under-hoodEmissions
(cont'd)
EmissionGroupldentification
Engineand EvaporativeFamilies
EngineFamily:
W HNX V 01.6JL2
Example:
Model Y6ar
W: 1998
Manutacturer
H N X :H o n d a
Type
VEHICTE
INFORIVIATION
EMISSION
CONTROL
RECULATIONSAPPLICABLE
STATOFCALTORNLA
TO 1933MOOELYEAR
NEWTLFVPASSENGEfr
V: LightDutyVehicle/Passenger
Car
Displacment
SequenceCharaqters
EvaporativeFamily:
INTBOOUCEOINTO
COMMERCE
FORSALE N TNE
CATALYST
two1r02s1?tEcR/sFt/0B0
| cEBTtF
E0
VAIVLASH
NONDAMOTORCO
LTD
50ST{50 States):
THISVEHICLE
CONFORMS
C A L I F O R N IR
A E G U L A T I O NASP P T I C A B LTEO I 9 9 8
MODELYEARNEWMOTORVEHICLES.
49ST(49 States/Fedral):
THISVEHICLE
CONFORMS
TO U.S.EPAREGULATIONS
APPLICABLE
TO 1998MODELYEARNEWMOTORVEHI.
LLEJ.
CAL (Calilornial:
THISVEHICLE
CONFORMS
C A L I F O R N IR
M O D E LY E A R N E W P A S S E N G E C
R A R SP R O V I D E D
THATTHISVEHICLE
IS ONLYINTRODUCED
INTOCOMMERCEFORSALEIN THESTATEOF CALIFORNIA,
1-26
ModlYear
W: 1998
Manufacturar
HNX:Honda
Type
E: EVAP
CaniaterWork Capacitylgrams)
SquoncaChrract6ls
W H N X E0065 AAD
Lift and SupportPoints

Lift and SafetyStands
When heavy rear componnts such as suspension, ful tank, spar6 tir, hatch, and trunk lid ara to bo
@
romovod, placa ldditional woight in the luggage rrea before hoisting. Whon substantial woight b ramovod from the r6a1
ot thc vohlcle,tha center of gravlty mty changa and can caussthe vehiclo to tip forwsld on tho hoist.
NOTE:
. Sinceeachtire/whelassemblyweighsapproximately30 lbs {14 kg). placingthe front wheelsin the luggageareacan
assistwith the weight distribution.
. Usethe samesupportpointsto supportthe vehicleon safetystands.
1. Placethe lift blocksas shown.
2 . R a i s e t h eh o i s t a f e w i n c h e (sc e n t i m e t e rasn) d r o c k t h e v e h i c l e t o b e s u r e i t i s f i r m l y s u p p o r t e d .
3. Raisethe hoisttolull height,and inspectlift pointstorsolidsupport.
REARSUPPORTPOINT
(cont'd)
1-27
Lift and SupportPoints

(cont'dl
FloorJack
l.
Set the parkingbrakeand blockthe wheelsthat are

not beinglifted.
When liftingthe rearof the vehicle,put the gearshift
lever in reverse (Automatic transmission/CW in E
position).
Alway3 u3a safoty stand3 whcn working on 01 undol

anv vchiclo that b 3upportod by only a iack.
Nover attompt to uso a bumper iack for lifting or
supporting tho vohicl.
Raisethe vehicle high enough to insert the safety

stands.
Adjust and place the safety stands so the vehicle
will be approximatelylevel.then lower the vehicle
onto them.
Center the jacking

bracket in the middle
of the jack lift platform.
LIFT PLA
REAR:
Center the jack

b.acketin the middle
of the jack lifr plattorm.
1-28
l l
k-
Towing
towIt the vehicleneedsto be towed,call a professional

ing service.Nevertow the vehiclebehindanothervehicle with just a ropeor chain,lt is very dangerous,
Front:
Em6rgencyTowing
Thereare threepopularmethodsof towing a vehicle:
Flat-bedEquipment- The operator loads the vehicle on
the backof a truck.This is the bestway oftransponing the
vehicle.
Wh6d Lift Equipmont- The tow truck usestwo pivoting
a.ms that go underthe tires (frontor rear)and liftsthem
o f f t h e g r o u n d .T h e o t h e r t w o w h e e l s r e m a i no n t h e
ground,
Sling-typ6 Equipmnt- The tow truck uses metal cables
with hookson the ends.Thesehooksgo aroundpartsof
the frame oJ suspension,and the cableslift that end of
the vehicleoff the ground.The vehicle'ssuspensionand
body can be seriouslydamagedit this methodof towing
is attemDted.
TIE OOWN HOOKS
lf the vehiclecannotbe transportedby flat-bed,it should

be towed with the front wheelsoff the ground.lf due to
d a m a g e ,t h e v e h i c l e m u s t b e t o w e d w i t h t h e f r o n t
wheelson the ground,do the following:
ManuslTransmission
and CVT
. Releasethe parkingbrake.
. Shiftthe transmissionto neutral(CVTto E position).
. Releasethe parkingbrake.
. Startthe engine.
. Shiftto lpl position,then E position.
. Turn off the engine.
CAUTION:
. lmproper towing propantion will damsgo the transmi3sion, Follow tho above procodur x6ctly. It you
cannot 3hift the lransmission 01 start th engine
(automltic trsnsmissionl.your vhicl9 mu3t be trang
portod on a ffot-bd.
It is best to tow tho vshicls no farthol th.n 5{t mibs
(80 km), lnd kosp tho sped bdow 35 mph (55 km/h).
Trying to lift or tow your vehicle by ths bumpeB will
causa sorious damage. The bumpers are not d*ignod
to support tho vohicl6'3 weight.
Roar:
TOWING
1-29
Specifications
Standardsand ServiceLimits ..............
3-2
D e s i g nS p e c i f i c a t i o n.s. . . . . . . . . . . . . . . . . . . .3. -. .15
....
Body Specifications
..........
3-18
Standardsand ServiceLimits
o
arlilil,r(rrr 6
Cylinder Head/Valve Train - Section
STANOARD
{NEW}
MEASUREMENT
Compression
250 rpm and wide open throttle

kPa (kgf/cm',psi)
Cylinder h6ad
Warpage
Height
Endplay
oil clearance
Camshaft-to-holder
Total runout
D16Y7
Cam lobeheight
Camshaft
D16Y5
D16Y8
(Cold)
Valveclearance
Valvestem O.D.
Stem-to-guideclearance
widrh
Stem installedheight
Vslvespring
Valveguide
Freelength
l.D.
Installedheight
Rockerarm
3-2
Arm-to-shaftclearance
SERVICE
UMIT
'1,270
Nominal
{13.0,184)
930 (9.5,135)
Minimum
Maximumvariation 200 Q.0,2al
o*
- gs.orta.arr- r.66gt
0.05- 0.15(0.002- 0.006)

0.050- 0.089(0.002- 0.004)
0.03(0.0 0 1 ) m a x .
lN
35.29911.3897)
EX
37.24111.4678)
Primary
38.127 1 1 . 5 1 2 9 )
IN
4l
Scondary 3 2 . 1 9 3i1.267
38,78411.5269)
IN
Primary
36.77411.4479)
Mid
38.21111.50681
Socondary 37.06511.4592)
38.00811.4964)
IN
0.18- 0.22{0.007- 0.009}
EX 0.23- 0.27(0.009- 0.0111
- 0.2161)
IN
5.48- 5.19(0.2157
- 0.2150)
EX 5.45- 5.46(0.2146
IN
0.02- 0.05(0.001- 0.002)
EX 0.05- 0.08 (0.002- 0.003)
IN
0.85- 1.15(0.033- 0.045)
EX
1.25- 1.55(0.049- 0.061)
IN
53.17- 53.6112.093- 2.112)
EX
53.17- 53.64(2.093- 2.112)
57.9(2.28)
Dl6Yt
D16Y5
IN
56,512.221
EX 57.9(2.28)
D,I6Y8
IN
58.0(2.28)
EX
58.7(2.31)
IN
5.51- 5.53(0.217- 0.218)
EX 5.51- 5.53(0.217- 0.218)
IN
17.45- 18.35(0.703- 0.722)
18.65- 19.15(0.734- 0.754)
IN
EX
- 0.0020)
0.0r7- 0.050(0.0007
- 0.054
- 0.0021
0.018
10.0007
)
0.05 {0.002)
0.5{0.02)
0.15(0.0061
0.04(0.0021
iEi.rtnut
5.12 10.21341
0.08{0.003)
0.11(0.004)
1.6(0.063)
2.0{0.079}
53.49Q.1221
53.89(2.122)
5.s5(0.219)
5.55{0.219}
0.08(0.003)
0.08(0.003)
Unitot length:mm (in)
EngineBlock- Seaion 7
MEASUREMET'lT
Cylinderblock
Piston
Pislonring
Pistonpin
STA]TDARD
INEWI
(0.003)
max.
0.07
75.00- 75.02(2.953- 2.954)
Warpageof decksurface
Eore diameter
Bore taPer
Rboringlimit
SkirtO.D. at 5 mm (0.2in)
from bottom of skirt
Cloa16ncein cylindor
Groovewidth {tor ring)
Top
Second
oil
Crankshatt
Bearings
Main bearing-to-journal
oil clearance
No. 1 and 5journals
N o . 2 . 3a n d4 j o u r n a l s
Rod bearing-to-journ8loil clarance
- 0.00'14)
0.018- 0.03610.0007
- 0.0017)
0.024- 0.042(0.0009
0.020- 0.038(0.0008- 0.0015)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
0.60 (0.024)
0.70 (0.028)
0.80(0.03r)
ororo.o'tur
ooosto.ooort
Soction 8
(NEW)
STANDARD
Capacity f (uS qt, lmp ql)
D16Y7
Dl6Y5, D16Y8
Reliofvalve
0.05{0.002)
1.05{0.041)
1.2s(0.049)
2.85(0.112)
0.13(0.005)
0.13(0.005)
- 0.0016)
0.040{0.0004
1.030(0.0402- 0.0406)
- 0.0484)
1.230(0.0480
- 0.1110)
2.820(0.1104
0.005{0.0002)
0.45{0.018)
0.04(0.002)
MEASUREMENT
Oil pump
0.010't.0201.2202.805-
Pin-to-rodinterlerence
Small end bore diameter
Largeend borediameterNominal
End play installedon crankshaft
Mainjournaldiameter
Rodiournaldiameter
Taper
Out-ot'round
Endplay
Totalrunout
o.D.
EngineLubrication
Engineoil
(2.9516)
74.970
0.15- 0.30(0.006- 0.012)

0.30- 0.45(0.012- 0.018)
0.20- 0.70 (0.008- 0.028)
18.994- 19.000(0.7478- 0.7480)
- 0.0009)
0.010- 0.022(0.0004
0.014- 0.040(0.0006- 0.0016)
18.96- 18.98{0.746- 0.747}
48.0(1.89)
0.15- 0.30(0.006- 0.012)
- 2.1654)
54.976- 55.000(2.16,14
-1.17171
44.976- 45.000/.1.1701
m6x.
0.0025(0.0001)
0.0025(0.0001)max.
0.10- 0.35(0.004- 0.014)
0.03{0.001)max.
Pin-to-pistonclearance
Connecting
roo
74.940- 74.990t2.9520- 2.95241
- 0.060
- 0.0024)
0.035
{0.0014
- 0,0022)
0.030- 0.055{0.0012
Ring-to-grooveclearance
Top
Second
Ringend gap
Top
Second
oil
SERVICE
UMIT
0.10(0.001)
75.07(2.956)
0.05(0.002)
0.5(0.02)
lnner-to-outerrotor radial clearance

Pumphousing-to'outer
rotorradialclearance
Pump housing-torotor axial clearance
Pressuresettingwith oil temperature176'F (80'C)
kPa (kg7cm,,psi)
at idle
at 3,000rpm
SERVICE
LIM]T
4.3(4.5.3.8)tor engineoverhaul
3.6(3.8,3.2)foroil change.includingfilter
3.3 (3.5,2.9)foroilchange.withoutfilter
3.7 (3.9,3.3)for engine overhaul
3.3 (3.5,2.9)for oil change,includingfilter
3.0 (3.2,2.6)Ioroil change,withoutfilter
- 0.006)
0.02- 0.14(0.001
- 0.007)
0.10- 0.18(0.004
0.03- 0.08(0.001- 0.003)
0.20{0.008)
0.20{0.008)
(0.006)
0.'15
7 0( 0 . 7 . ' 1 0 ) m i n .
340(3.5,50)min.
3-3
Cooling- Section 10
Radiator
Enginecoolantcapacity , (US qt, lmp qt)

includingengin6,heater,cooling
line and reservoir
Rosorvoircapacity:
0.41 (0.42US qt,0.35lmpqt,
Mll
Nf
CVT
Radiatorcap
Thermostat
Coolingfan
Opening pressure kPa (kgf/cm'.psi)

Start to opening 'F ('C)
Fullyopen 'F ('C)
valve lift al tully open
Thermoswitch"ON" temperature
Thermoswitch"OFF" t6mperature
STAiIDAROINEWI
MEASUREMENT
.F (.C)
"F (.C)
4.2 (4.4,3.7)tor overhaul

3.1 (3.3,2.7)tor coolsnt change
D16Y/
4.1 (4.3,3.6)tor overhaul
3.0(3.2,2.6)torcoolantchange
D16Y8
4.3 (4.5,3.8)for oveIhaul
3.2 (3.3,2.8)for coolantchange
4.3(4.5,3.8)foroverhaul
3.2 (3.3,2.8)tor coolantchango
93 - 123{0.95- 1.25,13.5- 17.8}
169- 176(76 - 80)
194(90)
8 . 0( 0 . 3 1 1 m i n .
'196- 203 (91 - 95)
"ON" temperatur
Subtract5 - 15 (3 - 8) from actual
FuelandEmission- Section11
STANDARD
{i{EWI
MEASUREMENT
Fuoltank
Pressurewith fuel pressureregulatorvacuum hose

disconnected kPa {kg7cm',psi)
CaDacity / (USqal,lmp gal)
Engine
ldle speed rpm
Fuel pr6ssu16
regulator
260- 310 (2.7- 3.2,38 - 46)

1 5( 1 1 . 9 , 9 . 9 )
M/T (neutral)
u.s.A.
016Y5
D16\.'
D16Y8
670r 50
670I 50
670I 50
M or CVr (E or E position)
Canada
u.s.A.
Canada
750r 50
750i 50
700I 50
700r 50
700f 50
750+ 50
750r 50
0.1 mx.
ldleCO %
L .
Clutch- Section12
MEASUREMENT
Clutchpedal
clutchdisc
plat
Pressure
Pedalheight
Stroko
Pedalplay
Disengaggmentheight
Clutchsurfac6runout
Rivet head depth
Thickness
Warpage
Diaphragmspringfingersalignment
STA'{DANDINEW)
(6
165 1/2)
to floo.
130- 140(5 1,4- 5 1/2)
12- 21l1t2- 13t161
to floor
83 t3 r/4)
to carpet 44(1 3/4)min.Reterence
SERVICE
UMIT
0.05{0.002}max.
0.15 (0.005)
- 0.07)
1.3- 1.9{0.05
- 0.36)
8.5- 9.1{0.33
max.
0.03(0.001)
0.6{0.02}max.
0.2(0.01)
5.510.221
0.15(0.(X)61
1.0(0.04)
ti."
3-4
Unit of length: mm (inl
ManualTransmission Section 13
MEASUREMET'lT
STANDAND
INEWI
Transmission
oil
Capacity f (US qt, lmp qt)
1.9(2.0,1.7)for overhaul
1.8(1.9,1.6)fo. oilchangs
Mainshaft
Endplay .
Diameterof ball bearingcontactarsa A
(Transmission
housingsids)
Diameterof 4th, sth gear contactarea B
Diameterof 3rd gear contactar6aC
Diameterof ball bearingcontac'tarea D
lClutchhousingsidel
Runout
- 0.007)
0.r1-0.18(0.004
- 22.000(0.8656
- 0.8661)
21.987
Mainshaft5th
gear
t.0.
Endplay
Thickness
Countershaft
Diameterof needleb6aringcontactarea A
Diameterof 1st gear contactarea B
Diameterol ball bearingcontact areaC
Runout
- 1.1817)
30.000- 30.015(1.1811
35.98,1-36.000(1.4167- 1.4173)
24.980- 24.993(0.9835- 0.9840)
max.
0.02(0.001)
Countershaftlst
gar
l.D.
Endplay(Whentightenedbylhe specifld
torque)
Thickness
t.D.
Endplay(Whentightenedby the spocitid
torque)
Thickness
t.D.
Endplay
Thickness
Countershaft2nd
gear
Spacercollar
(Countershaft2nd
gar)
Spacercollar
(Mainshaft4th
and sth goar)
LD.
Length
Length
Reverseidlergear
Synchroring
Shitt fork
Reverseshift fork
Shiftarm A
Shift arm B
Finaldrivengear
Differentielcarrier
3rd
4th
3rd
4th
o.D.
t.D.
o.D.
4th
5rh
ath
5rh
t.o.
Gear-to-revsrs6gear shaft clearance
Ring-to-gearclearance{Ring pushedagainstgear)
Forktinger thickness
lstnnd
3rd/4th
Fork-to-synchrosleeveclea16nce
Fork pawl groove width
Fork-to-revrseidler gear clarance
L-groovewidth
Fork-to-5th/reverse
shift oic6oin cl6a16nce
Inner diameterof shift arm C contactpoint
Shift arm A-to-shiftarm C clearance
Inner diameterof shift arm B shaft contact point
Shift arm B-to-shaftclearance
Shift arm B-to-shittpiece clearance
Diam6terot shift Diececontact Doint
Backlash
Pinion shaft boro diamter

Carrier-to-pinionshaft clearance
Driveshaftbore diameter
CarrieFto-driveshaftclearance
pinion Backlash
Differential
gear
Piniongear bore diameter
Piniongear-to-pinionshaft cl6aranca
Set ring.to-bearingorrterrace
Adjust
21.930(0.8634)
- 26.993(1.0622
- 1.0627) 26.930(1.0602)
26.980
33.984- 3..000fi.3380- 1.33861 33.930t1.3358)
- 1.02321 25.920(1.0205)
25.917- 25.99011.0221
max.
0.02{0.001)
- 39.025{1.5358
- '1.5364)
39.009
- 0.008)
0.06- 0.21{0.002
- 0.007)
0.06- 0.19{0.002
- 1.1921
30.22- 30.2711.190
- 1.188)
30.'t2- 30.17(1.186
37.009 37.025t1.4510- 1.15711
0.06- 0.19{0.002- 0.007)
24.42- 28.17t1.119- 1.1211
Mainshaft3rd and
4th gears
SERVICE
Ui T
0.05(0.002)
(1.538)
39.07
0.33{0.013}
0.31(0.012)
30.15(1.187)
(1.183)
30.05
37.07(1.459)
0.31(0.012)
28.35(1.1161
29.950{1.1791)
35.930(1.4146)
24.930(0.98151
0.05{0.002)
- 41.025
- 1.6152) 41.07{1.617)
41.009
t1.6145
- 0.004}
0.03- 0.10{0.001
0.22{0.009}
- 30.44
(1.197
- 1.198)
30.41
30.36(1.195)
- 44.025(1.7326
- 1.7333)
44.009
- 0.@5)
0.04- 0.12{0.002
- 3'1.96
(1.256
- 1.258'
31.91
-33.0r0
33.000
fi.2992- 1.2996)
-39.000{1.5350
- 1.535,r)
38.989
- 32.06
(1.261
- 1.262)
32.03
- 27.012
(1.06311.0635)
27.002
- 34.000(1.3381
- 1.3386)
33.989
- 32.000
(1.2594
- 1.2598)
31.989
22.83- 22.86t0.899- 0.9(X))
- 0.928)
23.53- 23.56{0.926
44.07(1.735)
0.24(0.009)
31.85(1.254)
- 0.5922)
15.016- 15.043t0.59'12
0.032- 0.077{0.0013- 0.0030)
15.08{0.594)
0.r4 (0.006)
0.73- 1.'r8(0.029- 0.046)
0.4(0.016)
6.2 - 6.1 1O.211-O.2521

7.4 - 7.6 (0.291- 0.299)
0.35- 0.65(0.014-0.026)
to roonr
33.04
fi.3011
3{'.93(1.533)
(1.260t
32.01
27.05{1.065)
33.93(1.336)
31.93(1.257)
22.81(0.898)
23.51(0.926)
- 0.5'l)
12.7- 13.0(0.50
- 0.043)
0.5- 1.1(0.020
- 0.289)
7.15- 7.35(0.281
- 0.014)
0.05- 0.35(0.002
0.5(0.02)
(0.514- 0.517)
13.05- '13.'t3
0.05- 0.23 (0.002- 0.009)
0.35{0.014}
- 14.000
- 0.5512}
13.973
{0.550r
- 0.0028)
0.013- 0.070{0.0005
- 0.020)
0.2- 0.5(0.008
12.9- 13.0(0.508-0.512)
- 0.0051)
0.07- 0.130{0.0028
- 0.7@81
- 18.028
(0.7091
18.010
- 0.0022)
0.023- 0.057t0.0009
- 26.04s
(1.0246
- 1.0254)
26.025
- 0.0034)
0.045- 0.086(0.0018
- 0.006}
0.05- 0.15{0.002
- ' I8.066
- 0.7113)
18.042
{0.7103
- 0.0037)
0.055- 0.095(0.0021
0 - 0.1(0- 0.004)
1.8(0.07)
0.16(0.006)
0.62(0.02441
't2.78(0.5031)
0.180(0.007r)
o.ogu
to.ooot
0.11{0.006)
0.15(0.006)
Adjust with shim
3-5
t t 14
t.l
Automatic Transmission-- Section
ctl;ttt
STANDARO
{NEWI
MEASUREMENT
Transmission
fluid
Capacity f {US qt, lmp q0
Hydraulic
pressure
Line pressureat 2,OOorpm in E or E position

lst clutch pressureat 2,000rpm in Pll position
.2nd clutch pressureat 2,000rpm in E position
(kgtcm', psi)
at 2,000rpm in lQl posi'

3.d and4thclutchpressure
tion
Stallspeedrpm (Chckwith vehicleon levelground)

Clutchinitialclearance
Clutch
Clutch return spring free longth
{A4RA,B4RATransmission)
(M4RATransmission)
Clutch disc thickness
Clutch plate thickness
Clutchend plate thickness
(A4RA,B4RATransmission)
Clutchend platethickness
{M4RATransmission)
5.9(6.2,5.2)toroverheul
2.7{2,9,2.4}lorfluidchange
830- 880 (8.5- 9.0,120- 130)
'124)
800- 850 (8.2- 8.7, 120with linearsolenoidconnector
disconnected
0 - 1 5 0( 0 - 1 . 5 , 0 - 2 1 )
with linear solsnoidconnectedto
batteryvoltage
- 125)
810- 860 (8.3- 8.8.1' 18
with linear solenoidconnector
disconnected
0-150(0-1.5,0-21)
with linear solenoidconnecledto
batteryvoltage
2,700
lst, 2nd
3rd, 4th
780 (8.0,110)
760 (7.7,110)
with linsar solenoid
connctordisconnected
1 5 0{ 1 . 5 2, 1 )
with linar solenoid
connectedto baftory
voltage
760 (7.8,111)
with linearsolenoid
connectordisconnocted
1 5 0( 1 . 5 , 2 1 )
with linear solnoid
connecteclto battery
voltage
2,550- 2,450
3 0 , 0{ 1 . 1 8 )
2a.st1.12)
2 9 . 1( 1 . 1 s )
28.5fi.12)
Untilgrooveswornout
Discoloration
Discoloration
II
Discoloration
Discoloration
Discoloration
\-
3- 6
0.6s - 0.85 (0.026- 0.033)

0.40- 0.60(0.016- 0.024)
32.0(1.26)
30.5{1.20)
31.1 11.22)
30.5(1.20)
1.88- 2.00(0.074- 0.079)
1.55- 1.65(0.061- 0.065)
lst
- 0.081)
2 n d , 3 r d , 4 t h 1.95- 2.0510.077
Mark 1
2.05- 2.10(0.081- 0.083)
Mark2
2.15- 2.20(0.085- 0.087)
Mark 3
2.25- 2.30{0.089- 0.091)
2.35,2.40(0.093- 0.094)
Mark 4
Mark 5
2.{5 - 2.50 (0.096- 0.098}
2.55- 2.60(0.100- 0.102)
Mark6
Mark7
2.65- 2.70(0.104- 0.106)
Mark8
2.75- 2.80(0.r08- 0.110)
2.85- 2.90(0.112- 0.114)
Mark9
Mark1
2.3 - 2.4 (0.091- 0.094)
Mark2
2.4-2.510.094-0.098)
Mark3
2.5- 2.6 (0.098- 0.102)
Mark 4
2.6- 2.7 (0.102- 0.r06)
2.7- 2.8 (0.106- 0,110)
Mark5
Mark6
2.8- 2.9(0.110- 0.114)
Mark 7
2.9- 3.0 (0.114- 0.118)
Mark8
3 . 0- 3 . 1( 0 . 1 1-8 0 . 1 2 2 )
Mark9
3.1- 3.2 (0.122- 0.126)
Mark 10 3.2- 3.3(0.126- 0.130)
M a r k1 l
2.0 - 2.1 (0.079- 0.083)
M a r k1 2 2.r ,2.2 (0.083- 0.087)
Mark13 2.2- 2.3(0.087- 0.091)
M a r k1 4 3.3- 3.4{0.130- 0.134}
Mark15 3.4- 3.5{0.134- 0.138)
Mark'16 .5 - 3.6(0.138- 0.1421
Mark 17 3.6- 3.7 (0.142- 0,146)
Mark 18 3.7- 3.8 (0.146- 0.150)
lst
2nd,3rd,4th
lst
2nd,3rd,4th
SERVTC
UM]T
unit of lngth:mm (in)
AutomaticTransmission Section 14
STANDAND NEWI
MEASUREMEifl
Transmission
Diameterof needlebearingcontsct arsa

on mainshaftstator shaft bearing
On mainshaft2nd gear
On mainshaft4th gear collar
On mainshaft1stgearcollar
On countershaft(left side)
On countershaft3rd gear collar
On countershaft4th gear
On countershaftr6versegear collar
On countrshaftlst gear collar
On reverseidler gear shaft
lnside diameterof noodlebearingcontactarea
On mainshaft1stgear
On mainshaft2nd gear
On mainshaft4th gear
on countershatt1st gear
On countershaft3rd 96ar
On countershaft4th gear
On countorshaftreversegear
On reverseidler gear
On stator shaft (ATFpump sid)
On stator shaft (statorside)
Reverseidler gear shaft holder l.D.
Endplay
Mainshatt1stgear
Mainshaft2nd gear
Mainshaft4th gear
Countelshaft1st gear
Countershaft3rd gear
Countershaft4th gear
Reverseidler gear
Countershaftreversegear
Selectorhub O.D.
Mainshaft4th gear collar lngth
Mainshatt4th gear collar flange thickness
Mainshatt1stgearcollarlength
Countershaftdistancecollar length
Countershaft3rd gear collar length
'96, '97 models

'98 model
Countershaftreverssgear collar length

Countershaltreversegear collar flange
thickness
Countershaft1st gear collar length
Countershaft1st gear collar flange thickness
LIM]T
SERVICE
22.980- 22.993(0.9047- 0.9052)

- r.4169)
3s.97s- 3s.991(1.4163
- 1.2595)
31.975-31.991(1.2589
30.975- 30.99'l(1.2195- 1.2201l- 1.4180)
36.004- 36.017(1.4175
- 1.4172)
35.980- 35.996(1.4165
- 1.1021)
27.980- 27.993(1.1016
- 1.2595)
31.975-31.991(1.2589
31.975- 31.99' (1.2589]
1.2595)
- 0.5512)
13.990- 14.000(0.5508
Wearor damage
- 1.3786)
35.000- 35.016(1.3780
- 1.6148)
41.000- 41.0't6(1.6142
- r.4967)
38.000- 38.016(1.4961
- 1.4967)
38.000- 38.016(1.4961
- 1.61481
41.000- 41.016(1.6142
- r.2998)
33.000- 33.0r6(1.2992
- 1.43671
38.000- 38.016(1.4961
18.007- 18.020(0.7089- 0.7094)
- 1.14221
29.000-29.01311.1411
27.O00- 27.021(1.0630- 1.0638)
- 0.5683)
14.416- 14.434(0.5676
Wearor damage
0.08- 0.19{0.003- 0.007)

0.05- 0.13(0.002- 0.005)
0.075- 0.185(0.003- 0.0071
0.'1- 0.5 (0.004- 0.020)
0.05- 0.17(0.002- 0.007)
0.10- 0.18(0.004- 0.007)
0.05- 0.18(0.002- 0.007)
0.10- 0.25(0.004- 0.010)
5r.87- 51.90(2.042- 2.0)
45.00- 45.03fl.771- 1.773)
- 0.178' l)
4.435- 4.525(0.1746
27.00- 27.15{1.063- 1.069}
38.87- 38.90 1.530- 1.5311
38.92- 38.95 1.532- !.533)
38.97- 39.00 1.534- 1,535)
39.02- 39.05 1.536- 1.537)
39.07- 39.'t0 1.538- 1.539)
39.12- 39.15 1.540- 1.541)
39.'17- 39.20 1.542- 1.543)
39.22- 39.25 1.544- 1.545)
39.27- 39.30 1.546- 1.547)
21.15- 21.20(0.833- 0.835)
20.65- 20.70{0.813- 0.825)
14.5- 14.6(0.571- 0.575)
2.4- 2.6{0.094- 0.102)
14.5- 14.6(0.571- 0.575)
2.4- 2.6{0.094- 0.102)
Wearor damage
Waror damage
wuu, o, du-"n"
Wearor damage
Wear or damage
Wear or damage
(cont'd)
3-7
Automatic Transmission {cont'd}
Section 14
MEASUREi'ENT
Taansmission
STANDARD
INEWI
3.974.024.074.124.174.224.274.324.371.12-
Mainshaft2nd gar thrust washgrthicknegs
Thrust wash6r thickngss

Mainehsfl ball boaring loft side
Mainshaft 1st gear
Counte6haft3rd garsplinedwasher '96,'97 models
'98 model
Rogulstor
valve body
Shifting deviceand
parking br6kecontrol
Servo body
ATFpump
DiffersntlaI
catnot
Diffsrential
piniongear
One-wayclutch contactarea
Countershaftlst gea. l.D.
Parkinggear O.D.
Mainshaftleed pipe A, O.D.(at 15 mm (0.59in) trom
end)
Mainshaftfoed pipe B. O.D.(at 30 mm {1.2in)trom end}
Countershaftfeed pipe O.D.{at 15 mm (0.59in}trom
ndl
Mainshattsealingring thickness
( 2 9m m ( 1 . 1i n ) a n d3 5 m m ( 1 . 4i n ) )
Mainshaftbushingl.D.
Mainshaftbushingl.D.
Couni6rhaft bu6hing l.D.
Mainshaftsealingring goovo widlh
Sealingring contactargo LD.
4.00(0.r56- 0.157)
4.05(0.158- 0.159)
4.10(0.160- 0.161)
4.15(0.162- 0.163)
4.20(0.164- 0. t651
4.25(0.166- 0.' t67)
4.30 (0.168- 0.1691
4.35{0.170- 0.171}
-0.1131
4.1010.172
1.15 10.171-0.1751
Wear or damage
Wsr or damag
8.95 (0.3s2)
5.95 (0.234)
7.95(0.313)
1.80{0.071)
- 0.2374)
6.018- 6.030(0.2359
- 0.3549)
9.000- 9.015{0.3543
- 8.015
- 0.3156t
8.000
{0.3150
- 0.04171
2.025- 2.075(0.0797
6.045(0.2380)
9.03 (0.356)
8.03(0.316)
2.08 (0.082)
- 35.025t1.3780
- 1.3782)
35.000
35.050(1.3799)
- 14.010{0.5512
- 0.5516)
14.000
37.000- 37.039(1.4567- 1.4582)
Set ring-to-bsaringout6r race clearance
Wear or damage
- 3.282r)
83.339- 83.365{3.2810
- 2.6259)
66.685- 66.698(2.6254
8.97- 8.98t0.353- 0.354)
- 0.2354)
5.97- 5.98(0.2350
- 0.3142)
7.97- 7.98(0.3138
- 0.078)
1.87- r.97{0.074
Shift fork shaft bore l.D.

Shift tork shaft valvo bore i.D.
ATF pump gear side clearance
ATF pump gear-to-bodyclearance
Eacklash
l.D.
Piniongear-to-pinion
shrftclearance
1I
;""i":,":",
- 0.236)
5.90- 6.00(0.232
ATF pump driven gesr l.D.

ATF pump driven gar shaft O.D.
Pinion shaft contactaroa l.D.
Carier-to-pinioncle616nc6
Driveshaftcontscl 8re LD.
Carrier-to-driveshatt
cloaranco
Wearor damage
2.95- 3.05(0.116-0.120)
2. - 2.50(0.096-0.098)
- 0.177)
4.15- 4.50(0.175
- 0.197)
4.95- 5.00(0.195
Reverseshift fork finger thickhoss

Parkingbrakopawl
Parkingggar
Drive
Drivan
SERVICEUMIT
s.40{0.213}
or otherdefect
lWear
37.045{1.4585}
0.03- 0.05{0.00t- 0.002)

0.07 (0.003)
- 0.0052}
0.r050- 0.1325
{0.0041
- 0.0025)
0.0350- 0.0625(0,00'14
- 14.034
- 0.5525} Wearor damage
14.016
{0.5518
- 0.5508) Wearor damage
r3.980- 13.990(0.5504
- 18.028{0.7091
- 0.7098)
18,010
0.023- 0.057(0.0009- 0.0022)
- 1.0254)
26.02s- 26.045{1.0246
0.045- 0.086{0.00r8- 0.0034}
0.1(0.004)
0.12{0.005)
0.05- 0.15t0.002- 0.006)

- 18.066
- 0.7113)
(0.7103
18.042
- 0.0037)
0.055- 0.095(0.0022
o"r to.ooot
0 - 0.15{0- 0.006}
Adjusr
Unit ot length:mm {in)
Automatic Transmission - Seqtion ltt

(NEWI
STANDARD
MEASUREMENT
Springs
cw
Regulatorvalve spring A
Regulator
valvespringB
Stator reactionspring
Modulatorvalvespring
Torqueconvonercheckvalvespring
Coolerreliefvalvespring
Relielvalve spring
2nd orifico control valve spring
1-2shift valve spring
2-3shiftvalvespring
3-4 shift valve spring
1st accumulatorspring
4th accumulatorspring B
4th accumulator
springA
2nd accumulalorspringA
springA
3rd accumulator
springI
2nd accumulator
3rd accumulatorspring B
2nd accumulator
springC
Lock-upshilt valve spring
Lock-uptiming v6lv6 spring
Lock-upcont.ol valve spring
3-4 orifico controlvalve spring
Servo control valve 6pring
CPCvalve spring
CPBvalve spring
1.8(0.071)
1 . 8( 0 . 0 7 1 )
4.5(0.177)
1.4(0.055)
1.0(0.039)
1.0(0.039)
1.1{0.043)
0.7(0.028)
0.9{0.035)
0.9(0.03s)
0.9(0.035)
2.1(0.083)
2.3(0.09r)
2.6(0.102)
2.4(0.094)
2.8(0.110)
1.6(0.063)
2.2(0.087)
2.210.0811
0.9{0.035)
0.9(0.035)
0.7(0.028)
0.7(0.028)
1.0(0.039)
0.6(0.024)
0.9(0.035)
0.9(0.0351
87.8(3.4s7)
44.0(1.732)
30.3(1.193)
35.0(1.378)
33.8(1.331)
3 3 . 8{ 1 . 3 3 1 )
3 7 . 1{ 1 . 4 6 1 )
34.8{1.370)
4'1.3('1.626)
57.0 t2.2441
57.0 12.2441
89.1 {3.508)
51.6{2.031)
a1.0 13.4251
39.0(1.535)
89.3(3.5161
20.7{0.815)
35.1(1.382)
68.0(2.677)
73.7 12.9021
80.7(3.r77)
38.0(1.4961
37.5( 1.4751
52.1{2.051)
12.2{0.480)
47.211.858)
36.4(1.433)
16.5
11.0
1.9
10.9
8,2
13.4
22.0
26.8
26.8
13.8
14.2
2.9
15.6
6.1
2.4
13.9
32.0
45.8
14.1
21.6
20.4
5.5
18.3
19.5
Sostion14
STANDABD
INEWI
MEASUBEMENT
Transmiasion
fluid
Capacity f (US qt. lmp. qr)
Hydraulic
pressure
MPa
(kg7cm,,psi)
Forwardclutch prssureat 1,500rpm in Lqlposition
Reverse
brakepressur
at 1,500rpm in El position
Drive pulley pre$ure at 1,500rpm in E position

Drivgn pulley pressureat 1,500rpm in Lll position
Lubricationpressureat 3.000rpm in E position
Stall sp6d rpm {Ch6ckwith vehicle on levsl ground)
E position
E, E, B positions
Clutch
14.7(0.584)
9.6(0.381)
35.4(1.407)
9.4(0.374)
8.4(0.334)
8.4{0.334)
8.6{0.342)
6.6(0.262)
7.6{0.302)
7.6{0.302)
7.6(0.302)
16.0{0.636}
r0.2 {0.402}
r7.0 (0.676)
29.0(1.152)
17.s(0.695)
9.0(0.3s8)
3 r . 01 1 . 2 2 0 )
14.5{0.576}
7.610.3021
8.1 (0.3' 19)
6.6 (0.262)
6.6 (0.262)
8.1 (0.322)
5.6(0.223)
8.1 (0.322)
6.1t0.2421
Clutch initisl clearance

Clutch return spring lree length
Clutchdisc thicknss
Clutch plate thicknss
Forwardclutch
Start clutch
Reversebrake
Forwardclutch
Start clutch
Reversebrake
Forwardclutch
Stan clutch
Roversbrake
Forwardclutch
Start clutch
Roversebrake
SERVICELIMIT
6.4 (6.8,5.6)for overhaul

3.9{4.1,3.4)for fluid change
- 17.A.203
- 2531
1.4- 1.75114.3
1.4 - 1.75 114.3- 17.8, 203- 2331
0 . 2- 0 . 71 2 .-01 . 1 , 2 8- 1 0 1 1
1.5- 2.3(15.3- 23.5.218- 334)
Above0.2(2,30)
2,500
3,000
0.6- 0.8(0.024- 0.031)
0.5- 0.7{0.020- 0.028)
0.45- 0.75(0.018- 0.030)
3 0 . 5( 1 . 2 0 1 )
40.9{1.6' t0)
29.4 t1.1571
1.88- 2.00{0.074- 0.079)
1.88- 2,00(0.074- 0.079)
1.94- 2.06{0.076- 0.081}
1.95- 2.05(0.077- 0.081)
2.25- 2.35{0.089-0.093}
1.90- 2.00(0.075- 0.079)
2.350- 2,650
2,800- 3,100
28.5 t1.122)
38.9(1.531)
27.4 11.O79J
Until groovesworn out
Untilgroovesworn out
Oiscoloration
Discoloration
Discoloration
(cont'd)
3-9
CvT {cont'dl - Section 14
STANDARD
IiIEW}
MEASUREMENT
Clutch
Forwardclutch end piate thickness
Mark 1 or 15
vlark2 or'16
Mark3 or 17
Mark4 or 18
Mark5 or 19
Mark6 or 20
M a r k 7o r 2 l
Mark8 or 22
N4ark9 or 23
Mark 10or 24
Mark11or 25
Msrk '12or 26
Mark13or 27
Reverse
brakeendplatethickness
U::I I
vlark3
vlark4
Vlark5
vlark6
t4ark7
vlark8
ATF pump
ATF pump drive gear shaft O.D.

ATF pump drivengearshaftO.D.
ATF pump body bushing LD.
Driv gar shaft

Drivengearshaft
ATFpump gearsideclearance
ATF pump gear-to-bodyclearance Drive gear
Orivengear
Transmission
3-10
Diameterof needlebearingcontactare
lnout shaft - flvwheel side
Input shaft - forward clutch side
Drive Dullevshaft - start clutch side
Drive pulley shaft - flywheel side
Drive oullev shaft - forward clutch side
Thrust clearance
Carrierand ring gear
Driven pulley shaft and start clutch hub
Input shaft and ATF pump drivon sprocket
Secondarygoar shaft and flywheel ball bearing
SERVICELMTT
3.4- 3.5(0.134- 0.138)

3.5- 3.6(0.138- 0.142)
3.6- 3.7(0.r42- 0.r46)
3.7- 3.8 (0.146- 0.150)
3.8- 3.9(0.150- 0.1s4)
3.9- 4.0{0.154- 0.157)
4 . 0 - 4 . t ( 0 . 1 5-7 0 . 1 6 1 )
4.1- 4.2(0.161- 0.165)
4.2- 4.3{0.165- 0.169}
4.3- 4.4(0.169- 0.1731
4.4- 4.5(0.173- 0.' 177)
4.5- 4.6(0.177- 0.r81)
4.6- 4.7(0.r81- 0.185)
3.55- 3.65 (0.140- 0.'|44)
3.75- 3.85(0.1 - 0.152)
3.95- 4.05(0.r56- 0.1591
4.15- 4.2s(0.r63- 0.t67)
4.35- 4.45{0.171- 0.175)
4.55- 4.65(0.r79- 0.1831
4.75- 4.85(0.187- 0.1911
4.95- 5.05{0.19s- 0.199)
9.98- 9.99 (0.3929- 0.3933)
9.98- 9.99 {0.3929- 0.3933}
10.000 10.015(0.3937- 0.3943)
10.000- 10.015t0.3937- 0.3943)
- 0.0014}
0.015- 0.035{0.0006
0.035- 0.0505{0.0014-0.0020)
0.035- 0.0505(0.0014-0.0020)
Discoloration
19.987- 20.000(0.7869- 0.7874)

19.987- 20.000(0.7869- 0.7874)
- 1.7319)
43.981- 43.991{1.7315
24.007- 24.020(0.945- 0.946)
24.007- 24.020(0.945- 0.946)
Wear or damaged
Wear or damaged
Wear or damaged
Wearor damagod
Wearor damagod
\--
Discooralron
Discootalton
Discoloration
Woar or damaged
Wsar or dmagd
Wear or damaged
W6ar or damagad
0.050(0.0021
0.050- 0.r 10 (0.0020- 0.004:))

0.000- 0.130(0.000- 0.005)
0.370- 0.650{0.015-0.026}
0.00- 0.1s(0.00- 0,006)
cw
Unit of length:mm (in)
Saction 1 4
MEASUREMENT
_.an3mission
Thrustshim.25x 31 mm thickness
conld)
Cottelslhickness
ATF pump drive sprocketthrust shim, 22 x 28 mfi

thickness
Secondarygear shaft thrust shim, 25 x 35 mm

thickngss
Input shaft l6ed pip O.D.

Drivs pulloy leed pipe
Forwardclutch feed pipe
Inputshaftbushingl.D.
Drivepullyfoed pipebushing
Forwardclutch feed pip bushing
Drivenshaft teed pipe O.D.
Start clutch f66d pipe (right side cover side)
Drivenpulleyteed pip
Start clutch feed pipe (flywhelhousing side)
DrivenpullsyshaftbushingLO.
Start clutch feed pip6 (right side cover sidel
Drive pulley feed pipe
Stan clutch feed pipe (fl)'wheelhousing sido)
drivengearsealingring groovewidth
Secondary
Stan clutch e-ndplate l.D.
Inputshaftsealingring groovewidth
Drivepulleyshaftl.D.at sealingring
Shifting device
and parking
brakecontrol
Parkingbrakocone
Parkingbrakepawl
Parkinggear
STANDARO
INEWI
1.02- 1.05(0.040- 0.041)
1.09- 1.12(0,043- 0.044)
' 1 . 1-6 1 . 1 9( 0 . 0 4 6 - 0 . 0 4 7 )
1.23- 1.26(0,048- 0.050)
1.30- 1.33(0.051-0.052)
1.37- 1.40(0.054- 0.055)
1.44- 1.47{0.057- 0.058)
1.51- 1.54(0.0s9- 0.061)
1.58- 1.61{0,062- 0.063)
1.65- 1.68(0.065- 0,066)
1.72- 1.75(0.068- 0.069)
1.79-' !.82 (0.070- 0.072)
- 0.0427)
1.05s- 1.085(0.0415
- 0.0454)
1.125- 1.155(0.0443
- 0.0482)
1.195- 1.225(0.0470
- 0.0510)
1.265- 1.295(0.0498
1.335- 1.365(0.0s26- 0.0537)
- 0.0565)
1.405- 1.435(0.0553
- 0.0593)
1.475- 1.505(0.0580
1.545- 1.575(0.0608- 0.0620)
- 0.0648)
1.615- 1.645(0.0636
- 0.0675)
1.685- 1.715(0.0663
- 0.0703)
1.755- 1.785{0.0691
(0.113
0.114)
2.87 2.90
2.97- 3.00(0.117- 0.118)
3.07- 3.10(0.121- 0.122)
3.17- 3.20(0.125- 0.126)
- 0.04st
1.12- 1.15(0.044
- 0.055)
1.37- 1.40(0.054
- 0.065)
1.62- 1.65{0.064
- 0.075)
r.87- 1.90(0.074
- 0.085)
2.'t2- 2.15(0.083
2.37- 2.40(0.093- 0.094)
- 0.112)
2.80- 2.85{0.110
- 2 . 9 5( 0 . 1 1-40 . 1 1 6 )
2.90
- 0.120)
3.00- 3.05(0.118
3 . 1 0- 3 . 1 5( 0 . 1 2-20 . 1 2 4 )
- 0.128)
3.20- 3.25(0.126
3.30- 3.35(0.r30- 0.1321
- 0.136t
3.40- 3.4510.134
- 0.140)
3.50- 3.5s10.138
- 0.1441
3.60- 3.65(0.142
- 0.148)
3.70- 3.7510.146
- 0.1521
3.80- 3.85(0.150
SERVICE
UMTT
or oamageo
or damaged
Wearor damaged
Wear or damaged
Wearor damagsd
+
I
I
Wearor damaged
or damaged
or oafiaqeo
6.97- 6.98(0.274-0.275)
- 0.4520)
11.47- 11.48(0.4516
6.95(0.274)
11.45(0.45' I)
- 0.2762)
7.000- 7,015(0.2756
- 0.4535)
11.500- 11.518(0.4528
7.030 10.2171
11.533(0.454)
6.97- 6.98(0.274- 0.275)

- 0.4520)
11.47- 11.48(0.4516
8.97- 8.98 (0.353- 0.354)
6.9510.27{}
11.45
{0.451)
8.95{0.352}
- 0.2762)
7.000- 7.015{0.2756
- 0.45351
- ' t1.518(0.4528
11.500
9.000- 9.015{0.3s4- 0.355)
2.50- 2.65{0.098- 0.104)
88.900- 88.935(3.500- 3.5011
2.00- 2.10{0.079- 0.083)
24.007- 24.020(0.945- 0.946)
7.030(0.277)
(0.454)
1'1.533
9.03 (0.3561
2.655(0.105)
Wear or damaged
2.105(0.083)
Wear or damagsd
W6ar or other defect
Wear or other dafct
Wear or other defect
(cont'd)
3-11
CW {cont'd} - Sectaon14
MEASUREMEiTT
Diffe rontiaI
carier
Pinionshaft contactarea l.D.

CarrieFto-pinion
cl6arance
Drive shaft contactarea l.D.
Carrier-to-driveshaft
clearance
Differentialpinion
gear
Backlash
t.D.
Piniongear-to-pinion
shaftclearance
Set ring'to-bearingouter raceclearance
MEASUREMENT
Springs
PH 169ulatorvalve spring
PH control valvo spring
PL 169ulatorvalve spring
PH-PLcontrolvalvespring
Clutchrducingvalvespring
Lubrication
valvespring
Shift valve spring
Shift control valve spring
Start clutch control valve spring
Pitot regulatorvalve spring
Start clutch valve accumulatorspring
Rgversecontrol valv6 spring
Shift inhibitor valve spring
STANDARD
{NEW}
- 0.7098)
18.010- 18.028(0.7091
0.023- 0.057(0.0009- 0.0022)
- 1.0254)
26.025- 26.045(1.0246
0.045- 0.086(0.0018- 0.0034)
SERVICE
LIMTT
0.1(0.004)
0.12(0.005)
(0.002
0.0s 0.15
0.006)
- 18.066
- 0.71r3)
(0.7103
r8.042
- 0.0037)
0.05s- 0.095(0.0022
nru to.oout
0 - 0 . 1 5( 0 - 0 . 0 0 6 )
Adjust
Wir. Dia.
o.D.
FJ.. Longth
No. of Coilt
1.2t0.0471
9.0(0.354)
25.7{1.051}
10.0
1.7(0.067)
13.4(0.528)
39.4(1.5511
4.7
0.9{0.035)
7.2 t0.283')
14.6(0.5751
1.0(0.039)
10.0(0.391)
31.4{1.236)
8.6
1.9(0.075)
16.8{0.661}
41.4 i'1.7481
8.0
1.6t0.063)
13.4(0.528)
51.6{2.031}
11.6
1.4{0.055}
8.2(0.323)
34.1(1.343)
13.0
1.0{0.039)
7.4{0.29r)
19.3{0.760}
0.4(0.016)
4 . 1{ 0 . 1 6 1 )
12.1(0.476)
6.8
0.6(0.024)
5.710.2211
9.5(0.374)
5.0
1.2{0.047)
8.3(0.327)
29.8('t.173)
12.3
1.2(0.047)
9.4(0.370)
31.4(1.236)
11.0
1.3{0.051)
13.2(0.s20)
48.3{1.902)
10.6
Steering- Section 17
(NEwl
STANDARD
MEASUREMENT
Steeringwheel
G6arbox
Play at steeringwheel circumference

Starting load at steeringwheel circumference
N {kgt. lbf)
lvlanualsteering
Powersteering
Enginerunning
Angle of rackguide screw loosened
M/S
trom lockedposition
Preloadat pinion gear shaft N.m (kgf.cm,lbtin) M/S
Powerstee ng
fluid
Pump pressurewith valve closed

40'C (105'F)min.,4dle.
{oiltemp./speed:
Do not run for morethan5 seconds).
kPa{kgflcmr,psi)
Recommendedpower steeringtluid
Fluid capacity f (US qt, lmp qt)
Powersteering
belt*
Deflectionwith 98 N ('10kgf, 22 lbt)

betweenpulleys
Pump
Reservoir
0-10{0-0,4)
15(1.5,3.3)
29 {3.0,6.5)
2015"
20 Max
0.5- 1.7{5 - 17,4.3- 14.8)
0 . 6 - 1 . 2( 6 - 1 2 , 5 . 2 -0 1 0 . 4 2 )
6,400- 7,400(65- 75, 920- 1.070)
HONDAPowerSteeringFluid-Vor S
0.85(0.90,0.75)
at disassembly
0.4{0.42,0.35)
10.5- 14.0{0.4'l- 0.55)with usod belt
7.5 - 10.0(0,30- 0.39)with new belt
Tonsion measuredwith belt tension gauge

N (kgt. lbf)
816A2 EngineTyp only 390 - 540 (40- 55, 88 - 120)with used belt
OtherEnginTypes
340- 490 (35- 50, 77 - 110)with used belt
816A2EngineTypeonly 740- 880 (75 - 90, 170- 200)with new belt
Othor EngineTypes
640 - 780 {65- 80, 143- '176}wirh new belt
M/S: Manual steering,P/S:Powersteering
*: When using a new belt, adjust deflectionor tensionto new values.Runthe
enginefor 5 minut6sthen turn it off.
Readjustthe deflectionor tonsionto used belt values.
3-12
Unit ot lgngth: mm (in)
Suspension Sestion18
STANDARD
I EWI
MEASUREMENT
Front
Rear
Front
Front
Rear
Camber
alagnment
Caster
Totaltoe
Frontwheelturningangle Inwardwheel
Outward wheel
Aluminumwheel
Rim runout
Steelwheel
Wheel bearing
Endplay
Axial
Radial
Axial
Radial
Front
Rear
SERV|CE
UitlT
0.00' l '1"
1.40' r 1.
In 1.0t 2.0(1/16t 1/16)
In 2.0:i3 {1/1611/15)
39"50'
33'10'(Reference)
000000-
0.7{0- 0.03)
0.7(0- 0.03)
1.0(0- 0.04)
1.0(0- 0.04)
0.05(0- 0.002)
0.05(0- 0.0021
2.0(0.08)
1.5{0.05}
2.0(0.08t
1.5(0.06)
Brakes Section 19
STANDANO
INEWI
MEASUREMENT
Parkingbrake
lever
Play in strokeat 196 N (20 kgf. 44 lbfl lover force
To be lockedwhen pulled
6 - 9 notchos
Foot brake
pedal
Pedalhoight(withfloormatrefioved)
156.5(6.16)
161(6 5/16)
1-5(1/16-3/16)
Freeplay
Mastercylinder
Disc brake
Piston-to-pushrodclarance
Discthickness
Oiscrunout
Discparallelism
Padthickness
M/T
A,/T,CW
SERV|CEUi,llT
0 - 0.4(0- 0.02)
Front
Front
Rear
Frontand rear
Front
Rearbrake
t.D.
Lining thickness
drum
*1. 5410Stampedon the caliperbody.
*2. 2056Stampedon the caliperbody.
20.9- 21.8(0.82- 0.86)
9.5- r0.5r1
8.5- 9.5*'
19.0{0.75}
0.1s,(0.004)
0.10(0.004)
0.015(0.00061
1.6{0.06)
1.6(0.06)
2000 .a7l
4.0(0.16)
201(7.911
2.0 (0.08)
- Section22
Air Conditioning
Conditioning
Compressor
Compressor
belt*
MEASUREMENT
Lubricanttype: SP-'10(P/N38897- P13- AoIAH or 3889
Condenser
Lubricantcapacity
m? lll oz,lmp oz)
Evaporator
Line or hose
Feceivr
Lubricanttype: SP-10
Lubricantcapacity mf (ll oz, lmp 02)
Fieldcoil resistanceat 68"F{20'C} o
plate clearance
Pulley-to-pressure
Deffectionwith 98 N (1Okgf,22lbtl
betweenpulleys
Belt tension N (kgf, lbf)
Measuredwith belt tension gauge
STANDARD {l{EW)
- P13- A01l{ForretrigerantHFC-134a
(R-134a})
20 l2/3 0.71
45 112f3, 1.61
10 (1/3,0.4)
1 0( 1 / , 0 . 4 )
130- 1s0(4 r/3- 4.6,5.0- 5.3)

3.05-3.35
0.5r 0.15(0.020r 0.006)
7.5 - 9.5 {0.30- 0.37)with used belt
5.0- 6.5 {0.20- 0.26)wilh new bolt
340 - 490 (35 - 50, 77 - '110)with usod belt
690 - 830 (70 - 85, 150- 190)with new blt
*: When using a new belt. adjust deflectionor tensionto new values.Run the engintor 5 minutesthen turn it off.
Roadjustdeflectionor tension to used belt values.
3-13
Electrical- Section 23
MEASUREMENT
lgnitioncoil
lgnitionwire
Sparkplug
lgnitiontiming
Alternatorbelt*
Ratedvoltage V
Primarywindingresistance
at 68'F(20'C) 0
STANDARD
INEWI
12
HITACHI 0,45- 0.55

TEC
0.63- 0.77
Scondarywinding resistanceat 68'F (20"C) kO
HITACHI 22.4- 33.6
12.4- 19.2
Resistanceat 68"F(20"C) k0
1-3-4-2
Firingorder
Tvpe
Seesection23
Gap
1,0- 1,1(0.043_ioo.)
Ar idle
12+2
" BTDC(Red)
Oetlectionwith 98 N 11okgl,22lbf'l
8.0- 10.5{0.31- 0.41)with usodbelt
6.0 8.5 (0.26 0.33)withnew belt
betlveenpulleys
Belt tension N lkgf, lbf)
340- 490(35- 50,77 - 110)with usedbelt
Measuredwith belt tension gauge
540- 740 (55- 75, 121- 165)with new belt
(NEWI
STANDARD
Alternator
(MITSUBISHI}
Startermotor
(MITSUBA
1.0kw
1.2kW)
Output 13.5v at hot A

Coil resistance(rotor) at 68'F 120"C) k0
Slip ring O.D.
Brushlength
Brushspringtonsion g (oz)
3.4- 3.8
22.7 t'.agl
1qnro76l
300- 450(10.6- 15.9)
Type
Commutator mica depth
Commutatorrunout
CommutatorO,D.
Brush l.ngth
Brushspringtension(new)
N (ksl, lbf)
Gear reduclion
0.4- 0.5 (0.016- 0.020)
0 - 0.02 (0 - 0.0008)
2 8 . 0- 2 8 . 1( 1 . 1 0-2 1 . 1 0 6 )
15.8 16.2(0.62- 0.64)
15.7- 17.7
(1.60- 1.80,3.5- 4.0)
SERVICE
UM]T
| 22.210.87)
|t -5 0
- {' 0 . 2 0 )
0.15(0.006)
0.05(0.002)
27.5(1.083)
11.0(0.43)
*: When using a new belt, adjust deflectionor tensionto new values.flun the enginelor 5 minutes then turn it off.
Readjustdeflectionor tension to used belt values.
3-14
DesignSpecifications
Unit ot lengthi mm {in)
DIMENSIONS
WEIGHT(USA)
WEIGHT(CANADA)
lTEM
METBIC
OverallLength 2 door Coupe/+door Sedan

2-door Hatchback {1996,1997)
(1998)
OverallWidth
OverallHeight 2-door Coupe/2-door
Hatchback
tl-door Sedan
Wheelbase
FronvRear
Track
GroundClearance
SeatingCapacity
GrossVehicleWeight Rsting {GVWR)
DX, HX M/I
2-door Coupe
HX A,/T
EX
HX CVT(1996)
HX CVT(1997)
2-doorHatchback CX.DX (1996,1997)
DX with ABS (1998)sMT
4AT
4-door Sedan
OX, LX M/T, LX Ay'T
LX A,/Twith ABS, EX
4,445mm
4,170mm
4,180mm
1,705mm
1.375mm
GrossVehicleWeight Rating{GVWR)
DX (1996)
2-door Coupe
DX (1997)
si(1996)
si(1997)
cX-G (1996)
2-doorHatchback cX (1996),
cx (1997),
CX-G(1997)
cx (1998),
DX {1998)
LX, EX M/T
4-door Sedan
EX A/T
ENGINE
CylinderArrangement
Bore and Stroke
Displacement
D16Y7,Dl6Y5
Compression
Ratio
016Y8
ValveTrain
LubricationSystem
Oil Pump Displacementat 6,800engine rpm
Water Pump Displacement
at 6,000engine rpm
FuelRequired
STARIER
Type/Make
NormalOutput
NominalVoltage
HourRatino
Directionof notation
1,390mm
2,620mm
1,47511
,175mm
'150mm
ENGUSH
'175.0
in
NOIES
164.2in
164.6in
67.1in
54.'1in
54.7in
103.1in
in
58.1/58.1
5.9in
3,290lbs
3,330rbs
3,440tbs
3,220tbs
3,330lbs
3,285tbs
3,290tbs
3,300lbs
3,330lbs
3,460lbs
1,500kg
1,510kg
1,560kg
1.570kg
1,495kg
1,505kg
1,510kg
1,510kg
't,540kg
wat6r-cooled,+stroke SOHC*',SOHC
VTEC'3,SOHCWEC-E*1gasolineengine
Inline 4-cylinder,transverse
2.95x 3.54in
75.0x 90.0mm
1
'1,590
97.0cu-in
cm3(m/)
1
9.4
9.6
Beltdriven,SOHC4 valveper cvlindr
Forcedand wet sump, trochoid pump
33.4f {35.3US qt,29.4lmpqt)/minute
*,: Dl6Y7
*3:Dl6Y8
*+:D'|6Y5
1251(132US qt, 110lmp qt)/minut

UNLEADEDgasolinewilh 86 Pump
OctaneNumbsror higher
gA
Gearreduction/MITSU
1.0kw, 1.2kw
12V
30seconds
Clockwise
asvigwedfrom gearend
(cont'd)
3-15
DesignSpecifications
(cont'dl
|TEM
STARTER(cont'd)
Weight
CLUTCH
ClutchType
METRIC
MITSUBA1.0,1.2kW
Mlf
CW
ClutchFacingArea
TRANSMISSION
TransmissionType
CW
PrimaryReduction
TRANSMISSION
1st
2nd
Jro
4th
5th
Beverse
FinalReduction
Gearratio
GartYPe
D16Y5
3.250
1.742
1.172
0.909
0.102
3.153
lst
2nd
3rd
4th
Reverse
Gear ratio
Geartype
Low - O.D.
Revelse
SecondaryReductionGear Ratio
FinalRgductionGearRatio
Gear Ratio
Type/Make
No. of Cylinder
Cspacity
Max.Speed
LubricantCapacity
Condenser
Type
Evaporator
Type
Blower
Type
Motor Input
SpeedControl
Max. Capacity
Refrigerant
3-16
D16Y8
3.250
1.182
1.172
0.909
0.102
3.153
3.250
1.909
1.250
0.909
0.702
3.153
4.250
*1: 2'doorHatch
oacx
*2: 2-doorCoup6,
and 4-door
Sedan
Single helicalgear
D,I6Y'
2.600
'L468
D16Y8
2.722
0.926
0.638
1.954
0.975
0.638
1.954
1.35"1
4.357
Singlehelicalgear
2.466- 0.449
2.466
4.357
3,530Kcal/h
TgmpratureControl
CompressorClutch
Enginetype
cw
Cooling Capacity
Compressor
D16r'
3.722'' 11.034*'
3.722
Automatictransmission
AIR
CONDITIONING
Enginetyp
GearRatio
Final Reductaon
NOTES
3.4kg
7.5 tbf
Single plate dry, diaphraomspring
Torque converter
Multi plateswet sanp, hydraulic
25 sq-in
160crn'
|
Synchronized5-speedforward, 1 reverse
4-speedautomatic,1 reverse
Non-stagespeedforward, 1 reverse
Direct 1 : 1
Manualtransmission
GoarRalio
ENGLISH
Type
PowerConsumption
Type
Ouantity
14,000
BTU/h
Scroll/SANDEN
u5,/ mt/tev
I
i.zz cu-rn/rev
10,000rpm
'130mf
4 1/3ll oz.
|
4 . 6 l m po z
|
fin
Corrugated
sP-10
Corrugatedfin
SiroccoIan
200w112v
4-speedvariable
460 m3/h
16.200cu-Vh
|
Dry. single plate,poly-V-belldrive
40 W max./12V at 68'F (20'C)
(R-134a)
HFC-134a
6sohs
22.9 -laoz
Unit of length mm lin)
ITEM
STEEBING
SYSTEM
METRIC
Type
P/S
M/S
OverallRatio
Turns,Lock-to-Lock
WheelDia.
Steering
SUSPENSION
Type
S h o c kA b s o r b e r
WHEEL
ALIGNMENT
Camber
Front and Rear

F r o n ta n d R e a r
Front
Rear
Front
Front
Bear
Caster
TotalToe
BRAKESYSTEM
Rear
Parking Brake
TIRE
Type
Size Front and Rear 2-door Coupe

2-door Hatchback
4 - d o o rS e d a n
S p a r eT i r e
t
WASHER
RESERVOIR
Capacity| (uS qt, lmp qt)
ELECTRICAL
Battry
Staner
I n U n d e r d a s h F u s e / R e l aB
y ox
In Under-hood Fuse/RelayBox
In Under-hood ABS Fuse/RelayBox
HighAow
Headlights
F r o n tT u r n S i g n a l / P a r k i nLgi g h t s
R e E rT u r n S i g n a lL i g h t s
Brek/Taillights
I n n e rT a i l l i g h t s * '
H i g h M o u n t B r a k L i g h t
Back up Lights
License Plate Lights
C e i l i n gL i g h t
T r u n kL i g h t s
G a u g eL i g h t s
Indicator Lights
l l l u m i n a t i o na n d P i l o tL i g h t s
Heater Control Panel Lights
NOTES
0.00'
1'40'
I n 1 . 0m m
I n 2 . 0m m
l / 1 6i n
I n 1 / 1 6i n
Power-assistedsel{-adiusting
ventilated disc
Powe.assisted self-adjusting solid disc
3 7 . 5c m , \ 2
5 . 8s q - i nx 2
4 4 . 1 c m ,x 2
Rear
ENGLISH
P o w s r a s s i s t e d r, a c ka n d p i n i o n
S a c ka n d p i n i o n
P/S:17.7,lt4/Sr20.3
P / S : 3 . 6 ,M / S : 4 . 1
380rnm
15in
i
I n d e p e n d e ndt o u b l ew i s h b o n e ,c o i l s p r i n s
T e l e s c o p i ch, y d r a u l i cn i t r o g e ng a s f i l l e d
6 . 9 4s q - i nx 2
6 7 . 2c m , x 2
10.4sq-inx2
7 . 8 s q - i nx 2
5 0 . 2c m , x 2
l,lechanicalactuating,rear Nvo wheel brakes
Unit:mm (in)
5,110Stamped on ths
2 0 5 6S t a m p e do n t h e
caliper body
O r u m l . D . : 2 0 0( 7 . 9 )
D r u m l . D . : 1 8 0( 7 . ' ! )
P175D0R18
3 2 S :D X
P 1 8 5 / 6 5 R ' 1845 S :E X , H X ( U S A ) ,S i ( C a n a d a )
P 1 7 5 t 0 R 1 38 2 S :C X , D X ( U S A ) ,C X G { C a n a d a )
P 1 7 5 t 0 R r 3 8 2 S :D X ( U S A ) ,L X ( C a n a d a )
Pl85/65R1485S: LX/EX (USA),
EX (canada)
T 1 0 5 / 8 0 D 1C
3 a r sw i t h o u t A B S E x c e p t
2 - d o o rC o u p eE X ( u S A ) ,S i
(Canada)
T 1 0 5 t 0 D 1 42 ' d o o r C o u p eE X ( U S A ) ,S ;
( C a n a d aC
) a r sw i t h o u t A B S
T 1 1 5 / 7 0 D 1D
4 X ( U S A ) ,4 ' d o o r S e d a nL X l U S A ) ,
) ars
2 - d o o rC o u p eD X ( C a n a d aC
with ABS
T 1 2 5 r 0 O 1 4C a r sw i t h A B S 2 d o o r C o u p e ,
4 d o o r S o d a nL X , E X ( U S A ) ,
4 ' d o o r S e d a nE X ( C a n a d a ) ,
) ars
2 - d o o rC o u p eS i ( C a n a d aC
with ABS
2-doot coupe 2.5 l.2.6,2.21
4'door Sedan 4.5 {4.8, 4.0}
2 - d o o rh a t c h b a c k2 . 5 ( 2 . 6 ,2.2)
4 . 5 ( 4 . 8 ,4.0)
12 V - 38AH/5HR
1 2 V - 1 . 0k W , 1 . 2k W
12V-154
USAmodel
model
Canada
DX
ExceptOX
7 . 5 A , 1 0A , 1 5A , 2 0 A
7.5 A, 10 A, 15 A, 20 A,30 A, 40 A, 80 A
7 . 54 , 2 0 A , 4 0 A
12V-60AsW
12V 21tsW
't2v - 21W
12V-21/5W
12V5W
12V_ 18W*" 21Wrl.+3
12V-21W
12V 5W
12V- 8 W (Withmoonroof)
12V-5 W (Witholtmoonroof)
12v-1.4W,3W
1 2 V - 1 . 1 2 W1 ,. 4W
1 2 V - 0 . 8 4 W1 ,. 4W
12V-1.4W
P/S:Powersteering,M/S:Manualsteering
*l: 2-doorCoupe *2: 2-doorHatchback *3: 4-doorSedan
*4: USA (HAM),Canada(HCM)produced
*5:JAPANoroduced
3-17
Body Specifications
L
2-door Coup:
U n i tm
: m( i n )
L
3-18
\,
2-door Hatchback:
lr'tgl91e'l
3-19
Body Specifications(cont'd)
L r '
4-door S6dan:
Unit:mm (in)
3-20
Maintenance
............4-2
LubricationPoints
MaintenanceSchedulefor 1996Model
........4-4
NormalConditions
4-6
.........
SevereConditions
........4-8
NormalConditions
4-10
.........
SevereConditions
........4-12
NormalConditions
.........4-14
SevereConditions
LubricationPoints
For th6 details of lubrication points and types of lubricants to b applied, rsfsr to the lllustrated Index and various work
procdurss(such as Asssmbly/Reassembly,Replacement,Overhaul,Installation,etc.)contained in each section.
No.
'I
LUBRICANONPOINIS
LUBRICANT
API ServiceGrade:Use SJ 'Energy Conserving"
grade oil.
The oil containerm8y alsodisplsythe APICenificationmark
shown below. Makesure it says "For GasolineEngines,"
SAEViscosity:Se6chart below.
Engine
Transmission
Manual
Automatic
CW
3
1
c
6
7
I
o
10
11
12
13
l'[
15
16
17
18
19
20
21
22
23
21
25
26
BrEkaLing
clutch Lin
Powr stering gesrbox
Shift leverpivots{manualtransmission)
Releasetork (manualtransmission)
Steering boots
Tailgate hinges and latches(2-door Hatchbackl
Steeringball joints
Shift lever (sutomatictransmission)
P6dallinkage
Braks mast6r cylind6r pushrod
Trunk hingesand lstch(,|-doorSedanand 2-door
Couoe)
Door hinges upper and lower
Door opening dstents
Hood hings and hood latch
Fuelfillor lid
Clutch m8st6r cylinder pushrod
Throttlecablond and thronl6linksge
Rear brakg shoe linkages
Steeringwheel (backside)
Caliper piston seal,dust seal,
caliperpin, piston
Throttle cable end (dsshboardlower Danel)
Pow6r st66ring system (for cars with P/Sl
Air conditioningcomprsssor
API SEFVICELABCL
GenuineHondaMTF*1
GenuineHondaPremiumFormula
AutomaticTransmissionFluid(ATF)*,
GenuineHondaCVTFluid'3
GenuineHond8DOT3BrakeFluid*.
GenuineHondaDOT3BrskeFluid'a
StesringgreaseP/N08733- 8070E
Gressewith molvbdenum disulfide
Super High Temp Urea Grease{P/N08798- 9002)
Multi-purposegrease
Honda White Lithim Grease
grease
Multi-purpose
Siliconsgrease
GenuineHondaPowerSteeringFluid-Vor S'5
Comoressoroil:
SANDEN:SP-10P/N38At - P13-A01AH or3@9- P13-A01
(ForR6frigsrant:
(R-f34a))
HFC-1348
API CERTIFICAIIOII SEAL
ffi
Recornmendod
EngineOil
,--;--i------
Engineoil viscosityfor
ambrenttempetureranges
NOTE: Th following information as marked *1, *2, 13, *4 and 15 on above chart details for 1997model.
Il: Alwsys use GenuineHonda MaoualTransmissionFluid (MTF).Using motor oil can causestiffer shifting becauseit
dogs not contain the propor additivs,
*2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect
shift quality.
*3: Us6 Genuin6HondaCVTfluid only. Using other fluid csn aftecttransmissionoperationand may reducetransmissionlif6.
r,l: Always uss GenuineHonda DOT3BrakeFluid. Using a non-Hondabrakefluid can causecorrosion and decressethe life
ot the system.
:5: Alwsys use Gonuine Honda Pow6r Stooring Fluid-V or S. Using 8ny other type of pow6r stssring fluid or sutomstic
transmissionfluid can causeincrasswar 8nd poor steoringin cold weathsr.
4-2
\-
@ (4{oo. s.d.n)
NOTE:Lubricateall hinges,latchesand locksoncea year.

In corrosiveareas.more frequentlubricationis necessary.
We recommendHondaWhite LithiumGrease.
4-3
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Engine
......".'.'....
5-1
EngineRemoval/lnstallation
6-1
Train ........'..'.'."..
CylinderHead/Valve
.....'.'..'7-1
EngineBlock..........
...........
8-1
EngineLubrication
System ........9-1
lntakeManifold/Exhaust
10-1
.........
Gooling
EngineRemovaUlnstallation
Removal
fnstalfation
.......5-2
...5-12
Removal
@
.
.
4.
Remove the battery and battery base.
Mako surs iacks and 3atety stands ar6 placed properly

and hoist brackets aro attached to ihe corroct positions on th engine.
Mako surc the brehiclowill not roll olf rtands and fall
whilo you are working und.r it.
I x 1.25mm
21 N.m l2.1kgl.m, 17 lbf-ftl
CAUTION:
. Uso tandar covors to ayoid damaging painted surface.
. Unplug the wiri||g connoctorscarefully whilo holding
the conn6ctor poiion to ayoid damago.
. Mrrk all wiring and hosss to lvoid misconnoction.
Abo, be sur6 that thoy do not contact other wiring or
hoss or interf?ro with othor parts,
Securethe hood as oDenas possible.
1,
2.. Disconnectthe batterynegativeterminalfirst, then

the positiveterminal.
3.
Disconnectthe battery cables from the under-hood

fuse/relaybox and battery positive terminal.
Disconnect
the connectorsfrom the ECM/PCM.
BATTERYCABLES
Disconnect
the main wire harnessconnsctor.
MAINWIREHARNESS
CONNECTOR
TERMINAL
ECM/PCM
5-2
\}
7.
Removethe intakeair duct and air cleanerhousing.
D16Y5,Dl5Y8 engines:
D16Y7enqine:
a.
a.
Removethe resonatorand intakeair duct.
D i s c o n n e c t h e I A T s e n s o r c o n n e c t o r ,t h e n
removethe intakeair duct and air cleanerhousIn g .
6x1.0mm
9.8N.m {1.0kgt.m,7.2lbt.ft)
6x1.0mm
INTAKE AIR
OUCT
INTAKE AIR
DUCT
RESONATOR
IAT SENSOR
CONNECTOR
o.
Disconnect
the intakeair temperature(lAT)sensor connector,
then removethe air cleanerhousing.
AIR CLEANER
8.
Disconnectthe engine wire harnessconnector

the leftside of the enginecompartment.
6x1.0mm
9.8 N.m 11.0kgf.m, t.2lbtft)
(cont'd)
5-3
Removal (cont'dl
9. Relievefuel pressure(seesection11),
uo not smot(ewhde working on th tuol
!@
system. Kogp open flams or spark away from tho
work arga.Drainfuel only into an approvedcoDtainer.
10. Removethe evaporativeemission (EVAp)control
canisterhoseand fuel feed hose
11. Removethe brakeboostervacuumhose,fuel return

hoseand vacuumhose.
D16Y7engine:
VACUUMHOSE
D16Y7engin:
Dl6Y5, D16Y8engines:
FUELFEEDHOSE
Dl6Y5. D16Y8engines:
BANJOEOLT
33N.m(3.4kg{.m,
2s tbf.ftl
5-4
I
12. Removethe throttlecableby looseningthe locknut,
then slip the cable end out of the acceleratorlink
age.
NOTE:
a Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
. Adjustthe throttlecablewhen installing(seesect i o n 11 ) .
1 3 . R e m o v et h e g r o m m e t a n d w i r e h a r n e s sc l a m p s ,
then pull out the ECM/PCM
connectors.
6x1.0mm
D16Y7engine:
LOCKNUT
1 4 . Removethe mountingbolt and lockbolt,then remove
the powersteering(P/S)pumpbeltand pump.

NOTE:Do not disconnect
the P/Shoses.
NUT
MOUNTINGBOLT
8 x 1.25mm
24 N.m (2.4kgf.m, 17 lbf.ftl
LOCKNUT
[ocK aoLT
8 x 1.25mm
24N.m(2.4kgf.m,17lbt.ftl
(cont'd)
5-5
Removal(cont'dl
1 5 . L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g
bolt, then remove the air conditioning(A/C)compressorbelt.
IOLERPULLEYCENTER
NUT
10 x 1.25mm
4,r N'm 14.5ksf.m.33 lbl.ftl
1 7 . R e m o v et h e c l u t c h s l a v e c y l i n d e r a n d l i n e / h o s e
assembly(M/T).
NOTE:
. Do not disconnectthe pipe/hoseassembly.
. Do not operatethe clutch pedal once the slave
cylinderhasbeenremoved.
. Takecarenot to bendthe line.
6x f.0mm
,t N.m (t.1 kg ,m,
8x1.25fifi
21N.m l2.1kgr.m,
6 tbr.ft)
17lbnftl
1 6 . Remove the transmission g r o u n d c a b l ea n d h o s e

clamp.
HOSECLAMP
6x1.0mm
18. Removethe shiftcable(CVT).

WASHER
LOCKNUT
29 N.m {3.0 kgt m, 22 lbtft)
PLASTIC
GROUNDCABLE
SHIFTCABLE
5- 6
1 9 . D i s c o n n e c t h e p o w e r s t e e r i n g p r e s s u r e( P SP )
s w i t c h c o nn e c t o r ,a n d r e m o v et h e w i r e h a r n e s s
clamp.
23. Drain the engine coolant (see page 10-6),Loosen

the drainplug in the radiator.
24. Drainthe transmissionfluid. Reinstallthe drainplug
usinga new washer(seesection13.14).
25. Drainthe engineoil. Reinstallthe drain bolt using a
new washer(seepage8-5).
26. Removethe shift rod and extensionrod (M,/T).
SHIFTROO
8 x 1.25mm
22 N.m(2-2kgf.m,16lbf,ft)
20. Remove the radiator cap.
use care when removing the radiator

E@@
cap to avoid scalding by hot coolant or steam.
27. Removethe A,/Ccompressor.

NOTE:Do not disconnectthe A,/Choses.
2 1 . Raisethe hoistto full height.

and splashshield.
22. Removethe front tires/wheels
8 x 1.25mm
2,r N.m {2.{ kgf.m, 17 lbf.ft}
6x1.0mm
9.8 N.m (1.0kd m,
7.2 rbl.ft)
A/C COMPRESSOR
SHIELD
(cont'd)
5-7
Removal(cont'd)
28. Removethe shiftcable(A,/T).

NOTE:
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one,
. Adjust the shift cable when installing(see section14).
29. Removeexhaustpipe A.
D16Y5,D16Y7engines:
8 x 1.25mm
22 N.m (2.2 kgt m, 16 lbl.ftl
Replace.
I x 1.25mm
22 N.m12.2kgd.m.
16lbtft)
SELF-LOCKING
8 x 1.25mm
16 N.m 11.6kgt.m,
12 tbf'ft|
Replace.
PIPEA
SELF.LOCKING
NUT
10 x 1.25m.n
33 N.m (3.4kgtm,
25 tbt.ftt
Replace.
{
Dl6Y8 engine:
6x1.0mm
14 N.m {1.4kgf.m. 10 lbf.ft)
8 x ' 1 . 2 5m m
22 N.m 12,2kgf.m, 16lbtftl
GASKET
Feplace.
NUT
SELF.LOCKING
8 x'1.25mm
16 N.m (1.6kg'i.m,'12lbf'ftI
Replace.
EXHAUST
PIPEA
NUT
SELF,LOCKING
10 x 1.25mm
5{ N.m {5.5kgt.m,,10lbf.tt}
Replace.
5-8
30. Removethe damperlorks (seesection'18).

Jt,
D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s
(seesection18).
Lowerthe hoist.
34. R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e sa n d
heaterhoses.
Removethe driveshafts.
CAUTION:
o Do not pull on the driveshaft, the CV ioini may
com apart.
. Use care when prying out the assembly.
Pull il straight to avoid damaging the difterential
oil seal or intermediats shaft dust seal.
RADIATORHOSE
N O T E ; C o a t a l l o r e c i s i o n - f i n i s h esdu r f a c e sw i t h
cleanengineoil. Tie plasticbagsover the driveshaft
enos.
35. R e m o v et h e A T F c o o l e rh o s e s ,t h e n p l u g t h e ATF
coolerhosesand Dipes(Ay'T).
HOSES
(cont'd)
5-9
Engine RemovaUlnstaflation
Removal(cont'd)
36. Attachthe chainhoistto the engine,
HOISTINGBRACKET
lnstall on the cylinder head
witha8xl.25mmbolr.
5-10
37. Removethe left and riqhtfront mount and bracket.
39. Removethe uooerbracket.

UPPER
4 0 . R e m o v et h e t r a n s m i s s i o nm o u n t b r a c k e t ,t h e n
removethe transmissionmount.
TRANSMISSIOt{
MOUNT
TRANSMISSION
MOUNT
BRACKET
FROI{T
MOUNT/BRACKET
Replace.
38. Remove the rear mount bracket.
4 1 . C h e c kt h a t t h e e n g i n e / t r a n s m i s s i o
i snc o m p l e t e l y
free of vacuum hoses,fuel and coolant hosesand
electricalwirino.
42. Slowly raise the engine approximately 150 mm (6 in).
Check once again that all hoses and wires are disconnectedf rom the engine/transmission
43. R a i s et h e e n g i n e a l l t h e w a y , a n d r e m o v e i t f r o m t h e
car,
5-11
t'
Installation
BracketBolts Torque Specifications:

10x 1.25mm
44 N.m {4.5kgf.m,
33 rbtft)
D16Y5.O16Y8enginGs(M/Tl:
REARSTIFFENER
10 x 1.25mm
54 N.m (5.5kgf.m,
a0 lbf.ftl
10 x 1,25mm
44 N.m {4.5 kgl.m,
33 tbtft)
8 x 1.25mm
24 N.m 12.4kgf.m, 17 lbtft)
ALTERNATOF
BRACKET
EXCEPTD16Y5, D16Y8 engines {M/T):

STIFFENER
Tightenthe boltson the stiffener
in the numberedsequenceas shown
(O-O).
O 10 x 1.25mm
44 N.m {4.5 kgf.m.
33 rbf.ft)
e)8x1.25mm
24 N.m(2.4kg[.m.
17rbt.ftl
10 x 1.25mm
/t4 N.m {4.5kgf.m,
33 rbtft)
10 x 1.25mm
,14N.m {4.5kgt m,
33 rbtftl
8 x 1.25mm
24 N.m {2.4kgf.m,
17 rbf.ft)
A/C COMPRESSOR
BRACKET
D16Y5.O16Y8
engine3lM/Tl:
FRONT
STIFFENER
8 x 1.25mm
24 N.m {2.4kgf.m,
17 tbf.ftl
E
4 6
c-tz
10x 1.25mm
44 N.m (4.5kg,tm.
33 rbf.ft,
10x 1.25mm
44 N.m {i1.5kgf.m,
33 tbtft)
ExceptCw:
Engine Installation:
Installtheenginein the reverseorderof removal.
Reinstallthe mount bolts/nutsin the followingsequence.
Failureto follow these proceduresmay causeexcessive
noiseand vibration,and reducebushinglife.
1.
TRANSMISSION
MOUNT
1 2x l 2 5 m m
64 N.m {6.5kgf.m,
17 tbt.ftl
I n s t a l lt h e t r a n s m i s s i o nm o u n t a n d b r a c k e t t, h e n
tightenthe boltson the frameside.
NOTE: Do not tighten the bolts/nutson the transmissionside.
CW:
38 N.m 13.9kgf.m,28 lbf.ftl
2.
lnstall the upper bracket,then tighten the nuts in

the numberedsequenceshown (O - @).
(412x1.25mm
?4N.m{7.5kgtm,
54 tbf.ftl
(il 12 x 1.25mm
74 N.m 17.5kg{.m,
54 rbf.ftl
UPPER
BRACKET
TNANSMISSION
MOUNTBRACKET
(cont'd)
5-13
Installation(cont'd)
Installthe rearmount bracket,then tightenthe bolts
in the numberedsequenceshown (O - @).
cvT:
4 . T i g h t e nt h e b o l t / n u t so n t h e t r a n s m i s s i o nm o u n t
bracketin the numberedsequenceshown (Ot- @).
O 12 x 1.25mm
59 N.m (6.0kgJm,
O 12x t.25mm
74N.m{7.5kg{.m,5il lbtft)
(} rbtfrl
Replace.
12x 1.25mm
59 N.m 16.0kgt'm,
a:l lbt ft)
Replace.
O 12 x 1.25mm
59 N.m 16.0kgJm,
tbf.fr)
Replace.
Except CVT:
O
't2 x 1.25mm
59 N.m 16.0kg{.m.
$ tbt.ft)
Replace.
12x 1.25mm
64 N.m (6.5 kgt.m,
47 tbtftl
5.
Tightenthe boltson the rightfront mounvbracketin

the numberedsequenceshown(O - O).
CW:
O14xt.5mm
tB N.m 18.5kgf.m,
61 tbf.ftl
Replace.
5-1 4
I
O to x t.zsmm
54N.m15.5kgt.m,
/r0 lbf.ftl
ExceptCVT:
7.
Performthe following:
a
a
a
a
a
10 x L25 mm
a4 N.m 14.5kgf.m,
33 tbt f0
Tightenthe bolts/nuton the left front mount in the

numberedsequenceshown (O - O)
O 1 2 x 1 . 2 5m m
and the
Cleanthe areaswhere the driveshaft(s)
intermediateshaft contactthe transmission(differential)thoroughlywith solvent or carburetor
cleaner.and drv with compressedair.
Checkthat the set rings on the ends of the driveshaftclickinto Dlace.
shaftand intermediate
CAUTION: Use new set rings.
Adjustthe shift cable(seesection'14,.
Adjustthe throttlecable(seesection11).
Adjustthe cruisecontrolcable(seesection23).
Refillthe enginewith engineoil (seepage8-5).
Refillthe transmissionwith fluid (seesection13,
14).
Refillthe radiatorwith enginecoolant(seepage
10-6).
Bleedair from the coolingsystemwith the heater
valveopen(seepage10-6).
Cleanthe batterypostsand cableterminalswith
sandpaper.assemblethem, then apply greaseto
prevenrcorroston.
Inspectfor fuel Ieakage(seesection11).
Afterassemblingthe tuel line,turn on {ll)the ignition switch(do not operatethe starter)so that the
fuel pump runs for approximatelytwo seconds
Repeatthis operaand the fuel line pressurizes.
tion two or threetimes,then checkfor fuel leakage at any point in the fuel line.
83 N.m (8.5 kgl.m, 61
44 N'm 14.5 kgt.m,

33 rbf.ftl
@ 12 x 1.25mm
59 N.m 16.0 kgt.m,
43 lbf'frl
Replace.
(cont'd)
5-15
(cont'd)
Installation
Mount and Eracket Bolts/Nuts Torque Value Specifications:
A: 10x '1.25mm
64 N.m (6.5 kgf.m,47 lbnft)
B r 1 0x 1 . 2 5m m
44 N.m (4.5 kgnm,33 lbift)
C : 1 2x 1 . 2 5m m
83 N.m (8.5kgf.m,61lbl.ft)
D : 1 2x 1 . 2 5m m
59 N.m (6.0kgt m, 43 lbl.ft)
Replace.
SIDEENGINE
MOUNT
RIGHTFRONT
MOUNT
5-16
SpecialTools
\
Rel. No.
o
@
@
@
@
@
orO-1
andO-2
@
Description
Tool Number
OTHAH- PJTOlOB
07JAA- 001010A
07JAB- 0010204
OTLAJ. PR3O2OB
07NAB- 0010404
07NAJ- P07010A
07406- 0020201
1A
OTMAJ- PY4O1
OTMAJ PY4O120
07406- 0070300
0 7 7 4 2- 0 0 1 0 1 0 0
oty
PageRetsrsnce
ValveGuideReamer,5.5 mm
Socket,17 mm
H o l d e rH a n d l e
Air Stopper
HolderAttachment,50 mm
PressureGaugeAdapter
A/'I PressureHose
A"/TPressureHose,2.210mm
A/T PressureAdapter
A/f Low PressureGaugeW/Panel
V a l v eG u i d eD r i v e r , 5 . m
5m
6,43
6-8,10
6-4
6-4
6-4
6-4
6-4
6-41,42
e='T------_ts
\ - J
@
\
@
6-2
.;*'
VTECControl System
Troubleshooting Flowchart
toolindicates
Diasnostic
TroubleCode(DTC)Pl259:A problemin theVTECPressure
Switchcircuitor
---tFl2Egl
Il"-:1"".
VItC Solenord
Valve
crrcuit.
Refer to page 11 38 through 11'55 before troubleshooting.

The MIL has beenreportedon.
DTCP1259is stored.
Checkthe VTECControl System:

1. Do the enginecontrolmodule
(ECM)/powertrain
control mod
(see
ule (PCM)ResetProcedLrre
section11).
2. Startthe engine.
3. Warm up the engineto normal
operalingtemperature(coolingfan comeson).
4. Do the RoadTest.*
l s D T C P 1 2 5 9i n d i c a t e d ?
* RoadTest:
A c c e l e r a t ei n l s t g e a r t o a n e n g i n es p e e do v e r 3 , 0 0 0r p m
(D16Y5engine)or 6,000rpm (D16Y8engine).
Holdthat enginespeedfor at leasttwo seconds.
lf the DTC P1259is not repeatedduring the first road test,
repeatthistesttwo moretimes.
Intermittent failure. system is OK
at this time.
Check tor poor conneqlionsor
loose wires at VTEC oressure
switch. VTECsolenoid valve and
ECM/PCM.
VTECPRESSURE
SWITCH
CONNECTOR
Test the VTECPresslre Switch:

'1. Turnthe ignitionswitchOFF.
2. Disconnectthe VTECPressure
swrtchconnector.
3. Checkfor continuitybetween
VTECpressureswitchconnector terminalNo. 1 and No. 2.
ls there continuity?
fleplace the VTEC pressrre switch.
TERMINALSIDEOF MALE
TERMINALS
vTM
/Ta
fll
\3-l
T6st the VTEC Pressur Switch

Wi16:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltagbetween
VTECpressureswitchconnec'
tor No. 1 and body ground.
{sr-ulelrt
I
{9)
Y
-L
ls thereapprox.12V?
YES
(To page6-4)
Inspect for an open oa short to

ground in the wir betweon tho
VTECpressureswitch and ECM/
PCMtCls).
It the wire is OK. sub3titute a
known-good ECM/PCM rnd
rech6ck.
WIFE SIOEOF FEMALE

TERMINALS
(cont'd)
6-3
VTECControlSystem
TroubleshootingFlowchart(cont'dl
SWITCH
VTECPRESSURE
CONNECTOR
(Frompage6-3)
Tost the VTEC Pt.ssure Switch

Wire:
Measurevoltageacrossthe VTEC
pressureswitchconnector.
ls thereapprox.12V?
Test the VTECSolonoidValve:

1. Turnthe ignitionswitchOFF.
2 . R e m o v et h e V T E Cp r e s s u r e
switch and installthe special
tool as shown,then reinstall
the VTECpressureswitch.
3. Connecta tachometer(seesect i o n1 1 ) .
4. Startthe engine.
5 - W a r m u p e n g i n et o n o r m a l
(cooling
temperature
operating
fan comeson).
6. Checkoii pressureat the following enginespeeds:D16Y5
e n g i n e :1 0 0 0a n d 3 0 0 0r p m ,
Dl6Y8 engine:1000,3000and
5000rpm.
ls pressurebelow 49 kPa
{0.5kgflcm' ,7psi)?
WIRESIDEOF FEMALE
TERMINAL
Ropair open in the wire batwe'n

VTEC Dr66ureswitch and A10 or
A23 ot tho ECM/FCM.
ll the wire ia OK, 3ubstilut a
known-good ECM/PCM .nd
rochock.
A/T LOWPRESSURE
W/PAiIEL
07406-0070300
L-
.-,,-t
HOSE
A/I PRESSURE
07i106- 0020201
N O T E : K e e p m e a s u r i n gt i m e a s s h o r t a s
possiblebecauseengineis runningwith no
load(lessthan one minute).
Insoectihe VTECsolenoidvalv6.
PRESSURE
GAUGE
ADAPTER
07NAJ - P07010A
A/T PRESSURE
HOSE,
2-210mm
07MAJ - PY4O11A
and
A/T PRESSURE
ADAPTER
OTMAJ- PY|{}l20
IOW PRESSUREGAUGE WPANEL
Test the VTECSolenoidValvel

2. Disconnect
the VTECsolenoid
valveconnector.
3. Attach the baftery positiveter
minal to the GFNIYELtermi'
nal.
4. Startthe engineand checkthe
oil pressureat the following
e n g i n es p e e d :D 1 6 Y 5e n g i n e
3000rpm, D16YBengine5000
rpm.
ls the pressureabove:D16Y5
engine:250kPa(2.5kgvcm?,
36 psi),D16Y8enginer390kPa
(4.0kgf/cm' ,57psi)?
(Topage6 5)
6-4
07406-O070300
HOSE
A/T PRESSURE
07406- 0020201
A/T PRESSURE
HOSE,
2,210nn
07MAJ - PYlOltA .nd
A/T PRESSURE
ADAPTER
OTMAJ- PYO12O
In3oocttha VTECsolonoidvalve.
PRESSURE
GAUGEADAPTER
07NAJ- P07010A
lFrom page6-4)
ECMCONNECTORS
c (3rP)
A (32P1
T6t lhe VTECPr6.sure Switch:

1. Turn the ignitionswitchOFF.
2. Reconnectthe VTEC pressure
swrtchconnector,
3. Staftthe engine.
4. With the batterypositiveterminal connectedto the VTEC
solenoidvalve,measurevoltage betweenC15 and A'10or
A.23
ls thsre approx. '12V above
5,000rpm?
WIRESIDEOF FEMALE
TERMINALS
Rplacthe VTECpressureswitch.
VTECSOLENOID
VALVE
CONNECTON
Testth. VTECSolenoidValve:
2. Disconnectthe batterypositive
terminalfrom the VTECsolenoidvalve,
the VTECsolnoidvalve conneclorterminal
No. 1 and body
grouno.
ls there14- 30 O?
tT------ I
l[-]f-r
I
I-L
I
TERMINALSIDEOF MALE
TERMINAL
ReDlacethe VTECsolonoid valve.
VTECSOLENOID
VALVE
CONNECTOR
ECMCONNECTOR
A (32P1
Tosi tho VTEC Solenoid Valv

Wi.e:
Checkfor continuity betweenthe
VTECsolenoid valve connector
terminalNo. I andA8.
ls therecontinuhy?
ws
{GRN/YELI
Rpair open in the wiro botweon

the ECM/PCM{48} and VTECaotenoid valvoconnoclor.
VTECSOLENOIDVALVE
CONNECTOR
r=
Tost tho VTEC Solenoid Valvo

Whe:
Checkfor continuity between the
VTECsolenoidvalveconnectortermin6lNo. 1 and bodyground.
ls therecontinuity?
WIRESIOEOF FEMALE
TERMINALS
t--l I
I
r5'
Y
RoDair 3hort in the wire betwoon

rho cM/PcM (A8land VIEC sotnoid valv6 connoctor,
WIRESIDEOF FEMALE
TERMINAL
Sub3tituto a known-good ECM/

PCM and roch6ck.lf symptom/
indic.tion goo3 away, .oplace
th. originel ECM/PCM.
6-5
VTECSolenoid Valve
Inspection
'1. Disconnect
'lP
the
connectorfrom the VTECsolenoid valve.
2.
Measureresistancebetweenthe terminaland body

grouno.
Resistance:14 - 30 O
4.
If the filter is not clogged,push the VTECsolenoid

valvewith your fingerand checkits movement.
.
lf the VTECsolenoidvalve is normal,checkthe

engineoil pressure.
6x1.0mm
12 N.m (1.2kgtm,8.7 lbtftl
lf the resistanceis within specifications,

removethe
V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m t h e c y l i n d e r
head.and checkthe VTECsolenoidvalve filter for
cloggrng.
.
l f t h e r e i s c l o g g i n g r, e p l a c et h e e n g i n eo i l f i l t e r
a n dt h e e n g i n eo i l .
VTECSOLENOIDVALVEASSEMBLY
VTECSOLENOID
VALVEFILTER
Replace.
6x1.0mm
12 N.m {1.2 ksf.m,8.7 lbf.tr}
o-o
VTECRockerArms
ManualInspection(D16Y5engine)
(D16Y8engine)
ManualInspection
1.
Setthe No. 1 pistonat TDC.
'1.
2.
Removethe cylinderheadcover.
2. Removethe cylinderheadcover.
Setthe No. I pistonat TDC.
NOTE:Referto page 6-46when installingthe cylinder headcover.
NOTE:Referto page6-46when installingthe cylinder headcover.
lvlovethe intakesecondaryrockerarm on the No. 1

c y l i n d em
r anually.
3 . Pushthe intakemid rockerarm on the No, I cylin-
Checkthat the intakesecondaryrockerarm moves

independently
of the primaryintakerockerarm.
d e rm a n u a l l y .
Checkthat the intakemid rockerarm movesindependently of the primary and secondaryintakerocker
arms.
MID ROCKER
ARM
SECONDARY
ROCKER
ARM
. Pushandpull.
SECONOARY
ROCKERARM
ROCKERARM
PBIMARYROCKER
PBIMARY
ARM
C h e c kt h e i n t a k es e c o n d a r yr o c k e ra r m o f e a c h
cylinderat TDC.
Checkthe intakemid rockerarm of each cylinderat

TDC.
lf the intakesecondaryrockerarm does not move,

removethe primaryand secondaryintakerocker
armsas an assemblyand checkthat the pistonsin
t h e s e c o n d a r ya n d p r i m a r yr o c k e ra r m s m o v e
smoothly.
. lf any rockerarm needsreplacing.replacethe primaryand secondaryrockerarmsas an assembly.
l f t h e i n t a k e m i d r o c k e ra r m d o e s n o t m o v e ,
removethe mid, primary and secondaryintake
rockerarmsas an assemblyandcheckthatthe pistons in the mid and primary rockerarms move
smoothly.
lf any rocker arm needs replacing,replacethe
primary,mid, and secondaryrockerarms as an
assemoly.
6-7
VTECRockerArms
(D16Y5engine)
Inspection
Using SpecialTools
CAUTION:
. Eelore using the Valve Inspection Tool. make sure
that the air pressuregaugs on the air compressor
indicatesover iloo kPa {4 kgt/cm', 57 psil.
a tnspectthe valve clearancebgfore rocker arm inspectlon.
. Coverthe timing belt with a shop towalto protect the
belt.
. Checkthe intakepdmary rockerarm of eachcylinderat
TDC.
1.
3.
Remove the sealing bolt trom the inspection hole

and connect the Valve Inspection Tool.
10 x 1.0mm
SEALINGBOLT
20 N'm {2 0 kgf'm, 14lbf'ft}
AIR STOPPER
OTLAJ- PR3O2OB
NOTE:Referto page6-46when installingthe cylinder headcover.
Plugthe reliefhole with the specialtool.
Y'
OTLAJ_ PR3O2OB
l0 x 1.0 mm
ADAPTER
TNSPECTTON
HOLE
. P u l l t h de i a a
l nd
turnto adjust,
Loosenthe regulatorvalve on the valve inspection

tool and apply specifiedair pressureto the intake
rockera.m timing piston.
SpecifiedAir Prossure:
250 kPa {2.5 kgt/cm,, 36 psil
6-8
VALVEINSPECTION
TOOL
(Commercially
available)
5.
With the specifiedair pressureapplied,push up the

timing plate;the synchronizingpiston will pop out
and engagethe intakesecondaryrockerarm.
Visuallycheckthe engagementof the synchronizing
piston.
6.
NOTE:
. The synchronizing
pistoncan be seen in the gap
betlveenthe secondaryand primaryrockerarms,
. W i t h t h e t i m i n g p l a t ee n g a g e di n t h e g r o o v eo n
t h e t i m i n g p i s t o n ,t h e p i s t o n i s l o c k e di n t h e
pushedout position.
Stop applyingair pressureand push up the timing

plate;the synchronizingpistonwill snap backto its
originalposition.
Visuallycheckthe disengagementof the synchronizingpistons.
NOTE:
. When the timing plate is pushedup, it releases
the timing piston,lettingthe returnspring move
pistonto its originalposition.
the synchronizing
. Replacethe intakerockerarms as an assemblyif
eitherdoes not work correctlt.
TIMI]TGPLATE
TIMII{GPLATE
TIMII{G
PLATE
SPRII{G
otL PASSAGE--il.
PRIMARYROCKER
ARM
SECO'{OAFY
ROCKERARII
TIMINGSPRIIIIG
RETURIT
SPRI G
SY CHRONIZING
PISTON
TIMINGPISTO
SECONDARY
ROCKERARM
1.
A|R PNESSURE
Removethe specialtools.
After inspection,
checkthat the malfunctionindicator
lamp (MlL)does not comeon.
PRIMARY
ROCKEBARM
TIMING
SYNCHRONIZI''IG
PISTON
TIMINGSPRING
6-9
I
VTECRockerArms
Inspection
Using SpecialTools(D16Y8engine)
CAUTION:
. Before using the Valve Inspection Tool, make sure
that the air pressuregauge on the air compressor
indicales over il00 kPa (4 kgt/cm,, 57 psi).
a Inspectthe valve clearancebelore rocker arm inspec.
tion,
. Cover the timing belt with a shop towel to protect
the belt.
. Checkthe intake primary rocker arm of each cylinder
at TDC.
1.
3.
Removethe sealing bolt from the inspectionhole

and connectthe ValveInspectionTool.
1 0x 1 . 0m m
SEALINGBOI-T
20 N.ln 12.0kgt.m, 14 lbf.ft)
NOTE:Referto page6-46when installingthe cylinder
neaocover.
Plugthe reliefholewith the specialtool.
Y '
\
TOOL
(Commercially
available)
. P u l l t h ed i a la n d
turn to adlust,
RELIEFHOLE
OTLAJ- PR3O2OB
6-10
4.
Loosenthe regulatorvalve on the valve inspection

tool and apply the specifiedair pressureto the rocker
arm synchronizingpistonAVB.
SDecifiedAir Prsssure:
250 kPa {2.5 kgf/cm,. 36 psi)
PRIMARY
ROCKER
ARM
MIDROCKER
ARM
7.
U s e a 1 0 m m d i a m e t e rr o d t o d e p r e s se a c h l o s t
motionassemblythroughits full movement.
Replaceany lost motion assemblythat does move
smoothly.
SECONDARY
ROCKER
ARM
TIMING
PISTON
SYNCHRONIZING
SYNCHRONIZING
PISTON
A
PISTON
B
Make sure that the intake primary and secondary
rockerarms are mechanicallyconnectedby the piston
and that the mid rockerarm does not move when
pushedmanually.
ASSEMBLY
After inspection,checkthat the MIL does not come

on.
lf any intakemid rockerarm moves independentlyof

the primary and secondaryrocker arms. replacethe
rockerarms as a set.
6-11
Valve Clearance
Adjustment
NOTE:
. V a l v e ss h o u l d b e a d j u s t e do n l y w h e n t h e c y l i n d e r
headtemperatureis lessthan 100"F(38"C).
. Alter adjusting,retorquethe crankshaftpulley bolt
(seepage6-16).
'1. Removethe cylinderheadcover.
5.
Loosenthe locknut,and turn the adjustmentscrew

until the feeler gauge slides back and forth with a
s l i g h ta m o u n to f d r a g .
D16Y7engine:
CAUTIONTDo not overtighten the locknuts; the
rockgrarms are madeol aluminum.
NOTE;RefertopageG46wheninstallingthe cylinder
neaocover.
VALVE
INTAKE
andExHAUST
LOCKNUTS
18 N.m (1.8kgt m, 13 lbf.ftl
Removethe uppercover(seepage5-19).
"UP" mark on the camSet the No. 1 pistonat TDC.
shaft pulleyshouldbe at top, and TDCmarksshould
align with the cylinderhead surface.
"UP" MARK
TOCMARKS
D16Y5, Dl6Yg engines:
INTAKEand EXHAUSTVALVE
LOCKNUTS
20 N.m 12.0kgf.m, 14 lbnft)
4.
Adiustvalveson No. 1 cylinder.

- 0.009in)
Intake: 0.18- 0.22mm 10.007
Exhaust:0.23- 0.27mm (0.009- 0.011inl
Adiusting 3crew locations:
INTAKE
No.4
No,3
o.2
t6
at^
o-tz
"/
6.
Tightenthe locknut,and checkthe clearanceagain.

Repeatthe adjustmentif necessary.
8.
R o t a t et h e c r a n k s h a f t1 8 0 " c o u n t e r c l o c k w i s teo
b r i n g N o . 4 p i s t o nt o T D C .B o t h T D C g r o o v e sa r e
onceagainvisible.Adjustvalveson No. 4 cylinder.
9.
Rotatethe crankshaft180"counterclockwise
to bring
No. 2 pistonto TDC.The "UP" mark should be on
the intakeside.Adjustvalveson No. 2 cylinder.
FEELER
GAUGE
7.
(camRotatethe crankshaft180"counterclockwise
shaftpulleyturns 90").The "UP" mark shouldbe on
the exhaustside.Adjustvalveson No. 3 cylinder.
.UP'MARK
-UP" MARK
6-13
Valve Seals
Replacement(Cylinderhead removalnot required)
N O T E :C y l i n d e rh e a d r e m o v a li s n o t r e q u i r e di n t h i s
procedure.
lntake Valve Sealsi

6,
Selectthe 7/8 in diametershort compressorattachment,and fastenthe attachmentto the No. 4 hole of

the leverarm with the speedpin supplied.
7.
lnsertan air adaptorinto the sparkplug hole.Pump

air into the cylinderto keep the valve closedwhile
compressingspringsand removingthe valve keepers.
The procedureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h

YA8845 2A7l8" attachment).
Alway wear approved eye protection when
!@
usingthe in-carvalvespringcompressol.
1.
2.
'l
Turn the crankshaftso that the No. and the No. 4
pistonsare at top deadcenter(TDC).
Removethe cylinderheadcoverand the rockerarm
assemoty.
NOTE:
. R e f e rt o p a g e 6 3 0 f o r r o c k e r a r m a s s e m b l y
removal.
W h e n r e m o v i n go r i n s t a l l i n gt h e r o c k e ra r m
a s s e m b l yd, o n o t r e m o v et h e c a m s h a f th o l d e r
b o l t s .T h e b o l t s w i l l k e e pt h e h o l d e r s ,s p r i n g s
and rockerarmson the shaft.
Referto page 6-46 when installingthe cylinder
headcover.
3.
Positionthe lever arm underlhe crossshaft so the

leveris perpendicular
to the shaftand the compressor attachmentrests on top of the retainerfor the
spring being compressed.Use the front position
slot on the leveras shown.
IN-CARSPRINGCOMPRESSOR
Removethe fuel injectorsand the wire harness.

Uslngthe 8 mm bolts suppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
c a m s h a l th o l d e r s .T h e u p r i g h t sf i t o v e r t h e c a m shaftas shown.
N O T E : P u t s h o p t o w e l s o v e r t h e o a l p a s s a g e st o
prevent the valve keepers from falling into the cylinOIL PASSAGES
5.
Insertthe cross shaft through the top hole of the

two uPflghts.
q
OIL PASSAGES
6- 1 4
L
J
9. Using a downward motion on the lever arm. compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
sPring.
15, Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spnng.
1 0 . Removethe valveseals(seepage6-38).
1 6 . Removethe valveseals(seepage6-38).
1 1 . Installthe valveseals(seepage6-43,.
1 7 . lnstallthevalveseals(seepage6-43).
1 2 . Installthe springs,the retainersand the keepersin

reverseorderof removal.
1 8 . Installthe springs,the retainersand the keepersin

ExhaustValve Seals:
1 9 . Repeatsteps6 to 18 on the othercylinders,
t5.
Selectthe 7/8 in. diametershort compressorattachment,and fastenthe attachmentto the No.2 hole of
the leverarm with the speedpin supplied.
1 4 . Positionthe lever arm underthe crossshaft so the

to the shaftand the compresleveris perpendicular
sor attachmentrests on top of the retainerfor the
spring being compressed.Use the front position
slot on the leveras shown.
N O T E :P u t s h o p t o w e l s o v e r t h e o i l p a s s a g e st o
preventthe valvekeepersfrom fallinginto the cylinder head.
IN.CABSPRINGCOMPRESSOR
7/8 in SHORTA
6-15
CrankshaftPulleyand PulleyBolt
Replacement
W h e n i n s t a l l i n ga n d tightening the pulley, follow the
procedurebelow,
1.
Tightenthe pulleybolt to the specifiedtorque.

Torque: 20 N'm (2.0 kgf.m, 14 lbf.ftl
C l e a n ,r e m o v e a n y o i l , a n d l u b r i c a t ep o i n t s s h o w n
below.
O: Clean
x: Removeany oil
a: Lub.icate
Use a felt tip pen to mark the pulley bolt head and
wasner.
CRANKSHAFT
TIMINGBELT
GUIDEPLATE
Crankshaftpully bolt siz and torque value:
14 x 1.25mm
20 N.m (2.0 kgf'm. lil lbf'ft] + 90"
EMBOSSINGMARKS
NOTE:Do not usean impactwrenchwhen installing.

3.
Tightenthe pulleybolt an additional90'.
}IOI.DERHANDII
o'JAB- tD1020A
HOLDERATTACHMENT.50 mm
07 AB - 00100A
SOCKET,17 mm
o'JAA - @1010Aot
lComm.rcillly rv.ihbl.)
MARKING
t^
at^
o-to
L-
Timing Belt
lllustrated Index
NOTE:
. Referto page6-20for howto positionthecrankshaft
andpulleybeforeinstalling
the belt.
.
a
.
.
.
Mark the direction of rotation on the belt before removing.

Do not use the upper cover and lower cover for storing removed items.
Clean the upper cover and lower cover before installing.
Replacethe camshaft seals and crankshaft seals if there is oil leakage.
Referto page 6-16 before installing the timing belt.
CYLINDERHEAD
COVER
Referto page6 46
when installing.
HEADCOVERGASKET
Replace
when leaking,
damagedor deterioraled.
Applyliquidgasketat
the tour cornersof the
recesses.
TIMINGBELT
page6-18
Inspectaon,
Adjustment,page6-18
Removal,page6-19
page6,20
lnstaliation,
@y
8 x 1.25mm
37 N.m (3.8 kg{.m.27 lbf.ftl
Applyengineoil to the bolt
threads.
CRANKSHAFT
SPEEDFLUCTUATION
ICKF)SENSOR
page6'22
Replacement,
UPPER
COVER
6x1.0mm
9.8 N.m 11.0kgf.m,
1.2 tbl.trl
RUBAERSEALS
Replace
when damaged
or deterioratod.
LOWERCOVER
RUBBER
PLUG
CRANKSHAFT
PULIEY
page6-16
Replacement,
TIMINGBELT
DRIVEPULLEY
page6-16
Replacement,
O.RING 6 x 1 . 0 m m
10r 1.25mm
Replace.1 2 N m 1 1 . 2 k g l ' m ,
4,1N.m {4.5 kgf.m, 33 lbtft)
8.7 lbf.ftl
PULLEYBOLT
1a x 1.25mm
20 N.m {2.0kgl.m,
lia lbf.ft) + 90'
Replacement,
page6-16
Do not use an impact
wranchwhen installing.
6x1.0mm
9.8 N.m ll.0 kgf.m,
7.2 tbtftt
6-17
Timing Belt
Inspection
TensionAdjustment
1 . Removethe cylinderheadcover.
CAUTION: Always adiust the timing belt tension wiih

th engine cold.
Referto page6-46when installing.
Removethe rtppercover(seepage6-19).
?
Inspectthe timing belt for cracksand oil or coolant

soaking.
NOTE:
. Replacethe belt if oil or coolantsoaked.
. Removeany oil or solventthat gets on the belt.
NOTE:
. The tensioneris spring-loaded
to applytensionto the
belt automaticallyafter makingthe following adjustmenr.
. Alwavs rotatethe crankshaftcounterclockwise
when
v i e w e df r o m t h e p u l l e ys i d e .R o t a t i n gi t c l o c k w i s e
may result in improper adjustmentof the belt tension.
. Inspectthe timing belt beforeadjustingthe belt tenston.
1 . Removethe cylinderheadcover,
.
Referto page6-46when instslling.
Removethe uppercover(seepage6-19).
Rotatethe crankshaftfive or six revolutionsto set
the belt.
4.
Setthe No. 1 pistonat TDC(seepage6-2'1).
5.
Loosenthe adjustingbolt 180'.
ADJUSTINGBOLT
44 N.m {4.5kgf m,
33 tbtft)
Rotatepulley
and inspectbelt.
After inspecting,retorque the crankshaftpulley bolt

(seepage6-16).
three teeth
Rotatethe crankshaftcounterclockwise
on the camshaftpulley.
7.
Tightenthe adjustingbolt.
After inspecting,retorquethe crankshaftpulleybolt
(seepage6-16).
Removal
NOTE:
. Replacethe timing belt at 105.000miles{168,000km)
accordingto the maintenanceschedule(normalconditions/severe
condition).
lf the vehicleregularyis driven in one or more of the
followingconditions,replaceth timing belt at 60,000
miles(U.S.A.)100,000km (Canada).
. In very high temperatures(over110'F,43"C).
. In very low temperatures{under-20"F,-29"C).
. Turn the crankshaftpulley so the No. 1 piston is at
top dead center(TDC)beforeremovingthe belt (see
p a g e6 - 2 1 ) .
. Inspectthe water pump before installingthe timing
belt {seepage10-12).
5.
Removethe dipstick,then removethe upper cover

and idler pulleybracket.
NOTE: Do not use the upper cover to store removed
|tems.
UPPERCOVER
6x1.0mm
9.8N.m {1.0kgf.m,
7.2
1 . Removethe splashshield(seepage5-7).
Loosenthe mountingbolt and lockbolt.then remove
the powe.steering(P/Slpump beltand pump.
IDLER
BRACKET
MOUNTINGEOLT
8 x 'l.25mm
24 N m {2.4 kgf.m, 17 lbt.ft)
6.
8 x 1.25mm
24 N.m l2.il kgf.m. 17 lbf.ft)
Removethe upperbracket(seepage6-29).
NOTE:
. Usea jackto supponthe enginebeforethe upper
bracketis removed.
a Make sure to place a cushion between the oil
pan and the jack.
P/S PUMP
BELT
8 x 1.25mm
24N.m(2.4kgfm, 17lbnftl
7.
Removethe crankshaftpulley(seepage6-'16).
8.
Removethe lower coverand dipstickpipe.

NOTE: Do not use the lower cover to store removed
tems.
L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g
bolt, then remove the air conditioning(A,/C)compressorbelt (seepage 5-6).
LOWER
Loosenthe mountingnut and lockbolt,then remove

the alternatorbelt.
ALTERNATOR
BELT
LOCKBOLT
8 x 1.25mm
2ir N.m 12.4kgt.m,
17 tbt.ft)
5xl.0mm
9.8Nm(1.0kgf.m.
7.2 tbt.ftl
MOUNTINGNUT
10 x 'l.25mm
44 N.m (4.5ksf.m,
33 tbtft)
(cont'd)
6-19
Timing Belt
Removal(cont'dl
Installation
9. Removethe CKFsensorfrom the oil oumo.
'i
Installthe timing belt in the reverseorderof removal;

Only key pointsare describedhere.
1.
Set the timing belt drive pulleyso that the No. 1 piston is at top deadcenter(TDC).Align the grooveon
the timing belt drive pulleyto the pointeron the oil
oumo.
TDCMABK
FOINTER
12 N.m lr.2 kglm,

8.7 tbt.trl
1 0 . Loosenthe adjustingbolt 180".Pushthe tensioner

t o r e m o v e t e n s i o n f r o m t h e t i m i n g b el t , t h e n
retightenthe adjustingbolt.
ADJUSTINGBOLT
+l N.m 14.5kgl.m,
33 tbtftt
11. Removethe timing belt.
TIMING BELT
ORIVEPULLEY
Clean.
2.
KEY
Set the camshaft pulley to TDC. Align the TDC

marks on the camshaft pulley to the cylinder head
surface.
a
3.
Installthe timing belttightly in the sequenceshown.

j@Adjusting
oTiming belt drive pulley(crankshaft)
pulley.
pulley-)@Waterpump pulley'-r@Camshaft
9. Checkthat the crankshaftpulley and camshaftpulley are both at TDC.

CRANKSHAFTPULLEY:
N O T E :M a k es u r et h e t i m i n g b e l t d r i v e p u l l e ya n d
camshaftDullevare at TDC.
(WHITEI
CAMSHAFTPULLEY:
"UP" MARK
Loosenand retightenthe adjustingbolt to tension

the timing belt.
Installthelowercoverand uppercover.
N O T E :C l e a nt h e u p p e r a n d l o w e r c o v e r sb e f o r e
installation.
6.
Installthe crankshaftpulley,then tightenthe pulley

bolt (seepage6-16).
7.
Rotatethe crankshaftpulley about five or sjx turns

counterclockwise
so that the timing belt positions
on the pulleys.
Adjustthe timing belt tension(seepage6-18).
TOC MARK
'10. l f t h e c a m s h a f to r c r a n k s h a f p
t ulleyis not positioned at TDC, remove the timing belt and adjust
the positionfollowingthe procedureon page 6-20.
Then reinstallthe timing belt.
' It . After installation,
adjustthe tensionof eachbelt.
.
.
.
See section23 for alternatorbelt tensionadjustment.

See section22 fot NC compressorbelt tension
adJustment.
Seesection 17for P/Spump belt tensionadjustment.
6-21
CrankshaftSpeedFluctuation
(CKF)Sensor
Replacement
1.
NOTE:Referto page6 46 when installing.
Removethe crankshaftpulley(seepage6 16).
R e m o v et h e u p p e r c o v e r a n d d i p s t i c k / p i p e( s e e
p a g e6 1 9 ) .
R e m o v et h e l o w e r c o v e r a n d i d l e r p u l l e yb r a c k e t
(seepage6-19).
Disconnectthe CKFsensorconnector,then remove
the CKFsensor.
CKFSENSOR
CONNECTOR
CKFSENSOR
6.
6x1.0mm
12 N.m {'1.2kgf.m,
8.7 tbtftl
InstalltheCKFsensorin reverseorderof removal.
6-22
CylinderHead
lllustratedIndex
CAUTION:
. To avoid damage, wait until the engine coolant temperature drops below 100"F138'Clbetore removing the cylinder
head.
. When handling a metal gaskel, take care not to told it or damagethe contact surface.
NOTE:Usenew O-ringsand gasketswhen reassembling.
WASHER
Replace
when damaged
or deteriorated.
CYLINDERHEAO
COVEB
Beferto page6-46,when
installingcylinderheadcover.
6x1.0mm
9.6 N.m (1.0kgf.m,7.2lbtft)
Applysoapsuds
to threadsand cylinderhead
contactsurfacewhen replacingthe rubber
seal,then remove any soapsudsafter installing rubberseal.
RUBBERSEAI.
Replacewhen damaged
or deteriorated.
CYLINDERHEADBOLT
10 x 1:25mm
67 N.m 16.8kgt.m, a9 lbf.ftl
Tightening,page&46
Applyongin6oilto the threads.
HEADCOVERGASKET
Replace
when leaking,
damagedor det6riorated.
Apply liquidgasketat
the four cornersofthe
recesses.
OISTRIBUTOR
Seesection23.
CYLINDER
HEAD
CYLINDER
HEAD
GASKET
Replace.
8 x 1.25 mm
24 N.m {2.4 kqf.m,
17 tbf.ftl
8 x 1.25mm
24 N.m (2.,0kgf.m, 17 lbfft)
OOWEL
PINS
{cont'd)
6-23
Cylinder Head
lllustratedIndex(cont'dl
Priorto.reassembling,
cleanall the partsin solvent,dry them and applylubricantto any contactparts.
D16Y7engine:
ROCKER
ARM
ASSEMELY
Bemoval,page6-30
page6-35
Inspection,
I x 1 . 2 5m m
20 N.m 12.0kgf.m, 14 lbf.ftl
Applyengineoil 10the
6x1.0mm
12 N.m (1.2kgf.m, 8.7 lbf.ft)
Applyengineoil to the
threaos.
VALVEKEEPERS
c"
B
AKE VALVE
SPRING
OIL CONTROL
ORIFICE
Clean.
AKEVALVESEAL
ReplaceVALVESPRING
SEAT
O-RING
Replace.
INTAKEVALVE
GUIDE
VALVEKEEPERS
SPRINGRET
EXHAUSTVAL
SPRING
EXHAUST
VALVE
SEAL
Replace.
8 x 1.25mm
37 N.m (3.8kgtm,
27 tbt.ftl
Applyengineoil to
the threads.
VALVESPRING
SEAT
EXHAUSTVALVE
GUIDE
page6-39
Inspection,
Replacement,
page6-41
Reaming,page6,43
INTAKEVALVE
Removal,page6-38
page6-43
Installation,
6-24
EXHAUST
VALVE
Removal,page6 27
Warpage,page 6-40
Valveseatreconditioning,
page 6-40
page6 45
Installation,
D16Y5engine:
8 x 1.25mm
20 N.m 12.0kg{.m, 14 lbf.ft)
Apply engineoilto the
threads,
ROCKERARM
ASSEMBLY
Removal,page6-30
page6-34
Inspection,
6x1.0mm
12 N.m {1.2kgf.m.8.7 lbf.ftl
Apply engineoilto the
threads,
CAMSHAFT
page6-36
Inspection,
6x1.0mm
12 N.m 11.2
8.7 rbt.ftl
VALVEKEEPERS
SPBINGRETAINER
wEc solENoro
INTAKEVALVE
SPRING
VALVE
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
INTAKEVALVE
GUIDE
VTECSOLENOID
VALVEFILTER
Replace.
OIL CONTROL
ORIFICE
Clean.
CAMSHAFT
PULLEY
VALVEKEEPERS
SPRINGRETAINER
EXHAUSTV
SPRING
EXHAUSTVALVE
SEAL
Beolace.
'
VALVE
SEAT
8 x 1.25mm
37 N.m 13.8kgf.m,
27 lbl-ltl
Applyengineoilto
the threads.
Replace.
GUIDE
page6 39
Inspection,
page6-41
Replacement,
Reaming,page6-43
EXHAUST
VALVE
INTAKEVALVE
Removal,page6-38
page6-43
Installation,
OIL SEAL
Replace.
HEAD
Removal,page6'27
Warpage,page6-40
page 6-40
page6-45
Installation,
(cont'd)
6-25
CylinderHead
lllustrated Index (cont'd)
'E
Priorto reassembling,
creanallthe partsin sorvent,dry them and apply rubricantto any contactparts.
D16Y8engine:
I x 1.25mm
2 0 N . m { 2 . 0k g f . m , 1 4 l b f f t l
Apply engine oil to the
threads.
LOSTMOTION
ASSEMBLY
6x1.0mm
12 N,m 11.2kgf m, 8.7 lbl ft)
Applyengineoil to the
threads.
ROCKERARM
ASSEMBLY
Bemoval,page6 30
Inspection,
page6-34
CAMSHAFT
lnspection,
page6 36
6x1.0mm
12 N.m (1.2
8,7 tbf.fil
VAI-VEKEEPERS
SPRINGRETAINEF
"E
F
INTAKEVALVE
SPRING
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
WEC SOLENOID
VALVEFILTER
Replace.
INTAKEVALVE
GUIOE
OIL CONTROL
ORIFICE
Clean.
VALVEKEEPERS
SPRINGRET
EXHAUSTVALVE
SPRING
EXHAUSTVALVE
SEAL
Replace.
O-R|NG
EXHAUSTVALVE
Reptace
cUtDE
lnspection,
page6-39
Replacement,
page6-41
Reaming,page6-43
8 x 1.25mm
37 N.m 13.8kgtm.
21 tbt.ftl
A p p l ye n g i n eo i l t o
the threads_
otL
Replace.
INTA(E VALVE
EXHAUST CYLINDERHEAD
Removal,page6 38 VALVE
Removal,page6-27
Installation,
page6,43
Warpage,page6 40
page6'40
lnsta,'ation,page6-45
6-26
\$
Removal
Engineremovalis not requiredfor this procedure.
Make surs lacks and safety stands are
@
placed properly and hoist brackets are aftached to the
corrcct positions on ihe engins,
CAUTION:
. Uso fonder covers lo avoid damaging painted surfacss.
. Unplug the wiring conneqtorscarefully while holding
th9 conngctol portion to avoid damage.
. To avoid damaging the cylinder head, wait until the
e n g i n e c o o l a n l t e m p o r a t u r od r o p s b e l o w 1 0 0 ' F
(38"G)before looseningthe retaining bolts,
8.
Removethe throttlecableby looseningthe locknut,

then slip the cableend out of the throttlelinkage.
NOTE:
. Takecarenot to bendthe cablewhen removingit.
Alwaysreplaceany kinkedcablewith a new one.
. Adjustthe throftlecablewhen installing(seesection11).
D16Y7engine:
LOCKNUT
NOTE:
o Mark all wiring and hoses to avoid misconnection.
Also. be surethat they do not contactother wiring or
hoses.or interferewith other parts.
. Inspectthe timing belt before removingthe cylinder
head.
pulleyso thatthe No. 1 pistonis at
. Turnthe crankshaft
top deadcenter(seepage6-21).
L
Disconnect
the negativeterminalfrom the battery.
Drainthe enginecoolant(seepage10-6).
.
Removethe radiatorcapto speeddraining.
Removethe intakeair duct and air cleanerhousing

(seepage5-3).
R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t , t h e n
remove the power steering (P/S) pump belt and
pump (seepage5-5).
L o o s e nt h e i d l e r p u l l e y c e n t e rn u t a n d a d j u s t i n g
bolt, then remove the air conditioning{Ay'C)
compressorbelt (seepage5-6).
L o o s e nt h e m o u n t i n g n u t a n d l o c k b o l t . t h e n
removethe alternatorbelt (seepage6-19).
7.
Removethe P/Spump bracket{seepage5-12).
{cont'd)
6-27
CylinderHead
Removal(cont'dl
9. Relievefuel pressure(seesectionl1).
Do not smokewhile working on the fuel
E@
systgm. Keep opn flame or 3park away from th9
work area. Drain tuel only into an approved containgr.
10. Removethe evaporativeemission (EVAP)control
canisterhose,fuel feed hoseand breatherhose.
11. Removethe brakeboostervacuumhose,fuel return

hoseand vacuumhose(seepage5-4).
12. Removethe water bypasshose and positivecrankcaseventilation(PCV)hose.
D16Y7engine:
WATEBBYPASS
D16Y7engine:
BANJOBOLT
33 N.m{3.4kgf.m,
25tbtftl
BREAIHERHOSE
D15Y5, D16Y8 engines:

BANJO BOLT
33 N.m 13.4kgf.m,
2s tbf.ft)
6-28
PCVHOSE
1 3 . R e m o v e t h e u p p e r radiatorhose, heater hose and

water bypass hose.
1 5 . R e m o v et h e s p a r kp l u g c a p sa n d d i s t r i b u t ofrr o m
the cylinderhead.
16. Removethe upperbracket.
WATER
BYPASS
HOSE
UPPER
RADIATOR
HOSE
NOTE:
. U s e a j a c k t o s u p p o r tt h e e n g i n eb e f o r et h e
upperbracketis removed.
. M a k e s u r e t o p l a c ea c u s h i o nb e t w e e nt h e o i l
pan and the jack.
12x 1.25fim
7{ N.m (7.5kgt m,
54 tbf.ftl
UPPER
BRACKET
HEATER
HOSE
and
1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r s
wire harnessclampsfrom the cylinderheadand the
intakemanitold.
a Fourfuel injectorconnectors
a E n g i n ec o o l a n tt e m p e r a t u r e( E C T )s e n s o rc o n -
17. Removethe cylinderheadcover.
nector
a ECTswitchconnector
a ECTgaugesendingunit connector
a Throttlepositionsensorconnector
M a n i f o l da b s o l u t ep r e s s u r e( M A P )s e n s o rc o n
nector
P r i m a r yh e a t e do x y g e ns e n s o r( p r i m a r yH O 2 S )
connector
S e c o n d a r yh e a t e do x y g e n s e n s o r ( s e c o n d a r y
HO2S)connector(D16Y7engine)
Exhaustgas recirculation(EGR)valve lift sensor
connector(D16Y5engine)
VTECsolenoid valve connector(Dl6Y5, D16Y8
engrnes)
VTECpressureswitch connector(D16Y5,D16Y8
engrnes,
ldle air control(lAC)valveconnector
(cont'd)
',l
6-29
CylinderHead
RockerArms
Removal(cont'd)
Removal
1 8 . Removethe timing belt (seepage6-19).
1.
1 9 . Removethe camshaftpulleyand backcover.
Loosenthe adjustingscrews.
ADJUSTINGSCREWS
CAMSHAFT
PULLEY
Cleanwhen installing.
6xl.0mm
8 x 1.25mm
37 N.m {3.8kgf.m,
2't tbftr)
f:,f'In:J$::'"''n"
2.
20. Removethe exhaustmanifold(seepages9-5and9-6).
21. Removethe intakemanifold(seepages9-2thru 4).
22. Removethe cylinder head bolts, then removethe
c y l i n d e hr e a d .
CAUTION:To prevnt warpage, unscrew the bolts
in sequencel/3 turn at a time; repeat the sequence
until allbolts are loossned.
CYLINDERHEADBOLTSLOOSENINGSEOUENCE:
6-30
Unscrewthe camshaft holder bolts, then remove

the rockerarm assembly.
NOTE:
. Unscrewthe camshaftholderboltstwo turns at a
time, in a crisscrosspattern,to preventdamag
ing the valvesor rockerarm assembly.
. When removingthe rockerarm assembly,do not
removethe camshaftholderbolts.The bolts will
keep the camshaftholders,the springsand the
rockerarms on the shaft.
CAMSHAFTHOLDERSOLTSLOOSENING
SEOUENCE:
Disassembly/Reassembly
NOTE:
. ldentifypartsas they are removedto ensurereinstallation
in originallocations.
. Inspectrockershaftsand rockerarms (seepage6-35).
. Rockerarms must be installedin the samepositionif reused.
. When removingor installingtherockerarmassembly,do not removethecamshaftholderbolts.The boltswill keepthe
holders,springsand rockerarmson the shaft.
Priorto reassembling,
cleanall the partsin solvent,dry them and apply lubricantto any contactpoints.
D16Y7 engine:
INTAKE ROCKER
ARM B
(4 pl.corl
INTAKEROCKER
ARMA
la pl.c$l
INTAKEROCKER
Letter "8" is stamped

on rockerarm.
II
ROCKERSHAFT
COLLAR
14placesl
"
ofr
dT*,.\ft
ffi*
t.l G t I
"' r' lJll--
No.3CAMSHAFT| | No.2CAMSHAFTIl
HoLDER
Lal HoLDER
[6]
I ru
n] [n, ,d"h] H
\d*hl
UTU
" l ^
R(rcKERSHAFT
SPRING
(4 plac.Bl
(cont'd)
6-31
RockerArms
(cont'd)
NOTE:
. ldentifypansastheyareremoved
to ensurereinstallation
in originallocations.
. Inspect
rockershaftsandrockerarms(seepage6-34).
. Rockerarms must be installedin the same positionif reused.
. When removingor installingthe rockerarm assembly,do not removethe camshaftholderbolts.The boltswill keepthe
holders,springsand rockerarms on the shaft.
/E
P r i o r t or e a s s e m b l i ncgl ,e a na l l t h e p a r t si n s o l v e n td, r y t h e ma n da p p l yl u b r i c a n t t oa n yc o n t a cpt o i n t s .

SHAFT
INTAKE
ROCKER
D16Y5engine:
ROCKERARMS
ROCKERSHAFT
COLLAR
No. 5 CAMSHAFT
HOLOER
[u
Hlw
l
'l
I
EXHAUSTROCKER
ARM 8
{4 placesl
EXHAUST
ROCKERARM A
14placesl
IR SHAFT
EXHAUSTROCKERSHAFT
Letter"8" is stamped
on rockerarm.
6-32
Letter "A" is stamped
D16Y8engine:
INTAKEROCKERSHAFT
ROCKERSHAFT
COLLAB
INTAK
BOCKERARM
ASSEMBLY
ROCKERARMS
"o,_.-o"
RUBBERAAND
coLLAR
,mil
\
tre /
0lluIJllt
LF
fla
H+nllf{
-
u
lu!4
Etue t
J
rs,urtg
I
l-
,fxll^\
rvni<
No. 4 CAMSHAFT
HOLDER
No. 3 CAMSHAFT
HOLDEB
NO,1 CAMSHNFT
HI
No. 2 CAMSHAFT
HOLDER
H.LDER
r-{W
l-t fll
)rJfiF
l-Jf
t v t
\
FOCKEBSHAFT
SPRING
(4 place3)
ARM B
-.\
XHAUST
ROCKEBA8M
{4 placesl
EXHAUSTROCKERSHAFT
Letter
"B"
is stamped
Letter
"A"
is stamped
6-33
RockerArms and Lost Motion Assemblies

(D16Y5,
Inspection
D16Y8enginesl
N O T E :W h e n r e a s s e m b l i n gt h e p r i m a r y r o c k e ra r m ,
c a r e f u l l ya p p l y a i r p r e s s u r et o t h e o i l p a s s a g eo f t h e
rockerarm.
1.
\.
D16Y5engine:
NOTE:Set the timing plate and returnspring as shown
Inspectthe rockerarm piston.Pushit manually.

- lf it does not move smoothly,replacethe rocker
arm assemory.
RETURN
D16Y5engine:
PRIMARYROCKERARM
TIMINGPISTON
TIMI G SPRING
SYNCHRO ENG
PISTOI{
CAMSHAFTHOI.DER
D16Y8engine:
.{
2.
Removethe lost motion assemblyfrom the holder

and inspectit. Test it by pushingthe plungerwith
your finger.
- l f t h e l o s t m o t i o n a s s e m b l yp l u n g e rd o e s n o t
move smoothly,replaceit.
MIOROCKEBARM
Pu!h
PRIMARYROCKER
LOSTMOTONASSEMBLY
sYt{cHRof$ztlrlc
PISTON
A
NOTE:
. Apply ojlto the pistonswhen reassembling.
a Bundlethe rockerarms with a band to preventthem
from separating.
6-34
RockerArms and Shafts

lnspection
Clearance
Measureboth the intakerockershaft and exhaustrocker
shaft.
1.
Measurethe diameterof the shaftat the first rocke.

tocauon.
2.
Zerothe gaugeto the shaftdiameter.
3.
Measurethe insidediameterof the rockerarm and

checkfor an out-of-roundcondition.
RockerArm-to-Shaft Clearance:
Standard lNew):
Intake:
0.017- 0.050mm
- 0.0020in)
(0.0007
Exhaust: 0.018 0.054mm
(0.0007- 0.0021in)
ServiceLimit:0.08mm (0.003in)
Inspectrockerarm
Reoeatthesemeasurements
on all the rockers.
- lf the clearanceis overthe servicelimit, replacethe
rockershaftand all overtolerancerockerarms.
6-35
r,
Camshaft
Inspection
NOTE:
. Do not rotatethe camshaftduring inspection.
. Removethe rockerarms and rockershafts.
L
Put the camshaftand the camshaftholderson the

cylinderhead,then tightenthe boltsto the specified
torque.
Spocifiodtorqu:
8 mm bolts: 20 N.m 12.0kgf.m 14 lbf'ft)
Apply engine oil to the threads.
6 mm bolts: 12 N.m (1.2 kgf.m 8.7 lbf.ft)
Apply engine oil to the th.eads.
'u
Seatthe camshaftby pushingit toward the rear of
the cylinderhead.
Zerothe dial indicatoragainstthe end ofthe camshaft.
Push the camshaftback and forth, and .ead the end
olav.
Camshaft End Play:
Standard{New):0.05- 0.15mm
(0.002- 0.006in)
ServiceLimit: 0.5 mm (0.02in)
6 mm bolts:@, @ @, @
.g
Removethe bolts.then removethe camshaftholders from the cvlinderhead.

- Lift the camshaftout of the cylinderhead,wipe it
clean. then inspect the lift ramps, Replacethe
c a m s h a f ti f a n y l o b e s a r e p i t t e d . s c o r d ,o r
excesslvely
worn.
- Cleanthe camshaftbearingsurfacesin the cylinder head,then set the camshaftbackin place.
- Placea plastigagestrip acrosseachjournal.
Installthe camshaftholders,and tightenthe boltsto
the soecifiedtorque.
6-36
6.
Remove the camshaft holders,then measurethe

widestportionof the plastigageon eachjournal.
8.
Checkthe cam lobe heightwear.
Cam lobe heightstandard{New)

Camshaft-to-HolderOil Cloarance:
Standard {New}:0.050- 0.089mm
{0.002- 0'004 in)
Limit:
0.15
mm (0.006in)
Sorvice
U n i tm m ( i n )
INTAKE
D 16Y7engine
D16Y5
engine
PRI
sEc
PRI
D16Y8
MID
engrne
EXHAUST
35.299{1.3897) 37.281(1.4678)
3 8 . 4 2 7( 1 . 5 1 2 9 )
38.784(1.5269)
32.193\1.2674l
36.77411.44191
38.274(1.5068) 38.008(1.4964)
37.065(1.45921
PRI:Primarycam lobe,SEC:Secondarycam lobe.

MID:Mid cam lobe,T/B:Timing belt.
lN: Intake,EX:Exhaust
PRIMIDSEC
7.
lf the camshaft-to-holder
oil clearanceis out of tolerance:
- A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d ,
you must replacethe cylinderhead,
- lf the camshafthas not beenreplaced,first check
the total runout with the camshaftsuDDortedon
V-blocks.
,/a
EX
tN
+ Dl6YS engine
EX
IIB
- D16Y8engine
CamshaftToial Runout:
Standard {Nw): 0.03 mm {0.001in) max.
ServiceLimit: 0.0,t mm {0.002in)
C h e c kt h i s a r e a f o r w e a r .
Botatecamshaft
while measuring.
lf the total runout of the camshaitis within tolerance,replacethe cylinderhead.

lf the total runout is out of tolerance,replacethe
camshaftand recheck.lf the bearingclearanceis
still out of tolerance,replacethe cylinderhead,
6-37
Valves,ValveSpringsand lalve Seals

Removal
N O T E :l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e
removedso that eachitem can be reinstalledin its original position.
3.
Installthe valveguidesealremover.
SEAL REMOVER
1.
socketand plasticmalUsing an appropriate-sized

let, lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compressor.
VALVEGUIDESEALREMOVER
LISLEP/N 57900or KD3350
available)
PLASTICIIIALLET
VALVE SEAL
SOCKET
\
4.
Installthe spring compressor.Compressthe spring

and .emovethe valvekeeper.
VALVE SPRINGCOMPRCSSOR
SnlD-on CF7'lI or KD-383
rYlth t32 JAWS
6-3 8
Remove the valve seal.
ValveGuides
ValveMovement
Measurethe guide-to-stemclearancewith a dial indicator while rockingthe stem in the directionof normal
thrust (wobblemethod).
Intake Vslve Stem-to-GuideClearance:
Standard{Newl: 0.04- 0.10mm
(0.002- 0.004in)
ServiceLimh:
0.16mm {0.006inl
ExhaustValve Stem-to-GuideClarance:
StandardlNewl: 0.10- 0.16mm
(0.00i1- 0.fi)6 in)
ServiceLimit:
0.22 mm {0.009inl
Valveextended10 mm out from seat.
Intake Valve Dimensions

A Standard(New): 29.9- 30.1mm
{ 1 . 1 8- 1 . 1 9i n l
B Standard lNewl: 117.Q.- 117.72mm
(4.623- il.635 in)
C Standard {NBw): 5.'18- 5.49 mm
- 0.2161in)
10.2157
C ServiceLimit:
5.,t5mm {0.2146in}
D Standard (New): 0.85- 1.15mm
{0.033- 0.045inl
D ServiceLimil:
0.65 mm (0.026inl
ExhaustValveDimensions
A St8ndard(Newl: 25.9- 26.1mm
(1.02- 1.03inl
B Standsrd lNew): 114.60- 114.90mm
14.512- 4.521in1
C Standard {Newl: 5.45- 5.'16mm
(0.2146- 0.2150inl
C ServiceLimit:
5.42mm 10.213,[
in]
D Standard (New): 1.05- 1.35mm
l0.0il1- 0.053inl
D ServiceLimit:
0.95mm (0.037in)
.:I
l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t .
recheckusinga new valve.
l f t h e m e a s u r e m e nits n o w w i t h i n t h e s e r v i c e
limit,reassembleusinga new valve.
l f t h e m e a s u r e m e n st t i l l e x c e e d sr h e l i m i t .
recheckusing the alternatemethod below. then
replacethe valveand guide,if necessary.
NOTE:An alternatemethod of checkingguide to

stem clearanceis to subtractthe O.D.of the valve
stem, measuredwith a micrometer,from the l.D.of
the valve guide, measuredwlth an inside
micrometeror ball gauge.Takethe measurements
i n t h r e e p l a c e sa l o n g t h e v a l v e s t e m a n d t h r e e
places inside the valve guide. The differencebet w e e n t h e I a r g e s tg u i d e m e a s u r e m e n ta n d t h e
smalleststem measurementshould not exceedthe
servicelimit,
Int8ke Valve Stem-to-GuideClearancs:
Standard (Nsw): 0.02- 0.05 mm
{0.001- 0.002inl
ServiceLimit:
0.08 mm 10.003in)
ExhaustValve Stem-to-GuideClearance:
Standard (New): 0.05- 0.08 mm
(0.002- 0.003inl
ServiceLimit
0.11mm 10.004
in)
6-39
GylinderHead
ValveSeats
Warpage
Reconditioning
N O T E : l f t h e c a m s h a f t - t o - h o l d eori l c l e a r a n c e s( s e e
page6-36)are not within specification,
the cylinderhead
cannotbe resurfaced.
1.
NOTE: lf the guides are worn (seepage 6-39),

r e p l a c et h e m ( s e e p a g e 6 - 4 1 )b e f o r e c u t t i n g t h e
valveseats.
lf the camshaft-to-holder
oil clearances
are within sDecifications.checkthe cylinderheadfor warpage.
lf warpageis lessthan 0.05 mm (0.002in), cylinder headresurfacingis not required.
lf warpage is between 0.05 mm (0.002in) and
0.2 mm (0.008in), resurfacethe cylinderhead.
M a x i m u m r e s u r i a c el i m i t i s 0 . 2 m m ( 0 . 0 0 8i n )
basedon a heightot 93 mm (3.66inl.
Renewthe valve seatsin the cylinderhead using a

valveseatcuner.
VALVESEAT
CUTTER
available)
lCommercially
o --\
.,o
:-e>
/-.\O
C a r e f u l l yc u t a 4 5 " s e a t , r e m o v i n g o n l y e n o u g h
materialtoensurea smoothand concentricseat,
3.
Bevelthe upperedge of the seatwith the 30'cutter

and the lower edge of the seatwith the 60' cutter.
Checkthe width of the seatand adjustaccordingly.
Make one more very light passwith the 45" cutter to
removeany possibleburrs causedby the other cutters.
Valv Seat Width:
Standard lNow):
Intake:
0.85- 1.15mm 10.033- 0.0,15in)
Exhaust
1.25- 1.55mm (0.0/l!'- 0.061in)
ServiceLimit:
Intake:
1.6 mm {0.06i1inl
Exhaust:
2.0 mm {0.079in)
Measurealongedges,and threeways acrosscenter.
Cylinder Head Height:

Standard {Nowl: 92.95- 93.05mm
(3.669- 3.66i1inl
6-40
5.
After resurfacingthe seat, inspectfor even valve

s e a t i n g :A p p l y P r u s s i a nB l u e c o m p o u n dt o t h e
valve face, and insertthe valve in its originalloca
tion in the head,then lift and snap it closedagainst
the seatseveraltimes.
ValveGuides
Replacement
VALVE
SEAT
PRUSSIANBLUECOMPOUND
The actualvalve seatingsurface,as shown by the

bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve steml, you
must make a second cut with the 60" cutter to
move it down, then one more cut with the 45"
cutter to restoreseat width.
. lf it is too low (closer to the valve edge), you
must make a second cut with the 30'cuuer to
move it up, then one more cut with the 45'cutter
to restoreseat width.
NOTE:The final cut shouldalwavsbe madewith

the 45' cutter.
7.
Insertthe intakeand exhaustvalvesin the headand

measurethe valvestem installedheioht.
Intako. ExhaustStem Installed Height:
Standard{Newl: 53.17- 53.6i1mm
12.W3- 2.112inl
ServiceLimh:
53.89mm (2.122in)
1. As illustratedbelow, use a commercially-available

air-impactvalve guide driver attachmentmodified
to fit the diameter of the valve guides.In most cases,
the same procedurecan be done using the special
tool and a conventionalhammer.
VALVEGUIDEDRIVER
(Commercially
available)
5.3 mm
t-
87 mm -]+|
13.43inl
s7 mm
i'2,24 inl
tr_r
1 O . 8m m
10.42inl
or
VALVEGUIDEDRlVEn,5.5 mm
077i+2- 0010100
guides.and chillthem
Selectthe properreplacement
in the freezer section of a refrigerator for about an
hour.
Use a hot plate or oven to evenlyheatthe cylinder
headto 300'F(150'C).Monitorthe temperaturewith
a cookingthermometer.
lf the valvestem installedheight is over the service

limit, replacethe valve and recheck.lf its still over
t h e s e r v i c el i m i t , r e p l a c et h e c y l i n d e r h e a d ;t h e
valveseat in the headis too deeD.
CAUTION:
. Do nol use a torch; it may warp the head.
Do not gst the head hottor than 300'F (150'C);
excessivehaai may looson the valvc seats.
To avoid burns, use heavy gloves when handling
the heatod cylinder hoad.
(cont'd)
6-41
ValveGuides
Replacement(cont'd)
Workingfrom the camshaftside.use the driver and
an air hammerto drivethe guideabout2 mm {0.1in}
towards the combustionchamber.This will knockoff
someoJthe carbonand makeremovaleasier.
GAUTION:
. Always wear safety gogglesot a tacs shieldwhon
driving valve guides.
. Hold the air hammer ditectly in line with iho
valve guido to prevent damaging tho driver.
7.
Apply a thin coat of clean engineoil to the outside

of the new valve guide. Installthe guide from the
camshaftside of the head; use the specialtool to
drivethe guide in to the specifiedinstalledheight.lf
you haveall 16guidesto do, you may haveto reheat
the head,
Turn the headover,and drive the guide out toward

the camshaftside of the head.
Valvo Guide Installd Height:

- 0.722inl
lntake: 17.85- 18.35mm 10.703
- 0.754in)
(0.734
19.15
mm
18.65
Exhaust:
VALVEGUIDE
lf a valve guide still won't move, drill it out with a

8 mm {5/16in) bit,then try again.
CAUTION: Drill guides only in extremo cases; You
could damagthe cylinder head il the guide breaks.
6.
Removethe new guidesfrom the treezer,one at a

time, as vou needthem.
6-42
Valves
Reaming
Installation
NOTE;For new valveguidesonly.
l.
1.
2.
Coat both the reamerand valve guide with cutting

orl,
Rotatethe reamer clockwisethe full length of the
valve guide bore.
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit lrom the bore,
4.
Thoroughlywash the guide in detergentand water

to removeany cuttingresidue.
Checkthe clearancewith a valve(seepage6-39).
Verifythat the valve slides in the valve guide without exenrngpressure.
Coat valve stems with engine oil. Insertthe valves

in the valveguides.
NOTE: Make sure the valves move up and down
smoothly.
2.
Installthespringseatson the cylinderhead.
3.
I n s t a l lt h e v a l v e s e a l su s i n gt h e v a l v e g u i d e s e a l
installer.
NOTE:Exhaustand intakevalvesealsare not interchangeable.
WHITE
SPRING
BLACK
SPRING
Turn reamerin
clockwisedirection
INTAKEVALVESEAL
REAMER
EXHAUST
VALVESEAL
VALVEGUIDESEAL
INSTALLER
KD2899(Commercialtv
avaitable)
NOTE:UsesmalltD end ot
o-.:
-c)
REAMER.5.5 mm
OTHAH- PJ'OIOB
(cont'd)
6-43
______---
Valves
lnstallation (cont'd)
I n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r ,t h e n
installthe valve spring compressor.Compressthe
springand installthevalvekeepers.
NOTE:Placethe end of the valvespringwith closely wound coilstowardthe cylinderhead.
Arms and
Camshaft/Rocker
CamshaftSeal/Pulley
lnstallation
CAUTION:
. Mske sure that all rockers are in alignmnt with theil
valves whon torquing ths rockor a3semblybolts.
. Valve locknuts should be loosgngd .nd sdiusiing
screws backed off belore installation.
. To prevent the rocksr arm as3ombly tlom coming
apart, leavs the camshaft holder bohs in the holde6.
1. After wiping down the camshaft.camshaftsealand
j o u r n a l si n t h e c y l i n d e rh e a d ,l u b r i c a t eb o t h s u r
facesand installthe camshaft.
Clean and install the oil control orifice with a new
O-ring.
OIL CONTROLORIFICE
COMPBESSOR
VALVESPRING
available)
{Commercially
CF711or KD- 383
Snao-on
with *32JAWS
Lightlytap the end of each valve stem two or three
times with a plasticmalletto ensureproperseating
of the valveand valvekeepers.
NOTE:Tap the valvestem only alongits axisso you
do not bendthe stem.
CAMSHAFTSEAL
Sealhousingsurfaceshouldbe dry.
Applya lightcoat of oil to camshaft
a n d i n n e rl i p o f s e a l .
3.
Turn the camshaft until its keyway is facing up (No. 1

piston TDC).
\'
6-44
CylinderHead
Installation
4.
Apply liquidgasket(PartNo. 08718- 0001or 087180003)to the head maling surfacesof the No. '1and
No. 5 camshaftholders.
- Apply liquidgasketto the shadedareas.
Installthecylinderheadin the reverseorderof removal:

NOTE:
. Alwaysusea new headgasket.
. C y l i n d e rh e a d a n d c y l i n d e rb l o c k s u r f a c em u s t b e
c l e an .
. " UP" markon the camshaftpulleyshouldbe at the top.
. Turn the crankshaftso the No. 1 pistonis at TDC(see
p a g e6 2 0 ) .
. Cleanthe oil controlorificebeforeinstalling.
a Do not use the uppercover and loweacoverto store
removeorlems.
Clean the upper cover and lower cover before instaltaton.
No. 1
1 . Cylinder head dowel pins must be aligned.

CYLINDERHEAD
Set the rockerarm assemblyin place and loosely

installthebolts.
- Makesurethat the rockerarms are properlypositionedon the valvestems.
Tighteneachbolt two turns at a time in the sequence
shown belowto ensurethat the rockersdo not bind
on the valves.
Spocitiedtorque:
I mm bolts:20 N.m (2.0 kgf.m. 1'l lbf.ft)
Apply engineoilto the threads.
5 mm bolts: 12 N.m (1.2 kgil.m,8.7 lbf.ft)
Apply engine oil to the threads.
6 mm bolts:O, @, @, @
/6\
PINS
't
7.
Installthe backcover,then installthe camshaftpultey.
(cont'd)
6-45
CylinderHead
Installation(cont'dl
2.
Positionthe camshaftcorrectly(seepage6-20).
3.
Tightenthe cylinderhead bolts sequentiallyin four

steps.
lsr step: O - @ 20 N.m {2.0 kgt'm, 14 lbl.fr}
2nd step: G) - @ 49 N.m {5.0 kgf.m, 36 lbf.ftl
3rd srop: O - @ 67 N'm 16.8kgf.m, 49 lbf ftl
,lth step: o, o 67 N.m (6.8 kgf.m, 49 tbt.ftl
NOTE:
. W e r e c o m m e n du s i n g a b e a m - t y p et o r q u e
wrench. When using a preset-typetorque wrench,
be sureto tjghtenslowlyand not to overtighten.
. lf a bolt makesany noisewhileyou aretorquingit,
loosenthe bolt,and retightenit from the 1ststep.
CYLINDERHEADBOLTSTOROUESEOUENCE:
7 . Installthe timing belt lsee page6-20).

Adjustthe valveclearance{seepage6-12).
9. Installthe head cover gasketin the groove of the
c y l i n d e r h e a d c o v e r . S e a t t h e r e c e s s e sf o r t h e
camshaftfirst, then work it into the groove around
the outsideedges.
NOTEI
. B e f o r ei n s t a l l i n gt h e h e a d c o v e r g a s k e t ,t h o r oughlycleanthe sealand the groove.
. When installing,make sure the head cover gask e t i s s e a t e ds e c u r e l y i n t h e c o r n e r s o f t h e
recesses
wrtn no gap.
CORNERS
OF
THERECESS
HEADCOVERGASI(ET
rxe iicess
covER
1 0 . Apply liquid gasketto the headcover gasketat the

four cornersof the recesses.
Installthe intakemanifoldand tightenthe nuts in a

crisscrosspatternin two or three steps,beginning
with the innernuts (seepages9-2thru 9-4).
.
Alwaysusea new intakemanifoldgasket.
Installthe exhaustmanifoldand tightenthe nuts in

a crisscrosspatternin two or three steps,beginning
with the innernut (seepages9-5 and 9-6).
.
Alwaysusea new exhaustmanifoldgasket.
I n s t a l lt h e e x h a u s tm a n i f o l d b r a c k e t .I n s t a l lt h e
exhaustpipeA andthe bracket,
then installthd cover,
6-46
NOTE:
. Use liquidgasket,PartNo. 08718- 0001or08718
- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
. Do not installthe parts if five minutesor more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e r .
Instead,reapplyliquid gasketafter removingold
residue.
o After assembly,wait at least30 minutesbefore
fillingthe enginewith oil.
11. When installingthe cylinder head cover, hold the

headcovergasketin lhe grooveby placingyour fingers on the camshaft holder contacting surfaces
(top of the semicircles).
Settho sparkplug sealon the sparkplug pipe.
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat
the headcovergasket.
12. Tightenthe nuts in two or three steps.In the final

step,tighten all bolts, in sequence.to 9.8 N.m (1.0
kgf.m,7.2lbf.ft).
NOTE: After assembly,wail at least 30 minutes
beforefillingthe enginewith oil.
NOTE:
. Beforeinstallingthe cylinder head cover,clean
t h e c y l i n d e r h e a d c o n t a c t i n gs u r f a c e sw i t h a
shop towel,
. Do not touch the parts where liquid gasketwas
aDolied.
. Take care not to damage the spark plug seals
when installingthe cylinderheadcover.
. Visuallycheckthe sparkplug sealsfor damage.
. Replacethe washer when damaged or deteriorated.
6x1.0mm
9.8 N.m 11.0kgf.m, 7.2 lbf.ftl
tl
After installation,check that all tubes, hoses and

connectorsare installedcorrectly.
SEAL
6-47
EngineBlock
SpeciafTools
.............7-2
lllustratedlndex ...................................
7-3
Flywheel and Drive Plate
Replacement
.........7-G
Connecting Rod and Crankshaft
EndPlay
.................
7-6
Main Bearings
-7
Cfearance
..,,,,,,,,,....7
Selection
................
7-8
Connecting Rod Bearings
Clearance
...............
7-B
^
Selection
................
7-9
|J
Pistons and Crankshaft
Removal
.................
7-9
Crankshaft
fnspection
..............7-11
Pistons
fnspection
.,,,,.,,,....,7-12
Installation
.............
7-20
Cylinder Block
lnspection
..............
7-13
BoreHoning
..........7-11
Piston Pins
Removal
.................
7-14
lnstallation
.............
7-15
Inspection
..............
7-16
Connecting Rods
Seleetion
................
7-15
Piston Rings
EndGap
.................
7-17
Repfacement
.........7-11
Ring-to-GrooveClearance...............
7-18
Alignment
..............
7-18
Crankshaft Oil Seal
Installation
.............
7-19
Crankshaft
fnstaffation
.............7-2O
Oil Pan
fnstaffation
.............7-22
Oil Seals
lnstaffation
.............7-24
SpecialTools
Raf. No.
Tool Numbor
07LAB- PV00100
07749- 0010000
079i17- S800200
07948- S800101
07973- P800200
07973- PE00310
07973- PE00320
0t913 - PE00400
07973- S800100
07973- 6570500
07973- 5570600
@
@
@
@
@
o
o
@
@
@
(Ny
DBcription
RingGearHolder
Driver
SealDriver
Driver Attachment
PilotCollar
PistonPin DriverShaft
Piston Pin Driver Head
Piston Pin Base lnsen
Piston BaseHead
Piston Base
PistonBaseSpring
1
1
1
1
1
I
1
1
1
1
1
Pag6 Rotorence
7-6
7 -19,25
7-24
7-'t9,25
7-141
,5
7-14.15
l-14,15
l - ' 1 4 ,1 5
7 - 1 4 ,1 5
7-'t4,15
7-'t4.15
0
o
t-1
!
c,
lllustrated lndex
D16Y7engine:
I
Lrori""t" "tl internalpartswith engineoil during reassembly.
NOTE:
. Applyliquidgaskettothematingsurfaces
ofthe rightsidecoverandoil pumpcasebeforeinstalling
them.
.
.
Use liquidgasket.part No. 08718- 0001or 08718- 0003.

Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit.
DRAINBOLT
44 N.m (4.5 kgf.m, 33 lbf.ftl
6 x 1.0mm
12 N.m (1.2 kgt.m, 8.7 lbt.ft)
6 x 1 . Om m
12 N.m {1 .2 kgf.m,
8 7 lbt'ftl
"i'.''
Hii,ilJ
,::::T:Î
y"::::ffi::: I
o[ rlt cnsrer
.*"'" I
OIL PAN
Refetto page7-22
when installing.
'y"
\\
$5./
fR..r'
gNliJ'J.f--
><-BL
Apply liquidgasketto
these points.
%S
BEARINGCAP
MAIN BEARINGS
Selection,page7-8
NOTE:New main bearingsmust
be selectedby rnatchingcrank
and block identilicationmarkings.
CRANKSHAFT
page7-'11
lnstallation,
6 x 1 . 0m m
1'l N.m (1.1 kgf.m, 8 lbf.ft)
OIL SEAL
CRANKSHAFT
lnstallation,
pages7-19and 7-25
OII SCREEN
6 x 1.0 mm
1 1 N . m l 1 . 1 kgf.m, a lbt.tt)
\{ePlace
6 x 1 . Om m
1'l N.m (l .1 kgf.m,
8 tbt.ftl
GASKET
Replace.
OIL PUMP
Overhaul.page8-9
Removal/lnspection,
page8-10.
DOWELPIN
CRANKSHAFTSEAL
/.\
lnstallation,pages7-24--rS)
Replace.
6x1.0mm
1 1 N , m 1 1. 1 kgt.ni,
8 tbr.ftl
,t/,oksf'm,87
rbt'ttr
@ff
1 1x 1 . 5m m
51 N.m
(5.2kgt m,3E
Applyengineoilto the bolt
threads.
NOT: After torquing
each cap, turn the crankshaft
to checklor binding.
MAI
FLYwHEELcovER
DOWELPIN
O-RING
Replace.
BRATHINGPORT COVER
MOUNT BOLTS
6 x 1 . Om m
11 N.m 11.1 kgf.m, I lbt.ft)
the bolt threads.
RIGHTSIDECOVER
Apply liquidgasker
to m6ting surface.
WASHERS
Groovedsides face outward.
NOTE:Ihrusr washerthickness
is fixed and must not be changed
by grindingor shimming.
(cont'd)
7-3
lllustrated Index
(cont'dl
rubricatealt internalpartswith engineoil duringreassembly.
NOTE:
.
!
.
Apply liquidgaskettothe matingsurfacesofthe right sidecoverand oil pump casebeforeinstallingthem.

Use liquidgasket,pan No. 08718- 0001or 08718- 0003.
Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit.
D16Y5.Dl6Y8 engin"",
DnAtNBoL,
39 N.m 14.0kgf'm,
29 tbf.f!)
WASHER
Apply liquid gaskerto

these potnts,
OII.PAN
Relerto page7-23
wheninstalling.
FLYWHEELCOVER
IM/T)
\
6r1.omm
\,-,
\%
12 x 1.0mm
1 1 8N . m
(12.O kst.m, 87 lbl.ftl
12 N.m (1.2kgf'm,
8.7 lbf.trl
1 1 x 1 . 5m m
51 N.m
15.2kgt m, 38 lbf.{t)
Applyengineoilto the bolt
threads.
NOTE:Aftertorquing
each cap, turn crankshaft
to checklor binding.
\s
FLYWHEELIM/TI
OIL PAN GASKET

Replace.
DRIVEPLATECOVER
lA/T or CVTI
MAIN
BEARING
1 2 x 1 . Om m
74 N.m
(7.5 kgf.m, 54 lbf.ft)
MAIN BEARINGS
page7-8
Selection,
NOTE:New main bearingsmust
be selectedby matching crank
DRIVEPLAYE(A/T or CVTI
Checkfor cracks.
6 x 1.0 mm
1 1 N . m 1 1 . 1k g t . m ,
8 tbf.frl
6 x 1.0 mrn
1 1 N . m { 1 . 1 k g t . m ,8 l b f . f r l
CRANKSHAFTOIL SEAL
pages7-19and 7-25
Replace.
OIL SCREEN
GASKET
Replace.
RIGHT SIDE COVER

Apply liquidgasket
to mating surface.
OIL PUMP
Overhaul,page I 9
Removal/lnspection,
page 8-10
DOWEL PIN
Apply liquidgasket
to mating surface.
CRANKSHAFT
SEAL
pages7-24
Installation,
a n d8 - 1 1
Feplace.
'1
6 x .0 mm
' 1 1N . m 1 1. 1 k g f . m ,
I lbt.fr)
7-4
THRUSTWASHERS
Groovedsidesface outward.
NOTE:Thrust washerthickness
is fixed and must not be changed
by grindingor shimming.
DOWEL PIN
BREATHINGPORT COVER
MOUNT BOLTS
6 x 1.0mm
11 N.m {1.1 kgf.m, 8 lbf.frl
the bolt threads.
NOTE:New rod bearingsmust be selectedby matchingconneclingrod assemblyand crankshaftidentificationmarkings

(seepage7-9).
PISTONINSTALLATIONDIRECTION:
Lubricate all internal parts with engine oil during

reassemblv.
EXHAUST
4\A6\/A
l o
l t . -
v\y\7v
t l
INTAKE
tl,^t
w,
*al
@
PISTONPIN
Removal,page7-14
page7-15
Installation,
hspection,page7-16
CONNECTING
ROD
End play, page7-6
S e l e c t i o n ,p a g e 7 - 1 5
PISTONRINGS
pase7-18
olisnment,
)
PISTON
page7-12
Inspection,
NOTE: Belore removing piston, inspectthe
top of the cylinderborefor carbonbuild,upor
ridge. Removeridge il necessary,page 7-'10
ENGINEBLOCK
page7-13
Cylinderboreinspection,
page7-'13
Warpageinspection,
Cylinderborehoning,page7'14
CONNECNNGROD
BEARINGS
Clearance.page 7-8
Selection,page 7-9
Inspecttop of each cylinder bore

for c6rbonbuild-upor ridge
before removing piston.
Removeridge if necessary,page7-'10
CONNECTING
ROOBEARING
page7-20
lnstallation.
NOTE: Installcaps so the
bearing recessis on the
same side as the recess
in the rod.
CONNECNNGRODCAPNUT
8 x 0,75mm
3 1N m ( 3 , 2 k g f . m ,
23 tbt.ft)
Applyengineoil to
the bolt threads.
NOTE: After torquing each bearing
cap, rotatecrankshaftto
checktor binding.
7-5
Flywheel and Drive Plate
GonnectingRod and
Crankshaft
Replacement
EndPlay
Manual Transmission:
Removethe six 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 a crisscrosspattern.
ConnGtingRod End Play:

Standard(New):0.15- 0.30mm {0.006- 0.012inl
ServiceLimit: 0.,[|)mm {0.016inl
RINGGEARHOLDER--4T-1
07LAB- PV00100
Htr
ENGINEBLOCK
RINGGEAR
Inspectring gear
teeth for wear or
damage.
12 x 1.0mm
118 N,m 112.0kgtm,87 lbl.ftl
I
.
.
ll out-of-tolerance,
installa new connectingrod.
lf still out-of-tolerance.replacethe crankshaft(see
pages7-9 and 7-20).
Pushthe crankshaftfirmly away from the disl indicator,

and zerothe dial againstthe end of the crankshaft.
Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimit.
RINGGEARHOLDER
07LAB- PV(x'l00
Automatic Transmission:
Removethe six drive plate bolts,then separatethe drive
platefrom the crankshaftflange.After installation,
tighten the bolts in a crisscrossoattern.
CrankshaftEnd Play:
Stsndard {Nw): 0.10- 0.35 mm {0.004- 0.0lit in}
ServicELimit: 0.45 mm (0.018inl
.
1 2x 1 . 0m m
74 N.m {7.5kgf m,54lblftl
7 -6
lf end play is excessive,inspectthe thrust wsshers

and thrustsurfaceon the crankshaft.
Replacepans as necessary.
NOTE:Thrustwasherthicknessis fixed and must not be

changedeitherby grindingor shimming.
Thrust washersare installedwith groovedsidesfacing
outward.
Main Bearings
Clearance
1.
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 j o u r n a l a n d b e a r i n gh a l t w i t h a
cleanshop towel.
Piaceone strip of plastigageacrosseach main journal.
NOTE:tt the engineis still in the car when you bolt
the main cap down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plastigage 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 i n ga t a
time.
lf the plastigagemeasurestoo wide or too narrow,

(removethe engineif it's still in the carl. removethe
crankshaft,and removethe upper half ol the bearing. Installa new, completebearingwith the same
color code (selectthe color as shown on the next
page),and recheckthe clearance.
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.
lst step: 25 N.m 12.5kgf'm, 18 lbf'ft)
Final step: 51 N'm 15.2kgl.m, 38 lbf'ft)
NOTE:Do not rotatethe crankshaftduring inspectton.
Removethe cap and bearing again. and measure
the widest pad of the Plastigage.
Main Bearing-to-JournalOil Clearance:
Standard lNew):
No. 1,5 Journals:
0.018- 0.036mm (0.0007- 0'001,+inl
No- 2, 3, i[ Jou]nals:
0.02/t- 0.0,[2mm {0.0009- 0.0017in)
Ssrvice Limit: 0-05 mm {0.002inl
CAUTION: Do not file, shim, or sqape the bearings

or the caps to adiust clearance.
7.
It the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(thecolor
listedaboveor belowthat one),and checkagain.
NOTE: lf the oroper clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings'
replacethe crankshaftand startover.
Main Bearings
ConnectingRod Bearings
Selection
Clearance
CAUTION: lf the codes are indeciDherablebecauseof an

accumulationot dirt and dust, do not scrub them with a
wire brush or scraper.Clean them only with solvent or
detergent.
1,
Removethe connectingrod cap and bearinghalf.
2.
C l e a nt h e c r a n k s h a frto d j o u r n a la n d b e a r i n gh a l f
with a cleanshop towel.
CrankshaftBore Code Location
3.
Placea strip of plastigageacrossthe rod journal.
Lettershave beenstampedon the end of the blockas a

codefor the sizeof eachof the 5 mainjournalbores.
Use them, and the numbersstamDedon the crankshaft
(codesfor main journalsizel,to choosethe correctbearinos.
4.
R e i n s t a lt lh e b e a r i n gh a l f a n d c a p ,a n d t o r q u et h e
nuts.
Torque
31 N.m (3.2 kgf.m. 23 lbf.ftl
NOTE:Do not rotatethe crankshaftduring inspectton.
Removethe rod cap and bearinghalf,and measure

the widestpart of the plastigage.
ConnctingRod Eearing-to-JouJnalOil Clearance:
StandardlNewl: 0.020- 0.038mm
- 0.0015in)
(0.0008
ServiceLimit: 0.05 mm (0.(X)2in)
I
Main Joulnal Code Location(Numbers)
I
PLASTIGAGESTRIP
lf the plastigagemeasurestoo wide or too narrow,

removethe upper half of the bearing,installa new,
completebearingwith the same color code (select
the color as shown on the next page),and recheck
the clearance.
Bearing ldentification
Colorcodeis
on the
edge of
the bearing.
crankoore
B
Smallerbearing{thicker)
Il l f-i--l
--Jl
tt l t. .3 - lt
7-8
Pink
G.een
Gren
+ tn t +
Smaller
main
journ8l
Red
Smaller
bearing
(thicker)
Green
Green
Brown
Brown
Black
Elack
CAUTION:Do not lile, shim. or scrapethe boarings

or the caps to adiust clearance.
Blue
7.
lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(the color
l i s t e da b o v e o r b e l o wt h a t o n e ) ,a n d c h e c kc l e a r a n c ea g a i n .
NOTE; lf the prooer clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
replacethe crankshaftand stan over.
Pistonsand
Crankshaft
Selection
Removal
CAUTION:lf the codes are indecipherablebecauseof

an accumulationol dirt and dust, do not scrub them
with a wire brush or scraper,Clean them only with solvgnt or detorgent.
1.
Removethe oil pan assembly.

Removethe right sidecover.
ConnectingRod Code Location

Numbershave been stampedon the side of each connecting rod as a code for the size of the big end. Use
them, and the lettersstampedon the crankshaft(codes
for rod journalsize),to choosethe correctbearlngs.
RIGHT SIDE
COVER
Halfof the numberis

stampedon bearing
capand the other
hall is stampedon the
rod.
connecting Rod Journal code Locations lLettersl

OIL SCREEN
Baring ldentif ication

Colorcodeis on the
Larger big end bore
edge of
the bearing.
Smallerbearing{thicker)
I F;.'l I
l l B o r l l l l
ll .-.------.ll
I
I Corlll | |
l - l
I l D o , r lr+r r
Smaller
rod
iournal
Red
Gren
Green
Pink
Green
Erown
Green
Brown
Black
Brown
Black
Blue
Pink
O-RING
RePlace
4.
Remove the oil pump.
Smaller
bearing
(thicker)
7-9
Pistonsand Crankshaft
Removal(cont'dl
5.
Removethe boltsand the bearingcap.
Removethe upper bearing halvesfrom the connecting rods and set them asidewith their respectivecaps.
CAUTION: To prev6nt warpago, unscrew the bohs

in soquencel/3 turn at a tims; rgpoat the sequenco
until 8ll bolts ara loosonsd.
MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE
Reinstallthe main capsand bearingson the engine

In properorder.
'10. you
lf
canfeela ridgeof metalor hardcarbonaround
t h e t o p o f e a c h c y l i n d e r ,r e m o v e i t w i t h a r i d g e
reamer.Follow the reamer manufacturer'sinstructions.
CAUTION: lf the ridgo is not removed, it may damage tho plstons as they are pushed out.
Removethe rod caps/bearings

and main caps/bearings.Keepall caps/bearings
in order
7.
't1.
Use the wooden handle of a hammer to drive the

pistonsout.
Lift the crankshaftout of the engine,being careful

not to damagejournals.
12. Reinstallthe connectingrod bearingsand capsafter

removingeachpiston/connecting
rod assembly.
CRANKSHAFT
1 3 . Mark each piston/connecting

rod assemblywith its
cylindernumberto avoid mixup on reassembly.
NOTE:The existingnumber on the connectingrod
does not indicateits position in the engine,it indicatesthe rod bore size.
7-10
Grankshaft
Inspection
.
Cleanthe crankshaftoil passageswith pipe cleaners

or a suitablebrush.
Checkthe keywav and threads.
Alignmont
.
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 differencebetweenmeasurementson each

journalmust not be more than the servicelimit.
Out-of-Roundand Tapel
.
Measureout-o{-roundat the middle of each rod

and main journalin two places.
The differencebetweenmeasurementson each

journalmust not be more than the servicelimit,
Journal Out-ot-Round:
Standard (Now): 0.0025mm (0.0001inl max.
ServiceLimit: 0.005mm (0.0002inl
CrankshaftTotal IndicatadRunout:
Standard {Nowl: 0.03 mm 10.001in} max.
SorviceLimh: 0.04 mm 10.002in)
DIAL INOICATOR
Rotate lwo complete
revolutions.
round at middle.
MeasurelaPer
at edges.
Suppon with lathe

lype tool or V-blocks.
Measuretaper at edges of each rod and main

journal.
The differencebetlveenmeasurementson each

journalmust not be more than the servicelimit.
JournalTaper:
Standard{Newl:0.0025mm (0.0001in) max.
ServiceLimit: 0.005mm 10.0002in)
7-11
Pistons
Inspection
1.
Checkthe pistonfor distortionor cracks.

NOTE:lf cylinderis bored,an oversizedpistonmust
be used.
2.
M e a s u r ep i s t o n d i a m e t e ra t d i s t a n c eA t r o m t h e
bottom of the skirt.
3.
Calculatethe difference between the cvlinder bore

diameter(seepage7-131and pistondiameter.
Piston-to-CylindrClearanca
Standsrd {New): 0.010- 0.0i|()mm
(0.000'l- 0.0016inl
ServiceLimit:
0.05 mm {0.002inl
A: 5 mm (0.2in)
Piston Diameter:
Standard (Nw): 74.990- 74.990mm
12.9520- 2.952itinl
ServiceLimh: 7i1.970mm {2.9516in}
SKIRTDIAMETER
lf the clearanceis near or exceedsthe servicelimit,

inspectthe piston and cvlinderblock for excessive
wear.
OversizPiston Dismatel
0.25175.23-75.21mn (2.9618- 2.9622inl
0.50:75.48- 75.49mm 12.9716- 2.9720in)
7-12
Cylinder Block
Inspection
'1. Measure
wear and taDerin directionsX and Y at th ree
levelsin eachcvlinderas shown.
lf measurementsin any cylinderare beyondthe

OversizeBoreServiceLimit,replacethe block.
lf the block is to be rebored.refer to PistonClear(seepage7 12)afterreboring.

anceInspection
NOTE;Scoredor scratchedcylinderbores must be

honed.
ReboringLimit: 0.50 mm (0.020in)
2.
Checkthe top of the blockfor warpage.

Measurealong the edgesand acrossthe centeras
shown.
SURFACES
TO 8E MEASURED
Cylinder Bore Size

Standard {New): 75.00- 75.02mm
(2.953- 2.95,1in)
SrvicoLimit: 75.07mm {2.955inl
OvsFize
O.25t75.25- 75.27mm (2.9626- 2.963,[in]
0.50:75.50- 75.52mm 12.9721-2.9732in1
Engine Block Warpage:

Standard(New):0.07mm (0.003in) max.
ServiceLimit: 0.10 mm 10.004in)
PRECISION
STRAIGHTEDGE
Bore Taper
Limit (Differencebetwoen tirst and third measure.
m6nt) 0.05 mm (0.002in)
7-13
).
Piston Pins
GylinderBlock
BoreHoning
l.
Removal
Measurecylinderboresas shownon page7-13.lf the

blockis to be reused,honethe cylindersand remeasurethe bores.
1.
Assemble the specialtool as shown.
PISTONBASEHEAD
07973- SB00100
Honecylinderboreswith honing oil and a fine (400

grit) stonein a 60 dagreecross-hatch
pattern.
f t
PISTONPIN BASE
INSERT
07973- PE00a00
NOTEi
. Use only a rigid hone with 400 grit or tiner stone
such as Sunnen,Ammco,or equivalent.
. Do not usestonesthat are worn or broken.
g
E.
g\
rr*,"o
Y .,rro")".
079?3- 6570600
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 metal particles.Wash the cylinder bores with hot soapy water, then dry and oil
immediatelyto preventrusting.
NOTE:Neverusesolvent,it will only redistribute
the
grit on the cylinderwalls.
lf scoring or scratchesare still presentin cylinder
bores after honing to the service limit. rebore the
cylinderblock,
NOTE:Some light verticalscoringand scratchingis
acceptableif it is not deep enoughto catchyour fingernailand does not run the full lengthof the bore.
CYLINDERBLOCK
2.
Assembleand adjust the length of the piston p t n

driverand shaftto 53 mm (2.1in) as shown.
PINDRIVER
HEAD
PISTON
07973- PE00320
Pres3
53 mm(21 in)
PISTONPIN
DRIVERSHAFT
0?973- PE00310
PILOTOOLLAR
07973- PE00200
CYLINDERHONE
NOTE:
. After honing,cleanthe cylinderthoroughlywith
soapy waler.
. Only a scoredor scratchedcylinderbore must be
noned.
7-14
NOTE|Usea hydraulicpress.
When pressingthe pin in or out,
makesure that the recessed
ponionofthe pistonaligns
with the lips on the collar.
Placethe piston on the specialtool and press the

pin out with the specialtoolsand a hydraulicpress.
GonnectingRods
PistonPins
Seleetion
Installation
Eachrod falls into one of four toleranceranges(from 0 to

+ 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in)
incrementsldependingon the sizeof its big end bore.lt's
then stampedwith a number 11,2, 3, or 4l indicatingthe
ran9e.
Y o u m a y l i n d a n y c o m b i n a t i o no l 1 , 2 , 3 , o r 4 i n a n y
engine.
1.
Normal Bore Size: ,18.0mm (1.89inl

NOTE:
ReferencenumbeG are for big end bore sizeand do
NOTindicatothe positionof the rod in the engine,
Inspectconnectingrod for cracksand heatdamage.
Usea hvdraulicDressfor installation.

a When pressingthe pin in or out, be sure you position the rscessedflat on the piston againstthe lugs
on the baseattachment,
The arrow must face the
timing belt side ol the
engineand the connecting
rod oil hole must face the
rear of the
PISTOI{P|r{DRIVERHEAD
07973- PEOO320
Adjust the length of the

piston pin driver to
53 mm (2.09in)
PISTO PII{ DRIVERSHAFT
07973-PE00310
ffi--Z
PFroI{Prr{
PILOTCOTLAR
07973- PEq)200
PISTOI{PINBASE I SERT
07973 - PCOO400
PISTOI{BASEHEAD
07973 - SB(xtl (xt
7-15
)
PistonPins
Inspection
'1. Measurethe diameterot the pistonpin.
Piston Pin Diamcter:
Standard (New): 18.994- 19.000mm
- 0.7{80 inl
(0.7,078
18.997- 19.003
OveIsiz:
{0.7,u9 - 0.7,181in)
pistonpins are oversize.
NOTE:All replacement
\
3.
Measurethe pistonpin-to-piston
clearance.
NOTE:Checkthe pistonfor distortionor cracks.
lf the piston pin clearanceis greaterthan 0.024mm
( 0 . 0 0 0 9i n ) , r e m e a s u r eu s i n g a n o v e r s i z e dp i s t o n
pin.
Piston Pin-to-PistonClsarance:
Standard {Newl: 0.010- 0.022mm
{0.0004- 0.0009inl
Checkthe differencebetweenthe pistonpin diameter and the connectingrod smallend diameter,

2.
Zerothe dial indicatorto the pistonpin diameter.

Piston Pin-to-ConnectingRod Intrferonc:
Standard (New): 0.014- 0.040mm
- 0.0016inl
10.0006
7-16
PistonRings
EndGap
Replacement
1 . Using a piston, push a new ring into the cylinder

bore 15- 20 mm (0.6- 0.8 in) trom the bottom.
1 . Usinga ring expander,removethe old pistonrings.

2.
Cleanall ring groovesthoroughly.
Measurethe pistonring end-gapwith a feelergauge:

.
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 limits on page7-13.
lf the bore is over the servicelimit. the cvlinder
blockmust be rebored.
NOTE:
. U s e a s q u a r e d ' o f fb r o k e nr i n g o r r i n g g r o o v e
cleanerwith bladeto fit pistongrooves.
. Top ring grooveis 1.0mm (0.039in) wide.
. Secondring grooveis 1.2mm (0.047in) wide.
. O i l r i n gg r o o v ei s 2 . 8m m ( 0 . 1 Ii n )w i d e .
. Filedown the bladeif necessary.
Piston Ring End-Gap:

Top Ring
St8ndardlNswl: 0.15- 0.30mm
{0.006- 0.012in)
ServiceLimit: 0.60 mm 10.024inl
CAUTION:Do not uso a wire brush to clean ring

lands, or cut ring lands doeperwith cleaningtool.
SecondRing
Standard lN6wl: 0.30- 0.,l5mm
{0.012- 0.018inl
ServiceLimit: 0.70 mm (0.028inl
Installnew rings in the proper sequenceand position {seepage7-18).
Oil Ring
Standard lNewl: 0.20- 0.70 mm
{0.008- 0.028inl
SorviceLimit: 0.80 mm (0.031in)
NOTE:lf the pistonis to be separatedfrom the connectingrod, do not installnew ringsyet.
NOTE:Do not reuseold pistonrings.

RINGEXPANDER
{Commercially
available)
15-20 mm
{0.6 -O.8 inl
7-17
PistonRings
Clearance
Ring-to-Groove
Alignment
After installinga new set of rings, measurethe ring-togrooveclearances:
1,
Installthe ringsas shown.
Top Ring Clearance

Standard lNew): 0.035- 0.060mm
{0.0014- 0.0024in}
mm (0.005inl
Limit:
0.13
Servic.
TOPBINGlchromo)
SecondRing Clearance
Standard (Now): 0.030- 0.055mm
(0.0012- 0.0022io)
ServiceLimit: 0.13 mm 10.005inl
Piston Ring Dimensions:
r-T-
I
I
| . - !
l r '
I '
Top Ring (Standatd):

A: 2.6 mm {0.10in}
B: 1.0mm (0.0/tin)
Second Ring {Standard):
A: 3.0 mm (0.12inl
B: 1.2mm (0.05inl
NOTE: The manufacturingmarks must be facing
upward.
,orrrno--"-@
SECONORING.>
7-18
CrankshaftOil Seal
lnstallation
2.
Rotatethe rings in their groovesto make sure they

do not bind.
The sealsurfaceon the blockshouldbe dry.

Apply a light coatof oil to the crankshaftand to
the lio of the seal.
Positionthe ring end gaps as shown

1.
SECONDRINGGAP
DO NOTpositionany rrnggap
at pistonthrustsurfaces,
Drivethe crankshaftoil seal into the right side cover

usingthe specialtools.
NOTE:Drivethe crankshaftoil sealin squarely.
DRIVER
07749- 0010000
Approx. 90"
TOP RINGGAP
DO NOTpositionsny ring gaP
in linewith the pistonpin hole.
OIL RINGGAP
Installseal with the

part numberside
facing oui.
Confirmequal clearanceall the way around with a

feelergauge.
Clearance:
0.5- 0.8 mm {0.02- 0.03inl
0 . 5- 0 . 8 m m
10.02-O.03in)
NOTE:Referto pages'I-24and 8-11for installation

of the oil oumo sidecrankshaftoil seal.
7-19
I
Crankshaft
Pistons
lnstallation
lnstallation
Beforeinstallingthe pistons,applya coat of
engineoil to the ring groovesand cylinder
bores.
1.
lf the crankshaft is already installed:
. Set the crankshaftto BDCfor each cylinder.

. Removethe connectingrod caps.and slip short
sectionsof rubber hose over the threadedends
of the connectingrod bolts.
. Installthe ring compressor,checkthat the bear
ing is securelyin place,then positionthe piston
i n t h e c y l i n d e r a. n d t a p i t i s u s i n gt h e w o o d e n
h a n d l eo f a h a m m e r .
. Stop after the ring compressorpops free, and
journal aligncheckthe connectingrod-to-crank
ment beforepushingthe pistoninto place.
. Installthe rod capswith bearings,and torquethe
nutsto:
31 N.m 13.2ksl.m,23 lbf.ti)
Apply engineoil to the bolt threads.
2.
lf the crankshaftis not installed:

. R e m o v et h e r o d c a p s a n d b e a r i n g s i,n s t a l lt h e
ring compressor,then positionthe piston in the
cylinderand tap it in usingthe woodenhandleof
a hammer.
. Positionall Distonsat top deadcenter.
The arrow must face
the timing belt side
of the engjne.
apply a coatot
Betoreinstallingthe crankshaft,
engineoil to the main bearingsand rod bearings,
1.
Installthe thrust washersin the No. 4 journal of the

cylinderblock.
Insertbearinghalvesin the cylinderblockand connectingrods.
Holdthe crankshaftso the rod journalsfor cylinders
No. 2 and No.3 are straightdown.
Lowerthe crankshaftinto the block,seatingthe rod
j o u r n a l si n t o c o n n e c t i n gr o d s N o , 2 , N o . 3 . I n s t a l l
the rod capsand nutsfinger-tight.
lrrn
---1l
)t--l
-'--tllf -l
ltll
THRUST WASHERS
Groovedsidestace
Rotatethe crankshaftclockwise.seat journals into

connectingrods No. 1 and No.4. lnstallthe rod caps
and nutsfinger-tight.
NOTE:Installthe caps so the bearingrecessis on
the sameside as the recessin the rod.
Check rod bearing clearancewith plastigage(see
page7-8).then torquethe capnuts.
RUBEER
NOTE:Maintaindownwardforce 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 f o r e
enteringthe cylinderbore.
RING
COMPRESSOR
(Commercially
available)
Torque:
31 N.m (3.2 kgf.m,23 lbf,ft)
Apply engineoil to the bolt threads.
NOTE: Referencenumbers on the connectingrod
are for big-endbore toleranceand do not indicate
the positionof the pistonin the engine.
\'
Lineup the markswhen
installingthe connectingrod
cap.
7-20
7.
Installthemain bearingcaps.
Checkclearanceswith plastigage(see page 7-7),
then tightenthe bearingcap bolts in 2 steps.
Fi6t st6p: 25 N'm (2.5 kgf'm. 18 lbt.ft)
Secondstsp: 5t N.m (5.2 kgf.m, 38 lbf,ft)
NOTE: Coat the thrust washer surfacesand bolt
thresdswith oil.
MAN BEAHNG CAP BOLTSTIGHTENINGSEOUENCE
8.
Apply liquid gasketto the block mating surfaceof

the right side cover, then install it on the cylinder
block.
NOTE:
. Use liquidgasket,part No. 08718- 0001or 08718
- 0003.
beforeapplyingliquidgasket
. Apply liquidgasketevenly,b6ingcarefultocover
allthe matingsurface.
. To preventoil leakage.apply liquidgasketto the
innerthreadsof the bolt holes.
. Do not install the parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket,
Insteadreapplyliquid gasketafter removingthe
old residue,
. After assemblv,wait at least 30 minutes before
RIGHTSIDECOVEB
CAUTION: Whenever any crankshaft bearing or

connecting rod bgajing is rgplacad, it is neces3ary
aft6r roassemblyto run the ongino at idling spood
until it reachesnormal operating temperalure, thon
continuo to run it for approximalely 15 minutes.
6 x 1.0mm
1 1 N . m { 1 . 1kgl.m,
8 tbt.ftl
DOWEL PIN
(cont'd)
7-21
O i l Pa n
Crankshaft
Installation
9. Apply liquid gasketto the oil pump mating surface

o f t h e b l o c k t, h e n i n s t a ltl h e o i l p u m p o n t h e c y l i n der block.
Apply greaseto the lipsof the oil seals.
T h e n ,i n s t a l tl h e o i l p u m p w h i l e a l i g n i n gt h e i n n e r
r o t o r w i t h t h e c r a n k s h a f tW
. hen the pump is in
place,clean any excessgreaseoff the crankshaft,
then checkthat the oil seallips are not distorted.
Apply laquidgasket
alongthe broken
O16Y7enginc:
1.
Apply liquid gasketon the oil pump and right side

covermatingareasas shown below.
NOTE:
. Use liquidgasket,part No.08718- 0001or 08718
- 0003.
. Apply liquid gasketas an even bead. centered
betweenthe edgesof the matingsurface.
. lo preventoil leakage,apply liquid gasketto the
. Do not installthe parts if five minutes or more
h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t .
old residue.
. After assembly,wait at least30 minutes before
CYLINOER
Br_ocK
OIL PUMP HOUSING
Apply liquid gasket

to these pornts.
NOTE:
. Apply a light coat of oil to the crankshaftand to
t h e l i po f t h es e a l .
. U s e n e w O - r i n g sa n d a p p l y o i l w h e n i n s t a l l i n g
them.
1 0 . I n s t a ltlh e o i l p u m pa n d o i l s c r e e n .
6x1.0mm
11 N.m {1.1kgf.m,
6 x 1.0mm
11 N.m {1.1kgf.m,
a tbt.{t}
OII- SCREEN
Apply liquid gasket

to these pornts,
DOWEL PIN
DOWELPIN
6 x 1.0mm
11 N.m
{'l.1 kgl.m, 8 lbf,lt}
.,
r -zz
,.t
,.i
O-RING
Replace.
2.
I n s t a ltlh e o i l p a ng a s k eat n d o i l p a n .
D16Y5,D16Y8engines:
NOTE:
. Usea new oil pan gasket.
. Installthe oil pan no morethan five minutesafter
applyingliquidgasket.
1.
OILPAN
Apply liquid
gasketto
these poants.
I n s t a ltlh e o i l p a ng a s k eot n t h e o i l p a n .
NOTE:
. Use liquidgasket,part No. 08718- 0001or 08718
, 0003.
o A p p l y l i q u i dg a s k e ta s a n e v e n b e a d .c e n t e r e d
betweenthe edgesof the matingsurface.
. To preventoil leakageapply liquid gasketto the
. Do not installthe parts if five minutesor more
haveelapsedsinceapplyingthe liquidgasket.
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least 30 minutesbefore
filling the enginewith oil.
OIL PAN
PAN
GASKET
to thesepoints.
3.
Replace.
Tightenthe bolts and n u t sf i n g e rt i g h ta t s i x p o i n t s

as shown below.
OIL PAN
GASKET
Replace.
Tightenall boltsand nuts,startingfrom boltO, clockwise in threesteps.

NOTE:Excessive
tighteningcan causedistonionof
oil pan gasketand oil leakage.
Torque:12 N.m (1.2kgl.m,8.7lbt.ft)
(cont'd)
7-23
Oil Seals
Oil Pan
2.
Installation
Apply liquid gasketto the block mating surfaces,

t h e n i n s t a l tl h e o i l p a n .A p p l y l i q u i dg a s k e t o t h e
shadedareas.
NOTE:
. Engineremovalis not required.
. The crankshaftoil sealhousingshouldbe dry.
Apply a light coat of greaseto the crankshaftand to
the lips of the seals.
1.
Usingthe specialtool, drive in the timing pulley-end

sealuntilthe driverbottomsagainstthe oil pump.
When the seal is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
OIL PAN
3.
Tighten the nuts finger{ight at six points as shown
o
07947-SB00200
lnstallseal with the
part number side
facingout.
4.
Tightenall boltsand nuts,startingfrom nut O, clockwise in threesteps.

NOTErExcessive
tighteningcan causedistortionof
oil pan gasketand oil leakage.
Torque:12 N.m (1.2kgf'm,8.7lbl.ft)
t-z+
2.
Measurethe flywheel-endsealthicknessand the oil

seal housingdepth.Usingthe specialtool. drive the
flywheel-endseal into the rear cover to the point
where the clearancebetweenthe boftom of the oil
seal and the right side cover is 0.5 - 0.8 mm (0.020.03in) (seepage7-191.
NOTE:Align the hole in the driver attachmentwith
the pin on the crankshaft.
07749-0010000
DRIVERATTACHMENT
07948-S800101
lnstallseal waththe
part numberside
facing out.
7-25
IHI
I
/
SpecialTools
t
Ref.No.
Tool Numbel
07746- 0010400
07749- 0010000
07912- 611000' ]
a2)
Description
Attachment.52x 55 mm
Driver
Oil FilterWrench
Oty
1
I
1
PageRoforance
a-12
a-12
8-7
I
8-2
lllustrated Index
NOTE:
o Usenew O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstallation.
. Use liquid gasket,Part No. 08718- 0001 or 087180003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallIn g .
CAUTION: Do not overtighten the drain bolt.

ENGINEOIL PRESSURE
SWITCH
18 N.m {1.8ksf m, 13 lbf.ft)
1/8in. BSPT(Eritish
StandardPipeTaper)
2Slhreads/inch.
Use
properliquidsealant.
Apply liquidgasketto the recessesof the oil pan gasket (seepage7-22).
D16Y7engin:
OILPUMP
Overhaul,page8-9
Inspectaon,
page8-10
Applyliquidgasket
to the matingsurface
of the block.
O-RING OIL BREATHER

Replace. CHAMBER
6x1.0mm
1 1 N . m{ 1 . 1kst.m,
8 lbl.fr)
OIL FILTER
Replacement,
page8-7
O.RING
Replace.
6x1.0mm
11 N.m (1.1kgl,m,
8 tbf.ft)
GASKET
Replace.
thesepornts.
OILPAN
GASKET
Replace.
PAN
Befertopage7 22
when installing.
6x1.0mm
1l N.m {1.1kgf.m, Apptvtiquidqasketro
8lbf ft)
rhesepoints.
6 x 1.0mm
12 N m (1.2kglm, 8.7tbf.ftl
DRAINBOLT
44 N.m 14.5kgf.m,33 lbtftl
Do not overtighten.
(cont'd)
8-3
lllustrated Index
t.
(cont'd)
NOTE:
. Usenew O-ringswhen reassembling.
. Use liqu;d gasket,Part No. 08718- 0001 or 087180003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstall,
ing.
D16Y5,D15Y8engines:
CAUTION: Do not overtighten the dlain bolt.
ENGINEOIL PRESSURE
SWITCH
18 N.m 11,8kgf.m, 13 lbt.ft)
1/8in. BSPT(British
StandardPipeTaper)
28 Threads/inch.
Use
properliquidsealant.
OILPUMP
Overhaul,page8-g
page8-10 DOWELplN
Inspection,
Applyliquidgasket
to the matingsurface
of the block.
6x1,0mm
11 N.m 11.1kgf.m,
8 tbf.ttl
page8,7
Replacement,
6x1.0mm
11 N.m 11.1kgt m.
8 tbf.ftl
BAFFLEPLATE
SCREEN
6x1.0mm
11 N.m 11.1kgf.m.
8 tbf.ft)
6x1.0mm
11 N.m 11.1kgl.m,
8 tbf.ftl
OILPAN
GASKET
Replace.
OIL PAN
Referto page7-23
when installing.
urr.o-*tn
12 N'm 11.2kgl.m,8.7 lbf.ftl
8-4
39 N.m {,r.0kgl.m, 29 lbf.ft}

Do not overtighten.
En g i neO il
Inspection
Replacement
1 . Parkthe vehicle on level ground, and turn off the

engine.Allow the oil a few minutesto drain back
into the oil pan so the dipstickwill show the actual
level.
CAUTION: Removo lhe drain bolt carfully whilo tho

engine is hot; tho hct oil may cau36scalding,
Make cenainthat the oil level indicatedon the dipstickis betweenthe upperand lower marks.
1. Warm up the engine.

2.
Drainthe engineoil.
DRAINBOLT
a,l N.m14.5kgt'm, 33 lbf.ft)
Do notovertighten.
Beplace.
D16Y5.Dl6Y8 6ngines:
lf the level has droDpedclose to the lower mark,

add oil until it reachesthe uooermark.
CAUTION:Insertthe dipstickcarefullyto avoid bending it.
DRAINBOLT
39 N.m (,1.0kgl'm, 29 lbt frl
Donot ovenighten.
(cont'd)
EngineOil
Replacement
{cont'd)
3.
Reinstallthe drain bolt with a new washer, and refill

the enginewith the rcommenddoil.
Requirement
Capacity
API ServiceGrade:Use an "Energy

Conserving"SJ gradeoil or an
"EnergyConserving
ll" SH gradeoil,
SAE 5W - 30 preferred.
You can alsousean oilthat bearsthe
API CERTIFICATION
mark.
D16Ytengine:
3.6f (3.8US qt, 3.2 lmp qt)
at change,includingfilter.
3.3f (3.5US qt, 2.9 lmp qt)
at change,without filter.
4 . 3 1 ( 4 . 5U S q t , 3 . 8l m p q t )
afterengineoverhaul.
3.3/ (3.5US qt. 2.9 lmp qt)
at change,includingfilter.
3.0/ (3.2US qt, 2.6 lmp qt)
at change.without filter.
3.7/ (3.9US qt,3.3 tmp qt)
afterengineoverhaul.
Every7,500miles (12,000km) or
12 months(NormalConditions).
Ev6ry3,750miles(6.000km) or
6 months (SevereConditions).
Change
NOTE:Under normalconditions,the oil filter should be

replacedat everyotheroil change.
API CERTIFICATION
MARK
62\"'
API SERVICELABEL
Fill the enginewith oil up to the specifiedlevel,run

the enginefor more than three minutes,then check
fof oil leakage,
Undersevereconditions,the oil filter shouldbe replaced

at eachoil change.
The numbersin the middle of the Apl Servicelabel tell
you the oil's SAE viscosityor weight. Selectthe oil for
your car accordingto this chart:
Ambienl Temperature
-30
20
A n o i l w i t h a v i s c o s i t y o f 5 W - 3 0 i s p r e f e r r e df o r
improved fuel economy and year-roundprotectionin the
car.You may usea 10W- 30 oil if the climatein your area
is limited to the temperaturerangeshown on the chart.
8-6
Oil Filter
Replacement
Installtheoil filter by hand.
Aftr the engine has been run, the exhaust pipe will
be hot; be careful when working around the exhaust
pipe.
Be careful when loosening the drain bolt while the
engine is hot. Burns can result becausethe oil tem.
perature is very high.
1.
Removethe oil filter with the oil filter wrench.
2.
Inspectthe threadsand rubbersealon the new filter.

Wipe oif the seaton the engineblock,then apply a
lightcoat of oil to the new filter'srubberseal.
Afterthe rubbersealseats,tightenthe oil filterclockwise with the oil filterwrench.

Tighten: 7/8 turn clockwise.
Tighteningtorque:22N.m (2.2kgf.m,16lbt.ftl
NOTE: Use only filters with a built-in bypass sysrem.
Apply oil to rubberseal

beforeinstalling.
8-7
Oil Filter
Oil Pressure
(cont'dl
Replacement
Testing
Usethis procedureto tightenthe filter if eight numbers(1 to 8) are Drintedon the surfaceofthe filter.
1) Makea markon the oil filterbaseunderthe num,
ber that shows at the bottom of the filter when
the rubberseal is seated.
2)
lf the oil pressurewarninglight stayson with the engine

running,checkthe engineoil level.lf the oil levelis cor
rect:
1.
Connecta tachometer.
2.
Removethe engineoil pressureswitch,and installan

orl pressuregauge.
Tightenthe filter by turning it clockwiseseven

numbersfrom the markedpoint. For example,if a
markis madeunderthe number2 whenthe rubber seal is seated,the filter shouldbe tightened
untilthe number1 comesup to the markedpoint.
ENGINEOIL PRESSURE
SWITCH
MOUNTINGHOLE
7, turn
clockwise.
MARK
Numberwhen rubber
seal is seated,
Numberaftertightening.
Numberwhen rubber
sealis seated
Numberaftertightening 8
4
2
5
4
6
5
at
ADAPTER
{1/8'r28, BSPT}
(Commercially
avsilable)
CAUTION:Using any procedureolher than those

shown could rsult in seriousengine damsge due
to oil leakage.
5.
Afterinstallation,
fill the enginewith oil up to the specifiedlevel,run the enginefor morethanthreeminutes.
then checkfor oil leakage.
OIL PRESSURE
GAUGE
lCommerciallv
available)
Stan the engine.Shut it off immediatelyif the gauge

registersno oil pressure.Repairthe problembefore
contrnurng.
4.
Allow the engineto reachoperatingtemperature(fan

comeson at leasttwice).The pressureshouldbe:
EngineOil Temperature:176'F(80.C1
EngineOil Pressure:
Ar ldle:
59 kPa10.7kgf/cm,,10 psi)
minimum
At 3,000rpm: 3,t0 kPa (3.5 kgt/cm,, 50 psi)
minimum
lf oil pressureis within specifications,
replacethe
oil pressureswitchand recheck.
lf oil pressureis NOTwithin specifications,
inspect
t h e o i l p u m p( s e ep a g e8 1 0 ) .
8-8
Oil Pump
Overhaul
NOTE:
a Usenew O-ringswhen reassembling.
. U s el i q u i dg a s k e tP, a r tN o . 0 8 7 1 8 - 0 0 0 o
1r08718-0003.
. The rotorsmust be installedto the samedirection.
. After reassembly,
checkthat the rotorsmove without binding.
6x1.0mm
7 N.m (0.7kgf m, 5 lbt'ft)
PUMPHOUSING
Inspection,
Page8-10
Applyliquidgasket
to mating surfaceof
the cylinderblock
when installing.
OUTERROTOR
page8_10
Inspection,
INNERROTOR
page8_10
lnspection,
DOWELPIN
PUMPCOVER
O-RING
Feplace.
6x1.0mm
11 N.m (1.1 kgt m. 8 lbt.ft)
OIL SEAL
Replace.
page8-11
Installation,
SPRING
Valvemust slidefteely
in hous,ngbore.
Replaceit scored.
g
@ .Hwlsren
E
-
-/SEALING BOLT
39 N.- l{o kgf.m,
29 tbtftl
8-9
Oil Pump
RemovaUlnspection/lnstallation
'L
D r a i nt h e e n g i n eo i l .
2.
Turn the crankshaftand align the white groove on

the crankshaftpulley with the pointeron the lower
cover.
1 0 . Removethe screwsfrom the pump hausing,then

separatethe housingand cover.
3.
Removethe cylinderheadcoverand uppercover.
4.
R e m o v et h e p o w e r s t e e r i n gp u m p b e l t ,a i r c o n d i ,
tioner beltand the aiternatorbelt.
1 1 . Checkthe inner-to'outerrotor radial clearanceon
the pump rotor.lf the inner-to-outer

rotor clearance
e x c e e d st h e s e r v i c el i m i t . r e p l a c et h e i n n e r a n d
ourerrorors.
Inner Rotor-to-OuterRotor RadialClarsnce
Standard(New):0.02- 0.14mm
{0.001- 0.006inl
ServiceLimit: 0.20 mm {0.008in)
Removethe crankshaftpulleyand removethe lower

cover.
OUTER
ROTOR
6.
Removethe timing belt.
7.
Removethe drive pulley.
8.
Removethe oil pan and oil screen.
DOWELPIN
O.RING
Replace.
1t
INNERROTOR
Cneclithe housing-to-rotoraxial clearanceon the
pump rotor, lf the housing-to-rotoraxial clearance
exceedsthe serviceIimit, replacethe set of inner
and outer rotorsand/orthe pump housing.
Housing-to-RotorAxial Clearance
Standard(New):0.03- 0.08mm
(0.001- 0.003inl
ServiceLimit: 0.15mm {0.006in)
OIL SCREEN
9.
Remove the oil pump.
ROTORS
8-10
13. Checkthe housing-to-outer

rotorradialclearance.
It the housing-to-outer
rotor radialclearance
exceeds
the servjcelimit, replacethe set of inner and outer
rotorsand/orthe pump housing
Hoqsing.to.OutorBotor RadialClearance:
Standard{New):0.10- 0.18mm
(0.004- 0.007in)
HOUSING
1 4 . Inspectboth rotorsand the pump housingfor scor-
' 1 7 .R e a s s e m b lteh e
o i l p u m p ,a p p l y i n gt h r e a dl o c kt o
the pump housingscrews.
1 8 . Checkthat the oil pump turnstreely.

1 9 . Apply a light coatof oil to the seallip.
20. Installthe two dowel pins and new O-ringon the oil
pump.
2 1 . Apply liquidgasketto the cylinderblockmatingsurfaceof the oil pump.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001or 08718
- 0003
. Apply liquidgasketevenly,in a narrowbeadcen
teredon the matingsurface.
. To preventoil leakage,apply liquidgasketto the
. Do not installthe pans if five minutes or more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
old residue.
. After assembly,wait at least 30 minutes before
ing or otherdamage.Replacepartsif necessary.

1 5 . Removethe old oil sealfrom the oil pump.
to.
Usingthe specialtool, gentlytap in the new oil seal

until the driverbottomsagainstthe pump.
Apply liquidgasket
alongthe brokenline.
NOTE:The oil seal alone can be replacedwithout

removingthe oil pump.
DRtvER
- 0010000
0?7i19
ATTACHMENT.
52x55mm
07746- 0010i100
(cont'd)
8-11
O il Pu mp
RemovaUlnspection/lnstallation
(cont'd)
22. Installthe oil pump on the cylinderblock.
Apply greaseto the lip of the oil pump seal.
Then,installtheoil pump onto the crankshaft.
Whenthe pump is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
6x1.0mm
11 N.m 11.1kgf m,
I rbt.ftt
6 x'l.Omm
11N'm(1.1kgtm,
8 tbt.ftl
11N.m(1.1kgf.m,
8lbfftl
23. l n s t a ltlh e o i l s c r e e n .
24. I n s t a l l t h eo i l p a n( s e ep a g e7 , 2 2 ) .
NOTE:Cleanthe oil pan gasketmatingsurfaces.
8-12
IntakeManifold/ExhaustSystem
lntakeManifold
Replacement
..........
-............................
9-2
ExhaustManifold
9-5
Rep|acement
.......................................
ExhaustPipeand Muffler
.......................................
9-7
Replacement
ThreeWay CatalyticConverter(TWC)
Inspection
......................
9-9
HeatedOxygenSensor{HO2S)
Replacement
.......................................
9-9
IntakeManifold
Replacement
NOTE:Use new O-ringsand gasketswhen reassembling,
CAUTION:
. Chckfor lolds or scratcheson the surtaceof the gasket.
. Replacewith a new gasket if damaged.
D16Y7engine:
8 x 1.25mm
22 N.m 12.2kgl.m, 16lbfftl
INTAKEMANIFOLO
Replaceif crackedor
it matingsurtacesare
oama9eo,
8 x 1.25mm
23 N.m (2.3kgt.m,
1? tbt.ftl
INTAKEMANIFOLD
ERACKET
E x 1.25mm
2a N.m 12./tkgf.m, 17 lbtftl
g-2
D16Y5engine:
6x1.0mm
12 N.m l'1.2kgt.m,8.7 lbtftl
EGRCHAMBER
INTAKEMANIFOLD
Replaceif crackedor
if mating surfacesarc
oamageo.
8 x 1.25mm
21 N.m {2.1 kgf.m,
15 tbf f0
EXHAUSTGAS
RECIRCULATION
{EGRIVALVE
INTAKEAIR CONTROL
IIAC}VALVE (M/TI
8 x 1.25mm
22 N.m (2.2 kqf.m, 16 lbf.ftl
INTAKE MANIFOLD
BRACKET
8 x 1.25mm
23 N.m 12.3kgf.m,
17 tbf.frl
8 x 1.25mm
22 N.m (2.2kgf.m,
16 tbt tr)
(cont'd)
9-3
Intake Manifold
(cont'dl
Replacement
NOTE:Usenew O-ringsand gasketswhen reassembling.
CAUTION:
. Checkfor folds or scraichss on the surfaceof the gasket.
. Replacewith a new gasket it damaged.
D16Y8engine:
INTAKEMANIFOLD
Replaceit crackedor
il mating surfacesare
oamageo.
INTAKEAIR CONTROL
{IAC)VALVE(M/T)
$"^
GASKET
Replace.
THROTTLE
BODY
See section 11.
I x 1.25mm
23 N.m {2.3 kgf.m,
17 rbt.ftl
INTAKEMANIFOLD
BRACKET
9-4
ExhaustManifold
Replacement
NOTE:Usenew gasketsand self-lockingnutswhen reassembling.
CAUTION:
. Checkfor folds or scraicheson the surtace of lhe gasket.
. Replacewith a new gaskei if damaged.
D16Y5,D16Y7engines:
I x 1.25mm
24 N.m {2,4 kgtm, 17 lbf,ft}
PRIMARYHEATED
OXYGENSENSOR
{PRIMARYHO2SI
44 N.m (4.5kgf.m, 33 lbt.ft)
page9 9
Replacement,
10 x 1.25mm
44 N.m 14.5kgt.m,
33 tbf.ftl
GASKET
Feplace.
8 x 1.25mm
31 N.m 13.2kgf.m.
23 tbt.ft)
Replace.
THREEWAY CATALYTIC
CONVERTER
{TWC)
page9'9
Inspection,
6x1,0mm
11 N.m (1.1kgf.m,8lbtft)
MANIFOLD
BRACKET
SECONDARY
HEATED
OXYGENSENSOR
ISECONDARY
HO2S}
4zlN.m 14.5kgf.m, 33 lbl.ftl
page9-10
Beplacement,
{cont'd)
9-5
)
ExhaustManifold
Replacement(cont'd)
NOTE:Usenew gasketsand self-lockingnutswhen reassembling.
CAUTION:
. Checktor lolds or scratcheson thg surfac6ol the gaskgt.
o Replacewith a new gasket if damaged.
D16Ygsngine:
8 x 1.25 mtn
2a N.m {2.4 kgf.m,
t7 tbf.ft)
E x 1.25mm
3l t&m13.2kgf.m,
23 tbt'ftt
Rplacs.
PNIMARYHO2S
14 N.m 14.5kgt.m, 33 lbt.ft)
page9-10
Replacement,
EXXAUSTMANIFOLD
BRACKET
9-6
10 x 1.25mm
44 N.m (4.5kgf.m,33 lbf.ft,
ExhaustPipe and Muffler

Replacement
NOTE:Use new gasketsand self-lockingnutswhen reassembling.
D16Y5,D16Y7engines:
EXHAUSTPIPNP
MUFFI.ER
6 x 1.0 m.n
9.8 N.m {1.0 kgt.m, 7.2 lbf.ftl
HEAT SHIEI.I)
6xt.0mfi
9.EN.ft (1.0kst'm, 7.2 lbl'ftl
"e*......------------
8 x 1.25mm
22 N.m 12.2kgt.m.
16 tbf.frl
Replace.
Tightenthe boltsin
steps,alt.naling
side-to-side.
8 x 1.25mm
22 N.m {2.2kgf.m, 16 |bfftl
Replace.
Tightenthe bolts in steps,
akernatingside-to-side.
------------->@
Replace.
SEI.f.LOCKINGNUT
10 x 1.25mm
33 N.m 13.4kgtm,
25 tbt ftl
Replace.
GASKET
Replace.
NUl
SELF.I-OCKING
8 x 1.25mm
16 N.m (1.6kg .m. 12 lbf.tt)
Replace.
(cont'd)
9-7
)
ExhaustPipe and Muffler

Replacement(cont'd)
NOTE: Use new gaskets and self-locking nuts when reassembling.
Dl6Yg engine:
EXHAUSTPIPETIP
MUFFLER
o.4/
GASKET
Replace.
-6r1.0mm
9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
8 x 1.25mm
22Nm12.2kgtm,
16 tbt.ft)
Feplace.
Tightenthe boltsin
stePs,alternating
side-toside.
HEATSHIELD
6x1.0mm
9.8 N.m {1.0kgf.m, 7.2 lbt.ftl
L
NUT
SELF.LOCKING
l0 x 1.25mm
33 N.m {3.4kgf.m,
25 tbt.ft)
Replace.
EXHAUSTPIPE
SECONDARY
H()2S
a4 N.m (4.5kgf.m, 33lbf.ftl
page9-10
Replacement,
GASKET
Replace.
TWC
page9-9
Inspection,
GASKETS
Replace.
8 x 1.25mm
22 N.m (2.2kgt.m, 16 lbf.ftl
Replace.
Tightenthe boltsin steps,
alternating
side-to-side.
EXHAUSTPIPEA
SELF.LOCKING
NUT
t0 x 1.25mm
54 N.m 15.5kgtm,40 tbtftl
Replace.
9-8
16 N.m {1.6kgl.m, 12lbt.ft)

Replace.
HO2S
TWC
Replacement
Inspection
1.
Usinga flashlight,makea visualcheckfor plugging,

meltingand crackingof the catalyst.
Primary HO2S:
1.
Removethe primaryHO2S.
D16Y5,D16Y7enginss:
D16Y5,D16Y7engines:
a.
Disconnectthe primary HO2Sconnector,then

removethe cover.
8 x 1.25mm
2ilNm12.4kgt'm,
b.
Removethe primaryHO2S.
a/)
D16Y8 engine:
FLASHLIGHT
I
l
PRIMARYH02S
44 N.m 14t kgf.m, 33tbtftl
(cont'd)
9-9
A
HO2S
(cont'dl
Replacement
Dl6Y8 engine:
a.
SocondaryHO2S:
Disconnectthe primary HO2S connectorthen

removethe primaryH02S.
1.
Removethe secondaryHO2S.
Dl6Y5, Dl6Y7 engin6:
a.
D i s c o n n e c t h e s e c o n d a r yH O 2 Sc o n n e c t o r ,
then removethe secondaryHO25.
()2 SENSOR
WRENCH
(Commercially
PRIMARYHO2S
4,0N.m {4.5kgI.m, 33 lbt.ftl
2.
lnstallthe DrimarvHO2Sin reverseorderof removal.
D16Y8engine:
a.
Removethe grommet,and pullout the secondary

HO2Sconnector,then disconnectthe secondary
HO2Sconnector.
SECONDABY
HO2S
CONNECTOR
9-10
a
b.
Removethe secondarvHO2S.
02 SENSORWRENCH
available)
lCommercially
SECONDARY
HO2S
{rr N.m (4.5 kgf.m, 33 lbf.frl
2.
I n s t a l lt h e s e c o n d a r yH O 2 S i n r e v e r s eo r d e r o f
removal.
9-1
Cooling
"." 10-2
lndex...........
flfustrated
Radiator
" " I 0-5
"."......
........................
Replacement
EngineCoolantRefillingand
10-6
........"".......'.'
Bleeding
10-8
...........'....'..'
CapTesting
.'..'.10-8
Testing
Thermostat
" " 10-9
"......
........................'..
Replacement
"....10-10
Testing
EngineGoolantTemPerature
(ECT)Switch
....'.10-10
Testing
WaterPump
.. 10-11
lllustratedIndex .....".'.
.10-12
fnspection
10-12
.......................'.'.'.......'."
Replacement
lllustratedIndex
!@@
system is under high pressurewhen the
engine is hot. To avoid danger of releasingscalding

enginecoolant,removethe cap only when the engineis
coor.
Total Cooling System Capacity ncluding heater and

reservoir{0.41 (0.,12
US qt,0.35 lmp qt))l:
M/I
4 . 2f ( 4 . 4U S q t , 3 . 7l m p q t )
Afi
4 . 1 i ( 4 . 3U S q t , 3 . 6 l m p q t ) * 1
4 . 3 f { 4 . 5U S q t , 3 . 8 l m p q t ) * '
CVT
4 . 3f 1 4 . 5U S q t . 3 . 8l m p q t )
* 1 :D 1 6 Y 7
engine
x 2 :D 1 6 Y ge n g i n e
UPPEN
RADIATOR
HOSE
CAUTION:lf any engine coolantspills on painted portions ol the body, rinse it off immediately.
NOTE:
. Checkall coolingsystem hosesfor damage.leaksor
deteriorationand replaceif necessary.
. Checkall hoseclampsand retightenif necessary.
. Use new O-ringswhen reassembling.
BADIATORCAP
Pressuretest, Page10-8
RADIATOR
Enginecoolantrefillingand bleeding,
page10 6
Leaktest,page10-8
Inspectsolderedjointsand
seamsfor leaks,
Blowout dirt from between
corefinswith compressed
air.
lf insects,etc.,are clogging
radiator,washthem off with
low pressurewater,
6x1.0mm
9.8N.m (1.0kgt m,
7.2 tbt.ftl
\
\
\
\
COOLANT
RESERVOIR
-E-
5x0.8mm
5.4N.m {0.55kgtm, 4.0lbffi}
6x1.0mm
7.2N.m {0.73kgJ.m,
5.3 tbf.f0
LOWER
CUSHION
DRAIN
PLUG
Referto sectionl4
when installing.
10-2
O-RING
Replace.
EngineHose Connoction3:
Dl6Y7 engin:
IACVALVE
HEATER
HOSES
HEATER
VALVE
(cont'd)
,.l
10-3
lllustratedIndex
(cont'dl
EngingHosgConnections:
D16Y5,D16Y8engines:
tAc vAtvE
IA/T)
CONNECTING
PIPE
Replace.
WATERBYPASS
HOSE
IAC VALVE
IM/T)
THEBMOSTAT
HOUSING
O.RING
Replace.
\
\
\
\
rn
/
CONNECTING
PIPE
HEATEB
VALVE
O.RING
Replace.
HATER
HOSES
10-4
Radiator
Replacement
1 . Drainthe enginecoolant.
2.
5,
R e m o v et h e u p p e ra n d l o w e r r a d i a t o rh o s e s ,a n d
ATFcoolerhoses.
3.
Disconnect
the fan motor connector.
4.
Removethe radiatorupper bracket,then pull up the

raqtalor.
RAOIA
Removethe fan shroudassembliesand other parts

from the radiator.
Installthe radiatorin the reverseorderof removal:

NOTE:
. Setthe upperand lower cushionssecurely,
. F i l l t h e r a d i a t o rw i t h e n g i n ec o o l a n ta n d b l e e d
the air.
6x1.0mm
9.8 N.m (1.0kg[.m,
7.2 tbl.trl
ATF COOLER
HOSES{A/TI
Referto section
when installing.
UPPERRADIATORHOSE
6x1.0mm
7.2 N.m (0.73kgt.m,
5.3 tbl.fr)
RESERVOIR
TANK
LOWEBCUSHION
DRAINPLUG
O.RING
Replace.
LOWERRADIATORHOSE
10-5
Radiator
EngineCoolantRefillingand Bleeding
CAUTION:When pouring engine coolant, be sure to
shut the rolay box lid and not to let coolant spill on the
slcirical parts or thc paint. ll any coolant spills. rinse it
off immdiatslv.
Apply liquid gasketto the drain bolt threads,then

reinstallthe bolt with a new washer and tighten it
securery.
Tightenthe radiatordrain plug securely.
1.
Slide the heatertemperaturecontrol lever to maxi

mum heat. Make sure the engine and radiatorare
cool to the touch,
2.
Removethe radiatorcao.
3.
Loosenthe drain plug, and drainthe coolant.
7 . Remove,drain and reinstallthe reservoir.Fill the

tsnk halfwayto the MAX mark with water,then up
to MAX the markwith antifreeze.
ORAINPLUG
4.
Removethe drain bolt from the cvlinderblock.
</on
7E N.m 18.0kgl m, 58 lbf ft)
10-6
MAX MARK
8.
M i x t h e r e c o m m e n d e da n t i J r e e z w
e ith an equal
amountof water in a cleancontainer.
9. Pour coolantinto the radiatorup to the baseof the

filler neck,and installthe radiatorcap looselv.
NOTEI
. Useonly genuineHondaantifreeze/coolant.
. For best corrosion protection,the coolant conc e n t r a t i o nm u s t b e m a i n t a i n e dy e a r - r o u n da t
50% minimum. Coolantconcentrations
lessthan
5 0 % m a y n o t p r o v i d e s u f f i c i e n tp r o t e c t i o n
againstcorrosionor freezing
. C o o l a n tc o n c e n t r a t i o n gs r e a t e rt h a n 6 0 % w i l l
i m p a i r c o o l i n g e f f i c i e n c ya n d a r e n o t r e c o m menoeo.
CAUTION:
. Do not mix differcd brands of antifreeze/coolants.
. Do not use additional rust inhibitors or anti.rust
produsts; thcy may not be compatible with the
coolant.
Engine Coolant Refill Capacity Iincluding reservoir
(0.4f 10.42US qt, 0.35lm' qt)ll.
M/I
A/T
3 . 8{ { 4 , 0U S q t , 3 . 3l m p q t )
3.7/ (3.9US qt,3.3 lmp qt)*'
3 . 9/ ( 4 . 1U S q t , 3 . 4l m p q t ) * ,
3 . 9{ ( 4 . 1U S q t , 3 . 4l m p q t )
CVT
* 1 : D 1 6 Y 7e n g i n e
* 2 : D 1 6 Y 8e n g i n e
1 0 . Startthe engineand let it run until it warms up (the

radiatorfan comeson at leasttwice).
1 1 . Turn off the engine.Checkthe level in the radiator.
add coolantif needed.

Put the radiatorcap on tightly,then run the engine
againand checkfor leaks,
10-7
)
Radiator
Testing
CapTesting
1.
Removethe radiatorcap, wet its seal with engine

tester.
coolant,then installit on the Dressure
'1.
Wait until the engine is cool, then carefullyremove

t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e
coolantto the top of the filler neck.
Attachthe pressuretesterto the radiatorand apply
a pressureof 93 - 123 kPa(0.95- 1.25kgt/cm?,'14
18 osi).
RADIATOR
RAOIATORPRESSURE
TESTER
(Commercially
available)
ADAPTOR
(for32 mm neck,low profile)
ADAPTOR
{for32mm neck,low Profile)
Apply a pressureof 93 - 123kPa(0.95- 1.25kgflcm' .

1 4- 1 8 p s i ) .
Checkfor a d.op in pressure.
lf the pressuredrops.replacthe cap.
Inspectfor enginecoolantleaksand a drop in pressure.

4.
Removethe testerand reinstalltheradiatorcap.

NOTE: Checkfor engine oil in the coolant and/or
coolantin the engineoil.
10-8
Thermostat
Replacement
NOTE:Usea new O-ringwhen reassembling.
THERMOSTAT
Installwithpin up.
RUEBERSEAL
THERMOSTAT
THERMOSTAT
HOUSING
TEMPERATURE
IECTI
swtTcH
24 N.m 12.{ kgt.m, 17 lbl.ftl
6xl.0mm
12 N.m 11.2kgf.m,8.7tbtft)
10-9
ECTSwitch
Thermostat
Testing
Testing
Replacethe thermostatif it is open at room temperature.
Removingthe EcT switch while the engine

@
is hot can causethe coolant to spray out, seriouslyscalding you. Always let the engine and radiator cool down
betore removing the ECTswitch,
To test a closedthermostat:
'L
Suspendthe thermostatin a containerof water as

shown.
NOTE:Bleedair from the coolingsystemafter installing

the ECTswitch{seepage10-6}.
1.
THERMOMETER
Removethe ECTswitch from the thermostathousing (seepage10-9).

Suspendthe ECTswitch in a containerot water as
shown.
THERMOSTAT
tl
Heat the water, and checkthe temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens.and at which it is fully open.
CAUTION:Do not let the thermometertouch the
bottom ot the hot container.
Heat the water, and checkthe temperaturewith a

thermometer.
M e a s u r el i f t h e i g h t o f t h e t h e r m o s t a tw h e n f u l l y
open.
CAUTION:Do not let lhe thormometertouch the

bottom of the hot container.
STANDARDTHERMOSTAT
Lift height:
above8.0 mm (0.31in)
Startsopening: 169'- 176"F(75"- 80"C)
Fullyopen:
194"F(90'C)
4.
Measurethe resistancebetweenthe A and B terminalsaccordingto the table.

Terminal
Op"r"ffi
ON
SWITCH
10-10
196"- 203"F
5" - 15.F(3"- 8"C)

O F F lower than the temperaturewhen I goeson
O_
Fueland Emissions
SpecialTools
..............
11-2
Component Location3
lndex
. . .1 1 . 3
Systom Description
Vacuum Connections
11.8
Electricrl Connaqtions
11-19
I 1.29
SystemConneqtors.........................,,.,..,...,.,.
Troubleshooting
Troubfsshooting
71.42
Procoduro!...............,........
EngineContlol Module/Poworftain
Control Module Terminal
Arrangement
11-'19
DiagnosticTroublCodeChart ....................
11-53
How to ReadFlowcharG...............................
1f -59
PGM-FlSystem
Systom Description
11.60
TroubleshootingFlowcharts
EnginoControl Module/Powrtrain
Control Module
11.(x'
Msnifold Absolute Pre3sureSen3or.............11-67
Intak Air TempraturoSensor
11-73
EngineCoolant TemperatureSensor ...........1I-76
ThrottlePositionSensor ...............................
11-79
Prim8ryHeatedOrygen Sensor(Sensor1) ... 11-8'l
Socondrry Hoatd Orygon Sonsor
11-95
lSensor2)................
HeatedOxygen Sensor Heatel
11-98
Fuel Supply System
11-103
Misfire Detectod in One Gylinder
11-105
Random Misfire
11-108
Knock Sensot
11-109
CKP/TDC/CYP
1 1 - 1t 0
Sensor.......................-....-.-.....
VehicloSpesdSensor,......,...,....,.....,.,...........
11-'112
Barometric PressureSen3or
1t-113
11-115
ElectricalLoad Detectol
CKFSensor
11-117
EGM/FCMInternalCircuit .............................
11-120
A/T Sisnal[rvlA/TMB] ..................................
11-121
ldle ControlSystem
System Description
.................
11-122
TroublshootingFlowchart3
. . . . .1. 1 - 1 2 4
ldle Control System
ldle Air Control Valve
11-126
..11-130
Starter Switch Signal .
AirConditioningSignsl .................................
11-131
AlternatorFRSignal ......................................
t1-133
Brake Switch Signal
11-13i1
Power Stoaring PressurcSwitch Signal ......11.135

A/T Gear Position Signal ....
11-137
11-139
ClutchSwitch Signal ..........
ldle SpeedSetting
11-141
Fuel Supply System

Fuel Lines
t 1-1i[5
11-117
Fusl Tube/Ouick.ConnectF ittin9s................,....
System Description........
1t-150
11-150
Fuel PressurG.........,.
11-152
Fuel Iniectors .......
I 1-15i1
FuelPressureRegulator.....,.,.............,..,...,..,.....
. . . . . . . . . . . . . . . . . . . .1. .1. ._. 1. .5. .5
Fuel Fiher
. . . . . . . . . . . . . . . . . . . .1. .1. .-.1. 5
. .6.
Fuel Pump
PGM-FlMain Relay
. . .1 1 - 1 5 7
FueT
l ank...................
. . . . . . . . . . . .1
. .1. .-.1 6 0
Intake Air System

System Description
t1-161
Emission Control System

11-167
Systm Description
11-167
Tailpipe Emission
Three Way Catalytic Converter
11-167
11-169
ExhaustGasRecirculation
System ...................
PositiveCrankcaseVentilation System ..-......-..11-171
I 1-178
EvaporativeEmissionControls..........................
Speci a l To ols
t
SpecialTools
Oty
Description
Rsl. No.
Tool Number
A 9 7 3 X - 0 4 1_ X X X X X
0 - 30 in.Hg
VacuumPump/Gauge,
07JAZ- 0010008
07PAZ- 0010100
07sAz - 0010004
07406- 0040001
07406- 0040304
Vacuum/Pressure
Gauge,0 - 4 in.Hg
SCSServiceConnector
BackprobeSet
FuelPressureGauge
FuelPressureAdapter,6x 15 mm
1
1
a
1
1
I
(^
./.
),
11- 2
PageRefelnc
't1-171,112,145,
186,188,192.193
1 1 - 1 9 21, 9 3
11-42
11-44
1 1 - 1 5 01,5 r , 1 5 4
11 - 1 5 0
ComponentLocations
lndex
D16Y5engine:
THROTTLEPOSITIONITPI
SENSOR
page11 79
Troubleshooting,
EXHAUSTGAS NECIRCULATION
{EGR)VALVEand EXHAUSTGAS
RECIRCULATION
IEGR}VALVE
LIFTSENSOR
pagel1 170
Troubleshooting,
MANIFOLDABSOLUTE
PRESSURE
IMAPI SENSOR
page'l 1-67
Troubleshooting,
IDLEAIRCONTROL
IIACIVAI-VE
{M/TI
page11-126
Troubleshooting,
EXHAUSTGAS RECIRCULATION
IEGR'CONTROLSOLENOID
valvE tcwt
INIAKE AIR TEMPERATURE

IIAT} SENSOR
page11-73
Troubleshooting,
page11 I70
Troubleshooting,
EVAPORATIVE
EMISSION
{EVAP}PURGECONTROL
SOLENOIDVALVE
pag11-190
Troubleshooting,
ELECTRICAL
LOAD
DETECTOR
IELD){USA model)
page11-115
Troubleshooting,
POWERSTEERINGPRESSURE
CRANKSHAFT
POStTTON/
TOPDEADCENTER/
swlTcH{usal
tPsP)
page11-135
roubleshooting,
1 =
CYLINDER
POStTtON
(CKP/TDC/CYP}
KNOCKSENSOR{KSI
(cw)
page11-109
Troubleshooting,
(Buikinrothe distributor)
T r o u b l e s h o o t i npga,g e1 1 - 1 1 0. /
CRANKSHAFT
SPEED
FLUCTUATION
ICKFISENSOR
page1'1117
Troubleshooting,
VEHICLESPEEDSENSOR
page1'l 112
Troubleshooting.
ENGINE
IOLEAIR CONTROL(IAC)VALVE
TEMPERATURE
SENSOR
{ECT)
page11-76
Troubleshooting,
tcwt
page11-128
Troubleshooting,
WAY CATALYTIC
CONVERTER
ITWC}
PRIMARYHEATED
SENSOR(PRIMARYHO2SI
{SENSOR1) {M/Tt
page1'1-88
Troubleshooting,
PRIMARYHEATEDOXYGEN
SENSOR{PRIMARYHO2S'
{SENSOR1t {CWl
page11-84
Troubleshooting,
paget 1-168
Troubleshooting,
SECONDARY
HEATEDOXYGEN
SENSORISECONDARY
HO2SI
{SENSOR2l
page11-95
Troubleshooting,
(cont'd)
11-3
Component Locations
Index(cont'dl
D16Y8engins:
THROTTLEPOSITIONITP}
SENSOR
page11 79
Troubleshooting,
INTAXEAIRTEMPERATURE
IIAT} SENSOR
page1'1-73
Troubleshooting,
EI."ECTRICAL
LOAO
DETECTOR
{ELDI(USAI
pageI1-t15
Troubleshooting,
MANIFOLOABSOLUTE
PRESSURE
{MAPISENSOR
page11 67
Troubleshooting,
IOLEAIR CONTROLIIACIVALVE
{M/T}
page11-126
Troubleshooting,
EVAPORATIVE
EMISSION
IEVAP)PURGE
CONTROL
SOLENOID
VALVE
CRANKSHAFT
POStTtON/
TOPDEADCENTER/
CYLINOEF
POStTtON
(CKP/TDC/CYP}
SENSOR
l8uilt into the distributori
page11'110/'
Troubleshooting,
page11-185,
Troubleshooting,
190
{PSP|SWTTCH
{USA)
page11-135
Troubleshooting,
KNOCKSENSOR{KSI
page11-109
Troubleshooting,
CRANKSHAFT
SPEED
FLUCTUANON
ICKFISENSOR
page11-'l17
Troubleshooting,
VEHICI."E
SPEEDSENSOR
page11-112
Troubleshooting,
IDLEAIRCONTROL
IIACIVALVE
IA/TI
page1'l-128
Troubleshooting,
TEMPERATURE
tEcTtsENson
page11 76
Troubleshooting,
PRIMARYI{EATEDOXYGENSENSOR
(PRIMARYHO2SIISENSOR1}
page11-84
Troubleshooting,
THREEWAY CATALYTIC
CONVERTER
{TWCI
page1l'168
Troubleshooting,
t?\..==.--
SEOONDARY
HEATEDOXYGEN
SENSOB
HO2S}{SENSOR2I
ISECONDABY
page11 95
Troubleshooting,
11-4
- --L------
--- - ----:
SENSOR
page11-79
Troubleshooting,
D16Y7engin6:
MANIFOLOABSOLUTE
(MAP)SENSOR
PRESSURE
page11-67
Troubleshooting,
VEHICLESPEEOSENSOR{VSSI
page1!-112
Troubleshooting,
INTAKEAIR TEMPERATURE
{IATISENSOR
page11 73
Troubleshooting,
ELECTRICAL
LOAD
DETECTOR
IELDIIUSAI
page11''1'!5
Troubloshooting,
CRANKSHAFT
POStTtoir/
TOPDEADCENTER/
CYLINDER
POSTT|ON
POWERSIEERINGPRESSURE
{PSP)SWTTCH|USA}
page11-135
roubleshooting,
--....-
IDLEAIR CONTROL{IACIVALVE
r o u b l e s h o o t i n g ,p a g e 1 1 ' ! 2 8
SENSOR
ICKP/TDC/CYPI
{Builtintothe distributor)
page11-110
Troubleshooting.
i
CRANKSHAFT
SPEED
FLUCTUATION
{CKF}SENSOR
page11 117
TroLrbleshooting,
PRIMARYHEATEDOXYGEN
SENSORIPRIMARYH02SI
ENGINECOOLANT
TEMPERATURE
IECTISENSOR
page11-76
Troubleshooting,
EVAPORATIVE
EMISSION
IEVAP)PURGECONTROL
SOLENOIDVALVE
page'l1-190
Troubleshooting,
CLUTCHSWITCH{D16Y56ngine
M,/T)
Selt-diagnosticProcedures,
page 11-42
lsENsoR
1)
page11 84
Troubleshooting,
SECONDARY
HATEDOXYGEN
SENSORISECONDARY
HO2SI
2t
{SENSOR
page11-95
Troubleshooting,
THREE
WAYCATALYTIC
CONVERTER
{TWC)
pageI 1-168
Troubleshooting,
PGM.FIMAIN RELAY
RelayTesting,page11-157
pag11-158
Troubleshooting.
t2Pl
Procedures,
Self-diagnostic
page11-42
ENGINECONTROLMODULE
IECMI/POWERTRAIN
CONTROLMODULE{PCM}
page11-63
Troubleshooting,
(cont'd)
11 - 5
ComponentLocations
Index(cont'dl
'96 Dl6Y8 engine

{coupe),
'97 Dl6Y7 engiDs(coupe:KL mod|, sedan: KL
{LX) modell,
'97 Dl6YBengine(coupo:all models,sedan:KL modell,'98-all
models:
FUELVAPORPIPE FUELGAUGESENDINGUNIT
FUELFEEOPIPE
Testing,seesection23
FUELFILTER
page11-155
Replacement.
FUELPUMP
Testing,page11-156
page11-156
Replacement,
EVAPORANVE
EMISSION
IEVAPICONTROL
CANISTER
VENTS}IUTVALVE
page'l1-185
Troubleshooting.
EVAPORATIVE
EMISSION
IEVAP)CONTROLCANISTER
page11-1
Troubleshooting,
FUELTANK
page11-160
Replacement,
APORATIVEEMISSION
{EVAPIBYPASSSOLENOID
VALVE
T r o u b l e s h o o t i n g .p a g e ' l 1 - ' 1 8 5
FUELINJECTORS
page11-152
Roplacement,
TIVEEMISSION
{EVAPITWOWAYVALVE
page11-193
Testing,
TANKPRESSURE
SENSOR
page11-181
Troubleshooting,
FUEI
REGULATOR
Testing,page'll-154
R e p l a c e m e n t ,p a g e 1 1 - 1 5 4
FUEL
FITTINGS
page11 147
Precautions,
page11 147
Disconnection,
page11-148
Connection,
'96 Dl6Y5
engino,'96 Dt6Y7 lngin,'96 Dl6Y8 ngin. {sedan),
'97 D16Y5.ngine, '97 D16Y7
ongine (coupe:KA, KC mod6ls,
sedan: KA, KC, KL {DX) modls, hatchback:8ll modlsl.
'97 D16Y8engine (sed!n: KA, KC
modls):
FUELVAPORPIPE
FUEL
FUELFILTER
page11155
Replacement,
EVAPORATIVE
EMISSION
IEVAPICONTROLCANISTER
page11-190
Troubleshooting,
FUELPUMP
Testing,page11 156
page I 1-156
Replacement,
FUELFILL
CAP
FUELTANK
page11-160
Replacement,
TIVE EMISSION
IEVAP)TWO WAY VALVE

Testing,page11 193
TUBE/OUICK.CONNECT
FUELPRESSURE
REGULATOR
Testing,page11-154
pageI 1-154
Replacement,
11-6
FITTINGS
page11-147
Precautions,
page1'1147
Disconnection,
page11 148
Connection,
D16Y5,D16Y8engine:
TITROTTLE
BODYITB}
page11-164
Inspection,
AIR CLEANERIACL)
Replacement,
R e m o v a l ,p a g e 1 1 - 1 6 5
D i s a s s e m b l y ,p a g e 1 l 1 6 6
THROTTLECABLE
Inspection/Adjustment,
page11-'162
page11,163
Installation,
VENTILATION{PCV}VALVE
page I1-177
Inspection,
D16Y7engine:
AIR CLEANER{ACL}
page11-'162
Replacement,
RESONATOR
POSITIVECRANKCASE
VENIILATION{PCVIVALVE
page'l1-177
Inspection.
THROTTLECABLE
page1'l-162
Inspection/Adjustment,
page1l 163
Installation,
THROTTLEBODY(TBI
page'l1-16,4
Inspection,
Removal,page11'165
page11 166
Disassembly.
11-7
SystemDescription
VacuumConnections
D16Y5engine{'96,'97 models):
To EvAPORATIVE
EMISSION
{EVAPI
TWOWAYVALVE
MANIFOLO
ABSOLUTE
(MAPI
PRESSURE
SENSOR
(EGRICONTROLSOLENOIO
VALVEIA/TI
\
EMISSION
EVAPORATIVE
IEVAP)PURGE
CONTROLCANISTER
\ ^
Tre)
EXHAUSTGAS RECIRCULA
(EGRIVALVEand EXHAUSTGAS
RECIRCULATION
{EGRIVALVE
LIFTSENSOR
(A/TI
l.--
-.'ry \
EVAPORA
EMISSION(EVAP}
PURGECONTROLSOLENOID
VAI-VE
To CRUISE
CONTROL
DIAPHRAGM
(withcruisecontroli
FRONTOF VEHICLE
REGULATOR
O: VacuumhoseNo.
11-8
D16Y5ongine1,98modell:
EVAPORATIVE
EMISSION{EVAP)
CONTROLCANISTER
VENTSHUTVALVE
To EVAPORATIVE
MISSION
{EVAPITHREEWAYVALVE
To EVAPORATIVE
EMISSION
(EVAP}
TWOWAYVALVE
and EXHAUST
GAS
IEGRIVALVE
IEGRIVALVE
LIFT SENSOR
tatfl
EXHAUSTGAS RECIRCULANON
{EGRICOiITROLSOLENOID
{CVTonlyl
VALVE
EV
i,ff------\-
nvE
EMISSION{EVAP}
PURGECONTNOL
CANISTER
I M,
I SP
PURGE
JOINT
L..-..-..-..-r
lin.;rrdiollesolure
- --
PRESSURE
tMAPI
SENSOR
I
I
EVAPORATIVE
EMISSION{EVAP'
VALVE
To CRUISE
CONTROL
DIAPHBAGM
(withcruisecontrol)
FRONTOF VEHICLE
REGULATOR
FUELPRSSURE
O: VacuumhoseNo.
(conr'd)
11 - 9
SystemDescription
VacuumConnections(cont'd)
D16Y8engine:
EVAPORATIVE
EMISSIONIEVAPI
CONTROLCANISTER
VENTSI{UT VALVE
('96 coup., 37 coup.: all models,
'97 aed.n: KL model, 'g8-modelsl
To EVAPOnATVEEMISSION
{EVAPITHFEEWAY VALVE
'97
l'96 coupo, coupo:all mod6b,
'97 sedan:KL model, 'g8-modols)
To EVAPORATIVE
EMISSION
IEVAPI
TWO WAY VALVE
EVAPORATIVE
EMISSIONIEVAPI
PURGECONTROL
CANISTER
{'96coupe, 37 coupe:ell modek,
3edan:KL model)
FUELPRESSURE
REGULATOR
MANIFOLD
AESOLUTE
(MAP}SENSOR
PRESSURE
EVAPORANVEEMISSION
IEVAPIPURGE
CO]TTROLCANISTER
('96 3.d.n, 37 r.drn: KA,
KC mod.lrl
EVAPORATIVE
EMISSION{EVAP}
VALVE
Qo
FNONTOF VEHICLE
11 - 1 0
To CRUISE
CONTROL
OIAPHRAGM
(withcruisecontrol)
D16Y7ongine l'96 modek,'97 coups: KA, KC models.'97 sedsn: KA, KC.KL {DX} models,'97 hatchback:all modolsl:
EVAPORATIVE
EMISSION
IEVAP'
PURGECONTROL
FUEL
PRESSURE
REGULATOR
To EVAPORATIVE
(EVAPI
EMISSION
TWOWAYVALVE
MANIFOLD
AASOLUTE
PRESSURE
IMAP)
SENSOB
To CRUISE
CONTROL
DIAPHRAGM
{withcruiso
control)
EVAPORATIVE
EMISSIONIEVAPI
PURGECONTROL
CANISTER
FRONTOF
vEHtcl-E
(cont'd)
11-11
r
SystemDescription
VacuumConnections(cont'dl
Dl6Y7 engine('97coupe:KL modcl,'97sedan:KL {LX)model,'98models}:
EVAPORATIVE
EMISSION(EVAPI
CONTROLCANISTER
VENT SHUTVALVE
To EVAPORATIVE
EMISSION
IEVAPITHREEWAY VALVE
To EVAPORATIVE
EMISSION
IEVAP)
TWOWAYVALVE
FUELPRESSURE
REGULATOR
MANIFOLDAASOLUTE
PRESSURE
IMAPI SENSOR
EVAPORATIVE
EMISSIONIEVAPI
PURGECONTFOL
CANISTER
To CRUISE
coNTROt
DIAPHRAGM
(withcruiscontrol)
EVAPORATIVE
EMISSION(EVAPI
PURGECONTROLSOI."ENOID
VALVE
FRONTOF VEHICLE
11-12
D16Y5enginenl'95,'97 modelsl:
,r;---l
ENGINEI
COOLANTi
I
i
l(D l+ |
t/6r IUI t
iLffii
i -I]FnL
l-,4
l-r-
i
I
:l: Vacuum ho3oNo.

': CVT only
o PRIMARYHCATEDOXYGENSENSORIPRIMARYHOzS,
1l
SENSOR
6i SECONDARY
HEATEOOXYGENSENSORISECONDARY
HOzS.SENSOR2l
aal MANIFOLDABSOLUTEPRESSURE
(MAP}SENSOR
IECTISENSON
@ ENGINECOOLANTTEMPERATURE
INTAKEAIR TEMPERATURE
{IATISENSOR
KNOCKSENSORIKS}
CRAITIKSHAFT
SPEEDFLUCTUATION(CKFISENSOR
@ IDLEAIR CONTROL(IACIVALVE
6\ THROTTLE
BOOY(TBI
[E FUELINJECTOR
FUELPULSATIONDAMPER
@ FUELFILTER
REGULATOR
@ FUELPRESSURE
(0 FUELPUMP(FP)
@ FUELTANK
o
o
EMISSIONIEVAP}VALVE
@ FUELTANK EVAPORATIVE
AIB CLEANER
a
(D
RESONATOR
@ POSITIVECRANKCASEVENTILAIION{PCVIVALVE
IEGRICONTROL
0 EXHAUSTGAS RECIRCULANON
SOLENOIDVALVE
{EGRIVALVE
@)EXHAUSTGAS RECIRCULANON
EXHAUSTGAS RECIRCULANON
IEGRIVALVELIFT
SENSOR
@ EVAPORANVEEMISSION{EVAPIPURGECONTNOL
sottNotDvALvE
EVAPORATIVE
EMISSION{EVAPICONTROLCANISTER
EMISSIONIEVAPITWO WAY VALVE

@ EVAPORATIVE
THREEWAY CATALYTICCONVERTEFITWCI
(cont'd)
11 - 1 3
SystemDescription
D16Y5enginel'98 model):
-: Vacuum hoaoNo.
*: CW only
(PRIMARY
HEATED
O PRIMARY
OXYGENSENSOR
HO2S.
SENSOR
1l
HEATED
oxYGENsENsoRISEGoNDARY
O SECoNDARY
HO2S.SENSOR
2)
ABSoLUTE
PRESSURE
O MANIFoLD
|MAP}sENsoF
(' ENGINC
COOLANT
TEMPERATURE
ICCI)SENSOR
AIFTEMPERATUBE
O INTAKE
{IAT}sENsoR
SENSOR
G) KNOCK
IKSI
spEEDFLUCTUAT|oN
O CRANKSHAFT
tcKFtsENsoR
@ IDI.EAIRcoNTRoL{IACIVALVE
BoDYtrBl
O THRoTTLE
(O FUELINJECToR
DAMPER
O FUELPULSATION
@ FUELFILTER
(} FUELPRESSURE
REGULAToR
(} FUELPUMP{FP)
@ FUELTANK
EMtsstoNtEvaplvALvE
@ FUE|-TANKEvApoRATtvE
@ AIRCLEANER
@ RESoNAToR
vENnLATtoN
@ posrnvEcRANKcasE
{pcvtvALvE
GAsRECIRCULATIoN
@ EXHAUST
coNTRoL
IEGn)
SOLENOID
VALVE
GAs RECIBCULATIoN
@ EXHAUST
{EGRIvALvE
@ ExHAUsrGAs REctRcuLATtoN
{EGRtvalvE L|FT
SENSOR
EMISSIoN
@ EVAPoRATIVE
IEVAPIPUnGEcoNTRoL
SOLENOID
VALVE
JOTNT
8] PURGE
EMIsstoNIEVAPIcoNTRoLCANISTER
@ EVAPoRATIVE
EMrsstoN(EvAp)BypAsssoLENoD
@ EvApoRATtvE
VALVE
EMtssIoN{EVAP)
THREE
@ EVAPoRATIVE
wAY vALvE
EMISSIoN
@ EVAPoRATIVE
IEVAPIcoNTRoLCANISTER
VENTSHUTVALVE
@ FUE|-TANKpREssuRE
sENsoR
EMtsstoNtEvAp)two wAy valvE
@ EVApoRATtvE
wAY cATALYTIC
@ THREE
coNvERTER
ITwcI
'97
'98 models):
D16Y8engine('96coupe,'97coupe:all models, sdan:KL model,
{M/T)
| - : - l
iI ( '
F@,
i liiffis r
:.. --''---
{A/T)
-
-l
E-NGim
6)toofl'!
HEATED
oxYGENsENsoRIPRIMARY
Hozs,
O PRIMARY
SENSOR
1l
HEATED
oxYGENsENsoR{SECoNDARY
) SECoNDARY
HO2S.SENSOR
2r
ABSoLUTE
PRESSURE
O MANIFoLD
IMAP)sENsoR
TEMPERATURE
COOLANT
IECTISENSOR
@ ENGINE
(IAT)sENsoR
AIRTEMPERATURE
O INTAKE
@ KNocKsEt{soRtKs)
spEEDFLUcruATroN(cKFlsENsoR
O CMNKSHAFT
@ |DLEAtRcoNTnoLltacl vALvE
@ THRofiLEBoDYITB)
@ FUELINJEcToR
O FUELFILTER
REGULAToR
@ FUELPRESSURE
G) FUELPUMP{FP)
@ FUELTANK
EMISSION(EVAP)VALVE
@ FUELTANKEVAPORATIVE
(1-6)AIR CLEANER
o RESONATOR
@ POSITIVECRANKCASEVENTILATION{PCV)VALVE
EMISSIONIEVAPIPURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
EMISSION{EVAP)CONIROLCANISTER
@ EVAPORATIVE
EMISSIONIEVAPIEYPASSSOLENOID
E1lEVAPORATIVE
VALVE
EMISSIONIEVAPITHREEWAY VALVE
@ EVAPORATIVE
EMISSION{EVAPICONTROLCANISTER
@ EVAPORATIVE
VENT SHUTVALVE
SENSOR
@ FUELTANK PRESSURE
c! EVAPORATIVEEMISSION{EVAPITWO WAY VALVE

adTHREEWAY CATALYTICCONVERTER(TWC)
(cont'd)
SystemDescription
VacuumConnections(cont'dl
Dl5Y8 engine ('96 sedan,'97 sedan: KA, KC modets):
IM/T)
I-@-l
ir'ffii
'_._:_..i
l,'
\
HEAIEDOXYGEN
SENSOR
.' PRIMARY
IPfiIMARYHO2S,
SENSOn
lt
oxycEN sENsoRrsEcoNDABy
] sEcoNDARyHEATED
HO2S.SENSOR
2l
(MAPIsENsoB
ABSoLUTE
PRESSURE
O MANIFoLD
cooLANTTEMPERATURE
O ENGINE
tEcD sCNsoR
AIRTEMPERATURE
O INTAKE
IIATIsENsoR
@ KNocKsENsoR{Ksl
spEEDFLUcruATtoN{cKFtsENsoR
O CRANKSHAFf
@ |DLEAtRcoNTRoLflActVALVE
BODYITBI
O THROTTI.I
@ FUELINJECToR
@ FUELFILTER
11-16
-
FUELPRESSURE
REGULATOR
FUELPUMPIFPI
FUELTANK
FUELTANK EVAP,ORATwE
EMISSION{EVAPIVALVE
AIR CLEANER
RESONATOR
@ POSITIVECRANKCASEVENNIANON {FCV} VAIVE
@ VAFORATIVEEMISSIONIEVAP}PURGECONTROL
SOLENOIDVALVE
@ EVAPORATIVEEMISSON IEVAPI CONTBOLCANIS1ER
EMISSION(EVAP}TWO WAY VAVE
@ EVAPORATIVE
@ IHREE WAY CATALYTICCONVERTERITWC}
@
@
@
@
@
(x
D16Y7enginel'96 models,'97coupe:KA, KC modets,'97sedan:KA, KC,KL (DXl models,'97h8tchback:all models):
COOLANT
HEATED
OXYGENSENSOR
O PRIMARY
HO2S,
{PRIMARY
SGNSOR
1l
oxyGENsENsoR(sEcoNDARy
O sEcoNDARyHEATED
HO2S.SENSOR
2)
pREssuRE
(MAptsENsoF
ABSoLUTE
O MAN|FoLD
COOLANT
TEMPERATURE
) ENGINE
{ECTISENSOR
(IAT)sENsoR
AIRTEMPERATURE
@ INTAKE
SPECD
FLUCTUANON
@ CRANKSHAFT
ICKF}SENSOR
O |DLEAtRcoNTRoL{tActvALvE
BoDYITBI
@ THRoTTLE
@ FUELINJEcTon
@ FUELFTLTER
REGULAToR
O FUELPRESSURE
FUELPUMPIFPI
FUELTANK
FUELTANK EVAPORATIVE
EMISSION(EVAP)VALVE
AIR CLEANER
RESONATOR
POSITIVECRANKCASE
VENTILATION{PCV)VALVE
EVAPOMTIVEEMISSIONIEVAPIPURGECONTROL
SOLENOIDVALVE
EMISSIONIEVAP)CONTNOLCANISTER
@ EVAPORATIVE
EMISSIONIEVAP}TWO WAY VALVE
@ EVAPORATIVE
THREEWAY CATALYTICCONVERTER
{TWC)
@
@
(}
@
@
all
@
(cont'd)
SystemDescription
D16Y7ongine l'97 coupe: KL modol, sed8n:KL (LX) model, g8.modols):
--[-
HEATED
oxYGCNsENsoRIPRIMARY
O PRIMARY
Ho2s,
SENSOR
1)
HEATED
oxYGENsENsoR{SECoNDARY
O SEGoNDARY
HO2S,SENSOR
2l
ABSoLUTE
PBESSURE
O MANIFoLD
IMAPIsENsoB
cooLANTTEMPERATURE
@ ENGINE
tEcTIsENsoR
AIRIEMPERATURE
O INTAKE
{IATIsENsoR
(CKFISENSOR
SPEED
FLUCTUATION
@ CRANKSHAFT
O IDLEAIRCONTROL
|IAC)VAI.VE
BoDy tTBt
@ THRoTTLE
O FUELINJECToR
@ FUELFILTER
REGULAToR
O FUELPRESSUFE
.IA FUELPUMP{FP)
{9 FUELTANK
Ii4 FUELTANKEVAPORANVE
EMISSION{EVAP}VALVE
f,, AIRGLEANER
11 - 1 8
@ RESONATOR
@ POSMVECRANKCASEVENTILATION(PCVIVALVE
EMISSION(EVAPIPURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
EMISSION(EVAP)CONTROLCANISTER
@ EVAPORATIVE
@ EVAPORANVEEMISSION{EVAPIBYPASSSOI.-ENOID
VALVE
@ EVAPORANVEEMISSION(EVAP)THREEWAY VALVE
@ EVAPORANVEEMISSIONIEVAPICONTROLCANISTER
VENTSHUTVALVE
SENSOR
@ FUELTANK PRESSURE
EMISSIONIEVAPITWO WAY VALVE
@ EVAPORATIVE
@ THREEWAY CATALYTICCONVERTRIIWC}
ElectricalConnections
-9
lo C*iCA6OR
Cl,UlCtt FIAY
lo A./CPfiC8dUiE a|lrTCH
ECr SW'ICtl
CHEC|(
.2: AII (Dlovt, Dr6Y8.neln.l

ra: AfI.nd OioYt.hgl..
r5: ElDt A/I.n<l Dr6Y7 ft9ir.
r?: CVTlDi6Y5 ooln.l .nd O16Y3.nsin.
ra:96
96 Di6Yadgln. Ic@p.|, 37 Dl6Y3.n9ln.
Dl6Y3.t
UCHI
O i liIIEES
n
lco!p.: .ll mod.l." t d.n: XL mod.il '$ Ol6Y5 .n9in., O tAC(
tâ lr? lt.6 A,i
'10: M/I lD16Y5mdn.l
11l: Eropt M/r OlaY5 .tr!4..1
.12: DiCY5,DltYgmdn.
'15: '9t Dl6lt d9ln. (@qp.: K- mo.Ll, ..d.n:
KL lLxl mod.ll, 16 D16rt .nein.
o xox
rAt
o tAtttl
orct
N., 13fUEL tlr$t
lll Al
t'|. rt &lEr|{AlOi A?*i.3oi tr.aAl

llo. 3t 6ta8fEi stol{^t tt.6 at
r: h ii.
lndr.lb.d
lr-/nld
5.r
{cont'd)
11 - 1 9
System Description
ElectricalConnections(cont'dl
.l
T:I
FUEL
PACITST'R
sEt{Bon
gEN90fi
EGN
EGN
tnAt(Ctt{ltcH
lo f,lEnJOCK
utrtt
@fttiot
VAIVE
aorliloo
A: EVA' tUiG clr||liol
a: EvAr cotltioa c tr*slEi wm $(rr vavE
qEv P av?ats aolEioo
valvE
O: CCi Coraliol Sotlltlolo VAIVE
V IVE
E: VIEC 6otli|oa
IVE
t: r,iEAns{r(EilOrOV
c: LOO(.I P Ot Ltxt! SOt'lilOlO VAYE A
lf,ot aot.iloD vAlvE I
tt toc(.(t@
v^lvE A
r SHfT @tvtioi, aottlllxt
VAIVE !
J: at||f @lvriol8OlIiIXt
2; A/t lolart, Olava rCDl
ra: AfI .nd Dlart ddn.
15: Espr A/T.nd Dttr,
- r------t Lll.J' 1t!r!]J l' ? l

r r D 11
l6
|
t,'r,, st llll
11-20
dsa.
.7: CVI iD'lav6milDl.nd DilV,.ndd

r3: ga Ol6Y3 dct
lcoup.), '97 DtaYS .|'|tu
mort lr..d..:
l(l n .Ul, ! DtaYE osl..,
ldD...t
'ror M/r tDrat6 oCn l
rll: Erc.pl M/T lDlaYt .nsl..l
'12: D'laY5, DlaYa..dD
rl5: It Oiart ddm ldrp.: IL h.d.l,..d.n:
xL lL]xlhodJ','S Dlart odd
MAP Si60f,
cl'!t
l""fi""-_
I
stu
l__.!-sru/YEL
EGi VAVE
uF sENsoB
sivtcE cHEcx
cot{NEcToi
a6scoNriol u r,
@l{t{cToi
(cont'd)
11-21
SystemDescription
ElectricalConnections{cont'dl
ro?aF c.,l
8lx/YyHTl
so2SHTC
ltvwHT,
cl3r ca46
iED/YEL"I
sEcotD aY
HO2S iSE|!SOR 2l
PAIMANY
FOzSHTC.x
sol.E|lo|D
cror
.2: a/t IOl6Yt, Dl6Y, .n!in.l
.a: a/I .nd OlaYt .n!i..
.6 Esoi Art.d
Dt6r, .n!ln.
.7: CW (Oia\6 ociml.nd DI6YS.nciM
.3:'94 OlaYl ncin. l.o{Fl, !7 ol6Ya 6ci..
Xtmod.ll,'9aOl6Y5.ngh,
tcour:.amod.lr..d.n:
11-22
.10: M/t lDl6YE osin.l

.lr: Erc.rt MtI lot5Y5 min.l
rl2: ol6Yt, Dl6Yaogin.
.t5: 9? D16Ytdgi..ldp.:
KL tFd.l. t d.n;
lG ltxl mod.D,'93 O|6YT.nsim
\i
:rva --f|:F-l
wtfii
l-,1 /ffi|
L__.dJ I
I
| |
8LX'-1FJ
LT GAiYWHT
CAI'IISTEAVEM
SHUTVALVE{.i$
N C D /- U
' ' _ _ _ - __ _ _
'''-'-
_ - _ __ __ -
F--+,
Ks"-I
aeo'-8rx-- Jl---l
1t+l
clurcH swrrcHn.
{cont'd)
11-23
System Description
.a
ElectricalConnectors(cont'd)
scr{90fi
rDc
stofi
cr(?
BLX
H?,H,?,"iI
t30
BFN/IL(I
{
BRN/BIXI
BA/
alx1
&
r*
L ]t . l
lTop.l.tt-2al
r1:USAmod
.2: Arr tD'r6\r, Dr5Y3dsin.
.3: C\/T tot6y6 net..l
.a: A/I .nd Dl6r, .nC,.
.E: Erc.ptA/T.nd Oi6Y'.ryin.
.arA/t tDt6y8 dctn.t
.7r CVt (Dl6V6 .nelal .nd DiOYs .ncin.
'0:'96Dl5Y0.nc.{dp.l,37Di6Y3.nsim
lcoup.:.llmod.L,..d.n:Klmod.ll,'9aot6Y5.nrin.,
11-24
.9i D'16Y5
mgim
l0: Mfl lDl6Y5.rsitul
.11: r..ct M/I lD'laY5 osim)
r12: OtaY5, OtSYt .natr.
.13: DltYa osin.
rla: DlaYt.nlln.
116:t7 Dl6ft .n!Nm l@p. XL nod.l, ..d..:
|(!tlxlh.d.ll,'!cDlaftosid
MAINSHAFI SPEED SENSOf,"
t3
BtU'
COUNT:RSHAFI
SPIEDSENSOR-
c121
ll
l l
e
l
3
I
|
(cont'd)
11-25
System Description
ElectricalGonnectors(cont'dl
orrr c*,2
cr3r caa6
oll0
cSlta
GRT/ATI:
d YCL
rr GFl{l ----
T
I
Brx/Bru
T*-
w{F-
FEo
l
GRN
--
uru,1
fi
a/r GE i fo6no|l swTcll
NtEn|-OCX
coifliot uttr
;.,
cnr'--
--.1
l .lc
ilr
BLU/BEB-- -
t'i
-
mffimi#
arun:u--
--
j'
ro ^/c s$rcH
U
cr3r c/r46
'2: A/T (Dl6Y7,Dl6Y3.ngin.t
.a: A/T .nd Di6rr.ncitu
rt: Erc.pt Alt .nd Dl6Yt .nsi..
.10: Mlt loloY5.ncitul

.i'l: Erc.Dr M/r ID|6Y5 ddn.l
'rA DiAY5,Dli\,t melm
r15: 'et Dl6rt oslo loop.: KL mo.bl,..d.n:

.t: Cw lol6Y5 6ein.l ..d D16YO
.nsin.
.8i'96 Ot6yt.ntin. l6uD.l, 97 Dt6Y3.nCln.
xl lDo m.<bll,'S olsYt.ncln.
tcoup.: .ll mod.lr..d.n: xt mod.ll,'96 o16Y5.n!in.,
11-26
WHT/BLU
lcr l/toal
]lonx tl6al
A/C CTUTCH
REIAY
["*
--o_
Fr,ISE/REI.AY
BOX
FCir-Fl
I'AIN REIAY
No. 3l STABTEn
srct{ar (7.5al
1-27
f-
System DescriPtion
ElectricalConnectors(cont'dl
tT GRn
GR /ALK'
o|or c555
ii
t-
t:l t"-l
TT
FED/ FED
GRN
VREFI
wxT/nED,
F
F
F
YEUBI-U
ITGRtsGA /a|.x
AUUWHI
3LU'-
[t
l " l
clit5
Hiriffi+
BEAXf,SWTTCX
.2: A/T {Or6Y?,Dl5Y8.nsin.l
'3: Cvr {Dl6Y5.ngi.}
.4: A/T .nd DlYr.ngin.
.5: ExDt A/T tnd Dl6Y7.ngin.
.5: A/T {D16Y8.ngln.l
17rCW tDtoYs!ngln.) lnd ol6YE .ngin.
r8:'96 Dl5Y8.nsin. {coupol,37 Dl6Y8!.sin.
'98 D16Y5.nsin.,
lcouo.r .ll mod.b, ..d.o: Nl mod.tl,
'$O16Y8login.
.9: D16Y5.ngin.
'10: Mff lDr6Y5.ngin.l
.tt: Exc.pi M/r {Dl6Y5.nein.,
.t2: Dl6Y5,Dt6Ya.ngin.
.13: D16YE..gin.
11-28
'15:,97 O'16Y7
.ngin.lcoup.r XL mod.l ..d.n:
KL {LXlood.ll,'98 Dl6Yt msin.
SystemConnectors[FuelPumpl
c792+r.*'5
,
c565
c792r.,r1s
E ffi
@
IITYT!BLU-___l
I"TGRN/BLxf'li-BN'
-
NOTE:.
tlr
c793r3.rE *2: USA model
A/T {D16Y7,D16Y8engine}
*3: CvT {D16Y5enginel
*4: A/T and Dl6Y7 engine
*5: ExceptA/T and D16Y7enginc
16:A/T lDl6Y8ensine)
*7: CVT {D16Y5engine}and D16Y8engine
*8: '96 D16Y8engine{coupel,'97D16Y8engine
{coupe:all models,sedan:KL model),
'98 D16Y5engine, '98
O'16Y7engine
'9: D16Y5engine
*10:M/T {D16Y5enginel
*11:ExceptM/T (D16Y5engine)
*12:D16Y5,D16Y8engine
*13:Dl6Ygengine
'14: D16Y7.ngine
*15:'97D16Y7enginelcoupe:KLmod6l.sdan:
KL {LX)modell,'98D16Y7en9in6
fr
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKI

and YEUBLK,are not the same).
O: Belatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline)rView from wire side
(cont,d)
11-29
SystemDescription
SystemConnectors[EngineGompartmentl(cont'dl
D16Y5,D16Y8sngine:
11 - 3 0
c101
c102
oo
.",t
F'fftt
l- Irl
l.l.l
c105
c106
f'frf
.l
lolwHr,nED"
ttlBLvyEL ItlwHlBLrJ-
ItrlwHr/RED,--l
Fl8iNiB.,. I
Ec" 1
16lBLrr,f
c10?
c104
(Canada,
c109r.
cl10
c'|13+1
cl1a
r'ft]
16loRN---l
ffiffi
l)lYEUsrK' I
bIBLX/BLtl-
c136..
c137r'
c138r5
C1,r2r'
fr
NOTE:.
Differentwireswith the samecolor havebeengivena numbersuffixto distinguish

them (for example,yEUBLKT
O: Relatedlo Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):
View from terminalsroe
- Connectorwith femaleterminals
{singleoutline):View from wire side
(cont'd)
11-31
System Description
SystemConnectors[EngineCompartmentl(cont'dl
D16Y5,D16Y8engine:
c14113
c112
cl23
11-32
c111
c112
ct15
fr
c116
r'tra
a 8LK
i9, B L K '
YEUBLKI
G) Y E U B L K '
@ YEVE!KI
YEUBLII
,!] Y E V B L K ]
YEUELK'
cl20
c118*'
c117
c122
fr
8LK'
.!3 E L K I
!l B L K '
SLK
c123
c124"
fr
8LU5
tJ) RED5
BIK'
YELI
BLU
10 ElxrYEL
c126r'
c121"
-_Et_
ffi
F I'I
FT-wHr-7---l
lDlFEp.
glnn
|6FED,--__-l
l_l
lSlwHl
c125
ffi
YEVGAN
f3-l-surwHr -
ELKI
ffi
--__l
lDlGRr,P
lEl-Lur-- -
FfBL{-l
i?l8L|(YEL
ti|wHr FED.__l
I]l
fiTGRN/BLF
l-3_ELK.YELl]]lI
lalir-r1wii'
c12E.'
c139*
fr
c14{}*f
fr
l6lELU/vEL-l
lETcRr^rHil
clalrl
FT'I
trTBLF---__-]
16lcRr.yYEL;_l
l ? l n eo ,
wH si_l
f-Fr
tilLr cnvwnl
Il
I-IBLKCi
;c;*
l-t
['lrl.)
16]wHrigLa_--l
l?liFN/BIK,
---1I
ItrItEUBLU
c35{'1
l r l 2 l 3 l
tiT l
It'|wHr/BLx_l
ll? GFN/BLKr I
I aTYELisLt-
lelBra-----l
-1
F
T
_
-_j6FNF
l 1l , I t f ; l
L4 6l;I;l
----_--.l
EBrx,r/yf,p I5T
l2lBtK
l6lwHT
I3 GFN,ELK' 7 BL('
8lqED"
l4lwHl'
l-T-
.-
l l2 wHTBLU
I I3 ItH] GRN
I 14 8-k
I. *"' "co
f6-wrr Rro
a w ' r TB . l r I l 2
9 WFTCFN I I1
10 | l!
-1 BL-\/r| |u
6 BL'q^/rf__l
BtUl/vHT 7
WFIBLK
S W H IG R N
w H rB L K
e wrrl
l e rr c a r o
|
I
I
f---
r'ft]
-.l
fclBtKi,,iHr
loleLK--'-ll]l
1olGRNFEo
NOTEI.
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,yEUBLKI

and YEVBLK,are not the same).
O: Relatedto Fueland EmissionsSvstem.
o - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
11 - 3 3
System Description
SystemGonnectors[EngineCompartment](cont'd)
D16Y7engine:
11-34
V., J
c10l
c102
9,''on
r+
| 1 l 2 l
r,frt
ffi
c107
ffi
r'1rtr
|jIJ
c105
ffi
-l
16lwHr/RED"
---1
ETBLX/vEr -'1
lTlwHrsru
lSlwHr/RED;_l
16TBuNsLKr--l
_-l
EfBLUmEo.
c106
C'loil
{C.nada)
c108
Etr
c112
ffi
c113*!
t=t
/
\2
I6ERN--l ll
Idfsr-r---
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside
(cont'd)
11-35
System Description
SystemGonnectors[EngineCompartment](cont'dl
D16Y7sngine:
11 - 3 6
c109
c'|10
c115
c114
cl16
fr
r'ff;r
fSloRN---__l
o'|
cl18 (A/Tl
cI17
r'frfl
ffi
c125
FF-'
lrl2l
['l.l
ftERN/Br-r;_-lI6liHT/REo'-_-l
lElYEL;---_-l lolREo,YEF-_-l
BLK'
YUBLK'
YEUELK'
BLKI
BLK'
BLK'
YEUBLK'
BLK'
ffi
ffi
lt ELK,YEL
_-l I
I-TBLUIrvHT
BLK'
cl23
ffi
lllBLr----l
c12r lalf I
BLK
.1) YEUELKI
ttl Y E V B L K '
YEVBLK'
IaIYEUBLK, I
lb]-Bar<,jLu
I
fiil RrD ,vHr-IdIGBIvBLK' I
c126lA/T)
fr
ItrlwHr'--__l
lOlBEp.
c127(A/Tl
c12A |dfil
c141.r5
ffi
-t+-t
IrI2l
l ' l zI
l6lwHr'
l@lREo,
-l
I
YEL--I
ITTTBLI
l.afcrll-NlrHT,ll
lEl LicRN^,Hrl
l6fsar<'EL I
lofBr-r</YEL I
lSlBLK/wHTi-l
c35{*'
l 1 l 2 l 3 l
16lBL&l"Hr__-l
l6lBLK
I
lO cRNiREo I
NOTE:.
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKT

and YEVBLK'are not the same).
O; Relatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
11-37
SystemDescription
SystemConnectorslDashand Floorl
11-38
6 l 7 l 8 l et 0 t 1 1 12
12 1 3
15
BLU,rvL
c'15
ottT'r
-r=l-
,-F-
lr l, I
l[TTtT;ll
t
I
l l . | 5 | 6| 7I l
ll
BL(vEr.
TiTsuqv/ir---'l
---l
ftl B.u,"Ep
lOlwHr,Lr I
t.8lx
la FFo'
litEli
tilwHr/6RN I
11
': scu.rYarrmsFtem
YEL
0125
ct|:|5
lwnhout crui! contolt (wtth ctuir controll
-FF-
ffiffi
I !'IGRNAI/HF I
ll WHI/GRN I
13
|
I 1 LLTGiN
12 GnY
lO cFNeHr'
f.T_
ltrlwHT/GRN-
,|
a 5 6 7 E 9 10
't2 1 3 t a 1 5 1 6 1 l 1E
20
't2
I
I
I
BLX'EL
1)
3
5
NOTE:.
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEL,/BLK1

- Connectorwith maleterminals{doubleoutline):Vjew from terminalside
(cont'd)
11 - 3 9
SystemDescription
SystemConnectors[Dashand Floor](cont'dl
c412
C131
c446
C135
11-40
c130
t
't'l 12 l 3
5 6 7
I t0
l 5 1 6 1 7 ta 't9 20
lD16Y5, Dl6Ya.ngin6l
YEL
Ct33., (FCM-B)
cr32 tEcM/PCM-A)
5
12 t 3 lit t 5 l 6 t t I E t 9 2l
25
27
t0
1l
23
2a
cr3a{EcM/PcM-ct
2a 29 30
cr!5 tEcM/FcM-Dl
ffi
fr
r'TftI;I
fiTwr/Brt-
l
-l
TtltErnrx
lfsri------l I]]l
rnwHr
ItTniKrysr I-l I
l-"rlcnN^v'tr
Itmsrneo l
f.. ErlwHr'--l
flwHrnEF l
I
aaFlBa(
Cr|]lil
a l 5
tl
't2 1 3
E 9
't1 t 8 1 9
to
ffi
rfir
ITFI
l-tlwr/nEdI;TcRN^,Nr--l
lrfttK,/,/H
lilBrx,v/Hr l
NOTE:.
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1

- Connectorwlth maleterminals(doubleoutline):View from termlnalside
11-41
Troubleshooting
TroubleshootingProcedures
How To BeginTroubleshooting
Whenthe MalfunctionIndicatorLamp(MlL)has beenreportedon. or there is a driveabilityproblem,usethe appropriate procedurebelowto diagnoseand repairthe problem.
A . W h e nt h e M I Lh a sc o m eo n :
'1. Connectthe HondaPGMTesteror an OBD ll scantool to the 16PDataLink Connector{DLC}locatednearthe left
k i c kD a n e l .
2, Turn the ignition switch ON (ll).
Check the DTC and note it. Also check and note
the treeze frame data.
Refer to the Diagnostic Trouble Code Chart and
begin troubleshooting.
NOTE:
. Seethe OBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
. The scantool or testercan readthe DiagnosticTroubleCodes(DTC),freezeframe data,currentdata.and other
EngineControlModule(ECM)/Powertrain
ControlModule(PCM)data
. Freezeframe data indicatesthe engineconditionswhen the first malfunction,misfireor fuel trim malfunctior
was detected.lt can be usefulinformationwhen troubleshootino.
B . Whenthe MIL hasnot come on , but there is a driveabilityproblem,reterto the SymptomCharton page11-46.
c. DTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp(MlL)with the SCSserviceconnectorconnected.

Connectthe SCS serviceconnectorto ServiceCheckConnectoras shown. (The 2P ServiceCheckConnectoris
locatedunderthe dashon the passenger's
sideof the vehicle.)Turn the ignitionswitchON {ll}.
OBD ll SCANTOOLor
HONDAPGM TESTER
DATA LINKCONNECTOR
{16PI
11-42
SERVICECHECK
CONNECTOR
I2P}
SCSSERVICECONNECTOR
07PAZ- 001011X'
ll.
ControlModule(PCM)ResetProcedure
Eitherof the followingactionswill resetthe ECM/PCM.
.
Usethe OBDll scantool or HondaPGMTesterto clearthe EcM's/PcM'smemorv.

NOTE:Seethe OBDll scantool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
. Turn the ignitionswitch OFF,Removethe BACKUP (7,5A) fuse from the under-hoodfuse/relaybox for 10 seconds.
NOTE:Removingthe BACKUP {7.5A) fuse cancelsthe clockand the radio presets.Make note of the customer's
oresetsso vou can resetthem.
lll. FinalProcedure(thisproceduremust be done afterany troubleshooting)

1, Removethe SCSServiceConnectorif it is connected.
the MIL will stay
NOTE:lf the SCSserviceconnectoris connectedand there are no DTCSstoredin the ECM/PCM,
on when the ignitionswitchis turned ON (ll).
2 . Do the ECM/PCMResetProcedure,
Turnthe ignitionswitchOFF.
(cont'd)
11-43
Troubleshooting
(cont'd)
Troubleshooting
Procedures
lf the inspectionfor a particularcode requiresvoltageor resistance
checksat the ECM/PCMconnectors,removethe right
kick panel.Pull the carpetbackto exposethe ECM/PCM.Removethe ABS control unit if so equipped.Unboltthe ECM/
PCM bolt. Turn the ignition switch OFF,and connectthe backprobesets and a digital multimeteras describedbelow.
Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon the followingpages.
l
)
KICK PANEL
How to Use the BackprobeSets

Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire insulation as a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectortrom the wire side
until it comesin contactwith terminalend of the wire.
BackproboAdapter
BACKPFOBE
SET
07SAZ- 001000AlTwo
OIGITALMULTIMETER
{Commcrcially.vaitablelor
KS-AHM-32-003
1 1-4 4
CAUTION:
. Puncturingthe insulation on a wire can causepoor or intermittcnt elesttical connestions.
. Bring th tester probe into contaqt with the terminal lrom the terminal sid6 of wire harnossconnectors in the enging
compadment. For Ismale connectors,iust touch lightly with ihe tester probe and do not ingert the probe.
RUBBERSEAL
TESTERPBOBE
TERMINAL
{cont'd}
11-45
Troubleshooting
TroubleshootingProcedures{cont'd)
Symptom Chart
Listedbeloware symptomsand probablecausesfor problemsthat DO NOTcausethe lvlalfunction
indicatorLamp(MlL)to
c o m eo n . l i t h e M I L w a sr e p o r t e d
o n ,g o t o p a g e ' 1 1 - 4 2 .
Troubleshooteachprobablecausein the order listedlfrom left to right)until the symptomis eliminated.
The probablecauseand troubleshooting
pagereferencecan be found below.
SYMPTOM
PROEABLECAUSE
Enginewill not start
4 , 2 , 3 , 5 , 2 01, 4 ,1
Hardstaning
2,4.11,16,13,'t9
Coldfast idle too low
7, 8, 6, 16
Cold fast idle too high
7 , 8 ,1 0 , 9
ldle speedtluctuates
7 , 8 ,1 0 , 9
M i s f i r eo r r o u g hr u n n i n g
Troubleshoottor misfireon pages11-105,108
Low power
2 ,9 , 1 0 , ' t 2 1
, 1 ,1 6 ,1 8 ,2 0
E n g i n es t a l l s
2 , 4 , 1 1 , 7 ,2 0 ,A , 5 , 1 5
OtherProbableCausesfor an enginethat will not start:

- Compression
- Startingsystem
- Intakeair leakage - Overheating
- Enginelockedup - Battery
- Timing belt
ProbableCauseList (Forthe DTCChart, see page 11-531
\
ProbableCause
1
Page
I t-oJ
1' t - 1 5 01,s 1
1I -157
4
System
ControtModule(PCM)
Fuelpressure
PGM-Flmain relay
Section23
lgnitionsystem
1 1 - 1 1 10 1, 7
Crankshaft
Position/Top
DeadCenter/Cylinder
Positionsensorcircuit,CKFsensor
circuit
11-73
IntakeAir Temperature{lAT)sensorcircuit
11-'t26,128
ldle Air ControlValve(IACV)
11-141,142,
143,144
ldle speedadjustment
1t-164
Throttle body
10
't1
11-162
Thronlecable
11-67
ManifoldAbsolutePressure(MAP)sensor
12
1' t-79
ThrottlePosition(TP)sensor
IJ
14
Barometricpressure(BARO)sensor
Section14,1'l-139 A/T gear posilionsignal(seepage'1'l-137)
or clutchswitchsignal
1 11 1 3
11 -1 3 4
Brakeswitchsignal
11-162
AirCleaner
11
Intakeair pipe
18
1l-168
Three Way CatalyticConverter(TWC)
19
11-181
Evaporative
emission(EVAP)control
20
11-4 6
Contaminated fuel
ECM/FCMData
By connectingthe OBD ll scantool or the HondaPGM Testerto the 16Pdata link connector(DLC),variousdata can be
The itemslistedin the table belowconformto the SAErecommendedpractice.
retrievedfrom the ECM/PCM.
reads
databevondthat recommendedby SAE.
The HondaPGMTesteralso
this datawill helpto find the causesof intermittentfailuresor engineproblems.
Understanding
NOTE:
a The "operatingvalues" given below are approximatevaluesand may be differentdependingon the environmentand
the individualvehicle.
. Unlessnotedotherwise,"at idle speed" meansidlingwith the enginecompletelywarmed up, A//Tin pe5ition@ or @,
turnedoif.
M/T in neutral,and the A/Cand all accessories
Data
Description
OperatingValue
FreezeData
Diagnostic
TroubleCode
(DTC)
lf no problemis detected,
lf the Ecl\4/PcM derectsa problem,it will storeit as a
four
numbers.
there
is no output.
code consistingof one letterand
code (P0xxx)
Dependingon the problem,an SAE-detined
code (P1xxx)will be outputto the
or a Honda-defined
rester.
YES
E n g i n eS p e e d
The ECM/PCM
computesenginespeedfrom the signals
sentfrom the CrankshaftPositionsensor.
This data is usedfor determiningthe time and amountot
fuel injection.
Nearly the same as

tachometer indication.
YES
The EClvl/PcM
convertspulsesignalsfrom the Vehicle
SoeedSensor(VSS)into speeddata
Nearlythe sameas
speedometerindication
YES
Manifold
The absolutepressurecausedin the intakemanifoldby
Absolute
engineload and speed.
Pressure(MAP)
With enginestopped:
Nearlythe sameas atmosphencpressure
At idle speed:
24 - 37 kPa(180- 280
m m H g ,7 . 1- ' 1 1 . i0n H g )
YES
EngineCoolant The ECTsensorconvenscoolanttemperatureinto voltThe sensoris a thermistor

Temperature
age and signalsthe ECM/PCM.
(ECT)
changeswith coolanttemperawhose internalresistance
ture.The ECM/PCMusesthe voltagesignalsfrom the
ECTsensorto determinethe amountof iniectedfuel.
With cold engine:

Sameas ambienttemperatureand IAT
With enginewarmedup:
'176 194.F(80- 90"C)
0 . 0- 1 . 2 5V
VehicleSpeed
HeatedOxygen The HeatedOxygenSensordetectsthe oxygencontent

Sensor(H02S) in the exhaustgasand sendsvoltagesignalsto the
(Primary,
con
ECM/PCM.
Basedon thesesignals,the ECM/PCM
S e n s o r1 )
trols the airfuel ratio.Whenthe oxygencontentis high
(Secondary
{thatis. when the ratiois leanerthan the stoichiometric
Sensor2)
ratio),the voltagesignalis lower.
Whenthe oxygencontentis low (thatis, when the ratio
is richerthan the stoichiometric
ratio),the voltagesignal
is hioher.
YES
At idle speed:
a b o u t0 . 1- 0 . 9V
NO
( S e n s o1r )
(cont'd)
11-47
Troubleshooting
(cont'dl
Data
HO2S
Feedback
LoopStatus
Description
"open" or "closed".
Loopstatusis indicatedas
deterClosed:Basedon the HO2Soutput,the ECM/PCM
minesthe airlfuelratioand controlsthe amountof injected fuel.
Open:lgnoringHO2Soutput,the ECM/PCMrefersto signalsfrom the TP,MAP,and ECTsensorsto controlthe
amountol iniectedfuel.
Operating Value
FreezeData
At idle speed:closed
YES
! 20%
for correctingthe
The airfiuelratiocorrectioncoefficient
amountof iniectedfuel when HO2Sfeedbackis in the
closedloop status.Whenthe signalfrom the HO2Sis
weak,shortterm fuel trim getshigher,and the ECM/PCM
increases
the amountot injectedfuel.The airlfuelratio
graduallygets richer,causinga higherHO2Soutput.
Consequently,
the shortterm lueltrim is lowered,and
the ECM/PCMreducesthe amountot injectedfuel.
This cvclekeeDsthe airlfuelratiocloseto the stoichiometricratiowhen in closedloop status.
YES
Longterm luel trim is computedfrom shortterm fuel

trim and indicateschangesoccurringin the fuel supply
systemover a long period.
l f l o n gt e r mf u e lt r i m i s h i g h e tr h a n 1 . 0 0t,h e a m o u n to f
injectedfuel must be increased.lf it is lowerthan 1.00,
the amountof injectedfuel must be reduced.
+ 200/o
YES
InlakeAir
Temperature
(IAT)
The IATsensorconvertsintakeair temperatureinto voltWhen intakeair temperaage and signalsthe ECM/PCM.

of the sensor
ture is low, the internalresistance
increases,
and the voltagesignalis higher.
With cold engine:

Sameas ambienttemperatureand ECT
Throttle
Position
pedalposition,the opening
Basedon the accelerator
anqleof the throttlevalveis indicated.
At idle speed:
approx.10 %
lgnition
Timing
lgnitiontiming is the ignitionadvanceangleset by the

ECM/PCM.
The ECM/PCMmatchesignitiontiming to the
drivingconditions.
At idle speed:12't 2"
from the MAP data.

CLVis the engineload calculated
At idle speed:
15-35%
At 2,500rpm with no load:
12 - 30%
Shon Term
F u e lT r i m
LongTerm
FuelTrim
Calculated
LoadValue
(CLV)
E' I UL Wtrn rne 5L5 Ser-
YES
YES
NO
viceconnectorconnected.
YES
Engine/Powertrain
ControlModuleTerminalArrangement
ECM/PCMCONNECTOR
A {32P)
1
2
a
I N J 4 INJ3 INJ2 I N J l
1 2 't3 1 4 1 5
ACV
1 6 1 7 1 8 1 9 20
PCS FLR acc MIL AtTC tcM
25
21
2a E 30
vsv SLU
LG1
22
LG2
t1
10
PGl
IGPl
PG2
21
IGP2
Wiresideof femaleterminals
ECM/PCMCONNECTOR
A {32P1
NOTE:Standardbattery voltage t s
Sig.al
YEL
2
3
BLU
FED
88N
BLI(WHT
BLK^/VHT
FED*3
l N J 4 { N o a F U E LI N J E C T O B }
l N J 3 ( N o . 3 F U E LI N J C T O R I
lNJ2(No,2 fUEL INJECTOR)
I N J I 1 N o .1 F U E L I N J E C T O F )
SO2SHTC(SECONOARY
HEATED
OXYGENSENSOFHEATERCON
TSOL)
PO2SHTCIPSIMARYHEATED
OXYGENSENSOEHEATER
CONTROL)
E S O LI E G FC O N T R O L
SOLENOIO
VALVEI
D r i v e s N o .4 i u e l n i e c r o r .
Drives No. 2 fuel injecto..
O n v e sN o . 1 l u e l ' n t e c t o r
Drives secondary hated oxygen sensor
W i i h i g n i l i o ns w i t c hO N ( l l ) : b a n e r yv o t a g e
W i l h i u l l y w a r m e d u p e n g i n er u n n i n g :d u t y c o n r f o t t e d
Drives prihary heated orygen s6nsor
Wirh ignitio. swhch ON (ll): batery vohage

W i l h t J l l / w a r m e du p e n g i l e . r 1 . n S .d J r \ ,, o r t . o l e o
Orives EGF conto solenoid valve.
W n 5 E G Ro o - , d r ' n 9d u . i r S d i v i a g w r F . J f y w a ' r - d
up engine: duty controlled
W i l h E G Rn o r o p e r a t i n q : 0V
W i l l - F C F o p e r a f i n gd u ' , n 9 d r ' v , rg w r h t u l l y w d n p d
! p e n 9 r n ed
r ulycontrolled.
W l h E G Rn o t o p e r a t i n q : 0V
WS (WC SOIENOID VALVE)
Drives VTECsoleno d valve.
W i l h e n g i n ea t l o w e n g i n es p e e d : 0V
Wilh enqine at hlqh enqine sD6ed:batre.vvokaoe
Ground for lhe ECi!4/PCM

conlrolclrcuit.
G ' o u n d l o r t h e E C M / P C Mp o w e r ( t r c ! f .
Pow6rsource tor the ECM/PCMco.trol
L e s sl h a n I 0 V a t a r lr i m e s
E EGR
GBN/YEL
9
BRN/BLK
L G 1( L O G I CG 8 O U N D )
IO
BLK
PG1 (POWERGBOUNO)
IGPl (POWERSOURCE)
ll
YEUBLK
15
FEOTYEL
IACV(IDLEAIR CONTAOLVALVE)
IACV N lIDLE AI8 CONTROL
VALVE NEGATIVESID)
IACV P (IDTEAIR CONTFOL
VALVE POSITIVESIDE)
PCS {EVAPPUsGE CONTROL
SOLENOIDVALVE)
16
GRNAEL
F L R{ F U E LP U M PF E L A Y )
Drvestue pump relay.
17
BLK/FED
A C C( A , / C
C L U T C HF E L A Y )
DrivesA,/C
clulch.etay.
12"
SLVALU
ORN
BLVBLU
18
G8N/ORN
ALTC (ALTEFNATOBCONTNOL)
20
YEVGRN
rclvr0GNrI|oNcoNTfloL
t!'IODULE)
22
23
BRN/ALK
L G 2( L O G i CG F O U N D )
YE|JLK
25'3
27'r
WHf/BED
GRN
8LU
PG2IPOWER
GFOUND)
I G P 2( P O W E RS O U F C E )
Wlth ignit on swilch ON (ll): batrerv vo taqe

w i t h r g n n i o ns w h c h O F F : 0V
W i l h e n g i n er u . n i n g : p u l s e s
Drives lhe IAC valve lnegai ve side).

D ' i v e sI A Cv a l v el p o s r t r v
srde).
Orives EVAP purge contro soleno d vaive.
MILlMALFUNCTIONINDICATOR
WHI/GFN
BLX
W i t h e n g i n ef u n n n 9 : p u l s e s
Sends alle.nator cohtrol signa
W l l h e n g i n er u n n i n g ,e n g i n ec o o l a n tb e o w 1 5 4 F
(64'Cl: battery vohage Wilh engine running eng ne
cocrant above 154'F {68'C): 0 V
0 v for ndo *(onds dier rJ .{ g 'gr't on sw ! h oN
w r t h c o m p r e s s oO
r N:0 V
Wth compressorOFF: battery vohaoe
W i i h M l L r u r n e dO N : 0 V
W i l h M l L t u r n e dO F F : b a t t e r yv o h a s e
Wilh lully warmed up engine running: b.ftery voltsge
Du.ingdrivingwilhsmallelectrcalload:0V
With ignition switch ON (ll):baltery voltage
W t h e n g i n er ! n n i n g : a b o u t 1 0 V ( d e p e n d i n go n
Ground fof lhe EC^4/PCMconrrolcncuil

G r o u n df o r l h e E C M / P C Mp o w e f c i r c u i t .
L o s s t h a nl . 0 V a r a l l i i m o s
Powe. source fof rhe ECM/PCMcont.ol
Drives EVAP bypass sol6nord valve
Wirh igniiion switch ON (lll: banery vohage

W i t h i 9 n i t i o ns w i t c hO F F : 0V
W i t h i g n i t i o ns w i t c hO N ( l l ) : a b o L t5 V
W i t h l g n i l i o ns w i l c h O F F : 0V
Wiih radiato. f8n running: 0 V
Wirh radialor tan stopped: banery vohaoe
w n h i g n i t i o ns w t c h O N ( l t ) : b a l l e r yv o t r a g e
Drives EVAP control canisrer v6nish!t
With ignilron swilch ON lll): battery vohage
Derecb lnter ock convol unit sisnal.
W t h i s n t i o n s w i i c h O N { 1 1 ) a n bd r a ( e p e d a l
dpressed:batieryvohaae
V R E F( R E F E N E N CVEO T T A G E )
Provides rslerencevo ltage to TCM.
FANC iRAOIATOSFAN
CONTFOL)
2WBS (EVAPBYPASS
SOIENOID VALVE)
VSV {EVAPCONTBOLCANISTEB
VENI SHUT VATVE)
S!U (lNTEELOCKCONTROL
UNIT)
Orives radiarorfan relay.
*2: A/T (D16\./. Dl6YSensine)

* 3 : C W ( 0 1 6 Y 5e n g i n e )
14: A"/Tand D16Y7 ensine
'5:Except A/T and 016\./ engine
16: AtlTlD16Y8 engine)
r T r C V T( O 1 6 Y 5o n q i n e )a n d D l 6 Y B e n s i n e
'8:'96 016Y8ensine {oupel. 97 Dl6YSensine (coupe:all modols,
sd.niKl
'98 D'I6Y5
sngin,'98 016Y8 engine
r 1 0 : M / T ( D 1 6 Y 5e n g i n e )
. 1 1 : E x c e p lM / I ( 0 1 6 Y 5e n g i n e )
i 1 2 : O 1 6 Y 5D
, 1 6 Y 8e n g i n e
moder),
' 1 5 : ' 9 t 0 1 6 Y 7e n g i n e( c o u p :K L m o d e s e d a n rK L
,
lLXl modet),
'98 D16Y7
engine
{cont'd)
11-49
Troubleshooting
Engine/Powertrain
ControlModuleTerminalArrangement(cont'dl
Wirg sideof femaleterminals
PCMCONNECTOR
B {25P)*'
Telminal
numoer
Wire
color
WHT
RED
BLU/YEL
GRN/BLK
YEL
PNK
1t
GRNA/VHT
NOTE: Standard battery voltage is l2

Terminsl
14
WHT
RED
WHT
17
8LU
22
GRN
BLU
Signal
LS- (LINEAR
SOLENOID
VALVE_ SIDE)
LS+(LINEARSOLENOID
VALVE+ SIDE)
SHA(SHIFTCONTROL
SOLENOID
VALVEA}
Groundtor linearsolenoidvalve.
With ignitionswitchON (ll):pulses
Driveslinearsolenoidvalve.
With ignitionswitchON (ll):pulses
DrivesshiftcontrolsolenoidvalveA.
LCB (LOCK.UP
CONTROL
SOLENOID
VALVEB)
LCA (LOCK.UP
CONTROL
SOLENOID
VALVEA)
ATPD3IA,/TGEARPOSITIONSWITCH)
SHB(SHIFTCONTROL
SOLENOID
VALVEB)
Driveslock-rrpcontrol solenoid
valveB-
With enginerunningin 2nd,3rdgears:

batteryvoltage
With enginerunningin 1st,4thgears:
about0 V
With lock-upON: batteryvoltage
With lock-upOFF:0 V
(INTERLOCK
CONWHT/RED SLU
GRN/BLK
De3cription
TROLUNIT}
D4 IND(D4INDICATOR
LIGHT)
Driveslock-upcontrolsolenoid
With lock-upON:batteryvoltage
With lock-upOFF:0V
DetectsA,/Tgear positionswitch
srgnat.
InEposition:0V
In any otherposition:batteryvoltaqe
Wathenginerunningin 1st,2nd:baftery
voltage
With enginerunningin 3rd,4th:about0 V
With ignitionswitchON (ll)and brake
pedaldepressed:0 V
Drives shift control solenoid valve 8.
Drivesinterlockcontrolunit.
DrivesD4 indicatorlight.
NMSG(MAINSHAFT
Groundfor mainshaftsoeedsensor.
SPEEDSENSORGROUND)
NM {MAINSHAFT
SPEED Detectsmainshaftspeedsensor
SENSOR)
srgnal,
ATPR{!VT GEARPOSIDetectsAy'Tgear position switch
TIONSWITCH}
signal
ATP2(A"/TGEARPOSIDetectsAy'Tgear position switch
TION SWITCH}
srgnal,
NCSG{COUNTERSHAFT Ground lor countershattspeed
SPEED
SENSOR
GROUND) sensor.
NC {COUNTERSHAFT
Detectscountershaftspeedsensor
SPEEDSENSOR}
srgnal.
With enginerunning:pulses
InEposition:oV
In any otherposition:batteryvoltage
InAposition:0V
In any otherposition:batteryvoltage
With ignitionswitchON {ll),and front

wheelsrotating:pulses
DetoctsA./Tgear position switch

In El position:OV
srgnal.
In any otherposition:5 V
gear position switch
Detects
A.rT
ln m orE position:
OV
25
LT GRN
srgnal.
ln anyotherposition:
battery
voltage
*1: USA model
'9: 016Y5engine
*2: A,/T{D16Yr,Dl6Y8 engine)
*10:M/T lD16Y5engine)
*3: CVT(D16Y5engine)
*11:ExceptM/T (D16Y5engine)
*4: A*/Tand Dl6Yl engine
* 12:D16Y5,D'|6Y8engine
*5: ExceptA,rf and 016Y, ongine
*13rDl6Y8engine
*6r IVT {D16Y8ngine}
i14: Dl6Y7engine
*7: CW (D16Y5engine)and D16Y8engine
*15:'97016Y7engine{coupe:KL model,sedan:KL (LX)model),
'98D16Y7
* 8 : ' 9 6 D 1 6 Y 8e n o i n 6( c o u p e ) , ' 9 7D 1 6 Y 8ehgine {coupe:all
engine
models. sedan:KL model),'98 D16Y5engine,'98 D16Y8
on9ine
24
11 - 5 0
YEL
ATPD4{A"/TGEARPOSITION SWITCH)
ATPNPiAlT GEAFPOSITIONSWITCH)
With D. indicatorlighrrurnedON:batter),
voltage
With E indicatorlightturnedOFF:OV
ECM/PCMCONNECTOR
C 131PI
1
2
CKfP CKPP TIrcP
11
12
13
CKFM
21
9
10
TMA vBu
z)
30
TMB
ACS sTs scs

1 4 15 16 1 7 18
vTM
ALTf vss
25
lP+
Wire sideof femaleterminals
ECM/PCMCONNECTOR
C {31PI
Torminal
numbot
l
2
3
BLU/RED
BLU
GRN
YEL
5
BLU/RED
BLU/ORN
BRN
LT8LU
CKFP{CKFSENSORP SIDE}
C K P P( C K PS E N S O RP S I D E )
10
WHT/BLU
t1
WHT/RED
17
Signrl
Detects CKF sensor.
W i t h e n g i n er u n n i n g :p u l s e s
Detects CKP sensor.
pulses
Withonginerunning:
With engine running: prils6s
ACS (P,/CSWITCHSIGNAL)
OetectsAy'Cswitch signal.
STS {STARTERSWITCH
SIGNAL)
EHECK
S C S( S E R V I CC
SIGNAL)
K - L I N E( D L C )
Detects starter switch signal,
With,!y'C switch ON: 0 V

With ,y'C switch OFF: battery voltage
With starter switch ON (lll): battery vollage
With starler switch OFF: 0 V
Detectsservicecheck connector signal

( t h es i g n a l c a u s i n ga D T Ci n d i c a t i o n )
S e n d sa n d r e c e r v e ss c a nt o o l s i g n a t ,
pulss
Withenginerunning:
With the connector connected: 0 V

With the connector disconn6ct6d: 5 V
W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u t 5 V
D a t ac o m m u n i c a t i o nw i t h T C M : E C M
c o n t r o l d a t ao u t p u t
W i t h i g n i t i o ns w i t c hO N ( l l ) :p u l s 6 s
VBU(VOLTAGE
BACKUP)
Power sourc6 for the ECM/PCM

control circuit. Power source for the
DTC memory
8.ttery voltage at alltimos
CKFI\4{CKF SENSOB M
SIDE)
CKPI\4(CKPSENSORM
SIOE}
G r o u n df o r C K Fs e n s o rs i g n a l .
G r o u n df o r C K Ps s n s o rs i g n a l .
RED
TDCM(TDCSENSORM
SIDE)
G r o u n df o . T D C s e n s o rs i g n a l .
BLK
C Y P M( C K PS E N S O RI V
SIDE)
G r o u n df o r C Y Ps e n s o rs i g n a l .
VTM {VTECPRESSURE
DetectsVTEC pressure switch signal.
BLU/8LK
,I6
Description
TDCP{TOCSENSORP SIDE} DetectsTDCsensor,

CYPP
{CYP
SENSOR
P SIDE) DetectsCYP snsor.
GRY
14
NOTE:Standardbatteryvoltageis 12 V,
T6rminal
swrTcH)
With engine at low6n9in6 spdr0 V

With engineat high enginspeed:batteryvoltEge
P S P S W( P / SO I L P R E S S U R E Detects PSPswitch signal.

SWITCH)
At idle with steering wheel in sk6ight ahaad

p o s i t i o n i 0V
At rdle with st6ring whsel at full lock: battery
voltage
ALTF(ALTERNATOE
FR
SIGNAL)
Detects alternator FR signal,
Withfullywarmedup 6nginerunning:
0V- batteryvoltage{depsnding
on electrical
VSS(VEHICLE
S P E E DS E N .
DetectsVSS signal.
BLK
l P +( H O 2 SP U M PC E L L+ )
C o n t r o l sH O 2 Sp u m p c e l l .
W i t h i g n i t ' o ns w i t c h O N { l l ) a n d f r o n t w h e e l s
rotating:cycles0V-5V
W r t h r g n i t i o ns w h c h O N t l l ) :a b o u t 0 . 5 - 5 . 3 V
RED
IP-, VS- {HO2SCOMMON)
R e f e r e n c ev o l t a g es u p p l y ,
VS+(VSCELLVOLTA6E)
ATPNP{4,/TGEARPOSI.
TroNswrTcH)
DetectsVS cell voltage.

Detectspy'Tgear position switch signal.
CLSW (CLUTCHSWITCH)
Detects clutch switch signal.
TM8
D a t ac o m m u n i c a t i o nw i t h T C M :
E C Mc o n t r o ld a t a i n p u t
GRN
WHT/RED
load)
18
23'to
BLU/WHT
25* ta
LTGRN*3
29
BED*r0
30
PNK
soR)
*1: USAmodl
+2rAlT(Dl6Yl,D16Y8
engine)
'3: CVT(D16Y5engine)
'4: A,/Tand D16Y7engine
'5: ExceptA,/Tand Dl6Yl engine
*6: Ay'T(D16YB
engine)
*7: CVT(016Y5engine)and
D16YB
engine
*8:'96 D16Y8engine(coupel,'97
D16Y8engine(coupe:
all models,
sedan:KLmodel),'98
D16Y5
engine,98 D16YB
ongine
With fully warmed up 6ngin6 at idle:

a b o u t 2 . 6 - 2 . 8V
W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u t T V
I n E o r E p o s i t i o n :V0
ln any otherposition:batteryvoltage
With clutchpedalreleasd:
about5 V
With clutch oedaldeoressed:0 V
W i t h i g n i t i o ns w i t c h O N { l l ) :p u l s e s
* 9 : D 1 6 Y 5e n g i n e
r 1 0 : M / T { D 1 6 Y 5e n g i n e )
* 1 1 : E x c e p tl v l / T( 1 6 Y 5e n g i n e )
' 1 2 : D 1 6 Y 5 ,D 1 6 Y 8e n g i n e
* 1 3 : D 1 6 Y ge n g i n e
' 1 4 : O 1 6 Y 7e n g i n e
* 1 5 : ' 9 7 D 1 6 Y 7e n g i n e ( c o u p e : K L m o d e l , s e d a n : K L ( L X ) m o d e l ) ,
'98D16Y7
engine
{cont'd)
11-51
Troubleshooting
Engine/Powertrain
(cont'dl
ControlModuleTerminalArrangement
ECM/PCMCONNECTOR
O {16P)
BXSW
ECI
lo
KS
13 11
15
EL
ECM/PCMCONNECTOR
D (16P}
NOTE:Standardbatteryvoltageis 12 V.
Terminal
Wire
IPS (THROTTLE
POSITION DetectsTPsensorsignal.
SENSOR)
(ENGINE
COOLANT
DetectsECTsensorsignal.
RED^^/HT ECT
TEMPEFATURE
SENSOB
MAP (MANIFOLD
ABSODetectsMAPsensorsignal.
RED/G
BN
LUTEPRESSURE
SENSOR)
2
3
YEURED
5
GRNîVHT
8
9*
14
EKSW(BRAKE
SWTCH)
Detectsbrakeswitchsignal.
With brakeDedalreleased:0 V
With brakepedaldepressed:
batteryvoltage
DetectsKS signal.
Detectsprimary heatedoxygen
sensor{sensor1) signal.
With engineknocking:pulses
YEL/BLU
10
With throttlefully open:about4.8V

With throftletully closed:about0.5V
With ignitionswitchON(U):
about0.1- 4.8V
(depending
on enginecoolanttemperature)
With ignitionswitchON(ll):about3 V
At idle:about1.0V
(dopending
on enginespeed)
W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u r 5 V
W i t h i g n i t i o n s w i t c h O F F r0 V
PH02S(PRIMARY
HEAT
ED OXYGENSENSOR,
SENSOR
1)
LABEL
IAT(INTAKE
AIRTEM,
BED/YEL
PERATURE
SENSOR}
(EGRVALVELIFT
WHT/8LK EGRL
SENSOR}
VCC2(SENSOR
VOLTAGE)
Signal
vccl (SENSOR
VOLTAGE) Powersourcefor MAPsensor.
RED/BLU KS (KNOCKSENSOR)
6*?
12
Description
RED/BLK
ll
T.minal
DetectsLABELresistance.
DetectsIATsensorsignal.
DetectsEGFvalvelift sensorsional.
P r o v i d e ss e n s o r v o l t a g e ,
With thronlefully openedfrom idlewith

fully warmedup engine:above0.6V
Withthrottlequicklvclosed:below0.4V
With enginerunning:about0.3- 4.9V
With ignitionswitchON {ll):about0.14.8V (depending
on intakeairtemperature)
At idlewithoutvacuum:about1.2V
With 27 kPa(200mmHg,8 in. Hg):about4.3V
With ignitionswitchON(ll):about5 V
With ignitionswitchOFF:0 V
(SENSOR
GROUNDi
(SENSOR
GRNAr'VHT SG1
GROUND)
SHO2SG(SECONDARY
GRN/8LK+I'
HEATEDOXYGENSEN.
REDt/EL*14
SOF,SENSOR
2 GROUND)
Sensorground.
Groundfor MAPsensor.
Ground for secondaryheatedoxygen sensor{sensor2),
L e s s t h a n1 . 0V a t a l l t i m e s
(SECONDARY
SHO2S
WHT/RED HEATED
OXYGENSENSOR,SENSOR
2)
Detectssecondaryheatedoxygen
sensor(sensor2) signal.
With throttle fully openedfrom idle with

tully warmedup engine:above0.6V
With thronlequicklvclosed:below0.4V
GRN/BLK
LT GRN
16*,
PTANK(FUELTANKPRES- Detectsfuel tankoressuresensor,

SURESENSOR)
EL (ELD)
DetectsELDsignal.
GBN/RED
*1: USA model

*2: IVT {D16Y7,D16Y8ensine)
*3: CW (D16Y5engine)
*4: ,VTand D16Y76ngine
+5:ExceptAy'Tand D16W engine
*6: A/T 1D16Y8
engine)
*7: CW (O16Y5engine)and 016Y8engine
1 8 : ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) , ' 9 7D 1 6 Y 8e n g i n e( c o u p o :a l l
m o d e l s ,s e d a n :K L m o d e l ) , ' 9 8D 1 6 Y 5 n g i n e ,'98 D16Y8
engrne
11-52
Lessthan 1.0V at alltimes
With fuel fill caDooend:about 2.5 V

With parkinglightsturnedon at idle:about
With low beamheadlights
turnedon at
i d l e :a b o u t1 . 5 - 2 . 5V
r9: D16Y5engine
* 10rM/T (D16Y5engine)
*11:ExcoptM/T (Dl6Y5engine)
*12:D16Y5,D16Y8engine
*13:D16Y8engane
'14: Dl6Y7engine
*15:'97 016Y7engine{coupe:KL model,sedan:KL (LX)
modet),
'98D16Y7
engine:
DiagnosticTroubleCode(DTC)Chart
DTC
(MlLindicationr)
P0106*15 (5)
P0'107
(3)
P0108
(3)
P 0 11 1 + r ,*41. 5{ 1 0 )
Dtection ltem
ManifoldAbsolute
PressureC:rcuit
Range/Performance
Problem
ManifoldAbsolute
PressureCircuit
Low Input
ManifoldAbsolute
PressureCircuit
H i g hI n p u t
IntakeAir Temperature
Circuit
Range/Performance
Problem
ProbableCause
. Vacuum connection
. MAP sensor
Page
1167
Openor short in MAP sensorcircuit

MAP sensor
ECMiPCt\,4
TCM*I
1169
Open in MAP sensorcircuit

MAP sensor
ECM/PCM
11-71
. IAT sensor
11-73
P01't2
(10)
IntakeAir
TemperatureCircuit
Low Input
Short in IAT sensorcircuit

IAT sensor
ECM/PCM
1l-74
P01' t3
(10)
lntakeAir
TemperatureCircuit
H i g hI n p u t
Openin IATsensorcircuit
IAT sensor
ECM/PCM
11-75
P0116
(86)
E n g i n eC o o l a n t
TemperatureCircuit
Range/Performance
Problem
P0117
(6)
EngineCoolant
TemperatureCircuit
Low Input
Shortin ECTsensorcircuit
ECTsensor
ECM/PCM
11-17
P0118
(6)
E n g i n eC o o l a n t
TemperatureCircuit
H i g hI n p u t
Open in ECTsensorcircuit
ECTsensor
ECM/PCM
l1-78
P0'122
(71
ThrottlePosition
Circuit
Low Input
Openor shon in TP sensorcircuit

TP sensor
ECM/PCM
TCM*1
11-79
P0123
t7l
ThrottlePosition
Circuit
High Input
Openin TP sensorcircuit
TP sensor
ECMiPCM
I 1-81
P0131*'
(1)
PO132+'
(1)
P0133*'
(61)
P0135*'
(41)
PrimaryHeatedOxygenSensor
CircuitLow Voltage
( S e n s o1r )
CircuitHighVoltage
(Sensor1)
Slow Besponse
{SensorI )
PrimaryHeatedOxygen
SensorHealer
CircuitMalfunction
(Sensor'l)
. ECTsensor
. Coolingsystem
11-76
Short in PrimaryHO2S{Sensorl)circuit
PrimaryHO2S(Sensor1)
Fuelsupplysystem
ECM/PCM
Openin PrimaryHO2S(Sensor1) circuit
ECtVr/PCM
. PrimaryHO2S(Sensorl)
' E x h a u s ts y s t e m
11-8J
. Openor short in PrimaryHO2S

( S e n s o1r ) h e a t e cr i r c u i t
. ECM
11,98
11-84
11-86
*: TheseDTCSwill be indicatedby the blinkingof the MalfunctionIndicatorLamp (MlL)with

the SCSserviceconnector
connected
* 1 : D l 6 Y 5e n g i n e( C V T )
(cont'd)
*2: ExceptDl6Y5 engine(M/T)
'97
*14:
model
* 1 5 : ' 9 6m o d e l
*16:'98 model
11 - 5 3
Troubleshooting
DiagnosticTroubleCode(DTC)Chaft (cont'd)
DTC
{MlL indication)
ProbableCause
Detection ltem
HO2S(Sensor
2) circuit
Shortin Secondary
HO2SlSensor2)
Secondary
ECM/PCM
Openin Secondary
HO2SiSensor2)circuit
HO2S(Sensor
Secondary
2)
ECt\4/PCM
P0137
(63)
HeatedOxygenSensor
Secondary
CircuitLowVoltage
(Sensor
2)
P0138
(63)
SecondaryHeatedOxygenSensor
CircuitHigh Voltage
(Sensor2)
(63)
HeatedOxygenSensor
Secondary
SlowResponse
(Sensor
2)
SecondaryH02S (Sensor2)
P0139
P0141
(65)
SecondaryHeatedOxygen Sensor
Heater
CircuitMalfunction
(Sensor2)
Open or short in SecondaryHO25 (Sensor

2) heatercircuit
ECM/PCM
SystemToo Lean
Fuel supply system

PrimaryH02S (Sensor1)
lvlAPsensor
Contaminatedfuel
Valveclearance
Exhaustleakage
Fuel supply system
PrimaryHO2S(sensor1)
MAP sensor
Contaminatedfuel
Valve clearance
P0171
{45)
System Too Rich

P0172
(45)
P0300*16
and
someof
P0301
P0302
P0303 l 7 3 l
P0304 \741
RandomMisfire
l#\
P0301
P0302
P0303
P0304
tr\
173|
\741
P0325'3
(23)
P0335
(4)
P0336
{4)
P0401.1
(80)
11-54
(67)
lgnitionsystem
Fuelsupplysystem
MAPsensor
EGRsystem
IACvalve
Contaminated
fuel
Lackof fuel
Fuel Injector
Fuel Injectorcircuil
lgnitionsystem
Low compressron
Valveclearance
Open or short in KnockSensor(KS)circuit
KnockSensor(KS)
ECM/PCM
Crankshaft
Position
SensorCircuit
Mallunction
Position
Crankshaft
Sensor
Range/Performance
CrankshaftPositionSensor
CrankshaftPositionSensorcircuit
ECM/PCM
CatalystSystem
EfficiencyBelow
Threshold
*3r Dl6Y5engine(CVT)andDl6Y8engine
*4: D16Y5engine
* 1 6 : ' 9 8m o d e l
P0420
11-95
11-96
11-97
- Cylinder1
- Cylinder2
- Cylinder3
- Cylinder4
Misfire Detected
KnockSensor(KS)Circuit
Maltunction
ExhaustGas
Recirculation
lnsufficient Flow Detected
Page
1 19 8
11-103
11,103
11 -1 0 8
11-105
11,109
11-110
. CrankshaftPositionSensor
. Timingbeltskippedteeth
' 11 - 1 1 0
. E G Rl i n e
11-170
. Three Way Catalyticconverter

. SecondaryH02S
11-168
DTC
(MlLindicationl
Detection ltem
EvaporativeEmissionControl
System lnsufficient
PurgeFlow
EVAPPurgeControlSolenoidValve
Open or short in EVAPPurgeControl
SolenoidValvecircuit
EVAPControlCanister
Vacuum lines
ECM/PCM
Shortin FuelTankPressure
Sensorcircuit
FuelTankPressure
Sensor
ECM/PCIV
Openin FulTankPressure
Sensorcjrcuit
FuelTankPressure
Sonsor
ECM/PCM
P0441*5
{92)
P0452*6
(91)
FuelTankPressure
SensorCircuit
Low Input
P0453*6
(91)
FuelTank PressureSensorCircuit
H i g hI n p u t
P0500.1,
(17)
P0501*13 (17)
P0505
(14)
P0700*E
and some of
P0715
P0720
(70)*
P0730
P0740
P0753
P0758
P0700*1
and
{70)*
P0725
P1107
(13)
P1108
(13)
Pl121+M.+16 17)
P 1 1 2 2 * 1 4* 1 5 l 7 l
P 1 1 2 8 * 1 4* '.6 ( 5 1
Probable Cause
VehjcleSpeed
SensorCircuit
lvlalfunction
VehicleSpeed
SensorCircuit
Range/Performance
ldle ControlSystem
Malfunction
Automatic
Transaxle
Page
11-'190
11 -1 8 1
11 -1 8 3
VehicleSpeed Sensor
VehicleSpeed Sensorcircuit
ECM
11-112
VehicleSpeedSensor
VehicleSpeedSensorcircuit
PCM
1 1112
. IAC valve
. Throttle Body
11-124
Section 14
AutomaticTransaxle
Section 14
Barometric
Pressure
Circuit
Range/Performance
Problem
Barometric
Pressure
Circuit
LowInput
. bCM/PCM (tsarosensorl
. ECM/PCM{8aro sensor}
Earometric
PressureCircuit
H i g hI n p u t
. ECM/PCM(Barosensor)
ThrottlePositionLowerThan
Expected
. TPsensor
ThrottlePositionHigherThan
Expected
ManifoldAbsolutePressure
Lower Than Expected
Manilold AbsolutePressure
HigherThan Expected
. TPsensor
11 1'13
'
'| 14
11-1't4
. MAP sensor
. MAP sensor
11-82
11-83
11-72
11-72
*: The
LD.jindicatorlight and the MallunctionIndicatorLamp (MlL) may come on simultaneously.
*1: D16Y5engine (CVT)
*5j '96 D16Y5engine,D16Y7engine,Dt6Y8
engine (sedanl,,97 O1dy5engine,O16y7engine (coupe:KA, KC models,sedan:KA,
KC,KL (DX) models,hatchback:a models),D16yg engine (sedan:KA;KC models)
*6:'96 D16Y8engine (coupe),'97D16Y7
engine {coupe:KL modet,sedanrKL (LX) model),'97 D16y8 engine (coupe:all models,
sedan:KL model), '98-allmodels
*12: ExceptA/T (D16Y7,D16Y8enginel
*'13:A"/T(D16Y7,D16Y8engine)
+14:'97modet
*T6: ,98 model
{cont'd)
11 - 5 5
Troubleshooting
TroubleCode(DTGIChart(cont'dl
Diagnostic
DTC
{MlLindication}
P1162*1
(48)
P1163*'
(61)
P1164*'
i61)
P1165*?
(61)
Detection ltem
(Senso1
r )Circuit
Mal{unction
(Senso1
r )Circuit
Slow Response
(Sensor'l) CircuitRange/
Problem
Performance
. PrimaryHO2S(Sensor1)
(Sensor'1)CircuitRange/
PerformanceProb em
(Sensor1) HeaterSystem Electrical
Problem
P1166*?
(41)
P1167*1
(41)
P1 1 6 8 * ?
(48)
PrimaryHeatedOxygen Sensor
(Sensor1) HeaterSystem
Malfunction
( S e n s o r1 ) L A B E LL o w I n p u t
P1169*7
(48)
{ S e n s o r1 ) L A B E LH i g hI n p u t
VTECSystem Malfunction
P1259*3
\22)
P1297*'
(20)
P1298*'
(20)
and
someof
P0301
P0302
P0303
P0304
1 7 I1
prl
l73l
\ 74 l
*7: D16Y5engine (M/T)
*8: D16Y5,D16Y8engine
*9: USA model
* 1 4 r' 9 7 m o d e l
+ 1 5 r' 9 6 m o d e l
11 - 5 6
Probable Cause
. Openor shortin PrimaryHO2Slsensor1

. PrimaryHO2S(Sensorl)
ElectricalLoad
DetectorCircuit
Low InPut
ElectricalLoad
DetectorCircuit
H i g hI n p u t
R a n d o mM i s f i r e
Page
'1188
PrimaryHO25 (Sensor1)
11-87
11-92
11-92
Open or short in PrimaryHO2S(Sensor'l)
heatercircuit
PrimaryHO2S(Sensor1|
ECM/PClvl
11-100
liVS+ circuit
HO2S(Sensor
Openin Primary
PrimaryHO2S(Sensor1) Heater
PrimaryHO2S(Sensor1i
11-102
. Shon in PrimaryHo2S (Sensor1) LABEL

carcuit
. Open in PrimaryHO2S(Sensor1) LABEL
circuit
. Short in ground circuit
VTECSolenoidValve
Open or short in VTECSolenoid
Valve circuit
v I tL PressureSwttcn
Open or short in VTECPressureSwitch
crrcurt
ECM/PCM
ElectricalLoad Detector
ElectricalLoad Detectorcircuit
ECM/PCrvl
ElectricalLoad Detector
ElectricalLoad Detectorcircuit
ECM/PCIV
lgnitionsystem
Fuelsupplysystem
MAPsensor
EGRsystem
IACvalve
fuel
contaminated
Lackol fuel
'11-94
Section6
11-115
11-116
11 -1 0 8
DTC
lMlL indicrtionl
P1336
(54)
P1337
(54)
P1359
(8)
P1361
(8)
P1362
(8)
P1381
(91
P1382
(9)
Detoction hem
CrankshaftSpeed
FluctuationSensor
Intermiftent Interruption
CrankshaftSpeed
FluctuationSensor
No Signal
CrankshaftPosition/Top
DeadCenterSensor
Disconnected
(e0)
CKFsensor
CKFsensorcircuit
ECM/PCM
CKP/TDC
sensorcircuit
11 117
1 11 1 9
CylinderPositionSensor
IntermiftentInterruption
CylinderPositionSensor
No Signal
. CYPsensor
Evaporative
Emission
Control
SystemLeakDetected(EVAP
ControlCanister
Area)
P1457+6
11 117
. TDCsensor
(90)
Page
. CKFsensor
Top DeadCenter
SensorIntermittent
Interruptron
Top Dead Center
SensorNo Signal
Evaporative
Emission
Cont.ol
(FuelTank
SystemLeakDetected
Area)
P1456*6
Probable Cause
1 11 1 0
TDCsensor
TDCsensorcircuit
ECM/PCM
CYPsensor
CYPsensorcircuit
ECM/PCM
F u e lf i l l c a p
Vacuum connection
Fueltank
Fueltank pressuresensor
EVAPbypasssolenoidvalve
EVAP two way valve
EVAPcontrol canistervent shut valve
EVAPcontrol canister
EVAPpurge control solenoidvalve
Vacuum connection
EVAPcontrol canister
EVAPbypasssolenoidvalve
EVAP two way valve
FuelTank
11-110
11-' '10
]
11 1 1 0
11-185
11,185
*6:'96 Dl6Y8 engine (coupe),'97 D16Y7engine (coupe:KL model, sedan: KL

1LX)model),'97 D16Y8engine (coupe:all models,
sedan:KL model),'98-allmodels
{cont'd)
11-57
Troubleshooting
DiagnosticTroubleCode(DTC)Chart(cont'dl
DTC
lMlLindicationl
Detection ltem
EGRValve
Lift Insufficient
Detected
P1491*.
l12l
Probablc Cause
EGRvalve (with lift sensor)
EGRvalve lift sensorcircuit
EGRcontrol solenoidvalve (4,/T)
EGRcontrol solenoidvalve circuit
Pags
11-171
EGRvalve circuit (M/T)

ECIV
P1498*.
\12)
P1508*'0
(14)
EGRValve
Lift Sensor
High Voltage
ldle Air ControlValve
CircuitFailLrre
P1s09*11 114)
ldle Air ControlValve

C i r c u iF
t ailure
EngineControl
Module/PowenrainControlModule
lnternal
P1607
P1655*1
P1705
P1706
P1 7 5 3
P1758
P1768
P1785
P1790
P1791
P1793
P1870
P1873
P1879
P1885
P1886
P1888
P1890
P1891
(30)
TMA,/TMBSisnal Line Failure

AutomaticTransaxle
EGRvalve lwith lift sensor)

EGRvalve lift sensorcircuit
ECt\4
IAC valve
IAC valve circuit
ECM
Openor shon in IACvalvecircuit

IACvalve
ECM/PCt\,,|
. ECM/PCM
11-126
11'128
11-120
Open or short in TMA/TMBcircuit
(70)*
*: The[D!]indicatorlightandthe Mallunction
Indicator
Lamp(MlL]maycomeon simultaneously.
*1: D'16Y5
engine(CVT)
*4: D16Y5engine1N4/T)
*10:ExceptA/TandD'16Y7
engine
*11:A,/TandD16Y7engine
11 - 5 8
11 - 1 7 6
11-121
Section14
How to ReadFlowcharts
A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware:
lf you go off the "map" anywherebut a "stop" symbol,you can easilyget lost.
ISTARN
{boldtype)
Describes
the conditionsor situationto starta troubleshootinq
flowchart.
jAcroNl
Asksyou to do something;performa test.set up a conditionetc.
QE!E]!!,
fsro-l
(boldtype)
Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting

direction.
The end of a seriesof actionsand decisions,describesa final repairactionand sometimesdirectsyou to
an earlierpan ot the flowchartto confirmyour repair.
NOTE:
The term "lntermittentFailure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks
out OK at this time. lf the MalfunctionIndicatorLamp {MlL)on the dash does not come on, checkfor poor connectrons
or loosewires at all connectorsrelatedto the circuitthat you are troubleshooting
(seeillustrationbelow).
. Most of the troubleshootingflowchartshave you resetthe EngineControlModule (ECM)/Powertrain
ControlModule
{PC[/)and try to duplicatethe DiagnosticTroubleCode(DTC).It the problemis intermittentand you can't duplicatethe
code,do not continuethoughthe flowchart.To do so will only resultin confusionand, possibly,a needlesslvreDiaced
ECM/PCM.
o "Open" and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidentalconnectionof a wire to ground or to anotherwire. In simple electronics,
this usuallymeanssomethingwon't
work at all. In complexelectronics(likeECM'S/PCM'S),
this can sometimesmeansomethingworks,but not the way it's
suoDosed
to.
.
LOOSE
PGM-FISystem
SystemDescription
INPUTS
CKP/TDC/CYP
Sensor
CKFSensor
MAP Sensor
ECTSenso.
IATSensor
TP Sensor
EGRValveLiftSensor*1
PrimaryHO2S
Secondary
HO2S
VSS
EAROSensor
ELD*'
KS*3
StarterSignal
ALT FRSignal
Air Conditionjng
Signal
A,/TGearPositionSignal
BafteryVoltage(lGN.1)
SrakeSwitchSignal
PSPSwitchSignal
FuelTankPressure
Ssnsor*a
VTECPressureSwitch*t
ClutchSwitchSignal*6
CountershaftSpeedSensor*3
Mainshalt SpeedSensor*3
ENGINE
C O N T R OM
L O D U L E( E C M ) i
POWERTRAIN
CONTROL
MODULE(PCM)
F*l |.r*a"r.Tl.il g ""d Dr*i";l

E r""t'.','l" ldb c-o-l*il
F,h*J--r---l Fr"*il]
Effi;r"sc;;il
FcM/PcMB""k,upFr*,or'sl
OUTPUTS
FuelInjectors
PGMFl Main Relay{FuelPump)
MIL
IAC Valve
A,/CCompressorClutch Relay
RadiatorFanRelay*'
Condenser
FanRelay
ALT*?
rcM
EVAPPurgeControlSolenoid
PrimaryHO25Heater
SecondaryH02SHeater
EGRControlSolenoidValve*7
EGRvalve*6
EVAPBypassSolenoidValve*a
EVAPControlCanisterVent Shut
VTECSolenoidValve*5
DLC
Lock-upControlSolenoidValve*3
ShiftControlSolenoidValv6*3
LinearSolenoidValve*3
'1: D16Y5
engine
*2:USAmodel
*3rCW (D16Y5
engineland
016Y8
engine
*4: '96016Y8engine{coupe},'97
D16Y7
engine{coupe:
KLmodel,sedan:
KL{LX)model),'97
D16Y8
engine(coupe:
all models,
sedan:
KL
model).'98'all
models
15:Dl6Y5,Dl6Y8engine
*6:M/T(016Y5
engine)
*7:CVT(D16Y5
engine)
*8:A/T(D16Y7,
D16Y8
ensine)
*9:'96 Dl6Y5engine,'96
D16Y7
engine,'96
D16Y8
engine(sedan),'97
D16Y5
engine,'97
D16Y7
engine(coupe:
KA,KCmodels,
sedan:
KA,KC,KL(LX)models,
hatchback:
all models),'97
D16Y8
engine(sedan:
KA,KCmodels)
PGM-FISystem
The PGM-Fisystemon this model is a sequentialmultiportfuel injectionsystem.
Fuol inisstor Timing and Duration
The ECM/PCMcontainsmemoriesfor the basicdischargedurationsat variousenginespeedsand manifoldair llow rates.
The basicdischargeduration,afterbeing readout from the memory,is further modifiedby signalssentfrom varioussensorsto obtainthe final dischargeduration.
ldlo Air Control
ldle Air ControlValve(lACValve)
Whenthe engineis cold,the Ay'Ccompressoris on, the transmissionis in gear,the brakepedalis depressed,
the P/Sload
is high,or the alternatoris charging,the ECM/PCM
controlscurrentto the IACValveto maintainthe correctidle speed.
lgnition Timing Co||trol
. The ECM/PCMcontains memorieslor basic ignition timing at various engine speedsand manifold air flow rates.
lgnitiontiming is also adjustedfor enginecoolanttemperature.
. A knockcontrolsystemwas adoptedwhich setsthe idealignitiontimingfor the octaneratingof the gasolineused.*3
Other Control Functions
1. StaningControl
Whenthe engineis started,the ECM/PCMprovidesa rich mixtureby increasingtuel injectorduration
2. FuelPumpControl
. When the ignitionswitchis initiallyturned on, the ECM/PCMsuppliesgroundto the PGM-FImain relaythat suppliescurrentto the tuel pump for two secondsto pressurize
the fuel system.
. When the engine is running,the ECM/PCMsuppliesground to the PGM-FImain relay that suppliescurrentto the fuel
pump.
. When the engineis not runningand the ignitionis on, the ECM/PCMcuts groundto the PGM-FImain relaywhich
cutscurrentto the fuel pump.
11-60
3.
FuelCut-offControl
. Duringdeceleration
with the throttlevalveclosed,currentto the fuel injectorsis cut off to improvefuel economyat
speedsoverthe {ollowingrpm:
. D16Y5engine(M/T):850 rpm
. D16Y5enginelCVT),D16Y8engine(USAM/T)r920 rpm
' D16Y8engine(USAA,/T),Dl6Y7 ensine(USAA"/T):910
rpm
. D16Y8engine(CanadaM//T),Dl6Y7 engine(Canada):990
rpm
. D'16Y8
engine(CanadaM/T):1,000rpm
. Fuelcut-offactionalso takesplacewhen enginespeedexceeds6,900rpm (D16Y5,Dl6Y7 engine;D16Y8engine:
7,000rpm),regardlessof the positionot the throttlevalve,to protectthe enginefrom over-rewing.
Ay'CCompressorClutchRelay
When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom
beingenergized,
and enrichesthe mixtureto assuresmoothtransitionto the Ay'Cmode.
5 . Evaporative
Emission(EVAP)PurgeControlSolenoidValve+s
Whenthe enginecoolanttemperatureis above '154.F(68"C).the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid
valvewhich controlsvacuumto the EVAPpurgecontrolcanister.
Evaporative
Emission(EVAP)PurgeControlSolenoidValve*a
Whenthe enginecoolanttemperatureabove 154"F(68"Ci,intakeair temperatureabove32"F(0"C)and vehictespeeo
above 0 mile 10 km/h)or [A,/Ccompressorclutchon and intakeair temperatureabove 160"F141.C)1,
the ECM/PCM
controlsthe EVAPpurgecontrolsolenoidvalvewhich controlsvacuumto the EVAPpurgecontrolcanister.
(EGR)ControlSolenoidValve*?
6. ExhaustGasRecirculation
When EGRis requiredfor controlof oxidesof nitrogen(NOx)emissions.the ECMcontrolsthe EGRcontrolsolenoid
valvewhich suppliesregulatedvacuumto the EGRvalve.
7 . AlternatorControl
The systemcontrolsthe voltagegeneratedat the alternatorin accordance
with the electricalload and driving mode,
which reducesthe engineloadto improvethe fuel economV.
CM/PCMFail-safe/Back-upFunctions
'L Fail-safe
Function
when an abnormalityoccursin a signalfrom a sensor,the ECM/PCN4
ignoresthat signsl and assumesa pre-programmedvaluefor that sensorthat allowsthe engineto continueto run.
2. Back-upFunction
When an abnormalityoccursin the ECM/PCMitself.the fuel injectorsare controlledby a back-upcircuitindependent
of the systemin orderto permitminimaldriving.
3. Self-diagnosis
Function[r4alfunctionIndicatorLamp(MlL)]
When an abnormalilyoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the MIL and storesthe DTC
in erasablememory.When the ignitionis initiallyturned on, the ECM/PCMsuppliesgroundfor the MIL for two secondsto checkthe MIL bulb condition.
4. Two Trip DetectionMethod
To preventfalse indications,
the Two Trip DetectionMethodis usedfor the HO2S,fuel metering-related,
idle control
system,ECTsensor.EGRsystem and EVAPcontrol systemself-diagnostic
functions.When an abnormalityoccurs,
the ECM/PCMstoresit in its memory.When the same abnormalityrecursafterthe ignitionswitch is turned OFFand
ON (ll) again,the ECM/PCMinformsthe driverby lightingthe MlL. However,to easetroubleshooting,
this functionis
cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelvwhen an abnormalitv
occurs.
5. Two (or Three)DrivingCycleDetectionMethod
A "DrivingCycle"consistsof startingthe engine,beginningclosedloop operation,and stoppingthe engine.lf misfiring that increasesemissionsis detectedduringtwo consecutivedrivingcycles,or TWC deteriorationis detectedduring three consecutivedrivingcycles,the ECM/PCMturns the l/lL on. However,to easetroubleshooting,
this function
is cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelywhen an abnormalitv
occurs.
(cont'd)
11-61
PGM-FISystem
SystemDescription(cont'd)
\.
LoanEurn Control(D16Y5enginerCVT)
SENSOR
TDC/CKP/CYP
MAP SENSOR
CKFSENSOB
of currentair
Comparison
fuel ratio to target ratio
SelectionoI basicfuel
iniectionduration
ECM
which occursin
increasein crankshaftangularacceleration
The lean burn controlsystem is basedon the characteristic
when the air-fuelratiogets leaner.
falls below
The CKFsensor,which is mountedon the crankshaft,monitorsenginespeed.lf crankshaftangularacceleration
a certainlevel(targetair-fuelratiolevel),the amountof injectedfuel is reduced.
lf crankshaftangularacceleration
exceedsthis level.the amountof fuel is increased.
This system improvestuel economyand driveabilityby controllingthe amount of iniectedfuel in the lean burn range
immediatelybeforecombustionstartsto deteriorate,
11-62
EngineGontrolModule/PowertrainGontrolModule{ECM/PCM)
The Maltunction Indicato. Lamp
{MlL) nover com.s on {even to.
two secondsl .tter ignition i!
tutned on.
NOTE:lf this symptomis intermittent,

checkfor a looseluse No. 25 llrETER7.5A) in the
underdash fuse/relaybox, a poor connectionat ECN4/PCM
terminal Al8, or an intermit,
tent openin the GRN/ORN
(Al8) and the gaugeassembly.
wire betweonthe ECM/PCM
Turnthe ignitionswitchON (ll).

ls the low oil pressurelight on?
-
Rgpair short or open in tho

wire betwo.n No. 25 (METER)
(7.5A)fusc rnd gauge r$omblv.
ReplecoNo.25 IMETERI17.5
A)tu...
Try to stan the engine.
ECM/PCMCONNECTOR
A (32P}
PGl {BLKI
Ch6cklor an open in the wiros

(PGlineslr
1. Turn the ignitionswitchON (ll).
2. Measurevoltage between
body ground and ECM/PCM
connectorterminalsA10 and
A23individually.
Checkfor an open in th6 wire or
bulb lMlL lino):
2 . C o n n e c t h e E C M / P C Mc o n
nectorterminal 418 to body
groundwith a jumperwire.
ls therelessthan 1.0V?
Substitute . known-good ECM/

PCM and rechock. lf 3ymptom/
indication goo3 away, rcplac6
tho o.iginal ECM/PCM.
ls the MIL on?

-
Substituto a known-good ECM/

PCM and rechsck. lI symptom/
indicetion goo3 away, replaco
the odgin.l ECM/PCM.

Repair opon in thc wi..l3)
botwen ECM/PCM and c10l
lloc.ted at tho tharmostat housinglthrt had more th.n 1.0V.
ECM/PCMCONNECTOR
A {32PI
Repai. open in tha wire3

betweon ECM/PCM(A181.nd
gaugc a$ombly.
Reolacethe MIL bulb.
(cont'd)
PGM-FISystem
ControlModule(ECM/PCMI(cont'd)
EngineControlModule/Powertrain
The Malfunction lndicator Lamo
lMlLl stays on or comos on after
NOTE:
. When there is no DiagnosticTrouble Code (DlC) stored,the MIL will stay on if the SCS
serviceconnectoris connectedand the ignitionswitch is on.
. lf this svmptomis intermittent,
checkforl
- A looseFl E/M{15A) fusein the underhoodfuse/relay
box
- A l o o s eN o .1 3 F U E L P U M P f u s e ( 1 5i A
n t)h e u n d e r ' d a sf hu s e / r e l abyo x
- An intermittentshortin the wire betweenthe ECM/PCM(C7)and the servicecheck
-
C h e c kt h e D i a g n o s t i cT r o u b l e
Code(DTC):
1. Connecta scantool or Honda
PGMTester.
2. Turnthe ignitionswitchON {ll).
3. Readthe DTC with the scan
tool or HondaPGMTester.
An intermittentshort in the wire between the ECM/PCM(A18)and the gauge
An intermittentshort in the wire betweenthe ECM/PCM(D4land the MAP sensor

An intermittentshort in the wire betweenthe ECM/PCM{D10},the TP sensor,the
EGRvalve lift sensor (D16Y5engine)and/or the Fuel tank pressuresensor ('96
016Y8engine(coupe),'97Dl6Y7 engine(coupeiKL model,sedan:KL (LX)model),
'97 D16Ygenginelcoupe:all models,sedan:KL model),'98-tllmodels)
- PGM-FI
mainrelay
. See the O8D ll scantool or HondaPGMTesteruser'smanualsfor specificoperating
Instructrons.
Go to troubl6hooting procdures.
{3eepag611-53)
Ch6ckthe DTCby MIL indication:

2. Connectthe SCSservicecon'
n e c t o rt o t h e s e r v i c ec h e c k
connector.
Doesthe MIL indicateany DTC?
Rpair opon or short in wire

between the EcM/PcM {c8)
and Oata Link Connector.
Go to troublashooting p.ocedure. (s6epage 11-531.
C I31PI
ECM/PCMCONNECTOR
scs (BRNI
Try to stan the engine.
Doesthe enginestan?
C h e c kl o r a s h o r t i n t h a w i r e
ISCSlinel:
'L Disconnectthe SCS service
(To page11-65)
2. Stop the engineand turn the

ignitionswitchON (ll).
3. N4easure
voltagebetweenthe
ECM/PCMconnectorterminal
C7and bodyground.
ls thereapprox.5 V?
(Topage11-65)
11-64
Repair 3hoft to body ground in

th wire botwoen ECM/PCM{C7)
tnd se ice checkconnctor.
(Frompage11-64)
Ch.ck to. . 3hort in the wirc {MlL

linol:
2. Disconnecrthe ECM,/PCi!4
connectorA (32P).
3. Turn tho ignitionswitchON (ll).
Roptir ahort to body ground in

th6 wir. b.twoon the ECM/PCM
lAl8l snd MlL.
Substitute a known-good ECM/
PCM and rech.ck. ll 3ymptom/
indication goes away, replace
the original ECM/PCM.
(From page 11-64)
InspectFl E/M ('10A) fuse in the

undeFhoodtuseJrelay
box.
R.prir 3hort in thc wi..
btw.en Fl E/M 115 A) luse
and PGM-FIm.in iolay.
Ropl.co Fl E/M (15 A)fu.e.
InspectNo. 13 FUELPUMP115A)
fuse in the undeFdashfuse/relay
box.
-
Repair short in the wire

betwoen No. 13 FUEL PUMP
{15 Al tus6 and PGM-FIm.in
retay,
ReplaceNo. 13 FUELPUMP
115A) luse.
Chcktor a short in a son3or:

'1. Turn
the ignitionswitchON (ll).
2. Disconnectthe 3P connector
from eachsensorone at time:
. TPsensor
. EGRvalve litt sensor{Dl6Y5
engtne)
. F u e l t a n k p r e s s u r es e n s o r
('96 D16Y8engine {coupe),
' 9 7 D 1 6 Y 7e n g i n e ( c o u p e :
K L m o d e l , s e d a n :K L ( L X )
m o d e l ) ,' 9 7 D 1 6 Y 8e n g i n e
( c o u p e :a l l m o d e l s .s e d a n :
KL model'98-allmodels)
(Topage11-66)
{cont'd)
1-65
PGM-FISystem
(cont'dl
EngineControlModule/PowertrainControlModule(ECM/PCMI
lFrompage11-651
ECM/PCMCONNECTOR
D {16PI
Does the MIL go OFF?
Rapbce the ranaor thrt cau3od

th6 light to go out,
Chect tor r short in th6 wiras

{VCClin.3l:
1. T{rrnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e E C M / P C M
connectorD (16P).
connectorterminals D4 and
D10individually.
Check tor en opcn in th. wire3

llGP linosl:
1. Disconnectthe fuel inioctors
and IACvalveconnectors.
A24 individually.
Repair ahon to bodY g.ound

in th. wire batwaon ECM/
PCMlD4l snd MAP s.n.or.
R.pair .hort to body ground
in tho wi.e botwoen ECM/
PCM lD10l, th. TP sensor,the
EGR v.lve lift son.or {D16Y5
.ngin.l and/or thc Fu.l tsnk
pra33u.escnso. ('96 D16Y8
onginc {coup.l,'97 D16Y7
6 n g i n 6 { c o u p o :K L m o d e l ,
3odan: KL lLXl modcll, '97
D16Y8ongino lcoupc: all
model3,seden:KL modol, '98all modobl,
Sub.titute . known-good ECM/

PCM and lochock. lf .ymptom/
indic.tion 9o. awry, roplace
the origin.l ECM/PCM.
11-66
A I32P}
ECM/PCMCONNECTOR
,I
IGP
(YEL/BLK)
t5 t 5 1 1 t8
12 t 3
21
l0
11
2a
22
20
2A 29 30
IGP2
(YEL/8LKI
-
ls there lessthan '1.0V?
25
Check for an opon in the wirg!

ILG line.l:
1. Reconnect
all sensorconnecrors,
2. Reconnectthe ECM/PCMconnectorD (16P).
3. Turn the ignitions,witchON {ll).
4 . N 4 e a srue v o l t a g e b e t w e e n
connectorterminals A9 and
A22 individually.
VCC1(YEL/RED)
Rapail opan in the srire{31

botwo.n ECM/PCM (A11.
A24l .nd PGM-FImrin roby.
Check lor poor connaction3
or loo3. wirc! .t th. PGM-FI
main ralay.
Tert lho PGM-FImain r.lay
l3ecpag611-1571.
LGl
IERN/
BLK}
a
12 t 3 t a t 5 t 6 7 7 t 8 t9 20
E
21
2A 23 3 0
LG2
IBRN/
BLKI
Rapair op.n in the wiro(rl

btween ECM/PCM lA9, A22l and
G101that had morothln 1.0V.
!l
to
!l
23
2a
ManifoldAbsolutePressure(MAP)Sensor
The scan tool indicatesDiagnosticTrouble Code (DTC)P0106:A mechanicalproblem (vacuumleak) in the
ManifoldAbsolutePressure(MAP)Sensorsvstem.
The MAPsensorconvertsmanifoldabsolutepressureinto electricalsignalsand inputsthe ECM/pCM.
OUTPUI
VOLTAGE
tvt3.5
3.0
2.5
2.O
1.5
1,0
o
The MIL has bo6nrponed on.
OTCP0106is stored.
Or from ProbableCauseUrt.
tq.
,5
lqt
2|x)
rs.
3(x) i(X,
10
30 lin. Hg) GAUGE
.25
5OO 600 7ql
READI'{G
lln]n Hgl
Problemverilication:
1. Do the ECM/PCMResetProcedure.
2. Start the engineand keep
enginespeedat 1,000rpm for
one minutewith the transmis,
sion in P or I position(M/T
in neutral).
ls DTCP0106indicated?
Ch6ckthe MAP sensoroutput:

2. Turnthe ignitionswitchON lll).
3. Checkthe MAP with the scan
tool.
C h e c kf o r v a c u u m l e a k a g eo r
blockagebetweenthe MAP sensor and throttle body.
ls there leakageor blockage?
Checkthe MAP sonso. outputr

1. Stopthe engine.
tool.
(To page11-68)
{To page11-68)
(cont'd)
ManifoldAbsolutePressure(MAPISensor(cont'dl
(Frompage11-67)
lFrompagel1-67)
Check{or poor r6ponse:

1 . S t a r t t h e e n g i n e .H o l d t h e
engineat 3,000rpm with Iy'T in
E or E] position, M/T in neutral untilthe radiatorfan comes
on, then turn the ignition
switchOFF.
2. Stanthe engine.
3. Checkth MAP with the scan
tool.
Ch6ckfor poor response:

engineat 3,000rpm with lVT in
E or E position,M/T in neu'
tral untiltheradiator
lan comes
on, then turn the ignition
switchOFF.
2. Start the engine.
3. Checkthe MAP with rhe scan
tool.
ls a MAP of 40.0 kPa 1300 mmHg,

1 2 . 0 i n . H g )o r l 6 s s i n d i c a l e d w i t h i n
one second after startingthe
engine?
The MAP sensor is OK at this tims.
ls a MAPot40.0kPa{300mmHg,
12.0in.Hg)or lessindicated
within
one secondafterstartingthe
engine?

PCM and recheck.It symptom/
indication go6s awsy, roplace
the originsl ECM/PCM.
11-68
The scan tool indicatesDiagnosticTrouble Code (DTC)P0107:A low voltage (high vacuum) problem in the
ManifoldAbsolutePressure(MAP)sensor.
The MIL has b6n reooned on.
DTC P0107 is stored.
'1. Turnthe ignitionswitchON (ll).
tool.
Intermittent f.ilure, svslem b OK

at this tirne. Chock to. poor connactionsor loose wiroa at C111
IMAPsnsorland ECM/PCM.
Checkfo. an open or short in th

MAP sensor:
2. Disconnectthe MAP sensor
3P connector.
tool.
MAP SENSOR3P CONNECTOR

ICTI'tI
vccl
{YEL/REDI
Checktor an open in wi.e {VCCI

lin6l:
M e a s u r ev o l t a g e b e t w e e nt h e
MAP sensorconnectorNo, 1 ter
minaland No. 2 terminal.

ls thereapprox.5V?
Repair opeo in the wire btwoen

ECM/PCMltxl and MAP 3mor.
Checktor . short in the TCM:

2. Disconnect
the 22Pconnector
from the TCM.
3 . T u r n t h e i g n i t i o ns w i t c hO N
flr).
tool.
(To page11-70)
(cont'd)
11-69
PGM-FISystem
ManifoldAbsolutePressure(MAPISensor(cont'd)

IC111}
C h o c kl o r . s h o r t i n t h o w i J e
(MAPlinel:
2 . D i s c on n e c t t h e E C M / P C M
connectorD (16P).
the MAPsensorconnectorNo.3
terminaland body ground.
MAP
(RED/GRNI
ReDair 3hort in the wire bstween

ECM/PCM{D3l and MAP sensor.
Substitute a known-good EGM/

PCM, and rechock. It norrnal MAP
b indiceted, replaco the o.iginal
ECM/PCM.
11-70
The scan tool indicatesDiagnosticTroubleCode (DTC)P0108:A high voltage (low vacuum)problem in the
ManifoldAbsolutePressure(MAP)sensor.
Tho MIL has bn reported on.
OTCP0108is sto.ed.
Problemverification:
l . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (Ay'Tin E or E position,
M/T in neutral)untilthe radiator fan comeson,then let h idle.
tool.
ls 101kPa(760mmHg,30.0in.Hg)
or higherindicated?
Intormittont lailwo. 3yst6m ir OK

at thia timc, Ch.ck tor poor connoctions or looaa wira! at Cllt
(MAP!nrorl and ECM/PCIV|,

{CI11I
Check for an open in the MAP

1. Turnthe ignitionswitchOFF2 . D i s c o n n e ctth e M A P s e n s o r
3P connector,
3. Installa jumper wire between
the MAP sensor3P connector
terminals
No.3 andNo.2.
4. Turnthe ignitionswitchON llll.
tool.
{RED/GRNI
JUMPR
WIRE
Wiresideof temaleterminals
ls 101kPa{760mmHg,30.0in.Hg}
or higherindicated?
vccl
(YEL/REDI
Check Ior an open in wirs (SGl

linel:
1. Removethe iumperwire.
2. Measurevoltagebetweenthe
MAP sensor3P connectorterminalsNo. 'l and No.2.
ls thereapprox.5 V?
Repairopen in tho wir6 bctwaon

ECM/PCMlDl2l .nd MAP sonror.
CCM/PCMCO NECTORD I16PI

JUMPERWIRE
Check for an open in lhe wire

IMAPlinel:
2 . C o n n e c tt h e E C M / P C M
connectorterminalsD3 and 012
with a iumPerwire.
tool.
ls 10'1kPa(760mmHg,30.0in.Hg)
or higherindicated?

PCM .nd rechock.ll normal MAP
is indicated, .oplace the originel
ECM/PCM.
MAP
IRED/GRNI
sG1
{GRN/WHTI
Wire side of femaleterminals
R.pair opn in tha wir63 botwocn
ECM/PCMlD3l .nd MAP.onsor.
(cont'd)
11-71
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor(cont'd)
The scantool indicatesDiagnosticTroubleCode (DTC)P1128;ManifoldAbsolutePressure(MAP)lower than
expected.
-
The MIL hes been.eoorted on.

DTC Pl128 is stored.
Problamvrific.tion:
ls 54.1kPa(406mm Hg, 16.0

in. Hg)or higherindicated?
Intermittont tailurc, system b OK

at thk time.
The scantool indicatesDiagnosticTroubleCode (DTC)P1129:ManifoldAbsolutePressure(MAP)higherthan

exoected.
-
The MIL h.s beenreportedon.

DTCPl'129is stor6d.
Probl6mveritication:
1 . S t a r tt h e e n g i n e .H o l d t h e
load (A,/Tin E or E position,
M/T in neutral)untilthe radiator tan comes on, then let it
idle.
tool.
ls 43.3kPa{325mm Hg, 12.8

in. Hg)or lessindicated?
11-7 2
lntermittent failure, 3y3temi3 OX

at lhis time.
IntakeAir Temperature(lATlSensor
problemin the lntakeAir
The scantool indicatesDiagnosticTroubleCode (DTC)P0111: A range/performance
(lAT)
Sensor
circuit.
Temperature
ot the thermistordecreasesas the intake
The resistance
The IAT Sensoris a temperaturedependantresistor(thermistor).
as shown below.
air temoeratureincreases
-
RESISTAI{CE
ft01
Th6 MIL has beenroportedon.

DTCP011t is stored,
O. from Probabl. C.us List.
Problmvoritication:
1. Turnrhe ignitionswitchOFF.
2. Disconnect
the IAT sensor2P
connector,
3. Removethe IAT sensor.
4. Reconnectthe IAT sensor2P
connector.
5. Leavethe IAT sensorexposed
to ambienttemperature.
7. Checkthe IAT with the scan
tool,
-a 32 X rO. t1a 212 24a t.jl

-20 0 20 /|o ao ao !00 t2o trcl
II{IAXE AIR TEI/IPERATURE
Reolacetho IAT sensor.
Checkthe IAT snsoroutput:

1. Warm the IAT sensorwith a
hairdryer.
tool,
Didthe IATrise2"F(1"C)or more

from the ambienttemperature?
Interrnittentlailure, system is OK
at this time.
Reolacothe IAT sensor.
(cont'd)
1-73
PGM-FISystem
IntakeAir Temperature(lAT)Sensor{cont'd}
The scantool indicatesDiagnosticTroubleCode(DTC)P0112:A low voltage(hightemperature)problemin the
IntakeAir Temperature{lAT)sensorcircuit.
-
The MIL he3 b6en Eoortcd

DTC P0112 b 3tor.d.
on.
RESTSTANC
ll0l
lo
to
I
Problamvo.ification:
tool,
. aa aa ro. tra 2t2 a{ frt
- 20 0 ro :|o ao ao t00 r20 tlcl
ITTAXEAN EMPERATURE
ls 302'F (150"C)or higher (or
H-Limit*rlindicated?
Replacethe IAT sensor.
Intormittent failurg, 3y3temis OK

at thb tims. Chackfor Door conncctions or looac wi.as at C112
(lAT sonsorl .nd ECM/PCM.
Checklor . .horl in the IAT s6nsot:
1. Oisconnect
the IAT sensorconnedot,
tool.
ls 302'F (150'C)or higher (or
H-Limit*1)
indicated?
RoplacGtho IAT senio..

IAT SENSOR2P CONNECTOR
{Cl12I
Chockfor. short in the wiro llAT

lin.l:
2. Disconnectthe ECM/PCMconnectorD 116P).
3. Checktor continuitybetween
the IATsensor2PconnectorterminalNo.2andbodyground.
--+-r
l l l 2
l
IAT
@ IRED/YELI
=
Wiresideof femalerermtnats
Rgpairlhort in tho wire betweon
ECM/PCMlDSl and IAT sensor.
Sub3titute e known-good ECM/

PCM and recheck. It normal IAT
is indic.lad, replaco the original
ECM/PCM.
* 1 : With HondaPGMTesterin Hondamode.
*2. lfthe engineis warm,it will be higherthanambienttemperature.
11-74
The scantool indicatesDiagnosticTroubleCode(DTC)P0113:A high voltage(low temperature)problemin the

lntakeAir Temperature(lAT)sensorcircuit.
-
The MIL has beenreportdon.

DTCP0113is stord.
Ploblem veriticationi
tool,
Inte.mittent lailura, system is OK
at this time. Checktor poor conneclionsor loose wires at C112
{lAT sensorl and ECM/PCM.
Checkfo. an open in the IAT sensor:

1. Disconnect
the IAT sensor2P
connector,
2. Connectthe IATsensor2P conn e c t o rt e r m i n a l sN o , ' l a n d
No.2 with a jumperwire.
3. Checkthe intakeair temperature with the scantool.
(C112)
IAT SENSOR2P CONNECTOR
----F-t
I ' l r IAT
l
sG2
ffi
(GRN/BLnI
(RED/YEL)
JUMPER
wtEE
Wire sideoI lemaleterminals
ECM/PCMCONNECTOR
D (16PI
Checklor an opn in the wires
{lAT,SG2 lines):
2. ConnectECM/PCMconnector
t e r m i n a l sD g a n d D l 1 w i t h a
tool.
IAT(RED/YELI
sG2
IGRN/8LK}
JUMPERWIRE
Repairopen in th wires between
ECM/PCM(D8, D11)and IAT sen-

PCM and recheck. It normal IAT
is indicated. replace the o.iginal
ECM/PCM.
*r With HondaPGMTesterin Hondamode.
PGM-FISystem
EngineCoolantTemperature{ECTISensor
The scan tool indicatesDiagnosticTrouble Code (DTC)P0116:A range/performance
problem in the Engrne
CoolantTemperature(ECT)Sensorcircuit.
The ECTSensoris a temperaturedependantresistor(thermistor).
The resistance
of the thermistordecreases
as the enoine
coolanttemperatureincreasesas shown below.
RESISTANCE
tkol
THERMISTOR
a 3 2 6 E1 0 a1 a 0 1 7 62 t 2 2 a 8( . r )
-20 0 20 ao o I to !20 Ic)
ENGINE COOLANT TEMPERATURE
NOTE:lf DTCP0117and/or P0118are storedat the same time as DTCP0116,troubleshootthose DTCSfirst, then troubleshootDTCP0116.
PossibleCausa
. ECTsensordeterioration
. Malfunctionin the coolingsystem
TroubleshootingFlowchart
-
The MIL has ben rcportodon.

DTCP0116k stored.
1. Start the engine.Hold the
load {A"/Tin E or El position,
M/T in neutral)until the radiator tan comes on, then let it
idle.
2. With the scan tool, checkthe
ECT.
Intermittent failure, system is OK

et this time. Checkthe cooling
Chock the cooling systom. lf the

cooling alElam i3 OK, replacothe
ECTsensor.
11-76
:Ipfln7'l
The.scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature]problemin the

E n g i n eC o o l a nTt e m p e r a t u r{eE C Ts) e n s o r c i r c u i t .
The MIL hes ben reooned on.

DTC P0117 is sto.ed.
Problomveriticrtion:
1. Turnthe jgnitionswitchON (lli.
2. Checkthe ECTwith the scan
tool.
Intormittent failure,lvstem k OK
at thi3 time. Checkfor poor connection3 or loo3o wirg! at Cl22
IECT3.n3or)and ECM/PCM.
Chocktor a short in the ECTson1. Disconnect
the ECTsensor2P
tool.
ls 302"F(150"C)
or higher(or
H-Limit*)indicated?
ECTSENSOR2P CONNECTOR
{C122I
Chock tor a sho.t in the wire
{ECTline):
2. Disconnectthe ECM/PCMconnectorD (l6P).
3. Checkfor continuitybetwoen
the ECTsensor2Pconneclorter
minalNo. 1 and bodyground.
Wiresideof fomaleterminals
Reoairshort in th6 wir6 botwoen
ECM/PCMlD2l and ECTsensor.
Subrtituto r known-good ECM/

PCM and rochock, f nolmal ECT
i3 indicated, r6plac tha origin.l
ECM/PCM.
*r With HondaPGMTesterin Hondamode.
(cont'd)
11-77
PGM-FISystem
(ECTISensor(cont'dl
EngineCoolantTemperature
The scantool indicatesDiagnosticTroubleCode{DTC)P0l l8: A high voltage(low temperature)problemin the
EngineCoolantTemperature(ECT)sensorcircuit.
The MIL hrs boon reported on.
P.oblemveritication:
L Turnthe ignitionswitchON (ll).
tool.
Intormittent tailuro, svstem is OK
at this time. Chock tor poor connestions or loose wires at C122
{ECTsonsorland ECM/PCM.
ECTSENSOR2P CONNECTOR
{C122I
Checktor an opon in the ECTsen-
ECT
{RED/WHTI
JUMPENWIRE
1 . D i s c o n n e c t h e E C Ts e n s o r
2P connector.
2 . C o n n e c tt h e E C Ts e n s o r2 P
connectorterminalsNo. 1 and
No.2 with a j!mperwire.
tool.
sG2
IGRN/BLK)
ECM/PCMCONNECTOR
D {16P)
JUMPERWIRE
Checklor an opon in th6 wir6s
{ECT,SG2 linesl:
2. ConnectECNI/PCM
connector
t e r m i n a l sD 2 a n d D 1 1w i t h a
sG2{GRN/BLKI
ECT
(RED/WHTI
l3

tool.
---l
l 3 l a l
I
9 to
t5
12
t6
Wire sideoJfemaleterminals
Repeiropen in the wires botween
ECM/PCM{D2,Dl1) snd ECTsen-
Substiluto a known-good ECM/

PCM and rocheck.It normal ECT
is indic.ted, .splac. the original
ECM/PCM.
*: With HondaPGMTesterin Hondamode.
11-7 8
ThrottlePosition{TPlSensor
scantool indicatesDiagnosticTroubleCode {DTC)P0122:A low voltageproblemin the ThroftlePosition
.Tj_:
t I l-l sensorcrrcull.
The TP Sensoris a potentiometer.
lt is connectedto the throttlevalve shaft.As the throttlepositionchanges,the throttle
positionsensorvariesthe voltagesignalto the ECM/PCM.
tFo-,
-
OUTPUTVOLTAGE{VI
The MIL has been reDortedon.

DTCP0122is stored.
5
4
Problomve.ification:
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool-
ls thereapprox.10%whenthe
throttle is fully closedand
approx.90%when the throttle
is fullyopened?
Inlermittent tailure,system is OK
et this time. Checklor Door connectionsor loose wires at Cl10
ITPsenso.land ECM/PCM.
TP SENSOF3P CONNECTOR
{Cl1OI
sG2
vcc2
IGRN/BLK}
Ch6ck for an opcn in lhe wire
(VCC2linell
2. Disconnectthe TP sensor3P
connector.
4. N,4easure
voltage between
the TP sensor3P connectorterminalsNo.'l andNo.3.
THROTTLE
OPENING
FULL
THROTTLE
(YEL/BLU)
Waresideof femaleterminals
D Il6PI
ECM/PCMCONNECTOR
ls thereapprox.5 V?
Checkfor an op6n in wire IVCC2

line):
Measurevoltage betweenECM/
PCMconnector
terminalsD10and
D1' ].
Checktor an open or 3hort in TP
sensoa:
2, At the sensorside, measure
resistancebetweenthe TP sensor terminalsNo. 1 and No. 2
with the throttlefullyclosed.
(Topage11-80)
ls thereapprox.5 V?
SG2 (GRN/BLKI
Wire side of female terminals
Repairopen in lhe wire between

ECM/PCM(D10)and TP sonsor.

PCM and rechock. It orescribed
voltage is now available, replac
the originel ECM/PCM.
Terminalsideof maleterminals
(cont'd)
PGM-FISystem
ThrottlePosition(TP)Sensor(cont'dl
(Frompage1'179)
TP SENSOR3P CONNECTOR
ls thereapprox.0.5- 0.9k0?
YES
CheckIor an open or short in the
TP sensori
Measureresistancebetweenthe
T P s e n s o rt e r m i n n a lN o . 2 a n d
No.3 withthe throftlefullyclosed.
ls thereapprox.3.6- 5.4kO?
TerminalsideoI maleterminals
Checklor an open in the ECM/

PCM{TPSline):
1 . R e c o n n e ct th e T P s e n s o r3 p
ECM/PCMCONNECTOR
O Il6PI
lh f f"i

ECM/PCM
connectorterminals
D 1a n dD 1 l .
TPS(RED/
BLKI
13 l a
ls thereapprox.0.5
V whenthe
throttle is tully closedand
approx.4.5
V whenthe throttle
;s fullyopened?
Sub3titute a known-good ECM/

PCM and recheck. It oroscribed
voltago is now availabl6, aeplace
-l
Checktor a short in rhe TCM:
L Turnthe ignitionswitchOFF.
2. Disconnect
the 22Pconnector
from the TCM.
4. MeasurevohagebetweenECM
c o nn e c t o rt e r m i n a l sD 1 a n d
D11.
l1rtt"
TPS (RED/
BLKI
8 9 r0lrt
l a 1 5 l lrG
sG2IGRN/BLKI
12
ls thereapprox.0.5V when the

throule is fully closedand
approx.4.5
V whenthe throttle
is fullyopened?
I
Repairshort in the wire betwen
ECM/PCM{Dll, TCM and TP s6n-
11-80
9 10 l l
12
ta
Wiresideof t6m6leterminals
(D16Y5engine
f
sG2(GRN/BLKI
The scantool indicatesDiagnoslicTroubleCode (DTC)P0123:A high voltageproblemin the ThrottlePosition

(TP)sensorcircuit.
-
The MIL has been.eoorted on.

Problemveritication:
with the scantool.
ls there approx.10%when the

throttleis fullyclosedand
approx.90%whenthethrottle
is fullyopened?
Intermittent failure, system b OK

at this tim6. Checktor poor conneciionso. loose wires at C110
(TPsensor]and ECM/PCM.
TP SENSOR3P CONNECTOR
ICl lOI
sG2
(GRN/BLKI
vcc2
IYEL/BLU)
Checklor en open in the TP sen1. Turnthe ignitionswitchOFF.

2. Disconnectthe TP sensor3P
connector,
4. At the harnessside,measure
voltagebetweenthe TP sensor
3P connecterterminalsNo. 1
a n dN o . 3 .
ls thereapprox.5 V?
Replacethe thronle body.

ECM/PCMCONNECTOR
D I16P)
Chock for dn open in the wire

(SG2line):
Measure voltage between ECM/
P C M c o n n e c t o rl e r m i n a l s 0 1 0 a n d
D]1.
SG2{GRN/8LKI
ls thereapprox.5 V?
Repairopen in the wire between

ECM/PCM(D11)and TPsensor.
Wire side of female terminats

PCM and recheck. ll presc.ibed
vohag is now available,replace
the originalECM/PCM.
11 - 8 1
PGM-FISystem
ThrottlePosition(TP)Sensor
P1121 | The scantool indicatesDiagnosticTroubteCode(DTC)p'I12j:Throttleposition(Tp)lowerthan exeected.
-
The MIL has been reported on.

DTC Pl121 is stord.
Problomve.ification:
1. Turnthe ignitionswitchON (lll.
with the scantool.
ls TP* % or higherindicated
whenthe throttleis fully opened?
* : 1 1 . 8l D 1 6 Y e
5nginei
12.91D16Y
e n7 g i n e )
12.2(D16Y8engine)
11-82
Intoimiftent tailure, systam i3 OK

at this time.
[Fil22-l
-
Th" """n tool indicatesDiagnosticTroubleCode{DTC)P1122:Throttle

Position(TP)higherthan expecred.
The MIL hes been reported on.

P.oblemverification:
with the scantool.
ls TP* % or lessindicatedwhen
the throttleis f!lly closed?
Intermittent tailurc, ay3tem is OK

at this time.
*r 16.5{Dl6Y5,D16YBengine)
16.9{D16Y7engine)
11-83
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (ExceptDl6Y5
engine(M/Tl)
The HeatedOxygenSensor(HO2S)detectsthe oxygencontentin the exhaustgas and signalsthe ECM/PCM.
In operation,
the ECM/PCMreceivesthe signalsfrom the sensorand variesthe durationduring which fuel is injected.To stabilizethe
sensor'soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin the exhaustmanifold.
HO25:
ztRcoNrA
HEATER
SENSOR
VOLTAGE{VI
TERMINALS
RICH. AIN- - LEAN

FUL
RATIO
scan tool indicatesDiagnosticTroubleCode (DTC)P0131:A low voltageproblem in the Primary Heated

tFor3I The
OxygenSensor{H02S)(Sensor1) circuit.
-
The MIL has bonreportedon.

DTCP013'lis storod.
Problomveritication:
1. Do the ECM/PCMFeset Pro
cedure.
load (A/rfin E or E position,
M/T in neutral)untilthe radia
tor fan comeson.
3. Test drive with the A/T in E
positionlM/T in 4th geari
4. Check the Primary HO25
(Sensor1) output voltagewith
the scantool during accelera
taonusingwide openthrottle.
Does the vohage stay at 0.1 V

or less?
Intormittent failure, systom i3 OK

at this time. Checkfor poor connections or loos wires rt C123
l P r i m a r yH O 2 S ,. 6 n 3 o r 1 | a n d
ECM/PCM,
lTo page11-85)
\-
11-8 4
(Frompage11-84)
Chockfor a shon in the HOzS:

2. Disconnect
the PrimaryHO2S
(Sensor1l 4P connector.
3. Stan the engineand let it idle.
4. Check the Primary H02S
lSensor1)outputvoltagewith
the scantool.
PRIMARYHO2S(Sen3or1l aP CONNECTOR
lC123l
Doesit stayat 0.1V or less?
Pr{o2s T-{wHTrI- I--]

f-l 1 2l
6
l s l r l
\z r r__i_l
Check for a short in the wir

IPHO2Sline):
1. Turnthe ignitaon
switchOFF.
2. Disconnect
the ECM/PCM
con,
nectorD (16P).
the PrimaryHO2S(Sensor1)
4 P c o n n e c t o tre r m i n a lN o . 1
andbodyground.
ls there continuityT
L
Rpairshort in the wire betwoan

ECM/PCM{D7)and PrimeryHO2S
{Sensor11.
Substitut a known-good ECM/

PCM and rocheck.It symptom/
indicstion goos awey, replacethe
original ECM/PCM.
{cont'd)
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) {ExceptD16Y5
engine{M/Tll (cont'dl
:[FO13t
The scan tool indicatesDiagnosticTroubleCode (DTC)P0'132:

A high voltageproblemin the PrimaryHeated
OxygenSensor(PrimaryHO2S)(Sensor1) circuit.
The MIL hes ben reooned on.

DTCP0132 b stored.
Problemvedfication:
'1. Do the ECM/PCMResetProcedure.
load {A,/Tin E or E position,
M/T in neutral)untilthe radiator fan comeson,
3. Test drive with the Arr in E
position (M/T in 4th gear).
4. Check the Primary HO2S
(Sensor1) outputvoltagewith
the scantool duringdeceleration using completelyclosed
throttle.
Doesthe voltagestayat 1.0V
or more?
Intermittent failuro, system b OK

at this time. Checktor ooor connections or loose wires at C123
lPrimary HO2S,Sonsor 1) and
ECM/PCM.
PRIMARYHO2Slsensor 1l ,lP CONNECTOR
sG2
PHO2S
{WHT)
Chckfor an opn in the Primary

H02S:
2. Disconnect
the PrimaryHO2S
(Sensor1l 4P connector.
3 . C o n n e c tt h e P r i m a r yH 0 2 S
(Sensor1) 4P connectortermin a l sN o . ' l a n d N o . 2 w i t h a
{GRN/
BLKI

(Sensor1l output voltagewith
the scaniool.
lsthere1.0V or more?
C h e c kt o r . n o p e n i n t h e w i r e
IPHO2Sline):
terminalsD7 and D11 with a
D {16PI
ECM/PCMCONNECTOR
JUMPERWIRE
PHO2S(WHTI
sG2(GRN/BLKI

(Sensor1) output voltagewith
the scantool.
ffi
I
ls there1.0V or more?
Repai. open in thc wire betwoen

E C M / P C M ( D 7) e n d P r i m e r y
HO2S{Son3or1} .
t3
l0 1 1
12
t6
Subltituto . known-good ECM/
PCM and roch.ck. lf 3ymptom/
indic.tion goe3 away, replace
the originel ECM/PCM.
11-86
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l
scantool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the PrimaryHeated
tFols3-lThe
OxygenSensor(PrimaryHO25)(Sensor1) circuit.
(DTC)P1163:A slow responseproblemin the PrimaryHeated
The scantool indicatesDiagnosticTroubleCode

P1163
l OxygenSensor(PrimaryHO25)(Sensor1)circuit.
DescriDtion
By controllingthe airlfuelratiowith a PrimaryHO2S(SensorI ) and a SecondaryHO2S(Sensor2), the deteriorationof the
PrimaryHO2S{Sensor1) can be evaluatedby its feedbackperiod.When the feedbackperiodof the HO2Sexceedsa cer,
tain valueduringstabledrivingconditions,the sensorwill be judgedas deteriorated.
Whendeterioration
hasbeendetected
duringtwo consecutive
trips,the MILcomeson and DTCP0133or P1'163*
will be stored.
NOTE:lf DTCP0131,P0132and/orP0'135
are storedat the same time as DTCP0133,troubleshootthose DTCSfirst, then
troubleshootDTCP0133.lf DTCP1'162,P1168and/orPl 169are storedat the sametime as DTCP1163,troubleshootthose
DTCSfirst.then troubleshootDTCP1163.
PossibloCause
. P r i m a r yH O 2 S( S e n s o1r ) D e t e r i o r a t i o n
o PrimaryHO2SHeater(Sensor1)Deterioration
. Exhaustsystemleakage
-
The MIL has beenreoortedon.

DTC P0133and/o. P1163.is
stored.
ProblemVorification:
2. Connectthe scantool.
engineat 3,000rpm with no
load (A"/Tin E or E position,
M/T in neutral)untilthe radiator fan comeson.
4. Connectthe SCSserviceconnector.
5 . T e s t - d r i v eu n d e r f o l l o w i n g
conditaons.
- 55 mph (88 km/hl steady
speed
- A/T in E position(M/T in
5th gear)
- Until readinesscode comes
Intermittent tailur6, sysiom i! OK

at this timo. Chgckfor pooa connections or loose wi.ss at C123
lC1/|5)*(PrimaryHOzS.Sensor1)
and ECM/PCM.
*: P1163tD16Y5engine1M/T))
11-87
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (D16Y5engine
(M/Tt)
The scan tool indicatesDiagnosticTrouble Code lDTC)P1162:A malfunctionin the PrimaryHeatedOxygen

y O 2 S () S e n s o1r ) c i r c u i t .
S e n s o (r P r i m a r H
Description
The PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1) operatesover a wide airlfuelrange.The PrimaryHO2S
( S e n s o1r ) i s i n s t a l l e idn t h e e x h a u sm
t anifold.
HEATER
TERMINALS
SENSOR
ELEMENT
SENSOR
TERMINALS
NOTE:lf DTCP1162is storedat the sametime as DTCP1167,troubleshootDTCP1162first,then troubleshootDTCP1167.

-
The MIL has been.eported on.

Problomverilication:
1. Dothe ECMResetProcedure.
2. Startthe engine.
3. Wait at leasttwo minutes.
ls DTC Pl162 indicated?
Test'drivefor severalmiles with

the transmission
in 3rd gear.Hold
the enginespeedat 1,500rpm.
ls DTCP'l162indicated?
Check for an open in the wire

(lP+line):
1. Turn the ignition switch OFF.
2. Disconnect ECM connector C
( 3 1 P ) f r o mt h e E C M .
3, Disconnect the 8P connector
from the Primary HO2S (Sen'l
sor ).
4. Check for continuitv between
the Primary HO2S (Sensor 1)
8 P c o n n e c t o rt e r m i n a l N o . 7
and ECM connector terminal
c23.
Intermittent tailure, system is OK

at this time. Ch6ckfor poo. connections or loose wires at C145
{ P r i m a r yH O 2 S ,S e n s o r1 ) a n d
ECM,
ECMCONNECTOR
C 131PI
PRIMARYHO2S
1} 8P
{SENSOR
(C1,15)
CONNECTOR
female terminals
of female
Iermrnats
Repeiropen in the wire between

E C M l C 2 3 )a n d P r i m a r y H O 2 S
(Sensor1).
Inspectfor poor terminalto telminal contact at the Primarv HO2S
lsensor 1) connectorand ECM.
lf terminal conlact is OK, replace
the PrimaryHO2S(Sensor1).
(Topage11'89)
11 - 8 8
ECMCONNECTORS
(Frompage11-88)
c {31P}
Chcck th. ECM input vohego {lP-/
VS- lino):
2 Turnthe ignitionswitchON {ll).
ECMconnectorterminalsC24
a n dD ' ] 1 .
o {16P}
sG2
{GRN/BLI(}
IP-/VS- {REDI
female terminals
3
ls there more than 0.5 V?
Ch6ckthe ECM:
2. DisconnectECM connectorC
{31P)from the ECM.
b o d y g r o u n da n d E C Mc o n
nectorterminalC24.
1 1 12
9 l0
t 3 1a 15 l6 11 18
23 21 25
22
z)
27 2t
30
o-\ rP-/vs7 rneot

-
Repair open in the wire

between ECM lc24l and Primary HO2S(Sensor'l I.
Substitutea known-goodECM
and .ach.ck. It symptom/indication goes awey, replacethe
originalECM.
Chocktor s short in the wire (lP-l

V9- linel:
from the PrimaryHO2S(Sen'
sor'l).
body ground and ECMconnector terminalC24.
2 3 1
t0
1 1 l 2 1 3 1 4 1 5 1 6 1 7 1 8 ,/
23 2a 25
21 2A
?2
30
fr) {RED}
R6pairshort in the wi.e between

the Primarv HO2S{Sensor'l) and
ECMtc24t.
Repl.c. the Primary HO2S {Senso.1).
Chock tho ECM output voltage
IVS+linol:
Measurevoltage between ECM
connectorterminalsC25and D'11.
ls theremorethan0.5V?
Checkfor a sho.l in tho wire {VS+

linel:
1. Turnthe ignitionswitchOFF2. DisconnectECMconnectorC
(31P)fromthe ECM.
3. Check for continuity between
b o d y g r o u n da n d E C M c o n nectorterminalC25.
10
22
1 1 12 13 14 15 16 1 7 1 8
23 21 25
21
2a
30
O) vs*
!
twHTt
{cont'd)
(To page11-90)
(To page11-90)
11 - 8 9
I
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1l (Dl6Y5 engine
(M/Tl) (cont'dl
lFrompage11-89)
Substitut a known-good ECM
and rccheck. lf symptom/indication goes away, replaco tho original ECM.
Check for a short in tha wiro {lP+
linel:
1. Disconnect the 8P connector
from the Primary HO2S (Sen
2 3
l 1 12
l5 t6 11
9 l0
r8
22
p lfi. w;,".ia"or
r e m a r el e t m t n a
I

body ground and ECM connector terminalC25.
ls therecontinuityT
r3
Rpairshort in th6 wire between

the PrimaryHO2S{Sensor1l and
ECMtC25).
Replacethe Primary HO2S {Sensor 11.
ls theremorethan 5.0V?
Checkthe EcM:
2, Disconnectthe 8P connector
from the PrimaryHo2S {Sensor'l).
3. MeasurevoltagebetweenECM
connector
C25and D11.
Checkthe ECMinput vohago(lP-/

vS- linel:
load (M/T in neutral)until the
radiatorfan comeson, then let
it idle.
connectorterminalsC24 and
01' j.
Substitut a known-good ECM

and recheck. lf symptom/indication goes away, replacth6 originslECM.
ls there2.6- 2.8V?
Check the ECM output voltage

{VS+ line):
Measure voltage between ECM
connectorterminals C25 and D'11.
Replace the Primary HO2S lSensor 11.
1 t 2 3
12 t 3
t5 t 6
9 10
rl
VS+
(WHT}
sG2
(GRN/8LKI
2 3
to
( T op a g e1 1 - 9 1 )
11 - 9 0
( T op a g e1 1 - 9 1 )
t5
16
tl
't2
l F r o mp a g e1 1 - 9 0 )
lFrompage11-90)
Roplacothe Primary HO2S (S6nsor 11.
ls thorelessthan 2.8V?
Substitute a known-good ECM

and recheck. lf symptom/indication gos away. replacethe original ECM.
c (3rP)
D t16Pl
Check the ECM output voltage

llP+line):
connector
terminalsC23and D'11.
sG2
(GRN/BLKI
lP+
IBLK)
Checkthe ECM:
(31P)fromthe ECM.
3. Checkfor continuity between
b o d y g r o u n da n d E C M c o n nectorterminalC23.
YES
Substiluta a known-good ECM

and recheck. It symptom/indication goes aw.y, rcplacethe o.iginalECM.
Wire side of
femaleterminals
2 3 a
1 1 12
r3 t a
23 21 25
29 30
IBLK)
ECMCONNECTOR
C 13lPI
PRIMARY
HO2S
tsENsoR118P
coNNECTOR
tCl{st
lP+
IBLKI
lP+
IBLK}
femaleterminals
Subsiitute a known-9ood ECM

and rocheck. lt symptom/indica'
tion goes eway, replacethe original ECM.
2 3
1 1 12 13 1 4
23 21 25
R.pair shon in th6 wirc btween
th Primary HO2Slsonsor 1) and
ECM{C23).
Replecethe Primary HO2S ls6nsor 1).
Wire side
of female
termrnats
Rpairopen in tho wi.o bstween

E C M ( C 2 3 ) . n d P r i m a r yH O 2 S
lsensor ll.
NO
Checktor a short in the wir (lP+

linel:
from the PrimaryHO2S(Sen
sor'll.
b o d y g r o u n da n d E C M c o n
nectorterminalC23.
22
lP+
I
Check for an open in lh6 wire
llP+line):
from the PrimaryHO2S(Sens o r1 ) .
the PrimaryHO2S{Sensor1)
8P connectorterminal No. 7
and ECM connectorterminal
c23.
t0
15 16 1 7 t8
6\
jjl
10
22
16 11 18
29 30
lP+
{8LKl
{cont'd}
11-91
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) (Dl6Y5engine
(M/T)l (cont'd)
lptrEl
:
-
problem in the Primary

HeatedOxygenSensor(PrimaryHO2S)(Sensor1) circuit.
The MIL h.3 ben .sportod on.

DTC Pl16il ii rtorcd.
ProblGmVerific.iion:
'1. Do the ECMResetProcedure.
l o a d u n t i l t h e r a d i a t o rt a n
3. Connectthe SCS servicecon
nector,
4. Tst-drivein 4th gear. Staning
at 1,600rpm, accelerateusing
wide opnthrottlefor at least5
seconds.Then deceleratefor at
least 5 secondswith the throttle complot6lyclosed.
ls DTCP]164indicated?
Intermittent frilurc. sy3tam b OK

at this time. Chcktor poo. connections or loos6 wire3 at C145
{Prima.y HO2S,Sensor 1) .nd
ECM.
Rpl.c. tho Primary HO2S (Sen3or 11.
problem the Primary

(Primary
(Sensor
1)
H02S)
circuit.
HeatedOxygenSensor
Th6 MIL has becn ooorlcd on.
DTCP1165b 3to.ed.
ProblomV.ritidtion:
1. Do the ECMResetProcedure.
2. Start the engine.Hold the
6ngine at 3,000rpm with no
l o a d u n t i l t h e r a d i a t o rf a n
3. Connectthe SCS servicecon4 . T e s t ' d r i v eu n d o r f o l l o w i n g
conditions.
- 55 rnph steadyspoed
- Transmission
in 5th gear
- Untilreadinesscod comes
ls DTCP1165indicatod?
Rsplrc6 th6 Primary HO2S lsonaor 11.
11-9 2
Intormitteni failure, sy3tsm ia OK

at thia tim6. Check tor poo. connections or looso wiroa at c145
lPrimary HO2S. Sentor 1l .nd
ECM.
The scan tool indicatesDiagnosticTroubleCode (DTC)P]168:A low voltage problem in the PrimaryHeated
lpi,';;l
|gjgggg!ggg
OxygenSensor(PrimaryHO2S)(Sensor1) LABELcircuit.
The MIL has boon ..ported on.
DTC Pl168 is stored.
Problemvedficalion:
2. Startthe engine.
3. Waitat leasttwo minutes.
IntermittGotlailuro, 3yst.m is OK
al this tim6. Chocktor poor connction3 or loo3e wiros at C145
{Primary HO2S, Sensor 1) and
ECM.
ECMCONNECTOR
D {16PI
LABEL{WHTI
Checkthe ECM:
2. Disconnectthe ECM connector D (16P).
E C M c o n n e c t o tr e r m i n a lD 7
and bodyground.

.nd rcchack. lf aymptom/indication goes swsy. r6placeth6 original ECM.
LABELIWHT}
Check for a short in the wires
(LABELlin.l:
1. Disconnect
the PrimaryHO2S
(Sensor1) 8Pconnector2. Check for continuity betlveen
ECM connector terminal D7
and body ground.
ls therecontinuity?
Replaceth6 Primary HO2S lsensor 11.
Ropair short in thg wir6 botweon

tho Pfimary HO2S(Sensor1l and
ECMtD7).
(cont'd)
11 - 9 3
)
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2S){Sensor1l (Dl6Y5engine
(M/Tl)(cont'dl
The scan tool indicatesDiagnosticTroubleCode {DTC)P1169:A high voltageproblemin the PrimaryHeated
OxygenSensor{PrimaryHO2S}{Sensor1)LABELcircuit.
[ti,r;ol
L]g
The MIL hs3 ben r6Dorted on.

DTC P1169 is stor6d.
Problmveritication:
1. Do the ECMResetProcedure2. Startthe engine3, Wait at leasttwo minutes,
PRIMARYHO2SISENSON1} 8P CONNECTOR
I145I
Intormittent failure, system is OK

at thi3 time. Checkfor ooor connections or loose wi.es at C145
{ P r i m a r yH O 2 S ,S e n s o rl l a n d
ECM.
Wire sideof
femaleterminals
Check for an opn in thg wiro

ILABELlinel:
1- Turnthe ignitionswitchOFF.
2. Disconnectthe Primary HO2S
(Sensor1i 8P connector.
Primary HO2S(Sensor1) 8P
connectorNo. 4 terminaland
bodyground.
ECMCONNECTOFD {16PI
,|
6
9 t0 1 l
Repai open in tho wirs bstwen

the Piimary HO2Slsensor 1) and
ECM(D71.

lSG2line):
2. DisconnectECM connectorD
(16P)from the ECM.
3. Checkfor continujtybetween
ECM connectorterminal D11
and PrimarvHO2S(Sensor1)
8P connectorterminalNo. 3.
12
sG2
16
1 4 15
ls thereapprox.5V?
IGBN/8LKI
sideof
le terminals
female
(11
\9
_l
;G2
{GRN/8LK}
2
6
Repairopen in the wire betwen

th. Primary HO2S(Sen3or1l and
ECMtD11l.
11-94
SecondaryHeated Oxygen Sensor (SecondaryHO2S)(Sensor2l

scantool indicatesDiagnosticTroubleCode(DTC)P0137:A low voltageproblemin the SecondaryHeated
lTol3ji]l lh"
.:
HO2SI(Sensor2) circuit.
OxygenSensor(Secondary
-
The MIL h.3 bo6n reported on.

'1. Do
the ECM/PCMResetPro
cedure,
load {A/Tin E or E position,
tor fan comeson.
3. With the scan tool, checkthe
S e c o n d a r yH O 2 S( S e n s o r2 )
outputvoltageat 3,000rpm.
Does the voltage stay at 0.3 V

or less?
Intermittont failuro, sy3tem is OK

at thi3 time, Checktor poor connections or loose wiao6at C131'
(locrtod under right 3ide ot da3hl.
C432r {located und.r middle of
dashl, C125 (C782lt (Secondary
HO2S)lsonlor 2l and ECM/PCM.
Chck fol a short in the Second!ry

HO2SI
Disconnect he Secondary
HO2S(Sensor2) 4P connector.
Startthe engine.
C h e c kt h e S e c o n d a r yH O 2 5
(Sensor2) outputwith the scan
tool.
SECONDARY
HO2S(S.n.or 2l
/aPCONNECTOR
1C125,C7E2r)
C h e c kl o l . 3 h o n i n t h . w i r o
{SH()2Slinel:
2 . D i s c o nn e c t t h e E C M / P C M
connectorD 116P).
the SgcondaryHO25 (Sensor
2) 4P connectorterminalNo. 1
and body ground.
Rco.ir 3hort in the wire bdtw.en

ECM/PCM lDl4l and Secondary
HO2Slsonsor 21.
Substitute . known-good ECM/

PCM and r.check. lf symptom/
indication go03 away, replaco
tho original ECM/PCM.
(cont'd)
*: D16Y8engine
11 - 9 5
PGM-FlSystem
SecondaryHeatedOxygenSensor(secondaryHO2SI(Sensor2l (cont'dl
The scantool indicatesDiagnosticTroubleCode{DTC)P0138:A high voltageproblemin the SecondaryHeated
OxygenSensor(SecondaryH02S)(Sensor2) circuit.
The MIL has been reDorted on.
1. Do the ECM/PCMFeset Procedure.
load (A/Tin E or E position,
M/T in neutral)untilthe radiatorfancomeson,
3. With the scantool, checkthe
S e c o n d a r yH O 2 S( S e n s o r2 )
outputvoltageat3,000rpm.
Does the voltage stay at 0.6 V
Intermittent failure, 3ystem b OK

at this time. Checkfor poor connections or loose wires st C131'
llocatedundor right side of dashl.
C432i (localed undor middle ol
da3h),C125 (C?82)*lsocondary
HO2SSensor2) and ECM/PCM.
HO2Slsontor2)
SECONDAnY
C125(C782lr
4PCONNECTOR
JUMPERWIRE
sH02s
IWHT/REOI
sH()2sG
(YEL/RED}
(GRN/BLKIT
Checkior an opn in the Seclndary

HO2S:
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2S(Sensor2) 4P connector.
3. Connectthe SecondaryHO2S
(Sensor2) 4P connectorter_
m i n a l sN o . 1 a n d N o . 2 w i t h a
iumperwire.
5 . C h e c kt h e S e c o n d a r yH 0 2 S
{Sensor2) outputvoltagewith
the scantool,
D Il6PI
ECM/PCMCONNECTOR
sHo2sG
(YEL/RED)
(GRN/BLKP
I I sHo2slwHT/REol
Check tor an open in th wire

(SHO25line):
terminalsDl4 and D13with a
JUMPERWIRE
3. Turnthe ignitionswitchON (lli.

4 . C h e c kt h e S e c o n d a r yH O 2 S
( S e n s o r2 ) o u t p u t v o l t a g e
with the scantool.

PCM and recheck.It symptom/
indicaiion goes away. replace
*: Dl6Yg engine
11 - 9 6
Repairop6n in the wire betweon

ECM/PCM{D13and,/orD14}and
SecondarvHO2S{Sensor2).
u)t
a
The scantool indicatesDiagnostic
TroubleCode{DTC)P0139:A slow responseproblemin the SecondaryHeated
OxygenSensor(HO2S){Sensor2) circuit.
-
Thc MIL haa bccn rcponed on.

DTCP0139i3 3iored.
P.obl6m vo.ificalion:
1. Do the ECM/PCMResetProc60ure,
load (A"/Tin E or E position,
M/T in neutral)untilthe radiator fan comes on,
3. With the scantool, checkthe
SecondaryHO2S{Sensor2)
outputat 3,000rpm.
Doesthevoltagestaywithin
0.3-0.6 V tor two minutes?
Intermittent lailure, system is OK

at this time. Checkfor poor connections or loose wires at C13'l*
llocatedunder right side ol dash),
C432' {locatedunder middle of
dashl C125 {C7821*{Secondary
HO2SI{Sensor2l and ECM/PCM.
11-97
PGM-FISystem
\,, .a
HeatedOxygenSensor(HO2S)Heater
The scan tool indicatesDiagnosticTrouble Code (DTC)P0135:An electricalproblem in the Primary Heated
fFor35lOxygenSensor(PrimaryHO2S)(Sensor1) Heatersvstem{ExceptD16Y5engine(M/T))'
TroubleCode(DTC)P0141:A problemin the SecondaryHeatedOxygenSensor

tool indicatesDiagnostic
scan
lFot+ilThe
(Secondarv
HO2S)(Sensor2) Heatercircuat.
-
The MIL haa bgon teDorted on.

DTC m135, and/or P0141a.e
stored.
Problomvorification:
1. Do the ECM/PCMResetProcedure,
2. Startthe engine.
Checkfoi en opon or short in the

HO2S:
the HO2S(Primary
2. Disconnect
or Secondary*)lSensor 1 or
Sensor2)4P connector.
3 . A t t h e H 0 2 S s i d e ,m e a s u r e
resistancebetween the HO25
4P connectorterminalsNo. 3
a n dN o . 4 .
lntermittont failure, swtem i5 OK

at thb time. Checkfot poor con'
noction3 or loose wiros at
C131** {located under right 3ide
ol dashl, C432** {located under
middle of d.sh), C123 (P.imary
HO2S,Sensor 1l C125 {C7821**
lSecondary HO2S, Sensot 2)*
and ECM,/PCM.
PRIMARYHO2S{S.n.ot l)]|P CONNECTOR

HO2s (S6nto12)4P CONNECTORT
SECONDARY
Terminalsidoot maleterminals
ls therel0 - 40 0?
C h e c kf o r c o n t i n u i t y b e t w e e n
b o d y g r o u n d a n d t h e H O 2 S4 P
c o n n e c t o rt e r m i n a l sN o . 3 a n d
No.4 individually.
(Cl23I
PRIMARYHO2SISENSOR1) 'P CONNECTOR
2) rP COI{NECTORlcl2s}*
sEcoNDARY HO2STSENSOR
_l=._1
sozsxrc
i|iru I t z leozsxrc.
YELI I-
T--
IBLK/WHTI
l - l
L--Cp
Wi16 side of f6male terminals
Checkfoi an open or short in the

SO2SXTC*lino):
wire IPO2SHTC,
1. Turnthe ignitionswitchoN (ll).
2. Measurevoltage between the
HO254P connectorterminals
No. 3 and No.4.
2l
Ho2slsENsoR
sEcoNoAnY
(C782)*.
lP CONNECTOR
so2sHTc
(BLK/WHT)
(To page11-99)
11-98
*r P0141
(To page11-99)
**: D16Y8engine
tG1
{BLK/WHTI
Wire sideof lemaleterminals
\, I
PRIMARYHO2SISENSOR1) ilP CONNECTOR
(cr23t
SECONDARYHO2S(SENSOR2l irP
coNNECTOR(C12s)r
Checktor an open or short in the
wire (lG1linell
HO2S4P connectorterm;nalsNo.3
( D 1 6 Y ge n g i n e N
: o.4)and body
ground-
lcl
-
Check fo. an open in the wire

SO2SHTC*linel:
{PO2SHTC,
2. Reconnectthe HO2S4P con-
1 1 2 l
- r
l
tL_r__.r.____J
3t { l
|BLK/ O)
YELI Y
Ropair open or short in the

wire between Prim.ry HO2S
{Sensor1), (No. 15 ALTERNATOR SP SENSORI17.5A) tuie
and SoconderyHOzS,Scnsot
2l+,
RoDlac.the No. 15 ALTEBNATOR SP SENSORl7.s Al tuso.
Wire sideot femaleterminals
SECONDABYHO2S
{SENSOR2I {P CONNECTOR
tc782t*r
3. Disconnectthe ECM/PCMcon
nectorA (32P).
ECM/PCM
connector
terminals
46 andA10(A5andA10)*.
ls there0.1V or less?
IGl {BLK/WHTI
-l.
(v)
Repairopen in the wire betweon

ECM/PCM{46, A5lt and HO2S
{Primary,Secondary*1.
Wirosideof femaletorminals
A I32PI
ECM,/PCM
CONNECTOR
Substituta a known-good ECM/

PCM and recheck.lt 3ymptom/
pozsxrc E/
^
so2sHrcIIBLK/WHTI
tBLK/wHn-Jr-----{vF
T-r
'11
{Frompage 98}
12 t 3
t5 t 6
27
PG1
IBLK)
rl lalglro
ta t 0 20
2A a 3o
21
23
ll
2a
Wire side ol female terminals

Chock lor a short in lhe wire
{PO2SHTC,
SO2SHTC.lino):
2. Disconnect
the ECM/PCM
connectorA {32P).
the ECM/PCMconnectorterminalA6 (A5)*and bodyground.
ls therecontinuity?
so2HTClBtX/WHTtr FO2SHTCIBLK/WlfTl
ReDairshort in tho wi.s bstween

ECM/PCM(46, As*l and HO2S
lPrimary,S.condary.l.
Subslitute r known-good ECM/

PCM and recheck.lf symptom/
indication goes away. rplace
the original ECM/FCM.
*: P0141
**: D16Y8engine
11 - 9 9
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater(D16Y5engine(M/Tll
The scan tool indicatesDiagnosticTrouble Code (DTC)P1166:An electricalproblem in the PrimaryHeated
OxygenSensor(PrimaryHO2S)Heatersystem.
-
Th MIL h.3 bean reoon.d
DTCP1165b stored.
2. Startthe engine.
Intermittent tailur., 3vt.m is OK

et thii time (te3i drive may bo
nccossaryl. Chock for poor connoctions oa looie wkas bgtween
C145 (Priftary HO2S,Sonsor 1)
and ECM.
Chockth6 Primery HO2S{S6nso1

'll re3btance:
2. Disconnect
the PrimaryHO2S
lSensor1) 8P connector.
3 . A t t h e P r i m a r yH O 2 S( S e n s o r 1 ) , m e a s u r er e s i s t a n c e
betweenNo. 1 and No. 2 ter
mrnal.
Terminal side of
maleterminals
ls there2 - 13 O?
Check for a shortsd Prima.y

HO2Slssn3or'll:
C h 6 c kf o r c o n t i n ! i t y b e t w e e n
body groundand eachterminal.
ls therecontinuity?
Ch.ck lor . 3hort6d Primery

HO2Slsensor 1):
Checkfor continuity betweenterminal No. 1 and terminalsNo.3,
4, 6, 7 and 8 individually.
Replacctho Primary HO2S (Scnsor 11,
( T op a g e1 1 - 1 0 1 )
11-100
PRIMARYHO2SISENSOR1} 8P CONNECTOR
(Frompage11-100)
PRIMARYHO2SISENSOR1l8P CONNECTOR
{Clirsl
PO2SI{TC
{BLK/WHTI
ch6ck the Po2sHTc circuir:

1. Start engineand keep engine
rpm at idle.
2. At the engine wire harness,
m e a s u r e v o l t a ge b e t w e e n
P r i m a r yH O 2 S( S e n s o r1 i 8 P
connectorterminalNo. 1 terminaland bodyground.
ls theremorethan 5 V?
PO2SHTC
(BLK/WHT)
Chsck for en open'in th6 wire

(PGlinel:
MeasurevoltagebeNveenPrimary
HO2S{Sensor1) 8P connectorter'
minalsNo. 1 and No.2.
Ropairopen in the wire between

thc HO2S.nd Gl01 llocated at
thermostat housingt.
V
Check ror a 3hort in the wire
(PO2SHTClinel:
1. Turntho ignitionswitchOFF.
2. DisconnectECNIconnectorA
(32P)from the ECM.
E C M c o n n e c t o rt e r m i n a l4 6
and body ground.

and .echock, lf symptom/indicelion goes rw.y, repl.c the originel ECM.
PO2SHTC
IBLK/WHTI
f)
ECMCONNECTOR
A
9L 10
t 0 1 9 2\
221 23
2a 4 30
|,-.'
12 l 3 t a r5 l a
25
21
2a
Iemaleterminals
Repair3hon in th6 wiae between
the ECM (A6l and the Primary
HO2Sls.nso.'l).

(PO25HTClin.l:
ECM connectorterminal46 and
the PrimaryHO2S(Sensor1) 8P
connectorterminalNo, 1,
Repairopen in the wirc between
ECM lA6l and the Prim.ry HO2S
lsen3or 'l ).
Substiiuto . known-good ECM

and r.ch.ck. lf symptom/indication 90e3.wry, ..pl.c the origin.l ECM.
(cont'd)
11 - 1 0 1
PGM-FISystem
HeatedOxygenSensor{HO2S)Heater(D16Y5engine(M/Tl) (cont'd)
scan tool in^dicates
DisgnosticTrouble Code (DTC)P1167:A system malfunctionin the PrimaryHeated
lTlLtl
lh"
.....-''.--.......
Oxygen Sensor (Primary HO2S)(Sensor1) Heatercircuit.
The MIL he! bcofl ..oort.d
DTC P1167 b stored.
on.
Problomveffication:
load 1A,/Tin N or E position,
M/T in noulral)untilthe radiator fan comeson.
ls oTC1167indicated?
Intermittent failure, systom k OK

at this time. Checkfor poor connoctions or looie wi.es at C145
lPrimary HO2S, Sen3or 1l and
ECM.
Ch6ck for an op.n in the wire

{VS+lin.):
2. Disconnect
the PrimaryHO2S
(Sensor'1)
8P connector.
4. Measurevokage between the
P r i m a r yH O 2 S( S e n s o r1 l 8 P
connectorterminalNo, 6 and
body ground.
ls theremorethan5 V?
PFIMARYHO2S(SENSOR1) 8P CONNECTOR
lClil5l
ECMCONNECTOR
C {3.IPI
a
6 7
't3
1 1 12
t 4 1 5 1 1 61 1 l 8
1
check rhe EcM:

ECMconnectorterminalC25and
body ground.
23 21 25
VS+
(WHT)
Sub3tilute a known-good ECM

and recheck, lf symplom/indication goes eway, leplaceth original ECM.
11-1 0 2
r0
2i 30
Wire side of female
terminals
Repairopen in thc wire ECM{C25}

and PrimaryHO2Slsensor 11.
PGM-FISystem
HeatedOxygenSensor{HO2S)Heater(D16Y5engine(M/Tl) (cont'd)
scan tool in^dicates
DisgnosticTrouble Code (DTC)P1167:A system malfunctionin the PrimaryHeated
lTlLtl
lh"
.....-''.--.......
Oxygen Sensor (Primary HO2S)(Sensor1) Heatercircuit.
The MIL he! bcofl ..oort.d
DTC P1167 b stored.
on.
Problomveffication:
load 1A,/Tin N or E position,
M/T in noulral)untilthe radiator fan comeson.
ls oTC1167indicated?
Intermittent failure, systom k OK

at this time. Checkfor poor connoctions or looie wi.es at C145
lPrimary HO2S, Sen3or 1l and
ECM.
Ch6ck for an op.n in the wire

{VS+lin.):
2. Disconnect
the PrimaryHO2S
(Sensor'1)
8P connector.
4. Measurevokage between the
P r i m a r yH O 2 S( S e n s o r1 l 8 P
connectorterminalNo, 6 and
body ground.
ls theremorethan5 V?
PFIMARYHO2S(SENSOR1) 8P CONNECTOR
lClil5l
ECMCONNECTOR
C {3.IPI
a
6 7
't3
1 1 12
t 4 1 5 1 1 61 1 l 8
1
check rhe EcM:

ECMconnectorterminalC25and
body ground.
23 21 25
VS+
(WHT)
Sub3tilute a known-good ECM

and recheck, lf symplom/indication goes eway, leplaceth original ECM.
11-1 0 2
r0
2i 30
Wire side of female
terminals
Repairopen in thc wire ECM{C25}

and PrimaryHO2Slsensor 11.
FuelSupplySystem
]TO17il Th" """n tool indicatesDiagnosticTroubleCode(DTC)P0171:The fuet systemis too lean.
I P0172 The scantool indicatesDiagnosticTroubleCode(DTC)P0172:The fuel systemis too rich.
D6scription
By monitoringthe LongTerm FuelTrim, longterm malfunctionsin the fuel systemwill be detected.
It a malfunctionhasbeendetectedduringtwo consecutive
trips,the MILwill come on and DTCP0171and/orP0172will be
stored.
NOTE:lf some ot the DTCSlistedbeloware storedat the sametime as DTCP0171and/orP0172,troubleshootthose DTCS
first,then troubleshootDTCP0171andlotP0172.
*5rMAP Sensor
P0106-8.
P1128-9*3.
P0135:PrimaryHO2SHeater
P0137-8:
SecondaryHO2S
P0141:SecondaryHO2SHeater
P0401:EGRFlow lnsufficient*1
P0441:EVAPSystemInsuificientPurgeFlow*6
P1259:VTECSystem*,
P1491rEGRValveLift Insuflicient*l
P1498:EGRValveLift SensorHighVoltage*1
* 1 ;D 1 6 Y 5e n g i n e
+,: D16Y5,D16Y8engine
*3:'97 model
*a:'96 model
*5:'98 model
*6:'96 Dl6Y5 engine,'96D16Y7engine,'96 D16YBengine(sedan),'97D16Y5engine,'97D16Y/engine(coupe:KA,KC mod
els,sedanKA.KC,KL (DX)models,hatchback:
all models),'97Dl6Y8engine(sedan:KA,KCmodels)
PossibleCause
D T CP 0 1 7 1
FuelPumpinsufficient
flovpressure
FuelFeedLineclogged,leaking
FuelPressureRegulatorstuckopen
FuelFilterclogged
FuelInjectorclogged,air inclusion
Gasolinedoesn'tmeetOwner'sManualspec.
PrimaryH02S (Sensor1) deteriorated
MAP Sensorrange/performance*a
EGRSystemmalfunction(too much flow)*1
ValveClearance
Exhaustleak
DTCP0172
FuelPressureRegulatorclogged,stuckclosed
FuelReturnPipeclogged
FuelInjectorleaking
Gasolinedoesn'tmeetOwner'sManualspec.
PrimaryH02S (Sensor1) deteriorated
MAP Sensorrange/performance+4
EGRSysteminsufticient
flowrl
EVAPPurgeControlSolenoidValveleaking,stuckopened
ValveClearance
{cont'd}
11 - 1 0 3
PGM-FISystem
FuelSupplySystem(cont'dl
-
The MIL has been reoortedon.

DTCP0171and/or P0172are
stored.
ls the fuel pressureOK?

ls the luel pressuretoo high
Checkthe P.imary HO2SI

load (.A/Tin N or E position,
tor fan comeson,
2 . C h e c kt h e P r i m a r yH O 2 S
( S e n s o r ' l )o u t p u tw i t h t h e
scantool.
Doesit stayat lessthan 0.3V
or morethan 0.6V?
Chock the fucl p.caaure reguletor

and fuel rcturn pip.
Checkthe fuel pump, luel fe.d

pipe, fuel lilter, and fuel pressu.e
regulator.
YES
NO
Check for a sticking or leaking
E V A Pp u r g c c o n t r o l s o l e n o i d
With a vacuumpump,applyvacuu m t o t h e E V A Pp u r g e c o n t r o l
s o l e n o i dv a l v e f r o m t h e i n t a k e
manifoldside.
Does it hold vacuum?
Checkthe MAP sensoroutputl

1. Turnthe ignitionswitchON ill).
2. Checkthe l,4APwith the scan
tool,
YES
Check the response of the MAP
Sensot:
1. Stanthe engine.
tool.
ls a MAPof40.0kPa(300mmHg,
12.0inHg)or lessindicatedwithin
one secondafter startingthe
engine?
L
-
11-104
Checkth6 valve clearance,

Checkthe EGRswt6m (D16Y5
en9inel.
It they are OK, replacethe luel
inlecto.s.
Misfire Detectedin One Cylinder

Cylinder1 misfiredetected.
I P0301 The scantool indicatesDiagnosticTroubleCode(DTC)P030'1:
I P0302 ths s636tool indicatesDiagnosticTroubleCode(DTC)P0302:cylinder2 mistiredetected.
119393-.1Th"""untool indicatesDiagnosticTroubleCode{DTC)P03O3r
Cylinder3misfiredetected.
P0304 i ths 56sntool indicatesDiagnosticTroubleCode{DTC)P0304:Cylinder4 misfiredetected
Description
Mistiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft.
lf misfiringstrongenoughto damagethe catalystis detected,lheMIL will blinkduringthe time ot its occurrence,
and DTC
P0301,P0302,P0303or P0304will be stored.Then,afterthe misfirehasceased,the MIL will come on.
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on, and DTC
P0301.P0302.P0303or P0304will be stored,
NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a mislireDTC,troubleshootthose DTCSfirst,then
troubleshootthe misfireDTC.
P0106rMAP sensor
P0131,P0132:HO2S
P017'1,
P0172tFuelsupplysystem
P0335,P0336:CKFsensor
P0401,P1491,Pl498:EGRsystem
P044'l:EVAPsystemInsufficientpurgeflow*6
P 1 3 5 9P, 1 3 6 1P, 1 3 6 2T: D Cs e n s o r
P l 3 8 1 ,P l 3 8 2 :C Y Ps e n s o r
* 6 : ' 9 6D ' 1 6 Ye5n g i n e , ' 9 6
7 1 6 Y 5e n g i n e , ' 9 7
D 1 6 Y 7e n g i n e , ' 9 6
D16YB
e n g i n e( s e d a n ) , ' 9D
D 1 6 Y 7e n g i n e( c o u p eK: A ,
KCmodels,sedanKA,KC,KL (DX)models,hatchback:
all models),'97D16Y8engine(sedan:KA,KCmodels)
PossibleCause
. Fuelinjectorclogging,fuel leakage,air leakage
. Fuelinjectorcircuitopenor shorted
. Sparkplug carbondeposits,fouling,malfunction
. lgnitionwires open.leaking
. Distributormalfunction
a Compressionlow
. Valveclearanceout of spec
. VTECsystemmalfunction{D16Y5,D16Y8engine)
. HO2S
. HO2Scircuit
)/
(cont'd)
11 - 1 0 5
PGM-FISystem
Misfirein DetectedOneCylinder(cont'dl
TroublshootingFlowchart
-
The MIL hra boenreDortedon.

oTc P0301,P0302,P0303,o.
P0304i3 indicatsd.
Chocktho luol injector tunction:

Slartthe engine,and listenlor a
clickingsoundat the fuel injector
in the problemcylinder.
Checkfor an openor shortin the

harnessbetweenECM/PCMand
the fuel injector.
Repairopen or short in the wire.
Problemvorilicationi
1. After checkingthe freezedata,
do the ECM/PCMResetProceoure,
2. Exchange
the sparkplug from
the problemcylinderwith one
of anothercylinder.
4. Test'drivethe vehicleseveral
times in the rangeofthe lreeze
oala.
(To page11-1071
11 - 1 0 6
Replacethe fu6l injoctoi.

Subslitute a known-good
E C M / P C Ma n d r e c h o c k .I t
symptom/indicrtion goos
aw.y, rcplactho originsl ECM/
PCM.
NOTE:
'lI thore is no lreezedata oI misliring,
just clearthe DTC.
. lf there is no freezedata of misfir;ng,
test drives under various conditions
/
{Frompage11-106}
ls DTCP0301,P0302,P0303,
or P0304indicated?
Doesthe misfireoccurin the

othercylinderwhosesparkplug
was exchanged?
Ch6ck for fuol injector malfunction:

1 . E x c h a n g et h e f u e l i n i e c t o r
trom the problemcylinder
with one lrom anothercylin'
der,
2. Letthe engineidlefor two minutes,
3. Test drive the vehicleseveral
times in the rangeot the freeze
data.
ls DTCP0301,P0302,P0303,
or P0304indicated?
Doesthe mislireoccurin the

othercylinderwhosefuel injector
was exchanged?
Intermittent mistire due to spark

plug fouling, etc- lfiring is OK al
this timel.
Replacelh6 faulty spark plug.
NOTE|It there is no lreezedata of mis

f;ring,test drives under variouscondi
tions are necessary,
Inte.mittont misfiro due to bad

contact in the fuel injector connecto.lfiringis OK at this time).
Rplac the faulty luel iniector.
Chockfollowing items
- Cylinderleak{own
- Comoaession
- Crank3heft soeed fluctuation
ICKFI3ensor
11-107
PGM-FISystem
RandomMisfire
The scan tool indicatesDiagnosticTrouble Code (DTC)
P 0 3 0 0 * so r P 1 3 0 0 + *31 a n d s o m e o f P 0 3 0 1- P 0 3 0 4 :
Randommisfire.
*'
[Fo3oo
l*' o' fFl3ool*'' "nd P0301
Dgscription
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft.
lf misfiringstrongenoughto damagethe catalystis detected,the MIL will blink duringthe time of its occurrence,
and DTC
P0300*5
or
and some of DTCSP0301through P0304will be stored.Then,after misfirehas ceased.the MIL will
c o m eo n .
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on. and DTC
*a and some of DTCSP0301through P0304will be stored.
P0300*5
or P1300*3.
NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a misfireDTC.troubleshootthose DTCSfirst,then
troubleshootthe misfireDTC.
MAP sensor
P 0 1 3 1P. 0 1 3 2H: O 2 S
P0171,P0172tFuelmetering
P0401,Pl491,Pl498:EGRsystem*r
P0505:ldle ControlSystem
P1253;VTECSystem*,
Pl361.Pl362:TDCsensor
Pl381.P1382:CYPsensor
P1508:IACvalve
PossibleCauso
. Fuelpump insufficientfuel pressure,amountofflow
. FuelIineclogging,blockage,leakage
. Fuelfilter clogging
. Fuelpressureregulatorstuckopen
. EGRsystemmalfunction*r
. Distributormalfunction
. lgnitioncoil wire open,leakage
. lgnitioncontrolmodulemalfunction
. MAP sensorrange/performance,
poor response*1
. Valvescarbondeposit
. Compressionlow
. IACvalvemalfunction*a
! VTECsystem malfunction*,
. Fueldoes not meetOwner'sManualspec..lackoffuel
. HO2S
. HO2Scircuit
* 1 : D 1 6 Y 5e n g i n e
*2: D16Y5,D16Y8engine
*3; '97 model
*4: '96 model
*5: '98 model
Troubleshooting
By test-driving,determinethe conditionsduring which misfireoccurs.Dependingon these conditions,test in the order
describedin the table below.
Possiblecause
\
\,
E GR * 1
system
,;;;
Condition
Only low rpm and
toao
1l-170
Crankshaft
Fuel
Distributorand
position(CKP)
pressure lgnitionwires
sensor
section6
11 - 1 5 0 ,
Not specific
rAc
Clearance Valve
section 6
o
ra\
section 23
Onlyaccelerating
Only high rpm and
toaq
section23
tcM
1't-126 11-67
@
@
NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owner,smanual

spec,lackof fuel, carbondepositson sparkplug,etc.
11 - 1 0 8
MAP
sensor
KnockSensor(KS)(Dl6Y5engine{CVTIand D16Y8enginel
The scantool indicatesDiagnosticTroubleCode(DTC)P0325:A malfunctionin the circuitof the KnockSensor
{KS).
-
Th MIL hes been reooned on.

DTC m325 is stored.
Problemv6rification:
1. Do the ECM/PCM
ResetProcedure2 . S t a r tt h e e n g i n e .H o l d t h e
load (A/Tin N or E position,
M/T in neutral)untilthe radiator fan comes on, then let it
idle.
3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm for at least 60 seconds.
DIAPHRAGM
Intormittenl tailure. system is OK

at this time ltest drive mev be
Ch6ck lor poor conncclions or

loose wi.es between C137(knock
sensorlKSl) .nd ECM/PCM.
Checktoi a shon in the wir. (Ks

linell
2, Disconnectthe knock sensor
2Pconnector,
3 . D i s c o nn e c t t h e E C M / P C M
connectorD {16P}.
4. Checktor continuity between
E C M / P C Mc o n n e c t o rt e r m i
nalsDOand body ground.
D (16P1
ECM/FCM
COtrl]\|CrOB
KS
IRED/
ALU)
Wir side of femal terminals

Repairshort in tho wire between
ECM/PCMlD6| and knock sensor.
KS 2P CONNECTOR
tcl37l
KS
IRED/BLUI
Chock lor an open in the wire

(KSlinel:
ECM/PCM
connectorterminalD6
and knock sensor 2P connector
terminalNo. 1.
ou1
Rapairopen in the wire btwo6n
ECM/PCMlD6) .nd knock sen-
s ide of
Substitutea known-goodknock
sensorand recheck.
Replacetho originalknock s6nsor.
fgm al
terlninil t s
KS
IREO/
BLU)
1
7
13 1 a
a
't0 1 1
12
16

PCM and r.check. lf symptom/
indication goos away, 16plac6
thc originrl ECM/PCM.
11 - 1 0 9
PGM-FISystem
GrankshaftPosition/TopDeadCenter/Cylinderposition(CKp/TDC/Cyp)
Sensor
scantool indicatesDiagnosticTroubleCode(DTC)P0335:A matfunctionin the Crankshaftposition(CKp)
il'oggslThe
sensorcircuit.
fFffi6l
The scantool indicatesDiagnosticTroubleCode(DTC)P0336rA range/performance

problemin the Crankshaft
Position(CKP)sensorcircuit.
The scantool indicatesDiagnosticTroubleCode(DTC)pl36.l: lntermittentinterruotionin the Top DeadCenter

tPr36rI {TDC)
sensorcircuit.
scantool indicatesDiagnosticTroubleCode (DTC)P1362:No signalin the Top DeadCenter(TDC)sensor
tn362l The
circuit.
The scantool indicatesDiagnosticTroubleCode{DTC)P1381:Intermittentinterruptionin the Cvlinderpositaon
tFtu8Tl
(CYP)sensorcircuit.
scantool indicatesDiagnosticTroublecode (DTC)P1382:No signalin the cylinder position(cyp) sensor
tPJ382lThe
circuit.
Doscription
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up{cranking)and when crankangle is abnormal.The CyF Sensordetectsthe
positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKpiTDClCyp
Sensoris built into the dastribu_
ror.
NOTE:lf DTCPl359 is storedat the sametime as DTCP0335,P0336,P1361,Pi362,pi381 and/orp1382,troubteshoot
DTC
P1359first. then troubleshootthose DTCS.
Ot6y5ongin.:
Di6y7,D16y8ongin6:
Th. MIL hs. b..n roportld on.

DTC P0335, P0336, Pl361.
P1362,P1381.nd/or P't382ero
storod.
Problcmv.riticetion:
2. Stan the engine,
b DTCm35, P0336.P1361,P1362.
P1381and/orP1382indicated?
CKP
CYP
SENSOR SENSOR
ROTOR ROTOF
CKP
TDC
SENSOR SENSOR
SENSORROTOR ROTOR
ROTOR
DISTRIBUTOR
lOP
coNNECTOR
tC120t TDCP
Intgrmittont failuro, systam is OK

et this time. Chockfor Door connections or loose wires at C120
ldbtributo.l and ECM,/PCM.
Chocktor an open in th. CKP/

TDC/CYP..nror:
2. Disconnectthe distributor 10P
connector.
3. Measureresistancebetween
th lerminals of the indicated
sensor(rseetable).
ls there 350 - 700 O?
CYPM{BLK)
R.pt.ce the di.tributor ignition

ho6in9 (3Gesoction23).
S E N S O R oTc
CKP
TDC
1 1 - 11 0
-
CYP
SENSOR ECMPCM W I R E
ERMINALIERMINAL COLOR
P0335
c2
m36
c12
P1361
P1362
8LU
GRN
cr3
RED
P1381
c4
YEL
P1382
cl4
BLK
v
( F r o mp a g e1 1 - 1 1 0 )
DISTRIEUTOR
10PCONNECTOR
tcl20l
Chock tor e 3hort in the CKP/

TDC/CYP3en3or:
C h e c kf o r c o n t i n u i t y t o b o d y
ground on both terminalsof the
i n d i c a t e ds e n s o r i n d i v i d u a l l y
('seetable).
TDC P IGRNI
Replace the distributor ignition

housing (see section 231.
CheckloJ an opgn in th6 wire3

linesl:
ICKP/TDC/CYP
1. Reconnect
the distributor10P
connecror,
2. Disconnectthe ECM/PCMconnectorC (31P).
3. Measureresistancebetween
the terminalsof the indicated
sensoron the ECM/PCMcon
nector('seetable).
ls there350- 7000?
TDC
Terminalsideof
maleterminals
Repai. open in the indicated sensor wiles ('see tabl).
\,
ECM/PCMCONNECTORS
C {31P|
CKPP TDCP
{BLUI IGRN}
CYPP
(YELI
Chock tor a 3hort in the wires

linosll
{CKP/TDC/CYP
body ground and EcM/PcMconnectorterminalsC2, C3 and/or C4
individually.
M
ls therecontinuity?
Subitituto a known-good ECM/

PCM, and recheck. lt 3ymptom/
indicdtiongo6s away, replecothe
origin!l ECM/PCM,
Ropair short in tho indicated 3onsor wiros ('see tablel.
{WHT)
Wiresid6of
femaleterminals
TDCP cYPP
CKP P
IBLUI
T
11-111
PGM-FlSystem
VehicleSpeedSensor(VSSI
The scan tool indicatesDiagnosticTrouble Code (DTC)P0500:A malfunctjonproblem in the VehicleSDeed
Sensor(VSS)circuitlexceptAy'T(D16Y7,D16Y8engine)].
LP@

problem in the Vehicle
(VSS)circuitlA/T (D16Y7,D16Y8engine)1.
SpeedSensor
The MIL has boonreDortedon.

DTCP0500or P0501is stored.
ECM/PCMCONNECTORS
A l32P)
Problem verificationi
1 . T e s t - d r i v et h e v e h i c l e .
2. Check the vehicle speed with
the scan tool,
IBRN/BLKI
1
12 l 3
ls the correctspeedindicated?
lcl
Intermittent f.ilure, 3ystem is OK

at this time. Checktor Door connections or loose wircs at C117
(VSS)and ECM/PCM.
t 5 15
27
CheckIor an open in the ECM/

PCM:
r. r urn Ine rgnrt|onswrtchut-t-.
2. Elockthe rearwheelsand set
the parkingbrake.
3. Jack up the front ot the vehicle
a n d s i r p p o r ti t w i t h s a f e t y
stands.
5. Blockthe right front wheel and
s l o w l y r o t a t et h e l e f t t r o n t
t0
2a
t 3 t 9 20
2A 4 30
ll
2a
c t3lPt
I tro
1t 12 13 t a t 5 1 6 t t I E
VSS{BLU/WHTI
Wire side ot fma16tgrminals
E C M / P C Mc o n n e c t o rt e r m i
nalsC18and A9.
Doesthe voltagepulse0 V
and 5 V?

PCM and recheck. lf symptom/
indication90e3 .way, replacetho
originalECM/PCM.
Check for a short in the ECM/

PCM:
'1.
2 . D i s c on n e c t t h e E C M / P C M
connectorC (31P).
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowly rotatethe left lront
LGl
(BRN/BLKI
6
t 6 'It ! t
12 t t
27
9
22
t0
2a
tt
21
2t 22 30
ECM/PCMconnectorterminals
C18andA9.
Doesthe voltagepulse0 V
and 5 V?
NO
-
Bepair 3hort in the wire

betwen ECM/PGMlC18)and

PCM and rech6ck.lf symptom/
indication 9o6s away, replsco
3
t 1 1Z l 3 t a | l 5 ] t 6 i 1 7
9 l0
ta
vss,TcM.

between ECM/PCM{C181and
vss.
lf wiie is OK. rest the VSS

{seepag23-120).
11-112
vss (Btu/wHTl
BarometricPressure(BarolSensor
problemin the Barometric
The scantool indicatesDiagnosticTroubleCode(DTC)P1106:A range/performance
Pressure(Baro)Sensorcircuit.
Th6 MIL has been rooortod on.
DTC P1106 b.tor.d.
1. Do the ECM/PCMresetprocedure,
load (A/T in E or E position,
M/T in neutral)until the radiator fan comes on, then let it
idle.
3. Connectthe SCSServiceconnefior.
4. Test-drivewith the A/T in E
position(M/Tin 4th gear).
5. Acceleratefor live seconds
usingwide openthrottle.
lntermitteni tailuro.system is OK
st this timo.
Subslitute a known-good ECM/

PCM end recheck. ll symptom/
indication goss away. .cplaco
(cont'd)
11-113
PGM-FISystem
BarometricPressure{BarolSensor(cont'd}
lTilOil
Th"""untool indicatesDiagnosticTroubleCode(DTC)Pl107:Alowvoltage problemin the Barosensorcircuit.
T h e s c a nt o o l i n d i c a t e sD i a g n o s t i T
c r o u b l eC o d e( D T C )P 1 1 0 8A: h i g h v o l t a g ep r o b l e mi n t h e B a r os e n s o r
-l P , i l O C l crrcutl.
-

DTCPl107or Pl108is 3tored.
1. Do the ECM/PCMResetPro
ls DTCP1'107
or P1108indicated?
Substitute e known-good ECM/

PCM and r6check. lf symptom/
indication gos away, replace
11-114
Intermittent tailure, 3ystemis OK

at this time.
ElectricalLoadDetector(ELDI
The scan tool indicatesDiagnosticTrouble Code (DTC)Pl297; A low voltage problem in the ElectricalLoad
Detector(ELD)circuit.
-
DTCP1297is slored.
Problemverificationi
2. Startthe engine.
3. Turnon headlights.
Intermittent feilure, svdam k OK

at this time. Chckto. poor connoctions or looso wir.s at C131
{locatedunder right 3id ot dashl.
Cil54{ELD}and ECM/PCM.
EID 3P CONNESTOR{qtsill
Check for an opn in the wire

{lGl linel:
1 . T u r n t h e i g n i t ; o na n d h e a d
lightsOFF.
2 . D i s c o n n e ctth e E L D 3 P c o n nector,
4. Measurevoltagebetweenbody
ground and the ELD3Pconnec'
tor terminalNo.1.
Wire sideof lemaleterminals

Ropairopen in the wire between
No. 15 ALTERNATOR
SP SENSOR
17.5Al tuse in thc undor-dash
tuse/relaybox and ELD.
f t ,
-T
L l l 2 l 3 l
Checktor short in the ELO:

Measurevoltage between body
groundand the ELO3P connector
t e r m i n aNl o . 3 -
O) IGRN/RED}
ls thereapprox.4.5V2
D (16PI
ECM/FCMCONNECTOR
Checktor a short in the wi.e (EL

linel:
2. Disconnect
the ECM/PCM
connectorD (16P).
3. Check{or continuitybetween
b o d y g r o u n da n d E C M / P C M
connectorterminalD16.
ls therecontinuity?
Repairshort in the wire betwcon

ECM/PCM{D161and ELO.
Wire side of temale terminals
Substituter known-goodECM/
PCM and recheck. Ifsyrnptom/
indication goes away. roplace
(cont'd)
1 1 - 11 5
PGM-FISystem
ElectricalLoadDetector(ELDI{cont'd)
The scan tool indicatesDiagnosticTroubleCode {DTC)P1298:A high voltage problem in the ElectricalLoad
Detector(ELD)circuit.
1. Do the ECM/PCMResetPro
cedure.
2. Startthe engine.
3. Turnon headlights.
Intermittent failuro, 3y3tem is OK

at thb time. Checklor ooor connection3 o. loose wire3 at C131
(locrted undcr right side of dashl,
C354lEtDland ECM/PCM.
Check lor rn open in the wire

(GNDlinell
1. Turn the ignition switch and
headlights
OFF.
2 . D i s c o n n e ct th e E L D 3 P c o n ,
necror,
3. Checklor continuitybetween
body ground and the ELD 3P
connectorterminalNo, 2,
ELD3P CONNECTOFlc3sil,
nepair opcn in the wirc between

El-Dconnectorand G4l)2.
EL {GRN/REO)
YES
Chackfor an opon in ihe wi.e (EL
line):
Checktor continuity between the
ELD3P connectorterminalNo. 3
and ECM/PCMconnectortermi
n a lD 1 6 .
Repairopen in lhe wire betwon

ECM/PCM{D16)and the ELO.
Chcckfor a malfunctionin tho

ELD:
Wire sideol femaleterminals
ECM/PCMCONNECTORS
1. Reconnectthe ELD 3P con2. Start the engine and allow it

to idle.
3. While measuring voltage
b e t w e e n E C M / P C Mc o n n e c t o r
t e r m i n a l s D ' 1 6a n d A 9 , t u r n
the headlightson (low).
Wire sideof temaleterminals

Does the voltage drop?
Substitutea known-goodECM/
PCM and rch6ck. lf symptom/
indication goes away, replaco
1 1 - 11 6
L
CrankshaftSpeedFluctuation(CKFISensor
scantool indicatesDiagnosticTroubleCode(DTC)P1336:Intermittentinterruptionin the Crankshaft
SDeeo
tPtg36-lThe
Fluctuation(CKF)sensorcircuit.
scantool indicatesDiagnostic
TroubleCode(DTC)P1337:No signalin the Crankshaft
(CKF)
SpeedFluctuation
tP-s37 The
sensorcircuit,
Description
The diagnosticsystemhasa pulserrotor on the crankshaftand a pulsepick-upsensoron the engineblock.The ECM/PCM
monitorsthe crankshaftspeedfluctuationbasedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif
the fluctuationgoes beyonda predetermined
limit,
The MIL ha3 ten reDortodon.

DTC P1336and/or P1337are
ltored.
P.oblemvelitication:
1. Do the ECM/PCM
ResetProcedure.
2. Startthe engine.
Intermittont failure, system i3 OK
at this time. Chack for poor connections or loose wires ai C102
(CKFsensorl and ECM/PCM,and
mak6 sure CKF sensor mounting
bolt is tigt|t.
Checklor an open in the CKFsen301:
2. Disconnect
the CKFsensor3P
connector,
3 . M e a s ur e t h e r e s i s t a n c e
between the CKF sensor 3P
connectorterminalsNo. 1 and
No.3.
CKF SENSOR 3P CONNECTOR

f' ----i l
iffil
1 1 l 2 1 3 l
cxrrrrf--fc*r
ls there1.6 3.2kO?
"
lwHrl L,,dJ
g/
|BLU)
Terminalsideof maletermanals
Checkfo. a rhort in tho CXFson3('t:
Check for continuity betwen

body groundand the CKFsensor
3P connectorterminalsNo. 1 and
No.3 indavidually-
l--l
lll 2 3ll
CKF M
{WHT)
( T op a g e1 1 ' l 1 8 )
-1
I-T--
.Yt XY
I
CKF P
(8t_ul
{cont'd)
11-117
PGM-FISystem
GrankshaftSpeedFluctuation(CKFISensor(cont'dl
{ F r o mp a g e1 1 - 1 1 7 }
Chcck for an op.n in the wires

(CKFlines):
1. Reconnect
the CKFsensor3P
C {31PI
ECM/PCMCONNECTOR

3, Measureresistancebetween
E C M / P C Mc o n n e c t o ri e r m i n a l sC 1a n dC 1 1 .
CKFP
(BLU/REDI
IT
ls there1.6- 3.2k0?
Repeiropen in tho wire between

ECM/PCM(C1,Cl'll end the CKF
sensol.
10
1 2 1 3 1 4 1 5 l 6 1 7 '18
23 21 25
21 2a
z) 30
CKFM
IWHT/RED}
Chck tor a short in the wire

ICKFlin6):
body groundand ECM/PCMconnectorterminalC1.
Ropairshort in the wire between

ECM/PCMlcl) and the CKFsen-

PCM, end rechck. lf 3ymptom/
indicrtion 90e3away, replacolhe
origin.l ECM/PCM.
Wire sideof female

terminals
CKFP
(BLU/REDI
\.
\4
11-118
CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYP)
Sensor
A problemin the CrankshaftPosition/TopDead
TD;
aEol The scantool indicatesDiagnosticTroubleCode (DTC)P'1359:
Ll=!g
Center/Cvlinder
Position{CKP/TDC/CYP)
sensorcircuit.
The MIL ha3 been roportad on.
2. Stan the engine.lftheengine
won't start,Crankit for at least
10seconds,
Intermittem tailure, system is OK.

Ch6ck for Door connection3or
loose wires at C120 {distributorl
.nd ECM/PCM.
C h e c kf o r p o o r c o n n e c t i o n so r
loose wires betweenthe distributor and the EcM/PcM_

PCM, and recheck. lf symptom/
indication go6s awaV, rgplace
ths original ECM/PCM.
11-119
PGM-FISystem
InternalCircuit
ECM/PCM
I P1607 The scantool jndicatesDiagnosticTroubleCode(DTC)P1607:An ECM/PCMInternalCircuitProblem.
-

DTCP1607is stored.
1. Do the ECM/PCMResetPro'
cedure,
3. Wait 10 seconds.

PCM and recheck.lf syrnptom/
indicationgoes away, replacethe
originalECM/PCM.
v
1-120
l/
A/T Signal(TMA/TMB){D16Y5engine(CVT))
I P1655 iThe scantool indicatesDiagnosticTroubleCode(DTC)Pl631:TMMMB signallinefaiture.
ECMCONNECTOR
C {31P)
TMA IGRY}
Problomverilication:
1. Dothe ECMResetProcedure.
2. Drive the vehiclefor several
milesat varyingspeeds.
Ch6ck tor an open in the wire

{TMA linol:
{31P)from the ECM.
E C M c o n n e c t o tr e r m i n a lC g
and bodyground.
ls there batteryvoltage?
Intermittent failure,syslm is OK
at this timo. Chockfor Door connections or loose wires at C131
(locatedunder right side of dash),
C4:t8{TCMI,nd ECM.
fcu22P
CONNECTOR
Chcck lor a short in the wire

ITMA line):
Measurevoltage betweenTCM
22PconnectorterminalNo. 7 and
body ground.
Chock tor rn open in tho wir

(TMB line):
2. ReconnectECM connectorC
(31P).
from TCM.
4. Turntho ignitionswitchON (ll).
5 , M e a s ur e v o l t a g e b e t w e e n
TCM 22P connectorterminal
No.6 and bodyground.
Wire sideot temale

termrnats

the ECMlcg, and the TCM.
C h e c kf o . a 3 h o r t i n t h e w i r e
{TMB line}:
connoctorterminalC30and body
grouno.
RoDairshort in the wire between

lhe ECM{C9land th6 TCM.
fcu 22P
CONNECTOR
10
11 1 2 1 3 l 4 1 5 1 6 1 7 l 8
23 21 25
Substitute r known-good ECM
and rccheck. lt 3ymptom/indication goe3away, roplacelhe original ECM.
29 30
Wire sideof female

terminals
TMBT
{PNK)
Repairshort in the wire between

the EcM lc30) and the TcM.
Reprir open in the wi.e bstwen

rhe EcM {c30) and rhe TcM.
11-121
ldle Control System

SystemDescription
The idle speedof the engineis controlledby the ldle Air Control(lAC)Valve.
The valvechangesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledby the
lhe valveopensto maintainthe properidle speed.
Whenthe IACValveis activated,
ECM/PCM.
D16Ys,D16Y8ensine(M/T):
,
I
-
T
r )
, :::/ __
BLK
_<
T *f,T.ir;tJ
MAINRELAY
VARIOUS
SENSOnS
aLk
IROTARY}
IACVALVE
D16Y5(CVTI,D15Y8engine(A/T):
EIVGINE
COOLANT
INTAKEMANIFOLD
;[i-
D16Y7engine:
11-1 2 2
<l;litf,U''j
vARtous
SENSORS
a
1 . After the enginestarts,the IACvalveopensfor a certaintime, The amountof air is increasedto raisethe idle speed
about 150- 300rpm.
When the coolanttemperatureis low, the IAC valve is openedto obtain the propertast idle speed.The amount of
bypassedair is thus controlledin relationto the enginecoolanttemperature.
IOLE SPEED
lrpml
176
80
Et{Gt1{E
COOLANTTEMPERATURE
(oF)
toc)
1.
When the idle speedis out of specification

and the scantool does not indicateDiagnosticTroubleCode{DTC}P0505
or P1508,checkthe followingitems:
. A d j u s t h e i d l es p e e d( s e ep a g e1 1 , 1 4 1 )
. S t a r t esr w i t c hs i g n a (l s e e p a g e l l - 1 3 0 I
. A i r c o n d i t i o n i nsgi g n a (l s e ep a g e1 1 - 1 3 1 )
. ALT FRsignal(seepage11 133)
' Brakeswitchsignal{seepage1'l-134)
' PSPswitchsignal(exceptCanadamodel)(seepage11-135)
. A/T gear positionsignal(seesection'14,D16Y5engine(CVT):
p a g e1 l - 1 3 7 )
. Clutchswitchsignal(D16Y5engine(M/T))(seepage 11-139)
. Hosesand connections
. IACvalveand its mountingO-rings
lf the aboveitemsare normal.substitutea known-goodIACvalveand readjustthe idle speed(seepage 11-141).
lf the idle speedstill cannot be adlustedto specification(and the scantool does not indicateDTCP0505or P1508)
after IAC valve replacement,substilutea known-goodECM/PCMand recheck.lf symptom goes away, replacethe
originalECM/PCM.
11-123
ldle ControlSystem
ldle ControlSystem
lT05O5l Th" """n toot indicatesDiagnosticTroubleCode{DTC)P0505:ldle controlsystemmalfunction.
NOTE:lf DTCP1508or P1509is storedat the sametime as DTCP0505,troubleshootDTCP1508or P1509first,then troubleshootDTCP0505.
Possiblecause
. IACvalvemechanicalmalfunction
. Throttlebody cioggedport, improperadiustment
r lntakemanifoldgasketieakage
. Intakeair hoselooseleakage
. V a c u u ml e a k
. ECTsensorincorrectoutput
. ThrottlePositionsensorincorrectoutput*1
Tloubleshooting Flowchart
-
Th6 MIL has beenreoortodon.

DTC P0505is stored.
Problsm vorificationl
load 1A,/Tin E or E position,
M/Tin neutraliuntiltheradiator
fan comeson, then let it idle.
*1 -Wi*i
t2.
tne scan toot, checLtt e-l
-
Throttleposilionshouldbe
approx.10%with the throt'
tle {ully closed.
- E n g i n ec o o l a n tt e m p e r a ture shouldbe 194- 205'F
(90- 96'C).
lf they are not within the
spec.,repairthe faultysensol9!!9'llj:-.-.-.l
L
3 . C h e c kt h e e n g i n e s p e e d a t
idle with no-loadconditions:
h e a d l i g h t sb, l o w e rf a n , r e a r
defogger,radiatorfan, and air
conditionerare not operating
(seepage11 139).
ls the idlespeedOK?
Intermittnt failure, system is OK

et this time.
ls it 550 rpm or less?
(Topage11-125)
* 1 : ' 9 6m o d e lo n l y
11 -1 2 4
{ T op a g e1 1 - 1 2 5 )
{Frompage11-124}
(A,/Tand D16Y7engine)
I
Checkthc IACvrlvo:
Disconnectthe 3P connectortrom
the IACvalve.
' {Dl6Y5,
- - - - D'|6Y8
- - - t enginwith M/T)
Chcckth. IAC valve:
D i s c o n n e c tt h e 2 P c o n n e c t o r
from the IACvalvo.
Doesthe enginespeeddrop or
the enginestall?
_ l
Dl6Y5, Dl6Y8 ongin:

Adi6t thc lbasll idle 3pa6d ls6c
p.9 11-1391.
ll it'. impo$ible,
cl6an th ports in tha throttle
body.
UPPER
lFrompage I1-124)
Putyour fingeron the upperport

in the throttle body.
Doeslhe enginspeeddrop?
Chack for vacuum laakr. make

3u.c th. throitla valvc is complctaly closrd, .nd ropair I necca3ary.
Dl6Y7 engine:
Adiust tho idlo sp..d (3e pag.

11-139).It it'5 impo$iblo, r.placo
tha IAC Yalve.
11-125
ldle GontrolSystem
ldle Air Control(lAClValve(Dl6Y5,Dl6Y8 enginewith M/T)
(lAC)valve
The scan toot indicatesDiagnosticTrouble Code (DTC)P1508:A problem in the ldle Air Control
crrcurt.
The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in
order to maintain the proper idle speed.
The MIL has b6n reDortgd on.

DTC P150a is stor.d.
Problomvorification:
2. Startthe engine,and warm it
up to normal operatingtemperature.
vat_vE
lntc.mittent tailure, svslem i5 OK

et thb time. Check for poor connoction3 or 10036wirg3 st C138
llAC v.lvel .nd ECM.
Check to..n open in tho wi.o

llGPl lin6l:
2. Disconnectthe IAC valve 2P
connector,
4. Measurevoltagebetweenbody
ground and the IAC valvo 2P
connectorterminalNo.2.
IAC VALVE2P CONNECTOR

ICl38}
/T\'--'J rcpr
t
\
2 J -
rYCLrBtXl
r$,
Y=
Wire sid6ot femaleterminals

Chacklor rn open o. short in the

wirc {lACv linel:
1. Turn the ignition switch OFF
and reconnectthe IAC valve
connecror,
2. Disconnectthe ECMconnector
A (32P).
3. Turn the ignilionswitchON lll).
4 . M e a s u r ev o l t a g e b e t w e e n
b o d y g r o u n da n d E C Mc o n nectorterminalA12.
Reprir opsn in the wiro bstwcen

IAC valvo and PGM-FImain rcltY.
A I32PI
ECMCONNECTOR
12 l 3
tAcv
IBLK/
BLUI
5 6
1 5 i 6 't, t l
! 1 9
t9
ao
to
2a
lzsVlztl lz.lzelnl/l | .,'
(To page 11-127)
11 -1 2 6
2a
(Frompage11-126)
ls ther batteryvoltage?
Ropairopen or short in the wiro

b.twen ECM lA12l and IAC
Checkthe IAC valvelunction:

MomentarilyconnectECM conn e c t o rt e r m i n a l sA 1 2 a n d A ' 1 0
with a iumoerwire severaltimes,
Wire side of female trrhinals
Doesthe IACvalveclickT
Substitute . known-good ECM

and rocheck. lt 3ymptom/indication 906 away, .oplaco tho origin.l ECM.
11-127
ldle Gontrol System
ldle Air Control(lAClValve (A/T and Dl6Y7 engine)

lTi509l
TroubleCode(DTC)P1509:Aprobleminthe idleAirControl(lAC)valvecircuit.
Th""""ntool indicatesDiagnostjc
The (Rotary)IAC Valvechangesthe amount ot air bypassingthe throttle body in responselo a currentsignaltrom the
ECM/PCM in order to maintain the proper idle speed.
BIMElAL
The MIL has beenreooned on.

DTCPl 5'lx)is sto.ed.
Problomverification:
ls DTCP1509iodicated?
STOP?ER
VALVE
SHAFT
Intermittent failuro, svstem ia OK
at lhis time. Check for poor connections or 10036wires at C109
{lACvalve) end ECM/PCM.
ECM/PCMCONNECTOR
A I32P}
PGl (BIK}
Checkfor an open in the wires

IPGlin6):
Measurevoltage between body
ground and ECM/PCMconnector
terminalsA10 and A23 individu
Repair op6n in lhe wires between

ECM/PCM and G101 {locat6d ar
the thermostat housing.l
\3
Wire sid ol temale terminals
Check the ECM/PCM inpul voltage:

2. Disconnect
ECM/PCM
connector A (32P)from the ECM/PCM3. Turnthe ignitionswitchON (ll).
4 . M e a s u r e v o l t a ge b e t w e e n
A13+individually.
ls therebafteryvohage?
Check the IAC valve:

1. Turn the ignition switch OFF.
2. Disconnect the IAC valve 3P
connector.
3. Measure resistance between
IAC valve 3P connector termi'
n a l N o . 2 a n d t e r m i n a l sN o . 1
and 3 individually.
ls there16- 28 O?
Substiluto a known-good ECM/

PCM and rocheck.lf symptom/
indicalion goes away, replace
*: IACV N line
11 -1 2 8
2
I
1 2 l 1 31 a 1 5 1 6 1 7 t8 t9
28 29
3o
. l
tAcv N {oRNt.
O)
27
8
22
IACVP IBLK/BLU}
(Topage11129)
IAC VALVE3P CONNECTOB
IACV N
IACV P
IGP
Terminalsideof male
Iermtnals
10
1'l
23
2a
{ F r o mp a g e1 l - 1 2 8 }
IAC VALVE3P CONNECTOR

{CIOI}
Check tor an open in the wire
(lGPline):
2. Disconnectthe IAC valve 3P
connector.
4. At the wire harness,measure
voltage between IAC valve 3P
connectorterminalNo. 2 and
body ground.
ls therebatteryvohage?
IGP {YEL/BLKI

lh6 IAC valvo and PGM-FImain
relav.
Checkfor an open in tho wires

(IACVP, IACV N' lines):
nectorA (32P).
IAC valve3P connectortermi
nal No. 3 and ECM/PCMcon'
n e c t o r t e r m i n a lA 1 4 ( a n d
betweenIAC valve 3P connector terminal No. 1 and ECM/
PCMconnector
terminalA13)*.
IACV N
toRNl*
' t 2
Repairopn in tho wire bctwoen

the IAC v.lve end ECM or PCM
(A14,A13*1.
7
Check tor a short in th wires

(IACV P, IACV Nr linesl:
Check tor continuity between
b o d y g r o u n d a n d E C M / P C Mc o n '
nector terminals A14 and 413*
individually.
IACV P
IBLK/BLUI
ECM/PCM
A t32Pl
CONNECTOR
IACV P
(BLK/BLU)
12 l 3 1 a t 5 l 6 1 7 ta t 9 2A
25
21
2a
lo
tt
2a
29 30

tho IACvalveand ECM/PCM1A14.
A13*).
3 a
Sub3titute a known-good ECM/

PCM and reched( lf syrYFtom/indication goes away, replacth6 o.igin.l ECM/PCM.
t 2 t 3 lil
t 5 t 6 1 7 l a t 9 20
a 9
t0
tl
24
Lry,"*"YYO
tacv N toRNl.
l,
': IACVN line
11-129
ldle ControlSystem
StarterSwitch Signal
This signalsthe ECM/PCM
when rhe engineis cranking.
NOTE:
. A/T:Transmission
in E] or @ posnion.
M/T: in neutral
ECM/PCMCONNECTORS
Chockfor an open or ihort in the
wire {STSlinol:
PCMconnectorterminals Ag and
C6 with the ignition switch in the
start(lll)position.
A I:PPI LGl
I
t 2 l 3 t 4 1 5 1 6 t 7 ta r 9 20
25
27
ut
c t3lPt
E
't0
1' |
22
23
2a
t t 12
29 30
3 a
r3 t a
t5 t6 1 l
2a 2a
sTstELu/oFNt
7
't8
9 t0
29 30
Wire side ot female terminsls
Inspecttho No. 31 STARTERStG,

NAL {7.5A) fuse in the undeFdash
Iuse/relaybox.
St.rior switch sign.l b OK.

-
Raplir rhon in thc wiro

b.tw..n the ECM lC6) and
tho No. 31 STARTERSIGNAL
(t.5 Al lu3. or th. PGM-FI
main relsy.
ReDhcotho No, 31 STARIR
SIGNAL17.5A1tu3..
Rapair open in tha wire batwatan

tho ECM/PCMlC6|and th. No.31
STARTER
SIGNAL17.5Al tu!..
\,
11-130
Air ConditioningSignal
when there is a demandfor coolingtrom the air conditioningsystem.
ECM/PCMCONNECTORS
A l32Pl
c t3lPl
ACSIBLU/REDI
LGl IBRN/BLK}
2
I
8 9
1 2 1 3 ta 't5 't6 1 7 t 8 1 9 a)
22
Check lor a ahort in th6 wir

{ACSlinel:
2. Disconnectthe A/C pressure
switch 2P connector(see sect i o n2 2 ) .
E C M / P C Nc4o n n e c t o rt e r m i nalsC5 and A9.
ls thereapprox.5V?
25
27
l0
It
23
2a
1
I
a
5
2
't'l 12 t 3 1 l t 5 t 5 1 7 t 8
2a xt 30
9 10
z, 30
23 2a 2a
Wiresideof lemaleterminals
ACS{BLU/RED}
Chockfo. a short in the wire IACS

linol:
connector
terminalC5,
Repairshort in the wire botwsn

the ECM/PCM (Csl .nd the A/C
pro3suraswitch.
Chock tor an open in the wire

IACClin.l:
2, Reconnectthe A/C pressure
switch 2P connector.
3. Turnthe ignilionswitchON (ll).
4. Momdntan'ly connect ECM/
PCM connectbrterminalsA9
and A17 with a iumper wire
severaltimes.
Substitute a known-good
ECM/PCM and rchock, lf proacribgd vohago i3 now aveil.ble, replace the original ECM/
PCM.
See the sir condhione. inspction l.oc s.ction 22).
LGTIBRN/BLKI
1 2 3 a
12 l 3 t a 1 5 1 6 1
25
(To page11-132)
ACC
27
- r l
; l s l r I l s l s l ! ol r r l
lnltslil/1zzl ze I z+ |
w-z-
IBLK/REDI
JUMPERwlRE
{cont'd)
1 1- 1 3 1
ldle Control System

Air ConditioningSignal (cont'dl
( F r o mp a g e1 1 - 1 3 1 )
UNDER.XOODFUSE/RELAY
BOX9P CONNECTOBtc3s2t
Check for an open in the wir

{ACCline):
Momentarilyconnectunder-hood
fuse/relaybox 9P connectorter
minal No. 5 to body groundwith
a jumperwire severaltimes.
ls therea clickingnoiselrom
the A,/Ccompressorclutch?
6 /
JUMPER
WIRE
3 a
8
ACC IBLK/REOI
IBLK/RI
Wire side
side ot
ot female
tefmrnalS
ls therea clickingnoisefrom
the A/Ccompressor
clutch?
See air conditioner inspection

lsee section22).

i h . E C M / P C Ml A 1 7 ) a n d t h 6
under-hood tu3e/relay box 9P
connector{C3521.
ECM/PCMCONNECTORS
A (32Pt
Check tor the operation of the
A/C:
1. Startthe engine.
2. Turnthe blowerswitchON.
3. Turn the A"/Cswitch ON.
c (31Pt
ACSIBLU/REDI
LGT
(BRN/ALKI
I
12 1 3 t a t 5 t 6 1 7 I E 1 9
25
27
zo
l0
tl
22
23
2a
30
t t 12
t4
2a 2a
lf,
1 7 't8
29 30
WiresideoI femaleterminals
{ACSlin6):
PCMconnectorterminalsAg and
Air conditioningsign.l is OK.

ls therelessthan1.0V?
11 -1 3 2
Substiluta. known-good
E C M / P C Ma n d r e c h o c k .l I
symptom/indicationgoes
a w a y , r e p l a c et h o o r i g i n a l
ECM,/PCM,
Seethe air conditionerinspection (seesection22).
Rprir open in tha wire bstween

the ECM/PCM lcsl .nd th. A/C
swhch.
'to
Alternator(ALT)FRSignal
when the Alternator(ALT)is charging.
lnspectionot ALI FRSignal.
A t32Pl
LG1
(BRN/BLKI
Ch6ck for a sho.t in the wire {ALT
F line):
1. Disconnectthe 4P (3P)*connectorfrom the ALT.
E C M / P C Mc o n n e c t o rt e r m i nalsC'|7and A9.
ls thereapprox-5 V?
Checkthe operation ot the ALT:

2. Reconnectthe ALT 4P (3P)*
connectorto the ALT.
load {A,/Tin E or E position,
M/T in neutral)untilthe radiator fan comes on, then let it
idle.
Cl7 andA9.
D o e s t h e v o l t a g e d e c r e a s ew h e n
h e a d l i g h t sa n d r e a r d e f o g g e r a r e
ECM/PCMCONNECTORS
ALT F
{WHT/BEO)
Wire sideot temaleterminals

Check tor a short in the wire IALT
F linel:
2. Disconnectthe negativebat
tery cablefrom the battery.
nectorC (31P).
4. Checklor continuitybetween
connector
terminalC17.
c t31Pl
6 l 7|
1 1 12 1 3 l 4 1 5 l 6
rlrl/
23 21
9 't0
,/ / ,/
E 30
(wHr/FED)
0) ALrF
Repair shon in the wire between

the ECM/PCM{C17)endthe ALT.
ls therecontinuity?

PCM and recheck. It prescribed
voltage is now available,replace
the originalECM/PCM.
ALT FR signal i3 OK.
ALT CONNECTORS
lcloirl
3Pr
4P
Chec* lor an opeo in the wire IALT
F lin):
2. Disconnectthe 4P (3P)*con
nectorfrom the ALT.
ALT 4P {3P}*connectortermi
n a l N o . 4 ( N o .1 ) * a n d b o d y
ground.
ls thereapprox-5 V?
-+r
1 1
ffi
2|
l 3 l ll
rr-r r -lr JUMPER
rwHr/(V) WIRE
REot Y
JUMPER
WIRE
ALT F
(WHT/RED'
Repair open wire between the

ECM/PCM{Cl7).nd the ALT.
':Canadamodel
11 - 1 3 3
ldle Control System

BrakeSwitch Signal
This signalsrne ECM/PCM
when the brakepedalis depressed.
Inspcctionol &ak Swhch Signal.
Are the brakelightson without

depressingthe brakepedal?
Do the brakelightscomeon?
Inspectthe HORN('15A) fu6e in

the under hoodtuse/ relaybox.
ngpaif shorl in the wire

betwoen thc br.k6 3whch and
the HoRN l't5 A) tuse.
R.placo the HORN{7.5Al tuse.

bgtw6cn the brrke iwitch and
thc HORN115Altuse.
Inspoci tho b.ake switch lsoe
Boctionl9l.
Check lor an op.n in th wiro
IEKSWlin6l:
1. Depressthe brakepedal.
2. Measurevoltage betwoen
ECM/PCN4
connectorterminals
A9 and D5 with the brakepedal
depressed.
ECM,/FCMCONNECTORS
A t32P)
1 2 t I
6
8 I
1 2 1 3 1 4 't5 l6 1 ' l8 t9 20
22
25
27
2A
30
Rop.il open in the wi.6 botween

tha ECM/PCMlDs) rnd thc b.ako
lwitch,
8r.ke 3witch 3ignal ia OK.
11-134
BKSW
IGRN/
WHT}
D tl6Pl
taRnu
10
tl
23
21
13 t4 15
10 1 1
12
16
Wir sid6 of lemale terminals
PowerSteeringPressureIPSP)Switch Signal(USAI
This signalsthe ECM/PCMwhen the power steeringloadis high.
ECM/PCMCONNECTORS
lNpction of PSP3witch rignal.
Ch.d( for .n op.n in the wi.. (PSP

SW lin.l:
1. Turn the ignitionswitchON {ll}.
2 . M e a s u 1 6v o l t a g e b e t w e e n
E C M / P C Mc o n n e c t o rt e r mi '
n a l s A 9a n dC ] 6 .
Wire side of femalo terminals

Chockfor .n opn in lhe wire (PSP
SW linol:
2. Disconnect
the PSPswitch2P
connecror,
3. Turn the ignitionswitchON lll).
4. At the harnessside, connect
the PSPswitch 2P connector
t e r m i n a l sN o . 1 a n d N o . 2
with a jumperwire.
Ag andC16.
PSPSW]TCH2PCONNECTOB
PSPSWtcBf{l
JUMPER
T-1 rJJ
w r F E- 2 /
GND IBLKI
Wir sid6 of temale terminals
Ch6ck thc opo.ation ot th6 PSP

rwhch;
1. Stanthe engine
2 . T u r n s l e e r i n gw h e e l t o I u l l
lock.
EC 4,/PCMconnectorterminals
Ag and C'|6.
Bepair opon in the wire

betwocn th6 ECM/PCMlcl6l
and the PSPswitch.
Ropeir open in BLK wir
btween the PSP 3wiich .nd
G101.
ls there bafteryvoltage?
PSP .whch tignal i3 OK.
{ T op a g e1 1 - 1 3 6 )
(cont'd)
1 1- 1 3 5
ldle Control System
(PSPISwitch
PowerSteeringPressure
Signal(USA)(cont'dl
(Frompage11-135)
C h e c kt o r s h o . t i n t h 6 P S P
switch:
from the PSPswitch.
4 . M e a s ur e v o l t a g e b e t w e e n
E C M / P C l vc lo n n e c t o rt e r m i n a l sA 9 a n dC 1 6 .
ECM/PCMCONNECTORS
Checkfor a shon in the wir6 {PSP

SW linel:
connectorterminal
C16.
ls therecontinuity?

PCM and recheck.lf p.escribed
voltage is now available,replace
11 - 1 3 6
9 10
1 t 12 13 14 15 1 6 1 7 18
23 21 25
30
PSPSW {GRN}
Rep.ir short in th6 wire between

the ECM/PCM{C16)and rhe PSP
switch.
\-
AutomaticTransaxle(CW) GearPositionSignal(D16Y5engine)
s inE or E position.
T h i ss i g n a l st h e E C Mw h e nt h e t r a n s m i s s i oi n
Check the ope.ation of th A/T

gear position switch:
2. Observethe A"/Tshift position
indicatorand selecteach posi
tronseparately.
Seethe A/T g6ar position indicator inspection{seesection 141.
ECMCONNECTORS
Ch6ckfor a short in ihe wir (ATP

NP linel:
2. Disconnect
the 14Pconnector
from the gaugeassembly.
lrom the TCM.
5. MoasurevoltagebetweenECl/l
c o n n e c t o tre r m i n a l sA 9 a n d
Wire sideof Iemaleterminals
ATP NP
{LT GRN)
c29.
ls thereapprox.5V?
Checklor .n open in th wiro IATP

NP linel:
2. Reconnect
the l4P connector
to the gaugeassembly.
3. Reconnect
the 26Pconnector
to the TCM.
4. Startthe engine.
5 . M e a s u r ev o l t a g e b e t w e e n
ECM connectorterminalsA9
a n d C 2 9w i t h t h e t r a n s m i s sion in E and E position.
Checkfor a shon in the wire IATP

NPline):
2. Disconnectthe ECM connec'
t o rC ( 3 1 P ) .
b o d y g r o u n da n d E C Mc o n
nectorterminalC29.
ls therecontinuity?
9 10
1 1 12 13 1 a 1 5 16 1 7 18
23 21
29 30
ATPI N P
I
ILT GRNI

the EcM {c29)and rhe gau96
assemblv.

and recheck.ll prescribadvoltege is now available,replacethe
originalECM.
(Topage11-138)
(cont'd)
1 1-137
ldle Control System

AutomaticTransaxle(CWl GearPositionSignal(D16Y5engine)(cont'd)
( F r o mp a g e1 1 - 1 3 7 )
-
l s t h e r e l e s s t h a n 1 . 0V ?

btween the ECM lc29l and
the gaugaa!3ombly.
between the gaugo assembly
rnd the A/T gear position
switch.
Checkfor a short in the wire IATP

NP linel:
connectorterminalsA9 and C29
with the transmission
in gear.
Wire side ol female torminals

A/T gear po6ilion signel is OK.
11 - 1 3 8

ECM(C291and gauge assembly.
ATP NP
ILT GRNI
ClutchSwitchSignal(Dl6Y5engine(M/Tll
This signalsthe ECMwhen the clutchis engaged.
Inapction of clutch .witch signal.
ECM COITNECTORS
A t32Pl
LGl IBRN/BLK}
Ch.ck for rn opcn in the wiro

(CI..SW
lin.l:
1. Turnthe ignitionswitchoN (lll.
A9.
Wire sid6of femaleterminals
ls thereapprox.5V?
(REDI
Checkth. clutch 3witch:

trom the clutch switch.
4. MeasurevoltagebtweenECM
A9.
ls thereapprox.5V?
Chock tor an opcn in the wiro

(CLSWlinel:
1. Depressthe clutchpedal.
2. MossurevoltagebetweenECM
connectortermin6lsC29 and
A9.
Check lor a shorl in tha wire

(CLSWlinel:
2. Disconnectthe EcM connector C (31P)fromthe ECM.
3. Checklor continuity between
ECM connectorterminal C29
and body ground.
9 't0
t t l 2 ! 3 1 a l 5 t 6 l 7 1E
cLsw
(REDI
Ropairshort in the wiro botwe.n

tho ECM {C29} rnd tho clutch
swhch.
{To page11-140}
Subititute a known-good ECM

and rcch6ck. ll pGacribcd vohrge
h now availabla,replacothe otiginrl ECM.
{cont'd)
11-139
ldle ControlSystem
ClutchSwitch Signal(Dl6YSengine(M/Tl) (cont'dl
(Frompage11,139)
CLUTCHSWITCH2P OONNECTOR
ls voltagelessthan '1.0V?
Chockthg clutch switch:

Irom the clutch switch.
the clutch switch connector
terminalsNo. 1 and No.2 with
the clutch pedaldepressed.
Terminalsideof male
terminals
-
Adiu.t the clutch switch.

Roplecothe clutch .witch.
CLUTCHSWITCH2P CONNCCTOFlcillTl
r-+-r
Checktor an opon in the wiro:
clutch switch connectorterminal No. 1 and body groundwith
the clutchpodaldepressed.
ls there approx. 5 V?
R.prir open in BLKwira batwaon

th. clutch 3witch snd G/O1.
Outch 3witch signal i3 OK.
11-1 4 0
LJ_J
clsw
(REDI 1;\
Y
Wire side of female
terminals
Rcpril opon in the wirc betwocn
th6 EcM lc29) .nd tha clutch
switch.
ldle SpeedSetting
Inspection/Adiustment
'96,'97 D16Y5,'96-'98Dt6Y8engine
{M/T}
NOTE:
. B e f o r es e t t i n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g
items:
- The MIL has not beenreponedon.
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCVsystem
o ( C a n a d aP) u l l t h e p a r k i n gb r a k el e v e r u p . S t a n t h e
engine.then checkthat the headlightsare off.
'1.
Adjustthe idle speed,if necessary,

by removingthe
cap and turningthe idle adjustingscrew.
NOTE: After adjustingthe idle speed in this step,
recheckthe ignitiontiming (seesection23).
lf it is out of spec,go backto step4.
IDLE
Startthe engine.Hold the engineat 3,000rpm with

no load {transmissionin neutral)until the radiator
Disconnect
the IACvalveconnector.
Turn the ignitionswitchOFF.

7 . Reconnectthe 2P connectoron the IAC valve,then
do the ECMresetprocedure.
Restartand idle the enginewith no-loadconditions
for one minute,then checkthe idle speed.
) u l l t h e p a r k i n gb r a k el e v e r u p .
N O T E : ( C a n a d aP
then
checkthat the headlightsare
Startthe engine,
off.
ldle speed should be:
670 t 50 rpm {USA}
750 t 50 rpm lcanadal
ldle the enginefor one minutewith headlights(Low)
ON.and checkthe idlespeed.
lf the enginestalls,restartthe enginewith the accelStabilizethe rpm at

eratorpedalslightlydepressed.
1,000,then slowly releasethe pedaluntil the engine
idles.
ldl8 spd should bo:

750 I 50 rpm
1 0 . T u r n t h e h e a d l i g h t so f t . l d l e t h e e n g i n ef o r o n e
minute with heaterfan switch at Hl and air conditioner
on,thenchecktheidlespeed.
Checkidlingin no-loadconditions:headlights,
blower
fan, rear defogger,radiatorfan. and air conditioner
are not operating.

8101 50 rpm
ldl 3pdshould be:

il50 t 50 rpm
NOTE:lf the idle speed is not within specification,

(cont'd)
seeSymptomCharton page 11-46.
11-141
ldle ControlSystem
ldle Speed Setting (cont'd)
'96, '97 Dt6Y5
engino {CvT), '96-'98 Dl6Y8 engine lA/T)
rnd '96-'98 D16Y7engine
D16Y5,D16Y8engine:
Adjustthe idle speedusing a HondaPGM Testerif possible.lf not, usethe followingprocedure:

NOTE:
. Leavethe IACvalveconnected.
. B e f o . es e t t i n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g
items:
- The MIL hasnot beenreportedon.
- l g n i t i o nt i m i n g
- Sparkplugs
- Air cleaner
- PCVsystem
1.
no load (A/T in N or E position, M/T in neutral)
until the radiatorfan comeson, then let it idle,
Checkthe idle speedwith no-loadconditions:headlights,blower fan, rear defogger,radiatorfan, and
air conditionerare not operating.
Dl6Y7 engine:
NOTE:When you removethe ACL housing,do not
disconnectthe IAT sensorconnector.
ldlc speed should be:

USA:
Dl6Y5 engine {CVT),D16Y7engine (A/T). Dl6Y8
.ngino lA/T):
700 i 50 rpm (in S or p position)
Dl6Y7 engine{M/T):
670 I 50 rpm
Crnada:
D15Y8engine,D16Y7engine:
MIT
AIT
750t 50 rpm
750i 50 rpm {in E or E position)
Adjustthe idle speed,if necessary,

by removingthe
c a p a n d t u r n i n gt h e i d l e a d j u s t i n gs c r e w 1 / 2 - t u r n
clockwiseor counterclockwise.
A i t e r t u r n i n g t h e i d l e a d i u s t i n gs c r e w 1 / 2 - t u r n ,
checkthe idle speedagain.lf it is out of spec,turn
the idle adiustingscrew1/2-turnagain.
NOTE: Do not turn the idle adjustingscrew more
than 1/2-turnwithout checkingthe idle speed.
l d l e t h e e n g i n e f o r o n e m i n u t e w i t h h e a t e rf a n
switch at Hl and air conditioneron, then checkthe
idle soeed.
MN
810t 50 rpm
A/T. CVT 8 1 0 1 5 0 r p m ( i nE o r E p o s i t i o n )
NOTE:
. Do not turn the idle adjustingscrewwhen the air
conditioneris on.
t lf the idle speed is not within specification,
see
SymptomCharton page 11-46.
11- 1 4 2
Inspection/Adiustmeni
lf necessary.adjust the idle speed. by removing the

c a p a n d t u r n i n g t h e i d l e a d j u s t i n gs c r e w .
'98 D16Y5engine(M/T)
NOTE:Beforesettingthe idle speed,checkthe followIng trems;
- The MIL hasnot beenreportedon.
- S p a r kp l u g s
- Aircleaner
- PCVsystem
After adjusting the idle speed recheck the ignition

timing (see section 23). lf it is out of spec, go back
to step 4.
|DLE
1 . Startthe engine.Hold the engineat 3,000rpm with

no load (transmissionin neutral)until the radiator
2.
Disconnect
the IACvalve2P connectorand the EVAP
purgecontrolsolenoidvalve2Pconnector.

7 . Reconnectthe 2P connectorsto the IAC valve and
the EVAPpurge controlsolenoidvalve,then do the

ECMresetprocedure.
8 . Restartand idle the enginewith no-loadconditions
for one minute,then checkthe idle speed.
EVAPPURGE
CONTROL
SOLENOIDVALVE
lf the enginestalls,restartthe enginewith the acceleratorpedalslightlydepressed.Stabilizethe rpm at

1,000,then slowly releasethe pedaluntil the engine
idles.
Checkidlingin no-loadconditions:
headlights,
blower
fan, rear defogger,radiatortan, and air conditioner
are nor operalrng.
450 I 50 rpm
ldle speedshouldbe: 6701 50 rpm

NOTE:lf the idle speed increasesto 810 t 50 rpm,
this meansthe EVAPsystemis purgingthe canister.
T o s t o p t h e p u r g i n gt e m p o r a r i l yr,a i s et h e e n g i n e
speed above 1,000rpm with the acceleratorpedal,
then slowly releasethe pedal.
l d l e t h e e n g i n eI o r o n e m i n u t ew i t h h e a d l i g h t s
(Low)ON, and checkthe idle speed.
ldle speedshouldbe:
750 I 50 rpm
1 0 . T u r n t h e h e a d l i g h t so f f . l d l e t h e e n g i n ef o r o n e
minute with heatertan switch at Hl and air conditioneron, then checkthe idle speed.
ldle speedshouldbe:
810t 50 rpm
l f t h e i d l e s p e e d i s n o t w i t h i n s p e c i f i c a t i o ns, e e
SymptomCharton page11-46.
{cont'd)
11-143
ldle ControlSystem
ldle Speed Setting (cont'dl
'98 D16Y5engine (CVTI
6.
Removethe cap and turn the idle adjustingscrew

1/2-turnclockwiseor counterclockwise.
IDLE
1.
Afterturningthe idle adjustingscrew'll2-turn,check

the idle speedagain.lf it is out of spec,turn the idle
adjustingscrew1/2-turnagain,
Adjustthe idle speedusing a HondaPGM Testerif possible.lf not, usethe followingprocedure:

NOTE:
. Leavethe IACvalveconnected.
. B e f o r es e t t l n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g
items:
- The MIL hasnot beenreponedon.
- Sparkplugs
- Air cleaner
- PCVsystem
l.
no load (transmission
in N or E position)until the
radiatorlan comeson, then let it idle.
C h e c kt h e i d l e s p e e d u n d e r n o - l o a dc o n d i t i o n s :
head lights,blower fan, rear defogger,radiatorfan,
and air conditionerare not operating.
ldle speed should be: 700 I 50 rpm
.
.
4.
lf the idle speed is within the specification,the

procedureis complete.
lf the idle speedis out of specification,
go to step 4.
l f t h e i d l e s p e e di s 8 1 0 1 5 0 r p m , t h i s m e a n sr h e
EVAPsystem is purging the canister.To stop the
purgingtemporarily,raisethe enginespeed above
1,000rpm with the accelerator
pedal.Slowly release
the pedal,and recheckthe idle speed.
. lf the idle speed is within the specification,the
procedureis complete.
. lf the idle speedis out of specification,
go to step5.
Disconnectthe EVAPpurge control solenoidvalve
2P connector.
SOLENOIDVALVE
1 1-1 4 4
NOTE: Do not turn the idle adlustingscrew more

than 1/2-turnwithoutcheckingthe idle speed.
Turn the ignition switch OFF,Reconnectthe EVAP
purge controlsolenoidvalve 2P connector,then do
the ECMresetprocedure.
Stan the engine.ldlethe enginetor one minutewith
heaterfan switch at Hl and air conditioneron. then
checkthe idlespeed.
ldl6 speed should be:
810 1 50 rpm (in @ or @ position)
l f t h e i d l e s p e e d i s n o t w i t h i n s p e c i t i c a t i o ns, e e
SymptomCharton page 1l-46.
Fuel Supply System

FuelLines
NOTE:Checkfuel systemlines,hoses,tuel filter,and other componentsfor damage,leaksand deterioration,
and replace
if necessarv.
22 N..n
12.2kgl.m, 16lbt.ftl
lD16Y5engin:28N m
2.8 kgl m, 21 lbf.fil
(conr'd)
11-145
FuelSupplySystem
FuelLines(cont'd)
NOTE:Checkall hoseclampsand retightenif necessary.
FUELTUBE/
OUICKCONNECT
FUEL
PUMP
PRESSUBE
NEGULATOR
FUEL
TANK
s\s\s\s\t\
Replace.
Clampin the middle
Clamp in the middle
1 0 - 1 6m m
10.39- 0.63 inl
11-1 4 6
Fittings
FuelTube/Ouick-Connect
Plecautions
Disconnection
Do not smok while working on the ful

@
systom. Kosp open tlamsg away from your work area.
Do not smoke while working on the luel

@
systgm. Keepopen tlames away from your work aroa.
fittings assemblyconnects
The fuel tube/quick-connect
the in-tankfuel pump with the fuelfeed pipe.For removing or installingthe fuel pump and fuel tank, it is necesfittings.
sary to disconnector connectthe quick-connect
Payattentionto tollowing:
1.
R e l i e v feu e lp r e s s u r (es e ep a g e s1 1 - 1 5 01,5 1 ) .
2.
Checkthe tuel quick-connectfittings for dirt, and

cleanif necessary.
3.
Hold rhe connectorwith one hand and pressdown

the retainertabs with the other hand,then pull the
connectoroff.
The fuel tube/quick-connect

fittings assemblyis not
h e a t - r e s i s t a nbt ;e c a r e f u ln o t t o d a m a g ei t d u r i n g
procedures.
weldingor other heat-generating
o The fuel tube/quick-connect

fittings assemblyis not
acid-proof;do not touch it with a shop towel which
was used for wiping batteryelectrolwe.Replacethe
tuel tube/quick-connect
fittings assemblyil it came
into contactwith electroiyteor somethingsimilar.
.
W h e n c o n n e c t i n go r d i s c o n n e c t i n gt h e f u e l t u b e /
q u i c k - c o n n e cf it t t i n g s a s s e m b l y ,b e c a r e f u ln o t t o
Replaceit if damaged.
bendor twist it excessively.
NOTE:
o Be carefulnot to damagethe pipe or other parts,
Do not usetools.
. lf the connectordoes not move,keepthe retainer
tabs presseddown, and alternatelypull and push
the connectoruntil it comesoff easilv.
. Do not removethe retainerfrom the pipe; once
removed,the retainermust be replacedwith a
new one.
LOCKINGPAWL
quick-connect
A disconnected
fittingcan be reconnected,
but the retaineron the mating pipe cannot be reused
once it has been removed from the pipe. Replacethe
retainerwhen
! Replacing
the fuel pump.
. Replacingthe tuel feed pipe.
. lt hasbeenremovedfrom the Dioe.
. lt is damsged.
ACCESS
PANEL
RETAIiIERTAA
CONNECTOR
Pressdown.
Checkthe contactareaof the pipe for dirt and damage.

. lf the surfaceis dirty,cleanit.
. lf the surface is rusty or damaged,replacethe
fuel pump or fuel feed pipe.
PIPE
(cont'd)
11-147
FuelSupplySystem
FuelTube/Ouick-Connect
Fittings(cont'dl
5.
To prevent damage and keep out toreign matter,

c o v e r t h e d i s c o n n e c t e dc o n n e c t o ra n d p i p e e n d
with plasticbags.
Connection
Do not smoke while working on the fuel
@
systom. Keepopen flames away lrom your work ars!.
1.
Checkthe pipe contact area for dirt and damage.

and cleanif necessary.
CONTACTAREA
PLASTICBAGS
Insert a new retainer into the connector if the retainer

is damaged, or after
. replacing the fuel pump.
. replacing the fuelfeed pipe.
. removing the retainer from the pipe.
NGw RETAINER
(lnsertinto
the connector.)
11 -1 4 8
Beforeconnectinga new {uel tube/quick-connect

fitting
assembly,removethe old retainerfrom the matingpipe.
4.
Make sure the connection is secure and the pawls

are firmly lockedinto place;checkvisuallyand by
pullingthe connector.
With the
tabs pulled
apan,romove
and discardthe
retainer
RETAIiIER
New FUELIUBE/
OUICK4ONNECT
FTTTINGASSEMALY
3.
Reconnectthe bafterynegativecable.and turn the

i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r
a b o u t t w o s e c o n d s .a n d f u e l p r e s s u r ew i l l r i s e .
Repeattwo or three times, and checkthat there is
no leakagein the tuel supplysysten..
Align the quick-connect

fittings with the pipe, and
align the retainerlockingpawls with the connector
grooves.Then pressthe quick-connect
fittingsonto
the pipe until both retainerpawls lock with a clicki n gs o u n d .
NOTE:lf it is hard to connect,put a small amount
of new engineoil on the pipe end.
Connectionwith new reiainer:
I
11-149
FuelSupplySystem
SystemDescription
The fuel supply system consistsof a fuel tank, in-tank
high pressurefuel pump, PGM-Flmain relay,fuel filter,
fuel pressureregulator.fuel injectors,and fuel delivery
a n d r e t u r nl i n e s .T h i s s y s t e md e l i v e r sp r e s s u r e - r e g u latedfuel to the fuel injectorsand cuts the fuel delivery
w h e nt h e e n g i n ei s n o t r u n n i n g .
Inspeqtion
1.
Relievefuel pressure.
Removethe servicebolt on the fuel filterwhile holding the banjo bolt with anotherwrench.Attachthe
specialtool.
FuelPressure('96model)
Relieving
Beforedisconnectingfuel pipes or hoses,releasepressure from the system by looseningthe 6 mm service
bolt on top of the tuel filter.
FUEL
PNESSURE
GAUGE
07405 - 0040001
FUELPRESSURE
AoAPTER,6x15mm
07(}6 - 00{0304
Do not smoke while working on the fuel system,

Keep open flames or sparks away lrom your work
area.
. Be suie to relieve fuel pressurewhile the ignition
switch is off,
'1. Write down the frequenciesfor the radio's preset
buttons.
2. Disconnectthe batterynegativecablefrom the battery negativeterminal.
3 . R e m o v et h e f u e l f i l lc a p .
4. Use a box end wrenchon the 6 mm servicebolt at
l a n j ob o l t
t h e f u e l f i l t e rw h i l e h o l d i n gt h e s p e c i a b
with anotherwrench.
5. Placea rag or shoptoweloverthe 6 mm servicebolt.
6. Slowly loosenthe 6 mm servicebolt one complete
turn.
NEGULATOB
Startthe engine.Measurethe fuel pressurewith the
engineidling and the vacuumhoseof the fuel presfrom the fuel pressure
sure regulatordisconnected
regulatorand pinched.lf the engine will not start,
turn the ignition switch ON (ll), wait for two seconds, turn it off, then back on again and read the
fuel pressure,
Pressureshould bs:
260 - 310 kPa (2.7- 3.2 kgif/cm',38 - 46 psil
4.
Reconnectvacuumhoseto the fuel pressureregulator.

Pressureshould b:
200 - 250 kPa l2-0-2.5kgllcm2,28 - 36 psil
lf the fuel pressureis not as specitied,first checkthe
It the fuel pump is OK.
fuel pump (seepage 11-'156).
checkthe following:
o A fuel pressuregaugecanbe attachedat the 6 mm

servicebolt hole.
. Alwavs reolacethe washer betweenthe service
bolt and the specialbanjo bolt wheneverthe service bolt is loosened.
. R e p l a c ea l l w a s h e r s w h e n e v e r t h e b o l t s a r e
removed.
11 - 1 5 0
l f t h e l u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d ,
inspectfor:
- Pinchedor cloggedfuel returnhoseor line.
- Faultyfuel pressureregulator(seepage 1l-'lg).
inspect
lf the fuel pressureis lowerthan specified,
for:
- Cloggedfuelfilter.
- Faultyfuel pressureregulato.(seepage11-154).
- Fuelline leakage.
FuelPressure('97and later modelsl

Rlioving
Betoredisconnecting
fuel pipes or hoses,releasepress u r e f r o m t h e s y s t e mb y l o o s e n i n gt h e 1 2 m m b a n j o
bolt on toD of the fuel filter.
Inspec'tior
l
Relievetuel pressure.
2.
Removethe 12 mm banio bolt from the fuel filter

w h i l e h o l d i n gt h e f u e l f i l t e r w i t h a n o t h e rw r e n c h .
Attach the specialtools.
Do noi smok while working on tho tuel system,

Keep open flames or sparks away from your work
area.
Bo surs to relieve tuel pressurewhile the ignition
switch is oft.
1.
Write down the frequenciesfor the radio's preset

buttons,
FUELPRESSURE
ADAPTERBOLT,12 mm
tgflDE - PD6- 0101
Disconnect
the batterynegativecablefrom the battery negativeterminal.
Removethe iuel fill cap.
4.
Use a box end wrench on the 12 mm banjo bolt at

the fuel filter while holdingthe fuel filter wirh another wrencn.
REGULAIOA
Placea rag or shoptowel overthe 12 mm banjobolt.
Stan the engine.Measurethe fuel pressurewith the

engineidling and the vacuum hoseof the fuel pressure regulator disconnectedfrom the fuel pressu.e
regulatorand pinched,It the enginewill not start,
turn the ignition switch ON (ll), wait for two seconds, turn it off, then back on again and read the
fuel pressure.
Slowfy foosenthe 12 mm banjo bolt one complete

IUIN.
12 mm EANJO
BOLT
Pressursshould be:
260 - 310 kPa (2.7- 3.2 kgf/cm,, 38 - '15psil
4.
Reconnectvacuumhoseto the fuel pressureregulator.

Pressureshould bo:
200 - 250 kPa (2.0- 2.5 kgf/cm,, 28 - 35 psi)
N O T E :R e p l a c ea l l t h e w a s h e r sw h e n e v e rt h e 1 2
mm banjo bolt is loosenedor removed.
lf the fuel pressureis not as specified,tirst checkthe

fuel pump (seepage 1'1-156).lf rhe fuel pump is OK,
checkthe following:
.
l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d ,
inspectfor:
- Pinchedor cloggedfuel returnhoseor line.
- Faulty fuel pressureregulator(see page 111541.
. lf the fuel pressureis lowerthan specified.inspect
for:
- Cloggedtuelfilter.
- Faultyfuel pressureregulator(see page 11154).
- Fuelline leakage.
11-151
FuelSupplySystem
Fuellnjectors
Replacement
!@
Do not smoke when working on the luel system. Keep open flames away lrom your wotk alea.
1, Relievethe fuel pressure(seepages11-150,151),

the connectorsfrom the fuel iniectors(D16Y7engine:Removethe air cleaner).
2. Disconnect
3. Disconnect
the vacuumhosesfrom the fuel pressureregulator.Placea shop towel overthe fuel returnhose,then disconnectit from the fuel pressureregulator,Disconnectthe vacuum hosesand 2P connectorfrom the EVAPpurge
controlsolenoidvalve(D16Y5,D16Y8engine).
4. Removethe retainernuts on the fuel rail.
the fuel rail.
5. Disconnect
6. Removethe fuel iniectorsfrom the intakemanifold.
D16Y7engine:
D15Y5,D16Y8engine:
NOTE:lllustrationshowsD16Y8engine.
D 1 6 Y 5e n g i n ei s s i m i l a r .
12 N.m
11.2kgf.m,
8.7 tbf.ft)
'r2N.m
kg{.m,
11.2
8.7tbtfr)
ffi ffi
g
V
EVAP
PURGECONTROL
SOLENOID
VALVE
O-RING
Replace.
CUSHION
RING
Replace.
ffi ffi
E
V
SEAL
RING
Replace.
7.
8.
9.
10.
Slidenew cushionringsonto the fuel injectors.

Coatnew O-ringswith cleanengineoil, and put them on the fuel injectors.
Insertthe fuel injectorsinto the fuel railfirst.
Coatnewsealringswith cleanengineoil, and pressthem intothe intakemanifold.
11 -1 5 2
E
Y
O.RING
Replace.
CUSHION
Replace.
SEAL
RING
Replace.
11. To preventdamageto the O-rings,installthe tuel injectorsin the fuel rail first, then installthem in the intakemanifo ld.
't2. Installand tightenthe retainernuts.

1 3 . Connectthe vacuum hosesand fuel return hoseto the fuel pressureregulator.Connectthe vacuum hosesand 2P
connectorto the EVAPpurgecontrolsolenoidvalve(D16Y5,D16Y8engine).
1 4 . Installtheconnectorson the fuel injectors(D16Y7engine:Installthe air cleaner),
Turn the ignitionswitchON (ll),but do not operatethe starter.Afterthe fuel pump runsfor approximately
two seconds,
the fuel pressurein the tuel line rises.Repeatthis two or threetimes,thencheckwhetherthereis anyfuel leakage.
11 - 1 5 3
FuelSupplySystem
FuelPressureRegulator
Testing
Replacement
Do not smoke during the test. Keep open

!@
tlamesaway lrom your work area.
Do not smoke while working on fuel sys@

tem. Keepopsn llame away from your work area.
1.
Attachthe specialtool(s)to the servicepon on the

f u e lf i l t e r( s e ep a g e s1 1 ' 1 5 01, 5 1 ) .
1.
Placea shoptowel underthe fuel pressureregulator,

151).
then relievefuel pressure(seepages11-150,
Pressureshould be:
260 - 310 kPa {2.7- 3.2 kgf/cm', 38 - 46 psi}
{with the fuel pressureregulator vacuum hose
disconnectedand pinched)
2,
the vacuumhoseand fuel returnhose.

Disconnect
3.
Removethe two 6 mm retainerbolts and the fuel

pressureregulator.
CLAMP
FUEL
PRESSURE
TOR
FUELPRESSURE
REGULATOR
12 N.m
(1.2kg{.m,
8.7 tbtft)
2.
3.
R e c o n n e ctth e v a c u u mh o s e t o t h e f u e l p r e s s u r e
regulator.
Replace.
Checkthat the fuel pressureriseswhen the vacuum

hosefrom the fuel pressureregulatoris disconnected
a g aIn .
l f t h e f u e l p r e s s u r ed i d n o t r i s e . r e p l a c et h e f u e l
pressureregulalor.
Apply cleanengineoil to a new O-ring,and carefully
installit into its properposition.
I n s t a l lt h e f u e l p r e s s u r er e g u l a t o ri n t h e r e v e r s e
orderof removal,
11-1 5 4
Fuel Filter
RoplEcement
r!@
Do not smoke while working on fuel systsm. K6op
open fbme away from your work area.
While roplacing th tusl filtar, be careful to keop a
safo distance betwssn battGry tgrminals and any
tools.
,96 MODEL:
12 mm
BAt{JO
AOLT
33 N.m
{3.4 kg{.m,
25 rbf.ftl
T h e f u e l f i l t e r s h o u l d b e r e p l a c e dw h e n e v e rt h e f u e l
pressuredrops belowthe specifiedvalue 1260- 310 kPa
12,7- 3.2 kgtlcm,,38 - 46 psi)with the fuel pressureregu l a t o rv a c u u m h o s e d i s c o n n e c t e ad n d p i n c h e d la f t e r
making sure that the tuel pump and the fuel pressure
regulatorare OK,
' 1 . Place
a shop towel underand aroundthe fuel filter.
Relievefuel pressure{seepages11-150,151).
9.8 N.m
.0 lg{ m,
R e m o v et h e 1 2 m m b a n j o b o l t a n d t h e t u e l f e e d
pipetrom the fuel filter,while supponingit with the
anotherwrench.as shown,
7.2rbt.ftt
(3.8ksf.m,
27 tbf.ftl
Removethe tuel filter clampand fuel filter.

I n s t a l l t h e n e w f u e l f i l t e r i n t h e r e v e r s eo r d e r
removal,and notetheseitems:
. When assembling.use new washersas shown.
. C l e a nt h e f l a r e d j o i n t o t h i g h p r e s s u r eh o s e s
thoroughlybeforereconnecting
them.
,97 AND LATERMODELS:
12mm
BANJO
BOLT
33 N.m
(3.4*gf.m,
25 tbf.ftl
37 N.m
13,8kgt m,
27 tbtftl
N.m
ll.0 kg(.rn,
1.2 tbt.trl
11 - 1 5 5
FuelSupplySystem
FuelPump
Testing
Rolacement
Do not smoke during the test. Keep oPen

@
tlame away trom you. work atea.
Do not smoke while wotking on luel 3Y3!!@

tem, Koopopen tlams away from your work area.
lf you suspecta problemwith the fuel pump, checkthat the

fuel pump actuallyruns;when it is ON (ll),you will hear
somenoiseif Vouholdyour earto the fuelfill portwith the
fuel fill cap removed,The fuel pump should run for two
secondswhen ignitionswitchis first turnedON (ll).lf the
fuel pump does not make noise,checkit as follows:
1.
Removethe seatcushion(seesection20).
2.
Removethe accesspanelfrom the floor.
1.
2.
3.
Make sure the ignition switch is OFF,then disconnectlhe fuel tank2P connector.
4.
Connectthe PGM-Flmain relay7P connectorterminal No. 4 and No. 5 with a jumperwire.
ACCESSPANEL
5.9N-m
10.6kgt m.
{.3 tbr.ftl
{C,a,|3)
PGM-FIMAINRELAY7PCONNECTOR
\,
FUELPUMP
{YEL/
GRNI
IGN 1
(YEL/GRNI
JUMPERWIRE
Wiresideof temaletorminals
Checkthat batteryvoltageis availablebetweenthe

fuel pump connectorterminalNo. 1 and body ground
whenthe ignitionswitchis turnedON (ll).
CONNECTOR
{c56sl
tr:
I
I
l----r
El d,
Y
FUELPUMP
(YEL/GRNI
Wire side of
female terminals
3.
Disconnect
the 2Pconnectorfrom the tuei pump.
4.
Removethe tuel pump mountingnuts.

Removethe fuel pump from the fuel tank,
checkthe tuel pump

lf batteryvoltageis available,
ground.lf the groundis OK,replacethe fuel pump.
lf there is no voltage.checkthe wire harness(see
p a g e1 ' l - 1 5 8 ) .
1 1 - 15 6
Installpartsin the reverseorderof removal.
PGM-FIMain
Relay
Descliption
The PGM-Flmain relay actuallvcontainstwo individual
relays.This relay is locatedat the right side of the cowl.
One relayis energizedwheneverthe ignitionis on which
suppliesthe batteryvoltageto the ECM/PCM,power to
the fuel injectors,and power for the secondrelay.The
secondrelayis energizedfor two secondswhen the ignition is switchedON (ll),and when the engineis running,
to supplypowerto the fuel pump.
FGM.FI
MAITI RELAY
RelayTesting
NOTE:
. It the enginestartsandcontinues
to run,the PGM-Fl
.
main relayis OK.

U s et h e t e r m i n anl u m b e r sb e l o w ;
ignorethe terminalnumbersmoldedinto the relay.
'1. Removethe PGM-FImain relay.

2. Attachthe batterypositiveterminalto the No. 2 terminal and the batterynegativeterminalto the No. 1
terminal of the PGM-Flmain relay.Then checkfor
continuitybetweenthe No. 5 terminaland No.4 terminalof the PGM-FImain relay.
. lfthere is continuity.go on to step3.
. lf there is no continuity.replacethe PGM-Flmain
relayand retest. No. 2
No.3
No. 1
FUELPUMP
No.
To lGN.
To GROUND
No.7
N o , 5 No. 6
To BAT @
To ECM,/PCM
{A1'1,A24}
To ST. SWITCH
To ECM/PCM(A
To FUELPUMP
Attachthe battervDositiveterminalto the No. 5 terminal and the batterynegativeterminalto the No, 3
terminalof the PGM-FImain relay.Then checkthat
there is continuitybetweenthe No, 7 terminaland
No. 6 terminalof the PGM-FImain relav.
. lf thereis continuity,go on to step4.
. lf there is no continuity,replacethe PGM-Fimain
relayand retest.
Attachthe batterypositiveterminalto the No. 6 terminal and the batterynegativeterminalto the No. 1
terminalof the PGM-Flmain relay.Then checkthat
there is continuitybetweenthe No. 5 terminaland
No. 4 terminalof the PGM-Fimain relay.
. lf thereis continuity,the PGM-Flmain relayis OK.
ll the fuel pump still does not work,go to Harness
Testingon the nextpage.
. lf there is nocontinuity,replacethePGM-Flmain
relay and retest.
{cont'd)
11-157
FuelSupplySystem
PGM-FIMain Relay(cont'dl
Circuit Troubleshooting
-
Engine will not siart.

Inspection ot PGM-FI main
relay and relay harness,
PGM.FIMAINRELAY7PCONNECTOR
lca,Bl
Check for an open in the wiro

IGNDline):
2. Disconnectthe PGM-FImain
relay7P connector.
3- Checkfor continuitybetween
the PGM-FImain relay7P con'
No.3 and body
nectorterminal
ground.
the PGM-FIm.in relay and G101.
Checkfor an open or short in the

wire (BATlinel:
PGM'Flmain relay 7P connector
terminalNo. 7 and body ground.
-
Repair open or short in tho

wire btw6n th6 FGM-FImain
r6lsy and the Fl E/M 115Al
fu3o.
ReDlecothe Fl E/M l'15Alfus6
in th6 undr-hood tuso/r.lay
box.
Checkfor an open or short in th6

wir (lGl line):
2. Measurethe voltage between
the PGM-Flmain relay7P connectorterminal
No.5 and body
ground,
-
ls there battery voltage?

-
Checklor an open 01 short in the

wi.e {STSline):
1. Turnthe ignitionswitchto the
START(lll) position.
NOTE:
. M/T: Clutch pedal must be
depressed.
. A"lT:Transmissionin E or
E position.
2, Measurethe voltage between
t h e P G M - F Im a i n r e l a y 7 P
connectortrminalNo, 2 and
body ground.
( T op a g e1 1 - 1 5 9 )
11 - 1 5 8
Ropair open o1 short in thg

wire bnrvonth PGM-FImain
r6layand the No. 13 FUEL
PUMP{15A} tusc.
Roolac the No. 13 FUEL
PUMP115A) fus6 in th underdash fuso/rolay box.
sls IBLU/WHTI
2
3
a 5 E 7
(Frompage11-158|
PGM-FIMAIN RELAY7P CONNECTOR

IC'4|II
-
Fcprir opono.3hon in tho

wirc baaw6.n the ftiu.Fl main
6lry .nd tho No. 31 STARTER
SIGNAL17.5A tuso.
Roplecotho No. 31 STARTER
SIGNAL {7.5 A} fuse in tho
undor-dalh fu3o/rclaybox.
Ch.ck to. an op6n in thG wir.

IFLRlin6l:
2. Oisconnectthe ECM/PCMcon,
nectorA (32P).
the PGM-FImain .elay 7P connectorterminalNo, 1 and ECN4/
PCMconnectorterminalA16.
FLR
rcRNNEL]
1
o
FLR
IGRN/YEL)
I
2
12 t l
ECM/PCMCONNECTOR
A t32Pl
t 5 l 6 t 7 ta t 9 20l,/
2A 4 l 3 0 l /
2t
21
ll
22
23
2a
Wirosideof lemalelerminals
Raprir op6n in the wire bgtwaen
t h o E C M / P C Ml A 1 6 ) a n d i h 6
PGM-FImain ..lay.
PGl (BLKI
Chack for an open in the wiro3

{lGPl. lGP2line3l:
1. Reconnect
the ECM/PCM
connectorA (32P).
2. Reconnectthe PGM-Flmain
relay connector.
4. Measurvoltage between
ECM,PCMconnectorterminals
A 1 1 a n d A 1 0 ,a n d b e t w e n
A24and A10.
l2 t 3
t 9 20
2A 4
22
z tI r l
30
IGP2
IYEL/BLKI
R.pair opon in th. wi.e betw.n th. ECM/FCM{A11,A24l

.nd thc PGM-FImain lolay.
R.pleo. tho PGM-FImain relay.
FLR
IGRN/YEL)
Ch.ck for sn opon in th. ECM/

PCM:
'1. Turn
the ignitionswitchOFF.
2 . M e a s ur e v o l t a g e b e t w e e n
A16and A10whenthe ignition
switchis firstturnedON (llltor
two seconds.
ls there'1.0V or less?
t5 t6 1 1 tl
12 I t
PGl IELK}
l s o l r l l e l e lr r
2
l a l 5 t6
21
ta l 9 20
2a 30
221 23
11
2a
Sub.titut. ! known-good ECM/

PCM and ..check. lf orcacribod
voltaga ii now rv.il.ble, rcplace
thc origin.l ECM/PCM.
Ch.ck lhe PGM-FI main rel.y

lroo pagc 11.1571.
11 - 1 5 9
FuelSupplySystem
FuelTank
Rsplacement
Do not smokewhile working on fuel system.Keepopanflame away from your work aroa.
Relievethe fuel pressure(seepages11-150,151).

Disconnectthe 2P (C565)and 3P (C564)connectors(96 D16Ygengine{coupe)'97 Dl6Y7 engine(coupe:
KL model,
sedan:KL (LX) model),'97D16Y8engine(coupe:all models,sedan:KL model '98-allmodels):and 6P (C568)connectorl.
5. Disconnect
the hoseand quick-connect
fittings(seepages11-146,147).
6. Jackup the vehicle.and supportit with jackstands.
7. Removethe fuel tank cover('96.'97 model)orthefuel hosejoint protector.
8. Bemovethe drain bolt, and drainthefuel into an approvedcontainer.
9. Disconnect
the hoses(seepage 11-146).
Slidebackthe clamps,then twist hosesas you pull,to avoiddamagingthem,
10. Placea jack,or othersuppon.underthe tank,
11. Removethestrapnuts,and let the strapsfall free.
12. Removethe fuel tank, lf it stickson the undercoatappliedto its mount.carefully pry it off the mount.
13. Installthe drain bolt with a newwasher,thencoatthedrain bolt with Noxrustl24B,Allowthe Noxrustdryfor20 minutes.
14. Installtheremainingpartsin the reverseorderof removal.
1.
2.
3.
4.
BASEGASKET
Replace.
38 N.m
(3.9kgl.m,
28 tbtft)
BASEGASKET
Replace.
WASHER
Replace.
TANK
STRAPS
DRAINBOLT
4t N.m {5.0kgl.m, 36 lbf.ttl
11 - 1 6 0
IntakeAir System
SystemDescription
The systemsuppliesair for all engineneeds.lt consistsof the intakeair pipe,Air Cleaner(ACL),intakeair duct,Throttle
Body {TB),ldle Air Control(lAC)Valveand intakemanitold.A resonatorin the intakeair pipe providesadditionalsilencing
as air is drawn into the svstem.
Dl6Y5, Dl6Y8 angine (M/Tl
YEL/
BLK _
- From PGM-FI
MAIN RELAY
VARIOUS
SENSORS
BLK
IROTARYI ENGINE
IACVALVE COOLANT
D15Y5engine{CWl, D16Y8enginelA/T)' lrutne umrrrolo
- From PGM-FI
I MAIN RELAY
YEL/
BLK
D16Y7sngin:
ORN
BLK/
VARIOUS
SENSORS
8tu
BLK
(ROTARYI
IAC VALVE
RESONATOR
11 - 1 6 1
lntakeAir System
Air Cleaner(ACLI
ThrottleCable
NOTE; Do not cleanthe ACL elementit with compressedair (exceptdry type).
Inspection/Adiustmont
1. Startthe engine.Hold the engineat 3,000rpm with
no load(ly'Tin E or @ position,Mff in neutral)until
the radiatorfan comeson,then let it idle.
2. Checkthat the throttlecableoperatessmoothlywith
no bindingor sticking.Repairas necessary.
3. Checkcable free play at the throttle linkage.Cable
deflectionshouldbe 10- 12 mm l3/8- 1/2in.l.
Dl6Y5,D16Y8engino:
ACL ELEMENT
Normal conditionsi
Replacgair cleanerelement every
30,000milos (48,000kml or 24
months whichovercomes first.
Sova.c conditionr:
(Usenormalschedule
except in dusty conditions)
Replaceevery 15,000
miles (24,000km) or '12months
whichevercomesfirct.
D16Y5.D16Y8engine:
CABLE
DEFLECTION
1 0 - 1 2m m
13l8- 112inl
HOUSING
Dl6Y7 engine:
Dl6Y7 engine:
LOCKNUT
AIUUSTING
DEFLECNON
10-12mm
B l a - 1 1 2i ^ l
ACL ELEMENT
Normrl condhion3:
Replaceair cleanerelementevery
30,000mil6s(48,000
km) or 24
months whichevercomes first.
Sovorocondhion3:
(Usenormalschedule
except
in dustyconditions)
Replace
every'15,000
whichever comesllrsl.
11 -1 6 2
It de{lection is not within specs, loosen the locknut,

turn the adjustingnut untilthe deflectionis as specified,then retightenthe locknut.
With the cableproperlyadjusted,checkthe throttle
valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe throttle valve to be sure it returnsto the idle position
wheneveryou releasethe accelerator
pedal.
lnstallation
'L
Openthe throttlevalvefully.then installthe throttle

, n d i n s t a l lt h e c a b l e
c a b l ei n t h e t h r o t t l el i n k a g e a
housingin the cablebracket.
4.
S e t t h e l o c k n u to n t h e c a b l e b r a c k e t .A d j u s t t h e
adjustingnut so that its free play is 0 mm.
5.
Removethe cablesheathfrom the throttle bracket,

resetthe adjustingnut and tightenthe locknut.
Dl6Y5,D16Y8engin:
D16Y5,D16Y8engine:
CABLE
LOCKNUT
NUT
ADJUSTING
D16Y7ngine:
ADJUSTING
NUT
9.8 N.m
{1.0kgf.m,
7.2 tbt'ttl

no load(A,/Tin E or E position,M/T in neutral)until
the radiatorfan comeson, then let it idle.
Hold the cablesheath,removingall slackfrom the
caore.
11-163
IntakeAir System
ThrottleBody
Doscription
side-drafttype
The throttlebody is eithera single-barrel
{ D 1 6 Y 5D
, 1 6 Y 8e n g i n e )o r a d o w n - d r a f t y p e ( D 1 6 Y 7
engine).The lower portionof the throttlevalve is heated
b y e n g i n e c o o l a n t f r o m t h e c y l i n d e r h e a d .T h e i d l e
adjustingscrewwhich regulatesthe bypassair is located on the top of the throttlebody.
Inspection
1 . C h e c kt h a t t h e t h r q t t l ec a b l e o p e r a t e ss m o o t h l y
without bindingor sticking.
It thereare any abnormalities,
checkfor:
. Excessive
wear or play in the throftlevalveshaft.
. Stickyor bindingthrottieleverat the fully closed
position.
. Clearancebetweenthrottlestop screwand throttle leverat the fully closedposition.
D16Y5,Dl6YB engine:
THROTTLESTOP SCBEW
{Do not adiust.}
D16Y7 engine:
{Do not adiust.)
Replacethe throttlebody it there is excessiveplay in the

throttlevalveshaftor if the shaftis bindingor sticking.
11-1 6 4
Removal
D16Y5,D16Y8engine:
D15Y7engine:
IAT SENSOR
AIF CTEANEF
IACLI
MAP SENSOB
22Nm
12.2*gl.m,
16tbf.ftt
GASKET
Repl6ce.
THROTTLECAALE
NOTE:
. Do not adjustthe throttlestop screw.
o After reassembly,
adjustthe throttlecable(seepage11-162).
. The TP sensoris not removable.
(cont'd)
11 - 1 6 5
IntakeAir System
ThrottleBody(cont'dl
Disassembly
Dl6Y5,Dl6Y8 engine:
2.1 N.m
(0.21kgf.m, 1.5 lbf.ftl
MAP SENSOR
page'1167
Troubleshooting,
TP SENSOR
O-RING
IDLEADJUSTING
SCREW
IAC VALVE
kgf.m,2.5lbtftl
3.5N.m 10.35
D16Y7engine:
2.1 N.m
10.21kgf.rn,
1.5lbt.ft)
11 - 1 6 6
MAP
SENSOR
p6ge11-67
Troubleshooting,
EmissionControlSystem
SystemDescription
ThreeWayCatalyticConverter
The emissioncontrol system includesa Three Way Catalytic Converter(TWC),ExhaustGas Recirculation

{EGR)
system*, PositiveCrankcaseVentilation(PCV)system and
Evaporative
Emission{EVAP)Controlsystem.The emission control system is designedto meet federaland state
emissionstandards.
*: D16Y5engine
Description
The Three Way CatalyticConverter(TWC) is used to
conven hydrocarbons(HC),carbonmonoxide(CO),and
oxides of nitrogen(NOx) in the exhaustgas to carbon
dioxide(CO?),
dinitrogen(Nr)and watervapor.
(TWC)
Dl6Y5, Dl6Y7 engine:
ENGINESIDE
TailpipeEmission
Inspection
Do not smoke during this procodure.Kep
E@
any open flam away from your work area.
1.
Stan the engine.Hold the engineat 3,000rpm with

no load (Ay'T
in E or E position,N4/Tin neulral)until
the radiatorfan comeson. then let it idle.
D16Y8engine:
Checkand, if necessary.adjustthe idle speed (see
p a g el l - 1 4 1 ) .
HOUSING
Warm up and calibratethe CO meteraccordingto the

metermanufacturer's
instructions.
Checkidle CO with the headlights.heater blower,
rearwindow defogger,coolingfan,and air conditioner off.
) u l l t h e p a r k i n gb r a k el e v e r u p .
N O T E :( C a n a d aP
Stan the engine,then checkthat the headlightsare
off.
CO metershouldindicate0.1%maximum.
NOTE:'98 D16Y5engine- lf the idle speedincreases to 810 f 50 rpm, this meansthe EVAPsystemis
purgingthe c8nister.To stop the purgingtemporarily. raisethe enginespeedabove 1.000rpm with the
pedal.then slowly releasethe pedal.
accelerator
(cont'd)
11-167
ThreeWayCatalyticConverter(TWC)(cont'dl
TroubleCode(DTC)PO42O:
Catalystsystemefficiencybelowthreshold.
] P0420 I tne scantool indicatesDiagnostic
Description
This systemevaluatesthe catalyst'scapacityby meansof the HO2S(Primaryand Secondary)
outputduringstabledriving
conditions.lf deterioration
has beendetectedduringtwo consecutive
drivingcycles,the MIL comeson and DTCP0420will
be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the same time as DTCP0420,troubleshootthose DTCSfirst, then
troubleshootDTCP0420.
P0137,P0138:SecondaryHO2S(Sensor2)
P0141:SecondaryH02S (Sensor2) Heater
PossibleCause
. TWC Deterioration
. Exhaustsystemleakage
-
The MIL hes beenreoortedon.

DTC P0420b stored.
Problgmverfficationi
1. Do the ECM/PCMResetProce'
dure.
load (A/Tin E or E position,
M/T in neutral)untilthe radiator fan comeson.
4 . T e s t - d r i v e4 0 - 5 5 m p h f o r
a p p r o x .t w o m i n u t e s .T h e n
deceleratefor at least 3 sec
o n d s w i t h t h e t h r o t t l ec o m
pletely closed. Then reduce
the vehiclespeedto 35 mph,
and try to hold it until the
readiness
codecomeson,
Intelmitlent trilure, ayrlom ia OK

at thi3 timc.
Ch.ck the TWC {seesection9}.

lf nocessary,roplacethe TWC.
1 1 - 16 8
{EGR)System(Dl6Y5enginel
Description
exhaustgasthroughthe EGR
The EGRsystemis designedto reduceoxidesot nitrogenemissions{NOx)by recirculating
valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve,EGRvacuumcontrolvalve,
EGRcontrolsolenoidvalve,ECMand varioussensors.
The ECMcontainsmemoriesfor ideal EGRvalve litts for varyingoperatingconditions.The EGRvalve lift sensordetects
the amountof EGRvalvelift and sendsthe intormationto the ECM.The ECMthen comparesit with the idealEGRvalvelift
which is determinedby signalssentfrom the other sensors,lf there is any differencebetweenthe two, the ECMcuts current to the EGRcontrolsolenoidvalveto reducevacuumaooliedto the EGRvalve.
EGRCONTROL
VALVE
SOLENOIO
cVT.
BLK
EGRVALVELIFTSENSOR
BLK
I
1-16 9
(EGR)System(D16Y5engine){cont'dl
The scantool indicatesDiagnosticTroubleCode(DTC)P0401:Insufficient
flow in the ExhaustGasRecirculation
(EGR)svstem.
DescriDtion
Deterioration(clogging,leakage,etc.)in the EGRline or EGRvalve is detectedby meansof the changesin MAP before
and afterthe operationof the EGRvalve.
It deteriorationhas been detectedduring two consecutivedriving cycles,the MIL will come on and DTCPO4O1
will be
stored.
PossibleCauses
. Clogging,leakagein the EGRline
. FaultyEGRvalve
-
The MIL has been.eoortadon.

DTC P0401b stored.
Problomveriticetion:
2. Connectthe SCSserviceconnector,
3. Testdriveunderthe following
conditions.
- Withoutany electdcalload
- D e c e l e r a t fer o m 5 5 m p h
{88 km/h)for at least 5 sec
onds
Intermittont tlilure, sy3tcm is OK

at thb time.
Cledn th6 intake mrnifold EGR

port with calburetor deana..
Clean the passaginside the
EGR valve with carburetor
cleanerot toplacthe velve.
11-170
The scantool indicatesDiagnosticTroubleCode (DTC)P1491:A malfunctionin the ExhaustGas Recirculation

(EGR)system.
CvT (M/T seepao 11-174):
-
Tha MIL h'3 boan.eDortedon.

DTCP1,191is sto.od.
Probl.m verificstion:
2. Connctthe SCS serviceconnector.
3 . S t a r t t h e e n g i n e .H o l d ! h e
engineat 3,000rpm with no
load (transmissionin E] or E
position) until the radiator fan
comeson.
4. Drivethe vehicleon the road
for approx. 10 minutes.Try to
keepthe enginespeedin the
'1,70O
- 2,500rpm range.
YES
Intermittgnt failure, systom is OK

at thb tirno. Checktor Door conngctions or looaa wire3 at, C144
{EGRvrlvol and ECM,
Ch.ck tor vacuum to the EGR

1. DsconnecttheNo.16hosetrom
th EGRvalve.
2 . C o n n e c ta v a c u u m p u m p /
gaugeto the hose.
3. Stanthe engineand let it idle.
EGRVALVE
LIFTSENSOR
Ch.ck tor a mrlfunction in tho

EGRcomrcl lolonoid v.lv.:
1 . D i s c o n n o ctth e E G Rc o n t r o l
solenoidvalve2Pconnector.
2. Rcheckthe No. 16 hose for
#16 HOSE
l T o p a g e1 1 - 1 7 2 )
PUMP/GAUGE,0-30in.Hg
A973X-fi1 -XXXXX
ls there6ny vacuum?
Check vacuum hose .outing ot

the entirs EGR 3y3tom. lf hose
routing is OK, .eplsce the EGR
control solenoidvrlve.
VALVE
Subrtitute a known-good ECM

.nd rcheck.lf lymptom/indication goar aw.y, r.placa th6 oJiginll ECM.
(cont'd)
11-171
ExhaustGasRecirculation(EGR)System(D16Y5engineGWI (cont'dl
( F r o mp a g e1 1 - 1 7 1 )
#16HOSE
,w;
VACUUM
- 30in.Hg
PUMP/GAUGE,0
A973X-041-XXXXX
*nj-
Check tor a malfunction in the

EGRvalve:
1. Movethe vacuumpump/gauge
to the EGRvalve.
2. With the engineat ;dle,apply
26.7kPa{200mmHg,8.0 in.Hg)
ofvacuumto theEGRvalve.
Doesthe enginestallor run

roughand doesthe EGRvalve
hold vacuum?
Checkthe vacuum routing:

1. Reconnect
tho vacuumpump/
gaugeto the No. 16 hose.
2. Startthe engineand let it idte.
3 . A t t h e E G Rc o n t r o ls o l e n o i d
valve side, connectthe baftery
positiveterminal to the EGR
control solenoidvalve connectorterminalNo,1,
4 . W h i l ew a t c h i n gt h e v a c u u m
g au g e , c o n n e c tt h e b a t t e r y
negativeterminalto the EGF
controlsolenoidvalve2P connectorterminal
No.2.
EGRCONTROLSOLENOIOVALVE
2P CONNECTOR
li;El
E
lo el
Terminalsideol
maleterminals
ls thereapprox.26.7kPa(200
mmHg,8.0 in.Hg)of vacuum
whhin l second?
Checkthe vacuum ho3a:
1. Turnthe jgnitionswitchOFF.
2 . I n s p e ct th e N o . 1 6 a n d N o .1 0
hosestor leaks,restrictionsor
mrsrout|ng.
\
(Topage11-173)
11-172
( F r o mp a g e1 1 1 7 2 )
EGRCONTROLSOLENOID
VALVE2P CONNECTOR
{Cl42I
Checkfor an open in the wire {E
SOLlinel:
from the EGRcontrolsolenoid
the ECMconnector
3. Disconnect
A (32P)Iromthe ECM.
E C M c o n n e c t o tr e r m a n a4l 7
and the EGRcontrolsolenoid
v a l v e2 P c o n n e c t otre r m i n a l
No.2.
Wire side
of female
terminals
ECM
CONNECTOR
A t32Pl
ESOL
IFEDI
ESOL
IREDI
Wire side
oI female
terminals
Repeirop6n in lhe wire b'twen

the EGR control 3olenoid valv6
and the ECM lA?).
Chck tor a short in the wir

(ESOLline):
Checklor continuitybetweenthe
EGRcontrolsolenoidvalve2P con
nectorterminal No. 2 and body
ground,
Repril short in th wi.e betwcen
th EGR control solenoid valve
and the ECMlA7l.
Check for an op6n in the wire

(GND linel:
Check {or continuity between the
EGR control solenoid valve 2P con
'1
nector terminal No.
and body
ground,
Bopair open in the wir betwoen

tho EGR control solnoidvalve
and G101.
GND
{8LKI
Substitute e known-good ECM

and recheck. lf symptom/indication goes away, replacethe originalECM.
(cont'd)
1 1-173
SystemlD16Y5enginel(cont'd)
M/T:
-
The MIL has benroportodon,

OTCPl{)l is stord.
Probl6mvorification:
enganeat 3,000rpm with no
load (transmission
in neutral)
untilthe radiatorfan comeson.
4. Drive the vehiclo on the road
for approx. 10 minutes.Try to
keepthe enginespeedin the
1,700- 2,500rpm rang,
l s D T C P 1 4 9 1i n d i c a t e d ?
EGRVA|V: 6PCOI{NECTOR
lC14,a)
Intermittont frilur., ry3tem i! OK
at this timo. Checktor poor conn.c{ion3 or looa6 wiros at Clil4
IEGRvllve) lnd ECM.
1
G101
IBLKI
Check tor r mallunction in the

EGRvalve:
L Startthe engineand let it idle.
2. Measurevoltage between th6
EGRvalve 6P connectortermi
nal No. 4 and No. 6.
3
6
PNK
IE.EGNI
Wire side of mal torminals
rr-
EGRVALVE 5P CONNECTOR
Sub3titute r known-good ECM

and rcch.ck. lf symplom/indication goe3.wey, replaceth original ECM.
Chockthe EGRv.lv.:
2. Disconnectthe EGRvalv6 6P
connector.
3. Connectthe battery positive
terminalto EGRvalve6P con'
nectorterminalNo,6.
4. Stan the engineand let it idle,
then conn6ctlh battery negative terminalto EGRvalve 6P
connectorterminal No. 4.
Wire side of fem.lo terminrls
\
( T op a g e1 1 - 1 7 5 )
11-174
(Frompage11-174)
EGRVALVE
6PCONNECTOR
tcla,al
1
I E.EGF
a
Chockfor an op6n in the wire {E EGRlinel:
2. Disconnectthe ECMconnector
A (32Plfromthe ECM.
E C M c o n n e c t o tr e r m i n a l4 7
and the EGRvalve6P connector terminalNo.6.
t32Pl
IorurrWire side
_j
E-EGR
IPNKI
8
3 a
12 1 3 1 4 t 5 t6 1 7 1 8 1 9 20
22
n a 30
25
21
2
Chock lor rn opgn in tho wir6

IGNDlinol:
Checklor continuity betveen the
EGRvalve6P connectorterminal
No.4 and body ground.
1
Repsir opn in the wir btwen
th. EGR control 3olnoid v.lve
and G101.
't0
11
23
21
Wire side
of female
terminals
Repairopon in tho wir6 betwcon

tho EGRvalvc and tho ECM lA7l.
ls therecontinuity?
of lemale
tsrminals
{
I
G101
0) ter-xt
Subrtituta r known-good ECM

.nd rcchock. lt 3ymptom/indicalion go.3 away, .apl.ca tha origind ECM.
(cont'd)
1 - 175
System(D16Y5engine){cont'dl
The scan tool indicatesDiagnosticTrouble Code (DTC)P'1498:A high volrage problem in the ExhaustGas
(EGR)valvelift sensorcircuit.
Recirculation
-
The MIL has boen reportedon.

DTCP14)8 is sto.ed.
Problemvs.iticstionl
1. Do the ECMBesetProcedure.
2. Startthe engine.
lntermittfi failuro. 3y3tem i3 OK
at thL tim.. Chcck to. ooor connoctions o. loo3. wire3 at Cl/14
IEGRvalv.l and ECM.
Check tor an op6n in the EGR
valve lift sonso.:
2. Disconnectthe EGRvalve lift
sensor3P {M/T:6P)connector.
4, Measurevoltage between the
EGRvalve lift seosor 3P (M/T:
6P)connectorterminalsNo. 3
a n dN o . 2 .
EGRVALVELIFTSENSOR3P lM/T: SPlCONNECTOR

{Ct14l
cw:
vcc2
IYEL/BLUI
SG2IGRN/BLKI
ls thereapprox,5 V?
sG2
(GRN/
BLK}
Chock tor opcn in the wire lSG2
linel;
connector
terminalsD10and D11.
ls thereapprox.5 V?
Ropairopon in th. wirg bctwoon

ECM(D11)and EGRvalv.litt.cnsor.
vcc2
(YEL/
ALUI
Wiro side of female teaminals
cM CoNNECTOR
O tl6Pl
and recheck. ll symptom/indication goe3away, replacthe original ECM.
vcc2
(YEL/BLUI
sG2
(GRN/BLKI
Wire side of female te.minals
11-176
PositiveCrankcase
Ventilation(PCV)System
Dscription
Inspgqtion
T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s y s t e m i s
designedto preventblow-by gas trom escapingto the
atmosphere.The PCV valve contains a spring-loaded
plunger.When the enginestarts,the plungerin the PCV
valve is lifted in proportionto intakemanifoldvacuum
and the blow-by gas is drawn directly into the intake
manifold.
1.
Checkthe PCVhosesand connectionsfor leaksand

clogging.
At idle,makesurethere is a clickingsoundfrom the
PCVvalve when the hose betweenPCVvalve and
intakemanifoldin lightly pinchedwith your fingers
or olters.
D16Y5,D16Y8ongine:
O16Y5,D16Y8engine:
Gentlypinchhere.
PCVVALVE
D16Y7engine:
D16Y7engine:
Gently pinch here.
:: ELOW-BYVAPOR
e: FRESHAIR
VALVE
l f t h e r e i s n o c l i c k i n gs o u n d ,c h e c kt h e P C Vv a l v e
grommetfor cracksand damage.lf the grommet is
OK,replacethe PCVvalveand recheck.
11-177
EmissionGontrolSystem
EvaporativeEmission(EVAP)Controls
Dsscripiion
The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The
systemconsistsof the followingcomponents:
A.
EvaporativeEmission (EVAP)Control Canister

An EVAPcontrolcanisteris usedtor the temporarystorageof luel vapor until the fuel vapor can be purgedfrom the
EVAPcontrolcanisterinto the engineand burned.
B. Vapor PurgeContfol System

EVAPcontrolcanisterpurgingis accomplished
by dr6wingfreshair throughthe EVAPcontrolcanisterand into a pon
on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.
EVAPPURGECONTROL
SOLENOID
VALVEDUTYCON.
TROLLED
AFTERSTARTINGENGINE
I ' 9 6O 1 6 Y 5e n g i n e , ' 9 6D 1 6 Y 7e n g i n e , ' 9 6D 1 6 Y 8
7 1 6 Y 5e n g i n e , ' 9 7D ' 1 6 Y 7
e n g i n e( s e d a n ) , ' 9 D
engine (coupe:KA, KC models,sedan: KA, KC,
K L ( D X ) m o d e l s ,h a t c h b a c ka: l l m o d e l s ) , ' 9 7
D16Y8engine(sedan:KA, KCmodels)l
ENGINCOOLANTTEMPERATURE
ABOVE154'F(68"C)
'97 D16Y7
l ' 9 6 D 1 6 Y 8e n g i n e ( c o u p e ) ,
engine
( c o u p e :K L m o d e l ,s e d a n :K L ( L X ) m o d e l ) , ' 9 7
D16Y8engine(coupe:all models.sedan:KL model,
'98-allmodelsll
ENGINECOOLANTTEMPERATURE
ABOVE154"FI68"C)
INTAKEAIRTEMPERATURE
ABOVE32"F(O'C)
ano
VEHICLE
SPEEDABOVE0 MILE(0 km/h)
or
A./CCOMPRESSOR
CLUTCHON
and
INTAKEAIRTEMPERATURE
ABOVE160"F(41"C}
C.
FuelTank Vapor Control System

Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand
regulatesthe flow of fuel vaporto the EVAPcontrolcanister.
11-178
'96 D16Y8
engine lcoupe), '97 D16Y8 engine {coupe: all models, sedan:KL model). '98 Dt6Y5 engine (all models}, '98
D16Y8engine(allmodelsl:
9:I'
FUEL
TANK
PRESSURE
SENSOR
tLl
\
EVAP
BYPASS
SOLENOID
VALVE
EVAPPURGE
CONTROL
SOLENOIDVALVE
7'
From
No. 15
ALTERNATOR
SP SENSOR
(7.sa)
YEL/
BLU
THREE
VAL
VAPCONTROL
VENT SHUT VAI
LT GRN
GRN/
BLK
BLU
LT GRN/
WHT
RED/
YEL
EVAP
TWOWAY
VALVE
BLK
FUELTANK
INTAKE
MANIFOLD
'97 Dl6Y7 engine
{coupe:KL model, sedsn: KL ILX) mod6l},'98 D16Y7engine:

YEL/
BLU
LT G'
GRN/
BLK
FUEL
TANK
PRESSURE
SENSOR
From
No. 15
ALTERNATOR
SP SENSOR
t7.5Al
'-<
9ii
BLU
LT GRN/
WHT
EVAP
BYPASS
SOLENOID
VALVE
RED/
YEL
BLK
EVAPCONTROL
CANISTER
EVAP
TWOWAY
VALVE
FUELFILL
CAP
FUELTANK
(cont'd)
11-179
EvaporativeEmissionControls(cont'dl
'97
'97
'96 D16YSengine,'96 D16Y8engine
lsedanl, D16Y5engine, D16YBenginelsedan:KA, KC models):
EVAP
PURGE
CONIROL
EVAP
TWO WAY
VALVE
sot_ENotD
VALVE
MANIFOLD
'96 D16Y7engine,'97 D16Y7engine (coupe:KA, KC mod6ls, sedan: KA, KC, KL IDX) models, hatchback:all models):
From
EVAP
PURGE
CONTROL
SOLENOID
VALVE
i:1"
-----
No. 15
ALTERNAToR
SP SENSOR
VARIOUS
SENSORS
BLK
J-
\,*ro..
MANIFOLD
11 - 1 8 0
FuelTank PressureSenso. I'96 D16Y8engine {coupe),'97D16Y7ngine (coupe:KL mod6l, sedan:KL (LXl modet),'97
D16Y8engins(coupe:allmodels,sodan:KL model,'98-allmodels)l:
The scan tool indicates Diagnoslic Trouble Code (DTCI P0452:A low voltage problem in the Fuel Tank Pressure
sensor.
The fuel tank pressuresensorconvertsluel tank absolutepressureinto electricalsignalsand inputsthe ECM/PCM.

OUTPUT
VOLTAGE
tv)
4.5
Th6 MIL has ben .eported on.

DTC P0452 b stored,
0.5
Chckthe vacuurnlinos:
C h e c kt h e v a c u u ml i n e s o f t h e
fueltankpressuresensorfor misr o u t i n g ,l e a k a g eb, r e a k a g ea n d
clogging.
-7 kPr
(-50 mmHg,
-2 in.Hgl
+t kP8
(50 mmHg,
2 in.Hgl
PRESSURE
Are the vacuumlinesOK?
Problemvorilication:
1. Do the ECM/PCM
ResetProce'
dure.
2. Removethe fuel fill cap.
4. Monitorthe FTPSensorvolta g e w i t h t h e H o n d aP G M
T e s t e r ,o r m e a s u r ev o l t a g e
b e t w e e nb o d y g r o u n d a n d
ECM/PCM
terminalD15.
ls thereapprox.2.5V?
Chockfor an opon in wire {VCC2

linel:
2. Reinstall
the fuelfill cap.
3. Disconnect
the fuel tank pressuresensor3P connector.
5, Measurevoltage between the
fuel tank pressuresensor3P
connectorNo, 1 terminaland
No.2 terminal.
ECM/PCMCONNECTOR
D Il6PI
Intermittent tailur6,systom is OK
at thb time. Checktor ooor connections or loose wire3 at C131
{locatedunder right sid6 of dashl,
C401 (located above unde.-daah
tuse/relay boxJ. C568 llocatod
under acce3s prnel), C792 (tuel
tank pre33uresonsorl and ECM/
FCM.
PTANK
{LTGRN'
Wiro side ol temale terminals
FUELTANK
PRESSUBE
SENSOB
3P CONNECTOR
tC792)
vcc2
(YEL/BLU)
Wire sideof femaletrminals

ls thereapprox.5V?
Repairopen in the wire belween

tho tueltank pre3sur6sen3o.and
the ECM/PCMlD10l.
(cont'd)
YES
(Topage11-182)
11 - 1 8 1
EmissionControl System
{ F r o mp a g e1 1 - 1 8 1 }
FUELTANK
PRESSURE
SENSOR
3P CONNECTOR
{C7921
PTANK
(LTGRN)
C h e c kt o r a s h o r t i n t h e w i r e
IPTANKline):
fueltank pressuresensor3P connectorNo. 3 terminaland No. 2
rermtnat,
sG2
{GRN/BLK)
ls thereapprox.5 V?
Check for a Short in the wire

(PTANKline):
con
2. Disconnect
the ECM/PCM
nectorD (16P).
the fuel tank pressuresensor
3P connectorNo. 3 terminals
and body ground.
ReoairShort in the wire between

the fueltank oressurcsensorand
ECM/PCMtD15).
Sub3titut6 a known-good ECM/

PCM and recheck.ll symptom/
orisinal ECM/PCM.
11-1 8 2
FuelTank PressureSensorf96 D16Y8ongine {coups),'97D15Y7ongins lcoupe:KL model, sedan:KL (LX} model},,97

D16Y8enginelcoupe:all models,s6dan:KL model,'98.allmodelsll:
The scantool indicatesDiagnosticTroubleCode(DTC)P0453:A high voltageproblemin the FuelTankPressure
sensor.
Th6 MIL has beenroportodon.
OTCP(X53 is stored.
Chackthc vacuum lines:
C h e c kt h e v a c u u m l i n e s o f t h e
fuel tank pressuresensorfor misrouting, leakage,breakageand
cloggrng.
Are the vacuumlinesOK?
ECM/PCM CONNECTORD (T6P}
Problcmverificetion:
1. Do the ECM/PCM
ResetProcedure,
2. Removethe fuelfill cap.
4. Monitor the FTPSensorvolt,
age with the HondaPGM
T e s t e r ,o r m 6 a s u r ev o l t a g e
b e t w e e nb o d y g r o u n d a n d
ECM/PCM
terminal015.
ls thereapprox.2.5V?
Chock for rn opon in the wire

lSG2linol:
2. Reinstall
the fuelfill cap.
3. Disconnect
the fuel tank pressuresensor3P connector,
5, Measurevoltagebetweenthe
fuel tank pressuresensor3P
connectorterminals No. 1 and
No.2.
ls thereapprox.5V?
Check tor an open in the wiro

(PTANKlinal:
fuel tank pressuresensor3P connector No. 3 terminaland No. 2
termanal.
PTANK
ILTGRNI
Intermittont tailu.e, sy3tem b OK
at this tim6. Chcck to. poor connoctions or loo.g wiros at C131
{locatodunder right side ol d.!h},
C401 llocrtod abovo und.r-dash
tuse/rolay boxl, C56Ellocatod
undor accossD6ncl),C792 (fuel
tank prossurc s6n3or) and ECM/
FCM.
Wiresidsof f6malsterminals
FUELTANK
PRESSUAE
SENSOR
3PCONNECTOR
tC792)
vcc2
(YEL/3LUI
sG2
IGRN/BLKI
Wir6 side of temale terminals
Repai. opn in thc wirc botwcn
the tuel tank pa633ure36nsorend
ECM/PCM(D111.
sG2
IGRN/BLKI
3
PTANK
IGRN/NEDI
ls thereapprox.5 V?
(To page11-184)
(cont'd)
11 - 1 8 3
EvaporativeEmissionControls(cont'd)
(Frompage11 183)
D (16PI
ECM/PCMCONNECTOR

{PTANKline}:
P C M c o n n e c t o rt e r m i n a l sD 1 5
a n d0 1 1 .
ls thereapprox.5V?
Sub3litute a known-good ECM/

PCM .nd rechck.lf symptom/
indicationgoes away, replaceth6
originalECM/PCM.
11-1 8 4
Rcp.ir open in th6 wir6 betweon

E C M / P C M{ D 1 5 )a n d f u e l t a n k
pt033utesensol.
PTANK
ILT GRNI
SG2IGRN/BLK)
Wire side of fsmal terminals
['96 Dl6Y8 engine(coupe],'97Dl6Y7 sngine{coupe:KL model,sedan:KL {LX}modeU.'97Dl6Y8 engine(coupe:alt models, sedan:KL model, '98-all modolsll:
scantool indicatesDiagnosticTroubleCode(DTC)P1456:EvaporativeEmission(EVAP)conlrolsystemteak
tPEs6l The
detected(fuel tank system).
(DTCIP1457:Evaporative
Emission(EVAp)controlsystemreaK
scantool indicatesDiagnosticTroubleCode
tPl45?-lThe
detected(EVAPcontrolcanistersystem).
PossibloCauso
. Fuelfill cao
. VacuumConnections
. FuelTank
. EVAPControlCanisterVentShutValve
. EVAPControlCanisterVentShutValveCircuit
o EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPBypassSolenoidValve
. EVAPBvDassSolenoidValveCircuit
. FuelTankPressureSensor
. FuelTankPressureSensorCircuit
. EVAPControlCanister
. Throttle Body
VACUUM
PUMP/GAUGE,0-30in.Hg
4973X- 041-
xxxxx
TroublshootingFlowchart
-
Th. MIL has bo.n reDoned
DTCP1456or P1457i. storcd.
Ch6ck the EVAP control c.nbtet

v.nt lhut valva:
1. Disconnectthe vacuum hose
from the EVAPthree way
valve and connecta vacuum
pumpto the hose.
2 . R m o v e t h e E V A Pc o n t r o l
canistervent shut valvelrom
the canister.
4. Applyvacuumto tho hose.
EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Replace.
Chock tor a short in the wiro

{VSV linol:
Disconnectthe 2P connectorfrom
the EVAPcontrol canister vent
Doesthe valve hold vacuum?

Rop.ir 3hort in the wirc betwen
lh6 EVAP control caniste. vnt
shut valvo and the EcM/PcM
la29l.
Doesthe valve hold vacuum?

Check tho EVAP control crnialc.
vont 3hut valvo:
terminal429 to body ground
with a jumperwire.
4. Applyvacuumto the hose.
Roplrce the EVAP control cani.tcr vont rhut valvo,
ECM/PCMCONNECTOR
A I32P)
a
I
2
12 t 3
t5 t3 t t
6
21
r8 t 3 20
a 4t 30
{LT GRN/WHTI
to
ll
23
2a
JUMPERWIRE
Doesthe valvhold vacuum?

Wiresideof lemaleterminals
(cont'd)
{To page11-186)
(To page 1l-186)
11 - 1 8 5
EmissionGontrolSystem
(Frompage11-185)
(Frompage'1'l-185)
EVAPCONTROL
CANISTER
VENTSHUT
VALVE2PCONNECTOR
{Cl41I
Check lor an op.n in th. wi.e
(lG1linel:
from the EVAPcontrolcanister v0nt shutvalv.
4. Measurevoltage betwen the
EVAPcontrolcanistervent shut
valve 2P connectorterminal
No.2 and bodyground.
tGl
IBLK/YEL)
Wire side of fmale torminal6
Rcpair opon in tha wirc batwoon

tho EVAP control crnirtor vont
lhut vdw rnd tho No. 15 ALTERNATORSP SENSOR{7.5Al tu!..
Ch.d( ior an op.n in tho wirr IVSV

lin l:
2. Roconnectthe 2P connector
to the EVAPcontrol canister
vent shutvalve.
4 , M e a s u r ev o l t a g e b e t w e e n
E C M / P C Mc o n n c t o rt 6 r m i
nalsA29and A10.
ECrir/FcM@NNECTOfiA {32P1
PGl (BLK)
I
'|
2
12 l 3
t5
-J-
I ' l ' l I' l r l r l r o I r r I
rrlrrlllll @ l / l z l a l u l
vsv (LTGRN^Vlff)
,JAA_]{
Wiro sid ot lomsle

t6rminals
Rapairop6n in thc wh6 batwaan

iho EVAP control caniatar vant
shut vrlvo end th. ECM/PCM
tA29t.
Raolaccth6 EVAP cont.ol canister vant rhut valva.
Ch6cktho vacuumwhan cold:

1. Disconnectth vacuum hos6
shown from the EVAPcontrol
canrsterand connecta vacuum
gaugeto the hose.
2. Stan the engineand allow it
to idle.
N O T E :E n g i n ec o o l a n tt e m peraturemust bo below 154"F
(68'C)or Iy'Cswitch OFF.
3. Ouicklyraisethe engine spegd
to 3.000rpm.
(Topage11-187)
1 1 - 18 6
VACUUM
PUII'P/
- 30in.Hg
GAUGE,0
A973X-
041- xxxxx
(Frompage11-186)
Ch.ck the EVAP purge control
robnoid velvol
from the EVAPpurge control
solonoidvalve.
2. Orricklyraisethe enginespeed
to 3,000rpm.
Inspectv.cuum hoaerouting.
lf OK, replaco lho EVAP purge
contrcl solonoidvalve.
Chacktha vrcuum whcn hoti

2. Block the rear wheels and set
the parkingbrak.
3. Jack up tho front ot the vehicle and support it with salety
slands.
4 . S t a r t t h e 6 n g i n e .H o l d t h e
engin at 3,000rpm with no
loed {A/r in E or E position,
WT in neutral)untilthe radiator
lan comeson, then let it idle.
5. Ch6cktor vacuum at the vac'
uum hos6 with lransmission
in ge6r {A/T in B position,
M/T in 1st gear) after starling
the ngine.
6. Ouicklyraisotho ongine sp66d
to 3,000rpm.
Chcck tor a short in the wir.

{PCSlincl:
2. DisconnectECM/PCMconnector A 132P).
3. Check for continuity botween
the EVAPpurge controlsole'
noid valve 2P connectorterminal No. 2 and body ground.
EVAPPURGECONTROLSOI:NOID
VALVE2P OONNECTOR
lC11,al
Wiro side ot
temale
trmrna|s
Repairshort in the wira bgtween
the EVAP purga control solonoid
valvo and rhe EcM/PcM lA15l.
Sub3titut. a known-good EGM/

PCM lnd r.ch.ck. lf symptom,/
indication eoo3 away, raplacc th.
o.iginrl ECM/FCM.
Chock th6 EVAP purg. control

.olonoid valvoi
l. Turnthe ignitionswitchOFF.
from the EVAPpurgo control
solenoid valve and worm it
up to normal operatingtom
peratureagain it necessary.
3. Startthe engine.
4. At the ha.nessside. moasure
v o l t a g e b e t w e e nt h e E V A P
purgo control solenoidvalve
2P connectorterminsl No. 1
a n dN o . 2 .
ls there batteryvohage?
Chcck for an opcn in th6 wire

llcl linoll
At the harnossside.measurcvoltago btwoenthe EVAPpurge control solenoidvalve 2P connector
terminal No. 1 and body ground.
PCS
{RED/YELI
Intpct vacuum hoa! routing.

It OK, roplace EVAP purg6 control solonoidv6lvo.
tGl
IBLK/YEL}
Ropai. open in the wiro lrotwean

EVAPpurga control 3olcnoid valv.
ANdthC NO. 15 ALTERNATORSP
SENSOR{7.5Al fu36.
(cont'd)
{Topage11-188)
(To page11-188|
11-187
EvaporativeEmissionControls{cont'd}
( F r o mp a g e ' 1 1 ' 1 8 7 )
|5
(Frompage11 187)
A {32P)
ECM/PCMCONNECTOR
PGI
{BLKI
{PCSline}:
2. Reconnect
the 2Pconnectorto
the EVAPpurge controlsole_
noidvalve.
4, Measurevoltage between
A 1 5a n dA 1 0 .
PCS
{RED/YELI
wire sid ot
female
!ermrnatS
Repairopen in the wire botween

th6 EVAP purga cont.ol solenoid
v.lve and the EcM/PcM lA15l.
EVAP TWO WAY
Subrtitute a known.good ECM/
PCMand ratest. It symptom/indication goe3 away, replace the
original ECM/PcM.
\
Checkthe EVAPtwo way valvsl
See EVAPtwo way valve test (see
p a g e1 1 ' 1 9 3 1 .
Repl.cthe EVAPtwo way v.lve.
PUMP/
-30 in.Hg
GAUGE.0
4973X041-
xxxxx
EVAPBYPASS
SOLENOIDVALVE
Checkthe EVAP bypa$ solenoid

1, Disconnectthe vacuum hose
from the EVAPtwo way valve
and connecta vacuumpump
to the hose.
2. Turnthe ignitionswhchON (lli.
3. Applyvacuumto the hose.
Doesthe valvehold vacuum?
U
Check tor a short in the wi.
I2WBSline):
lrom
the 2P connector
Disconnect
the EVAPbypasssolenoidvalve.
Does the valve hold vacuum?
O.RING
Replace.
EVAPTWOWAYVALVE
Rooair3hort in tho wirc botween
EVAP bypass 3ol.noid valve and
rhe EcM/PcM {A281.
l T o p a g 61 1 - 1 8 9 1
11-188
(Frompage11-188)
Checkthe EVAP bypasssolenoid

terminalA28and bodyground
with a iumperwire.
3. T!rn the ignitionswitchON (ll).
ECM/PCMCONNECTOR
A I32PI
'12 t 3
Check for an opon in tha wire

llGl linel:
from the EVAPbypass sole
r5 t 6
25
It
27
tl
I
1 9 2A
2a
23
Wire sid of
femal6
terminals
JUMPER
WIRE

EVAP bypasssolenoidvalve
2 P c o n n e c t otre r m i n a lN o . 1
and body ground.
lo
2A 29 3 0
2WBS
IBLUI
Does valve hold vacuum?
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
{C79i}l
tG1
(BLK/WHTI
Wire sido of
lemale
terminals
Ropai. open in the wirc botwoon

EVAPpurg6 control solonoid valve
snd the No. 15 ALTERNATORSP
SENSOR17.5A) tu36.
A (32PI
ECM/PCMCONNECTON
{2WBSlin6l:
2. Reconnectthe 2P connector
to the EVAPbypasssolenoid
4, Measurevoltage between
A28andA10.
Check the following part3 lor
l e a k a g e t o a t m o s p h e r e .a n d
repair or rcplaceit necessary:
' tucl till c.p
. luel tank
. tuel vapor pipe
. EVAPtwo wav vslve
. EVAPbypasssolenoidvalve
. Iuel tank pressuresensoa
. EVAPcontrol cenkter
. EVAPcontrol canistcr vant
shut valve
. EVAP pu196 control solenoid
PGl (BLK}
=
t6 1a 1 1 tt
12 l 3
6
21
-J--
l r l l . l e l r oI i r I
tolal.lal za l yl
2WBSIBLUI
wirs side of female
l6fmrn6ls
Ropai. opon in the wiro between

tha EVAP byp.33 3olenoid valv.
.nd tho ECM/PCM lA28|,
. vacuum hososand connoctions
(cont'd)
11 - 1 8 9
EvaporativeEmissionControls{cont'd}
'96 Dl6Y5 engine,'96Dl6Y7 engine,'96Dl6Y8 engine

{sedan},'97Dl6Y5 engine,'97D16Y7enginelcoupe:KA, KC models, sedan: KA, KC, KL (DX)models, hatchback:all models),'97 Dl6Y8 ngine (sedan:l(A, KC models):
The scan tool indicatesDiagnosticTrouble Code (DTC)P0441:EvaporativeEmission(EVAP)control system
I P0441 | ;n"r11;";.ntouroeftow.
Description
By monitoringthe purge line vacuum with the MAP sensor,the ECM/PCMcan detectinsufficientEVAPcontrol system
purgeflow.
PossibleCause
. EVAPPurgeControlSolenoidValve
. EVAPPurgeControlSolenoidValveCircuit
. EVAPControlCanister
. V a c u u mL i n e s
. ECM/PCM
-
Tho MIL has b6onreportedon,

DTCP(X4t is stored.
Problsmve.itication:
enganeat 3,000rpm with no
load (A,/Tin N or E poskion,
M/T in neutral)untilthe radia'
tor tan comeson.
2. Do the ECM/PCMResetProceoure,
4. Test-driveunderfollowingconditionson the road.
- Withoutany eloctricalload
- A/T in $ or E position
(M/Tin 3rd-5thgear)
- Engine speed between
1,200- 2,400rpm.
- Decelerate
from 50 mph (80
km,4')to 15 mph 124km/h)
ls oTC P0441indicated?
Intorrnittenttailu.e, 3wtem i3 OK
at thi3 timo. Chock for poor connctions or 10036wir$ at C144
(EVAP purge control solenoid
valve)andECM/PCM.
Chck for an opn in the wir (lcl

linell
2 . D i s c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P connector,
3. Turn the ignitionswitchON {ll).
4. Measurevoltagebetweenbodv
g r o u n da n d t h e E V A Pp u r g e
control solenoidvalve 2P connectorterminal
No. 1.
1 1 - 19 0
r+_r
' l ' l
lrci
rv)
oixrv..r
wir6 side of lemslo

terminals
Ropair open in th wiEs botwoon

the EVAP purgo control rolenoid
valve and th. No. 15 ALTERNA.
TORSP SENSOF17.5Al fuse.
{ T op a g eI 1 - 1 9 1 )
EVAPPURGECONTROL
SOLENOIOVALVE2P
CoNNECTORtctla)
D (32PI
ECM/PCMCONNECTOR
PG1IALK)
{ F r o mp a g e1 1 - 1 9 0 }
Chock tho EVAP purge control

30lenoidvalv6:
'1.Reconnec
t h e E V A Pp u r g e
controlsolenoidvalve2P con
nector.
2. ConnectECM/PCI,connector
terminalsA'15and A10 with a
Does the solenoid valve click

when the jumper is connected?
JUMPERWRE
Wire sideoI tomaleterminals
Chockfol rn op6n or 3hort in th6

wirc IPCSlin6l:
PCMconnectorterminalA15 and
bodyground.
PCS{RED/YELI
Ch6ckfor a shon in the wire IFCS

lin):
2. Disconnectthe ECM/PCMconnectorA {32P).
3 . D i s c o n n e ctth e E V A Pp u r g e
controlsolenoidvalve2P connector.
connectorterminalA15,
ls therebaneryvoltage?
t
ReD.ir 3hort in the wire! bdtween
the EVAP purge control 3olgnoid
vtlve .nd ECM/PCM(415).
ls therecontinuity?
Ropair opon in the wires bstwson

the EVAP purge control solenoid
valveand ECM/PCM{Al5}.
Chocktho vacuum lines:

Checkthe vacuumlinesof EVAP
systemIor misrouting,leakage.
breakage
and clogging.
Ar the vacuumlinesOK?
6 I
E
I
2
12 l 3 'l'a t 5 l 6 1 7 I E t 9 20
25
27
26 A
10
ll
23
21
30
O) Pcs {RED/YEL}
(cont'd)
{To page11-192)
11 - 1 9 1
EvaporativeEmissionControls(cont'd)
l F r o mp a g e1 1 - 1 9 1 )
D16Y5engine:
Check the EVAP purge control

solenoidvalve:
1. Disconnectthe vacuum hose
from the EVAPcontrolcanister.
2. Connectthe vacuumpump to
the hoseandapplyvacuum.
D15Y7,D16Y8ngine
VACUUM
PUMPI
GAUGE,
0-30 in.Hg
4973X 041 -
VACUUM
PUMP/
GAUGE,
0 - 30 in.Hg
A973X- 041 -
xxxxx
xxxxx
Doesit holdvacuum?
EVAPCONTROL
CANISTER
ECM/PCMCONNECTOR
D I32P}
Checkthe EVAPcontrol canister:

1, Reconnect
the vacuumhoseto
the EVAPcontrolcanister.
2, Connectthe vacuum/pressure
9augeto the purgeair hose.
terminals415 and 410 with a
PG1IBLKI
4. Start the engine.

5. Checkthe vacuum.
JUMPERWIRE
D16Y7,Dl6YBengine:
Check the EVAP two way valve
lseepage11 193).
0oesthe EVAPtwo way valve
Replacethe EVAPtwo way valve.
D16Y5engine:

PCM and recheck.lf svmptom/
original ECM/PCM.
VACUUM/PRESSURE
GAUGE
0 - il in.Hg
07JAZ- 0010004
11-192
VACUUM/
PRESSURE
GAUGE0- 4 in.Hg
07JAZ- 0010008
EvaporativeEmission(EVAP)Two Way ValveTesting

I'96 Dl6Y8 engine{coupel,'97Dl6Y7 engine(coupe:KL
model,sedan:KL (LX)model),'97 D16Y8engine{coupe:
all models,sedan:KL model,'98-allmodelsll:
1 . R e m o v et h e f u e lf i l l c a p .
2.
R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
valve, and connectit to a T fitting from a vacuum
g a u g ea n d a v a c u u mp u m pa s s h o w n .
f96 D16Y5engine,'96D16Y7engine,'96D16Y8engine
(sedanl,'97D16Y5engine.'97D16Y7engine(coupe:KA.
KC models,sedan:KA, KC, KL (DX) models.hatchback:
all modelsl,'97D16Y8engine(sedan:KA. KC models)l:
1.
R e m o v et h e f u e lf i l l c a p .
2.
R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y
valve on the fuel tank, and connectit to a T-fitting
f r o m a v a c u u mg a u g ea n d a v a c u u mp u m p a s
VACUUM/PRESSURE
GAUGE
0 - 4 in.Hg
07JAZ- 0010008
VACUUM/
PFESSURE
GAUGE,
0 -4 in.Hg
o?JAZ- 0010008
VACUUM
PUMP/GAUGE,
0 - 30 in.Hg
A973X-041-XXXXX
T.F|rTING
T-FITTING
3. Applyvacuumslowlyand continuouslywhile watch-
3.
A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l yw h i l e
w a t c h i n gt h e g a u g e .T h e v a c u u ms h o u l ds t a b i l i z e
m o m e n t a r i layt 0 . 7 2 . 0k P a( 5 - 1 5 m m H g , 0 . 2- 0 . 6
i n .H g) .
l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w
0 . 7 k P a ( 5 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 0 k P a
( ' 1 5m m H g ,0 . 6i n . H g )i,n s t a lal n e wv a l v ea n d r e t e s t .
4.
Move the vacuum pump hose from the vacuumfitting to the pressurefitting, and move the vacuum
gauge hose from the vacuum side to the pressure
side as shown.
f-E-
ing the gauge.The vacuumshouldstabilizemoment a r i l ya t 0 . 8- 2 . 1k P a( 6- 1 6m m H g ,0 . 2 0 . 6i n . H g ) .

l f t h e v a c u u m s t a b i l i z e s( v a l v eo p e n s l b e l o w
0 . 8 k P a ( 5 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k P a
( 1 6m m H g , 0 . 6i n . H g )i,n s t a lal n e wv a l v ea n d r e t e s t .
4.
Move the vacuumpump hosefrom the vacuumfitting to the pressurefitting, and move the vacuum
gauge hose from the vacuum side to the pressure
sideas shown.
5.
Slowly pressurize
the vapor line while watchingthe
gauge.The pressureshouldbe stabilizemomentaril y a b o v e 1 . 0k P a( 8 m m H g , 0 . 3i n . H g ) .
. l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e
o p e n s )a b o v e 1 . 0 k P a ( 8 m m H g , 0 . 3i n . H g ) t, h e
valveis OK.
. lf the pressurestabilizesbelow 1.0kPa(8 mmHg,
0.3 in.Hg),installa new valveand retest.
the vapor line while watchingthe

Slowly pressurize
gauge.The pressureshouldstabilizeat 1.3- 4.7 kPa
( 0 - 3 5 m m H g ,0 . 4 1 . 4i n . H g ) .
. l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e sl v a l v e
'1.4
o p e n s )a t 1 . 3- 4 . 7 k P a( 1 0- 3 5 m m H g ,0 . 4
in. Hg),the valveis OK.
. ll the pressurestabiljzes
below 1.3kPa(10 mmHg,
0.4 in.Hg)or above4.7 kPa(35 mmHg, 1.4in.Hg),
installa new valveand retest.
11 - 1 9 3
Transaxle
12-1
M a n u aTl r a n s m i s s i o" .n' . . . . . ' . . . " " " " ' 1 3 - 1
...'..."""""' 14-1
15-1
D i f f e r e n t i a .l . . . .
16-1
Driveshafts
Clutch
Clutch
"".--- 12-2
S p e c i aTf o o l s . . . . . . . .
."' 12-3
Index ........
flfustrated
clutch Pedal
..."""'.-"" 12'4
Adjustment
Clutch Master Cylinder
'." 12-5
Removal/lnstallation
Slave Cylinder
"" 12-6
PressurePlate
-'." 12-7
Removal/lnspection
Clutch Disc
.'." 12-8
Removal/lnspection
Flywheel
' 12-9
Inspection
R e p l a c e m e n. .t . . . .". . . . . ." . . . . ' . . . . . .".. 12 - 9
Clutch Disc, PressurePlate
...".....'.'...1
. 2-10
Installation
ReleaseBearing
..." 12-11
Removal/lnspection
12-12
lnstallation
rf,'
l l ,
SpecialTools
Ret. No.
o
l
/6
@
,A
Tool Number
11
A
OTJAF_PM70
OTJAF_PM7O124
OTLAB- PVOO1OOor
o7924-PD20003
07746-0010100
07749-O010000
07936-3710100
Dscliption
Oty
I P89e Reference
Clutch AlignmentDisc
Clutch AlignmentShaft
Ring Gear Holder
1
1
1
't2-7
12-7A
, , 1 0 ,1 1
12-7S
, , 1 0 ,1 1
Attachment, 32 x 35 mm
Driver
Handle
1
1
1
12-10
12-10
1 2 - 7, 8 , 1 0 , 1 1
12-2
lllustratedIndex
NOTE:
a Wheneverthe transmissionis removed,clean and greasethe releasebearingslidingsurface.
a It the parts markedwith an asterisk(*) are removed,the clutch hydraulicsystem must be bled (see page 12-6).
a Inspectthe hosesfor damage,leaks,interlerence,and twisting.
/6t-^
*REsERvorR
r
@
ASSTST
t=/
ov
g*______-__=
Fn
,,'
W.*ra
*CLUTCHLIN
15 N.m {1.5kgl.m,
11 tbt.Ir)
TCLUTCHLINE
19 N.m ll.9 kgl'm,
14 rbt.ttl
PEDALPIN
\F
fl
'CLUTCH MASTERCYLINOER
'12
5
Removal/lnstallation,
Page
CLUTCH PEDAL
Adjustment,page 12-4
\
RELEASEBEARING
page 12-11
Removal/lnspection,
lnstallation,page 12'1 2
I x ' 1 . 2 5m m
25 N.m (2.6 kgf.m,
19 tbf.fi)
FLYWHEEL
page12'9
Inspection,
page12-9
Replacement,
CLUTCH DISC
page 12_8
Removal/lnspection,
Installation,page 12-10
1 2 x 1 . Om m
118 N.m {12.0 kgf.m, 86.8 lbf.tt}
PRESSUREPLATE
page 12 7
Removal/lnspection,
Installation,page 12-10
6 x 1.0mm
9.8 N.m (1.0kgf,m,
7.2 lbt.Ir)
8 x 1.25mm
22 N.rn 12.2 kgf.m, 16 lbl.ttl
*SLAVE CYLINDER
page 12-6
*CLUTCHLINE
15 N.m {1.5kgl.m.11 lbf.{r)
12-3
Clutch Pedal
Adjustment
NOTE:
a To check the clutch interlock switch and clutch
switch, see section 23.
a The clutch is sell-adjusting
to compensatefor wear.
5. Turn the clutchswitch {or adjustingbolt) in an additional 3/4 to 1 full turn.

6. Tighten locknut A.
CAUTION: ll thefe is no clearance between the

master cylinder piston and push rod, the leleaso
bearingis held against the diaphragm spring, which
can resultin clutch slippageor other clutch problems,
7. Loosenlocknut B on the clutch interlockswitch.
'1.
Loosenlocknut A, and back off the clutch switch

(or adjustingbolt) until it no longertouchesthe clutch
oedal.
2.
Loosenlocknut C, and turn the push rod in or out

to get the specifiedstroke(@)and height(O) at the
clutch pedal.
'15-20 mm (O.59
9 . R e l e a s teh e c l u t c hp e d a l
0.79
in) from the tully depressedpositionand hold it there.
Adjustthe positionof the clutchinterlockswitch so
that the enginewill startwith the clutchpedalin this
postuon.
3.
Tighten locknut C.
4.
Threadin the clutch switch (or adjustingbolt) until

it contacts the clutch pedal
assjyear.lc
8. Measurethe clearancebetweenthe floor boardand

clutch pedal with the clutch pedallully depressed.
'10.
Threadthe clutch interlockswitch an additionalin

3/4 to 1 full turn.
1 1 . T i g h t e nl o c k n u tB .
-@{
{P/N
PUSH ROO
CLUTCH MASTER CYLINDER
LOCKNUT
8
9.8 N.m (1.0 kgt.m,7.2 lbf.ttl
INTERLOCKSWITCH
CLUTCH SWITCH
{or ADJUSTING BOLTI
LOCKNUTA
9.8 N.m (1.0 kgf.m, 7.2 lbl.lt|
LOCKNUTC
1 8 N . m ( 1 . 8 k g f . m ,1 3 l b l . f t )
a t P E D A L )1: 3 0 - 1 4 0 m m 1 5 . 1 2 - 5 . 5 1 i n )
@ (STROKE
PEDALFREEPLAYI:12-21 mm 1o.47-0.83 in) includethe pedalplay 1-1o mm {0.o4-0.39 in)
Clufcx
{fOrll
)
ao |CLUTCHPEDALHEIGHT):165 mm (6.50 in) to the flool
HEIGHT):83 mm 13.27 in) minimumto the floor
o) {CLUTCHPEDALDISENGAGEMENT
12-4
Clutch Master Cylinder

CAUTION:
a Do not spill brake fluid on the vehicle;it may damage
the paint; if brake fluid does contact the paini, wash
it off immodiately with water.
a Plugthe end ot the clutch line and reservoirhose with
a shop towelto pleventbrakefluid from comingout.
4.
Removethe clutch mastercylinder.
1. The brake fluid can be removed from the clutch

mastercylinderreservoirwith a syringe.
2.
Disconnectthe clutch line and reservoirhose from

the clutch master cylinder.
CLUTCHLINE
1 9 N . m( 1 . 9 k g t ' m ,
14 tbI.ft)
CLUTCHMASTERCYLINDER
5 . Installthe clutch mastercylinderin the reverseorderof removal.
(.
NOTE: Bleed the clutch hydraulic system {see

page12-6).
3 . Pry out the cotter pin, and pull the pedalpin out of
the yoke. Removethe nuts.
NUTS
8 x 1 . 2 5m m
13 N.m (1.3 kgf.m, 9.4 lbf,ftl
12-5
Slave Cylinder
CAUTION:
a Do not spill brake fluid on th vohiclo; it may damagc
the paint; it brake fluid doos contact tho paint. wash
it ott immsdiatoly whh water.
a Plug the end of the clutch line with a shop towel to
prevent brake tluid from coming out.
Install the slave cylinder in the reverseorder ol

removat.
3.
NOTE: Make surethe boot is installedon lhe slave

cylander.
CLUTCHLINE
15 N.m (1.5 kgf.m,1'l lbt.ttl
S u p e r H i g h T e m p U r e a G r e a s e { P iN
08798 9002).
-=-t"*'.]:].:Brake Assembly Lube or equivalentrubber
grease.
-.El:
SLAVECYLINDER
'1. Disconnect
the clutch line lrom the slavecylinder.
-C.
(P/N 08798 -9002)
8 x 1.25mm
22 N.m 12.2 k9l.n,
16 tbf'ttt
.:;?L.
-=-s!!rqil
(BrakeAssembly
Lubel
Bleedthe clutch hydraulicsystem.
2.
Removethe slavecylinderfrom the clutch housing.
12-6
a Attach a hoseto the bleederscrew, and suspend

the hose in a containerof brake fluid.
a Make surethere is an adequatesupplyof fluid ar
the clutchmastercylinder,then slowly pumpthe
clutch pedaluntil no more bubblesappearat the
bleederhose.
a Refillthe clutch mastercylinderwith fluid when
done.
a Always use GenuineHonda DOT 3 BrakeFluid.
Using a non-Hondabrakefluid can causecorrosion and dec.easethe liJeof the system.
a Contirmclutch operation,and check for leaking
fluid.
PressurePlate
Removal/lnspection
Inspectthe pressureplatesurlacefor weaf, cracks,
and burning.
1 . Inspectthe Jingersof the diaphragmspringfor wear

at the releasebearingcontact area.
Check the diaphragmspring tingers tor height using the specialtools and a feelergauge.
StandardlNew): 0.6 mm (0.02 inl max.
ServiceLimit:
1.0 mm (O.O4in)
FEELRGAUGE
6.
Inspectfor warpageusinga straightedge and feeler gauge.

NOTE: Measureacrossthe pressureplate at three
points.
Standard(New): O.O3mm (0.0O1inl max.
SrvicoLimit: O.15 mm (0.0O6inl
STRAIGHTEDGE
CLUTCH ALIGNMENTOISC
OTJAF_PM7O11A
CLUTCH ALIGNMENTSHAFT
OTJAF-PM7O12A
HANDLE
07936_3710100
lf the height exceedsthe servicelimit, replacethe
pressureplale.
3.
Installthe specialtools.
PRESSUBEPLATE
lf the warpageexceedstheservicelimit,replacethe
pfessureplate.
RING GEAR HOLDER

071A8-PV00100
ot
07924-PD20003
ENGINE
BLOCK
OTJAF_PM7012A
HANDLE
07936-3710100
GEARHOLDER
NUT
ADJUSTER BOLT
4.
To prevent warping, unscrew the pressureplate

mounting bolts in a crisscrosspattern in several
steps, then removethe pressureplate.
12-7
Clutch Disc
Removal/lnspection
1. Removethe clutch disc and specialtools.
CLUTCH DISC
4.
Measurethe depth lrom the lining surfaceto the

rivets, on both sides.
Rivet Depth:
Standatd(New):1 .3 - 1 .9 mm {0.O5-O'O7in} min'
SrviceLimit: O.2 mm (O.01 inl
07936-3710100
Inspectliningof the clutchdisc tor signsof slipping

or oil. lf it is burnedblack or oil soaked,replaceit.
Measurethe clutch disc thickness.
Clutch Oisc Thickness:
S t a n d a r dl N e w ) : 8 . 5 - 9 . 1 m m ( 0 . 3 3 - 0 . 3 6 i n l
ServiceLimit: 5.5 mm (0.22 in)
CLUTCH DISC
lI the depthis lessthan the servicelimit,replacethe

clutch disc.
lf the thicknessis lessthan the servicelimit,reolace

the clutch disc.
12-8
Flywheel
Inspection
Replacement
1.
Inspectthe ring gear teeth tor wear and damage.
1. Installthe sDecialtool.
2.
Inspect the clutch disc mating surface on the

flywheel for wear, cracks, and burning.
3.
FLYWHEEL
Measurethe flywheel runout using a dial indicstor

through at least two full turns. Push againstthe
flywheeleachtime you turn it to take up the crank,
shaft thrust washer clearance.
NOTE: The runoutcan be measuredwith engineinstalled.
Standard{Now}: O.O5mm (0.OO2in) max.
ServicaLimir: O.15 mm (0.006 inl
,
FLYWHEEL
MOUNTING
BOLTS
RI[{G GEAR HOLOER
071A8 -PV00100
ot
07924-PO20003
2 . Removethe flywheelmountingbolts in a crisscross

patternin severalsteps as shown, and removethe
flywheel.
lf the runout exceedsthe servicelimit, reolacethe
flywheel.
Removethe ball bearingfrom the flywheel.
Turn the innerraceof the ball bearingwith your finger. The ball bearingshouldturn smoothlyand quietly. lf the inner race does not turn smoothly and
q u i e t l y .r e p l a c et h e b e a r i n g .C h e c kt h a t t h e b a l l
bearingouter racefits tightly in the flyweel.lf it is
loose.replacethe ball bearing.
FLYWHEEL
BALL BEARING
{cont'd)
12-9
ClutchDisc,
Flywheel
PressurePlate
Replacement(cont'dl
4.
Installation
Drivethe new ball bearinginto the flywheel using

the sDecialtools as shown.
1.
Installth specialtool.
ON|vER
07749-OOtO(xX)
clurcH olsc
07936-37ioioo
ATTACHMENT,
32x35mm
07746-0010r00
FLYWI{EEL
(P/n 08798-90{'21
BEARII{G
RING GEAR HOLDER

07LAB-PVOOIOO
ot
07924-PD20003
lnstallthe clutch disc using the specialtools.
5 . Align the hole in the flywheel with the crankshaft

dowel pin and installthetlywheel.Installthemounting bolts fingertiqht.
o.
CI.UTCH ALIGNME T SHAFT

OTJAF_PM7012A
Installthe pressureplate.
Install the specialtool, then torque the flywheel

mountingbolts in a crisscrosspattern in severalsteps
as shown.
BOLTS
MOUNTING
1 1 8N . m 1 1 2 . 0k s t ' m ,
87 tbf'ft)
YWHEEL
RINGGEARHOLDER
oTLAB-PVOO100
ol
07924-PD20003
RINGGEARHOLDER
oTLAB-PV00100
ol
07924-PD20003
12-10
O7JAF.PM70l2A
HANDLE
07936-3710100
ReleaseBearing
Removal/lnspection
4.
Torquethe mountingbolts in a crisscrosspatternas

shown. Tighten them in severalsteps to prevent
warping the diaphragmspring.
1 . Remove the release fork boot from the clutch

housing.
Removethe releasefork from the clutch housingby
squeezingthe releasefork set springwith pliers.Remove the releasebearing.
BOLTS
@ MoUNTING
8 x 1 . 2 5m m
25 N'm 12.6kgf.m,19 tbt.ft)
RLEASEFORK
3 . Checkthe releasebearingfor play by spinningit by

hand.
CAUTION: The lelease bearing is packed with
grease. Do not wash it in solvent
RINGGEARHOLDER CLUTCHALIGNMENT
oTLAB-PVOo100
OTJAF_PM7O12A
ol
o7924,PD20003
HANDLE
07936- 3710100
lf there is excessiveplay, replacethe releasebearing with a new one.
12-11
ReleaseBearing
Installation
NOTE: Use only Super High Temp Urea Grease
(P/N 08798 9OO2).
1.
3.
Movethe releasefork rightandlelt to makesurethat

it fits properlyagainstthe releasebearing,and that
the releasebearingslidessmoothly.
4.
Installthe releasefork boot;makesurethe boot seals

aroundthe releasefork and clutch housing.
Wilh the release fork slid between the release bear

i n g p a w l s , i n s t a l lt h e r e l e a s eb e a r i n g o n t h e m a i n
shaft while insertingthe releaselork through the hole
in the clutch housing.
29 N.m 13.0 kgf.m, 22 lbl.fr)
--6i
oa798-9002)
(P/N08798-9002)
0 . 3- 0 . 9 g { 0 . 0 1 - 0 . 0 3o z }
2 . Align the detentoJ the releasefork with the release

{ork bolt,then pressthe releasefork overthe release
lork bolt sequarelv.
12-12
ManualTransmission
......... 13-2
SpeciafTools
Maintenance
T r a n s m i s s i oOni l . . . . . . . . . . . . . . . . . . . .1. .3. - 3
Back-upLight Switch
....... 13-3
Replacement
Troubfeshooting
..... 13-4
TransmissionAssembly
. . . . . . . . . . . .1. 3 - 5
Removal
...... ... 13-8
lnstallation
l l l u s t r a t el nd d e x . . . . . . . . . . . . . . . . . . . . . .1.3. .-.1. 0
TransmissionHousing
. . . . . . . . . . .1. .3 - 1 2
Removal
Reverse
S h i f tH o l d e r
C l e a r a n cIen s p e c t i o .n. . . . . . . . . . . . . . .1. .3 - 1 3
Reverseldler Gear
. . . . . . . . . . . .1. 3 - 1 4
Removaf
Mainshaft, Countershaft,Shift Fork
Disassembly
. . . . . . .1 3 - 1 4
Mainshaft Assembly
I n d e x. . . . . . . . . . . . .
. . . .1 3 - 1 5
C l e a r a n cIen s p e c t i o .n" . . . . . . . . . . . . . .1. 3. - 1 6
. . . . . . .1 3 - 1 7
Disassembly
Inspection
.........1
. 3-18
Reassembly
. . . . . . . .1 3 - 1 9
CountershaftAssembly
fndex.............
.... 13-20
. -21
C fe a r a n c efn s p e c t i o n. . . . . . . . . . . . . . . .1. 3
. ... ... 13-22
Disassembly
....... ... 13-23
lnspection
Reassembly
..... ... 13-23
Shift Fork Assembly

Index.............
....13-25
. . . . . . . . . . . . . . . .1. .3 - 2 6
C l e a r a n clen s p e c t i o n
MBS Shift PieceInspection......... 13-27
SynchroSleeve.SynchroHub
Inspection/lnstallation
................13-27
Synchro Ring, Gear
.........1
. 3-28
Inspection
Shift Rod
. . . . . . . . . . .1. .3 - 2 9
Removal
Differential
. . . .1 3 - 3 0
l n d e x. . . . . . . . . . . . .
I n s p e c t i o n. . . . . . . . . . . . . . . . .1. 3
. -30
Backlash
B e a r i n gR e p l a c e m e n. t. . . . . . . . . . . . . .1. .3 - 3 1
.... 13-31
FinalDrivenGear Replacement
T h r u s tS h i mA d j u s t m e n t. . . . . . . . . . .1. 3 - 3 2
Clutch Housing Bearing
. . . . . . .1 3 - 3 4
Replacement
Mainshaft Thrust Shim
. . . . . . . .1. 3 - 3 6
Adjustment
Transmission
. . . . . . . .1 3 - 3 9
Reassembly
OilSeals
. . . . . . .1 3 - 4 3
Replacement
GearshiftMechanism
. . . . . . . . . . .1. 3 - 4 4
Overhaul
Ref. No.
Tool Number
o
@
o
.@
,3)
@
(j)
(q)
)
@
(,
@
@
Description
oTGAJ-PG20110
oTGAJ-PG20120
07GAJ-PG20130
07736-AO10004
o7746-0010300
o7746-0010400
o7746-0030100
MainshaftHolder
Collar
MainshaftBase
AdjustableBearingPuller,25
Attachment,42 x 47 mm
Attachment. 52 x 55 mm
D r i v e r ,4 0 m m l . D .
o7746-0030300
o7746-OO30400
o7749-O010000
07JAD-PH80101
07JAD-PH80200
07947-6110501
07947-6110500
Attachment, 30 mm LD.
Attachment, 35 mm LD.
Driver
Driver Attachment
Pilot, 26 x 30 mm
Seal DriverAttachment
Oty
40 mm
1
1
1
1
I
I
I
I
1
1
1
1
1
I Page Relerence
13-38
13-37
13-37
13-34,35
1 3 - 3 4 ,3 5
1 3 - 3 4 ,3 5
13-19,24,
31,32
13-19,24
13-19,24
13-343
, 5,43
13-43
13-43
13-43
n Must be used with commerciallyavailable3/8 " -'16 Slide Hammer.
ll
\,
at\
(1]
/;i
\
@
13-2
(9
Maintenance
Back-upLight Switch
Transmission
Oil
Replacement
NOTE:Checkthe transmissionoil with the engine OFF

and the vehicleon levelground.
NOTE: To test the back-uplightswitch, seesection23.
1.
Removethe oil fille. plug, then check the leveland

conditionof the oil.
OILFILLERPLUG
44 I{.m (4.5 kgt.m, 33 lbl.ftl
1.
Disconnectthe connector,then removethe back up

light switch connectorlrom the connectorclamp.
2.
Removethe back-uplight switch.
ProperLevel
WASHER
Replace.
The oil level must be up to the filler hole. lf it is

below the hole, add oil until it runs out, then reinstall the oil filler plug with a new washer.
lf the transmissionoil is dirty, removethe drainplug
and drain the oil.
Reinstallthe drainplug with a new washer,and refill
the transmissionwith the recommendedoil to the
properlevel.
NOTE: The drainplugwashershouldbe replacedat
every oil change.
Reinstallthe oil filler plug with a new washer.
25 N'm 12.5 kgf'm, 18lbt.tt)
Replace.
3 . Installthe new washer and back-uplight switch.

Connectthe back-uplight switch connector.
Oil Capacity
1.8 f (1.9 US qt, 1.6 lmp qtl at oil change
1.9 t l2.O US qt, 1 .7 lmp qtl at overhaul
Always use GenuineHonda Manual Transmission
Fluid (MTF).Using motor oil can causestiffershifting becauseit does not contain the proper addittves.
13-3
Troubleshooting
ReverseGear Noise ReductionSystem
Wheneverthe clutch pedal is depressedto shift into reverse,the mainshaftcontinuesto rotate becauseof its inertia.
The resultingspeed differencebetween mainshaftand reverseidler gear producesgear noise.
The reversegearnoisereductionsystememploysa cam platewhich was addedto the reverseshift holder.When shifting
into reverse,the sth/reverseshift piece,connectedto the shift lever,rotatesthe cam plate.This causesthe sth synchro
set to stop the rotatingmainshaft.As there is no speeddifterencebetweenmainshaftand reverseidler gear,there will
be less gear noise.
gear noise reductionsystem.
NOTE: This system is not a fully-synchronized
Therelore,you may hear gear noise when
!) you shift inlo reversewith the vehiclenot yet completelystopped
i2) you shift quickly into reverseduring fast idling.
Gearnoiseis presenlwhen shifting into reverseafler lhe engine

rs slarleo.
ls the gear noisepfesentwhen

shilting into sth gear?
Replacetho sth synchto hub and

sEeve as a sel.
Measurethe clearancebetween
sth shift fork and 5th synchro
sleeve{seepage 13 26).
ls the clearance1.0 mm (0.04

in) or iess?
Measure the MBS shift piece pin

( s e ep a g e 1 3 - 2 7 ) .
l s i t 6 . 8 m m { 0 . 2 7 i n }o r m o r e ?
Reolace the revsrso shift holder.
13 -4
Roplacethe MBs shitt piece.
Removal
6.
Make sure jacks and satety stands are placed properly, and hoist bracksts are attached to correct pos;lion
on the engine.
Apply parking brsko and block rea. wheels so cal will
nol ,oll oft stands and lall on you whils working
under it.
Disconnectthe vehiclespeedsensor(VSS)connector.
vss
CONNECTOR
CAUTION: Use fender covers to avoid damaging

painted surlacas.
1 . Disconnectthe negative(-) cable first, then the
positive(+ l cable from the battery.

Draintransmissionoil (seepage13-3).
Removethe intakeair tube, intakeair duct and air
cleanerhousingassembly(seesection5).
Disconnectthe starter motor cables,transmission
groundwire and back-uplight switchconnector,
7.
6xl .O mm
9.8 N.m (1.0 kgt.m, 7.2 lbf'ft)
Removethe clutch line bracket,clutch line clamp,

and slavecylinder.
CAUTION:
a Do not operate the clutch pedal once the slave
cylinder has been removed.
a Take care not to bend the clutch line.
b
ARTER
8t1.25 mm
8.8 N.m (0.9kgf.m,6.5lbl.ttl
5.
Removethe wire harnessclamos.
(cont'd)
13-5
Removal(cont'd)
8.
10. Removethe shitt rod and extensionrod.
Removethe driveshafts(seesection 16).

NOTE: Coatall the precisionfinishedsur{aceswith
cleanengineoil or grease.Tie plasticbags over the
drivesha{tends.
SHIFTROD
SET RING
DRIVESHAFT
1 0 x 1 . 2 5m m
43 N.m (4.4 kgl.m,
8x22mm
SPRINGPIN
Replace.
\
1 l. Removethe enginestiffenersand clutch cover'
Dl6Y5, Dl6Yg onginos:
10 x 1.25mm
44 N.m {4.5 kgl.m,
COTTERPIN
Replace
12 x '1.25mm
Replace.
4 9 - 5 9 N . m l 5 . O 6 . 0 k g f ' m , 12 x 1 .25 mrn
36 43 tbt.ft)
64 N.m 16.5 kgt.m.47 lbt.ftl
L
33 tbhlrt
8 r 1.25mm
24 N.m (2.4 kgf.m
17 tbt.trl
Remove exhaust pipe A.

GASKETS
Replace.
COVER
ruur.-@
sELF-LocKrNG
EXHAUST
Replace.
PIPEA
I x 1 . 2 5m m
NUT
SELF-LOCKING
1 6 N . m 1 1 . 6k g t ' m ,
Replace.
12 tbf.ftl
D16Y5, Dl6Y7 engins:
NUT 1 0 x 1 . 2 5m m
SELF.LOCKING
Replace.
33 N.m (3.4 ksl'm, 25 lbI'ttl
8 x 1.25mm
D16Y8 engine:
22 N'nt. 12.2 kgl'm,
10 x 1.25mm
16 tbf.fr)
54 N.m (5.5 kgf.m,40 lbt'ft}
13-6
8 x 1.25mm
24 N.m (2.4 kgl'm,
'| 7 tbl.trl
O16Y7 engine:
1 4 . R e m o v et h e r i g h t l r o n t m o u n tb r a c k e t .
1 O x 1 . 2 5m m
4 4 N . m 1 4 . 5k g f. m ,
33 tbf'fr)
8 x 1.25mrh
24 N.m (2.4 kgf.m,
17 tbf.fr)
ENGINE
STIFFENER
1 0 X 1 . 2 5m m
44 N.m 14.5kgl.m,33 lbt.ttl
Installthe bolts in the cylinderhead and attach a
chainhoist to the bolts,then lilt the engineslightly
to unloadthe engineand transmissionmounts.
' 1 2x 1 . 2 5 m m
RIGHTFRONT
MOUNT/BRACKET
64 N.m (6.5 kgt.m,47 lbt.ttl
CHAINHOIST
1 5 . P l a c ea j a c k u n d e rt h e t r a n s m i s s i o n .
16. Removethe transmission
mountbracketand mount.
TRANSMISSION
MOUNT
TRANSMISSION
BRACKET
1 3 . B e m o v et h e s p l a s hs h i e l d .
SPLASHSHIELD
(cont'd)
13-7
Removal(cont'd)
Installation
17. Removethe threeuppertransmission

mountingbolts
and the lower starter mountingbolt.
Installthetransmissionassemblyin the reverseorderol

removal.
a Beforeinstalling,check that the two dowel pins are
i n s t a l l e di n t h e c l u t c hh o u s i n g .
a When installingthe startercable,make surethat the
crimped side of the ring terminalis facing out {see
s e c t i o n2 3 ) .
a Apply greaseto the parts as shown, then installthe
r e l e a s ef o r k a n d r e l e a s eb e a r i n g .
NOTE:Use only Super High Temp Urea Grease
( P / N0 8 7 9 8- 9 0 0 2 ) .
STARTER
MOUNTING
BOLT
1 0 x 1 . 2 5m m
44 N.m {4.5 kgl.m,
33 tbt.trl
TRANSMISSION
MOUNTINGBOLTS
1 2 x 1. 2 5 m m
64 N.m (6.5kgf.m,47 lbt,tt)
1 8 . R e m o v et h e r e a rm o u n tb r a c k e bt o l t sa n dt r a n s m i s
sion mountingbolts
spEcrALBoLT
Replace.
1 4 x ' l . 5m m
RELEASEFORKEOLT
1 2 x 1 . 2 5m m
29 N.m {3.0 kgt.m,
tPiN 08798-9002)
22 tht.trl
RELEASE
FORK
BOOT
a 4 N . m { a . Sk g f . m , 6 1 t b f , t t l
12 x 1.25mm
6 4 N . m 1 6 . 5k g f . m , 4 7 l b f . f t )
{P/N08798
9002)
RELEASE
FORK
lP/N08798-9002)
0 . 3 0 . 9s
{ 0 . O -10 . 0 3 o z )
WASHER
SPECIALBOLT
Replace.
14 x 1.5mm
84 N'm 18.5 kgl.m, 61 tbf.ft)
'1 Pull the transmission away from the engine until it

9.
c l e a r st h e m a i n s h a f t ,t h e n l o w e r i t o n t h e t r a n s m i s sion jack.
CAUTION: Take care not to bend the clutch line.
13-8
a Torquethe mountingbolt and nuts in the sequence

shown.
A 1 2 x 1 . 2 sn m
64 N.m {6.5 kgf.m,
a ) 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m,
47 tbI.tt)
a Apply greaseto the slave cylinderpush rod.

NOTE: Use only Super High Temp Urea Grease
( P / NO 8 7 9 8 9 0 0 2 ) .
6 x 1.0mm
9.8 N'm (1.0kgt.m,
7 .2 tbt.ltl
CLUTCH
PIPE
@ 1 2 x 1 . 2 5m m
7 4 N ' m 1 7 . 5k g f . m ,
54 lbt.tt)
a Check that the bushingsare not twisted or offset.
a Installthe clip as shown.
8 x 1.25mm
22 N.m 12.2 kgl.m,
tP/N08798_9002) 16 tbt.fl)
Turn the breathercap so that the "F" mark pointsat
the front of the car as shown.
FRONT
SHIFTROD
8 x 1 . 2 5m m
22 N.m 12.2 kgt,m, 16 lbt.ftl
gx22mm
SPBING
PIN
Replace.
I -/:'.G
BOD
,// EXTENSTON
/.t***rrm"'i@
,z-s;c,r
oown
).,,
a Turn the boot so the hole is facing down.

a Make sure the boot is installedon the shift rod.
Retill the transmission with the recommended oil

(seepage 13-3).
Connect the positive (+ ) cable first, then the negative {- ) cable to the battery.
a Check the clutch operation.
a Shift the transmission and check for smooth
operation.
'18).
Check the front wheel alignment (see section
lllustratedIndex
Referto the drawing below for transmissiondisassembly/reassembly

Cleanall the parts thoroughlvin solvent and dry with compressedail
I
LuOricateall the parts with oil belore reassembly.
NOTEI
a This transmission
usesno gasketsbetweenthe maiorhousings;useliquidgasket{P/N0871 I - 0001 or 08718 - OOO3)
( s e ep a g e 1 3 - 4 ' l ) .
a Always clean the magnet@ wheneverthe transmissionhousingis disassembled.
a Inspectall the bearingsfor wear and operation.
I
+v
d b +
;- 6
\"
13-10
Torqu Value
A - 15 N.m {1.5kgf'm.11 lbf.ft)
B - 27 N.m (2.8kgim,20 lbf.ft)
C - 31 N.m (3.2kgf.m,23 lbf.ft)
O BALLBEARING(*1I
ANGULAR
BALL EEARINGIT2)
@ sTH sYNcHRo HUB
O 5TH SYNCHRoSLEEVE
@ SYNCHROSPRING
RING
@ SYNCHRO
@ 5TH GEAR
@32xazxz:.5mm
NEEDLEBEARING
@ SPACERcoLLAR
@3lx3gxz3mm
NEEDLEBEARING
@ 4TH GEAR
O SYNCHRoRING
@ SYNCHROSPRTNG
@ 3RD/4THSYNGHRoSLEEVE
@ 3RD/4THsYNcHRo HUB
@ 3RD GEAR
@34x39x27.5mm
NEEDLEBEARING
@ MAINSHAFT
@ WASHER
@ SPRINGWASHER
@ BALL BEARING
Checkfor wear and
operalron.
@26x42x7mmOlLSEAL
Replace.
@ 28 mm PLUGBOLT
54 N.m {5.5 kgt.m, 40 lbf.ft)
@ 1ST/2NDSELECTSPRING
L. 36.26mm (1.428inl
SHIFT
ARM SHAFT
@
@ CLUTCHHOUSTNG
@ INTERLoCKGUIDEEoLT
39 N.m 14.0kst.m, 29 lbf.ft)
@ REVERSESHIFTHOLDER
@ REVERSEIDLERGEAR
GEARSHAFT
@ REVERSETDLER
@ 5 x 22 mm SPRINGPIN
Replace.
@ 3RD/4THSHIFI PIECE
@ sTH/REvEnsESHIFTPIECE
@ MBS SH|FTP|ECE
@ lsT/zNo SHIFI FoRK
3RD/.TH SHIFr FoRK

5TH/REVERSE
sHIFT FoRK
52 mm SNAP RING
65 mm THBUSTSHIMl*11
70 mm THRUSTSHIM l*21
Selection,page 13-36
@ OIL GUIDEPLATE
@ WASHERReplace.
@
@
O
@
LrcHT
swrrcH
@ BAcK.uP
25 N.m (2.5 kgt'm, 18 lbf.ft)
@ sETscREw
22 N.m (2.2 kgt.m, 16lblftl

WASHERReplace.
SPRINGL.31.6mm (1.24in)
STEELBALL (5/16 in)
BACK.UPLIGHT
SWITCHHARNESSSTAY
@ TRANSMISSIONHANGER
@ 32 mm SEALINGBOLT
25 N.m (2.5 kgf.m, 18 lbt,ft)
@ OIL SEAL
Replace.
@ OII DRAINPLUG
39 N'm {4.0 kgf.m, 29 lbf.ftl
@ WASHERReplace.
@ OIL FILLERPLUG
44 N.m (4.5 kgf.m. 33 tbf'ft)
@ WASHERReptace.
@ TBANSMISSIONHOUSING
@ RELEASEPIPESTAY
@ OIL GUTTERPLATE
@ REVERSELocK cAM
@ REVERSESELECTSPRING
L. 63.4 mm l2.i6 in)
@ REVERSESELECTRETAINER
@ SHIFTARM c
@ SHIFTARM B
@ INTERLOCK
@ COLLAR
@ SHIFI ARM A
@ SPBINGWASHER
@ MAGNET
@ SETEALL SPRINGBOLT
22 N.m (2.2 kgl.m, 16 lbf.ft)
@ r4 x 20 mm DOWELPIN
@
@
@
@
@ 72 mm THRUSTSH|M t'1)
80 mm THRUSTSHIM {*2)
Selection,page 13-33
ASSEMBLY
@ DIFFERENTIAL
Seepage 13-30
@ 14 x 25 x 17.5mm OtLSEAL
Replace.
@35x56x8mmOlLSEAL
Replace.
@sHrFrRoD
@ BOOr
@ oIL GUIDEPLATE
@30xlzx2tmm
('1}
NEEDLE
BEARING
3 0 x 5 5 x 2 1m m
NEEDLE
EEARING
IT2)
@ COUNTERSHAFT
@ 3 6 x 4 1x 2 5 . 5m m
NEEDLE
BEARING
Check
for wearand
ooeralton.
@ lsT GEAR
DAMPER
@ FRICTION
@ sYNcHRoR|NG
@ sYNcHRoSPRTNG
@ 1ST/2NDsYNcHRoHUB
GEAR
@ REVERSE
SPRTNG
@ SYNCHRO
FING
@ SYNCHRO
DAMPER
@ FRICTION
@ SPACER
@39xllx2zmm
NEEDLE
BEARING
@ 2NDGEAR
@ 3RDGEAR
@ 4THGEAR
@ 5THGEAR
{*1)
@ EALLBEARTNG
NEEDLE
BEARING
I*2I
@ BALLBEARING
WASHER
@ SPRING
Reptace.
@ LoCKNUT
1 0 8+ 0 * 1 0 8N . m
f r r . o* o * 1 1 . 0k g f . m , l
lrs.e* o- 79.6tbtft |
r 1 : D l 6 Y 7 n g i n .
12: D16Y5.D16Y8engines
13-11
Housing
Transmission
Removal
Loosenthe transmissionhousingattachingbolts in
a crisscrosspattern in severalsteps.then remove
them.
NOTE:Placethe clutch housingon two piecesof wood

t h i c k e n o u g ht o k e e p t h e m a i n s h a f tf r o m h i t t i n g t h e
workbench.
1.
Removethe back-uplight switch.
2.
Removetransmissionhanger.
5.
Removethe 32 mm sealingbolt.
Expandthe snap ring on the countershaftball bearing, and remove it from the groove using a pair of
snap ring pliers.
TRANSMISSION
HAt{GER
32 mm SEALINGBOLT
SNAP RIIIG
Removethe setting screws,washers,springs,and

steelballs.
Separatethe transmissionhousingfrom the clutch

housing,and wipe it cleanol the sealant.
Removethe thrust shim,oil guide plate,and oil gutter plate{rom the transmissionhousing.
STEELBALLS
D.5/16in
SPRING
L . 3 1 . 6 m m 1 1 . 2 4I n l
TRANSMISSIONHOUSING
13-12
ReverseShift Holder
ClearanceInspection
1 . Measurethe clearance
betweenthe reverseshiftfork
and sth/reverseshift Dieceoin.
3.
Measurethe clearancebetweenthe reverseidlergear

a n d t h e r e v e r s es h i f t f o r k .
Standard: 0.O5-O.35 mm (O.OO2-0.O14

in)
ServiceLimit: 0.5 mm {0,02 inl
Standardr 0.5-1.1 mm {O.02-0.04 in}

S e . v i c eL i m i t : 1 . 8 m m ( 0 . 0 7 i n t
IDLEBGAB
REVERSE
REVERSE
REVERSE
SHIFTFOBK
2 . lf the clearancesare more than the service limit,

measurethe widths of the groovein the reverseshift
fork.
Standard:7.15- 7.35 mm (0.281- 0.289inl
lf the clearanceis morethan the servicelimit,measure the width of the reverseshift fork.
S t a n d a r d 1: 2 . 7- 1 3 . O m m ( 0 . 5 0 0 - 0 . 5 1 2 i n )
REVERSE
SHIFTFORK
SHIFTHOLDER
REVERSE
REVERSE
SHIFTHOLOEB
lf the widths of the grooves are not within the

standard,replacethe reverseshift holderwith a
new one.
lf the width of the groovesare within the standard, replacethe sth/reverseshift piece with a
new one.
lf the width is not within the standard,replace

the reverseshift holderwith a new one.
lf the width is within the standard,reDlacethe
reverseidler gearwith a new one.
13-13
Reverseldler Gear
Removal
1.
Remove the reverse shift holder.

REVERSE
SHIFT
HOLDER
Mainshaft,Countershaft,
Shift Fork
Disassembly
1 . Remove the interlock guide boh trom under the
clutch housing.
SHIFTARM8
ATTACHINGEOLT
SPRING
WASHER
CLUTCH
HOUSING
2. Removethe reverseidlergearshattand reverseidler

geat.
II{TERLOCK
GUIDEBOLT
2 . Removethe shift arm B attachingbolt.

REVERSEIDLER
GEARSHAFT
Removethe mainshalt and countershaft assemblies

with the shift lork trom the clutch housing.
NOTE: Belore removingthe mainshalt and countertape the mainshaftsplinesto proshaft assemblies.
tect the seal.
Tape the mainshaft
sp nes.
WASHER
SPBING
WASHER
13 - 1 4
MainshaftAssembly
Index
Notethe followingduring reassembly:
. The 3rd/4thand sth synchrohubs are installedwith a press.
. Installthe angularball bearingwith the thin-edgeouter racefacingthe sth synchrohub.
. Installtheball bearingwith the bsll cagefacingup.
Priorto reassembling.
cleanall the partsin solvent.dry them and applylubricantto all contactsurfacesthe 3rd/i[th
and sth svnchrohubs,
Ball cage faces up.
BALLBEARING{T1}
ANGULARBALLBEARING('2I
Checkfor wearand operation.
Note the directionof installation.
3RD/4THSYNCHROSLEEVE
p a g e1 3 2 7
SYNCHROHUB
sTH SYNCHRO
SLEEVE
page13 27
lnspection,
SPRING
SYNCHROSPRING
SYNCHRORING
Inspection,
p a g e1 3 - 2 8
SYNCHRORING
Inspection,page 13'28
5TH GEAR
I n s p e c t i o np,a g e 1 3 - 1 7
3RO GEAB
Inspection,page 13'16
34 x 39 x 27.5 mm
NEEDLEBEARING
Checkfor wear
ano operalron.
MAINSHAFT
I n s p e c t a opna, g e 1 3 - 1 8
CHAMFER
NEEOLEBEARING
Checkfor wear and
operation.
SPACERCOLLAR
Inspection,page 13-'t6
34x39x23mm
NEEDLEEEARING
Check for wear
ano operalton.
4TH GEAB
I n s p e c t i o np,a g e 1 3 - 1 6
RING
Inspection,page 13-28
SPRING
D16Y7engine
D16Y5,D16YBengines
13-15
MainshaftAssembly
Inspection
Clearance
NOTE: lI replacementis required,always replacethe
svnchrosleeveand hub as a set.
1. Measurethe clearancebetween2nd and 3rd oears.
3.
Measurethe clearancebetween 4th gear and the

soacercollar.
inl
Standard:
0.06-o.19 mm (O.OO2-O.OO7
ServiceLimit: O.31 mm {0.012 in}
Standaid:
0 . 0 6 - O . 2 1 m m { O . O 0 2 - O . O Oi8n }
Ssrvice Limit: O.33 mm (O.O13inl
4TH GEAR
--,
t l,-
/ /hm
[nI
2ND GEAR
r[Jl]
i
r
tl-lll
q l
\ \-,l-LJ
\- cltl-l
3RD GEAB
5TH GEAR
lf the clearanceis morethan the seryicelimit,measure distance@ on the spacercollar.

Standard:
22-82-22.86nm
{ 0 . 8 9 8 - O . 9 O 0i n }
ServiceLimit: 22-81 mm (0.898 in)
2 . lf the clearanceis morethan the servicelimat.measure the thicknessof 3rd gear.
4TH GEAR
stoE
Standard:
30.22-30.27mm
{ 1 . 1 9 0 - 1 . 1 9 2i n l
S e r v i c eL i m i t :3 0 . 1 5 m m ( 1 . 1 8 7 i n l
3RO GEAR
SPACEB
COLLAR
lf distance@ is lessthan the servicelimit, replace

the spacercollar with a new one.
lf distance@ is within the servicelimit,measurethe
thicknessof 4th gear.
3 O . 1 2- 3 0 . 1 7 m m
1 1 . 1 8 6 -1 . 1 4 8i n )
Ssrvicelimit: 30.05 mm {1.183 in)
Standard:
4TX GEAR
a lf the thicknessot 3rd gear is lessthan the service limit, replace3rd gear with a new onea lf the thicknessof 3rd gear is within the servrce
limit,replacethe 3rd/4thsynchrohub with a new
one.
13-16
lf the thicknessof 4th gearis lessthan the service limit, replace4th gear with a new one.
It the thicknessof 4th gear is within the service
llmit, replacethe 3rd/4th synchro hub with a new
one.
Disassembly
6.
Measurethe clearance
betweenthe spacercollarand
sth gear.
1 . R e m o v et h e b a l l b e a r i n gu s i n ga b e a r i n gp u l l e ra s
shown.
BEARINGPULLER
(Commercially
available)
S t a n d a r d : O . 0 6 - O . 1 9 m m ( 0 . 0 O 2 - O . O O 7i n l
S6rvicelimit: O.31 mm (0.O12 in)
4TH GEAR
DIAL
INDICATOR
*3'4>
--t
sTH GEAR
1 . lf the clearanceis morethan the servicelimit.measure distance@ on the spacercollar.
Standard:
23.53-23.56mm
(0.926-0.928 inl
Servics Limit:23.51 mm (0.926 in)
CAUTION: Removethe synchrohubs usinga piess

and steel blocks as shown. Use of a.iaw-type puller
can causedamageto the gear teeth,
sTH GEAR
stoE
2.
lf distance@ is less than the servicelimit, replace
the sDacercoliar with a new one.
lf distance@ is within the servicelimit, measure
thicknessof sth gear.
Support4th gearon steelblocks,andpressthe main'

shaft out of the sth synchro hub as shown.
28.42-28.47mm
( 1 . 1 1 9 -1 . 1 2 1i n l
ServiceLimit: 28.35 mm l1 . l 16 in)
Standald:
sTH GEAR
It the thicknessof sth gear is lessthan the service limit, replace5th gear with a new one.
lf the thicknessof sth gear is within the service
limit,replacethe 5th synchrohub with a new one.
{ c o n t ' d}
13-17
MainshaftAssembly
(cont'dl
Disassembly
3.
Supportthe 3rd gearon steelblocks,and pressthe

mainshaltout of the 3rd/4thsynchrohub as shown.
Inspection
I.
Inspectthe gear surtaceand bearingsurfacefor wear

and damage,then measurethe mainshaftat points
A, B, C, and D.
A: 21 .987-22.OOO mm
{0.8656-0.8661 in}
B: 26.980-26.993 mm
11.0622- 1 .0627 inl
C: 33.984-34.OOO mm
( 1 . 3 3 8 0 - 1 . 3 3 8 6i n )
D: 25.977-25.990 mm
11.0227 -'l .0232 inl
ServiceLimit: A: 21.93O mm (O.8634 inl
B : 2 6 . 9 3 0 m m { 1 . 0 6 0 2i n }
C : 3 3 . 9 3 0 m m { 1 . 3 3 5 8i n }
D : 2 5 . 9 2 0 m m { 1 . 0 2 0 5i n }
Standard:
Checktor wearanddamage
lf any part of the mainshaftis lessthan the servicelimit,
replaceit with a new one.
2.
Inspecttor runout.
O.O2mm {O.0O1in} max.
Standald:
Ssrvico Limit: 0.05 mm {0.0O2 inl
NOTE: Suooort the mainshaft at both ends as
snown.
lf the runout is more than the servicelimit, replacethe

mainshaftwith a new one.
13-18
Reassembly
CAUTION: When installing the 3rd/,lth and 5th synchro
hubs, support the shaft on steel blocks. and instsll the
synchro hubs using a press.
3.
Installthe sth synchrohub using the specialtools

ano a oress.
NOTE:Referto page 13-15for reassemblysequence.

1.
Support 2nd gear on steel blocks,then install the

3rd/4thsynchro hub using the specialtools and a
press,
DRIVER,40 mm l.O.
07746 - 0030100
ATTACHMENT,
30 mm LD.
o7746-0030300
sTH SYNCHROHUB
ORIVER.40 mm l.D
o7746 -0030100
ATTACHMENT,
35 mm LO.
o7746 -OO30400
Installthe ball bearingusingthe specialtools and a

press.
2ND GEAR
2.
I n s t a l lt h e 3 r d l 4 t hs y n c h r os l e e v eb y a l i g n i n gt h e
stopsof the 3rd/4thsynchrosleeveand hub.
NOTE:After installing,checkthe operationof the
3rdl4thsynchrohub set.
SYNCHROSLEEVE
*1: D'16Y7
engine
*2r D16Y5,D16YBengines
13-19
GountershaftAssembly
Index
NOTE:The 3rd, 4th,and sth gearsare installedwith a press,
Prior_to
reassembling,
cleanall the partsin solvent,dry them and apply lubricantto all contactsurfacesexceptthe
3rd.4th,and 5th gears.
Snap ring groove laces up.
OCKNUTReplace.
108-0- lOgN.m
I 1 1 . 0 - 0 - . 1 1 . 0k g f . m l
| 79.6- 0- 79.6 lbnlr I
SYNCHROSPRING
SYNCHRORING
FRICTIONDAMPER
lST GEAR
l n s p e c t i o np,a g e 1 3 2 1 , 2 8
WASHER
BEARING
Checkfor wear and
operation.
(* 1)
/ BALL EEARTNG
(*2)
I NEEDLEBEARTNG
Check for wear
and operation.
GEAR
4TH GEAR
3RO GEAR
2ND GEAR
lnspection,page 13-21, 28
39x44x27 mn
NEEDLEBEARING
Checktor wear and
operation.
SPACERCOLLAR
FRICTIONDAMPER
36 x 41 x 25.5 mm
NEEOLEBEARING
Check for wear and operation.
I n s p e c t i o np,a g e 1 3 - 2 3
SYNCHRORING
SYNCHROSPRING
REVERSE
GEAR
page 13-27
lnspecta.on,
1ST/2NDSYNCHROHUB
*1: D16Y7engine
'2: D16Y5,D16Y8engines
13-20
ClearanceInspection
NOTE: lf replacementis required,always replacethe
synchrosleeveand hub as a set.
1 . M e a s u r et h e c l e a r a n c eb e t w e e nt h e c o u n t e r s h a f t
and lst geaf.
S t a n d a l d : O . O 3 - O . 1 Om m ( 0 . 0 O 1- 0 . 0 O 4 i n )
ServiceLimit: 0.22 mm {0.0O9 in}
3.
M e a s u r et h e c l e a r a n cbee t w e e n2 n d a n d 3 r d q e a r s
S t a n d a , d : O . O 4 - O . 1 2m m ( 0 . 0 0 2 - 0 . 0 0 5 i n )
ServiceLimit: 0.24 mm {0.009 in)
3RD GEAR
FEELER
GAUGE
SPACER
COLLAR
2NO GEAR
lf the clearanceis morethan the servicelimit,measure the thicknessot the spacercollar.
3 2 . 0 3 - 3 2 . 0 6m m
11.261- 1.262 inl
Standard:
GAUGE
2.
ServiceLimit: 32.01 mm l1 .260 inl
lf the clearanceis morethan the servicelimit,measu r e t h e t h i c k n e s so f 1 s t g e a r .
SPACER
COLLAR
Standard:
30.41-30.44mm
{ 1 . 1 9 7 - 1 . 1 9 8i n }
S e r v i c eL i m i t : 3 0 . 3 6 m m ( 1 . 1 9 5 i n )
1 S TG E A B
5 . lf the thicknessis lessthan the servicelimit. reDlace

the spacercollar with a new one.
lf the thicknessis within the servicelimit, measure
the thicknessof 2nd gear.
31.91- 31.96mm
- 1.258inl
11.256
S.rvicoLimit:31.85mm (1.25i1in)
Standard:
/-?:-
Af
2rlDGEAR
t
\
-
-N/
/
l
L'rz::---h_l
i I t h e t h i c k n e s so f 1 s t g e a ri s l e s st h a nt h e s e r v
i c e l i m i t ,r e p l a c e1 s t g e a r w i t h a n e w o n e .
lf the thicknessof l st gear is within the service
limit,replacethe 1st/2ndsynchrohub with a new
one.
lf the thicknessot 2nd gear is lessthan the servi c e l i m i t ,r e p l a c e2 n d g e a rw i t h a n e w o n e .

lf the thicknessof 2nd gear is within the service
limit,replacethe 1st/2ndsynchrohub with a new
one.
13-21
GountershaftAssembly
Disassembly
CAUTION: Remove the gears using a pr6ss and stel
blocks as shown. Use of a iaw-type pullor can damage
the gear toeth.
4.
Suppon4th gearon steelblocks,and pressthe countershaftout of sth and 4th gearsas shown.
1 , S e c u r 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 a
benchvisewith wood blocks.
2.
Raisethe locknuttab from the groove of the countershaft,then remove the locknut and the spring
wasner.
4TH GEAR
Support 1st gear on steel blocks,and pressthe countershaftout of 3rd gear as shown.
WOODBLOCKS
3,
R e mo v e t h e b e a r i n g su s i n g a b e a r i n gp u l l e ra s
shown.
BEARINGR'LLER
13-22
Inspection
t.
Inspectthe gear surfacesand bearingsurfacesfor

wear and damage,then measurethe countershaft
at pointsA. B. and C.
A: 30.000- 30.015mm
{ 1 . 1 8 1-1 1 . 1 8 1 i7n l
B: 35.984- 36.000mr'
{1.4167- 1.4r73inl
C: 24.980- 24.91t3mm
10.9835- 0.9840in)
SrviceLimh: A: 29.950mm (1.1791in)
B: 35.930mm (1.41i[6in]
C: 2/+.930mm (0.9815inl
Standard:
Reassembly
CAUTION:
. Prcssthc 3rd. 4th, and 5th gelrs on thc cour*crshaft
whhoul lubrication.
. When installing the 3rd, 4th, and sth gea.5, support
the shaft on 3te6l blocks and install the gas.r uring a
prass.
NOTE: Referto page 13-20for reassemblysequence.
1.
Installtheneedlebearingon the countershaft.

36 x 41 x 25.5 rnm
NEEDLEBEARII{G
COUNTERSHAFT
Check oil passages

for clogging.
2.
Assemblethe Dartsbelow as shown.

NOTE:Checkthat the fingersof the frictiondamper
are securelyset in the groovesof the 1sv2ndsynchro hub.
2.
lf anv oart of the countershsftis less than the

servicelimit, replaceit with a new one.
2 D GEAR
lnspectfor runout.
39r44x27mm
I{EOLE BEARIIIG
Standard:
0.02 mm {0.001in) max.
SorviceLimh: 0.05 mm 10.002in,
SPACERCOLLAB
FRICTIOII DAMPER
SY'{CHRO RING
SYI{CHROSPNING
REVERSEGEAB
lST/21{D
SYNCHNOHUB
SY]TCHROSPRING
SYNCHRORING
FRICTIONDAMPER
1ST GEAR
lf the runout is more than the servicelimit. replace

the countershaftwith a new one.
3.
Installthe oarts on the countershaft.

(cont'd)
CountershaftAssembly
(cont'd)
Reassembly
4.
SuoDortthe countershafton a steelblockas shown

and install 3rd gear using the specialtools and a
oress,
7.
Installthe bearingsin the directionshown usingthe

specialtoolsand a press.
CAUTION: Install the barings with a maximum
prssureof 7.8 kN (8m kd. 5.786lbf).
DRIVER,40 mm l.D.
o7746-0030100
ATTACHMENT,
35 mm LO.
07746 -OO30400
Snapring
faces up,
Ball cage faces up.
5.
Install4th gear usingthe specialtools and a press.
DRIVER,40 lnm
*1: D16Y/engine
+2:D16Y5,D16Y8engines
07746-0030100
ATTACHMENT,
35 mm l.D.
07746-OO3O/IOO
S e c u r 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 a
benchvisewith wood blocks.
TH GEAR
LOCKNUT
108*0-108N.m
111.0* 0 * 11.0kgf.m,79.6+ 0+ 79.6lbf.ft)
LOCKNUT
Replace.
6.
Installsth gear usingthe specialtoolsand a press.

DRlvER,40 mm l.O.
07746-0030100
ATTACHMENT,
30 mm l.O.
07746-0030300
sTH GEAR
13-24
Installthe spring washer,tighten the locknut,then

stakethe locknuttab into groove.
Shift Fork Assembly

lndex
---'rl
'f
erlorto reassembling,
cleanall the partsin solvent,dry them,andapplylubricantto anYcontactparts
3RO/4THSHIFTFORK
5TH/REVERSE
SHIFTFORK
1ST/2NDSHIFTFORK
MBS SHIFT
PIECE
5TH/REVERSE
SHIFTPIECE
3RO/4lH
SHIFTPIECE
'13-25
Shift ForkAssembly
ClearanceInspection
NOTE:The synchrosleeveand the synchrohub should
be replacedas a set.
1.
Measurethe clearancebetweeneach shift fork and

its matchingsynchrosleeve.
3.
Measurethe clearancebetweenthe shift oiece or

shiftfork and the shift arm B.
Standard:
0.2 - 0.5 mm (0.008- 0.02 in)
ServiceLimit: 0,62 mm {0.024ifin)
Standard:
0.35- 0.65 mm (0.014- 0.026in)
ServiceLimit 1.0 mm (0.0{ in)
SHIFTARMB
lf the clearanceis more than the servicelimit, measurethe thicknessof the shiftfork finqers.
".
lf the clearanceis more than the servicelimit, measurethe grooveof the shift pieceor shiftfork.
Stsndard:13.2- 13.4mm {0.520- 0.528in}
Siandard;
3rd/,fth:
7.4 - 7.6 mm {0.291- 0.299in)
lst/2nd, 5th: 6.2 - 6.,f mm (0.244- 0.252in)
SHIFTFORK
lf the thicknessof the shift fork fingers is not

within the standard, reDlacethe shift fork with a
new one.
lf the thicknessof the shift fork fingers is within
the standard.replacethe synchrosleevewith a
new one.
13-26
lf the groove of the shift piece or shift fork is not

within the standard, replacethe shift pice or
shift fork with a new one.
lf the groove of the shift piece or shift fork is
within the standard,reDlacethe shift arm B with
a new one.
SynchroSleeve,
SynchroHub
MBS Shift PieceInspection
1.
Measurethe width of the MBS shilt piece.
lnspection/lnstallation
1.
I n s p e c tg e a r t e e t h o n a l l s y n c h r o h u b s a n d s y n c h r o
s l e e v e sf o r r o u n d e d o l f c o r n e r s ,w h i c h i n d i c a t e
6.9-7.1 mm (O.272-O.2aO in)

Standard:
SoryiceLimit: 5.8 mm (O.268 inl
I n s t a l le a c h s y n c h r o h u b a n i t s m a t l n g s y n c h r o
sleeve, and check for freedom oI movement.
N O T E : l f r e p l a c e m e n ti s r e q u i r e d , a l w a y s r e p l a c e
the synchro sleeve and synchro hub as a set.
SYNCHRO
SLEEVE
lf the width of the MBS shift pieceis lessthan

servicelimit, replacethe MBS shift piece.
When assemblingthe synchrosleeveand synchro

hub, be sureto matchthe three sets of longerteeth
(120 degreesapart)on the synchrosleevewith the
three sets ol deepergrooves in the synchro hub.
CAUTION: Do not install the svnchro sleove with
its longer leeth in the synchro hub slots because it
will damagethe spring ring.
LONGERTEETH
13-27
SynchroRing,Gear
Inspection
SYNCHRO
I n s p e c t h e s y n c h r or i n g a n d g e a r .
A r I n s p e c t h e i n s i d eo f t h e s y n c h r o r i n g l o r w e a r .
8: lnspectthe synchro sleeveteeth and matching
teeth on the synchro ring for wear (rounded off).
oo
GOOOWORN
C: Inspectthe synchro sleeve teeth and matching
teeth on the gear for wear (rounded off).
/\... ,,-\.
\---l (rl
GOOOWORN
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe cone surfacefor wear and roughness.
F : I n s p e c t h e t e e t ho n a l l g e a r sf o r u n e v e nw e a r ,
s c o r i n gg, a l l i n ga, n dc r a c k s .
2.
Coatthe cone surfaceof the gear with oil, and place

t h e s y n c h r or i n g o n t h e m a t c h i n gg e a r .R o t a t et h e
synchroring, makingsurethat it does not slip.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e s y n c h r or i n g
a n dg e a ra l l t h e w a y a r o u n d .
NOTE: Holdthe synchroring againstthe gear evenl y w h i l em e a s u r i n tgh e c l e a r a n c e .
Synchro Ring-to-GearClearance
Standardi 0.73-1.18 mm (0.029-O.046inl
ServiceLimit: 0.4 mm (O.O2inl
l f t h e c l e a r a n cies l e s st h a nt h e s e r v i c el i m i t ,r e o l a c e
the synchroring and synchrocone.
13-28
SYNCHRO
shift Rod
Removal
6 . R e m o v es h i f ta r m sC a n d B , a n dt h e i n t e r l o c kt,h e n
r e m o v et h e r e v e r s es e l e c ts p r i n ga n d r e t a t n e r .
N O T E :T h es t e e bl a l l s a r e aol lf t h e s a m e s i z e ( 5 / 1 6 i n ) .
1.
Removethe diff;rential assemory.
2.
Removethe 28 mm plug bolt and 1st/2nd select

spring.
7 . R e m o v et h e s h i f t a r m A a t t a c h i n gb o l t ,t h e s e t b a l l
s p r i n gb o l t , s e t s p r i n g ,a n d s t e e lb a l l .
8 . R e m o v et h e s h i f tr o d ,t h e n r e m o v et h e s h i f ta r m A .
3 . Removethe shitt arm C attachingb o l t .

9 . Removethe reverselock cam.
Removethe shilt arm shalt.
1 0 . R e m o v et h e m a g n e t .
NOTE: Be careful not to lose the s t e e l b a l l .
5 . Removethe steel ball, spring,and c o a r .
REVESSE
LOCKCAM
SHIFTARM C
,Y/
REVERSE
SELECTRETAINER
\s
SHIFTARM B
SLECT SPRING
L. 63.4 mm (2.50 inl
INTERLOCK
SPRINGL. 21.4 mm
{0.843 in)
SET BALL
SPRINGBOLT
SHIFTARM A
COLLAR
SPRING
L . 2 5 . 6 m m 1 1 . 0 1i n )
14x20
DOWELPIN
CLUTCH
HOUSING
ASSEMBLY
DIFFERENTIAL
6p*
\
^s*
\
ssrrrinru spnrr
OIL SEAL
Replace.
\',)r,r*o
"r..", "r*,*o
L . 3 6 . 2 6 m m { 1 . 4 2 8i n l
SHIFTBOO
\
28 mm PLUG BOLT
13-29
Differential
Index
BacklashInspection
1.
Placedifferentialassemblyon V-blocks,and install

both driveshafts.
PINIONGEARS
:'ylT'Y:-1.91"*4w
checktorwear^;Ul
2 . Measurebacklashof both pinion gears.
BALL AEARING
Check lor wear and damage.
10x 1.0
1 0 1 N ' m 1O.3 kgl.m, 74.5 tbt'ft1
Left-hand threads
13-30
Standard{Newl:0.05-O.15 mm (O.0O2-O.006in)
3 . It the backlashis not within the standsrd,reolace

the ditterentialcarrier.
BearingReplacement
Final Driven Gear Replacement
NOTE: Check bearingsfor wear and rough rotation.

the bearingsare OK, removalis not necessary.
't
1.
Remove the bolts in a crisscross pattern in several

steps, then remove the final driven gear from the
differential carrier.
Remove the ball bearings using a bearing puller as

NOTE: The final driven gear bolts have left-hand
threads.
PULLER
(Commercially
available)
FINALDRIVENGEAR
Chamferon ansidediameterol
final drivengear faces carrier.
BALL BEARING
2.
Installnew ball bearingsusing the specialtool as

shown.
NOTE: Drivethe bearingssquarelyuntil they bottom againstthe carrier.
1 0 x 1 . 0m m B O L T
101 il.m (10.3kg{'tn,74 5 lbl'tt)
threads.
Left-hand
DRIVER,40 mm l.O.
7746- 0030100
2.
Installthe final driven gear by tighteningthe bolts

in a crisscrosspattern in severalsteps.
BALL BEARING
13-31
Differential
Thrust Shim Adjustment
1 . I n s t a ltlh e d i f f e r e n t i aals s e m b l ym
, a k i n gs u r ei t b o t t o m s i n t h e c l u t c hh o u s i n gu, s i n gt h e s p e c i a l t o oal s
sh o wn .
3 . Installthe transmissionhousing(seepage 13-41).

NOTE: Do not applyliquidgasketto the matingsurtace of the clutch housing.
Tighten the transmissionhousingattaching bolts
( s e ep a g e 1 3 - 4 2 ) .
8 x 1 . 2 5m m
27 N.m (2.8 kgt'm, 20 lbf.to
5.
Usethe specialtool to bottom the differentialassembly in the clutch housing.
DRIVER,40 mm l.D.
07746 -0030100
I n s t a l tl h e t h r u s ts h i m .
N O T E : I n s t a l tl h e s a m es i z et h r u s ts h i m t h a t w a s
removed.
6.
13-32
Measureclearancebetweenthrust shim and beari n g o u t e r r a c ei n t r a n s m i s s i ohno u s i n g .
7.
ll the clearanceis more than the standard,selecta

n e w t h r u s ts h i m f r o m t h e f o l l o w i n gt a b l e .
NOTEr lf the clearancemeasuredin step 6 is within
t h e s t a n d a r dg, o t o s t e p 1 O .
S t a n d a r dO
: -0.1O mm l0-0.OO4 in)
72 mm THRUSTSHIM: Dl6Y7 engine

Part Number
Thickness
8 0 m m T H R U S TS H I M :D 1 6 Y 5 ,D l 6 Y 8 e n g i n e s
Part Numbe?
4r441-PL3-800
41442-PL3
BOO
41443 PL3 800

41444-PL3-800
41445 PL3 800
41446- PL3 800
Thickness
1 . 0 m m ( O . O 3 9 4i n )
1 1 m m ( O . 0 4 3 3i n )
1 .2 mm lO.O472in')
1 . 3 m m ( O . O 5 1 i2n )
1 . 4 m m { O . O 5 5 i1n )
'1.5
m m ( O . O 5 9 1i n )
1. 0 m m ( O . O 3 9 4i n )
1. 1 m m ( O . O 4 3 3i n )
41441
41448- PL3 BOO
1 . 6 m m ( O . 0 6 3 0i n )
1 . 7 m m ( 0 . 0 6 6 9i n l
41443-PL3-A00
1.2 mm lO.0472 tn)
41449-PL3- 800
1 . 8 m m ( 0 . 0 7 0 9i n )
41444 PL3-AOO
1 . 3 m m { O . 0 5 ' 1i2n )
1. O 5 m m ( 0 . 0 4 13 i n )
41445-PL3-AOO
1 . 4 m m ( O . O 5 5 i1n )
41450 PL3-800
4 1 4 5 ' t- P L 3 - B O 0
41446-PL3-AOO
1 . 5 m m { 0 . 0 5 9 1i n )
41447
PL3 AOO
41452 PL3-BO0
4 1 4 5 3 - P L 3- B O O
1 . 2 5 m m ( O . O 4 9 2i n )
1 . 6 m m ( 0 . 0 6 3 0i n )
41448-PL3-AOO
1 . 7 m m ( 0 . 0 6 6 9i n )
41454 PL3-BO0
1. 4 5 m m { O . 0 5 7 1i n )
41449-PL3,AOO
41 450- PL3- AOO
1 . 8 m m ( 0 . 0 7 0 9i n )
41455 PL3-BO0
1 . 5 5m m { 0 . 0 6 1 0i n )
1. 0 5 m m ( 0 . 0 4 1 3 i n )
41456 PL3,B00
4 1 4 5 ' 1, P L 3- A O O
4 14 5 2 - P L 3- A O O
1. l 5 m m ( O . O 4 5 3i n )
41457 PL3 BO0
1 . 6 5 m m { 0 . 0 6 5 0i n )
1 . 7 5 m m ( 0 . O 6 8 9i n )
4t441
PL3 AOO
41442
PL3 AOO
41453-PL3-A00
41454-PL3 A00
41455-PL3-AOO
4 14 5 6 - P L 3- A O O
41457 PL3 A00
1 . 2 5 m m { O . O 4 9 2i n )
' 1 . 3 5m m ( O . O 5 3 2i n )
'1
. 4 5 m m { O . O 5 7 'i1n )
1. 5 5 m m ( 0 . 0 6 ' 1 0i n )
1 . 6 5 m m { 0 . 0 6 5 0i n )
'1
. 7 5 m m ( O . 0 6 8 9i n )
PL3 BOO
1. 15 m m ( O . O 4 5 3i n )
1 . 3 5 m m ( O . O 5 3 2i n )
8 . Removethe bolts and transmissionhousing.

9 . Replacethe thrust shim selectedin step 7. then
recheckthe clearance.
'lO. Removethe bolts and transmissionhousing.Apply
housliquidgasketto the surfaceo{ the transmission
ing and reassemble.
13-33
Clutch HousingBearing
Replacement
\J
Mainshafl
3.
Drivethe new oil sealinto the clutch housingusing

1 . R e m o v et h e b a l l b e a r i n gu s i n gt h e s p e c i atl o o l a s
s h o wn .
ATTACHMENT, 42 | 47 mm
07746-0010300
\ '
ADJUSTABLE EEARING
PULLER,25-40 mm
07736-A01000A
Remove the oil seal trom the clutch housing.
CLUTCH
HOUSING
Replace.
13-34
Drivethe ball bearinginto the clutch housingusing

the specialtools as shown.
J
2.
Countershatt
1.
Removethe needlebearingusingthe specialtool as

shown, then removethe oil guide plate.
I n s t a ltlh e o i l g u i d ep l a t e t, h e nd r i v et h e n e e d l eb e a r i n g i n t o t h e c l u t c hh o u s i n gu s i n gt h e s p e c i atl o o l s
as shown.
NEEDLEBEARING
)
GUIDEPLATE
25-40 mm
PULLER.
07736-AOtOOOA
* 1 : A T T A C H M E N T4,2 x 4 7 n n
07746-0010300
*2: ATTACHMENT.52 x 5s mm
o7746 -0010400
OIL GUIDEPLATE
*1: Dl6Y7 ngin6
+2: D16Y5, Dl6Yg onginos
13-35
MainshaftThrust Shim
Adjustment
I.
Removethe thrust shim and oil guideplatetrom the

t r a n s m i s s i ohno u s i n g .
THRUSTSHIM
S e l e c t h e p r o p e rs h i mo n t h e b a s i so f t h e f o l l o w i n g
calculatrons:
5.
N O T E : U s e o n l y o n e t h r u s ts h r m
:.____
( B a s i cF o r m u l)a
( B ) + ( C ) - O . 9 5 = s h i mt h i c k n e s s
OIL GUIDE
PLATE
1)/t' i':
''7
Exampleof calculation:
D i s r a n c e@ ( 2 . 0 Om m ) + D i s t a n c e ' e ( O . 0 9m m )
= 2.09mm
s u b t r a c t h e s p r i n gw a s h e rh e i g h t( 0 . 9 5m m ) = t h e
f e q u i r e dt h r u s ts h i m ( 1. 14 m m )
TRANSMISSION
HOUSING
2 . Installthe 3rd/4th synchro hub, spacercollar, 5th

synchrohub, ball bearing,and thrust washeron the
mainshaft.Installthe assemblyin the transmission
housrng.
65 mm THRUSTSHIM: Dl6Y7 engine

Part Numbet
23931 PL3 A10
B
c
@ gnolcru sYncHRoHUB
D
E
F
THRUSTWASHER
SPACERCOLLAR
5TH SYNCHROHUB
J
K
L
3 . Measurethe distance@ between the end of the

transmissionhousingand thrust washer.
NOTE:
a Use a straight edge and verniercaliper.
a Measure at three locations and average the
readings.
4.
Measurethe distance@ betweenthe surfacesot the

clutch housingand bearinginner race.
NOTE:
a Use a straightedge and depth gauge.
a Measure at three locations and average the
readlngs.
ENDOF CLUTCHHOUSING
2 3 9 3 623937
23938
23939 -
P L 3- A 1 0
PL3 A10
PL3 A10
PL3-A' t O
2 3 9 4 0 -P L 3- A 1 0
AE
23961-PL3-A10
o
R
T
AB
AC
AG
AH
AO
13-36
23935 PL3 Ar0
AD
M
N
AK
INNERRACEOF EALL BEARING
23933 PL3 A10

23934 PL3 A10
23941 PL3 A10

2 3 9 4 2- P L 3- A 1 0
23943 PL3 A10
23944 PL3 A10
23945 PL3 ArO
23946 PL3 A10
23947 PL3 A10
23948 PL3-A10
23949 PL3-A10
23950 PL3 A10
23951 PL3 A10
23952 PL3 A10
23953 PL3 A10
2 3 9 5 4 - P L 3- A 1 0
23955 PL3 A10
2 3 9 5 6 P L 3- A 1 0
2 3 9 5 7- P L 3- A 1 0
2 3 9 5 8- P L 3- A t O
23959 PL3-A10
23960-PL3 A10
o
BALL EEARING
23932 PL3 410
2 3 9 6 2- P L 3- A 1 0
23963 PL3 A10
23964- PL3-A 10
23965 PL3-A 10
2 3 9 6 6- P L 3 , A 1 0
23967-PL3-A10
2 3 9 6 8- P L 3- A 1 0
23969 PL3 A10
23970 PL3 A10
23971 PL3 A10
Thickness
0.60 mm {0.0236 in}
0 . 6 3 m m 10.0284
in)
O . 6 6m m { 0 . 0 2 6 0 ; n }
0 . 6 9 m m { 0 . 0 2 7 2i n }
0 . 7 2 m m ( 0 . 0 2 8 3i n )
0 . 7 5 m m ( 0 . 0 2 9 5i n )
O . 7 8 m m ( O . O 3 Oa7n l
O . 8 1 m m ( 0 . 0 3 1 9i n )
O . 8 4 m m 1 0 . 0 3 3 1i n )
0 . 8 7 m m 10.0343
inl
O . 9 0 m m 1 0 . 0 3 5 4i n )
O . 9 3 m m { 0 . 0 3 6 6i n }
O . 9 6m m ( O . O 3 7 8
in)
O . 9 9m m ( O . O 3 9 O
in
1 . O 2m m ( O . O 4 Oi2n
1 . 0 5 m m ( 0 . 0 4 1 3i n )
1 . 0 8 m m ( 0 . 0 4 2 5i n )
1 . 11 m m ( 0 . 0 4 3 7i n )
1 4 m m O.0449 in)
1 . 1 7m m 1 0 . 0 4 6 1
in)
1 . 2 0 m m ( 0 . 0 4 7 2i n )
l 2 3 m m l O . O 4 8 4i n )
L 2 6 m m { 0 . 0 4 9 6i n )
L 2 9 m m { 0 . 0 5 0 8i n )
1 . 3 2m m { 0 . 0 5 2 0i n }
1 . 3 5 m m { O . O 5 3 Ii n )
1 . 3 8 m m ( 0 . 0 5 4 3i n )
1 . 4 1 m m { 0 . 0 5 5 5i n }
1 . 4 4 m m 1 0 . 0 5 6 7i n )
1 . 4 7 m m ( 0 . 0 5 7 9i n )
. 5 0 m m ( O . 0 5 9 1i n )
- 5 3 m m 0 . 0 6 0 2i n )
. 5 6 m m ( O . 0 6 1 4i n l
. 5 9 m m ( O . 0 6 2 6i n )
L 6 2 m m ( 0 . 0 6 3 8i n )
' t . 6 5m m
0.0650 in)
L 6 8 m m { 0 . 0 6 6 1i n }
7 l m m 0.0673in)
1 . 7 4 m m { 0 . 0 6 8 5i n i
1 . 7 7 m m ( 0 . 0 6 9 7i n )
1. 8 0 m m ( 0 . 0 7 0 9' n )
70 mm THRUSTSHIM: D16Y5. D16Y8 enqines

A
a
D
E
F
G
H
M
N
o
o
R
S
z
AB
AC
AD
AE
AG
AH
AK
AN
AO
Part Number
23931 PL3 BOO
23932 PL3- BOO
23933-PL3 BOO
23934 PL3 800
Thickness
0 . 6 0 m m { 0 . 0 2 3 6i n }
0 . 6 3 m m { 0 . 0 2 8 4i n i
O . 6 6 m m { 0 . 0 2 6 0' n )
0 6 9 m m ( 0 . 0 2 7 2i n )
23935 PL3 800
0 . 7 2m m ( 0 . 0 2 8 3i n )
23936 PL3 800

23937 PL3 B00
23938 PL3 800
23939 PL3 800
2 3 9 4 0- P L 3 B O O
23941-PL3 BOO
23942 PL3 BOO
23943 PL3 BOO
23944 PL3 BO0
23945 PL3 800
23946 PL3- 800
23947 PL3 800
23944 PL3 800
23949 PL3 800
23950 PL3-800
23951 PL3 800
23Ss2 PL3 BOO
23953 PL3 800
23954 PL3-BOO
23955 PL3- 800
23956 PL3- 800
23957 PL3 800
23958 PL3-800
2 3 9 5 9- P L 3 - 8 0 0
23960 - PL3- 800
23961 PL3 800
23962 PL3 800
0 . 7 5 m m ( 0 . 0 2 9 5I n )
0 . 7 8 m m ( 0 . 0 3 0 7i n )
0 . 8 1 m m ( 0 . 0 3 1 9i n )
0 . 8 4 m m ( O . 0 3 3 1i n )
0 . 8 7 m m ( 0 . 0 3 4 3i n )
O . 9 0m m ( O . 0 3 5 4i n )
O . 9 3m m { O . 0 3 6 6i n )
O . 9 6m m { 0 . 0 3 7 8i n )
0 . 9 9 m m { 0 . 0 3 9 0i n }
LO2 mm {0.0402 inl
1. O 5 m m ( 0 . 0 4 13 i n )
1 . O 8m m { 0 . O 4 2 5i n )
1 . 11 m m ( 0 . 0 4 3 7i n )
'] 14 mm (O.O449
in)
1 . 1 7m m ( 0 . 0 4 6 1i n )
1 . 2 0 m m ( 0 . 0 4 7 2i n )
L23 mm {O.O484
in}
1 . 2 6 m m { 0 . 0 4 9 6I n )
l 2 9 m m { 0 . 0 5 0 8i n }
23963-PL3-800
23964 PL3- BO0
23965- PL3- BO0
23966 PL3 800
23967 - PL3 BOO
23968-PL3 BOO
23369 PL3 800
23970- PL3,800
23971 PL3 800
1 . 3 5 m m ( 0 . 0 5 3 1i n )
1 . 3 8 m m 1 0 . 0 5 4 3i n )
1 . 4 1 m m ( 0 . 0 5 5 5i n )
1 . 4 4 m m ( O . 0 5 6 7i n )
1 . 4 7 m m ( O . 0 5 7 9i n )
L 5 0 m m ( 0 . 0 5 9 1i n )
L 5 3 m m { 0 . 0 6 0 2I n )
. 5 6 m m { 0 . 0 6 1 4i n }
1 . 5 9 m m { 0 . 0 6 2 6i n }
L 6 2 m m { 0 . 0 6 3 8i n )
1 . 6 5 m m 1 0 . 0 6 5 0i n l
1 . 6 8 m m ( 0 . 0 6 6 1i n )
. 7 ' l m m ( O . 0 6 7 3i n )
1 . 7 4 m m ( O . 0 6 8 5i n )
1 . 7 7m m 1 O . 0 6 9 7
in)
1 . 8 0 m m ( O . 0 7 0 9i n )
NOTE:
a Cleanthe thrustwasher,springwasherandthrust
shim thoroughlybefore installation.
a Install the thrust washer, spring washer and
thrust shim properly.
O I LG U I D E
PLATE
TRANSMISSION
HOUSING
THRUSTWASHER
SPRINGWASHER
8 . Installthe mainshaftin the clutch housing.

9 . Placethe transmissionhousingover the mainshaft
and onto the clutch housing.
1O. Tightenthe clutch and transmissionhousingswith
severalI mm bolts.
NOTE: lt is not necessaryto use sealing agent
between the housings.
1 . 3 2m m { 0 . 0 5 2 0i n l
6. Installthe oil guide plate and selectedthrust shim

in the transmissionhousing.
THRUSTSHIM
7. Installthe thrust washer and spring washer in the

mainshaft.
:---.._
"):
i,I '"9
I x 1 . 2 5m m
27 N'm (2.8 kgf.m. 20 lbf.ftl
1 1 . T a p t h e m a i n s h a fw
t i t h a p l a s t r ch a m m e r .
12. Checkthe thrust clearancein the mannerdescribed
below.
CAUTION: Measurementshouldbe made at room
temperalute.
a. Slidethe mainshaftbase and the collarover the
mainshaft.
CLUTCH
HOUSING
MAINSHAFT BASE
07GAJ- PG20't30
COLLAR
oTGAJ-PG20120
a',/,
---[
{cont'd}
13-37
--
MainshaftThrust Shim
Adjustment (cont'd)
b. Attach the mainshaltholderto the mainshaftas
lollows:
e. Zero a dial gauge on the end of the mainshalt
NOTE:
Back-outthe mainshaftholderbolt and loosenthe
two hex bolts.
F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s
toward the transmission.
Align the mainshaftholder'slip aroundthe groove
at the insideof the mainshaftsplines,then tighten
the hex bolts.
MAINSHAFTHOLDER
EOLT
MAINSHAFTHOLDEF
07GAJ-PG20t 10
MAINSHAFT
HOLDR
07GAJ-PG20110
f . Turn the mainshalt holderbolt clockwise;stop
turningwhen the dialgaugehas reachedits maximum movement,The readingon the dial gauge
is the amount ot mainshaltend play.
CAUTION: Turning tho mainshatt hold6t bolt
mor6 than 60 dogroosatter the needls of the dial
gaugs stops moving may damage th6 transmissioo.
Seat the mainshaftfully by tappangon the end

with a Dlastichammer.
d . Threadthe mainshalt holderbolt in until it just
contactsthe wide surfaceof the mainshaftbase.
s . lf the readingis withinthe standard,the clearance

rs correcr.
lf the readingis not within the standard,recheck
the shim thickness.
S t a n d a . dO
: . 1 1 - O . 1 8 m m { O . O O 4 - 0 . O Oi7n )
13-38
Transmission
Reassembly
N O T E :T h es t e e bl a l l s a r e aol lf r h e s a m e s i z e ( 5 / 1 6 i n ) .
6 . Insertshift arm shatt in the clutch housing
1 . I n s t a l tl h e m a g n e ta n d r e v e r s el o c k c a m .
7 . Installthe collar,spring,and steelballinto the case.

Compressthe ball and insert the shift arm shaft.
2.
S e t s h i f t a r m A o n t h e c l u t c hh o u s i n gt,h e n i n s t a l l
the shiftrod.
8 . Installshift arm C in shitt arm A, then insertthe shift

arm shalt.
3 . Installthe springwasherand shitt arm A attaching

bolt.
9 . Installthe reverseselectretainerand reverseselect

spring onto shitt arm shaft.
Installthe steelball,spring,and set ball springbolr.
1 0 .lnstallthe differentialassembly.
5 . Installshitt arm B in the interlock,then set it on the
clutch housing.
SHIFTARM C
A:8x'l.Omm
31 N.m 13.2 kgf.m, 23 lbf.ft,
6 x 1 . 0m m
1 5 N . m { 1 . 5 k g t . m ,1 1 l b l . f t l
sHtFTARM " ___\..-
REVERSESELECTRETAINER
REVERSESELECTSPRING
L. 63.4 mm 12.50inl
-.-.-.-...uK,
ITNTERLOCK,\
NTERLOCK.
f!ir"---
-b
REVERSE
LOCKCAM
MAGNET
10.843 in)
SET BALL SPRINGBOLT

22 N.m 12.2 kgt.m, 16 lbf.ltl
SHIFTARM A
COLLAR
SPRING
L. 25.6 mm ('l.Ol inl
CLUTCH
HOUSING
OIFFERENTIAL
ASSEMBLY
OIL SEAL
Replace.
SHIFTARM SHAFT
SHIFT ROD
BOOT
(cont'd)
13-39
Transmission
Reassembly(cont'dl
11. Positionthe 36 mm springwasherand washeronto
the mainshaftbearing.
15. lnstallthe reverseidler gear and reverseidler gear

shaft.
MAINSHAFT/COUNTERSHAFT
SHIFTFORKASSEMBLIES
IDLER
REVERSE
GEARSHAFT
Tape the mainshaft
splrnes.
WASHER
1 2 .Installthe mainshaft,countershaft.and shift fork

assemblies.
NOTE: Align the finger ot the interlock with the
groove in the shitr fork shaft.
Installthe springwasher and shi{t arm B attaching
bolt.
8 x 1 . 0m m
31 N'm 13.2kgl'm, 23 lbl'ltl
GEAR
16. Installthe reverseshift holder.
REVERSE
SHIFT
1ST/2NOSELECTSPRING
L . 3 6 . 2 6 m m 1 1 . 4 2 8i n )
28 mm PLUGEOLT
54 N.m {5.5 kgl.m,
40 tbf.Irl
GUIDEEOLT
39 N.m 14.0 ksf.m,29 lbf.ftl
1 4 . I n s t a ltlh e 1 s t / 2 n ds e l e c ts p r i n g ,2 8 m m p l u g b o l t .
and interlockguide bolt.
N O T E : A p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - O O O 1o r
08 7'l I 0003) to the threadsof the 28 mm plugbolt
and interlockguide bolt.
13-40
6x1.Omm
15 N.m {1.5kgl'm,
11 lbI.fr)
1 7 . I n s t a l tl h e o i l g u t t e rp l a t e
2O. lnstallthedowelpinsand the transmissionhousing.
OIL GUTTERPLATE
21. Lower the transmissionhousingwith the snap ring

pliers,and set the snap ring into the groove of the
countershaftbearing.
NOTE: Checkthat the snap ring is securelyseated
in the groove of the countershaftbearing.
32 mm SEALINGEOLT
25 N.m {2.5 kgf.m, 18lbf.ttl
TRANSMISSION
HOUSING
1 8 . Installtheoilguideplateandthrustshimon the transmissionhousing.

1 9 . Apply liquidgaskel to the surfaceof the transmission housing mating with the clutch housing as
shown.
NOTE:
. Use liquid gasket (P/N O8718-OOO1 or
o8718-O003).
a Removethe dirty oil from the sealingsurface.
a lf 5 minutes have passedafter applying liquid
gasket.reapplyit and assemblethe housings.
a Allow it to cure at least20 minutesafter assembly before tilling the transmissionwith oil.
4.6 -8.3 mrr|

10.18 0.33 in)
Liquid gasker
2 2 . I n s t a l tl h e 3 2 m m s e a l i n gb o l t .
N O T E : A p p l y l i q u i dg a s k e t( P / NO 8 7 1 8 - O O O 1
0 8 7 1 8 - O O O 3 )t o t h e t h r e a d s .
(cont'd)
13-41
I -
Transmission
Reassembly(cont'dl
23. Tightenrhe rransmissionhousingattachingbolts in
the numberedsequencein several steps shown
oetow.
8 x 1. 2 5 m m
Totqnet 27 N'm (2.8 kgf.m, 20 lbl'fr)
2 5 . I n s t a l lt h e b a c k - u pl i g h t s w i t c h a n d l r a n s m r s s r o n
hanger.
8 x 1 . 2 5m m
27 N.t 12.8 kgt.m, 20 lbf.frl
BACK,UPLIGHTSWITCH
HARNESSSTAY
le
24. Installthe steel balls,springs,and set screws.
SPRING
L . 3 1 . 6 m m ( 1. 2 4 i n l
SETTINGSCREW
22 N.m l'2.2 ksf.m, 16 lbt.tt)
13-42
25 N.m {2.5 kgl'm, 18 lbf,ftl
Oil Seals
Replacement
TransmissionHousing:
Clutch Housing:
1.
Bemovethe oil sealfrom lhe transmissionhousing.
2 . Installthe oil sealinto the transmissionhousinqusing the specialtools as shown.
Removethe oil seal from the clutch housing.
Installthe oil seal into the clutch housingusingthe

soecialtools as shown.
DRIVER
SAL DRIVER
ATTACHMENT
07947-6110501 ot
07947-6110500
DRIVERATTACHMENT
oTJAD-PH80101
otL sEAt
neplace.
OIL SEAL
Replace.
T
13-43
GearshiftMechanism
Overhaul
NOTE:
replaceany worn or damagedparts.
a Inspectrubberpartsfor wearanddamagewhendisassembling;
a Installthe clip as shown.
a Turn the boot so the hole is facing down as shown.
a Make sure the boot is installed on the shift rod.
EXTENSION
BOLT
SHIFTLEVERKNOB
7.8 N.m (0.8 kgl.m,5.8 lbf.ftl
EXTENSION
xx'tt"
cuErfl
ffi
iiJ?t
3$i^\@
:r'.n Y
&_
e:---g
.,,,"1"I
ExrENsroN
END
BUsHrr{c
exrrfusror
noo
ENocoLLAR
ffi)'o"o*h--:l+:l
Y9 ,-,r:- \\
cL'P
i!l,1t'^-
\ J
Ant;:n;r
,:1i",""""""",,
sH,FrRoD
f
\\
r.zs.ex
exrertror,r o.n^c\\
,._,
r*H
d""
A'?''"
lii,i"r**,
se^LB
*tlp;t{^
_
,, _
fi+L-w^sHER
-' % \o
Boor
I 1
REARJo,Nr",i""YEo
aÂ
;#""*,\**
:rr,'"'iyss.
\
iKlp-dffi
5ii_-.ry
@
r.,or.rr, I
NUr
sELF.LocKrNG
Replace.
6 x 1 o mm
9.8 N.m l1.Oksf.m,7.2 lbt.frl
13-44
ffiW
/oown \ \a[ffi=
:"
CLIP
sinttc ptt't
neoraci.
HOLE
."' 14-1
AutomaticTransmission.'.'......'."....
ContinuouslyVariableTransmission
(cwl ..........
14-161
Automatic Transmission
SpecialToofs
.............-.-....-......14-2ATF Pump
Description
.............,.,.,..,......,..
14-3
Inspection
..........................
14-109
PowerFlow
........................
1i1.6
Main ValveBody
ElestronicControlSystem ..,.............................
14.13
Disassembly/lnspection/Rea$embly
......,......,
14-110
HydraulicControl
..............
14-18
SecondaryValve Body
HydrauficF|ow......
.,.....-.....
14-23
Disassembfy/lnspection/Reassembly
......-.-..-..
11-112
Lock-upSystem
.-......-....-.-.
1+32
RegulatorValv Body
EleqtricalSystem
Disassembly/lnspction/Reassembly
.......,....,.1{-'t13
ComponentLocations.......,..,....,.,.........
.................
1i1"39 Servo Eody
PCMCircuit Diagram
Disassembly/lnspection/Beassembly
..............
14.114
1il.40
{A/T ControlSysteml .........................................
Lock-upValve Body
PCMTerminsl Voltage/MeasuringConditions
Disassembly/lnspection/Reassembly
..............
14.115
A/T ControlSystem
..-.......14-42 Mainshatt
Troubleshooting
Procedures...........................,..,.,.
14-44
Disassembly/lnspection
Rsassembly...............
1,t"116
Symptom-to-ComponentChart
Inspection
........................,.
1+117
ElectricalSystem
.....,.....,.,.
l il-il8
Countershaft
ElectricalTroubleshooting
Dissssembly/lnspection/Reassembly
..............
14-119
Troubleshooting
Flowcharts.............................
14.50
.................................
14-120
Lock-upControl Solenoid Valve A/B Assambly
fnspection
.........-.-..............
14-121
Test ......................
.............
14-71 One-way
Clutch
Repfacement
...........-.-....,..,
11-74
Disassembly/lnspection/Reassombly
.....,,.......
1,[.123
Shift Control Solenoid Valve A/B Assembly
Clutch
Test ......................
. . . . . . . . . - . - . 1 4 - 7 5 lllustratsd
lndex {A'lRA.BitRATransmission}... 1Gl24
Replacement
.......,..............
lil-75
lllustrated lndex IM4RATransmission)
.........-..
14.126
Linear SolenoidAssemblV
Disassembly...
11-128
Test ......................
. . . . . . . . . .1. 4
. .- 7 6
Reassembly
........................
14-130
Reofacement
......,.,.,,,,.,.,,,,.
11-77
Differential
a Mainshaft/Counter3haftSpeedSensors
lllustrotedIndex
................
1+13/t
Repfacement
......................
1+77
t
BacklashInspection
..........
14-135
Hydraulic Systcm
BaringReplacement.............,.........,........,........
lil-l35
Symptom-to-ComponentChart
DitferentialCarrierReplacement..........,...........
1il.136
HydraulicSystem
...........-.11-78
Oil SalRemovsl
...............
14.137
RoadTest
................................
14-82
Oil SealInstallation/Side
Clea.anc.................
14-137
Stall SDeed
Torque Converter Housing Bsarings
Test ......................
.............
1/t-85
Mainshaft Bearing/OilSal Replacement........1,t-1,m
Fluid Level
CounteEhaftBearingReplacemsnt.................
lil-li[f
Checking/Changing
..........
lil-86
TransmissionHousing Bearings
PressureTesting
......,..............
1il-87
Mainshaft/CountGrshaftBearings
Transmission
Repfacement
-..........,.,.,,
11-112
Transmission
Reverseldlr Gear
R e m o v a .l . . . . . . . . . . . . . . .
. . . . . . . . . .1. .4.. 9 0
Installation
..,,.................,.,.
l+t/*l
lllustrated Index
Parking BrakeStop
Transmission/Right
SideCover ..............,..,.,....
1+g4
Inspection/Adiustment
..,.......................,,...,......
lil-li(|
Transmis3ion
Housing....,......,........................,..
14-96
Transmission
TorqueConverterHousing/ValveBody ..,....,...
14-98
Rea$embly...........
.............
14-144
Right Side Cover
TorqueConvrter/Drive
Plate ...................,.,..,.......
14-150
Removal................
.............
14-100 Transmission
TransmissionHousing
Installation
.........................
14-151
Removaf................
.............
1+102
CoolerFlushing
.................
l il-155
Torque Converter Housing/ValveBody
Shift Cable
Removal...........,....
.......,..,..
14-10i1
Removal/lnslallation........................,................
14-157
Valve Caps
Adiustment
........................
lil-158
Description
.........................
14-106 Shift Lever
...............................
1a-t5g
Valve Body
Shift Indicator Panel
Repai. ....................
.--........-.
1+107
Adiustment
. . . . . . . . . . . . . . . . . . .1. .{.-.1. .6. 0
.
alve
ATF Cooler Hoses
SpecialTools
v
Ref. No.
Tool Number
Description
Oty
07GAB- PF50101
07GAE- PG40200
07HAC- PK40' l0A
07JAD- PH80101
07JAD- PH80200
07LAE- PX40100
07PAZ- 00'10100
07sAz - 0010004
OTMAJ_ PY4O11A
07MAJ- PY40120
07406- 0020400
07406- 0070300
07736- A010004
07746- 0010500
07746- 0010600
07746- 0030100
07749- 0010000
07947-611501
MainshaftHolder
ClutchSpringCompressorBoltAssembly
ar
HousingPuller
DriverAttachment
@
Pilot,26 x 30 mm
ClutchSpringCompressorAttachment
@
SCSServiceConnector
@
BackprobeSet
@
A"/TOil PressureHose,2210mm
A,/TOil PressureHose,Adapter
@
A,/TOil PressureGauge Set w/panel
@
Ay'TLow PressureGaugew/panel
@
AdjustableBearingPuller,25 - 40 mm
@Attachment,62 x 68 mm
@
@
Driver40 mm l.D.
@
Driver
@
DriverAttachment,68 mm
@
*Must be usedwith commerciallv-available
3/8" - 16 slidehammer.
1
1
1
I
I
'l
1
I
1
1
1
I
1
I
'I
Prgo Reforenc.
1 4 -1 0 1 ,1 4 8
't 4-128,'t31
14-103
14-139
'14139
14-124,131
l4-45
14-46
't 4-47
14-87
14-87
14-87
14-140,14' 1
14-140,141,142
14-'t40,142
'14-121.
135,137,138
14-139,140,141,'142
14-139
Edttltr-
\l
6,
g
\,
14-2
Description
controlled
The automatictransmissionis a combinationof a 3-elementtorque convenerand a dual-shaftelectronically
automatictransmissionwhich provides4 speedsforwardand 1 reverse.
Torque Converter,Geats and Clutches
The torqueconverterconsistsof a pump.turbineand stator,assembledin a singleunit.They are connectedto the engine
crankshaftso they turn togetheras a unit as the engineturns.Around the outsjdeof the torque converteris a ring gear
which mesheswith the starterpinionwhen the engineis being started.The entiretorqueconverterassemblyservesas a
flywheelwhile transmittingpowerto the transmissionmainshaft.
The mainshaftis in line with the engine
The transmissionhas two parallelshafts:the mainshaftand the countershaft.
The mainshaftincludesthe 1st,2nd and 4th clutches,gearstor 2nd, 4th, reverseand 1st (3rd gear is integral
crankshaft.
with the mainshaft,while the reversegear is integralwith the 4th gear).The countershaftincludesthe 3rd clutch,and
gearsfor 3rd, 2nd. 4th, reverse,1stand parking.The gearson the mainshaftare in constantmesh with those on the countershaft.When certaincombinationsof gears in transmissionare engagedby clutches,power is transmittedfrom the
to providep, E, E, and E positions.
mainshaftto the countershaft
ElectronicControl
The electroniccontrol system consistsof the PowertrainControl Module (PCM),sensors,a linear solenoid and four
controlledfor comfonabledriving underall conditions.The PCMis
solenoidvalves.Shiftingand lock-upare electronically
side.
locatedbelowthe dashboard,underthe front lower panelon the passenger's
HydraulicControl
The valvebodiesincludethe main valvebody,the secondaryvalvebody,the regulatorvalvebody,the servobody and the
separatorplates,Theyare boltedon the torqueconverterhousing.
lock-upvalvebody throughthe respective
The main valve body containsthe manualvalve,the 1-2shift valve,the 2nd orificecontrolvalve,the CPB(ClutchPressure
Back-up)valve,the modulatorvalve.the servocontrolvalve,the reliefvalve,and ATF pump gears.The secondaryvalve
body containsthe 2-3shift valve,the 3-4shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand the CPC(Clutch
PressureControl)valve.The regulatorvalve body containsthe pressureregulatorvalve,the torque convenercheckvalve.
the coolerreliefvalve,and the lock-upcontrolvalve.The servo body containsthe servovalvewhich is integratedwith the
The lock-upvalve body containsthe lock-upshift valve and the lock-uptiming
reverseshift fork, and the accumulators.
valve.The linearsolenoidand the shift controlsolenoidvalveAy'Bare boltedon the outsideof the transmissionhousing,
and the lock-upcontrolsolenoidvalve!y'B is boltedon the outsideof the torque converterhousing.Fluidfrom regulator
ieed pipes
passesthroughthe manualvalveto the variouscontrolvalves.The clutchesreceivefluid from their respective
or internalhydrauliccircuit.
Shift Control Mechanism
Inputfrom varioussensorslocatedthroughoutthe car determineswhich shift controlsolenoidvalvethe PCMwill activate.
a line
Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shift valveto move.This pressurizes
to one of the clutches,engagingthat clutchand its correspondinggear.The shift controlsolenoidvalvesA and B are controlledby the PCM.
Lock-uoMechanism
fluid is drainedfrom the backof the torqueconverter
In E position,in 3rd and 4th, and in E positionin 3rd, pressurized
through a fluid passage,causingthe lock-uppistonto be held againstthe torque convertercover.As this takesplace,the
Togetherwith hydrauliccontrol.the PCMoptimizesthe timing of
mainshaftrotatesat the same as the enginecrankshaft.
the lock-upmechanism.The lock-upvalvescontroltherangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and
B, and linearsolenoid.When lock-upcontrolsolenoidvalvesA and B activate,the modulatorpressurechanges.The lockuo controlsolenoidvalvesA and B and the linearsolenoidare controlledby the PCM.
t
(cont'd)
14-3
Description
(cont'd)
Gear Selction
The shift leverhassix positions:E PARK,E REVERSE,
E NEUTRAL,E 1stthrough 4th gear ranges,E 1stthrough3rd
gear ranges,P 2nd gear.
Position
Description
E PARK
Frontwheelslocked;parkingbrakepawl engagedwith parkinggearon countershaft.

All clutches
reteaseq,
E REVERSE
gearand 4th clutchlocked.

Reverse;reverseselectorengagedwith countershaft.everse
E NEUTRAL
All clutchesreleased.
E] DRIVE
(1stthrough4thl
Generaldriving;stansoff in 1st,shiftsautomatically
to 2nd.3rd,then 4th, dependingon vehicle
speedand throttleposition.Downshiftthrough3rd,2nd and 1ston deceleration
to stop.The Iock-up
mechanismcomesinto operationin E positionin 3rd and 4th gear.
E DRIVE
(1stthrough3rd)
Usefor rapidacceleration
at highwayspeedsand generaldriving;up-hilland down-hilldriving;starts
off in 1st,shiftsautomatically
to 2nd,then3rd,dependingon vehiclespeedandthrottleposition.
Downshifts
through2ndto 1ston deceleration
to stop.The lock-upmechanism
comesintooperation
in 3rd gear.
E SEcoND
Usefor enginebrakingor bettertractionstartingoff on looseor slipperysurfaces;staysin 2nd

gear,does not shift up and down,
Startingis possibleonly in E and N positionsthroughthe useof a slide-type.neutral-safety

switch.
Automatic TransaxlslA/T) Gear Position Indicatot
The Ay'Tgear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down
at the console,
Clutchs
gears.
The four-speedautomatictransmissionuseshydraulically-actuated
clutchesto engageor disengagethe transmission
When hydraulicpressureis introducedinto the clutchdrum, the clutchpiston moves.This pressesthe frictiondiscsand
steel platestogether.lockingthem so they don't slip. Power is then transmittedthrough the engagedclutch packto its
hub-mountedgear.Likewise,
when the hydraulicpressureis bledfrom the clutchpack,the pistonreleases
the frictiondiscs
and the steelplates,and they are free to slide past each other. This allowsthe gear to spin independentlyon its shaft,
transmittingno power.
.
1st Clutch
The lst clutchengages/disengages
lst gear,and is locatedat the end of the mainshaft,just behindthe right sidecover.
The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft,
2nd Clutch
The 2nd clutchengages/disengages
2nd gear, and is locatedat the middle of the mainshaft.The 2nd clutch is joined
back-to-back
to the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circuitconnected to the internalhydrauliccircuit.
3rd Cluich
The 3rd clutchengages/disengages
3rd gear, and is locatedat the end of the countershaft.
The 3rd clutchis supplied
hydraulicpressureby its ATFfeed pipe within the countershaft.
4th Clutch
The 4th clutchengages/disengages
4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The
4th clutch is joined back-to-back
to the 2nd clutch.The 4th clutch is suppliedhydrauiicpressureby its ATF feed pipe
within the mainshaft.
14-4
One-way Clutch
1stgearand the parkinggear,with the parkinggearsplinedto the
The one,wayclutchis positionedbetweenthe countershaft
gear
provides
race
surface,
and the parkinggear providesthe inner racesurface.The onethe
outer
The
lst
countershaft.
'1st
way clutch locksup when power is transmittedfrom the mainshaft gear to the countershaft1st gear.The 1st clutch
and gearsremainengagedin the 1st,2nd,3rd, and 4th gear rangesin the E, E or @ position
are appliedin the D., o or E position.
However,the one way clutchdisengageswhen the 2nd,3rd, or 4th clutches/gears
"speedrange" of the
This is becausethe increasedrotationalspeedof the gearson the countershaftoverridesthe locking
the one-wayclutchfree-wheelswith the 1stclutchstill engaged.
one-wayclutch.Thereafter,
2ND CLUTCH
4TH CLUTCH
1STCLUTCH
MAINSHAFT
COUNTERSI{AFT
ONE-WAYCLUTCH
PABKINGGEAR
3AD CLUTCH
OUTSIDEOF ONE.WAY
CLUTCH
The sprags engage/
disengageoutside
and inside of the
one way clutch.
INSIDEOF ONE,WAY
CLUTCH
Splinedwilh counter
shaft
LOCKINGCONDITION
OVER.FIDING
LOCKINGSPEEOCONDITION
14-5
tDescription
PowerFlow
\enr
POSMON\.
E
E
E
2ND
D-a 3 R O
4TH
2ND
[o]
3RD
1STGEAR 2ND GEAR 3RD GEAR

TOROUE
1sT
2ND
3RD
CONVERTER
CLUTCH CLUTCH CLUTCH
o
o
o
o
o
o
o
o
a
o
o
4TH
GEAR
CLUTCH
REVERSE PARKING
GEAR
GEAR
o
4,2
o*i
o*,
o
o
o*!
o*,
o*'
o*'
o*1
O: Operates,x: Doesn'toperate.
*1: Althoughthe 1stclutchengages,driving power is not transmittedas the one-wayclutchslips.
*2: The one-wayclutchengageswhen accelerating,
and slipswhen decelerating.
,,
I
14-6
El Position
Hydraulicpressureis not appliedto the clutches.Poweris not transminedto the countershaft.
E Position
Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft
The countershaftis lockedby the parkingpawl interlockingthe parkinggear.
TOROUECONVERTER
1ST CLUTCH
FINALDRIVE
GEAR
3RD CLUTCH
(cont'd)
14-7
Description
Power Flow (cont'd)
lst Gear {lP!lor .D3lposition)
tn [D.]or lal position,the optimum gear is automatically
selectedfrom 1st,2nd,3rd and 4th gears,accordingto conditions
suchas the balancebetweenthrottleopening(engineload)and vehiclespeed.
1.
Hydraulicpressureis appliedto the 1st clutch,which rotatestogetherwith the mainshaft,causingthe mainshaftlst

gear to rotate.
2.
Poweris transmittedto the countershaftlst gear,which drivesthe countershaft

via the one-wayclutch.
3. Poweris transmittedto the final drivegear,which drivesthe final drivengear.
TOROUE
CONVEETER
MAINSHAFT1ST GEAR
1ST CI-UTCH
MAINSHAFT
ONE-WAYCLUTCH
FINAI.DRIVEGEAR
PARKINGGEAR
COUNTERSHAFT
1ST GEAR
FINAL DRIVEN GEAR
14-8
Znd Gear {[0!, or or @ positionl

E Positionis providedto drive only 2nd gear.
'1. Hydraulicpressureis appliedto the 2nd clutchon the mainshaft,and power is transmittedvia the 2nd clutchto the
mainshaft2nd gear.
2.
Powertransmiftedto the mainshaft2nd gear is conveyedvia the countershaft2nd gear, which drivesthe countershaft.
3.
Poweris transmittedto the final drive gear,which drivesthe final drivengear.

NOTE:Hydraulicpressureis also appliedto the 1st clutch.but sincethe rotationspeedof the 2nd gear exceedsthat
of 1stgear,powerfrom 1stgear is cut off at the one-wayclutch.
TOROUE
CONVERTER
2ND CLUTCH
MAIIISXAFT
COUNTERSHAFT
2ND GEAR
(cont'd)
14-9
Description
PowerFlow {cont'dl
3rd Gear ([ll or lg.l position)
'1. Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft
3rd gear.
2.
Poweris transmiftedto the final drive gear,which drivesthe final drivengear.

NOTE:Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 'lst
gear,powerfrom lst gear is cut off atthe one-wayclutch.
TOROUECONVERTER
MAINSHAFT3RD GEAR
MAINSI{AFT
COUNTERSHAFT
3RD GEAR
3RD CLUTCH
FINALORIVNGEAB
I
14-10
4th Gear {[t] position)

1.
Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,causingthe mainshaft4th

gear to rotate.
2.
Poweris transmittedto the countershaft4th gear,which drivesthe countershaft.

Poweris transmittedto the final drive gear.which drivesthe final drivengear.
NOTE:Hydraulicpressureis alsoappliedto the 1stclutch.but sincethe rotationspeedof 4th gear exceedsthat of 1st
gear,powerfrom 1stgear is cut off at the one-wayclutch.
TOROUE
4TH GEAR
4TH CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVENGEAR
(cont'd)
14-11
Description
Power Flow (cont'd)
E Position
l
Hydraulicpressureis switchedby the manual valve to the servo valve.which moves the reverseshift fork to the
reverseposition.The reverseshift fork engageswith the reverseselector,reverseselectorhub, and the counte.shaft
reversegear.
Hydraulicpressureis also appliedto the 4th clutch.Power is transmittedfrom the mainshaftreverseoear vta the
reverseidler gearto the countershaftreversegear.
The rotationdirectionof the countershaftreversegear is changedvia the reverseidlergear.
4.
Poweris transmittedto the final drive gear,which drivesthe final drivengear.

TOROUE
MAINSHAFT
COUNTERSHAFT
COUNTERSHAFT
REVERSE
GEAR
REVERSE
SELECTOR
HUB
REVERSE
SELECTOR
REVERSE
SHIFT
FORK
FINALORIVENGEAR
SERVOVALVE
14-12
ElectronicControlSystem
The electroniccontrolsystemconsistsof a PowertrainControlModule{PCM),sensors,a linearsolenoidand four solenoid
controlledfor comfortabledriving underall conditions.The PCMis located
valves.Shiftingand lock-upare electronically
panel
side.
lower
on the passenger's
the
front
belowthe dashboard.under
PGM-FI
Conirol Sy3tem
A/T Control SFtem
Shift Control
Lock-uDControl
(cont'd)
14-13
Description
ElectronicControlSystem(cont'dl
Shift Control
The PCM instantaneously
determineswhich gear should be selectedby varioussignalssent from sensors,and actuates
the shift controlsolenoidvalvesA and B to controlshifting.Also,a GradeLogicControlSystemhas beenadoptedto control shiftingin io.rpositionwhile the vehicleis ascendingor descendinga slope,or reducingspeed.
Shift Control Solenoid
Valve B
Shil't Control Solenoid

Valve A
Position
Gear
1st
OFF
Dr Dr
2nd
ON
ON
3rd
ON
OFF
4th
OFF
OFF
2nd
ON
ON
rq!
l
ON
ON
E*See page 14-30forreverseinhibitorcontroldescription.
Reverse
Lock-uoControl
From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol
solenoidvalveA and/orB accordingly.The combinationof driving signalsto lock-upcontrolsolenoidvalvesA and B and
the linearsolenoidpressureis shown in the table below.
Lock-up Control
Solnoid Valve A
Lock-upControl
Solenoid Valve B
Linear Solenoid
Pressure
Lock'upOFF
OFF
OFF
High
L o c k - u pH, a l f
ON
Dutyoperation
OFF- ON
L o c k - u pF, u l l
ON
ON
H i gh
ON
Dutyoperation
O F F* O N
Low
Lock-up Conditions
LOCX-Up
duringdeceleration
14-14
GRAOELOGICCONTROLSYSTEM
How it works:
The PCMcomparesactualdrivingconditionswith drivingconditionsmemorizedin the PCM,basedon the input trom the
vehiclespeedsensor,the throttlepositionsensor.the barometoricpressuresensor,the enginecoolanttemperaturesensor,
the brakeswitchsignaland the shift lever positionsignal.to controlshiftingwhile a vehicleis ascendingor descendinga
slope,or reducingspeed.
SIGNALSOETECTED
Judgemenl ot Controlling ArGa

OrivingRt3ktrncc
{Fuzzylogicl
' GradualA3cendingmode
' Steop Ascondingmode
. D6cnding mode
. GradualOoscondingmode
. Siep Odcending mode
(cont'd)
14-15
Description
ElectronicControlSystem(cont'dl
.
AscendingControl
When the PCMdeterminesthat the vehicleis climbinga hill in El position,the systemextendsthe engagementarea of
2nd gear and 3rd gear to preventthe transmissionfrom frequentlyshiftingbetween2nd and 3rd gears,and between3rd
and 4th gears,so the vehiclecan run smooth and have more power when needed.Thereare two ascendingmodeswith
different3rd geardrivingareasaccordingto the magnitudeof a gradientstoredin the PCM.
NOTE:
. The PCMmemorycontainsshift schedulesbetween2nd and 3rd gears,and between3rd and 4th gearsthat enablethe
PCM'sIuzzylogicto automatically
selectthe most suitablegearaccordingto the magnitudeof a gradient
. Fuzzylogic is a form of artificialintelligencethat lets computersrespondto changingconditionsmuch like a human
m i n dw o u l d .
.
DescendingControl
When the PCM determinesthat the vehicleis going down a hill in E position,the shift-upspeedfrom 3rd to 4th gear
when the throttleis closedbecomesfasterthan the set speedfor flat roaddrivingto widenthe 3rd geardrivingarea.
This, in combinationwith engine brakingfrom the decelerationlock-up,achievessmooth driving when the vehicleis
descending.
Thereare two descendingmodeswith differentdownshift(4 - 3) schedulesaccordingto the magnitudeof a
gradientstoredin the PCM.When the vehicleis in 4th gear,and you are deceleratingon a gradualhill. or when you are
applyingthe brakeson a steephill,the transmissionwill downshiftto 3rd gear.Whenyou accelerate,
the transmissionwill
then returnto 4th gear.
ASCENDINGMODE
DESCENDING
MOOE
,lTH SHIFTING
CHARACTERISTICS
CONTROLAREA
ir'.ff}",
vehicre
speod
ir'.111,",
v.hicre3ped
DecelerationControl
Whenthe vehiclegoes arounda corner,and needsto first decelerateand then accelerate,

the PCMsetsthe datafor deceleration
controlto reducethe numberof timesthe transmission
shifts.When the vehicleis decelerating
from speedsabove26 mph
(41km/h),the PCMshiftsthe transmission
from 4thto 2ndearlierthan normalto copewith upcomingacceleration.
14-1 6
CircuitDiagramand TerminalLocations
IGNITION
SWITCH
PG2
LOCK-UPCONT8OL
OVALVE
A
SOLENO
IGPl
IGP2
vcc2
TPS
sG2
LOC( UPCONTFOL
SOLENOIDVALVEB
SNIFTCONTSOL
SOLENOIDVALVEA
SHIFICONTFOL
VALVEB
SOLENOID
LNEIFSOLENOID
POSITONF
14-17
Description
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump.valves,accumulators,
and electronically
controlledsolenoids.
The ATF pump is drivenby splineson the end of the torqueconverterwhich is attachedto the engine.Fluidfrom the ATF
pump flows throughthe regulatorvalveto maintainspecifiedpressurethroughthe main valve body to the manualvalve,
directingpressureto each of the clutches.The valve body includesthe main valve body, the regulatorvalve body, the
lock-upvalve body, the secondaryvalve body, the servo body. the linear solenoid,the shift control solenoidvalve Ay'B
assembly,and the lock-upcontrolsolenoidvalveA,/Bassembly.The shift controlsolenoidvalveA,/Bassemblvand the linear solenoidare bolted on the outsideof the transmissionhousing,The lock-upcontrol solenoidvalveAy'Bassemblyis
boltedon the outsideof the torqueconverterhousing.
SHIFTCONTROL
SOLENOIDVALVEA/B
ASSEMBLY
LINEARSOLENOIO
VALVE
VALVEBODY
ATFPUMPGEARS
14-1 8
Main Valve Body

The main valve body houses the manual valve, the 1-2 shift valve, the 2nd orifice control valve, the CPB valve, the modulator valve, the servo control valve, and the relief valve. The primary functions of the main valve body are to switch fluid
pressure on and off and to control the hydraul;c pressure going to the hydraulic control system
2NOORIFICECONTROL
VALVE
1.2 SHIFTVALVE
MOOULATOFV
RELIEFV
VE
MANUALVALVE
VE
CONTROL
MAIN V
BODY
VALVE
SecondaryValve Body
The secondaryvalvebody is locatedon the main valve body.The secondaryvalvebody housesthe 2-3 shift valve,the 3-4
shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand CPCvalve
3.4 SHIFTVALVE
2-3 SHIFTVALVE
4TH EXHAUSTVALVE
CPCVAL
3.4 ORIFICECONTBOL
VALVE
VALVE
(cont'd)
14-19
Description
HydraulicControl (cont'd)
RegulatorValve Body
The regulatorvalve body is locatedon the main valve body.The regulatorvalve body consistsof the regulatorvalve,the
torqueconvertercheckvalve,the coolerreliefvalve,and the lock-uocontrolvalve.
REGULA
VALVE
COOI.ERRELIEFVALVE
CONTROLVALVE
Lock-upValve Body
The lock-upvalvebody with the lock-upshift valveand the lock-uptiming valveis locatedon the regulatorvalvebody.
LOCK-UPSHIFTVALVE
TIMINGVALVE
BODY
14-20
RegulatorValve
The regulatorvalve maintainsa constanthydraulicpressurefrom the ATF pump to the hydrauliccontrol system,while
alsofurnishingfluid to the lubricatingsystemand torqueconvener.The fluid from the ATF pump flows through B and B'.
The regulatorvalve hasa valveorifice.The fluid enteringfrom B flows throughthe orificeto the A cavity.This pressureof
the A cavitypushesthe regulatorvalveto the right side,and this movementof the regulatorvalve uncoversthe fluid port
to the torque converterand the reliefvalve.The fluid flows out to the torqueconverter,and the reliefvalveand regulator
valve movesto the left side.Accordingto the levelof the hydraulicpressurethrough B, the positionof the regulatorvalve
changesand the amountof the fluid from B' through D and C also changes.This operationis continued,maintainingthe
ltnepressure.
NOTE:When used,"left" or "right" indicatesdirectionon the illustrationbelow.
ENGINERUNNING
ENGINENOTRUNNING
To TOROUECONVERTER Lubrication
STATOBSHAFTARM
Stator ReactionHydraulicPressureControl
Hydraulicpressureincreasesaccordingto torque,are performedby the regulatorvalve using the statortorque reaction
The statorshaft is splinedwith the statorin the torqueconverter.and its arm end contactsthe regulatorspringcap.When
or climbing(TorqueConverterRange),the statortorque reactionacts on the statorshaft,and
the vehicleis accelerating
pushes
the regulatorspringcap in the directionof the arrow in proportionto the reaction.The statorreacthe statorarm
and the regulatorvalve movesto increasethe line pressurewhich is regulatedby the regulator
tion spring compresses,
valve.The line Dressurereachesits maximumwhen the statortorque reactionreachesits maximum.
TOROUECONVERTER
VALVE
REGULATOR
TORSPRINGCAP
'..- _..-7
3f
STATORSHAFT
ATORSHAFTARM
{cont'd)
14-21
Description
HydraulicControl(cont'd)
Servo Body
The servo body is locatedon the secondaryvalve body.The servo body containsthe servovalvewhich is integratedwith
the reverseshift tork,and the accumulators
2ND ACCUMULA
SERVOBODY
lST ACCUMULATOR
3RDACCUMULATOR
SERVOVALVE/SHIFT
FORKSHAFT
14-22
.J
HydraulicFlow
Genr8lChart of Hydraulic Pressure
ATFPumpRegulatorValve -;
l
L
ModulatorPressure-;LClutch
Pressure
LinePressure
LinearSolenoid
TorqueConverterPressure
LubricationPressure
Distribution of Hvdraulic Prssure

. RegulatorValveTorqueConvenerPressure
LubricationPressure
f
L
To requlateLinePressure
.
ManualValve--
To selectLinePressu.e
ModulatorValve
ModulatorPressure
ClutchPressure
l
.
.
.
1-2 Shift Valve

2-3 Shift Valve
3-4 Shift Valve
NO.
'1
Shift ControlSolenoidValves
Lock-upControlSolenoidValves
LinearSolenoid
Il]l
l
ClutchPressure
DESCRIPTION
OF PRESSURE N O .
DESCRIPTION
OF PRESSURE N O .
DESCRIPTION
OF PRESSURE
LINE
MODULATE
(SHIFT
CONTROL
SOLENOID 4 1
VALVEB)
4THCLUTCH
MODULATE
(LOCK-UPCONTROL
SOLENOID
VALVEA)
LINEARSOLENOID
6B
LINE
1"
LINE
6D
MODULATE
(LOCK-UPCONTROL
SOLENOID
VALVEB)
90
TOROUECONVERTER
LINE
6D'
MODULATE
(LOCK-UP
CONTROL
SOLENOID
VALVEB)
91
TOROUECONVERTER
LINE
LINE
92
TOROUECONVERTER
LINE
LINE/CPC
93
ATF COOLER
LINE
94
TOROUECONVERTER
LINE
LINE
4'
6A
10
1STCLUTCH
LUBRICATION
LINE
20
2ND CLUTCH
96
TOROUECONVERTER
LINE
204
2ND ACCUMULATOR
97
TOROUECONVERTER
cPc
25
LINE
99
SUCTION
MODULATE
30
3 R DC L U T C H
DRAIN
MODULATE
(SHIFTCONTROL
SOLENOID
VALVEA)
40
4TH CLUTCH
(cont'd)
14-23
Description
HydraulicFlow (cont'dl
N Position
(ATF)is drawn from (99)and disAs the engineturns,the ATF pump also startsto operate.Automatictransmissionfluid
(1)
line pressure(1) is regulated
chargedinro (1).Then,ATF flowing from the ATF pump becomesthe line pressure The
through the lock-up
(94)
converter
the
torque
of
by t;e regulatorvalve.The torque converterinlet pressure{92)enters
pressure
from rising'
converter
prevents
the
torque
valve
shift valveand dischargesinto (90).The torqueconvertercheck
clutches'
to
the
pressure
is
not
applied
Underthis condition,the hydraulic
"|eft" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
14-24
E Position
The line pressure(1)flows to the manualvalveand the modulatorvalve.The line pressure(1) changesthe line pressure
(4) and (25)at the manualvalve,and changesto the modulatorpressureat the modulalo.valve.But the modulatorpressure (6) does not flow to each shift valve becauseshiit control solenoidvalvesA and B are turned ON by the PCM.The
line pressure(4) passesthrough the CPBvalveand the CPCvalve,and changesto the line pressure(5),then flows to the
1-2shift valve.The line pressure(5)from the 1-2shift valvechangesto the 2nd clutchpressure{20)at the 2-3 shift valve.
The 2nd clutch pressure(20) is appliedto the 2nd clutch,and the 2nd clutch is engaged.The line pressure(4) passes
throughthe 1-2shift valve and the orifice,and changesthe 1st clutchpressure,The 1st clutchpressure(10)also flows to
the 1stclutch.However,no power is transmittedbecauseof the one-wayclutch.
NOTErWhen used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
(cont'd)
14-25
Description
HydraulicFlow (cont'd)
El or lOi Position
1.
lst Gear
The flow of fluid throughthe torque convertercircuitis sameas in N position.The line pressureflows to the manual
valveand the modulatorvalve.The line pressurechangesto the modulatorpressure(6) at the modulatorvalveand to
the line pressure(4)at the manualvalve.The modulatorpressure(6)flows to the left end of the 1-2shiftvalveand the
3-4 shift valvebecauseshift controlsolenoidvalveA is turnedOFFand B is turnedON by the PCM.The l-2 shift valve
'lst
clutchpressure110)at the 1-2shift valve and the
is movedto the right side.The line pressure(4) changesto the
the vehiclewill
orifice.The 1st clutchpressure('t0)is appliedto the lst clutchand the 1st accumulator;consquently,
move as the enginepower is transmitted.
"right" indicatesdirectionon the hydrauliccircuit.
NOTE:When used,"|eft" or
2.
2nd Gear
As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveA is turned ON by meansof the
PCM.The modulatorpressure(64l in the left end of the 1-2 shift valve is releasedby turning shift control solenoid
valveA ON. The 1-2 shift valve is moved to the left side and uncoversthe pon to allow line pressure(5) to the 2-3
shift valve.The line pressure(5)changesto the 2nd clutchpressure(20)at the 2-3 shift valve.The 2nd clutchpressure
(20)is appliedto the 2nd clutch,and the 2nd clutchis engaged.
Fluid flows bv wav of:
- Line Pressure(4)- CPBValve- LinePressure(5)- 'l-2ShiftValve- LinePressure(5)- 2-3 ShiftValve
- 2nd ClutchPressure(20)t 2nd Clutch
The hydraulicpressurealsoflows to the 1stclutch.However,no power js transmittedbecauseof the one-wayclutch.
NOTE;When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
(cont'd)
14-27
Description
HydraulicFlow (cont'd)
3.
3rd Gear
As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalve B is turned OFFby meansof the
pCM. Shift control solenoidvalve A remainsON. The modulatorpressure(6) tlows to the right end of the 1-2shift
valve and the left end of the 2-3 shift valve.The 2-3 shift valve is moved to the right side by the modulatorpressure
{68),The 2-3 shift valvecoversthe port to stop line pressure(5)to the 2nd clutchand uncoversto the 3-4 shift valve
as the 2-3 shift valve is moved to the right side.The line pressure(5) becomesthe 3rd clutchpressure(30)at the 3-4
shiftvalve.The 3rd clutchpressure(30)is appliedto the 3rd clutch,and the 3rd clutchis engaged.
Fluidflows by way of:
- Linepressure(4)- CPBValve- Line Pressure(5)- 1-2ShiftValve- LinePressure(5)+ 2-3 Shift Valve
- LinePressure{5)- 3-4 Shift Valve- 3rd ClutchPressure(30}* 3rd Clutch
The hydraulicpressurealso flows to the 1st clutch.However,no power is transmittedbecauseof the one-wayclutch
a s i n 2 n dg e a r .
When used,"left" or
14-28
i*.
4th G6ar ( qr Positionl

Asthe speedofthevehicle reachesthe prescribedvalue,shiftcontrolsolenoidvalveA is turnedOFFby meansof the
PCM.Shift control solenoidvalv6 B remainsOFF.The modulatorpressure(6) flows to the left end of the 1-2 shift
valve and the left end of the 3-4 shift valve.The modulatorpressure(64) in the left end of the 1-2shift valveequals
the modulatorpressure(68) in the right end of the 1-2 shift valve,the 1-2shiit valve remainsat left side by the tension of the valvespring.
The 3-4 shift valveis movedto the right side by the modulatorpressure(5A).The 3-4 shift valvecoversthe port to the
3rd clutchand uncoversthe port to the 4th clutchas this valveis movedto the right side.The 4th clutchpressure(41)
from the 3-4 shift valve becomesthe 4th clutch pressure(40) at the manual valve.The 4th clutch pressure{40} is
appliedto the 4th clutch,and the 4th clutchis engaged.
Fluidflows by way of:
- Linepressur(4)- CPBValve- LinePressure(5)+ l-2 Shift Valve- LinePressure(5)- 2-3 ShiftVarve
- LinePressure(5)* 3-4 ShiftValve- 4th ClutchPressure(41)+ ManualValve- 4th ClutchPressure(40)
+ 4th Clutch
The hydraulicpressurealsoflows to the 1stclutch.However,no power is transmittedbecauseof the one-wayclutch
as in 2nd and 3rd gear.
NOTE:When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
(cont'd)
14-29
Description
HydraulicFlow(cont'dl
lll Position
The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(1) changesto the
line pressure(3)and flows to the 1-2shift valve.The line pressure(3)changesto the line pressure(3')at the 1-2shift valve
and flows to the servovalve.The servovalve is movedto the right side (Reverserangeposition)and uncoversthe pon to
allow line pressure(3") to the manualvalve.The line pressure(3')from the 1-2shift valveflows throughthe servovalveto
the manualvalve and changesthe 4th clutchpressure{40).The 4th clutchpressure(40)is appliedto the 4th clutch,and
the 4th clutchis engaged.
ReverseInhibitor Control
Whenthe E positionis selectedwhile the vehicleis movingforwardat speedsover 6 mph (10 km/h),the PCMoutputsthe
1stspeedsignalto shift controlsolenoidvalvesA and B; shift controlsolenoidvalveA is turnedOFF,shift controlsolenoid
valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe port to stop line pressure{3') to the
servo valve.The line pressure(3') is not appliedto the servovalve,and the 4th clutchpressure{40)is not appliedto the
4th clutch,as a result.power is not transmittedto the reversedirection.
NOTE:When used,"|eft" or
14-3 0
E Position
The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(11changesto the
line pressure(3)and flows to the 1-2shift valve.The line pressure(3)changesto the line pressure(3')at the 1-2shift valve
and flows to the servovalve.The servovalve is movedto the right side {Reverserangeposition)and uncoversthe port to
allow line pressure(3")to the manualvalveas in E position.The line pressure(3")from the servovalveis interceptedby
the manualvalve.However,hydraulicpressureis not suppliedto the clutches,and the power is not transmitted.
When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
14-31
Description
Lock-upSystem
Lock-upClutch
1.
Operation(clutchon)
With the lockup clutchon, the fluid in the chamberbetweenthe torqueconvertercoverand the lock-uppistonis drained
off,and the converterfluid exertspressurethroughthe pistonagainstthe torqueconvertercover.As a result,the converter turbineis lockedto the convertercover.The effectis to bypassthe converter,
therebyplacingthe vehiclein directdrive.
LOCK-UPPISTON
DAMPERSPRING
The power flows by way of:

Engine
I
Driveplate
TOROUECONVERTER
COVER
t
Torque convertercover
t
Lock-uppiston
t
Damperspring
t
Turbine
I
lvlainshaft
MAINSHAFT
Operation(clutchoff)
With the lock-upclutch off, the fluid flows in the reverseof "clutch on." As a result.the lock-uppiston moves away from
the convertercover,and the torque converterlock-upis released.
TURBINE
Engine
TOROUE
COVER
t
Driveplate
{
Torqueconvenercover
t
Pump
To ATF coolel
Turbine
t
lvlainshaft
MAINSHAFT
14-32
In igd position,in 3rd and 4th, and D3-position in 3rd,

pressurized
fluid is drainedfrom the back of the torque
converterthrough a fluid passage,causingthe lock-up
pistonto be held againstthe torque convertercover.As
this takesplace,the mainshaftrotatesat the same speed
as the engine crankshaft.Together with the hydraulic
c o n t r o l ,t h e P C M o p t i m i z e dt h e t i m i n g o f t h e l o c k - u p
system. Under certain conditions,the lock-upclutch is
in 3rd and 4th gear.
appliedduring deceleration,
TOROUECONVERTER
The lock-upsystemcontrolsthe rangeot lock-upaccording to lock-upcontrol solenoidvalvesA and B, and the

linearsolenoid.When lock-upcontrol solenoidvalvesA
and B activate.modulator pressurechanges.Lock-up
control solenoidvalvesA and B and the linearsolenoid
a r e m o u n t e do n t h e o u t s i d eo f t h e t o r q u e c o n v e r t e r
housing,and are controlledby the PCM.
Lock-up Conditions/Lock-up Control Solenoid Valves/
Linear Solenoid Pressure
Lock-upControl
Solenoid Valve
Linear
Solenoid
Pressure
OFF
OFF
High
Lock-up,Half
ON
Duty operation
OFF- ON
Lock-up,Full
ON
ON
LOCX-Up
during
deceleration
ON
Duty operation
OFF- ON
Lock-up
Conditions
A
Lock-upOFF
IOROUECONVERTER
CHECKVALVE
High
MODULATORPRESSURE
RELIEFVAL
LOCK.UPTIMING
VALVE
",
<-
LINEARSOLENOIDPRESSURE
RELIEF
VALVE
.X,COOLER
ATFPUMP
(cont'dl
14-33
Description
Lock-upSystem(cont'dl
No Lock.up
.
.
.
TOROUECONVERTER
Lock-uoControlSolenoidValveA: OFF
Lock-uoControlSolenoidValveB: OFF
LinearSolenoidPressure:
High
The pressurized
fluid regulatedby the modulatorworks
on both ends of the lock-upshift valve.Underthis condition, the pressuresworking on both ends of the lock-up
shift valve are equal,the lock-upshift valve is moved to
the right side by the tension of the valve spring alone.
The fluid from the ATF pump will flow through the left
side of the lock-upclutchto the torque convener;that is,
the lock-uoclutchis in OFFcondition.
NOTE:When used,"left" and "right" indicatesdirection
on the hvdrauliccircuit.
-r
TOROUECONVERTER
I
CHECK VALVE
RELIEFVALVE
MOOULATORPRESSURE
LOCK-UPTIMING
VALVE
$ I L--r
COOLERRELTEF
VALVE
ATFPUMP
Half lock-up
.
.
.
TOROUECONVERTER
LOCK,UPCONTROL
SOLENOIDVALVE
t
TOBOUECONVERTEFI
CHECKVALVE
Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValveB: DutyOperation
OFF* ON
Low
LinearSolenoidPressure:
The PCMswitchesthe solenoidvalveA on to releasethe

modulatorpressurein the left cavity ot the lock-upshift
valve.The modulatorpressurein the right cavity of the
lock-upshift valve overcomesthe spring force;thus the
lock-upshiftvalve is movedto the left side.
The line pressureis then separatedinto the two passagesto the torque convener:
T o r q u eC o n v e r t e rI n n e r P r e s s u r ee: n t e r si n t o r i g h t
sideto engagelock-upclutch
Torque ConverterBackPressure:entersinto left side
to disengagelock-upclutch
The back pressure(F2)is regulatedby the lock-upcontrol valve, whereas the position of the lock-uptiming
valve is determinedby the linearsolenoidpressureand
tensionof the valvespring.Also the positionof the lockup control valve is determinedby the back pressureof
the lock-upcontrolvalve,torque converterpressureregulatedbv the torque convertercheckvalve,and modulator pressuredeterminedby the lock-upcontrolsolenoid
valve B. The PCM switchesthe lock-uDcontrol solenoid
valve B on and off rapidly(duty operation)undercertain
conditionsto regulatethe backpressure{F2)to lockthe
torqueconverterproperly.
NOTE:When used,"left" and "right" indicatesdirection
on the hydrauliccircuit.
MODULATOR
PRESSURE
RELIEF VALVE
LOCK.UPTIMING
VALVE
,.
^r
VALVE
r* cooLERRELTEF
ATFPUMP
(cont'd)
14-35
Description
Lock-upSystem(cont'd)
{
Full Lock-up
.
.
.
Lock-upControl Solenoid Valve A: ON

Lock-upControl Solenoid Valve B: ON
LinearSolenoidPressure:High
When the vehicle speed further inc.eases,the linear

solenoid pressureis increasedto high in accordance
with the linearsolenoidcontrolledby the PCM.
The lock-uptiming valve overcomesth spring force
and moves to the left side. Also. this valve closesthe
fluid port leading to the left side of the lock-up control
TOROUECONVERTER
Under this condition,the modulatorpressurein the left

s i d e o f t h e l o c k - u pc o n t r o l v a l v e h a d a l r s a d y b e a n
releasedby the lock-up control solenoid valve 8; the
lock-upcontrol valve is moved to the left side. As this
t a k e s p l a c e ,t h e t o r q u e c o n v e r t e r b a c k p r e s s u r e i s
releasedfully, causingthe lock-upclutchto be engaged
fully.
LOCK-UPCONTROL
VALVE
LOCK.UPCONTROL
SOLENOIDVAI.VE
NOTE:When used,"|eft" and "right" indicatsdirection

on the hvdrauliccircuit,
MODULATORPRESSURE
RELIEFVALVE
LOCK-UPTIMING
VALVE
^
vALvE
1,,__.r'cooLERRELTEF
ATFPUMP
14-36
DecelerationLock-up
.
.
.
Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValveB: DutyOperation
OFF- ON
Low
LinearSolenoidPressurer
The PCM switchessolenoidvalve B on and off rapidly

. h e s l i g h t l o c k - u pa n d h a l f
u n d e r c e r t a i nc o n d i t i o n sT
lock-upregionsare maintainedso as to lock the torque
converterproperly.
"right" indicatesdirection
NOTE:When used,"left" and
on the hydrauliccircuit.
TOROUECONVEATER
LOCK-UPCONTROL
SOLENOIOVALVE
,o*oua"otua"rlil
CHECKVALVE
MODULATORPFESSURE
RELIEFVAL
LOCK.UPTIMING
VALVE
PRESSUBE
LINEARSOLENOID
s
^r
---r'1 COOLERRELIEFVALVE
ATF PUMP
14-37
ComponentLocations
CONTROL
POWERTRAIN
MOOULEIPCM}
TICTRANSAXLEIA/TI
GEARPOSITIONSWITCH
COUNTERSHAFT
SPEEDSENSOR
i:.
i\\.i.'.
(-
tr',\i,
V'.:t
',
SOLENOIDVALVE
ASSEMBLY
SOLENOIDVALVE
ASSEMBLY
14-39
PCM Circuit Diagram(A/T ControlSystem)

-HOODFUSE/REIAY
UNOEfl
BOX
No.41(80A) No.42l40A)
(l5A)
No.13
UNOER
DASH
FUSE/RELAY
BOX
N o . 4 7{ 7 . 5A )
/8tu
BtK
c10
BLK
A10
423
L
ArpNp
l o r ^ o ] s L ul n r r n
lSlt l6lt lor*

824 l88 I817
YEL96:GRN BLU
'96:
BLU/RED
'97,'98:
GRN/BLK
G A U GA
ES S E M E L Y
',u,
f
,,,tro "I
,at
BLKETU
wHT
A/TGEAR
POSITION
INDICATOR
T T T
YEL
38-'cFN/BLK
F-
GRN BLU
BIK/BLU
|--wHT
I--
NorE:rf :To5v
T
GRN
D,
r T o1 2 V
14-40
VEHICLE
SENSOR
SPEEO
l'1Fr
.
CONNECTOR
SERVICE
CHECK
rlP
II
RED/WHT
BLUMHT
l.',
s23
l"'
BLU
REO
Lcl
GRN
010
D1
I"
83
I
RED
|811
BLU/ryELGRN,4A/HT
l"
122
I
I
I
GRN/BLKBRN/BTK
f_l_ _l__l_l__L
_l__l_
Tt lT
t
02
YEUBTURED/BtK
MAINSHAFT
SPEED
SENSOR
I T T T
TTTT
p*8
SPEoSENSoR L|NEARSOLENo|D
-UP CONTROL
LOCK
VALVE
SOLENOIO
ASSEMBLY
Locations
rcM TeminBl
14-41
PCMTerminalVoltage/Measuring
Conditions
A/T ControlSystem
The PCMterminalvoltageand measuringconditionsare shown for the connectorterminalsthat relateto the A,/Tcontrol
system.The other PCN4
terminalvoltageand measuringconditionsare describedin section1L
A l32P)Connector
I (25PlConncrol
C (3lPlConnector
D {16P)Connector
PCMCONNECTOR
A {32P}
TerminalNumber
Signal
Description
see section 11 -
41 to A8
A9
LGl
Ground
A't0
PGl
Ground
411
IGPl
Powersupplysystem
LG2
Ground
423
PG2
Ground
424
IGP2
Powersupplysystem
A.12ro 421
422
Measuring Condiiions/Terminal Voltage
With ignitionswitchON (ll):Batteryvoltage

With ignitionswitchOFF:0 V
- seesection11-
With ignitionswitchON (ll):Batteryvoltage

With ignitionswitchOFF:0V
- seeseclion11
A25 to A32
PCMCONNECTORB {25PI
TerminalNumber
Signal
B1
LS-
Linearsolenoidpower supply
negativeelectrode
l g n i t i o ns w i t c hO N { l l } :P u l s i n gs i g n a l
82
LS+
Linearsolenoidpower supply
positiveelectrode
l g n i t i o ns w i t c h O N t l l ) :P u l s i n gs i g n a r
SHA
Shift control solenoid valve A

control
In 2nd gear and 3rd gear in id, Ei position,

and in El, E position:Batteryvoltage
In lst gearand 4th gear in D3l,Bll position:OV
B4
LCB
Lock-upcontrolsolenoidvalve B
control
When full lock-up:Batteryvoltage

W h e nh a l fl o c ku p : P u l s i n gs i g n a l
B5
LCA
Lock-upcontrolsolenoidvalveA
control
When lock-upis ON: Batteryvoltage

With no lock up: 0 V
86 to 87
B8
89to 810
14-42
Description
Measuring Conditions/Telminal Voltage
Not used
ATP D3
Ay'Tgear positionswitch !c position signalinput

Not used
position:0 V
In .[D;]
In otherthan D3lposition:Batteryvortage
PCMCONNECTORB (25P)(cont'd)
Measuring Conditions/TerminalVoltage
Description
Terminal Numbel
Signal
811
SHB
Shift controlsolenoidvalveB
control
In 1stgear and 2nd gear in El, E position,

and in E position:Batteryvoltage
In 3rd gearand 4th gear in E, lp! position:0 V
SLU
lnterlockcontrol
B13
D4IND
D4 Indicatorlight control
When ignitionswitchis ON (ll).brakepedal

pedalreleased:
0V
depressedand accelerator
When ignitionswitchis first turnedON (ll):
Battery voltage for two seconds
In iDaposition:Batteryvoltage
814
NMSG
Mainshaftspeedsensorground
Always:0 V
NM
Mainshaftspeedsensorsignal
Input
Dependingon enginespeed:Pulsingsignal
When engineis stopped:0 V
B16
ATP R
A,/Tgear position switch @

positionsignalinput
InEposition:0V
In otherthan E position:Batteryvoltage
817
AJP 2
A/T gear positionswitchP position signalinput
InEposition:0V
In otherthan E position:Batteryvoltage
Not used
8 1 8t o 8 2 1
B22
NCSG
Countershaftspeed sensorground
Always:0 V
B23
NC
speedsensorsignal
Countershaft
Inpur
Dependingon vehiclespeed:Pulsingsignal
Whenvehicleis stopped:0 V
824
ATP D4
B25
ATP NP
A/T gear position switch Pj position signalinput

A/'f gear positionswitchE and
N positionsignalsinput
In -Drlposition:0V
In otherthan E! position:5 V
In E and El positions:0 V
In other than E and N positions:Batteryvoltage
C {31P)
PCM CONNECTOR
Terminal Number
Signsl
Description
- seesection11 -
Cl to C6
c7
Servicechecksignal
With ignition switch ON (lll and servicecheck

connectoropen:5 V
With ignition switch ON (ll) and servicecheck
connectorconnectedwith specialtool: 0 V
- seesection11-
Back-uppower system
Always battery voltage

- seesectionI I -
C8 to C9
c10
MeasuringConditions/Terminalvoltage
VBU
Cl 1 to C31
PCM CONNECTORD (16P)
TerminalNumber
Signal
Description
- seesection1 l -
D1 to D4
D5
D Ot o D 1 6
Measuring Conditions/TerminalVoltage
STOPSW
Brakeswitchsignalinput
Brakepedaldepressed:Batteryvoltage
Brakeoedalreleased:0 V
- seesection11-
14-43
Checkingthe DiagnosticTroubleCode{DTC)
with an OBD ll Scan tool or Honds PGM Testel
When the PCM sensesan abnormalityin the input or output systems,the ql indicatorlight in the gaugeassemblywill
blink When the 16PData Link Connector(DLC)ilocatedunder the dash on the driver'sside) is connectedto the oBD ll
ScanTool or HondaPGM Testeras shown,the scantool or testerwill indicatethe DiagnosticTroubleCode (DTC)when
t h e i g n i t i o ns w i t c hi s t u r n e dO N I ) .
when the E ] indicatorlight has been reportedon, connectthe oBD ll scan Tool conformingto SAEJ197gor HondapGM
Testerto the DLC(l6P). Turn the ignitionswitchON {ll), and observethe DTCon the screenof the OBD ll ScanTool or
HondaPGMTester'After determiningthe DTc, referto the electricalsystemSymptom-to-component
chart on pages14-48
and 14-49.
NOTE:Seethe OBD ll ScanTool or HondaPGMTesteruser,smanualfor specificinstruction.
OBD ll SCANTOOLor
HONDAPGM TESTER
(16P}
DATA LINKCONNECTOR
14-44
Checkingthe DiagnosticTroubleCode (DTC)

with the ServiceCheckConnestorand SpecialTool
Whenthe pCM sensesan abnormalityin the inputor outputsystems.the itj indicatorlight in the gaugeassemblywill blink
When the ServiceCheckConnector(locatedunderthe dash on the passengerside) is connectedwith the specialtool as
TroubleCode(DTC)when the ignitionswitchis turnedON (ll).
shown,the lD1indicatorlight will blinkthe Diagnostic
Whenthe @ indicatorlight has beenreportedon, connectthe ServiceCheckConnectorwith the specialtool.
Thenturn ON (ll)the ignitionswitchand observethe [o! indicatorlight
GAUGEASSEMBLY
.-.=-.-..--- . .
\.....-,-..-.""r
.-'
'i''
.-
c ,
a:
SERVICECHECK
CONNECTOR
I2P}
CONNECTOR
07PAZ- (x)'10t00
a seriesof long and short

codes 1 through9 are indicatedby individualshort blinks.codes 10 and aboveare indicatedby
the code After deterdetermine
to
blinks.one long blink equals10 short blinks.Add the long and short blinkstogether
14-49'
pages
and
14-48
on
Chart
miningthe code,referto the electricalsystemSymptom-toComponent
Short blink {once}
See DTC 1
See DTC2
Long blink
Short blinks lfive times)
See DTC 15
(cont'd)
14-45
{cont'd)
1.
Removethe kickpanelon the passenger's

side (seesection20).
2.
Removethe PCM,and turn the PCMover.
Inspectthe circuiton the PCMaccordingto the troubleshooting

llowchartwith the specialtools and a digitalmultimeter as shown.
How to Use the BackprobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cords to a multimeter.Using the wire
insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side until it comesin contactwith the terminalend of the wire.
EACKPROAE
BACKPROAE
SET
07sAz- 001000A
(tworequired)
OIGITALMULTIMETER
(Commrciallyavailable)
-aHM-32-003
or equivalent
14-46
PCM RasetProcadure
1.
Turnthe ignitionswitchoff.
2.
Removethe BACKUP fuse (7 5 A) from the under-hoodfuse/relaybox for 10 secondsto resetthe PCM'
NOTE:
. Disconnecting
the BACKUP fuse also cancelsthe radio presetstationsand clock setting.Make note of the radio
presetsbeforeremovingthe tuse so you can resetthem.
o The PCMmemorycan alsobe clearedby usingthe OBDll ScanTool or HondaPGMTester'
BACKUP
(7.5A) FUSE
Final Procedurg
NOTE:This proceduremust be done after any troubleshooting

1.
2.
Resetthe PcM.
3.
tool from
the OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector,or removethe special
Disconnect
the ServiceCheckConnector.
4.
Turn the ignitionswitchON (ll),and set the radiopresetsand clocksetting
14-47
Symptom-to-Component
Chart
ElectricalSystem
Diagnostic
TroubleCode El Indicator
Light
(DTC)*
P1753
(1)
P1758
t2l
P1705
(s)
P1706
(6)
P0753
t7I
Blinks
Symptom
PossibleCause
Referto
Page
Lock-upclutchdoes not engage.

Lock-upclutchdoes not disen
gage.
Disconnected
lock-upcontrolsolenoid
valveA connector
Shortor open in lock-upcontrol
solenoidvalveA wire
Faultylock-upcontrolsolenoidvalveA
l4-50
Disconnected
lock-upcontrolsolenoid
valveB connector
Shortor open in lock-upcontrol
solenoidvalveB wire
Faultylock-upcontrolsolenoidvalveB
14-52
Blinks
Blinks
OFF
Blinks
. Failsto shiftotherthan 2nd - 4th

gears.
. Lock-upclutchdoes not engage.
. Failsto shiftotherthan 2nd - 3rd
- 4th gears.
. Failsto shift (between1st- 4th,
o r 2 n d- 3 r d g e a ro n l y ) .
. Failsto shift (stuckin 4th gear).
. Short in Ay'Tgear positionswitchwrre

. FaultyA4 9"", Oositionswitch
Disconnected
A/T gear positionswitch
connector
Open in A"/Tgear positionswilchwire
FaultyAy'Tgear positionswitch
Disconnected
shiftcontrolsolenoid
valveA connector
Shortor open in shift controlsolenoid
14-54
14-s6
r4-58
FaultyshiftcontrolsolenoidvalveA
P0758
(8)
Failsto shift (stuckin 1stor 4th

gears).
Blinks

PO120
(9)
Blinks
Disconnected
shiftcontrolsolenoid
valveB connector
Shon or open in shiftcontrolsolenoid
valveB wire
Faultyshift controlsolenoidvalveB
'14-60
Disconnected
countershaft
speedsensor connector
Shon or open in countershaft
speed
sensorwrre
Faultycountershaft
speedsensor
14-62
(DTC)*:The DTcs in parentheses

are the numberof the E indicatorlight blinkswhen the servicecheckconnecrorrs connectedwith the specialtool (SCSserviceconnectorl.
14-48
Diagnostic
Indicator
TroubieCode E
Light
(Drc).
Symptom
'96,'97 models . Lock-upclutchdoes not engage.
P07r5
(1 5 )
P1 7 6 8
(16)
OFF
'98 model
Blinks
Blinks
P0740
(40)
P0730
(41)
P0700
(none)
. Transmission
jerkshardwhen
shifting.stuckin 4th gear.
OFF
Failsto shift (between1st- 2nd,

1st- 4th. 2nd - 4th,znd - 3rd, 3rd
- 4th, 1st- 2nd - 3rd, 1st-3rd 4th or 2nd - 3rd - 4th gearsonly).
Failsto shift (stuckin 1stor 2nd
gears).
Referto
Page
PossibleCause
mainshaftspeedsensor
Disconnected
connector
Shortor open in mainshaftspeedsensor wtre
Faultymainshaftspeedsensor
14-64
linearsolenoidconnector
Disconnected
Shortor open in linearsolenoidwire
Faultvlinearsolenoid
or loosedPGterminal
Disconnected
14-66
. Faultylock-upcontrolsystem
14-68
. Faultvshift controlsystem
14-69
problem,
Any automatic
transmission
To eliminateDTCP0700,troubleshootthe other automatictransmissionproblem(s)accordingto the DTC(S)indicated.
(DTC)*:The DTCSin parentheses

are the numberof the E indicatorlight blinkswhen the servicecheckconnectoris connectedwith the sDecialtool(SCSserviceconnector).
for the automatictransmissioncontrolsysNOTE:When the OBOll ScanTool or HondaPGMTesterindicatethe DTC(S)
Code P0700meansdetectionof some automatic
tem, the scan tool or tester also indicatescode P0700simultaneously.
transmissionoroblemon the PGMFl controlsystem.
lf the self-diagnostic
Ei!]indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom
E indicatorlight does not come on tor two secondsafter ignition
switchis first turnedON (ll).
E indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis ON (ll).
Shift levercannotbe movedfrom E positionwith the brakepedal
oeoresseo,
Inspection
Ref. page
14-70
't 4-12
Inspection
14-13
to recreatethe symptom by test-drivNOTE:lf a customerdescribesthe symptomfor code P1706(6),it will be necessary

ing,then recheckthe DTC.
14-49
ElectricalTroubleshootin
g
TroubleshootingFlowchart- Lock-upGontrolSolenoidValveA
. OBD ll ScanTool indicatesCode
P1753.
. Sell-diagnosi3 i-tl indicatol
light blinks once.
PossibleCsuso
. Disconnectedlock-up cont.ol
solenoid valve A connector
. Short or opon in lock-upcontrol
3olenoidvalve A wire
. Faulty lock-up control solenoid
valvo A
PCMCONNECTORS
Checkfor e Short to Power:

2. Disconnect
the A {32P)and B
( 2 5 P )c o n n e c t o r sf r o m t h e
PCM.
the 85 and A9 or A22 terminals.
WIRESIDEOF FEMAI.f TERMINALS
Ropairshort to power in the wirc

betweon the 85 terminal and the
lock-upcontrol solenoidvalve A.
Measur Lock-upControl Solenoid Valve A R*istanc:

2, Measure the resistance
betweenthe 85 and Ag or A22
terminals.
ls the resistance
12- 25 0?
To page14-51
14-50
Check tor loose P1CMconnectoJs.

It necossary, substituto a knowngood solenoid v.lvo assomblyor
PCM and r6chock.
From page14-50
Check Lock-up Control Solenoid

Valve A for a Shon Circuh:
from the lock-upcontrolsolenoid valveassembly.
the 85 and Ag or A22 terminals,
PCMCONNECTORS
A (32P)
WIRESIDEOF FEMALETERMINALS
ls therecontinuity?
Repair3hort to ground in the wire

between the 85 t6rminal and the
lock-uD conttol solenoid vahre A.
LOCK.UPCONTROL
SOLENOIDCONNECTOR
*T
. - F
ItrTt
M6asu.e Lock-uo Control Solonoid Valve A Rosistance at lho
SolenoidConnector:
Measure the resistancebetween
the No. 2 terminalof the lock-up
control solenoid connectorand
body ground.
ls the resistance
12- 25 0?
(o)
YEL
TERMINALSIDEOF
MALETERMINALS
Check for open in the wire

btwen the 85 terminel .nd the
lock-upcontrol solenoid valve A.
Replece the lock-up control solenoid valve assembly.
14-51
ElectricalTroubleshooti
ng
TroubleshootingFlowchart- Lock-upGontrolSolenoidValveB
OBD ll Scan Tool indicli.. Code
P1758.
Selt-disgnolb E indicltor light
blinks twice.
Po..iblo C!u&
. Diaconnacted lock"up control
rolanold valv. B connector
. Short oi opon In lock-upcom.ol
rolgnoid v.lva B wiro
. F ulty lock-up contol rolanoid
valva B
FCM CONNECTORS
Chockfor a Short to Power:
1. Turn thg ignitionswitchOFF.
2. Disconnact
the A (32P)and A
PCM.
4. Measurethe voltagg btween
the 84 and A9 or A22 terminals,
A t32P)
WIRESIOEOF FEMALETENMNALS
Rapair rhort to powar in tha wirc

brftv.en th. Ba tormin.l rnd th.
lock-upcontrol aolanoidvalva B.
Me!!u.e Lock-up Conlrol Solenoid Valvo B Rcrictlncc:

2. Measure the resistance
b e t w e e nt h e B 4 a n d A g o r
A22terminals.
ls the resistance
12- 25 O?
To page14.53
14-52
Ch.ck tor loo.. PrCi, conn.c'lor3,

It n6ca3t!ry. subttihrta r knowngood rolanoid valvo a$ombly or
PCM lnd rcch.ck.
From page 14-52
PCMCONNECTORS
Chack Lock-up Control Solenoid

Vslve B to. a Short Citcuit:
trom the lock-upcontrol solenoid valve assembly.
Rapair3hort to ground in th wir
betwaen the 84 torminal and th
lock-up control solenoid valvo B.
LOCK-UPCONTROL
SOLENOIDCONNECTOR
IFT']
Mea3ura lock-up Control Solenoid Vrlvc B Ro3irtrnc. at the

SolonoidConnoc{or:
the No. 1 terminalof the lock-up
control solenoid connectorand
bodyground.
t-
cnNreLxI
(o)
T
I
TERMINALSIDEOF
MALETERMINALS
12- 25 0?
ls the resistance
Chock for opon in the wir

botwon th. 84 torminal and the
lock-up control aolonoidvalva B.
R.phc. tha lock-up cont.ol solonoid valvc $!.mbly.
14-53
Troubfeshooting
Flowchart- AIT GearPositionSwitch (shortl
P1?05.
. SelI-disgno3isE indicrror light
blinks tive tim6.
Observeth6 A/T Gear Po3ition

Indicator:
2. Observethe A,/Tgear position
i n d i c a t o r ,a n d s h i l t t o e a c h
posttlon.
Do any indicatorsstayon
whenthe shiftleveris not in
thosepositions?
PossibleCause
. Shorl in A/T 96ar position switch
. FaultyA/T geal po3ition switch
NOTE:Code Pl705 (5) is causedwhen
t h e P C M r e c e i v e st w o g e a r p o s i t i o n
,nputsat the sametime-
The system is OK at this time.

Check the wile harnessfo. damage.
PCMCONNECTORS
MeasureATP R Voltage:
1. Shittto all positionsotherthan
E.
2. Measurethe voltagebetween
the 816 and Ag or A22 terminals,
Check for short in the wire
betweenthe Bl6termineland the
A/T gear position swilch or A/T
gear position indicator. lf wire is
OK, check lor loose PCM connectors. It noceasary,substitute a
known-goodPCMand recheck.
MeasureATP NP Voltage:
1. Shiftto all positionsotherthan
Nor@.
the 825 and Ag ot A22 te(mi
nals,
ls therebatteryvoltage?
MeasureATP 04 Voliage:
O..
ls thereapprox.5 V?
To page14-55
14-54
Check tor short in the wire

btweentho 825 terminal and the
A/T goar position indicator, o. a
shon in the wiaes beiween the
A/T gear position indicator and
the A/T gear posilion switch. It
wires are OK, check for loose
PCM conneclors. lf necssarv,
substitute a known-good PCM
end rechock,
Check for sho.t in the wiro

betweenthe B24terminaland the
A/T ge.r position switch. lf wire
is OK, check lor loose PCM GonnectoE. ff necessary,substituto a
known-goodPCMand recheck.
PCMCONNECTORS
Frompage14-54
M.tsuro ATP D3 Vohage:

'1. Shift to all positionsother than
E.

the 88 and A9 or A22 terminats.
WIBESIDEOF FEMALETERMINALS
Ch6ck for short in tho wire

batwen tho 88 terminel and the
A/T gear position switch ot A/T
gea. position indicator. It wire i3
OX, check for loos6 PCM conneclors. lf neces3ary, substitute a
known-good PCMand techeck.
BRN/ALK
Morsure ATP2vohage:
tr.
2. lvleasurothe voltage between

the 817 and A9 or 422 termi
nats.
BRN/BLK
Check for sho.t in the wire
btwenthe 817 terminal .nd thc
A/T goar position switch or A/T
gear position indicalo.. tf wire is
OK. check for loos6 PICMconnectors. lf necessary,substitute a
known-goodPCM.nd racheck.
Chockfor loo3o PCMconnGctors,

lf nccossrry, 3ubsthuto a knowngood PCM tnd r6chock.
14-55
TroubleshootingFlowchart- A/T GearPositionSwitch (Openl
. OBD ll ScanTool indicat$ Code
P1706.
. Self-di.gnosisq indicatorlight
blinks six iim*.
PGsibl. Causo
. DisconnectodA/T goal po3iilon
3witch connector
. Open in A/l gear position awitch
. Fauhy A/T go.r position switch
PCMCONNECTORS
BRN/BLK
Me8ure ATP R Voltage:

2. Shiftto E position.
3, Measurethe voltagebetween
BRN/BLK
Bepair open in the wile bstwaton
the 816 torminal and tha A/T goar
po3hion switch.
BRN/BLK
1. Shiftto N orE position.
the 825 and Ag or A22 termi
nals,
Ropail open in the wiae betweon

the B25torminal and the A/T g.at
position indicstor oi the A/T gear
Dositionswitch.
BRN/BLK
MeasureATP D4 Voltage:
the 824 and Ag or A22 termi-
8RN/BLK
Repairopen in the wire be4wcen

the 824 terminal and tho A/T gcrt
oosition swhch.
To page14-57
14-56
From pag 14-56

PCMCONNECTORS
Mqllurt ATP D3 Volt gt:

1. Shift to @ position.
2. Measurethe voltagg betwen
the 88 and A9 or A22 terminats.
Rapair opan In th6 wira b3twocn
tha 88 t.rminll snd tha A,lT go!1
Dolition .witcb.
Ma.$ra ATPz Voltaga:

1. Shift to E position.
2. Measurs th voltage betwesn
th Bl7 8nd Ag or A22 tsrminals.
Rop.ir opln in tha wir. b.twocn

th. Bl7 tlrminrl .nd tho A/T
gatr polhion switch.
Chack tor looaa PCM connactoB.

It nacoaaary, tubtihuta ! knowngood FCM .nd r.ch.ck.
14-57
g
TroubleshootingFlowchart- Shift ControlSolenoidValveA
. OBD ll ScanTool indicatosCode
m753.
. Sof-di.gno.is D; indicrtor llght
blinks 36v6ntimes.
PossibleCeuse
. Disconngcledshift cont.ol solenoid
valve A connoctot
. Short or open in shift control solenoid valve A wire
. Faulty shift control 3olenoid valve A
PCMCONNECTORS
BLU/YEL
Ch.rckfo. a Short to Powel:

2. Disconnect
rhe A {32P)and B
PCM.
4. Measlre the voltagebetween
the 83 and Ag orA22 terminals.
BRN/BLK
Ropairshort to power in the wire

between the 83 t6.minal and tho
shift control3olenoid valve A.
Mssure Shift Control Solenoid

Vrlve A Rosidance:
betweenthe 83 and Ag or A22
Iermrnats.
ls the resistance
12- 25 O?
Chocktor loose PCM connoctors.

It nace33ary,substitut a knowngood solenoid valve assemblyor
PCMand .echeck.
To page14-59
14-58
-
Frompage'14-58
PCMCONNECTORS
Chock Shilt Control Sol.noid
Velv. A lor a Short Circuit:
l. Disconnectthe 2P connector
from the shift control solenoid
valve assemblv.
2. Chgck for continuity between
the 83 and Ag or A22terminals.
A {32P)
Ropairlhort to ground in the wire

betweon the lIt torminal and lho
rhift control solenoid v6lvo A.
SHIFTCONTROLSOLENOID
CONNECTOR
Me.sure Shift Control Solonoid

Valv. A R6btanco .t the Solonoid
Connoctor:
the No. 1 terminal oI the shitt control solenoid connectorand body
ground.
BLU/YEL
TERMINALSIDEOF MALETERMINALS
ls the resistance
12- 25 O?
Chack lor opon in lhe wire

betwoen the 83 termin.l and tho
rhift control solenoid valv6 A.
14-59
TroubleshootingFlowchart- Shift ControlSolenoidValveB
P0758.
. Selt-diagnosisEi indicator ligln
blinks oight time6.
Possibl6Cause
. Disconnoctod shift contlol solenoid
velve B connector
. Short or ooen in shift control solenoid valve B wire
. Faulw shift control solenoid valve B
PCMCONNECTORS
Chockfo. a Short to Power:

l. Turnthe ignitionswitchOFF.
2. Disconnectthe A {32P}and B
(25P)connectors
from the PCM.
the 8'11and Ag or A22 termi
nals.
l32Pl
Repairshort to power in th6 wire

between the 811 termin.l and
the shift conlrol solenoidvelve B.
Measure Shift Control Solenoid

Valve B Resistance:
b e t w e e nt h e 8 1 1 a n d A g o r
A22terminals.
ls the resistance
12 25 0?
Ch6ckfor looso PCMconnectors.

lf nocessary,3ubitituta a knowngood sol6noid valvo a$ombly ol
PCMand rechock.
From page14 60
PCMCONNECTORS
BRN/BLK
C h c kS h i f t C o n t r o l S o l e n o i d
Valve B tor a Short Circuit:
lrom the shift control solenoid
valveassembly.
the 811 and A9 or A22 terminars,
BRN/BLK
ls therecontinuity?
Repairshort to ground in the wira

betweenthe 811 ierminal and the
shitt control solenoidvalve B.
SHIFTCONTROLSOLENOID
CONNECTOR
li; tt
I GRN,/WHT
(o)
Y
I
I
Measure Shift Control Solenoid

Velve B Resistanceat the Solonoid Connec'tor:
the No.2 terminalofthe shiftcontrol solenoidconnectorand body
oround,
l s t h e r e s i s t a n c el 2 - 2 5 0 ?
Check for open in the wire

between the Bll terminal and the
shift control solenoid valve 8.
14-61
TroubleshootingFlowchart- CountershaftSpeedSensor
. OBD ll Scrn Tool indicats Code

PO720.
. Solt-diagnosis Dj indicator
light blinks ninc times,
Po$ible C.u3o
. t"a*
". t*rlty ""."""t1*
botwoen the PCM .nd c.r harnoss
. Disconnectodcountarshaft
soeodson3orconnector
. Short or open in countorsh.ft
sp6ed sensor wirc
. F ulty count.shrft speod 3en-
ls the countershaftspeedsensor
installedproperly?
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
t'-tt
TT
9t ll
Measure Countorsh.ft Soeed Sensor R6istanc al ths Senror Connectot:

from the countershaftsDeed
sensofconnector,
2, Measurethe resistance
oI the
countershaftsDeedsensor,
L I
TERMINALSIDEOF MALETESMINALS
ls the resistance400- 600 0?
PCMCONNECTOR
B {25P)
Chack Coume6hatt Spod Sensor

for a Short Circuit:
1 . D i s c o n n e ct th e B ( 2 5 P )c o n
nectorfrom the PCM.
2. Checklor continoitybetween
the body groundand the 823
t e r mi n aI a n d 8 2 2 t e r m i n a l
individually.
Repairshort in the wires belwen
the 823 and 822 torminals and
the countershaft soeed sensor.
To page14-63
14-62
Frompage14-62
PCMCONNECTOR
B {25PI
Maasure CruntoFhaft Speod Sonsor Rosbtrnce:
1. Connect the countershaft
speedsensor2Pconnector.
between the 823 and B22 le''
minals,
SIOEOF FEMALETERMINALS
ls the resistance400- 600 O?
Ropair loose terminal or open in

tho wiies bstw66n tho B23 and
822 termin.ls and tha countorshaft speodsensor.
Check tor loos6 PICMconnectors.

lf necass{ry, substihJtg a knowngood PCMrnd roch.ck.
14-63
TroubleshootingFlowchart- MainshaftSpeedSensor
P0715.
. S e l t - d i a g n o s i sE i n d i c a t o l
light indic.t6 Cod 15.
Posible Ceuse
' DI*.""."1"d
-"l".h"ft
.*.d
3en30t connctot
. Short or op6n in main3hatt
speed sensorwire
. Faulty mainshaft speodsensol
N O T E : C o d e P 0 7 1 5 ( 1 5 )o n t h e P C M
doesn't always mean there's an electrical
problem in lhe mainshafl or countershaft
) at
s p e e d s e n s o r c i r c u i t : c o d e P 0 7 1 5 1 1 5m
also indicatea mechanicalproblem in the
transmtsston.
Checkthe mainshaftand counter'

shaftspeedsensorinstallation.
Are the mainshaftand countershaft

speedsensorinstalledproperly?
MAINSHAFTSPEED
SENSORCONNECTOR
MeasureMainshrft SpeedSensor
Resistanceat the Sensor Connector:
from the mainshaftspeedsen'
sor connector.
2. Measurethe resistance
of the
majnshaftspeedsensor.
TERMINALSIDOF MALETERMINALS
ls the resistance400- 600 {}?
PCMCONNECTOB
8 I25P}
Check MainahaftSpeed Sensot
for a Short Circuit:
1. Disconnect
the B (25Piconnector from the PCM.
bodygroundand 815terminal
and the 814 terminalindividn-
ls therecontinuity?
To page14'65
14-64
ReDairshort in the wires between

the 815 and Blil terminals and
lhe meinshrft soeedsensor.
Frompage14-64
PCMCONNECTOR
8 (25PI
MeasureMrinshaft SpeedSensor
Resistance:
1. Connectthe mainshaftspeed
sensor2P connector,
betweenthe 8'15and 814 termt n a l s .
ls the resistance
400- 600o?
Run iho Elect ical Troubleshooling

Flowchartfor code m720 l9l.
Checktor loose PCM connectors.
It ncossary,substitute a knowngood PCMand recheck.
MAINSHAFT SPEED SENSOR

CONNECTOR
CheckNM Wire Continuity:

from the mainshaftspeedsensor connector.
the 815terminaland the No. 1
terminal of the mainshaft
speedsensorconnector,
ls therecontinuity?

the 815 terminal and the main'
shaft speedsensor.
CheckNMSG Wire Continuity:

Checkfor continuitybetweenthe
814 terminaland the No. 2 terminal of the mainshaftspeedsensor
ls therecontinuity?
Bepair op6n in th wire between

th 814 terminal and the main3haft sDeedsnsor.
Checklor loos PCMconnectors.

It nocessarv,substitute a knowngood PCMand recheck.
14-65
g
TroubleshootingFlowchart- LinearSolenoid
. OBD ll ScanTool indicat6 Codo
P176a.
. Self-diagnosis [d indic.tol
light indicatesCode 16.
Po$ible C.Ge
. Oisconnectedlinar solonoid
. Short or op6n in linear solonoid
. F.uhy linorr 3olonoid
LINEARSOLENOIDCONNECIOR
trTt
-r-r
Msasure Linoar Solanoid Rosi3tanco at tho SolonoidConnector:

from the linearsolenoidconnector,
3. Measuretho resistance
ofthe
linearsolenoid.
rdl
Yt Il
t_i
TERMINALSIDEOF MALE TERMINALS
ls the resistance
aoorox.5.00?
PCMCONNECTOR
B (25P)
WHT
RED
Ch6ckLinor. Sol.noid for a Short

Circuit:
l Disconnectthe B (25P)connec,
tor from the PCM.
2. Checktor continuity between
the body ground and the 81
terminaland 82 terminalindividually.
Repairsho.t in the wire3 bgtwoon
tho 81 and 82 termin.ls rnd th6
lineal solonoid.
Me.iuie Linoar Solenoid Rcai3tance:

1 . C o n n e c t h e l i n 6 a rs o l e n o i d
connector.
2 . M a s u r e t h e r e s i s t an c e
betweenthe 81 and 82 terminals,
ls the resistance
approx.5.0O?
To page14-67
14-66
Ropair loo3o terminsl or open in

tho wirgs bgtween the B1 and 82
torminrl! rnd the linoar sol6noid.
Frompage14 66
PCMCONNECTOR
A I32P}
Ch6cktho Ground Cilcuit:
Ag and A10terminals.
. Rgpair open in the wire

between tho torminal3 A9 .nd
A 1 0 . n dG 1 0 1 .
. R6pair loo3o junction connector.
. Ropairpoor ground (G1011.
Chgckloi loo3a PCMconnecto.s.

lf necellrry, 3ubstituto a knowngood PCMand rochock.
14-67
TroubleshootingFlowchart- Lock-upControlSystem
OBD ll Sc{n Tool indicatss Code
m740.
Self'diagnosis ErJ indicdor light
indicatB Code /U).
Poitible Cru..
Faulty Lock.up control ryitcm
Chockfor Another Code:

Checkwhether the OBD ll scan
t o o l o r t h e E i n d i c a t o rl i g h t
indicatesanothercode.
Doesthe OBDllscantoolor
the E! indicatorl;ghtindicate
anothercode?
Test Lin Piessure:

M e a s u r et h e l i n e p r e s s u r e{ s e e
page14-87and 14-88).
ls the linepressurewithinthe
servicelimit?
Perform tho Troubla3hooting

Flowch.rt tor tho indic.t.d
Codols). Rocheck tol codo P0740
l40l after troublG.hooting.
NOTE:Do not continuewith this troubleshootino
until th causesof any
other DTCShave beencorrected.
Repai. tho hydrrulic sy3tom a.

necdsrry l3os pago'14-E61.
R e p l a c et h e L o c k - u p C o n t r o l
Solenoid Valve Assembly end
Recheck:
1 . R e p l a c et h e l o c k - u pc o n t r o l
solenoidvalve A/B assembly
(seepage14-74).
2. Turn the ignition switch OFF
and resetthe PCM by remov
ing the BACKUP {7.5A) tuse
in the under-hoodfuse/relay
box tor more than '10seconds.
3. Using the scan tool, checkto
be sure that the enginecoola n t t e m p e r a t u r ei s i n 1 7 6 " F
{80'C)and above.
4. Drive the vehicle at 55 mph
(88 km/h)constantlyfor more
than one manute.
5- Recheck
for codeP0740(40).
DoestheOBDll scantool
indicatecodeP0740(401?
The syltom ii OK at thb timo.
14-6 8
TroubleshootingFlowchart- Shift GontrolSystem

' OBD ll Scan Tool indic.t6 cod.
m730.
' s.lf-di.gno.i.
E indicator
lig]|t Indicat . Code 41.
PorsibleCauso
F.ulty shitt contol systom
Chacklor Anoth.r Codo:

Checkwhether the OBD ll scan
t o o l o r t h e E i n d i c a t o rl i g h t
indicateanothercod6.
Doe3the OBD ll scantool or

the E indicaro.lightindicste anothercode?
Parform the Troubl.shooting

Flowchrrt tor th6 indicatod
Codo(s).Rochockfor cod! m730
{41| rft ol troubl.ihooting.
NOTE:Do not continuwith this troubleshootinguntil the causesof any
other DTCghave beencorrected.
Tcat 13t, znd, 3rd and 4th Clutch

Prctauro:
Measurethe lst, 2nd, 3rd and 4th
clutch pressure{see page 14-87
thru'14-891.
ls each clutch pressurewithin

the servicelimit?
Rcpair tha hvdraulic aystom ra

nacaa3ary laaa p.g. 14-88 lnd
1a-891.
Repl.c. Shift Control Sol.noid

V.lYe A*rembly, Linorr Solonoid
A$.mbly .nd B.check:
1. Replacethe shift control
solenoidvalve A/B ass6mblv
(seepage14-?5).
2 . R e o l a c et h e l i n o a r s o l e n o i d
assembly(seepage 14-771.
3. Turn the ignirionswitch OFF
and rsset th PCMmemory by
romovingthe BACKUP (7.5A)
fuse in the under-hood{use/
r e l a yb o r I o r m o r e t h a n 1 0
seconos.
4. Drive the vehicle at ovgr 12
mph (20 km/h) in lst, 2nd. 3rd
and 4th geal,lor more than 30
secondsat [8d oosition.
(41).
5, Recheckfor code PO73O
Do6sthe OBD ll scantool or

the E indicatorlight indicate code P0730(41)?
Tho sydem b OK rt this time.
14-69
TroubleshootingFlowchart-
D.-lndicatorLight DoesNot GomeOn
Th6 E indicator light doos not

come on when the ignition switch
is lirst turned ON lll). {lt should
come on Ior about two 36conds.)
Checkthe ServiceCheckConnector:
Make sure the specialtool (SCS
SetuiceConnector)is not connected to the servicecheckconnector.
ls the specialtool(SCSService
Connector)
connectedto the service checkconnector?
Disconnectthe soecial tool from

the se.vice chock connoctor and
rachock.
Checkth E indicator Light:

Shiftto E position.
Checkto. loose PCM connectors.

lf necasary,substitute a known.
good PCMend iecheck.
PCMCONNECTOR
A (32P)
Checklhe Ground Circuit:
2. Disconnectthe A (32P)connec'
tor fromthe PCM.
t h e A g t e r m i n a la n d b o d y
ground and the A22 terminal
and body ground.
Repair opon in the wires botwoen
tho A9 or A22terminalsand G101.
Repairpoor ground(Gl01).
T o p a g e1 4 7 1
14-70
Frompage14-70
A I32P}
PCMCONNECTOR
Moasure Powo. Supply Circuit

Voltage:
2. Measureth voltage between
t e r m i n a l sA g a n d A 1 1 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
424.
R.p.ir open or short in the wire

botwoen the A11 tnd lor A2l terminals,the PGM-FImain .elay,
aod the fu3e box.
MoasuroD4 IND Voh.ge:

2. Connectthe A (32P)connector
to the PCM.
3. Connecta digital multitester
to the 813 and A9 or A22 termtnals,
4. Turnthe ignitionswitchON (ll)
and makesure that the vokage
is availablefor t\ivoseconds.
BRN/8LK
'96: BLU/RED
'97, '98: GRN/BLK
Check tor open in the wire

between the 813 lermintl and
the gauge as3embly.lf wiro is
OK, chock for a taulty E indic.tor light bulb or s faulty gsuge
r33embly printod circuit board.
Checkfor loo3o PCMconnedots.

Checkthe A/T ge.. position
switch. ll nec6$ary, substitute a
known-good PCMand recheck.
14-71
TroubleshootingFlowchart- E IndicatorLight On Constantly
The E indic.tor light b on con3lently {not blinking}whenever
the ignition switch b ON {lll.
PCMCONNECTOR
B I25PI
Me.sure Dil IND Voltage:

2. Disconnectthe B (25P)connector from the PCM.
t h e 8 1 3t e r m i n a a
l ndbody
ground.
Repairshort to power in the wire
betweon the 813 terminal and
the gauge a$embly.
MeasuraATP D{ Voltage;
2. Connectthe B (25Piconnector
to the PCM.
4. Shiftto any positionotherthan
D;.
t h e 8 2 4 t e r m i n a la n d b o d y
ground.
Checkfor a short to ground on the

wire. ff wire is OK. ropl.c the A/T
gearpositionindicator.
14-72
TroubleshootingFlowchart- BrakeSwitch Signal

Symptom
Shift lav6r crnnot be movod liom
E porition whh the bt.ko Pedal
Ch.ck Brr*. Light Op.r.tion:

Oeoressthe brakepedal.
Are the braklights ON?
Rapairtaulty brake switch circuit

l3oorction 231.
PCMCONNECTORS
M.arur. STOP Sw voh.gc:
2. Disconnoctth A (32P)and D
{ 1 6 P )c o n n e c t o r sf r o m t h e
PCM.
3. Measurethe voltage betwen
the D5 and Ag or A22 terminals with the brake peclal
depressd.
WINES|DEOF FEMALETERMINALS
ls there battoryvoltsge?
Rop.ir opan in thc wiro btwcen

th. D5 terminal lnd tha brako
swit*,
. 8..1. rwitch rign.l i. OK.

. Chad( to? looaa PCM connactoB.
It nacarlary, aubatituta a known.
goodFC .nd t!d|!ck.
. Inrp.ct th. brtlr .witch citcuit
{t . ..ction 23}.
14-73
Lock-upGontrolSolenoidValveA/B Assembly
Test
Replacement
1.
NOTE:Lock-upcontrolsolenoidvalvesA and B must be

removed/replaced
as an assembly.
Disconnectthe 2P connectorfrom the lock-upcon

trol solenoidvalveAy'Bassembly.
TERMINAL
SIDEOF
MALETERMINALS
1.
R e m o v et h e m o u n t i n g b o l t s a n d l o c k - u pc o n t r o l
solenoidvalveA,/Bassembly.
6 x 1.0mm
12 N.m {1 .2 kgt.m, 8.7 lbl.ltl
FILTER/GASKET
Replace.
LOCK.UP
CONTROL
SOLENOID
VALVEA/B
ASSEMBLY
2.
Measurethe resistancebetweenthe No. 2 terminal
( s o l e n o i dv a l v eA ) o f t h e l o c k - u pc o n t r o ls o l e n o i d
valveconnectorand body ground,and betweenthe
No. 1 terminal{solenoidvalveB} and body ground.
STANDARD:
12 - 25 O
Replace
t h e l o c k - u pc o n t r o ls o l e n o i dv a l v ea s s e m bly if the resistance
is out of specification.
lf the resistanceis within the standard,connectthe
No. 1 terminalof the lock-upcontrolsolenoidvalve
connectorto the bafterypositiveterminal.A clickjng
soundshouldbe heard.Connectthe No.2 terminalto
the batterypositiveterminal.A clickingsoundshould
be heard.Replacethe lockup controlsolenoidvalve
assemblyif no clickingsoundis heard.
Cleanthe mountingsurface
and fluid passages.
Cleanthe mounting surfaceand fluid passagesof

t h e l o c k u p c o n t r o ls o l e n o i dv a l v e a s s e m b l ya, n d
installa new lock-upcontrolsolenoidvalveA,/Bwith
a new filter/gasket.
Checkthe connectorfor rust,dirt or oil, and reconnectrt securely.
Shift ControlSolenoidValveA/B Assembly

Replacement
Test
1.
Disconnectthe 2P connectorfrom the shift control

solenoidvalveA'lBassembly.
NOTE: Shift control solenoidvalves A and B must be

as an assembly.
removed/replaced
1.
Removethe mountingboltsand shiftcontrolsolenoid

valve4!/Bassembly.
6x1.0mm
12 N.m
{1.2ksl.m,8.7 lbt'ft}
SHIFTCONTROL
VALVEA/8
SOLENOID
ASSEMBLY
2,
'1
Measurethe resistancebetweenthe No. terminal
(solenoidvalveA) of the shift controlsolenoidvalve
connectorand body ground,and betweenthe No. 2
terminal(solenoidvalveB) and body ground
FILTER/GASKET
Replace.
and fluid passages.
2.
Cleanthe mounting surfaceand fluid passagesof

t h e s h i f t c o n t r o l s o l e n o i d v a l v e a s s e m b l y ,a n d
installa new shift controlsolenoidvalveA,/Bwith a
and the clamp bracket.
new filter/gasket
3.
Checkthe connectorfor rust, dirt or oil, and reconnectit securely.
12- 25 O
STANDARD:
Replacethe shift controlsolenoidvalve assemblyif
the resistanceis out of specification.
BRACKET
CONNECTOR
lf the resistanceis within the standard,connectthe

N o . 1 t e r m i n a lo f t h e s h i f t c o n t r o ls o l e n o i dv a l v e
connectorto the batterypositiveterminal.A clicking
sound should be heard.Connectthe No. 2 terminal
t o t h e b a t t e r yp o s i t i v et e r m i n a l .A c l i c k i n gs o u n d
should be heard.Replacethe shift control solenoid
valveassemblyif no clickingsound is heard.
14-75
LinearSolenoidAssembly
Test
1.
Disconnect
the linearsolenoidconnector.
lf not, removethe linearsolenoidassembly.

6.
Checkthat the linearsolenoidfluid passagefor dust

or qrn.
7.
C o n n e c t h e N o . 2 t e r m i n a lo f t h e l i n e a rs o l e n o i d
connectorto the batterypositiveterminaland con
nectthe No. 1 terminalto the batterynegativetermi,
nal.Checkthat the valvemoves.
8.
Disconnectone of the batteryterminalsand check

that the valvereleases.
LINEARSOLENOID
NOTE: You can see the valve movement through

the fluid passagein the mountingsurfaceof the linear solenoidassembly.
LINEAR
SOLENOID
2.
Measurethe resistancebetweenthe No. 1 and the

N o .2 t e r m i n a l o
s f t h e l i n e a rs o l e n o i dc o n n e c t o r .
STANDARD:approx. 5 O
lf the resistanceis out of specification,replacethe
linearsolenoidassembly.
,.-,.
VALVE
Connectthe No. 2 terminalof the linearsolenoidconnectorto the batterypositiveterminaland connect

the No. 1 terminalto the batterynegativeterminal.A
clickingsoundshouldbe heard.
9.
14-76
lf the valve binds. or moves sluggishly, or the linear

solenoid does not operate, replacethe linear solenoid
assemory.
Mainshaft/Countershaft SpeedSensors
Replacement
Replacement
1.
Remove the mounting bolts and the linear solenoid

assemDly.
1.
Removethe 6 mm bolt and the countershaftspeed

sensorfrom the right sidecover
6x1.0mm
12 N.m {1.2kgJ.m, COUNTERSHAFT
8.7 rbr.frl
SPEEDSENSOF
and fluid passages.
5x1.0mm
12 N.m (1.2kgf.m,
8.7 tbf.ftl
O.RING
Replace.
MAINSHAFT
SPEED
SENSOR
@
@
GASKET
LINEAR
SOLENOID
ASSEMBLY
6x1.0mm
12 N.m 11.2kgl.m,
8.7 tM.ft)
Cleanthe mountingsurfaceand fluid passageof the

linearsolenoidassemblyand transmissionhousing.
R e m o v et h e 6 m m b o l t a n d t h e m a i n s h a f ts p e e d
senso.from the transmissionhousing.
Installa new linear solenoidassemblywith a new

gasket.
Repiacethe O-ringwith a new one beforeinstalling

speedsensoror the mainshaftspeed
the countershaft
sensor.
NOTE:Do not pinch the gasketwhen installingthe

linearsolenoid;makesurethat the gasketis installed
properlyin the mountinggroove of the linearsolenord.
4.
MAINSHAFTSPEED
SENSOEWASHER
{D16Y7engine)
NOTE:Installthemainshaftspeedsensorwasheron
the mainshaftspeed sensor.The mainshaftspeed
s e n s o rw a s h e ri s u s e d o n m o d e l sw i t h t h e D 1 6 Y 7
engine.
Checkthe linearsolenoidconnectorfor rust,dirt or

oil, and connectit securely.
14-77
Chart
HydraulicSystem
\
Checktheseitemson the
PROBABLE
CAUSELiSt
SYMPTOM
Engineruns,but vehicledoes not move in any gear.
Vehiclemovesin p. E, but not in pel,@, position.
Checktheseitemson
the NOTESList
1,2,3,5,6,'t,36,38
K,L,R,S
6, 8, 9, 10,30, 54
c,M,o
Vehiclemovesin E, E, E. but not in E position.

Vehiclemovesin E, E, E, but not in E position.
Vehiclemovesin E position.
6,11,12,24
C,L
4 , 6 ,1 4 ,1 5
c,L,o
10, 12,13,14,16,29, 33,34. 35
C,D
Excessive
idle vibration.
1 , 2 , 1 9 , 3 2 , 3 64, 5 ,4 7, 4 8
B.K.L
Pooracceleration;
flareson startingoff in ro.. @ position
Stallrpm high in lDl, E, El position.
1 , 2 , 3 , 6 , 3 A4, ' l
K.L,R
6, 8, 10
6,12
C,D
C,D
14
17, 32, 45,47. 48

't9,20,40,
48,49
22, 49
Stallrpm high in E, l,- position.

Stallrpm high in E position.
i Stallrpm is in specification.
Stallrpm low.
No shift
Failsto shift in @, @ position;from 1stto 3rd gear
Failsto shift in pl, @ position;from 'lsrto 4th gear
Erraticupshifting.
G,L
22, 23, 4A
1-2upshift,2-3 upshift.3-4upshift
58
1-2upshift
21, 48
2-3 uDshift
22, 49
3-4 upshift
_
Harshupshift{1,2).
Harshupshift{2-3).
Harshupshift(3-4).
23, 48
14, 19,20,25,28,29,50,51. 57,58
C ,D ,E ,I , L
Harshdownshift(2-1)
Harshdownshift(3-2).
Flareson 2-3 upshift.
1 9 , 2 0 , 2 44, 3 ,5 4 , 5 7, 5 8
12,'19,20,25,43,55,57, 58
13, 19,20,26, 43,56,57,5A
1 3 ,1 9 ,2 0 , 2 4 ,2 7 , 5 1
Flareson 3-4 upshift.
14, 19, 20, 25, 2A,5'l
E,L,N
Excessive
shockon 2-3 uDshift.
13,19,20,24,27, 43,50,51, 58
E,L,N
Excessive
shockon 3-4 upshift.
14, 19,20,25,28,43,50,51, 58
E.L,N
Harshdownshift(4-3).
Lateshift from E positionto E or lE! position.

Lateshift from E positionto E positron.
Noisefrom transmissionin all shift leverpositions.
Vehicledoes not acceleratemorethan 31 mph (50 km/h).
1 2 ,1 9 ,2 0 , 2 9 ,5 0 , 5 1 , 5 ,15 8
13,19,20,24,21,29,50,51,57,58
C,D,E,H,L
C,D.E,H
C, D, E, I
1 0 ,3 0
4,14,21,53
2,37
K,L,O
17
Shift leverdoes not operatesmoothly,
6, 39
Failsto shift;stuckin 4th gear.
19,48, 49
Transmission
will not shiftintoparkinggearin E] position. 6, 18.39
Stallrpm high; all clutchpressuresare in specification.
41
Lock-upclutchdoes not disengage.
19, 44,45,46,47,50,51, 58
'19,4't,
Lock-upclutchdoes not operatesmoothly.
44, 45, 46,47, 50, 51, 58
't9,
41,44,45,46,47,50. 51,57, 58
Vibrationin all positions
36
14-78
.
P
D.K.O
F
E,L
PROBABLE
CAUSE
2
ATF pump worn or binding.

Regulator valve stuck.
tc
Servo valve stuck.

Mainshaftworn/damaged.
Shiftcablebroken/outof adjustment.
Finalgearsworn/damaged.
One-way{sprag)clutchworn/damaged.
1stgearsworn/damaged(2 gears).
1st clutch defective.
2nd gearsworn/damaged(2 gears)2nd clutch defective.
3rd clutchdefective.
4th clutch defective.
Reversegearsworn/damaged(3 gears).
16
17
18
19
ExcessiveATF
Torqueconverterone-wayclutchdefective.
Pakingmechanismdefective.
Linearsolenoidassemblydefective.
20
CPCvalve stuck.
1-2shiftvalvestuck.
2-3 shiftvalvestuck.
3-4 shift valve stuck.
2nd accumulatordefective.
3rd accumulatordefective.
4th accumulatordefective.
2nd orificecontrolvalvestuck.
3-4 orificecontrolvalvestuck.
Foreignmaterialin main orifice.
5
6
7
I
10
l1
14
21
27
28
29
30
31
32
33
34
38
40
42
43
44
45
46
47
48
49
5U
52
53
54
58
Foreignmaterialin separatorplate.
CPBvalvestuck.
Lock-uptiming valvestuck.
Lock-upshift valvestuck.
Lock-upcontrolvalvestuck.
Lock-uppistondefective.
ShiftcontrolsolenoidvalveA defective.
ShiftcontrolsolenoidvalveB defective.
Lock-uDcontrolsolenoidvalveA defective.
Lock-uocontrolsolenoidvalveB defective.
Servocontrolvalvestuck.
1staccumulatordefective.
Foreignmaterialin 2nd exhaustorifice.
Foreignmaterialin 3rd exhaustorifice.
Foreignmaterialin 4th exhaustorifice.
MainshaftsDeedsensordefective.
sDeedsensordefective
Countershatt
Foreign material in 1st orifice.
Foreignmaterialin reverseorifice.
Engineoutput low,
Needlebearingworn/damaged.
Thrustwasherworn/damaged.
Clutchclearanceincorrect.
Driveplatedefectiveor transmissionmisassembly.
Torqueconverterhousingor transmlsslon
housingbearingworn/damaged.
ATFstrainerclogged.
Joint in shift cableand transmissionor body
Modulatorvalvestuck.
(cont'd)
14-79
Ghart
HydraulicSystem (cont'dl
The followingsymptomscan be caused
by improperrepairor assembly
\
Check
theseitemson the
PROBABLE
CAUSEDUETO
IMPROPER
REPAIR
List
Vehiclecreepsin N position.
R 1 ,R 2
Vehicledoes not move in .S or @ position.

Transmissionlocksup in E position
R4
Excessive
drag in transmission.
R6
Excessive
vibfation,rDm related,
R7
Noise with wheels moving only.
R5
Main sealpops out.
R8
Variousshiftingproblems.
R 9 ,R 1 O
R 3 ,R 1 ' 1
PROBABLE
CAUSEDUETO IMPROPER
REPAIR
R1
lmproperclutchclearance.
R2.
lmproper gear clearance.
R3.
Parkingbrakeleverinstalledupsidedown.
One-way(sprag)clutchinstalledupsidedown.
R4.
R5.
Reverseselectorhub installeduDsidedown.
R6.
A T Fp u m pb i n d i n g .
R7.
Torqueconverternot fully seatedin ATF pump.
R8.
Main seal improperly installed.
R9,
Springsimproperlyinstalled.
R10.
Valvesimproperlyinstalled.
R11
Shiftfork bolt not installed.
14-80
Items on the
NOTES List
K,R
NOTES
Seeflushingprocedure,page14-155and 156.
B,
set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in engine
section of this manual.
c.
lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining'
D.
worn, inspectthe otherclutchesfor wear,and checkthe orifice

lf the clutchpackis seizedor is excessively
controlvalves,CPCvalveand linearsolenoidlor free movement
E.
lf the linearsolenoidis stuck,inspectthe clutchesfor wear.

lf the l-2 shift valveis stuckclosed,the transmissionwill not upshift lf stuckopen,the transmissionhas
no lst gear.
lf the 2nd oriticecontrolvalveis stuck,inspectthe 2nd and 3rd clutchpacksfor wear.
H.
t.
J,
K.
L.
N.
o.
It the 3-4orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchpacksfor wear'

controlvalveis stuckclosed,the transmissionwill not shift out of 1stgear'
lf the clutchDressure
lmproperalignmentor main valvebody and torqueconverterhousingmay causeATF pump seizure.The
symptomsare mostlyan rpm relatedtickingnoiseor a high-pitchedsqueaklf the ATF strainer is clogged with particles of steel or aluminum, inspect the ATF pump and differential
pinion shaft. lf both are OK and no cause for the contamination is found, replace the torque convener.
l f t h e l s t c l u t c h f e e d p i p e g u i d e i n t h e r i g h t s i d e c o v e r i s s c o r e d b y t h e m a i n s h a f t , i n sbpeeacrtitnhge b a l l
for excessivemovementin the transmissionhousing.lf oK, replacethe right sidecoveras it is dented.The
O-ringunderthe guide is probablyworn
, Replace
the mainshaftif the bushingfor the 4th feed pipeis looseor damaged.lf the 4th feedpipeis damagedor out of round,replacethe rightsidecover.
. Replace
the mainshaftif the bushingfor the 1stfeed pipeis looseor damagedll the 1stfeedpipeis dam
agedor out of round,replaceit.
_
A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin iD1or lDapositionwhile
the wheelsrotatein reverse,suchas rockingthe vehiclein snow.
P,
Inspectthe lrame for collisiondamage.
o.
Inspectfor damageand wear:

1. Reverseselectorgearteethchamters
teethchamlersoI countershait4th and reversegear'
2. Engagement
3. Shifttork for scuffmarksin center.
4. Differentialpinionshaftfor wear underpiniongears
5. Bottomof 3rd clutchfor swirl marks
makesa clicking,grindingor whirringnoise,
Replaceitems1, 2, 3 and 4 if worn or damaged.lf transmission
4th gearin additionto 1,2,3 or 4'
afsorepfacemainshaft4th gear,reverseidlergear,and countershaft
and
assembly, replaceATFstrainer,andthoroughly
pinionshaftis worn, overhauldifferential
lf differential
lines
and
cooler
Ilushtorqueconverter,
cleantransmission,
andfinaldriven
makesgearnoise,replacethe countershaft
lf bottomof 3rd clutchis swirledandtransmission
gear.
S.
Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing.You

may alsodamagethe ATF pump when you torquedown the main valvebody.This will resultin ATF pump
seizureif not detected.Usethe propertools.
Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter
housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage'
14-81
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature(the radiatorfancomeson).

'1.
Apply parkingbrake and block the wheels.Start the engine,then shift to E positionwhile depressingthe brake
pedal.Depressthe accelerator
pedaland releaseit suddenly.The engineshouldnot stall.
2.
Repeatsametest in E position.
Test-drivethe vehicleon a flat road in the E] position.Checkthat the shift pointsoccurat approximatespeeossnown
on a flat road.Also checkfor abnormalnoiseand clutchslippage.
NOTE:Throftlepositionsensorvoltagerepresents
the throttleopening.
a. Unboltthe PCMfor roadtesting;referto page 14-46.
b Set the digital multitesterto checkvoltagebetweenD1 (+) terminaland A9 {-) or A22 l. l terminalof the pCM for
the throttlepositionsensor.
BACKPROBE
ADAPTER
BACKPROBE
SET
07sAz- 001000A
Itwo requiredl
DIGITALMULTIMETER
lCommerciallyavailablel
KS-AHM-32-003.
or equivalent
PCMCONNECTORS
B {2sP)
c {31P)
&l Position: Dl6Y7 engine

Upshift
Throttle Opening
Throttlepositionsensor
voltage:0.75V
v o l t a g e : 2 . 2V5
Fullyopenedthrottle
voltage:4.5V
znd * 3rd
3rd -
ilth
Lock-upON
Unit of speed
lsl + 2nd
mpn
9-12
km/h
mph
15- 19
21-25
km/h
34-40
65-73
mph
33-38
km/h
53-61
102- 115
Unit of sDeed
Lock-upOFF
4th * 3rd
mpn
19-22
1 7- 2 0
km/h
30-35
mph
9 5- 1 0 5
85-95
54-61
25-30
km/h
1 5 3- 1 6 9
1 3 7- 1 5 3
87-98
40-48
Unit of speed
lst * 2nd
2nd + 3rd
3rd + 'lth
Lock-upON
mph
9-12
20-23
28-32
2't- 24
km/h
15-l9
32-37
45-52
34-39
28-32
2 1- 2 4
1t _ a'f
45-52
34-39
40-45
59-65
9 5- 1 0 4
99 - 108
101- 112
99 - 109
163 180
' t76
159-
Downshift
Throttle Opening
throttle
Fully-closed
voltage:0.5V
throttle
Fully-opened
voltage:4.5V
3rd + 2nd
2nd * lst
6-9(3rd-1st)
10- 15 (3rd* 1st)
-9. Position: D16Y8engine

Upshift
Throttle Opening
voltage:0.75V
voltage:2.25V
throttle
Fully-opened
voltage:4.5V
40-45
mph
km/h
34-40
mph
62-67
99 - 108
62-70
9 5- 1 0 4
'107
96 -
1 0 0- 1 1 3
155- 172
1 5 3- 1 7 0
3rd - 2nd
2nd - lst
65-73
9 5- 1 0 6
km/h
52-60
Unit of speed
Lock-upOFF
ilth - 3rd
mph
19-22
1 1- 2 0
km/h
30-35
mpn
91 101
85-95
54-61
25-30
km/h
1 4 7- 1 6 3
1 3 7- 1 5 3
87-98
40-48
Downshift
Throttle Opening
Fully-closed
throttle
v o l t a g e : 0 .V
5
throttle
Fully-opened
voltage:4.5V
NOTE:
o Lock-uO
p N : T h el o c k - u p c o n t r so ol l e n o i dv a l v eA t u r n sO N .
. Lock-uoOFF:Thelock-upcontrolsolenoidvalve A tu rns OFF.
6-9(3rd- 1st)
' 1 0- 1 5 ( 3 r d-
lstl
(cont'd)
14-83
RoadTest
(cont'dl
Accelerateto about 35 mph (57 km/hl so the transmissionis in 4th, then shift from E
vehicleshouldimmedistelybeginslowingdown from enginebraking.
positionto @ position.The
CAUTION: Do not shift trom E or E position to E position at speeds ovcr 6:l mph (100 km/hl; you mly dlmlge
the tJansmission.
Checkfor abnormalnoiseand clutchslippagein the followingpositions
E (2nd cear) Position
a. Accelerate
trom a stop at full throttle.Checkthat there is no abnormalnoiseor clutchslippage.
b. Upshiftsand downshiftsshouldnot occurwith the selectorin this oosition.
Position
E (Reverse)
Accelerate
from a stop at full throttle,and checktor abnormalnoiseand clutchslippage.
Test in E {Parking)Position
Parkthe vehicleon slope{approx.16'),applythe ps.kingbrake,and shift into E position.Releasethe brake;the vehicle shouldnot move.
Stall Speed
Test
CAUTION:
. To prevent transmission dEmage,do nol test stall sPeedtol more than 10 secondgat 8 time.
. Do not shift th lver whils raising th sngine spoed.
. Bs sure to rsmove ths pressuregauge beforg lgting stall sPeed.
'1. Engagethe parkingbrake,and blockthe front wheels.
2.
Connecta tachometerto the engine.and startthe engine
3.
Makesurethe IVCswitchis OFF.
4.
Afterthe enginehaswarmed up to normaloperatingtemperature{the radiatorfan comeson), shift into E position.
5.
for 6 to 8 seconds,and noteenginespeed'

Fullydepressthe brakepedaland accelerator
6.
Allow two minutesfor cooling,then repeatthe test in E and E positions.

NOTE:
. Stallspeedtestsshouldbe usedfor diagnosticpurposesonly
. Stallspeedshouldbe the same in E, E and E positions.
Stall Speed RPM:

Spocmcation:2,700rpm
ServiceLimit: 2,550- 2,850rpm
PROEABLECAUSE
TROUBLE
stall rpm high in ld, El and E positions
Low tluid levelor ATF pump output

CloggedATF strainer
Pressureregulatorvalvestuckclosed
Slippingclutch
Stallrpm high in E position

. Slippageof 4th clutch

. Slippageof 2nd clutch
. Slippagof lst clutchor 1stgear one-wayclutch

. Engineoutputlow
' Torqueconvenerone-wayclutchslipping
stall rpm low in E, E and E Positions
14-85
FluidLevel
Checking/Changing
CAUTION: While checking 8nd changing, bo sure not to
allow du3t and other foreign particles to nter into the
transmission.
Changing
CAUTION: Keop all of the toreign particles out of the
transmiasion,
Checking
1.
CAUTION: Keep all of th loreign particles out of th
transmission.
NOTE:Checkthe fluid level with the engine at normal
operatingtemperature{the radiatorfan comeson}.
l.
2.
Parkthe vehicleon level ground. Turn off the

engrne.
Removethe dipstick(yellow loop) from the transmission,and wipe it with s cleancloth.
NOTE:lf a coolerflusheris to be used,seepage 141 5 5a n d 1 5 5 .

2.
Reinstallthe drain plug with a new sealingwasher,

then refill the transmissionwith the recommended
fluid* to the uppermark on the dipstick.
Automatic Transmi$ion Fluid Capacity:
2.7 I 12.9US qa,2-1lmp qt) at chang.
5.9 / {6.2 US $, 5.2 lmp qt} at overhaul
Bringthe transmissionup to operatingtemperature

b y d r i v i n g t h e v e h i c l e .P a . k t h e v e h i c l eo n l e v e l
g r o u n d . t u r n t h e e n g i n e o J f ,t h e n r e m o v e d r a i n
ptug.
RecommendedAutomatic Transmisrion Fluid:

Genuine Honda Prmium Formula Autometic
TransmissionFluid (ATF)..
\\ l Vl
tl
0OIPSTICKIYELLOWLOOPI
TRANSMISSION
RIGHTSIOECOVEF
UPPERMARK
LOWERMARK
3 . Insertthe dipstickinto the transmission.

4.
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l ,l t
shouldbe betweenthe upperand lower marks.
lf the levelis belowthe lower ma.k, pour the recommendedfluid+ into the filler hole to brino it to the
uppermarK.
Insertthe diDstickback into the trsnsmissionin the
directionshown.
FRONT
DRAINPLUG
1 8x 1 . 5m m
49 N.m {5.0kgf.m,36lbttr)
SEALINGWASHEE
Replace.
* Alwaysuse GenuineHondaPremiumFormula
AutomaticTransmissionFluid (ATF).Usinga nonHonda ATF can affect shift qualitv.
Installthedipstickin the extent

ol the directionshown.
PressureTesting
@
. While tosting, be careful of the rotating tront wheels
.
Maks sur lifts, iacks, and saloty stands are placed properlY{seesoction 11.
CAUTION:
. Betoretesting, bs sure the transmissiontluid is tilled to the proper level.
. Warm up the engine befote tssting.
1.
Raisethe vehicle(seesection1).
2.
Warm up the engine,then stop the engineand connecta tachometer.
3.
Connectthe oil pressuregaugesto eachinspectionhole.

TOROUE:18 N.m {1.8 kgf'm, 13 lbf'ftl
CAUTION: Connect the oil pressuregauges securely;be sure not to allow dust and other foreign particles to nter
th inspection holes.
A/T OIL PRESSUBE

GAUGE
SETWPANEL
07406 - 0020400
HOSE
A/T OIL PRESSURE
ADAPTER
07MAJ - PY,(}l20
(4 roquirodl
GAUGE
A/T LOWPRESSUBE
SETWPANEL
07'r()6- 0070300
HOSE
A/T OIL PRESSURE
2.10 mm
07MAJ - PYiOllA
{{ rsquirodl
Startthe engine,and measurethe respectivepressureas follows

a Line Pressure
. 1stClutchPressure
. 2nd.3rd and 4th ClutchPressure
Installa new washerand the sealingbolt in the inspectionhole,and tightento the specifiedtorque.
TOROUE:18 N.m (1.8kgf.m,13 lbf'ft|
NOTE:Do not reuseold sealingwashers;alwaysreplacewashers
(cont'd)
14-47
PressureTesting
(cont'd)
a Line Pressure/1stClutch PressureMeasurement
1.
Setthe parkingbrake,and blockboth rearwheelssecurely.
2.
Runthe engineat 2,000rpm.
3.
Shiftto E or E posltion,then measureline pressure,

are made in shift leverpositionsotherthan E or fl posiNOTE:Higherpressuremay be indicatedif measurements
tion.
4.
Shiftto E position,then measurelst clutchpressure.

1STCLUTCHPRESSURE
HOLE
INSPECTION
(Markedwith "L")
LOCK.UP
CONTROL
VALVEA/B
SOLENOID
ASSEMELY
VALVEA/B ASSEMBLY
PRESSURE
Line
'1st
Clutch
14-88
SHIFTLEVER
POStTtON
FLUIDPRESSURE
SYMPTOM
CAUSE
PROBABLE
Standard
Eo.E
No {or low)
lrnepressure
Torqueconverter,
ATF pump, pressure regulator,
torqueconverter
checkvalve
Noor low 1st

pressure
1 s tC l u t c h
830 - 880 kPa

(8.5- 9.0 kgf/cm' ,
1 2 0- 1 3 0p s i )
SrvicLimit
780 kPa
{8.0kgf/cm,,110psi)
2nd, 3rd rnd 4th Clutch Ptassurc Mclrurcmanl
LINEARSOLENOID
1 . Set the psrking brake,and block both tear wheels

sscurely.
2. Disconnectthe linsarsolenoidconnector.
3. Startthe sngine,and run the engineat 2,000rpm.
4.
Shift to E position,and measureeachclutchpressure,
5.
Connectbattery voltage and ground lo the linear

solenoid connectrtgrminals,then msasure each
clutch pr6ssure.
1THCLUTCH
INSPECTIONHOI.I
(M.rkedwith "4")
PRESSURE
CLUTCTI
HOLE
INSPECTION
PRESSURE
PfiESSURE
2nd Clutch
3rd Clutch
SHIFTI.EVER
POSmON
ilth clurch
ts
FLUIDPRESSURE
SYMPTOM
No or low 2nd
pressure
PROBABI.E
CAUSE
2nd Clutch
No or low 3rd
pressure
3rdClutch
No or low 4th
pressure
4th clutch
Servo Valve or 4th

Clutch
Standard
ServiceLimit
800 - 850 kPa

(8.2- 8.7 kg7cm',
120- l2il psi)
with the linearsolenoid
disconnec'ted
760 kPa
(7.7kgf/cm,,110psil
disconnected
0- 150kPa
(0-1.5kgflcm' ,
0 - 21 psi)
connectedto battery
voltageand ground
810- 860 kPa
(8.3- 8.8 kgflcm',
1 1 8- 1 2 5p s i )
disconnected
Above 150 kPa

{1.5kg?cm,,2l psi)
connectedto battery
vollage and ground
0 - 150kPa
(0-1.5kgf/cm' ,
0 - 21 psi)
connectedto battery
voltageand ground
Above 150 kPa

(1.5kgf/cm' .21 psi)
connectedto battery
voltage and ground
765 kPa
(7.8kgf/cm' ,111psi)
disconnected
14-89
Transmission
Removal
@Make suie lifts,
4.
Removethe transmissiongroundcable,and disconnectthe lock up controlsolenoidconnector.
5.
Disconnectthe vehiclespeedsensor(VSS)connec,
tor and the countershaft
speedsensorconnector.
iacks and safety stands are placed

properly, and hoist bracket are aftached to the colrect positionon the engine(seesection11.
Apply paiking brske and block rear wheels so vehicle
will not roll off standsand lall on you while working
undel it.
CAUTION: Use fender covers to avoid damaging painted surfaces.

1.
D i s c o n n e ct th e b a t t e r yn e g a t i v e( - ) t e r m i n a lf r o m
the battery,then removethe positive(+)terminal.
2.
Removethe intakeair duct.

D16Y7engine:
Removethe intakeair duct and resonator.
D16Y8engine:
R e m o v et h e i n t a k ea i r d u c ta n dt h e a i r c l e a n e hr o u s ing assembly.
R e m o v et h e s t a r t e rc a b l e sa n d c a b l eh o l d e rf r o m
the startermotor.
MOTORCABIE
VEHICLE
SPEED
MOTOECABLE
14-90
6.
Removethe transmissionhousing mounting bolts

and the rearenginemountingbolt.
8.
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e a u t o m a t i c
t r a n s m i s s i o nf l u i d ( A T F ) .R e i n s t a ltlh e d r a i n p l u g
with a new sealingwasher.
DRAINPLUG
1 8x 1 . 5m m
49 N.m (5.0 kgf.m,36 lbf ftl
7.
Disconnect
the shift controlsolenoid,the linearsolenoid.and the mainshaftsDeedsensorconnectors.
9.
SHIFTCONTROL
SOLENOIOCONNECTOR
Remove the splash shield.
LINEARSOI.ENOID
CONNECTOR
SPLASHSHIELD
CONNECTOR
BRACKET
(cont'd)
14-91
Transmission
Removal(cont'dl
10. Removethe cotter pins and castlenuts.then separate
the balliointsfrom the lowerarms(seesection18).
16. Removethe shift cablecover,then removethe shift

cableby removingthe controllever.
DAMPER PINCH BOLT
CAUTION: Take care not to bend the shift cable.

SHIFTCABLE
CONTROL
SHAFT
:\
NUT
FORK
COTTERPIN
Replace.
FORK
BOLT
WASHER
1 1 . R e m o v et h e r i g h t d a m p e rf o r k b o l t ,t h e n separate
r i g h td a m p e rf o r ka n d d a m p e r .
12. Prythe rightand leftdriveshafts
out of the differential.
P u l lo n t h e i n b o a r dj o i n ta n dt h e r i g h ta n d l e f td r i v e shaftslseesection16).
1 4 . Tie plasticbagsover the driveshaftends.
1 1 . Removethe rightfront mount/bracket.

1 8 . R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
lines.Turn the ends of the ATF cooler hosesup to
preventATF from flowing out, then plug the ATF
coolerhosesand lines.
NOTE:Coatall precisionfinishedsurfaceswith clean

e n g i n eo i l .
N O T E :C h e c kt o r a n y s i g n o f l e a k a g ea t t h e h o s e
joints.
ATF COOLER
LINE
Removethe exhaustpipeA.
N O T E :D ' 1 6 Y 8e n g i n e i s s h o w n ; D 1 6 Y 7e n g i n ei s
s i mi l ar .
Y;
"):
,
*S9e,
SELF.LOCKING
NUT
Replace.
EXHAUSTPIPEA
Replace.
14-92
RIGHTFRONT
MOUNT/BRACKET
HOSE
1 9 . R e m o v et h e e n g i n es t i f f e n e ra n d t h e t o r q u ec o n vertercover.
23. Placea jack under the transmission,and raise the

transmissionjust enoughto take weight off of the
mounts,lhen removethe transmisslonmount.
TRANSMISSION
MOUNTBRACKET
STIFFENER
CONVERTER
20. R e m o v et h e e i g h t d r i v e p l a t eb o l t s o n e a t a t i m e
while rotatingthe crankshaftpulley.
2 1 . Removethe distributor.
2 2 . Attacha hoistingbracketto the engine.then lift the
e n g i n es l i g h t l y .
2 4 . R e m o v et h e t r a n s m i s s i o h
n o u s i n gm o u n t i n gb o l t s
a n dt h e r e a re n g i n em o u n t i n gb o l t s .
25. Pull the transmissionaway from the engine until it
clearsthe 14 mm dowel pins, then lower it on the
transmissioniack.
TRANSMISSIONHOUSING
MOUNTINGBOLTS
REARENGINE
MOUNTINGBOLTS
Replace.
26. lf necessary,removethe torque convener and the

stanermotor.
14-93
lllustrated lndex
Transmission/Right
SideCover
(,
@
O
@
O
@
O
@
ROLLER
COLLAR
o-RtNGReplace.
FEEDPIPEFLANGE
o-RINGReplace.
SNAPRING
3RDcLUTcH FEEDPIPE
LOCKNUT{FLANGENUT)
COUNTERSHAFT
23 x 1.25mm Replace.
O CONICALSPRINGWASHERRepIace,
@ PARKINGGEAR
@ ONE-WAYCLUTCH
1STGEAR
@ COUNTERSHAFT
@ NEEDLEBEARING
1STGEARCOLLAR
@ COUNTERSHAFT
o-RlNGs
Replace.
@
@ RIGHTSIDECOVERGASKETRep|ace.
@ DowEL PINS
@ PARKINGBRAKEPAWLsToP
@ LocK WASHERReptace.
BRAKESTOPSelectivepart
@ PARKING
@ PARKINGBRAKELEVEB
@)PARKINGERAKELEVERSPRING
@ DRAINPLUG
@ SEALINGWASHERRepIace.
@ o-RINGReplace.
SPEEDSENSOR
@ COUNTERSHAFT
@ PARKINGBRAKEPAWL
@ PARKINGBRAKEPAWLSPRING
@ PARKINGBRAKEPAWLSHAFT
ASSEMBLY
@ LINEARSOLENOTD
SOLENOID
GASKETRepIace,
@ LTNEAR
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
RIGHTSIDECOVER
lsT cLUTcHFEEDPIPE
o-RlNGsReplace.
FEEDPIPEFLANGE
SNAPRING
MA|NSHAFTLoCKNUT(FLANGENUTI21 x 1.25mm
Replace.
CONICALSPRINGWASHERReplace.
lsT cLuTcH ASSEMBLY
o-RlNGs Replace.
THRUSTWASHER
THRUSTNEEDLEBEARING
NEEDLEBEARING
MAINSHAFTlST GEAR
MAINSHAFTlST GEARCOLLAR
ATF COOLERLINE
SEAL|NGwAsHERs Reptace.
JoINT BoLT
ATF DTPSTICK
ATF COOLERLINE
JOINT BOLT
SEAL|NGWASHERSReptace.
VEHICLE
SPEEDSENSOR
O.RINGReplace.
TOROUESPECIFICATIONS
Bolt/Nut No.
6A
6B
8F
12A'
18D
21M
Torque Value
12 N'm (1.2kgim,8.7 lbf.ft)
'14
'10
N'm (1.4kgf.m, lbf'ft)
22 N.m (2.2kgim, 16 lbf.ft)
28 N.m (2.9kgf.m,21lbf.ft)
78 N.m (8.0kgim,58 lbf.ft)
lbf.ft)
1 0 3N . m( 1 0 . 5k g n m , 7 5 . 9
Size
6 x 1 . 0m m
6x1.0mm
'1.2m
5m
8x
1 2x 1 . 2 5m m
1 8x 1 . 5m m
2 1 x 1 . 2 5m m
2 3 x 1 . 2 5m m
Remarks
Joint bolt
D r a i np l u g
Mainshaftlocknut:Left-handthreads
Countershaft
locknut:
Left-handthreads
14-95
lllustratedIndex
Transmission
Housing
6A
I
o
14-96
b
ill LOCKWASHERReplace.
(A REVERSE
SHIFTFORK
GEARCOLLAR
@ couNTERSHAFTREVERSE
REVERSEGEAR
.' COUNTERSHAFT
@ NEEDLEBEARING
(O REVERSESELECTOR
O REVERSESELECTORHUB
4TH GEAR
@ COUNTERSHAFT
O NEEDLEBEARING
COLLAR,
28 mm Selectivepart
@ DISTANCE
2ND GEAR
@ COUNTERSHAFT
@ THRUSTNEEDLEBEARING
3RD GEAR
[3 COUNTERSHAFT
(iI NEEDLEBEARING
3RD GEARCOLLAR
.(3 COUNTERSHAFT
(D THRUSTNEEDLEBEARING
(' SPLINED
WASHER
ASSEMBLY
3RD
cLUTcH
@)
@ o-RlNGsReplace.
@ COUNTERSHAFT
@ SNAPRING
@ THRUSTWASHER
GEAR
@ MAINSHAFT4THGEAR/REVERSE
@ NEEDLEBEARINGS
) MAINSHAFT4TH GEARCOLLAR
@ 2ND/4THcLUTcH ASSEMBLY
@ o-RlNGsReplace.
@ THRUSTWASHER,36.5x 55 mm Selectivepart
6] THRUSTNEEDLESEARING
2ND GEAR
@ MAINSHAFT
@ NEEDLEBEARING
89 THRUSTNEEDLEBEARING
@ MAINSHAFT
60 SEALINGRINGS,35 mm
6DSEALINGRING,29 mm
6!) NEEDLEBEARING
@ SETRING
@ SHTFTCONTROLSOLENOIDVALVEA/B ASSEMBLY
@ HARNESSCLAMPBRACKET
FTLTER/GASKET
Reptace.
6DsHtFT CONTROLSOLENOTD
@ CONNECTORBRACKET
.O TRANSMISSIONHANGER
cAP
@ BREATHER
sPEEDsENsoR
@ MAINSHAFT
@ MAINSHAFTSPEEDSENSORWASHER{O16Y7ENgiNEI
@ o-RINGReplace.
@ SNAPRING
TRANSMISSION
HOUSINGBEARING
@ MAINSHAFT
(5] COUNTERSHAFT
TRANSMISSION
HOUSINGBEARING
IDLERGEARSHAFTHoLDERASSEMBLY
@ REVERSE
D NEEDLEBEARING
6, olL SEALReplace.
@ SETRING,80 mm Selectivepart
d]TRANSMISSIONHOUSTNG
IDLERGEAR
@ REVERSE
@ DOWELPINS
@ TRANsMtssloNHoustNG GASKETReptace.
ASSEMBLY
@ DIFFERENTIAL
@ olL SEALReplace.
62TOROUECONVERTER
HOUSING
Bolt/Nut No.
6A
6B
10A
TorqueValue
'12
N.m 1l.2kgf.m,8.7lbf.ft)
'14
. 0lbnft)
N . m( 1 . 4k g f . m 1
44 N m (4.5kgnm,33lbnft)
Size
Remarks
6x1.0mm
6x1.0mm
1 0x 1 . 2 5m m
14-97
lllustrated Index
TorqueConverterHousing/ValveBody
'98 mod.l
i lll
iH
t
14-98
-
T)
O
@
@
.'
ATF FEEDPIPE
ATF STRAINER
SERVOBODY
sERVo SEPARAToRPLATE
SECONDARYVALVE BODY
@ ATF MAGNET
TOROUECONVERTER
HOUSTNG
@ COUNTERSHAFT
BEARING
@ ATF GUIDEPLATE
HOUSING
Q] TOROUECONVERTER
@ olL SEALReplace.
(.} MAINSHAFTTOROUECONVERTER
HOUSING
BEARING
@ olL SEALReplace.
@ LOCK.UPCONTROLSOLENOIDFILTER/GASKET
Replace.
@ LocK-UPcoNIRoL SoLENoIDVALVEA/B ASSEMBLY
BMCKET
@ CONNECTOR
a6)DowELPrNs
O SECONDARYSEPARATORPLATE
@ SERVODETENTBASE
O ATF FEEDPIPES
(o) ATF FEEDPIPES
O SHAFTsToP
@ coNTRoL SHAFT
(} DETENTARM SPRING
(D DETENTARM
@ DETENTARM SHAFT
@ FILTERReplace.
O CHECKBALLS
CHECKVALVESPRING
[o) TOROUECONVERTER
CHECKVALVE
@ TOROUECONVERTER
@ DOWELPINS
VALVEBODY
@ LOCK-UP
LOCK.UP
SEPARATORPLATE
@
VALVE BODY
@ REGULATOR
@ DowELPrNs
@ COOLERRELIEFVALVE SPRING
@ COOLERRELIEFVALVE
@ o-RINGReplace.
@ STATORSHAFT
@ STOPSHAFT
@ ATF FEEDPIPE
@ MAIN VALVE BODY
O ATF PUMPDRIVENGEARSHAFT
@ ATF DRIVENGEAB
@ DOWELPINS
@)ATF PUMPDRIVEGEAR
@ MAIN SEPARATORPLATE
@ SUCTIONPIPECOLLAR
Bolt/Nut No.
TorqueValue
Size
6A
1 2 N . m { 1 . 2k g f . m , 8 . 7l b f . f t )
6x1.0mm
Remarks
14-99
Right Side Cover

Removal
NOTE:
. Cleanall partsthoroughly
in solventor carburetor
cleaner,
anddrywithcompressed
air.
. Blowoutall passages.
.
When removingthe right sidecover,replacethe following:

O rings
- Mainshaftand countershaftlocknuts
- Conicalspringwashers
- Rightsidecovergasket
Lockwasher
S e a l i n gw a s h e r s
RIGHTSIDE
COVEB
ARAKELEVER
WASHER
lST GEABOOLLAR
JOINT BOLT
COUNTERSHAFT
SEALINGWASHERS
14-100
'13
1 . Removethe
bolts securingthe right side cover.
then removethe right sidecover.
Slipthe specialtool onto the mainshaftas shown.
5. Removethe specialtool from the mainshaftafter

removingthe locknuts.
6. Removethe 1stclutchand mainshaftlst gearassem
bly and mainshaftl st gearcollarfrom the mainshaft.
7 . Removethe parkingbrakepawl.springand shaft.
HOLDER
MAINSHAFT
o'GAB- PFs0'101
8 . R e m o v et h e p a r k i n gb r a k el e v e rf r o m t h e c o n t r o l
shaft.
Usinga universaltwo jaw puller,removethe parking
g e a r . o n e - w a yc l u t c h a n d c o u n t e r s h a f t1 s t g e a r
assemoty.
PULLER
(Commerciallyavailablel
PARKII{GGEAR
J.
E n g a g et h e p a r k i n gb r a k ep a w l w i t h t h e p a r k i n g
gear.
Cut the locktabs of the mainshaftand countershaft
locknutsusing a chisel as shown, then removethe
locknutsand conicalspringwashers.
CAUTION: Keep all of the chisoled particles out of
tho transmiS3ion.
NOTE:
. Mainshaftand countershaftlocknutshave lefthandthreads.
. Always wear safety glasses.
'10. R e m o v et h e n e e d l eb e a r i n ga n d t h e c o u n t e r s h a f t
1stgearcollarfrom the countershaft.
1 1 . Removethe ATF coolerlinesand ATF dipstick.
CHISEL
LOCKNUT
LOCKTA8
14-101
Transmission
Housing
Removal
TRANSMISSIONHOUSING
MOUNTINGEOLTS
18 Bolts
TRANSMISSION
HANGER
TRANSMISSIONHOUSING
MAINSHAFT
SUB.ASSEMBL
MAINSHAFT
SENSORWASHER
(D16Y7engine)
SPEED
SENSOR
TRANSMISSION
HOUSINGGASKET
TOROUE
CONVERTER
HOUSING
14-102
-
NOTE:
r C l e a na l l p a r t st h o r o u g h l yi n s o l v e n to r c a r b u r e t o r
cleaner,and dry with compressedair.
. Blow out all passages.
. W h e n r e m o v i n gt h e t r a n s m i s s i o nh o u s i n g ,r e p l a c e
the following:
- O-ring
- Transmissionhousinggasket
* Lockwasher
Removethe countershaftreversegear with the collar and needlebearing.

Removethe lock bolt securingthe shift fork. then
removethe fork with the reverseselectorfrom the
countershaft.
7.
R e m o v et h e c o u n t e r s h a fst u b - a s s e m b l ya n d t h e
together.
mainshaftsub-assembly
' t . Removethe mainshaftspeedsensorfrom the transmissionhousing.

2.
MAINSHAFT
SUB,ASSEMBLY
Removethe transmissionhousing mounting bolts

ano nanger.
COUNTERSHAFT
SU8-ASSEMBLY
Align the spring pin on the control shaft with the

transmissionhousinggrooveby turning the control
shaft,
8.
Removethe differentialassemblyfrom the torque

converterhousing.
PULLER
HOUSING
- PKa010A
07HAC
lnstallthe specialtool on the transmissionhousing,
then removethe housingas shown.
CAUTION: Make sure the mainshaft speed sensol
has been removed trom the transmission housing
before removing ihe transmission housing lrom the
torqug converter housing.
14-103
TorqueConverterHousing/ValveBody
Removal
6x1.0mm
1
ATF FEEDPIPE
x 1.0mm
2 Bolts
PIN
LOCK-UPVAL
BODY
6x1.0mm
SEBVODETENT
BASE
IOCK-UPSEPARATOR
PLATE
ATF FEED
REGULATOR
VALVEBODY
DOWEL
COOLERRELIEFVALVE
TOROUE
CHECKVALVE
TF STRAINER
CONTROL
SHAFT
x 1.0mm
7 Bolts
OETENT
ARM SHAFT
DETENT
ARM
SERVOSODY
SERVOSEPARATOR
PLATE
ATF FEEOPIPE
6x1.0mm
3 Bolts
6x1.0mm
5 Bolts
MAIN VALVE
BODY
ATFPUMP
GEARSHAFT
ATF PUMP
DRIVEN
SHAFT
STOP
VALVEBODY
PIN
ATF PUMP
ORIVEGEAR
MAIN SEPARA
PLATE
TOROUE
CONVERTER
HOUSING
14-104
SECONDARY
SEPARATORPLATE
NOTE:
o Clean all parts thoroughly in solvent o. carburetor
cleaner,and dry with compressedair.
. When removingthe valvebody, replacethe O-ring.
1 3 . C l e a nt h e i n l e t o p e n i n go f t h e A T F s t r a i n e rt h o r oughly with compressedair, then checkthat it is in

good condition,and the inletopeningis not clogged.
1. Removethe ATF feed pipes from the servo body,

secondaryvalvebody and main valvebody.
2, Remove the ATF strainer and servo detent base
(two bolts).
3. Removethe servo body and servo separatorplate
(seven boltsl.
Removethe secondaryvalve body, shaft stop and
secondaryseparatorplate(threebolts).
INLETOPENING
Removethe lock-upvalve body and separatorplate

{sevenbolts),
Removethe regulatorvalvebody {one bolt).
1 4 . Test the filter by pouring clean ATF fluid through
7 . Removethe stator shaft and stop shaft,

Removethe detentspringfrom the detentarm. then
remove the control shaft from the torque converter
housing.
t h e i n l e t o p e n i n g .R e p l a c et h e A T F s t r a i n e ri f i t i s
cloggedor damaged.
NOTE:The ATF strainercan be reused if it is not
croggeo.
Removethe detentarm and detentarm shaft from

the main valvebody.
1 0 . Removethe main valvebody (fivebolts).

NOTE:Do not let the eight checkballsfall outofthe
m a i n v a l v e b o d y w h e n r e m o v i n gt h e m a i n v a l v e
body.
1 1 . Removethe ATF pump driven gear shaft,then remove
the ATF pump gears.
12. Removethe main separatorplate and two dowel
prns.
14-105
ValveCaps
Description
Caps with one projected tip and one flat end are
i n s t a l l e dw i t h t h e f l a t e n d t o w a r d t h e i n s i d e o f t h e
valve body.
Caps with a projected tip on each end are installed
with the smaller tiD toward the inside oI the valve
b o d y .T h e s m a l l t i p i s a s p r i n gg u i d e .
Capswith hollow ends are installedwith the hollow

end awayfrom the insideof the valvebody.
CaDswith notchedends are installedwith the notch
towardthe insideof the valvebody.
Capswith llat ends and a holethroughthe centerare
i n s t a l l e dw i t h t h e s m a l l e rh o l e t o w a r dt h e i n s i d eo f
the valvebodv.
Toward outside of valve bodv.
Toward outside of valve bodv.
EflE
Toward inside of valve bodv.
Toward inside of valve bodv.
C a p s w i t h o n e p r o j e c t e dt i p a n d h o l l o w e n d a r e
installedwith the tip toward the inside of the valve
body.The tip is a springguide.
Capswith flat ends and a groovearoundthe cap are

installedwith the groovedside toward the outsideof
the valvebodv.
---'gJfr
Toward outside ol valve body.
Toward outside of valv6 bodv.
GROOVE
./
\:7
Sectional view.
Toward inside ol valve body.
Toward insideot valve bodv
14-106
E.
Valve Body
Repair
NOTE:This repair is only necessaryif one or more ot
the valvesin a valve body do not slidesmoothlyin their
bores.You may use this procedureto free the valvesin
the valvebodies.
1.
S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r
about30 minutes.
2.
C a r e f u l l yt a p t h e v a l v eb o d y s o t h e s t i c k i n gv a l v e
dropsout of its bore.
5.
Removethe #600 paper and thoroughly wash the

entire valve body in solvent,then dry it with compressedarr.
6.
Coatthe valvewith ATF,then drop it into its bore.

It should drop to the bottom of the bore under its
own weight.lf not, repeatstep4, then retest.
C A U T I O N :l t m a y b e n e c e s s a r yt o u s e a s m a l l
screwdriver to pry the valve free. Be carelul not to
scratchthe bore with the screwdriver.
3. Insoectthe valvefor anv scuff marks.Use the ATFsoaked#600 paper to polish off any burrs that are
on the valve,then wash the valvein solventand dry
it with compressedair.
VALVE EODY
paper,and insen
Roll up half a sheetof ATF-soaked
it in the valvebore of the stickingvalve.
Twistthe paperslightly,so that it unrollsand fits the
b o r e t i g h t l y ,t h e n p o l i s ht h e b o r e b y t w i s t i n gt h e
paperas you push it in and out.
ffiFS'
CAUTION:The valve body is aluminumand doesn't

require much polishing to remove any burrs.
ATF-so6ked
#0OO abrasivo papet
7.
Removethe valve,then thoroughlyclean it and the

v a l v e b o d y w i t h s o l v e n t .D r y a l l p a r t sw i t h c o m
pressedair, then reassembleusing ATF as a lubricant.
14-107
Valve
Assembly
NOTE:
Coatall partswith ATF beforeassembly.
.
Set the spring in the valve and i n s t a l il t i n t h e v a l v e

b o d y . P u s ht h e s p r i n g i n w i t h a s c r e w d r i v e rt,h e n
installthe springseat.
I n s t a l tl h e v a l v e ,v a l v es p r i n ga n d c a p i n t h e v a l v e
body and securewith the roller.
ROLLER
SPRINGSEAT
SPRING
VALVE BODY
\
VALVE BODY
Installthe valve,springand cap in the valvebody.

P u s ht h e c a p ,t h e ni n s t a ltlh e c l i p .
ROLLER
VALVE BODY
VALVE
SPRING
CAP
14-108
ATFPump
lnspection
'L
lnstallthe ATF pump gears and ATF pump driven

gear shaftin the main valvebody.
2.
Measurethe side clearanceof the ATF pump drive

and drivengears.
ATF Pump Geais Side (Radiallclearance:
Standard (New):
ATF Pump Drive Gear
0.105- 0.1325mm {0.00/t- 0.005in)
ATF PumpDrivenGear
0.035- 0.0625mm (0.0014- 0.0025in)
NOTE:
. Lubricateall partswith ATF during inspection.
. I n s t a l l t h e A T Fp u m pd r i v e rgr e a rw i t h i t s g r o o v e d
and chamferedsidefacingup as shown.
ATFPUMPDRIVENGEAR
Groovedand chamfereds cie
MAIN VALVEEODY
ATF PUMP
ATF PUMP
DRIVEGEAB
Inspectteethfor wear and damage.
I n s p e c tt e e t h f o r w e a r a n d d a m a g e -
3.
MAIN VALVE BODY
Removethe ATF pump driven gear shaft. Measure

the thrust clearanceof the ATF pump driven gearto-valvebody.
ATF Pump Drive/D ven GoarThrust lAxial)Clearance:
Standard (Newl: 0.03- 0.05 mm 10.001- 0.002inl
ServiceLimit: 0.07 mm 10.003in)
14-109
Main Valve Body

NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner.and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any pans are worn or damaged.
. Checkall valvesfor free movement.lf any fail to slidefreely,seeValveBody Repairon page 14-,|07.
. Coatall pans with ATF duringassembly.
CAUTION: Do not uss a magnet to remove the check balls; it may magnetizethe balls.
1-2 SHIFTVALVE
VALVECAPCLIP
{*4
2ND ORIFICE
CONTROLVALVE
CHECKBALLS,8
1STACCUMULATOf,CHOKE
MOOULATOR
VALVE
du:
RELIEFVALVE
VALVE
MAIN VALVEBODY
Inspectfor wear,scratches
and scoring.
SERVOCONTROLVAL
VALVECAP
14- 1 1 0
CHECKBALL
CHECKBALLS
CHCKBAI.LS
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standard (Newl
No.
o
\9/
Springs
Reliefvalvespring
Modulatorvalvesprang
CPBvalvespring
'1-2
shiftvalvespring
2nd orificecontrolvalvespring
Servocontrolvalvespring
Wire Dia.
1 . 1( 0 . 0 4 3 )
1 . 4( 0 . 0 5 5 )
0.9(0.035)
0.9(0.035)
0.7(0.028)
1.0(0.039)
o.D.
8.6 (0.342)
9.4 {0.374}
8 . 1( 0 . 3 2 2 )
7.6 (0.302)
6.6 (0.262)
8.1 (0.322)
FreeLength
3 7 .t { 1 . 4 6 1 )
3 5 . 0( 1 . 3 7 8 )
47.2{1.858)
4 1 . 3( 1 , 6 2 6 )
34.8(1.370)
5 2 . 1( 2 . 0 5 1 )
No. of Coils
13.4
10.9
18.3
16.3
22.0
20.8
14-111
SecondaryValve Body
Disassembly/l
nspection/Reassembly
NOTE:
o Cleanall pans thoroughlyin solventor carburetorcleaner,and drywith comp.essedair. Blow outall passages.
. Replacethe secondaryvalvebody kit, P/N27700- P4R- 305 (Thesecondaryvalvebody kit includesthe linearsolenoid
assembly)if any partsare worn or damaged.
. Checkallvalvesfor free movement.lf anyfail to slidefreely,seeValveBody Repaironpage'14-107.
. Coatall partswith ATF duringassembly.
. The CPCvalveis installedin the secondaryvalvebody, held in placeby the lockbolt.
2.3 SHIFTVAI.VE
3.4 SHIFTVALVE
LOCKBOLT
CAUTION: Oo not move.
SECONOARY
VALVEBODY
and
scofing.
3-4 ORIFICE
CONTROLVAL
VALVE
ROLLER
No.
Standald lNewl
Springs
Wire Dia.
o
6,
@
3-4 shift valvespring

2-3 shift valvespring
4th exhaustvalvespring
3-4 orificecontrolvalvespring
14-1 1 2
0.9(0.035)
0.9{0.035)
0.9(0.035)
0.7(0.028)
o.D.
7.6 (0.302)
7.6 (0.302)
6.1 (0.242)
6.6 10.2621
Free Lenglh
51.0 12.2441
51.0 \2.244)
3 6 . 4( 1 . 4 3 3 )
3 7 . 5( 1 . 4 7 6 )
No. oI Coils
26.8
26.8
19.5
24.6
RegulatorValveBody
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damaged
. checkall valvesfor free movement.It any {ail to slidefreely,seevalve Body Repairon page 14-107.
1.
Holdthe regulatorspringcap in placewhile removingthe stop bolt. Oncethe stop bolt is removed,releasethe sprang
cap srowry.
CAUTION: Thc regulator spring cap can pop out when the stop bolt is removed'
2.
is the reverseorderof the disassemblyprocedure

Reassembly
NOTE:
. Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe springcap into the valve
body,and tightenthe stoPbolt.
STOPBOLT
6x1.Omm
1 2N . m( 1 . 2
VALVEBODY
REGULATOR
Inspectfor wear, scratches
and scortng,
REGULATOR
VALVE
Standard(New)
No.
Springs
RegulatorvalvespringA
RegulatorvalvespringB
Statorreactionspring
Coolerreliefvalvespring
Torqueconvertercheckvalvespring
Lock-upcontrolvalvespring
Wire Dia.
1 . 8( 0 . 0 7 1 )
1 . 8( 0 . 0 7 1 )
4 . 5( 0 . 1 7 7 )
1 . 0( 0 . 0 3 9 )
1.0(0.039)
0.7 {0.028)
o.D.
14.7(0.584)
9 . 6( 0 . 3 8 1 )
3 s . 4( 1 . 4 0 7 )
8.4 (0.334)
8.4 {0.334)
6.6 (0.262)
Free Length
87.8(3.457)
44.0l'1.7321
3 0 . 3( 1 . 1 9 3 )
3 3 . 8{ 1 . 3 3 1 )
3 3 . 8( 1 . 3 3 1 )
38.0(1.496)
No. of Coils
1' I.0
1.9
8.2
8.2
14.1
14-113
ServoBody
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damageo.
. Replacethe O rings.
SERVOBOOY
lnspectfor wear,scratches
and scoring.
"----.-'g
2NDAccuMULAroR
==p
O-BING
Beplace.
g;li:':-Y
-^'":::#,
1STACCUMULATORPISTON
3RDACCUMULATORPISTON
4TH ACCUMULATOBPISTON
SNAPRINGS
No.
Standard (New)
Springs
Wire Dia.
o
A)
lJl
1staccumulatorspring
4th accumulato.springA
4th accumulatorspringB
3rd accumulatorspringA
3rd accumulatorspringB
2nd accumulatorspringC
2nd accumulatorspringA
2nd accumulatorspringB
14-114
2.1(0.083)
2 . 6( 0 . 1 0 2 )
2 . 3( 0 . 0 9 1 )
2 . 8( 0 . 1 1 0 )
2.2(0.087)
2.2(0.087)
2.4(0.094)
1 . 6( 0 . 0 6 3 )
o.D.
16.0{0.636)
17.0(0.676)
10.2{0.402)
17.5(0.695)
3 1 . 0{ 1 . 2 2 0 )
1 4 . 5( 0 . 5 7 6 )
2 9 . 0( 1 . 1 5 2 )
9.0 (0.358)
FreeLength
89.1(3.508)
87.0(3.425)
5 1 . 6( 2 . 0 3 1 )
89.3(3.516)
35.1(1.382)
68.0(2.677)
39.0(1.535)
20.7(0.815)
No. of Coils
16.2
14.2
13.8
15.6
2.4
1? O
2.9
Lock-upValve Body
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair, Blow out all passages.
. Replacethe valvebody as an assemblyiJany partsare worn or damaged.
. Checkall valvesfor free movement.lf any fail to slidefreeiy,seeValveBody Repairon page14-107.
. Coatall pans with ATF duringassembly.
LOCK.UPSHIFTVALVE
LOCK-UP
VALVEBODY
Inspect
for wear,scratches
VALVECAP
ano sconng,
LOCK.UPTIMINGVAL
\uo.*.or.,-,,
U n i t :m m { i n )
Standard (New)
No.
Springs
Wire Dia.
Lock-upshiftvalvespring
Lockup timing valvespring
0.9(0.035)
0.9(0.035)
o.D.
7.6(0.302)
8 . 1{ 0 . 3 1 9 )
Free Length
73.1|'2.902)
80.1t3.1771
No. of Coils
32.0
45.8
14-115
t-
Mainshaft
NOTE:
. Lubricateall partswith ATFduring reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement.
. Beforeinstallingthe O-rings.wrap the shaftsplineswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
LOCKNUT(FLANGENUTI
2 1 | 1. 2 5 n f i
78 N.m 18.0 kgl.m,58 lbl.ftl
Replace.
Lelt-handthreads
CONICAL SPRINGWASHER
Replace.
SNAP RING
lST CLUTCH
ASSEMBLY
THRUST WASHEN
MAINSHAFT
Check splinestor excessive
wear and damage.
Check bearingsurfacefor scoring,
scratchesand excessivewear.
THRUSTNEDLE
BEARING
THRUSTWASHER
4TH GEAR
THRUST
NEEDLE
BEARING
BEANING
NEEDI-EBEARINGS
2ND/4TH CLUTCH
ASSEMBLY
O.BINGS
Replace.
THBUST
WASHER,
36.5 r 55 mm
Selectivepart.
THRUSTNEEDLE
BEARING
Inslallthe sealingring
matlng faces as shown,
RING,
29 mm
lti
NEEDLEBEARING
SET RING
14-1 1 6
L.
,IST GEAR
THRUSTNEEDLE
EEARING
4TH GEAR COLLAR
SEALINGRINGS,
35 mm
O.FINGS
Replace.
2ND GEAR
BEARING
NEEDLE
BEARING
TRANSMISSION
HOUSINGEEARING
Inspection
.
3.
ClearanceMeasurement
Torquethe mainshaftlocknutto 29 N'm (3.0 kgf'm,

22 lbf.ft).
NOTE:Lubricateall partswith ATF during assembly.

NOTE:Mainshaftlocknuthas left-handthreads.
1.
Removethe mainshaftbearingfrom the transmission housing(seepage l4-142).
2.
Assemblethe partsbelow on the mainshaft.

NOTE:Do not assemblethe O-ringsduring inspection.
LOCKNUT
CONICALSPRINGWASHER
,IST CLUTCH ASSEMELY
THRUST WASHEB
1ST GEABCOLLAR
SNAP RING
TRANSMISSION
HOUSINGBEARING
Hold 2nd gear againstthe 2nd clutch,then measure

the clearancebetween2nd gear and 3rd gear with a
feelergauge.
NOTE:Take measurementsin at leastthree places,
and usethe averageas the actualclearance.
STANDARD:0.05- 0.13 mm {0.002- 0.005in)
THRUSTWASHER
4TH GEAR COLLAR
2ND/4TH CLUTCH
ASSEMBLY
THRUSTWASHER
36.5 x 55 mm
Selective part.
TI{RUST NEEDLE
BEARING
2ND GEAR
NEEOLEBEARING
THRUSTt{EEDLE
BEARING
MAINSHAFT
(cont'd)
14-117
Mainshaft
Inspection(cont'd)
5.
l f t h e c l e a r a n c ei s o u t o f t o l e r a n c e ,r e m o v et h e
thrustwasherand measurethe thickness.
6.
Selectand installa new washer.then recheck.
THRUSTWASHER36.5x 55 mm
No.
Thickness
9044' -t P4P- 010
4 . 0 0 m m ( 0 . 1 5 7i n )
90442-P4P-010
4 . 0 5m m ( 0 . 1 5 9i n )
90443-P4P-010
4 . 1 0m m ( 0 . 1 6 i1n )
90444-P4P-010
4 . 1 5m m ( 0 . 1 6 3
in)
4 . 2 0m m { 0 . 1 6 5i n )
90445-P4P-010
90446- P4P, 010
90447-P4P-010
4 . 3 0m m ( 0 . 1 6 9
in)
90448-P4P-010
4 . 3 5m m ( 0 . 1 7 1
in)
90449-P4P-010
4 . 4 0m m ( 0 . 1 7 3i n )
90450-P4P-000
4 . 4 5m m ( 0 . 1 7 5i n )
10
7.
Part Number
4 . 2 5m m ( 0 . 1 6 7i n )
A f t e r r e p l a c i n gt h e t h r u s t w a s h e r ,m a k e s u r e t h e
clearanceis within tolerance.
14-1 1 8
Gountershaft
NOTE;
. Lubricateall parts with ATF before reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement.
. Beforeinstallingthe O-rings,wrap the shaitsplineswith tapeto preventdamagingthe O-rings.
. Locknuthas left-handthreads.
LOCKNUT(FLANGENUTI
23 x 1.25mm
103 N.m
{10.5 kgf.m, 75.9 lbI.ft)
Replace.
Left-hand threads
CONICALSPRING
WASHER
Replace-
REVERSEGEAR
NEEDLEBEARING
SELECTOR
HUB
4TH GEAR
NEEDLEBEARING
BEARING
ST GEARCOLLAR
DISTANCECOLLAR,
28 mm
Selectivepart.
2ND GEAR
COUNTERSHAFT
Checksplines{or excessive
wear and damage,
Check bearingsurfacefor scoring,
wear.
scratchesand excessave
THBUSTNEEDLE
EEARING
3RD GEAR
NEEDLEBEARING
3RD GEARCOLLAR
THRUSTNEEOLEBEARING
SPLINEDWASI.IEB
3RD CLUTCHASSEMBLY
Replace.
14-119
Gountershaft
1.
Using a hydraulicpress,pressout the countershaft

while supporting4th gear.
NOTE: Placean attachment between the press and
to preventdamageto the shaft.
the countershaft
CAUTION: Do not allow the countershaftto fall and
hit the ground when Pressdclear.
2.
Assemblethe parts on the countershaftas shown

Delow.
NOTE:
. Lubricateall pans with ATFduring assembly.
. Beforeinstallingthe O-rings,wrap the shaft splines
with tapeto preventdamagingthe O-rings.
4TH GEAR
NEEOLEBEARING
DISTANCECOLLAR, 28 mm
Selective part.
2ND GEAR
THRUST NEEDLEBEARING
3RD GEAR
NEEDLEBARING
3RDGEARCOI.LAR
TI{RUSTNEEDIEAEABING
SPLINED
WASHER
3RDCLUTCHASSEMBLY
14-120
lnspection
3.
lnstallthe reverseselectorhub on the countershaft

sub-assembly,
and then pressthe reverseselector
hub usingthe specialtool and a pressas shown.
a Clearance
Measurement
NOTE:Lubricateall partswith ATFduringassembly.
'L
Removethe countershaftbearingtrom the transmissionhousing(seepage 14 142).
2.
Installthe partsbelowon the countershaftusingthe

specialtooland a pressas describedon this page.
NOTE:Do not assemblethe O-ringsduring inspec
tron.
DRIVER 40 mm l.D.
07746 -OO30tOO
REVERSESELECTOR
HUB
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR, 28 mm
Selectivepart.
2ND GEAR
THRUSTNEEDLEBEARING
3RD GEAR
NEEDLEBEARING
3RD GEARCOLLAR
THRUSTNEEDLEBEARING
SPLINEDWASHER
3RD CLUTCHASSEMBLY
{cont'd)
14-121
Gountershaft
Inspection {cont'd)
3.
I n s t a l lt h e p a r t s b e l o w o n t h e c o u n t e r s h a fst u b ,
a s s e m b l yt,h e n t o r q u et h e l o c k n u tt o 2 9 N . m ( 3 . 0
kgf.m,22blf.ft).
4.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e 2 n d g e a r a n d
the 28 mm distancecollarwith a feelergauge.
NOTE:Takemeasurements
in at leastthree places,
NOTE:Countershaft
locknuthas left-handthreads.
STANDARD:
0.10- 0.18mm (0.004- 0.007inl
Left-handthreads
CONICALSPRING
WASHER
PARKINGGEAR/ONE-WAY
CLUTCH/1STGEAR
ASSEMELY
NEEDLEEEARING
OISTANCECOLLAR.28 mm
1ST GEAECOLLAR
TRANSMISSION
HOUSING
BEARING
REVERSE
GEAR
COLLAR
COUNTERSHAFT
SUB-ASSEMELY
5.
lf the clearanceis out of tolerance,removethe 28

mm distancecollarand measurethe width.
6.
S e l e c ta n d i n s t a l la n e w d i s t a n c ec o l l a r ,t h e n
recnecK.
DISTANCECOLLAR.28 mm
No.
,]
1.
14-122
PartNumber
width
3 9 . 0 0m m ( 1 . 5 3 5
in)
90503-PCg-000
90504- PCg, 000
90505- PCg 000
3 9 . 2 0m m ( 1 . 5 4 3i n )
90507-PCg-000
3 9 . 3 0m m ( 1 . 5 4 7i n )
90508-PCg-000
3 9 . 0 5m m ( 1 . 5 3 7
inI
90509-PCg,000
3 9 . 1 5m m ( 1 . 5 4i1n )
90510-PCg-000
3 9 . 2 5m m i 1 . 5 4 5i n )
9 0 5 1 1- P C g 0 0 0
3 8 . 9 0m m ( 1 . 5 3 1I n )
90512-PCg-000
3 8 . 9 5m m ( 1 . 5 3 3i n )
3 9 . 1 0m m ( 1 . 5 3 9i n )
A f t e r s e l e c t i n ga n e w d i s t a n c ec o l l a r ,r e c h e c kt h e
c l e a r a n caen d m a k es u r ei t i s w i t h i nt o l e r a n c e .
One-way Clutch
nspection/Reassembly
Disassembly/l
1.
S e p a r a t ec o u n t e r s h a f1t s t g e a r f r o m t h e p a r k i n g
g e a r b y t u r n i n gt h e p a r k i n gg e a r i n t h e d i r e c t i o n
shown.
3.
Inspectthe partsas followsl
PARKING
GEAR
Inspectthe parkinggear
for wear and scoring,
PARKINGGEAR
ONE-WAYCLUTCH
Inspectthe one-way
clutch for damageand
faultVmovement.
COUNTERSHAFTlST GEAR
2.
Removethe one-wayclutchby prying it up with the

end of a screwdriver.
COUNTERSHAFT
1STGEAR
ONE.WAYCLUTCH
NOTE:Installin this direction.
.IST GEAR
Inspectcountershall'l
for wear and scoring,
4.
Afterthe partsare assembled,hold countershaft1st

g e a r a n d t u r n t h e p a r k i n gg e a r i n t h e d i r e c t i o n
shownto be sure jt turns freely,Also makesurethe
parkinggeardoes not turn in the oppositedirection.
ONE.WAY CLUTCH
COUNTERSHAFT,IST GEAR
COUNTERSHAFT
lST GEAR
SCREWDRIVER
14-123
Clutch
lllustratedIndex(A4RA,B4RATransmissionl
3RDCLUTCH
CLUTCH
DRUM
O-RINGS
Replace.
C L U T C Hp t S T O N
DISC SPRING
CLUTCHPLATES
Standardthickness:
2 . 0m m ( 0 . 0 7 i9n )
CLUTCHEND
PLATE
SNAPRING
lST CLUTCH
CLUTCHEND
TE cLurcsorscs
Standardthickness:
'1.94mm
{0.076in)
SNAPRING
SPRINGRETAINER
RETURNSPNING
DISCSPRING
o-"'"cs
!,L"urlcf
tleptace.
I
CLUTCHDRUM
CLUTCHPLATES
Standardthickness:
1.6mm 10.063
in)
CHECKVALVE
14-124
2ND/4THCLUTCH
SNAPRING
CLUTCHPLATES
CLUTCHPISTON
DISCSPRING
SNAP
SPRINGRETAINEB
RETURNSPRING
O.RINGS
Replace.
4TH CLUTCHDRUM
CLUTCHPLATES
StandardthicknessrO-RINGS
2.0mm {0.079in)
Reptace.
CLUTCHEND PLA
SNAPRING
14-125
Clutch
lllustratedIndex(M4RATransmissionl
3RDCLUTCH
CLUTCH
ORUM
CLUTCHPISTON
OISCSPRING
CLUTCHEND
PLATE
SNAPRING
1STCLUTCH
CLUTCHEND
SNAPRING
rll
CHECKVALVE
14-126
g
SNAPRING
2ND/4TH-CLUTCH
VALVE
CLUTCHPLATES
Standardthickness:
2.0 mm (0.079in)
\--2ND CI-UTCH
DNUM
CLUTCHPISTON
RETURNSPRING
O-RINGS
Replace.
SNAPRING
\---
SNAPRING
14-127
Clutch
Disassembly
1.
Removethe snap ring, then removethe clutch end

plate.clutchdiscsand olates.
3.
Installthe specialtoolsas shown.

CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SCREWORIVER
SNAP RING
;=
2.
_=:_-.-----
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
Removethe discspring.
NOTE:Except2nd clutch.
OISCSPRING
ol
CLUTCH
07HAE- P150100
COMPRESSOR
BOLTASSEMBLY
- PG40200
07GAE
ol
OTGAE- PGIO2OA
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCHDRUM
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
li
ll
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE- PG40200
OI
OTGAE_ PG4O2OA
14-128
g
07HAE- P150100
CAUTION:It eitherend of the specialtool issetoveran

area of the spring retainer which is unsupported by the
return spring, the retainer may be damaged. Be sure the
specialtool is adiusted to have tull contact with the
spring retainer.
SPECIALTOOL
5.
Removethe snap ring.Thenremovethe specialtools,

springretainerand returnspring.
6.
Wrap a shop rag aroundthe clutchdrum. and apply

air pressureto the ATF passageto removethe piston.
P l a c ea f i n g e rt i p o n t h e o t h e r e n d w h i l e a p p l y i n g
a r rp r e s s u r e .
OSHA-APPROVED
SPRING RETAINER
4.
Compressthe returnspring.
PISTON
14-129
Glutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleaner,and dry them with compressedajr.
. Lubricateall partswith ATF beforereassembly.
1.
Inspectthe checkvalve;if it's loose,replacethe piston,
3.
Installthe pistonin the clutchdrum. Apply pressure

and rotateto ensureproperseating.
NOTE:Lubricatethe piston O-ringwith ATF before
installing.
CAUTION: Do not pinch th8 O.ring by installing the
piston with too much force.
CLUTCHDRUM
CHECK VALVE
PISTON
2.
Install new O-rings on the clutch piston.
I n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r a
, nd
positionthe snap ring on the retainer.
O-RINGS
SNAP RING
SPRINGRETAINR
RETURNSPRING
CLUTCHDRUM
PISTON
14-130
5.
CAUTION:ll either end ot the special tool is set

over an ar6a of the spring retainer which is unsupported by the return spring, the retainer may be
damaged. Be sure the specialtool is adiusted to
have tull contact with the spring retainsr.
lnstallthe soecialtools as shown.
CLUTCHSPRING
COMPRESSOB
ATTACHMENT
07LAE- PX40100
SPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
ot
07HAE- PL50'100
Do not s6t hore.
SPECIALTOOL
OTGAE- PG4O2OA
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
oTLAE-PX40100
6.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE- PG40200
ot
OTGAE- PG4O2OA
07HAE- PL50100
(cont'd)
14-131
Clutch
(cont'd)
Reassembly
7.
'10. Soak
lnstallthe snap ring.
the clutchdiscsthoroughlyin ATF for a minimum of 30 minutes.
1 1 . staning with a clutch plate, alternatelyinstall the
clutch platesand discs.Installthe clutch end plate

with flat sidetowardthe disc.
NOTE:Beforeinstallingthe platesand discs,make
sure the insideof the clutch drum is free of din or
otherforeignmatter.
CLUTCH EI{D PLATE

Installin this direction.
SNAP RING
8.
9.
Installthe discspring.
N O T E : I n s t a l lt h e d i s c s p r i n g i n t h e d i r e c t i o n
shown,except2nd clutch.
DISC SPRING
12. Installthe snap ring.
SCREWDRIVER
SNAP RIIIG
!tf
14-132
-
13, Measurethe clearancebetweenthe clutchend plate

and top discwith a dial indicator.Zero the dial indicator with the clutch end plate lowered and lift it up
to the snap ring. The distancethat the clutch end
olatemovesis the clearancebetweenthe clutchend
plateand top disc,
Clutch End Plate-to-TopDisc Clearanco:
Clutch
Sowico Limit
0.650.650.400.40-
1st
2nd
3rd
4th
0.85mm (0.0260.85mm (0.0260.60mm (0.0160.60mm (0.016-
0.033in)
0.033in)
0.024in)
0.024inl
DIAL INDICATOR
tl
ENDPLATE
CLUTCH
A,[RA,B4RATransmission:
Plste No.
1
6
7
8
I
Clearance
CLUTCHDISC
1 4 . l f t h e c l e a r a n c ei s n o t w i t h i n t h e s e r v i c el i m i t s ,
select a new clutch end plate from the following
table.
22551- P4R- 003

22552- P4R,003
22553-P4R-003
22554-P4R-003
22555-P4R-003
22555-P4R-003
22557-P4R-OO3
22558-P4R-003
22559-P4R-003
Thicknoss
2.1mm (0.083in
2,2 mm (0.087in
in
2 . 3m m ( 0 . 0 9 1
2 , 4m m { 0 . 0 9 4
in
2.5 mm (0.098in
in
2 . 6m m ( 0 . 1 0 2
in
2 . 7m m ( 0 . 1 0 6
in
2 . 8m m ( 0 . 1 1 0
in
2 . 9m m ( 0 . 1 1 4
M4RATransmission:
Plaie No.
Part Number
Thicknoss
1
2
22551- PCg- 000

22552-PCg-000
22553-PCg-000
22554-PCg-000
225ss-PCg-000
22556-PCg-000
22557-PCg-000
22558-PCg-000
22559-PCg-000
22s60-PCg-000
22561- PCg- 000
22s62-PCg-000
22563-PCg-000
22574-P4V- 003
22561- P4V- 003
22562 - P4V- O03
22563-P4V-003
22564-P4V-003
2.4mm (0.094in
2.5mm {0.098in
2 . 6m m ( 0 . 1 0 2i n
2 . 7m m { 0 . 1 0 6 I n
2 . 8m m ( 0 . 1 1 0
in
2 . 9m m ( 0 . ' 1 1i 4n
3 . 0m m ( 0 . ' 1 1i 8n
3 . 1m m ( 0 .1 2 2i n
in
3 . 2m m ( 0 . 1 2 6
in
3 . 3m m ( 0 . 1 3 0
2.'l mm (0.082in
2.2mm (0.086in
2.3 mm (0.090in
in
3 . 4m m ( 0 . 1 3 4
in
3 . 5m m ( 0 . 1 3 8
3 . 6m m ( 0 . 1 4 2i n
3 . 7m m ( 0 . 1 4 6i n
3.8 mm (0.150in
CLUTCHEND
PLATE
Part Numbe.
6
7
8
9
10
11
12
'13
14
15
16
17
18
15. After replacingthe clutchend plate,make sure that

the clearanceis within tolerance.
NOTE; lf the thickesiclutch end plate is installed,

but the clearanceis still over the standard,replace
the clutchdiscsand clutchDIates.
CLUTCHEND PLATE
14-133
Differential
lllustratedlndex
SET RING, 80 mm
BOLT
10 x 1.0 mm
lol N.m (10.3 kgt.h,74.5 lbf.ftl
Lett-hand threads
FIiIIAL DRIVENGEAR
Inspectfor excessivewear.
Installin this dlrection.
lnspectlor taulty movement.
DIFFERENTIALCARRIER
Insoectlor cracks.
DRIVE
SPEEDOMETER
GEAR
5x 10mm
SNAP RING
Installin this direcrion.
BALL EEARING
Inspectfor faulty movement.
14-134
BacklashInspection
1.
Placedifferentialassemblyon V-blocksand install

both axles.
BearingReplacement
NOTE: Checkbearingsfor wear and rough rotation.
bearingsare OK. removalis not necessary.
1.
Removebearingsusinga bearingpuller.
BEARINGPULLER
(Commercially
availablel
Checkbacklashof both piniongears.

Siandard(Ncwl:0.05- 0.15mm (0 002- 0.006in)
lf backlashis out of tolerance,replacethe differential carrier.
2.
Installnew bea.ingsusingthe specialtool as shown.
DRIVER40 mm l.O.
07746-OO30100
14-135
Differential
DifferentialCarrierReplacement
1.
Removethe final driven gear from the differential

carner.
Align the hookedend of the snap ring with the pinion shaft as shown,then installthe snap ring in the
differentialcarriergroove.

threads.
SNAP RING
Installin this direclion.
Hooked end
2.
Prythe snap ring off differentialcarrier,then remove

the speedometer
drivegearand 5 x 10 mm roller.
SNAP RING
PINIONSHAFT
SPBING
Installthe final drivengear,then tightenthe boltsto

the specifiedtorque,
TOROUE:101 N.m 110.3kgf.m, 74.5 tbf.ft)
NOTE: The final d.iven gear bolts have left-hand
threads.
3.
Installthe5 x 10 mm rollerin the differentialcarrier.

BOITS
10 x t.0 mm
1Oi N'm 11O.3kgl.m,
74.5 tbf.ttl
Left-hand threads
SPEEDOMETER
DRIVEGEAR
Installin this
direction.
FINAL ORIVEN
GEAR
Installin this
direction.
Frlr
tril
4.
Installthe speedometerdrive gear with its chamfered side facingthe carrier.Align the cutout on the
bore of the speedometerdrive gear with the 5 x lO
mm ro er,
14-136
OIFFERENTIAL
CARRIER
7.
Install a new ball bearing (see page'14-'l3S).
Oil SealRemoval
1,
Removethe differentialassemblv.
2,
Removethe oil sealfrom the transmissionhousing,
Oil SealInstallation/SideClearance
1.
Installa 2.50mm (0.098in) set ring,80 mm in transmissionhousing.

NOTE:Do not installthe oil sealvet.
RING,80 mm
OIL SEAL
Replace.
R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r
housing.
TRANSMISSION
HOUSING
Installthe differentialassemblyinto the torque converterhousingusingthe specialtool as shown.
TOROUE
CONVERTER
HOUSING
TOROUECONVERTER
HOUSING
I n s t a l lt h e t r a n s m i s s i o nh o u s i n ga n d t i g h r e n t h e
bolts(seepage 14-146and 14-147).
(cont'd)
14-137
Differential
Oil Seal Installation/SideClearance(cont'd)
4.
Tap on the transmissionhousingside of the differentialassemblvwith the soecialtool to seatthe differentialassemblyin the torqueconverterhousing.
5.
Measurethe clearancebetweenthe 80 mm set ring

and outer race of the ball bearingin the transmiss i o nh o u s i n g .
STANDARD:
0 - 0.15mm (0 - 0.006inl
DRIVER40 mm LD.
-0030100
TRANSMISSION
HOUSING
6.
lf the clearanceis more than the standard,selecta

new set ring from the table,and insta :
SETRING,80 mm
Part Number
Thickness
90414 689- 000

90415- 689 000
90416-689-000
90417 689- 000
90418-689-000
90419- PH8 000
2.50mm (0.098n )
2 . 6 0m m ( 0 . 1 0 2n )
2 . 7 0m m ( 0 . 1 0 6n )
2 . 8 0m m ( 0 . ' 1 1 0
n)
2 . 9 0m m ( 0 . ' 1 1 4
n)
3 . 0 0m m ( 0 . ' 1 1 8
nl
NOTE:lf the clearancemeasuredin step 5 is standard,it is not necessary

to performsteps7 and 8.
7.
Removethe transmissionhousing.
8.
Replacethe 2.50mm (0.098in) 80 mm set ring wjth

the one of the correctthicknessselectedin step6.
ti{
14-138
9. lnstallthe new oil seal flush with the transmission

housingusing the specialtools as shown.
ORIVER
0?7/tg- 00'10000
PILOT,
26x30mm
07JAD- PH80200
DRIVERATTACHMENT,68 mm
07947- 6110501
1 0 . l n s t a l lt h e n e w o i l s e a lf l u s h w i t h t h e t o r q u ec o n verterhousingusingthe specialtools as shown.
DRIVER
07749- 0010000
14-139
TorqueGonverterHousingBearings
MainshaftBearing/OilSeal Replacement
1.
R e m o v et h e m a i n s h a t tb e a r i n ga n d o i l s e a l u s i n g
the specialtools as shown.
2.
Drivein the new mainshaftbearinguntil it bottoms

in the housingusingthe specialtools as shown.
3/8'-I6 SLIDEHAMMER
( C o m m e r c i a l l ya v a i l a b l e )
DBIVER
07749- 0010000
ATTACHMENT,
62x68mm
077{6 - 0010500
ADJUSTABLEEEARING
- 40 mm
PULLER,25
07736- A01000A
3.
Install the new oil seal flush with the housinq u s rn g

the soecial tools as shown.
ATTACHMENT,
72 x75 tnm
07746- 0010600
l;'.r
fri
14-140
CountershaftBearing Replacement
1.
Removethe countershaftbearingusing the special

tools as shown.
3/81T6SLIDEHAMMER
(Commercially
available)
AOJUSTABLE
BEANING
PULLER,
25-40mm
07736- A01000A
t
2.
A T Fg u i d ep l a t e .
Installthe
3.
D r i v et h e n e w b e a r i n gi n t o t h e h o u s i n gu s i n gt h e
specialtools as shown.
0 - 0.03mm
{0 - 0.001in)
ATF GUIDEPLATE
1+141
Transmission
HousingBearings
Mainshaft/CountershaftBearingsReplacement
1. To removethe mainshaftand countershaftbearings
from the transmissionhousing,expand each snap
ring with snap ring pliers,then push the bearingout
usingthe specialtools and a pressas shown.
Expandeach snap ring with snap ring pliers,insert

t h e n e w b e a r i n gp a r t - w a yi n t o t h e h o u s i n gu s i n g
the specialtools and a press as shown. Installthe
bearingwith the groovefacingoutsidethe housing.
N O T E rD o n o t r e m o v et h e s n a p r i n g s u n l e s si t , s
necessary
to cleanthe groovesin the housing.
NOTE:Coatall parrswith ATF.

Releasethe pliers.then push the bearingdown into
t h e h o u s i n gu n t i l t h er i n gs n a p si n p l a c ea r o u n di t .
PRESS
07749- 00r0000
ATTACHMENT,
62x68mm
07146 -
ATTACHMENT
. Mainshaft Bearir|gRemovaluse:
ATTACHMENT,72 x 75 mm
07745- 0010600
. CountershaftBearing Removal use:
07746- 0010500
MAINSHAFTBEARING
DRIVER
07749- 00r0000
ATTACHMENT
4.
After installingthe bearingverilythe following:

.
.
The snap ring is seatedin the bearinqand housIng grooves.

The ring end gap is correct.
ENOGAP:0-7mm
{0 - 0.28inl
ATTACHMENT
. Mainshaft B6aring Installation use:
077'16- 0010600
. CountershaftBearing Installation use:
ATTACHMENT.62 x 68 mm
07745- 0010500
14-142
SNAPRING
Reverseldler Gear
Inspection/Adjustment
Installation
1.
ParkingBrakeStop
Installthe reverseidler gear.
1.
Set the parkingbrakeleverin the E posrrron.
2.
M e a s u r et h e d i s t a n c eb e t w e e nt h e p a r k i n gb r a k e
pawl shaft and the parkingbrakelever roller pin as
STANDARD:72.9- 73.9 mm (2.87- 2.91 inl
'2:\
Measuring
Installthe reverseidler gear shaft holderand needle

bearinginto the transmissionhousing.then tighten
the bolts.
6 x 1.0mm
12 N.m (1.2kgf.m,
8.7 tbf.ftl
-.
BRAK
PARKING
PAWLSHAFT
lf the measurementis out of tolerance,selecl and

installthe appropriateparkingbrakestop from the
table below.
PARKINGBRAKE
STOP
PARKINGBRAKESTOP
Mark
I
2
3
Part Number
Lr
L2
mm
24537-PAg-003 1 1 . 0 0
(0.433in)
'10.80mm
24538-PAg-003
( 0 . 4 2 5i n )
11 . 0 0m m
(0.433
in)
2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m
( 0 . 4 1 7i n )
10.30mm
(0.406in)
1 0 . 6 5m m
( 0 . 4 1 9i n l
After replacingthe parking brake stop. make sure

the distanceis within tolerance.
14-143
Transmission
Reasembly
NOTE:
. Coatall partswith ATF.
. Replacethe followingpans:
- O-rings
- Lockwashers
- Gaskets
- Mainshaftand countershaftlocknutsand conicalspringwashers
- Sealingwashers
TOROUE:12 N.m (1.2kgf.m,8.7tbf.ft)
6x1.0mm
7 Bolts
ATF FEEDPIPE:A
6x1.0mm
2 Bolts
LOCK-UPVALVE
BOOY
LOCK-UPSEPARATOR
PLATE
ATF FEEO
PIPES:
B
REGULATOR
VALVE
EODY
o r9 l
il
DOWELPINS.2
cooLER RELrEFvALVe -----------E
CONTROLSHAFT
DETENT
ARM SHAFT
DETENT
ARM
ATF STRAINER
SERVODETENT
BASE
li lf: ln
l
6x1.0mm
7 Bohs
Yl l
SERVOBODY
TOROUECONVERTEB
CHECKVALVE
STATORSHAFT
SERVOSEPARATOR
PLATE
O-RING
STOPSHAFT
ATF FEEDPIPE:H
SECONDARY
VALVE
BOOY
i l
6x1.0mm
5 Bolts
MAIN VALVEEODY
ATFPUMP
GEARSHAFT
ATF PUMPDBIVEN
GEAR
MAIN SEPARATOR
PLATE
DOWELPINS,
2
14-144
PINS,2
ATFFEED
PIPES:
\l
SECONDARY
SEPARATOR
PLATE
CONTROL
SHAFT
('98model)
1 . lnstallthe ATF magnetand suctionpipecollarin the

tgrqueconverterhousing.if necessary.
2 . lnstallthe main seoaratorDlateand the two dowel
pins on the torqueconverterhousing.
3 . Installthe ATF pump drive gear, ATF pump driven
gear and ATF pump driven gear shaft on the torque
convenernousrng.
N O T E :I n s t a l lt h e A T F p u m p d r i v e n g e a r w i t h i t s
groovedand chamferedsidefacingdown.
ATF PUMP
GEAR
ATF PUMPDRIVEN
GEARSHAFT
r l a t eo n t h e
8. I n s t a l lt h e s e r v o b o d y a n d s e p a r a t o p
(seven
body
bolts).
secondaryvalve
L lnstall the servo detent base and the ATF strainer
Itwo bolts).
1 0 . Tightenthe five bolts on the main valve body to l2
N.m (1.2kgim, 8.7 lbf.ft).
Make surethe ATF pump drive gear and ATF pump
drivengear shaftmove smoothly.
1 l . It the ATF pump drive gear and ATF pump driven
gear shaft do not move freely,loosenthe live bolts

the valve
on the main valve body. and disassemble
bodies.
Realignthe ATF pumpdrivengearshaftand reassemble the valve bodies,then retightenthe bolts to the
torque.
specified
CAUTION: Failureto slign lhe ATF pump driven
gear shaft correctly will result in a seizedATF pump
drive gear or ATF pump driven gear shaft.
ATF PUMP
DRIVEN
Grooved and chafitered
side faces separalot
plate.
MAIN SEPARATOR
PLATE
Looselyinstallthe main valve body with five bolts.

Makesurethe ATF pump drivegearrotatessmoothly
in the normaloperatingdirectionand the ATF pump
driven gear shaft moves smoothly in the axial and
normaloperatingdirections.
Install the secondaryvalve body, separatorplate
and two dowel pins on the main valvebody.
NOTE: Do not installthe bolts.
7.
Installthe controlshaft in the housingwith the control shaftand manualvalvetogether.

l n s t a l lt h e d e t e n ta r m a n d a r m s h a f t i n t h e m a i n
valve body, then hook the detentarm sprangto the
detentarm.
PLATE
SERVOSEPARATOR
DETENTARM
SHAFT
MANUAL VALVE
DRIVENGEAR
SHAFT
12. Installthe statorshaftand stop shafi

1 3 . lnstallthe bolts and the shaftstop on the secondary
valvebody,then tightenthe bolts (threebolts).
1 4 . lnstallthe torqueconvertercheckvalve,coolerrelief
valveand valvespringsin the regulatorvalvebody,
t h e n i n s t a l lt h e r e g u l a t o vr a l v e b o d y o n t h e m a i n
valvebody (one bolt).
DETENTAFM SPRING
OETENTARM
ATF PUMP
DRIVENGEAR
Installthe lock-upvalvebody on the regulatorvalve

body (sevenbolts).
1 6 . Installthe ATF feed pipes in the main valve body,
the threeATF feed pipesin the secondaryvalveand
the four ATFfeed pipesin the servobody.
(cont'd)
14-145
I
I
Transmission
Reassembly(cont'dl
TRANSMISSION
HANGEB
TRANSMISSIONHOUSING
MOUNTINGBOLTS
1 0x 1 . 2 5m m
44 N.m (4.5 kg{.m,33 lbf.trl
TRANSMISSIONHOUSTNG
MAINSHAFT
SUE.ASSEMBLY
MAINSHAFTSPEED
SENSORWASHER
(D16Y7engine)
COUNTERSHAFT
SUB.ASSEMELY
MAINSHAFT
SPEEDSENSOR
DIFFERENTIAL
ASSEMBLY
TRANSMISSION
HOUSINGGASKET
TOROUECONVERTER
HOUSING
14-146
1 7 . I n s t a l lt h e r e v e r s ei d l e r g e a r a n d t h e g e a r s h a f t
h o l d e r( s e ep a g e1 4 - 1 4 3 ) .
2 1 . Install the needle bearing, countershaft reverse gear
1 8 . Installthe differentialassemblyin the torque convener housrng.
2 2 . Align the spring pin on the control shaft with the
and reverse gear collar on the countershaft.
transmission housing groove by turning the control

shaft.
1 9 . A s s e m b l et h e m a i n s h a f ts u b - a s s e m b l ya n d t h e
c o u n t e r s h a fst u b - a s s e m b l yt ,h e n i n s t a l lt h e m
togetherin the torqueconverterhousing.
SPRINGPIN
CONTROLSHAFT
COUNTERSHAFT
SU8-ASSEMBLY
Installthe two dowel pins and a new gasketon the

torqueconverterhousing.
24. Placethe transmissionhousingon the torque convener nousrng.
20. Turn the shift fork so the large chamferedhole is

facing the fork bolt hole, then install the shift fork
with the reverseselector,and torque the lock bolt.
Sendthe locktab againstthe bolt head.
SHIFTFORK
CAUTION: Make sule that the mainshaft speed

snsor is not installed on the transmission housing
before installingthe transmissionhousing on the
torque converter housing.
25. I n s t a l lt h e t r a n s m i s s i o nh o u s i n gm o u n t i n g b o l t s
a l o n g w i t h t h e t r a n s m i s s i o nh a n g e r .t h e n t i g h t e n
the bolts in two or more steps in the sequenceas
snown.
TOROUE:44 N.m {4.5 kgf.m, 33 lbt.ft,
TRANSMISSION
HANGEB
LOCKWASHER
Replace.
6 x 1 . Om m
14 N.m
(1.4 kgf.m, '10 lbf'ft)
a -&)H@
V
'
-_F
|
"fl:
Large chamfered hole
1+117
Transmission
Reassembly(cont'd)
26. Slip the specialtool onto the mainshaftas shown.
3 1 . I n s t a l lt h e m a i n s h a f t' 1 s tg e a r c o l l a ro n t h e m a i n ,
shaft.
MAINSHAFTHOLOER
- PF50101
32. Wrap the shaft splineswith tape to preventthe Orings,then installnew O-ringson the mainshaft.
33. Assemblethe thrust washer.thrust needlebearing,

n e e d l eb e a r i n g a
, nd mainshaf1
t s tg e a r i n t h e 1 s t
clutchassembly,then installthemon the mainshaft.
34. lnstallnew conicalspring washersand locknutson
eachshaft.
CAUTION: Install ihe conical spring washers in lhe
dirsction shown.
2 7 . lnstallthe parkingbrakeleveron the controlshaft.
MAINSHAFT
LOCKNUT
Left-hand
threads
28. Assemblethe one-wayclutchand the parkinggear

with the countershaft1stgear{seepage 14 '|.23).
29. Installthe countershaft1st gear collar,needlebear
i n g , a n d t h e c o u n t e r s h a f t1 s t g e a r / p a r k i n gg e a r
assemblyon the countershaft.
lSTCLUTCH PARKING
ASSEMBLY GEAR
PAWL
COUNTERSHAFT
LOCKNUT
Left handrhreads.
CONICAL
SPRING
WASHEBS
Installinthisdirection35. Tightenthe locknutsto the specifiedtorque.
30. Installthe parking brake pawl shaft, spring, pawl,

and pawlstopon the transmission
h o u s i n g t, h e n
e n g a g et h e p a r k i n gb r a k ep a w l w i t h t h e p a r k i n g
aear.
14-148
NOTE:
. D o n o t u s e a n i m p a c t w r e n c h .A l w a y s u s e a
torquewrenchto tightenthe locknut,
. Mainshaftand countershaftlocknuts have lefthandthreads.
TOROUE:
MAINSHAFT
78 N.m {8.0 kgt.m, 58 lbl.ft}
COUNTERSHAFT103 N.m {10.5kgt'm, 75.9 lbt ft)
36. Removethe special tool from mainshaft,then stske

eachlocknutusinga 3,5 mm punchas shown.
40. Installthe right side cover with two dowel pins and
I new gasket(thirteenbolts).
TOROUE:12 N'm 11.2kgt.m, 8.7 lbt'ft)
RIGHT
SIDECOVER
3 7 . Set the parkingbrakelever in the E position,then
verifythat the parkingbrakepawl engagesthe parking gear.
lf the pawl does not engagetully, checkthe parking
brakepawl stop clearance(seepage 14-143).
4 1 . Insrallrhe ATF cooler lineswith new sealingwashers.

TOROUE:28 N'm (2.9 kgt.m, 21 lbf.ft)
Installthe ATF dipstick.
Tightenthe lockbolt and bendthe locktab.
6 r 1 . Om m
1 4 ' m 1 1 . 4k g t . m , 10 lbt'frl
PAR(ING BRAKE PAWL
14-149
TorqueConverter/DrivePlate
\
6 x 1 . Om m
12 r 1.0 mm
74 N.m 17.5 kgt.m, 54 lbl.ftl
Torque in a crisscross Dattern,
E PLATE
lirl
14-150
Transmission
Installation
L
Flushthe ATF cooler as describedon page 14-155

and 14-156.
2,
Installthe torque converterassemblysecurelywith

a new O-ringon the mainshaft.
6.
lnstallthe transmissionmount bracket.
45 N.m 14.5kgf.m,
STARTERMOTOR
1a mm DOWELPIN
I n s t a l lt h e s t a r t e rm o t o r o n t h e t o r q u e c o n v e r t e r
housing,then installthe tlvo 14 mm dowel pins in
the torqueconverterhousing.
Placethe transmissionon a iack,and raiseit to the
engineassemblylevel.
5.
Aftach the transmissionto the engine,then install

two transmissionhousingmounting bolts and two
rearenginemountingbolts.
REARENGINE
MOUNNNGBOLTS
14x 1.5mm
TRANSMISSIONHOUSING
MOUNTINGBOLTS
12 x 1,25 mm
47 tbf.ftl
64 N.m 16.5
MOUNT
12 x'l.25 mm
7il N.m (7.5kgl.m,
54 tbf.ftt
7.
lnstallthe remainingtransmissionhousingmounting boltsand remainingrearenginemountingbolt.
WASHEB
REARENGINE
MOUNTINGBOLT
14 x 1.5rnm
8i] N.m 18.5kgt'm,
61 rbf.n)
Replace.
WASHER
83 N.m 18.5kg 'm, G1lbtft)

Replace.
HOUSING
MOUNTINGBOLTS
12 x 1.25mm
64 N.m (6.5kgf.m, 47 lbf.ftl
ENGINE
MOUNTING
BRACKET
8.
Remove the transmission iack.
{cont'd)
JACK
14-151
Transmission
9. Attachthe torque converterto the drive plate with
eight drive plateboltsand torqueas follows:
Rotatethe crankshaftpulleyas necessary
to tighten
the bolts to 1/2 of the specifiedtorque,then to the
finaltorque,in a crisscrosspattern.
After tighteningthe last bolt, checkthat the crankshaft rotatesfreely.
14. Installthe control lever with a new lock washerto

the controlshaft,then installthe shiftcablecover.
CAUTION: Tako care not to bend the shift cable.
SHIFTCABLE
TOROUE:12 N.m (1.2 kgf'm, 8.7 lbf.ftl

10 x 1.25mm
44 N.m 14.5kgl.m, 33 lbf.ft)
LOCKWASHER
Replace.
6x1.0mm
12 N.m {'1.2kg{.m,
8.7 tbf.ftl
8 x 1.25mm
22 N.m
{2.2 ks{.m, 16lbf.ftl
SHIFTCABLE
COVER 6x 1.0mm
1{ N.m11.lkgf.m,
10tbtftt
8 x 1.25mm
24 N.m {2.4kgf.m,
17 tbf.ftt
CONVERTER
15. Installthe exhaustpipeA.
COVER
1 0 . I n s t a l lt h e t o r q u e c o n v e r t e cr o v e r a n d t h e e n g i n e
stiffener.
1 1 .Tightenthe crankshaftpulley bolt, if necessary(see
section6).
1 2 . Connectthe ATFcoolerhosesto the ATFcoolerlines
(seepage14-160).
NOTE:D16Y8engineis shown;D16ft engineis similar.
ATF COOLER
LINE
J
Replace.
,4
1 0 x 1 . 2 5m m
"
44 N.m {4.5kgt.m,
33 lbf.f0
RIGHTFRONT
12 x 1.25mm
MOUNT/BRACKET64 N.m {6.5 kgf.m,
47 lbI.ft)
13. Installtherightfront mounvbracket.
14-152
GASKET
Replace.
NUT
SELF.LOCKING
Reolace.
8 x 1.25mm
22 N.m (2.2kgt.m. 16lbf.ft)
NUT
SELF.LOCKING
Replace.
10 x 1.25 mm
5,1N.m 15.5kgf.m,
40 rbf.ftl
NUT
ReDlace.
8 x 1.25mm
16 N.m ('1.6kgf.m,
12 tbf.ftt
16. lnstalla new set ring on the end of eachdriveshaft.

17. Installtheright and left driveshafts(seesection16).
CAUTION:While inslalling the driveshaftsin the
difforGntial,be sure not to allow dust and olher foroign particlos to enter into the transmission.
NOTE:
. Cleanthe areaswherethe driveshaftscontactthe
transmission(differential)thoroughly with solv e n t o r c a r b u r e t o cr l e a n e r a
, nd dry with comprssedatr.
. Turn the right and left steeringknucklefully outward, and slide eachdriveshaftinto the differential until you teel its set ring clip engagethe side
gear.
18. Installthe damperfork,then installthe right and left
ball jointsto the eachlower arm with the castlenuts
and new cotteroins.
20, Connectthe mainshaitspeedsensor,the linearsolenoid and the shiftcontrolsolenoidconnectors.
SHIFTCONTROL
SOLENOID
CONNECTOR
LINEAR
SOLENOIO
CoNNEcToR
5x1.0mm
12Nm(1.2kgf.m,
8.7 rbf.ft)
DAMPERPINCHBOLT
10 x 1.25mm
a3 N.m {4.4 kd.m,
32 tbnft)
MAINSHAFT
SPEEDSENSOR
CONNECTOR
CONNECTOR
ERACKET
2 ' t . Connectthe countershaftspeedsensorand the vehicle speedsensor(VSS)connectors.

VEHICLE
SPEED
SENSORCONNECTOR
VSS
\
SELF-LOCKING
NUT
12 x 1,25mm
6ir N.m (6.5 kgf.m, il7 lbf.ftl
Replace.
COTTER
CASTLENUT
Replace.
1 2\ 1 . 2 5n n
49 - 59 N.m
(5.0- 6.0 kgf.m, 36 - $ lbtftl
19. Install
lnstall the
the splash
solash shield,
shi
SHIELD
6r1.0mm
12 N.m (1.2kgt'm,8.7 lbf'ft)
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
(cont'd)
14-153
Transmission
22. Connectthe lock-upcontrolsolenoidconnector,and
installthe transmissiongroundcable.
24. Installtheintakeair duct.

D16Y7engine:
Installtheint6keair duct and the resonator.
6x1.0mm
12N.m{1.2kgtm,8.7lbtftl
D15Y8engine:
Installthe intakeair duct and the air cleanerhousing assembly.
Refillthe transmissionwith ATF (seepage 14-86).
Connectthe positive(+) cablefirst. then the negative {-) cableto the battery.
27. Checkthe ignitiontiming {seesection23).
Stan the engine.Setthe parkingbrake,and shiftthe
transmissionthrough all gears.three times. Check
the shift cableadjustment{seepage14-158).
Checkthe front wheelalignment{seesection181.
30. L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
Connectthe startercableson the startermotor, and
installthe cableholder.
cooling fan comes on) with the transmissionin E

or E position,then turn it off and checkthe fluid
levet.
3 1 . Roadtest as describedon pages14-82thru 14-84.
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 rc a b l et e r m i n a l ,
makesurethat the crimpedside of the ring terminal
is facingout (seesection23),
6xl.0mm
12 N.m 11.2kgtm,8.7 lbt.ft)
{0.9 kgf.m.7 lbI.ft}
STARTERCAALE
lllri
lltl
14-154
CoolerFlushing
To prevent iniury to lace and eyes, always
@
wear safety glassesor a face shield when using the
transmissionllusher.
7. With the water and air valves off, aftach the water and
air suppliesto the tlusher. (Hot water if available.)
NOTE:This orocedureshouldbe oerformedbetorereinstallingthe transmission.

1 . Checktool and hoses for wear and cracksbefore
using.lf wear or cracksare found,replacethe hoses
beforeusing,
Usingthe measuringcup,fill the tankwith 21 ounces
( a p p r o x i m a t e l2y/ 3 I u l l l o t b i o d e g r a d a b lfel u s h i n g
fluid {J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
container.
3 . Securethe flusherfiller cap,and pressurizethe tank

with compressedair to between550- 829 kpa {5,68.45kg?cm' ,80 - 120psi).
NOTE:The air line shouldbe equippedwith a water
trap to ensurea dry air system.
4.
H a n gt h e t o o l u n d e rt h e v e h i c l e .
5.
Attach the tank's dischargehose to the return line

of the transmissioncoolerusinga clamp.
8 . Turn on the flusherwater valve so water will flow

throughthe coolerfor 10 seconds.
NOTE:lf water does not flow throughthe cooler,it
is completelyplugged,cannotbe flushed,and must
be replaced.
Depressthe triggerto mix the flushingfluid into the
waterflow. Usethe wire clipto holdthe triggerdown.
Connectthe drain hoseto the inlet line on the transm i s s i o nc o o l e ru s i n ga c l a m p .
1 0 . W h i l ef l u s h i n gw i t h t h e w a t e ra n d f l u s h i n gf l u i df o r
two minutes,turn the air valve on for five seconds
every 15- 20 secondsto createa surgingaction.
AIR PRESSURE:
MAX 845 kpa (8.45kgf/cm,,120psi)
IMPORTANT:
Securelyclampthe oppositeend ofthe drainhoseto a
bucketor floor drain.
1 1 . Turn the water valve off. Releasethe trigger,then
reversethe hosesto the coolerso you can flush in

the oppositedirection.Repeatsteps8 through 10.
1 2 . Releasethe trigger,and rinsethe coolerwith water
o n l yf o r o n e m i n u t e .
Turnthe watervalveoff,andturn offthewatersupply.
1 4 . Turn the air valveon to dry the systemout with air
for two full minutesor until no moistureis visible

leavingthe drain hose.
CAUTION: Residualmoisture in the cooler or pipes
can damagethe transmission.
{r water
BUCKET
TRANSMISSIONCOOLER
FLUSHER
Kent-MooreJ38405-A
or oquivalent
Removethe flusherfrom the coolerline.Attachthe

drain hoseto a container.
I n s t a l tl h e t r a n s m i s s i o na,n d l e a v et h e d r a i n h o s e
attachedto the coolerllne.
(cont'dI
14-155
Transmission
CoolerFlushing(cont'd)
1 1 . Makesurethe transmissionis in the E position.
F i l lt h e t r a n s m i s s i ow
n i t h A T F ,a n d r u n t h e e n g i n e
f o r 3 0 s e c o n d so r u n t i la p p r o x i m a t e0l y. 9 5I ( 1 . 0U S
q t . ,0 . 8l m p q t . ) i sd i s c h a r g e d .
\,
TOOL MAINTENANCE
1.
Emptyand rinseaftereachuse.Fillthecanwith water

and pressurizethe can. Flushthe dischargeline to
ensurethat the unit is clean.
1 8 . B e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r
r e t u r nh o s et o t h e t r a n s m i s s i o(ns e ep a g e' 1 4 ' 1 6 0 ) .
2.
'19. Refillthe transmission

with ATF to the proper level
( s e ep a g e1 4 - 8 6 ) .
lf dischargeliquiddoes not foam,the orificemay be

blocked.
3.
To clean,disconnectthe plumbingfrom the tank at

t h e l a r g ec o u p l i n gn u t .
FILLERCAP
FILTER
\
\
- 0 - - \D
II
COUPLING
I{UT
-sq
I
\
ORIFICE
O-RING
14-156
4.
Removethe in-linefilterfrom the dischargeside and

cleanit necessary.
5.
The fluid orificeis locatedbehindthe filter.

Clean it with the pick stored in the bottom of the
tankhandleo
, r b l o w i t c l e a nw i t h a i r . S e c u r e l y
reassemble
all parts.
Shift Gable
f!!@
Makesure lifts are placedproperly(see
Removethe shift cableholder.
section11.
1.
Removethe front console(seesection20).
2.
Shift to N position,then removethe lock pin from

the adjuster.
5.
Removethe shift cablecover.
6.
R e m o v et h e c o n t r o l l e v e r f r o m t h e c o n t r o ls h a f t ,
then removethe shift cable.Takecare not to bend
the cablewhen removing/installing
it.
8 x 1.25mm
22 N.m
12.2kgt.m,
16 tbf.ftl
SHIFTCABLE
COVER
CONTROLLEVER
SHIFTCABLE
7 N.m
SHIFTCABLEHOLDER
SHIFTCABLE
LOCKWASHER
Replace.
6x1.0mm
12 N.m
{1.2kgf.m,
8.7 tbt.ftl
6x1.0mm
14 N.m
(1.4kgf.m.10lbtft)
7.
Install the shift cable in the reverse order of removal.
8.
Check the cable adjustment on reassembly (see

page 14-158).
10.7ksf.m.s lbt.ft)
3.
Removethe shift cablebracket.
SHIFTCABLE
BRACKET
6x1.0mm
9.8N.m
11.0kgl.m.7.2lbf.ft)
14-157
Shift Cable
Adjustment
!@
section1).
Make sure litts are placed properly (see
1.
2.
Shift to E position,then removethe lock pin from

the adiuster.
3 . C h e c kt h a t t h e h o l e i n t h e a d j u s t e ri s p e r f e c t l y
a l i g n e dw i t h t h e h o l e i n t h e s h i f t c a b l e .T h e r ea r e
two holes in the adjuster.They are positioned90'
a p a r tt o a l l o w c a b l ea d j u s t m e n itn 1 / 4 t u r n i n c . e ments.
Cable
Too Shorl
Cable
Too Long
Exact
Alignment
4 . lf the hole is not perfectlyaligned,loosenthe lock-
nul on the adjusterand adjustas required.

5 . Tightenthe locknutto 7 N.m (0.7kgf.m,5 lbf.ft).
6 . I n s t a l tl h e l o c k p i n o n t h e a d j u s t e rl.f y o u f e e l t h e
lock pin binding as you reinstallit, the cable is still
out of adjustmentand must be readjusted.
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r
securety,
7 N m 1 0 . kgf.m,
7
5lbtft)
8 . Move the shift leverto eachgear,and verifythat the

shift positionindicatorfollows the automatictransaxle gear positionswitch.
S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
gears.It any gear does not work properly,refer to
t r o u b l e s h o o t i n( sge ep a g e1 4 - 7 8t h r u 1 4 - 8 1 ) .
1 0 . Insertthe ignition key into the key cylinderon the
Aft gear positionindicatorpanel,and verifythat the
shift lockleveris released.
Ir
t'l
14-158
Shift Lever
PUSHKNOBSPRING
LEVERKNOB
SCREW
N.m {0,3 kgnm. 2 lbI.ft)
Applynon hardeningthreadlocksealant.
SILICONEGREASE
SCREW
3 N.m (0.3kgf.m, 2 lbl.ft)
GEANPOSITIONINDICATORPANEL
COVER
BUSHING
SHIFTINDICATORLAMP
-Gt
LEVER
SHIFTLOCK
SILICONEGREASE
SCREW
3 N.m {0.3
LEVERASSEMBLY
2/'o"*"'
,@__------
5x1.0mm
9.8 N.m 11.0kgf.m,
7.2 tbt.fr)
Gar
\oo.,rar.*
A/T GEARPOSITION
PI-ATE
A/T GEARPOSITIONSWITCH
SHIFTI-EVERERACKETBASE
SHIFTLEVER
BASECOLLAR
6x1.0mm
9.8 N.m (1.0kgl.m,7.2lbf.h)
14-159
Shift Indicator Panel
ATFCoolerHoses
Adjustment
Connection
1 . C h e c kt h a t t h e i n d e x m a r k o n t h e i n d i c a t o a
r ligns
with the E mark on the shift indicatorpanelwhen
t h e t r a n s m i s s i oi ns i n N E U T R A L .
l.
Connectthe ATFcoolerhosesto the ATFcoolerlines

and ATF cooler,and securethem with the clips as
shown.
INDEXMARK
TRANSMISSION
3 N'm (0.3 kgf.m,2lbf.ft)
CLIP
PANEL
lf not aligned.removethe front console(seesection

201.
Removethe shift indicatorpanel mounting screws
and adjustby movingthe panel.
NOTE:Wheneverthe shiftindicatorpanelis removed.
reinstall
the panelas described
above.
f "
14-160
-
ATF COOLER
HosEs
aoo'itoa
2-4 mm
1 0 . 1 - 0 . 2i n )
(CVT)
VariableTransmission
Continuously
. . . . . . . . . . . .. . . 1 4 - 1 6 2
S p e c i aTl o o l s
'14-163
.....................
Description
Brake/Planetary
Clutches/Reverse
. . . . . . . . . .1 4 - 1 6 6
Gear/Pulleys
. . . . . . . . . . . . . .1
. .4. .1. 6
.8
P o w e rF l o w
l y s t e m. . . . . . . . . . . . . . . . . . . . 1. .4. 1 7 1
E l e c t r o n iCco n l r oS
...... 14-173
H y d r a u f iC
control
......... 14-177
H y d r a u l iF
cfow
P a r k i nBg r a k eM e c h a n i s .m. . . . . . . . . . . . .... . . .1 4 ' 1 8 7
ElectricalSystem
C o m p o n e nLt o c a t i o n s , . . . . . . . . . . . . . . , . . . . . ... . . .1. .4. .-.' .t .8.9.
..... 14-190
t iagram
T C MC i r c u iD
Terminal
Voltage/
TCM
M e a s u r i n g C o n d i t i o.n. s. . . . . . . . . . . . . . . . . . . . . . 1. .4. .-.' .1 9 2
....... . ... . . .. ..... . 14 194
Procedures
Troubleshooting
Chart
. . . . . . . . .1.4 - 1 9 8
Electrica
Sly s t e m
Troubleshooting
Electrical
. .- 2 0 0
T r o u b l e s h o o t i nFgl o w c h a r t.s. . . . . . . . . . . . . . . . .1. 4
Solenoid
LinearSolenoids/lnhibitor
........14-223
T e s t. . . . . . . . . . . . . . . . . . . . . . . . .
Gear
Pulley/Secondary
DrivePulley/Driven
ShaftSpeedSensors
'14'224
......
..........
Replacement
StartClutchControl
StartClurchCalibrationProcedure........... 14-225
HydraulicSystem
Chart
..... . .14'226
HydraulicSystem
. . . . . . . . . . . . . . . . . . . .1. 4
. .-.2. .2. .4
R o a dT e s t
StallSpeed
........14'230
T e s t. . . . . . . . . . . . . . . . . . . . . . . . .
FluidLevel
.. ..14'231
Checking/Changing
............14-232
P r e s s u rTee s t i n g
LowerValveBodyAssembly
. . . . . . . . . ... . 1 4 ' 2 3 4
Replacement
ATF Filter
R e m o v a l / l n s t a l l a t i o n . . . . . . . . . . . . . . ...............1. 4
. -235
Transmission
Transmission
........14-236
R e m o v a.t. . . . . . . . . . . . . . . .
lllustratedIndex
ValveBody
Transmission/Lower
. . . . . . . . . . . . .1. 4 ' 2 4 0
Assembly
Housing/
Transmission
F l y w h e e l H o u s i n.g. . . . . . . . . . . . . . . . . .....,.,.... 1 4 - 2 4 2
RightSide Cover/
l n t e r m e d i a tHeo u s i n 9. . . . . . . . . . . . . . . . . . . . . .1. 4. .-.2 4 4
TransmissionHousing/
LowerValveBodyAssemblY
.....'14-246
R e m o v a. l. . . . . . . . . . . . . .
Housing
TransmissionHousing/Flywheel
........14-244
R e m o v a.l. . . . . . . . . . . . . . . .
Housing
RightSideCover/lntermediate
........14-250
R e m o v a.l. . . . . . . . . . . . . . . .
M a n u aV
l a l v eB o d y
....... 14'252
ForwardClutch
. .5. .3. . . . . .
l l l u s t r a t eldn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .4. -. 2
. . . . . . . . . . . . .1 4 - 2 5 4
Disassembly
. . . . . . . . .... . . . . 1 4 ' 2 5 6
Reassembly
SecondaryGearShaft
25 x 35 mm ThrustShim Selection. . ..... . . 14 260
Differential
l ndd e x. . . . . . . . . . . . . . . . . . . . . . . . . . .1 4 - 2 6 1
lflustrate
. .,..14-261
BacklashInspection
B e a r i n gR e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . . . ..... . .1. .4. '.2. 6 2
r e p l a c e m e n. .t. . . . . . . . . . .1. '4 - 2 6 2
D i f f e r e n t iC
a la r r i eR
14-263
...........
Oil SealRemoval
...14-263
O i l S e a ll n s t a l l a t i o n / S iCdlee a r a n c .e.
F l y w h e eHl o u s i n gI n p u tS h a f tO i l S e a l
. . . . . . . . . . .1 4 - 2 6 5
Replacement
T r a n s m i s s i oHno u s i n gB e a r i n g s
DrivenPulleyShaftBearing
.......
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4. .-.2. .6. 6
SecondaryGearShaftBearing
. . . . . . . .. 1 4 - 2 6 1
Replacement
F l y w h e eHl o u s i n gB e a r i n g
SecondaryGearShaftBearing
. .7
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . . ......... .1.4. .- .2. 6
R i n gG e a rB e a r i n g
. . . . . . . . . . . . .1. 4 - 2 6 8
Replacement
ControlShaftAssembly
....14-268
Transmission
. . . . . . .. . . . . . 1 4 - 2 1 0
Reassembly
F l y w h e e l / D r iP
v el a t e. . . . . . . . . . . . . . . . . . . . . . ...' . .........1.4 - 2 7 9
Transmission
. . . . . . . . . . . . . . .1. .4. -. .2. 8 0
lnstattaton
. . . . . . . . . .1 4 - 2 4 4
CooleF
r lushing
Shift Cable
.'.,.14-246
.
.
.
.
.
..
. ... 14-2aj
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
:.
.
...:
Adjustment .
. . . . . . . . . . . . . . . . . . 1. .4. .-.2. .8 8
s h i f tL e v e r
Shift IndicatorPanel
..............1
. .4 - 2 8 9
Adjustment
ATFCooler/Hoses
........14-289
..............
lnstallation
SpecialTools
\
Ref. No.
Tool Number
o
o
(D
07GAE- PG40200
07JAD- PH80200
07LAE- PX40'100
07PM- 0010100
07sAz - 0010004
07TAE- P4V0110
07TAE- P4V0120
07TAE- P4V0130
OTMAJ_ PY4OIlA
07MAJ- PY40120
07406- 0020400
07406- 0070300
07736- A010004
0 7 7 4 6- 0 0 1 0 1 0 0
07746- 0010500
07746- 0010600
07746- 0030100
07749- 0010000
ClutchSpringCompressorBoltAssembly
Pilot,26 x 30 mm
ClutchSpringCompressorAttachment
SCSServiceConnector
BackprobeSet
ReverseBrakeSpringCompressor
Start ClutchRemover
Start ClutchInstaller
A/T Oil PressureHose,2210mm
A,rIOil PressureHose.Adapter
A,/TOil PressureGaugeSet Wpanel
A,/TLow PressureGaugew/panel
AdjustableBearingPuller,25 - 40 mm
Attachment,32x 35 mm
Aftachment,62 x 68 mm
Driver40 mm l.D.
Driver
@
@
07947- 611050't
07941 - 6340201
DriverAttachment,68 mm
DriverAttachment,58 x 72
@
p,
o
o
6r
@
@
@
@-
(D
@
@
@
(hy
Description
,l
1
1
1
2
'l
1
1
4
1
1
1
I
1
1
1
'1
I
I
PageReferenco
14-254,257
14-254,25'l
14-195,225
14-196,228
14-251,271
14-249
14-274,275
14-232
14-232
14-232
14-232
14-261
14-265,268
14-267
14-266,261
14-262,263
't4-265,266,
267,
14-265
14-265
*Must be usedwith commercially-available

3/8" - 16 slidehammer.
E.!rnt!!---
\ l
g
l,
@
fi
14-162
@ @ @
(9
\
@)
Description
The ContinuouslyVariableTransmission(CVT)is a electronically

controlledautomatictransmissionwith drive and driven
pulleys,and a steelbelt.The CVTprovidesnon stagespeedsforwardand one reverse.The entireunit is positionedin line
w i t ht h e e n g i n e .
Transmission
Aroundthe outsideof the flywheelis a ring gearwhich mesheswith the staner pinionwhen the engineis being staned.
The transmissionhasfour parallelshafts:the input shaft,the drive pulleyshaft,the drivenpulleyshaft and the secondary
gearshaft.The input shaft is in linewith the enginecrankshaft.
The drive pulleyshaftand the drivenpulleyshaftconsistof
movableand fixedface pulleys.Eoth pulleysare linkedby the steelbelt.
The input shaft includesthe sun gear.The drive pulleyshaft includesthe torwardclutchwhich mountsthe carrierassembly on the forwardclutchdrum.The carrierassemblyincludesthe piniongearswhich meshwith the sun gear and the ring
gear.The ring gear hasa hub mountedreversebrakedisc.
The driven pulleyshaft includesthe startclutchand the secondarydrive gear whjch is integralwith the parkinggear.The
secondarygear shaft is positionedbetweenthe secondarydrive gear and the final drivengear.The secondarygear shaft
includesthe secondarydriven gear which servesto changethe rotationdirection,becausethe drive pulleyshaft and the
d r i v e np u l l e ys h a f t r o t a t et h e s a m e d i r e c t i o nW
. h e n c e r t a i nc o m b i n a t i o n os f p l a n e t a r yg e a r si n t h e t r a n s m i s s i o a
nre
engagedby the clutchesand the reversebrake,power is transmittedfrom the drive pulleyshaftto the driven pulleyshaft
to provideE, E, d, and E.
ElectronicControl
The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three linearsolenoids,and a
inhibitorsolenoid.Shjftingis electronically
controlledunderall conditions.
The TCM is locatedbelowthe dashboard,behindthe kickoanelon the driver'sside.
HvdraulicControl
The lower valve body assemblyincludesthe main valve body,the PressureLow (PL)regulatorvalve body,the shift valve
body, the start clutch control valve body, and the secondaryvalve body. They are positionedon the lower pan of the
t r a n s m i s s i ohno u s i n g .
The main valvebody containsthe PressureHigh (PH)controlvalve,the lubricationvalveand the pitot regulatorvalve.
The secondaryvalve body containsthe PH regulatorvalve,the clutch reducingvalve,the start clutchvalve accumulator
and the shift inhibitorvalve.The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrol valve
which is joined with the PH-PLcontrol linearsolenoid.The inhibitorsolenoidvalve is bolted on the PL regulatorvalve
DOOy.
T h e s h i f t v a l v eb o d y c o n t a i n st h e s h i f t v a l v ea n d t h e s h i f t c o n t r o lv a l v e ,w h i c h i s j o i n e dw i t h t h e s h i f t c o n t r o ll i n e a r
solenoid.The stan clutchcontrolvalve body containsthe start clutchcontrolvalve,which is joined with the start clutch
controllinearsolenoid.The linearsolenoidsand the inhibitorsolenoidare controlledby the TCM.The manualvalvebody
which containsthe manualvalveand the reverseinhibitorvalve,is boltedon the intermediatehousing.
The ATF pump assemblyis locatedon the transmissionhousing,and it is linkedwith the input shaft by the sprocketsand
the sprocketchain.The pulleysand the clutchreceivefluid from their respective
Ieed pipes,and the reversebrakereceives
f l u i df r o m i n t e r n ahl y d r a u l icci r c u i t .
Shift ControlMechanism
I n p u tf r o m v a r i o u ss e n s o r sl o c a t e dt h r o u g h o u t h e v e h i c l ed e t e r m i n e sw h i c h l i n e a rs o l e n o i dt h e T C M w i l l a c t i v a t e .
Activatingthe shift control linearsolenoidchangesthe shift controlvalve pressure,causingthe shift valveto move.This
pressurizes
the drive pulley pressureto the drive pulleyand the driven pulley pressureto the driven pulleyand changes
their effectivepulleyratio.Activatingthe startclutchcontrollinearsolenoidmovesthe startclutchcontrolvalve.The start
clutchcontrolvalveuncoversthe port, providingpressureto the startclutchto engageit.
(cont'd)
14-163
I
Description
(cont'd)
Gear Selction
The shift leverhassix POSitiONS:
E PARK,F] REVERSE,
ANdE LOW.
E NEUTRAL,
E DRIVE,E SECOND,
Position
Description
E PARK
Frontwheelslockedjparkingbrakepawl engagedwith the parkinggearon the drivenpulleyshait.

The startclutchand the forwardclutchreleased.
E REVERSE
Reverse;reversebrakeengaged.
E NEUTRAL
Neutral;the startclutchand the forwardclutchreleased.
{d DRrvE
Generaldriving;the transmissionautomaticallyadjuststo keepthe engineat the bestspeedfor

drivingconditions.
E] SECOND
For rapidacceleration
at highwayspeeds;the transmissionshiftsinto a lower rangeof ratiosfor
betteracceleration
and increasedenginebraking.
E LoW
For enginebrakingand powerfor climbing;the transmissionshiftsinto the lowestrangeot the

rataos.
Staningis possibleonly in @ and N positjonsrhroughthe useof a slide-type,neutral-safety

switch.
Automatic Transaxle{A/T) Gear Position Indicator
The A/T gear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down
at the console.
14-164
L )/
BING GEAR
FLYWHEEL
STEELBELT
STARTCLUTCH
INPUTSHAFT
DRIVEPULLEY
FORWARDCLUTCH
REVERSE
BRAKE
ARY GEARSET
ATF FILTER
14-165
Description
Clutches/Reverse
Brake/Planetary
Gear/Pulleys
Clutchs/ReverseBrake
T h e C V T u s e st h e h y d r a u l i c a l l y - a c t u a tcel u
d t c h e sa n d b r a k et o e n g a g eo r d i s e n g a g et h e t r a n s m i s s i o n
g e a r s .W h e n
hydraulicpressureis introducedinto the clutchdrum and the reversebrakepistoncavity,the clutchpistonand the reverse
brakepiston move.This pressesthe frictiondiscsand the steel platestogether,lockingthem so they don,t slip. power is
t h e nt r a n s m i t t e d
t h r o u g ht h e e n g a g e dc l u t c hp a c kt o i t s h u b - m o u n t e gd e a r ,a n d t h r o u g he n g a g e dr i n g g e a rt o p i n i o n
gears.
Likewise,when the hydraulicpressureis bledfrom the clutchpackand the reversebrakepistoncavity,the prstonreteases
the frictiondiscsand the steelplates,and they are free to slidepast each.This allowsthe gearto spin independently
on its
shaft,transmittingno power.
Start Clutch
The stan clutch,which js locatedat the end of the drivenpulleyshaft,engages/disengages
the secondarydrive gear.
The stan clutchis suppliedhydraulicpressureby its ATFfeed pipeswithin the drivenpullevshaft.
Forward Clutch
The forwardclutch,which is locatedat the end of the drive pulleyshaft,engages/disengages
the sun gear.
The forwardclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the drive pullevshaft.
ReveFe Brake
The reversebrake,which is locatedinsidethe intermediatehousingaroundthe ring gear,locksthe ring gear in
@ position The reversebrakediscsare mountedto the ring gear and the reversebrakeplatesare mountedto the intermediate
housing.The reversebrakeis suppliedhydraulicpressureby a circuitconnectedto the internalhydrauliccircuit.
PlanetaryGear
The planetarygearconsistsof a sun gear,a carrierassembly,and a ring gear.The sun gear is connectedto the Inputshaft
with splines The pinion gearsare mountedto the carrierwhich is mountedto the forward clutch drum. The sun gear
inputsthe enginepower via the input shaftto the planetarygear,and the carrieroutputsthe enginepower.The ring gear
is only usedfor switchingthe rotationdirectionof the pullevshafts.
In @, $, and E positions(forwardrange),the pinion gears don't rotate and revolvewith the sun gear, so the carrier
rotates ln S position(reverserange),the reversebrakelocksthe ring gear and the sun gear drivesthe prntongearsto
rotate.The pinion gearsrotateand revolvein the oppositedirectionfrom the rotationdirectlonof the sun gear,and the
carrierrotateswith piniongear revolution.
Pulleys
Eachpulley consistsof a movabletace and a fixed face, and the effectivepulley ratio changeswith enginespeed.The
drive pulleyand the drivenpulleyare linkedby the steelbelt.
To achievea low pulley ratio, high hydraulicpressureworks on the movableface of the driven pulley and reducesthe
effectivediameterot the drive pulley,and a lower hydraulicpressureworks on the movableface of the drive pulleyto
eliminatethe steelbelt slippage.To achievea high pulleyratio,high hydraulicpressureworks on the movableface of the
drive pulleyand reducesthe effectivediameterof the drivenpulley,and a lower hydraulicpressureworkson the movable
faceof the drivenpulleyto eliminatethe steelbelt slippage.
14-166
ATF PUMP
DRIVENSPROCKET
ATFPUMP
DRIVEPULLEY
RING GEAR
REVERSE
BRAKE
PISTON
FORWARDCLUTCH
REVERSEBRAKE
CARRIEB
FLYWHEEL
RINGGEAR
DRIVEPLATE
PLANETARY
PINIONGEARS
INPUTSHAFT
ATFPUMP
DRIVECHAIN
ATF PUMP
DRIVESPROCKET
DRIVENPULLEY
SHAFT
STARTCLUTCH
FINALDRIVEGEAR
SECONDAFYGEAR
SHAFT
a'-
ORIVENPULLEY
STEELEELT
ORIVEGEAR
SECONDARY
PARKINGGEAR
14-167
Description
PowerFlow
E Position
. StartClutch:released
. ForwardClutch:released
a ReverseBraketreleased
Hydraulicpressureis not appliedto the startclutch,forwardclutch,and the reversebrake.Poweris not transmatted
to the
secondarydrive gear.
E Position
.
.
.
Stan Clutch:released
ForwardClutch:released
ReverseBrake:released
Hydraulicpressureis not appliedto the stan clutch,forwardclutch,and the reversebrake.power is not transmitted
to the
secondarydrive gear'The secondarydrive gear is lockedby the parkingbrakepawl interlockingthe parkinggear.
FLYWHEEL
FORWARD
INPUTSHAFT
SUN GEAR
STARTCLUTCH
DRIVENPULLEY
FINAL DRIVE
GEAR
i{
B$
SECONDARY
GEAR
SHAFT
PARKINGGEAR
14-16A
FINALORIVENGEAR
E, E, 8nd E PGitions (Forward Range)

.
.
.
StartClutch:engaged
ForwardClutch:engaged
ReverseBrake:released
1.
The hydraulicpressureis appliedto the forward clutch and the stan clutch,and the sun gear drives the forward
clutch.
2.
The forwardclutchdrivesthe drive pulleyshaft,which drivesthe drivenpulleyshaftlinkedby the steelbelt.
3.
The drivenpulleyshaftdrivesthe secondarydrive gear,via lhe sta.t clutch.
4.
Poweris transmittedto the secondarydrivengear.which drivesthe final drivengear.
NOTE:The workinghydraulicpressureon the movablefaceof eachshaftdependson the throttleopeningposition.

FLYWHEEL
DRIVEPULLEY
CLUTCH
SUN GEAR
START CLUTCH
DRIVEN
SECONDARY
GEAR
(cont'd)
FINAL DRIVEN GEAR
14-169
Description
Power Flow (cont'd)
E Po$ition
.
.
.
StartClutchtengaged
ForwardClutch:released
ReverseBrake:engaged
1.
The hydraulicpressureis appliedto the reversebrakeand the startclutch.The sun gear drivesthe pinrongears,and
the piniongearsrevolvearoundthe sun gear.The carrierassemblyrotatesin the oppositedirectionfrom tne rotatron
directionof the sun gear.
The carrierassemblydrivesthe drive pulleyshaft via the forward clutchdrum, and the drive pullevshaft drivesthe
drivenpulleyshaft linkedby the steelbelt.
3.
The drivenpulleyshaftdrivesthe secondarydrive gearvia the startclutch.
4.
Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.

DRIVEPULLEY
STEELBELT
DRIVE
PULLEY
BEVERSEBRAKE
CARRIERASSEMBLY
INPUTSHAFT
STARTCLUTCH
FINALDRIV
SECONDARY
DRIVEN
GEAR
!il
FINALDRIVENGEAB
14-170
ElectronicControlSystem
The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three ljnearsolenoids,and a
controlledunderall conditions
inhibitorsolenoid.Shiftingis electronically
The TCM is locatedbelowthe dashboard,behindthe kickpanelon the driver'sside
to reduceenginespeedand retainthe engine'scoolingefficiencywhen the vehicleis
The TCM controlsthe transmtsston
drivenwith full throttleacceleration
t h, e T C M r e g u l a t e st h e p u l l e yh y d r a u l i cp r e s s u r et o
y r i v e na t f u l l t h r o t t l ea c c e l e r a t i o n
l f t h e v e h i c l ei s c o n t i n u o u s l d
and retainsthe designedcoolingefficiency.After
speed
increasethe pulleyratio,which, as the result,reducesthe engine
increases
the pulleyratioto the originalratio
TCM
for
a
while,
the
speed
the vehiclehasbeendrjvenat a lowerengine
the A,/Cclutch{if the IVC is on} and
to
cut
off
to
the
ECM
position,
a
signal
TCM
sends
the
in
the
For smooth starting
E
increases
the enginespeedto 900 rpm when the transmissionis shiftedto the E position
The start clutchfunctionsto make smooth startingpossible.To let the start clutchfunctionproperly,the TCM regulates
the startclutchhvdraulicpressurebasedon the engine'snegativepressurememorizedin the E position.
=
I
E
z
z
z
S@ond.ry Gelr Sh.tr
(cont'd)
14-171
Description
ElectronicControl System (cont'd)
Circuit Diagram and Terminal Locations
IGNITION
SWIICH
L]NEANSOLENOIO
SIAFTCLUICNCONTsOL
LINEAFSOLENOID
SC1
6
F
SIlIFTCONTROL
L]NEARSOLENOID
TXD/NXD
rM8
sNAKESWIICN
l\__
+B
8RA(EL]GHT
i\-
2
14
14-172
3
16 11
20
10 t l 12
23
25
1
12
5
'14
1 7 l8
rcr
s to
20
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump,the valves,and the solenoids.The ATF pump is drivenby the
input shaft.The ATF pump and the input shaft are linkedby the ATF pump drive chain and the sprockets.The inhibitor
solenoidvalveand the linearsolenoids,which are locatedon their valve body, are controlledby the TCM. Fluidfrom the
ATF pump flows throughthe PH regulatorvalveto maintainspecifiedpressureto the drive pulley,the driven pulley,and
the manualvalve.
The lower valve bodv assemblyincludesthe main valve body,the PL regulatorvalve body,the shift valve body,the start
clutchcontrolvalvebody,and the secondaryvalvebody.
Main ValveBody
The main valvebody containsthe PHcontrolvalVe,the lubricationvalve,and the pitot regulatorvalve.
PH Control Valve
with the PH-PLcontrolpressure(HLC),and supThe pH controlvalvesuppliesPHcontrolpressure(PHC)in accordance
plies pH control pressureto the PH regulatorvalve,which also regulatesPH pressure.At kick-down,it increasesPH
the high (PH)pressure.This shonensthe shift speedby releasingthe reverseinhibitor
controlpressurewhich increases
pressurelRl)from the inhibitorsolenoidvalve.
LubricationValve
The Iubricationvalvecontrolsthe lubricationpressureto eachshaft and maintainslubricationpressure.Whenthe presThis movesthe lubricationvalveand opensthe fluid leakpassage.
sureis too high,the spring is compressed.
Pitot RegulatorValve
with the enginespeed,when the electron
The pitot regulatorvalvecontrolsthe startclutchpressure{SC)in accordance
ic controlsvstemjs faulty.
LOWERVALVEBODY
ASSEMELY
TION VALVE
1+173
Description
HydraulicGontrol(cont'dl
SecondaryValve Body
The secondaryvalve body containsthe PH regulatorvalve,the clutchreducingvalve,the start ciutchvalve accumulator,
and the shift inhibitorvalve.
.
PH Regulatol Valve
The PH regulatorvalve maintainshydraulicpressuresuppliedfrom the ATF pump, and suppliesPH pressureto the
hydrauliccontrolcircuitand the lubricationcircuit.PH pressureis regulatedat the PH regulatorvalve by the PH control
pressure(PHC)from the PHcontrolvalve.
Clutch ReducingValve
The clutchreducingvalve receivesPH pressurefrom the PH regulatorvalveand regulatesthe clutchreducingpressure
valvesuppliesclutchpressure(CR)to the manualvalveand the startclutchcontrolvalve,and
lCR).The clutchredLrcing
suppliessignalpressureto the PH-PLpressurecontrolvalve,the shift controlvalve,and the inhibitorsolenoidvalve.
Start Clutch Valve Accumulator
The startclutchvalveaccumulatorstabilizes
the hydraulicpressurethat is suppliedto the startclutch.
Shift lnhibitor Valve
The shift inhibitorvalveswitchesthe fluid passageto switchthe startclutchcontrolfrom electroniccontrolto hydraulic
controlwhen the electroniccontrolsystemis faulty.lt alsosuppliesclutchreducingpressure(CR)to the pitot regulator
valveand the pitot lubricationpipe.
STARTCLUTCHVALVE
VALVE
SECONDARY
BOOY
SHIFTINHIBITORVALVE
CLUTCHREDUCINGVALVE
VAL
PH REGULATOR
fi
1i
1 4- 1 7 4
L
PL RegulatorValve Body
joined with the PH-PL
The pL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrolvalve,which is
body
valve
controllinearsolenoid.The inhibitorsolenoidis boltedon the PL regulator
PL RegulatorValve
The PL regulatorvalvesupplieslow pressure(PL)to the pulleyto eliminatesteelbelt slippage'
The PL pressureis controlledby the PH-PLcontrolpressure(HLC).
PH-PLControl Valve
The pH-pLcontrolvalve controlsthe PL regulatorvalve accordingto enginetorque.The PH-PLcontrolvalve supplies
pH-pLcontrolpressure(HLC)to the PH controlvalveto regulatePH pressurehigherthan PL pressure.The PH-PLcontrol valveis controlledby the PH-PLcontrollinearsolenoid,which is controlledby the TCM'
lnhibitorSolenoid
The inhibitorsolenoidcontrolsthe reverseinhibitorvalveby turningon and off, Also,the inhibitorsolenoidcontrolsPH
controlpressure(PHC)by applyingreverseinhibitorpressure(Rl)to the PH controlvalve The inhibitorsolenoidis controlledby the TCM.
Start Clutch Control Valve Body
The startclutchcontrolvalve body containsthe start clutchcontrolvalve.Both are ioinedto the startclutchcontrollinear
solenoid.
.
Start Clutch Control Valve

The startclutchcontrolvalvecontrolsstartclutchengagementaccordingto the throttleopening.The start clutchcontrol valveis controlledby the stan clutchcontrollinearsolenoid,which is controlledby the TcM.
STARTCLUTCHCONTROL
LINEARSOLENOID
STARTCLUTCHCONIROL
VALVE
INHIBITORSOLENOID
PL REGULATOR
VALVEBODY
LOWERVALVEBOOY
ASSEMBLY
PL REGULATOR
VALVE
PH.PLCONTROL
LINEARSOLENOID
(cont'd)
14-175
)
Description
HydraulicControl (cont'dl
Shift Valve Body
The shiftvalvebody containsthe shift valveand the shift controlvalve.Bothare joined
to the shift controllinearsotenoid.
e Shift Valve
The shift valve is controlledby shift valve pressure(SV)from the shift
control valve.The shjft valve distributespH
pressureand PL pressureto drive pulleyand the drivenpulley,
to shift the transmission.
.
Shift ControtValve
The shift controlvalve controlsthe shift valve in accordancewith the throftle
openingand vehiclespeed.The shift
control valve is controlledby the shift control linearsolenoid,which is
controlledoy tne rcv. wnen tne electronic
controlsystemis faultv,the shift controlvalveswitchesthe shift inhibitor
valveto uncoverthe pon leadingthe pitot
regulatorpressureto the startclutch.
SHIFTCONTROL
CONTROLVALVE
LOWERVALVEBODY
ASSEMBLY
VALVEBODY
Manual Valve Body

The manualvalvebody containsthe manualvalveand the reverseinhibitor
valve.The manualvalvebody is boltedto the
i n t e r m e d i a theo u s i n g .
.
ManualValve
The manualvarvemechanicatyuncovers/covers
the fruid passageaccordingto the shift reverposition.
ReverseInhibitor Valve
The reverseinhibitorvalve is controlledby the reverseinhibitorpressure(Rt).
lt interceptsthe hydrauliccircuitto the
reversebrakewhile the vehicleis movingforwardat speedsover approximately
6 mph (10km/h).
REVERSE
INHIBITOR
MANUALVALVE
BODY
14- 1 7 6
HydraulicFlow
GeneralChart of Hydraulic Pressure
. Shift Valve
. ShiftlnhibitorValve
,,/
SHIFTVALVE
PL REGULATOR
VALVE
PH REGULATOR
VALVE
NO.
coL
DESCRIPTION
OF PRESSURE
DESCRIPTION
OF PRESSURE
NO.
CLUTCHCONTROL
PP
PITOTPIPE
ATF COOLER
PR
PITOTREGULATOR
CR
REDUCING
CLUTCH
DN
DRIVENPULLEY
DR
DRIVEPULLEY
RCC
RI
RVS
RECIRCULATION
INHIBITOR
REVERSE
REVERSE
BRAKE
STARTCLUTCH
FWD
FORWARD
CLUTCH
HLC
PH-PLCONTROL
LUB
LUBRICATION
SUC
PH
P R E S S U RHEI G H
SV
SHIFTVALVE
PHCONTROL
LEAK
PHC
PL
sl
S H I F TI N H I B I T O R
SUCTION
PRESSURE
LOW
(cont'd)
14-177
L
Description
llj Position
As the engineturns,the ATF pump also startsto operate.Fluidfrom the ATF pump flows to the PH regulatorvalveand the
clutchreducingvalve.The PH regulatorvalveregulateshigh pressure(pH),and send,it to the shift valveand the pL regulator valve.The high pressure(PH)flows to the movableface of the driven pulleyvia the shift valve,and turns into low
pressure(PL)at the PL regulatorvalve.The low pressure(PL)flows to the movableface of the drive pulleyvia the shift
valve.At this time, the pulleyratio remainslow.
The high pressure(PH)becomesthe clutchreducingpressure{CR)at the clutchreducingvalve.The clutchreducingpres_
sure{CR)flows to the startclutchcontfolvalve,the manualvalve,the PH-PLcontrolvalve,and the shift controlvalve,and
is interceptedby thosevalves.
Underthis condition,hydraulicpressureis not appliedto the clutchesand reversebrake.
1 4-1 7 A
E position, at low speed range

position.The
The flow of fluid up to the drive pulley.the drivenpulley,and the clutchreducingvalve is the same as in E
pressure
{PL).
(PH),
puliey
low
receives
the
drive
pressure
and
pulleyratio is low becausethe drivenpulleyreceiveshigh
is
engaged.
forward
clutch
then
forward
clutch,
to
the
(CR)
valve
manual
through
the
pressure
flows
in" "tut"t reducing
The forwardclutchthen drivesthe drive pulleyshaft,which drivesthe drivenpulleyshaft'
pressure(CC).
Also, clutch reducingpressure(CB)flows to the start clutch control valve, and becomesclutch control
(SC)is
pressure
(SC)
clutch
valve.
Start
inhibitor
pressure
the
shift
(CC)
at
becomesstart clutch
Clutchcontrol pressure
clutch
aooliedto the startclutchto engagethe start
(contd
14-179
Description
lll position, at middle sped range
As the speedof the vehiclereachesthe prescribedvalue.the shift controllinearsolenoidis activatedby the TCM.The shift
controllinearsolenoidcontrolsthe shift controlvalveto activateshift valve pressure(SV).Clutchreducingpressure(CR)
from the clutchreducingvalvebecomesshift valvepressure(SV)at the shift cont.olvalve.Shift valvepressure(SV)flows
to the left end of the shift valve,the shift valveto the right side and positioningit in the middleof its travel.The shift valve
coversthe port to stop high pressure(PH)to the pulleys.and uncoversthe port leadinglow pressure(PL)to the pulleys.
The drive pulleyand the drivenpulleyreceivelow pressure(PL).At this time, the pulleyratiois in the middle.
Pressureremainsto applythe forwardclutchand the stan clutch.
NOTE:When used,"left" or "right" indicatesdirectionon the hydrauliccircuit.
$
14-180
E position, at high speed range

As the speedof the vehiclereachesthe prescribedvalue,the shift controllinearsolenoidmovesthe shift controlvalveto
increaseshift valvepressure(SVl at the left end of the shift valve.The shift valve movesto the right side comparedto its
positionat the middle pulteyratio.The shift valve uncoversthe port leadinghigh pressure(PH)to the drive pulley and
uncoversthe pon leadinglow pressure(PLlto the driven pulley.The drive pulleyreceiveshigh pressure(PH)and the driven pulleyreceiveslow pressure(PL).The pulleyratio is high
Pressureremainsto applythe forwardclutchand the startclutch.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit
NOTE:When used,
(cont'd)
14-181
Description
lll position
The flow of fluid up to the drive pulley,the driven pulley,and the clutchreducingvalve is the same as in E position.The
pulleyratio is low becausethe drivenpulleyreceiveshigh pressure(pH)and the drive pulleyreceiveslow pressure(pL).
The manualvalve is shiftedinto the E position,and it uncoversthe port that leadsreversebrakepressure(RVS)to the
reverseinhibitorvalve.The inhibitorsolenoidturns off by meansof the TCM,and reverseinhibitorpressure(Rl)is applied
to the right end of the reverseinhibitorvalve.The reverseinhibitorvalvemovesto the left side,and uncoversthe pon that
leadsreversebrakepressure(RVS)to the reversebrake.Clutchreducingpressure(CR)becomesreversebrakepressure
{RVS)at the manualvalve,and flows to the reversebrake.The reversebrakeis engaged,and it locksthe ring gear.
NOTE:When used,"1eft"or "right" indicatesdirectionon the hvdrauliccircuit.
14-182
Lll position
FeveBe lnhibitor Control
lf the E positionis selectedwhile the vehicleis moving forward at speedsover 6 mph (10 kmlh),the inhibitorsolenoid
doesn,tturn off by meansof the TCM. Reverseinhibitorpressure(Rl) is not appliedto the reverseinhibitorvalve as the
reverseinhibitor solenoidturns on. The reverseinhibitor valve is kept on the right side, and coversthe port to stop
(RVS)is not appliedto
reversebrakepressure(RVS)to the reversebrakefrom the manualvalve.Reversebrakepressure
reverse
direction.
to
the
not
transmjtted
is
brake,
and
the reverse
Dower
NOTE:When used,"left" or
(cont'd)
14-183
Description
HydraulicFlow(cont'dl
El position
The flow of fluid up to the drive pulley,the driven pulley,and the clutch reducingvalve is the same as in E position.
Clutchreducingpressure(CR)flows to the stan clutchcontrolvalve,th manualvalve,and the shift controlvalve.and is
interceptedby thosevalves.
Underthis condition,hydraulicpressureis not appliedto the clutchesand reversebrake.
14-144
E po3ition. when the electroniccontrol system is taulty.

When the electroniccontrolsystem(linearsolenoidsand sensors)is faulty,the transmissionusesthe pitot pipe pressure
(PP)to allow the vehicleto drive.
When all linearsolenoidsand sensorsare off becauseof a faulty electroniccontrolsystem,clutchreducingpressure{CR)
flows to the startclutchcontrolvalve,the manualvalve,the PH-PLcontrolvalve,and the shift controlvalve.Clutchreducing pressure(CR)becomesshift valve pressure(SV)at the shift controlvalve,and shift valve pressure(SV)is appliedto
the left end of the shift valve and the right end of the shift inhibitorvalve.The shift valve movesto the right side,and
uncoversthe port that leadshigh pressure(PH)to the drive pulleyand uncoversthe port that leadslow pressure(PL)to
the driven pulley.At this time, the pulley ratio is high. The shift inhibitorvalve movesto the left side,and uncoversthe
port that leadsshift inhibitorpressure(Sl)to the pitot lubricationpipe and the pitot regulatorvalve.The pitot lubrication
pipe dischargesfluid insideof the pitot flange,and dischargedfluid entersinto the pitot pipe and it is appliedto the left
end of the pitot regulatorvalve.The pitot regulatorvalve movesto the right side,and uncoversthe pon that leadspitot
regulatorpressure(PR)to the shift inhibitorvalve.Pitot regulatorpressure{PR)becomesstart clutchpressure(SC)at the
shift inhibitorvalve.and is appliedto the start clutch.The start clutch is engaged.The forward clutch pressure(FWD)is
appliedto the forwardclutch,and the forwardclutchis engaged.This allowsthe vehicleto drive.
(cont'd)
14-185
Description
E position, when the electroniccontrol system is faulty.
The flow offluid up to the drive pulley,the drivenpulley,and the startclutchis the sameas in E position.
The manualvalve is shiftedinto the E position,and it uncoversthe port that leadsreversebrakepressure(RVS)to the
reverseinhibitorvalve.Reverseinhibitorpressure(Rl)is appliedto the right end of the reverseinhibitorvalve becauseof
a faulty inhibitorsolenoid.The reverseinhibitorvalve moves to the left side, and uncoversthe port that leadsreverse
brakepressure(RVS)to the reversebrake.Clutchreducingpressure(CR)becomesreversebrakepressure(RVS)at the
manualvalve,and flows to the reversebrake.The reversebrakeis engagedand locksthe ring gear.This allowsthe vehicle to drive in reverse.
14-186
ParkingBrakeMechanism
The parkingbrakemechanismlocksthe transmissionby engagingthe parkingbrakepawl with the parkinggear which is
integralwith the secondarydrive gear.The secondarydrive gear engageswith the secondarydrivengear which engages
with the final drivengear.
Shiftingto E positioncausesthe parkingcone (installedat the end of the parkingbrakerod) to pressthe parkingbrake
pawl onto the parkinggear. Even it the end of the parkingbrakepawl rides on the top of the parkinggear teeth,slight
movementof the vehiclewill causethe parkingbrake pawl and the parkinggear to mesh with each other completely
becausethe parkingbrakecone receivesthe tensionfrom the parkingbrakerod spring.The parkingbrakepawl receives
the tension(whichactsto separatethe parkjngbrakepawl from the parkinggear)from the parkingpawl spring.
ART CLUTCH
PARKINGGEAR
PARKINGBRAKEROD
PARKINGBRAKE
PAWL
PARKINGBRAKE
RODSPRING
14-187
ComponentLocations
a
BRAKESWITCH
AUTOMATICTRANSAXLE{A/T)
GEARPOSITIONSWITCH
SECONOARY
GEARSHAFT
SENSOR
SPEED
MANIFOLDABSOLUTE
PRESSURE
{MAP)SENSOR
SENSOR
INHIBITORSOLENOID
STARTCLUTCHCONTROL
LINEARSOLENOID
PH-PL CONTROL
L I N E A RS O L E N O I D
SHIFTCONTROL
LINEARSOLENOID
14.1A 9
TCMCircuitDiagram
\
UNDER-HOOD
FUSE/RELAY
BOX
N o . 4 1l 8 0 A ) N o . 4 7 ( 7 . 5 A )
PARKING
BRAKE
SWITCH
I G N I T I OCNO I L
YI I
V
I
II
UNDER-DASH
FUSE/RELAY
BOX
I
II
BLU
oul
To12v
lGl
5V
REGULATOS
G A U GA
ES S E M B L Y
A/I GEARPOSITION
INDICATOR
L TG R N
8LK/8LU
_ RED
GRN/8LK
-GflN_ BLU
BLK
[,
I:
II
G401
G404
14-190
l A 4 l A 1 7l A 1 3 l A 2 6
8l,K
BRN/BL( |
I BRN/BLK I
I
BLK
L--.1 L---l
T ;i, T ,,t,,.T ?t T l
I J , T*t* I *-I*T*^,T,*
'lFr 'i Fl
--l+--++
;I. T".T"T 1P 1ts
Tt lTTI TI T| T| T.,^T,,T
| | I I I t.lI
i
LOJ L C @ @ @ @ l F l ,rr,r,.o,
RED/BLU
I
wHT
WHT/REDI
PNK/8LK I
PNK/BLU I
GRNTYELI
GRN/BLK
P K/BLK I
PNK/8LU I
GRNIYEL I
G8N/BLK
BLK
8RN/BLK
SECONDARY PH_PT
DNNEPULLEY DRIVEN
PUI-LEY
CONTROL
GEAR
SHAFT
SPEEO
SENSOR
SPEED
SENSOR
SPEED
SENSOR LINEAR
SOLENOID
START
CLUTCH
CONIROL
LINEAR
SOLENOID
s0LEN0r0
|
t
SHIFT
CONTROT
I.INEAR
SOLENOID
_o
:
L
l
_o_
:
G101
G101
TCMTerminalLocations
,,
14 1 5 l6 1 7
T C M- A { 2 6 P ) C o n n c t o r
20
10
23
11
,l t,
2 5 26
2
13 14
6
t 5
16
7
18
10
20
T C M - Bl 2 2 P ) C o n n e c l o r
14-191
TGM TerminalVoltage/MeasuringGonditions
--r-
3 4
la 15 16 11
1 I
20
TCM Torminal Locations
r 0 i 1 112
23,/
TCM-A(26P1Connoctor
26 1 2
14 15
a
6
10
1 7 l8
20
L)
TCM.Bl22PlConnector
TCM CONNECTOR A {26P}

TerminalNumbor
Measuring Conditions/Terminal Voltage

Start clutch control linearsolenoid
PH PL control linear solenoidpower
Shift control linear solenoidpower
E n g i n ei d l i n g ,E p o s i t i o n :
Aoorox. 0.4 V
Engineidling,lll positionl
A p p r o x . 0 . 7V
E n g i n ei d l i n g ,E l p o s i t i o n l
inerunningP
: u l s i n gs i g n a l
Ay'Tgear positionswitch L! position
In i!.1position:0 V
In other than E position:
410
I nE Jp o s i t i o n :V0
ln otherthanE position:
Approx.1OV
A,/TgearpositionswitchE position I nL l l p o s i t i o n :V0
In otherthanE position:Approx.1OV
Ay'Tgear positionswitchE or E
I n E o r E p o s i t i o nor V
411
gear positionswitch E position

A,,/T
A/Tgearpositionswitchlg position
s i g n a li n p u t
In other than N or E position:Approx. 1OV

I n L Ep
I o s i t i o n : 0V
: p p r o x .1 OV
I n o t h e rt h a n E p o s i t i o nA
With ignition switch ON 1ll):Batteryvoltage

wirh
switch OFF|0 V
A13
Start clutch control linearsolenoid
E n g i n ei d l i n g ,
A15
PH-PLcontrol linearsolenoidDower
A16
Shift control linearsolenoidpower
A o p r o x . 5 . 0V
ADorox.6.0
V
posation:
417
A18
A19
E indicatorlighr control
indicatorlight comes on: Approx. 10 V

indicatorlight OFF:0 V
Always banery voltage

424
With ignitionswitch ON (ll): Batteryvoltage
With ignition switch OFF|0 V
426
14-192
{
B (22P)
TCM CONNECTOR
Me6suring Conditions/Terminal Voltag
Terminal Number
B1
Manilold AbsolutePressure(MAP)
sensorsignal input
82
B3
B4
Throttle PositionlTP) sensorsignal

input
B5
Data communicationwith ECMI
Transmissioncontrol data oLltput
Datacommunicationwith EcM:
PGIM-Fl
control data input
B6
B7
With inhibitorsolenoidONr Batteryvoltage

W i t h i n h i b i t o rs o l e n o i dO F F : 0V
W i t h i g n i t i o ns w i t c hO N ( l l ) :A p p r o x . 2 . 5V
With engine idling: Approx. 1.0V (dependingon
e n g i n es p e e d )
With ignitionswitch ON (ll) and throttlefully open:
4 . 1 4- 4 . 4 2V
With ignitionswitch ON (ll) and throttlefully
closed:0.44- 0.56V
With ignitionswitch ON (ll) and rotatingfront
wheelsi0-SVcycle
With ignition switch ON (ll):Pulsingsignal
With ignition switch ON (ll)rPulsingsignal
B8
810
Driven pulley speedsensorsignal
: u l s i n gs i g n a l
I n o t h e rt h a n E a n d E p o s i t i o nP
Drive pulley speedsensorsignal
ln other than
Brakeswitch signal input
With brakepedal depressedrBatteryvoltage

V
released:0
With brake
position;Pulsingsignal
B tl
812
with ignitionswitchoN (ll):Approx.5.0v
813
814
SCS
I Servicechecksignal
816
Secondarygear shaft speedsensor

s i g n a li n p u t
817
818
Parkingbrakeswitch signal input
815
With ignition switch ON (ll) and servicecheckcon

nectoropen: Approx. S V
With ignition switch ON (ll) and servicecheckconnectorconnectedwith specialtool: 0 V
Dependingon vehiclespeed:Pulsingsagnal
When vehicleis stopped:0 V
p a r k i n gb r a k el e v e rp u l l e d : 0V
rkinq brakelever released:
voltage
819
820
821
822
W i t h i g n i t i o ns w i t c hO N ( l l ) :A p p r o x . 5 .
14-193
Procedures
Troubleshooting
l. How To Begin Troubleshooting
When the E indicatorlight has been reportedon, use the appropriateprocedurebelow to diagnoseand repairthe
proorem.
A. Whenthe E indicatorlight hascome onl
1. Connectthe HondaPGM Testeror an OBD ll ScanTool to the 16PData Link Conneclor(DLC)locatednearthe left
k i c kp a n e l .
3. Checkthe DTC and note it. Also checkand note
the freezetrame data.
Referto the DiagnosticTrouble Code Chan and
begintroubleshooting.
o0\-/oo
INOICATOR
LIGXT
NOTE:SeetheOBDll ScanToolor HondaPGMTesteruser'sman uals for specificoperatinginstructions.

Some PGM-Flproblemswill also makethe E indicatorlight come on. After repairingthe PGM-Flsystem,disconnectthe
BACKUPfuse (7.5A) in the under-hoodfuse/relaybox for more than 10secondsto resetthe TCM memory,then recheck.
the BACKUP tuse also cancelsthe radio presetstationsand the clock setting,Make note of the
NOTE:Disconnecting
radiopresetsbeforeremovingthe fuseso you can resetthem.
OBDtl SCANTOoL or
HONDAPGMTESTER
I16PI
OATALINKCONNECTOR
14-194
B. DTCSwill be indicatedby the blinkingof the E indicatorlight with the SCSserviceconnector connected.Connect
the SCS serviceconnectorto ServiceCheckConnectoras shown. (The ServiceCheckConnector(2P)is located
side of the vehicle.)Turn the ignitionswitchON (ll)
underthe dashon the passenger's
CONNECTOR
I2PI
CONNECTOR
07PAZ- @101tX)
Codesl through9 are indicatedby individualshort blinks.Codes10 and aboveare indicatedby a seriesof long and shon
blinks.One long blink equals10 short blinks.Add the long and shon blinkstogetherto determinethe code.After deterCharton pages14-198and 14-199.
miningthe code,referto the electricalsystemSymptom-to-Component
Shon blink {onc.l
S.. DYCI
S.c DlC2
Long blink
Sho.t blinkt {fiv. tim6l
S.c DTC15
system,disconnectthe
Some PGM-Flproblemswill also makethe E indicatorlight come on. After repairingthe PGN4-Fl
BACKUP fuse (7.5A) in the under-hoodfuse/relavbox for more than 10 secondsto resetthe TCM memory,then recheck.
(cont'd)
14-195
(cont'd)
C. lf the inspectionfor a particularcode requiresvoltageor resistancechecksat the TCM connectors,removethe
driver'sside kickpanel.Unboltthe TCM.Turn the ignitionswitchOFF,and connectthe backprobesetsand a digital
multimeteras describedbelow.Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)
listedon the followingpages.
How to use the BackprobeSet

Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cordsto a multimeter.Usingthe wire
insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side untilcomesin contactwith the terminalend of the wire.
BACKPROBE
SET
07sAz- (x)1000A
(two roquiredl
DIGITAL
MULTIMETER
rv.ilablol
lCommcrcirlly
KS-AHM-32-003,
or equivalent
ADAPTER
CORD
14-196
ll. TCM ResetProcedure

1. Turn the ignitionswitchoff.
2 . R e m o v et h e B A C KU Pf u s e( 7 . 5A ) f r o m t h e u n d e rh o o df u s e / r e l abyo x f o r l 0 s e c o n d s t or e s e t t h e T C M .
NOTEI
. Disconnecting
the BACKUP fuse also cancelsthe radio presetstationsand the clocksetting.Makenote of the radio
presetsbeforeremovingthe fuse so you can resetthem
BACKUP
(7.5A) FUSE
. The TCM can also be clearedby usingthe OBDll ScanTool or HondaPGMTester.

OBO ll SCAN TOOL ol
PGMTESTER
DATALINKCONNECTOB
I16P)
lll. FinalProcedure
NOTE:This proceduremust be done afterany troubleshooting.
1. Turn the ignitionswitchoff.
2. Resetthe TCM.
the OBD ll ScanTool or HondaPGMTesterfrom the DataLink Connector(16P),or removethe specialtool
3. Disconnect
from the ServiceCheckConnector.
4. Turn the ignitionswitchON (ll),and set the radiopresetsand clocksetting.
14-197
Chart
ElectricalSystem
Diagnostic
Indicaror
TroubleCode E
L i gh t
(DTC)*
P1790
(3)
\
Symptom
E n g i n er p m d o e s n o t i n c r e a s e .
Transmission does not kick-
Blinks
Transmission does not change
to higher ratio.
. No specificsymptomappears.
P1791
(4)
Blinks
P'1705
15)
Blinks
P'1706
(6)
OFF
P0725
( 11 )
Blinks
P1793
\121
P1870
(30)
P1873
( 3 1)
P1 8 7 9
(32)
14-200
14 201
Shortin A/T gear positionswitchwire

FaultyA"/Tgear positionswitch
14 202
Disconnected
A/T gear positionswitch
connector
Openin A,/Tgear positionswitchwire
FaultyAft gear positionswitch
14-204
Pooracceleration,
flareson
starting off.
Disconnected
ignitioncoil connector
Shortor open in ignitioncoil wire
F a u l t yi g n i t i o nc o i l
14-206
No speciticsymptomappears.
Disconnected
manitoldabsolutepres,
sure(I/AP) sensorconnector
Shon or open in MAP sensorwire
FaultyMAP sensor
14-207
Disconnected
solenoidharnessconnecror
Shortor open in shift controllinear
solenoidwire
Faultyshift controllinearsolenoid
14-208
Pooracceleration,
flareson
staningoff.
Disconnected
solenoidharnessconnector
S h o no r o p e ni n P H - P L
c o n t r ol i n e a r
solenoidwire
FaultyPH-PLcontrollinearsolenoid
't4-209
Pooracceleration,
flareson
startingoff.
Disconnected
solenoidharnesscon
nector
Shortor open in startclutchcontrol
linearsolenoidwire
Faultystartclutchcontrollinear
solenoid
't4-210
Disconnected
solenoidharnessconnector
Shon or open in inhibitorsolenoidwtre
F a u l t yi n h i b i t osr o l e n o i d
't4-2't1
. Transmission
shiftssameas E
positionin any positions.
. Transmission
shiftssameas @
positionin any positions.
Blinks
. Pooracceleration,
flareson
startingoft.
Blinks
Blinks
Blinks
Blinks
Disconnected
throttleposition(TP)
sensorconneclor
Shortor open in TP sensorwire
FaultyTP sensor
Referto
Page
Disconnected
vehiclespeedsensor
(VSS)connector
Shortor open in VSSwire
FaultyVSS
No specificsymptomappears.
P1882
(33)
PossibleCause
{DTC)*:The DTCSin parentheses

are the numberof the E indicatorlight blinkswhen the servicecheckconnectoris connectedwith the specialtool (SCSServiceConnector).
14-198
Diagnostic
E Indicator
TroubleCode
Light
(DTCT
P1885
(34)
P1886
(35)
P1888
(36)
PossibleCause
Symptom
Referto
Page
drive pulleyspeedsenDisconnected
sor connector
Shon or open in drive PulleYspeed
sensotwire
Faultydrive pulleyspeedsensor
14-212
. Pooracceleration,
flareson
starting off.
drivenpulleyspeedsenDisconnected
sor connecror
Shon or open in drivenPUlleyspeed
sensorwire
Faultydrivenpulleyspeedsensor
14-213
. Poor acceleration,flares on
starting off.
gear shaft
secondarY
Disconnected
connecror
speeclsensor
Shortor open in secondarygearshaft
speedsensorwtre
Faultysecondarygearshaftspeed
sensor
14-214
Shortor open in TMA wire between

87 terminaland ECIVI
Shon or open in TMB wire between86
t e r m i n aal n d E C M
FaultyECM
FaulryTCM
14-215
flareson
Pooracceleration,
startingoff.
Blinks
Blinks
Blinks
. Poorcreepingpowerwith brake
pedalreleased.
P1655
l31l
Blinks
P1890
\421
Blinks
flareson
Pooracceleration,
off.
starting
P1891
(43)
Blinks
Poor acceleration,flares on starting otf.
. Faultyshift controlsystem
Faultystartclutchcontrolsystem
14-217
14-214
(DTC)*:The DTCSin parentheses

are the numberol the E indicatorlight blinkswhen the servicecheckconneclorrs connectedwith the specialtool (SCSServiceConnector).
lf the self-diagnostic
E indicatorlighr does not blink,performan inspectionaccordingto the table below
SymPtom
E indicarorlight does not come on lor two secondsafterignitionswitch
is firstturn on {ll).
@ indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis on (ll).
Inspection
Ref. page
14-220
14-222
NOTE:
to recreatelhe symptom by test driving,
. It a customerdescribedthe symptomfor code P1706(5),it will be necessary
then recheckthe DTC.
lf so, repairthe
. Sometimethe E indicatorlight and the MalfunctionIndicatorlamp (MlL)may come on simultaneously.
p G M - F ls y s t e ma c c o r d i n gt o t h e D T c , t h e n r e s e tt h e m e m o r y b y r e m o v i n gt h e B A C KU P f u s e i n t h e u n d e r - h o o d
(50 km/h),then
fuse/relaybox for more than 10 seconds.Drivethe vehiclefor severalminutesat a speedover 30 mph
recheckthe DTC.
14-199
)
TroubleshootingFlowchart - Throttle Position (Tp) Sensor
. OBD ll ScanTool indic.les Code
P1790.
. Sef-diagnosisE indicaior light
blinks threo times.
PossibleCause
. Disconnoctdthrottle Dosition
(TP)sensorconnecior
. Short or open in TP sensorwire
. FaultvTP sonsor
CheckIor Anothe. Code or MIL

Blinking:
'1. Turn
the ignitionswitchON (ll).
2. Checkwhetherthe OBD scan
tool indicatesanothercode or
the MalfunctionIndicatorLamp
lMlL)blinks(seesection11).
Doesthe OBDllscan tool indicate

anothercode
or isthe MILblink
ing?
Repairthe PGM-Flsystem lse

section111.
TCM CONNECTORS
MeasureVREFVohage:
'L Turn
2. Disconnect
the A (26P)and B
1 2 2P ) c o n n e c t o r sf r o m l h e
TCM.
3 . T u r n t h e i g n i t ; o ns w i t c hO N
flr).
the 820 and A13 or 426 terminals,
ls thereapprox.5 V?
l26Pl
WHT/RED
WIRESIDEOF FEMAI-ETERMINALS
Repair op6n or short in the wir6

betweenthe 820 terminal and the
ECM.
RED/BLK
Measu.e TPS Voltagel

Measurethe voltage between the
B4 and A13 or A26 terminals.
ls there0.4-0.6V?
Chocklor loos6 TCM connectoB.

ff necossary,substitute a knowngood TCM and recheck.
Repairopen in the whe betwoen

the 84terminal and the TP sensor.
TroubleshootingFlowchart- VehicleSpeedSensor(VSSI
. OBD ll Scan Tool indicare. Codo
P1791.
. Sor-di.gnotb E indhttor light
blink3lour tim.i
PossibleCause
. Di3connected vehicls sPeed
ienaor (VSSIconnectol
. Short or ooan in VSS wile
. Faulty VSS
Refol to s.ction 23 tor vehicle

spood 3ensor {VSSI t6t.
check rh. vss voh.go:

1. Raisothe vehicle.
2. Shift the transmissionto E
posrt|on.
3. Disconnectthe A 126P)and B
TCM.
4. Turnthe ignitionswitchON lll)
5. Rotate the tront wheel and
checkfor the voltage between
the 85 and A13 or A26 terminals.Blockthe otherwheelso
it does not turn.
. Mak6 3ure lifts, iacks,and salety stands aro plsced properly lseo section 1l
. Set tho pa*ing brake socurgly,and block the rear wh6el3.
. Jack up the front of the vehicl,and supPort it with salety 3tands'
TCM CONNECTORS
Check lor open in the wiro

botwean tho 85 torminal and the
vehiclo speod sen30r (vSSl. lf
wire is OK, chock the VSS (see
3ction23).
Chack for loo3o TCM connoctoG.

ll nacaaarry,aubltituto t known'
good TcM rnd rechock.
14-201
g
TroubleshootingFlowchart- A/T GearpositionSwitch (Shortl
. OBD ll ScanTool indicatesCodo
P1705.
. Selt-diagnosis@ indicator tight
blinksfive timos.
Observethe A/T 9.r position

indicator:
1 . T u r n t h e i g n i t i o ns w i t c hO N
PossibleCause
.Short in A/T gear position
switch wire
. FeuttyA/T gear pGition switch
NOTE:Code5 is causedwhen the TCM
recerves
two gear posilioninputsat the
( ).
2. Observethe A/T gear position

a n d i c a t o ra, n d s h i f t t o e a c h
positionseparately.
Do any indicators stay on when the

shift lever is not in that position?
The syslem is OK at this tim.

Checkthe wire harnesstor demage.
TCM CONNECTOR
A I26P}
Mersure ATP R Voltagel

1. Shittto all positionsothe.than
tr.
the Al 1 and A13or 426 terminals.
ls thereapprox.10V?
Check for short in lhe wi.e

betwoenthe A11terminal and tho
A/T gear position switch or A/T
gear position indicator. ll wire is
OK, check for loose TCM connoctors. lf nocessary,substitute a
known-goodTCM and .echeck.
Measure ATP NP Voltagei

1. Shift to all positions other
t h a nE o r E .
the 410 and A13 or 426 termi,
nals,
ls thereapprox.l0 V?
Check for short in th6 wiro

between lhe A10 terminal and
the A/T gar position indicator.
or a short in tho wires botween
th A/T gear position indicator
and the A/T gear position
switch. lI wires are OK, check for
loose TCM connectors. ll necessary, substilute a known-good
TCM and rochck.
MeasureATP D Vohago:
E,
the A9 and A13 or 426 rerminals.
ls thereapprox.10V?
To page14'203
14-202
Check for short in the wire

bstwoon the Ag terminal and the
A/T gear position switch. ll wiro
is OK, check lor loose TCM connectoG. lf neces3ary,substitute a
known-goodTCM and rcheck.
WIRESIOEOF FEMALETERMINALS
A (26P}
TCM CONNECTOR
Frompage14-202
M.ssur6 ATP S Vohage:

1. Shjftto all positionsotherthan
ts.

the Ag and A13 or A26 termi
nals.
ls thereapprox.10V?
Check lor sho* in the wire

between tho A8 tolminal and the
A/T 9o.r po3ilion switch or the
A/T goar position indicrtor. lf wirc
is OK, check for loose TCM connctors. ll necessery,substitute a
known-goodTcM and rochck
MoasureATP L voltager
1. Shittto all positionsotherthan
E.

the A7 and A13 or A26 terminats,
ls thereapprox.10V?
Check for short in the wile

betwoen the A? terminal and the
A/T gear po3ition switch or the
A/f gear pGition indicttor. lf wile
is OK, check for loo3o TCM connectors. lf nocasi.ry.subditute a
known-goodTCM and rc.ch.ck.
Checktor looso TCM connoctors.

It neco$ary, substitute a known_
good TCM and rechock.
14-203
Electrical
Troubleshooting
TroubfeshootingFlowchart- AIT Gear positionSwitch (Open)
. OBD ll Scan Tool indicatesCode
P1706.
. Self-diagnosisE indicator tight
blinks six times.
PossibleCause
. OisconnectedA/T geer position
switch connector
. Openin A/T gearpositionswitch
. Faulty A/T gear position switch
MeasureATP R Voltage:
t h eA 1 1a n dA 1 3o r 4 2 6 t e r m i
nals,
Repairopen in the wire botween
lhe A11 terminaland the A/T
gear position switch.
1. Shiftto E or E position.
t h eA 1 0a n dA 1 3o r 4 2 6 t e r m i nals.
Bepair op6n in the wire between

the A10 termineland the A/T
gea. position switch.
MeasureATP D Voltage:
the Ag and Al3 or 426 termi
nals.
Repairopen in tho wire between

the Ag torminal and the A/T gea.
Dositionswitch,
Ii
To page14 205
14-204
A {26P}
TCM CONNECTOR
Frcm page 14-204
MeasuroATP S Voltage:
1. Shittto E position.
the Ag and A13 or A26 termi_
nals.
Repairopen in lhe wire between

the A8 terminal and the A/T gear
oo3iiion swilch.
MeesureATP L Voltage:
the A7 and A13 or A26 termi_
nals.

the A7 termin.l and th A/T goar
oosition switch.
Checkfor loose TCM connectors.

lf necessary,sub3titute a known'
good TCM and recheck.
14-205
TroubleshootingFlowchart - lgnition Goil
. OBD ll ScanTool indicatsCode
P0725.
' Selt-diagn6is E indicaior tight
indicat6sCod6 'l 1.
PosFiblsCause
. Oisconnectedignition coil conngctor
. Short or op6n ignition coil wire
. Faulty ignition coil
Maasu.oNE Voltag6:
1. Disconnectthe A l26p) connectorfrom the TCM.
2. Startthe engine.
the A5 and A13 or 426 termi,
nals.
Repair open or short in the wiro

between the A5 torminal and ths
ignition coil. f wire is OK, chsck
the ignhion coil tost {see section
23l..
Chock tor loose TCM connector.

It nec$sary, sub3titute a knowngood TCM and recheck.
Ii
14-206
TroubleshootingFlowchart- ManifoldAbsolutePressure(MAP)Sensor
. OBOll ScanTool indicat$ Code
P1793.
. Self.diagno.i3E indicator light
indicat* Cods 12.
Po$iblo Causo
. Dilconnoctodmanitold absolute
prG3u.a {MAP} sensor connoc_
lol
. Short or opan in MAP 3on3o.

MAP snsol
Check tor Anolhor Coda or MIL

Blinking:
2. Checkwhetherthe OBOll scan
tool indicatesanother code or
IndicatorLamP
the Malfr.rnction
(MlL)blinks(seesection11).
DoestheOBDllscantool indicate
anothercodeoristhe MILblinking?
Repair PGM-Fl syltem 13663ec'

tion 111.
TCM CONNECTORS
Mca3uroVREFVohtge:
l. Turnthe ignitionswitchOFF
the A (26P)and B
2. Disconnect
( 2 2 P )c o n n e c t o r sJ r o m t h e
TCM,
ls thereapprox.5 V?
WHT/REO
WIRESIOEOF FMALETERMINALS
R6pai. opon ot short in ths wire

botw.on the 820 tolminal and
rhe ECM.
Moasur. MAP (PBlvoltago:

Measurethe voltage betweenthe
82 and A13or 426 terminals.
ls thereapprox.3 V?
Repair open or shon in the wire

botween tho 82 terminal and tho
MAP snsor.
Chcktor loo3eTCM connectors.

lf n6ce$ary, 3ubstitut6 a known'
good TCM and rech6ck.
14-207
TroubleshootingFlowchart - Shift Control Linear Solenoid
P1870.
. Selt-diagnosisE indicator light
indicetesCod 30.
PossiblCau3e
. Disconnectedsolenoid harness
connector
. Short or op6n in shift cont.ol
linear solonoidwire
. Faulty shift control linear solcnoid
SOLENOID
HABNESS
8P CONNECTOR
8LU/WHT
MeasureShift ControlLine.r Solenoid Resistanceat lhe Solenoid

HarnessConnector:
fromthe solenoidharnessconnector.
2 , M e a s ur e t h e r e s i s t a n c e
beNveenthe No. 3 and the No.
7 terminalsofthe solenoidhar
nessconnector.
GRN/YEL
TERMINAL
SIDEOF MALETERMINALS
ls the resistance
3.8 6.8O?
TCM CONNECTOR
A I26PI
3 a
Check Shift Control Linear Solenoid for a Shon Circuit:

1 . D i s c o n n e ct th e A ( 2 6 P )c o n
nectorfrom the TCM.
body ground and the 43 term i n a la n d t h e A 1 6 t e r m i n a l
individually.
ls thereconlinuity?
GRN/YEL
7
9 l 0 1 1 12
20
11 l5 16 1 7
23
26
BLU/YEL
o
WIBESIDEOF FEMALETERMINALS
Repairshorl in the wi.es be'tween

the A3 and A16 terminals and the
body ground.
GRN/YEL
''
11 2
M a a s u r eS h i f t C o n t r o l L i n e a r
SolenoidR6istance:
1. Connectthe 8P connectorto
the solenoidharnessconnec
tor.
rJetween
the A3 and A16 termt n a l s .
ls the resistance
3.8- 6.8g?
Checklor loose TCM connectors.

ll nece$ary, substitute a knowngood TCM and recheck.
14-208
t'Ft
17
BLU/YEL
Repair loose terminal or open in

the wires between the A3 and
A16 terminals and the solenoid
harnessconnector.
1 0 1 t 1 2 13
23
25 26
Flowchart- PH-PLControlLinearSolenoid
Troubteshooting
OBD ll ScanTool indicatsCodo
P1873.
Self-diagnosisE indicrtor light
indicatsCodo 31.
Po$ib16Cau3e
. Disconnectedsolonoid hatn8s
connectol
. Short or opon in PH_PLcontol
linear 3olenoidwire
. FaultyPH-PLcontrol linear sole_
noid
SOLENOIDHARNESS
8P CONNECTOR
Mgasure PH-PLControl Lineet

Solenoid Rgsistancaal th6 Solenoid Harne3sConn6ctor:
from the solenoidharnessconnector.
betweenthe No. 2 and the No.
6 terminals
of the solenoidha.
nessconnector.
GRN/WHT
PNK/BLK
TERMINAL
ls the resistance3.8- 6.8 0?

A (26P)
TCM CONNECTOR
o
Check PH-PLControl Linoar
Sol.noid tor a Short Circuit:
1. Disconnectthe A (26P)connectorfrom the TCNI.
body ground and the A2 ter_
minaland the A15terminal
iodividually.
PNK/BLK
1
11
11 15
20
1 0 1 1 12 1 3
23
25 26
LGRN/WHr
R6pair 3hort in the wires
between the A2 and 415 torminals and the body ground.
- l PNK/BLK
_J()l-
Mea3ure PH-PLControl Linear

Solsnoid Ro3istance:
the solenoidharnessconnector.
2. Measure the resastance
betweenthe A2 and A15 termanals,
3.8- 6.80?
ls the resistance
t , t . 3 a
u1l] 16 1 7
20
8 9 t 0 11 12 1 3
25 26
23
GRN/WHT
Ropair loosa terminel or opon in

ihe wires between the A2 and
A'15torminals and the solonoid
haJnessconn6ctor.
Ch.ck for loosa TCM connectors.

It nece$ary, substhuto a known_
good ICM and rechck.
14-209
TroubleshootingFlowchart- Start ClutchControlLinearSolenoid
. OBOll Sc.n Tool indicst$ Code
P1879.
. Selt-diagnosisE indicator light
indicatesCode32.
PossibleCrule
. Disconnectodsol.noid harno33
connoctot
'Sho.l or opan in 6tart clutch
control lineff solonoidwire
. Faulty 3tart clutch control lineat
solenoid
SOLENOIDHARNESS
8P CONNECTOR
Measuro Slan Clutch Control

LinarSolenoidRosistanceat the
Solenoid HarnessConnoqtor:
from the solenoidharnessconnector,
betweenthe No. 4 and the No.
8 terminalsofthe solenoidharnessconnector.
YEL
PNK/BLU
ls the resistance3.8 - 6.8 O?
TCM CONNECTOR
A I26P)
Check Start Clutch Control Linear Solonoidtor a Shori Circuitr

1. Disconnectthe A (26P)connectorfrom the TCM.
body ground and the A1 terminaland the A14terminal
individually.
PNK/BLU
2 3 I
1 a t5 1 6
1
20
E 9 1 0 1 1 12 1 3
23
25 26
IYEL
0)
R6pair short in the wir6s
betwoen th6 Al and A1{ lerminals and the body grcund.
Measu.6 51.n Clutch Cont.ol

LinoarSolenoidRo3istance:
betweenthe A1 and 414 termrnals.
ls the resistance3.8 - 6.8 O?
Checkfor loos TCM connsctors.

lf necossary,substitute a knowngood TCM and rechock.
14-210
PNK/BLU
F
Jr
2 3 il 5
a 15 1 6 1 7
I YEL
Repair looae tormin.l o. open in
ih. wir6s botwoen th Al snd
414 terminals and tho solenoid
htanos3connectot.
20
8 9 10
23
12 1 3
25 26
TroubleshootingFlowchart - lnhibitor Solenoid

P1882.
. Self-diagnosisE indicator light
indicatesCode33.
Po$ible Cause
. Disconnectedsolenoid harn6s3
connectol
. Short or open in inhibitor sol.'
noid wi.e
. F.ultv inhibhor solenoid
SOLENOIDHARNESS
8P CONNECTOR
MasureInhibitorSolenoidRe3ist'
a n c e a t l h e S o l e n o i dH a r n e s s
Connector:
1. o;sconnectthe 8P connector
f r o m t h e s o l e n o i dh a r n e s s
connector.
2 . M e a s ur e t h e r e s l s t a n c e
betweenthe No. 5 terminalof
the solenoidharnessconnec_
tor and body ground-
TERMINAL
11.7- 21.0A?
lsthe resistance
TCM CoNNECTORB l22p)

Check Inhibitor Solenoid for a
Short Circuit:
1 . D i s c o n n e ct th e I ( 2 2 P )c o n nectorfrom the TCM.
t h e B ' 1t e r m i n a la n d b o d y
ground.
WIRES|OEOF FEMALETERMINALS
Repair3hort in the wire between

the B1 and the body ground.
MeasurelnhibhorSolenoidResisl'
ance:
the solenoidharnessconnec_
IOr.
betweenthe B1 and body
ground.
11.7-21.0{l?
ls the resistance
ReDairloose terminal or open in

the wire between the Bl and the
solenoidharnessconnectoa.
Checktor loose TCM connectors.

lI necessarv,substitute a knowngood TCM and recheck.
14-211
g
TroubleshootingFlowchart - Drive pulley Speed Sensor
P18a5.
. Selt-diagnosisEl indicator tight
indicat$ Codo3{.
Po$iblo Cause
. Dbconnectod drivo pulloy lpocd
30n301connectot
. Shon or op.n in diiv. pulley
tpasd sonaorwire
. Faulty drivr pull.y sp..d ronsoa
ls the drivepulleyspeedsensor installedproperly?
ORIVEPULEY SPEED
SENSOR2P CO NECTOR
Measurc D.iv6 Pulloy Sped Sensor Rasistlnce st the SorBor ConnctoJ:

from the drive pulley speed
sensorconnector,
ofthe
drivepulleyspeedsensor.
t|;Trl
*r-r
t9
LJ
TERMINALSIDEOF MALE TERMINALS

ls the resistance350 - 600 O?
TCM CONNECTOR
B (22P}
Check Driv6 PullGySpood S.nsor for s Short Ci.cuit:
1. Disconnectthe B (22p)connectorfromtheTCM.
2. Checkfor continlity between
body groundand the Bl0 tr,
m i n a la n d 8 1 7 t e r m i n a il n d i vidually.
RED/BLU
2
4 5 6 , E 9 t0
12 t3 1 1 t5 1 6 1 ' 1 8
m
GRN
t,
nepair shon in th. wiags botween
the B10.nd 817 torminals 6nd
the driv6 pulley spd 3onso..
MeasuroDrivo PulloySpood Sensor R6ktanco;

1. Connectthe drive pulleyspeed
sensor2P connector,
betweenthe 810 and 817 terminals.
REO/BLU
2
a 5
12 1 3 1 a t5 16
I
ls the resistance350 - 600 0?
Chock lor looso TCM connestor.

lf necessary.sub3titute e knowngood TCM and rechock.
14-212
RepaL looro toiminal or open in

tha wiro3 betw6on tho Bto rnd
817 t.rminak .nd the driv6 oullay !p6od an3or.
iTiT;f;Fdz
,I,ElVdVV
GRN
Troubleshooting Flowchart - Driven Pulley Speed Sensor

' OBD ll ScanTool indicatsCode
P1846.
. Solt-diagnosisE indicator light
indicatesCode 35.
PossibleCause
. D i s c o n n e c t e dd t i v e n P U l l e y
3pegdsensorconnec'tor
. Short or open in driv6n PulleY
so6dson3orwire
. Faulty driven pulley speed sen_
Checkthe driven Pulley sPeed

s e n s o r i n s t al l a ti o n ,
DRIVENPULLEYSPEED
SENSOR2P CONNECTOR
ls the drivenpulleyspeedsensor installedproperly?
t-
r-_- l
-T-r
lt @
l
t_.1
l t1 | 2 |
lL +
MeasureDrivenPulloySpeedSensor Resistanceat the SensorConnector:

1. Disconnectthe 2P connectol
from lhe driven PUlleYspeed
sensorconnectorof the
drivenpulleyspeedsensor,
350 6000?
ls the resistance
B (22P)
TCM CONNECTOR
WHT
Check Driven Pulley Speed Snsor for a Short Citcuit:

the B (22P)connec'
1. Disconnect
torfromtheTCM.
body ground and the 88 ter
minaland 89 terminalindividuaIy.
ls therecontinuity?
Reoairshort in the wirs bgtween

th 88 .nd 89 terminals and the
driven pulley spoedsensor.
10
20
12 13 14 15 1 6 1 7 1 8
MeasuleDrivenPulloySpeodSonsor Resistance:
1 . C o n n e c t h e d r i v e nP U l l e Y
speedsensor2Pconnector.
betweenthe 88 and Bg termi
nals,
350 600O?
ls the resistance
RED/BLUI WHT
Al
\j/
12 1 3 1 4 1 5 1 6 1 7 1 8
10
20
Eepair loose trminal or opon in

th wires botween the 88 and Bg
lerminals and the driven Pulley
soeedsensoJ,
Check lor loose TCM connector.

lf necessarv,substitute a known'
good TcM and recheck.
14-213
TroubleshootingFlowchart - SecondaryGear Shaft Speed Sensor
. OBD ll ScanTool indicatesCod
P1884.
. Self-diagnosisE indicalor light
indicatesCode36.
PossibleCause
. Disconnecled3econdarygea.
shaft speedsonsorconnctot
. Short or open in scondarygear
shaft speedsonsorwire
. Faulty secondary 9ea1 3haft
Check the secondary gear shatt

speed sensor installation.
SECONDARY
GEARSHAFTSPEED
SENSOR2P CONNECTOR
ls the secondary
gearshattspeed
sensorinstalledproperly?
lT- T ---1
t l l 2 l
-T--T-
MeasurSecondaryGear Shaft
Speed Sonsor Resistanceat the
Sensor Connectoa:
from the secondarygearshaft
speeosensorconnector.
ofthe
secondarygear shaft speed
ta
t
L__l
TERMINAL
ls the resistance
350- 600O?
TCM CONNECTOR
B (22PI
Ch6ck Countrsheft Speed Sensor for a Short Circuitl
1. Disconnectthe B (22P)connec,
tor from the TcM.
body groundand the 815 term i n a la n d 8 1 6 t e r m i n a il n d i
vidually.
1
a 5 6
8 9 10
12 1 3 '14 1 5 1 6 1 7 1 8
20
WHT/REDT '1 ORN/BLU
o) (o
Ropairshort in the wires betwoen
the 815 end 816 terminals and
the socondary g6ar 3haft speed
sensor.
MeasureSeconderyGoar Shaft
SpedSensorResistance:
1 . C o n n e c t h e s e c o n d a r yg e a r
shaftspeedsensor2P connector,
betweenthe 815 and 816 termtnals.
ls the resistance
350- 600O?
Check tor loose TCM connector.

It nocessary,substitute a knowngood TCM and recheck.
14-214
12 13 14 15 16 1 7 l8
A
I
WHT/REI
Bepair loose terminal or oDen in

the wires btween the 815 and
816 terminals and the secondery
gearshaft speedsensor.
ORN/BLU
10
20
TroubleshootingFlowchart- TMA and TMB Signals

. OBOll ScanTool indicate3Code
P1665.
. Seff-dirgnosisE indicator light
indicstosCod37.
Po$ible Csuse
. Short or open in TMA wire
between B? terminal and ECM
. Short or oDenin TMB wire
beiwoen 86 terminal and ECM
. Faultv ECM
' F.ultv TCM
CheckTMA Wire ContinuitY:

2. Disconnectthe B (22P)connectorfrom the TCM.
3 . D i s c o n n e ctth e C ( 3 1 P )c o n
nectorfrom the ECM.
t h e 8 7 t e r m i n a lo f t h e T c M
and the Cg terminalof the
ECM.
B I22P)
TCM CONNECTOR
GRY
6 t 7 8
1 2 't3 1 a 1 5 1 6 1 7 1 8
10
20
C 131P)
ECMCONNECTOB
GRY
sJs;lI
2 3 1
16 17lle/t./
1 1 12 t 3 t 4
//
//
22
l2s
WIRESIDEOF FMALETERMINALS
Rpairopen in the wiro between

the TCM and the ECM.
GRY
ChockTMA wite lor a Shorl Ci.cuiti
Checklor continuitybetweenthe
87 terminalof the TCM or the Cg
t e r m i n a lo f t h e E C M a n d b o d y
ground.
12 13 1 4
1 6 1 7 18
I
8
10
20
C {31P)
ECMCONNECTOR
ls therecontinuity?
GRY
Checkthe ECM:
1 . R e c o n n e ctth e C { 3 1 P )c o n
nectorto the ECM,and the B
{22P)connectorto the TCM.
t h e c 9 t e r m i n a lo f t h e E c M
and body ground.
ls thereapprox.10V?
To page14-216
1 2
11 12 1 3 1 4
5 6 7
t 5 1 7r 8
10
t/
4r 30
Checkfo. loose ECM connectors.

ll necessary,substitute a known'
good ECMand rcheck.
{cont'd)
14-215
TroubleshootingFlowchart - TMA and TMB Signals (cont'dl
ftom page 14 215
TCM CONNECTOR
B I22P}
CheckTMB Wire Continuity:

2. Disconnect
the C 13'1P)
connec
tor from the ECM.and the B
{22P)conneclorfrom the TCM.
t h e 8 6 t e r m i n a lo f t h e T C M
a n d t h e C 3 0t e r m i n a lo f t h e
ECM.
I | 9 10
12 1 3 1 4 l 5
20
17 18
ECMCONNECTOR
C {31P}
1 2
sl67
1 12 t 3 l 4
ls therecontinuity?
PNK
16 1 1
9 10
81/r,/)/
LA WU 14+
Repeir open in the wi.o between

the TCM and th6 ECM.
PNK I
WIRESIDEOF FEMALETRMINALS
CheckTMB Wire tor a Short Circuit:
8 6 t e r m i n a lo f t h e T C M o r t h e
C 3 0t e r m i n a lo f t h e E C M a n d
body ground.
PNK
o
7
1 2 1 31 a 1 5 1 6 1 7 1 8
10
20
ls therecontinuity?
check th6 TcM:

1 . R e c o n n e ctth e B ( 2 2 P )c o n nectorto the TCM, and the C
(31P)connectorto the ECM.
2. Turnthe ignitionswitchON {ll}.
t h e 8 6 t e r m i n a lo f t h e T C M
and bodyground.
ls thereapprox.5 V?
CheckIor loose TCM connectors.

lf nece3sery,substituto a knowngood TCM and rcheck.
14-216
PNK
4
6 1 8 9 't0
'15
12 1 3 11
16 17 l8
20
1
TroubleshootingFlowchart- Shift ControlSystem

. OgD ll Sc.n Tool indiclt6 Codo
P1890.
. S.lt diagno.b E indicator ligl|t
indic.tG Codo 42.
PoasiblaC.uta
. Faulty shitt control rystom
Ch6ckfor Anoth.r Cod.:

check whther the E] indicator
light indicatessnother code.
lsthe E indicatorlight indicato anothercod6?
Parlorm lha Troubl63hooting

Flowch.rt tor thc indicttcd
Codolrl.
Ch.ck Stlll Spo.d RPM:

M e a g u r et h e s t a l l s p e e d R P M
(seepag6 14-230).
ls the stall speedover 3,500rpm?
lsthe stallsoeedblow 2,000rPm?
T.!l-drivo .nd Ch.ok Engina

Spa!d:
t. Driv the vehicle at 30 mPh
(50 km/h) constantly for several minutes,
2. Checkthe enginesps6d.
ls th6 engino speedwithin tho

spocification(se6 page 14-228
and 1+229)?
14-217
TroubleshootingFlowchart - Start Clutch Gontrol System
P1891.
. Selt-diagnb E indicator tight
indicatesCode43.
PossiblGCause
. Feulty start clutch control system
Checkfor Another Code:

C h e c kw h e t h e rt h e E i n d i c a t o r
light indicates
anothercode.
ls the E indicatortightindi
cateanothercode?
P e r l o r mt h e T r o u b l e s h o o t i n g
Flowchart for the indicatod
Code(sl.
Test Start Clutch Operationl

2. oisconnectthe 8P connector
from the solenoidharnesscon3. Startthe engine,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c l e
moves,
ooes the vehiclemoveT
CheckCreepingSpeed:
2. Reconnect
the 8P connectorto
the solenoidharnessconnec,
tor.
3. Stan the engine,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c i e
creeps,and checkthe creep,
ing speed.
Doesthe vehicle move and is

the creeping speed approx. 3
mph (5 km/h)?
To page 14-219
14-218
Replacothe stan clutch,assemblv.
Frompage14-218
ChockStall SpeedRPM:
Measurethe stallsooedRPM(see
page14-230).
ls the stall sDeedover 3,500rpm?
Warm Up Eogine and Rochck

F.ilure:
1 . W a r m u p t h e e n g i n et o n o r
mal operating'aemperature
lthe radiatorfan comeson).
2. Checkwhetherthe startclutch
problemappearsagain.
The syst6m k OK rt this time.
a
14-219
g
TroubleshootingFlowchart- E] IndicatorLight DoesNot ComeOn
The E Indicator tight does not
come on whon lhe ignition switch
is first turned ON (lll. (lt should
come on tor about two seconds.l
Checkthe ServiceChockConnectot:
Make sure the specialtool 1SCS
S e r v i c eC o n n e c t o r i)s n o t c o n
nectedto the servicecheckconnector,
ls the specialtool (SCSService

Connector)
connected
to the servicecheckconnector?
Disconnsctth6 sDecialtool trom

the sgrvice chgck connector and
recheck.
Checkth E Indicator Light:

Shiftto E position.
Does the E indicator light
Chocktor loosc TCM connector3.

ff n6cess6ry,3ubstituta e knowngood TCM and rachock.
TCM CONNECTOR
A (26P)
BLI i r ( [ ,
Checkthe Ground Circuit:

2 . D i s c o n n e ct th e A ( 2 6 p )c o n nectorfrom the TCM.
t h e A 1 3 t e r m i n a la n d b o d y
ground and the 426 terminal
and body ground.
14 15 16 1 7
8 9 1 0 t 1 12
20
23
25
BLK
(o
WIRE SIDE OF FEMALE TERMINALS
Io page 14 221
l-
a
a
. Repair opan in the wi.s

botwean lho A13 or A26 terminalsand G101.
. Repairpoor ground ic101).
From page 14 220
A (26PI
TCM CONNECTOR
BLK/WHT I
(v)
YI
Measure Power SuPPIYCircuil

Voltege:
terminalA
s 1 2a n dA 1 3 a n d
b e t w e e nt e r m i n a l sA 2 5 a n d
426.
t a 15 16 1 7
20
BLK
'10 l t 1 2
23
25 26
)
BLK/WHT
BLK
ls Ihere banery voltage?
Repairopen or short in the wiro

between the Al2 and/or A25 terminals and the undeFdashfuse
box.
MeasureO IND Voltag6:

2. Connectthe A 126P)connec'
tor to the TCM.
3. Connecta digital multilester
10the A20 and A13 or A26ter
mrnals.
Turnthe ignitionswitchON (ll),
and makesure that the voltage
fortwo seconds
is available
GRN/BLK
Check tor oDen in the wire

btween the A20 terminal and
lhc gauge assembly. lf the wire
is OK, check for a faulty El indicator lighl bulb or a faulty gauge
assomblyprinted circuit boa.d
A (26P}
TCM CONNECTOR
CheckD IND lor an Short Ci.ctlit:

1. TLrrnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e A ( 2 6 P )c o n
nectorfrom the TCM.
the A20terminalandthe No.I
terminalof the gaugeassembly connectorlseesection23).

the A20 terminal and the gauge
essemblY,
WIEESIDEOF FEMALETERMINALS
Checktor loose TCM connectors.
C h e c kt h e A / T g e . r p o s i t i o n
switch. lf necessary.substitute a
known-good TCM and recheck.
14-221
TroubleshootingFlowchart- El IndicatorLight On Constantly
Tho llj indicator light b on constantly {not blinking}whenev.r

the ignition switch b ON (ll).
TCM CONNECTOR
A I26PI
Mea3ureD IND Voltag6:
2 . D i s c o n n e ct th e A ( 2 6 P )c o n nectorfrom the TCM.
3. Turn the ignitionswitchON {ll).
t h e 4 2 0 t e r m i n a la n d b o d y
ground.
20
t4 15 1 5 1 7
9 10 t l 12 13
23
25 26
GRN/8LK
Repairshort to powsr in the wir.
botwoon tha A20 t6rminal .nd
lhs gaug essombly.
Me.3ur6 ATP OVohage:

2. Connectthe A (26P)connector to the TCM.
3. Turn the ignitionswitch ON (ll).
4. Shiftto any positionotherthan
E.

t h e A S t e r m i n a la n d b o d y
ground.
Chock tor a short lo ground on

the wire. It wiro i3 OK, roplaco
the A/T goar pGition indic.tor.
rd
14-222
2 3
ta
l5 1 6 1 1
20
E 9 l0 I t 12 1 3
23
E 26
LinearSolenoids/lnhibitor
Solenoid
Test
'L
Disconnect
the 8P connectorfrom the solenoidharnessconneclor.
2.
M e a s u r et h e r e s i s t a n c o
e f t h e s h i f t c o n t r o ll i n e a r
solenoidbetweenthe No. 3 and No. 7 terminalsof
3.
7.
lf all of the resistancesare within the standard,a

c l i c k i n gs o u n d s h o u l db e h e a r dw h e n c o n n e c t i n g
the batteryterminalsto the solenoidharnesscon
nectorterminalsbelow:
.
lMeasurethe resistanceof the PH-PLcontrol linear

solenoidbetweenthe No. 2 and No. 6 terminals.
Measurethe resistanceof the start clutch control

linearsolenoidbetweenthe No. 4 and No. 8 terminals.
STANDARD:
3.8- 6.8 o
M e a s u r et h e r e s i s t a n c eo f t h e i n h i b i t o rs o l e n o i d
betweenthe No. 5 terminaland body ground.
Shift control linear solenoid

No.3: Battervpositiveterminal
No.7: Batterynegativeterminal
PH-PLcontrol linear solenoid
No.2: Baftervoositiveterminal
No.6: Batterynegativeterminal
Start clutch control linear solenoid
No. 4: Battervoositiveterminal
No. 8: Batterynegativeterminal
lnhibitorsolenoid
No. 5: Batterypositiveterminal
Bodyground:Batterynegativeterminal
SOLENOIDHARNESSCONNECTOR
STANDARD:
11.7- 21.00
SOLENOID
HARNESS
CONNECTOR
8.
l f n o c l i c k i n gs o u n d i s h e a r d ,r e p l a c et h e l o w e r
valvebody assembly.
N O T E |l f t h e l o w e r v a l v e b o d y a s s e m b l yr e p l a c e ment is required,see Lower Valve Body Assembly
Replacement
4-234).
{page'1
ATF DIPSTICK
6.
Replacethe lowervalve body assemblyif any of the

is beyondthe standard.
solenoidsresistance
14-223
Drive Pulley/DrivenPulley/SecondaryGear Shaft Speed
Sensors
Replacement
\ ,
CAUTION: While replacingthe speed sensor,be sure not to allow dust and other loreign particles to enter into the ttansmission.
1.
Disconnect
the drive pulley,the drivenpulley,or the secondarygear shaftspeedsensorconnector.
2.
Removethe 6 mm bolt from the transmissionhousing,and removethe drive pulley.the driven pulley,or the secondarygear shaftspeedsensol.
3.
Replacethe O-ringwith a new one beforereinstallingthe drive pulley,the driven pulley,or the secondarygear shaft
sDeedsensor.
6x1.0mm
12 N.m {1.2kgf.m, 8.7 lbl.ftl
DRIVENPULLEY
SPEEO
SENSOR
6x1.0mm
12 N.m (1.2kgf.m,
8.7 tbf fr)
14-224
Start ClutchControl
Start Clutch CalibrationProcedure
NOTE:When the following partsare replaced,the TCM
must memorizethe teedbacksignalfor the start clutch
control.
o
.
.
.
.
'96
S h i f t i n t o E o r E p o s i t i o n .T o s t o r e t h e e n g i n e
negative pressure in memory, let the engine idle in
E or E position for one minute under the following conditionsl
TCM
Transmission
assembly
Startclutchassembly
Lowervalvebody assembly
Engineassemblyor overhaul
.
.
.
.
.
Modl Only
NOTE: Start step 5 w;thin 60 seconds after the radiator Ian goes off.
CAUTION:Do not use this procedureon'97 -'98 mod.

els or you will damagethe transmission.On'97 -'98
models, the TCM memorizes the feedbacksignals when
you drive the vehicle.
1 . E n g a g et h e p a r k i n gb r a k e ,a n d b l o c kt h e f r o n t
wheelssecurely.
2.
With the brake pedal depressed.

With the A,/Cswitch OFF.
Wilh the combination light switch OFF.
With the heater fan switch OFF.
Turn OFF all other electrical systems.
Shift into E position, and let the engine idle lor two
minutes to store the feedbacksignal in memory
under the same conditions as in step 5.
7.
Connectthe SCS serviceconnectorto the Service

C h e c kC o n n e c t o ra s s h o w n . ( T h e S e r v i c eC h e c k
C o n n e c t o r( 2 P )i s l o c a t e du n d e r t h e d a s h o n t h e
passenger's
side of the vehicle.)
Connect the Honda PGM Tester. Check that the TCM

has completed the start clutch calibration.
NOTE:
o The TCM will not storethe feedbacksignalwhen
the CVTfluid temperatureis below 40'C (104'F)
even il the engine coolanttemperaturereaches
the normaloperatingtemperature.
a R e p e a t h e s e p r o c e d u r e su n t i l t h e s t a r t c l u t c h
calibrationis completed.
8.
D i s c o n n e ctth e S C S s e r v i c ec o n n e c t o rf r o m t h e
ServiceCheckConnector.
'97 - '98 Models
The TCM memorizesthe feedbacksignalwhen you
drivethe vehicleas follows:
(2PI
CONNECTOR
CONNECTOR
07PAZ- 0010100
Start the engine,and warm it up to normal operat

ing temperature(the radiatorfan comeson twice).
4.
A f t e r w a r n i n g u p t h e e n g i n e( t h e r a d i a t o rf a n
c o m e so n ) .
Shift into E position.
a Turn OFFall electricalsystems.
a D r i v et h e v e h i c l eu p t o t h e s p e e d3 7 m p h { 6 0
km/h).
A f t e r t h e s p e e d r e a c h e s3 7 m p h ( 6 0 k m / h ) ,
releasethe accelerator
for 5 seconds.

for 20
secondsin the E position.
14-225
Symptom-to-Gomponent
Chart
HydraulicSystem
SYMPTOM
Checktheseitemson the PROBABLE

CAUSEList
Engineruns,but vehicledoes not move in anv position.
1 , 2 , 3 , 4 , 5 , 6 , 1 , 89,, 1 0 ,2 0 ,3 4 ,3 5 ,3 6 ,3 8 ,4 1
Vehicledoes not move in @, [, S positions.

Vehicledoes not move in B position.
10,11,12,20,41
5 , 1 0 ,1 1 ,1 2 ,1 1, 1 a ,1 9 , 2 0 , 3 94, 1
No shift to higherratio.
9 , 1 3 ,1 4 ,1 5 ,1 6 ,3 5 , 3 7 4
,0
Poor acceleration.
9 , 1 3 ,1 4 ,1 s ,1 6 , 2 0 , 3 5 , 3 7 , 3 a , 4 0
F l a r e so n m o v i n g .
9, 10,20,21,35,36, 38, 40,42
Excessive
shockwhen depressingand releasing
pedal.
accelerator
9 , 1 0 ,2 0 , 2 1 , 3 5 , 3 6 , 3 84,2
N o e n g i n eb r a k i n g .
9, 20,21, 35,36,3A
Vehicledoes not accelerate

in E position.
9, 17, 18,19,20, 35,36,38
Vehiclemovesin N position.
(Shiftcableadjustmentis proper).
10,22,23
Lateshiftfrom @ positionto D position,and from @

positionto E position.
10,11,12,22,41
Lateshiftfrom N positionto E position,and from E

positionto @ position.
' t 1 ,1 2 ,
1 7 ,1 A , 2 2 , 4 1
Enginestopswhen shiftedto @ positlonfrom N position.
9, 10,20,35,37,3A
,
42
Enginestopswhen shiftedto E positionfrom E position.
9, 18,19,20,25, 26.35,31,38,42
Noisefrom transmissionin E position.*1
5 , 1 1, 1 8 ,1 9 ,2 5 , 2 6
Excessive
idle vibration.
2 , 3 ,8 , 2 1, 2 8
Noisefrom transmissionin E and E positions.
2 , 3 ,1 9 , 2 4 , 2 5 , 2 A
H u n t i n ge n g i n es p e e d .
16,35,37,38
Vibration in all position.
a, 2a
Shift leverdoes not operatesmoothty.
1 1 , 2 9 ,4 ' l
Transmission
will not shift into E positionor transmission cannotbe removedfrom p position.
11, 29,30,31,32,33
Vehicledoes not accelerate

to more than a certainsDeed.
9 , 1 0 ,1 4 ,1 5 ,1 6 , 2 0 , 3 5 , 3 1
Excessive
shockon staningoff.
38, 42
Flareson acceleratingat low speed.
20,21,34,42
Excessive
vibrationin @, p, p, @ posirions.
Low enginespeedin [, [, p, @ positions.
20,21,3A,42
S t a l ls p e e dh i g h .
1 0 ,2 0 , 3 8
Stallspeedlow.
9 , 2 0 ,2 1, 3 7, 3 a
Judder on starting off.
20,43
*1: Somegear noiseis normalin the
4-226
2 0 , 2 1 , 3 84, 2
E positiondue to planetarygear actton.
a
PROBABLE
CAUSELIST
1
Low CVTfluid tevel
ATF pump worn. AT gearsworn or damaged.Foreignmaterialin ATF pump.
ATFpump chain/ATFpump sprocketworn or damaged.
I n p u t s h a f tw o r n o r d a m a g e d .
Sun gearworn or damaged.

F i n a ld r i v e n g e a r w o r n o r d a m a g e d .
drivengearworn or damaged.
Secondarydrive gear/secondary
plateworn or damaged.
Flywheel/drive
housingassemblyworn or damaged.
Intermediate
10
Forward clutch defective.
11
Shift cable broken/out of adiustment.
12
M a n u a l e v e rp i nw o r n .
t5
ATFfeed pipe (pulleypressure)worn or damaged.
14
pulleyspeedsensordefective.
Drivepulleyspeedsensor/driven
Vehiclespeedsensordefective.
TCM defective.
17
Reverse brake defective.
18
Reversebrakepistonand relatedpartsworn or damaged.
19
P l a n e t a rgye a rw o r n o r d a m a g e d .
20
21
Start clutchdefective.
ATFteed pipe lstartclutchpressure)worn or damaged.
22
Clutch clearance/reversebrake clearance incorrect.
23
Reversebrake return spring/retainerworn or damaged-
24
Needlebearingon input shaftworn or damaged.
25
r o r no r d a m a g e d .
T h r u s tn e e d l eb e a r i n go n c a r r i ew
Thrustwasheron carrierworn or damaged.
,1
E n g i n eo u t p u t l o w .
2a
Flywheel assembly def ective.
29
C o n t r o ll e v e rw o r n o r d a m a g e d .
30
Parkingbrakepawl/parkingbrakepawl shaftworn or damaged.

brakerod assemblyworn or damaged.
Detentlever/parking
32
Parking gear worn or damaged.
34
filter clogged.
ATFstrainer/ATF
35
Lower valve bodv assemblv defective.
36
37
Lowervalvebody assemblydefective(PLregulatorvalvebody assemblydefective).
Parkingbrakepawl springworn or damaged.
38
Lowervalvebodv assemblvdefeclivelshiftvalvebody assemblydefective).

Lowervalvebodv assemblVdetective(startclutchcontrolvalvebody assemblydefective).
40
Solenoid harness worn or damaged.
41
M a n u a lv a l v e b o d y w o r n o r d a m a g e d .
42
PBfeedbacksystemdelective,
43
CVTfluid deteriorated.
Lowervalvebodv assemblvdefectivelinhibitorsolenoiddefective).
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature{the radiatorfan comeson).

1, Apply the parkingbrakeand block the wheels.Start the engine,then shift to the E positionwhile depressingthe
brakepedal.Depressthe accelerator
pedaland releaseit suddenly.The engineshouldnot stall.
2.
T e s ti n E p o s i t i o n
Parkthe vehiclein a slope (approx.16"),apply the parkingbrake,and shift into E position.Releasethe brake;the
vehicleshouldnot move.
3.
Test-drivethe vehjcleon a flat road in the positionshown in the table,Checkthat the enginespeedsmeetthe approximatevehiclespeedsshown in the table.
NOTETThrottlepositionsensorvoltagerepresentsthe throttleopening,To monitorthe throttlepositionsensorvoltage,useone of the followingmethods:
A. Connectthe HondaPGMTester,and go to the PGM-FIDataList.
OBo ll SCANTOOLoI
HONOAPGMTESTEB
B.'!. Removethe kickpanelto exposethe TCM for roadtesting;referto page 14-194.
2. Setthedigitalmultitesterto checkvoltagebetlveenthe 84 (+)terminalandA4(-) or A17 (-)terminaloltheTCM

for throttlepositionsensor.
TCM
84 T6rmin.l
BACKPROBE
SET
07sAz- 001000A
{two raquirad}
II
I
DIGITALMULTIMETER
lCommelcielly.v.ilabl.)
KS-AHM-32-003
or oquivilont
BACKPROBE
AOAPTER
STACKINGPATCH
CORD
TCM CONNECTORS
[''
14-228
E position: Engine Speedrpm

Vehicle Soeed
ThrottleOpening
25 mph (40 km/h)
37 mph (60km/hl
62 mph 1100km/hl
Throttlepositionsensorvoltage:0.75V
1,250 1,650
2,500 3,r 00
2,6s0 3,250
2,700 3,300
Throttlepositionsensorvoltager4.5 V
Fullthrottleposition
3,950 4,550
4,650 5,250
5,200 5,800
E position:EngineSpeed.pm
Vehicle Speed
Throttle Opening
positaon
Fullthroltle
.
2s mph (40 km/h)
37 mph 160km/hl
62 mph (100km/hl
1,800- 2,200
2,950- 3,550
2,200- 2,AOO
3,250- 3,850
3,550- 4.150
4,050- 4,650
4 , 1 0 0- 4 , 7 0 0
5,100- 5,700
5,900- 6,500
E position:EngineSpeedrpm
Vehicle SDeed
Throttle Opening
Throttle position sensor voltage: 2.25 V
Throttlepositionsensorvoltage:4.5
Fullthrottleposition
25 mph (40km/hl
37 moh 160km/h)
62 mph (100km/hl
3,' l00- 3,700

3.500- 4,100
3,650- 4,250
4,050- 4,650
4,450- 5,050
4,100 4,700
5 , 1 0 0- 5 , 7 0 0
5,900- 6.500
4,800 5,400
14-229
Stall Speed
Test
CAUTION:
. To preventtransmissiondamage,do notteststall speedfor more than 10 secondsat a time.
. Do not shift the lever while raising the engine speed,
. Be sure to remove the pressuregauge before testing stall speed.
. Stall speed tests should be used for diagnostic purposesonly.
1 . E n g a g et h e p a r k i n gb r a k ea, n d b l o c kt h e f r o n tw h e e l s .
2.
Connecta tachometerto the engine,and startthe engine.
3.
Makesurethe IVC switchis OFF
4.
After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan comeson),shift into E position.
5.

for 6 to 8 seconds,and note enginespeed.
6.
Allow two minutesfor cooling,then repeatthe test in E, E, and E positions.
Stall SpeedRPMin @ position:

Specilication:2,500rpm
ServiceLimit: 2,350- 2,650rpm
Stall SpeedRPMin p. I and @ positions:
Specification:
3,000rpm
ServiceLimit:2,800- 3,100lDm
TROUBLE
PROBABLE
CAUSE
S t a l lr p m h i g hi n E , E , E , a n dE p o s i t i o n s
Low fluid levelor ATF pump output

CloggedATF strainer
PH regulatorvalvestuckclosed
Slippageof forwardclutch
Faultystan clutch
S t a l lr p m h i g hi n @ p o s i t i o n
Slippageof reversebrake
Faultystart clutch
Stallrpm low in Dl, p, [, and @ positions
E n g i n eo u t p u tl o w
Faultystart clutch
Stuckshift valve
14-230
FluidLevel
Checking/Changing
CAUTION:while checkingand changing,be sure not to
allow dust and other foreign particles to enter into the
transmission,
Changing
1.
Bringthe transmissionup to normaloperatingtemperature(the radiatorfan comes on) by driving the

v e h i c l eP
. a r kt h e v e h i c l eo n t h e l e v e lg r o u n d ,a n d
turn oif the engine.
2.
Removethe drain plug,and drainthe CVTfluid.
Checking
NOTErCheckthe fluid level with the engine at normal
operatingtemperature(the radiatortan comes on iust
1.
P a r kt h e v e h i c l eo n t h e l e v e lg r o u n d .T u r n o f f t h e
engine.
2.
Removethe dipsrick(yellow loop) from the transmission,and wipe it with a cleancloth.

N O T E :C h e c kt h e t r a n s m i s s i o fnl u i d 6 0 t o 9 0 s e c onds aftershuttingoff the engine.
3.
NOTE:ll a coolerflusheris to be used,see page14'14-285.

284 and
3.
Reinstallthe drain plug with a new sealingwasher,

t h e n r e f i l l t h e t r a n s m i s s i o nw i t h G e n u i n eH o n d a
CVTFluidto the uppermarkon the dipstick.
FluidCapacity:
3.9? 14.1US qt, 3.4 lmp qtl at changing
6.4{ (6.8US qt,5.5lmp qtl at overhaul
Insenthe dipstickinto the transmission.

DIPSTICK{YELLOWLOOPI
AutomaticTransmissionFluid:
Recommended
GenuineHondaCVTFluid.
U s eG e n u i n eH o n d aC V Tf l u i do n l y .U s i n go t h e rt l u i d s c a n a f f e c t t r a n s m i s s i o no p e r a t i o na n d m a y
reducetransmissionlife.
l
4.
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l .l t
shouldbe betweenthe upperand lower mark.
5.
lf the level is below the lower mark. add fluid rnto

t h e f i l l e r h o l e t o b r i n g i t t o t h e u p p e r m a r k .U s e
G e n u i n eH o n d aC V TF l u i do n l y .
Insenthe dipstickinto the transmission.
ChangeInterval:
NormalCondition:30,000miles(48,000kml
SevereCondition:30,000miles {48,000kml, but if
you drive at high speedsin high
t90"F {32"C1and abovel temper'
a t u r e s ,t h e t r a n s m i s s i o nf l u i d
should be changed every 15'000
miles {24,000km).
DRAINPLUG
1 8x 1 . 5m m
49 N.m 15.0kgI m, 36lbfttl
SEALINGWASHER
Replace.
14-231
PressureTesting
L
. While testing, be careful of the rotating tront wheels.
. Make sure lifts, iacks, and safety stands are placed properly {seesection 11.
CAUTION:
. Belore testing, be sure the transmissionfluid is lilled to the proper level.
. Warm up the engine to normal operating temperature before testing.
. While testing, be sure not to allow dust and other foreign particles to enter into the transmission.
1.
Raisethe front of the vehicle,and supportitwith safetystands(seesectionI).
2.
Setthe parkingbrake,and blockboth rearwheelssecurelv.
3. Allow the front wheelsto rotatefreely.

Warm up the engine(the radiatorfan comeson),then stop and connecta tachometer.
5.
Connectthe specialtoolto each inspectionhole.

TOROUE:18 N.m (1.8kgf.m,13 tbf.ft)
CAUTION:
' Connectthe oil pressureg.uge securely,be sure not to allow dust and other toreign particles to enter the inspection hole.
. When troubleshooting by the E indicator light indicatesa problem, you must use an oil pressuregauge that mea
sures 4,900kPa {4.90MPa, 50.0 kgflcnf, 711 psil or more when measuringdrive pulley pressureand driven pulley
Dressure.
NOTE:
. Drivepulleypressuremay be above3,430kPa(3.43MPa,35.0kgf/cmr,498psi)when there is a transmissionproblem that causesthe TCM to go into the fail safemode.
. U s e a c o m m e r c i a l lay v a i l a b l eo i l p r e s s u r eg a u g et h a t m e a s u r e s4 , 9 0 0k p a ( 4 . 9 0M p a , 5 0 . 0k g t c m r ,7 1 1 p s i )
or
more,and the A,/TOil PressureHose,22j0 mm (071\itAJ
- py40j 1A).
A/T OIL PRESSURE
GAUGE
SETw/PANEL
07406- 0020400
A/T LOW PRESSURE

GAUGEW/PANEL
07406- 0070300
FORWARDCLUTCHPRESSURE
INSPECTION
( M a r k e dw i t h " F " )
DRIVEPULLEYPRESSURE
INSPECTION
HOLE
lMarkedwith "DR")
oJ..
LUBRICATION
PRESSUBE DBIVENPULLEY
PRESSURE
INSPECTION
HOLE
INSPECTION
HOLE
"
L
U
B
"
)
( M a r k ew
d ith
(Ma.kedwith "DN")
14-232
A/T PRESSURE
HOSE
ADAPTER
07MAJ - PY40120
(4 Requirad)
A/T PRESSURE
HOSE
2210 rnfi
OTMAJ- PY4O11A
(4 Bequired)
REVERSE
BRAKEPRESSURE
INSPECTION
HOLE
ATF OIPSTICK
STARTCLUTCHPRESSURE
INSPECTION
HOLE
(Markedwith "SC")
Stan the engine.

rpm.
7 . shift to the respectiveshift leverpositionas in the table,and measurethe followingpressuresat 1,500
.
.
.
.
ForwardClutchPressure
ReverseBrakePressure
DrivePulleyPressure
DrivenPulleyPressure
8 . Shiftto E position,and measurethe lubricationpressure.at 3.000rpm
PRESSURE
SHIFTLEVER
POStTtON
FLUIDPRESSURE
SYMPTOM
PROBABLECAUSE
Standard/ServiceLimit
'1.4- 1.75MPa
(14.3- 17.8kgtcm' , 203- 253psi)
Forward
Clutch
No or low forward clutch

pressure
Forward Clutch
Reverse
Brake
No or low
reversebrake
pressure
ReverseBrake
1 . 4- 1 . 7 5M P a
(14.3- 17.8kgf/cm' ,203- 253psi)
Drive
Pulley
No or low
drive pulley
pressure
ATF pump,PH regulatorvalve,PL

regulatorvalve,
Shiftvalve
0.2- 0.7 MPa

(2 - 7.1 kgflcm' ,28- 101psi)
Drivepulley
pressuretoo
h i gh
PH regulatorvalve,
PL regulalorvalve,
Shiftvalve,Shift
controllinear
solenoid
No or low
drivenpulley
pressure
ATF pump,PH reg'

ulatorvalve,Shift
valve.Shiftcontrol
linearsolenoid
Drivenpulley
pressuretoo
h i gh
PH regulatorvalve
No or low
lubrication
pressure
ATF pump,
Lubricationvalve
)a
Driven
Pulley
Lubrication
1 . 5- 2 . 3M P a
(15.3- 23.5kgficm' ,218- 334Psi)
Above0.2 MPa
(Above2 kgf/cm' ,30 psi)
the specialtool afterpressuretesting.

Disconnect
1 0 . Installthe sealingbolt with a new sealingwasherin the inspectionhole,and tightento the specifiedlorque
TOROUE:18 N.m (1.8 kgf'm. 13 lbt'ft)
CAUTION: Koep all ol the foroign particles out of the transmission.
14-2?:t
LowerValveBody Assembly
Replacement
Make sure lifts, jacks, and safety stands
!@
are placed properly {seesection 11.
C A U T I O N :W h i l e r e m o v i n ga n d i n s t a l l i n gt h e l o w e r
valve body assembly.be sure not to allow dust and
other toreign particlesto enter into the transmission.
1.
Raisethe front of the vehicle,and suoDortit with

safetystands{seesection1}.
7.
8.
9.
10.
11.
Removethe ATF cooleroutletpipe.

Removethe ATFcoolerDipebracketbolt.
Removethe ATF pan (fourteenbolts).
Removethe ATF strainer(two bolts).
R e m o v et h e o n e b o l ts e c u r i n gt h e s o l e n o i dh a r n e s s
connector.
' 1 2 .R e m o v e
t h e l o w e r v a l v e b o d y a s s e m b l y ( e i gh t
bolts).
SEALING
Replace.
Set the parkingbrake,and block both rear wheels

securely.
3.
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
R e i n s t atl h
l e d r a i np l u g w i t h a n e w s e a l i n gw a s h e r
(seepage14-231).
ATF COOLEE
OUTLETPIPE
CAUTION: Keep all ol other foreign particles out of

the transmission.
4.
JOINT BOLT
28 N.m (2.9 kgtm, 2l lbf.ft)
O.RING
Replace
SOLENOID
HARNESS
CONNECTOR
Disconnectthe 8P connectorfrom the solenoidhar

nessconnector.
DOWELPIN
R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
pipes,Turn the ends of the ATF cooler hosesup to
cooternoses.
O-RING
ATF
Replace.
STRAINER
CAUTION: Keep all of other foreign particles out ot

the transmission.
6.
6x1.0mm
12 N.m 11.2kgt m,
8.7 rbtftl
DOWELPIN
RIGHTFRONT
MOUNT/BRACKET
/
ATF COOLERPIPE
'10x 1.25mm
54 N.m (5.5kgt.m,
40 tbt.ft)
l14-234
ATF COOLERHOSE
LOWERVALVE
BODYASSEMBLY
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbtft)
Removethe right front mounvbracket.

'10x 1.25mm
44 N.m (,1.5kgtm, 33 lbnftl
6x1.0mm
12 N.m {1.2kgl.m,
8.7 tbf.tt)
ATF PAN
ATF PAN GASKET

Replace.
ATF COOLERINLET
PIPEBRACKETBOLT
I x 1.25mm
26 N.m (2.7kgt.m,
20 tbl.ft)
6x1.0mm
12 N.m (1.2kgf.m,8.7lbl.ft)
1 3 . I n s t a l lt h e n e w l o w e r v a l v e b o d y i n t h e r e v e r s e
orderof the removalprocedure
CAUTION: Keep all of other toreign particles out of
the transmission.
NOTE:
. Replacethe followingparts:
- O - r i n g so n t h e s o l e n o i dh a r n e s sc o n n e c t o r
and the ATFstrainer
- ATF pan gasket
S e a l i n gw a s h e r s
. l f t h e A T F c o o l e r i n l e t p i p e b r a c k e ti s b e n t o r
warped,put it backto the originalposition.
1 4 . P e r f o r mt h e s t a r t c l u t c hc a l i b r a t i o np r o c e d u r eo n
p a g e1 4 2 2 5 .
ATFFilter
Make sure lifts, iacks, and safety stands
@@
are placedproperly lsee section 11.
CAUTION: While removing and installing the ATF filter,
be sure not to allow dust and other foreign particles to
enter into the transmission.
1.
Raisethe front of the vehicle,and support it with

saletystands(seesection1).
2.
Ser the parkingbrake,and block both rear wheels

securely.
3.
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
Reinstallthe drain plug with a new sealingwasher
(seepage'14231).
CAUTION: Keep all of other foreign particles out of
the transmission.
Removethe ATF cooleroutletpipe

Removethe ATF coolerpipe bracketbolt.
Removethe ATF pan (founeenbolts).
Removethe ATF coolerinlet pipefrom the ATF pan
{threebolts).
10. Removethe ATFfilter,and cleanit.
11. Checkthat the ATFfilter is in good condition
12. Replacethe ATFtilter if it is clogged.
6.
7.
8.
9.
JOINT BOLT
28 N.m 12.9kgl m, 2'l lblftl
SEALING
Replace.
ATF COOLEROUTLET
6 x 'l.0mm
12 N.m (1,2kgf m,
8.7 tbtft)
ATF COOLERINLET
PIPEBRACKETBOLT
I x 1.25mm
26 N.m (2.7kgt m,
R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
Di9es.Turn the ends of the ATF cooler hosesup to
coolerhoses.
CAUTION: Keep all of othet loreign particles out ot
the transmission.
5.
DOWEL
Removethe rightfront mounvbracket.

1 0x 1 . 2 5m m
44 N.m (4.5kgt'm,33lbfftl
ATF P
GASKET
Replace.
O.RING
Replace.
ATF PAN
RIGHTFRONT
MOUNT/BRACKET
6x1.0mm
12 N'm {1.2 kgl m, 8 7 lbf'ft}
't3. l n s t a l l t h e A T F f i l t e r i n t h e r e v e r s e o r d e r o f t h e
removal procedure.
10 x 1.25mm
54 N.m (5.5 kgf'm,
40 rb{ft1
ATF COOLERHOSE
CAUTION: Keep all foreign particles out of the

transmission.
NOTEI
. Replacethe O-rings, the ATF pan gasket and
sealing washers.
. lf the ATF cooler inlet pipe bracket is bent or
warped, put it back to the original position.
14-235
Transmission
Removal
@@
Make
4.
sure lifts, iacks, and safety stands are placed

pfoperly, and hoist bracket are attached to the correct position on the engine (seeseqtion 1).
Apply parking brake and block rear wheels, so the
vehicle will not roll off stands and fall on vou while
working under it.
Disconnect
the solenoidharnessconnector,the drive
pulleyspeedsensorconnector,and the groundcable
terminals.
GROUNDCABLE
TERMINAL
GROUNDCABLE
CAUTION:Use fender coversto avoid damaging painted

surfaces.
'L
Disconnectthe battery negative(-) terminal from

lhe battery.then removethe positive{+)terminal.
2.
R e m o v et h e i n t a k ea i r d u c ta n d a i r c l e a n e h
r ousing
assemDty.
3.
R e m o v et h e s t a r t e rc a b l e sa n d c a b l eh o l d e rf r o m
the startermotor.
DRIVEPULLEY
SPEEDSENSOR
CONNECIOR
STARTERMOTON
SOLENOIOHARNESS
CONNECTOR
5.
Removethe clip,then separatethe shift cablefrom

the controllever.
GAUTION:Take care not to bend the shift cable.
SHIFICABLE
WASHER
WASHER
STARTERCABLE
Ft
14-236
CONTROLLEVER
6.
Disconnectthe vehiclespeedsensor(VSS)connector, the driven pulleYspeedsensorconnector,and

the secondarygear shaftspeedsensorconnector.
SECONDAFYGEAR
SHAFTSPEED
SENSOR
8.
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V Tf l u i d .
Reinstall
the drainplugwith a new sealingwasher'
CAUTION:while installingthe drain plug, be sure
not to allow dust and other foteign particles to
enter into the transmission
DRIVENPULLEY
SPEEDSENSOR
CONNECTOR
F(A --
,fi .
' - 1DRAINPLUG
18x 1.5mm
irg N.m {5.0kgl m.36lbt'ft)
SENSOR(VSSt
CONNECTOR
7.
SEALINGWASHER
Replace.
Removethe transmissionhousingmountingbolts.
9.
R e m o v et h e s p l a s hs h i e l d .
(cont'd)
14-237
Transmission
Removal(cont'dl
10. Removethe cotterpinsand castlenuts,then separate
the balljointstrom the lowerarm (seesection18).
16. Remove the right front mount/bracket.
TF COOLERPIPE
ATFCOOLER
HOSE
1 t . Removethe right damper fork bolt, then separate
r i g h td a m p e rf o r ka n d d a m p e r .
1 2 . Prythe right and left driveshaftsout of the differential.
Pullon the inboardjoint and the right and left drive,
shafts(seesection16).
't
4. Tje plasticbagsoverthe driveshaftends.
1 1 . R e m o v et h e A T F c o o l e r h o s e sa t t h e A T F c o o l e r
pipes.Turn the ends of the ATF cooler hosesup to
preventCVT fluid from flowjng out, then plug the
ATFcoolerhosesand pipes.
NOTE: Checkfor any sign of leakageat the hose
joints.
Removethe enginestiffenersand the flywheelcover.
NOTE:Coatall precisionfinishedsurfaceswith clean

e n g i n eo i l .
t5,
Removethe exhaustpipe A.
r")
SELF-LOCKING
NUT
Beplace.
SELF-LOCKING
NUT
Replace.
14-238
EXHAUSTPIPEA
ENGINESTIFFENER
r9. Remove the eight drive plate bolts one at time while
rotating the crankshaft pulley.
20. Removethe distributor.

t1
2 3 . R e m o v et h e t r a n s m i s s i o nh o u s i n gm o u n t i n gb o l t
and rearenginemountingbolts.
Attacha hoistingbracketto the engine,then lift the

e n g i n es l i g h t l y .
TRANSMISSIONHOUSING
MOUNTINGBOI-T
REARENGINEMOUNTING
BOLT
lP.WASHER
22. Placea jack under the transmission,and raise the

transmissionjust enoughto take weight off of the
mountbracket
mounts,then removethe transmission
24. Pull the transmissionaway from the engine until it

clearsthe 14 mm dowel pins, then lower it on the
transmissioniack.
MOUNT
TRANSMISSION
14-239
lllustratedIndex
Valve Body Assembly
Transmission/Lower
14-240
O) ATF DIPSTICK
@ o-RINGReplace.
O SOI-ENOIDHARNESSCONNECTOR
O LowER vALvE BODYASSEMBI-Y
O DowEL PIN
O JoINT aoLT
) ATF COOLERINLETPIPEBRACKETSOLT
@ A'F COOLERINLETPIPEASSEMBLY
o SEALINGWASHERReplace.
G, ATF COOI-EROUTLETPIPE
@ o-RING Replace.
Ci)ATF FILTER
@ o-RINGReplace.
G) ATF PAN
(9 DOWELPtN
@ O-RINGReplace.
) ATF STRAINER
G} ATF MAGNET
@ ATF PAN GASKETReplace.
) ATF MAGNET
@ DRAINPLUG
@ SEALINGWASHERBepIace,
Boh/Nut No.
Torque Value
Sizs
6A
8F
12J
18D
12 N m (1.2kgf.m,8.7lbf'ft)
28 N.m (2.9kgf.m,21lbi'ft)
49 N.m (5.0 kgnm, 36 lbf.ft)
6x1.0mm
8 x 1 . 2 5m m
'12x 1.25mm
1 8x 1 . 5m m
Remarks
Joint bolt
Drainplug
14-241
lllustratedIndex
Transmission
Housing/Flywheel
Housing
8G
14-242
af O-RINGReplace.
le oll sEAl- Replace.
HOUSING
:O FLYWHEEL
HOUSING
GASKETReplace.
i4l FLYWHEEL
ASSEMBLY
.1'-DIFFERENTIAL
G,IATF PASSAGEPIPEASSEMBLY
?l o-RINGReplace.
i8')DOWELPIN
.' ATF PUMPASSEMBLY
iio DOWELPlN, 18 x 10 mm
ll O-RINGReplace.
a1aOOWELPlN, 22 x 10 mm
O ATF PUMPoRIvE CHAIN
.iOSNAPRING
pan
i9 THRUSTsHlM,22x 28 mm Selective
(10)
ATF PUMPDRIVESPROCKET
.1I PITOTFLANGE
HUB
.O ATF PUMPDRIVESPROCKET
i!i) THRUSTWASHERS
6i PIToT PIPEBRACKET
PIPE
iz:i,PITOTLUBRICATION
., PITOTPIPE
ag OILSEALReplace.
ari SET BING,80 mm Selectivepart
29 ATF PASSAGEPIPEHOLDERASSEMBLY
!d O-RINGReplace.
LA STARTCLUTCHATF FEEDPIPE
e3 o-RING Feplace.
8 FEEDPIPEFLANGE
.O SNAPRING
BRACKET
@ CONNECTOR
A BALI BEARING
@ SNAPRING
@ COTTERRETAINER
25.5 mm Selectivepart
@ COTTERS,
@ STARTCLUTCHASSEMBLY
DRIVEGEARASSEMBLY
6I SECONDARY
@ o-RINGSReplace.
COVER
@ DIFFERENTIAL
@ THRUSTsHlM, 25 x 35 mm selecrivepart
GEABSHAFT
.4i SECONDARY
6DPABKINGBRAKEPAWLSHAFT
@ PARKINGBRAKEPAWLSPRING
'O PARKINGBRAKEPAWL
@ TONGUEDWASHERRepIace.
{3 PARKINGBRAKERODHOLDER
I BALLBEARING
io o-RINGReplace.
.4!)VEHICLESPEDSENSOB
60 OILSEALReplace.
TOROUE SPECIFICATIONS
Bolt/Nut No.
TorqueValue
Size
6A
8A
8F
8G
12 N.m ('1.2kgim,8.7 lbf'ft)

22 N.m 12.2kgf.m,16lbf.ft)
26 N.m (2.7kgf.m,20lbnft)
29 N.m (3.0kgtm,22 lbf.ft)
6x1.0mm
' l . 2 5m m
8x
8 x 1 . 2 5m m
8 x 1 . 2 5m m
Remarks
14-243
lllustratedIndex
Right Side Cover/lntermediateHousing
8B
tr
.i) RIGHTSIDECOVER
(.] ATF FEEDPIPE
i3. DOWELPIN
O O-RINGReplace.
i5) FEEDPIPEFLANGE
] FEEDPIPEFLANGPLATE
Ol'RoLLER
HOUSINGASSEMBLY
iq,]INTERMEOIATE
O CONTROLSHAFTASSEMBLY
HouSlNG
TRANSMISSION
1_oI
.11)
SHIFTCABI-EBRACKET
CAP
iO BREATHER
O olL SEALReplace.
(4 CONTROI-LEVER
(3 LOCKWASHERReplace.
ii6-iSECONDARY
GEABSHAFTSPEEDSENSOR
Ji DRIVENPULLEYSPEEDSENSOR
(8_'
O-RINGReplace.
t!9 SNAPR|NG
.9 TBANSMISSIONHOUSINGDRIVENPULLEY
SHAFTROLLERBEABING
2i RIGHTSIDECOVERGASKETFEPIACE.
(2?jO-RINGReplace.
POMANUALVALVEBODYLINEA
.]i MANUALVALVEBODYLINE8
a3 o-RINGReplace.
,! DETENTSPRING
!]) ATF FEEDPIPE
Q0O-RINGReplace.
EI MANUAL VALVEBODY
13o]
DOWELPIN
PLATE
51)MANUALVALVEBODYSEPARATOB
34 SNAPRING
$) FORWARDCLUTCHASSEMBLY
gl o-RINGFeplace.
69 SNAPBING
(30SPRINGRETAINEB/RETURN
SPRINGASSEMBLY
BRAKEPISTON
O REVERSE
(381
O-RINGReplace.
r SNAPRINGRETAINER
.4!)ATF FEEDPIPE
(t TRANSMISSIONHOUSINGGASKETReplace
@}DOWELPIN
@ ATF FEEDPIPE
@ O-RINGReplace.
6t o-RING Replace.
DRIVEPULLEYSPEEDSENSOR
.45)
(? TRANSMISSION
HANGER
(O SNAPRING
pa(
e0 THRUSTSHIM,25x 31 mm Selective
6i BALLBEARING
O RINGGEAR
69 SNAPRING
BRAKEEND PLATESelectivepan
6l REVERSE
BRAKEDISC
@IREVERSE
BRAKEPLATE
69 REVERSE
6! D|SCSPRTNG
@ THRUSTWASHER
6J'THRUSTNEEDLEBEARING
63 THRUSTWASHER
ASSEMBLY
@ CARRIER
6) THRUSTWASHER
@ SUN GEAR
@ SEALINGRINGReplace.
69 NEEDLEBEARING
@ INPUTSHAFT
@ NEEDLEBEARING
RINGReplace.
@ SEALING
69 SEALINGRINGIRUBBER)Replace.
@ ATF FEEDPIPE
Bolt/Nut No.
TorqueValue
Size
6A
6B
8B
8F
8G
12 N.m (1.2kgf.m,8.7lbf'ft)
1 4 N . m( 1 . 4k g n m ,1 0 l b i f t )
37 N.m (3.8kgim,27 lbf'fti
26 N.m 12.7kgf.m,20lbf.ft)
29 N.m (3.0kgf.m,22lbnft)
6x1.0mm
6x1.0mm
8 x 1 . 2 5m m
8 x 1 . 2 5m m
8 x 1 . 2 5m m
Remarks
14-245
TransmissionHousing/LowerValveBodyAssembly
Removal
NOTE:
o Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair.
. When removingthe lowervalvebody, replacethe following:
- O-rings
- ATF pan gasket
- Sealingwashers
O.BING
Replace.
SOLENOIDHARNESSCONNECTOR
OOWELPIN
6 x 1.0mm BOLT
LOWERVALVEBODYASSEMBLY
6 x 1.0mm EOLT
ATF PAN GASKET

Feplace.
ATF STRAINER
ATF COOLERINLETPIPE
BRACKETBOLT
8 x 1.25mm
ATF COOLERINLETPIPE
6 x 1.0mm BOLT
6 x 1.0mm EOLT
ATF PAN
14-246
1.
Removethe ATFcoolerinletpipe bracketbolt.
2.
Removethe ATFcooleroutletpipe.
3.
Removethe ATF pan (founeenbolts).
4.
Removethe ATFstrainer(two bolts).
5.
Removethe one bolt securingthe solenoidharness

connector,then pushthe connector,
6.
Removethe lowervalvebody (eightbolts).
7.
Cleanthe inletopeningof the ATFstrainerthoroughly

with compressedair, then checkthat it is in good
condition,andthe inletopeningis not clogged.
ATF STRAINES
Replace
the ATFstrainerif it is cloggedor damaged.
NOTE:The ATF strainercan be reusedif it is not
clogged.
14-247
Housing/Flywheel
Housing
Transmission
Removal
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair.
. When removingthe transmissionhousingflywheelhousing,replacethe followingl
- O-rings
- Secondarydrive gear assembl,
- Stan clutchassembly
- Flywheelhousinggasket
ATF PASSAGEPIPE
HOLOERASSEMBLY
8 x 1.25mm BOLT
CONNECTOR
BRACKET
fl
O.RING
Replace.
FLYWHEELHOUSING
fl
DOWELPIN
FLYWHEELHOUSINGGASKET
Reolace,
ASSEMBLY
OIFFERENTIAL
SNAPRING
COTTERRETAINER
COTTERS,
25.5 mm
Selectivepart
STARTCLUTCH
ASSEMBLY
Replace.
THRUSTSHIM,
25x35mm
Selectivepart
SECONDARY
GEARSHAFT
SECONDARY
DRIVE
GEARASSEMBLY
Replace.
PARKINGBRAKE
PAWLSI{AFT
ATF PASSAGE
PIPEASSEMBLY
O-RING
Replace.
6 x 1.0 mm BOLT
O-RING
Replace.
ATF PUMPDRIVECHAIN
SNAPRING
THRUSTSHIM,22 x 28 mm
Selectivepart
6 x 1.0mm BOLT
ATF PUMP DRIVE
SPROCKET
PITOTFLANGE
ATF PUMPDRIVE
HUB
SPROCKET
THRUSTWASHERS
PARKINGBRAKEPAWL
SPRING
INPUTSHAFT
PARKINGBRAKEPAWL
TRANSMISSIONHOUSING
ORIVENPULLEYSHAFT
14-248
1 . Removethe ATF passagepipe holderassembly.

Removethe flywheelhousing(twentybolts).
Removethe ATF passagepipe assembly(onebolt).
Removethe ATF pump drive sprocket(threebolts),
then removethe ATF pump drivecharn.
Move the pitot flange toward its cutout, then remove
the pitot flange.
10. Setthe specialtool on the startclutch,and attachthe

pawl of the specialtool to the parkinggear securely
as snown.
CAUTION:
. Do not place the pawl ol the special tool on the
start clutch guide. lf the pawl of the special tool
contacts the slart clutch guide. the start clutch
guide may be damaged.
. Be sure not to allow dust and other toreign particles to enter into the driven pulley shaft.
STARTCLUTCH
REMOVER
07TAE- P4V0120
STARTCLUTCH
ASSEMBLY
Replace.
PITOT PIPE
1 1 . R e m o v et h e s t a r t c l u t c ha n d t h e s e c o n d a r yd r i v e
gear assemblyusing the specialtool, then remove
the secondarygearshaft.
Removethe snap ring securingthe ATF pump drive
sprockethub, then remove the 22 x,28 mm thrust
shim,the ATF pump drive sprockethub and the thrust
washers.
7.
START CLUTCH
REMOVER
07TAE- P4V0120
Removethe difterentialassembly.
Removethe parkingbrake pawl shaft,the parking
brakepawl spring,and the parkingbrakepawl.
Removethe snap ring securingthe startclutch,then
remove the cotter retainerand the cotters.
PARKING GEAR
14-249
)
Housing
RightSideGover/lntermediate
Removal
NOTE:
. Cleanall partsin solventor carburetorcleaner,and dry with compressedair.
. Elow out all passages.
housing.replacethe followingparts:
. When removingthe right sidecover/intermediate
- O rings
- Rightsidecovergasket
- Transmissionhousinggasket
- S e a l i n gr i n g s
- S e a l i n gw a s h e r s
SNAPRING
REVERSE
BRAKE
END PLATE
Dtsc
PLATE
8 x 1.25mm BOLT
6 x 1.0mm BOLT
{u
DISCSPRING
SNAP
THRUSTSHIM.
2 5 x 3 1m m
pan
Selective
RINGGEAR
RIGHTSIDECOVER
GASKET
Replace.
DOWELPIN
THBUSTWASHER
THRUSTNEEOLE
BEARING
8 x 1.25mm BOLT
THRUSTWASHER
CARRIERASSEMBLY
THRUSTWASHER
THRUSTNEEDLE
SEARING
SUN GEAR
INPUTSHAFT
TRANSMISSION
HOUSINGGASKET
Replace,
SNAPRING
CLUTCHEND
PLATE
FORWARDCLUTCH
ASSEMBLY
SEALINGRING(BUBBER}
Beplace.
DOWELPIN
SNAPRING
SPRINGRETAINER/
RETURNSPRINGS
14-250
TRANSMISSION
HOUSING
1 . R e m o v et h e r i g h t s i d e c o v e r ( t h r e e6 m m b o l t s ,
eleven8 mm bolts).
2. Removethe manualvalvebody linesA and B.
3 . Removethe snap ring securingthe ring gear,then
removethe thrustshim and the ranggear.
11. Compressthe returnsprings.then removethe snap

ring.
C A U T I O N :l f t h e s p r i n g l e t a i n e r t a b i s o n t h e
leverse brake piston, the spring retainer may be
damaged.Be sure the spring retainertab is not on
the piston.
SPECIALTOOL
R e m o v et h e s n a p r i n g s e c u r i n gt h e r e v e r s eb r a k e
discsand plates,then removethe reversebrakeend
plate,brakediscs,brakeplates,and discspring.
Removethe carrierwith the thrust washersand the
thrustneedlebearing,from the forwardclutch.
6 . Removethe sun gear and the input shaft as a sub
assemblyby pullingir.
The sun gear is pressfittedtightly into input shaft.
7 . Removethe snap ring securingthe forward clutch,
and removethe snapringsecuringthe forwardclutch
end plate,then removethe forwardclutchend plate.
8 . R e i n s t a ltl h e c a r r i e ro n t h e f o r w a r d c l u t c h ,t h e n
securethe carrierwith the snap ring on the forward
ciutchend plate.
SPRINGRETAIiIER
TAA
12. R e m o v et h e s p e c i a tl o o l , t h e n r e m o v et h e s p r i n g
retainer/return
springassembly.
Removethe sealingbolt securingthe reversebrake
pressureinspectionhole.
1 4 . Apply air pressureto the inspectionhole to remove
the reversebrakepiston.
SPRNG RETAINER/
RETURNSPRING
ASSEMBLY
9 . R e m o v et h e f o r w a r dc l u t c ha n d c a r r i e ra s s e m b l y
together.
REVERSEBRAKE
PISTON
1 0 . I n s t a l lt h e s p e c i a lt o o l t o r e m o v et h e s n a p r i n g
securingthe reversebrakereturnspring retaineras
snown.
o-Rt Gs
Replace.
BRAXE
REVERSE
SPRINGCOMPRESSOR
07TAE- P4V01r0
REVERSE
BRAXE
PRESSUR
INSPECNON
HOIT
SEALING
WASHER
Replace.
8 x 1.25 mm
18 N.m {1.Ekgl.m, 13 lbf.ftl
15. Removethe snap ring retainerfrom the drive pulley

shaft.
16. Removethe manualvalvebody (fivebolts).
'17 Removethe roller,and Dushthe controlshaftassembly toward the outsideof the transmissionhousing,
housing(fourbolts).
then removethe intermediate
14-251
ManualValveBody
NOTEI
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages,
o Coatall partswith CVTFluidduringassembly,
SPRINGSEAT
RVERSEINHIBITOR
VALVESPRING
INHIBITOR
REVERSE
VALVE
N'
MANUAL VALVE
MANUALVALVEBODY
andscoring.
14-252
ForwardGlutch
lllustrated Index
CLUTCHORUM
\
\
DISCSPRING
\ _
RETURNSPRING
RETAINER
SNAPRING
CLUTCHPLATES
Standardthickness:
2.00mm (0.079in)
CLUTCHEND PLATE
CLUTCHPISTON
clurcH Dlscs
Standardthickness;
1 . 9 4m m ( 0 0 7 6 i n )
SNAPRING
14-253
ForwardClutch
Disassembly
1.
Remove the snap ring, then remove the clutch end

plate, clutch discs, and plates.
3.
Installthe specialtools as shown.

CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SNAP RING
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
OTHAE PLsO,IOO
2.
Removethe discspring.
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
oTGAE-PG40200
DISC SPRING
CAUTION: lf either end ot the specialtool is set over

an area ol the spring retainor which is unsupported
by the return spring, the retainer may be damaged,
Be sure the specialtool is adiustedto have full contact with the spring retsiner.
Do not st hre.
SPECIALTOOL
SPRINGRETAINER
14-254
4.
6.
Wrap a shop rag aroundthe clutchdrum, and apply

air pressureto the fluid passage
to removethe piston.
Placea fingertip on the otherend while applyingair
pressure.
OSHA.APPROVED
30 p3i NOZZLE
5.
Removethe snapring.Then removethe specialtools,

and returnspring.
springretainer,
SPRINGRETAINER
14-255
ForwardClutch
ReassemblY
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleaner,and dry them with compressedalr'
. Blow out all Passages.
. Lubricateall partswith CVTFluidbeforereassemDly'
1.
the prsInspectthe checkvalve;i{ it's loose'replace

ton.
3.
pressure
lnstallthe pistonin the clutchdrum Apply
and rotateto ensureproperseatlng'
CVT Fluid
NOTE: Lubricatethe piston O-ring with
beforeinstalling
the
CAUTION: Do not pinch the O-ring by installing
piston with too much lorce
CHECKVALVE
PISTON
2.
Installnew O-ringson the clutchpiston'
and
l n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r '
retainer'
positionthe snap ring on the
O.RINGS
SNAP RING
SPRINGRETAINER
RETURNSPRING
CLUTCHDRUM
PISTON
14-256
5.
Installthespecialtools as shown,
6.
7.
I n s t a l l t h es n a p r i n g .
CLUTCHSPRING
COMPBESSOR
ATTACHMENT
OTLAE PX4OlOO
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
oTHAE-P150100
CLUTCHSPRING
COMPRESSOR
EOLTASSEMBLY
07GAE-PG40200
CAUTION: lf either end ot the specialtool is set over

an area ol the spring retainor which is unsupported
by the return spring, the retainer may be damaged.
Be sure the specialtool is adlusted to have full contact with the spring retainer.
SNAP RING
8.
Sot here.
Do not set hre.
SPECIALTOOL
RETAINER
(cont'd)
14-257
/
ForwardClutch
Reassembly(cont'dl
1 2 . I n s t a ltlh e s n a pr i n g .
9 . I n s t a ltlh e d i s cs p r i n g .
NOTE: Installthediscspringin the directionshown.
DISC SPRING
SNAPRING
".urr* o.r*
1 0 . Soakthe clutchdiscsthoroughlyin CVT Fluidfor a

m i n i m u mo f 3 0 m i n u t e s .
1' ]. Starting with a clutch plate, alternatelyinstall the
clutch platesand discs.Installthe clutch end plate
with flat sidetoward the disc.
NOTE:Beforeinstallingthe platesand discs,make
sure the insideof the clutch drum is free of dirt or
otherforeignmatter.
13, Verifythat the snap ring end gap is correct.

CLUTCH
DRUM
M i n i m u m7 . 9m m { 0 . 3 1i n )
CLUTCHEND PLATE
14-254
I
i
I
14. Measu.ethe clearancbetweenthe clutchend plate

andtop discwith a dial indicator.
Zerothe dial indicator with the clutch end plate lowered,and lift it up to
the snap ring.The distancethat the clutchend plate
moves is the clearancebetweenthe clutch end Dlate
andtop disc.
15. lf the clearance

is out of tolerance,
selecta new clutch
end platefrom the followingtable.thenrecheck.
NOTE:It the thickestclutchend plateis installedbut
the clearanceis still over the standard,replacethe
clutchdiscsand clutchplates.
PLATE I{UM8ER
Thicknoss
Clutch End Plate-to-TopDisc Clearance:

STANDARD:0.6 - 0.8 mm (0.024- 0.031in)
CLUTCH END PI-ATE
FORWARDCLUTCHEND PLATE
Plale No.
Part Numbel
Thickness
1or15
22561- P4V- 003 3 . 5m m ( 0 . 1 3 8i n )
2ot16
22562-P4V-003 3 . 6m m ( 0 . 1 4 2i n )
3or17
2 2 5 6 3 - P 4 V - 0 0 33 . 7m m ( 0 . 1 4 6i n )
4ot18
2 2 5 6 4 - P 4 V - O O 33 . 8m m ( 0 . 1 5 0i n )
'19
2 2 5 6 5 - P 4 V - 0 0 33 . 9m m ( 0 . 1 5 4i n )
6or20
7ot21
2 2 5 6 6 - P 4 V - 0 0 3 4 . 0 m m ( 0 . 1 5 7i n )
22561 -P4V OO3 4 . 1m m ( 0 . 1 6 1i n )
8ot22
2 2 5 6 8 - P 4 V - 0 0 34 . 2m m ( 0 . 1 6 5i n )
9or23
'10 24
or
2 2 5 6 9 - P 4 V - 0 0 3 4 . 3m m ( 0 . 1 6 9i n )
5 or
1 1o r 2 5
or
or
22510 P4V OO3 4 . 4m m ( 0 . 1 7 3i n )

225't1 P4V , OO3 4 . 5m m ( 0 . 1 7 7i n )
225-72-PAV-OO3
4 . 6 m m ( 0 . 1 8 1i n )
22573 - P4V - OO3 4 . 7 m m ( 0 . 1 8 5i n )
After replacingthe clutchend plate,make surethat

the clearanceis within tolerance.
r'
14-259
SecondaryGearShaft
25 x 35 mm Thrust Shim Selection
1.
Measurethe distancebetweenthe flywheelhousing

surfaceand the ball bearing as shown, then note
the measurement(Measurement
A).
4.
Calculate25 x 35 mm thrust shim thicknessbv followingformula.

FORMULA:
25 x 35 mm Thrust Shim Thickness
= Measurement A - Measurement B + Flywheel
HousingGasketThickness:0.5 mm (0.020in)
FLYWHEEL
HOUSING
--"i<t=''
fi-i"r*,.goi.r".."\ I
ExamDle:
MeasurementA:32.7mm (1.287in)
MeasurementB:30.1mm (1.185in)
25 x 35 mm Thrust Shim Thicknss
= 32.7mm 11.287
inl -30.1 mm {1.185in}
+ 0.5 mm (0.020in)
= 3.1 mm 10.122
in)
Select 25 x 35 mm Thrust Shim D.
5.
Selectthe 25 x 35 mm thrust shim from the following the table.

BALL
BEARING
FLYWHEEL
HOUSING
Installthe secondarygear shaft in the transmission

housrng.
M e a s u r et h e d i s t a n c eb e t w e e nt h e t r a n s m i s s i o n
h o u s i n gs u r f a c ea n d t h e t h r u s t w a s h e rm o u n t i n g
surfaceof the secondarygear shaft as shown,then
notethe measurement{Measurement
B).
No.
Part Number
Thickness
9 0 5 5 '-1P 4 V - 0 0 0
2 . 8m m ( 0 . 1 1 0
in)
9 0 5 5 2 - P 4 V - 0 0 0 2 . 9m m { 0 , 1 1 4i n )
9 0 5 5 3 - P 4 V - 0 0 0 3 . 0m m ( 0 . 1 1 8i n )
9 0 s 5 4 - P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2 2i n )
9 0 5 5 5 - P 4 V - 0 0 0 3 . 2m m { 0 . 1 2 6
in)
9 0 5 5 6 - P 4 V - 0 0 0 3 . 3m m ( 0 , 1 3 0
in)
SECONDARY
GEARSHAFT
9 0 5 s 7 - P 4 V - 0 0 03 . 4m m ( 0 , 1 3 4i n )
H
9 0 5 5 8 - P 4 V - 0 0 0 3 . 5m m ( 0 . 1 3 8i n )
9 0 5 5 9 - P 4 V - 0 0 0 3 . 6m m ( 0 . 1 4 2i n l
14-260
9 0 5 6 0 - P 4 V - 0 0 0 3 . 7m m ( 0 . 1 4 6
in)
90561- P4V- 000 3 . 8m m { 0 . 1 5 0i n )
Differential
lllustratedlndex
BacklashInspection
AOLTS
10 r 1.0mm
101N.m {10.3kgf.m.
74.5 |bfit)
Left'handthreads
1.
Placethe differential
assemblyon V-blocks,
and install
both axles.
2.
Checkthe backlashof both piniongears.

Standard(Newl:0.05- 0.15mm {0.002- 0.006inl
PINIONGEARS
FINALORIVENGEAR
BALLBEARING
lf the backlashis out of tolerance,replacethe differentialcarrier.
14-261
Differential
BearingReplacement
DifferentialCarrier Replacement
NOTE:Checkthe bearingsfor wear and rough rotation.

lf the bearingsare OK, removalis not necessary.
1.
1.
Removethe ball bearingsusinga bearingpuller,
Removethe final driven gear from the differential

carrier.
threads.
BOLTS
1 0x 1 . 0m m
98 N.m {10.0kg{.m,
72 tbf.ft)
Left-hand
threads
BALLBEARING
Installthe new ball bearingsusing the specialtool

with a pressas shown.
DIFFERENTIAL
CARRIEN
2.
Installthe final driven gear with its chamferedside

on the innerborefacingthe differentialcarrier.
Torquethe boltsto the specifiedtorque in a crisscross
panern.
TOROUE:98 N.m {10.0kgf.m, 72 lbf.ftl
BALLBEARING
14-262
Oil Seal Installation/SideClearance
Oil Seal Removal

1.
Removethe differentialassembly.
2.
Removethe oil sealfrom the transmissionhousing.
1 . I n s t a l la 2 . 5 0m m { 0 . 0 9 8i n ) t h i c k8 0 m m w i d e s e t
r i n gi n t h e t r a n s m i s s i ohno u s i n g .
NOTE:Do not installthe oil sealyet.
SETRING,
80 mm
Seleclivepart
TRANSIflSStON
HOUSING
TRANSMISSION
HOUSING
3.
OIL SEAL
Replace.
Remove the oil seal from the flywheel housing.
Installthe difterentialassemblyinto the transmission housingusingthe specialtool as shown.
HOUSING
(cont'd)
14-263
,l
Differential
Oil Seal Installation/SideClearance(cont'd)
3.
l n s t a l l t h ef l y w h e e l h o u s i n g ,a n d t i g h t e nt h e b o l t s .
4.
Measurethe clearancebetweenthe 80 mm set ring

a n d o u t e r r a c eo f t h e b a l l b e a r i n gi n t h e t r a n s m i s s i o nh o u s i n g .
0 - 015 mm (0 - 0 006 inl
STANDARD:
8 x 1.25mm
29 N m (3.0kgtm,22 lb{ft}
uH fs
DIFFERENTIAL
ASSEMBLY
TRANSMISSION
HOUSING
FLYWHEEL
HOUSING
FLYWTIEEL
HOUSINGGASKET
lf the clearance is more than the standard, select a

new set ring from the table, and install it.
SET RING, 80 mm
Thickness
PartNumber
90414-689-000
90415- 689 000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
in)
2 . 5 0m m ( 0 . 0 9 8
in)
2 . 6 0m m ( 0 . 1 0 2
2 . 7 0m m 1 0 . 1 0i6n )
in)
2 . 8 0m m ( 0 . 1 1 0
2 . 9 0m m ( 0 . 1 1i4n )
3 . 0 0m m 1 0 . 1 1i8n )
NOTE|lf the clearancemeasuredin step 4 is stan

to performsteps7 and 8
dard.it is not necessary
h
14-264
6.
Removethe flywheelhousing.
1.
Replacethe 2.50mm (0.098in) set ring,80 mm with

the one of the correctthicknessselectedin step5
FlywheelHousing
InputShaftOil Seal
Replacement
8.
Installthe oil seal in the transmissionhousingusing

1.
Removethe input shaft oil seal from the flywheel

houstng.
DRIVER
07749- 0010000
Installthe oil seal in the flywheelhousingusingthe

soecialtools as shown.
Installrhe oil seal in the flywheelhousingusingthe

specialtools as shown.
FLYWHEEL
DRIVER
x 72 mm
ATTACHMENT,5E
079{?- 6340201
PILOT,
26r30mm
07JAD- PH80200
Installed depth:
2.5 - 3.5 mm
,"rf
fo"rrr'l,i.ttl,
t@
ATTACHMENT,
32x35mm
07746- 0010100
14-265
Transmission
HousingBearings
Driven Pulley Shaft Bearing Replacement
'1. To
removethe driven pulleyshaft bearingfrom the
t r a n s m i s s i o nh o u s i n g ,e x p a n dt h e s n a p r i n g w i t h
s n a p r i n g p l i e r s ,t h e n p u s h t h e b e a r i n go u t u s i n g
the specialtoolsand a pressas shown.
\
Expandthe snap ring with snap ring pliers. insert
the new bearing part-way into the housing using
the specialtools and a press as shown. Installthe
bearingwith the groovefacingoutsidethe housing.
NOTE:Do not removethe snap ring unlessit's necessaryto cleanthe groovein the housing.
N O T E :C o a ta l l p a n sw i t h C V TF l u i d .
Releasethe pliers.then push the bearingdown into
the housinguntil the ring snaps in placearound it,
u s i n gt h e s p e c i a l t o o lass s h o w n .
07749- 0010000
BEARING
ATTACHMENT,
72x75mm
07746 - 0010600
GBOOVE
SNAPRING
ATTACHMENT.
72x75mm
07746- 0010600
4.
After installingthe bearingverifythe following:

.
.
.
The snap ring is seatedin the bearingand housIng gfooves.

The snap ring operatesproperly.
The ring end gap is correct.
ENDGAP:0-9mm
(0- 0.35in)
BEARING
14-266
HOUSING
SNAPRING
FlywheelHousing
Bearing
SecondaryGear Shaft Bearing
Replacement
1.
Removethe secondarygear shaft bearingusingthe

s p e c i a l t o o lass s h o w n .
SecondaryGearShaft Bearing
Replacement
1.
Removethe secondarygear shaft bearingusingthe

soecialtool as shown,
3/8" - 16 SLIDEHAMMER
GEAR
SECONDARY
BEARING
ADJUSTABLE
- ,10mm
PULLER,25
07?36- 4010004
SHAFTBEARING
Installthe new secondarygear shaft bearinguntil it

bottomsin the transmissionhousing,usingthe spec i a l t o o l sa s s h o w n .
ADJUSTABLEBEARING
- 40 mm
PULLER.26
07736- A01000A
lnstallthe new secondarygear shaft bearinguntil it

bottoms in the flywheel housing,using the special
tools as shown.
DRIVER
07749- 0010000
ATTACHMENT,
72 x 75 mrn
07746- 0010600
ATTACHMENT.
62x68mm
07746- 0010500
14-267
RingGearBearing
ControlShaft Assembly
Replacement
RemovaUlnstallation
1.
1.
R e m o v et h e r i n g g e a r b e a r i n g .
Remove the bolt and lock washer.
CONTROLSHAFT
ASSEMBLY
TRANSMISSION
RING
RINGGEAR
Installthe new ring gear bearinguntil il bottoms in

the ring gear,usingthe specialtools as snown.
6x1.0mm
14 N.m (1.4kgf.m,
10 tbf.ttl
CONTROL
LEVER
LOCKWASHER
Replace.
DRIVER
0?749- 0010000
Removethe controlleverfrom the controlshaft.

3.
Removethe controlshaftassembly.
Installthe controlshaftassemblyin the transmission
nousrng.
b
14-268
5.
Installthe controlleverto the controlshaft.
6.
Installand tightenthe bolt with a new lockwasher.
Transmission
Reassembly
CAUTION:Whilereassembling,
be sure not to allow dust and other foreignparticlesto enter into the transmission.
NOTE:
. Coatall partswith CVTFluid.
. Replacethe followingparts:
- O-rings
- S e a l i n gr i n g s
- S e a l i n gw a s h e r s
- Gaskets
- Stan clutchassemblyand Secondarydrive gear assembly
8 x 1.25mm
37 N.m {3.8kgl.in, 27 lbt.ft)
SNAPRING
6x1.0mm
12 N.m lI.2 kgf.m,8.7lbnftl
MANUAL VALVE
REVERSEERAKE
ENDPLATE
RIGHTSIDECOVER
DOWEL
PIN
olsc
PLATE
RIGHTSIDECOVEBGASKET
O.RINGS
DISCSPRING
6x1.0mm
12 N m (1.2kgf.m.8.7lbf.ftl
THRUSTSHlM.25x 31 mm
part
Selective
SNAP
RING
RINGGEAR
THRUSTWASHER
8 x 1.25mm
29 N.m 13.0kgt ln.22lbtftl
MANUAL
VALVE
BODY
THRUSTNEEOLE
BEABING
INTERMEDIATE
HOUSINGASSEMBLY
THRUSTWASHER
CARRIERASSEMBLY
THRUSTWASHER
ROLLER
THRUSTNEEOLE
BEARING
SUN GEAR
ATF FEEDPIPE
INPUTSHAFT
TRANSMISSION
HOUSINGGASKET
O.RINGS
SNAPRING
FORWARDCLUTCH
CONTROLSHAFT
ASSEMBLY
SNAP AING
SPRINGRETAINER/
RETURN
SPRING
ASSEMBLY
DOWELPIN
REVERSE
BRAKEPISTON
O.RINGS
HOUSING
SNAPRINGRETAINER
ATF FEEDPIPES
14-270
Installthe ATF feed pipe in the transmissionhousing, and installthe three ATF feed pipeswith new
O - r i n g si n t h e t r a n s m i s s i ohno u s i n g .
hous2 . Installthe two dowelpinsand newtransmission
ing gasketon the transmissionhousing.
?
Pushthe controlshaft assemblytoward the outside
of the transmissionhousing,then installthe intermediatehousingassembly(fourbolts).
lnstall the manual valve body separatorplate and
the two dowel pins on the intermediatehousing.
then installthe manual valve body with the detent
spring (fivebolts).
Put the controlshaft assemblyback,then installthe
rollerin the intermediatehousing.
Installthe reversebrake piston in the intermediate
housing.
spring assemblyon
7 . lnstallthe springretainer/retu.n
the reversebrakePaston.
Compressthe return springs.then installthe snap

ring in the intermediatehousing above the spring
retarner.
1.
NOTE:Installthereturnspringson the springguides

oJthe reversebrake piston securelY
Installthe specialtool to compressthe returnsprlng
as shown.
REVERSE
BRAKE
SPRING
COMPRESSOE
1 0 . Verifythat the snap ring end gap is correct

M i n i m u m1 5m m ( 0 . 5 9i n )
,a7 "-,,,,.
\.,
/
,'t
SNAPRING
/,.'
ir
ir
/
'
',
/
.
:''
1 1 . S o a k t h e r e v e r s eb r a k e d i s c st h o r o u g h l yi n C V T
F l u i df o r m i n i m u m3 0 m i n u t e s
Installthe discspringon the reversebrakepiston.
t5.
S l a r t i n g w i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
installthe reversebrakeplatesand discs lnstallthe
reversebrakeend piate,and the snap ring
1 4 . Measurethe clearancebetweenthe reversebrake
end plateand the top discwith a dial indicator.Zero

t h e d i a l i n d i c a t o rw i t h a r e v e r s eb r a k ee n d p l a t e
lowered,and lift it up to the snap ring.The distance
that the reversebrakeand plate moves is the clearance between the reverseend plate, and the top
disc.
o?TAE- P4V0110
NOTE:Take measurements
and usethe averageas the actualclearance
0.45- 0.75mm (0.018- 0.030in)
STANDARD:
CAUTION:lf the spring letainer tab is on the reverse

brake piston, the spring retainer may be damaged.
Be sure the spring retainertab is not on the piston.
SPECIALTOOL
BRAKE
REVERSE
(cont'di
14-271
Transmission
Reassembly(cont'd)
lf the clearance
is not withinthe standard,removethe
reversebrakeend plateand measureits thickness.
S e l e c ta n d i n s t a l la n e w r e v e r s eb r a k ee n d p l a t e ,
then recheck.
22. Verily that the outside diameter of the snap ring is

correct.
Maximum4l 4 mm 11.63in)
N O T E : l f t h e t h i c k e s tr e v e r s eb r a k ee n d p l a t e j s
installed,but the clearanceis still over the standard,
replacethe reversebrakediscsand plates.
REVERSE
BRAKEENDPLATE
""^rr,""()
PlateNo.
Part Number
Thickness
22551 - P4V 003 3 . 6m m ( 0 . 1 4 2i n )

22552 - P4V 003 3 . 8m m ( 0 . 1 5 0i n )
2 3 . I n s t a l lt h e i n p u t s h a f t a n d t h e s u n g e a r a s a s u b
assembly.
22553-P4V
2 4 . I n s t a l lt h e t h r u s t n e e d l e b e a r i n g a n d t h e t h r u s t
washer on the sun gear.
OO3 4 . 0 m m ( 0 . 1 5 7i n )
22554- P4V 003 4 . 2m m 1 01. 6 5i n )

5
2 2 5 5 5 - P 4 V - 0 0 3 4 . 4m m ( 0 . 1 7 3i n )
2 2 5 5 6 - P 4 V - 0 0 34 . 6m m ( 0 . 1 8 1i n )
22551-P4V -OO3 4 . 8m m ( 0 . 1 8 9i n )
2 2 5 5 8 - P 4 V - 0 0 3 5 . 0m m ( 0 . 2 0 0i n )
1 7 . After replacingthe reversebrake end plate, make

s u r et h a tt h e c l e a r a n cies w i t h i nt h e s t a n d a r d .
1 8 . R e m o v et h e s n a p r i n g , r e v e r s eb r a k ee n d p l a t e ,
dascs,plates,and discspring.
1 9 . l n s t a l lt h e s n a p r i n g r e t a i n e ro n t h e d r i v e p u l l e y
shaft.
20. Wrap the drive pulleyshaftsplineswith tapeto prev e n t d a m a g et o t h e O - r i n g s ,t h e n i n s t a l ln e w O flngs.
Installtheforwardclutchassemblyon the drive pul
ley shaft,then installthe snap ring.
CARRIERASSEMBLY
THRUST
THBUSTNEEDLE
BEARING
SNAPBIT{G
O.RINGS
SNAP RING
RETAINER
25. Installthe carrierassemblyon the forwardclutch.
14-272
26. Installthe thrust washer,the thrust needlebearang,

and the thrustwasheron the carrierassembly.
THRUSTSHIM,
2 5 x 3 1m m
part
Selective
SNAPBING
30. lf the clearanceis out of tolerance,removethe 25 x

31 mm thrustshim and measureits thickness.
3'|. Selectand install a new 25 x 3'l mm thrust shim,

then recheck.
THRUSTSHIM.25 x 31 mm
RINGGEAR
Part Number
No.
THRUSTNEEDLE
BEANING
THRUSTWASHERS
Thickness
90451- P4V- 000
1.05mm (0.011in)
90452 P4V- 000
1 . 1 2m m ( 0 . 0 4 i4n )
90453 P4V- 000
1 . 1 9m m ( 0 . 0 4 i7n )
9 0 4 5 4 - P 4 V - 0 0 0 1.26mm (0.050inl
9 0 4 5 5 - P 4 V - 0 0 0 1.33mm {0.052in)
9 0 4 5 6 - P 4 V - 0 0 0 1.40mm (0.055in)
'1.47mm (0.058in)
90457-P4V-000
9 0 4 5 8 - P 4 V - 0 0 0 1.54mm (0.061in)
9 0 4 5 9 - P 4 V - 0 0 0 1.61mm {0.063in)
27. Installthe ring gearand the 25 x 31 mm thrustshim.

then installthe snap ring.
28. Verifythat the outsidediameterof the snap ring is

correct.
Maximu3
m0 . 7m m( 12 1i n )
F
1
't'":'
/./
i\
,
SruEP
RING,
K
L
90461- P4V 000

90462 P4V- 000
in)
9 0 4 8 0 - P 4 V - 0 0 0 1.085mm (0.0427
in)
9 0 4 8 1 - P 4 V - 0 0 0 1.155mm 10.0454
in)
9 0 4 8 2 - P 4 V - 0 0 0 1.225mm (0.0482
in)
9 0 4 8 3 - P 4 V - 0 0 0 1.295mm (0.0510
in)
9 0 4 8 4 - P 4 V - 0 0 0 1.365mm {0.0537
in)
90485 P4V- 000 1.435mm (0.0565
'
1.75rnm {0.069in}
1.82mm (0.072in)
in)
9 0 4 8 6 - P 4 V - 0 0 0 1.505mm (0.0593
rl
l\ r
/
9 0 4 6 0 - P 4 V - 0 0 0 1.68mm (0.066in)
\\
/l
in)
9 0 4 8 7 - P 4 V - 0 0 0 1.575mm (0.0620
in)
9 0 4 8 8 - P 4 V - 0 0 0 1.645mm (0.0648
in)
9 0 4 8 9 - P 4 V - 0 0 0 1.715mm (0.0675
'1.785
in)
mm {0.0703
90490-P4V-000
29. M e a s u r et h e c l e a r a n c eb e t w e e nt h e 2 5 x 3 1 m m
thrustshim and the snap ring.
STANDARD:0.05- 0.11 mm 10.0020- 0.00/B inl
32. After replacingthe 25 x 31 mm thrust shim, make

sure that the clearanceis within toleranceand the
snap ring outsidediameteris correct
Installthe discspringin the directionshown.
34. S t a r t i n g w i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
i n s t a l lt h e r e v e r s eb r a k eD l a t e sa n d d i s c s .l n s t a l l
selectedreversebrake end plate. then install the
snapflng.
BRAKE
REVERSE
END PLATE
,*"ua{t",",
'!
REVERSEBRAKE
PLATES
ttl.
RINGGEAB
Dtscs
OISCSPRING
lnstallin this direction
(cont'd)
14-273
Transmission
Reassembly(cont'dl
35. Verifythat the snap ring end gap is correct.
M i n i m u m1 8m m ( 0 . 7 1i n )
-t\
I'J
.,..
1' r
39. Installthe parkingbrakepawl, spring,and shaft on

t h e t r a n s m i s s i o nh o u s i n g ,t h e n m o v e t h e c o n t r o l
leverto any gearotherthan E position.
SNAPRING
THRUSTSHIM,
.\i
,
COTTER
RETAINER
COTTERS,
25.5mm
pan
Selective
SECONDARY
GEABSHAFT
sruapntruc-/ \ . : : ,/
36. I n s t a l tl h e m a n u a lv a l v eb o d y p i p e sA a n d B w i t h
new O-ringson the manualvalvebody and the intermediatehousing.
STARTCLUTCH
ASSEMBLY
PABKINGBRAKE
PAWLSHAFT
6x1.0mm
12Nm(1.2kgf.m.
8.7 tbt.ftl
t'tl\
8 x 1.25mm
37 N.m (3.8kgI.m,27 lbt.ft)
SECONDARY
DRIVEGEAR
ASSEMBLY
f, E
\
" J
E P
9>-
O-RINGS
PARKINGBRAKE
PAWLSPRING
PARKING
RIGHTSIDE
COVERGASKET
DOWELPINS
ORIVENPULLEY
SHAFT
O.RINGS
40. Installthe secondarygear shaft with selected25 x

3 5 m m t h r u s ts h i m( s e ep a g e1 4 - 1 0 0 ) .
MANUAL VALVE
BODYPIPEA
ATF FEEO
PIPES
MANUALVALVE
BODY
37. Installthe two dowel pins and new right side cover
g a s k e to n t h e i n t e r m e d i a t eh o u s i n g ,t h e n i n s t a l l
new O-ringson the ATFleed pipes.
38. Installthe right sidecover (three6 mm bolts,eleven

8 mm bolts).
N O T E :I n s t a ltlh e n i n e 8 m m b o l t si n t h e r i g h ts i d e
cover (two 8 mm bolts remainin the right side
cover)then tightenthe eleven8 mm bolts.
14-2 7 4
4 1 . W r a p t h e d r i v e n p u l l e ys h a f ts p l i n e sw i t h t a p e t o
preventdamageto the O-rings,then installnew Onngs.

42. Assemblethe secondarydrive gear assemblyin the
startclutchassemblv.
then installthem on the driven
oullevshaft.
43. P u l lt h e h a n d l eo f t h e s p e c i a tl o o l u p , t h e n i n s t a l l
the tip of it into the driven pulleyshaft hole,and set
the soecialtool on the startclutchCAUTION:While installing the start clutch and the
secondarydriv gear assemblyusing the special
tool, be sure not to allow dust and other toreign
particlesto enter into the transmission.
STARTCLUTCH
INSTALLER
07TAE- P4V0130
t r , ,n u n a ' " .
44. Pushthe handleof the specialtool, then tightenthe

nut to seat the secondarydrive gear assemblyon
the drivenpulleyshaftsecurely.
4't. It the clearanceis not within the standard.remove

the cottersand measureth eir thickness.
48. Selectand installnew cotters,then recheck.
S?ART CLUTCHINSTALLER
coTTERS,25.5mm
No.
Thickness
Part Numbel
9 0 4 2 9 - P 4 V - 0 0 02 . 9m m { 0 . 1 1 i4n )
9 0 4 3 0 - P 4 V - 0 0 0 3 . 0m m ( 0 . 1 1i8n )
90431- P4V- 000 3 . 1m m { 0 . 1 2 2i n )
9 0 4 3 2 - P 4 V - 0 0 03 . 2m m { 0 . 1 2 6i n )
49. After replacingthe 25.5mm cotters,make surethal

the the clearanceis the standard.
50. I n s t a ltlh e c o t t e rr e t a i n ear n dt h e s n a pr i n g .
Verifyrhat the outsidediameterof the snap ring is
correcI.
Minimum33.9mm 11.33in)
HANOLE
45. Pull the handleof the specialtool up, and remove

the specialtool46. Installthecotters,then measurethe clearancebetween
the cottersand the slart clutchguide.
STANDARD:
0 - 0.13mm {0 - 0.005in)
"no"*,/\--/
52. I n s t a l tl h e t h r u s tw a s h e r s t, h e A T F p u m p d r i v e
sprockethub and the 22 x 28 mm thrustshim on the
input shaft,then installthe snap ring.
SNAPRING\
anat leastthfee places,

NOTE|Takemeasurements
ATF PUMPDRIVE
SPNOCXET
HUA
Selectiveoan
THRUSTWASHENS
COTTERS,
25.5mm
GAUGE
li
l)
STARTCLUTCH
GAUGE
,l
lf
STARTCLUTCH
( c o n td )
14-275
Transmission
(cont'dl
Reassembly
53. Verifythat the outsidediameterof the snap ring is
correct.
r5
M a x i m u m2 6 . 3m m { 1 . 0 4i n )
5 1 . After replacingthe 22 x 28 mm thrust shim, make

sure that the clearanceis within toleranceand the
snap ring outsidediameteris correct
58. Installthe pitot flange using its cutout as shown to
clearthe pitot pipes.
INPUTSHAFT
54. Measurethe clearancebetween the 22 x 28 mm

thrustshim and the snap ring.
STANDARD;0.37- 0.65 mm 10.015- 0.026in)
Eq
THFUSTSHIM,
22x28 mm
lnstall the ATF pump drive sprocket.and put the

ATF pump drive chain on the ATF pump drive and
driven sprockets.then lnstall and tighten the bolts
(threebolts),
PUMPORIVECHAIN
6 x 'l.0mm
lf the clearanceis out of tolerance,removethe 22 x

28 mm thrustshim and measureits thlckness.
56. Selectand install a new 22 x 28 mm thrust shim,
then recheck.
12 N.m
(1.2kgf.m,8.7lbtft)
ATF PUMP DRIVE
SPROCKET
PITOTFLANGE
THRUSTSHIM.22 x 28 mm
No.
Part Number
Thickness
90573-P4V-000 1.'1m
5 m {0.045
in)
9 0 5 7 4 - P 4 V - 0 0 0 1.40mm (0.055in)
9 0 5 7 5 - P 4 V - 0 0 0 1.65mm (0.065in)
9 0 s 7 6 - P 4 V - 0 0 01 . 9 0m m ( 0 . 0 7 5i n )
ATF PUMP
9 0 5 7 7 - P 4 V - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n )
H
14-276
9 0 5 7 8 - P 4 V - 0 0 0 2.40mm (0.095in)
INPUTSHAFT
60. Installthe differentialassembly.

61. Installthe ATF passagepipe assemblywith new O-rings(one bolt).
62. Installthe three dowel pins and new flywheelhousinggasketon the transmissionhousing
63. Installthe flywheelhousingand connectorbracket(twentybolts).
64. InstalltheATF passagepipe holderassembly(two bolts).

8 x 1.25 mm
29 N.m (3.0k91.m,22lbl'ftl
6x1.0mm
12 N.m {1.2kgf.m,
8.7 tbI.ft)
arF PAssAGEPIPE
I
ASSEMBLY
HOLDER
I
\
E {u
FLYWHEELHOUSING
\n
f-{
\A
[tr1
o-RrNG-___\S/
CONNECTOR
ERACKET
ATF PASSAGEPIPE
DOWEI.PIN
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbtftl
DIFFERENTIAL
ASSEMBLY
DOWELPIN
DOWELPIN
at":
FLYWHEEL
HOUSING
GASKET
,):/;[
ri-{e
TRANSMISSIONHOUSING
( c on t ' d)
14-277
Transmission
(cont'dl
Reassembly
65. Installthe solenoidharnessconnectorwith a new O-ring{one bolt},then installthe lower valve body assemblywith
threedowel pins (eightboltsl.
66. Installthe ATFstrainerwith a new O-ring(two bolts).
67. lf necessary,
assemblethe ATF pan,ATFfilter,and the ATF coolerinlet pipe(seepage'14-235).
68. Installthe ATF pan with the two dowel pins and a new ATF pan gasket(fourteenbolts).
69. Installthe ATFcoolerinlet pipe bracketbolt.
70. lnstalltheATFcooleroutletpipe with the joint bolt and new sealingwashers.
6x1.0mm
12 N.m 11.2kgf m,
8.7 tbt.ftl
DOWELPINS
ATF STRAINER
O-RING
ATF COOLEROUTLETPIPE
OOWELPINS
ATF PAN/ATFFILTER/
ATF COOLERINLET
PIPEASSEMEI-Y
SEALING
WASHERS
O-RING JOTNTBOLT
28 N.m {2.9ksf.m, 21 lbf.ft)
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbf.ttl
HARNESS
CONNECTOR
5x1.0mm
12 N.m {1.2kgt.m,
8.7 tbf.ftl
LOWERVALVEBODY
ASSEMBLY
6x1.0mm
12 N.m 11.2kgt m,
8.7 tbf.ft)
ATF COOLEFINLET
PIPEERACKETBOLT
8 x 1.25mm
26 N.m (2.7kgf.m,20 lbf.ftl
14-278
Flywheel/DrivePlate
WASHER
DRIVEPLATE
6nKn,
wear.
teethot the ring gearfor excessive
1 2x 1 , 0m m
74 N.m {7.5kgI.m, 54lbl.ftl
Torque in 6 crisscrosspattern.
14-279
Transmission
Installation
Flushthe ATF cooleras describedon pages'14-284
a n d1 4 ' 2 8 5 .
2.
R e m o v et h e u s e d g r e a s ei n t h e f l y w h e e lh u b c a p
and flywheelsplines.
3.
Fillthe insideof the flywheelhub cap,andcoatthe fly

wheelhub splineswith SuperHighTempUreaGrease
(P/N08798- 9002)as shown.
6.
Placethe transmissionon a jack,and raise it to the

e n g i n ea s s e m b l lye v e l .
7.
Attach the transmissionon the engine,then install

h o u s i n gm o u n t i n gb o l t a n d r e a r
the transmission
e n g i n em o u n t i n gb o l t s .
TRANSMISSION
HOUSING
MOUNTINGBOLT
64 N.m (6.5kgt.m,
41
REARENGINEMOUNTING
BOLT
Replace.
'12x 1,25mm
59 N.m (6.0 kgf.m, 43 lbtftl
SPLINES
Apply SUPERHIGHTEMP
UREAGREASE
{P/N 08798- 90021
WASHER
.:_11
SUPERHIGHTEMP
UREAGNEASE
{P/N 08798- 90021

1.5- 2.5 g (0.05- 0.ogozl
8.
4.
) n the input
Instala
l n e w s e a l i n gr i n g ( r u b b e r o
shaft,and installtwo 14 x 20 mm dowel pins in the
llywheelhousing.
lnstallthe flywheelsecurelyon the input shaft,then
installthestartermotor on the flywheelhousing.
lnstallthe transmissionmount bracket Tightenthe

long bolt loosely,and tighten the nuts and bolt on
t h e m o u n t b r a c k e t o t h e s p e c i f i e dt o r q u e .T h e n
tightenthe long bolt to the specifiedtorque.
1 2x 1 . 2 5m m
64 N.m {6.5kgl.m, 47 lbl.ft)
44 N.m
(4.5kgf.m.33 lbf.ft)
INPUTSHAFT
STARTER
rtl
14x20mm
DOWEI-PIN
MOUNT
S E A L I N GR I N G
{RUBBER)
14 x 20 mm DOWELPIN
FLYWHEEL
14-280
12 x L25 mm
74 N.m {7.5kgl.m,54lbtft}
9. Installthe remainingtransmissionhousingmounting bolts.

PRIMARYOXYGENSENSOR
13. Tightenthe crankshaftpulleybolt, if necessary(see

section6).
1 4 . Connectthe ATF cooler hosesto the ATF cooler pipes
(seepage 14-2891.
CAUTION: While connecting the ATF cooler hoses,
be sure not to allow dust and other loreign particles to enter ioto the transmission.
Installthe rightfront mounvbracket.
10 x 1.25mm
4{ N.m (,1.5kgl m, 33 lbf ftl
RIGHTFRONT
MOUNT/EFACKET
ATF COOI.IRPIPE
1 0 . Removethe transmissionjack and the hoist, then

removethe hoist bracketfrom the engine.
1 1 . Attach the flywheel to the drive plate with eight
boltsand torqueas follows:
to tighten
Rotatethe crankshaftpulleyas necessary
the bolts to half of the specifiedtorque,then to the
final torque,in a crisscrosspattern.
A f t e r t i g h t e n i n gt h e l a s t b o l t , c h e c kt h a t t h e
crankshaftrotatesfreely.
'10x 1.25mm
54 N.m 15.5kgt m,
{0 rbf.ft)
ATF COOI.ERHOSE
16. Install the exhaust pipe A.
EXHAUSTPIPEA
1 2 . Installthe flywheelcoverand the enginestiffeners.
DRIVE
TE
6x1.0mm
12 N.m
10 x 'l .25 mm
11.2kotm. ENGINE
STIFFENER ,14N.m (4.5kgf.m,
e.zruittt
33 tbt.ftl
GASKET
Replace.
8 x 1.25mm
24Nm
(2.6 kgf.m,
17 tbf.ftl
oo"*ar-@
DRIVEPLATEBOLT
6x1.0x14mm
12 N.m {1.2kgt m,
8.7 tbl.ft|
FLYWHEEL
ENGINE STIFFENER
8 x 1.25mm
24 N.m (2.4 kgf'm, 17 lbt ft)
Replace.
8 x 1.25mm
26 N.m
12.7kgl..n.
20 rbf.ft)
10 x 1.25mm
44 N.m (4.5kgf.m,
33 rbtft)
SELF.LOCKING
Beplace.
8 x 1.25mm
22 N m {2.2kgf.m,16lbtftl
NUT
SELF.LOCKING
Replace.
10x 1.25mm
54 N.m (5.5kgf m,
4r) tbt.ftt
NUT
SELF.LOCKING
Replace.
8 r 1.25 mm
16 N.m 11.6kgf m,
12 tbf.ft)
(cont'd)
14-281
Transmission
1 7 . Installa new set ring on the end of eachdriveshaft.
\
20. Installthe splashshield.
1 8 . Installtheright and left driveshafts(seesection16).

CAUTION:While installing the drivcshalts in the
diflerential, be sure not to allow dust and other foreign particlesto enter into the transmission.
NOTE:
I Cleanthe areaswherethe driveshaftscontactthe
( d i f f e r e n t i atl h) o r o u g h l yw i t h s o l transmission
v e n t o r c a r b u r e t o cr l e a n e r ,a n d d r y w i t h c o m
pressedarr.
. Turn the right and left steeringknucklefully outward, and slideeach driveshaftinto the differential until you {eel its set ring clip engagethe side
gear.
1 9 . Installthe damperfork,then installthe right and left
b a l l j o i n t st o e a c h l o w e r a r m w j t h t h e c a s t l en u t s
and new cotterprns.
10 x 1,25mm
43 N.m
(4,4kgf.m,32 lbf.ftl
SPLASHSHIELD
6 x 'l.O mm
9.8 N.m {1.0kgf.m,
7 .2 tbl'ttl
2 1 . C o n n e c t h e v e h i c l es p e e ds e n s o rc o n n e c t o rt,h e
driven pulley speed sensorconnectorand the secondarygear shaftspeedsensorconnector.
VEHICLESPEEO
SENSOR
CONNECTOR
6x1.0mm
'12N.m
{1.2kgf.m, 8.7 lbl.ft}
DRIVENPULLEY
SPEEO
SENSOR
CONNECTOR
NUT
SELF-LOCKING
./*:,
./
cbr-rERPtN
Replace.
CASTLENUT
Beplace.
12x 1.25nm
1 2x 1 . 2 5m m
64 N.m
{6.5 ks{.m,47 lbf.ftl 4 9-- 5 9 N m 1 5 . 0 - 6 . 0 k g f . m ,
36 43 tbf.ftl
a'.
SECONDARY
GEAR
SHAFTSPEED
SENSORCONNECTOR
14-282
6x1.0mm
12 N.m 11.2kgl m, 8.7lbf.ftl
22. Installthe shift cableend on the control lever,and

installthe shift cableon the shift cablebracket.
CAUTIONT
Takecarenot to bendthe shift cable.
2 3 . I n s t a l l t h ce l i pi n t h e d i r e c t i o sn h o w n .
SHIFTCABLE
25. Connectthe startermotor cableon the startermotor,

and installthe cableholder.
NOTErWhen installingthe startermotor cable,make
s u r e t h a t t h e c r i m p e ds i d e o f t h e r i n g t e r m i n a li s
facingout (seesection23).
LOCKNUT
29 N.m (3.0 kgl.m, 22 lbfftl
STARTERMOTOR
SHIFTCABLE
BRACKET
WASHER
IPLASTIC}
STARTER
B TERMINAL
MOUNTINGNUT
I N.m 10.9kgt.m, 7 lbtft)
CONTBOL
LEVER
24. Connectthe solenoidharnessconnector,the drive
p u l l e y s p e e d s e n s o rc o n n e c t o r ,a n d t h e g r o u n d
c a b l et e r m i n a l s .
6x1.0mm
12 N.m {1.2kglm,
8.7 tbt.f0
GROUNDCABLE
6x1.0mm
TERMTNAL
12 N.m 11.2kgl.m,
8.7 rbf.ftl
26. Installall removedconnectorsand clamps.

27. Inslallthe distributor.
2 8 . I n s t a l tl h e i n t a k ea i r d u c t a n d a i r c l e a n e rh o u s i n g
assemDty.
2 9 . R e f i l l t h e t r a n s m i s s i o nw i t h t h e r e c o m m e n d e d
G e n u i n eH o n d aC W F l u i d( s e ep a g el 4 - 2 3 1 ) ,
CAUTION:While lilling the CVT Fluid,be sure not to
allow dust and other toreign particles to enter into
the transmission.
30. Connectthe battervpositive(+) terminalfirst, then
DRIVEPULLEY
SPEEDSENSOR
CONNECTOR
the negative{-) terminalto the battery.

Checkthe ignitiontiming (seesection231.
a ) Startthe engine.Setthe parkingbrake,and shiftthe
t r a n s m i s s i otnh r o u g ha l l g e a r st h r e et i m e s .C h e c k
shift cableadjustment(seepage14-287).
33. Checkthe front wheelalignment(seesection18).
3 4 . L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
r a d i a t o fr a n c o m e so n ) w i t h t h e t r a n s m i s s i oinn E
or E position,then turn it of{ and checkfluid level.
3 5 . P e r f o r mt h e s t a r tc l u t c hc a l i b r a t i o np r o c e d u r eo n
page 14-225.
36. Roadtest as describedon pages14 228 and 14-229.
14-283
Transmission
CoolerFlushing
To prevent iniury to face and eyes, always
!@
wear satety glassesor a face shield when using the
transmissionflusher,
\
7. With the water and air valves off, attach the water and
air suppliesto the flusher. (Hot water if available.)
NOTE:This procedureshouldbe performedbeforereinstallinqthe transmission.

1.
C h e c kt o o l a n d h o s e sf o r w e a r a n d c r a c k sb e f o r e
using.lf wear or cracksare found, replacethe hoses
be{oreusing.
2.
Usingthe measuringcup,fill the tankwith 21 ounces

(approximately213tulll ot biodegradableflushing
fluid (J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
container.
3 . Securethe flusherfiller cap,and pressurizethe tank

with compressedair to between550- 829 kpa (5.68.45kgf/cm,,80- 120psi).
NOTE:The air line shouldbe equippedwith a water
trap to ensurea dry air system.
4.
Hangthe tool underthe vehicle.
5.
Attach the tank's dischargehose to the return line

of the transmissioncoolerusinga clamp.
6.
8. Turn on the flusher water valve so water will flow

throughthe coolerfor 10 seconds.
NOTE:lf water does not flow throughthe cooler,it
is completelyplugged,cannotbe flushed,and must
be replaced.
9. Depressthe triggerto mix the flushingfluid into the
waterflow. Usethe wire clipto holdthe triggerdown.
Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamp.
10. While flushingwith the water and flushingfluid for

two minutes,turn the air valve on for five seconds
every '15- 20 secondsto createa surgingaction.
AIR PRESSURE:
MAX 845 kpa(8.45kgtcm,, 120psi)
IMPORTANT:
Securelyclampthe oppositeend ol the drain hoseto a
bucketor floor drain.
11. Turn the water valve off. Releasethe trigger,then

reversethe hosesto the coolerso you can llush in
the oppositedirection.Repeatsteps8 through 10.
Releasethe trigger,and rinsethe coolerwith water
o n l yf o r o n e m i n u t e .
Turn the water valveoff, and turn off the water supply.
1 4 . Turn the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible

leavingthe drain hose.
CAUTION: Residual moisture in the cooler or lines
can damagethe transmission.
1 5 . Removethe flusherfrom the cooler line.Attachthe
drain hoseto a container.
1 6 . I n s t a l tl h e t r a n s m i s s i o na,n d l e a v et h e d r a i n h o s e
attachedto the coolerline.
{Commerciallyavailablel
Kent-MooreJ384O5-A
or equivalent
14-284
't1. Makesurethe transmissionis in the position.

E
F i l lt h e t r a n s m i s s i o n
w i t h C V T F l u i d ,a n d r u n t h e
enginefor 30 secondsor until approximately0.95/
( 1 . 0U S q t . , 0 . 8l m p q t . )i s d i s c h a r g e d .
'18. R e m o v et h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r
returnhoseto the transmission(seepage l4 287).
1 9 . Refillthe transmissionwith CVT Fluidto the proper
l e v e l( s e ep a g e ' 1 42 3 1 ) .
TOOL MAINTENANCE
'1. Emptyand rinseaftereachuse.Fillthe canwith water
and pressurizethe can. Flushthe dischargeline to
e n s u r et h a tt h e u n i ti s c l e a n .
2.
lf dischargeliquiddoes not foam,the orificemay be

blocked.
3.
T o c l e a nd
, i s c o n n e ct ht e p l u m b i n gf r o m t h e t a n k a t
t h e l a r g ec o u p l i n gn u t .
FILLERCAP
couPLlf{G
NUT
I
-@q
I
\
ORIFICE
Removethe in-linefilterfrom the dischargeside and

cleanif necessary.
The tluid orifice is located behind the filter. Clean it
with the pick stored in the bottom of the tank han
dle, or blow it clean with air. Securely reassemble
all parts.
14-285
Shift Cable
Make sure lifts, iacks and salety stands ale
!@
placed properly (seesection 1).
1.
2.
Shift to ffi position,then removethe lock pin from

the adiuster.
\
3.
Removethe air cleanerhousingassembly.

Removethe clip from the control lever,and loosen
the locknut.
CLIP
SHIFTCABLE LOCKNUT
29 N.m {3.0 ksf.m, 22 lbtft)
WASHER
Tr(>
SHIFI CABLE
BRACKET
CONTROLLEVER
\
Removethe shift cable from the control lever,the
shift cablebracket,and the clamp.
Removethe shift cablebracketbolts and nuts,then
remove the shift cable.Take care not to bend the
shift cablewhen removing/installing
it,
SHIFTCABLEBRACKET
( 0 . 7 k g f . m ,5 l b f . f t l
ADJUSTER
{1.2 kgt.m,8.7 lbl.ft)
!
14-286
1.
Installthe shiftcablein the reverseorderof removal.
8.
Checkthe cableadjustment(seepage 14-2871.
Adjustment
Make sure lifts,lacks and safety stands are
@
placed properly {seesestion 11,
1.
2.
Shift to E position,then removethe lock pin from

the adjuster.
3. Checkthat the holein the adiusteris perfectlyaligned

with the holein the shiftcable.Therearetwo holesin
the adjuster.They are positioned90" apartto allow
cableadiustmentin 1/4turn increments.
lf the hole is not perfectlyaligned,loosenthe locknut on the adjusterand adjustas required.

Tightenthe locknutto 7 N.m {0.7kgf.m,5 lbnft}.
Installthe lock pin on the adjuster.lf you feel the
lock pin binding as you reinstallit. the cable is still
out of adjustmentand must be readjusted.
SHIFTCABLE
10.7 kgf'm, 5 lbf'ftl
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r
securely.
Movethe shift leverto eachposition,and verifythat
the shift position indicatorfollows the automatic
transaxlegear positionswitch.
q
S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
positions.If any gear does not work properly.reier
(seepage14-226and l4-227J.
to troubleshooting
Insen the ignition key into the key cylinderon the
A//Tgear positionindicatorpanel,and verifythat the
shift lockleveris released.
14-287
Shift Lever
PUSHKNOB
PUSHKNOBSPRING
,l
-6r
SILICONEGREASE
SHIFTINOICATORLAMP
LEVERCOVER
SHIFTLOCK
SOLENOID
LEVERCOVER
BUSHING
..@]
SILICONEGREASE
SCREW
3 N.m {0.3 kgt m, 2 lbtft)
SHIFTLEVERASSEMBLY
EJ
@'""'-rccretn
ADJUSTER
6xl.0mm
9.8N.m {1.0kgl m,
1.2 tbt.ltl
-6.,1
SILICONEGREASE
A/T GEARPOSITION
PLATE
3 N.m {0.3kgf.m,
2 tbf.ftl
SHIFTLEVERBRACKETBASE
SHIFTLEVERBRACKET
BASECOLLAR
6x1.0mm
9.8N.m (1.0kgf m,7 2lbtft)
14-288
Shift IndicatorPanel
ATFCooler/Hoses
Adjustment
lnstallation
r ligns
1 . C h e c kt h a t t h e i n d e x m a r k o n t h e i n d i c a t o a
with the E mark on the shift indicatorpanelwhen
s in NEUTRAL.
t h et r a n s m i s s i oi n
1.
I n s t a l lt h e A T F c o o l e r ,A T F c o o l e r p i p e a s s e m b l y
and the ATFcoolerhoses.
6x1.0mm
ATF COOLERPIPEASSEMBLY
ATF COOLERHOSE
RADtAfoR
/,/'
6xl.0mm
9.8N.m (1.0tgl m,7.8 lbf ftl
MOUNTINGSCREW
3 Nm {0.3kgt.rn.2lbtft}
TANEL
lf not aligned, remove the front console (see section

20).
HOSES
ATFCOOLER
C o n n e c t h e A T F c o o l e r h o s e st o t h e A T F c o o l e r
linesand ATF cooler,and securethem with the clips
a ss h o w n .
Remove the shift indicator panel mounting screws

and adjust by moving the panel.
NOTE: Whenever the shift indicatorpanel is removed,
reinstallthe panel as described above,
RADIATOR
&)
\-6-gmm
(0.2- 0.3in)
6-8mm
(0.2- 0.3 in)
33-35mm
( 1 . 3- 1 . 4i n l
2-4mm
10.1- 0.2 inl
I
14-289
Differential
seetion13
......................
ManualTransmission
section14
.................
Driveshafts
SpecialTools..........
Driveshafts
Inspection
Removal
Disassembly
Reassembly
lnstallation
""".."' 16-2
16-3
..."...'.'..'....'...
....16-3
16-5
..".'...."....."
16-7
......."...'."....
16-11
..'........'..'.'..'.
SpecialTools
Ref. No.
Tool Number
BallJoint Remover,28 mm
16-2
Driveshafts
Inspection
Removal
Drivoshafi Boot
Checkthe boots on the driveshaftfor cracks,damage,
leakinggreaseand loose boot bands.lf any damageis
found,replacethe boot and boot bands
1 . Loosenthe wheel nuts slightlY.

Raisethe tront of the vehicle,and support it with
safetystandsin the properlocations(seesection1).
Removethe wheel nuts and front wheels.
Loose Splines
Turn the driveshaftby hand and make sure the splines
and ioint are not excessivelyloose lf any damage as
found.replacethe inboardjoint.
Twisted or Cracked
Makesurethe driveshaftis not twistedor cracked.
ReDlace
it if necessary.
Drainthe transmissionfluid (seesection13 or 14).

R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut,
Removethe self-lockingnut and flangebolts.

FLANGEEOLT
10 x 1.25mm
BOOT BANDS
12 x 1.25mm
Replace.
7.
Remove the damper fork.
(cont'd)
16-7
Driveshafts
Removal {cont'd)
8. Removethe cotter pin from the lower arm ball joint
castlenut, and removethe nut.
1 2 . P u l l t h e i n b o a r dj o i n t , a n d r e m o v et h e d r i v e s h a f t
from the differentialcase as an assembly.Do not
pull on the driveshaft;the inboardjoint may come
apart.Use carewhen prying out the assembly,and
pull it straightto avoid damagingthe differentialoil
seal.
07MAC- St_00200
9 . I n s t a l la 1 2 m m h e x n u t o n t h e b a l l j o i n t . B e s u r e
that the hex nut is flush with the ball joint pin end,
or the threadedsectionof the ball joint pin might be
damagedby the specialtool.
1 0 . Usethe specialtool as shown in section18,to separate the ball ioint and lower arm. Be carefulnot to
damagethe ball joint boot,
SCREWDRIVER
13. Pullthe knuckleoutward.and removethe driveshaft

o u t b o a r dj o i n t f r o m t h e f r o n t w h e e l h u b u s i n g a
olastichammer.
NOTE: lf nece'ssary,
apply penetratingtype lubricantto loosenthe bsll joint.
1 1 . Pry the driveshaftassemblywith a screwdriver,as
shown, to force the set ring at the driveshaftend
pastthe groove.
SCREWDRIVER
3.5mm
ORIVESHAFT
16-4
Disassembly
1.
Caretullyclamp the driveshaftin a vise with soft

jaws, then remove the set ring from the inboard
joint.
It the boot band is double loop type, raise the

band bendas shown.
To removethe boot band, pry up the lockingtabs

with a screwdriverand raise the end of the band.
Takecarenot to damagethe boot.
DOUB1I I.OOPBAND
R6place.
Mark each roller and inboard ioint to identify the

locations of rollers and grooves in the inboard joint.
Then remove the inboard joint on the shop towel.
Be careful not to drop the rollers when separatang
them from the inboard joint.
SETRING
Replace.
lf the boot band is the welded type, cut it off as
snown.
BOOTBAND
Replace.
INBOARDJOINT
Checksplineslor wear or damage
Checkinsideborefor wear'
Inspect{or cracks.
lf the boot band is the crimpingtype, pry up the

end of the bandwith a screwdriver.
BOOTBAND
Replace.
Mark3
{cont'd)
16-5
Driveshafts
(cont'dl
Disassembly
4.
Mark the rollersand spiderto identifythe locations

of rollerson the sDider,then removethe rollers.
\
9. Wrap the splineson the driveshaftwith vinyltapeto
preventdamageto the bootsand dynamicdamper.
INBOARD
BOOT
for cracking,BOOTBAND
Inspect
splitting
andwear. R e p l a c e .
DYNAMICOAMPER
BAND
Replace.
OYNAMICDAMPER
Checkfor damage.
OUTBOARDBOOT
Inspectfor cracking,
splittingand wear.
1 0 . Removethe boot band and inboardboot.Takecare

not to damagethe boot.
1 1 . R e m o v et h e d y n a m i cd a m p e rb a n d a n d d y n a m i c
damper,if equipped.Takecare not to damagethe
dynamicdamper.
12. Removethe boot bsnds and outboard boot, then
removethe vinyltape.
1 3 . Inspectthe outboardjoint for faulty movementand

Removethe circlip.
wear. lf any roughnessor excessplay is felt, replace

the outboardjoint.
Mark the spider and driveshaftto identitythe position of the spideron the shaft.
7.
Removethe spiderusinga bearingremover.

Removethe stop ring (exceptJapanproduced).
OUTBOARDJOINT
16-6
Reassembly
Notetheseitemsduring reassemblyl
partswith solvent,and dry them throughlywith compressedair. Do not wash the rubberparts
. Cleanthe disassembled
with solvent.
.
-,.6l
: Thoroughlypackthe inboardjoint and both joint bootswith the ioint greaseincludedin the new driveshaft
Greasequantity:
lnboardJoint
OutboardJoint
JapanProduced
' 1 1 0- 1 2 0g { 3 . 9- 4 . 2o z )
'120- 130g
{4.2- 4.6ozl
70 - 80 g (2.5- 2.8 oz)
ExceptJapanProduced
1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z )
Japan Produced
ExceptJapanProduced
SCTRING
Replace.
INBOARDJOINT
ROLLER
\zn
STOPRING{ExceptJapan producod}
--"
Packcavitywith grease.
B(rcT
INBOARD
- - -
&l
Packcavity with groase.
DYNAMICDAMPER
BOOTBANDS
Replace.
DRIVESHAFT
OYNAMICDAMPERBAND
Replace.
OUTBOARDBOOT
-611
Packcavity wrtn grease.
(cont'd)
16-7
Driveshafts
Reassembly(cont'dl
1.
Wrap the splineswith vinyl tape to preventdamage

to the bootsand dvnamicdamoer.
V;
4.
APE
OUTBOAROBOOT
I n s t a l lt h e s t o p r i n g i n t o t h e d r i v e s h a f tg r o o v e
{exceptJapan produced),Always rotate the stop
ring in its grooveto be sure it is fully seated.
\zr|<-C|RCL|P
DYNAMIC
DAMPER
2.
Installthe spider on the driveshaftby aligningthe

markson the spiderand end of the driveshaft.
INAOARD
BOOT
I n s t a l lt h e o u t b o a r db o o t , d y n am i c d a m p e r a n d
i n b o a r db o o t t o t h e d r i v e s h a f tt.h e n r e m o v et h e
vinyl tape.Take care not to damagethe boots and
dynamicdamper.
Packthe outboardjoint with the joint greaseincluded
in the new driveshaftset,
Greasequantity:
Japan Producd:
7o- 80g (2.5- 2.aozl
ExceptJapan Produced:115- 1359 (i1.0- 4.8ozl
16-8
Fit the circlip into the driveshaftgroove. Always

rotatethe circlip in its groove to be sure it is fully
seated.
7.
Fit the rollersto the spiderwith their high shoulders

facingoutward,and notetheseitems:
. Reinstallthe rollersin their originalpositionson
the spiderby aligningthe marks.
. H o l d t h e d r i v e s h a f tp o i n t e du D t o prevent the
rollersfrom tallingoff.
8.
Packthe inboardioint with the joint greaseincluded

in the new driveshaftset.
Greasequantity:
110- 120g (3.9- 4.2ozl
Jaoan Produced:
ExceptJapan Produced:120- 130g (4.2- 4.6 ozl
10. Adjust the length of the driveshaftsto the figure

below, then adiust the boots to halfway between
f u l l c o m p r e s s i o na n d f u l l e x t e n s i o nT h e e n d s o f
bootsseatin the grooveof the driveshaftand joint.
Left driveshaft: 774- 779 mm 130.5- 30.7in)
Right driveshaft:501- 506 mm 119.7- 19.9in)
1L Positionthe dynamicdamperas shown below.
Fit the inboardjoint onto the driveshaft,and note

thesertems:
. Reinstallthe inboardjoint onto the driveshaftby
a l i g n i n gt h e m a r k so n t h e i n b o a r dj o i n rw i t h t h e
markson the rollers.
. Holdthe driveshaftso the inboardjoint pointsup
to preventit from fallingoff.
Left:
Without "SRl" mark:94 :t 2 mm 13.7t 0.1 in)
75 t 2 mm 12.9i 0.1 in)
With "SR1" mark:
Right5
: 5 1 2 m m ( 2 . 2t 0 . 1i n l
INBOARD
JOINT
DYNAMICDAMPERBAND
{cont'd)
16-9
Driveshafts
(cont'd)
Reassembly
12. Set the doubleloop band onto the boot and dynamic damperwith the band end toward to front of the
vehicle.
Threadthe free end of the band through the nose

sectionoJ the boot band tool and into the slot on
the winding mandrel.
Placea wrenchon the winding mandrslof the boot
band tool, and tighten the band until the mark you
madeon the bandmeetsthe edgeof the clip,
AOOTBAND
TOOL
(KD-3191
or equivalent)
Markon band.
Pullup the slackin the band by hand.

1 4 . Mark a positionon the band 10 - 14 mm (0.4- 0.6
in) from the clip.
1 7 . Raiseup the boot band tool to bend the free end of
the band90 degrees,then center-punch

the clip,
cuP
HAiIMER
16-10
lnstallation
18, Unwindthe boot bandtool, and cut oft the excess5
- l0 mm 10.2- 0.4 in) from the cliP.
1.
Installthe new set ring onto the driveshaftgroove.

Always use a new set ring wheneverthe driveshaft
is beinginstalled.
5-10mm
(0.2- 0.4 in)
INBOARDJOINT
SETRINGGROOVE
'19. Securethe end of the boot band by tappingit down

with a hammer,
2.
Installthe outboardjoint into the knuckle.
KNUCKLE
Notetheseitemsafter reassembly:
. Make sure the band and clip does not interferewith
anythingand the band does not move.
! R e m o v ea n y g r e a s er e m a i n i n go n t h e s u r r o u n d i n g
surtaces.
JOINT
OUTBOARD
(cont'd)
1 6 - 11
Driveshafts
(cont'd)
Installation
Cleanthe areas where the driveshaftcontact the
transmission(differential)thoroughlywith solvent
or carburetorcleaner.and dry with compressedair.
Insertthe inboardend of the driveshaftinto the differentialuntil the set ring locksin the groove.
INAOARD
JOINT
5. Installthe damperfork over the driveshaftand onto

t h e l o w e r a r m . I n s t a l lt h e d a m p e ri n t h e d a m p e r
f o r k s o t h e a l i g n i n gt a b i s a l i g n e dw i t h t h e s t o t i n
the damoerfork.
FLANGE
BOLT
10x 1.25mm
(3 N.mla.akgf.m.32lbf.trl
aLtGNtNG
TAB
DIFFERENNAL
Installthe knuckleon the lower arm. Be carefulnot
d a m e g et h e b a l l j o i n t b o o t . W i p e o f f t h e g r e a s e
before tighteningthe nut at the ball joint. Torque
the castlenut to the lowertorquespecification.
then
tighten it only far enoughto align the slot with the
pin hole.Do not alignthe nut by loosening.
SELF.LOCKING
NUI
12 x 1.25mm
fl N.m (6.5 kgf.m, it7 lbf'ltl
Repiace.
6. Loosely install the flange bolts and the new selflocking nut.
7 . Apply oil to the seating surface of the new spindle

nur.
FRONTWHEEL
WHEELNUT 12 x 1.5mm
108 N.m {11.0kgt m, 80lbt ftl
CASTLE
12 x 1.25 mm
alt - 59 N.m 15.0- 6.0 kg{.m, 36 - ail lbl.ftl
COTTERPIN
Replace.
On reassembly,
bend the cotter pin
SPINDLENUT 22 x 1.5 mm
181N.m 118.5kg{.m, 134lbf.tt)
NOTE: After tightening,use a drift to
stake
thespindlenutshoulder
against
thedriveshaft.
8. Installa new spindlenut,then tightenthe nut.
9. Cleanthe mating surfacesof the brakedisc and the
wheel, then installthe front wheel with the wheel
nutS,
10. Tighten the flange bolts and the new setf-locking
nut with the vehicle'sweighton the damper.
11. Refillthe transmissionwith recommended
fluid (see
section13 or 14).
'12. Check
the front wh;eltlbnment
and adjust if nec'il
essarv(seesection18).
f,
16-1 2
Steering
Tools
Speciaf
.............17-2 Inspestion and Adiustment
17-30
SteeringOperation..........................
Power Assist Check
ManualSteering
17-30
With VehicleParked ....................
ComponentLocations
SteeringLinkageand Gearbox .......17-31
.......17'3
fndex ................
..............
17-32
Pump Beft
Inspection and Adiustment
17-33
RackGuideAdjustment ...................
17-4
SteeringOperation..........................
17-33
FluidRep|acement...........................
17-5
RackGuideAdjustment...................
17-34
PumpPressure
Check......................
'Steering Wheel
*Steering
(Seepower steering sec'tion)
Wheel
*SteeringColumn
17-35
.................
Removal
(Seepower steering sectionl
.............
17-35
lnstallation
Steering Gearbox
I 7-36
...............
'Steering
17-5
.................
Removal
Column
17'7
...........
Disassembly
17-37
Removal/lnstallation.......................
............
17-9
Reassembly
..............
17.38
Inspection
.............
17-13 Power Steering Hoses,Lines
lnstallation
17-39
Fluid LeakageInspection.................
PowerSteering
..........17-39
Replacement
Component Locations
Power SteeringPump
.......17-15
lndex ................
17-tlo
System Description
...........
17-41
Disassembly
17-16
FluidFlow Diagram..........................
..............17-42
fnspection
-17
17
SteeringPump ..................................
............17-44
Reassembly
17-20
.............................
Gearbox
Steering
SteeringGearbox
Troubleshooting
17-47
,,,,.,...........
Removaf
-22
17
GenerafTroubleshooting................
17-lt!l
...........
Disassembly
17-26
Noiseand Vibration.........................
............
17-55
Reassembly
.............17-28 lnstallation
Ffuid Leaks
.............
17-65
Ball Joint Boot Replacement..........17-68
SpecialTools
\
Ref. No
a
aal
o
@
ao'r
o
@
@
@
@
@
@
@
Tool Number
07GAF- PH70100
07GAG- SD40l0Aor
07GAG- SD40100
07GAG- SD40204or
07GAG- SD40200
* 0 7 J G G- 0 0 1 0 1 0 A
07MAC- S100200
OTNAD- SR3O2OA
07NAG- SR3090Aor
07NAG- SR30900
0 7 R A K- 5 0 4 0 1 1 0
07RAK- 5040121or
07RAK- 5040120
07406- 0010004or
07406- 00'10001
07725- 0030000
07746- 0010100
07746- 0020'100
07746- 0030300
07749- 0010000
07916- SA50001
07965- SA50500
07974- SA5020Aor
07974- SA50200
07974- SA50800
Description
Oty
PageReferenco
P i l o tC o l l a r
PistonSealRing
11-54
17-59
PistonSealRingSizingTool
17-59
BeltTensionGauge
B a l lJ o i n tR e m o v e r , 2 m
Sm
CylinderEnd SealRemoverAttachment
PistonSealRingSizingTool
1
'l
17-6,47
17-51
17-56
I
1
P/SJoint Adaptor(Pump)
P/SJoint Adaptor(Hose)
17-34
't]-34
P/SPressureGauge
17-34
UniversalHolder
Attachment,32x 35 mm
Driver,22 mm l.D.
Attachment,30 mm l.D.
Driver
LocknutWrench,40 mm
FrontHub Dis/Assembly
Tool
SleeveSealRingSizingTool
17-42,46
17-57,58
l 7 -1 0
't7-44
17-57
17-68
17-51
@
EallJoint BootClip Guide
* Includedin the BeltTensionGaugeSet,07TGG001OOOA.
17-57,68
g/
,g
=fu*
(o)
l:1
7-2
(D
ComponentLocations
lndex
ManualSteering
NOTE:
. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound defectiveor damagedduring transit,storageor service,it shouldbe deployed{seesection24)'
. Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel
. After installingthe gearbox,checkthe wheelalignmentand adjustif necessary.
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
section{24}beforeperformingrepairsor service
WHEEL
STEERING
page17-35
Removal/lnstallaiion,
page17'36
Disassembly/Reassembly,
DRIVER'SAIRBAGASSEMBLY
seesection24
Bemoval/lnstallation,
STEEBINGCOLUMN
Page17 37
page'17-38
Inspection,
CABLEREEL
seesection24
Femoval/lnstallation,
IGNITIONSWITCH
Seesection23
STEERINGGEARBOX
RackGuideAdjustment,Page17-5
R e m o v apl ,a g e ' 1 7 - 5
page17-7
Disassembly,
page'179
Beassembly,
page17 13
Installation,
TIE.RODENOBALLJOINT
page17-68
BallJoint BootFeplacement,
17-3
Inspectionand Adjustment
SteeringOperation
SteeringWheel Rotational Play

Placethe front wheels in a straightahead positionand
measurethe distancethe steeringwheel can be turned
without movingthe front wheels.
Steering Eftort Check

Raisethe front wheelsoff the ground.
Turn the steeringwheelwith a springscaleand checkits
reaoIng.
PLAY:0 - 10 mm (0 - 0.4 in)

ROTATIONAL
Standard:15 N {1.5kgf,3.3 lbfl maximum
lf the play exceedsthe servicelimit, perform rackguide

adjustment(seepage17'5).
lf the play is still excessiveafter rack guide adjustment,
inspectthe steeringlinkageand gearbox as described
l f i t r e a d sm o r e , p e r f o r mr a c k g u i d e a d j u s t m e n (t s e e
page 17-5).
BOTATIONALPLAY
\ -J
TJ
TIE.RODLOCKNUT
Checkfor looselocknut.
BOOT
I n s p e c tf o r d a m a g e a n d d e t e r i o r a t r o n
JOINTS
STEERING
Checkfor looseioint bolts.
COLUMN
for loosecolumn
InsPect
mountingboltsand nuts
PINIONSHAFTGROMMET
for damageand deterioration
END BALLJOINT
Inspectfor faultymovement
ano oamage.
BALLJOINT BOOT
Inspectfor damageand deterioration.
Seepage17-68for replacement.
MOUNTING
GEARBOX
l n s p e c tf o r d e t e r r o r a t l o n
GEARBOX ASSEMBLY
Inspectfor loosemountingbolts.
17 -4
SteeringGearbox
RackGuide Adjustment
Removal
N O T E : P e r f o r mt h e r a c k g u i d e a d j u s t m e n tw i t h t h e
wheelsin the straightaheadposition.
NOTE:Using solventand a brush.to wash any oil and

dirt off the gearbox.Blow dry with compressedair.
1.
Loosenthe rack guide screw locknutwith the specialtool, then loosenthe rackguidescrew.
1.
Raisethe front of vehicle,and support it on safety

standsin the properlocations(seesection1).
2.
Removethe front wheels.
3.
Removethe steeringwheel (seepage 17-35).
4.
Removethe steeringioint cover
STEEBINGJOINTCOVER
07916- SA5000l
the
Tightenthe rackguidescrewuntil it compresses
springand seatsagainstthe rackguide,then loosen
it.
Retightenthe rackguide screwto 4 N.m (0.4kgf'm,
2.9lbtft), then backit off to specifiedangle.
5.
SpecitiedReturn Angle: 30' max.
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
Removethe steeringjoint lower bolt, and disconnect the steeringjoint by moving the joint toward
t h ec o l u m n .
STEERINGJOINT
Checkfor tight or loose steeringthrough the compieteturningtravel.

Rechecksteeringeffort (seepage 17-4).
{cont'd)
SteeringGearbox
Removal (cont'dl
Removethe cotter pin from the castlenut ('96-'97
model)or nut ('98 model)and removethe nut.
13, Removethe mountingbracket.
COTTERPINS
Replace.
7 . Installthe 10 mm hex nut on the balljoint.

Be surethat the 10 mm hex nut is flushwith the ball
joint pin end,or the threadedsectionof the ball joint
pin mightbe damagedby the balljoint remover.
NOTE:Removethe ball joint usingthe specialtool.
R e f e rt o s e c t i o n1 8 f o r h o w t o u s e t h e b a l l j o i n t
remover.
Separatethe tie-rodball joint and knuckleusingthe
specialtool.
CAUTION: Avoid damaging lhe ball ioint boot.
1 4 . Pull the steeringgearboxall the way down to clear

the pinionshaftfrom the bulkhead,then removethe
pinionshaftgrommet.
Move the steeringgearboxto right so the left rack
end clearsthe rearbeam,then tilt the lelt sidedown
to removeit from the car.
Removethe left tie-rod end, then slide the rack all

the way to the right,
1 0 . Separatethe exhaustpipeA or TWC (seesection_9).
PINIONSHAFTGROMMET
1 1 . Disconnectthe shift linkage(seesection13 or section14).
12. Removethe stiffenerplate,
STEERINGGEARBOX
17-6
Disassembly
l.
2.
Placethe gearbox in a vise with a soft jaws, then

c l a m p t h e g e a r b o xa t t h e m o u n t b r a c k e to r g e a r
noustng.
5.
Pushthe right end of the rackbackinto the cylinder

housing so the smooth surfacethat rides against
the sealwon't be damaged.
CAUTION: Be carful not to distort the gear housing by clamping it too tight in the vise incorrectly.
6.
L o o s e nt h e l o c k n u t ,a n d r e m o v e t h e r a c k g u i d e
screw.
Removethe tie-rodend and locknut.
7.
Remove the disc washer, spring and rack guide
from the gear housing.

3.
Removethe boot bands and tie rod clips. Pull the

bootsawayfrom the ends of the gearbox.
SPRING
OISCWASHER
LOCKNUT
E-RODC L I P
I
I
BOOT
Replace.
@
4.
H o l d t h e s t e e r i n gr a c k w i t h o n e w r e n c h , a n d
unscrewthe rackend with anotherwrench.
CAUTION:Be caretulnot to damagethe rack surface with the wrench.
STEENINGRACKENO
FACKGUIDE
SCREW
8.
R e m o v et h e p i n i o nd u s t s e a la n d t h e 3 5 m m s n a p
ring.
9.
Holdthe pinionshaftwith a visesecurely.

R e m o v et h e p i n i o n b y t a p p i n ge v e n l ya r o u n dl h e
flanged sectionof the gearboxwith a plasticham
m er .
CAUTION: Do not tap on the steering rack.
NOTE:Do not reusethe removedpinaon.
PINIONOUSTSEAL
Repl6ce.
SNAPRING,35 mm
STEERINGPINION
Feplace.
17-7
SteeringGearbox
Disassembly(cont'dl
10. Slidethe steeringrackout of the cylinderhousing.
CAUTION: Be caretul not to damagethe bushing in
the cylinderhousing.
12. Replace
the gearboxmountingcushionif necessary:
To removethe cushion,usea sharpknifeand make
a cut downthe lengthof the cushion.Becarefulnot
to damagethe painton the outsideof the cylinder
housing.Removethe old cushion.
Apply weatherstripadhesiveto the insideof the
new cushion.Installthe cushiononto the cylinder
housingand positionit 20- 22 mm (0.79- 0.87in)
from the end of the cylinderhousingas shown.
N O T E :A f t e r i n s t a l l i n gt h e c u s h i o n ,w i p e o f f a n y
e x c e s sa d h e s i v et h a t m a y h a v e d r i p p e d i n t o t h e
i n s i d eo f t h e c y l i n d e hr o u s i n g .
1 1 . R e m o v et h e r a c ke n d b u s h i n g .
GEARBOX
MOUNTINGCUSHION
- 0.87in)
20 - 22 mm 10.79
RACKENOBUSHING
Inspectinnerwall for wear or damage
1 7 -A
Reassembly
NOTE:
partswith solvent,and dry them with compressedair. Do not dip the rubberpartsin solvent.
. Cleanthe disassembled
partswith new ones beforeassembly.
. Alwaysreplacethe non-reuseable
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe steeringgearbox.
PINIONDUSTSEAL
Replace.
-6r
RACKENO BUSHING
GEARBOXMOUNTINGCUSHIONS
t_
-R4
r@
M."^pR,NG.3smm
-$d
RACKGUTDESCREW
DISCWASHER
RACKGUIDE
(cont'd)
17-9
SteeringGearbox
Reassembly(cont'd)
't.
Apply a thin coat of greaseto the insidesurfaceot

the rackend bushing.
5. Drivein the steeringpinion in the gear housingwith

t h es p e c i a l t o o l s .
Greasequantity:1 - 3 g (0.04-0.1 oz)

CAUTION:Do not fill the slots with greas;they
must remain open to serve as air passages.
2.
DRIVER,
22 .rlml.D.
071460020t00
I n s t a ltl h e r a c ke n d b u s h i n gb y a l i g n i n gt h e r o u n d
projectionon the bushingwith the hole in the cylind e rh o u s i n g
PINIONDUST
SEAL
Replace.
SNAPRING,35 mm
Vinyltape
STEERING
PINION
6 . I n s t a l lt h e 3 5 m m s n a p r i n g s e c u r e l yi n t h e g e a r
nousrnggroove.
1 . Apply vinyl tape to the pinion shaft,then coat the
v i n y l t a p ew i t h g r e a s e .
8. Installthe piniondust sealon the gear housinguntil
it seatsproperly,then removethe tape.
3.
Greasethe steeringrackteeth.
4.
I n s t a l lt h e s t e e r i n gr a c k i n t o t h e c y l i n d e rh o u s i n g
c a r e f u l ltyo a v o i dd a m a g i n g
t h e r a c ke n d b u s h i n g .
9 . G r e a s et h e s l i d i n gs u r f a c eo f t h e r a c k g u i d e ,a n d
i n s t a lilt o n t o t h e g e a rh o u s i n g .
'10.
Installthe spring,discwasherand rackguide screw

o n t h e g e a rh o u s i n g .
NOTE:Installthe disc washerwith its convex side
f a c i n gi n .
DISCWASHER
SPRING
LOCKNUT
CYLINDERHOUSING
17-1 0
'11.
RACKGUIDESCREW
Adjustthe rackguide screw(seepage 17-5).
12. I n s t a l lt h e n e w l o c k w a s h e r i n t h e g r o o v e i n t h e
steeringrack.
IJ.
Installthe steeringrackend into the rack.
LOCKWASHER
16. Apply grease around the outside of the rack end

houstng.
RACKEND 54 N.m 15.5kgifm, 40 lbtftl
Repiace.
t;J"'
"
.=-!!!r9i!l
SILICONE GREASE
TAB
RACK END
1 7 . A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
1 4 Hold the steering rack with a wrench and tighten

the rackend with another.
CAUTION: Be carelul not to damage the rack surtace with the wrench.
t 5 , After tightening the rack ends, stakethe four sections of the lock washer with a roll pin drift and a
mallet.
. Placethe wood blockon the presstable,then set
the lock washer section of the rack end on the
wood blocksecurely.
. Be sure the tool is alignedwith the flat sections
of the steeringrackend beforepressing
. S t a k et h e l o c k w a s h e ri n t h e c e n t e ro f t h e f l a t
sectionof the steeringrackend.
grooveson the rackends,

1 8 . I n s t a l lt h e b o o t s i n t h e r a c k e n d w i t h t h e t i e - r o d
clrps.
NOTE: Install the boot band with the rack in the
straight ahead position (right and left tie-rods are
e q u a li n l e n g t h ) .
NOTE:Wipe greaseoff
the threadsection.
ROLLPIN ORIFT:
(Commorciallyavailablel
Snap-OnNo. PPR8or equivalent
Press
NOTE:This dritt hasa flat

tip, to preventpunctunng
nncxl
srrenrruc
woooENELocK
CLIP
TIE.ROD
(cont'd)
17-11
SteeringGearbox
Reassembly(cont'd)
1 9 . Installthe boot band so that the lockingtabs of the
band (stakepoints)are in the rangeshown below.
(Tabsshouldface up and slightlyforwaro.J
22. Slide the rack right and left to be certainthat the

bootsare not deformedor twisted.
20. Bendboth setsof lockingtabs.

2 1 . Lightlytap on the doubled-overportionsto reduce
t h e i rh e i g h t .
CAUTION:Stakethe band lockingtabs firmly.
Stakepoints
L6ft Boot Band

(Viewedfrom the left side)
17-12
Right Boot Band

(Viewedfrom the right sidei
Front
lnstallation
1.
Slidethe rackall the way to the right.
Installthe pinion shaftgrommet,and insertthe pinion shaftup throughthe bulkhead.
4.
I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
mountingboltsand stiffenerplateattachingbolts.
N O T E rI n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n
them securelv.
PLATE
STIFFENER
NOTE:Align the notch in the pinion shaft grommet

with the tab on the gear housing.
PINIONSHAFTGROMMET
STEERINGGEARBOX
MOUNTING
BOLTS
GEARBOX
43 N.m(4.{kgf.m,32 lbf.ft)
5.
6.
3.
Installthe mountingbracketswith the two gearbox

mountingboltson the cushion.
Centerthe steeringrackwithin its stroke,

Slip the lower end of the steeringjoint onto the pinion shaft{line up the bolt hole with the groove
aroundthe shaft),and tightenthe lower bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
steeringwheel and steeringrackcentered.
B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t i s
securelyin the groove in the steeringgearbox
p r nr o n .
lf the steeringwheel and rack are not centered,
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringjoint.
JOINT
STEERING
14.0kgl.m,29lbtftl
NOTE:The arrowon the bracket
pointtowardthe front.
STEERINGJOINT
LOWERBOLT
22 N.m
12.2kgt m, 16 lbf.ftl
(cont'd)
17-13
SteeringGearbox
'1.
Centerthe cable reel by first rotating it clockwise

until it stops,Then rotate it counterclockwise
(approximatelytwo turns) until the arrow mark on
the label points straight up. Reinstallthe steering
wheel (seepage 17-35).
Installthe steeringioint cover with the clamps and
clros.
the tie-rodendsto the steeringknuckles,

9. Reconnect
then tighten the castlenut ('96 -'97 model)or nut
{'98 model)to the specifiedtorque,and installnew
cotter Dins.
NOTE:Betoreconnectingthe tie-rodends,wipe off
a n y g r e a s ec o n t a m i n a t i o nf r o m t h e b a l l l o i n t
taoeredsectionand threads.
CAUTION:Torquethe csstle nut to the lower torque
spocification,thn tightsn it only fsr enough to
Elign th slot with the pin hol6. Do not align the
nut by loosoning {'96 -'97 modol only}.
JOINT COVER
STEERING
TIE-ROD
'95 - '97 model:
,10- 48 N'm
(ir.o- 4.8 kgt m.
29 - 35 rbl.ftl
COTTERPINS
Replace.
bend
On reassembly,
the cotterPlnas shown.
38 model:
NUT
4,1N.m
(4.5 kgf'm,
33 lbf.frl
Installthe exhaustpipeA or TWC(seesection9)'

1 1 . Connectthe shift linkage(seesection13 or section
14).
12. Installthe front wheels.
After installation,performthe followingchecks'
.
.
Adjustthe front toe (seesection18).

Checkthe steeringwheel spokeangle'Adjust by
turningthe right and lefttie-rods,it necessary'
NOTE:Turn the right and lefttie-rodsequally'
1 7 -1 4
!=-
ComponentLocations
lndex
Power Steering:
NOTE:
. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has beenfound detectiveor dsmagedduring transit,storageor service,it shouldbe deployed(seesection24).
a Betoreremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel.
. After installingthe gearbox,checkthe wheelalignmentand adjustif necessary.
section(24)beforeperformingrepairsor service.
WHEEL
STEERING
page17-35
page17 36
DRIVER'SAIRBAGASSEMBLY
seesection24
STEERING
GEARBOX
RackGuideAdjustment,page17 33
Removal,page17-47
page17-49
Disassembly,
page17-55
Reassembly,
page17'65
Installation,
VALVEBODYUNIT
Overhaul,page17 52
COLUMN
page17-37
page17-38
Inspection,
CABLEREEL
seesection24
IGNITIONSWITCH
Seesection23
POWERSTEERINGPUMP
page17'32
PumpBeltInspection,
PumpBeltAdiustment,page17-32
PumpPressure
Check,page17 34
page17-40
Bemoval/lnstallation,
page17 41
TIE.RODEND BALLJOINT
page17-68
BallJointBootReplacement,
17-15
SystemDescription
FluidFlow Diagram
power steering,connectedto the steeringgearbox.The fluid pressureis proThe systemis a compactrotary-valve,type
pump
by the enginecrankpulley.The amountof fluid and pressureis regulatedby
which
is
driven
vane-type
vided by a
the flow controlvalvebuilt into the pump.The fluid pressurefrom the pump is deliveredto the valvebody unit aroundthe
pinjonof the steeringgearbox.The valveinsidethe valvebody unit controlsthe hydraulicpressureand changesthe direction of the flow. The fluid then flows to the power cylinder,where rackthrust is generated.Fluid returningfrom the power
"filtered"and suppliedto the pump again'
cylinderflows backto the reservoir,wherethe fluid is
RESERVOIB
VALVEBODYUNIT
SUB.VALVE
FLOWCONTROLVALVE
17-16
GEANBOX
STEERING
POWERCYLINDER
SteeringPump
Construction
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is drivenby a POLY-V-belt
operationsfor every rotafrom the crank pulley,The pump features10 vanes.Eachvane performstwo intake/discharge
tion of the rotor.This meansthat the hydraulicfluid pressurepulsebecomesextremelysmallduringdischarge.
FLOWCONTROLVALVE
ROTOR
VANE
CAM RING
Operation
The belt,drivenpulley rotatesthe rotor through the drive shaft.As the rotor rotates,the hydraulicpressureis appliedto
of the cam ring.
the vanechamberof the rotor and the vaneswill rotatewhile beingpushedonto the innercircumference
The inner circumferenceof the cam ring has an extendedportionwith respectto the centerof the shaft,so the vanes
move downwardin the axialdirectionas the rotor rotates.As a resultof this roller movement.the internalvolume of the
v a n ec h a m b ew
r i l l c h a n g er,e s u l t i n ign f l u i di n t a k ea n dd i s c h a r g e .
STARTOF FLUIDINTAKE:
FLUIDINTAKE:
FLUIDMOVEMENT:
FLUIDOISCHARGE:
T h e v a n e s a r e p u s h e do n t o
of the
the innercircumference
c a mr i n g .
The volumeof the vanecham

ber increasesso that fluid is
suckedin.
T h e s u c k e d - i nf l ui d m o v e s
pon.
towardthe dascharge
As the vanes return to the

t h e i ro r i g i n ap
l o s i t i o no n t h e
inner side, the volume of the
v a n e c h a m b e rd e c r e a s e s o
t h e f l u i d i s d i s c h a r g e df r o m
the dischargeport.
(cont'd)
17-17
SystemDescription
SteeringPump(cont'dl
The flow control valve and sub-valvein the pump performs the following stepsO through @ to control the
flow of fluid, that is to increasethe dischargevolume
when enginespeed is low. and to decreaseit when the
e n g i n es p e e d i n c r e a s e sT, h e a s s i s t a n c teh r u s t o f t h e
s t e e r i n gg e a r b o xc h a n g e si n c o m p l i a n c ew i t h t h e
changein the dischargevolume.
FLOWCURVE
l"
I
t r r
-..}
PUMPR.P.M.
When the engine starts,fluid dischargedfrom the

dischargeport stans to flow through oil passageA,
the fixed orificeand the variableorificeto the steering gearbox,When the engine speed is extremely
low, the return port is closed by the flow control
valve.
Fluid pressuredischargedfrom the dischargeport
is appliedto the top of the sub-valve,and the fluid
pressurethat passedthroughoil passageA is applied
to the bottom of the sub-valve.When this happens,
the pressuredifferencebetweenthe ends of oil passage A, which is causedby the resistanceoil passage
A w h e n t h e f l u i d f l o w s t h r o u g h t h e p a s s a g e ,i s
appliedto the sub-valve.However,the pressuredifferenceapplied to the sub-valve.that is the force
t h a t p u s h e st h e s u b - v a l v ed o w n , i s t o o s m a l l t o
overcomethe springforce,and the variableorificeis
fully openwhen the enginespeedis e)dremelylow,
To STEERINGGEARBOx
Becausethe fluid volume flowing throughthe fixed

oriticeand variableorificeincreases,
a pressuredifference is createdbetweenthe ends of these orifices, and it increasesin proportionto the engine
speed.As the lluid pressurethat passedthe fixed
orificeand variableorificeis directedto the bottom
of the flow control valve, a pressuredifferenceis
createdbetweenthe top and bottom of the valve,
w h i c h D u s h e sd o w n t h e f l o w c o n t r o l v a l v e a n d
opens the return port. As a result,part of the fluid
dischargedfrom the dischargeport returnsto the
pump suction port, keepingthe dischargevolume
conslanl,
In this condition,the sub-valvedoes not move, and
the variableorificestaysfully open.
To STEERINGGEARBOX
SUB-VALVE
Bottom //l'.zRx
=K.Aq
o'.io"l^LKq;OY
11\t/./
FLOWCONTROLVALVE
SUB-VALVE
ORIFICE
1 ) l
vr-
FLOWCONTROLVALVE
17 -1 8
To STEERINGGEARBOX
The fluid volumethat flows thoroughoil passageA

and the pressuredifferenceappliedto the sub-valve
i n c r e a s ei n p r o p o r t i o nt o t h e e n g i n e s p e e d .T h e
sub-valvelowers overcomingthe spring force,and
it startsto closethe variableorificeto regulatethe
dischargevolume,Whenthis happens,the fluid volume flowing to the steeringgearboxdecreasesas
the engine speed increases.At the same time. the
flow controlvalvecontinuesto controlthe fluid volume to the returnDort.
/z/ffi\\
+/A<Y?il
o',-lorlo[5o
zit)Y
-et27
\ \
FLOWCONTROLVALVE
To STEERINGGEARBOX
SUB.VALVE
@ As the enginespeedincreasesfurther,the pressure
furtheras well.
differenceat the sub-valveincreases
The sub-valvethen closesthe variableorificecomp l e t e l y ,r e g u l a t i n gt h e d i s c h a r g ev o l u m e f u r t h e r .
W h e n t h i s h a p p e n s t. h e f l u i d v o l u m e d i s c h a r g e d
from the pump to the steeringgearboxis regulated
a n d m a i n t a i n e da t a g i v e n l e v e l u n t i l t h e e n g i n e
speedreachesthe high speed range.The flow control valve functions continuesto control the fluid
volumeto the returnDort.
/X
TI-p..\
LTJ6("4")il
o"'ro"iio't?2ia)f
11"QJtYl
FLOWCONTROLVALVE
PressureRelief
P r e s s u r ea t t h e d i s c h a r g es i d e o f t h e f i x e d o r i f i c e i s
directedto the bottom of the flow control valve.When
the pressurebuilds up, the reliefvalve in the flow control valveopensto releasethe pressureat the bottom ot
t h e v a l v e .T h i s a l l o w s t h e f l o w c o n t r o l v a l v e t o b e
pushed back by the pressuredifference.and the fluid
volumeto the pump returnport increases.
As explained above,the system keepsthe pump discharge pressure (relief pressure)from exceedingthe
given level by controllingthe volume of the fluid to the
pump returnpon.
FLOWCONTBOLVALVE
DAMPINGORIFICE
(Decreasesexcessive
vibration in the valve.l
RELIEFVALVE (Openl
17-19
SystemDescription
SteeringGearbox
The rackand-piniontype steeringgearboxhas a valve body unit incorporatedwith the pinionlo controlthe steeringfluid
pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve body unit and is sentthroughthe cylin
der line to the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylinder returnsthroughthe cylinderline and valvebody unit to the reservoir.
VALVEBODYUNIT
LINE
CYLINDER
To RESERVOIR+
From PUMP ri
POWERCYLINDER
Valve Body Unit

Insidethe valve body unit is the valve.which is coaxialwith the pinionshaft,and controlsthe steeringfluid pressure.The
valve housingis connectedwith the fluid line from the pump, the returnline to the reservoir,and the two cylinderlines
from the respectivepower cylinder.The pinion shaft is double- structuredwith the input shatt connectedto the pinion
gear,both of which are interconnected
wlth the torsionbar.
The pin insertedin the valveand the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the
directionbetweenthe input sh8ftand the
the differencein anglein the circumferential
valve.Becauseof this construction,
However.maximumtorsion
valvebecomeslargeraccordingto the torsionalstrengthof the pinionor steeringresistance.
pin
to hold the torsionbar
engagement
section
of
the
shafts
at
the
engaged
splines
is
regulated
by
the
betlveenthe shafts
within the setvalue.
type steeringif the steeringfluid is not pressurThis allowsthe steeringsystemto functionas an ordinaryrack-and-pinion
izedbecauseof a faulty pump.
VALVE
Diflerencein angle between the
input shaft and pinion shaft
PINION SHAFT
la
-l
INPUTSHAFT
17-20
INPUTSHAFT
PressureControl
Low assistat higherspeeds:
When steeringresistanceis low, such as when driving at high speeds,or when driving straightahead,the input shaft is
nearor in the neutralposition,so there is littleor no flow to any of the power cylinderorifices.N4ostof the feed pressure
from the pump is bypassedto the reservoir.Becauseof this,the pressurestaysthe same in both sidesof the power cylinder, resultingin low or no assist.
VALVE
From PUMP
RETURNPASSAGE
lTo RESERVOIR)
VALVEBODY
UNIT
SECTIONA.A
. A
J
POWERCYLINDER
GEAREOX
High assistat lower speeds:

When steering resistanceis high, such as when driving at low speeds,or when turning the wheel with the vehicle
stopped,the differencein anglecreatedbetweenthe input shaft and the valve opensthe fluid passageon one side, and
closesthe fluid passageon the other side. at each pair of orifices,The fluid pressureincreasesin the side of the power
cylinderfed by the largerfluid passage.This increasedpressurepusheson the rackpiston,allowingthe steeringwheelto
be turnedwith light effort.On the otherside of the powercylinder,the returnpassageopensallowingthe steeringfluid to
returnthrough the input shaft to the reservoir.The fluid passagesto the power cylinderautomaticallychange in size,
increasingas the steeringresistanceincreases.In other words. the passagesbecomelargerand power assistincreases
when the steeringeffort would normallybe high, (for example,when parkingor making low speedturns),and the passagesbecomesmallerand power assistdecreaseswhen the steeringeffort would normallybe low, (for example,when
drivingat high speedsor straightahead).
---------\\
r
FLUIDPASSAGETO
POWEBCYLINDER
From PUMP
- /
SECTIONA-A
(High lluid pressurl
17-21
Troubleshooting
GeneralTroubleshooting
Checkthe followingbeforeyou begin:
. Hasthe suspensionbeenmodifiedin a way that would affectsteering?
. Are tire sizes,tire varietyand air pressurecorrect?
. ls the steeringwheel originalequipmentorequivalent?
. ls the powersteeringpump belt properlyadjusted?
. ls steeringfluid reservoirfilledto properlevel?
. ls the engineidle speedcorrectand steady?
HardSteering(Checkthe powerassist,seepage'17-30.
lflhe forceis over 29 N 13.0kgf,6.6lbf),Precedewith this troubleshooting.)
Checkthe pump fluid pressure

(seepage17-34).
Measuresteadystate fluid pres
sure while idling with the both
valvesfully open.
It shouldbe 1,500kPa(15kgvcm,,
213psi)or below.
Abnormal
Iluid pressure
{fluidpressure
is too high)
C h e c kt h e l e e d a n d r e t u r n c i r c u i t l i n e s a n d h o s e
b e t w e e nt h e g e a r b o xa n d p u m p f o r c l o g g i n ga n d
delormation.
Normalline
a n dh o s e
Normal
Faultyvalvebody unit
C h e c kt h e p u m p { l u i d p r e s s u r e
{seepage17-34).
M e a s u r ep u mp r e l i e f p r e s s u r e
while idling with the pressurecontrol valveIully closed.
It should be 6,400- 7,400kPa16575 kgflcm',920- 1,070psi)
Reliefpres-
Checkthe tlow control valve (seepage 17-42).

. Checkthe valvefor smooth movementin the housing.
' Checkthe reliefvalvefor leaks.
Normalreliefpressure
Go to page17 23
1 7- 2 2
Abnormal
Faultypump assembly
Faultyflow control valve

(Replace
the pump as an
assembly)
Checkthe lorce requiredlo turn

the wheol(seepage17-30).
Startthe engineand measurethe
force required to turn the wheel
to the right and left. Differenceof
t h e f o r c e r e q u i r e dt o t u r n t h e
wheel to the right and to the left
shouldbe 2.9 N (0.3kgl, 0.7 lbt)
Normal
Checkfor bent rack shaft.
Checkpump tluid pressure(see

page17-34).
Turn the steeringwheelfully to the
right and left while idling wirh the
pressurecontrol valvg Iully open,
and measurethefruid pressure.
lr shouldbe 6,400-7,400 kPa(6575 kgflcm,,920- 1,070psi).
Check rack guide adjustmgnt (see

page 17'33).
AdjustmentOK
Faultyvalvebody unit
Abnormal -
Checkthe gearbox.
Removethe gearbox and measurethe piniontorque.
Thetorqueshouldbe;
* 0.7- 1.2N.m (7 - 12 kgf'cm,6 10 lbl.in) with the steering rack
in th6 straightdrivingposition.
1 1 . 3 N . m ( 1 3 k g f . c m 1, 1 . 3l b f i n )
with the steering rack in any
other position.
Faultygearbox
Checkthe parts othor than the gearbox-relatedparts lor

Drooerrotation.
part(s)
. lmproperrotationofthe steedngcolumn-relatsd
. Faultysteeringjoint
. Faultyrackend ie-rodend ballioints
. Interferencein the steeringsystem
Abnormal
Adjust the rack guide (see Page

1 7 - 3 3 ) a, n d r e c h o c kt h e p i n i o n
torque.
Normal -
lmproperlyadiustedrackguide
Abnormal
Faultygearbox
(cont'd)
17 -23
Troubleshooting
GeneralTroubleshooting (cont'd)
Assist (excossivelylight steering)at
highspeed.
Checkthe rack guide for proper

adiustment(seepage17-33).
Shockor vibrationwhen wheelis

turnedto full lock.
Checkthe rack guide tor proper

adjustment(seepage17-33).
lf the problem is not correctedby

adjustingthe rack guide, adjust
the lront whel alignment (see
soction18).
Adjustthe rackguide.
Rackguideis adiustedproperly.
Checkthe belt tor slippageand

adjust as necessary(see page
17-321.
lf the problom is not correctedby

adiustingthe rack guide,replace
the gearbox.
Steeringwheelwill not roturn

smoothly.
A a n d I c y l i n d e rl i n e sa r e n o r mal. checkwheel alignment(see

soctionl8).
W h e e l a l ; g n m e n ti s a b n o r m a l ,
adjust as needed.
Wheelalignmentis normal.
R e m o v et h e g e a r b o xf r o m t h e
f r a m e a n d m e a s u r et h e p i n i o n
torqueon the gearbox.
' l t s h o u l db e 0 . 7- 1 . 2N . m ( 7 1 2 k g f . c m , 6- 1 0 l b t . i n )o r
below with the steeringrack in
the straightaheaddrivingposition.
. 1.3 N.m (13 kgf.cm,11.3lbf.inl
w i t h t h e s t e e r i n gr a c k i n a n y
otherposition.
lf the measurementsare out of

s p e c i f i c a t i o n sa, d j u s t t h e r a c k
gurde.
f''
lf the problemis not correctedby

adjlsting the rackguide,replace
the gearbox.
17-24
I
Mjust the rackguide(seepage17-33).
Unevenor roughsteering,
lf the problom is not coftected bY

adjustingthe rackguide,roplace
the gearbox.
Adiustthe belttension.Replacethe
(seepage17-321.
belt,if necessary
ldle speed low or erratic.
lfthe enginestallswhen the wheel

is turnd while car is stoppodor
moving at low speed,adjustthe
idle speed(seeseclion11).
Air in resgrvoir,or checkpowor

steeringfluid level.
Checkpower stoeringfluid level.lf

the level is excessivelylow, chock
tor leaks in the system.Add fluid
to the spcifiedlevel.
lf lluid level is OK, check O-rings

8 n d s e a l so n b o t h o n d s o f t h e
pump inlt hose,and the P/S
pump housing mating surfaces
and the pump shaft oil seal for
suction leaks. Replaceparts as
Stoeringwheelkicksback
duringwid turns.
P!mp belt slippingon pulley

{pumpstopsmomentarily).
Adlustthe belt tension{seePage

17-32)orreplacebeh.
Installthe power steeringpressure

gauge.Closethe pressurocontrol
valvelully and measurethe pump
pressure(seepage 17-34).
Checkit pump prssureis normal

and the gaugeneedletravel is 500
k P a ( 5 k g f l c m ' ,7 1 p s i ) o r l e s s .
Checkthe flow controlvalve if the
needle travel exceeds500 kPa 15
kgt/cm,,71 psi).lf the flow control
valve is normal,replacethe pump
as an assembly,
17 -25
Troubleshooting
NoiseandVibration
NOTE:Pumpnoisein first 2 - 3 minutesafterstaningin cold weatheris normal.
H u m mj n g
Rattleor chattering
Humming due to pulsationof fluid is normal, particularlywhen the wheel is

turnedwith the vehiclestoooed.
lf equippedwith automatictransr n i s s i o nt,h e h ! m c o u l d b e t h e

torqueconverteror pump noise.
Confirm by temporarily removing

the pump belt.
High-pressureline touching the

frame.
Repositjonthe line.
Loosesteeringshaft connector,
tie-rod,or ballioint.
C h e c ka n d t i g h t e n , o r r e p l a c e
parts as necessary.
Columnshaftwobbling.
Replacethe columnassembly.
Checkthe rack guide lor proper

adjustment(seepage17-33).
Adjust,if necessary.
Rattlingsoundand feelingwhen turningthe steeringwheelright and leftwith the

engineOFFis a soundwhen the valvebody unit contactsthe stoo.This is normal.
Pump noise,though not loud,from the valve body unit can be heardwhen turning the steeringwheelright or left.This is normal.
CAUTION: When inspecting, do not hold the steering wheel 8ll the way to
the right or the left.
f''
17-26
Pumpnoise
Gratingnoise
from pump
Cavitationcausedby air bubbles

in the fluid.
Checkthe fluid lev1.

l f l o w , f i l l t h e r e s e r v o i rt o t h e
propor level,and chockfor leaks.
Tighten or rplaceas necessary.
Checkfor a crushedsuctionhose
or a loose hose clamp allowing
air inlo the suction side ol tho
system.
Tightgn or replace8s necessary.
Pumpgearnoise
NOTE: Pump noise uP to 2 - 3

m i n u t e sa f t e r s t a r t i n gi n c o l d
weatheris normal.
Comparepump noiso at operating
temperature
to simularvehicle.
ll pump noiseis abnormallyloud,

removeand inspectthe pump tor
wear and damage(see page 1741t.
,Ou"u,,nn
Rattleor chattering
Tighten or roplacethe pully.

l f s h s f t i s l o o s o , r e P l a c el h e
pump.
17-27
,l
Troubleshooting
Fluid Leaks
.
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points,dependingon locationof the
faultyoil seals/seal
rings.Checkthe followingbeforeremovinglhe gearboxfrom the frame.
SteeringGearbox
Leakingfrom the oil seal on the

top of the valvehousing.
Replacethe valve oil seal from

the valvehousing.
Leakinglrom cylinder end into

left tie rod boot.
Replacothe valve oil seal from

the pinionshaft.
Replacethe cylinderend sealon

the garhousingside.
17 -28
Leakingfrom cylinder end into

right tie-rod boot.
Replacethe cylinderend sealon

the cylinderend side.
Leakingfrom the shaftupperend

sectionor pin engagemenlsection of the pinionshaft.
Replacethe valve body unit.
Leakinglrom cylinderline A or B
(atflarenut).
connections
Tighton th6 connector. lI it's still

leaking,replaceth lino,cylinder
or valvehousingunit.
L e a k i n gc a u s e db y a d a m a g e d
cylinderlineA or L
ReplacecylinderlineA or B.
Leakingfrom feed line and return

linejoint fittingon the valvebody
unit (atflare nut).
Tightenthe connector.lf it's still

leaking,replacethe line,joint fitting or valvehousing.
Replace
the housingO-rings.
lf the housingstill leaks,replace
the pump.
Reservoiris ov6rfilled.
Pull off the hose and drain the
reservoirto the proper lev1.
Air leak in suctionside ot the syslem {resrvoir,inlet hose,{ront

pump seal).
Pumpoutletline
(high-pressure)
Leakingat the lhreadedlitting.
Tighten the fining. It it's still leakin9, replacothe O-ringor feed line.
Leakingat the swsggedjoint.
af
Pumpinletline
(low-pressure)
Leakingbecauseof damage.deterioration,or improperassombly.
Replaceor ropairas necessary.
Steering Operation
PowerAssistCheckwith
VehicleParked
Placethe front wheels in the straight ahead position,

a n d m e a s u r et h e d i s t a n c et h e s t e e r i n gw h e e l c a n b e
turnedwithout movingthe front wheels.
1.
Checkthe power steeringfluid level (see page l733) and pump belttension(seepage 17-32).
ROTATIONALPLAY:0 - 10 mm l0 - 0.39 inl
2.
lf the play exceedsthe servicelimit, perform rackguide

adjustment(seepage 17-33).
lf the play is still excessiveafter rack guide adjustment,
inspectthe steering linkageand gearboxas described
on the next page.
Startthe engine,allow it to idle, and turn the steering wheel from lock-to-lockseveraltimes to warm
up the fluid.
3.
Attacha springscaleto the steeringwheel.With the

engine idling and the vehicleon a clean,dry floor,
Dull the scaleas shown and read it as soon as the
tires beginto turn.
ROTATIONALPLAY
7 t l
The scaleshould read no more than 29 N (3,0 kgf,

6 . 6 l b f ) . l f i t r e a d sm o r e , c h e c kt h e g e a r b o xa n d
oumo.
17-30
SteeringLinkageand Gearbox
TIE.RODEND BALLJOINT
Insoectfor faultvmovement
and damage.
BOOT
Inspect
damage and deterioration.
JOINTS
Checkfor loosejoint bolts.
SHAFTGROMMET
TIE.RODLOCKNUT
for looselocknut.
STEERINGGEARBOX
Inspectfor loosemountingbolts.
GEABBOXMOUNTINGCUSHIONS
lnsoecttor deterioration.
3ALL JOINT BOOT

See p49e 17-68for replacement.
17-31
PumpBelt
NOTE:When usinga new belt,first adjustthe deflection
or tensionto the valuesfor the new belt, then readjust
the deflectionor tensionto the valuesfor the used belt
a f t e rr u n n i n ge n g i n ef o r l i v em i n u t e s .
Adiustment
1.
Loosenthe power steeringpump mountingbolts.

PUMPMOUNTINGBOLT
24 N m 12.4kgt m, 17 lbffrl
Inspection
Attachthe specialtool to the belt and measurethe ten
sion of the belt.
Tensionr
used Belr: 340- 490N {35- 50 kgf. 77 - 110tbt)
New Belt: 640 - 780 N {65 - 80 kgl, 143- 176 tbfl
NOTE:
. lf thereare cracksor any damageevidenton the belt,
replaceit with a new one.
. Followthe manufacturer's
instructionsfor the tension
g au g e .
BELTTENSION
GAUGE
_ 001010A
07JGG
POWER
PUMP
PUMPMOUNTINGBOLT
24 N.m {2.4kgf.m, 17 lbr.ft)
2. Adjust the belt tensionby moving the power steering pump with a 1/2" drivebreakerbar to obtainthe
p r o p e r b e l t t e n s i o n ,t h e n r e t i g h t e nt h e m o u n t i n g
bolts.
3.
Inspectthe pump beltfor cracksor any damage.
Replacethe beltwith a new one if necessary.
Measurementwithout Belt TensionGauge:
Apply a force of 98 N (10 kgl,22 lbt) and measuret h e
d e f l e c t i o nb e t w e e nt h e p o w e r s t e e r i n gp u m p a n d t h e
c r a n k s h apf tu l l e y s .
Detlection:
UsedBelt: 10.5- 14.0mm (0.41- 0.55in)
New Belt: 7.5- 10.0mm (0.30- 0.39inl
17-32
Start the engine and turn the steeringwheel from

lock-to-lock
severaltimes,then stop the engineand
recheckthe deflectionof the belt.
RackGuideAdjustment
FluidReplacement
NOTE:Performrack guide adjustmentwith the wheels

in the straightaheadposition.
Checkthe reservoirat regularintervals,and add fluid as

necessary.
CAUTION: Always use Gonuin Honda Powsr Steering
Fluid-V or S. Using any oth.r type ot pow 3toering
fluid or sutomatic lrsnsmis3ion fluid can cause
increasedwear and poor steoring in cold woather.
SYSTEMCAPACITY:
0.85 litor 10.90US. qt, 0.75 lmp.qtl
at dkassembly
RESERVOIR
CAPACITY:
0.4 liter {0.42US. qt, 0.35 lmp.qt)
1.
'96 - 97 model:
Loosenthe rack guide screw locknutwith the specialtool, then loosenthe rackguidascrew.
UPPERLEVELLINE
LOWERLEVELLINE
tl
'98 modol:
Removethe old sealantoff of the threadedsection,
then apply new sealantto the first three threads.
Looselyinstalltherackguidescrew.
Tightenthe rack guide screwto 25 N'm (2.5 kgf m,
18 lbf.ft),then loosenit.
the returnhose
1 . Raisethe reservoir,then disconnect
to the discondiameter
Connecta hose of suitable
nectedreturn hose,and put the hose end in a suitablecontainer.
CAUTION:Taks car. not to spill tho lluid on tho
body and parts. Wipe off any spilled fluid at once.
Retightenthe rackguidescrewto 3.9 N.m (0.4kgf'm,

2.9 lbf.ft),then back it off to specifiedangle.
SpecifiedRetuh Angle: 20" max.
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
Checkfor tight or loose steeringthrough the completeturningtravel.
Performfollowinginspections:
.
.
HOSE
Steeringoperation(seepage17-30).
Powerassistwith vehicleparked.
4.
7.
Startthe engine,let it run at idle,and turn the steeri n g w h e e l f r o m l o c k - t o - l o cske v e r a lt i m s .W h e n

f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine.Discardthe fluid.
Reinstallthe returnhoseon the reservoir.
Fillthe reservoirto the uoDerlevelline.
Startthe engineand run it at fast idle,then turn the
severaltimes to bleed air
steeringfrom lock-to-lock
from the system.
Recheck
the fluid leveland add some if necessary.
CAUTION: Do not fill the reservoir beYond the
upper lovel line.
17-33
Inspectionand Adiustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e
whetherthe troubleis in the pump or gearbox.
NOTE: First check the power steering fluid level and
pump belttension.
CAUTION: Disconnectthe high pressurehose with care
so as not to spill the power steering fluid on the ftame
and other parts.
Disconnectthe outlet line from the pump outlet fitting, then jnstallthe P/Sjoint adaptor{pump)on the
pump outlet.
2. Connectthe P/S joint adaptor(hose)to the power
steering pressuregauge, then connectthe outlet
hoseto the adaptor.
3. Installthe power steeringpressuregaugeto the P/S
joint adaptor{pump)as shown.
6. Startthe engineand let it idle.

7. Turn the steeringwheel from lock-to-lockseveral
timesto warm the fluid to operatingtemperature.
fluid pressurewhile idling. lf
8. Measuresteady-state
t h e p u m p i s i n g o o d c o n d i t i o nt,h e g a u g es h o u l d
readlessthan 1500kPa(15 kgflcm' ,213psi).
lf it readshigh, checkthe outlet line or valve body
17-22).
unit (seeGeneralTroubleshooting
1.
6 x 1.0mm BOLT
9 . C l o s et h e p r e s s u r ec o n t r o l v a l v e ,t h e n c l o s et h e
shut-off valve gradually until the pressuregauge
needleis stable.Readthe pressure.
10. lmmediatelyopenthe pressurecontrolvalvefully.
CAUTION: Do not kp the pressure conlrol valve
closed more then 5 seconds or the pump could be
damaged by over-heating.
OUTLETHOSEFTTNNG
lf the pump is in good condition,the gaugeshould

read at least 6.400- 7,400kPa(65 - 75 kgflcn',920 1.070psi).A low readingmeanspump outputis too
low for full assist.Repairor replacethe pump.
P/S JOINTADAPTORIHOSE)
07MK - 5040121
oa
07RAK- S040r20
GAUGE
P/SPRESSURE
07405- 001000A
GAUGE
P/S PRESSURE
07{06 - 00'llD0A
ol
07,106- q)l0001
ot
lPart of tooll
1 1N . m
(1.1 ksf.m, I lbt'ft)
PRESSURE
CONTROLVALVE
.OFF
VALVE
PUMPOUTLET
FITTING
6 x 1.0mm BOLT
(Partot tooll
1 1N m
(1.1ksf.m,8lbtft)
5.
Openthe shut-offvalvefully.
Openthe pressurecontrolvalvefully.
17-34
SHUT.OFFVALVE
SteeringWheel
Removal
lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor service.
CAUTION: Do not tap on the steering wheel or steering

columnshaft when installingthe steeringwheel.
N O T E :B e f o r er e m o v i n gt h e s t e e r i n gw h e e l ,a l i g n t h e
front wheelsstraightahead.
N O T E :B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,a l i g n t h e
front wheelsstraightahead.
1.
' 1 . R e m o v et h e d r i v e r ' sa i r b a ga s s e m b l yf r o m t h e
steeringwheel(seesection24).
2.
D i s c o n n e ct th e h o r n c o n n e c t o ar n d c r u i s ec o n t r o l
switchesconnector.
CABLEREEL
2.
3.
B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e rt h e
cable reel. Do this by first rotating the cable reel
clockwiseuntil it stops.Then rotateit counterclockwise approximatelytwo turns. The arrow mark on
the cablereellabelshouldpointsstraightup.
lnstall the steeringwheel with the steeringwheel

nut.
N O T E :B e s u r e t h e s t e e r i n gw h e e l s h a f t e n g a g e s
the cablereel and cancelingsleeve.
Remove the steering wheel nut.
WHEELNUT
STEERING
Replace.
4.
Remove the steering wheel by rocking it slightly from

side to side as you pull steadilywith both hands.
3.
Attachthe cruisecontrol switchesconnectorto the

steerinw
g h e e lc l i P .
4.
Connectthe horn connector.
5.
I n s t a l lt h e d r i v e r ' sa i r b a ga s s e m b l y a, n d c o n f i r m
propersystemoperationlsee section24).
6.
C h e c kt h e h o r n a n d c r u i s e c o n t r o l s w i t c h e sf o r
properoperations.
17-35
SteeringWheel
*@*&*W
-:<z<z
17-36
SteeringColumn
NOTE: Before removing the steeringcolumn for SRS,
removethe driver'sairbagassemblyand cablereel (see
section24).
1. Removethe steeringwheel (seepage17-35).
2 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
driver'skneebolster(seesection20).
3. Removethe combinationswitchassemblvfrom the
the connecsteeringcolumn shaft by disconnecting
rors.
4. Disconnect
the ignitionswitchconnectors.
5. Removethe steeringjoint cover
6. Removethe steeringjoint bolts.
7 . D i s c o n n e ct th e s t e e r i n gi o i n t b y m o v i n gt h e j o i n t
toward the column,and removeit from the column
shaft.
8 . R e m o v et h e s t e e r i n gc o l u m n b y r e m o v i n gt h e
attachingnuts and bolt.
UPPER
9. Installationis the reverseof the removalprocedure.

NOTE:
. Makesurethe steeringjoint is connectedas follows:
a. Insertthe upper end of the steeringjoint onto the
steeringshaft (lineup the bolt holewith the flat on
the shaft),and looselyinstallthe upperjoint bolt.
b. Slip the lower end of the steeringjoint onto the
pinion shaft (line up the bolt hole with the groove
a r o u n dt h e s h a f t ) .a n d l o o s e l yi n s t a l lt h e l o w e r
joint bolt.
Be sure that the lower joint bolt is securelyin the
groovein the pinionshaft.
c . P u l l o n t h e s t e e r i n gj o i n t t o m a k e s u r e t h a t t h e
steeringjoint is fully seated.Thentightenthe joint
bolts.
. Be sure the wires are not caught or pinchedby any
partswhen installingthe column.
. Make sure the wire harnessis routed and fastened
properly,
. Makesurethe connectorsare properlyconnected.
STEERINGCOLUMN
COMBINATIONSWITCH
ASSEMBLY
RETAININGCOLLAR
NOTE:Takecarenot to letthe
retainingcollarfall out of
positionduringinstallation.
STEERINGJOINT BOLTS
22 N.m {2.2 kgt m, 16 lbl.ftl
FLANGEBOLTS
22 N.m 12.2kgl'rn,
15lbl tr)
UPPERJOINT BOLT
Bolt must line up
on shaft.
COLUMNCOVER
Groove.
JOINTCOVER
CLIP
JOINT BOLT
Bolt must line up with
g.oove around on shaft.
17-37
SteeringColumn
Inspection
NOTE:The tilt steeringcolumn type is shown; the conv e n t i o n asl t e e r i n gc o l u m n i s s i m i l a re x c e p tf o r t h e t i l t
mechanism.
Checkthe steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.lf
there is noiseor if there is excessiveplay,replacethe
steeringcolumnas an assembly.
C h e c kt h e r e t a i n i n gc o l l a rf o r d a m a g e .l f i t i s d a m aged,replacethe retainingcollar.
Checkthe absorbingplates,absorbingplate guides
and slidingcapsulesfor distonionor breakage.
Replacethe steeringcolumn as an assemblyif they
are distortedor broken.
ABSORBINGPLATES
ABSORBINGPLATEGUIDES
RETAINING COLLAR
COLUMNBALLBEARING
BEARINGS
IGNITION
Seesection23.
SLIDING
This part is attached
to the column bracket
with the plastic injections.
'1. lMovethe tilt lever from the loose positionto lock

p o s i t i o n3 t o 5 t i m e s ; t h e n m e a s u r et h e t i l t l e v e r
p r e l o a d1 0m m ( 0 . 4i n )f r o m t h e e n do f t h e t i l t l e v e r .
Preload:70 - 90 N {7 - I kgl. 15-20 lbf)
2.
l f t h e m e a s u r e m e ni ts o u t o f t h e s p e c i f i c a t i o n ,
a d j u s t h e p r e l o a du s i n gt h e f o l l o w i n gp r o c e d u r e s .
a. Loosenthe tilt lever,and set the steeringcolumn
in the neutralposition.
b. Removethe 6 mm lock bolt and removethe stop.
c. Adjustthe preloadby turningthe tilt lockbolt left
or ngnr.
d. Pullup the tilt leverto the uppermostpositionand
i n s t a l tl h e s t o p .C h e c kt h e p r e l o a da g a i n .l f t h e
measurementis still out of specitication,repeat
"c" to adiust.
"a"
the aboveprocedures through
CAUTION: Be calelul not to loosen the tilt level
when installing the stop or tightening the 6 mm
lock bolt.
17-38
TILT LOCKBOLT
Tightenthe lockbolt
the tilt leverraised.
9 . 8N . m{ 1 . 0k g l m , 7 l b l f t )
PowerSteeringHoses,Lines
Fluid LeakageInspection
HOSESand LINES
. I n s p e c th o s e sf o r d a m a g e ,l e a k s ,i n t e r f e r e n c eo r
rwrsI|ng.
. Inspectfluid linesfor damage,rustingand leakage.
. Inspectfor leaksat hose and line joints and connec
trons.
SWITCH
12 N.m (1.2ksf.m,9 lbthl
LINES
VALVEBODYUNIT-Io-CYLINoER
12 tbf ft,
1 7N . m1 1 . 7
LINES
vALVE BODYUNIT-to-FEED/RETURN
Feedline: 14 x 1.5 mm flare nut
37 N.rn 13.8kgf.m, 27 lbl.ft)
Rdurn Line Joint: 16 x 1.5 mm flare nui
28 N.m (2.7kgt m, 20lbf.ftl
CYLINDERHOUSING-to-CYLINDER
LINES
28 N.m {2.7kg{.m,20 lbf.ft)
BOOT
for leaks.
Check
GEARBOXand VALVEBODYUNIT
Checkfor leaksat the matingsurface
and flare nut conneclions.
OUTLETHOSE
1 1N . m
(1.1kgf.m,8
(DoubleRingType)
C h e c kf o r l e a k s a t t h e p u m p
seal, inlet and oudet fittings.
Replacement
NOTE:
pipesecurely
. Connecteachhoseto the corresponding
until it contactsthe stop on the line. Installthe clamp
or adjustableclamp at the specifieddistancefrom the
hoseend as shown.
. Add the power steeringfluid to the specifiedlevelon
the reservoirand checkfor leaks.
CAUTION: Check all clamps for deterioration or deformation; leplace with the clamps new ones it necessary.
ADJUSTABLEHOSECLAMP:
. P o s i t i o nt h e a d j u s t a b l eh o s e c l a m p s a t t h e p o i n t s
indicated(a) in the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop.
HOSECLAMP:
. P o s i t i o n t hh
e o s ec l a m p sa t t h e p o i n t si n d i c a t e{db ) i n
the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop.
tqtT-f*r--!-t__1
/Z\\\
g-
@ - f f_lli
_tr
2.5- 5.5mm
(0.01- 0.22inl
2 . 0 - 4 . 0m m
- 0.'16inl
10.08
2.5- 5.5mm
{0.01- 0.22in}
17-39
PowerSteeringPump
RemovaUlnstallation
NOTE:Beforedisconnecting
the hosesf.om the pump,
placea suitablecontainerunderthe car.
1.
Connectthe inlet hose and the outlet line. Tighten

the pump fittingssecurely.
Removethe belt by looseningthe pump mounting

bolts.
11 N.m {1.1kgt.m,
Looselyinstallthe pump in the pump bracketwith

mountingbolts.
7.
PUMPMOUNTINGBOLT
2{ N.m {2.4kgf.m, 17 lbf ft)
CAUTION:
. Mako suro that the power 3teering belt is properly positioned on the pulleys.
. Do not get power siesring fluid or gresse in the
power steering belt or pulley fac$. Cleanofl any
fluid or grcase before installation.
8.
PUMPMOUNTING
EOLT
2il N.m{2.4kgf.m,1?lbt.ft)
Coverthe A,/Ccompressorwith severalshop towels

to protectit from spilledpower steeringfluid.
Disconnectthe inlet hose and the outlet line from
t h e p u m p ,a n d p l u gt h e m .
NOTE:Takecare not to spill the fluid on the body
or parts.Wipe off any spilledfluid at once.
Removethe pump mountingbolts,then removethe
pump.
NOTE:
. Do not turn the steeringwheel with the pump
removed.
. Wrap the opening of the pump with a piece of
tape to prevent foreign material from entering
I n ep u m p .
17-40
Installthe oump belt.
Adjustthe pump belt (seepage17-32).

Fill the reservoirto the upper level line (see page
11-33t.
Disassembly
CAUTION: The power steering components are made of aluminum. Avoid damaging the componsnG during assembly.
NOTE:
. Cleanthe disassembledpartswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a solvent.
a Always replacethe O-ringsand rubbersealswith new ones beforeassembly,
. Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe powe. steeringsystem.
. Replacethe pump as an assemblyifthe pans indicatedwith asterisk(+)are worn or damaged.
FLANGEEOLTS
20 N.m (2.0 kgf.m.
14 tbtft)
4.5mm ROLLEB
PUMPCOVERSEAL
Replace.
*OUTERSIDEPLATE
PUMPCOVER
5 mm ROLLER
*PUMP FOTOR
.SIDE PLATE
3 t
SNAPRING
13 x 1.9mm O-RING
Replace.
.PUMPHOUSING
,SUB-VALVE
51 x 2.{ mm O-RING
Replace.
15.2x 2.4mm O-RING
PUMPSEAL
Replace.
Beplace.
PUMPSEALSPACER
INLETJOINT
BALLBEARING
Inspection
and Replacement,
seepage17-43
FLANGEBOLTS
11 N,m {1.1kgf.m,
8 rbf.ft)
a0 mm CIRCLIP
*FLOWCONTROLVALVE
Insoection
and Overhaul.
PULLEY
seePaselT"
fi
spnrruc/ d
'-tlu"i:3;'n^ô'^''o
FLOWCONTROLVALVECAP
4It N.m {5.0 kgf.m,
36 tbtft)
PULLEY
NUT
64N.m{6.5kgt.m,
47lbt.ft)
(cont'd)
17-41
PowerSteeringPump
Disassembly(cont'd)
1 . Drainthe fluid from the pump.
Hold the steering pump in a vise with soft jaws,

hold the pulley with the specialtool, and remove
the pulleynut and pulley.
CAUTION: Be carelul not to damage th6 pump
housing with thc iaws ot the viso and extension bar.
Inspection
Flow Control Valve:
1.
Checkthe flow control valve for wear, burrs, and

other damage to the edges of the grooves in the
valve.
FLOW
CONTROLVALVE
UNIVERSALHOLDER
C h e c kf o r
damage to edges.
Inspectthe bore the flow control valve for scratches

or wear.
Slip the valve back in the pump, and checkthat it
movesin and out smoothly.
\
Loosenthe flow controlvalvecap with a hex wrench
and removeit.
Removethe O-ring,flow controlvalveand spring.
Removethe inletjoint and O-ring.
Removethe pump coverand pump coverseal.
7 . Removethe outer side plate,pump cam ring, pump
rotor,pump vanes,side plateand O-rings,

Removethe snap ring, then removethe sub-valve
from the pump housing.
Removethe circlip, then remove the pump drive
shaft by tappingthe shaftend with the plastichammer.
1 0 . Removethe pump sealspacerand pump seal.
17 -4 2
lf OK, go on step 4; if not, replacethe pump as an

assembly,The flow control valve is not available
separately.
Attacha hoseto the end of the valveas shown.
VALVE
FLOWCONTFOL
HOSE
5.
Submergethe valve in a containerof power steering tluid or solvent.and blow in the hose.lf air bubb l e s l e a kt h r o u g h t h e v a l v e a t l e s st h a n 9 8 k P a
{1.0kgflcm,,14.2psi),repairit as follows.
Ball Bearing:
1.
Inspectthe ball bearingby rotatingthe outer race

slowly. lf any play or roughnessis felt, replacethe
ball bearing.
BALLBEARING
<--
POWERSTEERING
FLUIDor SOLVENT
Hold the bottom end of the valve with a open end

wrench.
7.
.{
D
Unscrewthe seat in the top end of the valve, and

removeany shims.the reliefcheckball, reliefvalve
and reliefvalvespring.
2.
Removeand discardthe ball bearingusing a press

as snown.
Installthe new ball bearingusinga pressas shown.
RELIEFVALVE
RELIEFCHECK BALL
Ball Bearing Replacement:
SEAT
9 N.m
{0.9kgl.m.6.5lbtft)
C l a m pt h i se n d i n
a openeno wtencn.
8.
FLOWCONTROLVALVE
C l e a na l l t h e p a r t s i n s o l v e n t ,d r y t h e m o f f , t h e n
reassembleand retestthe valve.lf the flow control
valve tests OK, reinstallit in the pump. lf the flow
control valve still leaksair, replacethe pump as an
assembly.The flow control valve is not available
separately.
NOTE: It necessary,relief pressureis adjusted at
the factory by adding shims under the check ball
seat.lf you found shims in your valve,be sure you
reinstallas manv as vou took out.
lnstallwith the
red shieldedside
facing down.
NOTE:Supponthe innerrace
with the toolsecurely-
17-43
PowerSteeringPump
Reassembly
1.
Align the pin of the sub-valvewith the oil passage

in pump housing,and push down the sub-valve.
Installthesnap ring properly.
OIL PASSAGE
Align the pin of
sub valve with
the oil passage.
Coat the pump cover seal and the cover bushing

with the power steeringfluid, then installthe pump
coversealinto the groovein the pump cover.
Installthe outer side olateoverthe two rollers.
ROLLERSET HOLES
OUTERSIDEPLATE
4.5 mm ROLLER
5 mm ROLLER
PUMPHOUSING
SNAPFING
2.
Installthe new pump seal in the pump housingby

hand,then installthe pump sealspacer.
NOTE: Insertthe pump seal with its grooved side
f a c i n gi n .
Positionthe pump drive shaft in the pump housing,
then drive it in usinga specialtool as shown.
Installthe 40 mm circlipwith its radiusedside facIng out.
40mm CtRCLtp
ATTACHMENT,30mm
- oososob
ozzls
PUMPCOVER
,rr","oE \
7 . Setthe pump cam ring over the two rollerswith the

" " " mark on the cam ring
upward.
PUMPCAM RING
q:D
BALLEEARING
PUMPDRIVESHAFT
ROLI.IR SET HO|'.CS
PUMPSEALSPACER
ROLIIRS
17-44
Assemblepump rotor to the pump cover with the

" o " markson the rotorfacingdown.
Coatthe O-ringwith power steeringfluid, and position it into the pump housing.
1 3 . Installthe pump cover assemblyin the pump hous-
9 . Setthe 10 vanesin the groovesin the rotor.
Ing.
NOTE:Be surethat the round ends of the vanesare
in contactwith the slidingsurfaceof the cam ring.
FLANGEBOLTS
20 N.m {2.0 kgl.m,
r4 tbf.ftl
PUi'P VANES
(10 plrt .)
PUMP ROTOR
aE
nn
't4. Coat the flow control valve with power steering
fluid.
D
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gl l u i d . a n d
installit into the groovesin the side plate.
1 l . Installthe side plateon the cam ring by aligningthe
rollerset holesin the side platewith the rollers.
1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gt l u i d . a n d
installit on the flow controlvalvecap.
't] . Installthe flow cont.olvalvecap on the pump housing, and tighten it.
SIDE PLATE
1 5 . I n s t a l lt h e f l o w c o n t r o l v a l v e a n d s p r i n g o n t h e
p u m ph o u s i n g .
15-2 | 2.1 mm O-RING

Replace.
ROU.R SET HOll
r
SPRING
Mv (64
15.2x 2.4rnm O-RING

Replace.
SET HOIf
\tbry
\
FLOWCONTROL
VALVECAP
49 N.m (5,0kgl.m,
36 rbtft)
ROU"EBS
(cont'd)
17-45
PowerSteeringPump
Reassembly(cont'dl
1 8 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit into the groovesin the inletjoint
1 9 . I n s t a ltlh e i n l e tj o i n to n t h e p u m ph o u s i n g
21. Holdthe pulleywith the specialtool, and tightenthe

p u l l e yn u t .
UNIVERSALHOLDER
PULLEYNUT
64 N.m {6.5 kgtm,
15.2x 2.4
Beplace.
11 N.m (1.1kgl.m,
8 tbtfr)
2 0 . l n s t a l lt h e D u l l e va s s h o w n b e l o w , t h e n l o o s e l y
I n s t a l tl h e p u l l e yn u t . H o l d t h e s t e e r i n gp u m p i n a
visewith softjaws.
CAUTION:Be carelul not to damagethe pump housing with the iaws of the vise.
17-46
Checkthat the pump turns smoothlyby turnrngrne

p u l l e yb y h a n d .
SteeringGearbox
Removal
NOTE:Usingsolventand a brush,wash any oil and dirt
off the valve body unit its lines,and the end if the gearbox. Blow dry with compressedair.
1,
Drainthe power steeringfluid as describedon page

1 7- 3 3 .
7. Removethe cotterpin from the castlenut ('96-'97

model)or nut ('98 model)and removethe nut.
END
TIE.ROD
Raisethe front of vehicle,and support it on satety

standsin the properlocations(seesectionl).
Removethe front wheels.
Removethe driver'sairbagassembly,and steering
wheel(seepage17-35).
Bemovethe steeringjoint cover.
Installthe 10 mm hex nut on the balljoint.

Be surethat the 10 mm hex nut is flush with the ball
j o i n t p i n e n d , o r t h e t h r e a d e ds e c t i o no f t h e b a l l
joint pin might be damagedby the specialtool.
NOTE:Removethe ball joint usingthe specialtool.

R e f e rt o s e c t i o n l 8 f o r h o w t o u s e t h e b a l l j o i n t
remover.
6.
Removethe steeringjoint lower bolt, and disconnect the steeringjoint by moving the joint toward
t h ec o l u m n .
Separatethe tie-rodball joint and knuckleusingthe

specialtool.
CAUTION: Avoid damaging tho ball ioint boot.
1 0 . Removethe lefttie-rodend,then slidethe rackall the

way to the right.
1 1 . Separatethe exhaustpipeA or TWC (seesection9).
Disconnectthe
shiftlinkage(seesection13or section
141.
(cont'd)
17-47
,l
SteeringGearbox
Removal(cont'dl
Loosenthe 14 mm flare nut and disconnectthe feed
l ne,
17. Removethe mountingbrackets.
1 4 . Loosenthe adjustablehose clamp and disconnect

the returnhose.
Loosenthe 16 mm flare nut and removethe return
hose iointfrom the valvebodv unit.
CAUTION: After disconnecting the hose and line,
plug or seal the hose and line with a piece of tape
or equivalsnt to prevent foreign materials from
entering the valve body unit.
N O T E : D o n o t l o o s e nt h e c y l i n d e r l i n e A a n d B
betweenthe valvebody unit and cylinder.
ADJUSTABI.EHOSE
CLAMP
1 8 . Pull the steeringgearboxall the way down to clear

the pinion shaftfrom the bulkhead,then removethe
pinionshaftgrommet.
1 9 . Move the steeringgearboxto right so the left rack
end clearsthe rearbeam,then tilt the left side down
to removeit from the vehicle.
14 mm FLARENUT
Removethe stiffenerplate.
CAUTION:Be careful not to bend or damage the

leed line and cylinder linss whn rmoving th6
gearbox.
NOTE:Some stiffenerplateattachingbolts are also

used as gearboxmounting bolts.The gearboxwill
tilt to sidewhen theseboltsare removed.
PLATE
STIFFENER
ATIACHING BOLTS
17 -48
STEERING
GEARBOX
Disassembly
5.
Steoring Rack Disassombly

NOTE:
. Beforedisassemble
the gearbox,wash it off with solvent and a brush.
. Do not dip sealsand O-ringsin solvent.
1.
Removethe steringgearbox(seepage l7-47).
2.
Removethe tie-rodend and locknut.
3.
Removeairtube and clips.
Holdthe steeringrackwith a wrench{'98 model:left

end onlv), and unscrewthe rack end with another
wrench.
CAUTION: Bo caroful not to damage tho rack surfac with tho wrench.
NOTE:'96 -'97 model is shown.
STEERINGRACKEND
STEERINGRACK
.l
Loosen the locknut, then remove the rack guide
screw('98 model)and O-ring{'96-'97 model only).
Removethe boot bands and tie-rod clips, Pull

bootsawayfrom the endsof the gearbox.
7.
Removethe springand the rackguidefrom the gear

housrng.
RACKGUIDE
scREws
BOOT
TIE-ROOCLIP
(cont'd)
17-49
SteeringGearbox
Disassembly(cont'dl
8. Remove cylinder lines A and B from the gearbox
1 1 . D r i l la 3 m m { 0 . 1 2i n ) d i a m e t e rh o l ea p p r o x i m a t e l y
2 . 5- 3 . 0 m m ( 0 . 1 0- 0 . 1 2i n ) i n d e p t hi n t h e s t a k e d
p o i n to n t h e c y l i n d e r .
CAUTION:
. Do not allow metal shavings to enter the cylin'
der housing.
. After removing the cylinder end, remove any
burrs at the staked Point.
Deprhr2.5- 3.0mm {0.10- 0.12in)
LINEB
CYLINDER
CYLINDERLINE A
9. Drain the fluid from the cylinder fittings by slowly

moving the steering rack back and forth
CYLINDER
10. Remove the two flange bolts, then remove the valve
body unit from the gearbox. (See page 17 52 for
valve body unit disassemblY.)
FLANGE BOLT
VALVE BODYUNIT
1 2 . H o l d t h e s t e e r i n gg e a r b o xu s i n g a C - c l a m pa s
shown.
,
I
'96 - '97 model:

32 mm SHIMS
'98 modol:
WAVE WASHER
13. Loosenand removethe cylinderend.
17-50
14. Assemblea '12x 1.25mm flangenut onto a 12 x 175

mm grade 10flangebolt as shown.
N O T E :W r a p t h e f l a n g e p o r t i o n o f t h e b o l t w i t h
vinyl tapeto protectthe cylinder.
'18. Removethe l2 mm bolt and nut from the steering

rack.
1 9 . R e m o v et h e c y l i n d e re n d s e a l f r o m t h e s t e e r i n g
rack.
HOUSING
CYLINDER
ENDSEAL
CYLINDER
Repiace,
l " \s-,'
r
|t
tP/N 90177- SLo- 0001
I n s t a l tl h e f l a n g eb o l t i n t o t h e e n d o f t h e s t e e r i n g
r a c k u n t i l i t b o t t o m s i n t h e h o l e , t h e n b a c kt h e
f l a n g eb o l t o u t 1 / 4t u r n . H o l d t h e f l a n g eb o l t , a n d
tightenthe flangenut againstthe rackby hand.
Installthe bearingseparatoron the gearboxhousing
as shown.
'12x 1t5 mm
FLANGEBOLT
r-,,'
Press
BEARINGSEPARATOR
o- 4112"I
(commerciallvavailablel
It
" . .
^
I o-tfl
Q)*
lol 3/8" drive extensionand the spe20. Inserta 24" long,

th cylinderfrom the gearboxs r d e .
cialtool into the
N O T E :M a k )e sure
s
that the specialtool is securely
positionedon
n the
t backupring edges.
CAUTION: Be careful not damage to inner surtace
of the cylinderhousingwith the specialtool.
21. Set the gearboxin a press,then pressout the cylinder end sealand backupring from the gearbox.
CAUTION:
. Keepthe tool straightto avoid damagingthe cylin'
der wall. Checkthe tool angle,and correctit if necessary,when removingthe cylinderend seal.
. Use a press to rcmove the cylinder end seal. Do
not try to remove the seal by striking the tool. h
will break the backup ring, and the cylinder end
sealwill remainin the gearbox.
Press
STEERINGRACK
24 "LONG 3/8" DRIVEEXTENSIONI

{Commerciallyavailable)
CYLINOER
END SEAL
17. Setthe gearboxin a pressso the gear housingpoint

upward,then pressthe cylinderend seal and steering rackout of the gearbox.
NOTE:Holdthe steeringrackto keepit from falling
when pressedclear.
CAUTION:
. Be carelul not damage to inner surtace of the
cylinderhousingwith the tlangebolt.
. Do not place your lingers under the steering
rack.
BACKUPRING
CYLINDERENOSEAL
CYLINDERENOSEAL
REMOVERATTACHMENT
07NAO- SB3020A
(cont'd)
17-51
SteeringGearbox
Disassembly(cont'dl
22. Carctullypry the pistonseal ring and O-ringoff the
prslonracK.
CAUTION:Be carefulnot to damagethe inside ot
seal ring groove and piston edgeswhen temoving
the sealring.
Valve Body Unit Disassembly

2 3 . B e f o r er e m o v i n g t h e
v a l v eh o u s i n ga, p p l y v i n ytla p e
to splinesof the pinionshaft.
24. Separatethe valve housingfrom the pinion shaft/
valveusrn9a press.
VALVEHOUSING
Vinyl tape
PINIONSHAFT
Replace.
l
2 5 Checkthe innerwall of the valvehousingwherethe
seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valvehousing.
NOTE;
T h e r em a y b e t h e s l i d i n gm a r k sf r o m t h e s e a l
r i n g o n t h e w a l l o f t h e v a l v e h o u s i n g .R e p l a c e
the valvehousingonly if the wall is stepped.
When the valve housingis replaced,installnew
shim(s)on the bearingsurfaceof the housingto
adiustthe thickness.
Checkthe insideof valvehousing
whetherthe wall is stepped.
t ,
17-52
2 6 . C h e c kf o r w e a r , b u r r s a n d o t h e r d a m a g et o t h e
edgesof the groovesin the sleeve.
NOTE:The pinion shaft and sleeveare a precision
m a t c h e ds e t . l f e i t h e rt h e p i n i o n s h a f t o r s l e e v e
must be replaced,replaceboth parts as a set.
SLEEVESEALRINGS
Checklorpeeloffor
28. Usinga cutteror an equivalenttool, cut and remove

the four sealringsfrom the sleeve.
CAUTIONTBe careful not to damage the edges of
the sleeve groovos and out6r sufaca whon romoving the 3eal rings.
SLEEVE
damage.
3 f
27. Removethe circlipand pinion shaft sleevefrom the

pinionshaft.
Using a cutter or an equivalenttool. cut the valve

seal ring and O-ringat the groovethe pinion shaft.
Removethe valvesealring and O-ring.
CAUTION: Be caretul not to damage the odges of
the pinion shaft groove and outor 3urfacwhen
rmoving ths valve seal ring 8nd O-ring.
Cuftingslot Position.
VALVESEALRING
Replace.
(cont'd)
17-5 3
)
SteeringGearbox
Disassembly(cont'd)
30, Removethe valveoil sealand backupring ('96-'97
model)or wave washer('98 model)from the pinion
shaft.
NOTE:
Inspectthe ball bearingby rotatingthe outer race
slowly.lf there is any excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
The pinion shaft and sleeveare a precisefiu do
not intermix old and new pinion shaftsand
sleeves.
BALLBEARING
'96 - '97 model:

BACKUPRING
Replace.
3 1 . Pressthe valve oil seal and roller bearing{'96 -'97

model)or bushing('98 modell out of the valve
h o u s i n gu s i n g a h y d r a u l i cp r e s sa n d s p e c i a tl o o l
shown below.
N O T E :D o n o t u s e a h a m m e r ;i t w i l l d a m a g et h e
specialtool.
'96 - '97 model:
PILOTCOLLAR
07GAF- PH70100
VALVEOIL SEAIReplace.
ROLLERBEARING
Beplace.
PILOTCOLLAR
07GAF- PH701(x)
VALVEOIL SEAL
Replace.
BUSHING
Replace.
t,,
17-54
Reassembly
NOTE:
partswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a sol. Cleanthe disassembled
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly,
. Apply the recommendedpower steeringfluid to the pans.indicated
in the assemblyprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
. Usethe appropriatespecialtools where necessary.
CYLINDERLINE A
CYLINDERLINE B
VALVEHOUSING
VALVEOIL SEAL
Replace.
FLARENUTS
17 N m 11.7kgt.m, 12 lbt.ft)
Replace
SLEEVE
SEALRINGS.-.--------..--
-S-.-
Replace.
RePIace
$<-----sueve
-.$}-S:"_------;T;i,',Tl"t',
- " - v >
BACKUP
Replace.
wAvEwASHER
itoilJoril."."
CYLINDERHouslNG
BEARING
",r"a,,
S
.o'S
VALVEOIL SEAL.
CYLINOER
ENDSEAL
Replace.
--=-..--
-;;oi;"*.
RING
valvESEAL
-_____
p***t.----..--..----_
ll
GEARHOUSING
\ \ - - - - . - W - - - P t . t t o ' r s " n modol

n only:
S,----'96-'97
S--
32 mm SHIMS
'96 - '97
'98 modol:
mod6l only:
O.RING
Replace.
CYLINDEREND
63 N'm {7.0 kqf.m,51 lbftll
{cont'd)
17-55
SteeringGearbox
(cont'd)
Reassembly
Valvs Body Unit Rsassembly
1. Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinvl taDewith
the power steeringfluid.
2 . I n s t a l lt h e b a c k u pr i n g ( ' 9 6 - ' 9 7 m o d e l )o r w a v e
washer ('98 model)with its taperedside as shown
3.
4.
C o a tt h e i n s i d es u r f a c eo t t h e n e w v a l v e o i l s e a l
with powersteeringfluid.
Slidethe valve oil seal over the pinion shaft,being
carefulnot to damagethe sealinglip.
Vinyl tape
lStepped ponion)
'96 - '97 modal:
8. Apply power steering fluid to the surface of the

v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
shaft.
9. Apply power steeringfluid to the insideof the special tool. Set th largerdiameterend of the special
tool overthe valvesealring.
10. Move the specialtool up and down severaltimesto
makethe valvesealring fit in the pinionshaft.
11. Removethe specialtool,
12. Turn the specialtool over,and setthe smallerdiameter end of the specialtool over the valveseal ring.
Move the specialtool up and down severaltimes to
m a k et h e v a l v e s e a l r i n g f i t s n u g l y i n t h e p i n i o n
shaft.
Taperedposition.
EACKUPRING
PISTONSEALRING
SIZINGTOOL
OTNAG- SR3G'OA
or
07NAG- SR3o900
Grooveside.
surethe springis
seatedin the oil seal.
PINION SHAFT
mvewAsHERt
S6aling lip
CAUTION: Instsllthe valve oit sealwhh its grooved

side facing opposite the bearing.
7.
Apply vinyl tape to the splinesand steppedportion

of the shaft, and coat the surfaceof the vinyl tape
with the powersteeringfluid.
Fit the new O-ringin the grooveof the pinion shaft.
Then slide the new valve seal ring over the shaft
and the groovein on the pinionshaft.
Removethe vinyltapefrom the pinionshaft.
VALVESEALRING
Replace
Do not over-expand.
17-56
(w(ffi
Use the larger diameter
end of the special
tool first to make
the valve seal ring
fit in the pinion
shaft.
Makethe valvesealring
fit snuglyin the pinion
shaftusingthe otherend
(smallerdiameterend)of
the specialtool.
Apply power steeringfluid to the surfaceof the specialtool. Setthe new sealrings over the specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l . a n d
expandthe seal rings. Do two rings at a time from
eachend of the sleeve.
18, Apply power steeringfluid to the surfaceof the pinion shaft.Assemblethe sleeveover the pinionshaft
b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e
sleevewith the cutout in the shaft.Then installthe
new circlipsecurelyin the pinionshaftgroove.
NOTE:
. Do not over-expand
the sealring. Installthe resin
seal rings with care so as not to damagethem.
After installation.be sure to contract the seal
rings usingthe specialtool(sizingtool).
. There are two types of sleeve seal rings: black
and brown. Do not mix the different types of
sleevesealringsas they are not compatible.
NOTE:
o B e c a r e f u l n o t t o d a m a g et h e v a l v e s e a l r i n g
when insertingthe sleeve.
.Install the circlipwith its radiusedsidetowardthe
sleeve.
1 4 . Setthe specialtool in the groovesin the sleeve,and
set each ring in eachgroovesecurely.

NOTE: After installation,compressthe seal rings
with your fingerstemporarily.
1 9 . Apply power steeringfluid to the seal ring lip of the

valveoil seal,then installthe seal in the valve housi n g u s i n g a h y d r a u l i cp r e s s a n d s p e c i a lt o o l s a s
shown.
CAUTION:lnstallthe valveoilsoalwith its grooved

side facing the tool.
15. Apply power steeringfluid ro the seal rings on the
sleeve,and to the entire insidesurfaceof the specialtool.
16. Insertthe sleeveinto the specialtool slowly.
1 7 , M o v e t h e s l e e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o
makethe seal ringssnuglyfit in the sleeve.
NOTE:Besurethat the seal rings are not turned
fr
ATTACHMENT,
32x35mm
07746- 0010100
up.
SLEEVESEALRING
SIZINGTOOL
07974- SA5020Aor
07974- SA50200
VALVE OIL SEAL

Replace.
spring is in the
oit seat. {cont.d)
17-57
SteeringGearbox
(cont'd)
Reassembly
20. P r e s st h e n e w b e a r i n g1 ' 9 6- ' 9 7 m o d e l ) o r n e w
bushing('98 model) into the valve housingusing a
hydraulicpressand specialtool as shown.
NOTE:Placethe roller bearing('96 -'97 model)or
bushing('98 model) on the valve housingwith the
s t a m p e dl e t t e r f a c i n g ( ' 9 6 - ' 9 7 m o d e l o n l y ) u p
towardsthe valveside.
DRIVER
Pres3
07749-0010000
ATTACHMENT.
32x35mm
077i16- 0010100
'96 - '97 model:

ROLLERBEARING
Letterstampedface
upward,
21. Apply vinyl tape to the pinion shaft,then coat the

vinyltapewith power steeringfluid.
Sealing lip lace.
VALVEOIL SEAL
VALVEHOUSING
PINION
r
SLEEVE
SEALRINGS
Replace.
Be surethat the
searfingsare not
turnedup, then
anstall.
22. Insertthe pinionshaft into the valvehousing.

CAUTION: Bo carotul not to damage the valve seal
rin9s.
23. Removethe vinyl tapefrom the pinionshaft.
17-58
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
pressas shown.
N O T E : C h e c kt h a t t h e p i n i o n s h a f t / s l e e v e
turns
smoothlyby turningthe pinionshaft,
Steering RackRoassembly
25. Coatthe pistonseal ring guide with power steering
fluid,then slideit onto the rack,big end first
31. Wrap vinyl tape aroundthe rackteeth and rackend

edges.then coat the surface of the tape with the
powersteeringfluid.
N O T E :M a k e s u r e t h a t t h e v i n y l t a p e i s w r a p p e d
carefullvso that there is no steppedportion.
26. Positionthe new O-ringand new pistonseal ring on

the specialtool, then slide them down toward the
b i g e n do f t h e t o o l .
NOTE:
. Do not over expand the resin seal rings. Install
the resin seal rings with care so as not to damage them. After installation,be sure to contract
tool)
t h e s e a lr i n gu s i n gt h e s p e c i a l t o o(ls i z i n g
. Replacethe piston'sO-ringand sealring as a set.
27. Pull the O ring off into the piston groove,then pull
the pistonsealring off into the pistongrooveon top
of the O-ring.
32. Coatthe insidesurfaceof the new cylinderend seal

with powersteeringfluid.
33. Installthe cylinderend seal onto the steeringrack
PISTON
with its groovedsidetowardthe piston.

CAUTION:when inslalling the cylinder ond seal.
be careful nol damago the sealing lip face of the
seal with th edges or teeth of the steering rack.
PISTON
SEALRING
GUIDE
07GAG- SD,OloAor
07GAG- SDIO100
CYLINDEREND SEAL
O.RING
Replace
PISTONSEALRING
Replace-
28. Coatthe piston seal ring and the insideof the specialtool with powersteeringfluid
29. Carefullyslide the tool onto the rack and over the
pistonsealring.
30. Move the specialtool backand forth severaltimes
Groovedsrde.
to makethe pistonsealring fit snuglyin the piston.
PISTON
Replace.
r
Makesurethe
sPringis in the cylinder
eno seal
34. Remove the vinyl tape from the steering rack

NOTE| Remove any residue oftape adhesive
(cont'd)
17-59
SteeringGearbox
Reassembly(cont'd)
35. Install the new backup ring on the steering rack.
then placethe cylinderend sealto piston.
BACKUPRING
Installthe flange bolt into the end of the steering

r a c k u n t i l i t b o t t o m s i n t h e h o l e .t h e n b a c kt h e
f l a n g eb o l t o u t 1 / 4 t u r n . H o l d t h e f l a n g eb o l t a n d
tightenthe flangenut againstthe rackby hand.
Installthe cylinderend seal into the bottom of the
c y l i n d e rb y p r e s s i n go n t h e b o l t w i t h a p r e s sa s
shown.
CAUTION: Do not push on the boft with sxcessive
lorca as it may damagetha cylinder nd seal.
Pre33
12 x 175mm FLANGEBOLT
(P/N 90177- SLo- 0001
36. Greasethe steering rack teeth, then insert the steer-
12 mm FLANGENUT
ing rackinto the gear housing.

CAUTION: Be careful not to damage to inner surfaco ot tho cylinder housing with tho rack edgB.
CYLINDERHOUSING
R e m o v et h e f l a n g e b o l t , a n d c e n t e rt h e s t e e r i n g
rack.
40. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s .a n d
coatthe surfaceof the tape with the power steering
fluid.
N O T E :M a k e s u r e t h a t t h e v i n y l t a p e i s w r a p p e d
carelullyso that there is no steppedportion.
17-60
with power steeringfluid.
46. C o a t t h e i n s i d es u r f a c eo f t h e c y l i n d e re n d w i t h
power steeringfluid,then installthe cylinderend by
screwingit into the cylinderhousing
Installthe cylinderend seal onto the steeringrack

with its grooved side toward the piston,
4 7 . Removethe C-cl8mpfrom the steeringgearbox.
4 1 . Coatthe insidesurfaceof the new cylinderend seal
43. Pushin the cvlinderend sealwith your finger.

CAUTION:Wh.n irstalling the cylindsr ond 3eal,
b6 csreful not damage the sealing face ol th seal
with the threads and burrs at the stakad position of
the cylinder housing.
ENOSEAL
CYLINOER
Replace.
Makesurethe spring
is in the cylinderend seal
48. After tighteningthe cylinderend, stakethe point of

t h e c y l i n d e rh o u s i n gs h o w n b e l o w .F o r ' 9 8 m o d e l
go to step51.
NOTE: Stakethe cylinder in the position opposite
from where the stakewas removed during disassemblY.
Stakepoint.Deplh:1.0mm 10.0{inl
mm {0.16in}
CYLINDEEEND
Staked
posr!on,
Groovedside
END
CYLINOER
SEAL
44. Removethe vinyl tapefrom the steeringrack.
NOTE:Removeany residueof tape adhesive.

45. Holdthe steeringgearboxusinga C-clampas shown.
GEARBOX
CYLINDEBEND
69 N.m {7.0 kgt m, 5l lbf.ft)
Be careful not to damage

the bushing when insening
the cylinder end.
49. Selectthe 32 mm shim(s)('96-'97 model only).

N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s )
when the steeringgearboxis reassembledwithout
replacingthe pinion shaft,valve housing,and gearbox housingwith new ones.
l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
housingare replaced,selectthe new shimls)as follows.
Shim selestion:
a. Setthe four 32 mm shims on the bearingsurfaceof
t h e g e a r b o xh o u s i n g .T o t a l t h i c k n e s so f t h e t o u r
shimsshouldequalno more than 0,70mm.
0,10 mm,
Shim set: four 32 mm shims (Thickness:
0.15mm, 0,20mm, 0.25mm respectively)
CAUTION; Tho four 32 mm shims do not havo
thickness identification ma1k3.Measuro iho thicknass of each shim using a micromster,and mark
the shim for identitication.
(cont'd)
17-61
SteeringGearbox
Reassembly(cont'dl
l n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d
tightenthe flangeboltsto the specifiedtorque.
VALVEBODYUNIT
FLANGEBOLT
20 N.m {2.0kgtm, l4lbfft}
Example:
is 0.28mm (0.011in):
lvleasurement
0 . 7 0- 0 . 2 8 = 0 . 4 2m m ( 0 . 0 2 8 - 0 . 0 1 1 = 0 . 0 1i n7)
T h e s e l e c t e ds h i m s s h o u l db e 0 . 2 5m m ( 0 . 0 1 0i n ) a n d
0 . 1 5m m { 0 . 0 0 6i n } i n t h i c k n e s s .
g
l f t h e r e q u i r e ds h i m t h i c k n e s si s 0 . 1 0 m m o r l e s s ,n o
snrmsare necessary.
50. Set the selected32 mm shims on the bearingsurfaceof the gearboxhousing.
VE EODYUNIT
O.RING
Replace.
M e a s u r et h e c l e a r a n c eb e t w e e nt h e g e a r b o xa n d
valvebody unit usinga feelergaugeas shown.
-61
NOTE: Measurethe clearanceat the point midway

betweenthe two mountingbolts.
32 mm SHIMS
BEARING
NEEDLE
--6'
Coatthe new O-ringwith grease,and carefullyfit it
on the valvehousing.
Apply greaseto the needlebearingin the gearbox
housrng.
d.
D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m
s h i m sb y s u b t r a c t i ntgh e c l e a r a n coeb t a i n e di n t h e
step "c" from the total thicknessof the four shims
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( c l e a r a n c e )=
R e q u i r etdh i c k n e sosf t h e s h i m s
NOTE:Selectthe shims so that the total thickness
is closeto, but lessthan,the requiredthickness.
Installthe valve body unit on the gearboxhousing

by engagingthe gears.
NOTE: Note the valve body unit installationposition (directionof line connection).
Tightenrhe flangeboltsto the specifiedtorque
[ ,
17-62
55. InstallthecylinderlinesA and B.

NOTE:
. C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e sA a n d B
thoroughly. The joints must be free of foreign
material.
. Instaltthe cvlinderlinesA and I by tightingthe
flare nuts by hand first, then tighten the fla.e
nutsto the specifiedtorque.
17 N.m {1.7kgl.m,12lbtft)
6 0 . l n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e
steeringrack.
61. Screweachrackendsinto the rack.
62. Holdthe steeringrackwith a wrench('98 model:left
end only),and tightenthe rackends.
CAUTION: Be careful not to damags tho rack surfacr whh the wrench,
NOTE:'96 -'97 model is shown
LOCKWASHER
STEERINGRACKEND
5il N.m 15.5kgf.m, 40 lbf'ft)
28 N.m {2.?kgf.m, 20 lbl.ft}
CYLINOERLINEB
CYLINDERLINEA
56. Greasethe sliding surfaceof the rack guide, and

installit onto the gear housing.
'97 model:
57. '95 Apply a thin coat of greaseto the new O-ring,and
installit on the rackguide screw.
'98 model:
Remove the old sealant off of the threaded section,
then apply new sealantto the firct threethreads.
Installthe spring,rack guide screw and locknuton
the gear housing.
59. Adjustthe rackguide screw(seepage 17-33).
NOTE:After adjusting,checkthat the rack moves
smoothlyby slidingthe rackright and left.
STEERINGRACK
63. After tighteningthe rack ends, stakethe four sections of lockwasherwith a drift and a mallet.
Placethe wood blockon the presstable,then set
the lock washer section of the rack end on the
wood blocksecurely.
Be sure the tool is alignedwith the flat sections
of the steering rack end before pressing.
Stake the lock washer in the centet of the flat
sectionof the steeringrackend.
..-6ll
O.RING
Replace.
'96 - .97 model:
NOTE:Thisdrift hasa flat,

to preventpuncturing
STEERINGRACK
RACKGUIDE
LOCKNUTS
scREws
WOODENELOCK
{cont'd)
17-63
SteeringGearbox
(cont'd)
Reassembly
64. Apply greaseto the circumferenceot the rack end
housing.
67. Adjust the air hose fitting positionof the boots by

turningit as shown below.
LEFTBOOT
(Viewedfrom the
leftside)
RIGHTBOOT
{Viewedfrom the
rightside)
=_.
:!4AEn
SILICONEGREASE
AI8 HOSEFITTING
65. A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
grooveson the rackends.
l n s t a l lt h e b o o t s i n t h e r a c k e n d w i t h t h e t i e - r o d
clrps.
NOTE:Installthe boots with the rack in the straight
ahead position (right and left tie-rodsare equal in
length).
68. Installnew boot bandson the boot, and bend both

setsof lockingtabs.
CAUTION: Stake the band locking tabs firmly.
RACKEND
a-.
.:!!!!t!H
SILICONEGREASE
@
\
\
TIE-ROO
17-64
69. Lightlytap on the doubled-overportionsto reduce

t h e i rh e i g h t .
Slide the rack right and left to be certainthat the
bootsare not deformedor twisted.
!'
lnstallation
7 1 , C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t
boot.
CAUTION: Be caletul not to bend or damag ths tood

line and cylinder linos when insialling tha gearbox.
72. Installthe clipspn the cylinderlines,then clampthe

air tube with the clips.
1.
Beforeinstallingthe gearbox,slide the rack all the

way to right.
2.
Installthe mounting cushion on the steeringgearoox.
3.
Installthe pinionshaftgrommet,then insertthe pinion shaft up throughthe bulkhead.
CYLINDERLINE A
NOTE:Align the notch in the pinionshaft grommet

with the tab on lhe valvehousing.
CLIP
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t i n g
cushion,then installtwogearboxmountingbolts.
MOUNTINGBRACKET
N O T E : I n s t a l lt h e b r a c k e t
with the arrow pointing
{4.0 kgf.m, 29 lbl ft)
(cont'd)
17-65
SteeringGearbox
Installation (cont'd)
l n s t a l l t h e s t i f t e n e rp l a t e w i t h t h e t w o g e a r b o x
mountingboltsand stiffenerplateattachingbolts.
CAUTION: Be sure the air tube is not caught ol
pinched by stiftener plate.
9 . Centerthe steeringrackwithin its stroke.

1 0 . Slip the lower end of the steeringjoint onto the pinion shaft(lineup the bolt hole with the groove
aroundthe shaft),and tightenthe lower bolt.
N O T E :I n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n
them securely.
NOTE:
. Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
Besurethatthe lowersteeringjoint bolt is securely
in the groovein the steeringgearboxpinion.
lf the steeringwheel and rack are not centered.
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringjoint.
STIFFENER
PLATE
STEERING
JOINT
ATTACHINGEOLTS
38 N.m (3.9 kg,f.m.28lbl.ftl
GEARBOXMOUNTINGBOLTS
, N.m ({.4 ksl.m, 32 lbl.fr}
Installthe returnhosejoint by tighteningthe l6 mm

flare nut.
1.
Connectthe return hose securely,and tighten the

a d j u s t a b l eh o s e c l a m p f r o m t h e e n g i n ec o m p a r t ment.
8.
Connectthe feed ljne and tighten the 14 mm flare

nut.
STEERING
JOINT
LOWER
BOLT
22N.m(2.2kgf.m,16lbl.ft)
NOTE: Makesure that there is no interference

betweenthe fluid lines,the rear beam or any other
pans.
ADJUSTAELEHOSE
CLAMP
(seepage17-39i
15 mm FLARENUT
28 N.m {2.7 kgf.m.20 lbtft)
1. Centerthe cable reel by first rotating it clockwise
until it stops.Then rotate it counterclockwise

(approximatelytwo turns) until the arrow mark on
the label points straight up. Reinstallthe steering
wheel(seepage17-35).
FETURNHOSE
1{ mm FLARENUT
37 N.m (3.8kgtm,27 lbf.tt)
17-66
'I
12. Installthe steeringjoint coverwith the clampsand a

clip.
1 4 . Installthe exhaustpipe A or TWC (seesection9).
1 5 . Connectthe shift linkage{seesectionl3 or section

14).
lnstallthe front wheels.
1 7 . Fill the systemwith power steeringfluid. and bleed
air from the system(seepage 17-33).
the tie-rodendsto the steeringknuckles,

Reconnect
tighten the castlenut ('96 -'97 model) or nut {'98
model)to the specifiedtorque,and installnew cotter
prns.
performthe followingchecks,
1 8 . After installation.
. S t a r tt h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e
steeringwheelfrom lock-tolockseveraltimes to
warm up the tluid. Chckthe gearboxfor lesks
(seepage17-39).
. Adjustthe tront toe (seesection18),
. Checkthe steeringwheel spokeangle.Adjust by
turningthe right and lefttie-rods,if necessary.
NOTE:Turn the right and lefttie-rodsequslly.
NOTE: Before connectingthe tie-rod ends, wipe off

from the balljoint tapered
any greasecontamination
sectionand threads.
CAUTION: Torquethe castlenut to the lower torque
specification, thn tighten it only far enough to align
the slot whh the pin hole. Do not align the nut by
,97 modd onlyl.
looeening('96NE.RODENO
COTTERPINS
Replace.
bend
On reassembly,
the cotterpin as shown.
NUT
CASTLE
,+0- ,18N'm
14.0- 4.8kgt'm,
29- 35lbf.fr)
NUT
il,l N.m
(4.5kgl'm,33 lbffrl
17-67
Balljoint BootReplacement
'96 - '97 modol:
'98 modol:
CAUTION: Do not contaminatetho boot instsllation sec.

tion with grease.
Removethe boot set ring and the boot.

GAUTION:Do not contaminatethe boot installation section with gtease.
2.
Packthe interiorof the boot and lip with grease.
3.
Wipe the greaseoff the sliding surfaceof the ball

pin,then packthe lower areawith freshgrease.
CAUTION:
. Keep grsase off th6 boot installation section and
the tapered s6stion ot the ball pin.
. Do nol allow dust. dirt, or othar foteign matorials to enter the boot.
LIP
SECTION
Wipeoff the grease-
4.
BALLPIN TAPERED
SECTION
Wipe off the grease.
BOOTINSTALLATION
SECTION
Wipeoff the grease.
1.
Removethe boot from the tie-rodend, and wioe the

old greaseoff the ball pin,
2.
Packthe lowerareaofthe ball pin with freshgrease.
3.
Packthe interiorof the new boot and liD with fresh

grease.
GAUTION:
. Kep grgaseofftha boot installation soction and
lhe tapered soction if the batl pin.
. Do not allow dust, dirt. or othor foroign materials
to enter ths boot,
BOOTINSTALI."A
sEcnoN
Wipe offthe grease.
Installthe boot in the grooveof the boot installation

sectionsecurelv,then bleedthe air from the boot.
Installthe new boot usingthe specialtool as shown
oerow,
ADJUSTINGBOLT
Adjustthe depth
by turningthe bolt.
NOTE: The boot must not be a gap at the boot instaf

lation sections.
FRONTHUB
DIS/ASSEMBLYIOOL
0796s - SA5o500
, . .^'
,'
,;i
. -,.-.:.SETRING
ir
f'
Adjust the specialtool with the adjustingbolr until

the end of the tool aligns with the groove on the
boot. Slidethe set ring over the tool and into posiIron.
CAUTION: After installing tho boot, chock the batt
pin taprod section tor gtsase contamination and
wipo il if necess8ry.
17-68
CAUTION: Aftr installing the boot, chock the ball

pin taperod sgction for grase contamination, and
wipo it il nocessary.
Suspension
18-2
.............
SpeciafToofs
ComponentLocations
......18'3
lndex ................
Wheel Alignment
...,,,18'4
Caster,..............
18-4
..................
Camber
Front Toe Inspection/
......'.18-5
Adiustment
RearToe Inspection/
........18-5
Adiustment
18-6
TurningAngleInspection...............'
Wheel/HubInspection
1a'7
BearingEnd Play..........................""
.......18-7
Wheel Runout
Front Suspension
SuspensionArms Replacement.....18-8
18-9
Knuckle/HubReplacement..'.......'.'
Lower Ball Joint Replacement.......18-15
Ball Joint Boot Replacement..........18-16
Front Damper
18-16
.................
Removal
"..' 1A-17
........'....
18-18
...........
Reassembly
18-18
.............
Installation
RearSuspension
SuspensionArms Replacement.....18-20
Hub BearingUnit Replacement......18-21
Upper Arm BushingReplacement. 18-22
RearDamper
t8-23
.................
Removal
y/lnspection ..............
".' 18'24
Disassembf
18'25
...........
Reassembly
18-26
.............
Installation
SpecialTools
Ref. No.
o
@
at\
@
!o,
o
@
6l
@
@
@
Tool Number
07GAF- SE00200
07GAF- SE00401
07GAG- SD40700
0 7 J A F- S H 2 0 1 1 0
OTJAF SH2O120
07JAF- SH20200
0TiilAC- S100200
07746- 0010500
07749- 0010000
07947- 6340201
07965- S800100
07965- S800200
07965- SD90100
07974- SA50700
Description
Hub AssemblyGuideAttachment
Hub Dis/Assembly
Base
B a l l J o i n tB o o tC l i pG u i d e
Hub Dis/Assembly
Pilot,38 mm
Hub Dis/Assembly
Shatr,22.4x25.4 mm
BallJoint RemoverBase
B a l lJ o i n tR e m o v e r2, 8 m m
Driver
DriverAttachment
BallJoint Remover/lnstaller
B a l lJ o i n tl n s t a l l eBr a s e
SupportBase
B a l lJ o i n tB o o tC l i pGu i d e
o.(}
Oty
PageReterence
18-14
18-13
18-16
' 1 81- 3
18-13
18-15
'1,
18-1 1 2
18-13
18-13
1 8 -1 4
18-15
1
'I
1
I
1
1
1
1
I
1
1
1
1
1
18-14
1e 1R 16
@,@
8-2
ComponentLocations
Index
Wheel Alignment, page 18-4
Front SusDension:
FRONTDAMPER
' Removal,page18-16
. Disassembly/lnspection,
page'18'17
. Reassembly,
page18 18
. lnstallation,
page18'18
UPPERARM
. Replacement,
page18-8
KNUCKLE/HUB
. Replacement,
page18 9
. WheelBearingReplacement,
page18.13
STABILIZER
BAR
. Replacement,
page18-8
. L o w e r E a l l J o i n t R e p l a c e m e n t ,p a g e 1 8 - ' 1 5
LOWERARM
. Replacement,
page18-8
RearSuspension:
REABDAMPER
' Removal,page18 23
. Disassembly/lnspection,
page18-24
. Reassembly,
page18-25
. Installation,
page18-26
UPPERARM
' Replacement,
page18-20
LOWERARM
. Replacement,
page18-20
. Replacement,
page18 20
TRAILINGARM
. Replacement,
page18-20
18-3
WheelAlignment
Caster
Camber
of the wheel
NOTE| For proper inspection/adjustment
checkthe
following
before
check
and
adjust
alignment
ing the alignment.
Inspection
.
.
.
.
Checkthat the suspensionis not modified.

Checkthe tire sizeand tire pressure.
Checkthe runoutof the wheelsand tires.
Checkthe suspensionball joints. (Holda wheel with
your handsand move it up and down and right and
leftto checkfor wobbling.)
co
l em p u t e r i z efdo u r
N O T E :U s e c o m m e r c i a l l y - a v a i l a b
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
instructions.
the equipmentmanufacturer's
1.
Camb6rangle:
Front: 0'00' I 1'
R e a r -: 1 " 1 1 '
2.
Inspection
co
instructions,
1.
Checkthe casterangle.
Casterangle:1"40't 1"
2.
lf out of specification,checkfor bent or damaged

componenrs.
suspensron
D=r$*
18-4
Checkthe camberangle.
lf out of specification,checkfor bent or damaged

suspensioncomponents.
FrontToe Inspection/Adjustment
RearToe Inspection/Adjustment
co
l em p u t e r i z e fdo u r
instructions.
co
instructions.
'1. Checkthe tire pressure.
1.
2.
Centersteeringwheelspokes.
3,
C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t
ahead.
Releaseparkingbrake.
NOTE:
. M e a s u r ed i f f e r e n c ei n t o e m e a s u r e m e n tw
sith
the wheelspointedstraightahead.
. lf the parkingbrakeis engaged.you may get an
incorrectreading.
Fronttoe: lN 1 t 2 mm (lN 1/16l: 1/16in)

Reartoe-in:2 1i mm ttlte:ljl8 int
4.
lf adjustmentis required,go on to step 4.
lf no adjustmentis required.remove alignment

equipment.
Loosenthe tie-rod locknuts,and turn both tie-rods

in the same directionuntil the front wheels are in
straightaheadposition.
lf adjustmentis required,go to step2.
lf no adjustmentis required,remove alignment

equipment.
Beforeadjustment,note the locationsof adjusting

boltson the right and left compensatorarms.
Loosenthe adjustingbolts. and slide the compensatorarm in or out, as shown,to adjustthe toe.
TIE.RODLOCKNUT
1 4x 1 . 5m m
{,1 N.m (,1.5kgt m, 33 lbtftl
ADJUSTINGBOLT
1 0x 1 . 2 5m m
64 N.m {6.5kgt.m. 47 lbtftl
IN
Turn both tie-rodsequally until the toe readingon

the turning radiusgaugeis correct.
4.
After adjusting,tightenthe tie-rodlocknuts.
NOTE:Repositionthe tie-rodboot if it is twisted or

displaced.
ARM
COMPENSATOR
Tightenthe adjustingbolts.
Example:
A f t e r t h e r e a r t o e i n s p e c t i o n t, h e w h e e l i s 2 m m
(0.08in) out of the specification.
M o v e t h e a r m s o t h e a d j u s t i n gb o l t m o v e s 2 m m
(0.08in) inwardfrom the positionrecordedbeforethe
adjustment.
The distancethe adjustingbolt is moved should be
equalto the amountout-of-specification.
18-5
WheelAlignment
TurningAngleInspection
co
the eouiDmentmanufacturer's
instructions.
1.
Turn the wheel right and left while applying the

brake,and measure the turning angle of both
wheels.
Turningangle:
lnward wheel: 39"50'
Outward wheol lreferencel:33"10'
2.
l f t h e t u r n i n ga n g l eis not within the specifications,

c h e c kf o r b e n t o r d a m a g e ds u s p e n s i o nc o m p o nenrs.
18-6
Wheel/HubInspection
BearingEndPlay
1.
Raisethe vehicleoff the ground.and supportit with

2.
Removethe wheels,then reinstallthe wheel nuts.
3.
Aftachthe dial gaugeas shown.
4.
lMeasure
the bearingend play by movingthe disc in
or outward.
WheelRunout
1.
Raisethe vehicleoff the ground,and suppon it wjth

Checkfor bent or deformedwheels.
3.
Attachthe dial gaugeas shown.

Measurethe wheel runoutby turningthe wheel.
Front and Rarwheel Axial Runout:
Stand8rd:
0 - 1.0 mm (0 - 0.0/tinl
Steel Wheel:
wheel:
0 - 0.7 mm {0 - 0.03in)
Aluminum
Front/Rear:
Standsrd:0- 0.05mm {0 - 0.002inl
Service Limit:
2.0 mm 10.08inl
Front and RearWheel RadialRunout'

Standard:
SteelWheel:
0 - 1.0mm (0 - 0.0/tinl
AluminumWheel:0 - 0.7 mm (0 - 0.03in)
ServiceLimit:
1.5mm (0.06inl
Measureend playat centero{

t h e h u bc a p .
lf the bearing end play measurement is m o r e t h a n
t h e s t a n d a r d ,r e p l a c et h e w h e e l b e a r i n g .
5.
lf the wheel runout is more than the servicelimit,

replacethe wheel.
18-7
I
FrontSuspension
Suspension
ArmsReplacement
CAUTION:
. Replacetho selt-lockingnuts after removal.
. The vehicle should be on the ground betore any bolts or nuts connectedto rubber mounts or bushings are tightened.
NOTE:
. Wipe off any dirt, oil from greaseon the threadsbeforetighteningthe fasteners.
. The right and left damper forks are not interchangeable.
The left damper fork is markedwith "AL" while the right
"AR
dampertork is markedwith
.
. The right and left upper arms are not interchangeable.
The left upperarm is markedwith "SO1-L"while the right arm
i s m a r k e dw i t h " S O 1 - R " .
. Beforetighteningthe upperand lower mountingnuts on the stabilizerlink,adjustthe locationof the link with the susp e n s i o nu n d e rv e h i c l el o a d .
. When installingthe radiusarm washers,the "FR" markfacesthe front of the vehicle.
. After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary(seepage 18 4).
UPPERARM
anddamage.
Checkthe bushingfor deterioration
BALLJOINT BOOT
STABILIZER
END
RUBBER
BUSHING
Checkfor deterioration
ano oamage,
. C h e c k f o r d e t e r i o r a t i o na n d d a m a g e .
. See page 18 16 for boot replacement.
STABILIZER
BAR
Checkfor bendingand damage.
FLANGEBOLT
l i l x ' 1 . 5m m
103N.m 110.5kgtm, \
76lbfftl
\
FLANGEBOLT
8 x 1.25mm
22 N.m 12.2kgt.m,
16 tbf.ftl
STABILIZER
BUSHING
STABILIZER
BAR
Alignthe stabilizer
mark
with end of stabilizer
bushi
FLANGEBOLTS
1 0 x 1 . 2 5m m
54 N.m {5.5 kgl.m,
40 tbf.ft)
LOWERARM
RUBBER
BUSHING
. Checkfor deterioration
ano oamage.
1 4x 1 . 5m m
Replace83 N.m 18.5kg{.m,61 lbtft}
1 4x 1 . 5m m
89 N.m (9.1kgf.m,66lbf ft)
SILICONEGREASE
RUBBER
BUSHINGS
FLANGEBOLT
10 x 1.25mm
i|i} N'm 14.4kgl'm.
32 rbf ft)
SELF-LOCKING
NUT 8 x 1.25mm
22 N.m (2.2kgl.m, 16 lbf.ft)
Replace.
SELF-LOCKING
NUT
12 x'1.25mm
Replace.
64 N.m (6.5kgf.m, {7 lbnft}
RUBBER
BUSHING
. Checkfor deterioration
and damage
SILICONEGREASE
STABILIZER
ENDRUBBER
BUSHINGS
Notethe direction
ot the bushings.
18-8
Knuckle/HubReplacement
CAUTION:
. Replacethe selt-lockingnuts after removal.
. The vehicle should be on the ground before any bolts or nuts connectedto rubber mounts or bushings are tightened.
. Torque the castle nut to the lower torque specification,then tighten it only far enough to slign the slot with the pin
hole.Do not alignthe nut by loosening.
NOTE:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weightsmay corrodeand damage
t h e a l u m i n u mw h e e l s .
. On the aluminumwheels,removethe centercapfrom the insideof the wheelafter removingthewheel.
o Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc.
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakediscand wheel.
. Wipe off the greasebeforetighteningthe nut at the balljoint.
CALIPERMOUNTINGBOLT
12x 1.25mm
108N.m (11.0kgt m,80 lbnftl
CASTLENUT
10 x 1.25mm
39 - 47 N.m 14.0- 4.8 kgf.m, 29 - 35 lbtft)
COTTERPIN
Replace.
WI{EELBEARING
Replace.
page18-13
Replacement,
GUARO
CIRCLIP
LOWERBALL
Inspectfor faulty
movementand wear.
page18 15
Replacement,
SCREW
5x0.8mm
4.9N.m {0.5kgtm.3.6lb{.ftl
FRONTHU8
C h e c kf o r d a m a g e 6 n d
SET
BALLJOINT BOOT
ano oamage.
COTTERPIN
Replace.
CASTLENUT
12 x 1.25mm
49 - 59 N m 15.0- 6.0 kgf m, 36 - iB lbf.ft)
Replacement,
page l8-10
SPINDLENUT
22 x 1.5mm
181N.m 118.5kgt.m, 134lbf.tt)
Replace.
NOTE:
. Betoreinstallingthe spindlenut,apply
engineoilto the seatingsurfaceofthe nut.
. Aftertightening,
usea driftto stakethe
spindlenut shoulderagainstthe driveshaft.
ERAKEDISC
C h e c kf o r w e a r a n d
rust.
R e p l a c e m e n t ,p a g e ' 1 8 ' 1 0
I n s p e c t a o ns, e c t i o n 1 9 ,
WHEELNUT
1 2x 1 . 5m m
't08 N.m
{11.0ksf.m,80lbf.ft)
6 mm BRAKEDISCRETAININGSCREW
9.8 N.m 11.0ksf m, 7 lbtft)
{cont'd)
18-9
FrontSuspension
Knuckle/HubReplacement{cont'd}
1.
Loosenthe wheel nuts slightly.
2.
Raisethe front of vehicle, and support it with safety

standsin the properlocations(seesection 1).
3.
Removethe wheel nuts and wheel.
7. Removethe 6 mm brakedisc retainingscrews.
WHEELNUT
108N.m
{11kgtm.80 lbf.ftl
6 mm BRAKEDISC
RETAININGSCREWS
9.8 N.m ll.0 kgl.m, 7 lbf.ft)
8 x 1.25mm BOLTS
8. Screwtwo 8 x 1.25mm bolts into the discto push it
awayfrom the hub.
SPINDI.fNUT
181N.m {r8.5kgf.m,134lbtft)
Replace.
NOTE:Beforeinstallingthe spindlenut, apply
engineoil to the seatingsurfaceof the nut.Atter
tightening,use a dritt to stakethe spindlenut
shoulderagainstthe driveshaft
NOTE:Turn eachbolt two turns at a time to prevent

cockingthe discexcessively.
9 . Removethe brakediscfrom the knuckle.
1 0 . Checkthe front hub for damageand cracks.

5.
Raisethe locking tab on the spindle nut, then remove

the nut.
Remove the brake hose mounting bolts.
BMKE HOSEMOUNNNG BOLT
8 x 1.25mm
12 N.m 11.2ksI.m,8.7 lbtftl
CAI-IPERMOUNTINGBOLTS
12 x 1.25mm
108N.m (11.0kgf.m,80lbl.ft)
6.
'+
't1. Remove
the wheel sensorfrom the knuckle(for cars
with ABS).
NOTE:Do not disconnectthe wheel sensorconnec-
ror.
9.8N.m
{1.0kgf.m,
7 rbr.ft)
R e m o v et h e c a l i p e rm o u n t i n gb o l t s a n d h a n g t h e
caliperassemblvto one side.
CAUTION;To prevent accidentaldamage to th
caliper assemblyor brake hose, use a short piece ot
wire to hang the caliper from the undercarriage.
18-10
MOUNTING
BOLTS
9.8N.m
11.0kgf.m,7lbf.ftl
NOTE: Use the specialtool to separatethe ball ioints

from the suspensionor steeringarm
CAUTION: Be careful not to damagethe ball ioint boot.
17. Oncethe specialtool is in place,turn the adjusting

bolt as necessaryto make the jaws parallel.Then
h a n d - t i g h t e nt h e p r e s s u r eb o l t , a n d r e c h e c kt h e
jaws to makesurethey are still parallel.
1 2 . Cleanany dirt or greaseoff the balljoint.

1 3 . Removethe cotter pin from the steeringarm and
removethe nut.
1 4 . Apply greaseto the specialtool on the areasshown.
T h i s w i l l e a s ei n s t a l l a t i o n
of the tool and prevent
damageto the pressureboltthreads.
ADJUSTINGBOLT
PRESSURE
BOLT
NOTE:After making the adjustmentto the adjusting bolt, be sure the headof the adjustingbolt is in
this positionto the allow the jaw to pivot.
18. With a wrench,tighten the pressurebolt until the
balljoint shaft pops loosefrom the steeringarm.
I n s t a la
l 1 0 m m h e x n u t o n t h e b a l l j o i n t .B e s u r e
that the hex nut is flush with the ball joint pin end to
p r e v e n td a m a g et o t h e t h r e a d e de n d o f t h e b a l l
Jornt.
wear eye protection. The ball ioint

@
can break loose suddenly and scatter dirt or other
deblis in your eyes,
I n s t a l lt h e s p e c i a lt o o l a s s h o w n . I n s e r tt h e j a w s
carefully,makingsure you do not damagethe ball
j o i n t b o o t . A d j u s tt h e j a w s p a c i n gb y t u r n i n gt h e
pressurebolt.
19. Removethe tool, then removethe nut {rom the end

of the balljoint and pull the balljoint out of the
steering/suspension
arm. Inspectthe ball joint boot
and replaceit if damaged.
N O T E :l f n e c e s s a r ya,p p l y p e n e t r a t i n g
type lubricantto loosenthe ball joint.
COTTER.PIN
Replace.
On reassembly,
bendthe cotterpin
CASTLENUT
10 x 1.25mm
';"
39 - 47 N.m
(4.0- 4.8 kgf.m, CASTLENUT
xei ruur
Replace.
BALLJOINT REMOVER,28 mm
07MAC- SL00200
{cont'd)
1 8 - 11
FrontSuspension
Knuckle/HubReplacement{cont'dl
20. Removethe cotterpin from the lower arm ball joint
castlenut, and removethe nut.
23. Removethe cotterpin from the upperball joint castle nut. and removethe nut.
COTTER.PIN
Replace.
On reassembly,
bendthe cotterpin
CASTLENUT
1 2x 1 . 2 5m n
49 - 59 N.m {5.0- 6.0 kgf.m, 36 - /H lbtftl
12 x 1.25mm
39 - 47 N.m
{4.0- 4.8 kgt m,
29 - 35 tbtft)
12 mm HEXNUT
24. Installthe 12mm hex nut on the ball joint.

Be sure that the hex nut is flush with the ball joint
pin end, or the threadedsectionof the ball joint pin
might be damagedby the balljoint remover.
Usethe specialtool as shown on page 18-11to separatethe ball joint and knuckle.
NOTE: lf necessary.apply penetratingtype lubricantto loosenthe ball joint.
CASTI-ENUT
1 2x 1 . 8 m m
BALLJOINT REMOVER,28 mm
07MAC- 5100200
2 1 . I n s t a l la 1 2 m m h e x n u t o n t h e b a l l j o i n t . B e s u r e
that the hex nut is flush with the ball joint pin end,
or the threadedsectionof the ball joint pin might be
damagedby the ball joint remover.
2 2 . Usethe specialtool as shown on page 18-11to separatethe balljoint and lowerarm.
N O T E :l f n e c e s s a r ya,p p l y p e n e t r a t i n g
type lubric a n tt o l o o s e nt h e b a l l j o i n t .
18-12
26. Pullthe knuckleoutwardand removethe driveshaft

outboardjoint from the knuckleby tappingthe driveshaft end with a plastichammer,then removethe
knuckle.
KNUCKLE
for damage.
Check
NOTE: Replacethe bearingwith a new one after removal.

27. Separatethe hub from the knuckleusingthe special
tools and a hvdraulicpress.
CAUTION:
. Take care not lo disto.t the splash guard.
. Hold onto lhe hub to keep it from falling when
preised clear.
a To prevenl damage to the tool. make Sure ihe
threads are fully engagedbefore pressing.
2 9 . P r e s s t h e w h e eble a r i n go u t o f t h e k n u c k l eu s i n g t h e
soecialtoolsand a pressas shown.
DRIVER
07749- 00'10000
Press
+
ATTACHMENT,
62x68mm
07746- 0010500
KNUCKLE
HUBDIS/ASSEMBLY
PILOT,38 mm
07JAF- SH20r10
l
KNUCKLE
HUBDIS/ASSEMBLY
BASE
07GAF- SE0040r
WHEELBEARING
Replace.
3 0 . P r e s st h e w h e e l b e a r i n gi n n e r r a c e f r o m t h e h u b
using the specialtools, a bearing separator, and a
pressas shown,
HU8 DIS/ASSEMELY
x 25.4mm
SHAFT.22.4
07JAF- SH20120
Pres3
BEABING
SEPARATOR
0 - 1112in.
(Commercially
available)
HUB DIS/ASSEMBLY
PILOT,38 mm
07JAF- SH20110
Removethe circlip and the splash guard from the

knuckle.
Checkfor bending and damage.
HUBDIS/ASSEMBLY
x 25.4mm
SHAFT,22.4
07JAF- SH20120
j
l
l
(cont'd)
18-13
FrontSuspension
Knuckle/HubReplacement(cont'd)
N O T E :W a s h t h e k n u c k l ea n d h u b t h o r o u g h l yi n
highflash point solventbeforereassembly.
Pressa new wheel bearinginto the knuckleusing
the specialtools and a pressas shown.
34. Installthe hub on the knuckleusingthe specialtools

shownand a hvdraulicDressas shown.
CAUTION:Takecare not to distort the splashguard.
NOTE:Placethe wheel bearingon the knucklewith

the Dackseal (metal color) toward the inside. Be
carefulnot to damagethe sleeveof the packseal.
HUB/ASSEMBLY
GUIDEATTACHMET'rT
07cAF- SEqt200
Press
HANDLE
o7749-
OOUBLELIPSEAL
IBLACKCOLOR)
DRIVER
ATTACHMENT
58x72mm
07947- 6340201
FRONTHUB
WHEEL
SPLASHGUARD
BEARING .,
I
I
I
KNUCKLE
SUPPORT
BASE
07965- SO90100
32. Installthecirclipsecurelyin the knucklegroove.
35. lnstallthe knucklein the reverseorder of removal,

33. Installthesplashguardand tightenthe screws.
B e c a r e f u ln o t t o d a m a g et h e b a l l j o i n t b o o t s
when installingthe knuckle.
Torque all mounting hardwareto the specified
t o r q u ev a l u e s .
Torquethe castlenuts to the lower torque specifications.then tighten them only far enoughto
align the slot with the pin hole, Do not align the
castlenut by loosening,
Install new cotter pins on the castle nuts after
torquing.
Avoid twisting the sensorwires when installing
the wheelsensor.
Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel,cleanthe matingsurfaceof the brakediscand the insideof the wheel.
Checkthe lront wheqlialignment,and adjustit if
necessary{seepage{S0.
scREws
4.9N.m(0.5kgf.m,4lbtft)
*_l
,:1S
18-14
and pay particularattentionto the followingitems:
LowerBallJoint Replacement
1.
Removethe knuckle(seepage18 10).
2.
Removethe boot by pryingthe set ring off.
3.
and damage,
C h e c kt h e b o o t f o r d e t e r i o r a t i o n
replaceif necessary.
8.
Installthe ball joint boot and set ring usingthe spe

c i a lt o o l ( s e ep a g e1 8 - 1 6 ) .
ADJUSTINGBOLT
Adj!st the depthby
turningthe bolt.
I n s t a ltlh e s p e c i atlo o l so n t h e b a l li o i n t a n dt i g h t e n
the castlenut.
P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s
shown, then set the assemblyan a vise. Pressthe
ball joint out of the knuckle.
5.
SALLJOINTREMOVER/INSTALLER
07965- 5800100
CASTLENUT
(
- BALLJOINT REMOVERBASE
07JAF- SH20200
6.
Placethe ball joint in position by hand.
7.
Install the special tools over the ball joint as shown,

t h e n p r e s st h e b a l l j o i n t i n .
BALLJOINT INSTALLERBASE
BALLJOINT REMOVER/
INSTALLER
07965- 5800100
9.
Installthe knucklein the reverseorder of removal,

and pay particularaftentionto the followingitems:
.
r
.
.
.
.
BALLJOINT HOUSINGSURFACE
B e c a r e f u ln o t t o d a m a g et h e b a l l i o i n t b o o t s
w h e n i n s t a l l i ntgh e k n u c k l e .
Torque all mounting hardwareto the specified
torquevalues.
Torquethe castlenuts to the lower torque specif i c a t i o n st,h e n t i g h t e nt h e m o n l y f a r e n o u g ht o
a l i g nt h e s l o tw i t h t h e p i n h o l e .D o n o t a l i g nt h e
castlenut by loosening.
Install new cotter pins on the castle nuts after
torquing.
Avoid twisting the sensorwires when installing
the wheelsensor.
Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel,cleanthe matangsurfaceof the brakediscand the insideof the wheel.
Checkthe front wheel alignment,and adjustit if
necessary(seepage 18-4).
18-15
FrontSuspension
Ball Joint Boot Replacement
Removethe set ring and the boot.
CAUTION:Do not contaminatethe boot installation section with grease.
FrontDamper
Removal
' 1 . Remove
the front wheels(seepage 18-10).
R e m o v et h e d a m p e r p i n c h b o l t f r o m t h e t o p o f
damperfork,
Packthe interiorof the boot and lip with grease.

LtP
OAMPERFORK
BALLPtN TAPREDSECTTON
DAMPER
FORK
BOLT
Wipe ofl the grease.
3.
BOOTINSTALLANONSECTION
Wipe otf the grease.
Wipe the greaseoff the sliding surfaceof the ball

pin and packwith freshgrease.
GAUTION:
. Keep greaseoff the boot installation section and
the taperd section of the ball pin.
. Do not allow dust, dirt, or other loreign matcrials to enter the boot.
lnstallthe boot in the grooveof the boot installation
sectionsecurely,then bleedair.
5.
DAMPER
PINCH
BOLT
1 0x 1 . 2 5m m
SELF.LOCKING
NUT
12x 1.25mm
Replace.
Removethe damper fork bolt and self-lockingnut

from the bottom of the damper fork, then remove
damperfork.
Removethe damperby removingthe two nuts.
lnstallthe upper and lower ball joint boot set rlngs

usingthe specialtools as follows:
OAMPER
L o w e r b a l l j o i n t : A d j u s t t h e s p e c i a tl o o l w i t h t h e
adjustingbolt until the end of the tool aligns with
the groove on the boot. Slide the set ring over the
tool and into position.
BALLJOINT
aooTcLrP
GUIOE
ADJUSNNG BOLT
Adiust the depth by
turningthe boh.
UPPERBALL
JOINT BOOT:
07GAG- SDr0700
LOWERBALL
JOINT BOOT:
07974- SA50700
CAUTION: Aftei installing the boot, check rhe batl

pin tapered section for greasecontaminationand
wipe it il necessary.
18-16
Disassembly
1. Compressthe damper spring with the spring comp r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r 'lsi n s t r u c tions,then removethe self lockingnut.
""----------------g
io'i'i'"?Tllo
29 N m 13.0kg{.m,22 lbtftl
Replace.
DAMPERMOUNTINGWASHEB
CAUTION: Do not compress the spring more than

neceaaeryto remove the nut.
10 mm SELFLOCKINGNUT
Replace.
BASE
DAMPERMOUNTING
RUBBEB
C h e c kf o r d e t e r i o r a t i o n
and oamage,
OAMPERSPBING
Checkfor weakenedcompression
ano oamage.
STRUTSPRING
COMPRESSOR:
ERANICKo T/N MST.58OA,T/N 7200,
or eouivalent
SPRINGMOUNTINGRUBBER
ano oamage,
Releasethe pressurefrom the spring compressor,

then disassemblethe damperas shown in the next
column.
BUMPSTOP
Checkfor weaknessand
damage.
BUMPSTOPPLATE
DUSTCOVER
PLATE
Inspection
1. Reassemble
all parts,exceptthe spring.
y ss h o w n .
2 . P u s ho n t h e d a m p e ra s s e m b l a
DUSTCOVER
Checkfor bendingand damage.
3 . C h e c kf o r s m o o t ho p e r a t i o nt h r o u g ha
4.
stroke,
DAMPEBUNIT
both compressionand extension.

N o T E r T h e d a m p e rs h o u l d m o v e s m o o t h l y l f i t
does not (no compressionor no extension),the gas
i s l e a k i n ga, n dt h e d a m p e rs h o u l db e r e p l a c e d .
C h e c kf o r o i l l e a k sa, b n o r m anl o i s e so r b i n d i n gd u r ing thesetests.
18-17
FrontDamper
Reassembly
Installation
1 . lnstallthe damperunit on a springcompressor.
2.
Assemblethe damper in reverseorder of removal

exceptthe damper mountingwasherand self locki n gn u t .
N O T E :A l i g n t h e b o t t o mo f d a m p e rs p r i n ga n d
spnng towerseatas shown.
Loosely install the damper on the frame with t h e

a l i g n i n gt a b f a c i n gi n s i d e ,t h e n l o o s e l yi n s t a l lt h e
two flangenuts.
FLANGE
NUTS
10x 1.25mm
49 N.m(5.0kgf.m,36 lbf.ft)
DAMPERASSEMBLY
STRUTSPRING
COMPRESSOR:
(Commarciallyavailablol
BRANICKO
T/N MST.58OA,T/N 7200,
or equivalent
SPRINGLOWERSEAT
Positionthe damper mountingbaseon the damper

u n r ta s s n o w n .
Compressthe damperspring.
5.
Installthe dampermountingrubber,dampermounting washerand a new 10 mm self-lockingnut.

Hold the dampershaft and tighten the 10 mm selflockingnut.
SELF.LOCKING
NUT
10x 1.25mm
29 N.m {3.0kgf.m, 22 lbf.ft)
MOUNTINGWASHER
18-18
2. Installthe damperfork over the driveshaftand onto

t h e l o w e r a r m . l n s t a l lt h e f r o n t d a m p e r i n t h e
damperfork so the aligningtab is alignedwith the
slot in the damDertork.
DAMPER
FORK
BOLT
ALIGNINGTAB
DAMPER
PINCH
BOLT
10 r 1.25mm
N.m 14.4kgf m, 32 lbf.ft)
NUT
SELF.LOCKING
1 2x 1 . 2 5m m
64 N.m {6.5 kgt m, 47 lbf,ft)
Replace.
Looselyinstallthe damper pinch bolt on the top of

the damperfork.
Looselyinstallthe damperfork bolt and a new selflockingnut on the bottom of the damperfork.
5.
Raisethe knucklewith a floor jack until the vehicle

just liftsoft the safetystand.
The floor iack must be securely posi'
@
tioned or personal iniury may rsuli.
6. Tightenthe damperPinchbolt.
nut.
7 . Tightenthe damperfork bolt and self-locking
8 . Tightenthe flangenuts on top of the damper.
9. lnstallthe brakehose mounts with the brakehose
mountingbolts.
10. lnstallthefront wheel.
18-19
RearSuspension
SuspensionArms Replacement
when the suspensionarms are to be removed, place additional weight in the trunk before hoisting. when
@
substantial weight is removed from the rear of the vehicle, the center of gravity may change causing the car to tip forward.
CAUTION:
. Replacethe self-lockingnuts after removal.
. The vehicle should be on the ground before any bolts or nuts connectedto rubber mounts or bushings are tightgn.
NOTEI
a Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection.
. " t U P L " o r " i U P L H G " o r " l U P L K " o r " t U p L S . ,i s s t a m p e do n t h e l e f tu p p e ra r m a n d , , t U p R , , o r , , t U p R H
G , ,o r
" t U PR K " " t
or
U P R S " o n t h e r i g h tu p p e ra r m .
. The right and left compensatorarm are symmetrical.lnstallso the "l UP" markstampedsidefacesforward.
. After installingthe suspensionarm,checktherearwheelalignment,and adjust if necessa (seepage .18-4).
ry
FLANGEBOLT
10x 1.25mm
54 N.m
15.5kgt.m, 40 lbl.ft)
ADJUSTINGEOLT
(FLANGEBOLT)
10 x 1.25mm
UPPER
ARM INNER
47 tbf.ft)
BUSHING
C h e c kf o r d e t e r i o r a t i o n
ano oamage,
SILICONE
-.-
.d@l
DAMPERMOUNTINGBOLT
{FLANGEBOLT)
10 x 1.25mm
sil N.m
{5.5 kgt m, 40 lbt.ft)
cREAsE
10 mm FLANGEBOLT
N.m 14.0kgf.m,29 lbt.ft)
UPPERARM
Checkfor bending
COMPENSATOR
ARM
Checkfor bending
ano oamage.
damage.
FLANGEBOL
'10x 1.25mm
54 N.m
I (5.5kgf m, 40 lbtft)
TBAILINGARM
FI-ANGEBOLT
10 x 1.25mm
54 N.m
{5.5kgt m, 40 lbtftl
COMPENSATOR
ARM
INNERBUSHING
S|L|CONE
,--
*@l
cnense
a n dd a m a g e .
FLANGEBOLT
10 x 1.25mm
64 N.m {6.5kgf.m.
47 tbf.ftl
18-20
FLANGEBOLT
12x 1.25mm
64 N.m 16.5kgl m,
rl7 lbf.ft)
LOWERARM
Checkfor cracks
ano oamage.
LOWERARM EUSHING
SILICONE
...,4@]
GREASE
ano oamage.
HubBearingUnit Replacement
NOTE:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weightsmay corrodeand damage
t h e a l u m i n u mw h e e l s .
. Onthe aluminumwheels,removethe centercap f rom the insideofthewheel after removingthewheel.
. Beforeinstallingthe brakedrum,cleanthe matingsurfacesof the rear hub and the brakedrum.
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakedrum and wheel.
TRAILINGARM
Checkfor cracking
ano oamage.
BNAKESHOE
SPINOLENUT
22 x 1.5 rnm
181N.m 118.5kgf.m,134lbt.ft)
Replace.
NOTE:Aftertightening,usea drift
punchto lockthe spindlenut shoulder
intothe spindle.
WASHER
SPINDLE
BACKINGPLATE
FLANGEBOLT
1 0x 1 . 2 5m m
5,1N.m (5.5 kgtm,,l0 lbtft)
REARWHEEL
HUBBEABINGUNIT
Checktor cracking
and oamage.
BRAKEDRUM
Checkfor wear
ano oamage.
WHEELNUT
1 2x 1 . 5m m
108N.m (11.0kgf'm,80lbtft)
(cont'dl
18-21
RearSuspension
Hub BearingUnit Replacement
(cont'dl
UpperArm BushingReplacement
1.
2.
1.
3.
Loosenthe wheel nuts slightly.

Raisethe rear of vehicle,and supportit with safety
standsin the properlocations(seesection1).
Removethe wheel nuts and rearwneel.
R e m o v et h e u p p e ra r m b u s h i n ga n d i n n e rb u s h i n g
as shown.
UPPER
ARMINNERBUSHING
SPINOLE
NUT
22 x 1.5mm
181N.m {18.5ksf.m,134lbth)
Replace.
NOTE:Aftertightening,usea drift to
stakethe spindlenut shoulderagainst
the spindle.
REARUPPERARM
2.
N 4 a r ak s c r i b el i n e o n t h e u p p e ra r m i n n e rb u s h i n g
so that it is in line with the bolt mountinosurface.
3.
Mark on the upper arm at two points so that they

a r e i n l i n e a n d m a k ea r i g h ta n g l ew i t h t h e a r m a s
shown.
MARK
REARWHEEL
HUBCAP
Replace.
NOTE:Takecarenot to damagethe hub bearingunit
on disassembly.
WHEELNUT
1 2x 1 . 5m m
4.
5.
6.
7.
8.
108N.mfi1.0 kgf.m,g0tM.ftl
Pullthe parkingbrakeleverup.
Removethe hub cap.
Raisethe lockingtab on the spindlenut,then remove
the nut.
Releasethe parkingbrakelever.
Removethe brakedrum, hub bearingunit and spin
d l ew a s h e r .
BOLTMOUNTING
SURFACE
Drivein the upperarm innerbushingwith the marks

aligned.
5.
D r i v et h e u p p e ra r m b u s h i n gi n t ot h e u p p e ra r m .
N O T E rD r i v ei n t h e u p p e ra r m b u s h i n ga n d i n n e r
bushinguntil their leadingedgesare flush with the
HUB BEARINGUNIT
Checktor cracksand damage
BRAKEORUM
SPINDLEWASHER
9.
Installin the reverseorderof removal.
18-22
RearDamper
Removal
1.
Remove the rearwheels(seepage 18-22).
2.
Removethe speakercoverand speaker(Hatchbackl.

Sedanand Coupe:Removethe trunk side panel(see
section20).
3.
6.
and removethe damper.

Lowertherearsuspension,
OAMPER
Removethe two flange nuts.

FLANGENUTS
10 x 1.25mm
4.
Removethe flangebolt from the damper.
FLANGEBOLT
1 0x 1 . 2 5m m
FLANGEBOLT
1 0x 1 . 2 5m m
Removethe flangebolt that connectsthe lower arm

to the trailingarm.
18-23
RearDamper
Disassembly/l
nspection
Disassembly
lnspection
1.
Reassemble
all parts,exceptthe spring.
2.
Pushon the damperas shown.
Compressthe damper spring with the spring comp r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r ' isn s t r u c ,

tions,then removethe self-lockingnut.
CAUTION: Do not compress the spring more than
necessaryto remove the selflocking nut.
WOODENBLOCK
STRUTSPRINGCOMPRESSOR:
BRANICI(@
T/N MST-580A,T/N 7200,or equivatent
Release the pressure from the spring compressor,

then disassemble the damper as shown on page 18-
Checkfor smooth operationthrough a full stroke.

both compressionand extension.
N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l y .l f i t
does not (no compressionor no extension),the gas
asleaking,and the dampershouldbe replaced.
Checkfor oil leaks.abnormalnoisesand bindingduring these tests.
I
18-24
Reassembly
SELF-LOCKINGNUT--------------- gr
10 x 1.25mm
Y
29 N.m (3.0kgt.m, 22 lbl.ft)
DAMPER
MOUNTING
WASHER
OAMPERMOUNTING
RUBBER
Checkfor
deterioration
ano oamage.
DAMPERMOUNTING
COLLAR
DAMPER
MOUNTINGBASE
1.
I n s t a ltlh e d a m p e ru n i to n a s p r i n gc o m p r e s s o r '
instructions.
NOTE:Followthemanufacturer's
2.
Assemblethe reardamperin reverseorderof disas

s e m b l ye x c e p tt h e d a m p e rm o u n t i n gw a s h e ra n d
s e l f l o c k i n gn u t .
N O T E rA l i g n t h e b o t t o mo f d a m p e rs p r i n ga n d
springlower seatas shown.
3.
Positionthe dampermounting base on the damper

unit as shown.
STRUTSPRINGCOMPRESSOR:
MOUNTING(Commerciallyavailable)
DAMPER
DAMPERMOUNTING
RUBBER
Checkfor
deterioration
DAMPERSPRING
ano oamage,
Checkfor weakness,
compression
and damage.
SPRING
RUBBER
ano oamage.
BUMPSTOP
Checkfor weakness
a n oo a m a g e .
DUSTCOVERPLATE
DUSTCOVER
Checkfor bending
T/N MST-580A.T/N 7200,

BRANICKO
or equivalent
SPRINGLOWERSEAT
Compressthe damper spring with the spring compressor.
DUSTCOVERBOOT
a n oo a m a g e ,
5.
I n s t a l tl h e d a m p e rm o u n t i n gw a s h e r ,a n d l o o s e l y
nut.
installa new self-locking
6.
Holdthe dampershaftwith a hex wrench and tighten

nut.
the self-locking
NUT
SELF-LOCKING
DAMPER
'10x 1.25mm
29 N.m {3.0kgf.m,22lbfft}
MOUNTING
WASHER
Replace.
DAMPERUNIT
18-25
RearDamper
Installation
L
Lowerthe rear suspensiona

, n d p o s i t i o nt h e
damperwith the springstop pointedtoward the left
sideof the vehicle.
,i
:..
SPRINGSTOP
2.
Looselyinstallthetwo flangeNUIs.
FLANGENUTS
10x 1.25mm
49 N.m {5 kgl.m, 35 lbf.ftl
Tightenthesenuts in
Step7.
Looselyinstallthe flangebolt.
FLANGE
BoLT
10x 1.25mm
'
54 N.m {5.5 kgl.m,40 lbf.ftl
i ' a - -: a
as'.( r'
FLANGEBOLT
10 x 1.25mm
54 N,m 15.5kgt.m,
40 rbf.ft)
Raisethe rearsuspensionwith a floor jack until the

vehicleiust liftsoff the safetvstand.
The floo. iack must be securely posi@
tioned or personal iniury may result
5.
Tightenthe flangebolt.
Tightenthe two flangenuts on top of the damperto
the specifiedtorque.
7.
Checkthe rearwheel alignmentand adjustit necessary (seepage 18-41.
18-26
Brakes
........19-1
Brakes
Conventional
19-31
Anti-lockBrakeSystem(ABS).............
GonventionalBrake
SpecialTools
.............
19-2
Rear Drum Brake
ComponentLocations
fndex/fnspection ..............................
19-21
lndex ................
......19-3
Inspection
..............
19-25
Inspection and Adiustment
BrakeShoe Disassembly.................
f 9-26
Brake System Rubber Parts
ErakeShoe Reassembly..................
19-26
and BrakeBooster...........................
19-4
BrakeHoses/Lines
BrakePedal
............
19-5
Inspection/TorqueSpecffications..... 19-28
ParkingBrake
........19-6
HoseReplacement
...........................
19-29
Bleeding
.................
19-7
ParkingBrakeCable
Front Brake Pads
Inspectionand Replacement..........19.30
Inspectionand Replacement..........19-8
Front BrakeDisc
DiscRunoutInspection...................
19-12
DiscThicknessand Parallelism
fnspection
..........19-12
Front BrakeCaliper
Disassembly
..........
19-13
Reassembly
...........
19-16
MasterCylinder/BrakeBooster
19-21
PushrodClearanceAdiustment ......19-22
BrakeBoosterInspection..............,,
19-23
SpecialTools
Ret. No.
Tool Number
07JAG- SD40100
Description
PushrodAdjustmentGauge
9-2
Oty
'l
PagRetorencs
't9-22
ComponentLocations
lndex
BRAKE
PEDAIInspection
and
page19-5
Adjustment,
BRAKEHOSESLINES
Inspection/Torquespecifications,page 19-28
page'19-29
HoseReplacement,
BOOSTER
MASTERCYLINDER/ARAKE
page19-21
Adiustment,page19_22
PushrodClearance
page19'23
BrakeBoosterInspection,
PARKINGBRAKECABLE
and RePlacement,
Inspection
page19-36
PARKINGBRAKE
Adjustment,page19 6
FRONT
NOTE: There are two types of front brakecalipers:
"5410"
The calipertypescan be identitiedby the
"2056"
stampdon the caliperbody.Checkthe
or
type ol the brakecaliperbelore servicing
FrontBrakePads
5410Type:page19-8
2056Type:page19-10
FrontBrakeDisc,page'19-12
FrontBrakeCaliper
5410Type:page19'13
2056Type:page19-14
REARORUMERAKES
page19-25
Inspection,
ErakeShoeReplacement,
Page19 26
19-3
andAdiustment
Inspection
BrakeSystemRubberPartsand BrakeBooster
Brake Hoses
Visuallycheckfor damageor signsof fluid leakage.
Replacethe brakehosewith a new one if it is damagedor leaking.
@ BrakeBoostel
Checkbrakeoperationby applyingthe brakes.
lf the brakesdo not work properly,checkthe brake
booster.Replacethe brakeboosteras an assembly
if it does not work properlyor if there are signs of
leakage.
) Piston Cup and PressureCup Inspeqtion

.

Visuallycheckfor damageor signs of fluid leakage.
R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f
the pedal does not work properly or if there is
damageor signsof fluid leakage.
C h e c kf o r a d i f f e r e n c ei n b r a k e p e d a l s t r o k e
b e t w e e nq u i c k a n d s l o w b r a k e a p p l i c a t i o n s .
Replacethe master cylinder if there is a differencein oedalstroke.
Caliper Piston Seal and Piston Boots

Checkbrakeoperationby applyingthe brakes,
lf the pedal does not operateproperly,the brakes
drag. or there is damageor signs of fluid leakage,
disassembleand inspectthe brakecaliper.Replsce
the boots and sealswith new ones wheneverthe
brakecaliperis disassembled,
@ Wheel Cylinder Piston Cup and Du3t Cover
19-4

It the pedal does not operateproperly,the brakes
drag, or there is damageor signs of fluid leakage,
disassembleand inspectthe wheel cylinder.lf necessary,replacethe wheelcylinderas an assembly.
Brake Pedal
PedalHeight
L Disconnectthe brakeswitch connector,loosenthe
brake switch locknut, and back off the brake switch
until it is no longertouchingthe brakepedal.
2.
4.
At the carpetcutout,measurethe pedalheightfrom

the right sidecenterof the pedalpad.
Screw in the brake switch until its plunger is fully

depressed(threadedend touching the pad on the
oedal arm). Then back off the switch 1/4 turn to
m a k e 0 . 3 m m ( 0 . 0 1i n ) o f c l e a r a n c eb e t w e e nt h e
threadedend and pad. Tightenthe locknutfirmiy.
Connectthe brakeswitchconnector.
CAUTION: Make sure that the brake lights go off
when th pdal is relea3ed.
PUSHROD
LOCKNUT
BRAKESWITCH
LOCKNUT
I
5.
MEASURING
POINT{CUTOUT}
Standsrd PedalHeight (with carpet removedl:

M/T:
156.5mm (5.15inl
A/T, CW: 161mm 16 5/16 inl
I
3.
Loosenthe pushrodlocknut,and screwthe pushrod

in or out with pliers until the standardpedal height
from the floor is reached.After adjustment,tighten
the locknutfirmly.
0.3 mm
{0.0'lin)
Checkthe brakepedalfree play as describedbelow.
PedalFreePlay
1. With the engine off, inspectthe play on the pedal
pad by pushingthe pedalby hand.
FreePlay:1 - 5 mm (l/16 - 3/16 in)
2.
adjust
lf the pedalfree play is out of specification,
the brakeswitch.
CAUTION: lf the pedal froe play i3 insufficient, it
may result in brake drag.
N O T E : D o n o t a d j u s tt h e p e d a l h e i g h t w i t h t h e
oushroddeoressed.
BRAKEPEDALPAO
PUSHRODLOCKNUT
15 N.m
11.5kg{.m.11 lbf.ftl
19-5
iInspectionand Adjustment
ParkingBrake
Removethe rearconsole{seesection20),
Inspection
1. Pullthe parkingbrakeleverwith 196N (20kgf.44 lbf)
force to fully apply the parkingbrake.The parking
brake lever should be locked within the sDecified
notches.
Pullthe parkingbrakeleverup one notch.

Tightenthe adiustingnut until the rearwheelsdrag
slightlywhen turned.
Levsr LockedNotches:6 - I
Pulledup with 196 N (20kgf,44 lbf)
AOJUSTINGNUT
2.
Adjustthe parkingbrakeif the lever notchesare out

of specification.
Adiustment
Releasethe parkingbrakeleveriully, and checkthat

the rear wheelsdo not drag when turned.Readjust
if necessary.
NOTE:After rear brakeshoe servicing,loosenthe parking brake adjustingnut, $tart the engine, and depress
the brake pedal severaltimes to set the self-adjusting
brakebeforeadjustingthe parkingbrake.
Make sure that the parkingbrakesare fully applied

when the parkingbrakeleveris pulledup fully.
7.
1.
Raisethe fear wheels off the ground, and support

the vehicleon safetystands.
Block th tront wheers before iacking
@
up the rear ol the vehicle.
9-6
Reinstallthe rearconsole.
Bleeding
CAUTION:
. Always use GonuinoHondaDOT3 BrakeFuid. Using a
non-Honda brake tluid can cause corro3ion and
dcr.ase th. liis ot tho 3wtam.
. Mako suro no dirt or other foroign matter is allowd
to contaminato tho brake tluid.
. Do not spill brako tluid on the vohicle.it may damage
the paint; if brake tluid does contact tho paint. wash
it off immediatoly with wator.
FRONT:
NOTE:The reservoir'onthe mastercylindermust be at

the MAX (upper)level mark at the start of the bleeding
p r o c e d u r ea n d c h e c k e d a f t e r b l e e d i n g e a c h b r a k e
caliper.Add fluid as required.
1.
Makesure the brakefluid levelin the reservoiris at

the MAX (upperllevelline.
MAX {UPPERILEVEL
LINE
BLEEDSCREW
I N.m 10.9kgl m, 6.5 lbf.ftl
REAR:
RESERVOIR
MASTERCYLINDER
Havesomeoneslowly pump the brakepedalseveral

times,then applysteadypressure.
Loosenthe brakebleedscrewto allow air to escape
f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w
scuretv.
4.
Repeatthe procedurefor each wheel in the sequence

shown below until air bubblesno longer appearin
the fluid.
/ i
BLEED
SCREW
7 N.m10.7kgl.m,5 lbf.ftl
Refillthe mastercvlinderreservoirto the MAX (upoer)levelline.

BLEEDINGSEOUENCE:
O F ont Risht
O RearRight
O Front Left
O Re.r Left
1 e t*
Front BrakePads
Inspectionand Replacement
NOTE:Therearetwo tvpesof front brakecalipers:

"5410"or
T h e c a l i p e rt y p e s c a n b e i d e n t l f i e db y t h e
"2056" stamped on the caliperbody 8s shown below.
Checkthe type of the brakecaliperbeforeservicing.
4.
Removethe pad shim. pad retainersand pads.

NOTE:When the caliperis equippedwith on outer
pad shim, replacethe shim togetherwith the pads
as a ser.
5410Typo:
see page
NOTE:For 2056type disassemblyprocedures,
19-10.
@
. Nver use an air ho3e or dry brush to clean brako
assemblies.
Use 8n OSHA approved vacuum claner io avoid
breathing brake dust.
1.
Loosenthe front wheel nuts slightly,then raisethe

vehicle. and support it on safety stands. Remove
the front wheels.
Removethe brakehosebracketfrom the knuckle.
Removethe caliper bolt, and pivot the caliper up
out of the wav.
. e a s u r et h e t h i c k n e s so f
U s i n g v e r n i e rc a l i p e r s m
eachbrakepad lining.
Brake PadThicknss:
Standard: 9.5 - 10.5mm (0.37- 0.,t1 inl
ServicoLimit: 1.6 mm (0.06in)
CALIPERBOLT
f i
NOTE:Checkthe hosesand pin boots for damage

and deterioration.
19-8
NOTE:Measurementdoes not includepad backing

platethickness.
lf the brakepad thicknessis lessthan servicelimit,
replacethe front padsas a set.
7 . Cleanthe caliperthoroughly;removeany rust.and

checkfor groovesand cracks,
o . Checkthe brakediscfor damageand cracks.
Installthe pad retainers.
12. Pushin the pistonso that the caliperwill fit overthe

pads. Make sure that the piston boot is in position
to prevent damaging it when pivoting the caliper
down.
CALIPERBOLT
N.m {3.3ksl.m, 24 lbnftl
rl
ii
10. Apply greaseto the points indicatedby the arrows

in the foilowingillustration:
NOTE:Use the pad greaseincludedin the pad set
or Molykote M77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
.
.
.
.
.
Pistonend and inner pad contactsurface

Padand caliperbracketcontactsurface
Outerpad and caliperbody contactsurface
OuterDadshim and outer oad contactsurface
Outerpad shim and caliperbody contactsurface
1 3 . P i v o tt h e c a l i p e rd o w n l n t o p o s i t i o n ,t h e n i n s t a l l
caliperbolt and tightenit.
CAUTION: Be careful noi damage tho pin boot
when pivoting tho caliper down.
1 4 . Installthebrakehosebracketon the knuckle.
NOTE: Inspectthe brake hose for interferenceor
twisting.
WEARINDICAIOS
OUTER
PAOSHIM
]
INNERPAO
OUTERPAD
5...1
ur
11. Installthe brakepadsand pad shim correctly.
Whon reusing the pads, always reinstall the

brake pads in thoir original positions to prevent
loss of braking efficiency.
Contaminatd brake disca or pads reduce stopping ability, Keopgreaseoff the discs snd pads.
1 5 . DeDress
the brakeDedalseveraltimes to makesure
the brakeswork,then test-drive.
N O T E : E n g a g e m e n ot f t h e b r s k e m a y r e q u i r ea
greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplicat i o n s o f t h e b r a k ep e d a l w i l l r e s t o r et h e n o r m a l
pedalstroke.
1 5 . After installation,checkfor leaksat hose and line
jointsor connections,
and retightenif necessary,
NOTE: lnstall the pad with the wear indicator on

the inside.
(cont'd)
19-9
FrontBrakePads
Inspectionand Replacement(cont'dl
5,
2056 Type:
@Nev6r usg an air ho3e or dry brush to cloan brakg
Using vernier calipers, measure the thickness of

eachbrakepad lining.
Brake P8dThickness:
8.5 - 9.5 mm (0.33- 0.37 in)
Standard:
sssembligs.
Usg an OSHA approved vacuum cleanor to avoid
breathing brako dust.
1 . Loosenthe front wheel nuts slightly,then raisethe
vehicle,and support it on safety stands. Remove
the front wheels.
t
Removethe brake hose bracketfrom the knuckle.
Removethe caliperbolt B, and pivot the caliperup
out of the wav.
BRAKEHOSEARACKET
BACKING PLATE
NOTE:Measurementdoes not includepad backing

olatethickness.
6.
CALIPER
BOLTB
7.
NOTE;Checkthe hosesand pin boots for damage

and deterioration.
Removethe pad shim, pad retainersand pads,
NOTE:When replacingthe pads. replacethe shim
togetherwith the
as a set.
OUTER
PADSHIM
Check
forwear.
INNER PAD
PAORETAINERS
Checkfor weaknessand
damage.
OUTERPAD
19-10
8.
9.
lf the brakepad thicknessis lessthan servicelimit.

replacethe front pads as a set.
Cleanthe caliperthoroughly;removeany rust, and
checkfor grooves and crscks.
Checkthe brakediscfor damageand cracks.
lnstalltheoad retainers.
10. Apply greaseto the points indicatedby the arrows

in the followingillustration:
NOTE:Use the pad greaseincludedin the pad set
or lvolykote M77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
.
.
.
.
.
Pistonend and inneroad contactsurface

Padand caliperbracketcontactsurface
Outerpad and caliperbody contactsurface
Outerpad shim and outer pad contactsurface
Outerpad shim and caliperbody contactsurface
12. Pushin the pistonso that the caliperwill fit over the
pads.Make sure that the piston boot is in position
to preventdamaging it when pivoting the caliper
oown.
PISTON
CALIPERBOLTB
26 N.m {2.7kgl.m,
20 tbt.ftt
WEARINDICATOR
OUTERPAD
OUTER
PADSHIM
1 3 , P i v o tt h e c a l i p e rd o w n i n t o p o s i t i o n ,t h e n i n s t a l l
caliperbolt B and tightenit.
1 4 . lnstallthe brakehosebracketon the knuckle.
NOTE:lnspectthe brakehose for interferenceand

twistrng.
1 5 . Depressthe brakepedalseveraltimes to makesure
the brakeswork,then road-test.
11. Install the brake pads and pad shim correctly.
o When reusing the pads, always reinstall the

brake pads in their original positions to prevent
loss of braking efficiency.
. Contaminatd brake discs or pads reduca stopping ability. Keepgrea3off the discs and pads.
t f t h e b r a k e m a y r e q u i r ea
N O T E :E n g a g e m e n o
greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplicat i o n s o f t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l
pedalstroke.
After installation,checkfor leaksat hose and line
jointsand connections.
and retightenif necessary.
N O T E :I n s t a l lt h e p a d w i t h t h e w e a r i n d i c a t o ro n
the inside,
1 9 - 11
FrontBrakeDisc
DiscRunoutInspection
t.
Loosenthe front wheel nuts slightly,then raisethe

vehicle, and support it on safety stands.Remove
the front wheels.
DiscThicknessand Parallelism
Inspection
1 . Loosenthe front wheel nuts slightly.then rsisethe
vehicle. and support it on safety stands, Remove
the front wheels.
Removethe brakepads(seepage19-8).
Removethe brakepads(seepage 19-8).
I n s p e c tt h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoroughlyand removeall rust.
4,
Use wheel nuts and suitableplain washersto hold

the disc securelyagainstthe hub, then mount a dial
i n d i c a t o ra s s h o w n , a n d m e a s u r et h e r u n o u t a t
'10mm (0.4in) from the outeredgeof the disc.
U s i n g a m i c r o m e t e r ,m e a s u r ed i s c t h i c k n e s sa t
eight points, approximately45" apart and 10 mm
(0.4in) in from the outer edgeof the disc.
Brake Disc Runout:

ServiceLimit 0.10 mm {0.00,1in)
W{EEL NUT AND

PLAINWASHER
108 N.m
(11kgf.m,80lbtft)
BrakeDisc Thicknsss:
Standard:20.9- 21.8 mm {0.82- 0.86 in)
Max. RefinishingLimil: 19.0mm (0.75in)
NOTE:ReDlacethe brakedisc if the smallestmeasurementis lessthan the max. refinishinglimit.
Erake Di3c Parallelism:0.015mm 10.0006inl max.
lf the disc is beyond the servicelimit, refinishthe

brake disc with an on-car brake lathe. The KwikLathe produced by Kwik-way manufacturingCo.
and the "Front BrakeDisc Lathe" offeredby Snapon ToolsCo.are approvedfor this operation.
M8x. RetinishLimit 19.0mm (0.75inl
NOTE:A new disc shouldbe refinishedif its runout
is greaterthan 0.10mm (0.004in)
NOTE: This is the maximum allowabledifference

betweenthe thicknessmeasurements.
lf the disc is beyondthe servicelimit for parallelism,
refinishthe brake disc with an on-car brake lathe.
The Kwik-Latheproduced by Kwik-WayManufac"Front ErakeDisc Lathe"offered
turing Co. and the
by Snap-onTools Co. are approvedfor this operatron.
NOTE:Seesection18for brakedisc replacement.
19 -1 2
Front BrakeGaliper
Disassembly
NOTE:Therearetwo typesof front brakecalipers:
"5410"or
T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e
"2056" stampedon the caliper body as shown below.
Checkthe type of the brakecaliperbeforeservicing.
R e m o v et h e c a l i p e rp i n s a n d p i n b o o t s f r o m t h e
calioerbracket.
PINB
CALIPER
CALIPER
BRACKET
3.
5410Type:
see page
NOTE:For 2056type disassemblyprocedures,
'19-13.
Nsvr use an air hose or dry brush to clean brake

assemblics.
Use an OSHA approved vacuum clganer to avoid
breathing brake dust.
CAUTION:
. Do not spill brske tluid on the vehicle; il may damage
the paint; if braka fluid does contact the paint. wssh
it off immediately with water.
. To prcvent spills, cover the hose ioints with rsgs or
shop towels.
. Clesn all parts in brake fluid and air dry; blow out all
passageswith compressedair.
L
CALIPERPIN A
lf necessary,apply compressedair to the caliper

fluid inlet to get the pistonout. Placea shop rag or
wooden blockas shownto cushionthe pistonwhen
it is expelled.Use low pressureair in shortspurts,
.
.
Do not place your fingrs in froni ot tho piston.

D o n o t u s e h i g h a i r p r e s s u r e ;u s G a n O S H A
approved 30 PSInozzle.
Removethe banjo bolt, and disconnectthe brake

hosefrom the caliper.
CALIPER
EANJO SOLT
Removethe pistonfrom the caliper,and checkthe

pistonfor scoring.
Removethe boot clip,pistonboot and pistonseal.
CAUTION:Take care not to damagethe cylinder
bore.
PISTONSEAL
Replace.
SEALING
Replace.
CALIPERBOLTS
Removethe caliperbolts, then remove the caliper

from the bracket.
BOOTCLIP
Beplace.
,
CALIPERBODY
Checkfor scoring
PISTONBOOT
Replace.
{cont'd)
19-13
L
Front Brake Caliper

(cont'dl
Disassembly
2056Type:
4.
@
. Never use an air hose or dry brush to clean brake
.
on cytinder wall.
assemblis.
Use an OSHA approved vacuum cleaner to avoid
breathing brak dust,
CAUTION:
. Do not spill brake fluid on tha vohicle; it may dsmage
the paint; if brake tluid dos contaqt the paint. wash
it otf immdiately with water.
. To prevent spills, cov6r tho hose ioints with iag3 or
shop towels,
. Cleanall parts in brake tluid and air dry; blow out all
pasragoswith compressedair.
1.
R e m o v et h e p i n b o o t , s l e e v eB a n d s l e e v eboot
from the caliperbody.
CALIPER
SODY
Checkfor scoring
Removethe banio bolt, and disconnectthe brake

hosefrom the calioer.
SEALINGWASHERS
Replace.
SLEEVEI
Replace.
st EEVE
I
Checklor damage.
lf necessary,apply compressedair to the caliper
fluid inlet to get the pistonout. Placea shop rag or
wooden blockas shownto cushionthe pistonwhen
it is expelled.Uselow pressureair in shortspurts.
a Do not plac your tingers in front of the piston.

a Do not us high 8ir prossur; usc an OSHA
approved 30 PSInozzle.
Removecaliper bolt B, pivot the caliper up out ol

the way, then removethe caliperfrom the bracket.
Removethe guide pin boot from sleeveA on the
caliperbracket.
Checkfor damage.
GUIDEPIN BOOT
Replace.
CALIPERBRACKET
CheckIor cracks.
19-1 4
Removethe pistonfrom the caliper,and checkthe

piston for scoling.
7.
Removethe boot clip, pistonboot and pistonseal.

CAUTION:Take care not to damage the cylinder
bore.
800T cLtP
Replace.
SEAL
PISTONEOOT
Replace.
Front BrakeGaliper
Reassembly
5,110Type:
NOTE;For 2056type reassemblyprocedures.
seepage 19-18,
o
.
.
.
Never use an air hose or dry brush lo clan brske t$embliss.

Use on OSHA approvsd vacuum cleanerto avoid breathing brako dust,
Contaminatedbraks discs or pads reducestopping ability.
when teusing the pads, always reinstall the brake pads in their original positions to prevent loss ot braking cfficiancy.
CAUTION:
. Do not spill brak lluid on the vehicle; it may damage tho paint; if brrke lluid does contact the paint, wash it off immediately with water.
. Cleanall parts in brake fluid 8nd air dry; blow out all pa$ages with compr63sedair.
. Bofore rea$embling, checkthai all parts a.o froo of dust and other lorsign particlog.
. Roplacepart3 with nw onss whenever spscifiedto do so.
. Make sure no dirt or othe. foreign mattor is allowed to contaminste tha brake fluid.
. Alway3 us Genuine Honda DOT 3 Brrke Fluid. Using a non-Hondabrako fluid c8n caus corrosion and decroasethe
lifs of the system.
NOTE:
. Coatthe piston,pistonseal.and caliperbore with cleanbrakefluid.
. Replaceall rubberpartswith new oneswheneverdisassembled.
#r-anrrsr-H:
Userecommendedrubbergreasein the cslipersealset.
-61'
Userecommendedsealgreasein the calipersealset.

BEAKEPAOS
rMA
(ln
|trf,
t \ '
WEABINDICATOR
TOR
CALIPERBRACKETMOUNTINGBOLT
PIN BOOTS
Replace.
_41
\ \J q l c A
\\r li
BRACKET
oUTER PADSH|M
ta,
---+-s'
caupeaetNa/
PADRETAINERS
=..
.H!!q9ril
PISTONSEAL
PISTONBOOT
Replace.
Replace.
-6r
/
BLEEDSCREW
9 N m (0.9kgr.m,6.5 lbf.ft)
CALIPEBBOOY
19-16
A
]
wo
eoorcue
Replace.
1 . Cleanthe piston and caliperbore with brakefluid,

and inspectfor wear and damage.
Coat the new Diston seal with the recommended
rubbergreasein the caliperseal set.and installthe
sealin the cylindergroove,
Apply the recommendedseal greasein the caliper
seal set to the sealinglips and insideof a new piston boot. and secureinstallit in the caliperwith the
new boot clio.
CAUTION: 8o carelul not to damage the caliper
cylinder wall.

seal set to the sliding surfaceof the pins and the
insideof the new Dinboots,
Installthe pin boots into the groovesin the caliper
bracketproperly.
PIN BOOT\
Replace. - \
CALIPERBRACKET
CALIPER
.@]
PINB
CALIPER
PIN BOOTS
Replace.
PISTONSEAL
Replace.
=^.
,->---!!!!!Lil
RUBBER GREASE
-6,l
CALIPEFPIN
PISTONBOOT
Replace.
.,'.{@l
SILICONEGREASE
7. Insertpin A and pin B into the caliperbracket.

8. Installthe pin boots into the grooves in the pins
properly.
9. Installthe brakepads in their originalpositions(see
page 19-9).
10- Pushin the pistonso that the caliperwill fit overthe
pads,and installthecaliper.
11. Tightenthe caliperbolts.
12. Connectthe brakehoseto the caliperwith new sealing washers,and tightenthe banjobolt.
BANJO BOLT
34 N.m (3.5kgl.m.25lbf ft)
SEALINGWASHERS
Replace.
L u b r i c a t et h e c a l i D e ra n d p i s t o nw i t h b r a k ef l u i d .
then installthe pistonin the cylinderwith the dished
end facingin.
CALIPERBOLT
32 N.m {3.3ksf.m,24lbf.ft}
1 3 . Fill the brakereservoirand bleedthe brakesvstem

{seepage 19-7).
1 4 . Performthe followingchecks.
. Checktor leaksat hose and line joints and connections,and retightenif necessary.
. Checkfor brakehosesfor interferenceand twisting.
(cont'dl
Front BrakeCaliper
(cont'd)
Reassembly
2056Type:
.
.
.
.
Ngver uso an air hose or dry brush to clean brake assemblies.

Uss an OSHA approved vacuum cleanerto avoid breathing brake dust.
Contaminatedbrake discs or pads reducestopping ability.
When reusing the pads. always reinstall ths brake pads in their original positions to prevent loss of braking efticisncy.
CAUTION:
. Do not spill brake fluid on the vehicle; it may dsmage th paint; if brak fluid does contact the paint, wash it off imme.
diately with water.
. Clanall parts in brake fluid and air dry; blow out all passageswith compre$d air.
. Betore reassembling,checkth8t all parts are free of dust and other toreign particles.
. Rplaceparts with new ones whenever specifiedto do so.
. Make sure no dirt or othsr forgign mattsr is allowed to contaminate the brake tluid.
. Always use Genuine Honda DOT 3 Erake Fluid. Using a non-Hondabrakc fluid can cause corrosion and decreasethe
lite ot the system.
NOTE:
. Coatthe piston.pistonseal.and caliperborewith cleanbrakefluid.
o Reolaceall rubberDartswith new oneswheneverdisassembled.
c''-"{@:
Use recommendedrubbergreasein the calipersealset.
-Gr,
use recommendedseargreasein the caliper searset.

@f "\
BRAKE
BNAKE
PADS
PADS
N
OUTERPAO
WEARINDICATOR
ir*l;r**t,;;ll;-fn
M lll'l r)
culoEP,NBoor \\
ERACKET
MoUNTTNG
BoLT
_.-cALrpER
toe ru'- {tt.o kg{.m.80rbtft)
H,
A-t
--
.ALTPER
BRA.KET
'ADRETA,NER
*6ry--
Pl
I ll I
l' I
\ l lt l d 6
% . -t'.---.**-y
u..(b
"""-,t"oo*tJ*,
o . , " , ""'*nW
*
\l
--\_^
BLEEDSCREW
s N.mro.s
ksr.m,6.s
tbr.ft)
SLEEVEA
'-b#\S"^.(*r1
/\
tr._ \
Tffi
6"1
YffA"
,o,,,,"o,,"/
W
26N.m{2.7ksf.m.2orbftt}
^/-^^..
\Uf->"
-
mFZ\
l(//
)A{
-,P,sroNBoor
Reorace.
;if;rqq
80()TcLtP
Replace.
l.'
19-18
'1.
Cleanthe piston and caliperbore with brakefluid,

and inspectfor wear and damage.
4.
Lubricatethe caliper and piston with brake fluid,

t h e n i n s t a l l t h e p i s t o n i n t h e c y l i n d e rw i t h t h e
dishedend facingin.
5.

seal set to the sliding surfaceof sleeveB and the
insideof the new pin and sleeveboots.
6.
Installthe new sleeveand pin boots and sleeveB

on the caliper.
Coata new pistonsealwith the recommendedrubber greasein the calipersealset,and installthe seal
in the cylindergroove.
seal set to the sealinglips and insideof a new piston boot, and secureinstallit in the caliperwith a
new boot clip.
CAUTION: Be caretul not to damage the calipel
cylinder wall.
BOOTCLIP
Replace.
NOTE:Be sureto installthe boots into the grooves

in the caliperand sleeveB properly.
BOOT
SLEEVE
Replace.
-e1
SILICONEGREAS
Replace.
re---.
- :-!!!r!ail
RUBBER
GREASE
SLEEVEB
P IN BOOT
Replace,
(cont'd)
19-19
Front BrakeCaliper
(cont'd)
Reassembly
7 . Apply the recommendedseal greasein the caliper
seal set to the sliding surfaceof sleeveA and the

insideof a new guide pin boot.
1 1 . Connectthe brake hose to the caliperwith n"w a6aling washers.and tightenthe banjobolt,
12. Tightenthe caliperbolt B.

I n s t a l lt h e g u i d e p i n b o o t i n t o t h e g r o o v e i n t h e
sleeveA.
Make sure that the brake pad retainersand brake
padsare in their originalpositions{seepage 19-10).
BANJOBOLT
34 N.m{3.5kgf.m,25lbt.ftl
26 N.m(2.7kgf.m,20 lbt.frl
1 3 . Fill the brakereservoirand bleedthe brakesystem

(seepage19-7).
10. Installthe caliperonto sleeveA, and pivot it down

into position.
NOTE:Installthe guide pin boot into the groove in
the caliperproperly.
o Checkfor leaksat hose and line joints and connections,and retightenif necessary.
. Checkfor brake hoses for interferenceand twistIn g .
SLEEVEA
_ 1
19-20
MasterCylinder/BrakeBooster
RemovaUlnstallation
CAUTION:
. 86 carefulnot to bend or damagethe brake lineswhen
removingthe mastercylinder.
. Do not spill brake fluid on tho vehicle; it maY damage
the paint; if brake tluid doas contaqt the paint, wash
. To prevent spill3, cover thg hose ioints whh rags or
shop towels.
the brakefluid levelswitchconnectors.
1 . Disconnect
2 . Removethe reservoircap trom the mastercylinder.
?
The brakefluid may be suckedout throughthe top
of the mastercylinderreservoirwith a syringe.
the brakelinesfrom the mastercylinder'
Disconnect
5. R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d
wasners.
6. Removethe mastercylinderfrom the brakebooster'
7. Disconnectthe vacuum hosefrom the brakebooster'
8. Removethe cofterpin and clevispin from the clevis'
CAUTION: Do noi disconnect the clovis by remov'
ing it from ths operating rod of the brake booster' lf
the clevis is loosenod, adiust the pushrod length
before installingthe brake booster (seepage 19-221
9. Removethe four boostermountingnuts

10. Pull the brake booster forward until the clevis is
clearof the bulkhead.
11. Removethe brake booster from the engine companmenr.
12. lnstallthe brakeboosterand mastercylinderin the
CAUTION:
. When connecting the brake lines, make sure
that lhere is no intrterence between the brake
lines and other Parts.
. Be caretul not to bend or damagethe brake lines
when installing the master cylinder.
N O T E : l f r e p l a c i n gt h e m a s t e rc y l i n d e ro r b r a k e
b o o s t e r ,c h e c ka n d a d i u s tt h e p u s h r o dc l e a r a n c e
beforeinstallingthe mastercylinder(seepage 19-22\.
, n d b l e e dt h e
1 3 . F i l l t h e m a s t e rc v l i n d e rr e s e r v o i r a
brakesystem(seePage19-7).
1 4 . After installation,checkthe brakepedal height and
brakepedal free play (see page 19-5)and adjust if
necessary.
BRAKE
BOOSTER
(WithABS:7" . S" tandembrakeboosier)
-6ll
CLEVIS PIN
BRAKEFLUIDLEVEL
SWITCHCONNECTORS
MASTEFCYLINDER
VACUUM HOSE
To RearWheelCylinders
13 N.m {1.3kst m,9 lbtft)
To FrontCaliper
(WithoutABS)
.--CONTROLVALVE
PROPORTIONING
15 N.m (1.5kgf.m,
11 tbt.ft)
15 N.m (1.5ksf'm,11lbfft)
(WithABSTTomodulatorunit)
19-21
MasterGylinder/Brake
Booster
PushrodClearance
Adjustment
NOTE:
. Mastercylinderpushrod-to
pistonclearance
mustbe
checked
andadjustments
made,if necessary,
before
installingmastercylinder.
ABStype is shown,conventional
braketvpe is similar.
l.
Setthe specialtool on the mastercylinderbody; push

in the centershaft until the top of it contactsthe end
pistonby turningthe adjustingnut.
of the secondary
PUSHRODADJUSTMENTGAUGE
07JAG- SD'(}l00
SECONDARY
PISTON
ADJUSTING
NUT
N O T E :l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y
8nd adjustingnut is 0.4 mm 10.02in), the pushrodto-pistonclearanceis 0 mm. However,if the clearance betweenthe gauge body and adjustingnut is
0 mm, the pushrod-to-piston
clearanceis 0.4 mm
(0.02in) or more.Thereforeit must be adjustedand
rechecked.
6. lf clearanceis incorrect,loosenthe star locknutand
turn the adiusterin or out to adjust.
NOTE:
Adjust the clearancewhile the specifiedvacuum
is appliedto the booster.
Holdthe cleviswhile adiusting.
7 . Tightenthe star locknutsecurely.
CENTER
SHAFT
8. Removethe specialtool.
0 - 0 . 4m m{ 0 - 0 . 0 2i n l
MASTERCYLINDER
2.
STARLOCKNUT
22 N.m
12.2kgt m, 16 lbf.ft)
Withoutdisturbingthe centershaft'sposition,install
the specialtoolupsidedown on the booster.
Installthe mastercylinder nuts and tighten to the
sDecified
toroue.
Connectthe boosterinline with a vacuumgaugeO101 kPa (0 - 760 mmHg, 30 in.Hg)to the booster's
e n g a n ev a c u u m s u p p l y ,a n d m a i n t a i na n e n g i n e
speedthat will deliver66 kPa(500mmHg,20 in.Hg)
vacuum.
With a feelergauge,measurethe clearancebetween
the gaugebody and the adjustingnut as shown.
CLEVIS
PUSHROD
ADJUSTMENTGAUGE
07JAG- SD40100
9. Adjust the pushrodlength as

ts removed.
'11610.m
5 m
(4.5710.02in)
Clearance:0 - 0.4 mm (0 - 0.02 in)

VACUUM GAUGE
{Commerciallyaveilable)
0 - 101kPe
{0- 760mm Hg,30 in.Hgl
AOJUSTINGNUT
HOSE
Connecta hoseof
suitablediameter.
PUSHROD
LOCKNUT
15 N.m (1.5kgl.m,11 lbf.ft)
CYLINDEB
NUT
FEELERGAUGE
1 5 N . m 1 1 . 5k g f . m , 1 1 l b f f i )
1 0 . lnstall the
19-22
master cylinder (see page l9-21).
BrakeBoosterInspection
FunctionalTest
'1. With
the engine stopped.depressthe brake pedal
severaltimes to depletethe vacuum reservoir,then
depressthe pedalhard and hold it for 15 seconds.lf
t h e p e d a l s i n k s ,e i t h e r t h e m a s t e r c y l i n d e rl s
bypassinginternally,or the brake system (master
c y l i n d e r ,l i n e s ,m o d u l a t o r ,p r o p o r t i o n i n gc o n t r o l
valve.or caliper)is leaking.
2 . S t a n t h e e n g i n ew i t h t h e p e d a ld e p r e s s e dl.f t h e
pedalsinksslightly,the vacuumboosteris operating
n o r m a l l y .l f t h e p e d a l h e i g h t d o e s n o t v a r y , t h e
boosteror checkvalve is faulty.
3. With the engine running,depressthe brake pedal
l i g h t l y .A p p l y j u s t e n o u g h p r e s s u r et o h o l d b a c k
a u t o m a t i ct r a n s m i s s i o nc r e e p .l f t h e b r a k ep e d a l
s i n k sm o r e t h a n 2 5 m m { 1 . 0i n . ) i n t h r e e m i n u t e s ,
t h e m a s t e rc y l i n d e ri s f a u l t y .A s l i g h t c h a n g ei n
pedal height when the A/C compressorcycles on
a n d o f f i f n o r m a l . ( T h e A / C c o m p r e s s o rl o a d
changesthe vacuumavailableto the booster.)
Leak Test
1. Depressthe brake pedal with the engine running,
then stop the engine. lf the pedal height does not
varv while depressedfor 30 seconds,the vacuum
b o o s t e ri s O K . l f t h e p e d a l r i s e s .t h e b o o s t e ri s
faultv.
2. With the engine stopped,depressthe brake pedal
. hen the
s e v e r a lt i m e s u s i n g n o r m a l p r e s s u r e W
pedal is first depressed,it should be low. On conthe pedalheight shouldgradsecutiveapplications,
positiondoes not vary, check
pedal
ually rise.lf the
the boostercheckvalve.
Booster CheckValve Test
1. Disconnectthe brake boostervacuum hose at the
booster.
2. Startthe engineand let it idle.Thereshouldbe vacuum. lf no vacuum is available,the checkvalve is
not working properly. Replacethe brake booster
vacuumhoseand checkvalve,and retest.
BRAKEBOOSTER
VACUUMHOSE
( C h e c kv a l v e
built-in)
19-23
RearDrumBrakes
Index/lnspection
a
a
a
a
N6vr use an air hos or dry brush to clean brako assemblies.

Use an OSHAapproved vacuum cleanerto avoid brealhing brake dust.
Contaminatedbrake linings or drums reducesiopping ability.
Block thc front wheels before iacking up the rear of ihe vehicle.
' 1 . Blockthe front wheels,

loosenthe rearwheel nuts slightly,supportthe rear of vehicleon safetystands,then remove
the rearwheels.
2.
Releasethe parkingbrake,and removethe rearbrakedrum.
WHEELCYLINOER
Inspectfor leakage.
It necessary,replaceas an assembly.
I N.m {0.9 kgt m, 6.5 lbf.ftl
u-cLtP
Replace.
UPPERRETURNSPRING
Checkfor weakness
ano oamage.
@
PIVOTPIN
/ {-l
TENSIONPIN
^ "*'"i
II
10 mm BOLT
64 N.m {6.5 kgf.m,
47rbf.ft)
&- d / /
ts
cLEV'sB
/
AOJUSTEREOLT
Checkratchetteeth
{or wear and damage.
BRAKESHOE
lnspection,
seepage19 30
lf brakeshoesare to be
reused,markand reassemble
in sameposition.
19-24
( r
LOWERRETURN
SPRING
Checklor weakness
and damage-
SELF.ADJUSTER
SPRING
Checkfor weakness
ano oamage,
,.to,n.*.r*,"n
, Install securely on
tensionpin.
Inspection
1.
Checkthe wheelcylinderJor leakage.
2.
Checkthe brake liningsfor cracking,glazing,wear

and contamination,
6.
M e a s u r et h e i n s i d ed i a m e t e ro f t h e b r a k ed r u m
usingthe insideverniercalipers,
Drum lnside Diametr:
199.9- 200.0mm (7.870- 7.874in)
Standard:
ServicsLimh: 201.0mm (7.913in)
3. Measurethe brakeliningthickness.
Brake Lining Thicknoss:
/1.0mm (0.157in)
Sisndard:
2.0
mm (0.08in)
ServiceLimit:
INSIDEVERNIERCALIPERS
WHEELCYLINDER
NOTE: Measurementdoes not include brakeshoe

\
thickness,
l f t h e b r a k e l i n i n g t h i c k n e s sr s l e s s t h a n s e r v i c e
limit, replacethe brakeshoesas a set
5.
Checkthe bearingsin the hub unit for smoothoperation.lf defective,referto section18.
7.
lf the inside diameter of the brake drum is more

than servicelimit, replacethe brakedrum.
8.
C h e c kt h e b r a k e d r u m f o r s c o r i n g ,g r o o v e sa n d
cracks.
RearDrumBrake
Brake Shoe Disassembly
1.
R e m o v et h e t e n s i o np i n s b y p u s h i n gt h e r e t a i n e r
springsand turningthem.
6,
Removethe wave washer,parkingbrakelever and

pivot pin from the brakeshoe by.emoving the UcliD.
PARKINGERAKE
LVER
WAVEWASHER
@G
u'cLrP
Replace.
RETAINER
SPRINGS
Lower the brake shoe assembly,and remove the
lower returnspring.
NOTE:Be carefulnot to damagethe dust cover on
the wheelcylinder.
BrakeShoeReassembly
Removethe brakeshoe assembly.
Apply brake cylinder grease (P/N:08733- 8020E)or

equivalentrubber greaseto the sliding surfaceof
the pivot pin, and insertthe pin into the brakeshoe.
Disconnect
the parkingbrakecablefrom the parking
brakelever.
Installthe psrkingbrakelever and wave wasneron

the pivot pin and securewith U-clip,
Removethe upper returnspring,self-adjuster

lever
a n d s e l f - a d j u s t esr p r i n g .a n d s e p a r a t et h e b r a k e
shoes.
NOTE: Pinchthe U-clip securelyto preventthe pivot

pin from coming out ofthe brakeshoe.
ADJUSTERBOLT
Checkratchettoeth tor
wear ano damage.
UPPERRETURNSPRING
Checkfor weakness
ano oamage.
rr\
\'
io
//
.:l
I'
SPRING
19-26
1.
C o n n e c tt h e p a r k i n g b r a k ec a b l e t o t h e p a r k i n g
brakelever.
Cleanthe threadedponionsof clevisesA and B.

Coat the threads of the cleviseswith grease.To
shortenthe clevises,turn the adjusterbolt.
Apply greaseon eachslidingsurface.

contaminated brake linings reduce
@
stopping ability. Keep greaseor oil off the brake lin'
ings. Wipe any excessgraseoft the parts.
.
Apply brakecylindergrease(P/N:08733- 8020E)

or equivalentrubber greaseto the sliding surfacesas shown.
6. Hook the self-adjusterspring to the self-adjuster

leverfirst,then to the brakeshoe.
1 . Installthe clevisesand upper return spring noting
the installationdirection,
NOTE;Be carefulnot to damagethe wheel cylinder
dust covers.
8. Installthelower returnsPring.
-|a
Slidingsurface
9. Installthe tensionpins and retainingsprings.
UPPERRETURNSPRING
CLEVISB
CLEVISA
SELF-ADJUSTER
SPRING
.
Apply Molykote44MAto the brakeshoeendsand

oppositeedgesof the shoesas shown.
+a
-)o
Opposite edge of the shoe

Brake shoe ends
1 0 . Installthebrakedrum.
1 1 . lf the wh6el cylinderhas been removed.bleedthe
brakc system (see page l9-6), and checkfor leaksat
brakeline connections,
1 2 . Depressthe brake pedal severaltimes to set the
self-adjustingbrake.
1 3 . Adjusttheparkingbrake(seepage l9-6).
19-27
BrakeHoses/Lines
Inspection/Torque
Specifications
1. Inspectthe brakehosesfor damage,deterioration,
leaks,interference
and twisting.
2. Checkthe brakelinesfor damage,rustingand leakage.Also checkfor bent brakelines.
3. Checkfor leaksat hoseand linejointsand connections,
4. Checkthe mastercylinderand ABS modulatorunit for damageand leakage.
CAUTION: Replacethe brake hose clip wheneverthc brake hose is serviced.
ABSMODULATOR
UNIT-Io-BRAKE
L|NE
19N.m11.9kgtm. 1albtftl
PROPORTIONING
CONTBOLVALVE.
Io.BRAKELINE
15 N.m (1.5kgf.m, 11 lbf.ft)
MASTERCYLINDER.TO.ARAKE
LINE
15 N.m {1.5 ksf.m, 11 lbf.ft}
aRAKELINE-Io-WHEEL
CYLTNDER
15N.m11.5kgf.m,11lbtft)
BLEED
SCREW
7 N.m{0.7kgtm, 5 lbl.frl
SRAKELINE-Io-BMKEHOSE
15 N.m (1.5kgf.m, 1r lbnftl
BRAKELINE-IO.BRAKE
HOSE
15 N'm {1.5kgf.m,11lbf ftl
BRAKEHOSE-io-CALIPEB
IBAIUJOBOLT}
3l N.ln(3.5ksf.m,25lbf'ft}
19-28
HoseReplacement
CAUTION:
o Before reas3embling,check that all parts are free ol
dust and other toreign particles.
. Replaceparts with new ones whenever spcified to
do so.
. Do not 3pill brak fluid on the vehicle; it may damage
the paint; il brake fluid does contact the paint, wash
1.
6, lnstall the brake hose bracketand brake hose on the

knucklefirst, then connect the brake hose to the
caliperwith the baniobolt and new sealingwashers
ReDlace
the brakehoseif the hoseis twisted,cracked,
or if it leaks,
the brakehosefrom the brakeline using
Disconnect
a 10 mm flare nut wrench.
FLARE
NUT
6 mm HOSEERACKET
BOLTS
9.8 N.m
{1.0 ksf.m, 7 lbf'ft)
(Commercially
available)
BRAKE LINE
BANJO BOLT
3,1N.m
(3.5 kgf.m.25 lbf.ft)
7. lnstallthe brakehose on the upper brakehose bracket

with a new brakehoseclip.
15Nm
{1.5 kgf.m, 11 lbf.ft)
Removeand discardthe brake hose clip from the

brakehose.
Connectthe brakelineto the brakehose.

9 . After installingthe brakehose,bleedthe brakesyst e m ( s e ep a g e ' 1 9 - 7 ) .
4.
5.
Removethe banjo bolt, and disconnectthe brake

hosefrom the caliper.
Removethe brakehosebracketfrom the knuckle.
. Checkthe brakehose and line joint for leaks,and
tightenif necessary.
. Checkthe brakehosesfor interferenceand twistIng.
19-29
ParkingBrakeCable
Inspectionand Replacement
CAUTION: The parking brake cables must not be bent or distortad. Thi3 will lad to stiff operation and premature cable
failure.
PARKINGBRAKECABLE
Checkfor faultymovement.
PARKINGBRAKESWITCH
Removethe parkingbrakecablefrom the backingplate

usinga 12 mm offsetwrenchas shown,
BACKINGPLATE
19-30
Anti-lockBrakeSystem(ABS)
19-32
...'.........
SpecialTools
19-33
ComponentLocations....."..............'...
(ABSI
Anti-lock Brake System
19-34
Features/Construction.....'...'..........
19-35
'..............
Operation
.........19-38
GircuitDiagram
ABS Control Unit Terminal
.........19-40
Arrangement
TroubfeshootingPrecautions....,.." " " 19-42
DiagnosticTroubleCode (DTG)
..
Diaonostic Trouble Gode (DTCI
19-44
...........
a
lnaication
19-45
...........
DTCErasure
19-46
Symptom-to SystemChart .....'.......
........19-52
Wheel Sensor
19-54
.................
Solenoid
19-56
ABS PumpMotor .............................
19-59
..........."
Main Relay
....
19-60
lgnition Voltage
CentralProcessingUnit (CPU)........19-61
Modulator Unit
19-62
ABS Control Unit
.....'...19-6:l
Replacement
Pulsers/WheelSensors
..........."'19-63
Inspection
Wheel SensorReplacement.......'....19-64
Troubleshooting
ABS Indicator Light Does Not
19-48
............
ComeOn
ABS IndicatorLight DoesNot
19-50
Go Off ............................................
SpecialTools
Rsl. No.
19-32
Tool Number
- 0010100
07PAZ
Description
SCSServiceconnector
Oty
1
Page Retorence
19-44
ComponentLocations
SERVICECHECKCONNECTOEI2PI
MODULATOBUNIT
ABS CONTROLUNIT
RIGHT-REAR
WHEEL
SENSORCONNECTOR
RIGHT.REAR
WHEELSENSOR
ABS
UNOER.HOOO
BOX
FUSE/RELAY
LEFT.REAR
WHEEL
SENSOFCONNECTOR
FUSE/RELAYBOX
UNOER.OASH
WHEEL
LEFT.FRONT
SENSORCONNECTOR
LEFT-FRONT
WHEELSENSOR
FUSE/RELAYBOX
UNDER-HOOO
rcl (40A' FUSE
nnn
-r n -fl
LIJn
rr
rr
flI]
'LJ
LJ
ft l ft l nt
Q!!
ABS INDICATORLIGHT
BOX
FUSE/RELAY
UNDER.DASH
METER{7,5A} FUSE
I,
(15A) FUSE
HORN/STOP
BOX
ABS FUSE/RELAY
UNDER-HOOD
ABS +B {20 A} FUSE
PUMPMOTORI40 A) FUSE
0000n
[0000 0 0 0 0u
[ 0000 0000[[
PUMPMOTORBEI-AY
RRDEFRLY{7.5A) FUSE
MTRCHECK{7,5AI FUSE
19-33
Features/Construction
when the brakepedalis depressedduringdriving,the wheelscan lock beforethe vehiclecomesto a stop. In sucha case.
the maneuverability
of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the
rearwheelsare locked.creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate ot the wheelsto
ensurethe grip forceof the tires,and it therebyensuresthe maneuverbility
and stabilitvof the vehicle.
Judgingthe vehiclespeed,the ABS calculatesthe slip rate of the wheelsbasedon the vehiclespeedand the wheetspeed.
then it controlsthe brakefluid pressureto attainthe targetslip rate.
Grip Force ol Tire and Road Surface

COEFFICIENT
OF
FRICTION
STOPPOINT
TARGETSLIPRATE
A: Distancewithout slio
B: Slipped distance
C: Actual distanceto stoo
SLIPRATE
19-34
sr.re
nnre=f
Operation
ABS Control Unit
Main Control
The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle
speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring decelerationbasedon the
rateof deceleration.
T h e A B S c o n t r o lu n i t c a l c u l a t etsh e s l i p r a t e o f e a c hw h e e l ,a n d i t t r a n s m i t st h e c o n t r o ls i g n a lt o t h e m o d u l a t o ru n i t
s o l e n o i dv a l v ew h e nt h e s l i pr a t ei s h i g h .
The pressurereductioncontrolis a three modesystem,that is pressurereduction,pressureretainingand pressureintensi
fvino modes.
ABS CONIFOLUN T
Function
Sell-diagnosis
The ABS controlunit is equippedwith a main CPUand a sub CPU,and the CPUScheckeachother.
The CPUScheckthe circuitof the system.
"systemdown mode" or the "controlinhibitionmode".
Whenthe CPUsdetectfailure,they shift to the
A B SI N D I C A T OLRI G H T
MAIN
RELAY
SYSTEM
DOWN
ON
No
operation
CONTROL
INHIBITION
ON
Drive
No
operation inhibition
MODE
SOLENOID
VALVE
Drive
inhibition
CPU
Restartcondition
DTC
Operation'l
lgnition
O F F- O N
switch
Memory
Automatic
lMemory
Operation
+ 1 : E x c e p tC P U f a i l u r e
can be classifieldinto thesefour categories.

The self-diagnosis
O r I n i t i adl i a g n o s i s
@: ExceptABS control
O : D ur i n gA B Sc o n t r o l
( D :D ur i n gw a r n i n g
On-board DiagnosisFunstion
The ABS controlunit is connectedto the data linkconnector(16P)
The ABS systemcan be diagnosedwith the HondaPGMTester'
(cont'd)
19-35
Operation {cont'd)
ABS Modulator
The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the
d a m p i n gc h a m b e r .
The modulatorreducesthe caliperfluid pressuredirectly.and it is alsoreferredto as a circulating
type becausethe brakefluid
circulates
throughthe caliper,reservoirandthe mastercylinder.
The hydrauliccontrolhasthreemodes:pressurereduction,pressureretainingand pressureintensifying.
The hydrauliccircuitis the independent
four channeltype, one channelfor eachwheel.
SOLENOIDVALVE
PUMPMOTOR
RF
LF
( N O F M A L L YO P E N )
lN: INLETVALVE
OUT: OUTLETVALVE (NOFl\,4ALLY
CLoSED)
Pressureintensiiyingmodel Inletvalveopen,outletvalveclosed
lvlastercylinderfluid is pumpedout to the caliper.
Pressureretainingmode: Inletvalveclosed,outletvalveclosed
Caliperfluid is retainedbv the inletvalveand outletvalve.
Pressurereductionmode: Inletvalveclosed,outletvalveopen
Caliperfluid flows throughthe outletvalveto the reservoir.
Motor operationmode:
Whenstaningthe pressurereductionmode,the pump motor is ON.
When stoppingABS operation,the pump motor is OFF.
The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master
cylinder.
19-36
Wheel Soeed and Modulator Control
SPEED
VEHICLE
VEHICLESPEED
REFERENCE
WHEELSPEED
OUTLET
VALVE
ON
OFF
INLET
VALVE
ON
OFF
MOTOR
ON
OFF
Whenthe wheelspeeddropssharplybelowlhe vehiclespeed,the inletvalveclosesto retainthe caliperfluid pressure.
When the wheel soeeddrops further,the outletvalve opens momentarilyto reducethe caliperfluid pressureThe pump
motor startsat this time.
As the wheel speedis restored,the inletvalveopensmomentarilyto increasethe caliperfluid pressure.
Wheel Sensol
type.
The wheelsensorsare the magneticcontactless
As the gear pulserteeth rotatepastthe wheel sensor'smagneticcoil,AC currentis generated.The AC frequencychanges
with the wheel speed.The ABS control unit detectsthe wheel sensors;gnalfrequencyand therebydetects
in accordance
the wheelspeed.
Thereare four wheelsensors,one for eachwheel.
The gear pulserhas50 teeth.
GEARPULSER
at LOW SPEED
19-37
CircuitDiagram
UNDEF.OASH
LEFI.FBONTSOLENOIO
-Fm-Feiu
.-..@u*
YE!8IK-1
F GHi.FRONTSOLENOID
REDDTU
YELTLU
- F O-YTL-
BtKa
ABSFUSE/RELAY
UNDER.HOOD
BOX
(a) number)
3PCONNECTOR
I
2 3 l
UNOEF DASH FUSE,/BELAY

BOX
20P CONNECTOR(C number)
l
5 6
t0 11
UNDER.HOOD
ABSFUSE/RELAY
BOX
2PCONNECTOR
i! number)
a 1 , f
ll
18 1920
15
UNDEB.DASHFUSE/RELAYBOX
1 8 PC O N N E C T O R( f n l m b e r )
1
3 alr,:15 6
9 t0 Il
21314/
1 6 t7 ,/
GAUGE
ASSEMBLY
5PCONNECTOR
(O numbsr)
fl"
l 1 l / 3
5 l
WIRESIDEOFFEMALE
TERMINALS
19-38
M O D U L A T OU
RN I T1 O PC O N N E C T O R
(C number)
P U M PM O T O R2 P C O N N E C T O R
(fl n!mber)
fi
I
E C MI P C M I S C S )
GF|//vvHI--GR^L&Hr
8tK
rL
rB
cor, coz
V
'n-, '_ l n
A ^
la 3
IoaTALNK
rr6P)
I? l3lcoNNEcroF
t'-
BTK
cot, ctoz
wln/GFN---E
-"**d
RIDE!I]
YtlrBlll
Tep*'
B!!/YEt
GNDl
;--l
*l:,1.J
cnoic.oz cnoicloz
ABS CONTROLUNIT26P CONNECTOR

(C number)
2 3
15
11
/ : a 9 10
t2 tl
t9
./ zt / 123
25 2E
ABSCONTROL
UNIT22PCONNECTOR
(l number)
4 /",/lt
12
/),
1 i / 1 9 /
SERVICE
CHECK
(2P)
coNNECTOF
W H E E LS E N S O R
2P CONNECTOF]
FRONT
llllrh
DATALINK
coNNECTOB (16P)
l0 tt
21 22
W I R ES I D EO F F E M A L ET E R M I N A L S
REAR
tTl
lT,
l-rl
T E R M I N AS
L I O EO F
MALETERMINALS
19-39
ABSGontrolUnit TerminalArrangement
ABSCONTROL
UNIT26PCONNECTOR
I
7-rt-Il:
I .li
;:,
WIRESIDEOF FEMALETERM
VB: BatteryVoltage
Wire
color
Terminal
numbel
Tormind sign
ITermin.l namol
PCOt\4
GRN^r'VHI (Primary
common)
scoM
BLIqWHT (Secondary
common)
BLK/BLU
(lgnition2)
RRO
BLU//EL (Rear-right
0)
8
I
GRY
RLO
(Rear-left
0)
GRN
FRO
(Front-right0)
GRNA/VHT
STOP
(Stop)
Voltago
Description
tafininlb
Powersourcetor the solenoid

valveandpumpmotor.
Condition3
(lgnition Switch ON (lll)
1-GND
Detects right-front wheel

sensorsrgnal.
Detects
brakeswitchsignal.
unnecessaryABS
{Prevents
operation)
3-GND
FLO
BRN^/vHT(Front-left
0)
14
16
17
19
)1
YEL
RL-OUT
(Rear-left
outlet)
RR-IN
REO/vVHT (Rearright
inlet)
B1
(Battery1)
53mVorabove
on
digitsltester{AC
(ffeferance)
rangel
150mvpporabove
onoscilloscope
Whenthe wheelis
turnedat 1 turn/
secono.
10-23
r'VHT/GRN (Battery
2)
GND2
BLK
(Ground2)
RR1
GRN/YEL(Rear-right
1)
R
L
l
LT BLU (Rear-left'l
)
FR1
GRN/BLK(Front-righr
1)
FLI
(Front-left1)
23
ON
12-GND
Drivesright-rearinlet solenoid
I3-GND
Power sourcefor the solenoid

valve and pump motor.
Ground for the ABS control
unit.
Detects right-rear wheel
sensorsignal.
Detectsleft-rearwheel sensor
signal.
Detects right-front wheel
sensorsignal.
Detects left-front wheel sensor
signal.
uJ
RL-IN
(Rear-left
inlet)
19-40
BLK
GND3
(Ground
3)
OV
AC:3-6 V
A p p r o x . 3V
VB
15,GND
16.GND
19,6
Below0.3V
When the wheel is turned

at 'l turn/second.
53 mV or above
on digital tester
(AC range)
(Referance)150
mVp-p or above
on oscilloscope
Stops
A p p r o x . 2 .V5
21-A
23-10
'6
ON
25.GND

unit.
-9
14-GND
26-GND
ON
OV
OFF
AC:3-6V
OFF
theSCS
seNicel
lconnect
I
26
ON
OFF
SCSservice]
lConnectthe
connector I
\
Drivesleft-rear
inletsolenoid
valve.
RED
Approx.2.5 V
'5
Drivesleft-rearoutlet solenoid
Powersourcefor the solenoid

valveandpumpmotor.
Approx.3 V
53mVorabove
on
digitaltester
{AC
Whenthe wheelis
(Referance)
turnedat 1 turn/second. range)
150mvtrporabove
onoscilloscope
8-21
Stops
ADprox.2.5V
Erakepedal depressed.
VB
9-GND
Erakepedal released.
OV
Stops
12
AC:3-6 V
VB
Detects left-front wheel sensor

signal.
10
OV
6
OFF
OFF
theSCSservice]
lConnect
connector l
\
2.GND
Detectsleft-rearwheelsensor
s r g nla.
ON
ON
Power sourcelor the solenoid
Detects ignition switch 2

signal.{Systemactivatesignal)
Detects right-rear wheel
sonsorsrgnal.
Output voltagg
Connector
Approx.3 V
Below0.3V
ABSCONTROL
UNIT22PCONNECTOR
VB: BatteryVoltage
Voltage
Tsiminal
numb6r
WiJe
cotol
FR.IN
RED/BLU (Front-right
inlet)
BRN
Terminal sign
lTo]minal nomsl
(Service check
signal)
BLU/RED (Warning
ramp,
Doscription
tef|ninak
Detectsservicechecksignal
(Diagnostictrouble code
indicationl
4-GND
DrivesABSlndicatorIight{The
indicatorlightgoesoff when
ABS controlunit outputsbattery voltage).
7-GND
11
FL-IN
RED/BLK (Front-let
inletl
17
Approx.5 V
Indicator
lightoN
Approx.2 V
1O-GND
Communicateswith Honda
PGM Tester.
12-GND
VB
ON
OV
OFF
AC:3'6 V
ON
OFF
theSCSseruiceJ
/Connect
conneclor I
\
Pump
1 7G N D motor
relay
ON
I9-GND
Drivesright-rear
outlet
solenoidvalve.

unit.
22-GND
ON
VB
OFF
OV
ON
OV
OFF
AC:3-6 V
OFF
servicq
theSCS
lconnect
connefior l
\
Pump ON
motor
reray OFF
OFF
theSCS
seNicq
lconnect
connedor I
\
ON
21-GND
Approx.3 V
Approx.5 V
14-GND
retay,
GND2
(Ground2)
Approx.3 V
SCSserviceconnector
disconn6cted,
Indicatorlight OFF
PMR
BLK
AC:3-6 V
OV
uJ
YEVRED (Pump motor
RR-OUT
{Rear-right
outlet)
OFF
11.GND
Detectspumpmotordrive
MCK
BRN/VEL (llotorcheck) s r g n a l .
BLU
OV
SCS service connector

connecleo.
Drivespumpmotorrelay.
19
Output voltago
ON
OFF
the
servicel
lconnsct SCS
connedor I
\
Drivesleft-frontinlet solenoid
FR-OUT
Drivesright-frontoutlet
YEUBLU (Front-right solenoidvalve.
outlet)
DLC
(Data link
connector)
ON
1-GND o
FL-OUT
Drives left-tront outlet
YEUSLK (Front-left solenoidvalve.
outlet)
LT BLU
'6
Drivesright-frontinlet
solenoidvalve.
10
l4
Conditions
(lgnition Switch ON lll)l
Approx,3 V
OV
AC:3-6 V
A p p r o x . 3V
Below0.3V
19-41
TroubleshootingPrecautions
ABS Indicato. Light

1. The ABS indicatorlight comeson when the ABS control unit detectsa problemin the system.However,eventhough
the system is normal.the ABS indicatorlight can come on. too, under the following conditions.To determinethe
actualcauseof problem,questionthe customerabout the problem,taking the following conditionsinto consideraI|on.
. Signaldisturbance
. W h e e ls p i n
. Only drivewheelsrotate
. Battery voltage Iluctuates
2. When a problemis detectedand the ABS indicatorlight comes on, the indicatorlight can stay on until the ignition
switchis turnedoff, or it can automaticallygo off, dependingon the mode.
. Lightstaysonuntil the ignitionswitchisturned off: Whenthesystemis inthesystem down mode.
. Lightautomatically
goesoff:
Whenthe systemis in the controlinhibitionmode.
(refer to symptom-to-systemchart)
3. The ABS indicatorlight stayson when the systemis reactivated
without erasingthe DTC,but it goes off after starting
the car.
When the wheel sensorsystem is faulty and the ABS indicatorlight comes on, the algorithm of the system automatically
turns off the ABS indicatorlight after the wheel speedsignal returnsto the normal speed.While,when the DTCis erased.
the CPUis resetand the ABS indicatorlight goes off when the systemcheckedout normal by the initial dlagnosis.
Therefore,test-drivethe car afterservicingthe wheelsensorsystem,and be surethat the ABS indicatorlight does not
come on.
4. Whenthe ABS controlunit outputsbatteryvoltageto gaugeassembly.the ABS indicatorlight goesoff,
DiagnosticTroublo Code (DTCI
1. The diagnostictroublecode (DTC)is memorizedwhen a problemis detectedand the ABS indicatorlight does not go
off, or when the ABS indicatorlight comeson.
The DTCis not memori?edwhen the ABS indicatorlight comeson unlessthe CPUis activated.
2. The memorycan hold any numberof DTCs.However,when the same DTCis detectedtwice or more,the laterone is
writtenover the old one.
Therefore,when the sameproblemis detectedrepeatedly,
it is recordedas one DTC.
3. The DTCSare indicatedin the orderof ascendingnumber,not in the orderthey occur.
4. The DTC$are memorizedin the EEPROM(non-volatile
memory).
Therefore,the memorizedDTCScannotbe canceledby disconnecting
the battery.Performthe specifiedproceduresto
erase.
Self-diagnosis
1. The self-diagnosis
can be classifieldinto thesefour catego.ies.
. Initialdiagnosis: Performedright afterthe enginestarts and untilthe ABS indicatorlight goesofJ
. ExceptABS control:Performedwhen the ABS is not functioning.
. DuringABS control:Performedwhen the ABS is functioning.
. Duringwarning;
Performedwhen the ABS indicatorlight is ON.
2. The systemperformsthe followingcontrolswhen a problemis detectedby the self-diagnosis.
! ABS indicatorlight ON
. Memory of DTC
. Modechangeto the "systemdown mode" or the "controlinhibitionmode".
ABS INDICATOR
LIGHT
MAIN
RELAY
SYSTEM
DOWN
ON
No
operatron
Drive
inhibition
Operation*1
CONTROL
INHIBITION
ON
No
opera on
Drive
inhibition
Operation
MODE
SOLENOID
VALVE
CPU
Restartcondition
lgnition
swatch
OFF* ON
Automatic
DTC
Memory
Memory
*1: ExceptCPUfailure
19-42
Kickbsck
1. The motor operateswhen the ABS is functioning,and the fluid in the reservoiris forcedout to the mastercylinder
causingkickbackat the brakepedal.
2.
The ABS controlunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosis.You may
hearthe faint solenoidvalveoperationsoundat this time, but it is normal.
Pump Motor
1. The pump motor operateswhen the ABS is functioning.
2.
You may hearthe faint operationsound

The ABS control unit checksthe pump motor operationduring acceleration.
at this time, but it is normal.
Brake Fluid Replacment/AirBleeding

1. Brakefluid replacement
and air bleedingproceduresare sameas conventionalbrakes.
Troubleshooting
1. The troubleshootingflowchartsexplainthe procedureson the assumptionthat the causeof the problemis still present and the ABS indicatorlight is still on.
followingthe flowchartwhen the ABS indicatorlight does not come on can resultin jncorNotethat troubleshooting
rectjudgment.
Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions
for troubleshooting.
is made at varioustimes such as the initialdiagnosis,exceptABS control,during ABS control,during
Self-diagnosis
acceleration,
during the specifiedvehiclespeed,etc. Therefore.the symptom cannot be checkedunlessthe check
conditionsmatchwith the problemconditions.
When the ABS indicatorlight does not come on duringthe test-drive,but the troubleshootingis performedbasedon
the DTC,checkfor the looseconnectors,poor contactof the terminals,etc,beforetroubleshooting.
Aftertroubleshooting,
erasethe DTCand test-drivethe car. Be surethat the ABS indicatorlight does not come on.
The connectorillustrationsshow the femaleconnectorswith a singleoutlineand the male connectorswith a double
ouI|tne.
The connectorterminalcavitiescontainingfemaleterminalsare alwaysnumberedby lookingat the connectorfrom
the wire side,and the cavitiescontainingmale terminalsare alwaysnumberedby lookingat the connectorfrom the
terminalside.
19-{f
TroubleCode{DTC}
Diagnostic
DiagnosticTroubleCode{DTG)Indication
NOTE:This operationcan also be carriedout with HondaPGMTester.
1.
side kickpanel
Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's
2,
Turn the ignitionswitchON (ll),but do not startthe engine

NOTE:Do not depressthe brakepedalwhen turningthe ignitionswitch.
3.
Recordthe blinkingfrequencyof the ABs indicatorlight.The blinkingfrequencyindicatesthe DTc.
4.
Turn the ignitionswitchOFF,and removethe SCSserviceconnector.

NOTE;The MalfunctionIndicatorLamp (MlL)will stay on after the engine is startedif the SCSserviceconnectoris
connected.
5.
Erasethe DTC.
condiiions for DTCindication

. The car is stoDDed.
. The SCSserviceconnectoris connectedbeforethe ignitionswitchis turned ON (ll).
. The brakepedalis released.
. The SCSserviceconnectorremainsconnectedduringthis procedure
The DTC indication stops and the ABS control unh executesthe software tunction if at least ono of the tollowing condi'
tions is satisfied,
. The car is not stopped.
. TheABScontrolunitreceivesthenormalsignal(whichisfortheABS controlunit)from a HondaPGMTester.
duringthis procedure.
. The SCSserviceconnectoris disconnected
u.s.A.
@
CANADA
ABS INDICATORLIGHT
o r c| 1 2
LIGHT
A8S INDICATOR
. 3sec.
8ff'?,1i'*"n
0. 3sc.
Sscond
x : Eulbchckmc'd
. When ignitionswitchis turnedON (ll),the ABS indicatorlight comeson to checkthe bulb. Do not count it as a DTC.
. The ABS controlunit can memorizeany numberof DTCs.
. The new DTCis not memorizedwhen the ABS controlunit has alreadymemorizedthe same DTC.
.lftheDTCisnotmemorized,theABSindicatorlightstaysONafteritgoesoftfor36seconds'
19-44
DTCErasure
,t
1.
side kickpanel.
Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's
2.
Depressthe brakepedal.
3.
Turn the ignitionswitch ON (ll) while holdingthe brakepedsl, but do not start the engine.The ABS indicatorlight
goes off after two seconds.
4.
Afterthe indicatorlight goesoft, roleasethe brakepedal.The indicatorlight comeson afterfour seconds.
5.
After the indicatorlight comes on. depressthe brakepedal again.The indicatorlight goes off again after four seconds.(the brakepedalis still depressed.)
6.
Afterthe indicatorlight goesoff, releasethe brakepedalagain,
7.
Afterfour seconds,the indicatorlight blinkstwice for 0.3secondand the DTCis erased.
8.
Confirmthe DTCindication,and checkthat the DTCwas erased.
NOTE; Always maintain these steps. lf you disconnectthe SCS service connector and/or fail to operate the brake pedal
accordingto the indicatorlight indication,the DTCwill not be erased.
Conditions tor DTCorasuro
. The car is stopped.
o The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON (ll).
. Thebrakepedalis depressedbeforethe ignitionswitchis turnedON {ll).
. The SCSserviceconnectorremainsconnectedduringthis procedure.
The DTCerasurs stops and ABS control unit xacutostho software tunction if 8t least ons of the following conditions is
satislid.
. The car is not stopped.
. The SCSserviceconnectoris disconnected
duringthis service,
. The ABS controlunit receivesthe normalsignal(whichisfortheABS controlunit)from a HondaPGMTester.
. The brakepedalis not operatedaccordingto the indicatorlight indication,
. The DTCerasureis finished.
0.3sec.
ABSINDICATOR
LIGHT
OFF
DEPRESS
BRAKEPEDAL
RELEASE
lqnilionswitch
oN ( )
19-45
)
Diagnostic
TroubleGode(DTCI
Chart
Symptom-to-System
OETECIIONTIMING
orc
s< xkY=
oTAGNOSTS/
SYMPTOM
>7
Z E zz
EXts
48"
16> xE
eP86az
PROBAELE
CAUSE
i:Y
Open in the power source circuitfo.the ABS indacatorlight
Elown ABS indicator lightbulb
Op6n in the ABS andicato.light drive circuit.
Shorrio powo. in th6 WALP ci.cuit
F6ultv ABS codtfol unit
Opsn in th lG2 cncuit
Opsn in lh +B circuit
Opsn and/or shon to body srcund in rhe WALP circuit
FaultYaBS controluoil
Op6n, shonto body sround and/orshonto pow6r inrhe whel
ABS indicEto. lisht do6s

nor come on whon ignirion
swirch is turnod on (ll)
NO
Drc
ON
ABS indacatorlight doos

not go ofi aftsrngine is
1l
Whe6l s6nsor (op6r'/shon
15
11
12
oNr
Faulty aBS contrclunit

RL
Shon io who6l sonsor (0)circuit inth whol scnsor (1)circuit
Faulty wheel sensor inst8ll6tion
oN'
16
(chipp6d pulssr ga/noise)
Faulty AgS controlunit
1E
RL
FR IN
F8.OUT
32
33
3,r
35
FLIN
Sol6noid {op6 sho.tio
ON
FL.OUT
opn, shonto body ground and/or shonlo powr inthe

Opsn in lhe COM circuit
Faulty AaS contrclunit
FA IN
RR-OUT
37
RT-IN
3a
RI.OUT
51
ON
Op.n in th6 motor poworsourco ci.cuit

Op6n in rh motor GNDcarcuit
Fautty AAS oontrol u.it
52
ON
53
ON
54
ON
6'I
ON
Open in lh COM, PMF and/or MCK circuit

Op6n.nd/or blown fus6 in th undeFhood ABS fus6/r6l6y box
Faulty pump motor rBlay

Fault ABS cont.ol unil
Shonto body ground in the PMB circuii
Shortto power in the pump motor power sou@ circuit
Faulty pump motor rcl.y
Faultv ABS cont.olunit
Opon, shorito body sround dncyor blown fuss in the B1 or 82
lgoilion voltago ilow voh'
Shonro body g.ound andlorshonto powor in rh COM circuit

Fsulty modulalor unit
F a ! l t v A B Sc o n t r o l u n i t
Conoction oltho 24v battery for engine start
Faulrycharuinq sy8tem
Opn in th6lG2 circuit
FaultvABS controlunit
Exteml feto sj can b lho c!u!(s) ol the preblem
F a u l t y A B Sc o n t r o l u n i t
81
ON
CPU
r: It DTCSt 1 18 (whool ssnsor codos) wsre detocredth6 last time th6 ca, w.s drav6n,the ABS indicator light will 3ray on unril the ignilion switch is tLrrnodoN (ll), 6nd the
conlrol unit confirms that th wheel sensoF arc OK,
19- 4 6
MANAGEMENT
CONDITIONFOR DETECTION
DURING
A8S CONTROL
EXCEPT
ASSCONTROL
FFER
TO
PAGE
19
19-50
Th ABS indicalor light comes on when vehicl is stopped and wheelsensora givn voltag does not
1952
The ABS indjcalorcomes on underrhe following conditions.

. When more than one ol wheels ar at a srandstill and the velocitY ofth. fasrsi wheel reachesa
. When the vl@ity ol the faste$ wheel reachesor erc@ds a givsn sp*d, and ifthere a.e som whels
whos vlo.ity is slowerthan a ce.lain parcnlaqeol the fastel wheelspd tor a given period.
. Whsn there aretempor.ry open orshort ctcuits of lhe wheel sensor, chippod pulsof gear, o. signal
The main relay repeats ON/OFFswitching aialltimes.
. When the main relav is ON, a shorttest pulse is sentto each valve.lfthere is some discrepancy,the
ABS indicalo. liqht comes on.
. Whn ti main r6lav is OFF,a shontest puls is soni ro each valve.lt lhe solenoid drive voltage is
oul of a given range, the ABS indicator light comes on.
. Th pump motor is aclivated once or twice afterevery ignition switch ON (ll)operation while lhe
vehicle accelerals,thon lhe moror drive vollag ischocked. Whan lhe voltags is abnormal,lhoABS
indi@ror light comes on.
.AfterABS conrrol comglerion, lhe motorswirchgd is ofiand the main CPU chects the motor drivo
voltaqe. Whn rhe voltaqe is abno.msl,tho ABS indicator lightcomas on
During an active mororresl or AaS cont.ol, the main CPU checksthe supply voltaqe to lhe motor.
W h e n t h e v o l t a g i s a b n o r m a l , l h e A B Si n d i c a r o lri g h t c o m e so n .
lf the moro. driv voltage indicates motor operarion when lhe main CPU does notswilch the motor
oN, rh ABS indicalorcomes on.
. When a solenoid valve failure is detected,rhe CPU checksrhe vottag ofrhe main relay output lfth
vottage is lowe.than a given vohage, the AgS indicator lighl comoson.
. The main relay rpeats ON/oFF switching atalltims- whon the main relay is oft, a shon test pulse
is sent lo each valve. The CPU monito.s tho relerencevoltage, lflh vollage is out ot 3 given rang.
the aBs indicator liohr comes on.
Whenrhe isnition voltaoe is lower or higherthan a given voltage, the CPU inhibirs ABS contoland
swirches offrhe main relay, and the ABS indicator lighr comes on. when the ignition vollage recovers
lo no.mal r.nge, ABS inhibition is canceled.
19,52
1954
'19,56
19-56
19-56
t9 59
l9-60
The main CPU.nd sub CPU check each other under certsin condirions. when the CPUSdetectthe lol_
lowing d iscrepansies,lhe ABS indicaror light comes on.
'When there is discrepancyin thecalculaled wheelspeed velocitylhatconiinuesfo. morethan a given
. Whnrh6re is discrepancyin the phase informarion thatcontinues for morethan a givon priod
. When thors is discreoancyin the calculstedconnolparameter.
'when the warch dos control pulse is faalslor a given period.. whsn rho checksum ofthe ROM is tails
.When there is discrepancyin ths dara radins and wrilins procadu.e of FAM.
1 96 1
19-47
Troubleshooting
ABSIndicatorLight DoesNot ComeOn
The ABS indicator light does not come on when ignhion switch is turned ON {ll)
Th ABS indicator light doos not
come on whn ignhion switch is
turned ON llll.
check the MEIER (7.5A) luse in

the under-dash
fuse/relay
box.
NOTE:All indicatorlights exceptthe charging systemlight will not come on when the
METER17.5A) fuse is blown.
Boplacothe tu3e and recheck.

YES
NOTE:
Reinstallthe
fuse it it is OK.
GAUGEASSEMBLY5P CONNECTOR
Chocklor .n open in tho lcl circuit:

1. Disconnect
the gauge assembly 5P connector.
the gauge assembly5P connectortermin6l No. 5 and
body ground.
IG1IYEL)
. Repair opcn in the wira
between the METER 17.5 Al
tus and gauga aitombly,
. Rookca lhe undor-dr3hfu3./
rolay box. (Opcn circuit insido
tho box.
c h e c k t h e A B s i n d i c a t o rl i g h t
bulb in the gaugeassembly.
Checklor a shon to oower in tho

WALPcircuit:
Measurethe voltagebeNveen
the
g a u g e a s s e m b l y5 P c o nn e c t o r
ls there batteryvohage?
(To page19-49|
19-48
Ropairshort to powo. in the wiro

between the gaugo a33omblv
and ABS comrol unit.
(Frompage19-48)
Checktho gaugo .$smbly:

2. Connctthe gauge assembly
5Pconnector,
3. Connectthe terminalNo. 3 to
b o d y g r o u n dw i t h a j u m p e r
GAUGEASSEMBLY5P CONNECTOF
Doesthe ABS ind;cator

lightcomeon?
Roplacethe ABS indic.tor light

drive cilcuit in tha grugg a33emblv.
.Ropair opon in tho wire

botwaen the g.uge ei3ambly
and body ground.
. Ropair pool ground lc,lo1.
cl{)2t.
19-49
Troubleshooting
ABSIndicatorLight DoesNot Go Off
Thc ABS indicator light does not 90 off after the 6ngine is slarted.
-
With engine.unning, ABS

indic.tor light is ON.
With the SCS srvice connector connocted (s6o pago 194,11,
no DTCis indicrted.
check the RRDEFRLY(7.5A) luse

in the under-dashfuse/relaybox.
Raolacotho fuso and Jachock.

YES
NOTE:Reinstallthe
fuse it it is OK.
Checkthe ABS +B (20 A) fuse in

the under-hoodfuse/relaybox.
Replacetho tuse and rech6ck.

YES
fuse if it is oK.
NOTE: Roinstallthe
ABS CONTROLUNIT 26P CONNECTOR

IG2 {BLK/BLU}
Checkfor an opcn in the lG2 circuh:

the ABS controlunit 26Pconn e c t o rt e r m i n a lN o . 3 a n d
body ground.
Checkfor .n open in the Bl and

82 ci.cuit:
M e a s u r et h e v o l t a g e b e t w e e n
bodygroundand terminalsNo. 14
and No. 15individually.
{To page19-51)
19-50
WIRESID OF FEMAI-ETERMINALS
Ropairopon in tha wira bstwaan

the RR DEF RLY 17.5Al tu30 rnd
ABS contrcl unh,
ABS CONTROLUNIT 26PCONNECTOR
81 IWHT/GRNI
Reprir opon in the wir6 brtwaan

the ABS +B 120Al furo snd ABS
control unh.
WIR SIDEOF FEMALETERMINALS
(Frompage19 50)

Checkfor a short to bodY ground
in the WALPcircuit:
2 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pand gaugeassemblY
5Pconnectors.
the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d
bodyground.
WALPIBLU/REOI
Repairshor! lo body ground in

the wire botween th ABS con'
trol unit and gauge assemblY.
Check the ABS control unat:

1. Connect the ABS control unit
22Pconnector.
2 . T u r n t h e i g n i t a o ns w i t c h O N ( l l )
3. Measure the voltage between
the ABS control unit 22P con
nector terminal No. 7 and
body ground.
ABS CONTROLUNIT 22PCONNECTOB

WALP (BLU/REO)
Checklor an open in th GND2
circuit:
1. Connectthe ABS controlunit
26PconnectorterminalNo 16
to body groundwith a jumper
the ABS controlunit 22Pcon
n e c t o rt e r m i n a lN o 7 a n d
body ground.
ls there batteryvoltageT

t
2 3 4
1 4 t 5 1 61 7
6 ,/8
/ ' , 1 s./ 21
I r0
12113
26
JUMPERGND2(8LK)
WIRE
. Repairopen in the wire between

the ABS control unit and bodY
ground.
. Repair poor ground {Gilo1,
G402).
Checkfor loose ABS control unit

connectors, It necessary.substitute a known-good ABS control
unit and recheck.
Chckfor an open in the WALP
circuit;
Measurethe voltagebetweenthe
g au g e a s s e m b l y5 P c o n n e c t o r
GAUGEASSEMELY5P CONNECTOR
Repairopen in th wire betwoen

the ABS control unit and gauge
assemblv.
Replacethe ABS indicator light

driv6 ci.cuit in the gauge assem'
blv.
19-51
Troubleshooting
Wheel Sensor
DiagnosticTroubleCode(DTCI11-18:WheelSensorDiagnosis
NOTE:TheABS indicatorlightcomeson when onlythe drivewheelsareturning.signaldisturbance
is detected.
etc.Therefore,
test-drivethe car at a speed of 12 mph (20 km/h) or more after turning the ignition switch from OFFto ON 0l). and if the ABS
indicatorlight does not come on, the systemis OK.
-
With tho ignition switch ON

llll, ABS indicltor lisht does
not go off.
After dliving, ABS indicator
light comes on.
With the SCS serviceconnector connocted ls page 1$501,
DTCa11-18ar indicated.
Checkthe wh6ol sensorcircuit:

l Disconnectthe ABS control
unit 26Pconnector.
betweenthe appropriatewheel
sensor10)and (1)circuittermi-
ls the resistanceOK?
/Front:750 1050o/20.c,68"F\
850- 1150020'C,68"F/
lRear.
RRO
IELU/YELI
AppropriateTerminal
(O)SIDE
(1)SIDE
1 1 ,l 2 ( R i g h r - l r o n t ) N o . 8 : F R o N o . 2 1 :F R l
DTC
13, 14 (Left-front)
N o 1 0 : F L o N o . 2 3 :F L l
1 5 ,1 6( R i s h t - r e a f ) No.4: RBo N o . 1 7 :R R 1
'17,
18 {Left-rear)
N o . 6 : R L o N o . 1 9 :R L ' l
. Roplir opcn in the l0l or ('l) circuit wire, or ahort to tho (0, circuit wir. in thc (1) circuit wire
betwoon tha ABS control unit
and appropriatawheal son3or.
' Roplacetho approprirto wh.el
3an30r,
Checktor a shon to body ground

in the wheel sensorcircuit:
ABS control unit 26P connector
appropriatewheel sensor(0) cir
cuitterminal*and body ground.
ls therecontinuity?
Checktor a short to power in the

wheel sensorcircuitl
1. Reconnect
the ABScontrolunit
26Pconnector.
2. Startthe engine.
the ABS controlunit 26Pconnectorappropriate
wheelsen
s o r ( 0 ) c i r c u i tt e r m i n a l a n d
body ground.
ls there4 V or more?
' Rspair 3hort to body ground in

the l0) or {11 circuit wire
between the ABS control unit
and appropriatowheel snsor,
. Replacethe appropiiate wheel
NOTE:Judgementvaluetor short to
Repair shon to powor in the (01

or {l) circuit wiro btween the
ABS control unit and appropriate
NO
NOTE
. Normalvoltage:Approx.2 V
. 0 V: Replace
the ABScontrolunit.
. 4 V or more indicatesa shortto power.
(To page 19-53)
19-52
RRl {GRN/YELI
RL1ILT 8LU)
FLl {GRN/ORNI
FRl {GRN/BLKI
(Frompage19-52)
Checkfor chippedpulsergear.
Ropl.ce the driverhrft or hub

unit. (Chippedpulst goerl
DTC 11. 13. 15, 17: Roplscothe

ABS control unit,
DTC 12, 1ir, 16, 't8: The ABS control unit may have dotected sig'
nil dbturbanco.
19-53
Troubleshooting
Solenoid
DiagnosticTroubleCode{DTC)31-38:SolenoidDiagnosis
-

FL-OUT{YEL/BLK}
With the ignition switch ON

(ll). ABS indicatorlight does
not go off, or ABS ifldicator
light comes on while ABS is
tunctioning.
With the SCS sewice connector connoctodlsoepage1$50).
DTCS31-38 are indicated.
DTC
Terminal
No.1
34i FL-OUT
22P
22P
22P
22P
35:RR-lN
26P
No. 13
36: RR-OUT
22P
No.21
37iRL'IN
26P
No.25
38:RL-OUT
26P
No.12
3 1 : F Rl N
32:FR-OUT
3 3 r F Ll N
Chocktor a short to powr in the

solenoidcircuit:
unit 22Pand 26Pconnectors.
2. Startthe engine.
the ABScontrolunitconnector
a p p r o p r i a t es o l e n o i dc i r c u i t
terminal*and bodyground.
No. 12
N o .1 1
No.10
ABS CONTROLUNIT26PCONNECTOR
RL.OUTIYEL}
R 6 p a i rs h o r t l o p o w e r i n t h e
appropriate solenoid circuit wire
between the ABS control unit
and modulator unh,
check lor a 3hort to bodY ground
in the solenoid circuili
Check {or continuity betlveen the
appropriate solenoid circuit termi
nal* and body groLrnd.
wlRE SIDEOF FEMALETERMINALS
. Repairshon to body ground in

the appropriatosolenoid circuit
wire between tho ABS control
unit end modulator unit.
. Replacethe inodulator unit.
oTc
Checkthe ABS control unit:
2. Connectthe ABS controlunh
22Pand 26Pconnectors.
the ABS controlunit 26Pconnectorappropriate
COMcircuit
terminal**and bodyground.
ls thereapprox.3 V?
YES
(Topagel9-55)
19-54
Terminal
3 1 :F R I N
No. 2: SCOM
32:FR-OUT
No.2:SCOM
33:FL-lN
No. 1: PCO[,
34:FL-OUT
No. l: PCOM
3 5 iR Rl N
No. 1:PCOM
36:RR'OUT
No. 1: PCO[,
3 7 : R LI N
No. 2: SCOM
38:RL-OUT
No. 2: SCOM
Chocklor loose ABS control unit

conneclors. lf oecessary,substitule a known-good ABS control
unit and recheck.
PCOM
(GRN/WHTI
RL.OUT{YELI
{Frompage19-54)
DTC
3 l : F Rl N
32:FROUT
33: FL]N
34i FL-OUT
35: RR lN
Checkfor an open in th. solenoid

circuit:
ABS control unit connedor aPPro_
priatesolenoidcircuitterminal*
and bodyground.
ls therespprox.3V?
36:RROUT
37:RLIN
38:RL.OUT
Appropnale
Connector
22P
22P
22P
22P
26P
22P
26P
26P
Appropriate
Terminal
FL.OUTIYEL/BLK)
No. l
No. 12
No. 1'l
No.10
No. 13
No.21
N o .2 5
No.12
. Repair open in the appropriate

COM circuit wire betwen the
ABS cortrol unit and modulator
unit.
. Repair open in the applopriate
solenoidcircuil wite bstween
the ABS control unit rnd modulator unit.
. ReDlacethe modulato. unit.
RL.OUT(YEL)
Checkfor looso ABS control unit

connostors, lf nocGaary, sub3ti'
tute 6 known-good ABS control
unit and recheck.
19-55
Troubleshooting
ABS PumpMotor
DiagnoeticTrouble Cod6 (DTC)51-53: ABS Pump Motor Diagnosis
-
With rhe ignition 3wilch ON

{lll, ABS indic.tor light do..
not 9o ott.
With the SCS srvice conn.ctor connoc{d 13pegg 19-50},
DTCa5l-53 .rc indlstod.
checktheMTRcHEcK0.5 A)tuse.
Rcplacothe tus6 and r6ch6ck.

yES
NOTE:Reinstall
the fuse it it is OK.
N O T E : S h o r t t h e P M Rt e r m a n a t o b o d y
groundfor a moment,and recheckthe fuse.
lf the fuse is blown, checkfor a short to body
groundin the MCKcircuit.

l
l4
,/117
1 8 / 1 0t l
1 9 1 , / 21
PMRIYEL/RED}
I JUMPER
I wrRE
Repl.co the fuso and .scheck.
YES
NOTE:Reinstall
thefuseif it is OK.
N O T E : S h o r t t h e P M Rt e r m i n a l t o b o d y
groundtor a moment,and recheckthe tuse.
lf the fuse is blown, checkfor a shon to body
ground in the wire be&veenthe underhood
ABS tuse/relaybox and pump motor.
Replacctho pump motor .alay.
Check th pump motor powet

sourcecircuit:
Doesthe pump motor operate?
Check tor a short to powoJ in tho

pump motot powar sourcocirc{it:
Removethe pump motor relay.
Doesthe pump motor operate?
Chocktor loose ABS control unit

connector!. lf nece$sry, subslitute a known-good A8S control
unit and recheck.
(Topage19-57)
19-56
Repair3hort to powar in tha wile

botwoon the under-hood ABS
tu3o/rolay box and ABS pump
motot.
T
I
ABS
UNDER-HOOD
FUSE/RELAYBOX
{Frompage19-56)
JUMPERWIRE
Checkthe pump motor circ!it:
1. Removethe pumpmotorrelay
3. Connectthe PUmPmotorrelay
connector+B and MOTORter_
minalswith a jumperwire for
a momenl.
Doesthe pump motoroperate?
Checkfor an open in the PumP

motor +B circuit:
1. Turnthe iOnitionswitchOFF.
2 . D i s c o n n e ct th e p u m p m o t o r
2P connector.
4. Connectthe pump motorrelay
connector+B and MOTORtet'
minalswith a iumPerwire.
the pump motor 2P connector
terminalNo. l and bodY
ground.
ls there baftery voltage?
Check the pump molor opera'

tion:
Connectthe battery(+)termanalto
the pump motor 2P connectorter
minaN
l o . ' 1a, n dt h e( ) t e r m i n a l t o
theterminalNo.2 for a moment.
Doesthe pump motor oPerate?
Checkfor a short to body ground

in the PMRcircuit:
unit 22Pconnector.
t e r m i n a lN o . 1 9 a n d b o d y
ground.
ls lhere continuity?
Repah open in the wita between

the pump motor rnd bodYground,
or poor ground (G/o31.
Repairshort to body ground in

th6 wire betweenlhe undrh o o d A B S t u s e / r e l a yb o x a n d
ABS control unit.
TERMINAL
TERMINA.
PUMP MOTOR2P CONNECTOR

MOTOR+B (WHTl,S
rv)
Y
TERMINALS
WIRESIDEOFFEMALE
Repairopen in the wire betwoen
the under-hoodABS fus/relav
box and pump motor.
MOTOR+B iRED)
MOTORGNDIBLKI
Beolacethe modulator unit.

{Fallty pump motorl
WIRESIDEOF FEMALETEFMINALS
(cont'd)
(To page19-58)
19-57
Troubleshooting
ABSPumpMotor (cont'dl
(Frompage19-57)
Check loi .n open in the PCOM

circuit:
1. Turnthe agnitionswitchOFF.
2 . R e c o n n e ctth e A B S c o n t r o l
unit 22Pconnector.
5. Measurethe vokagebetween
t h e p u m p m o t o r r e l a yc o n n e c t o r P C OM t e r m i n a l a n d
body ground.
ls thereapprox.3 V2
) t-1E
r.l
Bopair open in the wire betwoen

tha under-hoodABS tuse/reley
box and ABS cont.ol unit.
12 /
Checktor loose ABS control unit

connectors, It necessary,substituto a known-good ABS control
un;t and recheck.
14
11
10 t l
21 22
PMR{YEL/RED)
Ropairopen in the wire betwaen

the under-hoodABS fuse/relay
box and ABS control unit.
Check tor an open in the MCK

circuit:
2 . D i s c o n n e ctth e S C S s e r v i c e
connector.
4. Measurethe voltage betlveen
the ABS controlunit 22Pcon
n e c t o rt e r m i n a l N o . 1 7 a n d
body ground while connecting the pump motor relay
connector+B and MOTORter
minal with a jumper wire for
moment.
ABS CONTROI-UNIT 22PCONNECTOR
Chocktor an open in ihe PMRcircuit:

terminalNo. 19and bodyground.
ls thereapprox.3V?
tr
Repairopen in the wire betwoen

the under-hoodABS fuso/rl.y
box and ABS control unit.
WIRESIDEOF FEMALEIERMINALS
Main Relay
DiagnosticTrouble Code (DTC)54: Main RlayDisgnosis
-

{ll}, ABs indicator light do.s
not go off.
With the SCS 3oruics connector conn.ctod h6e Psgc 19601,
DTCg b indcst d.
check the ABs +B (20A) fuse.
Raplac!lha fuso snd lachock.
YES
N O T E :R e i n s t a l l
the fuse if it is OK.
Ch6ck for .n open in thc 81, 82

circuh:
M e a s u r et h e v o l t a g e b e t w e e n
body ground and the ABS control
unit 26Pconnectorterminal No. 14
and No.15individually.
B1
(WHT/GRNI
Ropairopen in th. wi.o bdtw.en

tho ABS control unit and under'
hood ABS tuse/rol.y box.
Checklor a ihon to body Itound

in the PMRcitcuit:
2, Removethepump motor relay.
3. Disconnectthe ABS control
unit 22Pconnector.
ground.
ls therecontinuity?
Checkfor a short lo bodY ground

in the PCOM,SCOMcilcuit:
unit 26Pconnector.
body ground and the ABS control unit 26PterminalsNo l
andNo.2 individually.
ls therecontinuity?
Ropair short to bodY ground in

tho wiro botwean th. undel'
hood ABS fu3e/.ehY box tnd
ABS control unil.
PCOM
SCOM
{GRN/WIIT) {BLK/WHTI
. Repairshort to bodY ground in

the PCOM circuit wirs bctween
tho ABS control unit and undor_
hood ABS t6o/r.lay box.
. Rpair3hon lo bodY ground in
th6 PCOMoJ SCOMcilcuit wiro
botwoen the ABS control unit
end modulator unit.
' R o p l a c et h e m o d u l t t o r u n i t .
(Short circuh in3ideth6 unitl
t6 17
(Topage19-60)
(cont'd)
19-59
Troubleshooting
Main Relay(cont'd)
(Frompage19,59)
PCOM
{GRN/WHT}
Checklor a rhort to power in the
PCOM,SCOMcircuit:
1. Stanthe engine.
body groundand ABS control
unit 26P connectorterminals
No. l and No.2 individualty.
ls there8 V or more?
Turn the ignhion switch OFFand

conn.ct thc SGS sorvics connoclo.. Then tuJn the ignition rwitch
ON lll) rnd m.rsuro th. voltago
betwcen the PCOM and SCOM
tt.minals and body ground. lf
there i3 0 V, rephco the ABS|control unit.
19-60
. Rcp.i. 3hort to powor in the

PCOM circuh wirc bqtwaen tho
ABS control unit and undoahood ABS fuso/relaybor.
. RopaiJshorl to powor in th6
PCOM or SCOM circuit wir.
botwoen tha ABS control unit
and modulato. unit.
. Repl.co the modulator unit.
lshorl to powol inside tho unitl
NOTE: 8 V or more indicatesa short to
lgnition Voltage
DiagnosticTrouble Code {DTC)61: lgnition Voltage Diagnosis
-
With the engine running, ABS

indic.lor light is ON.
With the SCS serviceconnoctor connected (saepage 19-501,
OTC61 is indicded.
Problemve.ification:
1. Erasethe DTC.
2. Startthe engine.
3. Make sure that the ABS indi
catorlight comeson and DTC
61 is indicated.
ls DTC61 indicated?
The swlern is OK at this time.

Chcckthe lG2 circuit:
Me6surethe voltagebetweenthe
ls there18V or above?
IG2IBLK/BLU}
ff the vohage is 0 V, check tor an

ooenin the lG2circuit.
lf there h 12 - 17 V, substitute a
known-goodABS control unit rnd
rchck.
9-61
Troubleshooting
CentralProcessingUnit (CPU)
DiagnosticTroubl Code {DTC}81: CPU Diagnosis
-

(ll), ABS indicato. light doos
not go off.
Wrth the SCS srvice connector connoctod lsee page 19601,
DTC81 i! indieted.
Ploblem v6dtication:
1. Erasethe DTC.
2. Test-drivetho vehicle.
3. M6ke sure that the ABS indicator light comes on and DTC
81 is indicated.
RopbcGtho ABS control unil.
The syitom b OK rt this time.
19-62
ModulatorUnit
CAUTION:
. Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
. Take care not to damage or deform the brake lines during lemoval and installation.
. To Drevent the brake fluid from flowing, plug and cover the hose ends and ioints with . shop towal or equivalent
material.
NOTE:Tightenthe flare nutsto 15 N.m ( 1.5kgf m, 11 lbf'ft).
Removal
1.
Disconnect
the modulatorunit 10Pand pump motor 2P connectors
2.
the brakelines,then removethe modulatorunit

Disconnect
lnstallation
1.
Installthe modulatorunit,then connectthe brakelines.
2.
Connectthe modulatorunit
3.
Bleedthe brakesystem.
4.
Startthe engine,and checkthat the ABS indicatorlight goesoff.
'l0Pand pump motor 2P connectors
PUMPMOTOR
2P CONNECTOR
ffi
t'
TORUNIT
'%
19-63
ABSControlUnit
Replacement
1.
Removethe right side kickpanel.
2.
Disconnect
the ABS controlunit connectors.
3.
4.
Pulsers/Wheel
Sensors
Inspection
1.
Checkthe front and rear pulserfor chippedor damagedteeth.
2.
Removethe ABS controlunit.
Measurethe air gap betweenthe wheel sensorand

pulserall the way aroundwhiie rotatingthe pulser.
Installthe ABS control unit in the reverseorder of

removal.
Standard:0.4- 1.0mm (0.02- 0,04inl

N O T E : l f t h e g a p e x c e e d s1 . 0 m m ( 0 . 0 4i n ) , t h e
p r o b a b i l i t yi s a d i s t o r t e ds u s p e n s i o na r m w h i c h
shouldbe replaced.
Front
0.4- 1.0mm
{0.02- 0.04inl
CONNECTORS
0.4- 1.0mm
(0.02- 0.04in)
19-64
Sensor
Pulsers/Wheel
WheelSensorReplacement
NOTE:
. Be carefulwhen installingthe sensorsto avoidtwistingthe wires.
. The torquevalueof the bolts is at 9.8 N'm (1.0kgf m, 7 lbift)
Front
WHEELSENSOR
1.
2.
Removethe hub bearingunit (seesection18).

Removethe four backingplatebolts
to disconnectthe
pull the backingplateawayfrom the trailingarm, then removethe wheelsensor.lt is not necessary
b r a k el i n e .
''-----_l'19-65
Body ('96 model)

Doors
FrontDoorIndex(4D)
RearDoorIndex(4D)
DoorfndexlzDl3Dl
Emblems
fnstallation
Exterior
.-'2O-2
..'..20-8
."""20'14
20'118
. .0. - 9 3
G o m p o n e n Lt o c a t i o nI n d e x ' . . . . . . . " . . 2
2O'12O
*FrameRepairGhart ........,.
*lnterior
ComponentLocationIndex....".'.....'.20-58
Mirrors
...."...'."...'..". " "' 20-24
MirrorReplacement
""'.'.""..' 20-25
MirrorHofderReplacement
"."""'."". 20-25
MirrorCoverReplacement
'..-""" 20'25
RearviewMirrorReplacement
Moonroof
..'......'.'.....'.'.20'50
l n d e x, . . . . . . . . .
and Latch/
OpenerCable/Opener
WiperandWasher
". 20-1oj
ComponentLocationIndex..'.......'.
Seatsand SeatBelts
"".20'73
ComponentLocationIndex..'..'....
."' 20-119
Sub-frame
RearWindowand OuarterGlass
Windshield,
20'26
'..'.".'."""'.'.'
fndex......'.'.
...""."20-123
Body ('97 modell .............
Body ('98 model) ......... .....'....20-131
Doors
FrontDoor Index
ilD:
SASHTRIM
WEATHERSTRIP
OETENT
ROO
o obn
fu-P
'aer7a
[q-/
POWERWINDOW
SWITCH
DOOR
Adjustment,page
20-23
DOOR
PROTECTOR
c
\f
R--2''
7t'<
DOOR
GRIP
COVER
DOOR
GRIP
r-\
-."v
"rrd*r,
COVER
20-2
ef'
DOOBPOCKET
GLASS
Replacement,
page 20'6
Adjustment,
page 20-20
CENTERLOWER
CHANNEL
LOCKROO
PROTECTOR
CYLINOER
PROTECTOR
REGULATOR
Replacement,
pa9e20-6
.^@
\lzl
dD
ô
e'
STRIKER
Adjustment,
page20-23
\ t l
\
\".ou.oro,
LOCK
CYLINDEB
RETAINER
CLIP
INNER HANOLE ROD
A
(
*
V*#a
/
CYLINDER
ROD
HANOLE
R e p l a c e m e n t ,p a g e 2 0 - 5
POWERDOOR
LOCKSWITCH
(driver'sonly)
LATCH
PROTECTOR
-w fi6*
$@
LATCH
Replacement,
20-6
INNER
HANDLE
20-3
Doors
Door PanelRePlacement
NOTE:Takecarenot to scratchthe door paneland other
pans.
1.
Releasethe clips that hold the door panel Remove

the door panelby pullingit upward
4.
NOTE:Removethe door panelwith as littiebending

as possibleto avoidcreasingor breakingit
Remove:
. Innerhandle(seePage20-3)
. Mirror mount coverpanel(seepage20'24l'
ll applicable, remove the regulator handle by pulling
the clip out with a wire hook
TORHANDLE
WIREHOOK
95 mm 13.74inl
.L
12 mm
{0.47in} T-
TRIM PAD
REMOVER
(Commercially
available)
Snap-on
,
L,-#4171,or
1mm
equivalent
10.04in)
/t4-
./zn
nu"
45 mm
{1.77inl
>: Cliplocations,5
3.
Removethe door grip coverand speakercover,then

removethe screws.
5
>: Sctewlocations,
J:lt{ [ i
POWERWINDOW
ltN i
swlTcH
cL,P l\
REMoVERi I
-E/
i
i
D i s c o n n e c tt h e
s p e a k e rc o n n e c l o r '
5.
20-4
Installationis the reverseof the removalprocedure'
OuterHandleReplacement
4.
NOTE:Raisethe glassfully.
1.
2.
Remove:
a Door panel
. Plasticcover {see page 20-21
Pull out the outer handle.Pry the outer handle rod

out of its joint usingdiagonalcutters.
NOTE:
. To easereassembly,
note location@ ofthe outer
it.
handlerod on the joint beforedisconnecting
. Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
door.
Pullout the retainerclip.

CYLINDERPROTECTOR
OUTERHANDLE
ROD
l
BUSHING
Replace.
DIAGONAL
CUTTERS
,1rl'.
LOCKCYLINDER
RETAINER
CLIP
Removethe bolts,then removethe cylinderprotector, lockcylinderand outer handle.
>: Bolt locations,2
r$\'*
\Af@
6 x 1.0mm
g.aN.mtr.otsr.m,
?.2 tbI.ft)
-_-_--/
I
i
I
)
CYLINDER
SHOP
TOWEL
5,
lnstallationis the reverseof the removalprocedure,

NOTEj Makesurethe door locksand opensproperly.
LOCKCYLINDER
ROD
CYLINOER
20-5
Doors
LatchReplacement
Replacement
Glass/Regulator
' t . Remove:
. Door panel(seepage20-4)
. Plasticcover(seepage20-2)
1.
2.
3.
Remove:
. Plasticcover(seepage20-21
. Outerhandle(seepage20-5)
Removethe bolt, then move the center lower channel
forward.
Disconnectthe connector,and detachthe harness
c l i p f r o m t h e d o o r . R e m o v et h e l a t c ht h r o u g ht h e
hole in the door.
Carefullymove the glassuntil you can seethe bolts,

t h e n r e m o v et h e m . C a r e t u l l yp u l l t h e g l a s so u t
throughthe window slot.
NOTE:Takecarenot to dropthe glassinsidethe door.
>: Boltlocations.
2
NOTE:Takecare not to bend the inner handlerod,

outer handlerod, cylinderrod and lock rod.
>: Screwlocations,3
GLASS
LOCKROD
REGULATOR
6x1.0mm
I N.m {0.8kgf.m,
6 tbf.ft)
4.
Installationis the reverseof the removalprocedure.

NOTE:
. M a k e s u r e t h e i n n e r h a n d l erod and connector
are connectedproperly.
. lvlakesurethe door locksand opens properly.
20-6
3.

c l i p ,t h e n r e m o v et h e r e g u l a t otrh r o u g ht h e h o l e i n
t h ed o o r .
4.
Greaseall the slidingsurfacesof the regulatorwhere

shown.
>: Bolt locations

8>,3
a>,4
6x1.0mm
6x1.0mm
REGULATOR
REGULATOR
5.
MOTOR
Installationis the reverseof the removalprocedure

NOTE:Rollthe glassup and down to see if it moves
freelywithout binding.Also make sure that there is
no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjust the positionof
(seepage20-20).
the glassas necessary
I
l
a: Nut locations,3
AR
@
i
6x1.0mm
rgt -,
e ru.- 1o.a
6rbf ft)
L-r
REGULATOR
(Manualtype)
20-7
Doors
RearDoorIndex
4D:
OUTER
WEATHERSTRIP
INNER
WEATHERSTRIP
...-\\\
iD\\
\b\
DOOR
Adjustment,
page20-23
fu4 R'r"'
\\
S"'P
Y-*^
HINGE
oooR
PROTECTOR
20-8
n
(2
REARCHANNEL\
\
\4\
\ \
\\
t\
Qll
a@
lll
I jl
"ro."*o""..*
coLLAB
J I
*-@\l'
OUTERHANOLE
page20-11
Replacement,
REGULATOR
HANDLE \
>-9
\n'
POWERWINDOW
MOTOR
LOCKROD
PROTECTOR
Replacement,
page20-12
POWERDOOR
LOCKACTUATOR
INNER
HANDLE
ROD
20-9
Doors
Door PanelReplacement
NOTEjTakecarenot to scratchthe door paneland other
parts.
3.
'1. Remove:
. Innerhandle{seepage20-9)
. Regulatorhandle(seepage20-4)
2.
Releasethe clips that hold the door panel.Remove

the door panelby pullingit upward,
NOTE:Removethe door panel with as little bending as possibleto avoid creasingor breakingit.
Removethe door grip cover,then removethe screws.
.L
1 2m m
{0.47in) T-
TRIM PAD
REMOVER
(Commercially
available)
Snap-on
t
./t '
44177,ol
1fim
-i-,.--t
6quivalent
I
,
L
10.04inl
45 mm
{1.77inl
/={
, cs"
I
>: Cliplocalions,7
4.
\20-10
e--'
Installationis the reverseof the removalorocedure.
OuterHandleReplacement
4.
'1. Remove:
. Door panel
2.
NOTE:
note location@ of the outer
it.
ooor.
Removethe screws.
>r Screwlocations,
3
6x1.0mm
6 N.m (0.6kgt m,
4 rbf.ft)
Pull out the outer handle.Pry the outer handlerod

I
)
BUSHING
Replace.
.41
:'"*',Yt:
DIAGONAL
ft_-..p
^\
r r---t--J-
4 t---\--pS\.. \]
\-V
OUTER
HANDLE
ROD
3.
Move the latch down, and remove the bolts.

>: Bolt locations,2
6@.1
----,!Sl/ s't.o--
g.a N.m
)
11.okd m,7 .2 tbt'ft| /
I
i
SHOPTOWEL
5.
Installationis the reverseof the removalDrocedure.

NOTE:Makesurethe door locksand opensproperly.
20-11
Doors
LatchReplacement
RePlacement
Glass/Regulator
1 . Remove:
. Plasticcover{seepage20-8)
1. Remove:
r Door panel(seepage20-10)
. Plasticcover{seePage20-8)
2.
2.
Removethe iockcrankand cliP.

>: Screwlocation,1
Carefullymove the glassuntil you can seethe bolts,

then removethem.
>:Clip location,1
2
>: Boltlocations,
fi s'r.o-@
-
9.8N m tl.o kgtm, J

L2 tbl.tlt , ,,-----/,/
\
Removethe rearchannelcollar.
NOTE:Takecare not to bendthe lock rod and inner
handlerod.
REARCI{ANNEL
LATCH
3.
\i
C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d
screwtrom the rearchannel,then removethe glass
trom the rearchannel.
NOTE:Takecarenotto dropthe glassinsidethe door.
>: Bolt.screwlocations
A'1
t't
II
@@!iT,--,,-,
,J @
6w.ftt
_-,/./ _
6x1.0mm
INm(0.8kgf.m,
6 tbf.ft)
D i s c o n n e c tt h e
connector.
4.
Removethe latchthroughthe hole in the door.
5.

NOTE: Makesurethe door locksand opensproperly.
20-12
B, 1
,,<\
t"<1'
Fllt--n]nTl
6r1.0mm
I N.m 10.8kgt m,6lbf ftl '
,/
4.
Caretully remove the glass from the window slot.
CLIP
Greaseall the slidingsurtacesof the regulatorwhere

shown.
NOTE:
a lf necessary,remove the power window motor
from the regulator.
. Beforeremovingthe powerwindow motor,scribe
a line acrossthe sectorgearand regulator.
REAR
CHANNEL
COLLAR
5.
SECTORGEAR
B
Removethe outer molding,then removethe quarter glass.
REGULATOF
OUARTER
wtNDow
POWER
>: Bolt locations.3
wtNDow
MOTOR
6x1.0mm
7 N.ml0.7kgf.m,
5 tbf.ft)
6.
Disconnectthe connector,and detachthe h a r n e s s

clip, then removethe regulatorthrough the h o l e i n
the door.
>: Boli locations
a>,2
6 x 'l.0mm
I
|
El sN-{o.a*gr.m,
o rrr.rt
ff
B> . 2
6x1.0mm
8Nmlo.8ksfm,
6 tbtftt
)
REGULATOR
8.
lnstallationis the reverseof the removalorocedure.

NOTE:Rollthe glassup and down to see if it moves
freely without binding.Also make sure that there is
no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjustthe positionof
the glassas necessary(seepage20-20).
20-13
Doors
DoorIndex
2Dl3Dl
GLASSGUIDE
CLIP
sAsH
S 61P \ \ 1
\
OUTER
WEATHERSTRIP
\ T a_\
\
:
h\>l\\-,-'\
9,, i
<an
ffi*'"o'
\i
ft{351'"'
{h
tuf
-re
".o.*.r\
INNERHANDLE
TRIM
(with powerdoor locks)
eowenooon
\
\
LOCKSWTTCH
\
\
ts1.,h.*
-\Q'-Qh.\\-*<y
\J'
INNER
HANDLE
tRtM
{withoutpower
tls!^
(t!5t
\\
ARMRE'T
POCKET
covER
\.l+--
[-\r
, \
",Ro,--"ou",
PANEL
r\J
\R]
- |
Cf-.
,.JL
oooR
Adjustment,
Pase20'23
W
+..-ooon
PROTECTOR
ARMREST
POCKET
1-O-14
GLASS
Replacement,
page20-19
Adiustment,
page20-20
GLASSRUN
CHANNEL
3ill,'î,i"**\N
\\
\\\\ REGULATOR
pas20.19
\\\\ Reptacement,
l\\\\
trq\\\t v.
,6@
POWER
MOTOR
CYLINDER
PROTECTOR
e'
\".or.oro*
HANDLE
RETAINER
LOCK
CLIP
CYLINDER
page20-17
Replacement,
RODPROTECTOR
HANDLEBOD
FRONTLOCK
ROD
REARLOCK
ROD
LATCH
PROTECTOR
20-15
Doors
DoorPanelReplacement
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d
other parts.
\
5.
1. Remove:
! Innerhandletrim (seepage20-14)
. Mirror mount cover panel{seepage20-241
2.
Releasethe clips that hold the door panel.Remove

the door panel by pulling it upward.Disconnectthe
soeakerconnector.
NOTE:Removethe door panelwith as littlebending
as possibleto avoid creasingor breakingit.
l f a p p l i c a b l e r. e m o v el h e r e g u l a t o rh a n d l e b y
pullingthe clip out with a wire hook.
HANDLE
REGULATOR
WIREHOOK
95 mm 13.74inl
-L
12 mm
TRIM PAD
10.47in) 1REMOVER
(Commercially
available)
Snap-on
*4177,or
1mm L---'"t/lf'
equivalnt
to.o4inl I :
/t1-]
45 mm
(1.77in)
>: Clip location3,
il_
JF
Remove the armrest pocket,then disconnectthe

oower window switch connector.
=l$
INOS
t\
-------l I
cr_rp
REMoVER
F?
rI
DOORPANEL
ARMREST
POCKET
4.
Removethe soeakercover.then removethe screws.

>i Screw localions,3
|
6hD:"
L"
.i
6.
COVER
20-16
CONNECTOR
Outer HandleReplacement
l.
2.
4.
Remove:
. D o o rp a n e l
Pull out the outer handle.Pry the outer handlerod

NOTE:
note location@ of the outer
it.
door.
P u l lo u t t h e r e t a i n ecr l i p .
PROTECTOR
CYLINDER
BUSHING
Replace.
LOCKCYLINDER
OIAGONAL
CUTTERS
,w,
\
CLIP
3 . Removethe bolts,then removethe cylinderprotec

tor, lockcylinderand outer handle.
>: Eolt locations.2
SHOP
TOWEL
5.
Installation is the reverse of the removal procedure.

NOTE: Make sure the door locks and opens properly.
LOCKCYLINDER
CYLINDERROD
20-17
Doors
Latch Replacement
3.
Removethe boltsand movethe centerlowerchannel.
l.
Remove:
NOTE:Take care not to bend the inner handle rod

and lockrods.
2.
Removethe rod protector.
>: Screw locataons

A>,3
8>,3
5x1.omm i
[v) ) 4 p 6 N m { 0 . 6 k e f m , i
4 tbt.h)
)
l
_)
CENTERLOWER
CHANNEL
CBANK
HOLDER
PROTECTOR
6xl.0mm
8 N.m {0.8 kgf.m,
6 rbr.ftl
R e m o v et h e i n n e r h a n d l e ,t h e n r e m o v et h e l a t c h
throughthe hole in the door.
lnstallationis the reverseol the removalprocedure.
NOTE:Makesurethe door locksand opensproperly.
20-18
Replacement
Glass/Regulator
1.
Remove:
. Plasticcover{seepage20-14)
2.
Caretullymove the glassuntil you can seethe bolts,

then loosenthem. Slidethe guide rearward.remove
t h e g l a s s f r o m t h e g u i d e , a n d c a r e f u l l yp u l l t h e
glassout throughthe window slot.
3.

clip, then removethe regulatorthrough the hole in
the door.
NOTE:Scribea line aroundthe rearrollerguidebolt
to show the originaladlustment
>: Bolt locations

B>,2
A>,4
>: Bolt localions,2
6x1.0mm
6x1.0mm
I N.m10.8ksl.m, I
6|lofttt
8 N m {0.8kst.m, I
6 rbrft
|
LOOSen.
6x1.0mm
E
,*
l
9.8N.m11.0
kg{.m,I
7.2tbrft)
|
Loosen.
ROLLER
BEGULATOR
BOLTS
GUIDE
(cont'd)
20-19
Doors
Glass/Regulator
(cont'dl
Replacement
Greaseall the slidingsurfacesof the regulatorwhere
shown.
NOTE:
a lf necessary,remove the power window motor
from the regulator.
. Beforeremovingthe powerwindow motor,scribe
a line acrossthe sectorgearand regulator.
GlassAdjustment
NOTE:
. Placethe vehicleon a firm, levelsurfacewhen adjusting the glass.
. Checkthe weatherstrips
and glassrun channelfor damage or deterioration,and replacethem if necessary.
1.
Remove:
. Door panel(seepages20-4,10,16)
. Plasticcover(seepages20-2,8,14)
2.
Adjustthe glass.
SECTORGEAR
REGULATOR
>: Bolt locations, 3
q(])
6xr.om;-
]
POWERWINDOW
4D:
a,
R a i s et h e g l a s sf u l l y .
o.
L o o s e nt h e g l a s sm o u n t i n gb o l t s ( f r o n td o o r )
and regulatormountingbolts.
c.
Push the glass rearward (front door glass)or

forward (rear door glass).
d.
Tighten the glass mounting bolts (front door)

and regulator mounting bolts.
A >: Glassmountingbolt
locations.
B >: Rgulato.mouting
bolt locations.
Front:
; l L //
- ^ ->
\
5.
Installationis the reverseofthe removalprocedure.

NOTE:Rollthe glassup and down to seeif it moves
freely without binding.Also make sure that there js
no clearancebetweenthe glassand glassrun chan
nel when the glassis closed.Adjust the positionof
the glassas necessary.
20-20
REGULATOR
Rear:
GLASS
REGULATOR
e.
Loosenthe front channelmounting bolts (tront

d o o r ) o r r e a r c h a n n e lm o u n t i n gb o l t ( r e a r
door).
f.
Lowerthe glass.
g.
P u s h t h e f r o n t o r r e a r c h a n n e l sa g a i n s tt h e
glass,then tightenthe mountingbolts.
2DI3D:
Raisethe glassas far up as possible,and hold
it againstthe glassrun channel.
o.
>r Fiontandrear
mounting
channel
bolt locations
L o o s e nt h e r o l l e rg u i d e b o l t s ,a n d a d j u s tt h e
glassso it is parallelwith the glassrun channel.
GLASSRUN
CHANNEL
Front:
ROLLERGUIDEBOLTS
(cont'd)
20-21
Doors
GlassAdjustment(cont'dl
c.
Tightenthe rollerguide bolts.
d.
Loosenthe front channelbolts.
e.
Lowerthe glass.
f.
Push the front channelagainstthe glass,then

tightenthe mountingbolts.
6.
Checkfor water leaks.

Spray water over the roof and on the sealingarea
as shown.
NOTE:
. Adjustthe water pressureas shown.
. Do not squeezethe tip of the hose.
GLASS
12 mm {0.47inl
hd
HOSE
300mm (11.8in)
MOUNTING
BOLT
3.
Checkthat the glassmovessmoothly.
4.
Raisethe glassfully and checkfor gaps.
5.
Checkthe glassoperation,
7.
NOTE:Checkthat the glasscontactsthe glass run

c h a n n eel v e n l y .
Attachthe plasticcover,then installthe door panel

(seepages20-4,10, 16).
lnstallthe regulatorhandleso it pointsforward and
up at a 45 degreeanglewith the glassclosed.
WEATHERSTFIP
Forward
20-22
g
PositionAdjustment
StrikerAdiustment
NOTE: Placethe vehicleon a firm. level surtacewhen

adjustingthe doors.
Makesurethe door latchessecurelywithout slamming.

lf it needsadjustment:
After installingthe door, checkfor a flush fit with the

body.then checkfor equal gaps betweenthe front, rear,
a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d
body edgesshouldalso be parallel.Adjust at the hinges
asshown.
N O T E rT h e s t r i k e r n u t s a r e f i x e d . T h e s t r i k e rc a n b e
adjusted1.5mm (0.059in) up or down,and 3 mm (0.1in)
tn or out.
1.
CAUTION:Placea shop towel on the lack to prevent

damageto the door when looseningthe door and hinge
mounting bolts lor adiustment.
BOLTS
DOORMOUNTING
5m
8 x ' 1 . 2m
28 N.m{2.9kgt.m,21 lbf.ftl
Loosenthe screws,then inserta shoptowel between

the body and striker.
1 . 5m m
(0.059in)
1 . 5m m
{o.059in}
Loosenthe door mountingboltsslightly

to movethe door lN or OUT until
it's flushwith the body.lf necessary,
you can installashim behindone
hingeto makethe door edges
with the body.
PARALLEL
Inserta shop towel

between the body and
PLASTIC
HAMMER
HINGEMOUNTINGBOLTS
8 x 1.25mm
28 N m {2.9 kgf.m,21 lbf.ft)
Removethe innerfender,
loosenthe hingemounting
bolts,and movethe door
BACKWARD
or FORWARD,
UP or DOWNas necessary
to equalizethe gaps.
Lowerthe glass.
8 x 1.25mm
l8 N.m {1.8kgl m,
r3 tbf ft)
TOWEL
2.
Lightlytightenthe screws.
3.
Wrap the strikerwith a shop towel, then adiustthe

strikerby tappingit with a plastichammer.
CAUTION: Do not sttike the striker too hard.
NOTE:Holdthe outer handleout, and pushthe door
againstthe body to be surethe strikerallowsa flush
fit.
The door and body edgesshouldbe parallel.

4.
lf the door latchesproperly,loosenthe screws,then

removea shop towel.Tightenthe screwsand recheck
,lJl:ril:x;T9#
NOTE:Checkfor water leaks.
20-23
Mirrors
Mirror Replacement
NOTE:Takecare not to scratchthe mirror, mirror base

coverano ooor.
I
L o w e rt h e d o o rg l a s s .
2.
Carefullypry out the mirror mount cover panel by

nano.
3.
Removethe mirror mounting nuts while supporting

the mrrror.
a: Nut locations,
3
Power milror:
)coNNEcToR
(Mirrorside)
MIRROR
{Doorharness
side)
CONNECTOR
MIRROR
MOUNT
PANEL
COVER
Manualmirror:
Installationis the reverseot the removalprocedure.
Removethe cap, screwand knob,then removethe

mirror mount cover panel.
NOTE:Make sure the connectoris connectedproperly.
MIRRORMOUNT
KNOB
20-24
Mirror Holder Replacement
RearviewMirror Replacement
CAUTION: Wear gloves to remove and install the mirror holder.
l.
Removethe rubberdamper.
2.
Pry the cover off using the end of a flat tip screwdnver.
' 1 . C a r e f u l l yp r y o u t t h e m i r r o r h o l d e rw i t h a f l a t t i p
screwdriveras shown.
CAUTION: When prying with a flat tip screwdriver,

wrap it wilh a shop towel to prevent damage.
PIVOT
-6r
JOINT PIN
3.
--Gl
Removethe screws,then removethe rearviewmirror.

lnstallationis the reverseof the removalprocedure
SCREW
5x0.8mm
4 N,m {0.{ kgf.m,
3 tbf.ftt
RUBBERDAMPER
JOINT PIN
-6,l
MIRRORHOLDER
SHOPTOWEL
2.

NOTE: Apply greaseto the locationsindicatedby
tne arrows.
REARVIEW
MIRROR
MirrorCoverReplacement
>: Screw locations
A>.3
d\.nri''i.'.'i.i-.
s>,2
]
':::_)
d\.,.,',r.,+.
II
\{ P#'/u2
)
-ln=T-
To removethe screws,
pullthe sealaway.
VIf.
.ll) |U
._.[__
SHOPTOWEL
MIRRORBASE
20-25
Windshield,RearWindow and OuarterGlass

Index
NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.
Windshield(2Dl3D/4D):
MOLDING
UPPERRUBEEF
RearWindow {2Dl4D}:
REARWINDOW
Removal,page20-32
page20-33
Installation,
FASTENER,
4
(Selt-adhesive-type,
glassside)
/
/
FASTENER,4
body side}
{Self-adhesive.rype,
* . /
SPACER,
w
g
20-26
RearWindow {3D):
,T
FASTENER,
glassside)
lSelf-adhesive-type,
SPACER,
,o.r.".*, n
Iff'".*-.Y'e'bod'side)
DAM,2
RUBBER
Removal,page 20-36
page20-37
Installation,
tI
SEALA, 1
SEAL8 , 2
Ouarter Glassi
3D:
UPPERCLIP
(Self-adhesive-type)
OUARTERGLASS
Removal,Page20-40
lnstallation,
Page20_41
rr-il
(--/
/:=
OUATERGLASS
Removal,page20-45
page20 46
Insrallation,
OUARTER
GLASSTRIM
h\f
(Selt adhesive-type,
body side)
n
\il
FASTENER
type,
{Sell-adhesive
glassside)
LOWERCLIP
(Self-adhesive
type)
LOWERRUBBER
DAM
2Di
LOWERCLIP
(SelI-adhesive
type)
20-27
Windshield
Removal
CAUTION:
. Wearglovesto removeand installthe windshield.
. Use seat coversto avoid damaging any surfaces,
1.
2.
4.
To removethe windshield,first removethe:

. Rearviewmirror (seepage20 25)
. Sunvisorsand holders(seepage20 64)
. F r o n tp i l l a rt r i m ( s e ep a g e s2 0 - 5 9 , 6 0 , 6 1 )
. Windshieldwiper arms and cowl cover(seepage
20 113\
Apply protectivetape along the edge of the dashb o a r d a n d b o d y a s s h o w n . U s i n ga n a w l , m a k e a

h o l e t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ef r o m
i n s i d et h e c a r . P u s ht h e p i a n ow i r e t h r o u g ht h e
hole,and wrap eachend arounda pieceof wood.
PIANOWIRE
UPPER
I
RUBBER
DAM
PROTECTIVE
tit'
WINDSHIELD
Peel oll the molding, and removethe glass brack

ets.
ADHESIVE
NOTE: When molding removal is difficult,cut the

moldingwith a knife.
MOLDING
PROTECTIVE
TAPE
DASHBOARD
wlNDSHIELD
aoxesrir lowEB
BUBBER
DEFOGGEB
SEAL
OAM
5.
W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n ow i r e
backand forth in a sawingmotion,and carefullycut
t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ea r o u n dt h e
entirewindshield.
CAUTION: Hold the piano wire as closeto the windshield as possible to prevent damage to the body
and dashboard,
3.
Pull down the front of the headliner{see page 2064).

CAUTION: Take care not to bend the headliner
excessively.
6.
20-28
Carefully remove the windshield.
lnstallation
1.
Using a knife,scrapethe old adhesivesmooth to a

thicknessof about2 mm (0.08in) on the bondingsur
Iacearoundthe entirewindshieldopeningtlange
4.
NOTE:Be carefulnot to touch the windshieldwhere

adhesivewill be applied.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding.
. Removethe rubberdams and tastenersfrom the
body.
. Maskoff surroundingsurfacesbeforepainting.
2.
G l u e t h e r u b b e rd a m a n d f a s t e n e r st o t h e i n s i d e
faceof the windshieldas shown.
Cleanthe body bondingsurfacewith a spongedampenedin alcohol.
{0.53inl
ALIGNMENT
\._- - !41Ks _
N O T E :A f t e r c l e a n i n g k, e e p o i l , g r e a s ea n d w a t e r
from gettingon the surface.
ALIGNMENT
MARK
3 . lf the old windshieldis to be reinstalled,use a putty

knife to scrapeoff all traces of old adhesive,then
c l e a nt h e w i n d s h i e l ds u r f a c ew i t h a l c o h o lw h e r e
new adhesiveis to be applied.
'13.smm
10.53in)
NOTE: Make sure the bonding surlaceis kept free

of water,oil and grease.
LOWERRUBBER
DAM
CAUTION:Avoid setting the windshield on its edges;

small chips may later developinto cracks.
NOTE:
. Cleanthe shadowedarea.
o Cleanarea@ as shown.
WINDSHIELD
5.
lnside
Align and glue the molding to the edgeof the wind

shield.
NOTE: Be careful not to touch the windshield where
JL
WINDSHIELD
WINDSHIELD
to edge
Apply primer(3M N 200,or equivalent)
of the windshield.
(cont'd)
20-29
Windshield
Installation (cont'dl
Installtheglassbracketsand fastenersas shown.
NOTE:The numbersafterthe part namesshow the
quantitiesot the partsused.
\
9. With a sponge,apply a light coat of glass primer
aroundthe edge of the windshieldas shown, then
lightlywipe it off with gauzeor cheesecloth.
NOTE:
. Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmixed
up.
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the windshieldproperly,causinga leakafterthe windshield
is installed.
. Keep water, dust, and abrasivematerialsaway
Applyglassprimer
from the primedsurface.
/fu
, apptygt .. primerhere.
9.5mm
{0.37in)
RUBBERDAM
FASTENER
WINDSHIELD
GLASSBRACKETS,
2
MOLDING
7.
Set the windshieldon the glass brackets,then cen

ter it in the opening.Make alignmentmarksacross
the windshieldand body with a greasepencilat the
four pointsshown.
NOTE:Be carefulnot to touch the windshieldwhere
WINDSHIELD
10. With a sponge,apply a light coat of body primer to
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e w i n d shield openingflange. Let the body primer dry for
at least10 minutes.
NOTE:
. Do not applyglassprimerto the body.and be careful notlo mix up glassand bodyprimersponges.
. Nevertouchthe primedsurfaces
with your hands.
. Maskoff the dashboardbeforepaintingthe flange.
)./////
///////
: Applr bodv wime. here.
6mm
(0.2{in)
BRACKETS
NOTE:Adjustthe glassbracketsto centerthe windshieldin
the opening,then tightenthe
8.
SCREW
R e m o v et h e w i n d s h i e l d .
20-30
16mm
{0.63in}
5mm
10.2in)
16 mm
In)
1 1 . Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mrxrng.
. Followthe instructionsthat come with the adhesive.
14. Use suction cups to hold the windshield over the

opening,align it with the alignmentmarks made in
. ightly
step7, and set it down on the adhesiveL
push on the windshielduntil its edge is fully seated
on the adhesiveall the waYaround.
NOTEI Do not openor closethe doorsuntil adhesive
is dry.
ALIGNMENTMARK
12. Beforelilling a cartridge,cut the end of the nozzle

as shown.
C u t n o z z l ee n d
10 mm (0.39in)
7 mm (0.27inl
Packadhesiveinto the cartridgewithout air pockets

to ensurecontinuousdelivery.Putthe cartridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the windshieldas shown.
NOTE|Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer.
12mm (0.47in)
1
-tl
i .,1 aouestvr
Make a slightly thicker

bead at each corner.
,T"Irr,,,",
5mm
(0.2in)
-_rr
MOLDING
-/lr:.-,j.'o'.uo
\--..
/
1 5 . Scrapeor wipe the excessadhesiveoff with a putty

knifeor towel.
from a paintedsurfaceor
NOTE:To removeadhesive
wipewith a softshoptoweldampened
the windshield,
with alcohol.
1 6 . Letthe adhesivedry for at leastone hour,then spray
water over the windshieldand checkfor leaks.Mark
the leakingareas,let the windshielddry, then seal
with sealant.
NOTE:
. Letthe car standfor at leastfour hoursafterwind
lf the car hasto be usedwithin
shieldinstallation.
hours.
it must be drivenslowly.
first
four
the
. Keepthe windshielddry for the first hour after
installation.
. Checkthat the ends of the side molding are set
underthe air scoop.
WINDSHIELD
FASTENER
LOWER
RUBBER
OAM
LOWER
RUBBER
DAM
10.04inl
WINDSHIELD
1 7 . Reinstallall remainingremovedparts.
NOTE:
. Installthe rearviewmirror rubber damper after
the adhesivehasdriedthoroughly.
. Advisethe customernot to do the following things
for two to three days:
- S l a m t h e d o o r sw i t h a l l t h e w i n d o w s r o l l e d
up.
- T w i s t t h e b o d y e x c e s s i v e l y( s u c h a s w h e n
going in and out of drivewaysat an angle or
drivingover rough,unevenroads).
20-31
RearWindow
Removal
2DI1D:
4.
CAUTION:
a Wgar gloves to remove and install the rear window.
. Use seat coversto avoid damaging any surfacss.
. Do not damage the rear window defogger grid lines,
window antenna grid lines, and terminals.
1. To removethe rearwindow,first removethe:
. Trunk lid
. Rearseatcushion(seepages20-79.81)
. Rearseatside bolsters(4D,seepage20-791
. Rearseat-back(2D,seepage20-81)
. Rearshelf(seepages20-59,61)
. Rearpillartrim (4D,seepage20-59)
. Sidetrim panel(2D,seepage20-61)
. Ouartertrjm panel(2D,see page20-61)
. Rearroof trim (seepage20-65)
2.
3.
Apply protectivetape alongthe edge of the body as

shown. Usingan awl, makea hole through the
adhesivefrom insidethe car. Push the piano wire
t h r o u g ht h e h o l e ,a n d w r a p e a c h e n d a r o u n da
pieceof wood.
PIANOWIRE
ADHESIVE
REARWINDOW
PEOTECTIVE
TAPE
D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r
from eachside.
PIANOWIRE
Peeloff the molding.

PROTECTIVE
TAPE
NOTE:When molding removal is difficult.cut the

moldingwith a knife.
ADHESIVE
MOLOING
With a helper on the outside, pull the piano wire

backand forth in a sawing motion,and carefullycut
t h r o u g ht h e a d h e s i v ea r o u n dt h e e n t i r er e a r w i n dow.
il"*t,
^D.HE:tyE
._ --,///
CAUTION: Hold the pisno wire as close to the rear

window as possibleto prevent damageto the body.
REARWINOOW
S
MOLOING
6.
20-32
Carefullyremovethe rearwindow.
lnstallation
1.

t h i c k n e s so f a b o u t2 m m ( 0 . 0 8i n ) o n t h e b o n d i n g
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g
flange.
4.
Apply the double faced adhesivetape (NITTO501,

or equivalent)to the edge of the rearwindow,then
installthe moldingaroundthe edge of the rearwin
dow as shown.
N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w
w h e r ea d h e s i v w
e i l l b ea p p l i e d .
NOTE:
b o nd i n g
. Maskotf surroundingsurfacesbeforepainting.
. R e m o v et h e f a s t e n e r sa n d s p a c e r sf r o m t h e
DOOy.
ALIGNMENT
MARK
ADHESIVETAPE
867mm {34.1in)
5mm
(0.2inl
C l e a nt h e b o d y b o n d i n g s u r f a c ew i t h a s p o n g e
in alcohol.
dampened
ADHESIVE
TAPE
Thickness:
0.'16mm {0.006inl
N O T E :A f t e r c l e a n i n g k, e e po i l , g r e a s ea n d w a t e r
3.
MOLDING
ALIGNMENT
MARK
usea putty
lf the old rearwindow is to be reinstalled,
knifeto scrapeoff all tracesof old adhesiveand the
rubberdam,then cleanthe rearwindow surfacewith
alcoholwherenew adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free
MOLOING
WlNDOW
CAUTION:Avoid setting the rear window on its

edges;small chips may later develop into cracks.
NOTE:Cleanthe shadowedarea.
5.
Gluethe fastenersand spacersto the insideface of

the rearwindow as shown.
N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w
w h e r ea d h e s i v w
e illbeapplied.
>: Fastener,spacer
loc6tions
A >. 4
FASTENER
MOLDING
--=,
I
ALIGNMENT
\ M MARKS
A
B> , 2
Outside
REARWINDOW
(cont'dl
20-33
RearWindow
(cont'd)
Installation
6.
Gluethe fastenersto the body as shown.

Fastenerlocations,4
9 . W i t h a s p o n g e ,a p p l y a l i g h t c o a t o f g l a s sp r i m e r
aroundthe edgeof the rearwindow as shown,then
FASTENER
\ e l
4i< )
l Y l
F_L^NGE
NycH,/,/
'//f
NOTE:
. Do not apply body primer to the rear window,
and do not get body and glass primer sponges
mixed up.
lf you do, the adhesivemay not bond to the rear
window properly, causing a leak after the rear
window is installed.
, appty gtassprimerhera.
10 mm 10.39in)
GLASS All around.
MOLDING
1.
Set the rear window, then centerit in the opening.

Make alignmentmarksacrossthe rear window and
bodywith a greasepencilat the four pointsshown.
ALIGNMENT
MABK
FASTENER
REARWINDOW
10. With a sponge,apply a light coat of body primerto

t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r
window openingflange.Letthe body primerdry for
at least10 minutes.
NOTE:
. Do not applyglassprimerto the body,and be careful notto mix up glassand bodyprimersponges.
''/fu7.
, oort, Aoa,orimerhere.
1 6m m
{0.63inl
16 mm
In,
8.
Removethe rearwindow.
20-34
7mm
10.28in)
1' t. Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewith a pufty knife
NOTE:
mrxrng.
. Followthe instructionsthat came with the adhe
sive.
'14. Use suctioncups to hold the rear window over the

opening,align it with the alignmentmarksmade in
. ightly
step7, and set it down on the adhesiveL
i
t
s
a
refully
u
n
t
i
l
e
d
g
e
s
p u s h o n t h e r e a rw i n d o w
seatedon the adhesiveall the way around
NOTE:Do not openor closethe doorsuntilthe adhesiveis dry.
1 2 . Beforefilling a cartridge,cut the end of the nozzle

as snown.
SUCTION
CUPS
ALIGNMENT
MARK
10 mm 10.39inl
7 mm {0.27inl
1 3 . Packadhesiveinto the cartridgewithout air pockets
to ensurecontinousdelivery.Put the canridgein a
c a u l k i n gg u n , a n d r u n a b e a do t a d h e s i v ea r o u n d
the edgeof the rearwindow as shown.
NOTE:Apply the adhesivewithin 30 minutesafter
12 mm 10.47inl
[/
-+-
oo"r'u.
8 mm (0.31in)
Make a slightly thicker

bead at each corner.
GLASS

knifeor towel.
NOTE:To removeadhesivefrom a paintedsurface
or the rear window, use a soft shop lowel dampenedwith alcohol.
1 6 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r
leaks.Mark the leakingareas,let the rear window
dry, then sealwith sealant.
NOTE:Let the car sland for at leastfour hoursafter
re4window installation.lf the car has to be used
within the first four hours,it must be drivenslowly.
1't. Reinstallall remainingremovedparts.

NOTE:Advisethe customernot to do the following
thingsfor two to threedays:
.
.
Slamthe doorswith all the windows rolledup.

Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough,unevenroads).
20-35
RearWindow
Removal
3D:
Upperportion:
CAUTION:
. Wear gloves to remove and install the rear window.
. Use seat coversto avoid damaging any surlaces.
. Do not damagethe real window defoggergrid lines.
. Take care not scratch the rear window molding.
t .
t o
removethe rearwindow,first removethel
a Rearcentershelf(seepage20-60)
a H a t c h u p p e r t r i m , h a t c ht r i m p a n e l a n d h a t c h
sidetrim (seepage20-63)
Rearwindow wiper arm {seepage20-115)
Hatchspoiler(seepage20-101)
TAPE
Side portion:
D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r
from eachside.
GLASS
3. Apply protectivetape to the inner edge of the tail

gare.
4.
From insidethe hatch,usea knifeto cut throughthe

rearwindow adhesiveall the way around.
NOTE:
. lf the rear window is to be reinstalled,take care
not to damagethe molding.
. lf the molding is damaged,replacethe rearwin
dow and moldingas an assembly
Lower Dortion:
MOLDING
HATCH
's>
G^Yb\
ADHESIVE
Carefullyremovethe rearwindow.
NOTE:Checkthe moldingfor damage,and replace
the rearwindow if necessary.
BEARWINDOW
20-36
lnstallation
'1.
Using a knife,scrapethe old adhesivesmoothto a

t h i c k n e s so f a b o u t 2 m m ( 0 . 0 8i n ) o n t h e b o n d i n g
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g
flange.
NOTE:
bonding.
. Removethe rubberdams, spacersand fasteners
from the hatch.
. Mask off surroundingsurfacesbefore applying
primer.
2.
C l e a nt h e h a t c h b o n d i n g s u r f a c ew i t h a s p o n g e
in alcohol.
dampened
4.
Glue the rubberdams to the insidetace of the rear

window, as shown, to containthe adhesiveduring
and gluethe fasteners,spacerand seals
installation,
as shown.
NOTE:
. Gluethe rubberdams usingthe printeddots as a
g ul d e .
. Be careful not to touch the rear window where
a d h e s i vw
e illbeapplied.
>: Fastener,
spacer6ndseal
locations
a >,4
B > ,1
SPACER
FASTENER
N O T E :A f t e r c l e a n i n g ,k e e p o i l , g r e a s eo r w a t e r
D> , 2
l f t h e o l d r e a r w i n d o w i s t o b e r e i n s t a l l e du, s e a
putty knife to scrapeoff all tracesof old adhesive,
t h e n c l e a nt h e r e a r w i n d o w s u r f a c ew i t h a l c o h o l
where new adhesiveis to be applied.
Insid.
NOTE:Makesurethe bondingsurfaceis keptfree of

water,oil and grease.
CAUTION:Avoid setting the rear window on its
edges;the molding can be psrmanently deformed.
NOTErCleanthe shadowedarea.
REARWINOOW
-d' -f--At
FASTENER
RUBBER
PRINTEDDOTS
REARWINDOW
RUBBER
DAM
MOLDING
(cont'd)
20-37
RearWindow
lnstallation {cont'd)
Installthe fastenersto the hatchas shown.
8.
With a sponge, apply a light coat of glass primer

around the edge of the rear window, then lightly
wipe it oif wirh gauzeor cheesecloth.
>: Fastener
locations,
4
NOTE:
. Do not apply body primer to the rear window,
mixed up.
Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
window properly, causing a leak after the rear
window is installed.
Keep water, dust. and abrasivematerialsaway
V//////7, , eppv stassc,im6, h6r6.
Insido
V,
llsmm
I W-- ]10.59 inl
N r t
AN I \\
cr-l'ss
SPACER
REARwlNOOW
Set the rearwindow uprighton the hatch,then center it in the opening.Make alignmentmarksacross
the rear window and body with a greasepencil at
the four pointsshown.
NOTE: Be carefulnot to touch the rearwindow where
adhesive
will be applied.
7.
Removethe rearwindow.
20-38
9. With a sponge,apply a light coat of body primer to

t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r
window openingflange.Letthe body primerdry for
at least10 minutes.
12. Packadhesiveinto the cartridgewithout air pockets

to ensurecontinuosdelivery.Put the canridgein a
c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d
the edgeof the rearwindow as shown.
NOTE:
. Do not applyglassprimerto the body,and be caretul not to mix up glassand bodyprimersponges.
NOTE:Apply the adhesivewithin 30 minutesafter

///////l
' aooV roay primerhere.
i:EI^,T_/:aDHEs,vE
8mm
{ 0 . 3 1i n l
l6 mm
{0.63in)
--_Jr-DZT ro.ornr
tEt
JI\
, / N \SPACER
GLASS
REARWINDOW
22 Jnm
1 0 . Thoroughlymix the adhesiveand hardenertogether

NOTE:
mrxrng.
. Followthe instructionsthat came with the adhesive,
11. Beforefilling a cartridge,cut the end of the nozzle
as shown.
MOLDING
-----ll
GLASS
Cut nozzle
f\-L,-int
to.oe
'10mm
{0.3Sin)
ffi-f
,,.17
MOLDING,-
7 mm {0.27in)
(cont'd)
20-39
RearWindow
OuarterGlass
Removal
13. Use suctioncups to hold the rear window over the

o p e n i n ga, l i g ni t w i t h t h e a l i g n m e nm
t a r k sm a d ei n
step6, and set it down on the adhesive.Lightlypush
on the rear window until its edgesare fully seated
o n t h e a d h e s i v ae l l t h ew a y a r o u n d .
3D:
NOTE:Do not openor closethe doorsuntilthe adhesiveis dry.
CAUTION:
a Wear gloves to remove and install the quarter glass.
a Use seat coversto avoid damaging any surfaces.
1.
To removethe quarterglass,first removethe:

. Rear seat-backand rear seat cushion (see page
20_80)
. Rear center shelf and rear side shelf (see page
20-60)
R e a rt r i m p a n e la n d s i d e t r i m p a n e l ( s e ep a g e
20-60)
Upper anchorbolts from the front and rear seat
belts{seepages20 86, 89)
Ouanertrim panel(seepage20-60)
2.
From insidethe car, use a knifeto cut through the

quarterglassadhesiveall the way around.
SUCTION
cuPs
.J
NOTE:
. lf the clip on the rear edge is broken,the quarter
glasscan be reinstalled
usingbutyltape(seepage
20-421.
. Apply protectivetape alongthe edgeofthe entire
quarterglassopeningflange.
knifeor towel.
or the rear window, use a soft shop towel dampenedwith alcohol.
L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r
leaks.Mark the leakingareas,let the rear window
NOTE:Let the car standfor at leastfour hoursafter
rear window installation.lf the car has to be used
1 6 . Reinstallall remainingremovedpans.
thingsfor two to threedays:
.
.
Slam the doorswith allthe windows rolledup.

i n a n d o u t o t d r i v e w a y sa t a n a n g l e o r d r i v i n g
20-40
GLASS
Installation
Upper portion:

t h i c k n e s so f a b o u t 2 m m ( 0 . 0 8i n ) o n t h e b o n d i n g
s u r f a c ea r o u n dt h e e n t i r e q u a r t e rg l a s s c p e n i n g
tlange.
NOTE:
bonding.
. Removethe rubberdamsfrom the body.
. lf any of the clips are broken,removethem from
the body.
. Mask off surroundingsurfacesbefore applying
pnmer.
RUABER
DAM
ADHESIVE
PROTECTIVE
TAPE
Lower portion:
2.
N O T E :A f t e r c l e a n i n g k. e e p o i l , g r e a s ea n d w a t e r
PROTECTIVE
TAPE
3.
ADHESIVE
lf the quaner glass is to be reinstalled,use a putty

cleanthe quarterglass surfacewith alcoholwhere
adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free
Pillar portion:
CAUTION:Avoid setting the quarter glass on its

OUARTER
GLASSTRIM
ADHESIVE
CLIP
3.
Carefullyremovethe quarterglass.
N O T E :C h e c kt h e q u a r t e rg l a s st r i m a n d c l i p s f o r
damage,and replacethem if necessary.
(cont'd)
20-41
OuarterGlass
Installation {cont'dl
Gluethe upperand lower rubberdams to the inside
face of the quarterglass,as shown, to containthe
adhesiveduring installation.
N O T E :B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied.
>: Alignment
mark
'o""tton"
oao""
UPPER
RUBBERDAM
OUARTER
GLASS
--f-_1_-
r-'J--.i..
mml tT13.5
I
i l 0 . 1 i4n l
\
\
I
RUBEER
DAM
6.
lf the old quarterglass is to be reinstalled(and the

c l i p o n t h e r e a r e d g e i s b r o k e no f f ) , a p p l y a l i g h t
coat of primer (3M C-100,or equivalent),
then apply
butyl tape to the quarterglass.as shown. and seal
the body holewith pieceof urethanetape.
NOTE:
o Be careful not to touch the quarter glasswhere
. Do not peelthe separatoroff the butyl tape.
'//////7r,
: eug tape tocstions(3M8628,or equivelent)

Thickn*s:3.2
mm 10.13
inl
Width:6.4mm 10.25
inl
LOWER
BUBBER
DAM
Installthe quarter glass trim on the quarter glass,
then gluethe upperand lower clipsas shown.
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
UPPER
OUARTER
GLASSTRIM
NOTE:Contactthe clipsagainstthe
quarter9lasstrim at the areas
indicatedby the arrows.
20-42
7.
With a sponge,apply a light coat of glassprimerto

the insideface of the quarterglass,as shown,then
NOTE:
. Do not apply body primer to the quarter glass,
mixed up.
It you do, the adhesivemay not bondto the quarter glassproperly,causinga leak afterthe quar
ter glassis installed.
////////
8. With a sponge,apply a light coat of body primerto

the originaladhesiveremainingaroundthe quarter
glassopeningflange.Let the body primer dry for at
least10 minutes.
NOTE:
. Do not apply glass primer to the body, and be
c a r e f u ln o t t o m i x u p g l a s sa n d b o d y p r i m e r
sponges.
. Maskoff the rearside trim panel beforepainting
t h ef l a n g e .
////////7 : aootvbodv odmerhere.
1 6m m
(0.63inl
' eooV st.,. primerhere.

21 mm 15 mm
lo.tB io) {0.59inl
OUARTER
GLASSTRIM
Thoroughlymix the adhesiveand hardenertogether

NOTE:
mr x r n g .
. Followthe instructionsthat came with the adhestve.
15 mm
{0.59in)
30 mm
lr.2 in)
10. Beforefilling a cartridge.cut the end of the nozzle

as shown.
C u t n o z z l ee n d
in)
10 mm 10.39
7 mm 10.27in)
(cont'd)
20-43
OuarterGlass
Installation {cont'd)
to ensurecontinuousdelivery.Putthe cartridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the quarterglassas shown.
NOTEI
. lf the old quarterglass is to be reinstalled,peel
the separatoroff the butyl tape afterapplyingthe
adhesive.
. Apply the adhesivewithin 30 minutesafterapplying the glassprimer.
12. Use suctioncups to hold the quarterglassover the

opening.alignthe clips,and set it down on the adhe
sive.Lightlypush on the quarterglassuntil its edges
arefully seatedon the adhesiveall the way around.
N O T E : D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
adhesiveis drv.
li.;l,l/:ADHE','E
8mm
{0 3'l inl
OUARTER
GLASSTRIM
22.5nm
{0.89in)
CLIP
UPPER
RUBBER
DAM
BUTYL
TAPE
Scrapeor wipe the excessadhesiveoff with a putty

knifeor towel.
or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
spray water over the quarter glass and checkfor
leaks.Mark the leakingareas,let the quarter glass
LOWER
RUBBER
DAM
NOTE:Let the car standlor at leastfour hoursafter

quarterglass installation.lf the car has to be used
1 5 . Reinstallall remainingremovedparts.
thingsfor two to three days:
RUBBER
DAM
20-44
.
.
Slam the doorswith all the windows rolledup.

Removal
Upper portion:
2Di
CAUTION:
. Wear gloves to remove and install th quarter glass.
. Use seat coversto avoid damaging any surfaces,
1. To removethe quaner glass,first removethe:
20-81)
. Sidetrim panel(seepage20-61)
. Rearshelf(seepage20-61)
o Upper anchor bolt from the front seat belt (see
page20 86)
. Ouanertrim panel(seepage20-61)
2.
Ftom insidethe car, use a knifeto cut through the

quarterglassadhesiveall the way around-
ADHESIVE
PROTECTIVE
TAPE
Rear edge portion:
NOTE:
. lf the quarterglassis to be reinstalled,take care
not to damagethe molding.
. Apply protectivetape alongthe edgeofthe entire
quarterglassopeningflange.
a
Pillar portion:
TAPE
GLASS
Carefullyremovethe quanerglass.
NOTE:Checkthe moldingfor damag,and replace
it if necessary.
20-45
OuarterGlass
Installation
' t . Using a knife,scrapethe old adhesivesmooth to a
t h i c k n e s so f a b o u t 2 m m ( 0 . 0 8l n ) o n t h e b o n d i n g
s u r f a c ea r o u n d t h e e n t i r e q u a r t e rg l a s s o p e n i n g
flange.
NOTE:
bonding.
. Removethe fastenerfrom the body.
. lf any ot the clips are broken,removethem from
the body.
o Mask off surroundingsurfacesbefore applying
primer.
NOTE: After cleaning,keep oil, greaseand water
lf the quaner glass is to be reinstalled,use a putty
cleanthe quarterglass surfacewith alcoholwhere
adhesiveis to be applied.
NOTE: Make sure the bonding surfaceis kept tree
CAUTION:Avoid setting the quarter glass on its
20-46
\
4.
Installthe molding around the edge of the quarter

glassas shown.
NOTE:
. It the old molding is to be reinstalled,scrapeoff
t h e o l d a d h e s i v et a p e f r o m t h e m o l d i n g ,a n d
c l e a nt h e m o l d i n g s u r f a c ew i t h a l c o h o lw h e r e
new adhesivetape is to be applied.Apply the
double-facedadhesivetape to the molding and
quarterglassas shown.
. Be carelul not to touch the quarter glasswhere
adhesivewill be aDDlied.
Adhesivetape A {3M 4215,or equivalentl
Thickness:0.4 mm (0.02inl
Width: 5 mm 10.2in)
Length:440mm (17.3in)
Adhesivetape B (NITTO501, or equivalontl
Thickness:0.16 mm (0.006inl
Width: 8 mm 10.3inl
Length:'140mm (17.3in)
Adhesivetape C {3M '1213,or equivalentl
mm (0.03inl
Thickness:0.8
Width: 5 mm (0.2in)
Length:30 mm (1.2in)
ADHESIVE
5.
lf the old quarterglass is to be reinstalled,glue the

upperand lowerclipsand fasteneras shown.
N O T E :B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
>: Clip,tastenerloc.tions
a>,2
ALIGNMENT
B> , 1
2.5mm
7.
With a sponge,apply a light coat of glassprimerto

the insideface of the quarterglass,as shown,then
lightlywipe it off wjth gauzeor cheesecloth.
NOTE:
. Do not apply body primer to the quarter glass,
mixed up.
lf you do, the adhesivemay not bondto the quarter glass properly,causinga leak after the quarter glassis installed.
t///////1 ' aooV wav orime,hero.
MOLDING
6.
15.5mm 10 mm
{0.61in) (0.39in)
Gluethe fastenerto the body as shown.

>: Fastener
locstion.1
ALIGNMENT
(cont'd)
20-47
OuarterGlass
With a sponge.apply a light coat ol body primer to
the originaladhesiveremainingaroundthe quarter
glassopeningflange.Let the body primer dry for at
least10 minutes.
NOTE:
. Do not apply glass primer to the body, and be
c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r
sponges.
. Maskoff the rear side trim panel beforepainting
the flange.
t///////7, , epptyroay erimerhere.

to ensurecontinuousdelivery.Put the cartrigein a
c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d
the edgeof the quarterglassas shown.
NOTE:
. lf the old quarterglass is to be reinstalled.peel
the separatoroff the butyltape afterapplyingthe
adhesive.
. Peel the separator off the adhesivetape after
applyingthe adhesive.
. Apply the adhesivewithin 30 minutesafterapplying the glassprimer.
1 . 5m m
i;.Ii^,/:
ADHE'T'E
8mm
(0.31in)
CLIP
9. Thoroughlymix the adhesiveand hardenertogeth,

er on a glassor metalplatewith a putty knife.
NOTE:
mixing.
. Followthe instructionsthat came with the adhe
sive.
10. Beforefilling a cartridge,cut the end of the nozzle
as shown.
Cut nozzleend
10 mm {0.39in)
20-48
12. Use suctioncups to hold the quarterglassover the

o p e n i n g ,a l i g n t h e c l i p s , a n d s e t i t d o w n o n t h e
adhesive.Lightlypush on the quaner glassuntil its
edges are fully seatedon the adhesiveall the way
around.
N O T E :D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
adhesiveis dry.
CLIP
1 3 . Scrapeor wipe the excessadhesiveoff with a puny

knifeor towel.
or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
s p r a yw a t e r o v e r t h e q u a r t e rg l a s sa n d c h e c kf o r
leaks.Mark the leakingareas,let the quarterglass
dry,then sealwith sealant.
NOTE:Letthe car standfor at leastfour hoursafter
quarterglass installation.lf the car has to be used
within the firstfour hours,it must be drivenslowly.
Reinstallall remainingremovedparts.
thingsfor tlvo to three days:
.
.
Slamthe doorswith all the windows rolledup.

Twist the body excessivelylsuch as when going
20-49
Moonroof
lndex
SWTTCHPLATE
Adiustment,page20-56
=-.
CABLEASSEMBLY
page20-55
Replacement,
SUNSHADE
page20 52
Replacement,
INNERCABLE
RAIL HOI-DERB
SLIDER
RAIL HOLDERA
REARDFAIN
TUBE
,
?<^
/ \
UBE
LfP
ll
ll
FRONTDRAINTUBE
20- 5 0
?'''
U 6
a"w
REARDRAIN
VALVE
Troubleshooting
ProbableCause
Symptom
Waterleaks
Wind noise
Motor noise
Glassdoes not move.but motor turns
Glassdoes not move and motor does not turn

(glasscan be movedwith moonroofwrench)
'1. Cloggeddraintube.
2. Gap betweenglassweatherstripand roof panel
3. Defectiveor improperlyinstalledglassweatherstrip
4. Gap betweendrainsealand roof panel.
clearancebetweenglassweatherstripand roof panel.
1. Excessive
1. Loosemotor.
2. Worn gear or bearing.
3. Cableassemblydeformed.
'1. Clutchout of adjustment.
2. Foreignmatterstuckbetweenguide rail and slider.
3. Innercableloose.
4. Cableassemblynot attachedproperly.
1.
2.
3.
4.
5.
Blownfuse.
Faultyswitch.
Batteryrun down.
Defectivemotor.
Faultyrelay.
GlassHeightAdjustment
The roof panel should be even with the glassweather
s t r i p , t o w i t h i n 1 . 7 l l t f m m ( 0 . 0 7l 3 & ' i n ) a l l t h e w a y
around.lf not, openthe glassfully, and:
1.7rl.3mm
in)
{0.0713:3i
1.
Removethe bracketcover.
Loosenthe nuts, and installthe shims betweenthe
glassframe and glassbracketas shown.
Shim thickness:Frontmax.3 mm {0.12inl
Rearmax. 2 mm (0.08inl
Repeaton oppositeside if necessary
6xl.0mm
9.8 N m (1.0kgl m,
7.2lbl.ltl
BRACKET
COVER
6x1.0mm
9.8 N.m {'1.0kgI.m.
7.2lbtft)
20-51
Moonroof
Glass,GlassBracketand SunshadeReplacement
1 . C l o s et h e g l a s sI u l l y .
6.
2.
Slidethe sunshadeall the way back.
3.
Removeboth bracketcovers.
R e m o v et h e d r a i n c h a n n e l .
DRAINCHANNEL
BRACKETCOVER
SCREW
Forward
4.
Remove the nuts trom both glass brackets.

7.
GLASSBRACKET
Remove the holder cover, then remove the

h o l d e rB .
NUT
6x1.0mm
9 N.m {0.9 kgf.m,
7 rbf.frl
{itt'za
6 x 'l.0mm
9.8N.m{1.0kstm,7.2lbfft)
Removethe glassby lifting up and pulling forward

as shown.
NOTE| Do not damagethe roof panel.
GLASS
20-52
RAILHOLDERB
Usingthe moonroofwrench,move the glassbracket

to the positionwherethe moonroofnormallypivots
down, and removethe screws.
scREws
9. Removethe rail holderA.
12. Slidethe sunshadeforward,then removeit.
NUT
6x1.0mm
9 N.m {0.9 kgf m,
1 3 . Installationis the reverseof the removalprocedure.

NOTE:Checkthe glassheight(seepage20-51).
1 4 . Checkfor water leaks.
water'
NOTE:Do not use high-pressure
ROOSTOP
DRAINCHANNEL
Rotate
asshownto removeit fromtheguiderail.
10, Removethe drain channelrod slider by moving the
cablesliderforwardusingthe moonroofwrench.
'11. Detachthe drain channelrod stop from the cutout
of the guide rail as shown,
20-53
Moonroof
Motor, DrainTubeand FrameReplacement
GAUTION:
. Wear gloves to remove and install the ftame.
. Be careful not to damagethe seats, dashboardand other interior trim.
1.
Removethe headliner(seepage20-64).
2.
Disconnect
the motor connectorand glasspositionswilch connector.
NOTE:when removingthe motor,detachthe connectorfrom the frame,removethe bolts and nuts.then removetne
motor.
3.
Removethe glass{seepage20-52).
4.
Disconnect
the draintubes,and detachthe ceilinglight harness.
5.
Removethe frame mountingbolts.

NOTE:
. An assistantis helpfulwhen removingthe bolts.
. Removethe front bolts last.
6.
Detachthe rearhooksby movingthe frameforward,then removethe frame.
Removelast,
BOLT
6x1.0mm
9.8Nm(1.0kgl.m,
7.2 tbl.tll
6 x 1.0mni
9.8 N.m 11.0kgf.m,7.2tbtfo
20-54
Guide Rails/CableAssemblY
Replacement
7.
Pullthe draintubesout the front and rearpillars

NOTE:Beforepullingout the draintube,tie a string
to the end ot it so it can be reinstalled.
CAUTION: Wear gloves to remove and install the guide

railsand cableassembly.
1.
Removethe frame.
2.
Removethe motor and glassbracket(seepage20 52)'
3.
Removethe nuts, and liit off each guide rail, then

removethe cableassemblywith slidersattached'
NOTE:Take care not to bend the cable tubes and
g u i d er a i l s .
REARDBAIN
VALVE
lnstallationis the reverseof the removalprocedure'

NOTE:
. Beforeinstallingthe frame,clearthe drain tubes
and drainvalvesby usingcompressedalr.
. Checkthe frame seal.
. Cleanthe surfaceof the frame.
. When installingthe trame, first attach the rear
hooksinto the body holes.
. When connectingthe draintube, slide it over the
frame nozzleat least10 mm (0.39in)
. Installthe
t u b ec l i Pa s s h o w n .
GROMMET
4.
Installationis the reverseof the removalprocedure'

NOTE:
. Damagedpartsshouldbe replaced
. Greasethe slidingportionwith SuperHighTemp
UreaGrease,P/N08758- 9002.
. Fillthe groovein eachgrommetwith sealant.
Upward
I
I
9.
TUBECLIP
DRAINTUBE
Checkfor water leaks.

water.
NOTE:Do not use high-pressure
I
f
a lnstallthe frame sealsecurelY

a Beforeinstallingthe motor, makesure both slid-
ers are parallel.

Beforeinstallingthe motor, installthe trame and
glass,then checkthe openingdrag (seepage2057).
20-55
Moonroof
Switch PlateAdjustment(FullyClosedPositionl
1.
Removethe headliner{seepage20-64).
2.
Usingthe moonroofwrench,closethe glassfully.
NOTE:Checkthe glassfit to the roof panel.

3.
Usingan open-endwrench,loosenthe switchplatemountingbolts.
4.
Adjustpositionof the switchplate(switchcam) as shown.
5.
Checkthe operationof the glass(fromtilt-up positionto fully closedposition,from the fully open positionto the fully
closedpositjon)by operatingthe moonroofswitch.
NOTE:Checkthe glassheight{seepage20-51}.
SWITCHPLATE
GUIOE
PLATE
Vt,
,
I
I
cneclthe
Check
rr switchplatecontactsthe
ccable
ao r eo
r
bracket.
CABLE
, ERACKET
SWITCHCAM
INNER CAELE END
While movingthe switchplate little by little,securethe switch

plate at the positionwherethe switchcam contactsthe switch
A (a faintclickis heard).
Closethe glassfully, and checktor water leaks.

NOTE: Do not use high-pressure
water.
2 0- 5 6
OpeningDragCheck
(Motor Removed)
ClosingForceCheck
(MotorInstalled)
Beforeinstallingthe motor, measurethe effort required

to openthe glassusinga springscaleas shown.
1 . A f t e r i n s t a l l i n ga l l r e m o v e dp a r t s ,h a v e a h e l p e r
hold the switch to close the glasswhile you measure the force requiredto stop it. Attach a spring
scaleas shown. Readthe force as soon as the glass
stops moving,then immediatelyreleasethe switch
and springscale.
CAUTION: When using a spring scale.plotest the lading dge of the glasswith a shop towel.
lf load is over 40 N (4 kgf,9 lbf),checkthe side clearance
a n d g l a s sh e i g h t( s e ep a g e2 0 - 5 1 ) .
SHOPTOWEL
CAUTION: When using a spring scale, protect the

leading edge ol the glass with a shop towel.
Closing Force:200 - 290 N
(20 - 30 ksf, /14- 66 lbf)
SCALE
installa new
lf the force in not within specification,
by
turning
the motor
tension
the
lockwasher,adjust
c l u t c h a d j u s t i n gn u t , a n d b e n d t h e l o c k w a s h e r
againstthe motor clutchadjustingnur.
LOCK
WASHEB
Replace.
aI
COUNTERcLocKwtsE
To decrease
20-57
lnterior
ComponentLocationIndex
SRScomponentsare locatedin the pans areasmarkedwith an asterisk(*). Reviewthe SRScomponentlocauons,precautions,and proceduresin the SRSsection(24)beforepertormingrepairsor service.
2D l3D llDl
CENTERPILLAR
UPPERTRIM
{seepage20 59)
CENTERPILLAR
LOWERTRIM PANEL
(seepage20 59)
FRONTPILLAR
TRIM
(seepages20'59,60,61i
REARPILLAR
TRIM
(seepage 20-59)
REAR
(seepage20-59)
TRUNK
TRIM
(seepage20-62)
SEAT
SIDETRIM
ComponentRemoval/lnstallation,
page20-68
Removal,page20-70
(seepage20-59)
TCARPET
page20-66
Feplacement,
PANEL
Replacement.page 20-67
3D:
2Dl
OUARTER
TRIM PANEL
(seepage20 60)
OUARTER
TRIM PANEL
REARROOFTRIM
(seepage20 65)
REARROOF
TRIM
{seepage20,65}
HATCH
UPPER
TRIM
(seepage20 63)
REARCENTER
SHELF
(seepage 20-60)
REAR
PANEL
(seepage20-60)
TRIM PANEL
(seepage 20'63)
2 0- 5 8
SIDETRIM
{seepage20-60}
SIDETRIM
PANEL
(seepage 20-60)
REAB
PANEL
(seepage20-62)
REAF
(seepage20-6'1)
lnteriorTrim
Replacement
CAUTION:
. Wear gloves to remove and install the trim and panels.
. When prying with a tlat tip screwdriver,wrap it wilh protective tape to prevent damage.
NOTE:Takecarenot to bend or scratchthe trim and panels
4D:
>: Clip locations
o>,2
c>,21
8>,6
a>,2
E> , 2
CLIP
retu n>(
\Zl\
^f
J
CLIP
REARSHELF
LOCKCYLINDERTRIM
FRONTPILLAR
TRIM
CENTERPILLAR
LOWERTRIM
PANEL
SEAT
BELTUPPER
ANCHOR
(seepage20 85)
the
Disconnect
high mount brake
lightconnector.
RIGHT KICK
PANEL
T SIOETRIM
Removethe rearseatcushionand rear
seatsidebolster(seepage20 79i.
lnstallationis the reverseof the removalprocedure.

NOTE:
. lf necessary,
replaceany damagedclips.
. Beforeinstallingthe front seatbelt upper anchor
and rear shelt, make sure there are no twists or
kinksin the seatbelts.
(cont,d)
20-59
InteriorTrim
(cont'dl
Replacement
3D:
>: Clip locations
a>,2
B>.3
c>,8
CLIP
s
##
_ _ -/ _
,\\ \ \ ul\ / l
/
F > ,1 {
G>,2
'.,.
N i 4 )
a>,3
B>,6
qHP Y l*@
\
/
c > .1
,r+n
CLIP
_ _ N
E> , 8
A i f , n \ l e
n l-,
rr,\\F\
>: Screw, bolt locations

D>,3
H>,2
REARSEATBELT
UPPERANCHOR
{seepage20-89)
rcig
i @ i
|_) _t),t
)_w/
\ - -
D> , 2
l@@
\--
REARSIDE
SHELF
SIDETRIM
PANEL
Removethe rearseat-back
and
rearseatcushion(seepage20-80)
Disconnect
the rearspeaker
connector(bothsides,
for somemodels).
FRONTSEAT
EELTUPPER
ANCHOR
(seepage20-86)
REARTRIM
PANEL
SIDETRIM PANEL
PROTECTOB
SIDETRIM
REARCENTER
SHELF
FRONT SEAT BELT
LOWER ANCHOR
(seepage 20 86)
H
SPABETIRE
LID
,
NOTE:
. lf necessary,
. Beforeinstallingthe anchorbolts,makesurethere
are no twistsor kinksin the seatbelts.
20-60
2D:
>: Screw locations,4
>: Clip locations
a>,2
c>, 14
B> , 3
D> , 3
E>,2
TRIM
H>,2
G>,4
F>,8
,.
r$H
N,tU ffi
FRONTPILLAR
SIDETRIM PANEL
and
Removethe rearseat-back
rearseatcushion(seepage
2 08 1 ) .
LOCKCYLINDER
TRIM
FRONTSEAT
EELTUPPER
ANCHOR
{seepage20-86)
SIDETRIM PANEL
the high
Disconnect
mount brakelight
connector.
SIDETRIM
PIVOTBRACKET
(seepage20-81)
w'
A
, \ .
/ " c
ntoirrrcx
SEATBELT
LOWERANCHOR
(seepage20-86)
LEFTKICK
PANEL
NOTE:
. lf necessary.
. Beforeinstallingthe anchorbolts and rear shelf,
makesurethereare no tvvistsor kinksin the seat
belts
20-61
TrunkTrim
Replacement
CAUTION:
. Wear gloves to remove and install the trim and panels.
. Whon prying with a flat tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:
. Takecarenot to bend or scratchthe trim and panels.
. When removingthe trunk sidetrim or trunktrim panel,fold the seat-back
torward.
Japan-produced:
4D:
REARTRIM
PANEL
RIGHTTRUNK
SIDETRIM
>: Clip locations

a >,6
NOTE:Do not push
the innerclip in too far.
I
CLIP
R-.--\ra
I l'3{aQ'F-
s:'\
I
, -
"
\\-
|NNER
cll
B>,6
i J
t -
\--
!l
/tt
i ) :Hook locations
Ai-), t
TRUNKMAT
2D:
B t-'),2
TRUNK TRIM

NOTE:
. lf necessary,
replaceany damagedcl;ps.
. To installthe A clips,pull the innerclip up, install
the clip,then pushthe innerclip until it'sflush.
20-62
HatchTrim
Replacement
CAUTION:
. Wear gloves to remove and install the trim.
. When prying with a flat tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:Takecarenot to bend or scratchthe trim and panel.
>: Cliplocations
a >' 2
NOTE:Do not pushthe I

innerclip in too far.
I
c>,13
B> , 7
r- r
vr:/
54@-,1
g * - \
|
M cr-rp.
Y , /
:?-
-N-l
IS]
",/
INNER ]
ct!,/
'Pr-u
a
.rt-ATa-a-a
;--'"[1"
c l
LEFTHATCH
SIDETRIM
HATCH
TRIM
UPPER
NOTE:
. lf necessary,replace any damaged clips.
. To install the A clips, pull the inner clip up. install
the clip, then push the inner clip until it's flush.
20-63
Headliner
Replacement
CAUTION: When prying with a flat tip screwdriver.
wlap it with protective tape to prevent damage.
2.
Remove the sunvisor and holder from each side.
3.
Removethe grab handlesand coathanger.
NOTE:
. Takecarenot to bendand scratchthe headliner.
. Be careful not to damagethe dashboardand other
interiortrim.
'1.
Remove:
4D:
a Frontpillartrim (bothsides,see page20-59)
a Centerpillarlowertrim panel(bothsides,seepage
20-59)
Upper anchorbolt from the front seat belt (both
sides,seepage20-85)
Centerpillaroutertrim and centerpillaruppertrim
(bothsides,seepage20-59)
a Ceilinglight (seesection23)
Rearviewmirror (seepage20-25)
ACCESS
LID
3D:
Frontpillartrim (bothsides,see page20-60)
Right rear seat-backand rear seat cushion (see
page20-80)
. Rearcentershelf(seepage20-60)
o R e a rs i d e s h e l f a n d s i d e t r i m p a n e l( r i g h ts i d e ,
seepage20 60)
. Upper anchorbolts from the front and rear seat
belts{right side,seepages20-86,89)
. Ouartertrim panel(rightside,see page20-50)
. Ceilinglight (seesection23)
. Rearviewmirror (seepage20-25)
.
.
2Dl
. Frontpillartrim (bothsides,see page20-61)
. Right rear seat-backand rear seat cushion (see
page20-81)
. Sidetrlm panel(rightside,seepage20-61)
. Upper anchorbolt from the front seat belt (rlght
side,see page20-86)
. Ouartertrim panel(rightside,see page20 61)
. Ceilinglight (seesection23)
. Rearviewmirror (seepage20-25)
20-64
ACCESS
LID
scREws
COATHANGER
BRACKET
4.
Remove the rear root trim and clips, and remove

the roof trim and socket plug (moonroof model)
2Dl
>: Clip locations

A> 20l40,7
B > With moonrool,1
3D,5
Withoutmoonrool,3
)At
% )
EE
& )
2D l3D l4Dl
REARBOOF
REAR
PILLAR
TRIM
OUARTER
TRIM PANEL
HEAOLINEB
3D:
5.
4D: Lowerthe rearpillartrim on both sides.

3D: Removethe upper anchor bolts from the front
and rearseatbelts(seepages20-86.89i,then lower
the quanertrim panelon left side.
2 D : R e m o v et h e u p p e ra n c h o rb o l t t r o m t h e f r o n t
seat belt (see page 20-86),then lower the quarter
trim panelon left side.
6.
L o w e rt h e h e a d l i n e r .
7.
Carefullyremovethe headlinerthroughthe passenger'sdoor opening(2Dl4D)or hatchopening(3D)
8.
Installationis the reverseoI the removalproceclure.

NOTE:
. W h e n i n s e r t i n gt h e h e a d l i n etrh r o u g ht h e o p e n ing, be carefulnot to fold or bendit. Also,be caretul not to scratchthe body.
. C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e
securelyattachedto the trim.
. W h e n i n s t a l l i n gt h e r o o f t r i m , i n s t a l lt h e j o i n t
towardthe right side (moonroofmodel)
20-65
Carpet
Replacement
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions,
and proceduresin the
SRSsection(24)beforeperformingrepairsor service.
4.
Removethe footrestand parkingbrakelevermounting bolts,and detachthe clips,then removethe carpet.

>: Clip locations,
1. Remove:
. Frontseat(seepage20-74l
. Rearseatcushion(seepages20-79,80,81)
Kickpanel(seepages20-59,60, 61)
Centerpillarlowertrim panel(4D.seepage20,59)
a Frontseat belt lower anchor(2Dl3D,see page2086)
a Sidetrim {seepages20-59,60, 61)
a Frontand rearconsoles
a Consolepanel
rft
>: Bolt locations

A>,2
B>.2
\ t l
9s l /
6x'l.0mm
tf
I e.sN.mt1.oksrm,
E / 7 2 tbrftl
2Dl3Dl4D:
FOOTREST
Removethe SRSunit covers.
3 . Cut areas@ and @ in the carpet,then pull it backas

snown.
>: Cliplocetions,
2
--.ils
- I
l@l
-llp -
LEFTSRS
UNIT COVER
2D l3Dl
SIDETRIM
5.

NOTE:
. Takecarenot to damage,wrinkleor twist the car
pet.
. Make surethe wire harnessesare routed correctly.
. lf necessary,
. Slip the carpet under the seat side trim (4D) or
sidetrim panel(2Dl3D)on eachside properly.
. Reattachthe cut areas@ and @ in the carpet
with wire ties.
20- 6 6
Panel
Consoles/Console
Replacement
NOTE:Takecarenot to scratchthe front and rearconsoles,front seatand relatedparts.
Disassemble
in numberedsequence.
>: Screw locations
A>,8
A>./t
>: Clip localions
-f
D7777777v-r
@@'
0F*
:
) "
B>,2
A>,2
) _ : )
(' FRONTCONSOLE
Remove the shif! lever knob {M,/T).
o REARCONSOLE
lwith armrest)
^\
of the removalprocedure.
Installation
is the reverse
NOTE:
.
.
.
lf necessary,
Makesurethe wire harnessesare not pinched.
Makesurethe connectoris connectedproperly.
20-67
Dashboard
ComponentRemoval/lnstallation
CAUTION:when plying with a flat tip screwdriver,wrap
it with protectivetape, and apply protectivetape around
the related parts,to prevent damage.
NOTE:Takecarenot to scratchthe dashboardand related
parts.
Driver'sdashboardlower cover and knee bolster removal:

SRScomponentsare locatedin this area.Reviewthe SRS
and proceduresin the
componentlocations,precautions,
performing
repairsor service.
before
SRSsection{24}
1.
Instrument panel removal:

1.
Lowerthe steeringcolumn.
2.
Removethe screws,and detachthe clips,then carefully removethe instrumentpanel.
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n
r e m o v e t h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r .l f
equippedwith power mirrorsand moonroof,disconnectthe connectors.
>: Screw,bolt locations

B>,2
a >,3
--'4.i
***\Y
>: Clip locations.2
"[]
p 1
l
/D,- ox lomm
((n1lfl )e.8 N m (l.o kgtm,
\)- 7.2tbf.ftl
>: Clip locations

B>, 1
a>.2
F-,,
POWERMIRROR
SWITCHCONNECTOR
(for somemodels)
PANEL
3.
lnstallationis the reverseof the removalDrocedure.

MU(,NTIUUI-
swtTcH
CONNECTOR
models)
DRIVER'S
DASHBOARD
LOWER
COVER
2.
Removethe bolts,then removethe kneebolster.
3.
Glove box removal:
Center dashboardlower covsr:
Removethe bolts,then removethe glove box.
'1.
>: Boltlocations,
2
5xo.8mm
Remove:
. Driver's dashboard lower cover
. Glove box
9 N m lO.9ksf.m,I
'::"
)
2.
Remove the screws and bolt. then remove the cen

ter dashboard lower cover. Disconnect the accessory socket connector.
>: 8olt, scrsw locations

A>, I
A ,ro.r--
B>,5
6:u;q9 Q,
lnstallationis the reverseot the removalorocedure.
Side air vent/Side defogger trim removal:

SIDEDEFOGGER
TRIM
C a r e f u l l yp r y r t a t t h e s i d e e d g e .
HOOKS
SIDEAIR VENT
Removethe driver'sdashboardlower
cover,or openthe glovebox,
then pushthe clipstrom each
openingby hand,and pullit
out. Disconnectthe connedors
(driver'sside).
CENTERDASHBOARO
LOWERCOVER
CLIP
HOOKS
3.
Instgllation is the reverse of the removal procedure
DASHLIGHTS
BRIGHTNESS
CONTROLLER
l-
[3LT'-""'31r",.,
CRUISECONTROL
MASTERSWITCH
CONNECTOR
(forsomemodels)
(cont'd)
20-69
Dashboard
ComponentRemoval/lnstallation
(cont'd)
Center panel removal:
'1. Remove:
. Centerdashboardlowercover(seepage20-69)
. Radio(seesection23)
2.
Removethe rear window defoggerswitch and haz

ard warningswitch,then disconnectthe connectors.
>: Screwlocations,5 >: Cliplocations
B> , 3
A>,4
Removal
SRS componentlocatlons,precautions,and procedures
in the SRSsection(24)beforepreformingrepairsor servtce.
NOTE:
. An assistanlis helpfulwhen removingand installing
t h ed a s h b o a r d .
. T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d y a n d
relatedparts.
1.
Remove:
. Frontand rearconsoles(seepage20-67)
. Consolepanel(seepage20-67)
. Driver'sdashboardlower cover and knee bolster
(seepage20-68)
. Glovebox {seepage20-69)
. Centerdashboardlowercover(seepage20-69)
2.
Lowerthe steeringcolumn(seesection17)
i'Y
6tr'
@-Y-r
CENTER
To avoid accidentaldeployment and

@@
possiblo iniury, always disconnsct the driver's
airbag connector before lowering the steering column lsee section 2,1).
/w4,
ew
I
I
HAZARD
WARNING
swrTcH
NOTE:To preventdamageto the steeringcolumn,

wrap it with a shoptowel.
wI
N<4
3.
Mtx
CONTROL
CABLE
REAR
WINDOW
DEFOGGER
SWITCH
CONTROL
UNIT
Disconnectthe dashboardwire harnessconnectors,

remove the nuts, then move the under-dashfuse/
relay box. Disconnectthe antennalead and moonroof relayconnectors.
oasHeolno
MOONROOF
FRAME
RELAY
CONNECTORS
(for somemodels)
9LlPs
SRSMAIN
HARNESS
the air mix controlcable,and removethe

Disconnect
screws,then pull out the centerpanel.
4.
Disconnectthe connectorsfrom the heatercontrol

unrt.
is the reverseof the removalprocedure.
Installation
UNDER.DASH
FUSE/RELAY
BOX
NOTE:
a Makesurethe connectorsare connectedproperly.
. Adjustthe air mix controlcable(seesection21).
ANTENNA
LEAD
DASHBOARO
OATA
CONNECTOR WIREHARNESS
CONNECTORS
Detach.
20-70
6x1.0mm
9.8 N.m 11.0kg{.m,
7.2 tbt.tll
4.
Removethe following partslrom the dashboard.

. Driver'sdashboardsidecover
. Passenger's
dashboardlower cover
. Dashboardcenterlid
5.
the connectorsand air mix controlcable.

Disconnect
To avoid accidental deployment and possible inlury, always disconnect the flont passenger'sai.bag
!!!@
connector when the SRSmain harnessis disconnested(seesection 241
>: Bolt, screw localions
A>,7
8x1.25mm I
22 N-m 12.2kgl.m, )
16 tbt ftl
/
>: Clip locations
A>, 1
B>,1
,Jiill
.ll
ft,ffits
/ffi)
"ffi j M,i
,,{\
I x 1.25mm
l[!,P
,"-- _,J
I l\-
___ L
_:_'_"o'nt
OASHBOARD
vt)
M
WT
' | . 1 , / - - t t / - - - J
6x1.0mm
22N.m{2.2ksrm, I LBJIP e.6N rn11.s

1s1m,I
c>,5
I
D>,1
c>,1
B>,1
DASHBOARD
AIR MIX CONTROL
PROTECTIVE
PLATE
UNOER.OASH
FUSE/BELAY
BOX
Loosenthe bolt.
r
I
PASSENGER'S
DASHBOARD
LOWERCOVER
6.
Removethe bolts,then lift and removethe dashboard.

CAUTION: Use protective platss on the bottom ol the front pillar trim.
(cont'd)
20-71
Dashboard
Removal (cont'dl
7.
removethe dashboardframefrom the dashboard

lf necessary,
>: Screw locations
a>,21
INSTRUMENT
PANEL
I( . -Fu'
-
B>,4
.4\
lft))@
!v
a: Nut locations,3
]r45 s'r.o-ksf.m,
\Gt"/ s.8N.m_11.0
r1,b,ft
\>: Clio locations
DASHBOARD
DASHBOARD
FRAME
DASHBOARD
WIREHARNESS
STRIKEB
DASHBOABD
SIDECOVER
8.
BRACKET

NOTEi
. Before tightening the bolts, make sure the dashboard wire harnessesare not pinched
. Make sure the connectors, antenna lead and air mix control cable are connected properly'
20-72
Seatsand Seat Belts

2Dl3Dl1D:
ANCHOR
SHOULDER
ADJUSTER
I4DI
lseepage20-85)
REAnSEATBELT12Dl,lDl
page20-88
Replacement,
page20-91
Inspection,
REARSEATBELTBUCKLE/
CENTERBELTTONGUE{2DI4DI
(seepage20'90)
FRONTSEATBELT
pages20 85,86
Replacement,
page20-91
Inspection,
FRONTSEATS
Removal,page20'74
page20-75
Replacement,
HarnessWiringand Becline
page20 77
CableLocations,
page20 77
SeatCoverFeplacement,
REABSEAT(2Dl4D)
Removal,pages20-79,81
Seat-backLatchReplacement,page 20 82
page20-83
SeatCoverReplacement,
BELTBUCKLES
(seepage20-87)
3D:
REARSEATBELTBUCKLE/
CENTERBELTTONGUE
(seepage20 90)
REARSEATBELT
page20-89
Replacement,
page20 91
Inspection,
REAR SEAT
Removal,page 20 80
S e a t b a c k L a l c h B e p l a c e m e n t ,p a g e 2 0 8 2
S e a t C o v e r R e p l a c e m e n t ,p a g e 2 0 8 3
20-73
FrontSeat
Removal
CAUTION: when prying with a flat tip screwdrivol,wrap
it with proteqtivetape to preventdamage.
2.
Lift the driver'sfront seat,then disconnectthe seat

belt switch connector.
NOTE: Takecare not to scratchthe seatcoversand body.

'1. Removethe seat track end cover,then removethe
bolts.
)
Removethe headrest.
Carefullyremove the front seat through the door
openrng.
FRONTSEAT
NOTE:Make sure the connectoris connectedproperly.
BOLT
10 x 1,25 mm
39 N.m (4.0kgf.m,
29
BOLT
I x 1.25mm
22 N.m 12.2kgl.m,
16 rbf.ftl
8 x 1.25mm
22 N.m 12.2kgl.m,
16 tbt.ftt
20-74
Replacement
CAUnON: When prying with a flat tip screwdriver,wrap it with protective tape to provent damage.
NOTE:
a Takecarenot to scratchthe seatcoversand body.
. Removethe front seatthroughthe door openang.
Drivel's:
NOTE:Referto page20-77for the seatbelt switchharnesswiring location.
HEADREST
SEAT.BACK
PIVOTNUT
8 x 1.25mm
22 N.n i'2,2
16 lbf.ft)
SEATCUSHION
vI
CENTER
1 0x 1 . 2 5m m
,17N.m {4.8 kgt m,
10x 1.25mm
47 N.m (4.8kgt.m,
35 tbt.fr)
RECLINEAOJUSTER
LOWER CAP
&
1 0x 1 . 2 5m m
t
RECLINE
WIRE
CONNECTING
To connect,twist 180'.
OUTERSEAT
TRACK
Installationis the reverseof the removalprocedure,
8 x 1.25mm
20 N.m (2.0 kgf.m,
1/rlbf.ft)
NOTE:
. M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e
installedproperly.
. T o p r e v e n tw r i n k l e sw h e n i n s t a l l i n gt h e s e a t back cover. make sure the materialis stretched
evenlyoverthe pad.
. Greasethe slidingportion.
(cont'd)
20-75
FrontSeat
Replacement(cont'dl
Passenger'slwith recline cablel:
NOTE:Referto page20-77for the reclinecablelocation.
HEADREST
SEAT.BACK
PIVOTNUT
I x 1.25mm
22 N.m(2.2kgf.m,
rbr.ftl
SEATCUSHION
PIVOT
WASHER
l0 x 1.25mm
47 N.m (4.8 kgf.m,
35 tbnfr)
LOWER
CAP
10 x 1.25mm
47 N.m {4.8 kgf.m,
35 tbf.ftl
INNERSEAT
RECLINE
rowER CAP
10x 1.25mm
47 N.m ({.7 kgf.m,
35 tbf.ft)
OUTERSEAT
TRACK
WIRE
T o c o n n e c t ,t w r s t 1 8 0 .

8 x 1.25mm
20 N.m (2.0kgf.m,
14 tbtft)
20-76
NOTE:
. M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e ra r e
installedproperly.
. To preventwrinkleswhen installingthe seat-back
cover,makesurethe materialis stretchedevenly
overthe pad.
. Adjustthe reclinecable.
. Greasethe slidingportion.
HarnessWiringand Recline
CableLocations
SeatCoverReplacement
CAUTION: Wear gloves to remove and install the seat
NOTE:When installingthe seat cushion,make sure the

seatbelt switchharness,connectorand reclinecableare
fastenedcorrectlyon the seatcushionframe.
GOVetS.
Driver's:
Seat-backcover removal:
>: Clip locations
NOTE:Take care not to tear the seamsor damagethe

seatcovers.
1.
Releasethe hook.and fold backthe seat-backcover.

HEADREST
2.
Releaseall inside springs,then foid back the seatDacKcover.
3.
Removethe headrest.
(with reclinecablel:
Passenger's
Removethe headrestguide,then removethe seatDacKcover.
TRACK

NOTE:To preventwrinkleswhen installinga seatbackcover. makesure the mateial is stretchedevenly
over the pad beforesecuringthe insidespringsand
hook.
(cont'd)
20-77
FrontSeat
SeatCoverReplacement(cont'dl
Seat cushion cover removal:
1.
Removethe seatcushion(seepages20-75,76).
2.
Removethe clipsfrom underthe seatcushion,then

loosenthe seatcushioncover.
>: Clip locations
\
4.

NOTE:
. To preventwrinkleswhen installinga seatcushion cover, make sure the material is stretched
evenlyover the pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
NEWCLIP
SEATFFAME
COVER
Pull backthe edge of the seatcushioncover all the

way around,then releasethe clips,and removethe
seatcushioncover.
>: Cliplocations
20-78
RearSeat
Removal
NOTE:Takecarenot to scratchthe seatcoversand body.
4D:
::-):Hooklocations,2
c>,1
D>,1
>: CliplocatioG,14
@
---------8tr-Fq
EU
-w
,/
CENTER
PIVOT
BRACKET
r>t
r--r
RIGHTSEAT-BACK
SEATCUSHION
SEAT.BACK
Pivot bolt construction:
TOOTHED
LOCK
WASHER
BUSHING
NOTE:
PIVOTBOLT
ERACKET
8 x 1.25mm
22 N.m {2.2 kgtm, 15 lbf.ftl
Apply liquidthreadlock.
a Beforeaftachingthe seat-backand seatcushion,make sure there are no twists or kinks in the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seat cushion.
. N4ake
surethe seat-backlockssecurely.
(cont'd)
o lf necessary,
adjustthe seat-backlatch(seepage20-82)and seat-back.
20-79
RearSeat
Removal(cont'd)
3D:
>: Bolt locations
A>,6
6x1.0mm
9.8 N.m (1.0kst m,l
':*2
(:) : Hook locations,2
ffi
It
>: Clip locations,14
c>,1
8 > ,1
6x1.0mm
22 N.m |.2.2kgl.m)
16tbt'-ft')
- -J)
STRIKER
Removethe sidetrim
panel(seepage20 60).
6 x 1.0mrn
9.8Nm(1.0kgf.m,
1.2 tbt.ftl
v@n
FE
E
e
6x1.0mm
E/
SEATCUSHION
TRUNK
STRIKER
T
STRIKER
A
CENTER
PIVOT
BRACKET
PIVOT
BRACKET
LEFT
SEAT.BACK
TOOTHED
LOCK
WASHER
SEATCUSHION
BUSHING
PtvoTBoLT BRACKET
8 x 1.25mm
22 N.m {2.2kgf.m,16lbtft)
NOTE:
. Beforeattachingthe seat-backand seat cushion,make sure there are no twists or kinksin the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushion.
. Makesurethe seat-backlockssecurely.
. lf necessary,
adjustthe strikerand seat-back.
20- 8 0
2Di
i) : Hooklocations,2
>: Bolt locations

A>,6
R
6x1.Omm
9.8Nm11.0ksf.m,;
':*'
>: Cliplocations,lil
c>,1
B>,1
,r@?r,
6 x 1 . o m m I ,\ff8 , u " , , 0 - 22N m t2.2kgtm,'
S.eN m tr.Oksf-,
16tbfitt
7.2rbr.tt)
FF
SEATCUSHION
SEAT-8ACKMAT
vv
PIVOTBRACKET
--v-.
CENTER
PIVOTBRACKET
RIGHTSEAT-BACK
|\
TOOTHD
LOCK
WASHER
BUSI{ING
PIVOT
BRACKET
SEATCUSHION
'..'
PIVOTBOLT
8 x 1.25mm
22 N m (2.2kgI.m, 16 lbf.ft)

NOTE:
. Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinksin the rearseat belts and
centerbelt.
. Makesurethe seat backlockssecurely.
. lf necessary,
adt'ustthe seat-backlatch(seepage20-82)and seat-back.
20-81
RearSeat
Seat-backLatchReplacement
2Dl1.D:
3D:
R e m o v et h e l o c k c y l i n d e rt r i m . t h e n r e m o v et h e r e a r
shelf(seepages20-59,61).
Pullthe trunk mat awayfrom the seat-back(seepage2080).
NOTE:Takecarenot to bend eachlockrod.

>: Bolt. screw locations
a>,2
>: Boh, scrow locrtions
A>,4
Ei
E
c
B> , 2
ort.o--
g.sw m tt.otot.-.
7.2tbr.ft,
7
r g l
/
/-\
ffifu
B>,1
6x1.0mm
s.aN.. tt.or,sf.-.
11'11 )
: l
SEAT-BACK
LOCKCYLINDER
TRIM
nstallationis the reverseof the removalprocedure.

BACKLATCH
Installationis the reverseof the removalprocedure,

NOTE:
a Makesureeachlock rod is connectedsecurely.
. M a k e s u r e e a c h s e a t - b a c kl o c k s s e c u r e l ya n d
opensproperly.
. lf necessary.
adjustthe seat-backlatch.
20-82
NOTE:
. Makesurethe seat-backlockssecurelyand opens
propeny.
Seat Gover Replacement

CAUTION: Wear glovs to remove and install the seat
covels.
4.
NOTE:
. To preventwrinkleswhen installinga seat cushion cover, make sure the material is stretched
NOTE; Takecare not to tear the seamsor damagethe seat

covers.
Soat-backcover removal:
3D:
2DI4D:
L
Removethe seat-back(seepages20-79,81).
'1.
Removethe seat-back(seepage20-80).
2.
L o o s e nt h e s e a t - b a c kc o v e r b y r e l e a s i n ga l l t h e
clrps.
2.
Loosenthe seat-back
coverby releasingallthe clips.
NOTE:Removethe lock knob, lock collar and latch
cover.
>: Cliplocations
>: Cliplocations
3.
SEAT.BACK
COVER
LEFTSEAT.BACK
RIGHTSEAT.BACK
COVER
COVER
Pull back the edge of the seat-backcover all the way
around. then releasethe clips.
>: Clip locations
3.
Pull backthe edge of the seat-backcoverall the way

around,then releasethe clips.
>: Cliplocations
SEAT.BACK
COVER
RIGHT
4.

NOTE:
. To preventwrinkleswhen installinga seat-back
cover,makesurethe materialis stretchedevenly
overthe pad beforesecuringthe clips.
(cont'd)
20-83
RearSeat
SeatGoverReplacement(cont'dl
Seat side bolster cover rmoval l,lDl:
2Dl3Dl
1.
Removethe seatside bolster(seepage20-79).
2.
Loosenthe seat side bolstercover by releasingall

the clips,then removeit.
EF*aa-bF-E<
V
\
,
f.I--l
f
r -r_I--t
lm n
rt=r/ {
>: Clip locations
SEATSIDE
BOLSTER
COVER
(!,
lr
.t=!l
COVER
Pull back the edge of the seat cushion cover all the
way around, release the clips, and remove the seat
cushron cover.
>: Clip locations
4D:
3.

NOTE:
a To preventwrinkleswhen installinga seat side
bolstercover,makesurethe materialis stretched
evenlyoverthe pad beforesecuringthe clips.
20 l3Dl
Seat cushion cover removal:

1.
R e m o v et h e s e a tc u s h i o n( s e ep a g e s2 0 - 7 9 , 8 0 , 8 1 ) .
2.
Loosenthe seat cushioncover by releasingall the

clrps.
COVER
>: Cliplocations
4D:
4.
_ - / -
v,la
-.lL J

NOTE:
. To preventwrinkleswhen installinga seatcusha o nc o v e r ,m a k e s u r e t h e m a t e r i a li s s t r e t c h e d
/.)
lL--Jl '.n
UPHOLSTERY
RINGPLIERS
lCommerciallv
available)
SEATFRAME
20-84
Front Seat Belt

Replacement
CAUTION: Check the tront seat belts for damage, and
replacethen if nacessary.B9 careful not to damage then
during removal and installation,
Removethe centerpillaruppertrim (seepage20-59).

6.
Removethe shoulderanchoradjuster.
Fronl seat belt removal {,[D):

1 . Slidethe front seatforwardfully.
2.
Removethe centerpillar lowertrim panel(seepage

20-59).
I x 1.25mm
23 N.m (2.3 kgf m,
17 tbf.ft)
Removethe upper anchorcover and lower anchor

cap.
UPPERANCHORBOLT
7/16-20UNF
32 N,m (3.3kgf.m,
24 rbf.ftl
ANCHOR
ADJUSTER
7.
UPPERANCHOR
COVER
FRONTSEA
BELT
RETRACTOR
MOUNTINGBOLT
6x1.0mm
9.8 N.m (1.0 kgf.m,
7.2 tbf.ftl

NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon page20-91.
. Makesureyou assemblethe washersand collars
on the uoDerand lower anchorbolts as shown.
are no twists or kinksin the front seatbelt.
Upper anchorboh construqtion:
RETRACTOR
COLLAR
UPPER
ANCHOR
UPPERANCHOR
BOLT
Apply liquidthread
RETRACTOR
BOLT
7/1&20UNF
32 N.m (3.3 kgt.m,
2a tbtft)
+I
LOWENANCHORBOLT
7,/16-20UNF
32 N.m (3.3 kgf.m, 24 lbf ftl
I
II
BEARING
LOWERANCHOR
CAP
Removeall the anchorbolts and the retractorbolt,

remove the retractormounting bolt. then remove
the front seatbelt and retractor.
(cont'd)
20-85
Front Seat Belt

Replacement(cont'dl
\
Front seat belt romoval (2Dl3D):
Lower anchor bolt construction:

SPRING
WASHEF
COLLARS
WASHERS
LOWER
ANCHOR
1.
Slidethe front seatforwardfully.
2.
Remove:
. Rearseat-backand rear seatcushion(seepages
2 08 0 , 8 1 )
. R e a r c e n t e rs h e l f a n d r e a r s i d e s h e l t ( 3 D ,s e e
page20-60)
. Reartrimpanel(3D,seepage20-60)
. Sidetrim panel(seepages20-60,61)
3.
Removethe upperanchorcoverand loweranchorcap.
BEARING
FRONTSEAT
BELT
Rtractor bolt construction:
UPPER
ANCHORBOLT
7/r6-20UNF
32 N.m 13.3kgt.m,
24 rbf.ft)
RETRACTOR
BOLT
I
llrrtnn-ffi\
RETRACTOR
MOUNTINGBOLT
6x1.0mm
9.8 N.m {'t.0kgt.m,
7.2 tbf.ftl
\Y **rss,t
LOWER
ANCHOR
CAP
RETRACTOR
I
I
o
RETRACTOR
BOLT
7/16-20UNF
32 N.m (3.3kgl.m,
24 tbI.ft)
4.
2 0- 8 6
LOWERANCHORBOLT
7/16-20UNF
32 N.m {3.3kgt m,24 lbf.ftl
Removeall the anchor bolts and the retractorbolt,

removethe retractormountingbolt,then removethe
front seat belt and retractor.
is the reverse
of the removalprocedure.
5. Installation
NOTE:
. Checkthatthe retractor
funclockingmechanism
tionsasdescribed
on page20-91.
Makesure you assemblethe washersand collars
on the uoDerand lower anchorboltsas shown.
Beforeinstallingthe anchorbolts,makesurethere
are no twists or kinksin the front seat beit.
Seat beh buckle removal:

1 . R e m o v et h e f r o n t s e a t t h r o u g ht h e d o o r o p e n i n g
(seepage20 74).
2.
Removethe centercover(seepages20-75,76).
Removethe centeranchor bolt, then removethe seat
beltbuckle.
SEATBELT
BUCKLE
Upper anchor bolt construclion:

WASHERS
SPRING
WASHER
ANCHORBOLT
BEARING
CLIP
4.
SPRING
WASHER
BEARING
COLLARS
32 N'm {3.3kgfm, 2't lbfft)
Driver's:Detachthe seat belt switch connectorand

harnessclip from the seatcushion(seepage20-77).
Removethe seat cushion mounting bolts from the
and movethe inner
innerseattrack{seepage20-751,
seattrack,then pull the seatbeltswitchharnessout.
NOTE:Takecarenot to damagethe hingebracket.
Center anchor bolt construction:

CENTERANCHOR
BOLT
WASHERS LowER
LOWERANCHOR
ANCHOR BOLT
LOCKWASHER
Retractorbolt construction:
TOOTHEO
LOCKWASHER
RETBACTOR
SPRING
WASHER
5.
WASHER

NOTE: Make sure you assemblethe washers and
bearingon the centeranchorbolt as shown.
RETRACTOB
20-87
RearSeat Belt
Replacement
GAUTION:Checkthe rear seat belts for damage,and
replacethen if necessary,Be careful not to damage then
during removal and installation.
Rearseat belt removal l2DllDl:.
1.
2.
Remove:
. Rearseatcushion(seepages20-79,81)
. Rearseat-back{2D,see page20-81)
. Sidetrim panel(2D,seepage20 61)
r Rearshelf(seepages20-59,61)
. Reartrim panel(seepage20-62)
. Trunksidetrim, Japan-produced
(seepage20-62)
. Trunktrim panel,USA-produced
(seepage20-62)
3.

NOTE:
. Make sure you assemblethe washersand collar
on the upperanchorbolt as shown.
. Beforeinstallingthe anchorbolt, make surethere
are no twists or kinksin the rearseat belt.
Upper anchorboh construction:
Removeall the anchorbolts and retractorbolt, then

removethe rearseat belt and retractor.
UPPER
ANCHOR
BOLT
7/16-20
UNF
RETRACTOR
BOLT
7/16-20UNF
32 N.m {3.3kgf.m,
24 rbf.ft)
TOOTHED
LOCKWASHER

LOWERANCI{OR
BOLT
LOWERANCHOR
7/1S20UNF
32 N.m 13.3kgI.m,24lbl.ftl
Retrastor bolt construqtion:
/7-'\
177--7,
trv-*q
,/Rr
TOOTHED
LOCKWASHER
20-88
/i\
ntz
\
RETRACTOR
ll
\
RETRACTOR
BOLT
Rearseat belt removal l3Dl:

1.
Remove:
20_80)
. Rear center shelf and rear side shelt (see page
20-601
. Reartrim paneland sidetrim panel(seepage2060)
2.
Removethe upperanchorcover
4.

NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon Page20-91
on the upperanchorbolt as shown
. Betoreinstallingthe anchorbolt, makesurethere
are no twistsor kinksin the rearseatbelt.
Upper anchorboh construqtion:
SPRING
UPPERANCHORBOLT
7/16-20UNF
32 N.m {3.3kgl m.24lbf ftl
UPPERANCHOR
BOLT
BOLT
RETRACTOB
7/16-20UNF
32 N.m (3.3kgf.m,
WASHER
TOOTHEO
LOCK
WASHER
Lower anchorbolt construction:
LOWEBANCHOB
7/15-20UNF
32 N.m (3.3kg{.m,24lbfft)
TOOTHED
LOCKWASHER
Retraqtorboh conslruction:
3.
Removeall the anchorboltsand retractorbolt.then

removethe rearseat belt and retractor'
TOOTHED
LOCKWASHER
BOLT
(cont'd)
20-89
RearSeat Belt
Replacement(cont'd)
Soat belt buckle/Canterbelt tongue removal:

1.
Removethe rear seat cushion(seepages20-79,80,

81).
2.
Removethe center anchor bolts, then remove the

seatbelt bucklesand centerbelttongue.
Centel anchor bolt construction:
CENTERANCHOR
2DI4'D:
CENTER
BELT
BUCKLE
7/16-20UNF
TOOTHEO
LOCKWASHER

NOTE: Beforeattachingthe seat-backand seat cushion, make sure there are no twists or kinks in the center belts.
CENTERBELTTONGUE
3D:
CENTERANCHORBOLTS
7/16-20UNF
32 N.m {3.3 kgf.m,
24 tbtftt
CENTERBELT
20-90
Seat Belts
Inspection
3D:
Retractor Inspection
'1.
Beforeinstallingthe retractor,checkthat the seatbelt

can be pulledout freely.
lvake sure that the seat belt does not lock when the
retractoris leanedslowlv up to 15'from the mounted
position.The seatbelt shouldlockwhen the retrador
is leanedover40".
CAUTION:Do not attempt to disassemblethe retractor.
RETRACTOR
Forward
*: Mounted Posilion
Front:
4D:
3.
Replacethe seatbelt with a new one if there is any

abnormality.
On-the-CarSeat Belt Inspection
Forward
1.
Checkthat the seat belt is not twisted or caughton

anyrnrng,
2.
After installingthe anchors,checkfor free movement on the anchorbolts.lf necessary.removethe

anchorbolts and checkthat the washersand other
partsare not damagedor improperlyinstalled.
3.
Checkthe seatbeltsfor damageor discoloration.

Cleanwith a shop towel if necessary.
lnside
2DI3D:
CAUTION: Use only soap and water to clean.

NOTE:Dirt build-upin the metal loops of the upper
anchorscan causethe seat belts to retractslowly.
Wipe the insideof the loopswith a cleanclothdamP
enedin isopropylalcohol.
lnside
Checkthat the seat belt does not lock when pulled

out slowly. The seat belt is designedto lock only
duringa suddenstop or impact.
Rear:
2Dl lDl
Makesurethat the seatbeltwill retractautomatically

when released.
For each passenger'sseat belt, make sure that the
l o c k i n gm e c h a n i s mi n t h e s e a t b e l t r e t r a c t o rw i l l
engagewhen the seatbelt is pulledall the way out.
7.
Forward
Replacethe seat belt with a new one if there is any

abnormality.
lnside
20-91
Seat Belts
GhildSeat Anchor Plate
Attachmentpointsare providedfor a rear seat mounted
childrestraintsystemwhich usesa top tether.The attachment points are locatedon the rear shelf or rear trim
panel,just behindthe rearseat-back.
When usinga child
seatwith a top tether,installthe chjld seatanchorplates
securely.
8 x 1.25mm
22 N.m (2.2kgf.m.16lbf.ftl
2Dl4Dl
N O T E : R e m o v et h e p l u g c o v e r sf r o m t h e a t t a c h m e n t
pointsof the rearshelf.
CHILDSEAT
ANCHOR
PLATE
PLUGCOVERS
WASHER
NOTE:
Do not removethe toothedwasherfrom the childseat

anchorplate.Usethe child seatanchorplatewith the
toothedwasherattachedto it.
. When installinga child seat on the rear seat,follow
the instructions
of the manufacturer
ot the childseat.
. Additionalanchorplatesare available.
Do noi use the child seat anchor plate for any other
purpose;it is designedexclusivelytor installation of a
child seat.
Make sure the rear seat-back is locked tirmlv when
installinga child seat.
REARSHELF
3D:
NOTE:The reartrimpanelhasperforations
ateachattachment point, Cut the rea. trim panel along the perforations
to makea hole.
REARTRIM
PANEL
20-92
a
Exterior
r a n u a l 1, 9 9 6M o d e lS e r i e sP, / N . 6 1 5 0 3 3 0 , f o r t hheo o d , t r u n kl i d a n d h a t c hr e m o v a l
N O T E :R e f e tr o t h e C i v i cB o d yR e p a i M
2D t3DtlD:
ROOFMOLDING
Replacement,
page 20 1O2
SIDEWINDOW
MOLOINGS
Replacement,
page 20-102
LICENSEPLATE
TRIM
Replacement,
page20 't00
TRUNKLID
Adjustment,page20 97
TorsionBarRemoval,
20 99
HOOD
Adjustment,Page20-96
HoodEdgeProtector
page20-99
TRUNKLID
WEATHERSTRIP
Replacement,
page20-100
REARBUMPER
Replacement,
page20'95
REARAIR OUTLET
Feplacement,
page20-106
PIPE
PROTECTOR
Replacement,
page20-106
TRIM
FENDERWELL
page20 106
Replacement,
FRONTGRILLE
(seepage20 99)
DOORand SIDEMOLDINGS
page20 103
Replacement,
SILLPANEL
R e p l a c e m e n t ,p a g e 2 0 - 1 0 5
INNER
Replacement,
page 20-106
3D:
HATCHSPOILER
Removal,page20-101
HATCH
WEATHERSTRIP
HATCH
Adiustment,
page20 98
LICENSEPLATETRIM
page20 100
Replacement,
REARAIR OUTLET
page20'106
Replacement,
20-93
FrontBumper
Replacement
CAUTION:Wsa.glovesto removeandinstallthe front bumper.
NOTE:
. An assistant
is helpfulwhenremoving
thefrontbumper.
. Takecarenotto scratch
thefrontbumperandbodv.
>: 8olt, screw locations

a >,2
>: Clip
locations,7
B>,2
c>,4
D> , 4
t165
ldb !J,J:ff,ry-"_.
FRONTBUMPERBEAM
\I/
_r6rbrftl
ABSOREER
I
A

NOTE:
. Make sure the front bumper engagesthe front
bumperside stiffeneron eachside securely.
. lf necessary,adjust the front bumper side stiffener
to obtainthe propergap.
20-94
FRONTEUMPER
SIOESTIFFENER
_g
6x1.0mm
9.8 N.m {'1.0kgf.m,
7.2 tbf.ft)
RearBumper
Replacement
CAUTION: Wear gloves to remove and install the rear bumpet.
NOTE:
. An assistant
is helpfulwhen removingthe rearbumper'
. Takecarenot to scratchthe rearbumperand body.
. 2D and 4D shown here;3Dremovalproceduresare the sameas 4D.
>: Screw, bolt locaiions
B >, 4
A>,2
i,,A
\r9{
>: Clip locations,7
,9iiffiF=*-..f
REARBUMPERBEAM
REARBUMPER
NOTE:
. lf necessary,
. Makesurethe rearbumperengagesthe side clip on eachside securely.
20-95
Hood
Adjustment
NOTE:Beforeadjustingthe hood,looseneachbolt slightly.
1. Adjustthe hood hingesright and lefr,as well as fore and aft, by usingthe elongatedholes.
2.
Turn the hood edgecushions,as necessary,

to makethe hood fit flush with the body at front and sideedges.
3.
Adjustthe hood latchto obtainthe properheightat the forwardedge.
4.
After adiustment,tighteneachbolt securely.
HOOD
\\"'
6x1.0mm
9.8N.m {1.0kgf,m,
1.2lbl.ttl
)
,/
_ _ _ , /
NOTE:Move the hood latch rightor leftuntilthe striker
is centeredin the hood latchasshown.
CUSHION
6x1,0mm
9.8 N.m 11.0kgf.m,
7.2 tblfrl
2 0- 9 6
TrunkLid
Adjustment
NOTE:Beforeadjustingthe trunk lid, looseneachbolt slightly
1.
Adjustthe trunk lid hingesrlght and left,as well as fore and aft, by usingthe elongatedholes.
2.
to makethe trunk lid fit flush with the body at the rearand side edges
Turn the trunk lid edgecushions,as necessary,
3.
Adjustthe fit betweenthe trunk lid and the trunk lid openingby movingthe striker'
4.
After adjustment,tighteneachbolt securely.

TRUNKLIDEDGE
CUSHION
21"
( i r/-\\
\
V,,''
/
NOTE: Take care not
to hit the rear window
when loosen ng the
bolts.
rY
\-2/\
TBUNKLID
srrucrs
./
:>
---
-)
6x1.0mm
9.8 N.m 11.0kgl.m,7.2lbf.ftl
NOTE:Remove
the rearshelflseepases20-59,61).
//
NOTE:Move the strikerright or left until it's centeredtn

the trunk lid latchas shown.
6x1.0mm
9.8 N.m (1.0kgf.m,
STRIKEB
20-97
Hatch
Adjustment
NOTE:
. Beforeadjustingthe hatch,looseneachbolt and nut slightly.
o The supportstrutsshouldbe removed.
. To adjust,removeboth hatchsidetrim {seepage20-63)and the rearroof trim (seepage20-65).
1.
Adjustthe hatchhingesright and left,as well as fore and aft, by usingthe elongatedholes.
2.
Turn the hatchedgecushions,as necessary,

to makethe hatchfit flush with the body at eachside.
3.
Adjustthe hatchfit to the hatchopeningby movingthe striker.
4.
After adjustment,tighteneachbolt and nut securely.

HATCH
EDGECUSHION
6x1.0mm
9.8N.m (1.0kgt.m,
HATCH
HINGE
Rearward
HA
EDGE
CUSHION
10 x 1.25
38 N.m {3.9kgl.m,
2.8 rbf.ft)
\
coVER
HATCH
HINGE
STRIKER
HATCH
EDGE
CUSHION
NOTE:Move the strikerright or left until it's centeredtn

the hatchlatch,as shown.
6x1.0mm
9.8N.m {1.0kgf.m,
7.2 tbl.ttl
FrontGrille/HoodEdge
Protector
TrunkLid Torsion
Bars
Replacement
Removal
Fronl grille:
CAUTION:Wear gloves to remove and installthe torsion

bars.
NOTE:Takecarenot to scratchthe front bumper.

NOTE:Takecare not to damagethe body.
Removethe front bumper (seepage20-94).Removethe
clips and screws.then slide the front grille forward by
detachingthe hooks.
Removethe torsion bars with the torsion bar assembly

t o o lw h i l eh o l d i n gt h e t r u n kl i d a s s h o w n .
>: Screwlocations,4
j
A l
:Y/
CENTERCLIP
Hoodedgeprolector:
NOTE:
.
.
When removing the clips, use a clip remover.

lf necessary,replace any damaged clips.
>: Cliplocarions,lS
NOTE:
. Adjustthe torsionbarsfore or aft with the tor
sionbarassembly
toolasshown.
HOOOEDGE
a = Normalposition
a = H i g h e tre n s i o n
Make sure the trunk lid opens properly.
20-99
Trunk Lid/Hatch
Weatherstrip
LicensePlateTrim
Replacement
Replacement
When installingthe trunk lid/hatchweatherstrip,align it

with the alignmentmarkon the trunk lid/hatchopening.
CAUTION: Wear gloves to remove and install the license

plate trim.
NOTE:
. Makesurethereare no wrinklesin the weatherstrip.
. Checkfor water leaks.
NOTE:Takecarenot to scratchthe trunk lid/hatch.

1.
Removethe ljcenseplate.
2D l4Dl
2.
3D: Removethe hatchtrim panel(seepage20-63).
3.
Removethe nuts and clips,and detachthe clip,then

removethe licenseplatetrim.
ALIGNMENTMARK
NOTE:Takecarenot to drop the nuts insidethe trunk

lid/hatch.
a: Nut locations,2
ffisxo.amm
>: Clip locations,3
\Y9l,/
- 1.8N.m{0.18kstm.l
13 tbtfr)
,/
nA
IEL
I
L
@ta9@
WEATHERSTRIP
ALIGNMENT
MARK
4.
STEEL
CORE
NOTE:lf necessary,
ALIGNMENT
MARK (2Dl4D)
BODY
20-100
Installationis the reverseofthe removalprocedure.
HatchSpoiler
Removal
NOTE:Takecarenot to scratchthe hatchand body.
1.
Removethe hatchuppertrim (seepage20-63).
2.
Removethe nuts, and detachthe clip, then Iift the

hatchspoilerup.
4.
removethe spoilertrim from the spoiler

lf necessary,
frame.
NOTE:The hatchspoilertrim for Canadaproduced
carscannotbe disassembled.
>: Clip locations
a: Nut localions,4
6x1.0mm
l
ksf.m.I
9.8N m 11.0
7.2
\t.to - _J/
>: Screw
locations,4 l
6
"ig \ l
GROMMET
HIGHMOUNT BRAKE
LIGHTCONNECTOR
SPOILER
SIDETRI
SPOILER
CENTER
TRIM
A
5.
ACCESSCAP
3.

NOTE:
. lf necessary,
a M a k e s u r e t h e c o n n e c t o ra n d w a s h e rt u b e a r e
connectedproperly.
Disconnect
the high mount brakelightconnectorand
r e a rw i n d o w w a s h e rt u b e ,t h e n r e m o v et h e h a t c h
spoIer.
20-101
SideWindow Moldings
RoofMolding
Replacement
Replacement
CAUTION: Wear gloves to remove and install the side

window moldings.
CAUTION;Whsn prying with a flat tip sc.ewdriver,wrap

it with protective tape to prevent damage,and use protective tape on the body.
NOTE:
. Takecarenot to scratchthe body.
. Removethe screw,and pull the side window molding
NOTE:Takecarenot to scratchthe bodv,
by hand.
>: Clip locetions
A>, 13
WINDSHIELO
MOLDING
I
)
Screw locations,
*@
(Bodyside)
ARACKET

NOTEi
. Takecarenot to damagethe windshieldmolding.
. Makesurethe roof moldingis installedsecurely.
MOLDING
ROOFMOLDING

NOTE:lf necessary,
20-102
Doorand SideMoldings
Replacement
CAUTION: When prying with a tlat tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:
. To removethe front side molding,removethe innerfender(seepage20-106).
. To removethe door molding,removethe door panel(seepages20 4, 10, l6) and plasticcover.
. To removethe rearside molding,removethe sidetrim panel(seepages20-60,61).
. Takecare not to bendthe door moldings.
. Before.eassembling,
cleanthe door bondingsurfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface
. lf necessary,
4D:
2Dl3Dl
REARSIDE
MOLDING
>: Clip locations
A >: ,lO,11
2013r),7
B> , 3
a: Plasticnut location, 1
c>.2
@)
_/
(cont'd)
20-103
Doorand SideMoldings
Replacement(cont'dl
Door moldingremoval:
Door moldinginstallation:
The following materialsand tools are requiredto repair

t h e d o o rm o l d i n g s .
G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g s a s
shown.
N\\N\l
instructionsNOTE:Followthe manufacturer's
.
.
.
60 mm
t2.1
820mm 132.3inl
Materials:{Reference}
. Striperemover
3M 08907
. Stripeadhesiveremover
3M 08908
. Adhesivetape
3M SuperAutomotiveAttachmentTape
Tools:
. Protectivetape
. Knifeor Cutter
. Spongeor Shoptowel
. Infrareddryer
: Adhesivetape locations
Forward
MOLDING
40 mm
(1.6in)
Film
Puttyknife
Alcohol
Forward
CLIP
HOLDER
2Dl3Dl
CAUTION: Wear gloves to remove and install the dool
moldings.
1.
R e m o v et h e d o o r p a n e l ,a n d p u l l b a c kt h e p l a s t i c
cover.
2.
Apply protectivetape on and aroundthe molding.
1,050mm {41.31inl
5 mm {0.2in)
ADHESIVETAPE
Thickness:1.2 mm 10.05inl
3.
Releasethe clips from insideof the door. Carefully

cut the adhesivetape with a knife or cutter while
pullingthe edgeof the moldingaway from the door
as shown.
2.
I n s t a ltlh e c l i p so n t h e m o l d i n g .
H e a t t h e b o n d i n g s u r f a c eo f t h e d o o r a n d d o o r
moldingwith an infrareddryer.
Door:
104- 140'F(40- 60'C)
Molding:68 - 86'F (20- 30'C)
NOTE:Take care not to scratchor bend the moldIng
NOTE: Use care when heatingto preventdeformat i o no t t h e m o l d i n g .
KNTFE
4.
Align the molding with the clip locations,and set

the molding. Lightly push on the molding until its
edgeis fully seatedon the adhesivetape.
NOTE: Do not spray water on the molding within
the first 24 hoursafterinstallation.
OOOBMOLDING
20-104
Reassemble
all removedparts.
SideSill Panel
Replacement
NOTEI
. Takecarenot to scratchthe body.
. 4D shown here;2Dand 3D removalprocedureis the sameas 4D.
>: Clip locations

A>,3
B>,7
I
)
NOTE:Loosenthe screw,
then removethe lowerclip
usinga clip remover.
SIDECLIP
Removethe sideclipsfrom the body
by turningthem 45'
NOTE:When removingthe side

sill panel,the sideclipswill
stayin the body.
SIDE SILL PANEL

Remove the lower clips,
then remove the side sill panel
by sliding it forward.
To installthe sidesill panel,removethe sideclipsfrom the body, installthem on the side sill panel,then installthe sidesill
oaneo
l n t h ec a r .
NOTE:
. Takecarenot to twist the side sill panel.
. lf necessary,
replaceany damagedside and lower clips.
20-105
InnerFender,FenderwellTrim, FuelPipeProtectorand Rear

Air Outlet
Replacement
NOTE:lf necessary,
lnner fender:
>: Screwlocations,
4
6h*l
: , /
>: Clip locations,7
CLIP
Fenderwelltrim/Fuel pipe protector/Rearair outlet:

NOTE:
. Takecare not to bendthe tenderwelltrim.
. Betoreinstallingthe fenderwelltrim, cleanthe body
bondingsurfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseor water from gettingon
the surface.
. To removethe fuel pipe protector,first removethe rear
wheel(seesection18).
. To remove the rear air outlet, first remove the rear
bumper(seepage20-95).
STEEL
20-106
FENDERWELL
>: Clip locations
a>,4
B>,4
'@
c>.2
OpenerCable/Openerand Latch/Wiperand Washer

zDl3Dl4Dt
*TNDSHTELD
wrPERaRMs
page20-1
13
Replacement,
page20-1
17
Adiustment,
WINDSHIELD
WASHERNOZZLES
Adjustment,page20-117
FUELLIDOPENER
CABLE
(seepage20-108)
TNUNK LID OPENER

CABLE
(seepage20 108)
LID/FUEL
LIDOPENER
{seepage20-111)
REI."EASHANDLE
(seep6ge20-110)
3D:
wlPER
REARWINDOW
ARMrnd MOTOR
page20-'l15
Eeplacement,
page20-'l17
Adjustment,
REARWINDOW
WASHERNOZZLE
Adiustment,page20-117
REARWINDOW
WASHER
TUBE
(seepage20 1161
HATCH/
FUELLIDOPENER
{seepage20-111)
FUELLIDOPENER
CABLE
{sepage20-'110)
(seepage20 111)
HATCI{OPENER
CABLE
(seepage20-110)
20-107
OpenerCables
Replacement
NOTE:
. When removingthe clips,usea clip remover.
. Takecarenot to bendthe openercables.
Hood openr cable:
NOTE:Removethe front bumper (see page 20-94)and
innerfender(seepage20-106).
>: Clip locations
A>,5
BD,1
#l
HOODRELEASE
HANDLE
{seepage20-110)
Trunk lid/Fuellid openercable(2Dli[D):

NOTE:Removethe following partsfrom the left side of
the vehicle.then pull the carpetback,as necessary{see
page20-66).
Rearseatcushion(seepages20-79,81)
Rearseatside bolster(4D,seepage20-79)
Rearseat-back{2D,see page20-81)
Centerpillarlowertrim panel(4D,seepage20-59)
Lower anchor bolt from the front seat belt (2D,
page20-86)
. Sidetrim (seepages20-59,61)
o Seatsidetrim (4D.seepage20-59)
. Sidetrim panel(2D.seepage20-61)
. Trunk mat and sparetire lid
. Reartrim panel(seepage20-62)
(seepage20-62)
. Trunksidetrim, Japan-produced
(seepage20-62)
. Trunktrim panel,UsA-produced
.
.
.
.
.
>: CliD.
cablecushion
locations
a>,4
I>,4D,r
#
l
B
_ L ) _-__l
D> , 3
Routethe opener
cable through the
hole in the body.

NOTE:
. Make sure the hood openercable is routed and
connectedproperly.
. Makesurethe hood opensproperly.
20-108
E> , 4 D ,1
2D,2
c >, 1 {4D)
ffi
\
_,)
TRUNK LID LATCH

(seepage20 112)
4D:
To trunklid
latch,
TRUNKLID/FUEL
LIOOPENER
( s e ep a g e2 0 ' 1 1 1 )
To trunklid
latch.
a
A \
TRUNKLID
OPENERCABLE
FUELLIO
OPENERCABLE
TRUNKLIO/FUEL
LID OPENER
( s e ep a g e2 0 - 1 1 1 )
(cont'd)
20-109
Openerand Latch
OpenerCables
Replacement(cont'dl
Replacement
Hatch/Fuellid opener cable (3D):
NOTE:Takecarenot to bendthe openercables.
NOTE:Bemovethe following parts,then pull the carpet

backas necessary(seepage20-66).
Hood releasehandle:
N O T E :R e m o v et h e k i c kp a n e l( s e ep a g e s2 0 - 5 9 . 6 0 , 6 1 ) .
.
.
.
.
.
.
.
Rearseatcushionand rearseat-back
{seepage20-80}
Lower anchorbolt from the tront seat belt (seepage
20-86)
Sidetrim (seepage20-60)
Sparetire lid
Rearcentershelfand rearsideshelf(seepage20-60)
Reartrim panel(seepage20-60)
Sidetrim panel(seepage20-60)
>: Clip,c.ble cushionlocations

A>,9
c>,1
B>,1
#)
*i
>: Boll locations,2
6 x 1 . 0 m mi
9.8N.m
I
HOOOOPENER
CABLE
{seepage20-108)
D>,5
HOODRELEASE
HANDLE
Hood latch:
Routethe opener
cablethroughthe
hole in the body.
NOTE:Removethe front bumper(seepage20-94).

FUELLID LATCH
(seepage20-112)
doo
STRIKER
FUEL LID
OPENER
CABLE
--\,"
o/l
HATCH
OPENERCABLE
HATCH/FUEL
LID
OPENER
Installationis the reverseof the removaiprocedure.

NOTE:
. N4akesure each openercable is routed and con
nectedproperly,
. Makesurethe hatchandfuel lid openproperly.
20-110
NOTE:
. Makesurethe openercableis connectedproperly.
. M a k e s u r e t h e h o o d o p e n s p r o p e r l ya n d l o c k s
securely.
Trunk lid or Hatch/Fuellid opener:
Striker l3D):
NOTE:Removethe sidetrim (seepages20-59,60.61).
NOTE: Removethe reartrim panel(seepage20-601.
>: Boltlocrtions,
2
a@-\
6x1.0mm
9.8N.m
(1.0kgt.m,
7.2 tbl.ftt
OPENERLOCK
CYUNDER
>: Bolt locations.2
la//tzDt4Dl
L-.-^
6x1.0mm
9.8N.m (1.0kgf.m, I
':-!, J
HATCH
OPENERCABLE
(seepage20-110)
TRUNKLID,/HATCH
OPENERCABLE
2 0 - 1 0 81, 1 0 )
{see
To trunklid latch
or striker.
To fuel lid latch.
lnstallation is the reverse of the removal procedure.

FUELLID
OPENERCABLE
(seepages20-108,110)
NOTEi
a Makesure each openercableis connectedprop'

erlY.
. M a k e s u r e the hatch opens properly and locks
securely.

NOTE:
. Makesurethe openercableis connectedproperly.
. Makesurethe trunk lid or hatchand fuel lid open
properly.
(cont'd)
20-111
Openerand Latch
(cont'dl
Replacement
Fuel lid latch:
Trunk lid latch/Lock cylinder:
NOTE:Removethe followingparts.
2Dl4Di
.
.
>: Bolt locations

A>,3
B > ,1
R e a rt r i m p a n e l{ s e e p a g e 2 0 6 2 )
Rear edge of the trunk side trim or trunk trim p a n e l
(leftside,seepage20-62)
3D:
.
Accesspanelon the sidetrim panel
>: Bolt locations, 2
5 x 1.0mrn
,-*Y:EiI::Y
TRUNKLID
LATCH
FUELLID LATCH
CYLINDER
ROD
LOCK
CYLINDER
FUELLID
After installingcheckfor
a flushfit with the body.
CONNECTOR
Disconnect.
a-
LOCK
CYLINDER
FUELLIDOPENER
CABLE
(seepages20'108,1'10i
FUEI-LID LATCH
Removethe fuel lid latch
by turningit 90'

NOTE:
. Make sure each openercableis connectedproperly.
. Make sure the fuel lid opens properlyand locks
secureiy.
20-112
NOTE:
. Greasethe trunk lid latch.
. Makesure the trunk lid opensproperlyand locks
securely.
. M a k e s u r e t h e c o n n e c t o ra n d c y l i n d e rr o d a r e
WindshieldWiper Arms
and Linkage
Replacement
CAUTION: Wear gloves to remove and inslall the windshieldwiper linkage.
Hatch latch/Lock cylinder:

NOTE: Remove the hatch trim panel (see page 20-63).
NOTE:Takecarenot to scratchthe hood and body.

>: Bolt locations
A>,3
6x1.0mm
9.8 N.m 11.0kgf.m,
7.2 tbt.ft)
8>, 1
R e m o v et h e w i n d s h i e l dw i p e r a r m s ,t h e n r e m o v e
the hood sealand cowl cover.
6x1.0mm
9.8N m (1.0kgf.m,j
1.2tbttij
/
HATCH
LATCH
>: Clip locations

a >,9
I >,9
I t L.-.-=1 0x ' 1 . 2 5m m
l8 N.m (1.8kgf.m.
i ?(lb L\--:.-a t r
t)
COWLCOVER
Disconnectthe connector,then remove the winds h i e l dw i p e rl i n k a g ea s s e m b l y .

Japan/Canada-produced:

NOTE:
. Greasethe hatchlatch.
. M a k e s u r e t h e h a t c ho p e n sp r o p e r l ya n d l o c k s
securely.
. Makesurethe cylinderrod is connectedproperly.
(cont'd)
20-113
WindshieldWiperArms and Linkage

Replacement(cont'dl
USA-produced:
USA-produced:
>: Boll locations,3
WINDSHIELD
WIPERLINKAGE
ASSEMBLY
l@.',,.0-E
\_q.
9.8N.mn.o ksf.m,
7 2 rbr'ftl
NOTE:Scribea line acrossthe link and windshield

wiper motor to show the o.iginaladjustment.
>: Bolt locations,2
R
tf
6x1.0mm
I N.mto.skstm,I
P,:!-Y
NUT
10 x 1.25mm
18 N.m 11.8kgf.m,
13 rbf.ft)
S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d shieldwiper motor.
Japan/Canada-produced:
NOTE:Scribea line acrossthe link and windshield
wiper linkageto show the originaladjustment.
WIPERMOTOR
WIPERMOTOR
'10x 1.25
mm
18 N.m (1.8kgt.m,
rbrftl
SPRING
WASHER

NOTE:
. Makesurethe connectoris connectedproperly.
. li necessary,
. I n s t a l lt h e w j n d s h i e l dw i p e r a r m s a s d e s c r i b e d
o n p a g e2 0 - 1 1 7 .
. Checkthe windshieldwiper motor operation.
. Greasethe moving parts.
WIPERMOTOR
WIPERLINKAGE
20-114
RearWindow wiper
WasherReservoir
Arm and Motor
Replacement
Replacement
1.
Removethe hatchtrim panel(seepage20-63).
2,
R e m o v et h e r e a rw i n d o w w i p e r a r m a n d w l p e r
motor as shown.
1.
Removethe front bumper(seepage20 94).

Disconnectthe connectorsand washertubes from
the washermotors,
>: Boll locations,
3
/)^
Gxl.o mm
s.eNmtt.orsr'm.
Ql(S)
\-/
7.2 tbf.f
- -
'/
)
H*?H"[*
Routethe washer tubes
to the washerreservoir
5x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbf.ft)
WIPERMOTOR
3.
MOTOR

NOTE:
a Makesurethe connectoris connectedproperly.
a Installthe rearwindow wiper arm as describedon
page20-117.
. Checkthe rearwindow wiper motor operation.
. Greasethe moving parts.
3.
MOTOR
WASHER
(3D,for somemodels)
Removethe bolts, then remove the washer reservoir.

NOTE:
. M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d
washertubesare connectedproperly.
. Checkthe washermotor operataon.
20-115
WasherTube
Replacement
NOTE:
. To removethe windshieldwashertube, removethe
left innerfender(seepage20-'106).
. To removethe rearwindow washertube (3D).remove
the followingpartsfrom the leftsideof the vehicle.
-
I n n e rf e n d e r( s e ep a g e2 0 - 1 0 6 )
Kickpaneland sidetrim (seepage20-60)
Rearseat backand rearseatcushion(seepage20
80)
Sparetire lid
Rearcenlershelf and rearside shelf lsee page 2060)
Reartrim panel and side trim panel (seepage 2060)
Ouartertrim panel{seepage20 60)
Rearrooftrim {seepage20-65)
Hatchspoiler(seepage20 101)
>: Washer nozzle, clip and cushion locations
A>,2
wrsren
lNozzLE CE
\f
\-
c>.1
B>,3
wtwospteloI
=--S1
D>,1
@
E>,1
-f7!
]\N
\ \ \
|g"
c
|
-,J:n
<:/1+-+3
F>, 11
WINDSHIELD
TUBE
A
REARWINDOW
WASHERTUBE
Routethe washertubes
to the washerreservoir
Routethe washertubes
underthe wire harness.
a
I
(seepage20-101).
REARWINDOW
WASHERTUBE
(forsome models)
Installation
NOTE:
. Takecarenot to pinchthe washertubes.
. lf necessary,
replaceanydamagedclips.
. After installing,adjustthe aim of the washernoz
zles(seepage20-117).
20-116
Wiper Arms/WasherNozzles
Adjustment
Rear Window Wiper/Washer (3D):
Windshield Wiper/washer:
Adjust the wiper arms so that their park positions
matchthe illustration.
1.
l.
Adjust the rear window wiper arm so that its park

positionmatchesthe illustration.
View from rear to front
View from front to rear
Centerline
REARWINDOW
WIPEFARM
WINDSHIELD
ARMS
WIPER
2.
B y i n s e r t i n ga t a c k a n d m o v l n g r t a s n e c e s s a r y ,
adjustthe washer nozzlesso that they aim at posit l o n sA . A ' , B , a n d B ' s h o w ni n t h e i l l u s t r a t i o n .
BLACK
CERAMIC
EDGE
B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y ,
adjustthe washer nozzleso that it aims at position
C as shown in the illustration.
NOTE:The fluid jet should hit within a 50 mm (2.0
i n ) r a d i u sa r o u n dp o i n tC .
NOTE:The tluid jets should hit within a 50 mm (2 0

in) radiusaroundeachof pointsA, A', B, and B'
Distance from center
\ II n e
Nozzleaim
4 0 0m m ( 1 5 . 7i n )
A a n dA '
B a n dB '
11 5 m m ( 4 . 5i n )
from black
ceramic edge
255mm (10.0in)
322 mm 112.1inl
20-117
Emblems
Installation
Apply the emblemswhereshown.
NOTE:
o Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface.
Attachment Points {Relerencel:
CIVICemblem
TRUNK LID
VBion emblem
20-118
Version emblem
Version emblm
Sub-frame
Sub-flame Torque Sequence:

CAUTION: Aftel looseningthe sub-frame mounting bolts, be sure to replacethem with new ones'
BOLTS
1 4x 1 . 5m m
90 N.m {9.1 kgf.m,
10 x 1.25mm
38 N.m 13.9kgf.m;
28 tbf.ft)
66 rb{.ft)
Replace-
20-119
FrameRepairChart
Unit:mm (in)
6: Innerdiameter
oETATLAREA:ll
> =
POINTd3
o15{0.591
Transmisaion
Mount Point
20-120
l:3D
SECTIONAA
UpperArm
o12 10.471
POINT
Upper
a12lo.0l
a25
-o20
o8(
otN'
LOCA
Hole
Tank
Strap
Point
{0r8) Locate
Hole
POINT w
o20 10.8)LocateHole
SECTION8B
Damoer Lower Bush Center
20-121
Body {'97 model}

FrontSeat Belt
RearSeat
WasherTube
..................
Repfacement
Windshield
lndex ..........
....20-128
.".20-126
20-129
20'124
i
i
Outline of
'97 Model Changes
The moldingsidesealwas added.

The methodof installingthe rearseatcushionwas changed.(2Dl3D)
(2Dl3D)
A middlefloor gussetwas addedand the methodof detachingthe seatbelt retractorwas changed.
The installationpositionof the washertube was changed.
Windshield
Index
NOTE:The numbersafterthe part namesshow the quantitiesof the pans used.
WINDSHIELO
MOLDING
UPPERRUEBER
DAM
FASTENER,
2
(Selt-adhesive-type,
glassside)
FASTENER,
2
WINDSHIELD
20-124
MoldingSideSeal
lnstallation
Gluethe moldingside sealto the windshieldmoldingon
eachside.
20-125
RearSeat
3D:
>: Boll locations

A>.6
c>,1
B>,1
tQ6't.o--
ps.a ru'-{r.orgr.-,
E 7.2 tbf.ftt
6x1.0mm
22N-m 12.2kgf -,]
16 tbf.ft)
,)
,/
STRIKER
Bemovethe sidetrim
panel(seepage20 60).
STRIKER
6xl.0mm
9.8 N.m {1.0kgt m,i
1.2tbt-ltl
!
V v
V Yvt
PIVOT
BRACKET
PIVOT
BRACKET
RIGHT
SEAT
--\--------
>: Cliplocations.14
SEATCUSHION
,-------\
I
I
F
F
lMwm
HOOK
\_
E
F
!t
Pivot bolt construclion:
WASHER
SEAT.BACK
PIVOTBOLT
BRACKET
8 x 1.25mm
22 N.m (2.2 kgf.m, 16 lbnftl
NOTE:
. Beforeattachingthe seat backand seat cushion,make sure there are no twists or kinks in the rear seat belts and
centerbelt.
. When installingthe seatcushion.slipthe seatbelt bucklesthroughthe slits in the seat cushion.
. lf necessary,
adjustthe strikerand seat-back.
i
I-!
20-126
8(-). t
2D:
>: Bolt locations

A>,6
B>,1
ii
c>,1
ksf.m,' v
93;mr,
g 7.2tbrftt
MIDDLEFLOOR
CENTER
GUSSET
>: Clip locations,14
SEAT-BACKMAT
@ni
------irl|H--|
E E )
qr
,/
PIVOTERACKET
RIGHTSEAT-8ACK
i i l
TOOTHED
LOCK
WASHER
BUSHING
SEATCUSHION
PIVOTBOLT
BRACKET
8 x 1.25mm
22 N.m (2.2kgtm. 16 lbf.ft)

NOTE:
. Beforeattachingthe seat-backand seat cushion,make surethere are no twists or kinksin the rear seatbelts and
centerbelt.
. lf necessarV,
adiustthe seat-backlatchand seat-back.
20-127
FrontSeat Belt
RemovaUlnstallation
2D l3Dt
1.
2.
3.
4.
Removethe upper anchorcover and lower anchor

cap.
Slidethe front seatforwardfully.

UPPERANCHORBOLT
7/16-20UNF
32 N.m {3.3 kgf..n,
24 tbtftl
Remove:
. Rearseat-backand rear seat cushion(seepages
20-126,1271
. R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D . s e e
page20 60)
. Reartrim panel(3D,seepage20-60)
. Sidetrim panel(seepages2G60,61)
@'a---
'PPERANcHoR
RETRACTOB
MOUNTINGAOLT
6x1.0mm
9.8 N.m (1.0kgt m,
7.2 tbl.ftl
Pull backthe carpetas necessary,and removethe

bolts.then removethe middlefloor gusset.
>: Boh locations,8
l-owER
10 x 1.25mm
38 N.m (3.9kgf.m.
28 tbt f0
ANCHOR
CAP
I
o
RETRACTOR
BOLT
7/16-20UNF
32 N.m (3.3kgf.m,
24 rbnft)
LOWERANCHORBOLT
7/16-20UNF
32 N.m 13.3kgl.m, 24lbl.ftl
Removeall the anchorbolts and the retractorbolt,

remove the retractormounting bolt, then removethe
tront seat belt and retractor.
Installationis the reverseof the removalorocedure.
NOTE:
on the upperand lower anchorboltsas shown.
are no twists or kinksin the front seat belt.
20-128
WasherTube
Replacement
NOTE:To removethe windshieldwashertube, removethe left innerfender(seepage20 106).
>: Washernozzle.clip and cushionlocations
B>,'l
a>,2
ffi,"td-<g *.\ |
wtNDSHtELD
.--7
@t"(
\3t / -----J
-r'v!
\T
\\\
,,
G>,1
F>,1
E>,1
D>,1
Ct',1
iJ ',',,4
W,'i | '*V
.<a>t,
l
_ WINDOW
_J
E -/ _'' _-/ REAR
_*)
REABWINDOW I wasHERTUBE
WASHER
TUBE I
\
9)
behind the EcM/PcM bracket.
WINDSHIELD
TUBE
A
REARWINDOW
WASHERTUBE
\;
Routeihe washertubes
to the washerreservoar
Installation
NOTE:
. Takecarenot to pinchthe washertubes.
. lf necessary,
(seepage20-117).
. Afterinstalling,
adjustthe aim of the washernozzles
(cont'd)
20-129
WasherTube
(cont'd)
Replacement
NOTE:To removethe rearwindow washertube (3D),removethe followingpartsfrom the leftside of the vehicle.
- Innerfender(seepage20-106)
- Kickpaneland sidetrim (seepage20-60)
- Rearseat-back
and rearseatcushion(seepage20-80)
- Sparetire lid
- Rearcentershelfand rearsideshelf(seepage20-60)
- Reartrim paneland sidetrim panel(seepage20-50)
- Ouartertrim panel(seepage20-60)
- Rearrooftrim (seepage20-65)
- Hatchspoiler(seepage20-101)
>: Washernozzle,clipandcushionlocations
A > ,9
B>,2
c>,1
-?) K)
./'-:.1
a/j
_____J
To rear window
washernozzle
(seepage20-101).

NOTE:
a Takecare not to Dinchthe washertubes.
. lf necessary,
replaceanydamagedclips.
. Afterinstalling.
adjustthe aim of the washernozzles(seepage20-1j7).
20-130
motor.
Body ('98 modell

Openerand Latch
..................
Replacement
Outline of
.
.
'98 Model Ghanges
The hood latch cover was added.

The hatch handle was added. (3D)
20'132
Openerand Latch
Replacement
Hatch Handle
HOODLATCHCOVER
1.
Removethe hatchtrim panel(seepage20 63).
NOTE:Takecarenot to the hood latchcoverand body.
2.
Removethe hatchhandlebolts.
>: Bohlocations,2
6x1.0mm
9.8 N.m {1.0kgf.m,I
HOODLATCHCOVER
HOODLATCH
"'o::___,/
HANDLEROD
20-132
HatchLatch/LockGylinder
4.
Notethe positionof the joint on the handlerod (A).

Pry the handlerod of the joint using diagonalcutt e r s ; t a k e c a r e n o t t o b e n d t h e r o d . R e m o v et h e
hatchhandle.
1 . Removethe hatchtrim panel(seepage20-53).

Removethe hatchlatchscrews.
>: Screw locations.3

6x1.0mm
9,8 N.m {1.0kg{.m.
7,2 tbtttl
EUSHING
Replace.
D i s c o n n e ctth e l o c k r o d , t h e h a n d l er o d , t h e l o c k
cylinder rod, and the connector,then remove the
hatchlatch,
l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
theseitems:
. Makesurethe handlerod is connectedproperly.
. Beforeinstallingthe hatchtrim panel,makesure
the hatchopensproperly.
LOCK
ROO
{'
LOCKCYLINDER
RoD
...Ly';
/)<
/
CONNECTOR
{cont'd)
20-133
Openerand Latch
(cont'dl
Replacement
Pullthe lockrod out.
LOCK
5.
removethe lockcylinder.
It necessary,
>: Bohlocation,1
6x1.0mm
I
9.8N.m 11.0kgf.m,l
!!,b,!)__J
l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
thesertems:
.
.
.
Apply greaseto the hatchlatch.

Makesurethe connectoris connectedproperly.
Beforeinstallingthe hatchtrim panel,make sure
the hatchopensproperlyand lockssecurely.
20-134
Heaterand Air Conditioning

Heater
A i r C o n d i t i o n i n g' . ' . . . . . . . . .
"""""'21-1
"' 22-1
SYSTEM(SRS}
RESTRAINT
SUPPLEMENTAL
(exceptsome
The civic sRS includesa driver'sairbag locatedin the steeringwheel hub. ln addition,all models
airbaglocatedin the dashboardabovethe glove box'
modelsfor Canada)havea passenger's
(*)
to safelyservicethe sRS is includedin this serviceManual.ttemsmarkedwith an asterisk
lnformationnecessary
these
or
replacing
disassembling
on the contentspage include,or are locatednear, SRS components.servicing,
itemswill requirespecialprecautionsand tools,and shouldthereforebe done by an authorizedHondadealer.
@
-;;Gia
rendsring the SRS inoperative, which could lead to petsonal iniury or death in the event ol severs
flontal collision, all SRSservicework must be pertormed by an authorized Honda dealer'
personal
. lmproper service procsdures, including incolrect removal 8nd installation of the sRs, could lesd to
ol
the
airbags.
activation
injury causedby unintentional
o Do not bump the sRS unit. otherwise, the system may tail in case of a collision, or the airbags maY dsploy
when the ignition switch is ON (lll
. All sRs electrical wiring harnessesare covered with yellow insulation. Related components are locatod in thg
glove box.
steeling column, tront console, dashboald, dashboard lower panel, and in the dashboard above the
Do not use elstricaltst equipment on these circuits.
tI
Heater
21-2
Temperature Control
fffustratedlndex ...................................
............21-23
Adiustment
,,,,,....21-3
CircuitDiagram
Motol
Mode
Control
Troubleshooting
.......21-24
21-4
Test .................
SymptomChan ...............................
.........21-24
Repfacement
HeaterControl PanelInput/Output
21-5
Signals..........................................
RecirculationGontrolMotor
Flowcharts
.......21'25
Test .................
21-6
BlowerMotor Speed ...................
,.,,,.,,.21-25
Repfacement
21-8
BlowerMotor ...............................
Relay
21-11
ModeControlMotor ....................
.......21-26
Test .................
RecirculationControl Motor ,,,....21-14 Heater Fan Switch
Blower Unit
.......21-26
Test .................
.........21-16 Mode Control Switch
Replacement
................21-17 Test .................
Overhaul
..,.,..21-27
* HeaterUnit
* Read SBS precautions before working in
.........21-18
Replacement
................21-20 this area.
Overhauf
HeaterControl Panel
.........21-21
Repfacement
................21-22
Overhauf
lllustratedIndex
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions.and proceduresin the SRS

section{24)beforeperformingrepairsor service.
BLOWERUNIT
page21'16
Replacement,
Overhaul,page21 17
HEATEBUNIT
page21,18
Feplacement,
Overhaul,page21-20
BLOWER
RESISTOR
Test,page21-7
CONTROLMOTOR
Test,page21-25
page21-25
Replacement,
A/C SWTTCH
{with A/c)
HEATERVALVECABLE
MODECONTROL
MOTOR
Test,page21-24
R e p l a c e m e n t ,p a g e 2 1 2 4
TER FAN
swrTcH
AIR MIX CONTROLCABLE

Adiustment,page21'23
page21 22
Replacement,
Test,page21-26
MODECONTROL
swtTcHEs
lest, page21-27
HEAIERCONTROL
PANEL
page21-21
Replacement,
Ovethaul,page21-22
TEMPERATURE
CONTROL
LEVER
page2123
Adjustment,
Defroster-aqtivatedA/C System
Turningthe defrosteron activatesthe A,/Cand sets the air flow mode to FRESH.It is possibleto turn the Ay'Coff or to
changethe air flow to RECIRCULATE
by pressingthe Ay'Cbuttonor the FRESH/RECTRCULATE
button.
21-2
CircuitDiagram
UNDEsOASH
BOX
UNDEN'HOOD
FUSE/RETAY
FECIRCULATION
BLOWEF
17
II
I
BLU/RED
eil+ji'^*'l-fl
Lf:}
Lr_l il:Y
i,fi*r.,{
| | Ieff{+jir*'It-}
?r,l -tr'-?
?r
HEATERCONTROL
PANL
G401
G'102
DASHLIGHTS
SRIGHTNESS
CONTNOLLEF
21-3
{
Troubleshooting
SymptomGhart
NOTE:
. Checkthe enginecoolantlevel,and allowthe engineto warm up beforetroubleshooting.
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements
needed,usea multimeterwhen testing.
. Beforeperformingany troubleshootingprocedurescheckl
._ Fuses*1No.47 \1.5 A), *1No.55 {40A}, *,No. 17 (7.5A)
- G r o u n d sN o .G 4 0 1 c, 4 0 2
- Cleanliness
and tightnessof all connectors
*rr In the under-hoodfuse/relaybox
*' : In the under-dash
fuse/relaybox
Symptom
Hot air flow is low.
No hot air flow.
r-
Blowermotor runs,but one or more

speedsare inoperative.
Performthe proceduresin the flowchan(seepage21 6).
Blowerruns properly.
Checkfor the following:

. Cloggedheaterduct
. Cloggedheateroutlet
. lncorrectdoor position
Blowermotor does not run at all.
Performthe proceduresin the flowchart(seepage21-8).
Blowermotor runs.
Checkfor the following:

. Cloggedheaterduct
. Cloggedbloweroutlet
. Cloggedheatervalve
. F a u l t ya i r m i x d o o r
. Heatervalve cable adjustment(see page 21-23l,
' Air mix controlcableadjustment(seepage21-23)
. Faultycoolingsystemthermostat(seesection10)
' Cloggedevaporator(with air conditioning)
. Frozenevaporator(with air conditioning)
Mode controlmotor does not run, or one or more modes

are inoperative.
Performthe proceduresin the flowchart(seepage21-l 1).
Recirculation
controldoor does not chanqebetween
FRESHand RECIRCULATE.
Performthe proceduresin the flowchart(seepage2'l-14).
II
Remedy
21-4
HeaterControlPanelInput/OutputSignals
HEATERCONTNOLPANEL14PCONNECTOR
Terminal
No.
Wire
color
Signal
YEL
HEAT/OEF
Wire
color
YEURED
VENT
INPUT
GRN/YEL
HEATA/ENT
INPUT
BLK
GROUND
OUTPUT
BLU/RED
A.iC THERMOSTAT
INPUT
12
GRN/WHT
FRESH
INPUT
GRN/RED
INPUT
BLVYEL
tG2
INPUT
WHT/BLU
+B
INPUT
YEUBLU
DEF
INPUT
RED
Terminal
No.
DASHLIGHTS
OUTPUT
BRIGHTNESS
CONTROLLER
'10
RED/BLK
LIGHT
COMBINATION
SWITCH
INPUT
13
BLU^r'r'HT
HEAT
INPUT
14
GRN
Signal
RECIRCULATE
HEATERFAN SWITCH
INPUT
OUTPUT
21-5
Troubleshooting
Blower Motor Speed
Blower motor runs. but one or
more spedsare inoperalive.
Check for a 3hort or an open in

the wire(s):
Turn the ignitionswitch ON (ll),
and the heaterfan switch OFF.
Doesthe blowermotor run?
HEATERFAN SWITCII6P CONNECTOR

Checkfor a shon in the wi.e{s}:
2, Disconnectthe blower motor
2P connector,
3. Removethe centerdashboard
lower cover (see section20),
and disconnect
the heaterfan
switch6P connector,
4. Disconnectthe blower resis
tor 4Pconnector,
the No. 2, 3, 4 and 5 terminals
o f t h e h e a t e rf a n s w i t c h 6 P
connectoa
r nd bodyground
individually.
Replace the heater f'n switch.
Repair short in the wirels)

between the blower resbtor, the
heater fan switch and the blower
6A
tl\
z t-r,
-
Frompage2'l-6
Checkth6 blower rsistor:

'1. Turnthe ignitionswitchOFF
2. Disconnectthe blower resis
tor 4P connector,
3. Measure the resrstance
betweenthe No. 2 and No. 4
terminalsof the blower resis'
tor.
BLOWEBRESISTOR
ls thereapprox.2- 3 ohms?
HEATERFAN SWITCH6P CONNECTOR
Checktor an open in thg witelslr

the blower.esistor
1. Reconnect
4Pconnector.
lower cover (see section20i,
the heaterfn
and disconnect
4. Ground each of these termiin the follownals individually
ing order;No.4, 2, 5 and 3.
BLU/WHT
BLU/BLK
2
1
BLUI
JUMPER
WIRE
IBLU/Y
WIRESIDEOFFEMALETERMINALS
Does the blower motor run at

p r o g r e s s i v e l yh i g h e r s p e e d s ?
Beolaco the heator fan switch.
Repairopen or causeof excessive

r e s i s t a n c ei n i h G a p p r o P . i a t e
wirels) between the blower resistor and tho heaterlan switch.
21-7
Troubleshooting
Blower Motor
Blower motor does not run al ell.
Checkthe No.55 {40A)tuse in the

undeFhoodfuse/relaybox, and
t h e N o . 1 7 ( 7 . 5A ) f u s e i n t h e
under-dashfuse/relaybox.
Roplacothe lu3o(!1,rnd rochock.

BLOWERMOTOR2P CONNECTOR
Checktho blowcr motor:
1. Connectthe No. 2 terminaloI
the blower motor 2P connector to body ground with a
l l l
l-,1
ruueeif6rureu
wrRE
1
Doesthe blowermotor run?
To page21'9
WIRESIDEOF FEMA1TTERMINALS
Checktor an open in the wire:

1 . D i s c o n n e ctth e j u m p e r w i r e
and the blowermotor 2P connector.
the No. l terminal and body
ground,
L'--r'|--]
L1J d)
Chackthe blower motor relay:

2 . R e m o v et h e b l o w e r m o t o r
rolayffom the under-hood
fuse/relaybox, and test it (see
page21-26).
Rcpltc tho blowo. motol r.l!y.
To page21-10
21-8
glulwxr
Frompage21-8
Checklor an open in the wite:

1. Turn the ignitionswitch OFF,
a n d d i s c o n n e ct th e j u m P e r
HEATERFAN SWITCH6P CONNECTOR
2, Removethe centerdashboard
lower cover (seesection20),
the heaterfan
and disconnect
switch6P connector.
l nd body
t h e N o . 3 t e r m i n aa
ground.
Ropair open in the wire between

the blower motor and the heatol
lan switch.
Checkfor an open in the wire:

the No. l terminaloftheheater
fan switch 6P connectorand
bodyground.
Replacethe heaier fan switch.
Check lor an oDen in the wire

between the h6ater tan switch
and body ground.It the wir is OK,
checklor poor ground at G401and
G&2.
(cont'd)
21-9
Troubleshooting
BlowerMotor (cont'dl
Frompage21 8
Check the under-hood fuse/relay

box:
Measure the voltage beNveen the
No. 3 terminal of the blower
motor relay 4P socket and body
ground.
BLOWERMOTORRELAY4P SOCKET
rD
{
rl,
l 2 1 1 l
Chockfor an open in the wi.e:

'1. Turnthe ignitionswitchON (ll).
2, Me6surethe voltage between
t h e N o . 4t e r m i n a l o f t h be l o w
er motor relay 4P socketand
body ground.
r r -
l r l 3|
IBLK/YEL
o)
Y
Repairopcn in the wire between

the No. 17 luse and the blowe.
motor reley.
Checktor an opon in the wire:
2. Check for continuity betlveen
the No. 2 terminal of the blower motor relay 4P socketand
body ground.
Check to. an oDen in the wiie
between lhe blowor motor relev
and body glound. lf the wire is
OK. check for poor ground at
G{01 .nd G{02.
R e p a i ro p o n i n t h e B L U / W H T
wiae bolwean the blower motor
relav snd the blower motor,
21-1 0
Mode ControlMotor
Mode control motoa does nol run,
or one or more modes are inoPen_
tive.
check the No. 17 (7.5A) fuse in

the under'dashfuse/relaybox.
ReDlacethe lus, and rechck.
MODECONTROLMOTOR7P CONNECTOR
ChscktoJ an open in the wire:

1. Disconnectthe mode control
motor7P connector,
2. Turn the ignitionswitch ON (ll).
the No. l terminal and body
grouno.
ls lhere battery voltage?
BLK/YEL
Repairopen in the wi.e between

the No. 17 fuse and the mode
control motor,
Checktor an open in the wite:

the No.7 terminalofthe mode
control motor 7P connector
and bodyground.
BLK
{l
Check for an opon in the wire
h$ro6n the modc control motor
and body ground.lllho wire is OK,
check lor poor gaoundtl G,Ol and
G402.
Test the mode control motor (soe

page21-24).
lsthe modecontrolmotor OK?
Check the mode control linkage

and doors:
1 . R e m o v et h e m o d e c o n t r o l
motor (seepage21 24).
2. Checkthe mode controllinkage
and doors for smooth movement.
To page21-12
Do the mode control iinkage
and doors move smoothly?
Roolacethe mode control motor.
(cont'd)
21-11
Troubleshooting
Mode Control Motor (cont'd)
F r o mp a g e2 1 - 1 1
HEATERCONTROLPANEL1{P CONNECTOR
Check for a short in the wire{sl:

1. Remove the center dashboard
Repeir any short in the wire(sl

between the mode control motol
and the heatercontrol panel.
Checkfor a short to Dower:

Checkthe samewiresfor voltaoe.
ls thereany voltage?
T o p a g e2 1 - 1 3
2 1- 1 2
Repairshort to power in the wir6

betweon the mode control motor
rnd the heater control oanel.
(This short damages the heatel
control oanel.l
HEATERCONTROLPANEL14PCONNECTOR
Frcm page21-12
Ch6ckfor an open in tho wirolsl:
followingterminalsof the mode
control motor 7P connectorand
the heatercontrolpanel14Pcon'
nector,
14P:
7P:
No.2-No.4
N o . 3 - N o .1
N o . 4 - N o .7
No.5- No.I
No.6- No.8
MODECONTROLMOTOR7P CONNECTOR
Ropeir lny opn in tha wilolsl

biwe6n tho modo conlrol motor
and th6 haaie. contol P.nal.
Ch6ck lo. looso wiro3 ot Pool

connoc'tion3 at iha haatcr conttol
prn6l l/aP conncctot. ll tho connactions !.o good, rcplace tho
hgelr control pancl.
21-13
Troubleshooting
Recirculation
ControlMotor
Recirculation control door does
not change btween FRESHand
RECIRCULATE.
Checkthe No. 17 (7.5Al {use in

the under-dashfuse/relaybox.
Roplacethe lus6, aod rscheck.

RECISCULATION
CONTROLMOTOR
4P CONNECTOR
Checkfor an open in th6 wi.e:
1 . D i s c o n n e ctth e r e c i r c u l a t i o n
control motor 4P connector.
3. Messurethe voltagebetween
t h e N o . ' 1t e r m i n a a
l nd body
ground.
BLK/YEL
Repairopen in tho wirc botweon

the No. 17 tuse and lhe recirculation control motor.
Check the recirculationcontrol

motor:
2. Test the recirculationcontrol
motor (seepage2l 25).
Check the rccirculation control
linkagoand door:
1. Removethe recirculation
control motor (seepage2l-25).
2. Checkthe recirculationcontrol
linkageand door for smooth
To page 21 'l5
Oothe recirculation
controllinkageand door move smoothly?
21-14
Repairthe recirculationcontrol
linkage or door.
HEATEFCONTROLPANEL14PCONNECTOR
F r o mp a g e2 1 - 1 4
CheckIor a short in the wite(s):

lower cover (seesection20),
and disconnedthe heatercon
trol panel14Pconnector'
2. Checkfor conlinuitybetween
the No. 12 and No 13 terminalsand body groundindivid
;-?
'olx
4
11 12
GRN/wHr
r3
|
14
GRN/REO
oo
R6air short in the wilo(a) bstween

the rdrculaiion conttol motor rnd
tfte heater control Panel.
Checkfor a short io powar:

Checkthe samewiresfor voltage
1 0|
11 12 1 3 1 4
GRN/RED
GRN/WHT
v)(v
Repairshort to Powsr in the wir

between the recirculstioncontrol
motor and tho heator control
penel. lThis short damagesthe
h6ater control pan6l'l
Checklor an opon in tho wire{s}:

tollowing terminalsof the recircu
lation control motor 4P connector
and the heatercontrolPanel14P
I
1
''l
10I
1 1 1 2 't3 1 1
-tl
GRN/RED
GRN/W
tI
A
o
I_
14P:
4P:
N o . 2 - N o .l 2
N o . 4- N o .1 3
GRN/WHT \ r Repair open in the wire(sl

between the recitculationcomrol
motor and lhe heeter conttol
oanel.
,lr\/
iRN/RTiD
CONTROLMOTOR
RECTRCULATION
4P CONNECTOR
Check for loose wiles or Poor

connectionsat the heater control
oanel l,lP connector. ll tha connections are good, replace the
heater control Panel.
21-15
BlowerUnit
Replacement
NOTE:The blower motor, recirculationcontrol motor
and blower resistorcan be replacedwithout removinq
the blowerunit (seenext page).
1.
Remove the glove box {see section 20).
2.
Remove the self-tapping screw and the passenger,s

dashboard lower cover. Remove the bolt, the nut
and the knee bolster, then remove the five bolts and
the glove box frame.
With Air Conditioning

3-b. Removethe evaporator(seepage22-25).
6x1.0mm
9.8 N.m
7.2 tbt tll
:r-
iCIi1,
KNEE
6x1.0mm
9,8N.m(1.0kgf.m,7.2
tbtf
GLOVEBOX FRAME
Disconnectthe connectorsfrom the blower motor,

blowerresistorand recirculation
controlmotor.
Removethe wire harnessclip from the recirculation
controlmotor,and releasethe wire harnessfrom the
clamp on the blower unit. Removethe two mounting bolts,the mountingnut and the blowerunit.
6x1.0mm
9.8 N.m {1.0 kgf m,
7.2 tbf.tr)
Without Air Conditioning

3-a. Removethe wire harnessfrom the heaterduct,then
removethe two self-tappingscrewsand the heater
quct.
tr
tr
6xl.0mm
9.8N.m(1.0kgf.m,
7.2tbl.ttl
Installin the reverseorder of removal.Make sure
that there is no air leakage.
HEATERDUCT
6a
t\
za-tr,
Overhaul
NOTE:
controldoor and linkagemove smoothlywithout binding'
. Beforereassembly,
makesurethat the recirculation
control door
make
sure its positioningwill not allow the recirculation
motor,
control
. when attachingthe recirculation
to be pulledtoo far.
control motor, connectpower and ground,and watch the movementof the recircula. After attachingthe recirculation
tion controldoor.
21-17
HeaterUnit
Replacement
SRScomponentlocations.precautions,and procedures
in the SRSsection124)beforeperformingrepairsor service,
4.
Disconnect
the heaterhosesfrom the heaterunit.
CAUTION:Enginecoolant will damage paint.
Ouicklyrinse any spilled sngine coolantftom painted
surtaces.
1 . Disconnect
the negativecablefrom the battery.
2.
NOTE| Enginecoolantwill run out when the hoses

are disconnected;
drain it into a cleandrip pan.
When the engine is cool, set the temperaturecontrol leverto MAX. HOT(openthe heatervalve),then
drain the enginecoolantfrom the radiator{seesection10).
HEATERHOSE
{OUTLETSIOEI
Do not remove the radiator cap when

!@
the engine is hot; the engins coolant is under pressure and could severelyscald you.
3.
Open the clamp, then disconnectthe heatervalve

cablefrom the heatervalvearm
CLAMP
5.
Removethe mountingnut from the heaterunit.

NOTE:When removingthe mountingnut, takecare
n o t t o d a m a g eo r b e n d t h e f u e l p i p e s ,t h e b r a k e
pipes,etc.
HEATERVALVE ARM
HEATERVALVECABLE
21-14
8 x 1.25mm
22 N.m (2.2kgl.m, 16lbf.ft)
Removethe dashboard(seesection20).
7.
Removethe heaterduct (seepage 21-16)or evaporator(seepage22-251.
8.
Disconnectthe connectorfrom the mode control

motor, and removethe wire harnessclips and wire
harnessJromthe heaterunit. Removethe clip from
the heater duct, then remove the two mounting
nutsand the heaterunit.
6x1.0mm
9.8N m 11.0kgf'm,7.2lblft)
TERDUCT
HEATER
UN]T
9.
lnstallin the reverseorderof removal.Makenote oi

the followingitems.
a Apply sealantto the grommets.
a Do not interchangethe inlet and outlet heater
hoses.Makesurethat the clampsare secure.

R e f i l lt h e c o o l i n g s y s t e mw i t h e n g i n e c o o l a n t
(seesection101.
Connectall cables,and makesurethey are properly adjusted(seepage21-23).
Makesurethat there is no air leakage.
21-19
HeaterUnit
Overhaul
1.
Removethe two self-tappingscrewsand the heater

corecover.
Pullout the heatercorefrom the heaterunit.
Pullout the grommetfrom the heatercore pipes.
NOTE: Be careful not to bend the inlet and outlet

pipesduring heatercore removal.
Removethe self-tappingscrewand the clamp.
Assemblein the reverseorderof disassembly.
HEATERCONECOVER
21-20
HeaterControlPanel
Replacement
'1. Remove the driver's dashboard lower cover, the
glove box and the center dashboardlower cover
(seesection20).
Disconnect
the air mix controlcablefrom the heater
unit (seepage21-23).
Removethe rearwindow defoggerswitch,the hazard
warningswitchandthe audiounit (seesection23).
Disconnectthe connectorsirom the heatercontrol
panel.Removethe five self-tappingscrewsand the
centerpaneltogetherwith the heatercontrolpanel.
NOTE:The lockingtabs are on the bottom of the
connectors,
AIR MIX CONTROL

CABLE
5.
Remove the four self-tapping screws and the heater
controlpanel,
PANEL
HEATER
CONTROI.
Installin the reverseorderof removal.Adjustthe 8ir

mix control cable and the heatervalve cable (see
page 21-231.
21-21
HeaterGontrolPanel
Overhaul
\n4.---
^Jj-
ffi
g
6:B
^gvry
f f i \

Adiustment,page21'23
HEATERFAN SWITCH
Test,page21-27
Air Mix Control CableReplacement

1. Cut the innercableon the leverside ofthe cableholder,then removeboth piecesofthe innercable.
2. Usinga sharpknife,cut completelylhroughthe end of the cablehousingat the two locations.
3. Slidethe largesectionofthecable housingoutofthecable holder,beingcarefulnot to damagethe cablestops.
4. Carefullyremovethe cut piecesof the cablehousingwith a smallflat tip screwdriver.
5. Hookthe tip of the new air mix control cableto the temperaturecontrol lever,then push the cable housinginto the
cableholderuntil it locksinto place.
CAALEHOLDER
TEMPERATURE
CONTFOLLEVER
NOTE:Afterassembly,checkthat the temperatu
re controlleverslidessmoothlythroughthe full strokefrom rightto left.
21-22
Control
Temperature
Adjustment
Under the hood, disconnectthe heater valve cable
from the heatervalve.
1.
6.
Underthe hood, move the heatervalve arm to the

f u l l v c l o s e dp o s i t i o n t, h e n a n a c ht h e h e a t e rv a l v e
cableto the heatervalvearm.
CLAMP
TER
HEATERVALVEA8M
2.
VALVE
CABLE
HEATER
VALVE
CABLE
Under the dash, disconnect the air mix control cable

housing from the cable clamP.
HEATERVALVE ARM
7.
3.
H o l d t h e h e a t e rv a l v ea r m i n t h e c l o s e dp o s i t i o n ,
and gentlypull on the heatercableouter housingto
take up any slack,then installthe heatervalvecable
h o u s i n gi n t ot h e c a b l ec l a m p .
Setthe temperaturecontrolleverto MAX. COOL

With the air mix control cable attachedto the air
mix controlarm, gently pull on the outer cable
housingto fully closethe door and to removeany
slackin the cable.Don't pull to hard,or the temperaturecontrolleverwill move.
Hold the air mix control arm againstthe stop, then
s n a p t h e a i r m i x c o n t r o l c a b l e h o u s i n gi n t o t h e
c a b l ec l a m p .
21-23
ModeControlMotor
Test
Replacement
1 . Disconnectthe 7P connectortrom the mode control

motor.
1 . Disconnectthe 7P connector from the mode control

motor.
Connectbattery power to the No. 1 terminal, and

g r o u n dt h e N o ,7 t e r m i n a l .
Removethe rod from the arm of the mode control

motor.
CAUTION: Never connect the battery in the opposite direction.
Bemovethe two self-tappingscrewsand the mode

controlmotor.
2.
U s i n ga j u m p e r w i r e , c o n n e c t h e N o . 7 t e r m i n a l
individuallyto the No. 2, 3, 4, 5 and 6 terminalsin
that order. Eachtime the connectionis made' the
mode controlmotor shouldrun smoothlyand stop.
7P CONNECTOR
NOTE:It the modecontrolmotor does not run when

jumping the first terminal,jump that terminalagain
afterjumpingthe otherterminals.The mode control
motor is OK it it runs when jumping the first termin a la g a i n .
MOOECONTROLMOTOR
Installin the reverseorderof removal.After installat i o n , m a k es u r e t h e m o d e c o n t r o lm o t o r r u n s

smoothlv.
4.
lf the mode control motor does not run in step 3,

removeit, then checkthe mode control linkageand
doorsIor smoothmovement.lf they move smoothly,
replacethe modecontrolmotor.
21-24
RecirculationControlMotor
Test
Replacement
1 . Disconnectthe 4P connectorfrom the recirculation

controlmotor.
1.
2.
Connectbattery power to the No. 1 terminal. and

groundthe No. 2 and No. 4 terminals;the recirculation controlmotor shouldrun smoothly.
Disconnectthe 4P connectorfrom the recirculation

c o n t r o l m o t o r , a n d r e m o v et h e w i r e h a r n e s sc l i p
from it.
Removethe two self-tappingscrewsand the recirculationcontrolmotor.
CAUTION: Never connect the battety in the opposite direction.

Disconnect
the No. 2 or No. 4 terminalsfrom ground;
the recirculation
controlmotor shouldstop at FRESH
or RECIRCULATE.
NOTE: Don't cycle the recirculationcontrol motor

for a long time.
CONTROLMOTOR
RECIRCULATION
CONTFOLMOTOR
Installin the reverseorder of removal.After installacontrol motor runs
tion, make sure the recirculation
smoothly.
4.
lf the recirculation
controlmotor does not run in step
controllink2. removeit, then checkthe recirculation
age and door lor smooth movement.lf they move
controlmotor.
smoothly,replacethe recirculation
21-25
Relay
HeaterFanSwitch
Test
Test
Thereshouldbe continuitybetweenthe No. I and No. 3

terminalswhen power and ground are connectedto the
No. 2 and No. 4 terminals,and there shouldbe no continuitywhen power is disconnected.
Checkfor continuitybtweenthe terminalsaccordingto

the table below.
Terminal
,1
Position
OFF
o
ooo-
o
-o
--o
rH [ Fa
'
ffi
"++
IF.=qI
l
21-26
Mode ControlSwitch
Test
Checkfor continuitybetweenthe terminalsaccordingto
the table below.
Terminal
Position
HeaVDef
Def
Vent
Heawent
o- -o
o
ooo-
Heat
7 8
10
;l t
-c
-o
-o
-o
21-27
T
I
Air Conditioning
Evaporator
.-."....22-25
Replacement
................22-26
Overhaul
Gompressor
Description
-......-.22-27
Repfacement
"""' 22'5
outfine ............
22-29
fffustratedfndex "........'.....'..."..'.."..
....'....22'6
Circuit Diagram
---22'30
Clutch Inspection...............'.....'.'.'
Tloubleshooting
...".. 22-31
Cfutch Overhaul'.....'..'........"....
22'7
SymptomChart ...................."..'---..'
Thermal Protector Replacement .... 22'33
" ". 22-8
CondenserFan ....."......'."..........,
22'33
RefiefValve Replacement.....-......".
."'...-'.'22'11
Compressor
..---.."'.22-15 A/C GompressorBelt
A/C System
.-."'..--..22-34
Adiustment
A/C Thermostat
"'.......".22'2
SpeciafTools
22-3
lffustratedIndex .........................'---...".
22-4
Wiring/ConnectorLocations'.............'
Condenser
..""'22'14
Test ............"'..
Repfacement
Relay
.......22-14 A/G System Service
Test ...'.............
Evacuation
A/C ServiceTips and Precautions....'.22-19
Charging
A/C System Torque Specifications ...-22-2O
LeakTest
A/C System Service
...".'...-.""22'21
Recovery
22-22
PerformanceTest .....................'..',,'.
...."' 22'24
PressureTest Chart ..'.......""....
-......'.22-35
........,....22'36
"'......".....22-37
....'..........22-37
SpecialTools
\
Ret. No.
Tool Numbor
o
o
*07JGG- 001010A
07sAz - 0010004
07947- 6340300
07965- 6920500
Ar
Description
Oty
BeltTensionGauge
BackprobeSet
DriverAttachment
Hub AssemblyGuideAttachment
1
2
'I
't
* Includedin the BeltTensionGaugeSet,07TGG-001000A.
,a
I
22-2
PageReference
22-34
22-12,14
22-3'l
lllustratedIndex
EVAPORATOR
page22-25
Replacement,
Overhaul,page22-26
A/C PRESSURE
SWITCH
pressureis below200kPa(2.0kgtcm' ,
Whenthe refrigerant
28 psi) due to refrigerantleakageor above 3200kPa 132kgflcm',
455 psi) due to refrigerantblockage,the A,/Cpressureswitch
opensthe circuhto the A/Cswitchand stopsthe air conditioning
to protectthe compressor.
SERVICEVALVE
SIOE}
ILOW.PRESSURE
Test,page22 18
CONDENSER
page22-35
Replacement,
RECEIVER,/DRYER
page22'27
Replacement,
22-3
Wiring/ConnectorLocations
DIODE,
FAN RELAY,
CONOENSER
COMPRESSOF
CLUTCHRELAY
box}
{Locatedin the underhoodfuse/relav
FAN
CONDENSER
CONNECTOR
COMPARTMENT
WIREHARNESS
CONNECTOR
22-4
Description
Outline
The air conditionersystemremovesheatfrom the passengercompartmentby circulatingrefrigerantthroughthe system
as shownbelow.
High-temperature/
h i g h - p r e s s u rlei q u i d
High-temperature/
h i g h - p r e s srue g a s
Suction and compression
Radiationof heat
t r a p so e D f l s ,
ano removes
motsture
High-temperature/
h i g h - p r e s s ulri q
euid
RECEIVER/DRYER
coMpREssoR
-CoNDENSERMoreliquidified
low-pressurevapor
Less moisturized
low-pressurevapor
Absorption of heat
E VAT\JhA
I UN \
EVAPORATOR
RECEIVERLINE
LINE
DISCHARGE
SUCTIONLINE
RECEIVER/DRYER
COMPRESSOR
Pay attentionto the following

refrigerantwhich does not containchlorofluorocarbons,
This car uses HFC-134a
{R-'134a)
rtems:
servtce
(R-134a)They are not compatible.
a Do not mix refrigerants
CFC-12(R-12)and HFC-134a
Use only the recommendedpolyalkyleneglycol(PAG)refrigerantoil (SP-10)designedfor the R-134acompressor.

Intermixingthe recommended{PAG)refrigerantoil with any other refrigerantoil will resultin compressorfailure.
expans'onvalve.
dischargeline,suctionline,evaporator,condenser,receiver/dryer,
All Ay'Csystemparts(compressor,
parts.
O-ringsfor joints)haveto be properfor refrigerantR-134a.Do not confusewith R-12
a Usea halogengas leakdetectordesignedfor refrigerantR-134a.
System
Useonly a Recovery/Recycling/Charging
servicingequipmentare not interchangeable,
R-12and R,134arefrigerant
systems.
R-134a
air
conditioning
J2210
to
service
ot
SAE
meet
the
requirements
is
certified
to
is
and
that U.L.,listed
any
Systembeforedisconnecting
with an approvedRecovery/Recycling/Charging
Alwaysrecoverthe refrigerantR-'134a
A,/Cfitting.
22-5
CircuitDiagram
UNDER DASH
FUSE/RELAY
8OX
AO
YX
U N D E R - H O OFDU S E / B E LB
N 0 . 4 1i 8 0 A )
N o . 1 7( 7 . 5 4 1
N 0 . 4 2( 4 0 A )
No.56l20A)
4
COMPRESSOR
CLUTCH
RELAY
BLU/ryVHT
iS. rc
(,r ) PRESSURE
\.:J./ SWITCH
CONDENSER
FANMOTOR
COMPRESSOR
cLUTcH
REsrsToR
.N..i.._-)
BIK
I
22-6
Troubleshooting
SymptomGhart
NOTE:
. Any abnormalitymust be correctedbeforecontinuingthe test.
needed,usea multimeterwhen testing.
. Becauseof the precisemeasurements
o Beforeperformingany troubleshootingprocedurescheck;
. 7 ( 7 . 5A ) , * 1 N o . 5 6( 2 0A ) , * , N o .1 7 ( 7 . 5A l
_ F u s e s* 1 N o 4
- GroundsNo. G401,G402,G751
- Cleanliness
and tightnessot all connectors
*r: In the under-hoodfuse/relaybox
*2:In the under-dashfuse/relavbox
Symptom
I
I
!
Remedy
Compressorclutchdoes not engage
Performthe proceduresin the flowchart(seepage22-8).

Performthe proceduresin the flowchart(seepage22-11)
A,/Csystemdoes not come on (compressorand tan).
Performthe proceduresin the flowchan(seepage22-15).
Condensertan does not run at all.
22-7
Troubleshooting
CondenserFan
Condensa
lan does noi run at ell.
Removethe condenserfan relay,

and test it {seepage22-18).
Replacethe condensertrn relay.

CONDENSER
FAN RELAY4P SOCKET
Checkthe unde.-hoodIuse/rlsy
box:
No. 3 terminalof the condenser
f a n r e l a y 4 P s o c k e ta n d b o d y
ground.
Checktho conden3e.tan:
Connectthe No. 'l and No. 3 ter
minafs of the condensetlan rclay
4P socketwith a jumper wire.
Doesthe condenserfan run?
To page22-10
22-8
To page22'9
Frompage22 8
FAN RELAY'P SOCKET

CONDENSER
wHTa------l
1 l
I
Checkfor an open in the wire:

1. Disconnect
the iumperwire.
the condenserfan
2. Disconnect
2Pconnector.
the No. 1 terminalol the condenserfan relay4Psocketand
the No. 1 terminalof the condenserfan 2Pconnector.
r--------------1
l f f i
I l n l ' l
6
\ \:/
II
r- r
L-r,T;l
wHT t-----l-----J
Repairopn in the wire betwoen

tho condenser fan relay and the
condensertan.
FAN 2P CONNECTOR
CONDENSER
Checkfor an op.n in the wire:

Checkfor continuity beNveenthe
No. 2 terminal ol the condenser
fan 2P connector and body
ground.
ls therecontinuity?
RsDlacethe condenserfan motor,
Chock Ior an ooen in lhe wile

between the condenser tan and
body ground. ll the wire i3 OK,
chsck for poor ground at G751.
(cont'd)
22-9
Troubleshooting
Condenser
Fan(cont'dl
Frompage22-8
Checkthe diode:
1. Disconnect
the jumperwire.
2 . R e m o v et h e d i o d e f r o m t h e
under-hood
fuse/relaybox.
3. Checkfor currentflow in both
directionsbetweenthe A and
B terminals.
ls therecurrentflow in only
one direction?
22-10
a o--J(-----o n
Compressor
Removethe compressorclutch
relay,and test it (seepage 22-18)COMPRESSOR
CLUTCHBELAY4P SOCKET
Checkthe under-hoodfuse/relay
box:
No. 3 terminalof the compressor
clutch relay 4P socketand body
ground.

JUMPER
WIRE
Checktho compr*sor clutchl
Connectthe No. 1 and No. 3 termi'
nalsotthe compressorclutchrelay
4Psocketwith a iumoerwire.
Doesthe comoressorclutchclick?
fo page22-12
Checklor.n oponin the wir:

1. Disconnect
the jlmper wire.
2 . D i s c o n n e ctth e c o m p r e s s o r
clutch1Pconnector.
the No. 1 terminalof the compressor clutch relay 4P socket
and the terminal of the com
pressorclutch1Pconnector,
ls therecontinuity?
Inspct tho compressor clutch

(sepago 22-301.
Rapairopen in tho wite botwoen

tha compa6sor clutch aelay ,nd
tho compressorclutch.
COMPRESSOR
CLUTCH1P CONNECTOR
WIRESIDEOF FEMALETERMINAL
(cont'd)
22-11
Troubleshooting
Compressor(cont'dl
t u o mp a g e 2 2 - 1 1
COMPRESSOR
CLUICH RELAY4P SOCKET
Checkfor an open in the wi.e:

1. Disconnect
the jumperwire,
the No. 4 terminalof the com
pressor clutch relay 4P socket
and body ground.
Is there batteryvoltage?
ECM/PCMCONNECTOR
A (32PI
Chocktor an open in thg wira:
then reinstallthe compressor
clutch relay.
2. Nlakesure the A/C and heater
tan switchesare OFF,then turn
the ignitionswitchON lll).
3. Using a *BackprobeSet (T/N
07SAZ- 001000A),measure
the voltagebetweonthe No. 17
terminal of the ECWPCMcon,
nector A {32P) and body
groundwith the ECM/PCMconn6ctorsconnected.
ls therebatteryvoltage?
fo page22-13
22-12
Repairopen in the wiro between

the compressor clutch .elay snd
rhe ECM/PCM.
*How to usethe backorobe

sets
Connectthe backprobeadaptersto the stackingpatchcords,and
connectthe cordsto a multimetor,Usingthe wire insulationas a
guldefor the contouredtip ot the backprobeadapter,gentlvslide
the tip into the connectorfrom the wire side untalit comesin contactwith theterminalendofthe wire lseesection11).
Frcm page22-12
SWITCH2P CONNECTOR
A/C PRESSURE
Chocklor an opon in tha wira;
2. Disconnoctthe Ay'Cpressure
switch 2P conneclor.
th No. l terminal and body
grouno.
Rsprir open in the wire between

lh6 condanser fan relav and th6
A/C oro$ure switch.
A/C PRESSURE
SWITCH
Ch6ckthc A/C pressuJorwitch:
2. Check for continuity betwesn
th No. 1 and No.2 terminals
of th NC Dressureswitch.
To page 22-14
Checktor Ay'Csystem pressure.
Rop.ir the A/C pr.3suroploblem.
Replaccth. A/C pr4sute swhch.
(cont'd)
22-13
Troubleshooting
Compressor{cont'd)
Frcmpage22 13
ECM/PCMCONNECTOR
C 131P)
Checkfor an op6n in the wire:

1. Reconnectthe ,a/Cpressure
swilch 2P connector,then turn
the ignitionswitchON {ll).
2. Using a *BackprobeSet {T/N
07SAZ- 001000A),measure
the voltage betweenthe No. 5
terminal ol the EcM,rrPcM
connector C {31P) and body
groundwith the ECM,PCMconnectorsconnected.
Ropairopon in the wire between

the A/C oresure switch and the
ECM/PCM.
Check lor loos6 wires or poor

c o n n e c t i o n sa t t h e E C M / P C M
connectorsA {32P}and C 131Pl.It
the connec,tionsare good, substitute a known-good ECM/PCM,
and recheck. lf the symptom/
the oriqinal ECM/PCM.
*How to usethe backprobe
sets
Connectthe backprobeadaptersto the st6ckingpatchcords,and
connectthe cordsto a multimeter.Usingthe wire insulationas a
guidetor the contouredtip of the backprobeadapter,gentlyslide
the tip into the connectorfrom the wire side until itcomes in contactwith the terminalend of the wire {seesection11).
22-14
I
l
A/C System
A/C aYstem does not come on
(compressotand fanl.
C h e c kt h e N o . 5 6 f u s e i n t h e
under-hoodfuse/relaYbox and
the No. 17 fuse in the under-dash
Iuse/relaybox.
Replacethe tuse(sl,and recheck.

FAN RELAY'P SOCKET
CONDENSER
Checkfor an open in the wi.e:

1 , B e m o v et h e c o n d e n s e rf a n
relayfrom the under-hood
fuse/relaybox.
3. i/leasurethe voltage between
the No. 4 terminalof the cond e n s e rf a n r e l a y 4 P s o c k e t
and body ground.
Ropairopgn in the wile botween

the No. 17 tuso and the con'
donssrlan relay.
Checkth under-hoodfuso/relaY
box:
No. 3 terminal of the condenser
f a n r e l a y 4 P s o c k e ta n d b o d y
grouno,
3P CONNECTOR
A/C THERMOSTAT
ChecktoJ an opon in lhe wire:
a n d r e i n s t a l tl h e c o n d e n s e r
Ian relay.
2. Disconnectthe NC thermostat
3P connector.
3. Turn the ignitionswitchON (ll)
4. Measurethe voltage betlveen
the No. 3 terminal and body
ground.
WIRESIDEOF FEMALETEBMINALS
Repairopen in the wite betwen

the No. l? fuse and tho A/C thetmostal.
(cont'd)
To page22 16
22-15
Troubleshooting
A/C System{cont'dl
Ftom page 22-15
Ch6ckfor an open in the wirsi

No. 1 terminalof the A"/Cthermo,
stat 3P connector and body
grouno,
Repai. open in the wire botwaen

the condonser fan rolay and th6
A/C thermGt.t.
Chcklhe A/C thermostat:

2. Reconnectthe Py'Cthermostat
3P connector,
3. Connectthe No. 2 terminalto
groundwith a iumperwire.
4. Startthe engine.
. -tlu----r---u
1 l 2 l 3 l
JUMPER
I BLU/RED
wrRE l
Do both fansrun and doesthe

compressorclutchengage?
HEATERCONTROLPANEL,I4PCONNECTOR
Checklor an open in the wire:
r , r u r n r n e r g n r t r osnw n c hu t - t - ,
t h e n d i s c o n n e ctth e j u m p e r
1
2. Flemovethe centerdashboard
lower cover (see section20),
and disconnect
the heatercon
trol panel14Pconnector.
4, Measurethe voltagebetween
the No. l1 terminaland body
ground.
''|
lol
It
12 1 3 14
WIRE SIDE OF FEMAI,TTERMINAU;

To page 22-17
22-16
Ropair open in tho wire bttt oon

the A/C th.rmGt.t.nd
th. hertor
conlrol panol.
HEATERCONTROLPANEL1'P CONNECTOR
Frompage22-16
Chocktor en opon in the wire:

2 . D i s c o n n e c tt h e h e a t e r f a n
3. Check for continuity beNveen
the No. 14 terminal of the
heatercontrolpanel 14Pconnectorand the No. 6 terminal
ofthe heaterfan switch6P connector,
;--?
2
8
10
11 1 2 1 3 1 4
GRN
2
4
Rpairopen in tho wire bstwoon

tho hoater control panl and the
hoater f.n switch.
GRN
HEATERFAN SW]TCH6P CONNECTOR

Chocklor an op6n in the wir6:

No. 1 terminal of the heaterfan
switch 6P connector and body
ground.
Ch6ck for an opon in the wirs
botwecn tho hsator fan switch
and body ground. lf the wire is OK,
check lor poor ground .t Gl01 and
G102.
Test the heater fan switch lsee

page21-26).
ls the heaterfan switch OK?
Replacethe hedter fan swiich.
Chgck lor loo! wires or Poor

connectionsat thg ho.ler coBtrol
panol 14P connecto.. It the con_
noction3 arg good, replace the
herler contlol Danol.
22-17
A/C Thermostat
Relay
Test
Test
Connectbatterypower to the No. 3 terminal,groundthe

No. 2 terminal,and connecta test light betweenthe No. 1
and No. 3 terminals.
Thereshouldbe continuitybetweenthe No. 1 and No.3

terminalswhen power and ground are connectedto the
No. 2 and No. 4 terminals,and there shouldbe no continuitywhen power is disconnected.
NOTE:Usea 12V, 3 W - 18W test tight.

Dip the !y'Cthermostatinto a cup filled with ice water, and
checkthe test light.
,t YI
Serpentinetype evaporator
The light shouldgo off at 36 - 39'F{2 - 4"C)or less,and
shouldcome on at 39 - 41"F(4 - 5"C)or more.
t>
.l nI
lo
Laminatetype evaporator
The light shouldgo off at 39 - 43.F{4 - 6.C) or less,and
shouldcome on at 43 - 45"F(6 - 7"Clor more.
l f t h e l i g h t d o e s n ' tc o m e o n a n d g o o f f a s s p e c i f i e d ,
replacethe Ay'Cthermostat.
12v,3w-18W
1.,
rE-],,'
A
Llt
i|
.,,fl--$-....
A/C ServiceTips and Precautions
EI
(PAG)refrigerantoil*' which are not

(R-134a)
refrigerantand polyalkyleneglycol
The air conditionersystemusesHFC-134a
or
mineraloil in this system,and do
refrigerant
R-12
Do
not
use
mineral
oil.
and
refrigerant
6p6-12
with
compatible
1n-tZ)
your
servicingequipmentwill result.
not attemptto useR-12servicingequipment;damageto the air conditionersystemor
*SandenSP-10:
. P/N38897- Pl3 - A01AH:120mf (4 fl'oz.4.2 lmp'oz)
. P/N38899- P13- A01:40 ml 11lBIl'oz, 1.4lmp'oz)
Use only serviceequipmentthat is U.L. listedand is certifiedto meet the requirementsof SAE J2210to removeR-134a
from the air conditionersystem.
CAUTION:Exposureto air conditioner rftigerant and lublicant vapor or mist can irritatg eyes, nose and lhroat. Avoid
breathing the air conditioner refrigerant and lubticant vapor or mist.
lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice'
R-134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor Ieaktestedwith compressed
air.
Some mixtures ol air and R.i34a havs been shown to b9 combusiible at elevated pressuresand can resuh
@
causing iniury or property damage. Nevet use compresscd air to pressuretest R-13/+aservica equipiiTiiffiiplo"ion
ment or vehicle air conditionor systems.
Additionalhealthand safetYinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers'

t. Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningparts.
any lines,plug or cap the fittings immediately;don't
2. Keepmoistureand dust out of the system.When disconnecting
removethe capsor plugs untiljust beforeyou reconnecteachline.
3. Beforeconnectingany hoseor line,apply a few drops of refrigerantoilto the O-ring'
4. Whentighteningor looseninga titting,usea secondwrenchto supportthe matchingfitting'
system; don't releaserefriger5. When dischargingthe system,use a R-134arefrigerantRecovery/Recycling/charging
atmosphere
ant into the
6. Add refrigerantoil after replacingthe followingparts:
NOTE:
do not returnthe oil to the containeronce dispensed,and nevermix it with other refriger. To avoidcontamination,
ant oils.
. lmmediatelyafterusingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption
. Do not spillthe refrigerantoil on the vehicle;it may damagethe paint;ifthe refrigerantoil contactsthe paint,wash
it off immediatelY.
.......20m/ (2/3fl'oz' 0.7 lmp'ozl
Condenser
ils m I 11213tl'oz' 1.6lmp'ozl
Evaporator........................................
10 ml (1/3fl'oz.0.4 lmp'oz)
Lineor hose...........
10 ml (1/3 fl'oz, 0.4 lmp'oz)
Receiver/Dryer
25
m/ (5/6 ll'o2, 0.9 lmp'ozl
Leakagerepair
For
compressot teplacement, subtract the volume of oil drained {rom the
..,
compressor
rmovedcomDressorfrom 130 m/ (4 1/3 fl'oz, '1.6tmpoz), and drain the calculated
volum of oil from the new compressor:130 m0 l'l l/3 floz, 4'6 lmp'oz)- volume
of removedcomprgssot= Volume to drain from new compressor'
NOTE:Even if no oil is drainedfrom the removedcompressor,don t draln more
than 50 m/ \1 2/3tl'o2,1.8lmp'oz)from the new compressor.
NEW
REMOVED
COMPRESSOR
COMPRESSOR
6(C
re
f f i f f i
w
l6_dr omrr,rrruc
l
ozr
uver-.ffir volunae 130
16rmP
m{t41/3rr'oz'
h['-saue
]
I I
22-19
A/C SystemTorqueSpecifications
O Dischargehoseto the compressor(6 x i.0 mm) ...............

........................
9.SN.m 0.0 kgf.m,7.2 lbf.ft)
@ Dischargohoseto the condenser(6 x 1.0mm)...................
.......................
9.8 N.m 0.0 kgf.m,7.2 tbf.ft)
@ Condenserpipe to the condenser{6 x 1.0mm|...................
......................
9.8 N.m fl.0 ksf.m,7.2 lbf.ft)
@ Condenserpipeto tho receiver/dryer
{6 x i,0 mm).........
..........................
9,g N.m (1.0kgt.m,7.2 lbr.ft}
@ Receiverpipe A to the roceiver/dryer(6 x 1.0mm)...,.....
.....................,....
9.8 N.m 0.0 kgf.m,7.2 tbf.ft)
@ Receiverpipe B to the receiverpipe A
t3 N.m {1.3 kgt.m, 9.4 tbf.ft)
O Receiverpipe Cto the receiverpipe B
t3 N.m (1.3 kgf.m,9.it lbf.ft)
@ Receiverpipe C to the evaporator(6 x 1.0mm) ...............
.........................
9.8 N.m 0.0 kgf.m,7.2 lbf.ft)
O Suctionpipe B to the evaporatol(6 x 1.0mm)................
..........................
9.8 N.m {1.0kgf.m,7.2 tbf.ft)
@ Suctionpipe A to the suctionpipe B
...........................
31 N.m {3.2kgf.m,23 tbf.ftl
@ Suctionhoseto tho sustionpipe A...
...........................
3t N.m {3.2kgt.m,23 lbf.ft)
@)Suctionhoseto the compressor(6 x 1.0mm),..............,...
........,,..............
9.8 N.m {i.0 kSf.m,7.2 lbf,ft}
@ Compressorio the comp.essorbracket(8 x 1.25mm)..,
.......,..,.......-....,,..24 N.m {2.4kgl.m,17 lbf.ft}
@ Compressorbracketto the cylindorblock {10x 1.25mm} ..................................................._......
/14N.m (4.Skgr.m,33 tbf.ft)
@ Compressorbracketio the left front enginemount {12x t.2S mm) ..........................................
59 N.m (6.0kgf.m,43 tbr.ft)
22-20
ru
A/C SystemService
Recovery
Useonly serviceequipmentthat is U.L-listedand is cerof SAEJ2210to remove
tifiedto meetthe requirements
(R-134a)
from the air conditionersystem
HFC-134a
g/Charging system
Recovery/Recyclin
CAUTION: Exposure to air conditioner rfrigersnt and

lubricant vapol or mist c8n irritate syes, nose and
ihroat. Avoid breathing the air conditioner lgfrigerant
and lubricant vapol or mist.
lf accidentalsystemdischargeoccurs,ventilatework
areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersystems shouldnot be pressuretestedor leaktestedwith
atr.
comDressed
some mixtures of air and R-134ahave been
!@
strown to be combustible at elovatedpressuresand can
resull in fire or explosioncausing inlury or prope y dam'
age. Nver use compressedair to pressure test R'i34a
srviceequipment ot vehicleair conditionsr systems.
Additionalhealthand safetyinformationmay be obtained
from the refrigerantand iubricantmanuJacturers.
1 . Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystemto the vehicle,as shown,following
instructions.
Measurethe amountof refrigerantoil removedfrom
the A,/Csystem after the recoveryprocessis completed.
NOTE: Be sure to installthe same amount of new
refrigerantoil backinto the ly'C system before chargIng.
22-21
A/G System Service

Performance
Test
The Derformance
test will helo determineif the air conditionersystemis operatingwithin specifications.
Useonly serviceequipmentthat is U.L.-listed
and is certified to meet the requirementsof SAEJ2210to remove
(R-134a)
HFC-134a
from the air conditionersvstem.
CAUTION: Exposure to air conditioner relrigerant and
lubricant vapor ol mist can irtitate eyes, nose and
throat. Avoid broathing the air conditioner retrigerant
and lubricant vapor or mist.
lf accidentalsystem dischargeoccurs, ventilate work
areabefore.esumingservice,
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak testedwith
compressedair.
som mixtures of air 8nd R-134ahave been
!@
shown to b combustible at elevated p.essuresand can
result in fire or explosion causing iniury or property
damage. Nev6r uss compressed air to pressuretogt R.
134a sarvice equipment or vohicl air conditioner sy3tems.
from the refrigerantand lubricantmanufacturers.
1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n R
t ecover/Recycling/
ChargingSystemto the vehicle.as shown, following the equipmentmanufacturer's
instructions.
2.
l n s e r t a t h e r m o m e t e ri n t h e c e n t e r v e n t o u t l e t .
Determinethe relative humiditv and air temDerature.
Testconditions:
. Avoid directsunlight,
o Openhood.
. Openfront doors.
. Setthe temperaturecontrolleverto MAX. COOL,
the mode control switch on VENTand the recirculationcontrolswitchon RECIRCULATE.
. Turn the IVCswitchon, and the heaterfan switch
on MAX.
. Runthe engineat 1,500rpm.
. No driveror passengers
in vehicle
After running the air conditioningfor 10 minutes
under the above test conditions,read the delivery
temperaturefrom the thermometerin the dashvent
and the high and low systempressurefrom the !y'C
gauges.
Recovory/Recycling/chargingSystom
5.
To completethe charts:
. Markthe deliverytemperaturealongthe verticalline.
o Markthe intaketemperature(ambientair temperature)alongthe bottom line.
. Drawa line straightup from the air temperatureto the humidity
. Mark a Dointone line aboveand one line belowthe humiditylevel(10%aboveand10%belowthe humiditylevel).
. Fromeachpoint,draw a horizontalline acrossthe deliverytemperature.
. The delivervtemoeratureshouldfall betweenthe two lines
. Completethe low side pressuretest and high side pressuretest in the sameway.
. Anv measurements
outsidethe line maYindicatethe needfor further inspection
kPa
lkgf/cm'l
lpsil
80/o
2900(30t
t0t
2500t25)
t3601
2000t20)
1280t
1500t15t
t2101
DELIVERY
PRESSURE
980 {10)
11lol
307o
DELIVERY
PRESSURE
80vo
kPa
"F
{kgt/cmz)
tpsil
{"c}
400 85
l,ll
{30t
t57l
300t3)
77
li(}l
200tzl
lI
l25l
68
(20t
I2Al
ll
100
{11
lt 4l
59
50
{10}
tlst
INTAKE
PRESSURE
DELIVERY
TEMPERATURE
INTAKE
PRESSURE
11
(5t
DELIVERY
TEMPERATURE
ri
6
a
l20l
n
a
(251
6
t30)
95
(35)
104
(,r01
"F
fC)
INTAKETEMPERATUFE
22-23
A/C SystemService
PressureTestChart
NOTE:Performance
Test is on page22-22.
Test results
Relatedsymptoms
Probablecause
D i s c h a r g(eh i g h ) After stoppingcompressor,prespressureabnor,

suredropsto about200kPa
m a l l yh i g h
{2.0kgflcm,,28psi)quickly.and
t h e nf a l l sg r a d u a l l y .
R e d u c e do r n o a i r f l o w t h r o u g h
condenser
Air in system
. Cloggedcondenserfins
. Condenserfan not working properly
Lineto condenseris excessively

hot.
Restricted
flow of refriger
ant in system
. FaultycompressordisDischargepresHighand low pressures
arebal
s u r ea b n o r m a l l y ancedsoon afterstoppingcompreschargevalve
sor.Lowsideis higherthannormal. . Faultycompressorseal
. Faultyexpansionvalve
Outletof expansionvalveis not
. Moisturein system
frosted,low pressuregaugeindicatesvacuum.
Suction(low)
pressureabnorm a l l yl o w
Expansion
valveis not frosted,and
low pressureline is not cold.Low
pressuregaugeindicates
vacuum.
Frozenexpansionvalve
Faultyexpansionvalve
Remedy
Recover,evacuate,and
rechargewith specifiedamount.
Evacuation:
see page22-36
Charging:seepage22-37
Clean.
Checkvoltageand fan rpm.
Checkfan direction.
Restricted
lines
Replacethe compressor.
. Replace.
. Recover,evacuate.and
rechargewith specified
amount.
Replacethe expansion valve.
Discharge
temperature
is low,and
Frozenevaporator
the air flow from ventsis restricted.
Runthe fan with compressor

off, then checkA,/Cthermostat.
Expansionvalveis frosted.
Cloggedexpansionvalve
Cleanor replace.
Receiver/dryer
outletis cool,and
inletis warm (shouldbe warm
Cloggedreceiver/dryer
Replace.
. Expansionvalveopentoo
l on g
. Looseexpansioncapillary
tube
Repairor replace.
11lr9i!99!:!.
SuctionpresLow pressurehoseand check

s u r ea b n o r m a l l y joint are coolerthan the tempera
high
tu re aroundevaporator.
Suctionpressureis loweredwhen
condenseris cooledby water.
Excessive
refrigerantin system
l-l,gh""d l"* pr""sureare equal- . Faultygasket
. Faultyhigh pressurevalve
izedas soon as the compressoris
stopped,and both gaugesfluctu ] . Foreignparticlestuckin
a t ew h i l er u n n i n g .
high pressurevalve
S""tl""""d d'; l Reducedair flow throughcon- I . Cloggedcondenserfins
cnargepres. Condenserfan not workdenser.
suresabnormally
ing properly
nrgn
Recover,evacuate,and
recharge
with specified
amount.
Suctionand dischargepressure
abnormallylow
Refrigerant leaks
22-24
Cleancondenser.
Checkvoltageand fan rpm.
Checkfan direction.
Low pressurehoseand metalend

areasare coolerthan evaporator.
Cloggedor kinkedlow pressure hoseparts
Repairor replace.
Temperaturearoundexpansion
valveis too low comparedwith
that aroundreceiver/dryer.
Cloggedhigh pressureline
Repairor replace.
Compressorclutchis dirty.
Compressorshaftsealleaking Replacethe compressor.
Compressorbolt{s)are dirty.
Leakingaroundbolt(s)
Tightenbolt(s)or replacecompressor.
gasketis wet with oil.

Compressor
Gasketleaking
Evaporator
Replacement
']
6.
Removethe battery.
2.
Recoverthe refrigerantwith a Recovery/Recycling/

ChargingSystem(seepage22 21).
3,
Removethe bolts,then disconnectthe suctionand

receiverlinesfrom the evaporator.
thermostat,
Disconnectthe connectorfrom the A,,/C
and removethe wire harnessfrom the evaporator'
Removethe four self-tappingscrews,the mounting
b o i t a n d t h e m o u n t i n gn u t . D i s c o n n e ctth e d r a i n
hose.then removethe evaPorator.
NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contaminatron.
ORAINHOSE
SUCTIONLINE
:1i
6x1.0mm
9.8N.m (1.0kgl.m,
7.2tbt.ftt
.,
i, I
THERMOSTAT
CONNECTOR
EVAPORATOR
1 . 0m m
N.m {1.0kgl.m.7.2lbtft}
RECEIVERLINE
Removethe glove box (seesection20).

7.
Removethe self-tappingscrewand the passenger's
d a s h b o a r dl o w e r c o v e r .R e m o v et h e b o l t ,t h e n u t
and the kneebolster,then removethe five boltsand
the glove box frame.
.1...
,;1 ,,
-;1t'i
i1:-.....
i',
r'l--.;:,i,,
,. i
Installin the reverseorder of removal.Make note of

the followingitems.
lf you'reinstallinga new evaporator,add refriger(seepage22-191.
ant oil (SP-10)
Replacethe O-ringswith new onesat eachfitting,
and apply a thin coat of refrigerantoil before
installingthem.
NOTE: Be sureto use the right O-ringsfor HFCto avoid leakage.
134a{R-134a)
a Apply sealantto the grommets.
a Makesurethat there is no air leakage.
a Charge the system (see page 22-311,and test its
performance(seepage22-22J.
22-25
Evaporator
Overhaul
1.
Pull out the Ay'Cthermostatsensorfrom the evaporatorfins.
2.
Removethe self-tappingscrews and clamps from

the housings.
3.
Carefullyseparatethe housings,then remove the

evaporator.
5.
Assemblein the reverseorderof disassemblv.

Make
noteof followjngitems.
Replacethe O-ringswith new onesat eachfitting,
a n d 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 not i l b e f o r e
installingthem,
NOTE:Be sure to use the right O-ringsfor HFC
134a(R-134a)
to avoid leakage.
Installthe expansionvalve capillarytube so that
it is in direct contactwith the suction line.Then
wrap wrth tape.
Reinstallthe Iy'Cthermostatsensorto its original
location.
lf necessary,
removethe expansionvalve.
NOTE:Whenloosening
valvenuts,use
the expansion
a secondwrenchto hold the expansionvalveor the
evaporatorpipe.Otherwise,they can be damaged.
6th fin trom inlet side
1 2 0 15 m m
{4.710.2 in)
UPPERHOUSING
Serpentinetype:
TAPE
Replace.
Makesurethereis no foreignmatterstuckbetween
the capillarytube and outletline.
a
Laminatetype:
6015mm
12.1! 0,2 inl
EVAPOBATOR
blow dirt out of tins
with compressed
air.
N.m {0.8 kgl.m,
rbr.ftl
6th fin from outlet side
CAPILLARY
TUBE
EXPANSIONVALVE
N.m {2.itkg{.m,
A/C THERMOSTAT
Testpage22 18
LOWERHOUSING
22-26
Compressor
Replacement
'1.
I t t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er, u n t h e
e n g i n e a t i d l e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r
work tor a few minutes,then shut the engineoff.
2.
Disconnect
the negativecablefrom the battery.
7.
L o o s e nt h e c e n t e rn u t o f t h e i d l e r p u l l e ya n d t h e
adjustingbolt,then removethe Ay'Ccompressorbelt
from the pulleys,Removethe two mounting bolts
from the left front engine mount, then removethe
A,/Ccompressorbelt by passingit through the gap
betweenthe body and the leftfront enginemount.

ChargingSystemlsee page22-211.
ADJUSTINGBOLT
CENTERNUT
Removethe bolts,then disconnectthe suctionand

dischargelinesfrom the compressor.
NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contamination.
6x1.0mm
LINE
DISCHARGE
LEFTFRONT
1.0x125mm
a4 N.m {4.5kg{.m,33 lbtftl
8.
Remove the four mounting bolts and the compressor.
SUCTIONLINE
COMPRESSOR
5.
Removethe condenser(seepage22-35).
NOTE:Do not disconnectthe dischargehose from
lhe condenser-
6.
Removethe power steeringpump belt {seesection

171.
2il N m 12.4kg[.m, 17 lbf.ftl
(cont'd)
22-27
II
Compressor
(cont'd)
Replacement
9.
lf necessary,
removethe compressorbracketas foltows.
-
Removethe nut and the washer.

NOTE:When tighteningthe nut of the left front
enginemount,makesurethe washeris set properly on the leftfront enginemount as shown.
Removethe four mounting bolts and the compressorbracket.
12 r 1.25mm
59 N.m {6.0 kgl.m,
43 tbf.ftl
COMPRESSOR
BRACKET
WASHER
LEFTFRONT
1.0x 1.25mm
ENGINEMOUNT
a{ N.m 14.5kgt m.33 tbf.ft)
22-28
10. lnstallin the reverseorderof removal.Makenote of

the followingitems.
lf you're installinga new compressor,drain all
the refrigerantoil from the removedcompressor,
and measureits volume.Subtractthe volume of
drainedoil lrom 130mf 14 1B fl.oz,4.6 lmp.oz);
the result is the amount of oil you should drain
from the new compressor(throughthe suction
fitting).
Replacethe O-ringswith new ones at each fitt i n g , a n d 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
beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFC134a(R-134altoavoid leakage.
Use refrigerantoil (SP-10lforR-134aSandenand
Hadsysspiraltype compressorsonly.
To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
lmmediatelyafter using the oil, replacethe cap
on the container.and seal it to avoid moisture
absorption.
Do not spill the refrigerantoil on the vehicle;it
may damagethe paint;if the refrigerantoil contactsthe paint,wash it off lmmediately.
Adjust the Ay'Ccompressor belt (see page 22-341
and the power steeringpump belt {seesection17).
Charge the system (see page 22-371,and test its
performance(seepage22-22').
lllustratedIndex
CENTER
NUT
Replace.
ARMATUREPLATE
page22-30
Inspection,
sHrM{s)
Replace.
Replace.
ROTORPULLEY
page22-30
Inspection,
SNAPRINGA
Replace.
FIELDCOIL
page22-30
Inspection,
q\
q \
a-
_-2
RELTEF
vALvE
page22-33
Replacement,
COMPRESSOR
{Do not disassemble.)----"-}l
THERMALPROTECTOR
Replace.
page22-30
Inspection,
page22 33
Replacement,
a
22-29
Compressor
Clutch Inspection
Checkthe platedpartsof the armatureplatefor color
c h a n g e sp, e e l i n go r o t h e r d a m a g e .l f t h e r e i s d a m age,replacethe clutchset.
Releasethe field coil connectorfrom the holder,then

disconnectit. Checkthe thermal protectorfor contin u i t y . l I t h e r e i s n o c o n t i n u i t y r. e p l a c et h e t h e r m a l
Drotector.
Checkthe rotor pulleybearingplay and drag by rotating the rotor pulley by hand. Replacethe clutch set
with a new one it it is noisyor hasexcessive
play/drag.
Checkresistance
of the field coil.
Measurethe clearancebetweenthe rotor pulley and
the armature plate all the way around. lf the clearance is not within specifiedlimits,the armatureplate
must be removed and shims added or removed as
required,followingthe procedureon page22-31.
Clearanca:
0.5t 0.15mm {0.02010.006in}
NOTE: The shims are availablein four thicknesses:
0 . 1m m , 0 . 2m m . 0 . 4m m a n d0 . 5m m
22-30
FieldCoil Resistance:3.2
t 0.15ohms at 68"F{20"C1
lf resistanceis not within specifications,
replacethe
field coil.
II
Clutch Overhaul
1.
Removethe centernut while holdinqthe armature

olatewith the tool.
3.
Removesnap ring B with snap ring pliers.

NOTE:
a B e c a r e f u ln o t t o d a m a g et h e r o t o r p u l l e ya n d
compressorduring removal/installation.
. Once snap ring B is removed,replaceit with a
new one,
CENTERNUT
17.6N.m {1.8kg{.m, 13 lbf.ft}
A/C CI-UTCH HOLDER

(Commercially available)
Robinai.: P/N 10204
Kent-Moore: P/N J37872
-..::::.:...-
2.
Removethe armatureplateby pullingit up by hand.

4.
ARMATURE
PLATE
Remove the rotor pulley from the shaft with a puller

and the special tool.
NOTE: Put the claws of the puller on the back of the
rotor pulley, not on the belt area; otherwise the
rotor pulley can be damaged.
/t,
.\\
.)'
.l
t
(cont'd)
22-31
Compressor
ClutchOverhaul(cont'd)
5.
Removethe screwfrom the field coil groundterminal,then disconnecthe field coil connector.
R e m o v es n a p r i n g A w i t h s n a p r i n g p l i e r s ,t h e n
removethe field coil,
NOTE:
. Be carefulnot to damagethe field coil and compressorduring remove/installation.
. Once snap ring A is removed,replaceit with a
new one.
. When installingthe field coil, align the boss on
the field coil with the hole in the compressor.
SNAP RING A
Replace.
6.
Positionthe rotor pulleysquarelyover the field coil.

Pressthe rotor pulley onto the compressor boss
w i t h t h e s p e c i a tl o o l . l f t h e r o t o r p u l l e yd o e s n o t
press on straight, remove it, and check the rotor
pulleyand compressorbossfor burrsor damage.
CAUTION: Maximum press load: 39,200 kPa
(400kgt/cm', 5,690psil
Preit
HUB ASSEMBLY
GUIDEATTACHMENT
07965 - 6920500
FOTOR
PULLEY
22-32
-
7.
A s s e m b l ei n t h e r e v e r s eo r d e r o f d i s a s s e m b l y .
Make noteof the followingitems.
.
.
.
.
.
Installthe fieldcoilwith the wire sidefacingdown.

C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g
surfaceswith non-pet.oleumsolvent,
Make sure the snap rings are fully seatedin the
groove.
Make sure that the rotor pulley turns smoothly
after it's reassembled.
Routeand clamp the wires properlyor they can
be damagedby the rotor pulley.
Thermal Protector Replacement

1.
Bemovethe bolt. the groundterminaland the holder. Disconnect

the field coil connector.then remove
the thermalprotector.
ReliefValve Replacement
1.
Removethe reliefvalveand the O-ring,

NOTE:
. Do not let the compressoroil run out.
. Make sure that no foreign matterentersthe system.
7.{ N.m {0.75kgl.m, 5,4lbf.ftl
Q
t)
.Y,/
,
THERMAL
PROTECTOR
RELIEF
VALVE
9.8 N.m (1.0kgt m,
7.2 rbnft)
O.RING
Replace.
Cleanthe matingsurfaces.
Replacethe O-ringwith a new one at the reliefvalve,
a n d 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 b e f o r e
installingit.
Replacethe thermal protectorwith a new one, and

apply siliconesealantto the top of the thermalprotector.
NOTE:
. To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
. lmmediatelyafter using the oil, replacethe cap
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint;if the refrigerantoil contactsthe paint,wash it off immediately.
Installand tightenthe reliefvalve.
SILICONESEALANT
3.
5.
Charge the system (see page 22-311,and test its

performance(see page 22-221.
lnstall in the reverse order of removal.
22-33
A/C CompressorBelt
Adjustment
Deflection Method
1.
Apply a force of 98 N (10 kgf, 22 lbf), and measure

the deflectionbetweenthe A,/Ccompressorand the
crankshaftpulley.
\
Tension Gauge Method
'1. Attach
the specialtool to the Ay'Ccompressorbelt as
shown below,and measurethe tensionof the belt.
A/C ComprossorBelt
Used Belt: 340 - it90 N (35 - 50 ksf, 77 - 110 lbfl
New Belt: 690 - 830 N (70 - 85 kgf, 150- 190 lbf)
A/C CompressorBelt
UsedBelt:7.5- 9.5 mm 10.30- 0.37in)
New Belt: 5.0- 6.5 mm (0.20- 0.26in)
NOTE:
o Follow the manufacturer'sinstructionstor the
belttensiongauge.
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for iive 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.
. "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.
2.
Loosenthe centernut ofthe idlerpulley,
3.
Turn the adjustingbolt to get properbelttension.
4.
Retighten
the centernut ofthe idlerpulley.
5.
Recheckthe deflectionof the Ay'Ccompressorbelt.
22-34
2.
Loosenthe centernut ofthe idlerpulley.
3.
Turn the adjustingbolt to get properbelttension,
4.
Retighten
the centernut ofthe idlerpulley.
5.
Recheckthe tensionof the Ay'Ccompressorbelt.
Condenser
Replacement
1.

ChargingSystem(seepage22 21).
2.
Disconnectthe condenserfan connectorfrom the

A/C wire harness,then removethe Ay'Cwire harness
from the condenserfan shroud.
4.
Removethe bolt from the suctionhose bracket,and

removethe two bolts and the upper mount bracket.
Removethe condenserassemblyby liftingit up
NOTE:Be carefuinot to damagethe condenserfins
when removingthe condenserassembly.
MOUNTBRACKET
UPPER
CONDENSER
FAN
CONNECTOR
6x1.0mm
9.8 N.m (1.0kgf.m.7.2lbfftl
6x1.0mm
9.8N.m 11.0kgl.m,7.2lbI.ftl
A/C WIREHARNESS
3.
R e m o v et h e b o l t s ,t h e n d i s c o n n e ctth e d i s c h a r g e
and condenserlinesfrom the condenser.
5.
NOTE: Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust conramlnaton.
6x1.Omm
DTSCHARGE
L|NE 9.8 N.m 11.0
CONDENSER
lnstallin the reverseorder of removal.Make note of

the followingitems.
lf you'reinstallinga new condenser,add refriger(seePage22-19).
ant oil (SP-10)
. Replacethe O-ringswith new ones at each fitt i n g , a n d 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
beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFcto avoid leakage.
1344(R-'134a)
a B e c a r e f u l n o t t o d a m a g et h e c o n d e n s e rf i n s
when installingthe condenserassembly.
. Chargethe system{seepage 22-37).and test its
performance{seePage22-221
6x1.0
9.8 N.m {1.0kgf.m, 7.2 lbf ft)
22-35
A/C System Service

Evacuation
Use only serviceequipmentthat is U.L.-listed
and is cer
tified to meet the requirementsof SAEJ2210to remove
HFC-134a
{R 134a)trom the air conditionersystem.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irrilate eyes, nose and throat.
Avoid breathing the air conditioner refrigerant and lubricant vapor or mist.
lf accidentalsystem dischargeoccurs,ventilate work
R-134aserviceequipmentor vehicleair conditionersystems should not be Dressuretested or leaktested with
compressedarr.
some mixtures ot air and R-134ahave bn
@
shown to be combustible at elevatd ptessuresand can
result in tire or explosion causing iniury or property
damage. Never use compressed air to pressure test R134a service equipment or vehicle air conditioner sysIems.
from the refrigerant
and lubricantmanufacturers.
'1.
2.
When an Ay'CSystemhas beenopenedto the atmosphere,such as during installationor repair,it must

be evacuatedusing a R-134arefrigerantRecovery/
Recycling/Charging
System.(lf the systemhas been
open for severaldays,the receiver/dryer
should be
replaced,and the system should be evacuatedfor
severalhours.)
Connecta R-134arefrigerantRecoverylRecycling/
ChargingSystemto the vehicle,as shown, following the equipmentmanufacturer's
instructions,
NOTE:lf low pressuredoesnot reachmorethan 93.3
k P a( 7 0 0m m H g , 2 7 . 6i n . H g )i n 1 5 m i n u t e st,h e r ei s
probablya leak in the system.Partiallychargethe
system,and checkfor leaks(seeLeakTest).
22-36
g/Charging System
Recovery/Recyclin
Charging
LeakTest
and is cerUse only serviceequipmentthat is U.L.-listed

titied to meet the reouirementsof SAEJ22,!0to remove
(R-134a)
HFC-'134a
Use only serviceequipmentthat is U.L.listedand is certified to meetthe requirementsof SAEJ2210to remove

(R-134a)
HFC-'134a
CAUTION:Exposureto air conditionerrefrigerantand

lubricant vapor or mist can irritate eyes, nose and
thloat. Avoid breathingthe air conditionerretrigerant
and lubricantvaooror mist.
CAUTION:Exposureto air conditionerrefrigerantand

lubricant vapor or mist can irritate eyes,nose and throat.
Avoid breathing the air conditioner retrigerantand lubricant vapor or mist.
l f a c c i d e n t asl y s t e md i s c h a r g eo c c u r s ,v e n t i l a t ew o r k
a r e a b e f o r e r e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t h a n d
safetyinformationmay be obtainedfrom the refrigerant
l f a c c i d e n t asl y s t e md i s c h a r g eo c c u r s ,v e n t i l a t ew o r k
Refrigerantcapacity:550:goI {22.9:qs oz)

CAUnON: Do not overchargethe system;the compressor
will be damaged.
Recovery/Recycling/Charging
Connecta R-134arefrigerant
Systemto the vehicle,as shown,followingthe equjpment
instructions.
manufacturer's
System
Recovery/Recycling/Charging
R l34a serviceequiDmentor vehicleair conditionersystems should not be pressuretested or leak testedwith

compressedair.
some mixtures ot air and R-13,1ahave
![@
been shown to be combustibleat elevatedpressures
and can result in fire or explosion causing iniury or
property damage. Never use compressedail to pressure
test R-134aservice equipment or vehicle air conditioner
systems.
from the refrigerant
1.
Connecta R-134arefrigerantRecoverylRecycling/
C h a r g i n gS y s t e mt o t h e v e h i c l e ,a s s h o w n i n t h e
previouscolumnfollowingthe equipmentmanufacturer'sinstructions.
NOTErBe sure to installthe same amount of new
refrigerantoil backinto the A,/CsystembeforechargIn g .
Open high pressurevalve to chargethe systemto
the specifiedcapacity,then closethe supplyvalve,
and removethe chargingsystemcouplers.
Refrigerantcapacity:650130
O 122.9:1aozl
3.
Checkthe systemfor leaksusing a R-134arefrigerant leak detectorwith an accuracyof l4 g (0.5 oz)

per year or better.
4.
lf you find leaksthat requirethe systemto be opened

(to repairor replacehoses,fittings,etc.),recoverthe
on page
systemaccordingto the RecoveryProcedure
22-21.
5.
After checkingand repairingleaks,the systemmust

on page22 36)
be evacuated
lseeSystemEvacuation
LOW.PRESSURE
SIDE
22-37
Electrical
.......-.-..........23-75
,fgnition Switch
.." """""'23-2
SpeciafToofs
23-88
"
lgnition System
Troubleshooting
""
23-133
*A/T
.
...
........
.....
....
Indicator
GearPosition
Tios and Precautions..............'. " " "" 23-3
23-140
ilntegrated
........,.........-.-...............,..
Unit
Control
Five-stepTroubleshooting........" """" """ 23-5
""""""""' 23-124
System
fnterlock
""
23-5
wire color codes
- """ " 23-146
Lighting System
SchematicSYmbols.........'.'......'. "" " 23-6
Lights, Exteriol
Relayand Control Unit Locations
""""23-151
Bsck-upLights
23-7
""""
"
.
..'.............'.
Compartment
Engine
"
"" 23-158
""
Lights
Brake
" " 23-8
Dashboard
Lights(Canadal...'. " "' 23-150
Running
Davtime
23-12
""""'
Door ......................
23-151
. ""
FrontParkingLights .......................
,Airbags ...,........,...
........Sestion24
"
23-151
"
Lights......'.........
Signal
FrontTurn
Section 2l
."
Air Conditioning
"" " 23-151
"
..
Headlights
.......,........,........,..23-98
Atternator
"" 23-159
High Mount BrakeLight ... ..........""
Anti-lock BrakeSvstem IABSI ... .." " " Section 19
" "" 23-156
LicensePlate Lights
Sestion 14
Automatic TransmissionSystem .. . ""
"23-153
"
Taillights...............
"""""""23-77
B a t t e l y. . . . . . . . . . . . . . . . . .
""""""23-162
....
Lights
fnterior
Section 21
Blower Controls
23-203
.................,...........
Moonrool
"
""""""23'72
System
Charging
""""""'23-57
Distribution
Powel
Connestorldentification and Wire Harness
""""""23-219
""""' 23-11
PowerDoor Locks
R o u t i n g. . . . . . . . . . . . . . . . .
""" " 23'180
""
" """""""'23-2oa
PowerMirrors
cruise contlof
"""""""23-72
""
23'160
"
"
Retays.........
.
Power
Dash Lights BrightnessController
" "" "'23-191
....... """ " 23-111
PowerWindows
FanControls
RearWindowDetogger.....'..........'......"""""23-176
.........""" Section11
FuelPump
" "' 23'97
..... ""
""""""23-52
SparkPlugs
F u s e s, . . . . . . . . . . . . . . . . . . . .
" 23-79
""
.....
11
Seqtion
""
StartingSystem
PGM-FIControlSystem... .................
23-167
*StereoSoundSystem ........,......,........................'
*G.uges
(SRSI .....Section 24
'supplemental
Systom
"23-116
Restraint
""
"
CircuitDi.gram
" "' 23-154
"" " """"'23-126
Turn Signal/HazardFlasherSystem ""
FuefGauge
23-71
+Under-dash
...............................
Box
"
23-114
"
Fuse/Relay
Speedometer........'
(VSS)
""""23"124
"
"
.
......
Sensor
...........23-65
Speed
Vehicle
cround Distribution
23-186
" ""
rwipers/Washers
"""" section 21
Heatet controls
*Horn .....................
.............-..23-173
NOTE:Unlessotherwisespecified.referencesto auto(A,/T)
in this sectionincludethe CVT'
matictransmission
SpecialTools
\
Rel. No.
o
o
o
{t*
Tool Number
A973X 041_ XXXXX

0 7 J G G- 0 0 1 0 1 0 4
OTLAJ_ PT3O2OA
0 7 N A C- S R 2 0 1 0 0
07PM- 0010100
Description
Oty
V a c u u mP u m pG a u g e0, - 3 0 i n . H g .
BeltTensionGauge
TestHarness
FuelSenderWrench
SCSServiceConnector
PageReterence
23-215
23-'t10
23-124,125
23-126
23-9'l
*: Includedin Belt Tension GaugeSet 07TGG- 0010004
ri
an
23-2
Troubleshooting
Tips and Precautions
N e v e rt r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n
their wires;pull on the connectorhalvesinstead.
Alwaysreinstallplasticcovers.
BoforeTroubleshooting
. Checkagplicablefuses in the appropriatefuse/relay
oox.
. Checkthe batteryfor damage,state of charge,and
cleanand tight connections.
. Checkthe alternatorbelttension.
CAUTION:
. Do not quick-chafgea battety unless the battery
ground cable has been disconnected,otherwise you
will damagethe alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connected or you will severely
damagethe wiring.
Beforeconnectingconnectors,make sure the terminalsare in placeand not bent.
Handling Connectols
. Makesurethe connectorsare cleanand haveno loose
wire terminals.
. Makesure multiplecavityconnectorsare packedwith
grease(exceptwatertightconnectors).
. All connectorshave push-downreleasetype locks.
LOCKINGTAB
.
Some connectorshave a clip on their side used to
attach them to a mount bracketon the body or on
anothercomponent.This clip hasa pull type lock
Some mounted connectorscannot be disconnected
unlessyou first releasethe lock and removethe connectorfrom its mount bracket.
Checkfor looseretainerand rubberseals.
RETAINER
T h e b a c k s o f s o m e c o n n e c t o r sa r e p a c k e d w i t h
grease-Add greaseit necessary.lf the greaseis contaminated,replaceit.
LOCKING
PAWL ON
OTHER
Pull to
HALF OF
drsengage
CONNECTOR
BRACKET
(cont'd)
23-3
Troubleshooting
Tips and Precautions(cont'd)
Insertthe connectorall the way and make sure it is
securelylocked.
Positionwires so that the open end of the coverfaces
down.
Seat grommets in their grooves properly.
NOT GOOO
Fsce
opon end
A & - /
-w--_w\\
ll
Handling Wires and Harnesses

. Securewires and wire harnessesto the frame with
their respectivewire ties at the designatedlocations.
. Removeclipscarefully;don't damagetheir locks.
Slip pliers under the clip base and through the hole at
an angle,then squeezethe expansiontabs to releasethe
c l lP .
Testing and Repairs

. Do not usewires or harnesses
with brokeninsulation.
Replacethem or repairthem by wrappingthe break
with electricaltaDe.
a A f t e r i n s t a l l i n gp a r t s ,m a k e s u r e t h a t n o w i r e s a r e
oinchedunderthem.
. W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. l f p o s s i b l e i, n s e r tt h e p r o b e o f t h e t e s t e rf r o m t h e
wire side (exceDtwaterDroofconnector).
Usea probewith a taperedtip.
SNAP.RINGPLIERS
After installlngharnessclips, make sure the harness

doesn'tinterferewith any moving parts.
Keep wire harnessesaway from exhaust pipes and
other hot parts. from sharp edges of bracketsand
holes.and from exDosedscrewsand bolts.
23-4
Referto the instructionsin the HondaTerminalKit for

i d e n t i f i c a t i o an n d r e p l a c e m e not f c o n n e c t o tr e r m i nals.
Five-stepTroubleshooting
1.
VerifyThe Complaint
Turn on all the componentsin the problemcircuitto
verifythe customercomplaint.Note the symptoms
Do not begin disassemblyor testing until you have
narroweddown the problemarea.
2.
AnalyzeThe Schematic
L o o k u p t h e s c h e m a t i cf o r t h e p r o b l e m c i r c u i t .
Determinehow the circuit is supposedto work by
tracing the current pathsfrom the power feed
throughthe circuitcomponentsto ground.lf several
circuitsfail at the sametime, the fuse or ground is a
likelycause.
Basedon the symptomsand your understandingof
the circuitoperation,identifyone or more possible
causesof the problem.
J.
lsolateThe ProblemBy TestingThe Circuit

Makecircuitteststo checkthe diagnosisyou made
in step 2. Keepin mind that a logical,simple proceTest for
dure is the key to efficienttroubleshooting.
the most likely cause of failure first. Try to make
testsat pointsthat are easilyaccessible.
Wire Color Codes

The following abbreviationsare used to identify wire
colorsin the circuitschematics:
W H T . . . . . . . . . . . . . . . . . . . .W
. . ,h. i. t. e. . .
. .e
. .l.l.o. w
...
Y E L. . . . . . . . . . . . . . . . . . . . . Y
B L K . . . . . . . . . . . . . . . . . . . . .B. .l.a. c. .k. . .
BLU..............................81ue
G R N . . . . . . . . . . . . . . . . . . . .G
. . r. .e. e. .n. .
R E D. . . . . . . . . . . . . . . . . . . . .R. .e. .d. . . . .
. . r. .a. n. .g. .e
O R N . . . . . . . . . . . . , . , . . . . .O
P N K. . . . . . . . . . . . . . . . . . . . .P. .i.n. k. . . . .
B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. .
. .r. a. .y. . . .
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
. reen
L T G R N . . . . . . . . . . . . . . , . .L. .i .g.h. .tG
T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h
anothercolor stripe.The secondcolor is the stripe.
WHT/ALK
FixThe Problem
Once the specificproblem is identified,make the
repair.Be sure to use propertools and sale proceoures.
MakeSureThe CircuitWorks
Turn on all componentsin the repairedcircuitin all
modes to make sure you've fixed the entire problem. lf the problem was a blown fuse, be sure to
test all of the circuitson the fuse.Makesure no new
problemsturn up and the originalproblemdoes not
recur,
23-5
Troubleshooting
SchematicSymbols
EATTERY
l,r
ril
t""l
II
II
_1
_d_
.:
r
RESISTOR
FUSE
GROUND
ground
Componenl
Groundterminal
COIL, SOLENOID
rh
lat
<'r.-e
VARIABLERESISTOR
THERMISTOR
/+'
BULB
IGNITIONSWITCH
CIGARETTELIGHTER
A
lTl
i7
HEATER
A
t=l
ilHq.r + +
+ + D
Q c
/c\ A+,
Y I4 v
Y T
I
Jl-
CIRCUITgREAKER
PUMP
MOTOR
DIODE
HORN
SPEAKER,BUZZER
TI
TRANSISTOR(Trl
ANTI:NNA
Mast
SWITCH lln n o.mal politionl

I Normally closed
Normally open
switch
'*i'"n
l'0\
RELAY {ln normal positionl

Normallyopen relay Normallyclosedrelay
t--.--'l
fT't
t
i
t i l
trf
Gt - l -
l r l
l-*'+
CONDENSER
CONNIicTtoN
lnput
Output
J-
LIGHTEMITTING
DIODE{LED)
\h/
CONNECTOR
--+>-r-l-
REEDSWITCH
It'rl
!
23-6
Relayand ControlUnit Locations

EngineGompartment
ELDUNIT
UNDER.HOOD
BOX
FUSE/RELAY
t:
tr
-fr@
D
T'lrrrl
tl
r-- --1
FAN
CONDENSER
RELAY
ABS
UNDER.HOOD
FUSE/RELAYBOX
BLOWER
MOTOR
RELAY
RADIATOR
A/C COMPRESSOR FAN RELAY
CLUTCHRELAY
23-7

Dashboard:96, 97 models
CRUISECONTROLUNIT
DAYTIME
RUNNINGLIGHTS
CONTROLUNIT
(Canad.)
DASHLIGI{TSBRIGHTNESS
CONTROLLER
(Hasbuilt-incontrolunit)
. MOONROOFOPENRELAY
CAru/Ae
O,l
[wire colors:GRN/ORw.
[WHT,YEL,andBLK
I
. MOONROOF
CLOSE
RELAY
[Wi]e colors:GRN/ORN,GRN/YEL,l
and BLK
IWHT,GRN/RED,
I
23-8
CUTRELAY
STARTER
Iwir6 colo]s:BLK/wHf,au/wxf,l
andBLK/RED
l
I BLU/aLK,
UNDER.DASH
FUSE/RELAYBOX
INTEGRATED
CONTROLUNIT
il-trral a\{\
fi |
POWERWINDOWRELAY
Fnnr-1nnnnn-r
FrJrJrJuuLluLrLJU|lJ
F-nnrr'-1nn|-1nrl
p!rrrLrLrrruLr'.uLJ|P
u_:;_:_:_l:_:_l_;E::
TURNSIGNAL/
HAZARORELAY
CONTROLUNIT
INTERLOCK
lTcM tcw)
.: Coupe
23-9

Dashboard:98model
CRUISECONTROLUNIT
DAYTIME
RUNNINGLIGHTS
CONTROLUNIT
{Cenada}
DASHLIGHTSBRIGHTNESS
CONTROLLER
[Wi]e colols: BLK/WHT,etX/WXf,l

IBLU/BI-K,and BLK/RED
J
Wire colors:WHT/GRN,BLU/RED,
GRYand WHT/GRN
MOONROOFCLOSERELAY
Cnn/Yel,l
lwilo colo]s:cRN/ORru,
andBLK
IWHT,GRN/RED,
I
23-10
POWERWINDOWFELAY
I\JJJ'IJJJIJJJ
LI
CONTROLUNIT
INTERLOCK
.TCM(CvT)
': Coupc
23-11

Dashboard/Door
AUDIO UNIT
(Hasbuilt in keylessreceivercircuit)
POWEROOORLOCK
CONTROLUNIT
PGM.FIMAIN RELAY
MASTERSWITCH
ABS CONTROLUNIT
23-12
Connectorldentificationand Wire HarnessRouting
How to ldentily Connectols:

"C" for connectors'
ldentificationnumbershave been assignedto all connectors.The number is precededby the lefter
"
T
"
" G " f o r g r o u n dt e r m i n a l o
f o r n o n g r o u n dt e r m i n a l s
sr
Location
Harness
EngineCompartment
Startercables
T 1 ,T 2 a n d@
Batterygroundcable
G l a n dO
Dashboard
Others lFloor. Door,

Trunk/Hatch, and Root)
E n g i n eg r o u n dc a b l eA
E n g i n eg r o u n dc a b l eB
T4
G3
Under-hoodABSfuse/relaybox wire
harness(with ABS)
t5 ano (?
Enginewire harness
C 1 0 1t h r u C 1 4 7
T 1 0 l a n dT 1 0 2
G'r01
Enginecompartmentwlre narness
C 2 0 lt h r u C 2 1 4
G201and G202
Main wire harness
C 3 0 1t h r u C 3 1 0
C351thru C360
C401thru C446
G401and G402
Dashboardwire harness
C501thru C520
Floorwire harness
C551thru C573{C574)
G551and G552
Rearwire harness
C 6 0 1t h r u C 6 1 7
G601
Driver'sdoor wire harness
C631thru C639
door wire harness

Passenger's
Left reardoor wire harness(Sedan)
C651thru C656
Rightreardoor wire harness(Sedan)
C671thru C674
Roofwire harness{Withoutmoonroof)
Moonroofwire harness(Withmoon'
roof)
C701thru C703
C661thru C664
C 7 1 1t h r u C 7 1 8
A
Heatersub-harness
C721thru C727
B
Heatersub-harness
C741thru C743
A,/Cwire harness
C 7 5 1t h r u C 7 5 4
Hatchwire harness(Hatchback)
C76l thru C768

G761
Rearwindow defoggergroundwire
c771
G77'l
Secondaryheatedoxygensensorsubharness
C 7 8 1a n dC 7 8 2
Fueltank pressuresensorsub-harness
C791thru C793
S R Sm a r nh a r n e s s
C801thru C807
G801
O : 9 7 , 9 8m o d e l
23-13
Starter Cables
Connectoror
Terminal
Numberol
Cavities
Location
Connectsto
T,1
T2
Rightside of enginecompanment
Rightside of enginecompartment
Under-hoodfuse/relaybox
Startermotor
Battery
Batterypositiveterminal
Notes
Battery Ground Cable

Connectoror
Terminal
Number of
Cavities
Location
Connectsto
Right front shock tower
Bodyground,via batteryground
cable
Baftery
Batterynegativeterminal
Notes
EngineGroundCableA
Connectoror
Tgrminal
Number of
Cavities
T3
Location
Connectsto
Leftside of engine
Powersteeringpump bracket
Leftsideof enginecompartment
Bodyground,via engineground
cableA
Notes
EngineGroundCableB
Connectorot
Terminal
Numberof
Cavities
T4
Location
Connectsto
Rightsideof enginecompartment
Transmission
Rightside of front frame
Bodyground,via engineground
c a b l eB
Notes
Under-hoodABS Fuse/RelayBox Wire Harness

Connoctoror
Terminal
Number of
Cavities
Location
Connaqtsto
T5
Under-hoodfuse/relaybox
Battery
Batterypositiveterminal
Notes
A/C Wire Harness

Connestoror
Terminal
Numberof
Cavities
Location
ConnecGto
c754
Enginecompartmentwire harness
(c209)
Compressorclutch
Condenserfan motor
Ay'Cpressureswitch
G751
Leftside of enginecompanment
Bodyground,via Ay'Cwire harness
c751
1
2
23-14
Notes
BATTERY
GROUND
CABLE
UNDER-HOOD
ABS FUSE/RELAY
BOXWIRE
HABNESS
GROUNO
CASLEB
A/C WIRE
HARNESS
23-15

EngineWire Harness(Dl6Y5,D16Ygenginesl
Left side of enginecompartment

Middle of engine
Niliddleot engine
Left side of engine compartment
Left side of enginecomPartment
Middle of engine
M i d d l eo f e n g i n e
Middle of engine
Middle of engine
Middle of engine
Irliddleof engine
Middle of engine
Middle oI engine
Middle of engine
Middle of engine
Middle of engine
Left side of engine comPartment
Middle ot engine
Middle ot engine
Middle ol engine
Middle of engine
c 101
c102
c103
c104
c104
c105
c106
c 107
c 108
c109
c110
c11l
cl12
c113
c114
c115
c116
cl17
c118
c119
c120
c121
10
3
c122
c123
c123
c124
c124
c125
cl26
c127
c128
c129
c130
8
2
2
c] 31
cl32
3
2
2
2
2
3
3
3
2
2
2
14
14
3
2
2
10
1
2
2
2
1
20
22
32
25
14
c136
c 137
c138
c139
c140
c141
c142
c143
c144
c144
c145
c146
c147
Middle ol engine
Middle ol engine
Middle ol engine
Middle o'f engine
Middle ot engine
Middle of engine
Middle of engine
Middle ot engine
Middle of engine
Rightside ol enginecomPartment
Eehind right kick Panel
Under right side ot dash
Under right side of dash
'14
2
2
1
2
2
2
2
2
8
2
Main wire harness{C303)

Crankshaftspeedfluctuation(CKF)sensor
Engineoil pressureswitch
Alternator
Alternator
No. l fuel injector
No.2 tuel injector
No. 3luel injector
No. 4 fuel injector
IAC valve
Throttleposition(TP)sensor
Manilold absolutepressure(MAP)sensor
Intakeair temperature(lAT)sensor
Power steering pressure(PSP)switch
Junctionconnector
Junctionconnector
Vehiclespeedsensor{VSSI
CountershaftsPeedsensor
Engine coolant temperature (ECT)switch A
Distributor
Engine coolant tefiperature (ECT)sending
unii
Engine coolanttemperature(ECT)sensor
PrimaryHO2S{sensor1)
1)
PrimaryHO2S(sensor
lightswitch
Back-up
Lock-up control solenoid valve

Secondary HO2S (sensor 2)
Mainshaftspeedsensor
Linarsolenoidvalve
Shift control solenoidvalve
Startersolenoid
Junction connector
Main wire harness(C446)
ECM/PCM
PCM
ECM/PCM
ECM/PCM
Main wire harness{c305)
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Left side of engine comPartment
Middle of engine
Middle of engine
Right side ol engine compartment
Rightsideof enginecomPartmenl
side of engine comPaftment
Left side oI engine comPartment
Knocksensor(KS)
IAC valve
VTECsolenoidvalve
VTEC pressure switch
EGRcontrol solenoidvalve
EGRvalve
EGRvalve
Drive pulley speedsensor
Solenoidconnector(CVT)
Driven pulley speedsensor
ground,via enginewire harness
*1: D16Y5engine
'2: D16Y8engine
*3: D16Y5(A,,/T),
D16YA
engines
23-16
-,(Arr)
Ay'T:
96 model
'1 (Avn:
97.98
models
AlT..
97,98
models
-,{A,/T)
-1(Arr)
., (A/r)
* 1{r\,riT)
-'(A/T)
*1 (CVT)
.,(A/T)
c132am
12
crog c138
c110
c113
T101
c141
T102.
c117c143
c't17
c144
c140
cl18
c139
c120
c129
c146
ENGINEWINE
HARNESS
cl'r5
c116
c137
c102
c145
23-17

\
EngineWire Harness{D16Y7engine):96model
Connectorot
Terminal
c 10'1
c102
Cavities
10
3
Location
Connectsto

Middleof engine

Crankshaft
speedfluctuation(CKF)
sensor
Alternator
Alternator
No. I fuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
IACvalve
Manifoldabsolutepressure(MAp)sensor
lntakeair temperature(lAT)sensor
Powersteeringpressure(PSP)switcn
EVAPpurgecontrolsolenoidvalve
Junctaonconnector
Junctronconnector
Vehiclespeedsensor(VSS)
Countershaft
speedsensor
Enginecoolanttemperature(ECT)
switchA
Distributor
s e n d i n gu n i t
Enginecoolanttemperature{ECT)sensor
PrimaryHO2S(sensor1)
Back-uplight switch
Lockup controlsolenoidvalve
SecondaryHO2S(sensor2)
Linearsolenoidvalve
Shiftcontrolsolenoidvalve
Startersolenoid
JunctionConnector
NIainwire harness(C446)
ECM/PCM
PCM
ECM/PCM
ECM/PCM
c103
c104
c104
c105
c106
c'107
c 108
c 109
c110
c111
cl12
13
C'1
c 11 4
cl15
cl16
c117
cl18
c119
Middleof engine
Middleof engine
[/iddle of engine
Middleof engine
Middleof engine
Middleof engine
Middle of engine
Middleof engine
fvliddleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middle of engine
Middleof engine
cl20
c121
Middle of engine
Middleof engine
Middle of engine
Middleof engine
Middleof engine
Middle of engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Right side of engine compartment
Behind right kick panel
U n d e rr i g h t s i d eo f d a s h
U n d e r r i g h ts i d eo f d a s h
Left side of engine compartmenl
Right side of engine compartment
Middleof engine
23-18
Engineground,via enginewire harness
USA
Canada
96 model:
ENGINEWIREHARNESS
c135 C134
c133 cl32
c130
T102
c1' r7
c119
c120
c118
c129
c106
cr07
t't, c"'
c103
c108
23-19

EngineWire Harness(D16Y7engine):97model
Connectoror
Terminal
Numberof
Cavities
Location
Conneqtsto
Crankshaft
speedfluctuation(CKF)
sensor
Alternator
Alternator
No. 1 fuel injector
N o . 2 f u e li n j e c t o r
No. 3 fuel injector
N o . 4 f u e li n j e c t o r
IACvalve
Manifoldabsolutepressure(MAP)sensor
Intakeair temperature(lAT)sensor
Powersteeringpressure(PSP)switch
EVAPpurgecontrolsolenoidvalve
Junctionconnector
Junc on connector
Vehiclespeedsensor(VSS)
Countershaft
speedsensor
switch A
Distributor
sendingunit
Enginecoolanttemperature(ECT)sensor
P r i m a r yH O 2 S( s e n s o1r )
Back-uplight switch
Lock-upcontrolsolenoidvalve
SecondaryHO2S(sensor2)
Linearsolenoidvalve
Shiftcontrolsolenoidvalve
Stanersolenoid
Junctionconnector
ECM/PCM
PCM
ECM/PCM
ECM/PCM
EVAPcontrolcanistervent shutvalve
c101
c102
10
Leftside of enginecompartment
cr03
c104
c104
c105
cr06
cl07
cl08
c109
c110
c111
cl12
c113
c114
1
4
3
2
2
2
2
3
N4iddle
of engine
lvliddleof engine
lvliddleof engine
Middleof engine
Middleof engine
c117
cl18
cl19
3
2
)
2
14
14
3
,
2
c120
c121
10
'l
c122
c124
c124
2
2
c't21
cl2A
c129
c130
c 13'r
c't32
c133
c134
c136
c137
2
2
2
1
20
22
25
16
8
2
Middleof engine
Middleof engine
Behindright kickpanel
Underright side of dash
Underright sideof dash
T101
r102
Leftside o{ enginecompartment Alternator

Rightsideof enginecompartment Under-hoodfuse/relaybox
G101
Middleof engine
23-20
Engineground,via enginewire harness
Notes
USA
Canada
USA
NT
NT
Alr
Alr
A/r
Alr
97 model:
WIREHARNESS
ctto
"',' '
23-21
EngineCompartment Wire Harnesg

Connectoror
Te.minal
Number ol
Cavities
c201
c202
c202
c203
c204
c205
c206
c207
c20a
c209
c210
10
6
2
4
2
c210
c211
c212
c213
c214
1
2
3
G201
G202
*'l: With cruisecontrol
*2: Withoutcruisecontrol
|I
I
23-22
Location
Connctsto
Leftsideof enginecompartment Main wire harness(C308)

Leftsideof enginecompartment Main wire harness(C309)
Leftsideof enginecompartment Main wire harness{C309}
Lelt sideof enginecompartment Cruiseactuator
Behindtront bumper
Windshieldwashermotor
Behindfront bumper
Rearwindow washermotor
Leftsideof enginecompartment Leftfront turn signaUparking
light
Behindtront bumper
Frontfog light
Leftsideof enginecompanment Leftheadlight
Leftsideof enginecompartment A,/Cwire harness(C751)
Behindfront bumper
Horn
Behindfront bumper
Rightsideof enginecompanment
Horn
Radiatorfan motor
Rightheadlight
Rightfront turn signal/parking
light
Rightsideof enginecompartment Bodyground.via enginecompartment

wire harness
Leftside of enginecompartment Bodyground.via enginecompartment
wire harness
Notes
Optional
models
98 model
ENGINECOMPABTMENT
WIREHARNESS
23-23

Main Wire HarnesslLeft side ol engine compartment branch)
Connectoror
Terminal
Number of
Cavities
c301
c302
c303
c304
c305
c305
c306
c307
c308
c309
c309
c310
5
10
14
8
I
1
10
2
Location
Connectsto
Notes
Windshieldwjper motor
Testtachometerconnector
E n g i n ew i r e h a r n e s (sC 1 0 1 )
Daytimerunninglightsresistor
Canada
Enginewire harness(C136)
Enginewire harness(C136)
Brakefluid levelswitch(+)
Brakefluid levelswitch(-)
Enginecompanment
wire harness(C2011
Enginecompartment
wire harness(C202)
Enginecompartmentwire harness(C202)
Left front ABS wheel sensor
A8S
* 1 : D 1 6 Y 5e n g i n e
*2: D16YBengine
*3: With cruisecontrol
*4: Withoutcruisecontrol
Main Wire Ha.ness(Right 3ide of engine compartment branch)
Connqtoror
Terminal
Number of
Cavities
c351
1'l
9
5
c354
c355
c357
c358
c3s9
c360
G403
23-24
I
3
2
2
10
Location
Rightsideof enginecompanment
Rightsideof enginecompaTtment
Connectsto
Under-hoodfuse/relaybox (C9081
Under-hoodfuse/relaybox (C906)
Enginecompartment
wire harness(C214)
Under-hoodABS fuse/relaybox {C927)
Under-hoodABS fuse/relaybox (C926)
Rightfront ABS wheelsensor
ABS solenoid
ABS pump motor
Rightsideof enginecompanment Body ground, via main wire harness
Notes
USA
ABS
ABS
ABS
ABS
ABS
UNDER-HOOD
FUSE/RELAYBOX
MAIN WIREHARNESS
(leftbranch)
23-25
Main Wire Harness (Left side of dash and floor branchl
Connectorol
Terminal
c401
c402
c403
c404
c405
c406
c401
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c419
c420
c421
c422
c423
c424
c425
c426
c421
c42A
c429
c430
c431
c432
Nurnberof
Cavities
14
4
4
14
4
8
2
2
1
10
24
?
l6
4
7
6
2
2
18
20
18
7
6
8
6
7
3
8
Location
Above underdashfuse/relaybox
Underleft sideof dash
Underleft side of dash
Behindunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
fuse/relaybox
Aboveunder-dash
Behindunder'dashfuse/relaybox
Behindunderdashfuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
fuse/relaybox
ln the steeringcolumncover
In the steeringcolumncover
U n d e rm i d d l eo f d a s h
c433
c434
c435
14
2
U n d e rm l d d l eo f d a s h
c437
c438
c439
26
22
1

Behindunder-dash
fuse/relaybox
G401
Left kick panel
*2: Withoutmoonroof
*4: With moonroof
*5: M//T(with cruisecontrolor for Dl6Y5 engine)
*6: With secondaryheatedoxygensensor(H025)
23-26
Connectsto
Floorwire harness(C555)
Securitysystem
Cruisecontrolunit
Daytimerunninglightscontrolunit
Roofwire harness(C701)
Moonroofwire harness(C7'1
1)
Frontfog light connector
lntegratedcontrolunit
Dashboardwire harness{C504}
Dashboardwire harness{C502)
SRSmain harness(C802)
Datalink connector
Startercut relay
lgnitionswitch
Securitysystem
Clutchswitch
Clutchinterlockswitch
fuse/relaybox (C919)
Under-dash
fuse/relay
Under-dash
box (C920)
Underdashfuse/relaybox {C922)
Underdashfuse/relaybox (C914)
Under'dashfuse/relaybox (C915)
Horn relay
Brakeswitch
Windshieldwiper/washerswitch
Rearwindow wiper/washerswitch
Turn signalswitch
Combinationlightûrnsignalswitch
Cablereel
Interlockcontrolunit
Secondaryheatedoxygensensorsubharness(C781)
A,/Tgear position switch
Shift locksolenoid
Parkingpin switchand IVT gear
positionconsolelight
Transmission
controlmodule(TCM)
Transmission
controlmodule(TCM)
Under-dash
Bodyground,via main wire harness
Notes
ABS
Optional
Canada
Canada
Optional
Atr
Mtr
Optional
M/T
A/r
CVT
cw
Optional
C410
-n--r--nr-n-rnn
UUUUUUUUUUUUqIU
23-27
Gonnectorldentificationand Wire HarnessRouting

Main Wile Harness(Left side of dash and floor branchl: 98 model
Connectoror
Terminal
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c41'1
c412
c413
c414
c415
c416
c417
c418
c419
c420
c42'l
c422
c423
c424
c425
c426
c421
c428
c429
c430
c431
c432
c433
c434
c435
c431
c438
Number of
Cavities
14
14
8
2
2
1
10
24
3
16
7
6
2
18
20
18
7
6
I
6
4
7
3
8
14
2
Location
Conneqtsto
tuse/relaybox
Aboveunder-dash
Underleit sideof dash
fuse/relaybox
Behindunder-dash
Above under-dash
fuse/relaybox
Under-dashrelaybox
Aboveunder-dash
fuse/relaybox
fuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
Behindunder-dash
fuse/relaybox
Under-dashrelaybox
ln the steeringcolumncover
Undermiddleof dash
Securitysystem
Cruisecontrolunit
Roofwire harness(C701)
Moonroofwire harness(C711)
Frontfog light connector
Integratedcontrolunit
Dashboardwire harness(C504)
SRSmain harness(C802)
Datalink connector
Startercut relay
lgnitionswitch
Securitysystem
Clutchswitch
Clutchinterlockswitch
Under-dash
Under-dash
Under-dash
Under-dash
Under-dash
Horn relay
Brakeswitch
Windshieldwiper/washerswitch
Rearwindow wiper/washerswitch
Turn signalswitch
Combinationlightnurnsignalswitch
Cablereel
lnterlockcontrolunit
heatedoxygensensorsubSecondary
harness(C781)
Ay'Tgear positionswitch
Shift locksolenoid
Parkingpin switchand A,/Tgear
positionconsolelight
Transmission
controlmodule(TCM)
Transmission
controlmodule(TCM)
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Leftkickpanel
G401
*2: Withoutmoonroof
*4: With moonroof
*5: M/T (with cruisecontrolor for D16Y5engine)
*6: With secondaryheatedoxygensensor(H02S)
23-28
Body ground, via main wire harness
Notes
ABS
Optional
Canada
Canada
Optional
Mfi
Optional
M/T
Atr
CVr
CVT
"n ,
98 model:
ctza c,81
c/(}0
c42A
I clzs
MAIN WIRE
HARNESS
c412 C411 C410
UNDEB.DASH
BOX
FUSE/RELAY
23-29
Main Wire Harnsss(Bight side of dash branchl

Conneclor or
Trminal
c440
c441
c442
c443
c444
c445
c446
G402
Number of
Cavities
20
7
22
26
Location
Connectsto
Undermiddleof dash
Heatersub-harness
A (C721)
Servicecheckconnector
Junctionconnector
PGM-Flmain relay
ABS controlunit
ABS controlunit
E n g i n ew i r e h a r n e s (sC 1 3 1 )
Rightkickpanel
Bodyground.via main wire harness
MAIN WIREHARNESS
23-30
Notes
DashboardWire Harness
Connectoror
Terminal
c501
c502
c503
c504
c505
c506
c507
c508
c509
c510
c512
L5 t5
c5l4
c515
c517
c5't8
c519
c520
Numberof
Cavities
20
24
16
12
5
3
20
5
5
14
'10
5
16
5
2
5
Connectsto
Location
Behinddashboardlower panel
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
Leftside of steeringwheel
Belowgauges
B e h i n dg a u g e s
Behindgauges
Rightside of gauges
Rightside of gauges
B e h i n dm i d d l eo f d a s h
B e h l n dm i d d l eo f d a s h
Behindmiddleof dash
G501
*1: With shift-upindicatoror cruisecontrolsystem(96,97models)
With cruisecontrolsystem(98model)
Under-dash
M a i nw i r e h a r n e s s( c 4 11 )
M a i nw i r e h a r n e s (sC 4 1 0 )
Cruisemain switch
Dashlightsbrightnesscontroller
Junctionconnector
Gaugeassembly
Gaugeassembly
G a u g ea s s e m b l y
Gaugeassembly
Hazardwarningswitch
Rearwindow defoggerswitch
Audio unit {Keylessreceivercircuit)
Securitycontrolunit
A u d i ou n i t
Securitysystem
Cigarettelighter
Notes
SRS
Optional
Optional
ABS
wireharness
Bodyground,via dashboard
cs09c511 cs10 c515

13 I C517
c520
c501 c502 c504
23-31
HarnessRouting
Connectorldentificationand Wire
Floor Wire Harnsss{Coupe/Hatchback)
'16
8
c553
c554
Lb55
c556
c556
cs57
LSCO
c559
L50 r
25
2
25
2
1
2
1
2
c563
c564
c565
c566
cs67
c568
c569
10
2
2
1
box
fuse/relaY
Behindunder-dash
box
fuse/relaY
Behindunder-dash
box
fuse/relaY
Aboveunder-dash
box
Juse/relaY
Aboveunder-dash
Driver'sdoor
Driver'sdoor
door
Passenger's
door
Passenger's
Middleof floor
Leftsideof floor
Left B-piller
lnsideof left rearwheel
LeftC-Piller
LeftC-piller
Fueltank
Fueltank
lnsideof right rearwheel
LeftB-Piller
Fueltank
Left kick Panel

Leftsideof floor
*1: With Powerwindows
*2: WithoutPowerwindows
'3: 97modelD
: 1 6 Y 3e n g i n e( C o u p e )
(Coupe/Hatchback'
98 model:D16Y8engine
23-32
box {C923)
Undetdashfuse/relaY
box (C921)
fuse/relaY
Under-dash
(C503)
harness
wire
Dashboard
(C402)
Main wire harness
(C631)
Driver'sdoor wire harness
(C63'l)
harness
wire
Driver'sdoor
(C651)
harness
wire
door
Passenger's
door wire harness{C651)
Passenger's
Parkingbrakeswitch
Driver'sseatbelt switch
door switch
Passenger's
LeftrearABS wheelsensor
Rearwire harness{C60'l)
Rearwire harness(C602)
Fuelgaugesendingunit
FuelPumP
RightrearABS wheelsensor
Driver'sdoor switch
{c791)
Powermirrorswitch
Bodyground.via floor wire harness
Bodyground,via floor wire harness
FLOORWIREHARNESS
c552
23-33
Floor Wire Harness{Sedanl:96 model

Connectoror
Terminal
Numberol
Cavities
c55'l
8
c553
c554
LCCC
c556
ucco
14
25
2
c557
c558
c559
c560
c561
c563
c564
c565
c567
c569
c570
c571
c572
c573
2
1
2
1
2
14
2
2
2
1
10
6
6
1
1
G551
G552
*1: With power windows

*2: Without powerwindows
23-34
Location
Connectsto
Notes
fuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Driver'sdoor
Driver'sdoor
Passenger's
door
Passenger's
door
Middleof floor
Leftside of floor
R i g h tB p i l l e r
LeftC-piller
LeftC-piller
Fueltank
Fueltank
Insideof right rearwheel
Left B-piller
R i g h tB - p i l l e r
Left B-piller
Leftquarterpanel
Rightquarterpanel
Under-dash
fuse/relaybox {C923)
Under-dash
ABS
M a i nw i r e h a r n e s (sC 4 0 1 )
Driver'sdoor wire harness{C631)
Driver'sdoor wire harness(C63'l)
(C651)
Frontpassenger's
doorwireharness
(C651)
Frontpassenger's
wire
harness
door
Parkingbrakeswitch
Driver'sseatbelt switch
Frontpassenger's
door switch
Left rearABS wheelsensor
ABS
F u e lp u m p ( F P )
ABS
Driver'sdoor switch
Powermirror switch
Rightreardoor wire harness(C671)
Left reardoor wire harness(C661)
Left rear door switch
Rightreardoor switch
Left kickpanel
Leftside of floor

Bodyground.via floor wire harness
96 model:
c558
FLOORWIREHARNESS
c573
c566
C564
c570
c560
23-35
Gonnectorldentificationand Wire HarnessRouting
Floor Wire Harness(Sedanl:97. 98 models

Connectorol
Terminal
c553
c554
L555
Number of
Cavilies
l6
8
16
14
LC50
L55b
c557
c558
c560
c562
1
2
1
2
16
t
c564
2
2
'I
l0
6
c57r
c512
c573
c514
,l
1
*1: With powerwindows

*2: Withoutpowerwindows
Location
Connectsto
Notes
Behindunder-dash
fuse/relaybox
Behindunderdashfuse/relaybox
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
Driver'sdoor
Driver'sdoor
Passenger's
door
Passenger's
door
Middleof floor
Left side ot floor
RightB-piller
LeftC-piller
LeftC-piller
Fueltank
F u e tl a n k
Insideof right rearwheel
Left B-piller
Leftsideof steeringwheel
RightB-piller
LeftB-piller
Leftquarterpanel
Rightquarterpanel
Fueltank
fuse/relaybox {C923)
Under-dash
Under-dash
tuse/relaybox (C921)
ABS
Driver'sdoor wire harness(C631)
Driver'sdoor wire harness(C631)
Frontpassenger's
doorwire harness(C651)
passenger's
Front
doorwireharness(C651)
Parkingbrakeswitch
Driver'sseatbeltswitch
Frontpassenger's
door switch
ABS
LeftrearABS wheelsensor
F u e lp u m p{ F P )
ABS
Driver'sdoor switch
Powermirrorswitch
Rightreardoor wire harness(C671)
Left reardoor wire harness(C661)
Left rear door switch
Rightreardoor switch
{c791)
Leftkickpanel
Left side of floor

Bodv ground,via floor wire harness
97.98 models:
HARNESS
23-37

RaarWire Harnoss{Hatchback)
Conneclor or
Tsrminal
Numberot
Cavities
c601
c602
c603
c604
14
2
2
c606
c607
c608
G601
Location
Connectsto
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Left side of cargo area
Rightside of cargoarea
Rightquarterpanel
Rightquarterpanel
Rightquarterpanel
Left rear speaker
Leftoutertaillight
Rightoutertaillight
Rightrearspeaker
Hatchwire harness(C761)
Hatchwire harness(C762)
Middleof cargoarea
Bodyground,via rearwire harness
REARwlRE HARNESS
Notos
Optional
Optional
Rearwire Harness(CouPe/Sedan)
Connectoror
Terminal
Number of
Cavities
c601
c602
c603
c604
c605
c606
c609
c6'r0
c611
c612
16
2
2
c614
c615
2
2
2
4
c617
G601
2
1
2
2
1
Location
Connectsto
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftsideof trunk
Rightside of trunk
Rightquarterpanel
Leftsideof rearwindow
Middleof rearshelf
Middleof rearshell
Rightside of rearwindow
Leftside of trunk
M i d d l eo f t r u n k
lMiddleof trunk
Rightside of trunk
Left rearspeaker
Leftoutertaillight
R i g h to u t e rt a i l l i g h t
Rightrearspeaker
Rearwindow defogger(+)
H i g hm o u n tb r a k el i g h t
T r u n kl i g h t
Rearwindow defogger(-)
Leftinnertaillight
Leftlicenseplatelight
Trunklatchswitch
Rightlicenseplatelight
R i g h ti n n e rt a i l l i g h t
Bodyground,via rearwire harness
Notes
REARWIREHARNESS
c617
c615
J--
23-39

Driver's Door Wire Harness(Couoe/Hatchbackl
Connectorol
Terminal
Numberof
Cavities
25
2
2
c634
c63s
c636
c638
c639
c640
2
12
5
8
12
Location
Connectsto
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Insideof left power mirror
Driver'sdoor
Leftfront door speaker
Driver'spower window motor
Driver'sdoor lockactuator
Tweeter
Powerwindow masterswitch
Driver'sdoor lockswitch
Leftpower mirror
Powerdoor lockcontrolunit
*'l: With powerwindows

Notes
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
Passenger'sDoor Wire Harness(Coupe/Hatchback)

Connectoror
Terminal
Numberof
Cavilies
c651
25
2
2
2
2
c653
c654
c655
c656
8
2
Location
Connectsto
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Insideof right power mirror
Passenger's
door

23-40
.
Rightfront door speaker
Frontpassenger's
powerwindow motor
Frontpassenger's
door lockactuato.
Frontpassenger's
powerwindow switch
Rightpower mirror
Tweeter
Notes
Coupe
Coupe
Coupe
Coupe
Coupe
DRIVER'SOOORWIREHARNESS
DOORWIREHARNESS
PASSENGER'S
23-41

Driver's Door Wire Harness{Sedanl
Connectoror
Terminal
c632
c633
c634
c636
c638
c639
c640
Numberof
Cavities
25
2
2
1
3
8
Location
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Insideof left power mirror
Driver'sdoor
Connectsto
Notes
Leftfront door speaker
Driver'spowerwindow motor
Driver'sdoor lockactuator
Driver'sdoor lockswitch
Leftpower mirror
Powerdoor lockcontrolunit

Front Passenger'sDoor Wire HarnesslSedanl
Connectorol
Terminal
c65l
c653
c654
Number of
Cavities
25
2
2
2
2
5
I
*1: With power windows

i2: Without power windows
23-42
Location
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Insideof right power mirror
Connectsto
Rightfront door speaker
powerwindow motor
Frontpassenger's
Frontpassenger's
door lockactuator
Frontpassenger's
powerwindow switch
Rightpower mirror
Notes
DNNEB'SDOOR
WIREHARNESS
c6:|7
c636 C633
23-43

Left Rea. Door Wire Harness{Sedanl
Connestorot
Terminal
c662
c663
c664
Number ol
Cavities
6
2
location
Left B piller
Left rear door
Left reardoor
Left rear door
Connectsto
Notes
Left rear power window motor
Left rear power window switch
Left reardoor lockactuator
Right Rear Door Wire Harness{Sedan}

Conneclor or
Terminal
Number of
Cavities
c671
c672
c673
c674
6
2
5
2
Location
RightB-piller
Rightreardoor
Rightreardoor
Rightreardoor
Connectsto
Rightrearpowerwindow motor
Rightrearpowerwindow swltch
Rightreardoor lockactuator
Left Rear Door:
LEFTREARDOOR
WIREHARNESS
Fight RearDoor:
RIGHTREARDOOR
WIREHARNESS
23-44
Notes
Heater Sub-harnessA
Connectoror
Terminal
Number of
Cavities
c721
c722
c723
c724
c125
c726
c727
r6
7
20
3
2
4
Connecisto
Location
Behindglove box
Behindglovebox
Behindglove box
Behindglove box
Behindglove box
Behindglove box
Notes

Mode controlmotor
B (C741)
Heatersub-harness
AVCthermostat
Blowermotor
Blowerresister
controlmotor
Recirculation
Heater Sub-halnessB
Connectoror
Terminal
Number ol
Cavities
cl4'l
c142
c743
20
6
14
Connectsto
Location
Behindglove box
Behindmiddleof dash
Behindmiddleof dash
Notes
A (C723)
Heatersub-harness
fan
switch
Heater
HeatercontrolPanel
B
HEATERSUB.HARNESS
2345
Connectorldentification
andWire HarnessRouting
Hatch Wire Harness(Hatchbackl
Connestoror
Terminal
Number ol
Cavities
c761
6
2
2
1
2
2
c764
c766
c767
2
G761
Location
Connectsto
Rightquarterpanel
Rightquaner panel
Rearof roof
Rightsideof tailgate
Middleof tailgate
Middleof tailgate
Middleof tailgate
Middleof tailgate
Highmount brakelight
Rearwindow defogger(+)
Rightlicenselight
Leftlicenselight
Rearwindow wiper motor
Tailgatelatchswitch
Middle of tailgate
Body ground,via tailgatewire harness
Notos
RearWindow DetoggerGround Wire lHatchback)

Connectot or
Terminal
Number of
Cavities
c711
G771
23-46
Location
Connectsto
Leftsideof tailgate
Rearwindow defogger(-)
Leftside of tailgate
Body ground. via rear window defogger

ground wrre
Notes
96, 97 models:
REAFWINDOWDEFOGGEB
GROUNOWIRE
TCHWIREHARNESS
c768
c766
c767
REARWINDOWOEFOGGER
GROUNDWIRE
TCHWIBEHARNESS
2347
Gonnectorldentification
and Wire HarnessRouting
Roof Wire Harness(Coupe/Hatchbackl
Connestoror
Terminal
Number of
Csvities
c701
c702
2
2
Location
Centerof roof
Connectsto
Notes

C e i l i n gl i g h t
Root Wire Harness{Sedan}

Connectoror
Terminal
Number ot
Cavities
c701
c702
c703
2
I
Location
Centerof roof
Centerof roof
Connectsto
Notes

Ceilinglight (Power)
C e i l i n gl i g h t( G r o u n d )
Moonroof Wire HarnesslCoupe/Sedanl

Connectoror
Terminal
Number ot
Cavities
c711
c712
c 7t 3
c714
c715
c716
c't17
c718
c719
2
3
6
6
3
2
1
Location
Behinddashboardlower panel
Leftsideof dashboardbracket
Leftside of dashboardbracket
Centerof roof
Rearof roof
Rearof roof
Frontof roof
Conneststo
Under-dash
Moonroofopen relay
Moonroofcloserelay
Moonroofswitch
C e i l i n gl i g h t
Moonroofmotor
Moonroofmotor (Tiltswitch)
Spot light
Notes
Optional
98 model
WIREHARNESS
23-49

RearHeatedOxygenSensorSub-harness
Connectoror
Terminal
Number of
Cavities
c7al
c7a2
4
4
Location
Under middleof dash
Undermiddleof dash
Connectsto
Notes

Secondaryheatedoxygensensor
(Secondary
HO25)
FuelTank PressureSensorSub-harness
Connectoror
Terminal
Numberol
Cavities
Location
c79'1
Middleof floor
c192
c793
3
2
Left side of fuel tank

Left side of fuel tank
Connectsto
Floorwire harness(C568:Coupe/
Hatchback,
C574:Sedan)
EVAPtwo way valve
FUELTANK PRESSURE
SENSOR
23-5 0
Notes
a
SRSMain Harness
Connectoror
Terminal
Numbcr ol
Cavities
c801
c802
2
3
c803
c804
c805
c806
c807
2
2
2
18
Location
Notes
box (c911)
fuse/relaY
Under-dash
(
C
4
12)
h
a
r
n
e
s
s
w
i
r
e
M
a
i
n
A b o v e u n d e r - d a s hf u s e / r e l a Y
DOX
G801
Conneststo
R i g h t s i d e o f u n d e r - d a s hf u s e /
relaybox
Under left side of dash
Underrightsideot dash
Middleof floor
Middle of floor
Middle of floor
Memoryerasesignal(MES)connector
Cablereel
airbagassemblY
Passenger's
Dummy resistorconnector
SRSunit
Body ground,via SRSmain harness
USA
Canada
SRSMAIN HARNESS
23-51
Fuses
Under-hoodFuse/RelayBox
ALTERNATOR
ITo engine wire harness(T101)l
BATTERY
lTo startercables(Tlll
t Er'1
r-'l
tr
tr
tr
IJ
47
LI
r'1
51
LI
n5 6
IJ
r'1
LI
c901
c904
lTo blowermotorrelayl
ITo condensertan relayl
c903
*: Not used
ITo radiator tan relayl
NOTErView from the backsideof the under-hoodfuse/relaybox.
cr06
lTo main wire hsrness(C352ll
c905
lTo mainwire harness{C353}l
lTo main wire harness{C354)l
23-52
lTo main wire harness{C351)l
FuseNumber
Amps
41
80A
Component(s)or Circuit(s)Protectod
Wire Colol
40A
WHT/BLK
Powerdistribution
To ignitionswitch(BAT)
43
7 . 5A
WHT/RED
Ceilinglight,data linkconnector,trunk light
44
1 5A
WHT/BLK
PGM-Flmain relay
Not used
45
46
40A
WHT/BLU
47
7 . 5A
WHT/BLU
48
30A
WHT
Powerwindow motors(viapowerwindow relay)

Audio unit,clock,TCM {CVT).ECM/PCM(VBU)
(headlight)
No. 33 (7.5A) fuse,To combinationlight switch
Not used
49
50
30A
WHT/GRN
5l
204
WHT/GRN
Rearwindow detogger(viarearwindow defoggerrelay)

Powerdoor lockcontrolunit, moonroofmotor
52
1 5A
WHT/GRN
Horn svstem,brakelights,brakesignal
53
1 0A
WHT/BLK
relay
Hazardwarninglight,turn signal/hazard
54
40A
WHT/RED
Option{+B)
5C
40A
BLU,4/VHT
Blowermotor (via blowermotor relay)

Condenserfan motor (via condenserfan relaYl
56
20A
57
20A
WHT
RED
BLIqRED
A/Ccompressorclutch(viaA\/Ccompressorclutchrelay)
Radiatorfan motor (viaradiatorfan relay)
,a
23-53
Fuses
Under-dashFuse/RelayBox
c912
wir6 harnesslC501ll
[Todashboard
c913
lTo ignitionswhchl
llo main wire h.rno.s lciP2)l
c915
lTo main wiro harn$3 1C423)l
r-t r-'l -
T-l Ft n El rl Fl Tt r'l
23 2a aa 26 27 2A 29 30 31 32 33
I-J LI tJ LI LI LJ LI L.J tJ TJ LI LI
r-r r"t T1 n r'r r't n |-l rt r.1 T1 r-1

12 13 ra 15 16
1a
20
19
17
21
22
LI IJ I.J LI LJ LI L-JIJ LI LI I.J I.J

r'l r;l El r't r-r r'l |;l r-l r't I;l T1 T1
1
01
lTo powar window relayj

1
TI IJ LJ LI TJ IJ LI LI IJ LI TJ LI
a: Canada
r: Not used
O: Cg26loption
@: C!t2?Ioption
G)r Gt28 loption
@: Cg2gloption
c!'17
lTo turn signal/he2ardrolayl
l+Bll
(drsh lightsll
lACCll
llc2ll
dotoggerrelayl
NOTE:View from the backsideof the under-dashfuse/relavbox.
C925(96,97 modebl
lTo msin wiro h.rncss (C/('g)l
lTo main wire harn*31C419)l
23-54
Fus6Numbel
Amps
Componsnt{s)or Circuit(s)Protscted
Wire Color
Not used
Not used
Rearwindow wiper motor,rearwindow washermotor
10A
GRN
1 0A
RED/BLU
Right headlight (high beam)
10A
RED/GRN
Left headlight thigh beam), high beam indicator light
Not used
6
1
20A
RED/WHT
Left rear power window motor
204
YEUBLK
Rightrearpowerwindow motor
Not used(96,97 models)
1 5A
RED
10
20A
GRN/BLK
l'l
204
BLU/BLK
12
13
1 5A
14
YEUBLK
Driver'spowerwindow motor
switch)
relay(viaturn signal/hazard
Turn signal/hazard
YEUGRN
PGM-Flmain relay
cRY or BLKI/EL SRSunit {VA)

Cruisecontrolsystem.audio unit
BLKI/EL
15
7 . 5A
8LK/WHT
to
7 . 5A
BLI</8LU
BLK/YEL
17
7 . 5A
10A
BLK/WHT
1 0A
REO,4ryHT
Daytimerunninglightscontrolunit (Canada)
Rightheadlight(low beam)
10A
L
RED|YE
Leftheadlight{low beam)
1 0A
GRYor PNK
7 . 5A
GRN/ORN
7 . 5A
YEL
20A.
GRN/BLK
1 5A
YEUGRN
Gaugeand indicatorlights,interlockcontrolunit
Windshieldwiper motor,windshieldwashermotor.
inteqratedcontrolunit {Canada)
Accessorvsocket (ACC)
YEURED
Audio unit,option (ACC)
19
20
28
ABS pump motor,rearwindow defogger

l'lc system,power mirror,option (lG2)
Daytimerunninglightsrelay(Canada)
7 . 5A
24
Alternator,VSS.ELDunit {USA),EVAPpurgecontrolsolenoidvalve,
oxygen sensors,TCM (CVT)
YEUBLK
YEURED
18
22
Distributor(ignitioncontrolmodule)(98model)
powerwindow motor
Frontpassenger's
10A,/15A'
Back-uplights
SRSunit (VB)
Moonroofrelays
Not used
29
30
7 . 5A
RED/BLK
31
7 . 5A
BLU/IVHT
Dashlights,option (dashlights)
PGM-Flmain relay.integratedcontrolunit
ECM/PCM,
7 . 5A
RED/BLK
Frontparkinglights,taillights,licenseplatelights
WHT/GRN
Interlockcontrolunit, key interlocksolenoid
*('98 ModelOnly)
23-55
Fuses
Under-hoodABS Fuse/RelayBox
lTo undor-hoodABS tuse/relav box wire harnssl
c926
c928
lTo ABSpumpmotorrelayl
lTo main wire harnesslC357ll
cs27
lTo main wire ha.ness{C350ll
FuseNumber
61
63
23-5 6
Wire Color
40A
WHT
7 , 5A
BRN//EL
20A
WHT/GRN
Component(s)or Circuitls) Proiected

ABS pump motor (viaABS pump motor relay)
ABS controlunit lmotor check)
A B Sc o n t r o ul n i t( + 8 1 )
PowerDistribution
Circuitldentification
UNDERHOODABS
FUSEiRELAYBOX
wHTGFN-]
CONTFOL
lBs.onuo'rn,t
WHT
ABSpumpmolof
GRNiWHT
BFN/YEL
YEURED
BLK-
ABSconlrol
unrt
s l a d em
r olor
UNDER-HOOD
BOX
FUSE/FELAY
wHTBLK-
wan nglighl
Hazard
relav
Turnsional,hazatd
(vras ilch)
ALTERNATOR
V
t#i',33),5i3i
L
Horn
Hornreay
ABS
conlrolunrl
PCM
ECMi
TCM(CVr)
Cruise
conlrolwil
Brakeights
I-*^
G401
G402
G R N / R E-D
PCM
ECMi
l--'NHrts-/-2>.=""1i")iis
cl'. t Ot'rSw-C- :.-
WHT/FED
Celinglighl
Trunklighl
lD-:
Dalalinkconneclor
InleEaled
conlroluni:
WHI/BLK-
P G MF L m a irne L a y
UNDER
DASi: '
FL.JSEIRELAV
page
(To
2: a'
TCM(CW)
ECM/PCM
23-57
PowerDistribution
Circuitldentification(cont'd)
UNDEFHOODFUSE]RELAY
BOX
UNDER.OASI,]
FUSEiRELAY
BOX
(Topage23-62)
COMBINATION
LIGHTSWLTCH
(Io page23.63.64)
IJNDER.DASH
FUSE/FELAY
BOX
(Topage23-64)
F\
.>
>/
t4,-TGF\ -.,i
V'/-- Gi\
Powe.doorlo(l (ortro u t r
Moonroolmolor
h\
1,.'
,"--...
,UNo-EF
, . , ^ - ^DaSH
^ " - , F-Sl ql I AYBoX
t apagFzrb \
-\DEqDAS-EUsE
FE-A'Box
llo oag"2j-6n
N o . 1 (77 . 5 4F) U S E
(Frompage23 59)
BLUMHT-
Bowermolor
"*-]
oot
G402
BLU/1flHT
ECMiPCM(Va ArCpressure
swilch)
ELUA&HT
,nClhermoslal
lanmoloa
Condenser
llo compressor
c ulch
23-5 8
BLK/REO
PCM
ECMi
BLK/RED-
Fadiatorlan
motor
N0.42(40A)FUSE
(Frompage23'57)
IGNITIONSWITCH
UNDEFDASHFUSAFELAYBOX
BLKELU
unit
ABsConlrol
q E A RW I \ D O WD E F O G G E
FR
ELAV
(V,arearsrldo$,deloqger
swilcF
(Topage23.51)
F\
+-l',
eN i,,
I
-.,
I
I
lACC
No17(7.5A)
(Fuse/relay
boxsocket)
l,z
>
swilcll
delogger
Rearwrndow
ighl
indicalor
(lG2)
Oplonalconneclor
. BLOWER
RELAY
MOTOR
.CONDENSER
FANFELAY
' ,vc coMPREssoR
RELAY
CLUTCH
. RADIATON
FANRELAY
{Io page2358)
Healerconlrolpanel
A/Cthermoslat
Modeconlrolmolor
Fecirculalion
conllolmolor
.|
lefl
|'\
j>
V'
YELBL( -l
. 8L(YEL+
L GH_S
DAvllMERLNN'NG
CO\TFO_UN (Caladd)
page
23-64)
llo
lgnilon
coil
molor
Rearwndowwasher
GRN
N 0 . 1 (27s A )
actualor
mwe,m,r,or
motor
Re windowwipel
GRN
YEUBLK
relaY
Turnsional/hazard
(Viaswitdr)
YEUGRN_
PGM-F
firain
relay
SRSlnil (VA)
N 0 . 1 (47 . s A )
BLK/VEL-lll-
CrJseco"lroturl rvrama,ns\rilch)
I'gtl
C'LEemarrswilchlrdrcalor
ctcuil)
AuoioJ1,rt(ey'e9s'ece'ver
N 0 . 1 (57 . 5 A )
vss
HO2S
venlshutvalve
EVAPconlrolcanisler
BL</w-+
:J"!i'.rT
F-"t
-BLXMHT
fTcM(cvTj
BLKtr/HT
lighl
syslem
chaGing
(cont'd'
23-59
PowerDistribution
Circuit ldentification (cont'd)
UNDER,DASH
FUSE/RELAY
BOX
Back-uplighls
G F Yi o ' P N < i -
GF\.CF\
S F SL r i l ( v a )
Moonroor
openreay
Moolroolctose.etay
POWEH
WINOOW
RELAY
(Topage
23-61)
No25(7.5A)
(Fuserelaybor sockel)
nlegfalpdconlro Llnil
.;. -l-
S ' l | r t o o ( s o r e n o o( , , - .
I n t e r l o c ^ c o n t o l LI nltrly r l
Gaugeassenby
SRSndlcalor
lighl
ABSindicalor
light
Mqear DosronndcatofJ
ormmrng
crrc!l
Cruriendcator
I
boxsocke0
{Fusgrelay
GRN/8LK
tGNtTtoN
sw TcH(ACC)
page
(From
23.59)
Inlegraled
conlrctunil
Windshleldwper
molor
Inlegraled
conlrol!nil
(VEwindshield
wlprswlch)
W ndshield
u/asher
motor
(Vasrvitch)
YEUGRN
power
Accessory
(ACC)
sockel
Oplonalconneclor
(ACC)
Audiounil
N0.54(40A)FUSE
(Frompage2358)
BOX
FUSEIRELAY
UNDER.DASH
ft
I
WHT/RED
(Fuse/f
elayboxsockel)
(+B)
conneclor
Oplional
No24(75A)FUSE
(Frompage2360)
N0.46(40A)FUSE
page23'57)
(From
f-;-7
tr*a
\7I
I
G401
G402
Wl.lTiELLJ
d-J ts-^ +
l-
GRN/BL(G R N / B L-KJ
'::
'oitFr wrnJo{n'o;le $ .1
Powefw nOOw
COntO
Lnrl
(viapowerwrndow
master
swlcn)
Power
] FronlPassengers
wn00wm0l0r
powerwrndow
maslersw ch\
/via
Power l
landlronlPassengels
I
\wndowswilch
-olor
i Le'lrearoowe,wrdow
'/Vla
$r.oowmdsleswdch\
Powr
w ndowswilclr
/
\and ell rearPower
::-
i Riohrealoowewndow-olor
'/v'a powerwlndowmasel swllcl
l
l o w e ' wd o w s wl c l /
\ a r on g l t ' e dp
:":"1
No 50 (30A)FUSE
(Frompaqe
23'58)
vI
WHT]GRN
No16(7.sA)FUSE
(Vaswilch)
(From
paqe23'59)
delogqer
Rearwindow
f,7
BLll/YEL
"n-f,G40t
G402
(cont'd)
23-61
PowerDistribution
Circuitldentification(cont'dl
(MT)
GN|T0N SWTCH{ST)
(Frompage23.59)
BLKMHI
i"'
tl
-fff
"n*n'
l
--TlBLK4THT
cu qELA"
cLUc- swlrcH
,,,,,,*
@**-f_
_
BLK,vHT
BLK/RED
T
srarrer
sotenoid G401
E L KRi E D
L-
NUTRAL
POSLT]ON
SWITCH
(Flse/relay
boxsockel)
In1egraled
conlrolunt
i,Y
",5
[l;'if'"od)
F-
**
BLUI/VHI
PGM-F|main
retay
_
BTUMHT
ECi?VPCM
..............-WI-]T/GRN
I
r-
*-,
'
23-62
Inle ockconrrotun
(Viaintedoct
swrlch)
Keyinleiocksotenord
[\
V
covB NATToN
LicH-swtrci
I'o Page
2363 6',
USA:
FUSE]RELAY
BOX
UNDER'DASH
COMBNATION
LIGHTSWITCH
N0.5110A)
No48(30A)
FUSE
\2358
l nPASSTNG
I
to
R E D i B L -U
FrghlheadlghllHrghbeam)
R E D T G R- N
H g hb e a r ni d c a l o!rg h l
R E D T G R- N
glrbeam)
Lellheadlighl(H
REDIWHT
R L g h t h e a d l{gL o wb e a m )
R E O I Y E-L
LellheadghllLowbeam)
N o4 8 1 3 0 A )
FUSE
/ F r o mp a g e\
\2362
/
(Fuse/reay
boxsoc(el)
(Dashghls)
Oplonalconneclor
(Fuseirelay
boxsockel)
nieoraled
conlro!n
warnrn!swtchlghl
Hazard
G a u gLeg h t s
swtch$h]
Feafwndowdeloggr
man sw(ch11
Cfurse
c r L t s en dc a t o r
) c m mn qc , r , r
r o s r 0 nn oc d r o r r
A qeap
conlroer
Dashighlsbnglrlness
-t
RED/BLK
A'Tgearposlonconsoielghl
Healerconlropanelghl
REDlBLK
l e f , | i , o n t o a 'nt ol o h t
Hqntl
FEDIELK
Hqnr
inn"'lu'gltt
r'trh1J
---:
e a l el o h l s
l censo
H q N IJ
(cont'd)
23-63
PowerDistribution
UNDER.DASH
FUSEiRELAY
BOX
R E D / B L -U
R g h th e a d i g h( H
t i gb
he a m )
--<
BEDiBtU
\23.59
l oPASSNG
I
to
\7
I
WHT
REDMHT
REssToF(Canada)
RED/GFN
Nighbeamindiclor
ighl
FEDTGRN
T
Lenheadlghl(H,qhbearn)
<
BEOMHT-
REs
sroRlcanada)
(Lowbeam)
Fighlheadlighl
No48(30A)
FUSE
/ F r o mp a g e \
\2362
l
Lellheadlght(Lowbeam)
{Flserelayboxsockel)
RED/GBN
Oplional
connector
(DashI ghls)
(Fuse/reay
bor sockel)
Inlegraled
conlrclunrl
RED/BLK
N ol 8 ( 75 A )
FUSE
/Frompage\
\23.59
J
Hazard
warning
swilchlighl
GalgeI ghls
Audioun1
Rearwindow
delogger
swlchlghl
Crlisenan swllchlght
Cruisendcator
I dlmmtng
lVTgearposilonindicalorJcrc!i1
Dashhtsbrlghhess
conlroler
N0.48(40A)
FUSE
\23 58
YELIBLK
REDTBLK
-
-t
RED/BLK
F,i6,'.E"
I
Y I
h,'fn,
) '-"'''"n*'
'nn,,
lt'j") '*n."o'"'"
.*o^,
'|
ITIIFLUD
t+
wHr/RED........+?
I f-llrr-t-
, JI L E V E L
I'*'"lBLK
REDIGRN
I A
I Y
.
G401
G402
'nn'
ou"'"n
l"'l'n'
) uon'
l"fn,]o''.'''"'nn"
l-.,-;
Mgear pos onconsoterght

Healercontropanetqhl
8LK
G40l
G402
RESSTOF
---D
FED,BLU
RGHT
HEADLGHT
(Hshbeanr)
-->
REo/GFN
LEFT
HEADL
cHT(Hish
beam)
GroundDistribution
Circuitldentification
Ballery
o,
Powersleerngpumpbrackel
i'
ng
nous
Transnissron
I
i
HO2S(M/T)I
Primary
(M/T)
E G Rv a l v e
| l O r s v S" n g , n . )
soenoidvave (AiT) l
BRN/BLK
IV
s,r. -lFIpLh
BLK
ECTswlch
BLK
VSS
BLK
PSPsw ch
BLK
( P G 1I)
BLK
fEoMTPCM
{PG2)l
'
trl
groundcableA
Engine
PGMFmenleay
E1tt"'tu-'
swilcfl
WEC pressure
( D 1 6 Y 05 1 6 Y 8e n g n er 9 8m o d e)
page23 66)
Ballerygroundcabe
: Engineground
B
cable
harness
Engnlvire
t',la
nwreturness
(cont'd)
23-65
GroundDistribution
page2365)
w
A
|l]
BRN/BLK
LG1I
l Ect,tPcM
roz J
f _{r
I enNierx
L ^ F S e n s o1r
L -E={ll
Erui RED
K n o cske n s o(rK S ) + i :
FED/BLU
PrmaryH02S*' -
WHT
Manshallspeed
sensor-
RED
Counlershall
speedse.sor -1Fl
BtU
l,."
Dl6Ygengrne
y:1=.":*:-]
[--;'*:+il;
Dl6Y5,016Y7engine
BRN/BLK
B R N / B L _K
.-!l
puleyspeed
Drive
sensor
23-66
wrr --+
WHT
WHTTRED
: Enginewre
harness
: Manwre
harness
reo[[,]- f tcvrc*1
RED/BLU
Drivenpuleyspeedsefsor =.j
----1Fl
S e c o n d a r y gsehaar lsl p e e sde n s o r
--:'--l
|
WHT/RED.+J
Shlelding
* 1: D]6Y5,
016Y8
engine
* 2: Excepl
D16Y5
(M/T)
engine
*3:016Y5
engne(M/I)
BL^-
r-
Fiqhl headliqhr
l-
;gn'ru,. Pc,"''e'sn
Riqhllronl lurn signalllghl
ll-
lighl
LerllronlParking
Leitlrontlun gqnalight
?
l--
malo'
!',/ndshield
wasrrr
molor
Fearwndowwashef
cruisocontroltclualor
o L ^ - - - - - ! -
8L<
, Engine
hatn"ss
cotpanmentwre
(conl'd
23-67
GroundDistribution
o_^ ---t_
6_^ ----
Yllnosr,eE wtcErmoro,
Bra{e llLto eve swilci
g1' or rev sw,lcrL
t.. co-.ecro,
o-c,
i oata
W ndshe d wiper/washer
swilch
:-'"
,r* -fi-f6
"-
B,L,oc^ -
ud^
s6's7m.dels
|
Re wlfdowwiper/waslrer
swilch
oL^-l-
8rK
l e 1 o c hc o n r r Jo r
oaaiT on swilc,r J! i a /' r ,
ctJlci irreroc\swrtcLt
lM-l
Cruseconlrolunil
8LK
I_
(Canada)
Daylime
runnng
ighlsconlrolunll
Clllchswitch
([,]/T
wlhcrrise
conlrolor
lorD]6Y5
engine)
(Fuse/relay
boxsockel)
Fearwndow
relay
delogger
(Fuse/relay
boxsockl)
Inlegraled
conlrcllnil
(Fuse/relay
boxsocket)
(Fuse/relay
borsocket)
Tornsignal/hazard
relay
BLK
;L^ ------
\u/
l--
G402
Faqe
( To
23 69-
a-1 ---.....-
tsL^--F
l-
1roon.oor.wrcr
voon.oot
oper'etay
Mool,oolctose,etay
lasr r'gnls
orqrrress
co'rorer
Key/ess
doo'ockcorro,u'r
Seculryconlto,
Jflr
oit
Crulsenrainswrlch
lighl
Cluseindicalor
dimming
circut
Re windowdslogger
swlchlght
l/T gsalposton indicator
dlmmngcncuit
companmenlwre
harness
@ : Englne
wrehaness
@ Main
: Dashboard
wrehaness
: Moonroolwire
harness
BLK-+
powersockel
ACCeSSOTy
SRSindicalor
lighrcircuil
BLK
Gauges
andindcaloas
BLK
ABSndcatorighlcircu[
BLK
Gaugelighls
rwih., I ARsr
-<
BLK
2,.6s)caol(Fom
ease
l
(wrhA8s)
BLK-
l/TiearPosition
swlch
BLK
Servrce
checkconneclor
UNDER.HOOD
FUSE/RELAY
BOX
ABSplmp molor
oro,
Audioun1
G501
la
lr-
Po{e! doot\od\ !oi\o\ uh\

Drveisdoorlochaclualof
Dfivers doortockswilch
I
tt4
l-
i Pow windowrraLnsw ci
)
Dfper s powerwrndowmolor
BLK +
Fuelunl
BLK
-
tr : Driversdoorwireharness
ttt
fit
trn
5ii.?i1!"f1,.,,'"n
Dashboard
wre harness
A
sub-harness
L r - ! l Heater
: Healersubharness
B
23-69
GroundDistribution
Circuitldentification(cont'd)
l-L!
I
J--. -t:JEL^
l
-l"r.,ln"'nno
l
-
lr
-d
'
3-{ -1_t-L:
I
1t
l"$$,)',r"n,"ou'.,,n'''.
I
Hghmoonlbrakelighl
;_K
G601
Rearwindowwiper
motor
G76l
(Halcnback
r96 97models)
t-.1-...--!"..
t
l
l
l
L.
-
< a_K-iJ-1:
ts-h
t-iin1Jtt't,ignt'
Leil ) .
rrcenePralerqn$
RrghtJ
Highmounlbrakelighl
Rearwindow
wipermotor
G60l
Trunklalchswilch
G761
_l
(Halchback:98
m00u
o*t""'u'nn"
h"'$,)
c:
Lefil.
Innellarl||gn$
RrghlJ
L e t ll .
lrcense
Prae{ms
R qhtJ
Trunklalchswitch
Highmounltake lighl
Rearwindow
delogger
G601
(Coupe/Sedan)
Condenser
lanrnolor
oir,
Rearwindow
(Nalchbach)
delogger
G77l
],,,,.'
out
window
ground
delogger
wire
U : Rear
:
harness
El sns main
rdl
23-70
Hatclr
wirehamess
* GRY: 96 97 models
GRN: 98 model
Under-dashFuse/RelayBox
SRS componeols'rle located in this area Reviewthe
lnstallalion:
1.
C o n n e c tt h e c o n n e c t o r st o t h e u n d e r - d a s hf u s e /
relaybox, then installthe under-dashfuse/relaybox
in the reverseorderof removal{seesection24).
2.
Disconnectthe batterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.
lnstallthe driver'sdashboardlower cover (seesection 20).
3.
Connectthe airbagconnectors(seesection24).
2.
the airbagconnectors{seesection24)
Disconnect
4.
Connectthe batterypositivecable,then connectthe

negativecable.
3.
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20).
5.
Conlirmthat all systemswork properly.
Removal:
t.
4.
Removethe t\rvomountingnuts,and pull the underdashfuse/relaybox out from underthe dash.
UNOER.OASH
FUSE/RELAYBOX
D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h
fuse/relaybox, and take out the under-dashfuse/
relaybox (seesection24).
2?-71
PowerRelays
RelayTest
NOTE:Seepage23-155for turn signal/hazard

relalinput
o Rearwindow defoggerrelay
Le5t.
Normally-opentype:
'1.
Checkfor continuitybetweenthe terminals.

. Thereshouldbe continuitybetweenthe No. 1 and
No. 3 terminalswhen power and groundare connectedto the No. 2 and No. 4 terminals.
. Thereshouldbe no continuitybetweenthe No. 1
and No.3 terminalswhen power is disconnected.
Terminal
3
ao*o o,o.= *o.if'

Disconnected
Connected
l(-lh-'I
ln
5
P
a Startercut relay:96,97models
Blowermotor relay
ABS pump motor relay
Horn relay:96,97 models
Five-lerminaltyPe:
Normally-opentype:
1.
Checktor continuitybetweenthe terminals
1.
. Thereshouldbe continuitybetweenthe No l and

No. 2 terminalswhen power and groundare con
n e c t e dt o t h e N o .3 a n d N o . 5 t e r m i n a l s .
. Thereshouldbe continuitybetweenthe No.2 and
No. 4 terminalswhen power is disconnected
. Thereshouldbe continuitybetweenthe No. 1 and

No. 2 terminalswhen power and groundare con
nectedto the No. 3 and No. 4 terminals
. Thereshouldbe no continuitybetweenthe No. 1
and No. 2 terminalswhen power is disconnected'
\
| ermrnal
Power(N0.3- No.4)
Terminal
t"i* r*"-, - t". u\
o-
Disconnected
Disconnected
Connectd
-----o
o-
Connected
(
9
---o
r.l
{
2
Powerwindow relay
a Radiatorfan relay
a Condenser
fan relay
IVCcompressorclutchrelaY
Startercut relaY:98model
a H o r nr e l a y : 9 8m o d e l
Moonroofopen relaY;96,97 models

a Moonroofcloserelay:96,97 models
23-73
PowerRelay
RelayTest
Five-terminaltype:
l.

.
There should be continuity betweenthe No. 1

a n d N o . 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
connectedto the No. 5 and No. 3 terminals.
There should be continuity between the No. .l
and No. 4 terminalswhen power is disconnected.
Terminal
Power(No. 5 - No. 3)
Disconnected
Connected
oo-
5
a Moonroofopen relay:98 model
a Moonroofcloserelay:98 model
|
L
23-74
----o
--o
lgnition Switch
Test
ElectricalSwitch RePlacement
SRS componentsare located in this area. Reviewthe

SRScomponentlocations,precautlons,and proceoures
or serin the SRSsection{24)beforeperformingrepaars
SRS componentsare locatd in this area Reviewthe

in the SRSsection(24)beforeperformingrepairsor service,
vtce.
1.
the batterynegativecable.
Disconnect
1.
Disconnect
2.
Remove the driver's dashboard lower cover and

knee bolster (seesection 20).
2.
Remove the driver's dashboard lower cover (see

section20).
3,
Disconnectthe 5P connectorfrom the under-dash

fuse/relaybox and the 7P connectorfrom the main
wire harness.
3.

fuse/relaybox and the 7P connectorfrom the main
wire harness(seeleft column).
4.
Checkfor continuitybetweenthe terminalsin each

switchpositionaccordingto the table.
4.
Removethe steering column covers (see section

171.
5.
Insenthe ignitionkey,and turn it to
6.
Removethe two screws and the electricalswitch

from the steeringlock.
Terminal
,olirton-__\
o {LocK)
E
(3)
1
(ACC) {BAT) 0 G 1 )
| (ACC)
o- ---o
lr(oN)
o-
Il\rZ,
"0 (LOCK)".
--o
---o
o-
III (START)
(1)
{ST)
[ ] :7P connector
Wire side of lemale terminals
WHT(BAT}
BLK/WHT(ST}
7P CONNECTOR
WHT/8LK
YEL{IG2)
BLK/YEL(IGlI
7.
lnstallin the reverseorderof removal
lf the continuitychecksdo not agreewith the table,

reolacethe electricalswitch
23-75
lgnition Switch
Steering Lock Replacement
Insiallation:
1.
Installthe new steeringlock assemblywithout the

key inserted.
Remove:
2.
Looselytightenthe new shearbolts.
1.
Disconnect
3.
2.
lnsertthe ignition key, and checkfor properoperation of the steeringwheel lock and that the ignition
keyturns freely.
4.
3.

fuse/relaybox and the 7P connectortrom the main
wire harness(seepreviouspage).
Tightenthe shearbolts until the hex headstwist off.
4.
Removethe steeringcolumn covers,then remove

the mounting bolts and nuts from the steeringcolumn (seesection17).
5.
Lowerthe steerlngcolumnassembly.
6.
Center-punch
eachof the two shearbolts,then drill
their headsoff with a 5 mm (3/16in) drill bit.
SHEARBOLT
TWIST-OFFPORTION
CAUTION: Do not damagethe steering lock body.
5.
7.
Removethe shearboltsand the steeringlock

ory.
Battery
Test
@
gets on your skin or in youl eyos weal
a Battery fluid (electrolytel Gontatnssulfuric acid. lt may causesevele burns if it
protective clothing and a face shield.
- lf electrolyte gets on youl skin or clothes, rinse it off with water immediately'
-||e|eqtro|ytegetsinyoureyes,||ushitoutbysp|ashingwaterinyoureyes|orat|sast15minutes;c8||aphysician
immediatelY.
.Abafterygivesof'hydlogengas.|fignitgd,thghydrogenwil|exp|odandcou|dcrackthebatterycaseandsp|atter
acid on you. Keepsparkg.flames, and cigarottesaway lrom ths battery'
ths electrolyte,This may force electrolyte to spray out of the battery vents.
. overcharging will raise the temperatur;
Fol|owthechargelmanufactuler,sinstructions,andchalgethebatteryataploper]ate.
procedures.lf you don't have one of thesecomputUseeithera JCI or BearARBSTtester,and follow the manufacturer's
test procedure:
erizedtesters,follow this conventional
Toqetaccurateresu|ts,thetemperatureofthee|ectroIytemustbebetweenTo.F(21.c)and100.F(38"c).
lf the caseis crackedor the postsare loose,replace

the battery.
CheckIndicatorEYEColor
lf the indicator shows low electrolyte, add distilled
TestLoadCapacity(#1)
. A p p l y 3 0 0 a m p l o a d f o r ' 1 5s e c o n d st o r e m o v e
surfacecharge.
. Allow 15 secondsrecoveryPerloo.
. Applytest load (seeTestLoadChart)
. Recordvoltageat the end of 15 seconds.
Staysabove9.6 volts;
batteryis OK.
{co'::
23-77
Battery
Test (cont'd)
Chargeon HighSening{40amps}
Chargeuntil EYEshows chargeis OK; plus an
additional30 minutesto assurefull charge.
NOTE: lf the battery charge is very low, it may
be necessaryto bypassthe charger'spolarity
protection circuitry.
lf the EYEdoes not show chargeis OK within
three hours,the batteryis no-good;replaceit.
Write down how long the batterywas
charged.
Test Load Capacity(#2)

Apply 300amp load for 15 secondsto removesurfacecharoe.
Allow l5 secondsrecoveryperiod.
Apply test load (seTest Load Chart,.
Recordvoltageat the end of 15 seconds.
Stays above 9.6 volts; batterv is OK.
Drops be]ow 9,6 volts; battery is no-good,
5582{L - MF ot
558241(St - MF
fr,
23-78
TESTLOADCHART
Usethe test loador 1/2the cold crankingamps (CCA)printedon the
labelon the top of the battery,lf neitheris indicated,usethe
informationbelow:
BATTERY
CODE
*: 5sB24L(S)- MF
COLDCRANKING
AMPS(CCA)
LOAD
tamps,
4 0 5( * 4 1 0 )
200
StartingSystem
ComponentLocationlndex
STARTERCUT RELAY(M/T)
les\, page za t z, t r
Test,page 23-138
page23 139
Replacement,
CLUTCHINTEBLOCK
swrTcH
BATTERY
Test,page23-77
STARTER
Test,page23-81
SolenoidTest,Page23-82
Replacement,
Page23 86
PerformanceTest, Page23-87
23-79
Starting System
IGNITION
S WT C H
UNDER.HOOD
FUSETRELAY
BOX
No41(80A)
No42 (40A)
WHT]BLK
{-WHT
SLKA/VHT
I
t
A,TTGEAR
P O ST I O NS W T C H
( C l o s e d : lpno s o n N o r E )
BLKWHT
BLKMHT
STARTER
CUTRELAY
BLI]/8LK
CLUTCN
swiTcll
Closed:Clulclrpedal)
lullydepressed /
BLK
STARTEF
(Permanenlmagnellype)
G40l
G4A2
23-80
StartingSystem
StarterTest (cont'd)
Starter Solenoid Test
Checklor Wear and Damage

T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d
s t e a d i l y l,f t h e s t a r t e re n g a g e s b, u t c r a n k st h e e n g i n e
erratically,removeit, and inspectthe starterdrive gear
and torqueconverteror flywheelring gearfor damage.
1.
Checkthe drive gear overrunningclutchfor binding

o r s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e
d r i v eg e a rh e l d .
- lf damaged,replacethe gears.
Checkthe hold-incoil for continuitybetweenthe S

t e r m i n a la n d t h e a r m a t u r eh o u s i n g( g r o u n d )T. h e
coll is OK if there is contjnuity.
ARMATURE
HOUSING
(GROUND)
S TERMINAL
CheckCranking Voltage and Current Draw

C r a n k i n vgo l t a g es h o u l db e n o l e s st h a n8 . 5v o l t s .
Currentdraw shouldbe no more than 350amperes.
M TERMINAL
lf crankingvoltageis too low, or currentdraw too high,

checkfor:
. deador low battery.
. o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g ,
menrs.
. stanerarmaturedraggtng.
. shonedarmaturewinding.
o excessivedrag in engine.
CheckCrankingrpm
E n g i n es p e e dd u r i n gc r a n k i n g
s h o u l db e a b o v e1 0 0r p m .
lf speedis too low, checkfor:
a loosebaneryor starterterminals.
a excessively
worn starterbrushes.
. open circuitin commutatorsegments.
. d i n y o r d a m a g e dh e l i c asl p l i n eo r d r i v eg e a r .
. defectivedrive gear overrunningclutch.
CheckStarter Disengagement
With the shift leverin S or E position(A,/T)or with the
clutchpedaldepressed(Mff), rurn the ignitionswitchto
, n d r e l e a s teo O N ( l l ) .
S T A R T( l l l ) a
The starterdrive gear shoulddisengagefrom the torque
converteror flywheel ring gear when you releasethe
key.
lf the drive gear hangsup on the torqueconveneror fly
wheelring gear,checkfor:
. solenoidplungerand switchmalfunction.
. d i r t y d r i v e g e a r a s s e m b l yo r d a m a g e do v e r r u n n i n g
clutch.
23-82
B TERMINAL
STARTER
CABLE
2.
B TERMINAL
MOUNTINGNUT
9Nm(0.9kgtm,
7 tbtft)
Checkthe pull-in coil tor continuitybetweenthe S

and M terminals.The coil is OK if thereis continuitv.
ArmatureInsPectionand Test
1.
Inspectthe armaturefor wear or damagedue to contactwith the permanentmagnetor fieldwinding.

VERNIER
CALIPEB
a lf there is wear or damage,replacethe armature.

for damage.
Inspect
2.
Checkcommutatorsurfaceand diameter.
lf the surfaceis dirty or burnt, resurfacewith emery
cloth or a lathe within the following specifications,
or reconditionwith #500or #600sandpaper.
. lf commutatordiameteris belowthe servicelimit,
replacethe armature
Commutator Diamate.
Standard(NEW)
28.0- 28.1mm
( 1 . 1 0-2 1 . 1 0 i6n )
ServiceLimit
27.5mm
( 1 . 0 8 3i n )
3.
Measurethe commutatorrunout.
.
lf the commutator runout is within the service

limit. checkthe commutatorfor carbon dust or
brasschipsbetweenthe segments.
lf the commutatorrunout is not within the ser
vice limit, replacethe armature.
Commutator Runout
Standard(NEW)
ServiceLimit
0 - 0.02mm
(0- 0.0008
in)
0.05mm
(0.002in)
COMMUTATOR
(cont'd)
23-83
StartingSystem
ArmatureInspectionand Test (cont'dl
4.
Checktor mica depth. lf necessary,undercutmica

with a hacksawbladeto achieveproperdepth.lf serreplacethe armature.
vicelimitcannotbe maintained,
6.
Placethe armature on an armaturetester. Hold a

hacksawbladeon the armaturecore.
ARMATURE
TESTER
NOT GOOD
MICA DEPTH
Commulator Mica DeDth

Standard(NEW)
0 . 4- 0 . 5m m
- 0 . 0 2i n )
(0.016
ServiceLimit
ARMATURE
0 . 1 5m m
(0.006
in)
.
5.
Checkfor continuitybetweenthe segmentsof the

commutator,lf an open circuit exists betweenany
segments,replacethe armature.
7.
lf the blade is attractedto the core or vibrates

while the core is turned.the armatureis shorted.
Replacethe armature.
Checkwith an ohmmeterthat no continuityexists

betweenthe commutator and armature coil core,
and betweenthe commutatorand armatureshaft.lf
there is continuity,replacethe armature.
corl coRE
23-84
COMMUTATOR
Brush Holder Test
BrushInspection
't.
Measurethe brush length.lf not within the servicelimit,

replacethe brush(or brushholderassembly)
Checkthat there is no continuitybetweenthe O and

O brush holders.
l f t h e r e i s c o n t i n u i t y r, e p l a c et h e b r u s h h o l d e r
assemDry.
O BRUSHHOLDER
O BRUSHHOLDER
2.
O ERUSHHOLDER
lnsenthe brushinto the brush holder,and bring the

brush into contactwith the commutator,then attach
a springscaleto the spring.Measurethe sprlngtension at the momentthe springlifts off the brush.
SPRINGSCALE
Brush Length
Standard(NEW)
1 5 . 8- 1 5 . 2m m
(0.62- 0.64in)
ServiceLimit
1 1 . 0m m
( 0 . 4 3i n )
NOTE:To seatnew brushesafterinstallingthem in their

holders,slip a strip of #500or #600sandpaper,with the
grit side up. over the commutatorand smoothly rotate
the armature.The contactsurfaceof the brusheswill be
sandedto the same contour as the commutator.
ClutchInsPection
Overrunning
1 . Slidethe overrunningclutchalongthe shaft.Doesit
move freely?lf not, rePlaceit.
Rotatethe overrunningclutch both ways. Does it
l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n
reverse?lf it dces not lock in either directionor it
locksin both directions,replaceit.
CLUTCHGEAR
BRUSH
SpringTension
15.7- 17.7 N (1.60- 1.80kgf,3 5 - 4.0 lbf)
23-85
StartingSystem
StarterReassembly
't.
StarterReassembly
Disconnect
1.
Pry backeach brushspringwith a screwdriver,

then
positionthe brush about halfwayout of its holder,
and releasethe springto hold it there.
2.
Installthe armaturein the housing.Next. pry back

each brush spring again,and push the brush down
until it seatsagainstthe commutator,then release
the springagainstthe end of the orusn.
Disconnect
the startercablefrom the B terminalon
t h e s o l e n o i d t, h e n d i s c o n n e ctth e B L K A T V H
wTi r e
from the S terminal.
MOUNTINGBOLT
44 N.m {4.5 kgf.m,32 lbf.ft)
S TERMINAL
BLK/WHT
WIRE
STARTER
CABLE
MOUNTINGBOLT
44 N.m {4.5kgl.m, 32 lbtftl
B TERMINAL
B TERMINAL
MOUNTINGNUT
9 N.m {0.9kgt m,
6.5 tbtfr)
R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r ,t h e n
remove the starter.
NOTE:When installingthe stanercable.make sure
thatthecrimpedsideofthe ringterminalisfacingout.
Crimpedsideol ring
termtnal
TERMINAL
Connectthe batterypositivecableand negativecable

to the battery.
23-86
aw
s
Installthe end coveron the brushholder.
Test
Performance
NOTE:Betorestaningthe following checks,disconnect
t h e w i r e f r o m t e r m i n a lM , a n d m a k e a c o n n e c t i o na s
describedbelowusingas heavya wire as possible(preferto the wire usedfor the car).
ablyequivalent
RelractingTest:
Pull-in Coil Test:
CAUTION: Do not leave the battery connectedfor more

than 10 seconds.
Disconnectthe batteryalso from the body. It the pinion

retractsimmediately,it is working properly.
Connectthe batteryas shown. lf the starterpinion pops

out, it is working properly.
CAUTION: Do not leave the battery connectedfor more
than 10 seconds.
Starter No-load Test:

L
Clampthe starterfirmly in a vise.

Connectthe starterto the battery as describedin
t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r
startsand keepsrotating.
Hold-in Coil Test:

Disconnect
the batteryfrom the M terminal.lf the pinion
does not retract,the hold in coil is working properly.
CAUTION: Do not leave the batterv connectedfor more
than l0 seconds,
"pcr"
/'4
F4
L / J
Y
,t-\
STARTER
BATTERY
l f t h e e l e c t r i cc u r r e n ta n d m o t o r s p e e d m e e t t h e
when the batteryvoltageis at 1 1.5V,
specifications
the starteris workingproPerly,
Specifications:
8 0 A o r l e s s ( E l e c t r i cc u r r e n t ) , 2 . 6 0 0r p m o r m o r e
{Motor-speed)
23-87
lgnition System
Component Location Index
IGNITIONTIMINGCONTROLSYSTEM
. Troubleshooting,
section11
. ldle speedInspection/Adjustment,
section11
. lnspectionand Setting,page23-91
SERVICECHECKCONNECTOR
{2PI
lwire colors:BRN and BLKI
TESTTACHOMETER
CONNECTOR
IGNITIONWIRES
Inspection
and Test,page23-96
PLUGS
page23-97
Inspection,
DISTRIBUTOR
page23'92
Replacement,
Overhaul,page23-93
lgnitionCoilTest,page23-96
lgnitionControlModule(lCM)
InputTest,page23-95
23-88
lgnitionSystem
CircuitDiagram: 96,97 models
GNTION
SWITCH
FUSE/FELAY
BOX
HOOD
UNDEF
DASH
UNDER
FUSE/RELAY
BOX
BLKYEL YELiGRN
BLK/YEL YEL/GRN
BLI(YEL
^l
i
GNT]ON
colL
I
T D C : T odpe a dc e n l e r
CKP: Crafkshaltposilion
posilron
CYP CyLnder
+i wlteLu
IGNTIONCONTROL
M O D U L(EC M )
/ H a sb ul l . n\
I noEe
l
TDC/CKPiCYP
SENSOR
TDC
CKP
CYP
BLU'
BLU' BLU
I A
.lJl-
++
Ji[3î''l=
TACHOMETER
TCt\4{CWr
* 1 HITACH]
*2 TEC
23-89
lgnition System
C i r c u i tD i a g r a m: 9 8 m o d e l
IGNITON
SWITCH
UNDER
HOOD
FUSE]RELAY
BOX
UNDER.OASH
FUSE/RELAY
BOX
/-1\,
I-*',il]
u''"'.-*
-un*'{_:z
BLx'EL-E_,}I,
EcMipcM
YELiGRN
1
T D C r T odpe a dc e n l e r
posilion
CKP:Crankshalt
C Y P T Ci ny d epr o s l i o n
"
+lBLU_
T D C / C K P i CSYEPN S O F
BLU'
liIl]'_r
++i+++|
-MFCM-
I
t
BLUl
B L UJ
t l
l n
I TEST
I TACHOMETER
\__7 CONNECTOR
TACHOMETER
TCM(CW)
I
X1 HITACHI
+2 TEC
23-9 0
lgnition Timing Inspectionand Setting

1 . Checkthe idle speed,and adjustit if necessary(see
s e c t i o n1 1 ) .
2.
Pullout the servicecheckconnector2P(BRNand BLK

wires)from the connectorholder locatedunderthe
dash on the front passengerside,then connectthe
it
SCSserviceconnector(T/N07PM - 0010100)to
6.
Adjust the ignition timing if necessary,as follows.

Loosenthe distributormountingbolts,and turn the
to
distributorignition{Dl)housingcounterclockwise
advancethe timing, or clockwiseto retardthe timIn g .
To ADVANCE
.r<,
3 . Startthe engine.Hold the engineat 3,000rpm with

no load (AfI in N or E, M/f in neutral)until the
radiator{an comes on, then let it idle
'l
Connectthe timing light to the No. ignitionwire,
pointer
on the timing
then point the light towardthe
belt cover.
C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s :
headlights,blower fan, rear window defogger,and
air conditionerare not operatlng.
lgnitionTiming:
1 2 ' t 2 " B T D C( R E Dd) u r i n gi d l i n gi n

neutral
1 2 "1 2 " B T D C( R E Dd) u r i n gi d l i n gi n @
orE
BOLTS
MOUNTING
kgt'm,13lbfft)
18N'm11.8
7 . Tightenthe distributormountingbolts,and recheck
r h e i g n i t i o nt i m i n g .
Disconnectthe SCSserviceconnectorfrom the ser
vice checkconnector.
POINTER
RED MARK
23-91
lgnition System
DistributorReplacement
Removal:
1.
4.
Connectthe ignitionwires to the distributorignition

( D l )c a pa s s h o w n .
Disconnect
the connectorfrom the distributor.
HITACHI:
2 - D i s c o n n e ct th e i g n i t i o nw i r e s f r o m t h e d i s t r i b u t o r
i g n i t i o n( D l )c a p .
3.
No. 1
CYLINDER
R e m o v et h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r ,
then removethe distributorfrom the cylinderhead.
DISTRIBUTOR
END
MARK
CAMSHAFI END
TEC:
No. 1
CYLINOER
MOUNTING
BOLT
18N.m{1.8kgt.m,13lbtft}
No.2
lnslallation:
NOTE:Beforeyou installthe distributor,bring the No. 1
pistonto compressionstrokeTDC.
1.
Coata new O-ringwith engineoil, then installit.
2.
Slip the distributorinto positiof

NOTE;The Iug on the end of the distributorand its
mating groovesin the camshaftend are both offset
to eliminatethe possibilityof installingthe distribu'
tor 180"out of time.
3.
l n s t a l l t h em o u n t i n gb o l t s a
, n dt i g h t e nt h e m l i g h t l y .
23-92
No. il
5.
Connectthe connectorto the distributor.
6.
Setthe ignitiontiming (seepreviouspage).
7.
After settingthe ignitiontiming, tightenthe mounting bolts.
DistributorOverhaul
HITACHI:
DISTRIBUTOR
IGNITION
{DOHOUSING
Checkfor cracksand damaqe.
IGNITIONCOIL
Test,page 23-96
)
section11
Troubleshooting,
Do not disassemble.
IGNTTION
CONTROLMODULE{ICMI
lnputTest,page23'95
CAPSEAL
Checkfor damage.
IGNITION(DII CAP
OISTBIBUTOR
Checkfor cracks,wear,
d a m a g ea, n df o u l i n g .
Cleanor replace.
(cont'd)
23-93
lgnition System
Distributor Overhaul (cont'd)
TEC:
LEAKCOVER
DISTRIBUTOR
IGNITION(DI)ROTOB
CAP SEAL
C h e c kf o r d a m a g e
DISTRIBUTOR
IGNITION{DIICAP
Checkfor cracks,wear,
damage,and fouling.
Cleanor replace.
WHT/BLU
IGNITIONCOIL
Test, page23-96
O-RING
Replace
vA
DISTBIBUTOR
IGNITION
{DI}HOUSING
C h e c kf o r c r a c k sa n d d a m a g e .
23-94
TDC/CKP/CYP
SENSOR
Troubleshooting,
section11
Do not disassemble.
lgnition GontrolModule (lCM)Input Test

NOTE:
. See section11 when the mallunctionindicatorlamp
(MlL)turned on.
. Performan input test for the ignitioncontrolmodule
( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atle s t sf o r t h e
ignitionsystemand the fuel and emissionssystems.
1.
Removethe distributorignition{Dl)cap,the distrib

utor ignition(Dl)rotor and the leakcover(TECl.
2.
the wires from the lCM.

Disconnect
3.
Turn the ignition switch ON (ll). Checkfor voltage

betweenthe BLK//ELwire and body ground.
Thereshouldbe batteryvoltage.
lf there is no batteryvoltage,checkthe BLK/YEL
wire betweenthe under-dashfuse/relaybox and
t h eI C M .
. lI there is batteryvoltage,go to step4.
Turn the ignition switch ON (ll). Checktor voltage

betweenthe wire*r and body ground.
HITACHI:
lf there is no batteryvoltage,check:
- t h e i g n i t i o nc o i l .
- t h e * r w i r e b e t w e e nt h e i g n i t i o nc o i l a n d t h e
tcM.
. lf there is batteryvoltage,go to step5.
* 1 : B L U 'w i r e ( H I T A C H I )
WHT/BLUwire (TEc)
Disconnectthe ECM/PCMconnectorA 132P).Chec.
f o r c o n t i n u i t yo n t h e Y E L / G R Nw i r e b e t w e e nt l " .
and the lCM.
ECI\I/PCM
Thereshouldbe contanuity.
6.
Checkfor continuityon the YEL/GRNwire to boc,

ground.
Thereshouldbe no continuity.
7.
C h e c kf o r c o n t i n u i t yo n t h e B L U r w i r eb e t w e e nt h e
testtachometerconnectorand the lcM.
Thereshouldbe continuity.
BLK/YEL
BLU'WIRE
YEL/GRNWIRE
TEC:
Checkfor continuityon the BLU'wire to bodyground

Thereshouldbe no continuity.
9.
lf all the testsare normal,replacethe lCM.
BLK/YELWIRE
23-95
lgnition System
lgnition Coil Test
lgnition Wire Inspectionand Test
Using an ohmmeter, measure resistancebetween the

terminals.lf the resistanceis not within soecifications,
replacethe ignitioncoil.
C A U T I O N : C a r e f u l l yr e m o v e t h e i g n i t i o n w i r e s b y
pulling on the rubber boots. Do not bend the wires; you
might break them inside.
NOTE: Resistancewill vary with the coil temperature;

specifications
are at 68'F (20'C).
1.
Checkthe conditionof the ignitionwire terminals.lf

anv terminalis corroded,cleanit. and if it is broken
or distorted,replacethe ignitionwrre.
HITACHI:
Primary Winding Resistance
(Betweenthe A and B terminalsl:
0.45- 0.550
SecondaryWinding Resistance
(Eetweenthe A and secondarywinding terminalsl:
22.4- 33.6 k{r
TERMINALB {-I
TERMINALA (+
Checkfor broken,
corroded,and benl
terminals.
2.
IGNITION
WIRE
Connectohmmeterprobesand measureresistance.
lgnition Wire Resistance:
25 kO max. at 68'F (20"C)
TEC:
{Betweenthe A and B terminalsl:
0.63- 0.770
(Betweenthe A and secondarywinding terminals):
12.8- 19.2kO
SECONDARY
WINDING
TERMINAL
O
IGNITION
WIRE
3.
TERMINALA {+
23 -9 6
TERMINALB (_)
lf resistanceexceeds 25 kO, replace the ignition wire.
lgnition System
lgnition Coil Test
lgnition Wire Inspectionand Test
Using an ohmmeter, measure resistancebetween the

terminals.lf the resistanceis not within soecifications,
replacethe ignitioncoil.
C A U T I O N : C a r e f u l l yr e m o v e t h e i g n i t i o n w i r e s b y
pulling on the rubber boots. Do not bend the wires; you
might break them inside.
NOTE: Resistancewill vary with the coil temperature;

specifications
are at 68'F (20'C).
1.
Checkthe conditionof the ignitionwire terminals.lf

anv terminalis corroded,cleanit. and if it is broken
or distorted,replacethe ignitionwrre.
HITACHI:
(Betweenthe A and B terminalsl:
0.45- 0.550
(Eetweenthe A and secondarywinding terminalsl:
22.4- 33.6 k{r
TERMINALB {-I
TERMINALA (+
Checkfor broken,
corroded,and benl
terminals.
2.
IGNITION
WIRE
Connectohmmeterprobesand measureresistance.
lgnition Wire Resistance:
25 kO max. at 68'F (20"C)
TEC:
{Betweenthe A and B terminalsl:
0.63- 0.770
(Betweenthe A and secondarywinding terminals):
12.8- 19.2kO
SECONDARY
WINDING
TERMINAL
O
IGNITION
WIRE
3.
TERMINALA {+
23 -9 6
TERMINALB (_)
lf resistanceexceeds 25 kO, replace the ignition wire.
SparkPlugInspection
1.
Inspectthe electrodesand ceramicinsulatorfor:
worn or deformod
Damaged
gasket
2.
Checkthe electrodegap.
!
. lmpropergap
. Oil-fouling
. Carbondeposits
. Crackedcenter
electrodeinsulator
Adjustthe gap with a suitablegappingtool.
ElectrodeGap
Standard
I t . t 8 m m ( 0 . 0 4 38 o o , i n )
'l.l mm
(0.043in)
Replace
the plug if the centerelectrodeis rounded
as shownbelow:
ROUNDED
ELECTRODE
I r----a
Burned or worn electrodesmay be causedby:

. Advancedignitiontiming
. Loosesparkplug
. Plug heat rangetoo low
. Insufficientcooling
Fouledplugs may be causedby:
. Retardedignitiontiming
. Oil in combustionchamber
. lncorrectsparkplug gap
. Plug heat rangetoo high
. Excessive
idling/lowspeedrunning
. cloggedair cleanerelement
. Deteriorated
ignitioncoil or ignitionwires
ll
EngineTypes
Fq-
SparkPlugs
D16Y5
Z F R 4 F . 1 1{ N G K )
K J l 4 C R - 1 1 1( D E N S O )
D16Y7,
D16Y8
NGK)
Z F R 5 F - 1( 1
(D
KJ16CR-11
1E N S O )
3.
Apply a small quantity of anti-seizecompound to

the plug threads,and screwthe plugs into the cylinder head finger-tight.Then torque them to 18 N m
(1.8kgf.m,13lbf.ft).
23-97
GhargingSystem
CHARGINGSYSTEMLIGHT
(ln the gaugeassembly)
UNDER.HOOD
FUSE/RELAY
BOX
j
ELECTRICAL
LOAD
i*Hasreplaceable
(ELD)
UNIT
I DETECToR
1
page23-100
Troubleshooting,
page23-105
Replacement,
RectifierRemoval,page23-106
Rectifier
Test,page23-107
page23-109
RearBearingBeplacement,
BATTERY
lest, page23-77
E]
ALTERNAIORBELT
Inspection
and Adjustment,page23-110
trr
CircuitDiagram
BOX
UNDERHOODFUSEiRELAY
No41(8OA)
No42(40A)
,.4\
,/T\
I BAT
\
tcl
\3-l
I ON]TION
,t S W T C H
I
BLKiYEL
UNDER,DASH
FUSE/BELAY
BOX
GRN]RED
I
WHT/GFN BLK/YEL
1,,*'
T"*
WHT/BLU
REGULATOR
VOLTAGE
ALTERNATOR
23-99
ChargingSystem
Troubleshooting
lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in
the order listedbelow:
1. Battery(seepage23 771
2. Chargjngsystemlight
3. Voltage
4. Alternatorcontrolsystem(USA)
5. Alternator/regulator
ChargingSystem Light Test
ChargingSystemLight Chck-1:
Make sure the charging system
lightcomeson.
Doesthe chargingsystem
lightcome on?
Ch.ck lor a blown No. 15 {7.5Al

fuse and a blown chargingsystem light bulb. lf the fu3e and
bulb are OK, ropair tho opon in
the wHT/BLU wila.
Charging Systcm Light Ch6ck-2:

Startthe enoine.
Doesthechargingsystem
lightgo off?
ALTERNATOR
4P CONNECTOR
{usAt
.-l1l 2l
Vollage Chock:
Measurethe voltageat the No. 1
lNo.2lterminalof the 4PI3Plconnectorwith the ignition switch ON
flr).
IG
{BLK/YEL)
I l-T;l
Wire sideof
femaleterminals
tI -
(v)
Ropair the opon in the BLK/YEL

wire bstwogn tho dternrtor and
under{a3h f uio/relay box.
3P CONNECTOR
ALTERNATOR
{Canadal
femaleterminals
(To next page)
[ ]: Canada
23-100
IG
IBLK/YELI
)
ALTERNATOR'PCONNEGTOR
(FrompreviousPage)
{usAt
.-r
l l l 2 l Wire sideof
-r-
t-T;t femaletermrnals
Chgck for an open in the L circuit-1:

2. Disconnectthe 4P [3Pl connectorfrom the alternator.
3. Groundthe No. 3 terminslof
the 4P[3Plconnector.
Doesthe charging system

lightcome on?
IWHT/BLUI
Turn the ignition switch OFF,and

repair tho opon in tho wHT/
gLU wile.
3P CONNECTOR
ALTERNATOR
{Crnadal
Wire sideof
temaleterminals
L
IWHT/BLU)
-+.t 2
-r-
1 1
l.T;l
'w"l".ur
Chock for an op6n in the L cir'
cuit.2:
the No. 3 terminalot
Disconnect
t h e 4 P t 3 P l c o n n e c t o trr o m t h e
ground.
l)
Doesthe chargingsystgm
lightgo ofi?
(WHT/8LUI
Turn the ignition 3witch OFF,and

rgpair tha 3hon to ground in the
WHT,/BLUwiro.
[ ]: Canada
(conl'd)
23-10
ChargingSystem
Troubleshooting {cont'dl
Alte.nator Control System Tost IUSAI
NOTE:Beforetesting,checkproperoperationof the ELDby confirmingwith the MIL (seesection11).
BATTERY
Chockfor a short in tha circuit
(Al-TClinel:
1, Reconnectthe 4P connector
to the alternator.
2. Startthe engine,and turn the
headlights(highbeam)ON.
4P connectorterminal No. 2
and the positive terminal of
the baftery.
CAUTION: Be sure to use a voltmetr

with its plus terminal connctedto bat,
tery plus and i$ minus torminal to the
4P connectortemrinal No. 2.
c
{WHT/GRNI
ALTERNATOR
ilP CONNECTOR
Wire sideof
femaleterminals
ECM/PCMCONNECTOR
A I32PI
1
ls there1 V or less?
9 , 1 0 11
1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22 23 2a

IALTClinel:
1 . T u r n t h e h e a d l a g hatn d i g n i taonswitchOFF.
2. Disconnect
the 32Pconnector
from the ECM/PCM.
the ECM/PCM32P connector
terminalNo. 19and alternator
4PconnectorterminalNo, 2.
25 26 21
30
Wire sideof
temaleterminals
ATLC
IWHT/GRN)
([,
_f
1
Wire sideof
femaleterminals 3
IWHT/GRN)
2 ALTERNATOR
.I'UUNNEUI(,K
4
Rep.i. open in tho wi.e bolwocn

the.lternator.nd ECM/PCM.
ls therecontinuity?
ECM/PCMCONNECTOR
A {32P}
Checkfor short in the wire {ALTC
line):
1 . T u r n t h e h e a d l i g hat n d i g n i
tion switchOFF.
2. Disconnect
the 32Pconnector
from the EClvl/PcM.
the ECM/PCM32P connector
grouno,
ls therecontinuity?
Repairshort in th wi.e betwen

th alte.nator and ECM/PCM.
23-102
i-_*_lffi*
12 13 lil
6 1 7
25 26
Wire side of
femaleterminals
30
I
I
[]
PCM,and recheck.
ll prescribdvoltage is now avail"
able, replacethe original ECM/
PCM,
10 11
l 5 1 5 1 1 1 8 t 1 9 20' 21 22123 21
ATLC
WXf/CnXl
Alternator/BegulatorTest
NOTE:Makesurethe batteryis sufficientlycharged(seepa9e 23-77]Alternator/Regulatorlest_'l :
1 . C o n n e c ta S u n v A T - 4 0 ( o r
equivalent tester), ano lurn
the selectorswitch to Posilion
1(stanang).
2. Shift to neutral(A,/Tin E or
E ) p o s i t i o n ,a n d s t a r t t h e
e n g i n e .H o l d t h e e n g i n e a t
3,000rpm with no load until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
3 . R a i s et h e e n g i n es P e e dt o
2,000rpm,and hold it there.
ls the voltageovor 15.1V?
LOADADJUSTER
ICARBONPILE)
lrffil @
.gdi
r[@*.:
VOLTMETER
NEGATIVE
(BLK}
VOLTMETER
POS|TIVE
LEADIREDI
FIELD
SELECTOR
swtTcH
Ahernator/negulatorTesl-2i
1. Feleasethe accelerator
Pedal,
and let the engineidle.
are
2. Makesure all accessories
turned off. Turn the selector
switchto position2 (charging).
3. Removethe inductivePick-uP,
and zerothe ammeter,
4 . P l a c et h e i n d u c t i v eP i c k - u P
over the battery groLrndcable
so that the arrow points to the
baftery negativeterminal.
5 . R a i s et h e e n g i n e s p e e d t o
2,000rpm,and hold it there
FULLFIELO
TESTER
LEAD IBLU}
INDUCTIVE
PICK-UP
{GRN)
NEGATIVETESTER
CABLEIBLKI
POSITIVETESTEi
CABLE(REDI
INDUCTIVE
PICK.UP
TIVE
TERMINAL
ls the voltagelessthan 13.5V?
Alternator/RegulatorTest-3:
Apply a load with a VAT-40until
the battery voltage droPs to
'13.5V.
between12-
To next page
(cont'd)
23-103
GhargingSystem
Troubleshooting(cont'dl
Frompreviouspage
ls the amperage50 A or more?
Alternator/RegulatorTest-4:
W i t h t h e e n g i n e s p e e ds t i l l a t
2,000rom,full-fieldthe alternator.
23-104
The chargingsystem is OK.
CAUTION:The voltago will rise quickly when the alteinato. is tull-fielded.Do not.llow
the voltage to exceed18 V; it may damagethe electricalsystem.
NOTE:Aftacha probeto a VAT 40 full fieldtest lead,and insertthe probeintothe fulj field
accessholeat the backof the alternator.
posiSwitchthe Iieldselectorto the "A (Ground),.
tion momentarily,
and checkthe amperagereading.
AlternatorRePlacement
NOTE: Removethe alternatorfrom belowthe vehicle
1.
Removethe batterynegativecable,then disconnect

the Positivecable.
2.
Disconnectthe 4P (or 3P) connectorfrom the alternaI0r.

TERMINALNUT
7.85 N.m (0.8kgf m, 5 79 lbtft)
R e m o v et h e a d i u s t i n gb o l t a n d t h r o u g h b o l t n u t ,
then removethe alternatorbeltfrom the pulley'
4.
UPPERMOUNT
BRACKETEOLT
44 N.m {4.5kgl.m,33lblftl
ALTERNATOR
ADJUSTINGBOLT
24 N.m {2.4 kgf'm, 17 lbf ft)
4P lor 3P)
CONNECTOR
| ): Canada
3.
44 N.m (4.5ksf m.33 lbIftl

LOWERMOUNT
BRACKETBOLTS
44 N.m {4.5kgf m.33 lbf ftl
Removethe terminal nut and the WHT wire from

the B terminal.
5.
b.
1.
P u l l o u t t h e a l t e r n a t otrh r o u g hb o l t , t h e n r e m o v e
the alternator.
lf necessary,removethe mount bracketbolts, and
the upperand lower mount brackets
Adjust the alternatorbelt tension after installation
( s e ep a g e2 3 - 1 1 0 ) .
23-105
ChargingSystem
RectifierRemoval
1.
Removethe four throughbolts.
3.
Sepa.atethe rear housingfrom the drive-endhousing by insertinga flat tip screwdriverinto the openings and pryingthem a part. Be carefulnot to damagethe statorwith the tip of the scfewdriver,
REARHOUSING
DRIVE-ENDHOUSING
S e p a r a t et h e r e a r h o u s i n ga n d d r i v e - e n dh o u s i n g
with the statorattachedto the rearhousinq.
Heatthe rear bearingseatwith a '1,000
W hair drier
for aboutfive minutes(120- 140"F,50 - 60"C),
HAIR DRIER
REAREEARING
SEAT
23-106
RectifierTest
5.
Separatethe rear housing from the stator/rectifier

assemblyby removingthe four screwsand the terminal nut.
NOTE:The diodesare designedto allow currentto pass

in one directionwhile blockingit in the oppositedirection. Since the alternator rectifier is made up of nine
diodes,each diode must be testedfor continuityin both
d i r e c t i o n sw i t h a n o h m m e t e rt h a t h a s d i o d e c h e c k i n g
capability;a total of 18 checks
1.
Checkfor continuityin eachdirectionbetween

- the B and P terminals.
- the B' and P terminals.
- E (ground)and the P terminals.
All diodesshould havecontinuityin only one direction.
Unsolderthe recti{ierfrom the statorleads

. To avoid damagingthe diodes with heat, pinch
the stator leads between pliers to carry heat off,
and applythe solderingiron only long enoughto
separatethe leadsfrom the rectiller.
. Use a 100W solderingiron.
lf anv of the diodesfails,replacethe rectifierassembly. (Diodesare not availableseparately.l
7.
lnstallthe new rectifierin the reverseorder of removal

. A p p l y t h e s o l d e r i n gi r o n o n l y l o n g e n o u g ht o
ensure a good connectionso the heat will not
damagethe diodes
. Use only a rosin core type solderor solderjoints
will corrode.
23-107
ChargingSystem
RotorSlip RingTest
AlternatorBrushInspection
1.
1 . Separatethe drive-endhousingfrom the rear housing as describedon page23-106.
Checkthe resistance
betweenthe slip rings.
Thereshouldbe 1.8- 3.0ohms.
. lf resistancemeetsthe specification,go to step 2.
. l f r e s i s t a n c ed o e s n o t m e e t t h e s D e c i f i c a t i o n .
replacethe alternator.
FOTORSHAFT
Separatethe rear housingfrom the stator/rectifier

assemblyby removingthe four scrswsand the terminal nut from the rearhousing(seepage23-,|06).
M e a s u r et h e l e n g t h o f t h e b r u s h e sw i t h v e r n i e r
calipers.
Alternator Brush Longth:
O Standard(NEW)
O ServiceLimit
19.0mm (0.75in)
5.0 mm (0.20in)
Checkthat there is no continuitybetweenthe slip

ringsand the rotoror rotor shaft.
lf the rotor fails eithercontinuitycheck,replacethe
alternator.
StatorTest
1.
Checkthat there is continuitybetweeneach pair of

leads.
lf the brushesare lessthan the servicelimit, replace

them.
cotL
CORE
Checkthat there is no continuitybetweeneach lead
and the coil core.
lf the coil fails either continuitycheck,replacethe
alternator.
23-108
RearBearingRePlacement
1.
AlternatorReassemblY
1.
Pulloff the rearbearing.
P u s ht h e b r u s h e si n , t h e n i n s e r ta p i n o r d r i l l b i t
(about1.8mm diameter)to holdthem there
Makesure the tips ot the bearingpullerjaws are

thin enough to fit betweenthe bearingand the
slip rings.
. Do not reusethe bearing.
BEARINGPULLER
SLIPRINGS
BRUSHES
REARBEARING
Use a hand pressto installthe new bearing.Apply

pressureonly on the inner raceto avoid damaging
the bearing.
H e a tt h e r e a r b e a r i n gs e a t i n t h e r e a r h o u s i n ga s
describedon page 23-106.After heating,continue
immediatelywith assemblingbeforethe rear bearing seatcoolscompletely.
assemblyand drive-end
Put the rear housing/stator
housing/rotorassemblytogether,tighten the four
throughboltsand pull out the Pin.
BRUSH ACCESS
BOI,T
THROUGH
REARBEARING
*,
SLIPRING
REAR
STATOBASSMBLY
After assemblingthe alternator,turn the pulley by

hand to make sure the rotor rotatessmoothly and
without noise.
23-109
ChargingSystem
AlternatorBelt Inspectionand Adjustment
DetloctionM6thod:
Apply a force of 98 N (10 kgt,22 lbf), and measurethe
deflectionbetweenthe alternatorand the crankshaftoulDeflection
Belt Tension Gaug Method:

Followingthe gauge manutacturer,s
instructions.attach
the specialtool to the belt,and measurethe tension.
Tension
| 8.0- 10.5mm {0.31- 0.41in}
NOTE: On a brand-newbelt {onethat has beenrun for less

than five minutes),the deflectionshouldbe 6,0- 9.5 mm
(0.26- 0.33in) when first measured.lf the belt is worn or
damaged.replaceit,
Measurehere.
I 340-490N(35-50kgf,77-j10tbf)
NOTE: On a brand-newbelt (onethat hasbeen run for less

than five minutes),the tension should be S4O-740 N
(55- 75 kgt 121- 165lbf) when firsrmeasured.lf the belt
asworn or damaged,replaceit.
24Nm12.4kgf.m,
CRANKSHAFT
PULLEY
BELTTENSION
GAUGE
07JGG- 0010'l0A
lf adiustmentis ncessary:
l.
Loosen
thelowermounting
nutandtheuppermounting bolt.
lf adiuslment is ncossary:
'L
2.
3.
Movethe alternator
to obtainthe properbelttension,
then retightenthe uppermountingbolt andthe lower
mountingnut to the specifiedtorques.
2.
Movethe alternatorto obtainthe properbelttension,

then retightenthe uppermountingbolt and the lower
mountingnut to the specifiedtorques.
3.
Recheckthe tensionot the belt.
Recheck
the deflectionof the belr.
23-110
Loosenthe lowermountingnut andthe uppermounting bolt.
FanControls
. -ri -rT _tF-1tr'l
t I r-r T-t T-l
RAOIATORFAN RELAY
Test,page23 73
,-, LJ L_JL_JI___I
tQr_-l
U LJL-Jrr
FAN RELAY
CONDENSER
Test,page23 73
UNOER-HOOD
CONOENSER
FAN MOTOR
FAN MOTOR
Removal,section 10
ENGINECOOLANT
(ECTI
TEMPERATURE
swlTcH
Removal,section10
Test, section10
23-111
FanControls
CircuitDiagram
UNDEF.HOOD
FUSEi
RELAY
BOX
No4r i80A)
IGNITIONSWTCH
UNDER.DASI-1
FUSEiRELAYBOX
l-'"----E
l
No42(40A)
-l
-YEL-.].--o.\-F-h
BrKyEL-J
BLKi
RED
II
l,^,^,",
,J"
1,,**,
T*' twl.i-:;"
BLK
BLK
II I
I
-:
G20l
23- 1 1 2
G101
GaugeAssembly
precautions'and proceduresin the sRS
sRS componentsare locatedin this area.Reviewthe sRS componentlocations,
service.
performing
repairs
or
section{24}before
6x1.0mm
9.8 N.m (1.0 kg{.m,
22 tbt.ftl
VEHICLESPEEDSENSORIVSS)
Troubleshooting,
Page23 124
UNIT
FUELGAUGESENDING
Test,page23'126
GAUGEASSEMBLY
Gauge/lndicator/Terminal
LocationIndex,Page23_114
Removal,page23-119
BulbLocation,Page23 120
page23-122
Disassembly,
BRAKESWITCH
FLUIDLEVELSWITCH
SWITCH
ENGINEOIL PRESSURE
IECT)GAUGE
SENDINGUNIT
23-113
GaugeAssembly
Gauge/lndicator/Terminal
LocationIndex
With tachometer:
"A"
CONNECTOR
(A/T GEARPOSITION
INDICATOR)
"8"
CONNECTOR
{GAUGEand INDICATOR}
t.t
----_..-ts|
47 - ->A14
c 1- - - - - - - - - > c 1 3
B1----------{-Bt6
A1- - --+A6
lrl..::.fi|
"C"
CONNECTOR
Jililil{ililt1
JililtHililL
.' "3{\
o
D1- --->D5
Fl- - --> F5
"O"
CONNECTOR
{ABSINDICATOB}
"E"
CONNECTOR
orcRU|sE
I sHrFr-up
I
lrNDrcAToR I
SPEEDOMETER:
Indicates 60 km/h at 637 rpm or
6 0 m p h a t 1 , 0 2 5r p m o f t h e
vehiclespeed sensor (VSS).
oa/
TACHOMETER:
Indicates100rpm at
200pulsesper minute
of the ignitioncontrol
m o d u l e( l C M ) .
2 3- 1 1 4
"F"
CONNECTOR
(SRSINDICATOB}
A/T GEARPOSITION
INDICATOR
Seepage23-133
\oo
FUELGAUGE
page23 126
Gauge/Sending
LJnitTest,
EI'
Without tachometer:
"C"
CONNECTOR
INDICATORI
IcAUGE and
"B"
CONNECTOR
IcAUGEandlNDlcAToRl
"A"
CONNECTOR
tA/T GEARPOSITIONINOICATOR}
8 1 . - - - - - - -- - - . - - - - - - + 8 1 6
---->414
C1-----.---.--->C13
lilillllllL
Innrruttttttl
\J
, 6
(Ju gr A
a-)
s :
Fl--) F5
Dl--->05
"D"
CONNECTOR
IABS INDICATOR)
SPEEDOMETER:
lndicates60 km/hat 637rpm or
60 mph at 1,025rpm of the
vehiclespeedsensor(VSS).
oo/
(ECT)GAUGE
Seesection5
\oo
FUELGAUGE
UnitTest,page23 126
Gauge/Sending
23-115
GaugeAssembly
CircuitDiagram
U N D E R . H OF
OU
DS E i F E L B
AO
YX
UNDER
DASH
FUSEiRELAYBOX
N 0 . 3 (075 A )
FUSE
VI
RED/BLK
GAUGE
LIGHTS
CHAFGING
SYSTEM
LIGHT
l"'
WHTIBLU
TEFNATOF
RED/BLK
l3wx4 |
FED
II
I l"
BLK I
RED/GRN
WHT/RED
t+
L'*'-
DASHLIGHTS
ERiGHTNESS
CONTFOLLEF
(Wilhshillup ndicalor
tighl)
G401
23- 1 1 6
Tt lt "
*i"'
I
t
t l
i I
l v
I
I
'
cRUlsE
CONTROL
UNIT
iI
I
olsyslem)
l"l'
BLK BLU
IJ
1",,-'
II
G401
G402
ECM/PCM
+
BLKAVHT
l_"'f"'
(With
lachomele0
No.5ll0A)
V
I
TUFNS]GNAL'
H A Z A RW
DARNING
SWITCH
LEFT
F]GHT
r-7
f-7
tt
: rc-,w'oi-_l
CoNTROL
I
I
|
I
I
i
t v I
il ,l l" ,i l
l
GRN/RED CRN/YEL
GAUGA
ESSEMBLY
To
NEXT
PAGE
RIGHT
TURN
SIGNAL
INDICATOR
L GHT
8LK BtUtRED
MODULE
(cM)
ENGINE
COOLANT
TEMPERATUFE
{ECT)
GAUGE
LOWFIJEL
INDCATOF
LIGHT
(3w)
BLK
ABS
CONTROL
IJNlT
G401
G402
ENGINE
COOLANT
TEMPERATURE
(ECT)
SENDNGI]N T
o,1o,
G4A2
BLK
G552
{cont'd)
23-117
GaugeAssembly
CircuitDiagram(cont'dl
GAUGE
ASSEMBLY
PREVOUS
PAGE
SEAT
BELT
REMINDER
LIGHT
(1.4W)
ERAKE
SYSTEM
LGHT
(1.4w)
C
't
)
./
LOWOtL
MALFUNCTION
PRESSURE
INDICATOS
INOICATOR
LiGHT
(MrL)
(1.4W)
0.4w)
TRUNK
INDICATOS
LIGHT
0.4w)
\
'./
B6
83
YEUFED GRN/ORN
v l ,.y."
I
_i
ERAKE
FLUIO
TEVEL
PARKING
BFAKE
SWTCH
up )
fclosedLever
(Opn Leverdown
J
folosed:Unbuckled
l
lopen :Euckled .l
(Open FloalLrp
c401
G402
23-118
rRUNK
swiTcH
down
lolosed: Floal
BLK
BLK
T
G552
,"",.
,,,,,,,**,
i'iiifl
rp rlt*i'!l*,
*.","n,
t
:
Removal
1.
Removethe two screwsfrom the instrumentpanel.
2.
Removethe instrumentPanel.
CAUTION: Carelully remove the instrument panel without damaging the clips'
3.
Tilt the steeringwheeldown with the tilt adjustmentlever.

Spreada protectivecloth overthe steeringcolumn
5.
Removethe four mountingscrewsfrom the gaugeassembly.
6.
Prythe gaugeassemblyout, and disconnectall connectorsfrom it'
7.
Takeout the gaugeassembly.
GAUGEASSEMBLY
INSTBUMENT
PANEL
23-119
GaugeAssembly
Bulb Locations(With Tachometerl
TRUNKINDICATOR
(1.4W)
LTGHT
GAUGELIGHT{1.4wl
CHARGINGSYSTEMLIGHTI1.4 WI
BRAKESYSTEM
{1.4Wl
HIGHBEAM
INDICATORLIGHT
{ 1 . 4W )
SEATBELT
REMINOER
LIGHT{1.4W}
LOW FUELINOICATOR
LIGHT 13W}
(1.4W)
LTGHT
LOW ENGINEOIL PRESSURE
INOICATORLIGHT{1,4WI
MALFUNCTION
INDICATOR
LAMP IMIL}
t 1 . 4W l
RIGHTTURN SIGNAL
INDICATORLIGHTI1.4WI
A/T GEARPOSITION
INDICATOR
11.12x 6l
{Onthe printed
circuitboard)
LEFTTURN SIGNAL
INDICATORLIGHT{T.4WI
GAUGELIGHTS{3 WI
aBs tNDtcAToR
t1.4Wt
{Ontheprinted
circuitboard)
23-120
SRSINDICATOR(1.4wl
{Onthe printedcircuitboard)
GAUGELIGHTI3.4W}
CRUISEor SHIFT-UPINOICATOR(1.12Wl
E'|
Bulb Locations(WithoutTachometerl
TRUNKINOICATOR
CHARGINGSYSTEMLIGHT(1.4WI
LTGHT
tl.4 W)
GAUGELIGHT{1.,1W)
GAUGELIGHTI1.{ W)
BRAKESYSTEM
LIGHT(1.{ W)
LOW ENGINEOIL PRESSURE
SEATBELT
TORLIGHTI1.4W)
REMINDER
LIGHTI1.4WI
MALFUNCTION
LOW FUELINOICATOR
INOICATOR
LIGHT(3 W)
LAMP {MILI
BULB(1.4W}
RIGHTTURN SIGNAL
INDICATORLIGHT
{1.4W}
LEFTTURNSIGNAL
INDICATORLIGHT{1.,rwl
o /
A/T GEARPOSITION
INDICATOR
{1,12x 6)
{Onthe printed
circLrit
board)
GAUGELIGHTS13W)
sRs tNDtcAToR
t1.4W)
ABStND|CATOR
t1.4Wt
circuitboard)
{OntheDrinted
GAUGELIGHT
13.4Wt
J
23-121
GaugeAssembly
Disassembly{With Tachometer)
NOTE: Handle the terminals and printed circuit boards

c a r e f u l l yt o a v o i d d a m a g i n gt h e m .
eg F - -.-
o
@', I
o 1
-^^
e\J
!=r c) ./
\ s\\.Q
ê'-----"'
,'@
I u t/@
;=1
".,,Yu
o,,o.
i'\
\\
.,:
@ /+i
PRINTEDCIRCUIT
d,@
,-@
ob,
.,- Il $
ts*u"El
| ""il\r
A/T GEARPOSITIONINDICA
PRINTEOCIRCUITBOARD
CRUISEor SHIFT-UPINDICATOR
PRINTEOCIRCUITBOARD
TACHOMETER
page23-114
Specification,
METERPANEL
ABS INDICATOR
PRINTEDCIRCUITBOARD
FUELand ENGINECOOLANTTEMPERATURE
{ECTI
GAUGE
AUGE
@ * lI
l6$\
23-122
\,/
Disassembly(WithoutTachometer)
NOTE:Handlethe terminalsand printed circuit boards
carefullyto avoiddamagingthem.
oOOo -z\\
ID
'.oo..-----..\
'.o.,'
\(
o\
i ;
, i
,,,Y
l
6,,
[ J e
ENGINECOOLANTTEMPEMTURE
GAUGEMOUNTINGSCREWSlx 3l
FUELGAUGE
MOUNTINGSCREWS{x 3}
' o @
,"o
"
rmhiffi
ôo
rugF5w
.w-r?ft
A
V
\\''$f
,a._d\
A/T GEARPoslrloN lNolcara

BOARO
PRINTED
CIRCUIT
ABS INDICATOR
BOARD
PRINTEDCIRCUTT
@
.nd
SPEEDoMETER
METER
ODO/TRIP
page23'115
Specification,
ri\\,.j 4
\.{
D,l
FUELGAUGE
Tost, page 23-126
METERPANEL
J
23-123
VehicleSpeedSensor(VSSI
Troubleshooting
Beforetesting,inspectthe No. l5 (7.5A) fuse in the under-dashfuse/relaybox.
Test ths 8LK wire:
trom the vehiclespeedsensor
(vss).
2. Connect the test harness

107LAJ- PT30200)only to the
enginewire harness.
3. Connectthe REDtest harness
clip to the positive probe of a
ohmmeter.
the REDtest harnessclip and
body ground.
Repairopen in th. BLK wire

botwoen the VSS and G101.
Tesi tho BLK/YELWir:

1. Connectthe WHT test harness
clip to the positive probe of a
voltmeter,and connectthe RED
test harnessclipto the negative
probe.
vss
Repairopen in the BLISYELwire

betwoon tho VSS and tho underdash tuso/.slay box.
(Tonextpage)
23-124
-
(From previouspage)
WHT TESTHARNESS
CLIP
Test rhe BLU/WHTwirer

C o n n e c t h e G R Nt e s t h a r n e s s
c l i p t o t h e p o s i t i v eP r o b e o f a
voltmeter,and connectthe RED
test harnessclip to the ngative
probe.
ls thereabout5 V or more?
TESTHARNESS
O7LAJ. PT3O2OA
REDTESTHASNSS
CLIP
PROTECTIVE
TAPE
Repairopen in ihe BLUMHT wire

bctween lh6 VSS and ECM/FCM,
TCM {CWl, snd ctui3 control unit
T6st the vSS:

2. Connect the other test harnessconnectorto the VSS
3. Raisethe front of the vehicle,
and support it with satety
stands,
4. Putthe vehiclein neutralwith
the ignitionswitchON (ll)
5. Slowly rotateone wheel with
the otherwheelblocked
GRNTESI HARNESSCLIP
Doesvoltage pulse from 0 to

approx,5V or more?
"8"
16PCONNECTOR
GAUGEASSEMBLY
SpeodometelTost:
the 16Pconnector
1. Disconnect
" B " f r o m t h e g a u g ea s s e m _
2. Toucha probeto the BLU,ryVHT
wire, and connect it to body
groundthrougha voltmeter.
3. Slowly rotate one wheel with
the otherwheelblocked.
Dosthe meterindicatepulsing voltage?
femaleterminals
Ropairopsn in th BLU/WHTwire
between tho VSS and the spo.d'
meter.
23-125
FuelGauge
Gauge/SendingUnit Test
Do nor smoKewnre worxrngon tne ruet
!@s@
7.
system, Keepopen flame away from yout work area.

NOTE:Referto page 23-117for the fuel gauge system
crrcutl.
CAUTION: Turn the ignition switch OFF betore the

pointerreaches"F" on the gaugedial. Failureto do
so may damagethe tuel gauge.
Checkthe No. 25 (7.5A) fuse in the under-dash

fuse/
relaybox beforetesting.
1.
2.
Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark.
NOTE|The fuel gauge is a bobbin (cross-coil)

type,
hencethe fuel level is continuouslyindicatedeven
w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r
movesmore slowly than that of a bimetaltype.

ACCESSPANEL
.
.
8.
lf the pointerof the tuel gaugedoes not move at

a l l ,r e p l a c teh e g a u g e .
lf the gauge is OK, inspectthe fuel gaugesend
ingunit.
Removethe fuel gaugesendingunit as shown.

Japan-produced
FUELGAUGE
SENDINGUNIT
femaleterminals
D i s c o n n e ct th e 3 P c o n n e c t o fr r o m t h e f u e l g a u g e
s e n d i n gu n i t .
4.
Connectthe voltmeter positiveprobe to the No. 2

terminaland the negativeprobeto the No. 1 termin a l ,t h e nt u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
Thereshouldbe between5 and 8 V.
.
.
lf the voltageis as specified,go to step 5.

lf the voltageis not as specified,checkfor:
- an open in the YEL/BLKor BLKwire.
- p o o rg r o u n d( G 5 5 2 ) .
5.
6.
Attach a jumper wire betweenthe No. 1 and No. 2

t e r m i n a l st h
, e nt u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
23-126
IJSA. Canada-Droduced
FUELGAUGE
SENDINGUNIT
E1
9.
Measurethe resistancebetweenthe No 1 and No. 2

t e r m i n a l sa t E ( E M P T Y ) ,1 / 2 ( H A L FF U L L )a n d F
(FULL)by movingthe float.
(Ceramicboardtypel:
USA,Canada-produced
FIoat Position
(O)
Resistance
105 108
1/2
29.5- 35.5
3.5-5
Japan-Produced{Wire-woundtype)'
FloatPosition
(O)
Resistance
1 0 5- 1 1 0
2 5 . 5- 3 9 . 5
T o p o t t h e w o r k b e n c h l B o t t o m o f t h e f L l e lt a n k )
lf the resistancereadingsare beyondthe range,replace

t h e f u e lg a u g es e n d l n gu n i t .
23-127
4
__r.*_
InterlockSystem
INTERLOCK
UNIT
InputTest,page23 130
KEYINTERLOCK
SOLENOID
SWITCH
and KEYINTERLOCK
(ln the steeringlockassembly)
Test,page23 131
6'm
, \-/
\-!J
PARKINGPINSWITCH
Test,page23-132
SHIFTLOCKSOLENOID
Test,page23-131
23-128
BOX
FUSE]RELAY
UNDER.HOOD
No41(80A) N0.42(40A)
GRN]WHT
YEL
ftoL{Eu'flil'
+
t
GRN/WHT
nrol
feurrr
sleern0
-
[o*
-]
tfl
I
l
GRN'1flHT
. BRAKE
LIGHTS
'CRUISE
CONTROT
UNIT
. ABSCONTROL
UN]T
. TCi,4
(CW)
YELTBLK
3
UN1T
NTERLOCK
CONTFOL
C RCUIT
KEYINTERIOCK
r'lTGEAR
POSTION
INDICATOR
17
WHT/BLK
IYr
BLK/BLU
NG
PARK
PLNSWTCH
G401
l'
A,TT
GEAR
POSITLON
SWITCH
( Co s e d I np o s r l oEn )
BLK
BLK
G401
G402
G401
BLK/BLU
23-129
lnterlockSystem
ControlUnit InputTest
Disconnect
the 8P connectorfrom the interlockcont r o lu n r t .
2 . I n s p e c t h e c o n n e c t o ra n d s o c k e tt e r m i n a l st o b e
surethey are all makinggood contact.
. lf the terminalsare bent,looseor corroded,repair
them as necessary,
and recheckthe system.
. l f t h e t e r m i n a l sl o o k O K , m a k et h e f o l l o w i n g
input testsat the connector.
lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- l f a l l t h e i n p u t t e s t s p r o v e O K , s u b s t i t u t ea
known-goodcontrolunit, and recheckthe system. lf the checkis OK, the control unit must
be faulty;replaceit.
N O T E :l f t h e s h i f t l o c k s o l e n o i dc l i c k sw h e n t h e
ignitionswitchis turned ON (ll) and you step on the
brakepedal(with the shift leverin E), the shift lock
s y s t e mi s e l e c t r o n i c a l lny o r m a l ;i f t h e s h i f t l e v e r
cannotbe shiftedfrom E, test the A//Tgear position
switch.parkingpin switch,and seesection14.
t.
WHT/BLU
1
INTERI-OCK
CONTROLUNIT
Key Interlock System:

Cavity
Wire
Test condition
lgnitionswitchturnedto
WHT/BLU A C C( l l a n dk e yp u s h e d ; n
Test: Desiredresult
C h e c kf o r v o l t a g e t o g r o u n d l
There should be batteryvoltage.
5
4
BLK
U n d e ra l l c o n d i t i o n s
Shiftleverin E
BLI(BLU
Checkfor continuityto ground:

Theresho(,ldbe continuaty.
Checklor continuityto ground:
wHT sLr/glu wHrlneo

Wire sideof
femaleterminals
Possible cause if result is not obtained
BlownNo. 48 (30A) fuse in the underhoodfuse/relay
box
BlownNo.33 (7.5Aifuse in the under
dashfuse/relaybox
Faultysteeringlockassembly
(keyinterlocksolenoid)
An openin the wire
. Poorground(G401,G402)
. An openin the wire
Poorground{G401,G402)
FaultyM gearpositionswitch
An openin the wire
the 8P connectorto the interlockcontrolunit.

Reconnect
Shift Lock System:
Cavity
Wire
YEL
YEUBLK
BLK/8LU
Testcondition
Possiblecause if result is not obtained

' BlownNo. 25 (7.5A) fusein the under
dashfuse/relay
box
lgnitionswitchON (ll)
Checkfor voltageto ground:

lgnition switch ON (ll)
Checkfor voltage to ground:

There should be battery voltage.
B l o w n N o . 2 5 ( 7 . 5A ) f u s e i n t h e u n d e r dash fuse/relay box

Faultyshift lock solenoid
A n o p e n a nt h e w i r e
ShiftleverIn E
Checkfor voltage to ground:

There should be 1 V or less.
Brakepedaldepressed
C h e c kf o r v o l t a g e t o g r o u n d :
There should be 1 V or less.
C h e c kf o r v o l t a g e t o g r o u n d :
Poorground(G401,G402)
FaultyA,/Tgearpositionswitch
An openin the wire
BlownNo. 52 (15Alfuse in the under
hoodfuserelaybox
FaultyPCM
Faultybrakeswitch(seesection11)
Faultythrottleposition{TP}sensor
{seesectionl1)
An open in the wire
WHT/RED B r a k e p e d a l a n d
accelerator depressed at
the same trme
23-130
Test: Desiredresult
KeyInterlockSolenoidTest
Shift Lock Solenoid Test
' 1 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster{seesection20).
1.
2. D i s c o n n e ctth e 7 P c o n n e c t o rf r o m t h e m a i n w i r e
harness.
Removethe tront console(seesection201.

Disconnect
the shift locksolenoid2P connector.
Connect battery power to the No. 1 terminal and
groundto the No. 2 terminalof the solenoidmomenrarIy,
NOTE: Do not connectpowerto the No. 2 (-) terminal (reversepolarity)or you will damagethe diode
insidethe solenoid.
3.

key positionaccordingto the table.
--
;il;
lgnition
switch
ACC{r)
4.
--\
Terminal
Key pushedin
o--
Key released
o-
--'o
o
Checkthat the key cannot be removedwith power

and ground connectedto the No. 7 and No. 5 termi
n al s .
.
.
Checkthat the shift lock releaseswhen the release

lever is pushed.and check that it locks when the
releaseleveris released.
lf the solenoiddoes not work, replacethe solenoid
lf the key cannot be removed,the key interlock

solenoidis OK.
lf the key can be removed,replacethe steering
lockassembly(the interlocksolenoidis not available separately).
I
23-131
InterlockSystem
ParkingPin Switch Test
1.
2.
Disconnectthe 4P connectorfrom the parking pin

switch.
Checkfor continuitybetweenthe No. 3 and No. 4
terminalswith:
- the shift leverany positionotherthan E. or
- the push buttonpushedin E.
Thereshouldbe continuity,
Checkfor continuity betweenthe No. 3 and No. 4
terminalswith the shift leverin E and the push button released.Thereshould be no continuity.It necessary,replacethe parkingpin switch.
NOTE: Parkingpin switch 4P connectorNo. 1 and

No, 2 terminals are for A,/Tgear position console
light,referto the circuitdiagramon page23-134.
23-132
A/T GearPositionIndicator
precautions,and proceduresin the sRs
sRs componentsare locatedin this area.Reviewthe sRs componentlocations,
performing
service
(24)
repairs
or
before
section
A/T GEARPOSITIONINDICATOR
InputTest,Page23-136
E
N
E
E
E
E
N
E
E
B
(cvr)
Test,page23-138
Replacement,
Page23-139
23-133
CircuitDiagram
CW:
FUSE/RELAY
BOX
UNDER.HOOD
UNDER-DASH
FUSEi
FELAY
8OX
IGNITION
SWTCH
t'*','uorl
f..*fl
I
t l
. ECM
. TCM
YEL
N0.30{7.54)
FUSE
\-/
RED/BLK
(n thegauge
A,4GEARPoSlTloNNDICATOR
assenrbly)
DIMMINGCIFCUIT
A"/TGEARPOSITIONNDICATOR
LTGRN
Vt Yt Vl Yt
No30(7 5A)
V
I
NED/8LK
t,
| ,,-kg'qen
I
llqlcoNsoLEl
I Y./ LGHT I
| | "'*'I
t
t'
RED
II
T/TGEAR
POSTTl0N
SWTCH
BLK
OASH
LIGHTS
BRIGHTNESS
CONTROLLER
23-134
G401
G402
CircuitDiagram
Except CVT:
UNDEF-OASH
BOX
FUSE/RELAY
YO X
. \ O E P H O O DL U S ER E L A B
RED/BLK
PCM
A2
(h thegalgeassemby)
l./TGEARPOST ONINDICATOR
D]MI!,IING
CIRCU]T
A,TGEARPOSITON NDICATOR
GRN]BL(
YEL
RED
YYYY
No300.54)
DASHLIGHTS
B RG H T N E S S
CONTNOLLER
V
I
REDiBLK
t,
e;"'lgn
|l { ,L
I
dlcoNsotEl
l Y i t e i l|
t
tI '
I
I
FED
DASHLIGHTS
BR]GHTNESS
CONTROLLEF
,t^jI
A"|tGEAR
P O ST O N
SWITCH
BLK
II
I-:
G401
G402
(COnt d
23-135
IndicatorInputTest
1.
Removethe gaugeassemblyfrom the dashboard(seepage23-1'19),

and disconnect
the t4p connectorfrom rne gauge
assembly.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
.
.
lf the terminalsare bent,looseor corroded,repair lhem as necessary,

lf the terminalslook OK,makethe followinginputtestsat the 14pconnector.
- lf a test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the inputtestsproveOK, but the indicatoris faulty,replacethe printedcircuitboard.
"A"
14PCONNECTOR
YEL
RED/BLK RED
A1
BLK
A2
A3
A8
A9
BLU
BRN(*1I
A6
A10
A 1 1 412 4 1 3 4 1 4
WHT
LT
GAUGEASSEMBLY
*1i Not used

'2: ExceprCVT
*3: CvT
23-136
Cavity
A'I
A2
Wire
Test condition
Test: Desiled result
lgnitionswitchON {ll)

C o m b i n a t i o nl i g h t
Checkfor voltagebetween
and REDterminals:
RED/BLK
Thereshouldbe batteryvoltage
YEL
RED/BLK switch ON and dash
A3
RED
lights brightness
control dial on full
bright
A4
BLU
Shift leverin E or E
410
GRN
RED
Shift leverin [q] or E

Shift leverin E
A.12
WHT
Shift leverin @
CheckIor continuityto groundl

Thereshouldbe continuity
NOTE:Thereshouldbe no
continuityin anYother Position
Possiblecauseil result is not obtained

. Blown No.25 (7.5A) fusein the
box
under-dashfuse/relaY
. An open in the wire
B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
box
fuse/relaY
under-dash
Faultycombinationlight switch
Faultydash lightsbrightness
controller
An open in the wire
. FaultyA//Tgearpositionswitch
Shift leverin E
413
BLVBLU NOTE:Don't depress

the brakepedal.
and shift leverin anY
positionexceptEl
GRN/BLK*' and shift leverin any
positonexcept@
YEL*1
A9
A8
A14
BLK
LT GRN

Thereshouldbe batteryvoltagefor
tlvo secondsafterthe ignition
switchis turnedON (ll),and then
lessthan 1 V.

Thereshouldbe continuitY.

. Thereshouldbe batteryvoltage*'
. Thereshouldbe about5 V*r
FaultyTCM*'
FaultyPCM*'
An openin the wire
FaultyTCM*'
FaultyPCM*i
An open in the wire
*1: Except
CVT
*2: CVT
23-137
A/T GearPositionSwitch Test
1.
Removethe front consolelseesection20).
2.
Disconnect
the 14Pconnectorfrom the Ay'Tgear positionswitch.
3.
Checkfor continuitybetweenthe terminalsin eachswitchpositionaccordingto the table.

.
.
Move the shift leverbackand fonh without pushingthe shift leverat eachswitchposition,and checkfor continuity
within the rangeof free play of the shift lever.
lf there is no continuitywithin the range of free play. adjustthe positionof the switch as describedon the next
page.
Terminal side o{ male terminals
Back- up
Light Switch
A/T Gear Position Switch

\ Terminal
t**"\
(Notused)
G-
a tr
CF
E E
E E
ooooo-
N N
tr tr
E tr
*1
I
1'
l3
14
l0
11
--o
* 1 : Withcruisecontrolsystem
23-138
Neutral
Position Switch
-_o
--o
-o
--o
-_o
--o
o- --o
o- --o
CF
--o
A/T GearPositionSwitch
A/T Gear Position Switch

Replacement
1.
Adjustment
Removethe lront console,then disconnectthe 14P

connectorfrom the A'/Tgear positionswitch
1.
Shiftto the E position,and loosenthe nuts'
2.
Slidethe switchin the directionof El or E position

Iwithin 2.0 mm (0.079in.)lso that there is continu'ty
betweenthe No. 1 and No.7 terminalsin the range
of free play of the shift lever'
3.
Recheckfor continuitybetweeneach of the terminals.
Removethe two mountangnuts

swrTcH
SLIDER
NOTE:
. It adjustmentis not possible,checkfor damage
t o t h e s h i f t l e v e r d e t e n t a n d / o rt h e b r a c k e t l f
there is no damage,replacethe consoleswitch'
. The engineshouldslart when the shilt lever is in
positionS in the rangeof free play
6 xl.0 mm
9 8 N m ( 10 k g f ' m , 7 l b n f t )
" N e u t r a l "a s s h o w n
P o s i t i o nt h e s w i t c h s l i d e rt o
above.
4.
Movethe shiftleverto
into posation.
"Neutral",then slipthe switch
Directiono{ IDI or E Position

Iwithin 2.0mm (0.079in)l
Fre play
Attachthe switchwith the two mountingnuts'

Testthe switchin the E and N positionof the shift
lever.The engineshould start when the shift lever
is in positionE anywherein the rangeof free play
't.
Connectthe 14Pconnector,clamp the harness,and

installthe front console.
LOCKPIN
23-139
IntegratedControlUnit
CircuitDiagram
UNDER,HOOD
FUSE/RELAY
BOX
+WH'I
WHT/8LK
WHT/RED
W NDSHIELD
WIPERi
WASHER
9WTTCH.
OFF/INT
f7
INT
f7
tt
8LU/BLK YEL/BLU
* COMBINED
WIPER
WASHEH
CIRCUIT
INTERMITTENT
WPERBELAY
CIRCUIT
--1-lun^r,r-r
l$'lli3fl*"'I
ELU,JWHT
I
II
r7
WINDSHELD
WIPER
MOTOR
i *'f--J
v I
|
|
i
BLK
| ,,^v.,,
I
* Withcombrned
wiper
washer
opeGl
on
wHnBLK
WASHER
"oto*
__
G40l
G402
(ffr)
A/TGEAR
POSITION
SWITCH( C l o s e dn: p o s | o nl g o r [ N ] )
BLKI\lvHl-
gr_r<rqrl
10\--l11
STARTER
CUI FELAY
BLU,BLK+[:'##"
I
COMBINATION
LIGHTSW]TCH
f7
REDiGRN
BOX
UNDERDASHFUSE/BELAY
GRNiRED
YEL
SEATBELT
NDER
FEII,I
LIGHT
UNIT
CONTROL
INTEGRATED
''o
|RED [t
BLUi
9]
l u '
I
I ttu,.'
LI
GRN
BLU/BED
A
Y
')lf#,]"J
l(3ix';
I,if;',"",",..
,
,
Doorcrosed
BLK
BLK
foeen
-:
G401
G402
c552
23-141
,
Input Test
and proceduresanthe SRS
1.
Removethe driver'sdashboardlower coverand kneebolster(seesection20).
2.
Disconnect
the 10Pconnectorfrom the integratedcontrolunit.
3.
Removethe integratedcontrolunit from the under-dashfuse/relavbox.
4.

. lf the terminalsare bent,looseor corroded,repairthem as necessary,
.lftheterminalslookoK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.
INTEGRATEO
CONTROLUNIT
1OPCONNECTOR
Wiresideof
femaleterminals
23-142
All Systems:
Cavity
Wire
A14
BLK
Test condition
Test: Desiredresult
Underall conditions

Thereshouldbe continuity
Underall conditions
Check for voltage to ground:

There should be battery voltage

Thereshouldbe batterYvoltage.
A9
A6
Possiblecauseif result is not obtained

Blown No. 43 (7.5A) fuse in the
box
under-hoodfuse/relaY
An open in the wire
. Blown No. 25 (7.5A) fuse in the
under-dashfuse/relaybox
Intermittent Wiper SYstem:

Cavity
Wire
Test condition
B1
lgnitionswitchON (ll),
BLU/BLK and windshieldwiPer
switchat OFFor INT
and
82
BLU,AiVHT
B3
and windshieldwiPer
YEUBLU
switchat INT
*A5
*84
WHT/BLK and windshieldwasher
switchON
Test: Desiredrssult
Checkfor continuitYbetweenthe
BLU/BLKand BLU/WHTterminals:
Thereshouldbe continuitY.
B l o w nN o . 2 6( 2 0A ) f u s ei n t h e
underdashfuse/relaybox
FaultywindshieldwiPerswitch
FaultywindshieldwiPermotor
An open in the wire

FaultywindshieldwiPerswitch
An open in the wire

box
An open in the wire

. Faulty windshield washer switch

*: With combinedwiper-washeroperation
(cont'd)
23-143
InputTest(cont'dl
al -- --- -- - --->A7
femaleterminals
BLU/RED
A8--------.->A14
Key-in/SeatBelt Reminder,Lights-on ReminderSystem:

Cavity
Wire
A8
81
Test condition
Test: Desiredresult
Check for voltage to groundl
B l o w n N o . 3 0 ( 7 . 5A l f u s e i n t h e
under-dash fuse/relay box
Faulty combination light switch
An open in the wire
l g n i t i o ns w i t c hO N ( l l ) ,

T h e r es h o u l db e 1 V o r l e s s .
P o o rg r o u n d( c 5 5 2 )
Faultyseatbelt switch
An open in the wire
RED/BLU and driver'sseatbelt

switchunbuckled
B9
GRN
8 1 0 BLU/RE
D
Possiblecause it result is not obtaineo
switch ON
Driver'sdoor open

Thereshouldbe i V or less.
. Faultydriver'sdoor switch
' An open in the wire
lgnitionkey inserted
into the ignitionkey
swrtcn

T h e r es h o u l db e ' l V o r l e s s .
P o o rg r o u n d( G 4 0 1c, 4 0 2 )
Faultyignitionkeyswitch
An open in the wire
Bulb CheckSystem (BrakeSystem Light):

Cavity
A4
Wire
Test condition
l g n i t i o ns w i t c ho N ( ) ,
brakefluid reservoir
GRN/RED
f u l l ,a n d p a r k i n gb r a k e
leverdown
lgnitionswitchat
START0 )
A 1 3 BtU/^/VHT
Test: Desiredresult
Possiblecauseil result is not obtained
Connectto ground:Brakesystem
l i g h ts h o u l dc o m eo n .

under dashfuse/relaybox
Blown brakesystemlight bulb
An open in the wire


Faultystartercut relay
A n o p e ni n t h e w i r e
23-144
l.r
LightingSystem
DAYTIMERUNNINGLIGHTS
RESISTOR(canadal
Test,page23-151
DAYNME RUNNINGLIGHTS
CONTROLUNIT (Canadal
InputTest,page23-150
.HEADLIGHT
'152
Adjustment,Page23
page23 151
Replacement,
SIGNALLIGHT
Replacement,
Page23-151
HIGHMOUNT BRAKELIGHT
page23 159
Replacement,
LICENSEPLATE
page23-156
Replacement,
INNERTAILLIGHT
page23-153
Replacement,
OUTERTAILLIGHT
RePlacement,
Page23 153
*: Headlight and front parking/front turn signal light cannot be separated
(cont'd)
23-145
LightingSystem
ComponentLocationIndex (cont'dl
HIGHBEAM INDICATORLIGHT
TURNSIGNALINDICATOR
LIGHT
DASHLIGHTSBRIGHTNESS
CONTROLLER
ControllerlnputTest,
page23-161
r-
rll
COMBINATIONLIGHTSWITCH
Test,page23 149
l......--,.'...-1F''------4
q L__.r
L__Jt
--:fft,1al
flfl
O
_
nnnnnnnnnn;n
11 f-
Lr u r,J rJ rJ [J LJ LJ rJ LJ LJ rJ
I-nnnnrr-nnrrnn
'
---l
|-;---l
\
)
L_J {_
r _ _ r f| l
!J
LJ
O
a-
IJ I-] IJ LI tJ IJ LJ t,J U T-J U LI
r'r n rr n it rr r't rl - n r.t 11it r'l

utJlJ|'JLl|JLJLILI|.JLj|'JtJLl
TURN SIGNAL/HAZARDRELAY
23-146
trtt
CircuitDiagram(USA)
FUSEiRELAYBOX
UNDEB,HOOD
--
---
.\--
-T\-" T,g,?..
--'r\-
To
---
'
FUSE/FELAY
BOX
I,JNDER.DASH
J No.5
00A)
?
I
N0.22
(104)
Zltl (
I
I
N0.4
00A)
BLK
G401
G402
I
oio,
RED/BLK
II
Y'
r?
DASHLIGHTS
DASHLIGHTS
BRIGHTNESS
CONTROLLER
BLK
i u',';
II
I
H]GI-]BEAM
NDICATOR
LIGHT
(1.4w)
FEDi
BLK
REDiGRN
No30
(7.5A)
PARKING
LIGHTS
TA]tL]GHTS
LIGHTS
PLATE
LICENSE
BLK
G201
23-147
LightingSystem
CircuitDiagram(Canadal
UNDEF
H O O DF U S E / R E L8AOYX
REDIW H T
RED
RED/GNN
]T
:L
UNDER.DASH
FUSE/FELAY
BOX
q
b
i
L_l
No.4
(10A)
)No 30
L {7.sA)
)to.:z
'r t75A)
N0.20 , N 0 . 1 8
(r0A) (7.54)
)
| | | | ,^,f,-,,,^,."f:",
t t l Eiffifg.'':trio.'''0-',
cLDvF.
FLDGF\
RFoW-
FFD8LU
qro e.,(
neoa_x
ftHT YEL'BLK
EBAKESYSTEM
L GHT
INTEGFATED
CONTBOL
UNIT
\-7
I
RED/GRN
I | | r*.",-lT1F*,,._
3t:'r{"is-t}6}"
OAYTIME
FUNNNGLIGHTS
C O N T R OULN I T
""t*
FED'GRN
l)tJ-;-,
I t&Jdt&JsJ
( e)i
REDi3RN
liE;;-""' lt*.'
ru$i'%H
I
I
Y*,0
t N c
8LK
I
G401
G402
BL(
G2A2
23-14A
BLK
G2A1
A
| )l
PARKING
BRAKE
ILG
l(ra
REDiGFN
swrTcH
FLIJID
I BRAKE
L WT C H
I L E V ES
upl
)l
lclosedLever
BLK
n:
G40l
G402
. Floar
downl
Icosd
I
BLK
-L
-
G401
G402
Combination Light Switch Test

(seesection20).
1 . Removethe driver,sdashboardlower coverand steeringcolumncovers
the 4P and 7P connectorsfrom the switch.
Disconnect
Insoecttheconnectorandsocketterminalstobesuretheyarea||makinggoodcontact'
.
.
and recheckthe system'

ll the terminalsare bent,loose.orcorroded,repairthemas necessary,
tables lf there
lf the terminalslook OK,checkfor continuitybetweenthem in eachswitchpositionaccordingto the
harness
switch
is no continuitybetweenany of them,checkfor continuityin the
- lf there is continuityin the switchharness'replacethe combinationlight switch'
- lf thereis no continuityin the switchharness,replacelt'
rffi]
t-l:
tAltA2!l
fl-
l a rm J l
COMBINATIONLIGHTSWITCH
7P CONNECTOB
Headlight/Dimmel/PassingSwitch :
Tetminal
\
Position
82
B1
B3
*84
B6
B5
\
OFF
o-- - o
cF- --o
o- ----o
:m:
Headlightswitch
LOW
=D
HIGH
o-
--o
----o
o-
OFF
switch
Passing
O-
ON
---{
* : Canada
Turn SignalSwitch :
Terminal
A1
A2
A4
Position
RIGHT
o-
NEUTRAL
LEFT
o
23-149
LightingSystem
DaytimeRunningLightsGontrolUnit Input Test (Canadal
1.
2.
D i s c o n n e ct th e c o n n e c t o r sf r o m t h e d a y t i m er u n n i n gl i g h t sc o n t r o ul n i t .
3.
I n s p e c t h e c o n n e c t o ra n d s o c k e tt e r m i n a l st o b e
surethey are all makinggood contact.
lf the terminalsare bent.looseor corroded,repair
them as necessary,
l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
input testsat the connector.
- lf any test indicatesa problem,find and correct
the cause,then recheckthe system.
- l{ all the input tests proveOK, the controlunit
must be faulty;replaceit.
Cavity
Wire
B1
BLK
A2
BLK /VHT
Test condition
Test: Desiredrgsult
Possiblecause il result is not obtained

. Poorground (G401.G402)
. Elown No. 20 (10A) fuse in the
Blown No. '18(7.5A) fuse in the
Faultyignitionswitch
An open in the wire
Underallconditions
C h e c kf o r c o n t i n u i t yt o g r o u n d :
T h e r es h o u l db e c o n t i n u i t y .
Checkfor voltageto groundl

IgnitionswitchON (ll)

"=d' position
switch in

Blown No. 48 (30Al fuse in the

under-hoodfuse/relaybox
Faultycombinationlight switch
An open in the wire
H e a d l i g h t s( h i g h b e a m ) s h o u l d
come on, (andhigh beam
i n d i c a t o rs h o u l d c o m e o n ) .
A1
C o m b i n a t i olni g h t
switchOFF;connecta
jumperwire between
WHT/RED t h e Y E U B L K
and
WHT/RED
terminals,
t h e nt u r n t h e i g n i t i o n
s w i t c hO N ( l l )
, 2 0 2G
P o o rg r o u n d( G 2 0 1G
. 401,
G402)
Blown bulbs
Faultydaytimerunninglights
resistor
An open in the wire
B3
l g n i t i o ns w i t c h O N ( l l ) ,
brake fluid reservoir
GRN/RED
full, and parking brake
lever down
Connectto ground:The brake

systemlight shouldcome on.
Blown No. 25 {7.5A) fuse in the

Blown brakesystemlight
An open in the wire
B6
RED/GRN
82
YEUBLK
RED
23-150
Parkingbrakeleverup

. Faultyparkingbrakeswitch
Turn
Headlights/Front
Lights
Signal/Parking
DaytimeRunningLightsResistor
Test (Canada)
CAUTION: The davtime running lights resistor becomes

very hot when the daytime running lights are on; do not
touch it or the attaching hardware immediatelyaftel
the lights have been turned oft.
1.
the 3P connectorfrom the resistor'

Disconnect
DAYTIMERUNNING
Replacement
CAUTION: Halogen headlights become very hot in uss;
do not touch them 01 the attaching hardware immediatelv after they have been turned oft.
1.
Remove the lront bumper (see section 20).
2.
Remove the mounting bolts
3.
Disconnect each connector, then remove the head

light/front turn signal/parking light assembly.
MOUNTING
BOLT
I
TURNSIGNAL/
HEADLIGHT,/FRONT
LIGHTASSEMBLY
PARKING
sideof male
Terminal
terminals
60/55W
HEADLIGHT:
LIGHT:2115W
FRONTTURNSIGNAL/PARKING
Measurethe resistancebetweenthe resistortermi_

'l
nals(No. and No. 2) and the powerterminalNo 3
Resistance:1,6 o i 0 08 o
Replacethe resistorwith a new one it any of the
are beyondspecilication.
resistances
23-15'
.
Headlights
Adjustment
Beforeadjustingthe headlights:
.
.
.
.
.
Parkthe vehicleon levelground.

lvlakesurethe fueltank is full.
The driver or someonewho weighsthe same should
sit in the driver'sseat.
Loadthe trunk with the itemsyou usuallycarry.
Pushdown on the front and rearbumoeGseveraltimes
to makesurethe car is sittingnormally.
CAUTION: Halogen headlights become very hot in use;

do not touch them or the attaching hardware immediately after they have been turned off,
Adjustthe headlightsto localrequirementsby turn,

ing the adjusters.
After headlightreplacement,
it may be necessary
to
readjustthe horizontalindicatorgear.
.
Firstinstalltheheadlight,and adjustits horizontal

a n d v e r t i c a al i m i n g sa c c o r d i n gt o l o c a lr e q u i r e menIs.
. Then checkthat the arrow on the horizontalindicator gear is alignedwith the mark on the horizontalindicator.
- lf they are not aligned,removethe screw,adjust
the indicatorgear,and retightenthe screw.
1 . O p e nt h e h o o d .
2.
Checkthe horizontaladjustmentindicator.
The "0" markon the horizontalindicatorgearshould
be alignedwith the markon the horizontalindicator.
HORIZONTALINDICATOR
HORIZONTAL
INDICATOR
3.
l f t h e i n d i c a t o irs n o t a l i g n e dw i t h i t s " 0 " m a r k a s

described
above,an adjustment
canbe madeby using
a PhilliDs
screwdriver.
23-152
NOTE:As the outer lensesa.e made of an acrylicoated,polycarbonatedmaterial,do not cover the

headlightswhen they are turned on.
Taillights
Replacement
NOTE:
. tnspectthe gaskeUreplaceit if it is distortedor stays
compressed.
. After jnstallingthe taillights,run water over them to
makesurethey do not leak
OuterTaillights:
1 . O p e nt h e t r u n kl i d / h a t c h .
2.
3.
Disconnectthe 4P or 6P connectorfrom the outer

taillight.
InnerTaillights(Coupe/Sedan):
s anel
1 . O p e nt h e t r u n kl i d ,t h e nr e m o v et h e a c c e s p
2.
the 4Pconnectorfrom the innertaillight

Disconnect
3.
R e m o v et h e I o u r l t h r e e ]m o u n t i n gn u t s .t h e n p u l l
o u t t h e i n n e rt a i l l i g h t .
I l: Sedan
Coupe:
INNERTAILLIGHT
R e m o v et h e f o u r m o u n t i n gn u t s ,t h e n p u l l o u t t h e
o u t e rt a i l l i g h t .
,lP or 6P CONNECTOR
Sedan:
INNERTAILLIGHT
Hatchback:
BRAKE/TAILLIGHT:2115W
TURNSIGNALLIGHT:21 W
BACK-UPLIGHT: 21W
Coupe/Sedan:
BRAKE/TAILLIGHT:2115w
TURNSIGNALLIGHT:21 W
4P CONNECTOR
BRAKE/TAILLIGHT:2115W
21W
BACK-UPLIGHT:
23-153
Turn SignaUHazard
FlasherSystem
CircuitDiagram
UNOERHOODFUSEiRELAYBOX
UNDER.OASH
FIJSEiRELAY
BOX
G NT ] O NS W I C H
N 0 . 1 (27 . 5 A )
"l
No30 (7.541
GRN/YEL
TUFNS GNALSWITCH
RED/BLK
(Nolused)
GRNMHT
tr ll
I
RIGHTTURNSIGNALLIGHTS
DASHLIGHTS
BRIGHTNESS
CONTROLLER
FRONT
(2rw)
BL(
NDCATOR
(1.4W)
INDlCATOR
BLK
BLK
G601.G76t Hatchback
G601 CouperSedan
23-154
G2A2
G201 CoOt,
GZOttlrt.nlr.t
G40l
G601
:Coupe/Sedan G4A2
trI\
.t
Turn Signal/HazardRelayInput Test

in the SRSsection(24)betoreperformingrepairsor ser-
vrce.
1.
relayfrom the underRemovethe turn signal/hazard

box.
fuse/relay
dash
2.
Inspectthe relayand fuse/relaybox socketterminals

to be surethey are all makinggood contact.
.
.
l f t h e t e r m i n a l sa r e b e n t , l o o s e o r c o r r o d e d ,
repairthem as necessary,and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
inDuttests at the fuse/relaybox socket.
- lf any test indicatesa problem'find and correct the cause,then recheckthe system.
- lf all the input tests prove OK,the turn signal/
hazardrelavmust be faulty;replaceit
r=\-:=
t
iln nE,\l
' ..lll L l l
........r------
FUSE/RELAYBOX
SOCKET
J
Ted: Desiredresults
Possible caus if lesult is not obtained
Cavity
Tesi condition
Hazardlightsshouldcome on.
'l
Hazardwarningswitch
ON;connectthe No. 1
terminalto the No. 3
terminal.
lgnitionswitchON (ll) and
turn signalswitchin right
or left;connectthe No. 1
terminalto the No, 3
te.minal.
Rightor leftturn signallightsshould

c o m eo n ,
. Faultyturn signalswitch
Underall conditions

' Poorground(G401,G402)
lgnitionswitchON (lll
Connectfor voltageto ground:

B l o w nN o . 1 2 ( 7 . 5A ) f u s ei n t h e
Faultyhazardwarningswitch
An open in the wire
HazardwarningswitchON
Connectfor voltageto ground:

Blown No. 53 (10A) fuse in the underhood fuse/relaybox

An open in the wire
, 2 0 2G
, 401,
P o o rg r o u n d( G 2 0 1G
G76' 1)
G402,G551.G552,G60' 1,
An open in the wire
23-155
Turn SignalI HazardFlasher
System
LicensePlateLights
HazardWarningSwitchTest
Replacement
CAUTION: Be careful not to damage the hazard warning switch or the center outlet panel when prying the
switch out.
Sedan/Coupe:
1.
Pry the hazardwarningswitchout of the centerout

let oanel.
2.
Disconnect
the 10Pconnectorfrom the hazardwarning switch.
3.

1.
Removethe two screwsfrom the licenseplatelight.

and pull the light out part of the way.
2.
Disconnect
the 2Pconnectorfrom the light.
3.
Takethe lensoff, then replacethe bulb.
2P CONNECTOR
lOPCONNECTOR
Halchback:
1.
Carefullypry the licenceplatelight out ofthe license

platetrim.
2.
Disconnect
the 2P connectorfrom the Iight.
2P CONNECTOR
Terminal
\
.-\
_
rostlton
10
.OFF
ON
o
o ooo
o
@
o
o
(9
Terminal
No.4is not used
LENS
23-156
I
Back-upLights
CircuitDiagram
IGN]TION
swtTcH
BOX
FI.JSE/RELAY
UNDER.HOOD
""'--""\9r--l
f[,,*.iliuit*t**
wnreLx..*wHr6-I
eLx/YeL
YELiRED
lr
/K
A TG E A R
PosrTloN
r
Vt[{,[H.,.
neosrrcn
Ell
lcLored
I
GFN/BLK
I
23-15i
BrakeLights
CircuitDiagram
'61
\,
UNDER.HOOD
FUSE/RELAY
BOX
*l
F!_*,.
|
wjcPN_l
I
fi--
V
H.BNSYSTEM
Pedardeoressedl
I,t'"t
GRNA'VHT
..,F.,,*,,r
. ABSCONTROL
UNIT
' ECi,I/PC[I
'TCM(CW)
.]NTEHLOCK
coNTRotUNT
'CRUISE
CONTNOL
UNIT
GRN,ryVHT
,l. ffi,!,.,
Yr,:"'
I P } BRAKE
BLK
* 2lW Coupe/Sedan
18W Hatchback
[ ] Wilhc.uisecontro
23-158
G601,G761 Halchback
G601:Coupe/Sedan
ffi; I
Ii t*i
r i
Li;
High Mount BrakeLight Replacement

Hatchback:
Coupe/Sedan:
1 . L o o s e nt h e t w o s c r e w s ,t h e n r e m o v et h e h i g h
m o u n t b r a k el i g h t . B e c a r e f u ln o t t o d a m a g et h e
hatchspoiler.
1.
Removethe rearshelf{seesection20)
R e m o v et h e t w o s c r e w s ,t h e n r e m o v e t h e h i g h
mount brakelight from the rearshelf.
2.
Removethe bulb socketfrom the light.
)
BULBSOCKET
TWO SCREWS
23-15
DashLightsBrightnessController
CircuitDiagram
\,
FUSE/RELAY
UNDER.HOOD
BOX
G401
c402
23-160
ControllerInput test
NOTE:The controlunit is built intothe dash lightsbrightnesscontroller.
1.
Carefullypry the controllerout of the dashboard
2.
the 3P connectorfrom the controller'

Disconnect
3.
Inspectthe connectorterminalsto be sure they are

all makinggood contact.
lf the terminalsare bent,loose,or corroded,repair
and recheckthe system
lhem as necessary,
. lf the terminalslook OK,makethe lollowinginput
testsal the connector.
- lf any test indicatesa problem,find and cor
rectthe cause,then recheckthe system'
- If all the input tests prove OK, the controller
must be faultyjreplaceii.
RED/BLK
Test: Desiredlesults
Possiblecauseif result is not obtained
switchON

B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
box
f use/relaY
under-dash
Faultycombinationlight swatch
A n o p e ni n t h e w i r e
Underall conditions
Check for continuity to ground:

T h e r es h o u l db e c o n t i n u i t y
switchON
Connectto groundl
D a s hl i g h t ss h o u l dc o m eo n f u l l
bright.
Test condition
Cavity
BLK
RED
. P o o rg r o u n d( G 4 0 1G
, 402)
. A n o p e ni n t h e w a r e
' A n o p e ni n t h e w i r e
23-161
InteriorLights
Component Location Index
CEILINGLIGHT
Test,page 23-165
SPOTLIGHTS
Test,page23-166
FRONTPASSENGER'S
oooRswtTcH
RIGHTREARDOORSWITCH
TRUNKLIGHT{Coup6/Sodan)
Test. page 23-166
LEFTREARDOORSwlTCH
IRUNK LATCHSWITCH
23-162
CircuitDiagram(Without Spotlights)
BOX
FUSE/FELAY
UNDER-HOOD
W].]T/RED
CEILING
LIGHT
ON
OFF
BLU/BLK
II
I
I &i*J,"'
I V
| ,,J,,, rf--l
T GRN/RED
| *tecroreo
lcoNTBotUNLT
!I
BLK
BLUi
I T-'.- )
6NN
LTG
A
A
\(
ftm'
Tn':ii
Tt*:r.:,
)
FRONT
PASSENGERS
DOOR
l[3'&'i'
8LK
swtrcH
'l
I TcosedDoo'open I
Door
open
closed
Door
-]
fcbsed
| [OPen
(Open :0oorclosed
J
LEFT
REAR
DOOR
SWITCH
folosed:Dooropen I
(Open Doorclosed
J
R]GHT
REAR
DOOR
swtTcH
fcbsed iDooropen )
(open :Doorclosed,
I
:
G60l G761:Halchbac(
G601: Coupe/Sedai
*1
a roduceo
3 4w:llsA,CanadP
5WlJapan'Produced
* 2 8 Wr W l hm o o n r o o l
5W :Wilhoulmoonroo{
23-163
lnterior Lights
t"
CircuitDiagram(With Spotlights|
UNDER-HOOD
FUSEi
BELAYBOX
WHT/REO
rhr
I I.l'-,-1
T !
I
II
BLU/BLK
t
**,,",
I'V
]NTEGRATEO
CONTFOL
UNIT
| .,J,,-
BLU/BLK
GRN
LTGRN/REO
A
A
Y*,urr" Yoo*
A
Y""
I REAR
[niH,,,,,,*,,ItfuTi::.Ll
li*r*.rt;:ff
l3$?rt"
BtK
CeOt CZOI ga"f,O""k

G601:Coupe/Sedan
xI
3.4W:USA,Canada-pfoduced
prodlced
5W:Japan
*2 8W Wlhmoonrool
5W Wlhoul
moonrool
23-164
L
IPASSENGEFS
I DOOF
I-
ll3;:1"'
ao
I(ooo
lDoorcrosed.J
:
Ceiling Light Test

Without moonrool:
1. Turn the light switchOFF.
Coupe/Hatchback:
2.
Pry off the lens.
3.
Removethe two mountingnuts (or a bolt) from the

housing,then removethe housing
4.
from the housing.

the connector(s)
Disconnect
5.

rermrnar
Position
2
or
2'
OFF
o-
MIDDLE
o-
ON
G_
/a\
\:/
/:\
\:./
/A
\./
3
ot
3'
--o
--o
-_o
BULB {5 WI
With moonroof:
3P CONNECTOR
1
4
2'
l'
23-165
InteriorLights
SpotlightsTest
Trunk Light Test
1. Turn the spotlightswitchOFF.
1.
Openthe trunk light coverfrom the housing.
2.
Pryoff the lens.
2.
Pryout the light assembly.
3.
Removethe two screwsand the housing.
3.
Disconnect
the 2P connectorfrom the housing.
4.
Disconnect
the 1Pconnectorfrom the housing.
4.
Make sure that the bulb is OK. Checkfor continuity

betweenthe No. 1 (+)and No.2 (-lterminats.
5.

BULBITT
Terminal
_\
*"t*
o-t (9
--o
/a\
\-.7
ON
23-166
\.
o- oJ
(9
/^
\,/
--o
--o
--o
rl 3.4 W: USA, Canad!-producod

5 W: Japan-produced
StereoSoundSystem
t
and proceduresin the sRS
sRS componentsare locatedin this area.Reviewthe sRS componentlocations,precautions,
performing
or
service.
(24)
repairs
before
section
AUDIOUNIT
(SfEREORADIOTUNER)
Replacement,
Page23 169
Terminals,page23 170
ANTENNAMAST
Replacement,
LEF1TWEETER
page23-171
Replacement,
RIGHTTWEETER
page23 171
Replacement,
RIGHTFRONTSPEAKER
page23-171
Replacement,
it
LEFTFRONTSPEAKER
page23_171
Replacement,
suB
LEAD
CASSETTEPLAYER
Replacement,
Page23-169
REARSPEAKERS
page23-171
Replacement,
23-167
StereoSoundSystem
CircuitDiagram
U N D E R , H OF
OU
DS E / F E LB
AO
YX
UNDEF
DASH
FUSEi
RELAY
SOX
GNITON SWTCH
t'*'fdl
-t-'---ll
I
II
ANTENNA
LEAD
R l G HN
T EAR
SPEAKER
YEURED FED/BLK
,,I;J,
REDTEr
RED
II
I
H
LEFTREAR
SPEAKER
WHT/BLU
No.30(7.5A)
LEFTFRONI
DOORSPEAKER
DASHLIGHTS
BRIGHTNESS
CONTROLLER
23-16 8
Removal
CassettePlayel:
Stereo RadioTuner:
1.
Removethe centerdashboardlower cover (seesection 20).
2.
Removethe two mountingbolts,and pullthe stereo

r a d i ot u n e ro u t
3.
D i s c o n n e ct th e 1 6 Pc o n n e c t o r ss, u b a n t e n n al e a d
and DIN cord (with cassetteplayer)'then remove
the stereoradiotuner.
16PCONNECTORS
Removethe front consolepanel(seesection20).
2.
Removethe DIN cord from the stereoradiotuner'
3.
Removethe lour mounting bolts,then removethe

cassettePlayer'
MOUNTINGBOLTS
STEREORADIOTUNER
{t
23-169
StereoSoundSystem
StereoRadioTunerTerminals
F o r k e v l e s se n t r v
To OIN CORD
MastAntennaReplacement
1.
Disconnect
the connectorbetweenthe antennalead
a n ds u b a n t e n n al e a d .
2.
Removethe two mountingscrews,then removethe

mast antenna.
MOUNTINGSCREWS
To DIN CORD
(forsecurity
system)
Cavity
A1
MAST ANTENNA
Wire
RED/GRN
Rightfront door speaker@,

righttweeterO
Leftfront door speakerO,
left tweeter @
A2
BLU
A3
RED/BLK
Lights-onsignal
A4
WHT/BLU
Constantpower (tuning
memory)
YEURED
ACC(mainstereopower
supply)
A7
BLUI/EL
Left reardoor speaker@
A8
REDI/EL
Rightreardoor speakerO
A9
BRN/BLK
Rightfront door speakerO,

righttweeterO
410
GRY/BLK
Leftfront door speakerO,

left tweeter O
412
RED
Dashlightsbrightnesscontroller
414
BLK
G r o u n d( G 5 0 ' 1 )
415
GRYA/r'HT Leftreardoor speakerO
416
BRN,^/VHT Rightreardoor speakerO
T e r m i n a lA
s 6 ,4 1 1
SpeakerReplacement
Rgarspaker:
Front speaker:
1.
Removethe speakercover'
2.
Removethe threescrewsfrom the speaker'
3.
Disconnectthe 2P connector,and removethe door

speaker.
1.
Removethe rearsideshelf or rearshelf(seesection

20).
2.
the 2Pconnectorfrom the speaker.

Disconnect
3.
Removethe four screws,then removethe speaker.
Hatchback:
SPEAKER
FRONT
g
Tweeter:
|'
1.
Removethe door panel{seesection20)
2.
the 2P connectorfrom the tweeter'

Disconnect
3,
Removethe mirrorgarnish.
4.
Removethe two screws,then removethe tweeter'
2P CONNECTOR
Coupe/Sedan:
REAR
TWEETER
2P CONNECTOR
23-171
Horn
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions.and proceduresin the SRS
HORNASSEMBLY
Test,page 23-173
a\
\
\-'/"''\
\ rap
HORNRELAY:
98 modot
cRy.l
lWirecolors:WHT/GRN,
BLU/RED
IWHT/GRN,
I
Test,page23-73
L-l
hJrrfl
a\ a\
-/ l i
fl f-
nFFrnn-r-rFrl'1llrLrurrLr!Lrrrr.rLrUrrrr
r ' rF r n n r ' rF r - n F r F r r r r l
---t
i
Ll
L--l
|
|
|
|
LJJ
J:::::::::tJ:-t l
UNDER.DASHFUSE/BELAYBOX
23-172
h-
HORNRELAY:96, 97 modots
lWiro color3:WHT/GRN,GRy,l
lwHT/cRN, BLU/RED
I
Test,psge 23-72
CircuitDiagram:96,97models
HornTest:96,97models
'L
Removethe tront bumper(seesection20).
2.
the 2Pconnectorfrom the horn'

Disconnect
BATTERY
HORN
RELAY
LOW HORN
rt
Removethe horn.
Test the horn by connectingbattery power to one

terminaland groundingthe other.lf the horn failsto
sound,replaceit.
Y--
BLU/RED
I
I
B LK
G401
G4o2
23-173
Horn
CircuitDiagram:98 model
HornTest 98 model
1 . Removethe front bumper(seesection20).
BATTERY
Oisconnect
the 1Pconnectorfrom the horn.
BRAKE
SWITCH
TERMINAL
Wlhl,eyessenry ";,
svsm
ir-?
lJ
!--oA"
t v i
3.
WHT/GRN
4,",,
It
I
':
23-174
Test the horn by connectingbattery power to the

t e r m i n a la n d g r o u n d i n gt h e m o u n t i n gb o l t l f t h e
horn failsto sound,replaceit.
Switch Test
1.
the batterynegativecable,thendisconnect
Disconnect
the positivecable,andwaitat leastthreeminutes'
2.
Disconnectthe driver's airbag connector(see section 24).
3.
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r { s e e
section20).
4.
3P connector
the cablereel sub-harness
Disconnect
from the main wire harness.
R e m o v et h e d r i v e r ' sa i r b a ga s s e m b l y( s e es e c t i o n
2 4 ) ,t h e n d i s c o n n e ctth e h o r n c o n n e c t o frr o m t h e
steeringwheel.
7 . Checkfor continuitybetweenthe No 2 terminalof
the cable reel sub-harness3P connectorand horn

positive
terminal.
HORNPOSITIVETERMINAL
REEL
MAIN WIRE
HARNESS
3P CONNECTOR
SUB.HARNESS
3P CONNECTOR
CABLEREEL
HORNCONNECTOR
.
.
Terminalsideof
maleterminals
5.
Checkfor continuitybetweenthe No. 2 terminalof

t h e c a b l er e e l s u b - h a r n e sasn d b o d y g r o u n dw i t h
the horn switchPressed.
l f t h e r e i s n o c o n t i n u i t yr, e p l a c et h e c a b l er e e l
(seesection24).
lf there is continuity,repairor replacethe horn
switch.
l f a l l t e s t s p r o v e O K , r e i n s t a ltl h e d r i v e r ' sa i r b a g
assembly(seesection24), and reconnectthe cable
reelsub harnessconnector'
9 . Reconnectthe driver's airbagconnector,and relnstallthe accesspanelon the steeringwheel.
1 0 . Reconnectthe batterypositivecable,then the negative
terminal.
Terminalsideol
maleterminals
a lf there is continuity,the horn switchis OK.

a lf there is no continuity,go to step6.
1 1 . After installingthe airbagassembly,confirm proper

systemoPeratlon:
Turn the ignition switch ON (ll);the SRS indicator light should come on for about six seconds
and then go off.
Makesureboth horn buttonswork.
23-175
RearWindowDefogger
UNDER-DASH
FUSE/RELAYBOX
t
-
o
_
t
t l
:--=-=-=;----------.l
:uuu
-n--nhnn-n;n
! !
uuuuuu!uluuu
.-1 fl
| | l
uu!uu!uu!u!u
----t
REARWINOOWDEFOGGER
FLrnctionTest,page 23-178
DefoggerWjre Repair,page 23-1j8
23-176
U
REARWINDOWDEFOGGEF
SWITCH
trt\
CircuitDiagram
**"-*9
IGNITION
SWTCH
BOX
UNDERHOODFUSE/FELAY
No41 (80A)
No42(404)
BOX
DASHFUSE/RELAY
UNDER
(7sA)
N0.30
FUSE
RED/BLK
tI
BLK]BLU
\t
I REAR
| wrNDow
I DEFOGGER
I| -r]]
I ;-
TI
BLK
BLK
II
DASHLIGHTS
ERIGHTNESS
CONTROLLER
rt
II
--
G6ol :Coupe/Sedan
G771 HalchbacK
G40l
G402
G401
G402
ZLITT
RearWindow Defogger
FunctionTest
DefoggerWire Repair
CAUTION:Be carefulnot to scratchor damagethe detogger wires with the tester probe.
NOTE: To make an effective repair, the broken section

m u s t b e n o l o n g e rt h a n o n e i n c h .
1. Checkfor voltagebetweenthe positiveterminaland

body ground with the ignitionswitch and defogger
switchON.
T h e r es h o u l db e b a n e r yv o l l a g e .
1.
Lightly rub the area around the broken section with

fine steel wool, then clean it with alcohol.
2.
Carclully mask above and below the broken portion

of the defogger wire with cellophane tape.
lf there is no voltage,checkfor:
- faulty defoggerrelay.
- faulty defoggerswitch.
- a n o p e ni n t h e E L I V B L U
wrre.
lf there is batteryvoltage,go to step2.
NEGATIVE
TERMINAL
OPEN
POSITIVETERMINAL
CELLOPHANE
TAPE
3.
Using a small brush, apply a heavy coat of silver

c o n d u c t i v ep a i n t e x t e n d i n g a b o u t 1 / g , , o n b o t h
sides of the break. Allow 30 minutes to dry.
NOTE: Thoroughly mix the paint before use.
Checkfor continuitybetweenthe negativeterminal

a n d b o d yg r o u n d .
l f t h e r e i s n o c o n t i n u i t yc, h e c kf o r a n o p e n i n t h e
defoggerg roundwire.
Touch the voltmeterpositiveprobe to the halfway
point of eachdefoggerwire, and the negativeprobe
t o t h e n e g a t i v tee r m i n a l .
Thereshouldbe approximately6 V with the ignition
switch and the deiogger switch ON.
lJthe voltageis as specified,the defoggerwire is
oK.
lf the voltage is not as specified, repair the defog
gerwire.
lf it is more than 6 V, there is a break in the
negative half of the wire.
- lf it is less than 6 V, there is a break in the
positive hall ot the wire.
23-178
4.
Checkfor continuityin the repairedwire.
5.
Apply a secondcoat of paint in the sameway. Let it

dry three hoursbeforeremovingthe tape.
Switch Input Test

CAUTION: Be careful not to damage the rear window
defoggerswitch or the center panel when plying the
switch out,
N O T E :B e f o r et e s t i n g ,c h e c kf o r b l o w n N o 1 6 ( 7 5 A )
fuse in the underdashfuse/relaybox
1.
Prythe switchout of the centerpanel(seesection20)'
2.
the 5Pconnectorfrom the switch.

Disconnect
3.
Turnthe ignitionswitchON {ll),and checkthe voltage

betweenthe BLVBLU(+)andthe BLK{-) terminals
.
.
ll there is no voltage,checkfor an open in the

BLVBLUwire
lf there is batteryvoltage,go to step 4.
RED
Wiresideof famaleterminals
4.
rt
Connecta jumper wire betweenthe BLK/BLUand

terminals.
the BLU/YEL
Turn the ignitionswitch ON (ll). and checkthat the
rear window defoggerworks; if it does, replacethe
defoggerswitch.
23-179
PowerMirrors
PowerMirror
FunctionTest,page23-182
PowerMirrorTest,page23-183
Replacement,
section20
ActuatorReplacement,
page23-184
POWERMIRRORSWITCH
Test,page23,183
23-180
hr-
CircuitDiagram
GNTION
swrTcH
BOX
FUSE/RELAY
UNDER.HOOD
YEL
UNDER.OASH
FUSE/RELAY
BOX
I lu";I
I
BLK/YEL
lt
*
f#'-_'":1:
3
BLUiBLK
GRN/WHT
G551
23-181
-...
PowerMirrors
FunctionTest
CAUTION: Be caretul not to damage the mirror switch
or the dashboard driver's lower cover when prying the
switch out.
1.
2.
Pry the switch out of the driver,sdashboardlower

cover.
Disconnect
the 10Pconnectorfrom the switch.
Left mirror inoperative:

Connectthe No. 2 (BLK/YEL)
terminalof the 1Opconnector to the No. 3 (YEURED)
terminatand the No. 5 (or No.
6) terminalto body ground with jumper wires. The left
mirror shouldtilt down (or swing left)when the ignition
switchis turnedON l).
lf the mirrordoesnot tilt down (or doesnot swing left),
removethe left door panel,and checkfor an open in
t h e B L U / W H T( o r B L U / B L K w
) i r e b e t w e e nt h e l e f t
powermirrorand the switch.
- lf the wire is OK,checkthe left power mrrroracrua_
tor.
lf the mirror neithertilts down nor swings left, repair
the YEVREDwire.
lf the mirroroperatesproperly,checkthe mirrorswitch.
Right mirror inoperative:
Connectthe No. 2 (BLVYEL)
te.minalof the 1Opconnector
to the No. 3 (YEURED)
terminatand the No. 9 (or No. 8)
terminalto body groundwith jumperwires.The rightmirr o r s h o u l dt i l t d o w n ( o r s w i n g l e f t )w h e n t h e i g n i t i o n
switchis turnedON {ll).
lOP CONNECTOR
YEL/REO
BLK
BLK/YEL
2
6
BLU/WHT
POWRMIRROR
swtTcH
/ 1 8
YEL/BLK
Mirror Test
Both inoperative:
'1.
Checkfor voltagebetweenthe No. 2 (BLK,/YEL)

terminal and body groundwith the ignitionswitch ON
( ).
. lf there is no voltage,checkfor:
- b l o w n N o . 1 7 ( 7 . 5A ) f u s e i n t h e u n d e rd a s h
fuse/relaybox.
- an open in the BLVYELwire.
. lf there is batteryvoltage,goto step 2.
2. Checkfor continuitybetweenthe No. 4 (BLK)termin a la n d b o d yg r o u n d .
. lf thereis no continuity,checkfor:
- a n o p e ni n t h e B L Kw i r e .
- p o o rg r o u n d( G 5 5 1 ) .
23-182
!.\-
lf the mirror does not tilt down (or does not swino
left), removethe right door panel,and checkfor ai
open in the GRN,Ar'/HT
(or YEUBLK)wire betweenthe
right power mi.ror and the switch.
- lf the wire is OK,checkthe right power mirror actuator.
lf the mif ror neithertilts down nor swings left. repair
the YEVREDwire.
l f t h e m i r r o r o p e r a t e sp r o p e r l y ,c h e c kt h e m i r r o r
switch.
PowerMirror Test
Switch Test
1.
Removethe switch as describedin FunctionTest

(seepage23-182).
2.

1.
Prv out the coverpanei{seesection20}
covR
Mirror Switch:
rermrnal
\
Position
UP
DOWN
L
LEFT
RIGHT
UP
DOWN
LEFT
RIGHT
o- o- -o -o
o- -o o- -o
-o
G -o G
-o
o- G -o
-o
o- o- _o
_o
o- _o oo- -o o-o
o- o- -o
Terminalsideof
maleterminals
the 8P connectorfrom the powermitrrt

Disconnect
Checkactuatoroperationby connectingpower-l
groundaccordingto the tables.
Terminal
-_\
P*t,i""--
TILTUP
POWERMIRROR
swlTcH
TILTDOWN
SWINGLEFT
S W I N GR I G H T
rt
23-183
PowerMirrors
Mirror ActuatorReplacement(DonnellyTypel
1.
Removethe power mirror from the door (see sect,on 20),and disconnectthe 8P connector,
2.
R e m o v et h e m i r r o r b a s e c o v e r f r o m t h e m i r r o r
housing.
6.
Removethe two screws,cut the wire harness,and

removethe actuator.
ACTUATOR
BRACKET
MIRRORHOUSING
MIRROR
HOLDER
Removethe mirror holderfrom the mirror housing.
Gentlypull it out by hand.
7.
Recordthe terminallocationsand wire colors.
8.
Routethe wire harnessof the new actuatorthrough

t h e h o l e i n t h e b r a c k e t .B e s u r et o p a s st h e w i r e
underthe bracketclip.
Removethe three screwsfrom the actuatorand the

t w o s c r e w sf r o m t h e b r a c k e ta t t h e b a s e o f t h e
assembly.
BRACKET
5.
Removethe bracketfrom the housino.
9.
23-184
\r-
Passthe connectorboot overthe wire harness.
a
10. lnsertthe terminalsinto the connectorin the origin a l a r r a n g e m e n (t r e c o r d e di n s t e p 7 ) , a s s h o w n
Delow.
Left:
PNK
rt
' ].
Right:
PNK
Apply tape to sealthe intersectionof the connector

boot and the wire harness.
in the reverseorder of disassembly.Be
Reassemble
carefulnot to breakthe mirror when reinstallingit
to the actuator.
1 3 . Reinstallthe mirror assemblyto the door.

1 4 . Operatethe power mirror to checkthat the actuator
workssmoothly.
rt
23-185
Wipers/Washers
WIPER/WASHER
SWITCH
Test,page23-189
WINDSHIELO
WIPERARMS/BLAOES
WINDSHIELDWIPERMOTOR
Test, page 23-189
WINOSHIELD
WASHER
MOTOR
Test,page23'190
FLUID
RESERVOIR
REARWINDOW
WASHERMOTOR{Hatchb.ck)
Tesl, page 23-190
23-186
\
nf-___]
l.,...--.--_
Ilfr
{ - J l l l
[ ]_ll-l
REARWINDOWWIPER
MOTORlHatchbackl
Test,page 23,190
CircuitDiagram(Windshield)
UNDR-DASH
8OX
FUSE/REtAY
FUSEiFELAYBOX
UNDEF.HOOD
]NTEGRATED
CONTROL
UNT
/ HasbuiLl'in \
I intem lenl I
I wperreray I
rt
WHTiBLK
\t
WINDSHIELD
WASHER
MOTOR
Y
I
BLK
BLK
BLK
G2A2
G401
G402
G401
G402
,I :W]lhCOMBINED
WIPERMASHER
OPERATION
23-187
Wipers/Washers
CircuitDiagram(RearWindow)
UNDER.HOOD
FUSE/RELAY
8OX
REAR
WINDOW
WIPER
MOTOR
REAFWINDOW
W]PERA/VASHER
SWITCH
,'/-\\:----
BLK
----l
BLK
G401
23-188
\
8LK
n\
tY
Wiper/Washer Switch Test
WindshieldWiperMotor Test
'1.
1.
Remove the driver's dashboard lower cover (see

section20).
2. Removethe steeringcolumncovers.
3 . D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e
switch, remove the two screws. and pull out the
switch.
Openthe hood, and removethe cap nuts.Carefully

remove the wiper arms so that they do not touch
the hood.
Removethe cowl cover by prying out the trim clips
(seesection20).
Disconnectthe 5P connectorfrom the windshield
wiper motor.
SWITCH
WIPER/WASHER
Terminalsideof
maleterminals
windshield:
1 1 23 4 l
|t 1_- a T
t|
l 5 6 j 7 8 |
RearWindow:
2
i l
3 l
li;i7-',611
4.
\t

Windshield Wiper/Wssher Swiich:

| ermrnsl
\
rostr|on
.o
o
o
o
OFF
INT
oo
o
LO
HI
l\4ist
switch"0N"
"
Washer
switch"0N
o
o
o
o
o
o
Test the motor by connectingbattery power a n o

groundaccordingto the table.
\
-\
Terminal
;;il-
LOWSPEED
H I G HS P E E D
o
@
RearWindow Wiper/WasherSwitch:
Terminal
lf the motor does not run or fails to run smoothly.

replaceit.
t*t*---__\
"0N"
switch
Washer
"0FF"}
switch
{Wiper
OFF
rt
ON
" 0N'
Washer
switch
"0N")
(Wiper
switch
o- -o
o- -o
o- -o
o- -o
o- -o G -o
5.
Connectan analogvoltmeterbetweenthe No. 5 (+)

and No. 3 (-) terminals,and run the motor at low or
high speed.
The voltmetershould indicate0 V and 4 V or less
alternately.
23-189
Wipers/Washers
RearWiper Motor Test (Hatchbackl
WasherMotor Test
t.
Removethe hatchlowertrim panel(seesection20).
1 . Removethe front bumper{seesection20).
2.
Disconnectthe 4P connectorfrom the wiper motor

assemDty.
2.
Disconnect
the 2P connectorsfrom the washer.
Test the motor by connecting battery power to the

No. 1 terminaland groundto the No.3 terminal.
3.
lf the motor does not run or fails to run smoothly,
replace[.
Testthe washermotor by connectingbatterypower

and ground accordingto the table.
Terminal
Reconnectthe 4Pconnectorto the wiper motor.

Connectan analogvoltmeterbetweenthe No. 4 (+)
a n dN o . 2 ( - ) t e r m i n a l s .
Runthe motor by turningthe wiperswitchON.
The voltmetershould indicate0 V and 4 V or less
alternately.
23-190
\
Battery
Disconnected
Connected
.
.
lfthe motor failsto run smoothly,replaceit.

lf the motor runssmoothly,but littleor no washer
f l u i d i s p u m p e d .c h e c kf o r a d i s c o n n e c t e do r
blockedwasherhose,or a cloggedpump outletin
the motor.
PowerWindows
ComponentLocationlndex
POWERWINDOWRELAY
Test,page23 73
P - ( ) ( ) ( )
( )
WINDOWSWITCH
FRONTPASSENGEB'S
Test,page23-200
BOX
FUSE/RELAY
\t
WINDOWMOTOR
FRONTPASSENGER'S
Test,page 23_202
POWERWNDOW
MASTERSWITCH
Test,page23-194
RIGHTREARWINDOWSWITCH(SEdAN)
Test,page23-200
RIGHTREARWINDOWMOTOB
{Sedanl
Test, page 23'202
DRtVER'SWINOOW
Test, page23-201
LEFTREARWINDOWSWITCHlS.Test,page 23-200
LEFTREARWINOOWMOTOR(Sedanl
Iest. page 23-202
\t
23-191
PowerWindows
CircuitDiagram(Coupe/Hatchback)
UNDER.HOOD
FUSEiFELAYBOX
\
UNDER.DASH
FUSE/BELAY
BOX
BLK
BLK
PASSENGERS
WiNDOWI'IOTOR
23-192
\
G55l
G551
G401
G402
EfI
J
CircuitDiagram(Sedan)
FUSEiFELAY8OX
UNDER.HOOD
U N D E R , D AFSU
HS E / R E L8AOYX
GNT]ONSWITCH
MASTERSWTCH
PASSENGER'S
lt
c 11 8 4
BLUIYEL
3 I L E F TR E A F
WINDOW
SWITCH
REDYEL
RED]BLU
\I'
LEFTREARWINDOW
MOTOR
3 I FIGHT
REAR
W NDOW
SWTCH
^| ':i"'
RED/YEL
4I
BLU]oRN
FIGHTFEARW NDOW
MOTOR
RED/YEL
3IFRONT
PASSENGERS
WINDOW
8ru;FED I SWTCH
rffi-r
lul
8LK
B5
MOTOR I4
D R I V ESFW N D O W
BLK
FRONTPASSENGER
S
WINDOW
MOTOR
BLK
G551
G551
G40l
G402
2s-193
PowerWindows
MasterSwitch Test (Coupe/Hatchback)
1.
Removethe master switch from the driver's door

panel(seepage23-196).
Passenger'sSwitch:
\
D i s c o n n e c t h e 1 2 P c o n n e c t o rf r o m t h e m a s t e r
switch.
Terminal
P",ir"'-T-mil\A2
ON
OFF
OFF
MAIN
swtTcH
UP
ON
A5
ooo- --o
OFF
DOWN
ON
OFF
AI
A2
A6 A 7
A3
A8
A4 A5
412
Terminal
sideol maleterminals
3.

switch position acco{dingto the table.
Driver's Switch:
The driver'sswitchis combinedwith the control unit so
you cannot isolatethe switchto test it. Instead,run the
master switch input test proceduresat termrnals A1, A3,
44, A8 and A12 on page 23-196.lf the tests are normal.
the driver'sswitchmust be faulty.
GG_
G_
A6
A7
--o
--o
o- --o
o- -o
*-o
--o
--o
MasterSwitch Test (Sedanl

1.
2.
Removethe armrest from the driver's door panel

(seepage23-198).
F ont Passenger'sSwitch:
Terminal
t".-*Tm;\
D i s c o n n e ctth e 1 6 P a n d 1 P c o n n e c t o r sf r o m t h e
masterswitch.
ON
o-
OFF
CF
OFF
MAIN SWITCH
UP
POWERWINDOW
MASTERSWITCH
SWITCH
oRtvER'S
B1
ON
OFF
ON
DOWN
GG-
swlTcH
Terminal
r".-*-f-m}
ON
OFF
OFF
J=\
ON
UP
OFF
Terminalsideof
maleterminals
00wN
ON
OFF
B1
B4 B5
B3
,/1,/
B8 B9 8 1 0 B r 1
B7
Terminal
ON
OFF
UP
ON
OFF
Driver's Switch:
814
o- --o
--o
o- --o
--o
o- --o
815
Bl6
-_o
G
CF
--o
o- --o
CF
--o
810
c1
o- --o
c)--o
oo- --o
P."-b"Tmm\B8
OFF
The driver'sswitch is combinedwith the control unit so

you cannot isolatethe switchto test it. Instead,run the
masterswitchinput test proceduresat terminals83, 84'
85, 86 and 87 on page 23-198 |f the tests are normal,
the driver'sswitchmust be faulty
--.o
Right RearSwhch:
8 1 48 1 5
Check for continuitv between the terminals in each

switch position according to the tables.
cl
Left Rear Switch:

\
Bl1
--o
o- --o
OFF
FRONT
PASSENGB'S
82
ON
DOWN
OFF
B9
o -o
o- --o
o- -_o
o- --o
G- --o
--o
o--o
o-o
oG_
23-195
PowerWindows
MasterSwitch Input Test (Coupe/Hatchback)
NOTE:The controlunit is built intothe powerwindow masterswitch,and only controlsd river'sdoor w jndow operations.
1.
Removethe driver'sdoor panel,a nd disconnectthe I2p connectorfrom the masterswitch.
2.
lnspectthe connectorand socketterminalsto be surethey are all makinggood contact.

a lf the terminalsare bent,looseor corroded,repairthem as necessary,
and recheckthe svstem.
. lf the terminalslook OK, makethe {ollowinginputtestsal the connector.
- lf all the input testsproveOK,the powerwindow masterswjtchmust be faulty;replace
it.
Wire side of femalet6rminals
23-196
L-
!-t\
I
'
l-l
v
Csvrty
Wire
A5
Ta3t condition
To3t Desirodresult
Underall conditions


Possiblecause if result is not obttined

. Poorground (G551)
BLK
A8
A1
BLU/BLK
A6
GRN/BLK
A4
A3
Checkthe driver'swindow motor:

connectthe BLU/BLK
It shouldrun (thewindow moves
RED/YEL
to
the
terminal
RED/BLU
terminal.and the RED/ down).
BLUterminalto the
BLKterminal,then turn
RED/YEL the ignitionswitchON
Blown No. 10 or 11 (20A) fuse in

box
the under-dashfuse/relaY
Faulty power window relaY
An open in the wire
. Faultydriver'swindow motor
flr).
A7
window
Connectthe GRN/BLK Checkthe passenger's
(the
window
run
lt
should
motor:
BLUI/EL
ro
the
BLUI/EL terminal
terminal,and the BLU/ movesdownl.
ORNterminalto the
BLU/ORN the ignitionswitchON
window motor
Faultypassenger's
window switch
Faultypassenger's
An open in the wire
flr).
A't2
BLU
A8
BLK
Connectthe BLU/BLK
terminal to the RED//EL
terminal,and the BLK
terminalto the RED/
BLUterminal,then
turn the ignitionswitch
Checkfor voltage betweenthe

BLUand BLKterminals:APProx.6
V shouldbe indicatedas the driver'swindow motor runs.
Faultypulser
Faultydriver'swindowmotor
An openin thewire
oN0r).
\y
23-197
PowerWindows
MasterSwitch Input Test (Sedan)
NOTE:The controlunit is built into the powerwindow masterswitch,and only controlsdriver'sdoor window opera!ons.
l
Removethe driver'sarmrest,and disconnectthe 16Pand 1p connectorsfrom the masterswitch.
2.

.
.
lf the terminalsare bent,looseorcorroded,repairthem as necessary,

lf the terminalslook OK,makethe followinginput testsat the connecror.
- lf all the input testsproveOK,the powerwindow maserswitchmust be faulty;replaceit.
POWERWTNOOW
swtTcH
ABMREST
Wire sideot
femaleterminals
23-198
L.
ry
Cavity
Test condition
Wire
B4
Test: Desiredresult
Underall conditions


Thereshouldbe batterYvoltage
Possiblecausc il resuh is not obtained

. P o o rg r o u n d( G 5 5 1 )
BLK
c1
B3
BLU/BLK
82
GRN/BLK
B8
YEUBLK
B l o w nN o .7 , 8 , 1 0o r 1 1 ( 2 0A )
fuse in the under-dashfuse/relaY
box
Faultypowerwindow relaY
An open in the wire
8 1 5 RDAr'VHT
B7
B5
Checkthe driver'swindow motor:

Connecrthe BLU/BLK
moves
RED/BLU terminalto the RED/YEL It shouldrun {thewindow
down).
RED/
the
terminal,and
BLUterminalto the
BLKterminal.then turn
RED/YEL the ignitionswitchON
Faultydriver'swindow motor
An open in the wire
0r ) .
Connectthe GRN/BLK
B1 BLU//EL terminalto the BLU/YEL
terminal,and the BLU/
ORNterminalto the
8 1 1 BLU/ORN the ignitionswitchON
flr).
Checkthe front passenger's

window motor:
oown).
window
Faultyfront passenger's
motor
window
Faultyfront passenger's
switch
An open in the wire
connectthe YEUBLK
to the YELterterminal
YEL
B9
m i n a l ,a n dt h e Y E U
GRNterminalto the
8 1 0 YEUGRN the ignitionswitchON
flr).
Checkthe right rearmotor:

oown).
Faultyright rearwindow motor

Faultyright window switch
An open in the wire
Connectthe REDny'VHT Checkthe left rearmotor:

It shouldrun {thewindow moves
8 1 4 GRNfYEL terminalto the GRN/
oown,.
YELterminal,and the
GRNterminalto the
GRN
816
the ignitionswitchON
0l).
Checkfor voltagebetweenthe
Connectthe BLU/BLK
BLUand BLKterminals:
terminalto the RED/
BLU
6 V shouldbe indicatedas
Approx,
the
and
YELterminal,
the driver'swindow motor runs.
BLKterminalto the
B4
BLK
Faulty left rear window motor

Faulty left rear window switch
An open in the wire
Faultypulser
Faultydriver'swindow motor
An open in the wire
terminal,
RED/8LU
then turn the ignition
switchON (ll).
{Y
23-199
PowerWindows
Passenger's
Window Switch Test
Coupe/Hatchback:
Switch side ot 5P terminal:
1 . R e m o v et h e a r m r e s tp o c k e tf r o m t h e d o o r p a n e l
(seesection20).
PASSENGER'S
WINDOWSWITCH
Terminal side of
male terminals

Terminal
ilil----t
UP
o-
OFF
5PCONNECTOR
2.
Disconnectthe 5P connectorfrom the passenger's

window switch.
Sedan:
1.
Removethe armrest(seesection20).
5P CONNECTOR
ARMREST
wtNDow
swtTcH
2. Disconnect
the5Pconnector,
thenremove
themounting screw from the passenger'sswitch.
23-200
L{-
DOWN
o-
-o
o- -o
o- -o
-o
o- -o
o- -o
E\
Driver'sWindow Motor Test

PulserTest:
Motol Test:
Removethe driver'sdoor panel(seesection20)'
1.
5.
Connectthe test leadsof an analogohmmeterto the

No. 3 and No. 4 terminals.
6.
Run the motor by connectingpower and groundto

the No. 1 and No. 2 terminalsThe ohmmeterneedle
shouldmove backand forth alternately.
Terminalsideot maleterminals
2.
Disconnectthe 4Pconnectorfrom the motor'
3.
Testthe motor in each directionby connectingbattery power and groundaccordingto the table.
Terminal
;;;;--_l\
UP
DOWN
CAUTION: When the motor stops running' disconnect one lead immedistelY.
4.
lf the motor does not run or fails to run smoothly,

replaceit.
ly
23-201
PowerWindows
Passenger's
Window Motor Test
Front:
'1.
2.
Rear:
R e m o v et h e p a s s e n g e r 'ds o o r p a n e l ( s e es e c t i o n
20t.
1.
R e m o v et h e p a s s e n g e r ' ds o o r p a n e l ( s e es e c t i o n
20).
D i s c o n n e ct th e 2 P c o n n e c t o fr r o m t h e w i n d o w
motor.
2.
D i s c o n n e c t h e 2 P c o n n e c t o rf r o m t h e w i n d o w
molor.
NOTE:The illustrationshowsthe right rearwindow
motor;the left rearwindow motor is symmetrical.
2P CONNECTOB
2P CONNECTOR
Terminalsideof male
terminals
3.
Checkwindow motor operationby connectingpower

and groundaccordingto the table.
-_-l
Terminalsideof male
terminals
3.
Terminal
il;;
UP
DOWN
o
o
Terminal
lf the motor does not run or fails to run smoothlv.

replaceit.
UP
DOWN
Direction
CAUTION:When the motor stops running,disconnectone leadimmediately.

4.
Checkwindow motor operationby connectingpower

and groundaccordingto the tabre.
CAUTION: When the motor stops running, discon_

nect ons lead immediately.
4.
lf the motor does not run or fails to run smoothlv.

replaceit.
23-202
f,.!*
Moonroof
Gomponent Location Index
SwrTCH
MOONROOF
Test,page23-206
. MOONROOFCLOSERELAY
IWirr colo]s: w T, GRN/YEL, I
IGRN/ORN,BLK,lNd GNN/REDJ
Test, page 23-73,74
. MOONROOFOPENRELAY
IWir. color.: WHT,GRN/REO,l
I
LGRN/ORN,BLK.nd YEL
Te6l. gage 23-73, 74
MOTOR
Test,page 23-206
\y
23-203
Moonroof
CircuitDiagram
* 1 : 9 6 , 9 7m o d e l s
x 2 : 9 8m o d e l
U N D E q . - O OFDU S ER E L A B
YO X
IGNITIONSWITCH
No4l (80A) N0.42(40A)
WHT/BLK
+_
WHT
UNDER.DASH
FUSURELAY
8OX
MOONFOOF
OPEN
BETAY
MOONROOF
SWITCH
BLK
-1r
'
G401
G402
23-204
b.,1
OPEN/CLOSESWITCH:
. DLrrinq
the llinoooeraUon
(:lr[!-p Filticlosed)
A andC lorminals
ate@nnected.
' Durm theslidnoooeraton
(Fullyilosedi
Fullvopn)
A andElermrna
s arecbnnecied
TILT/CLOSESWITCH:
. Du nqthelillinOOOeratron
(-Iillui Fulticlosed)
D andF terminalsare
corinpded
' DufirElheslidnoooeratron
(Fullyclosed-; Fltv oDen)
D arldE lermrnals
areconhecied
nl
ry
FunctionTest
CAUTION:8e carsftilnot to damagethe moonroofswhch
or the driver's dashboard lowet cover when prying the
switch out.
Connectthe No. 1 (YEL)terminal to body ground

with a jumperwire,then turn the ignitionswitchON
(ll),The moonroofshouldopen.
NOTE:Checkthe No. 51 {20 A) fuse in the under-hood

fuse/relaybox and No. 24 (7 5 A) fuse in the under-dash
fuse/relaybox, beforetestang
.
.
1.
Pry the switch out of the driver'sdashboardlower

cover.
2.
the 4P connectorfrom the switch.

Disconnect
lf the moonrooiopens,checkthe switch.

lf the moonroofdoes not open,checkfor:
- a n o p e ni n t h e Y E Lw i r e
- faulty moonroofopen relay.
- faulty moonroofcloserelaY.
- p o o rg r o u n d( G 4 0 1G
, 402).
terminalto body ground

Connectthe No. 3 (YEURED)
(ll).The moonroofshouldclose.
4P CONNECTOR
. lf the moonroofcloses,checkthe switch

a lf the moonroofdoes not close,checkfor:
- an open in the YEUREDor GRN/RED
wire.
- faulty moonroofcloserelaY.
- faulty moonroofopen relay.
- faultytilvcloseswitch.
Connectthe No. 2 (BLU)terminalto bodygroundwith
a jumper wire, then turn the ignitionswitch ON (ll)
The moonroofshouldtilt uP.
.
.
lf the moonrooftilts up, checktheswitch.

llthe moonroofdoes nottilt up, checkfor:
- an open in the BLUwire.
- faultytilvcloseswitch.
terminalto body ground

Connectthe No. 3 (YEURED)
(ll).The moonroofshouldtilt down.
lf the moonroof does not tilt down, the open/close
relay must be faultY.
7.
Checkfor continuityto body ground on the No 4

(BLK)terminal.
Wire sideoI femaleterminals
.
.
lf there is continuity.checkthe switch

lf there is no continuity,checkfor:
- a n o p e ni n t h e B L Kw i r e
- poor ground(G401,G402)
\y
23-205
Moonroof
Switch Test
Motor Test
1. Carefullyremovethe switchfrom the driver,sdash,

boardlower cover(seepage23-205).
1,
Removethe headliner{seesection20}.
2.
D i s c o n n e ctth e 2 P c o n n e c t o rf r o m t h e m o o n r o o f
motor.
2.

Terminal
t*,*--_\
OFF
OPEN
o-
CLOSE
TILT
o-
--o
o- --o
--o
Checkthe motor by connectingpower and ground

accordingto the table.
\_ __lg.-rq
Position
4.
OPEN
CLOSE
lfthe motor does not run, replaceit (seesection2O).

NOTE: See Closing Force Checkin section 20 for
motor clutchtest.
23-206
\
Open/Glose-Tilt/CloseSwitch Test
1.
Removethe headliner(seesection20).
2.
trom the moonthe 2P and 4Pconnectors

Disconnect
roo{ motor and the switch.
3.
Checkfor continuitYbetweenthe terminalsin each

switchpositionaccordingto the table
Terminal
Position
4.
CLoSE
TltT
o-- --o
CLoSE
oPEN
G-
o- -_o
-_o
ll thereis no continuity,adjustor replacethe switch'
\!y
23-207
CruiseControl
MAIN SWIICH
TesVReplacement,
page23 212
CRUISECONTROLUNIT
CABLEREEL
Replacement,
section24
. Test,page23-214
. PedalHightAdiustment,
section19
swtTctltM/T)
. Test,page23 214
. clutch PedalAdjustment,
section12
A/T GEARPOSMON
swtTcH
. Test,page 23-138
. Replacement,
page23 139
ACTUATORCABLE
VACUUM TANK
.
.
.
.
TORASSEMBLY
Test,page23-215
Replacement,
page23-216
SotenoidTest,page23_217
Disassembty,
page23-218
23-20a
\ -
-.
CircuitDiagram
GN]TION
SWTCH
AO
YX
U N D E R . H OF
OU
DS E ] F E LB
No41(80A)
FUSEiRELAYBOX
UNDER,DASH
No30{7.sA)
FUSE
No42(40A)
f7
+WHT
WHT/8LK
REDJBLK
NDCATOF
LGHT
(084W)
WHTiGRN
GAUGE
ASSEMBLY
CRNIWHT
BRAKE
TIGHTS
1l
10
7
C R US EC O N T F OULN I T
CRUISE
PNK
CONTROL
ACTUATOR
l'
BLK
I'
:
G202
+ r--l
ELL.JMHT
BLK
BLK
:;i",
I
i"$L:H;JF
) |
Yr",
A
\v
l3
G40l
G402
IoN:Pedareeasedl
/
T
l
G40l
G402
23-209
'ry
CruiseControl
ControlUnit Input Test
and procedu.esin the SRS
1.
Removethe driver'sdashboardlowercoverand kneebolster(seesection20).
2.
Disconnect
the 14Pconnectorfrom the controlunit.
3.

lf the terminalsare bent,loose,or corroded,repairthem as necessary,
lf the terminalslook OK, makethe followinginput testsat the connector.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
CONNECTOR
Wire sideol femaleterminals

CRUISECONTROLUNIT
GRN/WHT LTGRN/RED LT GRN/BLK
;--?\
I
2
I
10
1l
BRN/BLK
"-"0
12
13
l4
BLU/WHT
LT GRN
v
Cavity
9
Wire
BRN/VVHT
BRN
11
BRN/BLK
GRY
BLK
GRN/!VHT
LT GRN/
RED
7
LT GRN/
BLK
ly
Underall conditions
Underall conditions
to grouno:
Checkfor resistance
T h e r es h o u l db e 7 0 - 1 1 0O '
lonitionswitchON (ll),
riain switchoN and
brakepedalpushed,
then released
Checktor voltageto ground:

Thereshouldbe 0 V with the pedal
pushedand batteryvoltagewith
the Pedalreleased.
Under all condrtions

Thereshouldbe batterYvoltage
with the pedalpushed,and 0 V
with the pedalreleased.
Set button Pushed

ResumebuttonPUshed
RED/BLU
A/f: Shiftleverin E,
b'l or [f
PNK
ground:
, Check for continuity to
There should be continu'tY'
BrakepedalPushed,
then released
lgnitionswitchON {ll)
and main switchON;
't2 BLU/VVHT raisethe front of the
car,and rotateone
wheelslowlywith the
otherwheelblocked.
and main switchON
1 3 LT GRN
14
to ground:
Checkfor resistance
T h e r es h o u l db e 8 0 - 1 2 0O
to ground:
Checkfor resistance
Thereshouldbe 40 - 60 O'
Underall conditions
10
Test: Desiredtesult
Test condition
M/T: Clutch pedal

released
Attachto ground:
Cruiseindicatorlight in the gauge
assemblyshouldcome on.
Checkfor voltagebetweenthe
BLUMHT O and BLKO terminals:
T h e r es h o u l db e 0 - 5 V o r m o r e
-0 - 5 V or more rePeatedly.
Possiblecau3eit result is not obtained

Faultyactuatorsolenoid
Poorground (G202)
An open in the wire
. Faultybrakeswitch
. Poorground (G401,G402)
box
under-hoodfuse/relaY
Faultybrakeswitch
An open in the wire
Blown No. 52 (15A) tuse in the
Faultyhorn relaY
Faultysevresumeswitch
Faultycablereel
An open in the wire
B l o w nb u l b
Faultydimmingcircuitin the
gaugeassemDly
An open in the w,re
. Faultyvehiclespeedsensor(VSS)


box
Faultymain switch
An open in the wire

NOTE:Thereshouldbe no continuitywhen the clutchPedalis
depressedor when the shift lever
is in other positions.
Faulty A,rr gear Positionswitch

Faultyor misadjustedclutch
switch(M/T)
An open in the wire
'\ty
23-211
CruiseControl
Main Switch Test/Replacement
Removethe driver'sdashboardlowercover(seesection 20).
Set/ResumeSwitch
Test/Replacement
l.
Dlsconnectthe batterynegatjvecable,then disconnectthe positivecable,and wait at leastthree min_
Carefullypush out the swilch from behindthe dash_

ooarq.
3.
UIES.
Disconnectthe driver's airbag connector(seesecrion 24).
Disconnectthe connector from the switch.
Removethe dashboarddriver'slowercover(seesection 20).

4.
Disconnectthe cablereel sub-harness

3p connector
from the main wire harness.
MAIN SWITCH
BULBS{0.84W)
MAIN WIRE
HARNESS
3P CONNECTOR
Terminalsideof
maleterminals
4.

Terminal
ON
Terminal
t*t*-\
OFF
Checkfor continuity betweenthe terminals of the

cable reel sub-harness
3p connectorin each switch
positionaccordingto the table.
oo
/:\
\-/
/:\
\:,,
-o
G-
/5
o o-
/5
\-/
\:./
-o
-o
__\
t^,*
SET(ON}
(ON}
RESUME
o- -o
o- ---o
a l f t h e r e i s c o n t i n u i t ya
, n d j t m a t c h e st h e t a b l e ,
lf there is no continuity,reOlace
the switch.
the switchis OK.

a lf there is no continuityin one or both positions,
go to step6.
23-212
llL
6.
Removethe two screws,then removethe switch
lf all tests prove OK, reconnectthe cable reel and

connector.then reinstallthe
cable reel sub-harness
steeringcolumncovers.
9 . Reconnectthe driver'sairbag connector,and reinstallthe accesspanelon the steeringwheel'
SET/RESUME
the batterypositivecable,then the nega1 0 . Reconnect

tive cable.
1' ]. A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m
propersystemoperation:Turnthe ignitionswitchON
(ll);the SRSindicatorlight shouldcome on for about
six secondsand then go off
{y
7.
Checkfor continuitybetlveenthe terminalsin switch

positionaccordingto the table.
lermlnal
\
Position
SET(ON)
(ON}
RESUME
oo-- -o
---o
lf there is continuity, and it matches the table,

replace the cable reel.
lf there is no continuity in one or both positions,
replace the switch.
'st
23-213
CruiseControl
BrakeSwitch Test
GlutchSwitch Test (M/T)
1.
1.
Disconnect
l-N7-rl]]ll
1lx
lffl
|
|,
Disconnect
2 |
.
ll
I
4P CONNECTOR
CLUTCHSWITCH
BRAKE
PEOAL
Checkfor continuitybetweenthe terminalsaccording to the table.
2.
Terminal
\
tr**On----\
RELEASED
DEPRESSED
o- --o
Checkfor continuitybetweenthe terminalsaccording to the table.
4
Terminal
o- --o
-\
RELEASED
DEPRESSED
3.
at**",
lf necessary,replace the switch or adiust Dedal

height(seesectionl9).
3.
l f n e c e s s a r yr, e p l a c et h e s w i t c h o r a d j u s t p e d a l
height(seesestion12).
23-214
\^
Actuator Test
1.
Disconnectthe actuatorcablefrom the actuatorrod

and the 4Pconnector'
2.
Connectbattery power to the No. 4 terminal and

groundto the No. 1, No. 2 and No. 3 terminals
3.
Connecta vacuumpump to the vacuumhose Then

applyvacuumto the actuator.
5.
With voltageand vacuumstill applied,try to pull the

actuatorrod out by hand.You shouldnot be ableto
pull it out. lf you can,it is defective.
VACUUM PUMP
GAUGE,0- 30 in.Hq.
(A973X- 041 -
xxxxxt
ACTUATOR
groundfrom the No.3 terminal The actuDisconnect

ator rod should return. lf it does not return, but the
vent hose and filter are not plugged.the solenoid
valve assemblyis defective.
iy
.P CONNECTOR
4.
The actuatorrod shouldpull in completely.lfthe rod

pulls in only part-wayor not at all, checkfor a leaking vacuumline or defectivesolenoid.
ROD
ACTUATOR
7.
Repeatsteps 2 through 5, and disconnectground

from the No. 1 terminal The actuatorrod should
return.lf it does not return,but the vent hose and
filter are not plugged,the solenoidvalve assembly
is detective.
8.
lf vou reDlacethe solenoidvalve assembly,be sure

to usenew O-ringson eachsolenoid.
Disconnectpower and ground from the 4P connector'
Disconnectthe vent hose from the actuator.Connect
a vacuumpump to the actuatorvent hose pon, and
applyvacuum.The actuatorrod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n .
Reolacethe aduator.
23-215
CruiseControl
Actuator Replacement
Actuator GableAdjustment
t.
Pullbackthe boot,and loosenthe locknut.Then disconnectthe cablefrom the bracket.
1 . Checkthat the actuator cable operatessmoothly

with no bindingor sticking.
2.
Disconnect
the cableend from the actuatorrod.
Stan the engine.Hold the engineat 3,000rpm with

no load (Aff in N or E . MfI in neutral)until the
radiatorfan comeson. then let it idle.
Measurethe amount of movementof the actuator
r o d u n t i l t h e c a b l e p u l l s o n t h e a c c e l e r a t olre v e r
(enginespeed startsto increase).Free play should
b e 1 1i 1 . 0m m ( 0 . 4 3t 0 . 0 4i n ) .
ACTUATORROD
ACTUATOR
CABLE
LOCKNUT
Disconnect
the 4Pconnectorfrom the actuator.
Disconnect
the vacuumhosefrom the vacuumtank.
Pullout the vent hose.
5.
LOCKNUTFREEPLAY:11 t 1.0mm
{0.43t 0.0i1in}
Removethe three mounting bolts and the actuator

with the bracket.
VACUUM HOSE
lf free play is not within specs,loosenthe locknut.

and turn the adjustingnut as required.
NOTE: lf necessary,check the throttle cable free
play (seesection1I ), then recheckthe actuatorrod
free play.
5.
CABLE
6.
lf necessary,
disconnectthe cableend from the linkage over the acceleratorpedal,then turn the grommet 90' in the bulkhead,and removethe cable.
7.
Installin the reverseorder of removal,and adjust

tree play at the actuator rod after connectingthe
cable(seenextcolumn).
23-216
rL-
4PCONNECTOR
Retightenthe locknut,and recheckthe free play.
trll
ActuatorSolenoidTest
Disconnect
1.
ACTUATOR
Checkfor resistancebetweenthe terminalsaccording to the table.
2.
Terminal
{y
;rb"*"Q)---\
o-- --o
VENTSOLENOID
40 - 60()
SOLENOID
SAFETY
40 - 60c)
-o
o-
SOLENOIO
VACUUIVI
30- 50()
--o
o-
NOTE: Resistancewill varv slightly with temperais at 70'F (20'C).

ture;specifiedresistance
SAFETYVALVE
VACUUM VALVE
From VENT
HOSE
To VACUUM
TANK
{y
23-217
CruiseControl
ActuatorDisassembly
ACTUATORCABLE
ACTUATOR
BRACKET
CHECK
VALVE
@,
WIRESUPPORTERACKET
ACTUATOR
Test,page23-215
SOI.ENOIDVALVES
Tesr.page 23-217
\9
o
I
elR
YAJ
e
FILTERCOVER
23-218
E
PowerDoorLocks
Y
NOTE(With keYlessentry system):
LED is faulty;
. lf the doors unlockor lock with the transmitter.but the LEDon the transmitterdoes not come on, the
replacethe transmatter.
(However,
. when you unlockthedoorswith the transmitter,the ceilinglight (middleposition)comeson tor 30 seconds.
on
l
if the audio unit is not installed,the light does not come
a lf any door is open,you cannotlockor unlockthe doorswith the transm'tter'
the horn
. The horn soundsonly the first time you press a transmitterbutton. (Pressingrepeatedlydoes not activate
agatn.l
doors relock
. lf vou unlockedthe doors with the trsnsmitter,but do not open any of the doors within 30 seconds,the
automaticsllv.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is insertedin the ignitionswitch.
the transmitter
. lf you pressthe PANICbuttonfor more than two seconds,the horn soundsfor about 30 seconds,and
panic mode is
The
switch.)
ignition
is
in
the
LEDcomes on. (The panic mode will not be activatedif the ignition key
cancelledby pressingany of the transmitterbuttons.
transmltter'
o After replacingthe t;nsmitter battery.pressthe lockand unlockbuttonsfive or six timesto activatethe
LEFTREAROOORLOCKACTUATOR
Test, page 23-229
section20
Replacement,
RIGHTREARDOORLOCKACTUATOR
Test, page 23-229
Replacemnt,section20
DOORLOCKACTUATOR
FRONTPASSENGER'S
Test, page 23-229
Replacemnt,section20
AUDIOUNIT
{STEREORADIOTUNER)
keylossl
/Hasbuih-in
I
\tecorvorqrcu|l
Replacemont.page 23-169
Input Test,page 23-226
Terminals,page23-228
LOCKACTUATOR
Test, page 23 229
section20
Replacement,
t-.a
{y
F,,
@
\ql
TRANSMITTER
KEYLESS
Codes,page23-231
StoringoI Transmitter
TesvReplacement,
Page23 230
DRIVER'SDOORLOCKSWITCH
Test,page 23'228
POWEBOOORLOCK
CONTROLUNTT
lnputTest,page23-224
23-219
PowerDoor Locks
CircuitDiagram(With KeylessEntrySystem)
UNDEFHOODFUSE/RELAY
BOX
No41(804)
N0.42(40A)
WHT/BLK
WHT/RED
WNT/BLU
POWER
DOOR
LOCKCONTHOL
UNT
unLocx@
rocx@
BLK
DOOFLOCK
LOCK
KNOB
KNOB
n
]
WHT/FED
GRN,4VHT
GRN/ORN
xev
r--1--n1
i-H__!J
l , l
i-A-r
I
LIJ I
FEARllro* L
PASSENGER'S
LOCK
io'
lRsi^"s'
YEUFED
G551
23-220
I
gLK
G551
BLK
G551
]GNITION
swrTcl.l
WHT/REC
WHT/BLKBLK/YEL
|-+-_-+-l
'J
|
r'ro.zg
) Norq I UNDEF-DASH
USE/RELAY
(7.5A) FBOX
(roA)
(
HORN
|
f,
|
RELAY
YEUREDBLK/YEL
T RUNK
LIGHT
GFY
CIRCUlT
KEYLESSRECEIVER
(lnlheaudioun()
T GRN/BED
BLU/RED
l*recnereo
UN|T
I coNTRoL
I Y
r
|
,,u'rro
| *rrurorro
UN|T
I CONTRoT
t'---l-----"--------'7
tr(
IL,.-)
GRN
BLU/FED
LTG R N / F E D
GRN/RED
I
I
A
d\
A
v-,
Y,,,
f*,o"
l::;=:-'
Il$'.i')""'
I'r,t*rt*
l:xH
;
i
liff.ii
LTGRN/RED
ilt)
I REAR
I DoOF
| :,.s!.
| | loe.
BLK
oio,
G402
8silsr.:,
l to*"
I
I
lt3'tri'
t_
v
lccf opn
loor c osed
FIGHT
REAR
DOOR
SWITCH
ubseo:uooropenI
(Open :0oorclosed
,l
I
-l
G401
G402
23-221
PowerDoor Locks
CircuitDiagram(WithoutKeylessEntrySystem)
UNDEF.HOOD
FUSEiRELAY8OX
DOORLOCKKNOB
t
l
I
DEIVER'S
DOOH
LOCK
SWTCH
BLU/WI-17
WHT/FED
BLUi
NED
POWER
DOOR
LOCK
CONTROL
UNIT
BLK
BLK
G551
G55l
23- 2 2 2
\
Troubleshooting
sequence
NOTE:The numbersin the table show the troubleshooting
Itemto be inspected
E
:
o
_9
.z
t 3
)
{ p
; o
-o
o
: ;
:
9 c
Symptom
ry
Powerdoor locksystemdoes not work at all.
Doorsdon't lockwith driver's

door lockknob switch.
All doors
Doorsdon't lockor unlock

with driver'sdoor lockswitch.
All doors
E5
O n eo r m o r e
doors
* The powerdoor locksystemworksproperlybut
the keylessentry system doesn't.
=
E
3 n ' .z
O Y o
(J
o
F
< :
IL
G551
WHT/GRN
BLU,ryVHT
O n eo r m o r e
doors
.g
9 - )
YEUREDor
WHT/RED
GRN,ryVHT,
GRN/ORN,
YEUREDor
WHT/RED
YEUREDor
WHT/RED
2
1
G401
G402
or
GRNAVHT
GRN/ORN
*: with keylessentrysystem
NOTE:
. When the remotetransmitterbutton is pressedthe first time, only the driver'sdoor will unlock.When the button is
Dressedthe secondtime, all the doorswill unlock.
after30 secondsifa door is notopened,orthe key isout ofthe ignitionswitch
. Thedoorswill relockautomatically
. The keylessentrysystemwill not lockor unlockthe doorswhen the key is in the ignitionswitch.
!y
PowerDoor Locks
ControlUnit InputTest
' t . Removethe
driver'sdoor panel(seesection20).
2.
Disconnect
the 12Pconnectorfrom the controlunit.
a lf the terminalsare bent,looseor corroded,repairthem as necessary,
. lf the terminalslook OK,makethe followinginputtestsat the connector.
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
12PCONNECTOR
YEL/RED
GRN/WHT
2
1
1
I
5
12
BLU/WHT
*r With keylessentry system
t-
23-224
v
Disconnect
the l2P connectorfrom the power door lockcontrolunit.
CAUTION: To prevent damage to the actuator, apply battery voltage only momentarily.
Wire
Cavily
BLK
't2 WHT/GRN
ry
5
Test condition
Test: Degiredresult
Under all conditions


Connectthe YEURED
terminalto the WHT/
GRNterminal,andthe
YEURED
WHT/REO
terminalto
the BLKterminal
momentarily.
Checkdoor lockoperation:
All passenger's
doorsshould
untocK.
connectthe BLU/RED
terminalto the WHT/
GRNterminal.and the
BLU/RED
WHT/RED
terminalto
the BLKterminal
momentarily.
Driver'sdoor shouldunlock.
Connectthe WHT/RED
terminalto the WHT/
G B Nt e r m i n a la, n dt h e
WHT/RED
YEUREDterminalto
the BLKterminal
momenranry.
All passengerdoorsshouldIock.
Underall conditions.
BLUI/EL
power door lockcontrolunit 12P
connectorNo.6terminaland audio
unit 16PconnectorNo.3terminal:

. P o o rg r o u n d( G 5 5 1 )
. Blown No. 51 {20A) fuse in the
Blown No. 51 (20A) fuse in the
Faultyactuator
An open in the wire
*: With keylessentry system

Reconnect
the 12Pconnectorto the powerdoor lockcontrolunit.
Cavity
Wire
Test condition
GRN/WHT
Driver'sdoor lock
switchin LOCK
GRN/ORN
Driver'sdoor lock
switchin UNLOCK
Driver'sdoor lockknob
BLU,Mr'HT in LOCK
Test: Desiredresult

Thereshouldbe 1 V or less.
Faultydriver'sdoor lockswitch
r o o r g r o u n ot ( l 5 5r ,
An open in the wire

Faultydriver'sdoor lockactuator
P o o rg r o u n d{ G 5 5 1 )
An open in the wire
ty
23-225
PowerDoor Locks
Audio Unit (KeylessReceiverCircuitl Input Test (with keylessentry systeml
Removethe audio unit,then disconnectthe A and B connecto.s(seepage23-169).
.
.

lf the terminalsare bent.looseor corroded,repairthem as necessary,
lf the terminalslook OK, makethe followinginput testsat the connector'
- lf anv test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceat.
B CONNECTOR
A CONNECTOR
AUDIOUNIT
CIRCUIT)
{KEYLESSRECEIVER
23-226
\.
v
the A and B connectorsfrom the audio unit
Disconnect
A4
lgnition switch ACC {l}


Underatl conditions

There should be continuitv.
An open in the wire
lgnitionkey inserted
into the ignitionkeY
switch

lgnition key removed

from the ignitionkey
switch

Thereshouldbe 4 V or more.
Poorground {G401.G402)
Faultyignitionkey switch
An open in the wire
Shortin the wire
Under allconditions
Checktor continuity betweenthe

audio unit 16PconnectorNo. 3 terminal and power door lockcontrol
unit 12PconnectorNo. 6 terminal:
BLfiEL
BLK
BLU/RED
B3
BLU//EL
B8
LT GRN/
BLK
814
LT GRN/
RED
B16

under-hood{use/relaybox
Blown No. 28 (10A) fuse in the
An open in the wire

Thereshould be batteryvoltage.
YEURED
BI
Possiblecauseif result is not obtaind
Underall conditions
WHTiBLU
B6
Test: Desiredresult
Test condition
Wire
Cavity
Ceiling light switch in

"middle position"
Connectto ground:
The ceilinglight shouldcome on.
Eachdoor open,one at
a Irme

Underall conditions
Connectto ground:
Horn shouldsound.
GRY


under-hoodtuse/relaybox
Blown ceilinglight bulb
Faultyceilinglight
An open in the wire
. Faulty door switch
Blown No.52 (15A) fuse in the
Faultyhorn
Faultyhorn relay
An open in the wire
the B connectoronly to the audio unit.

Reconnect
Cavity
wire
B9 GRN/ORN
8 1 0 GRN/WHT
Tsst condition
Test: Desiredresult
Driver'sdoor lock
switchin UNLOCK

Driver'sdoor lock
switchin LOCK

Driver'sdoor lock
switchin UNLOCK

Checkfo. voltageto ground:
Driver'sdoor lock
switchin LOCK
Possiblscause if r93ult is not obtaingd

Poorground(G551)
An open in the wire
Shon in the wire
Poorground (G551)
An open in the wire
Short in the wire
23-227
PowerDoor Locks
Audio Unit (keylessreceiver
circuitlTerminals
16PCONNECTOR
Cavity
Wire
B1
'B2
BLU/RE
D
lgnitionkey switch
LT GRN
Trunk latchswitch
B3
B4
*85
*87
88
B9
1.
Removethe innerhandle(seesection20).
2.
D i s c o n n e ctth e 3 P c o n n e c t o rf r o m t h e d o o r l o c k
Dsstination
BLU/YEL Unlock(Driver'sdoor)
BLU
Valetswitch
LT BLU
Security(lN)
BLK/YEL
N o . 1 4 ( 7 . 5A ) f u s e
ORN
Security(D2)
LTGRN/BLK C e i l i n gl i g h t
G R N / O R N U n l o c k( A l ld o o r )
8 1 0 GRN^r'r'HTLock(Output)
* B 1 1 BLU^ll/HT
LED O
*812
WHT/BLK Secufity(D0)
*Bl3
Driver's Door Lock Switch Test
YEUBLU

\
Terminal
I
Position
LOCK
----o
OFF
UNLOCK
Security(D1)
B l 4 LT GRN/RED Door switch

815
BLK
, 402)
G r o un d ( G 4 0 1G
GRY
HOrn
*i Forsecuritysystem(option)
DRIVER'S
DOOR
LOCK
swtTcH
Driver'sDoor LockActuatorTest
1.
Removethe driver'sdoor panel{seesection20).
2.

Disconnect
DoorLockActuatorTest
Passenger's
'1.
Remove the passenger'sdoor panel {see section

20t.
Disconnect
NOTE:The front passenger'sdoor lock actuatoris
shown;the left rear and right rear door lock actuators are similar.
v
Termin.l srdc ol
mele l.rminals
3.
Checkfor continuity between the terminals in each

knob switchpositionaccordingro the table
TerminalsideoI maletorminals
Terminal
Position
3.
LOCK
o--l
UNLOCK
4.
Checkactuator operation by con.!ct'ng power ano

ground accordingto the table.To p.went damage
to the actuator, apply battery voltage only momentarilv.
Terminal
-\
LOCK
;".ltfi
Checkactuatoroperationby connectingpower and

ground accordingto the table. To preventdamage
to the actuator,apply batteryvoltageonly momentarily.
Terminal
r-*r,r""----_\
4.
LOCK
UNLOCK
lf the actuatorfailsto work properly,replaceit
UNLOCK
{y
5.
lf the actuatorfails to work properly, .eplace it.
23-229
PowerDoor Locks
TransmitterInspection/Replacement
NOTE:
. lf the doors unlockor lock with the transmitter,but the LEDon the transmitterdoes not come on, the LEDis faulty;
replacethe transmitter.
. lf any door is open,you cannotlockor unlockthe doorswith the transmitter.
. lf you unlockedwith the transmitter,but do not open any of the doors within 30 seconds.the doors relockautomatically.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is insertedin the ignitionswitch.
Door3cannot bo locked o.
unlockedwith the transmittor.
Pressthe lock or (rnlockbutton

five or six times to r6sotthe
transmtter.
CQ
BATTERY
Replacethe transmitter battery

with a new one, and try to lock/
unlockthe doors with the trans,
mitter. Pressthe lock or unlock
button fiv6 or six times.
Rewriteand registerthe transmitter cod, then try to lock/unlock

the doors(seepage23-231).
\*
23-230
Storing of Transmitter Codes

NOTE:
(lf a fifth code is stored'the code which was
. The codesof up to four transmitterscan be stored in the control unit
storedtirst will be erased.l
. Whenthe systementersthe registrationmode,all previouslystoredcodeswill be erased'
. The systemleavesthe registrationmode and returnsto the normalmode if you
- turn the valetswitchOFF.or
- turn the ignitionswitchOFF,or
- do not Dressthe transmitterbuttonfor more than 10 seconds'
Procedure:
1. lnsertthe ignitionkev into the

ignitionswitch.
2. Turn the ignition switch ON
flr).
VALETSWITCH
Within 1Oseconds,go to step3.
ry
3. Pressand hold the valet switch

lor at leastfive seconds.
(Youwill hearthe soundof the
actuatorst! rningto UNLOCK.)
NOTE:lf the tuner is turned ON, it will

go off and come on againwhen the registrationprocedureis completed
r-r . l-r l-l

I t ' t t t l
Within 10seconds,go to steP4.
4. Pressone of the transmrtter

buttons.
(Youwill hearthe soundof the
turningto UNLOCK.)
actuators
NOTE: lf you want to registerthe codes

of more than one transmitter,repeatstep
4 within 10 secondswith the ne)dtransmitter,
NOTE:Afterstoringits code,makesure
the transmitter works properly oy
repeatedlypressingone of its buttons.
(The system starts to work when You
pressany transmitter button six times )
TRANSMITTER
23-231
SupplementalRestraintSystem (SRSI
Troubleshooting
-....'24'13
Seff-diagnosticProcedures.......
24-13
Readingthe DTC ........'.."...............'.
Erasingthe DTGMemory ...."......"' 24-15
Troubleshooting Intermittent
.'--..........24-15
Faifures
Precautions/Procedures
24-16
GenerafPrecautions...."..................21'7 SRSUnit ldentification....'..."...'..'...
DiagnosticTroubleCode (DTCI
Airbag Handlingand Storage ......".21-7
'96 - 97 Mode|s............'...
24-17
Chart2/t-8
SRSUnit Precautions....'.................
(DTCI
DiagnosticTroubleCode
lnspectionAfter Deployment '......'.24-8
'98 Model .....""""" """"" 24-19
chart 2tt-9
WiringPrecautions".....",........"......
SRSIndicatorLight Wire
Backprobing SPring-loadedLock
......24'25
Connections
.-.,....2+S
Connectors
.............24-26
Flowcharts
Spring-loadedLock Connector......'2+10
Airbag
Spring-loaded Lock Connector with
....",..24-67
Repfacement
2it-10
Built-inShortContact'......'.........
.................24-70
Disposaf
Disconnectingthe Airbag
......21-11 CableReel
Connector(s)
2+12
..."....24'72
-..--...
..
Repfacement
Steering-relatedPrecautions
21'2
..........'
SpeciafTools...
Component/WiringLocations
"""21'3
fndex .'..............
2/t-5
................
Description
..'.,,,..2+6
GircuitDiagram
SRS Unit
Repfacement
'c
\y
.'.......24-76
SpecialTools
\
Ref.No.
o
6,
@-
Tool Numbel
07HAZ07PAZ071AZ 07TAZ-
SG00400
0010100
5250200
0010204
Description
Oty
DeploymentTool
SCSServiceConnector
SRSServiceConnector{2 0)
BackprobeAdapter,17 mm
1
1
1
PageReferencs
24-70
24-' t4
24-42
24-30
*: Usewith the stackingpatchcordsfrom T/N 07SAZ- 0010004,BackprobeSet.
SRSINFLATOR
SIMULATOR
07sAz - TB4011A
SNSSMULATOR
LEAOC
07TAZ-525011A
N O T E :T h e S R S S e r v i c eC o n n e c t o {r 2 O ) ,T / N 0 7 T A Z- 5 2 5 0 2 0 0 i, s n o t a v a i l a b l eI.n s t e a d ,u s e t h e S R S I n f l a t o r
Simulator,T/N 07SAZ- T8401'lA,and the SRS Simulator Lead C, T/N 07TAZ -525011A. When the SRS Service
Connector{2 O),T/N 07TAZ- 5250200,is calledfor, connectthe leadto one of the simulator's"2 0" iacks.
Locations
Gomponent/Wiring
v
Airbag
lndex:With FrontPassenger's
SRSINDICATOBLIGHT{ln the gauge assemblv)

Troubleshooting,Page24-13
section23
GaugesssemblY,
To HORN
CABLEREEL
Replacement,
page 24-72
To ORIVER'SAIRBAG
DASHBOABDWIRE HARNESS
ro SRSINDICATORUGHT in
GAUGEASSEMBLY
5P CONNECTOR
ry
ORIVER'SAIRBAG
ASSEMBLY
Replacement,
page 24-67
Disposal,page 24-70
AIRBAG
FRONTPASSENGER'S
ASSEMBLY
Replacement,Page24-67
Disposal,Page24-70
sRSMAINHARNESS
ro CABII EEEL
2POONNECTOR
CHECK
SERVICE
{2Pl
coNNECTOn
IBRN,BLKI
SRS MAIN HABNESS

to FRONTPASSENGER'S
AIREAG
2P CONNECTOR
SBS MAIN
to UNDER.DASH
BOX
FUSE/RELAY
2PCOT{NECTOR
SRSMAINHARNESS
to sRSUttlT
18PCONNECTOR
MAIN
SRS MAIN I{ARNESS

to MAIN
WME HANNESS
3P OONNECTOR
MEMORYEMSE SIGNAL
EPI
IMES)CONNECTOR
IGRY,GRYIot [GRN,GRNI
MAINWIREHABNESS
WIREHARNESS
to DASHBOARD
24PCONNESTOR
HARNESS
SRS UNTT
{lncludingsaling snsor
and imPactsensor)
Page24-76
Replacement,
24-3
Component/Wiring
Locations
Index:Without FrontPassenger's
Airbag(Partof CANADAModel)
SRSINDICATOR
UGHT(ln the gaugeassembly)
page24-13
Troubleshooting,
Gaugeassembly,section23
DASHEOARDWIREHARNESS
tO SRSINOICATOR
LIGHTiN
GAUGEASSEMBLY
5P CONNECTOR
DRIVER'SAIREAG
ASSEMBLY
Replacement.
page2+67
Disposal,page 24-70
swtTcH
CABLEREEL
Replacement,
page 24-72
To CRUISECONTROL
sEt
swtTcH
To DRIVER'SAIRBAG
SERVICECHECK
CONNECTOR
{2PI
IBRN,BLK]
SRSMAIN HARNESS
SRSMAIN
to UNOER-DASH
FUSE/RELAYBOX
2P CONNECTOR
SRS UNIT
{lncludingsafingsensor
and impactsensor)
Replacement,page 24-76
SRSMAIN HARNESS
to SRS UNIT
18PCONNECIOR
DUMMYRESISTOR
SRSMAIN HARNESS MEMORYERASESIGNAL
io MAIN
{MESICONNECTOR
I2PI
WIRE
IGRY,GRYIo. [GRN,GRNI
HARNESS
3P CONNECTOR
24-4
Description
v
(and
seatbelt,is designedto help protectthe driver
The sRS is a saletydevicewhich,when used in conjunctionwith the
lrontpassenger)inafronta|lmpactexceedingacertainset|imit'ThesystemconsistsofthesRSunit(inc|udingsafin
(andlront passenger's
airbag)'
sensorand impactsensor),the cablereel,the driver'sairbag
ORIVER'SAIBBAG
CABLEREEL
Operation
ThemaincircuitintheSRsunitsensesandjudgestheforceofimpactand,ifnecessary,ignitesthein'|atorcharge(s
batteryvo|tageistooloworpowerisdisconnectedduetotheimpact,thevoltageregu|atorandtheback.uppowerci
will keepvoltageat a constantlevel'
respectively
Fol the SRSto operate:

to the microprocessor'
{1) The impactsensormust activate,and sendelectricsignals
signalsto the airbaginflator(s)'
must
send
and
the
signals,
mu$ compute
(2) The microprocessor
the
airbag(s)'
deploy
ignite
and
{3) The inflator(s)must
*;_--l
ff*:
+
i*wt
t
gsIF'-'"
Self-diagnosisSysiem
turned oN (ll)' the sRS indicatorlight comes
circuitis built into the sRs uniu when the ignitionswitch is
A self-diagnosis
normally
on and golesoff afteraboutsix secondsif the systemis operating
if it comeson while driving,it indicatesan abnormallf the light does not "o." on, o. do""-iot go ofi "ft", "i" ""condi, or
as possible'
itv in tn'" "y"t".. fne system must be inspectedand repairedas soon
{y
Forbetterserviceabi|ity,thememorywilIstorethecauseofthema|function.andthedataIinkcircuitpassesonthe
mationfromthememorytothedata|inkconnector(DLc)'ThisinformationcanbereadwiththeHondaPGMTester
nectedto the DLC(16P).
24-5
CircuitDiagram
IGNITION
SWITCH
UNOERHOOD
FUSE/NETAY
80X
WHT/BIK
+-WHT
UNDEROASH
FUSE/RELAY
BOX
SRSINDICATOR
CIBCUIT
{lnthegauge
assmblyl
SRSINOICATOR
t-tGHT
t1.4W)
Bfakesystmlight
passenge/s
airbag
p8ssnger's
aib8g
[**-*i-l
BLKffEL
PGM-FI
DRIVER'S
AIRBAG
INFLATOR
I lfrsEsATGE*s
I
rNFr.AroR
! sytru%,
I Ii /
- \ i
BLK
16
GRY
(GRN}
GRY
IGRN}
10
14
13
17
6
SRS
UNIT
15
GRY
IGBN)
LT8LU
I
G401
G402
24-6
ti
G80t
TIVA)
t8
GRY
IGRN)
BRN
t
t
8RN
f7
l
l
t.rTl
DATATINK
ECM/PCMSERVICE
CONNECTOR
CHECK
{DLC)(16P)
CONNECTOR
t " " t
MEMORY
ERASE
(MES)
SIGNAL
CONNECTOR
I2PI
SRSUNITTERMINALS
Teminalsideof lnaleierminals
3{VB)
res
Precautions/Procedu
v
GeneralPrecautions
Carefullyinspectany SRSpart before you install it Do
not install any part that shows signs of being dropped
or improperly handled,such as dents, cracksor defor-
maI|on:
- Airbagassemblies
- Cablereel
- S R Su n i t
Airbag Handlingand Storage

the airbagassemblylt has no
Do not try to disassemble
parts.
airbag has been operated
an
Once
serviceable
(deployed),it cannotbe repairedor reused.
Fortemporarystorageof the airbagassemblyduringser
vice,pleaseobservethe followingprecautions:
Storethe removedairbagassemblywith the pad surface up. The driver's {and front passenger's)airbag
connector(s)has (have)a built-in short contact{see
page24-11J.
r the airbagis improprlYstored face down,

!!@
i6ilEftil?eptoyment could propel the unit with enough
Iorceto causeserious iniurY.
r Use only a digital multimeterto checkthe system lf

it's not a Honda multimeter,make sure its output is
1OmA (0.01A) or lesswhen switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
output could damagethe airbagcrrcultor causeaccldentaldeploymentand possibleiniury.
) Do not install used SRS parts lrom anothervehicle
When makingSRSrepairs,useonly new pans'
AIRBAGCONNECTORS
{Withbuilt'inshortcontact)
r E x c e p tw h e n p e r f o r m i n ge l e c l r i c a il n s p e c t i o n s ,
alwaysdisconnectboth the negativecableand positive cable from the battery,and wait at least three
minutesbeforebeginningwork.
. R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r /
w a s h e rs w i t c h e sa n d c r u i s ec o n t r o l s w i t c hc a n b e
donewithout removingthe steeringwheel:
-
{y
F o r c o m b i n a t i o nl i g h t a n d w i p e r w a s h e rs w i t c h
seesection23
replacement,
For cruisecontrolsevresumeswitch replacement,
seesection23.
Wheneverthe ignition switch is ON tllr, or has been

turned OFFfor lessthan three minutes be carefulnot
t o b u m pt h e S R Su n i Ut h e a i r b a g ( sclo u l da c c i d e n t a l ly deployand causedamageor injury'
Store the removedairbagassemblyon a secureflat

surfaceawav from any high heat source(exceeding
and free of any oil, grease,detergentor
212'Ft1OO"CI
water,
CAUTION: lmproper handling ot storage can internally

damagethe airbag assembly,making it inoperative'
lf you suspeqtthe airbag assembly has been damagGd,
install a new unit, and refer to the Deployment/Disposal
proceduresfor disposingof the damaged airbag.
. Whenever the airbag(s)has(havelben activated,

reolacethe SRSunit.
24-7
Precautions/Procedu
res
SRSUnit Precautions
Takeextracarewhen paintingor doing body work in
the area belowthe dashboard.Avoid directexposure
o f t h e S R Su n i t o r w i r i n gt o h e a tg u n s ,w e l d i n g ,o r
sprayingequipment.
D i s c o n n e ctth e a i r b a gc o n n e c t o r ( sb) e f o r ed i s c o n nectingSRSharnessconnectors(seepage24-11l,.
After any degreeof frontal body damage,or after a
collisionwithout airbagdeployment,inspectthe SRS
unit for physicaldamage.lf it is dented,cracked,or
deformed,reDlaceit.
Be surethe SRSunit is installedsecurely.

Do not disassemble
the SRSunit.
Store the SRS unit in a cool (lessthan about '104.F/
40'C)and dry (lessthan 80% humidity,no moisture)
place.Do not spill water or oil on the SRS unit, and
keepit awayfrom dust.
During installationor replacement,be carefulnot to
bump (impactwrench,hammer,etc.)the areaaround
the SRSunit. The airbag(s)could accidentally
deploy
and causedamageor injury.
24-8
\
lnspectionAfter Deployment
A f t e r a c o l l i s i o n i n w h i c h t h e a i r b a g ( s )w a s ( w e r e )
deployed,replacethe SRSunit,and inspectthe following:
l.
Inspectall the SRS wire harnesses.ReDlace,

don't
repair,any damagedharnesses.
2.
Inspectthe cablereelfor heatdamage.lf thereis any

damage,replacethe cablereel.
3.
A f t e r t h e v e h i c l ei s c o m p l e t e l yr e p a i r e dt,u r n t h e
ignitionswitchon, lf the SRS indicatorlight comes
on for aboutsix secondsand then goes off. the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting.
I
v
Wiring Precautions
.
Neverattemptto modify,spliceor repairSRSwiring

NOTE:SRSwiring can be identifiedby specialyellow
outer Protectivecovering.
Lock
BackprobingSPring-loaded
Connectors
.
When checkingvoltageor resistanceon this type of

to removethe
connectorthe first time, it is necessary
wire side
probes
the
from
retainerto inserttester
NOTE: lt is not necessaryto reinstallthe removed
retainer;the terminalswill stay lockedin the connec
tor housang.
Be sureto installthe harnesswiresso that they are not

Dinchedor interferingwith otherparts.
RETAINER
* Discardafterremoval.
v
To removethe retainer,insert a flat tip screwdrtver
betweenconnectorbody and retainer,and carefully
pry out the retainer'
NOTE;Takecarenot to breakthe connector'
RETAINER
FLATTIP
SCREWDRIVER
M a k e s u r e a l l S R S g r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-tometalcontact.Poor groundingcan causeintermittent
Droblemsthat are difficultto diagnose.
RETAINER
24-9
Precautions/Procedu
res
Spring-loadedLock Connector
SomeSRSsystemconnectorshavea spring-loaded
lock.
Disconnecting
To releasethe lock,pull the spring-loaded
sleevetoward
the stopwhile holdingthe oppositehalfof the connector.
Thenpull the connectorhalvesapart.
N O T E : B e s u r e t o p u l l o n t h e s l e e v ea n d n o t o n t h e
connectorhalf.
SPRING.LOADED
SLEEVE
Spring-loadedLock Connectorwith
Built-in Short Contact
The driver's airbag (and front passenger.s)airbag has
( h a v e )a s p r i n g - l o a d e d
l o c k c o n n e c t o rw i t h a b u i l t - i n
short contact.When this connectoris disconnected.
the
p o w e r t e r m i n a la n d t h e g r o u n dt e r m i n a li n t h e a i r b a g
connectorare automatically
shorted.
Conneqtothalves disconnected:
GROUNOTERMINAL
D o n o t p u l l o nt h i s
halfot the connector.
Connecting
1.
Holdthe pawl-sideconnectorhalf,and presson the

backof the sleeve,side
connectorhalf in the direction
shown. As the two connector halves are pressed
together,the sleeveis pushedbackby the pawl.
SHORTCONTACT
NOTE:Do not touch the sleeve.
CASLEREELCONNECTOR
Connegtor halves connected:

GROUNDTERMINAL
Whenthe connectorhalvesarecompletelyconnected.
the pawl is released,and the spring loadedsleeve
locks the connector.
| 24-1O
It
SPRING-LOAOED
SLEVE
the AirbagGonnector(s)
Disconnecting
disconnect the nogltiv! blttrty

To provant accidenlal ai.bag dsploymsnl, turn the ignition switch oFF'
!u@
..lt-.. and wait th,ee minutes before disconnectingany sRs connostors'
(C' D)'
the SRSmain harness(A)from the SRSunit' disconnectboth airbaqs
Beforedisconnecting
(C)'
2P
connector
airbag
(B),
the
driver's
disconnect
nector
the cablereel2P con
Beforedisconnecting
.
.
1.
2.
Disconnectthe negativebatterycable,and wait at

leastthrse minutes.
the airbagconnector(sl.
Disconnect
Driver's Side:
.
Removethe accesspanel from the steeringwheel,

then disconnectthe driver'sairbag2P connectorand
cablereel2Pconnector.
AOCESSPANEL
{y
Front Passonger'sSids:
.
Removethe glove box.then disconnectthe front passenger'sairbag2P connectorand SRSmain harness

2P connector.
Precautions/Procedu
res
Steering-related
Precautions
SteoringWheel and Cable ReolAlignment
SteeringColumn Romoval
NOTE:To avoid misalignmentof the steeringwheel on

reassembly,make sure the wheels are turned straight
aheadbeforeremovingthe steeringwheel.
GAUTION:
. Betoro rmoving the steering column. first disconnect tho connector between ihe cable 1a9l and tho
SRSmain harness.
. lf the steering column is going to be removed without dismounting the stering wheel, lock the stecr.
ing by turning the ignition key to o-LOCKposition. or
remove the key from the ignition so thal lhe steering
whed will not turn.
Rotatethe cablereelclockwiseuntil it stops.

(approximately
Then rotateit counterclockwise
two and
a halfturns) until the arrow mark on the cablereel label
pointsstraightup.
NOTE:
When the airbagassemblyand cablereel are disconnected.and the batteryis reconnectedand the ignition switch is turned ON (ll), the SRS unit will store
this as an open in the driver'sairbaginflator,and the
S R S i n d i c a t o rl i g h t w i l l c o m e o n , I n s u c h a c a s e .
make sure to confirm the DTC,then clear the SRS
unit memorv.
For disconnectingthe spring-loadedlock type connector, refer to page24-10.
ARROWMARK
SRSMAINHARNESS
2PCONNECTOR
Do not replacethe originalsteeringwheelwith any other
d e s i g nb e c a u s ei t w i l l m a k e i t i m p o s s i b l et o p r o p e r l y
installthe airbag(only use genuineHonda replacement
parts).
After reassembly,confirm the wheels are still turned
straightaheadand that the steeringwheel spokeangle
is correct.lf minor spokeangleadjustmentis necessary,
do so only by adjustingthe tie-rods,not by removing
and repositioning
the steeringwhee..
24-12
\)
Troubleshooting
Y
Procedures
Self-diagnostic
to storethis intormafunctionof the sRs systemallowsit to locatethe causesot systemproblemsand
The self-diagnostic
this datacan be retrievedvia a data link circuit'
tion in mem-ory.Foreasiertroubleshooting,
.whenyouturntheignit|onsw|tchoN(||},thesRsindicatorwi||comeon.|fitgoesoffattersixseconds,thesys
normar.
in memory.and turns
. lf there is an abnormality,the systemlocatesand definesthe problem,storesthis information
thesRsindicator|ighton.Thedatawi||remaininthememoryevenwhentheignitionswitchisturnedof'orif
tery is disconnected.
(2P),and turn the ignitionswitch oN (ll)'
. when you connectthe scs serviceconnectorto the sewicecheckconnector
(DTC)by the numberol blinks'
the SR3 indicatorlight will indicatethe diagnostictroublecode
for this code'
troubleshooting
proceed
with
the
the
DTC,
recording
. After readingand
Precautions
its outputis 10 mA (0.01A)
. Useon|y a digita|mu|t|meterto checkthe system.|f it,s not a Hondamultimeter,makesure
with a higher output could damagethe
or lesswhen switchedto the smallestvalue in the ohmmeterrange.A tester
airbagcircuitor causeaccidentalairbagdeploymentand possibleiniury'
be caretulnot to bump the
r Wheneverthe ignitionswitchis oN (ll),or has beenturned oFF for lessthan three minutes,
injuries'
or
damage
cause
and
deploy
SRSunit;the airbagscould accidentally
airbag
(and the front passenger's
. Beforevou removethe sRS main harness,disconnectthe driver'sairbagconnector
connector).
measuringvalueswon't be
. Make surethe batteryis sufficientlycharged(seesection23). lf the batteryis dead or low,
.
correct.
and do not connectthe terminals
Do not touch a testerprobeto the terminalsin the sRS unit or harnessconnectors,
with a jumperwire. Useonly the backprobeset and the SCSserviceconnector'
locktype connectors,referto page24-9'
For backprobingspring-losded
Readingthe DTC
Whenthe SRSindicatorlight is on, readthe DTCusingone of thesemethods:
(DLC),and follow the tester'sprompts' lf the tester

A. Connectthe HondaPGM Testerto the 16PData Link Connector
indicatesnoDTc,doub|e-checkbyjumpingtheservicecheckconnectorandwatchingthesRsindicator
next page).
HONDAPGMTESTER
{16P)
DATA LINKCONNECTOR
2+1'
Troubleshooting
B . The SRSindicatorlight can also indicatethe DTCby the numberof blinkswhen the SCSserviceconnectoris connected to the servicecheckconnector{2P}.
1 . Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck
connector(2P).lf you do not wait ten seconds,the SRSunit will not be completelyresetand will not output DTCS.
SERVICE
CHECK
(2PI
CONNECTOR
IGRY,GRYIor [GRN,GRNI
SCSSERVICECONNECTOR
07PAZ- (x)101(xt
Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand goesoff. Then it will indicate the DTC:
- The DTCconsistsof a main code and a sub-code.
- Includingthe most recentproblem,up to three differentmalfunctionscan be indicated.
- In caseof a continuousfailure.the DTCwill be indicatedrepeatedly(seeexample1 below).
- ln caseof an intermittent
failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexarnple 2 below).
- lf both a continuousand an intermittentfailureoccur,both DTCswill be indicatedas continuousfailures.
* In casethe systemis normal{no DTC},the SRSindicatorlight will stay on (seeexample3}.
Readthe DTC.
Turn the ignitionswitch OFF,and wait for ten seconds.Then disconnectthe SCSserviceconnectorfrom the service
checkconnector{2P).
Ex8molosof DTCIndications:
1.
Continuousfailure,SRSIndicatorLight is:
[.- , s --]
- l1'"*0" f - . f -
- l F M.in.ods
ll)
Sub,code l2l
-4
t-
Main cod. (l)
--t F
Sub.cod. (1)
!._.--!-
oTc r.2
DTC2.1
Mosr rocntp.obt.m
D T Cr . 1
Thnd moll r66.t
Intermittentfailure,SRSIndicatorLightis:
l-ight 3rry3 on in e$
oTc5.1
3.
Normal(no failure),SRSIndicatorLight is:
ot
\"
g Intermittent
Troubleshootin
Failures
Erasingthe DTCMemorY
To erase the DTC(s)from the SRS unit, use a Honda
P G M T e s t e r{ s e et h e H o n d aP G M T e s t e rS R Sv e h i c l e
SystemSupplement)or the followingprocedure'
1.
2.
Makesurethe ignitionswitchis OFF

Connectthe SCSserviceconnectorto the MES connector(2P).Do not usea iumperwire
I L
&
MEMORYEMSE
{2PI
SIGNAL{MESICONNECTOR
IGRY,GRYIor [GRN,GRNI
coruruscron
ics senvtce
07PAZ- 0010100
lf therewas a malfunction,but it doesn'trecur,it will be

storedin the memory as an intermittentfailure.and the
SRSindicatorlight comeson.
After checkingthe DTC,troubleshoot as tollows:
1.
"Readingthe DTc")
Readthe DTC(see
2.
" E r a s i n gt h e D T C
E r a s et h e D T C m e m o r y ( s e e
Memory").
3.
With the shift leverin neutral,turn the ignitionswitch

ON (ll),and let the engineidle.
4.
The SRSindicatorlight comeson for about six seconds and goes off.
ON
--

The SRSindicatorlight comeson for aboutsix seconds and goes off. Removethe SCS serviceconnector from the tat "onn"61or{2P)within four seconds
after the SRSindicatorlight went off.
5. The SRSindicatorlight comeson again Reconnect
the SCS service connectorto the MES connector
{2P)within the four secondsafterthe SRSindicator
light comeson.
The SRS indicatorlight goes off. Removethe SCS
(2P)
s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o '
within four seconds
7 . The SRSindicatorlight indicatesthat the memory ls
erasedbY blinkingtwo times.
Turn
the ignition switch oFF, and wait for ten sec8.
onds.
6.oc l<-
I
-J
3.
4 sec or less
Blinkiog
stay on.
--l ** F
::ff
Problemrecurs,light staYson'
L .--
lt|Il
SRS indic.tor
figlrr
MES
connactoi
to.minal!
Shakethe wire harnessand the connector,take a test

quick braking,cornering),
drive (quickacceleration,
fully left and right,and
wheel
and turn the steering
to find the cause
seconds
ten
five
to
for
it
there
hold
of the intermittentfailure
l f t h e p r o b l e mr e c u r s t, h e S R Si n d i c a t o rl i g h t w i l l
CONNECTED
failure.the sYslf you can't duplicatethe intermittent

tem is OK at thistime.
DISCONNECTED
24-15
Troubleshooting
SRS Unit ldentification
*: On '98 models,the troubleshootingprocedures
are differentfor eachtype of SBS unit. ldentifythe SRSunit in the vehicle usingthe chartbelow,then follow the properflowchartin the followingpages.
'98 Model
SRSunits
MAKER
NEC
KEIHIN
SIEMENS
PARTSNUMBER
IDENTIFICATION
MARK*
Remark
77960-S04-A91
[/41
Driver'ssideSRSairbagonly
7 7 9 6 0 ,S 0 4- N 9 1
M1
Driver's& Passenger's
side
SRSairbag
77960-S04-N91
M2
side
SRSairbag
77960-S02-A82
M3
side
SRSairbag
'96 - 97 Models
SRSunits
MAKER
PARTSNUMBER
Remark
77960-S04-C81
Driver'ssideSRSairbagonly
77960-S04-N8l
side
SRSairbag
TAKATA
77960-S04-N82
side
SRSairbag
SIEMENS
77960-S02-A81
side
SRSairbag,'97 Modelonty
NEC
24-16
-'96 - 97 Models
DiagnosticTroubleCode (DTC)Chart
FaultySRSindicatorlight circuit
Faulty SRS indicator light circuit, internal
failure of SRS unit.Iaulty SRS power supply
1-1
ODenin the driver'sairbaginflator

in the driver'sairbag
lncreasedresistance
inflator
Troubleshooting
Shortto anotherwire in the driver'salrbag

inflatoror decreasedresistance
Shortto Dowerin the driver'sairbaginflator
Shortto groundin the driver'sairbaginflator
airbag:
With front passenger's
airbaginflator
Open in the passenger's
airbag:
Withoutfront Passenger's
reslstor
dummy
in
the
Open
airbag:
airbag
in the passenger's
lncreasedresistance
inflator
airbag:
dummy reslstor
in
the
resistance
lncreased
airbag:
Shortto anotherwire in the passenger's
airbaginflatoror decreasedresistance
airbag:
dummy reslstor
in
the
wire
another
to
Short
or decreasedresistance
airbag:
airbag
Shortto power in the passenger's
inflator
airbag:
Shortto power in the dummy resistor
airbag:
With front Passenger's
airbag
Shortto ground in the passenger's
inflator
airbag:
Shon to ground in the dummy resistor
(cont'd)
24-17
Troubleshooting
DiagnosticTroubleCode (DTCIChart-'96 -'97 Models (cont'dl
SRSindicatorlight
DTC
Possiblecause
Correctiveaction
See page
5-1*'
Internal failure of the SRS unit
S R Su n i t
repracement
2 41 6
lnternalfailureof the SRSunit
SRSunit
reptacemenl
24-16
Internalfailureof the SRSunit
S R Su n i t
replacement
24-76
SRSunit
replacement
24-76
Internalfailureof the SRSunitor two failu.esat a

time
Troubleshooting
24-62
Internalfailureofthe SRSunit
S R Su n i t
replacement
24-76
S R Su n i t
repracement
24-16
FaultySRSpower supply(VBline)
Troubleshooting
24-64
SRSunit replacement
code (SRSunit must not
be usedany longer)
S R Su n i t
replacement
2476
5 4
6-1
6-2
6-4
7-2
comeson
8-1
8-2
8-3
8-4
8-5
8-6
8-6*3
10-1
NOTE:
*11In caseof an intermittentfailureDTC9-1,it meanstherewas
an internalfailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting
for intermittentfailures(seepage24-15).
*2: lt both DTC9-2 and DTC5-1 are indicated,do the troubleshooting
for DTC9-2.
*3: Apply to the '97 modelcoupeHX and DX.
*4: DTCcannotbe readwith a HondaPGMTester;checkby jumping
the SCSserviceconnector.
DiagnosticTroubleCode(DTC)Ghart-'98 Model
NECSRSUnh
none*. I FaultySRSindicatorlight circuit,internal
(doesn't I fallureolsRs unit.JaultvSRSpowersupply
No DTC'r
{li9ht
comes on
Faulty SRS power supply (VA line)
Troubleshooting
Openin the driver'sairbaginflator

in the driver'sairbag
lncreasedresistance
inflator
Shortto anotherwire in the driver'sairbag
inflatoror decreasedtesistance
Shortto power in the driver'sairbaginflator
Troubleshooting
Shortto ground in the driver'sairbaginflator

airbag:
airbaginflator
Openin the passenger's
airbag:
resistor
dummy
in
the
Open
airbag:
airbag
in the passonger's
lncreasedresistance
inflator
airbag:
in the dummy resistor
lncreasedresistanc
airbag:
Shon to anotherwire in the passengers
airbag:
Withoutfront passenger's
Shortto anotherwire in the dummy reslslor
or decreasedresistance
2-4
2-5
Troubleshooting
24-52
24-59
airbag:
I With front Passenger's
airbag
o.t to power in the passenger's
St
I
inflator
airbag:
Withoutfront passenger's
Shortto power in the dummy resistor
airbag:
With front Passenger's
airbag
passenger's
the
ground
in
Shon to
Inialor
airbag:
tvnhout front Passenger's
Shortto ground in the dummy resistor
v
(cont'd)
24-19
Troubleshooting
DiagnosticTroubleCode(DTC)Chart-,9g Model (cont,dl
SRSindicator light
DTC
5-1
5-4
Possiblecause
Correctiveaction
Ses pago
SRSunit
repracement
24-16
S R Su n i t
replacement
24-76
5l|5 Unrt
replacement
24-76
SRSunit
repracement
24-76
Internalfailureof the SRSunit or two failures

at a time
Troubleshooting
24-62
SRSunit
reptacement
24-16
Internalfailureof the SRSunir
SRS unit
reptacement
24-76
SRSairbagsdeployed(SRSunit must be
replaced)
SRSunit
reptacement
24-76
6-1
o-J
6-4
7-2
comeson
8-1
a-2
8-6
9-2*' *1
l0-1
NOTE:
r1: In caseof an intermittentfailureDTC9-1,it meansthere
was an internaltailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting
for intermittentfailures(page24-15).
+2:In caseof an iniermittentfailu.e DTc 9-2, it meansthere was
an internalfailureof the power supply(vB line).Do the
troubleshooting
for intermittentfailures.
*3: DTCcannotbe readwith a HondaPGMTester;check jumping
by
the SCSserviceconnector,
KEIHINSRS Unit
SRSindicator light
doesn'tcome on
DTC
none
(doesn't
come on)
none*3
(doesn't
go off)
1-1
1-3
1-4
comeson
1,5
2-3
ry
2-5
Correctivesction
Ses page
Troubleshooting
24-26
FaultvSRSindicatorlight circuit,internal
failureoJSRSunit,taultySRSpower supply
(VB line)
Troubleshooting
24-34
Possiblecause
24-42
Open in the driver'sairbaginflator

lncreasedresistancein the driver'sairbag
inflator
Short to another wire in the driver's airbag
inflator or decreased resistance
24-12
Troubleshooting
24-44
Shortto power in the driver'sairbaginflator

24-46
airbaginflator
airbag
lncreasedresistancein the passenger's
inflator
Shon to anotherwire in the passenger's
24-50
airbag
inflator
airbag
Shortto groundin the passenger's
inflator
24-48
24-50
Troubleshooting
24-52
24-54
24-56
v
(cont'd)
24-21
'...-'--.
Troubleshooting
DiagnosticTroubleGode(DTG)Ghan-'98 Model {cont,d}
sRs indicarortighr I
DTc
Possiblocause
Correstiveaction
See page
5-1
lnternalfailureof the SRSunit
S R Su n i t
replacement
24-76
SRSunit
replacement
24-76
SRSunit
replacement
24-76
SRSunit
replacement
24-76
9 - 1 + 1* 3
-rI5 untr
replacement
24-76
9-2*, *3
SRSunit
replacement
24-76
reolaced)
SRSunit
replacement
24-76
5-3
5-4
6-2
6-3
6-4
comeson
1-3
8-'l
8-2
8-6
10-1
NOTE:
*l: In caseof an intermittentfailureDTCg-1,
it meansthere was an internalfailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting
for intermittentfailures(page24_15).
*2: In caseof an intermittentfairure
DTc 9-2, it meanstherewas an internarfairureof the power suppry(vB rine).Do the
troubleshooting
*3; DTCcannotbe readwith a HondapGM
Tester;checkby jumpingthe SCSserviceconnector.
24-22
-'-'.-
.J
SIEMENSSRSUnit
SRSindicator light
doesnt come on
Possiblecause
DTC
none
(doesn't
c o m eo n )
none*, I FaultySRSindicatorlight circuit,internal

(doesn't failureof SRSunit,faulty SRSpowersupply
(VBline)
go off)
Openin the driver'sairbaginflator
1,1
1-4
comeson
1'5
2-1
zr
t-4
2-5
Shortto anotherwire in the driver'sairbag

inflatoror decreasedresistance
Shortto oower in the driver'sairbaginflator
Correctiveaction
SeL page
Troubleshooting
24-26
Troubleshooting
24-34
24 42
24-44
Troubleshooting
24 46

airbaginflator
24-44
Shortto anotherwire in the passenger's

airbag
24-52
24-50
Troubleshooting
24-54
rnltaror
alrbag
Shortto ground in the passenger's
inflator
24-56
l/
(cont'd)
24-23
Troubleshooting
DiagnosticTroubleCode {DTC)Chart-'98
SRSindicatorlight
DTC
5-l
Model (cont'dl
Possiblecause
See pago
S R Su n i t
replacement
24-76
Internalfailureof the SRSunir
S R Su n i t
replacement
24-76
S R Su n i t
replacement
24-76
a-2
Internal failure of the SRS unit
SRSunit
reptacement
24-76
g _ l* r * 3
S R Su n i t
reptacement
24-76
9-2*2 *3
l n t e r n afla i l u r eo f t h e S R Su n i t
SRSunir
replaced)
SRSunit
replacement
5-4
6-4
7_?
comeson
Correstiveaqtion
8-1
10-1
replacement
24-76
24-76
NOTE:
"1: ln caseof an intermittentfailure
DTC9-1,it meansthere was an internalfailureof the SRSunit or a faulty SFS indicator light circuit.Do the troubleshooting
for intermittentfailures{page24-15).
*2: In caseof an intermittentfairureDTc g-2,
it meanstherewas an internarfairureof the power suppry(vB rine).Do the
troubleshooting
*3: DTCcannotbe readwith a HondapGN4
Tester;checkby jumpingthe SCSserviceconnector.
24-24
SRSIndicatorLightWire Connections
SRS Indicator Light Power Circuit
WIREHARNESS
OASHBOARO
C508 -+
To GAUGEASSEMBLY
To UNOER-DASH
BOX <_
FUSE/RELAY
2OPCONNECTOR
C411, C412 : Torminalside of mslo trminsls

csor. csoz, csog. c801, c802, c8o7 : wire sidoot f.male to'minals
SRS Indicator Light Control Cilcuit

To SRSUNIT
tI
a.j
MAIN WIREHARNESS
SRS MAIN HARNESS
GRY
IGRN)
8LU
c411
GRY
|GRN)
I
|
_ _ - lI l
+f;I? csol
t--qt
I
To GAUGEASSEMBLY
To UNDER-DASH
BOX
FUSE/RELAY
2P CONNECTOR
2OPCONNECTOR
WIREHARNESS
CsO1 : DASHAOARD
CSO8 : DASHBOABDWIREHARNESS5P CONNECTOR
CONNECTOR
C8O'l : SRSMAIN HARNESS2P
'l8P CONNECTOR
C8O7 : SRSMAIN HARNESS
C8O2 : SRSMAIN HARNESS3P CONNECTOR

3P CONNECTOR
C412 : MAINWIREHARNESS
24P CONNECTOR
c411 : MAINWIREHARNESS
C5O2 : DASHBOARDwlRE HARNESS2rtP CONNECTOR
24-25
Troubleshooting
TheSRSIndicatorLight Doesn'tGomeOn
CAUTION:Wheneverthe ignition switch is ON (lll. or
has been turned OFF tor less than three minutes, be
caretul not to bump the SRS unit; the airbag(s)could
accidentally
deployand causedamageor iniuries,
Checkthe power supply llu3e):
Turnthe ignitionswitchON (ll),and checkwhetherthe other
indicatorlightscome on or not {brakesystem,etc.).
Do the other indicator lights como on?
YES
NO
Checkihe fuse:
Checkthe No.25 (7.5Alfuse in the undeFdashfuse/relav
box.
ls th6 fuse OK?
YES
NO
))
Checktho bulb:
Replacethe No. 25 (7.5 A) Iuse, and checkthat the
SRSindicatorlightcomeson.
Doesthe SRSindicalor liqht come on?
I YES
No
END
Checkthe wir harnessbetween fuse and gauge assemblyl
Checkfor an open in the wire harnessbetween fuse
No. 25 {7.5A) and the gaugeassembly,and repair.Check
that the sRs indicatorlaghtcomeson.
Doe3the SRSindicator liqhl come on?
II yEs
No
END
Checkth SRSindicato.lightbutb:
2, Removethe gaugeassembly,
3. Checkfor blownSRSindicatorliohtbutb.
ls the SRSindicator light butb OK?
YES
NO
Checkthe SRSindicatorlight circuit:

R e p l a c et h e b u l b , a n d r e c o n n e ctth e g a u g ea s s e m b l y
connectors.
Thenturn the ignilionswitchON (tl).
Doesthe SRSindicator light come on?
YES
No
:ND
lAl ro page24-27
I
$
24-26
lBl10 page24-27
No. 25 (7.sAl FUSE
J
Frompage24-26
(A)
Frompage24-26
(B)
DASHBOARDWIBEHARNESS
Chockthe SRSindicator light circuit:

1. Disconnectthe dashboardwire harness5P connoctor
from the gaugeassembly
2. Connecta voltmeterbetweenthe No l terminal(+) of
the 5Pconnectorand ground
3. Turnthe ignitionswitchON (ll).and measure
ls there 8.5 V or lgsi tor six soconds aftor the ignition
switch has beon tumed ON
F ulty SRS indicitor light circuit in th6 gauge a$embly;

rplace the SRS plinted circuit board in the 93uge
v
Chsckth. wir6 harnessot the SRSindicator light circuit ll l:
2, Disconnectthe main wire harness24P connectorfrom
the dashboardwire harness
3. Connecta voltmeterbetweenthe No 5 terminal {+) of
the mainwire harness24Pconnectorand ground
4. Turnthe ignitionON {ll),and measurevoltage
ls there 8.5 V or less for six seconds after the ignition
switch has beentumed oN llll?
MAIN WIREHANNESS
Short to Dowor in the BLU wire ot the dashboard wire
DASHBOARDWIRE
HARNESS2iIP
CONNECTOR
To page 24-28
c411
(cont'd)
24-27
Troubleshooting
The SRS Indicator Light Doesn't Come On (cont'dl
Frcm page24-27
Checkth wire harnessotthe SRSindicator light circuit (2):

2. Disconnect
the SRSmain harness3P connoctorfrornthe
main wire harness,
3. Connecta voltmeterbetweenthe No. 1 terminal(+) of
the SRSmain harness3P connectorand ground.
4. Turnthe ignitionswitchON (ll),and measurevoltage.
ls there 8.5 V or less tor six seconds .tter the ignition
switch has ben turnod ON llll?
Shori lo powq in the BLU wire of lhe main wirs hrnolis:
SRSMAIN HARNESS
3P CONNECTOR
c802
SRSUN]T
Checkthe wire harnossofthe SRSindicator circuit 13)i

'L Turn
2. Disconnectthe battery nagative cable, then the positive
cable.and wait threeminutes.
3. Disconnectthe drivor's(andfront passenger'slairbagconnecto(s)(s6epage2+11).
4. Disconnectthe SRS main harness18p connectorfrom
the SRSunit.
5. Connecta voltmeler betweenthe No. 6 terminal (+) ol
the SRSmain harness18Pconnectorand ground.
6. Turn the ignitionswitchON (ll),and measu.evoltage.There
shouldbe 0.5V or less.
SRSMAIN HARNESS
16PCONNECTOR
SRSMAIN HARNESS18PCONNECTOR
SRSunit; roplacotho unit (seepaq6 2+
Short to power in the BLU wire of the SRS main harne$:
24-28
The SRSIndicatorLight Doesn'tGo Off -'96
-'97 Models
CAUT|oN:whengve'theignitionswitchisoN(l|},olhasbeenturnedoFFfor|ossthanthreeminutes,becarolu|notto
or iniuries'
bump the SRSunit; the airbag(slcould accidentallydeploy and causedamage
Try to reproducotho SRSindicator light:
1. Erasethe DTCmemory (seepage24'15)
2. Turn the ignitionswitch OFF,and wait for ten seconds'
3. Turn th ianitionswitchON lll), and checkthat the SRSindicator lighicomes on for about slx seconds and goes otf
Doesthe SRSindicator light stay on?
lntelmittent lailur6, sYstem is OK at lhis time See

Intormittent Failuroson Page2{_15.
ch6ck th6 No. 13 115Al .nd No. 23 (10 Al tuses:

N o . 1 3( 1 5A ) a n dN o . 2 3( 1 0A ) f u s e si n
2. Checkfortlown
fusekelaYbox.
the under-dash
v'
Replacathe fuses, and erasethe memory

L Replacethe luses.
2. Connectthe SCSserviceconnectorto the MES connector,
3. Erasethe DTCmemory(seepage24-15)
the SCS
4. Turn the ignitionswitchOFF,then disconnect
seryiceconnectorfrom the MES connector'
5. Turnthe ignitionswitchON lll)
Doesth. SRSindicator light go ofl aftol six soconds?
No. 13 (15Al FUS
SBS UNIT
SRSMAIN HARNESS
YES
Confirm tho OTC,snd continuo

Checklo. an open in the SRSmain harnoss{vA lino}:
1. Turn the ignitionswitchOFF
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes
3. Disconnectthe driver's (and Iront passenger's)airbag
(seePage24_11).
connector(s)
4. Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
a voltmeterbetweenthe No 7 terminal (+) of
6. Co-nnect
the SRSmain harnoss18Pconnectorand groLlno
7. Turnthe ignitionswitchon
SRSMAIN HARNESS18PCONNECTOR
To page 24-30
ODonin th6 SRS main harne3slvA linol; roplacethe SRS
v
(cont'd)
24-29
,_
Troubleshooting
The SRS Indicator Light Doesn't Go Off -'96
- 97 Models (cont'd)
From page 24-29

(A)
SRSUNIT
SRSMAIN HABNESS
18PCONNECTOR
Checkthe SRSunit:
Connectthe SRSmain harness'l8PconnectorterminalsNo.
6 and No.7 with a iumoerwire and
Faulty SRSunit or pool contact at tho SRSmain harness

18Pconnector;chockthe connoctor.
lfth connectoris OK, replacethe SRSunit.
07TAZ- @1020A
JUMPERWIRE
Wiresideot fsmaleterminals
OASHBOARDWIRE HARNESS
Frompage24-30
{B)
Chockthe SRSindicator circuit:

1. Turnthe ignitionswitchOFF
2. Removethe gaugeassemblY
the dashboardwire harness5P
NOTE:Do not disconnect
connectorfrom the gauge assembly
4. Connectthe dashboardwire harness5P connectorterminalsNo. 1 and No 5 with a jumperwire.
Do.s the SRSindicator light go otff
y;T7f;V4csoe
Llr.-L_v)fr
Fsulty SRS indic.tor light circuit in the g.uge ts3embly;

replace the SRS printed circuil board in the gauge
BLU
IYEL
JUMPERWIRE
wire.sideof female
termlnals
DASHBOARDWIREHARNESS
Check to. a short to ground in rhe SRS indicator light circuit:

2. Disconnectthe dashboardwire harness5P connector
3. Checkresistancebetweenthe No. 1 terminal ot the dashboardwire harness5P connectorand ground.Thereshould
be 1 Mo or more.
7o page 24-32
Checkfor an oDenin th6 SRSindicttor light circuit:

betweenthe No 6 terminalof the SRS
1. Checkresistance
main harness18Pconnectorand No 1 terminalof the
dashboardwire harness5P connector;there should be
0 - 1 . 00 .
Wire side of female

Iermtnats
SRSMAIN HARNESS
,I8PCONNECTOR
(D)
To page24-33
a.t
(E)
To page24-33
DASHBOARDWIRE HARNESS
5P CONNECTOR
{cont'd}
24-31
Troubleshooting
The SRS Indicator Light Doesn,tGo Off - ,96 - 97 Models (cont'd)
Frompage24 3l
{c)
MAIN WIREHARNESS
Checkfor a shon to ground in the main wir6 harness:
1. Disconnectthe dashboardwire harness24p connector
from the main wire harness,
2. Checkresistance
betweenthe No. 5 terminalof the main
wrre harness24Pconnectorand ground.Thereshouldbe
1 N40or more.
Short to ground in the dashboard wire harness; reoai.

the dashboerdwire harn6ss.
HARNESS
MAIN WIREHARNESS
3P CONNECTOR
Checktor a short to ground in the SRSmain harness:

'1. Disconnect
the SRSmain harness3p connectorfrom the
maanwire harness,
2. Checkresistance
betweenthe No. i terminalofthe SRS
main harness3P Connector
and ground,Thereshouldbe
1 MOor more.
Short to ground in the main wire ha.ness;r6peir the

main wire harnoss,
Short to ground in the SnS main harness;replacethe SRS

main harness.
SRS MAIN HARNESS

3P CONNECTOR
Wire side of female

terminals
\,1
WIREHARNESS
DASHBOARD
5P CONNECTOR
From page 24-31

(D)
Checkthe SRSindic.to. circuit input voltag:

1. Reconnectthe SRS main harness18Pconnectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No 1 lerminal l+) o{f
the dashboard5Pconnectorand ground'
3. rurn theisnitionswitchol!!!!jl!lg!:ylly9!j399-
ls thorc 8.5 V or more lix secondsafter the ignhion swhch

has benlurned ON (fll7 NO
YES
The problom ha3 dirappcared due to ditconnecting and

conncqting the connactor3. Bo sure all tgrminal3 makc
oood contact, and racheck the system {sco
iroubleshooting Intermittent Failuros on pago 24'151
Poor contect at tha SRSm.in harncss18Pconnoctor;chock

thc connectot.
. It tho conn6ctori3 OK, substitulc a known-good SRS unit'
and rochock.
. lf th. probl6m is 3till p.esnt, tepltco the SRS m'in har'
ncss.
Frompage24-31
(E)
SRSMAIN HARNESS
18PCONNECTOR
c807
Checkfor an opsn in tha drshbo.rd wi.o harnos:

1. Oisconnectthe dashboardwire harness24P connector
lrom the mainwire harness
2. Checkresistancebetween the No O terminal of the SRS
main harness18Pconnectorand No 5 terminal of the
m a i n w i r e h a r n e s s2 4 P c o n n e c t o r t; h e r e s h o u l d b e
c411
MAINWIREHARNESS Terminalsideof maleterminals

24P CONNECTOR
Opon in tho BLU wir. ot the dGhboard wire harngis;
thc daahborrd wit6 ha]n.it.
SRSMAIN HARNESS
18PCONNECTOB
Chocktor an opon in tho main wire harness:

the SRSmain harness3P connectorfrom the
1. Disconnect
main wire harness.
2. Checkresistancebetweenthe No. 6 terminal oI the SRS
main harness18Pconnectorand No l terminalof the
SRSmain harn6ss3P connector;there shouldbe 0 1 0 O
SRS MAIN HARNESS

3P CONNECTOR
Oocn in th BLU wi.o of tho mein wire hamess; repalr
thc msin wire haness.
)
Oo6n in tho SRS main ham6r; ropl.ce the SRS main har'
24-33
Troubleshooting
The SRS Indicator Light Doesn't Go Off - ,9g Model
CAUTION:Wheneverthe ignition switch is ON fll), or
has been turned OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator light:
1. Erasethe DTCmemory(seepage24-15).
2. Turn the ignitionswitchON (ll),and checkthat the SRS
indicatorlight comeson for aboutsix seconosano ooes
off.
Doesthe SRSindicator lioht stav on?
Inte.mitlent failure, systom b OK at thi3 tim6. See TroubleIntrmittentFailur3on page2+lS.
checkthe No. 23 {10Alfuse:

2. Checktor blown No. 23 (10 A) tuse in the under-dash
Replacethe fuse, and erassthe memory

1 . R e p l a cteh e N o .2 3 ( 1 0A ) t u s e .
2. Erasethe DTCmemory(seepage24,1S).
No. 23 {10A} FUSE

FUSE/RELAY
BOX
Doesth6 SRSindicstor light qo off after six seconds?
Check lor an oDen in the SRS main h.rn6ss [vB line):

1. Disconnectthe battervnegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver's (and front passenger's)airbag
(seepage24'11).
connectorls)
3. Disconnectthe SRS main harness18Pconnectorlrom
the sRS unir.
4. Reconnectthe batterv positive cable, then reconnectthe
negativecable.
5. Connecta voltmeterbetweenthe No. 3 terminal (+) of
the SRSmain harness'18Pconnectorand oround.
6. Turnthe isnitionswitchON (il).
Open in rhe SRS main harn63s (VB line); replace the
To page24-35
24-34
SRSMAIN HARNESS
18PCONNECTOF
18P CONNECTOR
SRSMAIN HARNESS
Frompage24_34
(A)
sBsUNIT
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo
adapt
6 and No.3 with a jumperwire and backprobe
go
oll?
indicato.light
Doesthe SRS
YES
NO
Faultv SRSunit or poor contact al the SRS main harnass

18Pconnector;checkthe connector.
lf the connectoris OK, replacothe SRSunit
SBS MAIN HARNESS18PCONNECTOR

Did fuse No. 23 (10A) blow?
YES
NO
JUMPERWIRE
( Il )
f o p a g e 2 4 ?6
Check for a short to ground in the SRS indicator light cir'

cuit:
betweenthe No 1terminalofthedash
3. Checkresistance
r nd ground There
b o a r dw i r e h a r n e s s5 P c o n n e c t o a
shouldbe 1 MO or more.
ls the resistanceas specitied?-
YES
Wiresideot lemaletermanals
5P CONNECTOR
NO
(c)
Io page 24'37
Short to ground in the gtuge assembly;replacethe gauge
DASHBOARDWIRE HARNESS
5P CONNECTOR
c50a
l of female
(cont'd)
24-35
Troubleshooting
The SRS Indicator Light Doesn't Go Off -'98
From page 24 35
(B)
Model (cont'dl
OASHEOARO
W|REHARNESS
5P CONNECTOR
Checkthe SRSindicator circuit:

2 . R e m o v et h e g a u g ea s s e m b l y D
. o n o t d i s c o n n e ctth e
dashboardwire harness5P connectorfrom the gauge
4. Connectthe dashboardwire harness5P connectorterminalsNo. 1 and No.5 with a iumDerwire.
Do6sth6 SRSindicator liqht go oftT
YES
NO
Faultv SRS indicator light circuit in the gauge assembly;

roplaca the SRS printed circuit board in the gauge
assombly.
Checkfor an open in the SRSindicator light circuit:

from the gaugeassembly.
3. Checkresistancebetween the No. 6 termanalof the SRS
main harness18Pconnectorand No. 1 terminalof the
dashboardwire harness5P connectorithere should be
0 - 1 . 00 .
ls the resistancoas 3pecified?
YES
OASHBOARDWIREHARNESS
5P CONNECTOR
l;rfr-zr-cuo"
\J#
Bru
I
IYEL
JUMPER WtRE
Wire side of female

tormanats
SRSMAI[{ HARNESS
18PCONNECTOR
NO
Wire sideot temaleterminals
(D)
To page24-38
, 24-36
[r.
(E)
To page24-38
DASHBOARDWIRE HANNESS
5P CONNECTOR
From page24-35
(c)
Chockfor a short to ground in the main wiro harness:

from the main wire harness
beNveenthe No 5terminalofthedash_
2. Checkresistance
bosrd wire harness24P connectorand ground There
shouldbe 1 MO or more.
Short to glound in the dashboard wire hamoss; repail
DASHEOARDWIRE
HARNESS24PCONNECTOR
WIREHARNESS
OASHBOARD
BLU
24P CONNECTOR
Wire sideof female

lermrnals
MAIN WIREHANNESS
3P CONNECTOR
Checkfor a short to ground in lhe SBS main hamess:

1. Disconnect
mainwire harness
betweenthe No. I terminalof the SRS
2. Checkresistance
main harness3P connectorand ground Thereshouldbe
1 MO or more,
SRSMAIN HARNESS
3P CONNECTOR
Short to ground in tho main wire herness;rspair ihe
Short to glound in the SRS main harness;repl.ce the SRS
SRSMAIN HARNESS
3P CONNECTOR
c802
(cont'd)
24-37
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'98
Frompage24-36
rD)
Model (cont,d)
5P CONNECTOR
Checkthe SRSindicato. circuit input voltago:

'1. Reconnect
the SRS main harness1gPconnectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No. I terminal{+) of
the dashboard5P connectorand ground.
3. Turn the ignition switch ON (lli, wait for six seconds,
then measure
ls there 8.5 V or moreT
The problem has disappeareddue to disconnectingand

connecting the connoctors. Be sure all terminals make
good contact, and recheckthe sy3tem ls6e TroubleIntermittent Failuleson paqe 24-
Poor contact ai the SRSmain h.rness 18p connector;check

the connoctor.
. lf ihe connector is OK, subslituto a known-good SRS unit,
and recheck.
. It the problem is still presont, repbce the SRS main harness.
DASHBOARD
WtREHARNESS
5P CONNECTOR
c508
Frompage24 36
Check lor an open in th dashboa.d wire narness:

1, Disconnect the main wire harness 24P connector from
the dashboard wire harness.
2 . C h e c k r e s i s t a n c eb e t w e e n t h e N o . 6 t e r m i n a l o f t h e S R S
main harness 18P connector and No. 5 terminal ofthe main
wire harness 24P connector; there should be 0 - 1.0 0.
SRSMAIN HARNESS
lAP CONNECTOB
c807
ls the resistanceas sDecifiedT
YES
NO
c411
Open in the BLU wire of the dashboard wire harness;
repairthe dashboardwire ha.noss.
Checktor an open in the main wire harnsss:
1. Disconnect
the SRSmain harness3p connectorfrom the
mainwire harness,
2. Checkresistance
betweenthe No_6 term;nalof the SRS
mainharness18Pconnector
and No. 1 terminalot the SRS
main harness
3Pconnector;there
shouldbe 0 _ 1.0O.
SRSMAIN HARNESS
18PCONNECTOR
ls the resistance as soecified?
YES
NO
Open in the BLU wire of the main wire harness;reDair

the main wire harn6ss.
Open in the SRS main harnoss; replace the SRS main har-
243A
\
c802
SRSMAIN HARNESS
3P CONNECTOR
No DTC-'98
Model
CAUTION:Wheneverthe ignition switch is ON (ll), or

deployand causedamageor iniuries'
accidentally
Check the fu3e:
Check for blown No. 13 (15 A) {use in the under-dash fuse/
(A)To page24-40
R e p l a c et h e f u s e . T u r n t h e i g n i t i o n s w i t c h O N { l l ) , a n d c h e c k
thatthe luse doesn'tblow.
No. 13 (15A) FUSE

The problom has disappearedTest'driveth vehiclo and
seTroubleshootingIntermittentFailureson Page2+15'
Check for short to ground between the undet-dash fuse/

relay box and the SRSunit.
the positivecable,and wait for threeminutes
3, Disconnectthe driver's (and front passenger'sairbag)
connecto(s)(seePage24'11)
4 . Disconnectthe SRS main harness18Pconnectorlrom
the sRS unit.
betweenthe No 7 terminalof the SRS
5 . Checkresistance
main harness18Pconnectorand ground
Thereshouldbe 1 MO or more
sRs
18PCONNECTOR
ls the resistanceas specified?
FauftySRSunit; replacethe SRSunit {seepage21'761'
{B)
To page24-40
(cont'd)
24-39
Troubleshooting
No DTC-'98
Model (cont'd)
trom page 24-39
1B)
Chacktor short to ground in the SRSmain harness:

1. Disconnect
under-dashluse/relaybox.
2. Checkresistancebetween the No. 7 terminal of the SRS
main harness18Pconnectorand ground.Thereshould
be 1.0MO or more.
Short to ground in tho unde.-dash fuse/r6lay box;
Short to ground in the SRS main harnoss;.eplace thc SRS

mein halno3s.
SRSMAIN HARNESS
2P CONNECTOR
FUSE/RELAY
BOX
SRSMAIN HARNESS
18PCONNECTOR
c807
(A)Frompage24-39
Checklor an opgn in the SRSmain hrlness:

2. Disconnectthe battorynegativecable,thn disconnect
3. Disconnectth6 driver's land front passenger's)airbag
(seepage24-11).
conneclor(s)
negativecable.
6. Connect a voltmeter btween the No. 7 terminal oI the
SRSmain harness18Pconnectorand oround.
7. Turnthe ignitionswitchON (ll),and measure
Poor conlact at ths SRS main harnoss 18P connoctor;

checkthe connoctoa,
. lf the connector is OK, sub3tituta a known-good SRS
unit. and rschack.
' lf the p.oblem is still prosent, raplaca lhe SRS main
harness.
To page24 41
24-40
SRS MAIN HARNESS

18P CONNECTOR
caoT
From page24'40
Checkfor an oDenin the SRSmain ha.ness:

2, Disconnect
box.
undeFdashfuse/relay
3. Checkresistance
betweenthe No. 1 terminalof the SRS
main harness2P connectorand No. 7 terminal of the
SRSmain harness18Pconnector.
Thereshouldbe 0 0.5o.
Poor contact at the SRS main harness2P connector;

checkthe connector.
. lf the connector is OK, substitute a known-good under'
dash fu3e/relaybox, and recheck.
. It lhe problem is still present, replace the SnS main
harness.
FUSE/RELAY
BOX
SRSMAIN HARNESS
18PCONNECTOR
caoT
Open in the SRS main harness;replacethe SRS main har'
ness,
SRSMAIN HARNESS
2P CONNECTOR
24-41
Troubleshooting
DTC1-1and DTC1-2
CAUTION:Wheneverthe ignition switch is ON (tt),or
has besn tulned OFF lor less than three minuts, be
carelul not to bump the SRS uniti the airbag(slcould
accidentallydeploy and causedamage or iniuries.
DRIVER'SAIRBAG
2P CONNECTOR
DRIVER'SAIRBAG
ASSEMBLY
Try to reproducethe SRSindicator lighti

1. Erasethe DTCmemory{seepage24,15i.
2. Turnthe ignitionswitchON {ll),andcheckthatthe
SRSindicatorlight comeson for aboutsix secondsand goesoff.
Doe3the SRSindicaror light stay on?
YES
CABLEREEL
2P CONNECTOR
NO
Intrmittem tailure, svstem is OK ai thb time. S6eTroublr

shooting Intermittent Failuroson page 2G15.
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TB401rA
Chcktor an opon in the driver's airbag inflator

2. Disconnectthe batterynegativecable,then disconnectthe
positivecable,andwait for threeminutes.
3. Disconnect
the driver'sairbag2Pconnector
from the cable
reel 2P connector,
CAUTION:Do not disconnectthe psssenger'sairbagconnec{or,
4. Connectthe specialtool (2 O)to the cablereel2Pconnec
tor.
5. Beconnectthe battery positive cable,then reconnectthe
negativecable.
7. Readthe DTC(seepage24 13i.
ls DTC1-1 or DTC1-2 indicatod?
YES
(2 0l
CoNNECTOR
07TAZ- 5250200
NO
Opon or increasedaesidancein the driver's airbag inflator;.eplace th driver'sairbagessemblv(seepase 2+671.
Chocklor sn open in the cable reel:

l- Disconnectthe batterynegativecable,then disconnect
2. Disconnect
the specialtool (2 0) Irom the cable reel 2P
connector.
3. Removethe dashboardlower cover,and disconnectthe
cablereel2P connectorfrom the SBSmain harness.
4. Connectthe specialtool (2 0) to the SRS main harness
2P connector.
{cont,d}
fo page 24'43
SRSSERVICE
SRSMAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
t2 0 JACK)
07sM - T84011A
SRSSERVICE
CONNECTOR
{2 O'
07TAZ- 5250200
24-42
1
Frcm page 24-42
Checkfor an opon in the cable loel (cont'd)

5. Reconnectthe batterv positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemorylseepage24-15).
7. Readthe DTC{seepage24-13).
ls DTC1-1 or DTC 1-2 indicated?
YES
NO
Ooen or increased rcsisttnce in the cable reel; replace

the cable reel (see paq 24-721.
Checktor an oDenin ths SRSmain hamo3s:

2. Disconnoctthe front passenger'sairbag connectorftom
airbag)
the SRSmain harness(withfront passenger's
the SRS unit. Do not disconnectthe specialtool (2 O)
from the SRSmaln harness2P connector'
betweenterminalsNo 1 and No 13 of
4. Checkresistance
the SRSmain harness18Pconnector.
Thereshouldbe approx.2.0- 3.0o.
ls the residance as specitied?
YES
NO
Poor contac't at the SRS main harnoss 18P connoctor;

chockthe connector.
. lf the connodor is OK. substitute a known_goodSRS
unh. and recheck.
.ll lhe problem b still prelenl, replacetho SRS main
haaness.
Op6n or increasedresi3tsncoin the SRS main harness;

replacethe hlmess,
24-43
Troubleshooting
DTC1-3
CAUTION:Wheneverthe ignition switch is ON (lll, ol
has been tu.ned OFF for less than three minutes, be
caretul not to bump the SRS unit; the airbag{s)could
accidentally
deployand causedamageor iniuries.
DRIVER'SAIRBAG
ASSEMBLY
DRIVER'SAIRBAG
2P CONNECTOR
Tryto rproducetha SRSindicator light:

2. Turnthe ignitionswitchON (ll),andcheckthatthe
SRSindi
catorlight comeson for aboutsix secondsand goesoff.
Doesihe SRSindicator light stay on?
YES
CABLE
REEL
2PCONNECTOR
NO
lr e.mittent failure,systomis OK at this limo. S6eTroubleshooting Intermittent Feilureson page 2il-15.
Checklor a short to another wire in the driver's airbao inflalor:

3. Disconnectthe driver's airbag 2P connectorlrom the
cablereel2P connector,
CAUTION:Do not disconnectthe passenger'sairbag
connector.
4. Connectthe specialtool (2 0) to the cablereel2Pconnector.
5. Reconnect
the baftervpositivecable,then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24 15).
7. Beadthe DTClseepage24 13).
ls DTC1.3 indicatod?
YES
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
120 JACK)
07saz - T8401'tA
5(\
\
\
\,/'
sRssERvtcE
coNNECToR
12ol
07TAZ - 5250200
NO
Short in the driver's airbag inflator; replacelhe driver's airbag assembly(seepaqe 24-67).
S8S MAIN HARNESS

2P CONNECTOR
CABLE
REEL
2P CONNECTOR
Checktor a short in the cable reel:

2. Disconnect
the specialtool (2 0) from the cable reel 2P
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
120 JACK)
07sAz - TB4011A
3. Removethe dashboardlower cover,and disconnect

the
cablereel2P connectorfrom the SRSmain harness,
4. Connectthe spacialtool (2 0i to the SRS main harness
(cont'd)
2P connector,
To page24 45
or
,^F--.-
SRSSERVICE
coNNECTOR{2 0)
07TAZ - 5250200
24-44
Frompage24-44
Checkfor a shon in the c.ble tool lcont'd):

negativecable.
6. Erasethe DTCmemorv(seepage24-15).
7. Readthe DTC{see page24-13).
Short in lhe cablo rool; replac the cable re6l (see
SRSUNIT
Chocktor a short in tho SRSmtin harn$s:

1. Disconnoctthe bafterynegativecable,then disconnect
the Dositivecable,and wait for threeminutes
airbagconnectorfrom
the front passenger's
2. Disconnect
the SRSmain harness(with front passengor'sairbag)
the SRS unit. Do not disconnectthe specialtool (2 0)
lrom the SRSmain harness2P connector'
betweenterminaisNo. 1 and No 13 of
4. Checkresistance
the SRSmain harness18Pconnector.
- 3.00.
Thereshouldbe aPDrox.2.0
SRSuniu replac. th. SRSunit lse6 pagG2+
Short in the SRS main hamo3s;roplacetho SRS mtin har-
24-45
Troubleshooting
DTC1-4
DRIVER'SAIRBAG
ASSEMBLY
CAUTION:Wheneverthe ignition switch is ON fll), or

carefulnot to bump the SRS unit; the airbag{s)could
accidentally
deployand causedamageor iniuries.
Try to reproducethe SRSindicator light:
1. ErasetheDTCmemory(seepage24 15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe
SRSindi
catorlight comeson for aboutsix secondsand aoesoff,
Doesthe SRSindicrtor liqht stav on?
CAELEREEL
2P CONNECTOR
NO
Intormittentfailure,sydem is OK atthis time. SeTroubleInlermittent Failureson page 24-15.
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
{2 0 JACKI
07sAz - TB401lA
Checkfor a shon to power in the driver's airbag inflator:

2. Disconnectthe batterynegatave
cable,then disconnect
the positivecable,and wait lor threeminutes.
3. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2P connector.
CAUTION: Do not disconnect the passongr,s airbag
connactor.
4. Connectthe SRSserviceconnector(2 O)to the cablereel
2P connector.
5. Reconnectthe battery posiitive cable,then reconnectthe
negativecable.
7. Readthe DTC(seepase24 t3).
SRSSERVICE
CoNNECTOR
{2 0}
07TAZ- S250200
Short to power in the driver's airbag intlator; replace

SRSMAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
Check lor a short to power in the cable rel:

1. Disconnect the battery negative cable, then disconnect
the positivecable,and wait for three minutes.
2. Disconnectthe special tool (2 0) from the cable reel 2p
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TB4011A
3. Remove the dashboard lower cover, and disconnect the

cable reel 2P connector from the SRS main harness.
4. Connect the specjal tool (2 O) to the SRS main harness
2P connector,
(cont,
fo page24-41
---
"*" ,a"u,"a
GoNNECTOR{2 O)
07f az - s250200
24-46
L
Frompage24-46
Check for a short lo power in tho cable reel {cont'dl:

5 . R e c o n n e c tt h e b a t t e r y p o s i t i v e c a b l e , t h e n r e c o n n e c t t h e
n e g a t i v ec a b l e ,
6 . E r a s et h e D T C m e m o r y ( s e e p a g e 2 4 - 1 5 )
7. Readthe DTC(seePage24'13)
ls DTC 1nl indicated?
Short to power in the cable reel; replace the cable reel
SRSUNIT
Checkfor a short to power in th SRSmain hatness:

1.Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes'
airbagconnectorfrom
the front passenger's
2. Disconnect
airbagi
the SRSmain harness(withlront passenger's
3. Removethe specialtool (2 0ifrom the SRSmain harness
2Pconnector.
'l8P connectorlrom
4. Disconnectthe SRS main harness
the sRS unit.
the batterYpositivecable,then reconnectthe
5. Reconnect
negativecable.
a voltmeterbetweenthe No 1 (+) terminal of
6. Co-nnect
the SRSmain hatness18Pconnectorand bodv ground'
7.Turn the ignilion switch ON (llr, and measurevoltage'
Thereshouldbe 0.5V or less
L Turnthe ignitionswitchOFF.
9. connect; voltmeterbetweenthe No 13 (+) terminalof
the SRSmain harness18Pconnectorand bodyground
lO.Turn the ignitionswitch ON (ll), and measurevoltage
Thereshouldbe 0.5V or Iess
Short lo power in lhe SRS main harness;leplace the SRS
24-47
Troubleshooting
DTC1-5
CAUTION:Wheneverthe ignition switch is ON (lll, or
has been turned OFF lor less than three minutes, be
caretulnot to bump the SRS unit; the airbag(s)could
accidentallydeploy and causedamagc or iniuries.
DRIVER'SAIRAAG
2P CONNECTOR
DRIVER'SAIRBAG
ASSEMBLY
TrVto reproducetho SRSindicator lightl

1. Erasethe DTCmemory(Seepage24 15).
2. Turnthe ignitionswitchON {ll),andcheckthatthe SRSindi,
cator light comes on for about six seconds and goes off.
Do6sthe SRSindicator liqht 3tev on?
lmehittent tailure, svstem is OK at tfiis timc. See lroubleIntermittent Failureson Daqe24-15.
Checkfor a short to ground in the driver's airbag intlator:

cablereel2Pconnector.
CAUTION:Do not disconnoclthe passangei'3airbag
connoctot,
4. Connectthe specialtool (2 0) to the cablereel2P connec,
tor.
negativecable.
7. Readthe DTC{seepage24,13).
Short lo ground in the ddvo.'s airbag inflator; replacethe
%.. sRssERvrcE
\ \
\,/
CoNNECTOR
t2 0l
07TAZ- 5250200
SRSMAIN HARNESS
2P CONNECTOR
CABLE
REEL
2P CONNECTOR
Ch6ckfor a short to ground in the cable reet:

L Disconnectthe batterynegativecable,then disconnect
2. Disconnect
the specialtool (2 0) from the cablereel 2P
connector,
3. Bemovethe dashboardlower cover,and disconnectthe
cablereel2Pconnectorfrom the SRSmain harness.
4. Connectthe Specialtool (2 O) to the SRSmain harness
2Pconnector(cont'd).
SRSSIMULATOR
LEADC
07TAZ- SZ5011A
and SRSINFLATOR
SIMULATOR
{2 0 JACK)
07sAz - TB4o11A
To page24-49
^P*---.sRssERvrcE
( -,
coNNECTOR
t20t
07TAZ - 5250200
24-48
\__
From pag 24-48

Ch.ck for ! Bhortto gtound in tho clble rool (cont'dl:
5. Reconnectthe battry positive cable, then reconnectthe
negativecabl.
6. Erasethe OTCmemory(seepage24-15).
7. Readth6 DTC{seepage24-13).
ls OIC 1-5 indicrtodT
NO
YES
Short to ground in the ctble r.cl; t.Placo thc cable teol

{3o. psse 24-721.
Chcckfor a lhort to ground in tho SRSmain hlrn.ss:

the positivecable,and wait for three minutes'
2. Disconnectthe lront passenger'sairbag 2P connector
f r o m t h e S R S m a i n h a r n e s si w i t h t r o n t p a s s e n g e r ' s
airbag).
3 Removothe specialtool (2 0)Irom th6 SRSmain harness
2P connector.
4. Checkresistancebetweenthe No- 1 terminal of th SRS
main harness18Pconnectorand ground,and between
the No. 13terminalof the SRSmain harness18Pconnector and ground.
Thereshouldbe 1 Mo or more.
b th. r$bt.nc6
SRSUNIT
13 spocifiod?
YES
SRSunit;6pl.ce th. SRSunit l3eo page 2&
Shon to ground in tho SRS m.in harne3s;iopl.co the SRS

main hrrn.3s.
24-49
Troubleshooting
DTC2-1and DTC2-2 -Wath FrontPassenger's
Airbag
CAUTION: Whenever tho ignition switch is ON { }, or
has been turned OFF for less th8n thre minute3, be
accidentallydoploy and causedamage or iniuries.
Trv to reproducethe SRSindicstor light:
1. Erasethe DTCmemory(seepage24,15).
2. Turnthe ignitionswitchON (ll),and checkrhattheSRSindicatorlight comeson for aboutsix secondsand goesoff.
YES
NO
Intermiftcm tailure, 3ystem is OK at thb lime. S6e Trouble

shooting Intermittent Failureson pag6 2+15.
Checklor an open in the passenger'sairbag inllator:

2. Oisconnect
the batterynegativecable,then disconnect
3. Disconnectthe front passenger'sairbag connector from
the SRSmain harness(seepage24-11).
4. Connectthe specialtool (2 O) to the SRSmain harness
2P connector.
CAUTION: Do not disconnocttho driver's airbag connector.
negativecable.
7. Readthe DTC(seepag24-13).
ls DTC2-1 or DTC2-2 indic.t6d?
YES
NO
Open or increasdresiitance in lhe prssenger's airbag

intlator; replec6 the pa3sgnger'sairbag e3sombly lsee
page 24-67).
To page24'51
24-50
\
SRSSERVICE
CoNNECTOR
t2 0l
07TAZ- SZ5m00
E\
From page 24-50
Chackfor rn ooen in ths SRSmain hatnossi
'1. Disconnectths bafteryngativecable,then disconnect
the positivecable,and wait tor threeminutes.
2. Disconnectthe driver's airbag 2P connectorlrom the
csblereel2Pconnector{seepage24-11).
the SRS unit. Do not disconnectthe specialtool {2 0)
from the SRSmain harness2P connector'
4. Check@sistancebe8voenthe No. 10 terminal and No. 14
terminalof the SRSmain harness18Pconnector.There
-3.0 o.
shouldbe aDorox.2.0
ls tho r4irtance a3 3pecifiad?
YES
SRSUNIT
NO
'l8P connector;
Poor conlact at lhe SRS mtin ha]ngss
ch.ck tho connctor.
. lf the connoctol is OK, subitituta . known-good SRS
unit, .nd rochcck.
.ll lh. probl6m is still ptesont, replsce the SRS main
hatnas!!.
SRSMAIN
18PCONNECTOR
Opcn or incrarsad re3ist!nc6 in tha SRS m.in harnoss;

rcplac! tho harnots.
24-51
Troubleshooting
DTC2-3- With FrontPassenger's

Airbag
CAUTION: Whsnevor the ignition switch is ON ([), or
has been turned OFFfor l6ss than th.6 minut6s. be
caretul not to bump tho SRS unit; the airbags could
accidsntallydaploy and caus6damage or iniuries.
Tryto roproductho SRSindic.to.light:
1. Erasethe DTCmemory (ssepage2+15).
2. Turn the ignitionswitchON { ), and checkthat the SRSindic6torlight comeson for aboutsix secondsahd goes off.
Oo.3 tho SRSindic.tor light ltrv on7
Into.mitt.nt tailurc, rwtam b OK st thb tim6, S.e TroubloIntermittont Friluraa on gaqe 24-15.
FRONTPASSENGER'S
AIRBAG2P CONNECTOR
Chack to. . Bhon to another wir. or docroasod r$irtanca in

tho pr3sgngor'r airbag intlator:
2. Disconnectthe batterynegativecable.then disconnect
the positive cable.and wait for three minutes.
3. Disconnctthe tront passenggr'sairbag 2P connector
trom the SRSmain harnss{seepage24-11).
4. Connectthe specialtool (2 0) to the SRS main harness
2P connector,
CAUTION: Do not dbconnect tho driver'r airbag connoctor.
negativecable.
6. Erasethe DTCmemory(seepase24-15).
7. R6adthe DTC(see pag'e24-131.
Short to anothoi wi.e or docrgagodr63btancoin the parsangg/s airbf,g inflator; roplaco thg passongor,r ai.b6g
To page 24-53
\ _
24-52
SRSSERVICE
CoNNECTORt2 0)
07TAZ - 5250200
Frompage24-52
Chock for a lhort to anothor wiro or dacrcatad lotittancc in

th. SRSfi.in hamo3s:
1. Disconnectth6 batterynegativecable,then disconnect
the positivecable.and wait for three minutas'
cablereel2P conngctor.
'l8P conngctorfrom
3. Disconnectthe SRS main harn6ss
the SRSunit. Do not disconnectthe specialtool (2 O)from
the SRSmain hsrness2P connedor'
betweenthe No. 10terminaland No 14
4. Checkresistance
terminal of the SRS main harness 18Pconnector' Thsre
shouldbg approx 2.0
b thc .eai3tlnca
SRSMAIN HARNES9
18PCONNECTOR
ss aPacifiad?
YES
NO
F.ultv SRSunit; r.pl.c. th. SRSunh l3.e prge 2il'761
Short lo anolhar wiro or docrgatod rasist'nc' in th' SRS

mlin ha.n.!3; rcpllco th! SBq!q!L!g!9!a--
24-53
r-
Troubleshooting
DTC2-4 - With Front Passenger'sAirbag
CAUTION:Whenevertho ignition switch is ON (ll), or
has been turned OFF for less thar thrse minutes. be
careful not to bump the SRS unit; the airbsgs could
accidentallydeploy and causdamag or iniu.ies,
Try to reproducotho SRSindicator light:
1. Erasethe DTCmemory (sepage24-15).
2. Turn the ignitionswitchON (ll),and checkthatthe SRSindicatorlight comeson for aboutsix secondsand goesoff.
YES
NO
lrtermittont fsilure, 3ystom is O|( at this time. SeTroubleshooting Intormittent Failuroson pago 2{-15.
Ch6ckfor a shon to powsr in the psssengor'sairbag inflalor:

2. Disconnoctthe bafterynegativecable,then disconnect
the positive cable,and wait tor three minutes.
3. Disconnectthe tront passenger'sairbag 2P connector
from the SRSmain harnesslseepage24'11)4. Connectthe specialtool (2 0) to the SRS main harness
2P connector.
CAUIION: Oo not disconnestthe d.iver's airbag connoctor.
the batterypositivecable,then reconnectthe
5. Reconnect
negativecable.
6. Erasethe DTCmemory(seepage24 15).
7. Readthe DTC(seepage24 13).
ls DTC2-4 indicat.d?
YES
FRONTPASSENGER'S
AIRBAG2P CONNECTON
HARNESS
2P CONNECTOR
NO
SBSSIMULATOR
LEADC
07TAZ- SZ5011A
.nd SRSINFLATOR
SIMULATOR
(2 0 JACK)
07sAz - TBa011A
Short to pow.r in the p.$eng6r's airbag inflator; .cplace

thg pa$enger's airbag a$ombly {s.e p.ge 24-67).
To page 24-55
24-54
N-_
/,4\
( - /,/
sRs SERV|CE
GoNNECTOR
t2 0l
07TAZ- SZso200
a
Frompage24 54
Chocklor a short to oower in tho SRSmain harnss:
the positivecable,and wait lor threeminutes.
2. Disconnectthe drivr's airbag 2P connectorfrom the
cable reel 2P connector.
the SRSunit.
4. Removethe specialtool (2 O)from the SRSmain harness
2Pconnector,
5. Reconnectthe battery oositive cable, then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 10 (+) terminalol
SRSmain harness18Pconnectorand ground.
7. Turn the ignition switch ON (ll), and measurevoltage.
Thereshouldbe 0.5V or less.
L Connecta voltmeterbetweenthe No. 14 (+) terminalof
the SRS main harness18Pconnectorand ground,and
measurevohage.Thereshouldbe 0.5V or less.
SRS UNIT
SRSunit; rsDlacetho SRSunit (sopage 24'76)
main harness;replace tha SRS
24-55
Troubleshooting
DTC2-5- With FrontPassenger's
Airbag
CAUTION: Whenever the ignition switch is ON 0ll. o.
has been turned OFF for less than thros minutos, be
aqcidentallydeploy and causedamage or iniuries.
Try to roproducetho SRSindicator light:
1. Erasethe DTCmemory (seepage24-1S).
2. Turn the ignitionswitchON 0t),and checkthat the SRSindi_
catorlight comeson for aboutsix secondsand aoesotf.
Doostho SRSindicator light stsy on7
YES
NO
Intermittent feilurc, syrtem is OK at this timo, SeeTroubl.shooting Intormittont Failureaon page 24-lS.
Chockto. a short to ground in tho passongs/sairbagir ator:

the positivecablo,and wait for threeminutes.
3. Disconnectthe tront passengsr'sairbag 2p connoctor
from the SRSmain harness(seepage24,11).
4. Connectthe specialtool (2 0) to the SRS main harnass
2P connector,
CAUTTON:Do not disconnectthe drivor.sairbrg connecloa,
negativecable.
6. Erasethe DTCmemory {see page24,15).
7. Readthe DTC(seepage24-13).
b DTC2-5 indicatod?
YES
NO
Shon to ground in the pa*lengart airbrg inflator;raplac6

the pa3r6nge/i ailb.g '3.ombly lsoo pago 2+67),
To page24-57
24-56
N-
SRSSERVICE
CoNNECTOR(2 0l
07TAZ - 5250200
\ I
From page 24-56
Cha.t to. a ahon to ground in th. SRSmrin harnda:

1. Oisconnecithe banery negativecable,then disconnect
the positivecable,and wail tor threeminules.
2. Disconnectthe driver's airbag 2P connectortrom the
cable reel 2P connector.
3. Oisconnccl tha SRS main harnass 18P connector from
SRSUNIT
!\. s s u^n
a Rarnoyr thc sp6itl tool {2 O)from the SRSmain harness

2P @nnctor.
betweenthe No 10terminaloftheSRS
5 Checl resistance
maanharness18Pconnectorand ground,and between
rhe No. l4 terminalol the SRSmain harness18Pconnec'
lor and qround. There should be 1 MO or more.
b tha l.aaat|nc!
!3
YES
Shon lo ground in th. SRS mein h.m6s; replacothe SRS

mlin ham6a.
24-57
-
1.3T
Troubleshooting
DTC2-1and DTC2-2- Without Frontpassenger,s
Airbag
CAUTION:Wheneverrhe ignition switch is ON ( ), or
hrs been turned OFF for less than three minuies. be
cr.etul not to bump the SRS unit; the ailbag could acci.
dentally deploy and causedamage or injuries.
Try to reproducothe SRSindicstor light:
1. Erasethe DTCmemory{seepage2+15).
2. Turn the agnitionswitchON 0), and checkthattheSRSindi_
catorlight comeson tor abootsix secondsand goesoff.
Doesthe SRSindicator lisht stav on?
SRSUNIT
lntormittent failu.e, system is OK at this time. See Trouble.

Inte.mittent F ilures on paq 24-15.
DUMMY RESISTOR
Check for .n open or increased rosistance in th dummy
lesistori
2. Removethe dummy resistortrom the SRSmain harness
2P connector.
3. Checkthe resistance
betweenthe A and g terminalsof
the dummy resistor.Thereshouldbe 1.5 2.50.
ls the rsistancas sDecifiod?
Checkfor an open or increasedrcsistancein the SRS main

harness:
1- Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threemtnutes.
2. Disconnectthe driver,s airbag 2p connectorfrom the
cablereel2P connector{seepage24-11).
3. Disconnectthe SRS main harness1gp connectorfrom
the sRs unit.
4. Connectthe dummy resjstorto the SRSmain harness2p
connector.
5. Checkresistance
betweenthe No. l0terminal andNo. 14
terminalof the SFS main harness1gp connector.There
shouldbe approx.1.5- 2.50.
Poor contect at the SRS m.in hamess lBp connector;

chckthe connector,
. It lhe connector is OK, substituto a known-good
SRS
unit. and recheck.
. It lhe problem is stilt present. replaco the SRS
main
haaness.
Open or incre.sed re3istancein tho SRS main harness;

th harness.
24-58
SRSMAIN HARNESS
2P CONNECTOR
DUMMY
REStSTOn
SRSMAIN HARNESS
18PCONNECTOR
ffi
Airbag
DTC2-3- Without FrontPassenger's
CAUTION: whensver ths ignition switch is ON (ll), or
has been turned OFF tor l3s than three minutes, be
careful nol to bump th SRS unit; lhe airbag could accidntally daploy and causdamag or iniuries.
Try to rep.oduc. th. SRSindicatot ligM:
1. Eraseth DTCmemory {seepage24-15).
2. Turn the ignitionswitchON (ll),and checkthat the SRSindicom6son lor aboutsix secondsand gogsoff
Doo! th. SRSindicltor light stey on?
SRSUNIT
lntarmittont leilure, 3ystam i3 OK at this time. See
Intormittgnt Failutoson page 2+15.
Chackfor a rhort to anothar wits or d6ctcarod ]$btance in

the dummy la5i3tor:
2. Remov6the dummy resistorfrom the SBSmain harness
2P connsctor.
3. Checktho resistancebetween the A and B tsrminals of
the dummv resistor.Thereshouldbe 1 5 - 2 5 0.
13tho rgsistancg as 3pocified?
DUMMY RESISTOR
SRSMAIN HARNESS
2P CONNECTOR
Chacklor a ahort to rnothd wile or dccreasedrelbtance in

the SRSmain harn6s:
the Dositivecable,and wait for threemanutes
2. Disconnectthe driver's airbsg 2P connectorfrom the
cablereel2P connector(seepage24-111
the SRSunit.
NOTE: Do not connoctthe dummy resistorto the SRS
msin harness2P connector,
4. Checkresistancebetwonthe No. 10 terminal and No. 14
terminalof the SRSmain harness18Pconnector'There
shouldbe 1 M0 or more.
SRSUNIT
SRSMAIN I.IARNESS
18PCONNECTOR
F.ulty SRSunit; lepl.co the SRSunit lso6 pege 24'76).
Short to anothar wirc ot decro.sed resbtence in the SRS

mrin hsrnoaa;taplacoths SRSmain harness.
24-59
-
Troubleshooting
DTC2-4- Without FrontPassenger,s
Airbag
CAUTION: Whenever the ignition switch is ON llll, or
has be6n turned OFF for less than ihreo minutes, be
careful not bump tha SRS unit; the sirbag could acci_
dentally doploy and cau3damago or iniuries.
Try to rep.oducothe SRSindicator light:
1. Eraethe DTCmemory {s6epage24-15).
2. Turnthe ignitionswitchON 0t),and checkthatthe SRSindi_
catorlight comeson for aboutsix secondsand goesoff.
Do.i the SRSindic.tor light stly on?
YES
NO
SRSUNIT
Intormltlont failur., 3yrtom b OK !t thb tim.. S.e Troubl6.

thooting Int.rmittent Failuroson p.g.2+tS.
Chockfor a short to power in th. SRSmjn h.rno3ii

1. Disconnectthe battery negativd cable, then disconnect
the positivecable,and wait for three minutes.
2. Disconnectthe driver.s airbag 2p connectorfrom the
cable reel 2P connector(seepsge 2+1.1).
3. Disconnectthg SRS main harnesslgp connectorfrom
the SRSunit.
4. Feconnectthe battery positive cable, thn reconnectthe
negativecable.
5. Connecta voltmeter between th No. 10 (+) terminal ot
the SRSmain harness18pconnectorano grouno.
6. Turn the ignitionswitch ON ll, and moasurevoltage.
There should be 0.5 V or less.
7. Connecta voltmeterbetweenthe No. 14 (+) terminalof
the SRS main harness18p connectorand ground,and
measurevoltage.Thereshouldb6 0.5V or less.
Aro vohtgos as rpocili.d?
YES
SBSMAIN HARNESS
18PCONNECTOR
NO
F.uftySRSunit;replacethe SRSunit l.oo p ago2+761. I
Sho to power in tha SRS main harno!3 or tha dummy

rsi3tor; chcck tor contact betwoen tho dummy rosistor and
another wiro. It tharo is no contact. ,oplace tho SRS mrin
natnoss.
24-60
\
Airbag
DTC2-5- Without FrontPassenger's
CAUTION: whenver the ignition switch i3 ON (ll), ot
has been tutned OFF fot less than thres minutos, be
careful not to bump the SRS unit; the sirbag could acci'
dentally deploy and causedamago or iniuries.
Try to reproducetho SRSindicator lightl
l. Erasethe DTCmemorvtseepsge24_15).
2. Turn the ignition switch ON (ll), and check thal lhe SRS indi-
catorliqht comeson for aboutsix secondsand gosoff

Oo.3 tho SRSindicator light .t!Y on?
SRSUN]T
Chockfor e short to ground in tho SBS main halne3si
the Dositivecable, and wait for three minutes'
2. Dis;onnectthe driver's airbag 2P connectorfrom the
cablereel2Pconnector(seepage24-11)
3. Disconnectthe SRS main harness18Pconnectorlrom
the sRS unit.
4. Checkresistancebelween No lO terminal of the SFS
main harness18Pconnectorand ground,and belween
the No. 14terminalof the SFS main harness18Pconnec_
tor and ground. There should be 1 l\/toor more
SRSMAIN HARNESS
18PCONNECTOR
FaultySRSunit; replacothe SRSunit {36epag.21-761
Short to ground in tho SRS main harnosi or the dummy

resistor;checklor conttc{ between the dummy rcablor and
ground. ll lhero b no contact, roplsco the SRS main har'
24-61
,tl
rr-
Troubleshooting
DTC8-6
CAUTION:Wheneverthe ignition switch is ON l ), or
hss been turnod OFFfor lss than thre minules, bs
carsful nol to bump the SRS unit; the airbags could
sccidentallydeploy and causodamage or iniulies.
Besidesindicatingan abnormalityin the SRS unit, DTC
8-6 may also indicatethat two problemsequivalentto
DTC'f-l and 2-4, 1-4 and 2-1,ot 1-4and 2-4 occurredat
the sametime, Proceedin the ordershown below.
Checkthe SRSmain harn$s:
the positivecable,and wait for thrceminutes.
2. Disconnectthe driver's airbag (and tront passenger,s
airbag)connecto(s) (see page 24-111.
the SRSunit.
negativecable.
6. Connect a voltmeter and measure voltage betlveen the
No. 10 terminalof the SRSmain harnessl8p connector
and ground,and btweenthe No. '14terminaland ground.
Thereshould be approx.0 - 0.5 V.
Aro voltag.3 as spocifi.d?
YES
NO
Short to powsr in tho SRS main h6rnoss; roplace the SRS

msin hamesl.
Checkthe SRSmein hr]ne3s rnd the csble recli

Connect a voltmoter and moasure voltage between the
No. 1 terminalof the SRS main harness18p connector
a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
ground.Thereshouldbe aDprox.0-0.5V.
Aro voltag$ a3 apecifiod?
YES
NO
FauftySRSunit; replacethe SRSunit {3cepage 2+761,
To page24-63(A)
24-62
\_
sRs
18PCONNECTOR
E1
Frompage24'62(Al
Chocktho ceble ro.l:

2. Disconneitthe cable reel 2P conn6clot f'om the SRS
matnharness.
4, Connect a voltmeter and measure vohaga btreen the
No. 1 terminalof the sRS main harness18Pconnodtor
a n d q r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
.,o'n'd- Thereshouldbe aoprox.O- O 5 V.
Short to power in the crbl6 toel; roplsco th' c'ble 16ol
Short to pow.l in tho SRS m.in hamoss; lopltc' th SRS
)
)
24-63
-/
Troubleshooting
DTC9-2
CAUTION: Whedover tho ignition switch is ON ([). o,
h!3 bsen turned OFF for less than thre minutes, bo
clrctul not to bump tho SRS unit; the airbag(sl could
lccidontally deploy and cau3edemage or iniuries.
Checkth6 tu3ei
2. Checkfor blown No. 23 (10 A) fuse in the underdash
(A) To page 24-65

Replace
the fuse.Turnthe ignitionswitchON (ll), and check
that the fuse doesn't blow.
Thc problornhr3 dblppoa.ed. Tcat-drivethe vehicla ,nd

3eeTroubl*hooting Int.rmiftant F ilu..s on page2+15.
No.23 110A) FUSE

FUSE/RELAYBOX
SRSUNIT
Chock tor 3hort to g.ound betwoan tho undgr-dashfus6/

reby box and tho SRSunii.
the positivocable, and wait lor three minutes.
3. Disconnectthe driver,s(and tront passengsr,s)
airbag
(seepage2/t-1'l).
connector{s)
4. Disconnectthe SRS main harnesslgp connectorlrom
the SRSunit.
5. Checkresistancebotweenthe No. 3 terminal of the SRS
main harness18Pconnectorand Oround.
Thereshouldbe 1 M0 or more.
SRSMAIIIIHARNESS,I8P CONNECTOB
SRSunh; replacsth. SRSunir {3oopage 2+761.
1B)
To page 24-65
24-64
fl
(B)from page24-64
ChaFktor lhort to ground in th. SRSm'in h'mo3t:

the SRSmain harness2P connector{rom the
1. Disconnect
underdash fuse/rlaYbox.
2. aheck resistancebetweenthe No 3 terminal ot the SRS
main harness18Pconnectorand ground There should
be 1.0Mo or mor
ls tho l.3itt nco .. 3P.cifi.4l-
NO
YES
0t'@r
Short to gtound in tha undor'dtth fu3'/tolf,Y box;

r.of.ca th. und.rdssh rusolrelaV box.
-sho.t
m groundin th. sRs m.in htrnes;;r'plrct th' sRs
FUSE/RELAYBOX
fiain h!mo$.
SRSMAIN HARI{ESS
18P CONNECTOR
(A) From page 24-64

Chackloa an opcn in lha SRSmain harne3s:
1. Turn the iqnitionswitchOFF
2. Disconne;tthe batterynegativecable,then disconnect
the positivecable,and wait tor threemrnutes'
airbag
3. Disconnectthe driver's (and lront passenger's)
connector(seePage24-11).
/t. Disconnectthe SRS main harnessl8P connectorfrom
the sRs unit.
5. Reconnectthe battery positivo cabl,then reconnectthe
neoativecable.
S. Co-nnecta voltmeter betlveon the No 3 terminal of the
SRSmain harness18Pconnctoranclgrouno'
7. Turnth ionitionswitchON {ll},and measure
SRSMAIN HARNESS
18P CONNECTOR
Poor contact st th SRS main harnasa 18P connoctor;

chrck tho conn6ctor'
. ll tha connactot b OK, 3ubltituta a known-good SRS
unit, and tschgck.
. It th. Droblem i. still pJcrent, ].pt.ce tho SRS mtin
To page 24-66
(cont'd)
24-65
."
froubleshooting
DTC9-2 (cont'd)
Frompage24-65
Chockfor an open in tho SRSmain harness:

2. oisconnecttheSRSmain harness2pconnectorlromthe
under-dashfuse/relaybox.
3. Checkresistancebotweenthe No. 2 terminal of the SRS
main harness2P connectorand No. 3 terminal of the
SRSmain harness18Pconnector.
Thereshouldbe 0 - 0.50.
Poor contsct at the SRS main harness2p conneclor:

chackthe connector.
. lf the connoctor is OK, 3ubstitute a known-good
under_
d.sh tuse/rlaybox, and r6chgck,
.lt the problem is still pro3ont, replace the
SRS mrin
hamess.
UNDER.DASI{
FUSE/RELAY
8OX
Open in tho SRS main harncs3;replacothe SRS main harnosli,
SRSMAIN HARNESS
18PCONNECTOR
CaOl
Wire side of female

terminals
SRSMAIN HARNESS
2P CONNECTOR
i\
"L
24-66
Airbag
Replacement
After a coltisionin which the airbagswere deployed,the
airbagassemblissand the SRSunit must be replaced'
sb'! r'..-eycd l*bag whh the oad sur'
!@
r tm ri6r9 b improPorly storod lac down'
iiFup.
accidcnti d.plovnanl Gaald proprl lht unit with
f{u.V.
nough to.6 to Glr !-iqt
F ont P[.Jrga/t
.
Sld.:
Disconnectthe 2P connec'torbetween the tront p88sengr'saitbagand SRSmsin harnsss'

NOTE: When disconnected,the airb8g connoctor ls
shoned.
FRONTPASEltlGER's
automatically
AIRBAG
2P @NNECIOR
CAUTION:
. Always disconnoctthc airblg connoctol(s) when the
harnessis disconnactad.
. Oo not disa3sembloor ttmper with ths airbag'
NOTE:
. Do not installusedSRSp8rtsfrom anothervehicle'
when repairing,usa onty new SRSparts'
Do
. CareJullyinspectthe airbag beforeyou installit
b
e
i
ng
o
f
s
i
g
n
s
not insiall 8n airbag that shows
cracKs
dents'
as
such
droooedor improperlyhandled,
or deformation.
1.
Disconnectthe battery negative cable' then disconat

nect the positive cable from the battery' and wa't
leastthtee minutes.
2.
the airbagconnector(sl:
Disconnect
Driver's Side:
.
4.
wheel'
Removethe accesspanel from the steering
drivthe
between
connector
2P
the
disconnect
then
er's airbagand cablereel'
is
NOTE:When disconnected,the airbag connector
shorted
automaticallY
S
DRIVER
AIRBAG
Removethe sirbag(s):
Diivar's Side:
then
o Removethe two Torx bolts using a Torx T30 bit'
removethe drivers airbag'
TORXBOI-TS
U.. . Torr F0 bit.
DRIVER'SAIRBAG
2P CONNECTOR
(cont'd)
24-67
.
Airbag
(cont'd)
Replacement
Front Passenger'sSide:
.
.
CAUTION: B sure to instsl the SRSwiring so that it is

not pinched or intertsring with othr parts.
Removethe three mounting nuts from the bracket,

then removethe harnesscliD.
Liftthe front passenger's
airbagout of the dashboard
by coveringthe lid and dashboard\ /ith a cloth, and
pryingcarefullywith a flat-tipscrewdriver,
4.
Installthe new airbag(s):
Driver'sSide: Placethe driver'sairbaginto the steering

wheel.and secureit with new Torx botrs.
TORXBOLTS
9.8N.m ll.0 kgf.m,7.2lbtfrl
Replace.
N O T E :T h e l i d o f t h e a i r b a gh a s p a w l s o n i t s s i d e
which attachit to the dashboard.
DRIVER'SAIRBAG
Front Passenge.'sSide:
.
.
P l a c et h e f r o n t p a s s e n g e r , a
s irbaginto the d6sh_
board.
Tightenthe front passenger,s
airbagmountingnuts.
AIRBAGMOUNTINGNUTS
9.8 N.m 11.0kgf.m,7.2lbf.ft)
Reolace.
2+68
5.
Reconnectthe airbag connector(s).
Frod P.ss.nga/s Sidc:

.
Aftach ths ai.bag connector to the connector holder'

then rinstallths glove box.
RT'T
Driver's Side:
Connectthe driver'sairbag2P connectorto the cable
reel2P connector,then installthe accesspanelon the
steeringwheel.
?ASSE'{GER'S AIRBAG
)
AIRBAG
DRIVEN'S
2PCONNECTOR
CONNECTOB
KOTDR
Connectthe batterypositivecable,then connectthe

negativecable.
1.
After installingthe airbag,confirm proper system

operatlon:
. Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds
and then go off.
. Makesure both horn buttonswork'
24-69
1T
Airbag
Disposal
Beforescrappingany airbags(includingthose in a whole
vehicleto be scrapped),
the airbagsmust be deployed.lf
the vehicleis still within the warrantyperiod,beforeyou
deploythe ai.bags,the HondaDistrictServiceManager
must giveapprovaland/orspecialinstructions,
Onlyafter
the airbagshavebeendeployed{as the resultof vehicle
collision,tor example),canthey be scrapped.
lf the airbagsappear intact {not deployed),treat them
with extremecaution.
Followthis procedure:
Front Passngsr'sAirbag:
4,
Removethe glove box, then disconnectthe 2P connector between the front passenger'sairbag and
sRS main harness
FR.NTpAssENGER's
AIRBAG
Deployingthe Airbags: In-vohicl

NOTE:It an SRSvehicleis to be entirelyscrspped,its
airbagsshouldbe deployedwhile still in the vehicle.The
airbagsshould not be consideredas salvageablepans
and shouldneverbe installedin anothervehicle.
confirm that esch airbag assemblyis
!@
3.cursly mounted; otherwisg, soverg ptsonal iniury
could result from doploymont.
l.
Disconnectthe bafterynegativecable,then disconnectthe positivecable.
2.
Confirmthat the specialtool is tunctioningproperly

by following the checkprocedureon the tool label
ot on page 24-7'l.
SRSMAINHARNESS
5.
Driver's Airbag:
3.
Cut off the airbag connector,strip the ends of the

airbagwires,and connectthe deploymenttool alligator clips to the airbag.Placethe deploymenttool
at leastthirty teet (10meters)awayfrom the airbag,
DRIVER'S
AIRBAG
Removethe accessDanel,then disconnectthe 2P

connecto. betweenthe driver's airbag and the cable
reel.
DRIVER'S
AIRBAG
2P CONNECTOR
BATTERY
t'4-70
FRONTPASSENGER'S
AIRBAG
Deployingthe Airbag: Out-ot-vehicle
Connecta 12 volt batteryto the tool:

lf the green light on the tool comes on' the airbag ignitercircuitis defectiveand cannotdeplov
t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l
7.
Procedure.
lf the red light on the tool comeson, the airbagis
readYto be dePloYed.
N O T E : l f a n i n t a c t a i r b a g h a s b e e n r e m o v e df r o m a
scraooedvehicle,or has been found defectiveor dama g e d d u r i n g t r a n s i t ,s t o r a g eo r s e r v i c e ,i t s h o u l d b e
deployedas follows:
Posilion the airbag face up, outdoors on
tffi
l"ast thirtv feet (10 ml trom anv obstacles
iiffiat
or people.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h T h e a i r b a g
should deplov (deploymentis both highly audible
and visible;a loud noise and rapid inflalionof the
bag,followedbY slow deflation).
lf the airbagsdeploy and the green light on the
tool comeson, continuewith this procedure
. lf an airbag doesn't deploy,yet the green light
comes ON. its igniter is delective Go to Dam
aged Airbag Specia\Procedure'

ri.,-.d .l.nlovment the airbag assem=E
u"co-. hot enough to burn you wait thirF".n
the
w'minut.s after deployment before touching
assemulY.
8.
part
Disposeof the completeairbag assembly No
plastic
bag'
sturdy
it
in
a
Place
of it can be reused
and sealit securely,
CAUTION:
. wear a lace shigtd and gloves when handling a
deploYedairbag.
r Wash your handsand rinse them well with
water after handling a deploYedailbag'
1.
2.
properlY
Confirmthat the specialtool is functioning
page
or on
thrs
on
procedure
by followingthe check
the tool label.
Follow steps5, 6, 7, and 8 of the in-vehicledeploY
ment Procedure.
DamagedAitbag SpecialProcedure
r an ailbag cannot be deployed' it should
!!@
considnot be treatgd as normal scrap; rt should still be
serlcause
can
that
ered a potentiallY explosive device
ous iniury.
1.
AIRBAG
2.
proce
lf installedin a vehicle,follow the removal
dure on Page24-67'
ln all cases.makea shortcircuitby twistingtogether
the two airbaginflatorwlres
packaging
Packagethe airbag in exactlythe same
In
part
came
that the new replacement
"DAMAGEDAIRBAG
4. Mark the outside of the box
sQ it does not get confusedwith
NOT DEPLOYED"
your Partsstock.
for
5 . C o n t a c ty o u r H o n d aD i s t r i c tS e r v i c eM a n a g e r
for
disposal
it
return
to
where
and
how
3.
DeploymentTool: CheckProcedure
1.
2.
3.
protector
Connectthe yellow clips to both switch
battery'
a
to
tool
the
handleson the tool; connect
is
Pushthe operationswitch:green meansthe tool
is
faultY
OK; red meansthe tool
the batteryand the yellowclips'
Disconnect
24-71
T:
GableReel
Replacement
sto.e a remove airbag assembly with the
@
pad surface up. lf the 8irbag is improperly stored face
down, accidontaldeployment could propl the unit with
enough torce to causeserious iniury,
Makesurethe wheelsare alignedstraightahead.

4.
Removethe driver'sdashboardlowercover.
TORXBOLTS
Use a Torx T30 bh.
CAUTION:
. Always dkconnest th6 airbag conneqtor(s)when the
harnsssis disconnected.
. Do not disassembleor tampor with the airbag.
N O T E :C a r e f u l l yi n s p e c tt h e a i r b a ga s s e m b l yb e f o r e
installingit. Do not installan airbagthat shows signsof
b e i n g d r o p p e do r i m p r o p e r l yh a n d l e d s, u c h a s d e n t s ,
cracksor deformation,
1.
Disconnect
the batterynegativecabl,then disconnectthe positivecablefrom the battery, and wait at
leastthreeminutes.
Removethe accesspanel from the steeringwheel,
then disconnectthe 2P connectorbetweenthe driver's airbagand cablereel.
DRIVER'SAIRBAG
NOTE:When disconnected,
the airbagconnecrorts
automatically
shorted.
DRIVER'S
AIRBAG
DRIVER'SAIRBAG
2P CONNECTOR
DRIVER'SDASHBOARDLOWERCOVER
5.
Removethe two Torx boltsfrom the steeringwheel.

and disconnectthe horn connector.Then remove
the driver'sairbag.
-El
fromthe hornandcruise
6. Disconnect
the connectors
cont.olsevresumeswitches,then removethe steer-
8. Romovetho columnrdverq
ing wheel nut,

WHEEL
STEERING
CABLEREEL
2P CONNECTOR
1.
Removethe steeringwheel using a steering wheel

puller.
the 3P connectorbetweenthe main wire

9 . Disconnect
and the 2P conharnessand cablereelsub-harness,
nectorbetlveenthe cablereeland SRSmain harness.
CABLEREEL
WHEELPULLER
STEERING
(Commercially-available)
SRSMAIN HARNESS
2P CONNECTOR
CABLEREELSUB
HARNESS
3P CONNECTOR
1 0 . R e m o v et h e c a b l er e e lf r o m t h e c o l u m n .
(cont'd)
24-73
GableReel
Replacement(cont'd)
NOTE:
. B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,t h e f r o n t
wheelsshouldbe alignedstraightahead.
. Be sure to lnstallthe harnesswires so that they
are not pinchedor interferingwith other parts.
. After reassembly,confirm that the wheels are
still turned straightaheadand that the steering
wheel spokeangle is correct(roadtest).lf minor
spokeangleadjustmentis necessary,
do so only
by adjustingthe tie-rods,not by removing and
repositioning
the steeringwheel.
r 3 , Installthe steeringcolumncovers.
1 4 . lf necessary,centerthe cable reel. (New replacement
cablereelscome centered.)Do this by first rotatingthe

cable reel clockwiseuntil it stops.Then rotate it counterclockwise(approximatelytwo and a half turns) until
the arrow markon the cablereellabelpointsstraight
uD.
1 1 . S e t t h e c a n c e ls l e e v es o t h a t t h e p r o i e c t i o n sa r e
alignedvenically.
ARROWMARK
CANCEL
SLEEVE
PROJECTIONS
12. Carefullyinstallthe cable reel on the steeringcol

u m n s h a f t .T h e n c o n n e c t h e 3 p c o n n e c t o tro t h e
cablereel sub-harness,
and connectthe 2p connector to the SRSmain harness.
SRSMAIN HARNESS
o'1
: _ - - - - - - -
- - - - - - <
1 5 . I n s t a l lt h e s t e e r i n gw h e e l ,t h e n c o n n e c t h e h o r n
connectorand cruisecontrolsevresumeswitchcon_
neclor.
STEERING
WHEEL
CRUISECONTROL
SET/RESUME
SRSUnit
Replacement
CAUNON:
. Beforo disconnesting any part of the SRS wire harness,disconneetthe ailbag connector(s).
. During installation or rsplacement, do not bump
(impact wronch, hammor etc.) the aroa near tho SRS
unit.
3.
Removethe right sidecoverfrom the SRSunit.
SRSUNlT
NOTE:
. Do not damagethe SRSunit terminalsor connectors.
. Do not disassemblethe SRS unit; it has no serviceableoarts.
. Storethe SRSunit in a clean,dry area.
. Do not useany SRSunit which has beensubjectedto
wateror showssignsof beingdroppedor improperly
handled,suchas dents,cracksor deformation.
l.
Disconnectthe batterynegativecable,then disconnectthe positivecablefrom the battery,andwaitat

leastthree minutes.
2.
Disconnect
the airbagconnector{s}:
NOTE:When disconnected,
the airbagconnectoris
automatically
shorted.
Driver's Side:
o Removethe accesspanel from the steeringwheel.
then disconnectthe 2P connectorbetweenthe driver's airbagand cablereel(seepage24-11).
Front Passenggr'sSidg:
. Disconnectthe 2P connectorbetweenthe front passenger'sairbagand SRS main harness(seepage 2411).
TORX
BOL?S
U3ar Torx
T30 bit.
RIGHTSIDE
COVER
Removethe left side cover from the SRS unit. then
d i s c o n n e ctth e S R S m a i n h a r n e s s1 8 Pc o n n e c t o r
from the SRSunit,
l,---, $'
SRS UNIT
Removethe four Torx bolts from the SRSunit,then

pull out the SRSunit from the driver'sside,
\-./
tt
r,i
9. Reconnecttho drivgr's airbr 2P :onnector lo the
cable reel 2P connctor,than rernstallthe access
panelon the steeringr*reel-
lnstallthenew SRSunit.
6.
1 0 . Reconnectthe front passenger'sai.bag conneclor

to the SRSmain harness.
the batterypositivecable,thn lho n6ga1 1 . Reconnect
tive cable.
After installingthe SRSunit, confirmpropersystem
operation:Turn the ignitionswitchON (ll);the SRS
indicatorlight shouldcomeon for aboutsix seconds
and then go off.
SRSMAIN HARNESS
18PCONNECTOR
TORXBOLTS
9.8 N.m 11.0kgf.m, 7.2 lbfft)
Uso a Torx T30 bh.
Replace.
TORXBOLTS
9.8N.m(1.0kgtm.7.2lbtftl
Usoa TorxT30bit.
Replace.
7.
Connectthe SRSmain harness18Pconnectorto the

SRSunit;push it into positionuntil it clicks
8.
I n s t a l lt h e S R S u n i t c o v e r s( r i g h t a n d l e f t ) .M a k e
surethe coverssnaptogetherin the middle

96-98 Service Manual Honda Civic

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96-98 Service Manual Honda Civic

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GeneralInformation

2HG: HONDAOF CANADA

Vehicle ldentification Number

U.S. 1996Model {4-doorSedanl

Lino, Body 8nd EngineTyp

Vehicle ldentification Number

Lino, Body and EnginaTypc

3; OX with ABS, HX with ABS

Vehicle ldentification Number

Line, Body and EnginoTyps

Vehicle ldentification Number

lHG EJ653*TL 800001

Lino, Body and EnginoTyp6

CANADA 1996Model (2-doorCoupel

Lins, Body and EngineTypa

Lino, Body and EnginoTypr

Vehicle ldentification Number

U.S. 1997Model l4-door Sedanl

Lino, Body snd EngineTypo

A4RA: 4-soesdAutomatic Transmission

A4RA(U.S.A.): 6000001B4RA{U.S.A.): 60000012000001M4RAUAPAN):

Vehicle ldentification Number

Vehicle ldentification Number

A4RA: 6000001B4RA: 6000001S40 :1000001M4VA:2000001-

CANADA 1997Model (2-door Hatchbackl

Line, Body lnd EnginTypo

Vehicle ldentification Number

Lino, Body and EngineTyps

CANADA 1997Model (2-doorCoupel

Lino. Eody and Engins Type

44RA: 4-speedAutomatic Transmission

L: East Liberty, Ohio Plant. U.S.A.

Vehicle ldentif ication Numbel

2HGEJ632 *WH 1 00001

Vehicle ldentification Number

U.S. 1998Model (4-doorSedanl

Line, Body and EngineType

Lin., Body and EnginaTypo

CANADA 1998Model l2-door Hatchbackl

CANADA 1998Model (4-doorSedan)

2HG: HONDAOF CANADA

B4RA(U.S.A.): 7000001M4RA(JAPAN):3000001S40(JAPAN) : 1000001-

Line, Body and EnginType

4!8q{Gt ALwAYsWEARyouR SEATBELT

U.S. mod.l 198modell

' Exc.et CANADACX

Hrr.n u stcv'ct MA\uArro' aDoflror{A,

50ST {50 States}:

Lift and SupportPoints

Lift and SupportPoints

Set the parkingbrakeand blockthe wheelsthat are

Alway3 u3a safoty stand3 whcn working on 01 undol

Raisethe vehicle high enough to insert the safety

Center the jacking

Center the jack

towIt the vehicleneedsto be towed,call a professional

TIE OOWN HOOKS

lf the vehiclecannotbe transportedby flat-bed,it should

250 rpm and wide open throttle

0.05- 0.15(0.002- 0.006)

Unitot length:mm (in)

Capacity f (uS qt, lmp ql)

0.15- 0.30(0.006- 0.012)

74.940- 74.990t2.9520- 2.95241