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I NT RO DUCT ION I G e n e ra l n fo

How to Use This Manual -


This manualis dividedinto 23 sect
tion is markedwith a blacktab that lin€sup with its co.responding
thumb indextab on this paqeand the back cover. you can auicklv
tind the tirst pageof each sectionwithout lookingthrougha full ta-
ble of contents.The symbolsprintedat the top cornerof each page
can also be used as a quick referencesystem.

Each section includes: Specifications f,|tr


1. A table of contents,or an explodedview index showing:
a Partsdisassemblvsequence.
a Bolt torquesand thread sizes.
a Pagereterencesto descriptionsin text.
2. Disassembly/assembly proceduresand tools. Maintenance t
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Engine ll=
SpecialInformation
@@ tnai""tes a strong possibility ot sevoro p€rsonal injury
Cooling It
or losa of lite it instluctions ar€ not tollowed.
ri!
CAUTION: Indicates a possibility of poBonal iniury ol oquipmont
damage if instructions aro not tollowed.

NOTE: Gives helpful information. Fueland Emissions


ZZ
CAUTfON: Detaifoddescriptionsol st ndard wo*shop procedures,
satety p nciplesand servic€opalationsaro not includod.pleasonot6
that this manualcontainswamings and cautionsagainstsoms spocit-
ic s€rvice methods which could cause PERSONALlNJURy, d8mag6
*Transaxle
a vahicl€ or mako it unsafe. Pleaaaund€ratandthat thos6 warnings
cannot cover all conc€ivableways in which sorvice, whethgr 01 not
recommended by HONDA might b6 dono, or of tho possible
hazardous consequences of evely conceivablo way, no. could
*Steering
HONDA invostigateallsuch ways. Anyono using sorvics proceduros
01toofs. whether or not rocommendedby HONDA,must satjslyhim- If." r
sel, thoroughly that ngithor p€r3onal aatety nor vohicl€ s8fety will
be jsopardized.

All informationcontainedin this manualis basedon the latest Droduct


info.mationavailableat the time of printing.We reservethe right
to makechangesat any time without notice.No part of this publica-
tion may be reproduced,storedin retrievalsystem.or transmitted,
in any form by any means,electronic.mechanical,photocopying, * Brakes
recording,or otherwise,without the prior written permissionoJ the
publisher.This includestext, figures and tables. (lncludin
First Edition9/92 1516 pages HONDA MOTORCO..LTD.
All Rights Reserved Seruic€ Publication Offics * Bo d y
Specilicationsapply to U.S.A. and Canada

* H e a te ra n d
Ai r C o n d i ti o n i n
* Electrical
-
I
L'___
As soctions with * includ6 SRS comDononrs.
sp€cial piocautions aro roquirad whoit so.vicing. (lncluding
- +
GeneralInformation

Chassis and PaintCodes................. 1-2


ldentification NumberLocations....... 1-4
Warning/Caution Labels.................. 1-s
Lift and SupportPoints
Lift ........... . . . . . . . . . . . . .1. .-.9
F l o o Jr a c k . . . . . . . . . . . . . .1. -. .1 0
S a f e t yS t a n d s . . . . . . . . . . .1. - 1 1
Towing .......1-12
ServicePrecautions
Handlingof SpecialNuts
and Bolts 1-13

'!.
7t
Chassisand Paint Codes
U.S. Model
EngineNumber
JHMBA814'PCOOOOol F22A1-9200001

Engine Type
Type of Vehicle F22A1; 2.2 / SOHC SequentialMulti-
port Fuel-injectedengine
J H M : H O N D AM O T O RC O . , L T D .
HONDA, PassengerCar H22A1t 2-2, DOHCVTEC Sequential
Multiport Fuel-iniectedengane
BA8: Prelude2.2 / H23A1t 2.3, DOHC SequentialMulti-
port Fu€l-injectedengine
BBl : Prelude2.2 t VfEC
BB2: Prelude2.3 / EmiesionGroup
Body and TransmissionTYPe lOO: Califolniawith H22A1 engine
1: 2-door s-sDeedManual 130: 49ST with H22A1 engine
2t 2-doot 4-speedAutomatic 2OO:Californiawith H23A1 engine
Vehicle Grade 23O: 49ST with H23A1 engine
4: PreludeS 920: Calilorniawith F22A1 engine
5: PreludeSi 923: 49ST with F22A1 engine
6: PreludeSi 4WS Serial Numbel
7: PreludeSi VTEC
Chock Digit
Model Yoat
'1993
P:,
M2F4-1000001

M2F4: Manualwith H22A1 engine


M2L5: Manualwith F22Al engine
M2S4: Manual with H23A1 engine

M2F4: l OOOOO1 -
-
Exceot M2F4: 20OOOO1

Vehicle ldentificationNumbel Paint Code


and FederalMotor Vehicle
Safety Standard Certification' COLOR
Fresco Blue Pearl
B-64P Brittany Blue Metallic
GranadaBlsck Peatl
SeablingSilver Metallic
Frost White
Mirano Red
ii
ir
i[i
CanadaModel
Vehicle ldentificationNumber
J H M B A 8 1 4 *P C 8 0 0 0 0 1

F22A1: 2.2 / SOHC SequentialMulti


J H M : H O N D AM O T O RC O . . L T D . port Fuef injected engine
HONDA, PassengerCa. H22A'l:2.2 / DOHC VTEC Seouential
Multiport Fuel-injectedengine
BA8: Prelude2.2 / H23A1: 2.3 / DOHC SequentialMulti-
B B 1 :P r e l u d2e. 2 . l E C pon Fuel-injected engine
BB2: Ptelude 2.3 I
Body and T.ansmission Type F22A1 engine; 928OOO1-
1: 2-door s-sDeedManual l-
H22A1 engine: l TOOOO
2', 2-doot 4-speedAutomatic H23A1 engine: 27OOOO1-
Vehicle Glade
4: Prelude
5: PreludeSR
6: PreludeSR 4WS
7: PreludeSR-V
M2F4-1000001
Check Digit
Model Y6at
P: 1993
M2F4: Manual with H22A1 engine
M2L5: Manualwith F22Al engine
C: SaitamaFactoryin Japan
M2S4: Manual with H23A 1 engine

M2F4: l OOOOOl -
-
ExceptM2F4: 2OOOO01

Vehicle ldentificationNumbe] Paint Code


and CanadianMotor Vohicle
Safety Standard Certification. COLOR
8,64P F esco Blue Pearl
Brittany Blue Met8llic
Granada Black Pearl
SeablingSilverMetallic
Frost White
Mirano Red

1-3
ldentificationNumberLocations

Vehicle ldentif ication


Number

V.hicl€ ldontitication
Numbo.

TransmissionNumber
(Automaticl

t Tiansmission Number
lManual)

'l i,
,l
Warning/CautionLabelLocations

A: CABLE REELCAUTION A D: DRIVERMODULEWARI{|]{G


CAUTION: ISRSI A WARI{ING
BEFOREINSTA-I.IINGCABLE REEL: THEAIRBAGI'{FLATOR IS EXPLOSIVE
AND,IF ACCIDEN.
. CENTERTHE FRONTWHEELS. TALLYDEPLOYED, CAt{ SERIOUSLY
HURTOF KILLYOU.
. ALIGN THE MARKS. . DOI{OI USEELECTRICAL TESTEOUIPMENT ORPNOB-
. READ SERVICEMANUAL. II{G DEVICES.THEY CAN CAUSE ACCIDENTAL
DEPTOYI'EI{T.
B: CABL€ REELCAUTION B . NO SERVICEABLE PARTSINSIDE,DO OT DISAS.
SEMBLE.
cAUTtOt{: . PLACEAIRBAGUPf,IGHTWHEI{BEMOVED.
NO SERVICEABLE
PARTSINSIDE;DO NOT DISASSEMBLE a Fou.ow sERvtcE MAI{UAL |]{STRUCT|O]{S
OR TAMPER. CAREFULLY.

C: DRIVERMODULE DANGER E: I FLATOR WARNING TAG

A DANGER A WARNING
EXPLOSIVE/FLAMMABLE ACCIDENIAL AIRBAG DEPLOYMEI{I CA]T SERIOUSLY
CONTACTWITH ACID, WATEROR HEAVYMETALSSUCH HURTOR KILLYOU. II{STALLTHE REDSERVICECONNEC-
AS COPPER.LEAD OR MEFCURYMAY PRODUCEHARM- IOB WHENTHE INFLATORHARITESSIS DISCONNECTED.
FUL AND IRRITATING GASES OR EXPLOSIVE COM-
POUNDS.STORAGETEMPERATURES MUST I{OT EXCEED F: STEERINGWHEEL t{OllCE
2OO"F{1OOOCI.FORPROPERHANDLII{G,STORAGEAND
DISPOSALPROCEDURESREFERTO SERVICEMANUAL, NOTICE
SRS SUPPI.EMENT. IMPROPERSTEERINGVYHEELREMOVAL OR II{STALLATION
POTSON CAN DAMAGE SRS COMPOT{EI{TS.
COI{TAINSPOISONOUSSODIUMAZIDEAND POTASSIUM FOLLOWSERVICEMA UA! INSTRUCTIONCAREFULLY.
NITRATE,
FIRSTAIO
IF CONTENTSARESWALLOWED.II{DUCEVOMITING.FOR
EYE CONTACT, FLUSH EYES WITH WATER FOR 15
MINUTES.IF GASES (FROMACID OR WATER CONTACT)
ABE INHALED, SEEI( FRESHAIR. IN EVERY CASE, GET
PROMPTMEDICAL ATTENTION.
KEEPOUT OF REACHOF CHILDREN.
(cont'd)

1-5
I Warning/CautionLabelLocations
(cont'dl

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


G: SRSWARNING{ENGINEHOOOI K: DRIVERINFORMATION
ISUNVISOB)

SUPPLEMENTALRESTRAIIIITSYSTEM ISRS) ALWAY WEARYOURSEATBELT


THIS VEHICLE IS EOUIPPEDWITH DRIVERAND FRONT CAR IS EOUIPPEDWITH A DRIVERAIRBAG AS A
SEAT PASSENGEB AIRBAGSAND FRONTSEAT BELTTEN. SUPPLEMENTALRESTRAINTSYSTEM {SRSI.
SIONERSYSTEMS. . IT IS OESIGNEDTO SUPPLEMENTTHE SEAT BELT.
ALL SRS ELECTRICALWIRING AND CONNECTORSARE . BEFORE ORIVINGREADLABELINSIDETHEGLOVEBOX.
COLOREOYELLOW.
TAMPERINGWITH, DISCONNECTING OR USINGELECTRI- 'K: DRIVERINFORMATION
CAL TEST EOUIPMENTON THE SRS WIRING CAN MAKE
THE SYSTEMINOPERATIVEOR CAUSEACCIDENTALFIR-
ING OF THE INFLATOR. ALWAY WEARYOURSEATBELT
CAR IS EOUIPPEOWITH A DBIVERAIRBAG AND
A WARNING A FRONTSEAT PASSENGER AIRBAGAS A SUPPIEMEN-
THE AIRBAG INFLATORIS EXPLOSIVEAND. IF ACCIDE . TAL RESTRAINTSYSTEM ISRS).
TALLY OEPLOYED.CAN SERIOUSLYHURTYOU. FOLLOW . IT IS DESIGNEDTO SUPPLEMENTTHE SEAT BELT.
SERVICEMANUAL INSTRUCTIONSCAREFULLY. . BEFOREDRIVINGREAOLABELINSIDETHEGLOVEBOX.

H: STEERING
COLUMNCAUTION L: GLOVEBOX INFORMATION

CAUTION ISRS DRIVER'SAIREAG INFORMATION


To AvotD DAMAGIIGrHE sRs CABLEoB REE|-.
wHtcH . SUPPLEMENTAL RESTRAINTSYSTEMISRSICAN PRO-
COULDMAKETHESYSTEMINOPERATIVE, REMOVETHE VIDE AOOITIONALPROTECTIONFORTHE DRIVERIN A
STEERING WHEELB€FOREREMOVING THE STEERING FRONTALCOLLISION.A FUNCTIONALDESCRIPTION OF
SHAFTCONNECTOR BOLT. THE SRS IS IN YOUR OWNER'S MANUAL.
. THE SYSTEMMUST BEINSPECTEDTEN YEARSAFTER
DATE OF MANUFACTURE,AS NOTEDON THE CERTIFI-
l: FRONTSEAT PASSENGER
AIRBAGMODULEDANGER CATION PLATE.
. ANY REPAIR,INSPECTIONOR NEARBYACCESSORYII{.
A DANGER STALLATIONSHOULD8E DONE BY AN AUTHORIzED
EXPLOSIVE/FLAMMABLE HONDA DEALER.
CONTACTWITH ACID, WATEROR HEAVY METALSSUCH . IF YOUR SRS INDICATOR:
AS COPPER,LEAD OR MERCURYMAY PRODUCEHARM. . LIGHTSWHILE DRIVINGOR FLASHES;
FUL AND IRRITATING GASES OR EXPLOSIVE COM- . FAILSTO LIGHTOR STAYS ON AFTERTHE IGNITION
POUNDS.STORAGETEMPERATURES MUST NOT EXCEED IS FIRSTTURNEDON:
2OOOF(lOOOC}FORPROPEB HANDLING,STORAGEANO SEE YOUR AUTHORIZEDHONDA DEALER.
DISPOSAL PROCEDURESREFERTO SERVICEMANUAL,
SRS SUPPLEMEI\'T.
'L: GLOVEBOX INFORMATION
POISON
CONTAINSPOISONOUSSOOIUMAZIDEAND POTASSIUM
NITRATE. DRIVER'SAND FRONTSEAT PASSENGER'SAIRBAG IN-
FIRSTAID FORMATION
IF CONTENTSARESWALLOWED,INOUCEVOMITING.FOR . SUPPLEMENTAL RESTRAINTSYSTEM{SRSICAN PRO.
EYE CONTACT, FLUSH EYES WITH WATER FOR T5 VIDEADDITIONALPROTECTION FORTHE DN|VERAND
MINUTES.IF GASESIFROMACID OR WATERCONTACTI FRONTSEAT PASSENGERIN A FRONTALCOLLISION.
ABE INHALED, SEEK FRESHAIR. IN EVERY CASE, GET A FUNCTIONALDESCRIPTION OF THE SRS IS IN YOUR
PROMPTMEDICAL ATTENTION. OWNER'S MANUAI..
KEEPOUT OF REACHOF CHILDREI\'. . THE SYSTEMMUST BE INSPECTEO TENYEARSAFTER
DATE OF MANUFACTURE,AS NOTEDON THE CERTIFI-
A WARNING
CATION PLATE.
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDEN. . ANY REPAIR,INSPECTION ORNEARBYACCESSORYIN-
TALLY DEPLOYED,CAN SEBIOUSLYHURT OR KILL YOU.
STALLATIONSHOULD BE DONE BY AN AUTHORIZEO
. DO NOT USEELECTRICAL TEST€OUIPMENTOR PROB- HONDA DEALER.
ING DEVICES. THEY CAN CAUSE ACCIDENTAL . IF YOURSRS INDICATOR:
DEPLOYMENT. . LIGHTS WHII-E DRIVINGOR FLASHES;
. NO SERVICEABLEPARTS INSIDE. DO NOT DISAS- . FAII.STO LIGHTOR STAYS ON AFTERTHE IGNITION
SEMBLE. rs FrRsTTUBNEDON;
. PLACEAIRBAG UPRIGHTWHEN BEMOVED. I
. SEEYOUR AUTHORIZED HONDA OEALER.
. FOLLOW SERVICEMANUAI- INSTRUCTIONS
CAREFULLY.
M: SRS UNIT CAUTION

CAUTIONi
. NO SERVICEABLEPARTS INSIOE.
. DO NOT OISASSEMELEOR TAMPER.
. DO NOT DROP.
. STOREIN A CLEAN,DRY AREA,

*This versionof the label is used on cars with lront passengerairbag. (cont'd)

1-7
Warning/CautionLabelLocations

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

tl i-l atl
;DZ"N

t:

RAOIATORCAP
CAUTION

I
I
I
.

\..
1-8
Lift and Support Points

@Q wnen heavy real components such as suspension, fuel tank. spare tile and trunk lid are to be removed,
plac€ additional weight in tha trunk betole hoisting. When substantial weight is removed trom the lear of th6 cal, the
center of gravity may change and can causs the car to tip forward on tho hoist.

NOTE: Sinceeach tire/wheelassemblyweighs approximately30 lbs { 14 kg), placingthe front wheels in the trunk can
assist with weight dist.ibution.

1. Placethe lift blocks as shown.

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

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

DH
REARSUPPORTPOINT
(cont'd)

1-9
Lift and SuPPortPoints
Floor Jack
Set the parkingbrakeand blockthe wheelsthat are @
o Always uso sal€ty stands when wolking on or
not being lifted.
undor any vehiclo that is supponed only by a
jack.
When liJtingthe rear of the car, put the gearshift
lever in reverse{Automatictransmissionin @ po- a N€ver att€mpt to use a bumpel iack for lifting ol
sition). supporting tho cat.

Raisethe ca. high enoughto insertthe safety stands'

Adjust and placethe satety standsas shown on page


1-1 1 so the car will be approximatelylevel,then low-
er the car onto them.

CENTERBEAM

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

Centerthejacking
bracketin the middle
LIFT PLATFORM
ol the iack lift Platform

1-10
Safety Stands

DH
FRONTSUPPORTPOINT SAFEW STANDS REARSUPPORTPOINT

1-11
j
Towing

ll the car needsto be towed. call a proJessional


towing
service.Nevertow the car behindanothercar with just
a roDeor chain. lt is verY dangerous

Emelgency Towing
There are three popularmethodsof towing a car:
TtEDOWIIHOOKS
Flat-bedEquipment- The operatorloadsthe car on the
back ol a truck. This is the best way of transponingthe
car.

Wheel Litt Equipmont - The tow truck uses two plvor-


ing arms that go underthe tires {tront or rear)and lifts
them otf the ground. The other two wheels remainon
the ground.

Sling-type Equipmont - The two truck uses metal ca-


bles with hooks on the ends. These hooks go around
Dartsof the trame or suspensionand the cableslift that
end of the car oft the ground.The car's suspensionand
body can be seriouslydamagedif this methodof towing
is attempted.

lf the car cannotbe transportedby flst-bed,it shouldbe


towed with the front wheels off the ground. lf due to
damage,the car must be towed with the front wheels TOWINGHOOK
on the ground, do the following:

5-spe6d Manual Tlansmission


a Releasethe Parkingbrake.
a Shift the transmissionto Neutral.
Automatic Tlansmission
a Releasethe Parkingbrake.
a Start the engine.
a Shift to @ position,then @ position.
a Turn off the engine.

NOTICE:lmpropertowing preparationwill damagethe


transmission. Followthe aboveprocedureexactly.It you
cannot shift the transmissionor start the engine(auto-
matic transmission), your car must be transponedon a
flat-bed.
.-)
t: a lt is best to tow the car no farther than 50 miles
(8okm),and keepthe speedbelow 35 mph (55 km/hl'

f NOTICE:Tryingto lift or tow the car by the bumperswill


'l causeseriousdamage.The bumpersare not designedto
suooortthe car's weight.

\.
1-1 2
Service Precautions
Handlingof SpecialNuts and Bolts
Becausethe tront sub frame sectionson this car a.e con- l. When replacing nuts and bolts, use only the same
structed with aluminum alloys. use only the special type.
"Dacro" type nuts and bolts recommendedby Honda.
Tighten the nuts and bolts with I torqua wrench to
NOTE: ths specificationsprovidedin this manual.
a Dacro finish can be identitiedby gray plating.
a Some Dacro tinish bolts have a green coating on J. Clean all thread ridges with a non wire type bristle
the th.ead sectionof the bolt for easielapplica- brush. Foroignmatter in the threads may cause the
tion. This type ot bolt is calleda "Torqu6r" bolt, bolt to loosen.
a Use of other types ot nuts and bolts may cause
electrolvsisand corrosion,which in turn could 4 . S€ctions on this car requiringthe use of Dacro nuts
caus€ the bolt to loosen. and bolts will be indicatedbv a l* I in this manual.

Gray

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

Gray plsting: "Dacro" type


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

1-13
Specifications

Standards
and ServiceLimits ...........3-2
DesignSpecifications
......................
3-15
BodySpecifications ....... 3-18
Standardsand Service Limits
-
CytinderHead/ValveTrain {F22A1 engine} Section 6
I TTaEASuREMENT J sraruolnotruewt I senvtceumtr
Compression 25O rpm and Nominal 1.250 112.5,1781
wide open throttle Minimum 9 5 0 { 9 . 5 ,1 3 5 )
psi)
kPa{ks/cm2, r49l'm!Il9!919! 200 12.0.2al
0.o5 (0.002)
Cylind€rhead Warpage
Hoight 9 9 . 9 5 - 1 0 0 . 0( 53 . 9 3 5 - 3 . 9 3 9 )
o.05-o.15 (0.002-0.006) o.5 {0.02)
Camshaft End play 0.15 (0.006)
oil clearance
Camshalt-to-holder 0.o50-0.089(o.oo20-o.oo35)
0.03 {0.0o1)max. o.06 (0.002)
Total runout
Cam lobe height IN 3 8 . 5 2 6( 1 . 5 1 6 8 )
EX 3a.77a11.52671
Valve clearance IN o.23-0.28(0.o09-0.o1 1)
EX 0.27-0.30 (0.01 '0.01 3)
Valve stem O.D. IN 5 . 4 8 5 - 5 . 4 9150 . 2519 - 0 . 2613 ) oossro.:I oet
EX 5.450-5.460(0.2146-0.21 50) 5.4201o.21341
IN 0.o20-0.045{o.0008-o.oo20) 0.08(o.oo3)
Stem-to-guide clearance o.12 (0.oo5)
EX 0.055,0.o80{0.0022-o.oo3'l )
IN 1.25-1.55 ( 0 . 0 4 9 - 0 . 0 6
) 1 2.0 {0.08)
Valve seat width 2.0 10.08)
EX 1 . 2 5 - 1 . 5(5O . 0 4 9 - 0 . 0)6 1
IN 48.245-48.7 15 (1.8994-1.91 79) 4 8 . 9 6 5t 1 . 9 2 7 8 1
Stem installed height ( 1 . 9 8 0 9 - 1 , 9 9 9 4 ) 5 1 . 0 3 5( 2 . 0 0 9 2 1
EX 5 0 . 3 15 - 5 0 . 7 8 5
Valve spring Freelength lN 5 4 . 8 11 2 . 1 5 8 )
54.82(2.r 58) 2
EX 5 6 . 2 6{ 2 . 2 1 5 )
56.2A12.21612
IN 5.515,5.53010.217 1-0.2177| 5 . 5 3( 0 . 2 1 8 )
Valve guide t.D.
EX 5.515-5.5301o.211 1-O.21771 5 . 5 3{ 0 . 2 1 8 1
height
Installed IN 23.75-24.25(O.91 5-0.954)
EX 15.05-'5.55 1 {O.593-0.61 2)
Bocksr arm Arm-to-shaft clearance IN o.o17-o.050 l0.oo07'o.oo20) 0.08 (0.003)
EX o.o18-0.054(0.ooo7-o.0021
) o.08{o.oo3)

''l: CHUO HATSUJOmanulacturedvalve sprrng.


'2: NIHONHATSUJOmanulactllredvalve spring

I
Unit of tength:mm (in)
Cylinder Head/ValveTrain (H23A1 enginel - Section 6
MEASUREMENT srAr{DARDtt{Ewl I stnvtce urirr
Compression 250 rpm and Nominal 1,250 112.5,1181
wide open throttle Minimum 9 5 0 { 9 , 5 ,1 3 5 }
kPa lkg/cm2, psi) Maximumvaiation 200 12.o,2al
Cylinderhead Warpage 0.o5{0.oo2)
Heighr 1 3 1 . 9 5 - 1 3 2 . 0 5( 5 . 1 9 5 , 5 . 91 9 )
Camshatt End play 0.05 0.15 (0.oo2-o.006) o.5 {0.02}
Camshaft-to-holder
oil clearance o.050-0.089(o.0020-o.oo35) *1 o . 1 5{ 0 . 0 0 6 ) . 1
0. 100,o.139 (o.0039-0.0055)*2 0.20 (o.oo8)*,
Total runout 0 . O 3( 0 . O 0 1m1a x . 0.06 (0.oo2l
Cam lobe height IN 3 3 . 6 6 1{ 1 . 3 2 5 2 }
EX 3 3. 72 5 t 1. 3 2 78 )
Valve clearance IN o.07-0.11 (0.003-0.004)
EX o . 15 - 0 . 1 9t 0 . o o 60 . 0 0 7 )
Valve stem O.D. IN 6.580-6.590(O.2591 -0.2594) 6 . 5 5( O . 2 5 8 )
EX 6.550-6.560(O.2579-0.2583) 6.32 t0.257l
Stem to-guide clearance IN o.o2-o.05(o.oo1-0.002) 0.08 {o.oo3)
EX 0.o5-o.08(o.oo2-0.o031 0 . 1 1( O . O O 4 )
Valve seat Widrh IN 1 . 2 5 - 1 . 5(50 . 0 4 9 - 0 . 0)6 1 2.0 (o.081
EX 1 . 2 5 - ' 1 . 5( 5
0 . 0 4 9 , O . 0)6 1 2.0 (0.081
Stem anstalledheight IN 3 9 . 3 6 5 - 3 9 . 8 3t '51 . 5 4 9 8 - 1 . 5 6 8 3 )4 0 . 0 8 5{ 1 . 5 7 8 1 )

I.l Valvo spring

Valve guide
Freelength

t.D.
EX
lN
EX
IN
3 9 .19 5 , 3 9 . 6 3 (51 . 5 4 3-11 . 5 6 0 4 t 3 9 . 8 8 5{ 1 . 5 7 0 3 )
4 7 . 1 41 1 . 8 5 6 1
47.r4 (1.856)
6.61-6.63(O.260-0.261 I 6.70 to.264l
EX 6.61,6.63 ( 0 . 2 6 0 - 0 . 2)6 1 6.70 {0.264)
Installed height IN 13.25-13.75 1O.522-0.541 |
EX 13 . 75 - 14 . 2 5( O . 5 4-10 . 5 6 )1
' 1: ExhaustNo. 5 journal.
'2: ExceptexhaustNo. 5 journal.

{cont'd)

3-3
Standardsand Service Limits
-
CylinderHead/ValveTrain (H22A1 engine) Sectit)n 6
STANDARDtNEwl I sERvlcELlMlr
MEASUREMENT

250 rpm and Nominal 1 , 3 0 O( 1 3 . 0 ,1 8 5 )


Compression 950 {9.5, 135)
wide open throttle Minimum
kPa (kg/cm2,psi) Maximum varlatron 200 (2.o, 28)
o.o5{0.002}
Cvlinderhead Warpage
Heisht 1 4 1 . 9 51 4 2 . 0 5{ 5 . 5 8 9 - 5 . 5 9 3 )
5 {O.OO2-0.006}
o.o5-o.1 0.5(0.02)
Camshaft End play (o.o020-o.oo35) o . 1 5( 0 . 0 0 6 )
Camshalt-to_holderoil clearance o.050-0.o89
0 . 0 3( O . 0 0|1m a x 0.06 {o.oo2)
Total runout
Cam lobe height lN Primary 34.04' 1{1.3402)
Mid 3 6 . 8 5 6( 1 . 4 5 1 0 )
Secondary 3 4 . 9 7 1{ r . 3 7 6 8 }
EX PrimarY 3 3 . 7 4 5{ 1 . 3 2 8 5 )
Mid 3 6 . 3 2 3( 1 . 4 3 0 0 1
Secondary 3 4 . 6 8 3( 1 . 3 6 5 5 )
Valve clearance lN 0.15-O.1 9 (0.006-0.oo7)
EX o.17 0.21 (O.OO7-O.OO8|
Valve stem O.D. lN 5.475-5.4851O.2'56'0.21 l 59) i.oou to.z'tool
EX 5.475-5.485(0.2156-0.2159) 5.445{0.2144)
lN o.025-0.055(0.0010-0.oo22) 0.08 (0.003)
clearance
Stem-to-guide
EX o.o5o-0.080{0.0020-0.0031 ) 0.11 (0.oo4)
IN 1.25-1.55 ( 0 . 0 4 9 - 0 . 0 6
) 1 2.0 10.079)
Valve seat widrh 2.0 t0.079)
EX 1 . 2 5 - 1 . 5(50 . 0 4 9 - 0 . 0)6 1
IN 37.465-37.935 (1.4750-' |.4935) 3 8 . 1 8 5( 1 . 5 0 3 3 )
Steminstalledheight
EX 3 7 .16 5 - 3 7 . 6 3 (51 . 4 6 3 2 - 1 . 478)1 3 7 . 8 8 5{ 1 . 4 9 1 5 }
Freelength lN Outer 4 5 . 1 6( 1 . 7 7 8 )' r
Valve spring
4 5 . 7 6 ( 1 . 8 0 2 )' 2
lnner 4 1 . 7 8 { 1 . 6 4 5 ') 1
41 .75 11.6441 '2
-r
EX Outer 46.72 (1.839)
'2
46.74 11.8401
tnner 3 9 . 3 2 ( 1 . 5 4 8 )* r
'2
39.28 (1.546)
IN 5.51o-5.530 1O.21 69-0.217 7 | 5 . 5 5( 0 . 2 1 9 )
Valve guide t.D. 5.60 {O.220)
EX 5 . 5 3 5 - 5 . 5 5 5( 0 . 2 17 9 ' 0 . 2 18 7 )
IN 12 . 5 5 - 13 . O 5 ( O . 4 9 4 - 0 . 5 1 4 1 1 3 . 3 0{ O . 5 2 4 }
height
Installed 1 3 . 3 0( 0 . 5 2 4 )
EX 12.55-13.O5 (O.494-0.51 4)
IN 0.025-0.052(O.OO1
0'0.0020) 0.o8(o.003)
Rockerarm Arm-to-shaft clearance o.08i0.oo3)
EX o.025-o.052(O.001
0 0.oo20)

CHUOHATSUJOmanufacturedvalve spr'ng'
, 2 | NIHONHATSUJOmanufacturedvalve spring'

ii
ii

3-4
_]] Unit of length:mm linl
EngineBlock Section
MEASUREMENT STANDARD{NEW} I SERVICELIMIT
Cylinder block Warpageof deck surtace 0.07 10.003)max. 0 . 1 01 0 . 0 0 4 1
Bore diameterF22A1 engine 8 5 . 0 10 8 5 . 0 2 0( 3 . 3 4 6 8 , 3 . 3 4 7 2 )
-'] 8 5 . 0 0 0 , 8 5 . 0 1( 03 . 3 4 6 53 . 3 4 6 8 ) 8 5 . 0 71 3 . 3 4 9 )
H23Al, H22A1engines 87.O'f 0-87.020\3.4256-3.4260)
87.OOO 87.01013.42523.42561 87.O7t3.4281
Bore taper 0.o5 (0.002)
Reboringlimit F22A1 engine 0 . 5 0( 0 . 0 2 0 )
H23A1, H22A1 engines 0 . 2 51 0 . 0 1 0 )
Piston Skirt O.D.*1 F22At engine No Letter (A) 8 4 . 9 8 0 - 8 4 . 9 9{ 30 . 3 4 5 7 - 3 . 3 4)6 1 8 4 . 9 7 0( 3 . 3 4 5 3 )
Letter B 8 4 . 9 7 08 4 . 9 8 0{ 3 . 3 4 5 33 . 3 4 5 7 ) 84.960(3.3449)
H2341, H22A1 enginesNo Letter {A} 86.990-87.003 13.424A-3.42531 87.980(3.4638)
Letter B 86.980-86.993 13.4244-3. 42491 87.97013.4634)
Cfoarancein cylinder F22A1 engine 0.020-0.o40(0.ooo8,0.001 6) 0 . 0 5{ 0 . 0 0 2 )
H 2 3 4 ' 1 ,H 2 2 A 1 e n g i n e s o.007-0.030(0.0003-0.001 2) o . 0 4{ o . 0 0 2 )
Groovewidth F22A1 engine Top 1.220-1.230 {O.04800.0484) 1 . 2 5( 0 . 0 4 9 )
{for ring} Second 1.220-1. 230 {O.0480,0.0484) 1 . 2 5( 0 . 0 4 9 )
oil 2.405-2.420(O.1104-0.11101 2 . 8 5( 0 . 112 )
H 2 3 A 1 ,H 2 2 At e n g i n e s T o p '1.230- 1.245{0.0484-0.0490t 1 . 2 6 5{ 0 . 0 4 9 8 )
Second 1.230-1.245t0.0484-O.0490) 1 . 2 6 5{ 0 . 0 4 9 8 )
oil 2.405-2.820(0.1104-0.1110) 2 . 8 5t O . 1 1 2 l
Pistonring Ring-to-grooveclearance Top 0.035-0.060(o.0014-0.0024) 0 . 1 3( 0 . o o 5 )
Second 0.030-0.055to.oo12-o.oo22l 0 . 1 3( 0 . 0 0 5 )
Ring end gap F22Al engine Top 0.20-o.35(0.008-0.01 4) 0.60 {0.024)
Second 0.40-o.ss(0.o16-0.022) 0,70 {0.028)
oil 0.20-0.70(0.0080.028) o . 8 0( 0 . 0 3 1 )
H 2 3 A 1 ,H 2 2 A 1 e n g i n e s T o p o . 2 5 - 0 . 3 {50 . 0 1
0-o.014) o.60 (0.024)
Second 0.60,0.75(o.0240.o30) 0 . 9 0( 0 . 0 3 5 )
oil 0.20-o.50{0.008-0.o20) *2 0.60 10.024)
0.20-0.70(0.oo8-0.0281 *3 0 , 8 0( o . 0 3 1 )
Piston Pin o.D. 21.994-22.OOO(0.8659-0.866
1)
Pin-to-pistonclearance F22A1 engine o.o12-0.o24{o.0005-o.ooo9}
H23Al, H22A1 engines 0.012-0.026to.0005-0.0o10)
Connecting rod Pin-to-rodinterlerence 0.o13-o.o32(o.ooo5-o.001
3l
Small end bore diameter 2 1 . 9 6 8 - 2 1 . 9 8 1( 0 . 8 6 4 9 - O . 8 6 5 4 )
Largeend bore diameter Nominal 5 1 . 0{ 2 . O 1 )
€nd play installedon crankshaft o. 15-0.30 (0.006-0.012) 0 . 4 0( o . o 1 6 )
Srhallend bore-tolargeend bore parallelism 0 . 1 2 ( 0 . O 0 5 ) / 1 0m0 ax. 0 . 15 ( 0 . o o 6 y 1 0 0
Crankshaft Main journaldiameter No. 1 and 2 journals 4 9 . 9 7 6 - 5 0 . 0 0 0( 1 . 9 6 7 6 - 1 . 9 6 8 5 )
No. 3 journal 4 9 . 9 7 24 9 . 9 9 6 ( 1 . 9 6 7 4 , 1 . 9 6 8 3 1
No. 4 journal 4 9 . 9 8 4 - 5 0 . 0 0 8( 1 . 9 6 7 9 - 1 . 9 6 8 8 )
No. 5 journal 4 9 . 9 8 8 - 5 0 . 021 ( 1 . 9 6 8 0 - 1 . 9 6 9 0 )
Rod journaldiameter 4 7 . 9 7 6 4 9 . 0 0 0 { 1 . 8 8 8 81- . 8 8 9 8 )
Taper 0.005 (0.0002) max. 0.006 (0.0002)
Out-of-round 0.OO5(O.0002)max. 0.006 {0.0002)
End play o.10,o.35 (0.oo4,0.014l 0 . 4 5{ O . 0 1 8 )
Total runoul O.03 {0.OOl) max. o.04 {o.002)
Eearings Main bearing-to-journal
oil clearance
_ No.1and2 journals 0.021-0.045(o.00080.0018) 0.050 (0.0020)
No. 3 journal 0.025-0.049(0.0o10-0.001
9) 0.055 (0.0022)
No. 4 iournal 0.013-0.037(0.ooo5-o.001
5) 0.050 {0.0020)
No. 5 journal 0.009-0.033(0.0004,0.001
3) 0 . 0 4 0{ o . 0 0 1 6 )
Rod bearing-to-journal
oil clearance
F22A1 engine 0.021-0.049{o.0008-0.oo20) 0.055 (0.oo22)
H 2 3 A 1 ,H 2 2 A t e n g i n e s 0.027-0.055(o.001'l-0.oo22) 0.060 (0.o024t
'1: Measuredat 2l.O mm (O.83inl on F22A1
engineand 15.0 mm (0.59 in) on H23A1. H22A1 enginesborh from bottom o{ skirt.
'2: TEIKOKUPISTONRINGmanufacturedpisron
ring.
'3: RIKENmanufacturedpiston ring.

3-5
Standardsand Service Limits
Engine Block - Section 7 (cont'd)
MEASUREMENT STANOARD
INEW} I LIMIT
SERVICE

Balancershatl Journaldiameter No. 1 iournal(lront) 42.722-42.734(1.6820'1.68241 4 2 . 7 ' l{ 1 , 6 8 9 }


No. 1 journal(rear) 20.938-20.950 {O.8243-0.8248) 20.92 Q.A24l
No. 2 journals 3A.712-3A.724 11.5241-1.52461 3 8 . 7 0( 1 . 5 2 4 )
No. 3 iournals 34.722-34.7 34 (1.3670-1.3675) 3 4 . 7 1{ 1 . 3 6 7 )
Journaltaper 0.005 (0.0002)
End play Front 0. 10,0.35(O.OO4-0.O14)
Rear o.06-0.18 to.002-0.o07)
Total runout 0 . 0 2( o . o o 1 ) o.osro.oot t
Oil clearance No. 1 journallrear) o.050-0.075to.oo20-0.0030) o.09{o.oo4)
No. 1 (front)and No 3iournal 0.066-0.1 18 (0.0026-0.0046) 0 . 1 2( O . 0 0 5 )
No. 2 iournals o.o76-0i 2a {o.oo30-0.0050) 0 . 1 3{ 0 . 0 0 5 )
Balancershalt LO. No. 1 journal(frontl 42.AOO-42.820 {1.6850-1.6958) 4 2 . 8 3( 1 . 6 8 6 )
beanng No. 1 journal{rear) 3 { 0 . 8 2 6 8 - 0 . 8 2 7 3 ) 21.O2@.A2Al
2 1 . 0 0 0 -12. 0 1
No.2,ournals 38.800-38.820 11.527 6-1.52431 3 8 . S 3( 1 . 5 2 9 )
No. 3 iournals 34.8OO-34.82O (1.3701-1.3709) 3 4 . 8 3( 1 . 3 7 1 )

EngineLubrication- Section 8
MEASUREMENT STAI{DARD(IIEW} I SERVICE
LIMIT

Engineoil Capacityt (US qt, Imp qt) F22A1 engine 4.9 {5.2, 4.3} for engineoverhaul
3.8 14.0,3.3) for oil change,includinglilte.
H23A1 engine 5.4 (5,7, 4.81 for engineov€rhaul
4.0 (4.2, 3.5) lor oil change,includinglilter
H22A 1 engine 5.9 (6.2, 5.2) for engineoverhaul
4.A $i, 4.21 tor oil ch€nge,includingfilter
Oil p'rmp Displacement ? IUS qt, lmp qtl/min @rpm 73.5 177.7,64.7) @6,000
lnner-toouter rotor radialclearance
-o.006)
o.02-0.16 10.001 o.20 (0.008)
Pump body-toouter rotor radialclearance 0.10,0.19 (0.004-0.007) 0.21 (O.OO8)
Pump body-to-rotoraxialclearance o.02-0.07(o.oo1-0.003) 0 . 1 2( 0 . 0 0 5 )
Fleliefvalve Pressuresettingat oil termperature176oF (80oC)
kPa (kg/cm2,psi) at idle 70 {0.7, 1O}min.
at 3,0OOrpm 350 (3.5, 50) min.

Cooling - Section o
MEASUREMENT STAI{OARD(NEW}

Radiator Enginecoolantcapacity F22A1 engine M/T: 7.1 (7.5, 6.2) for overhaul
includingengine, 3.5 (3.7, 3.1) for coolantchange
heater,cooling AlTt 7.O 17.4, 6.2) tor ovorhaul
line and reservoir 3.4 (3.6, 3.0) for coolantchange
{ (US qr, lmp qt) H23A1 engine MlTt 7.4 17.9,6.5) for overhaul
3.8 (4.0, 3.3) for coolantchange
All: 7.3 17.7, 6.4) lor overhaul
3.7 (3.9, 3.3) lor coolantchange
H22A1 engine M/T: 7.8 (8.2, 6.9) Ior overhaul
4.2 14.4,3.7) for coolantchange
ReservoircapacitY o . 6( o . 6o, . 5 )
i; 9 5 - 1 2 5 ( 0 . 9 5 - 1 . 2 5 1, 3 . 5 ' 1 7 . 8 )
OpeningpressurekPa {kg/cm2,Psi)
I! Badiatorcap
oF {oc) 169-177 {76-80)
Ir
I i
Thermostat Start to open
F u l l yo p e n
'F {oC) 194 (90)
Valve lifi at Iully open 8 . O 1 O . 3 1m ) in.
,l
't Waler pump Displacement F22A1 engine 1 6 5 ( 1 7 4 ,1 4 5 )@ 6 , 0 0 0
I f {US qt. lmp qt)hin @rpm H23Al engine 1 s 9 1 1 6 8 1, 4 0 )@ 6 , 0 0 0
H22A1 engine 1 6 3 ( 1 7 2 ,1 4 3 )@ 6 , 0 0 0
Radialorfan E C Ts w i t c h" O N " F 2 2 A 1 ,H 2 3 A 1 e n g i n e s 194,205(90,96)
temperature H22A I engine 198-208(92-98) "ON" temperature
ECT switch "OFF" tempetatureoF (oC) Subtruct4'13 {l-7} tfom actual
Fuel and Emission- Section 1 1 Unil ol lengthi mm (in

MEASUREMENT STANDARD(NEW)
Fuel pump Displacement cc {US oz, lmp oz} in 10 seconds 205 (6.93, 7 .221 tnin.
Pressureregulator Pressurewith regulatorvacuumhose dtsconnected
k P a{ k g / c m 2p, s i } F 2 2 A 1 ,H 2 3 A 1 e n g i n e s 255-305(2.55,3.05,36-43)
H22A1 engine 230-280{2.3-2.8.33-40)
Fuel tank Capacity{ {US gal, lmp gal) 6 0 ( 1 5 . 9 ,1 3 . 2 )
Engine Fast idle rpm 1,400
ldle speedrpm with headlightand 700 150 (M/T:neurral)
cooling fan ott 7OO150 {A/T:E o. E position)
ldle CO % 0.1 max.

Clutch Section 1 2
MEASUREMENT STANDARD INEWI I SERVICE
LIMIT
Clutch pedal Pedal height ro ttoor 2 0 8( 8 . 1 1 )
Stroke 1 3 5 - 1 4(55 . 3 1 - 5 . 7 1 )
Pedalplay 1 . 0 - 7 . 0( 0 . O 4 - O . 2 8 )
Disengagement height to floor 9 4 { 3 . 7 0m ) in.
Flywheel Clutch surlacerunout 0.05 {O.002}max. o.15 (0.006)
Clutch disc Rivet head depth 'l.3 (0.O51)min.
o . 2(0.008)
Surface runout O.8(0.03)max. 1 . O(0.04)
Thickness 8 . 4 - 9 . 1( O . 3 3 1 - 0 . 3 s 8 ) 6 . O (0.2361
Clutch cover Pressureplate warpage 0 . 0 3( O . 0 0 1m1a x . o . 1 5( 0 . 0 6 )
-]']
Manual Transmission Section 1 3
MEASUREMENT STANDARo{NEw} I sERvIcELIMIT
Transmissionoil Capacityt (uS qt, lmp qt) 1 . 9 1 2 . O1
, . 7 1 f o ro i l c h a n g e
2.O 12.1, 1.Al tor overhaul
Mainshaft End play 0. 10-0.16 {0.0039-0.0063) Adjustwith a shim.
Diameter ot ball bearing contact area 2 7 . 9 7 7- 2 7 . 9 9 0( 1 .1 0 15 1 .10 2 0 ) 27.94 11.1001
Diameterof third gear contact ar€a 3 7 . 9 8 4 - 3 8 . O O1O1 . 4 9 5 41 . 4 9 6 1) 3 7 . 9 3( 1 . 4 9 3 )
Diameter ol ball bearing contact area 2 7 . 9 8 7- 2 8 . O O O( 1 .10 18 - 1 .1 0 2 4 ) 2 7 . 9 4( 1 . 1 0 0 )
Runout 0.02 (0.0008) max. 0.o5 (0.0021
Mainshatt3rd and LD. 4 3 . O O 9 - 4 3 . 0(215. 6 9 3 3 , 1 . 6 9 3 9 ) 4 3 . 0 8 0{ 1 . 6 9 6 1 )
fourth gears End play 0.06,0.21(0.0024,O.0083) o . 3 0( 0 . o 1 2 )
Thickness 3rd gear M2L5, M2S4 3 2 . 4 2 - 3427. t l . 2 76 -1 . 2 78 l 3 2 . 3( 1 . 2 7 2 1
M2F4 34.92-34.9711.37 5-1.3771 3 4 . 81 1 . 3 7 0 1
4th gear M2L5, M2S4 3 0 . 9 2 - 3 0 . 9171 . 2 1-71 . 2 1 9 1 3 0 . 8( 1 . 2 1 3 )
M2F4 31.42-31.4711.237-1.2391 3 1 . 3{ 1 . 2 3 2 )
Mainshaltsth gear t.D. 4 3 . 0 0 94 3 . 0 2 5{ 1 . 6 9 3 31-. 6 9 3 9 } 4 3 . 0 8 0( 1 . 6 9 6 1 )
Endplay 0.06-0.21(o.0024,0.oo83) 0 . 3 0{ 0 . 0 1 2 }
Thickness 3 0 . 9 2 - 3 0 . 9171 . 2 1-71 . 2 91l 3 0 . 8( 1 . 2 1 3 )
Countershaft End play 0.05,0.40 (0.0019-0.0157) o . 5 0{ o . 0 2 )
Oiameterof needlebearingcontact area 3 8 . O O O - 3 8 . 5O {11 . 4 9 6 '-11 . 4 9 6 7 ) 3 7 . 9 5( 1 . 4 9 4 )
Diameterof ball bearingand needlebearing
conlact area 24.947-25.OOO(O.9837-0.9845) 24.94lO.982l
Diameterot low gear contact area 39. 984-40.OOO11.5742-1.574al 3 9 . 9 3{ 1 . 5 7 2 }
Runout O.02 {O.0OO8) max. o.05 (o.oo2)
_]]] Countershaltlsl t.D. 4 6 . 0 0 9 - 4 6 . 0 2 5{ 1 . 8 114 - 1 . 8 12 0 } 46.08 (1.8't4)
gear Endplay 0.04,0.10 (o.002 0.oo4) Adiust with a washer.
Countershatt 2nd LD. 4 7. O O 9 - 4 7 2 5( 1 . 8 5 0 71 . 8 5 1 4 )
.O 47.08 ('t.854)
gea( Endplay o.04-0.10 {0.002-o.004) Adjust with a collar.

l Thickness 2 8 . 9 22 a . 9 7( 1 . '3t 9 , 1 . 1 4 1 ) 2 8 . 8( 1 . 1 3 )

(cont'd)

3-7
Standardsand Service Limits
Manual Transmission- Section 13 (cont d l
MEASUREMENT STANOARD INEW) I SERVICELIMIT

Spacercollar LD. 36.48-36.49{1.4362-1.4366) 3 6 . 5 0( 1 . 4 3 7 1


lCountershaft o.D. 4 1 . 9 8 9 - 4 2 . O {010. 6 5 3-11 . 6 5 3 5 ) 4 1 . 9 4( 1 . 6 5 2 )
29.O2-29.O ( 14. 14 2 5 - 11. 4 3 3 )
2nd gear) Length
B 29.O7 -29.09(' |.144-1.145)
-Jo 3 1 . 0 0 2 - 3 1 . 20 1( 1 . 2 2 0 5 - 1 . 2 2 0 9 ) 3 1 . 0 6( 1. 2 2 3 )
Spacecollar LD.
(Mainshaft4th and o.D. a- 3 7 . 9 8 9 - 3 8 . O (O1O . 4 9 5 6 - 1 . 4 9)6 1 3 7 . 9 4( 1 . 4 9 4 )
5th gear) Length 56.45,56.5512.222-2.2261
la B 26-03-26.08 (1.0248-1.0268)
LD. 20.o16-20.O43(0.7880-0.7891 l 20.09(o.7909|
Reverseidlergear
Gear-loreversegearshalt clearance 0.036-0.084{o.oo14-0.00331 0.160 to.ooo6l
Syncro ring Ring-togear clearance(ringpushedagainst o.85-1.10 (0.034-0.043) 0 . 4 0{ o . o 1 6 l
gearl
Dual cone Clearance(ringpushedagainstgear)
sYncnronng Outer synchroring to_gear 0.95-1.68(0.037-0.066) 0.6 (0.024)
Innersynchroring-togear o.5-1.O(0.02-0.04) o . 3( 0 . o 1 1
Outersynchroring-tosynchrocone o.5-1.O(0.02-O.041 0 . 3( 0 . 0 1 )
Shift fork Fingerthickness M215, M2S4 6.2,6.41O.244-0.2521
M2F4 7 . 4 , 7 . 6( O . 2 9 1 - 0 . 2 9 9 )
Forkto syncrosleeveclearance o.35-0.65t0.014-0.026) 1 . O( 0 . 0 3 9 )
Reverseshitt fork r i ' w , groove
Pawl width
srouvc w ,uu, 1 3 . 0 - 1 3 .(30 . 5 1 - 0 . 5 2 )
A
Fork'to reverse idle gear clearance I 0 . 5 - 1 . 1( 0 . 0 2 - 0 . 4 3 1 1 . 8( 0 . 0 7 )
Groove width atA 7.O5-7.2510.27a-O.25541
atB 7.4-7.7 tO.29-O .301
Fork-to-tifth/ atA o.o5-0.3510.002-o.o14) o.5 to.02l
B 1 . 0{ o . 0 4 )
reverseshift atB 0.4,o.8{o.02-0.03)
shalt clearance
Shift arm LD. 15.973-16.000 {O.6289-0.6299)
Shift arm-to-shaftclearance o.005,0.059to.ooo2-o.oo23)
Shift tork diameterat contact area 12.9-13.O(0.508-0.512)
lork shaft clearance
Shift-arm-ro-shaft 0.2-o.5to.ol -o.02l
Selectlever Pin sizeof contact area 7.9,8.O (O.311-0.3' I5)
Selectleverto-shitt peice clearance o.o5 0.25 10.002-o.o10) o.5 (0.o20)
Shaft outer diameler 15 . 4 1 -15 . 6 8 ( 0 . 6 0 7 - 0 . 6 1 7 )
Shift arm cover clearance 0.032-o.102 (0.OO1 3-0.0040)
Shift arm lever o.D. 15.941-15.968 {0.6276-0.62871
Tlansmissionhousingclearance 0.027-0.139 (O.0011-O.OO55)
lntedock Eorediameter 16.00-16.O510.630'0.632)
Shitt arm lever clearance 0.032-0.109 (0.0013-o.oo43)

I
{r
I
Automatic Transmission- Section 14 Unit of length mm (in)

MEASUREMENT STANDARD {NEWI SERVICELIMIT


Transmission Capacityf (US qt, lmp qt) 6.0 (6.3, 5.3) Ior overhaul
tluid 2 A 1 2 . 5 ,2 . 1 1 t o rl l u i d c h a n g e
Hydraulic Line Dressureat 2.OO0rom 8 0 0 t 8 . 0 ,1 1 4 1 7 3 O1 1 . 5 1, O 7 l
pressure inEorEpositron throftleIully-closed throttlemorethan3/16
(F22A1 engine) open
I
8 5 0 ( 8 . 5 ,1 2 1 )
kPa lkg/cm2, lhrottlemorethan3/16 open
psr,
4th clutch oressureat 2.000 rom 530 (5.3, 75) 480 (4.8, 68) throttte
in @ position throttle fully,closed lully-closed
I I
850 (8.5.'121) 750 17.5,1071
throttle more than 3/16 open throttlemorethan3/16
open
3rd and 2nd clutch pressureat 2,000 rpm 5 0 0{ 5 . 0 , 7 1 ) 450 (4.5, 64)
in E posrtion throttleIullv-closed throttle fully-closed
I I
8 5 0 ( 8 . 5 ,1 2 1 ) 750 (7.5,107)
throttlomorethan3/16 open throttle more than 3/16
open
2nd clutch pressureat 2,OOOrpm
in Lzl position 8 0 0 - 8 5 0( 8 . 0 - 8 . 51.1 4 - 1 2 1 1 7 5 0 1 7 . 5 1, O 7 l
1st and 1st-holdclutch pressure
at 2.000 rpm in LLI position 800-850{8.0-8.5,114-121} 750 17.5,1071
Throttle B pressure Throttle fully closed 0 (0.o)
Throttle fully open 8 0 0 - 8 5t08 . 0 - 8 . 511. 4 - 1 2 1 1 7 5 0 1 7 . 5 ,1 0 7 )
Hydraulic Line pressureat 2.000 rom 8 5 0 ( 8 . 5 ,1 2 1 ) 8O0(8.0. t 14l
pressure in E or E]position thro le tully-closed throttlemorothan 3/16
(H23A1 engine)
I open
900 (9.o, 129)
kPa {kg/cm2, throttlemorethan 3/16 open
pst,
4rd clutch pressureat 2.OOOrDm 5 3 0( 5 . 3 , 7 5 ) 48O (4.8, 68) throtte
in @ positron throttlefully-closed tully-closed
I I
900 (9.o, 128) 800 (8.0,114)
throttlemorethan3/16 open throttle more than 3/16
open
3rd and 2nd clutch pressureat 2,0OOrpm 5 O O( 5 . 0 . 7 1 ) 450 {4.5, 64)
in E position throtlle tullv-closed rhrottle fully-closed
I I
900 (9.o, 128) 8 0 0 { 8 . 0 ,1 1 4 }
throttlemorethan3/16 open throttlemorethan3/16
open
2nll_glutch pressrue at 2,OOOrpm
in L2l position 8 5 0 , 9 0 0 1 8 . 5 - 9 . O1. 2 1 - 12 8 ) 800 {8.0,114}
1st and 1st-holddutch pressure
at 2,000 rpm in Lll posirion 850-900{8.5-9.0,121-128) 800 {8.0,114)
Throttle I pressure Throttle fully closed o (o,o)
Throtttefully open 850-900(8.5-9.0,121-128) 8 0 0 ( 8 . 0 .1 1 4 )
Stalf speed rpm F22A1 engine 2,350-2,650
{Checkwith car on level ground) H23A1 engine 2,600-2,900

{cont'd)

3-9
Standardsand Service Limits
Automatic Transmission- Section 14 (cont'd)
MEASUREMENT STANDARD(I{EW) SERVICELIMIT

Clutch Clutch initialclearance lst-hold 0.80-1.00{0.031-0.039}


1st, 2nd 0.65-0.85{0.026'0.033}
3rd' 4th 0.4-o.6{o.016-0.024)
Clutchreturnspringfree length 1sr, 2nd, 3rd' 4th 33.511.32) s1.g tr.zat
Clutch disc thickness 1.88-2.00lO.O74-O.079) Untilgroovesworn out.
Clutch plate thickness 1st, 1st'hold 1.95-2.O5 (O.077-O.O81 ) Discolorataon
2nd, F22A1 engine
H234 1 engine
2.55-2.65(O.089-0.093)
1.95-2.O5 (0.077-0.081 |
tV
3rd,4th 2.25-2.35(O.089-0.0931 Discoloration
Mark l 2.05-2.10 (O.081 -O.083) Discoloration
Clutch end plate thickness
Mark 2
Mark 3
Mark 4
2.15-2.20(O.085-0.O87)
2.25-2.30(0.089-0.091)
2.35-2.40(0.093-0.094)
tI
Mark 5
Mark 6
2.45-2.50 t0.096-0.O98)
2.55-2.60(O.100-0.102) I
Mark 7
Mark 8
Mark I
2.65-2.70{0.104-0.

2.85-2.90(O.112-O.1
106)
2 . 7 5 - 2 . 8 10 0 . 1 0 8 -1o1. 0 1
14)
I
Discoloration

Valve body Stator shah needlebearingcontact l.D


Torque converter side 27.OOO-27.O21 (1.0630-1.
1638) wear ol damage
Oil pump side 29.OOO-29.O13 11.1417-1.14221
Oil pump gear side clearance 0.03-0.05{o.oo1-0.oo2l 0.07to.oo3)
Oil pump gear-to-bodyclearance Drive o.210-0.265l0.OO83-0.01 041
Diven 0.070-0.125 {0.OO28-O.00491
Oil pump drivengear I.D. 14.01F14.034(0.551 84.5525) ie", o, d"."ge
Oil pump shatt O.D. 13.980,13.990 (0.55040.55081 wear or damag€
Reverseshitt lork finger thickness 5.90,6.00(o.232-0.236) 5 . 4 0( O . 2 1 3 1
Shilting device,
parking brake Parkingbrakeratchet Pawl \ Wearor
Parkingbrakegear t otherd€fect
and throttle
control system Throttle cam stopper height 17.O-17.1{O.669-0,673)
Seryo body Shitt fork shaft bore l.D. r 4.00G14.010(0.551 6l
2-O.551
Shift lork shatt valve bore l.D- 37.OOO-37.039{1.4567-1.4582) 3 7 . 0 4 5t 1 . 4 5 8 5 )
Sealingring contact LD. 35.OOO-35.025(1.3780-1.3789) 3 5 . 0 5( 1 . 3 7 9 9 )
Regulatorvalve
body
Accumulator
Sealingring contact l.D. 3 {1.2598-1.2604)
32.OOG32.O1 3 2 . 0 5 0( 1 . 2 6 1 8 1
DOOy
Sealingring contact l.D. l'l.1417-1.14221
29.0OG29.013 2 9 . 0 5 0( 1 . 1 4 3 7 1
Stator shalt
Transmission Diameter ot needle bearing contact area
On mainshaft of stator shaft 22.9A4-23.@O (0.9049-O:90551 Wear or damage
On mainshaftot 3rd gear collar 45.984-46.000(1.8104-1.8110)
gear collar
On mainshalt oI 4th'tst 31.984-32.OOO 11.2592'1.2598)
On countershattof gear collar 40.984-41.OOO (1.6135-1.6142)
On countershaft of 4th gear 31.975'31.991 (' |.2589-1.2595)
On countershaftof Parkinggear 39.984-40.000 11.5742-1.57 4a'l
On countershaftof reversegeat 35.979-36.OOO (' 1.4165'1.41 73)
On secondaryshaft ot 1st gear 3 1 . 9 7 5 - 3 1 . 9 9 (11 . 2 5 8 9 - 1 . 2 5 9 5 )
On secondary shaft ol 2nd gear 3 ' t . 9 7 5 - 3 1 . 9 9(11 . 2 5 8 9 - 1 . 2 5 9 5 )
On reverseidler gear shaft 13.990-14.000 {0.5508-0.551 2)
lnsidediameter
ii Mainshaft3rd gear 52.OOO-52.O19 12.O472"2.O4aOl
i : Mainshaft4th gear 38.OOs-38.021 (1.4963-1.4969)
It Counte.shaftlst gear 47.OOO-47.O1
38.000-38.O1
6 {1.8504-1.8510)
6 (1.4961-1.4967)
f 'ji Countershaft 4th gear
Countershaftreversegear 42.OOO-42.O16 (1.6535-1.6542)
Countershaftidler gear 48.000-48.016 {1.8898'1.8904)
:t
Secondaryshatt lst gear 37.00G37.016 (1.4567'' 1.4573)
I 37.000,37.o16 {1.4567'1.4573}
Secondaryshaft 2nd gear
Reverseidlergear shaft holder 14.41 6-1.434 (O.5676-0.5683) Wear or damage
Unlt ot l€ngthi mm (in)
Automati c Transmission- Section 14
MEASUREMENT STANDARD {NEWI SERI/ICE LIMIT
Transmission Mainshaft3rd gear collarlengrh 1 9 . 5 01- 9 .s 5 ( 0 . 7 6 8 - 0 . 7 7 0 ) Wear or damage
{cont'd) Mainshaft4th gear collarlength 4 7 . 5 0 - 4.75 5 l t . 8 1 0 - 1 . 8 7 2 ) wear or damage
Countershatt1st gear collar length 2 7 . 5 0 - 2 7 . 5(51 . 0 8 3 - 1 . 0 8 5 ) Wear or damage
Thrust washerthickness
Countershaft1st gear 1 . 4 5 - 1 . 5(00 . 0 5 7 , O . 0 5 9 ) Weor or damage
Countershaft idler gear 3.45-3.55(0.136-0.140) Wear or damage
Countershaltparkinggear length 25.030-25.048 (0.98544.9861 l Wear or damage
Secondaryshaft 1st gear distancecollar
length 4.95-5.00{O.195-0.197) Wear or damage
Secondary shaft 2nd gear thrust washer
thickness 4.35-4.45 tO.t 7 13-O.17 521 Wear or damage
Secondaryshaft 2nd gear splinewasher 4.O2-4.05(O.158-0.159)
thickness 4.07-4.'t0 (0.160-0.161 )
4 . 12 - 4 . 15 ( 0 . 1 6 2 - 0 . 1 6 3 )
4. 17-4.20 (0.164-0.165)
4.22-4.25 tO.166-0.167)
4.27,4.30 {O.168-0.169)
4.32-4.35 lO.17 0-O.17 1|
4.37 -4.40 lO.17 2-O.173l
4.42-4.45 tO.17 4-O.17 5l
STANDARDINEWI
MEASUREMEI{T
Wir6 Dia. o.D. Frco Longth No, ot Collr
Spring Regul€tor valvespringA F22A1 engine 1 . 8( O . 0 7 1 ) 1 4 . 7( 0 . 5 7 9 ) 86.5 (3.406) to.5
H23A1engine 1 . 8( 0 . 0 7 1 ) 14.1 lO.579l 88.6 (3.488)
' 1 . 8( 0 . 0 7 1 )
Regulatorvalve springB 9.6(0.378t 44.Ot1.732t
Stator reaction spring 4.5 lO.177l 3 5 . 4( 1 . 3 9 4 ) 3 0 . 3t 1 . 1 9 3 1 1.92
Torqueconve er check valve spring 1. 1 ( O . 0 4 3 ) 8 . 4 ( 0 . 3 3 I1 3 6 . 4( 1 . 4 3 3 ) 12.0
Reliofvalve spring 1 . 0{ 0 . 0 3 9 ) 8.4(0.331) 3 9 . 1( 1 . 5 3 9 1 15.1
Coolerreliefvalve spring 1 . 1( 0 . 0 4 3 ) 8.4 t0.331) 4 6 . 8( 1 . 8 4 3 ) 1 7. O
2nd orificecontrol valve spring 0.6 10.o24) 6.6 (O.2601 58.3 (2.295) 15.8
Oriticecontrol valve spring 0.8(0.031) 6.6 (O.2601 52.5 t2.O61l 33.0
Servo control valve spring 1 . 0( 0 . 0 3 9 ) 8.1{0.319) 52.6 (2.O711 22.4
4th exhaust valve spring 0.9 (0.035) 7.1(0.280' 6 0 . 8( 2 . 3 9 4 1 28.9
Throttlevalve B adjustingsprang o.8 (0.o31) 6.2 lo.244l s 0 . 0{ 1 . 1 8 1 } 8.0
Throttlevalve B spring 1 . 4( 0 . 0 5 5 ) 8.5lO.335l 4 1 . 5{ 1 . 6 3 4 ) 10.5
1 . 41 0 . 0 5 5 1 8.5{0.335t 4 1 . 5{ 1 . 6 3 4 ) 11.2
1 . 4( O . O 5 5 ) 8 . 5 ( O . 3 3 5 ) 4 1 . 6( 1 . 6 3 8 1 12.4
1-2 shilt valve spring 1 . 0( 0 . 0 3 9 ) 8.6 tO.339) 4 1 . 3{ 1. 6 2 6 ) 16.9
2-3l3-4 shift valve spring o.9 (0.035) 7 . 6t O . 2 9 9 t 57.Ot2.2441
1st-holdaccumulatorspring 4.0(0.157) 2 5 . 0( 0 . 9 8 4 ) 64.7 12,547) 7.3
lst accumulatorspring 1 . 81 0 . 0 7 1 ) 1 6 . 3( 0 . 6 4 2 t 11 5 . 4( 4 . 5 4 3 ) 18.6
4th accumulatorspring 2 . 9{ 0 . 1 1 4 t 22.0 {0.866) 9 0 . 1( 3 . 5 4 7 ) 10.9
2nd accumulatorspring 3.3{0.130) 22.0 (0.866) 8 4 . 9( 3 . 3 4 3 ) 11 . 1
3rd accumulatorspring 2.6t0.102) 1 7 . 5( 0 . 6 8 9 ) 1 0 4 . 51 4 . 1 1 4 ) 18.0
Lock-up shitt valve spring 0.910.035) 7.6 tO.229l 73.7 t2.9021
Lock-uptirningvalve spring 0.8{0.031) 6.6 {0.260} 5 1 . 11 2 . 0 1 2 ) 14.7
CPC valve spring 'l.4
{o.055) 9.4{0.370) 3 3 . 0( 1 . 2 9 9 ) 10.5
Modulatorvalve spring 1 . 4( 0 . 0 s 5 ) 9.4 (0.370) 3 3 . O( 1 . 2 9 9 1 10.5
Lock-up control valve spring 0.7 (0.028) 6.6 (0.260) 3 8 . 01 1 . 4 9 6 ) 14.1
3rd kick-downvalve spring 1. 1 ( 0 . 0 4 3 ) 7 . 6 1 0 . 2 9 9 ) 4 8 . 3( 1 . 9 0 2 )
3-2 kick down valve spring 1 . 2t O . O 4 1 l 7 . 1{ 0 . 2 8 0 ) 4 6 . 9( ' t . 8 4 6 )

3-11
Standardsand Service Limits
Differential (Manualtransmission) Section 1 5
MEASUREMENT STANDARD INEW} I SERVICELIMIT

Final driven Backlash 0.085-o.142 {O.OO33-0.0056) o.20(o.o08l


geal
'18.000,18.018 {0.7087-0.7094}
Dillerontial Pinionshaft contact area l.D.
carriet Carrier-to-pinionclearance 0.013-0.047(0.0005-o.oo1 9l 0.10{o.oo4t
Driveshatt contact aroa LD. 28.005-28.025 {' 1.1026-1.10331
Carrisr-to-driveshaftclearance Right 0.025-o.066(0.0010-o.oo26l 0 . 1 2t o . o o s t
Left 0.o55-0.091{o.oo22-o.oo36l 0.15 (0.006I
Dillerential Backlash o.05-0.'t5 to.o02-0.0061 ' l AdjLrstwith a shim
t.D. 18.042-18.066 tO.7103-0.71 3)
Piniongearto-pinion
shaftclaarance 0.055-o.095(0.oo22-o.0037) o.15 {0.006)
Taperroller StartingTorqueN.m {kg-cm,lb-in) 1.4-2.6( 4-26, 12-231 Adjust with a shim
bearingpreload

Differential (Automatic tlansmission) Section 1 5


MEASUREMENT (NEW}
STANDARO SERVICELIMIT

Finaldriv€ng€ar Escklash o.o85-o.142 {O.0033-0.0056) 0.20(o.oo8)

I Dlflerential
carnef

Differcntial
Pinionshaft contact area l.D.
Caftier-to-pinionclearance
Driveshaft contact area l.D.
CarrieFto-driveahaftclearanace
Backlash
18.000-1 8.018 t0.7087-0.7094)
o.o17-o.o47 {0.0007-0.oo1 9}
2 8 . 0 O 5 - 2 8 . 0{215.1 0 2 6 - 1 . 1 0 3 3 )
0.025-0.066to.oo10-o.oo26)
15 (o.oo2-o.oo6t
0.05,0.
0 . 1 0( 0 . 0 0 4 )

o . 1 2( 0 . 0 0 5 )
Adjust with a shim
LO. (O.7103-0.71
18.042,18.066 13)
Pinion gear-to-pinionshaft clearance (o.oo23-o.oo37)
0.059-o.o95 o.12 (O.OO5)
Taperroller Starting Torque New bearing 2.A-4.OQA-40, 24-3sl Adjust with I thim
bearim preload N.m lkg.cm, lb-inl Reusedbearing 2.5-3.7 t25-37, 22-321
F
Ste6ring Section1 7
MEASUREMEl{T STAI{DARDINEW}
St€sring whsel Play at steering wheel circumterence o-10(o-o.4)
Starting load at stoering wheel circuml€ronce N {kg, lbsl
Engine running 30 {3.O,6.61
When the hydraulic system to the power steerang
soeed sensor is cut ofl 50 (5.0,11.Ol
Gearbox Angle ot rack-guide-screwloosengd trom locked position

Pump Pump pressure with valve closed (oil temp./spoed: 1O5"F


{4OoCl min./idle. Do not run for more than 5 s€conds}.
kPa {kg/cm2, psi} 7.O00-8,OOO (70-80,995-1,138t
Power steering Recommend€dfluid Hondapowersteoringfluid-V
lluid Fluid capacity System 1 . 7 { 1 . 8 0 ,1 . 5 0 1
, (US qt. lmp qt) Reservoir 0.5 {o.53,0.441
'lOON (1o kg, 22 lbs) betweenpulleys 13.5-16.5 10.53-0.65)with used belt
Power st€gring Deflectionwith
belt' 9.5-11,5 {0.37-0.451with new belt
t Belt tension N (kg, lbsl 350-5OO{35-50. 77-1101with used bslt
!i Mgasured with belt tension gauge 7OO-9OO (7O-9O,154-198) with new b€lt

li * When using a nsw belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off.
Readiust deflsction or tension to used belt values.

i !
Suspension- Section18 Unit of lengthmm {in

MEASUREMEIIT (NEWI
STANDARO SERVICELIMIT
Wheel Camber Front o" oo' r 10
argnment Rear -o" 45' 1 ' to
{2WS) Caster Front 20 40' !10
Total toe Front 0 r 2.0 (o !0.081
Rear rN 2.0 ! 2.0 t0.08 10.08)
Front whe€l turning angle Inward wheel 360 20' 12.
Outward wheel 290 40'
Carhber Front o" oo' i 10
alrgnment Bear -oo 45, 1300
{4WS} Caster Front 2040'!1.
Total toe Front o t 2.o(0 10.08)
Rear t N 2 . Ol 2 . O ( 0 . 0 8t O . O 8 l
Whgel turning angl€ Inward whoel Front 3 6 02 0 ' ! 2 "
Rear 6 . O O '! 1 "
Outward wheel Front 29" 20'
Rear 6" 20'
Rim runout {Aluminumwhe€l} Axial o-0.7 10-0.03) 2.OtO.08l
Radial o-o.7 (0-0.03) 1 . 5( 0 . 0 6 )
Rim runout (Steel wheell Axial o-1.0 (o-0.041 2.0 (o.08)
Radial 0-1.0 (o-0.041 r.5 to.o6)
Wheel bearinq End play Front 0-0.05(o.oo2)
Rear o-0.05(0.oo2l

Brakes Section
MEASUREMENT STANDARD(NEWI SEFVICELIMIT
Parkingbrake Playin strokeat 2OON (20 kg, 44lbsl lev€rforce To be locked when pulled
lever 6-10 notches
F""r braL Pedal height (with floor mat removod) M/T 1 6 5 { 6 . 5 }m i n .
pedal Atf 1 8 6 { 7 . 3 )m i n .
Free play 1-5(1/16-13/64)
M*t"|. "y["d* Piston'to-pushrod clearance Cars without ABS o-o.4(o-0.02)
Cars with ABS 0 - 0 . 2t o , o . 0 1 )
Oisc brake Disc thickness Front 23.O(0.09) 2 1 . O( 0 . 8 3 )
Rear 1 0 . 0( 0 . 3 9 ) 8.0(0.31t
Disc.unout Front 0,10 {o.004)
Rear o.10 (o.oo4)
Disc parsllslism Front ano rear 0.015 (0.ooo6t
Pad thickness ftont H22A1, H23A1 engine t r.u to.ogt 1 . 6( 0 . 0 6 )
H22A 1 engine 1 1 . O{ 0 . 4 3 ) 1 . 6( 0 . 0 6 )
Rear 9.0 {o.35) 1 . 6( 0 . 0 6 )

3-13
Standardsand Service Limits
Air Conditioning Section 22
MEASUREMENT STANDARD{NEW)
Air conditioning Lubricant capacity Condenser 10(1/3)
system cc (ll oz) Evaporator 30(1)
Line or hose 10 {r/3)
R€servoir 10(1/3)
Compressor Lubricant capacity cc {tl oz} 1 3 0 - 1 5 0( 4 1 / 3 - 5 )
Fieldcoil resistanceEt 68oF {2OoC)0 3.05-3.35
Pulley-to-pressureplate clearance 0.35-0.65(0.014-0.026)
Comprgasor Dollectionwith lOO N (10 kg, 22 lbs) 10.0-12.0{0.39-0.471with usedbelt
belt' between pulleys 4.5-7.0{0.18-O.28} with new b€lt
Belt tsnsion N (kg. lbs) 450-600 (45-60, 99-132) with used bslt
M€asured with belt tension gauge 950'1.150 (95'115, 209-254) with new bslt
. Wh* u"ing I new belt, adjust dellection or tension to now values. Run tho engine lor 5 minutes thsn turn it o{f
R€Ediustd€flgction or tension to used belt values

Electlical - Section 23
MEASUREMENT STAI{DARDINEW)
lgnitioncoil Rated voltage V 12
Primarywinding resistanc€8t 68 oF (2OoC)o 0.6-0.8
S€coodarvwinding resistanceat 68 oF (20ocl kO
Spark Plug Type S6e Sgction 23
Gap 1 . 0 - 1 . 1{ 0 . 3 9 - 0 . 4 3 )
lgnitiontiming At idling o BTOC 1 5 ol 2 o { R e d )STDC
Alternator belt' Defloctionwith 1OON (10 kg, 22 lbs) 10.5-12.5 (0.42-0.51) with used belt
between pulleys 8.O-10.0 {0.32-O.4Olwith new b€lt
Belt tension N (kg, lbsl 3OO-45O{30-45, 66-99} with usod belt
Mgasured with belt t€nsion gauge 550-750 {55-75, 121-165) with new belt
MEASUREMENT STANDARD{NEW) SERVICELIMIT
Alternator Output 13.5 V at hot A 80/90
(NIPPONDENSOCoil r€sistance (rotor) O 2 . 7- 3 . 1
SIip ring O.D. 1 4 . 2 - 1 4 .{40 . 5 6 - 0 . 5 7 } t r.e to.sot
Erush l€ngth 1 0 . 5( O . 4 1 ) 1 . 5t 0 . 0 6 )
Brush spring t€nsion g {oz) 300-360t10.6-12.7)
Starter motor Tvpo Spargearreduction,Permanent magn€t
(MITSUBA Mica depth 0.4-0.5(0.016-0.o20) 0.15 t0.oo6)
1.4 kW) Commutator runout o-0.02{o-0.ooo8) o.o5(0.oo2)
CommutatorO,O. 2 8 . 0 - 2 8 . (11 . 1 0 2 , 1 . 1 0 6 ) 2 7 . 5( 1 . 0 8 3 )
Brush length 15.8-16.2(0.62-O.64t 10.0(0.39)
Brush spring t6naion (new) N (kg, lbsl 1 6 . 0 , 1 8 . (01 . 6 0 - 1 . 8 0 ,
3.53-3.93)
Starter motor Tvpe Spargearreduction,Permanent magnet
(MITSUBA Mic8 depth 0.4-0.5(o.0'16-0.o20l 0 . 1 5( 0 . 0 0 6 )
1.6 kW) Commutator runout o-o.02{o-o.ooo8) 0.o5 t0.o02)
CommutatorO.D. 2 8 . 0 - 2 8 . (11 . 1 0 2 - 1 . 1 0 6 ) 2 7 . 5{ 1 . 0 8 3 )
Brush length 15 . 8 - 1 6 . 2 (0.62-0.64) 10.0 (0.39)
Brushspringtensionln€w) N lkg, lbs) 1 6 . 0 - 1 8 .(O1 . 6 0 - 1 . 8 0 ,
il 3.53-3.93)

ii
:1
!I
* When usanga new belt, adjust detlection or tonsion to new valuos. Run the engine lor 5 minutes then turn it ofl.
Re€djust detloction or tension to used bolt and values.

I
Design Specifications

Overall Length 4,440mm I 1 7 4 . 8j n


Ov€.all Width 1 , 7 6 5m m I 69.5 in
OverallHeight 1 , 2 9 0m m | 5 O . 8i n
Wheelbase 2 . 5 5 0m m I t O O . qi n
Track F/R 1 , 5 2 5 / 1 , 5 1 5m m i 6 0 . 0 / 5 9 . 6j n
GroundClearance 145 mm | 5.7 in

Type F22A1 engine Water-cooled, 4,srroke SOHC


gasolineengjne
H23A1 engine Water-cooled, 4-stroke DOHC
gasolineengine
H224l engine Water-cooled, 4-stroke DOHC
VTECgasolineengine
CylinderA.rangement Inline4-cyljnder,transverse

l Bore and
Stroke
F22A1 engine
H23A1 engine
H22A 1 enigne
8 5 . 0 x 9 5 . Om m
8 7 . 0 x 9 5 . Om m
8 7 . Ox 9 0 . 7 m m
3 . 3 5x 3 . 7 4 i n
3 . 4 2x 3 . 7 4 i n
3.43 x 3 57 in

l
OisplacementF22A1 engine 2 , 15 6 c m 3 ( c c ) 132cu-in
H23A1 €ngine 2,259 cm3 {cc) 138 cu-in
H22A'l engine 2,157cm3 (cc) 132 cu-in
Compression F22A1 engine 8.8 : 1
Ratio H23A1 engine 9.8:1
H22At engine 1 0 . 0: 1
Valve Train F22A1 engine

l
Belt driven,SOHC4-vatveper cytinder
H2341 engine Belt driven.DOHC4-valveper cytinder
H22A'l engine Belt drive,DOHC4,valveper cylinderVTEC
Lubrication System Forcedand wet sump, trochoidpump
Fu€l Required F22A1 engine UNLEADEDgradegasolinewith 86 pump
OctaneNumberor higher
H23A1, H22A1 engines PremiumUNLEADEDgradogasolinewith
91 Pump OctaneNumberor
Makes/Type MITSUBA/Spurgear reduction,
permanentmagnet
Normal Output 1.4 kW, 1.6 kW
NominalVoltage 12V
Hour Rating 30 seconds
Directionof Rotation Counterclockwise as viewedfrom gearend
3 . 7k s | 8 . 2l b s
MIT Singleplatesdry, diaphragmspring
Torque converter
M/T 203 cm2 | 31
TRANSMISSION Synchronized s-speed forward, 1 reverse
Electronically
controlled
-speed automatic, 1 reverse
Direct 1 : 1

GearRatio lsr
2nd
3rd
4th
5th
Reverse

4.062 1 4.266 1 4.266

(cont'd)

3-15
Design Specifications
(cont'd)
ITEM METRIC ENGLISTI NOTES

Automatic Engine tYPe F2241 H23A1


TRANSMISSION
{conl'dl GearRatio lst 2.705 2.705
2nd 1.442
3rd 1.028 1.057
4th o.701 0.750
5rh
Reverse 2.O47 2.O47
Final Rsduction Gear tYPe Singl€helicalgear
Gear ratio 4.285 | 4.428
'14,682BTU/h
AIR CONDITIONING Cooling Capacity 3,7O0Kcauh
Conditions:
compressor Speed 1 , 8 0 ( rpm
Outsid€ Air Temparature 81 0F
Outeide Air HumidilY 50 %
Cond€nserAir TemPerature 35 0C 95.F
CondenserAir VelocitY 2.5 mlsec 8.2ltlsec
Blower Capacity 460 m3/h 16,247 ctt-ftlh
Compressor Typg/M€kes ScrooltyP€/SANDEN
No. oI cylinder
CaPacitY 85.7 cc/rev | 5.23 cu-in/rev
Max. Sp€sd 10,000 rpm
Lubric8nt CaPacitY 130 cc I 4 1/3 tl oz sP-10
Condenser TyPe Corrugatodlin type
Evaporator Type Corrugated lin type
Elower Type Sirocco lan
Motor Input 220 Wl12 V
Speod Control 4-spsod
Max. CaPacity 460 m3/h I 16.247 cu-ft/h
Temp. Control Air-mix type
Comp, Clutch Type Dry, single plat€, poly-V'belt drive
Power ConsumPtion 42 W max.l12 V
Rotrigerant Type F-l34a
Ouantity osO-8os 1 t8.a-9.ao
oz
STEERNG Type Power as8isted, rack and Pinion
SYSTEM Ovorgll R€tio 2 W S : 1 5 . 8 6 , 4 W S :1 5 . 1
Turns, Lock-to-Lock 2wS: 2.91, 4WSt 2'77
Steedng Whosl Di6. 380 mm I 15.0 in
SUSPENSION Type. Front lndependent double wishbone,
coil spring with stabilizer
Type, Rsar lndeDendentdouble wishbone,
coil spring with stabilizer
Shock Absorber, Front and R€ar Tolescopic, hydraulic nitrogen gas-filled

t,
l.,i
Camber Front
Rear
Caster
Front Omm i oin
Rear In 2.O mm I In 0.08 in
BRAKESYSTEM Type, Front Power-assistedselt,adjusting
ventilated disc
llear Power-assistodselt-adjustingsotid disc
Pad and LiningSurfaceArea: Front 5 8 . O c m 2x 2 8.99sq-inx2
I
Rear 27.Ocmzx2 | 4 . 1 9 s q - i n x2
ParkingErakeKind and Type Mechanical actuating, rear two whsel
brakes
Size 1 8 5 / 7 0R 1 4 8 7 H . 1
'1:S 2 0 5 / 5 5R 1 5 8 7 V * 2
f125l7o O l5 {Sparetirel *r
T135/80D 15 {Sparerire)*2
ELECTRICAL Battery 12 V-55AH/5HR
Starter 1 2 V - 1 . 4k W , 1 2 V - . t . 6k W
Allernator 1 2 V - 9 0A , 8 0 A
FusesIn UndeFdashFuse/Relay Box 7 . 5 A . ' 1 0A , 1 5 A , 2 0 A , 3 0 A
In UndeFhoodFuse/Flelay
Box 7 . 5A , 1 0 A , 1 5 A , 2 0 A , 4 0 A ,
50 A. 60 A, 100 A
1 2 V - 6 5W
1 2 V - 5 5W
FrontTurn SignalLights 1 2 V - 3 2C P
Front ParkingLights 1 2 V _ 5W
RearTurn SignalLights 1 2 V - 4 5C P
Brake/Taillights 12 V-43t3CP
High Mount BrakeLight 12 V -21 CP
Side Marker Lights Front 1 2 V - 3C P
Rear '12v-3 cP
Back{p Lights 1 2 V - 3 2W
LicensePlateLights 1 2 V - 8W
InteriorLights 1 2V , 8W
Trunk Lights 1 2 V - 3 . 4W
GaugeLights 1 2 V - 3 . 0W , 1 . 4W
IndicatorLighrs 'l2v-1.12W ,
1 . 4W , 3 . 0 W , 3 . 2 W
WarningLights 12V-1.4 W
llluminationand Pilot Lights 1 2 V - 1 . 4W , 1 . 1 2W , 0 . 8 4W , L E O
1 2 V - 1 . 4W

3-17
Body Specifications

Unit: mm (in)

I
lr;i
Maintenance

Lubrication
Points ..........4-z
MaintenanceSchedule ... 4-4
I
{lI LubricationPoints

Indexand variouswolk pro-


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

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

Transmission Manual API ServiceGrade:SF or SG


SAE viscosity:
10W-30or1OW-40
Automatic HondaPremiumFormulaAulomaticTransmission
Fluidor an equivalentDEXRON@II Automatic
transmissionfluid
Brakefluid DOT3 or DOT4
Brak€fluid DOT3 or DOT4
SteeringgreaseP/N 08733 - BOTOt

Shift lever pivots (Manualtransmission)


Releasefork {Manualtransmission)
Steeringboots
Steeringball joints
Selectlever (Automatictransmission)
Pedallinkage
lntermediateshaft
Brakemaster cylinderPushrod
Trunk hingesand latch
Door hingesupper/lowerand latches
Door openingdetents
Fuelfill lid
Enginehood hingesand enginehood latch
Clutch mastercYlinderPushrod
Throttle cable end
Caliper Pistonseal. Dust seal,
Caliperpin, Piston
Shift and select cable ends
Hondapower steeringfluid-V
Comoressoroil SPlO P/N 38899-P13-OO3

Selectthe oil for your car accordingto this chart:


l

I 'l
F22A1,H23A1ongine
Amblent Temoeraturo

An oil with a viscosityoJ 5 W-30 is preferredfor im- An oil with a viscosityof 1O W-30 is preferred
provedtuel economyand year-roundprotectionin the for improved{uel economYand year-roundprotec-
car. You may use a 1O W-30 oil il the climatein tion in the car. You may use a 5 W-30 oil if the
your area is limitedto the temperaturerange snown climatein your area is within the temperature
on the chart. range shown on the chart

L 4-2
4-3
MaintenanceSchedule

3.e .g
E.9
e9 P E
B E
z 6
[€
dcicicidd 3 *
o o'- L l l
'=u ;z ;z "- 1x E '
+r+rE 1! 6:-:---
stststdstst6 Oo r
o ; o . 9 == *2 .!:
];;.
22-?=
a a96
q 6
.l c? ': ': ': ''l 6
t : - E ; F-..j.". B '
gci ai.+

; p
l l l i
i ; 9
P ; 4 P1 :td:
,i.ib9-
= c ; 6
P.9 BETH-I
t i ;!. t P . :E i; Eq -o N N A : ; is.sd
t_c ::r^H
E,i!,iE,i=i ; d
u J ; Ee
z 2 z z o
e c . r c .;Y =s

.eE

t o >

i i3FF
1 e : - -
E 3-E<3S
3
ie'Nll

'

ll E

l.'i ;g
E
8
.::
< 9
a 9

Q !
c 6

6 5
9 o
; b 6
= :
'd
i 6
6 3

z
.E -x

b i
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E< 6 E
F:
!E! E! iE! ; !J: E E :
,6 9,.oi o. )rdc, 99o o; ; :
e
I:-;-;-;E;-;i a E
9 +
9 o
; E 3 3 3 e F3 3 ;
; !r'.on.goo
-Ee
-: aj + { 6 ci ai ; 95
H5**-*-E:*i
S:|t)6o:nF -o *iS
(J:('l'!r<ooo . , ii k 'st 5B
6 . >
q 3 5

: -5
€ d E

i S ee P P
i - ' . sb i.i 6, F
; P :
6P ; * g t
aisiis!

-g
E

E
I
':
l

i l

4-5
MaintenanceSchedule(cont'd)

P P " ;
E * 6 - b
g 6 : ( l .
> . o ; 6

t t < = . 9
s €:R E
(,) * Ee6- ts
3 E EE! E
o E E l3! s
2 \ i o E
t ; E e i EE
: E € E:
!;,i.8 !
I i i E
9 E
o
F
'E ;-E
5 o :
o
a

o 6
6 i
c'6
' 6 C
- g

BE
li
3 r;E;i
i
8ri n;;
ai
tE€ii:5
;3 5
5 . e3
<
z EE R # ; : T
; i ; oo E
-;;;Eg;E
EE::i;EF
9i:!;srs
;
i$:EsiEi
.i;"qHE!.i€
L 6
;;igxB:E
.9
a
li ;oEdds-:s
; , t t t I

P
E

ir E

l E -
.4
E 9 9 . 8
i

E
b c E
ri c
i -
r a
: >
- b
i
. ! c ; t

st : 6E E !E- €; !; E=
E
I
,e!EE tEE '9!ccE E
r
!*
!

I
.9
I cii€Fi:!i;
ri 3E8 <,iddci,ii,!

4-6
Engine

Constructionand Function
lH22Al engine) . . . . . . . . . .5 - 1
E n g i n eR e m o v a l / l n s t a l l a t i.o. .n. . . . . . . . . . .5. - 1 7
C y l i n d eH
r e a d / V a l vTer a i n . . . . . . . . . . . . . . . .6. - 1
E n g i nB e f o c k. . . . . . . . .........7-1
E n g i n eL u b r i c a t i o n . . . . . . . . .8 - 1
IntakeManifold/Exhaust System ........ 9-1
Cooling . . . . . .1 0 - 1
Construction
and Function
lH22A1 enginel
Outline
Description ................5-2
VTEC
Outline .... 5-4
Mechanism ................5-6
Control System ...........5-7
GylinderHead
Outline .... 5-9
Camshafts . . . . . . . . . . . . . .5. .-.1 0
ValvesandValveSprings............... 5-11
BeltTensioner
Outfine ....5-12
A u t o - T e n s i o n. .e. r. . . . . . . . . . . . . . . . . . . .5. .-1
. .3. .
C y l i n d e r B l o c. .k. . . . . . ......5 . -14
OilFlow ......5-15
Outline
Description
cooledand
ThenewH22A1 engineis an in-line4-cylinderDoHc designdisplacing2,157 cm31131.6 cu in) lt is water
equipped with a centerplug type pent-root combustion chamber. lt is specifiedto use premium unleadedfuel and usesa
pGM-Fl(SequentialMultipon FuelIniection)system.This engineincorporatesa mechanism calledHonda Variable Valve
Timing and Valve Lift ElectronicControl (VTEC) System.
This ststem allowsthe timing and litt oJthe intakeand exhaustvalvesto be changedsimultaneously. The enginealsoin-
cludesa electronically-controlled intake manitold system that varies the volume of the intake chamber.

i
I
il

5-2
L.
nd ll!i)r Specificstions

Type Water cooled4-stroke,In-line4-cylindergasolineengine


Oisplacement 2 , 1 5 7 c m 3( 1 3 1 . 6 c u - i n )
tn-
Eore x Stroke 8 7 . Ox 9 0 . 7 m m t 3 . 4 3 x 3 . 5 7 i n l
CompressionRatio 1O.O:1
Cam, Valve Mechanism Dual over-headcamshaft,VTEC
Valve Train
FuelSupply System SequentialMultipon Fuel Injection{SFl)

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

5-3
VTEC
Outline

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

i CAMSHAFT

lr
r'l
CAM LOBESFOR LOW RPM
CAM LOBESFOR HIGH RPM
PRIMARYBOCKERARM
MID ROCKERARM
il SECONDARYROCKERARM
HYDRAULICPISTON(A}
HYORAULICPISTOI{ {AI
STOPPERPISTON
LOST MOTION ASSEMBLY
EXHAUST VALVE
INTAKE VALVE

5-4
rd In g€noral,it would be idealif the high rpm performanceof a racingengineand the low rpm pertormanceot a standard
!d passengercar enginecould be combinedin a singleengine.This would resultin a maximumperformanc€enginewith a
wid6 power band. Two of the major differencesbetweenracingenginesand standardenginesare the timing ot the in-
take/6xhaustvalvesand the degreeof valve lift. Racingengineshsve longerintake/exhaust timing and a highervalvelift
than standardengines,The Honda VariableValve Timing and Valve Lift ElectronicControlSystemtakes this into ac-
count, Wh€n valve actuationis set for low rpm timing and lift, low rpm torque is betterthan in a standardengine.Whon
valve actuationis then switchedlor high rpm timing and lift, output improvesto the levelgiven by a racingengine.Until
now. tew variablevalvetiming systemshave beencommercialized, In thosethat have,only the time that both vatves8re
open (intake/exhaust overlap)could be changed.Honda'ssystem is the first in the world in which both the valvetiming
and the degreeof valve litt can be changedas needed,makingit the most advancedvalve train mechanismavailable.

RacingEngine VTEC Engine StandardEngine

Valve Timing
(exhsust/intake) i
Valve Lift
Erh.u.t lntrk€ Erhrurt lntlk Exhlult Intrko

Max. Power
Low rpm Torque
ldling stability
'TDC = Top Dead Center *BDC = Bottom Dead Center
O = Ootimum Characteristic

The engineis equippedwith two valve timing and valve lift settingswhich changeaccordingto drivingconditions.

RPM switch ovgr


pornt

5-5
VTEC
Mechanism
At Low rpm:
Asshown,theprimaryandsecondaryrockelarmsalenotconnectedtothemidrockerarmbutaledrivenseparSte|yby
cam|obesAandBatdifferenttimrngandIift.A|thoughthemidrockera.misfo||owingthecentercam|obewiththe|ost-
valvesin the low rpm range'
motion assembly,it has no effect on the openingand closingof the

At Low rpm:
CAM PROFILESFOR
LOW RPM

CAMSHAFT

*A and B cam lobes


ddve the rocker arma
sepsrot6lY

RETURNSPftNG

HYDRAULIC
PISTON(AI PISTON
STOPPER
HYDRAULIC
PISTONIBI SECONDARY
PRIMARY MID ROCKEBARM
ROCKERARM ROCKERARM

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

At High Dm:
CAM PNOFILEFOR
HIGHRPII

I *The rock€r arms ere linked

l, ;
+ via the hydraulic Piston.
Cam lobe C drives the rocker
arms.
il
STOPP€R
PISTON

HYDRAULIC HYDNAULIC
PISTON (AI PISTON(B)

5-6
ControlSystem
The controlsystemfor this mechanism,as shown below, constantlymonitorsthe changesin enginestatussuch as load,
rpm and vehiclespeed.this intormationis transmittedto the EngineControlModule {ECM).

Valv€ Timing ChEngeConditions


Englne Speed: 4,9OO nm or higher
Vohicle Spood: 19 mph (3O km/hl 01 tastel
Engino Coolant Temperature: lrtooF {6OoC) or higher

ControlSystem

VTEC PRESSURESWITCH
VTECSOLENOIDVALVE

Et{Gtt{E
CONTROL
MODULE
F.oft {ECM)
OILPUMP +

5-7
ControlSystem(cont'd)
I

Lost Motlon Machanbm


at low sps€ds' At low spoeds' th€ lost motion
The mid rock€r arm is always driven by the high-spesd cam lobe' even
mechanismkeepsthemidrockerarmincontactwiththehigh.speedcam|obe'Athighsp6€ds,the|ostmotion
mechanismscts as part of the valve spring load'

CAM PfiOFILE

SPRII{G

SPRIIIGA

RETAINEN

GUIDEHOLDER

LOSTMOTIONASSEMELY

I Hydraulic Prg$ure Contlol Machanism


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

i
I's
t. l:

5-8
CylinderHead
Outline

The one-piececylinderhead is made of aluminumalloy to reducethe weight while increasingefficiency


The combustionchamberis a compactpent roof shape,centerplugtype. The cylinderheadusesa DOHC4-valvesystem
with 2 intakevalvesand 2 exhaustvalvesarrangedfor cross flow. Combustionis stabledue to the optimizationof the
ignitiontiming, compressionratio and valve timing.

EXHAUST
CAMSHAFT
INTAKE
CAMSXAFT
EXHAUST
ROCKERARM

II{TAKE
ROCKERARM

EXHAUSTPORT

INTAKE PORT

INTAKEVALVE

EXHAUSTVALVE

5-9
GylinderHead
Camshafts

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

EXHAUST A: PRIMARY
B: MID
C: SECONOARY

CAMSHAFTJOURNALS

II{TAKE

CAMSHAFTJOURNALS

Low-speedvalve timing High-speod valve timing

<F i Intok6 valva opon


- : Exhau3t vslvg opon

INTAKEA INTAKE B

€XHAUSTB

INTAKE C

TDC: Top dead center


BDC: Bottomdead center
Valves and Valve Springs

t€- The valves are openedand closedby rocke. arms driven by the camshatt.
,c Light weight and large diametervalves made ot a high strength metal with small diameterstems are used. The air
lm resistanceis decreasedby the slenderstems and the intakeefticiencyis inc.easedby inlet ports that match with laroe
diametervalves,

Valve specitications
U n i t :m m ( i n )
VALVE
ITEM INTAKE EXHAUST

HEAD DIAMETER 3 5 . O( 1 . 3 8 ) 3 0 . o{ 1 . 1 8 )
STEMDIAMETER 5.5 tO.22l 5.5 lO.22l
OVERALLLENGTH r 0 6 . 7 5( 4 . 2 0 3 ) ' 1 0 6 . 9(54 . 2 r
1)
VALVE LIFT Secondary:8.O (O.31) S e c o n d a r y : 7 . 5( O . 3 O )
Mid: 11 . 5 ( O . 4 5 ) * Mid: 1 O . 5( O . 4 1 1 *
Primary: 6.5 (O.26) P r i m a r y : 6 . O{ 0 . 2 4 )
* Indicateshigh-speed valves

I oVERALLLENGTH

Fr
| | ,/|l

ffir HEAD
DIAMETER

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

EGG SHAPE LEMON SHAPE

5-11
Belt Tensioner
Outline
ThetensionersforthebaIancersha'tdrivebe|tandthetimingbe|tarearrangedinpara||e|onasing|eaxisforamolecom
pact configuration,This tensionerallows easv belt maintenance'

TIMING BELT

WATER PUMP
PULLEY

TENSIOI{ERSPRINGfol
TIMING BALAIIICERBELT

AUTO.
for TIMING BELT

MAINTENANCEBOLT

TIMI G AELT
AOJUSTER

BALANCERBELT
TENSIONER

5-12
- Auto-tensioner

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

SCREWIMALEI

Machanbm:
8€lt Ro6ctlon Fo.ce

o The male screw is


rotated by the
ri The lemale rod is O The rod stops when the force
pushedout as lhe oI the torsion spring and
lorsron spflng. rod rotates, the timing belt equalize.

5-13
CylinderBlock

madeoJ FRM,a composite


The cylinderblock is a closeddeck designmadeof aluminumalloy . The cylindersleevesare
materialof aluminum, alumina tiber and carboniiber. The boresin the cylinderblockfor the shaftsand the deep
balancer
skirt designimprovethe rigidityof the block.

Cylinder spocitications

Bore x Stroke 8 7 . Ox 9 0 . 7 m m ( 3 . 4 3 x 3 . 5 7 i n )
Bore Pitch 9 4 . Om m ( 3 . 7 Oi n )
Block Height 2 1 9 . 5 2( 8 . 6 4 3i n )
Skirt Depth 5 0 . Om m ( 1. 9 7 i n )
Displacement 2 . 1 5 7 c m 3( 1 3 1. 6 c u - i n )

7.0 mm {0.28 inl

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

iEff
^ ,.\ /zr .\ ^

BALA'{CERSI{AFT
BORES
Oil Flow

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

INTAKECAMSHAFT

OIL CONTROL
ORIFICE
VTEC SOLENOID
VALVE

CAMSHAFT HOLDER
PIPEOIL VTEC
PRESSUBE
swtTcH

€IHAUST CAMSHAFT
.XXJRI{AL

ENGINEOIL COOLER

ENGINECOOI"ANT
ENGINEOIL FILTER
FRONTBALANCER
ENGINEOIL PRESSURESWITCH

OIL JET
NOZZLE

REAR BALANCER

(cont'd)

5-15
Oil Flow
(cont'd)

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

r
)
VTEC SOLEIIOIDVALVE

OIL CONTROL
ORIFICE
ENGINEOIL FILTER
ENGINEOIL COOLER

OIL JET
NOZZLE
EngineRemoval/lnstallation
EngineRemoval/lnstallation

@
frla-i6iwe iacks and saletY stands 8re placod ploper-
5. Loosenthe drain plug on the radaator.

ly and hoist brackots are attachod to the corr'ct 6. Drainthe transmissionoil/lluid. Reinstallthe drain
positions on th€ 6ngin6. plug using a new washer.
a Mako suls tho car will not roll ofl stands 6nd lall
whlle you are working undal it. 7 . Orainthe engineoil. Reinstallthe drainplug usinga
new wasnef.
CAUTION:
a Use tend€l covers to svoid damaging paint€d CAUTION: Do not ovsrtighlan tho dlain plug'
surtacas.
a Unspocified itoma alo common 8. Lower the hoist.
a Unplug th€ wiring connoctolE carstullY while holding
the connoctor portion to avoid damago. 9. Removethe air cleanerhousingand intakeair duct'
a Mark all wiring and hosas to avoid miaconnection. 6 x 1.O ]||m
Also. bo 3u1€that thoy do not contact othar witing ol 10 .m {1.0 ks-m, 8 lb-ftl
hosos or into.ler€nco with othar parts.

NOTE: The radiomay hsve a codedthett protectioncir-


cuit. Be sureto get the customer'scode numb€rbelore
- Disconnecting the battery.
- Romovingthe No. 43 (10 A) Juse(ln the under-hood
tuse/relavboxl.
- Removingthe radio.
Atter service,reconnectpower to the radio and turn at
on.
"CODE" is displayed. enter the
When the word
customer's5-digit code to restoreradio operation.

1. Securethe hood as far open as possible.

2. Disconnectthe batterynegativeterminaltirst, then


the positivetetminal.
AIRCLEA'{EFHOUSI'{G
3. Removethe radiatorcap
1O. Removethe pulsed secondaryair iniectionIPAIR)
use care vuhonremoving tho radiator vacuum tank and bracket.
!@
cap lo avoid scalding by hot coolant ol atoam. PAIR
VACUUMTANK
4. Raisethe hoist to full height.
Remove the Jront wheels and the engine splssh
shield. 6x1.Omm
lO N.m 11.0kg-m,
I rb-trl

6 x 1 . Om m
'10t{.m (1.O kg-m,
a tb-ft|

BRACKET

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

5-18
11. Remove the battery, battery base, battery cable CAUTION:
and starter cable. a B€fore disconnocting any fu6l line, r6li€vs the
tuel pr€ssur€ os dosc.ibod above.
MANUALTRANSMISSION
tM/TI: a Place I shop towol ovel the tu€ltilter to prevent
prossulizod tuol trom sprsying ovor tho ongine.
8 r 1,25rnm
22 tt.m 12.2kg-m,
16 tb-ft) 13. Removethe fuel feed hose from the fuel rail.

WASHER

STARTER CABLE
AUTOMATIC
TRANSMISSION
{A/r}:

NOTE: When installingthe starter cable clamp.


make sure the tab is in the hole in the bracket,

14. Removethe injectorresistorconnectoron th8 left


side of enginecompartment.

INJECTOR
6x1.0mm RESISTOR
10 N.m {1.0 kg-m, INJECTOR

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

1 2 . Relievefuel pressureby slowly looseningthe ser-


vice bolt on the fuel rail aboutone turn (seesection
11 ) .

@ Do not smoke while working on tu€l


systom. Keop opsn tlame or spark away ttom work
alaa. Drain tuol only into an apptoved containet. (cont'd)

5-19
EngineRemoval/lnstallation
(cont'd)
emis-
15. Removethe throttlecableby looseningthe locknut' 18. Removethe brakeboostervacuum hoss and
sion control vacuum tubes from the intake
then slip the cableend out of the throttle linkage'
manilold.
NOTE; IEVAPICONTROL
EMISSION
EVAPORATIVE
a Take care not to bend the cablewhen removlng
it. Always replaceany kinked cable with a new
one.
a Adiust the throttle cable when installing(see
s e c t i o n1 1 ) .

BRAKEBOOSTER
VACUUMHOSE

1 9 .Disconnect the connector and vacuum tube' th€n


I remove th€ cruise control actuatol.

NUT
ADJUSYING

Ir to. Removethe engine wire harnessconnectors.rer-


minal snd clamps on the right side of engine
compartment.
CRUISECO'{TROL
ACTUATOR

8r1.Omm
10 .m (1.o kg-m,
7 tb-frl
Bemove the power cable from the under-hood
tuse/relaybox.

POWERCABLE UNDER.HOOD

t l

Il'
20. Remove the engine g.ound cable from the body 23. Loosenthe alternatormounting bolt, nut and ad-
side. justing nut, then removethe alternatorbelt,
21. Removethe power steering (p/Sl pump belt and
pump. MOUNTING EOLT
a Do not disconnectthe p/S hoses.

8 x 1.25 rhm
22 .m (2.2 kg-m.
t8

ALTERNATOR
AELT
PI,MPBELT
LOCKI{UT

r 1 . 2 5m m
22 N.m {2.2 kg-m, 16 tb-frl
P/S PUMP 24. Loosen the mounting bolt, then remove the A/C
compressof.Disconnectthe connector.
a Do not disconnectthe A/C noses.
22. Rsmove the air conditioning{A/C} condenserlan
shroud. then install a protector Dlate on the
radiator.

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

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

(conr'd)

5-21
EngineRemoval/lnstallation
(cont'd)

25, Removethe upperand lower radiatorhosesandthe 27. Removethe shift cable and selectcable (M/T)'
heaterhoses.
NOTE:
a Take care not to bend the cablewhen removing
it. Always replaceany kinkedcablewith a new
one.
a Adjust the shiJtcable and seleci cable when in-
stalling(seesection 13).
I x 1 . 2 5m m

WASHER

BRACKET

i WASHER
\ SELECT
CAELE
COTTER
Roplace. PI.ASTIC WASHCR
STEELWASHER
26. Remove the transmissionground cable and the
automatic transmissionfluid (ATF) cooler hoses Removeth€ clutch slave cylinder and the pipe/hose
(A/T).
assembly(M/T).

NOTE:
a Do not ooerate the clutch pedal once the slave
cvlinderhas been lemoved.
a Take care not to bend the PiPe.

ASSEMBLY

SLAVECYLINDEB

t
I

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

5-22
29, Removethe clutch damperassembly. 31. Raisethe hoist to ful hoight.

NOTE: Take care not to bend the pipe. 32. Removethe exhaust pipe A and bracket.
tng

CLUTCHDAMPER GASKET SEI.F-LOCKIIIGNUT


rin- 18 N.m {1.8 ks-m, t3 tb-ft}
Replace.

@'

tHER

8 r 1 . 2 5m m
nc 22 N.m 12.2kg-m,
IER t6 tb_ftl
I{UT
55 N.tn (5.5 kg-h, 40 b-trl EXHAUSTPIPEA
Replace.
30. Remove the vehicle speed sensor {VSS)/power
steeringlPlS) speedsensorassembly.
33. Removethe A/T shift cable (A/T).
NOTE: Do not disconnectthe noses.
NOTE:
a Take ca.e not to bend the cable when removing
18 N.m (1.8 kg-m, it. Always r€placeany kinkedcable with a new
one.
ilave
a Adiust the shift cable when installing (see sec-
tion 14).

ISLY

P/S

6 x 1 . Om m
10 N.m (1.0 kg-m, 7 lb-ft)

tg N.m (1.8 kg-m,


13 tb-ftl (cont'dl

5-23
EngineRemoval/lnstallation
(cont'd)

34. Bemove the damper fork.


36. Removethe driveshafts.

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

I
I
h
t

I 1 2 x 1 . 2 5m m
65 N'm 185 kg-m,47 lb-ftI
DRIVESHAFT

RePlace.

|l 35. Disconnectthe suspensionlower arm balljointwith


the special tool. Refer to section 18 tor the
37. Swing the driveshaftunder the fender.

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

PLASTICBAG

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

fl 36-43 tb-ft)
38. Lower the hoist.
39. Attach the chain hoist to the engine.

5-25
EngineRemoval/lnstallation
lcont'd)

40. Removethe rear mount bracket 42. Removethe lelt side enginemount.

BEAR STIFFENER

4 3 . Remove the transmrsslon and mount


bracket.
41. Removethe front mount bracket.

44. Raisethe chain hoist to removeall slack from the

l
i'
chain.

45. Checkthat the engineis completelyfree of vacuum


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

46, Slowly raisethe engineapproximately150 mm {6


an).
Check once again that all hoses and wires have
been disconnectedtrom the engane.

47. Raisethe engineallthe way and removeit Jromthe


car.

5-26
48. Installth8 enginein the reverseord€r of removal. a Check that the spring clip on the end ot each
driveshaftclicks in to olace.
NOTE: After the engineis in place:
a Torque the engine mounting bolts in the s€- CAUTION: lnstall now spring cllps
quence shown below.
Eleed air from the cooling system at the bleed
CAUTION: Fallur€to tlghton the bolts In the p?opor bolt with the heatervalve open.
aoquencccln cauae orcegtivo noiar and vlbrstion. a Adjust the throttle cable tension.
and rcduce bushing litc; check thst thc bushing! a Checkthe clutch pedalfree play {M/T).
aro not twirtrd or offsot. a Check thst the transmissionshifts into gear
smoothly.
l 2 x 1 . 2 6m m
1 0 r 1 . 2 5m m REAR MOUITIT @ es .m le.s tg-m,
TRAIISMISSIOT{
MOUI{T @2r 'm t2.1 1s b-ft} 47 b-trl
1 0 r 1 , 2 5m m R€place.
39 .m {3.9 kg-m.28lb-ft}

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

O Tightsnsnugonty. 12 x 1.25mrn
1 2 r 1 . 2 5m m
@ 65 t{.h {6.5 kg-h, 47 b-trl O 55 .m 15.5ks-m, 40 tb-trl
ReDlace.

12 x 1.25mm
@ 65 .ln (6.5 kg-m, 47 tb".ft)
RgDlac6.
FROI{TMOUI{T
SIDEE'{GI E
IIOUNT

the
12| 7.29
@ 55 .m (5.5lg-ln, 40
tum
'acal

r {6

6Ve NOTE:
. Torque th€ mounting bolts/nuts in the
numbgred s€quenceas shown (O-@).
. After road t6sting, loosen and r€tighten @ Tighten only.
@ Tighton snug onty.
the l O x 1 . 2 5m m the thre€ bolts on the front r'lount 1 2 r 1 . 2 5m m
@ 39 N.m (3.9 kg-m,28 tb.ft} brackoi. O 65 t{.m lO.5 kg-m,47 tb-ftl (cont'dl

5-27
EngineRemoval/lnstallation
(cont'd)

a Adiust the tensionof the following drive belts: a InsDectfor fuel leakage.
Alternatorbelt (section23). After connectingall tuel line parts. turn on the
Power steeringpump belt (section17). ignition switch (do not operate the starterl so
Air conditionercompressorbelt {section22). that the fuel pump operatesfor approximately
a Clean battery posts and cable tetminals with two seconds and the fuel line is pressurized.
sandpaper,assemble,then apply greaseto pre- Repeatthis operationtwo or three times, then
vent corrosron. check for fuel leakageat any point in the Juel
line.

Mount and BracketBolts/NutsTorque Value Specifications:

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

REABMOUNT
TRANSMISSION 10 r 1.25mm
MOUNT '10 r '1.25mm 39 N.m 13.9kg-m,
BRACKET 39 N.m (3.9 kg-m, 28 lb-tt)
2a tb-ft|

(Standardfor
some tvpos)

SIDE ENGINE '10x 1.25mrr


MOUNTING BRACKET 48 N.m (4.8 kg-m.
35 tb-ft|

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

Et{GINEMOUNT
BRACKETA
h
!r
lO x 1.25mm
45 N.m {4.5 kg-m,
33 lb-tr)
12 x 1.25mm
95 N.m (9.5 kg-rn,69 lb-ftl FRONTMOUNT 8 x 1 . 2 5m m
22 N.n 12.2ks-m,
16 rb-ft|

lO x '1.25mm
48 N.m (4.8 kg-m, 35 lb-ft)

5-28
AdditionalTorqueValue Specifications;
P/S BRACKET
{F22A1 onginol

TRANSMISSIONMOUNT BOLTS
65 N.m 16.5kg-m,47 lb-ftl
8 x 1,25mm
22 N.m 12,2 kg-m,
16 tb-ftt

.ft)
INTAKE MANIFOLO

x 1.25mm
50 N.m {5.O kg-m,
36 rb-ftt
8 x 1.25mm
N.m {2.2 kg-m, 16lb-ftt

EXHAUST MANIFOI.D
BRACKET 10 x 1.25mm
50 N.m {5.O kg-m, 36 lb-frl
P/SBRACKET
(H23A1,H22Al ongino)

tg-m,

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

I for 1 0 x 1 . 2 5m m
es) 50 .m {5.Okg-m,36 lb-trl

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

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

5-29
Cylinder Head/ValveTrain

F22A-1engine ............... 6-1


H 2 3 A 1e n g i n e . . . . . . . . . . . .6. .- 3 7
H22Al engine .............. 6-71
CylinderHeadA/alveTrain
lF22A1 enginel
SpeciafTools .........6-2 Valve Seats
l l l u s t r a t oIdn d e x . . . . . . . . . . . . . . . . . . . . . . .6. .-.3. Reconditioning .... 6-17
Valve Seals Valve Guides
Replacement (Gylinder head V a l v eM o v e m e n.t. . . . . . . . . . . . . . . . . .6. -. .1. 8
removalnot r€quiredl .............6-5 Replacement .......6-19
CylinderHead Reaming .............6-20
Removal . . . . . . . . . . . .6. - 7 Camshaft/Rocker Arms and
Warpage ............6-18 CamshaftSeals/Pulley
Installation .........6-23 fnstalfation .........6-22
Camshaft Pulley Timing Belt and Timing BalancerBelt
Removal .............6-12 lllustrated Indox ........................ 6-25
Rocker Arm Assembly Replacemont .......6-29
Removal . . . . . . . . . . . . . 6 - 1 2 Timing Belt
Rocker Arms lnspection ..........6-26
Overhaul . . . . . . . . . . .6. - 1 3 TensionAdjustment ................... 6-26
Clearance ...........6-15 PositioningCrankshaftBefore
Camshaft lnstalling TimingBelt .............. 6-28
Inspection . . . . . . . . . . 6 - 1 4 Timing BalancerBelt
Valves, Valve Springs and Valve Seals fnspection ..........6-27
Removal . . . . . . . . . . . .6. - 1 6 Valve Clearance
Valve Spring and Valve S6al Adjustment .........6-34
InstallationSequence..............6-21
Valve Installation....................... 6-2 1
SpecialTools

Ref. No. I Tool [tlumber


6-20
o 07HAH-PJ701OAor Valve Guide Reamer,5.5 mm
OTHAH_PJ701OB
6-22
o OTNAF_PTOOlOA InstallerCUP
lnstaller Shalt 6-22
@ OTNAF_PTOO20A
OA Seal Guide 6-22
@ OTNAG-PTOOl
Valve Guide Driv€r, 5.5 mm 6 - 1 9 ,2 0
@ o7742-OO10100

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

@
o @

@
fllustratedIndex

CAUTION:
a To avoid damaging the cyllnder head. wsit until th6 engine coolant tompe.aturo drops bolow loooF {38ocl b€foro
romoving it.
a In handling a metal gaskot. tak6 caro not to fold it or damago the contacl surtaco ot tho gasket.

NOTE:
a Use new O-ringsand gasketswhen reassembling,
a Cleanthe oil control orifice before installino.

CAP NUT
6 r 1.0 rrn ?
10 N.m11.Okg-m.7lb-ftI

HEADCOVER
CYLII{OER

RUBEER SEALS
R€placowhon dEmag€d
or d€teriorst€d.
Put longer bolt
CYUITDER HEADBOLT
1 2 r 1 . 2 5m m
R 1OO ,m (lO.Okg{n, 72 lb-ft}

T Tightening.page6-23
Apply sngineoil to the thrgadg.

CYLII{DERHEAD

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

DOWELPI'{

otl coilTRol oRtFtcE


Clean.

O.RING
Roplace.

8 r 1.25mrn
CYLINDERHEADGASKET 22 t{,m (2.2 kg-m, 16 lb-ftl
{METALGASKETI
R€olacg. TIMINGBELT
Rsplacement,page 6-29
Inspoction/Adjustmont,
page 6-26

--- AD.'UST|IG ruT


./--'77'---)
10 r 1.25mm
45 [.m 14.5 kg-m, 33 lb-ft,
Loos6n, but do not r6movg.

(cont'd)

6-3
lllustratedIndex
(cont'd)
nl cleanall the partsin solvent,dry them.nd applylubricantto any contsctparts'
,rto, to teassembling,

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

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

ROCKEBARM ASSEMBLY
VALVE ADJUSTING SCREW Ovorhsul,pag€ 6-13
7 r 0.75 mm lnspoction, page 6-1 5
20 .m (2.0 kg-m, 14 lb-ft,
Apply oil.
Adjustment, psge 6-34

SEAL
lnstdflation, page 6-22
R€place.
oo*:..rn-y' E
;
CAMSHAFTPULLEY
Romovsl, page6-12
Installation,pago6-22

CAMSHAFT 8 x 1.25 mm
38 .m (3.8 kg-m.27 lb-ft)
VALVE KEEPERS-*_-_-\
-'^"'-"-'-"-' -------Ib
--_
spRtl{GRETATNER

vALvE
ExHAUsr
---ro

spRrNG...-_____la
;ili'
--"i
vALvE spntitc
i

I
w VALVEIGEPERS
I
q I ExHAUsr
ExHAUsrvALvEsEAL rgli valvE RETAII{ER
p8g€s6-5 8nd 16
Replac€ment,
Reptace. Fz-->.- I @ .Ve-une ITTAIG VALVE SPfiI C
II{TAKE VALVE SEAL
R€Dlace.
SEAT
VALVESPRING
II{TAKEVALVE GUIDE

EACr COVER

CYLINDERHEAD

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

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

6-4
Valve Seals
Replacement(Gylinderhead removalnot requiredl
NOTE: Cylinder head removal is not required in this Intake V!lv. Soals:
orocedure. 6. S€lgct the 7/8 in diameter long compressor attach-
m€nt 8nd fasten the gttachment to th6 No. 5 hole
Ths proc€dur6shown below applies when using the in- of th€ levor arm with the speed pin suppli€d.
car valve spring compressor. (Snapon YA8845 with
YA8845-2 A 7/8' attachmentl Ins€rt an air adaptor into the spa.k plug hole. Pump
air into the cylinder to ke6p the valve closod whils
@E Alway woar approv.d oyc prot.ctron compr€ssing springs and rsmoving th€ valv€
whon uslng th6 in-cel valvo spring compt!3!or. ke6o6rs.

1. Turn the crankshaftso that th6 No. I 8nd the No. 6. Position the lev€r arm und6r ths cross shaft so the
4 pistons are at top desd center (TDC). lover is porpondiculsrto th€ shaft and the compres-
8or sttachm6nt rests on top of the rgtsinsr tor the
2. Removeth€ cvlinder head cover and the rocker arm spring being compress€d.Us€ th€ tront position slot
assembly. on ths l€vsr as shown.

NOTE; NOTE: RJt shop towek over the oil passagesto pre-
a Rsf€r to p8ge 6-12 for rocker arm assembly vent th6 valvo ke€p€B from falling into the cylindsr
removal. h6ad.
I When removing or installing the rocker arm 8s-
sambly, do not r6mov6th€ camshaft holdorbolts,
Th6 bolts will keepthe holders,sprir€s and rocksl
arms on th€ shaft,
OII. PA&gAGES
3. Remove the fuel injectors and the wire hsrn€ss.

4. Using the 8 mm bolts supplied with the tool, mount


the two uprightsto the cylinderh6adatthe end cam-
shaft holders. Th€ uprights tit ov8r the camshatt as
shown,

5. Insertthe cross shaft through th6 top hola of th€ two


uprights.

trl

(cont'd)

6-5
Valve Seals
lGylinderheadremovalnot required)(cont'dl
Replacement
'15. Using a downwatd motion on the levsr arm, com-
9. Using a downward motion on the l€ve, arm, com-
pressthe valvespringand removethe keepersfrom press the valve spring and remove the keepersfrom
the valve stem. Slowly release pressureon the the valve stem. Slowly release paessuleon the
sprlng. sprlng.

1 O . R e m o v et h e v a l v es e a l s( p a g e6 - 1 6 ) . 16. Removethe valve seals(page6-16).

1 1 . Installthe valve seals (page6-21). 17. Installthe valv€ seals lpage 6-21).

12. Installthe springs,the retainersand the keepersin 18. Installthe springs,the r€tainers8nd th€ koop€.sin
reverseorder of removal. rgvorso ord€r of romovSl,

ExhaustValv6 Seals: 19. Repeatsteps 6 to 18 on the other cylinde,s.

13. Selectthe 7/8 in. diametershortcompressor attach-


ment and lasten the attachmentto the No. 4 hole of
the lever arm with the speedpin supplied.

14. Positionthe lever arm under the cross shaft so the


leveris perpendicularto the shaft and the compressor
attachment rests on top of the retainerfor the spring
being compressed.Use the front position slot on the
lever as shown.

NOTE: Put shop towels over the oil passagesto pre-


vent the valve keepersfrom falling into the cylinder
head.

6-6
CylinderHead
Removal
Engineremovalis not requiredtor this procedure. 1 . Disconnectthe negativeterminalfrom the battery.

2 . Drainthe enginecoolant{seesection101.
o Make sur6 iacks and sefsty stands are placed propsdy . Removethe radiatorcap to speeddraining
and hoist bfackets are sttachod to co.roct @shions on
tho ongin€, 5. Relievethe fuel pressure.
o Maks sure the car will not roll off stfltds and tall whilo
you are working under it.
@ Do not snoke whlc wo*rng on ftrc
sydem, krop oFn ffrnc or spark away trom wor*
CAUTION:
s!. Drdn ft|ol ody into an approvrd contrlnor.
a Us€ t€nd€r covors to avoid damaging paintod surtacas.
a Unspecifiad h€ms arc common.
o Unplug tho wiring connec{ors carefully whil€ holding ths SERVICE EOLT
connoctor Fprtion to avok ddylago. SHOPTOWEI- 12 N.m {1.2 kg-m,9 tb-ft}
. Mark a[ wMng and hosos to avokt miEconnection.Abo,
bo su.o that they do not contact oth6. widng or hosos ol
innerto?e with othq parts.
o To avoid damaging th€ cylinder hoad. wah untilthe sn-
gine coolant temp€.aturs drop6 b€low 100oF (38oC)
botor€ loosoning tho l€taining boh.
o Inspect th€ timing beh bofore removing the cylnder FUELRAIL
hoad.
. Tum the crankshaft pulley so that tho No. 1 dston is at
top doad center {pag€6-281.
a Maks all emission hos€s betore disconnocting th€m.

NOTE; The radio may have a coded theft protectioncir- 4. R€movethevacuumtube,breatherhoseand intskeair
cuit. Be sure to get the customer'scode numberbefore duct.
Disconnectingthe battery.
- Removingthe No.43 (1OA)tuse (ln the under-hood Removethewater bypasshosefrom the cylinderhead
fuse/relavboxl.
Removingthe radio. Removethe fuel feed hose and evaDorativeemission
After service,reconnectpower to the radioand turn it on. (EVAP)controlcanisterhosefrom the intakemaniJold.
Whenthe word "CODE" is displayed.enterthe customer's
s-digit code to restoreradioope.ation.

(cont'dl

6-7
CylinderHead
Removal(cont'd)
7. Removethe brakeboostervacuum hose and vacu- 10. Removalthe ignitioncoil.
um hosemount (A/T only)fromthe intakemanitold.
* 8x 1.25mm
22 N.m(2.2kg-m,16lb-ftl
8 . Removethe luel return hose and cruisecontrol vacu-
um hose.

CRUISE

Removethe spark plug caps and the distributor,

9. Removethe throttle cableand the throttle control ca 1 2 . Removethe connectorand the te.minalfrom the alter-
bl; (A/T only) from the throttle body. nator, then removethe enginewire harnesstrom the
cylinderhead cover.
NOTE:
o Take care not to bend the cablewhen removingit. 1 3 .Removethe followingenginewire harnessconnectors
Always replaceany kinkedcable with a new one. and clamps f.om the cylinder head and the intake
a Adjust the throttle cable when installing(seesec- manitold:
tion 1 I ). a Fourtuel injectorconnectors
o Intakeair temDerature{lAT) sensorconnector
o ldle air control (lAC) valve connector
6r10mm . Throttle position (TP)sensorconnector
1 2 N . m( 1 . 2k g - mI, l b - f t l o Exhaustgas recirculation(EGR)valve lift sensor
connector
. Groundcableterminals
. Enginecoolant temperature(ECT)switch B con-
necror
o Heatedoxygen sensor (HO25)connector
a ECTsensorconnector
o ECTgaugesendingunit connector
. lgnition coil conneclor
THROTTLECONTROL . CKP/TDC/CYPsensorconnector
CABLE (A/T onlyl
. Vehiclespeedsensor(VSS)connector
a ECTswitch A connector

r!: CORROSION BOLT


RESISTANT
14. Removethe upper and lower radiatorhosesand heat- 18. Disconnectthe connectorandvacuumtube,then re-
er noses. move the cruisecontrol actuator

CNUISECONTROL
ACTUATOR

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

\
VACUUMTUBE

HEATEROUTLET
HOSE

HEATERINLET
HOSE
cor{r{EcToR ,//
,4
15. Remove the emission vacuum hoses and water ./
bypasshosesfrom the intake manifoldassemblv.
'16.
Removethe water bvoass hose from thermostat 1 9 .Removethe enginegroundcablefrom the bodyside.
housing.
20. Removethe power steeringlP/S)pumpbelt and pump.
17. Remove the thermostat assemblv from intake
er- manifold. NOTE:
ne a Do not disconnect the P/S hoses.
. After installingsdiust the tension of the P/S pump
belt (seesection 17).

ke

P/S PUMP

THERMOSTATASSEMALY

I x 1.25mm
LOCKNUT 22 N-lm 12.2 kg-m,
1 5 N . m l t . 5 k g - m ,1 1 l b - f t ) 16 tb-ftt

P/S PUMPBELT

(cont'd)

6-9
CylinderHead
Removal{cont'd)
24. Removethe heat insulator(carsequippedwith air con-
21. Remove the intake manitold bracket and intake
ditioningonlY).
mani{old.
25. Removethe self]ocking nuts and disconnectthe ex-
haust manifoldand exhaustPiPeA.
MANtFoLo GASKET
TNTAKE
26. Bemove the exhaust manifold bracket and exhaust
manifold.

BRACKET

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

EXHAUSTPIP€A
Mako sure lifts, iacks and safaty stands aro dacsd
propsdy. and hoist brack€ts are attach€d to the cor-
r€ct position on the ongin€ (seo page 1-10 rhlu
1-121.
Apply pa*ing b.ake and block rear wheeb, so car
will not roll oft slands and lsll on you wh e workng
HEAT INSULATOR
und91il. (Carsoquippedwith air conditioningl

23. Removethe front wheelsand the enginesplashshield 2 7 . Remove the positive crankcase ventilation (PCV)
(page5-18). hose, then removethe cylinderhead cover.

24. Removethe upPercover.

29. Loosanthe adjuatingnut 27O - 3600.

30. Pushthe tensionerto releasetensionfrom the timing


b€lt, then retightenthe adiustingnut.

6-10
31 . Removethe timing belt from the camshaft pulley. NOTE: Separatethe cylinderhead from ihe block with a
llat bladescrewdriveras shown.

ex

CAUTION: Do not crimp or bend


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

GA No Good

32. Removethe cylinderhead bolts. then removethe


cylinderhead.

CAUTION: To prevont warpag€. unscrow tho bolts


in soquonc€ 1/3 turn at a timo; rop€at untllall bohs
ars loosonad.

CYLIT{OER
HEAOSOLTLOOSENING
SEOUENCE

ning)
>cv)

mrng

6-11
CamshaftPulleY RockerArm AssemblY
Removal Removal

1. To easereassembly,turn the camshaftpulleyuntilthe 1. Loosenthe sdjustingscrews, then remove the bolts


"UP" mark faces up, and the front timing mark is and the rockerarm assembly.
alignedwith the cylinderhead upper surface.
NOTE:
. Unscrsw the camshaft holderbolts two tums at a
time, in a crisscrosspsnern to pre\€nt damaging
the valvesor rocker arm assmbly.
,.UP"MARK . When removingthe rocker arm assembly.do not
remove the camshaft holder bohs. The bolts will
keep the camshaft holders, the springs and the
rockerarms on the shafts.

b%
TDCGROOVES
Alignfronttimingmarkon
Pulleywith the cylinder
headuppersurfac€,

Removethe timing belt.

J. Removethe retaining bolt, the special washer, the 6 mm BOLTS


camshaft pulley and the key, then removethe back
cover.

CAMSHAFT
PULLEY

BACK COVER

6-12
RockerArms
r Overhaul
NOTE:
a ldentifypartsastheyareremovedto ensurereinstallation
in originallocations.
a Inspectrockershafts and rockerarms (page6-15).
. Rockerarms must be installedin the same positionif reused.
a When removingor installingrockerarm assembly,do not removethe camshaftholderbolts. The bolts will keepthe
holders,
springsand rockerarms on the shaft.
o when reassembling,fit the projectionof the intakerocker shaft to the notch in the camshaftholder.

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

Letter "9" is stamped Lefter "A" is stampod


on tocker atm. on tocker arm.

IITITAKE
BOCKER INTAKEROCKER INTAKEROCKER
sHAFr@ sxmr @ ARMs
lshon, 2 placesl (long, 3 places) (4 plsces)

lh,,tr"o.,
HoLDER
I liif.ro" I ti;or"or, ll"t "o'
HoLDER I I HoLDER HoLDER

I I | | | .,nou.,,,or".^
|
ll | | l ' u " ' T I" '
| | t . l^ l , l ^
#,dffifu,Lffi,#u/=m
- *
LpC .ffig*ffir
l
|flry 16tr
l " r * l

' o s ' g U f "#


t [ U
or.,t o "*,n(' ROCKERARM
(short, 2 palces) (long, 3 places) (8 places)
rc
/
EXIIAUST ROCTERSHAFT

6-13
Camshaft
Inspection
Removethe bolts, then removethe camshaftholders
Note:
. Do not rotate the camshaftduringinspection. lrom the cylinderhead.
a Removethe rockerarms and rockershafts.
- Lift camshaftout ot cylidnerhead,wipe clean,then
1. Rrt the camshaft and the camshaft holders on the inspectlift ramps.Replacecamshaftif lobesarep't-
cylinder head, then tighten the bolts to the specilied ted, scored,or excessivelyworn.
torque.
- Cleanthe camshaftbearingsurfscesin the cylinder
head,then set camshaft back in place'
Specified tolque:
8 mm bohs: 22 N m (2.2 kg-m, 16 lb-ft)
- Insertplastigagestrip acrosseach iournal'
6 mm bohs: 12 N'm (1.2 kg-m,9 lbjt)

6 mm BOLTS lnstall the camshaft holders,the tighten the bohs to


the specijiedtorque as shown in the left column on
this page.

o. Measurewidest portionof plastigageon eachjournal'

Camshatt-tolloldcr Oil Clearance:


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

8 mm BOLTS
PTASTIGAGE STNIP

Seatthe camshaftby pushingittoward distributorend


of cylinderhead.

Zerothe dial indicatoragainstend ol distributordrive.


then push the camshaft back and forth and read the
end play.

Camshaft End Play:


StandardlNow): 0.o5-o.1 5 mm
(O.0O2-O.0O6in)
S€rviceUmh: O.5 mm {O.O2in)

CAMSHAFT

6-14
RockerArms
Clearance
efs 7. lf camshaft-to-holderoil clearanceis out ot tolerance: Measureboth the intake rockershafts and exhaustrocker
shaft.
- And the camshaft has alreadybeen replaced,you
!€n must replacethe cylinderhead. Measure diameter ot the shaft at the tirst rocker
pit- - lt camshafthasnot beenreplaced,tirst checktotal location.
runout with the camshaft supportedon V-blocks.

der Canshaft Total Runout:


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

tto
on

nal.
Surfaceshouldbe smooth.

Zero the gaugeto the shaft diameter.

- lf the total runout of the camshaft is within toler-


ance, replacethe cylinderhead.

- lf the total runout is out of tolerance,reDlacethe


camshaftand recheck,lfthe oilclearanceis stillout
ol tolerance,replacethe cylinderhead.
Measurethe insidediameterof the.ocker arm and
Measurecam lobe height. check tor out-of-roundcondition.

Cam Lob€ Height: Rock€r Am-to-Shaft Cloarance:


lntakeStanda.d: 38.526 mm (1.5168in) Standdd(N€w)
Erhaust Standard: 38.778 mm { 1.5267 in) lmak6: O.O17-O.O5O mm
(0.OOO7-O.OO2O in)
Exhaust: O.O18-O.054mm
{O.OOO7-O.0O21 in)
Ssrvico Linit: 0.O8 mm
(O.0O3in)

Inspectrocker arm
laca tor wear,

Repeatfor all rockers.lf over limit, replacethe rocker


Inspectthis areator wear. shaft and all over-tolerancerockerarms.

6-15
Valves, Valve Springsand Valve Seals
Removal
4. Removethe valve seal.
NOTE: ldentify valvesand valve springsas they are re-
moved so that each item can be reinstalledin its original
Dosition.

1. Tap each valve stem with a plastic mallet to loosen


valvekeepersbeforeinstallingthe springcompressor'

2. Install the spring compressor.Compressthe spring


and removethe valve keepers.

COMM€RCIALLYAVAILABLE

3. Installthespecialtoolas shown.

lntako Valvo txrronsions


VALVEGUIDESEALREMOVER
LISLEP/N57900or KD3350 A Standtd(tlowl: 33.90-34.1O mm
COMMERCIALLY AVAILABLE (1.335- 1.343 in)
B Standtdocw): 1 1O.88-l 1 1.18 mm
(4.365-4.377 in)
C Strdard{ ow}: 5.485- 5.495 mm
{ O . 2 1 5 9 - O . 2 1 6 i3n )
C SorviceLinit: 5.455 mm (0.2148 in)
D Standard(t{ow}:0.85-1.1 5 mm
(0.033-O.045 in)
D S€rvbr Linit: 0.65 mm (0.026 inl

Exha.|3t Valvo Dlmonsions


A Sta.!dsd(t{ow): 28.90-29.10 mm
I t 1 . 1 3 8 - 1 . 1 4 6i n )
8 Stard1*d(ltswl: 122 15 -122.45 mm
(4.809-4.821 in)
C Siandsdl ewl: 5.450- 5.460 mm
( 0 . 2 1 4 6 - O . 2 1 5 0i n l
C SorvicoUmh: 5.420 mm (O.2134 in)
D Standard(Now): I .O5- 1.35 mm
(O.O41 -O.O53 in)
D S€rvicoLimit: 0.95 mm {0.037 in)

6-16
Valve Seats
Reconditioning

Renew the valve seats in the cylinder head using a 5. After resurfacingthe s€at, inspectforeven valveseat-
valve seat cutter. ing; Apply PrussianBluecompoundto the valve face,
and insertvalvein originallocationin the head,then lift
NOTE: lf guidesare worn (page6-18),replacethem it and snap it closedagsinstthe seat severaltimes.
(page6-191beforecutting the valve sears.

PRUSSIAI{

6. The actualvslveseatingsurface,as shown bythe blue


compound,should be centeredon the seat.
. lf it is too high {clos€rto the valvestem), you must
make a secondcut with the 600 cutter to move it
doun,then one mor€ cut with the 45o cutter to re-
store sest width.
a lf it is too low (closerto the vslve edge),you must
make a secondcut with the 3Oo cutter to move it
2. Carefully cut a 45o seat, removing only enough
up, then one more cut whh the 45o cutter to re_
materialto ensurea smooth and concentricseat.
store seat width.
NOTE:The final cut should alwavs be made with
3. B€velthe upper edge ot the seat with the 3Oo cutter
the 45o cutter.
and the lower edge of the seat with the 600 cutter.
Check width of seat and adjust accordingty.
7. Insertintakeandexhaustvalvesin the headand meas-
ure vatve stem installedheight.
4. Make one more very light passwith the 45o cutter to
removeany possibleburrscausedbv the other cutter.
Intako Valv6 Stam lnstalsd H€ight:
Standnd (New): 48.245-48.]15 mm
Valve S€at Width:
(1.8994- 1.9179 inl
Stsdard (Nowl: 1.25-1.55 mm
SsrviceLimh: 48.965 mm (1.9278in)
(O.049-O.061in)
Exhaust Valve Stem I]rrtaH Hotght:
ServiceLimit: 2.OOmm (0.079 in)
Standrd (t{ow}: 50.315-8O.785 mm
1 1 . 9 8 0 91- . 9 9 9 4i n l
Sorvice Linh: 51.O35mm (2.OO92 in)

SEAI WIDTH

8. lf valve stem installedheight is over the servicelimit,


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

6-17
CylinderHead ValveGuides
Warpage Valve Movement

NOTE: lf camshaft-to-holderoil clesrance{page6-14) are Measurethe guide-to-stemclearancewith a dial indicator


not within specitication, the cylinder head cannot be while rocking the stem in the direclion ol normal thrust
(wobblemethodl.
resurfaced.

lf camshaft-to-holderoil clearancesare within specitica- lntako Valve Stem-to4ulde Clearanca:


tions. check the cvlinderheadfor warpage. Standrd {New}: 0.04-O.O9 mm
(O.OO2-0.OO4 inl
. lf warpageis lessthan O.05 mm {0.OO2in)cylinderhead ServiceLimh: 0 16 mm (0.006 in)
resurfacingis not .equired.
. lf warpageis betweenO.O5mm (O.0O2in) and 0.2 mm Exhaust Valve Stom'to4uite Clea.ance:
(0.008 in), resurtacecrinder head. Standard(New): 0.1 1 -0.16 mm
a Maximumresurfacelimit is 0.2 mm {0.008 in) basedon {0.0O4-0.0O6in)
a heightof 10Omm {3.94 in). SorvicoLimit: O.24 mm (0.OO9in)
Valve extended 1Omm out from seat
STRAIGHTEDGE
PRECISION

o --\-_z
\ ' =

a lf measurementexc€edsthe servicelimit, recheck


using a new valve.
a l{ measurementis now within service limit, reas-
s€mbleusing a new valve,
a lf measurementstill exceedslimit, recheckusingal-
ternate method below. then replace valve and
guide, it necessary.

NOTE: An ahemate method oJ checking guide to


stem clearanceis to subtract the O.D. ol the valve
stem, measuredwith a micrometer,from the l.D. of
the valve guide, measuredwith an insidemicrometer
or ball gauge.
Takethe measurementsinthree placesalongthe valve
stem and three placesinsidethe valve guide.
The difference between the largest gulde measure-
ment and the smalleststem measurementshouldnot
exceedthe servicelimit.

Measurealong edges,and 3 ways acrosscenter. lntako Valvo Stom-to€ukle Clearance:


Standqd (Newl: 0.020-0.045 mm
Cyfnd€r Hoad Hoight: (0.ooo8-o.oo18
in)
Strdard lNew): 99.95- 1o0.O5mm S€rvicoLimit; O.Ogmm (O.OO3in)
(3.935- 3.939 in)
Exhaust Valvo St€m-to-Guide Clearancr:
Standcd (Newl: o.055-o.08o mm
(O.OO22-O'OO31 in)
SorvicaLimh: 0.1 2 mm {O.OO5in}

6-18
- Replacement

1. As illustratedin the removalst6ps of this procedure, 4. Workingtrom the camshaftside.Usethe driverand an


use a commercially-available air-impact ddver at- air hammer to drive the guide about 2 mm {0.1 in)
tachment modified to fit tho diameter of the valve towards the combustionchamber.This will knock off
guides. ln most cases, tho same procedurecan be some of the carbon and make removaleasier.
done usingthe ValveGuideOriverand a conv€ntional
nammer.
GAUTION:
o AlwEys woar satsty goggles or a face shiold when
VALVEGUIDEORIVER uCng tha air hamnr6r.
COMMERCIALIY
AVAILABLE . Hold th6 ak hdnmcf dkecdy in lina wlth iha valv€
guue to prev€ni darnaglng th€ driv$.

5. Turn the headover and drive the guideout toward the


camshaftside of head.

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

Selectthe properreplacementguidossnd chillthem in


the treezersectionot a refrigeratorJor about an hour.

Usea hot plsteor ovento evenlyheattha cylinderhead


to 3OOoF(150oC). Monitor the temperaturewith a
cookingthermometer.
eck

)as-

J al-
and

,to
alve
r. ol
eler

alve c)o
iure-
nor
CAUTION:
. Oo mt uso a tordr; h may wrp thc hoad. lf a valveguidestillwon't move, drillit out with a I mm
. Do not glt dro he.d hotter rhan 3{X)oF fi5oocl: (5/16 inch)bh, then try again.
oxccsslvc hoat may looaan tl|c vdw rcat3.
a To avoid brrB. uco heavy gbves whon hsnding CAUTION: Ddd gridos only in €xtr€m6 casas; you
tho hoad cyrer h.ad. couH damago tho cytndcr hoad if ths guilo breaks.

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


8 time, as you needthem.
(cont'dl

6-19
Valve Guides
(cont'dl
Replacement Reaming

7. Slipa 6 mm (0.2 in)steelwashet andthe correctdriver NOTE: For new valve guidesonly.
attachmert ov€r the end of the driver(Thewasherwill
absorbsome ot the impact and €xtend the life of the 1. Coat both reamerand valve guide with cutting oil
driver).
2. Rotatethe reamerclockwisethe full lengthol the valvs
guide bore.

3. Continueto rotatethe reamerclockwisewhile remov-

F:-p-qo
t t t 4.
ing it from the bore.

Thoroughlywash the guide in detergentand water to


DROER 6 mm (0.2In) ATTACHMENT removeany cutting residue.
WASHER
5. Check clesrancewith a valve {page6-181.
- Verify that the valve slides in the intake and ex-
Instsllthe new guide(s)trom the camshaftside of the haust vslve guideswithout exertingpressure.
head;drive each one in until the attachmentbottoms
on the head.lf you have all sixteenguidesto do, you
mav have to reheatthe headone or two more times.

VALVEGUIDEREAMER, HANDLE
REAMER
5.5 mft
OTHAH-PJ7OlOA ot
oTHAH-PJ70l08

Turn teamgrin
VALVEGUIDEDRIVER, clockwise diroctiononlY.
07742-OOlO100

Valve Gulde Insta{od H.iglrt:


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

6-20
Valves,ValveSpringsand VatveSeals
ValveSpringand ValveSealInstallationSequence
NOTE: Exhsustand intakevalve s€alsare NOT intsrchangeable.

@A=----UO|-UEKEEPERS
NOTE: Pl6cs the snd ot valve
spring wilh clos€ly wound coitg
towa.d tllo cvlinds. he6d.
INTA(EVALVESEAL VALVERETAIT{ER
(WHTTESPRINGI
Replace.

ALVESPRII{G
VALVEGUIDESEAI-
I STALTIR
KD-2899
COUMERCIAI,I.YAVAILABT"E
t{OlE: UsgsrnalllO endof tool.

EXHAUSTVALVESEAL
IBLACTSPRIITGI
Replace.

I{OTE: Installlhe vatve springcests


bofore installinothe vstvg seals.

ValveInstallation
When installingvalves in cylinderhead, coat valve stems
with oil before insertinginto vslve guides,and make sure
valvesmove up and down smoothlv,

Whenvalvesand springsare in place,lightlytap the end of


eachvalvestem two or th.ee times with a plasticmalletto
ensureproperseatingof valve and valve keepers.

NOTE: Tapthe valvestem only alongits axisso you do not


bend the stem.

6-21
Arms and CamshaftSeals/Pulley
Camshaft/Rocker
lnstallation
OIL SEAL
CAUTION:
. Mako suro that alltoc*€rs aro in algffn€nt vvith valvas
wh€n to(qukrg rockr assambly bohs'
. Vshrs tocknds shodd bo bosonad and 8di$t Ecrows
backed ofi beloro in3tal8don'
. To Fovont rocker arm as!6mbly trom coming apart'
leavo baring crp holding bohs h tho hobs'

1. After wiping down the camshaft and journals in CUP


INSTALLEF
cylinder heod. lubricate both sur(aces and install SEAL GUTOE OTNAF_PIOOlOA
camshaft. o7t{AG - PT0010A

aubrt""a"""m tobesafterreassembly. o. Tiohteneach bolt two turns at a time in the sequence


I sh-ownbelowto ensurethatthe rockersdo not bind on
Turn the camshaftuntil its keywsy is facing up. the valves.
(No.1cylinderTDC).
Spcdffod torcuo:
Apply liquidgasketto the headmating surfacesof the 8 mm bolts: 22 N'm (2'2 kg-m, 16 lb-ft)
No. 1 and No. 6 camshaftholders' 6 mm bohs: 12 N'm ( l .2 kg-m, 9 lb-ft)
- Apply liquidgasketto the shadedareas.
6 mm BOLTS

No.1

-B
\J-

lt
v

Setthe rockerarm assemblyin place8nd looselyinstall 8 mm BOLTS


the bolts.
- Make sure that the rockerarms are propeflyposl-
7. lnstallthe back cover.
tioned on the valve stems.
8. Installths key and the camshaftpulleyonto the cam-
lnstallthe camshaftoil s8al using the speci8ltools as
shaft, then tighten the retaining bolt to the torque
shown.
shown.

CAMSHAFT SEAL GUIDE BACKCOVER


o7l{ac-PTOOl0A
Applyoil.
CAMSI{AFT

Mw
PULLEY

Sssl housing sudace


I
should b€ dry.
RETAININGBOLT
CAMSHAFT OIL SEAL 8 x 1.25 mm
Apply a light coar oI oil . N.rn{3.8 kg-m,
1 2 N m ( ' 1 . 2 k g - m38
to camshaft and inner INSTALLER SHAFT 27 tb-ft)
OTNAF_PTOO2OA I lb-ftl
lip of seal.

6-22
CylinderHead
Installation
Installthe cylinderhead in the reverseorder of removal: Installthe bolts that securethe intake manifoldto its
FT bracketbut do not tighten them yet,
NOTE:
,A
a Always use a new headgasket.
J. Positionthe camshaftcorrectly (page6-29).
. Cylinderheadand engineblock surfacemust be clean.
a "UP" mark on camshaftpulleyshouldbe at the too.
4. Tighten the cylinder head bolts sequentiallyin three
. Tum the crankshaftso the No. 1 cylinderis at TDC (psge
steps.
6-28t.
o Cleanthe oil contrclorifice before installino.
1rt stop to.que: 40 N.m (4.0 kg-m, 29 lb-ft)
\ 2nd stop torque: 70 N.m (7.0 kg-m, 51 tb-ft)
1. Cylinderhead dowel pins and oil control orifice must 3.d ctep to?quo: 10O N.m (10.Okg-m. 72 tb-ft)
be aligned.
nce
NOTE:
,on a W€ recommendusinga beam-typetorque wrench.
When using a preset-typetorque wrench, be sure
DOWELPIN
to tighten slowly and not to overtighten.
CYLINDER HEAD a lf a boh makesany noisewhile you are torquingit,
GASKET loosenthe boh and retightenit from the I st steo.
Replace.

ooml P {

a/ CYLI'{DERHEADBOLTSTOROUESEOUENCE
OILCONTROL
ORIFICE
Clean.

O-RING
Replace.

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

(cont'd)

6-23
Cylinder Head
lnstallation(cont'd)
thenuts n a
the nuts In-a 7 . lnstall the exhaust mdtifold and tighten
"5. Installthe intakemanifoldandtighten "ri"""roo putt"a in 2 or 3 steps' beginning with the
in 2 ot 3 steps' beginningwith the
"t't"""too p.orn innel nut'
innernuts. a Always use 8 now exhaust manifoldgasket'
o Alwavsusea newintakemanifddgasket'
th€n instsll the
8 . lnstall th€ exhaust manifold bracket'
GASXET i"h"tt pip",q and the bracket, and then install the
Replace. cov€f.

GASKET
Replace.

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

I x 1.25mm
22 N.m(2 2 kg-m'
MANIFOLD 8 x 1 . 2 5m m 16 tb-ft)
22 N.m {2.2 kg-m'
16 rb-ftl

1Ox 1.25mm
45 N.m(4.5kg-m,
33 tb-ft)

and the
lnstallthe heat insulatorto the cylinderhead 10 x 1.25 mm
block. GASKET 55 N.m {5.5 kg-m.
R€placo. 40 lb-ft)
Replace,
6r1.Omm
1ON.m(1.0kg-m,
7 tb-ft) EXHAUSTPIPEA

6-24
TimingBelt and TimingBalancerBelt
lllustratedIndex
NOTE:
o Referto page 6-28 tor positioningcrankshaftand pulley beforeinstallingtiming belt.
o Beforeremoving,mark directionof rotation.

ADJUSTING NUT
POWERSTEERING BELT 45 N.m(4.5kg-m, UPPER
COVER
Adjustment,
section17 33 rb-ft)
6x l.Omm RUBBER SEALS
12Nm(1.2kg-m, Replace whendamaged
\ I tb-ft) or detsrioratod.
\

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

CYLINDER
HEAD
COVER

6r l.Omm
12 N.m {1.2 kg-m,_,-
glb-tr) ,.'
-
l- CRAr{KSHAFT .^
::aNm(22.0ks-m,
/ WIIIV UAMSHAFT
:3 bft) ltrcnNartia aelr i"-*" PYLEY
"n" oir.
\:ot engineoil to the Adjustment, section 23
:crr threads,but not
u '- surfacethat
r.--ts the washet. SEALS
Replacewhen damaged
.uGAELT or dgt€rioroled.
.lo.ction, page 6-26
Sustm€nt, Page6-26
:,.dacement, pago 6-29
BELT
TE SIOITERS

AELT 8 x 1.25 mm
ADJUSTING BOLT 38 N.m (3.8 kg-m,27 tb-ft)
Remove 68 N.m(6.8ks-m,
any oil. SPRII{G 49lb-ft)

SPRING Installwith concave


6r 1.Omm surfacefacing in.
r 2 N . m( 1 . 2k s - m . Femove any oil.
I rb,ft) TIMII{G AALA CEREELT
Inspection,page 6-27

6-25
TimingBelt
Inspection TensionAdiustment

Disconnectthe altelnatorterminaland the connector. CAUTION: AhtvavsadFst timing boh tensbn with th6 on-
gin6 cold.
then removethe enginewire harnessfrom the cylinder
head cover.
Removethe cYlinderhead cover' NOTE:
o The tensioneris springloadedto applypropertens'onto
the belt sutomaticsllYafter making the lollowing ad-
Removethe upper cover.
justment.
a Always rotate the crankshaftcounterclockwisewhen
4. Inspect the timing belt for cracks and oil or coolant
soaking. viewed lrom the pulleyside. Rotatingit clockwisemay
result in improperadlustmentof the belt tension
. Inspectthe timing balancerbelt beforeadiustingthe belt
NOTE:
. Replacethe belt if oil or coolant soaked. tension.
a Removeany oil or solventthat gets on the belt' . Do not loosenthe adjustingnut morethan one full turn'

1. Disconnectthe alternatorterminaland the connector'


then removetheenginewire harnessflom the cylinder
Inspectthis arealor wear. headcover.

Removethe cylinderheadcover'

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

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

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

Rotate the crankshaft counterclockwise3-teeth on


the camshaftpulley.then reloosenthe adiustingnutto
createtensionon the timing belt.

to Tightenthe adjustingnut.
: 5, After inspecting,retorquethe crankshaftpulleybolt 6.
220 N.m (22.Oks-m, 1 59 lb-ftl'
After sdiusting,retorquethe crankshaftpulleybolt to
22ON.m (22.0 ks-m, 159 lb-ft).
TimingBalancerBelt
Inspection

1. Disconnectthe altematorterminaland the connector,


then removethe enginewire harnesstromthe cylinder
headcover.

2. Removethe cylinderheadcover

3. Removethe uppercover.

4. Removethe crankshaftpulley.

5, Removethe lower cover,

6. Installthe crankshaftpulley.

7. Inspectthe timing balancerbelt for c.acks and oil or


coolantsoaking.

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

Inspectthis areator wear.

Botatepulley
andrnspectbelt.

After inspecting,retorquethe crankshaftpulleybolt to


22O N'm (22.Oks-m, 159 tb-ftl.

NOTE: Refer to page 6-32 tor timing batancerbelt


tension adjustment.

6-27
Timing Belt
PositioningCrankshaftBeforeInstallingTimingBelt
NOTE:
. Installthe timing belt with the No. 1 piston at TDC.
. After installingretorquethe crankshaftpulley bolt to
220 N.m (22.0 kg-m, 159 lb-ft).

CAMSHAFTTDC POSITION: CRANKSHAFTTDC POSITIO]T:

,,UP"MARK MANUAL TRANSMISSION:

FLYWHEEL INSPECTIOI{HOLE

AUTOMANC TRANSMISSION:

DRIVEPTATE INSPECNO HOLE

TOC MARK POINTERS


(WHITEI ot{ BLocK

NOTE: When turning the crankshaft with a socket


wrench, installthe crankshaftpulleyand rhe pulleybolt'

6-28
TimingBeltand TimingBalancerBelt
Replacement.
CAUTION: Inspoct tho walor pump whon radachg th6 3. Removethe mounting bolts, nuts and P/S pump belt
timing b€lt (Pag610-12) from the power steering(P/S)pump.

NOTE: Turn the crankshaftso that the No. 1 piston is at NOTE:


TDC (page6-28). a Do not disconnectthe PiS pipe and hose.
. After installing,adiustthe tensionof the P/Spump
I . Removethe splashshield. belt {seesection171.
LOCKNUT
POWEBSTEERING 1 5N . m{ 1 . 5k g - m ,
PUMP 11 tb-ft)
MOUNTINGBO(TS

8x1.25mm
22 N.m 12.2kg-m,
SPLASH SHIELD 1E rb-ftl P/SPUMPAELT
., Disconnectthe connector. then remove the cruise 4 . Disconnectthe alternatorterminaland the connector,
control actuator. then removetheenginewire harnessfrom the cvlinder
head cover.
NOTE:
a Do not disconnectthe control cable. Loosenthe alternatormountingbolt/nut and adjusting
a Takecarenot to bendthe cablewhen removingthe bolt, then rernovethe altematorbelt.
actuator.Always replacea kinkedcablewith a new
one. NOTE: After installing,adjustthe tensionof the alter-
nator bett lsee section 231.
CRUISE
ACTUATOR 6x1.Omm
10 t{.m {1.0 kg-m, MOUNTIM! EOLT
7 tb-ttl 1 Ox 1 . 2 5m m
45Nm{4.5kg-m,
33 tb-fr)

ALTENNATOR
AELT

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

6-29
TimingBeltand TimingBalancerBelt
(cont'd)
Replacement
Removethe cylinderheadcover. I 1. Removethe pulleybolt and the crankshaftpulley Re-
move the two rearboltsfrom the centerbeamto allow
Removethe sideenginemount bracketB {standardfor the engineto drop down and give clearanceto remove
some typesl. the lower cover.

Removeth€ uppercover. 12. Removethe rubbsr seal aound the adiustingnut. Do


not loos€n the adiusting nut.
Removethe side enginemount.
13. Removethe lower cover'
'10.Removethe dipstick and the pipe.

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

CYUNDERHEAD
DIPSTICK/PIPE
COVER e
e

RUBEER
SEALS
l2 x 1,25 mm R€placewh€n
65 N.m (6.5 kg-m, SIDE damag€dor
47 tb-ft) MOUNT deterioratsd.

UPP€R
COVER RUBBERSEALS
Replacewhen
6xl.Omft damagedor
1 2 N . m ( 1 . 2k g - m , deterior6ted.
I rb-ft)

SEAL
RUEBER
Replacewhsn damaged
or detorioratod.

AOJUSTINGNUT
1 0 x 1 . 2 5m m
45 N.m (4.5 kg-m,
33 lb-ft)

PULTfYEOLT
14 x 1.25mm TIMING BALAITCEFBELT
Inspection,Page6-27
220 N.m 122.0ksn, 159 lb-ftl
Apply 6n9ineoil to th€ boli ihraads, 6xt.Omm
but not to the sudace that n LLEY 12 N m (1.2kg-m,
contads the washer. Removs
anyoil. I lb-ft)

6-30
'1
e- 4. Lockthe timing belt adjusterarm in placeby installing 17. Loosenthe 6 x 1.0 mm lock bolt andthe adjustingnut.
one of the 6 x 1.0 mm lower cover mounting bolts, Pushon the timing belt adjusterpulleyto removeten-
sion from the belt, then tighten the adiustingnut.
15. Loosenthe timing belt adjusringnut. push on the pu!
ley to removetension trom the timing balancerbelt, 18. Removethe timing belt.
)o then tighten the adjustingnut.
19, Installthe timing belt in the reverseorderof removal.
16. Removethe timing balancerbelt. Adjust the valve clesrances(page6-34)
- Betoreinstallingthe riming b€lt, the crankshaftand
NOTE: It you are removingonly the timing balancer camshaft pulleysas shown on page 6-28.
belt, goto step 22. lf you areremovingboth belts,con,
tinue with this procedure. 2O. Perform the timing belt tension adjustment lpage
6-26).

TIMINGBELT 21 . Tightenthe 6 x 1.0 mm bolr to tockthe timing belt ad-


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

DRIVEPULLEY

(cont'd)

6-31
Timing Belt and Timing BalancerBelt
Replacement(cont'dl

22. Make surethe crankshaftis positionedwith the No 1 27. Turn the crankshaft pullev about one turn counter-
piston at TDC. clockwise,then tighten the adjustingnuit to the speci-
{ied torque.
23. Alignthe grooveon the front balancerafter pulleywith
the pointeron the oil pump housingas shown, NOTE: Both belt adiusters are spring-loaded to
properlytensionthe behs.Do not spply any extm pres-
24. Align the rear balancershaft pulleyby using 6 x 1OO sure to the pulleysor tensionerswhile performingthe
mm bolt or equivalentas an alignmenttool. adiustment,
Scribea line 74 mm (2.9 in) from the end ol the bolt. REARBALANCERSHAFT
Inserttheboh intothe maintenanceholeto the scribed
line.

25. Loosenthe adjusting nut and verity that the timing


balancerbelt adjustermovesfreely.

Installthe timing balancerbelt. Removethe 6 x 1OO


mm bolt from the rear balancershaft.

74 mm 12.9in) MAII{TENANCE
HOLE
6 x 10O mm BOLT
WASHER
Replace.
6 x 100 1'|mBOLT
12 mm SEAU G BOLT
30 N.m(3.0 kq-tn,22 lb-ftl
NOTE:Tightenthe boltafter
installingthe belt.

AI'JUSTII{GNUT

Align the groove of the


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

TIMINGBALA'TCERBELT
DRIVEPULLEY
Set the crankshaftat TDC.

6-32
24. Removethe 6 x 1.Omm bolt from the timing belt ad- 32. Installthe upper cover.
Justerarm.
33. Installthe crankshaftpulley.
29. Removethe crankshaftpultey.
34. Coat the threads and seatingtace oJ the putley bolt
30. Installthe lower cover. with engine oil. Install and tighten to the specified
rorque.
3 1 .Installa rubberseal aroundthe adjustingnut. Do not
loosenthe nut. Specifiodtorqus: 220 N.m {22.Okg-m. 159 tb-ft}

UPPERCOVER

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

ADJUSTING I{UT SEAL


1 0 x 1 . 2 5 rn Replgcswhon damsged
45 N.m (4.5 kg-m, or dsterioratsd.
33 rb-ft)

PULLEYBOLT
1 4x 1 . 2 5m m
22O N.m {22.0 kg-m, 159 lb-ft)
Apply engineoilto the
bolt threads. 6x1.0mm
12 N.m {1.2 kg-m,9 lb'ft}

6-33
Valve Clearance
Adiustment
NOTE: Adjust valves on No. 1 cylinder.
. Valvesshouldbe adjustedcold when the cylinderhead
temoerature is lessthan loOoF {38oC). in}1333fll13.ffi!lll
Intake:0.26mm{o.o1o
. After adiusting,retorquethe crankshaftpulley bolt to
in)13.33ffi13ffi9ili
Exhaut:o.30mm{0.o12
22ON.m (22.0 kg-m, 159 lb-ft).
Loosenlocknut and turn adjustmentscrew untilJeeler
1. Removethe cvlinderheadcover. gaugeslidesbackandforth with slightamountofdrag.
INTAKE

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

N o . 4 N o . 3 N o . 2 N o .1 LOCKlrlUTTxO.T5mm
20 N.m(2.0kg-m,14lb-ft)
Applyengineoil.
EXHAUST

GAUGE
FEELER

"UP" mark on the camshaft 5. Tightenlocknut8nd checkclearanceagain.Repeatad-


2. Set No. 1 piston at TDC.
pulleyshouldbe at top, and TDC grooveson the cam- justment if necessary.
shaft pulleyshould alignwith cylind€rh€ad surface.

Numbor1 riston at TDC:

@-€
\ Ut\-/
) l-24

6-34
6. Rotatecrankshaft180o counterclockwise(Camshaft 8. Rotatecrankshat180o counterclockwiseto bring
pulley turns 9Oo). The "UP" mark should be at ex- No. 2 pistonto TDC. The "UP" mark shoutdbe at
haust side, Adjust valveson No. 3 cylinder. intske side. Adjust valves on No. 2 cylinder.

Number 3 Piston at TDC: Number 2 Pbton at TDC:

,,UP" MARK

7, Rotatecrankshaft180o counterclockwiseto bring


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

Numbor 4 Piston at TDC:

6-35
CylinderHead/ValveTrain
(H23A1engane)
SpecialTools .........6-38 Valve Guldes
lllustratodlndex ...........................
6-39 ValveMovement....................... 6-52
Valve Seals Replacernent .......6-53
Replacement (Cylinder head Reaming .............6-54
removalnot requiredl .............6-41 RockerArms/Camehafteand
Cylinder Head Camrhaft Soals/Pulleys
Romoval .............6-43 lnstallation .........6-57
Warpage ............6-52 Tlmlng Belt and Timing BalancerBelt
Installation .........6-56 lllustratodIndex ........................
6-59
Camshaft Pulleys Replacement .......6-63
Removal .............6-48 Timing Belt
Camshafts Inspoctlon ..........6-60
lnspection ..........6-48 TensionAdjustment ...................
6-60
Valves, Valve Springs and Valve Seala PositionlngCrankshaftBefore
Removal .............6-50 Installing
TlmingBelt .............. 6-62
Valve Spring and Valve Seal Timing BalancerBeh
InstallationSequence..............6-55 Inspoction ..........6-61
Valv€ Installation.......................
6-55 Valve Clearance
Valve Seats Adjustment .........6-68
Recondltioning ..... 6-51
SpecialTools

Ret.l{o. \ Too\ l{urnbor O6r,cdgl0tr\ qq \ Prq. Rd.r.nca

o 07GAD-PH70100 Valve Guide S€al lnstall6] 1


I
6-55
6-50
@ o7757-PJ1010A Valve Spring Compressor Attachment
@ 07942-6570100 Valve Guide Driver,6.6 mm 1 6-53,54
@ O 7 9 8 4 - 6 5 7 O 1 OoCr Valve Guide Reamer,6.6 mm 1 6-54
07984-657010D

t
o

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

6-38
lllustratedIndex

CAUTION: To avoid darnaglngtho cylinder head, wait until tho engino coolant tomporature drop6 b€low 100oF (38ocl
betoro romoving it.

NOTE: Use new O-ringsand gasketswhen reassembling.

6 r 1 0m m
6 r 1 . 0m m 10 N'm {1.0 kg-m,7 lb-ftl
10 N..n l1.O kg-m.7 lb-ft}

o
e
WASHER

RUBBEB
SEAIS 8 x 1.25mrn
Replace wlrsn 22 .m (2.2 lg-m, lE lb-ttl
or doteriorat€d.
6rlOmm
12 N.m (1.2 kg-m,9 lb-ttl

frI n-'-''
E
6x10mm
lO N.m (1.2 kg-m,7 lb-ft}

flEufl-
DOWEL PIII
ffiHnfl
,&V,
ui /tt{TAKE CAMSHAFT
HOLDER
8 x 1 . 2 5m m
18N.ft11.a 13 lb-frl

W# L!, e
8-

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

DISTRIBUTOR

EXHAUST
CAMSHAFT

ROCKERARM
ADJUSTING SCREW
Adjustment, page 6-68
LOCKT{UT
27 N.n 12.7 kg-m, 20 lb-ft) 8 x 1.25mm
38 N.m (3.4 ks-m. 27 lb-ftl

tor ntanual
p.r-lllgnriant ot
caftah6tt {cont'd)

6-39
lllustratedIndex
(cont'd)
CAUTION: In handllng a motal gasket. tako car6 not to lold it or damage tho contact surtaco of tho gssk€t.

NOTE: Cleanthe oil control orifice beJoreinstalling.


'11
I clean all the pans in solvent, dry them and apply lubricantto any contact parts,
Priorto reassembling,

HEADBOLT
INTAKE VALVE GUIDE 12 x 1.26 mrn
Insp€ction, page 6-52 lOO N.m (10.0 ks-m, 72 lb-ft)
Replacement,page 6-53 Apply cleanongineoil to
Rsaming,pag€ 6-54 threadsand underthg
VALVE bolt heads.

SPRINGRET

nfl
EXHAUSTVALVE

EXHAUSTVALVESEAL VALVEKEEPERS
Rsplaca.
VALVESPRINGSEAT SPEINGRETAINER
A(E VAIV€ SPNI G
EXHAUSTVALVE I]{TAXEVALVE SEAL
Replacam€nt,
psg€s 6-41 and 50
ALVESPRI G SEAT
EIID PIVOTEOLTS
64 N'm 16.4kg-m,46 lb-ftl
CYLINDERHEAD
R€moval. page 6-43
Reconditioningvalve
BACK COVER seat, pago 6-51
Warpage, page 6-52
ENGII{EMOUNT Installation, pag€ 6-56
BRACKET B
1 0 r 1 . 2 5m m CYLINDERHEAD GASKET
45 N.m (4.5 kg-m, IMETAL GASKET}
33 rb-ft) Roplace.
8 x 1 . 2 5m m
22 N.m
{2.2 kg-m, 16 lb-ftl OOWEL PIN
INTAKEVALVE
Replacemont, OIL CONTROL
Dimonsions, pag€ 6-50 ORIFICE
Reconditioningvslve Clean.
s€at, pag€ 6-5'l
Adiustment. paga 6-68 O-RING
TIMING BELT Feplace.
Inspection/Adiristment,page
R6placoment.page 6-63

ADJUSTIT{G
10 x '1.25mm
45 N.m (4.5 kg-m,
33 tb-ft)
Loosen,but do not remove.

6-40
Valve Seals
Replacement{Cylinderhead removalnot requiredl
NOTE: Cylinder head removal is not required in this Intako Valva Sorb:
proc€dure. 8. Selectthe 1-1l18 in. diameterlongcompressorat-
tachment and fasten the attachment to the hole of
Usethe procedureshown below applieswhen usingthe the lever arm with the speed pin supplied.
in-car valve spring compressor(Snap-onYA8845).
9 . Insert an air sdaptor into the spark plug hole. Pump
l@ Alway waar approved oye protcction air into the cylinder to keep the valve closed while
when using tho in-car valvo spring comp€as{rr. compressing springs and removing the valve
keeoers.
1. Turn the crankshaftso that the No. 1 and the No.
4 Distonsare at TDC. 1 0 . Positionthe lever arm under the cross shalt so the
lever is perpendicularto the shaft and the compres-
2. Removethe cvlinderhead cover. sor attachment rests on top of the retainer for the
spring boing comp.essed, Use the tront position
3. Loosen and remove timing belt from the camshaft slot on the lever as shown.
pulleys.
NOTE: Put shop towels over the oil passagesto
4. Remove the distributor. prevent ths valve keepers from lalling into the
cvlinderhead.
5. Removethe camshsft holder bolts, then removethe
camshaft holders, the camshafts, and the rocker
arms. OIL PASSAGES

Usingthe 6 mm boltssuppliedwith the tool, mount


the two uprights to the cylinder as shown.

Insert the cross shaft through the bottom holes ol


the two uprights.

OIL PASSAGES

(cont'd)

6-41
Valve Seals
Replacement(Cylinderhead removalnot required)(cont'dl
1 1. Usinga downward motion on the leverarm, com- 1 8 . Using a downward motion on the lever arm, com-
pressthe valve spling and removethe keepersfiom pressthe valve spring and removethe keepersfrom
ths valve stem. Slowly releasepressureon the the valve stem. Slowly release pressurs on the
spnng. spflng.

12. Repeatstep 1 1 for the other intakevalve in that 1 9 . Repeatstep 18 tor the othor exhaust valve in that
cvlinder. cylinder.

13. Removethe valve seals (page 6-50). 20. Removethe valve s€als (page 6-50).

14. Replacethe valve seals (page6-55). 2 1 . Replacethe valve ssals (page 6-55).

15. Installthe springs,the retainers8nd the keepers 2 2 . Install the springs, the retainers and the keepers
in reverse order of removal. in reverse order of removal.

Exhaust Valvo Soals: 23. Rep€at st€ps 8 to 22 for the other cylinders.
16. S€lectthe 7/8 in. diametercompressorattachm€nt
8nd tasten the attachment to the No. 5 hole of the
lever arm with the speed pin.

17. Positionthe lever arm under the cross shaft so it


is perpendiculsrto the shaft and the compressor
attachment rests on top of the retainer for the
spring being comprcssed. Use the front position
slot on the lever as shown.

ll NOTE: Put shop towels over the oil passagesto


prevent the valve keepers from Jalling into the
cvlinderhead.

6-42
CylinderHead
Removal
Enginer8movalis not requiredJor this procedure. l. Disconnect the negative terminal trom the battery.

2 . Drainthe enginecoolant (seesection 1O).


a Mako sure iscks and safoty stands ars placad a Removethe radiatorcap to speed draining.
propedy and hoist bfacksG era attachod to cor-
ract positions on ths oingino. 3 . Relievethe fuel pressure,
a Mako suro tho car will not roll oft stands and fall
while you ar6 working und€r it. @ Do not smoko whilo workino on fuel
aystem, koop open flamo or spark arlay from work
CAUTION: area, Draln fuol only into an approved containar.
a Uso fendor covors to avoid damaging paintod
surtaces. 4. Removethe intske air duct.
a Unspocifiod items ara common.
a Unplug tlF widng connectoB caroft.fy while hol+ E Removethe fuel teed hose and evaporativeemission
ing th6 connocto? ponion to avoid damags, (EVAP) control canister hose from the intake
a Ma.k 8t wHng and hoss3 to rvdd rrisconncctlon. manifold.
Also, bo sur6 that thsy do not contact othor wir-
ing oi hosos o. intorfats with other parts.
a To avoid damaging the cylindar herd, w8it untll
tho engine coolant t€mporaturo &opr bclow
100oF (38ocl befoio loosanlng the rotllnlng
bohs.

NOTE:
a Inspect the timing belt befo.e removing the
cvlinder head.
a Turn the crankshaftpulleyso that tho No. 1 piston
is at top dead csnter (page 6-62).
a Mark 8ll emission hoses belore disconnecting
them.
a The radio may have a coded theft protection cir-
cuit. Be sure to get the customer's code number 6. Removethe throttle control cabletrom the throttle
before. body (A/T onlyl.
- Disconnecting the battery.
- Removingthe No. 43 (lOAl fuse. NOTE:
(ln the under-hood fuse/relav boxl a Take care not to bendthe cable when removing
- Removingthe radio. it. Always replaceany kinkedcablewith a new
After service. reconnect Dowe. to th€ radio and one.
turn it on. Whenthe word "COOE" is displayed, a Adiust the throttle cable when installing(seesec-
enter the customer's 5-digit code to restore ra- t i o n 11 1 .
dio ooeration.

6 x l.O mm
12 .ft 11.2kg-m, 9lb-ftl

THROTTLECAALE

THROTTLECONTROL
CABLE

LOCKNUT

(cont'd)

6-43
CylinderHead
Removal(cont'd)
7. Removethe tuel feed hose,the tuel returnhoseand 9. R€moveth€ engine ground cable Jtom th€ cylinder
the brake boostervacuum hose. head cover.

FUELFEEDHOSE 10, Disconnect the alternator terminal and connector,


then remove the engine wire harness from tho
cvlindsr head cover.

WASHER EI{GINEWIRE
Replace. HARNESS

6r 6x l.Orr|m
8 t{.m (0.8 kg-m, 6 lb-ftl 10 'm (1.0 kg-m,7 lb-ftl

11. Removothe powsr steeringlP/S)pump belt and


pump.
a Do not disconnectthe P/S hosos.
Removethe lollowingenginewire hsrnessconnec-
tors and clamps ftom the cylind€r head and the in- 8 x 1.25mm
take manifold: 22 .|n (2.2 kg-m,
16 tb-ft1
o Four fuel injectorconnectors
a lntake air temDerature(lAT) sensorconnector
a ldle air control (lACl valve connector
a Throttle position (TP) sensor connector
a Exhaust g8s recirculstion (EGR)valve lift sensor
connecror
a Groundcableterminals
a Enginecoolanttemperature(ECT)switch B con-
necror
o Heatedoxygen sensor (HO2S)connectot
a ECT sensor connector
a ECT gauge sendingunit connector
a lgnition control module llCMl connector
a CKP/ToC/CYPsensorconnector
a VehiclesDeedsensor (VSS)connector
15 N.m ll.5 *g-m,
a lgnition coil connector I I lb-ftl
a Intake air bypass solenoid valve connsctor
a ECT switch A connector
a Knock sensorconnector

6-44
12. Removethe ignitioncoil. 16. Remove the intake manifold bracket and intake
manitold.

IGNITIONCOIL

*8 x 1.25lnm *6x LOmm


22 N.m 12.2 ke-m, CO ECTOR 12 rr| {1.2 kgn,
16 tb-trl 9 tb-ft1

13. Remove the emission vacuum hoses and water


bypass hoses from the intake manifold asemblv.

14. Removethe radiatorupper hose and heater hose 17. Removethe selt-lockingnuts and disconnectthe ex_
from the cvlinderhead. haust manitold8nd exhaustpipe A.

1 5. Removethe water bypass hose and the thermostst 18. Removethe heat insulator(carsequippedwith A/Cl,
housing. exhaustmanifoldbracketand exhau$ manifold.

6 x 1.0mm
12 tt.m 11.2 kg_m,9 tb-ft|
HEAT INSULATOR
{carsoquippedwith A/C)
*: CORNOSIONRESISTANTBOLT EXHAUST PIPEA
(cont'd)

6-45
CylinderHead
Removal{cont'd)
1 9 . Remove the PCV hose, then remove the cylinder 24. Remove the camshatt Pullsys.
head cover.
NOTE: To set the camshafts at TDC for No. 1
20. Removethe middlecover. cylinder,alignthe holesin the camshaftswith thg
holesin the No. 1 camshaftholdersand insert 5.O
2 1 . Loosenthe adjustingnut 180". mm oin punches.

Pushthe tensionerto releasetension from the tim-


ing belt, then retightenthe adjustingnut.

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

23, Removethe timing belttrom the camshaJtpulleys.


ADJUSTING SCREWS
CAUTION: Do not crimp or bond
tho timing belt more than 90 o ol lsss
than 25 mm ( l inl in diametor.

G4z
No Good

ADJUSTING SCREWS

6-46
Removethe side engine mount bracket B and back NOTE: Separatethe cvlinderheadfrom the block with
covea. a flat tip screwdriveras shown.

ENGII{EMOUI{T
SRACKET B 10 r 1.25mm
45 N.m (4,5 kg-m,
33 rb-ft}

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

27. Removethe cylinderhead bolts, then removethe


cylinderhead.

CAUTION: To prevont vvalpaga,unscrlw tho bohr


in sequenc€ 1/3 turn at a timo; rapaat until all bohr
arg loosaned,

CYLINOERHEAD BOLT LOOSEI{INGSEOUEI{CE

6-47
Gamshaft Pulleys Camshafts
Removal Inspection
"UP"
1. To easereassembly,turn the pulleyuntil the NOTE: Do not totate camshaft during inspection'
marks face up, and the front timing marks are aligned
with the marks on the Dullevs. 1. Removethe rocker arms.

NOTE: Rockerarms musi be installedin the same


oosition if reused.

"UP" m6rks 2. Put the camshaftsand the camshaftholderson the


cylinder head, then tighten the bolts to the specified
toroue.

Specifled torque:
Exc8pt Intake @, @. Exhaust @, @:
l0 N'm (1'0 kg'm, 7 lb'ft|
Intake @, @. Exhaust @' @:
12 N'm (1.2 kg-m, 9 lb-ft1

SEOUECE
TIGHTEI{II{G

Align the marks on the pulleys.

Removethe timing belt,

Removethepulleybolts,then removethe camshaft


pulleys.

NOTE: To set the camshafts at TDC for No. 1


cylinder,alignthe holesin the camshsftswith the @ @ @
holes in the No. 1 camshaftholdersand insert 5 0
mm pin punches.

t ,

PULLEYBOLTS

6-48
I
? Seatcamshaftsby pushingthem toward distributor 7. lf camshaft-to-holderoilclearancsis out oftolerance:
end of cylinderhead.
a And th6 camshaft has alreadybeen replaced,you
4. Zero dial indicatoragainstend of camshsft, then must r6placgthe cylinderhead.
push camshaft back and forth, and readthe end play. r lf camshaft has not been replaced,first check to-
tal runout with th6 camshaft supported on V-
Camshaft End Play: blocks.
Standard(New): 0.O5-O.15 mm
(0.0O2-O.006 in) Crmrheft Total Runout:
Sorvice Limit: 0.5 mm {0.02 in} Standard (Nowl: 0.03 mm (O.0Ol Inl max.
Sorvlce Llmh: 0.06 mm (0.002 Inl

Rotate camshaft
while msssuring

5. Removethe camshaft holder bolts from the cylinder


head.

a LiJt camshaft out of cylinder head, wipe clean,


then inpsect lift ramps,/Replac€camshaft if lobes - lf the total runout of the camshsft is within toler-
are pitted, scored, ot excessively worn,
ance, replace the cylinder head.
a Clean the camshaft beadng surfaces in the
cylinderhead.then set csmshaft back in place. - lf the total runout is out ot tolerance, replacethe
a Insert plastigagestrip acrosseach journsl.
camshaft and recheck. lf the oil clearanceis still
a Install the camshaJt holders and torque bolts to
out of tolerance,replacethe cylinderhead.
the valuesand in the sequenceshown on page
6-48.
8. Measurecamshaft lobe height.
6. Measure widest portion ot plastigage on each
journal.
Intak. Standlrd: 33.661 mm (1.3252 inl
Exhlurt Stlnda.d: 33.725 mm (1.3278 Inl
Camshsfi-to-Holdor Oil Cloaiance:
Standard(Now): O.O5O-0.089 mm
(0.0020-O.OO35 inl
SorvicaLimit: O.15 mm (0.0O6inl

Exhaust No. 5 Jounal:


Standard(Newl: O.lOO-0.139 mm
{0.0039-0.OO55 inl
Servics Limit: 0.20 mm (O.OOBinl

Inspect this are for wear.

6-49
Valves,Valve Springsand Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are re- 4. Removeth€ valve se8l.
mov6d so that €ach item can be reinstalledin its original
position.

1. Tap €ach valve stem with a plastic mallet to loosen


valve keepers before installing the spring com-
Dressor.

2. Installthespling compressor.Compressspringand
remove valve keeper.

VALVESPFINGCOMPRESSOR
COMMERCALLY AVAILABLE

VALVESPRING
COMPRESSOR
ATTACHMENT
07757-PJIOIOA

3. Installthe sDecialtools as shown,


lntake Valvo Dlncndons
A Standard (Nowl: 33.90-34.10 mm
(1.335- 1.343inl
B Standard l]{.wl: 102.6O-1O2.8O mm
VALVE GUIDESEALRETVIOVER (4.035-4.047 lnl
LISLEP/N57900 or KD335o C Standard {rw}: 6.58O-6.590 mm
COMMERCIALLY AVAILABLE 10.2691-O.2594inl
C Sorvic. Llmh: 6.55 mm 10.258Inl
D StandErd ( !rv): O . 8 5 -1 . 1 5m m
(O.O33-o.o45Inl
D Servic€ Llmh: 0.65 mm (O.O26inl

Exhoust Valvo Dlmcnalonr


A Standsrd(Newl: 28.9o-29.10 mm
( 1. 1 3 8 - 1 . 1 6 1I n l
B stand.rd lt{cw}: 1 0 1 . 4 0 -1 O 1 . 7 0m m
(3.992-4.oO4inl
C StandErd lt{ewl: 6.550-6.560 mm
Inl
10.2579*O.2583
C Servico Lknh: 6.52 mm 10.257inl
D Standard (Nrw): 1 . 0 5 - ' 1 . 3 5m m
(O.O41-0.O53 In)
D Sorvico Lirit: o.85 rnm (O.O33inl

6-50
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a After resurfacing the seat, inspect Jor even valv€
valve seat cutter. seating: Apply PrussianBlue compound to the valve
face, and insen valv€ in originallocation in the he8d,
NOTE: lf guidesare worn (page6-52), replacethem then lift it and snapit closedagainstthe seatsever-
(page6-531betorecutting the valve seats. al times.

ACTUAL
SEAN G
SURFACE

VALVE
SEAT

o PRUSSIANBLUE COMPOUI{D

K@"8 The actualvslve seatingsudace, as shown by the


blue compound,should bo centeredon the seat.
a lf it is too high (closer to the valv6 stem), you
must make a second cut with the 600 cuttef to
move it down, then onB more cut with the 45o
cutter to rgstore saat width.
a ]f it is too low (closeto th6 valve edge), you must
make a second cut with the 30o cutter to move
it up, then one more cut with the 45o cutter to
restore seat width.
Carefully cut a 45o se8t. removing only enough
materialto ensurea smooth and concentricseat. NOTE: The tinal cut shoutdalways be made wirh
the 45o cutter.
Bevelthe upper edge of the seat whh the 3Oo cutter
and the lowsr edg€ of the seat with the 600 cutter, Insen intake and exhaust valves in the head and
Check width of sest and adjustaccordingly. measurovalve stem installedheight.

Make one more very ligt|t pass whh tha 45o cutte, to Intake Valve St.m Inliall.d Hright:
removeany possibleburrscaussdby the other cufters. Standard (l{cwl: 39.365-39.835 mm
(1.5498- 1.5683 inl
VCv. Sct Wld$ (ht!k lnd.xhaltl: Scrvlce Limlt: 4O.Oa5 (1.5781 tnl
Standlrd: 1.25- 1.55 mm Exhau* Valve Stom lnstallcd Hdght:
(O.O49-O.061int Standard(Now): 39.165-39.635 mm
Sendcellmh: 2.0O mm (0.079 in) 1 1 . 5 4 1 9 -1 . 5 6 0 4i n l
S.rvlce Limit: 39.885 mm ('1.5703inl

)
VALVESTEM
INSTALLEDHEIGHT

8. It valve stem installedheight is over the servicelimit,


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

6-51
CylinderHead Valve Guides
Warpage Valve Movement

NOTE: lf camshaft-to-holderoil clearances(page 649) Measurethe guide-to-stemclearancewith € dial indicstor


are not within specitication,the cylinder head cannot be while rocking the stem in the direction of normsl thrust
resurfaced. (wobblemethod).

lf camshaft-to-holderoil clearancesare within specifica- lntsko Vdvo St.m-to{iukla Clearance:


tions, check the cylinderheadlor warpage Standard(New): 0.04-0' 10 mm
{0'002-0.0O4 in)
. lf warpageis lessthan0'05 mm (0.0O2in)cylinderhead Sewlca Umh: O.16 mm (0.006 in)
resurfacingis not requar€d
. lf wsrpage is b€tw6€n O.05 mm {0.0O2 in) 8nd 0.2 Exha6t Valve Stom-to4ulde Clearanca:
mm (0.008 in), rosurfacecylinderhead. Standrd lNow): O.10-0.16 mm
. Maximumresurfacelimit is 0.2 mm (0.OO8in) basedon (O'0O4-O.006 in)
a heightof 132.o mm (5.20 in) Sowic. Limh: 0 22 mm (0.OO9in)

1O mm out trom s€at.

.. .o

a lf measuremantexce€dsthe servicelimit, r8check


using a new valvs.
a lf measurement is now within the servic€ limit.
M€ssuro along gdggg. and 3 ways across center' reassembleusing a ngw valv€.
a lf measurementstill excaads limit, recheck using
alternate m€thod b€low, then replace vslve snd
guide, if necessary,

NOTE: An altsrnate m€thod of ch€cking guide to


stem clearanceis to subtract the O.D. of ths valve
stem, measurgdwith a micrometer. from the l.D. ot
the valve guide, measured with an inside microme-
ter o. ball gauge.
Take the measurements in three places along the
valve stem and three placesinsidethe valve guide.
The difference betwesn the largest guide measure-
ment and the smalleststem measurementshouldnot
exceedthe servicelimit.

Cyllrdor H6ad H€ight: Intake Valvo Stom-tecuida Closrsnca:


Stardard(Nowl: 131.95- 132.05mm Stardtd lt{rw}: 0.02-0.05 mm
15.1955
- . 1 9 9i n l (O.OOl-O.OO2 in)
Servba Limit: O.08 mm (O.0O3in)

Erhaust Valw Stom-to4uidc Cbarancs:


Stsrdrd (ltlew): O.05-O.O8 mm
(O.OO2-0.OO3 inl
ServlccLimit: O.11 mm (O.0O4in)

6-52
Replacement
1. As illustratedin the removalsteps of this procedure, 4. Workingfrom the camshaftside, usethe driverand an
use a commercially-available air-impact driver at- air hammer to drive the guide about 2 mm (0.1 in)
tachment moditied to fit the diameter ot the valve towards the combustionchamber.This will knock off
guides. In most cases, the same procedurecan be some oJthe carbonand make removaleasier,
done using Valve Guide Drivers and a conventional
hammer. Tool numbers are at the end of this CATUION:
Drocedure. a Always wear sal€ty goggles 01 a taco shield when
using th€ aL hamm6..
. Hold the ak hammer directly in lin€ with tho valve
VALVECUIDEDRIVER
Y AVAILAELE $.rido to pr8vont damaging the driver.
6,4 mm
{O.25ln} 5, Turn the headover and drivethe guideout toward the

l_l camshaftside of head.

87 mm +tr+- 57mln lr_r


l3.rt:l In) I l2-24h,tl 1 1 . 3m m
O.44In)
R€moval
andinstallation
VALVEGUIDEDRIVER. 6.6 mm
07942-6570100

Selectthe properreplacementguidesand chillthem in


the freezersectionof a refrigeratorfor about an hour.

Usea hotplate oroven to evenlyheatthecylinderhead


to 3OOoF{150oC). Monitor the temperarure\^iith a
cooking thermometer.

VALVEGUIDEDRIVER
COMMEBCIALLY
AVAILABLE

lo -\

R@ig
CAUTION: lf a valve guide still won't move, drill it out with a
a Do not uss a lorch; h may wan rh€ h€ad. I mm (5/16 inch) bit, then try again.
. Do not got ths head hotr6r than 3O0oF (1soocl;
oxcasaivo hsat may loosen tho valve seats. CAUTION: Drill guides only in extremo casos; you
a To avoid burns. uso hoavy glovas when handling could damage tho cylinder head it th€ gukte breaks.
ths heatod cylinde. hoad.
6. Removethe new guide(slfrom the refrigerator,one at
a time, as you needthem.

{cont'd)

6-53
Valve Guides
Replacement
{cont'd} Reaming

7. SliDa 6.5 mm (0.26 in) steel washer and the correct NOTE: For new valve guidesonly.
driver attachment over the end of the driver (The
washerwill absorbsome of the impact and extendthe 1. Coat both reamerand valve guide with cuning oil.
life of the driver).
2. Rotatethe reamerclockwisethe fulllengthofthe valve
guide bore.

T:-r-w
3. Continueto rotatethe teamerclockwisewhile remov-
ing it trom the bore.

4. Thoroughlywash the guide in detergentand water to


DRIVER 6.5 rm 10.26hl ATTACHMET removeany cutting residue.
WAHSER
5. check clearance with a valve (page 6-52)

o Verify that the valve slides in the intake and ex-


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

REAMER
HA'{DLE
VALVEGUIDEDRIVER,
6.6 mm
07942-65701fi,

07984-65701OC ol
07984-657010D
Vdvo Guide InstatredHoight:

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

VALVEGUIDE

6-54
Valves,ValveSpringsand ValveSeals
ValveSpdngand ValveSealInstallationSequence
NOTE: Exhaustand intake valve sealsare NOT interchangeable.

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

VALVESPNNO

VALVEGUIDESEAL
IITSTALLER
oTGAO-PH701(x)

EXHAUSTVALVESEAL
(BTACKSPRING}
Replac€.

SPRINGSEAT
NOTE:Installthe valve springseats before
installinothe valve seals.

ValveInstallation
When installingvalves in cylinderhead. coat valve stems
with oil before insening into valve guides,and make sure
valvesmove up and down smoothly.

When valvesand springsare in place,lightlytap the end of


each valvestem two or three times with a plasticmalletto
ensureproperseatingof valve and valve keeprs.

NOTE; T8p the valvestem only alongits axisso you do not


bendthe stem.

6-55
CylinderHead
lnstallation
in three
2. Tightenthe cylinderheadboltssequentially
Installthe cylinderheadin the reverseorderol removal:
steps.
NOTE:
a Always use a new head gasket lst stoptorque: 40 N m (4.0 kg-m,29 lb-ft)
a Cylinderhead and engineblock surfacemust be clean 2ndsteptorque:70 N'm (7.0kg-m,51 lb-ft)
a "UP" marks on camshaft pulleysshouldbe at the top. 3rd stoptorquo: 10ON m {10.0kg-m,72 lb-ft)
. Turn the crankshaftso the No. 1 piston is at TDC (page
6-62). NOTE:
a We recommend usinga beam-typetorquewrench'
a Cleanthe oil control orifice beforeinstalling
When usinga preset-type
torquewrench, be sure
to tightenslowlyandnot to overtighten'
1. Cylinderhead dowel pins and oil control orifice must . It a boltmakesanynoisewhileyou aretorquingit,
be aliqned. loosenthe bohandretightenit tromthe Ist step'

BOLTS
HEAD
CYLINOER SEOUENCE
TONOUE

DOWEL
\ CYLINOER
\ HEADGASKET
Replace.
\
0

OIL CONTROL
ORIFICE
Clean.

O-RING
Replace.

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

6-56
RockerArms/Camshafts
and Seals/Pulleys
Installation
lnslallthe intakemanifoldand tighten the nuts in a
criss-crosspaltern in 2 or 3 steps. beginningwith . Mak6 sura drat the keyways on th€ camdrafts a]€ fac-
the Inner nuts. krg up. (No. 1 r* on TDCI.
a Valv€ locknuts should b€ loosonedand boforo scrsws
GASKET backed off botoio installation.
a Replac€the rocker arms in thsir origlnal positions,

1. Placethe rockerarmson the pivotboltsandthe valve


srems.

2. Installthe camshaftsand the camshalt sealswith


the open side (spring)facing in.

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

22 N.m(2.2kg-m,
16 tb_ft}
ROCKERARM
4. Installthe exhaustmanifoldand bracket.Tightenthe
3. Apply liquidgasketto the head mating surtacesof
nuts in a criss-crosspatternin 2 or 3 steps, begin-
the No.1 and No. 6 camshaft holders,then install
ning with the inner nuts.
them, along with No. 2, 3. 4 and 5.

GASKET NOTE:
I x 1.25mm Replace. a "1" or "E' marks are stampedon the camshaft
32 N.m{3.2kg-m,
23 rb-ft) holders.
a Do not apply oil to the holdermating surfaceof
camshaftseals.
a Apply liquid gasketto the shadedareas.
a The a.rows marked on the camshaft holders
should point toward the timing bett.

No.2

l"'ln_m*ll
1

1 0 x 1 . 2 5m m
^/'""1"'"1*"
trBfr m ffi ,
/No.

I x 1 . 2 5m m
22 N.m (2.2 kg-m,
45 N.m (4.5 kg-m,
33 rb ft)
6 x 1 . 0m m
K g H H F HWi TNTAKE

M H
16 rb-ft) 1 ON . m ( 1 . Ok g m ,

ffi4.n**"
GASKET 7 tb-tr) 6r 16r
Replace. Ili H H &{
pI
M

tru
HEAT INSULATOR liT

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

{cont'd)

6-57
RockerArms/Camshaftsand Seals/Pulleys
lnstallation(cont'd)
Torque:Exhaust
SDecifi6d
4. Tightenthe camshaftholderstemporarily'
ExceotG), (O: 10 N m {1.0kg-m,7lb-ft)
a Make sure that the rocker arms are properlyposl- 1 2 N . m{ 1 . 2k s - m 9
, lb-ft)
tioned on the valve stems' @, @i

\ lnstallthe back cover.

5. Pressin the camshaftsealssecurely. 8 . Installkeys into camshaftgrooves.

NOTE: To set the camshaftsat TDC positionfor No'


1 piston, align the holes in the cdnshafts with the
holesin llo. 1 camshaftholdersand insert 5'O mm pin
punchesin the holes.

Tighteneach bolt in two stepsto ensurethat the rock-


ers do not bind on the valves.

Specified Torque: lntake


qceq@,O, 1ON.m (1.Okg'm, 7 lb-ft)
(9,(r, 12 N.m (1.2 kg-m,I lb-ft)
INTAKE

I x 1 . 2 5m m

9. Push camshaft pulleys onto camshafts,then tighten


the retainingbolts to the torque specified'

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

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


connectorsare installedcorrectly.

6-58
Timing Belt and Timing BalancerBelt
lllustratedIndex
NOTE:
. Referto page 6-62 for posilioningcrankshaftand pulley beJoreinstallingtiming belt.
a BeJoreremoving,mark directiono{ rotationon each belt.

POWERSTEERING IP/SI ALTERNATOR


PUMPBELT BELT LOWERCOVEB
Adiustment,section17 Adjustment,
section23 ADJUSTTNG
NUT COVER Removethe tive bolts.
45 N.m {4.5 kg-m,
33 rb-ft)
6x1.0mm
12Nm(1.2kg-m, RUEBERSEALS
9 ReDlace
when
damagedor deto.iorated.

CAPt{UT
6 r 1 . 0] n m
'lON.m
l1.Okg-m,7 lb-ftl

CYLINDERHEAD
6x1.0mm
1 2 N . m ( 1 . 2k g - m ,
CRANKSHAFI I lb'ft)
PULLEY8OL R'LLEY WASHEB------+o
14 x 1.25 mm Removgany oil.
RUEBER SEALS
220 N.m (22.0 kg-m, 159 tb-ft) Roplacewhen damaged
Apply engineoil to th6 bolt
or detoriorated.
thrcads, but not to the
surfacethat contacts the 8 r 1.25 mm
washer. 38 N.m(3.8ks-m,27lb-ft)
KEYS
TEI{SIO'{ER
SPAII{G

BELT CAMSI{AFT PULLEYS


TE SIOI{ER tENStOa{ERS
SPRII{G

I(EY

TIMINGBELT
ADJUSTING BOLT
68 N.m(6.8kg-m,49lb'ft)
Remove BELT
any ofl. Inspection,pag6 6-60
6 x 1,0 rhm Adjustment,page 6-60
12 N.m (1.2 kg-m,I lb-ftl Beplacement,page 6-63

TIMING BALANCERBELT surlacelacing in.


Inspectjon, page 6-61. Bemoveany oil.

6-59
TimingBelt
Inspection TensionAdiustment

1. Disconnectthe alternatorterminaland the connector, CAUTION: AtwaF adiust timing boh tension with thew
then removetheenginewire harnessfrom the cylinder enginecold.
head cover.
NOTE:
2. Removethe cylinderheadcover. o The tensioneris springJoadedto applypropertensionto
the belt automaticallyafter making the following ad-
3. Removethe middlecover. justment.
. Alwavs rotate the crankshaft counterclockwise when
4. lnspect the timing belt for cracks and oil or coolant viewed trom the pulleyside. Rotatingit clockwisemay
soaking. result in improperadiustmentot the belt tension.
. Inspectthe timing balancerbelt beforeadjustingthe belt
NOTE: tension.
a Replacethe belt if oil or coolant soaked. a Do not loosenthe adjustingnut morethan one full turn'
. Removeany oil or solvent that gets on the belt.
1. Disconnectthe alternatorterminaland the connector,
Inspectthis
area{or wear.
then removetheenginewire harnesstrom the cylinder
head cover.

2. Removethe cylinderheadcover.

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

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

Rotatepulley
ano rnspect
belt.

After inspecting, retorque the crank*|aft pulley bolt to Rotatethe crankshaftcounteclockwise3-teethon the
22ON.m (22.Okg-m, 159 lb-ft). camshafqpr.rlley,then reloosenthe adjusting nut to
createtensionon the timing belt.

o. Tightenthe €diustingnut.

After adiusting,ratorquethe crankshaftpulleybolt to


22O N.m {22.Okg-tn, 159 lb-ft).

6-60
TimingBalancerBelt
Inspection
1, Disconnectthe alternatorterminaland the connector,
then removethe enginewire harnessfrom the cylinder
headcover.

2. Removethe cylinderheadcover.

3. Removethe middlecover.

4. Removethe crankshaftpulley.

5. Removethe lower cover.

6. Installthe crankshaftpulley.

7. Inspect the timing belt for cracks and oil or coolant


soaking.

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

Rotatepullgy
andinspectbglt.

After insp€cting,retorquethecrankshaftpulleybolt to
22O N.m (22.Okg-m, 159 lb-ft).

NOTE: Refer to psge 6-66 for timing batancerbelt


tensionadiustm€nt.

6-61
Timing Belt
PositioningCrankshaftBeforeInstallingTimingBelt.
NOTE: TDCFOSITION:
CAMSHAFT
. Installthe timing belt with the No. 1 piston at TDC.
. After installing,retorquethe crankshaftpulley bolt to ,,UP''MARKS
22ON.m (22.Oks-m, 159 lb-ft).

CMN(SHAFTTDCFOSITION:

POINTERS
ON BLOCK

TDC MARKS
Align the marks
on the pullays.

FLYWHEEL DRIVEPLATE
PI Pt CHES,5.0nm

CAUTIOI{: Romovc thr pln Frnchos attor installlng


th. tlming boh.

NOTE: When turning the crankshaft with a socket


wrench, installthe crankshaJtpulleyand the pull€y
bolt.

6-62
TimingBeltandTimingBalancer
Belt
Replacement
CAUTION: lmpoct tho water pump whon roplacing the 3. Removethe mountingbolts,nutsandpoly-V-b€lt
from
timing b€h lpags 10-12). the powersteering(P/Slpump.
NOTE; Turn the crankshaftso that the No. I oiston is at NOTE:
TDC (page6-62). . Oonot disconnect the P/SpiDeandhose.
. Afterinstalling,
adiustthetensionot the P/Spump
1. Removethe sDlashshield, belt (seesection 171.

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

BOLTS/T{UTS
8 r 1.25rfn
SPLASHSrmU) 22 N.m 12.2kg-m,
16 rb-ftt
Disconnectthe connector, then remove the cruise 4. Disconnectthe alternatorterminaland the connector,
control actuator. then removethe enginewire hamessfrom the cylinder
headcover.
NOTE:
a Do not disconnectthe control cabte. Loosen the altemator mounting bolt, nd rnd the ad-
. Takecarenot to bendthe cablewhen removingthe
iusting boh, then removethe ahernatorbeh.
actuator.Always replacea kinkedcablewith a new
one. NOTE: After installing,adiustthe tensionof the alter-
CNU|sECONTROL nator beh {seesection 23).
ACTUATOR 6r1.0mm
1oNm(1.okg-m, MOUI{TIXGBOLT
7 tb-ft) J:aLIERNlton tO x 1.25mrn
ool{]{ECTOR 45 N.m(4.5kg{, 33 lb-ft)

ADJUSTING MOUNTI{G NUT ALTERI{ATOR


BOLT 8xt.25mm BELT
22 N.m {2.2 kg-m,
16lb_ft} (cont'd)

6-63
TimingBeltandTimingBalancerBelt
(cont'd)
Replacement
6. Removethe cylinderheadcover. 1 0 . Removethe pulleybolt and the crankshaftpulley.Re-
move the two rearboltsJromthe centerbeamto allow
7. Removethe middlecover. the engineto drop down and give clearancetoremove
the lower cover,
8. Removethe side enginemount.
1 1 .Removeth€ rubberseal aroundthe adiustingnut. Do
9. Removethe dipstick and the pipe. not loos€nthe adjustingnut.

12. Removethe lower cover.

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

O-RING
Replace.

1 2 x 1 . 2 5m m
65 N.m {6.5 kg-m,
47 tb,ft)

RUBBERSEALS
Replacewhsn
damagedor
deterio.ated.

RUBBERSEALS
Replace
when
RUBBERSEAL
Replacewhen MIDDLE COVER oamageool
damagedor
det€aiorated.
Semove any
o .
6x1.0mm
12 N.m (1.2 kg-m.9 lb-ft)

PULLEYBOLT
1 4 x 1 . 2 5m m
220N.m(22.Okg-m,159lb-ft)
Apply engineoil to the
bolt threads, but not
to the surfac€that
TIMII{G BELT
contacts the washer. Inspoction, pago 6-60
Adiusting, page 6-60
CRAI{KSHAFT ADJUSTIf{GNUT 6 x 1 . O m m
PUI.LEY 10 r 1.25 mm 1 2 N . m { 1 . 2k g - m ,
Removeany oil. 45 N.m {4.5 kg-m, 9lb-ft)
33lb-ft)

6-64
t

13. Lockthe timing belt adlusterarm in placeby install- 16. Loosen6 x 1.O mm lock bolt and the adjustingnut.
ing one of the 6 x 1 .O mm lower cover mounting Pushon the timing belt adjusterpulleyto removeten-
bolts, sion trom the belt, then tighten the adjustingnut.

14. Loosenthe timing belt adjustingnut. Pushon the pul- 17. Removethe timing b€lt.
leyto removetensionfrom the timing balancerbelt,
then tighten the adjustingnut. 18. lnstallthe timing beh in the reverseorderof removal.
- Beforeinstallingthe timing belt, positionthe crank-
'15.
Removethe timing balancerbelt. shaft and camshaft pulleys as shown on page
6-62.
NOTE: lf you are removingonly the timing balancer
belt, go to step 21 . li you are removingboth belts, 19. Per{orm the timing belt tension adiustment {page
continuewith this procedure. 6-60t.

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


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

(cont'd)

6-65
Timing Belt and Timing BalancerBelt
(cont'd)
Replacement
21 , Make surethe crankshaftis positionedwith the No. 1 26. Tu(n the crankshaft pulleYabout one turn counter-
piston at TDC. clockwise. then tighten the adiusting nut to the specl-
tied torque.
22, Alignthe grooveon the front balancershaft pulleYwith
the pointeron the oil pump housingas shown. NOTE: Both belt adiusters are spring-loaded to
properlytensionthe belts.Do not applyanyextra pres-
23. Align the rearbalancershaft pulleyby usinga 6 x 1OO sure to the pulleYsor tensionerswhile performingthe
mm bolt or equivalentas an alignmenttool. adjustment.
Scribea line 74 mm (2.9 in) Irom the end of the bolt. REARBATANCER
lnsertthe boh into the maintenanceholeto the scribed
line.

24. Loosenthe adjusting nut and verifY that the timing


balancerbelt adiustermoves freely.

25. Installthe timing balancerbelt. Removethe 6 x 1OO


mm bolt from the rear balancershaft.

74 mm (2.9 in)

6 r 1OOmm BOLT

R€place.
6 x 100 rm BoLT
12 mm SEALI G AOLT
30 N.m (3.0 kg-m, 22lb-ft)
NOTE: Tighten the bolt after
installingthe belt.

ADJUSTING]{UT

Align the g.oove oI the TIMII{GBALAT{CER


EELT
front driven pulley with DN|VEIT
PULI..EY
the pointer on the oil
pump housing

BALAI{CER BELT
ORIVEPULLEY
Set the crankshaft
at TDC.

6-66
27. Removethe 6 x 1,Omm bolt from the timing belt ad- 31. Installthe middlecover.
juster arm.
32. Installthe crankshaftputley.
28. Removethe crankshaftpulley.
33. Coat the throads 8nd seating face of the pulley bolt
29, Installthe lowercover. with engine oil. Install and tighten to the specified
toroue.
30. Installa rubberseal aroundthe adiustingnut. Do not
loosenthe nut. Spocifiedto|ql|3: 220 N.m {22.0 kg-m, 159 tb-ft)

RUBBERSEAL RUBEERSEAL RUEBERSEALS


Replacewhen Replac€when Repl6c6when
damagedor damagedot damag€dor
deteriorat€d. MIODLECOVER deteriorated. dsteriorated.

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

PULLEYEOLT
1 4 r 1 . 2 5m m
22ON.m 122.0ks-tn 6 x 1.Orrn
159lb-ft) 12 N.m ll.2 kg-m,I lb-ftl
CRANKSHAFT
PUI.LEY 10 x 1.25rm
Bemoveanyoil. 45 N.m(4.5 kg-rn,33 lb-ftl

6-67
Valve Clearance
Adjustment
NOTE: Adjust valves on No. 1 cylinder.
. Valvesshouldbe adjustedcold when the cylinderhead
temperature is lessthan 1oOoF(38oC). Valve Cl6a?anca:
. After adjusting,retorquethe crankshaftpulley bolt to lntak€: 0.07-O.11 mm (O.0O3-0.0O4in)
220 N.m (22.0 ks-m, 159 lb-ft) Exhaust:0.15-0.19 mm (0.006-0.007 in)

1. Removethe cylinderheadcover 4, Loosenlocknut and turn adjustingscrew until feeler


gaugeslidesback andJonhwith slightamountofdrag.
INTAKE

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

"UP" markson the camshaft Tightenthe locknut andcheckclearanceag8in.Repeat


2. Set No. 1 pistonat TDC.
pulleysshouldbe attop. andTDC Arooveson the cam- adjustmentif necessary.
shaft pulleysshould align with cylinderheadsurface.

Number 1 fiston at TDC:

,,UP" MARKS

TDC MARKS
Align the marks
on the pulleys.

6-68
6. Rotatecrankshsft 18Oocounterclockwis€(C8mshaft 8. RotatecrankshaftI8Oo counterclockwiseto bring
pulleystums 9Oo).The "UP" marks should b6 at €x- No.2 Distonto TDC. The "UP" marks shouldbe at
haust side. Adjust valveson No. 3 cylindor. intake side. Adjust valveson No. 2 cylinder.

filumber 3 Diston at TDC: Number 2 dston at TDC:

,,UP" MARKS

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

Numbor 4 piston 8t TDC:

6-69
1

GylinderHeadA/alveTrain
lHz2!-l engine)
SpecialTools ...........6-72 Camshafts
lllustrated
lndex..............................
&73 Inspectbn ............6-93
wEc Vdves, VafueSpringsand ValveSeals
Troubleshooting Flowc*rart - Removal ..............6-95
WEC Solenoid Vdve ................6-75 Vdve Springand Vdve Seal
WEC PressureSwitch... . . ....... . .. 6-77 lrutalationSequence................. 6-101
VTEC Sol€noidValve Inspoction...... 6€0 Vdve lnstallation ... 6-102
Rocker Arms Vaho Seats
ManualInspection. . . . . . . . . . . . . .. . . . . . . . . . 6€1 Reconditioning ......6-97
Inspeabn UsingSpecialToo|s........6€1 Vdve Gukles
Inspectbn . .... .... . .. 6-92 Valve Movernent ........................,6-98
Cylinder llead Replacemst..... ..,.6-99
Removal ..............6€:l Reaming .........,....6-t0O
Warpage......... .....6-98 TimingBdt and nming BalancerB€at
Instalhtion ...........6-103 ltusratodlndex....................,.....
. 6-107
Rocker Armg and Shafts Feplacemem..... ....6-109
Removal ..............6€g TimingB€lt
Locations. . . . . . . . . ....6-90 Inspection ............6-108
Clearance ...... .. .....6-91 TimlngBdancerBeh
Installation ...........6-102 Inspoction ............6-10g
Lost motion AssemHies Vaho Cbarance
Inspection ............ 6-92 Adfu3rnora ..........6-1tE
Ref. No. I Tool Number Descfption Oty ] Page Rotorcncr

o OTHAH_PJ701OA
or O'?HAH-Pl'lO1OB vaNe Gu\de Reame(, 5.5 mm 1 6-100
@ OTLAJ_PR3O2OA Air Stopper 1 6 - 8 1 ,8 2
@ oTMAA-PR70t10 Tappet Adiuster 1 6 - 11 5
@ 07MAA-PR70120 Tappet Locknut Wrench 1 6-115
\!, OTMAF_PR90IOA Valve SpringCompr€ssorAttachment
Extension 6-95
@ 07NAG-P130100 Timing Belt Slider 6-106
o 07742-O010100 Valve Guide Driver, 5.5 mm 6-99, 100
6-95
@ o7757-PJ10l0A Valve Spring Compressor Attachment

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

o
il
B
A---J
U @ \9 @

:r------------ r-blrrrlllsaf q:\


"_-___e.dD/

o @

6-72
lllustratedIndex

CAUTION: To avokl damaging the cylinder h6ad, wait until the engine coolant t€mporatur€ dlope below IOOoF (38oC) before
removing h.

NOTE:
a Use new O-ringsand gasketswhen reassembling.
. Use liquidgasket, Pan No. 08740-OOO1.
a Clesnthe oil controlorifice betoreinstalling.

Prio,to r"""sembling, clean all the parts in solvent.dry them, and apply lubricantto any contact pans.
I
x 1 . 0m m
PLUGWINE 1 0 N . m ( 1 . 0k g - m ,7 l b - t t )
COVER

CLAMP

CYLINDERHEAD
COVER

6 x 1 . 0m m
1 ON m ( 1 . 0k g - m , 7 l b ' f t )

WASHER

Apply liquid gask€t


to these pornts.
RUBBEB
SEALS
Replacewh€n I r 1 . 2 5m m
or deteriorated. 26Nm{k2.6kg-m,
't lb,ftl
9
6r t.Omm 6x1.Omm
1 2N . m( 1. 2 k g , m ) 1 2 N . m { 1 . 2k g - m ,
RUBBERCAP 9tbft)
Replacewhen
damagedor CAMSHAFTHOLOER
dete orated.

AKE CAMSHAFT
8 x 1.25 mm page 6-93
18Nm(1.8kg-m
13 tb-ft)
page6-105
Installation,
Replace. CAMSHAFTPULLEYS
DISTBIBUTOR Removal,page 6-86
page6-105
Installation.
KEYS
wEc
SOLENOID
VALVE

1 0 x 1 . 2 5m m
5 x kl.0 mm 5 1 N . m ( 5 . 1k g - m ,
12 N . m ( 1 . 2k g - m 37 tb-ft)
I tb-ft) EXHAUST 'lO
x 1.25 mm
CAMSHAFT 45 N m (4.5 kg m, 33 tb ftl
VTEC SOLENOID O-RING
VALVE FILTER Replace.
Replace. 8 x 1.25 |nrl
22Nm(2.2koJn-
OIL CONTROL 6x1.0mm qo.' r o ru--ttt
ORIFICE 1 2 N . m ( 1. 2 k g m
Clean. BACKCOVER I lb{tl enctrue
uourur {cont'd)
BRACKETB

6-73
lllustratedIndex
(cont'd)
CYLINDERHEAD
NOTE: Cleanthe rocksr shaft orificeswhen installing. BOLTS
1 2 x 1 . 2 5m m
100 N.m {10.0 kg-m,72 lb-ft)
Apply clean engineoil
VALVE KEEP€RS
ROCIGRABM ASSEMBLY to threads and
EXHAUSTVALVE IPRIMARY,MIO, SECOI{DARY) underthe bolt heads.
SPRIG NI{ER VALVEKEEPERS
,f,"*'*o"'o'n"
INTAKEVALVE
EXHAUSTVAL SPRINGINNER
SPRINGOUTER

SEALINGBOLTS20 mm INTAKEVALVE
60 N.m (6.0 kg-m,43lb-ftl SPNINGOUTER
O.RINGS
Replace.
WASHEB Replacement,pag€s6-95
Replace.
SPRINGSEAT
ROCKERSHAFTS ALVE GUIDE
Inspection,page 6-98

I
Replacement,page 6-99
Roaming,page6-10O
LOSTMOTION
ASSEMBLY
VALVESEAL INTAKEBOCKER
SHAFTORIFICE
Clean.
VALVE
CYI"INOER HEAD
Removal,page 6-83
Roconditioningvslve
LOSTMOTION s€st, page 6-97
ASSEMBLY Warpage,page 6-98
Installation,page 6-103
EXHAUSTROCKER
SHAFTORIFICE
Clean. EXHAUST VALVE
i INTAKE VALVE
R€placement,
Oimension,pag€ 6-95
CYLINDER HEADGASKET Reconditioningvalve
{METALGASKETI seal, pago 6-97
Replace. Adiustment, page 6-1 '15

DOWEL
PINS

NOTE: Do not installthe oil control orifice.

6-74
VTEC
TroubleshootingFlowchart - VTEC SolenoidValve

-f6il lttll Indicato.Lamp(MlL)indicatesCliagnostic


Maffunction TroubleCode(DTC)21:A problemin the \rrEC
Solenoid
ValvecircNJit,

-r-' \
---.1- /
116l -l 21l--
----i-

- MIL hr! b€on ,aoon6d on.


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

Do tho onglno c-ontrol modole


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

Wann up ongino to normd op€rat-


ing tompo.ature lradiator t6n
como! onr. *Road Test:
Acceleratein 2nd gear to an onginespgedover 6000 rpm.
Hold that enginesp€edfor at least two seconds.
Do thg RoadTest.r Ropeatthis test at least threo times.

Intorrnlttaot lailuro, 3y8tom ir OK


ls MIL on and does it indicate at thi! tim6.
code 21? Ch6ck tor poo. connoctiona o.
10036 wiro. at VTEC aolonoid
valve and ECM,

Dbconnoc-t tho 1P connoctd from


tho VTEC aolonold vdv6.

Ch6d( lor cootinuitv betwoon lP


connoctoa torminal and body

ls there 14-300?

lTo page6-761

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

Reconnoct 1P connoctof to VTEC


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

Measuro the rosfutanco botween


A4 t€rmlnaland 426 t6rminal.

Ch€d( lor ogdt or !ho.l In wlto ba-


ls there14-30 0? tw.on ECM lnd VTEC lohnold
vdvg.

substituts a known{ood ECM


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

6-76
TroubleshootingFlowchart- VTECPressureSwitch
@'l l2rl I Uafun"tionIndicatorLsmp{MlLlindicatesDiagnostic
TroubteCodelDfcl 221 A Droblem in the
VTECPressureSwitch circuit.

r.-l - f-;;r
!r{=r j- ta I

- MIL h6 baan rcponod on.


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

Do the ongine control moduls


(ECMI Bgset Procedure lpags
11-43).

Warmup engineto normaloper-


ating temp€mtur€lradiEtorfan *Ro6d Test:
comesonr. Accelorgte in 2nd 96.r to on gngine spoed ovfl 6000 rpm.
Hold that engino speod for at loast two s€conds.
Repsat this test 6t lgagt thr6€ timos.
Do the RoodTest.'

lr tmltt nt dura, !y!t!m b OK


rt lhl! tlmc.
Chlck td poor conn.ctlionr ot
loota wklr rt VTEC prct.or.
rwltch lnd EM, VTECPRESSURE
Tu.n the ignition switch OFF.

Digconnoct the 2P connoctor from


th€ VTEC oressuro switch.

Chsckfor continuivbstwoentho
2 terminalson the VTECpreasurs
switch.

Turn the ignition switch ON.

Mga6urcthe voltags betw66n the


8LU/BLK wire 6nd body grolnd.

{To pags 6-78)

(cont'd)
VTEC
TroubleshootingFlowchart- VTECPressureSwitch (cont'dl

(Frompage 6-77)
Inspoct lor an opon oa thort to VTECPRESSURE
ground ln th. BLU/BLKwiro b.- swtYcH
tw6€n tho 2P connccto. tnd D6
ls there approx. 10 V? t.rmlnll ol th. EcM. It wko b oK,
rub.iltuto r known-good ECM
and ictort.
Measurs the voltage across the
8LU/BLKand BLK wires in 2P con-
nector.

Rgpolropon d.ori In BLK wko bo-


ls ther6 approx. 10 V? twc€n lha 2P connoctor gnd body
ground.

Turn the ignitionswitch OFF. 1 0v ?

Reftove 10 mm soaling bolt €nd


connect oil prgss!re gauge. OIL PRESSURE
GAUGE
COMMERCIALLY
AVAILABLE
Connoct a tachomster {se€ sec-
tion 1'1).

Start the €ngine and warm it uP


I to normsl operatingtemperature.

WASHER
Replaco.

Check oil prossure at engine


'l,OOO,3,0OOand 5,0OO
speedof
rpm.
NOTE: Keepmeasutingtimo as shon SEALINGEOLT GAUGE JONT ADAPTOR

ri as Dossiblebecausgengineis running
with no load (lessthan one minutel.
20 N.m (2.Okg-ln, SNAP.ON MT26-17
t 4 tb-ftt 10 x l.O mm
. Use new wash€r when
ls pressurebelow 50 kPa (O.5 In3pocl tho VfEc tol.nold v.lv!. installing the sealing bolt.
kg/cm', 7 psi)7

'l
Disconnectth€ P connectorfrom
the VTEC solenoid valve,
F.
iiri Aftach the battory positive termi-
;i nal to the GRN/VVHTtermin6l

{To p€ge 6-79)

6-78
(From page 6-78)

Start th6 engine €nd check oil


p.essure at 5,OOOrpm.
PRESSUREGAUGE
COMMERCIAI.IYAVAILAALE

WASHER
R6place.

NOTE: Keep rl|ossuring timg as short


as poasiblebgcauseengin€is running
with no losd (l6ssthan one minute).
SEALIIIGBOLT
20 N.ln l2.O kg-ln, S]{AP-ONMT26-17
14 tb-frl 10 r 1.0 rnm
. Usonew washgrwhen
installingthe sealingbolt.

ls p.essure above 4OO kPa


(4 kg/cm', 57 psi)? Inrpoct tho VTEC rol.nold vCv..

Turn the ignition switch OFF.

Reconnect the 2P conn€ctor to


the VTEC Dressureswitch.

Install the tgst hamess (page


11-251.

Stsrt the engins and run above


5,OOOrpm. Measurethe voltage
between D6 l+l and O22 l-l
terminal ol the ECM.

Subrlhute a known,good ECM


.nd r.chock, It rymptoh/lndic.-
tlon gooa lwsy rcplsce tha o.igi-
nll ECM.

6-79
t-

WEC
WEG SolenoidValve InsPection

1. Disconnectthe 1P connectorfrom the VTECsolenoid 4. lf the filter is not clogged, push the VTEC solenoid
valve. valve with your finger and check its movement'
2. Measureresistancebetween the terminal and body o lf VTECsolenoidvalve is normal,checkthe engine
grouno. oil oressure.
Resistance: approx 14-30 ohms

6x1.0mm
12 N.m 11.2kg-m,9lb-ft)

lf the resistanceis within specifications,removethe


VTEC solenoid valve from the cylinder head, and
check the VTECsolenoidvalve filter for clogging.
o lf there is clogging,replacethe engineoil filter and
the engineoil.

;.1

Fl VTEC SOLENOIDVALVE
i
' Il
r t
I

VTEC SOLENOIDVALVE
FILTER
Replace.
6x1.0mm
l 2 N . m ( 1 . 2k g - m ,g l b ' f t )

6-80
RockerArms
ManualInspection InspectionUsingSpecialTools
Removethe cylinderheadcover.
o B€toro using the spodd tool (Valv! lmp€ction Tooll,
Push the mid rocker a.m on the No, 1 cylinder mak6 sure that tho aL pnesaurogauga on th6 air com_
manually. pressor indkrat.s ovor 250 kpa (2.S kg/cmr, 36 p3l).
o Inspect th€ valv€ clearance before rock€r arm in-
Checkthatthe mid rockerarm movesindependentlyof spoctbn.
the primaryand secondaryintake rockerarms. a Covcr thc dming bah with a lhop towol to fotoct thc
beh frcm o0 roakhg,
MID ROCKER . Check th. mH rocksr e]m of 6sch xilton Et TDC.
ARM
1. Removethe cylinderhead cover.

2. Plugthe relief hole with th€ speciattool.

EXHAUST

4. Checkthe mid rockerarm of each cylinderat TDC.


a lf the mid rocker arm does not move, r€movethe
mid, primaryand secondaryrocker arms as an as-
sembly and check that the pistons in the mid and
pfimary rockerarms move smoothly.
o lf any rocker arm needs .eplacing, replace the
primary,mid, and secondaryrockerarms as an as_
semblv.

(cont'dl

6-81
RockerArms
InspectionUsingSpecialTools(cont'd)
3. Removethe bolt and w8sherfrom the inspectionhole 4. Loosenthe regulatorvalveon the valveinspectiontool
and connectthe valve inspectiontool. . and applythe specifiedair pressureto the rockerarm
pistons.

Sp6dfied A Pr$sui€:
250 kPa (2.5 kg/cm', 36 psil
- 5Oo kPa (5.0 kg/cm', 71 Fil

Makesurethat the intakeprimaryand secondaryrock-


REGULATOR VALVE
Pullthe leverand er armsaremechanicallyconnectedby the pistonsand
turn to adiust. that the mid rocker arms do not move when pushed
manuallv.

MID ROCKER
ARM

LOSTMOTION
ASSEMBLY

1 0x 1 . Om m
ADAPTER o lt any mid rockerarm independentlyof the primary
SEAUNGBOLT
1 Ox 1 . 0m m S]{APONMT26-17 and secondary rocker 8rms, replace the rocker
20 N.m(2.0kg-m, o. EOUIVAEI{T
arms, as a ser,
14 lb-ft)
,,1 Removethe tools.

Checkfor smooth operationoI the lost motion assem-


'f

bly. lt is compressedslightlywhen the mid rockerarm


is lightlypushedand compresseddeeplywhen the mid
rockerarm is stronglyPushed.
. ReDlacethe lost motion assembly iJ it does not
move smoothly.

After insDection,check that the malfunctionindicator


lamo lMlL) does not come on.

6-42
CylinderHead
Removal
Engineremovalis not requiredlor this procedure. 1 . Disconnect the negative terminal from the battery.

@E Drainthe enoinecoolant(seesection 1Ol.


. MalG surs Fcks and salaty stands re dac.d p(opody a Removethe radiator cap to speed draining
ard hoist brack6is ar€ attachod to co.roct positions on
ths engln6. J. Relievefuel pressure.
. Mako sur€ the car wlll not loll off stards and fall while
you aro working undor it. @ Do not moke whllo wor{ng on ft,"l
sFt€m, k€3p opan f!|m or rFrt away from work
CAUTION: Eroa. Drain fr.rCor{y lnto an apFov€d contakrr.
. Uss tender covors to avokl damaglng paintad surfaces,
o Undug rhe wiing connoctoB ceefuf,y whte holdlng th€ 4. Removethe intak€ air duct,
conn€ctor ponion to avokt damage,
a Ma.k aI wiing and hosos to avoH misconnectbn. Also, Removeth€ fud feed hose and evaDorativeemission
bo sur€ that they do not contact othor widng or hosa3 01 (EVAP)controlcanistor
hos€from the intakemanifold.
interfere whh oth€r DarB.
. To avokl dsmaging the cytrder hrad. wait until tho
coolanttemp€raturedropobelow IOOoF(38oC)engine
b€foro bosening the rotaining bolts,

NOTE:
. Inspect the timing belt belore removing the cylinder
head.
a Turn the crankshaftpulleyso that the No, 1 piston is at
top dead center (page6-1061.
a Mark allemissionhosesbeforedisconnectingthem.

NOTE: The radiomay have a coded theft protectioncir-


cuit. Be sure to get the customer'scode numberbefore POSITIVECRANKCASE
- Disconnectingthe b8ttery.
- Removingthe No. 43 (1O A) tuse (ln the under-hood
fuse/relavboxl. o. Removethe throttle cable from the throttle body,
- Removingthe radio.
After service,reconnectpower to the radio and turn it NOTE:
on. a Take care not to bend the cablewhen removing
When the word "CODE" is displayed.enrerthe cus- it. Always replaceany kinkedcable with a new
tomer's s{igit code to restoreradiooperation. one.
a Adjust the throttle cable when installing(see
s e c l i o n1 1 ) .

ADJUSNNGNUT {cont'd)

6-83
{
"t.

CylinderHead
Removal(cont'dl
7. Removethe fuel teed hose, the tuel return hose and 9. Remove the engine ground cable lrom the cylinder
the brakeboostervacuum hose. head cover.

FUELFEEOHOSE 10. Disconnect the alternator terminal and connector,


, thsn removetheenginewire harnessflom the cylinder
h9€d cover.

6 x 1 . 0m m 6 x 1 . 0m m
8 N.m(O8 kg-m,5.8lb-ft) 10 N.m (1.0 kg-m.7 lb-ft)
l ,}

1 1. Rdmovethe power stsering (P/S)pump bolt and pump.


a Do not disconnecl the P/S hoses.

Removethe Jollowingenginewire harnessconnectors


and clamps from the cylindet head and the intake u'o-n,
li,l.3u,ll*n-..'
manifold:
a Fourfuel injectorconnectors
a lntake air temperature{lAT) sensolconnector
a ldle air control (lAC) valve connector
a Throttle position {TP)sensorconnector
a Exhaustgas recirculation(EGR)valve lift sensorcon-
nector
a Groundcableterminals
fo Enginecoolanttemperature(ECTIswitch B connector
a Heatedoxygen sensor(Ho2S)connector
a ECTsensorconnector
o ECTgaugesendingunit connector
o lgnition control module (lCMl connector
o CKP/TDC/CYPsensorconnector
o VehiclesDeedsensor {VSS}connector LOCKNUT
a lgnitioncoil connector 1 5N . m( 1 . 5k g - m ,
a VTECsolenoidvalve connector 1't rb-ft) P/SPUMPBELT
o 8 x 1.25 mm
VTECpresserswitch connector 22 N.m (2.2 kg-m.
a Intake 8ir bypasssolenoidvalve connector 16 rb-ftl
a ECTswitch A connector
a Knock sensorconnector

6-84
I

I
1 2 .Bemovethe ignitioncoil. 16, Femove the bracket and intake manifold.

*: CORROTION
RESISTANT
BOLT

* 8x1.25mm
22 N.m (2.2 kg-m, 16 lb-ft)

* 8x 1.25mm
22N,n 12.2kg-r'|,,
16 tb_ft)

1 3 . Remove the emission vacuum hoses and water '17.


Removethe selflocking nuts and disconnectthe ex,
bypasshosesfrom the intakemanifoldassembly.
haust manitoldand exhaustpipe A.
1 4 . Removethe radiStorupperhose and heaterhosetrom '18.
Remove the heat insulator, brackets and exhaust
the cylinderhead.
manifold.
15. Removethe water bypass hose and the thermostat
housing.
BBACKETS

o-Rt]{G
Replace.

6-85
CylinderHead
Removal(cont'd)
1 9 . R€movethe cylinderheadcover. 23, Removethe belt from the camshaftpulleys.

20. Removethe middlecover.

Use a wrench to loosen the maintenancebolt lf it CAUTION: Do not caimp oi b.nd


cannot be loosenedwilh an open-endwrench, a box tho tlr$ng bdt mors fran 9Oo or
wrench can be used after pullingout the lock pin bss thtn 25 mm | 1 in) h damcter'

NOTE: Useof a tool shotildbe limhedto initialloosen-


ing only.

22, Loosen the maintenanceboh by hand until it stops'


The auto-tonsionerbracketis now tixed.

NOTE:
a Neverusea tool to loosenthe maintenancebolt af-
G4?
ter initisl loosening. No Good
a ll tha auto-tensioner has been extendsd 8nd the
timing beh cannot b€ install€d,remove the auto-
tensionsr,@mpressit and lainstsllh (page6-1 12).

24. Removethe camshaftPulleYs'

CAMSHAFTPULLEYS

MAINTENANCE
AOLT

Auto-tonsioner
funstistl.
;*,6r*;i*

MAINTENAI{CE
BOLT

Auto-tensaoner
fixed in plac6.

6-86
25. Loosenthe rockerarm adjustingscrews,then remove 27, R€move ihe cylinder head bolts, then remove the
the camshaft holdersand camshafts cylinderhead.

CAUTION: To p.event warpag€, unscr€w the bolts in


soqu€nce 1/3 tutn at a time; rspeat the sequonce until
ADJUSTINGSCREWS
all bohs aro loossned.

CYLINDER
HEADSOLTLOOSENING
SEOUENCE

ADJUSTINGSCREWS

24. Rsmovethe side enginernount bracket B and timing


b€h back cover.

NOTE: Separatethe cylinderheadfrom the block with a


flat tip screwdriveras shown.

'lO
x 1,25 mm
45 N.m (4.5 kg-m,
33 rb-ft)

8 x 1 . 2 5m m
22Nm12.2kg-n',
16 tb ft)

6-87
RockerArms and Shafts
Removal

Loosenthe adjustingscrews, then remove the bolts


and the rockerarm assemblY

NOTE:
a Unscrew the camshaft holderbolts two turns at a
time, in a crisscrosspattem, to preventdamag'ng
the valvesor rocker arm assembly.
a when removingthe rocker arm assembly,do not
remove the camshaft holder bolts. The bolts will
keep the camshaft holders, the springs and the
rockerarms on the shafts.

INTAKE
No.4 No.3 No.2 No.1

i t
2. Removethe VTECsolenoidvalve 8nd fiher.

wEc solEflolD
VALVE
No.4 No.3 No.2

EXHAUST

,i"

VTECSOLENOID
VALVEFILTER 6 x k 1 . Om m
Replace. 1 2 N . m { 1 . 2k g - m ,
I tb-ft)

6-88
3. Hold the rocker arms together with a rubber band to Screw 12 mm bolts into the rocker arm shafts. Re-
preventthem trom separating. move each rockerarm while slowly pullingout the in-
lake and exhaustrockerarm shafts.

RUBBER
BAND

BOCKER
ARMS

12 mm EOLTS

4. Removethe intake and exhaustrockershaft orifice.


ROCKERSHAFT
NOTE: The shapesof the rockershaft ori{icesof the
intakeand exhaustare difterent. ldentify the parts as
they areremovedto ensurereinstallationin the original
locations.

6-89
RockerArms and Shafts
Locations
h8s ba€n im€rtod
CAUTION: Attd hstafling the ]ockor shrtt odfic.. try to tum ihe locker shaft to mak€ sura that iho oriffco
in th6 holo ot rodcr shaft conectlY. lf th. odfica b in plsce' it ehorld not tum'

NOTE:
a ldentify parts as they are removedto ensurereinstallationin originallocations'
. Inspectrockershafts and rockerarms (pages6-93 and 941.
a Rockerarms must be installedin the same positionit reused.
o Cleanthe intakeand exhausttocket shaft orificesbetoreinstalling.

erior to reinstalling,clean all the parts in sopent, dry thern and apply lubricantto any contact surfaces,
I

ARMASSEMBLIES
ROCKER
TNTAKE
cyLtNoERNUMBEB

m
I , |/ | t /
No.3 No.2 No.1

SEALINGBOLTS20 mm TNTAKE
ROCKER
60 N.m{6.0ks-m,43lb-ft} SHAFT

ri
i
I

II

ll
I
rli No.4 No.3 No.2 *oi,
\

\
RUBBER
BAND

t \
EXHAUSTROCKERARM ASSEMBLIES
\
CYLINDERNUMBER

6-90
RockerArms and Shafts
Clearance
Measure both the intake rocker shaft and exhaust rocker 3. Measureinsidediameterof rocker arm and check tor
shaft. out-of-roundcondition.

1, Measurediameterof shaft at first rockerlocation. Rocksr Arm-to-Shatt Clearance:


l sko and Erhaust
Standard{N€w}: 0.025-0.052 mm
(O.OO1O0.OO2Oin)
S€wice Limit: O.08 mm (0.003 in.)

2. Zero gaugeto shaft diameter.


Surfaceshould be smooth.

Repeatfor all rockers.


- lf over limit, replace rocker shaft and all ove.-
tolerancerockerarms.

NOTE: lf any rocker arm needsreplacement,replace


all three rocker arms in that set (primary.mid. and
secondarvl.

MICROMETER

6-91
RockerArms Lost MotionAssemblies
Inspection Inspection

NOTE: When reassemblingthe primaryrocker arm, care- Removethe lost motion assemblyfrom the cylinder
fully applyair pressureto the oil passageol the rockerarm. head and inspect it. Pushingit gently with the linger
will causeit to sink slightly.Increasingthe force on it
1. Inspectthe rockerarm piston.Pushit manually. will causeit to sink deeper.
- ll it does not move smoothly, replacethe rocker - lf the lost motion assemblydoesnot move smooth-
arm assemblY. ly, replaceit.

I
il PRIMARYROCKENARM LOSTMOTIONASSEMBLY

Check piston movement

a Apply oil to the pistonswhen reassembling.


a Bundlethe rocker arms with a rubberband to pre-
vent them from separatlng.

6-92
Camshafts
Inspection
NOTE: Oo not rotate camshaftduring inspection. Seat camshafts by pushingthem toward distributor
end ot cylinderhead.
1. Removethe .ocker arms and rockershafts,
4. Zero dialindicatoragainstend of camshaft.then push
NOTE; Rockerarmsmust be installedin the samepo- camshaft back and torth and readthe end play.
sition if reused.
CamshaftEnd Play:
2, fut the camshafts,camshaftholdersand holderpipes Standa.d{New): O.O5-O.'15 mm
on the cylinder head, then tighten the bolts to the {O.OO2-O.006 in)
specitiedtorque. S€rvicoLimh: O.5 mm lO.O2in)

Specified tolque:
@-@: 8x 1.25mm
26 N.m (2.6 kg-m, 19 tb-ft)
@-@: 6x 1.Omm
1 2 N . m ( 1 . 2k g - m ,I t b - f t )

Removethe camshaft holdersand holderoiDes


trom the cylinderhead.

. Lift camshaftout of cylinderhead.wipeclean,then


inspect lift ramps. Replacecamshaft if lobes are
pitted, scored,or excessivelyworn.
. Cleanthe camshaftholdersurfacesin the cylinder
head,then set camshaft back in olace.
a Insertplastigagestrip acrosseach journal.
o Installthe camshaft holdersand holder oiees and
torque bolts to the values and in the sequence
shown in left column.

(cont'd)

6-93
Gamshafts
Inspection(cont'd)
Measure widest portion ot plastigage on each Measurecam lobe height.
journal.

Camshaft-to-Holder Oil CNearance:


StandardlNowl: 0.050-O.089 mm
(0.0020-0'0035 in)
ServiceLimh: O.15 mm (0.006 in)

lnsooct this arca tor wear.

INTAKE EXHAUST
Pf,I MID SEC SEC MID PBI

it
7. lf camshaft-to-holderoil clearanceis out of tolerance:

a And the camshaft has alreadybeen replaced,you


\
T/B
T/B
t, T/8

must replacethe cylinderhead. Pql: PRIMARY MID: MID SEC:SECO DARY


o lf camshsft has not been replaced,first check to- T/8: Tlill G BELT
tal runout with the camshaft supported on V-
blocks.

Camshatt Total Runout: Cam l-obe Holght Standrd (Ncwl:


Standad {Newl: O.O3mm {O.OOIin} max.
Servica Limit: O.O6 mm (0.0O2 Inl II\ITAKE EXHAUST
34.041 mm 33.745 mm
PRIMARY ( 1 . 3 4 0 2i n ) ( 1 . 3 2 8 5i n l
36.856 mm 36.323mm
MID (1.451Oin) {1.43OO inl
34.971 mm 34.683mm
SECONDARY ( 1 . 3 7 6 8i n ) { 1 . 3 6 5 5i n }
Rotate camshaft
while measuring

N
- lf thetotalrunout ot the camshaftis within toler-
ance, replacethe cylinderhead,

- lf the total runoutis out of tolerance,replacethe


camshaftand recheck.It the beanangclearance
is still out of tolerance. replacethe cylinder head.

6-94
Valves, Valve Springs and Valve Seals
Removal

NOTE: ldentify valves and valve sprinos as they are re- 2. Install spring compressor. Compress spring and re-
moved so that each item can be reinstalledin its original move valve keeDef.
position.

1. Using an appropriately-sized socket and Dlastic


mallet. lightly tap the valve retalner to loosen the
valve keepersbefore installingthe valve spring com-
pressor. VALVESPNI G VALVESPRING
COMPRESSOR ATTACHMENT COMPRESSOR
EXTENSION ATTACHMENT
OTMAF_PR90lOA 07757-PJ1010A

PLASTICMALLET

SOCKET

{cont'd)

6-95
Valves, Valve Springs and Valve Seals
Removal (cont'd)

3. lnstallthe specialtool as shown. Valve Dimemions:

VALVE GUIDESEALREMOVER
LISLEP/t{ 579oo or KD 3350
COMMERCIALLY AVAILABLE

lntako Valvo
A Stsndrrd (Now): 34.9O-35.10mm
(1.374- 1.382 In)
B Standard (Ncwl: 105.rO- 1O5.7O
mm
1 4 . 1 5 0 - 4 . 1 6 1l n l
C StEndard {t{ew}: 5.475-5.483 mm
4. Removethe valve seal. (O.2156-0.2159lnl
C Ssrvlco Limit: 5.W 10.2144lnl
;r D Standard (Newl: 1 . 0 5 - 1 . 3 5m m
(O.O41-0.O53In)
D Scruico Limit: 0.86 mm (O.O34Inl

ExhaGt vllvc
A Standard {Nsw}: 29.90-3O.1Omm
( 1 . 1 7 -7 1 . 1 8 5i n l
B Standard (t{ow,: 105.OO-105.30mm
(4.134-4.1116inl
C Standard (Ncw): 5.475-5.485 mm
(O,2156-0.2159In)
5.rt45 (O.21.14Inl
iri C Service Llnh:
D Stand8rd (Ncwl: 1 . 6 5 - 1 . 9 5m m
(O.O05-O.o78In)
D S€rvico Limit; 1.45 mm (O.O57inl

6-96
Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a
valve seat cutter.

VALVE
SEAT

PRUSSIANBLUE COMPOUI{D

o. The sctual valve seating surface, as shown by the


blue compound, should be centered on the seat.
a lf it is too high (closer to the valve stem), vou
must make a second cut with the 600 cutter to
move it down, then one more cut with the 45o
cutter to restoreseat width.
a lf it is too low (closeto the valve edge),you must
make a second cut with the 3Oo cutter to move
it up, then one more cut with the 45o cutter to
restore seat width,
NOTE: lf guidesare worn (page6-98), replacethem
(page 6-991 before cutting the valve seats. NOTE: The final cut shouldalways be made with
the 45o cutter.
Carefullycut a 45o seat, removing only enough
material to ensure a smooth and concentric seat. Insert intake and exhaust valves in the head and
measure valve stem installed height.
Bevel the upper edge of the seat with the 30" cut-
ter and the lower edgeof the seatwith the 60o cut- Intak€ Valv. Stsm lmtallod Height:
ter. Check width of seat and adjust accordingly. Standa.d {Now}: 37.465-37.935 mm
(1.4750- 1.4935 int
Mak€ one mor€ very light pass with the 45o cutter So.vic€ Limit: 38.185 mm {1.5033 inl
to remove any possible burrs caused bv the other
cutters. Exhalst Valve Stom Installad Height:
Standard(Newl: 37.165-37.635 mm
Valvo Soat Width (lntake and exhaustl: (1 .rt632- 1.rt817 in)
Standard(N6w): 1.25- 1.55 mm Servicol-imit: 37.885 mm (1.4915 inl
(0.0r1!l-0.061 inl
Sorvice Llmit: 2.0O mm 10.079 in)

SEATWIDTH

VALVESTEM
INSTALLEDHEIGHT

5. After resurfacing the seat, inspect for even valve


seating; Apply PrussianBluecompound to th€ valve 8. lf valve stem installedheight is ove. the servicelimit,
fEce, and insert valve in originallocation in the head, replace valve and recheck. lf still over th€ service
then lift it and snap it closed against the seat sever- limit, replacecylinderhead;the valve seat in the head
al tames. is too deeD.

6-97
Cylinder Head Valve Guides
Warpage Valve Movement

oil clearances(page6-93)
NOTE: lf camshaft-to-holder Measure the guide-to-stem clearance with I di6l indi-
are not within speci{ication,the head cannot be cator while rocking the stem in the dirsction of nor-
resurfaced. mal thrust (wobblemethodl.

oil clearancesare within specifica-


lf camshaft-to-holder lntako valvo Stsm-to-Guldo Clearancc:
tions, check the head tor warpsge Standard(Now): 0.05-O.11 mm
tO.O02-0.OO4in)
. lf warpageis lessthan O.05 mm (0.OO2in) cylinder Servic6 Limit: 0.16 mm (O.OO6Inl
head resurlacing is not required
o lf warpageis between O.O5mm (0.OO2in) and O.2 Exhaust Valvo Stem-to-Guldc Cloarancc:
mm (O.OO8in), resurlacecylinderhead. standard (Now): 0.1O-0.16 mm
a Maximumresurfacelimit is 0.2 mm (o.oo8 in) based (O.oO4-o'006 inl
'132.0 0.22 mm (O'OO9Inl
on a height of mm (5.20 in). Sarvice Limh:

vrlvs anondcd 10 mm out trom t!|t'


PRECISIONSTRAIGHTEDGE

.rl
.,il

. . o

a lf measursmentexceedsthe servicelimit, recheck


using a new valv6.
a lf measurement is now within th€ service limit,
reassemble using a new valve.
a lf measurementstill exceeds limit, rechack using
alt€rnate method below, then replsce valve and
Measurealong edges, and 3 ways acrosscente.. guide, if nec€ssary.

NOTE: An ahernate method of ch€cking guide to


stem clearanceis to subtract the O.D. ol the vslve
stem, measuredwith a micrometer, from the I'D of
the valvs guide, measuredwith an inside microm€-
ter or ball gauge
Take the measuromentsin three plsces along th€
valve stem and three placas inside the vslve guide.
The difference between the largest guids measurs-
ment and the smalleststem measurem€ntshouldnot
exceed the service limit.

lntako Valvo Stam-to-Gddo Clcalanco:


Standard{Now): O.O25-O'055 mm
t0.O01O-O.0O22in)
Sorvlce Limit: 0.O8 mm lO.0O3 inl
Cylindol Head Hoight:
Standard(New): 141.95-142.05 mm Exhaust valvo Stom-to-Guida Cbarlncai
(5.589-5.593 in) Standard (New): O.O50-O.080 mm
(0.o020-0.0O31 inl
Sorvice Limit: 0.1 1 mm (0'0O4 Inl

6-98
Replacement
l. As illust.ated in the removalsteps o{ this procedu.e, 4. Workingfrom the camshaftside,use the driverand
use a commercially-available air-impactdriver attach- an air hammer to driver the guide about 2 mm
ment modifiedto tit the diameterof the valve guides. (O.1in) towa.dsthe combustionchamber.This will
In most cases,the same procedurecan be done us- knock off some of the csrbon and make removal
ing Valve GuideDriversand a conventionalhammer. easier.
Tool numbersare at the end of this procedure.
CAUTION:
a Always wear satoty goggles or a tace shield whon
using th€ ai. hammot.
a Holdthe air hamnrerdhectly in line with th€ valvo
VAI.VE GUIDEDBIVER guide to prev€nt damaging the driver.
Y AVAIIAALE 5.3 mm
lO.2'l in) Turn the head over and drive the guide out toward
I the camshaftside of head.
l r
t-
l_rl
10.8 mm
10.42 Inl

Removaland Installation
VALVEGUIDEDR|VER,5.S ftm
07742-d)10100

2 . Select the proper replacementguides and chill them


in the freezer section of a retrigerator for about an
hour.

Use a hot plate or oven to evenly heat the cylinder


head to 3OOoF(150oC). Monitor the temoerature VALVEGUIDEDRIVER,
with a cookingthermometer. COMMERCIAIIY
AVAILABTI

<reDi-k
lf a valve guide still won't move, d,ill it out with a
8 mm (5/16 inchl bit, then try again.

CAUTION: CAUTION: Drill guidos only in extrcmo cas€s; you


a Do not us6 a torch; lt may warp th6 hoad. could damagotho cyllnd€r head lftho guide breaks,
a Do not get tho h6ad hotter rhan 3OOoF(150"C);
€xcesslvo heat may looron tho valvo soats, 6. Removeth€ new guide(sltrom ths refrigerator.one
a To avoid burns, uso hoavy glovos whon handling at a time, as vou need them.
tho h€Eted cylindsr head.
{cont'd}

6-99
I

Valve Guides
(cont'd)
Replacement Reaming

7. Slip a 6 mm (0,2 in) steel washer and the correct NOTE: Fo. n€w valve guidesonly.
driver attachment over the end ol the driver (the
washerwill absorbsome ot the impact and extend 1. Coat both reamerand valve guide with cutting oil.
the lite ot the driver).
Rotate the reamer clockwise the full length of th€
valve guide bore.

Continue to rotate the reamer clockwise whil€


/--Tr-
-1-l--l- al;\ -r rnr removing it from the bore.
\---jY
Y
t
DRIVEB
t
6 mm 10.2in)
t
ATTACHMENT
4. Thoroughly wash the guide in dstergent and water
to removeany cutting residue.
WASHER
Check clealancewith a valve (page 6-98).

a Verify that the vslve slides in the intake and ex-


8 . tnstallthe new guide(s)Jromthe camshaftside oJ haust valve guides without exerting pressure.
the head;driveeachone in untilthe attachmentbot-
toms on the head.It you have 8ll sixteenguidesto
F do, you may have to reheatthe head one or two
more times.

VALVE GUIDEDRIVER,
5 . 5m m
07742-@10100

9*6W
)/>-A()
5.5 mm
OTHAH-PJTOIOA
oTHAH-PJ70108

Valvo Guid6 Install€d Hoight:


Standard {New):
lnrak€: 12.55-13.O5 mm (O.494-0'514 in)
Exhaust:12.55- 13.O5 mm (O.494-O.514Inl

VALVEGUIDE

6-100
Valves, Valve Springsand Valve Seals
ValveSping andValveSealInstallationSequence
NOTE: Exhaustand intakevalve sealsare NOT interchangeable,

VALVEKEEPERS

e{t'
---.,-VALVE SPRING
RETAINER
A\---.'-
v VALVE SPRING
NOTE: Pt.c. the ond ot valvo OUTER
.prlng whh clo3.ly wound coll!
row..d tho cyllndor herd.

VALVE SPNNG
INNER

II{TAKEVALVE SEAL
{WHITESPRING}
Replace.

:,.^,7
NOTE: In6tallthe valve spring seats
before installingth6 valv€ seals.

VALVE GUIDESEALINSTALLER
KD-2899
NOTE:Usesmalllo
€ndol tool.

wre
6-101
Valves,Valve Springsand
Valve Seals RockerArms
Valve Installation lnstallation

When installing valves in cylinder head, coat valve 1 . lnstallthe rockerarms in the reverseorderof removal:
stems with oil bejore insertinginto valve guides, and o Valve adjustinglocknuts should be loosenedand
make sure valvesmove up and down smoothly. adjustingscrew backedoff betore installation.
o The comDonentDans must be reinstalledin the
Whenvalvesand springsare in place.lightly1apthe end originallocations.
ol each valve stem two or three times to ensureproper
seating of valve and valve keepers (use hammer.grip Installthe lost motion assembly.
bottom).
3 . Installthe rocker arms while passingthe rocker arm
NOTE: Tap the valvestem only alongits axisso you do shaft through the cylinderhead.
not bend the stem.
NOTE: Removedthe rubber band after installingthe
rockerarms.

Il
I

4. lnstallthe rockershaft orifices.lf the holesin the rock-


er 8rm shaft and cvlinderheadare not in line with each
other, threadsa 12 mm boh into the rockerarm shaft
and rotate the shaft.
ri NOTE:
a The shapesof the rockershaft orificeslor the intale
and exhaustare different.The oriticesmust be in-
stalledin the originallocations.
o Cleanand installthe rockershaft oriticeswith new
O-rings.

EXHAUSTROCKER
SHAFTORIFICE

6-102
CylinderHead
lnstallation
Install the cylind€r head in the reverse ord6r ol 3. Tighten the cylinder head bolts sequentiallvin thr6e
removal: steps.
a Always use new h€adand manifoldgaske$.
. The cylinder head gask€t is a m6tal gasket. Take lst stop torquo: 40 N.m (4.0 kg-m, 29 lb-ft)
care not to bend it. 2nd stop torquo: 70 N.m {7.Okg-m, 51 lb-ftl
. Rotate the crsnkshaft, s6t the No. 1 piston at TDC &d st€p torque: 10O N.m {10.Okg-m, 72 lb-ftl
(pase&106).
NOTE:
Installthe cylinderhesd gasketand dowd pins on the o We recommendusinga beam-typetorque wrench,
cvlind€rhead. When using a preset-typetorque wrgnch, be sure
to tighten slowly and not to overtighten.
. lf a bolt makesany noisewhile you 8re torquingit,
loosenthe bolt and retightenit from the lst step.
CYLINOERHEAO

CYUNDERHEADBOLTSTOROUESEOUENCE

DOWELPIN
oowEl n

CYUI{DERHEADBOLTS
12 x 1,25mm
1OON.m(10.0kg-m.72 lb-ftl
Applyclean€nginooilto bolt
thrsads8ndunderboltheads.

{cont'd)

6-103
CylinderHead
Installation(cont'd)

4. lnstall the int€ke manifold and tighten the nuts in a 6. lnstallthe camshaftsand camshaft oil seals.
crisscrosspattern in 2 or 3 steps, beginningwith the
Innernuls. NOTE:
o Installthe camshaftswilh keyway facing up.
INTAKEMANIFOLD
GASKET . Installth€ oil s8al with the springside fscing in.
. The dl seal housingsurfaceshouldbe dry.

7 . Cleanand installthe oil controlorificewith new O-ring


in the oil passageof the No. 3 camshaft holde..

I x 1 . 2 5m m
22Nm{2.2kg-m,
16 lb-ft)

I x 1.25 mm
2 2 N . m1 2 . 2 l . g - m , ERACKET
16 tb-ft) o-RrNG
;;;--
ReDlac€.

Instsllthe exhaustmanifoldand brackets.Tightenthe a Apply liquidgasketto the headmating surtaceof the


nuta in a crisscrosspattern in 2 or 3 steps, b€inning No. 1 and No. 5 camshaftholderson both the intake
with th€ innernuts, and exhaustside. Confirmthat the csmshaft k€vway
are face up, then plscethe holders,togetherwith the
EXHAUSTMANIFOLD No. 2. No. 3 and No.4 camshaftholders,on the
8 x f.-$.mm GASKET
Replace. cylinderhead.
32 N.m-|C.2ks-m,
23 tb-ir)
NOTE; The arrows markedon the camshaft holders
8xL25mm shouldpoint to the timing b€lt.
22 N.m12.2kg-m,
16 tb-ft)
CAMSHAFTHOLDERS

I No.5 o.4 No.3 No.2 t{o.l

I
Ifr Ai ,:)t Bqt
I

I i
o
6x1.Omm
FA
t t l IITTAKE
10N.m We)
M H S
BFl f'q ffiTn
( 1 . 0k g - m ,
7 tb-ft) n A
' 1 0x 1 . 2 5m m ffil"t EXHAUST
I

SEI.f,-LOCKING NUT 8 x 1.25 mm


45Nm14.5kg-m,
33 tb-ft) K- \t \t ta/\el

l O x 1 . 2 5m m APPIvliquid gasket
22Nm(2.2kg-m, to tne shadedareas.
55 N.m (5.5 kg-m, 16 lb-fr)
40 tb-ft)
Replace.

6-104
9. Temporarilytighten the bolts ot the camshaft holders 1 1. Tightenthe bolts in the sequenceshown below.
and the camshaftholderoioes.

1 0 . fush the camshaftoilseal securelyagainstthebaseof O-@:8x1.25mm


the camshaft holder. 26 N.m (2.6 kg-m, 19 lb-ft)
@-@:6x1.Omm
12 N.m (1.2 kg-m,9 lb-ft}

12. Installthebackcoverot the timingbelt.

13. Installthecamshaftpulleys.

.. KEY

l
,7*, I
W&

CAMSHAFTPULLEY 1 0 r 1 . 2 5m m
5 1 N m 1 5 . ' k1 g - m , 3 7 l b - f t )

6-105
CylinderHead
Installation(cont'd)
1 4 . Installthe timing belt in the reverseorder of removal. 16. Installthe timing belt.
Adjust the valve clearanceslpage 6-1 151
- Beforeinstallingthe timing belt, positionthe crank- NOTE:
shaft and camshaft pulleysas shown a It the autotensioner has been extended and the
timing belt cannot be installed.remove the auto-
TDCPOSITION:
CAMSHAFT tensioner.@mpressit ard reinstallit {page6-1 12}.
,,I" MARKS . Take care not to damagethe timing belt when in-
stallingit.

TDC MARKS

CRANKSHAFTTDG POSITION
:

17. Tighten the maintenance bolt to make the auto-


tensionertunctional.

NOTE: Turn the maintenancebolt bv hand until it


stoos.

TDC MARK ON
THEFI.YWHEEL
Auto-tensioner
1 E lnstallthe specialtool on the intake camshaftpulley. tix€d in ploce.

EXHAUST
CAMSHAFT
PtJLLEY

Auto-tensioner
lunctional.

6-106
Timing Belt and Timing BalancerBelt
lllustratedIndex
NOTE:
a Reterto page 6-1OOtor positioningcrankshaftand pulley beforeinstallingtiming belt.
o Beforeremoving,mark directionof rotationon each belt.
ADJUSTING NUT
'lOt 1.25mm
MIDOLE
45 N.m (4.5 kg-m,33lbJt)

RUBEERSEAL
RUBBERSEALS Replacewhen damaged
Replacewhen or deteriorated.
damagedor deteriorated.
CRANKSHAFT
PULLEY
Removeany ojl.
CAP NUT
6xl.Omm PULLEYEOLT
10Nm{1.0kg-m,7lb-ft) 1 4 r 1 . 2 5m m
220 N.m {22.Okg m, 159 lb-tt}
Applyengineoilto the bolt
threads, but not to the
WASHER surtacethat contacts the

LOWERCOVER
Romovethe five bolts. POWER STEERING
BELT
Adiushent, s€ction17
RUBBERSEALS
Replacewhen damaged
or deteriorated.
6x1.Omm
'l2
N.m (1.2 kg,m, 9 lb-ft)
CAMSHAFTPULLEYS

1 Ox 1 . 2 5m m
5 1 N . m ( 5 . 1k g - m ,
37lb-ftl

ALTEBNATOR

Adjustment,section 23

TIMINGEELT
Inspectaon, page6-108
Installation,page 6 109

AUTO.TEI{SIONER
AI'JUSTING BOLT
68 N.m (6.8 kg-m,49 tb-ftl TIMING BALANCERBELT
Apply liquid gasker page6-'l08.
Inspectaon,
to the bolt lhreads
installedin the
blockside. lnstall with concave
surtacefacing in.
Removeany oil.

6-107
Timing Beft Timing BalancerBelt
lnspection Inspection

1. Disconnectthe alternatorterminaland the connector' 1. Disconnectthe alternatorterminaland the connector,


then removethe enginewire harnessfromthe cylinder then.emovethe enginewire harnessfromthe cylinder
head cover. headcover.

2. Removethe cylinderheadcover 2. Removethe cylinderheadcover

3. Removethe middlecover. 3. Removethe middlecover.

4. Inspect the timing belt for cracks and oil or coolant 4. Removethe crankshaftpulley.
soakang.
5. Removethe lower cover.
NOTE:
a Replacethe belt if oil or coolant soaked. 6. Installthe crankshaftpulleY.
. Removeany oil or solventthat gets onthe belt.
7. Inspect the timing belt for cracks and oil or coolant
soaking.
Inspectthis
areafor wear, NOTE:
. Replacethe belt if oil or coolant soaked.
a Removeany oil or solventthat gets on the belt.

Inspectthis
areator wear,

Rotatepulloy
and inspect belt.

pulleyboltto
crankshaft
retorquethe
Afterinspecting, After inspecting,retolquethe ctankshaftpulleybolt to
220 N.m(22.Oks-m,159lb-ft). 220 N.m (22.Oks-m, 159 lb-ft).
.{d.,
NOTE: Reterto page 6-1 l3 for timing balancerbelt
tension adiustment.

6-108
TimingBelt and TimingBalancerBelt
Replacement
CAUTION: Insp€ct th€ wst€r Frmp whon roplacing tho Removethe mounting bolts, nuts and belt from the
timhg boh (pag61O-121. power steering(P/S)pump.

NOTE: Turn the crankshaftso that the No. 1 Distonis at NOTE:


TDC {page6-106}. o Do not disconnectthe P/S pipe and hose.
o After installing,adjustthe tensionof the P/Spump
1, Removethe splashshield. belt (seesection 171.

MOUNTINGEOLTS LOCKNUT
15Nm(1.5kg-m,
l l

SPLASH
SHIELD
8 x 1 , 2 5m m P/SPUMPBELT
2. Disconnectthe connector, then remove the cruise 22N,m 12.2kg-m,
control actuator, 16 tb-ft|

NOTE: Disconnectthe ahetnatorterminaland the connector.


a Oo not disconnectthe control cable. then removethe engine wire ha.nessfrom the body
a Takecarenot to bendthe cablewhen removingthe srde.
actuator,Always replacea kinkedcablewith a new
one. Loosenthe ahernatormounting bolt, nut and th€ ad-
justing nut, then removethe alternatorbelt.
CBUISECONTROL
ACTUATOR 6x1.0mm NOTE: After installin€,adjustthe tensionof the atter-
10 N.m ('l.Okg-m, nstor belt (seesection 23).
7 tb-fr) MOUNTNG AOLT
1Ox 1.25 mm
ALTERNATOR 45 N.m (4.5 kg-m,
COI{NECTOR 33 tb-ft)

AL
MOUNTINGNUT BELI
CONNECTOR 8 x 1.25 mm
TERMINAL 22N m 12.2kg-m,
16 tb-ft) (cont'dl

6-109
Timing Belt and Timing BalancerBelt
Replacement(cont'dl

Bemovethe cylinderhead cover. 1 0 .Removethe crankshaftbolt and the pulley.


Removethe two rear bolts lrom the center beam to
Removethe middlecover. allow the engineto drop down and give clearanceto
removethe lower cover.
Removethe side enginemount.
1 1 .Removethe adiusterrubber seal. Do not loosenthe
1 2x 1 . 2 5m m adjustingnut.
5 5 N . m{ 5 . 5k g m ,
40 rb-ft)
1 2 . Removethe lower cover.

1 3 . Loosenthe adjustingnut. Pushon the pulleyto remove


tensiontrom the timing balancerbelt, then tightenthe
adjustingnut.

il
il
t ,
l l

1 4 . Removethe timing balancerbelt.

12 x 1.25 fifi tD. Removethe timing belt.


65Nm(6.5kg-m,
47 tb-fr)
1 6 . Removethe auto-tensioner.

9. Removethe dipstick and the PiPe

6x1.0mm
1 2 N . m( 1 . 2k g - m ,9 tb ft)

Replace.

6-110
CYLINOERHEAD
COVER

TIMING BELT
Inspection,page 6-108

6x1.Omm
12 N.m(1.2kg-m,9 lb-ft)

MIDOLECOVER

TIMINGBALANCERBELT
page6-108
Inspection,

ADJUSTIT{GNUT
l 0 x 1 , 2 5m m
45 N.m {4.5 kg-m,
33lb-tt)

RUBBER SEAL
Replace whendamaged
or deleriorated.

AUTO.TENSIONER
rullEY BOLT
1 4 x 1 . 2 5m m
220 N m (22.0 kg-m, 159 lb-ft)
RUBBER
Replacewhen
damagedor
deteriorated.
6t1.0mm
12Nm(1.2kg-m,
9 tb-ft)
PULLEY
Remove any oil.

6-111
Timing Belt and Timing BalancerBelt
Replacement{cont'd}

1 7 . Installthe timing belt in the reverseorder ol removal. NOTE: Take care not to damagethe threads or the
- Beforeinstallingthe timing belt, positionthe crank- gasketcontacl surfacewith the sctewdriver'
shaft and camshaft pullevsas shown
MAINTENANCE
,,T" MARKS BOLT
FLAT BLADE
SCREWDRIVER

STOPFER
P/N 14540-Pl3-003

2 1 . Removethe screwdriverand reinstallthemaintenance


bolt.

NOTE: Be sureto ube a new gasket.

i
MAINTENANCE
BOLT Replace.
I N.m(0.8kg-m,
6lb{r)

TDC
MARK

the auto-tensionerwith the maintenancebolt


.l , pointingup. Loosenand removethe maintenancebolt. Make sure no oil is leakingaround the maintsnance
bolt. Installthe auto-tensioneron the engine.
NOTE: Handlethe auto-tensionercarefullyso the
oil insidedoes not spill or leak. Replenishthe auto- NOTE: Make sure the stopperstays in place.
t tensionerwith oil if any spills or leaks. The total
' capacityis 8 cc {1/4 ii oz). STOPPER

I 19. Clamp the boss oJ the auto-tensionerin a vise. Use


P/N

; DiecesoJ wood or a cloth to protect the boss,


I NOTE: Do not grip the housingot the auto-tensioner.

20. lnsert a flat blade screwdriverinto the maintenance


hole. Placethe stopper {P/N 1454O-P13-OO3)on the
auto-tensionerwhile turning the screwdriver clock-
wise to comDressthe bottom.

8 x 1 . 2 5m m
22 N.m (2.2 kg-m,
16 rb-ft)

6-112
23. Removethe stopper. 26. Align the rearbalancershsft pulleyby usinga 6 x 10O
mm bolt or equiv€lentas an alignmenttool.
ADJUSTER Scribea line 74 mm (2.9 in) trom the end of th€ boh.
Insertthe bolt into the maintenanc€holeto the scribsd
line.

27. Loosen the adjusting nut and verify that the timing
balancerbelt adiustermoves freely.

28. Instsll the timing balancerbelt. Removethe 6 x 10O


mm bolt trom the rear balsncershsft.

29. Turnthe crankshaftpulleyaboutoneturn, then tighten


the adjustingnut to the specifiedtorque.

P/N 14540-P't3-OO3 NOTE: Both belt adjusters are spring-loaded to


properlytensionthe belts.Do not applyany extra pros-
24. Make surethe crankshaftis positionedwith the No. 1 sureto the pulleysor tsnsionerswhile performingtha
cylinderat TDC. adjustmenl.

25. Align the grooveon the front balancershaft pulleywith REARBALANCERSHAFT


the pointeron the oil pump housingas shown.

74 mm 12.9in)

6 r 100 mm BOLT

12 mm SEALINGBOLT
30 N.m {3.0 kg-m, 22lb-ft}
NOTE:Tighten the bolt after
installingthe belt.

Align the groove of the


tront driven pulley with REARTIMING BALANCEREELT
the pointer on the oil DRIVENPULLEY
pump housing.

BALANCERBELT
DRIVEPULLEY
Setthe crsnkshaftat TDC. (cont'dl

6-113
Timing Belt and Timing BalancerBeh
(cont'dl
Replacement
30. lnstallthe lower cover. 32. Installthe middlecover.

3 ' 1 Install
. a rubberseal aroundthe adjustingnut. Do not 33. Installthecrankshaftpulley.
loosenthe nut.
34. Coat the threads and seating face of the pulley bolt
with engine oil. Install and tighten to the specified
torque.

Spocifiedtorquo: 22O N'm (22.Okg-m. 159 lb-ft)

6x1.Omm
MIDDLECOVER 12 N.m (1.2 kg-m,9 lb-ft1

I SEALS
AD.'USTINGt{UT

Ii
RUBBER
when
Roplace
damagedor deteriorated.
1Ox 1.25tnm
45 N.m(4.5kg-m,33lb-ft)

RUBBER SEAL
Roplace whgndarn€ged
or deteriorated.

A'LLEY EOLT
-ldl
1 4 r 1 . 2 5m m
220 N.m {22.0 kg-m, 159lb-ft)
Apply engineoil to the
bolt thrsads, but not
to the surfacethat
contacts the washer.

ALTEN ATORBELT
Adiustm€nt,soction23
6x1.Omm
'12N.m(1.2kg-m,I lb-ft}

iili
I
f,

PULLEY

6-114
ValveClearance
Adjustment

NOTE: 3. Adjustvalveson No.1cylinder.


. Valvesshouldbe adjustedcold when the cylinderhead
temperatureis lessthan 1oOoF(38oC). Valve Cloalance:
. After adjusting,retorquethe crankshaftpu ey bolt to Intaks: O.15-0.19 mm {0.0O6-0.O07in}
22ON.m (22.Okg-m, 159 lb-ft). Exhaust:O.17-0.21 mm (O.O07-O.OO8in)

1. Removethe cvlinderheadcover. 4. Loosenlocknut and turn adjustingscrew until feeler


gaugeslidesbackandfonh with slightamountof drag.

INTAKE TAPPET
ADJUSTER
o7MAA-PR70'110

2. Set No.l pistonat TDC. "f" markson the pulleys 20 N.m(2.Okg'm, WRENCH
14 tb-ft) oTMAA-PR70120
should be at top. and TDC grooves on the pulleys
shouldalign with cylinderheadssurface.
Tightenthe locknutandcheckclearanceagain.Repeat
Number1 pistonat TDC: adjustmentit necessary.

FEELENGAUGE

TDC MARKS
Alignthe marks
on the pulleys

(cont'dl

6-115
Valve Clearance
Adjustmentlcont'd)
6. Rotate crankshaft 180o counterclockwise(camshaft 8. Rotate crankshaft 18Oo counterclockwiseto bring
"i" marks shouldbe at in-
pullevsturns 9Oo). The "f" marks should be at ex- No. 2 piston to TDC. The
haust side. Adjust valves on No.3 cylinder' take side. Adjust valves on No. 2 cylinder.

Numbd 3 glstonat TDc: Numbrr2 Di.tonat TOC:

,,I,, MARKS

1
I

7. Rotate crankshaft 1800 counterclockwiseto bring


No. 4 pistonto TDC, The TDC groovesare once again
aligned.Adjust valves on No. 4 cylinder.

Number4 Dl.tonat TDC:

li
I
ld
l
I

6-116
EngineBlock
SpeciafToofs ..................................7-2
lllustratedIndex................ .............
7-3
Flywheeland DrivePlate
Replacement ,.........,,..................7-7
ConnectingRod and Crankshaft
EndPlay ..........7-7
Main Bearings
Clearance ....,,..7-g
Selection .........7-9
ConnectingRod Bearings
Cfearance ....,,..7-10
Sefection .........7-11
Crankshaft, BalancerShafts and Pistons
Removal ........,,7-12
Crankshaft
Inspection .......7-15
Pistons
Inspection .......7-16
fnstallation ......7-25
CylinderBlock
fnspection ..,....7-17
Bore Honing lH23A1,H22Al enginesl ................7-18
BoreHoning(F22A1engine)............................... 7-19
Piston Pins
Removal ..........7-19
fnstallation ......7-20
fnspection .......7-21
ConnectingRods
Sefection .,.,,,,..7-2O
Piston Rings
EndGap ...........7-22
Repfacement ,.............,.,........,,...7-23
Ring-to-GrooveClearance ........7-23
Afignment .......7-24
CrankshaftOil Seal
fnstaflation ......7-25
Crankshaftand BalancerShaft Oil Seal
Installation(engineremoval is not requiredl ....7-30
Crankshaft and balancershafts
fnstration ,.......,7-26
BalancerShafts
fnspection .......l-91
SpecialTools

I
R.l. No. I Tool Number D6cripiion Oty I Pag6Rdorence

O I oTcAF- PH6o3oo PistonPin BaseInsert 1-19,20


07GAF- PH7ol00 PilotCollar 7 -19,20
o
O I orcar-seoozoo Hub AssemblyGuideAttachment 7-30
oTHAF-PL2o1o2 PistonBaseHead 7 -19,20
@ |
oTLAD- PT3oloA Se8lOriver 7-30
@ I
@ | o;Lnr - lvootooor RingGearHolder
| 07924- PD20oo3
07746- oo3o3oo Attachment,30 mm l.D. 7-30
O |
07749- ooloooo Driver 1-25,30
@ I 7- 2 5 , 3 0

I
O | 07948-sBoo101 Driver Attachment
07973- PEoo3lo PistonPin DriverShaft 7-19,20
@ |
07s73- PEoo32o PistonPin DriverHead 7-'t9,20
@ |
07s73- 6570500 Piston Ease 7 -19,20
@ |
07973- 6570600 Piston BaseSpring 1-19,20
@ I

t
i
1
l

o o @

1 o @ @
@
!1
ti
t
I
.'

(0 o @

7-2
lllustratedIndex

Lroric"t" "tl inrernalpartswith engineoil during reassembly.


I

6x1.0mm
12 N.m 11.2

OIL SCAEEN
6x1.Omm GASKET
12 t{.m 11.2kg-m. Roplace.

6x1.0mm
12 N.rnlt.2 kg-m,9lb'ftI

BAFFLEPLATE

11 x 1.5mm AEARINGCAP
75 N.rn {7.5 lg-m, BRIOGE
54 tb-ttl
Applyengineoilto the bolt
throada. DOWEL PIN
NOTEr
Aftor torquing o6chcap.
-rx
turn crankshaftto check TOROUECONVERTER
Ior binding. COVERIA/T)

12 x 1.0mm
75 N.m 17.5kg-m,
5t tb-ftl
Torquesequence,
DOWEL PINS page7-7

WASHER

DRIVEPLAIE {A/T)
Checkfor cracks.

CLUTCH COVER
(M/T)

6 t 1 . Om m
12 N.m (1.2 kg-m,
9 rb-ftl

FLYWHEEL 12 x 1.0mm
105N{n (10.5kg-m, 76lb-ft,
Torquesequence,page7-7
(cont'd)

7-3
lllustrated Index
(cont'dl

Luuri"ut""tl internalpartswith engineoil duringreassembly. CRANI€}IAFT


I Endplay,Page7'7
Runout.Tapor 6nd
Out-of-Round,Page7-15
NOTE: Installation,Page7-26
Apply liquid gasketto the mating surfacesot the right
side coverand oil pump casebetoreinstallingthem
Useliquidgasket,part No. 08718- 0001

MAIN BEARINGS
Oilclearance,page7-8
S€lection,page7-9
NOTE:New main boaringsmust
be selectedby matchingcrank and
markings.
blockidentification

I
:l Groovedsidestac€ outward.
NOTE: Thrust washerthicknoss
ll

I 8 x 1.25mm
25 N{n {2.5 kg-m,
is lixed and must not be changed
by grindingor shimming.
CRAI{KSHAFTOIL SEAL
Install6tion,pag* 7-25and 30

18 tb-frl O.RINGS
Replace.

CRANKSHAFT OIL SEAL


psges7-308nd 8-'11
Installation,
Replace.

THRUSTWASHER
RIGHTSIDE @VEB
Apply liquid g88k€tto
AALANCERDRIVEN block mating surface.
GEAR
Gr1.0mm
12Nrn (1.2
9IEftI

I PIN

OIL PUMP
Apply liquid g8skstto
the boft threads.

'Il
S€e page8-9
Apply liquid gssk6t
6x1.0mm to block mating surtace.
12 l$m 11.2kg-m,9 lb"ftl
il Apply liq!id gasketto
the bolt threads.
il
BALANCERSHAFTOIL SEAL
pages7-30and 8-11
Installation,
Reolace.

TIMINGBALANCERBELT
DRIVENPULEY

7-4
OIL JET
Handlethe nozzlewith
OII-JET BOLT care.Do not damage or
ito N.rn {a.0tg-m, 29 lb-ftl detormed.
Inspection,page 8-8
Inspection,page 8-8

H22Al engincl

REARBALANCERSHAFT
End play, p6ge 7-31 BALANC€R SHAFT
Runout.Tapor and BEARINGS
Out-of-Round,psges 7-31,32 page7-31
Insp€ction,
Inst6llation,pag€ 7,26

BETAINER
NOTE: Retainerthicknossis tixed
and must not bs changedby
Orindingor shimming.

\ )

BALANCER

(cont'd)

7-5
lllustratedIndex
lcont'd)
lruri""t" "tl internalpartswithengineoil orr'nn,"u""".b'J;ron
I
INSTALLATIONDIRECTION

NOTE; New rod bearingsmust be selectedby matching EXHAUST


markings
connectingrod and crankshaftidentification
( p a g e s7 - 1 0 1
, l ) .
A ?/ A Ae-l
A
\3 -/ (3 \9,-// \Eo.J
1r;--..l@
ft##**if{*{"}H
\7 \7

INTAKE
'\7 '\r'

PISTON
Removal,page7-12
M6asurement, page7-16
PISTONPIN NOTE:To maintainproperclearance,
Removal,page7-19 matchthe lefter on the piston top with
page7-20
Installation the lettor for eachcylinder stamped on
lnspection,page7'21
the block.
On the pistontop On the block
No letter <- A or I
Bor'l

CONNECNNGROO
Endplay,page7-7 ENGINEBL(rcK
Selection,page 7-20 Cylinderboreinspection, p6oo7'17
Page7-21
Smallend measurement, Warpageinspection,Page7-17
Cylinderborehoning,pag667-18,19
Inspecttop of each cylinder bore
tor carbon build-up or ridge before
removing Pigton.
Removeridge if n6cessary,pagB7.14

CONNECTING ROD
BEARINGS
page7-10
Clearance,
page7 11
Selection,

CONNECNNGRODBEARINGCAP
Installation,page7-26
NOTE:Installcap so the bearingrocessis
on the samesideasthe recessin the rod CYUNDERBORESIZES
(A or l, B or rl)
NOTE: To maintain proper piston
clearance,rnatchthese lefterswith
the letterson the pistons.The letters
on the block readfrom left to right,
CONNECTING RODNUT..-_.-....-__-.} No. 1 throughNo. 4 cylinders.
9 x 0.75 mm
47 N{n (i1.7kg-m, 34 lb-ft, e On the block On the pistontop
A or | --------------- > No letter
After torquing each bearingcaP, B or,l --------------- > B
rotate crankshaftto checklor No.4
binding.

7-6
GonnectingRodand
Flywheel and Drive Plate Crankshaft
Replacement End Play
ManualTransmission: ConnectingRod End Plsy:
Standard (Newl: 0.15- 0.30 mm
Remove the eight flywheel bolts, then separatethe fly- {0.006- 0.012in)
w h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n , SorviceLimit 0.40 mm 10.016inl
tightenthe bolts in the sequenceshown.
CONNECTING
ROO
RINGGEAi
07LAB- PVtDl(x)
or 0792it - PO20O03

BINGGEARHOLDER
07LAB- Pv(xrltx)
or 07924- PD2qr03

. lf out-of-tolerance,install a new connecting rod.


aoo . lf still out-of-tolerance,replacethe crankshaftlpages
\o; 7-11and7-26]..

Pushthe crankshaftfirmly away from the dial indicstor.


and zerothe dial againstthe end of the crsnkshaft.Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimit.

Inspgctring gear 12x 1.0mm


teoth for w6ar or damage. 105 N.rn 110.5kg-m, tG lb-ft,

AutomaticTransmission:
Removethe €ight drive plate bolts, thon separatethe
drive platefrom the crankshaftflange.After installation.
tightenthe bolts in the sequenceshown.

SCREWDRIVER
CrankshaftEnd Phy:
Standard lNqwl: 0.10- 0.35 mm
(0.004- 0.014in)
/ AXid-*a\Ao Ssrvice Limit 0.45 mm {0.018inl

. lf end play is excessivethan the servicelimit, inspect


the thrust washersand thrust surfaceon the crank,
shaft.Replacepartsas necessary.

NOTE:Thrustwasherthicknessis fixed and must not be


changedeitherby grindingor shimming.
Thrust washersare installedwith groovedsidesfacing
outwaad.

7-7
Main Bearings
Clearance

L T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves

L C l e a ne a c h m a i n i o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshoptowel. STRIP
PLASTIGAGE

l. Placeone strip of plastigageacrosseach main jour-


nal.

NOTE:lf the engineis still in the car when you bolt


the main cap down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plastF
gage further than just the torque on the cap bolt.
and give you an incorrectreading.For an accurate
r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e
c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r , n ga t a
time.

4. R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
bolts.

75 N.m {7.5kg-m,54lb-ft) lf the plastigagemeasurestoo wide or too narrow,


(removethe engine if it's still in the car). remove
NOTE:Do not rotatethe crankshaftduring inspec- the crankshaft,and remove the upper half of the
tron. bearing.Install a new, complete bearingwith the
same color code (selectthe color as shown on the
5. Removethe cap and bearingsagain,and measure next pags),and recheckthe clearance.
the widest part ot the Plastigage.
CAUTION: Do not fi16,3him, or 3crapoth€ b.arings
Main Bearing-to-JournalOil Clearance: or the caps to adiu3t clearance.
Siandard {Newl:
No. 1. 2: 0.021- 0.0i15mm 7 . lf the plastigageshows the clearanceis still incor-
{0.(xn8 - 0.0018in) rect,try the next largeror smallerbearing(the color
SqrviceLimit 0.050mm (0.0020inl listedaboveor belowthat one),and checkagain.
No. 3 0.025- 0.0,19mm
{0.0010- 0.0019in} NOTE: lf the groper clearancscannot be obtained
ServiceLimii: 0.055mm 10.0022inl by usingthe appropriatelargeror smallerbearings,
No. 4 0.013- 0.037mm reDlacethe crankshaftand startover.
10.0005- 0.d115in)
ServiceLimit: 0.050mm {0.1X120 in)
No. 5 o.(xlg- 0.033mm
(0.0004- 0.0013in)
ServicaLimii: 0.040mm (0.0015inl

7-8
Selection
CAUTION: lf the codes ars indecipherabls b€causo of Main Journal Code Locations
an accumulationof dirt and dust, do not scrub them (Numbers or Bars)
with a wiro brush or scraper,Cleanthgm onlv wiih sol.
vent or .tot€rgont. H22Al engine:

CrankshaftBors Code Location


{Numbers,Lettgrs or Bars} Main JoumalCodeLocationslNumbersor Ba'sl

Numbersor Lettersor Bars have been stampedon the


end of the blockas a code for the size of each of the 5
main journalbores.
Use them, and the numbersstampedon the crankshaft
(codesfor main journalsize),to choosethe correctbear-
Ings.

H23A1.F22Al engines:
The Main Journal Codesare stampedin one of the fol-
lowing locations.

Main Jou.nalCodoLocations(Numbalsor Bar3)

No. 5 JOURNAL
IPULI.TYEND} {FLYWHEEL ENDI
BcaringDosign

PROJECTION

LOWER

Berring ldentitication ---------------- Largercrankbore Main Journrl Coda Locationi {Numbersor Br.!}

Colorcodeis on the
edgeofthe bearing. No. 5 JOURNAL No. 1 JOURNAL
----------> Smaller bearing (Thicker) IFLY WHEELENDI (PULLEY ENDI

No. 1 CRANK WEB

Smaller Smaller NOTE:When usingbearinghalvesof


main bearing different colors, it does not matter
iournal (Thicker) whichcolor is usedin the top or bottom.
GonnectingRod Bearings
Clearance
Removethe connectingrod cap and bearinghalf. lf the plastigagemeasursstoo wide or too narrow,
removethe upper half ot the bearing,installa new,
Cleanthe crankshaftrod journal and bearing half complete bearing with the same color code (select
with a cleanshoptowel. the color as shown on the next page),and recheck
the clearance.
Placeplastigageacrossthe rod journal.
CAUTION: Do not file, shim, or scrapothc boaring3
Reinstallthe bearing half and cap, and torque the or tha cap3to adiust cloaranc€.
nutsto:
1. lf the plastigageshows the clearanceis still incor-
47 N.m (4.7 kg-m, 34 lb-ft) rect,try the next largeror smallerbearing(thecolor
listed above or below that one), and check clear-
NOTE:Do not rotatethe crankshaftduring inspec- anceagarn.
tion.
NOTE: lf the proper clearancecannot be obtained
5. Removethe rod cap and bearinghalf and meassure by usingthe appropriatelargeror smallerbearings,
the widestpart of the plastigage. reolacethe crankshaftand startover.

ConnectingRod Bearing.to.Journll Oil Clearsnce:


P'AAI €ngin6:
Standard (Newl: 0.021- 0.049mm
10.0008- 0.0019in)
Servic€Limh: 0.05 mm (0.002in)
H23A1,ll22Ai enginos:
Standald {Newl: 0.027- 0.055mm
(0.0011- 0.0022inl
Ssrvice Limh: 0.06 mm (0.002in)

PLASTIGAGESTRIP

iI
H
t;,

ili
tit
il
it;
'll
:'l
I!:

7-10
Selection

CAUTION: lf th6 cod6s aro indscipherable because of Conn€qtingRod Journal Code Locations
an accumulationof dirt and dust, do not scrub them (Lettersor Barsl
with a wirg brush or licrapor.Clsan them only with sol
v6nt or detergent. H22A1engine:

ConnectingRod Journal Code Locations


{Numbersor Bars) ConnectingRod Journal Code Locliion! lLstterr or BrBl

N u m b e r so r B a r s h a v e b e e n s t a m p e do n t h e s i d e o f
each connectingrod as a code for the size of the big
end. Use it, and the lettersor barsstampedon the crank
lcod€sfor rod journal size),to choosethe correctbear-
ings,

H23Al, F22Al cngincs:


The ConnectingRod Journal Codesare stampedin one
Halfot numberor bar ol the followinglocations. ..,:-.
is stampedon bearingcap
and the otherhalf is
stampedon rod
ConnoctingRod Journrl Codo Locltion3 {Latta'3 or B!1!}
BoaringD6i9n

PBOJECTION
ConnectingRod Journd Coda Location3llatta.3 or B.rrl

No. 5 JOURNAL No. 1 JOURNAL


Eoaring ldantif ication .---..-----+ Largerbig end bore IPULTIY END}
Colorcodeis on the
edgeol the bearing.

+ Smallerbearing(Thicker)

Elue

No. I CRANKWEB
Smaller Smaller
rod bearing
journal lThicker)
Grankshaft,BalancerShaftsand Pistons
Removal

1. Removethe right side cover. 3. Removethe front balancordrivenpulleyas thown.

BALANCER
DOWELPIN DF]VENPULEY

MANTE'{ANCEHOI€

;
I
I
) SCREWT'RIVER
I
t1 Align the bolt hole and the bslancershaft hole.thon

il
;l
insert a 6 x 100 mm bolt to hold the rear balsncsr
shaft.
2. Removethe balancergearcase.
Ii Removeth6 bolt and the balancordrivengs8r.

REARBALA]IIGEB
DOU'ELPIN SHAFT

8 x 1.25mm
25 N.m 12.5kg-m, 18lb-ft)

6 x lm .nm BOLT

va mm {2.9inl

BALANCER DOWELPIN
GEARCASE

REARBALANCERSHAFT

7-12
R€movethe oil screenand the oil pump. 8. Removethe bolts and the bearingcap bridge,then
removethe bearingcaps.
7. Rsmov€the baffle plate.
CAUTION: To provent wsrpago. un3crew tha bolts
in loqucnc€ 1/3 turn at a timc; ropcst tho srqucnco
until rll bolt3 are loosGnod.
o|LscaEE BAFFLEPLATE
MAIN BEARINGCAP BOLTSLOOSENINGSEOUENCE

7-13
Grankshaft,BalancerShaftsand Pistons
Removal(cont'dl
9. Turn the crankshaftso No. 2 and 3 crankpinsare at 15. lf you can teel a ridge of metal or hard carbon
the top. around the top of each cylinder,remove it with a
ridge reamer. Follow the reamer manufactursr's
1 0 . Removethe rod caps/bearings and main caps/bear- instructions.
in order.
ings.Keepall caps/bearings
CAUTION: lf the ridgo k not rcmoved, h mly dtm-
1 1 . Lift the crankshaftout of the engine,being careful ag6 the pistons a! thcy lrc purhod out.
not to damagejournals.

Use the wooden handle of a hammer to drivo the


pastonsout.
CRANKSHAFT
CAUTION:
. Tako caro not to dtmago thc contlct turflcc of
tho motal g.!kot.
. Whan romoving thc pirton/connactlng rod trka
'12. Removethe bolts and the retainer.then removethe cara not to hit thr oil irt (H22Al cngine onlyl.
. It th. oil ict nozzlo is drmlg.d or d.formld, rr-
front balancershaftand the rearbalancershaft.
placo the oil iet .srombly {H22Al .ngin. only,
page 8-81.

't1. Reinstalltheconnectingrod bearingsand capsaftor


RETAINER removing each piston/connectingrod assombly.
1 3 . Removethe upperbearinghalvesfrom the connect- 1 8 . Mark each piston/connectingrod 8ss€mbly with its
ing rods and set them aside with their respective cylindernumberto avoid mixup on .eassembly.
caps.
NOTE:The existingnumbsr on the connsctingrod
1 4 . Reinstallthe main caps and bearingson the engine does not indicateits positionin the engine,it indi-
in properorder, catesthe rod bore size.
Crankshaft
Inspection
C l e a n t h e c r a n k s h a f to i l p a s s a g e sw i t h p i p e Out-of-Roundand Taper
cleanersor a suitablebrush.
Checkthe keywayand threads, o Measure out-of-round at the middle of each rod
and main journalin two places.
Alignment . The differgncebetyveenmeasurementson each
journalmust not be more than th€ servic€limit,
a M e a s u r er u n o u t o n a l l m a i n i o u r n a l st o m a k e
surethe crankis not bent, Journal Oui-ot.Round:
. The difference between measurementson each Standa.d (Ncw): o.qE mm {0.0002in}
journalmust not be more than the servicelimit. SorvicoLimit: O.q)6mm (0.0002inl

CrsnkehaftTotal lndicatod Runouti


Standard (N€w): 0.03 mm (0.001in)
Ssrvico Limit: 0.04 mm (0.002in)

DIALINDICATOR
Rotatecrankshafttwo
compteterovolutions.

M6asursin two
pl6cesat middl€.

Suppon with lathe- Measu16 taper


type tool or V-blocks. near edg€s.

Measuretaper at the edge of each rod and main


journal.
The difference between measurementson each
journalmust not be more than the servicelimit.

Journal Taper:
St.ndrrd (Now): 0.005mm (O.(xXr2int m!x.
Scrvicc Limit 0.006mm (0.(xn2 in)
Pistons
Inspection
Checkthe Distonfor distonionor cracks. C a l c u l a t et h e d i f f e r e n c eb e t w e e nc y l i n d 6 r b o r e
diameteron (page7-17)and pistondiamet6r.
NOTE:lf the cylinderis bored,an oversizedpiston
must be used. Pbton-to-CvlinderClsrranco:
F22Al engine:
Measurethe piston diameterat a point F22A1:21 mm Standard (N€w): 0.020- 0.0/(, mm
(0.8in),H23A1,H22A1:15mm (0.6in)from the bottom l0.00oB- 0.0016in)
of the skirt. ServiceLimil: 0.05 mm {0.002in)

e i s t o n s( N o
N O T E :T h e r ea r e t w o s t a n d a r d - s i zp H2341,H22A1engines:
Letter(A) or B). The letteris stampedon the top of Standard (Newl: 0.007- 0.030mm
the piston. There letters are also stamped on the (0.0003- 0.0012in)
blockas cylinderbore sizes. SorviceLimit: 0.04 mm (0.002inl

Piston Diameter:
F22Al engine:
Standard lNewl:
No Letter lA): 8i[.980- 8i1.990mm
(3.3457- 3.3451inl
B: 84.970- 84.980mm
13.3453- 3.3,157in)
ServiceLimit:
No Letter {A}: 8i0.970mm (3.3453in}
B: 84.950mm (3.3449in)

H23A1,H22A1enginss:
Standard lNewl:
No Letter (A): 86.990- 87.003mm
(3./1248- 3.4253inl
B: 86.980- 86.993mm
- 3.42,19inl
{3.,[2/14
ServiceLimit: lf the clearanceis near or excesdsthe servicelimit,
No Lettor {A}: 86.980mm {3.,12,14 inl inspectthe piston and cylinderblockfor excessive
B: 86.970 mm (3.,[2'10in] wear.

F22Al sngino: SKIRT


DIAMETER
OvorsizePiston Diamoter:
21 mm 10.8inl
F22A1engine:
0.25:85.230- 85.2/0 mm {3.3555- 3.3559in}
0.50:85.,180- 85.tlln mm {3.3653- 3.3657in}

H23A1.H22Al rngin.3:
O.25t87.230- 87.2,(l mm (3./8/02- 3.,13{8in)

4. Checkthe piston pin-to-pistonclearance.Coat ths


piston pin with engineoil. lt should then be possi-
ble to push the piston pin into the piston hole with
thumb Dressure,

Piston Pin-to Piston Clctrtnco:


F22Al engine:
Standard (Newl: 0.012- 0.02amm
(0.fi)05- 0.qt0o in)

H23Al, H22Al ongines:


Standard {N€w}: 0.012- 0.026mm
10.000t- o.(XllOin)

7-16
CylinderBlock
Inspection
1 . M e a s u r ew e a r a n d t a p e r i n d i r e c t i o nX a n d Y a t Boro Taprr:
three levelsin eachcvlinderas shown. Limil: {Diftorcncabotw.on lirst snd third
6 mm 10.2in) maasuromcntl 0.05 mm {0.002inl

Firrt . l f m e a s u r e m e n t si n a n y c y l i n d e r a r e b e y o n d
Ma!!urcmant OversizeBore ServiceLimit, replacethe block.

w
S.cond . l f t h e b l o c k i s t o b e r 6 b o r e d ,r e f e r t o P i s t o n
Mar!uramcnt Clearance Inspection(page7-16)afterreboring.
Third
Mer3uramant NOTE: Scored or scratch€dcylinder bores must be
6 mm 10.2inl honed.

F22Al engine: 0.50 mm (0.020inl


H2341,H2/IA1rngincr: 0.25 mm (0.010inl

2, Checkthe top of the block for warpage.


Measurealong the edgesand acrossthe centeras
snown.

SUNFACES
TO BEMEASUBED
CYLINDERBORESIZES
lA or I, B or rll
Readth€ l€tterstrom lelt-to'right
for No. 1 throughNo.4 cylinders.
CYLINDER
BONE

Enginc Block W..prge:


Stlndlrd {Ncw): bclow 0.07 mm (0.003in}
Cylindcr Boro Size: S.rvico Limit: 0.10 mm (0.(Xt4inl
F22Al engino:
Stendlrd (Ncw): PRECISIONSIRAIGHT EDGE
A or l: 85.010- 85.020mm {3.3458- 3.3/t?2in)
B ot ll: 85.000- 85.010mm (3.3i165 - 3.3i168in)
Sorvicr Limit: 85.070mm (3.3492in)
H23A1,HPAI ongines:
Stlndffd {Now,:
A or l: 87.010- 87.020mm {3.4256- 3.4260in)
I or ll: 87.000- 87.010mm (3.'1252- 3.i1256in)
Srrvicc Limit: 87.070mm {3.i|:l79inl

OvoEizo:
F22Al cngino:
0.25:85.250- 85.260mm (3.356:t- 3.3569inl
0.50:85.500- 85.510mm {3.3661- 3.3665in)
H2341, H22Al 6nginsr:
0.25:87.260mm 13.4:l5i[inl

7-1
CylinderBlock
BoreHoning(H2341,H2241engines)
l. rbv^ ,,

CAUTION: Thir cylinder linor ussr FRM (Fiber 3. W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a nt h e


ReinlorccdMatall. Hono only !s diroctod below. cylinderblockof all metal particles.Washthe cylin-
der bores with hot soapy water. then dry and oil
1. M€asurecylinderboresas shown on page7-16. immediatelyto preventrusting.
It the block is to be reused,hone the cylindersand
remeasurethe bores, NOTE: Never use solvent, it will only redistribute
the grit on the cylinderwalls.
2. To honecylinderbores;
. Useonly a rigid hone. 4. lf scoring or scratchgsare still presentin cylinder
. Honingstone: GC- 600- J or finer stone boresafter horningto servicelimit, reborethe cylin-
(for nonf6rrousmetals) der block.
. Pressure: 2OO- 3OOkP;
(2-3 kg-cm', 28 - 43 psi) NOTE:Some light verticalscoringand scratchingis
. Honingrpm: 45 - 50 rpm acceptableif it is not deepenoughto catchyour fin-
. Honingthickness;Lessthan 0.02mm (0.0008in) gernailand does not run the full lengthof the bore.
Do not hone mote than
20 cvcl€s
. Honinglubricant Oil type
. Roughnessof
finishedsurfaces:VVV or 1.2S
. Honingpattern: 60 degr€ecross-hatch

CAUTION: Cloantho honing stono oyory 5 cyclos.


PistonPins
BoreHoninglF22A1enginel Removal
Measurecylinderboresas shown on page7-16. Assemblethe PistonPin Toolsas shown.
lf the block is to be reused,hone the cvlindersand
rem€asurethe bores. PISTONSASEHEAD
OTHAF-PUM102
Honecylinderboreswith honing oil and a fine (400
grit) stone in a 60 degree cross-hatchpattern, PISTON PIN BASE INSENT
OTGAF- PHq'3U'

NOTE:
. Use only a rigid honewith 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
. Do not use stonesthat are worn or broksn.

tl
PFTONBASE
0tt3 - 65t0500

Adjust the length A of the piston pin driv8r.


A: 51.5 mm (2.G1inl
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
engine block of all metsl particles.Wash the cylin-
der bores with hot soapy water, then dry and oil PISTON PIN DRIVERHEAD
immediatelyto preventrusting. 0t9t3 - PE|D320

NOTE; Never use solvent, it will only .edistribute


the grit on the cylinderwalls.
\
lf scoring or scratchesare still presentin cylinder R
bores after honing to the servicelimit, rgbore the l l
cvlinderblock.
H
trl-
PISTOI{PII{ DRlvENSHAFT
or9r3- Fdto3ro
NOTE:Some light vsrticalscoringand scratchingis
u
m--.--
acceptableit it is not deep enough to catch your fin-
g€rnailand does not run the full lengthof the bore. PILOTOOLLAN
o'GAF- PHt0100
Emboesed
marklacingup.

CYLINDEBHONE

NOTEiUEea hydraulicpro6s.
When prossingpin in or out,
make sure that th€ rgco$ad
ponionofthe pistonoligns
with tho liD3on th€ collar.
NOTE:
. After honing,cleanthe cylinderthoroughlywith
soapy water.
o Only a scored or scratchedcylind€r bore must be Placeths piston on the piston base and pressthe
honed. pin out with a hydraulicpress.

7-19
ConnectingRods PistonPins
Selection lnstallation

Each rod falls into one of four toleranceranges(from 0 1. Usea hydraulicprossfor installation.
to 0.024mm {0.0009in), in 0.006mm (0.0002in) incre-
ments) dependingon the size of its big end bore. lt's . Wh6n pressingthe pin, in or out, bo sureto posi-
then stampedwith a numberor bar \'1,2,3, ot 4ll, t, ttl, tion ths recessodtlat on the piston againstthe
or Irl) indicatingthe range. lugs on the base8ft8chment.
'1,2,3, ot 4/1,t, ttl,o(
You may find any combinationoI
Irl in any engine.

Normal Boro Sizr: 51.0 mm (2.01in) The arrow must laco the
timing belt side of the
6nOine.
NOTE:
Refer€nc€numbersor bars are for big end bore
sizeand do not indicatethe positionof th€ rod in
the engine.
Inspectconnectingrod for cracksand heat dam-
age.

CONNECTING RODBORE Tho ma* must faco


BEFEBEITCE NUMBERoi BAR the timing beltsid6
Half ot number is sttmpsd on ol th6 engin6.
bearingcap, ths other half on
connectingrod.

2. Adjust the length B of the piston pin driver.


B: 51.5mm (2.G1in)

PISTONPINDRTVER
HEAO
- PEqB2o
0797:1

PISTONPIIIIDBIVERSHAFT
07973- PE00310

Emboss€dmark
I
ffi*r,"ron'n
PILOTCOLLAR
07GAF- PH701d)
Inspgctbolts
and nuts for
strogscracks.

PISTONPIN BASE NSEBT


07GAF- PH6o3q)

PISTONBASE HEAD
07HAF- P120102

PISTONBASE
07973 - 6705{X'

NOTE: Installthe assembledpiston and rod with


t h e o i l h o l e f a c i n g t h e i n t a k em a n i f o l d ( E r ( c e p t
H22A1enginel.

7-20
PistonPins
Inspection
Measurethe diameterof the pistonpin. Measurethe pistonpin-to-piston
clearance.

Pbton Pin Diamoter: NOTE:Checkthe pistonfor distortionor cracKs.


Standard (Nawl: 21.994- 22.(XX'mm
(0.86s9- 0.8561inl l f t h e p i s t o n p i n c l e a r a n c ei s g r e a t e rt h a n F 2 2 A 1
Ov6rsizg: 21.997- 22.003mm e n g i n e : 0 . 0 2 4 m m { 0 . 0 0 0 9i n ) H 2 3 A 1 ,H 2 2 A 1
{0.8560- 0.866:linl engines:0,026mm (0.0010in), remeasureusing an
oversizepistonpin.
NOTE:All replacementpistonpins are oversize.
Piston Pin-to.PistonClearanco:
F22A1engine:
Standird (Ncw): 0.012- 0.024mm
{0.0005- 0.q)(xt in,

H2341, H22Al ongines:


Stlndsrd lNewl: 0.012- 0.026mm

2. Zerothe dial indicstorto the DistonDindiameter. 4. Checkthe diferrencebetweenpiston pin diameter


and connectingrod smallend diameter.

Pbton pin-to ConnoctingRod Interfa.oncs:


Standa.d (Ncwl: 0.013- 0.032mm
{0.00OS- 0.0013in)

7-21
PistonRings
EndGap
1. Using a piston, push a new ring into th€ cylindor
'15
bore - 20 mm {0.6- 0.8 in) from the bottom.

M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l € r
gauge:

lf the gap is too small,checkto see if you have


the properringsfor your engine.

lf the gap is too large,recheckthe cylinderbore


diameteragainstthe wear limitson page7-17.
lf the bore is over the servicelimit, the cylinder
blockmust be rebored. I
Pistoo Ring End-Gap:
F22Al ongio€:
PISTONRING iiii
r.---iLi.i----
Top Ring
Standard (Newlr 0.20- 0.35 mm
(0.008- 0.014in)
SorvicoLimil: 0.60 mm 10.024in)

S€condRing
ENDGAP
Slandard {N6wl: o.i(t - 0.55 mm
(0.015- 0.022inl
SorviceLimh: 0.70 mm (0.028inl

Oil Ring
Standard (Newl: 0.20- 0.70 mm Ovg6izo:
{0.008- 0.028in} F22Al lnginel
Servic€Limit 0.80 mm (0.03'linl 0.25185.25mm (3.356inl
0.50:85.50mm (3.366inl
H23A1,H22Al engine3:
Top Ring H23A1. H22Al .nginc:
Standard {New): 0.25- 0.35 mm 0.25:87.25mm (3.i|il5inl
10.010- 0.014in)
SorvicaLimit: 0.61tmm (0.02'lin)

Socond Ring
Standard (N6w): 0.60- 0.75 mm
10.02,t- 0.030in)
ServiceLimit: 0.90 mm {0.035inl

Oil Ring
Stsndard (Newl:
TEIKOKUPISTONRINGmanufacturs:
0.20- 0.50 mm (0.fi)8 - 0.020inl
RIKENmanufacture:
0.20- 0.70 mm (0.008- 0.028inl
S€rvics Limit:
TEIKOKUPISTONRINGmanutactur€:
0.60 mm (0.02i1in)
RIKENmanutaqture:
0.80mm (0.031in)

7-22
Replacement Ring-to-Groove
Clearance
1. Usinga ring expander,removethe old pistonrings, After installinga new set of rings. measurethe ring-to-
grooveclearances:
2. Cleanall ring groovesthoroughly.
Top Ring Cl€arlnc6
NOTE: Standard (New): 0.035- 0.060mm
. U s e a s q u a r e d - o fbf r o k e nr i n g o r r i n g groove {0.0014- 0.002,tinl
cleanerwith bladeto fit pistongrooves. SorvicoLimit: 0.13 mm (0.005in)
. Top and 2nd ring groovesare 1.2 mm ( 0 . 0 5i n )
wide and the oil ring groove is 2.8 mm ( 0 . ll i n ) Second Ring Clsaranco
wide. Standard (Now): 0.030- 0.055mm
. Filedown bladeif necessarv. (0.fl)12- 0.fl122inl
SorvicoLimit: 0.13 mm (0.005inl
CAUTION: Dq not uss a wire brush to clean the ring
groovgs, or cut ring groove3 d9€per with cloaning
tools.
NOTE:lfthe pistonis to be separatedfrom the con-
nectingrod, do not installnew ringsyet.

Installnew rings in the proper sequenceand posi-


tion (page7-24).

NOTE:Do not useold pistonrings.

RINGEXPANDER
PistonRings
Alignment
I
1 , lnstalltheringsas shown. Rotatethe rings in their groovesto make sure they
do not bind.
ldentifyrop and secondrings by the chamferon the
edge.Makesurethey are in their propergrooveson
the paston. MARK
TOP RING

NOTE: The manufacturingmarks must be facing


upwaro.
SECONDRING

3. Positionthe ring end gsps 8s shown:

DO NOT position any rinOgap


SECONDRINGGAP at piston thrust surfaces.

H23A1,H22Al onginos:
Approx.90'

OIL RING
Appiox. GAP
90"
TOPRINGGAP GAP

DO NOT posilion any ring gap


in linewith the oistonoin hole. OIL RINGGAP
CrankshaftOil Seal Pistons
;I Installatio lnstallation

| .11 The sealsurfaceon the blockshouldbe dry. B e f o r e i n s t a l l i n gt h e p i s t o n , a p p l y a c o a t o f


'E
| Apply a light coat of oit to the crankshaftand to engine oil to the ring groovesand cylinder
the lip of the s6al. bores.

l. Drivein crankshaftoil sealagainstright sidecover. 1. ll the crankshaftis alreadyinstalled:


. Setthe crankshaftto BDCfor eachcvlinder.
NOTE:Drivethe crankshaftoil sealin squarely. o Removethe connectingrod caps and slip short
sectionsof rubber hose over the threadedends
DRIVER of the connectingrod bolts.
07749- 0or(xDo . Installthe ring compressor,checkthat the bear-
ing is securelyin place,then position-thepiston
in the cylinder and tap it in using the wooden
handleof a hammer.
a Stop after the ring compressor pops free and
checkthe connectingrod-to-crankjournal align-
ment beforepushingpistoninto place.
. Installthe rod capswith bearings,and torquethe
nutsto:
47 N.m {4.7kg-m.34lb-ft)
2. lf the crankshaftis not installed:
Installsealwith the . Removethe rod caps and bearings,install the
part number sid6 nng compressor,then positionthe piston in the
facingout. cylinderand tap it in usingthe wooden handleof
a nammer.
. Positionall pistonsat toD deadcenter,
DRIVEBATTACHMCNT
079ir8- SBlXtl01
The arrow must tace the
timing beltsideot the
C o n f i r m t h a t t h e c l e a r a n c ei s e q u a l a l l t h e w a y engine.
aroundwith a feelergauge.

Cloarancc:0.5 - 0.8 mm (0.02- 0.03 inl

The mark muBttace


the timing beltside
RIGHTSIDE of the engine.
COVER

NOTE:Maintaindownward force on the ring com-


0.5 - 0.8 mm p r e s s o rt o p r e v e n tr i n g s f r o m e x p a n d i n gb e t o r e
enteringthe cylinderbore,
Usethe wood€nhandle
of a hammorto push,or

NOTE:Referto pages7-30and 8-11for installation


of the oil pump sidecrankshaftoil sear.
Grankshaftand BalancerShafts
lnstallation

Betoreinstallingthe crankshaft,apply a coat of 6. Installthe thrust washers,main bearingcaps and


e n g i n eo i l t o t h e m a i n b e a r i n g s .r o d b e a r i n g s bearingcap bridge.
and balancershaft bearings. Check clearancewith plastigage(page 7-8), then
tightenthe bearingcap boltsin 2 steps.
Insertbearinghalvesin the cylinderblockand con- ln the first step tighten all bolts in sequence,to
nectingrods. about 30 N.m (3.0 kg-m, 22 lb-ft);in the finsl step
tighten in same sequenc€,to 75 N.m {7,5 kg-m.54
Holdthe crankshaftso rod journaisfor cylindersNo. tb-ft).
2 and No,3 are straightup.
NOTE:Coatthe bolt threadswith engineoil.
Lowerthe crankshaftinto the block,seatingthe rod
journalsinto connectingrods No. 1 and No. 4.
lnstallthe rod capsand nutsfingertight.

CAUTION: Whlnovor any crankshaft or connccting


rod baaring i3 roplacad, it ir nocosarY lftcr lc!s-
scmbly to lun tho cngin. Ei idling tpoed until it
RODNo. 2 WASHERS RODNo. a rcacho! normal opcrrting iamporltula. thcn Gon.
tinue to run it lor approximataly 15 minut6.

7. Insenthe balancershaftsinto the block,then install


Rotatethe crankshaftclockwise,seat journals into the retainerto the front balancershaftand block.
connectingrods No, 2 and No.3, and installthe rod
I capsand nuts fingertiqht.
I
NOTE:Installcaps so the bearingrecessis on the
\ sameside as the recessin the rod.
'l
Checkrod bearingclearancewith plastigage(page
7-10),then torquothe capnuts.
47 N.m (4.7kg-m.34lb-ft)

NOTE: Referencenumbers on connectingrod are


for big-endbore toleranceand do not indicatethe
positionof pistonin the engine.

7-26
NOTE:
. Useliquidgasket,parrNo.087t8-0001.
Apply liquidgasket
. Checkthat the matingsurfacesare cleanand dry to block mating surface.
beforeapplyingliquidgasket.
. Apply liquidgasketevenly,beingcarefulto cover
allthe matingsurface.
. To preventleakag€of oil. apply liquid gasketto
the innerthr6adsof th6 bolt holes,
. Do not install the parts if 20 minutes or more
haveelapsedsinceapplyingthe liquidgasket.
Insteadreapplyliquid gasketafter removingthe
old residue,
. After assembly, wait at least 30 minutes before
filling th6 enginewith oit.
6 x 1,0 rnm
12 N.m (1.2 kg'm, 9 lb-ft)
8. Apply liquid gasket to the block mating surfaee of Apply liquid gasket RIGHTSIDECOVER
the right side cover, then install it on the cylinder to the bolt threads.
block.

BIGHTSIDECOVER:
9. Apply liquid gaskstto the oil pump mating surfac€
of the block,then installthe oil pump on the cylin-
der block.

. Apply greaseto the lips of the oil seals.


T h e n , i n s t a l lt h e o i l p u m p w h i t e a l i g n i n gt h e
inner rotor with the crankshaft.When the pump
i s i n p l a c e , c l e a n a n y e x c e s sg r e a s e o f f t h e
crankshaftand the balancer shaft, then check
that the oil se8llips are not distorted.

OIL PUMP:

Apply liquid gaskst along


the broken line.

{cont'd)

7 -27
Crankshaftand BalancerShafts
Installation (cont'd)

12. Holdthe rearbalancershaftwith a 6 x 100mm bolt,


then installthebalancerdrivengear.
OIL SCREEN
6x1.0mm REAFBALANCERSHAFT:
12 N.m (1.2kg-m,9lb-ftl

8 x 1.25mm
25 N'm {2.5 kg-m, 18 lb-trl

O.RINGS
Applyengineoil. 6 r lOOmm BOIT
Replace.

DOWELPIN 74 mm 12.9inl

6x1.0mm
12 N.m 11.2kg-m, OIL PUMP
9 tb-ft) Applyliquidgasketto
Applyliquidgasket block mating surface.
to the bolt threads. Applygreaseto the seallips.

REARBALANCERSHAFT
10. Installthebaifleplate,then installtheoil screen.
'11. Apply molybdenumdisulfideto the thrust surfaces
of the balancergears as shown, before installing '13. Hold the front balancershaft with a screwdriver,
t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
then installthetiming balancerbelt drivenpulley.
case.
Applymolybdenum FRONTBALANCERSHAFT:
disutfide. EALANCER SHAFT
DRIVEN

BALANCERBELT BALANCERDRIVEGEAR
DRIVENPULLEY AALANCERGEAR CASE

7-28
14. lnstallthebalancargea|.caseto the oil pump. 16. Install the oil pan.

NOTE:Align the groovo on the pulley sdg€ to the


pointoron the gear casswhile holdingths rear bal- OIL PAN GASKET Apply liquid
ancer with 6 x 100 mm bolt, then install the gear Replace. gasketto here.
casg.

DOWELPIN

E x 1.25mm
25 N.rn 12.5lg.m.
18 rb-ft|

O.RING
Applyengineoil,
BALAI{CER DOWELPIN Roplace.
GEAR$SE WASHER 6xl,0mm
Replace. 12 N.m {1.2kg.h,
POINTEB 9 rb-ft}
Alignthe groov€
to pornter. 45N.m(4.5kg.m.
33tb-ftt
Donot overtighten,

1 1 . Tightenthe boltsand nuts as shown below,

Torqu.: 12 N.m (1.2 kg-m, 9 lb.ft)

GROOVE

Checkalignmentof pointersafter installingthe gear


case.
POINTER
ONTHEPUL1TY

NOTE:Tightenthe bolts and nuts in two stoosand


torquethem in a criss-cross
pattern.

7-29
Crankshaftand BalancerShaft Oil Seals
Installation{engineremovalnot requiredl
NOTE:The crankshaftand front balancershaft 3. Using the specialtool, drive in the crankshaftoil
oil sealhousingsurfaceshouldbe dry. seal into ths right side coverto the point where the
Apply a light coat oJgreaseto the crankshaft,the clearancebetween the bottom of the crankshsft oil
balancershaftand to the lips ot the seals. seal and right side cover is 0.5 - 0.8 mm (0.02-
0.03in) lpage7-251.
Using the specialtool, drive in the crankshaftoil
sealuntil the driverbottomsagainstthe oil pump. NOTE:Align the hole in the driver attachmentwith
When thg seal is in place.clean any excessgrease the pin on the crankshaft.
off the crankshaftand checkthat the oil seal lip is
not distorted.

SEALDRIVER - (x)1|xno
07749
O'LAD - PI':IOIOA
lnslall se6l with the
part number sido
facing out.

DRIVERATTACHMEMT
079a8- SB@r01
lnstollsealwiththe
part number side
2, Using the specialtool, d.ive in the front balancer facing out.
shaft oil seal until the driver bottomsagainstthe oil
pump. When the seal is in pl8ce,clean any excess
greaseoff the balancershaft 8nd checkthst the oil
I sealliDis not distorted.

HUBASSEMBLYGUIDE ATTACHMEITT,
ATTACHMENT 30 mm l.D.
OTGAF_ 077t6 - @30300

7-30
BalancerShafts
Inspection
NOTE: Inspectthe balancershaft before removingthe Removethe balancershafts(page7-12).
right sidecoverand the balancergearcase{page7-12).

'1. NOTE:Cleanthe balancershsfts,


Push the balancershaft firmly away from the dial
indicator,and zerothe dial againstthe front end of Inspectthe surfaceof the balancershaftjournaland
the balancershaft,then pull the balancershaftfirm- balancerbearing.
ly backtoward the indicator.
Replaceif there is wear,damageor discolorationon
Froni BalancorShaft End Play the surfaceof the bearingor the balsncershaftjour-
Standard (Nsw): 0.10- 0.35 mm nal. When replacingthe rear No. 1 bearingbe sure
l0.00il- 0.014in) to replacethe oil pump housingwith a new one.

NOTE;A mirro.-likesurfaceis normat.

Measuretaperat the edgesof eachjournal.

. The differencebetweenmeasurementson each


lournal.

Journal Tapor
Standard (Newl: 0.005mm (0.0002in)

. lf end play is excessive,inspectthe retainerand


thrustsurfaceson the balancershaft.

Rsar BalancorShrft End Play


Stsndard(N€w):0.06- 0.18mm
10.002- 0.007inl

. lf end play is excessiv€,inspectthe thrust wash-


er and thrust surfaceson the driven qear and oil
pump Dody.

N O T E :T h e t h i c k n e s so f t h e r e t a i n e r( f r o n t ) a n d
t h r u s t w a s h e r ( r e a r )a r e f i x e d a n d m u s t n o t b e
changedeitherby grindingor shimming. {cont'd)

7-31
BalancerShafts
Inspection(cont'd)
6. Measurerunout on the No. 2 journal of each bal-
ancershaftto makesurethe balancershaltsare not
bent,

Ealanc6rShaft Total IndicatodRunout


Standrrd (Now): 0.02 mm (0.001inl
Sewice Limit: 0.03 mm 10'001inl

Journal Diamot€r
Stlndard (New)
No, 1 ioutnal:
Front: 12-722- 12..731mm
11.6820- 1.6824inl
Rear: 20.938- 20.950mm
{0.824:l- 0.82'18in}
Measurethe diametersof the balancershaft jour- No. 2 iourn.l: 38.712- 38.724mm
n al s . l1.52al- 1.5245inl
: No. 3 iourn.f : 31.722- 31.731mm
I
(1.3670- 1.3675inl
MEASURINGPOINTS
Scrvica Limit:
No. I iournal:
i Front: 42.71mm {1.681in)
I Rcar: 20.92mm 10.82,1 inl
No. 2 iouinll: 38.70mm (1.524inl
No. 3 iournal:34.71mm (1.367in)

Removethe crankshaft,the pistons and the other


oartsfrom the block,then cleanthe balancershaft
I i o u r n a l b e a r i n g so f t h e b l o c k a n d t h e o i l p u m p
housingwith a cleanshoptowel.

9. Checkthe surfaceof the bearings,if there is wear.


damage or discoloration,replacethe bearingsor
i the oil pump housing.

7 -32
1 0 . Measurethe inner diametersof the balancer shaft Bearing Inner Diametor
journalbearings. Standard {Nswl:
No. I iournals:
MEASUREPOINTS
Fronl: 12.8OO- 12-82Omm
No. 2 BEARING (1.6850- 1.6858in)
IBLOCKI Rear: 21.flD - 21.013mm
{0.8268- 0.8273inl
No. 2 iournals: 38.800- 38.820mm
(1.5276 - 1.5283in)
No. 3 iournals: 34.800- 3,1.820mm
{1.3701- 1.3709inl
ServicoLimit:
No. l iournals:
Front: 42.8:lmm 11.686inl
R6ar: 21.02mm (0.828in)
No. 2 iournals: 38.tIl mm (1.529in)
No.3 iournsls:3i1.83 mm (1.371in)

11. Calculatethe shaft-to-bearings


oil clearances.

BEARINGl.D. - JOURNALO.D. = OtL CLEARANCE

Boaring-to-shaftOil Cl.aranc€
No. 2 BEARING Standard (Newl
IBLOCK) No. I iournal front and No. 3 iournsls:
0.066- 0.118mm {0.0026- 0.0046inl
BLOCK No. 2 iournab:
0.076- 0.128mm (0.0030- 0.0050in)
No. 1 iournal r€ar:
0.050- 0.075mm (0.0020- 0.0030in)

S6rviceLimit:
No. I iournal tront and No. 3 iournats:
0.12mm (0.005inl
No. 2 tournsls: 0.13mm {0.005inl
No. I iournal roar: 0.09 mm (0.004in)

DIALGAUGE

No. 1 REARBEARING
IOIL PUMP HOUSINGI

7-33
EngineLubrication
Speciaf Tools.......... ...........9-2
lllustratedlndex........... .....8-3
EngineOil
Inspection ......................
8-5
Replacement .......................................
8-5
Oil Filter
Rep|acement .......................................
8-6
Oil Pressure
Testing ......8-8
OilJet
fnspectionlHz2Al engineonly) ........8-8
Oil Pump
Overhaul .........................
8-9
RemovaUlnspection/lnstallation ......8-10
SpecialTools

Rs{. No. I Tool Numbel Drtcription Oty I PEg. Rctercnc.

o OTLAD- PT3O1OA SealDriver 8-11


8-1 1
@ 07746- 0010300 Attachment,42 x 47 mm
Ar 07749- 0010000 Driver 8-1' I
@ 0 7 9 1 2- 6110001 Oil Filterwrench a-7

I
o

o o

8-2
lllustratedIndex

NOTE: CAUTION: Do not overtighten the drain plug.


a Us€ new O-ringswhen reassembling.
. Apply oilto O-ringsbeforeinstallation.
. Useliquidgasket,PartNo. 08718- OOO1.
. Cleanthe oil controlorificewhen installing. OILPUMP
8 x 1.25mm Overhaul,pageI 9
Inspection,page8-10
Apply liquidgasketto
blockmatingsurface.

O-RINGS
Replace. F22A1,H23At enginesj
8 x 1.25mm OIL CONTROLORIFICE
30 N.m (3.0 kg-m, Do not installit on the H22A1engine.
22tb-ft1 Clean.
O.RING
Replace. F22Al engin€:
ENGINEOIL PRESSURE SWITCH
BALANCEN 18 N.m (1.8 kg.m, t3 tb-ft)
GEARCASE 1/8in. BSP{British
standardpipetaper)
28 threads/inch.Use
properliquidsealant.

H23A1,H22At engin.s:
KNOCKSENSOR
32 N.m 13.3kg-m, 23 tb-ftl

O.RING
Replace.

DOWEL
PIN
8 x 1.25mm ENGINEOIL COOI..ER
25 N'm 12.5kg-m, i8 tb-ft} {H23A1,H22Al ongin6)

DOWELPIN

GASKET
Replace.
OIL SCREEN OIL FILTER
7/8 turn or
22 N.m l2.2lg-m, i6 tb-ft|
Replacemg6lp6gs g 6
6x1.0mm Replaceevery 7,500miles
OIL PAN GASKET 12 N.m 11.2kg-m,9 tb-ft| {12,000km) or 6 months.
Roplace. H23A1,H22At engin$:
ENGINEOIL PRESSURE SWITCH
18 N.m {1.8 kg-m, t3 tb-ftl

6x1.0mm
12 N.rn(1.2kg-m.9 tb-ft)
WASHER
Replace.
DRAINBOLT
1 4x 1 . 5m m
OIL PAN 45 N.m 14.5kg-m,33 lb-ttl
Do not overtighten. (cont'd)

8-3
lllustratedIndex
lcont'd)
NOTE:
a Usenew O-ringswhen reassembling.
. Apply oilto O-ringsbeforeinstallation
. Use liquidgasket,PartNo. 08718- 0001.

1 1x 1 , 5m m
75 N.m (7.5kg-m, 5x1.0mm
54 tb-ft} 12 N.m 11.2kg-m,9lb-ft|
Applyengineoiltolhe bolt
threads and th€ washers
NOTE:
Alter torquing each cap,
turn crankshaftto chock
for binding. BAFF1TPLATE

EEARINGCAP
BRIDGE

OIL JET BOLT


40 N.m {a.0 kg-m,
29 tb-ft)

OIL JET
Handlethe nozzlewith
care.Replaceil any pan
is damagedor detormed.
6x1.0mm
12 N.m {1.2lg-m,9lb-ft}

i
CRANKSHAFT

i THRUSTWASHERS
Groovedsidesface outward.

a-4
EngineOil
Inspection Replacement
Checkengine oil with the engine off and the car CAUTION:Removs the drain bolt carofullywhile th6
parkedon levelground. ongine is hot oil m8y caus6scalding.

Makecertainthat the oil level indicatedon the dio- L W a r mu p t h e e n g i n e .


stickis betweenthe upoerand lowe. marks.
2. Drainthe engineoil.
lf the level has dropped close to the lower mark.
add oil until it reachesthe upDermarK.

CAUTION: In36rt thc dipstick cardully to avoid


bonding it.

WASHER
45 N.m{a.5kg-m,33 tb-ft| R6placo.

R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r , a n d
refillwith the recommendedoil.

CAUTION: Do not ov6rtight6n the drain bolt.

Requirement API ServiceGrade:Use "Energy Conserving


ll" SG gradeoil.
F22A1,H23A1engines:5 W- 30 preferred.
H22Al engine:10W - 30 preferred.
Capacity F22A1enginel
3.8f (4.0US qt,3.3 tmp qt)
change,includingfilter.
4 . 9 1( 5 . 2U S q t , 4 . 3 l m pq t )
atter engine overhaul.
H23A1engine:
4.3f (4.5US qt, 3.8tmp qt)
chang€,includingfilt6r.
5.4f (5.7US qt, 4.8lmp qt)
afterengineoverhaul.
H22A1engino:
4.8f (5.1US qt, 4.2 lmp qO
change,includingfitter.
5.9f (6.2US qt, 5.2lmp qt)
aflerengineoverhaul,
Change Every7,500miles {12.OOO
krn) or 6 months

{cont'd)

8-5
Engi n eOi l Oil Filter
Replacement(cont'd) Replacement

The numbersin the middle of the API Servicelabeltell


you the oil's SAE viscosityor weight. Selectthe oil for o Ltter tte engine has been run. the exhaurt pipo will
your car accordingto this chart: be hot; be caroful when working around the axhau3t
pipo.
F22A1.H23A1engines: Be careful when loo3oning the drain bolt while tho
engino i3 hot, Burns can rosult becausothG oil lgm'
peraturc is very high.
Ambi€nt Temperaturo
R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r
wrench.

Inspectthe threadsand rubber seal on the new fil-


ter.
Wipe off seat on engine block,then apply a light
coat of oil to the filter rubberseal.

NOTE: Use only filters with a built-in bypasssys-


A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r rem.
improved fuel economy and year-roundprotection in
the car. You may use a 10 W - 30 oil if the climate in
your area is limitedto the temperaturerangeshown on Applyengineoilto rubb€r
the chart. sealbeforeinstalling.

H22A1engine:

Ambiont Temo6raturs

-20

An oil with a viscosity of 10 W - 30 is preferredfor


improved tuel economy and year-roundprotectionin
the car. You may use a 5 W - 30 oil if the climate in
your area is within the temperaturerangeshown on the
chan.

N O T E : T h e o i l f i l t e r s h o u l d b e r e p l a c e da t e a c h o i l
change.

8-6
Installtheoil filter by hand. eight numbers(1 to 8l are printedon the surfaceof the
filter.
A f t e r t h e r u b b e rs e a l s e a t s .t i g h t e n t h e o i l f i l t e r
clockwisewith the specialtool. The following explainsthe procedurefor tighteningfil,
ters usingthesenumbers.
Tighten: 7/8 turn clockwise
Tightoning torque: 22 N.m (2.2 kg-m, 16 lb-ftl 1) Make a mark on the cylinderblock under the num-
ber that shows at the bottom of the filter when the
CAUTION: lnstallation other than the abov€ procs- rubbersealis seated.
dur6 could result in sgrious ongine damage due to
oil l6ak.go.
I
2) Tightenthe filter by turning it clockwisesevennum-
bersfrom the markedpoint. For example,if a mark
is made under the number 2 when the rubberseal
OIL FILTERWRENCH i s s e a t e d t, h e f i l t e r s h o u l d b e t i g h t e n e du n t i t t h e
07912- 611t)00r number1 comesup to the markedpoint.

Numberwhen rubber Numberaftertightening.


sealis seated.

Numberwhen rubber
4 7 8
sealis seated
ENGINEOIL COOLER
(H23Al, H22A1engine3l Numberaftertightening 8 1 1

5. After installation,fill the engine with oil up to the


specifiedlevel,run the enginefor more than 3 min
utes,then checkfor oil leakage.

a-7
Oil Pressure Oil Jet
fnspectionlH22A1engineonlyl
lf the oil pressurewarning light stayson with the engine Removethe oil jet (page8-4) and inspectit as fol-
running.checkthe engineoil level.lf the oil level is cor- rows.
rect:
Make sure that a 1.1 mm {0.04in} diameterdrill
'1.
Connecta tachometer. will go throughthe nozzlehole {1.2mm t0.05in)
diameter).
Removethe engine oil pressureswitch and install Insertthe other end of the same 1.1mm {0,04in}
an oil pressuregauge. drill into the oil intake(1.2 mm (0.05in) diame-
ter). Make sure the check ball moves smoothlv
S t a r t t h e e n g i n e . S h u t i t o f f i m m e d i a t e l yi f t h e and has a strokeof approximately4.0 mm (0.16
gauge registersno oil pressure.Repairthe problem In,.
beforecontinuing. Checkthe oil jet operationwith an air nozzle.lt
should take at least200 kPa (2.0 kg/cm,,28 psi)
Allow the engine to reach operatingtemperature to unseatthe checkball.
(radiatorlan comeson at leasttwice).The pressure
shouldbe: NOTE:Replacethe oil jet assemblyif the nozzl€
is damagedor bent,
Engine Oil Tamp6rrture: 176'F {80'C)
EngineOil Pressure:
At ldle: 70 kP8 (9.7 kg/cm,, 10.0psi)
minimum
At 3,flt0 rpm: 350 kPa (3.5kg/cm,, 50 p3il
minimum
1!
lf oil pressureis within specifications, replacethe
I oil pressureswitch and recheck.
l f o i l p r e s s u r ei s N O T w i t h i n s p e c i f i c a t i o n s ,
:. inspectthe oil pump (pages8-10,11|.
'

ENGINEOIL PRESSURE OIL PRESSURE


GAUGE
SWITCHMOUNTINGHOLE
{F22A1engino}
I

I
i

I
I

ENGINEOIL PRESSURE SWiTCH Mounting torque is critical.Be very precisewhen


MOUNTINGHOLE installing.
lH23A1,H22Al cneinos)

lH23A1,H22A1.ngin.!l Torquo: 40 N.m (4.0 kg-m, 29 lb-ft)

8-8
Oil Pump
Overhaul

NOTE:
Usenew O-ringswhen reassembling,
Apply oilto O-ringsbeforeinstallation.
Use liquidgasket,PartNo.08718- 0001.

6x1.0mm
7 N.m {0.7 kg-m, 5.1 lb-ftl
PUMPCOVER

OUTERROTOR
OOWELPIN page8-10,11
Inspection,

6x1.0mm
INNERROTOR
12 N.m {1.2kg-m,9lb-ft}. page8-10,t 1
Inspection,
Apply liquid gasker
to the bolt threads,

OIL SEALS
Replace. PUMPHOUSING
pageI 10.11
Insp€ction,

8-9
Oil Pump
Removal/lnspection/lnstallation

1 . D r a i nt h e e n g i n eo i l . 9. Removethe screwsfrom the pump housing,then


separatethe housingand cover.
2. Turn the crankshaftso that the No. 1 pistonis at top
'10.
d e a d c e n t e r( F 2 2 A 1e n g i n e :p a g e 6 - 2 8 ,H 2 3 A 1 Checkthe inner-to-outerrotor radial clearanceon
engine:page6-62,H2241engine:page6-106). the oumo rotor.

Removethe timing belt and the timing balancerbelt lnner Rotor-to-OuterRotor RsdialClea.anc€
(F22A1engine:page6-29,H23A1engine:page6-63, Sland8ld (Newl: 0.02- 0.16 mm (0.001- 0.006in)
H22A1engine:page6-'l07). ServiceLimit: 0.20 mm 10.008inl

R e m o v et h e t i m i n g b e l t t e n s i o n e ra n d t h e t i m i n g
balancerbelttensioner.

Bemovethe timing belt drive pulleyand the timing


balancerbelt drivenpulley(page7-12).

6. R e m o v et h e b a l a n c e .g e a r c a s ea n d t h e b a l a n c e r
drivengear(page7-121.

Removethe oil pan and the oil screen.

R e m o v et h e m o u n t i n gb o l t s a n d t h e o i l p u m p
assemory.
t
ii
I

DOWELPIN OIL PUMP


- lf the inner-to-outerrotor clearanceexceedsthe
servicelimit, replacethe innerand outer rotors.

1'1. Checkthe housing-to-rotoraxial clearancson the


oumo rotor.
O.RINGS
Replace-
Housing-to-RotorAxial Clcaranco
Standard lNewl: 0.02- 0.07 mm (0.001- 0.003in)
SorvicoLimit 0.12 mm 10.005inl

PUMPHOUSING OUTER
OUTERROTOR
ROTOR
Replace.

OIL SCREEN

- lf the housing-to-rotoraxial clearanc€exceeds


t h e s e r v i c el i m i t , r e p l a c et h e s e t o f i n n e r a n d
outer rotorsand/orthe pump housing.

8-10
12. Ch€ckthe housing-to-outer
rotor radialclearance,

Housing.to-OuterRolor RadialClrarsnc€
Stlnda.d {Nsw}: 0.10- 0.19 mm (0.004- 0.007in}
SorvicaLimit: 0.21 mm (0.fi)8 in)

,rJ:|xaTmm
077a6_ 00,t0300

Rsassemblethe oil pump, applying liquid thrcad


lockto the pump housingscrews.

1 7 . Checkthat the oil pump turnsfreely,

?8. Installa dowel pin and the new O-ringon the pump,

NOTE:
a Useliquidgasket,Pan No. 08718- 0001.
a Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
Apply liquidgasketevenly,in a narrowbeadcen-
- l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e teredon the matingsurface.
exceedsthe service limit, replacethe set of inner . To preventleakageof oil, apply liquid gasketto
and outer roto.sand/orthe pump housing. the innerthreadsof the bolt holes,
. Do not install the parts if 20 minutes or more
1 3 . Inspect both rotors and the pump housing for scor- haveelapsedsinceapplyingliquidgasket.
ing or other damage.Replaceparts if necessary. Insteadreapplyliquid gasketafter removingthe
old residue.
Removethe old oil sealsfrom the oil pump. . After assembly, wait at least 30 minutes before
filling the enginewith oil.
t5. Gentlytap in the new oil sealsuntil the specialtool
bottomson the pump. 19. Apply liquidgasketto the oit pump and insta it.

NOTE:The oil sealsalon€ can be reolacedwithout . Apply greaseto the lips of the crankshaftoil seal
romovingth€ oil pump usingthe specialtool. and the balancershaft seal.Then, installthe oil
pump Inner rotor onto the crankshaft.When the
pump is in place,cleanany excessgreaseoff the
crankshaftand the balancer shaft, then check
that the oil seal liDsare not distorted.

Apply iiquidgasket
alongthe brokenline.
(cont'd)

8-11
Oil Pump
Removal/lnspection/lnstallation
{cont'd}
23, Hold the rear balaocorshaft with the 6 x 100 mm
bolt,then installthe balancerdrivengear.
Apply grease
to the seallips. 6 x 10 mm REARBALANCER:
OIL PUMP 12 N.m 11.2kg-m, 9 lb-ft|
Applyliquidgasket Apply liquidgasketto the
to block mating surface. bolt threads.

I x 1.25mm
O.RINGS 25 N.m {2.5 kg-m, 18lb-ft}
Applyengineoil.
Replace.

6 x 100mm EOLT

6x1.0mm t4 mm 12.9inl
12 N.m (1.2kg"m,
OIL SCREEN 9 tb-ttl

Installthe baffleplate.

2 1 . Installthe oil screen.

Apply molybdenumdisultideto the thrust surfaces REANBALAI{CERSHAFT


of the balancergears.as shown, before installing
t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
case.
Apply molybdonum BALANCERDBIVEN 24. Hold the front balancershaft with a screwdriv€r,
disulfide. GEAR then installthe timing balsnce.b€lt driv€npull6y.

FRONTBALANCER:

BALANCERDRIVE
GEAR

8-12
25, lnstallthebalancergear caseon the oil pump. 27. Install the oil pan.

NOTE;Align the groove on the pulley edge to the


pointeron the gear casewhile holdingthe rear bal- Apply liquid
OIL PAN GASKET gask€there.
ancerwith the 6 x 100mm bolt,then installthe gear Replace.
case.

DOWELPIN

8 x 1.25mm
25 N.m 12.5kg-m, 18 lb-ftl

O.FING
Apply6ngin€oil. WASHER
BALANCER Replace. Replac6. 6x1.0mm
GEARCASE DOWELPIN

DRAINEOLT
POINTER ils .m 14.5ks-m, 33 tb_ft)
Alignthe O.ooveto Donotovertightsn.
pornter,

24. Tightenthe boltsand nuts as shown below.

Torquo: 12 Nfl (1.2tg-m,9 lb-ft)

GROOVE

26. Checkalignmentof pointersafter installingthe gear


case.
POINTER
ONTHEPULLEY
a -------_

POINTERON
THEOIL PUMP
NOTE:Tightenthe bolts and nuts in two stepsand
torquethem in a crisscrosspattern.

8-13
Intake Manifold/Exhaust
System
Intake Manifold
Replacemen . .t. . . . . . . . . . . . . . . . . . . . . . .9. .- .2. . .
ExhaustManifold
R e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . . . . . . . .9. .- .4. . .
ExhaustPipe and Muffler
R e p | a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . 9
. .-.7. .
Intake Manifold
Replacement

NOTE: Use new O-ringsand gasketswhen reassembling.

a Chock tof folds or scratchos on ths surlace of th6 gaskot.


a Replaco with a new gasket it dsmaged.
8 r 1,25mm
H2341, H2241 engines: 22 N.m (2.2 ks-m, 16 lb-tll

STARTINGAIR VALVE
INTAKE MANIFOLD 6xl.0mm
CHAMBER 12 N.m 11.2 kg-m, 9 lb-ft|
Replacoif cracked or
if mating surfaces are IDLE AIR CONTROL
damaged. {tAc}val-vE

8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft}

THROITLEBODY

O-RINGS
Replace.
GASKET
Replsce.

INTAKE AIR BYPASS FAST IDLE TXERMO VALVE


IIAB}VALVEBODYASSEMELY 8 r 1.25mm
Replaceif crackedor 6 x 1 . 0m m 22 N.m 12.2 kg-m, 16 lb-ft)
if mating surlaces are 12 N.m ('1.2kg-m,I lb-ttl
oamageo.

GASKET

Y"Sft
Replace.

|l['sJ!'J[*%''
(fAT) SE[{SOR
EXHAUSTGAS
NECIBCULATIOI{
IEGR}VALVE
./
O.RING
Replace.

INTAKE
Replaceit crackedor
if mating su aces are 8r1.25mm
damaged. 22 N.m
(2.2 ks-m,l6 lb-tt)
GASKET
Replace.

8x1.25mm
22 N.tn 12,2 kg-m, 16 lb-ftI

8 x 1.25mm
22 N.m 12.2 kg-m, '16 lb-ftl INTAKE MANIFOLD BRACKET

9-2
NOTE: Use new O-ringsand gasketswhen reassembling.

CAUTION:
a Check fol tolds or scfatchos on tho surfac6 ot the gaskst.
a Roplsco with a n€w gasket if damaged.

F2241 engino:

8 x 1.25mm
FAST IDI-ETHERMOVALVE
22 N'm 12.2ks-m, 16 lb-ftl
I x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ftl

STARTINGAIR VALVE IAC VALVE


O-RINGS
Replace.

6 x 1.0 mm
12 N.m 11.2 kg'm, 9 lb-ft}
6 x 1.0 mm
12 N.m 11.2 kg-m, 9 lb-ttt O.RINGS
Replace. THROTTLEBODY
INTAKE MANIFOLD
CHAMBER 8 x 1 . 2 5m m
Replaceif cracked or 22 N.m 12.2kg-m,
if mating surfaces are 16 tb-ftl
damaged.

GASKETS
Replace.
8 x '1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

EGR VALVE

GASKETS
Replace.

8 r 1.25mm
22 N.rn 12,2 kg-m, 16 lb-ft)

INTAKE MANIFOLD
8 x 1.25mm BRACKET
22 N.m 12.2 kg-m, 16 lb-ft)

9-3
Exhaust Manifold
Replacement

NOTE: Use new gasketsand seltiocking nuts when reassembling'

CAUTION:
a Check for folds or scratchas on the sutfaca of tho gasket'
a Rsplace with 6 new gaskot il damagod.

H23A1 engine:

SELF-LOCKINGNUT
I x 1.25mm
32 N.rn (3.2 kg-m, 23 lb-ft) GASKET
Replace. R6place.

8 r 1.25mm
22 N.n 12.2 kg-m, 16 lb-ft)

EXHAUSTMA IFOID
BRACKET

lO x 1.25mm
45 t{.m (4.5 kg-m. 33 lb-ft}
r 1.25mm
GASKETS 22 N.m 12.2 kg-m, l6 lb-ftl
Roplace.

1 0 r 1 . 2 5m m
45 N.m t4.5 kg-m.33 lb-ft)
6 x 1.0 m]n
12 N.m ll.2 kg-m. 9 lb-ft)
T INSULATOR

SELF-LOCKING NUT 6 x 1.0 mm


10 x 'l,25 mm 10 N.m (1.0 kg-m, 7 lb-ft)
55 N.m t5.5 kg-m,40 lb-ftl

9-4
NOTE: Use new gasketsand selflocking nuts when reassembling.

GAUTION:
a Check tor folds or sclatches on th€ surfacs of the gask€t.
a Replacewith a new gaskot if damaged.

F2241 ongine:

GASI(ET
Replace.

EXHAUST

SELF.I.OCKING 1{UT
8 x 1 . 2 5m m
32 'm 13.2 kg-m, 23 lb-ft|
Replace. ,.(

HEATEDOXYGEI!
SENSOR{HO2Sl
45 N.m 14.5 kg-m, 33 lb-ft)
Be carelul not to EXHAUSTMANIFOI.D
BRACI(ET

8 x 1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

GASKET
Replace.

10 x 1.25mm
45 N.m {4.5 ks-m, 33 lb-ft}

SELF.I-OCKIl{GNUT
10 x 1.25mm
55 N'm 15.5 kg-m. 40 lb-fi)
Replace.

COVER HEAT INSULATOR


HO23
CONNECTOR lCars equippedwith air conditioningl

6 x 1 . Om m
10 N.m (1.O kg-m, 7 lb-fil

9-5
Exhaust Manifold
Replacement
NOTE: Use new gasketsand self-lockingnuts when reassembling.

CAUTION:
a Chock tor folds or scratchoa on tho surface of the gasket.
a Replaco with a now gaskot it damaged.

H22A'l ongino:

SELF.LOCKINGt{UT
8 r 1.25mm
32 N.m {3.2 kg-m, 23 lb-ft) GASKET

lr
I
Replace.

EXHAUST MAf{IFOLD
Replace.

COVER

1 0 r 1 . 2 5m | n
.m 14.5 lg.|n,
33 lb-tt)

GASKETS
R6place.

8 x '1.25mm
22 N.m 12.2 kg-m, 16 lb-ft)

HEATINSULATOR
SELF-LOCKII{GNUT
10 x 1.25mm 8 x 1.25mm
55 N.m (5.5 kg-m, il.O lb-ft) 22 N.m 12.2 ks-m, 16 lb-ft1
EXHAUST PIPEA 6 x 1.0 mm
10 N.m (1.0 ks-m, 7 lb-ft|

9-6
Exhaust Pipe and Muffler
Replacement

NOTE: Use new gasketsand self-lockingnuts when reassemblino.

6 x 1 . 0m m
10 N.m {1.Okg-m.7 lb-ftl

HEAT SHIELD
SELF-LOCKINGNUT
1 2 x 1 , 2 5m m
55 N.m {5.5 kg-m,4O lb-ft|
Replace.
€.
€ \
EXHAUST PIPETIP
THREEWAY
CATALYTIC
COI{VERT€R
TTWCI
TOROUESEOUENCE MUFFLER

GASKET
Replace.

EXHAUSTPIPEB

SEI.F.LOCKINGNUT
45 N.ln 14.5 kg-m, 33 lb-ft| 10 x 1.25mm
Be carefulnot to damage. 34 N.m {3.4 kg-m, 25 tb-ftl
Replace.

oor*rrr\ 3
Replace.
V SELF-LOCKINGNUTS
I x 1,25mm
18 N.m (1.8 kg-m, 13 tb-ftl
GASKET Replace.

SELF-LOCKINGNUT
10 x 1-25mm
34 N.m (3,4 kg-m, 25 lb-ttl
R6place.
SELF-LOCKINGNUT
10 x 1.25mm
55 N.m (5.5 kg-m,40 lb-ttl
Replace.

I
9-7
Cooling
Radiator
fffustrated Index......... . 1O-2
R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1. .O. .-.5.
EngineCoolantRefilling
a n dB l e e d i n g . . . . . . . . . . .1. 0 - 6
C a pT e s t i n g . . . . . . . . . . . . .1. .0 - 7
Testing ..... 1O-7
Thermostat
R e p | a c e m e.n. .t . . . . . . . . . . . . . . . . . . . . . . 1. .O. .-.8.
Testing ..... 10-9
Water Pump
lllustrated Index......... . 1O-1O
fnspection . 10-12
Repfacement .............. 1O-12
Radiator
lllustratedIndex

@ sy"t". is under high pressurewhon engino CAUTION: Wh€n poudng ongino coolant, be suts
is hot, To avoid dangel ot releasingscaldingcoolant, re- to shut the relay box lid and not to spill coolant on
move cap only when engine is cool. the electlical parts or tha paintsd po ion. lf 8ny
coolant spills, rinse it off imm€diately.
Total Cooling System capacity {lncluding hoater and
res€rvoir) NOTE:
a Checkallcoolingsystemhosesfor damsge,leaks
F2241 engin€: or deteriorationand replaceif necessSry.
", a Check all hoss clamps and retightenif necessary.
Manuaf: .1 | l7 .5 US qt, 6.2 lmp qt)
Automatic: 7 .O | (7 .4 US qt, 6.2 lmp qt) a Use new O-ringswhen reassembling.
H23A1 sngin€:
Manuaf: 7 ,4 (. 0,A US qt, 6.5 lmp qtl RADIATOR
Automatic: 7 .3 I 17.7 US qt. 6.4 lmp qt) Engine
coolant
Refillingand bleoding.p6ge 'l0-6
H2241 engin€: Leak test, page 1O-7
Manual: 7.6 | (8.O US qt, 6.7 lmp qt) Inspect soldered joints and
seamsfor leaks.
Reselvoircapacity:O.6 t {0.6 US qt, O.5 lmp qt) Blow out dirt from between
core fins with compregsedair.
l{ insects,etc., are clogging
radiator, wash them off with
low oressule water.

RADIATOB CAP
testing,pago 1O-7
Pressure

6 x 1.0 mm
1 0 N . m { ' l . Ok g - m ,
7 tb-ft)

FLUID (ATF) COOLER

FAN MOTOR

O-RING
DRATNPLUG Replace.
6 r 1 . 0m m
' l ON . m( 1 . 0rg-m,
o. -
7 tb-ttl ;t'i.*:l:XS[YJ,,,
Replace.

COOLINGFAN

FAN SHROUD

10-2
Engino Ho86 Connoctions:

F22A1 engine: IOLEAIR CONTROL


{IACI VALVE
FAST IDLE
THERMO V
THERMOSTAT
HOUSING

HEATEROUTLET

LOWERHOSE

CONI{ECTINGPIPE HEATERINLET
HOSE
BYPASS HOSE
Replace.

H23Al engine: POSITIVECRANKCASE


VENTILATION(PCV} PIPE
IAC VALVE

EYPASS HOSES

O.RING
Replace.

OIL COOLER
BYPASS HOSE

O-RING
HEATER Replace.
* 8 x 1 . 2 5m m CONNECTINGPIPE
22 N'm
12.2 kg-rn, OIL COOLER
16 tb-ft) BYPASS HOSE COOLER

r:: CORFOSIONRESTSTANT
BOLT (cont'd)

10-3
Radiator
lllustratedIndex (cont'd)

I
Engin€ Hose Connections:

H22A'l €ngin€:

THERMOSTAT
HOUSING

HEATERINLET
HOSE
HEATEROUTLET
HOSE O-RING COOLER
PIPE
CONNECTING Replaco.

* 8 x 1 . 2 5m m
22 N.m 12.2kg-m,
16 tb-ft}

RESISTANTBOLT
*: CORROSION

10 -4
Replacement
1 . Dr€inenginecoolant. 5. Removethe fan shroudassembliesand other parts
from radiator.
Romovethe upper and radiatorhoses,and ATF
coolor hoses. Instsllthe radiatorin the reverseorder of removal:
a Disconnect the fan motor connectors. NOTE:
a Set the upper and lower cushionssecurly.
4. R€movethe radiatorupper brackets,then pull up the a Fillthe radistorwith enginecoolantand bleedthe
radiator. ai''.

6 x 1.0 mm
10 N.m (1.0 kg-n, 7lb-ft1
RADIATOR
page 1O-7

BADIATOR CAP
6x1.0mm Testing,page 'lO-7
10 N.m ll.O kg-m,7 lb-ft}
UPPERBRACKET
UPPERI{OSE ANDCUSHION

:tt'l13l3l=.--_g F/o
"l F
sng
7.r.
I x 1.0 mm
lO N.in (t.O kg-m.7 tb-frt @

FAN MOTOR P
CON'VECTOR
1\ RESERVOIRHOSE
owER CUSHTON

ATF COOLER
DRAIN PLUG HOSE$

O-RING
Replace.
LOWERHOSE

RESERVOIR

10-5
Radiator
EngineCoolantnefill\ and Bleeding
CAUTlOttl: When pouting enginocoolaisQgsuro to shut H23Al engine:
th6 ralay box lid and not to lst coolanl spill on tho elec- Manual: 3.8 X (4'O US qt, 3.3 lmp qrl
trical part6 or lh€ paint. lf any coolant spills, rinse it off Automatic: 3.7 t {3.9 US qt, 3.3 lmp qt}
immodiat6ly. H22Al engino:
1. Set the heatertemperaturelever or conttol dial to Manuaf: 4.O f 9.2 US qt, 3'5 lmp qt)
maxamumheat.
9 . Loosenthe air bleed bolt in the thetmostat housing,
then fillthe radiatorto the bottom of the tiller neck
2. Removethe engine splashshield.
with the coolantmixtu.e. Tightenthe bleedbolt as
soon as coolant stans to run out in a steadv stream
3. When the radiatoris cool, removethe radiatorcap.
without bubbles.
Loosenthe drain plug, and drain the coolant.

4. Removethe drain bolt trom the rear side of the BLEEDBOLT


cylinderblock to drain the block and heater,

5. Apply liquidgasketto the drain bolt threads,then


reinstall the bolt with a new washer and tighten it
securely.

6. Tightenthe radiatordrain plug securely.

7, Remove,drainand reinstallthereservoir.Fillthetank
haltway to the MAX mark with water, then up to the
MAX mark with anti-freeze.

8. Mix the recommendedanti-freezewith an equal


amount ol water in a clean container.

NOTE:
a Use only genuineHonda anti-Jreeze/coolant.

a Fof best corrosionDrotection,the coolant concen-


tration must be maintainedyear-roundat 50
minimum.Coolantconcentrations lessthan 50%
may not provide sutficient protection againstcor-
rosion or treezing.

a Coolantconcentrationsgreaterthan 60% will im-


paif cooling efficiency and are not recommended.

CAUTION:
a Do not mix dilferent brands of anti-freoze/
coolants.
a Do not uso additional rust inhibitors or anti-rust
products; they may not be compatible with tho DRAII{ BOLT
g€nuine coolant. 60 N.m {6.0 kg-m,43 lb-ft}
Applvliquidgasketto the
boltthreadswheninstalling.
Engine Coolant Refill Capacity: including reservoir
{0.6 t {0.6 US qt, 0.5 lmp qt}l and heatar{0.6 f (o.6 1O. With the radiatorcap oft, start the engineand let it
US qt, 0.5 lmp qt)|. run until warmed up (Radiatorfan goes on at least
twice). Then,if necessary,add more coolantmix to
F22Al engine: bring the level back up to the bottom ot the filler
Manual: 3.5 I (3.7 US qt,3.1 lmp qt) neck.
Automatic: 3.4 f {3.6 US qt, 3.0 lmp qtl
11. Put the radiatorcap on tightly, then run the engine
again and check tor leaks.

10 -6
Cap Testing
Removethe radiatorcap, wet its seal with engine
coolant,then insmll it on the pressuretester.

A p p l y a p r e s s u r eo f 9 5 - 1 2 5 kpa (0.9b-1.25
k g / c m , ,1 4 - 1 8 p s i ) .

Check for a drop in pressure.

4. lf the pressuredrops, replacethe cap.

RADIATORPRESSUBETESTER
COMMERCIALLYAVAILABLE

ADAPTOR
{for smallcap)

Testing

1. Wait until the engineis cool. then carefullyremove


the radiator cap and fill the radiator with engine
coolant to the toD of the filler neck. RADIATOR
PBESSURE
TESTER
COMMERCIALLYAVAILABLE
2, Attach the pressuretesterto the radistorand apply
a p r e s s u r eo f 9 5 - 1 2 5 k P a ( 0 . 9 5 - 1 . 2 5 k g / c m r ,
14. 18 psi).

3. Inspect for enngine coolanl leaks and a drop in


pressure,

4, Removethe tester and reinstallthe radiatorcao.

NOTE; Check for engineoil in the coolant and/or


coolant in engineoil.

10-7
Thermostat
Replacement
NOTE: Use new O-ringswhen reassembling.
F22A1, H23Al engin6s:
ELEED BOLT
10 N.m lt.0 kg-m,7 lb-ftl

6 x 1.0mm
'12 N.m (1.2 kg-m, 9 lb-ft)
ENGIfTE COOLANT
TEMPERATURE (ECT}
SWITCHA
28 t{.m (2.8 ks-m, 20 lb-ft|

CONNECTING
PIPE
6 x ' l . Om m
12 N.m l'1.2kg-m,9 lb-ft}

RUBBERSEAL
Replace.
THERMOSTAT
Installwith pin up.
AT COVER

H22Al enginor
BLEEDBOLT
10 N.m (1.0 kg-m.7 lb-ftl

THENMOSTAT
Instaliwith pin up.
ECTSWITCHA
28 N.m {2.8 kg-m,20 lb-ft|

6x1.0mm AT COVER
'12 N'm
11.2 kg-m, 9 lb-ttl

10-8
Testing
Replacethe thermostat if it is open at room temperature,

To test a closed thermostat;

1. Suspendthe the.mostatin a containerof wate. as


snown.

2. Heat the water and check the temperaturewith a


thermometer.Checkthe temperatureat which the
thermostatfirst opens.and at which it is fully open.

CAUTION: Do not l6t the thelmometor touch tho


bottom of hot containor.

3. Measurelift height ot the thermostat when fullv


ooen.

STANDARD THERMOSTAT
Lift h.ight: above 8.0 mm {O.31 in.}
Stans oponing: 169 - 176oF {76-8OoCl
Fully open: 194oF (9OoC)

THEBMOSTAT

10-9
Water Pump
lllustrated Index
NOTE: Use new O-ringswhen reassembling.
F22A1, H23Al onginsE:
WATER OUTI.ET
HOUSING
Apply liquidgasketto
ENGINECOOLANT cylind€rhead mating
TEMPERATURE{ECT) surface.
SENSOR '13lb-ft)
18 t{.m (1.a kg-m'

ECTGAUGE
SEI{DINGUNIT
9 N.m lO.9 kg-m,6.5 lb-ft|

x 'l,O mm
12 N.m (1.2 kg-m,
€t{Gtl{EOILCOOLER 9 tb-fr)
(H234l engine) B
28 N.m {2.8 kg-m, 20 tb-ft|

ECT SWITCH A
2a .m (2.8 kg-m, 20 lb-ft)

BLEEDBOI.T
10 x 1.25mm
1 O N . m 1 1 . 0k g - m ,
7 tb-trl

6 x l.O mm
12 N.m (1.2kg-m,
I rb-ft)

O-RINGS
Replace.

*8 x 1.25mm
22 N.m 12.2 kg-n,
16 tb-fr)
6 x 1 . 0m m
1 2 N . m( 1 . 2k g - m ,
9 rb-ft)
DRAIN BOLT
O-BING
60 N.m 16.0 kg-m, Repl6ce.
43 rb-frl
Apply liquid gasket to bolt
threadswhen installing.

CONI{ECTINGPIPE
(F22A1 enginel

R€SISTANTBOLT
*: CORROSION

10-10
H22A1 cnglne:
ECT SEI{SOR
18 N.m (1.8 kg-m, 13lb-ft}
6 x 1.0 mm
12 N.m {1.2kg-m,
9 rb-ttl

ECTGAUGE
SENDIT{G UNIT
9 N.m lO,9kg-m,
6.5 rb-ft|

ECTSWITCHB
28 N.m (2.a kg-m,20 lb-ftl

6 r 1.0 ir|m
1 2 . m 1 1 . 2k g - m ,
glb.ft) BLEEDBOLT
10 x 'l.25 mm
lO N.m {l.O kg-m,
7 tb-ftl

E GINE OIL COOLER

A
28 N.m 12.8kg-m,
20 rb-frl
WATEFR,MP o-Rtt{Gs
Replace.

*8 x 1.25mm
22 N'm 12.2 kg-m, 16 lb-fr)

CONNECTINGPIPE

6 x l.O mm
12 .ln lt.2 kg-m. 9 lb-ft}

*: CORROSION
RES|STANT
BOLT

1 0 - 11
Water Pump
Inspection Replacement

Removethe timing balancerbelt and timing belt Removethe timing balsncerbelt and timing b€lt
(F22A1 engine: page 6-29, H23Al engine: page (F22A1 engine: page 6-29, H23A1 engine: page
6-63, H22A1 engine:page 6-109) 6-63, H22A1 engine:Page6-1091

check that the water pump pulleY turns freely. Unscrew the bolts, then remove the water pump'

Check for signs ol seal leakage.


"weeping" Irom bleedhole
NOTE: Smsllamountof
is normal.

6x1.Omm
12 N.m {1.2kg-m. O.RING
9 tb-ft| R6place.

I
, 3. Install the water pump in the reverse order of
removal.
BLEEDHOLES

BLEEDHOLE RUBBERSEAL
Apply liquid gaskst
to the water pump
mating surtace.

10-12
Fuel and Emissions

S p e c i aTl o o l s . . . . . . . . . . . - . . .1. ' l - 2


ComoonentLocations 1-113
I n d e x. . . . . . . . . . . . . . . . . . . . . . .1 1 - 3 ' t- ' l 1 4
System Description 1 - 11 4
V a c u u mC o n n e c t i o n. .s, . . . . . . . . . . . . . , . . . . . .1.1.-. 8, . Fuel Injectors 1 - 11 6
E l e c t r i c aCl o n n e c t i o n.s. . . . . . . . . . . . . . . . . . . , . . .1. .1.- 12 Iniector Resistor 1-'t21
S y s t e mC o n n e c t o r s. . , . . . . . . . . . . , . . . , . . . . . . . . .1.l.-. 2 O Fuel PressureRegulator 't-122
Troubleshooting Fuel Filter 1-123
T r o u b l e s h o o t i nGgu i d e . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 4 0 1-124
S e l f - d i a g n o s tPi cr o c e d u r e s , , , . . . . . . . . , . , . . .1. '. l.- 4 2 t-tzo
H o w t o R e a dF l o w c h a r t s. . . . , . , . . . . . . . . . . , , . ,1. 1 . -47 1 -1 3 0
PGM-FISystem Intake Air System
System Description ....... 1 1-48 System T.oubleshootingGuide 11-13r
Troubleshooting Flowchans System Description 11-132
Engine W i l l N o t S t a r t. . . . . . . . . . . . . . . . . . . . . . .1.1.-. S . .0 Air Cleaner 11-133
E n g i n eC o n t r o lM o d u t e. . . . . . . . . . . . . . . . . . . . . . .1. .1.- 5 1 Intake Control Svstem
H e a t e dO x y g e nS e n s o r , , . . . . . . . . . . , . . . . . . 1 . .1.-. 5. .6 lExcept F22A't engine(Sll 1-134
H e a t e dO x y g e nS e n s o rH e a t e r. . . , . . . . . . . . . ,1. 1 - 5 8 Throttle Cable 1-138
F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . . . . . . . . . . .1. 1 . .- .6. 2
. Throttle Bodv 1 - 13 9
ManifoldAbsolute PressureSensor .,...... l1-64 Intake Air Bypass Control System
Top Dead Center/Crankshsft position/ lExcepr F22A'l engine(Sll 1-143
C y l i n d eP r o s i t i o nS e n s o r . . . . . . . , . . . . ....., . ' l 1- 7 O I n t a k eM a n i f o l dI F 2 2 4 1 e n g i n e ( S l .] . . . . . . . . . . . . 1 - 14 8
EngineCoolantTemperatureSensor ....... 11-72
T h r o t t l eP o s i t i o nS e n s o r. . . . . . . . . . . . . ...... .- . .- 1 ' l- 74 EmissionControl System
I n t a k eA i r T e m p e r a t u rS e e n s o r. . . . . . . . . . . . . .1. 1 - 7 6 System TroubleshootingGuide .... 1-149
B a r o m e t r iP c ressurS e e n s o r. . . . . . . . . . . . . . . . . 1 . .l - 7 8 System Description 1 - 15 0
l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .I. .1.- 8 0 TailpipeEmission 1-150
V e h i c l eS p e e dS e n s o r. . . . . . . . . . . . ...... . . . . . . . . 1 . 1- a 2 T h r e eW a y C a t a l y t i cC o n v e n e r. . . . . . . - . . . . . . . . . .1 - 1 5 1
E l e c t r i c aLlo a dD e t e c t o r. . . . . . . . . . . . . . . . . . . . . .1.1. - 8 4 E x h a u sG
t a s R e c i r c u l a t i oSnv s t e m . . . . . . . . . . . . . 1 - 1 5 3
Knock Sensor PositiveCrankcaseVentilationSystem .,.,.,.. 1 - 15 9
l E x c e p tF 2 2 A 1 e n g i n e { S ).l . . . . . . . . . . . . . . .I .1- 8 8 EvaporativeEmissionControls 1-160
A / T F l S i g n aAt / B . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. .9.0.

ldle Control System


S y s t e mT r o u b l e s h o o t i nGgu i d e . . . . . . . . . . . . . . . . I. .1- 9 2
System Description ....... 1 1-93
TroubleshootingFlowcharts
l d l eA i r C o n t r o Vl a l v e . . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 9 6
A i r C o n d i t i o n i nSg i 9 n a 1. . . . . . . . . . . . . . . . . . . . . .I. .1.- 9 8
A l t e r n a t oFr RSignal .. I1-1OO
AutomSticTransaxle
G e a rP o s i t i o S n i g n a l. . . . . . . . . . . . . . . . . . . . 1. 1- 1 0 2
S t a r t e .S w i t c h S i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .- 10 4
B r a k eS w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . 1. .1.-.1.0. 6
Power SteeringPressufeSwitch Signal ... 1l-108
F a s tl d l eT h e r m oV a l v e. . . . . . . . . . . . . . . . . . . . . . . I. .1. -. .1.0 9
S t a r t i nA g i r V a l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1.-.1. 1. .O.
l d l eS p e e dS e t t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.l.j .1.
Special Tools

Rel. No. Tool Number Dascription I O'ty I Pag€ Roforence

o A973X_041_XXXXX Vacuum Pump/Gauge 1 1 1 - 6 8 ,1 3 5 , 1 3 9 ,


144, 154, 162, 165
KS-AHM_32 OO3 DigitalMultimeter 11 - 4 5 ,5 8 , 6 3
,ar OTLAJ PT30l OA Test Harness 11 - 4 5
@ 07JAZ-OO1000B Vacuum/Pressure Gauge0-4 in. Hg 1 1 - 1 6 4 1, 6 5
/A 07406-OO40001 Fuel PressureGauge 1 ' l - 1 1 5 ,1 2 2

I \a) \9

11-2
ComponentLocations
Index

H23A1 engine (USA: Si/Canada:SRI:

ELECTRICAL
LOADDETECTONIELOI
THROTTTE (TPISENSORMANIFOLO
POSITIOI{ ABSOLUTE
Troubleshooting, page 1 I-74
Troubleshooting, PRESSURE IMAPI SENSOR
page 1 1-84 Troubleshooting,
EXHAUST GAS RECIRCULATION{EGR) FAST IDLE page 1 1-64, 68
VALVE LIFT THERMO
sEr{son VALVE IDLE AIR CONTROL(IACI VALVE
Troubleshooting, Inspection Troubleshooting,
p a g et l - 1 5 3 p a g e1 1 - 1 O g page 1 1-96

IGNITIONCONTBOLMODULE (ICM)
page |'l -80
Troubleshooting, EVAPORATIVEEMISSION
(EVAP} PURGECONTROL
INTAKE CONTROL SOLENOIDVALVE
SOLENOIDVALVE page 1 1-162
Troubleshooting,
\ Troubleshooting,
\ . o a q e1 1 1 3 5
TOPDEADCEITTER/ STABTING AIR VALVE
} Description,
POSITION/\. //'
CRANKSHAFT p a g e1 1 - 1 1 0
CYLII{DERPOS]TION
ITDC/CKP/CYP'
Troubleshooting,
page11-70 IIIIJECTOBRESISTER
Testing,page 11-'121

'trt
?,{oL

AKE AIR TURE


IIATI SENSOR
Troubleshooting,
p a g e1 1 - 7 6

ENGINECOOLANT EXHAUST GAS RECIRCULATION{EGR}


TEMPERATUBE{€CT) SENSOR VACUUM CONTBOLVALVE
Troub16shooling, Troubleshooting,
page 11-72 p a g e1 1 - 1 5 3
KNOCK SENSOR{t(Sl
page 1 1-88
Troubleshooting,
HEATEDOXYGEN
SENSOR tHO25)
Troubleshooting,
p a g e 11 - 5 6 EXHAUST GAS RECIRCULATION{EGR)CONTBOL
INTAKE AIR BYPASS {IAB} VALVE
SOLENOIDVALVE
Testing.page 1 1-146 page 1 1-153
Troubleshooting,

POWER PRESSURE(PSP}SWITCH
page 1 1-108
Troubleshooting,

INTAKE AIR BYPASS IIAEI CONTBOLSOLENOIOVALVE


page 11-144
Troubleshooting,

11-3
Component Locations
lndex
H22Al ongino {USA: Si VTEC/Canada:sB-v)
EI-ECTRICALLOAD DETECTOB{ELD)
Troubleshooting,
p a g e1 1 - 8 4 IDLE AIR CONTROL{IAC) VALVE
Troubleshooting,
11 - 9 6
€XHAUST GAS RECIRCULATIONIEGRI THBOTTLE POSITION ITPISENSOR
VALVE LIFT SENSOR Troubleshooting, 11-74
page 1 1-153 Page
Troubleshooting,
FAST IDLE
INTAKECONTROL THERMO MANIFOLOABSOLUTE
SOLENOID VALVE VALVE PFESSUNEIMAP} SENSOR
Troubleshooting, lnspection Troubleshooting,
p a g eI 1 - 1 3 5 p a g o1 1 - 1 O g page '11-64,68

IGNITIONCONTROLMODULE (|CM} EVAPOBATIVEEMISSION


page 1 1-80
Troubleshooting, (EVAP} PUFGECONTROL
ToP DEAOCENTER/ .. SOLET{OIDVALVE
page 1 1-162
\ Troubleshooting,
CR} .KSHAFT^POSITION/\
CYLINDERPOSITIOl{ STARTII{G AIR VALVE
{TDC/CI(P/CYP}SENSOR Description,
Troubleshooting,
p a g e11 - 11 0
page 'l 1-70 INJECTOR RESISTER
T e s t i n gp,a g e1 1 - 1 2 1

INTAKEAIR TEMPERATURE
0AT) SEI{SOB
Troubleshooting,
p a g e1 1 - 7 6

GAS
(EGRI
RECIRCULATIOT{
VACUUMCOI{TROL VALVE
ENGIf{ECOOLANT page11-l53
(ECTISENSOR Troubleshooting,
TEMPERATURE
Troubleshooting,
page 11-72
EXHAUST GAS RECIRCULATIONIEGRI
CONTROLSOLENOIDVALVE
page 1 1-153
Troubleshooting,
KNOCK SEI{SOB {KS}
Troubleshooting, page 11'88 POWERSTEERINGPRESSURE(PSPI SWITCH
HEATEDOXYGEN p89e 1 1-1OB
Troubl€shooting,
SENSOR tHO2S)
Troubleshooting,
p a g e1 1 - 5 6
INTAKE AIR BYPASS (IAB) VALVE INTAKE AIR BYPASS {IABI CONTROLSOLENOIDVALVE
'l1-146 page 1 1-144
Troubleshooting,
Testing.page

11-4
F22Al ongins (S):

ELECTRICALLOAD DETECTOR
{ELDI IDLE AIR CONTROL{IAC} VALVE
Troubleshooting. Troubleshooting.
psge11-84 p a g e1 1 - 9 6
MANIFOLD
ABSOLUTE
THROTTLEPOSITIOT{ PRESSURE
ITP) SEITISOR {MAPI SENSON
EXHAUST GAS BECIRCULATION{EGRI Troubfeshooting.page 1 1-74 Troublsshooting.
VALVELIFTSEI{SOR page 11-64, 68
pago11-,|53
Troubleshooting.
EVAFORATIVEEMISSION (EVAP)
IGNITIONCO TBOLMODULEIICM} PURGECONTROL SOLENOID
pag611-80\\
Troubleshooting. VALVE
Troubleshooting.
page11-,|62
TOPDEADCENTER/
CRAN(SHAFTPOSITIOI{/
CYLINDER
POSITION FASTIDLE
{TDC/CKP/CYP} THERMOVALVE
Troubleshooting. page11-110
Inspoction,
p a g e1 1 - 7 O
II{JECTOR
RESISTER
Testing, 11-121

STARTII{G
AIR VALVE
Description,
p a g e1 1 - 1 1 0

I TAKE AIR
TEMPERATUR:
(IAT} SENSOR
Troubleshooting.
page 1'l-76

EXHAUSTGASRECIRCULATION IEGR)
VACUUiI CO TROLVALVE
page11-153
Troubleahooting,
. ,-/ /
ENGINECOOLANT
TEMP€RATURE(ECT) SENSOR
'-''./
EXHAUSTGAS RECIRCULATIOI{ (EGRICONTROL
Troubl€shooting, SOLEiIo|DVALVE
page 11-72 page11-'l53
Troubleshooting,

POWER STEERII{G PNESSUREIPSPI SWITCH


HEATEOOXYGEI{ Troubleshooting, pago 1 1-1OB
(Ho2st
sEr{soR
Troubleshooting,
page 1 1-56

11-5
ComponentLocations
Index

EVAPORATIVE EMISSIOI{ FUEL


ruMP
{EVAPITWO WAY VALVE Tosting,p6ge 'l t -125
Testing,page11-165 Roplacemgnl,paoo 11-125

FUEL FUELFILL
CAP I

FUEL FIITER
Replacoment,page 1 1-123

EVAPORATIVEEMISSION
IEVAP)CONTROL CAI{ISTEB
page11-'162
Troubleshooting,

TAI{K
Replacemgnt,
p s g € 11 - 1 3 0

FUEL
PNESSURE REGULATOR
Testing,page11-122
R€phcomont, p.g6 11-123

FUEL VAPOR
HOSE FUEL RAIL

I]{JECTORS
Troubleshooting,
ptgo11-116
Replacomedt, page 11-1 19

11-6
AIR CLEANER{ACL) THROTTLE BOOY
Oisass6mbly. page11,139
Inspection,
p a g e1 1 - 1 3 3 Disassembly,pagel l -141
II{TAKEAIB
II'ITAKE
cot{TRoL
DIAPfIRAGM
(Exclpt F22A1
.ngin.l
Troubloshooting
p a g €1 1 - 1 3 5

lnspection/Adjustment,
page 1 1- l38
Installation, page 1 1-'l 38

POSITIVECRAI{KCASEVENTILATIOI{ (FCV) VALVE


Insp€ction.pago 1 1-159

PGM-FI MAII{ RELAY


RolayT6sting,page 'l 1-126
page 1 1-128
Troubloshooting,

ENGINECO TROL MODULE {ECMI


Sell-diagnostic Procedures.page 1 1-42 SEBVICECHECK CONNECTOR(2PI
Troubleshooting.page 1 1-50 S€ff-diagnosticProcedures,page 1 1-42
Romoval,page 11-45

11-7
System Description
Vacuum Connections

H23Al engine{USA: Si/Csnada:SR}


SR-V}
H22Al engine{USA: Si VTEC/Canada:

EVAPORATIVEEMISSIOI{IEVAPI
PURGECOI{TROL
VALVE
SOLEI{OID

EVAPORATIVE EMISSION
{EVAP)R'IRGECONTROL VALVE
DIAPI.IRAGM
EVAPORATIVEEMISSIOI{
{EVAPI COI{TROLCANISTER

TO
EVAPORATIVEEMISSION
{EVAPITWO WAY VALVE

EXHAUSTGAS RECIRCULATION
IEGR)
VALVELIFTSENSOB
EXHAUSTGAS RECIRCULATION
I€GR)
VALVE

MAI{IFOLDAESOLUTE
PREESURE I API 8E1{8OR

STARTII{GAIR VALVE

I TAKE AIR BYPASS


IIABI CHECTVALVE

INTAKE
CONTROL
SOLENOID
VALVE
:?'
FRONTOF VEHICLE FUEL
INTAKEAIR BYPASS
IIABI CO TROL
REGULATOR SOLEI{OID VALVE

TO
CRUISECOI{TROL
INTAKE AIR BYPASS IIAB} COI{TROL ACTUATOR
OIAPHRAGM EXHAUSTGAS
RCCIRCULATIO
IEGR)VACUUM
CO TROLVALVE

EXHAUST GAS (EGR)


CONTROL SOLEI{OID
CONTROL VAIVE
DIAPHRAGM

11-8
F22Al ongine (S):

EVAPORATIVEEMISSION
IEVAPI CONTROI.CANISTER EVAPORATIVEEMISSION
{EVAP}
EVAPORATIVEEMISSION ruBGE COTITROL
(EVAPI PUBGECONTROLDIAPHRAGMVALVE SOLENOIDVALVE

TO
EVAPORATIVEEMISSION
{EVAPITWO WAY VALVE

EXHAUST GAS
RECIRCULATIONIEGR}
VALVE LIFT SENSOR

MANIFOLD AESOLUTEPNESSURE
(MAP} SENSOR

EXHAUSTGAS STARTII{G AIR VALVE


RECIBCULATION
IEGR}VALVE (EGR}
EXHAUSTGAS NECIFCULATION
VACUUMCOI{TROLVALVE

FUEL PRESSURE
REGULATOR

TO
CRUISECONTROL
ACTUATOR

EXHAUST GAS BECIRCULATIOI{(EGR}


CONTROLSOLEI{OIDVALVE

11-9
System Description
Vacuum Connections

H23A1 ongino (USA: Si/Canada:SR)


H22A1 ongine{USA: Si VTEC/Canada:SR-V}

o) HEATED (Ho2s) \--J@


oxycENsENsoR @ II{TAKEAIR BYPASSIIABIVACUUMTANK
O MANIFOLD ABSOLUTE PRESSURE {MAPISENSOR @ ra{TAKEArRBYPASS0AB)CHECI(VALVE
O ENGINE COOLANTTEMPERATURE (ECT)SENSOR @ II{TAKECOI{TROLDIAPHRAGM
@ TNTAKE AIR TEMPERATURE (IAT}SEI{SOR SOLENOTD
@ tt{TAKECOIT|TROL VALVE
@ KNocK sENsoR(Ksl @ I TAKECONTROL VACUUMTANK
@ |DLEAtR co rRoL flact vALvE @ INTAKECONTROL CHECKVALVE
O IDLEADJUSTING SCREW @ THREEWAY CATALYTTC CONVERTEn (TWCI
@ FASTIDLETHERMOVALVE @ postT|vE CRANKCASE VENTILATTON{FCV)VALVE
@ STABTING AIR VALVE @ EXHAUSTGASBECTRCULAIION (EGRIVALVE
@ FUEL[rtJEcToR @ EXHAUSTGASRECIRCULATION (EGR}VALVELIFT
@ FUELFILTEB SENSOR
@ FUELPRESSURE REGULATOF @ EXHAUSTGAS REC|RCULAT|OII (EGRIVACUUM
@ FUELPUMP CONTBOL VALVE
@ FUELTANK @ EXHAUSTGAS RECTRCULATTON {EGR}CONTROL
@ AIRCLEANER SOLENOID VALVE
@ RESONATOR @ EVAPORATTVE (EVAP}CONTROL
EM|SS|OT{ CAt{ISTER
@ INTAKEAIR BYPASS(IAB}COIIITROL DIAPHRAGM @ EVAPORATTVE EMTSSION(EVAP)PURGE COI{TROL
@ TNTAKEAtR BYPASSflABl CONTROLSOLENOIDVALVE SOLENOID VALVE
@ EVAPORATTVE EMTSSTON{EVAP}PURGE CONTROL
DIAPHRAGM VALVE
@ EvapoRATtvEEMtsstoN{EvaPl rwo wAY vALvE

11-10
F22A1 ongine

O HEATEDoxYGEr{sEr{soR(Ho2sl @ THREE way caTALyTrccoNvERTEn fiwcl


O MAr{rFoLDABSOLUTE pREssuREtMApt sENsoR c) posrTlvEcRAl{KcasE (PcvtvalvE
vEr{TrLATror{
@ ENGINE coolA T TEMPERATUBE tEcTI sEI{soR @ EXHAUST (EGR}
GAsREcrRcuLATtOr{ valvE
@ II{TAKEAIR TEMPERATURE (IAT)sEI{soR @ EXHAUST (EGR}
GAsREcrRcuLATror{ valvE L|FT
O |DLEAtR co rRoL 0Acl valvE SENSOR
@ IDLEADJUSTI G scREw (EGRI
@ ExHAUsrGAsREctRcuLATtot{ vAcuuM
@ FASTIDLETHERMOVALVE COI{TROL
VALVE
@ START|NG ArRvALv€ @ EXHAUST (EGR}
GAsBEcrRcuLATror{ coNTRoL
@ FUELI JEcToR SOLEIIOID
VALVE
@ FUELFILTER @ EVAPORATIVEEMISSION(EVAPIcO TRoL CAI{ISTER
O FUEI.PRESSURE REGULAToR @ EVAPORATTVEEMTSSIONTEVAP) PUnGECOI{TROL
@ FUELPUMP SOLENOIDVALVE
@ FUELTANK @ EvApoRATrvEEMrssroN(EvAp)PURGE conrRol
@ AIR CLEANEn DIAPHRAGM VALVE
@ RESOI{ATOR @ EvapoRATrvEEMtsstoN(EvApl Two wAy vALvE

11-11
System Description
ElectricalConnections

FUEL
PUMP

'1_

CYP
SEI{SOR

TDC
sEf{soR
CKP
sEitsoR

wEc
PfiESSURE
swtTcH
SERVICE
CHEGX
cot{t{EcroR

col{DEl{SOR
FAl{
RELAY

A/C
swtTcH

GAUCE ASSEMSIY

i FUsEs
c) clocx RADrot10al. o. 4 BACKUP(10 A)
@ SATTERY tlOOAt. ECUGcill (15 Al
@ rGsw tso A). t{o. 13 ttlETER{1OAl
A/T GEAR @ sToPHORir(15Al. cot{oEI{sERFAt{ t15 At.
POStTtOt{ @ FUSE BOXtr$ Alr o. 11 nEARDEFROSTER REIAY110At
swtrcH l{o.2 ATARTER SIG AL 17.5Al
L _ _ _ _ _ _ _ _ _ _ _ _
': in the UI{OER-HOOOFUSE/RELAYBOX

at-tz
TIAP
sE son

TP
8EI{SOR

EGR
vAt-vE
LIFT
SEI{sOR

SOLEOIDVALVE r--=-l
H22Al .nglnc)

€Gn co TnoL solEftolo valvE


EVAP PUNGECO TNOLSOLEI{OIDVAIVE
IAB CO[{TROLSOlEtrtOtOVALVE
INTAXE COITROL AOLETTOID VALVE

o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o
o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o

TERMI AL LOCATIONS

(cont'dl

11-13
System Description
ElectricalConnections(cont'd)

Cttt HO23

YEIiTLK
oR /wlft

nco/Btu-

f
t
E

I
WHT/GRt{
WHT/RED- w,si
1l ,arn*"rfl

q101

cl13
---J------'l
vrr.rvyxr
R€D,srx---l lrP sE SoR I
GRx/wHTr _!l________J

---------.r-T------------'l
__jl.:l*r1l

tto prg. 1I -16l lTo p.gp t1-151 lTo p.!. 11-15)

11-14
11-141 ( F r o r np . g . 1 l - 1 4 1 l F r o m p . g . 1 1 - j 4 )

c425
TDC/CXP/CYP
c 133 SEI{SOR

:-:wHT---_----

c102
nroisrxl-[dfiiiJidi5il
BRn---l-[I:jl__l
clo3

c1(x
nronu---1-f
iiliifididil
BLU- ]lltro. 3l I
c105
n:omx --j-liiiiili6i5i-l
YEL-l
lr o. a) |

cl11
srr'---1-ffii----l
RED/GR'{ ]-E!lf9r-___l
ct 09
sLxryel ---- iid--]
ox{ I| lsolCtoro I
| vatvE I
lErccpt F22A1 .ngin.)
cl22

Hiiii;l I."' ".n"o*


|
c10g

$ffiElfl | ,"r senson


I

BED^^rHrlJ-----l
wxrierr I I EGRVALVE I
cRil/wHr,l I tlFr sEI{soRI
System Description
ElectricalConnections(cont'dl
c31O-..._-
at-K/YEt---l l€ci co liol I
RED, ----llj95:g:i1:l

sa".;-l
ffi#ffll
TO COi{DEiISER FAI{
Bt-u/RED_____'

-----i Toa/cHcRoMPnEssoR
RED/8LU

-----> TO A/C SYVITCH

-l I r^ra co|rnol I
I lsor.Er{oro I
llJ !!E-J
lErc.Dl F2241 f,{arl

J I6ERVTCE I
llcHEct( |
ll-99!!!9r98--J

t-Jl
r C43-
T GRX/RED LT GFI{/RED_Il DATA Lt K I
BLI(/RED-l I cO ECTORI

[E+_ REDiErx

E<-YEL/BLU

TCil lA/Tl
ORIIl

PI{K

[T GN[{/BLX

11-16
UI{DED.HOOO
FUSE/RELAYBOX Ut{DED-HOOD
BATTERY {1(x)A) FUSE/RELAY
tG sw l5o Al
FUSE8OX liro Ar c421
CLOCKRADIO{10 A) c422
sToP HOR[{t15 Al WHT/RED

WHTA'EL WHT/YEL
c424
WHT/YEL
c420
ATKATEL

I
r BIK

Grl03
BATTERY

PGM.FI

YE|-/SL(

YEL/BLK

GRI/BLKt

E<--BLK
FUEL
-C537 pUMp
fl_ v:l- _-____j-1 ____h
(PJ
Eszzaer-x ll
G52r tc tTtON
swrTcH

UI{DER.DASH TO
FUSE/REI.AYBOX M/T: STARTER
c) ECUiECMItls At CUTRELAY
@ Ito. 2 STAKTERstcilAl A/T: A/T GEAR
t7.5Al POStTtot{
@ o.4 BACKUPt10 Al SYVITCH
O o. 13 METER tlo A)
c466

c471

BLU/RED

GRiUwHT' GRt{/WHTI
GRI{MIHT

FUSE/RELAYBOX
c479..-........................"-.".-.-
rHrljl
GRr{^ BRAKE I
wnrrrer-ll_llcH l
lTo p!96 11-18, (cont'd)

11-17
System Description
ElectricalConnections(cont'dl

l F . o mp ! g ! 1 1 . 1 7 1 GAUGE ASSEi'BLY

N |-'FFGEF_I
I I HPOSmOI{ |
ll ltrlswmcx I

c13a
c4a4 - cr39
cRr/YEL-- wEc solEl{olD
VALVE
lH22A'l.n!rn.l

swrTcH
tH22.A1
ri

11-18
System Description
System Connectols lEngine Compartment]
SR-V}
H22Al engine{USA: Si VTEC/Canada:
H23A1 ongine{USA: Si/Canada:SR)

ENGINE
WIRE HARTTESS
MAIN WIR€
HARNESS

11-20
c114 cll5 c117 c122

rF|-r
l l l 2 1 |3

IO) IGRN^^/HTZ I l-6''I"*t----.',


lEilwlr-- - lO IBL(,"/eL I
O loRt,M/Hr I l6F'it------1
ldlYE BLK i

C137 lH22Al onglnql C138 (H22Al .nginol c420

lrJ
tr
l-6'l6iNrEi-----'l

c422

r-FF-r 1 2 4 5
l l j 2 1 3 l
7 8 9 10 1 1

r'-T"*----l REO/6LU
2IBLX/GRI-- ---1
I
f5-lwxr 3 a LX tASSt
FEOr'GFN LKI''EL IA65)
5

NOTE: Diflerent wi,es with the same color have been given a number suffix to distinguish them {for example YEL/BLK1
and YEL/BLKzare not the samel.
l: Relatedto Fuel and EmissionsSvstem.
System Description
SystemConnectors[EngineCompartment](cont'd]
H22Al engine (USA: Si VTEC/Canada:SR-V)
H23A1 engine (USA: Si/Canada:SRI

6'
!,,-

.lv

c432
c135
MAIN WIRE
HARNESS c4a4
c139

ENGINEWIRE
HARNESS

11-22
c426 c429

c/*12 (M/Tl C484 (H22Ai onglnrl

{,t( --l
lO--lCiNrEL
IBLUI"'EL IT

'It,,YEL RED/II.U

\oTE: Diffotent wir€s with the same color hsve baen given a number suffix to distinguish them (for example YEL/BLK1
and YEL/BLK, are not the same).
O: R€lated to Fuel and Emissions Svst€m.

(cont'd)

11-23
System Description
SystemConnectorslEngineCompartment](cont'd]
H22A1 engine (USA: Si VTEc/Canada: sR-vl
H23Al ongina (USA: Si/Canads:SRI

LEFTE GIT{E
COIIPARTIIIENT
WIREHARI{ESS

HARNESS

11-24
ct 02 c103 c 104 c105

tr-r-rl tr---T---ll tr---r---rl t--T----rl


2tl tl ti 2tl tl ll 2 I 1 ll ll 2 | 1 ll

---- -'l
|6'TREo/BIK - - - - to) tRED/Blx I l6TnED/aLi----- lSTiED/ELr ---]
j@ leRN -----
lZiTREp-l f6-lilu l6ltrL

c106 c107 c108 cl 09 clt1.

c310 c320 c321

r+
l l l 2 l

NOTE: Difterentwi.es with the samecolor have beengiven a numbersuffix to distinguishthem (tor exsmpleyEL/BLKI
and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSvstem.
System Description
SystemGonnectors[EngineCompartment](cont'd]
F22Al ongino{Sl:

I
ti

MAIN WIRE
HARNESS

HART{ESS

11-26
clr3 cl14 c 11 5 c117 c122

rf:lr
l 1 l 2 1 3 l

16loRNi------l
lO IBLK/YEL ---l I
loFii'-

c420 c421

E
r--Fl_____1
lrl2l3l

FT-,--__l
2
l l8r(/GFN I
16lwii-.

c424

1 2 4

8 9 10 tt

1 REO/6LU 6
2
3 I
I ALK/YELIAAS)
5 10

NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (for
exampteyEL/BLKr
and YEL/BLK2are not the samel.
O: Relatedto Fuel and EmissionsSvstem.
System Description
SystemGonnectors[EngineCompartment](cont'd]
F22A1anginolsl:

MAIN
WIBE
HARNESS

ENGI'{E WIRE
HARI{ESS

11-28
c426 c432 (Mtf I

ALK/BIU
RED/6LK
LU'EL
ALK/iED
FEO'
8LU
YEL BLI.I/GiN

c432 lA/Tl

'LU/GRIiI BfiI'I/6LK

a
HT

NOTE: Different wires with tho same color have been given a number suffix to distinguish them (for example yEL/BLK1
and YEL/BLK2are not the sam€).
O: Related to Fuel and Emissions Svstem.
System Description
SystemConnectors[EngineCompartment](cont'd)
F22A1 engine{S):

'j

11-30
ct ol cl02 c103 c104 c105

J r-----r1-
I I----T-----rI -J r-----rl-
tffJl tErll ll 2 | 1 ll Il2 | 1 ll

c106 c107 c108 c111

c3lo c320

l 1 l 2 l

NOTE: Oifferent wires with the same color have been given a numbe. sulfix to distinguish them (tor exampte YEL/BLKi
and YEL/BLK,are not the same).
.-r:Relatedto Fuel and EmissionsSvstem.
System Description
System Connectors [Dash and Floor] lcont'd)

DASHBOARDWIRE
HARNESS
MAIN WIRE
HARNESS

I-EFTENGINE
COMPARTMENT
WIRE

LEFT SIDE
WIRE HARNESS

11-32
c442 c443 c445 (A/Tl c451

r-EFr 2 3 4 r-----.-t I
| 1 1 2| 1 l / 1 3|
|r------y.____J__l 6 8 9 llol11 ll;Tvrtl
I r_____lz_____r_J
I

I(, ]LTGRN/RED I lElwH------l


2 ALK t 2 t I
lO lBLx/R€o . 3 GRNTYEL | 3 BLKIVHT I
t o Y€L
5
12

c461 c463 c466

l1l2l3l

l BLU/REO
2 BLX/GFN" 12 q) RED/ALU
3 l 3 RIO/SLK 3 YEL/BLK @ BIU/BLK
15
Y€L 16

7 aLu
8 BCU,IYEL 1A
I 1 9 RED/YEL BLK/ryEI
1o 20
FED/GRN

c469

12
2 BIU/REO 2 ALK 1 3 ALK
YEL/BLU 10 L&'YEL
BLK,YEI
5 6LU 12 BLK/YEL BLK/REO
8L( 1 3 BLU
YEL BLK/tEL 1A
8 1 9 BLK,YEL
YEL/BCO 20

Y€L/8LK

NOTE: Differentwi.es with the samecolor have beengiven a numbersuftix to dastinguish


them (for exampleYEL/BLK1
and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSvstem.
* : Canada
* *: Canada(with heatedseatsl

11-33
System Description
SystemConnectors[Dashand Floor](cont'd

OASHBOARDWIFE
HARNESS

MAIN
WIRE
HARI{ESS

11-34
c479 c601 c612

I 4 X ,/t7
I 9 t 0 1 1 l2lxh3 1 4 1 5 1 €

RED/BLK
2 GRA/YEL
3 AtK'/EL 3 1t
YEL 12 12
LIJ/FEO GFN
BLK 6
ALU
I GiN/ALU r 6 ALK/RED l 6 BLK

c614

1€
2 BLK/ryEL 17
3 YEL'
ALU' t9
20 GFN/BLK
21 GhN/REO
22
a YEL
REO
BLU/FEO
26
1 2 YEL/iED 2 7 RED/BLK
13

15 3(

NOTE: Ditferentwires with the same color have beengiven a numbersuffix to distinguishthem (for exampleYEL/BLK1
and YEL/BLK,a.e not the same).
O: Relatedto Fuel and EmissionsSvstem.

*: Canada
System Description
System Connectors [Dash and Floorl (cont'dl

OASHBOARD
WIBE
HARNESS

MAIN WIRE
HARNESS

11-36
c404 c411 (A/Tt c415 {ECM-A}

1t 12
2 YEL
3 RED
giN/BLK r5 H?2rlri?rul I
GRNTYI!
15 YEL/BLU

RED/gL( LI GFN]BLK
ta 8 19 YEL/GFN
I I 20 €LK/8!U
I
AED/BLU 20 BLK'
22 o

c4t6 (ECM-BI c417 tECM-D)

311'r9 7 5 3 1
ldl/rfl 210 8 4 2

YEL/BLK BLU/FED WHI/YEL ['


GRN/IYHT' (}
AEo/BLlr"' l@
BRN,IVHT I(' a€0//EL
BLU/ALK i1a
@ LT3{urtr22lrmnr l{il
8LU/GAN o
BLU/^rlt

REO/ALK

NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem {for exampleYEL/BLK1
and YEL/BLKrare not the same).
O: Relatedto Fuel and EmissionsSvstem.

* * * : E x c e p tF 2 2 A 1 e n g i n e
System Description
SystemConnectorslFuel Pump](cont'd)

11-38
c537

E
NOTE: Ditfe.ent witos with the same color have been given I number suffix to distinguish them (for example YEL/BLKr
and YEL/BLKzare not the same).
O: Related to Fuel 8nd EmissionsSvstem.

11-39
Troubleshooting
TroubleshootingGuide

NOTE: Across each row in the chart, the systems that could be sourcesof a symptom are ranked in the o.der they should
be inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likely source,then refer
to the pagelistedat the top of that column,It inspectionshows the systemis OK, try the next most lik€lysystemO, etc,

SYSTTM
TOPDEADCENIER/ TNGINC
at'iclNE HEAIEO THNOTTLE EANOMEIRIC IGNITON vtHtclE
ABSOLUTE COOTANT TEM.
CONTROI OXYGEN
PNESSUfiE POSITON/CYUNDES
PO9TtOtl
FCi^TURE
PitssuSE OUTPUT SPfED
MOOULE SENSOR
SENSOR POSftOt'tsE|so8 fuiE sEt{sof
sc soR SENSOR
sfNsoR stcNA! sE[son
50 56, 54, 62 64, 6a 70 76 7A 80 a2
-r.tr-
MALFUNCTIONINDICAIOR
LAMP IMIII" TURNS ON n or-Ll
.o: :i6):
-mi :r6t:
/---\
:r6t1
/---\ -mi rg: lrm.t: \.--r-r /
MAIFUNCTION INOICATOB
EorEl lll or Lll O or-8.o.:ft - --i-t r t - \.--l-
- t r t / - - t__i-r t l - - t t l t - -t---i-15l- \.--1-,
-l_--l-\
t? t-
LAMP IMILl" BLIN(S . \ ---'_-\ / \ /'_-i- \ / \ /

ENGINEWON'T STAFT @ @ @
OIFFICUITTO STAFT
ENGINEWHEN COID
IBU) @ @ o
WHEN COLO
FAST IDLE
OUT OF SPEC.
@ @
ROUGHIOLE @ @
IDTING

HIGH
@
a9
'
:l FREOUENT
IBU)
@
'lr STALLING
@
ROUGH
RUNNING
@ @ @
ANCE
EMTSSTON
TEST
@ @ @
LOSS OF
@ @ @
* lf codesother then those listedaboveare indicated,count the numberof blinksagain. It the MIL is in fact blinking
these codes, reDlacethe ECM.
@ tt ttr" MIL is on while the engineis running,jump the servicecheck connector.lf no code is displayed(MlL stays
on steady),the back-upsystem is in operation.
Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM.

** USA: Canada:
MALFUNCTTON -[tglt- r-tr- '6+r-
CHECK
;ND;CATOR ENGTNE ;t-\+:
,
LAMP {MILI LIGHT
'** E x c e p tF 2 2 A 1 e n g i n e( s )
engine (USA: Si VTEC/Canada: SR-V)

11-40
IOLECONTFOL FUELSUPPTY EMISSIONCONTFOL
ETH USI GAS
ELECTRICAL XNOCK IOIEAIF OTH'i OTHER nEcncu.
FUEI INIAKT OTHER
LOAO uFrE|lcTnoMc LIFTELECNOMC SENSOF CON'FOL IDL' FUEL EMtSS|ON
DETCCTOR :o{TnoLsoLENoto
:OIITROL
PiESS!iI SIGNALA SIGNAL
8 INJECTOF
c0NTROTS c0[TioL coNTiots
sYstE
84 6-75 677 8a 90 90 96 92 116 r13 131 153 149

tf -q. rg- / - \ D E ffil


/---\
-r6t-
/_l-\
-r6t-
- ' .
\.--r-l
-t 201 -t-_-i--2r I t 2 2| -t 23I 11361,lrt- - l r 6I \.--.1- /
/---,_-. , \ /-....-. @ | | 2t\ -
z --"i--

@ o

o @
o @ @
o @
@ o @
o o @
@ o @
o @
o
@ @ @ o @

11-41
Troubleshooting
Self-diagnosticProcedures

When the MaltunctionIndicatorLamp (MlL) has been reponed on, do the following:

1. Connectthe servicecheckconnectorterminalswith a jumperwire as shown (the servicecheck connectoris lo-


cated behindthe center console).Turn the ignitionswitch on.

OATA LINK
co it€cToR{3Pl
Do not attach
the jumperwire.

CHECK
SERVICE
CONNECTOR(2P)
JUMPERWIRE

2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesa code by the lengthand numberof blinks.The MIL
h can indicstesimultaneouscomponentproblemsby blinkinqseparatecodes,one atter another.Codes 1 through
I are indicatedby individualshon blinks.Codes10 through43 are indicatedby a seriesof long and shon blinks.
The numberof long blinks equalsthe first digit, the numberoJ short blinks equalsthe seconddigit.

USA: CANADA:
MALFUNCTION CHECK
INDICATOR ENGINE
LAMP LIGHT
{MIL}

S6pa1.t. Ptobl.mr:
Shon
l-1 -jl-rL- = Soe DTC 1
tU-X-r- r]r1.f1--JlrrL = Seo OTC 3
X{I- = scoDTC13
Long sho.l
SimuhanoouaProbloms:
J rJTxrL-----n l'lr]rL = 566 DTc 1 and 3
Jltll-r-r]f1J-1l-L-
--n-trxrrl_nnrL = 566 OTC 3 and 4
J-lt-x-L-J = Soo DTC 3 and 14

11-42
ll. EngineControl Module {ECM}ResetProcedure

1. Turn the ignitionswitch off.

2. Removethe the CLOCKRADlO ( 1O A) f use f rom the under-hoodtuse/relavbox for 1O secondsto resetthe ECM.

NOTE:
a Disconnectingthe CLOCKRADIO(10 A ) fuse also cancelsthe radio preset stationsand the clock setting.
Make note of the radio presetsbefore removingthe fuse so you can.eset them.
a The radio may have a coded theft protectioncircuit. Be sure you get the customer's code numberbefore removing
the CLOCKRADIO{10 A) fuse.

t . FinalProcedure(this proceduremust be done sfter any troubleshooting)

1. Removethe jumper wire.

NOTE: lf the servicecheck connectoris jumped, the MIL will stay on.

2, Do the ECM ResetProcedure.

3, Set the radio presetstationsand the clock.

11-43
Troubleshooting
Self-diagnosticProcedures(cont'dl

DIAGONOSTIC
TROUBLE SYSTEMINDICATED Page
coDE (DTC)
o ENGINECONTROLMODULE(ECMI 11 - 5 0
HEATED
OXYGEN (HO23)
SENSOR I t-50

11 - 6 4 ,
(MAP SENSOR)
MANIFOLDABSOLUTEPRESSURE
5 68
4 CRANKSHAFTPOSITION(CKPSENSOR} 11-70
6 ENGINECOOLANTTEMPERATURE (ECTSENSORI
7 THROTTLEPOSITION(TP SENSOR} 11-74
I TOP DEAD CENTERPOSITION(TDC SENSOR} 11-70
9 N o , 1 CYLINDERPOSITION{CYP SENSOR) 11-70
10 (IATSENSOR}
INTAKEAIRTEMPERATURE 11-76
't2 EXHAUST GASRECIRCULATION
IEGRVALVELIFTSENSOR) 11 - ' l5 3
13 EAROMETRIC (8ARO SENSOR)
PRESSURE 11-79
14 IDLEAIR CONTROL(IAC VALVE) 11 - 9 6
tc IGNITION
O U T P U TS I G N A L 11 - 8 0
to FUELINJECTOR 11-116
VEHICLESPEEDSENSORIVSS) 1' 1-82
20 ELECTRICAL (ELD) 'I
LOADDETECTOR 1-84
'.1

21 VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC


CONTROL{VTEC}
6-75
SOLENOIDVALVE*'
'tJ
22 VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC
CONTROL{VTECI
6-77
PRESSURESWITCH**
23 K N O C KS E N S O R( K S } I 11 - 8 8
4'l HEATEDOXYGEN (HO2S)HEATER
SENSOR 11 - 5 8
43 FUELSUPPLY
SYSTEM 11-62
*: ExceptF22A1 engine(Sl
": H22A'l engine{USA: Si VTEC/Canada:SR-V)

a lf codesotherthan those listedaboveare indicated,verify the code. It the code indicatedis not listedabove,replace
the EcM.
a The MalfunctionIndicatorLamp (MlL) may come on, indicstinga system problemwhen, in fact, there is a poor or
intermittentelectricalconnection.First,check the electricalconnections,clean or repairconnectionsif necessary.
a The MIL and D4 indicatorlight may light simultaneouslywhen the code blinks 6, 7 and 17.
Checkthe PGM-FIsystem accordingto the PGM-FIsystem troubleshooting,then recheckthe D4 indicatorlight. lf
it lights, see page l4-36.
a The MIL does not come on when there is a maltunction in the A/T Fl signalor slectricsl losd detector circuits. However,
it will indicatethe codes when the servicecheck connectoris iumDed.

11-44
lf the insp€ctionfor a panicularfailurscode requiresthe test harness,removethe right door sill moldingand the small
coveron the right kick panel8nd pull the carpetbsck to exposethe ECM.Unboltthe ECMcover.With the ignitionswitch
off, connectthe test harn€ss.Checkthe system accordingto the proceduredescribedtor the appropriatecode(s)listed
on the following pages.

DIGITALMULTIMETER
KS-AHM-32-003

o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o
o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o

TERMII{AL LOCATIOI{S {cont'd)

11-45
Troubleshooting
Self-diagnosticProcedures(cont'd)

a Punctudng th6 insulation on a wile can causa poor or Intermittent eloctdcal connectlona,
a For lasling at connectora othor than ths test harness, brlng tho taster probo into contact wltlr tho telmlnll tlom tho
connoctor side of wiro harnoaaconnoctors in th€ engin€ companmont. For temelo connectoB,lust touch llghtly whh
tho tostsr probe and do not insort th€ probe.

TERMII{AL

t,-l

l-rI
,i,1i
-it1

11-46
How to Read Flowcharts

A flowchart is designedto be used from start to final repair.lt's like a map showing you the shortestdistance.But be-
ware: it you qo off the "map" anywherebut a "stop" symbol, you can easilyget lost.

TSTAR-T] Describesthe conditionsor situationto start a troubleshootingflowchart.


Eotaivpet

Fdfibxl Asks you to do something;perform a test, set up a conditionetc,

@ Asks you about the resultof an action,then sendsyou in the appropriatetroubleshootingdirection.

trroFl The end of a seriesof actionsand decisions.describesa tinal repairaction and sometimesdirects
(bold typel you to an earlierpart of the flowchart to confirm your repair.

NOTE:
a The term " lntermittentFailure"is usedin thesecharts.lt simplymeansa systemmay havehad a tailure.but it checks
out OK at this time. It the MaltunctionIndicatorLamp(MlL)on the dashdoesnot come on, checkfor poorconnections
or loose wires at all connectorsrelatedto the circuit that you are troubleshooting(see illustrationbelow,.
a Most of the troubleshooting flowchartshaveyou resetthe EngineControlModule(ECM)and try to duplicatethe diag-
nostic troublecode (DTC).lf the problemis intermittentand you can't duplicatethe code, do not continuethrough
the tlowchart. To do so will only result in confusionand, possibly,a needlesslyreplacedECM.
a "Open" and "Short" are common electricalterms. An open is a break in a wire or at a connection.A short is an
accidentalconnectionof a wire to groundor to anotherwire. In simpleelectronics,this usuallymeanssomethingwon't
work at all. In complexelectronics{likeECM's),this can sometimesmeansomethingworks, but not the way it's sup-
poseoro.
a It the electricalreadingsare not as specifiedwhen usingthe test harness,checkthe test ha.nessconnectionsbefore
proceeding.

11-47
PGM-FISystem
System Description

ENGINECONTROLMODULE{ECM) OUTPUTS
TDC/CKP/CYPSensor Fuel Injectors
MAP Sensor PGM-FlMain Relay(FuelPump)
ECT Sensor MIL
IAT Sensor IAC Valve
TP Sensor A/C CompressorClutch Relay
HO2S rcM
vss F"*li"",---fl-ni-l-".M;l EVAP Purge Control Solenoid Valve
BAROSensor --_]l HO25 Heater
StarterSignal @;bbc-t.d VTEC Solenoid Valve"
ALT FR Signal ALT
Air ConditioningSignal EGR Control Solenoid Valve
A/T Gear PositionSignal Fit"rJ,,"o,,"-',....-,,,"o.*-,,cont,ot,,cont.trr".**-_-l
IAB ControlSolenoidValve'
BatteryVoltage(lGN. 1) lntake Control Solenoid Valve*
BrakeSwitch Signal Eil,*"s c-,'d I
PSP Switch Signal
EGR Valve Lift Sensor
Knock Sensor* fEcMB*k',p F;tb";-ll]]l
VTEC PressureSwitch* *

': Exc€ptF22A1 enqine


": H22A'l engine

PGM-FISvst.m
The PGM-FIsystem on this model is a sequentialmultipon fuel injectionsystem
't,
Fuel Inlector Timing and Duration
i:r The ECM containsmemo.iesfor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The
basicdischargeduration,after beingreadout from the memory,is further moditiedby signalssent from varioussansors
fii to obtain the final dischargeduration,

ldle Air Control


ldle Air ControlValve (lAC Valve)
When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) or the alternatoris charging,
the ECM controlscurrent to the IAC Valve to maintsincorrect idle speed.

lgnition Timing Control


o The ECMcontainsmemoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming
is also adjustedtor enginecoolanttemperature.
a A KnockControlSystemisalsoused.When detonationis dotectedbythe knocksensor,the igntiontiming is retarded
(ExceptF22A1 engine).

Other Control Functions


1. Starting Control
When the engineis started,the ECM providesa rich mixture by increasing{uel iniectorduration.
2. Fuel Pump Control
a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-FImain relay that supplies
current to the fuel pump fo. two secondsto pressurizethe fuel system.
a When the engineis running.the ECMsuppliesgroundto the PGM-Flmain relaythat suppliescurrentto the fuel pump.
a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relaywhich cuts
currentto the fuel pump.
3. Fuel Cut-off Control
a Duringdecelerationwith the th.ottle valveclosed.currentto the fuel injectorsis cutoff toimprove fuel economy
'l
at speedsover ,1OOrpm.
a Fuel cut-otf action also takes place when engine speed exceeds, F22A1 (S): 6,6O0 rpm. H23A1 (USA: Si/
Canada:SR): 6,8O0 rpm. H2241 (USA: Si VTEC/Canada:SR-VI: 7,7OOrpm, regardlessof the positionof the
throttle valve. to protect the enginetrom over-revving.

11-48
4. A/C CompressorClutch Relay
When the ECMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorJrombeing
energized,and enrichesthe mixture to assuresmooth transitionto the A/C mode.

5. EvaporativeEmission(EVAP)purge ControlSolenoidValve
when the enginecoolanttemperatureis betow 167 oF (75 "Cl IH22A'| engine(USA:Si VTEC/Canada: SR-V):1bg oF
(70oC)1,the ECMsuppliesa groundto the EVAPpurgecontrolsolenoidvalvewhich
cuts vacuumto the EVAp purge
control diaphragmvalve.

6. IntakeAir Bypass(lAB) ControlSolenoidValve


When the enginespeed is below 4,8OOrpm IH22A1 engine(USA: Si VTEC/Canada: SR-V):4,600 rpml, the IAB
controlsolenoidvalveis activatedby a signalfrom the ECM,intakeair tlows throughthe long intakepath, then high
torque is deliveredAt speedshigherthan 4,8OO(or 4,600) rpm, the solenoidvalve is deactivatedby the ECM.
and
intake air flows through the short intake path in order to reducethe resistancein airflow.

7. Intake Control SolenoidValve


When the enginespeedis below 4,000 rpm, the ECM suppliesa groundto the intakecontrol solenoidvalve. This
opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.

8. ExhaustGas Recirculation{EGR)Control SolenoidValve


when the EGRis requiredtor control of oxidesof nitrogen(NOx)emission,the ECM suppliesground to the EGR
control solenoidvalve which suppliesfegulatedvacuum to the EGRvalve.

9. Alternator(ALT) Control
The system controlsthe voltagegeneratedat the altematorin accordancewith the electricalload and drive mode,
and reducesthe engineload to improvethe fuel economv.

ECM tail-safe/back-upFunctions
1. Fsil-safeFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM ignoresthat signaland assumesa pre-programmed
value fof that sensot that allows the engineto continueto run.

2. Back-uDFunction
When an abnormalityoccursin the ECM itself,the fuel injectorsare controlledby a back-upcircuit indeDendent
ot
the system in order to permit minimaldriving.

3. Self-diagnosisFunctionIMalfunctionIndicatorLamp (MlL]1
When an abnotmalityoccurs in a signalfrom a sensor,the ECM lights the MIL and stores the code in erasablememory.
When the ignitionis initiallyturned on, the ECMsuppliesgroundtor the MIL for two secondsto check the MIL bulb
condition.

11-49
PGM-FISystem
Flowchart- EngineWill Not Stan
Troubleshooting

Watch the Mallunction Indicator


Lamp (MlL)and turn th€ ignition
swirch ON.

Porfo.m tioubleshooting on pago


Did the MIL come on at all? 11-51.

Portorm t.oubloshootingon pago


11-52.

Turn the ignitionswitch OFF.

Connectthe test harnessb6tw96n


the ECM and connectors (see
page 1 1-45).

1 . OV ?
Turn the ignitionswitch ON.

Measure voltage between body


ground and the tollowing termi-
I nafs individually:A23, A24.

R6psir op6n in wir6(61 botwoon


ECM 6nd GlOl llocst€d at ther-
ls there less than 1.O V?
moltat houringl that had mo.6
thsn 1.0 V.

Inspect tuel pressure (see page


1 1 - 11 5 ) .

Popair as nocoaaa.y {ago pag6


11 - t t 5 ) .

Portorm ignition systom chock


{3o6 Baction 231.

11-50
TroubleshootingFlowchart - EngineControl Module (ECM)

Tho Maltunction Indlc.tor Lamp


(MlLl nover com6! on l6vcn tor
two sgcondsl aftei ignition i3
tuhgd on.

Inspect No. 13 METER110 A)


ls the low oil p.essurelight on? fuse (in the under-dashfuse/relay
oox,.

Turn the ignitionswitch OFF.

Connectthe test harnessbetween


the ECM and connectors (se€ R6palropan in YEL wir6 botwoon
page 1 1-45). No. 13 METER(1O A) ture.nd
gaugo alrombly.

o o o o o o o o o o o o o ooooo ooo I o@#qPt}| ooooooooooo


ooooo odooo ooo I oooooo oo ooooooooooo
Turn the ignition switch ON.

- RaDlocoth6 MIL bulb.


- Ropairop6n in 8LU/WHT wire
ls the MIL on?
botwoon ECM lA13l and
gaugs a88ombly.

| 423
t-.-----+-
II LoooooooooooQo I ooooo999l1!9!t!1!!lg{ ooooooooooo I
|---T-
L Le.. than 1 .0 V? --{
a,
+-
Measure voltage between body
ground and the tollowing termi-
nals individuallv: A23, A24.

Ropalr opon in wiro(sl botwson


ls thsre less than 1.0 V? ECM and GlO1 {locatod at thor-
mostat housing) that had moro G101
than 1.0 V.

Subrtituto a known-good ECM


6nd rechock, lf symptom/lndica-
tlon gooa away, raplaco tho origi
nal ECM.

11-51
PGM-FISystem
TroubleshootingFlowchart - Engine Control Module IECM)
NOTE: When there is no code stored,the MIL will stay
The Mallunction Indicator L6mP on if the servicecheck connectoris jumped.
(MlL) 3tays on or com63 on allo.
two soconoS.

Connect the service check con-


nector terminalswith a jumper
wire {see page 11-42).

Turn the ignitionswitch ON.

Does the MIL indicate Go to rslf-diagnoatic ptocodutos


any Diagnostic Trouble
lso6 pags 11401.
code (DTc)?

o oooooooo oooo I oooooooom oooooooooo


ooooo ooooo oo ol oooooooo
R€movethe iumper wire from the D 4l + l
service check connoctor. r_S V?
{A/T:
Turn the ignition switch OFF.
Try to start the engine.

Connectthe test harnessbetween


the ECM and conneclors {see
p a g e1 1 - 4 5 ) .

Turn the ignitionswitch ON.

Measurevoltage between D4 (+)


terminaland D21 l-) terminal.

Connect the service


ls thereapprox.5V (A/T: 11 V)? check connector terma-
nalswith a jumper ware.

Bopair shorl to body ground in


BRN/ WHT wiro botwo€n tt|o ECM Mgasure voltage be-
{t}4}, lrsnsmission Control Mod- tween D4 (.t ) terminal
ulo lTCMl, ABS contrcl unit or and D21 {-) terminal.
4WS control unit and seryico
chock connoqtor.

- Repairopen in BRN/WHTwite
botwoon ECM (O4l and sorv- ls there spprox. 5 V
ico chock connoctor. ( A / T :1 1 V l ?
Removeand inspectthe NO. 4 - Repairop6n in BLU/WHTwite
BACKUP(10 Altuse in the under- botwoon sorvico check con-
dash fuse/relaybox. noctor and ECM {O211.
Remove the ,umper
wire from the service
check connector.
ls the fuse OK7
page 11-53)
YES 'NorE: After reDair,disconnectrhe servicecheck con- lro
nector iumper wire, test drive the car, and recheck the
{ T o p a g e1 1 - 5 3 ) MIL for code.

11-52
11-52)

Insp6ctthe ECU (ECM) (15 A)


Iuse anthe underdash tuse/relay
box.

Disconnect"A" con,
nectorlrom the EcM.

Turn the ignitionswitch ON.

Substituto . known{ood ECM


Disconn6ct the 3P connector of and rochock. lt lymptom/indica-
tion gooa awsy, roplaca the origi- ls the MIL ON?
each sengor one at a time:
. MAP sensor n8l ECM.
. EGRvalve litt s€nsor
. Throttle Position (TP) sensor
R€prir rhort to body
ground in BLU/WHT
wlro betwoontho ECM
{A131rnd th6 MlL.
Doesthe MIL romainON? RoDlacatho aenaor that causod
thc light to 9o our.

Turn the ignition switch OFF.

"l;_-l
Connect the test harness.
Oisconnoct the "O" connector I o o o o o o o o o o o o o I o o o o o o o o f , S & l * * * * No o o o o o o o o o o |
I
|
Irom the ECMonlv, not the m6in
wire hamess(seepage | 1-451. D20
-l-
\:-----:J
Continuitv?
Check tor continuity between
body groundterminalsD'l9, D2O.
- Bopair .hort to body ground in
RED/WHTwiro bctwe.n ECM
{Dl9} ond MAP 3onso.or EGR
ls th€re continuityT valve lift sonror.
- Bopair shon to body g.ound in
NO YEL/WHT wlre botw66n ECM
lD2Ol and TP !on3or.
Reconnect all the sensor con-
nectors.
Reconnectthe "D" connector to
the ECM.

Turn th€ ignirionswitch ON.

(To page 1 1-54)

(cont'd)

11-53
PGM-FlSystem
TroubleshootingFlowchart - Enginecontrol Module IECMI (cont'd)
(Frompage 1 '!-53)

Measurevoltage between body


groundandthe tollowingterminal
individually:A26, B2.

A26 82
l l
'1.0 v?
Less than
]L

Repai.op6nin BLK/REDlA26) or
ls rhere lessthan 1.0 V? BRN/BLK(B2l.nd G101 llocatod
6t thormoslat housingl.

A 2 5( . r ) 8 1 { + )

Measurevoltage between A26


I - ) andthe following:81 {+ ) and
A25 (+). BATTERY
BATTERY
VOLTAGE? VOLTAGE?

- Repair opon in YEL/BLK wir6


betweon ECM (425, 81) and
PGM-Fl main iolay.
- Check PGM-FImain tolaY .nd
wiring connoctors at PGM-FI
main r6lav.
Substitute a known-good ECM
and recheck. lf symptom/indica-
tion goes avray, replacethe otigi-
nal ECM.

11-54
Y
PGM-FISystem
TroubleshootingFlowchart - Heated Oxygen Sensor (HO2S)

The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTroublecode {DTC)1: A problemin th€


mr-
ff'_
ri--ri
_.-i- _ HeatedOxygen Sensor(HO2S)circuit.

The HeatedOxygen Sensor(HO2S)detectsthe oxygen content in the exhaustgas and signalsthe ECM. In op€ration,
the ECM receivesthe signalsfrom the sensorand variesthe durationduring which fuel is injected.The HO25 has an
(H2341 engine
internalheater,The heaterstabilizesthe sensor'soutput. The HO2S is installedin the exhaustmanifold
(USA: Si/Canada:SR). H22A1 engine(USA: Si VTEC/Csnada:SR-VI:in the exhaust pipe A)'

HEATER
TEBMINALS
VOLTAGEIVI

SENSOR
TERMINALS - LEAI{
RICH- AIR.
FUEL
lm;rl lrirl RATIO
-Y- -.-i-
- Tha MIL hsa becn roDortodon.
- Yvlth sorvico chack connoclor
iumpod l.60 page I 142), codo
1 i3 indicatod.

Do the ECMResetProcedure{see
p a g e1 1 - 4 3 ) .

Warm up engine to normal oPeF


atingt€mperature(the radiatorfan
comeson),

Run enginetor 60 seconds.

Roadtest with the manualtrqls-


mission in 4th geat I AfIt lA
position).
Starting st 1,600 rpm, accelerate
using wide open throttl€ for at
least 5 seconds.Then doceler€te
tor at least 5 seconds with the
throttle completoly closed.

Intormittont lrllur., systom l. OK


al thb time. Ch.ck to,. poot con-
ls the MIL on and does it indi- noctlons o. loorc wiror at C432
cate code 1? {locatod al tight shock towcr),
C114 (HO2S)and ECM.

Go !o pagl. and p€rtorm tcat for


.-.3 l- p.fo 11-62).

-
11-56
PGM-FISystem
Flowchart- HeatedOxygenSensor(HO2SlHeater
Troubleshooting
:ml1:f,f-f : The MattunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)41: A problemin
-Y- -*- the HeatedOxygen Sensor(HO2S)Heatercircuit.

-[6]- ]l-rTll
-]-\
/ 7.---:- \

- Engino ia running,
- Tho MIL hsr bcon roportodon.
With rervica chock connoctol
iumpod (soopage 11421, codo
41 ir indicalod.

Do the ECM RssetProcedure(see H23Al ongino {USA: Si/Clnada: SR)


p a g e1 1 - 4 3 ) . H22Al engin. {uSA: Si vTEc/Canada: SR-VI:

lrrtd$frqrttS$6,3ys-
tom 13OK at thi! tlmo
Itost drlvo maY bo
nacrsrsryl. D
ls the MIL on and does it indi- Chock lor poot connoc-
cate code 41? tionr or 10036wirot rt
C432 llocat.d at right
shock toworl, C114 10-r|o
lHO2Sl and EcM. o?
Turn the ignition switch OFF.

DIGITAL
MULTIMETER
KS-AHM-32-003

Disconnectthe 4P connectorfrom
the HO25.

Me6sute tesistance betweon ter-


minsls C and D on the HO2S.

ls there 1O-4O 0?

DIGITAL
MULTIMETEB
( T o p a g e1 1 - 5 9 ) KS-AHM-32-003

11-58
11-58)
H23A1 engino
IUSA: Si/Canada:SRl.
H22Al ongino
Check lor continuity to body (USA: Si VTEC/Canada:SB-V):
ground on telminalsC and D ot
the HO2S.

Check foi continuity between ter-


minalD and terminalsA and B in-
dividually.
HO2S
45 N.m
F22A1 ongine (S): (4.5 kg-m,

Turn the ignitionswitch ON.

At HO25 harness,measurevol,
tage between YEL/BLK{+ I termi-
nal and ORNMHT {- ) terminat.

YES Disconnectthe "A" connector HO2S


ls there battery voltage?
from the ECM. 45 N.m
{4,5 kg-m, 33 tb-ftl

Meosure voltage bstween YEL/


BLK (+l re.minal and body At HO25 harness, measure vol-
ground. tage between YEL/BLK(+ )termi
nal and ORN/WHT(- ) teiminal.

Repair 3hon in ORf{/


ls there battery voltage? WHT wire botwoen
ECM (A6l and HO2S.

Ropairopon in YEL/BLK
wiro botwoon HO2S
and PGM-FImsin rolav.

Turn the ignirionswitch OFF.

Reconnectthe HO25 connector.

{To page 1 1-60} {To page 1 1-60)

{cont'd}

11-59
iM-Fl System
PGM-FI
TroubleshootingFlowchart - HeatedOxygen Sensor(HO2S)Heater {cont'd)
(Frompsge 11-59)

"A"
Connoct the tesl harness
connector to the main wile haF
ness only. not the ECM (seepage
11-45).

Connect an ammetet b€tween tel-


minalsA6 { + ) and A26 (- )

' Monitor over a 5 minutes period.

ls the curront less than


0.1A?'

Subrtltut. a knownSood ECM


lnd rochock. ll .ymptom/indica-
tion 9o6a away, roplaco tha origi_
nal ECM,

Reconnect the 4P connector to


the Ho2s.

"A" oooooooo ooooooooooo


Connect the test hahess BATTERY o o o o o o o o o o o o o
connector to the main wi.e haF VOLT oo ooooooooooo oooooooo ooooooooooo
ness onlv, not the ECM (s.e page
11-45).

Turn th6 ignitionswitch ON.

Measurevoltage between A6 {+}


terminsland A23 {- } terrninal.

Rep.lr op€n in OR /WHl wir. bc-


ls there battery voltage? twcrn ECM lA6) .nd HO2S.

Subllltuto 6 known-good ECM


and$chock. ll symptomlindica-
t'roril'golr ay{ay, rsplaco tho otigil_
nal ECM.

11-60
F
PGM-FISystem
TroubleshootingFlowchart - Fuel Supply System

:r,*n-- \r-r-l
-t 13l The MatfunctionIndicatorLamp (MlL) indicatesDiagnosticTroublecode (DTC)43: A problemin
- - - | t / | \ the HeatedOxygen Sensor{HO25) circuit or a problemin the Fuel Supply System

l@r rE.
- Tho MtL hc! b.cn roportod on . Fiom cod. 1 troubb-
'l
- Wlth rorvico chock connoctoi 3hootlng lpag. I -561.
iurDod t!.3 p.Oe 1 142), codo
43 l. indicatod.

ls the codo 43 accompaniod by Go to Fu.l Supply Systam (3.o


the MIL and poor driveabilitY? p!9. l1-'1131.

Do the ECM Reset Procedure


lse6 page 1 1-43).

warm up engineto normSloper'


ating tompgrature{the radiatorfan
comes on).

Hold engineat 3,OOOrpm lor two


mtnutes.
(A/T:NorEposition.)
Intlrmlttdrt t ilurc, ly.tom is OK
,,ti at thir dm€ (t6st drlv. may ba
nocoalarYl.

i,l
ls the MIL on and doss it
indicate code 43? Chock tor ooor connactiona o.
loor. wirst at C432 lloclt.d !t
rtght rhock low.tl, C1f4IHO2S) -
and ECM.

Turn the ignition switch OFF.


NOTE:
. Use DIGITALMULTIMETER
(KS-AHM-32-OO3)or equival6nt.
Connect the test hamess bgtween . Use 2 Volt range.
the ECM and connoctors {see
page 1'l-45).

With the ignitionswhch OFF,wait


tor st least two minutes. 6 A26
JUMPERWIRE
Install a iumper wire on the test
harnessbotween A6 and A26.

Voltaga .hould ttan tl D 1 4( + l


Turn the ignition switch ON.
A26{-t
I 0.4-0.5 v wh.n thc
ignltion .whch i. fit8t
tunad oo, and dactaaso
Measure voltage between Dl4 to b.low O.l V In L.t
l+) terminaland A26 {- ) termi- than two mlnut6a.
nal as soon as the ignition switch
is turned on,

lTo page 11-63)

11-62
lFrom page 11-62)

ls there 0.1 V or l€ss when the


ignition switch is tirsr turned
on?

Measurevoltage belween D14


{ + ) t e r m i n a la n d A 2 6 ( - )
telminal.

ls there more than 0.1 V?

Disconnect the "D" connector


trom the main wire harness.

Measurevoltage between D14


{+} terminaa
l nd A26 {-) rer
minal.

Bop.ir rhon in WHT


ls there more than 0.1 V? wlro b.tw.on ECM
(Dl4l andHO2S.

Measu.e voltage at the engine Substitute a known{ood ECM


wi.e harness side ot the HO2S and r6.hock. lf symptom/indlca-
connector between GRNMHT tion goos away, roplact the orlgl-
( - ) a n d W H T( + ) . nal ECM.

ls th€re mor€ than 0.1 V?

Chock for oDcn in IIVHTwiro be-


tw..n ECM (D141 and HO2S. lf
wlrs ir OK, r6poir opcn in
GBN/WHT wiro berw66n ECM
(D221and HO2S. H23A1 ongin6 (USA: Si/CanadarSR), GRl{/ W H T( + )
H22Al ongino (USA: Si VTEC/Conada:SR-V); WHT
F2241 sngino {S):

GRI{/ WHT
IVHT - l (+l

moro than
o.'t v?
DIGITAL MULTIMETER HO25 HO2S
45 .m DIGITAL MULTIMETER
KS-AHM-32-OO3 45 N.m KS-AHM-32-OO3
(4.5 kg-m,33 lb-ft|
14.5 kg-m, 33 lb-ft)

11-63
PGM-FISystem
-
TroubleshootingFlowchart -Manifold Absolute Pressure(MAP) $gn5s1
- -l-- - ---1- - The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 3: An electricsl
t 1 6 l - /- l 3, l \-
/--l-\ oroblemin the ManifoldAbsolutePressure{MAP) Sensorsystem.
\ | /-
{-61--fr-r- The MalfunctionIndicatorLamp {MlL) indicatesDiagnosticTroublecode (DTC) 5: A mechanical
/- | problem(vacuumleak) in the ManifoldAbsolutePressure(MAP) SensorSystem'
\ /---i- \

The MAP sensorconvertsmanifoldabsolutepressureinto electricalsignalsand inputs the EcM.

CAVITY OUTPUT
VOLTAGE
(vl3.5
3.0
2.5
2.0
1.5

-16l- - 0.5
/-\/
o lar. Hll OAUOE
N: DING

- Engin6 is watm ond running.


- Tho MIL has b6€nloPortodon
- With soryico ch6ck connoctot
jumpod (so€ pago 1'142), codo
3 is indicalod.

r',i Do the ECM ResetProcedure{see


i , l' p a g e1 1 - 4 3 ) .

I'iI
l l

Intgrmittont failuro, 3yltam is OK


at this time ltort ddve may D6
noc{r!ry}.
ls the MIL on and does it indi- Chock tor Poor connoction! ol
cate code 3? loose wiror at O163 (locatod un-
dor loft 3ideol drshl, C32O IMAP
3.n3otl and ECM.

Turn the ignitionswitch OFF.

Disconnectthe 3P connectorfrom
the MAP sonsor.

Turn the ignitionswitch ON.

(To psge l1-65)

11-64
l F r o mp s g e 1 1 - 6 4 )

Measure voltage between RED/


WHT (+) terminal and body
ft
D 1 9t r l D 2 1( _ l
ground. ooooooooooooo I o oooo ooo
ovooooooooooo I oooooooo

Measure voltage between RED/


ls there approx. 5 V? WHT (+ ) terminaland BLUMHT
{ - ) terminal.

Turn the ignirionswirch OFF. Ropai. op6n in BLU/


ls there approx. 5 V? WHT wiro betwoon
ECM {D21} and MAP
s6n8l't.
Connect the test harness "D"
connecto.to the ECMonly, notto
the main wire harness (see page
1145).

Turn the ignitionswitch ON.

Measurevollage between D19


l + ) t e r m i n a la n d D 2 1 ( - )
terminal.

Measure voltage betweon WHT/


ls there approx. 5 V? BLU {+ ) terminaland ELUMHT
{ - ) terminal.

Ropairopon in RED/WHTwiro bo-


twcon ECM (D191 and MAP
son3()r.

Sub3tituto a known-good ECM


and rochock. lf 3ymptom/indica-
tion 9003away, .eplacotho origi-
nal ECM.

ls there approx. 5 V?

Turn the ignitionswitch OFF.

Reconnect the 3P connector to


the MAP sensor.

Connectthe test harnessbetween


the EC|VIand connectorlsee page
11-45).

Turn the ignitionswitch ON.

{ T o p a g e1 1 - 6 6 } (cont'd)
{To page 1 1-66)

11-65
PGM-FISystem
(MAPISensorlcont'dl
Flowchart- ManifoldAbsolutePressure
Troubleshooting

{Frompsge 11-65) (Frompage 1 1-65)

MeasuG voltage bstween D'l7


(+l terminaland D21 (-)
terminal.

Turn the ignitionswitch OFF.

"D"
Connect the test harn€ss
connectorto the ECMonly, not to
the main wire harness {see page
11-45). ls there approx. 3 V?

Sub.tituls . known{ood ECM


rnd r.chock. lf 3ymptom/lndica-
Turn the ignitionswitch ON. tion goo! 6w!y, r.plact th. odgi
nal ECM.

Measurevoltage betweon D17


( + l t e r m i n a la n d D 2 1 { - )
tetmlnal.

- Roplir rhort In WHT/BLU wiro


botworn ECf,l {D17) rnd MAP
loflto],
ls there approx. 5 V7 - R.prir opon in WHT/BLU wlrc
botwo.n ECM (Dl7l.nd MAP
36nao..

Substltuto a known{ood ECM


and rochock. lf aymptorn/indicr-
tion goo3 away, taplace tho origi-
nal ECM.

11-66
PGM-FISystem
{MAP}Sensorlcont'dl-
Flowchart- ManifoldAbsolutePressure
Troubleshooting

,g: -g-
- The MIL has boon reponod on.
- With sorvic€ chock connector
jumpod ls6opago 1 142), code
5 is indicatod.

Do the ECM ResetProcedure{see


p a g e1 1 - 4 3 ) .

Start the engine and keep engine


speed at 2,000 rpm tor one
minutewith the manualtransmas
sion in neutral {A/T: @ or S po-
sition).
- Intgrmitl6nt lailuro, 3y3tom is
OK al this tlm6 lt$t ddvo mav
bo nocoasaryl.
ls the MIL on and does it indi- - Chock vacuun ho3or, PiPo3
cate code 5? ond connoctionS.
- Mako turo all conn9ctota ar6
30cu16,
MAP SENSOR
l l
'1i
Turn the ignitionswitch OFF.

r:ttl
Hrl
Disconnect#21 hose lrom the
throtle body, connect vacuum
pump to the hose and apply

VACUUMPUMP/
GAUGE
A973X-041-XXXXX

#21 HOSE

Connect a vacuum pump to the


MAP sensorand apply vacuum.

Does it hold vacuuml

Connecta T-titling from a vacu- Repairvscuum lsak in hoa€ rout-


um gauge between the throttle ing betwaon MAP asn3or lnd
body and #21 hose. rhrottlo body .

{ T o p a g e1 1 - 6 9 }

11-68
{Frompag6 1 1-68)

Start the engine.

ls there manifoldvacuum?

Turn the ignitionswitch OFF.

Connectths test harnessbetween


the ECM and connectors (see
p a g e1 1 - 4 5 ) .
T-FITTING

Turn the ignitionswitch ON. 3V?


n
D l 7 t + l D 2 1{ - }

Measurevoltage between D17


(.t ) terminal and 021 ( - )
lermrnal,

ls there approx.3 V?

Start the engineand allow it to


idle.

ls there approx. 1 V?

Subltitute a known-good ECM


and rocheck. ll symptom/indica-
tion 9063away, ropl6cotho o.igi-
nal ECM.

11-69
PGM-FISystem
Flowchart- TDC/CKP/CYP
Troubleshooting Sensor
- I 7 -

16l- Tr-l- The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)4: A problemin the


-Yt-._r-- CrankshaftPosition(CKP)Sensorci,cuit.

\ \ The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTtoubleCode{DTC)8: A problemin rhe


- l r G./l - --_-1_/
l 8l-
/-i-\ / \ Top Dead Center (TDC)Sensorcircuit.

\_ j_'-,2 \_ _/ IndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)9: A problemin the


The fiilalfunction
- 1--t-\
16l--l e l-
/ /---- \ CvlinderPosition(CYP)Sensorcircuit.

The CKP Sensordeterminestiming fo. fuel injectionand ignitionof each cylinderand also detects enginespeed.The
TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects
the position of No. I cylinder for sequential fuel injection to each cYlindet.

-@Jtrl:;m:-;F-
- Tho MIL ha. b€€n Jooortod on.
; - lilfith loruice ch€ck conn.ctol
iump€d (3ooprgo 1142), codc
.ir 4. 8 rnd/or 9 aro indicstgd.

l,l Do the ECM Resetprocedurelsee


pago 1 1-43).

l ormittont l.ilur., syltom b OK


at this timo ltelt driv6 may bo
neco$aryl.
ls lhe MIL on and does it indi Chock for Door connoctiona or
cate code 4. 8 and/or 9? loos6 wir.s at Al25 (locatod at
dght shock towo.), Cl25 (TDC/
CKP/CYPionsorl .nd ECM.

H23A'l ongino{USA: Si/Canada:SRl, .,.


Turn the ignition switch OFF. vrew rrom
H22a1 engino
sa-vt,
iiisr, si vlicrca"aaa $jT'"'

Disconnectthe 8P conn€ctorfrom
the TDC/CKP/CYPsensor.

( T op a g e1 1 - 7 1 )

11 -7 0
1 1-70)

Measurerosistancebetween ter-
minals of the indicnted senso.. SENSOF ECM
'9oo tsblg SENSOR oTc
COLOF
815 ALU/GRN
cxP
416 SLUTYEL
Roplacathe di.Mbuto. c al3 OFN/aLU
ls there 350- 700 O? houalng {16o soction TOC a
G at4
231. Bll OFN
Bt2
Ch€ck lor continuitv to bodv
ground on both terminals of the
indicatgd sensor.

RoDlrc. th. di.trlbutor


houling (soo aocdon
231.

Connect the test harness to the


main whe harnossonlv, nottothe 8:16 350-7OOO?
ECM (seepag€ 1 1-45).

Measurerosistancebetween t€r- o oooooooooooo I oooooo o l:1E$iq#Cittl o o o oo o oo oo o


minals of the indicated sensoron ooooo oooooooo I oooooo
test harness.
o ooooo oo oo o
'see tablg B1l-
350-7ooo?

o o o o o o o o o o o o o I o o o o o o o o r . s E t $ d i 6 d qo o o o o o o o o o o
ooooo oooooooo I ooooo0oo lfrlE#lls*llooooooooooo
350-7000? 812

R9pai.op.n In tho indi-


ls there 35O-7OO 0? catad alnlor wi10a.
'!oo trble

Check tor continuity to body


groundon Bl 5, 813 or 81 1 ter-
mtnals,

Subltltuto a known-good ECM


lnd r6chock. lt aymptom/indicr-
tion goor away, rcphca tho origi-
n.l ECM.

11-71
PGM-FISystem
TroubleshootingFlowchart - Engine Goolant Temperature(ECTI Sensot -

f'at-
-
lri-tl The MalfunctionIndicatorLamp (MlL) indicstesDiagnosticTroubleCode (DTC)6: A problemin
, - ---;-- the EngineCoolantTemperature(ECT)Sensorcircuit.

The ECTSensoris a temperaturedependantresistor(thermistor).The resistanceof the thermistordecreasesas the en-


gine coolanttemperatureincreasesas shown below.

RESISTANCE
(KO)

-
- h- l 6
--
l- -r - -l---i-
-!/
5l-
/----, - - -20 0 ,ro ao ao r roo 12o (rc,
. 12 aa r0. !.ro 1ta 2r2 2.r r.fl
- The MIL has b6onroDongdon.
- With sorvica ch6ck connoctol COOLANTTEMPERATURE
ENGIT{E
'l
,ump6d l.oo pag€ 1421, c!d6
6 is indicatsd.

Do the ECM ResetProcedure{see


page 1 1-43).

Turn the ignition switch ON,


j Intermitt€nt failure, systgm i3 OK
at thir timo lt6st d.ivr m.y b.
n6ce!l|'yl.
ls the MIL on and does it indi Chock tor poor connootions or
cate code 6? looro wir6 at 9125, 9126 (locrt-
od at righl shock toworl, Cl22
IECT lenrotl, AIf: C411 (TcMl
and ECM.
Warm up engine to normal oper-
ating temperature(th€ radiatorfan
comeson).

Turn the ignitionswitch OFF.

Disconnectthe 2P connectorfrom
the ECT sensor.

Measureresistancebetween the
2 terminals on the ECT sensor.

ls there 2OO-4OO0?

{To pagc 1 1-73)

11-72
( F r o mp a g e 1 1 - 7 2 )

Turn the ignitionswitch ON.

Measure voltage between YEL/ GBN/


BLU and body ground. wHT

YEL/BLU

Measure voltage between YEL/


ls there approx. 5 V? BLU (+ ) torminaland GRNA/VHT
(- ) terminal.

Turn the ignitionswitch OFF. Repair op€n in GRN/


ls there approx. 5 V? WHT wlra brtw.on
EGM (D22) and ECT
tonaoa.
A/T only
Subrrituto r known{ood ECM
Disconnect the 22P connector and iocheck. lf lymptom/lndlcr-
trom the TCM. tion goaa aw!y, rol aco tha origi-
nal ECM.

Turn the ignitionswitch ON.

YES
ls there approx. 5 V?

NO
I
Turn the ignitionswitch OFF. I
I

Connect the test harness "D"


connectorto the ECMonly, notto
the main wire harnsss ls€e page
11 - 4 5 ) .
v?
T-5
O13l+l
Turn the ignitionswitch ON.

D22 t-l
Measurevoltage belween D13
( + l t e r m j n a la n d D 2 2 ( - )
rermtnat.

Ropairopen or rhon in YEL/BLU


ls there approx. 5 V? wir. betwoon ECM lDl3l snd
ECT sensor.
NO
Subatituto a known-good ECM
and rechock. lt symptom/indica-
tion goos away, r6pl6cothe origi-
nal ECM.

11-73
PGM-FISystem
TroubleshootingFlowchart - Throttle Position (TP) Sensor

lf1=lllfifl The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode IDTC) 7: A problemin


.:. : the Throttle Position{TP) Sensorcircuit.

The TP Sensoris a potentiometer.lt is connectedto the throttle valve shaft. As the throftle positionchanges,the TP
Sensorvariesthe voltage signalto the ECM.
ERUSH
HOLDER OUTPUTVOLTAGENI

BRUSH 5
4
3
RESISTOR
2
lr6t1 :.t1 1
-Yr -t- o.5 THROTTLE
0 oPEt{rNG
- Engino b running. TERMINAL ;;ii-
- Tho MlLhas beonreDortedon. THROTTLE
- With sorvico check connoctot
iumpsd ls6opage 1 142), codo INNER
7 is indicatod. BRUSH

Do the ECM ResetProcedure(see


p a g e1 1 - 4 3 ) .

I Inlormittont Iailure, systom b OK

i ls the MIL on and does it


at this timo lt6st d.ivs m6y b6
nocossaryl.
Chock tor Dooi connections or
indicatecode 7? loos€ wiros at O125, g*13 llocat-
od at right shock rowerl, C113
(TP sonsorl, A/T: C4'l l ITCMI
and ECM.
Turn the ignitionswitch OFF.

Disconnectthe 3P connectorfrom
the TP sensor.

Turn the ignitionswitch ON.

Measure voltage between YEL/


WHT (+ ) terminaland GRNMHT
(- ) terminal.

Measure voltage between YEL/


ls there approx. 5 V? WHT (+) rorminal and body
grouno,
YES YEL/ RED/ GNN/
WI{T BLK WHT
{ T o p a g e1 1 - 7 5 }
(To page 'l1-75)

11-7 4
(F om p8O€11-741 (Frompage 1 1-74)

Repaii opon in GBN/


WHT wiro botwo6n
ls there 6pprox. 5 V?
ECM (D221 End TP
Turn the ignition switch OFF. 30n3('t.

Turn th6 ignition switch OFF.

Connoct
th€testharness
b€tween
tho ECM snd connectors{see
p8ge11-451.

Connoct the test hamess b9tw6€n Turn the ignition switch ON.
the ECM and connoctors ls€e
p a g e1 1 ' 4 5 1 .

Measure voltage betwgen D2O


( + ) t e r m i n a la n d D 2 2 { - )
terminal.

Turn the ignhion switch ON. Rop.ir op.n in YEL/


ls there aoo.ox. 5 V? WHT wlra bolwoon
ECM {D2O} a.|d TP
aonlot,

Subltltut. . known{ood ECM


Measurevoltago b€tween Dll .nd r.ch.ck. It piclcribcd voltage
{+) t€rminaland D22 (-, i! now lvoilabl., rrphco tho orlgi-
terminal. n.l ECM.

o o o o o o o o o o o o o I o o o o o o o o E f f n f f i n S HoFol o o o o o o o o o
o o o o o o o o o oo o o I o o o o o o o o ooooooooo
D 2 0t + l D 2 2 l - l
tsv,J
0.5 V at tull close throttle?
4.5 V at lull open throttle?

ls voltago 0.5 V at full clos€


throttle, and approx.4.5 V 8t
full open throttls?
NOIE: There should be a Diaconngct the 22P connecto.
smooth transition from O.5 V from th6 TCM.
to approx.4.5 V as the throttle
is depressgd.
ls voltageO.5 V at full clos6 - Roplac6 the TP
throftls, and 4.5 V at full
open throttl€? lonaoa.
Sub.litulc ! known-good ECM - Rapairoponoarhon
.nd rochsck. lf symptom/lndic.- NOTE: Thero should be a
smooth transition from 0.5 V in RED/BLKwiro be-
tlon goat rway, ropl.c. the odgi- tw.€n ECM {Dl 11,
nll ECM. to 4.5 V 8s the throftlo is
d€pressed. TCM and TP r.n!or.

11-75
PGM-FISystem
Flowchart- IntakeAir Temperature(lAT) Sensor
Troubleshooting

f6l F The MaltunctionIndicatorLamp(MtL)indicatesDiagnosticTroubleCode(DTC)1O:A problemin the


---:- l-
Intake Air TemDerature(lATl Sensorcircuit.

The IAT Sensofis a temperaturedependantresistor(thermistor).The resistanceofthe thermistordecreasesas the intake


air temoeratureincreasesas shown below.

RESISTANCE(KO}

THERMISTOR
. 12 aa ro4 1aolta :12 t a |.Fr

INTAKEAIR TEMPERATURE
IA7 SENSOR GR N'VHT

:[611:frnl
--i-
/ / --T-
\ \

- Tho MIL har b6onropon6d on.


- Wlth s6rvico chock connoctol
iumpod {3€opago 1142}. cod6
i: 10 is indicsrod.

Do the ECM ResetProcedur€(see


p a g e1 1 - 4 3 ) .

Turn the ignitionswitch ON.


Intermitl.nt tailu.o, sydom iB OK
at thir tims (tost ddvo may bo
noc6ssttyl.
ls the MIL on and do€s it
Chock for poor connoction! ol
indicatecod6 10?
loo!. wircr .t O+25, 9126llocll-
ed ot right .hock towor), CiOS
llAT sonsorl and ECM.
Turn the ignitionswitch OFF.

Disconnectthe 2P connectortrom
the iAT sensor.

Measureresistanc6between the
2 terminalson the IAT sensor,

ls there 0.4 -4.0 k0?

lro page 11-771

11 -7 6
(Frompag€ 1 1-76)

Turn the ignitionswitch ON.

Measurevoltage between RED/


YEL (+) terminal and body
ground.

Mgasure voltage betweon BED/


ls th6re approx. 5 V? YEL (+ ) terminaland GRNMHT
{- ) terminal.

Ropair opcn in GRN/


Turn the ignitionswitch OFF. WHT wlr6 botwoon
li there approx. 5 V?
ECM (D221 and IAT
lon301.

Connect the test hamess "D" Subrtitut. . known-good ECM


connectorto the EcM only, notto and rochock. ll lymptom/indica-
the main wire harness lsee page tioh goe! aw!y, r6pl.ce th. orlgl-
11-45). nel ECM.

Turn the ignitionswitch ON.

Measurevoltage between Dl5


{+} terminafand D22 l-)
terminal.

Ropairoponor lhort in REOrYEL


ls ther6 approx.5 V? wirebotweenECM{D15}.ndIAT
aona{tr.

Substilute a known-good ECM


and .ochock. lI symptom/indica-
tion go6s awsy, roplac6tha origi-
nal ECM,

11-77
PGM-FISystem
Flowchart- BarometricPressure(BARO)Sensor
Troubleshooting

lmil frrf: ThsMalluncrionIndicatorLamp{MlLlindicst€sDiagnosticTroubleCode(DTC)13: A problemin the


.(-- .+. B a r o m e t rPi cr e s s u r(eB A R OS) e n s o r .

The BAROSensoris builtinto the ECM.

-\ 13\-
/--i- -

- Tho MIL hsr boon r.ponod on.


- With sr|.ico chack connacto.
iumpcd l!.o p.06 I 142), cod€
13l! Indlcstod.

Do the ECM R€sotProc6dlre (se6


page 'l1-43).

Turn the ignitionswitch ON.

ls the MIL on and do6s it Int.rmltt.nt f.llut . lyltgm Ir OK


indicatecode 13? at thlr tlm. lt6!t drlv. mly b.
nacoar!ry1.

Subrtituto a known{ood ECM


.nd rcchock. lf symptom/indlc!-
tion goo! away, r6phca tha odol-
nsl ECM.

11^78
i - t
PGM-FISystem
TroubleshootingFlowchart - lgnition Output Signal

i151 :16: The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)15: A problemin the


: lgnitionOutput Signalcircuit.

H23Al ongine IUSA: Si/Caneda:SRl,


H22A1 ongino IUSA: Si VTEC/ Clnada
sR-v):
- Tho MIL ha5 beenroponod on.
- With sorvice chock connoctot
iumpod {!€€ p.g€ 1142), code
15 is indic.ted.

Do the ECM ResetProcedure(see


p a g e1 1 - 4 3 1 .

NOTE: lf the engino won't stari. it


mav take 20 seconds of cranking to
set the code.

lnt€rmittant failute. tYllam i! OK


.t this timo (t.!l drive may bo
nac6slary).
ls the MIL on and doos it Chcck for poot connactions or
indicatecode 15? looso wi.or ot C433 {locrtod at
.ight shock towet). Ct2S llgntdon
Conlrol Modulo llCMl) and ECM.

Turn the ignitionswitch OFF.

Turn the ignitionswitch ON.

Measure voltage betwegn YEL


(+ ) termin€land body ground.

YES
{ T o p a g e1 1 - 8 1 } (To page 1 1-81)

1 1 -8 0
Turn the igniitionswitch OFF.

Reconnectthe 2P connector.
ls the ignirioncoil OK?

Connectthe test harnessbetween


the ECMand connector(seepage - Repsii opon in YEL wiro bo-
11-45). twoon tho 2P oonngcto. and
ignition coil,
- Ropaii opon in BLK|'EL wi.o
botwoon tho ignition coil ond
Turn the ignition switch ON. ignition $witch.

Measurevoltage individually be-


t w e e nA 2 1 ( + ) , A 2 2 { + l t 6 r m i -
nals and A26 t-) terminal.

1OV? ---r
A 2 1{ + }
oooooooooooo
oooooooooooo
A 22l+t 426 l-l
t-J
1 0v ?

- Roolocs lho lCM.


- Repair opon oi lhon in YEL/
ls th6ro approx. 10 V?
GRN wir. botwo€n ICM lnd
ECM {A2l or A221.

NOTE:lf the YEL/GRNwire was shorted.


the ICM may be damag6d.
Substituto . known-good ECM
and roch.ck. lf symptom/lndic.-
tlon goos awsy, .oplacoth6 origi-
nal ECM.

11 - 8 1
PGM-FISystem
Flowchart- VehicleSpeedSensor(VSSI
Troubleshooting
-c+l - -
:'; r- The MaltunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCod€(DTC)17: A problemin the
I r'' l- vehicle speed sensor {vss) circuit.
--lKgll-

The VSS generatesa pulsingsignalwhen the front wheels turn.

- Th6 MIL has bo6n r€portodon.


- With sorvico ch6ck connoctor
iumped ls6opage I 142), cod€
'17 is indicatod.

Do the ECM Res€tProcedure(see


p a g e1 1 - 4 3 ) .

Road test necessary.


With manualtransmission in 2nd
gear (A/T: E position)accelerate
to 4,000 rpm, th€n decelerateto
1,5OO rpm with throttle tully
croseo.

Intormlttont lallurc, 3ystcm ls OK


at this tim€.
ls the MIL on and does it Chock tor Door connoctiona ol
indicatecode 17? loose wir6s at C433 {locrtod at
.ight shock tow6.). Cl15 {VSSI
and ECM,

Block rear wheels and set the


I parkingbrake.Jack up the front
oI the car and support with sale- @emr
rl ty stands. ro.l wheel beloro
jacking up front ot
cat,
Turn the ignitionswilch OFF.

Connectthetest harnessbetween
the ECM and connectors (see
p a g e1 1 - 4 5 ) .
o oooooo ooo ooo I oooooooo &ruffi ooooooooooo
ooooooooooooo I oooooooo EEwryl oooooooo ooo
Turn the ignitionswitch ON. A 2 6l - ) 8 1 0( + )
O - 1 2v
Block the right front wheel and ot O *5.o v?
slowly rotate left lront wheel and
measurevoltage between B1O
{ + } t e r m i n a la n d A 2 6 { - ) NOTE: Transmissionin @ position{A/T).
Iermrnat.

Does voltage pulse 0 V and


'12 V Turn the ignition switch OFF.
lH22A1 engine{USA: Si
VT€C/Canada: SR'V)5.0 V)?

Substituto a known-good ECM


( T o p a g e1 1 - 8 3 )
and rochock, lf symptom/indica-
tion gooaaway, roplacoth6 origi-
nal ECM.

11-82
(From page 1 'l-82)

Disconnoctthe B connector trom


the ECM only, not the main wire
harngss.

Turn the ignition switch ON.

Block the right front wheel and


slowly rotate left front wheel and
m€asurevoltage between 810
(+) terminaland A26 (-) - Reprir 3hort in ORN
tefmrnal. wi.e b6twoon ECM
(8101and tho VSS,
Tianlmission Con-
trol Modulc, spo6d-
Does voltage pulse O V 8nd omotor, 4WS con-
12 V lH22A1 engine (USA: trol unit, or cruiso
Si VTEC/Canada: SR-V):5.0 contrcl unit.
VI? - Ropoiropon in ORN
wire b6two6n ECl,
{8101and VSS.
- lf wlr€ i8 OK. tort th€
Sub.tituto r known{ood ECM VSS {!oo .oction
.nd r.ch.ck. lf lymptom/indica- 23t.
tion goar rway. roplace tho origi-
nal ECM.

11-83
PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad gs1s61q1(ELD)
- --r--' The MalfunctionIndicatorLamp(MlL)indicatesDiagnosticTroubleCode(DTC)20: A problemin the
tf I 20 l- EtectricalLoad Detector(ELD)circuit.

With sorvice chock connoctor


jumpcd (3oepago 1142), code
20 is indicatod.

Do the ECM Resetprocedure{see


page 1 1-43).

Start engineand keep enginerpm


at idle.
Turn on headlighls.
Intormitlgnl lalluro, system is OK
at this timo {to.t ddv€ m.Y bo
nocoa!4ry1.
Doesthe MIL indicatecode 20? Chock tor ooor connociion3 ot
looso wlr6s at C420 IELD) 8nd
ECM.
Turn the ignitionswilch OFF.

Remove the undeFhood tuse/


,i
relay box and remove the fuse/
relay box lower cover,

it
(+ }
SLKTYEL

Turn the ignitionswitch ON.

Measure voltage between BLK/


l nd BLK (-l
Y E L ( + ) t e r m i n aa
terminal. LOWERCOVER

Measure voltage between BLK/


YEL {+) terminal and body
ground.

Roplir opon In BLK rvk.


batwcan tha 3P con-
ls there battery vollage? n ctor and erc3 llocat-
cd undor middlo ol
dashl.

Ropairopon in BLK/YELwlto bo-


tweon ECU IECMI {'15Al fu3o {in
tho undor-dash tuso/rolay boxl
and lho 3P connector.

(To page 1 1-85)

11-84
{Frompsge 1 1-84}

Measure voltage between GRN/


8LK termin€l and body ground.

Rep.ir opon or short in GRN/BLK


rvi.€ brtwoon ECM lDlO) and tho
ls there 4.5- 5.0 V? 3P connoctoa.
It wiro is OK, aubstitut6a known-
good ECM and ..chock.

GRI{/BLK
I+ )

Turn the ignition switch OFF.

LOWERCOVER

Connectth6 t€st hsmossbetween


the ECM and conneclors (see
p a g e1 1 - 4 5 ) .

{To poge 1 1-86}

(cont'd)

11-85
PGM-FISystem
TroubleshootingFlowchart - ElectricalLoad Detectol (ELDI (cont'd)

Condition Voltage
Headlightswitch, first position (.) 1 . 5 - 3 . OV
Headlightswitch, second position( a) 1 . 0 - 2 . OV

Underthe conditions list€d in the


chart to the right, measure vol_
tage between D1O {+ } terminal
and A26 (- l terrninal.

Substituto a known{ood ECM


and recheck, ll symptom/indica-
tion goos away. 6phco tha otigi-
' nel ECM.
it

11-86
PGM-FISystem
Flowchan- KnockSensor(KSl [ExceptF22A1 engine(S]l-
Troubleshooting

t-7=.l- -r#-
-l .l l- The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)23: A problemin
_lltlllll- the Knock Sensor(KS) circuit.

-e-tm-
- Thc MlLhas boenroponed on.
- With !6wico chack connoctol
lump€d l..o pago I 1421, codo
23 is indicatod.

Do tho ECM Res€tProcedursls€e


p a g e1 1 - 4 3 ) .

Warm up the sngine to normsl


opgratingtempotature (tho radia-
tor lan comgs on).

Hold engine8t 3,OOo- 4,0OOrpm


tor 1Osecondswith manualtrans-
miesion in neutral {A/T: lll or lq
position).
Int.mittonl l.llur., sy.t.m b OK
at thir tim. (tod driv. maY bo
nocolaorYl.
ls the MIL on and does it Chack for poot conncctlon! ot
indicats code 23? loolq wlro3 al O+32 (loortrd rt
right shod( tow.r), Cl l2lKS) and
ECM,
Turn the ignition swirch OFF.

Connect the test harness to the


engine wire harneasonly, not to
the ECM (seepage 1 1-45), o3
t_
-
Continuity?

Ch6ck lor continuity between D3


t€rminal and body ground.

Rop6ir.hon in RED/BLUwite bc-


trY.en ECM lD3l snd th. KS.

(To page 11-89)

1 1-88
Check tor continuity on RED/BLU
wire betweenD3 terminaland2p
connectorof enginewhe harness. l-
Continuity?
Ropairopon in RED/BLUwiro bo-
twoon ECM lD3) and tho KS.

Warm up tho engineto normal


operatingtemperature{theradia,
tor fan comgs on).

Hold engineat 3,OOO-4,OOOrpm


lor 1Osgcondswith manualtrans-
missionin noutral (A,rf: @ or @
oosr!onl.

ls the MIL on and does it


indicatecode 23?

Subslituto a known-good ECM


and rsch6ck. lt symptom/indic!-
tion goos aw6y, .oplacothe origi-
nal ECM.

32 N.m 13.2ks-m.23 lb-ftl

11-89
PGM-FISystem
Flowchart- A/T Fl SignalA/B (A/T only)
Troubleshooting
---l-- The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)30: A problemin
-l 30 l-
tne A/T Fl Signsl A circuit between TransmissionControl Module {TCM) and ECM.

- - (MlLl indicatesDiagnosticTroubleCode {DTCI 31: A problemin


r;;--] The MaltunctionIndicatorLamp
I Jr l- the A/T Fl SignalB circuit between Transmissioncontrol Module {TCM) and ECM.

\.----_/\r---:-/
- l 3 0l - o , - l 3 l l
------ - ---j- \

With 3orvico chock connactor


jumpod, (ra. pagc 1142), codo
30 .nd/or 31 arc indicatod.

Do the ECMR6setProcedure{see
p a g e1 1 - 4 3 ) .

Test drive necessarv.


Drive th3 car for severalmiles so
that the transmissionupshiftsand
downshifts soveral times.

lhtdmittont failurs, gylt.m i. OK


l ai thir tlmo.
Does th€ MIL indicat€ code Chock for poot connoction! or
30 and/or 31? loo.. wiro. at C4ll (TCMI snd
I
I ECM,
r'l
Turn the ignition switch OFF.

Connect the test harnssg to the


msin h€rnessonly, nottothe ECM
'l1-45).
{see page

Disconnect the 22P connector


from rhe TCIV.
+
Conlinuity? Continuity
Check for continuity between 93
and/or 84' terminal and body
grouno. *r codo 31 {A/T Fl signal B)

RoDairrhort in ORN or Pf{Kr wilo


botw.€n ECM {B3 or B4r I .nd rh.
TCM.
NO
( T op a g e1 1 - 9 1 )

11-90
(Frompsge 11-9O)

Check lor continuity on ORN or


PNK'wire between 83 or 84*
and 22P connectorot rhe TCM.

Ropsiiopon in ORI{ or P{lK. wir6


botween ECM {8:} o?84. I and rhc
TCM.

Subltitute a known{ood ECM


and rochack. lt lymptorh/indica-
tion gogs rway, roplaca tha origi-
nal ECM.

11-91
ldle Control System
System TroubleshootingGuide

NOTE:
a Acrosseachrow in the chart,the sub-systemsthat couldbe sourcesof a symptomare rankedin the orderthey should
then refer
be inspected,startingwith @. Findthe symptomin the left column,read aclossto the most likelysource.
to ths page listed at the top ot that column. lf inspectionshows the system is OK' try the next system @' etc'
a lf the idle sDeedis out ot specificstionand the MalfunctionIndicatorLsmp (MlLl does not blink DiagnosticTrouble
Code {DTC) 14, go to inspection described on page 11-95.

IOLE ALIER, HOSES


PAGE STARTER ERAKE STEERING FAST IDLE STAFTING AND
ADJUST I D I E A I R coNDr- NATOs swtTcH swtTcH PFESSUNE THERMO
l s u s - s Y s T € M ING CONTROL
TIONING FR srGt'rALSIGNAL SIGNAL
CONNEC.
SCREW SIGNAL S I G N A I TIONS
-'\ -
SYMPTOM 100 102 l04 106 104 l09 110
ttl 96 98

TO START
DIFFICULT
ENGINEWHENCOLO
O
WHEI.{COLDFASI IDLEOUTOF
SPEC.(1,000- 2,000rpm) @ @ o
ROUGHIDLE @ o
WHENWARMRPiNTOOHIGH @ O @ @ @

load)
@ o
o
WHEN @ o
T00 Low
liomr in ON
@ \,

@ o
@ @ o
FREOUENT
WHII,EWARMING
UP @ o
STALLING
AFTERWARMING
o @
TEST
FAILSEMISSION O

11-92
System Description
The idle speed of the engine is contro ed by the ldte Air Control ACI Vatve.
The vElve chsnges th€ smount of air bypassing into the intake manifold in responseto
electric current contro ed by the
ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle
speed.

TO PGM.FI
MAIN RELAY

.,\ vARtous
\r- SENSORS

STARTITIG FAST
AIB VALVE IOLE
THERMO
VALVE

11-93
ldle Gontrol System
System Description(cont'd)

1. After the enginestarts,the IAC valveopensfor a certaintime. The amountof air is increasedto raisethe idle sp6€d
'l
about 50- 3OOrPm.

2. When the engine coolant temperatureis low, the IAC valve is openedto obtain the prope. fast idle speed. The amount
of bvoassedair is thus controlledin relationto the enginecoolanttemperature'

IDLE SPEEO
{rpml

104 140
& 60

11-94
l. When the idlespeedis out of specificationand the MalfunctionIndicatorLamp(MlL)does not blinkDiagnosticTrou-
ble Code lDTC) 14, check the following items:
. Adjust the idte speed (page I 1- l 1 I
)
. Air conditioningsignal (page 11-99)
. A L T F R s i g n a t{ p a g e1 1 - 1 0 0 )
. A/T gear positionsignat{page 11-1O21
. Starterswitch signal (p8ge 1j-1O41
. Brakeswitch signal(page 11-106)
. PSPswitch signat(page t 1-108)
. Fast idle thermo valve (page l.l_109)
. Starting air valve
. Hosesand connections
. IAC valve and its mountingO-fings

2. It the above items are normal,substitutea known-goodIAC valve and readiustthe idle speed
{page 11-l1l).
. lf the idle speed still cannot be adjustedto specification(and the MtL does not blink
code 14) sfter IAC valve
replacement,substitutea known-goodECM and recheck.ll symptom goes away, replscethe originalECM.

11-95
ldle Control System
TroubleshootingFlowchart - ldle Air Gontrol (lAC) Valve
-r---i
-tgll - - -;lr The MaltunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 14: A problemin
I l_ the ldte Air controt {tAc) vatve circuit.

The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in
order to maintainthe proper idle speed.
TO INTAKE FROM AIR
MANIFOLD CLEANER

VALVE SPRING

--t6t-
-
:Frl
l- ---r--

- Tho MIL has boen r6portodon.


- With sgrvico check connoctor
jumped ls€opago 1 1421, codo
l4 is indicatod.

Do the ECMResetProcedure(see
p a g e1 1 - 4 3 1 .

With lhe engine running and the


ls the MIL on and does it indi- accelerator pedal released, dis-
cale code 14? connect the 2P connector lrom
the IAC valve. Intormitlant lafluro, ay8-
tom is OK dt this timo
{to3t d.iving may bo
Remove the 2P connector ttom nocassa,yl.
the IAC valve. ls there a reduction Chock tor ooor connoc-
in enginerpm? tion or looso wiros at
c+25, C433 (locarod at
right ahock towoil.
C106 llAC valvo) and
Substhute a known-good IAC ECM.
valve and retost.

( T op a g e1 1 9 7 )

11-96
(Frompage 1 1-96)

Measure voltage between the


YEL/BLKwire 8nd body ground.

Rop6iropen in YEL/BLKwiro bo-


twoon ths IAC valvc.nd PGM-FI
main relay.

Turn the ignition switch ott and


reconnectthe 2P connectorto the
IAC valve.

Connect the test hamess "A"


connector to the main wire har-
ness only. not the ECM lsee page
11 - 4 5 ) .

Turn the ignition switch ON.

Mofientarily connect Ag terminal


to A26 terminsl several times.

Subrtitut . known{ood ECM


Doosthe IAC valve click? .nd r.to.t. lt rymptom/ktdicrtkrn
gooa away, raplaca tho original
ECM.

Ropairopon or .hort in BLX/aLU


wirc b.tw.on IAC v.lvo and ECM
(A9l . It tho wlr. i! OK, r6pl.co th6
IAC valv6.
ldle Control System
Troubleshooting Flowchart - Air Conditioning Signal

This signalsthe ECM when there is a demandfor coolingfrom the ai. conditioningsystem.

Connectthe test hatnessbetween


the ECM and connectors.
Disconnect"B" connectorfrom
the main wire harness only, not
the ECM (seepage 11-45)

Turn lhe ignitionswitch ON.

A26 t-t
Measurevoltage between 85 (+)
terminaland A26 (-) terminal.

Substituto a known-
good ECM and ]e fieck.
ls there approx. 5 V? It prssc bod voltago i3
now availablo, rapl6c6
th6 origln.l ECM.

Reconnect "8" connector to the


main wirc harness.

Clicklng?
Momentarily connect A15 ter-
minal to /q26 t€rminal several
times.

ls thsre a clicking nob€ ftom the Connecrrho RED/BLU torminrl ot


A/C comprc$or clulch? ihe 4P conneclor on tho A,/C
clutch rolty to body g.ound.

Vigw from wire harness side

S6a alr condltlonat in-


13thorc I clicking noiaetrom the
rpaetlon lrac toction
A/C comore6sor clutch ?
22t.

Ropairopen in RED/BLUwlr6 bo-


rwo.n ECM {A 15} rrd A/C drnc*l
relay.
{ T o p a g e1 1 - 9 9 }

11-98
r- Lo!! rhan 1.0 v? --------.1
(Fromp8g6 1 1-98)
I es t*t
| | ooooooo ooooo o looooc
I looooooooooooQ I ooooc
r----------------
I A26 t_l

Measure voltage between 85 (+)


terminaland A26 {-) terminal.

Ropairopen in BLU/BLK
ls voltagelessthan 1.O V? wiro botwoon ECM lB5l
Air conditioning iignal i3 OK. and A/C awitch.

Substituto a known-good ECM


and rodrock. ll proscribod voltago
is .row availoblo, rsplacg tho origi-
nal ECM.

11-99
ldle Control System
TroubleshootingFlowchart- Altelnator (ALT) FR Signal

This signalsthe ECM when the alternatoris charging.

Inspoction ol ALT FR sign.l.

Connectthe test harnessbetween


the ECM and connectors.
Oisconnect"D" connectorfrom
the main wire harnessonly, not
the ECM (see page 11-45).
4.5 V? -

Turn the ignirionswitch ON.

A26 t-l
Measure voltage between D9
(+) rerminal and 426 (-) ter-
mrnat,

Subltitut. a khown{ood ECM


ls thereapprox.4.5 V? and r..hock. lf pr.rcribed voltlgo
ir now availabl., rophce lh. ottgi-
nel ECM.

'l
Turn the ignitionswrtchOFF.

li Reconnect
"D"
connector to the
main wire harness.

Warm up engineto normaloPer


ating temperatu€ (the radiatortan
comes onl. Vohfo ?
D 9l + l

Measure voltage between Dg ooooooooooo


l+) terminal and A26 {-) ter- ooooooooooo
minal.

Does the vohage decreasewhen


heedlighls and rear d€fogggr 8re Turn the ignition switch OFF.
turnedon ?

Do the ECM ResetProcedure(see


p a g e11 - 4 3 ) .

ALT FR sign.l is OK.

(To page 'l 1-10'l)


(Frompage 1 1-1OO)

NOTE: The radio may have a coded theft protection


Disconnect"O" connectortrom
ECM only, not the main wire circuit. Be sure you get the customer'scode num-
harness. ber before disconnectingthe battery cable.

Disconnecl the negative banery


cable trom the battery.

Check tor continuity between D9


t€rmanaland body ground.

DisconnectGRNconnectorfrom
the ALT.

Check tor continuity between D9


t€rmin.l and body g.ound.

Check for continuity betwoon Dg


terminaland body ground.

Ropair3hon in WHT/REDwiro bo-


twoon ECM (Dgl snd ALT.

Ropoi.op€n in WHT/REDwiro b6-


two€n ECM lDgl and ALT.

11 - 1 0 1
ldle Control System
TroubleshootingFlowchart - AutomaticTransaxle(A/Tl Geat Position-
Signal(A/T only)
This signalsthe ECM when the automatictransmissionis in @ or@] position.

Tum the ignition switch ON.

Observethe A/T gear position in-


dicator and select gach Position
separately.

S6e A/T goar position indicatoi in-


Ooesrhs indicatorlight ProP€rlY? specdon (soction 141.

Turn the ignitiongwitch OFF.

Connectthe test harnessbetween


the ECM and connectors.
"B" connector trom
Disconnect
the main wire hamess only, not
the ECM (see page 11-451 5V?
87(+)

Turn the ignitionswilch ON.

A26 (-l
Measure voltage between 87
{+} terminal and A26 (-} ter-
minal.

Subltituto a known-good ECM


and rech.ck. ll prsc.ibod voltago
ls there approx. 5 V?
b now avriloblo, taplaco the origi-
nal ECM.

Turn the ignition 3wilch OFF.

Reconnect"8" connectorto the


main wire harness.

(To page 1 1-1031

11-102
( F r o mp a g e1 ' l - 1 0 2 )

L6s8 than 1.O V7 --.--


87 l+l
ooooooooooooo
oooooooooooo
A26 t-l

Measurevoltago botween 87 (+ )
terminal and A26 (-) tellninal
gith the trsnsmission in LNI and
lll position individually.

Ropair opon in LT GBN wir. be-


ls there lessthan 1.0 V? twoon ECM lB7) .nd gaug6 ae-
lombly.

12V7-

Measure voltage b€tween 87


{+l terminal and A26 (-) ter,
minal with the transmission in
gear.

Ropalr rhort ir| LT GRN wir6 b.-


ls ther€ approx. 12 V7 tw.cn ECM {87} and gaugo .r-
lombly.

A/T gear poritlon .lgn.l i. OK.

11-103
ldle Control System
Troubleshooting Flowchart -Starter Switch Signal

This signalsthe ECM when the engineis cranking.

BATTERY

ooooooooooooo
Connectthe test harnessbetween oooooooooooo
the ECM and connectors {see A26 (-t
p a g e1 1 - 4 5 )

NOTE:
a M/T: Cluich pedal must be
Measurevoltage between Bg (+) deoressed.
terminal and ,426 (-) terminal o Ait: Transmission in @] or @
when the ignitionswitch in the posltlon.
start posrton.

InsoectNo. 2 STARTER SIGNAL


ls there battery vollage ? (7.5 A) fus€ (in the und€r-dash
fusefielavboxl.

Rap.i. opon In BLU/REDwlr. b.-


tw.sn ECM (B9l rnd t{o. 2
STARTER SIGNAL17.5Al lur!'

Start€r switch signol i3 OK.


ldle Control System
TroubleshootingFlowchart - Brake Switch Signal

This signalsthe ECM when the brake pedal is depressed.

Inspoclion ol Brak6 Srvhdi Signal.

Are the brake lights on without Inapoct th6 br!k6 3wltch (!€o aoc-
depressingthe brake pedal? tion 19).

InspectSTOPHORN('l5 A) luse
Oo the brake lighB come on7 (in th€ under-hood Iuse/rel8y
boxl.

Connect the t6st harnoss to the - Roprir op.n In WHT^'EL wlrc


main wire harn€ssonlv, nottothe b.twoon bruks lwitch lnd
ECM (see page 11-45). STOP HOR[{ 115 A} tu!o.
- Inrpgcl tho b'r6ko rwltch l!o.
lection l9l.

( T op a g e1 1 - 1 0 7 1
( F r o mp a g e 1 1 - 1 0 6 )

02 t+l
MeasurevoltagebetweenD2 (+) I BAI-TERY
lerminal and A26 (-) terminal VOLTAGE?
with the brake oedal deDressed.

Roplir opon in GRII/WHT wlro be-


ls there bane.y voltage t twoon th. brakq lwltch rnd ECM
{D2t.

Br.k. .wilch lional i. OK.

11-107
ldle Control System
Troubleshooting
l ,uurEJl l ! ! t l , r l I I l g Flowchart
flt.,Yvvrrql I - Power
rvYYtEI Steering
r Pressure(PSP)Switch Signal
This signalsthe ECM when the power steeringload is high.

Inrp.clion ol PSP twltch Signal

ooooooooooooo oooooooo ooooooooooo


Connectthe t€st harnes6between oooooooooooo oooQoooo oooooooooo
the ECM and connectors (see
p a g e1 1 - 4 5 ) .

Tu.n tho ignilion swilch ON.

Moasurevoltage b€tween 88 {+}


torminsland A26 (-l terminsl.
Disconnectthe 2P connectorfrom
the PSPswitch.
ls rhere more than 1.0 V?

Tum rtaaring whool slowly. ls ther6 more than 1.0 V?

M66sure voltage betw66n BB (+) Repairopon in RED/GRNwir6 b6-


t6rminal and A26 {-} torminsl tw6on ECM (88) snd PSPswitch
whilo stggring wheel is turning. or BLK wir. bolwog.i PSP.wilch
a n dG l O l .

ls there battery voltage?

Disconnectthe 2P conneclorfrom
PSP 3wirch slgnal i! OK. the PSPswitch. swtTcH

Measurevoltage between 88 {+ )
terminaland 426 l- l terminal.

ls there battery voltage?

Rooairshon in RED/GRNwilo bo-


twoon ECM {88) and P1SP switch.
lI wire is OK, substituto a known-
good ECM and rochock. lf
proscdbodvoltege ir now availa-
bl6, roplace tho original ECM.

11-108
Fast ldle Thermo Valve
Description lnspection
To preventerraticrunningwhen the engineis warming H23A1 engino(USA: Si/Canada:SR),
up, it is necessaryto raisethe idls speed.The fast idle H22Al 6ngin€ (USA: Si VTEC/Canada:SR-V)
thermo valve is controlledby a thermowax plunger.
When the engineis cold, the enginecoolant surround- NOT€: The fast idle thermo valve is factory adiusted;
ing the thermowax contractsthe plungef,allowingad- it should not be disassembled.
ditionalair to be bypassedinto the intake manifoldso thst
the engineidlesfaster.When the enginereachesope.-
1. Removethe intakeair duct from the throttle bodv.
ating temperature,the valve closes.reducingthe amount
of air bypassinginto the manitold.
2. Stan the engine.

3. Put your finger over the lower port in throttle body


and makesurethat there is air flow with the engine
cold {engine coolant temperature below 860F,
300c).

FAST
IDLE
THERMO
VAIVE
thermo valve and

12 .m
(1.2 kg-m, 9 lb-ttl
4. Warm up the engine (the radiatorfan comes on).

Check that the valve is completelyclosed. lf not,


air suctioncan be telt at the lower gort in the throt-
tle body.
a lf any suclion is felt, the valve is leaking.Check
enginecoolantlevelandforair in the enginecool-
ing system (seesection 1O).
lf OK, reDlacethe tast idle thermo vslve and
recheck.

11-109
ldle Control System
Fast ldle Thermo Valve (cont'd) Starting Air Valve

F22A'l onginelS): Description


Whencrankingthe engine,the startingair valvesuppliss
NOTE: The tast idle thermo valve is factory adjusted; additionalair to the intake maniJoldto ease engine
it should not be disassembled. starting.

1. Removethe cover of the fast idle thermo valve.

2. Start the engine.

3. Put your fingeron the valveseat areaand makesure


thst ther€ is 8ir flow with the enginecold {engine
coolanttemperaturebelow 86oF, 30oCl and idling.

I DIAPHRAGM

iI
i
I
TO INTAKE
MANIFOLD
ADDITIONAL
AIR FROM
lf not, replacethe tast idle thermo valve and AIR CLEANER
retest. 't2 N.m
(1.2 ks-m.I lb-ttl

4. Warm up the engine (the radiatortan comes on).


radaatorfan

5. Checkthat the valveis completelyclosed.lf not, air


suction can be {elt in the valve seat area.
a It any suction is felt, the valve is leaking.
Checkenginecoolantleveland for air in the en-
gine coolingsystem (see section 'lO).
It OK, replacethe fast idle thermo valve and
recheck.

1 1 - 11 0
ldle Speed Setting

lnspect