oHOP MANUAL HONDA CIVIC CHASSIS MAINTENANCE AND REPAIR 88QINTRODUCTION [— How to Use This Manual ‘This manual contains service information for the CIVIC COUPE CRX. Separate volumes are Published regarding vehicle construction, engine, and transmission; the applicable reference rmanwals are listed below. ‘This manual is divided into sections. This first page of each section is marked with a black tab that lines up with one of the thumb index tabs on the next page. You can quickly find the first page of each saction without looking through a fulltable of contents. The symbols printed at the top corner of each page can also be used as a quick reference system. Each section includes: 1. A table of contents, or an exploded-view index showing: ‘+ Parts disassembly sequence. + Bolt torques and thread sizes: + Page referonces to descriptions in text. 2. Disassembly/assembly procedures and tools. 3. Inspection. 44. Testing/traubleshooting, 5. Repair 6. Adjustments. [— Reference Manuals Description Code No. | Remarks peel ‘CIVIC COUPE CRX Construction | 62SH210 | ‘Dec. 1987 and Function D126/0138/0144/0186/016A | E2PMT00| 1.2. SOHC 1-Carbureted Engine |Nov. 1987 Engine Maintenance and Repair 1'3.eSOHC 1-Carburted Engine 114 tSOHC 2-Carbureted Engine 1'5ESOHC 1-Carbureted Engine 115 SOHC 2-Carbureted Engine 115ESOHC PGW Engine 1-6 250HC PGW-FI Engine 1.62 DOHC PGM-FI Engine 13 Manual Transmission 6271300 | 5 Speed Nov. 1967 Malntanance and Repat Special Information Indicates a strong possibility of severe personal injury or loss of life if instruc- tions are not followed. CAUTION: Indicates a possiblity of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does comain warnings fend cautions against some specific service methods which could couse PERSONAL INJURY, oF could demage a vehicle or make it unsafe. Please understand that these ‘warnings cannot cover all conceivable ways in which service, whether of not recommend- ‘ed by Honda Motor, might be done, or of the possible hazardous consequences of each ‘conceivable way, nor could Honda Motor investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda Motor. must satisfy himsell thoroughly that neither personal safety nor vehicle safety will be jeopardized. All information contained in this manual fs based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part ‘of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by ‘any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. First Edition 12/87 728 pages All Rights Reservec HONDA MOTOR Co... LTD. Service Publication Office7-18 General Info || Special Tools E Specifications spec} Maintenance EE Engine sooo Fuel and Emissions 3 a, Transaxle 7 i“ Steering 101 — Suspension Brakes Body Heater and Air Conditioner Lt Electrical I 7General Information Chassis and Engine Numbers Identification Number Location: Label Locations .. Lift and Support Points Towing ..., Preparation of Work Symbol Marks Abbreviation+hassis and Engine Numbers ~Vehicle Identification Number ———————, i eae q { ‘Manufactuere, Mab ‘Type of Vehicie JHM: HONDA MOTOR CO., LTD., JAPAN. HONDA, Passomger car Line/Body and Engine Type: ED9: CIVIC COUPE CRX 1600 Transmission and Body Type: 3; S-speed menual/2-Door Coupe nd 1600, SOHC) 7: DI (1600, BOHC) Fixed code: S: SUZUKA Factory Serial Number -—Engine Number D1 Engine Type ——————______] D1GAS: 1.6 £ SOHC PGM-FI ‘With catalytic converter 1647: 1.61 SOHC PGM-FI Without catalytic converter D16AB: 1.6: DOHC PGM-FI With catalytic converter D168: 1.61 DOHC PGM-Fi i Without catalytic converter H Model Year: 1988 Emission Group” 0: Without eatalytic converter and KX, KO. 7: KS, KW with catalytic converter ‘Serial Number: [—Transmission Number £3-1000001 Transmission Typ9————_] L3: Manual 5-speed ‘Soria! Number ———________|Identification Number Locations is | Vehicle Identification Number Vehicle Idensitication Number Vehicle identification Number (KS only) ransmission Numt (Manual Vehicle Wdentiieation Number-abel LocationsLift and Support Points “Hoist 1. Place the lift blocks as shown 2. Raise the hoist 3 few inches and rock the car to be sure 11s firmly supported. 3. Raise she hoist to full eight and inspect lit pomnts fr sole support. [EEEIIIES wen heavy rear components such as suspension, fuel tank, spare tite and trnk idihatch ae to be ‘Place additional weight in the trunk before hoisting. When substantial weight is removed from the rear of the car, the center of gravity may change and can cause the car to tip forward on the hoist. NOTE: Since each tie/wheel assembly weighs approximately 14 kg (30 Ibs), placing the front wheels in the trunk will assist with the weight transfer. FRONT UFT BLOCKS REAR (cont'd) ) 1-5ift and Support Points (cont'd) Floor Jack $$ 1. Set the parking brake and block the wheels that are ot being lilted Use sofety stands when working on or under any vehicle that is supported by only 2 2. When lifting the rear of the car, put the gearshift jack. lever in reverse. © Never attempt to use a bumper jack for lifting or Supporting the car. 3. Raise the car high enough to insert the safety stands. 4. Adjust and place the safety stends as shown on age 1-7 so the car will be approximately level, ‘then lower the car onto the stands. Conter thé ecking bracket in the middle (of the jack it platform JACK LIFT PLATFORM Ceemter the jacking bracket nthe middle lof the jack itt platorm, JACK LIFT PLATFORM, uwSafety Stands oO FRONT SUPPORT POINT SAFETY STANDS 1-7Towing > Towing ——______ {f towing is necessary, we recommended the following: Fiat Bed Equipment: Entire car is winched on a fat bed vehicle. This isthe best way of towing the car. Wheel Lift Type: Front or rear of the car is lifted at the wheels and is suitable for the car. CAUTION: If @ sling type tow is used, the tow ‘truck driver should position wood spacer blocks between your car's frame and the chains and lift ‘straps to avoid damaging the bumper and the body. Do not use the Bumpers to lift the car oF to support ‘the car's weight while towing. Check local regul tions for towing. ‘TOWING HooKs ‘mergency towing with a four wheels on the ground: Inder certain emergency conditions, the car may need 2 be towed with all four wheels on the ground. if the aris towed with all four wheels on the groune, check loeel ‘gulations end observe the following precautions: © Shift the transmission to neutral © Release the parking brake, ‘Turn the ignitien to the “1" position to uniock the steering. © Do not exceed 55 kph (35 mph) or tow for distances of more than 80 km (50 miles) 2 frame mount tow bar is used with 2 four wheel tow: © Do not attach it to the bumper. © Follow the tow bar manufacturer's instructions. FRIES Never use tow chains orrope to tow a ar; your ability to safely control the car may be adversely affected,Preparation of Work * |Special Caution Items For This Car 1 ) ‘SHOP ToweL Fuel Line Servicing * Relieve fuel pressure by loosening the service bolt provided on the top of the fuel filter before disconnecting a fuel hose or a fuel pioe. SERVICE BOLT 12 Norm (9.2 kg-m, 9 Ib FURL FILTER + Be sure to replace washers, O-rings, end rubb ‘seals with new ones when servicing fuel ine parts. + Always apply ci to the surfaces of O-rings and seal rings before instalation. Never use brake fluid, radiator fluid, vegetable oils or alcohol: based oils. — ee FUEL INJECTOR + When assembling the flare joint of the high- pressure fuel fine, clean the joint and coat with new engine oil. + When installing an injector, check the angle of ‘the coupler. The center line of the coupler should align with the setting mark on the Injector holder. FUEL PIPE SETTING MARKS. Inspection for fuel leakage + After assembling fuel ine parts, turn ON the ig- nition switch (do not operate the starter) go that the fuel pump is operated for approximately two seconds and the fuel is pressurized. Repeat this ‘operation two or three times and check whether ‘any fuel leakage hes occurred in any of the vari- ‘ous points in the fuel fine. Installation of an amatour radio for cers equipped with PGM-FI. Care has been taken for the PGM-FI ECU (computer) ‘and its wiring to prevent erroneous operation from ‘ecemal interference, but erroneous operation of the Computer may be caused by extremely strong radio waves. Attention must be paid t0 the following items to prevent erroneous operation of the computer + The antenna and the body of the radio must be ‘t least 200 mm (7.9 in.) away from the computer. ‘The computer locations: ‘+ PGM-FI ECU: Passenger’ side front lower panel + Do not lead the antenna feeder and the coaxial cable over a long distance parallel to the car's ‘wiring. When crossing with the wiring is required, execute crossing at a right angle. + Do not install @ radio with a large ouput (max. 10 w. ‘Apply liquid gasket to the transmission, oil pump ‘cover. ‘ight side cover and water outlet. Use HONDA PART NO 08740-99986 as a liquid gesket, + Check that the mating surfaces are clean and ‘ty before applying liquid gasket. Degrease the mating surfaces if necessary. + Apply liquid gasket evenly, being careful to cover all the mating surface, ‘the inner threads of the bolt holes. + Donot allow liquid gasket to stand for mor 20 minutes before assembly. + Wait at least 30 minutes before filing with the appropriate liquid (engine oi, coolant etc) thanPreparation of Work CAUTION: Observe all safety precautions and notes while working. 1 2. Work safely and give your work your undivided atten- tion. When either the front or rear wheels are to be ‘ised, block the remaining wheels securely. Commu. nicate signals as frequently as possible when work Involves two or more workers. Do not run the engine unless the shop or working area is well ventilated, 2) A Gee a Mark or place al removed parts in order in @ parts rack 40 they can be reassembled in their original places. 4. Use special tools when use of such is species 5. Pans must be assembled with the proper torgue ‘aecording to the maintenance standards established 6. When tightening a series bolts or nuts, begin with the enter oF larger dismeter Botts and tighten them in ‘crisscross pattern in two or more steps, 7. Use new packings, gaskets, O-rings and cotter pins ‘whenever reassembling oS © OF OGG} 8. Use genuine HONDA parts and ibricants or those equivalent. When parts are to be reused, they must be, inspected carefuty to make sure they are not damaged (oF deteriorated and are in good usabie condition Go gl 10Electrical 9. Coat or fil parts with specified grease as specified 10. 12. {Page 4-2). Clean all removed parts with solvent upon disassembly, Brake fluid and hydraulic components + When replenishing the system, use extreme care to prevent dust and dir from entering the system, + Do not mix different brands of fluid as they may not bbe compatible. + Do not reuse drained brake fluid rake fluid can cause damage to painted surfaces. ‘Wipe up spilled fluid at ones. + Attar disconnecting brake hoses or pipes, be sure to plug the openings to prevent loss of brake fluid. + Clean all disassembled parts only in clean BRAKE FLUID. Blow open ali holes and passages with ‘compressed air + Keep disassembled parts from ai-bomne dust and abrasives. + Check that parts ore clean before assembly. ‘Avoid oil or grease getting on rubber parts and tubes. unless, specified Upon assembling, check every part for proper installa- tion and operation. &ee q \ + Before making any repairs on electric wires or parts, reparation of Work — Electrical (cont'd) ‘© When removing tocking couplers, be sure to disengage the lock before disconnecting (© Couplers may be of tio types, those in which the lock is, Pressed to remove. and those in which the lock is pulled lp to remove. Be sure to ascertain the type of locking device before beginning work. The following is 8 depic~ tion of the means of disconnecting various typical cou- Press to disengage: Pull up to disengage: CO » When sisconnecting locks, first press in the coupler tightly (to provide clearance to the locking device), then operate the tab fully and remove the coupler in the designated manner. See — = ee -»> - 12 + All lastic plugs have locking tabs that must be released before disconnecting, and must be aligned when re- — + When cisconnesting 2 coupler, pull it off from the ‘mating coupler by holding on both couplers. + Never try to disconnect couplers by pulling on their + Before connecting couplers, check to see that the termi nals are in place and are not bent or distorted. + Insert couplers fully until they wall no longer go. + Some couplers have locking tabs that must be aligned land engaged securely. + Don’t use wire hamesses with @ loose wire or coupler. cop % Pob~x + Place the plastic cover over the mating coupler after reconnecting. Also check that the caveris not distorted. <<+ Before clamping, check each connector cover for damage, Also make sure that the female connector js tight and not loosened from the previous use. * Insert male connectors into the female connectors fully ‘nti! they will no longer go. + Be sure that plastic cover s placed over the connection. * Position the wires 20 that the open end of the cover is ot facing upward. + Secure wires and wire harnesses to the frame with thei espective wire bands at the designated locations Fosition the wing in the bands eo that only the insulat- 0 surfaces contact the wires oF wire hamesses. wire harness or cable can be a hazard to safety After clamping, check each wire for security ints clamp. ¥ \_O x ao Qin * Do not squeeze wires against the weld when a weld-on clamp is used, O x Ge reparation of Work ~ Electrical (eo) + Protect wites and harnesses with tape ar a tube Hf they ‘re in contact with a sharp edge or corner. *+ Clean the attaching surface thoroughly if an addhesive is. used. First, wipe with solvent or alcohol in necessary. o + Seat grommets in their grooves properly. + a + Do not damage the insulation when connecting » wire. + Do not use wires or harnesses with @ broken insulation Repair by wrapping with a protective tape or replace with new ones if necessary. O x + After instaling parts, make sure that wire hamesses are = + After routing, check that the wire hamesses ate not twisted or kinked. 7 + Wire harnesses shovld be routed ¢o that they are not pulled taut, slackened excessively, pinched, or inter- fering with adjacent or surrounding parts in al steering positions. + When using the Service Tester, follow the manufacturer's instructions and those described in the Shop Manvel. + Do not drop parts. EX ey + Rust is the enemy of all finished surfaces. Before con- ‘necting connectors and couplers, check the terminals {and remove, if any, rust using afine sand paver or emery oe OSS “14Symbol Marks Abbreviation i The following symbols stand for: TR] Apply engine of, Bernsen —GEEN Apply grease Be soniy Power stein Fu "Apply or check vacuum. Sequence for removal. ) Air Conditioner Battery Catalytic Converter Electronic Air Control Vaive PGM-FI Eleetronie Contr, Unit Exhaust Ground lgnition Intake Intermittent Left Side Left Hand Drive Manual Transmission Positive Crankcose Ventiation Programmed Fuel-injection Power Steering Right Side Right Hand Drive ‘Switch Solencid Vaive ‘Top Dead Center ey 1-15Special Tools Existing Tools (Common with Other Models).......ipecial Tools Existing Tools (Common with Other Models) —5. Engine Too! Number Description ow I Romarks ®889008¢068080800000 e0lF (07966—6340011 07944-8110100 077570010000 07HAD~P.J70200 07742--0010100 07743~0020000 O7HAH—PJ70100 (07GMD—PH70100 077420010200 07984~6570101 07947—sB00100 079738570002 07373—-6570500 07973-sB00100 (07973—-PE00200 07973--P£00400, 07873—-PEO0302 07948-0080000 O7HAD—PJ70100 077490010000 079126110001 07406-03000 Engine Block Hanger Pin Driver § mm Valve Spring Compressor Valve Guide Seal Installer Valve Guide Driver 6.5 mm Adjustable Valve Guide Driver Valve Guide Reamer, 5.5 mm Valve Guide Seal Instalier Valve Guide Driver, 6.6 mm Valve Guide Reamer, 6.6 mm it Seal Driver Piston Pin Dis/Assembly Too! Set Piston Base Piston Base Head Pilot Coli: Piston Pin Base insert Adjustable Piston Pin Oriver Driver Attachment Driver Driver it Fiter Socket Wrench Oil Pressure Gauge Adopter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7 Used to set the piston at TDC (DOHC engine) 07957—3280001 may also be used. For camshaft seal ‘Crankshaft (Clutch side) Crankshaft (Pulley sie} Crankshaft (Clutch side) For pressure messurement -6. Fuel and missions ptJ4_\ No. | Toot Number Description | ay Remarks © | 07sA2—SH20100 | APM. Connecting Adapaor 1 ® | 07999-PD6000A | PaM-ri Test Harness 1 @ | 074080040001 | Fuel Pressure Gauge : @1 | 074060040100 | Pressure Gauge 1 @-2 | 07406—0040201 | Hose Assy 1 | J Somponent Toots ® | o7GnJ—ntLeo100 | Test Horness Joa © | 074110020000 | disital creut meter 1 “7. Clutch No. | Toot Number Description oy Remarks © | 07824—PD20003 | Ring Gear Holder {oo 07924—PD20002 may also be used. @ | 075aF—PM70100 | ciutcn Dise Atgnment Too! 1 @ | 07746-o010100 | arechment, 32+ 36 nvm 1 ® _| 07743-0010000 | Driver 1ae ;— 8. Manual Transmission No. | Too! Number Description oy Remarks @ 07744—0010400 | Pin Driver, 5 mm 1 07944—6110100 may also be used. @ | 07836-6340000 | Bearing Remover Set 1 & | Srrae—oo10900 | Attachment 42 x27 mm 1 | 97974~6110100 may sso be use & | o7ras—doro000 | Ore 1 | 079ze—6110000 may alse be teed © | O7740~0010800 | Atachment, 52x56 mm 1 | 679678320200 may aio he ued & | 07978-Ps40000 | Negnet Stand Base 1 oO 07GAJ—PG20101 | Mainshaft Clearance 1 Inspection Too! ® 07746--0030100 | Driver 1 ec 07944—SA00000 | Pin Driver 4.0 mm 1 @ | 078476110500 | Oil Seat Driver 1 & | o7eea=se20200 | Oi Ses! Diver : @ 07947—-6340500 | Oil Seal Driver Attachment E 1 +10. Driveshafts No. | Too! Number Description oy Remarks © | 07749-00100 | orver 7 @ | 07746-0040800 | 25 mm Pot 1 @ | 07746-0010900 | Arechment, 42 x47 mm 1 © | 07947=8090100 | oi Sel Driver Attachment 1 © O7JAD—SH30100 | Oil Seal Driver Attachment 1 ® 077460030100 } Innes Handle (C) 1 (cont'd)Special ! Tools Existing Tools (Common with Other Models) r—11. Manual Steering No. | Too!Number | Description on Remarks © | 07816—SA50001 | Steering Gearbox Lock Nut Wrench 1 | 07816—6920100 may aiso be used. ® | 670418020003 | Bail Jom Remover ; © _| 07974—Sa50800 | Ball Joint Boer Cip Guide 8 La p— 11. Power Steering $A Now| TootNumber | Description Loy Remarks @ | G7408-0010101 | Bypass Tube Joint 7 © | o7916~sAs0001 | Steering Gearbox Lock Nut Wrench 1 & |} 07406-0010200 | P/S Pressure Gauge Set 1 @-1 | 07406-0010300 | Pressure Contol Valve 1 @-z | 074060010400 | Pressure Gauge 1 | F-Somponent Toots ® _ | o7Gak-SECO100 | P/S Pressure Gauge Adaptor Set 1 @ 1+ | 07GAK—SEO0110 | /S Joint Adaptor (Pump) + | 074080011100 may also be used. ©-2* | 07GAK-$z00120 | /S Joint Adaptor (Hose) 1 | 074080011200 may also be used. © | 07841-6920003 | Ban Joint Remover 1 © | 077490010000 | Driver 1 | 079486110000 may aso be used. ® | 07746-0010300 | attachment, 42x47 mm 1 © | 079476340300 | Driver Attachment 1 © | 67@aG—so40000 | F/S Too! Kit 1 @1 | 07GAG—S040100 | Piaton Seat Ring Guide 1 @2_ | 07GaG—S040200 | Piston Seat Ring Sizing Toot 1 @-3 | 07Gac—s040300 | Cylinder End Sea! Slider 1 Component Toots ©-4 | 07GAG—Soa0400 | Cytinder End Seal Guide 1 @-s | 07Gac—so40600 | Too! Box 1 @ | 07974—sa50600 | Pinion Seal Guide 1 © _| 077250030000 | Universal Holder 1_[ 07725-0010101 may aso be use. 1 and @= 2": Component Toole —12. Suspension No. | Tool Number Description Low Remarks: @ | 074GK—0070100 | Wheel Aignment Gauge Attachment 7 ® | a7941-6820003 | fall Joint Remover 1 ® | 07965—6340301 | Hub Dis/Ascemby Base 1 © | O7AF—SH20110 | Hub Dis/Assembly Pilot, 38 mm 1 © | o7sar—sH20120 | Hub Dis/assembly Skat 1 22.4 25.4 mm ® | 077490010000 | Drver 1 ® | 07746-0010400 | Atachment, 52 x 58 mm 1 © | o7Gar—se00401 | Hun Dis/Assembly Base 1 6 07965~6920201 | Hub Dis/Assembly Base 1 @ | 27746-01080 | anacrment, 72 x 75 mm 1 ® | 07GAF—SE00200. | Hub Assembly Guide Attachment 1 @ | 07965—s800100 | Bat Joint Remover/instaler 1 @ | o7saF—sw20200 | Bat Joint Remover Base 1 @ | 073¢5-3800200 | wat Join: insialer Base 1 & | 07874-8150700 | Bal Joint Boot Cip Guide A 1 © | 07974—Sa50800 | Bl Joint Boot Clip Guide 8 1 @ _|_07GAe—SEOO100 | Spring Compressor i rs13. Brakes No. | Too! Number Descristion Low | Remarks oO (079210010001 | Flare Nut Wrench 1 ® | 07510~6340300 | Vacuum Joint Tube A 1 ® (07404—5790300 | Vacuum Gauge 1 © | 074105790500 | Tube Joint Adaptor 1 ® 07406—5790200 | Oil Pressure Gauge 2 © | 07410-5790100 | Pressure Gauge Attachment C 2 oO (07510—6340100 | Pressure Gauge Joint Pipe 2 ® | 07749-0010000 | Diver + | 079496110000 may also be used @ | 07747=6890300 | Driver tachment ¢ 1 © | 07GAG—SE00100 | Pustrod Adjustment Gauge 1 © | a7#AE=S600100 | Brake Spring Compressor t @ | 07914~8x50001 | Snap Ring Piers 1 15, Heater and Air Conditioner No._| Too! Number Description ow Remarks ® | 07746-0080100 | Diver c + | Paley nstaaton ® | O7HAF—SF10300 | seal Seat Remover + | Cover piate removal ® | o7Har—Se10400 | Sool Remover/netaler + | shat eat Femova'instalation 16. Electrical No. | __Tool Number Desorption ow, Remarks © _ | 07820-88200 | Fuel Sender Wrench 7 2-5Specifications Standards and Service Limits Design Specifications Body Specifications ...Standards and Service Limits p 5. Engine/Cylinder Head, Valve Train (SOHC Engine) ————_______ I MEASUREMENT, i STANDARD (NEW) SERVICE LIM Gorsrenion 2508" vam! and weno woe | fom BATE MPa TS. Osg/em, 185 pal : Sen saz trai’ torent Vas so Naum variauon 588 Era (2 kaye de a ‘ringer nea | waree = | 0.08 (0.0021 orcad 94 95-95.05, i Conahat Ena say 2.05-0,15 10.002—0.008) 25,003) Ghecernce | 080"6 bas 855-285, Sisioobe) Runowt 855.05 00.001) me 8.03 (80H) Carmlabe neoht WN ge Ry Secon rasity = w 36.587 (3518), = & Ber 35 rer (220%) = By 36.386 0 S581 = Vows ® i = & i = ie | Sab 217 ; & | 542 03154 Stemto-guideeasrnee 8:98 19.003" & 8.52 16-908) Stem insted height x 47,705 (sre i & i 28:58s 1.9981) Vevevet | Wom i T og8=1 15 (0 033-0088 18 (0.95) i & | SEC 38 (0.888°8.065), 2000.38 : ‘abe spare | Free enath w | 8561; si26) ‘oe arse) : oe & j ais 8388} 22:39 fh gone) Seuarenes tex | “28 50h 52". 060970.0077 Vave evite | 10. Wand& | 8.61589 (0 aveS-02I771 B5 (0.2705) ecareom | Amtoahah dewance w @.919-2.08 (0,0057~0 0020, 2.08 10-009) Fx | e180 B54 te-8007 0030) 0.08 (0:003) — 5. Engine/Cylinder Head, Valve Train (DOHC Engine) ———________ MEASUREMENT { STANDARD (New) [ SERVICE LIMTT ‘Comressn | 280 mn" com and wrdt-open tone Ronin ] (Eesha BS ew, 108 pa Minions | s82'te0 o's coven 83 pa Maxum vacation [86 te te naren ze oa ‘rider boas | warpage — 0.05 (0.002) ton 13595-192.05, =! Comahor Ee per 9.98- 0,75 10.002-0.008) 25,0021 Getince 8.080°0. 688 10.605 S08) 8.13006) Ronost 96,03 100.001) mat. 8:03 (000) Esme magne w $3.02" 4 3500) = & 32382 12700) = Vowe ‘Vane earance we 2 19-0.17 ©.0908-0.00n = & 8.4808:18 (0.998~0:908, = ) Vave stem 0.0. i 8:98-8:58 10 295126 2805) 838 2870) ex §:35-€ 86 10 2579-0:2505) 8:33 (0 2800, Stemo-gvide clearance ik 2108-9108 (o-aarmo ea" 8.98 19.005) i & 9,880.88 (6:902-0.098) 8:73 0008) Stem instates eight x SeSeg-40 O18 Pastore | Se aes ees, & 46.735748.205 fi foiz—1 9999) | 28.268 (S228) Vane set] win Wang @x | 1.25@1.58 (0.088-0.081) 2010.08 Voir sean | Free name N | a2 480 8097 3.46 (ez & 36.89 08883, 53.35 [h poay, Seutroness Rex ee T6680 c6s/0.088) Give awa) v0 Nerd eK, 661-663 (02602-0010) | 858 @aB7eT") B. Engine/Engine Block Unit: mm tn.) MEASUREMENT i STANDARD (NEW) | sevice ur Cylinder block | Warpage of deck surface 9.07 (0.0028) max. T 0.100. Seed | CREB Size 200s | SERRE, ay 2 Bete [RSS = Boe Fae BOD. aiden baps Tascraw annie | marae seater carmen ee eei-20%w.000e-20018 | 9.059000 Se etree sabe geome geores | gts en 1 Be eae ee Mey | S13 BS Panna Riga Cie 3 Dee—THIa c8 9.08 $35-035 Bope-g gig 23838 | 838-688 0.90829 944 $5893 Cannnig oa | Prova maroc gie-a p10 .990e-0.01 | — Cerow eee, aoe = eres SE See soeto ora oa 0.016 Canaan] Wan at sonar aagi6oa5.o00 0 ver] See ean ar | seatioseeee. ©5370 0.000 ane, RCSB or—s.705 | 29 Se a mera Sos SaaS A 2210 0.000 eer Bae ee a oe g215,ceee rag Bie es 833 8) fous | wheertpminre agene ' Are Te eeze-on2 wone-00017 | os iecun ) No.3 journal 0:030-0.048 (0.0012—9.0018) 0.5 (0.002) \ 1 et cuenee Sbae-e cee 88805-89518 | SEVER, : ls mm 6 -- 8. Engine/Engine Lubrication, —£ J _____wsr nnes MeasuneMeNT | senvice um ‘Engine oil Cepacity £(U-S.qt.. ime. gt ‘sone | $262.3. er? cone | 288228 BE 6823 Gipeae | Daneman SE | Gt 38 VS oe 87 rp. om) 62590" om SSE | SUNSUE gs Winner, topos a eiaseame 315 8.008 23 0.08 ote eae Sy at are, 336.5938 o.cou-o.007 2200 ins Says ou ape ces Beene SH icine | Frese sting 000 1767 ioe SORE | 197 we 7 wren 38 pl Se [ BEATEN es ee Ecos Ber 451 we wer B5 r=) ; SSS | Mo ts iger Bs r- 8. Engine/ Coo img ama ‘Thesrosmitch ON" temperature ‘Theemoneten "OFF" epee | MEASUREMENT | STANDARD (NEW) Taaeir Gases Weaknened « US.ar rapan) | DONE 2548 40 rete fence we OMS SEN | BONE Sh 38 Radeworeap | Prove can opening peste [2416 we (0.757105 gre TEP Trent | Stexevo open Tees 2 7228) Risen sense [vk tt ts open stosiinm Ww: pune | Pate ae lent a Saas Sera tm) 108'27 US. ge, 23 mp. g1/5,000 min pm ‘Cooing fn | Fan-tozore dearance (conta) 3-33tandards and Service Limits (cont'd) — 6. Fuel and) Emission ttJtaz aA | MEASUREMENT STANDARD (NEW) Toeipame | Does ree ZED eh beg atom Bessa eee Fe oir oe an REINS Sorry pressure ERSTE Sie Bans on Presa | rs {F073 70 Pe (2. 38-2.78 ron 35-30 pa) ious Fusion | Gamo Wr WNOUS gu, B0ims USeeT Festi 7.000=3,000 min Tae soped | wan nang o9d SORE | 790 = Bo mn tome a Re | Biber ie one £6"Y | 389 2 som fom Exo | 800 2 80 (om) wee Wh Gants Comer OM WRSEANG Soe ae cs - 7. Clutch | MEASUREMENT STANDARD (NEW senvice una Cwrch pedst | Pega! height 213 (8.39) t0 floor — ven 340-150 (5.58.9) = Feat ty isPasie Sono 75) = Seamer hit 18d bo mo new = Fires | Gute tac wnoat 9.95 6 0001 na ans 0.08) heh 662 | et end aon 3 9081 mn 9210.08 Sauce 31885) me $3 oer eee PeBa038) 3313 Suenos | 12, 1, 0=34.15 6.2201 236) FTES SEUTEGS | bentonite eee cance eer Baa nen cover |_Uneeres of dntrgm son 0.8 (0.03) mae 101 oa uch voees | Caer lor $08.0 10.16-0.20 = » 8, Manual Transmission —-aA | easunement STANDARD (NEW! sence un iranmnason of | Ganaeny #18 ate et) eer rerrs 2264 28 soho wnat | Be omy 9,339.28 0,608-0.000) Bago Bure of nate being comic wen | $3'875-98'80% 2229, oon, | AEP ooo) Somers of tr gear cots rh 33 $01-33 099 fr Se 33330) Bamere of tn Sige cone wee 26 350-9 99 1 Bez] gaan) | 38-98 388) Bars ef a bends ans Hg67-28 e000 seseo.eer) | 2195 908) Rete 36246 ctom mae Sse toes? Iemaran we | 2. 39,008-99025 0 SaGB—y SaeH | 99.07 Gear Sea | ES ay ae | BRS Esa Eos S513? a am | 888-83 8 Sose—9.S0rm, 83) oer, chee 2 | Soag sear teases | Soe’. Sh SORT AARC | S028 ‘en we | 1 37,g28-97 5 0.45709. 4577 | 30,07 1590) 2 £8 iy 3600518 Soli dors B77 relate Seanad Rites Ciao | Badeierton ‘Sonera Ena aay 9,372.38 6 0087=0 0180) 9.53 0.073) Biiatof erge eamng contrary | Seas 9 STG | BEBO, Bioessays cae 32.980-24 999 fo 98u0—o.snuy | 32-93 (ces) Gamer 3 tm ger Conse | deSee de 88 aterae I) | ess gen Soot i S526 oboet rae abe wees onan) 1. Figgas mE 0 Sias—I. STE | LOT eT woe | Romy $1928.75 tse Sons gutrs'eser She Bea Mee aon) | BEET EER, sewer | 0D PE wR aR | ager ogee Swear | ER aay $F Soo se oes (sey fer | Frenets j Beszczeer i iveost te) | 23a iam8. Manual Transmission (cont'd) MEASUREMENT t STANDARD ew! sevice LMA ‘Spacer cover | 1.0. 1" 32.975—32.986 (1-2982—1.2986) | 33.03 17.300 ‘KCounnersnatt | 0.0. | 38.989—39 000 (15350-15354); 38.93.(1.533) ~ rer |. [Reade | BRR = TP Eee aeanaices Taenes tener (us ao ( REARSNeE | menos a en £ TRG ae | PR Reverse wer | 1, 7 35,010-15.043 (0.5971-0.5922) | 15.08 10.598) I" Biveewsennenm | SMEARS | RT Sakae | Rete monn G OT TsaT0mH-o) | ba aT Sorter | Bes ee rere = BRIAR RET SENSE | oan Reverse shit | Shif fork paul grcove vn | 12,7—13.0 10.600-0.512) ,— fork Forkato-reverse idler gees clearence | g'5—1.1 10.020-0.083) | s800.07 eee Parana as Eeieeeconnamewra | EIR RCR | ose Sarena | Bega oe ReREEE OE [oa ones eames RERERET ISI | oar eone Tani free datmapeases | aeivemogen-oao | — ; Beeniehmenamem: | ARSABEE CRE” | oreo ‘Shift arm B-to-shift piece clesrance | 0.20.6 10.0078-0.0197), 0.62 (0.0248) diintgon surat an Se vee-mewarmasna | sazsesen) Taps [a ee ieee | Fae So sesame ares | a ee ae PERRET | oxi eames EE REEEtIns | Ot Sas reareuesee” | cea SEER | SBEEMBRE TRE | o1i Bem ust ee Sieeaa | om a aie rar pepe tn ene neeageemne agin | te ee Ree te ae 10. Driveshaft (MEASUREMENT STANDARD (NEW! i SERVICE LIMIT. a aemage nee 7 Ee oon | SEER R 7 rennet Sareea = Beem oot | Hertel ea Bon = 11. Steering | (MEASUREMENT | STANDARD (NEW) ‘SERVICE LIMIT ‘Steering whee! | Ploy 10 (0.39) max, — Gate | maormamame Wa PERRY | BARS OAR TOOT | ath PIS (0.036 (6.01, 0.072) ramromre | REE [ages ane Reset ae coms ES, | SEMprRcen eneMIOU, | | Raescte RAISE | aes-sane no-one. EE wate (aura | | sees gence | beeen naa ae RaR A ack end ‘osung torque Nem (kgm, (O-f}| ©.49—2,94 10.05-0.3, 0.961.271 |Standard and Service Limits (cont'd) p92. Suspemsiom AtmH§jAjm ma eH MEASUREMENT I STANDARD (NEW) SERVICE Limit Whee! afanmenr 5 Toon ember See so Turning angle MAX.) awa wheat L ra ee) ‘Whee! Fen runout Bee | ‘Wet beating | End pny rer i (8: Masimam ciewing angle at wach ro > 13. Brake 1 ear when place, MEASUREMENT STANDARD (NEW) SERVICE Lint arta brake | Pym etohe 20ON (20 kp #8 Ba To be locked when puled 610 . Foot brake ne RHO 1961 (6.31 fom hoor ) fore resale tHD | 153 16.01 fom for Free oty is(Goe20" ‘Master eyinge | Patonto-push rod Gemance (o-0.4 (0-0.016) = Dec bake | Our thickness Fron 13.0 10.78) 17,0,0,57) ear 10:00:38), Bo1033) Bee runout 83 (9.008) Die porate = 8.018 fo-0be) Pad thickness” Front 10.010.39) ¥8'0.08 Rew Bo(0.s2) 18 (0.08) Brake Dum | 1p, jo7oH 1a 713) ing thickness Berar 200.08) Brake boosar | Cheracteneics Vacuum rm Ha) Pec Pasarela) {ine Pressure KPa Ka/em, pal o 29 aa) 208 30 (aa) i 50 Bote)/16. Electrical nit: mm tin) | smeasunEMENT | STANDARD (wow Tanion cor Rated vor aver Pemary wining esate |_B.378=0.462 onme |" Seeonaary mincing estes T5.4d0=14.100 ome Taran wie | Resmance | 25.600 ohms mon Sean pve | Toe ‘ee Seton 16 on 10-1 0.039~0.08) Tprtor swing | Ariana SORE ie = (Ren roe BONE ie 2 F iheg roe Bane Lprang capacny GOchew sn) 20, 45, 47 Ampere Hore ‘String expec (ces a | a6 inn o°'385 amos crow Tremor | Ove t 73.6 760A MEASURERTENT i SaNOARD RET SERVE Ta Col reseaes (ot T 2.8-3.0. 050 20.3 ohm Sie m9 6.8. i 328 (ae) Bt n20 anh nat i 15.5 0.641 5300.20 300-5 : Brush Song tendon aco nas ‘rane mo TOT Di hw i MSUGA LO The 7 BAR Tec STAN aRD ‘Senge MEASUREMENT ‘new rita iNew ‘uM ae 35-08 02 24-05 078 ic eo (008-8830) (0.659) (0.018-8.520) soe, O-80 0.85 e002 0.05 Comet (0.008) om ‘6.008, 9.002, 75-300 73.0 28.0-28.3 2.8 ae ey Ba iS, (68) Sane Tas-i35 35 vasa? 23 a (045-085) oa 288-055) on tes, 19.12.89 w _ 20,1-26.5 = ree [nose fs « wl le.05-F ing 4 56.0Design Specifications rrews I nau wores Simensrons | mai om Tan ‘wan uncer cue | iets Orn ern wee 10, RE Oma eg i re tae WS Per xo. Kv & & creund Cuore ‘et ce conan ee ee ooo weigits | Eagne wanted eae ‘SOHC 2350. ise ze care wesne vont sae. | Ege ae | EE aoe | Bee ae | sone ge | gee | see | ane |S it Dotan Rew She zeae | wx ree | meme | Be | Bee saree | By sone Bee | a 3078) aaae | ene. | 8 x, Pei Wh 6) BE | Bas Mesinum ane Vil Wo ie | 8 Mena ast a as ee aweme ——ae one RE pint aangenet saree neee Seem seree seen, Raine ed ‘Win Euan comer Wooreh saat coer etna snd va rl Ate sa at vend carta EEE sen are Son caure Cone xg gc vi 95 rch octane rb i SOUS wan Sais’ Gone tae fasine wth St renreh octane nue orate sens sreeahres car [sept ib aes wine oheas usin ausn ves a CT = Troms er aos e peat ithe | a eos sxe Tn ont BE es a ren Ste a8 aman Bam Sein iy, coke eee ne vend a AEN Ewa | pee tse Bs oe a hE & oa i fore — n8 Spee ie . a Eater ce a reo 7 aig mony ‘31850 Keath ‘Compressor Revolution Speed 1.800 min tm See eee: sae OE aoe es Se ren 6 See dae fie safe mene! “lis Pres a=. ie corr RR, even 9 ee sty yf g8. fe eon sod of Bet | nog OO a renin nin AE | Face 7 Code canner Conard re = aah Stor oput vowurw Be. wa mes Serine sare Soe ianDesign Specifications res [___ meric | _encuisi ores AR GQNDL | Cone Gu Tipe T On, pugs om tet Gace Pier Consnston ieearay Teingean ype i or pee nity [__ossoosi *]? soscorre | Heaney a ed pion : Sean Brat rove Yana eure Tus, tscctoseck an ‘a7 ine a [Sterna wut Came ts Frontear ‘SUSPENSION | Tyre Syerem Shock Absorber Fron ear “Independent by Gaulle wisrbones, co¥ sponge Tebseope, nivogen gee tes ‘Festcope: Rogen $22 od eee Wher [Ep is ee wee te Seto ae Re [TS RE maraich ge vin ste tow | gal eu treme tome fa |S a a ue ring tne ea SEE ins we rn a Tesora BE aaa cone HEN Teer Por am so ae 4 the man fuse Box 60, | ee a, jemtatet say Bie ey ace ee eee sea, amet i isis eh SE wa rertg way one uo sen mewn ve pr 10Maintenance Lubrication Points.. Maintenance Schedule ...Lubrication Points LUBRICATION POINTS LUBRICANT Engine ‘API Service Grade: SE or SF SAE Viscosity: See cher below Transmission Manual API Service Grade: SE or SF Brake reservoir Broke fluid DOT 3 Power steering reservoir i | SAE30. 10W—30, 10W—40 or 20W—<40 grade oi! 1 |_Henda power steering fiuid P/N 08208-90061 |. Steering gearbox (Power) | "onde stering grease 67 08740—99065 3 4 5 6 ‘Steering gearbox(Manval) 7 | Tit steering 8 Steering ball joins 3 ‘Suspension ball joints 10 Steering boots u Shift lever pivot 12 ‘Steering column bushings 13 Pedal linkage 14 15 16 7 1B 19 20 Brake master cylinder push rod Tailgate hinges Door hinges upper and lower Door opening detents Fuel fier ti Engine Rood hinges Engine hood latch Multi-purpose Grease Piston seal Dust seal Caliper pin Piston 21 Caliper Silicone Grease Recommended Engine O (SE 0+ SF Grade oi) 30-20 -10 0 -20. 0 20 40 60 Engine oil viscosity for ‘embient temperature ranges, 30 2030 40cc 80 TO0er Recommended Menual Transmission Oi ry -200 20 a6 To9er -30=20-10 0 10 2036 aoe Transmission olt viscosity for ambient temperature ranges.Maintenance Schedule ‘SERVICE AT THE INTERVAL OF LISTED KM IWILES] OR MONTHS. WHICHEVER OCCURS FRGT 1,000 km {20 [40 “760.1 80700 rrems 1.000 mies “123435 I aa} 80 months "i 1224] 36 2a] 80" IDLE SPEED AND IDLE CO Toot VALVE CLEARANCE ro T ‘ALTERNATOR DRIVE BELT T ENGINE OIL AND OIL FILTER TRANSMISSION O1L RADIATOR COOLANT ‘COOLING SYSTEM, HOSES AND CONNECTIONS AIR CLEANER ELEMENT (Viscous tyoe)"™ ‘AIR CLEANER ELEMENT (Ory typel" FUEL FILTER, TANK, FUEL CINE AND CONNECTIONS EVAPORATIVE EMISSION CONTROL SYSTEMT™ IGNITION TIMING AND CONTROL SYSTEM ‘SPARK PLUGS (For cars using unleaded gasoinel ‘SPARK PLUGS (For cars using leaded gasoline) FE DISTRIBUTOR CAP AND ROTOR H IGNITION WIRING. CRANKCASE EMISSION CONTROL SYSTEM. BRAKE FLUID. BRAKE HOSES AND UNES T FRONT BRAKE PADS (nepect every 70, G00 km (8.000 miles) or 6 months FRONT BRAKE DISCS AND CALIPERS r REAR BRAKE DISCS, CALIPERS AND PADS PARKING BRAKES ‘CLUTCH RELEASE AR TRAVEL EXHAUST PIPE AND MUFFLER ‘SUSPENSION MOUNTING BOLTS, FRONT WHEEL ALIGNMENT ‘STEERING OPERATION, Tie ROD ENDS, STEENING GEAR BOX AND BOOTS: POWER STEERING SYSTEM™ POWER STEERING PUMP BELT CATALYTIC CONVERTER HEAT SHIELD (Car eauipped with catalvie Comaaa Replace Inspect. After inspection, clean, adjust, "' Thereafter, replace every 2 years of 40,000 km repair or replace if necessary (24,000 miles), whichever comes frst. REMARK: These service intervals assume routine checking * For European and KQ types. 1d replenishment has been done, as needed. by the customer, ‘Except for European and KO types. * Only for Ka type, “For cars using unleaded gasoline and KY type. Mor to tha caacneavng items must be serviced more frequently on care normally used under savero driving conditions for to the chart bolow for the appropriate maintenance intervals, evere driving conditions” include: i tT u 4 To 70,000 ie or 6 months |-|>}-|-|-|-»}0}-| =|] ~|-|--0} Repeated short dietance driving : Driving on rough and/or muddy roads Driving in dusty conditions F : Towing a taller Driving in severe, cold weather Replace Driving in areas using road salt or other corrosive Inspect. After inspection, clean, adjust, reper or replace if materials necessary, Condition Maintenance item | | Interval B= =F) Engine oF and al ior i a Every 5,000 eri (8,000 rly or 3 mone 5 2 E! Transmission : R Every 20.000 km {12,000 mies) or 12 months B= DE F| Front brate discs and caliper: I 1 Every 10.000 km (6,000 miles) or 6 months B + DE F] Rear brakes (cece, capo and pads) | ' Every 20,000 km (12,000 miles) or 12 manthe BC + E +| Clutch release orm wave! | ' Every 10,000 ken (6.000 miles) or & months +8 CE | Powar steering system L Every 10,000 kr (6,000 mies) or 6 monthsEngine Engine Tune-up 51 Timing Belt .. 5-13 Cylinder Head Removal/installation 5—27 Engine Removal/Installation 5-43, Exhaust Pipe and Muffler .. 5-53 Radiator .. 25-55,Engine Tune-up Radiator Cap Testing ... Coolant Level Inspection Engine Oil Level Inspection Engine Oil Replacement... Air Cleaner Inspection/ Replacement ... Compression Pressure Inspection Spark Plug Inspection Drive Belt Inspection Alternator Belt Adjustment P/S Pump Belt Adjustment A/C Compressor Belt Adjustment Valve Clearance Adjustment... Idle Speed Inspection/Adjustment Tailpipe Emissions Inspection Ignition Timing Inspection and Setting ..Engine Tune-up Radiator Cap Testing r Coolant Level Inspection See] QEKEEMIY system is under high pressure when 1. Check wether the coolant level in the coolant reser fengine fg Rot. To avoid danger of releasing scalding voir tank ie between "MAX and “MIN coolant, remove cap only when engine i cos 1. Remove the radiator cap, wet its seal with coolent, them install it on the pressure tester 2. Apply pressure of 74-103 kPa (0.75~1.05 kg/em?, 11-15 psi. 3. Check for a drop in pressure UPPER ie 4. Where ise drop in pressure, replace the cap, Level MAX Lowen —e ff LEVEL mI 2. Supply the coolant reservoir tank with coolant to “MAX”, ifthe coolant lavelis ower than “MIN or near to “MDC. RADIATOR CAP Note: © Use only HONDA RECOMMENDED anti-freeze / coolant. © For best corrosion protection, the coolant concen- ‘ration must be maintained’ year-round at 50% MINIMUM. Coolant concentrations less than 50% ‘may not provide sufficient protection against corro- sion or freezing '© Coolant concentrations greater than 60% willimpsir ‘cooling efficiency and are not recommended. CAUTION: © Do not mix different brand anti-freeze/coolants. (© Do not use a additional rust inhibitors or antirast products; they may not be compatible with the recommended coolant. Radiator Cootant Refill Capacity #(U.S.at., Imp.ct.) 1.6 DOHC 4.5 (4.7, 4.0) 1.6 1 SOHC AA (6.6, 3.9) Including the reservoir tank capacity: 0.4¢ (0.42 U.S.qt., 0.35 Imp. qt.) 3. See page 6-59 for refiling.“Ingine Oil Level Inspection ——— - Engine Oil Replacement ———— 1 2 Check engine oll wth the engine off and the car parked (on level ground. Make certain that the oil level indicated on the dipstick 's between the upper and lower marks. If the level has dropped close tothe lower mark, ad cil ntl it reaches the upper mark CAUTION: Insert the dipstick carefully to avoid bending it. b= 1. Warm up the engine. 2. Drain the engine oi NOTE: Remove the filer cap to speed draining OIL PAN DRAIN PLUG 45 Nem (6.5 kgm, 33 Ib-F 3. Reinstall the drain plug with @ new washer, and refi ‘with the recommended al ‘SOHC: 3.0 fr (3.2 US at, 2.7 Imp. at) DOHC 3.3 lt (3.5 US qt. 2.9 Imp. at) exctucing oi fiter SOHC: 3.5 lt (3.7 US at, 3.1 Imp. at) DOHC 3.8 lt (4.0 US qt. 3.4 Imp. at) at change, including fer SOHC: 4.0 lt 4.2 US at, 3.5 Imp. at) DOHC 4.3 lit (4.6 US at. 3.8 Imp. at) Every 10,000 km (6,000 miles) ‘or 6 months ‘Recommended Engine OW (SE or SF Grade only] Capacity Change =20-10_ 0 10 ~30 0 20 40 60 80 1009F Expected Ambient Temperature before next olf change NOTE: Oil filter should be replaced at each oil change. 2030 40°c 5-3Engine Tune-up Air Cleaner Element Inspection/ — Replacement Inspection 1. Remove the air cleaner element. 2. Check the air cleaner element for fouling NOTE: No cleaning is necessary for the air cleaner ‘element, because its filter takes in ol (: viscous type) Replace: every two years (© The air cleaner clement should be replaced more frequently on cars normally used under severe driving conditions. Replacement 1. “Remove the air cleaner cover, ‘AIR CLEANER cover 2. Replace the element, install the air cleaner cover and tighten the clip, nut or bolts securely f- Compression Pressure Inspection | 1. Before inspection, run the engine until it warms up (radiator fan comes on} 2. Disconnect spark plugs (a) 3. Disconnect the 2-P connector (ignition col primary lead) from the aistributor. 2.P CONNECTOR : 4. Fit the compression gauge adapter into a plug hole. (© Measure compression pressure at each cylinder. Compression pressure: ‘SOHC Engine: 1.275 kPa (13.0 ko/em®, 185 psi) 181 250 min" (rpm) DOHC Engine: 1.324 kPa (13.5 kg/em?, 192 psi) ‘at 250 min" (rpm) 992 kPa (9.5 kg/em?, 135 psi) at 250 min": (rpm) Difference between cylinders: 169 kPa (2.0 kg/em?, 28 pei) Limi: NOTE: Use a full charged battery. 5. If compression pressure is low, itis caused by wear or damage of piston rings or head gasket, and improper seated valves.“Spark Plug Inspection 1. Inspect the electrodes and ceramic insulator for: orn ‘teeter ater Ccrsceat ‘insulator Burned or worn electrodes may be caused by: + Lean fuel mixture = Advanced ignition timing + Loose spark plug + Plug heat range too high + Insufficient cooling Fouled plug may be caused by: Rich fuel mixture Retarded ignition timing il in combustion chamber + Incorrect spark plug gap + Plug heat range too low + Excessive idling/low speed running + Clogged air cleaner element + Deteriorated ignition coit or ignition wires 4. Screw the plugs into the cylinder head finger tight, b=] 2. Replace the plug if the center electrode is rounded 2s shown below: ‘Spark Plug: Standard Optional ‘BCPREEY-NTT Uneades INGK| BCPREE-11 BCPR7E-11 une BCPR7EY-N11 ND | G20PA-UTT O23PR-U11 ~ ‘BCPREE-11 (=) Ink] BcPRee-11 an TEPR-UT1 (#) | leaded A6PR-UL11 () 2OPR-U11 sasoime | ND | 20 R-ULIT () 22PR-ULI1 (*) (4): 1.6 £ DOHC only 1.0-1.1 mm ~ ROUNDED (0.039--0.043 in) ROUNDED Le ‘Adjust the gap with a suitable gapping tool Electrode Gap: 1.0—1.1 mm (0.039~0,043 in) then torque them to 18 Nem (1.8 kg-m, 13 lb-ft). NOTE: Apply a small quantity of anti-seize com- pound to the plug threads before installingEngine Tune-up Drive Belts Inspection ——————__ Drive Bets Deflecti {When applying a force of 8.8 N (10 kg, 22 Ibsi) T_Used Bent New Belt @ S=11 mm | 7=9 mm DAKeraror Belt 19,350.43 n.)(0.28-0.36 in.) @ALE Compressor] 8—itmm | 79mm Belt (0.35~0.43 in.JN0.28-0.35 in. 912mm) 710 mm jenn N0.35—0.47 in.)|(0.28-0.39 in.) (CRANKSHAFT PULLEY Alternator Belt Adjustment Apply a force of 98 N (10 kg, 22 Ib} and measure the Gofiection between the alternator pulley and the crank- shaft pulley. Deflection: 9—11 mm 10.35—0.43 in.) NOTE: On @ brand-new belt, the deflection should be 7-8 men {0.28 0.35 in.) when frst measured, ALTERNATOR NUT. 22 Nem (2.2 kgm, 16 Bot) Measure here. ALTERNATOR THROUGH BOLT AE Nem (6.5 kgm, 33 te) CRANKSHAFT PULLEY ALTERNATOR BELT Loosen the alternator nut and through bolt Move the alternator by turning the adjust aut 10 obtain the proper belt tension, then retighten the bolt and ut. Recheck the deflection of the bel. “6)P/S Pump Belt Adjustment ———, ‘Apply a force of 98 N (10 kg, 22 Ib) and measure the efiection, between the P/S pump pulley and the crankshaft pulley Detlection: 9—12 mm (0.35~0.47 in.) NOTE: On a brand-new belt, the deflection should be 7=10 mm (0.28-0.39 in.) when firs, measured. P/S PUMP PULLEY P/S PUMP BELT CRANKSHAFT PULLEY Loosen the P/S adjust pulley bott, ‘Tum the adjust nut to get the proper belt tension, then retighten the bolt and nut. Recheck the deflection of the bet. A/C Compressor Belt Adjustment 5 1. Apply 2 force of 98 N (10 kg, 22 te) and measure the Gefiection, berween the A/C compressor adjusting pulley and the crankshaft pulley. Deflection: 9—11 mm {0.35--0.43 in.) NOTE: On 2 brand-new belt, the deflection should be 7-9 men (0.28~0.35 in.) when first measured. ADJUST PULLEY NUT 2. Loosen the adjust pulley nut. 3. Tum the adjust bolt 10 get the proper belt tension, ‘then retighten the bolt and nut. 4. Recheck the deflection of the bett. 5-7ingine Tune-up ~ Valve Clearance Adjustment te SOHC Engine: NOTE: Valves should be adjusted cold when the evlinder head temperature is less than 38°C (10°F). Adjustment is the same for intake and exhaust valves. Remove vaive cover. INTAKE Noa No3 No.2 Not TOMOS OOS ' y, f No.4 NBS No.2 NOT EXHAUST 2. Set No. 1 piston at TOC. “UP” matk on the pulley should be at top. and TDC grooves on the pulley shoud align with cylinder head surface. The distributor Fotor must be pointing towards No, 1 plug wie. Number 1 piston at TOC ‘TDG Grooves 3. Adjust valves on No.1 eylinder. Intake: 0.17—0.22 mm (0.007~0.009 in.) Exhaust: 0.22—0.27 mm {0.009—0.011 in.) 1. Loosen tecknut and turn adjustment screw until feeler gauge slides back and forth with slight amount of arag, LOCKNUTS 7 x 0.75 mm 14 Nem (1.4 kgm, 10 toe) 5. Tighten locknut and check clearance again. Repeat adjustment if necessary. 6. Rotate crankshaft 180° counterclockwise (cam Pulley turns 90°1. The “UP” mark should be at ex. hhaust side. Distributor rotor should point to No.3 lug wire. Adjust vaives on No. 3 cylinder. Number 3 piston at TDC 7. Rotate crankshaft 180° counterclockwise to bring 'No. 4 piston to TDC. Both TDC grooves are once again visible and distributor rotor points to No.4 lug wire. Adjust vaives on No.4 cylinder. Number 4 piston at TOC 8. Rotate crankshaft 180° counterclockwise to bring ‘No. 2 piston to TDC. The “UP” mark should be at intake side. Distributor rotor should point to No. 2 plug wire. Adjust valves on No. 2 cylinder. Number 2 piston at TDC UP MARKNOTE: Valves should be adjusted cold when the cylinder head temperature is less then 36°C (110°F), Adjustment is the some for intake and exhaust valves. 1, Remove the valve cover. EXHAUST No.1 NO.2 NO. NOs NO.1 N02 NO.2 Noa INTAKE ‘Set the No. 1 piston at TOC. “UP” marks: should be at top, pulley should align with cylinder head surface. The distributor rotor must be pointing towards No. 1 plug ‘Number 1 piston at TDC “uP” MARK 2. Adjust valves on No.1 cylinder. Imake: 0.13—0.17 mm (0,005— Loosen tocknut and tum adjust sctew until feeler gouge slides back and forth with sight amount of daag. LOCKNUT 70.75 mm 25 Nem (2.5 kgm, 13 lb-ft) 5. Tighten locknut and check clearance agsin. Repeat adjustment if necessary. 6. Rotate crankshaft 180° counterclockwise (cam pulley ‘urns 907. The “UP” marks should be at exhaust side Distributor rotor should point to No.3 plug wire. ‘Adjust valves on No. 3 cylinder. Number 3 piston ot TDC “UP* MARKS EXHAUST CAM PULLEY INTAKE CAM PULLEY. 7. Rotate crankshaft 180" counterclackwise to bring No. 4 piston to TDC. Both “UP” marks should be at bottom and distributor rotor points to No.4 plug wire. Adjust valves on No.4 eyinder. Number 4 piston at TOC "UP" MARKS 8. Rotate crankshaft 180" counterclockwise to bring No. 2 piston to TDC. “UP” marks should be at intake side. Distributor rotor should point to No.2 plug wire. ‘Adjust valves on No.2 eyfinder. Number 2 piston at TDC 5-9ingine Tune-up -Idle Speed Inspection/Adjustment 1. Start the engine and warm it up to normal operating ‘temperature (the cooling fan comes on 2. Connect a tachometer RPM CONNECTING ADAPTER TACHOMETER ‘07JAz—SH20100 cacy IDLE ADJUSTING SCREW 5. Reconnect the 2P connector on the EACV, then remove HAZARD fuse in the main fuse box for 10 seconds to reset ECU. 6. Idle the engine with no-load conditions in which the headlights, blower fan, rear defogger. cooling fan, and air condhtioner are not operating for one minute, then check the idle speed, KQ, SOHC with CATA | ‘750250 min-' (rpm) iy 780250 min" pm) [DOHC Ex. Ka 800250 min" (rpm) 7. Ide the engine for one minute with headlights (Hi) and rear defogger ON end check the idle speed, die Speed should be: KQ. SOHC with CATA 750260 min“ (rpm) ‘Check iding in no-toad conditions in which the head- lights, blower fan, rear defogger, cooling fan, and air Conditioner are not operating, Idle speed should be: 650250 min“: (pm) ‘Adjust the idle speed. if necessary, by turning the idle ‘adjusting screw, NOTE: If the idle speed is excessively high, check the throttie control system (page 6-86). Ky 78050 min" (rom) DOHC Ex. Ka, {800250 min“ (ppm) 8. Ide the engine for one minute with heater fan switch {tH (right end) and air conditioner en, then check the idle speea, late Speed should be: 1 SOHC ang Ka’ 780250 min rom) [bone ex Ko 800250 min (rom) NOTE: Ifthe ile spaed isnot within specications, see System Troubleshooting Guide on page 6-59. 10Engine Tune-up " Tailpipe Emissions Inspection Inspection EXIM be not smoke during his procedure. Keep any open flame away from your work sea 1. Start the engine and warm un to normal operating Temperature icooling tan comes on 2. Connect tachometer, 3. Check ile speed ang adjust the wle speed, if necessary (page 6-69) 4. Warm up and calibrate the CO meter according to the meter manufacturer's instructions 5. Check idle CO with the headlights. heater blower. reer window defogger, cooling fan, and ax condi. tioner off ) Specified CO%: With CATA: 0.1% maximum Without CATA: 1.0 = 1.0% © If unable to obtain this reading, ‘On With CATA, see ECU troubleshooting (nage 6-14 or 16). On other models, adjust by turning the adjusting serew of the IMA sensor. ADJUSTING SCREW = unable to obtain 2 CO reading of specified % by this procedure, check the engine tune-up conci- b=} Ignition Timing Inspection and Setting = 1. Start the engine and allow it to warm up (cooling fan ‘comes on} 2. Remove the rubber cap (YEL) from the ignition timing ‘adjusting connector located left rear engine compart- ‘ment and connect the BRN and GRN/WHT terminals, with a jumper wie. RI CAP (VEL) IGNITION TIMING ADJUSTING CONNECTOR JUMPER WIRE 3. Connect a timing light to the engi idles, point the light toward the pe belt cover. (cont'd) 5-11Engine Tune-up Ignition Timing Inspection and —— Setting (cont'd) 4. Adjust ignition timing, if necessary, t0 the following, specifications: Ignition Timing 1.61 SOHC (With CATA): 18'2°BTDC (RED) at 750: 1,61 SOHC (Without CATA): 18'£2°BTDC (RED) 8t 780250 min- 1.84 DOHC (EX. KA model): 16=2'BTDC (RED) a 1,81 DOHC (Ka model: 1622°BTDC (RED) at 75050 min }=50 min-' (rpm) in neutral * (7pm) in neutral 30 min" (rpm) in neutral (rom) in neutral a PK ‘CRANKSHAFT PULLEY tes eae 5. Adjust as necessary by loosening the distributor adjust- ing bolts, and turn the distributor housing counter. ‘lockwise to advance the timing, or clockwise to retard the timing, ADJUSTING BOLTS 5. Tighten the adjusting bolts and recheck the timing Remove the jumper mire and install the rubber cap to the ignition timing adjusting connector. 12 aTiming Belt SOHC . DOHC ..Timing Belt Mlustrated Index. Inspection Tension Adjustment .. Replacement .... Positioning Timing Belt .Timing Belt Mlustrated Index nove: © Refer 1o page 5-20 for positioning erank and pulley hefore instaling belt © Refer to page 5-6, for atternator belt adjustment. © Refer to page 5-7, for A/C compressor belt adjustment. © Mark direction of rotation before removing. CROWN NUT 6x1.0 mm ‘TimInG BELT WASHER ang TON'M(T.O gem, 7 i) Inspection. page 6-17 ae ‘Aajusment. page 5-17 @ £1.25 mm Sone Oe kom, — vatvecoven 27 wal ‘Apply abricen. ADSUST BOLT 45.Nem (4.5 kg-m, 33 tos For adjustment onty. do not remove TIMING BELT UPPER COVER BACK COVER 6x1.0 mm 10 Wem [1-0 kgm, 7 tht LOWER CovER Remove the four bots. Install with concave surface facing In ‘CRANKSHAFT ‘stall with concave TIMING BELT PULLEY srtace facing out UBBER SEAL be 1241.25 mm 115 Nim (CRANKSHAFT PULLEY (11.5 kgum, 83 thf SPECIAL WASHER Inst withthe unchamtered edge facing pulley -16“yspection —————_______ Nore: © Replace belt if oi soaked. © Remove any oil or solvent thet gets on the belt. Inspect tis ‘ree for wear Rotate pulley and inspect bert [- Tension Adjustment CAUTION: Always adjust timing belt tension with the engine cold. i NOTE: Tensioner is spring-loaded to apply proper Tension to the belt automatically after making the following adjustment: 1. Set the No. 1 piston at TOC. 2. Loosen adjust bolt, ADJUST BOLT 45 Nem (2.8 kgm, 33 bf) Direction of Rotation. Rotate crankshaft counterclockwise 3-teeth on cemshatt pulley to create tension on timing belt. - Tighten agjust bolt. {f pulley bolt broke loose while turning crank, retoraue eto 115 Nem (11.5 kgrm, 83 Ib-tt) NOTE: Put transmission in gear and set parking brake belore retorquing pulley bolt. 5-17Timing Belt Replacement C) 1. Remove the wheel well splash shield. 3. Remove the side bracket, 4. Loosen the alternator adjust bolt and through bolt, then remove the belt ALTERNATOR, a ‘ADJUST BOLT : 5 8x1.25 mm 24 Nem (2.4 kam, 17 Ib) a 1 ‘SIDE BRACKET ‘THROUGH BOLT 101.25 mm ) \ @ 2 feet ALTERNATOR veseet wen. JBN'm oko, Seuasi SmrELD Bea 5. After instaon, asst se tension of each bet 2. Remove the A/C compressor acs ule with bracket See page 5-8 for aterntor bet encion adjustment sna the bet (with AE), See page 5-7 for A/C compressor bet tension agfst= iment 5. Remove the engine support bolts and nut, then ee remove these mount rubber — peer 101.25 mm “hig apsust puuey CON (6-0 gen, 49 Shagrer Encine sibE Mount RUzeER ) 841.25 ma 28 Nem (2.4 ko-m, 17 tot Alc BELT / 12% 1.25 mm 80 Nem {6.0 kom, 43 lol i-18 fRemove the valve cover. 9. Remove the special bolt, then remove crankshaft pulley. 10. Remove the timing belt upper cover and the lower cover " Loosen the adjust bolt, then remove the timing belt, VALVE COVER 6x1.0.mm. 10 Norm (1-0 kg-m. 7 Ib) CRANKSHAFT PULLEY SPECIAL WASHER NOTE: Release ie tensioner bracket with a diver Do not push the bet. 12. Install in the reverse order of removal; adjust the valve timing (page 5-20). 13. Carry out timing belt tension adjustment (page 5-17) CROWN NUT 6x1.0 mm 10 Nem (1.0 kgm. 7 Wf) WASHER AND GROMMET TIMING BELT ‘Adjustment, page 5-28 (4.5 kg-m, 33 bf) For agustment ony: BELT TENSIONER 5-19Timing Belt - Positioning Crankshaft Before Installing Timing Belt ————_____ NOTE: Insta the timing bet withthe No.1 piston at 1 (Top Dead Center) of he compression stoke, “UP” MARK pointer on AU BELT COVER Toc mark _}4 (Painted Write! 20Timing Belt Illustrated Index , inspection Tension Adjustment .. Replacement .... Positioning Timing BeltTiming Belt Mlustrated Index Note: CROWN NUT 6 «1.0. mm 1® Refer 10 page 5-26 for positioning crank and pulley before instaling belt. 10 Nem (1.0 ko-m, 7 Ib © Refer to page 5-6 for alternator bait adjustment. WASHER AND ® eter to pape 8-7 for YS pump bak ahs (Kony) omer 3 fete to nge 6. or We came eur KO (© Mark direction of rotation before removing VALVE COVER 851.25 mm 38 Nm (3.8 kom, 27 bt Apply Wbrican. TIMING BELT lspection, nage 5-23 Adjustment, page 5-23 RUBBER SEALs, 8x1.0mm 10 Wm (1.0 ko-m, 7 lot Tumine BELT ADJUST Bout BACK COVER 45. Nem (2.5 kg-m, 33 tosh) For adjustment only. {60 not remove, CAMSHAFT PULLEY UPPER covER 6x1.0 mm! 10 Nm (1.0 kg-m, 7 be) 10 Wm (1-0 kgm, 7 tol Instat wth concave surface facing in lnstat with concave Fimneneity sortce meeereav® TIMING BELT PULLEY 118 Wim RUBBER SEAL 7.5 kgm. 83 Ibe CRANKSHAFT POLLEY SPECIAL WASHER Insta vith the unchamteres edge facing pute -22Inspection ——____ NOTE: © Replace belt if oil soaked (© Remove any oil or solvent thet gets on the belt. Inspect tis area for wear, Rotate pulley ‘and inepect bat. r- Tension Adjustment ————____ CAUTION: Always adjust timing belt tension with the engine cold. NOTE: Tensioner is spring-loaded to apply proper tension to the belt automatically after making the following adjustment: 1. Ser the No. 1 piston at TDC. 2. Loosen acjust batt ADJUST SOLT 45. Nem (6.8 kgm, 33 bt) Direction of Rotation 3. Rotate crankshaft counterclockwise 3-teeth on ‘camshaft pulley to create tension on timing belt. 4. Tighten adjust bott. 5. If pulley bolt broke loose while turning crank. retoraue it to 115 Nem (11.5 kg-m, 89 lb-ft). NOTE: Pur transmission in gear and set parking brake before retorquing pulley bolt, 5-23Timing Belt —Replacement 1. Remove the whee! well slash shield WHEEL WELL SPLASH SHIELD 2. Remove the power steering (P/S) pump (KO) conditioning (A/C) idle pulley and bett. 25 mm mm (2.4 kgm, 17 Wo) A/C ADJUST PULLEY RACKET 4 P/s PUMP ed 81.25 mm Arc BELT 24 Nim (2.4 kgm, 17 fot) P/S BELT 4. Remove the P/S bracket (KO) 5. Loosen the alternator adjust bolt and through bolt. then remove the bel. ALTERNATOR ‘ADJUST BOLT 81.25 mm 2 Nem (2.4 kgem, 17 tb.) THROUGH BOLT 101.25 mm 45 N-m (4.5 kgm. 33 tot “10 «1.25 mm 45 Nem (6.5 kon, 33 Ib) P/S SIDE BRAGKET ©. After instalation. agjust the tension of each belt. ‘See page 5-6 for alternator belt tension adjustment. ‘See page 5-7 for A/C compressor belt tension adjust- ‘ment. ‘See page 5-7 for P/S pump bett tension adjustment 7. Remove the engine support bolts and nut, then remove the side mount rubber. 1241.25 11.28 mm to Nmieotom, ae sisi 13 lb-ft) 40 Wf) = 246. Remove the timing belt upper cover 7. Remove the valve cover 8 Remove the special bol, then remove crankshaft pulley, 9. Remove the timing belt lower cover CROWN NUT 6x 1.0 mm 10, Loosen the adjust bolt, then remove the timing belt 10 Nem (1.0 lege, 7 leh) 8x1.0 mm 10 Noe (1-0 kgm, 7 fost) WASHER AND GROMMET VALVE COVER LoweR cover TIMING BELT Ajustmant, page 5-23 ‘ADJUST BOLT 45 Nem 18.5 ko-m. 33 fol Fer scjuetment only: 1 not remove > ‘ue NOTE: Reteass the oN bracket with 9 erver Bo nor push the bet SPECIAL WASHER 118 Nm (17.5 kgm, 83 Wot) BELT TENSIONER 11. Instat in the reverse order of removal: adjust the valve timing (page 5-26). 12. Carry out timing belt tension adjustment page 5-23) ) 5-25iming Belt - Positioning Crankshaft Before Installing Timing Beit NOTE: Install the timing belt with the No. 1 piston at TDC (Top Dead Center) of the compression stroke. “UP* MARK. ‘TDC mark aligned wit ‘the evlinger head upper surface POINTER ON BELT COVER: Tc MaRK (Panes Whitel CRANKSHAFT PULLEY ROTATION With engine instatieg, turn crank with socket wrench and extension a shown, 26Cylinder Head Removal/Installation SOHC DOHCCylinder Head Removal/Installation Removal InstallationCylinder Head ~ Removal (engine removal not required) —— CAUTION: To avoid damagin "9 the cylinder head. wait until the coolant temperature drops below 38°C (100°F] before removing it NOTE: Use new O-rings and gaskets whenever reassembling. CYLINDER HEAD BOLTS 10%1.25 mm 68 Nem {6.8 kom, 49 lb-ft} ‘Apply clean engine oi SPECIAL WASHER | WTAKE MANIFOLD TIMING BELT re Inepeston/Agjustment, | page 5-17, Freplacement, page 5-16 INTAKE MANIFOLD BRACKET Apsust BOLT 43 Nem (4.3 kg-m. 31 Io Loosen but do not remove. 24 Norm (2.4 kgm, 17 Ih 30b=] CAUTION: To avoid damaging the cylinder head, wait until te coolant temperature drops below 38°C [10°F] before loosening the retaining bolts, aH ener Note: © ‘Inspect the timing belt before removing the cylinder head. (© Turn the crankshaft pulley so that the No. 1 cylinder is at top-dead-cemtr. (© Mark all emissions noses before ciscannecting them. Disconnect the negative terminal from the battery . ‘i ba Drain the cooling system (See page 5-59) Remove the brake booster vacuum hose from the brake muster power booster. 4. Remove the engine secondary ground cable from the vane cover. if 5. Remove the air intake hose from the throttle body Se ner 5. Ralove fos pressure (See Section 6). Fev HOSE HOSE KEIM} 06 not smoke while working on fuel Lr septa noel pence behind [ieee pests oy ste area, Drain fuel only into an approved container. from the cylinder hens. Disconnect the fuel hose and fuel return hose Remove the ait intake hose and resonator hose. Disconnect the throtte cable at the throttle body (See Section 5). 7. Disconnect the charcoal canister hose at the throttle valve '8. Disconnect the vacuum hoses end the water bypass hoses from intake manifold and the throttle body. 9. Remove the PCV hose, charcoal canister hose and ‘vacuum hose from intake manifold, and remove the ‘vacuum hose from the brake muster power booster BREATHER TUBE. UPPER RADIATOR HOSE CONTROL BRACKET 11, Disconnect the engine wire connectors and clamps from the cylinder head, throttle body, and IN/EX manifolds. + Ignition coll connector (from distributor) + EACV connector + Engine ground wire + Thermounit connector + Coolant temperature censor connector + Intake air temperature seneor connector + Throttle angie sensor connector + Injection connectors + TOC/CRANK sensor connector (from distributor) WATER BYPASS HOSE CHARCOAL CANISTER (cont'é) : 5-31Cylinder Head Removal (engine removal not required) (cont’d) ———________ A/C ADJUST BOLT AIC IDLE PULLEY NUT A0%1.25 mm ‘45Nom (4.5 kgm, 33 tb) NOTE: Release the tensioner bracket with @ driver, Do not push the bet BRACKET ‘ADJUST BOLT 15, Remove the ethaust manifold shroud. then remove exhaust manifold. 16, Remove the distrioutor and valve cover. 17. Remove the timing belt upper cover. 18. Loosen the timing belt adjust bolt, then remove the timing beit from the camenaft pulley. CAUTION: DO not crimp o bend timing belt more erereneoniaLe: than 90°0r tess than 25 mm (1 in.) in diameter wiptH 13. Remove the intake manifold bracket. 14, Remove the exhaust manifold bracket, then remove the header pipe 19. Remove the cylinder head, 20. Remove the intake manifold from the eylinder head. -32nstallation 1 Replace CYLINDER HAED ASK! Intall the cylinder head in reverse order of removal: © Always use a new head gastet, © Cylinder head and engine block surface must be clean. “UP” mark on timing belt pulley should be at the top. Cylinder head dowel pins and oil control jet must be aligned. eT een CONTROL JET 'S— o-RING Replace INTAKE fg) MANIFOLD IACKET 5 6 CYUNDER HEAD BOLT 107.25 mm Adjust the valve timing, Instll the exhaust manifold and bracket. 3. Install the intake manifold and tighten the nuts in 2 criss-cross pattern, beginning with the inner nuts. INTAKE MANIFOLD GASKET Replace INTAKE MANIFOLD | INTAKE MANIFOLD RACKET 81.25 mm’ 23 Nom (2.3 kom, 7» ‘Tighten cylinder head bolts in two steps. Inthe frst step tighten al bolts and nuts, in sequence, to about 30 N-m (3.0 kg, 22 tbl; in the final step tighten, in some sequence, to 68 N-m (6.8 kg-m, 48 fe NOTE: Apply engine oil to the cylinder head bolts and ‘the washers. CYLINDER HEAD TORQUE SEQUENCE ‘Nem (6.8 kgm, 49 to tcont'a) 5-33Cylinder Head Installation (cont'd) 1.64 with CATA: EXHAUST MANIFOLD ‘MANIFOLD GASKET Replace SHROUD i Heap BRACKET Zt 841.28 mm 24 Nem (2-4 kgm, 81.25 mm aoa 34 Nm (3.4 kom. 25 10-4 / suZoup 841.25 mm 34 Nem (3.4 kg-m, 25 tot 1.64 without CATA: EXHAUST MANIFOLD MANIFOLD GASKET Replace 8x1.25 mm 24 Nem 2.4 kom, 7 to) SHROUD 8.6 kgm, 26 tet) o = “exnau: MANIFOLD Jey BRACKET 81.25 mm. as 22 Nim (2.2 kgm, 52.25 ren 24 Nem (2.dkgem, 16 A} 17 we) EXHAUST MANIFOLD TORQUE SEQUENCE RA A 8 BFS. OVO ID @ tT = = © id -34Cylinder Head Removal/Installation Removal .. InstallationCylinder Head — Removal (engine removal not required) —————___ CAUTION To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C {100°F) before removing it. NOTE: Use new O-rings and gaskets whenever reassembling. ‘crown wuT 6x1.0 mm 10.Nem (1.0 kam, 7 bf) & a o WASHER AND GROMMET / e ®. 8x1.0 mm 10 Nom {1.0 ko-m, Tio} Se RUBBER VALVE COVER Ingpect for signs “CAP of wear and omage. emaust f ‘CAMSHAFT HOLDERS a & e 2 ae Fo nociien anna DISTRIBUTOR CAMSHAFT HOLDER o INTAKE CAMSHAFT exuaust CAMSHAFT Lock NUT 4 einem, em Of 351.25 0m Cocca when 38 Nem (3.8 kg-m. ba Ban CAMSHAFT PULLEY 36CYLINDER HEAD Bouts 111.25 mm 66 Nem (6.6 kg-m, 48 A) Soa ceon ene ob VAVEREEPERS~ spine nevamen Aran on oe Unde” the Bott heeds. SPRING RETAINER EXHAUST VALVE SPRING rane vatve \ VALVE KEEPERS ———__§ STEM SEAL 7 END PIVvoT BOLT EXHAUST VALV sense e ca (6.4 kom, 46 1b) j “ 2(o* Sy VALVE sPRine—e E> INTAKE VALVE sear @ ee SPRING _———" EXHAUST VALVE ‘suibe: AY ; VALVE SPRING SEAT INTAKE VALVE GUIDE CYLINDER HEAD. INTAKE VALVE Adhustment, page 5-9 Exnaust vawwe—*"| > on contro set CYLINDER HEAD GASKET” Replace (ee O-RING Replace (cont'a} 5-37Cylinder Head Removal (engine removal not required) (cont'd) CAUTION: To avoid damaging the cylinder head, weit ‘until the coolent temperature drops below 38°C (10°F) before loosening the retaining bolts. Note: (© Inspect the timing belt before removing the cylinder head. (© Turn the crankshaft pulley so that the No. 1 cylinder is at top-dead-center. (© Mark all emissions hoses before disconnecting them. Disconnect the negative terminal from the battery. Drain the cootant system, Relieve fue! pressure (See Section 6) Disconnect the fuel feeder hase and fuel return hose. 7"De nat smoke white working on ful system, oop open flame or spark away from work naa + Bins fel ony to on approved sonesnes 5. Remove the brake booster vacuum hose, 6. Disconnect the PCV hose. BRAKE BOOSTER Pov Hose S a FUEL RETURN HOSE Disconnect the breather tube and air intake hose. Disconnect the vacuum hose from the intake manifold. Disconnect the charcoal canister hose. }0. Disconnect the water bypass hose. 11, Disconnect the engine wire connectors and clamps from the cylinder head, throttle body, and IN/EX manifolds. + Ignition coil connector (from distributor) + EACV connector + Engine ground wire + Thermounit connector + Coolant temperatuer sensor connector / pom BREATHER, pipe “eo Ne vacuum Hoses. WATER BYPASS. Hose AIR INTAKE HOSE + Intake air pressure sensor connector + Throttle angie sensor connector Injection connector + TDC/CRANK sensor connector 12. Disconnect the radiator upper hose at the engine. 13. Remove the heater hose, aaa UPPER HOSE HEATER HOSE44. 15. 16. 17, 18. 19. 20. 2 22. 23, Remove the power steering (P/S) pump belt (KQ only} ‘and the alternator bert. Loosen the air conditioning (A/C) idle pulley and remove the A/C ett Remove the P/S pump bracket (KO only) 101.25 mm 45 Nem (4.8 kg-m, ALTERNATOR BELT Ps SIDE BRACKET Flemove the bolts from the intake monifold bracket. Remove the exhaust mandfold shroud. Remove the bolts from the exhaust manifold bracket. Remove the self lock nut from the exhaust header bipe. Remove the exnaust manifold assy, Remove the timing belt upper cover, Remove the valve cover. 24. Loosen the timing belt adjust bolt, releasing the timing bel, and fic the bolt ARE gout yf NOTE: Release he tensioner bracket witha drive. Do not push the bat. ‘TENSIONER BRACKET 26. Remove the timing belt from the driven pulleys. CAUTION: 00 not crimp oe bend timing bet more than 90° or less than 25 mm (1 in.) in diameter. ae 26. Remove the cylinder head, 25 mm f CAUTION: Loosen the the inside to outsid sad bolts diagonally from 27. Remove the intake manitold from the eylinder head. 5-39Cylidner Head Installation 1. Instat the eylinder head in reverse order of removal: © Always use 2 new head gasket. © Cylinder head and engine block surface must be clean, (© “UP™ mati on timing belt pulley should be at the 0p. NOTE: Cylinder head dowel pins and oil control jet ‘must be aligned. DOWEL PIN CYLINDER HEAD 2. Tighten cylinder head bolts in two steps. In the first step tighten all bolts, in sequence, to about 30 N-m (3.0 kg-m, 22 Ib-fy; in the final step tighten, in same sequence, 10 68 N-m (6.8 kg-m, 49 lb-ft) NOTE: ‘© Apply engine oil to the cylinder head bolts and the washers, © Use the longer bolts at the position No.1 and No.2 as shown. CYLINDER HEAD BOLTS TORQUE SEQUENCE 3. Install the intake manifold and tighten the nuts in a criss-cross pattern in 2 or 3 steps, beginning with the inner nuts. 8x1.25 mm 23 Nim (2.3 ym. 17 tote 4. Insta the extaust manifold and bracket. MANIFOLD GASKET Replace Js 8.01.25 mm 24Nem (2.4 koe, ena 839.25 mm 8x1.25 mm 34 Nm (3.4 kgm, 34 Nm (3.4 kg-m, 25 I-A) 25 tba) -40CAUTION: (© Moke sure that the keyways on the camshatts are 19 up. (NO. 1 cylinder TOC). © Valve tocknuts should be loosened and adjust /s backed off before installation. Place the rocker arms on the pivot belts and the valve. stems. 6. Install the camshafts and the camshaft seals with the ‘pen side (spring) facing in Note: “I" or “E* marks are stamped on the comshaft holders. : © Do not apply oil to the holder mating surface of camshaft seals. EXHAUST CAMSHAFT HOLDERS INTAKE CAMSHAFT HOLDERS 7. Apply liquid gasket to the head mating surfaces of the No. 1 and No, 6 camshatt holders, then install them, along with the No. 2.3. 4 and 6. 8. Tighten the camshaft holders temporarily. . sure that the rocker arms are properly positioned on the valve stems, ‘Apply non-iaring eestant to these areas (also opposite sides) before instaling ‘camshaft holders 9. Press in the camehatt ol seal securely with the special tool. Seal housing surace should be dry. ‘Apply a ight coot of ol 1 camshaft ‘and inner ip of seal. CAMSHAFT SEAL DRIVER, 078¢7—SB00100 (cont'é) 5-41Cylinder Head - Installation (cont'd) ————_____ 10. Tighten cach bot wo tuns ata time inthe sequence ‘shown below to insure that the rockers do not bind on the vaives. 6x10 mm 12 Wem (9.2 kg-m, 9 ib) 11. Insta keys into grooves in camshafts. NOTE: To set the No. 1 piston at TOC, align the hole ‘on the camshaft with the hole in the No.1 camshaft holders and drive 5.0 mm pin drivers into the hotes. PIN DRIVERS. 5.0 mm key, 17944511000 Q aS CAMSHAFT PULLEY 27 mm SPANNER, SPECIAL STAINING BOLTS WASHERS. £1.25 mm ENSm (3.8 kgm, 27 tot) 2, Push camshaft pulleys onto camshafts, then tighten retaining bolts to torque shown, 3. Adjust the valve timing (page 5-9) |, After instalation, check that ali hoses and connectors, are installed correctly. eee eee eee 42Engine Removal/InstallationEngine Removal/Installation (© Make sure jacks and safety stands are placed properly and hoist brackets are attached to cor- ‘ect positions on the engine. (See Section 1). © Apply parking brake and block rear wheels. so car will not roll off stands and fall on you while working under it. CAUTION: Use fender covers to avoid damaging painted surfaces. Disconnect the battery negative terminal frst then the positive terminal. Remove battery. Unbott the hood brackets and remove the hood, © Disconnect the washer fluid tube. CAUTION: Use care when storing the hood to avoid damaging the paint. LHD: AIR INTAKE DUCT cuurcH FRONT AIR INTAKE DUCT Drain the engine oi. Remove the oi filler cap to speed raining, Reistall the drain plug with a new washer. Drain the cootant from the radiator into a clean pan so. it may be re-used. Remove the radiator cap to speed draining, Use care when removing 1 10 avoid scalding by hot coolant er steam. iator cap Drain transmission oi/fiuid.Use a 3/8” drive ratchet ‘wrench to remove the drain plug. Remove the oil filer plug to speed draining, Reinstall the drain plug with a new washer Remove the air intake duct and front air intake duct. Remove the battery base, SPEEDOMETER CABLE ENGINE GROUND CABLESERVICE BOLT 12 Nem (1.2 kgm, 9 tb-f) ENGINE COMPARTMENT. HARNESS CONNECTORS. TRANSMISSION GROUND CABLE distawuTOR oni Replace y it 22 Nem (2.2 kgm, 16 Bett) * "puet Hose / 8. Relieve fuel pressure by slowly loosening the service bolt on the fuel filer about one turn."{Section 6). Do not smoke while working on fuel system. Keep open flame away from work area. Drain fuel only into an approved container. CAUTION: © Before disconnecting any fuel line. the fuel pres: ‘sure should be relieved as descr ve. © Place 2 shop towel over the fue! filler to prevent Pressurized fuel from spraying over the engine. DISTRIBUTOR 9. Disconnect the engine compartment harness con- ectors, battery wires and transmission ground cable, ). Disconnect the engine wire connectors and spark plug Remove the cap and bolts, then remove the distributor from the eylinder head. soHe: 841.25 om 24 Nom (2.4 kg-mn. 17 Ios) feont'a 5-45igine Removal/Installation (cont'd) 12. Remove the throttle cable by loosening lock the nut {nd the throttle cable acjust nut, then silp the cable ‘end out of the throttle bracket and accelerator linkage. NOTE: Take care not to bend the cable when removing it, Do not use pliers to remove the cable from the linkage. Always replace a with 3 new: Tea 9, Always replace a kinked cable with a new one. BRAKE BOOSTER VACUUM HOSE ‘SUB-ENGINE HARNESS CONNECTORS PUMP Kd only HARNESS CLAMP FUEL RETURN HOSE Do not smoke while working on fuel system. Keep open flame away from work area. Drain fuet only into an approved container. 13. Remove the acjust bolt, mounting bolts and V-belt for ‘the power steering pump, then without disconnecting the hose, pull the pump away ftom its mounting bracket (KQ only)b=] 14, Disconnect the radiator hoses and heater hoses. 17, 15. Remove the spesciometer cable. SPEEDOMETER CABLES RADIATOR HOSE HEATER HOSE RADIATOR HOSE cur : Do not remove the holder because the speedometer gear may fall into the transmission housing. 16. Remove the alternator: (LHD only) © Disconnect the alternator wire harness connectors. (© Remove the adjust bolt and remove the bel (© Remove the belt alternator mount bolt and cemove the alternator. 81.25 mm 24 Nem (2-4 kom, 17 Ios) 45 Nem (6.5 kg-m. 33 ttt (On cars with A/C: Loosen the belt adjust bolt and idle pulley nut. (© Remove the compressor mount bolts, then lift the ‘compressor out of the bracket with hoses attached. ‘and wire it up to the front beam. NOTE: The compressor can be moved without dischar- sing the air conditioner system BELT ADJUST Bott SX1.0 mm 10 Nom (1.0 ko-m, 7 tot} ‘COMPRESSOR BELT ComPRESsOR necessary © Disconnect the suction and discharge hoses from ‘the compressor. SUCTION HOSE O-RINGS Replace. DIscHARGE HOSE feont's) 5-47agine Removal/Installation (cont'd) 18, Remove the shift over torque rod, shift rod and clutch cable. NOTE: On reassembly, slide the retainer back into place after driving in the spring pin. Shea lias Sonne aed Cage hee 6 ? 2 SHIFT R¢ Ca haK ic SHIFT LEVER Co TORQUE ROD 22 Nee (2.2 kgm, 16 toy = ‘8 mm PIN PUNCH CLUTCH CABLE ADJUST NUT (Manuel only] ‘NHEELWELL SPLASH SHIFT ROD SHIELD = ~O SHIFT LEVER: AO anaes x ae Sawn hx nour Sele Locks NUT TEE eS AT \ A Replace. Ga SME Ete. ont ~~ COTTER PIN Replace IE SPLASH SHIELD peer SELF LockiNG NUT 155 Nem (5.5 kgm, 40 lo) Repsce. NOTE: Cost al precision finished surfaces with lean engine oil or grease. Tie Plastic bags over the drivehaft ends.be] 20. Attach 2 chain hoist to the engine block hoist brackets and raise the hoist just enough to remove slack from the chein 55 Nom (5.5 kam. 401-6 note: ‘To attach rear engine chain, remove the plastic radia- SPECIAL BOLT tor hose bracket and hook chain to top of cluteh cable / 60 Nem (6.0 kom, 43 fof) bracket e Do not loosen the bot Intoasened, replace the bot. 21. Remove the rear transmission mount bracket. 22, Remove the bolts from the front transmistion mount. 23. Remove the bolts from the engine side mount. 24, First remove the mount nut from under the transmis sion housing and remove the bolt from the side trans ‘mission mount, ‘REAR TRANSMISSION MOUNT BRACKET ‘SIDE TRANSMISSION {80 Nem (6.0 kgm, 43 A) Mount NUT 60 Nem (8.0 kgm, 43 tot) Nem (5.5 ke-m, 40 tb-H) 155 Nem (5.6 kg-m, 40 tot) 60 Nem (6.0 kg-m, 43 Ib} FRONT TRANSMISSION SPECIAL BOLT } {80 Nem (6.0 kgm, 43 Ib. EMoeee ‘Do nat loosen the bot Shi 40 Nem (6.0 kg-m. 29 to) Wioasened. replace te bolt. S 25. Check that the engine/tvansaxle 1s completely free of vacuum, fuel, and coolant hoses, and electral wires, 26. Slowiy raise the engine approximately 6” and stop ‘Check once again that all wires and hoses have been disconnected from the engine/transaxe. 27. Raise the engine/transaxle all the way and remove ‘rom the car. (cont'd 5-49igine Removal/Installation (cont'd) 28. Install the engine in the reverse order of removal. ‘After the engine is in place: © Torque engine mount bolts in sequence shown. CAUTION: Failure to tighten the bolts in the proper ‘sequence can cause excessive noise and vibration, ‘and reduce bushing life: check that the bushings aro not twisted or offset. (© Check that the spring ip on the end of each riveshatt clicks into place. CAUTION: Use new spring clips on installation. (© ‘Inspection for fuel leakage. ‘After assembing fuel ine parts, turn on the igni- tion switch (do not operate the starter) so that the fuel pump is operated for approximately two seconds and the fuel is pressurized. Repeat this ‘operation two or three times and check whether any fuel leakage has occurred at any point in the fuel line. ENGINE MOUNT TORQUE SEQUENCE NOTE: Check the mount and bracket for damage. MOUNT ‘SPECIAL BOLT Feplace SIDE TRANSMISSON REAR TRANSMISSION MOUNT BRACKET FRONT TRANSMISSION 60 Nem (6.0 kgum, 43 I-A) © Bleed air from the cooling system at the bleed bolt with the heater valve open. ‘@ Adjust the throttle cable tension. (See Section 11) ‘Adjust the alternator belt tension. ‘© Check the clutch pedal free play. (© Check that the transmission shifts into gear smooth- . . We Reinstall the A/C compressor and A/C wiring Clean battery posts and cable terminals with sand- Paper, assemble, then apply grease to prevent ‘Check the ignition timing. {See Section 16). Charge the system and test performance. (See Section 15). ‘Speedometer cable Instaiation: © Align tab on cable end with slot in holder page 5-45). (© install clip so bent leg is on groove side. ‘After instaling, pull speedometer cable to make sure itis secure. ‘SPECIAL BOLT (©60 Nem (6.0 kg-m, 43 Bo-R ie Replace. ENGINE SIDE MOUNT DSEN-m(5.5kg-m, OID]‘additional Torque Specifications: ‘SIDE TRANSMISSION MOUNT AND BRACKT REAR TRANSMISSION MOUNT BRACKET 40 Nem (6.0 kg-m, 29 tbl 55 Nem (5.5 ko-m, 40 Not) BOLT Replace, 60 Nm (6.0 kom, 43 tb.) 65 Nem (6.8 kgm, 47 BA) 155 Nem {5.5 kgrm, 60 Ib-f) lites we a 40 Nem (4.0 kgm, 60 N-m 29 A (6.0Kg-m, 43 to) ALTERNATOR BRACKET 155 Nem (8.5 kg. 40 tht) POWER STEERING KO only: UMP UPPER BRACKET 25 Nem (2.5 ko-m, 18 mA) ENGINE SIDE MOUNT BRACKET 45 nm Som] Ee Ewaine sive MOUNT POWER STEERING PUMP LOWER BRACKET| 160 Nem (6.0 kg-m, 43 Ibs} 55 Nem (5.5 kgem. 40 fost) eer i| COMPRESSOR BRACKET 45 Nem (4.5 kg-m, She | as Nim 6.5 kom. 33 bf ; 5-51Exhaust Pipe and Mufflerchaust Pipe and Muffler Replacement exHaust PIPE TIP MUFFLER ieaigiee 40Nem {1.0 kgm Tied EXHAUST PIPE B HEADER PIPE GASKETS 8.1.25 mm 22 Nm Gasket (2.2 kom, 16 tote) TA 3.25 mm Nem (2.2 gums I SELF-LOCKING — KT Nurs 40x 1.25 mm ce PIPE 34 Nem (3.8 kom, 25 ba) Heapen rire replace Fuge Tank HEAT SHIELD Ng 2 ve. 4! 1.25 mm (Nem (2.2 kgom i oe ” $ oe tee ie. CATALYTIC ee 1 & ‘CONVERTER: 8 esa! Vv fabices 22m 2.2 kgm. 16 bs) SOHC Engine with CATA:Radiator Mlustrated Index... Replacement .... Refilling and Bleeding Cap Testing. Radiator Testing Thermostat Replacement Water Pump Replacementdiator lustrated Index 6£SOHC Fuel-injected Engine note: © Check all cooling system hoses for damage. leaks oF TIMMS system is under high pressure when eng) eterioration and replace necessary, Ts not. To avoid danger of releasing scalding eoolent, © Check all hoge clamps and retighten f ‘nove aap only whan engine is cool. 1 Use new Onings whenever reassembling .cessary. tal Cooling System Capacity (Incl. heater, and reser- ir tank 0.4 liters 4 liters (6.7 U.S. RADIATOR ey Refilling, page 5-59 Leak wt, page 5-89 Inapoct seams between core fine and tak for leaks. RADIATOR CAP Blow drt out from between core fns with eomprecsod ar insects, etc., ae elogsing rachator, woah them off with low pressure water. 2OOLANT ESERVOIR i MOTOR {for operation 1 12V DC spplied, UPPER RADIATOR Hose x Lower OS RADIATOR TEMPERATURE Hose GAUGE ‘SENDING UNIT 5 Nem {0.9 kgm, FAN SHROUD WATER PUMP THERMOSENSOR 18 Nem (1.8 kom, 13 mR | THERMOSTAT opr NOUSING ~*~ ‘THERMOSENSOR 1B Nem (1.8 kgm. 131A) HEATER HOSESDOHC Fuet-Injocted Engine: NOTE: © Check a cooling system hoses for'samage, lak of FEEIIIINS system is uncer high pressure when enpi- Ceterioration snd replace i necessary. ot. To avoid danger of releasing scalding coolant, @ Check allhoce came and retighton'f necessary. temove cap anly when engine is cool. ‘Total Cooling System Capacity (Incl. heater. and reser voir tank 0.4 liters): 5.5 liters (6.8 U.S. at, 4.8 Imp. gt.) coo.anr RESERVOIR jj } wD ranworon ‘Test for operation with 12V'DC applies 6x1.0mm 40 Wem (1.0 kgm, 7 ott FAN SHROUD WATER PUMP INLET PIPE ‘THERMOSENSOR 1 Nery (1.8 kgm, Bb J THERMOSTAT Housing pe © Use new O-rings whenever reassembling. RADIATOR Fefiting. page 5-69 Leak 10st, page 5-50 Inspect seams between core fins ane tanks fr leak. RADIATOR CAP Blow dirt out from between Pressure test, page 6-60 core fine with compressed ait. insects, ete, are clogging radiator. wah them off with ‘ow preseure water. UPPER RADIATOR HOSE DA cower RADIATOR ‘TEMPERATURE cause Te SENDING UNIT HEATER HOSES: 5-57idiator Replacement Drain the coolant from the radiator. 3. Disconnect the upper and lower radiator hoses from + Remove the reciator cap to speed draining evlinder heed Use care when removing radiator to -«~-~Remove the radiator bracket and radiator. void scalding by hot coolant or steam. Remove the connectors from the cooling fan motor and thermoswiteh, 6x1.0 mm 10 Norm (1.0 kav, 0.7 tof) RADIATOR BRACKETS. 6x1.0mm. 30 Nem (1-0 ko-m, 0.7 Ios RESERVOIR TANK UPPER CUSHION RADIATOR Lower Custion FAN MOTOR LOWER RADIATOR HOSE Peeled ‘Te: Install the radiator in the reverse order of removal Before instaling the radiator, set the radiator lower cushion securely under it. 58Radiator ~ Refilling and Bleeding Set the heater temperature lever to maximum heat, ‘When the radiator is cool. remove the radiator cap. fend drain plug. and drain the radiator Reinstall the radiator drain plug and tighten it se- curely Remove, drain and reinstall the reserve tank, Fill ‘the tank halfway to the MAX mark with water, then up to the MAX mark with coolant. Mix the recommended anti-freeze with an equal amount of water, in a clean container NOTE: Use only HONDA RECOMMENDED anti-freeze / coolant. © For best corrosion protection, the coolant con- centration must be maintained year-round at 50% MINIMUM. Coolant concentrations less than 50% may not provide sufficient protection. ‘against corrosion or treezing © Coolant concentrations greater than 60% will impair cooling efficiency and are not recom- mendes CAUTION: ‘© Do nor mix different brand anti-tresze/coolants. © Do not use additional rust inhibitors or anti-rust products; they may not be compatible with the recommended coolant, Radiator Coolant Refill Capacity: #(U.S.qt., Imp.at) (4.7, 4.0) Induding reservoir tank capacity: 0.41 (0.42 U.S.qt., 0.35 Imp. qt.) DRAIN PLUG 6. Loosen the air bleed bolt in the water outlet, then fil the radiator to the bottom of the filler neck with the coolant mixture. Tighten the bleed bolt as soon coolant starts to run out in a steady stream without bubbles. BLEED BOLT 101.25 mm 9.Nem (0-9 kgm, 7 DRAIN BOLT UPPER RADIATOR HOSE 45 Nem (6.5 kg-m, 93 +t) 7. With the radistor cap off, start the engine and let it run until warmed up (fan goes on at feast twice). if necessary add more coolant mix to bring the level back up to the bottom of the filer neck, ‘8. Put the radiator cap on, then run the engine again ‘and check for leaks. 5-59tadiator - Cap Testing 1 2. Apply a pressur Remove the radiator cap, wet its seal with coolant, then instal it on the pressure tester f 74-103 KPa (0.75—1.05 kg/em?, 1115 psi 3. Cheek for a drop in pressure, 1 RADIATOR PRESSURE TESTER Radiator Testing Wait until the engine is cool, then carefully remove ‘the pressure cap and fillthe radiator with coolant to the top of the filler neck 2, Attach the pressure tester to the radiator and apply @ pressure of 74~103 kPa (0.75—1.05 kglem?, 11-15 psi). 3. Inspect for cootant leaks and a drop in pressure. 4. Remove the tester and reinstall the pressure cap. NOTE: Check for engine oil in coolant andor coo!- ant in engine ait, RADIATOR PRESSURE 60Thermostat |Replacement NOTE: Use new gaskets and O-rings whenever reassem- bling ~dl 4 6x1.0mm 12 Nem (1-2 kom, 9 ft) THERMOSTAT HOUSING 6x1.0mm ner 12 Nim (1-2 kom, ) tet ‘THERMOSTAT house Ae casket $891,000, ‘THERMOSTAT nas (1-2 kgm, 9 A) Install with in up. Testing Replace thermostat if itis open at room temperature. To test a closed thermostat: 1. Suspend the thermostat in @ container of water as shown. 2, Heat the water and check the temperature with a thermometer. Check the temperature at which the thermostat first opens and at full lift. CAUTION: Do not let thermometer touch bottom of hot conta 3. Meas lift height of thermostat when fully open. STANDARD THERMOSTAT Lift height: 8 mm (0.31 in.) Starts oponing:78 C +2 C172 F 3 FI Fully open: 90 C (194'F) : 5-61later Pump Replacement ee | Remove the timing belt (SOHC: page 6-18, DOHC: page 5-24), Remove the water pump by removing five bolts. WATER PUMP Inspect for signs of seal leakage or bearing deterioration. NOTE: Smal amount of “weeping” from bleed ale fg normal I2Nem 1.2 kgm, 9 it) 101.25 mm 45 Nem (4.5 kgm, ALTERNATOR 33 tot BRACKET Install the water pump in the reverse order of removal.Fuel and Emissions Special Tools .. Component Locations Index System Description Vacuum Connections. Electrical Connections .. ‘Troubleshooting Troubleshooting Guide .. Seif-diagnostic Procedure How to Read Flowcharts.. PGM-FI Control System Troubleshooting Flowcharts Electronic Control Uni Oxygen Sensor . Mainfold Absolute Pressure SENSOF eeoneeenrsne: TDC/CRANK Sensor. ‘TDC/CRANK/CYL Sensor .. Coolant Temperature Sensor Throttle Angle Sensor .. CYL Sensor eevee IMA Sensor ‘Atmospheric Pressure Sensor... Ignition Output Signal Vehicle Speed Sensor ) CYL Sensor . Idle Control System System Troubleshooting Guide ......6— 59 Troubleshooting Flowcharts Electronic Air Control Vaive ......6—61 Air Conditioning Signal 6-64 Alternator FR Signal... 8-66 Starter Switch Signal 6-68 Idle Speed Setting .. 6-69 Fuel Supply System System Troubleshooting Guide Fuel Pressure Fuel Injectors Injector Resistor Pressure Regulator Fuel Filter Fuel Pump. Main Relay Fuel Tank Air Intake System System Troubleshooting Guide Throttle Cable Throttle Body ... Throttle Control System... Emission Control System ‘System Troubleshooting Guide.......6—~89 Tailpipe Emission Positive Crankease Ventilation System Catalytic Convepecial Tools Special Tools [a Too! Number Description ay Remarks (07JAZ—=SH20100 | F.P.M. Connecting Adaptor 7 8 07406-0040001 Fuel Pressure Gauge 1 eo 07405—-0040100 Pressure Gauge a ae @2 | 07406-00402: | Hoos Assy (1) FEF Component Toot ® 07999-PDE000A | PGM-Fi Test Harness 1 ® 07411~0020000 _| Digital Circuit Tester 1Component Locations adex SOHCWith CATA ea PURGE CUT-OFF MANIFOLD ABSOLUTE ‘SOLENOID VALVE, PRESSURE (MAP) SENSOR Troubleshooting. Troublashacting. page 6.26 LE iNsecToR 1D VALVE RESISTOR eating. page 6-76 Troubleshooting, ‘TDC/CRANK/CYL SENSOR: Troublesnoating, page 6-36 ———_| ‘OXYGEN (02) SENSOR ‘Troubleshooting, page 6-24 INTAKE AIR TEMPERATURE (Ta) SENSOR ‘Troubleshooting, page 6-48 COOLANT TEMPERATURE fm senson ‘SOHC Without CATA ‘Troubleshooting. page 6-42 pasnpor contnot SotzworD valve a tmamroup aasouute tumormis ante peasant (marr secon Touaenoctg, Benson ‘Troubleshooting, page 6-26 4 Troubleshooting. page 6-44 Tel INJECTOR Trovbleshootng, page 6-61 = RESISTOR Testing, page 0-75 ‘TDC/CRANK/CYL SENSOR INTAKE AIR TEMPERATURE ‘Troubleshooting, page 6-36 (Ta) SENSOR Troubleshooting. page 6-48 COOLANT TEMPERATURE (rw sensor Troubleshooting, page 6-42omponent Locations Index DOHC without CATA, MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, page 6-26 ‘TDC/CRANK SENSOR Troubleshooting, page 6-32 vu SENSOR ‘oubleshooting, page 6-66 ‘COOLANT TEMPERATURE (Tw) Sensor “Troubleshooting, page 6-42 with CATA becatadheiaiois MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, page 6-26 ‘TOC/CRANK SENSOR ‘Troubleshooting, page 6-32 L SENSOR ubleshooting, page 6-6 OXYGEN (0,) SENSOR Troubleshooting, page 6-24 COOLANT TEMPERATURE (TW) SENSOR DASHPOT CONTROL SOLENOID VALVE Troubleshooting, page 6-86, THROTTLE ANGLE SENSOR “Troubleshooting, pege 6-44 Eacv Troubleshooting, page 6-61 INJECTOR RESISTOR Testing, pace 6-76 RAE tra seNvon oO vest 0-8 DASHPOT CONTROL SOLENOID VALVE Troubleshooting, a PURGE CUT-OFF SOLENOID vatve Troubleshooting, page 6-92 EACV “Troubleshooting, poge 6-67 injecror RESISTOR Testing, page 6-76 INTAKE AIR TEMPERATURE (TA) SENSOR Troubleshooting, page 6-48 Troubleshooting, page 6-42 twnortie anal senson__- “Troubleshooting, page 6-44LHD IMA SENSOR (Without CATA] Troubleshooting, page 6-50 ATMOSPHERIC PRESSURE (PA) SENSOR ‘Troubleshooting, page 6-52 ‘MAIN RELAY Relay Testing, page 6-79, Hamess Testing, 6-80 SureTnonte conTmoL UNIT ECU) ‘Troubleshooting, nage 6-2 IMA SENSOR [KE] Troubleshooting, page 6-50 van neal j a a ng 0.78 Macnee ATMOSPHERIC PRESSURE (PA) SENSOR [KE] Trovbleshootng, page 6-52 ELECTRONIC CONTROL UNIT (ECU) ‘Troubleshooting, page 6-21»mponent Locations Index ‘THROTTLE BODY ‘AIR CLEANER ELEMENT Inspection, page 6-84 (@EC, KO: Replace every 2 yeare Disessembiy, page 6-85 ‘+ 40,000 km (24,000 mules) whichever comes fest ‘© Others: Replace every 1 year DASHPor DIAPHRAGM Troubleshooting, page 6-86 ACY fe ay, rae AIR INTAKE TUBE SHARCOAL CANISTER [With CATA] FUEL PUMP roubleshooting. page 6-2 or 96 ee Testing, page 6-78 Replacement, page 6-78 FUEL VAPOR PIPE FUEL FILLER CAP placement, page 6-77 > "EL FILTER ‘TWO-WAY VALVE Testing, page 6-100 FUEL GAUGE SENDING UNIT ‘Testing, section 16 EL INJECTORS ‘oubleshootng, age 6-72 placement, page 178 PRESSURE REGULATOR Testing, page 6-76 FUEL RETURN PIPE Replacement, page 6-77 uwSystems Description Macuum Connections. i A With CATA NOTE: The ilustration is SOHC type. DOHC type is the same as of SOHC type, except for the cylinder head. DASHPOT. CONTROL SOLENOID VALVE MANIFOLD ABSOLUTE Trovleshooting. page 6-66 PRESSURE (MAP) SENSOR ‘Troubleshooting, page 6-26 ‘To Two-way VALVE ) charcoat SamisreR S.WAY JOINT B PURGE CUT-OFF SOLENOID VALVE “Troubleshooting. FRONT OF page 8-92 or 96 VEHICLE ) S.WAY JOINT A 6-7ystems Description Vacuum Conneetions£@£$7}7VWAAHLSANYa a_i ky (MANIFOLD ABSOLUTE DASHPOT CONTROL PRESSURE (MAP) SENSOR SOLENOID VALVE Troubleshooting, page 6-26 Troubleshooting, page 6-86 ‘To TWO-WAY VALVE .WAY JOINT B SWAY JOINT Arz ‘Without CATA Ex. KY 6-9Systems Descriptions Vacuum Connections [With CATA] © OXYGEN (0,) SENSOR @ DASHPOT CONTROL SOLENOID VALVE @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ PCV VALVE @ ELECTRONIC AIR CONTROL VALVE (EACV) CHARCOAL CANISTER @ AIR CLEANER @ PURGE CUT-OFF SOLENOID VALVE © FUELINJECTOR G PURGE CONTROL DIAPHRAGM VALVE © PRESSURE REGULATOR ® TWO.WAY VALVE @ FUEL FILTER ® FUEL PUMP ® FUEL TANK @ DASHPOT DIAPHRAGM -10, Vacuum Connections [Without CATA] (© MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR @ FUEL TANK @ ELECTRONIC AIR CONTROL VALVE (ECV) @ DASHPOT DIAPHRAGM, AIR CLEANER @ DASHPOT CONTROL SOLENOID VALVE @ FUEL INJECTOR @ PCV VALVE @ PRESSURE REGULATOR @ CHARCOAL CANISTER @ FUEL FILTER @ PURGE CONTROL DIAPHRAGM VALVE FUEL PUMP @ TWo.way vaLvE 6-11iystems Description Electrical Connections [With CATA] Fuses. TECU MSA @ No.1 0A ZNo.14 (10a) D HAZARD (10A)" © No.2 (10a) = in the main fuse box = Sheol FES =] 7 fal FF g a 7 | Sees oa oe ees oS + 009000000 fF 0000000005 focos0000 200999000 Ff 0000000000 §00000000 “12 TERMINAL LOCATION) Electrical Connections [Without CATA} Fuses DECU ISA) © No.1 (108) f © No.14 (104) © HAZARD (70A)* f @ No.2 (TOA) : In the main fuse box 19099900000} 5000090 [20000000 L LOCATION 6-13roubleshooting Troubleshooting Guide [With CATA] NOTE: Across each row in the chart. the systems that could be sources of a symptom are ranked in the order they should be Inspected starting with T.. Find the symptom in the left column, read across to the most likely source, then refer to the page isted 1 the top of that column. if inspection shows the system ie OK, try the next most likely system 2, ete rane 7 Pace system WANFOID) —TOrr TEOOUANT. ecu | grew |Aesauue] chan | OW, [ToclcRawwevt| Fate |TeROTE SENSOR PRESSURE) senson | SERSOR | Tne | ANSE iseuson | Seo! | ston Eddi [ai | 26 Z % ee a CHECK ENGINE WARNING eae oo] oor ict melee] wor [ese] we Sean ee ot Oetiden| @ ome] @ | a | ENGINE WONT START ® DIFICULT TO START ENGINE WHEN COLD ® WAN COLD Brwieon | @ ® rouse | @ ® ] anecutan | DLING WHEN WARM LESFeED | @ roo ich | WHEN WARE bese” | © 106 tow wae ® Ee segue rnc ur | @ st AFTER wartanc up | @® ® TigeRE OF mouse ENGIN ® ® “oon FAs "EiroRM- | EMssion ae ie ® ® t oss oF Power ® ® ® {f codes other than those listed above are indicated. count the number of blinks again. Ifthe indicator isin fect blinking these , substitute 2 known-good ECU and recheck. If the indication goes away, repiace the original ECU. /; When the Check Engine warning ight and the self-diagnosis indicator are on, the back-up system is in operation. Substitute a known-good ECU and recheck. IF the indication goes away, replace the original ECU = SOHC, ¥* DOHC 14t PGM-FI Due CONTROL FUEL SUPPLY | 48 52 54 st 61 To 72 70, 82 8 Ha | ESE | SSE | AS | Ea @la@lelole & ® ®@|o @ ® | @ ®|@ ®@ | @ lol|lo ©} ®@ ® | © | @ ® @®@| @ oO ®@ | @® 6-15roubleshooting Troubleshooting Guide [Without CATA] ————__________ JOTE: Across each row in the chart, the systems thet could be sources of a symptom are ranked in the order they should be spected starting with . Find the symptom in the left column, read across to the most likely source, then refer to the page listed 1 the top of that column. If inspection shows the system is OK, try the next most likely system 2. etc. once svsrew aNFELD] TD cooLaNT TRE ecu [ABSOLUTE] chan | SX, (TOCZCRANK/CM ripen THROTTLE] Pupena Sessune| uso | Sex608 (" ine” | angie [WER sencoer| Sa sitste stNSOR ieee otne [Soy KOSI | TESE ESE] GEST [rear | gear | ses 3ELF-DIAGNOSIS INDICATOR | | eae eee BO [Dero Ge | aD | 7 7 ii INGINE WONT START | @ ‘scour sa NEE WHEN ESS @|® ® ee icie our OF SPEC ® | ®@ rousxioe | @ | @ | saecutan LING [WHEN WARM bts Spee. ® SEN WAR Iu eee. @ 5 to ete @lo sage [hls fo Mansur | @ | ® toe Roxie @|® 098 Fas Brtomm. [Eon ne a @ ! Loss oF 1 ie @ | ® | odes other than those listed above ae inceated, count the numberof blinks asin. the inceator iin ft licking these es, substtute »Krowh-9o0u ECU and recheck W the nceaon goes away, replace she angel ECU When the Check Engine warning ight ana the sel-diagrosisindator ore on, the bec-upeeyten in operation Substtue »known-good ECU and Techeck. the ndeaton goes away, renoce the ongias £60 + Sone, ss Done 16[ POW [IBLE CONTROL 1 mya | gereae | NON | VEHCLE noMe an] OFFER | run | an | emission | sen |ResUre| QHR | ER, [MPRA its] sty | wide | ESSTCY Tse ex es || si et et ca 70 @ w S/9/e/e/e/e g/eE/Ee;Ee/e;/s/e e/e;e;e 6-17roubleshooting Self-diagnostic Procedure ‘When the Check Engine warning light has been reported on, turn the ignition on, pull down the passenger's side carpet from tunder the dashboard and observe the LED on the top of the ECU, The LEO inieates a system failre code by banking frequency. ‘The ECU LED can indicate any number of simultaneous component problems by blinking seperate codes, one after anster, 1 _ __— sc0 Probie CODE 1 nA 785 prouiem cove 2 IATA. £8 Problem CODES EV _11_F11___ sce prottem cove 1 ana2 | “AIT E88 Problem CODE 2 sna 2 UL I_IPP__FL £88 Problem CODE 4,2 and 3 REE DASHORS, SYSTEM INDICATED PAGE 3 roo oa 1 (OXYGEN CONTENT (itn GATAI e2a $ MANIFOLD ABSOLUTE PRESSURE os a CRANK ANGLE 6:22, 36 é COOLANT TEMPERATURE oz 7 THROTTLE ANGLE ea p TOC POSITION 628, 88 3 Not CYLINDER POSTION 640, 46 10 INTAKE AIR TEMPERATURE ea " IMA (without CATA) 50 73 "ATMOSPHERIC PRESSURE (Ex. KG) 652 4 ELECTRONIC AIR CONTROL 661 5 TGNITION OUTPUT SIGNAL oa 6 FUEL INJECTOR 7 7 VEHICLE SPEED SENSOR 56 ‘codes other than those listed above are ingicated, count the number of blinks again. If the indicator is in fact blinking these ‘odes, substitute @ known-good ECU and recheck. if the indication goes away, replace the original ECU. hhe Check Engine warning light and ECU LED may come on, indicating an system problem, when, in fect, there ie a poor or termittent electrical connection. First, check the electrical connections, clean or repair connections if necessary. the Check Engine warning light is on and LED stays on, replace the ECU 18{1 the inspection for a particular failure code requires the PGM-FI test harness, remove the right door sil moiding, the small cover ‘on the right kick panel. and pull the carpet back to expose the ECU. Unbott the ECU bracket. Connect the PGM-FI test harness. ‘Then check the system according to the procedure described for the appropriate code(s) sted on the following pages. DIGITAL CIRCUIT TESTER, 10020000 PGM-FI TEST HARNESS (07989—-PD60008 (00000000 JFocodc00000ocec0000 009000000 0000000000f. 90009000 ‘TERMINAL LOCATION CAUTION: 7 fe Puncturing the insulation on a wire can cause poor of intermittent electrical connections. For tasting at connectors other than the PGMC-Fl test harness, bring the tester probe into contact with the terminal from the connecter side of wire hamess connectors in the engine compartment. Far female connectors, just touch lightly with the tester probe and do not insert the probe. RUBBER SEAL, TESTER PROBE WIRE HARNESS TERMINAL 6-19oubleshooting How to Read Flowcharts “flowchart is designed to be used from star to final repair. I's like a map showin, © off the “map” anywhere but a “stop” symbol, you ean easily get lost. Wold type) Describes the conditions or situation to start a troubleshooting flowchar 19 You the shortest distance. But beware: if you ACTION | Asks you to do something: perform a test, set up a condition, ete ‘sks you about the result of an action by giving an “answer” and asking did you get the same en DECISION) ASAE YoU about the reel ofan ection by giving 1d asking did you get the same a STOP] The end of Bold type) you to an es ies of actions and decisions, describes a tinal repait action and sometimes directs F part of the flow to confirm your repai oTe: ‘The term “Intermittent Failure’ is used several times in these charts. It simply means a system may have had a failure, but it checks out OK through all your tests. You may need to road test the ear to reproduce the failure or if the problem was a loose connection, you may have unknowingly solved it while doing the tests. “Open” and ““Short’” are common electrical terms. An open is a break in a wire of at a connection, A short is an ‘accidental connection of a wire to ground. In simple electronics, this usually means something won't work at all, In complex electronics (like ECUs!, this can sometimes mean something works, but not the way it’s supposed to, the electrical readings are not as specifies when using the PGM-FI test harness, check the test harness connections before proceeding.fuse. -- Troubleshooting Flowchart ECU eck Engine warning the tae te eee ee Is oil pressure warning light on ? NO Inspect No. 1 fuse. we “Turn the ignition switch OFF leo. 1 fave OK? No. ves Corres he FM Fen haan iraseeeee etc Scnran ha COU ancora ‘Seton NET fant ond foe toe 1a Rotor Meade 1 ) [Sees emia to oar ome - earn TRepisce warning tse le Check Engine warn ~ Biepeir ope ‘Goa Engine wang Tabt\No_| ~ BARH 2am ere Seo” contin) ve ? Connect the following terminals | indnidvally to B66 Ae A | 1s Check Engi on? Substitute a known-good ECU and recheck. if symp- ‘tom/ indication goss away, replace the original ECU. ves 000000060] POCO} mM eS ston] | ~Repair open in BLK wire between ECU (a2) and 6101. Repair open in BLK wite botween ECU (Al and G101. 00000000ffo0c0c000000ffoo000000 00000000ff0090000000ffo0000000 lo000000000] }O0000 loopoo00000ffo0000000 (wont) 6-213M-FI Control System Troubleshooting Flowchart ECU (cont'd) ——~A———_—_________ ~ LED doesn’t blink Connect the PGM-Fl test harness betwoen the ECU and connector (page 6-18). Disconnect * connector from ECU only, not the main wire harness ‘Turn the ignition switeh ON, ‘Doos Check Engine wa remain on ? yes NO, 00000 Reconnect “8” connector 10 lo0000000 ECU. “Aig ANB. 2 Connect folowing terminals inai- Vidually to AZ'« AIG. ATB. Repair open in BLK/ RED wite between Is Check Engine waming igh\No_| Eeu lata) ommeen, on? “Repair open in BRN/ BLK wire between ves ECU (A16) ano G101 AIST) AIS U4) Measure voltage between AIS (4), 815 (4+) terminals ano AT j2v3_ | 900000660ffoo0cc00c000ffooac0000 ©) terminal Q0CCO00OHAoCOCODR000ffo0000000 ai 18 (=) Repair open in YEL/BLK wire be- tween ECU {A13, —— Ais) and: Is there bauery votage ? NO | olay, Sue =Check main relay ves. and wiring connec. tors at main relay (age 6.79). (To page 6-23)(From page 6-221 1 Tur the ignition switch OFF. Disconnect the 3P connector of ‘each sensor one at a ume: (© MAP sensor (© Thvote angle sensor © PA sensor Ex. KO) (© Ima sensor (Witnovt CATA) ‘Start the engine, Replace the sensor that did not hie LED indieate the CODE for \NO. 9 cease the CODE to appoar upon poner ceamase= = iabaneueteiat YES Reconnect all connectors. Tura the ignition switch OFF. ‘Connect the PGMFI test har ‘ese between the ECU and con rector (page 6-19). Disconnect 'C™ connector trom ECU only, ‘not the main wire hares ‘Check for continuity between the body ground and the following terminals individually: «C13 2c ein? ES. NO ‘Substitute @ known-good ECU and recheck. If symp- tom/ indication goes away. replace the original ECU. 00000000ffo000000000} 00000000ffo0000000000} ~ Repair short to ground in VEL/ RED wire botweon ECU (C15) and MAP sensor. = Repair short to ground in YEL/ WHT wire between ECU (C13) and PA sensor (Ex. KO) oF ‘throttle angle sensor. = Repair short to ground in YEL/ WHT wire between ECU (C13) ‘and IMA sensor (Without CATA) 6-233M-FI Control System Troubleshooting Flowchart ——— Oxygen Sensor [With CATA] “SIE 2G set cacnosis 120 blinks once: A roblem inthe Onvoen(0,) Sensor eet = Check Engine warning light has been reported on. = LED indicates CODE 4 “Turn the ge Remove HAZARD fuse ia the main fuse box for 10 teconds to reset ECU, Inspect pressure regulator (page 8-76) Replace the pressure < Tet moval ? SHO regulator toage 6.77). ves Worm up engine to normal oper ating temperature (cooling fan comes on}. Hota engine at 1500 min-* (wom) for 18 minutes. NOTE: Do not elo pletely during th thvotle com: ‘Is. Check Engine warning tght\ yo [Intermittent failure on? (test drive moy be Does LED indicate CODE 1 ? necessary). ves: (o page 6-25) 24as me wire harness ‘Warm up engine to normal oper- ating. temperature again, then ‘open the throttle wide apen then, clase i voltage between the connecter terminal and body ‘rounds Connect the PGM-FI test harness between the ECU and connector (age 6-19). * pieirat circurr Tester (07411-02000 ©; Sensor 48 Nm ( Replace 0, sensor. 200000009ff0000000000} looo00000 jlooo00009 r Restart and warm up engine 10 formal “operating temperature then open the throttle wide open then close it PassinssNARaasannsssSueruaa ‘Measure voltage between C16 (+) and A18 (=) rerminais "ie vetage above 0.6V during widd\ ‘open accelerotion? Ie vetage \ no, below 0.4V curing closed throne ‘eesieration fiom 5,000 min (com? me) caste) Above 067 Below 04 V7 Oz sensor. Repair short or open in WHT wire between ECU (C16) and ves Substitute ECU and recheck. If symp- ‘tom/ indication goes away, replace the original ECU. 6-25iM-Fl Control System Troubleshooting Flowchart Sal es = Seldiognosis LED indicator blinks five tines: Most Hs 2 mechanical problem (broken hose) inthe Manifold EL HE Reser Ab) Senco stm “Engine is warm and running. ~ Check Engit ion. LED indicates CODE 3. MAP Sensor ltiagnasis LED inaicator blinks three times: Most likaly an electical problem in the Manifold Absolute Pressure P) Sensor system So warning light “Turn the ignition switch OFF. Remove HAZARD fuse inthe in fuse Box for 10 seconds 10 ECU. Star the engine and allow to idle. ‘Is Check Engine warming light on? Does LED indicate CODE 3? NO ves: Torn the ignition switch OFF Disconnect the 3P connector ‘rom the MAP sensor “Turn the ignition ewiteh ON, ‘Measure volge between YEL/ RED (+) terminal and GRN/ WAT (2 teiminat {To page 6.27) 26re Na ‘Measure voltage between YEL/ RED (+) tormingl and body ground, YES Repair open in GRN/ a ; yes | WHT ‘wire between <_ bites approx. 8.¥ ECU (C14) and MAP NO, eed Tum the ignition ewach OFF. Connect the PGM-FI est hamess ‘between the ECU and connector {age 6-19). ‘Measure voltage between C15 (+) terminal ane Cra {-) termi- nal withthe ignition switch on. Measure voltage between WHT (=) wrminal ane GAN/WHT (-) terminal ae nin YEL/ ‘between <_ fs there aprox. V7 ECU(G?S) and MAP oI sensor. ‘Substitute a known-good ECU and recheck. It pr scribed voltage Is now avai able, replace the original Fou. is there approx. 5 V7 Ne Turn the ignition switeh OFF, YES ‘Turn the ignition switch OFF. ‘Saeed Easi-eieaarate ‘between the ECU and connector {age 6-149) Connect the PGM-Fl est harness between the ECU and connector (ape 6-18). Turn the ignition switeh ON (0 page 6-28) fe eee (cont) ; 6-27‘GM-FI Control System - Troubleshooting Flowchart (rom page 6-27) MAP Sensor (cont'd) (rom page 6-27) Reconnect the 3P connector, ‘Turn the ignition switch ON. Measure voltage between C11 (+) terminal and C14 (-) termi- al ‘Massure voltage between CIT (Ge) terminal and C14 (-) temic ral 00000000ffo000000000ffo0000600 00000000ff0000000000ffo00000g0 '000000000ff0000000000ffoo000600 200000000ff0000000000ff00000090 cn Repair open in WHT aay, yes | wire between ECU Eo tomeamen sv? ST) rare, measteee Se 7 sor. Repair short in WHT wire be- tween ECU (C11) and MAP -— one ee Is there approx. $V? No Replace MAP sensor. ves, Substitute a known-good ECUandrecheck.tfsymptor/ indication goes away the original ECU. -286-29PGM-FI Control System — Troubleshooting Flowchart “So MAP Sensor (cont’d) ———___ #21 HOSE = Check Engine warning light as ~ LED indicates CODE 5. Tum the ignition switeh OFF, 7 a) Remove HAZARD fuse in the ‘main fuse box for 10 seconds to reset ECU. ‘Sta the engine vacuum PUMP/GAUGE “Make sure all connectors Check Engine warning tisht\ yo, ~Check vacuum hoses, pipes. ‘on? ‘end connections, Does LED incicate CODE § 7 rmittent failure (est drive may be necessary). ves ‘Stop engine, ject vacuum pump to -21 snd apply vacuum, No Connect a vacuum pump to the Does it hold vacuum? MAP sensor and apply vacuum. YES No Does ic hold vacuum? Replace MAP sensor. ves. Disconnect »21 hose from the throttle bedy and connect 8 T- fitung trom a vacuum gauge be- tween the throttle body and MAP Replace +21 hose. (0 pege 6-31) i-30(rom page 6-30) Connect the PGM-FI test harness Derween the ECU and connector (page 6-19). Tura the ignition switch ON, ‘Measure voltage between C11 (+) teminal and C14) tori “Remove restriction from ‘throttle body, Replace throttle body. ves: Inspect for an open in WHT wire between te MAP sensor end ECU. If wire iz OK, replace the MAP eonsor. ‘Substitute @ known-good ECU and recheok. If ymp- tom/indication goes’ sway. ‘replace the original ECU. 6-31PGM.-FI Control System Troubleshooting Flowchart TDC/CRANK Sensor [DOHC] GSE 38E setrciegnosis LE instr inks fur ime: A problem in the CRANK eeu ofthe TOC/CRANK Senco GRE] 8 ser-crgnosis LED ingicator blinks eight times: A problem in the TOC ekcuit ofthe TOC/CRANK Sensor, Ge ~ Check Engine warning light has been reported on. LED indicates CODE 4. Ture the ignition switen OFF. Remove HAZARD fuse in the ‘main fuse box for 10 seconds to reset ECU. ‘Start engine. “is Check Engine warning light Intermittent failure on? NO | (test drive may be Dees LED indicate CODE 4? necessary). Yes ‘Stop engine, Disconnect 6P connector from the TOC/CRANK sentor ‘Measure resistance between D 1d E terminal Ts theve 350-5500? No ‘place te distributor assembly (section 16). ves: See EERE EEE EEE Check for conninuity 10. boy ‘ground on O terminal and tet rriral individual, (to page 6-33) 3-32{From page 6-32) Doe coninuiy exin? YES Replace te devibuor assembly {section 18), NO Reconnect the connector. Connect the PGM-F1 test harness ony tothemsinwite hares, but ae reread erie '900000000ffo000000000]fooo00000 000000000} 90000ffo000G000 Measure resnance between B10 670] 812 terminal and B12 terminal as0~Ss007 No ‘open in ORN andior ie thre 350-550 .07 Repair ope ves ‘Substitute a known-good ECUandrecheck. It symptom/ indication goes away. replace the original ECU. feont's) 6-33?GM-FI Control System - Troubleshooting Flowchart ok = Check Engine warning Hight has been reported on. = LED indicates CODE 8. ——_ Turn the ignition ewiteh OFF. TDC/CRANK sensor [DOHC] Remove HAZARD fuse in the main fuse box for 10 seconds 10 reset ECU. ‘Star engine, eCheck Engine warning Haht\ wo Intermittent failure on? (test drive may be neces- Does LED indicate CODE 8 ? sary). Yes, ‘Stop engine, Disconnect. the GP connector ‘rom the TDC/CRANK sensor Measure resistance between 6 terminal and € terminal 1s there 3508509? No. Replace the davibteratcembly Yes Check for continuity to body ‘ground on 8 terminal and C ter ‘minal individual yes. lace the distributor assembly {section 16) Dots continuity exist? NO) ‘Reconnect the connector. ‘To pape 6-38) -34(From page 6-24) Connect the PGM.-FI est hamess Cniy te the main wire harness, But not to the ECU {page 6-19), Measure resistance between C3 terminal and C4 termina. 85007 ves, Repair open in ORN/ NO} BLU angio WHT) BLU wires, Jsupstiute a known-good ECUandrecheck.Itsymptom/ indication goes away, replace the original ECU. 000000000ffoo0c000000ffod000000 00000000ffo000000000ffog000000 ce ° { EASSESSSEBSERBESHEG 6-35'GM-FI Control System —Troubleshooting Flowchart TDC/CRANK/CYL Sensor [SOHC] (ESE JE settciagnose Led inceator blinks fur time: A problem inthe CRANK cicuit ofthe TDC/CRANKICYL Sensor. EE s-ciagnoss LED nesting tn A pst in he TOC cut TOC/ERANKICY Senor EE seston LED nal bine ne a Aram nh EL tue he TOCICRARKICW. Sr Bod ight has been reported on, = LED indicates CODE 4, Turn the ignition ewitch OFF. Remove HAZARD ‘use in. the ‘main fuse box for 10 seconds to reset ECU, ‘Star engine. 's Check Engine weming ligt\ yo | Intermittent failure on? (test drive may be Does LED indicate CODE 4 ? necessary) ia Yes ‘Stop engine. ae paea. Disconnect the BP connector | fiom the TDC/CRANK/CYL sen- Measure resistence between C terminel end D terminal 1s there 950-550 07 YES (To page 6-37)(rom page 6-36) ‘Check for continuity to body ‘ground on C terminal and D ts ‘inal ingividvally. ves penn 088 continuity exis? place the dstibutor 2 a assembly (section 16). NO Reconnect the connector Comect the PGM-FI west harness erly to te main wre harness, but roto he ECU tage 6-19) | 00000000ffooo0000000ffoo000000 206000000ff0000900000ffo0000000. Bios: 350 soc” Measure resistance between B10 terminal ang 812 termina. ir open in ORN <_sstere 350-55007 NO | Repair open in On ves. ‘Substitute 9 _known-good ECUandrecheck-Htsymptom/ indication goes away, replace the original ECU. (eons) ’ 6-37?>GM-FI Control System —_Troubleshooting Flowchart TDC/CRANK/CYL sensor [SOHC] ——_____ “ ) ~ Check Engine warning light fed on. been reported on. LED indicates CODE 8, “Turn the ignition switeh OFF, Remove HAZARD fuse in the main fuse box for 10 seconds to reset ECU. = Check Engine warning light oes LED indicate CODE 8? ) Inermittent failure wd (test drive may be. necessary). a ves ‘Stop engine. Disconnect the 8° connector from the TOC/CRANK/CYL sen: ‘Measure resistance between A Terminal and 8 terminal 's there 350-5509? Yes NO_| Replace te diswibunor assembly (section 16). CCheck for continuity 10 body ‘ground on A terminsl and B ter. ‘inal individually, Dees continuity exist > No NES | Replace the diswibutor bly (seetion 16), ‘Reconnect the connector, (7 page 6-39)(From page 6-38) Connect the PGM-Fi test hamese only to the main wire harness, but ‘ot tothe ECU (page 6-19). ‘Measure resistance between C3 terminal and Cé termina. ) (From page 6-61) Does continuay exist? »SY°S | Reptace cacy. Mesture vologe between BLK YEL (=) teminol ond BLUPYEL terminal 1s there Bote votiage ? YES Disconnect the 17° connector ‘tom the ECU. No ) ves | Repair shore in BLU) Messure volage between BLK/ He there battery voltage ? YEL. wire. betweon YEL“() terminal and. body ECU (ATI) and EACY. round. NO no | BEpsit open in BLK > YEL” wire between <_tnitee baer vonage ? SMO] YEU wire "between = fuse, Substitute a known-good “Turn the ignition swach OFF. EcUand recheck. eymptom! Indication goes away. re place the original ECU. |" Reconnest ine 2° connector wo} EAC. Connect the PGM-FI est nares °R" connector to the main wre harness only. not the ECU (oage 6-19) Turn the igition awntch OW. qe nv |900006000Jfooocc0a000ffocoG0000 20000000f0000000000ff00000000 (o emina and A2 (-) termina 4) (To page 6-63) -62‘From page 6-62) No Repair open in BLU/ YEL_ wire between ECU (ATT) and EACV, ‘Connect and disconnect A1T ier ‘minal te A2 terminal. (0085 EAC click when the con rector is connected and discon YES. (000006000) 00000000] Replace EACV. [ooo0000000ffoo000000 jloooo000000ffo0000000 6-63Idle Control System — Troubleshooting Flowchart Connect the PGM-FI test har- ness between the ECU and con sector (page 6-19). Disconnect "8" connector from tha main wire hhamess ony, not the ECU. Air Conditioning Signal ————__—___ Turn the ignition switeh ON, ‘Measure voltage between BB (+) terminal anc ATE (-) termi- 00000000ffo000000000ffoo000000 200000009f0009000000ffo0000000 ANI) BBE) awe a Substitute a known- aro heck. if preseri eee eel ‘oteage is how avail: 5 Teplace the ori Reconnect “B™ connecior to the 3, main wie harness : Qo0000000ffodo00Gc000ffooo00000 oonsiad ba taeseal aaa 000000009f}0000000000ff00000000 minal sen Connect the YEL terminal of the <_ des AVC operate? we. 4P connector on the AVC clutch ‘ely to boay ground ves Sanwa mma ye | ae (section 15). ves -——______ Blower switch ON, (To page 6-65) Repair open in YEL wire be- tween ECU (B3) and a/c clutch(From page 6-64) ‘AIC switch ON. Does A/C operate ? no ‘See Alt conditioner inspection (section 15) YES ‘Measure voltage between 88 (+) terminal and A18 (=) termi- al << tsvotage tetow tv? SO] ) ves (000000000ffo000000000ffo0000000 00000009ffoo: 10000ff00000000 L Repair open in BLU/ RED wire ECU (Ba) switeh. ‘Air conditioning signal is OK. 6-65Idle Control System — Troubleshooting Flowchart Alternator FR Signal —————__________ pection of Alternator FR signal ‘Connect the PGM-FI test harness between the ECU and connector (age 6-18). Disconnect “B" ‘connector from the main. wire harness only not the ECU. ‘Turn the ignition switch ON, Measure voltage between B14 (+) terminal and A1B (-) termi al Substitute a known-good sane > So soot ge ves Ect Turn the ignition switeh OFF. Reconnect “B connector to the main wite hamess, ‘Warm up engine to normal opet- ating temperature. (cooling tan ‘comer on}. voteas between 64 200000000ffoooc000c00ffooo0c000 norminel ar a 000000009ffo00000g000ffoc000c00 AB Buc votagex— Does the voluge decrease when tumned-on ? ves ‘Alternator FR signal is OK. -—— (0 page 6-67)(From page 6-66) 1 Disconnect “5 connector from ECU only. not thie main wire ha Disconnect the negative battery, cable from the banter. Check fer continuity between 1814 terminal and body ground Cows co NO. Disconnect GRN connector fom ) ere ahernater. YES. Connect BLU wire to body ‘round. ‘Check for continuity between ) Bra terminal and body ground ves ity exit ? NO) Repair open in BLU wire between ECU (B14) and alter eter. SRN CONNECTOR Disconnect GRN connector from the akemator. (Check for continuity between B14 terminal ana body groune. YES Repair short in BLU wire be tween ECU (B14) and alter- See Alt spection cernotor_in-| (section ‘See Alternator_tn- spection (section 16) 6-67dle Control System ~ Troubleshooting Flowchart Starter Switch Signal —————-______ ‘This signals the PGM-FI ECU when the engine is cranking lon of Starter Switeh a | a13(0) ‘Connecti FON-Hl es a 00000000]fo000006000ffo0000000 between the ECU and connector ™'" Looococ00pffooc0000000ff00000000 (aoe 6-19), ah ESSESEESSSESESSRESSS | na ANB (-) ten al with ignition switch in Stan position No 's there banery voltage ? Inspect No. 2 fuse. YES NO, 1s No. 2tuse OK? Replace fuse. ves 68ile Speed Setting Inspection/Adjustment 1. Start the engine and warm it up to normal operating temperature (ihe cooling fan comes on) 2. Connect a tachometer RPM CONNECTING ADAPTER (075Az~SH20100 TACHOMETER 3. Disconnect the 2° connector from the EACV. cacy E' IDLE ADJUSTING SCREW 5. Reconnect the 2P connector on the EACV, then remove HAZARD fuse in the main fuse box for 10 ‘seconds to reset ECU, 6. Idle the engine with no-load conditions in which the headights, blower fan, reer defogger, cooling fon, ‘and air conditioner are not oparating for one minute, then check the idle speed. SOHC With CATA and Ka] 750250 min“ (opm) Ky 780250 min-* (rpm) DOHC Ex. KO. 800250 min (rpm) 7. le the engine for one minute with headlights (Hi} anc rear defogger ON and check the idle speed. Idle Speed should be: SOHC With CATA and Ka] 750250 min-' (rom) | 4. Check idling in no-load conditions in which the head- lights, blower fan, rear defogger, cooling fan, and air conditioner are not operating Idle spaed should be: 650250 min-* (rpm) ‘Adjust the idle spe ‘ajusting screw. if necessory, by turning the idle NOTE: If the idle speed is excessively high, check the throttle control system (page 6-86), Ky 780250 min-* (rpm) DOHC Ex. KO 800250 min (rpm) 8. Idle the engine for one minute with heater fan switch {at HI (right end) and air conditioner on, then check the idle speed. Idle Speed should be: SOHC and KO 780250 min-* (rpm) DOHC Ex. KO. ‘800 50 min" (rpm) NOTE: If the ide speed is not within specifications, see System Troubleshooting Guie on page 6-59. 6-69Fuel Supply System System Troubleshooting Guide ——__________ NOTE: Across each row in the chart, the systems that could be sources of a symptom ore ranked in the order they should be Inspected staring with {Find the symptom in the left column, read across tothe most likely source, then refer to the page sted ‘at the top of that column. If inspection shows the system is OK, try the next most likely eystem @, ete, SUE 7 Pace Srey] ya Tuscon nessa oe | om | saw | mum [comm snuscTor | RESISTOR REGULATOR FicTeR | Fume | Asay | TK alin eee 72. 76 76 77 78 73 a1 * T i ENGINE WONT START ® |®@|o|o t i LF TO START ENGINE ! WHEN co “FT ® | i ®/| oO ROUGH IDLE i @ | ® ® WHILE WARM ®!]® cerca [ROU ® | rr 7 Nour A) @ ®|O}®@ WISFRE OR fun. Rouen hun. @ ® E eMISSIO Fesrommance [esr MSS" | ) 108s oF power ®1@|o @ * Fuot with dir, water or 2 high percentage of alcohol is considered contaminated.tel Pressure rm Relieving . © De not smoke while working on the fue system Keep open flames ov sparta away from the work /e fuel pressure while the engine is NOTE: Betore disconnecting fuel pipes or hoses, release pressure from the system by loosening the 6 mm service bolt at top of the fuel filter 1. Remove fue filer cap. 2. Disconnect the battery negative cable from the bat tery negative terminal 3. Use a box end wrench on the 6 mm service bolt at $00 ofthe fuel iter, while holding the special banjo ‘bolt with another wrench. 4. Place @ rag or shop towel over the 6 mm service bolt 5. Slowly loosen the 6 mm service bolt one complete SERVICE BOLT 12 Nem (1.2 kgm, 9 i.) q ‘SHOP TOWEL FUEL FILTER NOTE: A fuel pressure gauge can be attaches at the 6 mm service bol hole. © Always replace the washer between the bolt and the special banjo bolt, wher service bolt is loosened to relieve fuel pressure ‘© Replace all washers whenever the bolts are re: moved to disassemble parts, Inspection 1, Relieve Fuel pressure. 2. Remove the service bolt on the top of the fuel fiter ‘while holding the banjo bolt with another wrench and: attach the fuel pressure gauge. 3. Start the engine. Measure the fuel pressure with the ‘engine idling and vacuum hose of the pressure regule- tor disconnected, Pressure should be: 240-279 kPa (2.45~2.85 kg/em?, 35-41 psi FUEL PRESSURE GAUGE FUEL FILTER, PRESSURE REGULATOR © If the fuel pressure is not as specified, first check the fuel pump {page 6-78), If the pump is OK. check the following: — ithe pressureis higher than specified, inspect for: Pinched or clogged fuel return hose oF piping. Faulty pressure regulator (page 6-76). — I the pressure is tower than specified, inspect for Clogged fue! iter. Pressure regulator failure (page 6-78) Leakage in the fuel tine. 6-71Fuel Supply System — Fuel Injectors PReEEETeeee ee eee eee CEL Troubleshooting Flowchart SESE 38 wen cara SESE 3 wn cara NOTE: On With CATA models, start the troubleshooting = Check Engine warning light eee: 7 - LED indicates CODE 16. ‘Turn the ignition ewitch OFF, Remove HAZARD fuse in the mein fuse box for 10 seconds to reset ECU, sanosis LED indicator Blinks sixteen times: A problem in the fuel injector circuit ‘Tum the ignition swish to NOTE: On Without CATA models, start the throbleshoot- START position. ing from this procedure. Does the engine start ? ves =~ + ‘J — e | With CATA, ic eck Engine warning oht\ yo [intermittent fature |) oo | Come (Feat are. may’ be 1 \ Does LED indicate CODE 16 7 necessary.) i | ease seer PES) Go page 6-73) (Check the clicking sound of each injector by means of 3 stetho- scope when the ‘Substitute @ known- good ECU and re- check. If symptom? indication goes away. replace the original EGU. << Dothe injectors lick ? NO) (to page 6-73) ‘72(From page 6-72) (from page 6-72) “Tura the igeition ewiteh OFF. Turn the ignition switch OFF 2P connector that dees not Disconnect from the injeste chek. Measure resictance between the 2 termenals of the injector. Disconnect the 2P connector from each injector. ‘Measure resistance between the 2 terminals of the injector. \s there 1.5250? ves ‘Turn the ignition switeh ON, ‘Measure voiege between RED/ BLK (+) terminal on the 2P con= nector and body ground. (to page 6-74) (cont'd) 6-73Fuel Supply Syst em Fuel Injector. ‘Troubleshooting Flowchart (cont'd) No Repair open in the YEL/BLK be- ‘tween the injector relay. tron ap 678 Tin in wa OF Grand Disconnect 6P connector on the felicia [seaeteeeiem tort inet as aa tgnee am ae Ty terete Soe aeatas Sy Seer teitiey a cmos ame ae © No. 2 injector: RED/BLK (+) seta SH aetna? crn sigete Gas mutans ome) ™ pare ee eee Replace the injector resistor. liseeren treo \s there battery voltage ? from the ECU, NO, Reconnect the 2P connector to the inectr. ‘Connect the PGM-FI test harness berween the ECU and connector (age 6-19) ls there battery voltage ? Measure voltage between A2 (-) torino folowing tra STR} Secor AI" Stemi Ned inestor Ad tinal [sa No.3 injector AS (+) termi AS rH] AT Hh 1 Ned injector A? (2) toma parchl as] No Substitute 2 known-good ECU end. recheck. If pre scribed voltage is now avell- ‘able, replace the original Repair open in the wire be- tween the ECU (AT, 03, A5 or A7) and the injector. Repair short in the wire betwoen th ECU (A1, 3, A5 or 1A7) and the injector.mz Replacement Do not smoke during the work. Keep open flames away from your work area. 1. Disconnect the battery negative cable from the bat. tery negative terminal. 2. Relieve fuel pressure (page 6-71). 3. Disconnect the connectors from the injectors. 4. Disconnect the vacuum hose and fuel return hose from the pressure regulator. NOTE: Place a rag or shop towel over the hoses before disconnecting them, Lossen the retainer nuts on the fue! pipe and har- ? ness holder. 6. Diconnect the fuel pipe. 7. Remove the injectors from the intake manifold. FUEL PIPE INSULATOR, CUSHION RING Replace SEAL RING Replace 8, Slide new cushion rings onto the injectors. 9, Coat new O-rings with clean engine oll and put them on the injectors. 10. Insert the injectors into the fuel pipe first. 11, Coat new seal rings with clean engine oll and press ‘them into the intake manifold. 12. Install the injectors and fuel pipe assembly in the manifold CAUTION: To prevent damage to the O-ting, in- ‘stall the injectors in the fue! pipe first, then install ‘them in the intake manifold. FUEL PIPE 13. Align the center line on the connector with the ‘mark on the fuel pipe. FUEL PIPE a MARKINGS 14, Install and tighten the retainer nuts. 15. Connect the vacuum hose and fuel return hose to the pressure regulator. 16. Install the connectors on the injectors. 17, Turn the ignition switch ON but de not operate the starter. After the fuel pump runs for approximately, ‘two seconds, the fuel pressure in the fuel line rises, Repeat this two or three times, then check whether there is any fuel leakage. 6-75Fuel Supply System Injector Resistor Testing 1. Disconnect the resistor connector. 2. Check for resistance between each of the resistor terminals (E, D, C and B) and the Power terminal A. Resistance should be: 5—7 0 INJECTOR RESISTOR © Replace the resistor with @ new one if any of the resistances are outside of the specification. -76 [- Pressure Regulator ————___ Testing Do not smoke during the test. Keep open flames away from your work area. 1. Attach a pressure gauge to the service port of the fuel filter [page 6-71), Pressure should be: 240-279 kPa (2.45—2.85 kgicm?. 35—41 psi) (with the regulator vacuum hose disconnected) FUEL PRESSURE GAUGE 16-0040001 o7a0e PRESSURE REGULATOR FUEL FILTER, 2. Check that the fuel pressure rises when the vacuum hose from the regulator is disconnected. © If the fuel pressure did not rise, check whether it rises when the return hose is lightly pinched. PRESSURE REGULATOR, RETURN HOSE SHOP TOWEL, — If the pressure does not rise, replace the reg- lator and retest.Replacement [EXTENT 0 not smoke while working on fuel sys- ‘em. Keep open flame away from work area. 1. Disconnect the negative terminal of the battery 2. Place 2 shop towel under pressure reguistor, then relieve fuel pressure (page 6-71). 3. Disconnect the vacuum hose and fuel return hose. 4. Remove the two 6 mm retainer bolts Note: © Replace the O-ring '® When assembiing the regulator, apply clean engine ‘oll to the O-ring and assemble it into ts proper Position, taking care not to damage the O-ring, r— Fuel Filter mz Replacement FORTE Do not smoke while working on fuel sys- ‘em. Keep open flame away from work area, ‘ne fiter should be replaced: every 2 years or 40,000 km (24,000 mies), whichever comes fret or whenever the fuel pressure crops below the specified value (240-279 koa, 2.45—2.85 kg/cm? , 25—41 psi with the pressure regula: ‘or vacuum hose disconnected) after making sure that the {fuel pump and the pressure regulator are OK. 1. Disconnect the battery cable from the negative termi- ral 2. Place a shop towel under and around the fuel fiter 3, Relieve fuel pressure (page 6-71). 4, Remove the 12 mm banjo bolt and the fuel feed pipe ‘trom the fiter 5. Remove the fuel fiter clamp and fuel fier. 6. When assembling, use new washers, as shown. BANJO BOLT SERVICE BOLT Replace 10 Nom (1.0 kgm. 7 B.A 6-77Fuel Supply System Fuel Pump- Testing © 1 fue slow is ess thon 230 cm? (7.8 or, orthereis 10 fuel flow, check for FEXZEIN 00 not smoke during the test. Keep open + Clogged fu! iter. flame away from your work area. Clogued fuel fe Pressure reguistor fai 1. With the ignition switch OFF, disconnect the con- HO page 6-76). rector from the main relay at left side of the cow 2. Connect the BLK/YEL wire and YEL BLK wire with > jumper wie, '¥ you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it ie ON, you will hear some ‘noise if you hold your ear to the fue! filer port with the fuel filler cap removed. If the pump does not make noise, check 28 follows: 1, Remove the rear seat, 2. Disconnect the 3P connector. CAUTION: Be sure to turn the ignition switch OFF before disconnecting the wires. 3. Check that battery voltage is avaiable at the fuel pump {connector when the ignition switch is turned ON {post ‘tive probe to the YEL/BLK wire, negative probe to the BLK wire). LEVEL: ‘VEL BLK JUMPER WIRE BLK 3. Relieve fuel pressure as described on page 6-71 ‘then tighten the service bolt. ‘4. Disconnect the fuel return hose from the regulator. 5. Tum the ignition switch ON for 10 seconds and ‘measure the amount of fue! flow. ‘Amount should be: ‘VEL/BLK 230 em? (7.8 02) min. in 10 seconds at 12V VS PRESSURE REGULATOR © If battery voltage is available, replace the fuel pump. (© If thereis no voltage, check the main relay and wire hharness (page 6-79).re Replacoment FEXTINI D0 not smoke while working on fuel sys- ‘tem. Keep open flames away from your work area. 1. Remove the fuel tank (oage 6-81). 2. Remove the fuel pump mounting nuts 3. Remove the fuel pump from the fuel rank. 5 Nm (0.6 kg-m, Alb) FUEL PUMP a ttt i UEL PUMP -- Main Relay Relay Testing 1, Remove the main relay. 2. Attach the bettery positive terminal to the No. 4 ter- ‘minal and the battery negative terminal to the No, 8 terminal of the main relay. Then check for continu ty between the No. § terminal and No. 7 terminal of the main relay, © IT there is continuity, go on to step 3. © 1F there is no continuity, replace the relay and retest. nes No.8 No.2 {3] To ecu 1a 13. 15) 3. Attach the battery positive terminal to the No. 5 ter- ‘minal and the battery negative terminal to the No. 2 terminal of the main relay. Then check that there 's continuity between the No. 1 terminal and No. 3 terminal of the main relay. To ecu arz. 14) [B} 11 there is continuity, go on to step 4. iS no continuity, replace the relay and 4, Attach the battery positive terminal to the No. 3 ter ‘minal and battery negative terminal to the No. & ter ‘minal of the main relay. Then check that there is Continuity between the No. 5 terminal and No. 7 te minal of the main relay, 18 If there is continuity, the celay is OK; |f the fuel pump still does not work, go te Har- ress Testing in the next column, ‘© 11 there is no continuity, replace the relay ang retest. 6-79Fuel Supply System Main Relay Hames Testing 7 1. Keep the ignition switch in the OFF position 2. Disconnect the main relay connector. 3. Check for continuity between the BLK wire 2 in the connector and body ground, Attach the positive probe of voltmeter to the YEL/WHT wire @ and the negative probe to the BLK @. a Battery voltage should be aveileble. 9. ‘© If there is mo voltage, check the wiring between the battery and the main relay as well a8 ECU fuse (154) in the main fuse box, 5. Attach the positive probe of voltmeter to the BLK/VEL wire © and the negative probe to the BLK wire @. 10. 6. Turn the ignition switch ON. Battery voltage should be availabe, ‘© If there is no voltage, check the wiring from the ‘gnstion switch and the main relay as well as No, 14 (108) fuse Attach the positive probe of voltmeter to the BLU/ WHT wire @ and the negative probe 10 the BLK wire @ @etk %o BLU Tuen the ignition switch to START position. Battery voltage should be available, '© If there is no voltage, check the wiring between the ignition switch and main relay as well as No. 2.(10) fuse. Connect a jumper wire between the BLK/YEL wire © and YELIBLK wire @. @ BLK VEL JUMPER WIRE Turn the ignition switch ON. The fuel pump shouls work © the fuel pump does not work. check the wiring Detween the main relay and fue! pump, and the wiring from the fuel pump to the ground (BLK wire}“uel Tank Replacement EIEN De not smoke wi ‘working on fuel system. Keep open flame away from work area. 1. Block front wheels. Jack up the rear of the car and support with jackstands, 2. Remove the drain bolt and drain the fuel into an approved container. 3. Remove the rear seat and disconnect the 3P connector. 4, Remove the two-way valve cover and fuel hose protector. 5. Disconnect the hoses. CAUTION: ‘© When disconnecting the hoses. slide back the clamps. then twist hoses a¢ you pull, to avoid damaging them. © Ciean the flared joint of high pressure hoses thoroughly before reconnecting them. 6. Place a jack, or other support, under the tank. 7. Remove the strap nuts and let the straps fall fee, 8. Remove the fuel tank. NOTE: The tank may have stuck on the undercoat applied to its mount. To remove, carefully pry it off the mount. 9. installa new washer on the drain bolt, then inetall parts in the reverse order of removal 38 Nem (3.8 kam, 27 bf) FUEL PUMP. DRAIN BOLT 50 Nem (5.0 kgm, 36 Ib) : FUEL GAUGE SENDING untr FUEL HOSE PROTECTOR Two.way VALVE cover MOUNTING NUT 22 Nem 2.2 kgrm, 16 Wott 6-81Air Intake System System Troubleshooting Guide ——— ceinenceecee cach row in the char. the sub systems that could be sources of a symptom are ranked! in the order they should tee oe ne ar 9 ith. Find the symptom in the lft column, read across tothe most lkely source, then refer to the nose {sted ot the top of that column. If inspection shows the system is OK. try the next system @ ote rei SFT somscane | nearer | RE SYMPTOM Ed e 35 ENGINE WONT START ® DIFFICULT To START ENGINE WHEN COLD ® |WHEN COLD FAST IDLE OUT OF SPEC @ ® ® | WHEN WARM ENGINE SPEED TOO HIGH @ ® oO WHEN WARM ENGINE SPEED TOO LOW @® FREQUENT STALLING WHILE WARMING UP ® @® ® LOSS OF POWER ® ®hrottle Cable: Inspection/Agjustment 1.” Warm up the engine to normal operating temperature (cooling fan comes on). 2. Check that the throttle cable operates smoothly with ‘no binding or sticking. Repair as necessary. 3. Disconnect #6 and #22 hoses from the dashpot dio- phragm end connect @ vacuum pump to the diaphragm Using a T-fiting as flustrated betow. Apply vacuum. TITTING $6 Hose #22 HOSE 4. Check cabie free play at the throttle linkage. Cable deflection should be 10—12 mm |0.39—0.47 in.) ADJUSTING NUT Deflection 10-12 mm 5. If deflection is not within specs, loosen the locknut and {ura the adjusting nut until the defection is as spect fied, 6. With the cabie properly adjusted, check the throttle valve to be sure it opens fully when you push the ‘accelerator pedal to the floor. Also check the throttle valve to be sure it returns to the icle position whenever you release the accelerator Installation 2. 3 {8 HOSE 4 5. 6. 7 Locknur Fully open the throttle valve, then install the throne Cable in the throttle linkage and instal the cable hous- ing in the cable bracket. Warm up the engine to normal operating temperature {the cooling fan comes on) Disconnect #6 and #22 hoses from the dashpot dia- phragm and connect a vacuum pump to the diaphragm Using 2 T-fitting as illustrated bellow. Apply vacuum. TEITING 422 HOSE Hold the cable sheath, removing all slack from the cable. ‘Turn the adjusting nut until it ig 3 mm away from the cable bracket Tighten the ocknut 3mm ADJUSTING NUT ‘CABLE BRACKET Disconnect the vacuum pump snd conneet the #6 and #22 vacuum hoses. 6-83Air Intake System Throttle Body Inspection CAUTION: Do not adjust the throttle stop serew since it can not be reset except at the factory.” 1. Start the engine and allow to reach normal operating temperature (caoting fan comes on) Disconnect the vacuum hose (to the canister} from the 0p of the throttle body; connect a vacuum gauge to the throttle body. VACUUM/PRESSURE GAUGE 3. Allow the engine to idle and check that the gouge indicates no vacuum, = If there in vacuum, check the throttle control sys- ‘tem (page 6-86). 4. Check that vacuum is indicated on the gauge when the throttle is opened sightly from idle. If the gauge indicates no vacuum, check the canis- tor port. If the canister port is clogged, clean it with carburetor cleaner, 5. Stop the engine and check that the throttle cable ‘operates smoothly witout binding or sticking. (© there are any abhormaities in the above steps, ‘check for: = Excessive wear or play in the throttle valve shaft. = Sticky or binding throttle lever at full close position. ~ Clearance between throtte stop screw and throttle lever at full close position ‘THROTTLE LEVER, THROTTLE STOP SCREW (Nor-adjustable) Replace the throttle body if there is excessive play in the ‘hrotte valve shaft or if the shaft ie binding or sticking.CAUTION: © The throttle stop screw in non-adjustable. © After reassembly, adjust the throttle cable (page 6-83). 6-85Air Intake System Throttle Control System ‘Troubleshooting Flowchart “6 HOSE. Inspection of Throttle Control System Ss 2 ‘Start the engine and alow to ie Disconnect #6 hose from the da- ‘shp0t diaphragm and connect vacuum gauge. Nno__| ~Check the S-way joint A. < |e there vacuum? DO] Repair blockage at port or pinch in #6 hose, Disconnect £22 hose from the da- ‘shpot diaphragm and connect vacuum gauge. Note: ‘*Coolant temperature must be below 10 (Ta'F) ‘9 Fast idle speed must be below 1, 1800 min" (rpm ves | Disconnect the 2P (Without Is there vacuum? CATA) or 4P [With CATA) con rector NO Measure voltage between BLK/ ‘YEL (+) terminal and BLU (~ 1 ter- minal (with catay (Without cata) BLK/VEL (+) BLU (-) Buu) BLK/YEL (+) ES_{ Replace tho dashpot control | 1s there battry voltage? eee i nO. Fee eee Mesure vote tenses BLK YEL (+) termina and body around Repair open in BLK/VEL wi between No.1 fuse and (To page 6-87) (To page 6-87) 3-86(From page 6-86) (From eage 6-86) ‘Warm up engine 19 normal operst- ing. temperature {cooling fan ‘Turn tne igntion switch OFF comes om T (Check for vacuum at £22 vacuum hose. i | CLI eee reer vas ‘Throtle contol system is OK. Connect the PGM-Fl test harness between the ECU end connector {age 6-19). CCheck for continuity of BLU wive between ECU (82) and the 4P oes continuity exist? es NO Subeitute a known-good ECU land recheck. If symptom goes ‘away replace the original ECU. Disconnect the 2P (Without CATA) er 4° (With CATA) con rector. L Is there vacuum? No Repair op between ECU (B2) and the con- nectar. Flploce the dashpot contol -olenoid valve. re Torn the ignition switch OFF. Disconnect ECU. ‘connector trom CCheek fer cominulty 49 ground in the BLU (to ECU, 82) wie Ino Cis there continuity 9 grouna? YES Substinte » known-good ECU nd recheck. I symptom goes away, replace the original ECU. Repair short to ground at BLU wire between ECU (B2) and the connector 6-87Air Intake System —Throttle Control System Dashpot Diaphragm Testing 1. Start the engine and warm up to normal operating temperature (the cooling fan comes on) 2. Disconnect #6 vacuum hose from the dashpot dia- phragm and check the engine speed. Engine speed should be 2,500:500 min-" (rpm) DASHPOT DIAPHRAGM #8 HOSE © If the engine speed is out of specified engine speed, Inspect the throttle body (page 6-84),Emission Control System ystem Troubleshooting Guide a NOTE: Across each row in the chart, the systems thet could be sources of @ symptom are ranked in the order they should be inspected starting with @. Find the symptom in the eft column, read across to the most likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK, try the next most likely system @. etc. T Pa Sue syeTen Fosme se | carmune | ceeikesbe | evazonarve SStioRG | SENESSA | “BRS [sewprow a 3 z ROUGH ue ® rag EMISSION Oo ® POOR TEST PeRPbewance [oes op D roves 6-89Emission Control System [. Tailpipe Emission sspection Do not smoke during this procedure. Keep, any open flame away from your work area, 1, Start the engine and watm up to normal operating temperature (cooling fan comes onl 2. Connect tachometer 3. Check idle speed and adjust the idle speed. if necessary (page 6-69) 4. Warm up and calibrate the CO meter according to the meter manufacturer's instructions. 5. Check idle CO with the headlights, heater blower, tear window defogger, cooling tan, and sir condi tioner off. ‘Specified CO%: With CATA: 0.1% maximum. Without CATA: 1.0 = 1.0% © if unable to obtain this reading: ‘On With CATA, see ECU troubleshooting (page 6-14 oF 16). On other models, adjust by turing the agjusting screw of the IMA sensor ADJUSTING SCREW 2 CO reading of specified % by eck the engine tune-up cond- [- Positive Crankcase Ventilation —— System Inspection 1. Check the crankcase ventilation hoses and connec- tons for feake and clogging. Pov HOSE BREATHER HOSE PCV VALVE 2. Aiding, make sure there is 2 clicking sound from the PCV valve when the hose between PCV valve and intake marifold in lightly pinched with your fingers or pliers. Gent pinch ere ‘@ If there is no clicking sound. check the PCV valve ‘grommet for cracks or damage. If the grommet is OK, replace the PCV valve and recheck.atal Converter Inspection If excessive exhaust system back-pressure is suspected, emove the cetalytic converter from the cor and make & visual check for plugging, melting or cracking of the cate~ lyst. Replace the catalytic converter if more than 50% of the visible area is damaged or plugged. 36 Nom (a kgm, 25 tb-A HEAT SHIELD GasKeT 22nim 22 kom, 16 ws) eee HEAT SHIELD catauynic CONVERTER Femoval lnstataion, section S Inspect housing for eraces ot commer damge. Inspect element for clogging by looking through te ince, 6-94Emission Control System Evaporative Emission Controls [With CATA Ex. KO] Troubleshooting Flowchart Inspection of Evaporative Emission Controls Disconnect “7 hose from the purge control diaphragm valve {on the charcoal coniste:) and ‘connect 2 vacuum gauge to the hose, ‘Stan the engine and allow to idle NOTE: Engine coolant tempera- ‘ute must be below 87 °C (135, 7 PURGE CONTROL DIAPHRAGM VALVE Is there vacuum ?| yes Dicomect the AP connect, | NO (To page 6-89) Measure voltage between GRN (+) terminal and BLK (-) termi al. VACUUM PUMP/GAUGE Cte there battery votage? ES] Replace purge cut- off solenoid valve No, ‘Measure voltage between GRN (=) terminal and body ground. (To page 6-93) 92(From page 6-82) Warm up the engine to normat ‘operating temperature (cooling fan comes on). (From page 6-82) 4. To prevent warping, unscrew the pressure plate ‘mounting bolts two turns at a tite ia @ crisscross pattern using 2 10 mm T-wrench, then remove the Pressure plate and clutch disc, RING GEAR HOLDER 07924~PD20002, eet 5. Inspect the pressure plate surtace for wear, cracks, (0r burning, 6. Inspect for warpage using a strsight edge and teeler gauge. Service Limit: 0.15 mm (0.006 in.) Max. Measure across these pois FEELER GAUGE STRAIGHT EDGE 7-6Clutch Disc + Inspection 1. Inspect lining of the clutch disc for signs of slipping ‘0 oil, Replace it if it is burned black or cil soaked. cLuTcH Disc 2. Measure the clutch dise thickness. CLUTCH Disc Clutch Dise Thickness: Standard (New): 8.18.8 mm (0.319-0.346 in.) Service Limit: 5.7 mm (0.224 in.) 3 4 ‘Check for loose rubber torsion dampers. Replace the clutch disc if any are loose. Messure the depth from the lining surface to the rivets, on both sides. Rivet Depth: Standard (New): 1.3 mm (0.051 in.) min. 0.2 mm (0.008 in.) Service Limit: ‘TORSION DAMPER ‘Measure the clutch plate runout with the mainshaft ‘and a cial indicator. (Clutch plate runout: ‘Standard: 0.8 mm (0.031 in.) max. ‘Service Limit: 1.0 mm (0.039 in.)Flywheel [- 'nspection/Removal 1. Inspect the ring gear teeth tor wear or damage. 2, Inspect the clutch disc mating surface on the fly wheel for wear, cracks or burning. 3, Measure the flywheel runout using a dial indicator through at least two full turns, Push ageinst the fiywheel each time you turn it to take up the crank- shaft thrust washer clearance. NOTE: The runout can be measured with engine installed Standard (New): 0.05 mm (0.002 in.) max. 0.15 mm (0.006 in.) Service Limit: DIAL INDICATOR 4. Remove the six flywheel! mounting bots and flywheel RING GEAR Hi 07324~PD20002 ‘mounting Bouts PuYWieeL Flywheel Bearing r— Inspection/Replacement 1, Tuen the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check ‘that the bearing outer race fits tightly in the flywheel Replace the bearing if the race does not turn smoothly ‘quietly, oF fit tightly inthe flywheel FLYWEEL BEARING FLYWHEEL,2. Remove the beating from the flywheet. FLYWHEEL BEARING 3. Drive in the new bearing in the flywheel DRIVER | ATTACHMENT 32x35 mm. (07746--0910100 “eg Flywheel and Clutch r— Installation 1. Align the hole in flywheel with the crankshaft dowel pin and assemble. Install"the bolts only finger tight, 2. Install the Ring Gear Holder, then torque the fiy- a5 shown, wheel bolts in a crisscross patter RING GEAR HOLDER 07824-PD20002 (07924-20003 1210 mm 120 Nem (12.0 ko-m, 87 To-f) FuvwheeL, 3. Install the clutch disc and pressure plate by aligning the flywhee! dowels with dowel holes in the pres- sure plate. FLYWHEEL PRESSURE PLATE (Molybdenum Disulide) 4, Install the attaching bolts finger tight. (cont'a 7-9Flywheel and Clutch r— Installation (cont'd) 5. Insert the Clutch Disc Alignment Tool in the splined hole in the ciuteh dise. CLUTCH DISC ALIGNMENT TOOL O75AF—PM70100 6. Torque the bolts in a crisscross pattern as shown, Tighten them two turns at a time to prevent warp. ing the diaphragm spring. 8x1.25 mm 26 Nem (2.6 ko-m. 19 tbst) ToRQUE 7. Remove the Alignment Too! and Ring Gear Holder, Pee eS eeeeeeoeeey 7-10Manual Transmission Maintenance ... Back-up Light Switch Gearshift Mechanism Transmission Removal InstallationMaintenance Oil Level Inspection 1 oil Check with oil at operating temperature, engine OFF, and car on level ground. 2. Remove oil filler plug and check level with finger. 3. Oil level must be up to fill hole. If it is below hole, ‘249 oi! until it runs out, then reinstall plug Oil Change Use only SAE 10W-30 or 10W-40 oll rated SE or SF grade. Drain with transmission oil at operating temperature, gine OFF, and cor on level ground. Remove the oi filer plug, then remove the drain plug and drain transmission. Reinstall drain plug with new washer, and refill to proper level NOTE: Drain plug washer should be replaced at every cil change. Capacity at.) after drain q 1a nsus, 1.94 (2.0 U.S. qt) after overhaul OW FiueR PLUG 45 Nem (4.5 kgm. 33 bt) DRAIN PLUG 40 Nem (4,0 kg-m. 29 Io-A) Back-up Light Switch ~ Replacement NOTE: Check the switch see Section 16. 2. Remove the back-up light switch, BACK-UP LIGHT swiTcH ‘No washer type. 3. Install the back-up light switch, 1. Disconnect the back-up light switch wire connectors.Gearshift Mechanism Overhaul 22 Nem (22 kom, 16 extension CHANGE LEVER KNOB eracker EXTENSION por ecpmmoucm of Le nuseen Boot ecenson END RUBBER Torave noo oer cance meu ay oer ene |\ cxance a ze. \\_ gam coe ey Toft Replace cuancs BALL SEAT (2 EXTENSION O-RING chance “@J_MOUNT StoPER__fenewe | | REAR JOINT aUSHING ever nm bust Seas niet ~ ShiFr ROD CHANGE BALL HOLOER mn "22 Nem (2.2 kg-m, 16 lb-ft)r~ Removal Transmission oom (© Make sure jacks and safety stands are placed prop- ‘erly (See Section 1), and hoist brackets are attached to correct positions on the engine (See Section 5) brake and block rear wheels, so cor Disconnect the back-up light switch connector from the engine Disconnect the clutch cable at release arm. Drain twansmission fluid. Use socket wrench 10 remove the drain plug. Remove the oil filer plug to © Apply will not roll off stands and fall on you while working under it. ‘speed draining. Reinstali the drain plug with a new washer CAUTION: Use fender covers to avoid damaging painted surfaces. . 41, Disconnect the battery negative (—} and positive (+) cables from the battery. 2. Remove the 3 mount bolts and loosen the 1 bolt located at the side of the bsttery base. Remove the intake hose band of the throttle booy. 3. Remove the air cleaner case complete with the intake hose (See Section 6) 4. Disconnect the starter motor and transmission ground cables. 5. Disconnect the speedometer cable. NOTE: Do not disassemble speedometer gear holder SPEEDOMETER CABLE BACK-UP LIGHT ‘SWITCH CONNECTORS BATTERY BASE STARTER MOTOR: CABLES. A Tnansutssion aa ‘GROUND eASLE cadres case Loosen the bolt9. Disconnect the connectors and remove the mount bolts, then remove the distributor from the cylinder head, 10. Remove the bolts attaching the starter motor, and remove the starter motor. 11. Remove the engine splash shield and the right wheelwell splash shield. 12. Remove the header pipe. 113, Remove the cotter pin and lower arm ball joint nut, separate the bal joint and lower arm 14. Remove the bolts and nut, then remove the right radius rod. 15. Remove the right driveshaft (See Section 10). Remove the left driveshaft and intermediate shaft if equipped (See Section 10} ‘SELF Lock NUT 5 Wim (6.5 kom, 47 Ibs) BALL JOINT NUT 55 Nem (5.5 kg-m, 40 tot) COTTER PIN’ Replace ( DAMPER FORK BOLT DisTRIBUTOR car, e : STARTER MOTOR / ra) eae NOTE: Coat al precision finished surfaces with clean engine ol or grease, ‘Tee plastic bags over the drivechakt ends. SET RING. Replace RADIUS ROD. eo 6 7 HEADER PIPE SELF-LOCKING NUT- 55 Nem (8.5 kgm, 40 Ib-f) (cont'a) 8-5Transmission (Removal (cont'd) 16, Remove the header pipe bracket. 17, Remove the shift lever torque rod and shift rod from cluteh housing. 18, install the bolt @ at the cylinder head and attach a hoist chain to the bolt ang the other end to the engine hanger plate ©, then lift the engine slightly to unload ‘the mounts. 19. Place a jack under the transmission and raise tranemis- sion just enough to take the weight off the mounts. 20. Remove the bolts from the front transmission mount. 21. Remove the rear transmission mount bracket by removing the 4 mounting bolts. 22. Remove the bolts and nut, then remove the side trans- mission mount 23, Remove the 5 transmission mount bolts ‘TRANSMISSION MOUNT BouT REAR TRANSMISSION MOUNT BRACKET SPECIAL BouT SIDE TRANSMISSION TRANSMISSION — 24, Pull the wansmission away from the engine until it Clears the 14 men dowel pine. 25. Separate the mainsheft from the clutch pressure plate and remove the transmission by lowering the jack. HOIST CHAIN FRONT TRANSMISSION ‘MOUNT BRACKET HEADER PIPE BRACKET SHIFT ROD ‘SHIFT LEVER ‘TORQUE ROD ‘8 mm PIN PUNCH. ‘TRANSMISSION MOUNT BOLT (Engine side) 8-6‘> Installation 1. Place the transmission on the transmission jack, and ‘alse to the engine level. 2. Check that the two 14 mm dowel pins are installed in the clutch housing, 3. Loosely install the transmission mount bolts, then torque in the sequence shown, 4. Secure the transmission to engine with the engine side ‘mounting bolt (12x 1.25%70 mm) and torque to 68 Nem (6.8 kg-m, 50 lb-ft). 5. Insta the transmission to rear transmission mou bracket. 66. Install the wansmission to front end side transmission mounts. a ‘MOUNT BOLT {Engine side) SIDE TRANSMISSION ‘MOUNT ‘TRANSMISSION MOUNT SLT é ~X vom w.0%0m. 8m REAR TRANSMISSION MOUNT BRACKET 20 Nem (4.0 kon, 29 Ib-f) FRONT TRANSMISSION MOUNT Special bolt: Replace 7. Install the starter motor. STARTER MOTOR 8. Remove the transmission jack. 9. Remove the chain hoist by removing the hanger plate ‘and 10 mm Boks. 10. Install the shift lever torque rod and shift rod. HEADER PIPE BRACKET SHIFT LeveR TORQUE ROD SPRING PIN Feplace NOTE: On reassembly, side the retainer back into place after diving in te soning in 11, Inetall the header pine bracket. feont'a} 8-7Transmission t—Installation (cont?) AAA 12. Install @ new set rings on the end of each driveshaft. 17. Connect the speedometer cable, 13. Inetall the right driveshaft (See Section 10). 18. Connect the clutch cable to release arm. Instal the left driveshaft and intermediate shaft removed (See Section 10) 19. Connect the back-up light switch connector. NOTE: Turn the right steering knuckle fuly outward, 20, Install the 3 bolts located at the side of the battery ‘and slide axle into the differentia! unt you fee! its base, and retighten the intake hose band of the throt- ‘spring clip engage side gear. te body. ‘SPEEDOMETER CABLE Bf CK a Le Zee a air swrrcn ~ CONNECTORS, ee we ~ Sie RaDIUB noo TRANSMISSION stanren moron GROUND CABLE cate CLUTCH CABLE 14, Install the damper fork and radius rod jefil the transmission with oi. 15. Install the ball joints to the lower atm, Seen 22. Connect the starter motor and transmission ground 16. install the splash shields and exhaust heac pit Instat the disinbutor. 23. Connect the battery positive (+) and negative (—) cables to the battery O-RING 24. Instail the air cleaner case and intake hose. 25. Check the ignition timing (See Section 16) DISTRIBUTOR a a 28. Check the transmission for smooth operation. 8-8Driveshafts Driveshafts Special Tools Removal .... Disassembly/Inspection Reassembly .... Intermediate Shaft Replacement Disassembly Index/Inspection Reassembly .... [Special Tools. Ret. No. | Tool Number Description oy Remarks ‘077480070000 _| Driver 0746—0040800 | 35 mm Pitot 07746—0010300 | Attachment 42 x 47 mm 079478090100 | Oil Seal Driver Attachment 07JAD—SH30100_| Oil Seal Driver Attachment 07746—0030100 _| Inner Handle (C) 98ee00 |Driveshafts 2, Raise the front end of the car and place eafety stands the proper locations. Remove the front wheels. 3. Drain the transmission oil, NOTE: It is not necessary to drain the transmission oi! when oniy the left driveshaft is removed. 4. Raise the locking tab on the spindle nut and remove #t ‘with 2 36 mm (1-7/16 i.) socket wrench. 5. Remove the damper fork nut and damper pinch bolt Remove the damper fork. 101.25 mm 4am (4.4 kom, 32 ef ‘SELF-LOCKING NUT 121.25 mm 65 W. (6.5 kg-m. 47 I-A) Replace. 6. Remove the knuckle-to-lower arm castle nut, and seperate the lower arm from the knuckle using @ puller with the paws applied to the lower arm, CASTLE NUT Hang puller 1241.25 mm paws on lugs 55 Nm fon lower am 5.5 kgm 40 bet) 8 Es f- Removal | 1 7, Pu ‘outboard joint from the knuckle using a plastic ham- mer. Pry the driveshaft assembly with a screwdriver as shown to force the set ring at the driveshaft end past the groove. Pull the inboard joint and remove the driveshaft and. CV joint aut of the differential case as an assembly. caution: © Do not pull on the driveshaft, as the CV joint may come apart. © Use cate when prying out the assembly and pull it straight to avoid damaging the differential oi! ‘seal or intermediate shatt dust seal. 10-2