I NT RO DUCT ION I

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 table of contents.The symbolsprintedat the top cornerof each page can also be used as a quick reference system. Each section includes: 1. A table of contents,or an explodedview index showing: a Partsdisassemblv sequence. a Bolt torquesand thread sizes. a Pagereterences descriptions text. to in 2. Disassembly/assembly procedures and tools. 3. Inspection. 4. Testing/troubleshooting. 5. Repair. 6. Adjustments.

Ge n e ra l n fo

Specifications
Maintenance Engine
Cooling

f,|tr
t ll=
It

SpecialInformation
tnai""tes a strong possibility ot sevoro p€rsonal injury @@ or losa of lite it instluctions ar€ not tollowed. CAUTION: Indicates a possibility of poBonal iniury ol oquipmont damage if instructions aro not tollowed. NOTE: Gives helpful information. CAUTfON: Detaifoddescriptionsol st ndard wo*shop procedures, satety p nciplesand servic€opalationsaro not includod.pleasonot6 that this manualcontainswamings and cautionsagainstsoms spocitic s€rvice methods which could cause PERSONAL lNJURy, d8mag6 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 HONDA invostigateallsuch ways. Anyono using sorvics proceduros 01toofs. whether or not rocommendedby HONDA,must satjslyhimsel, thoroughly that ngithor p€r3onal aatety nor vohicl€ s8fety will be jsopardized. All informationcontainedin this manualis basedon the latest Droduct info.mationavailable the time of printing.We reservethe right at to makechanges any time without notice.No part of this publicaat tion may be reproduced, storedin retrievalsystem.or transmitted, in any form by any means,electronic.mechanical, photocopying, recording, otherwise,without the prior written permission the or oJ publisher. This includestext, figures and tables.

ri!

Fueland Emissions ZZ *Transaxle

*Steering

If." r

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

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

-

L'___

I

As soctions with * includ6 SRS comDononrs. sp€cial piocautions aro roquirad whoit so.vicing.

* Electrical (lncluding

-

+

GeneralInformation
Chassis PaintCodes................. and 1-2 ldentification Number Locations ....... 1-4 Warning/Caution Labels.................. 1-s Lift and SupportPoints Lift ........... . . . . . . . . . . . . .1 .-.9 . F l o oJ a c k r . . . . . . . . . . . . . .1 - . 0 ..1 Safety tands 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 MultiF22A1; 2.2 / SOHC Sequential port Fuel-injectedengine H22A1t 2-2, DOHCVTEC Sequential engane Multiport Fuel-iniected MultiH23A1t 2.3, DOHC Sequential port Fu€l-injectedengine EmiesionGroup lOO: Califolniawith H22A1 engine 130: 49ST with H22A1 engine with H23A1 engine 2OO:California 23O: 49ST with H23A1 engine 920: Calilorniawith F22A1 engine 923: 49ST with F22A1 engine Serial Numbel

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

M2F41000001

M2F4: Manualwith H22A1 engine M2L5: Manualwith F22Al engine M2S4: Manual with H23A1 engine M2F4: l OOOOO1 Exceot M2F4: 20OOOO1

Vehicle ldentificationNumbel and FederalMotor Vehicle Safety Standard Certification'

Paint Code

COLOR B-64P

Fresco Blue Pearl Brittany Blue Metallic GranadaBlsck Peatl SeablingSilver Metallic Frost White Mirano Red

ir
i[ i

ii

CanadaModel
Vehicle ldentificationNumber
JHMBA814* C800001 P

J H M : H O N D AM O T O RC O . . L T D . HONDA, Passenger Ca. BA8: Prelude2.2 / B B 1 :P r e l u d2 . 2 . l E C e BB2: Ptelude 2.3 I Body and T.ansmission Type 1: 2-door s-sDeed Manual 2', 2-doot 4-speedAutomatic
Vehicle Glade 4: Prelude

F22A1: 2.2 / SOHC Sequential Multi port Fuef injected engine H22A'l:2.2 / DOHC VTEC Seouential Multiport Fuel-injected engine H23A1: 2.3 / DOHC Sequential Multipon Fuel-injected engine F22A1 engine; 928OOO1 H22A1 engine: l TOOOO lH23A1 engine: 27OOOO1

5: Prelude SR 6: Prelude 4WS SR 7: PreludeSR-V Check Digit Model Y6at P: 1993 C: SaitamaFactoryin Japan

M2F41000001
M2F4: Manual with H22A1 engine M2L5: Manualwith F22Al engine M2S4: Manual with H23A 1 engine

M2F4: l OOOOO l ExceptM2F4: 2OOOO01

Vehicle ldentificationNumbe] and CanadianMotor Vohicle Safety Standard Certification.

Paint Code

COLOR 8,64P

F esco Blue Pearl Brittany Blue Met8llic Granada Black Pearl SeablingSilverMetallic Frost White Mirano Red

1-3

NumberLocations ldentification
Vehicle ldentif ication Number

V.hicl€ ldontitication Numbo.

TransmissionNumber (Automaticl
t

'l i,
,l

Tiansmission Number lManual)

Warning/Caution LabelLocations

A: CABLE REELCAUTION A CAUTION: ISRSI BEFORE INSTA-I.IING CABLE REEL: . CENTERTHE FRONTWHEELS. . ALIGN THE MARKS. . READ SERVICEMANUAL. B: CABL€ REELCAUTION B

D: DRIVER MODULE WARI{|]{G A WARI{ING THEAIRBAG I'{FLATOR EXPLOSIVE IS AND,IF ACCIDEN. TALLYDEPLOYED, CAt{ SERIOUSLY HURTOF KILLYOU. . DOI{OI USEELECTRICAL TESTEOUIPMENT PNOBOR II{G DEVICES.THEY CAN CAUSE ACCIDENTAL DEPTOYI'EI{T. . NO SERVICEABLE PARTSINSIDE,DO OT DISAS. SEMBLE. . PLACE AIRBAG UPf,IGHT WHEI{BEMOVED. a Fou.ow sERvtcE MAI{UAL |]{STRUCT|O]{S CAREFULLY.
E: I FLATOR WARNING TAG A WARNING ACCIDENIAL AIRBAG DEPLOYMEI{I CA]T SERIOUSLY HURTOR KILLYOU. II{STALLTHE REDSERVICE CONNECIOB WHENTHE INFLATORHARITESS DISCONNECTED. IS F: STEERING WHEEL t{OllCE NOTICE IMPROPER STEERING VYHEEL REMOVAL OR II{STALLATION CAN DAMAGE SRS COMPOT{EI{TS. FOLLOWSERVICEMA UA! INSTRUCTION CAREFULLY.

cAUTtOt{:
NO SERVICEABLE PARTSINSIDE;DO NOT DISASSEMBLE OR TAMPER. C: DRIVERMODULE DANGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVYMETALSSUCH AS COPPER. LEAD OR MEFCURYMAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGE TEMPERATURES MUST I{OT EXCEED 2OO"F{1OOOCI. FORPROPER HANDLII{G,STORAGE AND DISPOSALPROCEDURES REFERTO SERVICEMANUAL, SRS SUPPI.EMENT. POTSON COI{TAINSPOISONOUS SODIUMAZIDEAND POTASSIUM NITRATE, FIRSTAIO IF CONTENTS ARESWALLOWED. 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

LabelLocations Warning/Caution
(cont'dl

F

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

G: SRSWARNING{ENGINE HOOOI SUPPLEMENTAL RESTRAIIIIT SYSTEM ISRS) THIS VEHICLE IS EOUIPPED WITH DRIVERAND FRONT SEAT PASSENGEB AIRBAGSAND FRONTSEAT BELTTEN. SIONERSYSTEMS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLOREO YELLOW. TAMPERING WITH, DISCONNECTING USINGELECTRIOR CAL TEST EOUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEMINOPERATIVE CAUSEACCIDENTALFIROR ING OF THE INFLATOR. A WARNING THE AIRBAG INFLATORIS EXPLOSIVE AND. IF ACCIDE . TALLY OEPLOYED. CAN SERIOUSLY HURTYOU. FOLLOW SERVICEMANUAL INSTRUCTIONS CAREFULLY. H: STEERING COLUMNCAUTION

K: DRIVER INFORMATION ISUNVISOB)

ALWAY WEARYOURSEATBELT
AIRBAG AS A CAR IS EOUIPPED WITH A DRIVER SUPPLEMENTAL RESTRAINTSYSTEM {SRSI. . IT IS OESIGNED SUPPLEMENT TO THE SEAT BELT. . BEFORE ORIVING READLABELINSIDE THEGLOVEBOX. 'K: DRIVER INFORMATION

ALWAY WEARYOURSEATBELT
CAR IS EOUIPPEO WITH A DBIVERAIRBAG AND A FRONT AIRBAGAS A SUPPIEMENSEAT PASSENGER TAL RESTRAINTSYSTEM ISRS). . IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. . BEFORE DRIVING REAOLABELINSIDE THEGLOVEBOX. L: GLOVEBOX INFORMATION DRIVER'SAIREAG INFORMATION . SUPPLEMENTAL RESTRAINT SYSTEMISRSICAN PROVIDE AOOITIONALPROTECTION FORTHE DRIVERIN A FRONTAL COLLISION. FUNCTIONAL A DESCRIPTION OF THE SRS IS IN YOUR OWNER'S MANUAL. . THE SYSTEMMUST BEINSPECTED TEN YEARSAFTER DATE OF MANUFACTURE, NOTEDON THE CERTIFIAS CATION PLATE. . ANY REPAIR, INSPECTION NEARBY OR ACCESSORY II{. STALLATIONSHOULD8E DONE BY AN AUTHORIzED HONDA DEALER. . IF YOUR SRS INDICATOR: . LIGHTSWHILE DRIVINGOR FLASHES; . FAILSTO LIGHTOR STAYS ON AFTERTHE IGNITION IS FIRSTTURNEDON: SEE YOUR AUTHORIZEDHONDA DEALER. 'L: GLOVEBOX INFORMATION DRIVER'S AND FRONTSEAT PASSENGER'S AIRBAG INFORMATION . SUPPLEMENTAL RESTRAINT SYSTEM{SRSICAN PRO. VIDEADDITIONALPROTECTION FORTHE DN|VER AND FRONTSEAT PASSENGER A FRONTALCOLLISION. IN A FUNCTIONAL DESCRIPTION THE SRS IS IN YOUR OF OWNER'S MANUAI.. . THE SYSTEMMUST BE INSPECTEO TENYEARSAFTER DATE OF MANUFACTURE, NOTEDON THE CERTIFIAS CATION PLATE. . ANY REPAIR, INSPECTION NEARBYACCESSORY OR INSTALLATIONSHOULD BE DONE BY AN AUTHORIZEO HONDA DEALER. . IF YOURSRS INDICATOR: . LIGHTS WHII-E DRIVINGOR FLASHES; . FAII.STO LIGHTOR STAYS ON AFTERTHE IGNITION rs FrRsTTUBNEDON; I . SEEYOUR AUTHORIZED HONDA OEALER. M: SRS UNIT CAUTION CAUTIONi . NO SERVICEABLE PARTS INSIOE. . DO NOT OISASSEMELE TAMPER. OR . DO NOT DROP. . STORE A CLEAN,DRY AREA, IN

CAUTION ISRS To AvotD DAMAGIIGrHE sRs CABLE REE|-. oB wHtcH COULDMAKETHESYSTEM INOPERATIVE, REMOVE THE STEERING WHEELB€FORE REMOVING THE STEERING SHAFTCONNECTOR BOLT.
l: FRONTSEAT PASSENGER AIRBAGMODULEDANGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALSSUCH AS COPPER, LEAD OR MERCURYMAY PRODUCE HARM. FUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.STORAGE TEMPERATURES MUST NOT EXCEED (lOOOC} 2OOOF FORPROPEB HANDLING, STORAGE ANO DISPOSAL PROCEDURES REFERTO SERVICEMANUAL, SRS SUPPLEMEI\'T. POISON CONTAINSPOISONOUS SOOIUMAZIDEAND POTASSIUM NITRATE. FIRSTAID IF CONTENTS ARESWALLOWED, INOUCE VOMITING.FOR EYE CONTACT, FLUSH EYES WITH WATER FOR T5 MINUTES. GASESIFROMACID OR WATERCONTACTI IF ABE INHALED, SEEK FRESHAIR. IN EVERY CASE, GET PROMPTMEDICAL ATTENTION. KEEPOUT OF REACHOF CHILDREI\'. A WARNING THE AIRBAG INFLATORIS EXPLOSIVE AND, IF ACCIDEN. TALLY DEPLOYED, CAN SEBIOUSLY HURT OR KILL YOU. . DO NOT USEELECTRICAL TEST€OUIPMENT PROBOR ING DEVICES. THEY CAN CAUSE ACCIDENTAL DEPLOYMENT. . NO SERVICEABLEPARTS INSIDE. DO NOT DISASSEMBLE. . PLACEAIRBAG UPRIGHTWHEN BEMOVED. . FOLLOW SERVICEMANUAI- INSTRUCTIONS CAREFULLY.

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

(cont'd)

1-7

LabelLocations Warning/Caution

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

;DZ"N

tl i-l atl

t:
RAOIATORCAP CAUTION

I

I
.

I

\..

1-8

Lift and Support Points
wnen heavy real components such as suspension, fuel tank. spare tile and trunk lid are to be removed, @Q plac€ additional weight in tha trunk betole hoisting. When substantial weight is removed trom the lear of th6 cal, the center of gravity may change and can causs the car to tip forward on tho hoist. NOTE: Sinceeach tire/wheelassemblyweighs approximately lbs { 14 kg), placingthe front wheels in the trunk can 30 assist with weight dist.ibution. 1. Placethe lift blocks as shown. 2. 3. Raisethe hoist a few inches (centimeters) and .ock the car to be sure it is firmly supponed. Raisethe hoist to tull height and inspect lift points for solid support.

DH
REARSUPPORT POINT

(cont'd)

1-9

Lift and SuPPortPoints
Floor Jack
Set the parkingbrakeand blockthe wheelsthat are not being lifted. When liJtingthe rear of the car, put the gearshift in lever in reverse{Automatictransmission @ position). Raisethe ca. high enoughto insertthe safety stands' Adjust and placethe satety standsas shown on page level,then low1-1 1 so the car will be approximately car onto them. er the

@ o Always uso sal€ty stands when wolking on or
undor any vehiclo that is supponed only by a jack. a N€ver att€mpt to use a bumpel iack for lifting ol supporting tho cat.

BEAM CENTER

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

PLATFORM

Centerthejacking bracketin the middle
ol the iack lift Platform

LIFT PLATFORM

1-10

Safety Stands

DH
FRONTSUPPORTPOINT SAFEW STANDS REARSUPPORTPOINT

1-11
j

Towing
towing ll the car needsto be towed. call a proJessional service.Nevertow the car behindanothercar with just a roDeor chain. lt is verY dangerous Emelgency Towing There are three popularmethodsof towing a car: loadsthe car on the Equipment- The operator Flat-bed This is the best way of transponingthe back ol a truck. car. Wheel Litt Equipmont - The tow truck uses two plvoring arms that go underthe tires {tront or rear)and lifts them otf the ground. The other two wheels remainon the ground. Sling-type Equipmont - The two truck uses metal cables with hooks on the ends. These hooks go around and the cableslift that Dartsof the trame or suspension and end of the car oft the ground.The car's suspension if damaged this methodof towing body can be seriously is attempted. by lf the car cannotbe transported flst-bed,it shouldbe towed with the front wheels off the ground. lf due to damage,the car must be towed with the front wheels on the ground, do the following: 5-spe6d Manual Tlansmission the Parkingbrake. a Release to a Shift the transmission Neutral. Tlansmission Automatic a Release the Parkingbrake. a Start the engine. a Shift to @ position,then @ position. a Turn off the engine. will damagethe lmpropertowing preparation NOTICE: procedure exactly.It you Followthe above transmission. or shift the transmission start the engine(autocannot your car must be transponedon a matic transmission), flat-bed.

TtEDOWIIHOOKS

HOOK TOWING

.-) t:

a lt is best to tow the car no farther than 50 miles (8okm),and keepthe speedbelow 35 mph (55 km/hl' will Tryingto lift or tow the car by the bumpers NOTICE: to are The bumpers not designed damage. serious cause suooortthe car's weight.

f 'l

\.

1-1 2

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

When replacing nuts and bolts, use only the same type. Tighten the nuts and bolts with I torqua wrench to providedin this manual. ths specifications

J.

Clean all thread ridges with a non wire type bristle brush. Foroignmatter in the threads may cause the bolt to loosen.

4 . S€ctions on this car requiringthe use of Dacro nuts
bv and bolts will be indicated 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 Service and Limits ...........3-2 Design Specifications ...................... 5 3-1 BodySpecifications ....... 3-18

Standardsand Service Limits
CytinderHead/ValveTrain {F22A1 engine} Section 6 I
Compression

TTaEASuREMENT
25O rpm and wide open throttle Nominal Minimum

J

sraruolnotruewt
1781 1.250 112.5, 9 5 0 { 9 . 5 ,1 3 5 ) 200 12.0.2al

I

umtr senvtce

psi) kPa{ks/cm2,
Cylind€rhead Camshaft

r49l'm!Il9!919!

Warpage Hoight End play oil Camshalt-to-holder clearance Total runout Cam lobe height Valve clearance Valve stem O.D. Stem-to-guide clearance

IN EX

IN

EX
IN

EX
IN

Valve seat

width Stem installed height

EX IN EX
IN

EX
lN

Valve spring

Freelength

EX
Valve guide

t.D. height Installed

IN EX IN EX

Bocksr arm

Arm-to-shaft clearance

IN EX

0.o5 (0.002) (3 99.95-100.05 .935-3.939) o.5 {0.02) 5 o.05-o.1 (0.002-0.006) (o.oo20-o.oo35) 0.15 (0.006) 0.o50-0.089 o.06 (0.002) max. 0.03 {0.0o1) ( 38.526 1.5168) 3a.77a11.52671 (0.o09-0.o1 1) o.23-0.28 ( 3 0 . 2 7 - 0 . 3 00 . 0 1 ' 0 . 0 1 ) ooss I oet ro.: 1 5 . 4 8 5 - 5 . 4 9 5 . 25 9 - 0 . 26 3 ) 10 1 5.4201o.21341 (0.2146-0.21 50) 5.450-5.460 0.08(o.oo3) {o.0008-o.oo20) 0.o20-0.045 o.1 (0.oo5) 2 ) 0.055,0.o80 {0.0022-o.oo3'l 2.0 {0.08) ( 0 . 0 4 9 - 0 . 0) 1 6 1.25-1.55 2.0 10.08) ) 1 . 2 5 - 1 . 5( O . 0 4 9 - 0 . 0 6 1 5 48.965 1.92781 79) t 15 48.245-48.7 (1.8994-1.91 ( ( 5 5 0 . 3 1 - 5 0 . 7 8 51 . 9 8 0 9 - 1 , 9 9 9 4 ) 5 1 . 0 3 5 2 . 0 0 9 2 1 5 4 . 8 11 2 . 1 5 8 ) 54.82(2.r 58) 2 5 6 . 2 6{ 2 . 2 1 5 ) 56.2A12.21612 5 . 5 3( 0 . 2 1 8 ) 1 7 5,5.53010.217-0.217 | 5.51 5 . 5 3{ 0 . 2 1 8 1 1 5-5.5301o.211-O.21771 5.51 (O.91 5-0.954) 23.75-24.25 2) 15.05-'5.55 {O.593-0.61 1 7-o.050 o.o1 l0.oo07'o.oo20) 0.08 (0.003)

(0.ooo7-o.0021 ) 8-0.054 o.o1

o.08 {o.oo3)

''l: CHUO HATSUJOmanulactured valve sprrng. '2: NIHONHATSUJOmanulactllred valve spring

I

Cylinder Head/ValveTrain (H23A1 enginel - Section 6
MEASUREMENT
Compression 250 rpm and wide open throttle kPa lkg/cm2, psi) Nominal Minimum Maximumvaiation

Unit of tength:mm (in)

srAr{DARD tt{Ewl
1,250 112.5, 1181 9 5 0 { 9 , 5 ,1 3 5 } 200 12.o,2al
( 1 1 3 1 . 9 5 - 1 3 2 . 0 55 . 1 9 5 , 5 . 9 9 )

I

stnvtce urirr

Cylinderhead Camshatt

Warpage Heighr End play Camshaft-to-holder clearance oil Total runout Cam lobe height Valve clearance Valve stem O.D. Stem to-guide clearance

0.o5{0.oo2)

IN

EX
IN EX IN EX IN EX IN EX IN EX lN EX
IN

Valve seat

Widrh Stem anstalled height

I .l

0.05 0.15 (0.oo2-o.006) o.5 {0.02} *1 (o.0020-o.oo35) o.050-0.089 o . 1 5{ 0 . 0 0 6 ) . 1 0. 100,o. 39 (o.0039-0.0055)*2 0.20 (o.oo8)*, 1 0 . O 3( 0 . O 0 1 1a x . m 0.06 (0.oo2l 33.661 1.3252} { 3 3. 72 5 t 1. 3 2 7 ) 8 o.07-0.1 (0.003-0.004) 1 o . 15 - 0 . 1 9 0 . o o 6 . 0 0 7 ) 0 t -0.2594) (O.2591 6.580-6.590 6 . 5 5( O . 2 5 8 ) (O.2579-0.2583) 6.550-6.560 6.32 t0.257l -0.002) (o.oo1 o.o2-o.05 0.08 {o.oo3) (o.oo2-0.o031 0.o5-o.08 0 . 1 1( O . O O 4 ) 6 1 . 2 5 - 1 . 5 ( 0 . 0 4 9 - 0 . 0) 1 5 2.0 (o.081 (0 1 . 2 5 - ' 1 . 5 5 . 0 4 9 , O . 0)6 1 2.0 (0.081 3 9 . 3 6 5 - 3 9 . 8 3'5 . 5 4 9 8 - 1 . 5 6 8 3 )4 0 . 0 8 5{ 1 . 5 7 8 1 ) t 1 1 3 9 .19 5 , 3 9 . 6 3 ( 1 . 5 4 3-1 . 5 6 0 4 t 3 9 . 8 8 5 1 . 5 7 0 3 ) 5 {
4 7 . 1 41 1 . 8 5 6 1 47.r4 (1.856)

Valvo spring Valve guide

Freelength

t.D.
Installed height

EX
IN

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

(O.260-0.261 6.61-6.63 I ( 6 6 . 6 1 , 6 . 6 30 . 2 6 0 - 0 . 2) 1 13.25-1 5 1O.522-0.541 3.7 | 0 1 13 . 75 - 1 . 2 5( O . 5 4-1 . 5 6 ) 4

6.70 to.264l 6.70 {0.264)

{cont'd)

3-3

Standardsand Service Limits
MEASUREMENT Compression 250 rpm and wide open throttle kPa (kg/cm2,psi)

)n 6 CylinderHead/ValveTrain (H22A1 engine) Sectit
tNEwl STANDARD
1 , 3 0 O( 1 3 . 0 ,1 8 5 ) 950 {9.5, 135) 200 (2.o, 28)

I

sERvlcELlMlr

Nominal Minimum Maximum varlatron

Cvlinderhead Camshaft

Warpage Heisht End play oil Camshalt-to_holder clearance Total runout lN Cam lobe height EX

o.o5{0.002}
0.5(0.02) 5 o.o5-o.1{O.OO2-0.006} (o.o020-o.oo35) o . 1 5 ( 0 . 0 0 6 ) o.050-0.o89 1 { 141.95 42.05 5.589-5.593)

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

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

widrh height Steminstalled

m 0 . 0 3( O . 0 0|1 a x 34.04' 1 {1.3402) ( 36.856 1.4510) 34.971 r.3768} { 33.745 1.3285) { ( 36.323 1.43001 ( 34.683 1.3655) 9 0.15-O.1 (0.006-0.oo7) o.17 0.21 (O.OO7-O.OO8| 59) 56'0.21 1O.2' l 5.475-5.485 (0.21 59) 56-0.21 5.475-5.485 (0.001 0-0.oo22) o.025-0.055 ) {0.0020-0.0031 o.o5o-0.080 ( 0 . 0 4 9 - 0 . 0) 1 6 1.25-1.55 1 . 2 5 - 1 . 5( 0 . 0 4 9 - 0 . 0)6 1 5 (1.4750-' |.4935) 37.465-37.935 8 5 3 7 .16 5 - 3 7 . 6 3 ( 1 . 4 6 3 2 - 1 . 47 )1
' 4 5 . 1 6( 1 . 7 7 8 ) r 4 5 . 7 6 ( 1 . 8 0 2 )' 2 4 1 . 7 8 { 1 . 6 4 5 ') 1 .6441 '2 41 .75 11 ( 1 . 8 3 9 )- r 46.72 '2 46.74 11.8401 3 9 . 3 2 ( 1 . 5 4 8 )* r '2 39.28 (1.546) 69-0.217 7 | 5.51o-5.530 1O.21 ( 8 7 5.535-5.5550.21 9'0.21 7) 3 12 . 5 5 - 1 . O 5 ( O . 4 9 4 - 0 . 5 1 4 1 4) 12.55-13.O5 (O.494-0.51

0.06 {o.oo2)

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

i.oou to.z'tool

2.0 10.079) 2.0 t0.079) ( 38.185 1.5033) 3 7 . 8 8 51 . 4 9 1 5 } {

Valve spring

Freelength

lN

Outer lnner

EX

Outer tnner

Valve guide

t.D. height Installed

IN EX
IN

EX
IN EX

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

Rockerarm

Arm-to-shaft clearance

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

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

, 2 | NIHONHATSUJOmanufactured valve spring'

valve spr'ng' CHUOHATSUJOmanufactured

ii

ii

3-4

_]]

EngineBlock
Cylinder block

Section
MEASUREMENT STANDARD{NEW} I

Unit of length:mm linl SERVICE LIMIT

-']

Warpageof deck surtace Bore diameterF22A1 engine H23Al, H22A1engines Bore taper Reboring limit F22A1 engine H23A1, H22A1 engines Skirt O.D.*1 F22At engine No Letter (A) Letter B H2341, H22A1 enginesNo Letter {A} Letter B Cfoarancein cylinder F22A1 engine H 2 3 4 ' 1 , 2 2 A 1e n g i n e s H Groovewidth F22A1 engine Top {for ring} Second oil H 2 3 A 1 ,H 2 2 At e n g i n e s T o p Second oil Ring-to-groove clearance Top Second Ring end gap F22Al engine Top Second oil H 2 3 A 1 ,H 2 2 A 1 e n g i n e s T o p Second oil

Piston

Pistonring

0.07 10.003) max. 0 . 1 01 0 . 0 0 4 1 ( 85.01 85.020 3.3468,3.3472) 0 8 5 . 0 71 3 . 3 4 9 ) (3 85.000,85.010.3465 .3468) 3 87.O'f 0-87.020 4256-3.4260) \3. 87.O7t3.4281 87.OOO 87.01013.4252 3.42561 0.o5 (0.002) 0 . 5 0( 0 . 0 2 0 ) 0 . 2 51 0 . 0 1 0 ) ( 8 4 . 9 8 0 - 8 4 . 9 93 . 3 4 5 7 - 3 . 3 4 6 1 8 4 . 9 7 0 3 . 3 4 5 3 ) {0 ) 8 4 . 9 7 0 4 . 9 8 0 3 . 3 4 5 3 . 3 4 5 7 ) 84.960(3.3449) 8 3 { 86.990-87.003 424A-3.42531 87.980(3.4638) 13. 86.980-86.993 42491 87.97013.4634) 13.4244-3. (0.ooo8,0.001 0.020-0.o40 6) 0 . 0 5{ 0 . 0 0 2 ) (0.0003-0.001 o.007-0.030 2) o . 0 4{ o . 0 0 2 ) 1.220-1. 230 {O.0480 0.0484) 1 . 2 5( 0 . 0 4 9 ) 1.220-1. {O.0480,0.0484) 230 1 . 2 5( 0 . 0 4 9 ) (O.1 2.405-2.420 104-0.1 101 1 2 . 8 5( 0 . 1 2 ) 1 '1.2301.245{0.0484-0.0490t 1 . 2 6 5{ 0 . 0 4 9 8 ) 1.2301.245t0.0484-O.0490) 1 . 2 6 5{ 0 . 0 4 9 8 ) (0. 2.405-2.820 1104-0. 110) 1 2 . 8 5t O . 1 1 2 l (o.001 0.035-0.060 4-0.0024) 0 . 1 3( 0 . o o 5 ) 0.030-0.055 2-o.oo22l to.oo1 0 . 1 3( 0 . 0 0 5 ) (0.008-0.01 0.20-o.35 4) 0.60 {0.024) 0.40-o.ss(0.o1 6-0.022) 0,70 {0.028) (0.0080.028) 0.20-0.70 o . 8 0( 0 . 0 3 1 ) o . 2 5 - 0 . 3{ 0 . 0 1 - o . 0 1 4 ) 5 0 o.60 (0.024) (o.0240.o30) 0.60,0.75 0 . 9 0( 0 . 0 3 5 ) *2 0.20-o.50 {0.008-0.o20) 0.60 10.024) *3 (0.oo8-0.0281 0.20-0.70 0 , 8 0( o . 0 3 1 )

Piston Pin

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

Connecting rod

Crankshaft

( 2 1 . 9 6 8 - 2 1 . 9 8 10 . 8 6 4 9 - O . 8 6 5 4 ) 5 1 . 0{ 2 . O 1 ) o. 15-0.30 (0.006-0.01 2) 0 0 . 1 2 ( 0 . O 0 5 ) / 1 0m a x . ( 4 9 . 9 7 6 - 5 0 . 0 0 01 . 9 6 7 6 - 1 . 9 6 8 5 ) 4 9 . 9 7 24 9 . 9 9 6 ( 1 . 9 6 7 4 , 1 . 9 6 8 3 1 ( 4 9 . 9 8 4 - 5 0 . 0 0 81 . 9 6 7 9 - 1 . 9 6 8 8 ) 4 9 . 9 8 8 - 5 0 . 02 ( 1 . 9 6 8 0 - 1 . 9 6 9 0 ) 1 4 7 . 9 7 6 4 9 . 0 0 0 { 1 . 8 8 8 81 . 8 8 9 8 ) 0.005 (0.0002) max. 0.OO5(O.0002)max. o.10,o.35 (0.oo4,0.01 4l O.03 {0.OOl max. )

(0.8659-0.866 21.994-22.OOO 1) o.o1 2-0.o24 {o.0005-o.ooo9} 0.01 2-0.026 to.0005-0.0o10) (o.ooo5-o.001 0.o1 3-o.o32 3l

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

0.006 (0.0002) 0.006 {0.0002) 0 . 4 5{ O . 0 1 8 ) o.04 {o.002) 0.050 (0.0020) 0.055 (0.0022) 0.050 {0.0020) 0 . 0 4 0{ o . 0 0 1 6 ) 0.055 (0.oo22) 0.060 (0.o024t

Eearings

-0.045(o.0008 0.021 0.001 8) (0.0o10-0.001 0.025-0.049 9) 0.013-0.037(0.ooo5-o.001 5) (0.0004,0.001 0.009-0.033 3) -0.049{o.0008-0.oo20) 0.021 'l (o.001 -0.oo22) 0.027-0.055

'1: Measured 2l.O mm (O.83inl on F22A1 at engineand 15.0 mm (0.59 in) on H23A1. H22A1 enginesborh from bottom o{ skirt. '2: TEIKOKU PISTON pisronring. RINGmanufactured '3: RIKENmanufactured piston ring.

3-5

Standardsand Service Limits
Engine Block - Section 7 (cont'd)
MEASUREMENT
Balancershatl Journaldiameter No. 1 iournal(lront) No. 1 journal(rear) No. 2 journals No. 3 iournals Front Rear

STANOARD INEW}

I

LIMIT SERVICE

Journaltaper End play

shalt Balancer beanng

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

(1.6820'1.68241 4 2 . 7 ' l{ 1 , 6 8 9 } 22-42.734 42.7 {O.8243-0.8248) 20.92 Q.A24l 20.938-20.950 -1.52461 3 8 . 7 0( 1 . 5 2 4 ) 24 3A.712-3A.7 11.5241 22-34.7 (1.3670-1.3675) 3 4 . 7 1{ 1 . 3 6 7 ) 34 34.7 0.005 (0.0002) 0. 10,0.35(O.OO4-0.O14) 1 o.06-0. 8 to.002-0.o07) o.os ro.oot t 0 . 0 2( o . o o 1 ) o.09{o.oo4) o.050-0.075 to.oo20-0.0030) 0 . 1 2( O . 0 0 5 ) 18 0.066-0.1 (0.0026-0.0046) 0 . 1 3{ 0 . 0 0 5 ) i o.o76-0 2a {o.oo30-0.0050) 42.AOO-42.820 {1.6850-1.6958) 4 2 . 8 3( 1 . 6 8 6 ) 2 1 . 0 0 0 -1 . 0 1 { 0 . 8 2 6 8 - 0 . 8 2 7 3 ) 21.O2@.A2Al 2 3 ( 6-1.52431 3 8 . S 3 1 . 5 2 9 ) 11.527 38.800-38.820 ( (1.3701-1.3709) 3 4 . 8 3 1 . 3 7 1 ) 34.8OO-34.82O

EngineLubrication- Section 8
MEASUREMENT
Engineoil Capacity (US qt, Imp qt) t F22A1 engine H23A1 engine H22A 1 engine Oil p'rmp ? Displacement IUS qt, lmp qtl/min @rpm lnner-toouter rotor radialclearance Pump body-toouter rotor radialclearance axialclearance Pump body-to-rotor 176oF (80oC) Pressure settingat oil termperature at idle kPa (kg/cm2,psi) at 3,0OOrpm

(IIEW} STAI{DARD

I

SERVICE LIMIT

4.9 {5.2, 4.3} for engineoverhaul lilte. 3.8 14.0,3.3) for oil change,including 5.4 (5,7, 4.81 for engineov€rhaul lilter 4.0 (4.2, 3.5) lor oil change,including 5.9 (6.2, 5.2) for engineoverhaul filter 4.A $i, 4.21 tor oil ch€nge,including 73.5 177.7,64.7) @6,000

-o.006) 1 o.02-0. 6 10.001 9 0.10,0.1 (0.004-0.007) -0.003) (o.oo1 o.02-0.07
70 {0.7, 1O}min. 350 (3.5, 50) min.

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

valve Flelief

Cooling - Section
Radiator

o
MEASUREMENT (NEW} STAI{OARD
M/T: 7.1 (7.5, 6.2) for overhaul 3.5 (3.7, 3.1) for coolantchange .4, AlTt 7.O 17 6.2) tor ovorhaul 3.4 (3.6, 3.0) for coolantchange MlTt 7.4 17.9,6.5) for overhaul 3.8 (4.0, 3.3) for coolantchange .7 All: 7.3 17 , 6.4) lor overhaul 3.7 (3.9, 3.3) lor coolantchange M/T: 7.8 (8.2, 6.9) Ior overhaul 4.2 14.4,3.7) for coolantchange F22A1 engine

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

H23A1 engine

H22A1 engine

I! Ir I i
,l
't I

i;

Badiatorcap Thermostat

ReservoircapacitY kPa {kg/cm2,Psi) Openingpressure Start to open F u l l yo p e n Valve lifi at Iully open Displacement f {US qt. lmp qt)hin @rpm oF {oc) 'F {oC)

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

, 9 5 - 1 2 5( 0 . 9 5 - 1 . 2 51 3 . 5 ' 1 7 . 8 ) 169-177 {76-80) 194 (90) 8 . O 1 O . 3 1m i n . )

Waler pump

Radialorfan

F22A1 engine H23Al engine H22A1 engine F 2 2 A 1 ,H 2 3 A 1 e n g i n e s E C Ts w i t c h" O N " H22A I engine temperature ECT switch "OFF" tempetatureoF (oC)

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

Fuel and Emission- Section 1 1
MEASUREMENT
Fuel pump Pressureregulator Displacement {US oz, lmp oz} in 10 seconds cc Pressure with regulator vacuumhose dtsconnected k P a{ k g / c m 2p s i } F 2 2 A 1 ,H 2 3 A 1 e n g i n e s , H22A1 engine Capacity{ {US gal, lmp gal) Fast idle rpm ldle speedrpm ldle CO % with headlightand cooling fan ott 205 (6.93, 7 .221 tnin.

Unil ol lengthi mm (in STANDARD(NEW)

Fuel tank Engine

255-305(2.55,3.05, 36-43) 230-280{2.3-2.8. 33-40) 60 (15.9, 3.2) 1 1,400 700 150 (M/T:neurral) 7OO150 {A/T:E o. E position)
0.1 max.

Clutch
Clutch pedal

Section 1 2
MEASUREMENT Pedal height Stroke Pedalplay Disengagement height Clutch surlacerunout Rivet head depth Surface runout Thickness Pressureplate warpage ro ttoor to floor

Flywheel Clutch disc

-]']

Clutch cover

STANDARD INEWI 2 0 8( 8 . 1 1 ) 5 1 3 5 - 1 4(5 . 3 1 - 5 . 7 1 ) ( 1 . 0 - 7 . 00 . O 4 - O . 2 8 ) 9 4 { 3 . 7 0m i n . ) 0.05 {O.002} max. 'l.3 (0.O51) min. O.8(0.03)max. ( 8 . 4 - 9 . 1O . 3 3 1 - 0 . 3 s 8 ) 0 . 0 3( O . 0 0 1 1 a x . m

I

SERVICE LIMIT

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

Manual Transmission
Transmissionoil Mainshaft

Section 1 3
MEASUREMENT STANDARo {NEw}
1 . 9 1 2 . O 1 . 7 1 f o ro i l c h a n g e , 2.O 12.1, 1.Al tor overhaul

I

sERvIcELIMIT

Capacity (uS qt, lmp qt) t End play Diameter ot ball bearing contact area Diameter third gear contact ar€a of Diameter ol ball bearing contact area Runout LD. End play Thickness

Mainshatt3rd and fourth gears

3rd gear M2L5, M2S4 M2F4 4th gear M2L5, M2S4 M2F4

Mainshaltsth gear

t.D. Endplay Thickness
End play Oiameter needlebearingcontact area of Diameter ball bearingand needlebearing of conlact area Diameter low gear contact area ot Runout

Adjustwith a shim. 27.94 11.1001 3 7 . 9 3( 1 . 4 9 3 ) 2 7 . 9 4( 1 . 1 0 0 ) 0.o5 (0.0021 1. 4 3 . O O 9 - 4 3 . 0(2 5 6 9 3 3 , 1 . 6 9 3 9 ) 4 3 . 0 8 0 1 . 6 9 6 1 ) { 0.06,0.21(0.0024,O.0083) o . 3 0( 0 . o 1 2 ) 3 2 . 4 2 - 3 4 7 t l . 2 7 -1 . 2 7 l 2. 6 8 3 2 . 3( 1 . 2 7 2 1 34.92-34.97 5-1.3771 11.37 3 4 . 81 1 . 3 7 0 1 1 3 0 . 9 2 - 3 0 . 91 1 . 2 1-7 . 2 1 9 1 7 3 0 . 8( 1 . 2 1 3 ) 31.42-31.47 11.237-1.2391 3 1 . 3{ 1 . 2 3 2 ) 4 3 . 0 0 9 3 . 0 2 5 1 . 6 9 3 3 -. 6 9 3 9 } 4 3 . 0 8 0( 1 . 6 9 6 1 ) 4 1 { (o.0024,0.oo83) 0.06-0.21 0 . 3 0{ 0 . 0 1 2 } 1 1 3 0 . 9 2 - 3 0 . 91 1 . 2 1-7 . 2 9 l 7 3 0 . 8( 1 . 2 1 3 )
0.05,0.40 (0.0019-0.0157) 1 3 8 . O O O - 3 8 . 5 { 1 . 4 9 6 '-1 . 4 9 6 7 ) O1 (O.9837-0.9845) 24.947-25.OOO 39. 984-40.OOO 42-1.574al 11.57 O.02 {O.0OO8) max. 4 6 . 0 0 9 - 4 6 . 0 2 51 . 8 1 4 - 1 . 8 1 0 } 1 { 2 0.04,0.10 (o.002 0.oo4)

0. 10-0.16 {0.0039-0.0063) 2 7 . 9 7 7 2 7 . 9 9 0( 1 .1 0 15 1 .10 2 0 ) 3 7 . 9 8 4 - 3 8 . O O1 1 . 4 9 5 41 . 4 9 6 1 O ) (1 2 7 . 9 8 7 2 8 . O O O .10 18 - 1 .1 0 2 4 ) 0.02 (0.0008) max.

Countershaft

o . 5 0{ o . 0 2 )

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

_]]]

24.94lO.982l 3 9 . 9 3{ 1 . 5 7 2 } o.05 (o.oo2)
46.08 (1.8't4) Adiust with a washer. 47.08 ('t.854) Adjust with a collar. 2 8 . 8( 1 . 1 3 )

Countershalt lsl gear Countershatt 2nd gea(

l

t.D. Endplay LD. Endplay Thickness

4 7. O O 9 - 4O 2 5 1 . 8 5 0 7 . 8 5 1 4 ) .7 ( 1 o.04-0. {0.002-o.004) 10 t 2 8 . 9 22 a . 9 7( 1 . '3 9 , 1 . 1 4 1 )

(cont'd)

3-7

Standardsand Service Limits
Manual Transmission- Section 13 (cont d l
MEASUREMENT Spacercollar lCountershaft 2nd gear) Spacecollar (Mainshaft 4th and 5th gear) idlergear Reverse Syncro ring Dual cone nng sYncnro STANOARD INEW) I SERVICELIMIT

LD. o.D.
Length LD.

B -Jo a-

o.D.
Length

la

B

LD. gearshalt clearance reverse Gear-lo
(ringpushedagainst gear clearance Ring-to gearl (ringpushedagainstgear) Clearance Outer synchroring to_gear Innersynchroring-togear Outersynchroring-tosynchrocone M215, M2S4 Fingerthickness M2F4 Forkto syncrosleeveclearance
ri'w, srouvc w,uu, Pawl groove width A Fork'to reverse idle gear clearance I

3 6 . 5 0( 1 . 4 3 7 1 36.48-36.49 {1.4362-1.4366) 1 ( 4 1 . 9 8 9 - 4 2 . O { 1 . 6 5 3-1 . 6 5 3 5 ) 4 1 . 9 4 1 . 6 5 2 ) 00 (1. 4 . 2 9 . O 2 - 2 9 . O 4 1 2 5 - 11 4 3 3 ) -29.09(' |.144-1.45) 1 29.O7 3 1 . 0 0 2 - 3 1 . 2 1 1 . 2 2 0 5 - 1 . 2 2 0 9 ) 3 1 . 0 6( 1. 2 2 3 ) 0( ) 3 7 . 9 8 9 - 3 8 . O ( 1O 9 5 6 - 1 . 4 9 6 1 3 7 . 9 4( 1 . 4 9 4 ) O .4 56.45,56.55 12.222-2.2261 (1.0248-1.0268) 26-03-26.08 (0.7880-0.7891 20.09(o.7909| l 20.o1 6-20.O43 0.160 to.ooo6l 4-0.00331 0.036-0.084 {o.oo1 o.85-1.10 (0.034-0.043) (0.037-0.066) 0.95-1.68 (0.02-0.04) o.5-1.O (0.02-O.041 o.5-1.O 6.2,6.41O.244-0.2521 ( 7.4,7.6O.291-0.299) 4-0.026) o.35-0.65 t0.01 1 3 . 0 - 1 3 .( 0 . 5 1 - 0 . 5 2 ) 3 ( 0.5-1.10.02-0.431 a-O.25541 7.O5-7.2510.27 .301 .7 .29-O 7.4-7 tO o.o5-0.35 10.002-o.o14) 0.4,o.8{o.02-0.03) 6.000 {O.6289-0.6299) 15.973-1 o.005,0.059 to.ooo2-o.oo23) 2) 12.9-1 (0.508-0.51 3.O 0.2-o.5to.ol -o.02l
1-0.3' I 5) 7.9,8.O (O.31 o.o5 0.25 10.002-o.o10) 15 . 4 1 -15 . 6 8 ( 0 . 6 0 7 - 0 . 6 1 7 ) 3-0.0040) 0.032-o.102 (0.OO1 15.941-15.968 {0.6276-0.62871 1 0.027-0.139 (O.001 -O.OO55)

0 . 4 0{ o . o 1 6 l 0.6 (0.024) o . 3( 0 . o 1 1 0 . 3( 0 . 0 1 )
1 . O( 0 . 0 3 9 )

Shift fork

Reverseshitt fork

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

Groove width Fork-to-tifth/ reverseshift shalt clearance Shift arm B

atA atB atA atB

LD. clearance Shift arm-to-shaft Shift tork diameterat contact area lork t Shift-arm-ro-shaft shaf clearance Pin sizeof contact area Selectleverto-shitt peice clearance Shaft outer diameler Shift arm cover clearance

Selectlever

o.5 (0.o20)

Shift arm lever lntedock

o.D.
housingclearance Tlansmission Eorediameter Shitt arm lever clearance

6.O510.630'0.632) 16.00-1 3-o.oo43) 1 0.032-0.09 (0.001

I

{r

I

Automatic Transmission- Section 14
MEASUREMENT
Transmission tluid Capacityf (US qt, lmp qt) STANDARD {NEWI 6.0 (6.3, 5.3) Ior overhaul 2 A 1 2 . 5 ,2 . 1 1 t o rl l u i d c h a n g e

Unit of length mm (in) SERVICELIMIT

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

8 0 0 t 8 . 0 ,1 1 4 1 throftleIully-closed I 8 5 0 ( 8 . 5 ,1 2 1 ) lhrottle morethan3/16 open
530 (5.3, 75) throttle fully,closed 850 (8.5.'121) throttle more than 3/16 open

7 3 O1 1 . 5 1 O 7 l , throttle morethan3/16 open
480 (4.8, 68) throttte lully-closed

4th clutch oressure 2.000 rom at in @ position

I

750 17.5,1071 throttle morethan3/16 open
450 (4.5, 64) throttle fully-closed 750 (7.5,107) throttle more than 3/16 open

I

3rd and 2nd clutch pressure 2,000 rpm at posrtion in E

5 0 0{ 5 . 0 , 7 1 ) throttleIullv-closed 8 5 0 ( 8 . 5 ,1 2 1 ) throttlo morethan3/16 open

I

I

2nd clutch pressure 2,OOO at rpm in Lzl position 1st and 1st-holdclutch pressure at 2.000 rpm in LLI position Throttle B pressure Hydraulic pressure (H23A1 engine) kPa {kg/cm2, pst, Throttle fully closed Throttle fully open Line pressure 2.000 rom at in E or E]position

( 8 0 0 - 8 5 0 8 . 0 - 8 . 5 .1 4 - 1 2 1 1 1 800-850{8.0-8.5, 14-121} 1

7 5 0 1 7 . 51 O 7 l , 750 17.5,1071
7 5 0 1 7 . 5 ,1 0 7 )

0 (0.o) 8 0 0 - 8 5t0 . 0 - 8 . 51 4 - 1 2 1 1 1. 8
8 5 0 ( 8 . 5 ,1 2 1 ) thro le tully-closed 900 (9.o, 129) throttlemorethan 3/16 open 5 3 0( 5 . 3 , 7 5 ) throttle fully-closed 900 (9.o, 128) throttle morethan3/16 open

I

8O0(8.0. t 14l throttlemorothan 3/16 open
48O (4.8, 68) throtte tully-closed 800 (8.0,114) throttle more than 3/16 open 450 {4.5, 64) rhrottle fully-closed

4rd clutch pressureat 2.OOOrDm in @ positron

I

I

3rd and 2nd clutch pressure 2,0OOrpm at position in E

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

900 (9.o, 128) throttle morethan3/16 open
2nll_glutch pressrue at 2,OOOrpm in L2l position 1st and 1st-holddutch pressure at 2,000 rpm in Lll posirion Throttle I pressure Throttle fully closed Throtttefully open Stalf speed rpm F22A1 engine {Checkwith car on level ground) H23A1 engine 8 5 0 , 9 0 0 1 8 . 5 - 9 . O .2 1 - 1 8 ) 1 2

I

8 0 0 { 8 . 0 ,1 1 4 } throttle morethan3/16 open
800 {8.0,114} 800 {8.0,114)

I

850-900{8.5-9.0, 21-128) 1

o (o,o)

850-900(8.5-9.0, 21-128) 1 2,350-2,650 2,600-2,900

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

{cont'd)

3-9

Standardsand Service Limits
Automatic TransmissionClutch

Section 14 (cont'd)
(I{EW) STANDARD -0.039} 0.80-1.00 {0.031 0.65-0.85 {0.026'0.033} 0.4-o.6{o.016-0.024) 33.511.32) 1.88-2.00 lO.O74-O.079) (O.077-O.O81 ) 1.95-2.O5 2.55-2.65(O.089-0.093) (0.077-0.081 | 1.95-2.O5 (O.089-0.0931 2.25-2.35 -O.083) 10 2.05-2. (O.081 2.15-2.20(O.085-0.O87) (0.089-0.091) 2.25-2.30 (0.093-0.094) 2.35-2.40 50 2.45-2. t0.096-0.O98) (O. 2.55-2.60 100-0.102) 106) 2.65-2.70 {0.104-0. 2 . 7 5 - 2 . 8 1 0 . 1 0 8 -11 0 1 0 o. (O. 1 2.85-2.90 112-O.14) (1.0630-1. 1638) 27.OOO-27.O21 4221 3 11.1 29.OOO-29.O1 417-1.1 0.03-0.05 {o.oo1-0.oo2l 041 o.21 0-0.265l0.OO83-0.01 0.070-0.125 {0.OO28-O.00491 84.5525) 14.01 F14.034(0.551 3.990 (0.55040.55081 13.980,1 (o.232-0.236) 5.90,6.00 \ t LIMIT SERVICE

MEASUREMENT Clutch initialclearance lst-hold 1st, 2nd 3rd' 4th Clutchreturnspringfree length 1sr, 2nd, 3rd' 4th Clutch disc thickness Clutch plate thickness 1st, 1st'hold 2nd, F22A1 engine H234 1 engine 3rd,4th Mark l Clutch end plate thickness Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Mark 8 Mark I Stator shah needlebearingcontact l.D Torque converter side Oil pump side Oil pump gear side clearance Drive clearance Oil pump gear-to-body Diven Oil pump drivengear I.D. Oil pump shatt O.D. Reverseshitt lork finger thickness Parkingbrakeratchet Pawl Parkingbrakegear Throttle cam stopper height Shitt fork shaft bore l.D. Shift lork shatt valve bore l.DSealingring contact LD. Sealingring contact l.D. Sealingring contact l.D. Diameter ot needle bearing contact area On mainshaft of stator shaft On mainshaftot 3rd gear collar gear On mainshalt oI 4th'tst collar gear collar of On countershatt On countershaft of 4th gear of On countershaft Parkinggear of On countershaft reversegeat shaft ot 1st gear On secondary On secondary shaft ol 2nd gear On reverseidler gear shaft lnsidediameter Mainshaft3rd gear Mainshaft4th gear Counte.shaftlst gear Countershaft 4th gear reversegear Countershaft idler gear Countershaft shatt lst gear Secondary shaft 2nd gear Secondary idlergear shaft holder Reverse

g s1. tr.zat

Untilgroovesworn out. Discolorataon
Discoloration Discoloration

t V

t I
I

Discoloration wear ol damage

I

Valve body

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

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

5 . 4 0( O . 2 1 3 1 Wearor otherd€fect

17.O-17.1 {O.669-0,673) 6l 2-O.551 4.010(0.551 r 4.00G1 t 37.OOO-37.039 {1.4567-1.4582) 3 7 . 0 4 5 1 . 4 5 8 5 ) (1.3780-1.3789) 3 5 . 0 5( 1 . 3 7 9 9 ) 35.OOO-35.025
3 32.OOG32.O1 {1.2598-1.2604)

( 32.050 1.26181 ( 29.050 1.14371

-1 29.0OG29.013.1417 .14221 l'l

Wear or damage 22.9A4-23.@O (0.9049-O:90551 04-1.8110) 45.984-46.000(1.81 11.2592'1.2598) 31.984-32.OOO (1.6135-1.6142) 40.984-41.OOO .2595) 31.975'31.991 (' |.2589-1 42-1.57 4a'l 39.984-40.000 11.57 (' 73) 35.979-36.OOO1.4165'1.41 3 1 . 9 7 5 - 3 1 . 9 9( 1 . 2 5 8 9 - 1 . 2 5 9 5 ) 1 1 3 ' t . 9 7 5 - 3 1 . 9 9(1 . 2 5 8 9 - 1 . 2 5 9 5 ) 2) 4.000 {0.5508-0.551 13.990-1 2"2.O4aOl 9 52.OOO-52.O1 12.O47 (1.4963-1.4969) 38.OOs-38.021 1.851 0) 6 {1.850447.OOO-47.O1 6 38.000-38.O1 (1.4961-1.4967) 6 (1.6535-1.6542) 42.OOO-42.O1 6 48.000-48.01 {1.8898'1.8904) 6 37.00G37.01 (1.4567'' 1.4573) 6 37.000,37.o1 {1.4567'1.4573} 5676-0.5683) 14.41 6-1.434 (O.

i :

ii

f 'ji
:t

It
I

Wear or damage

Automati c Transmission- Section 14
MEASUREMENT
Transmission {cont'd) Mainshaft3rd gear collarlengrh Mainshaft4th gear collarlength Countershatt gear collar length 1st Thrust washerthickness Countershaft gear 1st Countershaft idler gear parkinggear length Countershalt Secondary shaft 1st gear distancecollar length Secondary shaft 2nd gear thrust washer thickness Secondary shaft 2nd gear splinewasher thickness STANDARD {NEWI

Unlt ot l€ngthi mm (in) SERI /ICE LIMIT Wear or damage wear or damage Wear or damage Weor or damage Wear or damage Wear or damage Wear or damage Wear or damage

1 9 . 5 01 9 . 5 ( 0 . 7 6 8 - 0 . 7 7 0 ) - s 4 7 . 5 0 - 4.7 5 l t . 8 1 0 - 1 . 8 7 2 ) 5 1 2 7 . 5 0 - 2 7 . 5(5 . 0 8 3 - 1 . 0 8 5 ) 1 . 4 5 - 1 . 5( 0 . 0 5 7 , O . 0 5 9 ) 0 (0.1 3.45-3.55 36-0. 140) (0.98544.9861 25.030-25.048 l 4.95-5.00 195-0. 97) 1 {O. 4.35-4.45 tO.t 7 13-O. 7 521 1
4.O2-4.05(O.1 58-0.159) 4.07-4.'t0 (0.160-0.161 ) 4 . 12 - 4 . 1 ( 0 . 1 6 2 - 0 . 1 6 3 ) 5 4. 17-4.20 (0.164-0.165) 4.22-4.25 tO.1 66-0.167) 4.27,4.30 {O. 68-0.169) 1 4.32-4.35 lO.17 0-O.1 1| 7 4.37 -4.40 lO.1 2-O. 73l 7 1 4.42-4.45 tO.1 4-O.1 5l 7 7

MEASUREMEI{T
Spring Regul€tor valvespringA F22A1 engine H23A1engine Regulator valve springB Stator reaction spring Torqueconve er check valve spring Reliofvalve spring Coolerreliefvalve spring 2nd orificecontrol valve spring Oriticecontrol valve spring Servo control valve spring 4th exhaust valve spring Throttlevalve B adjusting sprang Throttlevalve B spring 1-2 shilt valve spring 2-3l3-4 shift valve spring 1st-holdaccumulator spring lst accumulator spring 4th accumulator spring 2nd accumulator spring 3rd accumulator spring Lock-up shitt valve spring Lock-uptirningvalve spring CPC valve spring Modulatorvalve spring Lock-up control valve spring 3rd kick-downvalve spring 3-2 kick down valve spring

STANDARDINEWI
Wir6 Dia.

o.D.

Frco Longth

No, ot Collr
to.5

1 . 8( O . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) '1.8 0.071) ( 4.5 lO.177l 1. 1 ( O . 0 4 3 ) 1 . 0{ 0 . 0 3 9 ) 1 . 1( 0 . 0 4 3 ) 0.6 10.o24) 0.8(0.031) 1 . 0( 0 . 0 3 9 ) 0.9 (0.035) o.8 (0.o31) 1 . 4( 0 . 0 5 5 ) 1 . 41 0 . 0 5 5 1 1 . 4( O . O 5 5 ) 1 . 0( 0 . 0 3 9 ) o.9 (0.035) 4.0(0.157) 1 . 81 0 . 0 7 1 ) 2 . 9{ 0 . 1 1 4 t 3.3{0.130) 2.6t0.102) 0.910.035) 0.8{0.031) 'l.4 {o.055) 1 . 4( 0 . 0 s 5 ) 0.7 (0.028) 1. 1 ( 0 . 0 4 3 ) 1 . 2t O . O 4 1 l

1 4 . 7( 0 . 5 7 9 ) 86.5 (3.406) 14.1 lO.579l 88.6 (3.488) 9.6(0.378t 44.Ot1.732t 3 5 . 4( 1 . 3 9 4 ) 3 0 . 3t 1 . 1 9 3 1 1 8 . 4 ( 0 . 3 3I 3 6 . 4( 1 . 4 3 3 ) 8.4(0.331) 3 9 . 1( 1 . 5 3 9 1 8.4 t0.331) 4 6 . 8( 1 . 8 4 3 ) 6.6 (O.2601 58.3 (2.295) 6.6 (O.2601 52.5 t2.O61l 8.1{0.319) 52.6 (2.O711 7.1(0.280' 6 0 . 8( 2 . 3 9 4 1 6.2 lo.244l s 0 . 0{ 1 . 1 8 1 } 8.5lO.335l 4 1 . 5{ 1 . 6 3 4 ) 8.5{0.335t 4 1 . 5{ 1 . 6 3 4 ) 8 . 5 ( O . 3 3 5 ) 4 1 . 6( 1 . 6 3 8 1 8.6 tO.339) 4 1 . 3{ 1. 6 2 6 ) 7 . 6t O . 2 9 9 t 57.Ot2.2441 2 5 . 0( 0 . 9 8 4 ) 64.7 12,547) 1 6 . 3( 0 . 6 4 2 t 11 5 . 4( 4 . 5 4 3 ) 22.0 {0.866) 9 0 . 1( 3 . 5 4 7 ) 22.0 (0.866) 8 4 . 9( 3 . 3 4 3 ) 1 7 . 5( 0 . 6 8 9 ) 1 0 4 . 5 4 . 1 1 4 ) 1 7.6 tO.229l 73.7 t2.9021 6.6 {0.260} 5 1 . 11 2 . 0 1 2 ) 9.4{0.370) 3 3 . 0( 1 . 2 9 9 ) ( 9.4 (0.370) 33.O 1.2991 6.6 (0.260) 3 8 . 01 1 . 4 9 6 ) 7 . 6 1 0 . 2 9 9 ) 4 8 . 3( 1 . 9 0 2 ) 7 . 1{ 0 . 2 8 0 ) 4 6 . 9( ' t . 8 4 6 )

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

3-11

Standardsand Service Limits
Differential (Manualtransmission)
MEASUREMENT
Final driven geal Dillerontial carriet Backlash Pinionshaft contact area l.D. Carrier-to-pinionclearance Driveshatt contact aroa LD. Carrisr-to-driveshaftclearance

Section 1 5
STANDARD INEW} I SERVICELIMIT

Right Left

Dillerential

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

Taperroller preload bearing

1 0.085-o.42 {O.OO33-0.0056) '1 8.000,1 8 {0.7087-0.7094} 8.01 9l 0.013-0.047(0.0005-o.oo1 28.005-28.025 1. {' 1026-1.10331 (0.001 0-o.oo26l 0.025-o.066 0.o55-0.091 {o.oo22-o.oo36l 5 o.05-0.'t to.o02-0.0061 ' l 3) 18.042-18.066 tO.7103-0.71 (0.oo22-o.0037) 0.055-o.095 1.4-2.6( 4-26, 12-231

o.20(o.o08l 0.10{o.oo4t 0 . 1 2t o . o o s t 5 0.1 (0.006I
AdjLrstwith a shim o.15 {0.006) Adjust with a shim

Differential (Automatic tlansmission)
MEASUREMENT Finaldriv€ng€ar Dlflerential carnef Escklash Pinionshaft contact area l.D. Caftier-to-pinionclearance Driveshaft contact area l.D. CarrieFto-driveahaftclearanace

Section 1 5
(NEW} STANDARO
SERVICELIMIT

I
F

1 o.o85-o.42 {O.0033-0.0056) 18.000-1 8 t0.7087-0.7094) 8.01 9} 0 . 1 0( 0 . 0 0 4 ) o.o17-o.o47 {0.0007-0.oo1 1 2 8 . 0 O 5 - 2 8 . 0{2 5 0 2 6 - 1 . 1 0 3 3 ) 1. o . 1 2( 0 . 0 0 5 ) 0-o.oo26) 0.025-0.066 to.oo1

0.20(o.oo8)

Differcntial

Taperroller bearim preload

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

Adjust with a shim 1 0.05,0.5 (o.oo2-o.oo6t (O.7103-0.71 13) 18.042,18.066 (o.oo23-o.oo37) o.12 (O.OO5) 0.059-o.o95

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

Adjust with I thim

Ste6ring
St€sring whsel

Section1 7
MEASUREMEl{T
Play at steering wheel circumterence Starting load at stoering wheel circuml€ronce N {kg, lbsl Engine running When the hydraulic system to the power steerang soeed sensor is cut ofl Angle ot rack-guide-screwloosengd trom locked position Pump pressure with valve closed (oil temp./spoed: 1O5"F {4OoCl min./idle. Do not run for more than 5 s€conds}. kPa {kg/cm2, psi} Recommend€dfluid Fluid capacity System Reservoir , (US qt. lmp qt) 'lOON (1o kg, 22 lbs) betweenpulleys Deflection with

STAI{DARD INEW}

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

Gearbox

Pump
Power steering lluid Power st€gring belt'

(70-80, 995-1, 38t 1 7.O00-8,OOO fluid-V Hondapowersteoring 1 . 7 { 1 . 8 0 ,1 . 5 0 1 0.5 {o.53,0.441

!i

t

li
i
!

with used belt 13.5-16.5 10.53-0.65) with new belt 9.5-11,5 {0.37-0.451 350-5OO{35-50. 77-1101with used bslt Belt tension N (kg, lbsl (7O-9O,154-198) with new b€lt 7OO-9OO Mgasured with belt tension gauge * When using a nsw belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readiust deflsction or tension to used belt values.

Suspension Section18
MEASUREMEIIT
Wheel argnment {2WS) Front Rear Caster Front Total toe Front Rear Front whe€l turning angle Inward wheel Outward wheel Carhber Front Bear Caster Front Total toe Front Rear Whgel turning angl€ Inward whoel Front Rear Outward wheel Front Rear Rim runout {Aluminumwhe€l} Axial Radial Rim runout (Steel wheell Axial Radial End play Front Camber

Unit of lengthmm {in

(NEWI STANDARO
-o" 45' 1 ' to 20 40' !10 0 r 2.0 (o !0.081 rN 2.0 ! 2.0 t0.08 10.08) 360 20' 12. 290 40'

SERVICELIMIT

o" oo' r 10

alrgnment {4WS}

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

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

Wheel bearinq

Rear

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

Brakes
Parking brake lever F""r braL pedal M*t"|. "y["d* Oisc brake

Section
MEASUREMENT Playin strokeat 2OON (20 kg, 44lbsl lev€rforce Pedal height (with floor mat removod)

(NEWI STANDARD
To be locked when pulled 6-10 notches 1 6 5 { 6 . 5 }m i n . 1 8 6 { 7 . 3 )m i n . 1-5(1/16-13/64)

SEFVICELIMIT

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

M/T Atf

o-o.4(o-0.02) 0 - 0 . 2o , o . 0 1 ) t
23.O(0.09) 1 0 . 0( 0 . 3 9 ) ( 21.O 0.83) 8.0(0.31t 0,10 {o.004) o.10 (o.oo4) 0.015 (0.ooo6t 1 . 6( 0 . 0 6 ) 1 . 6( 0 . 0 6 ) 1 . 6( 0 . 0 6 )

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

3-13

Standardsand Service Limits
Air Conditioning
Section 22
MEASUREMENT
Air conditioning Lubricant capacity cc (ll oz) system Condenser Evaporator Line or hose R€servoir

STANDARD {NEW) 10(1/3) 30(1) 10 {r/3) 10(1/3) ( 1 3 0 - 1 5 04 1 / 3 - 5 ) 3.05-3.35 (0.014-0.026) 0.35-0.65 with usedbelt 10.0-12.0 {0.39-0.471 4.5-7.0{0.18-O.28} with new b€lt

Compressor

Comprgasor belt'

Lubricant capacity cc {tl oz} Et Fieldcoil resistance 68oF {2OoC)0 plate clearance Pulley-to-pressure Dollectionwith lOO N (10 kg, 22 lbs) between pulleys

450-600 (45-60, 99-132) with used bslt Belt tsnsion N (kg. lbs) 950'1.150 (95'115, 209-254) with new bslt M€asured with belt tension gauge . Wh* u"ing I new belt, adjust dellection or tension to now values. Run tho engine lor 5 minutes thsn turn it o{f R€Ediustd€flgction or tension to used belt values

Electlical - Section 23
MEASUREMENT
lgnitioncoil Rated voltage V Primarywinding resistanc€8t 68 oF (2OoC)o S€coodarvwinding resistanceat 68 oF (20ocl kO

STAI{DARD INEW) 12 0.6-0.8
S6e Sgction 23 1 . 0 - 1 . 1{ 0 . 3 9 - 0 . 4 3 )

Spark Plug lgnitiontiming Alternator belt'

Type Gap
At idling BTOC (10 kg, 22 lbs) with 1OON Defloction between pulleys Belt tension N (kg, lbsl Mgasured with belt t€nsion gauge o

STDC 1 5 ol 2 o { R e d ) 10.5-1 2.5 (0.42-0.51 with used belt ) with new b€lt 8.O-10.0 {0.32-O.4Ol 3OO-45O{30-45, 66-99} with usod belt 550-750 {55-75, 121-165) with new belt SERVICE LIMIT STANDARD {NEW) 80/90 2 . 7- 3 . 1 t r.e to.sot 1 4 . 2 - 1 4 .{ 0 . 5 6 - 0 . 5 7 } 4 1 . 5t 0 . 0 6 ) 1 0 . 5( O . 4 1 ) 300-360t10.6-12.7) magn€t Permanent Spargearreduction, 5 0.1 t0.oo6) 0.4-0.5(0.016-0.o20) o.o5(0.oo2) o-0.02{o-0.ooo8) 2 7 . 5( 1 . 0 8 3 ) 2 8 . 0 - 2 8 .( 1 . 1 0 2 , 1 . 1 0 6 ) 1 (0.62-O.64t 10.0(0.39) 15.8-16.2 1 6 . 0 , 1 8 .( 1 . 6 0 - 1 . 8 0 , 0 3.53-3.93) magnet Permanent Spargearreduction, 0 . 1 5( 0 . 0 0 6 ) 0.4-0.5(o.0'16-0.o20l 0.o5 t0.o02) o-o.02{o-o.ooo8) 2 7 . 5{ 1 . 0 8 3 ) 2 8 . 0 - 2 8 .( 1 . 1 0 2 - 1 . 1 0 6 ) 1 ( 10.0 (0.39) 15 . 8 - 1 6 . 20 . 6 2 - 0 . 6 4 ) 1 6 . 0 - 1 8 .( 1 . 6 0 - 1 . 8 0 , O 3.53-3.93)

MEASUREMENT
Output 13.5 V at hot A Alternator (NIPPONDENSOCoil r€sistance (rotor) O SIip ring O.D. Erush l€ngth g {oz) Brush spring t€nsion Tvpo motor Starter (MITSUBA Mica depth Commutator runout 1.4 kW) CommutatorO,O. Brush length N (kg, lbsl Brush spring t6naion (new) Starter motor (MITSUBA 1.6 kW) Tvpe Mic8 depth Commutator runout CommutatorO.D. Brush length Brushspringtensionln€w)

ii
:1 !I
I

il

N lkg, lbs)

* 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.

Design Specifications
Overall Length Ov€.all Width OverallHeight Wheelbase Track F/R GroundClearance 4,440mm 1 , 7 6 5m m 1 , 2 9 0m m I I | 1 7 4 . 8j n 69.5 in 5 O . 8i n 6 0 . 0 / 5 9 . 6j n 5.7 in

2 . 5 5 0m m
1,525/1,515 m m 145 mm

I
i |

t O O . qn i

Type

F22A1 engine H23A1 engine H224l engine

l

l
l
TRANSMISSION

Cylinder A.rangement Bore and F22A1 engine Stroke H23A1 engine H22A 1 enigne OisplacementF22A1 engine H23A1 €ngine H22A'l engine Compression F22A1 engine Ratio H23A1 engine H22At engine Valve Train F22A1 engine H2341 engine H22A'l engine Lubrication System Fu€l Required F22A1 engine H23A1, H22A1 engines Makes/Type Normal Output NominalVoltage Hour Rating Direction Rotation of

Water-cooled, 4,srroke SOHC gasoline engjne Water-cooled, 4-stroke DOHC gasoline engine Water-cooled, 4-stroke DOHC VTECgasolineengine Inline4-cyljnder, transverse 8 5 . 0 x 9 5 . Om m 3 . 3 5x 3 . 7 4 i n 8 7 . 0 x 9 5 . Om m 3 . 4 2x 3 . 7 4 i n 8 7 . Ox 9 0 . 7 m m 3.43 x 3 57 in 2 , 15 6 c m 3 ( c c ) 132cu-in 2,259 cm3 {cc) 138 cu-in 2,157cm3 (cc) 132 cu-in 8.8 : 1 9.8:1 1 0 . 0: 1 Belt driven,SOHC4-vatveper cytinder Belt driven.DOHC4-valveper cytinder Belt drive,DOHC4,valveper cylinderVTEC Forcedand wet sump, trochoidpump gradegasolinewith 86 pump UNLEADED OctaneNumberor higher PremiumUNLEADED gradogasoline with 91 Pump OctaneNumberor MITSUBA/Spur gear reduction, permanent magnet 1.4 kW, 1.6 kW 12V 30 seconds Counterclockwise viewedfrom gearend as

3 . 7k s

|

8 . 2l b s

MIT M/T

Singleplatesdry, diaphragm spring Torque converter 203 cm2 31 | 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
TRANSMISSION {conl'dl Automatic GearRatio Engine tYPe lst 2nd 3rd 4th 5rh Reverse Gear tYPe Gear ratio METRIC F2241 ENGLISTI H23A1

NOTES

2.705 1.442 1.028 o.701 2.O47

2.705 1.057 0.750 2.O47

Final Rsduction AIR CONDITIONING

Cooling Capacity Conditions: compressor Speed Outsid€ Air Temparature Outeide Air HumidilY Cond€nserAir TemPerature CondenserAir VelocitY Blower Capacity Typg/M€kes Compressor No. oI cylinder CaPacitY Max. Sp€sd Lubric8nt CaPacitY Condenser Evaporator Elower TyPe Type Type Motor Input Speod Control Max. CaPacity Type Power ConsumPtion Type Ouantity

Singl€helicalgear 4.428 4.285 | '14,682BTU/h 3,7O0Kcauh

1 , 8 0 ( rpm 50 %

81 0F

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

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

sP-10

Temp. Control Comp, Clutch Rotrigerant STEERNG SYSTEM

osO-8os

1

t8.a-9.ao oz

Type Ovorgll R€tio Turns, Lock-to-Lock Steedng Whosl Di6. Type. Front Type, Rsar Shock Absorber, Front and R€ar

SUSPENSION

Power as8isted, rack and Pinion 2 W S : 1 5 . 8 6 , 4 W S :1 5 . 1 2wS: 2.91, 4WSt 2'77 15.0 in 380 mm I wishbone, lndependent double coil spring with stabilizer lndeDendentdouble wishbone, coil spring with stabilizer Tolescopic, hydraulic nitrogen gas-filled

l. ,i

t,

Camber Caster

Front Rear Front Rear

Omm
In 2.O mm

i

oin

BRAKESYSTEM

Type, Front
llear

Pad and LiningSurfaceArea: Front Rear ParkingErakeKind and Type Size '1:S ELECTRICAL Battery Starter Allernator FusesIn UndeFdash Fuse/Relay Box In UndeFhood Fuse/Flelay Box

In 0.08 in I Power-assistedselt,adjusting ventilated disc Power-assistodselt-adjustingsotid disc 58.Ocm2 2 x 8.99sq-inx2 I 27.Ocmzx2 4.19sq-inx | 2 Mechanical actuating, rear two whsel brakes

185/70 14 87 H .1 R 205/55 1587 V *2 R f125l7o O l5 {Spare tirel *r T135/80D 15 {Spare rire)*2 12 V-55AH/5HR 12V-1.4 W,12V-.t.6 W k k 1 2 V - 9 0A , '10 , 15 80 A 7 . 5A . A A, 20A, 30 A 7 . 5A , 1 0 A , 1 5 A , 2 0 A , 4 0 A , 50 A. 60 A, 100 A 1 2 V - 6 5W 1 2 V - 5 5W 1 2 V - 3 2C P 1 2V _ 5 W 1 2 V - 4 5C P 12 V-43t3CP 12 V -21 CP 1 2 V - 3C P '12v-3 cP 1 2 V - 3 2W 1 2 V - 8W 1 2V , 8W 1 2 V - 3 . 4W 12V W ' l 2 v - 1 . 1 2 W-,3 . 0 , 1 . 4W 1 . 4W , 3 . 0 W , 3 . 2 W 12V-1.4 W 1 2 V - 1 . 4W , 1 . 1 2W , 0 . 8 4W , L E O 12V-1.4 W

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

3-17

Body Specifications
Unit: mm (in)

lr ;i

I

Maintenance
Lubrication Points Maintenance Schedule .......... 4-z ... 4-4

I

{l I

Points Lubrication
Indexand variouswolk proreferto the lllustrated to points and types of lubricants be applied, For detailsof lubrication cedures(suchasAssemb|y/Reassemb|Y,RepIacement,overhau|,Insta||ation,etc.)containedineachsection.

"Energy Conserving II" 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 HondaPremiumFormulaAulomaticTransmission II DEXRON@ Automatic Fluidor an equivalent fluid transmission Brakefluid DOT3 or DOT4 Brak€fluid DOT3 or DOT4 greaseP/N 08733 - BOTOt Steering Shift lever pivots (Manualtransmission) fork {Manualtransmission) Release Steeringboots Steeringball joints Selectlever (Automatictransmission) Pedallinkage shaft lntermediate Brakemaster cylinderPushrod Trunk hingesand latch Door hingesupper/lowerand latches Door openingdetents Fuelfill lid Enginehood hingesand enginehood latch Clutch mastercYlinder Pushrod Throttle cable end Caliper Pistonseal. Dust seal, Caliperpin, Piston and selectcable ends Shift Hondapower steeringfluid-V oil Comoressor SPlO P/N 38899-P13-OO3

Automatic

I
!

l

to Selectthe oil for your car according this chart: H23A1ongine F22A1,
Amblent Temoeraturo

'l

for An oil with a viscosityoJ 5 W-30 is preferred improtectionin the provedtuel economyand year-round car. You may use a 1O W-30 oil il the climatein range snown your area is limitedto the temperature on the chart.

An oil with a viscosityof 1O W-30 is preferred protecfor improved{uel economYand year-round in the car. You may use a 5 W-30 oil if the tion climatein your area is within the temperature range shown on the chart

L

4-2

4-3

Schedule Maintenance

3.e e9
dcicicidd L l l

E.9

.g
z 6

P E
B E

[€
'=u

o o'-

+r+rE

1!

; ; " 1x zz
Oo
o . 9

3 * E '
6:-:---

stststdstst 6
.l c? ': ': ': ''l 6 l l l i

o ;

== *2 22-?= ];;.
gci ai.+
t : - E ;

r

.!:

a a96
q 6

F-..j.". B ' is.sd e c . r c .;Y = s
.eE

; p P.9
t_c

i ; 9 t i ;!.

= c ; 6

d P ; 4 P 1i : it b 9: , .
N N A : ;

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

BETH-I

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

e u2 Jz;oE z z

t

o >

i i3FF
E 1 e : - -

3

3-E<3S

ie'Nll

'

E

E

l. 'i

ll

E

; g
E

.::

8

< 9 a 9 Q ! c 6

;
'd

6 5 9 o b 6

= : i 6

6 3 z .E -x

-:r

;:3

^ F

b i

I:-;-;-;E;-;i ; E 3 3 3 eF 3 ; 3 ; !r'.on.goo
-: aj + { 6 ci ai ;
S:|t)6o:nF (J:('l'!r<ooo

, 9.oi o. )rdc99 o ; : , ; 6 , o

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

E< F:

6 E

e

9 + a E
9 o

-Ee 95

H5**-*-E:*i
-o

*iS . , ii k

's 5 tB
6 . > q 3 5

: -5 € d E i S ee P P
; P :

i - ' . s i.i 6 F , b
6P ; * g t
aisiis! a E
-g

E

E

g

E

E I

':

l
i

l

4-5

Schedule(cont'd) Maintenance
P P " ; E * 6 - b g 6 : ( l .
> . o ; 6

t (,) 3
o E

t

<

=

.

9

s * E E
2

€:R E Ee6- ts EE! E l3! s
\ i o E

t ;

E e i EE : E€E :
E 9 E
- g ' 6 C

I

i i o 6 6 i c'6

o
F li

!;,i.8 !
'E ;-E 5 o :

BE

3

8ri n;; ;3 5
5 . e3
; i ;

ai
<

r;E;i i

o a

tE€ii:5

z
oo E

EE::i;EF
;
L 6

-;;;Eg;E
9i:!;srs
;oEdds-:s t t t I ; ,

E E R#;:T

i$:EsiEi .i;"qHE!.i€
P

.9

li

;;igxB:E

a
E

ir
l
i

E

E E 9

9 . .4 8

ri
.

E

b
c

r

a

c
;

-

b t

E

i
!

-

c

:

>

i

s : 6 E !E- € !; E E ; = t

E ,e!EE tE '9!cc E ! * E E r I
! I .9

I

cii€ Fi:!i;
ri 3E8 <,iddci,ii,!

4-6

Engine
Constructionand Function . . . . . . . . . .5 - 1 lH22Al engine) E n g i n e e m o v a l / l n s t a l l a t i.o . . . . . . . . . . . .5 - 1 7 R .n . C y l i n d eH e a d / V a l vT r a i n . . . . . . . . . . . . . . . . . - 1 r e 6 E n g i n B f o c k. . . . . . . . e .........7-1 Engine ubrication L . . . . . . . . .8 - 1 IntakeManifold/Exhaust System ........ 9-1 Cooling . . . . . .1 0 - 1

Construction Function and lH22A1 enginel
Outline Description ................5-2 VTEC Outline .... 5-4 Mechanism ................5-6 Control System ........... 5-7 Gylinder Head Outline .... 5-9 Camshafts . . . . . . . . . . . . . .5.-.1 0 . Valves Valve and Springs............... 5-11 BeltTensioner Outfine ....5-12 A u t o - T e n s i o n . . r . . . . . . . . . . . . . . . . . . .5.-1.3 . .e. . . . C y l i n d e r B l o c.k . . . . . . . ......5-14 . OilFlow ......5-15

Outline
Description
.6 2,157 cm31131 cu in) lt is water cooledand ThenewH22A1 engineis an in-line4-cylinderDoHc designdisplacing fuel and usesa to chamber.lt is specified use premiumunleaded with a centerplug type pent-rootcombustion equipped Valve calledHondaVariable a pGM-Fl(Sequential system.This engineincorporates mechanism Multipon FuelIniection) (VTEC)System. Control Timing and Valve Lift Electronic The simultaneously. enginealsoinThis ststem allowsthe timing and litt oJthe intakeand exhaustvalvesto be changed intake manitoldsystem that variesthe volumeof the intakechamber. cludesa electronically-controlled

I
il

i

L.

5-2

nd

ll!i)r

Specificstions Water cooled4-stroke,In-line4-cylindergasoline engine 2 , 1 5 7 c m 3( 1 3 1 . 6 c u - i n ) 8 7 . Ox 9 0 . 7 m m t 3 . 4 3 x 3 . 5 7 i n l 1O.O:1 Dual over-head camshaft,VTEC Sequential Multipon Fuel Injection{SFl)

Type Oisplacement
tn-

Eore x Stroke Compression Ratio Cam, Valve Mechanism
Valve Train

FuelSupply System

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 balancer shaftsare drivenby the timing balancerbelt. Belt tension is automatically adjusted. a The cylinderblock is made of aluminumalloy using fiber reinforced metal (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,semechanism reducesecondary to enginevibration. 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-barrel side-drafitype. a The ignitionsystem is a fully-transistorized, contactless type. The spark advanceis electronic. a The air cleaneris equippedwith a resonator. a The radiatoris of a corrugated type. and th€ coolingtan is el€ctrically powered.

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 | v e I i is p r o ' i | e a t I o w s p e € and f t selecied electronically' speed.switch-overfrom one profileto the other is controlled and a differentproiileat hagh by monitoringcurrent enginespeed and load.

lr
il
r'l

i

CAMSHAFT CAM LOBESFOR LOW RPM CAM LOBESFOR HIGH RPM PRIMARYBOCKERARM ARM MID ROCKER SECONDARYROCKERARM HYDRAULICPISTON(A} HYORAULICPISTOI{ {AI PISTON STOPPER LOST MOTION ASSEMBLY EXHAUST VALVE INTAKE VALVE

5-4

rd
!d

In g€noral,it would be idealif the high rpm performance a racingengineand the low rpm pertormance a standard of ot passenger enginecould be combinedin a singleengine.This would resultin a maximumperformanc€ car enginewith a wid6 power band. Two of the major differences betweenracingenginesand standardenginesare the timing ot the intake/6xhaust valvesand the degreeof valve lift. Racingengines hsve longerintake/exhaust timing and a highervalvelift than standardengines,The Honda VariableValve Timing and Valve Lift Electronic ControlSystemtakes this into account, Wh€n valve actuationis set for low rpm timing and lift, low rpm torque is betterthan in a standard engine.Whon valve actuationis then switchedlor high rpm timing and lift, output improves the levelgiven by a racingengine.Until to now. tew variable valvetiming systemshave beencommercialized, thosethat have,only the time that both vatves8re In 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 mechanism available.

RacingEngine

VTEC Engine

StandardEngine

Valve Timing (exhsust/intake) Valve Lift

i

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 changeaccording drivingconditions. to

RPM switch ovgr pornt

5-5

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

CAMSHAFT

*A and B cam lobes ddve the rocker arma sepsrot6lY RETURNSPftNG

HYDRAULIC (AI PISTON
HYDRAULIC PISTONIBI

PISTON STOPPER PRIMARY ARM ROCKER MID ARM ROCKER SECONDARY ARM ROCKEB

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: FOR CAM PNOFILE HIGHRPII

l,
il

I

+ ;
STOPP€R PISTON
HYDRAULIC PISTON (AI HYDNAULIC PISTON(B)

*The rock€r arms ere linked via the hydraulic Piston. Cam lobe C drives the rocker arms.

5-6

ControlSystem
The controlsystemfor this mechanism, shown below, constantlymonitorsthe changes enginestatussuch as load, as in 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 PRESSURE SWITCH

VTECSOLENOID VALVE

F.oft

OILPUMP +

Et{Gtt{E CONTROL MODULE {ECM)

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 A SPRIIIG

RETAINEN

GUIDEHOLDER

ASSEMELY LOSTMOTION

I

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

I' s
t l: .

i

5-8

CylinderHead
Outline
The one-piece cylinderhead is made of aluminumalloy to reducethe weight while increasing efficiency The combustion chamberis a compactpent roof shape,centerplugtype. The cylinder headusesa DOHC4-valvesystem with 2 intakevalvesand 2 exhaustvalvesarranged cross flow. Combustion stabledue to the optimization the for is of ignitiontiming, compression ratio and valve timing.

EXHAUST CAMSHAFT

INTAKE CAMSXAFT

EXHAUST ROCKER ARM II{TAKE ROCKER ARM EXHAUST PORT

INTAKE PORT

INTAKEVALVE EXHAUST VALVE

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- u m s p a c g inim with on five bearing iournals tween cams,thus a owing a more compactcylinderhead.Eachcamshaftis supported I intakecyctesrequire totaloJ 24 cam on ed lubrication. the left end of eachcamshaftis a drivenpulley.The exhaustand lobesto oDenand closethe valves

EXHAUST

A: PRIMARY B: MID C: SECONOARY

CAMSHAFTJOURNALS

II{TAKE

CAMSHAFTJOURNALS

valve timing Low-speed

High-speod valve timing <F i Intok6 valva opon : Exhau3t vslvg opon -

INTAKEA

INTAKE B

B €XHAUST

INTAKE C

TDC: Top dead center BDC: Bottomdead center

Valves and Valve Springs
t€,c lm

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

INTAKE
3 5 . O( 1 . 3 8 )

EXHAUST

HEAD DIAMETER STEMDIAMETER
OVERALL LENGTH VALVE LIFT

3 0 . o{ 1 . 1 8 )
5.5 lO.22l

5.5 tO.22l r 0 6 . 7 5( 4 . 2 0 3 )
Secondary: 8.O (O.31 ) Mid: 11 . 5 ( O . 4 5 ) * Primary: 6.5 (O.26)

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

I

Fr
|

oVERALL LENGTH

|

,/|l

ffir

HEAD DIAMETER

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

EGG SHAPE

LEMON SHAPE

5-11

Belt Tensioner
Outline

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

TIMING BELT

WATER PUMP PULLEY

SPRINGfol TENSIOI{ER BELT TIMING BALAIIICER

AUTO.
for TIMING BELT

MAINTENANCEBOLT

TIMI G AELT AOJUSTER

BALANCERBELT TENSIONER

5-12

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

SCREW IMALEI

Machanbm: 8€lt Ro6ctlon Fo.ce

o The malescrew is rotated by the
lorsron spflng.

ri The lemale rod is
pushedout as lhe rod rotates,

O The rod stops when the force oI the torsion spring and the timing belt equalize.

5-13

CylinderBlock
are madeoJ FRM,a composite The cylinderblock is a closeddeck designmadeof aluminumalloy . The cylindersleeves shaftsand the deep aluminatiber and carboniiber. The boresin the cylinderblockfor the balancer materialof aluminum, skirt designimprovethe rigidityof the block.

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

^

,.\

/zr

.\

^

iEff

BALA'{CERSI{AFT BORES

Oil Flow
Lubrication the c.ankshattand connectingrod bearings done by oil pumpedthroughthe main bearing of is caps ano Inro passages the crankshalt.The pistonsand cylinderwalls are lubricated oil spray nozzlesmountedon the cvlinder in by block.

INTAKECAMSHAFT

OIL CONTROL ORIFICE VTEC SOLENOID VALVE CAMSHAFT HOLDER PIPEOIL

swtTcH

VTEC PRESSUBE

€IHAUST CAMSHAFT .XXJRI{AL

ENGINE OIL COOLER

ENGINEOIL FILTER FRONTBALANCER

ENGINECOOI"ANT

ENGINEOIL PRESSURE SWITCH

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 valve.At high RPM.this valveopensand oil is pumpedat high to arms and valves.oil is alsosupplied the VTECsolenoid through the rockerarm shatts to operatethe VTEC' Dressure

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 ploperly and hoist brackots are attachod to the corr'ct positions on th€ 6ngin6. a Mako suls tho car will not roll ofl stands 6nd lall whlle you are working undal it. CAUTION: a Use tend€l covers to svoid damaging paint€d surtacas. a Unspocified itoma alo common a Unplug th€ wiring connoctolE carstullY while holding the connoctor portion to avoid damago. a Mark all wiring and hosas to avoid miaconnection. Also. bo 3u1€that thoy do not contact othar witing ol hosos or into.ler€nco with othar parts. cirNOTE: The radiomay hsve a codedthett protection cuit. Be sureto get the customer'scode numb€rbelore - Disconnecting the battery. - Romoving the No. 43 (10 A) Juse(ln the under-hood tuse/relavboxl. - Removing the 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. terminaltirst, then the 2. Disconnect batterynegative the positivetetminal. HOUSI'{G AIRCLEA'{EF 3. Removethe radiatorcap use care vuhonremoving tho radiator !@ cap lo avoid scalding by hot coolant ol atoam. 4. Raisethe hoist to full height. Remove the Jront wheels and the engine splssh shield. 1O. Removethe pulsed secondaryair iniectionIPAIR) vacuum tank and bracket. PAIR TANK VACUUM 5. Loosenthe drain plug on the radaator. the drain oil/lluid. Reinstall 6. Drainthe transmission plug using a new washer. the 7 . Orainthe engineoil. Reinstall drainplug usinga new wasnef. CAUTION: Do not ovsrtighlan tho dlain plug' 8. Lower the hoist. the air cleanerhousingand intakeair duct' 9. Remove
6 x 1.O ]||m 10 .m {1.0 ks-m, 8 lb-ftl

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

I rb-trl

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

a tb-ft|

BRACKET

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

I
Front

5-18

11. Remove the battery, battery base, battery cable and starter cable. MANUAL TRANSMISSION tM/TI: 8 r 1,25rnm 22 tt.m 12.2kg-m, 16 tb-ft)

CAUTION: a B€fore disconnocting any fu6l line, r6li€vs the tuel pr€ssur€ os dosc.ibod above. a Place I shop towol ovel the tu€ltilter to prevent prossulizod tuol trom sprsying ovor tho ongine. 13. Removethe fuel feed hose from the fuel rail.
WASHER

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

14. Removethe injectorresistorconnectoron th8 left side of enginecompartment.
6x1.0mm 10 N.m {1.0 kg-m, INJECTOR RESISTOR

INJECTOR

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

1 2 . Relievefuel pressureby slowly looseningthe service bolt on the fuel rail aboutone turn (seesection 11 ) . Do not smoke while working on 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)
the the 15. Remove throttlecableby loosening locknut' end out of the throttle linkage' then slip the cable NOTE; a Take care not to bend the cablewhen removlng it. Always replaceany kinked cable with a new one. a Adiust the throttle cable when installing(see s e c t i o n1 1 ) . emis18. Removethe brakeboostervacuum hoss and vacuum tubes from the intake sion control manilold. CONTROL IEVAPI EMISSION EVAPORATIVE

BOOSTER BRAKE HOSE VACUUM

I
NUT ADJUSYING

1 9 .Disconnect the connector and vacuum tube' th€n
remove th€ cruise control actuatol.

Ir

to.

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

CRUISECO'{TROL ACTUATOR

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

t l

Il'

20. Remove the engine g.ound cable from the body side. 21. Removethe power steering (p/Sl pump belt and pump. a Do not disconnectthe p/S hoses.
8 x 1.25 rhm 22 .m (2.2 kg-m.

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

t8

LOCKI{UT

PI,MPBELT

ALTERNATOR AELT

P/S PUMP

r 1 . 2 5m m 22 N.m {2.2 kg-m, 16 tb-frl 24. Loosen the mounting bolt, then remove the A/C compressof. Disconnect the 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)
the upperand lower radiatorhosesandthe 25, Remove heaterhoses. 27. Removethe shift cable and selectcable (M/T)' NOTE: a Take care not to bend the cablewhen removing it. Always replaceany kinkedcablewith a new one. a Adjust the shiJtcable and seleci cable when installing(seesection 13). I x 1 . 2 5m m

WASHER

BRACKET

i
\ COTTER Roplace. STEEL WASHER 26. Remove the transmissionground cable and the automatic transmissionfluid (ATF) cooler hoses (A/T).

WASHER SELECT CAELE

PI.ASTIC WASHCR

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

SLAVECYLINDEB

t
I

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

5-22

29, Removethe clutch damperassembly. NOTE: Take care not to bend the pipe.
tng

31. Raisethe hoist to ful hoight. 32. Removethe exhaust pipe A and bracket. GASKET

CLUTCH DAMPER
rin-

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

@'

tHER

nc
IER

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

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

I{UT

EXHAUST PIPEA

30. Remove the vehicle speed sensor {VSS)/power steeringlPlS) speedsensorassembly. NOTE: Do not disconnectthe noses.
18 N.m (1.8 kg-m, ilave

33. Removethe A/T shift cable (A/T). NOTE: a Take ca.e not to bend the cable when removing it. Always r€placeany kinkedcable with a new one. a Adiust the shift cable when installing (see section 14).

ISLY

P/S

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

(cont'dl

5-23

EngineRemoval/lnstallation
(cont'd)
34. Bemove the damper fork. BOLT SELF-LOCKING 10 r 1.25 mm /+4 N.m (4.4 kg-m, 32 lb-frl

36. Removethe driveshafts.

I
I
t

h

I
|l

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

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

PLASTICBAG

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

fl

36-43 tb-ft)

38. Lower the hoist. 39. Attach the chain hoist to the engine.

5-25

EngineRemoval/lnstallation
lcont'd)
40. Removethe rear mount bracket 42. Removethe lelt side enginemount.

BEAR STIFFENER

4 3 . Remove the transmrsslon
41. Removethe front mount bracket. bracket.

and mount

l
i' 5-26

44. Raisethe chain hoist to removeall slack from the chain. free of vacuum 45. Checkthat the engineis completely hoses, fuet and coolant hoses, and elect.ical wiring. 150 mm {6 46, Slowly raisethe engineapproximately an). Check once again that all hoses and wires have trom the engane. been disconnected the engineallthe way and removeit Jromthe 47. Raise car.

48. Installth8 enginein the reverseord€r of removal. NOTE: After the engineis in place: a Torque the engine mounting bolts in the s€quence shown below. CAUTION: Fallur€to tlghton the bolts In the p?opor aoquencccln cauae orcegtivo noiar and vlbrstion. and rcduce bushing litc; check thst thc bushing! aro not twirtrd or offsot.

a Check that the spring clip on the end ot each driveshaftclicks in to olace. CAUTION: lnstall now spring cllps

TRAIISMISSIOT{ MOUI{T

Eleed air from the cooling system at the bleed bolt with the heatervalve open. a Adjust the throttle cable tension. a Checkthe clutch pedalfree play {M/T). a Check thst the transmissionshifts into gear smoothly. l 2 x 1 . 2 6m m 1 0 r 1 . 2 5m m REARMOUITIT @ es .m le.s tg-m, 1s b-ft} @2r 'm t2.1 47 b-trl 1 0 r 1 , 2 5m m R€place. .m {3.9 kg-m.28lb-ft} 39

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

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

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

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

FROI{T MOUI{T SIDEE'{GI E IIOUNT the 12| 7.29
@ 55 .m (5.5lg-ln, 40

tum 'acal

r {6
6Ve @ Tighton snug onty. l O x 1 . 2 5m m NOTE: . Torque th€ mounting bolts/nuts in the numbgred s€quenceas shown (O-@). . After road t6sting, loosen and r€tighten the thre€ bolts on the front r'lount brackoi.

the

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

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

@ Tighten

only.

5-27

EngineRemoval/lnstallation
(cont'd)
a Adiust the tensionof the following drive belts: Alternatorbelt (section23). Power steeringpump belt (section17). belt {section22). compressor Air conditioner a Clean battery posts and cable tetminals with then apply greaseto preassemble, sandpaper, vent corrosron. 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

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

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

2a tb-ft|

(Standardfor some tvpos) SIDE ENGINE MOUNTING BRACKET

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

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

h

!r

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 es)

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

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

ALTERNATORBRACKET

10 x '1.25 m m 50 N.m {5.O kg-m, 36 lb-ftl

A/C BRACKET

5-29

Cylinder Head/ValveTrain
F22A-1 engine H 2 3 A 1e n g i n e H22Al engine ............... 6-1 . . . . . . . . . . . .6.- 3 7 . .............. 6-71

CylinderHeadA/alve Train lF22A1 enginel
Speciaf Tools .........6-2 Valve Seats l l l u s t r a t oId d e x . . . . . . . . . . . . . . . . . . . . . . .6.-.3 n . . Reconditioning .... 6-17 Valve Seals Valve Guides (Gylinder head Replacement V a l v e o v e m e n.t. . . . . . . . . . . . . . . . . .6 - . . 8 M ..1 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 Balancer Belt 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 . Tension Adjustment ................... 6-26 Clearance ...........6-15 Positioning CrankshaftBefore lnstalling Timing Belt .............. Camshaft 6-28 Belt Inspection . . . . . . . . . . 6 - 1 4 Timing Balancer fnspection ..........6-27 Valves, Valve Springs and Valve Seals Valve Clearance Removal . . . . . . . . . . . .6 - 1 6 . Adjustment .........6-34 Valve Spring and Valve S6al Installation Sequence .............. 6-21 Valve Installation ....................... 1 6-2

SpecialTools

Ref. No. I

Tool [tlumber or 07HAH-PJ701OA OTHAH_PJ701OB OA PTOOl OTNAF_ OTNAF_PTOO20A OA OTNAG-PTOOl o7742-OO10100
Valve Guide Reamer,5.5 mm CUP Installer lnstaller Shalt Seal Guide Valve Guide Driv€r, 5.5 mm

o o

6-20 6-22 6-22 6-22 6 - 1 9 ,2 0

@ @ @

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.O kg-m.7lb-ftI

?
HEADCOVER CYLII{OER RUBEER SEALS R€placo whon dEmag€d or d€teriorst€d.

Put longer bolt

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

R

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

CYLII{DER HEAD

DOWEL PI'{ otl coilTRol oRtFtcE
Clean. O.RING Roplace. CYLINDER HEADGASKET GASKETI {METAL R€olacg. 8 r 1.25mrn 22 t{,m (2.2 kg-m, 16 lb-ftl TIMING BELT
Rsplacement,page 6-29 Inspoction/Adjustmont, page 6-26

./--'77'---)

---

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

(cont'd)

6-3

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

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

@
I

u

e
I

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

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

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

oo*:..rn-y'

E

SEAL lnstdflation, page 6-22 R€place.

;

PULLEY CAMSHAFT page6-12 Romovsl, pago6-22 Installation,

CAMSHAFT

8 x 1.25 mm

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

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

i vALvE spntitc

-'^"'-"-'-"-' -------Ib
vALvE ExHAUsr
vALvEsEAL ExHAUsr
p8g€s6-5 8nd 16 Replac€ment, Reptace.

;ili' spRrNG...-_____la
q
rgli Fz-->.I @

--"i

w
VALVEIGEPERS RETAII{ER ITTAIG VALVE SPfiI C
II{TAKE VALVE SEAL R€Dlace.

I ExHAUsr
e-une .V valvE

I

I

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
(Gylinder Replacement head removalnot requiredl
NOTE: Cylinder head removal is not required in this orocedure. Ths proc€dur6shown below applies when using the incar valve spring compressor. (Snapon YA8845 with YA8845-2 A 7/8' attachmentl Intake V!lv. Soals: 6. S€lgct the 7/8 in diameter long compressor attachm€nt 8nd fasten the gttachment to th6 No. 5 hole of th€ levor arm with the speed pin suppli€d. Ins€rt an air adaptor into the spa.k plug hole. Pump air into the cylinder to ke6p the valve closod whils compr€ssing springs and rsmoving th€ valv€ ke6o6rs.
6.

@E

Alway woar approv.d oyc prot.ctron

whon uslng th6 in-cel valvo spring compt!3!or. 1. Turn the crankshaftso that th6 No. I 8nd the No. 4 pistons are at top desd center (TDC). 2. Removeth€ cvlinder head cover and the rocker arm assembly. NOTE; a Rsf€r to p8ge 6-12 for rocker arm assembly removal. I When removing or installing the rocker arm 8ssambly, do not r6mov6th€ camshaft holdorbolts, Th6 bolts will keepthe holders,sprir€s and rocksl arms on th€ shaft, 3. 4. Remove the fuel injectors and the wire hsrn€ss. Using the 8 mm bolts supplied with the tool, mount the two uprightsto the cylinderh6adatthe end camshaft holders. Th€ uprights tit ov8r the camshatt as shown, Insertthe cross shaft through th6 top hola of th€ two uprights.

Position the lev€r arm und6r ths cross shaft so the lover is porpondiculsrto th€ shaft and the compres8or sttachm6nt rests on top of the rgtsinsr tor the spring being compress€d.Us€ th€ tront position slot on ths l€vsr as shown. NOTE: RJt shop towek over the oil passages preto vent th6 valvo ke€p€B from falling into the cylindsr h6ad.

OII. PA&gAGES

5.

trl

(cont'd)

6-5

Valve Seals

(cont'dl not headremoval required) Replacement lGylinder
'15. Using a downwatd motion on the levsr arm, compress the valve spring and remove the keepersfrom the valve stem. Slowly release paessuleon the sprlng. 16. Removethe valve seals(page6-16). 17. Installthe valv€ seals lpage 6-21). 8nd th€ koop€.sin 18. Installthe springs,the r€tainers rgvorso ord€r of romovSl, 19. Repeatsteps 6 to 18 on the other cylinde,s.

9. Using a downward motion on the l€ve, arm, comfrom pressthe valvespringand removethe keepers valve stem. Slowly release pressureon the the sprlng. t 1 O . R e m o v e h e v a l v es e a l s( p a g e6 - 1 6 ) . 1 1 . Installthe valve seals (page6-21). 12. Installthe springs,the retainers and the keepersin reverseorder of removal. ExhaustValv6 Seals: attachshortcompressor 13. Selectthe 7/8 in. diameter 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 to leveris perpendicular the shaft and the compressor attachment rests on top of the retainerfor the spring Use the front position slot on the being compressed. lever as shown. to NOTE: Put shop towels over the oil passages prevent the valve keepersfrom falling into the cylinder head.

6-6

CylinderHead
Removal
Engineremovalis not requiredtor this procedure. 1 . Disconnect the negativeterminalfrom the battery.

2 . Drain engine the coolant{seesection101.
o Make sur6 iacks and sefsty stands are placed propsdy and hoist bfackets are sttachod to co.roct @shions on tho ongin€, o Maks sure the car will not roll off stfltds and tall whilo you are working under it. CAUTION: 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 connoctor Fprtion to avok ddylago. . Mark a[ wMng and hosos to avokt miEconnection.Abo, bo su.o that they do not contact oth6. widng or hosos ol innerto?e with othq parts. o To avoid damaging th€ cylinder hoad. wah untilthe sngine coolant temp€.aturs drop6 b€low 100oF (38oC) botor€ loosoning tho l€taining boh. o Inspect th€ timing beh bofore removing the cylnder hoad. . Tum the crankshaft pulley so that tho No. 1 dston is at top doad center {pag€6-281. a Maks all emission hos€s betore disconnocting th€m. NOTE; The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode numberbefore Disconnecting battery. the - Removing the No.43 (1OA)tuse (ln the under-hood fuse/relavboxl. Removing the radio. After service,reconnectpower to the radioand turn it on. Whenthe word "CODE" is displayed. enterthe customer's s-digit code to restoreradioope.ation. 4. . Removethe radiatorcap to speeddraining
5.

Relieve the fuel pressure. @ Do not snoke whlc wo*rng on ftrc sydem, krop oFn ffrnc or spark away trom wor* s!. Drdn ft|ol ody into an approvrd contrlnor. SERVICE EOLT 12 N.m {1.2 kg-m,9 tb-ft}

SHOP TOWEI-

FUEL RAIL

R€movethevacuumtube,breatherhoseand intskeair duct. Removethewater bypasshosefrom the cylinderhead Removethe fuel feed hose and evaDorative emission (EVAP) controlcanisterhosefrom the intakemaniJold.

(cont'dl

6-7

Head Cylinder
(cont'd) Removal
7. Remove the brakeboostervacuum hose and vacuum hosemount (A/T only)fromthe intakemanitold. 10. Removalthe ignitioncoil. * 8x 1.25mm 22 N.m(2.2kg-m,16lb-ftl

8 . Removethe luel return hose and cruisecontrol vacuum hose.

CRUISE

Removethe spark plug caps and the distributor, 9. Removethe throttle cableand the throttle control ca bl; (A/T only) from the throttle body. NOTE: o Take care not to bend the cablewhen removingit. Always replaceany kinkedcable with a new one. a Adjust the throttle cable when installing(seesection 1 I ).

1 2 . Remove connectorand the te.minalfrom the alterthe
nator, then removethe enginewire harnesstrom the cylinderhead cover.

1 3 .Removethe followingenginewire harnessconnectors
and clamps f.om the cylinder head and the intake manitold: a Fourtuel injectorconnectors o Intakeair temDerature {lAT) sensorconnector o ldle air control (lAC) valve connector . Throttle position (TP)sensorconnector o Exhaustgas recirculation(EGR)valve lift sensor connector . Groundcableterminals . Enginecoolant temperature(ECT)switch B connecror o Heatedoxygen sensor (HO25)connector a ECTsensorconnector o ECTgaugesendingunit connector . lgnition coil conneclor . CKP/TDC/CYP sensorconnector . Vehiclespeedsensor(VSS)connector a ECTswitch A connector
BOLT r!: CORROSION RESISTANT

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

THROTTLECONTROL CABLE (A/T onlyl

14. Removethe upper and lower radiatorhosesand heater noses.

18. Disconnect connector the andvacuumtube,then remove the cruisecontrol actuator
CNUISE CONTROL ACTUATOR

UPPER RADIATOR HOSE

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

\

VACUUMTUBE

HEATER OUTLET HOSE HEATER INLET HOSE

cor{r{EcToR
15. Remove the emission vacuum hoses and water bypasshosesfrom the intake manifoldassemblv. '16. Removethe water bvoass hose from thermostat housing.

,4

,//

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

erne

17. Remove the thermostat assemblv from intake manifold.

ke

P/S PUMP

THERMOSTATASSEMALY

LOCKNUT 1 5 N . m l t . 5 k g - m ,1 1 l b - f t ) P/S PUMPBELT

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

(cont'd)

6-9

Head Cylinder
Removal {cont'd)
21. Remove the intake manitold bracket and intake mani{old. with air conthe 24. Remove heat insulator(carsequipped onlY). ditioning 25. Removethe self]ocking nuts and disconnectthe exhaust manifoldand exhaustPiPeA. 26. Bemove the exhaust manifold bracket and exhaust manifold.

MANtFoLo TNTAKE

GASKET

BRACKET

22. Lift the tront of the car up andplaceit on safetystands' PIP€A EXHAUST

Mako sure lifts, iacks and safaty stands aro dacsd propsdy. and hoist brack€ts are attach€d to the corr€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 und91il. the 23. Remove front wheelsand the enginesplashshield (page5-18).

HEAT INSULATOR (Carsoquippedwith air conditioningl

2 7 . Remove the positive crankcase ventilation (PCV)
hose, then removethe cylinderhead cover.

24. Removethe upPercover. 29. Loosanthe adjuatingnut 27O - 3600. 30. Pushthe tensionerto releasetensionfrom the timing
b€lt, then retightenthe adiustingnut.

6-10

31 . Removethe timing belt from the camshaft pulley.

NOTE: Separate the 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
Removal
1. turn the camshaftpulleyuntilthe To easereassembly, "UP" mark faces up, and the front timing mark is alignedwith the cylinderhead upper surface.

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

,.UP"MARK

b%
TDCGROOVES Alignfronttimingmarkon with the cylinder Pulley surfac€, headupper Removethe timing belt.
J.

Removethe retaining bolt, the special washer, the camshaft pulley and the key, then removethe back cover.

6 mm BOLTS

CAMSHAFT PULLEY

BACK COVER

6-12

Rocker Arms
r Overhaul
NOTE: a ldentify partsastheyareremoved ensure to reinstallation original in locations.
a Inspectrockershafts and rockerarms (page6-15). . Rockerarms must be installedin the same positionif reused. a When removingor installingrockerarm assembly, not removethe camshaftholderbolts. The bolts will keepthe do holders, springsand rockerarms on the shaft. o when reassembling, the projectionof the intakerocker shaft to the notch in the camshaftholder. fit ' ! Priorto reassembling. clean all the part in solvent, dry them and apply lubricantto any contact parts.

Letter "9" is stamped on tocker atm.

Lefter "A" is stampod on tocker arm.

IITITAKE BOCKER

sHAFr @

INTAKE ROCKER

lshon, 2 placesl

sxmr @ (long,

INTAKE ROCKER

3 places)

ARM s

(4 plsces)

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

I
I

ti;or"or, HoLDER

ll"t "o' HoLDER

I

ll

I

|

|

|
l l

|

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

| t . l^ l , l ^
s ' g U f " #[ U t
/

|

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

l'u"'TI ' "

' o

or.,t o

(short, 2 palces)

"*,n('

(long, 3 places)

rc
EXIIAUST ROCTER SHAFT

ROCKER ARM (8 places)

6-13

Camshaft
Inspection
Note: . Do not rotate the camshaftduringinspection. a Removethe rockerarms and rockershafts. 1. Rrt the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specilied torque. Specified tolque: 8 mm bohs: 22 N m (2.2 kg-m, 16 lb-ft) 6 mm bohs: 12 N'm (1.2 kg-m,9 lbjt)
6 mm BOLTS

Removethe bolts, then removethe camshaftholders lrom the cylinderhead. - Lift camshaftout ot cylidnerhead,wipe clean,then camshaftif lobesarep'tinspectlift ramps.Replace worn. scored,or excessively ted, - Cleanthe camshaftbearingsurfscesin the cylinder head,then set camshaft back in place' - Insertplastigage strip acrosseach iournal' lnstall the camshaft holders,the tighten the bohs to the specijiedtorque as shown in the left column on this page.
o.

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

8 mm BOLTS
PTASTIGAGE STNIP

Seatthe camshaftby pushingittoward distributorend of cylinderhead. Zerothe dial indicatoragainstend ol distributordrive. then push the camshaft back and forth and read the end play. Camshaft End Play: Standard lNow): 0.o5-o.1 5 mm (O.0O2-O.0O6 in) in) mm {O.O2 O.5 S€rviceUmh:

CAMSHAFT

6-14

RockerArms
Clearance
efs

7.

lf camshaft-to-holder clearance out ot tolerance: oil is - And the camshaft has alreadybeen replaced,you must replacethe cylinderhead. - lt camshafthasnot beenreplaced, tirst checktotal runout with the camshaft supportedon V-blocks. Canshaft Total Runout: Standard(N€w): O.O3mm (0.0O1in) max. Srvice Limit: 0.06 mm (0.002 in)

Measureboth the intake rockershafts and exhaustrocker shaft. Measure diameter ot the shaft at the tirst rocker location.

!€n

pit-

der

tto on

nal.
Surfaceshouldbe smooth.

Zero the gaugeto the shaft diameter.

- lf the total runout of the camshaft is within tolerance, replacethe cylinderhead. - lf the total runout is out of tolerance,reDlace the camshaftand recheck,lfthe oilclearance stillout is ol tolerance,replacethe cylinderhead. Measurecam lobe height. Cam Lob€ Height: lntakeStanda.d: 38.526 mm (1.5168in) Erhaust Standard: 38.778 mm { 1.5267 in) Measure the insidediameter the.ocker arm and of check tor out-of-roundcondition. Rock€r Am-to-Shaft Cloarance: Standdd(N€w) lmak6: O.O17-O.O5O mm (0.OOO7-O.OO2O in) Exhaust: O.O18-O.054mm {O.OOO7-O.0O21 in) Ssrvico Linit: 0.O8 mm (O.0O3in)

Inspectrocker arm laca tor wear, Inspectthis areator wear.

Repeatfor all rockers.lf over limit, replacethe rocker shaft and all over-tolerance rockerarms.

6-15

Valves, Valve Springsand Valve Seals
Removal
NOTE: ldentify valvesand valve springsas they are rein moved so that each item can be reinstalled its original Dosition. 1. Tap each valve stem with a plastic mallet to loosen the valvekeepersbeforeinstalling springcompressor' Install the spring compressor.Compressthe spring and removethe valve keepers. 4. Removethe valve seal.

2.

AVAILABLE COMM€RCIALLY

3.

as specialtool shown. Installthe

SEALREMOVER VALVEGUIDE LISLE 57900or KD3350 P/N AVAILABLE COMMERCIALLY

lntako Valvo txrronsions A Standtd(tlowl: 33.90-34.1O mm (1.335- 1.343 in) B Standtdocw): 1 1O.88-l 1 1.18 mm (4.365-4.377 in) C Strdard{ ow}: 5.485- 5.495 mm n { O . 2 1 5 9 - O . 2 1 6 i3 ) 5.455 mm (0.2148 in) C SorviceLinit: 0.85-1.1 5 mm D Standard(t{ow}: (0.033-O.045 in) 0.65 mm (0.026 inl Linit: D S€rvbr Exha.|3t Valvo Dlmonsions A Sta.!dsd(t{ow): 28.90-29.10 mm i t 1 . 1 3 8 - 1 . 1 4 6n ) 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 0n l i 34 5.420 mm (O.21 in) C SorvicoUmh: D Standard(Now): I .O5- 1.35 mm -O.O53 in) (O.O41 0.95 mm {0.037 in) D S€rvicoLimit:

I

6-16

Valve Seats
Reconditioning
Renew the valve seats in the cylinder head using a valve seat cutter. NOTE: lf guidesare worn (page6-18),replace them (page6-191beforecutting the valve sears. 5. After resurfacing s€at, inspectforeven valveseatthe ing; Apply Prussian Bluecompoundto the valve face, and insertvalvein originallocationin the head,then lift it and snap it closedagsinstthe seat severaltimes.

PRUSSIAI{

6.

2.

Carefully cut a 45o seat, removing only enough materialto ensurea smooth and concentricseat. B€velthe upper edge ot the seat with the 3Oo cutter and the lower edge of the seat with the 600 cutter. Check width of seat and adjust accordingty. Make one more very light passwith the 45o cutter to removeany possibleburrscausedbv the other cutter. Valve S€at Width: Stsdard (Nowl: 1.25-1.55 mm (O.049-O.061in) ServiceLimit: 2.OOmm (0.079 in)

3.

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 restore sest width. a lf it is too low (closerto the vslve edge),you must make a secondcut with the 3Oo cutter to move it up, then one more cut whh the 45o cutter to re_ store seat width. NOTE:The final cut should alwavs be made with the 45o cutter. Insertintakeandexhaustvalvesin the headand measure vatve stem installedheight. Intako Valv6 Stam lnstalsd H€ight: Standnd (New): 48.245-48.]15 mm (1.8994- 1.9179 inl Ssrvice Limh: 48.965 mm (1.9278in) Exhaust Valve Stem I]rrtaH Hotght: Standrd (t{ow}: 50.315-8O.785 mm Sorvice Linh:

7.

4.

1 1 . 9 8 0 91 . 9 9 9 4n l i 51.O35 (2.OO92 mm 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

Head Cylinder
Warpage
oil NOTE: lf camshaft-to-holder clesrance{page6-14) are not within specitication, the cylinder head cannot be resurfaced. are oil lf camshaft-to-holder clearances within speciticacheck the cvlinderheadfor warpage. tions. in)cylinderhead . lf warpageis lessthan O.05 mm {0.OO2 resurfacingis not .equired. in) . lf warpageis betweenO.O5mm (O.0O2 and 0.2 mm (0.008 in), resurtacecrinder head. a Maximumresurfacelimit is 0.2 mm {0.008 in) basedon a heightof 10Omm {3.94 in). EDGE STRAIGHT PRECISION

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

o --\-_z
\ ' =

a lf measurement exc€edsthe servicelimit, recheck using a new valve. a l{ measurementis now within service limit, reass€mbleusing a new valve, limit, recheckusingala lf measurement exceeds still below. then replace valve and ternate method 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. inthree placesalongthe valve Takethe measurements stem and three placesinsidethe valve guide. The difference between the largest gulde measureshouldnot ment and the smalleststem measurement exceedthe servicelimit. Measurealong edges,and 3 ways acrosscenter. Cyfnd€r Hoad Hoight: Strdard lNew): 99.95- 1o0.O5mm (3.935- 3.939 in) lntako Valvo Stom-to€ukle Clearance: Standqd (Newl: 0.020-0.045 mm S€rvicoLimit; in) O.Ogmm (O.OO3

(0.ooo8-o.oo18 in)

Exhaust Valvo St€m-to-Guide Clearancr: Standcd (Newl: o.055-o.08o mm (O.OO22-O'OO31 in) in} 0.1 2 mm {O.OO5 SorvicaLimh:

6-18

- Replacement
1. As illustratedin the removalst6ps of this procedure, use a commercially-available air-impact ddver attachment modified to fit tho diameter of the valve guides. ln most cases, tho same procedurecan be done usingthe ValveGuideOriverand a conv€ntional nammer. 4. Workingtrom the camshaftside.Usethe driverand an air hammer to drive the guide about 2 mm {0.1 in) towards the combustionchamber.This will knock off some of the carbon and make removaleasier.

VALVE GUIDE ORIVER COMMERCIALIY AVAILABLE

GAUTION: o AlwEys woar satsty goggles or a face shiold when uCng tha air hamnr6r. . Hold th6 ak hdnmcf dkecdy in lina wlth iha valv€ guue to prev€ni darnaglng th€ driv$. 5. Turn the headover and drive the guideout toward the camshaftside of head.

RcmovC.nd lrddlrtlon VALVE GUIDE DR|VER. mm 8.5 07742-0Or0100

Selectthe properreplacement guidossnd chillthem in the treezersectionot a refrigerator about an hour. Jor Usea hot plsteor ovento evenlyheattha cylinderhead to 3OOoF(150oC). Monitor the temperaturewith a cookingthermometer. eck )asJ aland

,to alve r. ol eler alve iurenor

c)o

CAUTION: . Oo mt uso a tordr; h may wrp thc hoad. . Do not glt dro he.d hotter rhan 3{X)oF fi5oocl: oxccsslvc hoat may looaan tl|c vdw rcat3. a To avoid brrB. uco heavy gbves whon hsnding tho hoad cyrer h.ad. 6.

lf a valveguidestillwon't move, drillit out with a I mm (5/16 inch)bh, then try again. CAUTION: Ddd gridos only in €xtr€m6 casas; you couH damago tho cytndcr hoad if ths guilo breaks. Remove new guide(s) the from the refrigerator, one at 8 time, as you needthem. (cont'dl

6-19

Valve Guides
(cont'dl Replacement
7. Slipa 6 mm (0.2 in)steelwashet andthe correctdriver attachmert ov€r the end of the driver(Thewasherwill absorbsome ot the impact and €xtend the life of the driver).

Reaming
NOTE: For new valve guidesonly. 1. 2. Coat both reamerand valve guide with cutting oil Rotatethe reamerclockwisethe full lengthol the valvs guide bore. Continueto rotatethe reamerclockwisewhile removing it from the bore. Thoroughlywash the guide in detergentand water to removeany cutting residue. Check clesrancewith a valve {page6-181. - Verify that the valve slides in the intake and exhaust vslve guideswithout exertingpressure.

F:-p-qo t t
DROER

3.

6 mm (0.2In) WASHER

ATTACHMENT 5.

t

4.

Instsllthe new guide(s)trom the camshaftside of the head;drive each one in until the attachmentbottoms on the head.lf you have all sixteenguidesto do, you mav have to reheatthe headone or two more times.

REAMER, VALVEGUIDE
5.5 mft

HANDLE REAMER

OTHAH-PJ7OlOA ot

oTHAH-PJ70l08
Turn teamgrin clockwise diroctiononlY.

VALVEGUIDEDRIVER, 07742-OOlO100

Valve Gulde Insta{od H.iglrt: 5-O.947 inl fntak€: 23.75-24.25 mm (O.91 Exhaust: 15.o5- 15.55 mm (0'593-0.61 2 in)

6-20

Valves,ValveSprings and VatveSeals
ValveSpringand ValveSealInstallation Sequence
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(EVALVE SEAL (WHTTE SPRINGI Replace.

VALVERETAIT{ER

ALVESPRII{G

VALVEGUIDE SEAII STALTIR KD-2899 COUMERCIAI,I.Y AVAILABT"E t{OlE: Usgsrnall endof tool. lO

EXHAUST VALVESEAL 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

Seals/Pulley Arms and Camshaft Camshaft/Rocker
lnstallation
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 cylinder heod. lubricate both sur(aces and install camshaft. OIL SEAL

SEAL GUTOE o7t{AG - PT0010A o.

CUP INSTALLEF OTNAF_PIOOlOA

I

afterreassembly. ""m tobes aubrt""a"
Turn the camshaftuntil its keywsy is facing up. (No.1cylinder TDC). Apply liquidgasketto the headmating surfacesof the No. 1 and No. 6 camshaftholders' - Apply liquidgasketto the shadedareas.
No.1

Tiohteneach bolt two turns at a time in the sequence belowto ensurethatthe rockersdo not bind on sh-own the valves. Spcdffod torcuo: 8 mm bolts: 22 N'm (2'2 kg-m, 16 lb-ft) 6 mm bohs: 12 N'm ( l .2 kg-m, 9 lb-ft) 6 mm BOLTS

-B
\J-

lt

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

8 mm BOLTS 7. 8. lnstallthe back cover. Installths key and the camshaftpulleyonto the camshaft, then tighten the retaining bolt to the torque shown. BACKCOVER
CAMSI{AFT PULLEY

o7l{ac-PTOOl0A Applyoil.

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

w M
I
INSTALLER SHAFT OTNAF_PTOO2OA

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

6-22

Cylinder Head
Installation
Installthe cylinderhead in the reverseorder of removal: FT ,A NOTE: a Always use a new headgasket. . Cylinderheadand engineblock surfacemust be clean. a "UP" mark on camshaftpulleyshouldbe at the too. . Tum the crankshaftso the No. 1 cylinderis at TDC (psge Installthe bolts that securethe intake manifoldto its bracketbut do not tighten them yet,
J.

Positionthe camshaftcorrectly (page6-29).

4. Tighten the cylinder head bolts sequentiallyin three
steps. 1rt stop to.que: 40 N.m (4.0 kg-m, 29 lb-ft) 2nd stop torque: 70 N.m (7.0 kg-m, 51 tb-ft) 3.d ctep to?quo: 10O N.m (10.Okg-m. 72 tb-ft) NOTE: a W€ recommendusinga beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. a lf a boh makesany noisewhile you are torquingit, loosenthe boh and retightenit from the I st steo.

6-28t.

o Cleanthe oil contrclorifice before installino. \ nce ,on 1. Cylinderhead dowel pins and oil control orifice must be aligned.

DOWEL PIN CYLINDER HEAD GASKET Replace.

ooml P {

a/
OILCONTROL ORIFICE Clean.
O-RING Replace.

CYLI'{DER HEADBOLTS TOROUE SEOUENCE

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

(cont'd) lnstallation
the 7 . lnstall the exhaust mdtifold and tighten "ri"""roo innel nut' a Always use 8 now exhaust manifoldgasket' nuts n a putt"a in 2 or 3 steps' beginning with the

the nuts In-a and " 5. Installthe intakemanifold tighten with the in 2 ot 3 steps' beginning "t't"""too p.orn innernuts. o Alwavsusea newintakemanifddgasket'
GASXET Replace.

th€n instsll the 8 . lnstall th€ exhaust manifold bracket'

pip",q and the bracket, and then install the i"h"tt cov€f.

GASKET Replace.

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

MANIFOLD

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

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

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

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

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

A PIPE EXHAUST

6-24

TimingBelt and TimingBalancer Belt
lllustrated Index
NOTE:
o Referto page 6-28 tor positioningcrankshaftand pulley beforeinstallingtiming belt. o Beforeremoving,mark directionof rotation.

ADJUSTING NUT POWER STEERING BELT 45 N.m(4.5kg-m, Adjustment, section 17 33 rb-ft) 6x l.Omm 12Nm(1.2kg-m, I tb-ft) \ \

UPPER COVER RUBBER SEALS Replace whendamaged or detsrioratod.
CAP NUT

I

LOWER COVER 6 x l . O m m Remove five 1 0 N . m ( 1 . 0k g - m , the 7 tb-ft) bolts.

CYLINDER HEAD COVER

::aNm(22.0ks-m, :3 bft) \:ot engineoil to the :crr threads,but not u '- surfacethat r.--ts the washet. .uGAELT .lo.ction, page 6-26 Sustm€nt, Page6-26 :,.dacement, pago 6-29

ltrcnNartia

/

l-

Adjustment, section 23

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

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

SEALS Replace when damaged or dgt€rioroled.

BELT TE SIOITERS

Remove any oil. SPRING

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

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

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

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

TIMII{G AALA CEREELT Inspection,page 6-27

6-25

TimingBelt
Inspection
the Disconnect altelnatorterminaland the connector. from the cylinder then removethe enginewire harness head cover. head cover' Removethe cYlinder Removethe upper cover. 4. Inspect the timing belt for cracks and oil or coolant soaking. NOTE: . Replace belt if oil or coolant soaked. the a Removeany oil or solventthat gets on the belt'

TensionAdiustment
CAUTION: AhtvavsadFst timing boh tensbn with th6 ongin6 cold. NOTE: to o The tensioneris springloaded applypropertens'onto the belt sutomaticsllYafter making the lollowing adjustment. a Always rotate the crankshaftcounterclockwisewhen viewed lrom the pulleyside. Rotatingit clockwisemay result in improperadlustmentof the belt tension the belt beforeadiusting belt . Inspectthe timing balancer tension. . Do not loosenthe adjustingnut morethan one full turn' 1. terminaland the connector' the Disconnect alternator flom the cylinder then removetheenginewire harness headcover. Removethe cylinderheadcover'
a 4.

Inspectthis arealor wear.

Set the No. 1 piston at TDC (page6-28). Loosenthe adiustingnut 2/3-1 turn, then tighten it'

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

Rotate the crankshaft counterclockwise3-teeth on nutto the the camshaftpulley.then reloosen adiusting createtensionon the timing belt.

:

5,

to the After inspecting,retorque crankshaftpulleybolt N.m (22.Oks-m, 159 lb-ftl' 220

6.

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

TimingBalancer Belt
Inspection
1. Disconnect altematorterminaland the connector, the then removethe enginewire harnesstromthe cylinder headcover. Removethe cylinderheadcover Removethe uppercover. Removethe crankshaftpulley. Removethe lower cover, Installthe crankshaftpulley. Inspectthe timing balancerbelt for c.acks and oil or coolantsoaking. NOTE: o Replace belt if oil or coolant soaked. the a Removeany oil or solventthat gets on the belt. Inspect area wear. this tor

2. 3. 4. 5, 6. 7.

pulley Botate andrnspect belt. After inspecting,retorque crankshaftpulleybolt to the 22O N'm (22.Oks-m, 159 tb-ftl. NOTE: Refer to page 6-32 tor timing batancerbelt tension adjustment.

6-27

Timing Belt
TimingBelt BeforeInstalling Crankshaft Positioning
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:

TDC POSITIO]T: CRANKSHAFT MANUAL TRANSMISSION: FLYWHEEL HOLE INSPECTIOI{

,,UP"MARK

AUTOMANC TRANSMISSION:

DRIVEPTATE

INSPECNO HOLE

TOC MARK (WHITEI

POINTERS

ot{ BLocK

NOTE: When turning the crankshaft with a socket wrench, installthe crankshaftpulleyand rhe pulleybolt'

6-28

TimingBeltand TimingBalancer Belt
. Replacement
CAUTION: Inspoct tho walor pump whon radachg th6 timing b€lt (Pag610-12) NOTE: Turn the crankshaftso that the No. 1 piston is at TDC (page6-28). I . Removethe splashshield. 3. Removethe mounting bolts, nuts and P/S pump belt from the power steering(P/S)pump. NOTE: a Do not disconnectthe PiS pipe and hose. . After installing,adiustthe tensionof the P/Spump belt {seesection171. POWEB STEERING PUMP MOUNTING BO(TS LOCKNUT 1 5N . m{ 1 . 5 g - m , k 11 tb-ft)

8x1.25mm SPLASH SHIELD

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

P/SPUMP AELT

.,

Disconnectthe connector. then remove the cruise control actuator. NOTE: a Do not disconnectthe control cable. a Takecarenot to bendthe cablewhen removingthe actuator.Always replace kinkedcablewith a new a one.

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

CRUISE ACTUATOR

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

ALTENNATOR AELT

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

6-29

Belt TimingBeltand TimingBalancer
(cont'd) Replacement
Removethe cylinderheadcover. for Remove sideenginemount bracketB {standard the some typesl. Removeth€ uppercover. Removethe side enginemount. I 1. Removethe pulleybolt and the crankshaftpulley Remove the two rearboltsfrom the centerbeamto allow to the engineto drop down and give clearance remove the lower cover. 12. Removethe rubbsr seal aound the adiustingnut. Do not loos€n the adiusting nut. 13. Removethe lower cover'

'10.Removethe dipstick and the pipe.

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

DIPSTICK/PIPE

HEAD CYUNDER COVER

e
e

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

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

RUBBER SEALS when Replace damagedor deterior6ted.

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

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

TIMING BALAITCEFBELT Inspection,Page6-27

6-30

e-

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

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

)o

TIMINGBELT ADJUSTER ARM

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

t

DRIVE PULLEY

(cont'd)

6-31

Timing Belt and Timing BalancerBelt
Replacement(cont'dl
22. Make surethe crankshaftis positionedwith the No 1 piston at TDC. after pulleywith 23. Alignthe grooveon the front balancer the pointeron the oil pump housingas shown, 24. Align the rear balancershaft pulleyby using 6 x 1OO mm bolt or equivalentas an alignmenttool. Scribea line 74 mm (2.9 in) from the end ol the bolt. holeto the scribed Inserttheboh intothe maintenance line. 27. Turn the crankshaft pullev about one turn counterclockwise,then tighten the adjustingnuit to the speci{ied torque. NOTE: Both belt adiusters are spring-loaded to properly tensionthe behs.Do not spply any extm pressure to the pulleysor tensionerswhile performingthe adiustment,
SHAFT REARBALANCER

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) 6 x 10O mm BOLT

MAII{TENANCE HOLE WASHER Replace. 12 mm SEAU G BOLT 30 N.m(3.0 kq-tn,22 lb-ftl the NOTE:Tighten boltafter installingthe belt. AI'JUSTII{GNUT BOLT 6 x 100 1'|m

Align the groove of the front driven pulley with the pointer on the oil pump housing.

BELT TIMINGBALA'TCER DRIVEPULLEY Set the crankshaftat TDC.

6-32

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

32. Installthe upper cover. 33. Installthe crankshaftpulley.

29. Removethe crankshaftpultey. 30. Installthe lower cover. 3 1 .Installa rubberseal aroundthe adjustingnut. Do not
loosenthe nut. Specifiodtorqus: 220 N.m {22.Okg-m. 159 tb-ft}

34. Coat the threads and seatingtace oJ the putley bolt
with engine oil. Install and tighten to the specified rorque.

UPPER COVER

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

ADJUSTING I{UT 10x1.25r n
45 N.m (4.5 kg-m, 33 rb-ft)

SEAL
Replgcswhon damsged or dsterioratsd.

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

6-33

Valve Clearance
Adiustment
NOTE: . Valvesshouldbe adjustedcold when the cylinderhead is temoerature lessthan loOoF {38oC). . After adiusting,retorquethe crankshaftpulley bolt to 22ON.m (22.0 kg-m, 159 lb-ft). 1. headcover. the Remove cvlinder INTAKE Adjust valves on No. 1 cylinder.

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

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

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

EXHAUST

LOCKlrlUTTxO.T5mm 14lb-ft) 20 N.m(2.0kg-m, oil. Applyengine GAUGE FEELER

2.

"UP" mark on the camshaft Set No. 1 piston at TDC. pulleyshouldbe at top, and TDC grooveson the camshaft pulleyshould alignwith cylind€rh€ad surface.

5.

adagain.Repeat Tightenlocknut8nd checkclearance justment if necessary.

Numbor1 riston at TDC:

@-€
\

) l-24

Ut\-/

6-34

6.

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

8.

Rotatecrankshat180o counterclockwise bring to No. 2 pistonto TDC. The "UP" mark shoutdbe at intske side. Adjust valves on No. 2 cylinder.

Number 3 Piston at TDC:

Number 2 Pbton at TDC:

,,UP" MARK

7,

Rotatecrankshaft180o counterclockwise bring to 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/Valve Train

(H23A1engane)

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

Valve Guldes ValveMovement ....................... 6-52 Replacernent .......6-53 Reaming ............. 6-54 RockerArms/Camehafte and Camrhaft Soals/Pulleys lnstallation .........6-57 Tlmlng Belt and Timing Balancer Belt lllustratod Index ........................ 6-59 Replacement .......6-63 Timing Belt Inspoctlon ..........6-60 Tension Adjustment ................... 6-60 Positionlng CrankshaftBefore Installing Tlming Belt .............. 6-62 Timing Balancer Beh Inspoction ..........6-61 Valve Clearance Adjustment .........6-68

SpecialTools

Ret.l{o.

\

Too\ l{urnbor 07GAD-PH70100 o7757-PJ1010A 07942-6570100 or O7984-657O1OC 07984-657010D

O6r,cdgl0tr\ Valve Guide S€al lnstall6] Valve Spring Compressor Attachment Valve Guide Driver,6.6 mm Valve Guide Reamer,6.6 mm

qq
1 I 1 1

\

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

o

@ @ @

I

t
o
--fl'------------

o

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 10 N'm {1.0 kg-m,7 lb-ftl

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

e

o

WASHER

RUBBEB SEAIS
Replace wlrsn or doteriorat€d.

8 x 1.25mrn 22 .m (2.2 lg-m, lE lb-ttl 6rlOmm 12 N.m (1.2 kg-m,9 lb-ttl

DOWEL PIII

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

13 lb-frl

ui ffiHnfl ,&V, W#
L!, e

I fr n-'-'' flE uflE

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

/tt{TAKE CAMSHAFT HOLDER

8-

iih qub
o

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

HEX

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,
INTAKE VALVE GUIDE Insp€ction, page 6-52 Replacement,page 6-53 pag€ 6-54 Rsaming,

VALVE
SPRINGRET

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

EXHAUSTVALVE EXHAUSTVALVESEAL Rsplaca. SEAT VALVESPRING VALVE EXHAUST

nfl

VALVEKEEPERS RETAINER SPEING A(E VAIV€ SPNI G I]{TAXEVALVE SEAL
Replacam€nt, psg€s 6-41 and 50

ALVESPRI G SEAT EIID PIVOT EOLTS 64 N'm 16.4kg-m,46 lb-ftl
CYLINDERHEAD R€moval. page 6-43 Reconditioningvalve seat, pago 6-51 Warpage, page 6-52 Installation, pag€ 6-56 CYLINDERHEAD GASKET IMETAL GASKET} Roplace. OOWEL PIN OIL CONTROL ORIFICE Clean. O-RING Feplace.

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

45 N.m (4.5 kg-m,

33 rb-ft) 8 x 1 . 2 5m m 22 N.m {2.2 kg-m, 16 lb-ftl INTAKEVALVE Replacemont,
Dimonsions, pag€ 6-50 Reconditioningvslve s€at, pag€ 6-5'l Adiustment. paga 6-68 TIMING BELT Inspection/Adiristment,page R6placoment.page 6-63

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

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

6-40

Valve Seals
Replacement head removalnot requiredl {Cylinder
NOTE: Cylinder head removal is not required in this proc€dure. Usethe procedure shown below applies when usingthe in-car valve spring compressor(Snap-on YA8845). Alway waar approved oye protcction l@ when using tho in-car valvo spring comp€as{rr. 1. Turn the crankshaftso that the No. 1 and the No. 4 Distonsare at TDC. 2. 3. Removethe cvlinderhead cover. Loosen and remove timing belt from the camshaft pulleys. Remove the distributor. Removethe camshsft holder bolts, then removethe camshaft holders, the camshafts, and the rocker arms. Usingthe 6 mm boltssupplied with the tool, mount the two uprights to the cylinder as shown. Insert the cross shaft through the bottom holes ol the two uprights. Intako Valva Sorb: 8. Selectthe 1-1l18 in. diameter longcompressor attachment and fasten the attachment to the hole of the lever arm with the speed pin supplied.

9 . Insert an air sdaptor into the spark plug hole. Pump
air into the cylinder to keep the valve closed while compressing springs and removing the valve keeoers.

1 0 . Positionthe lever arm under the cross shalt so the
lever is perpendicular the shaft and the compresto sor attachment rests on top of the retainer for the spring boing comp.essed, Use the tront position slot on the lever as shown. NOTE: Put shop towels over the oil passagesto prevent ths valve keepers from lalling into the cvlinderhead.

4. 5.

OIL PASSAGES

OIL PASSAGES

(cont'd)

6-41

Valve Seals
1 1.

(cont'dl (Cylinder head removalnot required) Replacement
Usinga downward motion on the leverarm, compressthe valve spling and removethe keepersfiom ths valve stem. Slowly releasepressureon the spnng. Repeatstep 1 1 for the other intakevalve in that cvlinder. Removethe valve seals (page 6-50). Replace the valve seals (page6-55). Installthe springs,the retainers8nd the keepers in reverse order of removal.

1 8 . Using a downward motion on the lever arm, compressthe valve spring and removethe keepersfrom the valve stem. Slowly release pressurs on the spflng.

12.

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

13. 14. 15.

20. Removethe valve s€als (page 6-50). 2 1 . Replacethe valve ssals (page 6-55). 2 2 . Install the springs, the retainers and the keepers
in reverse order of removal.

Exhaust Valvo Soals: 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. to NOTE: Put shop towels over the oil passages prevent the valve keepers from Jalling into the cvlinderhead.

23. Rep€at st€ps 8 to 22 for the other cylinders.

ll

6-42

Cylinder Head
Removal
Enginer8movalis not requiredJor this procedure.
l.

Disconnect the negative terminal trom the battery.

2 . Drainthe enginecoolant (seesection 1O).
a Mako sure iscks and safoty stands ars placad propedy and hoist bfacksG era attachod to corract positions on ths oingino. a Mako suro tho car will not roll oft stands and fall while you ar6 working und€r it. CAUTION: a Uso fendor covors to avoid damaging paintod surtaces. a Unspocifiod items ara common. a Unplug tlF widng connectoB caroft.fy while hol+ ing th6 connocto? ponion to avoid damags, a Ma.k 8t wHng and hoss3 to rvdd rrisconncctlon. Also, bo sur6 that thsy do not contact othor wiring oi hosos o. intorfats with other parts. a To avoid damaging the cylindar herd, w8it untll tho engine coolant 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 circuit. Be sure to get the customer's code number before. - Disconnecting the battery. - Removing the No. 43 (lOAl fuse. (ln the under-hood fuse/relav boxl - Removingthe radio. After service. reconnect Dowe. to th€ radio and turn it on. Whenthe word "COOE" is displayed, enter the customer's 5-digit code to restore radio ooeration. a Removethe radiatorcap to speed draining.

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

Removethe intske air duct. Removethe fuel teed hose and evaporativeemission (EVAP) control canister hose from the intake manifold.

6.

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

THROTTLECONTROL CABLE LOCKNUT

(cont'd)

6-43

Head Cylinder
(cont'd) Removal
7. the Remove tuel feed hose,the tuel returnhoseand the brake boostervacuum hose. FUELFEEDHOSE 9. R€moveth€ engine ground cable Jtom th€ cylinder head cover.

10, Disconnect the alternator terminal and connector, then remove the engine wire harness from tho cvlindsr head cover. WIRE EI{GINE HARNESS

WASHER Replace.

6r

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

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

the lP/S)pump belt and 11. Removo powsr steering pump. the a Do not disconnect P/S hosos.
the lollowingenginewire hsrnessconnecRemove tors and clamps ftom the cylind€r head and the intake manifold: o a a a a a a o a a a a a a a a a Four fuel injectorconnectors (lAT) sensorconnector lntake air temDerature ldle air control (lACl valve connector Throttle position (TP) sensor connector Exhaust g8s recirculstion (EGR)valve lift sensor connecror Groundcableterminals (ECT)switch B concoolanttemperature Engine necror Heatedoxygen sensor (HO2S)connectot ECT sensor connector ECT gauge sendingunit connector lgnition control module llCMl connector sensorconnector CKP/ToC/CYP VehiclesDeedsensor (VSS)connector lgnition coil connector Intake air bypass solenoid valve connsctor ECT switch A connector Knock sensorconnector 8 x 1.25mm 22 .|n (2.2 kg-m, 16 tb-ft1

15 N.m ll.5 *g-m, I I lb-ftl

6-44

12. Removethe ignitioncoil.

16. Remove the intake manifold bracket and intake manitold.

IGNITION COIL

*8 x 1.25lnm *6x LOmm 22 N.m 12.2 ke-m, CO ECTOR 12 rr| {1.2 kgn, 16 tb-trl 9 tb-ft1 13. Remove the emission vacuum hoses and water bypass hoses from the intake manifold asemblv. 14. Removethe radiatorupper hose and heater hose from the cvlinderhead. 1 5. Removethe water bypass hose and the thermostst housing. 17. Removethe selt-lockingnuts and disconnectthe ex_ haust manitold8nd exhaustpipe A. 18. Removethe heat insulator(carsequippedwith A/Cl, exhaustmanifoldbracketand exhau$ manifold.

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

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

6-45

CylinderHead
Removal {cont'd)
1 9 . Remove the PCV hose, then remove the cylinder head cover. 24. Remove the camshatt Pullsys. NOTE: To set the camshafts at TDC for No. 1 alignthe holesin the camshaftswith thg cylinder, holesin the No. 1 camshaftholdersand insert 5.O mm oin punches.

20. Removethe middlecover. 2 1 . Loosenthe adjustingnut 180".
Pushthe tensionerto releasetension from the timing belt, then retightenthe adjustingnut.

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

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

G4z
No Good ADJUSTING SCREWS

6-46

Removethe side engine mount bracket B and back covea.

NOTE: Separate the cvlinderheadfrom the block with a flat tip screwdriveras shown.

ENGII{E MOUI{T SRACKET B

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

BRACKET

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

27. Removethe cylinderhead bolts, then removethe cylinderhead. CAUTION: To prevont vvalpaga,unscrlw tho bohr in sequenc€ 1/3 turn at a timo; rapaat until all bohr arg loosaned, CYLINOER HEAD BOLT LOOSEI{INGSEOUEI{CE

6-47

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

Camshafts
Inspection
NOTE: Do not totate camshaft during inspection' 1. Removethe rocker arms. NOTE: Rockerarms musi be installedin the same oosition if reused.

"UP" m6rks

2.

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

Align the marks on the pulleys.

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

@ @

@

t ,

PULLEYBOLTS

6-48

I
?

Seatcamshaftsby pushing them toward distributor end of cylinderhead. Zero dial indicatoragainstend of camshsft, then push camshaft back and forth, and readthe end play. Camshaft End Play: Standard(New): 0.O5-O.15 mm (0.0O2-O.006 in) Sorvice Limit: 0.5 mm {0.02 in}

7.

lf camshaft-to-holder oilclearancsis out oftolerance: a And th6 camshaft has alreadybeen replaced,you must r6placgthe cylinderhead. r lf camshaft has not been replaced,first check total runout with th6 camshaft supported on Vblocks. Crmrheft Total Runout: Standard (Nowl: 0.03 mm (O.0Ol Inl max. Sorvlce Llmh: 0.06 mm (0.002 Inl

4.

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 are pitted, scored, ot excessively worn, a Clean the camshaft beadng surfaces in the cylinderhead.then set csmshaft back in place. a Insert plastigage strip acrosseach journsl. a Install the camshaJt holders and torque bolts to the valuesand in the sequence shown on page 6-48.

- lf the total runout of the camshsft is within tolerance, replace the cylinder head. - lf the total runout is out ot tolerance, replacethe camshaft and recheck. lf the oil clearanceis still out of tolerance,replacethe cylinderhead. 8. Measurecamshaft lobe height. Intak. Standlrd: 33.661 mm (1.3252 inl Exhlurt Stlnda.d: 33.725 mm (1.3278 Inl

6.

Measure widest portion ot plastigage on each journal. 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.OOB inl

Inspect this are for wear.

6-49

Valves,Valve Springsand Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are remov6d so that €ach item can be reinstalledin its original position. 1. Tap €ach valve stem with a plastic mallet to loosen valve keepers before installing the spring comDressor. Compress springand Installthespling compressor. remove valve keeper. 4. Removeth€ valve se8l.

2.

COMPRESSOR VALVESPFING AVAILABLE COMMERCALLY

VALVESPRING COMPRESSOR ATTACHMENT 07757-PJIOIOA

3.

Installthe sDecial tools as shown, lntake Valvo Dlncndons A Standard (Nowl: 33.90-34.10 mm

VALVE GUIDESEALRETVIOVER LISLE P/N57900 or KD335o AVAILABLE COMMERCIALLY

(1.335- 1.343inl mm B Standard l]{.wl: 102.6O-1O2.8O (4.035-4.047 lnl C Standard {rw}: 6.58O-6.590 mm inl 10.2691-O.2594 Inl 6.55 mm 10.258 C Sorvic. Llmh: D StandErd ( !rv): O . 8 5 -1 . 1 5m m (O.O33-o.o45 Inl inl 0.65 mm (O.O26 D Servic€ Llmh:
Exhoust Valvo Dlmcnalonr A Standsrd(Newl: 28.9o-29.10 mm

( 1. 1 3 8 - 1 . 1 6 1I n l (3.992-4.oO4inl

m B stand.rd lt{cw}: 1 0 1 . 4 0 -1 O 1 . 7 0 m
C StandErd lt{ewl: 6.550-6.560 mm

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

(O.O41-0.O53 In) inl o.85 rnm (O.O33

6-50

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

VALVE SEAT o
PRUSSIANBLUE COMPOUI{D

K@"8
Carefully cut a 45o se8t. removing only enough materialto ensurea smooth and concentricseat. Bevelthe upper edge of the seat whh the 3Oo cutter and the lowsr edg€ of the seat with the 600 cutter, Check width of sest and adjustaccordingly. Make one more very ligt|t pass whh tha 45o cutte, to removeany possible burrscaussdby the other cufters. VCv. Sct Wld$ (ht!k lnd.xhaltl: Standlrd: 1.25- 1.55 mm (O.O49-O.061 int Sendcellmh: 2.0O mm (0.079 in)

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. NOTE: The tinal cut shoutdalways be made wirh the 45o cutter. Insen intake and exhaust valves in the head and measurovalve stem installedheight. Intake Valve St.m Inliall.d Hright: Standard (l{cwl: 39.365-39.835 mm (1.5498- 1.5683 inl Scrvlce Limlt: 4O.Oa5 (1.5781 tnl Exhau* Valve Stom lnstallcd Hdght: Standard(Now): 39.165-39.635 mm 1 1 . 5 4 1 9 -1 . 5 6 0 4i n l S.rvlce Limit: 39.885 mm ('1.5703inl

) VALVESTEM INSTALLED HEIGHT

8.

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

6-51

CylinderHead
Warpage
oil NOTE: lf camshaft-to-holder clearances(page 649) are not within specitication,the cylinder head cannot be resurfaced. oil lf camshaft-to-holder clearancesare within specifications, check the cylinderheadlor warpage . lf warpageis lessthan0'05 mm (0.0O2in)cylinderhead resurfacingis not requar€d . lf wsrpage is b€tw6€n O.05 mm {0.0O2 in) 8nd 0.2 mm (0.008 in), rosurfacecylinderhead. in) . Maximumresurface limit is 0.2 mm (0.OO8 basedon a heightof 132.o mm (5.20 in)

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

..

.o

M€ssuro along gdggg. and 3 ways across center'

a lf measuremant exce€dsthe servicelimit, r8check using a new valvs. a lf measurement is now within the servic€ limit. reassembleusing a ngw valv€. a lf measurementstill excaads limit, recheck using alternate 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 micrometer o. ball gauge. Take the measurements in three places along the valve stem and three placesinsidethe valve guide. The difference betwesn the largest guide measureshouldnot ment and the smalleststem measurement exceedthe servicelimit.

Cyllrdor H6ad H€ight: Stardard(Nowl: 131.95- 132.05mm 1 5 . 1 9 5 5 . 1 9 9i n l -

Intake Valvo Stom-tecuida Closrsnca: Stardtd lt{rw}: 0.02-0.05 mm -O.OO2 in) (O.OOl O.08 mm (O.0O3in) Servba Limit: Erhaust Valw Stom-to4uidc Cbarancs: Stsrdrd (ltlew): O.05-O.O8 mm (O.OO2-0.OO3 inl in) O.11 mm (O.0O4 ServlccLimit:

6-52

Replacement
1. As illustratedin the removalsteps of this procedure, use a commercially-available air-impact driver attachment moditied to fit the diameter ot the valve guides. In most cases, the same procedurecan be done using Valve Guide Drivers and a conventional hammer. Tool numbers are at the end of this Drocedure. 4. Workingfrom the camshaftside, usethe driverand an air hammer to drive the guide about 2 mm (0.1 in) towards the combustionchamber.This will knock off some oJthe carbonand make removaleasier, CATUION: 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 $.rido to pr8vont damaging the driver. 5, Turn the headover and drivethe guideout toward the camshaftside of head.

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

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

57mln
l2-24h,tl

l_l lr_r

1 1 . 3m m O.44In)

R€moval installation and VALVE GUIDE DRIVER. mm 6.6 07942-6570100 Selectthe properreplacement guidesand chillthem in the freezersectionof a refrigerator about an hour. for Usea hotplate oroven to evenlyheatthecylinderhead to 3OOoF{150oC). Monitor the temperarure\^iith a cooking thermometer.

VALVE GUIDE DRIVER COMMEBCIALLY AVAILABLE

lo

-\

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

6-53

Valve Guides
Replacement {cont'd}
7. SliDa 6.5 mm (0.26 in) steel washer and the correct driver attachment over the end of the driver (The washerwill absorbsome of the impact and extendthe life of the driver).

Reaming
NOTE: For new valve guidesonly. 1. 2. Coat both reamerand valve guide with cuning oil. clockwisethe fulllengthofthe valve Rotatethe reamer guide bore. Continueto rotatethe teamerclockwisewhile removing it trom the bore. Thoroughlywash the guide in detergentand water to removeany cutting residue. check clearance with a valve (page 6-52) o Verify that the valve slides in the intake and exhaust valv€ gurUeswithoui exerting pressufe.

T:-r-w
DRIVER hl 6.5 rm 10.26 WAHSER T ATTACHME Insta,,thenew guidels)trom the camshaftside ot the head:drive each one in until the attachmentbottoms on the head.lf you have allsixteen guidesto do, you mav have to rcheat the head one ot two more times DRIVER, VALVEGUIDE 6.6 mm 07942-65701fi,

3.

4.

5.

REAMER HA'{DLE

07984-65701OC ol 07984-657010D

Vdvo Guide InstatredHoight: Standard(Newl: l m a k e : 1 3 . 2 5 - 1 3 . 7 5m m ( O . 5 2 2 - O . 5 4 1n ) i Erhaust: 13.75- 14.25 mm ( O . 5 4 1 - O . 5 6 1n ) i VALVEGUIDE

6-54

Valves,ValveSprings and ValveSeals
ValveSpdngand ValveSealInstallation Sequence
NOTE: Exhaustand intake valve sealsare NOT interchangeable.

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

IIITAKEVALVESEAL WHITESPRIIIGI Beplace.

VALVERETAINER

VALVESPNNO VALVEGUIDE SEAL IITSTALLER oTGAO-PH701(x)

EXHAUST VALVESEAL (BTACK SPRING} Replac€.

SPRING SEAT 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

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

in headboltssequentially three the 2. Tighten cylinder steps. lst stoptorque: 40 N m (4.0 kg-m,29 lb-ft) 2ndsteptorque:70 N'm (7.0kg-m,51 lb-ft) 3rd stoptorquo: 10ON m {10.0kg-m,72 lb-ft) NOTE: wrench' torque a a We recommend using beam-type torquewrench,be sure usinga preset-type When slowlyandnot to overtighten' to tighten it, whileyou aretorquing . It a boltmakes noise any it tromthe Ist step' the loosen bohandretighten SEOUENCE TONOUE HEAD CYLINOER BOLTS

DOWEL

\ \ \

CYLINOER HEADGASKET Replace.

0

OIL CONTROL ORIFICE Clean. O-RING Replace.

HEADBOLTS CYLII{OER m 1 2x 1 . 2 5 m 72lb-ft) 1OO llO.Okg-m. N.m oil engine bolt Applyclean boltheads threads under and

6-56

RockerArms/Camshafts and Seals/Pulleys
Installation
lnslallthe intakemanifoldand tighten the nuts in a paltern in 2 or 3 steps. beginningwith criss-cross the Inner nuts. GASKET . Mak6 sura drat the keyways on th€ camdrafts a]€ fackrg up. (No. 1 r* on TDCI. a Valv€ locknuts should b€ loosonedand boforo scrsws backed off botoio installation. a Replac€the rocker arms in thsir origlnal positions, 1. Place rocker the armson the pivotboltsandthe valve srems. Installthe camshaftsand the camshalt sealswith the open side (spring)facing in.

2.

8 r 1.25 m m 22 N.m(2.2kg-m, 16 tb-ft) 22 N.m(2.2kg-m, 16 tb_ft} 4. Install exhaustmanifold the and bracket. Tighten the patternin 2 or 3 steps, beginnuts in a criss-cross ning with the inner nuts. GASKET I x 1.25mm Replace. 32 N.m{3.2kg-m, 23 rb-ft)

ROCKERARM

3.

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

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

33 rb ft) 6 x 1 . 0m m

K g H H F HWi
Ili H

l"'l_m*ll ^/'""1"'"1*" trBfr m ffi n
/No.

No.2

1

,

TNTAKE

GASKET Replace.

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

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

tru

M H
H

6r &{ pI
LOJ

16r M

tl

liT

4.n**" ffi
{cont'd)

6-57

and Seals/Pulleys RockerArms/Camshafts
(cont'd) lnstallation
4. Tightenthe camshaftholderstemporarily' a Make sure that the rocker arms are properlyposltioned on the valve stems'

Torque:Exhaust SDecifi6d 7lb-ft) Exceot (O: 10 N m {1.0kg-m, G), k , 1 2 N . m{ 1 . 2 s - m 9 l b - f t ) @, @i

\
5. Pressin the camshaftsealssecurely.

lnstallthe back cover.

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

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

(9,(r,

INTAKE

I x 1 . 2 5m m

9.

Push camshaft pulleys onto camshafts,then tighten the retainingbolts to the torque specified'

(page6-68). 1 0 . Adjust the valve cle316nes check that the all tubes, hosesand 1 1 .After installation, connectorsare installedcorrectly.

6-58

Timing Belt and Timing BalancerBelt
lllustrated Index
NOTE:
. Referto page 6-62 for posilioningcrankshaftand pulley beJore installingtiming belt. a BeJore removing,mark directiono{ rotationon each belt.

POWER STEERING IP/SI PUMP BELT Adiustment, section17

ALTERNATOR BELT Adjustment, section ADJUSTTNG 23 NUT
45 N.m {4.5 kg-m, 33 rb-ft)

LOWER COVEB COVER Remove tive bolts. the

6x1.0mm
12Nm(1.2kg-m,

9

RUEBER SEALS ReDlace when damaged deto.iorated. or

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

Removg oil. any 14 x 1.25 mm RUEBER SEALS 220 N.m (22.0 kg-m, 159 tb-ft) Roplace when 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) TEI{SIO'{ER SPAII{G KEYS

PULLEY 8OL

R'LLEY

------+o WASHEB

TE SIOI{ER SPRII{G

BELT tENStOa{ERS

CAMSI{AFT PULLEYS

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

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

TIMING BALANCERBELT Inspectjon, page 6-61.

surlacelacing in. Bemoveany oil.

6-59

TimingBelt
Inspection
1. the Disconnect alternatorterminaland the connector, from the cylinder then removetheenginewire harness head cover. Removethe cylinderheadcover. Removethe middlecover. lnspect the timing belt for cracks and oil or coolant soaking. NOTE: a Replace belt if oil or coolant soaked. the . Removeany oil or solvent that gets on the belt.
this Inspect area{or wear.

TensionAdiustment
CAUTION: AtwaF adiust timing boh tension with thew enginecold. NOTE: to o The tensioner springJoaded applypropertensionto is after making the following adthe belt automatically justment. . Alwavs rotate the crankshaft counterclockwise when viewed trom the pulleyside. Rotatingit clockwisemay result in improperadiustmentot the belt tension. the belt beforeadjusting belt . Inspectthe timing balancer tension. a Do not loosenthe adjustingnut morethan one full turn' 1. terminaland the connector, the Disconnect alternator then removetheenginewire harnesstrom the cylinder head cover. Removethe cylinderheadcover. Set the No. 1 piston at TDC (page6-62). Loosenthe adiustingnut 2/3-1 turn, then tighten it'

2. 3. 4.

2. 3. 4.

Rotatepulley ano rnspect belt.

After inspecting, retorque the crank*|aft pulley bolt to 22ON.m (22.Okg-m, 159 lb-ft).
o.

3-teethon the Rotatethe crankshaftcounteclockwise then reloosenthe adjusting nut to camshafqpr.rlley, createtensionon the timing belt. Tightenthe €diustingnut. After adiusting,ratorquethe crankshaftpulleybolt to 22O N.m {22.Okg-tn, 159 lb-ft).

6-60

TimingBalancer Belt
Inspection
1, Disconnect alternatorterminaland the connector, the then removethe enginewire harness from the cylinder headcover. Removethe cylinderheadcover. Removethe middlecover. Removethe crankshaftpulley. Removethe lower cover. Installthe crankshaftpulley. Inspect the timing belt for cracks and oil or coolant soaking. NOTE: a Replace belt if oil or coolant soaked. the o Removeany oil or solventthat gets on the belt.

2. 3. 4. 5. 6. 7.

pullgy Rotate andinspect bglt. 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
TimingBelt. BeforeInstalling Crankshaft Positioning
NOTE: . Installthe timing belt with the No. 1 piston at TDC. . After installing,retorquethe crankshaftpulley bolt to 22ON.m (22.Oks-m, 159 lb-ft). CMN(SHAFTTDCFOSITION: TDC CAMSHAFT FOSITION: ,,UP''MARKS

POINTERS ON BLOCK

TDC MARKS Align the marks on the pullays.

FLYWHEEL

DRIVEPLATE PI Pt CHES,5.0 nm

CAUTIOI{: Romovc thr pln Frnchos attor installlng th. tlming boh.

NOTE: When turning the crankshaft with a socket pulleyand the pull€y wrench, installthe crankshaJt bolt.

6-62

TimingBeltandTimingBalancer Belt
Replacement
CAUTION: lmpoct tho water pump whon roplacing the timing b€h lpags 10-12). NOTE; Turn the crankshaftso that the No. I oiston is at TDC (page6-62). 1. Remove sDlash the shield,

3. Removethe mounting bolts,nutsandpoly-V-b€lt from (P/Sl pump. the powersteering NOTE: . Oonot disconnect P/SpiDe hose. the and . Afterinstalling, adiust tension the P/Spump the ot
belt (seesection 171. LOCKI{UT ' 1 5 . m( 1 . 5 g - m , N k 11 tb-ft)

P/S PUMP

SPLASH SrmU) Disconnectthe connector, then remove the cruise control actuator. NOTE: a Do not disconnectthe control cabte. . Takecarenot to bendthe cablewhen removingthe actuator.Always replace kinkedcablewith a new a one. CNU|sE CONTROL ACTUATOR 6r1.0mm 1oNm(1.okg-m, 7 tb-ft) 4.

BOLTS/T{UTS 8 r 1.25rfn 22 N.m 12.2 kg-m, 16 rb-ftt Disconnect alternatorterminaland the connector, the then removethe enginewire hamessfrom the cylinder headcover. Loosen the altemator mounting bolt, nd rnd the adiusting boh, then removethe ahernatorbeh. NOTE: After installing,adiustthe tensionof the alternator beh {seesection 23). J:aLIERNlton ool{]{ECTOR MOUI{TIXG BOLT tO x 1.25mrn 45 N.m(4.5kg{, 33 lb-ft)

ADJUSTING BOLT

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

ALTERI{ATOR BELT (cont'd)

6-63

Belt TimingBeltandTimingBalancer
(cont'd) Replacement
6. Removethe cylinderheadcover. 7. Removethe middlecover. 8. Removethe side enginemount. 9. Removethe dipstick and the pipe. 1 1 .Removeth€ rubberseal aroundthe adiustingnut. Do not loos€nthe adjustingnut. 12. Removethe lower cover. 6x1.0mm k 9 1 2 N . m( 1 . 2 g ' m , rb-ftt
12 x 1.25 mft 55 N.m (5.5 kg-r(, 40 tb-ft)

1 0 . Removethe pulleybolt and the crankshaftpulley.Remove the two rearboltsJromthe centerbeamto allow the engineto drop down and give clearancetoremove the lower cover,

O-RING Replace.

1 2 x 1 . 2 5m m 65 N.m {6.5 kg-m, 47 tb,ft) SEALS RUBBER whsn Replace damagedor deterio.ated.

SEAL RUBBER Replace when damagedor det€aiorated.

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

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

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

TIMII{G BELT Inspoction, pago 6-60 Adiusting, page 6-60

6-64

t

13. Lockthe timing belt adlusterarm in placeby installing one of the 6 x 1 .O mm lower cover mounting bolts, 14. Loosenthe timing belt adjustingnut. Pushon the pulleyto removetensionfrom the timing balancer belt, then tighten the adjustingnut. '15. Removethe timing balancerbelt. NOTE: lf you are removing only the timing balancer belt, go to step 21 . li you are removingboth belts, continuewith this procedure.

16. Loosen6 x 1.O mm lock bolt and the adjustingnut. Pushon the timing belt adjusterpulleyto removetension trom the belt, then tighten the adjustingnut. 17. Removethe timing b€lt. 18. lnstallthe timing beh in the reverseorderof removal. - Beforeinstalling timing belt, positionthe crankthe shaft and camshaft pulleys as shown on page 6-62. 19. Per{orm the timing belt tension adiustment {page

6-60t.

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

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

(cont'd)

6-65

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

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

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

6 x 100 rm BoLT

ADJUSTING ]{UT

I

Align the g.oove oI the front driven pulley with the pointer on the oil pump housing

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

BALAI{CER BELT ORIVEPULLEY Set the crankshaft at TDC.

6-66

27. Removethe 6 x 1,Omm bolt from the timing belt adjuster arm. 28. Removethe crankshaftpulley. 29, Install lowercover. the 30. Installa rubberseal aroundthe adiustingnut. Do not loosenthe nut.

31. Installthe middlecover. 32. Installthe crankshaftputley. 33. Coat the throads 8nd seating face of the pulley bolt with engine oil. Install and tighten to the specified toroue. Spocifiedto|ql|3: 220 N.m {22.0 kg-m, 159 tb-ft)

RUBBER SEAL Replacewhen damagedor deteriorat€d.

MIODLE COVER

RUBEERSEAL Replac€ when damagedot deteriorated.

RUEBER SEALS Repl6c6 when damag€dor dsteriorated.

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

PULLEY EOLT 1 4 r 1 . 2 5m m

22ON.m 122.0 ks-tn 159lb-ft) CRANKSHAFT PUI.LEY Bemove oil. any 10 x 1.25rm 45 N.m(4.5 kg-rn, lb-ftl 33

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

6-67

Valve Clearance
Adjustment
NOTE: . Valvesshouldbe adjustedcold when the cylinderhead (38oC). is temperature lessthan 1oOoF . After adjusting,retorquethe crankshaftpulley bolt to 220 N.m (22.0 ks-m, 159 lb-ft) 1. headcover Remove cylinder the INTAKE 4, Adjust valves on No. 1 cylinder. Valve Cl6a?anca: in) lntak€: 0.07-O.11 mm (O.0O3-0.0O4 Exhaust:0.15-0.19 mm (0.006-0.007 in) Loosenlocknut and turn adjustingscrew until feeler gaugeslides back andJonhwith slightamountofdrag.

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

2.

"UP" markson the camshaft Set No. 1 pistonat TDC. pulleysshouldbe attop. andTDC Arooves the camon shaft pulleysshould align with cylinderheadsurface.

ag8in.Repeat Tightenthe locknut andcheckclearance adjustmentif necessary.

Number 1 fiston at TDC:

,,UP" MARKS

TDC MARKS Align the marks on the pulleys.

6-68

6.

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

8.

RotatecrankshaftI8Oo counterclockwise bring to No.2 Distonto TDC. The "UP" marks shouldbe at intake side. Adjust valveson No. 2 cylinder.

filumber 3 Diston at TDC:

Number 2 dston at TDC:

,,UP" MARKS

7.

Rotatecrankshaft18Oocounterclockwise bring to 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

Gylinder HeadA/alve Train lHz2!-l engine)
Camshafts Inspectbn ............ 6-93 wEc Vdves, VafueSpringsand ValveSeals Troubleshooting Flowc*rart Removal .............. 6-95 WEC Solenoid Vdve ................ 6-75 Vdve Springand Vdve Seal lrutalation Sequence................. WEC Pressure 6-101 Switch... . . ....... . .. 6-77 Vdve lnstallation VTEC Sol€noidValve Inspoction...... 6€0 ... 6-102 Vaho Seats Rocker Arms Reconditioning ......6-97 ManualInspection . . . . . . . . . . . . .. . . . . . . . . . 6€1 . Vdve Gukles Inspeabn UsingSpecial Too|s........6€1 Valve Movernent ........................, Inspectbn 6-98 . .... .... . .. 6-92 Replacemst..... ..,.6-99 Cylinder llead Reaming .........,.... Removal 6-t0O .............. 6€:l TimingBdt and nming Balancer Warpage......... B€at .....6-98 ltusratod lndex ...............,..... .... . Instalhtion . 6-107 ...........6-103 Feplacemem..... Rocker Armg and Shafts ....6-109 TimingB€lt Removal .............. 6€g Inspection Locations. . . . . . . . . ............6-108 ....6-90 TimlngBdancerBeh Clearance . .. ..... .....6-91 Inspoction Installation ............6-10g ...........6-102 Vaho Cbarance Lost motion AssemHies Adfu3rnora Inspection ..........6-1tE ............ 6-92 Special Tools ...........6-72 lllustrated .............................. lndex &73

Ref. No.

I

Tool Number

Descfption vaNe Gu\de Reame(, 5.5 mm Air Stopper Tappet Adiuster Tappet Locknut Wrench Attachment Valve SpringCompr€ssor Extension Timing Belt Slider Valve Guide Driver, 5.5 mm Valve Spring Compressor Attachment

Oty 1 1 1 1

]

Page Rotorcncr

o
@ @ @
\!,

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

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

@

o

@

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

il
o

B

U
@
:r-----------r-blrrrlllsaf

A---J
\9

@

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

CYLINDER HEAD 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. I r 1 . 2 5m m 26Nm{k2.6kg-m, 't lb,ftl 9 6x1.Omm 1 2 N . m { 1 . 2k g - m , 9tbft) CAMSHAFTHOLOER

RUBBEB SEALS
Replacewh€n or deteriorated.

6r t.Omm 1 2N . m( 1. 2 k g , m )
RUBBER CAP Replacewhen damaged or dete orated.

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

AKE CAMSHAFT page 6-93 page6-105 Installation, Replace. CAMSHAFTPULLEYS Removal,page 6-86 page6-105 Installation.

DISTBIBUTOR

KEYS

wEc
SOLENOID VALVE

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

1 0 x 1 . 2 5m m 5 1 N . m ( 5 . 1k g - m , 37 tb-ft)

EXHAUST CAMSHAFT
O-RING Replace. OIL CONTROL ORIFICE Clean. BACKCOVER 6x1.0mm 1 2 N . m ( 1. 2 k g m

'lO x 1.25 mm 45 N m (4.5 kg m, 33 tb ftl 8 x 1.25 |nrl 22Nm(2.2koJn-

qo.'

r o ru--ttt

I lb{tl

enctrue uourur
BRACKET B

{cont'd)

6-73

Index lllustrated
(cont'd)
NOTE: Cleanthe rocksr shaft orificeswhen installing.
CYLINDER HEAD BOLTS 1 2 x 1 . 2 5m m 100 N.m {10.0 kg-m,72 lb-ft) Apply clean engineoil to threads and underthe bolt heads.

EXHAUST VALVE SPRIG NI{ER

ROCIGRABM ASSEMBLY IPRIMARY,MIO, SECOI{DARY)

VALVE KEEP€RS

VALVEKEEPERS

,f,"*'*o"'o'n"
VALVE INTAKE INNER SPRING VALVE INTAKE SPNING OUTER
pag€s6-95 Replacement, O.RINGS Replace.

VAL EXHAUST
OUTER SPRING SEALINGBOLTS20 mm 60 N.m (6.0 kg-m,43lb-ftl

WASHEB Replace.
SHAFTS ROCKER

I
VALVESEAL VALVE MOTION LOST ASSEMBLY EXHAUST ROCKER SHAFT ORIFICE Clean. i HEADGASKET CYLINDER GASKETI {METAL Replace. DOWEL PINS

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

INTAKE BOCKER SHAFT ORIFICE Clean.
HEAD CYI"INOER Removal,page 6-83 Roconditioning vslve s€st, page 6-97 Warpage,page 6-98 Installation,page 6-103 EXHAUST VALVE INTAKE VALVE R€placement, Oimension,pag€ 6-95 Reconditioning valve seal, pago 6-97 Adiustment, page 6-1 '15

NOTE: Do not installthe oil control orifice.

6-74

VTEC
Troubleshooting Flowchart - VTEC SolenoidValve
-f6il lttll Maffunction Indicato. Lamp(MlL) indicates Cliagnostic Trouble Code(DTC) 21:A problem the \rrEC in Solenoid ValvecircNJit,

-r-' ---.1116l -l 21l----iMIL 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€rating tompo.ature lradiator t6n como! onr.

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

Do thg RoadTest.r

ls MIL on and does it indicate code 21?

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
-VTEC Solenoid Valve(cont'd) Flowchart 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.

ls there14-30 0?

Ch€d( lor ogdt or !ho.l In wlto batw.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

Troubleshooting Flowchart@'l

VTECPressure Switch

Lsmp{MlLlindicates l2rl I Uafun"tionIndicator Diagnostic Troubte CodelDfcl 221 A Droblem in the VTECPressure Switch circuit.
- f-;;r ta I

r.-l !r{=r j-

-

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 engine normaloperto ating temp€mtur€lradiEtorfan comes onr.
Do the RoodTest.'

*Ro6d Test: 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. 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.

Chsck continuivbstwoen for tho preasurs 2 terminals the VTEC on switch.

Turn the ignition switch ON.

Mga6urcthe voltags betw66n the 8LU/BLK wire 6nd body grolnd.

{To pags 6-78)

(cont'd)

VTEC

FlowchartTroubleshooting
(Frompage 6-77)

Switch (cont'dl VTECPressure
Inspoct lor an opon oa thort to ground ln th. BLU/BLKwiro b.tw6€n tho 2P connccto. tnd D6 t.rmlnll ol th. EcM. It wko b oK, rub.iltuto r known-good ECM and ictort.

VTECPRESSURE

swtYcH

ls there approx. 10 V?

Measurs the voltage across the 8LU/BLKand BLK wires in 2P connector.

ls ther6 approx. 10 V?

Rgpolropon d.ori In BLK wko botwc€n lha 2P connoctor gnd body ground.

Turn the ignitionswitch OFF.

1 0v ?

Reftove 10 mm soaling bolt €nd connect oil prgss!re gauge.

GAUGE OIL PRESSURE COMMERCIALLY AVAILABLE

Connoct a tachomster {se€ section 1'1).

I

Start the €ngine and warm it uP to normsl operatingtemperature. WASHER Replaco. Check oil prossure at engine 'l,OOO, 3,0OOand 5,0OO speedof rpm.

ri
ls pressurebelow 50 kPa (O.5 kg/cm', 7 psi)7 'l th€ P connectorfrom Disconnect the VTEC solenoid valve,

timo as shon NOTE: Keepmeasuting becausgengineis running as Dossible with no load (lessthan one minutel.

EOLT SEALING GAUGE JONT ADAPTOR 20 N.m (2.Okg-ln, SNAP.ON MT26-17 t 4 tb-ftt 10 x l.O mm

In3pocl tho VfEc tol.nold v.lv!.

. Use new wash€r when installing the sealing bolt.

F.
iiri ;i
Aftach the battory positive termitermin6l nal to the GRN/VVHT {To p€ge 6-79)

6-78

(From page 6-78)

Start th6 engine €nd check oil p.essure at 5,OOOrpm. PRESSURE GAUGE COMMERCIAI.IYAVAILAALE

WASHER R6place.

NOTE: Keep rl|ossuring timg as short as poasiblebgcause engin€is running with no losd (l6ssthan one minute).

SEALIIIGBOLT 20 N.ln l2.O kg-ln, 14 tb-frl

S]{AP-ON MT26-17 10 r 1.0 rnm . Usonew washgrwhen installing sealing the bolt.

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,OOO rpm. Measurethe voltage between D6 l+l and O22 l-l terminal ol the ECM.

Subrlhute a known,good ECM .nd r.chock, It rymptoh/lndic.tlon gooa lwsy rcplsce tha o.iginll ECM.

6-79

t-

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

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

removethe lf the resistanceis within specifications, the cylinder head, and VTEC solenoid valve from check the VTECsolenoidvalve filter for clogging. o lf there is clogging,replacethe engineoil filter and the engineoil. ;.1

Fl
' Il
r t

VALVE VTEC SOLENOID

i

I

VALVE VTEC SOLENOID FILTER Replace.

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

6-80

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

Inspection UsingSpecial Tools

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 assembly and check that the pistons in the mid and pfimary rockerarms move smoothly. o lf any rocker arm needs .eplacing, replace the primary,mid, and secondaryrockerarms as an as_ semblv.

(cont'dl

6-81

Arms Rocker
3.

Tools(cont'd) UsingSpecial Inspection
Removethe bolt and w8sherfrom the inspectionhole and connectthe valve inspectiontool. 4. Loosenthe regulatorvalveon the valveinspectiontool to . and applythe specifiedair pressure the rockerarm pistons. Sp6dfied A Pr$sui€: 250 kPa (2.5 kg/cm', 36 psil - 5Oo kPa (5.0 kg/cm', 71 Fil VALVE REGULATOR and Pullthe lever turn to adiust. rockMakesurethat the intakeprimaryand secondary connectedby the pistonsand er armsaremechanically that the mid rocker arms do not move when pushed manuallv. MID ROCKER ARM

MOTION LOST ASSEMBLY m 1 0x 1 . O m ADAPTER S]{APONMT26-17 o. EOUIVAEI{T of o lt any mid rockerarm independently the primary and secondary rocker 8rms, replace the rocker arms, as a ser, Removethe tools.
'f

BOLT SEAUNG 1 Ox 1 . 0m m 20 N.m(2.0kg-m, 14 lb-ft)

,,1

oI Checkfor smooth operation the lost motion assemslightlywhen the mid rockerarm bly. lt is compressed deeplywhen the mid is lightlypushedand compressed is stronglyPushed. rockerarm . ReDlace the lost motion assembly iJ it does not move smoothly. check that the malfunctionindicator After insDection, lamo lMlL) does not come on.

6-42

CylinderHead
Removal
Engineremovalis not requiredlor this procedure. 1 . Disconnect the negative terminal from the battery. Drainthe enoinecoolant(seesection 1Ol. a Removethe radiator cap to speed draining
J.

@E

. MalG surs Fcks and salaty stands re dac.d p(opody ard hoist brack6is ar€ attachod to co.roct positions on ths engln6. . Mako sur€ the car wlll not loll off stards and fall while you aro working undor it.

Relieve fuel pressure. @ Do not moke whllo wor{ng on ft,"l sFt€m, k€3p opan f!|m or rFrt away from work Eroa. Drain fr.rCor{y lnto an apFov€d contakrr.

CAUTION: . Uss tender covors to avokl damaglng paintad surfaces, o Undug rhe wiing connoctoB ceefuf,y whte holdlng th€ conn€ctor ponion to avokt damage, a Ma.k aI wiing and hosos to avoH misconnectbn. Also, bo sur€ that they do not contact othor widng or hosa3 01 interfere whh oth€r DarB. . To avokl dsmaging the cytrder hrad. wait until tho coolanttemp€rature dropobelow 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 allemissionhosesbeforedisconnecting them. NOTE: The radiomay have a coded theft protectioncircuit. Be sure to get the customer'scode numberbefore - Disconnecting b8ttery. the - Removingthe No. 43 (1O A) tuse (ln the under-hood fuse/relavboxl. - Removingthe radio. After service,reconnectpower to the radio and turn it on. When the word "CODE" is displayed.enrerthe customer's s{igit code to restoreradiooperation.

4.

Removethe intak€ air duct, Removeth€ fud feed hose and evaDorative emission (EVAP)controlcanistor hos€from the intakemanifold.

POSITIVECRANKCASE

o.

Removethe throttle cable from the throttle body, NOTE: a Take care not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one. a Adjust the throttle cable when installing(see s e c l i o n1 1 ) .

ADJUSNNG NUT

{cont'd)

6-83

{

"t.

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

10. Disconnect the alternator terminal and connector, flom the cylinder , thsn removetheenginewire harness h9€d cover.

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

6 x 1 . 0m m

10 N.m (1.0 kg-m.7 lb-ft)

1 1. Rdmovethe power stsering (P/S)pump bolt and pump. a Do not disconnecl the P/S hoses.

a a a a a a

fo

a a o o o o a a o a a a

connectors the Remove Jollowingenginewire harness and clamps from the cylindet head and the intake manifold: Fourfuel injectorconnectors lntake air temperature{lAT) sensolconnector ldle air control (lAC) valve connector Throttle position {TP)sensorconnector valve lift sensorconExhaustgas recirculation(EGR) nector Groundcableterminals Enginecoolanttemperature(ECTIswitch B connector Heatedoxygen sensor(Ho2S)connector ECTsensorconnector ECTgaugesendingunit connector lgnition control module (lCMl connector sensorconnector CKP/TDC/CYP sensor {VSS}connector VehiclesDeed lgnitioncoil connector VTECsolenoidvalve connector VTECpresserswitch connector Intake 8ir bypasssolenoidvalve connector ECTswitch A connector Knock sensorconnector

u'o-n, li,l.3u,ll*n-..'

LOCKNUT k 1 5N . m( 1 . 5 g - m , 1't rb-ft)

BELT P/SPUMP

8 x 1.25 mm 22 N.m (2.2 kg-m. 16 rb-ftl

6-84

I
I

I
1 2 .Bemovethe ignitioncoil.
RESISTANT BOLT *: CORROTION
* 8x1.25mm 22 N.m (2.2 kg-m, 16 lb-ft) 16, Femove the bracket and intake manifold.

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

1 3 . Remove the emission vacuum hoses and water
bypasshosesfrom the intakemanifoldassembly. 1 4 . Remove radiStorupperhose and heaterhosetrom the the cylinderhead. 15. Removethe water bypass hose and the thermostat housing. o-Rt]{G Replace.

'17.

Removethe selflocking nuts and disconnectthe ex, haust manitoldand exhaustpipe A. Remove the heat insulator, brackets and exhaust manifold.

'18.

BBACKETS

6-85

CylinderHead
(cont'd) Removal
1 9 . R€movethe cylinderheadcover. 20. Removethe middlecover.
Use a wrench to loosen the maintenancebolt lf it cannot be loosenedwilh an open-endwrench, a box wrench can be used after pullingout the lock pin NOTE: Useof a tool shotildbe limhedto initialloosening only. 22, Loosen the maintenanceboh by hand until it stops' bracketis now tixed. The auto-tonsioner NOTE: bolt afa Neverusea tool to loosenthe maintenance ter initisl loosening. a ll tha auto-tensioner has been extendsd 8nd the timing beh cannot b€ install€d,remove the autotensionsr,@mpressit and lainstsllh (page6-1 12). CAUTION: Do not caimp oi b.nd tho tlr$ng bdt mors fran 9Oo or bss thtn 25 mm | 1 in) h damcter' 23, Removethe belt from the camshaftpulleys.

G4?
No Good

24. Removethe camshaftPulleYs'

PULLEYS CAMSHAFT

MAINTENANCE

AOLT

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

MAINTENAI{CE BOLT

Auto-tensaoner fixed in plac6.

6-86

25. Loosenthe rockerarm adjustingscrews,then remove
the camshaft holdersand camshafts

27, R€move ihe cylinder head bolts, then remove the cylinder head. CAUTION: To p.event warpag€, unscr€w the bolts in soqu€nce 1/3 tutn at a time; rspeat the sequonce until all bohs aro loossned. CYLINDER HEAD SOLT LOOSENING SEOUENCE

ADJUSTINGSCREWS

ADJUSTINGSCREWS

24. Rsmovethe side enginernount bracket B and timing
b€h back cover. NOTE: Separate cylinderheadfrom the block with a the flat tip screwdriveras shown.

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

'lO

8 x 1.25 m 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.

No.4

No.3

No.2

wEc solEflolD VALVE

EXHAUST

,i"
VTECSOLENOID FILTER VALVE Replace.

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

6-88

3.

Hold the rocker arms together with a rubber band to preventthem trom separating.

Screw 12 mm bolts into the rocker arm shafts. Remove each rockerarm while slowly pullingout the inlake and exhaustrockerarm shafts.

RUBBER BAND

BOCKER ARMS

12 mm EOLTS

4.

Removethe intake and exhaustrockershaft orifice.
ROCKER SHAFT

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

6-89

Arms and Shafts Rocker
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 plsce' it ehorld not tum' in th6 holo ot rodcr shaft conectlY. lf th. odfica b in NOTE: in a ldentify parts as they are removedto ensurereinstallation originallocations' . Inspectrockershafts and rockerarms (pages6-93 and 941. a Rockerarms must be installedin the same positionit reused. o Cleanthe intakeand exhausttocket shaft orificesbetoreinstalling. I clean all the parts in sopent, dry thern and apply lubricantto any contact surfaces, erior to reinstalling,

ARM ROCKER ASSEMBLIES TNTAKE

m , |/ I
No.3

cyLtNoER NUMBEB

|
No.2

t /
No.1

BOLTS mm 20 SEALING TNTAKE ROCKER 60 N.m{6.0ks-m,43lb-ft} SHAFT

ri
i

I

I I

ll

rl i

I

No.4

No.3

No.2

*oi,

RUBBER BAND
\

t
EXHAUSTROCKER ARM ASSEMBLIES

\

\
\ NUMBER CYLINDER

6-90

Rocker Arms and Shafts
Clearance
Measure both the intake rocker shaft and exhaust rocker shaft. 1, Measurediameterof shaft at first rockerlocation. 3. Measureinsidediameterof rocker arm and check tor out-of-roundcondition.

Rocksr Arm-to-Shatt Clearance: l sko and Erhaust Standard {N€w}: 0.025-0.052 mm (O.OO1O 0.OO2O in) 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

Arms Rocker
Inspection
the NOTE: When reassembling primaryrocker arm, careol to fully applyair pressure the oil passage the rockerarm. 1. arm piston.Pushit manually. the Inspect rocker - ll it does not move smoothly, replacethe rocker arm assemblY.

Lost MotionAssemblies
Inspection
Removethe lost motion assemblyfrom the cylinder head and inspect it. Pushingit gently with the linger the will causeit to sink slightly.Increasing force on it will causeit to sink deeper. - lf the lost motion assembly doesnot move smoothly, replaceit.

il

ARM PRIMARYROCKEN

I

ASSEMBLY LOST MOTION

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. 1. Removethe .ocker arms and rockershafts, 4. NOTE; Rockerarmsmust be installedin the sameposition if reused. 2, fut the camshafts,camshaftholdersand holderpipes on the cylinder head, then tighten the bolts to the specitiedtorque. 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 ) Zero dialindicatoragainstend of camshaft.then push camshaft back and torth and readthe end play. CamshaftEnd Play: Standa.d 5 {New): O.O5-O.'1 mm {O.OO2-O.006 in) S€rvicoLimh: O.5 mm lO.O2in) Seat camshafts by pushingthem toward distributor end ot cylinderhead.

Removethe camshaft holdersand holderoiDes trom the cylinder head. . 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 Insertplastigage strip 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 journal. Camshaft-to-Holder Oil CNearance: StandardlNowl: 0.050-O.089 mm (0.0020-0'0035 in) ServiceLimh: O.15 mm (0.006 in) Measurecam lobe height.

lnsooct this arca tor wear.

INTAKE Pf,I MID SEC

EXHAUST

7.
it

is oil lf camshaft-to-holder clearance out of tolerance: a And the camshaft has alreadybeen replaced,you must replacethe cylinderhead. o lf camshsft has not been replaced,first check total runout with the camshaft supported on Vblocks. Camshatt Total Runout: Standad {Newl: O.O3mm {O.OOIin} max. Servica Limit: O.O6 mm (0.0O2 Inl

\
T/B T/B

t,

SEC MID

PBI

T/8

Pql: PRIMARY MID: MID T/8: Tlill G BELT

SEC:SECO DARY

Cam l-obe Holght Standrd (Ncwl:

II\ITAKE
PRIMARY MID 34.041 mm ( 1 . 3 4 0 2i n )

EXHAUST
33.745 mm ( 1 . 3 2 8 5i n l

36.856 mm (1.451O ) in
34.971 mm ( 1 . 3 7 6 8i n )

SECONDARY
Rotate camshaft while measuring

36.323mm in {1.43OO l 34.683mm i { 1 . 3 6 5 5n }

- lf thetotalrunout ot the camshaftis within tolerance, replacethe cylinderhead, - lf the total runoutis out of tolerance, the replace clearance camshaftand recheck.It the beanang is still out of tolerance. replacethe cylinder head.

N

6-94

Valves, Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve sprinos as they are removed so that each item can be reinstalledin its original position. 1. Using an appropriately-sized socket and Dlastic mallet. lightly tap the valve retalner to loosen the valve keepersbefore installingthe valve spring compressor. 2. Install spring compressor. Compress spring and remove valve keeDef.

VALVESPNI G COMPRESSOR ATTACHMENT EXTENSION OTMAF_PR90lOA

VALVESPRING COMPRESSOR ATTACHMENT 07757-PJ1010A

PLASTICMALLET

SOCKET

{cont'd)

6-95

Valves, Valve Springs and Valve Seals
Removal (cont'd)
3. lnstallthe specialtool as shown. Valve Dimemions:

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

lntako Valvo A Stsndrrd (Now): 34.9O-35.10mm

(1.374- 1.382 In) mm B Standard (Ncwl: 105.rO- 1O5.7O l 1 4 . 1 5 0 - 4 . 1 6 1n l
4. Removethe valve seal. C StEndard {t{ew}: 5.475-5.483 mm

(O.2156-0.2159lnl

;r

5.W 10.2144lnl C Ssrvlco Limit: D Standard (Newl: 1 . 0 5 - 1 . 3 5m m
D Scruico Limit:

(O.O41-0.O53 In) Inl 0.86 mm (O.O34

ExhaGt vllvc A Standard {Nsw}: 29.90-3O.1O mm

( 1 . 1 7- 1 . 1 8 5 n l 7 i (4.134-4.1116 inl

B Standard (t{ow,: 105.OO105.30mm C Standard (Ncw): 5.475-5.485 mm

(O,2156-0.2159In) (O.O05-O.o78 In) 1.45 mm (O.O57 inl

iri

Inl C Service Llnh: 5.rt45 (O.21.14 (Ncwl: 1 . 6 5 - 1 . 9 5m m D Stand8rd
D S€rvico Limit;

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: The final cut shouldalways be made with the 45o cutter. Insert intake and exhaust valves in the head and measure valve stem installed height. Intak€ Valv. Stsm lmtallod Height: Standa.d {Now}: 37.465-37.935 mm (1.4750- 1.4935 int So.vic€ Limit: 38.185 mm {1.5033 inl Exhalst Valve Stom Installad Height: Standard(Newl: 37.165-37.635 mm (1 .rt632- 1.rt817 in) Servicol-imit: 37.885 mm (1.4915 inl

NOTE: lf guidesare worn (page6-98), replacethem (page 6-991 before cutting the valve seats. Carefullycut a 45o seat, removing only enough material to ensure a smooth and concentric seat. Bevel the upper edge of the seat with the 30" cutter and the lower edgeof the seatwith the 60o cutter. Check width of seat and adjust accordingly. Mak€ one mor€ very light pass with the 45o cutter to remove any possible burrs caused bv the other cutters. Valvo Soat Width (lntake and exhaustl: Standard(N6w): 1.25- 1.55 mm (0.0r1!l-0.061 inl Sorvice Llmit: 2.0O mm 10.079 in)

SEATWIDTH

VALVESTEM INSTALLED HEIGHT

5.

After resurfacing the seat, inspect for even valve seating; Apply PrussianBluecompound to th€ valve fEce, and insert valve in originallocation in the head, then lift it and snap it closed against the seat several tames.

8.

lf valve stem installedheight is ove. the servicelimit, replace valve and recheck. lf still over th€ service limit, replacecylinderhead;the valve seat in the head is too deeD.

6-97

Cylinder Head
Warpage
(page6-93) oil NOTE: lf camshaft-to-holder clearances are not within speci{ication,the head cannot be resurfaced. are oil lf camshaft-to-holder clearances within specifications, check the head tor warpsge in) . lf warpageis lessthan O.05 mm (0.OO2 cylinder head resurlacing is not required in) o lf warpageis between O.O5mm (0.OO2 and O.2 mm (O.OO8 resurlacecylinderhead. in), limit is 0.2 mm (o.oo8 in) based a Maximumresurface '132.0 mm (5.20 in). on a height of

Valve Guides
Valve Movement
Measure the guide-to-stem clearance with I di6l indicator while rocking the stem in the dirsction of normal thrust (wobblemethodl. lntako valvo Stsm-to-Guldo Clearancc: Standard(Now): 0.05-O.11 mm tO.O02-0.OO4in) 0.16 mm (O.OO6Inl Servic6 Limit: Exhaust Valvo Stem-to-Guldc Cloarancc: standard (Now): 0.1O-0.16 mm (O.oO4-o'006 inl 0.22 mm (O'OO9Inl Sarvice Limh: vrlvs anondcd 10 mm out trom t!|t'

PRECISION STRAIGHTEDGE

.rl .,il

.

.

o

Measurealong edges, and 3 ways acrosscente..

a lf measursmentexceedsthe servicelimit, recheck using a new valv6. a lf measurement is now within th€ service limit, reassemble using a new valve. a lf measurementstill exceeds limit, rechack using alt€rnate method below, then replsce valve and 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 measursshouldnot ment and the smalleststem measurem€nt exceed the service limit. lntako Valvo Stam-to-Gddo Clcalanco: Standard{Now): O.O25-O'055 mm t0.O01O-O.0O22in) 0.O8 mm lO.0O3 inl Sorvlce Limit:

Cylindol Head Hoight: Standard(New): 141.95-142.05 mm (5.589-5.593 in)

Exhaust valvo Stom-to-Guida Cbarlncai Standard (New): O.O50-O.080 mm (0.o020-0.0O31 inl 0.1 1 mm (0'0O4 Inl Sorvice Limit:

6-98

Replacement
l. As illust.ated in the removalsteps o{ this procedu.e, use a commercially-available air-impactdriver attachment modifiedto tit the diameterof the valve guides. In most cases,the same procedure can be done using Valve GuideDriversand a conventionalhammer. Tool numbersare at the end of this procedure.
4.

Workingfrom the camshaftside,use the driverand an air hammer to driver the guide about 2 mm (O.1in) towa.dsthe combustion chamber. This will knock off some of the csrbon and make removal easier. CAUTION: a Always wear satoty goggles or a tace shield whon using th€ ai. hammot. a Holdthe air hamnrerdhectly in line with th€ valvo guide to prev€nt damaging the driver.

VAI.VE GUIDEDBIVER Y AVAIIAALE

5.3 mm lO.2'l in)

tl_r l
10.8 mm 10.42 Inl

l r

I

Turn the head over and drive the guide out toward the camshaftside of head.

Removal Installation and VALVEGUIDE DR|VER, ftm 5.S 07742-d)10100

2 . Select the proper replacementguides and chill them
in the freezer section of a retrigerator for about an hour. Use a hot plate or oven to evenly heat the cylinder head to 3OOoF(150oC). Monitor the temoerature with a cookingthermometer.

VALVEGUIDE DRIVER, COMMERCIAIIY AVAILABTI

lf a valve guide still won't move, d,ill it out with a 8 mm (5/16 inchl bit, then try again. CAUTION: a Do not us6 a torch; lt may warp th6 hoad. a Do not get tho h6ad hotter rhan 3OOoF(150"C); €xcesslvo heat may looron tho valvo soats, a To avoid burns, uso hoavy glovos whon handling tho h€Eted cylindsr head.

<reDi-k
{cont'd}

CAUTION: Drill guidos only in extrcmo cas€s; you could damagotho cyllnd€r head lftho guide breaks, 6. Remove new guide(sltrom ths refrigerator. th€ one at a time, as vou need them.

6-99

I

Valve Guides
(cont'd) Replacement
7. Slip a 6 mm (0,2 in) steel washer and the correct driver attachment over the end ol the driver (the washerwill absorbsome ot the impact and extend the lite ot the driver).

Reaming
NOTE: Fo. n€w valve guidesonly. 1. Coat both reamerand valve guide with cutting oil. Rotate the reamer clockwise the full length of th€ valve guide bore. Continue to rotate the reamer clockwise whil€ removing it from the bore. 4. Thoroughly wash the guide in dstergent and water to removeany cutting residue. Check clealancewith a valve (page 6-98). a Verify that the vslve slides in the intake and exhaust valve guides without exerting pressure.

/--Tr-1-l--lDRIVEB

t

6 mm 10.2in) WASHER

t

al;\ Y

-r

rnr \---jY

ATTACHMENT

t

F

8 . tnstallthe new guide(s)Jromthe camshaftside oJ botthe head;driveeachone in untilthe attachment toms on the head.It you have 8ll sixteenguidesto do, you may have to reheatthe head one or two more times.
VALVE GUIDEDRIVER, 5 . 5m m 07742-@10100

o

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 andValveSealInstallation Sequence
NOTE: Exhaustand intakevalve sealsare NOT interchangeable, VALVEKEEPERS e{t' A\---.'---.,-VALVE SPRING RETAINER

v
NOTE: Pt.c. the ond ot valvo .prlng whh clo3.ly wound coll! row..d tho cyllndor herd.

VALVE SPRING OUTER

VALVE SPNNG INNER

II{TAKEVALVE SEAL {WHITESPRING} Replace.

:,.^,7
NOTE: In6tallthe valve spring seats before installingth6 valv€ seals. VALVE GUIDESEALINSTALLER KD-2899

NOTE:Usesmalllo €ndol tool.

wre
6-101

Valves,Valve Springsand Valve Seals
Valve Installation
When installing valves in cylinder head, coat valve stems with oil bejore insertinginto valve guides, and make sure valvesmove up and down smoothly. Whenvalvesand springsare in place.lightly1apthe end ol each valve stem two or three times to ensureproper grip seating of valve and valve keepers (use hammer. bottom). NOTE: Tap the valvestem only alongits axisso you do not bend the stem.

Arms Rocker
lnstallation
1 . lnstallthe rockerarms in the reverseorderof removal: o Valve adjustinglocknuts should be loosenedand adjustingscrew backedoff betore installation. o The comDonentDans must be reinstalledin the originallocations. Installthe lost motion assembly.

3 . Installthe rocker arms while passingthe rocker arm
shaft through the cylinderhead. NOTE: Removedthe rubber band after installingthe rockerarms.

Il
I

4.

lnstallthe rockershaft orifices.lf the holesin the rocker 8rm shaft and cvlinderheadare not in line with each other, threadsa 12 mm boh into the rockerarm shaft and rotate the shaft. NOTE: a The shapesof the rockershaft orificeslor the intale and exhaustare different.The oriticesmust be installedin the originallocations. o Cleanand installthe rockershaft oriticeswith new O-rings. EXHAUST ROCKER SHAFT ORIFICE

ri

6-102

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

CYLINOER HEAO

CYUNDER HEADBOLTS TOROUE SEOUENCE

DOWEL PIN

oowEl n

CYUI{DER HEADBOLTS 12 x 1,25mm 1OO (10.0kg-m. lb-ftl N.m 72 Applyclean €ngino oilto bolt thrsads underboltheads. 8nd

{cont'd)

6-103

CylinderHead
Installation(cont'd)
4. lnstall the int€ke manifold and tighten the nuts in a crisscrosspattern in 2 or 3 steps, beginningwith the Innernuls. INTAKE MANIFOLD GASKET 6. lnstallthe camshaftsand camshaft oil seals. NOTE: o Installthe camshaftswilh keyway facing up. . 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 , 16 tb-ft)

ERACKET

;;;-a

o-RrNG
ReDlac€.

Instsllthe exhaustmanifoldand brackets.Tightenthe nuta in a crisscrosspattern in 2 or 3 steps, b€inning with th€ innernuts, EXHAUST MANIFOLD GASKET Replace.

8 x f.-$.mm ks-m, 32 N.m-|C.2 23 tb-ir) 8xL25mm kg-m, 22 N.m12.2 16 tb-ft)

Apply liquidgasketto the headmating surtaceof the No. 1 and No. 5 camshaftholderson both the intake and exhaustside. Confirmthat the csmshaft k€vway are face up, then plscethe holders,togetherwith the No. 2. No. 3 and No.4 camshaftholders,on the cylinderhead. NOTE; The arrows markedon the camshaft holders shouldpoint to the timing b€lt.

CAMSHAFTHOLDERS

I
I

No.5

I
6x1.Omm 10N.m ( 1 . 0k g - m , 7 tb-ft) ' 1 0x 1 . 2 5m m 45Nm14.5kg-m, 33 tb-ft) SEI.f,-LOCKING NUT l O x 1 . 2 5m m 55 N.m (5.5 kg-m, 40 tb-ft) Replace. 8 x 1.25 mm 22Nm(2.2kg-m, 16 lb-fr)

FA l t t
We)

o

i

I

i I A ,:)t Bqt fr
\t \t ta/\el

o.4

No.3

No.2

t{o.l

n A

I

K-

ffil"t

BFl f'q ffiTn

M H S
EXHAUST

IITTAKE

APPIvliquid gasket to tne shadedareas.

6-104

9.

Temporarily tighten the bolts ot the camshaft holders and the camshaftholderoioes.

1 1. Tightenthe bolts in the sequenceshown below.

1 0 . fush the camshaftoilseal securelyagainstthebaseof
the camshaft holder.

O-@:8x1.25mm 26 N.m (2.6 kg-m, 19 lb-ft) @-@:6x1.Omm 12 N.m (1.2 kg-m,9 lb-ft} 12. Installthe backcoverot the timingbelt. 13. Installthe pulleys. camshaft

..

KEY

W&

,7*,

I

l

CAMSHAFTPULLEY

1 0 r 1 . 2 5m m 51 N m 15.'kg-m,37lb-ft) 1

6-105

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

TDC MARKS TDG POSITION : CRANKSHAFT

17. Tighten the maintenance bolt to make the autotensionertunctional. NOTE: Turn the maintenancebolt bv hand until it stoos.

TDC MARK ON

THEFI.YWHEEL
1 E

lnstallthe specialtool on the intake camshaftpulley. EXHAUST CAMSHAFT PtJLLEY

Auto-tensioner tix€d in ploce.

Auto-tensioner lunctional.

6-106

Timing Belt and Timing Balancer Belt
lllustrated Index
NOTE:
a Reterto page 6-1OO positioningcrankshaftand pulley beforeinstallingtiming belt. tor o Beforeremoving,mark directionof rotationon each belt. ADJUSTING NUT 'lOt 1.25mm MIDOLE

45 N.m (4.5 kg-m,33lbJt)

RUBBER SEALS Replace when damagedor deteriorated.

RUBEER SEAL Replace when damaged or deteriorated. CRANKSHAFT PULLEY Removeany ojl.

CAP NUT 6xl.Omm 10Nm{1.0kg-m,7lb-ft)

WASHER

PULLEY EOLT 1 4 r 1 . 2 5m m 220 N.m {22.Okg m, 159 lb-tt} Applyengine oilto the bolt threads, but not to the surtacethat contacts the

LOWER COVER
Romovethe five bolts. RUBBER SEALS Replace when 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

POWER STEERING BELT Adiushent, s€ction 17

ALTEBNATOR
Adjustment,section 23

TIMINGEELT page6-108 Inspectaon, Installation,page 6 109

AUTO.TEI{SIONER AI'JUSTING BOLT 68 N.m (6.8 kg-m,49 tb-ftl Apply liquid gasker to the bolt lhreads installedin the blockside. TIMING BALANCER BELT page6-'l08. Inspectaon,

lnstall with concave surtacefacing in. Remove any oil.

6-107

Timing Beft
lnspection
1. the Disconnect alternatorterminaland the connector' then removethe enginewire harnessfromthe cylinder head cover. headcover Remove cylinder the Removethe middlecover. Inspect the timing belt for cracks and oil or coolant soakang. NOTE: a Replace belt if oil or coolant soaked. the . Removeany oil or solventthat gets onthe belt.

Timing BalancerBelt
Inspection
1. the Disconnect alternatorterminaland the connector, fromthe cylinder then.emovethe enginewire harness headcover. Removethe cylinderheadcover Removethe middlecover. Removethe crankshaftpulley. Removethe lower cover. Installthe crankshaftpulleY. Inspect the timing belt for cracks and oil or coolant soaking. NOTE: . Replace belt if oil or coolant soaked. the a Removeany oil or solventthat gets on the belt.

2. 3. 4.

2. 3. 4. 5. 6. 7.

Inspect this areafor wear,

Inspectthis areator wear,

Rotatepulloy and inspect belt.

pulley to bolt crankshaft retorquethe Afterinspecting, ks-m,159lb-ft). 220 N.m(22.O
.{d.,

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

6-108

TimingBelt and TimingBalancer Belt
Replacement
CAUTION: Insp€ct th€ wst€r Frmp whon roplacing tho timhg boh (pag61O-121. NOTE: Turn the crankshaftso that the No. 1 Distonis at TDC {page6-106}. 1, Removethe splashshield. Removethe mounting bolts, nuts and belt from the power steering(P/S)pump. NOTE: o Do not disconnectthe P/S pipe and hose. o After installing,adjustthe tensionof the P/Spump belt (seesection 171. LOCKNUT
15Nm(1.5kg-m,
l l

MOUNTING EOLTS

SPLASH SHIELD 2. Disconnectthe connector, then remove the cruise control actuator, NOTE: a Oo not disconnectthe control cable. a Takecarenot to bendthe cablewhen removingthe actuator,Always replace kinkedcablewith a new a one. CBUISE CONTROL ACTUATOR
8 x 1 , 2 5m m 22N,m 12.2kg-m,

P/SPUMP BELT

16 tb-ft| Disconnect ahetnatorterminaland the connector. the then removethe engine wire ha.nessfrom the body srde. Loosenthe ahernatormounting bolt, nut and th€ adjusting nut, then removethe alternatorbelt. NOTE: After installin€, adjustthe tensionof the atternstor belt (seesection 23).
ALTERNATOR COI{NECTOR

6x1.0mm 10 N.m ('l.Okg-m, 7 tb-fr)

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

CONNECTOR

TERMINAL

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

6-109

Timing Belt and Timing BalancerBelt
(cont'dl Replacement
Bemovethe cylinderhead cover. Removethe middlecover. Removethe side enginemount. m 1 2x 1 . 2 5 m k 5 5 N . m{ 5 . 5 g m , 40 rb-ft)

1 0 .Removethe crankshaftbolt and the pulley.
Removethe two rear bolts lrom the center beam to to allow the engineto drop down and give clearance removethe lower cover. 1 1 .Removethe adiusterrubber seal. Do not loosenthe adjustingnut.

1 2 . Removethe lower cover. 1 3 . Loosenthe adjustingnut. Pushon the pulleyto remove
belt, then tightenthe tensiontrom the timing balancer adjustingnut.

il
t , l l

il
1 4 . Removethe timing balancerbelt.
12 x 1.25 fifi 65Nm(6.5kg-m, 47 tb-fr)
tD.

Removethe timing belt.

1 6 . Removethe auto-tensioner.

9.

Removethe dipstick and the PiPe

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

t

Replace.

6-110

HEAD CYLINOER COVER

TIMING BELT Inspection,page 6-108

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

MIDOLE COVER

TIMINGBALANCER BELT page6-108 Inspection, ADJUSTIT{G NUT 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

Belt Timing Belt and Timing Balancer
Replacement {cont'd}
1 7 . Installthe timing belt in the reverseorder ol removal. - Beforeinstalling timing belt, positionthe crankthe shaft and camshaft pullevsas shown ,,T" MARKS NOTE: Take care not to damagethe threads or the gasketcontacl surfacewith the sctewdriver'
MAINTENANCE BOLT

FLAT BLADE SCREWDRIVER

STOPFER P/N 14540-Pl3-003

and 2 1 . Removethe screwdriver reinstallthemaintenance bolt. NOTE: Be sureto ube a new gasket.

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

TDC MARK the auto-tensionerwith the maintenancebolt bolt. .l , pointingup. Loosenand removethe maintenance carefullyso the NOTE: Handlethe auto-tensioner the oil insidedoes not spill or leak. Replenish autotensionerwith oil if any spills or leaks. The total capacityis 8 cc {1/4 ii oz). in 19. Clamp the boss oJ the auto-tensioner a vise. Use oJ wood or a cloth to protect the boss, Dieces NOTE: Do not grip the housingot the auto-tensioner. 20. lnsert a flat blade screwdriverinto the maintenance 3-OO3) the on hole. Placethe stopper {P/N 1454O-P1 auto-tensionerwhile turning the screwdriver clockthe wise to comDress bottom.
8 x 1 . 2 5m m 22 N.m (2.2 kg-m, 16 rb-ft)

Make sure no oil is leakingaround the maintsnance on bolt. Installthe auto-tensioner the engine. NOTE: Make sure the stopperstays in place.
STOPPER P/N

t
'

I
;

I

6-112

23. Removethe stopper.
ADJUSTER

26. Align the rearbalancershsft pulleyby usinga 6 x 10O mm bolt or equiv€lentas an alignmenttool. 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

24. Make surethe crankshaftis positionedwith the No. 1
cylinderat TDC.

NOTE: Both belt adjusters are spring-loaded to properlytension belts.Do not applyany extra prosthe sureto the pulleysor tsnsionerswhile performingtha adjustmenl.
REARBALANCER SHAFT

25. Align the grooveon the front balancer shaft pulleywith
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 the pointer on the oil pump housing.

REARTIMING BALANCER EELT DRIVENPULLEY

BALANCER BELT

DRIVE PULLEY Setthe crsnkshaft TDC. at

(cont'dl

6-113

Timing Belt and Timing BalancerBeh
(cont'dl Replacement
30. lnstallthe lower cover. 3 ' 1 Installa rubberseal aroundthe adjustingnut. Do not .
loosenthe nut. 32. Installthe middlecover. pulley. crankshaft 33. Installthe 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)

MIDDLE COVER

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

I
i

I

SEALS RUBBER when Roplace or damaged deteriorated.

t{UT AD.'USTING 1Ox 1.25tnm 33lb-ft) 45 N.m(4.5kg-m, RUBBER SEAL Roplace whgndarn€ged or deteriorated.
A'LLEY EOLT 1 4 r 1 . 2 5m m 220 N.m {22.0 kg-m, 159lb-ft) Apply engineoil to the bolt thrsads, but not to the surfacethat contacts the washer.

-ldl

ii li
I
f,

6x1.Omm '12N.m(1.2kg-m, lb-ft} I

ALTEN ATORBELT Adiustm€nt,soction23

PULLEY

6-114

ValveClearance
Adjustment
NOTE: . Valvesshouldbe adjustedcold when the cylinderhead temperatureis lessthan 1oOoF(38oC). . After adjusting,retorquethe crankshaftpu ey bolt to 22ON.m (22.Okg-m, 159 lb-ft). 1. Remove cvlinder the headcover. 3. Adjustvalveson No.1cylinder. Valve Cloalance: Intaks: O.15-0.19 mm {0.0O6-0.O07in} Exhaust:O.17-0.21 mm (O.O07-O.OO8 in) 4. Loosenlocknut and turn adjustingscrew until feeler gaugeslidesbackandfonh with slightamountof drag. TAPPET ADJUSTER o7MAA-PR70'110

INTAKE

2.

Set No.l pistonat TDC. "f" markson the pulleys should be at top. and TDC grooves on the pulleys shouldalign with cylinderheadssurface.

20 N.m(2.O kg'm, 14 tb-ft)

WRENCH oTMAA-PR70120

Number pistonat TDC: 1

Tightenthe locknutandcheckclearance again.Repeat adjustmentit necessary.

FEELEN GAUGE

TDC MARKS Alignthe marks on the pulleys

(cont'dl

6-115

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

at Numbd 3 glston 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. Number Dl.tonat TDC: 4

li
ld
l
I I

6-116

EngineBlock
Speciaf Toofs ..................................7-2 lllustrated Index................ ............. 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(F22A1 engine)............................... 7-19 Piston Pins Removal ..........7-19 fnstallation ......7-20 fnspection .......7-21 ConnectingRods Sefection .,.,,,,..7-2O Piston Rings EndGap ...........7-22 Repf acement ,.............,.,........,,...7-23 Ring-to-Groove Clearance ........7-23 Afignment .......7-24 Crankshaft Seal Oil fnstaf lation ......7-25 Crankshaft and Balancer Shaft Oil Seal Installation(engineremoval is not requiredl ....7-30 Crankshaft and balancershafts fnstration ,.......,7-26 BalancerShafts fnspection .......l-91

SpecialTools

R.l. No.

I

I

Tool Number

D6cripiion PistonPin BaseInsert PilotCollar GuideAttachment Hub Assembly PistonBaseHead Se8lOriver RingGearHolder 30 Attachment, mm l.D. Driver Driver Attachment PistonPin DriverShaft PistonPin DriverHead Piston Ease Piston BaseSpring

Oty

I

Pag6Rdorence 1-19,20 7 -19,20 7-30 7 -19,20 7-30

O o

I

oTcAF PH6o3oo 07GAF PH7ol00

O
@ @ @ O @ O @ @ @ @

I
| I | | | I | | | | I

-seoozoo orcar

I
t
1 l

oTHAF-PL2o1o2 oTLAD PT3oloA o;Lnr - lvootooor 07924 PD20oo3 07746 oo3o3oo 07749 ooloooo 07948-sBoo101 07973 PEoo3lo 07s73 PEoo32o 07s73 6570500 07973 6570600

7-30 1-25,30 7- 2 5 , 3 0 7-19,20 7-'t9,20 7 -19,20 1-19,20

i
o

o

@

1

!1
ti
I

@

o

@

@

t
.'

(0

o

@

7-2

lllustratedIndex
I Lroric"t" "tl inrernal partswith engineoil during reassembly.
6x1.0mm 12 N.m 11.2

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

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

BAFFLEPLATE

11 x 1.5mm 75 N.rn {7.5 lg-m, 54 tb-ttl Applyengineoilto the bolt throada. NOTEr Aftor torquing o6chcap. to turn crankshaft check Ior binding.

AEARINGCAP BRIOGE

DOWEL PIN

-rx
TOROUE CONVERTER COVER IA/T)
12 x 1.0mm 75 N.m 17.5 kg-m, 5t tb-ftl Torquesequence, 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

DOWEL PINS

FLYWHEEL

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

(cont'd)

7-3

lllustrated Index
(cont'dl
I Luuri"ut""tl internalpartswith engineoil duringreassembly.
CRANI€}IAFT Endplay,Page7'7 Runout.Tapor 6nd Out-of-Round, Page7-15 Installation,Page7-26

NOTE: Apply liquid gasketto the mating surfacesot the right them side coverand oil pump casebetoreinstalling part No. 08718 0001 Useliquidgasket,

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

:l
ll

I

I

Groovedsidestac€ outward. NOTE: Thrust washerthicknoss is lixed and must not be changed by grindingor shimming. 8 x 1.25mm 25 N{n {2.5 kg-m, 18 tb-frl O.RINGS Replace.

CRAI{KSHAFTOIL SEAL Install6tion,pag* 7-25and 30

OIL CRANKSHAFT SEAL psges7-308nd 8-'11 Installation, Replace. THRUSTWASHER AALANCER DRIVEN GEAR RIGHTSIDE @VEB Apply liquid g88k€tto block mating surface. Gr1.0mm 12Nrn (1.2 9IEftI Apply liquid g8skstto the boft threads.

I
'I l
il

PIN OIL PUMP S€e page8-9 Apply liquid gssk6t to block mating surtace.

il

6x1.0mm kg-m,9 lb"ftl 12 l$m 11.2 Apply liq!id gasketto the bolt threads. BALANCER SHAFTOIL SEAL pages 7-30and 8-11 Installation, Reolace. BELT TIMINGBALANCER PULEY DRIVEN

7-4

OII-JET BOLT ito N.rn {a.0tg-m, 29 lb-ftl page 8-8 Inspection, H22Al engincl

OIL JET Handlethe nozzlewith care.Do not damage or detormed. Inspection, page 8-8

REARBALANCERSHAFT End play, p6ge 7-31 Runout.Tapor and psges 7-31,32 Out-of-Round, Inst6llation,pag€ 7,26

BALANC€R SHAFT BEARINGS page Insp€ction, 7-31

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

\

)

BALANCER

(cont'd)

7-5

lllustratedIndex
lcont'd)
I parts oil withengine orr'nn,"u""".b'J;ron lruri""t" "tl internal
INSTALLATIONDIRECTION EXHAUST

by must be selected matching NOTE; New rod bearings markings identification rod connecting and crankshaft (pages -101l). 7 ,

1r;--..l@ ft##**if{*{"}H
PISTONPIN page7-19 Removal, page7-20 Installation page7'21 lnspection, ROO CONNECNNG Endplay,page7-7 Selection,page 7-20 7-21 Smallend measurement, Page

\3 -/ (3 \7 \7

A ?A Ae-l / A

\9,-// \Eo.J '\r' '\7

INTAKE PISTON page7-12 Removal, page7-16 M6asurement, properclearance, NOTE:To maintain matchthe lefter on the piston top with the lettor for eachcylinder stamped on the block. On the block On the pistontop A or I No letter <Bor'l

BL(rcK ENGINE p6oo7'17 Cylinder boreinspection, Warpageinspection,Page7-17 7-18,19 Cylinder borehoning,pag66 Inspecttop of each cylinder bore tor carbon build-up or ridge before removing Pigton. pagB7.14 Removeridge if n6cessary,

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

CAP RODBEARING CONNECNNG Installation,page7-26 is rocess cap so the bearing NOTE:Install in on the samesideasthe recess the rod

RODNUT..-_.-....-__-.} CONNECTING 9 x 0.75 mm kg-m, 34 lb-ft, 47 N{n (i1.7 After torquing each bearingcaP, to rotate crankshaft checklor binding.

e
No.4

CYUNDER BORESIZES (A or l, B or rl) NOTE: To maintain proper piston clearance, rnatchthese lefterswith the letterson the pistons.The letters on the block readfrom left to right, No. 1 throughNo. 4 cylinders. On the block On the pistontop A or | --------------- > No letter B or,l --------------- > B

7-6

Flywheel and Drive Plate
Replacement
ManualTransmission:
Remove the eight flywheel bolts, then separatethe flyw h e e l f r o m t h e c r a n k s h a f f l a n g e .A f t e r i n s t a l l a t i o n , t tightenthe bolts in the sequence shown.
RINGGEAi

Gonnecting Rodand Crankshaft
End Play
ConnectingRod End Plsy: Standard (Newl: 0.15- 0.30 mm {0.006 0.012in) SorviceLimit 0.40 mm 10.016 inl
CONNECTING ROO

07LAB PVtDl(x)

or 0792it - PO20O03

BINGGEAR HOLDER 07LAB Pv(xrltx) or 07924 PD2qr03

aoo

\o;

. .

lf out-of-tolerance, install a new connecting rod. lf still out-of-tolerance,replacethe crankshaftlpages 7-11and7-26]..

Pushthe crankshaft firmly away from the dial indicstor. and zerothe dial againstthe end of the crsnkshaft. Then pull the crankshaft firmly backtoward the indicator; dial readingshouldnot exceed servicelimit.
Inspgctring gear teoth for w6ar or damage. 12x 1.0mm 105 N.rn 110.5 kg-m, tG lb-ft,

AutomaticTransmission:
Removethe €ight drive plate bolts, thon separatethe drive platefrom the crankshaft flange.After installation. tightenthe bolts in the sequence shown.

SCREWDRIVER

/ AXid-*a\Ao

CrankshaftEnd Phy: Standard lNqwl: 0.10- 0.35 mm (0.004 0.014in) Ssrvice Limit 0.45 mm {0.018inl . lf end play is excessive than the servicelimit, inspect the thrust washersand thrust surfaceon the crank, shaft.Replace partsas necessary.

NOTE:Thrustwasherthickness fixed and must not be is changedeitherby grindingor shimming. Thrust washersare installedwith groovedsidesfacing outwaad.

7-7

Main Bearings
Clearance
L o 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 a li l c l e a r a n c e , removethe main capsand bearinghalves C l e a ne a c h m a i n i o u r n a l a n d b e a r i n gh a l f w i t h a cleanshoptowel. acrosseach main jourPlaceone strip of plastigage nal. NOTE:lf the engineis still in the car when you bolt the the main cap down to checkclearance, weight and flywheelwill flattenthe plastF crankshaft of the 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 , 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 s c o u n t e r w e i g h t a n d c h e c ko n l y o n e b e a r , n ga t a s 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) during inspecNOTE:Do not rotatethe crankshaft tron. 5. Removethe cap and bearingsagain,and measure the widest part ot the Plastigage. Oil Main Bearing-to-Journal Clearance: Siandard {Newl: mm No. 1. 2: 0.021 0.0i15 {0.(xn8 - 0.0018in) inl SqrviceLimit 0.050mm (0.0020 mm 0.025- 0.0,19 No. 3 in} {0.0010 0.0019 inl ServiceLimii: 0.055mm 10.0022 0.013- 0.037mm No. 4 10.0005 0.d115in) in) ServiceLimit: 0.050mm {0.1X120 o.(xlg- 0.033mm No. 5 (0.0004 0.0013 in) inl ServicaLimii: 0.040mm (0.0015 measures too wide or too narrow, lf the plastigage (removethe engine if it's still in the car). remove and remove the upper half of the the crankshaft, bearing.Install a new, complete bearingwith the the color as shown on the same color code (select the next pags),and recheck clearance. CAUTION: Do not fi16,3him, or 3crapoth€ b.arings or the caps to adiu3t clearance. is shows the clearance still incor7 . lf the plastigage rect,try the next largeror smallerbearing(the color listedaboveor belowthat one),and checkagain. cannot be obtained NOTE: lf the groper clearancs largeror smallerbearings, by usingthe appropriate the and reDlace crankshaft startover.

L

STRIP PLASTIGAGE

l.

7-8

Selection
CAUTION: lf the codes ars indecipherabls b€causo of an accumulationof dirt and dust, do not scrub them with a wiro brush or scraper,Cleanthgm onlv wiih sol. vent or .tot€rgont. CrankshaftBors Code Location {Numbers,Lettgrs or Bars} 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 (codes main journalsize), choosethe correctbearfor to
Ings.

Main Journal Code Locations (Numbers or Bars) H22Al engine:

Main JoumalCodeLocations lNumbers Ba'sl or

H23A1.F22Al engines: The Main Journal Codesare stampedin one of the following locations. Main Jou.nalCodoLocations (Numbals Bar3) or
No. 5 JOURNAL {FLYWHEEL ENDI

END} IPULI.TY BcaringDosign

PROJECTION

LOWER Berring ldentitication Colorcodeis on the edgeofthe bearing. ----------> Smaller bearing (Thicker) ---------------Largercrankbore Main Journrl Coda Locationi {Numbersor Br.!} No. 5 JOURNAL IFLY WHEELENDI No. 1 JOURNAL (PULLEY ENDI

No. 1 CRANK WEB Smaller main iournal Smaller bearing (Thicker) NOTE:When usingbearing halves of different colors, it does not matter whichcolor is usedin the top or bottom.

Rod Bearings Gonnecting
Clearance
rod the Remove connecting cap and bearinghalf. Cleanthe crankshaftrod journal and bearing half with a cleanshoptowel. plastigage the across rod journal. Place the bearing half and cap, and torque the Reinstall nutsto: 1. 47 N.m (4.7 kg-m, 34 lb-ft) during inspecNOTE:Do not rotatethe crankshaft tion. 5. Remove the rod cap and bearinghalf and meassure the widestpart of the plastigage. ConnectingRod Bearing.to.Journll Oil Clearsnce: P'AAI €ngin6: Standard (Newl: 0.021- 0.049mm 10.0008 0.0019in) 0.05 mm (0.002in) Servic€Limh: H23A1,ll22Ai enginos: Standald {Newl: 0.027- 0.055mm (0.0011 0.0022inl 0.06 mm (0.002in) Ssrvice Limh: too wide or too narrow, measurss lf the plastigage removethe upper half ot the bearing,installa new, complete bearing with the same color code (select the color as shown on the next page),and recheck the clearance. CAUTION: Do not file, shim, or scrapothc boaring3 or tha cap3to adiust cloaranc€. is shows the clearance still incorlf the plastigage rect,try the next largeror smallerbearing(thecolor listed above or below that one), and check clearanceagarn. cannot be obtained NOTE: lf the proper clearance largeror smallerbearings, by usingthe appropriate and reolace crankshaft startover. the

PLASTIGAGESTRIP

i I
H t;,
ili tit
il

it; 'll
:'l

I !:

7-10

Selection
CAUTION: lf th6 cod6s aro indscipherable because of an accumulationof dirt and dust, do not scrub them with a wirg brush or licrapor.Clsan them only with sol v6nt or detergent. ConnectingRod Journal Code Locations {Numbersor Bars) 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 letters barsstampedon the crank or lcod€sfor rod journal size),to choosethe correctbearings, Conn€qtingRod Journal Code Locations (Lettersor Barsl H22A1engine:
ConnectingRod Journal Code Locliion! lLstterr or BrBl

Halfot numberor bar is stamped bearing on cap and the otherhalf is stampedon rod BoaringD6i9n

H23Al, F22Al cngincs: The Connecting Rod Journal Codesare stampedin one ol the followinglocations. ..,:-.

ConnoctingRod Journrl Codo Locltion3 {Latta'3 or B!1!}

PBOJECTION ConnectingRod Journd Coda Location3llatta.3 or B.rrl

No. 5 JOURNAL Eoaring ldantif ication Colorcodeis on the edgeol the bearing. .---..-----+ Largerbig end bore

No. 1 JOURNAL IPULTIY END}

+

(Thicker) Smaller bearing

Elue

Smaller rod journal

Smaller bearing lThicker)

No. I CRANKWEB

Shaftsand Pistons Balancer Grankshaft,
Removal
1. Remove right side cover. the 3. drivenpulleyas thown. Remove front balancor the

DOWELPIN

BALANCER DF]VENPULEY

HOI€ MANTE'{ANCE

;

I I
)

I
t1
;l
Ii

SCREWT'RIVER

il
2. gearcase. the Remove balancer
DOU'ELPIN 8 x 1.25mm kg-m, 18lb-ft) 25 N.m 12.5

shaft hole.thon Align the bolt hole and the bslancer insert a 6 x 100 mm bolt to hold the rear balsncsr shaft. drivengs8r. Remove bolt and the balancor th6
REARBALA]IIGEB SHAFT

6 x lm .nm BOLT

inl va mm {2.9
BALANCER GEARCASE DOWELPIN

REARBALANCERSHAFT

7-12

R€move oil screen the and the oil pump. 7. Rsmov€the baffle plate.

8.

Removethe bolts and the bearingcap bridge,then removethe bearingcaps. CAUTION: To provent wsrpago. un3crew tha bolts in loqucnc€ 1/3 turn at a timc; ropcst tho srqucnco until rll bolt3 are loosGnod.

o|LscaEE

BAFFLEPLATE

MAIN BEARING CAP BOLTSLOOSENING SEOUENCE

7-13

Balancer Shaftsand Pistons Grankshaft,
(cont'dl Removal
are so 9. Turn the crankshaft No. 2 and 3 crankpins at the top. and the rod caps/bearings main caps/bear1 0 . Remove in ings.Keepall caps/bearings order. out of the engine,being careful 1 1 . Lift the crankshaft not to damagejournals. 15. lf you can teel a ridge of metal or hard carbon around the top of each cylinder,remove it with a ridge reamer. Follow the reamer manufactursr's instructions. CAUTION: lf the ridgo k not rcmoved, h mly dtmag6 the pistons a! thcy lrc purhod out.

Use the wooden handle of a hammer to drivo the pastons out.
CRANKSHAFT

'12. Remove then removethe the bolts and the retainer. shaft. front balancer shaftand the rearbalancer

CAUTION: . Tako caro not to dtmago thc contlct turflcc of tho motal g.!kot. . Whan romoving thc pirton/connactlng rod trka cara not to hit thr oil irt (H22Al cngine onlyl. . It th. oil ict nozzlo is drmlg.d or d.formld, rrplaco the oil iet .srombly {H22Al .ngin. only, page 8-81.

RETAINER 1 3 . Remove the upperbearinghalvesfrom the connecting rods and set them aside with their respective caps. the 1 4 . Reinstall main caps and bearingson the engine in properorder,

't1 Reinstallthe rod bearings and capsaftor . connecting
removing each piston/connectingrod assombly. 1 8 . Mark each piston/connectingrod 8ss€mbly with its cylindernumberto avoid mixup on .eassembly. NOTE:The existingnumbsr on the connsctingrod does not indicateits positionin the engine,it indicatesthe rod bore size.

Crankshaft
Inspection
C l e a n t h e c r a n k s h a f to i l p a s s a g e s i t h p i p e w cleaners a suitablebrush. or Check keywayand threads, the

Out-of-Roundand Taper
o Measure out-of-round at the middle of each rod and main journalin two places. . The differgncebetyveen measurements each on journalmust not be more than th€ servic€ limit, Journal Oui-ot.Round: Standa.d (Ncw): o.qE mm {0.0002in} SorvicoLimit: O.q)6mm (0.0002inl

Alignment
a M e a s u r er u n o u t o n a l l m a i n i o u r n a l st o m a k e surethe crankis not bent, . The difference between measurementson each journalmust not be more than the service limit. CrsnkehaftTotal lndicatod Runouti Standard (N€w): 0.03 mm (0.001in) Ssrvico Limit: 0.04 mm (0.002in)

DIALINDICATOR Rotatecrankshafttwo comptete rovolutions. M6asursin two pl6cesat middl€.

Suppon with lathetype tool or V-blocks.

Measu16 taper near edg€s.

Measure taper at the edge of each rod and main journal. The difference between measurementson each journalmust not be more than the servicelimit. Journal Taper: St.ndrrd (Now): 0.005mm (O.(xXr2 m!x. int Scrvicc Limit 0.006mm (0.(xn2 in)

Pistons
Inspection
for Check Diston distonionor cracks. the piston NOTE:lf the cylinderis bored,an oversized must be used. 21 Measurethe piston diameterat a point F22A1: mm (0.8in),H23A1, 15 in) H22A1: mm (0.6 from the bottom of the skirt. e N O T E : T h e r e a r e t w o s t a n d a r d - s i z p i s t o n s( N o Letter(A) or B). The letteris stampedon the top of the piston. There letters are also stamped on the blockas cylinderbore sizes. Piston Diameter: F22Al engine: Standard lNewl: mm No Letter lA): 8i[.980- 8i1.990 (3.3457 3.3451inl 84.970- 84.980mm B: in) 13.3453 3.3,157 ServiceLimit: mm (3.3453in} No Letter {A}: 8i0.970 84.950mm (3.3449in) B: H22A1 enginss: H23A1, Standard lNewl: No Letter (A): 86.990- 87.003mm (3./1248 3.4253inl 86.980- 86.993mm B: inl {3.,[2/14 3.42,19 ServiceLimit: inl No Lettor {A}: 86.980mm {3.,12,14
B: F22Al sngino: 21 mm 10.8 inl 86.970 mm (3.,[2'10in] SKIRT DIAMETER

t C a l c u l a t e 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 on diameter (page7-17)and pistondiamet6r. Pbton-to-CvlinderClsrranco: F22Al engine: Standard (N€w): 0.020- 0.0/(, mm l0.00oB 0.0016in) mm {0.002in) 0.05 ServiceLimil: H2341,H22A1engines: Standard (Newl: 0.007- 0.030mm (0.0003 0.0012in) SorviceLimit: 0.04 mm (0.002inl

the servicelimit, is lf the clearance near or excesds inspectthe piston and cylinderblockfor excessive wear. OvorsizePiston Diamoter: F22A1engine: 0.25:85.230- 85.2/0 mm {3.3555 3.3559in} - 85.tlln mm {3.3653 3.3657in} 0.50:85.,180 H23A1.H22Al rngin.3: O.25t .230- 87.2,(l mm (3./8/02 3.,13{8in) 87 4. Coat ths clearance. Checkthe piston pin-to-piston piston pin with engineoil. lt should then be possible to push the piston pin into the piston hole with thumb Dressure, Piston Pin-to Piston Clctrtnco: F22Al engine: Standard (Newl: 0.012- 0.02amm (0.fi)05- 0.qt0o in) H23Al, H22Al ongines: Standard {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 three levelsin eachcvlinderas shown.
in) 6 mm 10.2 Firrt Ma!!urcmant S.cond Mar!uramcnt Third Mer3uramant

Boro Taprr: Limil: {Diftorcncabotw.on lirst snd third maasuromcntl 0.05 mm {0.002inl . . l f m e a s u r e m e n t sn a n y c y l i n d e r a r e b e y o n d i OversizeBore ServiceLimit, replacethe block. l f t h e b l o c k i s t o b e r 6 b o r e d ,r e f e r t o P i s t o n (page7-16)afterreboring. Clearance Inspection

6 mm 10.2 inl

w

NOTE: Scored or scratch€dcylinder bores must be 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 BEMEASUBED TO
CYLINDER BORESIZES lA or I, B or rll Readth€ l€tterstrom lelt-to'right for No. 1 throughNo.4 cylinders.

CYLINDER BONE

Cylindcr Boro Size: F22Al engino: Stendlrd (Ncw): A or l: 85.010- 85.020mm {3.3458 B ot ll: 85.000- 85.010mm (3.3i165 Sorvicr Limit: 85.070mm (3.3492in) H23A1,HPAI ongines: Stlndffd {Now,: A or l: 87.010- 87.020mm {3.4256 I or ll: 87.000- 87.010mm (3.'1252 Srrvicc Limit: 87.070mm {3.i|:l79inl

Enginc Block W..prge: Stlndlrd {Ncw): bclow 0.07 mm (0.003in} S.rvico Limit: 0.10 mm (0.(Xt4 inl
PRECISION SIRAIGHT EDGE

3.3/t?2in) 3.3i168 in)

3.4260in) 3.i1256 in)

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
H2241engines) BoreHoning(H2341,
l. rbv^ ,,

CAUTION: Thir cylinder linor ussr FRM (Fiber ReinlorccdMatall. Hono only !s diroctod below. 1. M€asure cylinderboresas shown on page7-16. It the block is to be reused,hone the cylindersand remeasure bores, the To honecylinderbores; . Useonly a rigid hone. . Honingstone: GC- 600- J or finer stone (for nonf6rrous metals) . Pressure: 2OO 3OO kP; (2-3 kg-cm', 28 - 43 psi) . Honingrpm: 45 - 50 rpm . Honingthickness; in) Lessthan 0.02mm (0.0008 Do not hone mote than 20 cvcl€s . Honinglubricant Oil type . Roughness of VVV or 1.2S finishedsurfaces: . Honingpattern: 60 degr€ecross-hatch CAUTION: Cloantho honing stono oyory 5 cyclos.

3.

t W h e n h o n i n g i s c o m p l e t e , h o r o u g h l yc l e a nt h e Washthe cylincylinderblockof all metal particles. der bores with hot soapy water. then dry and oil to immediately preventrusting. NOTE: Never use solvent, it will only redistribute walls. the grit on the cylinder

2.

4.

are still presentin cylinder lf scoring or scratchgs limit, reborethe cylinboresafter horningto service der block. is NOTE:Some light verticalscoringand scratching if acceptable it is not deepenoughto catchyour fingernailand does not run the full lengthof the bore.

PistonPins
BoreHoninglF22A1 enginel
Measure cylinderboresas shown on page7-16. lf the block is to be reused,hone the cvlindersand rem€asurethe bores. Honecylinderboreswith honing oil and a fine (400 grit) stone in a 60 degree cross-hatchpattern, NOTE: . Use only a rigid honewith 400grit or finer stone suchas Sunnen, Ammco,or equivalent. . Do not use stonesthat are worn or broksn.

Removal
Assemble PistonPin Toolsas shown. the PISTON SASE HEAD OTHAF-PUM102
PISTON PIN BASE INSENT OTGAF PHq'3U'

tl
PFTONBASE 0tt3 - 65t0500 Adjust the length A of the piston pin driv8r. A: 51.5 mm (2.G1 inl W h e n h o n i n g i s c o m p l e t e , h o r o u g h l yc l e a n t h e t engine block of all metsl particles. Wash the cylinder bores with hot soapy water, then dry and oil immediately preventrusting. to NOTE; Never use solvent, it will only .edistribute the grit on the cylinder walls. lf scoring or scratches are still presentin cylinder bores after honing to the servicelimit, rgbore the cvlinderblock. NOTE:Some light vsrticalscoringand scratching is acceptableit it is not deep enough to catch your fing€rnailand does not run the full lengthof the bore.

PISTON PIN DRIVERHEAD 0t9t3 - PE|D320

\

R

l l

H trl-

m--.--

u

or9r3 Fdto3ro

PISTOI{ DRlvEN PII{ SHAFT

PILOT OOLLAN o'GAF- PHt0100 Emboesed lacingup. mark

CYLINDEB HONE

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 honed. Placeths piston on the piston base and pressthe pin out with a hydraulic press.

7-19

Rods Connecting
Selection
Each rod falls into one of four toleranceranges(from 0 in) in), in 0.006mm (0.0002 increto 0.024mm {0.0009 ments) dependingon the size of its big end bore. lt's then stampedwith a numberor bar \'1,2,3, ot 4ll, t, ttl, the or Irl) indicating range. t, oI '1,2,3, ot 4/1, ttl,o( You may find any combination Irl in any engine. Normal Boro Sizr: 51.0 mm (2.01in) NOTE: Refer€nc€ numbersor bars are for big end bore the sizeand do not indicate positionof th€ rod in the engine. rod for cracksand heat damInspect connecting age.

PistonPins
lnstallation
1. prossfor installation. Usea hydraulic . the Wh6n pressing pin, in or out, bo sureto positlat on the piston againstthe tion ths recessod lugs on the base8ft8chment.

The arrow must laco the timing belt side of the 6nOine.

RODBORE CONNECTING NUMBERoi BAR BEFEBEITCE Half ot number is sttmpsd on bearingcap, ths other half on connectingrod.

Tho ma* must faco the timing beltsid6 ol th6 engin6.

2.

Adjust the length B of the piston pin driver. in) B: 51.5mm (2.G1 PIN HEAO PISTON DRTVER 0797:1 PEqB2o

PISTONPIIIIDBIVERSHAFT 07973- PE00310 Emboss€dmark

I ffi*r,"ron'n
PILOTCOLLAR 07GAF- PH701d) PISTONPIN BASE NSEBT 07GAF- PH6o3q) PISTONBASE HEAD 07HAF- P120102 PISTONBASE 07973 - 6705{X'

Inspgctbolts and nuts for strogscracks.

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
Measure diameter the pistonpin. the of Pbton Pin Diamoter: Standard (Nawl: 21.994(0.86s9 Ov6rsizg: 21.997{0.8560 Measure pistonpin-to-piston the clearance. NOTE:Check pistonfor distortion cracKs. the or 22.(XX' mm 0.8561inl 22.003mm 0.866:linl l f t h e p i s t o n p i n c l e a r a n c es g r e a t e rt h a n F 2 2 A 1 i e n g i n e : 0 . 0 2 4 m m { 0 . 0 0 0 9i n ) H 2 3 A 1 ,H 2 2 A 1 engines:0,026 mm (0.0010 remeasure in), using an pistonpin. 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

NOTE:All replacement pistonpins are oversize.

2.

Zerothe dial indicstor the Diston diameter. to Din

4.

Checkthe diferrencebetweenpiston pin diameter and connecting smallend diameter. rod 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,recheck cylinderbore the diameter against wear limitson page7-17. the lf the bore is over the servicelimit, the cylinder blockmust be rebored. Pistoo Ring End-Gap: F22Al ongio€: Top Ring Standard (Newlr 0.20- 0.35 mm (0.008 0.014in) in) SorvicoLimil: 0.60 mm 10.024 S€condRing Slandard {N6wl: o.i(t - 0.55 mm (0.015 0.022 inl SorviceLimh: 0.70 mm (0.028inl Oil Ring Standard (Newl: 0.20- 0.70 mm {0.008- 0.028in} 0.80 mm (0.03'linl Servic€Limit H23A1,H22Al engine3: Top Ring Standard {New): 0.25- 0.35 mm 10.010 0.014in) mm (0.02'lin) SorvicaLimit: 0.61t Socond Ring Standard (N6w): 0.60- 0.75 mm 10.02,t 0.030in) mm {0.035inl ServiceLimit: 0.90 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 (0.02i1 in) RIKENmanutaqture: 0.80mm (0.031 in)
RING PISTON

r.---iL i.i----

iiii

I

ENDGAP

Ovg6izo: F22Al lnginel 0.251 85.25mm (3.356inl 0.50:85.50mm (3.366inl H23A1. H22Al .nginc: 0.25:87.25mm (3.i|il5inl

7-22

Replacement
1. 2. Usinga ring expander, removethe old pistonrings, Cleanall ring groovesthoroughly. NOTE: . U s e a s q u a r e d - o fb r o k e nr i n g o r r i n g groove f cleaner with bladeto fit pistongrooves. . Top and 2nd ring groovesare 1.2 mm ( 0 . 0 5i n ) wide and the oil ring groove is 2.8 mm ( 0 . ll i n ) wide. . Filedown bladeif necessarv. CAUTION: Dq not uss a wire brush to clean the ring groovgs, or cut ring groove3 d9€per with cloaning tools. NOTE:lfthe pistonis to be separated from the connectingrod, do not installnew ringsyet. Installnew rings in the proper sequence and position (page7-24). NOTE:Do not useold pistonrings.

Ring-to-Groove Clearance
After installing new set of rings. measurethe ring-toa grooveclearances: Top Ring Cl€arlnc6 Standard (New): 0.035- 0.060mm {0.0014 0.002,tinl SorvicoLimit: 0.13 mm (0.005in) Second Ring Clsaranco Standard (Now): 0.030- 0.055mm (0.fl)12- 0.fl122inl SorvicoLimit: 0.13 mm (0.005inl

RINGEXPANDER

PistonRings
Alignment
1 , lnstalltheringsas shown. I 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. NOTE: The manufacturingmarks must be facing upwaro.

TOP RING

MARK

SECOND RING

\

3.

Position ring end gsps 8s shown: the

RINGGAP SECOND

DO NOT position any rinOgap at piston thrust surfaces.

H22Al onginos: H23A1, Approx.90'

Appiox. 90" TOPRINGGAP DO NOT posilion any ring gap in linewith the oistonoin hole.

OIL RING GAP GAP OIL RINGGAP

Crankshaft Seal Oil
; Installatio I
| | .11 'E The sealsurface the blockshouldbe dry. on Apply a light coat of oit to the crankshaft and to the lip of the s6al.

Pistons
lnstallation
B e f o r e i n s t a l l i n gt h e p i s t o n , a p p l y a c o a t o f engine oil to the ring groovesand cylinder bores. 1. ll the crankshaft alreadyinstalled: is . Setthe crankshaft BDCfor eachcvlinder. to o Removethe connectingrod caps and slip short sectionsof rubber hose over the threadedends of the connecting bolts. rod . Installthe ring compressor, checkthat the bearing is securelyin place,then position-the piston 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-crank journal alignment beforepushingpistoninto place. . Install the rod capswith bearings, and torquethe nutsto: 47 N.m {4.7kg-m.34lb-ft) lf the crankshaft not installed: is . Removethe rod caps and bearings,install the nng compressor, then positionthe piston in the cylinderand tap it in usingthe wooden handleof a nammer. . Position pistonsat toD deadcenter, all

l.

Drivein crankshaft sealagainstright sidecover. oil NOTE:Drivethe crankshaft sealin squarely. oil DRIVER 07749 0or(xDo

2.
Install sealwith the part number sid6 facingout.

DRIVEB ATTACHMCNT 079ir8 SBlXtl01 C o n f i r mt h a t t h e c l e a r a n c e s e q u a l a l l t h e w a y i aroundwith a feelergauge. Cloarancc: - 0.8 mm (0.02- 0.03 inl 0.5
The mark muBttace the timing beltside of the engine. The arrow must tace the timing beltsideot the engine.

RIGHTSIDE COVER

0.5 - 0.8 mm

NOTE:Maintaindownward force on the ring comp r e s s o rt o p r e v e n tr i n g s f r o m e x p a n d i n gb e t o r e entering cylinderbore, the
Usethe wood€nhandle of a hammorto push,or

NOTE:Referto pages7-30and 8-11for installation of the oil pump sidecrankshaft sear. oil

Shafts and Balancer Grankshaft
lnstallation
apply a coat of Betoreinstallingthe crankshaft, r 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 . o d b e a r i n g s shaft bearings. and balancer Insertbearinghalvesin the cylinderblockand connectingrods. so Holdthe crankshaft rod journaisfor cylindersNo. 2 and No,3 are straightup. into the block,seatingthe rod Lowerthe crankshaft journalsinto connecting rods No. 1 and No. 4. lnstallthe rod capsand nutsfingertight. 6. Installthe thrust washers,main bearingcaps and bearingcap bridge. Check clearancewith plastigage(page 7-8), then tightenthe bearingcap boltsin 2 steps. ln the first step tighten all bolts in sequence,to about 30 N.m (3.0 kg-m, 22 lb-ft);in the finsl step to tighten in same sequenc€, 75 N.m {7,5 kg-m.54 tb-ft). with engineoil. NOTE:Coatthe bolt threads

RODNo. 2

WASHERS

RODNo. a

CAUTION: Whlnovor any crankshaft or connccting rod baaring i3 roplacad, it ir nocosarY lftcr lc!sscmbly to lun tho cngin. Ei idling tpoed until it rcacho! normal opcrrting iamporltula. thcn Gon. tinue to run it lor approximataly 15 minut6. 7. Insenthe balancer shaftsinto the block,then install shaftand block. to the retainer the front balancer

I

I
\ 'l

seat journals into clockwise, Rotatethe crankshaft rods No, 2 and No.3, and installthe rod connecting capsand nuts fingertiqht. NOTE:Installcaps so the bearingrecessis on the in sameside as the recess the rod. (page with plastigage Checkrod bearingclearance 7-10), then torquothe capnuts. 47 N.m (4.7kg-m.34lb-ft) numbers on connectingrod are NOTE: Reference for big-endbore toleranceand do not indicatethe positionof pistonin the engine.

7-26

NOTE: . Useliquidgasket, parrNo.087t8-0001. . Checkthat the matingsurfaces cleanand dry are beforeapplyingliquidgasket. . Apply liquidgasket evenly,beingcareful cover to allthe matingsurface. . To preventleakag€ oil. apply liquid gasketto of the innerthr6adsof th6 bolt holes, . Do not install the parts if 20 minutes or more haveelapsed sinceapplying the liquidgasket. Insteadreapplyliquid gasketafter removingthe old residue, . After assembly, wait at least 30 minutes before filling th6 enginewith oit. 8. Apply liquid gasket to the block mating surfaee of the right side cover, then install it on the cylinder block.

Apply liquidgasket to block mating surface.

6 x 1,0 rnm 12 N.m (1.2 kg'm, 9 lb-ft) Apply liquid gasket to the bolt threads.

RIGHTSIDECOVER

BIGHTSIDECOVER: 9. Apply liquid gaskstto the oil pump mating surfac€ of the block,then installthe oil pump on the cylinder block. . Apply greaseto the lips of the oil seals. T h e n , i n s t a l lt h e o i l p u m p w h i t e a l i g n i n gt h e inner rotor with the crankshaft. When the pump i s i n p l a c e , c l e a n a n y e x c e s sg r e a s e o f f t h e crankshaftand the balancer shaft, then check that the oil se8llips are not distorted.

OIL PUMP:

Apply liquid gaskst along the broken line.

{cont'd)

7 -27

Shafts and Balancer Crankshaft
Installation (cont'd)
shaftwith a 6 x 100mm bolt, 12. Holdthe rearbalancer drivengear. then installthebalancer
6x1.0mm 12 N.m (1.2kg-m,9lb-ftl OIL SCREEN

SHAFT: REAFBALANCER
8 x 1.25mm 25 N'm {2.5 kg-m, 18 lb-trl

O.RINGS Applyengineoil. Replace. DOWELPIN 6x1.0mm OIL PUMP kg-m, 12 N.m 11.2 Applyliquidgasket to 9 tb-ft) block mating surface. Applyliquidgasket to the bolt threads. Applygrease the seallips. to

6 r lOOmm BOIT
74 mm 12.9 inl

10. Installthebaifleplate,then installtheoil screen. '11. Apply molybdenumdisulfideto the thrust surfaces of the balancergears as shown, before installing t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r case. Applymolybdenum EALANCER SHAFT disutfide. DRIVEN

REARBALANCERSHAFT

'13. Hold the front balancershaft with a screwdriver, belt drivenpulley. then installthetiming balancer SHAFT: FRONTBALANCER

BALANCERBELT DRIVENPULLEY

BALANCERDRIVEGEAR AALANCERGEAR CASE

7-28

14. lnstallthebalancar gea|. caseto the oil pump. NOTE:Align the groovo on the pulley sdg€ to the pointoron the gear casswhile holdingths rear balancer with 6 x 100 mm bolt, then install the gear casg.
DOWELPIN E x 1.25mm 25 N.rn 12.5 lg.m. 18 rb-ft|

16. Install the oil pan.

OIL PAN GASKET Replace.

Apply liquid gasketto here.

BALAI{CER DOWELPIN GEAR $SE
POINTEB

O.RING Applyengine oil, Roplace.

WASHER Replace.

6xl,0mm 12 N.m {1.2kg.h, 9 rb-ft}

Alignthe groov€ to pornter.

45N.m(4.5 kg.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 installing gear the case. POINTER THEPUL1TY ON

NOTE:Tightenthe bolts and nuts in two stoosand torquethem in a criss-cross pattern.

7-29

Shaft Oil Seals and Balancer Crankshaft
Installation {engineremovalnot requiredl
and front balancershaft NOTE:The crankshaft shouldbe dry. oil sealhousingsurface the to Apply a light coat oJgrease the crankshaft, the lips ot the seals. balancer shaftand to Using the specialtool, drive in the crankshaftoil the sealuntil the driverbottomsagainst oil pump. When thg seal is in place.clean any excessgrease and checkthat the oil seal lip is off the crankshaft not distorted. 3. Using the specialtool, drive in the crankshaftoil seal into ths right side coverto the point where the clearancebetween the bottom of the crankshsft oil seal and right side cover is 0.5 - 0.8 mm (0.020.03in) lpage7-251. with NOTE:Align the hole in the driver attachment the pin on the crankshaft.

SEALDRIVER O'LAD - PI':IOIOA lnslall se6l with the part number sido facing out.

07749 (x)1|xno

2,

I

Using the specialtool, d.ive in the front balancer shaft oil seal until the driver bottomsagainstthe oil pump. When the seal is in pl8ce,clean any excess greaseoff the balancer shaft 8nd checkthst the oil sealliDis not distorted.
ATTACHMEITT, 30 mm l.D. 077t6 - @30300

DRIVERATTACHMEMT 079a8- SB@r01 lnstoll sealwiththe part number side facing out.

GUIDE HUBASSEMBLY ATTACHMENT
_ OTGAF

7-30

Balancer Shafts
Inspection
NOTE: Inspectthe balancershaft before removingthe right sidecoverand the balancer gearcase{page7-12). '1. Push the balancershaft firmly away from the dial indicator, and zerothe dial againstthe front end of the balancer shaft,then pull the balancer shaftfirmly backtoward the indicator. Froni BalancorShaft End Play Standard (Nsw): 0.10- 0.35 mm l0.00il 0.014in) Remove balancer the shafts(page7-12). NOTE:Clean the balancer shsfts, Inspect surfaceof the balancer the shaftjournaland balancer bearing. Replace there is wear,damageor discoloration if on the surfaceof the bearingor the balsncer shaftjournal. When replacing the rear No. 1 bearingbe sure to replace oil pump housingwith a new one. the NOTE;A mirro.-like surfaceis normat. Measure taperat the edgesof eachjournal. . The differencebetweenmeasurements each on lournal. Journal Tapor Standard (Newl: 0.005mm (0.0002in)

.

lf end play is excessive, inspectthe retainerand thrustsurfaces the balancer on shaft.

Rsar BalancorShrft End Play Stsndard(N€w):0.06- 0.18mm 10.002 0.007inl

.

lf end play is excessiv€, inspect the thrust washer and thrust surfaces the driven qear and oil on pump Dody.

N O T E :T h e t h i c k n e s s f t h e r e t a i n e r( f r o n t ) a n d o 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 changed eitherby grindingor shimming.

{cont'd)

7-31

Shafts Balancer
(cont'd) Inspection
6. Measurerunout on the No. 2 journal of each balshaltsare not ancershaftto makesurethe balancer bent, Ealanc6rShaft Total IndicatodRunout Standrrd (Now): 0.02 mm (0.001inl inl Sewice Limit: 0.03 mm 10'001

Measurethe diametersof the balancershaft journ al s .

:
I

MEASURINGPOINTS

i
I

Journal Diamot€r Stlndard (New) No, 1 ioutnal: mm Front: 12-722- 12..731 11.6820 1.6824inl 20.938- 20.950mm Rear: in} {0.824:l 0.82'18 No. 2 iourn.l: 38.712- 38.724mm inl l1.52al- 1.5245 No. 3 iourn.f : 31.722- 31.731mm (1.3670 1.3675 inl Limit: Scrvica No. I iournal: in) 42.71mm {1.681 Front: inl 20.92mm 10.82,1 Rcar: inl No. 2 iouinll: 38.70mm (1.524 in) No. 3 iournal:34.71mm (1.367 the pistons and the other Removethe crankshaft, oartsfrom the block,then cleanthe balancershaft i o u r n a l b e a r i n g so f t h e b l o c k a n d t h e o i l p u m p housingwith a cleanshoptowel. 9. if Checkthe surfaceof the bearings, there is wear. damage or discoloration,replacethe bearingsor the oil pump housing.

I

i

7 -32

1 0 . Measurethe inner diametersof the balancer shaft journalbearings.
MEASURE POINTS No. 2 BEARING IBLOCKI

Bearing Inner Diametor Standard {Nswl: No. I iournals: Fronl: 12.8OO- 12-82O mm (1.6850 1.6858 in) Rear: 21.flD - 21.013 mm {0.8268 0.8273inl No. 2 iournals: 38.800- 38.820mm (1.5276 1.5283 in) No. 3 iournals: 34.800- 3,1.820 mm inl {1.3701 1.3709 ServicoLimit: No. l iournals: Front: 42.8:lmm 11.686 inl R6ar: 21.02mm (0.828 in) No. 2 iournals: 38.tIl mm (1.529in) No.3 iournsls:3i1.83 (1.371 mm in) 11. Calculate shaft-to-bearings clearances. the oil BEARING - JOURNALO.D. = OtL CLEARANCE l.D. Boaring-to-shaftOil Cl.aranc€ Standard (Newl No. I iournal front and No. 3 iournsls: 0.066 0.118mm {0.0026 0.0046 inl 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 (0.005 inl No. 2 tournsls: 0.13mm {0.005 inl No. I iournal roar: 0.09 mm (0.004in)

No. 2 BEARING IBLOCK) BLOCK

DIALGAUGE

No. 1 REARBEARING IOIL PUMP HOUSINGI

7-33

EngineLubrication
Speciaf Tools.......... ...........9-2 lllustrated lndex........... .....8-3 Engine Oil Inspection ...................... 8-5 Replacement ....................................... 8-5 Oil Filter Rep|acement ....................................... 8-6 Oil Pressure Testing ......8-8 OilJet fnspection lHz2Al engineonly) ........ 8-8 Oil Pump Overhaul ......................... 8-9 RemovaUlnspection/lnstallation8-10 ......

SpecialTools

Rs{. No.

I

Tool Numbel OTLAD 07746 07749 07912 PT3O1OA 0010300 0010000 6110001

Drtcription SealDriver 42 Attachment, x 47 mm Driver Oil Filterwrench

Oty

I

PEg. Rctercnc. 8-11 8-1 1 8-1' I a-7

o
Ar

@ @

I
o

o

o

8-2

lllustratedIndex
NOTE: a Us€ new O-rings when reassembling. . Apply oilto O-ringsbeforeinstallation. . Useliquidgasket, PartNo. 08718 OOO1. . Clean the oil controlorificewhen installing. 8 x 1.25 mm CAUTION: Do not overtighten the drain plug.

OILPUMP Overhaul, pageI 9 Inspection, page8-10 Apply liquidgasket to blockmatingsurface. O-RINGS Replace. F22A1,H23At enginesj OIL CONTROL ORIFICE Do not install on the H22A1 it engine. Clean. O.RING Replace. F22Al engin€: ENGINEOIL PRESSURE SWITCH 18 N.m (1.8 kg.m, t3 tb-ft) 1/8in. BSP{British standard pipetaper) 28 threads/inch. Use properliquidsealant. H23A1,H22At engin.s: KNOCKSENSOR 32 N.m 13.3kg-m, 23 tb-ftl

8 x 1.25mm 30 N.m (3.0 kg-m, 22tb-ft1

BALANCEN GEARCASE

O.RING Replace. DOWEL PIN

8 x 1.25mm 25 N'm 12.5 kg-m, i8 tb-ft}

ENGINE OIL COOI..ER {H23A1, H22Al ongin6)

DOWEL PIN GASKET
Replace. OIL SCREEN OIL FILTER 7/8 turn or 22 N.m l2.2lg-m, i6 tb-ft| Replacemg6lp6gs g 6 Replace every 7,500miles {12,000 or 6 months. km) H23A1,H22At engin$: ENGINEOIL PRESSURE SWITCH 18 N.m {1.8 kg-m, t3 tb-ftl

OIL PAN GASKET Roplace.

6x1.0mm 12 N.m 11.2 kg-m,9 tb-ft|

6x1.0mm 12 N.rn(1.2kg-m.9 tb-ft) WASHER Replace. DRAINBOLT 1 4x 1 . 5m m 45 N.m 14.5 kg-m,33 lb-ttl Do not overtighten.

OIL PAN

(cont'd)

8-3

lllustratedIndex
lcont'd)
NOTE: a Usenew O-ringswhen reassembling. . Apply oilto O-ringsbeforeinstallation PartNo. 08718 0001. . Use liquidgasket,
1 1x 1 , 5m m 75 N.m (7.5kg-m, 54 tb-ft} Applyengineoiltolhe bolt threads and th€ washers NOTE: Alter torquing each cap, to turn crankshaft chock for binding.

5x1.0mm kg-m,9lb-ft| 12 N.m 11.2

BAFF1TPLATE

EEARINGCAP BRIDGE

OIL JET BOLT 40 N.m {a.0 kg-m, 29 tb-ft) OIL JET with Handle nozzle the il care.Replace any pan is damagedor detormed. 6x1.0mm 12 N.m {1.2lg-m,9lb-ft}

i

CRANKSHAFT

i

THRUST WASHERS Groovedsidesface outward.

a-4

Engine Oil
Inspection
Checkengine oil with the engine off and the car parkedon levelground. Makecertainthat the oil level indicated the dioon stickis betweenthe upoerand lowe. marks. lf the level has dropped close to the lower mark. add oil until it reaches upDermarK. the CAUTION: In36rt thc dipstick cardully to avoid bonding it.

Replacement
CAUTION:Removs the drain bolt carofullywhile th6 ongine is hot oil m8y caus6scalding. L 2. W a r mu p t h e e n g i n e . Drainthe engineoil.

45 N.m{a.5kg-m, tb-ft| 33

WASHER R6placo.

R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r , a n d refillwith the recommended oil. CAUTION: Do not ov6rtight6n the drain bolt.
Requirement API ServiceGrade:Use "Energy Conserving ll" SG gradeoil. F22A1,H23A1engines:5 W- 30 preferred. H22Al engine: W - 30 preferred. 10 Capacity F22A1 enginel 3.8f (4.0US qt,3.3 tmp qt) change, including filter. 4 . 9 1( 5 . 2 S q t , 4 . 3 l m p t ) U q atter engine overhaul. H23A1 engine: 4.3f (4.5US qt, 3.8tmp qt) chang€,includingfilt6r. 5.4f (5.7US qt, 4.8lmp qt) afterengineoverhaul. H22A1 engino: 4.8f (5.1US qt, 4.2 lmp qO change, including fitter. 5.9f (6.2US qt, 5.2lmp qt) aflerengineoverhaul, Every7,500miles {12.OOO or 6 months krn)

Change

{cont'd)

8-5

Engi n eOi l
(cont'd) Replacement
The numbersin the middle of the API Servicelabeltell you the oil's SAE viscosityor weight. Selectthe oil for your car according this chart: to F22A1.H23A1engines:

Oil Filter
Replacement
o Ltter tte engine has been run. the exhaurt pipo will be hot; be caroful when working around the axhau3t pipo. Be careful when loo3oning the drain bolt while tho engino i3 hot, Burns can rosult becausothG oil lgm' peraturc is very high. R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r wrench. the threadsand rubber seal on the new filInspect 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 bypasssysrem.

Ambi€nt Temperaturo

A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r improved fuel economy and year-roundprotection in the car. You may use a 10 W - 30 oil if the climate in rangeshown on your area is limitedto the temperature the chart. H22A1engine:

Applyengineoilto rubb€r sealbeforeinstalling.

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 rangeshown on the your area is within the temperature 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. 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 clockwise with the specialtool. Tighten: 7/8 turn clockwise Tightoning torque: 22 N.m (2.2 kg-m, 16 lb-ftl CAUTION: lnstallation other than the abov€ procsdur6 could result in sgrious ongine damage due to oil l6ak.go.

eight numbers(1 to 8l are printedon the surfaceof the filter. The following explainsthe procedure tighteningfil, for ters usingthesenumbers. 1) Make a mark on the cylinderblock under the number that shows at the bottom of the filter when the rubbersealis seated. 2) Tightenthe filter by turning it clockwise sevennumbersfrom the markedpoint. For example,if a mark is made under the number 2 when the rubberseal i s s e a t e d t h e f i l t e r s h o u l d b e t i g h t e n e du n t i t t h e , number1 comesup to the markedpoint.

I

OIL FILTER WRENCH 07912- 611t)00r

Numberwhen rubber sealis seated.

Numberaftertightening.

Numberwhen rubber sealis seated
ENGINEOIL COOLER (H23Al, H22A1engine3l

4 8 1

7

8 1

Numberaftertightening

5.

After installation, the engine with oil up to the fill specified level,run the enginefor more than 3 min utes,then checkfor oil leakage.

a-7

Oil Pressure
lf the oil pressure warning light stayson with the engine running.checkthe engineoil level.lf the oil level is correct:
'1.

Oil Jet
fnspection engineonlyl lH22A1
Removethe oil jet (page8-4) and inspectit as folrows. Make sure that a 1.1 mm {0.04in} diameterdrill will go throughthe nozzle hole {1.2mm t0.05in) diameter). Insertthe other end of the same 1.1mm {0,04in} drill into the oil intake(1.2 mm (0.05in) diameter). Make sure the check ball moves smoothlv and has a strokeof approximately mm (0.16 4.0
In,.

Connect tachometer. a Removethe engine oil pressureswitch and install gauge. an oil pressure S t a r t t h e e n g i n e . S h u t i t o f f i m m e d i a t e l yi f t h e gauge registers oil pressure. no Repair the problem beforecontinuing. Allow the engine to reach operatingtemperature (radiator comeson at leasttwice).The pressure lan shouldbe: 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

Checkthe oil jet operationwith an air nozzle. lt should take at least200 kPa (2.0 kg/cm,,28 psi) to unseat checkball. the NOTE:Replace oil jet assemblyif the nozzl€ the is damagedor bent,

1!

I
:. '

lf oil pressure within specifications, is replace the 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 , inspect oil pump (pages the 8-10,11|.

I
.

ENGINE OIL PRESSURE SWITCH MOUNTINGHOLE {F22A1engino}

OIL PRESSURE GAUGE

I
i

I I

ENGINE OIL PRESSURE SWiTCH MOUNTINGHOLE lH23A1,H22Al cneinos) lH23A1,H22A1.ngin.!l

Mounting torque is critical.Be very precisewhen installing. 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

OOWEL PIN

OUTER ROTOR page 11 Inspection, 8-10,

6x1.0mm 12 N.m {1.2kg-m,9lb-ft}. Apply liquid gasker to the bolt threads,

INNERROTOR page8-10,t 1 Inspection,

OIL SEALS Replace.

PUMPHOUSING pageI 10.11 Insp€ction,

8-9

Oil Pump
Removal/lnspection/lnstallation
t o 1 . D r a i n h ee n g i n e i l . 2. Turn the crankshaft that the No. 1 pistonis at top so d e a d c e n t e r( F 2 2 A 1e n g i n e :p a g e 6 - 2 8 ,H 2 3 A 1 engine:page6-62,H2241engine:page6-106). the belt Remove timing belt and the timing balancer (F22A1 engine:page6-29,H23A1 engine:page6-63, H22A1 engine:page6-'l07). Remove he timing belttensioner nd the timing t a belttensioner. balancer Bemovethe timing belt drive pulleyand the timing balancer belt drivenpulley(page7-12). 6. g R e m o v e h e b a l a n c e . e a r c a s ea n d t h e b a l a n c e r t drivengear(page7-121. Remove oil pan and the oil screen. the 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

9. Removethe screwsfrom the pump housing,then separate housingand cover. the '10. rotor radial clearance Checkthe inner-to-outer on the oumo rotor. lnner Rotor-to-OuterRotor RsdialClea.anc€ Sland8ld (Newl: 0.02- 0.16 mm (0.001- 0.006in) ServiceLimit: 0.20 mm 10.008 inl

ii
I
DOWELPIN OIL PUMP

-

lf the inner-to-outer rotor clearance exceeds the service limit, replace innerand outer rotors. the

O.RINGS Replace-

1'1. Checkthe housing-to-rotor axial clearancson the oumo rotor. Housing-to-RotorAxial Clcaranco Standard lNewl: 0.02- 0.07 mm (0.001- 0.003in) SorvicoLimit 0.12 mm 10.005 inl

Replace.

PUMP HOUSING

OUTERROTOR ROTOR OUTER

OIL SCREEN

-

lf the housing-to-rotor axial 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€ck housing-to-outer the 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)

_ 077a6 00,t0300

,rJ:|xaTmm

Rsassemblethe oil pump, applying liquid thrcad lockto the pump housingscrews. 1 7 . Check that the oil pump turnsfreely, ?8. Installa dowel pin and the new O-ringon the pump, NOTE:
a Useliquidgasket, Pan No. 08718 0001. a Check that the matingsurfaces cleanand dry are

-

l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e exceedsthe service limit, replacethe set of inner and outer roto.sand/orthe pump housing.

1 3 . Inspect both rotors and the pump housing for scoring or other damage.Replaceparts if necessary. Remove old oil sealsfrom the oil pump. the
t5.

beforeapplyingliquidgasket. Apply liquidgasketevenly,in a narrowbeadcenteredon the matingsurface. . To preventleakage oil, apply liquid gasketto of the innerthreadsof the bolt holes, . Do not install the parts if 20 minutes or more haveelapsed sinceapplyingliquidgasket. Insteadreapplyliquid gasketafter removingthe old residue. . After assembly, wait at least 30 minutes before filling the enginewith oil. 19. Apply liquidgasket the oit pump and insta it. to . Apply greaseto the lips of the crankshaft seal oil and the balancershaft seal.Then, installthe oil pump Inner rotor onto the crankshaft. When the pump is in place,cleanany excess greaseoff the crankshaftand the balancer shaft, then check that the oil seal liDsare not distorted.

Gentlytap in the new oil sealsuntil the special tool bottomson the pump. NOTE:The oil sealsalon€ can be reolaced without romovingth€ oil pump usingthe specialtool.

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 drivengear. bolt,then installthe balancer
Apply grease to the seallips. 6 x 10 mm 12 N.m 11.2kg-m, 9 lb-ft| OIL PUMP Apply liquidgasket the to Applyliquidgasket bolt threads. to block mating surface.

REARBALANCER:

O.RINGS Applyengineoil. Replace.

I x 1.25mm 25 N.m {2.5 kg-m, 18lb-ft}

6 x 100mm EOLT
6x1.0mm 12 N.m (1.2kg"m, 9 tb-ttl t4 mm 12.9inl

OIL SCREEN

Install the baffleplate. 2 1 . Install oil screen. the Apply molybdenumdisultideto the thrust surfaces of the balancergears.as shown, before installing t h e b a l a n c e rd r i v e n g e a r a n d t h e b a l a n c e rg e a r
case. Apply molybdonum disulfide. BALANCER DBIVEN GEAR REANBALAI{CERSHAFT

24. Hold the front balancershaft with a screwdriv€r, b€lt driv€npull6y. then installthe timing balsnce. FRONTBALANCER:

BALANCER DRIVE GEAR

8-12

gear caseon the oil pump. 25, lnstallthebalancer NOTE;Align the groove on the pulley edge to the pointeron the gear casewhile holdingthe rear balancerwith the 6 x 100mm bolt,then installthe gear case.
DOWELPIN 8 x 1.25mm 25 N.m 12.5kg-m, 18 lb-ftl

27. Install the oil pan.

OIL PAN GASKET Replace.

Apply liquid gask€there.

BALANCER GEARCASE

DOWELPIN

O.FING Apply6ngin€oil. Replace.

WASHER Replac6.

6x1.0mm

POINTER Alignthe O.oove to pornter,

DRAIN EOLT ils .m 14.5 ks-m, 33 tb_ft) Donotovertightsn.

24. Tightenthe boltsand nuts as shown below. Torquo: 12 Nfl (1.2tg-m,9 lb-ft)

GROOVE

26. Checkalignmentof pointersafter installing gear the case. POINTER THE ON PULLEY
a -------_

POINTER ON THEOIL PUMP

NOTE:Tightenthe bolts and nuts in two stepsand pattern. torquethem in a crisscross

8-13

Intake Manifold/Exhaust System
Intake Manifold R e p l a c e m e n.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 . . . . . . . . . . . . . . . . . . . . . . . . . 9.-.7. .t . .

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. H2341, H2241 engines: 22 N.m (2.2 ks-m, 16 lb-tll
STARTINGAIR VALVE 6xl.0mm 12 N.m 11.2 kg-m, 9 lb-ft| IDLE AIR CONTROL 8 r 1,25mm

INTAKE MANIFOLD CHAMBER Replacoif cracked or if mating surfaces are damaged.

{tAc}val-vE
8 x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft}

THROITLE BODY

d
O-RINGS Replace.

GASKET Replsce.
INTAKE AIR BYPASS FAST IDLE TXERMO VALVE

IIAB}VALVEBODYASSEMELY
Replace crackedor if if mating surlaces are oamageo.

6 x 1 . 0m m 12 N.m ('1.2kg-m,I lb-ttl

8 r 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)

GASKET Replace.

|l['sJ!'J[*%''
(fAT) SE[{SOR ./ O.RING Replace.

Y"Sft

EXHAUST GAS NECIBCULATIOI{ VALVE IEGR}

INTAKE
Replace crackedor it if mating su aces are damaged.

8r1.25mm 22 N.m (2.2 ks-m,l6 lb-tt) GASKET Replace.
8x1.25mm 22 N.tn 12,2 kg-m, 16 lb-ftI

8 x 1.25mm 22 N.m 12.2 kg-m, '16 lb-ftl

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-ETHERMO VALVE
I x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ftl

22 N'm 12.2ks-m, 16 lb-ftl

STARTINGAIR VALVE O-RINGS Replace.

IAC VALVE

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 INTAKE MANIFOLD CHAMBER Replaceif cracked or if mating surfaces are damaged. O.RINGS Replace.

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

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)

8 x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)

INTAKE MANIFOLD BRACKET

9-3

Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when reassembling' CAUTION: a Check for folds or scratchas on the sutfaca of tho gasket' a Rsplace with 6 new gaskot il damagod. H23A1 engine:

NUT SELF-LOCKING I x 1.25mm 32 N.rn (3.2 kg-m, 23 lb-ft) Replace.

GASKET R6place.

8 r 1.25mm 22 N.n 12.2 kg-m, 16 lb-ft)

MA IFOID EXHAUST BRACKET

lO x 1.25mm 45 t{.m (4.5 kg-m. 33 lb-ft} GASKETS Roplace. r 1.25mm 22 N.m 12.2 kg-m, l6 lb-ftl

1 0 r 1 . 2 5m m 45 N.m t4.5 kg-m.33 lb-ft)
6 x 1.0 m]n 12 N.m ll.2 kg-m. 9 lb-ft) T INSULATOR

NUT SELF-LOCKING 10 x 'l,25 mm 55 N.m t5.5 kg-m,40 lb-ftl

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

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.

,.(

HEATED OXYGEI! SENSOR {HO2Sl
45 N.m 14.5 kg-m, 33 lb-ft) Be carelul not to

EXHAUST MANIFOI.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{G NUT 10 x 1.25mm 55 N'm 15.5 kg-m. 40 lb-fi) Replace.

HO23 CONNECTOR

COVER

HEAT INSULATOR lCars equippedwith air conditioningl

6 x 1 . Om m 10 N.m (1.O kg-m, 7 lb-fil

9-5

Exhaust Manifold
Replacement
nuts when reassembling. NOTE: Use new gasketsand self-locking CAUTION: a Chock tor folds or scratchoa on tho surface of the gasket. a Replaco with a now gaskot it damaged. H22A'l ongino:

lr I

t{UT SELF.LOCKING 8 r 1.25mm 32 N.m {3.2 kg-m, 23 lb-ft) Replace. EXHAUST MAf{IFOLD

GASKET Replace.

COVER

1 0 r 1 . 2 5m | n 33 lb-tt)

.m 14.5 lg.|n,

GASKETS R6place.

8 x '1.25mm 22 N.m 12.2 kg-m, 16 lb-ft)

HEATINSULATOR
SELF-LOCKII{G NUT 10 x 1.25mm 55 N.m (5.5 kg-m, il.O lb-ft) EXHAUST PIPEA 8 x 1.25mm 22 N.m 12.2 ks-m, 16 lb-ft1 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-locking nuts when reassemblino.

6 x 1 . 0m m 10 N.m {1.Okg-m.7 lb-ftl
HEAT SHIELD SELF-LOCKING NUT 1 2 x 1 , 2 5m m 55 N.m {5.5 kg-m,4O lb-ft| Replace.

€. €

\
EXHAUST PIPETIP

THREE WAY CATALYTIC COI{VERT€R TTWCI TOROUE SEOUENCE

MUFFLER

\ GASKET Replace.

EXHAUSTPIPEB

45 N.ln 14.5 kg-m, 33 lb-ft| Be carefulnot to damage.

SEI.F.LOCKING NUT 10 x 1.25mm 34 N.m {3.4 kg-m, 25 tb-ftl Replace.

oor*rrr\

Replace. V

3
SELF-LOCKING NUTS I x 1,25mm 18 N.m (1.8 kg-m, 13 tb-ftl Replace.

GASKET

SELF-LOCKING NUT 10 x 1.25mm 55 N.m (5.5 kg-m,40 lb-ttl Replace.

SELF-LOCKING NUT 10 x 1-25mm 34 N.m (3,4 kg-m, 25 lb-ttl R6place.

I
9-7

Cooling
Radiator fffustrated Index......... . 1O-2 R e p | a c e m e.n t . . . . . . . . . . . . . . . . . . . . . . 1. . .-.5 .. .O . EngineCoolantRefilling a n dB l e e d i n g . . . . . . . . . . . .0 - 6 1 C a pT e s t i n g . . . . . . . . . . . . .1 . - 7 .0 Testing ..... 1O-7 Thermostat R e p | a c e m e.n . . . . . . . . . . . . . . . . . . . . . . . 1.O.-.8 .t . . . Testing ..... 10-9 Water Pump lllustrated Index......... . 1O-1O fnspection . 10-12 Repfacement .............. 1O-12

Radiator
lllustratedIndex
sy"t". is under high pressurewhon engino @ is hot, To avoid dangel ot releasingscaldingcoolant, remove cap only when engine is cool. Total Cooling System capacity {lncluding hoater and res€rvoir) F2241 engin€: ", : .1 | l7 .5 US qt, Manuaf Automatic: 7 .O | (7 .4 US qt, H23A1 sngin€: Manuaf : 7 ,4 (. 0,A US qt, Automatic: 7 .3 I 17.7 US qt. H2241 engin€: Manual: 7.6 | (8.O US qt, CAUTION: Wh€n poudng ongino coolant, be suts to shut the relay box lid and not to spill coolant on the electlical parts or tha paintsd po ion. lf 8ny coolant spills, rinse it off imm€diately. NOTE: a Checkallcooling systemhosesfor damsge,leaks or deterioration and replaceif necessSry. a Check all hoss clamps and retightenif necessary. a Use new O-ringswhen reassembling. RADIATOR Engine coolant

6.2 lmp qt) 6.2 lmp qt) 6.5 lmp qtl 6.4 lmp qt) 6.7 lmp qt)

Reselvoircapacity:O.6 t {0.6 US qt, O.5 lmp qt)

p6ge 'l0-6 Refilling and bleoding. Leak test, page 1O-7 Inspect soldered joints and seamsfor leaks. Blow out dirt from between core fins with compregsedair. l{ insects,etc., are clogging radiator, wash them off with low oressule water.

RADIATOB CAP Pressure testing,pago 1O-7

6 x 1.0 mm 1 0 N . m { ' l . Ok g - m , 7 tb-ft)

FLUID (ATF) COOLER

FAN MOTOR

6 r 1 . 0m m ' l ON . m( 1 . 0rg-m, 7 tb-ttl

o.

-

O-RING DRATNPLUG Replace.

;t'i.*:l:XS[YJ,,,
Replace.

FAN COOLING

FAN SHROUD

10-2

Engino Ho86 Connoctions:
IOLEAIR CONTROL {IACI VALVE FAST IDLE THERMO V THERMOSTAT HOUSING

F22A1 engine:

\
HEATER OUTLET

LOWERHOSE

CONI{ECTINGPIPE BYPASS HOSE Replace.

HEATER INLET HOSE

H23Al engine:
IAC VALVE

POSITIVECRANKCASE VENTILATION(PCV} PIPE

EYPASS HOSES O.RING Replace. OIL COOLER BYPASS HOSE

HEATER

O-RING Replace.

* 8 x 1 . 2 5m m PIPE CONNECTING 22 N'm kg-rn, OIL COOLER 12.2 16 tb-ft) BYPASS HOSE COOLER
r:: CORFOSION RESTSTANT BOLT

(cont'd)

10-3

Radiator
lllustratedIndex (cont'd)
Engin€ Hose Connections:

H22A'l €ngin€:

I

THERMOSTAT HOUSING

INLET HEATER HOSE

OUTLET HEATER HOSE
PIPE CONNECTING

O-RING COOLER Replaco.

* 8 x 1 . 2 5m m 22 N.m 12.2kg-m, 16 tb-ft}

RESISTANT BOLT *: CORROSION

10 -4

Replacement
1 . Dr€inenginecoolant. Romovethe upper and coolor hoses.
a

5. radiatorhoses,and ATF

Removethe fan shroudassemblies and other parts from radiator.

Instsllthe radiatorin the reverseorder of removal: NOTE: a Set the upper and lower cushionssecurly. a Fillthe radistorwith engine coolantand bleedthe ai''.

Disconnect the fan motor connectors. R€movethe radiatorupper brackets,then pull up the radiator.

4.

6 x 1.0 mm 10 N.m (1.0 kg-n, 7lb-ft1

RADIATOR
page 1O-7 BADIATOR CAP Testing,page 'lO-7

6x1.0mm 10 N.m ll.O kg-m,7 lb-ft} UPPER I{OSE

UPPER BRACKET ANDCUSHION

:tt'l13l3l=.--_g
I x 1.0 mm lO N.in (t.O kg-m.7 tb-frt @

F/o "l

sng 7.r.

F

d
FAN MOTOR CON'VECTOR

P

owE CUSHTON R
ATF COOLER HOSE$ O-RING Replace. LOWERHOSE

HOSE 1 RESERVOIR \

DRAIN PLUG

RESERVOIR

10-5

Radiator
Engine Coolantnefill\ and Bleeding
CAUTlOttl: When pouting enginocoolaisQgsuro to shut th6 ralay box lid and not to lst coolanl spill on tho electrical part6 or lh€ paint. lf any coolant spills, rinse it off immodiat6ly. 1. Set the heatertemperaturelever or conttol dial to maxamum heat. 2. 3. Removethe engine splashshield. When the radiatoris cool, removethe radiatorcap. Loosenthe drain plug, and drain the coolant. Removethe drain bolt trom the rear side of the cylinderblock to drain the block and heater, Apply liquidgasketto the drain bolt threads,then reinstall the bolt with a new washer and tighten it securely. Tightenthe radiatordrain plug securely. Fillthetank reservoir. Remove, drainand reinstallthe the MAX mark with water, then up to the haltway to MAX mark with anti-freeze. 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, coolant concenthe year-roundat 50 tration must be maintained less concentrations than 50% minimum.Coolant may not provide sutficient protection againstcorrosion or treezing. a Coolantconcentrationsgreaterthan 60% will impaif cooling efficiency and are not recommended. CAUTION: a Do not mix dilferent brands of anti-freoze/ coolants. a Do not uso additional rust inhibitors or anti-rust products; they may not be compatible with tho g€nuine coolant. Engine Coolant Refill Capacity: including reservoir {0.6 t {0.6 US qt, 0.5 lmp qt}l and heatar{0.6 f (o.6 US qt, 0.5 lmp qt)|. F22Al engine: Manual: 3.5 I (3.7 US qt,3.1 lmp qt) Automatic: 3.4 f {3.6 US qt, 3.0 lmp qtl H23Al engine: Manual: 3.8 X (4'O US qt, 3.3 lmp qrl Automatic: 3.7 t {3.9 US qt, 3.3 lmp qt} H22Al engino: 4.O f 9.2 US qt, 3'5 lmp qt) : Manuaf

9 . Loosenthe air bleed bolt in the thetmostat housing,
then fillthe radiatorto the bottom of the tiller neck with the coolantmixtu.e. Tightenthe bleedbolt as soon as coolant stans to run out in a steadv stream without bubbles. BLEED BOLT

4.

5.

6. 7,

8.

DRAII{ BOLT

60 N.m {6.0 kg-m,43 lb-ft} Applvliquidgasketto the boltthreads wheninstalling. 1O. With the radiatorcap oft, start the engineand let it fan run until warmed up (Radiator goes on at least add twice). Then,if necessary, more coolantmix to bring the level back up to the bottom ot the filler neck. 11. Put the radiatorcap on tightly, then run the engine again and check tor leaks.

10 -6

Cap Testing
Removethe radiatorcap, wet its seal with engine coolant,then insmll it on the pressure tester. Apply a pressure f 95-125 o k g / c m , ,1 4 - 1 8 p s i ) . Check for a drop in pressure.
4.

kpa (0.9b-1.25

lf the pressuredrops, replacethe cap. RADIATOR PRESSUBE TESTER COMMERCIALLY AVAILABLE

ADAPTOR {for smallcap)

Testing
1. Wait until the engineis cool. then carefullyremove the radiator cap and fill the radiator with engine coolant to the toD of the filler neck. 2, Attach the pressure testerto the radistorand apply a pressure f 95-125 kPa (0.95-1.25 kg/cmr, o 14. 18 psi). Inspect for enngine coolanl leaks and a drop in pressure, Removethe tester and reinstall the radiatorcao. NOTE; Check for engineoil in the coolant and/or coolant in engineoil.

RADIATOR PBESSURE TESTER
COMMERCIALLY AVAILABLE

3.

4,

10-7

Thermostat
Replacement
NOTE: Use new O-ringswhen reassembling. F22A1, H23Al engin6s: ELEED BOLT 10 N.m lt.0 kg-m,7 lb-ftl

6 x 1.0mm '12 N.m (1.2 kg-m, 9 lb-ft)

ENGIfTE COOLANT (ECT} TEMPERATURE A SWITCH 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} RUBBER SEAL Replace. THERMOSTAT Install with pin up.
AT COVER

H22Al enginor BLEED BOLT 10 N.m (1.0 kg-m.7 lb-ftl

A ECTSWITCH 28 N.m {2.8 kg-m,20 lb-ft|

THENMOSTAT Instali with pin up.

6x1.0mm '12 N'm 11.2 kg-m, 9 lb-ttl

AT COVER

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 temperature which the at 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 cylind€rhead mating surface.

ENGINECOOLANT {ECT) TEMPERATURE 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, 9 tb-fr)

€t{Gtl{E OILCOOLER (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 60 N.m 16.0 kg-m, 43 rb-frl Apply liquid gasket to bolt threadswhen installing. O-BING Repl6ce.

CONI{ECTINGPIPE (F22A1 enginel

BOLT R€SISTANT *: CORROSION

10-10

H22A1 cnglne:
ECT SEI{SOR 18 N.m (1.8 kg-m, 13lb-ft} 6 x 1.0 mm 12 N.m {1.2kg-m, 9 rb-ttl

ECTGAUGE UNIT SENDIT{G 9 N.m lO,9kg-m, 6.5 rb-ft| ECTSWITCH B 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)

CONNECTING PIPE

6 x l.O mm 12 .ln lt.2 kg-m. 9 lb-ft}

*: CORROSION RES|STANT BOLT

10-1 1

Water Pump
Inspection
Removethe timing balancerbelt and timing belt (F22A1 engine: page 6-29, H23Al engine: page 6-63, H22A1 engine:page 6-109) check that the water pump pulleY turns freely. Check for signs ol seal leakage. NOTE: Smsllamountof is normal. "weeping" Irom bleedhole

Replacement
Removethe timing balsncerbelt and timing b€lt (F22A1 engine: page 6-29, H23A1 engine: page 6-63, H22A1 engine:Page6-1091 Unscrew the bolts, then remove the water pump'

6x1.Omm 12 N.m {1.2kg-m. 9 tb-ft|

O.RING R6place.

I
,
HOLES BLEED 3. Install the water pump in the reverse order of removal.

HOLE BLEED

RUBBER SEAL Apply liquid gaskst to the water pump mating surtace.

10-12

Fuel and Emissions
S p e c i aT o o l s l . . . . . . . . . . . - . . .1 ' l - 2 . ComoonentLocations I n d e x. . . . . . . . . . . . . . . . . . . . . . .1 1 - 3 System Description V a c u u m o n n e c t i o n . , . . . . . . . . . . . . . , . . . . . . .1-. 8. C .s 1. , E l e c t r i c a l o n n e c t i o n.s . . . . . . . . . . . . . . . . . . , . . .1 . .- 12 C . .1 S y s t e mC o n n e c t o r s . , . . . . . . . . . . , . . . , . . . . . . . . . .l.- 2 O . 1 . Troubleshooting T r o u b l e s h o o t i n gu i d e . . . . . . . . . . . . . . . . . . . . . . .1. .- 4 0 G .1 S e l f - d i a g n o s tPc o c e d u r e s , , , . . . . . . . . , . , . . .1 '. l.- 4 2 ir . H o w t o R e a dF l o w c h a r t s. . . , . , . . . . . . . . . . , , . ,1 1 - 4 7 . .. 1-113 ' t- ' l 1 4 1 - 11 4 1-1 6 1 1-'t21 't-122 1-123 1-124 t-tzo 1 -1 3 0

Fuel Injectors Iniector Resistor Fuel Pressure Regulator Fuel Filter

PGM-FISystem
System Description ....... 1 1-48 Troubleshooting Flowchans E n g i n e i l l N o t S t a r t. . . . . . . . . . . . . . . . . . . . . . . .1-. S.0 W 1. . E n g i n e o n t r o lM o d u t e. . . . . . . . . . . . . . . . . . . . . . .1.1- 5 1 C . . H e a t e d x y g e n e n s o r , , . . . . . . . . . . , . . . . . . 1.1-. 5.6 O S . . . H e a t e d x y g e nS e n s o r e a t e r. . . , . . . . . . . . . ,1 1 - 5 8 O H . F u e lS u p p l y y s t e m . . . . . . . . . . . . . . . . . . . . . . .1 1. .6 2 S . .. - .. ManifoldAbsolute Pressure Sensor .,...... l1-64 Top Dead Center/Crankshsft position/ C y l i n d e P o s i t i o n e n s o r . . . . . . . , . . . . ....., . ' l 1- 7 O r S EngineCoolantTemperature Sensor ....... 11-72 T h r o t t l eP o s i t i o n e n s o r. . . . . . . . . . . . . ...... .- . .- 1 ' l- 74 S I n t a k eA i r T e m p e r a t u rS e n s o r . . . . . . . . . . . . .1 1 - 7 6 e . . B a r o m e t r iP r e s s u r S e n s o r. . . . . . . . . . . . . . . . . 1.l - 7 8 c e . l g n i t i o n u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .I. . .- 8 0 O 1 V e h i c l e p e e dS e n s o r. . . . . . . . . . . . ...... . . . . . . . . 1 1 - a 2 S . E l e c t r i c a lo a dD e t e c t o r. . . . . . . . . . . . . . . . . . . . . . .1 - 8 4 L 1. Knock Sensor l E x c e p tF 2 2 A 1 e n g i n e { S ).l . . . . . . . . . . . . . . . .1- 8 8 I A / T F l S i g n aA / B . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 - . .0 t . ..9 .

Intake Air System
System T.oubleshooting Guide 11-13r System Description 11-132 Air Cleaner 11-133 Intake Control Svstem lExcept F22A't engine(Sll 1-134 Throttle Cable 1-138 Throttle Bodv 1-1 9 3 Intake Air Bypass Control System lExcepr F22A'l engine(Sll 1-143 I n t a k eM a n i f o l d F 2 2 4 1 e n g i n e ( S l . . . . . . . . . . . . . 1 - 1 8 ] I 4

EmissionControl System
System Troubleshooting Guide .... 1-149 System Description 1-1 0 5 TailpipeEmission 1-150 T h r e eW a y C a t a l y t i c o n v e n e r. . . . . . . - . . . . . . . . . .1 - 1 5 1 C E x h a u s G a s R e c i r c u l a t i o nv s t e m . . . . . . . . . . . . . 1 - 1 5 3 t S PositiveCrankcase VentilationSystem .,.,.,.. 1 - 1 9 5 Evaporative EmissionControls 1-160

ldle Control System
S y s t e mT r o u b l e s h o o t i n gu i d e . . . . . . . . . . . . . . . . I .1- 9 2 G . System Description ....... 1 1-93 Troubleshooting Flowcharts l d l eA i r C o n t r o V a l v e . . . . . . . . . . . . . . . . . . . . . . . .1 . .- 9 6 l .1 A i r C o n d i t i o n i nS i 9 n a 1 . . . . . . . . . . . . . . . . . . . . .I. .1- 9 8 g . . A l t e r n a t oF R S i g n a l r .. I1-1OO AutomSticTransaxle G e a rP o s i t i o S i g n a l. . . . . . . . . . . . . . . . . . . . 1 1- 1 0 2 n . 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 e w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . 1.1-.10 6 S . . .. Power SteeringPressufe Switch Signal ... 1l-108 F a s tl d l eT h e r m o a l v e. . . . . . . . . . . . . . . . . . . . . . . I .1 - . .0 9 V . ..1 S t a r t i n A i r V a l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1-.1 1. . g . . ..O l d l eS p e e d e t t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.-.l. .1 S . 1. j .

Special Tools

Rel. No.

Tool Number A973X_041_XXXXX KS-AHM_32 OO3 OTLAJ PT30l OA 07JAZ-OO1000B 07406-OO40001

Dascription Vacuum Pump/Gauge DigitalMultimeter Test Harness Vacuum/Pressure Gauge0-4 Fuel Pressure Gauge

I O'ty I 1

Pag€ Roforence 1 1 - 6 8 ,1 3 5 , 1 3 9 , 144, 154, 162, 165 11 - 4 5 ,5 8 , 6 3 11 - 4 5 1 1 - 1 6 41 6 5 , 1 ' l - 1 1 5 ,1 2 2

o
,ar

@
/A

in. Hg

I

\a)

\9

11-2

ComponentLocations
Index
H23A1 engine (USA: Si/Canada: SRI:
Troubleshooting, page 1 1-84 EXHAUST GAS RECIRCULATION {EGR) VALVE LIFT

ELECTRICAL LOADDETECTONIELOI (TPI THROTTTE POSITIOI{ SENSOR MANIFOLO ABSOLUTE
page 1 I-74 Troubleshooting, FAST IDLE THERMO VALVE Inspection p a g e1 1 - 1 O g PRESSURE IMAPI SENSOR Troubleshooting, page 1 1-64, 68 IDLE AIR CONTROL(IACI VALVE Troubleshooting, page 1 1-96 EVAPORATIVE EMISSION (EVAP} PURGECONTROL SOLENOIDVALVE page 1 1-162 Troubleshooting, STABTING AIR VALVE Description, p a g e1 1 - 1 1 0

sEr{son

Troubleshooting, p a g et l - 1 5 3 IGNITIONCONTBOLMODULE (ICM) page |'l -80 Troubleshooting, INTAKE CONTROL SOLENOIDVALVE Troubleshooting,

\ \. oaqe 1135 1 TOPDEADCEITTER/ } \. //' CRANKSHAFT POSITION/ CYLII{DERPOS]TION

ITDC/CKP/CYP' Troubleshooting, page11-70

IIIIJECTOB RESISTER Testing,page 11-'121

'trt
?,{oL
AKE AIR IIATI SENSOR Troubleshooting, p a g e1 1 - 7 6

TURE

ENGINECOOLANT TEMPERATUBE {€CT) SENSOR Troub16shooling, page 11-72 KNOCK SENSOR{t(Sl page 1 1-88 Troubleshooting, INTAKE AIR BYPASS {IAB} VALVE Testing.page 1 1-146

EXHAUST GAS RECIRCULATION {EGR} VACUUM CONTBOLVALVE Troubleshooting, p a g e1 1 - 1 5 3

HEATED OXYGEN SENSOR tHO25) Troubleshooting,
p a g e 11 - 5 6

EXHAUST GAS RECIRCULATION {EGR)CONTBOL SOLENOIDVALVE page 1 1-153 Troubleshooting,

(PSP}SWITCH POWER PRESSURE page 1 1-108 Troubleshooting, VALVE INTAKE AIR BYPASS IIAEI CONTBOLSOLENOIO page 11-144 Troubleshooting,

11-3

Component Locations
lndex
H22Al ongino {USA: Si VTEC/Canada:sB-v)
LOAD DETECTOB{ELD) EI-ECTRICAL Troubleshooting, IDLE AIR CONTROL{IAC) VALVE p a g e1 1 - 8 4 Troubleshooting, 11 - 9 6 €XHAUST GAS RECIRCULATION IEGRI POSITION SENSOR ITPI THBOTTLE VALVE LIFT SENSOR Troubleshooting, 11-74 Page page 1 1-153 Troubleshooting, FAST IDLE MANIFOLOABSOLUTE THERMO INTAKECONTROL PFESSUNE IMAP} SENSOR VALVE VALVE SOLENOID Troubleshooting, lnspection Troubleshooting, page '11-64,68 p a g o1 1 - 1 O g p a g eI 1 - 1 3 5 EVAPOBATIVEEMISSION (EVAP} PUFGECONTROL SOLET{OID VALVE page 1 1-162 Troubleshooting,

IGNITIONCONTROLMODULE (|CM} page 1 1-80 Troubleshooting,

ToP DEAOCENTER/ .. \ CR} .KSHAFT^POSITION/ \
CYLINDERPOSITIOl{ SENSOR {TDC/CI(P/CYP} Troubleshooting, page 'l 1-70

AIR STARTII{G VALVE Description, p a g e11 - 1 0 1 INJECTOR RESISTER p T e s t i n g ,a g e1 1 - 1 2 1

INTAKEAIR TEMPERATURE 0AT) SEI{SOB Troubleshooting, page 1-76 1

ENGIf{ECOOLANT Troubleshooting, page 11-72

(ECTI TEMPERATURE SENSOR

(EGRI RECIRCULATIOT{ VALVE VACUUMCOI{TROL page Troubleshooting, 11-l53
IEGRI EXHAUST GAS RECIRCULATION CONTROLSOLENOIDVALVE page 1 1-153 Troubleshooting, (PSPI SWITCH PRESSURE POWERSTEERING p89e 1 1-1OB Troubl€shooting,

GAS

KNOCK SEI{SOB {KS} Troubleshooting, page 11'88

HEATEDOXYGEN SENSOR tHO2S) Troubleshooting, page 1-56 1
INTAKE AIR BYPASS (IAB) VALVE 'l1-146 Testing.page

INTAKE AIR BYPASS {IABI CONTROLSOLENOIDVALVE page 1 1-144 Troubleshooting,

11-4

F22Al ongins (S):
IDLE AIR CONTROL{IAC} VALVE Troubleshooting. p a g e1 1 - 9 6 MANIFOLD ABSOLUTE THROTTLEPOSITIOT{ PRESSURE ITP) SEITISOR {MAPI SENSON EXHAUST GAS BECIRCULATION {EGRI Troubfeshooting.page 1 1-74 Troublsshooting. VALVELIFTSEI{SOR page 11-64, 68

ELECTRICAL LOAD DETECTOR {ELDI Troubleshooting. psge11-84

pago Troubleshooting. 11-,|53 IGNITION TBOLMODULE CO IICM} pag6 Troubleshooting. 11-80\\ TOPDEADCENTER/ CRAN(SHAFT POSITIOI{/ CYLINDER POSITION {TDC/CKP/CYP}
Troubleshooting. p a g e1 1 - 7 O

(EVAP) EVAFORATIVE EMISSION PURGE CONTROL SOLENOID VALVE Troubleshooting. 11-,|62 page FASTIDLE THERMO VALVE page11-110 Inspoction, II{JECTOR RESISTER
Testing, 11-121

STARTII{G AIR VALVE Description, p a g e1 1 - 1 1 0 I TAKE AIR TEMPERATUR: (IAT} SENSOR Troubleshooting. page 1'l-76

ENGINECOOLANT (ECT) SENSOR TEMP€RATURE Troubl€shooting, page 11-72

EXHAUST GASRECIRCULATION IEGR) VACUUiI CO TROLVALVE page11-153 Troubleahooting, . ,-/ / '-''./ (EGRI EXHAUST GAS RECIRCULATIOI{ CONTROL VALVE SOLEiIo|D page11-'l53 Troubleshooting,
POWER STEERII{G PNESSUREIPSPI SWITCH Troubleshooting, pago 1 1-1OB

HEATEO OXYGEI{

(Ho2st sEr{soR
Troubleshooting, page 1 1-56

11-5

ComponentLocations
Index

EMISSIOI{ EVAPORATIVE {EVAPITWO WAY VALVE page11-165 Testing,
FUEL FUEL FIITER page 1 1-123 Replacoment,

Tosting,p6ge 'l t -125 paoo 11-125 Roplacemgnl, FUELFILL CAP I

FUEL ruMP

EVAPORATIVE EMISSION CONTROL CAI{ISTEB IEVAP) page Troubleshooting, 11-'162

TAI{K
Replacemgnt, p s g € 11 - 1 3 0

FUEL REGULATOR PNESSURE page11-122 Testing, p.g6 11-123 R€phcomont,

FUEL VAPOR HOSE

FUEL RAIL

I]{JECTORS
Troubleshooting, ptgo11-116 page 11-1 19 Replacomedt,

11-6

AIR CLEANER{ACL) Oisass6mbly. p a g e1 1 - 1 3 3

THROTTLE BOOY page11,139 Inspection, page Disassembly, l l -141

II'ITAKE cot{TRoL

II{TAKEAIB

DIAPfIRAGM (Exclpt F22A1 .ngin.l Troubloshooting p a g €1 1 - 1 3 5

lnspection/Adjustment, page 1 1- l38 Installation, page 1 1-'l 38

POSITIVECRAI{KCASEVENTILATIOI{ (FCV) VALVE pago 1 1-159 Insp€ction.

PGM-FI MAII{ RELAY RolayT6sting,page 'l 1-126 page 1 1-128 Troubloshooting,

ENGINECO TROL MODULE {ECMI Sell-diagnostic Procedures.page 1 1-42 Troubleshooting.page 1 1-50 page 11-45 Romoval,

(2PI SEBVICECHECK CONNECTOR S€ff-diagnosticProcedures,page 1 1-42

11-7

System Description
Vacuum Connections
SR} H23Al engine{USA: Si/Csnada: SR-V} H22Al engine{USA: Si VTEC/Canada: EMISSIOI{ EVAPORATIVE IEVAPI PURGE COI{TROL VALVE SOLEI{OID EMISSION EVAPORATIVE VALVE DIAPI.IRAGM CONTROL R'IRGE {EVAP)
EMISSIOI{ EVAPORATIVE {EVAPI COI{TROLCANISTER

TO EVAPORATIVE EMISSION {EVAPITWO WAY VALVE EXHAUST GAS RECIRCULATION IEGR) VALVELIFTSENSOB EXHAUST GAS RECIRCULATION I€GR) VALVE MAI{IFOLDAESOLUTE PREESURE API 8E1{8OR I STARTII{GAIR VALVE I TAKE AIR BYPASS VALVE IIABI CHECT
INTAKE CONTROL SOLENOID VALVE

FRONT VEHICLE FUEL OF

:?'

REGULATOR

AIR BYPASS INTAKE IIABI CO TROL VALVE SOLEI{OID TO

INTAKE AIR BYPASS IIAB} COI{TROL OIAPHRAGM

CRUISECOI{TROL ACTUATOR

EXHAUST GAS RCCIRCULATIO VACUUM IEGR) CO TROLVALVE
(EGR)

EXHAUST GAS CONTROL DIAPHRAGM

SOLEI{OID VAIVE CONTROL

11-8

F22Al ongine (S):

EVAPORATIVE EMISSION IEVAPI CONTROI.CANISTER EVAPORATIVEEMISSION (EVAPI PUBGECONTROLDIAPHRAGMVALVE

EVAPORATIVE EMISSION {EVAP} ruBGE COTITROL SOLENOID VALVE

TO EVAPORATIVE EMISSION {EVAPITWO WAY VALVE

EXHAUST GAS RECIRCULATION IEGR} VALVE LIFT SENSOR

MANIFOLD AESOLUTEPNESSURE (MAP} SENSOR

GAS EXHAUST RECIBCULATION VALVE IEGR}

STARTII{G AIR VALVE

(EGR} EXHAUST GAS NECIFCULATION VALVE VACUUMCOI{TROL

\

FUEL PRESSURE REGULATOR

TO CRUISE CONTROL ACTUATOR
(EGR} EXHAUST GAS BECIRCULATIOI{ CONTROLSOLEI{OIDVALVE

11-9

System Description
Vacuum Connections
SR) H23A1 ongino (USA: Si/Canada: SR-V} H22A1 ongine{USA: Si VTEC/Canada:

(Ho2s) \--J@ oxycEN sENsoR o) HEATED

ABSOLUTE PRESSURE {MAPISENSOR O MANIFOLD (ECT) TEMPERATURE SENSOR COOLANT O ENGINE (IAT} AIR @ TNTAKE TEMPERATURE SEI{SOR @ KNocK sENsoR(Ksl @ |DLEAtR co rRoL flact vALvE SCREW O IDLEADJUSTING VALVE @ FASTIDLETHERMO AIR @ STABTING VALVE [rtJEcToR @ FUEL FILTEB @ FUEL PRESSURE REGULATOF @ FUEL PUMP @ FUEL TANK @ FUEL @ AIRCLEANER @ RESONATOR (IAB}COIIITROL DIAPHRAGM AIR BYPASS @ INTAKE VALVE AtR SOLENOID @ TNTAKE BYPASSflABl CONTROL

TANK AIR BYPASS IIABIVACUUM @ II{TAKE VALVE ArR 0AB)CHECI( @ ra{TAKE BYPASS DIAPHRAGM COI{TROL @ II{TAKE SOLENOTD VALVE COIT|TROL @ tt{TAKE VACUUM TANK @ I TAKECONTROL CHECK VALVE CONTROL @ INTAKE (TWCI WAY CATALYTTC CONVERTEn @ THREE VENTILATTON {FCV)VALVE @ postT|vE CRANKCASE (EGRI GASBECTRCULAIION VALVE @ EXHAUST (EGR} GASRECIRCULATION VALVELIFT @ EXHAUST SENSOR (EGRI GAS REC|RCULAT|OII VACUUM @ EXHAUST VALVE CONTBOL GAS RECTRCULATTON CONTROL {EGR} @ EXHAUST VALVE SOLENOID (EVAP} CAt{ISTER EM|SS|OT{ CONTROL @ EVAPORATTVE (EVAP) PURGE COI{TROL EMTSSION @ EVAPORATTVE VALVE SOLENOID PURGE CONTROL EMTSSTON {EVAP} @ EVAPORATTVE VALVE DIAPHRAGM @ EvapoRATtvEEMtsstoN{EvaPl rwo wAY vALvE

11-10

F22A1 ongine

oxYGEr{sEr{soR(Ho2sl O HEATED pREssuRE ABSOLUTE O MAr{rFoLD tMApt sENsoR coolA T TEMPERATUBE sEI{soR @ ENGINE tEcTI (IAT) AIR TEMPERATURE sEI{soR @ II{TAKE O |DLEAtR co rRoL 0Acl valvE @ IDLEADJUSTI G scREw VALVE @ FASTIDLETHERMO ArR @ START|NG vALv€ I @ FUEL JEcToR FILTER @ FUEL PRESSURE REGULAToR O FUEI. PUMP @ FUEL TANK @ FUEL @ AIR CLEANEn @ RESOI{ATOR

way caTALyTrc coNvERTEn fiwcl @ THREE (Pcvt cRAl{KcasE vEr{TrLATror{ valvE c) posrTlvE (EGR} GAs @ EXHAUST REcrRcuLATtOr{ valvE (EGR} GAs @ EXHAUST REcrRcuLATror{ valvE L|FT (EGRI GAsREctRcuLATtot{ vAcuuM @ ExHAUsr COI{TROL VALVE (EGR} GAs @ EXHAUST BEcrRcuLATror{ coNTRoL
SENSOR

SOLEIIOID VALVE (EVAPI EMISSION cO TRoL CAI{ISTER @ EVAPORATIVE EMTSSION PUnGE COI{TROL TEVAP) @ EVAPORATTVE SOLENOID VALVE EMrssroN(EvAp)PURGE conrRol @ EvApoRATrvE DIAPHRAGM VALVE EMtsstoN(EvApl Two wAy vALvE @ EvapoRATrvE

11-11

System Description

Electrical Connections

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
t10 c) clocx RADro al. tlOO @ SATTERY At. @ rGsw tso A). (15 @ sToPHORir Al. BOX @ FUSE tr$ Alr
o. 4 BACKUP(10 A) ECUGcill (15 Al t{o. 13 ttlETER Al {1O FAt{ t15 At. cot{oEI{sER REIAY110At o. 11 nEARDEFROSTER SIG l{o.2 ATARTER AL 17.5Al

A/T GEAR POStTtOt{

swtrcH
L _ _ _ _ _ _ _ _ _ _ _ _

': in the UI{OER-HOOO FUSE/RELAY BOX

at-tz

sE son
TP 8EI{SOR EGR vAt-vE LIFT SEI{sOR

TIAP

SOLEOIDVALVE r--=-l H22Al .nglnc)

€Gn co TnoL solEftolo valvE EVAP PUNGE CO TNOLSOLEI{OID VAIVE 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 TERMI AL LOCATIONS

o o o o o o o o o o o o o o o o o o o o o o

(cont'dl

11-13

System Description
(cont'd) Electrical Connections

Cttt

HO23

YEIiTLK

oR /wlft

nco/Btu-

E I
WHT/GRt{ WHT/RED-

t

f

w,si
,arn*"rfl

1l

q101

---J------'l vrr.rvyxr ---l R€D,srx lrP sE SoR I
GRx/wHTr _!l________J

cl13

---------.r-T------------'l

__jl.:l*r1l

tto prg. 1I -16l

lTo p.gp t1-151

lTo p.!. 11-15)

11-14

11-141 c425

( F r o r n . g . 1 l - 1 4 1 l F r o mp . g . 1 1 - j 4 ) p

c 133 :-:wHT---_----

TDC/CXP/CYP SEI{SOR

c102

nroisrxl-[dfiiiJidi5il BRn---l-[I:jl__l
clo3

nronu---1-f iiliifididil
BLU]lltro. 3l I

c1(x

--j-liiiiili6i5i-l n:omx -l
YEL lr o. a) cl11

c105

|

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 VALVE I wxrierr I I EGR cRil/wHr,l I tlFr sEI{soRI

System Description
(cont'dl Connections Electrical
c31O-..._at-K/YEt---l l€ci co liol ----llj95:g:i1:l

RED,

I

sa".;-l ffi#ffll
TO COi{DEiISER FAI{ Bt-u/RED_____'

-----i Toa/cHcRoMPnEssoR RED/8LU
-----> TO A/C SYVITCH

-l I r^ra co|rnol I I lsor.Er{oro I llJ !!E-J
lErc.Dl F2241 f,{arl

J I6ERVTCE llcHEct(

ll-99!!!9r98--J
t-Jl r T GRX/RED

I |

C43LT 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/RELAY BOX

BATTERY {1(x)A) tG sw l5o Al FUSE 8OX liro Ar CLOCK RADIO A) {10 sToP HOR[{ Al t15 WHTA'EL

Ut{DED-HOOD

FUSE/RELAY c421 c422
WHT/RED

WHT/YEL c424 WHT/YEL c420
ATKATEL

I

r

BIK

Grl03 BATTERY

PGM.FI

YE|-/SL(

YEL/BLK
GRI/BLKt

E<--BLK
FUEL

fl_

Eszzaer-x ll
G52r

v:l- _-____j-1

-C537

____h

pUMp

(PJ

swrTcH

tc tTtON

UI{DER.DASH FUSE/REI.AY BOX iECMI At tls c) ECU stcilAl @ Ito. 2 STAKTER t7.5Al UP @ o.4 BACK t10 Al tlo O o. 13 METER A)

TO M/T: STARTER CUTRELAY A/T: A/T GEAR POStTtot{ SYVITCH c466 c471

BLU/RED

GRiUwHT'

GRt{/WHTI GRI{MIHT

c479..-........................"-.".-.rHrljl GRr{^ BRAKE I

FUSE/RELAY BOX

wnrrrer-ll_llcH
lTo p!96 11-18,

l
(cont'd)

11-17

System Description
(cont'dl Connections Electrical

l F . o mp ! g ! 1 1 . 1 7 1

GAUGE ASSEi'BLY

N |-'FFGEF_I
ll ltrlswmcx
I I HPOSmOI{

|

I

c4a4 - cr39

c13a cRr/YEL-wEc solEl{olD VALVE lH22A'l.n!rn.l

swrTcH
tH22.A1

ri

11-18

System Description
System Connectols lEngine Compartment]
SR-V} H22Al engine{USA: Si VTEC/Canada: SR) H23A1 ongine{USA: Si/Canada:

i

ENGINE WIRE HARTTESS MAIN WIR€ HARNESS

11-20

c114

cll5

c117

c122

rF|-r l l l 2 1 |3

IO) IGRN^^/HTZ

I

lEilwlr-O loRt,M/Hr ldlYE BLK

I i

l-6''I"*t----.',
lO IBL(,"/eL

l6F'it------1

I

C137 lH22Al onglnql

C138 (H22Al .nginol

c420

tr
l-6'l6iNrEi-----'l

lrJ

c422

l l j 2 1 3 l

r-FF-r

1

2
7

4

5

8

9 10 1 1

----l r'-T"*
f5-lwxr
2IBLX/GRI

REO/6LU 3 FEOr'GFN 5

I -- ---1

a

LX tASSt
LKI''EL IA65)

NOTE: Diflerent wi,es with the same color have been given a number suffix to distinguish them {for example YEL/BLK1 and YEL/BLKz not the samel. are l: Relatedto Fuel and Emissions Svstem.

System Description
(cont'd] Compartment] SystemConnectors [Engine
SR-V) H22Al engine (USA: Si VTEC/Canada: SRI H23A1 engine (USA: Si/Canada:

6'

!,,-

.lv

c432 c135
MAIN WIRE HARNESS

c4a4 c139

ENGINEWIRE HARNESS

11-22

c426

c429

c/*12 (M/Tl

C484 (H22Ai onglnrl

{,t(
IBLUI"'EL IT

lO--lCiNrEL

--l

'It,,YEL

RED/II.U

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.

\oTE:

(cont'd)

11-23

System Description
(cont'd] SystemConnectors lEngineCompartment]
H22A1 engine (USA: Si VTEc/Canada: sR-vl SRI H23Al ongina (USA: Si/Canads:

LEFT GIT{E E COIIPARTIIIENT WIREHARI{ESS

HARNESS

11-24

ct 02

c103 tr---T---ll ti 2tl tl

c 104

c105 t--T----rl ll 2 | 1 ll

tr-r-rl 2tl

tl

tr---r---rl ll 2 I 1 ll

---|6'TREo/BIK - - - j@ leRN

to) tRED/Blx

I

lZiTREp-l

l6TnED/aLi--------f6-lilu

-'l lSTiED/ELr ---] 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 distinguish them (tor exsmpleyEL/BLKI and YEL/BLK, are not the same). O: Related Fuel and Emissions to Svstem.

System Description
(cont'd] SystemGonnectors [EngineCompartment]
F22Al ongino{Sl:

i

I

ti

MAIN WIRE HARNESS

HART{ESS

11-26

clr3

cl14

c 11 5

c117

c122

l 1 l 2 1 3 l

rf:lr

loFii'c420

16loRNi------l lO IBLK/YEL I ---l

c421 r--Fl_____1

E
c424
1

lrl2l3l

FT-,--__l 2
l l8r(/GFN

I

16lwii-.

2
8 9

4

10 tt

1 2

REO/6LU

6

3
5

I
I

ALK/YEL IAAS)

10

NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguish them (for exampteyEL/BLKr and YEL/BLK2 not the samel. are O: Related Fuel and Emissions to Svstem.

System Description
F22A1angino lsl:

(cont'd] SystemGonnectors [EngineCompartment]

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/BLK2 not the sam€). are O: Related to Fuel and Emissions Svstem.

System Description
F22A1 engine{S):

(cont'd) [EngineCompartment] SystemConnectors

:

'j

11-30

ct ol

cl02
J r-----r 1I I----T-----rI

c103 -J r-----rl-

c104

c105

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:Related Fuel and Emissions to Svstem.

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
4 2 3 8 9 llol11

c451
r-----.-t

| 1 1 2 |

| 1 l / 1 3| r------y.____J__l

r-EFr

6

I r_____lz_____r_J I

ll;Tvrtl
BLKIVHT

I

I(, ]LTGRN/RED I lO lBLx/R€o . 2 3 GRNTYEL 5 12 ALK

lElwH------l
t 2 t
| 3

I
I

t o Y€L

c461

c463

c466

l1l2l3l

l

2 3

BLX/GFN"

12 l 3 RIO/SLK

BLU/REO q) RED/ALU 3 YEL/BLK

@ BIU/BLK
15 16

Y€L 7 8 I

aLu
BCU,IYEL

1o

1A 1 9 RED/YEL 20

BLK/ryEI FED/GRN

c469

2

BIU/REO YEL/BLU 6LU 8L( YEL

2 10 12 1 3 BLU BLK/tEL 8

5

ALK L&'YEL BLK,YEI BLK/YEL

12 1 3 ALK

BLK/REO 1A 1 9 BLK,YEL 20

YEL/BCO 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 Emissions Svstem. * : Canada * *: Canada(with heatedseatsl

11-33

System Description
SystemConnectors [Dashand Floor](cont'd

OASHBOARDWIFE HARNESS

MAIN WIRE HARI{ESS

11-34

c479

c601

c612
I 4 X ,/t7 I 9 t 0 1 1 l2lxh3 1 4 1 5 1 €

RED/BLK

2 3
YEL LIJ/FEO 12 BLK ALU r 6 ALK/RED 6 AtK'/EL 3 1t 12

GRA/YEL

GFN

I

GiN/ALU

l 6 BLK

c614

2 BLK/ryEL 3
ALU'

1€ 17 YEL' t9 20 GFN/BLK 21 GhN/REO

22 a
REO BLU/FEO 26 2 7 RED/BLK YEL

1 2 YEL/iED 13 15

3(

NOTE: Ditferentwires with the same color have beengiven a numbersuffix to distinguish them (for exampleYEL/BLK1 and YEL/BLK,a.e not the same). O: Related Fuel and Emissions to Svstem. *: Canada

System Description
System Connectors [Dash and Floorl (cont'dl

OASHBOARD WIBE HARNESS

I

MAIN WIRE HARNESS

11-36

c404

c411 (A/Tt

c415 {ECM-A}

1t 2

12

3
giN/BLK 15 YEL/BLU RED/gL( LI GFN]BLK 19 20 22

r5

YEL RED H?2rl GRNTYI! ri?rul I

ta
I

8
I

YEL/GFN I €LK/8!U BLK'

AED/BLU

20

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"'
BRN,IVHT BLU/ALK

l@
I(' a€0//EL i1a l{il

@ LT3{urtr22lrmnr
8LU/GAN BLU/^rlt

o

REO/ALK

NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguish them {for exampleYEL/BLK1 and YEL/BLKr are not the same). to O: Related Fuel and Emissions Svstem. * * * : E x c e p tF 2 2 A 1 e n g i n e

System Description
SystemConnectors lFuel 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/BLKz not the same). are 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 shows the systemis OK, try the next most lik€lysystemO, etc, to the pagelistedat the top of that column,It inspection
SYSTTM at'iclNE CONTROI MOOULE 50
MALFUNCTION INDICAIOR LAMP IMIII" TURNS ON MAIFUNCTION INOICATOB LAMP IMILl" BLIN(S ENGINE WON'T STAFT OIFFICUITTO STAFT ENGINE WHEN COID WHEN COLO FAST IDLE OUT OF SPEC. ROUGHIOLE IDTING HIGH HEAIEO OXYGEN SENSOR 56, 54, 62 TOPDEADCENIER/ TNGINC THNOTTLE EANOMEIRIC IGNITON COOTANT TEM. ABSOLUTE PO9TtOtl PitssuSE OUTPUT FCi^TURE PNESSUfiE POSITON/CYUNDES sc soR sfNsoR stcNA! SENSOR SENSOR POSftOt'tsE|so8 fuiE sEt{sof

vtHtclE SPfED

sE[son
a2

64, 6a

70

n

or-Ll

.o:

:i6):
lll or Lll

-mi
O or-8.o.:ft

-r.tr-

76

7A

80

:r6t: :r6t1 -mi rg: lrm.t: /---\ /---\
\.--r-r
\

EorEl

- --i-r t - \.--l- r t / - - t r t l - - t t l t t -t __i.
---'_-\
/ \ /'_-i\

-t---i- l- \.--1-, t15 \ -l_--l-\ t? / /

/

@
IBU)

@ @ @

@

o
@

@ @ @
a9

@

'

:l

IBU)
FREOUENT STALLING

@

'lr

@
ROUGH RUNNING EMTSSTON TEST LOSS OF

@ @ @ @

@ @ @

@ @

ANCE

*

lf codesother then those listedaboveare indicated, count the numberof blinksagain. It the MIL is in fact blinking these codes, reDlace the ECM. @ tt ttr" MIL is on while the engineis running,jump the servicecheck connector.lf no code is displayed(MlL stays on steady),the back-upsystem is in operation. Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM. ** USA: Canada: '6+rr-trMALFUNCTTON -[tgltCHECK ;ND;CATOR ENGTNE ;t-\+: , LAMP {MILI LIGHT '** E x c e p tF 2 2 A 1 e n g i n e( s ) SR-V) engine (USA: Si VTEC/Canada:

11-40

IOLECONTFOL ELECTRICAL LOAO uFrE|lcTnoMc LIFT ELECNOMC DETCCTOR :o{TnoL soLENoto :OIITROL PiESS!iI 84 6-75 677 XNOCK SENSOF IOIEAIF CON'FOL OTH'i IDL' c0NTROTS

FUELSUPPTY FUEI INJECTOF 116 OTHER FUEL

EMISSIONCONTFOL ETH USI GAS INIAKT

nEcncu. c0[TioL sYstE

SIGNAL A

SIGNAL 8

OTHER EMtSS|ON

coNTiots
149

8a

90

90

96

92

r13

131

153

tf

-q.
\.--r-l

rgt22 | /-....-.

/ - \

D E

ffil /---\

-r6t/_l-\

-r6t\.--.1z --"i--

- ' .

-t 20 -t 2r I 1 /---,_-. , -_-i-- \

-t 23I 11361,lrt-

@

- l r 6I

| | 2t\ -

/

@

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 located behindthe center console).Turn the ignitionswitch on.

OATA LINK

co it€cToR{3Pl
Do not attach wire. the jumper

JUMPERWIRE

CHECK SERVICE (2P) CONNECTOR

h

a TroubleCode (DTC):The MIL indicates code by the lengthand numberof blinks.The MIL 2. Note the Diagnostic codes,one atter another.Codes 1 through componentproblemsby blinkinqseparate can indicstesimultaneous by shon blinks.Codes10 through43 are indicated a seriesof long and shon blinks. I are indicated individual by The numberof long blinks equalsthe first digit, the numberoJ short blinks equalsthe seconddigit.
USA: MALFUNCTION INDICATOR LAMP {MIL} CANADA: CHECK ENGINE LIGHT

S6pa1.t. Ptobl.mr: Shon l-1 -jl-rLtU-X-r- r]r1.f1--JlrrL = Soe DTC 1 = Seo OTC 3

X{ILong sho.l SimuhanoouaProbloms: J rJTxrL-----n l'lr]rL Jltll-r-r]f1J-1l-LnnrL --n-trxrrl_ J-lt-x-L-J

= scoDTC13

= 566 DTc 1 and 3 = 566 OTC 3 and 4 = Soo DTC 3 and 14

11-42

ll.

EngineControl Module {ECM}ResetProcedure 1. Turn the ignitionswitch off. 2. Remove the the CLOCKRADlO ( 1O A) f use f rom the under-hood tuse/relav box for 1O seconds resetthe ECM. to NOTE: a Disconnecting CLOCKRADIO(10 A ) fuse also cancelsthe radio preset stationsand the clock setting. the 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.

(this procedure t . FinalProcedure must be done sfter any troubleshooting) 1. Removethe jumper wire. NOTE: lf the servicecheck connectoris jumped, the MIL will stay on. 2, Do the ECM ResetProcedure. 3, Set the radio presetstationsand the clock.

11-43

Troubleshooting
Self-diagnosticProcedures(cont'dl
DIAGONOSTIC TROUBLE coDE (DTC)

SYSTEMINDICATED

Page 11 - 5 0
I t-50

o

ENGINE CONTROL MODULE(ECMI

(HO23) HEATED OXYGEN SENSOR
5 4 (MAP SENSOR) MANIFOLD ABSOLUTE PRESSURE (CKPSENSOR} CRANKSHAFT POSITION (ECTSENSORI ENGINE COOLANTTEMPERATURE (TP SENSOR} THROTTLE POSITION (TDC SENSOR} TOP DEAD CENTER POSITION N o , 1 CYLINDER POSITION {CYP SENSOR)

11 - 6 4 , 68 11-70 11-74 11-70 11-70

6
7

I 9 10 't2 13
14
tc to

(IAT INTAKE TEMPERATURE SENSOR} AIR EXHAUST GASRECIRCULATION VALVELIFTSENSOR) IEGR
(8ARO SENSOR) EAROMETRIC PRESSURE (IAC VALVE) IDLEAIR CONTROL IGNITION UTPUT IGNAL O S FUELINJECTOR VEHICLE SPEED SENSOR IVSS)

11-76 11 - ' l 3 5
11-79 11 - 9 6 11 - 8 0 11-116

1' 1-82
'I 1-84

20
'.1

(ELD) ELECTRICAL LOADDETECTOR
VARIABLE VALVE TIMING& VALVE LIFT ELECTRONIC CONTROL {VTEC} SOLENOID VALVE*' VARIABLE VALVE TIMING& VALVE LIFT ELECTRONIC CONTROL {VTECI PRESSURE SWITCH** ( K N O C KS E N S O RK S } I

21

'tJ

6-75 6-77

22 23
4'l

11 - 8 8 11 - 5 8
11-62 *: ExceptF22A1 engine(Sl ": H22A'l engine{USA: Si VTEC/Canada: SR-V)

43

(HO2S) HEATED OXYGEN SENSOR HEATER FUEL SUPPLY SYSTEM

a lf codesotherthan those listedaboveare indicated, verify the code. It the code indicated not listedabove,replace is the EcM. a The MalfunctionIndicatorLamp (MlL) may come on, indicstinga system problemwhen, in fact, there is a poor or intermittentelectrical connection.First,check the electricalconnections, if clean or repairconnections necessary. a The MIL and D4 indicatorlight may light simultaneously when 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€ction a panicularfailurscode requires for the 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 according the procedure to described the appropriate tor code(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 TERMII{AL LOCATIOI{S

o o o o o o o o o o o o o o o o o o o o o o

{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 designed be used from start to final repair.lt's like a map showing you the shortestdistance.But beto ware: it you qo off the "map" anywherebut a "stop" symbol, you can easilyget lost.

TSTAR-T]
Eotaivpet

Describes the conditionsor situationto start a troubleshooting flowchart. Asks you to do something;perform a test, set up a conditionetc, Asks you about the resultof an action,then sendsyou in the appropriate troubleshooting direction. The end of a seriesof actionsand decisions. describes tinal repairaction and sometimesdirects a you to an earlierpart of the flowchart to confirm your repair.

Fdfibxl @

trroFl

(bold typel

NOTE: a The term " lntermittentFailure"is usedin thesecharts.lt simplymeansa systemmay havehad a tailure.but it checks out OK at this time. It the Maltunction Indicator Lamp(MlL)on the dashdoesnot come on, checkfor poorconnections (see illustration or loose wires at all connectorsrelatedto the circuit that you are troubleshooting below,. a Most of the troubleshooting flowchartshaveyou resetthe Engine ControlModule(ECM) and try to duplicate diagthe 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 needlessly replacedECM. a "Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection.A short is an accidental connection a wire to groundor to anotherwire. In simpleelectronics, usuallymeanssomething of this won't work at all. In complexelectronics meansomething works, but not the way it's sup{likeECM's),this can sometimes poseoro. a It the electrical readings not as specified are when usingthe test harness, checkthe test ha.nessconnections before proceeding.

11-47

PGM-FISystem
System Description
MODULE ENGINE CONTROL {ECM)
Sensor TDC/CKP/CYP MAP Sensor ECT Sensor IAT Sensor TP Sensor HO2S

OUTPUTS
Fuel Injectors PGM-FlMain Relay(FuelPump) MIL IAC Valve Clutch Relay A/C Compressor

vss

F"*li"",---fl-ni-l-".M;l

rcM

BAROSensor StarterSignal ALT FR Signal Air Conditioning Signal A/T Gear PositionSignal BatteryVoltage(lGN. 1) BrakeSwitch Signal PSP Switch Signal EGR Valve Lift Sensor Knock Sensor* VTEC Pressure Switch* *

EVAP Purge Control Solenoid Valve HO25 Heater VTEC Solenoid Valve" @;bbc-t.d ALT EGR Control Solenoid Valve Fit"rJ,,"o,,"-',....-,,,"o.*-,,cont,ot,,cont.trr".**-_-lValve' IAB ControlSolenoid lntake Control Solenoid Valve*

--_]l

Eil,*"s c-,'d

I

B*k',p F;tb";-ll]]l fEcM

': Exc€ptF22A1 enqine ": H22A'l engine

't,

PGM-FI Svst.m multipon fuel injectionsystem The PGM-FIsystem on this model is a sequential Fuel Inlector Timing and Duration The The ECM containsmemo.iesfor the basic dischargedurationsat variousenginespeedsand manifoldpressures. memory,is further moditiedby signalssent from varioussansors duration,after beingreadout from the basicdischarge duration, to obtain the final discharge ldle Air Control ldle Air ControlValve (lAC Valve) is is When the engineis cold, the A/C compressor on, the transmission in gear (A/T only) or the alternatoris charging, the ECM controlscurrent to the IAC Valve to maintsincorrect idle speed. lgnition Timing Control lgnitiontiming o The ECMcontainsmemories basicignitiontiming at variousenginespeedsand manifoldpressures. for is also adjustedtor enginecoolanttemperature. is a A KnockControlSystemisalsoused.When detonation dotectedbythe knocksensor,the igntiontiming is retarded (ExceptF22A1 engine). Other Control Functions 1. Starting Control {uel iniectorduration. When the engineis started,the ECM providesa rich mixture by increasing 2. Fuel Pump Control main relay that supplies a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-FI the current to the fuel pump fo. two secondsto pressurize fuel system. a When the engineis running.the ECMsuppliesgroundto the PGM-Flmain relaythat suppliescurrentto the fuel pump. main relaywhich cuts a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FI currentto the fuel pump. 3. Fuel Cut-off Control is a Duringdeceleration with the th.ottle valveclosed.currentto the fuel injectors 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/ of SR-VI: 7,7OOrpm, regardless the positionof the Canada:SR): 6,8O0 rpm. H2241 (USA: Si VTEC/Canada: throttle valve. to protect the enginetrom over-revving.

i:r
fii

11-48

4.

A/C Compressor Clutch Relay When the ECMreceives demandfor coolingfrom the air conditioning a system,it delaysthe compressor Jrombeing energized, and enrichesthe mixture to assuresmooth transitionto the A/C mode. Evaporative Emission(EVAP)purge ControlSolenoidValve when the enginecoolanttemperature betow 167 oF (75 "Cl IH22A'| engine(USA:Si VTEC/Canada: is SR-V):1bg oF (70oC)1, ECMsupplies groundto the EVAPpurgecontrolsolenoid the a valvewhich cuts vacuumto the EVAp purge control diaphragmvalve. IntakeAir Bypass(lAB) ControlSolenoidValve When the enginespeed is below 4,8OOrpm IH22A1 engine(USA: Si VTEC/Canada: SR-V):4,600 rpml, the IAB controlsolenoid valveis activatedby a signalfrom the ECM,intakeair tlows throughthe long intakepath, then high torque is deliveredAt speedshigherthan 4,8OO(or 4,600) rpm, the solenoid valve is deactivated the ECM.and by intake air flows through the short intake path in order to reducethe resistance airflow. in Intake Control SolenoidValve When the enginespeedis below 4,000 rpm, the ECM suppliesa groundto the intakecontrol solenoid valve. This opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm. 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. Alternator(ALT) Control The system controlsthe voltagegenerated the altematorin accordance at with the electrical load and drive mode, and reducesthe engineload to improvethe fuel economv.

5.

6.

7.

8.

9.

ECM tail-safe/back-upFunctions 1. Fsil-safe Function When an abnormality occursin a signalfrom a sensor,the ECM ignoresthat signaland assumes pre-programmed a value fof that sensot that allows the engineto continueto run. 2. Back-uD Function When an abnormality occursin the ECM itself,the fuel injectors are controlledby a back-upcircuit indeDendent ot the system in order to permit minimaldriving. Self-diagnosis FunctionIMalfunctionIndicatorLamp (MlL]1 When an abnotmalityoccurs in a signalfrom a sensor,the ECM lights the MIL and stores the code in erasablememory. When the ignitionis initiallyturned on, the ECMsupplies groundtor the MIL for two seconds check the MIL bulb to condition.

3.

11-49

System PGM-FI
Will Not Stan Flowchart- Engine Troubleshooting

Watch the Mallunction Indicator Lamp (MlL)and turn th€ ignition swirch ON.

Did the MIL come on at all?

Porfo.m tioubleshooting on pago 11-51.

Portorm t.oubloshootingon pago 11-52.

Turn the ignitionswitch OFF.

Connectthe test harnessb6tw96n the ECM and connectors (see page 1 1-45).

V 1.O ?
Turn the ignitionswitch ON.

I

Measure voltage between body ground and the tollowing terminafs individually: A23, A24. R6psir op6n in wir6(61 botwoon ECM 6nd GlOl llocst€d at thermoltat houringl that had mo.6 thsn 1.0 V.

ls there less than 1.O V?

Inspect tuel pressure (see page 11 - 1 5 ) . 1

Popair as nocoaaa.y {ago pag6 11 - t t 5 ) .

Portorm ignition systom chock {3o6 Baction 231.

11-50

Troubleshooting Flowchart - EngineControl Module (ECM)
Tho Maltunction Indlc.tor Lamp (MlLl nover com6! on l6vcn tor two sgcondsl aftei ignition i3 tuhgd on.

ls the low oil p.essure light on?

Inspect No. 13 METER110 A) fuse (in the under-dashfuse/relay oox,.

Turn the ignitionswitch OFF.

Connectthe test harnessbetween the ECM and connectors (se€ page 1 1-45).

R6palropan in YEL wir6 botwoon No. 13 METER(1O A) ture.nd gaugo alrombly.

o o o o o o o o o o o o o ooooo ooo I o@#qPt}| ooooooooooo
ooooo odooo ooo I oooooo oo
Turn the ignition switch ON. - RaDlocoth6 MIL bulb. - Ropairop6n in 8LU/WHT wire botwoon ECM lA13l and gaugs a88ombly.

ooooooooooo

ls the MIL on?

I LoooooooooooQo I

| t-.-----+-

423

|---TMeasure voltage between body ground and the tollowing terminals individuallv: A23, A24.

I ooooo999l1!9!t!1!!lg{ ooooooooooo I

L Le.. than 1 .0 V? --{

+-

a,

ls thsre less than 1.0 V?

Ropalr opon in wiro(sl botwson ECM and GlO1 {locatod at thormostat housing) that had moro than 1.0 V.

G101

Subrtituto a known-good ECM 6nd rechock, lf symptom/lndicatlon gooa away, raplaco tho origi nal ECM.

11-51

PGM-FISystem
TroubleshootingFlowchart - Engine Control Module IECM)
The Mallunction Indicator L6mP (MlL) 3tays on or com63 on allo. two soconoS.

NOTE: When there is no code stored,the MIL will stay on if the servicecheck connectoris jumped.

Connect the service check connector terminalswith a jumper wire {see page 11-42).

Turn the ignitionswitch ON.

Does the MIL indicate any Diagnostic Trouble code (DTc)?

Go to rslf-diagnoatic ptocodutos lso6 pags 11401.
o oooooooo oooo I oooooooom ooooo ooooo oo ol oooooooo oooooooooo

R€movethe iumper wire from the service check connoctor. 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.

D 4l + l r_S V? {A/T:

ls thereapprox.5V (A/T: 11 V)?

Connect the service check connector termanalswith a jumper ware.

Bopair shorl to body ground in BRN/ WHT wiro botwo€n tt|o ECM {t}4}, lrsnsmission Control Modulo lTCMl, ABS contrcl unit or 4WS control unit and seryico chock connoqtor. - Repairopen in BRN/WHTwite botwoon ECM (O4l and sorvico chock connoctor. - Repairop6n in BLU/WHTwite botwoon sorvico check connoctor and ECM {O211.

Mgasure voltage between D4 (.t ) terminal and D21 {-) terminal.

Removeand inspectthe NO. 4 BACKUP(10 Altuse in the underbox. dash fuse/relay

ls there spprox. 5 V ( A / T :1 1 V l ?

ls the fuse OK7

Remove the ,umper wire from the service check connector.

YES
{ T o p a g e1 1 - 5 3 )

lro page 11-53) 'NorE: After reDair, rhe servicecheck condisconnect nector iumper wire, test drive the car, and recheck the 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.

Disconn6ct the 3P connector of each sengor one at a time: . MAP sensor . EGRvalve litt s€nsor . Throttle Position (TP) sensor

Substituto . known{ood ECM and rochock. lt lymptom/indication gooa awsy, roplaca the origin8l ECM.

ls the MIL ON?

R€prir rhort to body ground in BLU/WHT wlro betwoontho ECM {A131 th6 MlL. rnd
RoDlacatho aenaor that causod thc light to 9o our.

Doesthe MIL romainON?

Turn the ignition switch OFF.

"l;_-l
Connect the test harness. Oisconnoct the "O" connector Irom the ECMonlv, not the m6in wire hamess(seepage | 1-451.

I o o o o o o o o o o o o o I o o o o o o o o f , S & l * * * * No o o o o o o o o o o | D20
-l\:-----:J

I
|

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 valve lift sonror. - Bopair shon to body g.ound in YEL/WHT wlre botw66n ECM lD2Ol and TP !on3or.

Continuitv?

ls th€re continuityT

NO
Reconnect all the sensor connectors. Reconnectthe "D" connector to the ECM.

Turn th€ ignirionswitch ON.

(To page 1 1-54)

(cont'd)

11-53

PGM-FlSystem
Flowchart - Enginecontrol Module IECMI (cont'd) Troubleshooting
(Frompage 1 '!-53)

Measurevoltage between body terminal groundandthe tollowing A26, B2. individually: A26 82 l l

]L

Less than

'1.0 v?

ls rhere lessthan 1.0 V?

Repai. op6nin BLK/RED lA26) or (B2l.nd G101 llocatod BRN/BLK 6t thormoslat housingl.

A 2 5( . r ) 8 1 { + )
Measurevoltage between A26 81 I - ) andthe following: {+ ) and A25 (+).

BATTERY VOLTAGE?
- Repair opon in YEL/BLK wir6 betweon ECM (425, 81) and PGM-Fl main iolay. - Check PGM-FImain tolaY .nd wiring connoctors at PGM-FI main r6lav.

BATTERY VOLTAGE?

Substitute a known-good ECM and recheck. lf symptom/indication goes avray, replacethe otiginal ECM.

11-54
Y

PGM-FISystem
TroubleshootingFlowchart - Heated Oxygen Sensor (HO2S)

mr- _.-i- _ The MaltunctionSensor(HO2S)(MlL)indicatesDiagnosticTroublecode {DTC)1: A problemin th€ ri--ri HeatedOxygen IndicatorLamp circuit. ff'_
The HeatedOxygen Sensor(HO2S)detectsthe oxygen content in the exhaustgas and signalsthe ECM. In op€ration, the signalsfrom the sensorand variesthe durationduring which fuel is injected.The HO25 has an the ECM receives in the The heaterstabilizes sensor'soutput. The HO2S is installed the exhaustmanifold(H2341 engine internalheater, SR-VI:in the exhaust pipe A)' (USA: Si/Canada: SR). H22A1 engine(USA: Si VTEC/Csnada: HEATER TEBMINALS VOLTAGE IVI

SENSOR TERMINALS

lm;rl lrirl
-Y-.-i- Tha MIL hsa becn roDortod on. - Yvlth sorvico chack connoclor iumpod l.60 page I 142), codo 1 i3 indicatod.

- LEAI{ RICH- AIR. FUEL RATIO

Do the ECMResetProcedure {see p a g e1 1 - 4 3 ) .

Warm up engine to normal oPeF (the radiatorfan atingt€mperature comeson),

Run enginetor 60 seconds.

Roadtest with the manualtrqlsmission in 4th geat I AfIt lA position). Starting st 1,600 rpm, accelerate using wide open throttl€ for at least 5 seconds.Then doceler€te tor at least 5 seconds with the throttle completoly closed. Intormittont lrllur., systom l. OK al thb time. Ch.ck to,. poot connoctlons o. loorc wiror at C432 {locatod al tight shock towcr), C114 (HO2S)and ECM.

ls the MIL on and does it indicate code 1?

Go !o pagl. and p€rtorm tcat for p.fo 11-62). .-.3 l-

-

11-56

PGM-FISystem
Flowchart- HeatedOxygenSensor(HO2SlHeater Troubleshooting
:ml1:f,f-f -*-Y: TroubleCode (DTC)41: A problemin IndicatorLamp (MlL) indicatesDiagnostic The Mattunction 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.

(see Do the ECM RssetProcedure p a g e1 1 - 4 3 ) .

H23Al ongino {USA: Si/Clnada: SR) H22Al engin. {uSA: Si vTEc/Canada: SR-VI:

ls the MIL on and does it indicate code 41?

lrrtd$frqrttS$6,3ystom 13OK at thi! tlmo Itost drlvo maY bo nacrsrsryl. Chock lor poot connoctionr or 10036wirot rt C432 llocat.d at right shock toworl, C114 lHO2Sl and EcM.

D

10-r|o o?

Turn the ignition switch OFF.

DIGITAL MULTIMETER KS-AHM-32-003

the Disconnect 4P connectorfrom the HO25.

Me6sute tesistance betweon terminsls C and D on the HO2S.

ls there 1O-4O 0?

( T o p a g e1 1 - 5 9 )

DIGITAL MULTIMETEB KS-AHM-32-003

11-58

11-58)

Check lor continuity to body ground on telminalsC and D ot the HO2S.

H23A1 engino IUSA: Si/Canada: SRl. H22Al ongino (USA: Si VTEC/Canada:SB-V):

Check foi continuity between terminalD and terminals and B inA dividually. F22A1 ongine (S):

HO2S 45 N.m (4.5 kg-m,

Turn the ignitionswitch ON.

At HO25 harness,measurevol, tage between YEL/BLK{+ I terminal and ORNMHT {- ) terminat.

ls there battery voltage?

YES

Disconnectthe "A" from the ECM.

connector

HO2S 45 N.m {4,5 kg-m, 33 tb-ftl

Meosure voltage bstween YEL/ BLK (+l re.minal and body ground.

At HO25 harness, measure voltage between YEL/BLK(+ )termi nal and ORN/WHT(- ) teiminal. Repair 3hon in ORf{/ WHT wire botwoen ECM (A6l and HO2S.

ls there battery voltage?

Ropairopon in YEL/BLK wiro botwoon HO2S and PGM-FImsin rolav. Turn the ignirionswitch OFF.

Reconnect HO25 connector. the

{To page 1 1-60}

{To page 1 1-60)

{cont'd}

11-59

PGM-FISystem iM-Fl
Flowchart - HeatedOxygen Sensor(HO2S)Heater {cont'd) Troubleshooting
(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 telminalsA6 { + ) and A26 (- ) ' Monitor over a 5 minutes period. ls the curront less than 0.1A?'

Subrtltut. a knownSood ECM lnd rochock. ll .ymptom/indication 9o6a away, roplaco tha origi_ nal ECM,

I
Reconnect the 4P connector to the Ho2s.

"A" Connect the test hahess connector to the main wi.e haF ness onlv, not the ECM (s.e page 11-45).

BATTERY o o o o o o o o o o o o o oo ooooooooooo VOLT

oooooooo oooooooo

ooooooooooo ooooooooooo

Turn th6 ignitionswitch ON.

Measurevoltage between A6 {+} terminsland A23 {- } terrninal.

ls there battery voltage?

Rep.lr op€n in OR /WHl wir. bctwcrn ECM lA6) .nd HO2S.

Subllltuto 6 known-good ECM and$chock. ll symptomlindicat'roril'golr ay{ay, rsplaco tho otigil_ nal ECM.

11-60
F

PGM-FISystem
TroubleshootingFlowchart - Fuel Supply System

:r,*n-- \r-r-l13l -t
- - - | t

/

|

\

Troublecode (DTC)43: A problemin The MatfunctionIndicatorLamp (MlL) indicatesDiagnostic problemin the Fuel Supply System the HeatedOxygen Sensor{HO25) circuit or a

l@r rE.
- Tho MtL hc! b.cn roportod on . - Wlth rorvico chock connoctoi iurDod t!.3 p.Oe 1 142), codo 43 l. indicatod. ls the codo 43 accompaniod by the MIL and poor driveabilitY? Go to Fu.l Supply Systam (3.o p!9. l1-'1131. Fiom cod. 1 troubb'l 3hootlng lpag. I -561.

Do the ECM Reset Procedure lse6 page 1 1-43). warm up engineto normSloper' ating tompgrature {the radiatorfan comes on). rpm lor two Hold engineat 3,OOO mtnutes. (A/T:NorEposition.)

,,ti

i,l

ls the MIL on and doss it indicate code 43?

Intlrmlttdrt t ilurc, ly.tom is OK at thir dm€ (t6st drlv. may ba nocoalarYl. Chock tor ooor connactiona o. loor. wirst at C432 lloclt.d !t rtght rhock low.tl, C1f4IHO2S) and ECM.

Turn the ignition switch OFF. NOTE: . Use DIGITALMULTIMETER (KS-AHM-32-OO3) equival6nt. or . Use 2 Volt range.

Connect the test hamess bgtween the ECM and connoctors {see page 1'l-45).

With the ignitionswhch OFF,wait tor st least two minutes. Install a iumper wire on the test harnessbotween A6 and A26.

6

A26 WIRE JUMPER

Turn the ignition switch ON. Measure voltage between Dl4 A l+) terminaland 26 {- ) terminal as soon as the ignition switch is turned on, lTo page 11-63)

A26{-t

I

Voltaga .hould ttan tl 0.4-0.5 v wh.n thc ignltion .whch i. fit8t tunad oo, and dactaaso to b.low O.l V In L.t than two mlnut6a.

D 1 4( + l

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 l {+} terminaand A26 {-) rer minal.

ls there more than 0.1 V?

Bop.ir rhon in WHT wlro b.tw.on ECM (Dl4l andHO2S.

Measu.e voltage at the engine wi.e harness side ot the HO2S connector between GRNMHT ( - ) a n d W H T( + ) .

Substitute a known{ood ECM and r6.hock. lf symptom/indlcation goos away, roplact the orlglnal ECM.

ls th€re mor€ than 0.1 V?

Chock for oDcn in IIVHTwiro betw..n ECM (D141 and HO2S. lf wlrs ir OK, r6poir opcn in GBN/WHT wiro berw66n ECM (D221and HO2S. F2241 sngino {S): GRI{/

H23A1 ongin6 (USA: Si/CanadarSR), H22Al ongino (USA: Si VTEC/Conada:SR-V);

GRl{/ WHT

W H T( + )

IVHT - l

WHT

(+l

moro than

o.'t v?
DIGITAL MULTIMETER KS-AHM-32-OO3

HO25 45 .m (4.5 kg-m,33 lb-ft|

HO2S 45 N.m 14.5 kg-m, 33 lb-ft)

DIGITAL MULTIMETER KS-AHM-32-OO3

11-63

PGM-FISystem
t 1 6 l - /- l 3 l \/--l-\ ,
\ |
|

TroubleshootingFlowchart -Manifold Absolute Pressure(MAP) $gn5s1
- -l-- ---1- TroubleCode (DTC) 3: An electricsl The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic {MAP) Sensorsystem. oroblemin the ManifoldAbsolutePressure

Troublecode (DTC) 5: Lamp {MlL) indicatesDiagnostic {-61--fr-r- The MalfunctionIndicatorthe ManifoldAbsolutePressure(MAP) SensorSystem' A mechanical (vacuumleak) in problem
/\ /---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.
I

r',i i , l'

{see Do the ECM ResetProcedure p a g e1 1 - 4 3 ) .

I'iI
l l

ls the MIL on and does it indicate code 3?

Intgrmittont failuro, 3yltam is OK at this time ltort ddve may D6 noc{r!ry}. Chock tor Poor connoction! ol loose wiror at O163 (locatod undor loft 3ideol drshl, C32O IMAP 3.n3otl and ECM.

Turn the ignitionswitch OFF.

the Disconnect 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 ground.

D 1 9t r l D 2 1( _ l
ooooooooooooo ovooooooooooo I o oooo ooo I oooooooo

ft

ls there approx. 5 V?

Measure voltage between RED/ WHT (+ ) terminal and BLUMHT { - ) terminal. Ropai. op6n in BLU/ WHT wiro betwoon ECM {D21} and MAP s6n8l't.

Turn the ignirionswirch OFF. ls there approx. 5 V? 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/ BLU {+ ) terminaland ELUMHT { - ) terminal.

ls there approx. 5 V?

Ropairopon in RED/WHTwiro botwcon ECM (D191 and MAP son3()r.

Sub3tituto a known-good ECM and rochock. lf 3ymptom/indication 9003away, .eplacotho original ECM.

ls there approx. 5 V?

Turn the ignitionswitch OFF. Reconnect the 3P connector to the MAP sensor. Connectthe test harnessbetween the EC|VI and connectorlsee page 11-45). Turn the ignitionswitch ON. { T o p a g e1 1 - 6 6 }

{To page 1 1-66)

(cont'd)

11-65

PGM-FISystem
(MAPISensor Pressure lcont'dl Absolute Flowchart- Manifold 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 not to connectorto the ECMonly, the main wire harness {see page 11-45).

ls there approx. 3 V?

Turn the ignitionswitch ON.

Sub.tituls . known{ood ECM rnd r.chock. lf 3ymptom/lndication goo! 6w!y, r.plact th. odgi nal ECM.

Measurevoltage betweon D17 ( + l t e r m i n a la n d D 2 1 { - ) tetmlnal.

ls there approx. 5 V7

- Roplir rhort In WHT/BLU wiro botworn ECf,l {D17) rnd MAP loflto], - R.prir opon in WHT/BLU wlrc botwo.n ECM (Dl7l.nd MAP 36nao..

Substltuto a known{ood ECM and rochock. lf aymptorn/indicrtion goo3 away, taplace tho original ECM.

11-66

PGM-FISystem

Sensor Pressure lcont'dlAbsolute {MAP} Flowchart- Manifold Troubleshooting

,g:

-g-

- The MIL has boon reponod on. - With sorvic€ chock connector jumpod ls6opago 1 142), code 5 is indicatod.

Do the ECM ResetProcedure {see p a g e1 1 - 4 3 ) .

Start the engine and keep engine speed at 2,000 rpm tor one minutewith the manualtransmas sion in neutral {A/T: @ or S position). - Intgrmitl6nt lailuro, 3y3tom is OK al this tlm6 lt$t ddvo mav bo nocoasaryl. - Chock vacuun ho3or, PiPo3 ond connoctionS. - Mako turo all conn9ctota ar6 30cu16, MAP SENSOR Turn the ignitionswitch OFF.

ls the MIL on and does it indicate code 5?

l l

'1i
r:ttl

Hrl
Disconnect#21 hose lrom the throtle body, connect vacuum pump to the hose and apply

VACUUMPUMP/ GAUGE A973X-041-XXXXX
#21 HOSE Connect a vacuum pump to the MAP sensorand apply vacuum.

Does it hold vacuuml

Connecta T-titling from a vacuum gauge between the throttle body and #21 hose.

Repairvscuum lsak in hoa€ routing betwaon MAP asn3or lnd 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 harness between the ECM and connectors (see p a g e1 1 - 4 5 ) .

T-FITTING

Turn the ignitionswitch ON.

D l 7 t + l D 2 1{ - }
Measurevoltage between D17 (.t ) terminal and 021 ( - ) lermrnal,

n

3V?

ls there approx.3 V?

Start the engineand allow it to idle.

ls there approx. 1 V?

Subltitute a known-good ECM and rocheck. ll symptom/indication 9063away, ropl6cotho o.iginal ECM.

11-69

System PGM-FI
Sensor Flowchart- TDC/CKP/CYP Troubleshooting
I

-Yt-._r-\ \

16l-

7

-

Tr-l-

TroubleCode(DTC)4: A problemin the Diagnostic Lamp(MlL)indicates The MalfunctionIndicator CrankshaftPosition(CKP)Sensorci,cuit. Diagnostic TtoubleCode{DTC)8: A problemin rhe Lamp(MlL)indicates Indicator The Maltunction (TDC)Sensorcircuit. Top Dead Center TroubleCode(DTC)9: A problemin the Diagnostic Lamp(MlL)indicates Indicator The fiilalfunction (CYP)Sensorcircuit. CvlinderPosition

- l r G./l - --_-1_/l 8l
/-i-\ / \

-116l--l e l/ --t-\ /---- \

\_

j_'-,2

\_

_/

timing fo. fuel injectionand ignitionof each cylinderand also detects enginespeed.The The CKP Sensordetermines The CYPSensordetects and when crank angleis abnormal. ignition timing at start-up(cranking) TDC Sensor determines to each cYlindet. the position of No. I cylinder for sequential fuel injection

-@Jtrl:;m:-;F;

.ir

- Tho MIL ha. b€€n Jooortod on. - lilfith loruice ch€ck conn.ctol iump€d (3ooprgo 1142), codc 4. 8 rnd/or 9 aro indicstgd.

l,l

Do the ECM Resetprocedurelsee pago 1 1-43).

ls lhe MIL on and does it indi cate code 4. 8 and/or 9?

l ormittont l.ilur., syltom b OK at this timo ltelt driv6 may bo neco$aryl. Chock for Door connoctiona or loos6 wir.s at Al25 (locatod at dght shock towo.), Cl25 (TDC/ CKP/CYPionsorl .nd ECM. SRl, .,. H23A'l ongino{USA: Si/Canada: vrew rrom H22a1 engino

Turn the ignition switch OFF.

sa-vt, iiisr, si vlicrca"aaa

$jT'"'

Disconnect 8P conn€ctorfrom the the TDC/CKP/CYPsensor.

( T op a g e1 1 - 7 1 )

11 -7 0

1 1-70)

Measurerosistancebetween terminals of the indicnted senso.. '9oo tsblg

SENSOR

oTc

SENSOF

ECM COLOF 815 416 ALU/GRN SLUTYEL

cxP ls there 350- 700 O? Roplacathe di.Mbuto. houalng {16o soction 231.
TOC

a

c
G

al3 at4
Bll

OFN/aLU
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 ECM (seepag€ 1 1-45).

8:16

350-7OOO?

Measurerosistancebetween t€rminals of the indicated sensoron test harness. 'see tablg

o oooooooooooo I oooooo ooooo oooooooo I oooooo

o l:1E$iq#Cittl o o o oo o oo oo o o ooooo oo oo o

B1l-

350-7ooo?

o o ooooooo o ooo I ooooo ooo r.sEt$di6dq oooooooooo o 350-7000? 812

ooooo oooooooo I ooooo0oo lfrlE#lls*llooooooooooo

ls there 35O-7OO 0?

R9pai.op.n In tho indicatad alnlor wi10a. '!oo trble

Check tor continuity to body groundon Bl 5, 813 or 81 1 termtnals,

Subltltuto a known-good ECM lnd r6chock. lt aymptom/indicrtion goor away, rcphca tho origin.l ECM.

11-71

PGM-FISystem
TroubleshootingFlowchart - Engine Goolant Temperature(ECTI Sensot -

f'at- lri-tl , - ---;--

TroubleCode (DTC)6: A problemin The MalfunctionIndicatorLamp (MlL) indicstesDiagnostic (ECT)Sensorcircuit. the EngineCoolantTemperature

as of The resistance the thermistordecreases the enresistor(thermistor). dependant The ECTSensoris a temperature gine coolanttemperatureincreases shown below. as
RESISTANCE (KO)

- -- hl 6 l -

-

/----,

r / -- -l- ! 5 l ---i-

-

-

-20

- The MIL has b6onroDongdon. - With sorvica ch6ck connoctol 'l ,ump6d l.oo pag€ 1421, c!d6 6 is indicatsd.

0 ,ro ao ao r roo 12o (rc, . 12 aa r0. !.ro 1ta 2r2 2.r r.fl

COOLANT TEMPERATURE ENGIT{E

Do the ECM ResetProcedure {see page 1 1-43).

Turn the ignition switch ON,
j

ls the MIL on and does it indi cate code 6?

Intermitt€nt failure, systgm i3 OK at thir timo lt6st d.ivr m.y b. n6ce!l|'yl. Chock tor poor connootions or looro wir6 at 9125, 9126 (locrtod at righl shock toworl, Cl22 IECT lenrotl, AIf: C411 (TcMl and ECM.

Warm up engine to normal oper(th€ radiatorfan ating temperature comeson).

Turn the ignitionswitch OFF.

the Disconnect 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/ BLU and body ground.

GBN/ wHT

YEL/BLU
ls there approx. 5 V? Measure voltage between YEL/ BLU (+ ) torminaland GRNA/VHT (- ) terminal. Repair op€n in GRN/ WHT wlra brtw.on EGM (D22) and ECT tonaoa.

Turn the ignitionswitch OFF. ls there approx. 5 V? A/T only Disconnect the 22P connector trom the TCM. Subrrituto r known{ood ECM and iocheck. lf lymptom/lndlcrtion goaa aw!y, rol aco tha original ECM.

Turn the ignitionswitch ON.

ls there approx. 5 V?

YES

NO
I

Turn the ignitionswitch OFF.

I
I

Connect the test harness "D" connectorto the ECMonly, notto the main wire harnsss 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.

ls there approx. 5 V?

NO
Subatituto a known-good ECM and rechock. lt symptom/indication goos away, r6pl6cothe original ECM.

Ropairopen or rhon in YEL/BLU wir. betwoon ECM lDl3l snd ECT sensor.

11-73

PGM-FISystem
TroubleshootingFlowchart - Throttle Position (TP) Sensor
lf1=lllfifl .:. : TroubleCode IDTC) 7: A problemin The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic the Throttle Position{TP) Sensorcircuit.

lt The TP Sensoris a potentiometer. is connectedto the throttle valve shaft. As the throftle positionchanges,the TP Sensorvariesthe voltage signalto the ECM.
ERUSH HOLDER

VOLTAGE OUTPUT NI
BRUSH

5 4 3

RESISTOR

lr6t1
-Yr

:.t1
-tTERMINAL

2 1 o.5 0 THROTTLE

- Engino b running. - Tho MlLhas beonreDortedon. - With sorvico check connoctot iumpsd ls6opage 1 142), codo 7 is indicatod.

;;ii-

oPEt{rNG

THROTTLE

INNER BRUSH

(see Do the ECM ResetProcedure p a g e1 1 - 4 3 ) .

i

I

ls the MIL on and does it indicatecode 7?

Inlormittont Iailure, systom b OK at this timo lt6st d.ivs m6y b6 nocossaryl. Chock tor Dooi connections or loos€ wiros at O125, g*13 llocatod at right shock rowerl, C113 (TP sonsorl, A/T: C4'l l ITCMI and ECM.

Turn the ignitionswitch OFF.

Disconnect 3P connectorfrom the the TP sensor.

Turn the ignitionswitch ON.

Measure voltage between YEL/ WHT (+ ) terminal and GRNMHT (- ) terminal. Measure voltage between YEL/ WHT (+) rorminal and body grouno, YEL/ RED/ GNN/ WI{T BLK WHT (To page 'l1-75)

ls there approx. 5 V?

YES
{ T o p a g e1 1 - 7 5 }

11-7 4

(F om p8O€11-741

(Frompage 1 1-74) Repaii opon in GBN/ WHT wiro botwo6n ECM (D221 End TP 30n3('t.

ls there 6pprox. 5 V? Turn the ignition switch OFF. Turn th6 ignition switch OFF.

Connoct testharness th€ b€tween tho ECM snd connectors{see p8ge11-451.

Connoct the test hamess b9tw6€n the ECM and connoctors ls€e p a g e1 1 ' 4 5 1 .

Turn the ignition switch ON.

Measure voltage betwgen D2O ( + ) t e r m i n a la n d D 2 2 { - ) terminal. Turn the ignhion switch ON. ls there aoo.ox. 5 V? Rop.ir op.n in YEL/ WHT wlra bolwoon ECM {D2O} a.|d TP aonlot,

Measurevoltago b€tween Dll {+) t€rminaland D22 (-, terminal.

Subltltut. . known{ood ECM .nd r.ch.ck. It piclcribcd voltage i! now lvoilabl., rrphco tho orlgin.l ECM.

o o o o o o o o o o o o o I o o o o o o o o E f f n f f i n S Ho o o o o o o o o o o Fl o o o o o o o o o oo o o I o o o o o o o o ooooooooo
D 2 0t + l D 2 2 l - l

tsv,J
0.5 V at tull close throttle? 4.5 V at lull open throttle? ls voltago 0.5 V at full clos€ throttle, and approx.4.5 V 8t full open throttls? NOIE: There should be a smooth transition from O.5 V to approx.4.5 V as the throttle is depressgd.

Diaconngct the 22P connecto. from th6 TCM.

Sub.litulc ! known-good ECM .nd rochsck. lf symptom/lndic.tlon goat rway, ropl.c. the odginll ECM.

ls voltageO.5 V at full clos6 throftls, and 4.5 V at full open throttl€? NOTE: Thero should be a smooth transition from 0.5 V to 4.5 V 8s the throftlo is d€pressed.

- Roplac6 the TP lonaoa. - Rapairoponoarhon in RED/BLKwiro betw.€n ECM {Dl 11, TCM and TP r.n!or.

11-75

PGM-FISystem
(lAT) Sensor Troubleshooting Flowchart- IntakeAir Temperature
f6l F l---:Diagnostic TroubleCode(DTC)1O:A problem the in The Maltunction Indicator Lamp(MtL)indicates (lATl Sensorcircuit. Intake Air TemDerature

The IAT Sensofis a temperature dependant resistor(thermistor). resistance The ofthe thermistor decreases the intake as air temoeratureincreases shown below. as
(KO} RESISTANCE

THERMISTOR
. 12 aa ro4 1aolta :12 t a |.Fr

INTAKEAIR TEMPERATURE
IA7 SENSOR

GR N'VHT

:[611:frnl --i/ --T/ \ \

i:

- Tho MIL har b6onropon6d on. - Wlth s6rvico chock connoctol iumpod {3€opago 1142}. cod6 10 is indicsrod.

(see Do the ECM ResetProcedur€ 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. Chock for poor connoction! ol loo!. wircr .t O+25, 9126lloclled ot right .hock towor), CiOS llAT sonsorl and ECM.

ls the MIL on and do€s it indicatecod6 10?

Turn the ignitionswitch OFF.

Disconnect 2P connectortrom the 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.

ls th6re approx. 5 V?

Mgasure voltage betweon BED/ YEL (+ ) terminaland GRNMHT {- ) terminal. Ropair opcn in GRN/ WHT wlr6 botwoon ECM (D221 and IAT lon301.

Turn the ignitionswitch OFF.

li there approx. 5 V?

Connect the test hamess "D" connectorto the EcM only, notto the main wire harness lsee page 11-45).

Subrtitut. . known-good ECM and rochock. ll lymptom/indicatioh goe! aw!y, r6pl.ce th. orlglnel ECM.

Turn the ignitionswitch ON.

Measurevoltage between Dl5 {+} terminafand D22 l-) terminal.

ls ther6 approx.5 V?

Ropair oponor lhort in REOrYEL wirebotween ECM{D15}.ndIAT aona{tr.

Substilute a known-good ECM and .ochock. lI symptom/indication go6s awsy, roplac6tha original ECM,

11-77

PGM-FI System
lmil .(-frrf: .+.

(BARO) Sensor Pressure Troubleshooting Flowchart- Barometric
in 13: Diagnostic Trouble Code(DTC) A problem the Indicator Lamp{MlLlindicst€s ThsMalluncrion (B B a r o m e t rPc e s s u r e A R O ) e n s o r . ir S

is The BARO Sensor 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 indicatecode 13?

Int.rmltt.nt f.llut . lyltgm Ir OK at thlr tlm. lt6!t drlv. mly b. nacoar!ry1.

Subrtituto a known{ood ECM .nd rcchock. lf symptom/indlc!tion goo! away, r6phca tha odolnsl ECM.

11^78
i t

PGM-FISystem
TroubleshootingFlowchart - lgnition Output Signal
i151 : :16: in Trouble Code(DTC)15: A problem the Diagnostic Indicator Lamp(MlL)indicates The Malfunction 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.

(see Do the ECM ResetProcedure 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). Chcck for poot connactions or looso wi.or ot C433 {locrtod at .ight shock towet). Ct2S llgntdon Conlrol Modulo llCMl) and ECM.

ls the MIL on and doos it indicatecode 15?

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 11-45).

Turn the ignition switch ON.

- Repsii opon in YEL wiro botwoon tho 2P oonngcto. and ignition coil, - Ropaii opon in BLK|'EL wi.o botwoon tho ignition coil ond ignition $witch.

Measurevoltage individually bet w e e nA 2 1 ( + ) , A 2 2 { + l t 6 r m i nals and A26 t-) terminal.

1OV? ---r A 2 1{ + } oooooooooooo

oooooooooooo
A 22l+t 426 l-l 1 0v ?

t-J

ls th6ro approx. 10 V?

- Roolocs lho lCM. - Repair opon oi lhon in YEL/ GRN wir. botwo€n ICM lnd ECM {A2l or A221. NOTE:lf the YEL/GRN wire was shorted. the ICM may be damag6d.

Substituto . known-good ECM and roch.ck. lf symptom/lndic.tlon goos awsy, .oplacoth6 original ECM.

11 - 8 1

PGM-FISystem
Troubleshooting Flowchart- VehicleSpeedSensor(VSSI
-c+l --lKgll- :'; rI r'' lin Diagnostic TroubleCod€(DTC)17: A problem the The Maltunction Indicator Lamp(MlL)indicates vehicle speed sensor {vss) circuit.

The VSS generates pulsingsignalwhen the front wheels turn. a
- Th6 MIL has bo6n r€portodon. - With sorvico ch6ck connoctor iumped ls6opage I 142), cod€ '17 is indicatod.

(see Do the ECM Res€tProcedure p a g e1 1 - 4 3 ) .

Road test necessary. With manualtransmission 2nd in 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€. Chock tor Door connoctiona ol loose wir6s at C433 {locrtod at .ight shock tow6.). Cl15 {VSSI and ECM,

ls the MIL on and does it indicatecode 17?

I

rl

Block rear wheels and set the parkingbrake.Jack up the front oI the car and support with salety stands.

@emr ro.l wheel

beloro jacking up front ot cat,

Turn the ignitionswilch OFF.

Connectthetest harnessbetween the ECM and connectors (see p a g e1 1 - 4 5 ) .

o oooooo ooo ooo I oooooooo &ruffi ooooooooooooo I oooooooo EEwryl A 2 6l - ) 8 1 0( + ) O - 1 2v ot O *5.o v?

ooooooooooo oooooooo ooo

Turn the ignitionswitch ON.

Block the right front wheel and slowly rotate left lront wheel and measurevoltage between B1O { + } t e r m i n a la n d A 2 6 { - ) Iermrnat.

NOTE: Transmission @ position{A/T). in

Does voltage pulse 0 V and '12 V lH22A1 engine{USA: Si VT€C/Canada: SR'V)5.0 V)?

Turn the ignition switch OFF.

Substituto a known-good ECM and rochock, lf symptom/indication gooaaway, roplacoth6 original ECM.

( T o p a g e1 1 - 8 3 )

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 (-) tefmrnal.

Does voltage pulse O V 8nd 12 V lH22A1 engine (USA: Si VTEC/Canada: SR-V):5.0 VI?

Sub.tituto r known{ood ECM .nd r.ch.ck. lf lymptom/indication goar rway. roplace tho original ECM.

- Reprir 3hort in ORN wi.e b6twoon ECM (8101and tho VSS, Tianlmission Control Modulc, spo6domotor, 4WS control unit, or cruiso contrcl unit. - Ropoiropon in ORN wire b6two6n ECl, {8101and VSS. - lf wlr€ i8 OK. tort th€ VSS {!oo .oction 23t.

11-83

PGM-FISystem
(ELD) TroubleshootingFlowchart - ElectricalLoad gs1s61q1

tf

- --r--' I 20 l-

in Trouble Code(DTC)20: A problem the Diagnostic Lamp(MlL)indicates Indicator The Malfunction Etectrical Load 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. Chock tor ooor connociion3 ot looso wlr6s at C420 IELD) 8nd ECM.

Doesthe MIL indicatecode 20?

Turn the ignitionswilch OFF.

,i

Remove the undeFhood tuse/ relay box and remove the fuse/ relay box lower cover,

it
( SLKTYEL+ }

Turn the ignitionswitch ON.

Measure voltage between BLK/ l Y E L ( + ) t e r m i n aa n d B L K ( - l terminal. Measure voltage between BLK/ YEL {+) terminal and body ground.

LOWERCOVER

ls there battery vollage?

Roplir opon In BLK rvk. batwcan tha 3P conn ctor and erc3 llocatcd undor middlo ol dashl.

Ropairopon in BLK/YELwlto botweon ECU IECMI {'15Al fu3o {in tho undor-dash tuso/rolay boxl and lho 3P connector. (To page 1 1-85)

11-84

{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 3P connoctoa. It wiro is OK, aubstitut6a knowngood ECM and ..chock.

ls there 4.5- 5.0 V?

GRI{/BLK ) I+

Turn the ignition switch OFF.

LOWER COVER

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 Headlightswitch, first position (.) Headlightswitch, second position( a) Voltage 1 . 5 - 3 . OV

V 1.0-2.O

Underthe conditions list€d in the chart to the right, measure vol_ tage between D1O {+ } terminal and A26 (- l terrninal.

'

it

Substituto a known{ood ECM and recheck, ll symptom/indication goos away. 6phco tha otiginel ECM.

11-86

PGM-FISystem
t-7=.l_lltlllll-r#-l .l l-

Flowchan- KnockSensor(KSl [ExceptF22A1 engine(S]l Troubleshooting
TroubleCode (DTC)23: A problemin The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic (KS) circuit. the Knock Sensor

-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 radiator lan comgs on).

Hold engine8t 3,OOo 4,0OOrpm tor 1Osecondswith manualtransmiesion 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. Chack for poot conncctlon! ot loolq wlro3 al O+32 (loortrd rt right shod( tow.r), Cl l2lKS) and ECM,

ls the MIL on and does it indicats code 23?

Turn the ignition swirch OFF.

Connect the test harness to the engine wire harneasonly, not to the ECM (seepage 1 1-45),

t_ Continuity?

o3

Ch6ck lor continuity between D3 t€rminal and body ground.

wite bcRop6ir.hon in RED/BLU trY.en ECM lD3l snd th. KS.

(To page 11-89)

1 1-88

Check tor continuity on RED/BLU wire betweenD3 terminaland 2p connectorof enginewhe harness.

lContinuity? Ropairopon in RED/BLUwiro botwoon ECM lD3) and tho KS.

Warm up tho engineto normal operating temperature {theradia, tor fan comgs on).

Hold engineat 3,OOO-4,OOO rpm lor 1Osgcondswith manualtransmissionin noutral (A,rf: @ or @ oosr!onl.

ls the MIL on and does it indicatecode 23?

Subslituto a known-good ECM and rsch6ck. lt symptom/indic!tion goos aw6y, .oplacothe original ECM.

32 N.m 13.2ks-m.23 lb-ftl

11-89

PGM-FISystem
Flowchart- A/T Fl SignalA/B (A/T only) Troubleshooting
TroubleCode (DTC)30: A problemin ---l-The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic -l 30 lControl Module {TCM) and ECM. A/T Fl Signsl A circuit between Transmission tne (MlLl indicatesDiagnostic TroubleCode {DTCI 31: A problemin r;;--] The MaltunctionIndicatorLamp I Jr l- the A/T Fl SignalB circuit between Transmission control 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 transmission upshiftsand downshifts soveral times. lhtdmittont failurs, gylt.m i. OK ai thir tlmo. Chock for poot connoction! or loo.. wiro. at C4ll (TCMI snd ECM,

l
I I

Does th€ MIL indicat€ code 30 and/or 31?

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? Check for continuity between 93 and/or 84' terminal and body grouno.

+
Continuity *r codo 31 {A/T Fl signal B) RoDairrhort in ORN or Pf{Kr wilo botw.€n ECM {B3 or B4r I .nd rh. TCM.

NO
( T op a g e1 1 - 9 1 )

11-90

(Frompsge 11-9O)

Check lor continuity on ORN or PNK'wire between 83 or 84* and 22P connectorot rhe TCM.

Ropsiiopon in ORI{ or P{lK. wir6 botween ECM {8:} o?84. I and rhc TCM. Subltitute a known{ood ECM and rochack. lt lymptorh/indication gogs rway, roplaca tha original ECM.

11-91

ldle Control System
Guide System Troubleshooting
NOTE: of that couldbe sources a symptomare rankedin the orderthey should a Acrosseachrow in the chart,the sub-systems refer startingwith @. Findthe symptomin the left column,read aclossto the most likelysource.then be inspected, the system is OK' try the next system @' etc' to ths page listed at the top ot that column. lf inspectionshows Trouble and the MalfunctionIndicatorLsmp (MlLl does not blink Diagnostic a lf the idle sDeedis out ot specificstion go to inspectiondescribed page 11-95. on Code {DTC) 14,

PAGE
SYMPTOM

ALIER, IOLE coNDr- NATOs ADJUST I D I E A I R CONTROL l s u s - s Y s T € M ING FR TIONING SIGNAL S I G N A I SCREW -'\ 100 96 98 ttl

STARTER ERAKE STEERING FAST IDLE STAFTING

swtTcH swtTcH PFESSUNE THERMO srGt'rALSIGNAL SIGNAL
l04 106 104

HOSES AND CONNEC. TIONS

102

l09

110

TO DIFFICULT START WHENCOLO ENGINE WHEI.{ COLDFASI IDLEOUTOF SPEC.(1 ,000- 2,000rpm) ROUGH IDLE

O
@ @ @ @ @

o

o
@ @ @

TOOHIGH WHENWARMRPiN

O

load)

o o
@

WHEN T00 Low
liomr in ON

o
\,

@ @ @

o
@

o

FREOUENT STALLING

WARMING WHII,E UP AFTER WARMING

@

o
@

o

TEST FAILS EMISSION

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

.,\ \r-

vARtous
SENSORS

STARTITIG AIB VALVE

FAST IOLE THERMO VALVE

11-93

ldle Gontrol System
System Description(cont'd)
to 1. After the enginestarts,the IAC valveopensfor a certaintime. The amountof air is increased 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 specification the MalfunctionIndicator and Lamp(MlL)does not blinkDiagnostic Trouble Code lDTC) 14, check the following items: . Adjust the idte speed (page I 1- l 1 I ) . Air conditioning signal (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 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.

2.

11-95

ldle Control System
TroubleshootingFlowchart - ldle Air Gontrol (lAC) Valve
-r---i -tgll - - -;lr l_ I TroubleCode (DTC) 14: A problemin The MaltunctionIndicatorLamp (MlL) indicatesDiagnostic the ldte Air controt {tAc) vatve circuit.

to the throttle body in response a currentsignalfrom the ECM in The IAC Valve changesthe amount of air bypassing proper idle speed. order to maintainthe
TO INTAKE MANIFOLD FROM AIR CLEANER

VALVE

SPRING

--t6t- :Frl ---r-l- Tho MIL has boen r6portodon. - With sgrvico check connoctor jumped ls€opago 1 1421, codo l4 is indicatod.

(see Do the ECMResetProcedure p a g e1 1 - 4 3 1 .

ls the MIL on and does it indicale code 14?

With lhe engine running and the accelerator pedal released, disconnect the 2P connector lrom the IAC valve.

Remove the 2P connector ttom the IAC valve.

ls there a reduction in enginerpm?

Substhute a known-good IAC valve and retost.

Intormitlant lafluro, ay8tom is OK dt this timo {to3t d.iving may bo nocassa,yl. Chock tor ooor connoction or looso wiros at c+25, C433 (locarod at right ahock towoil. C106 llAC valvo) and ECM.

( T op a g e1 1 9 7 )

11-96

(Frompage 1 1-96)

Measure voltage between the YEL/BLK wire 8nd body ground.

Rop6iropen in YEL/BLKwiro botwoon ths IAC valvc.nd PGM-FI main relay. Turn the ignition switch ott and reconnectthe 2P connectorto the IAC valve.

Connect the test hamess "A" connector to the main wire harness only. not the ECM lsee page 11 - 4 5 ) .

Turn the ignition switch ON.

Mofientarily connect Ag terminal to A26 terminsl several times. Subrtitut . known{ood ECM .nd r.to.t. lt rymptom/ktdicrtkrn gooa away, raplaca tho original ECM.

Doosthe IAC valve click?

Ropairopon or .hort in BLX/aLU wirc b.tw.on IAC v.lvo and ECM (A9l . It tho wlr. i! OK, r6pl.co th6 IAC valv6.

ldle Control System
Troubleshooting Flowchart Air Conditioning Signal
system. This signalsthe ECM when there is a demandfor coolingfrom the ai. conditioning

Connectthe test hatnessbetween the ECM and connectors. "B" connectorfrom Disconnect the main wire harness only, not the ECM (seepage 11-45)

Turn lhe ignitionswitch ON.

A26 t-t
Measurevoltage between 85 (+) terminaland A26 (-) terminal.

ls there approx. 5 V?

Substituto a knowngood ECM and ]e fieck. It prssc bod voltago i3 now availablo, rapl6c6 th6 origln.l ECM.

Reconnect "8" connector to the main wirc harness. Clicklng?

Momentarily connect A15 terminal to /q26 t€rminal several times. ls thsre a clicking nob€ ftom the A/C comprc$or clulch?

Connecrrho RED/BLU torminrl ot ihe 4P conneclor on tho A,/C clutch rolty to body g.ound.

Vigw from wire harness side

13thorc I clicking noiaetrom the A/C comore6sor clutch ?

S6a alr condltlonat inrpaetlon lrac toction 22t.

Ropairopen in RED/BLUwlr6 borwo.n ECM {A 15} rrd A/C drnc*l relay. { T o p a g e1 1 - 9 9 }

11-98

(Fromp8g6 1 1-98)

r-

Lo!! rhan 1.0 v? --------.1

I
| I

es t*t

| ooooooo ooooo o looooc looooooooooooQ I ooooc r---------------A26 t_l I
Measure voltage between 85 (+) terminaland A26 {-) terminal.

ls voltagelessthan 1.O V? Air conditioning iignal i3 OK. Substituto a known-good ECM and rodrock. ll proscribod voltago is .row availoblo, rsplacg tho original ECM.

Ropairopen in BLU/BLK wiro botwoon ECM lB5l and A/C awitch.

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. "D" connector from Oisconnect the main wire harnessonly, not the ECM (see page 11-45). 4.5 V? Turn the ignirionswitch ON.

A26 t-l
Measure voltage between D9 (+) rerminal and 426 (-) termrnat,

ls thereapprox.4.5 V?

Subltitut. a khown{ood ECM and r..hock. lf pr.rcribed voltlgo ir now availabl., rophce lh. ottginel ECM.

'l

Turn the ignitionswrtchOFF.

li

"D" Reconnect connector to the main wire harness.

Warm up engineto normaloPer ating temperatu€ (the radiatortan comes onl.

Vohfo

?

D 9l + l
Measure voltage between Dg l+) terminal and A26 {-) terminal.

ooooooooooo
ooooooooooo

Does the vohage decreasewhen heedlighls and rear d€fogggr 8re turnedon ?

Turn the ignition switch OFF.

(see Do the ECM ResetProcedure p a g e11 - 4 3 ) .

ALT FR sign.l is OK.

(To page 'l 1-10'l)

(Frompage 1 1-1OO) "O" connector Disconnect trom ECM only, not the main wire harness.

NOTE: The radio may have a coded theft protection circuit. Be sure you get the customer'scode number before disconnecting the battery cable.

Disconnecl the negative banery cable trom the battery.

Check tor continuity between D9 t€rmanaland body ground.

Disconnect GRNconnector from 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 botwoon ECM (Dgl snd ALT.

Ropoi.op€n in WHT/REDwiro b6two€n ECM lDgl and ALT.

11 - 1 0 1

ldle Control System
(A/Tl Geat PositionTroubleshootingFlowchart - AutomaticTransaxle Signal(A/T only)
is This signalsthe ECM when the automatictransmission in @ or@] position.

Tum the ignition switch ON.

Observethe A/T gear position indicator and select gach Position separately. S6e A/T goar position indicatoi inspecdon (soction 141.

Ooesrhs indicatorlight ProP€rlY?

Turn the ignitiongwitch OFF.

Connectthe test harnessbetween the ECM and connectors. "B" connector trom Disconnect the main wire hamess only, not the ECM (see page 11-451

5V?

87(+)

Turn the ignitionswilch ON.

A26 (-l
Measure voltage between 87 {+} terminal and A26 (-} terminal. Subltituto a known-good ECM and rech.ck. ll prsc.ibod voltago b now avriloblo, taplaco the original ECM.

ls there approx. 5 V?

Turn the ignition 3wilch OFF.

"8" connector the to Reconnect 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. betwoon ECM lB7) .nd gaug6 aelombly.

ls there lessthan 1.0 V?

12V7Measure voltage b€tween 87 {+l terminal and A26 (-) ter, minal with the transmission in gear. Ropalr rhort ir| LT GRN wir6 b.tw.cn ECM {87} and gaugo .rlombly.

ls ther€ approx. 12 V7

A/T gear poritlon .lgn.l i. OK.

11-103

ldle Control System
Troubleshooting Flowchart -Starter
This signalsthe ECM when the engineis cranking.

Switch Signal

BATTERY

between Connectthe test harness the ECM and connectors {see p a g e1 1 - 4 5 )

ooooooooooooo oooooooooooo A26 (-t
NOTE: a M/T: Cluich pedal must be deoressed. o Ait: Transmission in @] or @ posltlon.

Measurevoltage between Bg (+) terminal and ,426 (-) terminal when the ignitionswitch in the start posrton.

ls there battery vollage ?

SIGNAL Insoect 2 STARTER No. (7.5 A) fus€ (in the und€r-dash fusefielav boxl.

wlr. b.Rap.i. opon In BLU/RED tw.sn ECM (B9l rnd t{o. 2 SIGNAL STARTER 17.5Al 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 depressingthe brake pedal?

Inapoct th6 br!k6 3wltch (!€o aoction 19).

Oo the brake lighB come on7

InspectSTOPHORN('l5 A) luse (in th€ under-hood Iuse/rel8y boxl.

Connect the t6st harnoss to the main wire harn€ssonlv, nottothe ECM (see page 11-45).

- Roprir op.n In WHT^'EL wlrc b.twoon bruks lwitch lnd STOP HOR[{ 115 A} tu!o. - Inrpgcl tho b'r6ko rwltch l!o. lection l9l.

( T op a g e1 1 - 1 0 7 1

( F r o mp a g e 1 1 - 1 0 6 )

Measure voltagebetweenD2 (+) lerminal and A26 (-) terminal with the brake oedal deDressed.

I

BAI-TERY VOLTAGE?

02 t+l

ls there bane.y voltage t

Roplir opon in GRII/WHT wlro betwoon th. brakq lwltch rnd ECM {D2t.

Br.k. .wilch lional i. OK.

11-107

ldle Control System
I TroubleshootingfFlowchart l ,uurEJl l ! ! t l , rl I I l g lt.,Yvvrrql

(PSP) Switch Signal PowerrSteeringPressure rvYYtEI

This signalsthe ECM when the power steeringload is high.
Inrp.clion ol PSP twltch Signal

ooooooooooooo
between Connectthe t€st harnes6 the ECM and connectors (see p a g e1 1 - 4 5 ) .

oooooooo

oooooooooooo oooQoooo

ooooooooooo oooooooooo

Tu.n tho ignilion swilch ON.

Moasurevoltage b€tween 88 {+} torminsland A26 (-l terminsl. Disconnect 2P connectorfrom the the PSPswitch. ls rhere more than 1.0 V?

Tum rtaaring whool slowly.

ls ther6 more than 1.0 V?

M66sure voltage betw66n BB (+) t6rminal and A26 {-} torminsl whilo stggring wheel is turning.

Repairopon in RED/GRN wir6 b6tw6on ECM (88) snd PSPswitch or BLK wir. bolwog.i PSP.wilch a n dG l O l .

ls there battery voltage?

PSP 3wirch slgnal i! OK.

Disconnect 2P conneclorfrom the the PSPswitch.

swtTcH

Measurevoltage between 88 {+ ) terminaland 426 l- l terminal.

ls there battery voltage?

wilo boRooairshon in RED/GRN twoon ECM {88) and P1SP switch. lI wire is OK, substituto a knowngood ECM and rochock. lf proscdbodvoltege ir now availabl6, roplace tho original ECM.

11-108

Fast ldle Thermo Valve
Description
To preventerraticrunningwhen the engineis warming up, it is necessary raisethe idls speed.The fast idle to thermo valve is controlledby a thermowax plunger. When the engineis cold, the enginecoolant surrounding the thermowax contractsthe plungef,allowingadditionalair to be bypassedinto the intake manifoldso thst the engineidlesfaster.When the enginereachesope.ating temperature,the valve closes.reducingthe amount of air bypassinginto the manitold.

lnspection
H23A1 engino(USA: Si/Canada: SR), H22Al 6ngin€ (USA: Si VTEC/Canada:SR-V) NOT€: The fast idle thermo valve is factory adiusted; it should not be disassembled. 1. Removethe intakeair duct from the throttle bodv. 2. 3. Stan the engine. Put your finger over the lower port in throttle body and makesurethat there is air flow with the engine cold {engine coolant temperature below 860F,

300c).

FAST IDLE THERMO VAIVE thermo valve and

12 .m (1.2 kg-m, 9 lb-ttl

4.

Warm up the engine (the radiatorfan comes on). Check that the valve is completelyclosed. lf not, air suctioncan be telt at the lower gort in the throttle body. a lf any suclion is felt, the valve is leaking.Check engine coolantlevelandforair in the engine cooling system (seesection 1O). lf OK, reDlacethe tast idle thermo vslve and recheck.

11-109

ldle Control System
Fast ldle Thermo Valve (cont'd)
F22A'l onginelS): NOTE: The tast idle thermo valve is factory adjusted; it should not be disassembled. 1. 2. 3. Removethe cover of the fast idle thermo valve. Start the engine. Put your fingeron the valveseat areaand makesure thst ther€ is 8ir flow with the enginecold {engine coolanttemperature below 86oF, 30oCl and idling.

Starting Air Valve
Description
the Whencranking engine,the startingair valvesuppliss additionalair to the intake maniJoldto ease engine starting.

I
i I
i

DIAPHRAGM

I
TO INTAKE MANIFOLD lf not, replacethe tast idle thermo valve and retest. 't2 N.m (1.2 ks-m.I lb-ttl
ADDITIONAL AIR FROM AIR CLEANER

4. 5.

radiatortan fan Warm up the engine (the radaator comes on). closed.lf not, air Checkthat the valveis completely suction can be {elt in the valve seat area. a It any suction is felt, the valve is leaking. Checkenginecoolantleveland for air in the engine coolingsystem (see section 'lO). It OK, replacethe fast idle thermo valve and recheck.

1 11 - 1 0

ldle Speed Setting
lnspection/Adjustment
NOTE: (Canada) Pull the parkingbrake lever up. Start the engine,then checkthat the headlights olf. are 1. Startthe engineand warm it up to normaloperating temperature(the radiatorfan comes on). Turn the ignitionswitch OFF. Connecta tachometer. Disconnect 2P connectorfrom the ldle Air Conthe Adjust the idle speed, if necessary, turning by the idle adjustingscrew. IOLEADJUSTING SCREW

2. 3. 4.

7 . Turn the ignirionswitch OFF. Reconnect 2P connectoron the IAC valve.then the (1OA) Iuse in the under-hood remove CLOCK RADIO fuse/relaybox tor 1O secondsto reset the ECM. Restartand idle the enginewith no-loadconditions for one minute, then check the idle speed. NOTE: {Canada)Pull the parking brake lever up. Start the engine,the checkthat the headlights are off. pedalslightly Start the enginewith the accelerator depressed. the rpm at 10O0,then slowly Stabilize releasethe pedal until the engineidles. Checkidlingin no-load conditions: headlights, blower fan, reardefogger,radiatorfan, and air conditioner are not operating. ldle speed should be; H23A1 engine (USA: Si/Canada: SRI: ldle speed shoul.dbe; H23A1 engine(USA: Si/Canada: SRI: M/T 7OO I 7OO 1 50 rpm 50 rpm {in @ or @ position)

H22Al engine (USA: Si VTEG/Canada: SR-V): 7OO 1 50 rpm F22Al engine {S}: Mfi AlT 7OO t 7O0 1 50 rpm 50 rpm (in S or @ position)

M/T
A/T

55O t 50 rpm 55O + 50 rpm {in S or @ position}

H22A1 engine {USA: Si VTEC/Canada: SR-V): 55O 1 50 rpm F22Al engine (Sl: M/T 55O I 550 t 50 rpm or @ position) (cont'd)

NT

50 rpm (in I

11-111

ldle Control System
ldle Speed Setting (cont'dl
1O. ldle the enginefor one minute with headlights{Hi} and rear defoggerON and check the idle speed, ldl€ speod should be; SR}: H23A1 engine {USA: Si/Canada:

M/T A/T

78O t

50 rpm or @ posirionl

78O 1 50 rpm {in S

SR-V): H22A1 ongino (USA: Si VTEC/Canada: 79O t 50 rpm F22Al engine {S): l\illT Afi 77O t 50 rpm

770 I 50 rpm (in S or E position)

1 1 .Turn the headlightsand rear defoggeroff. ldle the enginefor one minute with heatertan switch at Hl and air conditioneron, then check the idle speeo. ldlo speod should be;
I I

: ri ,

SRI: H23Al engin€ (USA: Si/Canads:

M/T NT

78O t 50 rpm

78O t 50 rpm (inI

or E position)

SR-VI: H22A1 engin€ (USA: Si VTEC/Canada: 79O 1 50 rpm F22A1 engina (S): M/T 77O i 50 rpm

NT

770 t 50 rpm lin S or @ Fosition)

NOTE: lf the idle speedis not within specification, Guideon page 1'l-92. see SystemTroubleshooting

11-112
t

FuelSupply System
System TroubleshootingGuide
NOTE; Across each row in the chart,the sub-systems that could be sourcesof a symptom are rankedin the orderthey shouldbe inspectedstartingwith O. Findthe symptom in the left column,read acrossto the most likelysource,then referto the page listedat the top of that column.It inspection shows the systemis OK, try the next most likelysystem !), etc.

PAGE

SU8-SYSTEM

------SYMPTOM ENGINE WON'T START OIFFICULT STARTENGINE TO WHEN COLD HOT OR ROUGH IDL€ MISFIFE OR ROUGH RUNNING FAILS POOR PERFORMANCE EMTSStON

FUEL FUEL FUEI. PRESSURE FILTER INJECTOF REGULATOR
116

FUEL PUI\4P 124

PGM-FI MAIN RELAY

coNTAtrl NATED FUEL

122

123

126

*

@

o

@

o

o
O
@ @ @

@ @

o

Loss 0F
POWER WHILE WARMING UP AFTEF WARMING UP

o
o e

@

@

FREOU€NT STALLING

Fuel with din, water or a high percentage atcoholis considered of contaminated.

11-113

Fuel Supply System
System Description
The tuel supplysystem consistsof a Jueltank, in-tank high pressure fuel pump, PGM-Flmain relay,fuel filter, fuel pressure regulator,fuel injectors,injectorresistor, and Juel deliveryand return pipes and hoses. fuel This systemdeliverspressure-regulated to the fuel iniectorsand cuts the fuel deliverywhen the engineis not running.

FuelPressure
Relieving

@ a

Do not smoke while working on the fu6l syst€m. Keep open llames or sparks away ftom your work alea. a Be sure to relieveluel pressulewhile the €ngins is off.

NOTE: Beforedisconnectingluel pipes or hoses,release pressure the 6 mm servfrom the system by loosening ice bolt on top of the fuel rail. 1. Disconnect batterynegative the cablefrom the battery negativeterminal. NOTE: The radiomay havea codedthett protection circuit. Be sure you get the customer'scode number before disconnecting the battery cable. 2. 3. Removethe fuel fill caD. Use a box end wrench on the 6 mm servicebolt at the fuel rail,while holding special the banjobolt with anotherwrench. Placea rag or shop towel over the 6 mm servicebolt. Slowly loosenthe 6 mm servicebolt one complete turn.
12 N.m {1.2 kg-m, 9 lb-ft)

4. 5.

NOTE: gaugecan be attachedat the 6 a A fuel pressure mm servicebolt hole. a Always replace the washerbetweenthe service bolt and the specialbanjobolt, wheneverthe service bolt is loosened. a Replace all washers whenever the bolts are removed.

11-114

Inspection
( 1 . R e l i e v eu e l p r e s s u r es e ep a g e 1 1 - 1 1 4 1 . f 2. Removethe servicebolt on the fuel rail while holding the banjobolt with anotherwrench. Attach the tuel pressuregauge. Start the engine. *Measurethe fuel pressure with the engineidlingand vacuumhose ot the fuel pressure regulatordisconnected from the fuel pressure regulatorand pinched. Plessur€ should be; H23A1 ongine (USA: Si/Canada: SR), F22Al engine (S): 2 5 5 - 3 O 5 k P a( 2 . 5 5 - 3 . O 5 k g / c m 2 , 3 6 - 4 3 p s i ) H22A1 engine (USA: Si VTEC/Canada: SR_V): 23O-2AO kPa 12.3-2.8 kg/cmr. 33-4O psi) 4. Reconnect vacuum hose to the fuel Dressure regulator. Pr€ssureshould b€: H23Al engine (USA: Si/Canada: SR). F22A1 ongine (S): 195-245 kPa (1.95-2.45 kg/cm2,28-35

a lf the fuel pressure not as specified. is first checkthe fuel pump(seepage1 1-125).lf the pumpis OK, check the following: lf the fuel pressure higherthan specified. is inspect loti a Pinchedor cloggedJuel return hose or pipe. a Faultyfuel pressure regulstor {seepage 11-1221, lf the fuel pressure lower than specifiedinspect, is for: a Cloggedfuel filter. a Faultyfuel pressure regulator {seep age 11-1221, a Leakagein the tuel pipes or hoses.

3.

-

psi)

H22A1 engine (USA: Si VTEC/Canada: SR-V): -2.2 kg/cmr. 24-31 psi) 17O-22O kPs 11.7

PRESSURE REGULATOR ': lf the engine will not stan, turn the ignition switch on, wait for two seconds,turn it otf then back on again and read the iuel pressure.

11-115

Fuel Supply System
Fuel lnjectors
Flowchart Troubleshooting
Troublecode (DTc) 16: A problemin The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic the Fuel Injectorcircuit. The Fuel Iniectors are a solenoid-actuatedconstant-stroke pintle type consisting ol a solenoid, plunger needle valve and the tuel coil, the valve lifts up and pressurized is injected.Because neeto When currentis applied the solenoid housing. by pressure constant,the injectionquantityis determined the lengthof time that the valvo are dle valve liJtand the fuel to is open (i.e.,the durationthe current is supplied the solenoidcoil).The FuelIniectoris sealedby an O-ting and seal ring at the top and bottom. These sealsalso reduceoperatingnoise.

PLUNGER

SEAL BII{G

- __l=-

-

\.__.,:_

/

FUEL INJECTOR INSULATOR

-tFJ- ;ull:
- Th6 MIL has boonrooortodon. - With sorvice chock conncctor iumpod {s6€pago 11421, codo 'l6 is indicatod.

(see Do the ECM ResetProcedure p a g e1 1 - 4 3 ) .

NOTE:lf enginewill not start, it may take to 10 seconds cranking set the code. of Into.mittent lailuro, 3yst6m ir OK at this tim€ (to3t drivo moy bs nocossary). Chock fo. Door connoctiona ot looso wires at C433, C425 llocatod ar right shock towotl, C1O2, ClO3, ClO4, C1O5 (tuel ini.ctoBl, Cl07 {iniocto. r€isto.), and ECM.

ls the MIL on and does it indi cate code 16?

'1-1 (To page '1 171

11-116
r f

2P CONNECTOR Starl engingand lislenai 6ach luel injector a clicking ror sound.

Turn the ignitionswitch OFF.

Disconnect 2P connectorfrom the the fuel injector that dogs not click.

Measure rgsistancebetween the 2 terminals of luol injector.

l s t h e r e1 . 5 - 2 . 5 O ?

Ropl.c. th6 tu.l ini€ctor/inioctor! thlt aro not 1.5-2.5 O.

FUEL IITJECTOB

Turn the ignition switch ON.

Measuro voltaoebetweenREO/ 8LK { + } terminalin rhe 2P conngctorand body ground.

Tu.n tho ignition switch OFF.

Turn the ignitionswitch ON.

Measure voltsge between YEL/ BLK {+) terminal and body ground.

(To page 1 1-118)

{To page 1 1-l 18)

11-117

Fuel Supply System
Fuel Injectors(cont'dl
{Frompage 1 1-'l17} ( F r o mp a g e 1 1 - 11 7 ) Rgpair op6n in tho YEL/BLKwire botws6n the inioctor resistot and tho PGM-FImain ,olaY. Testthe injectorresistor(seepage 11-1211.

Reconnect the 2P connector to the tuel iniector. B€pair op6n RED/BLK wiro botwe€n lhe 2P connocto. end inioctor roaistor.

Turn the ignitionswitch OFF.

Connectthe test harnessbetwoen the ECM and connectors (see p a g e1 1 - 4 5 ) .

Turn the ignitionswitch ON.

Measure voltage between A23 {-) terminal and following termrnal: . No. 1 tuel iniector: A1 {+) terminal. . No. 2 fuel iniector: A3 (t)terminal. . No. 3 fuel injector: A5 {+ | terminal. . No. 4 tuel injector: 42 {+) terminal.

13. rott.*t
A 1 { + } lA 5 l + )

$Li6iiitl'-oooooooooo oooooooo

oooooooooooo oooooooo

ooo ooo ooooo ooooooooooo

ls there battery voltage?

Ropairop6n in tha wire batwoon the ECM(A1, A3, A5 or A2) and tho luol inioctor.

Substilute a known-good ECM and rechock. ll symptom/indication goos away, roplacetho origi nal ECM.

11-118

Replacoment
@@
l

oo not smoke when working on tha fuel system. Keep open llam6s away from your wolk a.sa,

Relieve fuel pressure(see page 11-114).

2 . Disconnect connectorsfrom the fuel injectorsand IAC valve. the
Disconnect vacuumhose trom the fuel pressure the regulator and EGRvalve,and the luel returnhosefrom the fuel pressureregulator. NOTE: Placea rag or shop towel over the hoses before disconnecting them. 4. 5. 6. 7. Disconnect the tuel hose from the fuel rail. Loosenthe retainernuts on the fuel rail and harnessholder. Disconnect the PCV valve and fuel rail. Removethe fuel injectorstrom the intake manifold.

SEALING WASHER Replsc6.

00
00

CUSHION RING Replace.

8. 9.

Slidenew cushionrings onto the fuel injectors. Coat new O-ringswith clean engineoil and put them on the fuel injectors.

1O. Insertthe fuel iniectorsinto the fuel rail first. 'I 1. Coat new seal rings with clean engineoil and press them into the intake maniforo. (cont'd)

11-119

Fuel Supply System
Fuel Injectors lcont'dl
12. lnstallthe tuel injectorsand fuel rail assemblyin the manifold' CAUTION: a To prevent damag€ to ths O{ings, install the lu€l inioctors In th€ fuol rall first. then inslall th€m in tho intaks manifold.

FUEL RAIL

13. Align the center line on the connectorwith the mark on the Juel rail. '14, Install and tighten the retainernuts. 15. Connectthe Juel hose to the fuel rail with new washers. 16. Connectthe vacuumhoseto the tuel pressure regulator and EGRvalve,and the fuel returnhoseto the tuel pressure regulator. 17. Installthe connectorson the fuel injectorsand IAC valve. the 6 mm servicebolt washer and tighten the bolt. 18. Replace two seconds, 19. Turnthe ignitionswitch ON. but do not operatethe starter.After the fuel pump runsfor approximately in this two or three times, then check whetherthere is any tuel leakage. the luel pressure the fuel line rises.Repeat

11-120

InjectorResistor
Description
The resistorlowersthe currentsupplied the fuel to injectorsto preventdamageto the fuel injectorcoils. This allows a faster responsetime of the fuel inrectors,

Testing
1. 2. Disconnectthe injectorresistorconnector. Check for resistance between each of the inisctor resistor terminals D, C 8nd B) and the power t€r{E, minal (A). Resistance should be: 5-7 O

LLLLL

FUEL a Replace injectorresistorwith a new one if any the of the resistances outsideof the sDecification. are

11-121

Fuel Supply System
Fuel PressureRegulatol
Description
The fuel pressureregulatormaintainsa constant fuel pressure the fuel injectors.When the differencebeto exceeds and manifoldpressure tween the luel pressure is 300 kpa (3.0 kg/cm' , 43 psi), the diaphragm pushed uDward,and the excessfuel is fed back into the fuel tank through the return line. CLOSE INTAKE MANIFOLD VACUUM

Testing
Do not smok€durlngtho test. K€ap Iry opan flamesaway lrom your work area.
gaugeto the serviceport of 1 . Attach a fuel pressure t h e f u e l r a i l ( s e ep a g e 1 1 - 1 1 5 ) . Pressurs should be; SR), H23A1 engino (USA: Si/Canada: F22A1 engino (S): 255-3O5 kPa (2.55-3.05 kg/cm2,36-43 psi) H22Al engino (USA: Si WEC/Canada:SR-VI: 23o-2ao kPa (2.3-2.8 kg/cm2.33-4o psil {with the fu6l pressuro logulator vacuum hose disconnectod and pinchedl

INTAKE MANIFOLD VACUUM

DIAPHRAGM

REGULATOR PRESSURE 2. Reconnect the vacuum hose to the fuel ptessure regulator. rises when the vacuCheck that the fuel Dressure is regulator disconum hose from the tuel pressure nected again. lf the fuel pressuredid not rise, replacethe fuel pressure regulalor.

ar t FUEL \INLET

3.

FUELRETURN

11-122

Fuel Filter
Replacement E@ oo not smok6 whilewolking fuelsyson
t€m. Keep open flame arvay from yout work area. 1. Placea shop towel unde. the tuel pressure regulator, then relievefuel pressure(see page 1l-114). 2. 3. Disconnect the vacuum hose and fuel returnhose. Removethe two 6 mm mounting bolts.
O,RING Replace

Replacement
oo not amoko whib working on fuol sys@ tem. Kesp open flame away ftom yout wolk atea. The fuel filter should be replacedevery 4 yea.s or 60.OOO miles(96,000 kml, whichevercomesfirst or whenever the fuel pressure drops below the specifiedvalue IH23A1 e n g i n e ,F 2 2 4 1 e n g i n e :2 5 5 - 3 O 5 k P a , 2 . S 5 - 3 . 0 s kg/cm' , 36-43 psi (H22A1 engine: 23O-280 kpa, 2.3-2.8 kg/cm2,33-40 psi) with the fuel pressure regulato. vacuumhosedisconnected and pinchedlafter making sure that the fuel pump and the fuel pressure regulatorare OK. 1. 2, 3. Placea shop towel under and aroundthe fuel rail. R e l i e v eu e l p r e s s u r es e ep a g e 1 1 - 1 ' 1 4 ) . ( f Remove the 12 mm banjobolt and the fuel feed pipe trom the fuel filter. Removethe fuel Jilterclamp and fuel filter. When assembling, use new washers,as shown. 28 N.m (2.8 ks-m,20 lb-ft) FUEL PRESSURE REGULATOR

VACUUM HOSE

4. 5.

NOTE: a Replace the O-ring. a Whenassembling fuel pressure the regulator, apply clean engineoil to the O-ringand assemble it into its proper position, taking care not to damagethe O-ring.

NOTE; Cleanthe flaredjoint of high pressure hoses thoroughlybefore reconnecting them.

11-123

Fuel Supply System
Fuel Pump
Description
savingspaceand simplifyinsidethe tuel tank. therebY design,the iuel pump is installed of Because its compactimpeller ing the fuel line system.

FUEL PUMP CROSS SECTION(Side vtew) rFrrFFvar VALVE RELIEF vF FUEL COVER PUMP

FUEL pUMp CROSS SECTION(ToD viowl
DISCHARGEPORT

,
IMPEI.LER

POBr rNrET

CASING

VALVE CHECK COIL ARMATUBE

GROOVES
CASING FUEL PUWIP

IMPELLER

the flow pump,a telietvalvetor protecting fuel linesystems, of The fuel pumpis comprised a DC motor, a circumterence port. The fuel pump assemblyconsistsof an check valve for retainingresidualpressure, inlet port, and a discharge a pumpingchamber), and the fuel pump cove,. the imoeller(drivenby the motorl, the fuel pump casing{which forms the OPERATION "o telaYactuatesthe fuel pump' and the motor turns tlle impeller' (1) When the engineis stsrted, the PGM-FImain relav actrrates by pressureis generated the numerousgroovesaroundthe impeller' Differential (2) Fuetenteringthe inlet port flows insidethe motor from the pumpingchambefand is torced throlgh the dischargo side of the fuel line, the reliefvalve will open oort via the check valve. lf fuel Jlow is obstructedat the discharges the fuel to the inlet port and prevent excessive fuel pressure' to bypass However,a checkvalveclosesby springactionto retain (3) Whe; the enginestops,the fueipump stops automatically. to restart more easily' in the residualpressure the line. helpingthe engine

11-124

Testing
Do not smokeduringthe test. Ke€popon E@E flame away from your work area,
lf you suspecta problemwith the fuel pump,checkthat the tuel pump actuallyruns;when it is ON, you will hear somenoiseif you holdyour ea. nearthe tuel till port with the fuel fill cap removed.The fuel pump shouldrun for two secondswhen the ignitionswitch is first turnedon. lf there is no noiseat the fuel fill port, check as follows; 1. Removethe accessDanelin trunK,

Replacement @@l
tam. Ke€p open flsmes away ttom yout wotk area. 1 . R e l i e v eu e l p r e s s u r es e ep a g e 1 1 - 1 1 4 ) . ( f 2. 3. 4. 5. Removethe accesspanel in t.unk. Disconnect the 2P connectorJrom the tuel pump. Removethe fuel pump mountingnuts. Removethe tuel pump from the fuel tank.
6 N.m (O.6 kg-m, 4 tb-ftl

Donot smoke whilowolking fuetsyson

CAUTION: B€ sure to turn tha ignition switch OFF betore disconnecting tho wiles. 2.
?

Disconnect the 2P connectorDisconnectthe PGM-Ftmain relay conneclor and connect the BLK/YEL wire and yEL @ wirc with @ a jumper wire.

FUELPUMPUNIT

\< \ ..-\

pcm-H
MA|N

I
28 N.m (2.8 kg-m, 20 tb-ftI

BLK/ YELG)

JUMPER 'WIRE

YEL€)

Check that battery voltage is available the fuel at pump connectorwhen the ignitionswitch is turned ON (positive probeto the yEL wire, negativeprobe to the BLK wire).

YEL +} { lf battery voltage is available,replacethe fuel
DUMO.

lf there is no voltage, check the fuel pump grouno and wire harness(see page 1j- 128).

11-125

Fuel Supply System
Main Relay PGM-FI
Descdption
main relayactuallycontainstwo individual The PGM-Fl retavs. The relay is located at the left side of the cowl. the ignitionis on which whenever One relayis energized supplies the battery voltage to the ECM, power to the fuel injectors,and power for the secondrelay. The second r€lay is energizedlor 2 seconds when the ignitionis switched on, and when the engineis running which suppliespowet to the fuel pump.

Relay Testing
NOTE: lf the car starts and continues to run, the PGM-FImain relay is OK 1. 2. Removethe PGM-Flmain relay. Attach the b8ttery positivete.minalto the No' 6 terminal and the batt8ry negativeterminalto the No. main relay.Then checktot I terminalof ths PGM-Fl the No. 5 terminal 8nd No' 7 tetcontinuity between minal of the PGM-FImain r€laY. a It there is continuity.go on to step 3. a ll there is no continuity, replacethe relay and

FGM.FI MAIN RELAY

TO IGN.1

TO 8AT C)

TO GROUND

to EcM (A25,Btl

TO ST. SWTTCH

TO ECM{A7, 8} 3.

TO FUELPUMP

Attach the battery positive terminal to the No' 5 tsrminal and the battery negative terminal to the No. 2 terminslof the PGM-Flmain relav.Then check that there is continuitybetweenthe No. 1 terminal8nd No. 3 terminalot the PGM-FImain relay. a lf there is continuity, go on to step 4. a lf there is no continuity, replacethe relay and relesl.

4.

Aftach the baftery positive terminal to the No. 3 terminal and the batterY negative terminsl to the No. 8 terminalof the PGM-Flmain relav. Then check that there is continuitv between the No. 5 terminsl and No. 7 terminalof the PGM-Flmain relay' a lf there is continuity,the relay is OK. a lf there is no continuity, replacethe relay and retesl (cont'dl

11-126
! t

FuelSupplySystem
PGM-FlMain Relay(cont'd
Flowchart Troubleshooting
- Engino will not 3tan. - InlDcction ot PGM-FI rclay.

Check for continuitY between BLK terminal @ and bodY ground. Ropairopon in 8LK wirc b6tw.en PGM-FImain relay and GlOl {locatod at th6amostot housing).

Measure the voltage between YEL/BLU terminal O and bodv gtouno. - Roplace tho No. 4 BACK UP {10 Al tu36 {in tho undordash fu3o/rolay borl. - Ropoir op6n in rho YEL/BLU wire b€tweon tho NiM-Fl rnain relay and ths No. 4 BACK uP {10 Al lu8o.

ls there battery voltage?

Turn the ignitionswitch ON.

Measure the voltago between BLK/YEL terminal @ and body glouno, - Roolaco th. ECUIECMI {15 A} tuis {in tho und6r{eh tut /rolay boxl. - R6pai opgn In tho BLK/YEK wiro b€tween d|o FGM-FI tnein r6laYand tho Ecu (ECM) {15 Al fu3e.

PGM-FI MAIN RELAY

ls there battery voltage?

Turn the ignition swilch to the START position.

Measure the voltage betw€en terrninal@ and body BLU/RED ground.

NOTE: . M/T: Clutch pedal must be depressed. in a A/T: transmission I n I or [E position.

BLK @

ls there baltery voltage?

- Replaco lhc No. 2 STARTER SIGNAL {7.5 A} furo lin tho undor-dashf uso/ralay borl. - B.p.ir op.n in tho BLU/RED wiro b.twoon th6 FGM-FI rtain r6lay .nd lh. ignition twitch

(sr).

BLK€)

YEL€)

( T op s g e I ' l - 1 2 9 )

11-128

11.12Al Turn the ignitionswitch OFF.

Connectthe test harnessbetwgen the ECM and connectors. Disconnoct "A" connector from the ECMonlv, not the main wire harness(see page 11-451.

Check tor continuity between GRN/BLK terminal @ and rhe followingterminals; A7. A8.

R6palropen in GRN/BLKwlr. b€twoon ECM lA7, A8l and PGM-FI main rohy.

Turn the ignitionswirch ON.

Measure the voltage between 423 1-) terminaland the tollowing terminals: A25 (+) 81 lf). R.pair opon in tho YEL/BLKO rvi 6 botwoon th. ECM (A25, 811 lnd PGM-FIh.in iohy. R.pl.c. PGM-FImain r6lay.

ls there battery vokage?

Turn lhe ignilion switch OFF.

o o o o o o o o o o o o o o ooooooo lfitoHruffs{sl ooo ooooo ooo o oooo ooooo ooo I oo oooo oo ooooooooooo
Connect a voltmeter between A7 l+l te.minal and A23 l-) rer mtnat.

ls there batt€ry voltage tor lwo seconds when the ignition switch is first tu.ned on?

Subrtltulc 6 known-good ECM and raatrock. ll p.eacriH voltago b now svail.Hg, rgf aco tho original ECM.

Chock th. PGM-FI mlin r.l6y (.eo pag. l1-126).

1-1 29

FuelSupplySystem
FuelTank
Replacement
@ 1. 2. 3. 4. Do not smoke while working on fuel syst€m. Keep open llame away from your work area.

Ir

Block front wheels. Jack up the rear of the car and supportwith jackstands. Removethe drain bolt and drain the fuel into an aoorovedcontainer, Removethe accesspanel. Disconnect from the fuel gaugesendingunit and the fuel pump,then removethe fuel feed line and the connectors return hose. CAUTION: Be sur€ to turn the ignition switch OFF before disconnecting the wires.

5. Removethe fuel hose protectors. 6. Oisconnect the hoses. CAUTION: Whon disconnocting the hos6s. slide back ths clamps, then twist hosos as you pull to avoid damaglng them. 7. Placea iack, or other support,underthe tank. 8. Removethe strap bolts and nuts. and let the strapsfall free. 9. Removethe fuel tank, NOTE: The tank may stick on the undercoatappliedto its mount. To remove,caretullypry it off the mount. 1O. lnstalla new washer on the drain bolt and the fuel pump line, th€n installpans in the reverseorderol removal.

ks-m.28 lb-ft| 38 N m 13.8 CAUTION: Cloanthe flared ioint of high prossu.oho8e3 thloughly botoro .oconnecting thom.
FUEL PUMP GAUGE SENOINGUNIT FUELTANK WASHER R€place DRAII{ BOLT 50 N.m (5.o kg-m, 36 lb-tt)

3a N.m (3.8 ks-m. 28 lb-ft|

11-130

Intake Air System
System TroubleshootingGuide
NOTE: Acrosseach row in the chan, the sub-systems that could be sourcesof a symptomare rankedin the orderthev shouldbe inspectedstartingwith O. Findthe symptom in the left column, read acrossto the most likelysource,then refer to the page listed at the top of the column. lf inspectionshows the system is OK, try the next system @, etc.

SYMPTOM WHEN COLD FAST IDLEOUT OF SPEC W H E NW A R M I D L ET O O H I G H LOSSOF POWER *: Except F224 1-engine{S)

11-131

Intake Air System
System Description
(ACL).intakeair pipe, intakeair duct, Throttle The systemsupplies lor all engineneeds.lt consistsof the Air Cleaner air *intakecontrol Bodv {TB},ldle Air Control(lAC)Valve,tast idlethermo valve, *lntake Air Bypass(lAB)ControlSystem, additional silencing air is drawn intothe system. as in A system,and intakemanifold. resonator the intakeair pipeprovides *: Except F22A1 engine (S)

.IAB CONTROL SOLENOID VALVE

.tA8 VACUUM TANK

?!t'----_'o ECU|ECM){'r5 A' FUSE Xll'----'oPGM.FIMAINRELAY
VARIOUS SENSORS INTAKE AIR DUCT
r|AB CONTROL DIAPHRAGM

BODY :II{TAKE
CONTROL SOLENOID VALVE

FAST IOLE THERMO VALVE

SLK/ YEL WHT

(15 . TO ECU{ECM} AI - FUSE
RESOI{ATOR

INTAKE AIR PIPE

.If{TAKE CONTROL CHECK VALVE

-1 32

Air Cleaner{ACL}
Air Cl6anel (ACL) Element Raplacemont

ACL HOUSINGCOVER

ACL HOUSING

ACL EL€MENT Roplac€€very 3O,OOO miles (48,OO0 kml or 24 months. 'l5.OOO Cleanair cleanerelementeverv (24,OOO mil6s kml or 12 months under conditions, rough or muddv roads.

INTAKE AIR DUCT

11-133

Intake Air System
Intake Control System [Except F22A1 engine (S)l
Description
The intake control svstem decreases intake noise. air

INTAKE CONTROISOLENOIDVALVE

BLK/ ------? - TO ECU (ECMIll5 Al FusE YEL

II{TAKE CONTROL

VACUUMT
INTAKE CONTROL CHECKVALVE

BLK

I =

I

RESONATOR

When the engine speed is below 4,OO0rpm, the ECM provides ground for the intako control solenoid valv6. This opens the solenoidvalve sendingintake manifoldvacuum to the intake control diaphragm.

11-134

Troubleshooting Flowchart

VACUUMPUMP/GAUGE -XXXXX A973X-O41

AKE CONTROL SoLENOTO VALVE

St.n onginernd allow to idle.

Remove the #8 vacuum hos6 from the hose joint and connect a vacuum gaug€ to the solenoid

Oisconnect lhe lower vacuum hos€ofthe solonoidvalv6from the air chamb6r and connecl a vacuum gau96 to th€ hos6. Chcck tho v.cuum lina tor profEr conn6ctlon, crack!, blockrg! or dtr;onn*tod ho!o. Closn manltold m.t. Disconnect th€ 2P connector from the intake control solehoid

Measurs votiag€ botwson BLK/ YEL (+ l terminaland WHT (- ) tornanal.

INTAKE
CONTROL SOLENOID VALVE

ls there battery vollag€?

R.pl.co th. Intlko control aobndd volve.

Measure voltage betwe€n BLK/ YEL {+l torminal and body ground.

{To page 11-136)

(To page 1 1-136)

(cont'dl

11-135

Intake Air System
Intake Control System lExcept F22A1 engine (S)l {cont'd}
{ F r o mp a g o1 1 - 1 3 5 } lFrom psge 1 1 - 1 3 5 ) Ropairopoo in BLK|/EL wi.o botwoon tho 2P connoctor and ECU (ECMI (15 Al tuso lin tho undo.-dsshfus€/r6l6y box).

ls there battery voltage?

Turn the ignirionswitch OFF.

Connectthe test harnessbetween the ECM and connectors (see page 1 1-45). Turn the ionition switch ON. Connect a jumper wire between A19 terminaland A26 terminal.

Ropair opon in WHT wiro betwoon ECM lA19) and tho 2P connectot.

Substituto s known-good ECM and .ochock. lf symptom/indication goos away, replgceth6 odginal ECM.

Turn the ignilion swilch OFF.

Check for continuity to ground

(To pago 1 1 - ' t 3 7 ) { T o p a g e1 1 ' 1 3 7 )

11-136

(Frompage 11-136)

lFrom psge 1 1-136)

R6pai. ahort lo ground in WHT wira b6tw€en ECM {A19).nd rhe 2P connoctot.

Subltitute a known-good ECM and rechock. lf symptom goaa away, .oplaco tho originsl ECM.

Connect a vacuum pump to the #8 vacuum hose.

Does it hold vacuumT

Chack dr€ vecuum line for propor connaction oa diaconnected noaa. lf OK. '.plac6 tho inllk. control dl.phrlgm.

l aha contol ayatam b OK,

11-137

Intake Air System
Throttle Cable
Inspection/Adjustment
1. Warm up the engineto normaloperating temperature (the radiatorfan comes on). 2. Check that the throttle cable operates smoothly with no bindingor sticking.Repairas necessary. Checkcablefree play at the throttle linkage.Cable d e f l e c t i o n h o u l db e 1 O - 1 2 m m ( O . 3 9 - 0 . 4 7 i n . ) s

lnstallation
1. Fully open the throttle valve,then installthe throttle cablein the throttle linkageand installthe cable housingin the cable bracket. Warm up the engine10 normaloperatinqtemp€rature (the radiatortan comes on).

2.

3.

2

DEFLECTION 10- 12 mm 1O.39-O.47 in.)

Hold the cable sheath. removingall slack from the cable. Turnthe adiusting untilit is 3 mm (0.12 in.)away nut from the cable bracket. Tightenthe locknut. The csbledetlectionshouldnow b e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . ) .l f n o t ,s e ei n s p e c tion/adjustment.
CABLE ARACKET

It deflection not within specs,loosenthe locknut. is turn the adjusting untilthe deflection as specinut is fied, then retightenthe locknut, 5 . With the cableproperly adjusted, checkthe throttle valve to be sure it opens fully when you push the accelerator to Dedal the tloor. Also checkthe throttle valve to be sure it returnsto the idle position pedal. wheneveryou releasethe accelerator

38

Throttle Body
Description
type. The throttls body is ot the single-barrel side-dratt The lower portion oJ the throttle valve is heated by engine coolant which is fed from the cylinder head.The idle bypass 8ir adjustingscrew which increases/decreases Emission and the EvaDorative {EVAP)ControlCsnister port are locatedon the top ot the throttle body.
IDLEADJUSTING SCREW

Inspection
CAUTION: Do not adiust the throttls stop screw, It i3 presot at tho tactory. 1. Stan the engineand allow it to reachnormaloper ating temperature(the radiatorfan comes on). 2. ' contro Disconnect the vacuum hose (to the EVAPc o n t r o l trom the top of the throttle body; connec canister) connect I vacuum gaugeto the throttle body.

VACUUM PUMP/GAUGE A973X-04t -XXXXX

\

3 . Allow the engineto idle and check that the gauge
indicatesno vacuum. a lf there is vacuum,check the throttle cable (see p a g e11 - 1 3 8 ) . 4. Checkthat vacuumis indicated the gaugewhen on the throttle is op€nedslightlyfrom idle. a lf the gauge indicates no vacuum, check the throttle body port. ll the throttle body port is clogged,cloan it with carburetorcleaner. Stop the engine and check that the throttle cable operatessmoothly without bindingor sticking. a It there are any abnormalities the abovesteps, in check for: - Excessivewear or play in the throttle valve sh8tt. - Sticky or binding throttle lever at full close position. - Clearance between throttle stop screw and throttle lev€r at full close oosition,

11 - 1 3 9

Intake Air System
Throttle Body (cont'd)
THROTTLE LEVER

There should be no clearance.

THROTTLE STOPSCREW (Non-adiustable)

play in the Replace throttlebody if there is excessive the throttle valve shatt or if the shatt is bindingor sticking.

11-140

Throttle Body
Disassembly

GASKET Rgplaco

THROTTLE CABLE

(2.2 kg-m, 16 lb-ft}

A/T THROTTLE CONTROL CABLE

11-141

r
Intake Air System
Throttle Body (cont'd)
a The throttle stop scr€w is non-adiustable, a Aftd rrllrombly. adiust tho throftle cabl€ {seo pag6 'l 1-138}. and A/T throttlo control cable (s66 section 141tor cars l whh A/T. F22A1 angine (S):

IDLEADJUSTING SCREW

H23Al €ngino (USAr Si/Can8d8: SR), H22Al engine (USA: Si VTEC/Csnada: SR-VI:

FAST IDLETHEBMO VAVLE pago1'l-110 Inspection,

('1.2kg-m, 9 lb-lt)

11-142

lntake Air Bypass (lABl Control System fExcept F22A1 engi,ne(Sll
Description
Two air intake paths are providedin the intake manifoldto allow the selectionof the intake path most tavorablefor a given enginespeed. Optimum perlormance at any RPM is achieved by c\osing and opening the \ntake Air ByDass(tA,Bl\ratves. High torque at low RPM is acheivedwhen the IAB valves are closed, whereashigh powe, at high RPM is achievedwh€n the IAB valves are ooened.

tA8 CHECK VALVE

IAB CONTROL DIAPHRAGM

9i['-_-------> I$.i"u

(15 tEcM] A]

tA8 CONTROL SOLENOID VALVE

IAB VACUUMTANK
VARIOUS SENSORS

IAB CONTROLSOLENOIDVALVE OFF

ET{GINE RPM IS ABOVE 4,800 rpm (H23A1 onginel or 4,600 .pm (ll22Al €nginol

(cont'd)

11-143

IntakeAir System
(lABlGontrol System F2241engine (cont'd)lntakeAir Bypass [Except {S}]
Troubleshooting Flowchart
In.poction ot IAB Control Sy.t.m #13 VACUUM HOSE

COI{TROLDIAP}IRAGM

Stan ongino lnd allow to idl€.

Remove # vacuum hose trom the lAg control diaphragm €hd connecl vacuum gauge to th6 nose,

'l3

VACUUM PUMP/GAUGE A973X-O4t-XXXXX

/f

Disconnect 2P connectorfrom the the IAB control sol€noid valve.

Measure voltagg between BLK/ YEL (+) terminaland PNK (-) terminal.

IAB COI{TROL SoLENO|O VATVE

' t
I

I

I I
I I I I

Pl{K

ls tho.o banory vohrgo ?

Rcp.lr th. block.g. or vlcuu|n lark bltwaan lh. intlk€ m.ntlold .nd d!ph.!gm, it vrqrxn l! OK, r.pl.c. the IAB contrcl lolcnold vllva.

Matturu voh.ge b€twe€n BLK/ YEL (+) t.rmin.l and bodv gaouno, R.p.lr op.r| in BLK|rEL wlre bctwaon th! 2P connaclor lnd ECU IECMI (15 Al tur. {ln tha undardrah lura/.chy boxl.

13there bancry vohage ?

Turn the €nrtion swilch OFF.

(To page 1 1-145)

(To page 1 'l-145)

11-144

(Frompage 1 1-1441

{Ffom page 1 1-144)

Reconnect the 2P connector to the IAB control solenoid valve.

Connect the tost harness to the mainwire harness only {seepage 11 - 4 5 ) .

Turn the ignitionswitch ON and connect a jumper wiro between A17 terminaland A26 torminal.

Does the solenoid valve click

Rop.ir opon in P K wlro botwoon ECM {A17) ond tho 2P conn€ctor. lf tho wiie i. OK, ,oDlac6. th6 IAB cootol 8olongid

Substhuto a known-good ECM and .echack. lf proacriH vohlgo i3 now sveilabloroplacetho originll ECM.

Disconnect 2P connectorfrom the the IAB controisol€noidvalve.

Turn the ignilion swatchOFF.

Check for continuity to ground on rhe PNK wire. IAB control syrtom i! OK. Ropair short to giound rt PNK wir6 b6twoen ECM {A17) and tho 2P conneclol. Substituts a known-good ECM and rachock. lt symptom goos away, rcplaco the original ECM.

11-145

Intake Air System
(lABlControl System Intake Bypass Air F22Al engine (cont'd} {S}l lExcept
IAB Valve Testing
CAUTION: Do not adjust the IAB valve full-close5c1€w. It was preset 8t the factory. 1. 2. 3. Check the IAB valve shaft for bindingor sticking, Check the IAB valve for smooth movement. With the engineOFF,ctreckthat @ of the bypass valve is in close contact with the stoDper.

4.

With the engine at idle, check that (9of the IAB valve is in close contact with the full-closescrew.

a ll sny fautt is found, cl€anthe linkagoand shafts with calbuistor clssner. still exists after cleaning,disassemlf the Droblem ble the intakemanifoldand check the IAB valve ( s e ep a g e 1 1 - 1 4 7 )

11-1 4 6

fntake Air Bypass (lAB) Control System lExcept F22A1 engine (S)l

22 N.m 12.2kg-m, 16

e s H lle s
E

22 N.m (2.2 kg-m,16 lb-ttl

IA8 VALVE

@ ^ ^
IAB tCONTROL

@-,rrn.^
{2.2 kg-m, 16 tb-frl

SOLENOIDVAI-VE

11-147

Intake Air System
fntake Manifold 1F22A1engine (S)l

e
22 N.m (2.2 kg-m.

16 rb.ftl

-l€9

HEn

g

@
* ^\,,^^

EmissionControl System
System TroubleshootingGuide
NOTE: Acrosseach row in the chan, the sub-systems that could be sourcesof a symptom a.e rankedin the orderthey should be inspectedstartingwith O. Find the symptom in the left column,read acrossto the most likelysource,then referto the pagelistedat the top of that column.It inspection shows the system is OK, try the next most likelysystem @. etc.

PAGE

SUB-SYSTEM THREE WAY
CATALYTIC CONVERTER

POSITIVE EXHAUSTGAS CRANKCASE RECIRCULATION VENTILATION SYSTEM SYSTEM
t55

EVAPORATIVE EMISSION CONTROLS 160

SYMPTOM

t 5 l

159

ROUGHIDLE

o
WARMINGUP MISFIRE OR ROUGH RUNNING

o

FREOUENT STALLING

o

o
o o
@ @ @

POOR PERFORMANCE

FAILS EMTSSTON TEST LOSSOF POWER

11-149

EmissionGontrol System
SystemDescription
The emissioncontrol system includesa Three Way Cata(TWC),Exhaust lytic Converter GasRecirculation IEGR) system, Postitive CrankcaseVentilation (PCV) system Emission(EVAP)control system. The and Evaporative emission controlsystemis designed meet federaland to state emissionstandards,

Tailpipe Emission
lnspection
Do not smoke during this procedure.Keep @ any open flame away ltom your wotk alea. 1. Start the engineand warm up to normaloperating by temperature driving on the road. Connect a tachometer. Check and adjustthe idle speed,if necessary(see p a g e1 1 - 1 1 1 ) . to the CO meter according Warm up and calibrate instructions. the meter manufacturer's heaterblower, Check idle CO with lhe headlights, rea. window defogger,coolingfan. and air conditioner oft. CO meter should indicateO.1 % maximum,-

11-150

ThreeWay CatalyticConverter(TWC)
Description
The ThreeW8y CatalyticConverter(TWC) is used to convert hydrocarbons (HC),carbon monoxide(CO),and oxides of nitrogen(Nox) in the exhaustgas to carbon dioxide {co2), dinitrogen(N2)and water vapor.

HOUSING

WAY THREE CATALYST

FROI{TOF VEHICLE

11 - 1 5 1

EmissionControl System
Three Way Catalytic Converter (TWC) (cont'd)
Inspection
lf sxcessiveexhaust systgm back-pressureis suspected, .emove the TWC from the car and make a visual check for plugging, meltingor crackingof the cstalyst. Replace the TWC if any of the visiblearea is damagedor plugged.

34 N.m 13,4 kg-m,

SD
SN
HEAT SHIELD 34 N.m 13.4 kg-m, 25 lb-ft) 10 N.m 11.O kg-m, 7 lb-ft)

IJ

ia"\

FRONTOF VEHICLE

11-15,2

(EGRI Exhaust GasRecirculation System
Troubleshooting Flowchart
\ l / -lra-ll-

-

|

l lf;-f \ . L-l!J _

The MalfunctionIndicatorLamp (MlL) indicatesDiagnostic TroubleCode (DTC) 12: A problemin (EGR)system. the ExhaustGas Recirculation

The EGRsystem is designed reduceoxidesof nitrogenemissions to {NOx)by recirculating exhaustgas throughthe EGR valveand the intakemanifoldinto the combustion chambers. is composed the EGRvalve.EGRvcuum cont.olvalve. lt of EGRcontrol solenoidvalve, ECM and varioussensors. The ECM memorycontainsidealEGRvalve lifts tor varyingoperatingconditions. The EGRvslve lilt sensordetectsthe amount of EGRvalve lift and sendsthe informationto the ECM. The ECM then comparesit with the jdeal EGRvalve lift which is determined signslssent from the other sensors.lf there is any di{ferencebetween the two, the ECM by variescurrent to the EGRcontrol solenoidvalve to further regulatevacuum appliedto the EGRvalve.

EGR CONTROL sol-Et{otD VALVE

---l> BLK/YEL EGB VACUUM CONTROL VALVE RED/ EGRVALVE 5-J WHT LIFTSENSoR I.+-WHT/BLK

ECUIECMI A} {15

BLK

I

I

:

{cont'd)

11 - 1 5 3

EmissionControl System
System{cont'd) Exhaust GasRecirculation {EGR)
--J-h6l\ ---r-l

-.-_:-

-l12l/--\

- lho MIL has boon roportedon. ' With rsNico chcck connoctot iumpedlsoopa06 1142), cod. 12 is indicatod.

Do the FCM ResetProcedure {see p a g e1 1 - 4 3 1 .

Roadtost necessary: Warm upthe engine to normal operating temperature {the radiator fan comes on). Drive the car on lhe road for approx. 10 minutes.Keep th6 engine speedin the 1.700-2.500 rpm.

VACUUMPUMP/ GAUGE 4973X-04't -XXXXX

I I
| Intormitlrnt t llur6, .yltom ir OK at thi! tlm.. Chock for poor connaction! ot loo.. wlr.s at Ot25, gl28llocatod at rlght ihock towqr), C463 (locatod at loft .ida und.r dashl, C1 17 (EGR vllvo lift $n.or), C31O GGB comrol .olonoid vrlv.l and ECM. #16 HOSE

ls the MIL on and does it indicatecode 12?

With the engineat idle, disconnect the # 16 hosefrom the EGR valve and connect a vacuum pump/gauge to the hose.

ls there any vacuum?

Disconnoct2P connoctorfrom the EGR control solgnoid valve and checkthe # 16 hosgfor vacuum again.

EGRVALVE

to Move the vacuum pump/gauge

# 16 HOSE

EGR VALVE LIFTSENSOR

{To page

EGR VALVE l T o p a g e1 1 - 1 5 5 1

1 1 -1 5 4

{Frompage 1 1-154}

(Frompage t 1-154) Check vacuum hoso rouling of the ontiro EGR system. It hoss routing ir OK, roplac. EGR control 3olenoid

With the engineat idle, apply 2O0 mm Hg (8 in Hglof vacuum the to EGRvalve.

ls there any vacuum?

Turn the ignitionswitch OFFand disconnect the "A" conngctor from the ECM.

Checktor continuity to ground on REDwire of the 2P connector. Ropairsho.t in REDwir6 botween EGR control solonoid valvo ard ECM {A11t. Substitut. a known€ood ECM and rot$t. It symptom/indication goos away, roploco tho odginol ECM. EGR CONTROL SOLENOID VALVE Ooesthe enginestall or run rough and does the EGR valve hold vacuum?

Disconnect 2P connectorfrom the the EGRcontrol solenoid valve.

Measurevoltage between BLK/ YEL(+lterminalon the mainwire harness and body ground. Repairopon in BLKrYELwir6 botween th6 EGR contrcl iolenoid v6lv. .nd ECU (ECM)(15 Al fuso (in tho und6r{a.h turo/,olay borl.

ls there battery voltage?

Reconnectthe vacuum pump/ gaugeto the # |6 hose.

( T op a g e11 - 1 5 6 )

{cont'd)

11 - 1 5 5

GontrolSystem Emission
(EGRI System(cont'dl ExhaustGas Recirculation
{ F r o mp a g e '11-1551

Connect battery oower lerminal to the A terminal of the 2P connector. While watching the vacuum gauge, ground the B terminal.

ls there approx.2OOmm Hg (8 in.Hg)within 1 second?

Turn the ignitionswitch OFFand inspectthe # 16 and #24 hoses for leaks, restrictions, or misrouting.

Turn the ignition swith OFF and reconnect the 2P connector,

Are the hoses OK?

EGRVALVE LIFT

VACUUM EGR VALVE CONTROL

COI{TROL EGR VALVE SOLENOID

(
Disconnect the lower hose on EGR control solenoid valve and connect a vacuum gaugeto the hose.

PUMP/ VACUUM GAUGE A973X-O4t -XXXXX

3P Disconnect connectorfrom the EGR valve lift sensor. Roobca the EGB vacuum control valvg.

Turn the ignitionswitch ON.

ls there 150-250 mrn Hg 16- 1o in.Hg) ol vacuum?

Measure voltage between RED/ wHT (t ) terminal and GFN^dHT {- ) terminal. Measure voltage betwe€n RED/ WHT {+} terminal and bodv ground.

ls there approx. 5 V?

( T op a g eI l - 1 5 7 )

l T o p a g e1 1 - ' l 5 7 1

11-156

{Frompage 1 1-156}

't {Frompage 1 - 1 5 6 ) Ropair open in GRN/ WHT wii. botweon EGR vrlv6 lift sonsor ond ECM (D22). Connect the test harness "D" connectorto the ECMonly. not to th6 main wire harness (see pags 11 - 4 5 ) .

Turn the ignitionswitch ON.

Measure voltage botween D19 (+) terminaf and O22 l-l terminal. Rgpair opon in RED/ WHT wir. batwoon EGR valv. litt !.n3or .nd ECM (Dl91. Subrtituto a known{ood ECM and .ech6ck, lf symptom/lndic€tion go6i away, ,ophc6 rha original ECM.

Turn the ignition switch OFF.

Reconnoct the 3P connector to the EGRvalve lift sensor.

D 1 2t + t D 2 2 t - l
Connectthe test h€messbelween the ECM and connectors (see p a g e1 1 - 4 5 ) .

t

l

1.2 V wirh no vacuum appli.d? 4.3 V rvith 2OO mm Hg (8 in.Hol of vacuum appliod?

Turn the ignition switch ON.

Measure voltage between O'l2 f+) terminaf and D22 l-) terminal.

ls the voltageapprox. 1.2 V with no vacuum applied and approx.4.3 V with 2OOmm Hg {8 in Hg) of vacuum applied to the EGR valve?

Ropair opon or lhort in WHT/ BLK wir. botwo.n EGR valvo lift !.n.or and ECM {D12}. ll YYi.o OK, r.Dlac. th. EGR b

(To page 1 1-158)

(cont'd)

11-157

EmissionControl System
(EGR)System (cont'd) ExhaustGas Recirculation
( F r o m a g e1 1 - 1 5 8 ) p

,:

Does the voltageconsistenly as increase/decrease the vacuum increases/decreases?

Connecl 41 1 terminalto 426 teF minal with a jumper wire.

Did the enginestall or run rough?

Ropair open in RED uviro botwoon ECM lAl ll and EGRconlrol3donoid valv6.

Substitute a known-good ECM and rech€ck. ll symptom/indication goes away, replac€the original ECM.

11-158

Positive CrankcaseVentilation (PCVI System
Description
The Positive CrankcaseVentilation (PCV) system is designedto preventblow-by gas from escapingto the atmosphere.The PCV valve contains a springjoaded plunger. When the enginestarts.the plungerin the PCV valve is lifted in proportionto intake manifoldvacuum and the blow-by gas is drawn directly into the intake manifold.

Inspection
1. Checkthe PCVhosesand connections leaksand for clogging.

PCV HOSE

BREATHER PIPE

VALVE

- : BLOW-BYVAPOR Cf I FRESHAIR

At idle,makesurethere is a clickingsoundfrom the PCV valve when the hose betweenPCV valve and intakemanifoldin lighttypincfiedwirh your fingers or olrers.

Ll\l

.t

Gently pinch here

lf thereis no clickingsound.checkthe pCV valve grommetfor cracks or damage.ll the grommet is OK, replacethe PCV valve and recheck.

11 - 1 5 9

EmissionControl SYstem
EvaporativeEmission(EVAPI Controls
Description
The to the amountof fuel vapor escaping the atmosphere' to emissioncontrotsare designed minimize The evaporative system consistsof the following components: A. Evaporative Emission (EVAPI Control Caniatot be purgedfrom An EVAPcontrol canisteris used tor the temporarystorageof fuel vapor until the fuel vapor can burned the EVAP control canisterinto the engineand Vapor Putgo Control System EVAPcontro|canisterpurg|ngisaccomp|ishedbydrawingfreshairthroughtheEVAPcontro|canisterandintoa portonthethrott|ebody.Thepurgingvacuumiscontro||edbytheEVAPpurgecontro|diaphragmva|veandthe EVAP putge control solenoidvalve VALVE OFF AFTER SOLENOID CONTROL EVAP PURGE ENGINE STARTING

B

ABOVE I67OF (75OC) ENGINE COOLANTTEMPERATURE S e n g i n e( U S A :S i V T E C / C a n a d a :R - V ) :1 5 8 " F ( 7 O o C ) 1 [H22A1

Fuel Tank Vapor Conttol SYstem in When fuel vapor pressure the fuel tank is higherthan the set value of the EVAPtwo way valve,the valve opens the flow of fuel vapor to lhe EVAPcontrol canister. and regulates

11-160

EVAP PURGE

cot{TRoL
SOLENOID VALVE

TO ECU(ECM) {15 A} FUSE

FUEL FILL CAP

FUELTANK

FRE SH

t

EVAP CONTROL CANISTER

11-161

EmissionControl System
EvaporativeEmission{EVAP) Controls (cont'd
FLowchart Troubleshooting
EVAP CONTROL PURGE OIAPHRAGMVALVE

# 3 VACUUMHOSE

Disconnect #3 vacuum hose from the EVAP purge control diaphragmvalve (on the EVAPcontrol canister) 6nd connect a vacuum gaugelo lhe hose.

VACUUMPUMP/GAUGE A973X-041-XXXXX

Start the ongine and allow it to idle. NOTE: Enginecoolant temperature mustbe below 158oF{70oC}

EVAP CONTROL CANISTER

Measure voltage between BLK/ YEL (+ ) terminaland REO/GRN (- ) terminal. Inspoct vacuum hoso routin9. lf OK, .oplaco EVAP purge control solenoid

ls there battery vollage ?

Measure voltage betwgon BLK/ YEL (+) terminal and body ground.

(Topage11-163)

{To page 1 1-'163)

11-162

( F r o mp a g e 1 1 - 1 6 2 )

l F r o mp a g e1 1 - 1 6 2 ) Ropairopon in BLK/YEL wir6 betwoon ECU (ECM) (15 Al lus6 lin tho undordash fuso/rolay boxl 6nd ths 2P connoclor.

Warm up the engine to normal operating temperature {th6radiator fan comes on).

ls there battery vohage ?

lBpoct RED/GRN wlro tor an op€n beiw€en ECM (4201 end tho connocrot. lf wir6 is OK. substitut6 a knowngood ECM and rcchock. lf symptom go€s away, ioplaco tho original ECM. Hold engineat 2,OO0rpm.

Check for vacuum at rF3 vacuum hose after starting the engine.

ls theremanifoldvacuum? InSD6ct vocuum hose routing. It OK. r6placo EVAP purge control 3olenoid

ls there manifoldvacuumT

Insp6ct lor . short in RED/GRN wiro b6tw6on ECM lA2O) and tho conn6ctol, ll wir6 is OK, sub3titutoa knowngood ECM and rech6ck. lt 3ymptom goo3 away, r6placo tho original ECM.

(To page 'l 'l - 164)

(cont'd I

11-163

EmissionControl System
EvaporativeEmission(EVAP) Controls {cont'd)
{Frompage 1 1-1631 VACUUM PRESSUNE GAUGE0-4 in. Hg o7JA2 -OO10008

Connect a vacuum gauge to EVAP control canister purge air nose,

Does vacuum appgar on gauge 'l within minute?

Connect a vacuum gauge to the purge hose and raise lhe €ngine sDeed 3,5OOrpm. to

Soo EVAP two way valvo tost to comoloto. Evaoorativo ombsion control! aro

Inlpacl tho purgo hoas ..d throt r body po.t tor pinch or blockag..

oK.

Rsol6c6 th6 EVAP conttol caniator.

11-1 6 4

EVAP Two Way Valve Test
1. 2. Removethe fuel fill cap. Removevapor line lrom the fuel tank and connect to T-tittinglrom vacuumgaugeand vacuum pump as snown.
VACUUM/PRESSURE GAUGE 0-4 in. Hg 07JAZ-0010008 VACUUM PUMP/ GAUGE A973Xo4'l -

xxxxx

F
T-FITTING

3.

while walching Applyvacuumslowly and continuously the gauge. momentarily 5 to 15 mm at Vacuumshouldstabilize H g ( O . 2t o 0 . 6 i n . H g ) . (valveopens)below 5 mm a lf vacuum stabilizes H s ( 0 . 2 i n . H g )o r a b o v el 5 m m H g { o . 6 i n . H g l , installa new valve and retest.

4.

Move vacuum pump hose from vacuum to pressure tifiing, and move vacuumgaugehosefrom vacuum side as shown. to oressure

the Slowly pressuraze vaporline while watchingthe gauge. at Pressure should stabilize 1O to 35 mm Hg {O.4 to 1.4 in. Hg). (valveopens) a It pressure momentarily stabilizes t a t 1 Ot o 3 5 m m H g ( O . 4 o 1. 4 i n . H g ) .t h e v a l v e is OK. a lt pressure below 1Omm Hg (O.4in. Hg) stabilizes l o r a b o v e3 5 m m H g ( 1 . 4 i n . H g ) , i n s t a l a n e w valve and retest.

11-165

Transaxle
Clutch ...........12-1 Manual Transmission ............................ 13-1 Automatic Transmission .................. 4-1 .....1 Differential Manual Transmission ......................... 15-1 Automatic Transmission ................... 0 15-1 Driveshafts ... 16-1

Clutch
Special Tools.......... ...........12-2 fffustrated Index........... .....12-3 ClutchPedal Adjustment .................... 12-4 ClutchMasterGylinder RemovaUlnstallation ....12-5 SlaveGylinder Removal .... 12-6 Installation ..................... 12-6 Release Bearing Disassembly/f nspection.................... 12-7 fnstaf lation................;.... ..................... 12-7 Pressure Plate RemovaUlnspection ......12-8 GlutchDisc Inspection ...................... 12-9 Flywheel fnspection/Removal ...... 12-10 Flywheeland ClutchDisc lnstaf lation ..................... 12-10

SpecialTools
Re{.No I Tool Numbqt O T J AF 07LAB 07924 07LAF 07936 PM7011A PV00100 or PD20003 PT00110 3710100 ClutchAlignmentDisc RingGearHolder ClutchAlignmentShaft Handle 12-8 1 2 - 89 , r 0 , 12-4,10 1 2 - 8t 0 .

I

g
o
6,

I

B
@

12-2

lllustratedIndex
NOTE: a Whenever transmission removed, the is cleanand grease the release bearingslidingsurface. a When partsmarked"*" are removed, clutchhydraulic the systemmust be bled. . Bleedthe clutchhydraulic system(seepage 12-6). . Inspect hosesfor damage,leaks, the interference, twisting. and
PEDAL PIN r19 N.m lt.g kg.m, la lb-fil

8 x 1.25mm 22 N{n 12.2 kg-m, 16 lb-ft)

6x1.0mm 10 N.m {1.0lg.m,

7 rb.ftl
.RESERVOIF .CLUTCHMASTER CYLINDER R6moval/lnstall6tion. pag6 12-5

J

.rg runrfl.g tg-m, 14lb-ft1
8 x 1.25mm 22 N.ln {2.2 kg-m, 16 |b-ft)

'15 N{n l'1.5kg-m, 11 tb-ft|

.OIL BOLT 30 t&n {3.0kg-m, z2tb-ftI

\

WASHER R.pl|c..

Y*
\_-/

l/A+,

'REsERvolR HosE

Pro
CLUTCH DAMPER

(fr&..]{{r+--->
I x1,25 mm ..-

\

7 ^r*V " lJYr-'
n x r.o mm 10N.m{1.0ls-m, 7 tb.ft}

'Fr

| \\l t \\

^*i!-

rg.m, IJUz tt.r"tz.z
r15 N{n {1.5rg-., lt tb-ft|

virh.
V

tW

/
\ ^

r15 N{n 11.5 kg-ft, 11 tb.ftl

RET-EASE SEANING p8go Romoval, l2-7 pago12-7 Inspoction,
page12-7 Installation,

DOU'EL PIN

FLYWHEEL page Inspection/Removal, 12-10
page12-10 Installation, CLUTCH DISC page12-9 Inspection, psge 12-10 Installation, PRESSURE PLATE pa96 12-8 Femoval/lnspection, page12-10 Installation, RELEASE FORK page12-7 Removal. page12-7 Installation, *CLUTCH 15 N{n (1.5kg-m, 11 tb-ft}

TRANSMISSION See section 13

TSLAVE CYLINOER R e m o v a l / l n s t a l l a t i o n p a g e 12 ' 6 ,

12-3

GlutchPedal
Adjustment
NOTE . To checkthe clutchpedalswitchA and B, seesection . The clutchis self-adjusting compensate wear. to for Threadthe clutchpedalswitchA in until it contacts the clutchpedal. Turn the clutchswitchA in 114 '12lurn further. TightenlocknutA.
7.

CAUTION: ll th€ro is no cl6aranc6betwo€n tho mastel qylindor piston and push rod, the releasebearing is held lgainrt tho diaphrrgm spring, which can result in clutch slippago or other clutch probl€ms. 1, L o o s e nl o c k n u tA , a n d b a c k o f f t h e c l u t c h p e d a l switchA or bolt until it no longertouchesthe clutch peoal. LoosenlocknutC, and turn the push rod in or out to g e t t h e s p e c i f i e d t r o k ea n d h e i g h t a t t h e c l u t c h s Deoat. TightenlocknutC,

LoosenlocknutB and clutchpedalswitchB.

8 . Measursthe clsarance between the floor board and clutchpedal.lvith clutchpedalfully depressed, the
q

2.

Release clutchpedal '15- 20 mm (0.59- 0.79 the p i n ) f r o m t h e f u l l y d e p r e s s e d o s i t i o na n d h o l d i t there. Adjust the positionof clutch pedalswitch B so that the engine will start with the clutch pedal in this position. 112-tu'n

3.

10. Thread the clutch pedal switch B in 114further, 11. TightenlocknutB.
LOCKNUT C 15 N.m 11.5

tl tb-ft}

LOCKNUT B 10N.m{1.0 kg-m,7 lb.ftl
CLUTCH PEDAL SWITCH B

CLUTCII PEDAL SwlTCHA
PUSHROD

L(rcKNUT A
10 l,I.|n(1.0kg.m, 7 lb.ft)

CLUTCH MASTERCYLINOER

Padrl in contld

whh awhch

CLUTCH ASSISTSPRING

-6El

@ @ @ @

(STROKE PEDALI:135- 1ir5mm (5.31- 5.71 in) 8t (TOTALCLUTCHPEDALFREE PLAY):9.0 - 15.0mm 10.35 0.59 in) includo ths psdal plsy 1 - 7 mm t0.0t - 0.28 in). PEDAL HEIGHT): mm (7.48in) 190 ICLUTCH PEDALDISENGAGEMENT HEIGHT): mm (3.70in) minimum to the ftoor. 9,[ ICLUTCH

2-4

ClutchMasterCylinder
Removal/lnstallation
CAUTION:Avoid spilling brake fluid on paint.d surtacos,as it may damagoths tinish. NOTE:Plug the end of the res€rvoirhose,and cap the end of the clutchpipe,with a plug and cap suchas those discardedfrom an A/C kit. 1. Removethe reservoirhose from the clutch master c v l i n d e ra n d d r a i n t h e b r a k ef l u i d i n t o a s u i t a b l e contarner, NOTE:The brakefluid csn be suckedout through the top ot the reservoir with a syringe. 2. from the enginecompartment Remove reservoir the bulkhead. Disconnect clutch pipe from the clutch mastsr the cylinder. CLUTCH PIPE
19 N.m 11.9 kg-m, la lb-ttl 6x1.0mm

5.

Remove clutchmast€rcvlinder. the

3.

10ll.rn 11.0 ke-m, 7 tb-ft)

CLUTCHMASIER CYLINDER

6.

Install the clutch mastor cylinder in the rev€rse order of removal. NOTE: Blsed the clutch hydraulic systom (see psge 12-6t.

RESERVOIR CLUTCH RESEBVOIR HOSE MASTER CYLINDER Pry out the cotterpin, and pull the pedal pin out of the voke.Remove nuts. the
COTTERPIN Replac€. PEDALPIN

-6rl

NUTS
13 N{n (1.3kg.m,9lb-ft|

2-5

SlaveCylinder
Removal
Disconnect clutchpipefrom th€ slavecylinder. the CAUTION: Avoid spilling braks tluid on the paintod 3u.facos,as it may damagoth€ tinish. NOTE:Plug the end of the res€rvoir hose,and cap the end of the clutchpipe,with a plug and cap such as those discardedfrom an IVC kit. Remove slavecylinderfrom the clutchhousing. the
CLUTCH PIPE 15 N'm {1.5kg-m.

lnstallation
-6ll, (P/N08798 SuperHighTemp LJrea Grease 9002). : BrakeAssemblyLubeor equivalent rubber grease.

1 . Install the slave cylinder on the clutch housing.
Connect the clutch pipe.

CLUTCH PIPE

SLAVE CYUNDER

l,

BLEEOER SCREW 10 N{n (1,0kg-m,

7 tb-ft|

8 x 1,25mm 22 N.m {2.2 kg-m, 16 tb-ft| (P/N08798-

-#,1

BOOT
Relhov€and chocktor signs of leaking and deterioration.

(BraksAssembly Lub6)

3.

Bleed the ciutch hydraulic system:

Attacha hoseto the bleederscrewand suspend the hosein a container brakefluid. of Makesurethere is an adequate supplyof fluid at the mastercylinder, then slowly pump the clutch pedaluntil no more bubblesappearat the bleeder hose. a Refillthe mastercvlinder fluid when done. a Useonlv DOT3 or 4 brakefluid.

12-6

Release Bearing
Disassembly/lnspection
Remove boot trom the clutchhousing. the Remove the release fork from the clutchhousingby squeezingthe releasefork set spring with pliers. Remove release the bearing.

lnstallation
N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e( P / N 08798 9002). Install the release fork set springon the release tork. RELEASE FORK RELEASE FORK SPBING SET

-#l
RELEASE FOBK

{P/N08798-

-6El

{P/N08798*

With the release fork slid betweenthe release bearing pawls, installthe releasebearingon the mainshaft while insening the releasefork through the hole in clutchhousing. Align the detentof the release fork with tlle release f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e release fork bolt souarelv.
RELEASE FOBK RELEASE FoRK SETSPRING RELEAS€ BEARING

(P/N08798- 9002t

RELEASE FORK SET SPRING

CLUTCH HOUSING

Checkthe release b€aringfor play by spinningit by h an d . CAUTION: Tho reloass besring is packed with groas€.Do not wa3h it in solvsnt.
BELEASE FORKBOLT 30 N.rn {3.0 kg-m, 22 lb-ftl

f-

Installthe boot, being sure that there is no clearance:release fork-to-boot, and boot-to,clutch housing, .Move the releasefork right and left to make sure that the release fork fits properlyagainstthe release bearing, and that the release bearingslidessmoothRCLEASE BEARING

play, replacethe releasebear lf there is excessive ing with a new one.
FORK RELEASE

12-7

Plate Pressure
RemovaUlnspection
springfor wear Inspect fingersof the diaphragm the area. at the release bearingcontact as Assemble specialtools shown. the N O T E :A s s e m b l e h e C l u t c hA l i g n m e n tD i s cw i t h t springas shown. side "A" facingthe diaphragm springfingersfor heightusrrg Check diaphragm the and a feelergauge. the specialtools Standard(New): 0.6 mm {0.02in) max. 0,8 mm {0.03in) ServiceLimit: To prevent warping. unscrew the pressure plate mounting bolts in a crisscrosspattern in several steps.then remove the pressureplate.

I

PRESSURE PLATE

CLUTCH ALIGNMENT

Dtsc

plate surfacefor wear, cracks, Inspectthe pressure a n db u r n i n g .
FEELER GAUGE

OTJAF PM7O11A

1.

Inspectfor warpage using a straight edge and a feelergauge. NOTE:Measureacrossthe pressureplate at three pornts. in) Standard (lrl6wl: 0.03 mm (O.0Ol max. 0.15 mm (0.006in) Sorvicc Limit
FEELER GAUGE

SHAFT CLUTCH ALIGNMENT 07LAF- PTOo110 HANDLE 07936- 3710100

I

4.

Install the special tools as shown.

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

HANDLE 07936 3710100

* /

/ '

CLUTCH L I G N M E N T IA SHAFT 07LAF PT00110 RINGGEARHOLDER ENGINEBLOCK 00 07LAB- PV001 07924- PD20003 RING GEAR HOLDER ADJUSTER NUT AOJUSTEB BOLT BOLT STRAIGHT EDGE

WASHER

12-8

ClutchDisc
Inspection
L 2.

Remove clutchdisc. the lnspect the lining of the clutchdiscfor signsof slipp i n g o r o i l . R e p l a c e t i f i t i s b u r n e d b l a c ko r o i l i soaked.

Measurethe depth from the lining surfaceto the rivets,on both sides, Riv€t Dspth: StandardlNewl: 1.3mm {0.05in) min. S€rvicoLimit: 0.2 mm (0.01in)

xi (

@
CLUTCH OISC

CLUTCH DISC 3. Measure clutchdiscthickness. the Clutch Disc Thickn€ss. Standard(New|: 8.4- 9.1 mm {0.33 0.36in} ServiceLimit: 6.0 mm 10.24 inl

12-9

Flywheel
Inspection/Removal
1,

Flywheeland ClutchDisc
lnstallation
.-Alignthe hole in the flywheel with the crankshsft Installthe mountingbolts dowel pin and assemble. only tingertight. Installthe specialtool. then torque the mounting p b o l t s i n d c r i s s c r o s s a t t e r n i n s e v e r a ls t e p s a s shown.

the Inspect ring gearteethfor wear and damage, Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks, Sndburning. Measurethe flywheel runout using a disl indicator through at least two full turns. Push the flywheel thrust towardsthe engineto take up the crankshaft washerclearance. w N O T E :T h e r u n o u t c a n b e m e a s u r e d i t h e n g i n e installed. Standard lNowl: 0.05 mm {0.002in) mrx. in) 0.15 mm {0.(X)6 ServiceLimit the the servicelirnit, reDlace lf the runout exceeds flywheel. (}

2.

FLYWHEEL

rLvwxeel

07LAB PV00100 MOUNTTNG or BOLTS 07924 PD2fi)O3 tO5N.rntj9.5 k,-m, ?G tb-ft1

l "
4. R e m o v et h e e i g h t f l y w h e e l m o u n t i n g b o l t s i n a crisscrosspattern in ssveral steps, and remove the flywheel. FLYWHEEL

I n s t a l lt h e c l u t c h d i s c u s i n g t h e s p e c i a lt o o l s a s shown.

FLY\AIHEEL

HANDI.I 07936- 3710100

CLUTCH DISC

CLUTCH ALIGNMENT SHAFT 07LAF- PT|X)I10

RII{GGEARHOLDER o?LAB- PVO010O ol 0?924 - PD2o003

(P/N08798- 9002)

4.

Install the Dressure Dlate.

Pf,ESSUREPLAIC

patternas Torquethe mountingbolts in a crisscross shown.Tightenthem several stepsto preventwarping the diaphragm spring.

MOUNTINGBOLTS 26 N.m (2.6kg-m, 19 lb-ft|

6.

Remove soecial the tools.

12-11

ManualTransmission
Tools... Speciaf ........... 13-2 Maintenance Transmission .............................. Oil 13-3 Back-up Llght Switch Replacement .,.,,.... 13-3 Transmission Assembly Removal ................. 13-4 Gearshift Mechanism Overhaul ................ 13-9 lllustrated Index ................................... 13-10 Shift Arm Assembly fndex ................ ......13-12 Disassembly/Reassembly ............... 13-13 Transmission Housing Removal ................. 13-15 ReverseShift Fork Glearance Inspection,,,....,.............., 13-1 6 Reverseldler Gear Removal ................. 13-17 Mainshaft, Countershaft Removal ................. 13-17 Mainshaft lndex ............... ....... 13-18 Clearance Inspection ......,................ 13-19 Disassembly .......... 13-20 Inspection .............. 13-21 Reassembly ........... 13-22 Countershaft fndex ................ ......13-23 Cfearance fnspection....................... 13-24 Disassembly .......... 13-25 Inspection .............. 13-26 Reassembly ........... 13-25 Shift Fork Assembly Disassembly/Reassembly ............... 13-28 Clearance Inspection ....................... 13-29 SynchroSleeve,SynchroHub Inspection Installation ............. 13-30 SynchroRing,Gear Inspection .............. 13-31 MainshaftBearing/Oil Seal Replacement .....,.,, 13-32 Countershaft Bearing Replacement ......... 13-33 MainshaftThrust Shim Adiustment ............ 13-34 Transmission Reassembly ........... 13-37 Transmission Assembly Installation ............. 13-40

NOTE:The radio may havea codedtheft protection circuit.Be sureto get the customer's code numberbefore - Disconnecting battery. the - Removing No. 43 {10A)fuse in the under-hood the fuse/relay box. - Removing radio. the After service, powerto the radioand turn it on. reconnect Whenthe word "CODE"is displayed, enterthe customer's 5-digitcodeto restore radiooperation.

SpecialTools

R€{.No.

I

Tool Number 07GAJ07GAJ*07736 07746 07746 07746 07746 07749 07947 Pc2o' r'r0 PG20130 A010004 0010300 0010500 0030100 0030400 0010000 6890100

Description Holder Mainshaft Mainshaft Base Adjustable BearingPuller,25 40 mm 42 Attachment, x 47 mm Attachment. x 68 mm 62 Driver,40 mm l.D. Attachment mm LD. 35 Driver SealDriver

Oty 1 1 ,l 1 ,| 1 1 1 1

I

Pag€Referonc€
tJ-JO, J/

o
@
/a\

@ @ @

13-32.33 't3-22,21 ,32 13-32.33 't3-22 13-22 13-22,21 ,32,33 't3-21

o @ o

* Must be usedwith commerciallv SlideHammer. available in x 16 thread/in 3/8

o

o

@

@

o

13-2

Assembly Transmission
Removal

@ 3uro Makr

4.

iacks and safoty 3tlnds aro placed proper' ly, rnd hoi3t brlckot! aro sftached to corroqt posi' lion on tho cngins. Apply parking brako and block roar whool3 30 car will not roll off stand3 lnd fdl on you whilo working uodor it.

Removethe intakeair duct and air cleanerassemDtv.

CAUTION: U3o lcndrr coveB to 8void dEmlging print' ed surfaces. NOTE: The radio may have a coded theft protection circode numberbefore cuit.Bo sureto get tha customer's - Disconnecting the battery. - Removing No. 43 (]0 A) fuse. the fuse/relay box) {Under-hood - Removing radio. the After service,reconnectpower to the radio and turn it on. " C O D E "i s d i s p l a y e de n t e rt h s c u s , When the word tomer's5-digitcodeto restoreradiooperation. 1. Disconnect negative(-) and positive(+) cabl€s the from the b8ttery,then remove the battery. oil Drainthe transmission (seepage13-3). Removethe battery base and bsse stay, Removethe intakecontrol vacuumtank and brack€t, Do the NOTE: not disconnect hoses, INTAKE OONTROL

fti

2. 3.

13-4

6. Disconnect the starter motor cables,then remove the startermotor. 7. Disconnect back-uplight switchconnectors the and groundcable. transmission 8. Remove wire harness the clamp. WIRE
HARNESS

1 1 .Disconnect vehiclespeedsensor(VSS)connecthe tor and removethe VSS/power steeringspeedsensor, but leaveits hosesconnected.

vss coNNEc?oR

LIGHT BACK.UP SWITCH

POWER STEERING SPEED SENSOR

STARTEB MOTOR
STARTER MOTOR CABLES TRANSMISSION GROUND CABI.T O-RING Replace.

12. Remove slavecylinder. the 9 . Shiftthe transmission into reverse. 1 0 . Firstremovethe cablebracket, then disconnect the from the top housingof the transmission. cables NOTE:Removeboth cablesand the bracket together. CAUTION: Take crre not to bond ths cables.
Do not aamovo.

NOTE: . Do not operatethe clutch pedal once the slave cylinderhas beenremoved. . Takecarenot to bendthe clutchpipe.
HOSE CLUTCH

WASI{EB
WASHER Inspect for '}{FT CAALE
and

Replace. STEEL PLASTIC I WASHER WASHER Inspectfor wear and oamage. SLAVECYLINDEB

(cont'd)

13-5

Assembly Transmission
(cont'd) Removal
1 3 . R e m o v €t h e c l u t c h d a m p e r m o u n t i n g b o l t s , a n d raisethe clutchdamDer. Remove cotterpins and ball joint nuts,then septhe arate the ball joints and lower arms on both sides (seesection'18). the right damperfork bolt. 1 6 . Remove
CLUTCH OAMPER

't1. Remove the right radius rod.
BOLTS SELF.LOCKING Replace. SELF.LOCKING NUT
Replace.

I,
l '

36i'J'--*€ NUr
MOUNTINGBOLTS a.

f

DAMPER NUT SELF.LOCKING Replace.

I

COTTERPIN Replace.

stay. the 14. Remove rearenginemount bracket

shaft (see and intermediate 18. Remove the driveshafts 16). section w f N O T E : C o a t a l l D r e c i s i o n i n i s h e ds u r f a c e s i t h Tie cleanengineoil or grease. plasticbags over the driveshaftends.

REAR ENGINE MOUNT BRACKET S?AY

SHAFT INTERMEDIATE

13-6

19. Remove centerbeam. the

21. Remove the intakemanifoldstav.

INTAKEMANIFOLO STAY

20. Remove front enginestiffener the and clutchcover.

22. Removethe rear beam stiffener.

REARBEAMSTIFFENER

13-7

Assembly Transmission
(cont'dl Removal
mounthe 23. Remove three rearenginemount bracket ting bolts. housingmounRemove two uppertransmission the ting bolts.

G

! :
and raise Placea floor jack under the transmission just enoughto take weight oft of the transmission the mounts. mount and mount brackRemovethe transmission et.

UPPERMOUNTING BOLTS

27. R e m o v et h e t h r e e l o w e r t r a n s m i s s i o nh o u s i n g mountingbolts.

MOUNNNG BOLTS LOWER

MOUNT BRACKET

away ftom the engine until it 28. Pull the transmission clearsthe mainshaft.

13-8

Gearshift Mechanism
Overhaul
NOTE: . Inspect parts wearanddamage rubber for whendisassembling. . Check the newcotter is seated pin that firmly.

6x1.0mm 10 N.rn (1.0 kg-m, 7 tb-ft) SELECT CABLE

CHANGE WIREPLATE Replace.

tr
6x1.0mm l0 N.m {1,0kg-m, 7 tb-ftt

I

COTTER PIN Replace.

l',
@---=.6x1.0n '10N.m kg-n kg-m,7 lb-ft} 11.0

PLASTIC WASHER Inspectfor damsge.

sELF-LocKrNG NUT
Replace. '10N.m (1.0 kg-m, 7 lb-ft|

CHANGE LEVER LINKAGE
CHANGEI,.EVER CHANGE LEVER O-RINGS Feplace. CHANGEBALL

\ \ - -

\-ry \ \\\ N \
I L

\

&

WAVE *ou.)@o\
WASH WASHER SELF.LOCKING SELF.LO NUT Replace. CHANGE BALL HOLOER

CHANGELEVER

Ptvot
PIVOT CHANGE GUIDE 6x1.0mm kg-m, 10 N.m 11.0 7 tb-ft) SHIFTLEVER BRACKET

FLOATING COLLAR

13-9

lllustratedIndex
disassembly Referto the drawingbelowfor the transmission air. Cleanall pans thoroughlyin solventand dry with compressed

I

reassembly. oil Luuri""t""tl partswith before
use liquidgasket(P/N08718 0001) between the major housings; usesno gaskets This transmission (seepage 13-14.39). housingis disassembled. the Alwayscleanthe magnetO whenever transmission

t
.>_._------.\\ _._i---.---'l
__----.--

.-.-_.-.-_---

/---ry
o CLUTCHHOUSING o
oll SEALReplace. . Seesection15 an 14 x 20 mm DOWELPIN OIL GUIDEPLATE BEARING NEEDLE . Inspect wear and oporation. for 0 RETAININGPLATE 7 MAGNET IDI.IR GEARSHAFT @ REVERSE IDLER GEAR @ REVERSE @ OIL SEALReplace.

o BALLBEARING '

for Inspect wear and operation.

WASHER @ SPRING @ WASHER SHIFI FORK @ REVERSE

G' SHIFTFORKASSEMBLY . Index,page 13-28 ASSEMBLY G' MAINSHAFT . lndex,page13-18 ASSEMBLY E) COUNTERSHAFT ' Index, pago13-23 ASSEMBLY CD DIFFERENTIAI. Seesection15

13-10

L
q

6
l_

_l I 'ei ,w
H '

0n

r

I I

sHrM @ THnusr
@ @ @ @ @ Ql @

E9 SHIFTARM ASSEMELY . Index, page13-12 PLATE E4 OIL GUTTER
. S e l e c t i o n ,p a g e 1 3 - 3 4

oIL GUIDE PLATE WASHER Replace. BACK-UP LTGHT swITcH sErflNG scREw WASHER Reptace. SPRTNG 30 mmt lL. srEELEALL s/16inl {D.

HANGER €9 TRANSMISSION @ 28 mm SEALINGBOLT 60 32 mm SEALING BOLT 6D waSHER Reptace. IDIEN GEAR €' BEVERSE SHAFTBOLT T8]OIL SEAL . Seesection 15 .'9 OIL DRAINPLUG WASHER Replace. a{o)

(' @ Q} @

OIL FILIfR BOLT WASHER Replace. TRANSMISSION HANGER TRANSMISSIoN HoUSING

13-1 1

Shift Arm Assembly
lndex
NOTE: in with the transmission the car. . The shift arm covercan be removedand installed with grease. . Lubricate movingand slidingsurfaces all . Turn the boot so the hole is facingdown
LEVER SELEGT

08798 - 9lD2l

-G1

6x1.0mm 12 N.m {1.2kg-m, 9 rb-ftt

OIL SEAL Replac€. SHIFTARM . Inspoction, page 13_29 8x1.0mm 29 N.m 12.9kg-m, 2'l tb-ftl

SHIFTARM COVER

PIN RETURN SELECT 6x1.0mm '12N.m 11.2 kg-m, 9 tb-ft} 5TH/REVERSE SELECT SPRING INTERLOCX

6xl.0mm kg-m, 15 N.m 11.5

WASHEB LOCK Replace.

11tb-ftI

BOLT

sE[rcT
RETURN SPRING ARM SELECT

/N 08798-

-6ll

OIL SEAL Replace.

4xBmm DOWELPINS

13-12

Disassembly/Reassembly
NOTE:Duringreassembly, greaseall slidingparts. 1. Remove shift arm coverassembly. the 6x1.0mm 12N.m(1.2 kg-m,9lb-ft|
SHIFTARM COVER ASSEMALY

4.

Remove the reverse lockcam.
6x1.0mm 15 N.m (1.5kg-m,11 lb-ftl

{x8mm DOWEIPINS

R e m o v et h e s p r i n g p i n , t h e n r e m o v e t h e s e l e c t lever,selectarm and springs. Remove selectreturnpin. the
SELECT ARM ,/

5.

Remove oil seal. the

OIL SEAL R€place.

5x22mm PIN SPRING

-'

SELECT RETURN SPRIMi SELECT RETURN PIN 6x l.0mm 12 N.m 11.2 kg-m,9lb-ft| 5TH/REVERSE SELECT SPRING

SELECT LEVER

.JG

(cont'dl

13-13

Shift Arm Assembly
(cont'dl Disassembly/Reassembly
gend the tab of the lock washer,then remove the bolt. bolt. Remove interlock the NOTE: Apply liquid gasket(P/N 08718the threadsbeforereassembly. 0001)to 9. orderof in the shift arm assembly the reverse Install removal. NOTE: . Use liquidgasket(P/N08718 0001). o Remove din oilfrom the sealingsurface. the of . Sealthe entirecircumference the bolt hole to preventoil leakage. . lf 20 minutes have passedafter applying liquid t g a s k e t ,r e a p p l yi t a n d a s s e m b l e h e h o u s i n g s a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t a sa f t e r with oil. beforefillingtransmission assembly

8x1.0mm 29 N.m {2.9kg-m, 21 tb-ft)

o
\ .oi* *os".^
Replace.

--: LIOUID GASKET

8.

the Remove shift lever,shift arm. and interlock. NOTE:Turn the boot so the hole is facingdown,

13-14

Transmission Housing
Removal
NOTE: . lf the transmissionhousing or clutch housingwere replaced, bearingpreloadmust be adjusted. the o Place the clutchhousingon two piecesof wood thick enough to keep the mainshaftfrom the hitting the workbench. '1. Remove (seepage 13the shift arm coverassembly 131. Remove the reverse idlergear shaftbolt. Remove the settingscrews,then removethe washers,springs. and steelballs.
STEELBALLlD.5/16 in)

Remove 32 mm sealingbolt. the 7. Expandthe snap ring on the countershaft ball bearing and remove it from the groove using a pair of snap ring pliers. Separate the transmission housingfrom the clutch housingand wipe it cleanof the sealant.
SNAPRING

r-^

-/

Replace. WASHER SETTINGSCREW

9.

Removethe 28 mm sealing bolt, then removethe oil gutterplate. NOTE:The transmission housingcan be removed with the oil gutter plate in the transmissionhousing. 28mm SEALTNG BOLI
OIL GUTTER PLATE

4.

Remove back-up the light switch. Remove the l0 mm bolts and 8 mm bolts in a crisscross pattern in severalsteps.

OIL GUTTER PLATE

LIGHT BACK.UP

swlTcH

13-1 5

Reverse Shift Fork
Inspection Clearance
1. Measurethe clearancebetween the reverseshift fork and 5th/reverse shift piecepin. A: 0.05- 0.35 mm 10.002 0.01i|in) B: 0.,1- 0.8 mm {0.016 0.031in) ServicoLimit; A: 0.5 mm (0.020inl in) B: 1.0mm {0.039 Standard:
l.

Measurethe clearancebetween the reverseidler gear and reverse shiftfork. 0.5 - 1.1 mm (0.020- 0.043in) Standard: Srrvico Limit: 1.8 mm (0.071inl

lf the clearance exceedthe service limit, measure shiftfork. the width of the groovein the reverse Stand8rd:A: 7.05- 7.25 mm (0.278- 0.285inl -0.303 inl 8: 7.4- 7.7 mm (0.291

4.

lf the clearance exceeds the servicelimit, measure the width of the reverseshift tork. Standard: 13.0- 13.3mm {0.512- 0.52'l in)

REVERSE SHIFTFONK

REVERSE SHIFT FORK

lf the width of the groove exceedsthe standard, replace reverse the shiftfork with a new one. It the width of the groove is within the standard, reolace sth/reverse shift Diece with a new one. the

l f t h e w i d t h e x c e e d st h e s t a n d a r d ,r e D l a c e h e t reverse shiftfork with a new one. l f t h e w i d t h i s w i t h i n t h e s t a n d a r d ,r e o l a c et h e reverse idlergearwith a new one.

13-16

Reverse ldler Gear
Removal
1. Remove reverse the shift fork.

Mainshaft, Countershaft
Removal
1.

Remove and countershaft assemblies the mainshaft with the shift forksfrom the clutchhousinq. NOTE:Tape the mainshaftspline before removing the mainshaft and countershait assemblies.

REVERSE SHIFT MAINSHAFT ASSEMBLY

COUNTERSHAFT ASSEMBLY

Tapethe mai shattspline. SPRING WASHER

Remove idler gear shaftand the reverse the reverse idlergear.
CLUICH HOUSING

2.

Remove differential the assembly.

DIFFERENNAL ASSEMBLY

REVERSE IDLER GEAR SHAFT

13-17

Mainshaft
lndex
I air, dry B"for" """"mbling. cleanall partsin solvent, them with compressed then coatthem with cleanoil.

RING STOPPER 3RD/irTH SYNCHRO HUB 3RD/4TH SYNCHRO SLEEVE HUB 3RD/irTH SYNCHRO page'13 30 Inspection,

t

TAPERRING

1,.

NEEOLE BEARING Check wear and ooeiation. SPACERCOLLAS SYNCHRO RING page13 31 lnspection, SYNCHRO SPRING sTH SYNCHRO HUB page13-30 Inspection, sTH SYNCHRO SLEEVE page13-30 Inspection, SYNCHRO SPRING SYNCHRO RING page13-31 Inspection,

I

SYNCHRO SPRING SYNCHRO RING

SYNCHRO SPRING

" o oro /

SYNCHNO RING page13-31 Inspection, 3ROGEAR page Inspec!on, 13,19,31 NEEDLE BEARING Check wear and operation. MAINSHAFT page13?1 Inspection,

13-18

NOTE:lf replacementis required,always replacethe synchrosleeveand hub as a set. 1 . Support the bearing inner race with a socketand push down on the mainshaft. Measure clearance the between 2nd and 3rd gears. 0.06- 0.21 mm {0.002- 0.008in) Service Limit:0.3mm 10.012 inl I Stands.d:

Measurethe clearancebetween 4th gear and the soacer collar. Standard: 0.06- 0.21 mm {0.002- 0.fl18 in} ServiceLimit: 0.3 mm {0.012in}

I

v

5.

lf the clearance exceeds the servicelimit, measure distance on the spacer collar. @ 26.03- 26.08mm (1.025- 1.027in) Standard: Limit:26.01mm {1.024 Service inl

lf the clearance exceeds the servicelimit. measure the thickness 3rd gear. of Transmission Type Standard Service Limit M215.M254 M2F4 6.

6J-l-l L+
SPACER coLLAR ----+l_J

1,

.nrcean
S|DE

-32.41 mm 34.92 34.97mm 32.42 - 1.2'18 inl { 1 . 3 7 - 1 . 3 7 7n ) i 1'1.276 5 32.3mm .27 11 2 inl 34.8mm ( 1 . 3 7 0n ) i

lf distance is lessthan the servicelimit, roplace O the spacer collarwith a new one. tf distance@ is within the service limit, measure the thickness 4th gear. ot M215,M254 M2F4

3RD GEAR

Transmission Type Standard Service Limit

30.92 30.97 mm 3 1 . 4 2 3 1 . 4 7 m m inl ( 1 . 2 3 7 1 . 2 3 9n ) i 11.217 1.219
30.8mm ( 1 . 2 1 i3 ) n
I

3 1 . 3m m inl l'1.232

El r| ^J-_-6
lf the thickness 3rd gear is lessthan the service of limit,replace gearwith a new one. 3rd lf the thickness f 3rd gear is within the service o limit, replacethe 3rd/4thsynchro hub with a new one.

t,A

\--t 1 I

. .THGEAn

l lf the thickness 4th gear is lessthan the service of limit, replace gearwith a new one. 4th lf the thickness f 4th gear is within the service o limit, replacethe 3rd/4thsynchro hub with a new one. (cont'd)

Mainshaft
Inspection{cont'dl Glearance
Measurethe clearancebetweenthe spacer collar and 5th gear. 0.06- 0.21mm (0.002- 0.008in) inl SsrviceLimit: 0.3 mm 10.012 Standsrd:

Disassembly
CAUTION: Removethe synchro hubs using a press and steel blocks as shown. Use of a iaw.typ€ puller can damagethe gsar teeth, Removethe ball bearingusing a bearingpuller as shown.

BEARING PULLER

BALLBEARING

lf the clearance exceeds the servicelimit, measure collar. distance on the spacer @ 26.03- 26.08mm in) {1.025 1.027 Limit: 26.01mm {1.02'l in) Sorvice Standard:
SPACER COLLAR BAI-L BEARING STOPPER RING

sTHGEAR SIDE lf distance is lesathan servicelimit, replacethe €) spacer collarwith a new one. lf distance@ is within the service limit, measure thickness sth gear. of -1.219inl Standard: 30.92 30.97mm (1.211 Limit: 30.8mm 11.213 inl Service
5TH GEAR

MAINSHAFT

lf the thickness sth gear is lessthan the service of limit, replace gearwith a new one. 5th lI the thickness f 5th gear is within the service o limit, replace sth synchrohub with a new one. the

13-20

lnspection
S u p p o r t s t h g e a r o n s t e e l b l o c k sa s s h o w n a n d the Drsss shaftout of the sth synchrohub. '1. Inspectthe gear surtace and bearing surface for wear and damage,then measurethe mainshaftat pointsA, B, and C. Standard: A {88ll bearing surlacol: B (Needlebearing surfaco): C (Ball bearing 3urface): Ssrvico Limit A: 27.940mm B: .37.930 mm C: 27.940 mm

27.987- 28.000mm ( 1 . 1 0 1-8 1 . 1 0 2 'i ln ) 37.98'l- 38.000mm (1.irgsit- 1.,t961in) 27.977- 27.99O mm ( 1 . 1 0 1-5 1 . 1 0 2 0n ) i (1.1000in) (1.4933 in) (1.1000 in)

I n s p e c t o i l p a s s a g e sf o r c l o g g i n g .

In the same manneras above,supportthe 3rd gear on ste€l blocks and pressthe shaft out of the 3rd/4th svnchro hub as shown.

lf any part of the mainshaftis lessthan the service limit, replace with a new one. it Inspect runout. for Standard: 0.02 mm (0.001in) max. in) Seivico Limit: 0.05 mm 10.002 N O T E : S u p p o r t t h e m a i n s h a f ta t b o t h e n d s a s snown.

lf the runout exceeds the servicelimit, reolacethe mainshaft with a new one,

13-21

Mainshaft
Reassembly
NOTE: Refer page13-18 reassembly for sequence. to 1. Support 2nd g€ar on steel blocks as shown, then i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n gt h e s p e c i a l tools and a pressas shown. NOTE:After installing, inspectthe operationof the 3rd/ 4th synchrohub set. (T..nsmi$ionTypol: M2L5, M2S4
PRESS

Installthe sth synchro hub using the spocialtools ano a pressas snown.
,40 ORIVER. mm l.D. 07746- (x)30100

HUB sTHSYNCHRO

1
3RD/4TH SYNCHRO HU8 3. lnstallthe ball bearingusingthe special tools and a pressas snown.

Typel: M2F4 {Transmis3ion

BCARING ATTACHMENT,35 mm l.D. 07745 - (x}301o0

ATTACHMENT, a2xaTmm 07?46 0010300

2ND GEAR

13-22

Countershaft
lndex
I air, B"for" """"mbling. cleanall partsin solvent, them with compress€d then coatthem with cleanoil. dry

Replsce. LOCKNUT 130 + 0 + 130N.m + 0 + 13kg-m, 113 r 9a + 0 + 9a lb-ft

GEAB REVERSE

WASHER SPRING BALLBEARING Checkwear and oporation.

lSI/2ND SYNCHRO HUB Insp€ction,page 13-30

NEEDLE BEARING Checkwear and operation. FRICTION DAMPER Check w€ar and d6mag€. SYNCHRO SPRING ilTH GEAR RING SYNCHRO pa96 13-31 Inspection, 5TH GEAR

lST GEAR

3RD GEAR

page 3'l Inspection, 13-24, BEARING NEEDLE wearsndoporation Check THRUSTWASHER page13-?4 Solection,

2ND GEAR pag€13-24, Inspoction, 31

NEEDI..E BEARING Chsck wear and operation. SPACER COLLAB pag€13-24 Sel6ction,

OOUNTERSHAFT p8g€ 13-26 InsDection,

FRICTION OAMPER Checkwear and damage. page13-25 Removal, page13-27 Installation, INNERSYNCHRO RING page13-31 Inspection, SYNCHRO CONE OUTERSYNCHRO RING page'13-31 Insp€ction, SYNCHRO SPRING

13-23

Gountershaft
Clearance Inspection
l, Measurethe clearancebetweenthe 1st gear and thrustwasher. 0.04- 0.10mm {0.002- 0.0O'lin} ServicaLimit: 0.18 mm 10.007 inl Standard: 3. Measurethe clearance betwoenthe 2nd gear and 3rd gear. Strndlrd: 0.0,1- 0.10mm {0.002- 0.00il in) Sorvico Limil:0.18mm (0.007 in)

THBUST WASHER

2.

lf the clearance exceeds servicelimit. selectthe the appropriate thrust washerfor the correctclearance from the chartbelow,

4.

lf the clearanceexcesdathe service limit, selectthe appropriatespace.collar for the correctclearance from the chart below.

THRUSTWASHER Part Number 23921 PG1- 000 2 3 9 2 2 - P G 10 0 0 23923-PG1-000 D 23924-PG1-000 23925 PGl -000 Thicknaes 1 . 9 6 m ( 0 . 0 7 7 i1 ) m n 1.99mm (0.0783 in) 2.02mm (0.0795 in) 2.05mm (0.0807 in) 2.08mm 10.0819 inl

SPACER COLLAR

Prrt Numbcr
A 23917-P21-O10

Thickn..s

B

29.02 29.04 mm ( 1 . 1 4 2 51 . 1 4 3i 3 ) n
29.07- 29.09mm ( 1 . 1 4 4-5 1 . 1 4 5 i n ) 3

B

23918-P2'r-010

E

13-24

'1.

S e c u . e l yc l a m p t h e c o u n t e r s h a f t s s e m b l yi n I a benchvisewith wood blocks. Raisethe locknuttab from the groove ot the shaft and removethe locknutand the springwasher,

4.

Remove the friction damper trom the spacer collar using a prgss and a socket as shown.
PRESS

+

CHISEL

SPRING WASHER BENCH

vtsE

BLOCKS WOOD

Replac€.

3.

Remove ball bearingusinga pressas shown. the

PRESS

ATTACHMENT

4TH GEAR

COUNTERSHAFT

STEEL BLOCKS

3-25

Countershaft
Inspection
'1. lnspect the gear surface and bearing surface for wear and damage,then measurethe countershaft at pointsA, B, and C. StandErd: A:38.fi10l1.i(t61 B: 39.984{1.5742 C: 24.987 {0.98:17 38.015mm f.il967 inl /{1.000mm 1.57'18 inl 25.000mm 0.9843in)

Reassembly
NOTE: Refer page13-23 reassembly to for sequence. 1, Installthe thrustshim, needlebearing,lst gear,friction damper,synchroring,and synchrospring. NOTE:Reassemble lst gear and frictiondamper th€ beforeinstallation.
SYNCHRO SPRING SYNCHRO RING FBICTION DAMPER lST GEAR NEEDI.E BEARING THRUSTSHIM

Limit:A:37.950 (t.t*t41 Sorvico mm in) B:39.930 (1.5729 mm inl C:2il.9il0 mm (0.9819 inl

Inspect wearand damage. for

COUNTERSHAFT

lf any part ot the countershaft lessthan the seris vice limit. replace with a new one. it Inspect runout. for St.ndard: 0.02 mm 10.001 in) S€rvicoLimh: 0.05 mm (0.002in) 2. NOTE:Support th6 countershaftat both ends as snown. Installthe 1sv2ndsynchrohub by aligningthe frict i o n d a m p e r f i n g e r s w i t h 1 s t / 2 n ds y n c h r o h u b grooves.
lST/2ND SYNCHRO HUB

Rotate two complele revolutions,

It the runout exceeds the servicelimit, reDlace the countershaft with a new one.

13-26

Install Jriction the damperon the spacercollarusing the soecialtools and a Dress shown. as

Install the needlebearing, Installthe ball bearing using a specialtool and a pressas shown.
PRESS

PRESS

DRIVER 077€ - 0010000

+
ATTACHMENT,42 x 47 mm 07746- (X)103q)

t

COLLAR SPACER

ffi!--;.+a'-,
1. 8. I n s t a l t h e 2 n d g e a r b y a l i g n i n g h e s y n c h r oc o n e l t fingerswith 2nd geargrooves.
o

Install springwasher. the S e c u r e l yc l a m p t h € c o u n t e r s h a f t s s e m b l yi n a a benchvisewith wood blocks. Tightenthe new locknutto the correcttorque,th€n stakethe locknut tab into the groove Torqus:130+ 0 + 130N.m (13.0 13.0kg-m, 9 4 + 0 + 9 al b - f t )
LOCKNUT Replace.

GROOVE

FINGER BENCH

vtsE

t

wooD Bl-ocKs

13-27

Shift ForkAssembly
Disassembly/Reassembly
I e,ior. reassembling, cleanall the partsin solvent, them and apply lubricant any contactparts. to ,o dry

5 mm PIN PUNCH

1ST/2NDSHIFTFORK

13-24

NOTE:The synchrosleeveand synchrohub should be replaced a set. as 1. Measure the clearance betweeneach shift fork and its matching synchrosleeve. Standard: 0.35- 0.65mm {0.014- 0.026in} ServiceLimit: 1.0{ mm {0.039in)

3.

Measurethe clearance betweenthe shift fork and the shift arm. Standard: 0.2 - 0.5 mm l0.fi)8-0.019in) Sorvic€Limit 0.6 mm (0.02i1 inl

sTH/REVERSE SHIFT PIECE

SIfEVE SYNCHRO

3ND/'TH SHIFTFORK

SHIFTFORK SHIFTARM

lf the clearance exceeds the servicelimit, measure the width of the shift arm. 2. lf the clearance exceeds the servicelimit, measure the thickness the shiftfork fingers. of Stlndard: 12.9- 13.0mm (0.508 0.5f2 inl

Standard: M2F4(Transmission Type) 3rd/4th shift fork (Transmission M2L5/M2S4 Type) 3rd/4th shift fork 7 . 4- 7 . 6m m (0.291 0.299in) 6.2- 6.4 mm |'0.244 0.252inl

iy
SHFTFORK lf the thicknessof the shift fork finger is less than the standard, replace shjftfork with a new one. the lf the thickness the shift fork finger is within the of standard, replacethe synchro sleeve with a new one.

d

SHIFTARM

lf the width of the shift fork finger is less than the replace shiftarm with a new one. standard, the lf the width of the shiftfork finger is within the standard, feplace the shift fork or shift piecewith a new ones.

SynchroSleeve, SynchroHub
Inspection
1.

lnstallation
Eachsynchrosleevehas three sets of longerteeth (120 apan)that must be matchedwith the three sets degrees of deepergroovesin the synchrohub when assembled. NOTE:Installing the synchrosleevewith its longer synchrohub slots will damage teeth in the 1sV2nd the spring ring.

gear teeth on all synchrohubs and synchro Inspect sleevesfor rounded off corners. which indicates

I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o sleeveand checkfor freedomof movement. NOTE:lf replacementis required,always replace ths synchrosleeve and synchrohub as a set.

TEETH LONGER SYNCHRO HUB SLOT

SYNCHRO HUB

13-30

Synchro Ring,Gear
Inspection
1. Inspect synchroring and gear. the A: Inspect insideof the synchroring for wear. the B: Inspectthe synchrosleeveteeth and matching t e e t h o n t h e s y n c h r or i n g f o r w e a r { r o u n d e d off).
GOODWORN C: Inspect the synchro sleeve teeth and matching SYNCHBO

SYNCHRO

teethon the gearfor wear (rounde;$).
GOOO WORN

D: Inspect gear hub thrustsurface wear. the for

E: Inspectthe cone surfacefor wear and roughness. F: Inspect the teeth on all gearsfor unevenwear. galling,and cracks. scoring, 2. C o a t t h e c o n e s u r f a c eo f t h e g e a r w i t h o i l a n d p l a c et h e s y n c h r o r i n g o n t h e m a t c h i n gg e a r . Rotate rjng, makingsurethat it does not slip. the Measurethe clearance betweenthe synchro ring and gear all the way around. N O T E : H o l d t h e s y n c h r o r i n g a g a i n s tt h e g e a r evenlywhile measuring clearance. the Synchro Ring-to-Gear Clearance Standard: 0.85- 1.10mm (0.033- 0.0,|:|inl Servico Limit: 0.4 mm {0.015 in) Doubl€ Cone Synchro-to-Gear Clearance Standard: @:(Outer Synchro Ring to Synchro Con€) 0.5- 1.0mm (0.020-0.039 inl @: (synchro Cone to Gear) 0.5- 1.0mm (0.020 0.039in) Synchro Ring to Gear) @:lOuter 0.95- 1.68mm (0.037- 0.066in) Ssrvice Limit: in) @:0.3mm (0.012 in) @:0.3mm (0.012 in) @:0.6mm (0.024 l f t h e c l e a r a n c ei s I e s s t h a n t h e s e r v i c e l i m i t , replace synchroring and synchrocone. the
INNEN SYNCHRO RING

SYNCI{FORING

SYNCHRO RING

13-31

Bearing/Oil Seal Mainshaft
Replacement
1.

C
4. side Drivethe new oil seal in from the transmission as usingthe specialtools shown.

Remove differential the assembly. l R e m o v e h e b a l l b e a . i n gw i t h t h e s p e c i a t o o l a s t snown.

3.

Remove oil sealfrom the clutchside. the

DRIVER 07749 001(x)00

3/8 in r( 16 thr.rd/in SLIDEHAMMER {Comm.rci.lly .v.il.blc)

ATTACHMEN?, U 2 x 1 7m m 07746 - (x)l0300

Aq,USTABLEBEARING PULER, 25 - 40 mm 07736- A01rDoA OIL SEAL Replacs.

6

Drivethe new ball besringin from the transmission side usingthe specialtools shown. as

BALLBEABING

AALLBEARING

ATTACHMENT, 62x68mm 077a6 - (X)105(x)

AALLAEARING

13-32

Countershaft Bearing
Replacement
1. platefrom the clutchhousing. Remove the retaining Position the oil guide plateand new needlebearing in the bore of the clutchhousing. NOTE:Position the needlebearingwith the oil hole facingup.
OIL HOLES BEARING NEEDLE

Removethe needle bearing with the specialtool, then removethe oil guide plate.

Drive the needlebearingin using the specialtools as shown. DRIVER 07749 (xll(xx)O

3/8 in x 16 throad/in SLIDEHAMMER (Commc.ciallyrvailrblel

ADJUSTAB1IBEARING PULLER, - i(, mm 25 0t736 - A01@0A

NEEDl-E NEEDLE BEARING

(cont'd)

13-33

Bearing Countershaft
Replacement(cont'dl
plsteand stakethe bolt headsin lnstallthe retaining plate. the groovein the retaining
6x1.0mm 12 N'm {1.2kg-m,9lb-ftl Replaco.

MainshaftThrustShim
Adjustment
1. Removethe thrust shim and oil guide plate from housing. the transmission PLATE otl GUIDE rHnr rcr qHlM

RETAINING PLATE

Installthe 3rd/4thsynchrohub, spacercollars,sth synchro hub, and ball bearing on the mainshaft, then installthe aboveassemblyin the transmission housrng. lnstallthewasheron the mainshaft. Measuredistance betweenthe end of the trans@ missionhousingand washer. NOTE: a Usea straightedgeand verniercaliper. a Measure three locations at and average readthe
Ing.

ENDot TRANSMISSION
HOUSING MAINSHAFT

WASHER

HUA 3RD/4THSYNCHRO SPACER COLLAR sTH SYNCHRO HUB SPACER BALLBEARING

1 3 -3 4

5.

Measure distance @ between the end of th€ clutch housingand bearinginnerrace. NOTE: . Usea straightedg€and depthgauge. ! Measure three locations at and averagsthe readings.

78 mm THRUSTSHIM Part Numbor 23941 PK5- 000
Thiqkno!!

'1.20 mm (0.0472 in) 1.23mm (0.0484 in) 1 . 2 6 m ( 0 . 0 4 9 i6 ) m n 1.29mm (0.0508 in) 1.32mm (0.0520 in) 1.35mm (0.0531 in) 1.38mm (0.0543 in) 1.41mm (0.0555 in) 1.44mm (0.0567 in) 1.47mm {0.0579 in) 1.50mm (0.0591 in)

23942-PKs-000
a

23943-PKs-000
23944-PK5-000

D E
ENDof CLUTCH HOUSING

23945-PKs-000 23946-PKs-000 23947-PKs-000 23948-PKs-000 23949-PKs-000 23950-PKs-000 23951 PKs 000 23952-PKs-000 23953*PKs-000 23954-PK5-000 23955-PKs-000 23956-PKs-000 23957-PKs-000 23958-PKs-000 23959-PKs-000 23960-PKs-000 23961 PKs- 000 23962-PKs-000 23963-PKs-000

F

H

K L
BEARING

1.53 mm (0.0602 in)
1.56mm (0.0614 in) 1.59mm (0.0626 in) 1.62mm (0.0638 in) '1.65 mm (0.0650 in) 1.68mm (0.0661 in) 1.71mm (0.0673 in) 1.74mm (0.0685 in) 1.77mm (0.0697 in) 1.80mm (0.0709 in) 1.83mm (0.0720 in) 1.86mm (0.0732 in) '1.89 mm (0.0744 in) 1.92mm (0.0756 in 1.95mm (0.0768 in L98 mm (0.0780 in 2.01mm (0.0791 in 2.04mm {0.0803 in 2.07mm {0.0815 in 2 . 1 0m m ( 0 . 0 8 2 i7 n 2.13mm (0.0839 in 2.16mm (0.0850 in 2.19mm (0.0862 in)

M N

o
P

o
6. S e l e c tt h e p r o p e rt h r u s t s h i m f r o m t h e c h a r t b y usingthe formulabelow. NOTE: Useonly one thrustshim. Shim SoleqtionFormula: you Fromthe measurements made in steps4 8nd 5: -1. Add distance {step5) to distsnce (step4). @ @ -2. Ftom this number,subtract0.93 (which is the midpoint of the flex rangeof the clutchhousingbearing springwasher). -3. Take this number and compare it to the available shim sizesin the chart. (Forexample) B: 2.39 + C: O.22 = . ,.tr/ , /,/ 2.61 0.93 R

s
T
U

X

23964-PK5-000 23965-PK5-000 23966-PKs-000 23967-PKs-000 23968-PKs-000 23969-PKs-000 23970-PKs-000 23971 PK5 000 23972-PKs-000
23973-PK5-000

z
AB
AC

AD AE
AF AH AI AJ

= t*

23974-PKs-000 23975-PKs-000 23976-PKs-000
23977-PK5-000

Try the 1.68mm (0.0661 shim. in)

2.22 mm (0.0874 in)
2.25mm {0.0886 in} 2.28mm (0.0898 in) 2.31mm (0.0909 in) 2.34mm (0.0921 in) 2.37mm (0.0933 in) {cont'd)

AK
AL

AM AN

23978-PKs-000 23979-PKs-000 23980-PKs-000

13-35

MainshaftThrustShim
Adiustment(cont'd)
in Checkthe thrust clearance the mannerdescribed below, at NOTE:Carryout the measuremsnt normal room temperature. -1. Installthe thrust shim selectedand oil guide platein the transmission housing.
OIL GUIDEPLAYE

-7. Slidethe mainshaft baseover the mainshaft.
MAINSHAFT TRANSMISSION

-2. Install the spring w a s h e ra n d w a s h e ro n t h e ball bearing. NOTE: . Clean the springwasher,washerand thrustshim throughlybeforeinstallation. . l n s t a l l t h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t shim properly.

-8, Attachthe mainshaft holderto the mainshaft as follows: NOTE: o B a c k - o u tt h e m a i n s h a f t h o l d e r b o l t a n d loosenthe two hex bolts. . Fit the holderover the mainshaft its liD is so towardsthe transmission. . Align the mainshaftholder'slip around the groove at the insideof the mainshaft splines, then tightenthe hex bolts. MAINSHAFT HOLDER EOLT

g

WASHER

aSttRrNGwasHER
in Installthemainshaft the clutchhousing. -4. Placethe transmission housingover the mainshaftand onto the clutchhousing. Tighten the clutch 8nd transmissionhousings with several mm and l0 mm bolts 8 Tap the mainshaft with a plastichammer.

l:vli ffir"
MAINSHAFT HOLDER O?GAJ PG2O11O

lla-F.

BASE MAINSHAFT 07GAJ PG20130 -9. Seatthe mainshaft fully by tappingits end with a plastichammer. -10. Threadthe mainshaftholderbolt in until it just c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t Dase. -1 1.Zero a dial gaugeon the end of the mainshaft.

13-36

Transmission
Reassembly
-12, Turn the mainshaftholder bolt clockwise; stop t u r n i n gw h e n t h e d i a l g a u g eh a s r e a c h e d t s i maximum movement.The readingon the dial gaugeis the amountof mainshaft end play. CAUTION: Turning iho mainshaft holder bolt mor€ than 60 dogrecs after tho noodle of ths d i a l g l u g a 3 t o p s m o v i n g m a y d a m a g ot h e transmission.
DIALGAUGE

Installthe differential assemblyin the clutch housing.
OIFFERENTIAL ASSEMBLY

MAINSHAFT HOLDER 07GAJ FG20110 -13. lf the readingis within the standard. the clearance is correct. lf the reading is not within the standard. recheckthe shim thickness. Strndard:0.100.16mm (0.00i1- 0.006in)

CLUTCH HOUSING Installthe springwasherand washerwith the angle against clutchhousingas shown the lnsertthe mainshaftand countershaft into the shift forks 8nd installthemas an assemblv. NOTE: Beforeinstalling the mainshaft and countershaft assemblies, tape the mainshaft splinesto protectthem.
MAINSHAFT ASSEMBLY

Tapethe mainshaft splrn6.

(cont'd )

13-37

Transmission
(cont'dl Reassembly
4. Installthe reverseidler gear and reverseidler gear shaft in the clutchhousing. 6. NOTE: the thrust shim according the meato Select madeon page13-34. sur€ments Installthe oil guide plate and thrust shim into the transmission housing.

CLUTCH
TRANSMISSION HOUSING

5.

Installthe reverseshift fork in the clutch housing in with th€ sth/reverse shift piecepin positioned the slot of the reverseshift fork, NOTE: Check that the steelball is in the properposiIlon.

7.

housInstallthe oil gutter plate in the transmission ing. NOTE:Bendthe hook of the oil gutter plateinto the holeon the transmission housing. Installthe28 mm sealingbolt.

REVERSE SHIFTFORK

6x1.0mm 15 N'm 11.5 kg-m.11lb-ft,

NOTE:Apply liquid gasket(P/N 08718the threads.
28 mm SEALING BOLT 15 N.m 14.5 kg-m, 33 lb-ftl OIL GUTTER PLATE

0001)to

HOUSING TNANSMISSION

13-38

Apply liquid gasketto the clutch housing mating surface shown. as NOTE: . Useliquidgasket(P/N08718 0001). . Remove dirt oil fromthe sealing the surface. . Seal the entirecircumference the bolt hole to of preventoil leakage. . lf 20 minutes have passedafter applying liquid g a s k e t ,r e a p p l yi t a n d a s s e m b l e h e h o u s i n g s t a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r assembly beforefillingtransmission with oil.

12. Lower the transmission housingwith the snap ring p l i e r sa n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e countershaft bearing.
SNAPRING

---: Liquid g6k.t *: Dow6l pin

1 0 . Installthe14 x 20 mm dowel pins.
1 1 . Set the stopperring as shown. Placethe transmission housingover the clutchhousing,being careful to line up the shafts. NOTE:Align the long arm of sth shift fork with the hook on the stopperring.

1 3 . Checkthat the snap ring is securelyseated in the grooveof the countershaft bearing. DimensionA as installed: 3.60 - 6.32 mm l0.i,r2_ 0.249inl
1 4 . Install the 32 mm sealingbolt.

NOTE:Apply liquid gasket(PiN 08718the threads. 32mm SEAI-ING BOLT 25 N.m12.5 kg-m,18lb-ftl

0001)to

sNAperN.:

{cont') d

13-39

Transmission
Reassembly(cont'dl
tc,

Assembly Transmission
lnstallation
1. the dowel pins. Install

pattern in several Torque the bolts in a crisscross stepsas shown. I x 1.25mm bolts: 28 N'm (2.8 kg"m, 20 lb-ft) 10 x 1.25mm bolts: ,15N.m (4.5 kg-m, 33 lb-ft|
1O mm BOLTS

O Or 8 x 50 mm bolts 8 Other: x /U'mm bolts idlergearshaft bolt. the reverse 16. Install 17. Installthe steel balls,springs,washersand settlng screws. BALL 5/16in) lD. STEEL
WASHER Beplace. G SCREW 22 N.m {2.2kg-m, 16lb-ft)

to Apply grease the pans as shown,then installthe fork (seepage 12-7). release bearingand release N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e (P/N08798 9002).

FORK RELEASE

FORK RELEASE SETSPRING

I
I

RELEASE FORK BOOT FORKBOLT kg-m, 22 lb-Itl 30 N.m 13.0

3. BOLT 18 13). through all the gears before 19. Shift the transmission installing it.
kg'm. 40 lb'ttl 55 N.m 15.5 shift arm cover assembly (see page 13-

fork boot. lnstalltherelease

1 3 -4 0

P l a c et h e t r a n s m i s s i o n n t h e t r a n s m i s s i o na c k , o i and raiseit to the enginelevel. Install three lowertfansmission the mountinqbolts.

7.

R a i s et h e t r a n s m i s s i o n , h e n i n s t a l l t h e m o u n t t bracket and transmission mount. NOTE: . T o r q u e m o u n t i n gb o l t s a n d n u t s i n s e q u e n c e snown. . Makesurethe bushings not twistedor offset. are
TBANSMISSION MOUNT

12 x 1.25mm 65 N.m 16.5kg-m.

O Tighren 10x 1.25 mm

O Tighten 10 x 1.25mm 39 N.m 13.9 kg-]n, tb-ft)

BRACKET 66 N.m (6.5kg-m, ia1lb-ft) O Tighton 10x 1.25mm 10 x 1.25mm 39 N.m (3.9kg-m, 39 N.rn 13,9 kg-m, 28 tb-ft) 28 rb-ft) O Tight.n t.mpor..ily @ Tighron 12x 1.25mm 65 N{n (6.5 kg-m, a7 lb"ftl 8. Install the th.ee rear engjne mount bracketmounting bolts.

O tidhron

6.

Install two uppertransmission the mountingbolts.

MOUNTINGBOLTS Replace. 12 x 1.25mm 55 N.m 15.5 kg-m, 40 lb-ft)

12 x 1,25mm 65 N.m (6.5kg-m, 4t lb-ft}

(cont'd)

Assembly Transmission
(cont'dl Installation
9. lnstalltherearbeamstiftener. and clutchcover. the 11. Install front enginestiffener NOTE:Torque the front engine stiftenermounting sequenca. boltsfollowingthe numbered kg-m. 28 lb-ft) Torque: 39 N.m 13.9

3!, N.m {3.9 kg-rn, 28 tb-ft)

'10. Install the intake manifold staY.

INTAKEMANIFOLD STAY

12. lnstallthe centerbeam,

10 x 1.25mm 60 N.m 16.0 kg-m, 43 lb-ftl

13-42

Installthe intermediate shaft and driveshafts{see section161. 10x 1.25mm 39 N.m13.9 kg-m,28lb-ft|

1 7 . Install the rearenginemount bracket stay. NOTE: Loosely installthe stay mounting bolt and nut, then torque in the sequence shown.

SPECIALBOLT 10 x 1.25mm 39 N.m (3.9tg-m, 28 tb-ft,

10x 1.25mm 21 N.m {2.'l kg-m, 15 tb-ft|

1 4 . Installtheradiusrod. NOTE: Check for deteriorationor damage of the radiusrod rubberbushings. 1 5 . Connect the ball joint to the lower arm, then install t h e b a l l j o i n tn u t .
16. Installthe damper fork bolt, SELF.LOCKING BOLTS Replac€. 12 r 1,25mm 105 N{n (10.5kg-m, ?6lb-ft| SELF.LOCKING NUT Replace. 12 x 1.25mm 55 N{r| (5.5 kg-m,

10x 1.25mm 39 N.m 13.9kg-m, 28 lb-ft)

18. Installtheclutchdamoer.

40 tb-ft|

ROD

Replace. / AALLJOINT NUT 14xZtmm 55 N.m 15.5 kg-m. 40 lb-ltl

/

/1*-

corrERPrN

SELF.LOCKING NUT Replace. 12x 1.25mm 65 N.m {6.5 kg-m, a7 lb-ft| I x 1.25mm 22 N.m 12.2 kg-m, 16 lb-ft|

(cont'd)

13-43

TransmissionAssembly
lnstallation (cont'dl
then installthe clutch pipe 19. Installthe slavecylinder, joint and stay. CAUTION: Take care not to bend the clutch pipe. 21. Installthe shift cable and selectcable to the shift leverand to selectleverrespectavely. CAUTION: Tako care not to bsnd the cabl€s. NOTE: firmly. ! Check that the new cotterpin is seated . Turn the boot of the shift leverso the hole is facI x 1.25 mm kg-m, 16 lb'ft} 22 N.m 12.2 Ing down. I x 1.25mm {P/N 08798- 90021 PIN COTTER ReplaceSTEEL WASHER PLASTIC WASHER SELECT CABLE CABLE

6x1.0mm 10 N.m {1.0kg-m, 7 rb-ft}

)
tP/N 08798- 9002) 8 x 1.25mm 22 N.m {2.2kg-m, 16lb-ft}

PIN COTTEB Replace.

BOOT SHIFTLEVER WASHER WASHER

groundcableand back-up the 22. Connect transmission light switchconnectors. steer20. Installthe vehiclespeedsensor(VSS)/power the then connect VSSconnector' ing speedsensor, I x 1.25mm kg-m, 14lb-ft) 19N.m11.9 clamp. 23. Installthewire harness 24. Installthe starter motor, then connect the starter motor cables.
S CONNECTOR

Mr"'

POWER STEERING SENSOR SPEED

N O T E : W h e n i n s t a l l i n gt h e s t a r t e r m o t o r c a b l e , makesurethat the crimpedside of the ring terminal is facingout (seesection23).
6x1.0mm

(il5 33 t io r'i'"'ii.i 11n--, 'o-ft1 45N'm ks-m, lb-ft|

l0 x 1.25mm

fnt$rtt ,"o""",..to"
GROUND CABLE

WIRE HARNESS- , CLAMP STARTER MOTOB CABLES

8 x 1.25mm 22 N.m (2.2kg-m, 16 tb-ft)

12 x 1.25mm 75 N.m (7.5kg-m, 54 tb'ft) 6x1.0mm 't0 N.m 11.0 kg-m,7 rb-ft)

13-44

25. Install the bracket and intakecontrolvacuumtank.
INTAKECONTROL

27. Installthebasestayand batterybase.

x 1,0mm 10 N.m 11.0 kg-m, 7 tb-ft|

BASE STAY

6x1.0mm 10 N.rn (1.0kg-m, 7 tb.ftl

BRACKET

I
Front

8 x 1,25mm 22 N.m (2.2 kg-m, 16 rb-ft}

26. Install the air cleaner assemblv and intakeair duct.

6x1.0mm 10 N.m {1.0kg-m,7 lb-ft|

24. Refillthetransmission with oil (seepage13-2). 29. Install the battery. then connect the battery positive (+) and negative cables the battery. (-) to 30. Check clutchoperation. the 3 1 . Shift the transmission and checkfor smooth operatron. 32. Check front wheel alignment the {seesection18).

{cont'd)

13-45

Assembly Transmission
Installation (cont'd)
the 33. Loosen three mountingbolts of the front engine t mount bracket, hen torque the three mounting bolts. NOTE:Make sure the bushingsare not twisted or offset. BRACKET ENGINE MOUNT FRONT

13 -4 6

Automatic Transmission
Tools..... Speciaf ........14-2 OilPump Description ........ ........14-3 Inspection.......... ....14-101 C1utches.............................................1 Valve Bodv 4-6 Main PowerF|ow.......................................1 Disassembly/lnspection/Reassembly. 4-9 4-1 .....'l 02 Electrical Control Svstem................1 4-10 Secondary ValveBody Hydraulic Flow.................................,1 4-13 4-1 Disassembly/lnspection/Reassembly. .....1 04 Lock-up System...............................1 Regulator 4-22 Valve Body Hydraufic Contro1..............................1 4-28 14- 106 Disassembly/lnspection/Reassembly...... ThrottleValveBody EloctricalSystom 4'1 Disassembly/lnspection/Reassembly. .....1 07 Component Location .......,...................1 4-31 Servo Body Circuit Diagram. ........14-32 1+ 108 Disassembly/lnspection/Reassembly...... * Troubleshooting Procedures...,,,,.,,,,,,,1 4-g 1st/2ndAccumulator Body Symptom-to-Component Charr 14- 109 Disassembly/lnspection/Reassembly...... Electrical Svstem..............................1 Mainshaft 4-36 Electrical Troubleshooting +1 Disassembly/lnspection/Reassembly. .....1 1O Troubleshooting F|owchart...............,.... 14-38 Countershaft Mainshaft/Countershaft Sensors Soeed 4-1 Disassembly/lnspection/Reassembly. .....1 1 1 Replacement .........14-61 Remova1............. ....14-112 Lock-upControlSolenoid ValveA/B 13 lnstallation .,...........14-1 Test..........,......... ....14-62 One-wavClutch Repfacement .........14-62 +1 Disassembly/lnspection/Reassembly. .....1 14 Shift ControlSolenoid ValveA/B Secondarv Shaft Test.................... ....14-63 15 Disassembly/lnspection/Reassembly......14-1 Replacement .........14-63 Insoection.......... ....14-116 Clutch HydraulicSystom flfustrated fndex................... +1 17 ..............1 Symptom-to-Component Chart Hydraulic System.............................1 +64 * Road Test....... ...........14-68 StallSoeed Test....................................................1 4-71 FluidLevel +1 28 Countershaft Bearing Replacement...,.,..1 Checking/Changin9....................... ....1 +72 4-128 Secondary ShaftBearing Replacemen1...1 Pressure Testin9.................,,..,,..,...,.....1 Transmission 4-73 Housing Bearings 4-1 Removal/lnstallation ..................... 29 ....1 Transmission Transmission Transmission Reassembly ....... ....1+130 Remova1............. ....14-80 RightSideCover lllustrated lndex +1 36 Feed PipeInsta;;ation......................,.1 Right SideCover...............................1 Parking 4-86 BrakeStopper Transmission Housin9......................1 4-88 4-1s?6 Inspection/Adlustment ....................1 Torque Converter Housin9...........,,.1 4-90 ToroueConverter RightSideCover Disassemblv ..........1+'137 Remova1............. ....14-92 Transmission Transmission Housing Installation .............1+138 Remova|............. ....14-94 CooferFlushing.. ..,.14-142 Torque Converter Housing/Vafue Body shifr cable *Removal/lnstallation Remova|............. ....14-96 ..............,... 4-144 .,,,,,.1 *Adjustment...... ValveBodv ......14'146 * Gearshift Repair................. ....14-98 4'147 Selector .............,,..,,.,,,,,.,...,.1 Valve A/T GearPosition Indicator Panel *Adjustment...... Assembly........... ....14-99 .,'.1+148 ValveCaos ThrottleControlCable Description ...,.... ....14-100 Insoection.......... ....14-149 Adiustment........ ....14-150

'i45"Hgffi *i:|i'',i',

SpecialTools

I

Rot. t{o.

Tool Numbar 07GAB-PF5010O or 07GAB-PF50101 oTGAE-PG40200 oTHAC-PK4010A 07HAE-PL50100 07LAE-PX40100 OTLAJ-PT3O1OA 07406-@20201 07406-@20@3 07106-0070@0 07730-A010@A 07746-@10400 07746-OO10500 07746-0010600 07749-OO10000 07947-63zto5@ J38405-A

Dolcrlptlon MainshsttHoHer Clutch Sprino Compressor Ass€mbv Bolt HousingPullor Attachment Clutch SpringCompressor Attachm6nt Clutch SpringCompresaor Test Harnass Hos€s} A/T oilPressure Hose {ReDlacement A/T OilPressureGsugeS€t A/T Low Pressure Gauge AdjustableBesringPuller,25-40 mm Attschment, 52 x 55 mm Attachment, 62 x 68 mm Attachment, 72 x 75 mm Oriver Attachment Transmission Cool€rFlushor

otv
1 1 1 I I I I 1 1 1 1 1 1 1 1 'I

PagoRoferanca

o
ri

1+92,1U 1+121,124 1+93 1+121,124 1+121,124 1+35,68 1+73 1+73 1+73 1+1n 1+18 1+127,'128 1+'127 1+127,14 1+127 1+142

o o o

@ @ @ @ '@ @ @ @

G

@ @

6,rmr--€

I

o
@

\!,

@

o

@

o

o

@

G

0
'0

a

Must be used with commercially available in, x 16 throads/in.slid6nammer. 3/8

14-2

Description
The Automatic Transmissionis a combination of a 3-element torque converter 8nd tripls-shaft electronicaly controllod sutom8tic transmissionwhich provides 4 speedsforward and 1 speed reverse.The entire unit is poshionedin line with the engrne. Torqug Convarter, G6arsand Clutches The torque converter consistsof a pump,turbine and stator Sssembled a singlsunh, in Thsy are connectedto the enginecrankshsJtso they turn togeth€r as a unh as the engineturns. Around th€ outside of the torque conv€rter is a ring gear which meshes with the stsrtel pinion wh6n the engin€ ig b€ing st8rt6d. The antir€ torque converter assemblyservesas a flywheel while transmittingpower to the transmission mainshaft. The transmissionhas three psrsllelshatts: the mainshatt,the countershaft, and ths secondaryshaft. The mainshaftis in line with the enginecrankshsJt. The mainshaftincludesthe clutchestor 3rd. snd 4th, and gearsfor 3rd, 4th, R6vsrseand ldlor (Rsverse gesr is intogralwith 4th gear). The countershaftincludesthe lst-hold clutch and gearsfor 2nd, 3rd, 4th, Reverse,lst EndHler. Th6 secondaryshaft includes the 1st and 2nd clutches,andgesrstor 2nd, 1st and Hler. The 4th 8nd reverse g€arscan be lockedto the countershaft 8t its center, providing4th gear or Reverse,depending which on w8v the selectoris moved. Ths gears on the msinshaJtare in constsnt m€sh with thosa on ths countershatt and the secondaryshaft. When certain combinationsof gears illbe lMsDl9giol lre etglged by the clutches, power is tr8nsmitted from the mainshalt to the countershaft pro"ia" O.-l,f-O"-l,f , T and@oosirions. to EleqtronicControl The electroniccontrol system consistsof the Transmission Control Module{TCM),sensors,and 4 solonoidvalves.Shifting 8nd lock-upare €l6ctronicslly controlledfor comtonable drivingunder allconditions, The TCM is locatedb8low the dsshboard, behindthe right sido kick panolon the psss6ng6r's sids. Hydr8ullcConilol The vslve bodiesincludethe main valve body. secondaryvafue body, servo body, regulatorvafue body, throttl€ vsve body and lst/2nd accumulatofbody.They 8re bohedto the torque converter housingas an assembly, The main vslve body containsthe msnualvalve, 1-2 shift valvs, 2-3 shift valvs, coolel relief valve, lock-up shift vafue, lock-up control valve, 3-2 kick-down valve, modul8torvatue.CPCvalve and oil pump gears, The secondaryvalvo body includesthe 4th exhaust valve, 3rd kick-down v8lve,3-4 shift vafu€, servo control vslve, orific€ controlvalve andthe 2ndotificecontrolvalv6. The servo body contains the accumulator pistons 8nd servo valve. The rogulEtorvafus body contains the roguhtor valve, torque converter check valve, and lock-uptiming v8lve. The throttle valve body contains ths throttle valve B and relief valve. Fluidfrom the regulatorpasses throughthe manuslvatveto the variouscontrol valves. The clutchesreceiveoiltrom their respectivefeed pip6sor internalhydrauliccircuit, Shlft Control Mechanism Input from various sensors located throughout the car determin€swhich shift control solsnoidvalve the TCM will activate. Activating 8 shiJt control solenoidvalve chsngesmodulator pressure,causingI shtft valve to move. This pressurizes line to a gear, one of the clutches,engaging that clutch and its corresponding Lock-up Machanlsm InL91l position,in 2nd, 3rd and 4th. andI D3 | positionin 3rd, pressurized fluid is drainedfrom the back of the torque converter througir an oil pass8ge,csusing the lock-up piston to be heH agsinst the torqus converter cover. As this takes phcs, th€ mainshaftrotates 8t the samespeedas the enginecrankshaft.Togetherwith hydrsuliccontrol, the TCM optimizesthe timingof the lock-upmechanism. The lock-upvatuescontrolthe rangeof lock-upaccording lock-upcontrolsolenoidvalves A and B, andthrottle valve B. to When lock-up controlsolsnoid vslves A and B activate, modulatorpressurechanges.Lock-up controlsolenoidvslv€s A and B are mountedon the torque converter housing.and are controlledby the TCM, lcont'dl

14-3

Description
(cont'd)
Gaar Sobction

4th Thesetector tever sevenpositions:@PARKt, REVERSe, rueurnef-,1 11stthroush gear,"n0"", @ has o. Fl @ 1stthrough gear 3rd rangss,2l2ndgearandl llstge8r. 1 |
Position Dolcrlptlon Front wheelslocked;p8rkingpswlengsgsdwith parkinggesr on countershaft.Allclutches released. Reve.se;reverseselectorengaged with countershaftreversegear8nd 4th gearclutch locked. Allclutches released. to on Generaldriving; starts oft in lst, shifts automatically 2nd, 3rd, thsn 4th, depending vehiclespeed and throttle poshion. Downshift tEglgh 3rd, 2nd and 1st on decelerationto stop. The lock-up mechanism comes into operstionin LP1Jpositionin 2nd, 3rd and 4th speed. starts otf in For rapidacceleration highwayspeedsand genersldrivlng; at up-hillanddown-hilldriving; lst, shifts automsticslly to 2nd, then 3rd, dspsnding on vehicle speed and throttl€ position. DownshiJtsthrough 2nd to 1st on dsceler€tionto stop. The lock-up mechsnismcomes into operation in 3rd sDeed. For enginebrskingor better traction starting off on looseor slipporysurfaces;stsys in 2nd gsar,doos not shitt up or down. For enginebrsking;stays in lst ge8r,does not shift up.

@ernr I nl nevensr r.reurnnrI n-] oo-l I(1st onve
through 4th)

I o.lonve
Flst throush 3rdl

@secor.ro

f rrnsr

positionsthrough th€ use ol 8 slide-type,n€utral-ssfetyswitch. St8rting is possible only in Ll,l andL!_.1 Automatlc TransaxlolA/Tl GoEl PoshlonIndlcatol A/T gear position indicator in the instrument panelshows what gear has been selectedwithout hsving to look down at the consore.

14-4

VA\
,IST CLUTCH

RINGGEAR

N

TOBOUE COT{VERTER

2I{D CLUTCH

COU TEASHAFT SPEED SE SOR

lST-HOLD CLUTCH

PARKINGGEAR

4TH CLUTCH

3RD CLUTCH

14-5

Description
Clutches
The four-speed automatic transmissionuses hydraulically actuated clutches to engageor disengage the transmissiongears. When clutch pressureis introducedinto the clutch drum, the clutch piston is Epplied. This press€sthe friction discs and sts€l plstes together. locking them so they don't slip. Power is then transmitted the through the engagedclutch psck to its hubgear. mounted Likewise,when clutch pressureis bledlrom the clutch pack, the piston releases triction discs and stsel plstes,snd th€y are the tree to slidepast each other while disengaged. This allowsthe gearto spin independently its shaft, trsnsmittingno power. of 13t Clutch lst The lst clutch eng€ges/disengages gear,and is locatedat the center of the secondaryshaft. to The lst clutch is joinedback-to-b8ck the 2nd clutch. The 1st clutch is suppliedclutch pressureby its oilfeed pipe within the secondsryshaft, 1st-hoH Clutch 'l The 1st-holdclutch engages/disengages st-holdor 1 1 i position,and is locatedat the end of the countershaft,just behind the torque converter housing. The I st-holdclutch is-supplied clutch pressureby its oil teed pipe within the countershsft. 2nd Clutch The 2id clutch engages/disengages gear,and is locatedat the center of th6 secondaryshaft, The hd clutch is ioined back2nd to-back to the 1st clutch. The 2nd clutch is suppliedclutch pressurethrough th€ socondaryshsft by a circuit connectedto th6 internal hydraulic circuit. 3rd Clutch The 3rd clutch engages/disengages geaf,and is locatedat the center of the msinshsft. 3rd The 3rd clutch is joinedback-to-back the 4th clutch. to The 3rd clutch is suppliedclutch pressurethroughthe mainshaftby a circuit connoctodto ths regulatorvalve body, 4th Clutch The 4th clutch engages/disengages gear, as well as reverse gear, and is located at the c6nt6r of the msinshaft.The4th 4th clutch is joined back-to-back to the 3rd clutch. The 4th clutch is supplied clutch proasuraby its oil feed pipe within the mainshaft. One-way Clutch The one-wayclutch is positionedbetweenthe countershaft lst gear and 3rd 968r,with the 3rd gsar splinedto th€ countsrshsft. The 1st gear providesthe outer racs surface, and the 3rd gear providesthe inner race surfacs, The on€-way clutch locks up when power istransmitted from the mainshaft1st gearto the countershEft1st gear. _ The lst clutch and gearsremainengaged the 1st. 2nd, 3rd, and 4th g€sr rangssin the ll1l, fQg,lor l ll oosition. in position. However, the one-wayclutch disengages when the 2nd, 3rd, or 4th clutches/gsErs aooliedin th@ are , I olorl2l This is becausethe increased rotationalspeedof the gesrson the countershstt overridesths locking"spe6d range" of th6 onsway clutch,Thereafter,the one-way clutch freewheelswith the 1st clutch still6ngaged.

COUNTERSHAFT 1ST GEAA LOCKS

FREE

NOTE: Viewlrom rightsid€covorsid€.

14-6

COUNTERSHAFT 3RDGEAR MANSHAFT COUI{TERSHAFT 1ST GEAB 3RD CLUTCH 4TH CLUTCH MAII{SHAFT 4TH GEAR MAIITSHAFT REVERSE GEAR

MAII{SHAFT IDLER GEAR
COUNTERSHAFT 4TH GEAR

MAIl{SHAFT

REVERSE SELECTOR SEI.ECTOR HUB COUTTERSHAFT IDLER GEAR

FII{ALDRIVE lST.HOLD SECOI{DARY SHAFT
ARKINGGEAR

COUNTERSHAFT 2NDGEAR COUiITERSHAFT REVERSE GEAR
SECONDARY SHAFT IDLERGEAN

SECOI{DARY SHAFT 2NO GEAR 2ND CLUTCH

FI AL DRIVEI{ GEAR

14-7

Description
(cont'd) Clutches
Lock-up Clutch 1. Operation{clutchon) With th€ lock-up clutch on, ths oil in the chsmbor between the converter cover and lock-up piston is drsined otf, snd the converter oil exerts pr€ssurethroughthe piston againstthe convertsr cover. As a resuh,the converter turbine is lockedto the the converter cover. The effect is to bypassthe converter, thereby placing car in direct drive.

tF"*"'ffil
The power flows by way of: Engine Driv€ plat€ Torqueconverter cover Lock-up piston Dsmperspring Turbine Msinshalt

PISTON LOCK.UP

DAMPERSPRING

J J J J

J J

MAINSHAFT

2. Operation(clutchotf) With the lock-upclutch off, the oil flows in the revers€ of CLUTCHON.As s resutt,the lock-up piston moves away from the converter cover andth€ torouo converter lock-uDis rel€as€d, TURBINE

Engine tirive plate J Torque conv€rter cover J Pump J Turbine J Mainshaft

MAINSHAFT

14-8

PowerFlow

}K
E

tr'|

t^-l
sT
2ND 3RD
4TH

tr

TOROUE1STGEAR lST GEAF 1 S T E A F GEAF3RDGEAR G 2ND 4TH REVERSE PARKING coN- 'IST-HOLD l S T ONE-WAY 2ND 3RD GEAR GEAR VERTER CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH

o

X
X

X

X X X X

X

X

X

o
X

o
o

X X

X

X
X
X

o
X X X

o
X X X X X X X X X X

o o o
o
X

o -o -o
.o

o
X

X X X X X X

o

X

X

o
X

X

X

o
X X X X

o
X X X X X

E
f;t
Lil

t5l

2ND 3RD

tr

o o o o o

o .o
X

o
X

X

X X

.o
.o o
X

o o
X

o
X
X

X
X X

o

o

X

driving pow6r in not transmittsd as the one-wav clutch O: Operates, x: Doesn't operate, *: Akhough the 1st clutch engsges, sliDs.
COUNTERSMFT MAINSHAFT 1STGEAR 3RD GEAR 3RDCLUTCH MANSHAFT

GEAR 4THCLUTCH REVERSE COUt'ITERSHAFT 3RDGEAR 4TH GEAR
MAII{SHAFT / REVERSE IDLER GEAR

MAINSHAFT IDLER GEAR MAINSHAFT COUiITERSHAFT GEAR 2I{D
COUNTERSHAFT IDLERGEAR PARKI G GEAR

<-

coul{TERSHAFT
PARKI]'IG PAWL SECONOARY SHAFT

OIL PUMP

TOROUE CONVEBTER
FINAL GEAR lST.TIOLDCLUTCH SHAFT 1ST GEAR lST CLUTCH

SECONDARY SHAFT IDLERGEAR

2NDCLUTCHI

SECODARY SH/TFT 2NDGEAR COUI{T€RSHAFT REVERSE OEAR REVERSE SELECTOR COUI{TERSHAFT
4TH GEAR

SERVO VALVE

14-9

Description
Electronic ControlSystem
Eloctror c Contlol Systom valves. Shitting8nd Control Module{TCM},sensors,and 4 sol€noid The sloctroniccontrol system consistsot the Transmission lock-upars sloctronicslly controllsdfor comfortabledrivingundersllconditions, sida, behindthe right side kick panelonthe passengar's The TCM is locatedbslow the dsshboard, Shlft Control Gstting a signslfrom each sensor,the TCM determinesthe appropriategearand activatesshift controlsolenoidvavos A and/or to The combinationof drivingsignals shift controlsolenoidvafuesA and B is shown in the tsble below. valve \Shitt control solenoid Position(gesr) \ ON ON OFF OFF ON

A

B

f

trstt

@a'at os-ltrstt 1o.-ll

ON ON
OFF OFF OFF

I o.-llo.-lrznar o.-lts,ar 15.-ll

ON
ON OFF ON

E

(4th)

tr

Lock-up Contlol From sensor input signals, the TCM determineswhether to turn the lock-up ON or OFFand activates lock-up control solenoid valve A and/or B accordingly. The combinationot drivingsignals lock-upcontrolsolenoidvalves A and B is shown in th6 table below. to Solenoid valve A t*"*"-*----\ Lock-up OFF Lock-up,slight Lock-up,hstf Lock-up,full
LOCI(-Up during dec6leration

\

B
OFF Duty operstion OFF1) ON

urr

ON ON ON ON

ON ON
Duty operation OFF<J ON

14-10

Throttlo Position SonsorSignal Shift Control EnginoCoolam Senso. Sienal ENGINE IECM}

I U

Shlft Conlrol SolenoidValve A Shift Control Sobnoid Valve B

cot{TRoL MODULE

Sorylco Check Connector

Lock.up Control SoLnoid V.tue A Lock-up Control Lock-upControl Solonoid Valv6 B

EngineSpood

P

I]]]

II{TERLOCK CONTROL UNIT

Alr Conditioning Signal

'

R

BrakoSwitch Signal Main!haft/Countor$haft Spo6dSsnso. Signal

N

D.

Vohlclo Sp€edSeNor Slgnal

Dr

@

not"ao,Lret r

2

1

Solt-Diagnosi3 Signol

14-11

Description
ElectronicControl System (cont'd)
Clrcuh Diagramand Terminal Locstion

; -:.'

nr
r 1 r9 : n{FoTrt! 9osllroN r 2 ECT ENGIIE : COOLiTTTIMPIiATLJRI

'/;scs

ms|rtFlcoiTior

rocx utco{nol

A13lA1! A1€

TCM TERMINALLOCATION

14-12

HydraulicFlow
No, 1 DESCRIPTION OF PRESSURE LINE LINE LINE LINE LINE LINE LINE LINE No. DESCRIPTION OF PRESSURE No. DESCRIPTION OF PRESSURE No, DESCRIPTION OF PRESSTIRF OILCOOLER LUBRICATION

6'
I

MODULATE (DUTY CONTROL)
l ST CLUTCH lST.HOLDCLUTCH lST.HOLDCLUTCH LINE 2NDCLUTCH 2NDCLUTCH LINE

30 31
4A
41

3RDCLUTCH
3RD CLUTCH 4TH CLUTCH 4TH CLUTCH

93
5

10
15 18

qA

4
L'

THROTTLE B
90 9l

s9

TOROUE CONVERTER
SUCTION

n

6

MODULATE

21 zc

THROTTLE B X TOROUE CONVERTER

BLEED

TOROUE CONVERTER 92 TOROUE CONVERTER

I N I Position As the enginetufns, the oil pump alsostarts to operate.Automatic transmissionfluid (ATFI is drawn from (g9l and dischsrged into (1).Then, ATF pressureis controlledby the regulatorvalve and becomesthe line pressure{1).The torque converter intet pressure(921 jnto (90). enters (94)of torque converter throughthe orifice and discharges The torque conve,ter check valve preventsthe torque converter pressurefrom rising. Underthis condition,the hydraulicpressureis not appliedto the clutchesas the manualvalv6 stoDsline oressure{l ). NOTE: When used,"lett" or "right" indicatesdirectionon the flowchart.

(cont'd)

14-13

Description
HydraulicFlow (cont'dl
I 1 lPositlon (1) to and line {4) Th6 linepressure becomes pressure at the manualvalve passes the lst clutchand lst accumulator. The power is transmittedonly during pressure(4) flows throughthe 1st-holdclutch and 1st-holdaccumulator. Then line the lst-holdclutch, deceleration through Fluidflows bv wav of : (31)+ 3-4 Shift Vslve-4th ClutchPressure - LinePressure l4)+ 1-2 Shift Vatve+ 2-3 Shift Valve- 3rd ClutchPressure (16)J 1st-hold (41)r Manual Clutch ClutchPressure Valve- I st-hold (6) pressure is supplied the 1-2and2-3 shift valves. to The modulator The line pressure(1)alsotlows to throttle valve B. NOTE; "left" or "right" indicatesdirectionon the flowchart. When used,

14-14

I 2 lPosition (1) The linepressure becomes linepressure as it passes throughthe manualvslve. then goesthroughline (2O) the 2nd {4) h to (1) clutch.Also.linepressure goesto the modulator valvethroughthe fiher andbecomes modulator (6l,Modulator pressure the pressure is not supplled the l-2, 2-3 and3-4 shift valves. {6) to (1) Lin€pressure alsoflows to throttlevalveB. NOTE: When used,"lett" or "right" indicatesdirectionon the flowchart,

{cont'd)

'14-15

Description
HydraulicFlow {cont'd}
I oglo.lEl Positio"
1. 1st Sp€od circuitis the sameas inI N lposition. The f low of f luidthroughthe torqueconverter The line pressure (1) becomesline pressure{4} and it becomesthe 1-stclutch pressure{10).The lst clutch prossureis the consequently, vehiclewill move as the enginepower is transmitted. aooliedto the 1st clutch and 1st accumulator; (1) becomesthe modulatorpressure(6) by the modulatorvalve snd travsls to 1-2 8nd 3-4 shift v8lv€s. The line Dressure The 1-2 shitt vave is moved to the right side becausethe shift control solenoidvalve A is turned ofJ 8nd B is turned on by the TCM, This valve stops 2nd clutch pressureand the power is not transmittedto the 2nd clutch. Lins pressure{4)alsoflows to the servo valve and line pressure{1)slso tlows to throttle valve B NOTE: "left" or "right" indicatesdirectionon the flowchart. When used,

14-1 6

2nd Speed The flow of fluid up the 1-2 and 2-g shift valves ls the same as in the lst spe€d. As the speed of th6 car reachesthe prescribedv€lue,the solenoidvalve A is turnad on by meansof the TCM. As a resuh, the 1-2 shift vav€ is moved to the left and uncoversthe port leading the 2nd clutch; the 2nd clutch is engaged. to Fluidflows by way of ; -Line pressure + 1-2 Shift Valve+ 2-3 Shift Valve-2nd ClutchPressure {4) {21)J Orifice-2nd ClutchPressure (20)-r 2nd Clutch The hydraulicptessurealsoflows to the 1st clutch. However, no power is transmittedbecauseof the one-wavctutch. NOTE: When used,"left" or "right" indicatesdirectionon the flowchart.

(cont'dl

14-17

Description
HydraulicFlow (cont'd)
3rd Spoed The flow of tluid up to the 1-2, 2-3 and 3-4 shift valves is the sameas in the 2nd speed.As the speedof the car roachesthe prescribedvalue,the shift control solenoidvalve B is turned oft (shift control solenoidvalve A remainson). The 2-3 shift to valve is then moved to the laft, uncoveringthe oil port leading the 3rd clutch. Sincethe 3-4 shitt valve is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on. Fluidtlows by w8y of : -Line Pressure J 1-2Shift ValveJ 2-3 Shift Valve- 3rd ClutchPressure (31)J 3-4 Shift Valve (not controlled) (41 -3rd Clutch Pressure(30)-r 3rd Clutch The hydraulicpressurealsotlows to the 1st clutch, However, no power is transmitted becauseof the one-wayclutch as in the 2nd sDeed. NOTE: When used, "left" or "right" indicatesdirectionon the tlowchart.

E aFt

Thc prrt Asd shift

Fbn

Tho M

wh

NO

14-18

!he hft the

I Da lPoshion Fth Speed The flow of fluid up to ths 1-2, 2-3 and 34 shift vslves is the same as in the 3rd speed.As th€ spe€d of tho car reachesthe pr€scribed valu€,the shitt control sol8noid vatueA is turned olt (shitt control sol€noid valv€ B remsinsoff). As this takos place,3-4 shift valve is moved to th€ left and uncoverstho oil port leading ths 4th clutch, Sincathe 1-2and 2-3 to shift vslves are kept on the l€ft side,the fluid flows th.ough the 4th clutch; the power is trsnsmitted throughthe 4th clutch. Fluidflows by way of : -Line Pressure(4) J1-2 Shift Vslvo J 2-3 Shift Vslve-3rd Clutch Pressure(31) + 3-4 Shift Vslvs-4th Clutch pressuro (41)+ ManualVslve-4th Clutch Pressure(4O) 4th Clutch J Ths hydraulicprossurealsoflows to th8 1st clutch, However, no power is transmittedbecsuseof ths one-wsy clutch 8s in 2nd and 3rd sDeed. NOTE: When used,"left" or "right" indicatesdirectionon the flowchan.

Ed)

tin

?

(cont'd)

14-19

Description
HydraulicFlow (cont'd)
I R lPolhlon Th; tlow of fluid through th6 torque converter circuit is the same ss in the I N I position.The fluid {1)trom the oil pump flows the throughth€ manualvatveand becomesline prsssure(3). lt then flows throug-h 1-2 shift valv€ to the servo valve {3),causing the shift tork shsft to be moved in the rovorsedirection, this condition,the shift controlsolenoidvalve A is turned on whereasthe valve B is turned off 8s in 3rd speedinLqllor Undeq I D3 I position.As a resuh, tho 1-2 shift valve is also moved to th8 lsft. The Jluid (3') will flow through the seryo valve and m:Ei[alvalve to the 4th clutch; power is transmittedthroughthe 4th clutch, Rev6rsoInhibito!-.lE=ontrol When the I R I positionis selectedwhile the vehicleis movingforward at a speed over 6 mph (10 km/h), the TCM outputslst;i6;al (A: OFF,B; ON),and the 1-2shift valve is moved to the right side.Th6 line pressure(3)is interceptedby pow6r ia not transmittedas the 4th clutch and servo vatueare not operated. th€ 1.2 shift vave; consequ€ntly, NOTE: "right" indicstesdirectionon the tlowchart. When used,"left" or

tr

The prst End Hot\

NOI Wix

14-20

ins
,J

I P I Poshlon The flow of fluid th.ough the torque converter circuit is the same as in fTl position.Tho line prsssuro {11bscomes the tine prsssure{31as it passesthrough the manualvatue.Then line pressure(3)*flowsthrough the l-2 shitlgrvs to the sarvo v8vs and the servo control valve,causingthe shift tork shatt to be movedto rhe reversepositionas in th€ R position. I I However,the hyd.auilcpressureis not supptied the crutches. to The power is not trsnsmittod. NOTE: When used,"left" or "right" indicatesdirectionon the flowchart,

rrd

CM

E
a

14-21

Description
System Lock-up
fluid is drainedjrom the back oJ the torque convsrtsr h l5r-l positionin 2nd, 3rd and 4th, andI 03 | position in 3rd, pressurized th;o6h an oil passage,causingthe lock-up piston to be held against the torquo converter cover. As this takes pl8cs, th€ mainshsttrotates at the samesp€edas the enginecrankshaft.Togetherwhh hydrauliccontrol, th€ TCM optimizosthe timing of in the lock-upsystem. Undercenain conditions,the lock-upclutch is appliedduringdecsleration, 3rd 8nd 4th sp66d. The lock-up systam controls the rangeof lock-up accordingto lock-up control solenoidvav€s A and B,8nd throttle valve B' When lock-up control solenoidvslves A and B activate. modulstor pressurechanges.Lock-up controlsolenoidvalvos A 8nd B and are controlledby the TCM, are mountedon the torque converter housing, NOTE: When used, "left" or "right" indicatesdirectlonon the flowchart,

LOCKUP II coNrRoL ll S O L E N O II l D VALVE: ll A

V

1 L O C K u pC O N T R O L SOLENOTO LVE: VA

FEGULATOF

14-22

l,lo Lock-up The pressurized fluid regulstedby the modulatorworks on both ends of the lock-up shift vsfue and on the left side of the lockup controlvslvo. Underthis condition,the pressures working on both ends of the lock-upshift valveireequat. ttre stritt vatve is movsd to the right side bv the tensionof the v8tuespringalone.The fluid trom the oil pump willflow throught;e bft side of the lock-upclutch to the torque converter; i,e.,the lock-upclutch is in OFFcondition. NOTE; When used,"left" or "right" indicatesdirectionon the flowchart,

!BRi?'", I

v 1

;9ii?9P! !B:i,VBS",jffi?f"

I\4ODULATOR PRESSURE

T O R O U €C O N V E R T E R CHECK ALV€ V

(cont'd)

14-23

Description
Lock-upSystem (cont'd)
PartialLoqk-up VslveB: OFF ControlSolenoid Valve A: ON Lock-up Lock-upControl Solenoid Tho The TCM switches the solenoidvalve A on to releasethe modulatorpressurein the lett cavity of the lock-up shift valve' pressurein the right cavity ot the lock-up shilt valve overcomes the spring forc8, thus the lock-up shitt valve is modulator movedto the left side, to The modulatorpressureis separated the two passages: lock-upclutch enters into right side-toengage Torque Converter InnerPressure: lock-upclutch enters into left side-todisengage Torque ConverterBack Pressure: The bici pressure(FA is regulatedby the lock-upcontrol vave whereasthe positionot the lock-uptiming valve is doterminad by tension ot the valve springand pressureregulated the modulator.Also the positionoJ the lock-up by the throttle B pressure, is determindedby the back pressuieoithe lock-upcontrolvalve and torque converter p.essurer€gulatedby the controlvalve end of th€ lockin check valve.With the lock-upcontrolsolenoidvalve B kept oJf, ihe modulatorpressureis maintained the left in other woios, the tock-upcontrol vave is moved slightlyto the leJtside.This slightmovement of the lock-up ,p--nt-iu"V"; in controlvalve causesthe back pressureto be lowered slightly,resutting partiallock-up' NOTE: "left" or "right" indicatesdirectionon the tlowchart. When used,

IOCKUP CONTfiOL SOLENOID

LOC(UP CONTFOL V S O L E N O I D A L v E :B

PRESSURE MODULATOR

TOROIJE CONVERT€A

14-24

Half Lock-up Lock-up ControlSolenoid Vafue ON Lock-upControlsolenoid A: ValveB:ON The modulator pressureis releasedby the solenoidvalve B, causingthe modulator pressurein the l€ft cavity of ths lock-up controlvalve to lower. Also the modulator pressurein the leJtcavity ot the lock-uptiming v8lve is low. However the throttle B pressurois still low at thjs.time;consequently, the lock-uptimingvalve is kept on the righi side by the springforce. With the lock-upcontrolsolenoidvalve B turned on, the lock-up controlvalve is moved somewhat to tho lelt side,causing ths back pressure(F2)to lower. This allows a greater amount of the fluid (Fi ) to work on the lock-u; ;bich ;; 8s ro engage the clutch. The back pressure(Fa which stillexists preventsthe clutch from engaging fully. NOTE: When used,"left" or "right" indicatesdirectionon the flowchart.

ixi"iivflL

!3:i",3,3"J:'&?."

MODULATOR PRESSURE

VALVE

TOFOUE ONVERTER C CHECK ALVE V

(cont'd)

14-25

Description
Lock-upSystem (cont'd)
Ful Lock-up VaMe B: ON VaVe A: ON Lock-up ControlSolenoid Lock-uDControlSolenoid with the throttl€ opening. in the When the vohiclespeedfurther increases, throttle B pressureis increased accordance to The lock-upttmingvalve overcomssthe springforca and movesto the left side.Also, this vslve closesthe oil port leading the torou€ conv€rter chsck vave. Underthis condition,the throttle B pressuraworking on the right end ol the lock-upcontrolvalve becomesgleatsr than that on vatue B); i.e.,the lock-upcontrolvalve the left end (modulatorpressurein the lelt end has alreadybeen relessedby the solenoid is mov6d to ths l6ft. As this happ6ns,the torque convertar back pressureis releasedtully, causingthe lock-up clutch to bs Jully. €ng8ged NOTE: "left" or "right" indicatesdir€ctionon the flowchart. When used,

coNlROL ll SOLENOID II VALVE: A ll

X LOCKUPCONTROI SOIENOIDVALVE: A

THROTTLE PRESSURE B

MODULATOR PRESSURE

TOROUE ONVERTER C C X E C KV A L V E

orr cooLEA

14-26

Dacoleratlon Lock-up Lock-up controlsorenoid Vatve oN Lock-up A; controrsoronoid (oN€oFF) vatueB:Dutyoperation TheTCMswitches solsnoid vslveB on andotf iapidlyunder ceitainconCitions. slightlock-up halflock-up Tfre and regions 8re msintEined 8sto lockthe torqueconverter so properV. NOTE: "left" or "right" Whenused, indicatos direction the flowchan. on

33i,'^i":i I
LOCXIJ

rocr(uP JI

MOOULATOR PRESSURE

TOROUE ONVERTER C CHECK ALVE V

F E L I E FV A L V E

14-27

Description
HydraulicControl
TheValvebodyinc|udesthemainva|Vebody,the'egulatorVa|vebody,thethrott|evalvebody,thesecondaryvslv€body,the body. servo body and the 1st/2ndaccumulator oilllows throughthe The oil pump is driven by splineson the right snd of the tolqus convener which is attachedto the engine' through the main valve body to the manualvalv€ and the servo bodv, dirocting ,"si,[i;, rriv" t" mainiiin specitieJ pies--sure oressureto eachof the clutches.

VALVE THROTTLE BODY

SERVO BOOY

VALVE REGULATOR BODY
SHIFTCONTROL VALVE SOLE]TOID ASSEMBLY

VALVE SECONDANY BODY MAINVALVEB(X'Y

VALVEB THROTTLE

LO[{G THROTTLE VALVE

l ST/2ltD ACCUIUIULATOR BODY

RELIEF VALVE

COrTROL LOCK.UP VAI.VE SOLENOID Ot purip ASSEMBLY

GEAR DRIVE OILPUMP

ORIVEiIGEAR

4TH ACCUMULATOR 3RD ACCUMULATOR
lST-HOLD ACCUMULATOR

sEnvo
VALVE

REGULATOR VALVE

LOCK.UPTIMING VALVE

CONVERTER TOROUE VALVE CHECK

1STACCUMULATOR 3RDKICK-DOWI{ VALVE
CPC VALVE

2]IDACCUMULATOR 2 D ORIFICE VALVE COT{TBOL VALVE

VALVE VAL MODULATOR
COOLER VALVE LOCK.UP SHIFT VALVE

1-2 SHTFT VALVE

34 SHIFT VALVE

co oRrFrcE TnoL
SERVO cot{TRoL VALVE

4THEXHAUST VALVE

MANUAL VALVE

VALVE 2-3 SHTFT

14-28

RogulatorValve The regulstorvalv8 maintainsa constant hydraulicpressuresent trom the oil pump to th€ hydrsuliccontrol svstem, while also turnishingoilto the lubricsting system and torque convarter. Oil flows through B and B', The oilwhich enters through B flows through ths vslve orifice to A, pushingtho regulatorvalve to the right. Accordingto the level ot hydraulicpressurethrough B, the poshion ot the valve changes,and the smount of th€ oil through B'from D alsochanges. This operationis conttnued,maintaining prossure. line

I{OT RUN II{G) IENGI]TE

GiIGI]TE RUN ING) To TOROUECOIWERTER

To RELIEF VALVE

Stator RoactionHydtaulc P1!ssur6Control Hydraulicprossuroincreaseaccordingto torque is performod by the regulatorvalve using stator torqus reaction.The stator shEft is spllnedin the ststor, and hs arm end contacts the ragulatorspringcap. wh€n the car is acc€lerEting climbing(Torque or Converter Range), stator to.que reaction acts on the stator shaft, snd the stator arm pushesthe r€gulsto; springcap in the -) direction in proportion to the reaction.The stator roaction spring compressos,and the regulatorvalve movss to increasethe regulated control pressureor line pr€ssure. Line prgssureis maximumwhen the stStor reactionis maximum.

REGULATOR VALVE

STATOR REACTION SPRII{G

REGULATOf, SPRING CAP STATOR SHAFTARM

STATON SHAFT

{cont'd}

14-29

Description
HydraulicControl (cont'd)
Thlottle V8tuo B Throttle vave B converts changesin the throttle openingto changesin transmissionhydraulic pressute.The end ot throttle vave B contscts the throttle cam which is connectedby a cable to the throttle body. The cable pullsthe cam which, in turn, moves the throttle valve B. The throttle valve B-to-camengagementis adiustablefor shitt smoothnessand lock-up.Throttle to valve B controlsthe accumulators, make smooth changesfrom one gearto snother.An assist tunction is used to lessenthe throttle load. ModulEtor Valv6 The modulstorvalve maintainsline pressureJrom the regulator,to the pressureshitt control sol€noidvatuesA/B and lock-up accurateshi{t and lock-upcharacteristics. valves A/8, thus maintaining control solenoid 2nd Ollflce Contiol Vslvo For smooth shifting between 2nd and 3rd. the 2nd orifice controlvalve relievesthe 2nd clutch pressure. the the is As 3rd clutch Dressure incressed, 2nd orilice controlvalve movesto uncover the oil port relieving 2nd clutch pressure.

C

14-30

ComponentLocation

TRAl'ISMISSION CO]\ITROL (TCMI MODULE

BRAKE SWITCH (ECM} ENGINE CONTROI. MODULE
AUTOMATIC TRANSAXLE(A/TI GEARPOSITION SWITCH

LOCK.UP CONTROL SOLENOID VALVE ASSEMBLY

VEHICLE SPEED SENSOR {VSS}

THROTTLE POSITION SENSOR {TPI

COUNTERSHAFT SPEED SENSOR

ENGINE COOLANT TEMPERATURE {ECT}SENSOR MAINSHAFTSPEED SENSOR SHIFTCONTROL SOLENOID VALVE ASSEMBLY

14-31

Circuit Diagram

HOOD FUSE/FELAY UNDER8OX
t l o . 4 t( 1 5 4 i

tlo.32l100Al

No.43ll0A|

423 424 AIO A8

A2O D2 IRAI{SMISSION CONTROL MODULE {TCM} A19 A7 Ar8 A21

A17

A15

At3

All

A/T GEAR POSITIOI'I I DtCAT0R 8LK

I

:

G40r

4
G40l

8U(

14-32

SERVICE CHECX I CONNECTOR I

REO/BIX

I sENsoR +iHr*_ SENSOR

THROTTTE ENGINT POSInON CoOtANr

Dl8

A22

D9 013 Otl

Dt6

D6

D7

D5

A25

A26

TRANSMISSION CONTEOL MOOUIE IICM} 017 Dt5 D19 012 A6 A4 A5 A3

wHT/EU(
GRN/BL(

I

8LU,^TEL

r,oct( uPcoNTRot-sHtFr corTRolSO[TNODVALVE SOI-EI\OID VAI.VE

COUTIIERSHAFI SPEEDSENSOR

MAINSHAFI SPIED SENSOR

A3 A 5

A9 A11 A13A l 5 A 1 7Ar9 421

atr

A4 A6 A8 A ! C

A18 ^ tttta t'ltt ) aa, t
TCMT.nnin.lLocnbns

14-33

Procedures Troubleshooting
When the TCM sensesan abnormslityin the input or output systems, th€ | D4 lindicator light in the gsugeasseEUlLwillblink. with I jumper wire, the I Da lindicator Wh€n the Service Check Connector (locatedbehindthe center console)is-E6nnectod TroubleCode (DTC)when the ignitionswitch is turned on' light will blinkthe Diagnostic When the I D;l indicatorlight has beenreported on, connect the two terminalsof the ServiceCheck Connectortogether whh a iumperwire, Thon turn on the ignitionswitch and observethel Da lindicator light.

DATA LI'{K

coNiEcToR t3Pt
GAUOE ASSEMELY
JUiIPER

cAUTlOir:
Do not attadr tha lumper wlre,

3'S,Y,!"3reJl'ii['
short blinks,codes 10 throught 15 8re indicatedby a soriesof longand short blinks. Codes1 throuqh 9 are indicatedby individual the code, On€long blink equals10 short blinks.Add the long and short blinkstogether to determinethe code. After dstermining Chart on pages1+36 8nd 37. refer to the electricalsystem Symptom-to-Component rhort

n
S.. DTC I Soo DTC 2 s.. DTC '14

L]
rhort

Some PGM-FIproblemswill also make the I D4 lindicator light com€ on. After repairingthe PGM-FIsyatem, disconnectth€ tuse/relavbox for more thsn 1Osecondsto reset the TCM memory. CLOCKRADIOfuse (1OA)in th6 under-hood NOTE; . PGM-Fl system muhipon tuel iniectionsystem. The PGM-Flsystsmon this modelis I sequenti8l . Disconnecting CLOCK RADIOfuse also cancelsthe radio antFthett code, preset stations 8nd the clock setting. Get the the custom€r'scode numbe. and make note oJ the radio presetsbefore removingthe Juseso you can .eset th€m.

14-34

CAUTION: . Al SRS electrlcal whlng haro6sres are covorod with yelow outor insuhtlon. . Before dsconnoctlng the SRS wila harnoss, install th€ lhort connoclor(s)on tho ailbag(s)(so6soction 23 I. . Roplaceiho snllro affectod SRS harness assombly if it ha! sn opon circuit or damagodwlring.

. TCM Roset Procodure 1. Turnthe ignition switchoft. 2. Remove the No. 43 CLOCK RADIO fuse (10A) lrom the under-hood tuse/relaybox tor 10 secondsto reset the TCM. NOTE: Disconnecting No.43 CLOCK RADIOluse aho the cancelsthe radio anti-theft code, Dr€setstations and the clock setting. Get the customer's code number 8nd mske note of the rsdio presets befors romoving the fuse so vou can resat them.

CLOCK RADIO FUSE

lf the insp€ctionfor a particularfailure code requiresthe usa ot Test Harnesa(07LAJ-PT3010A); 1, 2. 3, Removethe right door sill molding,door trim and right side kick psnel(seesection 20). Pullthecsrpetbackto expose TCM. the Connectthe wire harnessto the Test Harness.and/or connect ths Test Harness the TCM according the to to troubl€shooting lowchart. f NOTE: . OnV the A and D terminalsof the Test Harnessare usedfor A/T troubleshooting. . Unloss otherwise noted, use only the Digital Muhimeter, KS-AHM-32-003, tor testing.
DIGITALMULTIMETER KS-AHM-32-O03

UI{DER-HOOD FUSE/RELAY BOX . FinalProcodure NOTE: This proceduremust be done after any troubleshooting.
l.

Remove the iumper wire from the Ssrvice Chsck Connector. Resetthe TCM. Sst the rsdio preset stations and clock setting.

, o o o o o o o o o o o olio o o o o oo qo o o o o 6to o o o o r o o o ) c

14-35

Chart Symptom-to-Component
Syst Electrical
NumbsroI Da indicatorlight blinkswhile Ssrvice Check Connectoris jumped. I

Da indicator light

Possible Cause

Symptom

Referto page

Blinks

Disconnectedlock-up controi solenoidvafue A connector Shon or open in lock-up control solenoid vafueA wire Faultvlock-uocontrolsolenoidvalve A Disconnectedlock-up control solenoidvafue B connector Short or open in lock-up control solenoid valve B wire Faultylock-upcontrolsolenoidvalve B Disconnectsd throttle position (TP) sensor connector Short or oDenin TP sensorwire FauhvTP sensor Disconnected vehicle speed sensor {VSS) connector Shortor openin VSS wire FauftyVSS Short in A/T 9e8r positionswitch wire FauhyA/T gear poshionswitch

Lock-up clutch does not engage. Lock-up clutch does not disengage. Unstableidlespeed. Lock-up clutch does not engage.

14-38

2

Blinks

1+39

5

Blinks or OFF

Lock-up clutch does not engage.

1440

4

Blinks

Lock-up clutch does not engage.

1441

Blinks

' Failsto shi{t other than zrde4th gears. ' Lock-up clutch does not engage, Failsto shift other than 2ndo4th ge8rs, Lock-up clutch does not engage. Lock-up clutch sngages ahernateand disengages ' Failsto shitt (between 1 ste4th, 2nde4th or 2 nde3rd gesrsonly). ' Failsto shift (stuck in 4 th gear) ' Failsto shift (stuck in I st or 4th gears).

1442

OFF

geat position switch Diconnected Nf connector Open in A/T gear positionswitch wire FaultyA/T gear positionswitch

1444

Blinks

Disconnectedshift control solenoidvalve A connector Short or open in shift control solenoidvalve A wire valveA Fauhyshift controlsolenoid Disconnectedshift control solenoidvalve B connecror valve B Short or oDBnin shitt control solenoid Fsuhv shift controlsolenoidvalve B

1446

I

Blinks

14-47

9

Blinks

Disconnected countershaft speed sensor connector Short or opon in the countershaft speed sensorwir€ Fauhycountershaftspeedsensor

Lock-up clutch does not engage.

1+44

14-36

Numberof Dr indicslor light blinkswhile ServiceCheck Connsctoris iumped.

Da indicator light

Possible Csuse

Symptom

Referto pa9e

10

Blinks

Disconnected engine coolsnt temperature (ECT)sensorconnector Short or open in ECTsensorwire FauhvECTsensor Disconnected ignitioncoil connector Short or open in ignitioncoil wire Fauhyignitioncoil

Lock-up clutch does not engage.

14-50

11

OFF

Lock-up clutch does not engage.

1+51

't4

OFF

'Short or open in FAS wire be- ' Transmissionjerks hard {ORIVRED} tween the D16 terminaland ECM when shifting. ' Troublein ECM Disconnectedmainsh8ft speed sensor connector Shon or openin mainshatt speed sensor wire Faulty mainshaftsDeed sensor Transmissionjerks hard when shifting.

14-52

OFF

1+U

f the setf-diasnois to L91l indicatoflight does not blink,perform an inspectionaccording the tabtebelow. Symptom Da indicator light does not come on for 2 seconds atter ignhion is first turn€don. D4 indicstorlight is on steady,not blinkingwheneverthe ignitionis on. Lock-upclutch does not have duty operation{ON-OFF). Lock-upclutch does not engage. Shift lever cannot be moved from d€oressed. P Check A/C signal with A/C on. Probable Cause
RBf. page

14-56

1+58 1+59

Dosition with the brake oedal Checkbrakeswitchsignal.

14-60

. It a customer describesthe symptoms f or codes 3, 6, or t t , inaicatorlight is not blinking,it wilt be necessaryto Jeqn" I Oo--l r€crsglg1lie symptom by tost driving,andthen checkingthe I D4 | indic8torlightwith the ignitionstill ON. o lf the aboveor stays lit continuously, TCM is tauhy. the ElJindic$gllight displsyscodesother than those liste-d . Sometimesthe light and the MalfunctionIndicatorLamp (MlL)/CheckEngine light may come on simuhaneously. Lgllind;cator It so, chsck the PGM-FIsyst€m accordingto the number ot blinkson the MIL/CheckEnginelight. then reset the memorv bv removingthe CLOCK RADIOfuse in the under-hoodfuse/relaybox tor more than 10 seconds.Drive the vehicle for several minutesat speedover 30 mph (50 km/h).rhen recheckthe MIL/CheckEnginetight. NOTE: . PGM-FI svstem The PGM-Fl system on this modelis a sequentiat muhiport fuel iniectionsystem. ' Disconnecting th€ CLOCK RADIOfuse also cancelsthe radio anti-thett code. preset stations and the clock setting. Get the cuatomer'scode numberand make note of the radiopresetsbefore removingthe fuse so you can reset them.

14-37

Electrical Troubleshooting
Flowchart Troubleshooting
Soff-dirgnosis I I,a I indicstor lght blink. onc.-Possib16 Caus6 . Oisconn6ct€dlock-up control valv6 A connector sol€noid ' Short or open in bck-up controlsol€noidvslv6 A wire ' Fauhylock-upcontrol solenoid

Disconnect the 26 P connector trom the TCM,

NOTE: Vi6w f rom terminalsid6.

Turn the ignitionswhch ON.

Msasure the vohago betw€6n th6 AO (RED/WHT) and A25 (BLK/RED) A26 (BRN/BLK) or terminals. Ropairthorl to power rouaca in REDMHT wlro botwo6n tho AO tormln l and the lockuDconlrol lolonold valvo A. Turn the ignitionswitch OFF.

Measure the resistance b6tw€6n th€ A6 (RED/WHT) and A25 (BLK/RED) A26 (BRtl/ or BLKlterminals. Chcck for bo.o TCM cor|r|octorg. It nacollgry, lubrtftute a known-good aolenoid vtlvo assombly o. TCM ond rochock.

ls th6 resistanco 12-24 O ?

Diconn6ct th6 2P connector i.om the lock-up control sob. noidvalve assembv.

Check tor continuity betw€on the A6 (BED/WHT) snd A25 GLKiRED)or A26 (BRIVBLK) tgrminsls. Bopah lhort to ground In RED /wHT wire betwoon tho AB tormlml and tho bck-uD control 3olonoldvrlva A. Mgasureth6 resistanceot the solenoid at the 2P connsctor (1+62). Chock for opon In RED/WHT wire between thc A6 tarmlnal and the lock-up control roLnold valve A.

fs the resistanc€12-24 A?

Rophce the bck-up cofirol aolonoid vafuo a$ombly.

14- 3 8

Possibls C6use ' Disconn6ctod lock-up control aolono'xtvafu6 B connoctor . Short or oD6n in bck-uD coft trolsolenoidvafueB wko ' Fauhybck-up controlsolonoil vafueB

Diocomect the 26 P conn6cto. f.om the TCM.

Vi6w f rom terminalside.

Turn th6 ignitionswitch ON.

Meaaur6tho vohago b€twoon th6 A4 {WHT/BLK) and A25 (BLK/RED) A26 {BRIVSLK) or terminab. Rapllr ahort to Dowar aolrca In WHT/BLK wlr. b.twoon ths A4 t.rmlnal lnd th. loct. up control roLnold vrlva B. Turn tho ignitionswitch OFF.

6.\ 12-24 Q7 BRN/BLK-r-Y-WHT/BLK I V,, Voh.sa?

M€rsua€ th6 resistanc6 b€tweon th€ A4 {WHT/BLK)and A25 (BLK/REDI A26 lBFl! or BLKltormingls. Chad( tor loota TCM connoctoaa. ll nacaltary, tubttltuta r known-good toLnold vllva .t!.mbly or TCM !nd rachack.

ls th€ r€sistance12-24 Q ?

Disconn€ctth6 ? connector lrom th€ lock-up cootrol solonoidvafueassernbv.

Ch6ck for continuity betw6en the A4 (WHT/BLKI 8nd A25 (BLK/RED) A26 {BRI,I/BLK) o. tsrminsb. Rapalr rhort lo ground In WHT/BLX wh. brtw.on thr A4 t.ri| ml rnd lha lock-uo control aoLnold valva B. Me63uretho rosistanceof th6 aolonoidat th6 2P connector t1+6,4. Ch.ck tor oD.n In WHT/BLK wlra baiwaon tho A4 tarmlnal ard th. lock-up control aob" nold v.lv.8.

ls tho rosbtance 12-24 O ?

R.pbc. th. bck-up control rcLnold vtlva r'!an|blv.

(cont'd)

14-39

Electrical Troubleshooting
(cont'd) Flowchart Troubleshooting
S.ltdlomrl! { Xr4| lndlc.tor leht bl|rb thr..-i6.r. Possibh Csus€ ' Disconnected throttl€ position {TP}sonsorconnoctor ' Shon or op€n in TP sonsor ' FEulty TP sonsor

Turn the ignitiooswitch ON.

Chock whothor tho Malfunction Indicato. Lamp (MlL) blinkslsse soction 111.

ls th6 MIL blinking?

R.p.h th. PGM.FI Sy.t.m {r....ctlon l1}.

Disconnoct th6 26P and 22P connectorstrom th€ TCM. C o n n o c tt h 6 T 6 s t H a r n e s s "4" arfr "D" connoctora to the wire harno$ onv, not to the TCM 114-3$.

oooooooooooo oooooooooooo

ooooooooooo ooooooooooo 4 . 7 5 - 5 . 2 5V ?

Turn the ignhionswitch ON.

Mosgursths vohsg€ b€twe6n the D1I ard A29A26 torm'F na|s.

ls the vohago4.75-5.25 V?

R.plli op.n or rhort In LT ORiUBLK wl.. b.tw..n th. D I I tcrmlnll aid thc ECM.

Turn the ignitionswitch OFF.

Appror.0.5V?
C o n n e c tt h 6 T e s t H a r n e s s "A" snd "0" conn6ctors to tho TCM.

oooooooooooo oooooooooooo
A26

ooooooooooo
ooooooooooo

Turn th€ ignitionswitch ON,

Moasurotho voltago b€twe€n th6 D7 snd A2tA26 torminal€.

ls tho vohagbapprox.O.5V?

R.pdr op.n or thon In RED/ BLK wlrr b.twarn lh. D7 tcrmlnd lnd lha TP $naor.

YES
Chack tor boao TCM connacto.a. ll nacoraary, aubrlhula a known-good TCM lnd mclract.

14-40

Selt-diagnosl. I 04 | Indlcator llght blnk! four tm.,

Possiblo Caus€ ' Disconnoctod v€hicl€ spood s€nsor{VSS)congctor . Short or op€n in VSS wir6 ' FauhyVSS

R.l.J to S.ctlon 23 tor v.Hcle speed s.nlor (VSSI l.{.

. Mak. ru16 lft!,lrckr, end lrloty stends are plac.d properly (!oo sactlon 11, . Sot tho parklng blaks r.cul.ly lnd block lhc rcer whccb. . Jeck up tho troni ol the clr .nd ruppoit whh srtcty .t!rdr.
Disconnect the 26P and 22 connoctorg trom th6 TCM. C o n n e c tt h s T 6 s t H a r n e s s "4" and "D" connectors to th6 wire harnessonv, not to tho TCM {1+35).

oooooooooooo oooooooooooo

ooooooooooo
ooooooooooo

Turn th6 ignhionswitch ON.

Botate the f.ont wh€61 snd check for voltag€botweonthe Dg and A2ryA26 terminats. Block th6 other whe6l so it do€s not tum,

Doesth€ vohageO-12 V spp6arsh€rn€teV?

Chock for lhort or oDon ln ORI{ wh! bglwaln th. Dg tcrmlnll .nd th. VSS. It wl.a lr OK, check rh. VSS (rc. lecllon 23).

Chack to. bosa TCM conrEclor3. lf n€ceaaary,aubatftuto a known-good TCM tnd .echock.

(cont'd)

1441

Troubleshooting Electrical
(cont'd) Troubleshooting Flowchart
s.fil|lno.lt I D4 | Indcliot |!t'n b&*! tlv!-m.t. Possiblo CauE6 ' Sho.t in A/T g6sr position switch wir6 ' Faulty A/T g€sr positioh switch

Turn th6 ignhionswhch ON.

Obs€rvetho A/T 906r position indbator, 6nd saloct oach posF tion sopr6aat6ly.

NOTE:
Codg 5 is causod wh6n th€ TCM rsc6iv6s two gpar position inputs at tho 3ametim6,

Do ony irdicalors tail to lightwh€n shift€dthrough sll positionsT

So. A/T g€.r po.hlon Indl€ior l.Epactlon (raa aactlon 23).

Turn tho ignitionswhch OFF.

Connoct the Tost Hamoss b€twoon th6 TCM and connoctors {'l+3$.

Turn the ignhionswhch ON.

Bsnery vohaoo? r@l a21 A25 o o ooooooooOo O I O:66irO ooo ooooooo o O:fto:lG6{ticie,Ol ooooooooooooo I oogsgooc,l'g ottgoo I oooooooo ooo 426

Mo.surc tho vohago botwoen tho A21 and A2gA28 termi nals.

ls th€re battory volta€g?

Chock to. .ho.l ln GRI{/RED wl.. b.tween tho A2l to.irjnrl |nd th. A/T o.!r po.hlon lwhch or A/T gelr po.ltlon Indhlto.. It wlr. l! OK, chack fof bolo TCM connoctorr. ll nacallary. aubtthula a known.goodTCM and rochock.

.-@r A19 A25 Msssure th6 vohag€ b€twoen tho A19 ard A2tA26 tormina|s.

Estt€rv voftaoo?

oooooooooooo oooooooooooo

ooooooooooo ooooooooooo

YES
To paga1+43

Chock loJ .hort ln LT GRN wlr. belw..n tho A19 tormlnll rnd th. A/T gelr po.ltlon Indlcltor or . lhort In GRN/IVHT o. GRI{ wlrer b.tw..n th. A/T g€lr po.ltio.r Indlcltor lnd tho A/T golt pothlon awhch. lf wlia b OK. c$acl tor loora TCM c$nactot!. lf nacoatlry, .ubrtltut. t known-good TCM .nd r.chock.

14-42

Frcm. page 1442

r-@-r
Moasurothe vohsge betwosn the Af7 and A2gA tetminals. A26

Battery vohag6?

ls thore battery vohag€?

Chock fo. lhon In GRN/8LKwire betwoon th. Al7 t.rmln.l rnd tho A/T g.ar polition luyitch. lf wiro is OK, chock fo. loolo TCM connoctor!.It noco$ary, 3ubstllutc a known-goodTCM and.ochock.

M€asur€the vohage between the A15 and A2tA26 termin6ls.

A26

ls ther6 battory vohago?

Check tor.hort in GRN/BIUwlro botwoon ths A'15 torminal rnd tho A/T gear position switch or A/T g6ai po.hlon indlcator.lf wira ls OK, chock for looso TCM connesto''. It necersa.y, lubatliuto a knowngood TCM and rochock.

Moasurethe vohago b€twogn trho A13 and 429A26 t6rminals.

oooooooooooo oooooooooooo
426

ooooooooooo ooooooooooo

ls th6r€ battery vohage?

Chock tor short in GRN/YEL wire betwoon tho A13 t.rmlnal and the A/T goor posltlon swltch or A/T g.ar porition indlc.tor. lf wl.o b OK, check lo. loor6 TCM connociors, It n6cas3!rv, subatitute a knowngood TCM and recheck.

oooooooooooo oooooooooooo
Moasurethe voltage botwe€n th6 A11 and A2tA26 termina|s. a26

ooooooooooo ooooooooooo

Check for short in LT GRN/W}|T wiro botw.on the A11 torminrl and the A/T opar polition lwitch or A/T go.i po.hion indicator. lf wi.e i! OK, chack for loose TCM connoctora. lf nocorsa.y. rubrtltuto a known-goodICM and rachock. Ched( tor bo36 TCM connactor!. It necolsa.y, substilute a known-good TCM and rochock.

lcont'd)

1443

Troubleshooting Electrical
Flowchart (cont'd) Troubleshooting
Solf-dlrgno.lr I D4 I Indlcrtor Ight bll.I(. !h tma. Possibl€C.uso . Disconn€ctod A/T gpa. posF tion sw?tchconnector ' Op6n in A/T g6ar position switch wirs ' Faulty A/T 066r position switch

Connoct tho Tgst Hamess b€tweon th€ TCM and conn6ctors {1+35}.

Turn th6 ignitionswitch ON.

M€esurstho vohage b€twoen th6 A21 6nd A29A26 terminab.

o o oooo o oo o o o o t:ltoooojs9$:*:occD.gol ooo oo o oo ooo o oo oo o oo o o oo o l,(to.ooogrri6:{lifxl{lotllt:lo oo oooo o oo o

R.pdr op€n In GR /RED wlr. batwaan th. A21 tarmlnal lnd th. Al g.!r po.ltlon rwhch.

M€ssuroth6 vohag€ b€two6n the A19 and A2tA26 te.minals.

Rcprlr opln In LT GB wl.. b.two.n th. A19 tormlnC and th. A/T g.!r po.lllon hdlclto..

To psg€ 1+45

14-44

From p.g6 1/+-44

Voh6g.? Measur6ths vohago botwaon tho A17 dld A2dA26 r6rmF nab.

ooooooooOooo oooooooooooo

ooooooooooo ooooooooooo

R.p!h op.n ln GRN/8L|( wiro b.tw.cn th€ A17 t.rmln l .nd tho A/T g6a. polhlon .wltch,

Volt.go?

Mo!8uro vohag€ tho botweon th6 415 ard A2gA26 tsrminab.

oooooooooooo oooooooooooo

ooooooooooo ooooooooooo

Ropll op.n In GRT BLU wlro betw..n thr Al5 t.rmlnll ..rd th. A/Y 96r. l|orhlon !wltch. Vollrg.?

Moasuro the vohago t atweon th€ A13 sd A2dA28 t6.tr* n6b.

oooooooooooo oooooooooooo

ooooooooooo ooooooooooo

R.pllr op.n In GRT YEL wl.. b.tw.en tno 413 t.rmlnll rnd lh. A/T g€ar polhlon twltch.
Voh!96?

oooooooooooo oooooooooooo
Meaguretho vohago bgtwoon th6 A11 and A2ryA28 terminab.

ooooooooooo ooooooooooo

R.pllr op.n In LT GRN/WHT wlra b.tw..n tho All t.rmln.l .nd tho A/T gclr poohlon lwhch.

Chact lo. loo.. YCM codr.ctora. lt nacaaaary. lr$atltuta t known-good TCM .nd rochodr.

{cont'dl

1445

Troubleshooting Electrical
(cont'd) Flowchart Troubleshooting
Caus€ Possibl€ . Disconngctod shilt control vafu6A connector solonoid ' Short or opon in shift control valve A wire solsnoft, ' Fauhy thift control sol€noid

ths 26P connsctor Disconnoct trom th6 TCM.

Turn th6 ignitionswitch ON.

12-24 A? {rslK-l 6\ _ ___r_5_ BLU/YEL BLK/RED

Moasureth6 vohag€ b€twson tho A5 {BLU/YEL} ANd A25 GLK/REo) or A26 (BRII/BLK) t6rminals. Roplir ahon to powai loulca ln BLU/YELwh. botw.en tho A5 tordml ard thc lhlft control loLnold valvc A. Turn tho ignitionswhch OFF,

NOTE:

View from terminals'Nls.

M6aure the resistanco b€tws6n th€ AS (BLU/YEL)snd or A25 (BLK/RED) A26 (BRiU BLK)t6rminals. Chock fo. loo.. TCM codr.ctor!. lf naceaaary, rubltlistc ! known-gpod lolonold vllvo lrtambly or TCM rnd iechack.

ls tho resistanc612-24 Q ?

Disconn€ctth6 3P connoctor trom the shift control solonoid valvs assombv.

Chgck for continuity bstw€on th€ A5 (BLU/YEL}8Nd A25 (BLK/RED) A26 (BR|I/BLK) or t6rminals. Ropllr rhort to g.ound in BLU /YEL wlro botw€en tho A5 totrnlnll and th6 lhllt corttol aolenold vllvo A. Measur€th€ resistanc6of tho solgnoid at the 3P connsctor {1+63). Ch.ck tor opon In BLU/YEL wlre botwoon the A5 tormlnal .nd tho rhlfl comrol lolenold valva A.

fs the r€sistsnce12-24 Q7

Roolace lho !hlft control sobnoid valvo a!!€mblY.

14-46

Self-diagnoli3 | D4 Indlcator light btnkr oight tlm.s,

PossibhCause . Disconn€ctod shitt control valv6 g connoctor solenoid ' Short or opsn in shift control sol€noid valvo B wire ' Fauhy shift control solonoid vslv€ B

Disconnectth€ 26P conn€ctor trom the TCM.

Turn th6 ignitionswitch ON.

Measurethe vohag€ b€tween th6 43 (GRN/YEL) snd A25 (BLK/RED) A26 (BRN/BLK) or lermanals. Ropllr rhort to powar tource In GRIIUYEI wlro botw..r th. A3 termln.l and rhlfl coDtrol lolenold vrlvo B. Turn the ignitionswitch OFF.

NOTE:

View from t€rminalsid6.

Measure th€ resistance be^ tween the 43 (GRN/YEL) and A25 (BLK/BEO) A26 (BRll/ or BLK)terminals. Chack for bolo TCM conn.cto.r. It noco$ary. lubrtltuto a known-good roLnold valvo !rrembly or TCM ond rachack.

ls th€ resistsnc612-24 O ?

Disconnsct the 3P connoctor lrom the shift control solonoid vave assembv.

Chsck tor continuity bstw€en the 43 (GRi.i/YEL)and 425 (BLK/RED) 426 {BRN/BLK) or t6rmrnals. Rcpalr rhort to g.ound In GRN /YEL wlr. b.twe.n lhe A3 termlnal and the lhift control lolonold valvo B, Measureth6 resistanceof the solenoid th6 3P conn€ctor at (1+63). Chock to. oD.n ln GFTUYEL wl.g botwoon tho A3 tormlnal and the lhlfl conlrol lolonold vllvo B.

ls the rosistance12-24 O ?

Replaca the 3hilt control lolonold valvo a$amblv.

(cont'd)

14-47

Troubleshooting Electrical
Flowchart (cont'd) Troubleshooting
S.ltdl.g|lorl! | Da I lrdlcltor lghtbtr*.nln.-il-m... Cause Possibl€ ' Loose or falhy connoction b€tweon th€ TCM and car har_ ness. ' Disconn€ct6d count6rshatt gpoedsonsoa connoctoa ' Shon or op€n in tho count6t_ shaft sp€edsenaorwire ' Fauhy countorshaft sp€€d sonsot

ls tho coumsGhaft sposd proporv? s€nsorinstalled

Disconnsct th€ 2P connoctor Irom tho count€rshaft spood sensorconnector,

Moasureth6 rosistancoof th6 countsrshaftsPeeds6nsor.

lsthe r€sistance 400- 6@ o ? (at7OoF. 2OoC)
Cootl Disconnecttho 22P connoctor from th€ TCM. Connoct the "O" connoctoa Tost Hsrn6ss to th€ wir6 harnossonlY, not to tho TcM {14-3$. lty?

Check for cottinuitY betwoon body ground8nd D17 torminsl and D15 terminalindividuslly. R.o.l. rhort In BLU/GRN or BLU/YEL wlr. b.tw..n D17 lnd Dl5 tcrmlnaL and lh. coumorrhaft apead tdrtor. Roconn€ct th6 countershoft sp6edsensorconnector.

To pdss1+/{)

14-48

From pag€ 14-/18

400 -600 0?

l\teaaurc thg roaisttnco botw6€n Dl7 E ld Dl5torminah.

b th6 a6!iat6nc6

4@-8(D O? 2OoC) lar 7OoF,

Rapllr boaa tarmlnrl or opan In BLU/GR o. BLU/YELwlr. b.tw...r D17 did D16 farrtnala |r|d tha coumarlhnft apaad lanror.

Chad( for loa. TC co.rrcior. lf r|.c...Jy, rubathul. . lnown-good TCM lnd rachad(.

1449

Troubleshooting Electrical
Flowchart (cont'd) Troubleshooting
Solt-diagnoslsI D4 | indicatoi lghl blinks tont-ime.. Possibl€ Cause ' Disconnacted engine coolant t6mperature (ECT) sensor connector ' Short or op6n in th€ ECT sensorwire ' FauhyECTsensor

Turn the ignitionswitch ON.

Chock whethor the Malfunc_ tion Indicator Lamp (MlL) blinkslse6 section 11).

Booah lho PGM-FI Syttem l!.o 3oction 111.

Turn the ignitionswhh OFF

Disconnect the 26P and W connectors lrom the TCM. C o n n e c tt h e T e s t H a r n e s s "A" and "O" connoctors lo th€ wire harnessonly, not to the TCM(14-35).

A?5

Turn tho ignitionswitch ON.

oooooooooooo oooooooooooo

ooooooooooo oooooooo

Measurethe vohage betwoen the 018 ard A2tA26 termina|s. Ropair opon or rhort in LT GRN/BLKwir. botween the O 18 t.rmin6l and tho ECM,

ls the vohag64.75-5.25V?

Turn the ignitionswitch OFF.

C o n n 6 c tt h e T 6 s t H a r n e s s ..A,. and ,,D,, connectols to tho TCM.

oooooooooooo oooooooooooo

ooooooooooo ooooooooooo

Start th€ engino and warm it temperup to normalop€rating ature (the radiator fan comes on).

Measurethe voha96 betwoen the D5snd A2ryA26 terminals 'lV? Ropoil opon or short in YEL/ the D5 tor_ BLU wiro botvvsen mlnrl and th6 ECT!on3or.

ls the vohagel€ssthan

check for loolo TCM connoc_ tor!. ll noce!.s.Y, subatitut6 a lnown-good TCM snd aactEck.

14-50

PorrlbL Caula . Disconn6cted ignition coil connocror . Short o. opon in ionhioncoil Oiaconngct the 26P connector from tho TCM. . F6uhyignhioncoil

Turn ths ignitionswhch ON.

Moasurotho vohago botwoon tho A9 IBLU and A25 (BLK/ RED) or A26 {BRN/BLK) torminab. Vi€w trom l€rminal6id6.

Raprl? opon or .hort ln BLU wh. b.tw.on tho A9te.mlnal lnd tho lgnhloncoll. Chod. fof l@q. YCM conlracto.a. lf naca$lry, tubttltqt. a known.good TCM lnd aachad(.

14-51

Troubleshooting Electrical
(cont'd) Flowchart Troubleshooting
s.||d.enodt I D4 | Indlcato. leht bld.. to|rtTi'tlmrt.
PorrlbL cluto

Shortor openin FAS{OBiY wi.€ RED) Troubl€ ECM in
n.o!L th. PGM.FI SYltem (r.. !.ctlon 111.

r Make sure llfts, iacks and satety stands 416 placed propsrly, and hoisl blackots aro attachad to the corl6c-t position on tho ongino (seosection 1). . Whlle testing, bo caroful of the lotatlng flont wheels.

15 ths Maltunction hdicator L.mp (MlL)on ?

Start th€ ongin€ and wtrm it up to normal operrlino temp6ratuao{tho rsdiator fan comesonl.

Approx.5 v?

swhch OFF. Turn tho ignitfttn

oooooooooooo oooooooooooo

ooooooooooo
oooooooQooo

Connoct th6 Tolt Harnoss botwo€n th6 TCM tr|d coonector3 (1+351.

Turn the hnition swhch ON a.d wait Ior at l6aat two ggcotxt5.

l\reaaure voh.go tgtweon the the 016 {+) rnd A2gA26(-l torminab.

Ch.d( to. l@a TcM conrrcto.r, ll nacortxy, !t bttitul. ! known-good TCM and rcch.ck. Turn th6 ignitionswitch OFF.

Dkconnoct ths ToEt Haangss from tho TCM. L66ve conn6ct6d lo car n6anoa8.

switch ON. Turn th6 i{tnit'ron

To prg61+lB

14-52

From pag€14-52

Msasurgth6 vohago botwoon the D16(+) and A2gA26(-) torminab.

Ch.ck tor bola TCM corr nacto[. lt ]raca$ary, rubtdtut. ! known-good TCM ard rachack. Disconnoctthe 26P connector from th€ ECM.

Check for continuity b€tw€sn the D18 and A25lA26 torminalsot th€ Test Harn6ss.

R.o.h .hort ln OR /RED Tcltl {FAS} wh. b.tw..n lnd ECM.

Ch6ck for continuity on tho OR^I/REO wire botween the D 18 t€.min8l on ths TCM snd tho AlStorminalontho ECM.

Ch.d( tor loot! TCtt oo.r nactora. It nacattary. tubttltuto r known-gogd TCM and rcchack. R.p!|. lhoit In OR /REO (FASI wlr. b.tw..n TCM ..d ECM,

(cont'd)

14-53

Troubleshooting Electrical
Flowchart (cont'd) Troubleshooting
Po.rlblo C!u!. . Disconnectodmainshaft 9pe6dsonsorconnector . Shon or op6n in mainahaft wilo sp€€dSonsor . F6uhymainshaftsp66d €0nsoa A cod€ 15 on th€ TCM doesn't th/vay6msan th6re'e an sl6ctricsl probl€m in ths main8h.ft or countorahatt sp6€d sonsor circlh; code 15 may 8bo indicato 6 probl€min th€ transmbsion. mochanical

NOTE:

Ars th€ mainshstt and count6rshaft sPsed senaors properly? install€d

Disconnectthe 2P connector trom th6 mainshaft spood s6nsor.

M€asur6th€ resistanceof the mainshrft spoodsengor.

4OOls th€ rssistanc€ 2OoCl 600 O 7 (6t7OoF,

Disconnectth€ 22P conn6ctor trom th6 TCM. C o n n 6 c tt h e T o s t H a r n o s s "0" conn€ctor to ths wire harnoss only, not to thg TCM

(1+35).

ooooooooooooo ooooooooooooo

ooooooooooo ooooooooooo

Ch6ck th€ continuity botwoen D19 and D12 torminalsand body ground. Ropllr lhort In O8N/8LU or WHT/BLU w1..3 b.tw..n D 19 and Dl2 t.lmlnab lnd lhc rmlmhlfl apaed tanaoa. Roconnsct the 2P connoctor apeodsonaor' to th€ rnsinshdft

To psg€ 1+55

14-54

From p6ge1+54

D' l I

Measure th€ resistance between D19 and O12 t€rminals.

ooooooooooooo ooooooooooooo

ooooooooooo ooooo9ooooo

400-600 0? ls th€ resistance 4OO600 Q ? lat 70oF.2OoCl Chgck tor corninuity between D19 terminal and the mainshaf sp6edsensor. t

R.palr op.n in ORN/BLUwi.e batwaan D19 t..min!l and tha malnlhatt spcad r.n!or. Ch6ck fo. continuity b€tw66n O12 terminal and th6 mainshaf spg6dsensor. t

Rep.ir opon In WHT/BLU wlro botwaan D12 tormlnal and tho malnahlft rDoodlanror. Run El.clricsl Troublcrhooting to. codc 9. Ch.ck tor looro TCM cfinecto.. It necsrrlry. rubatltuta ! known-good TCM lnd rochock,

Ch.ck tor loor. TCM cor! nacto6. It nacalatry, aubrtltute t known-good TCM and rachack.

(cont'dl

14-55

Troubleshooting Electrical
Flowchart {cont'd) Troubleshooting
I or I tndicator llght do.t not 6-m. oo with the lgnition ON. lh thouH c!m. on 3vYttch lor gbout 2 aocond!.)

Does tne @

indicator lhhl

Ch.ck lo. bot. TCM connac_ tola, lf nacoraary, aubllltut. r known-good TCM lnd Echrck,

Turn the ignitionswitch OFF

the 26P connector Disconngct {rom the TCM. connect th6 T€st Harn6ss "A" connector to tho wire harnsss only, not to the TCM (1+35).
Cor ollty?

Check for continuity b€tweon rhe A25 lorminal and bodY ground and 426 and body ground. R.Drl, opon BLK/REDo. BR / BLK wirc. b.tw.!n A25 ot A 20 t.rrnln.lt .nd GI 01 .

Turn tho ignitionswitch ON.

vatecr [P oattc,v A23A25

Measurethe vohage betw€on th€ A23 or A24 and A25 or A 26 t€rmlnals. R.prlr opon o. lhon In BLK/ YEL wlr. botwoon tho A23 andloJ A24 taamlnala and undo?-hoodf uaa/r.ltY box.

ls thers batterYvohag€? YES Turn the ignitionswitch OFF. To psge 1+57

14-56

From page1+56

C o n n 6 c tt h e T 6 s t H a r n e s s "A" connsctor to the TCM.

Turn the ignition switch ON. Be sure th6t voltago is availabl6 tor 2 seconds b6tween the Ag terminal and A2gA26 t€rminal.

oooooooooooo oooQoooooooo A8 Lo-.._----J
Voh!ge?

ooooooooooo ooooooooooo

A25

Chack lor opan or ahort In GRN/OR wlro betwe.n tho AB tormlnsl ond tha gaugo a!!omblv. Turn ths ignitionswhch OFF.

Oisconngct the T€st Hsrness "A" connector from the TCM.

Check ior cominuhy between th6 A8 t€rminal and rhe GRI/ ORN wiro at the gauge assemDry.

Ropairop.n In GRwOnN wh. betwo€n the A8 tormlnll .nd tho gaug€llrombly.

Chod( for loo6o TCM connoctor!. Ch.ck tho A/T gear po!ftlon awftdr. lf noco3aary, aubstltut. I known-good TCM and rechock.

(cont'd)

14-57

Troubleshooting Electrical
Flowchart (cont'd) Troubleshooting
I D4 I Indlc.tor llght It on ;i--adY {not bllnllng} whon.vd th. lgnltlon twttch b oN.

Turn tho ignitionswitch OFF.

oisconhoctths 26P connoctor trom the TCM. C o n n o c tt h o T 6 s t H a r n e s s "A" coonectoa to the wiro harngssonv, not to the TCM. (1+35).

Iurn the ignitiooswitch ON.

Measuroth€ voltago betwoen th6 A8 torminal and bodY ground.

C o n n 6 c tt h o T o s t H a r n 6 s s "A" connectorto the TCM.

Moasureth€ vohag6 b6tw69n the GR[{/ORN wir6 at th6 gaug6 assembt and to bodY gaouno.

A8

I

Volt.gc?

RaDllr rhort to powot toutco oo G8N/ORNwlr. brtweon A 8 tarml[l and lEugp a!!em_ blv.

14-58

l.Ep.ctlon ot rh. A/C tlgnll.

Symptom . Lockrp chnch doos not havo duty opo.dtion(ONe OFFI. . Lock-up chjtch do€s not eng6g6.

Tu.n tho bbwer switch ON.

Pu3htho A,/Cswitch ON.

8c. Alr Condhlonlng Inrp.ctlon (... r.cilon 22).

NOTE:
Disconnoctth6 26P connector from th6 TCM.

trom torminalsid€.

Measuroths vohag€ botweon the A22 IRED/BLU)6nd A25 IBLK/RED)or A26 {BRwBLKI tsrminals. {A/C comDaealror OFF)

RED/BLU Eanaryvoltage?

Rcpah open lo RED/BLU wlr. b.tw..n th. A22 t.rmln.l and A/C compr.$or clutch rcLy. 'A/C.ler|llbOK. ' CH( lo. loor. TCM corF .racto.a, It nacaaatay, ar5. .inul. a Lnown-good TCM and rachack. ' lnlD.ct th. .lr cor|dtlonftt (!.. r.ctlon 22,.

(cont'd)

14-59

Troubleshooting Electrical
Svmptom Shift hv6r camot bo mov6d irom E position with tho brako p€d6ld6prsssed. Ch6ck that the brak€ lights come on with the brake P€dal dopressod.

Disconnect the 26P and 22P connectorsfrom the TCM. C o n n e c tt h e T o s t H a r n e s s "A" and "O" connoctors to th6 wil6 harn€ssonly, not to the TCM (1+35).

oooooooooooo oooooooooooo
Moasuroth6 vohagg betwoon th6 02 and A2tA26 termin3k with the br6ko Podal depresssd.

ooooooooooo
oooooooooo

ris

t_----{}-

^

D2
Baitery voh.g.?

Rrplh op.n In GRN/WHT wlrc b.lw..n lh. D2 t rmlnd and b]ak. lwhci.

' Br.ko rrvhch tlgnal OK. . Chod( for loot€ TCM connacto.r. lf nocoltary, tub_ rtltuto a known-good TCM and rcchack. . lnrDoct the brgka twhch circuh {!.a aociion 23}.

14-60

Mainshaft/Gountershaf t SpeedSensors
Replacement
1. Remov€the 6 mm bolt f.om th€ transmissionhousing and remove the mainshaft and countershaft soesd sensors.
6 x 1 . 0m m 12 N.m {1.2 ks-m , g b-tt}

COUNTERSHAFT SPEED SENSOB

o-R[{GS R€plsc6.

6x1.Omm 12 N.m (1.2 ks-m , I lb-ft)

MAINSHAFTSPEED SE SOR

Replac€the O-ringswith a new one before reassemblingthe mainshaftand countershaftspeedsensors.

14-61

ValveA/B Lock-upControlsolenoid
Test
NOTE: vaves A and B must be removed/ Lock-up control solenoid as reDlaced an assembly. 1. 2. Disconnect the connector trom the lock-up control vave A/8. solenoid Measure the resistsnce between the No, 1 terminal (solenoldvalve. A) of the lock-up control solenoid valve connector and body ground, and between the valve B) and body ground. No. 2 terminsl (solenoid 2,

Replacement
1. Remove the mounting bolts and lock-up control valve assembly. solenoid NOTE: Be sure to r€move or replsce the lock-up control vakes A and B 8s an assembly. solenoid Check the tock-up control solenoidvalv€ oil passages for dust ot din, 8nd replscs 8s sn sssembv, if necessarv. CONTROL LOCK-UP VALVE SOLENOID ASSEMBLY
6r1.0mm 12 N.m {1.2 kem , 9 lb-ft)

STANDARD: 12- 24Q

CONTROL LOCK-UP VALVE SOLENOID ASSEMBLY

Cloanth€ mountingaurface andoil passag68.

FILTER/GASKET Roplac6.

the ReDlace lock-uDcontrol solanoidvatue assemblyil the resistanceis out of specification. lf the resistanceis within the standard, connect the No. 1 terminal of the lock-up control solenoid valve connector to the batterv positive terminsl' A clicking sound shouldbe he8rd. Connect th€ No. 2 terminsl to the battery positive terminsl. A clicking sound should be heard. Replacethe lock-up control solenoidvave assemblyif no clickingsound is heard'

Clean the mounting surface and oil psss€gesof the klck-up control solenoidvslve assembly,8nd install I new tilter/gasket. Check the connector for rust, dirt or oil, and raconnect it securely.

14-62

Valve A/B Shift ControlSolenoid
Replacement
NOTE: Shift control solenoidvalves A and B must be remov€d/ reolacedas an assemblv. 1. 2. Disconnect the connector from the shiJt control solenoid vave A/8. M€asurethe resistance between the No. 1 terminal (solenoidvalve A) of the shitt control solenoidvalve connactor and body ground, snd between the No. 2 terminal(solenoid valve B) and body ground. 2. 1. Removethe mounting bohs and shift control solenoid vafueassamblv. NOTE: Be sure to remove or replacethe shift control solenoid valvesA and B as an assembly. Check the shift control solenoidvatue oil passages for dust or dirt, and replaceas an assembly, necesssry. if

6x1.Omm 12 N.m11.2kg"m, 9 lb-ft)

STANDARD: 12- 24Q

Cl6anthe mountingsurfac6 and oilpass€gBs. FILTER/GASKET sHtFT COI{fROL R6placs.

SOLENOID VALVE ASSEMBLY

3.

Clean the mounting su ace and oil passagesof the shift control solenoidvalve assembly, and installa new fiher/gasket, Chsck the connector for rust, dirt or oil, and reconnect it securely.

4. Replacethe shfft control solenoid valve assembtyif th€ r€sistanceis out of soecification. lf the resistsnce is within the standard, connsct the No. 1 terminal of the shift control solenoid valve connector to the battery positive terminsl. A clicking sound shouldbe heard.Connect the No, 2 terminalto the battery poshive terminsl. A clicking sound should be he8rd. Replace the shiJt control solenoid valve assemblyif no clickingsound is hesrd,

14-63

Chart Symptom-to-Component
HydraulicSystem
SYMPTOM
Emine runs, but.car oasnot move m anYgaar. "8" and "2" but not in "Dg" "D+" or "1" Car movos in , , oosition. "Ds" "D1" "1" "R" but not in "2" Car moves n , , , , Dosition. "'1" but not in "R" "Ds" "Dt" "2' Car moves in . , , , Dosition. ''Dosition. C8r moves in "N Excessiveidlevi )rauon. liosin 8 oaars. "1" No enqinebrakinqin Dosition. os in 1st oe8r, rs in 2nd qear. rs in 3rd gear, lios in 4t n oear SliDsin reversegsar. Flsres on uos Flares 2-3 uDs t . on Flares 3- uos on stays in 1st gear. No upshift; transmission No downs ift to lst qeat h Late upshift. Erraticshittins. Harshshi t {uDand down s tnHar Checktheso items on ths CAUSEList PROBABLE Check these items on th8 NOTESList

a,8,44,4a 9, 30,49 ,22, 34,34,39,&
.4

c,M,o
C,L

K, , . R , S

N

t 12Har t(3 Harshkick-dowr h kick-down shi 8t closedtl Harshdowns ngto "1" Dosition. s Har h shift when manuallv on Axle s) slipsout of transmission turns. Axle sl stuck in transmission. "R" position. ns noisewh€n shifting into Ratc "R posrtion. Loud ooooinono sewhen takins off in "R" to "P" positionor noisewh8n shifting from Ratcheting from "R" to "N" oosition. in Noisefrom transmission all selectorl€ver positions, on Noise{rom transmission v when wheeF are rollrnq. Gesr whine, rom relsted (Ditchchanseswith shi tanges wnn spee( 16 Goarwhine.sDeed "D4" w to 4th qesr in Dosition, Transmission nor s lock-upsmool .ock-uoclutch does not .ock-uD clutc r does not oDerateDroDel has Transmission multitudeof problemsshifting. At disass€mbly,large particlss ot metsl are found on maqnet.

4

i.H

2

38,39,40, 45
.4i ,41 7

L,O

43

L,O

14-64

PROBABLE CAUSE 2.
4. Shift cablebroken/out of adiustment Throttls cabletoo short. Throttls cabletoo lono. Wronq tvoe ATF. e rDmtoo low/hish. il oumDworn or bindino. ressurerequlatorstuck, st clutch defective. nd clutch defective, 3rd clutch defective. clutch defective. st-holdclutch d6fectivs. Mainshatt,countsrshatt,and s€condarvshatt idlsrq6arsworrvdsmaosd. Modulatorvalve stuck. e vafueB stuc TF strainercloqoed. oroue converter defective. oroue convgrter check valvs stuck,
- 2 shift vefue stuck-

5.
7.
e

2

z

2i

shift valve stuck. shift valve stuck. orvo control vSlvestuck. ftch oressurecontrol (CPC) valve stuck. 2nd oritice controlvalve stuck. Ori{icecontrol valve stuck,
3-2 kickdown velve stuck.

z

3i 35.
2A

37. 38. 39.
4 4 4i 4 47.
t.

3rd kick-down valve stuck. 4th exhaustvalve stuck. st accumulator dafectivs. nd accumulator defective. 3rd accumulatordefective. 4th accumuletor defective, st-holdaccumulator detective. ervo vave stuck. ock-uo timinq valve stuck. ock-uo shit'tvalve stuck ock-uo control valvs stuck. Shift tork bent. qearsworn/damaoed qsars}. Reverae {3 €versesebctot worn. (2qesrs). rd q6arsworn/damaqed (2 inaloearsworn/damaqed osars). DitferentialDinion shaft worn. esdoiDe O-rinqbroken, r searsworn/damased(2ssars). eat cl€arance incorgct. Clutch clssranceincorrect. ne-way (soraq) clutch dsJective. worn. ealinqrinqs/quide Axl€-inboard ioint clip missino.

14-65

Ghart Symptom-to-Gomponent
HydraulicSystem (cont'dl
The followingsymptoms can be caused by improperr€pairor assembly. )ar creeosin N Dosition. "D3" or "D4" position. )ar do€s not move in ransmission locks uD in "R" position. (cgssivedraqin transmission, ve vibration,rom r€ Noisewith wheels movinoor
n aeal DoDsout.

th€ssitemson th6 Check PROBABLE CAUSE DUE To IMPROPER REPAIR List

hsms on th6 NOTESList

R

ariousshiftins problems. HarshuDshifts.

PROBABLE DUE IMPROPER TO REPAIR CAUSE

14-66

NOTES A.
R

D,

procedure, Seeflushinq Daqe 1+142snd 143. Sst idle rpm in gear to specitiedidle speed.lf stillno good, adjust rnotor mounta as outlinsd in enginesection ol service manuel. lf th€ l8roeclutch oiston O-rinois broken,insoactthe Distonqroovefor rouqh machininq. It the cfutch psck is seizedor is exceasivelyworn, inspect the oth€r clutchgstor wear, and chsck th6 orifice controlvefuesand throttle valves for free movem€nt. lf throttle valve B is stuck. insoectthe clutchesfor wear. lf the I - 2 shift v8lve is stuck closed,th6 transmission will not upshift. lf stuck open, the transmission has no
lst oaer.

K.

th€ 2nd orifice controlvalve is stuck, insDectthe 2nd and 3rd clutch oscks tor wear. th€ oaificecontrol valve is stuck. insDecttho 3rd 8nd 4th clutch Dscksfor wear. the clutch oressurecontrolvalve is stuck closed.th€ trsnsmissionwill not shift out of lst qe8r. lmpropor alignmentor main vav€ body snd torqus conv€rt€r ho$ing may causo oil pump seizure.The
svmbtoms er6 mostlv en rom-rdletgd tickino noise or d hioh-Ditchod sdueek-

M.
N.

o.

R.

s.
r.
U.

tf the ATF strainer is clog€edwith particlesol steelor aluminum,inspoct the oil pump 8nd diff6rentialpinion sheft- lf both 616OK snd no caus6lor the conteminetionis {ound. roolecethe tordua convertor. lf th€ lst clutch feedpipe guide in the right sida cover i8 scorod by the secondaryshaft, insp€ct tho ball be8ring €xc6ssiv6mov6m6ntin tho transmission lor housing,lf OK, roplacoth6 right sid6cov6r as it is dsntad. Th€ O-rinound€rtho ouideis Drobablv wo.n. the Replaco mainshaftiJ the bushingfor th€ 4th feedpipeis looseor dsmag€d. lf th6 4th {eedpipeis dsmsgedor out of round, roplacsit. Bsplsceth€ countershaftif the bushingfor the 1st-hoHfgedpipeis loossor dsmsged. lf th€ 1si-hoHfeedpipeis damaged out of round,replac€h. or Rsplace the secondaryshaft it the bushingfor the 1st feodpipeis looseor damgod. lf the 1st f66doiDe damaodd out of round.rsDlacsh. is or A worn or damagad spragclutch is mostly a result oJ shitting the transmissionin "D3" or "D4" posrtionwhile the wheels rotato in aoverse. such as rockinothe caain snow. nsDectthe frame tor collisiondamase. Inspectlor damage wear: or 1. Reverseselectorgearteeth chamfers, teeth chamfersof countershatt4th snd revsrseg€ar, 2. Engsgement 3. Shift fork for scuff marks in center. 4. Differentialpinionshatt lor wear under piniongears. 5. Bottomof 1st-hold clutchfor swirlmsrks. Replace items 1, 2, 3 and 4 it worn or damaged. transmissionmskes clicking,grindingor whirring noise,also lf replacemsinshaft4th gear and reverseidlergear andcountershsft 4th gear in additionto 1, 2, 3 or 4, lf differential pinion shaft is worn, overhaul differential€ssembly,and replsceATF strain6r,and thoroughly flush torque convartsr, cooler and lines. cleantransmission, lf bottom oJ 1st-holdclutch is swirled and transmissionmakes gear noise, replaceth€ countershaft and tinal driven oeer86 very careful not to damagethe torque converter housingwhen replaclngth€ main bsll besring.You may also damagethe oil pump when you torque down the main valve body. This will resuh in oil pump seizureif not detected.[Jseorooertools. Installthe main s6alflush with the torque converter housing.lf you push it into the torqus converter housing until it bottoms out. h willblock the oil return Dassaoe resuftin damaoe. and Harsh downshifts when coasting to a stop with zero throttle may be cauaed by a bent-in throttlo valve retainer/camstooDer.Throttle cablesdiustmentmav clearthis Drobl€m. th€ check vave may have been pushed Check if servo vatue stopper cap is installed.lf it was not installod, out bv hvdraulicoressurecausinoa leak (internal) atfectinq sllforward qears. Throttle cable adjustmentis essentialfor proper operation of the transmission.Not only does it sffect the but shift points if misadjusted, alsothe shift qualityand lock-upclutch operation. A cable adjustedtoo long will resuh in th.ottle pressureb6ingtoo low for th6 amount of enginetorque input into the trsnsmissionand m8y causeclutch slippage. cablesdjustedtoo short will resuttin too highthrottle A oressurewhich mav causeharshshitts, erratic shitts andtorque conveter hunting,

14-67

RoadTest
NOTE: Warm up the enginsto normsloporatingtemperature(the radiatortsn comes on). position while 1. AppV parking brake 8nd block th€ wheels. Start the engine, thon mov€ the selector lever to @] shouldnot stall. it th€ depressing brak6 pedal.Dopressthe accelaratorpedaland release suddenly.Engine test in I D3 l poshion 2. Repeetsame tol 3. ShiJtthe selectorlev-er Dn-lpositionand check that the shiJ'tpoints occur at approximatsspeedsshown. Also check slippage. and clut-ch for abnormalnoise NOTE: Throttle positions€nsorvoltagBtepresentsth€ throttls opening. - 1. -2. Connectthe Test Harnessbetween the ECMand connector (seesection 11l' Set the digital multimst€r to check voltage betw€en Dl1 (+) terminal and D22 {-) t€rminal for the throttle posiiionaenaor.

CAUTION: . Al SRS oloctrlcal wldng harnot3as aro covolad whh yelow outor Inrulatlon. . Bololo dsconnecllng tho SRSwlro herna$, Installtho short connoctor{ll on tho !lrb.g(!}. . Replac6tho or|tlle sffocted SRS hlrnoss ass.mblY if h has an opon chcuh or damrgod wlring.

SRS MAI'{ HARI{ESS

MULTIMETER DIGITAL KS_AHM_32

14-68

F22Al Engln.:l Da I Polhlor 1st+2nd Throttlo polhlon lorEor voltago: 2ndJ3rd Lock"up Cinchof'l

o.83V

mph km/h mph km/h mph km/h

13- 15

26-24
42-45 37 -4'l 60-66

36-40
58- 64 57-63

l4-17

Coaatlngdown-hll from a stop

21-24
17- 2'l

23-27
6 1- 6 7

Throttlcporhlonlomor vohago: 2.'t8V Accobratlon from a stop
Fu[throttlo AcceLrltlon from a stop Dowruhltt Throftlo porhlon sg]lor voltego:

27-34 E-34 47 -55
Lock-up Clutch oFF

92-101 88- 94 142-'151
3rdJ2nd 18-22l4tHld) E-35{4thrhdl

98- 108
8t -86

60-65 97- 105
4thJ3rd

130-138
2nd-+ l st 6- 10

o.83V Corstlng braklng ! stop or to

mph

13- 16 2't-26 53- 59 &5-95 77-82 124-132 76-42 123-132

km/h
mph km/h mph

10-16

Throttb po3ltlon lsmor Yoftago: 2.18V When car is sbwed by increr3od grldo, wlnd, oic. Fd-throttlo When car lr tbwed grada,wlnd, etc. by Increased

52-

al

2'l -26 34- 42

km/h

u-92

{cont'd)

14-69

RoadTest
(cont'd)
H23Al Engine: Da I Position I 'Upshift lst-2nd mph km/h mph km/h mph km/h 2nd--r3rd 3rd -,4th Lock-up Clutch 0N 14-'17

Throttleposition sonsolvohago: o.83V from a stop Coasting down-hlll Thlottls position sensor vohago: 2.18V from I stop Accaloration
Full-throttle Accelerationtrom a stop .Downshift

13-15

26-A
42*45

36-40
58- 64

23-27
58- 64

1A-22 29-35 E-34
47-55 Lock-uD oFF Clutch

36-40 58- 64 57-62 92- 100
4th-J3rd

54-60
87 -97

93- 103

&l-88
134-142 3rdJ2nd 18- 22(4thJzd) 29-35{4th+hd}

s-85
l?9-137 2nd+lst

Thlottleposition sensolvoltago: 0.83V
Coasling 01 blaking to a stop

mph km/h mph km/h mph km/h

13- 16

6- 10 10-16

21-26
48-5/. 77-47

Throttle position 3onsorvohage: 2.18V wh6n car is slowed by incleased grado,wind. otc. Full-throttlo When car is slowed by Incroased grade,wind, etc. 4.

73-& 117-lE

73-79
117 127

51-56 82- 90

24-A 39- 47

Accelersteto about 35 mph(57km/h) so the transmisionis in 4th, then shift lE+-Jpositionto f Z-l position.The car should immediately boginslowingdown from enginebraking, GAUTION:

the transmission.

you over to at DonotshifrtromIoi lor lE-l position E-lor F-l posltlon sposds 63 mph(1ookm/h]; meydamaso in and clutch slippage the following positions. Check lor abnormalnoise

5.

L! ] {lst Gear)Position -1. Accelerate or trom a stop €t lullthrottle.Checkthat ther€is no abnormalnoise clutchslippago. - 2. Upshiftsshouldnot occur with the selectorin this position. [7 (2ndcear) Position - 1. Acceleratefrom I stop at tull throttle. Checkthat there is no abnormal noiseor clutch slippage. - 2. Upshiftsand downshifts shouldnot occur with the selectorin this position, T-:-1,tl |lr|eversel rostuon A.ccelerste from 8 stop at fullthrottle, and check to. abnormslnoiseand clutch slipp8ge. 6. Test in I P I lParkino) Position Release brake;the car should the Parkcar on slope(approx.16o),sppv the parking brake,and shift intoI P I position. not move.

14-70

StallSpeed
Test
CAUTION: . To provont tlansmissiondamago,do not t6st stall spoodfor mors than 1Olocond! at r tlma, . Do not shlft tho lovel whlle lalsing tha enginespeed. . 86 suro lo romovo the prossuregaugobefolo testlng stal spood. 1. 2, 3. 4. parkingbrakeand block the front wheels. Eng€ge Connecttachometer.and sta.t the engine. Makesurethe A/C switchis OFF. After the enginehas warmed up to normaloperatingtempersture (the rad;8tortan comeson), shift into @ Ooshion.

and for and sp€ed, 5. Fully depress brakepedal accelerator 6 to 8 seconds, noteengins the for thenrepeat test inloil, [Tl , ana[_] oositions. the 6. Allow2 minutes coolins, NOTE: . St8llspeed restsshould used diasfEtiplqrpos€sonly. be lor . Stall in speed should the same L91l , L?l , L1l andL!_l positions. be

Stall SoeedRPM: F22Al Engin€ Spoclficatlon: Sarvice Limit: H23Al Engino Sp€cification: Service Limit:

2,500rpm 23&-2,6fu

rpm

2,7@rpm 2,60O-2,90O rpm

TROUBLE

PROBAELE CAUSE
Low fluidleveloroil pumpoutput Clogged ATF strsiner Pressurer€gulstolvafuestuck clossd Slipping clutch Slippage 4th clutch ol Slippage 2nd clutch of Slippage 1st clutch or lst gesr one-wayclutch of Engine output low Torque converter one-way clutch slipping

starlrpm i" F;] ,E .E -o E hish posruons

Stallrom hiohin @ nosition

Stall rom hiehin@ and@ oositions Stall rpmhish E position in

stallrpm i" [D;l .E low
positions

,f

a.a@

14-71

FluidLevel
Checking/Changing
Chocklng NOTE: Chsck ths fluid l€vsl with th6 6ngin6 at normal opsrstingtemperaturs (th€ rsdistorf8n comes on). 1. 2. 3. Psrk the car on l€v6lground,Turn oft th€ 6ngin6. Remov6 ths dipstick {yellow loop) from th€ transmission, and wipe it with a cls8ncloth. 2 Insertths diDstickinto th€ trsnsmission, DIPSTICK LOOPI {YELLOW Roinstsllths drain plug with a nsw s€aling wssh€r; to thon rsfill ths tranamisaion the uDDermark on th€ dipstick. Automatlc Tranlmllllon FhrldCapachy: at chsngins 2.4 t (2.5 US qt , 2.1 lmp qt) at ovsrhaul 6.0 e (6.3 US $ , 5.3 lmp qt) NOTE: lf 8 cool€r flushar is to be usad, sa6 paee 14-142 and 143. ChEnglng 1. Bring the trsnsmission up to normal op€rating tampsrature lths radistorf8n com€s on) by drivingthe car. P6rk ths car on l6vel ground,turn the 6ngin6olf, andth€n romovothe drain plug.

Romoveths dipstick and ch6ck ths fluid bvel. lt shouH be bstw66n th6 uDDer and lowgr marks. DRAI'{PLT'G 18r 1.5rnm 50 N.m(5O ks-m , 36 lb-tt)

DIPSTICK

I A
Ell-

UPPER LOWER

lf the l€vel is below the lower mark, add lluid into tho tub€ to bringh to the upper mark. Use HondsPremium Formula Automstic Transmission Fluid or an equivalentDEXROIIall Automstic TrsnsmissionFluid (ATF)only. hsert th€ dipstick bsck into th6 transmission.

14-72

I
. Whlle t$tlng, bs careful of ths rotallng tront whoob, . Mak6 suro tfts, lackr. End safoiy stands aro phccd proparly(3oosoctlon 1l. CAUTION: . Botora toltlng, bo surc tho tra]lmirlion fluld lr flled to tho plopol loval. . Wsrm up tha onglneb€toro toltlng. 1. 2. 3. Raise car.{seesection1). the Warm up the engine, thon stop ths sngine End connect a tachometer. Connect the oil pressuregaugeto esch insp6ction hole. TOROUE: 18 N.m (1.8 kg-m, 13 lb-ft)

4.

Stsrt the engins, and msasurs ths rospoctivs Dr€ssuro follows: as ' LinePr6ssuro . Throttl€ B Prossur€ . Clutch Pr6ssur6 ' Clutch Low/High Prassurs Instsll a new waahsr and the sesling boh in th6 inspectionhols, andtighton to th6 sp6cifi6dtorqus. TOROUE: 18 N.m (1.8 kgm , 13 lb-ft)

R

NOTE: Do not rsuse old aluminumwashers.

CAUTION: Connect tho oll pr€ssuragaugo 3ecuroly;be rure noi to allow dust and other folelgn partlcl$ to ent.l th€ lmpoctlon hol€.

A/T OILPRESSURE GAUGE SET 07406- 0020003

A/T OILPRESSURE HOSE 07406- 0020201

A/f LOW PRESSURE GAUGE

07408-OO7o(xXr

(cont'd)

14-73

Testing Pressure
(cont'd)
. Llno Prcrluro Maalurcmcnt - 1. -2. - 3. Set the psrkingbrake 8nd block both rear wheels securely. RunthE 6ngineat 2,000 rpm. Shift ths s6l6ct l6v6r to N or E position .

NOTE: prossures boindicEted measurements made sol€ctor positions in oth€rthanLryl orLll position, Highsr msy it ar€
-4, M€8sursline pressur€.

PRESSURE LINE I SPECTION HOLE F22A1 Engin€ PRESSURE Line

SELECTOR POSITtON

FLUID PRESSURE
SYMPTOM No (or low) line pressure

PROEABLE CAUSE
Standard Scrvlcc Llmh Torqu6conv6rt6r, oil pump, prossurs regulator, torque converter check valve

E*E

&O- 85O kP8 750 kPa(7.5 ks/cm,, (8.O-8.5 ks/cm' , 107 psi) 1 1 4 - 1 2 1p s i )

H23A1 Englno

PRESSURE
Ltne

SELECTOR POST|oN

FLUIDPRESSURE

SYMPTOM
No (or low) line pressu,e

PROBAELE CAUSE
Stand!rd

Scrvlco Llmh

Eo'E

Torqueconverter, oil pump, pressure regulator, torqug convert€r check vatve

85O-9OOkPa &O kPa(8.Oks/cm,, (8.5-9.O ks/cm, , '114psi) 1 2 1 - 1 2 8p s i )

14-74

. Thlotllo I Prossul€Moasurement - 1. Set the parkingbrakesecurelyand block the wheels. -2, -3. Runthe ongine8t 1,00Orpm. Disconnectthe throttle control cable lrom the throttle control lev6r and set the throttle control l€ver in full throttle position. THROTTLE PRESSURC B INSPECTIOI{ HOLE

THROTTLE COiTTROL CABLE

THROTTLE COiITROL LEVER F22Al Englno

PRESSURE
Throttle B

SELECTOR POStTtot{

FLUIDPRESSURE

SYMPTOM Pr€ssure too hish

PROBABLE CAUSE
Standard SorvlceLlmlt Throttls VElveB 0 kP8 (O kgy'cm', 0.0 psi) throttle l€ver tullyclosod kPa &0-850 18.0-8.5 ke/cnt' , 114-121 psi) throttl€ lever fullyopensd 75O kPa (7.5 kg/cm, , 1O7 psi) throttle lever fullyopeneo

E

No or low pressure

H23A1 Engine PRESSURE Throttle B SELECTOR POSITtON FLUIDPRESSURE

SYMPTOM
Pressure too high

CAUSE PROBABLE
Standard SorvlcoLimh Throttl€ Vslve B 0 kP8 (0 ks/cm' , O.O psi) throttle lever fulvclos€d 85O- 9OO k P8 (8.5-9.0 kdcnP . 121- 128 psi) throttle leve. fullyopen6d SO kPa {8.0 ksr'crn,. 114 psi) throttle lever fullyopened {cont'dl

E

No or low pressure

14-75.

Testing Pressure
(cont'dl
. Clutch PressuloMeaaurmant

@
Whila t$ting, bo ca.€fulof tho totatlng front wheals. -'1. -2. -3. -4, -5. brskeandblockboth rearwheelssecurely. Set the parking Raisethe front of the car and support h whh salety stands. Allow the Jront wheelsto rotate freely, Runthe engineat 2,0OO rpm. Measure eachclutchpressure.

PRESSURE lST CLUTCH INSPECTION HOLE

PRESSURE 2NDCLUTCH II{SPECTION HOLE

lST-HOLD CLUTCHPRESSURE INSPECTION HOLE

PRESSURE 4TH CLUTCH II{SPECTK)]T HOLE

PFESSUBE 3RDCLUTCH INSPECTIOI{ HOLE

CENNEB BEAM

14-76

F22Al Englno

SELECTOR PRESSURE POSITtON
1st Clutch 1st-hold Clutch 2nd Clutch 2nd Clutch

SYMPTOM No or low lst pressure No or low lsthold pressure No or low 2nd pressure No or low 2nd pressure No or low 3rd pressure llo or low 4th pressur€

PROBABLE CAUSE
Standard lst Clutch 1st-holdClutch 2nd Clutch 2nd Clutch SO-85O kPa {8.0-8.5 kgy'cm', 114-121 psi)

FLUID PRESSUBE
Servic6 Limit 75O kPa (7.5 ks/cm, . 1O7 psil

E",F;]

tr
tr;-] L1l

E

3rd Clutch

3rd Clutch

4th Clutch

4th Clutch

5OOkPa (5.0 kg/cm, , 71 psi) (Throttlelsv€r fully closedl 85O kPa (8.5 kg/cm, , 121 psi) {Throttlelever more than 3/16 oDened) 53O kPa {5.3 kg,icm,, 75 psi) (Throttlelever fully clos€d) 85O kPa (8.5 ks/cm, , '121psi) (Throttlelever more than 3/16 ooen6d)
gJO-a5O kP8 lE.O-8.5 kg/cm, , 114-121 psi)

tr
H23Al Englne SELECTOR PRESSURE POSITrON lst Clutch 1st-hold Clutch 2nd Clutch 2nd Clutch

Servo Vslve or 4th Clutch

450 kPa (4.5 kg/cm, , 64 psi) (Throttlel€ver fully closedl 75O kPa (7.5 ks/cm' . 107 psil (Throttlelsver more than 3/16 oDenedl 4$ kPa 14.8 kg/cm, , 68 psi) (Throttle levor fully closed) 75O kPa {7.5 kg/cm, , 107 psil (Throttle lever more thsn 3/16 oD€nedl 75O kP8 (7.5 kg,/cm', 107 psi)

SYMPTOM
No or low 1st pressure No or low lsthold pressure No or low 2nd prsssure No or low Zrd pressure No or low 3rd pr€ssure No or low 4th pressure

PROBABLE CAUSE
Standrrd 1st Clutch 1st-holdCluich 2nd Clutch 2nd Clutch

FLUID PBESSURE
Sorvico Limlt

E-[5.']

tr
tr;-l

85O 9OO k Pa (8.5-9.0 ks/cmz , 1 2 1 - 1 2 8p s i )

&O kPa{8.0 ks/cm' , l14 psi)

IA

r=---l l u 4I

3rd Clutch

3rd Clutch

4th Clutch

4th Clutch

E

S€rvoValve or 4th Clutch

50O kPa (5.O kslcm, , 71 psil (Throttle lever fully closed) 90O kPa (9.0 kg/cm' . 128 psil (Throttle lover more than 3/16 oDencdl 53O kPa (5.3 ks/cm, , 75 psi) (Throttlelever fully closed) 9OO kPa (9.O kg/cm, , 128 psi) (Th.ottle lever more than 3/16 ooened) 8S-9OO kPa (8.5-9.0 ks/cm' , 121-128 psi)

45O kP8 (4.5 ks,/cm' , 64 psi) (Throttlelever tully closed) 800 kPa (8.0 kgy'cm,, 114 psi) {Throttlo lever more than 3/16 ooened) 4m kPa (4.8 ks,/cm' , 68 psi) (Throttle lever fully closed) 80O kPa (8.0 kg/cm, , 114 psi) (Throttlelever more than 3/16 ooened) DO kPa (8O ks/cm' , 1'14 psi)

14-77

Pressure Testing
(cont'd)
. Low/Hlgh ProssuroTost -1, -2. -3. -4. Set the psrkingbrake and block the rear wheels securety. Raisethe car and support with satety stands. pressure Attach the gaugeset to the approp.iate inspectionholes. Remove the throttle control cable end of the throttle control lever, NOTE: Do not loosen the locknuts; simply unhook the throttle control cableend. THROTTLE TROL CO CABLE LOCKNUT -8. With the engin€idling,lift the throttle control l6v€r up approximately 1/2 of its possible travel and increasethe engine.pm until pressureis indicated on the appropriate gaug€. Record th8 highest pressurereading obtained.

THROTTLE CONTROL LEVER THROTTLE COIVTNOL LEVER -9. -5. Warm up the engine to normal operating temperature(the radiatorfan comeson). Repe8tsteps -7. and -8. tor each clutch pressure beinginspect€d.

E
-7.

with the engineidling,move the slector leverto
position.

Slowly move the throttle linkageto increasesngin€ rpm until pressure is indicated on the appropriate gauge. Then releasethe throttle linksge,sllowingthe engineto return to an idle. and record the pressure reading.

THROTTLE LINKAGE

14-78

CE TERBEA]II

Englno

PRESSURE
2nd Clutch 3rd Clutch

SELECTOR POSITtON

FLUID PRESSURE SYMPTOM
No or low 2nd pressure No or low 3rd pressure
DD'IEADI E 'TA I ICE

Standard

SorYiceLlmlt 45O kPa {4.5 ks/cm, , 64 psil lever fullycbsed) {Throftle 75O kPa (7.5 kg/cm, , 107 psi) (Throttlelever more than 3/16 open€d) 4& kP8 {4.8 ks/cm, , 68 psi) lever fulv closed} {Throttle 75O kPa (7.5 ks/cm, , 107 psil (Throttle lever more than 3/16 opened)

L9!

2nd Clutch 3rd Clutch

5OO- 85O kPa lc.u-5,9 Kg/cm' , 71-121 psi) vsries with throttle lever op€ning

4th Clutch

No or low 4th pressure

4th Clutch

53O-850 kPa (5.3-8.5 ksy'cm, , 75-121 psi) varies with throttle lever opening

Engino PRESSURE 2nd Clutch 3rd Clutch SELECTOR POSITtON FLUIDPRESSURE SYMPTOM No or low 2nd pressure No or low 3rd pressure

PROBABLE CAUSE
StEndard Sorvlce Llmit 45O kPa (4.5 ks/cm, , 64 psil lever fullycbsed) {Throttle &O kPa (8.O kg/cm, , 114 psi) (Thfottle lever more than 3/16 opened) 48O kPa {4.8 kg/cm, , 68 psil lever fulv cbs€d) {Throftle 8OO kPa (8.O kg/cm2, 114 psi) (Throttle lever more than 3/16 opened) 2nd Clutch 3rd Clutch 50O- 9OO kPa (5.0-9.O ksy'cm, , 71- 128 ps') varieswith throttle leveropening

E

4th Clutch

No or low 4th pressure

4th Clutch

53O- 90O kPa (5.3-9.O ksy'cm' , 75-128 psi) varieswith throttle lever opening

14-79

Transmission
Removal
t.

Disconnectthe battery negative (-) 8nd positive {+) cablesfrom the battery. Remov€ the battery set pl8te, then remove the battery.

. Make Eu16ltfts. iacks and safoty stands aro placed properv, 8nd hoist brackots ato attachod to the corroct positlon on th6 6n9lne(360soctlon 1). . Apply psrklng brak6 and Hock roar wheols, so car will not roll otf stands and ta[ on you while worklng und6r h. CAUTION: Uso f€nder covols to avold damagingpaintodsurfac€s. CAUTION: . A[ SRS olsctrical wi]ing halnossas are covet€d whh yellow outor insulation. . Bofore dlsconn€cting the SRS wlro harnoss, install tho short connoclor (3)on the slrbag ls). . Reolacotho entlre affocted SRS ham$s assemHy if it has an open circuit or damagedwirlng. NOTE: The radio mav have I cod€d theft protection circuit. Be sure to get the customer'scode numberbefole. - Disconnecting battery. the - Removing No.43 (10 Alfuse. the fuse/relayboxl {ln the under-hood - Removing radio, the AJter service, reconnect power to the r8dio and turn it on. "CODE" is displsyed, enter the When th€ word customer's Sdigh code to restore radiooperation.

5.

Remove the drsin plug, and drain the automatic the transmissionlluid (ATFl. Reinstall drsin plugwith a washer. new sealing TOROUE: 50 N'm (5.O kem , 36 lb-ft)

DRAINPLUG 18x 1.5 rrm 50 N.m (5.0 ks-m , 36 b-ft)

4.

Removethe resonator,intaks air duct and air clesnet housing. Disconnect the connectot from the intak€ conttol vacuum tank, then removs the intake control vacuum tank 8ndtank bracket. NOTE: Do not remove the vacuum tube from the intsko tank. controlvacuum

HOUSIM! AIRCLEAI{ER

VACUUMTANK I]YfAKECOi{TROL

14-80

6.

Disconnect the glound cabsl from the transmission and body. Removethe bEttery basewhh th€ groundcable.

1 3 . Removethe starter rnotor cables. 1 4 . Disconnectthe countershattspeedsensorconnector.
COUNTERSHAFT SPEED SENSOR CONNECTOR

6.

Removsthe battery bassstay.
GROUND CABLE

BATTERY BASE STAY
q

STARTSER MOTOR 15. Disconnect the vehicle speed sensor connecter. Remove the rear stiffener, then remove the vehicle speedsensor/powersteeringspaedsensor. NOTE: Do not disconnectthe power steeringpressurehoses from the vehicls speed sensor/pow€r steering speed s9nsor, POWER STECRING VEHICLE SPEED PRESSURE HOSES SENSOR REAR EI{GINE MOUI{T

Disconnectthe lock-upcontrol solenoid valve and shift control solenoid valve connectors. controllever.

1 0 . Disconnectthe throttle control cablefrom the throttle 1 1 . Disconnectthe mainshaftspeedsensorconnector. 12. Removeths ATF cooler hosesat the joint pipes.
Turn the ends of the ATF cooler hoses uo to Drevent ATF from flowing out, then plugthe ioint pipes. NOTE: Check for any signsof leakage tha hose joints. at
MAI]TSHAFT SPEED SE SOR COI{NECTOR

SOLENOID VALVE coNf{EcToRs

TRANSMISSK)N

GROUD CABLE

\

POU'ER STEERIT{G SENSOR \SPEED

REARSTIFFENER

O-RING Replac6.

(cont'dl

14-81

Transmission
Removal(cont'd)
housingmountingbohs. 16. Removethe transmission mount. 1& Removsthe transmission TRAl{SMlsSOt{MOUI{T

HOUSING TRANSMISSION BOLTS MOUI{TING

17. Loosenthe Jront enginemount brscket bolts.
FROiIT E]{GII{E MOUNTT BRACKETBOLTS

19. Rsmovethe splsshshield.

SHIELD SPLASH

FRONTENGINE MOUiTT

14-82

20. R€movethe center beam8nd r6ar beamstifJener.

B.

Pry the driv€shaftsout ot ths differentisl. driv€shafts(s€6ssction 16).

24. Pullon the inboardjoint and remove the right and left
Tie plasticbagsov6r the driv€sh8ftenos. NOTE: Coat 8ll precisionfinished 9urf8c6s with clean ongine oilor groass.

DRIVESHAFT D E

21. Romovsths cott€r pins and castls nuts, thsn sep8r8t6
the ballioints from the low6r arm (seesection 18), dampertork and lower arm.

26. Removethe right dsmpsr pinch boh, then separatetho damoerfork and dsmoor, 27. Remove the self-locking bolts and self-locking nut, then romoveths right radiusrod. SELF.LOCKIIIG NUT ReDhco.

22 Remove the damper tork bohs. then separste tha

r
SELF.LOCKING UT Roploco.

DAMPER PII{CH EOLT R6plac€.

DAMPER FORK

P6*ii53., cAsrLENur

rY

sELF-L(rcKhIG BOLT
R6place,

RADIUSROD

(cont'd)

14-83

Transmission
(cont'd) Removal
n.
E.
R€movo ths torque convorter cov€r and shift csbb covgt. R6moveths lock bott sscuringthe control l€ver, then rsmovo the shift cablswith the controllsvsr. CAUTION: Tlks care nol to b.nd tha lhlft cable whllo removlng h. 31. Plsce 8 jack und€r the transmission, and raise th€ transmissionjust enough to take weight oft of the mount. 32. Romovethe intake manitoHbracket. 33, Removethe trsnsmissionhousingmountingbolts 8nd rear anginemountingbolts, 34. Pull the transmissionaway trom the €ngine until it clesrs the 14 mm dowel pins, then lower it on the jack. transmission
HOUSING TRANSMISSION MOUiTTI'{G EOLTS

SHIFT CABLE INTAKE TIAI{IFOLD ERACKET

TOROT,E COI{VERTER COVER

30. Rsmovoths eight drive plate bolts one at a tims whils
rotatingth€ cr8nkshEftpulby. TRANSMISSION JACK

DN|VE PLATC BOLT 6x1.Omm

PLATE DRIVE

14-84

lllustratedIndex
Right Side Cov

14-86

SIDECOVER PROTECTOR SPEED SENSOR Replace,

SIDECOVER
Replace. TH CLUTCH FEED PIPE SIDECOVERGASKETReDlsce. Replace. PIPEGUIDE RING ST CLUTCHFEEDPIPE Replace. PIPE GUIDE RING Replace. SPEED SENSOR lST.HOLDCLUTCH FEED PIPE PIN

@O-RlMisReDtsce. P|PE @FEED GUTDE OSNAPR|NG @CouITERSHAFT LocKNUT,24 x 1.2s mm (Flange nutlReplsce.
SPRING WASHERReDlace. ARKINGGEAR NEEDLE BEARING IDLERGEAR EEARING

SHAFTLOCKNUT, x 1.25 mm 24 @SECONDARY nut) R€place. {Flange SPRING WASHER Reptace. @CONICAL SHAFT IDLERGEAR CISECONDARY Replace. @LOCKWASHER LEVER @THROTTLECONTROL @THROTTLECONTROLLEVERSPRING HANGER @'TRANSMISSION @ATF LEVELGAUGE @DRAINPLUG @SEALINGWASHERReplace. E)PARKINGBRAKEPAWL BRAKEPAWL SPRING @)PARKING @PARKINGBRAKEPAWL SHAFT @PARKINGBRAKEPAWL STOPPER @LOCK BOLT @LOCK WASHERReplace. BRAKE LEVER @PARKING OPARKINGBRAKESPRING g) PARKII{GBRAKESTOPPER HOUSTNG 6)TRANSMTSSTON HOUSING GASKETReDtace. 6)TRANSMISSION @)DOWEL P[rl 6)ATF COOLEFPIPES WASHERSReplace. @ SEALING 6)JOTNTBOLT @SEALINGWASHERSReplace. STEERING @VEHIGLESPEEDSENSOR/POWER SPEED SENSOR Replace. @ O-Rll,lG IDLERGEARSHAFT HOLDER G)REVERSE BEARING @ NEEDLE

BOLT @tJorNT

(Flange nut)Replace. NOTE:Left-handthreads WASHERReptace. OCONICALSPRTNG IDLERGEAR @)MAIN!|HAFT

NEEDLE BEARIMi WASHER LOCKNUT, x 1.25 mm 24

TOROUE SPECIFICATIONS
Ref No. A B E H TorqueValue 1 2 N . m( 1 . 2 k g - m , I l b - t t ) 14 N.m (1.4 ks-m, 10 lb-ft) 18 N'm (1.8 ks-m, 13 lb-ft) 55 N.m (5.5 ks-m ,4O lb-ftl 29 N.m (2.9 kg-m,21 lb-ft) 50 N.m (5.0 kg-m,36 lb-ftl 23O N.m (23.0 ks-m, 166 lb-ft) 170 N.m (17.0 kgrm, 123 lb-ft) 230 N'm (23.0 ksFm,166 lb-ft) 1 7 0 N . m( 1 7 . 0k s - m , 1 2 3 l b - f t ) 23O N.m (23.0 ks-m , 166 lb-ft) 170 N.m (17.0 kg-m, 123 tb-ft) 8 N'm (0.8 ks-m , 5.8 lbjtl Bolt Size 6x1.Omm 6x1.Omm I x 1.25 m m 1 0x 1 . 2 5 m m 12x1.25 m m 1 8x 1 . 5m m z+x t.zcmm 24 x 1.25mm z4 x t.zc mm 5x0.8mm Remarks

K

Joint Boft DrainPlug MainshartLocknut Left-handthreads SecondarySh8tt Locknut Countershaft Locknut

14-87

lllustratedIndex
Housing Transmission

@ B @ @

@

@ @

@

o
{}

@

o
(t

@

@

@

14-88

WASHER OTHRUST NEEDLE OTHRUST BEARING OSEcoNDARY SHAFT 2NDGEAR BEARINGS @NEEDLE NEEDLE @THRUST BEARING WASHER @SPLINED Stective osrt @1ST/2ND CLUTcH ASSEMBLY Reptace. @o-RlNGs (9)SECONDARY SHAFT @THRUST NEEDLE BEARING BEARING ONEEDLE @SECoNDARY SHAFT lsr GEAR @DtsrANcEcoLLAR.s.o mm @corrERs, 29 mm
RETAINER RING RINGS, mm 32

Replace.

NEEDLE EEARING
4TH/REVERSE GEAR BEARII{GS I{EEDLE BEARING GEARCOLLAR TH CLUTCHASSEMBLY GEARCOLLAR

THRUST ]TEEDLE BEARIITIG BEARING
3RD GEAR

NEEDLE 8EARI]{G Rephce.
RINGS,35mm RING,29 mm BEARING

BOLT
WASHER Replace. FORK 2ND GEAR REVERSE GEAR BEARING

SELECTOR HUB SELECTOR
4TH GEAR BEARING RING

RII{G IDLER GEAR SHAFf HOLDER BEARING
SEAL Reolace. HOUSING SEAL Reolace. OIL SHIM SelectiveDart OUTERRACE HOUSING GASKETReplsce. HOUSII{GMAINSHAFTEEARII{G HOUSIMI SECOI{DARY SHAFT

32 mm TERS, mm 29 ANCECOLLAR
3RD GEAR NEEDLE BEARING @oNE-WAY CLUTCH 1ST GEAR €}COUMIERSHAFT BEARING €)NEEDLE @THRUSTWASHER lST GEARCOLLAR @COUNTERSHAFT @tlsT-HoLD cLuTcH ASSEMBLY TOROUESPECIFICATIONS Ret No. TorqueValu€ 1 2 N . m( 1 . 2k g - m , 9 l b - f t ) 14 N.m (1.4 kg-m, 10 lb-ftl

EEARI'{G HOUS|NG COUI\TTERSHAFT BEARTNG @)TRANSM|SS|OI{ IDLER GEAR @NEVERSE ASSEMBLY GDIFFERET\ITIAL OUTER RACE G)EEARIIIIG COI{VERTER HOUSING SEALReDtace. OIL @)TOROUE COI{VERTER HOUStitc @TOROUE

Boh Size

Rsmsrks

B

6x1.Omm 6x l.Omm

14-89

lllustratedIndex
Housing TorqueConverter

\l
@.-.

q

il

I U
I
lL? a

@

@@ '

&P

l

14-90

OATF STRATNER @MAGNET PIPE @OILFEED P|PE @otl FEED covER @4THACGUMULAToR @o-Rlltc Reohce. OLOCKwAsHERReotace. BASE @sERvoDETENT BoDY @sERvo SEPARAToR @SERVO PLATE @cHEcKBALL vALvE BoDY @SECoI{DARY PIN @DOWEL @SECoNDARY SEPARAToR PLATE @AccuMULAToR BoDy covER @lsT AccuMUrAToR cHoKE @cHEcKBALL @1sT/2 D ACGUMULAToR BoDY vALvE BoDY @THROTTLE pt-arE SEPARAToR @THRoTTLE PrN @oowEtCOTTROL SHAFT €!THROTTLE Replace. @ERING Replace. @FILTER VALVEBODY @REGULATOR Replace. @O-RllJG SHAFT @STATOR SHAFT @STOPPEB COiTVERTER CHECK VALVE @TOROUE CONVERTER CHECK VALVESPRING @TOROUE

FEED PIPE
BALL TERReplace. PIN

FEED PIPE VALVEBODY
PUMPDRIVENGEARSHAFT PUMP DRIVEGEAR PUMP DRIVENGEAR SHAFT SPRIiIG ARM ARM SHAFT PIN SEPARATOR PLATE

NEEDLE BEARIM! GUIDE PLATE
SHAFT BALL EEARING

GUIDE PLATE SEAL COiITROL SOLEI{OID FILTER/GASKET Replace. COiITROL SOLEI{OID VALVEA$SEMBLY -UPCONTROL SOLENOID VALVEASSEMBLY -UPCOTIITROL SOLENOID FILTER/GASKET
Replacs. CONVERTER HOUStt{c @TOROUE 6)II'AINSHAFTBALL BEARING @OlLSEAL Replace. HOLDER

1 2 N . m ( 1 . 2k g . m , I l b - f t ) 18 N.m (1.8 ksFm 13 ltsft) ,

6x1.0mm 8 x 1.25mm

14-91

RightSide Cover
Removal
NOTE: . Clean all parts thoroughly in solvent or carburetor cleanersnd dry with compl€ssedair. . Blow out allpasssges. . When removing the transmission right side cover, replacethe following: , Rightsidecover gasket . Lock washers . Transmission housinggasket . O-rings . Eachshatt locknut and conicalspringw8sher . Sealing wsshers L Removethe elev€nbolts s€curingthe right sido covet, then removethe right sidecover. NOTE: h is not necessarv to remove ths right side covsl protector. Slipthe specialtoolonto th€ mainshsft. HOLDER MAII{SHAFT or 07GAB-PF5010O 07GAB-PF50lOl

LOCKNUT

cott|cAl sPRlltG
WASHER R6phc€.
RIGHTSIDECOVER GCAN PARKIT{G GEAR IDLER COUNTERAHAFT

GEAR IDLER REVERSE SHAFTHOLD€R

PAWL ERAKE

W-

n
\
RIGHTSIDE

I

LEVER "o rNGBBAKE

V-TRA]{SM|SS0i{HOlrSlNo BOLTS TRANSMISSO HOUANG

p

GASKET COVER R€place.
TRANSMISSION HANGER ATF LEVELGAUGE

E x 1 . 0m m BOLT

GEAR IDLER REVERSE

HOUSII{G TRA SMISSIO|{ GASKET
R6Dlsco.

ATF COOLER PIPES

JOINTBOL

}IOUSII{G CO TOROUE VERTER
WASHERS SEALII{G Rophc6.

14-92

J.

Engage parkingbrake pawl with the parkinggear. the Cut the lock tabs of each shaft locknut usinga chisel as shown. Then remove the locknuts and conical springwashersfrom esch shaft, NOTE: . Mainshaftlocknut has left-handthreads. . Cleanthe old locknuts; they are used to installthe press fit idler gearson the mianshaftand secondary shaft andthe parkinggearon the countershaft. . Always wear safety glasses, CAUTION: Keep all of ths chiselod particlos out ot tho tranamission.

12. Removethe reverseidlergear shaft holder. NOTE; The steel ball does not pop out becsuseit is stsked in the shaft. 13. Move the reverse idler gear to disengage trom the it countershaftand mainshsftreverseg€arsas shown. NOTE: The transmissionhousingwill not separate from the torque converter housing if the reverse idlsr gesr is not removed. REVERSE IDLER GEAR Moveinthisdirsction.

4.

MAINSHAFT

LOCKTAB

Rsmove the special tool from the mainshaft after removingthe locknuts.
o.

,! o_ -:.-.:{>, a

\!r' l

Remove the parkinggear using a puller f.om the countershaft as shown. Then remove the idler gesrs usinga pullerfrom the mainshaftand secondaryshaft.

i
COUNTERSHAFT

l

\

14. Align the spring pin of the control shstt with the transmission housing groove by turning the control shaft. 15. Install the speci8l tool on the transmission housing, then removethe housing shown. as
HOUSING PULLER

Remove the countershaft idler gear, needle besring. thrust needle bearing. and thrust washer from the countershaft. 8. Removethe parkingbrake pawl, spring,shaft. and stopperfrom the housing. throttle control shaft. GROOVE

9 . Removethe throttlecontrolleverand springfrom the 1 0 . Removethe ATF coolerpipe mounting boh from the
transmission hanger. 1 1 .Removethe transmission housingmountingbotts.
SPRING PIl{ CONTROL SHAFT

14-93

Housing Transmission
Removal

HOUSI G TRANSMISSION Removal 14-92

2ND GEAR COUNTTERSHAFT GEAR REVERSE COUiITERSHAFT

I{EEDLE BEARII{G
TRANSMISSO

HOUSlttc GASKET Replace.

HUB REVERSE SELECTOR
SHIFTFORK

SELECTOR BEVERSE
MAII{SHAFT SUB.ASSEMBLY

COUITTERSHAFT 4TH GEAR THRUSTWAS}GB BEARIiIG THRUST I{EEDLE COUTYTERSHAFT SUB.ASSEMBLY
SHAFT SECONDARY 2'{D GEAR

BEANI GS NEEDLE ]{EEDLE BEARIiIG THRUST SPLII{ED WASHER SECOI{DARY SHAFT SUB-ASSEMBLY

DIFFEREICTI,AL ASSEMBIY

HOUSING TOROUE COIWERTER

14-94

NOTE: . Cl€8n 8ll parts thoroughly in solvent or carburetor cleansrand dry wilh comDressed air. . Blow out all passsges. . Whsn r€moving the transmissionhousing, roplace the following: . Trsnsmission housinggaskst . Lock w8sh6r 1. 2, 3. Removethe trsnsmissionhousing(seepage14-94. Rsmove the reverse idler g€ar from the transmission housing. Removs ths count€rahaft 2nd go8r, reverse gear, socondaryshaft 2nd gear, thrust wash€r, and thrust ns€dl€ besring togsther from the countershaft and secondaryshaft. Remove the lock bott socuring the shift fork, then romovs ths fork with tho rav€rse s€lector from the countershaft. R€move tho n66dle besrings,thrust nesdle besring, 8nd splinedwasher from the socondaryshaft. Romovethe secondsryshaft sub-Ess8mbly, Removethe msinshaftsub-ass€mbly. Removethe countershaftsub-assembv. Removethe differentialass6mbv.

4.

5. 6. 7. 8. 9.

14-95

Body Torque ConverterHousing/Valve
Removal

THROTTLE COI.ITROL SHAFT.

O.RING Roplace,

\

\

fi nllltn \s ll llUlfllle t il ril,H|Jil _
1 II s 1!1 ' U I

^3a

o r FEED F

P'PE \

\

f,
a

ATF STRAINER

;HROTTLE VALVE BODY

E-R.NG fl Replace.
. \ -

ll u

S1
-

>[nN * /

rHRorrLGsEpARAroR
PLATE

4TH ACCUMULATOR COVER

\
STOPPER SHAFT

ff

n

REGUtAroBvAtvE
O-RING Rephce. STATORSHAFT

LOCK WASHER Replac6. DETENT SEBVO BASE

I
BODY SERVO SEBVO SEPARATOR PLATE
CHECKBALLS

TOROUE CONVERTER CHECK VALVE CHECK VALVE
SPRING OIL FEEDPIPE

OETENT ARMSHAFT ARM DETENT

colvrRoL
SHAFT

VALVE SECONDARY BODY DOWEL PIN
MAIN VALVE BODY

SECONDABY SEPARATOR

OILPUMPDRIVEN GEAR SHAFT OILPUMPDRIVEN GEAR OILPUMP DRIVE GEAR ACCUMUI.ATOR BODY COVER IST/2NDACCMULATOR BODY

MAIN SEPARATOR PLATE DOWELPIN

HOUSING TOROUECONVERTER

14-96

NOTE: . Cl€sn all parts thoroughly in sotuent or carbur€tor air. cle8n€rand dry with compressed . Blow out all p8ss8g€8, . Whsn removingthe vslve body, replscethe following; . O-rings . Lock w88h6rs 1. 2. 3. 4. Removsthe two bohs securingthe servo detent base, th€n rsmovs ths aervo detent bass. Removsthe two bohs sgcuringth6 ATF strsiner,then removs th€ ATF strainsr. Remove the oil fe6d pipes from the s€rvo body and mainvalve body. R€movethe three bofts securingthe 4th accumulator covsr, thsn removethe 4th accumulator cov€r. NOTE; Ths 4th accumulator covsr is spring loaded, to prsvsnt strippingthe threads in the s€rvo body, press down on tha accumulstorcover while unscrewingthe bohs in a crisscrossDsttern. 5. 6. 7. R6movethe seven bohs securingth8 servo body, then removs the sarvo body snd s6parstor plats. Removethe secondsryvalve body and soparstorpl8te. Rsmove the seven bohs securing th€ throttle valve body, then remove the throttle valve body and soparatorplata. Rsmove the boh securing the regulator vslve body, then removethe rsgulatorvElvebody.

9 . Romovethe ststor shsft snd stopper shaft. 1 0 . Romov€the dstsnt spring from ths dstsnt arm, thsn
remove the control shaft trom the toroue converter housing. 1 1 .Rsmov€the detent arm snd detent srm shalt from the m8inv8fus body.

12. Removoth€ four bohs securingtho main valve body,
th6n r€moveth€ mainvalve body.

1 3 . Remove the six bofts securing the lst/2nd accumulstor body, th€n rsmovs the 1st/2ndaccumulator body. 1 4 . Remove the oil pump drivon 968r shatt, then remove the oil pump gears. 1 5 . Rgmov€ th6 main seDarator Dlat6 with three dow6l Dins.

8.

14-97

Valve Body
Repair
NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores.You may use this ptocedule to free the vaves in the valve bodies. Soak a sh€et of $600 abrasive paper in ATF for about 30 minutes, Carefully tap the vatve body so the sticking vslve droDsout of its bore. CAUTION: h may bo necossaryto us€ a 3mal3crewd vor to plY tho valve fioo. Be carsful not io scratch the bot€ whh ths sclowdrlvor. InsDectthe vave tor any scutf marks. Use the ATFsoaked #60O paperto polishotf any burrs that are on the valve, then wash the vatue in solvent 8nd dry it 8ir. with compressed Rotl up h€lf a sheet of ATF-soaked f60O paper and insert it in the valve bore ot the stickingvalve. Twist ths paper slightly,so that it unrollsand fits the the boretightly,then polish boreby twistingthe paper as you push it tn and out. CAUTION: Th6 valve My is aluminum and doosn't roquito much polshing to remove any bulls. VALVE Remov€the #600 paper.Thoroughlywash the entire air. vavs body in solvent,then dry with compressed

6. Cost the vslv€ whh ATF, then drop it into its bor8. h
shouH droD to thg bottom of the bore under its own weight. ll not, ropeat step 4, then retest.

ffi
t

VALVE BODY

7. Romovs tho vslve 8nd thoroughv clean it 8nd the

valve body wilh solvent. DrY 8ll parts with comDroasedair, then reassemble using ATF 8s a lubricant.

snl [ssYi
vV/fJ
,.llJ'"-Q)

14-98

Valve
Assembly
NOTE: Cost all psns with ATF before assembly. . lnstallthovalvs, valve springandcap in the vavo body, and secur€with ths rollsr. Sst the springin the valv6 and installth6m in tha valvs body. Push th€ spring in with 8 scrowdrivor, th6n instsllthe springssat.

VALVEBODY

ROLLER

14-9!)

Valve Caps
Description
Caps with one projocted tip and one flat end are installedwith the flat end towsrd the inside ot the valve body. Caps with a projectod tip on €ach end are instslled with th6 smsller tip toward th8 inside ot the valve body. The smslltip is I springguide. Caos with hollow ends ar6 installedwith the hollow awav trom the insideof the valve body. CaDswith notched ends are instslledwith the notch toward the insideot the valve body, Caps with flat gnds and a hole through the center are installsdwith the smallerhole towsrd the insideof the vave body.

TOWARD OUTSIDE VALVEBODY OF

TOWARD OUTSIDE VALVEBODY OF

EEEA
TOWARD II{SIDE VALVESODY OF TOWARO SIT'E VALVEBODY I OF Caps with one projected tip snd hollow end sre instslledwith the tip toward tho inside oJ the valve body. Th6 tip is I springguide.

TOWARD OUTSIDE VALVEEODY OF

TOWARD INSIDE VALVE BODY OF

14-100

Oi l Pu mp
lnspection
1. Install the oil pump gears 8nd oil pump driven gear shsft in the mainvslve bodv. Measurethe side clearsnceof the oil pumDdrive and driven g€ars. OilPump Ga.lE Side (Radial) Cloalance: Standard(New)l Oil Pump Ddva goal 0.210-0.265 mm (0.0083-0.0104 inl Oll Pump Drlvan g6al 0.035-0.063 mm (O.OO14-O.0O25 in)

OILPUMP ORIVE GEAR Inspect t€ethlor wearor damage. 3. Remove the oil pump driven gesr shaft, Measurethe thrust clearanceof the oil pump driven gear-to-valv€ body. OllPump Drlvo/DrivonG6sr Thrust (Axiall Clearance: Standard(Now): 0.03-0.05 mm (0.001-0.002 in) Selvico Limit: 0.07 mm (O.0O3in)

STRAIGHTEDGE

MAIN VALVE BODY

14-101

MainValve Body
Disassembly/lnspection/Reassembly
NOTE: . Clean8ll parts thoroughlyin solvent or carburetorcleaner,and dry with compress€d8ir. Blow out all psssages. . Replace valve body as an assemblyif any parts are worn or damaged' . Check allvav€s tor free movement.lf any fail to slidefreely, seeVafueBody Repairon page1+98. CAUTION: Do not use a magnotto tomovo tho ctrock balb; it may magnotizotho bak.

MODULATOR VAIVE

CPCVALVE

3-2 K|CK-DOWN FILTER VALVE SEAT
R6phc6. lnstsll in this diroction-

OIL FEEDPIPE

\n U
SHIFT CHECK BALLS 3pcs.

DETENT ARM

VALVE 1_2 SHIFT

VALVECAP

R u
VALVE 2_3 SHIFT ROLLER
MAIN VALVE BODY Inspectlor scoring or domag€. MANUAL VALVE

14-102

FILTER Rephce.

-

E E

CHECKBALLS

MAIN VALVE BODY (S€ctionalView)

DETEN|T ARMSHAFT

SPRING SPECIFICATIONS Standard(New) No. Spring Wire Di8. Lock-up control valve spring Lock-up shift valve spring Coolerrelist valve spring Modulatorvalve spring CPCvatuespring vatuespring 3-2 kick-down 1-2 shitt valv€spring 2-3 shift valve spring

Unit:mm (in)

o.D.
6.60(0.260) 7.60(0.299) 8.40(0.331) 9.40{0.370) 9.40(0.370) 7.10{O.2m) 8.60(0.339) 7.60(0.299)

Free Length

No. ot Coils 14.1 32.O 't7.o 10.5 10.5 20.6 16.9 26.8

o

@ @

o o @ o
@

o.70(0.028) o.90 {0.035) (0.043) 1.10 1.40(O.O55) 1.40(0.055) 1.20(O.O47t 1.00(0.039) o.90(0.035)

(1.496) 38.00 73.70 .2.9021 (1.8431 46.80 (1.299) 33.OO 33.00 {1.299) 46.90{1.846) (1.626) 41.30 57.@t2.2441

14-103

Valve Body Secondary
Disassembly/lnspection/Reassembly
NOTE: . Clesnall parts thoroughlyin solv€nt or carburetorcleansr,and dry with compressod8ir. Blow out all passages. . Check allvalvesfor lree movsment.lf sny fail to slidefreely, seeVave Body Rep8iron page1+98. . Coat all parts with ATF befor€ assembling. . Replace vave body as 8n assemblyif any pans 8re worn or damaged. the CAUTION: Do not uso a mrgnoi to romova th€ chock balls;h may magnatizotho bak'

3_4 SHIFTVALVE

o

,n4u %

0 l

BALLS CHECK 7 pcs.

SECONOARY

VALVE BODY Inspect scoring for or damag6.

-p^
'cqtcrco/

\

COI{TROL 21{DOR|F|CE VALVE

/
SLEEVE @

/"%

14-104
L

CHECKBALLS

CHECK SALLS

n LJ

r 1 n n - l-_\)v, V U l-l

r.,f7

CHECKBALLS

SECO DARYVALVEBODY (SoctionslVisw)

SPRITIIG SPECIFICATIONS Stsndard(llew) No, Springs Wir€ Dia. 4th sxhsust valve spring 3-4 shift vatuespring 3rd kickdown vslve spring Sarvo controlvalva spring Orifice control vslve spring 2nd orifice controlvalve spring

Unh: (in) mm

o.D.
7.10(0.2&) 7.@ (0.299) 7.60{0.299) 8.10(0.319) 6.60(0.260) 6.@ (0.260)

Free L€ngth

No, of Coils

O
@ @

o

@ @

0.90(o.o35t 0.90(o.o35) (0.043) 1.10 1.@(0.039) 0.s to.031) 0.60(0.024)

60.e (2.394) 57.@ l.2.244l. 48.30(1.902) 52.60l2.O71l 52.&12,06,7l 5A30 (2.295)

4.9 26.8 4.3 22.4 33.O 15.8

14-105

Valve Body Regulator
Disassembly/lnspection/Reassembly
NOTE: . Cleanatlparts thoroughlyin solvent or carburetorcleaner,and dry with comprsssadair. Blow out all p8ssages. . Replace valve body 8s an assemblyif any parts are worn or dsmaged. . Ch6ck 8llvalvesfor tree movement.lf 8ny tailto slidefreely, see Valve Body Repairon page1+98. 1. Holdthe regulatorspringcap in plscewhile removingthe stopper boh. Oncethe stopper bolt is removed,releasethe spring c8p slowty. CAUTION: Th€ rogulatorspllng cap can pop oui whon tho lock boh is romovod. 2. R8assembly the revers€ordgr of disassembly. is NOTE: . co8t 8ll parts with ATF. . AliSnthe hole in the rogulatorspringcap with the hole in th€ valve body; thsn pressthe spring c8p into the valve body and tight€n the stoppor boh.
REGULATOR SPRING CAP

BOLT STOPPER 6x1.0mm 12 N.m(1.2ks-m,9 lb-ft) VALVE REGULATOB

FILTER Rophce. LOCX.UP TIMING VALVE E BOOY
Inapgctfor w6ar. scratchos or scorng.

TOROUE CONVERYER CHECK VALVE

ROLLER SPRING SPECIFICATIOTSS Standard(New) No. Springs Wire Di8. Regulator valve springA Regulator valve springB Stator reactionspring Lock-uptlming vaVe spring Torque converter check valve spring F22A1 engine H23A1 engine Unit:mm (in)

o.D.

FreeLength

No. of Coils 16.5 16.5 12.7 1.92 't4.7

O
t
i

3 ra

1.O (0.O71) 14.70(O.579) 86.50(3.406) 1.80(0.071) 14.70 (0.579) 88.60{3.488) r.s (0.071) 9.60 (0.378) rr4.oo(1.732) (1 4.50(0.177) 35.40(1.394) 30.30 .193) (2.012) o.s {o.o31) 6.60 (0.260) 51.10 (0.043) 8.40(0.331) 36.rto(1.433) 1.10

't2.o

14-106

Throttle Valve Body
Disassembly/lnspection/R€assembly
NOTE: . Cleanall parts thoroughlyin solvent or carburetorcleaner,anddry with compross€d Blow out all passagas. air. . Check allvalvesfor free movement,It any failto slidefreely, see Valve Body Repairon page14-98. . Coatallpartswith ATF beloreassembling. . Replace valve body as an assemblyif any parts are worn or damaged. the AOLT 5r0.8 8 N m(0.8 s m , 5 . 8 l b - f i ) k

\ \ \
THROTTLE SHORT VAIVE B

THROTTLE LOI{GVALVE

THROTTLE CAM STOPPER

THROTTLE ADJUSTING BOLT CAUTION: Do not loosen or remove. RELIEF VALVE

THROTTLE VALVEBOOY InsDect wear, lor scratches scoring. or

SPRING SEAT

SPRING SPECIFICATIONS Unit:mm (in) Stsndard{New) No. Springs Wire Dia. ThrottlevalveB spring Throttle vaVe I adjusting spring Relietvalve spring

o.o.

FreeLength

No. of Coils 10.5 11.2 't2.4 8.O '15.1

o
@

1.40{O.O55) 1.40{O.O55) (O.Oss) 1./tO 0.& (0.o311 (O.O39) 1.OO

8.so(0.335) 41.50(1.634) 8.50(0.335) 41.50(1.6341 ( 8.50(0.335) 4 1 . 6 0 1 . 6 3 8 ) ( 6.20tO.2Ml 3 0 . 0 0 1 . 1 8 1 ) (1.539) 8.40(O.331) 39.10

14-107

Servo Body
Disassembly/lnspection/Reassembly
NOTE: . iiel"n attp"rts t6oroughlyin sofuentor carburetorcl6aner,anddty whh compt6ss€dEir.Blow out all passag.s. . n"ptt"" itt" ""*o body as an assemblyil anYparts are worn or damsg€d' . Replace ATF strainet if its inlet openingis clogged. . Cost all Dartswith ATF before assembly. TORCOVER

MAG[{ET Clean.

(<
\j ATF STRAINER Cleanor roplac€.

4TH ACCUMULATOR PISTON

BASE DETET{T SERVO

PIPE OILFEED

BODY SERVO

Inspoctlor woar scratchg8or scoing. O.RING Replace,

VALVE SHAFT/SERVO SHIFT FONK for Inspoct sco ngor dama€|o. 3RD ACCUMULATOR PISTON

SPECIFICATIONS SPRING Stsndard(New) No. Springs sPring 4th accumulator spring 1st-holdaccumulator spring 3rd accumulator Wire Di8.

Unit: mm (in)

o.D.

FreeLengrth

No. of Coils

o t\

(3.547) 2.90(O.114) 22.@ (0.866) 90.10 (0.157) 25.@ (0.984) 64.702.5/.71 4.OO (4.114) 2.60 (O.102) 17.50(0.6€9) 104.50

10.9 7.3 18.O

14-108

1st/2nd AccumulatorBody
Disassembly/lnspection/Reassembly
NOTE: . Cleanall parts thoroughlyin solvont or carbur€to.claaner,and dry with comprsssadair, Blow out all passsges. . Cost sll psns with ATF b€fore sssembly. CAUTIO : Do not usa r mrgnot to temoya the cfiack bal!; h may megnotlzo tho bals. ACCUMULATOR EODY COVER

CHECK BALL

PrsTot{

lST ACCUMULATOR

2I{DACCUMULATOR PISTON

sPRtt{G SPEC|F|CAT|O S
Unit:mm (in) No. Standard(Nsw) Springs Wire Di8.

o.D.

FreeLength

No. ol Coils 18.6 11 . 1

o

@

lst accumulatorsprim zrd accumulatorspring

1.e (o.o71) 16.30 to.64a 115.40 (4.543) 3.30 to.130) 22.@ (0.866) 84.90 (3.343)

14-109

Mainshaft
Disassembly/lnspection/Reassembly
NOTE: . Lubricate reassembly. allpartswith ATF during .Instellthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher. . Inspectthrust needle and needlebearingsforgalling and roughmovement. . Before instslling O-rings,wrap the shaft splineswith tape to prevent damage the O-rings. to the
NUT} LOCKNUT{FLANGE Replace. NOTE: Lotr-handthr6ads 23O N m (23O ks-m , 166 lb-ft} +O ) 170 N.m (17.0 ks-m.123 lb-ft) WASHER CONICALSPRING R6place. IOLER GEAR TRANSMISSION HOUSING BEARING

RING SNAP COLLAR BEARING THRUST NEEDLE 4TH/REVERSE GEAR

NEEDLE BEARINGS

O-RINGS Replaco.

EEARIiIG THRUSTNEEDLE 4THE GEARCOLI.AR

3RO/4TH CLUTCH ASSEMBLY
MAINSHAFT Ch€ck splinesfor excessive w6ar or oamage, Check beadngsurtacetor scorang, scratchesor

3RD GEARCOLLAR

?I{RUST EEDLE BEARING NEEDLE BEARING

3RDGEAR BEARING THBUSTNEEDLE

SEALING RINGS. mm 35 RING,29 mm NEEDLE BEARING SET RING,23 mm

14-110

Countershaft
Disassembly/lnspection/Reassembly
NOTE: . Lubricateallparts with ATF duringreassembly. .Installthethrustneedlebearingswithunrollededgeofbearingretainerfacingwasher, . Inspectthrust needle and needlebesringstor galling and rough movement. . Before installing O-rings, the wrap the shaft splineswith tape to prevent damage the O-rings. to

2ND GEAR LOCKNUT(FLA'IIGE NUTI Replace. 230 N.m (23.0 ks"m , 166 lFft) --r O -) 1 7 0 N . m( 1 7 O k s - m , 1 2 3h - t t l NEEOLE BEARING CONICALSPRING WASHER RsDhca.

REVERSE SELECTOR

REVERSE SELECTOR
4TH GEAR

PARKII{G GEAB THRUST NEEDLE BEARII{G IDLER GEAR

NEEDLE BEARING COLLAR. mm 32 COTTERS, mm 29 DISTANCE COLLAR
3RO GEAR

EEDLE BEARING THRUST EEDLE BEARhIG THRUST WASHER TRAl{SMtSStot{ HOUSII{G BEARING

ONE-WAYCLUTCH

1STGEAR

COUI'ITERSHAFT Ch6ck splin€sfor excessive w€ar or damage. Check b€aring surtacetor scoring.scratchesor

1ST GEARCOLLAR

lST-HOLD CLUTCH ASSEMgLY

14-111

Countershaft
Removal
1. Using a press, press out the countershEft while supponingth€ lst-hold clutch. NOTE: Place an attachment betwoen the press 8nd countershaftto prevent dsmagsto the shalt.

14-112

lnstallation
NOTE: Lubricateall parts with ATF duringEssembv. 1, Instslltwo new O-ringson the countershaft, NOTE; Before installingthe O-ring6,wrap ths shaft splines with tape to prsvent dsmagsto the O-rings. 2. Assemblsthe 1st-holdclutch assembly,lst gearcollar, thrust washer, needl€ bearing, lst gaar, one-way clutch, thrust needlebearingand 3rd gear. NOTE: . Also align the shaft splines with those of th€ lsthoH clutch when pressing the countershaft into the 3rd gear. . Use 8n attachment between the shaft and a press to provant damage the countershatt. to . Stop pressingthe countershaJtwhen the 1st-hold clutch contacts the finaldrive gear. 4. Align the shaft splin€s with thoso of 3rd gaar, then pressthe countershaftinto 3rd gearwith a press.

3RDGEAR

PRESS

THRUST '{EEDLE BEARIl{G

O]TE-WAY CLUTCH lnstall thisdirection. in

1ST-HOLD CLUTCH

lST GEAR

I{EEDLE BEARING

THRUSTWASHER

lST GEANCOLLAR

1ST-HOLD CLUYCH ASAEMBLY

3.

Installth8 above assemblv the countershaft. on

14-113

One-wayClutch
Disassembly/lnspection/Reassombly
1. Separatecountorshstt 3rd g€ar from countershaft 1st gear by turning3rd g€arin the directionshown, 3. Inspectthe parts as follows:

COU]YTERSHAFT 3RDGEAR
Inspsct3rd gear for wear oascoring-

COUNTEBSHAFT IST GEAR

ffi.-

V

Inspoct the thaust noodls bearing tor damage or faulty mov€mgm.

Inspectth€ ono-way clutch for damagoor fauhy movement.

Remove the one-way clutch by prying h up with the end of a screwdriver,

Inspect lst gear tor w€ar or scoring.

ONE.WAY CLUTCH

holdcountershatt After the Dartsare sssembled, 1st gesr and turn countershatt 3rd gear in directionshown to be sure it turns Ireelv. 3RD COUI{TERSHAFT GEAR

1ST COUT{TERSHAFT GEAR

14-114

Secondary Shaft
Disassembly/lnspection/Reassembly
NOTE: . Lubricstesll parts with ATF duringreassembly, o lnstalltho thrust needlebesringswith unrollededgeof bearingretaineffacingwasher. . Insp€ctthrust needle and needlebesringstor galling 8nd rough movement. . BsJoreinstalling O-rings, the wrap the shatt splineswith t8pe to pravent damage ths O-rings. to

LOCKNUT{FLANGE NUT}
Roplsc6.

23ON.m(23,0kg-m, 166 |tsft) -JO-) 170 N.m(17.0 ks-m.123lb-ft) CONICAL SPRING WASHER Replsco. GEAR IDLER TRAI{SM|SS|OI{ HOUST G BEARII{G THRUST WASIGN THRUST NEEDLE BEARING 2NDGEAR

SECONDARY SHAFT Check splin€sfor oxcossive w6ar or d6magE. Chgck bearing surfacofor scoring,scrotchesor excosstvowoat.

NEEDLE BEARI]IIGS

THRUST NEEDLE BEABII{G SPLIT{ED WASHER p€rt Sol6ctiv€

THRUSTNEEDLE BEARII{G I{EEDLE BEARIMi

1STGEAR

DISTANCE COLLAR. mm 5 COTTERS, mm 29 COTTER RETAINER SNAP RING SEALING RINGS, mm 32

14-115

SecondaryShaft
Inspection
. CbarancaMaasurement NOTE: Lubricst€all parts with ATF duringsssemblv. 1. R€move the secondsry shaft bearing trom the housing(seepsgo 1+129). transmission 2. Assomble the s6condsry shEft sssembly without O-rings.Instsllth6 idler gear usinga press,then to.qu€ the 36cond8rythaft locknut to 30 N.m (3.0 ksFm, 22 lb-tt) NOTE: Do not instsllthe O-ringsduringinspection. 4.

while moving2nd Messure gearsaxialclearance 2nd gear, in) 0.07-0.15 mm(0.003-O.0O6 STANDARD: NOTE: and in Takemeasurements at loastthlee plscos, use clearance. as the average the actusl

LOCKITUT

5. Attach the disl indicatorto 2nd gearas shown. DAL INOICATOR

It the clearanceis out of tolerance,removethe splinsd the washer and measure thickness. WASHER SPLINED No. Pari l{umbol fhbknols in) 4.05 mm 1O.159

3.

90406- PX4- 700 90407-PX4-7@ 90408- PX4- 700
4 5
o

in) 4.10 mm(0.161 in) 4.15 mm(0.163 in) 4.20 mm(0.165
4.25 mm (0.167 in) 4.30 mm {0.169 in) in) 4.35 mm 10.171 4.2!Omm {0.173 inl 4.45 mm {0.175in)

90rto9- PX4- 700
90410-PX4-7@

90411-PX4-7m 90412-?X4-70o

8

90413-PX4-700
90414-PX4-700

I

2ND GEAR

6.

the splinedwashsr, make sur€ that the After r8plscing is clearance within tolgrance.

14-116

Clutch
lllustrated Index
3RD/4TH CLUTCHASSEMBLY

SI{AP RII{G

CLUTCH EI{DPLATE

ct uTcH Drscs
Stshdardthickness: 1.94 mm {0.076 inl

CLUTCH PLATES Standard thicknoss: 2.30 mm(0.091in)

nEruRNsPuu'rc---'--@
SNAP RII{G

srRrnc aeurnea.-(C) s APRTNG--o
SPRI]TG RETAINER

RETURN SPRII{G

PISTON

CLUTCHDISCS Standard thickn6ss: 'l .94 mm (0.076 inl

O.RINGS Rsplacs.

CLUTCH DRUM

(cont'd)

14-117

Clutch
lllustratedIndex (cont'd)
H23A1 Ensino ASSEMBLY: 1ST/2NDCLUTCH

CLUTCHENDPLATE

SPRING RETAINER

SPRING RETAINER

CLUTCHENDPLATE

SNAP RING 2ND CLUTCHDRUM

DRUM lST CLUTCH

14-118
L

1ST/2ND CLUTCH ASSEMBLY: F22A1Enstn€

O-RINGS Replace.

----.....-__----l/ PrsroN Xtt

qfluansrnrNcre
SPRTNG -=...._<> RErarr{ER
SNAPRtNG--___..v-)

v

CLUTCH PLATES Standard thicknoss: 2.60 mm(0.102in)

Y)
&

smr nnc--..-...-

-l-,,

sPRrRETATNEB----__.._<> G
RETURN SPRING DISCSPRING

2ND CLUTCH DBUM

1ST CLUTCHDBUM

{cont'd}

14-119

Clutch
lllustratedIndex (cont'd)
1ST-HOLDCLUTCHASSEMBLY

E CLUTCH O PLATE

PLATES CLUTCH thicknsss: Standard 2.00 mm(0.079inl

R|NG sr{AP -----------....

13

RETATNER SPRTNG ------..-..-<>
RETURN
DISCSPBING

PISTON

O-RllrlcS B6placs.

CLUTCHDRUM

14-120

Disassembly
1. Remove the snap ring, then remove the clutch end plate,clutch discs and plates. NOTE: For a clutches Installthe specialtoolsas shown. NOTE: For lst-hold clutch

SNAP RING

CLUTCHSPBING COMPRESSOR ATTACHMENT oTLAE-PX40100

SCBEWDRIVER

CLUTCHSPRING COMPRESSOR ATTACHMEI{T 07HAE-P150100

Remove discspring. the NOTE: For 1st-hold€nd 2nd clutches NOTE: For 1st,2nd,3rdand4th clutches.
DISCSPRING

CLUTCHSPRING COMPRESSOR ATTACHMEiIT OTLAE-PX/[O1OO

CLUTCHSPNNG COMPRESSOR ATTACHMEIYT 07HAE-P150100

CLUTCHSPRING COMPRESSOR AOLT ASSEMBLY 07GAE-PG40200 {cont'dl

14-121

Clutch
(cont'd) Disassembly
CAUTION: It olthor ond of tho comproraor attachmont i! 3ot ovel an aroa ol the sprlng rotalner which ls unsuppo od bY the rsturn sprlng.the rotalnor may be d8magod. Removethe snap ring.Then remove the spscialtools, 8nd retainer retrunspring. spring

Do not s6t hore.

NOTE: SteDs4 thru 6 are for allclutches. the Compr€ss returnspring.

the clutchdrum and apply8ir Wrap a shop rag around pressureto the oil passage removethe piston.Plsco to a tingertip on the other €nd while appving air pres6ure.

t

14-122

Reassembly
NOTE: . Clean sll parts thoroughly in solv€nt ot carburetor cleangr,and dry with compressed arr. . Blow out all psssages, . Lubricateall parts with ATF beJoreassembv. 1. Inspectthe piston for a loosecheck vslve, if the check valve is loose,replaceth€ p;ston. CHECK VALVE 4. Installthe piston in the clutch drum. Apply pressure and rotate to ensureproper seating. NOTE: . Forallclutches . Lubricate the piston O-ring with ATF before installing. CAUfION: Do not dnch O-ringby instaling the ],iston whh force.
PISTON

PISTON

Be sure that the disc springis securelystaked. NOTE: For 1st, 3rd and 4th clutches Installnew O-ringson the piston.
O-RINGS CLUTCHDRUM

Installthe return springand springretainerand position the snapringon the retainer. NOTE: For allclutches

(cont'd)

14-123

Clutch
(cont'd) Reassembly
6. as specialtools shown. Installthe clutch NOTE: For 1st-hold CAUTION: lf otthor end of lho comprslsol attachmcnt b 8ct ovor an lroa of the sp ng lelalnor whlcft k unrupportod by tha toturn sprlng.tha rctalnel may b€ dam!god.

CLUTCHSPRIiIG COMPRESSOR ATTACHMEiTT 07LAE- PX40100

CLUTCHSPRI G COMPRESSOR ATTACHMENT oTHAE- Pl601 00 Do not set h6ro. CLUTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE-PG402q)

NOT€: Steps 7 thru I 8re for allclutches. 7. the ComDresa retuln sPring.

NOTE: For 1st, 2nd, 3rd and 4th clutches

SPRING CLUTCH COMPRESSOR ATTACHMEITT 07LAE PX40lOO

CLUTCHSPRI G COMPRESSOR ATTACHMET{T oTHAE-P150100

SPRING CLUTCH COMPRESSOR SOLTASSEMALY OTGAE PG4O2OO

14-124

8.

Installthe snap ring.

NOTE: Steps11 thru 15 aretor allclutchos. 11. Soak the ctutch discs thoroughv in ATF tor I minimum ot 30 minutes. 12. Starting with I clutch plats, ahernately instsll ths clutch platesand discs,Installthe clutch end platewith flat sidetoward the disc. NOTE: Before installingthe platss snd discs, mske sure the insideof the clutch drum is free of dirt or other forsign mattot.
CLUTCHENDPLATE

CLUTCH

Dtsc
9 . Remove special the tools. 1 0 . Installthe disc spring.
NOTE: . For 1st-holdand 2nd clutches . Installthe disc springin the directionsnown. 13. Installth€ snspring. Dtsc SPRI{G

SCREWDBIVEB

(cont'dl

14-125

Clutch
(cont'd) Reassembly
14. Measurethe clearancebetween th€ clutch snd plate 8ndtop discwith a dislindicator. Zero the dial indicstor with the clutch end plste lowered and lift it up to the snap ring. The distancs that the clutch end plate moves is the cleatance botween th€ clutch end plate8nd top disc. NOTE: Measureat three locations. Clutcfi End Plato-to-TopDisc Glearance: Clutch 1st 2nd 3rd 4th 1st-Hold Seryico Llmh
1E

It the clearanceis not within th€ service limits,select a new clutch €nd platefrom the followingtable' NOTE: It the thickest clutch €nd plst€ is installsd but the clearanceis still over the st8ndatd,roplacethe clutch discs 8nd clutch plstes. CLUTCHENDPLATE Phte t{o. 1 3 4 5
o

Part Number

Thlckncrs mm (lnl

0.65-0.85 mm(0.o26-O'033in) 0.65-0.85 mm(0.026-0.033 in) 0.40-0.60 mm(0.016-0.024 in) 0.40-0.60 mm(0.016-0.024 in) in) O.&-1.0O mm(0.031-0.039

I 9

22551-PX4-@3 2,562-PX4-m3 22553-PX4-OO3 22554-PX4-0o3 22555-PX4-@3 22556-PX4-@3 22557-PX4-@3 22558-PX4-003 22569-PX4-003

(0.o&') 2.10 2.n lo.oaTl
2.30(0.091) 2.40 to.og4l 2.50(0.098) 2.60(0.102 2.70(0.106) 2.& (0.110) 2.90(0.114)

TOPDISC

ENDPLATE CLUTCH

14-126

TorqueConverterHousingBearings
Mainshaft Bearing/Oil Replacement Seal
1. Driv€ out th€ mainshaftbearingand oil seal, usingthe sDecisltools shown, as 3. Installthe n€w oils6alflush with the housing,usingthe as sDscialtools shown.

DRIVER 07749-OOTOOOO

DRIVER 07749-001o(xro

ATTACHMEIYT 07947- 6340500

ATTACHMEI\IT. 72x75mm 07740-(x)lo6{x, TOROUE COI{VERTER HOUSIT{G

Orive in the new mainshaftbsaringuntil it bottoms in the housing, usingthe specialtoolsas shown.

DRIVER 07749-OOl(xXX'

ATTACHMENT, 62x68mm

07746-(xrlos(x,

14-127

TorqueGonverterHousingBearings
CountershaftBearingReplacement
1. Remove the countershaft bearing using the special toolas shown.

Replacement Secondary ShaftBearing
1. Remove the secondary shaJt bearingby heating the torque converter housing to 212oF {10O"C) with a heat gun, then tap the housinguntil the bearinglalls our. CAUTION: Do not hoat tho case in excsss of 212oF (1OOoCl.

Comrnarclaly AvoiLbL 3/8 ln, r 16 throad./ln.
![de hammai

ADJUSTAELE BEARII{G PULLER, 25-4O mm 07736-AO1000A

COUTttTERSHAFT NEEDLE BEARII{G

/-\.=\-\ \, _-,/-_--_\,

Installthe oil guideplate. Drive th6 new bearing into th€ housing, using the specialtoolsas shown.

2. Installthe oil guideplate,
5.

Drive the new bea.ing into the housing, using the as specialtools shown.

DRIVER 07749-(x)lOqro

DRIVER 07749-OO10000

ATTACHMEifT, 62x88mm 07746-0010500

BEARING

BEARING

0 -0.03 l0 0.01inl

O-0.03 mm (0-0.01 In)
HOUS[{G

HOUSING

OII GUIDEPLATE

OIL GUIDEPLATE

14-128

Housing Bearings Transmission
Removal/lnstallation
1. To r€rnovsths mainshait,countershsft and secondary shaft bearingslrom the tranamissionhousing,expand each snap ring with snap ring plisrs, thon push th€ bearing out. NOTE: to Do not remove th€ snap rings unlessit's necesaary cl€anthe groovesin the housing. insert Expsnd€ach snap ring with snap ring pliers,ins the :he new b€aringpart-way into it. then releasethe pliors. I until the Push the bearingdown into the transmissionu ringsnapsin placaaroundit, NOTE: inside Inst8llwith groove side o{ the housingfacing ins the transmission housing.

lnstali

I
Remov€

I

After installing bosringverify the following: th6 . The snap ring ls se8tedin the bearingand hol housing groovas. . Th6 snap ring operatesproperly. . Ths ring6nd gap is correct.
P: 0-7mm (O-o.28 in) SNAP RING

14-129

Transmission
Reassembly
NOTE: . Coat all parts with ATF. . Replace partsbelow: the .O-rings . Lock washers . Gaskets . Locknuts washers andconicalspring . Sealing washer . Torque mm Bohs: the 6 x 1.O k 1 2 N . m( ' 1 . 2 s m , 9 l b - f t )

6xl,Omm 2 Bohs

THROTTLE
CONTROL SHAFT

F;flilf":-.
STOPPER

Iw

Tluffir
e:'1
1 Boh VALVE REGULATOR BODY
O-Rlf{G Replace. 7 STATORSHAFT DETEI{T ARM S}IAFT DETENf ARiI

ATF STRAINER

4TH ACCUMULATOR COVER
8x1.Omm 2 Bohs LOCKWASH€R Reolace.

SERVO DETET{T BASE SERVO SODY SEPABATOR SERVO PLATE CHECK BALLS VALVE SECOI{DARY BODY

COIWERTER TOROUE CHECK VALVE
CHECKVALVE SPRING

OIL FEEDPIPE

cot{TRoL
SHAFT

6x 1.0 1 Boh 8 x 1.25mm '18N m (1.8ks-m '13lb-ftl MAINVALVEBODY
OIL PUMPDRIVEN GEARSHAFT GEAR OIL PUMP DRIVEN

SEPAFATOR SECONDARY PLATE

V
GEAR OILPUMP DRIVE
PLATE MAIN SEPARATOR

6 x l.O inm 6 Eohs

ACCUMULATOR BODY COVER lST/2ND ACCUMULATOB EODY

DOWELPIN

CO HOUSIT{G TOROUE VERTER

14-130

L

Installthe main sepa.ator plate with three dowel pins on the torque converter housing.Then install the oil pumpgearsandoil pumpdrivengearshaft. NOTE: Installthe oil pump driven gear with its grooved and chamteredsidefacingdown,
OIL PUMP DRIVEN GEARSHAFT

8. Installtho s€condarysaparator plate with two dowol
pins on the mainvalve body. Installth€ control shali in the housingwith the control together. shaft and msnualvafue

1 0 . Installthe d€tent arm and alm shatt in the main valve
body, then hook the detent springto tho detent arm.

\ orl PUMP
DRIVEGEAR

\

\

rr-'rr \

SERVO SEPARATOR PLATE

11 ll

|

\U

II

II

GRoovE
SECO DARYVALVEBOOY OII PUMP DRIVEN CHAMFER GEAB

Grooved€nd chamfer6d aidefac€s separatorplats.

COIVTBOL SHAFT

Installthe main vafue bodv whh tour bohs. Maks sure the oil pump drive gear rotates smoothly in the normal operating direction and oil pump driven gsar shaft movss smoothly in the axial and normal operating directions. lf the oil pump drive gear and oil pump driven gear shatt do not move treely, loosenthe main valve body bohs, realignthe oil pump driven gear shatt, and th8n retightento the specifiedtorque. CAUTION: Failuro to align tho oll pump drlvan goEr shaft correctly wlll rosuh In a seizadoll pump drlva getl 01 oil pump driven gear shalt.

DETEI{T SPRING

MANUAL VALVE 1 1 . Installthe secondaryvslve body, servo separatorplate and servo body with seven bohs.

't2. Installth6 oil fosd pipe in tho servo body, then install
the 4th 8ccumulator cover whh three bohs.
OIL PUMPORIVEN GEARSHAFT
12

Installth6ATF strainerwith two bohs.

:/ )
OIL PUMP DRIVEGEAR OIL PUMP DRIVENGEAR

14. Installthe servo dotont base with two bohs and new lock w8shers.

1 5 . Inst8llthe lst/2nd sccumulstorbody with six bohs. 1 6 . Installtwo oil ts6d pipes in the main valv€ body and
th€ pipe in the servo body,

4. 5.

Installthe stator shaft and stoDDer shaft. Install the two dowel pins, torque converter check vafue and torque converter check valve spring in the mainvalve body. Installthe.egulator valve body with the bolt on the mainvalve body.

7.

Installthe two dowel pins and separator plate on the regulator vatue body, then install the throttle vave bodv with seven bohs.

(conr'd)

14-131

Transmission
(cont'd) Reassembly
17. Install the differential assembly, countershaft subassembly, mainshatt sub-sssembly, and secondary in shaft sub-assemblv the torque converter housing.
MAINSHAFT SUB-ASSEMBLY

20. Turn the shitt tofk shaft so the largechamferedhole is facingthe fork bott hole.Th€n installthe shift fork and the lock boh with a new lock washer, and torque Bendthe lock tab againstthe boh head

COUNTERSHAFT SUB-ASSEMBLY SH|T FORKBOLTHOLE

SHAFT SCCONDARY SUB.ASSEMBLY

LOCKWASHER R€plac6.

BOLT LOCK 6x1.Omm 14 N.m{1.4 kg-m, 10 rb-ft) FOBK SHAFT SHIFT HOLE BOLT hole Large chsmt€red facssthisway.

TOROUE COi|vERTER HOUSING 1 8 . Installthe splined washer, thrust needle besring 8nd needlebearings the secondaryshaft. on

2 1 . lnstsll the secondary shaft 2nd gear, thrust needle
boaring and thrust washer on the socondary shalt. Installthe countershaft reverse gear and 2nd gear on the countershaftas shown.

1 9 . lnstall the needle bearings. countershaft 4th gear,
reverse selector hub, and reverse selector with the shift fork on the countershaft. NEEDLE BEARING REVERSE SELECTOR REVERSE
lnsta in this direction.

THRUST WASHER SHIFT FORI( THRUST NEEDLE BEARIMi

COU TERSHAFT GEAR 21{D

COUUTERSHAFT REVEBSE GEAR SECONDARY SHAFT 2NDGEAR

EEDLE BEARINGS

COUNTERSHAFT

THRUST NEEDLE BEARING

COUNTERSHAFT 4TH GEAR

SECONDARY SHAFT

NEEDLE BEARIiIG COUNTERSHAFT

SECOI|I'ARY SHAFT

14-132

22. Slipthe r€verseidlsr gearinto the transmissonhousing €s snown.

m. hstall the trsnsmissionhousingbolts and t.ansmission hanger,then torque the bolts to 55 N.m (5.5 kg-m, rlo lb-ft) in two or more steps in the pattern shown.

v|>=l

,Adlafu

R@P
23. Align the spring pin of the control shaft with the transmission housing g.oove by turning the control shaft. 24. Install thr6€ dowel pins and a new gasket on thg torqus converter housing, 25. Plscs ths transmission housing on the torque convert€r housing. CONTROL SHAFT the reverse idler gear to the countershaft and 27. Engage mainshattreverse gesrs, then installthe reverse idler gesr shaft holderon the transmission housing,

6x1.0mm 12 N.m (1.2 ks-m , I lb-ft)

1 0r 1 2 5 m m 55 N'm (5.5 kg-m , 40 b-ftt

DOWEL PI

P

h E
28. Install the parking brske lever on the control shaft, then torque the lock bolt loosely with a naw lock wasner. NOTE: Do not tighten the lock boh to the specifiedtorque and bendthe lock t8b in this steD.

DOWEL PIN

14-133

Transmission
(cont'dl Reassembly
the 29. Sliothe sDecialtoolonto mainshaft.
MAINSHAFTHOLDER OTGAB-PF50100ol 07GAB-PF50101

35. Placea 24 mm socket on the parkinggeEr,and instslla 10 x 1.25 mm boh in the count8rshaft. Then engage the parking brake pawl with the parking gesr by movingup the parkingbrake pawl. CAUTlOltl: K€ap anof tho particlosout of tho transmissionwhon insialllng a bolt. 36. Tightenthe boh and lightlyseat the parkinggear. NOTE: Do not drive the parkinggearon whh a hammer. 37. Removethe boh and socket. 38. Use the old locknut to tighten the press fit parking gearto the specifledtorque, then loosenit. TOROUE:230 N'm {23.Oks-m,166 lb-ft)

30. Installthe mainshaftidlergear.
21

Installthe old locknut on the mainshaftto seat the idler gear. NOTE: . The mainshaftlocknut has left-handthresds, . Do not drive the idlergearon with a hammer. TOROUE:230 N m (23.Oks-m, 166 lb-ft)

mm SOCKET.24
PARI(ING GEAR

32. Installthe secondaryshaft idlergear on the secondsry
shaft.
10 x 1.25 mm BOLT PARKING BRAKE

33. Installthe thrust wash€r, thrust needlebearing,needle
bearing,countershatt idler gear and parking gear on the countershatt. PAWL

34. Installthe old locknut on the secondaryshaft. Tighten

the old locknut to seat the secondaryshaft idler ge81 the while holding countershsJtidlergear. NOTE: Do not drive the idlergearon with a hammer. TOROUE: 30 Nm(23.0 ks-m,166 lb-tt) 2

39. Remove th€ old locknuts, th8n install new conical springwashers8nd new locknutson each shstt' CAUTION: Insts[ th€ conical spfng washora In tho di]octlon shown,
MAINSHAFTLOCKNUT Left-h8ndthr€ads

PARKII{GGEAR

COUMTERSHAFT LOCK'{UT
St€mp siJs

CONICALSPRING WASHERS hstall in this diroction.

SHAFT SECONDARY IOLER GEAR

14-134

40, Tightenthe locknutsto sp€cifiedtorque. TOROUE: Mainrhaft Countorshaft Secondaryshaft 170 N'm {17.Okg-m, 123 lb-Jt) 170 N.m (17.0 ks-m , 123 lb-ftl 't70 N.m (17.0 ks-m, 123 lb-ft)

42. S€t rhe psrking brake lever in tne lT-l position, thon

the verity that the parkingbrake pswl ei-gages parking 9ear.

4i,. lf th€ pswl doss not engagefully, check the psrking brake pawl stopper clearanceas describedon page 1+136. 44. Tightenthe lock boh, and bendthe lock tab againstthe bolt head. PARKIMiBRAKE ROLLER LEVER

NOTE: threads locknut lelt-hand has Themainshsft

TOROUE WRENCH

SECONDARY SHAFT IOLER GEAR

PARKINGBRAKE PAWLSHAFT

PAWL

45. lnstallthe right sidecover.
41. Stake each locknut into its shsJt using a 3,5 mm puncn.

TOROUE: 12 N'm {1.2 kg-m, 9 lb-ftl

0.7-1.2 mln 10.o3-0.05Inl

washers. 46. InstalltheATF cooler pipeswith new sealing TOROUE:29 N'm (2.9 ks-m , 21 lb-ft) 47. Installthe ATF levelOauge.

14-135

V

RightSideCover
FeedPipeInstallation
Installthe feed pipes in the right side cover with new the lugs with the grooves in the right O-,ings,aligning side over. Installthe snap rings,

ParkingBrakeStopper
Inspection/Adjustment
1. 2. brakeleverin thel P lposition. Set the parking Measurethe distancebetween the psrkingblake pawl shaJtand the parkingbr8ke lever roller pin as shown. STANDARD:64.5-65.5 mm {2.54-2 58 in)
PARKINGBRAKE PIN LEVERROLLER LOCK BOLT 6xl.0mm 14 N.m (1.4 kg-m , 10 tb-ft)

PARKINGGEAR

Distanc6

BRAKE PARKING STOPPER
PARKING BRAKELEVER

NGHTSIDE COVER

Fififtflllf*

PARKTNGBRAKE

ff the measuremant is out oJ tolerance, select and parking brakestopperfrom the install sppropriate the tablebelow.

, '.l r - - f f i - T , , . --Tr

I r lr \ , l\ ,l , / |
\ \t-l /

PARKINGBRAKESTOPPER

,/r>

BRAKE STOPPER PARKING
Mark
I

Part Numbor

Ll

Lz

-PA9-OO3 11.0Omm 24537
(0.433 in)

11.00mm (o.433in)
10.65 mm (0.419 in)

2

24538-PAg-m3

1O.8Omm (0.425 in)

24539-PAg-OO3 10.60mm

(0.417 in)

10.30mm (0.400in)

brakestoppor,make sure the After replacing parking the distanceis within tolerance.

14-13 6

TorqueConverter
Disassembly

ErlOm.r| 75 N.m{7.5kem , 54 b-ftl

DRIVE PLATE lnsD€ct crackg. for

TOROUE VERTER CO GEAR ASSEMBLY/RI'{G

1 2x 1 . 0m m 75 N.m(7.5kgtsm54 b-ft) , Torquo crisscrogs in Dattgrn.

14-137

Transmission
lnstallation
1 . Flush ths ATF cooler as describedon psges 14-142 and 143. 5. Installth€transmission housingmountingbolts.

2. lnstall the stsrter motor on the torque converter
housing, inst8llthetwo 14 x 20 mm dowel pinsin and the torque converter housing, ATARTER MOTOR

45 N.m 14.5 kg-m ,

33 tuft)

DOWEL '14x 20 PIN mm

HOUSIG TRAI{SMISSION MOUiITING BOLTS 12 r '1.25 mm 65 N.m(6.5 kgtsm lb-ft) ,47 PIN DOWEL 14r20mm TOROUE CONVERTER ASSEMBLY

Roplaca.

o.

Place the transmission on I jack, and raise to th€ engine8ss€mblylevel. 4. Attach the transmissionon the engine,then installthe transmission housing mounting bolts, raar engine mountingbohs and intake maniJold bracket botts.
INTAKEMANIFOLD ERACKETBOLTS I x 1.25 mm 2. N.rn 12,2 kg-m , 16 tb-ft)

Tighten the front engine mount bracket bolts to sp6cifiedtorque.

FROT{T EI{GII{E MOUNf BRACKETBOLTS 10 x 1.25 mm 39 N.m (3.9 ksFm, 28 lb-ft)

I1{TAKE MANIFOLD

BRACKET
TRANSMlsSION HOUSING MOUNTING BOLTS 12 r 1.25 mm (6.5 kg-m , 65 N.m 47 tb-ft}

FNOI{T E GINE MOUNTBRACKET

FROI{TE'{GINE MOUl{f

TRAfISMISSK)N JACK

MOUNfiNG REARENGINE BOLTS 12 x 1.25 mm R€plac€. 55 N.m (5.5 ks-m ,40 lb-ft)

14-138

Installthe transmissionmount. Tighten the bott then tighten the nuts to specifiedtorque, and retightenthe boh to specified torque. NUTS 1O 1.25mm x 39 N'm(3.9kem,28 b-ft)

10. lnstafi the control lsvsr with the shift cable on the control shaft, CAUTION: Tak6 cara not to bondtho shlft cEHo. 11. lnstallthe lock boh with a new lock washer,then bend ths lock tab. 12. Instsll the toroue converter cover and shift cable covar.

cot{TRoL LEVER

SHIFT CABEL

LOCK WASHER R6plsc€.

CONTROL SHAFT
SHIFTCABLE COVER

1 2 r 1 , 2 5m m 65 N.m {6.5 kgim , 47 h-ft)

LOCI( BOLT 6x1.Omm 14 N'm (1.4ks-m, 10 b-ft)

TOROUE COI{VERTER COVER

8 x 1.25 mm 18 N.m (1.8 kg-m , 13 lb-ftl

0 x 1.0 nvn 12 N.m (1.2 kg-m,9 lb-ft)

8. o

jack. Removethe transmission

13. Install rightradius anddamper the rod fork.
Attach the torque converter to the drive plats with eight bolts, snd torque to 12 N.m (1.2kg-m, 9lb-ft). Rotate the crankshsJt 8s necessary to tighten th€ 'll2 botts to of the specifiedtorque, then linaltorque, in I crisscrossDattern. After tightening the last bolt, check thst the crankshaft rotstes freslv.
6x1.Omm 75 N'm (7.5 kgtsm 54 h-ft) .

NOTE: Checkfor dotsrioration damage the radiusrod or of rubber bushings.
SELF.LOCKING NUT 12x1.25 m m
DAMPEBPINCHBOLT 1Ox 1.25 ftm Roplace. 55 N.m {5.5 kg-m ,40 b-ft}
R6place.

44 N.m(4.4kem,32 b-tr)

RUBBER BUS}IINGS RADIUS ROD
l2 x 1.25 mm 105 N.m (10.5 kgFm.76 lb-ft) Roplaco. {cont'dl

14-139

Transmission
(cont'd) lnstallation
1 4 . Instsllnew set ringson th€ end of th€ drivsshsfts' 1 5 . Installthe right snd left driveshafts. NOTE: Turn the right 8nd lelt steeringknucklesfully outward, and axisllv into th€ difterential until you f8sl th€ set th€ ring engage sidegear.
to.

19, Installthe vehicle speed sensor/powersteeringspeed ssnsor and roar stiffoner. Conngcl the vehiclo spe6d

connecror. sensor

BOLT SPECIAL 6x1.Omm 12 N'm(1.2kgFm.9b-ft)

lnstallths damDerfork to the lower arm. Thsn instsll the bslljoint to the lower arm. Usethe castls nuts whh new cotter olns.

POWER STEERIl{G SPEED SE\lsqR 10x 1.25mm 21 N'm (2.'lks-m, 15 tb-ft) O-RING R6pbc6.

REARSTIFFENER

1Or1,25 m m 39 N.m(3.9 ks-m, 28 lb-ft)
NUT SELF-LOCKING 12 r 1.25 mm 65 N.m {6.5 kem , 47 b-ft} R6phco.

n.
CASTLE IUT l2 x 1.25mm 65 N.m16.5ks-m, 47 h-ft) COTTER PI Replaca.

Connoctth€ ATF cooler hosesto the ioint pip6s. solsnoid vslve connectors, 8nd the throttle control cabls.

21. Connect the lock-up control solenoid, shift control

22. Connectths msinshaftsp66dsenaorconnector.
17. Installth€ rear beamstiff€ner 8nd center be8m. SOLEM)ID VALVE col{t{EcToRS

CEI{TER BEAM 1 0x 1 . 2 5 m m 39 N.m{3.9 ks-m. 28 b-ft) 18. hstat the solashshield. 10 x 1.25mm 60 N.m{6.0 krm , 43 tb-ft)

Installthe ground cablein step 26.

,t

14-140

B . Connectthe countershaitsoeedsensorconnector. 24. Connectth€ starter motor cables.
NOTE: When installingthe starter cable, mak€ sur6 that the crimped side ot the ring terminal is facing out (see section 23). COUI{TERSHAFT SPEED SEITISOR CONNECTOR

27. Install the intske control vacuum tank and intake control vacuum tank brscket, then connect the connecror. 28. lnstallthe air cleanerhousingand intake air duct. with ATF (see page14-74. 29. Refillthetransmission 30. Connect the battery positive (+) and negative (-) cablesto the battery. Set the parkingbrake,and shitt the 31. Start the engine. trsnsmissionthrough all gears three times. Check tor proper shift cablesdjustment. 32. Check 8nd adjust the front wheel alignment (see section 18).

33, Let the enginereach operatingtemperatur!_lthe ralie-tor com€s with the transmission I N I or f8n on) in thenturn it off andch6cktluidl8vel. I P I position,
34. Roadtest as describedon pages1+68 thru 14-7O. 35, R8setths radiostations. 36. Loosenthe tront enginemount bracket botts after the road test, and retightenthem to specitiedtorque.

CABL€S

25. lnstallthe bsttery bsseand basestay. 26. Connect the ground cable to the body and the
transmission. GROUND CABLE
FRONTENGINE MOUNTERACKET BOLTS 1Ox 1.25 mm

39 N.m(3.9 ks-m, 28 lb-ft)

FROl{f ENGINE MOUiff BATTERYBASESTAY

14-141
I

Transmission
CoolerFlushing
7. To prcvent iniury to faco and eyes, always woar salety glasses 01 a laco shleld when using tho lransmlssion tlusher, NOTE: the This procedureshouldbe performedbefore reinstalling transmission. 1. Checktool andhosesfor wear or cracksbeforeusing. It wear or cracks are found, replacethe hoses betore using. Usingthe measuring cup, fillthe tank with 21 ounces (approximately full)of biodegradable fluid tlushing 23 (J35S44-20). Do not substitute with any other tluid. procedureon the tluid container. Followthe handling the Securethe flusherfiller cap and pressurize tank a w i t h c o m p r e s s i r t o b e t w e e n5 6 0 - 8 4 5 k p a { 5 . 6 8.45ks/cm,,80- 120 psi). NOTE: The air line should be equippedwith a water trap to I ensure drYair system. 4. 5. 6. Hsngthe tool underthe vehicle. Attach the dischsrgehose of the tank to the return lineot the transmission cooler usinga clamp, Connect the drain hose to the inlet line of the transmission cooler usinga clamp. IMPORTANT: Securelyclampthe oppositeend of the drain hose to a bucketor floordrain, With ths water and air valves oft, attach the wat€r (Hot water it svailsbl8.) 8nd air suDDlies the Jlusher, to

OFF

2.

3.

Turn on the flusher water vave so water will flow the for through oilcooler 10 seconds NOTE: lf wster doos not flow through the oil cooler it is completoly plugged.cannot be flushed, and must be reolaced.

9. Depressthe trigger to mix the flushing fluid into thg
water flow. Usethe wire clip to holdthe triggerdown.

1 0 . While flushing with the wat6r and flushing fluid {or 2
every 1S minutes, turn the sir valveon for 5 seconds 20 secondsto create a surgingaction. AIR PRESSURE; MAX 845 kp8 (8.45kg/cm', 120 psi) the trigqer,then 11. Turn the water vave off. Release reversethe hosesto the cooler so you can tlush in the oppositedirection.Repeatsteps I through 1O. 12, Releasethe trigger and allow wster only to rinss the cool€r with water tor one minule 13. Turn the water vslve ofl 8ndturn off the water supply. 14. Turnthe air vslveon to dry the systemout with airJor two Jull minutes or until no moisture is visible leaving the drainhose. CAUTION: Rosldual moisturo In the oil coolor or plpo3 can damagethe tiansmlssion. 15. Removethe flusherfrom the coolerline.Attach the drainhose to a oil container, 16. Install the transmission and leave the drain hose attachedto the coolor line.

COOLER TRANSMISSION FLUSHER J38405-A

14-142
L

1 7 . Make sure the transmission inl P lposition. is Then tillthe trsnsmissionwith ATF and run the engine for 30 secondsor until approximately0.95 0 (1.0 US qt.,O.8lmpqt.l is discharged.

TOOL MAINTENANCE 1. Emotyandrinseatter eachuse.Fillthecan with watsr and pressurizethe can, Flush the discharge lino to ensurethat the unit is clean. lf dischargeliquiddoes not foam. the orifice may be blocked. To clean,disconnectthe plumbing trom the tank at the large coupling nut. Remove the inline tiher from the dischargeside and cleanif necessary. The Jluidorifice is locatedbehindthe fiher. Cleanit with the pick stored in the bottom of the tank handleor blow it cleanwith air. Securelyreassemble all
DArtS.

1 8 . Remove the drain hose and reconnect the cooler
return hose to the transmission.
tcl

2. 3. 4. 5.

Refillthe transmission with ATF to the orooer level (seep89e 1+74.

FILLER CAP

14-143

E

t

shift cable
Removal/lnstallation
1. . Make suro llfts, lacks and sat€ty stands aro dacod plopelly, and hobt brackots ars attachod to the corroct positlon on the englne{se6sectlon 1). . Apply parklng brake and block roar whoob, so car wlll not lol olf stands and fal on you whllo working undorh. CAUTION: . A SRS olectllcal wiring harnorsos aro coverod whh ydbw oui61 imulaiion. . Boforo dlsconnectingthe SRS who harness, Instal tho short conn€ctor(s)on the aiftag(sl. . Roelacetho 6nthe aft€ctod SRS harn63sa$cmbly lf h has an opon circuh or damag€dwiring. Z. Removethe front console{seesection 2O}' Stritt to I tttl position, then remove the lock pin from the cabte-adiuster. Removethe bohs securingthe bracket.

3.

LOCK PI 6 x 'l.Omm 10 N.m (1.0 kg.m , 7 luft)

BRACKET ADJUSTER

4.

Removethe shitt cablecover. Remove the lock boh securingthe control lever, removethe control lever with the shift cable'

SRSMAIN HARI{ES8

COt{TROL LEVER
6x1.Omm 1 2 N . m( 1 kem , I lb-lt)

SHIFTCABLE

sHtFT CABLE COVER
8 x 1.25 mm 18 N.m (1.8 ks-m, 13 b-ft)

BOLT LOCK 6x1,0mm '10lb-ftl 14 N'm 11.4kem ,

14-144

6.

Removeth€ exhaust pipeB and heat shiell. SELF.LOCKING NUT 34 N'm(3.4 kem . 25 b-ft)
R6pl8c€.

8.

Removethe cotter pin and lock pin, then separatetho control l€ver from the shift cable.

SHIFTCABLE SELF.LOCKING NUT 56 N.m (5.5 k$m ,40 b-ft) HEAT SHIELD

PIN COTTER Rspbca. PIPE B EXHAUST GASKET R6phc€. 9. lnstallth8 shift cabl€in the reverseorder of removal, 10. Check the cable adiustment after instsllingthe shift cable (seepage1+146).

7,

Romovethe cablsguideand grommet.

Exl.Omm 12 N.m (1.2 ksFm,I b-ft)

14-145

Shift Cable
Adjustment
CAUTION: . All SRS oloctlical wirlng harno3sos alo covorod whh ydbw ouier insulation. . Befolo disconneclingtho SRS who harn6ss, lnllall tho short connoctor (s) on tho ai6ag (s). . Replscsthe sr iro 8fiect6d SRs halno$ Esrembly lf h has an open circuit or damag€dwiring. 4. Check that the hole in the adiusteris pertectv sligned with the holein the shift cable.

AIT'USTER

Cabh Too Shon

Cabl€ Too Long

Exact Alignm€nt

Stan the engine.Shift to reverseto see il the reverse on gear engages. not, reJerto Troubleshooting page lf 1+64 thru 67. With the engine off, remove the tront console (sae section 20). Snit to I tt l position, then remove ths lock pin from the cable-adjuster,

NOTE: There are two holesin the end of the shift cable.They 9Ooapart to allow cable adiustmentsin are Dositionad 1/4turn increments. loosenthe locknut on the shift lf not pertectly alignod, cable,and sdiust as required.

6. Tightenthe locknut.
Installtho lock pin on the adiuster.lf you tesl the lock pin bindingas you reinstall it, the cable is still out of adjustmentand must be readiusted. Move the shift lever to eachgearand verify that the A/T gear position indicator follows the A/T gear positionswitch.
l'.

Start the engineand check the shift lever in allgears.lf any gear does not work properV, reler to troubleshootingon page14-64 thtu 67, g€ar indicatot panel,8nd verify that the shift lock lever is released.

1 0 . Insertthe ignitionk€y into the key cylinderon the A/T

SHIFTCABLE

LOCK NUT 7 N'm lO.7kg-m 5.1 tb-it)

AOI'STEN

14-146
E.

GearshiftSelector
CAUTIOI{: . A[ SRS olectrlcal wlrlng hamossos alo cove]ad with yellolYouter inlulation. . Baloro dlsconnectlng tho SRS who harn6ss, Instsll the short connector (s) on the alrbsg (sl. . Raplacotho entilo affectsd SRS harnoss assombly lf it h!3 an opon circuit or damagedrylrlng.

SELECT LEVER KNOB

SRS MAIN HARI{EAS

,,J:::$

3 N.m(0.3 ks-m, 2.2 b-ft) AppV non-hardening thre8d locksoalsnt.

A/T GEAR POSITION INDICATOR PANEL

-Gl
ICONE GREASE

COVER LEVER

10 N.m ('1.0kgFm, 7 h-ft)

MOUNT BRACKET SELECTOR

14-147

Panel Indicator A/T GearPosition
Adiustment
CAUTIO : r Al sRS clectrlcd wl ng h!m.rsc! ar. covoled wlth yalow outcr lmuhlon. . Bcforo dtconncctlng th. SRS wlr. harn33s, lmtal tha rhort comoctor bl on tha ahbrg lsl. . Replrct th..ntlrc eff.ct.d SRS harn.3. assombly lf h ha! an opan drcuh or damagpdwlrlng. 1 . With the transmissionin I N I position, chsck that the alignswith ths N mark on index msrk on the indicst-or gosr plgtion indicator panel when th€ the A/T t.ansmissionis in Lll position. lf not sligned,rsmovs the front conaole (sso section

2ol.
3. Remove the A/T gear position indicstor pansl
mountingscrews, and adiustby movingth8 pansl' NOTE: Whenever the A/T g€8r position indicstor panel is removed,.sinstallths psnelas d6scribedabovo. POSITIOI{ A/T OEAR PAI{EL II{IXCATOR

14-148,

ThrottleControlCable
Inspection
NOTE: Before inspecting the throttle control cable, make sure that: . Throttle cablefree Dlayis correct {seesection 11), . ldlespeed correct(seesection11). is . You warm up the engineto normal operating temperature{theradiator comeson), tan 1. Verify that the throttle control lever is synchronizsd with the th.ottle linkagewhile depressino and releasing the acceleratoroedal. 2. ff the throttle control lever is not synchronizedwhh the throttle linkage. ad.iust throttle controlcable. the 3. Check that there is plsy in the throttle control levsr while depressingth€ accGlerator pedal to the fulF throttle oosition.

THROTTLE LINKAGE

Remove the cable end oJ the throttle control cablo trom tho throttls controllavsr. 5.
THROTTLE CABLE

Check that the throttle control lsv6r moves smoothly.

THROTTLE CONTROL LEVER

THROTTLE COI\ITROL LEVER

1 4 -14 9

Throttle ControlCable
Adiustment
NOTE: the Beforeadjusting throttle controlcable,make sure that: . Throttle cablefree play is correct (seesection 11). . ldlespeedis correct(s€esection11). . You warm up the engine to normal operatingtemperfan ature(theradiator comeson l, 1. Verify thst the throttle linksge is in the fully-closed oosition. 4. Tightenthe locknuts.

LEVER THROTTLE CONTROL

LINKAGE THROTTLE

5.

A{ter tightening the locknuts, inspect the synchronization8ndthrottle control lever movemsnt.

Loosenthe locknut on the throttle control cableat the throttle control lever. Removethe free play in the throttle control cablewith the locknut, whil6 pushingthe throttle control lav€t to the tullv-closed Doshionas shown.

NOTE: To tailor the shift/lock-up characteristicsto 8 particular customer's driving exp€ct8tions, you can adiust the throttle control cabl€up to 2mm {0.078inl shorter thsn tho "synchronized" point.

LEVEB THROTTLE COI{TROL Pushin this direction.

t-

14-150

Differential
Manual Transmission ............................ 15-t Automatic Transmission ....................... 15-10

(ManualTransmissionl Differential
Special Tools.......... ...........15-2 Differential lllustrated Index................................. 15-3 Backlash Inspection ...... 15-4 FinalDriven GearReplacement ........ 15-4 Tapered RollerBearing Replacement ....................................... 15-5 Oil SealRemoval ........... 15-5 Bearing OuterRace Replacement ....................................... 15-6 Tapered RollerBearing Preload Adjustment .................... 15-7 OilSeallnstallation ....... 15-9

SpecialTools

Re{.No.

I

Tool Numblr 07GAD07HAJ 07JAD07JAD07LAD07746 07746 07746 07749 PG40'100 PK40201 PH80101 PH80400 PW50601 0010400 0010500 0010600 0010000 Driver Attachment Tool Inspection Preload Driver Attachment Pilot.28 x 30 mm 40 Attachment, x 50 mm l.D. Attachment,52 x 55 mm Attachment.62 x 68 mm 72 Attachment, x 75 mm Driver 15-9 15-7 15-9 15-5 15-6 '|5-6 15-6 I 15-6,

o @ o
@ @

o

@ @

@

o

@
,6

a

@

o

15-2

(ManualTransmissionl Differential
lllustratedlndex
NOTE:lf the ' mark partswere replaced, taperedrollerbearingpreloadmust be adjusted (seepage15-9). the

OIL SEAL Removal,page 15-5 Installation,p8ge 15-9

.BEARIT{GOUTERRACE page 15-6 Replacsment, Inspecttor wear and damage, .TAPERED ROLLER BEARING page 15-5 Replacement, Inspgctfor wear and damag€. 'TAPERED ROL1IR BEARING page 15-5 Replacement, Inspoctfor wear and damagg. TBEABINGOUTEB RACE page 15-6 Replgcement, Inspectfor wear and dam6ge.

.THRUST Sel6ct,Adjustment,page 15-7 10 x 1.25lnm kg-m,7a lb-ftl 103 N.m 110,3 Left-handthreads.

DRIVENGEAR page 15-4 Replacement Inspectfor wear and damage.

(@o..._
ITHRUSTSHIM CAFBIER Inspectfor cracks.

I

I

t

-

r;-

page 15,5 Remov€1, lnstallation, pag€15-9

15-3

(ManualTransmissionl Differential
BacklashInspection
1. assemblyon V-blocksand inst8ll Placedifferential both driveshafts. of the Measure backlash both piniongears. mm Standard {Newl: 0.05- O.'15 10.002 0.006in)

FinalDrivenGearRePlacement
1, Remove the bolts in a crisscrosspattern in several steps,and removethe final drivengearfrom the ditcarrier. ferential NOTE: The final driven g€ar bolts have left-hand threads,

2.

Chamferon inside diametor of final driven goar facoscarraer' DIAL INDICATOR PINIONGEARS

10 mm EOLT 103 N.m (10.3kg-m, 74lb-ft|

Installthe final driven gear by tighteningthe bolts in a crisscrossDatternin severalsteps.

lf the backlashis not within the standard,replace carrier. the differential

t

15-4

Tapered RollerBearing
Replacement
NOTE: . T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e shouldbe replaced a set. as . Inspect and adjustthe taperedroller bearingpreload wheneverthe taperedrollerbearingis replaced. . Check taperedrollerbearings wear and rough the for rotation.lf taperedrollerbearings are OK, removalis not necessary. 1. Remove the taperedroller bearingsusinga bearing puller.
BEARING PULLER

Oil SealRemoval
1. 2.

Remove differential the assembly. Remove oil sealfrom the transmission the housing.

OIL SEAL Replace.

3.

Remove oil sealfromthe clutchhousinq. the

Installnew taperedroller bearings usingthe special tool as shown. N O T E ;D r i v et h e t a p e r e dr o l l e r b e a r i n g s n u n t i l o they bottomagainst differential the carrier.

CLUTCH HOUSING

ATTACHMENT, 40 x 50 mm l.D. 07LAD - PWSo€ol

otl sEAt_
Replace.

15-5

(ManualTransmissionl Differential
OuterRaceRePlacement Bearing
NOTE: . T h e b e a r i n go u t e r r a c e a n d t a p e r e dr o l l e r b e a r i n g as shouldbe replaced a set. . Inspectand adlustthe taperedroller bearingpreload the whenever taperedrollerbearingis replaced. 1. housing the Remove oil sealsfrom the transmission (see age'15) h a n dc l u t c h o u s i n g P 5 Drivethe bearingouter raceand thrust shim out of o h t h e t r a n s m i s s i o n o u s i n g , r r e m o v et h e b e a r i n g outer race and thrust shim from the transmission h h o u s i n gb y h e a t i n gt h e t r a n s m i s s i o n o u s i n gt o ( ) a b o u t2 1 2 " F 1 0 0 ' Cw i t h a h e a tg u n . CAUTION: Do not reus€ the thrust shim if the outer racGwas driven out. h N O T E : D o n o t h e a t t h e t r a n s m i s s i o n o u s i n gi n of excess 212'F(100'C).
TRANSMISSION HOUSING: ORIVER 07749- OOl(Xno

3.

After installingthe thrust shim. install 8n bearing outer race in the transmissionhousing and clutch tools as shown. housingusingthe special NOTE: . Installthebearingouter racesquarely. . Check that there is no clearancebetween the bearing outer race,thrust shim, and transmission housin9.

2.

TRANSMISSION HOUSING: DRIVER 077a9 (xn(xx)o

ATTACHMENT, fi:l x 68 mm 077i16- (x)los(x)

ATTACHMENT, 52x55mm 07715- (X)10400 THRUSTSHIM

THNUSTSHIM

CLUTCH HOUSING:

BEARING OUTEFRACE

:'----J)-4
ATTACHMENT. 72xt5mm 07746 - 0011}600

DRIVER - 00tqx)0

EEARING

OUTER THRUST Install the oil seal{seepage15-9).

4.
THRUST SHIM

RACE OUTER

15-6

RollerBearing Preload Adjustment Tapered
NOTE: lf any of the items listed below were replaced, the taperedrollerbearingpreloadmust be adjusted. . o . o . 1. Trsnsmission housing Clutchhousing Differentialcarrier Tapered rollerbearingand bearingouter race Thrustshim After installingthe thrust shim, installthe bea bearing outer race in the transmissionhousing (see t re page 15-6). NOTE: . Install the bearingouter racesquarely. . C h e c kt h a t t h e r e i s n o c l e a r a n c e e t w e e nthe b between transmis bearingouter race,thrust shim and transmission nousrng.
4.

R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m from the transmission housing(seepage 15-6). NOTE:Installthe thrust shim onlv on the transmission housingside. CAUTION: Do not reusothe thru3t shim it the boaring outer rrco wls drivcn out, NOTE:Let the transmission cool to the room temperature if the bearing outer race was removed by heatingthe transmission housing befo.e adjusting the taperedfoller bearingpreload.

W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e mo v e d , o' i n s t a l lt h e d i f f e r e n t i a a s s e m b l y , n d t o r q ue t h e l a e housing, clutchhousingand transmission TOROUE: x 1.25mm:45 N.m 10 ('1.5kg-m, 33 lb-ft| 8 x 1.25mm: 28 N.m (2.8 kg-m, 20 lb-ft1 N O T E : l t i s n o t n e c e s s a r y o u s e s e a lI in g a g e n t t ng ( betlveen housings. the

5. 2. F i r s tt r y t h e s a m e s i z et h r u s t s h i m t h a t w a s r e moved. 6. CAUTION: Use only ono thrust rhim.

Rotatethe differential assemblyin both direct directions to seatthe taperedrollerbearings. Measurethe startingtorque of the differentialasrent|al semblywith the special tool and a torquewrenc wrench. 1.4 STANDARD: - 2.6 N.m 114 26 kg-cm,12 - 23 lb-inl

THRUSTSHIM

I
C
HOUSING TRANSMISSION

NOTE: . M e a s u r e h e t a p e r e dr o l l e r b e a r i n gp r e l o a o I roa A t normSlroom temperature. a M e a s u r e h e t a p e r e dr o l l e r b e a r i n gp r e l o a oi n t both directions.

WRENCH

TOOL INSPECTION PRELOAD 07HAJ- PK40201

{ c o n td I

15-7

Differential {ManualTransmission)
Tapered Roller BearingPreloadAdiustment {cont'dl
7. ll the tapered roller bearing preload is not within selectthe thrust shim which will give the standard, the correcttaperedroller bearingpreloadfrom the followingtable. NOTE: Changingtho thrust shim to the next size o t w i l l i n c r e a s e r d e c r e a s e a p e r e dr o l l e r b e a r i n g preloadabout3 - 4 kg-cm(2.60 3.47lb-in). THRUSTSHIM Part Numb€r 41381 PXs- 000 B 41382-PX5-000 41383-PX5-000 Thickneee in) 1.90mm (0.075 i 1 . 9 3 m ( 0 . 0 7 6n ) m in) 1.96mm {0.077 '1.99 mm (0.078 in) inl 2.02mm (0.079 in) 2.05mm (0.081 in) 2.08mm (0.082 i 2 . 1 1m m ( 0 . 0 8 3n ) i 2 . 1 4m m ( 0 . 0 8 4n ) i 2 . 1 7m m { 0 . 0 8 5n } in) 2.20mm (0.087 in) 2.23mm (0.088 in) 2.26mm (0.089 in) 2.29mm {0.090 in) 2.32mm (0.091 in) 2.35mm (0.092 in) 2.38mm (0.094 i 2 . 4 1m m ( 0 . 0 9 5n ) in) 2.44mm (0.096 in) 2.47mm (0.097 10 TOROUE: x 1.25mm: 45 N'm {,[.5kg-m, 33 lb-ftl 8 x 1.25mm: 28 N'm (2.8kg-m, 20 lb-ft| assemblvin both directions 1 1 . Rotatethe differential seatthe taperedrollerbearings. to thrustshim: the 9. How to select correct - 1 ) C o m p a r et h e t a p e r e d r o l l e r b e a r i n gp r e l o a d you get with the thrust shim that was removed, preloadof l4 - 26 kg cm ('12 with the specified - 23lb-in). -2) lf your measured taperedrollerbearingpreload subtractyours irom the is lessthan specified. specified. , l f y o u r s i s m o r e t h a n s p e c l f i e ds u b t r a c t h e from your measuremenl. specitied with a 2.17mm thrustshim: For example 26 kg-cm(23 lb-in) @ specified you measure 6 kg-cm(5 lb-in) 2 0 k g - c m 1 8 l b - i nl)e s s { @ you measure 34 kg-cm(30 lb'in) - specified 26 kq-cm(23 lb-in) 8 kg-cm(7 lb-in)more -3) Eachshim size up or down from standard makesabout 3 - 4 kg-cm (2.60- 3.47 lb-in) in difference taperedrollerbearingpreload. . taperedroller In exampleA, your measured p r e l o a dw a s 2 0 k g - c m l e s s t h a n bearing s t a n d a r ds o y o u n e e d a t h r u s t s h i m f i v e sizesthickerthan standard(try the 2.32mm thrustshim,and recheck) . In exampleB, yours was 8 kg-cm more than s standard, o you needa thrust shim two s i z e st h i n n e r( t r y t h e 2 . 1 1m m t h r u s ts h i m , and recheck).

c
E
F

41384-PXs-000
41385-PX5-000

41386-PXs-000 41387-PXs-000 41388-PXs-000
41389-PX5-000

H

J K L M
N

41390-PXs-000
4 1 3 9 1P X 5 - 0 0 0

41392-PXs-000 41393-PXs-000
41394-PX5-000 41395-PXs-000

o
P

41396-PXs-000
41397-PX5-000

o
R T 8.

41398-PXs-000
41399-PX5-000 4' 1400-PX5-000

'10.After adjustingthe tapered roller bearingpreload,
and installthe transmisthe assemble transmission sion housing(seepage'13-3'l).

Recheck taperedrollerbearingpr€load. the

15-8

Oil Seallnstallation
lnstallthe new oil seal flush with the transmission tools as shown. housingusingthe special 2. Installthenew oil sealinto the clutchhousingusing as the sogcialtools shown,

TRANSMISSloN HOUSING

CLUTCH HOUSING

DRIVER 077it9 001qxto
OIL SEAL Replace. OR]VERATTACHMENT otGAD - FG('lrX) PILOT,2E x 30 mm 07JAD - PHE0/00 OIL SEAL Roplace.

DRIVER 077a9 001o{xlo
DRIVERATT 07JAD- PHgtl01

PILOT, x 30 mm 28 07JAD - PH8o4{r0

15-9

(AutomaticTransmissionl Differential
15-12 Tools.......... ........... Special (Automatic Differential Transmission) .. 15-13 lllustrated lndex .......... Backlash Inspection ...... 15-14 ......................... 15-1 4 Bearing Replacement .................... 15-15 Inspection/Disassembly Reassembly .................... 15-16 15-17 Oil SealRemoval ........,.. TaperRollerBearing Preload .................... 15-18 Adjustment Bearing ..... OuterRaceReplacement 15-20 ....... 15-20 Oil SealInstallation

SpecialTools

R€{.No.

I

Tool Number 07GAD07GAD07HAJ 07HAD 07JAD07JAD07LAD0774907947or SD40101 SD40100 PK40201 SF10r 00 PH80101 PH80400 PW50601 0010000 SD90200

Do3cription DriverAttachment Tool Preload Inspection Driver Attachment Driver Attachment P i l o t , 2 8 3 0m m x Attachment,40 x 50 mm Oriver DriverAttachment

oty
1 ,l 1 I 1 I 1 1

j

Poge Refercncc

o
@

15-20
1E_14

o @ o @ o

@

15-19 15-20 15-20 15- 4 1 15-19,20 15-20

@ @ > a @

IT @
@

I
t9

I
@
@

cro)
o

15-12

(AutomaticTransmission) Differential
lllustratedIndex

THRUSTSHIM page15-18 Selection,

OUTERRACE

eg 9"
FII{ALORIVEN GEAR page 15-15 Disa6s6mbly, psge 15-15 Inspgctaon, Insp6ctfor exc6ssive

10 mm BOLT kg-m,7a lb-ft1 103 N.m 110.3 Left-handthreads

ROLLEB BEARING TAPER lnspect f6ultymovement. for

lnstall in this direction. DIFFERENNALCARBIER lnsoocttor cracks. THRUSTWASHEB

PINIONWASHER

TAPER ROLI..ER

PIN SPRING PINIONGEAR page15-14 inspection, Backlash

BEARIiIG OUTERRACE

PINIONSHAFT Inspgct{or wear or damage.

15-13

(AutomaticTransmissionl Differential
Inspection Backlash
' t . P l a c et h e d i f f e r e n t i a a s s e m b l yo n V - b l o c k s l installboth axles. Checkbacklash both side gears. of StandardlNowl: 0.05- 0.15mm 10.002 0.006in.l

BearingReplacement
NOTE:Checkthe bearings wear and rough rotation. for lf the bearings OK, removalis not necessary. are Removethe taper r o l l e rb e a r i n g s s i n ga b e a r i n g u puIer. BEARING PULI.IR

DIALINDICATOR SIDEGEARS

BEARING TAPER ROLLER Installthe new taper roller bearings. usingthe specialtool and a pressas shown, 3. lf out of tolerance, disassemble differential the and from the table below. selectnew pinionwashers NOTE: . Drivethe bearings until they bottom. on . Usethe special tool: . large end for torque converterhousing side bearing. housingside bearsmall end for transmission Ing.
ATTACHMENT, ,(t x 50 mm 07LAD- PW5o601

PINIONWASHEB Part Numbcr 4135-PGI -000 1 41352 PG1 000 41353 PG1 000 * PG1 000 41354 41355 PG1 000 41356-PGl-000 41357 PG1 000 41358 PG1 000 Thickness 0.70mm (0.028n ) 0.75mm (0.029n ) 0.80mm (0.031n ) 0.85mm (0.032n ) 0.90mm (0.035n ) 0.95mm (0.036n ) 1.00mm (0.039n ) 1.05mm (0.041n )

NOTE: . The bearingand outer race should be replaced as a set. . lnspectand adjustthe bearingpreloadwhenever a bearingis replaced. . Drivein the bearings securely that there is no so clearance betweenthe bearingsand differential carner.

15-14

Inspection/Disassembly
Removethe final driven gear and inspectteeth for wear or oamage. NOTE: The final driven gear bolts have left-hand threads, 3, Remove the pinion shaft, pinion gears, washers, and side gears. thrustwashers,

FINAL DRIVENGEAR PINIONGEARS

SIDEGEAR CARRIER DIFFERENTIAL

Driveout the springpin with a pin punch.

Wash the pans thoroughlyin solventand dry them with compressed air. Inspoctall pans for wear or any that are defective. damageand replace

5.0 mm PIN PUiICH

15-15

(AutomaticTransmissionl Differential
Reassembly
'1. Installthe side gears, with thrustwashersin tho differential carrier. NOTE: Coat all gears with molybdenum disulfide greaseon all sides. Rotatethe gears until the shaft holes in the pinion gearsIine up with the shaft holesin carrier. Insertthe pinionshaftand alignthe spring pin holes in one end with the matchinghole in the carrier.
Alignthe holes.

THRUSTWASHER

5.

Drivein the springpin with a pin punch.

Set the pinion gears in the place exactlyopposite each other in mesh with side gears,then install a pinion washer behind each one. Wsshersmust be of equalthickness. NOTE: Selectthe correct Dinion washer from the tableon page15-14.

Checkbacklash both piniongearsagain. of Standard {New}: 0.05- 0.15 mm {0.lxt2- 0.006in} It still out of tolerance, replac€both thrustwashers. lf still out of tolerance. replace the side and pinion gears,and recheck backlash. lf still out of tolerance, replace carrierassemthe ory.

15-16

Oil SealRemoval
7. Installthe final driv€n gear.Torquethe boltsto 103 N.m (10.3kg-m,74 lb-ftl. NOTE:The final driven gear bolts have left-hand th.eads. ass6mbly. 1 . Remove differential th€ Remove oil sealfromthe transmission the housing.

FINAL DRIVENGEAR

Chamf6ron innsr side ot final driven gear fac6s cSrner.

10 mft EOLT 103 N,m 110.3 kg.rn, 74 lb-ftl Lett-h8ndthreads

OIL SEAL

TRANS| tsstotrl
HOUSI G

Remove th€ oil seal from the toroue conv€rter housing.

CONVERTER TOROUE HOUSING

OIL SEAL Replace.

15-17

Differential {AutomaticTransmissionl
Adjustment TaperRollerBearingPreload
NOTE: lf the transmissionhousing, torque converter housing,differential carrier,taper roller bearing.outer the bearingpreload raceor thrust shim were replaced, must be adjusted. 1. R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m housingby heatingthe housfrom the transmission with a heatgun. ing to about212"F(100'C) CAUTION; . Do not h6at tha houling in oxcass ol 212'F {100"c1. . Roplacothc tapsr rollor bearing when tho outer race is to bs rgplacad. . Do not uso a ghim on the torqug convsrt9r hou3ing sid6. h N O T E :L e t t h e t r a n s m i s s i o n o u s i n gc o o l t o t h e r o o m t e m p e r a t u r eb e f o r e a d j u s t i n gt h e b e a r i n g preroao. Selectthe thrust shim from the table below so that is in). theirtotal thickness 2.60mm (0.102 CAUTION: Do not use mor€ than two shims to adiust tho bearing prelosd.
BEARING OUTER RACE

HEATGUN

THRUSTSHIM No. Part Numb6r 41441 PK4- 000 41442-PK4-000 41443-PK4-000 41444-PK4-000 41445-PK4-000 41446-PK4-000 41447-PK4-000 41448-PK4-000 41449-PK4-000 J K L M
N

Thickncss 2.20mm (0.087 in) in) 2.25mm (0.089 2.30mm (0.091 in) 2.35mm (0.093 in) i 2 . 4 0m m ( 0 . 0 9 4n ) in) 2.45mm (0.096 in) 2.50mm (0.098 i 2 . 5 5m m ( 0 . 1 0 0n ) i 2 . 6 0m m ( 0 . 1 0 2n ) i 2 . 6 5m m ( 0 . 1 0 1n l i 2 . 7 0m m ( 0 . 1 0 6n ) 2 . 7 5m m ( 0 . 1 0 8n ) i i 2 . 8 0m m ( 0 . 1 1 0n ) 2 . 8 5 m { 0 . 1 1 2n ) m i 2 . 9 0m m ( 0 . 1 1 4n l i 2 . 9 5m m ( 0 . 1 1 6n ) i n 3 . 0 0m m ( 0 . 1 ' 1i8 ) 3 . 0 5m m ( 0 . 1 2 0n ) i
* Standard shim

B D
E F G
n

41450-PK4-000 4 1 4 5 1P K 4 - 0 0 0 41452-PK4-000 41453-PK4-000 41454-PK4-000 41455-PK4-000 41456-PK4-000 41457-PK4-000

o

R

41458-PK4-000

15-18

3.

After instaliing thrustshim, installthe outer race the in the transmission housing,usingthe special tools as snown. CAUTION: . Install the outsr .ace squaraly in tho trsnsmi!. sion housing. . Check that thero is no cloaranco bciwocn th, outsr race,shim and t ansmissionhousing. . Install tho gasket whon chocking pr6lo6d.

6,

M e a s u r et h e s t a r t i n g t o r q u e o f t h e d i f f e r e n t i a l with the special assembly tool and a to.que wrench. STANDARD: Now bosrings:

2.8 -,[.0 N'm 128- ,l|) kg-cm, 2,1- 35 lb-inl Rculod bslrings: 2.5 - 3.7 N.m (25 - 37 kg-cm, 22 - 32 lb-in)

07?49 qlrqtoo

,'l
TOOL PRELOADINSPECTION 07HAJ - PKIO201

NOTE: ! Measu.e starting the torque normal at roomtemp6.ature bothdirections. in
lf out of spec,selecttwo thrust shimswhich will give the correct preload,and repeatsteps 1 - 6. Changingone of the shims to the next sizewill increase decrease or staningtorque about3 - 4 kg-cm(2.60 3.,17 lb-ln). T o i n c r e a s e h e s t a r t i n gt o r q u e , i n c r e a s e h e t t t h i c k n e s so f s h i m s . T o d e c r e a s e h e s t a r t i n g t torque,decrease thickness shims. the of

With the mainshaft,countershaftand secondarv shaft removed,installthe differential assemblyand torquethe transmission housing. TOROUE: N.m 15.5 55 kg-m. /r0 lb-ft| Rotatethe differentialassemblyin both directions to seatthe bearings.

15-19

(AutomaticTransmission) Differential
OuterRaceReplacement Bearing
Remove the bearingouter racefrom the torqueconv e r t € r h o u s i n g b y h e a t i n gt h e h o u s i n gt o a b o u t 212"F(100"C) with a heatgun. CAUTION: Do not hcat the hou3ing in excassof 212"F(100"c). NOTE: . Replace the bearingwith a new one whenever the outer raceis to be replaced. . Do not use shims on the torque converterhousing side. . Adjust preloadafter replacing the bearingouter raceand bearing.
TAPERROLLER HEATGUN

Oil SealInstallation
1. h I n s t a l lt h e o i l s e a l i n t h e t r a n s m i s s i o n o u s i n g , u s i n gt h e s p € c i a tl o o l s a s s h o w n .

DRTVER 07749 00ltXXtO

OIL SEAL

2.

housing, Drivethe oil seal into the torqueconverter usingthe special tools as shown.

I n s t a l lt h e n e w b e a r i n go u t e r r a c ef l u s h w i t h t h e housingusingthe specialtools.

07749 - 001(xXlO

ATTACHMENT DRIVER or 07GAD- SO|O101 o]GAD - SD.O100

15-20

Driveshafts
S p e c i aT o o l s . . . . . . . . l Driveshafts Removal Disassembly Disassembly/lnspection Reassembly Installation IntermediateShaft Replacement............. .. Disassembly Disassembly/lnspection Reassembly

16-2 16-3 16-5 16-6 16-7 16-9 16-11 16-12 16-13 16-14

SpecialTools

Rel. No.

I

Tool Numbel

o
6\ /?\

@
rA
\of

@

oTGAD-PH70201 oTGAF-SD40700 oTMAC-SLOO100 o7746-OO10200 07746-O010400 07746-OO30400 o7749-OO'OOOO l

Oil Seal Driver Base Hub Dis/Assembly BallJoint Remover,32 mm Attachment,37 x 40 mm Attachment,52 x 55 mm Attachment,35 mm LD. Driver

16 - 1 4 1 6 - 1 2 ,1 4
I o-J

16-1 2 16-14 16-14 1 6 - 1 2 ,1 4

\

re
l---:z-----.1

I

,;A
@

@

tll
@
ct_@
o

16-2

Driveshafts
Removal
INSPECTION Drivoshaft Boot Check the boots on the driveshaftfor cracks,damage, leakinggreaseor loose boot bands. It any damageis found. replacethe boot. Spline Looseness Turn the driveshaftby hand and make sure the spline and joint are not excessively loose. It damageis found, replacethe inboardjoint. Twisted or Crscksd Make sure the driveshaftis not twisted or cracked. Replace necessary. if l. Raisethe car and placesatety standsin the proper locations(seesection 1). Removethe tront wheels. Dralnthe transmission or fluid. oil 4. Raise the lockingtab on the spindlenut and remove rt,
OAMPEB

5. Remove the damper tork nut, bolt and damper pinch bolt. 6. Removethe damperfork.
OAMPERPINCH BOLT (SELF.LOCKING BOLT) 10 r 1.25mm

NUTI ISELF.LOCKING 1 2 x 1 . 2 5m m Replace.

DAMPERFORK BOLT

7, Remove the cotter pin from the lower arm balljoint castle nut and removethe nut. 8. Installa 14 mm hex nut on the ball joint, Be sure that the 14 mm hex nut is flush with the ball joint pin end. or the threadedsectionot the balljoint pin might be damagedby the ball joint remover.

FRONT WHEEL

9. Use the ball ioint remover, 32 mm as shown on page 18-13 to separatethe ball joint and lower arm. 1O, Positionthe specialtool between the knuckleand lower arm as shown, then separdte the lower arm. CAUTION: B€ careful not to damag€ the ball ioinr boot.

CASTLEXUT

SPINOLE NUT 24 r 1.5 mm Replace. 14 mm H€X NUT

Replace.

(cont'd)

16-3

Driveshafts
Removal(cont'd)
11. Pry the driveshaftassemblywith a screwdriveras shown to force the set ring at the driveshaftend past the groove, Shaft: with lntermediate Removethe left driveshaftfrom the bearingsuppon by tapping the inboardjoint of the driveshaJt with a Dlastichammer. CAUTION: a Do not oull on the driveshaft. as the CV joint may come apan. a Use care whsn prying out the assembly and pull it stlaight to avoid damaging the diffelsntial oil s€al.

12. Pullthe inboard ioint and removethe driveshaftand case as an assembly. CV joint Jromthe ditferential

13, Pulltheknuckleoutward and removethe driveshaft outboard ioint from the front wheel hub using a olastichammer.

KNUCKLE

OUTBOARDJOINT INBOARDJOINT

I

16 -4

Disassembly
CAUTION: Do not try to disass€mble the outboard joint. 1. To r€movethe boot band, pry up the lockingtabs with a screwdriverand raisethe end of the band. CAUTION: Tak€ care not to damage the boots. NOTE: Carelullv clamp the driveshaft in a vise with solf jaws. Removethe inboardjoint and rollers. Removethe circlip.then removethe spiderusinga commercially available bearingremover. NOTE: Before disassembly, mark the spider and driveshaft they can be reinstalled their original so in positions.

BEARINGREMOVER

STOPPER RING

INBOAROJOII{T

16-5

Driveshafts
Disassembly/lnsPection
NOTE: duting reassembly. to a Mark the rollersand rollergroovesduringdisassembly ensureproperpositioning in reinstalled their originalposilions. mark the spiderand driveshaftso they can be a Beforedisassembly, a The inboardjoint must be removedto .eplacethe boots. a lf the boot band is the welded type, cut off as shown. CAUTION: Take care not to damag€ tho boots.

DRIVESHAFT

INAOARDJOINT Checksplinestor wear or damage. Check insideborelor wear. Inspectfor cracks, SET R|NG __571 Replace. LEFT INBOARD JOINT lYvith int6rmodlato Checksplineslor wear or damage. Check insidebore for wear. Inspect for cracks.

SPIOEB

ROLLER STOPPER RING

BOOT INBOARD lor Inspect cracking, splittingand wear.

CIRCLIP DYI{AMIC OAMPERBAND (A/T mod.b, loft ddvosh.ft onlYl Replace.

BOOTBAND Replace. AOOTBAND Replace.

------.,
OUTBOAROJOINT Inspect Ior faulty movement and wear. Inspect ball bearings whilo rotaiang Do not try to disassemble

BOOT BANO Replace. OUTBOARD EOOT Inspect cracking, for splittingandwear.

OUTAOARORING Checkfor damage. DRIVESHAFT

16 -6

Reassembly
Cleanthe driveshattsbeforereassemblv. Wrap the splineswith vinyl tape to preventdamage to the boots and dynamicdamper(A/T models,l€tt driveshaftonly). Installthe outboardboot, dynamicdamperand inboard boot to the driveshaft, then removethe vinyl
IADE.

6.

Pack the outboard joint with the joint gr€ase cluded in the new driveshaftset. crease Ouantity. 130-140 9 (4.6-4.9 ozl

BOOT OUTBOARO

VIf{YL TAPE

DYNAMICDAMPER lA/T modob, loft ddvGhaft onlvl

INBOARD BOOT Installthe stopperring into the driveshaftgroove, Rotatethe stopperring in its grooveto be sure it is fully seated. 4. Installthe spider on the driveshaftby aligningthe marks on the spiderand end of the driveshaft. groove.Rotatethe Fit the circlipinto the driveshaft circlip in its grooveto be sure it is fully seated,
CIRCLIP

to Fit the rollers the spiderwith their high shoulders facing outward. CAUTION: a Rainstalltho rollor3 in their o ginal posilions on the sDidel. a To prsv€nt it from talling off, hold tho drlveshatt assembly so th€ spidor and lollor point up.

b """@

SPIDER

STOPPER RING

1S7

Driveshafts
Reassemblylcont'd)
8. Packthe inboard ioint with the ioint greaseincluded in the new driveshaftset. GroasoOuantity: 130-140 g (4.6-4.9 oz) A/T mod€ls, Laft ddveshaft 120- 130 g 14.2-4.6 ozl 9. Fit the inboardioint onto the driveshaft. CAUTION: To provant it from falling oft, hold tho drivoshaft assomblYso tho inboard joint points up.
INBOARDJOINT OnlY: ManualTransmission Align the holder direction of the rollers toward the slot of inboard joint as

1 1 .lnstall new boot bands on the boot and bend both sets ot locking tabs portionsto reduce 1 2 . Lightlytap on the doubled-over their height.

HOLOER

1 0 .Adjust the length of the driveshafts to the tigure below. then adjust the boots to halfway between and Iull extension. full compression
NOTE: The ends oJ boots seat in the grooveof the driveshaftand joint. i R i g h r :5 0 7 . 9 - 5 1 2 . 9 m m ( 2 O . O O - 2 0 . 1 9n ) Left: . A/T modelg 8 6 2 . 9 - 8 6 7 . 9 m m ( 3 3 . 9 7- 3 4 . 1 7 i n l

13. Positionthe dynamicdamperas shown below. a Install a new dynamic damper band and bend down both sets of lockingtabs. a Lightly tap on the doubled-over portion of the band to reduceits height.

DYNAMIC OAMPEB

a 175 r 2 mm 16.9 O.l In)

.

M/T models 52O.9- 525.9 mm (2O.50-20.7O inl

DAMPERBAND

t

16 -8

lnstallation
joint in the knuckle,then loose1 . Installtheoutboard ly installthe spindlenut. Apply 1 .O- 1 .5 g (O.O4-O.O5 oz) of specified grease to the whole spline surface of the intermediateshatt, NOTE: Atter applyinggrease,remove the grease from the splinegroovesat intervalsof 2-3 splines and Jromthe set ring grooveso air can bleedfrom the inboardjoint.
J.

Installthe new set ring onto the driveshaftor intermediateshaft groove. CAUTION: Always use a new set dng whon6va? th6 drivoshatt is being installod.
NOTE: Atter applying grease, rcmove the )ve grease from the spline grooves at int( tntervats g groove, ot 2-3 splines and trom the set ring g

4.

Installthe inboardend of the driveshaft into the ditferentialor intermediate shaft.

NEWSETRIIIG INTERMEDIATE SHAFT

SETRINGGROOVE

INBOARD JOINT

SET RING RIGHT Make sure the right driveshaft locks in the dit{erential side gesr groove, and the CV ioint sub-axle bottoms in the ditterential. LEFTDRIVESHAFT Insert the le{t driveshaft CV joint sub-axle anto (cont dI the intermediate shaft until the intermediate shaft set ring locks in the groove in the lelt driveshaft.

16-9

Driveshafts
(cont'd) Installation
5. and Installthe damperfork overthe driveshaJt onto arm. Install the damper in the damper the lower tork so the aligningtab is alignedwith the slot in the damperfork. Looselyinstallthe damperpinch bolt, and the new damoerfork nut and bolt. NOTE: The bolts and nut shouldbe tightenedwith the vehicle'sweight on the damPer.
DAMPERPINCH BOLT BOLTI {SELF-LOCKING 10 x 1.25mm 44 N'm 14.4 kg-m, 32 lb-ft)

8. Tightenthe new spindlenut 9, lnstsll the wheels with the wheel lug nuts. NOTE: Before installing the wheel, clean the mating surtaceof the brakedisc and insideof the wheel.

6.

FRONTWHEEL

WHEELLUG NUT 1 2 x 1 . 5m m 1 1 ON ' m (11 kg-m, 80 tb-ft)

kg-m,47lb-ft| 65 N.m 16.5 knuckle on the lower arm, then tighten l. t",i"tbtrf,+r" the castlenut and installnew cotter pln. CAUTION: a 8e calotul not to damago tho ballioint boot. a Torque the castle nut to the lowol torque specitication, thon tightsn it only far snough to align tho slot with ths pin hol€. Do not 8li9n tho nut by loosening.

FORK DAMPER NUTI TSELF-LOCKING 1 2 x 1. 2 5 m m

NUT SPINDLE 24 x 1.5 mm 25o N.m 125kg'm, 'l8l lb-ft} use NOTE:Aftertightening, a dritl nut to stakespindle shoulder the against d veshatt.

1 0 .Tightenthe damperpinch bolt and the new damper
tork nut with the vehicle'sweight on the damper. 1 1 .ReJillthe transmissionwith recommendedoil or tluid.

1 2 .Check the tront wheel alignment and adjust if
necassary(seepage 18-4).

COTTERPIN On reassembly, bendthe cotter pin

CASTLENUT 14 x 2.0 mm 5 0 - 6 0 N ' m ( 5 0 - 6 . 0 k9_m' 36-43 tb-ftI

16-10

Intermediate Shaft
Replacement
1 . Drainthe transmission or fluid. oil 2. Remove the left driveshstt assembly (see page 16-4). Removethe flange bolt and hex bolts. 5. Installin the reverseorder of removal. FLANGE BOLT 39 N.m 13.9 kg-m, 2a |b-fr) \
I

HEX BOLTS

p

\ t

,a\,

-

HEXBOLTS 39 N.m 13,9 kg-m, 28 tb-ftl

Removethe intermediate shaft assemblyfrom the differential. CAUTION: To prevent damage to th€ diftersntial oil s€81,hold ths intormediate shaft horizontal until it is clear ot tho diffsrontial.

rrrrnme6lhrrsxlrr

16-11

lntermediateShaft
Disassembly
NOTE: Be carefulnot to damagethe metal ringson the shaft during disassembly intermediate 1. 2. Removethe set ring. shaft outer seal from the Removethe intermediate bearingsupport. Removethe externalcirclip. 5. Removethe internalcirclip.

3.

EXTERNALCIRCLIP

{) \J l
SEAL OUTER Replace. 4.
SET RII{G R€place.

6.

Press the intermediate shaft bearing out oJ the bearingsuppon usingthe specialtoolsand a press.

Press the intermediate shatt out to the shaft bearing using the specialtools and a press. NOTE: Positionthe specialtools so they do not damagethe metal ring on the shafr.
Pres!

I
SHAFT BEARING INTERMEOIATE HUB DIS/ ASSEMBLYBASE 07GAF-SD40700

16-12

Disassembly/lnspection

INTERMEDIATE SHAFT RING Checkfor damageor distonion. INTERMEDIATE SHAFT Checkfor damage.

BEARINGSUPPORTRING Check tor damage or distortion.

HEXBOLTS

FLANGEBOLT

INTERITAL CIRCLIP

BEARINGSUPPORT Checktor damage.

INTERMEDIA SHAFT ATE ! EEARING Replace.

@,, @ I
EXTERNAL CIRCLIP

d^
OUTER SEAL Repl.ce.

I

0\
SET RING Replace.

16-13

IntermediateShaft
Reassembly
NOTE: Be carefulnot to damagethe metal ringson the shalt during reassembly intermediate 1. shaft bearinginto the bearPressthe intermediate ing supportusing the specialtools and a press
Pre3s DRIVER o7749-OO10000

Seat the external circlip in the groove of the in termediateshaft. CAUTION: Installthe circlip with the taperedend tacing out, 5 , Pressthe outer seal into the bearingsupportusing the specialtools and a Press. CAUTION: Do not damage the lip on outer seal duringinstallation. NOTE: Press the seal flush with the bearing support.

I
ATTACHMENT 52x55mm 07746-OO10400

Packthe interiorand lip of the outer seal. 2 . O - 3 . 5 g ( O . 0 70 . 1 2 o z l

HUB DIS/

oTGAF-SD40700 2. Seatthe internalcirclipin the grooveof the bearing supPort. shaft into the shaft bearing Pressthe intermediate tool and a Press. using the special
Pr6ss

3.

F-t F4

n +*:-+
F
| .,-.t

m
6, shaft Installthe new set ring in the intermediate groove.
ATTACIlMENT, 35 mm l.O.

46-0030400

HUB DIS/ 07GAF-SD40700

16-14

Steering
. . . . . . . . . . . . . . . . .7 - 2 1 SpecialToofs General lnformation I . 4 W S S e r v i c en f o r m a t i o n . . . . . . . . . . . . . . . . . , . . ,7 - 3 1. Component Location I n d e xl 2 W S i 4 W S ) . . . . . . .1 7 - 5 Component Location . . . . . . . . . . . . .1 7 - 6 . I n d e x( 4 w s l System Descliption FluidFlow Diagram 1 7- 7 1 7- 8 Steering Pump . F l u i d e s e r v o i r / F i l t.e... . , , . .- . . . . .- . . . . . . . .... . ' t 7- 9 R . , 1 7- 1 0 4-way Valve F u l l - l o cU n l o a d eS y s t e m . . . . . . . . . . . . . . . . . . .1 . - 1 2 k r .7 PowerSteering SpeedSensor 1 7- 1 2 ElectronicallvControlled P o w e rA s s i s t e d W S . . . . . . . . . . . . . . . . . . . . . . 1.7 - 15 4 . . Troubleshooting (Power Steering System) T . . G e n e r a l r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . . . - 1.7- 2 5 ..,.. 17-24 Noissand Vibration Ffuid eaks L . . . . . . . . . . . . . . .1 7 - 2 9 . Troubleshooting l4WS) L . . ... C o m p o n e n to c a t i o n. . . . . . . . . . . . . . . . . . . . . . 1.7 - 3.0 C o n n e c t oL o c a t i o n s , . . , . . , . . , . , . . . . . . . . . . . . .17-31 r . ... Cilcuit Diagram 17-32 4WS CONTROL UNIT Terminal 17-34 Arrangement Diagnostic TroubleCode(DTCI 17-36 Precautions 17-37 S y m p t o m - t o - S y s t sC h a r t. . . , . . . , . . . . . . . . . . .1 . - 3 8 m .7 r .. 4 W S I n d i c a t oL i g h tC i r c u i t. . . . . . . . . . . . . . . . . . .17-42 TroubleCodes {DTCS): Diagnostic 17-45 1 0 , 1 2 ,r 6 DiagnosticTlouble Codes (DTCsl: 1 1 , 1 3 ,1 7 17-50 DiagnosticTiouble Codes (DTCsl: 2 0 , 2 2 , 2 4 , 2 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 . . .5 . . -5 . Diagnostic Trouble Codes (DTCsl: 2 1, 2 3 . 2 5 , 2 9 17-59 TroubleCodes (DTCsl: Diagnostic 17-63 30,34 ............... Tlouble Codes (DTCSl: Diagnostic 17-64 3 1 .3 5 . . . . . . . . . . . . . . . Diagnostic Troubls Codes (DTCs): 32,36 ............... 17-66 TroubleCode(DTCI:33 .......... 1 7 - 6 8 Diagnostic TroubleCode(DTC):50 .......... 1 7- 7 0 Diagnostic D i a g n o s t iT r o u b l e o d e{ D T C } 5 1 . . . . . . . . . .1 7- 7 1 c C : TroubleCodes {DTCS}: Diagnostic 1 7- 7 1 6 0 , 6 1, 6 2 , 6 3 Maintenance P u m pB e l tA d i u s t m e n t. . . . . . . . . . . . . . . . ........ . . .17 - 74 On-Car Checks A . . R a c kG u i d e d i u s t m e n t. . . . . . . . . . . . . . . . . . . . . . 1.7- 75 FluidReplacement ,..,.. 17-77 P u m p r e s s u r eh e c k. . . . . , . . . . . . . . . , . . , , . . , .7 - 74 P C 1 ,... P . S t e s r i n g h e e f o t a t i o n a l l a y. . - . . . . . . - . . - . 1.7 - 7 9 W S Power Assist Chsck w i t h C a rP a r k e d . . . . . .1 7 - 7 9 A s s i s tC h e c ka t R o a dS D e e d. . . . . . . . . . , . . . . . . 1.7 - 8 O . Power Steering Speed Sensor Replacement . . . . . . . . . .1 7 - 8 0 Steering Wheel 1 R e m o v a, l. . . . . . . . . , . . ..,.... 7-81 1. D i s a s s e m b l y / R e a s s e m . .l.y , . . . . . . . . . . . . . . . .7 - 8 3 .b . Installation 2 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . - 8.4 . . . . 7 .. . 4 W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.-.8 .6 . . . .. . . SteeringColumn R e m o v a.l. . . . . . . . . . . . ....... 7-89 1 . . . . . . . . . . . . . . . . .7 - 9 2 1 fnsoection Installation . . . . . . . . . . . . . . .1 7 - 9 3 . SteeringPump 17-96 Beolacement P u l l e R e p l a c e m e . . t. . . . . . . . . . . . . . . . . . . . . . .1 7.-.9 . y n .. .6 Flow Control Valve Insoection 17 -97 and Rsplacement 17-99 Disassemblv lllustrated Index 17-102 17 - 1 0 3 Ass6mblv Steering Gearbox l n d e x. . . . . . . . . . . . . . . . . ....... 7-105 1 . . . . . . . . . .1 7 - 1 0 6 V a l v eB o d yU n i r . . . . . . .1 7 - 1 1 4 Gearbox emoval R n . . . . . . . . . .1 7- 1 1 7 l l f u s t r a t sfd d e x O v e r h a u.l. . . . . . . . . . . ....... 7-118 1 . . . . . . . . . . . . . . .1 7- 1 3 4 . fnstallation Rear Steering Actuator (4WS) f f f u s t r a t efd d e x n . . . . . . . . . .1 7 - 1 3 7 1 R e m o v a. l. . . . . . . , . . . . ......, 7-138 Disassembly . . . . . . . . . . . . .1 7 - ' l 4 O . . . . . . . . . . . . . . . .1 . . - 1 4 1 .7 Asssmbfv fnstallation . . . . . . . . . . . . . . .1 7- 1 4 4 . 4WS Control Unit . R e m o v aa n dl n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . ' l7 - 14 5 l Tie-rod End Boot . . . . . . . . . . . . .1 7 - 1 4 5 . Replacement 4WS System Inspection 1. E l e c t r o n iN e u t r aC h e c k . - . . - - . . . . . - . . - . . - . . - .7.- 1 4 6 c l 4WS System Adiustment 4 W S S y s t e m d j u s t m e n t . . . . . . . , . . . . . , , . . , . . .7'-l 15 1 A . . Sub SteeringAngle Sensor ........... 7-153 1 Adjustment

S p e ci a l To ols

Ref. No.

I

Tool Numbel OTGAF SD40TOO oTJGG-OO10100 OTLAG_SM401OA OTLAG SM402OA OTLAG SM403OA o7t\4AA-SLOo20A oTMAC-SLOO200 'IA 1 OTNAK SR3O OTNAK_SR3012A oTNAB-SSOO100 OTNAJ_SSOO2OA 07406-OO10101 o7406-OO10001 o7406-oo10300 07406-OO10400 o7725-OO30000 o7746-0010200 07746 0010300 07749-OO l OOOO o7947-6340500 o7974-6920500

DoscriDtion Base Hub Dis/Assembly Belt TensionGauge PistonSeal Ring Guide PistonSeal RingSizingTool CylinderEnd Seal Slider LocknutWrench, 43 mm BallJoint Remover,28 mm P/S Joint Adapter {Pump) P/S Joint Adapter(Hose) Rack Hold€r RearSteeringCenterLock Pin BypassTube Joint (lncluded ith 07406-001OO01 l w P/S Pressure Gauge Pressure ControlValve Gauge Pressure Holder Universal Attachment,37 x 40 mm Attachment,42 x 47 mm Driver DriverAttachment Hub AssemblyGuideAttachment

Oty 1 'I 1 1 1 I I 1 1 I 1 I 1 1 1 1 1 1 I 1 1

Page Relerence 17 - 1 0 8 17-74 1 7- 1 2 5 1 7- 1 2 5 1 7- 1 2 6 17 15,76, 132 1 7- ' t1 4 , 1 3 4 17-74 1778 1 7- 1 4 0 , 1 4 2 17-4,144, 150, 15 6 . 1 5 7 17-80 17-78 1 7- 7 I 1 7- 7 4 '17-96 17-103 1 7- 1 2 0 , 1 2 3 1 7- ' t2 3 17-103 17,145

o (;\
aa) @
Lcf

@

o
,G)

@ @

o

@ @ @-1 @-2 @

(t

@ @ @ @

o
/g)

\Z'cfp
@

/t-\

i=
@@

7-2

GeneralInformation
4WS ServiceInformation
power assisted controlled 4WS (4-wheelsteeringsystemi, note the foliowOn modelsequippedwith the electronically befo.e service. ing specialprecautions a After performing and the following operations, check and adiustthe 4WS systemto be sure that it is electronically mechanically neutral(all 4 wheels in properalignment). in

Operation Rack guide adjustment Steeringwheel removal/installation Steeringwheel replacement Steeringcolumn removal/installation or Front steeringg€arboxremoval/installation dissssemblv Rearactuatorremoval/installation Ffont/rear sub steeringangle sensor removal/installation Front msin steeringangle sensor removal/installation Rearmain steeringanglesensor removal/installation

Check for mechanical neutral

Checkfor electronic neutral

Relerence page 1 77 6 1 7 - 8 ' ,l 8 6 17-86 17 89, 93 17 - 11 8 , 13 1 17 137
1 7 - 1 1 71 3 7 ,

o o
o

o
o

o
o

o o o o
o

o

o
o

1-t -92 17 137

Perform the following in a Th6 4WS Systemmust be ( l ) mechanically (2) electronically neutralfor Woperoperation. and first, then performthe followingelectronicneutral neutralcheck on the system and adjustas necessary mechanical (4WS system adiustmeni:see page 17-151 ) check and adjust as necessary. (l) Mechanically neutrsl: Be surethat the front and rearwheelsalignpfoperlywith the steeringwheel in the straightdrivingposition(i.e.dif four wheel alignmentequipmentreadingbetweenthe right and left wheels is within 0.5 ferencein computerized mm/O.02 inl. neutral: {2) El€ctronic wheelin the straightdrivingposition. in are Be surethat the tollowingsensors electronically neutralwith the steering neutralpositionis indicatedby blinkingor lightingof the 4WS indicatorlight. Electronic Front Main SteeringAngle Sensor Front Sub SteeringAngle Sensor Rear Main SteeringAngle Sensor RearSub SteeringAngle Sensor

4ws tNDtcaToR LtcHT I . ,.. I at{rt4-

( c o n t ' d)

7-3

Generallnformation
4WS Service lnformation (cont'd)
o It the spokesngleof steeringwheel is not atthe designated anglewhiledrivingstraight,checkwhetherit was caused of simply by an improperlyinstalledsteeringwheel or by the misalignment the lront and rear wheels. Check the wheels for properalignmentbefore adjustingthe steeringwheel spoke angle. check Installtherearsteeringlock pin in the rearactuatorand. with the steeringwheelin the straightdrivingposition, readingbetweenthe in four wheelalignment equipment the wheelsfor properalignment(i,e.difference computerized right and left wheels is within 0.5 mm/0.02 in). Checkthe sensorsfor electronicneutralto be sure that the rearwheels are in correctsteeringanglewhile driving. and the a Do not contaminate front and rea. sub steeringanglesensors, front and rearmain steeringanglesensors, the rear steeringactuatormotor terminalswith mud, oil, and grease. " a Thephrase"the steeringwheel in the straightdrivingposition meansthat the front wheels are in the straightdriving positionwith the steeringwheel spokesat a horizontal angle. a lf the power to the 4WS controlunit was shut down for the followingoperations, start the engineand turn the steering wheel tully right and left before checkingand adjustingthe 4WS system. - Battery removal/installation - 4WS control unit removal/installation - No,43 fuse CLOCKRADIOremoval(in the under-hood fuse/relay box) CAUTION; a The roar whoel steoring angle is not controlled when the engine is OFF. When the engine is staned, the rear whaels aro ste6r6d to an angle in accordancewith the front whoelangle. We recommendthat the steering system b6 sorviced wilh the steering whoel set in th6 straight driving position, a Do not st8n the engino with the lock pin sot in the rear acluator. The rear actuator might be damaged whsn the rear whools aro steorod. Bo surs to removs ths lock Din after service.

CAPBOLT 22 N.rn 12.2kg-m.16 tb-ftt

SEALINGWASHER Replace.

17-4

ComponentLocation
Index (2WS/4WS)
NOTE: lf an intact driver's airbag assemblyhas been removedfrom a scrappedcar or has been found defectiveor damagedduringtransit, storageor service,it shouldbe deployed{seesection23}.

WHEEL STEERING Removal l2WS/4WS).page 17'81 page Disassembly/Reassembly, 17-83 Installation {2WS}, page 17-84 Installation {4wS}, page 17-86 STEERING COLUMN page 17-89 Removal, p6ge 17-92 Inspection, page'l7-93 Installation, FRONTMAIN STEERING ANGLE SENSOR{4WSI Adiustment,page 17-15'l IGNITIONSWITCH Steering Lock Replacomentand Swirch Test, see ElectricalSection STEENI G GEARBOX pago 17-75 RackGuideAdiustment(2WS/4WS), p€ge 17-114 Removal, Index,page 17-1 17 page 17-118 Ov€rhaul,

SPEEDSENSOR POWERSTEERING Rgplscement,pag€ 17-8O

VALVEBODYUNIT
page 17-106 Ovsrhaul, FROI{T SUB STEERING ANGLE SENSORI4WS) Adiustment, p a g e1 7 - 1 5 3 FLUIORESERVOIR FluidReplacement, page 17 77

ENO TIE.ROD BallJoinr Eoot Replacement, p g a e1 7 - 1 4 5

STEERING PUMP page 17 74 Pump Belt Adjustmenr, page 17-77 FluidRepfacement, PumpPressure Check,page 17-78 page 17-96 Pump Replacement, page 17-97 and Replacement, ControlValve Inspection page 17-99 Disassembly, page 17-103 Reassembly,

17-5

GomponentLocation
Index (4WSl
4WS COTTROL UI{IT page | 7-145 Removal/lnstallation, 4WS SYSTEM I SPECTION.nd ADJUSTMET{T page 17-15'l Insp€ction,

RACK EI{O page 17-138 Removal, page 17-144 Installation,

ANGLE SENSOR REARSUB STEERING Adjustmenl,page 17 155 page 17 138 Romoval, page 17-141 Installation,

ANGLE SENSOR REARMAIN STEERING R e m o v a lp a g e1 7 1 4 1 , fnstaf lation,page 17'1 42 TIE-RODEND Boot Replacement, p a g e1 7 | 4 5

ACTUATOR REARSTEERING Index,page 17-137 lllustrated page 17-138 ActuatorRemoval, Actuator Dissssembly, Page 17-140

17-6

SystemDescription
FluidFlow Diagram
the The reservoirsuppliespower steeringtluid to the pump; the pump pressurizes fluid and deliversit through a high pressure hose to the valve body unit on the gearbox. The 4-way valve {in the valve body unit) controlsthe directionof the turn by shiftingfluid to the left or right side of the piston on the rack {in the power cylinder). the stroke of the 4 way The gain control valve jn the valve body unit controlsthe amount ot the assistby regulating which is regulated the pressure by control ot valve.The operation the gain controlvalveis atlectedby the fluid pressure, valve, sensororifice and power steeringspeed sensor. Constant pressureis generatedby the pressurecontrol valve. This pressureis used as a referencepressuretor the this pressure the power steeringspeedsensorthroughthe sensororilice, to response the car speed.By introducing to is pressure downstreamol the orificeis changedaccording the speedof car. This pressure then used to operate to the of the gain control valve.Two orificesare pfovidedaroundthe circumference the gain controlvalve.Theseorificesprovide th€ steplessreductionof the pressuretrom the pump accordingto the changesin the car speed.The reduced in the pressu.eis then sent to the reactionchambers.Theretore the assistvariesby regulating lluid pressure the valve body unit accordingto the speedot car. throughthe cooler. lrom the power cylinderflows back throughthe 4-way valveand out to the reservoir FIuidretrrrning

VALVE EODY UNIT

tr---------ORIFICE SENSOR

------l
PRESSURE CONTROL VALVE

RESERVOIR

GAIN CONTROLVATVE REACTIONPLUNGER

a-say y4s-ys{

GEARBOX I I

CYLINDER FLOW CONTROLVALVE lhas s built-in reliel valvel

WHEEL STEERING

7-7

System Description
Construction
reliefvalve)and is drivenby a V-beltfrom a The pump is a vane-typeincorporating tlow controlvalve(with an integrated lor operations every rotationof the crank pulley.The pump features1Ovanes.Eachvane performstwo intake/discharge pulse becomesextremelysmall duringdischarge. th€ rotor. This meansthat the hydraulicfluid pressure

FLOW CONTROLVALVE

DRIVESHAFT

Operation
pressure applied to is pullevrotatesthe rotor throughthe drjve shaft. As the rotor rotates,the hydraulic The belt-driven of beingpushedonto the innercircumference the cam rlng' the vane chamberof the rotor and the vaneswill rotatewhile so the rollers of The inner circumterence the cam ring has an extendedportionwith respectto the centerof the shaft, volumeof the the directionas the carrierrotates.As a resultof this rollermovement, internal move downward in the axial vane chamberwill change,resultingin fluid intake and discharge
FLUIDMOVEMENT FLUIDDISCHARGE

START OF FLUID INTAKE INLET POBT

FLUID INTAKE

The vanes are pushed onto the inner circumferenceof the cam ring.

The volume of the chamber increases so t h a t tluid is suckedin.

The sucked-in fluid moves toward the discharge port,

As the vanes return to the their original position on the inner side, the volume of the vane ch6mber decreases so the fluid is discharged from the discharge pon.

17-8

Fluid Reservoir/Filter
Flow Control
Fluidtrom the pump runs through a meteringorificeto diJference the valve body unit. This createsa pressure between the pump and valve body unit sides of the orifice.When pressurein the pump side is higherthan the force ot the spring holdingthe flow control valve closed, it pushesthe valve down (openl, and excess fluid returnsto the Dumoinlet. The combinedetiect ot and the flow controlvalve provides the metsringoriJice constantflow of Jluidto the valvebody unit. a relatively reservoir and filter is attachedto the tender A one-piece apron on the left side of the enginecompartment.The should be replacedif the fluid and the filter/reservoir or system is openedfor repairs, if the fluid gets water or dirt in it. CAUTION: Use only Honda Powsr sleering Fluid-V,The use ot othel fluid such as A.T.F., or othor manufacturor's power stsering fluid. will cause damago to the system.

METERING ORIFICE

<To Valve bodv Unit

Prossure Relief
As pr€ssureon the valve body unit side builds up, it pushes the relief valve ball (inside the tlow control valve)up againstits spring,and excessfluid returnsto underthe flow control the pump inlet. As the pressure valve drops,the reliefvalve ball is closedby its spring, and the flow control valve is forced down again.allowing excesslluid from the pump side to returnto the invalve cylinder keeps let. This tlow control valve-relief pump output pressure between TOOO-8OOO kPa ( 7 O - 8 0 k g i c m ' .9 9 5 - 1 , 13 8 p s i ) .
VALVE OPEN RELIEF From Valve body Unit

Steering SpeedSensor

<r
To Steering Pump

RELIEF VALVE EALL

1 7- 9

System Description
4-Way Valve
by Mountedon ihe lower sideof the gearboxis a 4-way valvethat is movedhorizontally a pin on the pinionholderto shift to tluid pressure the right or left side of the power cylinderwhen the steeringwheel is turned. one on each side. reactionchambers, It has thrust pins at both ends, and two inter-connected plungersthat rise againstright and lelt thrust pins. Eachreactionchambercontainsa pair of spring-loaded are The valve body fluid passages controlledby the 4-way valve. by is in Fluidpressure the reactionchambers reduced the gaincontrolvalvein orderto changethe amountof the assistin with the changein the car's speed accordance

VALVE BODY UNIT SENSORORIFICE

RESERVOIR

GAIN CONTROLVALVE

4-WAYVALVE +

I

l r >

matl ontrtce

i ----------JJ-l-

L________
FLOW CONTROLVALVE lha! I built-ln toliot valvo)

POWERCYLINDER

+WAY VALVE

17-10

(for left or in unit, the methodusedto directa singlesourceot fluid pressure eitherof two directions In the power steering "message" oJ directionto the tluid in the 4-way valve a right turns) involvesthe piniongear transferring which are in turn mountedin a pinionholdercylinderthat The pinionis mountedslightlyoff-centerin a pairot bearings, At rotates,centeredin its own outer bearings. the bottom ol the PinionHolderis a pin, which fits in a slot in the 4-way valve. it it As the pinionis turned (to turn lett or right),because is off-center. alsomovesslightlyalongthe rack.This movement to to is transferred the holder.The pin in the holderthen movesthe 4-way valve,to directfluid pressure eithersideof the in th€ power cylinder. rack The bsck edgesot the pinionholder(facingaway lrom the rack)hit the stopscast into both sidesof the gearhousingto The tront edgeof the pinionholdercuts off assistat full lock as avoidpushingthe 4-way valvetoo far in eitherdirsction, described the next page. on

POWERCYLINDERS

NEEDLE ROLLER BEARIG
BALL BEARING Plt{

RACK STEERING

+WAY VALV€
HOLOEB

4.WAYVALVE

RACK

1 7- 1 1

System Description
Full-lockUnloaderSystem
The 4-way valveshifts the directionof fluid flow when the steeringwheel is turned right or left. However,when the wheel is turned to the right or left lock at parking speed, the edge of the pinion holder ridesup on the end of the rack, movingthe pin in the opposite directionwhich pulls the 4-way valve back to nsutral. This keeps pump pressure from building up (which could cause idl€ speedto drop), and improvessteering leel by increasing resistance left and right lock. at

Power SteeringSpeedSensor
The power steering speed sensor is a trochoid-rotor, hydraulicpump combinedwith a reliefvalveand a onegear shatt way valve. lt is driven by the speedometer which in turn is driven by a helical gear on the differential.

INNERROTOR OUTERROTOR

ONE-WAY VALVE
Controlin "assist" position

SPEEDOMETER GEAR The power steeringspeed sensorturns only when the car is moving.controllingthe gain control valve. The constant pressureis generatedby the pressure conlrol valve. This pressureis used as a relerencepressurefor the response to the car's speed. Bv introducing this pressureto the power steeringspeed sensor through the sensor oritice, the pressuredownstream of the to orifice is changedaccording the speedof the car.
PRESSURE CONTROLVALVE To power steeringspeedsensor

4-way valve moves back to "neutral" position

Pressure response in to vehiclespeed FEEO SIDEORIFICE

17-12

With the engine running at idle in a parked car, fluid flow through the sensor rotors is blockedbecausethe rotors are not turning.Theretorethe gain control valve movesto the left. On the gain controlvalve.the oritice is resistance high on pump side, while it is low on the in reservoir side, with the resultthat pressure the reaction chambe,is loweredand steeringassist is high.

When the car is moving at high speed, the sensor turther and the gain control valve reducesthe pressure moves furthsr to the right. The orifice pressure the on pump side is low and the pressure the reservoir on side in is high,the fluid pressure the reactionchamberis also high giving the steeringwheel less assist.
Hydraulic prossurein response to the car's speed(Lowl

FEEDSIOEORIFICE RESERVOIR SIDE OiIFICE

Hydraulic pressurein response thg car's to speed{High}

RETURl{ RETURN GAr{ CO|{TRO|VALVE
Pressurein reaction chamber(Low)

As th€ car is driven.the rotorsstart turningand the fluid returns to the reservoir, reducing the fluid pressure at the the gaincontrolvalve.Theretore, gain controlvalve on bsginsto move to the right. The orifice resistance balanced, sidesis appropriately the pump and reservoir with the result that the reaction chamber is in the is mediumrangeand the steeringresistance moderate.

in Hvdraulic Pressure reaponse (M€dium) ro the car'ssDeed SIDE RESERVOIR ORIFICE FEED

REACTIONCHAMBER

(cont'd)

17-13

System Description
PowerSteeringSpeedSensor(cont'd)
Speed Valve(ln PowerSteering One-way Sonsorl
Wh6n the car is moving at high speed, negative pressure develops at the sensor inlet because the power steeringspeedsensoris pumpingfasterthan the for To fluid can be supplied. compensate this, the outlet and inlet ports are connectedinternsllyby a passage containinga one-way valve that lets output tluid recir pressure. culate to the inl€t pon to equalize Driving at Hlgh Speed:

ReliefValve (ln PowerSteeringSpeedSensorl
When the car is moving in reverse,the power steering speed sensor also turns backward and pumps tluid in in the oppositedirection.To avoid buildingup pressure steeringefthe reactionchambersthat would increase ton while driving in reverse,the inlet and outlet-ports containing are connectedby a secondinternalpassage a relief valve that allows the tluid to recarculate.

Driving in Reve.se:

ONE.WAYVALVE

ROTORS
VALVE RELIEF

17-1 4

Electronically ControlledPower Assasted 4WS
Outline
The electronically controlledpower assisted4WS (4-wheelsteeringsystem)consistsof the hydraulicpower steering systemthat steersthe front wheels,the rearactuatorthat steersthe rearwheels,the 4WS controlunit, and the sensors gearboxandthe rearactuatorare connected The front steering that detectthe car's speedand othersteeringconditions, The rearsteeringangleis controlled electrically, allowingthe rearwheelsto be set at any desigrated by a wire harness. steeringangle.

ANGLE SENSOR FRONTMAIN STEENING

VEHICLE SPEED

17-15

System Description
ElectronicallyControlledPower Assisted 4WS (cont'd)
System Operation
The 4WS control unit receivesinput from the VehicleSpeedSensor(VSS),front main steeringanglesensor,and the turningangle,steering speed the f.ont sub steeringanglesensor.The 4WS controlunit calculates vehiclespeed,steering the best angleto steer the rear wheels. and steeringdijectionto determine

(System op€ration flow)

VSS ggrves the soeedmeter as well.

Front main st66dng angle sgnsol

Front gub stooring angl€ sonaol

Calculation of the car's apggd

C.lculation ot steoring rotation speed

Calculation ot stooring angle lor toar whgels

4WS Control unit

17-16

The rear wheels are turned by a motor built into the rearsteeringactuator.The motor is activedby the power circuit in the 4WS controlunit. The actualsteeringangleof the rearwheelsis detectedby the rearmainsteering anglesensor,and the rearsub steeringanglesensor.The 4WS controlunit adjusts the angleaccording the difference to betweenthe sensed steeringangle of the rear wheels and the targetedsteeringangleof the rear wheels.

FRONTMAIN STEERING ANGLESENSOR SENSOR REARSUB STEERING ANGLESENSOR

ACTUATOR REARSTEERING FRONTSUB STEENING ANGLE SENSOR 4WS CONTROLUNIT REARMAIN ANGLE STEERING SENSOR

(cont'd )

1 7- 1 7

System Description
Electronically ControlledPower Assisted 4WS {cont'd)
System Operation
Featuresol rear wheol steering: controlledpower assisted4WS sets the rear wheels at the best steeringanglelor the car's speed, The electronicsllv steeringrotationspeed,steeringwheel angle,etc. a Car speed direction the front wheels of When the car is travelingat low speed,the 4WS systemturns the rearwheelsin the reverse to in proportion the rotationangleof the steeringwheei. When the car is travelinga higherspeed,the system increases the steeringangle of the rear wheels in the same directionas the front wheels. to of the Changing steeringangleperformance the rearwheelsin relation the car's speedgivesthe car improvedhandling characteristics. a Steeringspeed 18 mph (3O km/h) or above The rear wheel steeringanglevarieswith how rapidlythe steeringwheel is rotated.See graph

lSto6ring angl€/sp€ed portoamanco cuwol

Slow st€6.ing

Rapid stooring

0. 5 200 0 -0. 5

300

400

100

17-18

Component Function & Operation
Roa?actuator: The rearactuatoris mountedat the rearoI the car to steerthe rearwheels.The motor, built into the actuator,is madeup of a stato. with a permanentmagnet. a rotor. and brushesthat pass electricjtyto the commutators.The motor is mountedon the sameaxis as the steering shaft screw, makingthe rearactuatorcompactand light in weight. The rearactuato. also containsthe rear main steeringanglesensorand the rear sub steeringanglesensor. The 4WS control unit drivesthe electricmotor with DC current.lt switchesthe currentpolarityto changethe motor's direction.Two strong return springs,one at each end ot the actuator,providea centeringaction.They returnthe rear positionwhenevercurrent is cut to the motor. wheelsto the straight-ahead
REARSUB STEERING ANGLESENSOR

ACTUATOR HOUSING

STATOR REARMAIN STE€RING ANGLESENSOB

RETURN SPRING

STEERII{G SHAFT SCREW

COMMUTATOR BRUSHES ROTOR

RECIRCULATING BALL SCREW <RETURN SPRINGOPERATION >
Mov6s to l€ft:

Moves to right:

The return spring compresses when the steeringshaft screw moves to right or left. When the motor is OFF, the stesring shaft screw is held in the straight ahead (neutral) positionby the force oJ the return spring. {cont'd)

17-19

Maintenance
Transmission Oil
NOTE:Check oil with the engineOFF, the and the car on levelground. 1. Removethe oil tiller plug, then checkthe level and conditionof the oil.

Back-up Light Switch
Replacement
NOTE:Check switchseesection23. the 1. Disconnect the back-uplight switch wire connecrors. Remove back-up the light switch,

2.
WASHEN
Replace.

Proper Level.

OILFILI.IR PLUG 45 N.m(4.5kg-m,33lb-ftl 2. The oil levelmust be up to the fill hote.lf it is below the hole, add oil until it runs out. then reinstall the o i l f i l l e rp l u g . l f t h e t r a n s m i s s i o n i l i s d i r t y , r e m o v et h e d r a i n o p l u ga n dd r a i nt h e o i l . R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d refillthe transmission to the properlevel. oil NOTE:The drain plug washershouldbe replaced at everyoil change. 5. Reinstall oil filler plug with a new washer. the Oil Capacity 1.9/ 12.0 qt, 1.7lmp qtl ar oil chango. US 2.0 / {2.1 US qt, 1.8 lmp qtl at overhaul. Useonly SAE 10 W - 30 or 10 W - 40,SF or SG grade.

3.

4.

3.

Installthenew washerand back-up light switch,

OIL FILLER PLUG '15N.m (4.5kg-m. 33 lb-ft) WASHER Feplace.

13-3

System Description
Electronically GontrolledPower Assisted 4WS (cont'd)
Component Function & OPeration
Front main stso.ing anglg sensor: The front main steeringanglesensoris mountedin the stee,ing column. lt sens€sthe directionand angle of steering wheel {otation and converts it to electrical signalsthat are sent to the 4WS control unit.

CIRCUIT

MR ELEMENT

HALL IC

Roal main ste€dng angle 9en9o1: The rear main steeringanglesensoris mountedon the rear actuator. lt sensesthe directionand angle of the rear wheels and sendssignalsto the 4WS control unit. as The 4WS controlunit usesthis information feedback to determineif the actual rear wheel positionmatches the desiredDosition.

HALL IC

MR ELEMENT

17-20

Front tub stoering angl€ s€nsor: The front sub steeringangle sensoris mountedon the front stgering gearbox. lts purpose is to detect the posi tion of the front wheels and convert this inJormationto an slectrical signal for the 4WS control unit. The front sub steering angle sensor uses a springloadedplungerthat ridesin a slopedgroovein the rack. As ths rack turns the tront wheels,the plungerridesup the slope and is pushed into the differential transformer The plunge.'spositionis used to determine assembly. how tar the rack is turned.

ANGLE SENSOR FROI{T SUB STEERING

RACK STEERING

Rgar sub gtoodng anglg aensor: Th6 r6a. sub steeringangle sensor is mounted on the rear actuator spring cover. lts detects the position oI the rear wheels as a feedbacksignalfor the 4wS contrcl unit. lt ogerates in exactlv the same wav as the front sub steering angle sensor.

11-21

System Descripton
ElectronicallyControlled Power Assisted 4WS {cont'd)
Componont Function & Operation (cont'dl
a Average moving curent control movThe 4WS controlunit monitorsthe averagemovingcurrentol the motor to protectthe system.Whenthe average ing currentexceedsa given value,the 4WS control unii lowers the currentto changesteeringangleof the rear wheels graduslly(approximately degrees/3osecondsl.When the averagemoving currentto the motor is below the given 6 minutes). 6 steeringangle slowly {approximately degrees/2 value,the rear wheels returnto the designated a Over-voltage control An increasein battery voltage (due to a voltageregulatorfailure,for example)could causeexcessiveactuationof the motor and grraticcontrolof the r€arwheels.To preventthis, the 4WS controlunjt monitorsthe voltage.lI it exceedsa voltageto the givenvalue,the 4WS controlunit slowly returnsthe rearwheelsto the straightaheadpositionby reducing motor and turns the 4WS indicatorlight ON.

17-2 2

Fail-sat€ Function: When the 4WS controlunit sensesa tailurein the system,it switchesto fail-safe mode. In this mode, it powersthe tailsafe and damper relays.The fail-salerelay cuts power to the rear steeringmotor, while the damper relay slows the motor's returnto neutral.As a result,the rearwheelsreturnslowly to the straightaheadpositionand then remainthere. The car then drives like conventional 2WS. When the 4WS control unit switchesto fail-safe mode, it storesa Diagnostic TroubleCode(DTC)and turns on the 4WS indicatorlight to notify the driver of a problem.This code can be read by connecting the servicecheck connectorter minals with a iumoerwire under the dash. The code is read as blinksof the 4WS indicatorliqht.

4WS INDICATORLIGHT

;=;

..

.

=' -:-

Flr,\-n-'Puf

I

/

/

i

="1

.

:

-

:a.

JUMPER WIRE

Damper Control: relay.Without sometype mode,it cuts power to the motor by poweringthe fail-safe When the system goesinto fail-safe position too rapidly,adversely atlecting of damping,the returnsspringswould turn the rearwheelsto the straight-ahead the car's handling. motor is To counteractthis, the 4WS control unit also powersthe damperrelay.The armatureo{ the now deactivated by The voltagegenerated this spun by the movementof the steeringshaft. This causesthe motor to act as a generator. action is appliedback to the motor throughthe damperrelay.This causesthe motor to resistthe force ot the returnsprings. allowingthe rear wheels to go back to the straightaheadpositionslowly.

1 7- 2 3

System Descripton
PowerAssisted4WS (cont'dl Controlled Electronically
Componont Function & Operation (cont'dl
a El€ctronic neutral Position alignment ln other For the 4WS system to work correctly,it must be in el€ctronicalignmentas well as mechanical words,thesYstem,s'rontandrealsensorsmustSigna|thatthewhee|sarepointedstraightaheadwhenthewhee|sare "electronicstraightahead" by connecting the service pointedstraightahead.The techniciancan test tor mgchsnically terminalswith a iumper wire and turning the front and rear wheels' ch6ck connector

17-24

(PowerSteeringSystem) Troubleshooting
GeneralTroubleshooting
Check the following betoreyou begin: a a a a a a Has the suspension been modifiedin a way that would affect steering? Are tire sizesand air Dressure correct? ls the steeringwheel originalequipmentor equivalent? ls the power steeringpump belt properlyadjusted? ls steeringfluid reservoir filledto properlevel? ls the engineidle speedcorrect and steady?
HardSteering

Littleor no assistin both directions with car parked.

Assislin one direction only, littleor no assistin the olher.

Check for bubbles in power steering fluid.

l{ there are no bubbles, check i{ assist improveswhen engine speed is increasedlC| 3,O00 rpm.

It there are bubbles, check the reservoir inpul side hoses and pump front seallor air leaks. Repairas necessary.

Remove the valve body unrt and check the pinion pin for free movement. lf OK, check lhe 4 way valve for free movement (see page 1/,107|. Repair as necessary.

checkthe pump lf assistimproves, flow control volve lor internal leak' ing, and clean or replace as (seepage 17-98). lf the necgssary valve is OK, replacethe steering

lI assist does nol improve,check tluid pressure, using power steering pressure gauge with shut off valve closed(seepage 17-78).

Fluid pressurebelow 7,000 kPa (7O kglcm2, 995 psi).

Fluid pressure7,00O 8.O00 kPa l 7 o - 8 0 k s l c n ' . 9 9 5 - 1 .1 3 8 p s i ) .

Checkthe pump flow controlvalve Ior internal leaking,and clean or replace 6s necessary {see page 17-98). lf the valve is OK, replace the pumP.

The pump is OK. Measurethe force requiredto turn the wheel with the speed sensor hose plugged and the car parked (see page 17 79).

Steering effort above30 N (3.0 kg, con' 6.6 lbs)- Check the pressure trol valve for stickingor a clogged orifice; clean or replacethe valve (seepage 17'107). lf as necessary the pressurecontrol valve is OK, checkthe pinionpin for free move_ ment. lf seizedor bindingoverhaul the steeringgearbox,

Steering effon below 30 N (3.o kg, speed 6.6 lbs).The power steering internallyi replace sensoris leaking the power steeringspeed s€nsor ( s e ep a g e1 7 B 0 ) .

(cont'd

17-25

(PowerSteeringSystem) Troubleshooting
GeneralTroubleshooting(cont'd)
Beltslipping the pulley. on Replace Adiustthe belttension. (seepage the belt,iJ necessary 17-141.

Checkgaincontrolvalve;clean or replace gaincontrol the valve or valvebodyunit.

ldle speed low or erratic.

lI the engine stallswhen wheel is turnedwhilecar is stopped or movingat low speed, adjustidle speed(seefuel section).

rough ataering.

Air in reservoirtank, o. low powersteering lluid level.

Check power steeringfuid level, lf levelis excessivelylow. check for leaks in the system. Add tluid to the soecitiedlevel.

It fluid levelis OK, check O-rings and sealson both ends ot the pump inlet hose, and the oil pump housingmatingsurfaces tor suctionleaks.ReDlace Darts as necessarv.

Adjustthe rackguide(seepage 1 7 75 r ' .

lf the rack guide adjustmentis OK, check the pinion bearings for wear or damage. Replace them as necessary.

7-26

Pump belt slipping on pulley (pump stops momenlarily). Shock or vibrationwhen wheel turned to tull lock.

(seepage Adiustthe belttension 17-74)or replace belt.

pressure Set the powersteering gauge.Closethe shut-offvalve fully and measurethe pump (seepage17 781. p.essure

The pump pressure should be 7,000 8,000 kPa (70 80 k g / c m ,9 9 5 - 1 , 1 3 8p s i )w i t h , needle fluctuation of t 5OO k P a ( t 5 k g / c m , ,a 7 0 p s i )o r l e s s .l l t h e n e e d l e l u c t u a t i o n f exceeds :t 5O0 kPa (t 5 kg/cm' ,:t 70 psii checkthe f l o w c o n t r o v a l v e ,o f t h e J l o w l controlvalve is OK, replace the pump.

Assist (excessively light steering)at high speed:

Measure force required turn to wheel with bypass tube joint installed, and car parked on dry paved surface (see page 17-80).

lf below, check gain con trol/pressure control valves and valve body unit and replace parts as necessary.

Adjust the belt tension (see page 17 74l' or replacebelt.

Steering kicks back during wide turns.

Sticking gain control valve or valve body unit.

Replace the gain control valve or valve body unit.

Rackguideadjustedtoo loose.

Adjust the rack guide (see page 17 751.

Wheel will not return shoothlv.

Readjust front wheel align, the ment or replace parts as necessary.

1 7- 2 7

(PowerSteeringSystem) Troubleshooting
Noiseand Vibration
NOTE:PumDnoise in first 2-3 minutesafter starting in cold weather (-2o'c, -4oF or colder)is normal

when wheel is turned of Hummingdue to pulsation fluid is normal,particularly wilh car stopped. lf equipped with autolnalic the transmission, hum couldbe torque converter or pump noise,
High p.€ssure lrame. line touching lhe

Confirm by temporafily removrng pump bert.

R e p o s i l r o nl h e f i n e .

Pinion shaft seal nol lubricatod Horn contact nol lubricaled, or
Grease the conlacl, or bend rl to reduce tne pres3ure.

"clunk" maY bo e notmal amount of linkageclearance' To NOTE: A sangte this lyp€ ol clunk, turn th€ wl|€el back and lorth with lhe engineOFi distinguish Tighten or replace pulley ll sh6lt is loose, raplacelh€ pump.
Check and tighlen, or teplace gans

Loosc pump pull€y.
Rattle or chr(e.ing Loos6 sleerinO shtfl conn6ctor, ti6_ rod, or ball pant.

Columnshaft wobbling.

the Replace columnassemblY.

Lines or hoses from the valve bodY unit louching each other. Noise from valve body unil.

Pump gea. norse

NOT€: Pump noise up to 2-3 mrnutes afler starting in cold weather (-2OoC, -4oF or colde.) Compere pump norse at ope.atrng lemperalure to another car

loud, lf pump noise is abnormally check the pump ball bearingand any parts.(seepage 17-102).
Check llurd level l l l o w , f r l l r e s e r v o r rl o p r o p e r l e v e l . and check for leaks Trghten or replace as necessatY

Gratrngdorselrofi pump

Check lo. crushed suclron hose o. a loose hose clamp allowrng ar Inio Trghten of replace as necessary

17-28

Fluid Leaks
NOTE: When tluid leaks lrom one side of the rack the balance tube transfers the fluid to the other side, giving the appearance that both sides are leaking. To troubleshoot, remove both boots, clean the rack and locate the leak.

Bemove the 4 way valve and inspect the 11 mm O-ring and rhe port housing bore for pits, burrs or s c r a t c h e s( s e e p a g e 1 7 1 0 7 ) . Repair as necessary.

Resealgearbox and inspect the rack sealingsurfacebetweenthe steeringrack piston and the righl
e n d { s e ep a q e 1 7 1 1 7 ) .

lf no abnormalrty is found, replace the O ring, reseal the gearbox and Inspect the steeflng rack seaiing surface lor burrs or scratches be tween the steenng rack gear teelh and the piston. Inspect the seal re tainer bore in the gearbox housing for proper chamfer and sharp e d g e s ( s e ep a g e 1 / 1 1 7 1 .

Trghten attachrng bolls or replace valve body or port housrng. Sreeflng gearbo'(
Leaking l.om erlher side of valve

Replace all valve body unit seals and O-rings.

Replacethe valve body.

Replace the front seal.

Pump housrng leaks et €ither end

Replace housing O rngs. ll lhe housrng st|ll leaks, replace the pump

Leaking from around cap,

R e s e r v o i ro v e r l i l l e d Pullolt the hose and drarnto proper

Air leak in s€4r,.

lhrgh pressure)

LO\/vpfessure hoses

Lealrng because ol damage, delefioralron, or rmproper as.

Replac€or repar as necessary

Tighten connector. lf still leaking. the prpeor vaive bodv unrt.

Leaking at gearbox connection {at O ring jojnt).

1 7- 2 9

Troubleshooting(4WS)
ComponentLocation
NOTE: The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode number betore - Disconnecting battery. the - Removing the No. 43 CLOCK.RADIO (1O Al fuse. - Removingthe radio. After service,reconnectDowerto the radioand turn it on. When the word "CODE" is displayed,enter the customer's 5-digit code to restoreradio operation.

CLOCK,RADIO(10 AI FUSE UNDER'HOOD BOX FUSE/RELAY

ANGLE REABMAIN STEERING SENSOR

ABS CONTROLUNIT

REARSUB STEERING ANGLESENSOR FRONT MAIN STEERING ANGLE SENSOR

REARACTUATOB UNDER,DASH BOX FUSE/RELAY VEHICLESPEEOSENSOR

{vss)

ANGLE FRONTSUB STEERING SENSOR I2P} CHECK CONNECTOR SERVICE Behindthe cenler console

No. 22 4WS tto Al FUSE

17 -3 0

Connector Locations

UNIT CONNECTOR ABS CONTROL TERMINAL UNIT POWER 4WS CONTROL G 503 \ 4WS CONTROLUN|T CONNECTOR {4p)

4WS CONTROL UNIT CONNECTOR {18P) SPEED SENSOB VEHICLE CONNECTOR I3P)

CONTROL UNIT CONNECIOR I12PI

SERVICE CHECKCONNECTOR {2P} Behind the conler console.

1 7- 3 1

(4WS) Troubleshooting
CircuitDiagram
UNO€R.HOOD FUSENELAY BOX
wffi--------*-No. FUSE 23
FUSE LABELNAME

ECU F/C MIRNOR

METER
1WS

UNDER-OASH 80X FUSEiRELAY

LIGHT SYSTEM CI'IARGING

IGNITION SWITCH l|G1l

VEHICI.E SPEEDSENSOR

GRNETD

41., ,ro* \ ll^ ,/ LEVEL
STEERING REAR STEERING FRONTSUB SUB ANGLE SENSOR ANGLE SENSOR

*1- swrcr
A -= G301

-+YELtsLU V'/HTALU€BLK+YEUBI( B[K/r{HI------OGRY

ANGTE SENSOR SITIRING FRONTMAIN

WHTELU-.+GRYmt
---.€BLK GRY/BLK

*l
SENSOR AMNGLE MAIN SIIERING REAR

cIr

GO2 G101

17-32

SERVICE CHECK CONNECTOR IGNITION SW]TCH l|G2) ABS CONNOL UNII
IGRt{nED

l--':*ln'"-Io'j
J91,v116g

(lL PARKTNG ,

rr\

anlxeY'

IWSCONTROL UNIT POWER TERMINAT

I8PCONNECTOR 1 4 7
U

12P CONNECTOR 1 9 20

21 27 28

23

10

't2

1 4 1 5 16 1 7 1 8

IWS CONTIOL CONNECTOR UNIT

interiorside

17-33

(4WS) Troubleshooting
Arrangement UNITTerminal 4WS CONTROL
(AI 18P CONNECTOB (B) 12P CONNECTOR (C) 4P CONNECTOR TERMINAL POWER ID}

l

2 10

3

4

5

6

7

8

192 0 24 2 5

22 2 3

13 14 1 5 16 17 18

26 1 , / 2 8

View from controlunit terminalside

concon_ necror necror No.

Check W i r ec o l o r name Termanal Measurement condition
While the wheel is being rotated slowly Engine ON

Normal voltage 5V-OV Batteryvoltage. O V 5 V-O Battery voltage O V O V 5V-OV O V
Battery voltage

Measuremt termimals 1- 2 4 2-24 3-24 4-24

G R Y / R E D R e a rr i g h tp u l s e

2 3

WHT/BLU GRY/WHT BLK/YEL

Charge Rear left pulse
lgnition 2

EngineOFF While the wheel is being rotated slowly IG SW ON IG SW OFF, ACC, START IG SW ON While actuatormotor is runningslowly
Light ON

5
6 1

RED WHT/GRN PNK GRN

Rearmain steering angle sensorground Rearmain steerang angle sensorA phase
Warning 1

5 -ground 6-24

Lisht OFF While steeringwheel is being rotated slowlY Short Open While steeringwheel is being rotated slowlY While actuatormotor is runningslowly ON
OFF

I
I

Front main steering angle sensorA phase

5V-OV

8-24

OV 5V(AT:1lV)

10
1 1
1')

B R N / W H T Service check signal

10-24

BLU
BLU/GRN

Front main steerlng angle sensorZ phase Rearmain steerrng angle sensorB phase

5V-0V 5V€OV
O V Battery voltage

12,24

13
14
I D

G R N / R E D Parking brake

1 4- 2 4 15,24 16-ground 1 7- 2 4

YEL/RED
BLK

Front main steerlng angle sensorB phase Ground2 Rearsub steering anble sensorcenter

While steeringwheel is being rotated slowlY IG SW ON Analogtester DC range At all times

5 V-0
O V approx. 2 . 5V Battery voltage

17 18

GRY/YEL

WHT/YEL I Back up Power source

18- 24

s w i t c h ,A C C :accessory{'l position)

17 -34

18P CONNECTOR IAI 1

12P CONNECTOR IB} 7

CONNECTOR {c)

3 t0

4

6
1 4 l 5

t9 20
24 25 26

21 2 2 2 829

12 1 3

16 17 18

ffi Eqql
Ch e c k Normal voltage

View from control unit terminalside

interior side

connector

connector No.

Wire color

Terminalname

Measurement condition While front wheel is being rotated slowly While actuator motor asrunningslowly Analog tester AC range Analog tester AC range
Light ON Light OFF

Measuremt rermtmats

'19 20 21

ORN GRN

Vehiclespeed sensor Rearmain steering angle sensorZ phase Front sub steering angle sensor left Front sub steering angle sensorright Warning 2 Ground 1 lgnition 1 Front sub steering angle sensorcenter

5 V*O 5 V.,O
Left CenterrRight

19-24 20 24

YEL/BLK YEL/BLU

s.ovT2svb.o v
Left O V Battery voltage O V
Baltery voltage Right

21 26

2 . OV 2 . 5 V 3 . 0 v

22 26
23
24

23
B

PNK BLK

24
gtound

24 25

IG SW ON IGSW ON I G S W O F F ,A C C
Analog tester DC range

YEL/RED
YEL/GRN

O V
approx. 2.5 V

25 24
)6 ?4

27 2S 29 GRY/BLK
GRY Rearsub steering angle sensorleft Rearsub steering angle sensorright Analog tester AC range Analog tester AC range
Left Cen! Right

2 . OV 2 . 5 V
Left

3 . 0v
Right

2A 17 29 17

3 . 0v 2 . 5V 2 . OV

31 32 YEL
34 BLU Damper Damper Motor power source power (motorl ground Motor terminal
Start the engine

Resistance range Disconnect4P connector. Start the engine At all times IG SW ON

Continuity Momentarily open, no conI|nutry Battery voltage

33- 34
control untt Iermtnal ground ground ground

WHT
FI

A B C

BRN RED

O V O V Battery voltage

D

D

BLK

Motor terminal

D -- ground

The normalvoltage is the value when the system is working properly.

17-35

Troubleshooting(4WS)
Diagnostic Trouble Code(DTC)agnOSIlC I rOUOle UOOe tu I l-f
To display the DiagnosticTrouble Code (DTC)
( 1 ) Pullout the servicecheck connector(2P) locatedbehindthe centerconsoleand connectthe two terminalsof the connectorwith a iumper wire.
(3 DATA LINK CONNECTOR P)

NOTE:
Do not attach the jumper wire.

,-->,/
' _ \

JUMP€R

SERVICE CHECK coNNECIOR (2Pt

(2) Turn the ignitionswitch ON. but do not start the engrne.

( 3 ) Watch as the 4WS indicatorlight blinksto displaythe code
{4) Recordthe codes. NOTE: a Be sure to recordthe code. lf you do any oI the following, the code will be erased. - Disconnect the battery terminals - RemoveNo. 43 CLOCKRADIO (10 A) fuse from the under-hood fuse/relaybox - Disconnect the 4WS control unit connector. IndicatorLamp (MlL) will stay on a It the engineis started with the serviceconnectorjumped, the N,lalfunction pattern DTCindication Main - sub
V.fv6 chock t+ #12, o.g 0.4 t--0.8 #22 o.g o.4 --,

--+' l'.""i11,n"i""
signsl 3.0

sub *

5'u" --"

Main
12

F-#22=,

t<-#

0.8 0.4 0.8 0.4 light can displaymultiplecoma light displays code by a seriesof long and short blinks.This indicator The 4WS indicator ponent problemsby blinkingseparatecodes,one after another.The numberof long blinksequalsthe lirst d;git of the code. the numberof short blinksequalsthe seconddigit. When there are multiplecodes,there is a two secondpause betweenthe codes. in units (CPUS) the 4WS control unit System problemscan be detectedby both the main and sub centralprocessing Each CPU can memorizeup to 1O codes. lf both CPUshave stored codes, the 4WS indicatorlight will: a Blink quickly once as an indicatorlignt check, (this happensonly when the ignitionswitch is first turned on). a Pausetor three seconds. a DisDlav the codes stored in the main CPU. a Pausefor 1.6 seconds. a Blink rapidlytor three secondsto indicatethe switch betweenthe main and sub CPU. a Pausefor 1.6 seconds. a Displaythe codes stored in the sub CPU. a Pausefor three seconds,then repeatthe cycle. This cycle will continueuntil the ignitionis turned OFF. NOTE: a Be su.e to check both CPUsfor at least 10 codes betoreturning OFF the ignitionswitch a lf the main and sub CPUSdisplaythe same codes,those codes need only be checkedonce.

7-36

Precautions
DiagnosticTrouble Code (DTC):
even if it was a temporarycondition.To The DTC is memo.izedwhen the 4WS control unit detects an abnormality, light cameon, and try to duplicate when the 4WS indicator troubleshoot, the customerin detailaboutthe conditions ask duringthe test drive.lt the 4WS indicatorlight does not come on duringthe test drive,do not continue those conditions procedures assumethat the symptom is occuning. the to troubleshoot; system is OK at this time, The troubleshooting Check for loose connections poor contacts at the connectorsby wigglingthe harness.etc. or

in on lightcomeson when the 4WS controlunit detectsa problem the system.Depending the problem, The 4WS indicator by the 4WS indicatorlight may be canceled turningthe ignitionswitch ofl, or it might requireremovingthe CLOCK,RAfuse/relaybox. It a problemis detectedin the main steeringangle sensorsystem, DIO (10 A) tuse in the under-hood you must removethe CLOCK,RADIO{1O A) fuse to cancelthe 4WS indicatorlight. lI a problemis detectedin any other part of the system, turningthe ignitionswitch off will canceithe 4WS indicatorlight. of NOTE: It the 4WS light comes on because a temporaryproblemin the main steeringanglesensorsystem, it cannot be canceledby simply removingthe causeof the problemand cyclingthe ignitionswitch; the CLOCK,RADIO (10 A) fuse must be removed. The 4WS indicatorlight does not come on when the DTC is 71 , 72, ot 73. However.the 4WS indicatorlight will flash these codes when the servicecheck connectoris iumoed.

TemporaryDriving conditions:
it harshor abnormal conditions, 4WS controlunit interprets as a problem the underextremely Whenthe vehicleis operated the DTC. and memorizes

DTC

Operation The ignitionis turned from OFF to ON while driving. on with the driver and three passengers The car is driven aggressively board. or the steeringwheel is turned with a rear wheel blocked by the curb, etc.
The engine is started while quick-charging the battery.

4WS IndicarorLight ON

70
71

74

Drivingthe car with the parkingbrake ON.

ON 5 minutes after detection

Fail-safe control:
When the fail-safe conditions are met, the 4WS control unit stops the 4WS control and returns the rear wheels to the straight driving position slowly.

17-37

Troubleshooting(4WSl
Symptom-to-SystemChart
FAIL SAFE(F/S)ITEM
l5
F

AFFECTED

l F

z a
-LE o t

z 3;
F14

It

z
F X

c 4
t--

= .rr nr T
zz. A H > ;
riz

t z ; o
Z

i

z
f

tr9
o:l z ,,,
F

& z
F

I > o

l

(r o
F f

F

-'z ) a

o z o
c F C) c0

o
E F

t
F IE F E

z i

36
O O

z -

6 =

;E
7 +23
18 25 2

z = i z i z tr< t <

> 6 Eul [ <

a=

t-z crii'i

= z

z
(J

t-

2 o

ACTION

<(r

nfr

o l(l. < D < i aa E t1) t a

2=,

< 3 #A 5

2e R+

z
lr F

(, =

NO code

o o

Go to trouble shoo!ng
Go to trouDte snoorng

No code

o

o

1 74 2

10

FRONT

22

Go to

o

o

o
snoorng Go to

1 14 5

1t

REAR

17

o

o

a)
snoorng
Go to trouole snooflng Go to trouble snooflng Replace

1750

FRONT

o
11

o

1 74 5

REAR

o v,
14 FRONT

2a

c)

o

1750

(, z
(9

o
Replace

z tr
F

REAR

o
trolunrt

at) l

16

FRONT

22 26 21

Go to

o o

o
shootrng Go to trouble snoorng

1t 45

17

REAR

17

O

,-l

17 50

2a

18

Repiace 4WScon

17-38

(F/S)ITEM FAIL-SAFE
(9

4 (E
lDz F q

z ) i z

tr<

rroLrble- 17 59

Go to

1 7- 3 9

Troubleshooting(4WS)
Chart (cont'dl Symptom-to-System
FAIL-SAFE {F/S)ITEM
(9
F

AFFECTED

l E F F p tD F^

z i l o -.lE o l E Z
F

=

o =
t;i

(9 2

= ;o ;o
t z

t z
I l

t z ) o
F

E F l F

F

o
F E

l5

z,,, <5
o(J

2za x
;fr

@ z Ful Z:! i z

-'z

o - z
E"'
E

z.z t z ) <1, < = = 6

z o
co

z o
O

o < E

F

o

z

tr< aa<E <

s:

z i O ltr . TL

<tr

*E

^ 3 < ;5 P $ E

la iE

z

E d) (9

z 2 o

ACTION

4

z
cc
E

i

33

REAR R/L

3
'l

o

o

o

Go to trouble- 1 7 - 6 8 snoorng

34

o

FRONT

19

o o o o o

o o o o

o

Go to

17-63

REAR L
I

3
I

17-64

=

REAR R

o

17-66
shooting

37

REARL

Replace 4WS con-

VEHICLE SPEED

o o o o o

Replace 4WS con trol unrt

40

CONTROL UNIT CONTBOL UNIT

41

42 43
44

L z :) o F z o o =

CONTROL UNIT

UNIT

o
UNIT

45

UNI-T
4WS CONTROL UNIT

o o
C +

46

o o

o

a

Go to

1770 1 7- 7 1

z o 5 t 6

C + D _

o

o

17-40

Go to trouble' shooting

11-11

1 77 1

1 7- 4 1

Troubleshooting (4WSl
4WS IndicatorLight Circuit
4WS CONTROL UNIT 18P/12PCONNECTORS The 4WS indicarorlight does noi como on whon ignition switch is first turned ON.

Connect

View from terminal side.
Turn the ignition switch ON and pull the parking brake.

Does the brake indicator light

f c h e c k t h e N o . 1 3 M E T E Ru s e 1 1 0A ) i n t h e u n d e rd a s hf u s e k e '

ls the luse OK? No. Connect 4WScontrolunit the and No. 23 ter7 terminal(PNK) minal(PNK) wire to body ground.

Reolaceth€ fuso and rocheck.

ReDairopen in the YEL wire b€ tuso 110 tw€€n rhe No. 13 METER Al .nd the 4WS indicator light.

Does the 4WS indicator light

Reolacerhe 4WS control unft.

The 4WS indicator light does not go oft alier stariing €ngineand no DTC is shown.

Start the engine and check the charging system light.

Does the light go off?

Turn the rgnrlronswitch OFF.

RADIO Checkthe No. 43 CLOCK, fuse (10 A) in the under_hood

ls the fuse OK?

Reolace the fuse and recheck,

{ T op a g e1 7 4 3 )

17-42

lFrom page 17-42)

Checkthe No. 22 4WS luse (10 A) in the undeFdashluse/rel8y box.

ls the fuse OK?

Replacoth. lulc 6nd rochock.

checktheNo.I R/c MlRRoRluse (15 Alin theunder-d8sh fuse/retayDox.

Roolacotha fula and rochock.

Disconnect 4WS controlunit thg 'l8P connector and 12P connector.

Repalrihort in tho Pf{K wlrc! b6tw6en tho 4WS cont.ol unit and tho indicrtor light.

Connect lhe 4WS contiol unit 18P connoctor and 12P con' nector,

UNIT 18P CONNECTOR 4WS CONTROL

8aft6ry Voltsgo? Measure voltage between the 4WS controlunitNo. 18 terminal (WHTrY€L)and body ground. Ropalrop.n in WHT|'EL wlro botwcon tho 4WS control unit .nd undor-hood fuaa/rolay bor.

ls there bsttery vollage?

{To page 17-44}

(4WS) Troubleshooting
4WS IndicatorLight Circuit (cont'd)
(Frompage 17-43) 4WS CONTROLUNIT CONNECTOR 12? Measure voltage between the 4WS control unit terminals:No. '|8 (WHTryEL) and No. 16 (BLK), and botw€enNo. 18 (WHT,ryEL) and No. 24 (BLK). Ropairtho poor ground lcso'l) o. oDon in BLK wir6 bolwesn tho 4WS control unit and body ground. Turn the ignitionswitch ON.

View lrom terminalside

Measure voltag€ between the 4WS controlunit No. 25 terminal (YEL/RED) body ground, and wlr6 Reprir op6n in tho YEL/REO b€tw6€n the 4WS conlrol unh and und€r-d6ahfuse/rolav box. 18P Measure voltage betwe€n the 4WS control unit No. 4 terminal and body ground, {BLK/YEL) Ropairopen in tho 8LK/YELwir6 botwoon tho 4WS control unit and tho under-dashtusoholay box.

ls there battery voltageT

4WS CONTROL UNIT CONNECTOR 12P

v

V ) Bsttory
View from terminal side.

ls there battery voltage?

Measure voltage between the 4WS controlunit No. 2 terminal and body ground. {WHT/BLU) Ropairop€nin th6 WHT/BLUwir6 b€twoon tho 4wS conttol unit and tho undor-dashfuso/rolav box. Roplacoth6 4WS control unit.

Diagnostic Trouble 10, 12, 16 Codes(DTCs):
-Thc 4WS indicoro. light has boan roDortodon. -With sorvico ch6ck conn6ctor irmpod codos 10. 12, 16 610indlc.tcd.

Disconnectthe front sub steering anglesensorconnector,

Measur€resistancebetween the No. 1 terminal {BLK)and No. 2 ot terminal{WHT/BLU} the sensor side connector.

l s t h e r e8 . 4 - 1 2 . 2 O ?

Measureresistancebgtween the and No. 2 terminal {WHT/BLU) No. 3 terminal(BLKMHTI ot rhe senaor side connector.

ls rhere8.4- 12.2O?

ANGLESENSOR FNONTSUB STEERING SENSONAIDE CONNECTOR

Checkfor continuity between the sensor side connsctor No. I te.minal (8LK)and body ground.

Continyity? 8.4-12.2 A? View from terminalside.

Turn the ignitionswitch ON.

(To page '17-46)

1 7- 4 5

(4WSl Troubleshooting
DiagnosticTroubleCodes {DTCs): 10, 12,16 {cont'd)
lFrom page 17-45)

Measurethe voltsge betweenthe 4WS control unit side of the ssnsor connector No. 1 torminal (YEL/BLK)and body ground.

ANGLESENSOR FRONTSUB STEERING UNIT SIDECONNECTOR 4WS CONTROL

i+_I-} /J\ z.svr Y
View from terminalside. Disconnect 4WS controlunit the 12P connector. SIDECONNECTOR UNIT 12P SENSOR 4WS CONTROL

2.5 ls there approximat€ly V?

Checktor continuity between the 4WS controlunitNo.21 terminal and body ground. {YEL/8LK) Vi€w from terminalside. R.o.li short in the YEL/BLKwire botwoontho 4WS controlunil and tho front sub steering angle sonsor.

Connect the 4WS control unit 12P connector. UNIT 12P CONNECTOR 4WS CONTROL Measurevoltag€between the No. 21 terminal{YEL/BLKI the 4WS ol control unit and body ground.

2.5 ls there approximarely V?

R6plac6 the 4WS conlrol unit.

lfo page 17-471

Ropairop6n in tho YEL/BLKwiro botwoon tho 4WS control unit and th€ tront sub stooring anglo 30nsot.

17 -46

(Frompage 17-46)

Measurethe voltage belween the 4WS control unit side of the sensor connector No. 2 terminal and body ground. IYEL/GRN)

ANGLESENSOR FRONTSUB STEERING UNIT SIOECONNECTOR 4WS CONTROL

rlTf-\ w
(V) 1 25 v?

Y
View from terminalside. Disconnectthe 4WS control unit 12P connector. SIDECONNECTOR 4WS COI{TROL UNIT 12P SENSOR

1.25 V? ls there app.oximately

Checktor continuity between lhe 4WS controlunit No. 26 terminal and body ground. {YEL/GRN)

Continuity? View trom terminalside.

Ropairshort in the YEL/GRNwire botw66n the 4WS control unit and tho sub steeJingangle sensor.

Connect the 4WS control unit 12P connector. UNIT 12P CONNECTOR 4WS CONTROL

Measur6 voltage betwoen the 4WS controlunitNo. 26 terminal and bodv ground. {YEL/GRN) View from terminalside.

1.25 V? ls there approximatoly

Rool6c6the 4ws control unit.

{To page 17-481

R6pai opon in tho YEL/GRN wire borwoon tho 4ws contol unit and tho front rub staering anglo aonaot.

17 -47

Troubleshooting(4WS)
DiagnosticTroubleCodes (DTCs):10, 12, 16 (cont'd)
lFrcnr,page 17'471 ANGLESENSOR FRONT SUB STEERING 4WS CONTROLUNIT SIDE CONNECTOR

Messurethe voltage betweenthe 4WS control unit side ol the sensor connector No, 3 terminsl(YEL/BLU) body ground. and

( v )2 . 5 V l

:r

View from terminalside.

2.5 ls lhere approximately V?

Disconnectthe 4WS control !nit 12P connector, SIDECONNECTOR UNIT 12P SENSOR 4WS CONTROL

Checkfor continuity between the 4WS controlunit No. 22lerminal (YEL/8LU) and body ground. View from terminalside. Ropai.shorl in the YEL/BLUwiro b,6two6nth6 4WS contiol unh 6nd 3ub stooring 6n9lo sonsor.

Connect the 4WS control unit 12P connector. 4WS CONTROLUNIT 12P CONNECTOR

Measure voltage between the 4WS controlunitNo. 22 terminal (YEL/BLU) and body ground.

View trom terminalside. ls there approximately 2.5 V? Raolac6tho 4wS control unit.

(To page 17 49) Rop6iropon in tho YEL/BLUwiro botrYoontho 4WS control unh ald the front sub 3t66ring angl6 sonsor.

17 -48

(Frompage 17-48) 4WS CONTROL UNIT 12P CONNECTOR

Conneclthe front sub steeringangle sensorconnector. List6d Voltage? View from terminalsideFRONTSUB STEERING ANGLESENSOR TERMINALVOLTAGE IREFEBENCE}

STEERING WHEEL P0stTt0N
Whileturningthe steering wheel, measure voltagebetweenNo. 22 (YEL/BL|) and No. 26 (YEL/GRN) terminalsol the 4WS control unit usingAC rangeof analogtester.

LEFT approx 2 . OV

CENTER approx 2 . 5V

RIGHT approx

Voltage

3 . 0v

Analog tester AC range

Does voltage change as shown in the table?

Check the neutral point of the front sub steeringanglesensor. { s e ep a g e1 7 1 4 6 ) .

ls the neutralpoint OK?

Adtust the noul.al point ot tho troni 3!b steering sensor.

ReDlacoth6 4WS control unit

17-49

Troubleshooting(4WS}
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7

-Th6 4WS indicator light has boon toDorled on. -With sorvic6 chock connoctor 'l7 are iniumpod cod6s 1l, 13, dicatod.

ANGLESENSOR REARSUB STEERING SIDECONNECTOR SENSOR l|l 12.3Lua\ lr /^\ Ir,/ \"/ \ ..r/ Continuitv?
/z\ -r_

Disconnectthe rear sub steerang anglesensorconnector.

ur\u \"/

/-\rFP

a . 4 - 1 2 . 2A ? +
View from terminal side.

Measure resistancebetween the No. 1 terminal {BLKMHT), and oI the No. 2 terminal{WHT/BLU} connector' th€ sensorsade

l s r h e r e8 . 4 - 1 2 . 2 0 7

Measure rosistancebetween the and No. 2 terminal (BLK,ryVHT), th6 No. 3 terminal (BLK)of the sensor sadeconnector,

l s t h e r e8 . 4

1 2 . 20 ?

Chock for continuity between the sensorside connectorNo. 3 ter minal (BLK)and ground.

Turn the ignitionswitch ON.

llo page r /-5l l

17-50

lFrom page 17-5Ol REAR SUB STEERING ANGLE SENSOR 4WS CONTROL UNIT SIDECONNECTON

r-Ffi-r
Measurethe voltage bGtweenthe 4WS control unit side of the sensor connector No, 1 terminat (GRYI and body ground.

(V) z.svz Y
View from terminalside.

ls there approximately 2.5 V?

Disconnect 4WS conlrolunit the 12P connector. 4WS CONTROL UNIT 12P SENSOR SIDECONNECTOR

fl-ll
Check for continuity between the 4WS controlunit No. 29 terminal (GRY)and body ground.

wrl
I
YES

rarfT l

continuiry

View from terminal side.

RoDairshort in the GRY wiro between the 4WS control unit and the rearsub steeringanglesonsor.

Connect the 4WS control unit 12P connector. 4WS CONTROL UNIT 12P CONNECTOR

Measure voltage between the 4WS controlunit No.29terminal (GRYIand body ground. View from terminalsrde,

ls there approximately V? 2.5

fio page 17-52l, R6pairopon in tho GRY wir6 b6twoon the 4WS control unit and tho roar sub stooring anglo aonsor.

17 - 5 1

Troubleshooting(4WSl
T D i a g n o s t i c r o u b l eG o d e s( D T C s ) :1 1 , 1 3 ' 1 7 ( c o n t ' d l
( F r o m a g e1 7 - 5 1 ) p ANGLESENSOR REARSUB STEERING UNIT SIDECONNECTOR 4WS CONTROL

Meas!re the voltage betweenthe 4wS control unit side of the sensor connector No, 2 terminal wire and body ground. {GRY|Y€L)

1.25V?

View lrom terminalside.

'1.25V? ls there approximately

Disconnectthe 4WS control unit 18P connector. SIDECONNECTOB UNIT 18P SENSOB 4WS CONTROL

Check for continuitv between lhe 4WS controiunit No. 17 terminal and bodv ground. {GRY/YEL)
View from terminal side.

Reoahshort in the GRY/YELwire betwoontho 4WS conttol unit and anglesensor. the rearsub stG€ring

Connect the 4WS control unit 18P connector. UNIT 18P CONNECTOR 4WS CONTROL

Measure voltage between the 4WS controlunitNo. lTterminal (GRY/YEL) body ground. and View from terminalside. '1.25V? ls there approximatelv Roolaceth6 4WS control unit.

(To page 17-53)

Ropairopen in the GRYI/EL tYire b6lwo6n tho 4WS control unit and tho roar sub steoring englo sonsor.

17-52

(Frompage 17-52)

REARSU8 STEERING ANGLESENSOR 4WS CONTROL UNIT SIDECONNECTOR (3.1 I !

M€asurethe voltage betwoen the 4WS control !nit sido of the sensor connector No. 3 terminal (GRY/BLK) and body ground.

(V) z.svz Y
View trom terminalside

ls there approximately 2.5 V?

Disconnect 4WS controlunit the 12P connector, SIDECONNECTOR UNIT 12P SENSOR 4WS CONTROL

Checklor continuity between the 4WS controlunir No. 28 terminal and body ground. {GRY/BLK)

Repai. shon in the GRY/8LK wiro hw€6n the 4WS controlunitsnd tho rotr sub st€oringanglosonsor.

Connect the 4WS control unit 12P connector,

4WS CONTROL UNIT ,I2P CONNECTOR Measure voltage between the 4WS controlunit No. 28 terminal and body ground. {GRY/BLK)

View from terminalside. ls there approximatelv V? 2.5 Reolace4WS control unit.

{To page 17-54)

Ropairop.n in tho GRY/BLKwire between $€ 4WS control unit and th€ roaasub Stseaingangle sensor.

17-53

Troubleshooting(4WSt
Diagnostic Trouble C o d e s( D T C s ) :1 1 , 1 3 , 1 7 { c o n t ' d )
(Frompage 17-531 UNIT'I8Pi12P 4WS CONTROL CONNECTOR Connectthe rear sub steeringangle sensor connector-

TERMINAL VOLTAGE ANGLESENSOR REARSUB STEERING (REFEREI{CE)

While turning the steering whool voltagebetweenNo. and measure and 17 lGRY,ryELl No. 29 (GRY) terminalsof the 4WS controlunit using AC range ot an analog tester.

WHEEL STEERING P0stTt0N Voltage

LEFT
approx

CENTER approx 2.5V

RIGHT approx 2 . OV

3 . 0v

Analog tester AC

Doos voltage change as shown in the table?

Checkthe neutralpoint ot the rear sub steering angle sensor (sse page 17-1461.

ls the neutral point OK?

Aqu3t dre iratural point of tt|€ tolr aub ltoailng aanlor.

Replacotha 4WS control unit

17 -54

DiagnosticTroubleCodes (DTCsl: 20, 22, 24,28
-Th6 4WS indicator light has bggn reDortodon. With service chock conngctot iumpod codes 20. 22, 24. 28 are indicated. Disconnect front main steerthe Ing anglesensorconnector, Turn the ignitionswilch ON. Measure voltage between the 4WS controlunit sideconnector No. 1 terminal {BLK/YEL} and body ground. Ropair op6n in th6 harnoss wiro betwoen tho No. 22 4WS tuso and tho tront main stoering angle sonsor. Measurethe voltage between the 4WS controlunit sideof the senNo. 4 terminal(LT sor connector GRN)and body ground.

ANGLESENSOR FRONTMAIN STEEBING 4WS CONTROL UNIT SIDECONNECTOR

BsnoryVoltago?

View from terminalside.

ANGLESENSOR FRONTMAIN STEEBING 4WS CONTROLUNIT SIDE CONNECTOR

fT-fFlt -X( V.)c.svr

:r

View from ierminalside.

UNIT 18P 4WS CONTROL SENSON SIDECONNECTOR Disconnectthe 4WS controll unit 18P connector.

ls there approximately V7 4.5

Checkfor continuity between the 4WS control unit No. 8 terminal (GRN)and body ground.

View from terminalside.

Rooairshort in tho GRN wiro betwoon tho 4WS control unit and th6 main ste€dng angle aonsor. Connect the 4WS control unit 18P connector.

4WS CONTROL UNIT 18P CONNECTOR

Measure voltage between the 4WS controlunit No. 8 terminal (GRN)and body ground. View from terminalside. ls there approximately V? 4.5 Roolaceth6 4WS cont.ol unit.

( T op a g e1 7 - 5 6 )

Ropah open in the GRN wiro betweon the 4WS control unit and the front main sloo.ing anglo

17-55

Troubleshooting(4WSl
DiagnosticTroubleCodes (DTCs):20, 22, 24, 28 (cont'd)
{Frompage 17-55) ANGLESENSOR FRONTMAIN STEERING 4WS CONTROLUNIT SIDE CONNECTOR

Measurgthevoltage between the 4WS control unit side of the senaor connoctorNo.3 terminal(BLU) and body ground. View from terminalside.

4.5 ls there approximately V?

Disconnectthe 4WS control unit 18P connector.

UNIT 1AP 4WS CONTROL SIDECONNECTOR SENSOR

Check tor continuity between the 4WS controlunit No. 3 terminal {BLU}and body ground. View lrom terminalside. R.Dair short in tha BLU wire b6twoon tho 4WS cont.ol unit and the main stooring angl€ aonsor.

Conn6cl the 4WS control unit 18P connector.

UNIT 18P CONNECTOR 4WS CONTROL

Moasure voltage between the 4WS controlunitNo. 12 terminal (BLU)and body ground. View from terminalside.

4.5 V? ls there €pproximatoly

Roplsce the 4WS control unit.

(To psge 17-57) Repair opon in tho BLU wiro betwoon th6 4WS control unit 6nd th6 front main stoodng anglo 30n3('t.

17-56

{Frompage 17-56}

ANGLESENSOR FRONTMAIN STEERING 4WS CONTROL UNIT SIDECONNECTOR

Megsureth€ voltago between the 4WS control unit side of the sensor connectol No. 2 t€rminal (YEL/REDI and bodyground. wire View from terminalside.

ls th6re approximat6ly 4.5 V?

Disconnect 4WS controlunit the 18P connector.

4WS CONTROL UNIT 18P SIDECONNECTOR SENSOR

Checkfor continuity between the 4WS controlunit No. 15 terminal and {YEL/RED) body ground. View from terminalside,

Ropairshon in tho YEL/RED wire botweon lhe 4WS control unit and tho main st€ering sngle s€nsor. Connect the 4WS control unit 18P connector. UNIT 18P CONNECTOR 4WS CONTROL Measure voltage between the 4WS controlunit No. 15 terminal and {YEL/BEO) body ground.

View from terminalside. ls there approximately 4.5 V? Reolacethe 4WS control unit.

lTo page 17-58)

Ropairopon in th6 YEL/REDwire botwo6n tho 4WS control unit and th6 front main sto6.ing angle aon30r.

1 7- 5 7

Troubleshooting(4WS)
Diagnostic Trouble Codes IDTCs):20, 22, 24, 2A (cont'd)
(Frompage 17-57) ANGLESENSOR FRONTMAIN ST€EBING 4WS CONTROLUNIT SIDE CONNECTOR

Check for voltage between the and No.2 terminalIYEL/RED) the No. 5 terminalIELK)of the 4WS control unit side connectorof the anglesensor. front main steering Rcpair tho poor ground lG 4Ol, 402, 4041or oDenin rhe BLKwiro botwo€n th6 front main atooring anglo 3onsor and body ground.

[T'T-TT;I
l ^

\:/

4.5 V?

View from terminalside

4.5 ls there approximately V?

Reconnect front main steering th€ anglesensor5P connector,

While turning the steeringwheel, check for the signalsbetweenthe following 4WS control unit termi' nals and the body ground with an analogvoltmoteron the DC range. A-phase: Betwsentho No. 8 terminal(GRN) and body ground: should pulse O-4.5 V rspidly {every2o) B-phas6: Between th€ No. 15 terminal (YEL/RED)and body ground: (ev pulse0e4.5 V rapidly should €ry 2o) Z-ph8se: Bgtween the No. 12 terminal IBLU) and body ground: should pulse0*4.5 V onceper steoring wheel revolution

UNIT 18P CONNECTOR 4WS CONTROL

0-4 . 5 v ? ( V ) ( V )

(V

View from terminalside

Are the signalsavailable between the resp€ctive terminal and the body ground?

Checkthe Z-phaseneutralposi' t i o n ( s e ep a g e1 7 - 1 4 6 ) .

ls the Z'phasein the straight drivingposition? YES

adjust the front main stooringanglo sonsor noutral poaition {soo pago 17-15) Srraight l revolustion A-phase o B-phase Z-phase
4.5 0 4.5

Podorm lor troublgshooting OTCa . 1 0 . ' 1 21 6 . pag6'17451. {3e6

---------------- Time

L-

17 -58

DiagnosticTroubleCodes (DTCs):21 , 23, 25,29

-Th6 4WS indicalor light hss b6on rooorlod on, -V\fth sorvica check connecto. .iumpodcod6s 21 , 23. 25, 29 ato indicatod.

REARMAIN STEERING ANGLESENSOR 4WS CONTROL UNIT SIDECONNECTOR

\\.)t t..
w \:/
I

tlt

JJ

I

Battery voltaqo?

Disconnectthe rear main steering angresensorconnector.

View from terminalside

Turn the ignitionswitch ON. REARMAIN STEERING ANGLESENSOR 4WS CONTBOL UNIT SIDECONNECTOR Measure voltage between the 4WS conlrol unit side connector No. 1 terminal (RED)and body grouno. Ropair open in thg hahoss wire bolweon tho No.22 4WS fuse and the reaamain gtoering tngla sensot.

ls there battery voltage? YES Measurethe voltage between the 4WS control unit side No.3 termi nal {WHT/GRN} and body ground.

View from terminalside 4WS CONTROL UNIT 18P SENSOR SIDECONNECTOR

ls there approximately V? 4.5

Disconnecl the 4WS control unit 18P connector.

YES
Checktor continuity belwoen the 4WS controlunit No. 6 terminal (WHI/GRN)and body ground. View from terminalside

ls there continuity? NO Connect the 4WS control unit 18P connector.

Repair short in the WHT/GRNwire betwecn tho 4WS controlunit and the main steering angle sensor, 4WS CONTROL UNIT 18P CONNECTOR

Measure voltage between the 4WS controlunit No. 6 terminal {WHT/GRN} and body ground.

ls there approximately 4.5 V?

ReDlacothe 4WS control unir.

lTo page I7-60)
I

Repairopon in th6 WHT/GRN wi.o botwoon the 4WS contol unit and the aoaa main stooring angle sensot.

J

17-59

Troubleshooting(4WS)
DiagnosticTroubleCodes (DTCs):21, 23, 25, 29 lcont'd)
{Frompag6 17-59) ANGLE SENSOR REAR MAIN STEERING 4WS CONTROLUNIT SIDE CONNECTOR Measur€the voltage betw€en the 4WS controlunit side No 4lerminal (ORN) wire and body 9rouno.

View from lerminalside 4.5 V? ls ther€ €pproximately Disconnectth€ 4wS control unit 12P conneclor. 4WS CONTROLUNIT 12P SIDECONNECTOR SENSOR

l--T--fl nr lEf-l
Checklor continuity between the 4WS controlunit No. 20 terminal {ORN)snd body ground.

ffiwx)
(p Continuitv?
View trom terminalside RoDairshon in ths ORN wiro botweon tho 4WS control unit 6nd tho .oar main stoering anglo 80n8('t.

Connoct the 4WS control unit 12P connector. 1 CONTROL,UNIT2P CONNECTOR

Measure voltage belwoen the 4WS controlunitNo. 20terminal {ORN)snd body ground

r'.l-H-tD ff
(V) +.svr

:r

View trom terminalside

4.5 V? ls there approximately

Roplacotho 4WS conttol unit

{ T o p a g 61 7 - 6 1 )

Ropairopon In tho OBN wi.c bo_ twoon tho 4WS conttol unit and the roar main 3loaring angle 30nlot.

1 7 -6 0

{Frompage 17 601

REARMAIN STEERING ANGLESENSOR 4WS CONTROL UNIT SIDECONNECTOR .-rnfla / F vl5,l,/t )

Measurethe voltage betweon the 4WS control unit side No. 6 ter m i n a l ( B L U / G R N )a n d b o d y gtouno,

( V ) a . sv r Y
View trom terminalside

ls there approximately 4.5 V?

Disconnect 4WS controlunit the 18P connector.

4WS CONTROL UNIT 18P SENSOR SIDECONNECTOR

Checktor continuity between the 4WS controlunit No 13 terminal and body ground. {BLU/GRN)
View from terminal side

YES

ReDai.short in the BLU/GRN wire betweenthe 4WS controlunit and the rear main stgoring angle sensor.

Connect the 4WS control unit l8P connector.

4WS CONTROL UNIT 1AP CONNECTOR

Measure voltage between the 4WS controlunit No. 13 terminal (BLU/GRN) and body ground.
View from terminal side

ls there approximately V? 4.5

Raolace the 4WS control unit.

{To page 17-62)

R6pai.op.n in the BLU/GRNwire botween tho 4WS control unit and tho ioaa main Stoaring anglg sensor.

1 7- 6 1

Troubleshooting(4WSl
21' 23, 25, 29 lcont'dl Trouble Codes(DTCs): Diagnostic
(Frompage 17-611 ANGLE SENSOR REAR MAIN STEERING UNIT SIDECONNECTOR 4WS CONTROL

M€asure voltsge betwson the and the No,6 terminsl {BLU/GRNI No. I terminal (RED)of the 4WS contrcl unit aide connector ot the reat main steedng angle sensor. R.p.l opcn In th. RED wir. botwocn tho 4WS cont?ol unit and tha ra.] maln ltooting anglo Itn!o1, View from terminalside

4.5 ls there €pproximately V?

Rsconngctthe rear main ateering sngle sonsot 8P connector.

While turning th€ steering whe€|, check for the signalsbetwe€nthe following 4WS conttol unit termin6ls and the body ground with an analogvoltmeteron the DC range. A-phase: Eetween the No. 6 terminal (WHT/GRN)ahd body ground: shouldpulseO-4.5 V rapidlylevery 2o) B-phase: Between thc No. 13 terminal (BLU/GRN) and body ground: shouldpulseO-4.5 V rapidly(ov' ery 2ol Z-phaae: Betwesn the No. 20 terminal IORN) and body ground: should pulsoO€4.5 V once per ste6ring wheel revolution

UNIT 18P/12P 4WS CONTROL CONNECTOR
I

O-4

. 5v ? ( V

v

ri+ffi M
(v)
Y

l2oHl

I

View from terminalside

Are the signals availablebetween lhe resDectiveterminal and the body ground?

Check the Z-phase neutral Position {seo page 17-'146).

ls the Z-phase in the straighi driving position?

Porform trouble.hooting of the DTCs 11, 13, 17. (.o6 psgo t7-501

A-phase B-phase Z-pha86

4.5

4.5 0 4.5 0

o

---------------- Time

17-62

DiagnosticTroubleCodes (DTCsl: 30, 34
vehicle speed sensor (VSS) NOTE: DTC 34 may have been memorized 4WS control unit after the using ALB checker. on It so, disconnectNo. 43 CLOCK,RADIO(10 A) fuse in under-hood tuse/relavbox to reset the 4WS control unit.
-Tho 4WS indicator light has boon roDortedon. -With aervice check connector iumpod codos 30 and 34 are indicated.

Disconnectlhe 43 fuse{'l0 A) No. in the undeFhoodfuse/relaybox.

Tesl drive the car.

Do codes 30 and 34 appear?

Sy3tom is OK at trrb tims. Inlpoct tho vohicle spoed sonso. tominal connecrots.

Does the speedometer operate properly?

(Go to pago 23-1181

Disconnect 4WS controlunit the 12P connector,

4WS CONTROL UI{IT 12P SENSOR SIOECONNECTOR

Turn the ignitionswitch ON.

Measurevoltage betweenthe No. l9 terminal(ORN) sensorside of connector ot 4WS control unit and body ground.

View from terminalside

ls there more than 5 V?

Rool6c6 the 4WS control unit lwhon tho symplom rocurrod.)

Repaii opon or short in the ORN wh€ to body ground betwoen the vehiclospeedsensorand rhe 4WS contol unil.

17-63

(4WS) Troubleshooting
(DTCs): 35 (cont'd) 31, DiagnosticTroubleCodes

-Tho 4WS indicator light ha6 boon ropott6d on. -With asivico chock connoctol jumpod codos 31 and 35 oro indicatod.

UNIT 18P CONNECTOR 4WS CONTROL

View trom terminalside Does the ABS indicator light stay ON? Go to pago 19-54 Problem in ABS rystom

Stop the engine.Then turn the ignition switch back ON.

With the loft rear wheel raisedoll ground, slowly rotate the wheel while checking {or voltage be tween the 4WS control unit No. 3 terminal{GRYMHT) and body ground. Record lhc DTC rnd clear the 4WS contiol unit. Tost drive th6 car, if th6 DTC doo3 not roaPpear, chock tho to.minal connoctions ol th€ 4WS co.rtrol unii 18P conn€c'l4P tor and tho A8s contiol unit connoctor.

Does the voltage alternate from zero to approximately 5 V?

(Topage1 7 - 6 5 )

7-64

l F r o mp a g e1 7 - 6 4 )

Turn the ignitionswitch OFF.

4WS CONTROL UNIT 18P SENSOR SIDECONNECTOR

Disconnectthe 4WS control unit connectorand the ABS control unil connector, View from terminalside Checklor continuity betweenthe 4WS control unit No. 3 terminal (GRY/WHT) and body ground. Repeir shon in tho GBY,^/HT wire bctwoon tho 4WS control unh and tho ABS control unit.

4WS CONTROL UNIT lAP CONNECTOR

Turn the ignitionswitch ON.

Measurevoltagebetween the No. 3 terminalof the 4WS control unit connectorand body ground.

View from terminal sade

ls there approximately V? 5

Rophco tho 4WS control unit. ABS CONTROL UNIT 14P SENSOR SIDECONNECTOR

Measure voltage betweon the No. 3 terminal (GRY/WHT) of sensor side connector oI ABS control unit 14P connector and body ground.

Rsp.ir opsn in tho GRY/WHTrYiro botwoon tha 4WS control unh snd th€ ABS control unit. R6olacothe ABS control unit.

View from terminalside

(4WSI Troubleshooting
32, 36 TroubleCodes(DTCs): Diagnostic

-Th. 4WS indlcator light h$ baan ropo.tgd on. -Yvlth lowica chack connoctor iumpod code. 32 and 36 sro indiclt.d.

4WS COI{TROLUNIT IAP CONNECTOR

View trom terminalside YES co to p!9.'19-54 ftoblem in ABS .y.t.m

Stop the engine.Then turn the ignition switch back ON.

With the right rear wh€ol .aised off the ground. slowly rotate the wheel while checking for voltag€ betweenth€ 4WS contrclunit No. 1 terminal IGRY/RED)and bodv grouno. Rocord tha DTC .nd cl..t th. 4l rS control unll. l.al driv. tho c.r, it tha DTC dodc not ro.ppaat, afFck tra tarmind connacdonr ot d|. 4WS cont ol unit 18P cofir.c_ toi and th. ABS control unit l4P connoqtoi.

Does the voltage alte.nate trom zero to approximstely 5 V?

NO
{To page 17-67}

17-6 6

(Frompage 17-66)

Turn the ignitionswitch OFF.

4WS CONTROLUNIT

'I8P SENSORSIDE CONNECTOR

Disconnectthe 4WS control unit connector and the ABS control unit connoctor, Vi€w from terminalside Check tor continuity between the 4WS control unit No. 1 terminal and {GRY/REO} body ground. wi?o Rap.i. .hon In th. GRY/RED bltwa.n th.4WS conltol onh and th. ABS conlrol unit.

4WS CONTFOLUNIT 18P CONNECTOR Turn the ignitionswitch ON.

Moasurevoltagebetweenthe No. 1 terminal (GRY/REDlotth€ 4wS conlrol unit conneclor and body ground.

View trom terminalside

ls there approximately 5 V?

Rcplscr lh. 4WS control unii
SIOECONNECTOR UNIT 14P SENSOR ABS CONTROL

Measurevoltag€between the No. 1 terminsl IGRY/RED)of sensor sideconnectorof ABS controlunit and body ground. 14Pconnector Rcplli opcn in th! GBY/REDwite b.twran th.4WS coiltol unh lnd th. ABS control unit. Roplacalhc ABS conttol unit.

17-67

Troubleshooting(4WS)
Trouble Code(DTCI:33 Diagnostic
NOTE: Problem code 33 is memorized when the front wheelsare turned at a speedot 30 km/h for 2 minuteswith the brake must be off to test this code.) lront wheels raisedoff the ground and the rear wheels blocked.(Parking

-The 4WS indicator light has boon roDortodon. -Whh sorvic6 chack connoctor iumpod codo 33 ir indicsted.

4WS CONTROL UNIT 18P CONNECTOR
3

V

V

0-5 V?

Does the ABS light stay ON?

View from terminalside Perfo.m troubleshooting ol tho ABS system (pag6 '19-541

Stop the engino.Then turn the ignition switch back ON.

Rotate the rear left wheel slowly and check for voltage b€tween the 4WS unit control No. 1 terminal IGRY/RED) body ground, and and betweenthe No. 3 terminal (GRYA HT) and body ground. Record tho DTC and clear th6 4WS control unit. T6st driv€ th€ car, if th6 DTC doos not rsappoar, chock tho torminal3 connoctions ot tho 4WS control unit 18P connector and tho ABS control unlt 14P connoctor.

Doesthe voltage from both rear wheel sensorsalternatefrom 5 zero to approximately V?

(To page 17-69)

17-68

(Frompage 17-68) 4WS CONTROL UNIT Disconnoctthe 4WS control unit connector and the ABS control untl connectol, 'I8P SENSOR SIDECONNECTOR

Chockfor continuity between the 4WS control unit No. 1 terminsl (GRY/RED) body ground. and wire Ropai.shorl in tho GRY/RED botwoen 4WS control unit and the ABS control unit.

View from terminalside

SIDECONNECTOR UNIT 18P SENSOR 4WS CONTROL Check for continuity between the 4WS controlunit No. 3 terminal and body ground. {GRY/WHT) Ropairlhon in th6 GRY/WHT wiro between tho 4WS control unit snd tho ABS control unit.

View from terminal side

4WS CONTROL UNIT 18P CONNECTOF

Measure voltage between the 4WS control unit No. 1 terminal (GRY/RED) body ground. and View from terminalside 5 ls there approximately V? Roplac6ths 4WS control unit.

YES
{To page 17'70)

17-69

(4WSl Troubleshooting
Code{DTC}:50 Trouble Diagnostic Trouble Code(DTCI:33 (cont'dl-Diagnostic
{Frompage 17-691 UNIT 18P CONNECTOR 4WS CONTROL

Measure voltage between thg 4WS control unit No. 3 terminal IGRYMHTI and body ground. View from terminalside ls there approximately 5 V? Beolaco tho 4WS control unit. UNIT 14P CONNECTOR ABS CONTROL Measure vollage between the ot No. 7 terminal{GRY/RED} the 14Pconnectorof the ABS control unit and body ground.

9;;;
wiro. Ropair op€n in th6 GBY/RED UNIT ABS CONTROL

TERMINAL

View from terminalside ls there approximstely 5 V? 'I4P CONNECTOR

Measure voltage between the No. 8 tgrminalof the 14Pconn6ctor of the ABS control unit and body Oround. View from interiorside ls there approxinately 5 V?

Baplaco the ABS control unit.

REARACTUATOR MOTOR TERMINAL

Diogno.tic Trouble Cod6 (DTCI: 50

-The 4WS indicato. light hes boon rcooned on. -with aoavico Ghock connectol iumped codo 50 is indicolod.

Start the engine. Turn the stoeF ing wheel and check the rear ste€ring motor lor function, Cloa. tho 4WS control unit and rotort, if tho DTC roccouB, then .6placo tho contlol unit.

TERMINAL UNIT POWER 4WS CONTROL

Does it operate properly?

8LK MOT _

l
Roplacotho r6aaactuator motot. R E DM O T + BRN GND

I
l

WHT+B

View from terminalside

17-70

(DTCsl: 61, 62, 63 (DTCI: 60, Trouble Codes 51-Diagnostic Trouble Code Diagnostic
Diagnostic Trouble Codo {DTC}: 51

I

-Tho 4WS indicstor light ha8 boon rgportod on. -Wlth s6rvico chock connoctoi iump6d codo 51 is indicatod.

Start the engine. Turn the steer ing wheel and check the rear steeringmotor for function. Th6 DTC 51 blinkt whon lhg roar whoals cannot bo atoerod bgcause th6y aia blockad wfth tho cuab, otc. ll tho DTc 51 blink! aftor rhr rg3t drivo, tho control unit i. taultY. 4WS CONTROLUNIT POWERTERMINAL

Does it operate properly?

R€olacoth6 roar actuatoamolor.

Diagnostic Troubl€ Codes {DTCS):60, 61, 62, 63
-Th6 4WS indicator light h.s boen roportod on. -With sorvico chock connoctor iumpod codos 60, 61,62, 63 aro indicatad.

B.tt.ry Voltago? Batt.ry Voltage?

check the No.38 4ws fuse (60 AI in the under-hood fuse/re-

Battory Volrage? View from interiorside

Roplaco th€ turo lnd rccheck

Measure voltage between the A rarminal(WHTI of the 4WS con body trol unit powerterminaland grouno. Ropairopon in th6 WHT wi.a botwo.n thq undo,-hood fute/tol.y box and tho 4WS control unlt. Measure voltage between the B terminallBRN)of the 4WS control unit power torminal and body grouno. Rop.lr tho poor gtound lG5O2l or opon in ths ERltl wiro balw.dr lh6 4WS cont.ol unlt and bodY ground lG5O2l. Startthe engineand immediately (withinapproximately seconds 2 after starting the engine) check for voltage between the C termi nal {RED) the 4WS controlunit of pow€rterminal and bodyground.

Roplsco th6 4WS control unit.

7-7

Troubleshooting(4WS)
60, 61, 62, 63 (cont'd) DiagnosticTroubleCodes(DTCs):
l F r o mp a g €1 7 - 7 1 ) TERMINAL UNIT POWER 4WS CONTROL

Stop the engineand turn the ig_ nition switch ON.

Measure voltage between the D terminal (BLK)ot rhe 4WS control unit power terminal and body groundimmediately after {wilhin 2 approximately seconds)starting the engrne.

Roplacolh€ 4WS control unit

Measure voltage between the C terminal(BED)of the rear actu ator motor and body ground after{withinapproximmediately imately 2 seconds)startingthe engine. Repair opsn in the RED wi.o betwoen tho 4WS control unit and tho roar actuator motor.

ls there battery voltage?

Measurevoltagebetweenthe D rerminal{BLK}of the rearactua tor motor and body ground alter {withinapprox' immediately imately 2 seconds)startingthe engine. Ropair opon in the BLK wir6 between tho 4WS control unit and the rcar actuator motor.

ls there battery voltage?

Measure voltage between the of No. 33 terminal{YEL} the rear actuatormotor and body ground immediatelyafter lwithin approximalely 2 secondslstartingthe engine.

ACTUATORMOTORTERMINAL

D U P + N O .3 3 I Y E T I

(To page 17 73)

Battery Voltag6?

17-72

lftonl. page 17-721

ls there battery voltage?

Raolacotho rsar actuato. motor.

ACTUTOR MOTOR TERMINAL

Measure voltage between the No. 34terminal(8LU)of the rear actustor motor and body ground immodiatelyafter (within approximately 2 secondsl slarting the engrn9.

ls there battery voltage?

Roplacotho roar actuator motor.

Meaaure voltsge between the (YEL) controlunitNo. 33 terminal and body ground immediatelvafter (within spproximately 2 seconds) starting the engine. Ropair op.n in tho YEL wir6 botwo6n the 4WS cont.ol unit and tho roar actuator motot. 4WS CONTROLUNIT 4P CONNECTOR 'rT\

Measure voltage between the control unit No. 34 terminal (8LU) and body ground immediatelyatter (within approximstely 2 seconds) starting the €ngine. Repaii opon in the BLU wir6 b6twoon th6 4ws control unil and the ioai actuator motoi.

( v ) ( vBattory Voltago? )
Y:T
View from terminalside

ffi

ls there baftery voltage?

Roplacs lhc 4wS control unit.

Maintenance
Pump Belt Adjustment
NOTE: When using a new belt, first adiustthe deflection or tensionto the valuesfor the new belt.then read just the deflectionor tensionto the valuesfor the used belt after runningenginefor tive mjnutes. 1 . A p p l ya l o r c eo f 1 0 ON ( 1 Ok g , 2 2 l b s )a n d m e a s u r e the deflectionbetween the power steeringpump and the crankshaftPulleys. Doflection: U s 6 db e l t : 1 3 . 5 - 1 6 . 5 m m { 0 . 5 3 - 0 . 6 5 i n l New belt: 9.5-11.5 mm (0.37-0.45 in) NOTE: lf there are cracks or any damageevident on the belt, replaceit with a new one. PULLEY POWER STEERING 2, Loosen the power steering pump mounting bolt, nuts and adjustingbolt locknut. Turn the adjustingbolt to get the properbelt ten sion, then retightenthe adiustingbolt locknut and mountingbolts. Start the engineand turn the steeringwheel lrom times,then stop the engineand several lock-to-lock recheckthe deflectionof the belt

3.

4.

POWER STEERING BOLT MOUNTING kg-m,16lb-ftl 22 N.m 12.2

AOJUSTING BOLT LOCKNUT .5 15 N.m 11 kg-m, 1 1 lb-tt)

Measurewith Belt TensionGaugel Attach the belt tension gauge to the belt and measurethe tension of the belt. T6nsion: U s € db o l t : 3 5 0 - 5 O O N ( 3 5 - 7 0 k g , 7 7 - 1 1 Ol b s l Now belt: 7oo-9oo N {70-90 kg, 154-198 lbs} NOTE: lf there are cracks or any damageevident on the belt, replaceit wilh a new one. lor instructions the tenFollow the manufacturer's srongauge. PULLEY STEERING POWER

ADJUSTING STEERING POWER NUTS MOUNTING 2 2 N ' m ( 2 . 2k s ' m , 1 6 l b - t t )

CRANKSHAFTPULLEY

17-74

On-CarChecks
RackGuideAdjustment
CAUTIONTwhen servicing,be careful not to damage the power steering fluid linss with the special tool.
SCREW RACK GUIOE

NOTE: Adjust the rack guide at the center ol the rack stroke. 2WS: '1. Removethe gearboxshield. 2. Loosen the rack guide screw locknut with the specialtool. Tighten,loosenand retightenthe rack guide screw two times to 4 N.m (O.4kg-m, 2.9 lb-ft) then back * it oft 20 3". T i g h t e nt h e l o c k n u tt o a b o u t 2 5 N . m ( 2 . 5 k g - m , 18 lb-ft) while holdingthe guide screw. Checkfor tight or loosesteeringthrough the complete turning travel. s a R e c h e c k t e e r i n g s s i s t( s e ep a g e1 7 7 9 ) .

3.

4.

5.

6.

1 7- 7 5

Checks On-Car
Rack Guide Adjustment {cont'd)
4WS: '1. Removethe gearboxshield. 2. Cut wire tie trom the cover, then removethe cover from the front sub steeringangle sensor, CAUTION: Cut the wire tie with carefullv,so as not to damago the harness. 4. Loosen the rack guide screw locknut with the specialtool. the rack guidescrew 5. Tlghten.loosenand retighten two times to 4 N.m (O.4kg-m, 2,9 ib-ft) then back * it olf 20 !'. 6. Tighten the locknut to about 25 N.m (2.5 kg-m, 18 lb-ft) while holdingthe rack guide screw. 7. Check for tight or loosesteeringthrough the complete turningtravel. 8. Rechecksteeringassist (seepage l7-79i.

WIREHARNESS SENSOR

cot{t{EcToR

COVER

zo.3'
ANGLE SENSOR FRONT SUBSTEERING

3. Remove the sub steeringanglesensorwire harness from the clamDand disconnectthe connector. RACKGUIDESCREW LOCKNUT

43 WRENCH, mm LOCKNUT 07MAA-S10020A RACKGUIDESCR€W

9. Reconnectthe connector and secure the sensor wire harnesswith the clamp and installthe cover. NOTE: a Be sure the sensor wire harness dois not interfere with the stabilizer and other moving parts. a Be certain that the sensor wire harnessis not twisted before connectingit. angle sen1O. Set the cover on the tront sub steerang sor. Securethe cover with the new wire tie. NOTE: After rack guide adjustment,perform the electrical check on the 4WS system (see page 17-146).

17-76

Checks On-Car
Fluid Replacement
Fluid Level Inspection
Check the power steeringfluid level with the engine cold and the car parkedon levelground.Make surethe levellines and LOWER fluid levelis betweenthe UPPER lf on the reservoir. the level is near or below the lower level line, check the system for leaks.lf the system is not le€king.and fluid levelis low, add fluid to the upper level line.

FluidReplacement
1. Raisethe reservoirand disconnectthe hose that goes to the oil cooler. Connecta hose of suitablediameterto the disconnected hose that goes to the oil coolerand put the hose end in a suitablecontainer. Startthe engine,let it run at idle,andturn the steering wheel from lock-to-lockseveraltimes When tluid stops running out ol the hose, shut off the engine. Discardthe fluid.

2.

3.
RESERVOIR

4.

the return hose to the reservotr. Reconnect to Fill the reservoir the upoer levelline. NOTE: Take care not to spill the fluid on the body and parts. Wipe oll the spilledat once, CAUTION: Uso only Honda Power Stsering Fluid-V. Using other fluids such as ATF or othor manufactuer's pow6r steering fluid will damagethe syst€m. System Capacity: 1 . 7 l i t e r( 1 . 8 0 U S q t , 1 . 5 o l m p q t l 8 t c h a n g o RosorvoirCapacity: O.5 liter 10.53 US qt, 0.44 lmp qt) Start the engine and run it at idle, then turn the severaltimes bleedair to steeringfrom lock-to-lock from the system.

7.

the fluid leveland add some if necessary. Recheck beyondthe upCAUTION: Do not fill the reservoir oer lovgl line.

1 7- 7 7

Checks On-Gar
Pump PressureCheck
Check the fluid Dressureas follows to determine whether the trouble is in the pump or gearbox. NOTE: First check the power steeringtluid level and pump belt tension. CAUTION: Dlsconn€ct tho high plossule hosa carofully, so as not to spill tho power steering tluid on thg trame and other parts. 1. Disconnectthe outlet hose from the pump outlet Jifting, and install the pump joint adaptor on the pump outlet. 9. 2. Connectthe hoseioint adaptorto the power steergauge,then connectthe outlet hoseto ing pressure the adaotor. Install the power steering pressuregauge to the pump joint adaptoras shown. O p e nt h e s h u t o f f v a l v ef u l l y . control valve fully. 5 . Open the pressure 6 . Start the engineand let it idle. '1. Turn the steeringwheel from lock-to-lockseveral times to warm the fluid to operatingtemperature. Close the shut oft valve, then close the pressure control valve gradually until the pressuregauge needleis stable.Readthe pressLrre. l m m e d i a t e lo p e nt h e s h u t o l f v a l v ef u l l y . y CAUTION: Do not keep the shut-oft valve closed mol€ than 5 secondsor the pump could be damaged by over-heating. l l t h e p u m p i s i n g o o dc o n d i t i o nt,h e g a u g es h o u l d k r e a d a t l e a s t7 , O 0 O - 8 , O O 0 P a ( 7 0 8 0 k g / c m ' , m 9 9 5 1 , 1 3 8 p s i ) .A l o w r e a d i n g e a n sp u m p o u t put is too low for full assist. Repairor replacethe pump.

l

8.

3.

P/S JOII{T ADAPTOR{PUMPI oTNAK-SR30l1A

P/S JOINT AOAPTORIHOSE) 07NAK-SR3012A

VALVE

VALVE SHUT-OFF

17-78

SteeringWheel RotationalPlay
1 . Placethe lront wheels in the straight ahead position and measurethe distancethe steeringwheel can be turned without movingthe front wheels. the servicelimit.checkall steer2 . lf the play exceeds ing components.

Power Assist Check with Car Parked
'1. Check the power steering fluid level and pump beil Iensron.

2,

Start the engine.allow it to idle, and turn steering severaltimes to warm up wheel from lock-to-lock the Jluid. Attach a spring scaleto the steeringwheel. With the engineidling and the car on a clean.dry floor, pull the scale as shown and read it as soon as the tires begin to turn.

3.
0- 10 mm (O-0.4 inl

SPRING SCALE The scaleshouldread no more than 30 N (3.O kg, 6.6 lbs). lf it readsmore or less,go on step 5. Stop the engine. Disconnectthe hose from the power steeringspeedsensorand plugthe hoseand the sensorfitting as shown.

POWERSTEERING SPEED SENSOR

o.

Start the engineand let it idle. a I t t h e r e a d i n gs n o w 3 0 N ( 3 . 0 k g , 6 . 6 l b s ) o r i less. replacethe power steeringspeed s e n s or , see page 1 7-8O. a lf the readingis still more than 30 N a 6 . 6 l b s ) ,c h e c kt h e g e a r b o x n d p u m p

17-79

Checks On-Car
Assist Check at Road Speed
'1.

P o w e r S t e e r i n gS p e e d S e n s o r Replacement
1. 2. Removethe rear mountingbracketstay. Disconnectthe sensor wire connector trom the power steenngspeeo sensor.

Check the power steering fluid level lsee page 17-771and pump belt tension (see page 17 74).

2 . Sta.t the engine,let it warm up to normaloperating
temperature(the cooling fan comes on), and turn the steering wheel lock-to lock a few times to warm up the fluid. Stop the engine.To simulatespeedsabove 50 mph (80 km/h), disconnectthe hoses from the power steering speed sensor and connect them to the bypasstube joint. PIugthe end of the bypasstube joint. TUBE JOINT BYPASS 07406-0010101
(lncluded with

3 . Remove the sensor mounting bolt and pull the
power steeringspeed sensorlrom the diflerential nousrng. 4. the sensorhosesand plug the tittings. Disconnect

07406-0010001)

MOUNTING BOLT SENSOR 6 x 1 . Om m 19 N.m (1.9 kg-m, 14 lb-ft) NEARMOUNTING HOSES

POWERSTEERING SPEED SENSOR

BRACKET STAY

Plugs.

4.

Attach the springscaleto the steeringwheel.With the engineidling and the car on a clean,dry floor, pull the scale as shown and read it as soon as the tires beginto turn.

10 x 1.25mm 21 N.m ( 2 . 1k s - m ,1 5 l b - f t I 'l 10 r .25 mm N.m 39

O-RING Replace.

(3 9 kg-m' 28 lb-ftl

Alter installing new power steeringspeedsensor, a turn the steeringwheellock to lock with the engine idlingto bleed air lrom the system. (see and add fluid if necessary 6 . Checkthe reservoir p a g e1 7- 7 7 1 . lf the scalereadsa normal50 N (5.o kg, 1 1 lbs), or more the assistproblemat high speedsis being caused by reduced power steering speed sensoroutput. Replace the power steeringspeed sensor. r l l f t h e s c a l e e a d s e s st h a n 5 0 N ( 5 , Ok g , I 1 l b s ) , the power steeringspeed sensoris OK and the problemis in the sensorleed line, the pump, or lhe valve body unit. Seeif the feed line is pinchedor bent then check pump(seepage 17-25). Troubleshooting See General

17-80

SteeringWheel
- Removal
with sRs:
store a removed driver's airbag !@ assemblywith the pad surlace up, i{ lhe airbaqis impropelly stored face down, accidentaldeployment could propel tho unit with enough lorc€ to cause sedous injury. CAUTION: a Eefore removing the steering wheel, align the front wheels straight ahead. a Do not installused SRS parts Jrom anolhercar. use only new SRS parts. When repairing, a Caretully inspecl the airbag ass€mbly belore installing. Do not install an airbagassemblythat shows signs of being dropped or imp.oparly handled,such as dents, cracks or deformation. a Always keep the shon connector(s) the airon bag(s)when the harnessis disconnected. a Do not disassemble tamper with the airbag or assembly. NOTE: The radio may have a coded theft protectioncircuit. Be sure to get the customer's code number betore - Disconnecting battery. the - R e m o v i n gh e N o . 4 3 ( 1 OA ) t u s e l i n t h e u n d e r t hood fuse/relaybox). - Removing the radao. After service, reconnect power to the radio and "CODE" is displayed, turn it on. Whenthe word enter the customer's s-digit code to restoreradio ooeration.
a

Disconnectthe negative and positive cable from the battery. Removethe accesspanel from the steeringwheel lower cover, then remove the short connector (RED). Disconnectthe connectorbetweenthe airbagand c a b l er e e l . 4. Connect the short connector (RED)to the airbag side ot the connector.

ACCESS PANEL

Removethe covers. Remove the two TORXo T3O bit bolts, then removethe driver's airbagassembly.
AIREAGASSEMBL DRIVER'S

t

I

1..-\

&

\

I\T
TORXO
Replace.

SRSMAIN HARNESS

(cont a

17-81

SteeringWheel
Removal(cont'd)
7. Disconnect the connectors from the horn and switches connector' cruisecontrol set/resume Without SRS: - Removethe emblemand steeringwheel nut' NOTE: Be carefulnot to damagethe emblemand steering wheel. - Remove the steering wheel by rocking it slightly from side-toside as you pull steadily with both hands. WHEEL STEERING EMBLEM NUT Replace.

t-

CRUISECONTROL SWITCHES SET/R€SUME

bo

V

I I

WHEEI. STEERING

- Removethe steeringwheel nut - Remove the steering wheel by rocking it slightly Irom side-to-sideas you pull steadily with both hands,

17-82

Disassembly/Reassembly
store a rsmoved driver's airbag assombly @ with the pad su.face up. ll the airbsg is improperly stored faco down. accidental deploymont could propol th€ unit with 6nough forc6 to cause serious inlury. NOTE: lf an intact driver's airbag assemblyhas been removedfrom a scrapoedcar or has beenfound defective or damaged during transit, storage or service, it shouldbe deploved(seesection 23). <With SRS:> WHEEL NUT STEERING 5ON'm (5.Oks-m, 36 lb-ft) CAUTION: a Carelullyinspectths driver'sairbagass6mbly betore Do installing. not installthe driver'sairbagassembly that shows signs ol being dropped o. impropo.ly handled,such as dents, cracks or deformation. a Always keep the short connector{s} the airbag(s} on when the halnessis dioconnected. o Do not disassemble temper, with the d.ivsr's airor bag assembly.

\ roRx@ BoLr \

@ -Rg p^

WHEEL STEERING

ii#I'i" b
\*.R=

$q>
I

-

DRIVER'SAIRBAG ACCESSPANEL

<Without SRS:>

Qlt

@

EMBLEM

I I

@

7 -83

SteeringWheel
lnstallation
2WS/With SRS: CAUTION: a B€fore installing the stearing wheel, align the front wheels straight ahead. a Be suro to install the ha.ness wires so that they are not pinched or interfering with other ca. pans. a Do not replace the original steering wheel with any othor d€sign, since it will make it impossible to properly install the airbag. lOnly use gsnuine HONDA replacement pans) a Aftel ieassembly, contirm that the wheels are still straight ahead and that steering wheel spoke angle is co ect. lf minor spokeangle adiustm€nt is necessary, do so only by adiustment of tho ti€ rods, not by lemoving and lspositioning the stesring wheel. conlirm that ths driver's airbag l@ assembly is socutely attached to lhe steering whe6l; othorwise, sgvgie personal iniury could result during airbag dgploYment 1. Before installing the steering wheel, center the cable reel, Do this by first rotatingthe cablereelclockwiseuntil it stops. Then rotate it counterclockwise(approximately two turns) until: - The yellow gear tooth lines up with the alignment mark on the cover. - The arrow mark on the cable reel label points straight uP. 2. Installthe steeringwheel and tighten the steerang wheel nut. NOTE: Be sure the steeringwheel shaft engages the pins of the cable reel.
CABLEREEL PIN

WHEEI STEERING NUT 50 N.m l5.O kg-m, 36 lb-ft)

WHEEL lnsert the cruise control set/resume swltches connector to the steering wheel clips. Connect the horn connector.

MARK ALIGNMENT

17-84

5,

Install the driver's airbag assembly with new TOBXo bolts.
DRIVER'S AIRBAGASSEMBLY

9. Connect the battery positive terminal and then connectthe negativeterminal. '10. After installingthe driver's airbagassembly,con firm propersystem operation: a Turn the ignition to ll position:the instrument p a n e l S R S i n d i c a t o r i g h t s h o u l dc o m e o n f o r l about six secondsand then go off. a Confirmoperationof horn buttons. a Confirm operationof cruise control set/resume S\/!r'rrcns. a Turn the steeringwheel counterclockwise and m a k e s u r e t h e y e l l o w g e a r t o o t h s t i l l I i n e su p with the alignmentmark.

TORX@ BOLT lO N.m {'l.O kg-m, 7 lb-ft|

TORX@ BOLT

10 N.m 11.0kg-m, 7 lb-ftl

6.

from the airthe short connector(RED) Disconnect bag connector. Connect the airbag connector and cable reel connector. Attach the short connector {BED) to the access panel, and installthe accesspanelon the steering lower cover.

7,

8.

YELLOWGEAR TOOTH CAELE REEL CONNECTOR

SHORTCONNECTOR

17-85

SteeringWheel
Installation(cont'd)
2ws/without SRS: 1. Installthe steeringwheel and tighten the steering wheel nut. NOTE: Align the slots on the steeringwheel and sleeve. tabs on the turn signalcancelling 2. Installthe emblem. WHEEL STEERING
SIGNAL

4WS/With SRS: CAUTION: a The tront main steeringangle sensor with the neutrallock mechanismis mounted on the column shall ot the car. When the steeringwheelis removed,the rotationpart oJ the sensoris locked at the electricallyneutral position,and it is unlock€dwhen the steelingwheel is inserted to position. the specifiedinstallation angle a lf the spokeangleis not at the designated while driving straight, check the front and rear beforeadjusting the wheelsfor properalignment spokg angle. Pertorm the electronic n6utral check ot the 4WS systemto be surethat the rearwheelsare at the correct steedng angle while driving {see page 17-146). a B6fore installingthe steering wheel. align the f.ont whsels straight ahead. a B€ su.e to installthe harnesswiles so that they aie not pinched or interfering with other car oarts. a Do not replacethe originalsteeringwheel with any other design,sinceit will make it impossible to properlyinstallthe airbag.lOnly use genuine parts) HONDA replacement confirm that the airbag assemblyis !@ attachedto the steedngwheel;otherwise, securely sevorepersonalinjury could tesult during later airbag dsployment. 1. the steeringwheel, centerthe ca Beforeinstalling ble reel. Do this by first rotating the cable reel clockwise until it stops. w Then rotate it counterclock ise (approximatelv two turns) until: - The yellow gear tooth lines up with the align ment mark on the cover. The arrow mark on the cable reel label points strarghtuP.
ARROWMARK

WHEEL STEERING

J

EM BLEM

STEERING WHEEL NUT 50 N.m {5.Oks-m, 36 lb-ft|

ii.

fr. l

CABLEREEL

MARK ALIGNMENT

17-86

2 . Temporarilyinstall the steering wheel aligning it
with the column shaft serration. Turn the steeringwheel fully to the right and left and set the steering wheel in the center of the rangewhere the front wheels move (i.e.centerthe steeringrack). NOTE: a Be sure that the tront wheels are in the straight aheaddrivingposition. a Be sure the steering wheel shaft engagesthe Dinsof the cable reel.

6.

Reinstall the steering wheel in the straight ahead d r i v i n g p o s i t i o n ,b e i n g c a r e f u ln o t t o m a k e i t o f f t o either side from the position set in step 3. NOTE: a A l i g n t h e h o l e i n t h e s l e e r i n gw h e e l w i t h t h e p i n of the cable reel. a Align the steering wheel with the sefiations which makes the spoke angle closest to horizontal.

\,'
CABLEREEL

e

/^\

tE#

i rj
7. lf the spoke angle is not horizontal, adjust the steer ing wheel slightly right or left, without pushing in the steering wheel too deep.

I

\rD,,
4. Removethe steeringwheel. Check whether the yellow paint mark of the tront main steering angle sensor rotor is facing down (i.e. in neutral lock position where the rotor does not turn). NOTE: lf the paint mark is not facingdown, adjust as tollows. 1) Temporarilyinstallthe steeringwheel with the spokesat a horizontal angle. 2) Turn the steeringwheel until the mark is facing down. 3) Returnthe steeringwheel spokesto the horizontal angle set in the step 1, being carefulnot to push in the steeringwheel. Remove the steering
wneet. 8. FRONTSTEERING ANGLE

ffi

)

WHEELNUT STEERING 50 N'm {5.0 kg-m, 36

With the spoke angle set at the horizontal, then push the steering wheel in fully. Tighten the steer ing wheel nut while pushing the steering wheel NOTE: Do not turn the steering wheel when pushing the steering wheel. Check the four front and rearwheelsfor alignment and perform the electronic neutral check on the 4 W S s y s t e m ( s e e p a g e 17 1 4 6 ) .
ICOn: -

sEilsoR

17-87

SteeringWheel
lnstallation{cont'd)
switches con9. Insertthe cruisecontrol set/resume nector to the steeringwheel clips. Connectthe horn connector' r th 1 1 . D i s c o n n e c t e s h o r tc o n n e c t o( R E D f)r o m t h e a i r bag connecror. '12. Connect the airbag connector and cable reel connector.

SWITCHES SET/RESUME

13. Attach the short connector (RED)on the access panel,and installthe accesspanel on the steering lower cover.

IREDI

10. Install the driver's airbag assembly with new TORX@bolts.

14. Connectthe batterypositiveterminalandthen con nect the negativeterminal, con 15. After installingthe driver's airbag assemblY, sYstemoPeration: lirm ProPer a Turn the ignition to ll positionl the instrument panel SRS indicator light should come on for about six secondsand then go off. a Confirm operationof horn buttons. a Contirm operationot cruise control set/resume switches. and a Turn the steeringwheel counterclockwise make sure the yellow gear tooth still lines up with the alignmentmark.

AIREAGASSEMBLY ORIVER'S

BOLT
10 N.m {1.O kg-m 7 rb-ft1

TORXO EOLT 10 N.m 11.0kg-m, 7 lb-ftl

17-88

SteeringColumn
Removal
Wirh 4WS: CAUTION: Th6 front main steering angle sonso. with the neutral lock machanism is mounted on the column shaft ol the car. When the steering wheelis removed, the rotation part ol the ssnsof is locked at tho olectrically nautral position, and it is unlock€d whgn the stooring whoel is inserted to th€ spociliod installation position. 1 . Removethe driver's airbagassemblyand steering w h e e l( s e ep a g e 1 7 - 8 1 ) . Remove the steeringjoint bolt and toothed lock washer (from the enginecompartment).

TOOTHEDLOCK WASHER

with sRs:
CAUTION: a All SRS glsctrical wiring hamossas are coversd with yellow outer insulation. a Before disconnocting thg SRS wire harness install th6 $hort connector(s) on the airbag(s)(s6e page 23-290|. a R€place tho entire affected SRS harnass assembly it has an open circuit or damagsd wiring. NOTE: The radio may have a coded theft protectioncircuit. Be sure to get the customer'scode number betore - Disconnecting battery. the - Removing the No. 43 (1O A) fuse lin the underhood Juse/relay box). Removing the radio. After service, reconnect power to the radio and "CODE" is disolayed, turn it on. When the word enter the customer's s-digit code to restoreradio oDeratlon.

Remove the dashboard lower cover and driver's knee bolster.

KNEEBOLSTER DRIVER'S

SRSMAIN HARNESS

OASH BOARD LOWER COVER

(cont'd)

17-89

Column Steering
(cont'd) Removal
4. Removethe upper and lower column covers. 6. Removethe cable reel assembly(SRSonly).

ASSEMBLY CABLEREEL

Removethe cable reel harnesslrom the underside oJ the column bracket by removingthe clip (SRS onlv).

7.

sleeve,combinathe turn signalcanceling Remove and front main steeringangle tion switch assembly sensor(4wS only) by removingthe circlip NOTE: After removingthe combinationswitch assembly, place it on the floor gently so that it does the not hinderyou in service.Do not disconnect cables from the combinationswitch assembly.

CIRCLIP

@!
\
TURNSIGNAL CANCELING SLEEVE CLIP SRS WIRE HARNESS FRONTMAIN STEERING ANGLESENSOR (4WS Only)

17-90

8.

Removethe air duct.

1O. Disconnect the ignitionswitch wtre connecror. 1 1 . Remove the steeringcolumnassembly removing by the attachingnuts. bolts and column holder.

AIR OUCT

COI-UMNHOLDER

9.

Removethe steeringjoint cover.

STEERING JOINT COVER

1 7- 9 1

SteeringGolumn
Inspection
and steeringshaft for propermovementand damage steeringioint bearings NOTE: Checkthe tilt mechanism, as an assemblyif damagedor faulty. CAUTION: Do not apply an impact load to the column shaft in the axial direction Front Main Stooring Angle Sensor (4WS): Checkwhether the Yellowpaint mark of the front main steering angle sensor rotor is facing down {i.e in neutral lock position where the rotor does not turn). that the front main steeringanglesensor This indicates in is electronically neutral. CAUTION: It th€ tront main steering angle sensor is unlocked onca, turn it to tho locking position and lock sgcu16ly.
COLUMN STEERING FRONTMAIN STEERING ANGLESENSOR I4WS ONLY}

Replace

PAINTMARK YELLOW

RETAINING COLLAR Checkfor damage.

@
FRONTMAIN STEERING ANGLE SENSOR

rN-\

I

qt

t4ws oNLY)

FLANGENUT I x 1 . 2 5m m 't6 t{.m ('1.6kg-m, 12lb-ft)

tr
,,,\ colur'rr ttot-DER
FLANGEBOLT 39 N.m (3.9 kg-m, 28 lb-fil

,{g

(2.2 kg-m, 16 lb-tl)

for a Check the tilt mechanism propermovement and damage. - Attach a springscaleto the knob of the tilt lever. to the preloadrequired move the lever. Measure Prsload:7O-9O N U-9 kg, 15-20 lbs)

SPRINGSCALE TILT LOCKBOLT

-6.1
STOPPER

- lJ the preload measured is not within the removethe 6 mm bolt and stopspecification. per. Then adjust the preload by tightening or the tilt lockboltat the lever pulledup. loosening - Reinstall the stopper and 6 mm bolt, then recheckthe preloadagain. CAUTION: Do not loosen the tilt lover when setthg dp ltoppor and when iightening the bolt.
6 mm EOLT 1 0 N . m { 1 . 0 k g - m ,7 l b - f t l

17-92

lnstallation
NOTE: a Be sure the pinion shaft and the steeringshaft are aligned;the joint should sllp on freely. lf not, repositionthe steering rack to correct the misalignment. a Coat the interiorof the steeringjoint grommet with grease. 1. Guidethe steeringshaft through the enginecompartmentbulkhead. Align the bolt hole in the steering joint with the slot in the steeringshaft, and insert the shaft into the steeringjoint.
STEERING JOINT BOLI Bolt rnust line up with lhe tlat on shaft22 N.m SHAFT (2.2 kg-m, 16 lb-fi) STEERING JoINT COVER 5. CLIP

4.

Installthe steeringjoint cover with the clampsand cliP.

Install the front main steering angle sensor (4WS o n l y ) , c o m b i n a t i o ns w i t c h a s s e m b l ya n d t u r n s i g n a l c a n c e l i n gs l e e v e w i t h a c i r c l i p . NOTE: a Be sure the wires are not caught or pinched by any parts when connecting the combination switch and the cable reel. a A l i g n t h e s l o t s I n t h e t u r n s i g n a lc a n c e l i n gs l e e v e w i t h t h e t a b s o n t h e f r o n t m a i n s t e e r ; n ga n g l e

SREERIITG JOINT joint onto the steering Slip the upperend of the steering shafi (lineup the bolt hole with the groovearoundthe shaft) and inslallthe steering ioint bolt.

Installthesteeringcolumnassembly with the nuts, bolts and column holder. Connectthe ignitionswitch connector.

sensor,
TURNSIGNALCANCELING MAIN STEERING SLEEVE

FRONT

COMBINATION SWITCH

16 N.m 11.6kg-m, 12 lb-ft) HOLDER

39 N.m 13.9kg-m,28 lb-ftl
FRONTMAIN STEERING ANGLESENSOR l4WS Onlyl tconl c

17-93

SteeringGolumn
Installation(cont'd)
6. (SBSonlv). Installthe cable reel assemblY NOTE: Align the slot in the cancelingsleevewith the projectionon the cable reel (2wS only). 2WS:
PROJECTION UPPER COLUMNCOVER

8.

Installthe upper and lower column covers

ANGLE SENSOR FROI{T MAII{ STEERING

9.

Installthe air duct.

Connect the cable reel harness and SRS wire harness,then attach the cable reel harnesson the ot underside the column bracket with the clip.

AIR DUCT

SRS WIRE HARNESS

17-94

1O. Install the driver's knee bolster and dashboard tower cover.

DRIVER'S BOLSTER
6 mm BOLT WASHER 1 ON . m (1.O kg-m, 7 lb-ltl DASH BOAND LOWERCOVER

1 1 . I n s t a l l t h e s t e e r i n gw h e e l a n d d r i v e r ' s a i r b a g ( a s s e m b l y s e ep a g e 1 7 8 4 o r 8 6 ) .

17-95

SteeringPump
Replacement
the NOTE: Beforedisconnecting hosesfrom the pump, place a suitablecontainerunder the car. 1. 2. Orainthe tluid from the system (seepage 17-77). Removethe belt by looseningthe power steering mountingbolt, nut and adjustingbolt Disconnectthe inlet and outlet hoses from the pump and plug them. NOTE: Take care not to spill the fluid on the body and parts. Wipe oft the spilledat once 4. Removethe power steeringmountingbolt and nut, then removethe pumP. ADJUSTING HOLDER UNIVERSAL 07725-O030000

PulleyReplacement
Hold the steeringpump in a vise with soft jaws, and hold the pulleYwith the specialtool, and remove the p u l l e yn u t a n d P u l l e Y t n N O T E : P u l l e y u t h a s l e l t - h a n dh r e a d s .

3.

o9llEr eolr

BOLT

't 't N.m

11.1kg-m, 8 lb-ft) PUMP ASSEMBLY

O.RING Replace. NUT PULLEY thread Left-hand STEERING NUTS MOUNTING 22 N.m 12.2kg-m, 16 lb-ftl INLET HOSE

HOSECLAMP

the pulleyin the reverseorder ol removal Reinstall NOTE: Installthe pulleyas shown

BELT POWERSTEERING PULLEY POW€R

NUT PULLEY
65 N'm (6.5 kg-m,47 lb-ft)

BOLT MOUNTING 22 N.m
(2.2 ks-m. 16 lb'ft)

NOTE: Do not turn the steeringwheel while the pump removeo. 5. 6. 7. Looselyinstalla new pump on the bracket. Connectthe inlet and outlet hosesto the pump. lnstalland adiust the belt (seepage 17-741. CAUTION: a Mak€ sure that the powel steering belt is securoly on the groove of tho pulleys a Do not get powor ste€ring fluid or groase in the powsr steeiing belt or pulley {aces. Cl€an ofl any fluid or gloase bsforo installation. 8. level with new fluid to the UPPER Fill rhe reservoir fine on the reservoir {see page 17 -771
Check that the pump turns smoothly by turning the pulley.

17-9 6

Flow Control Valve Inspectionand Replacement
Removethe controlvalve cap by removingthe two tlange bolts. Removethe flow controlvalve,springand O-rings. 4. Slip the flow control valve back in the pump and check that it moves in and out smoothly.

FLOWCONTROL VALVE
SPRING

FLOWCONTROL VALVE

@-'@h,
,q/@

|

"o"r*o,- uo.u. "o,

lf OK. go on to step 5; if not. replacethe flow control vatve: a The original valvewas selected a precise in the for {it pump housingbore, so make sure the new one has the same identification mark.
IDENTIFICATION

Check lor wear, burrs, and other damageto the edges of the groovesin the flow control valve,

Mark

Part Name FLOW CONTROL VALVE A

S i z em m ( i n ) 17.991 17.996 (o.7083-O.7085) 17.996-18.OO1 (o.7085-O.7087)

B

FLOW CONTROL VALVE B

lconl dI

17-97

SteeringPump
(cont'd) Flow Control Valve Inspectionand Replacement
Attach a hose to the end of the flow control valve as shown. the bottom end of the {low controlvalvein a 7. ClamD vise with sott jaws. 8. Unscrewthe seal in the top end of the tlow control valve, and removeanv shims,the reliefcheck ball, relief valve and relief valve spring. BALL RELIEF CHECK
VALVE RELIEF

'%
| "*,",.,
11.3kg-m, 9 lb-ft)

FLOW CONTROLVALVE Clamp this end in
a visg with sott jaws.

SPPING

9. Clean all the parts in solvent, dry them olf then and retest the flow control valve. reassemble relief pressureis adjustedat NOTE: lf necessary. the factory by adding shims under the check ball seat. It you found shims in your valve, be sureyou as reinstall many as You took out. 'lO. lnstallthetlow controlvalve in the reverseorderof removal. NOTE: a Coat the tlow control valve with power steering fluid, then installit and sPring. a When replacing the flow control valve, be sur€ flow controlvalvehasthe same the replacement identificalionletter as the originalflow control VALVE

Submergethe llow control valve in a containetof power steering fluid or solvent. and blow in the hose. lf air bubblesleak through the relief valve. or reDlace repairit as Jollows.

AIR PRESSURE No mor6 than 20 kPa {0.2 kg/cm2, 0.3 plll

a-fuh,
J contnoL vlle

clp

**@'.

FLANGEBOLT 11N.m (l .1 kg-m, a lb-ft|

22.1 x 1.9 mm O-RING

5.8 x 1.9 mm O'RING

17-9 8

Disassembly
CAUTION: The pump components are made ot aluminum. Be careful not to damago th€m wh6n sorvicing. 1. 2. 3. 4. Removethe pump from car (seepage 17-96). Removethe pulley (seepage 17-96). Removethe flow control valve (see page 17-971. Removethe inlet joint and 13 x 1 .9 mm O-ring.
HOUSING PUMP CAM RING

6 . Remove the pump cam ring from the
housing.

INLETJOINT

1 3 x ' 1 . 9m m O-RING Replace.

5.

Remove the pump cover and O-ring.

7.

Removethe pump rotor and pump vanes.

PUMP VANES

68.5 x 1 O-BING Replace.

"d
f..!

PUMP COVER

(cont'dt

7-99

SteeringPump
Disassembly(cont'd)
8 . Removethe two rollersfrom the side plate. 9 . Removethe side plate and preloadspring.
ROLLER x 26.8 mm CIRCLIP SIOE PLATE

11. Remove the circlip. then remove the drive shaft from the pump housingusing a plastic hammer. 12. Removethe pump seal spacerand oil seal.

-:. U,s-' ' - . . ., -OAtVe e) / sHAFf

A

ff t-\v1t
Il
\:/

\a__-/
A1/sP^cER
PUMPHOUSING

U -.ryv:jjAr
orr sFA OIL SEAL Replace.

1O. Removethe O-ringsfrom the side plate.

1 3 .Inspectthe bearingby rotatingthe outer raceslowis ly. lf any play or roughness felt, it must be replaced. Performstep 14 and 1 5

1 6 . 8x 1 . 9 m m O-RING Replace. Sx1.9mm O.RING Replace.

SIOE PLATE

BEARING

17-100

14. Remove the bearing using the special tool and pressas shown. Pross

+

HUB OIS/ASSEMBLY BASE OTGAF-SDi+O7OO

15. Installthe new bearingusingthe pressand special tool as shown.

+
Blacksealside.
Red seal side.

Plo!!

HUB DIS/ASSEMBLYBASE oTGAF-SD40700 NOTE:Hold the innerrace with the tool securely.

17-101

SteeringPump
lllustlated Index
CAUTION: Pump components aro made ot aluminum, Be careful not to damago lhem when servicing' NOTE: parts thoroughly. a Cleanall of the disassembled a Replaceall O-ringsand seals.Do not dip new O-ringsand sealsin solvent; coat O-ringswith power steeringfluid and make sure they stay in placeduring reassembly. before installation, a lf any part denotedwith an asterisk(*) is worn or damaged,replacethe completepump.

NEEDLE ROLLER EEARING FLANGEBOLT

20 N.m (2.0kg-m,14

PUMP COVER Check for damage to face. sealing ROLLER 4.5 x 49.8 rnm

iPUMP CAM RIf{G Check lor damage and wear, 'PUMP VANES (10 platBl Checkfor damage

88.5x 1.9 mm O.RING R€place.

.PUMP HOUSING Chock {or damage to s€alingfaces.

-6.l

16.8x 1.9 mm O.RING Replace.

1 3x 1 . 9 o-Rtt{G Rgplace.

OIL SEA Replace. PUMP SEAL SPACER ORIVE SHAFT Checkfor damage and wear.

--(cL
FLANGEBOLT 11 N.m (1.1 kg-m, 8 lb-ft} JOINT IT{LET FLOW CONTROLVALVE Check lor pressure leak. 22.1 x 1.9 mm O-Rl 6 -'>Q

PULLEY for Check distortion
and cracks.

*{@

B1.2'""'-"
CONTROLVALVE CAP

BEARING Checklor

excessive ptay.

f^@'
PULLEYNUT 65 .m 16.5 ks-m, 47 lb-ft)

FLANGEAOLT 11 N.m (1.1 kg-m, 8 lb-lt)

17-102

Assembly
'I . Coat the lip of the new oil sealwith steeringgrease P { H o n d a / N0 8 7 3 3 - B o 7 o E ) . Install the new oil seal in the pump housing by
hand. o.

Installthe preloadspringin the pump housing.

2.

7 . Set the 4.5 x 49.8 mm rollerin the 4.5 mm hole in the pump housing. 8 . Set the side plateover the rollerand installit on the pump housrng,
o Set the 5 x 26.8 mm rollerin the 5 mm hole in the

Installthe pump seal spacer,then installthe drive shaft in the pump housingusingthe specialtools. Installthe circlipwith its taperedside facing out.

side plate. 5 x 26.8 mm ROLLER

CIRCLIP

)
ATTACHMENT DRIVER 07947 -6340500
ATTACHMENT, 37 x 40 mm 07746*0010200

ruI\

9=-o*,ve

Y
\v

sHAFr

4.5 x 49.8 mm ROLLER

x

senl FI purrrp SPAGER Jl

PRELOAD SPRING

HOUST G

4.5 mm HOLE

10. Assemblethe pump rotor to the drive shaft with the "O" mark on the.otor facing upward. 5 . Coat the side plate grooves with power steering fluid, then positionthe 16.8 x 1 .9 mm and 54 x 1.9 mm O-ringson the side plate.
16.8x 1.9 mm O-RING

1 1 . Set the 1O vanes in each groove in the rotor. NOTE: Be sure that the round end of the vanes is in contact with the slidingsurfaceol the cam ring.

O

/E

,,O" MARK 54 x 1.9 mm O.BING Round 6nd

PUMP ROTOR

4 o
{cont d

VANE

17-103

SteeringPump
Assembly{cont'dl
1 2 .Set the pump cam ring over the two rollerswith the
" : " m a r ko n t h e c a m r i n g u p w a r d . 1 3 . Apply clean power steeringfluid to the vanes and pump cam flng.
PUMPCAM RING

'17 o . S e t t h e 1 3 x 1 . 9 m m O - r i n g n t h e i n l e tj o i n t ,ano installthe inlet joint on the pump housing,

INLETJOINT

FLANGEBOLT 11 N'm (1.1 kg-m, 8 lb-ftl

18. Installthe flow control valve (seepage 17-98). 1 4 . I n s t a l lt h e 6 8 . 5 x 1 . 9 m m O - r i n go n t h e p u m p cover. 1 5 .Align the rollerset holesin the pump cover with the rollers. Align the projectionon the pump housingand the projection the pump cover,then tightenthe tour on bolts. FLANGE BOLT 20 N.m
(2.O kg-m, 14 lb-ft)

19. Installthe pulley (see page 17-96) and check that the pump turns smoothly by turning the pulley.

68.5 x 1 . 9 m m O-RING

E

ROLLEBS

17-104

SteeringGearbox
Index
CAUTION: Betore diEassambling the gsarbor, wash it oll with solvent and a brush.

€--=.-

ss t.13.9 kg-m, 28 lb-ft)

VALVEBODYUNIT page17'106 Overhaul,

GEARBOXSHIELD

lr.O tg-m, 7 lb-ftl RIGHTMOUNTING BRACKET AIR
CLAMP TIE.ROD LOCKNUY 45 N.m (4.5 kg-m, 33 lb-ftl TIE.RODEND \ RACKEND BOOTBAND 65 N.m 16,5kg-m,47 lb-ft) neptace. \

8o,or \s \ =K\ \)

MdNNry:
\
TUBE CI-AMP TRANSFER HOSE TRANSFERHOSE CLAMP

9-I
I

t

a

50-60 N.m (5.0-6.0 kg-m, 36-43 tb-ft)

Ss'..t
/-

-ArR HOSE BAND RUBBER

AIR HOSE BAND

COTTER-PIN Replace.

17- 105

SteeringGearbox
Valve Body Unit
Romoval
1. 2. Drsin the power steeringfluid (seepage 17-77). 6. Removethe gearboxshield. Remove the O-rings and port orifices trom the gearbox. the two I mm flangebolts and removethe Remove valve body unit from the gearbox.

9.8 x 1.9 mm O.RING Replace.
PORT ORIFICE 45.5 x 2 mm O.RING Replace.

GEARBOXSHIELD

Usingsolventand a brush.wash any oil and dirt off the valve body unit, its lines, and that end of the gearbox.Blow dry them with compressed air. UsingJlarenut wrenches,disconnect the four lines Jrom the valve body unit. A: To oil cooler: 17 mm wrench 8: To power st€qring spsed sensor: 12 mm wrench C: To reservoir:12 mm wrench D: From pump: 14 mm wronch

8 mm FLANGEEOLT

UNIT

17-106

Valve Body Unit
Disassembly
1. Removethe three 6 mm flange bolts, then remove the valve body cap trom the valve body. Removethe cap seal trom the valve body cap. VALVEBODY VALVE CONTROL PRESSURE for or Check scoring and scratches, rough opgration. 4. control valve: Checkthe Dressure Inspectits surfacefor scoringor scratchss. Slip it back into the valvebody. and makesure it slides smoothly without drag and without slde play.

2.

6 mm FLANGEBOLT

NOTE: lf the valve body is damaged,replacethe controlvalve. valvebody unit (valvebody, pressure gain control valve,4-way valve)as an assembly. the pressure controlvalveand valvespflng Remove from the valve body. 5 . Remove the gain control valve and valve spring irom the valve bodv.

VALVE BODY

VALVE BODY

\(C

\, .la

4*
VALVESPRING
VALVE SPRING (conl ct

17-107

SteeringGearbox
Valve Body Unit (cont'd)
6. Checkthe gain control valve: a Inspectits surJace scoringor scratches. Jor a Slip it back into the valve body and make sure it slides smoothly without drag and without side pray. VALVE GAIN CONTROL for Check scoring, scratches, rough or
operation.

9. Remove the rollers from the 4-wav valve bv pushingthe valve out one side of the valve body, and then the other. NOTE: When removing the rollers, hold the plungerswith your linge.s to keep them ffom popprng our.

PLUNGERS

NOTE: lf the valve body is damaged,replacethe valvebody unit (valvebody, pressure controlvalve, gain control valve, 4-way valve) as an assembly. the valve body and port housing. Separate

1O. Remove the plungers, return springs and 4-way valve from the valve body. 11. Removethe 11 mm O-ringt.om the 4-way valve. 12. Check the plungers.

Removethe port seal and dowel pins trom the port housing.

a Inspecttheir surfacefor scoringor scratches. a Slip each plungerinto the valve body, and make sure it slides smoothly, without drag or side play. lf any plungeris damaged.replaceit. VALVEBOOY
PLUNGERS Check for scoring or scratches, and rough sliding. PLUNGERS Check lor scoring or scratches, and rough sliding.

DOWEL PIN

17-108

'13.

Checkthe 4-way valve. Inspectits surfacefor scoringor scratches. Slip it into the valve body, and make sure slidessmoothly.without drag or side play,

4.WAY VALVE Checkfor scoring, scratches, or rough operation,

(

NOTE: lf the valve body is damsged,replacethe valvebody unit (valvebody, pressure controlvalve, gain control valve,4-way valve)as an assembly. 1 4 . Using a 3 mm (1/64") drill bit, removethe sensor oriJiceand 3.4 m O-ring,

gh

PORTHOUSING

17-109

SteeringGearbox
Valve Body Unit
Assembly
lllustrat€d lnd€x parts shown below. 1, Throughlycleanthe disassembled 2. 3, Coat the plungers,pressurecontrol valve, gain control valve and 4-way valve surfaceswith power steeringfluid. Beassemble pans in the reverseorder of disassembly. the CAUTION: a Replacothe O-rings and ssals with n€w onos, a Do not dip tho O-dngs and saals in solvent. a Apply tb€ power ste€dng fluid in the e€al groovos to keep tho leals in pl8cs, (Pa.t Numb€rO8733-BO?OE| . -6f : STEERING GREASE

PORT HOUSING
1l mm O-RING

45.5 x 2 mm O.RING Replace.

PRESSURE

DOWEL PII{S

cof{TRoL VALVE

uo.u."r*nol trN
VALVE EODY PLUNGERS 6 mm FLANGEBOLT I N.m lO.9 kg-m, 7 lb-ft)

S*"MS^"..'.
.\/lil ' "/)H -^d qq \ + w r vv t v e \\

1 \ sENsoR
SPRINGS ROLLER 3.4 m]n O-RING R6place.

oo,n "onrro. vALvE
oRtFtcE

\

NOTE: lf the valve body is damaged,replacethe valve body unit (valvebody. pressure controlvalve,gain control valve, 4-way valve)as an assembly.

17-1 1 0

4.

Coat the surface of the 4-way valve with power steeringfluid, and installinto the valve body.

7. Coat the pressurecontrol valve and gain conttol valvewith power steeringfluid, and installtheminto the valve body, 8. Installthe valve springs.

5 . Coat the surfaceo{ the plungers with power steering tluid, and install the plungers,return springs and rollerson the valve body.

VALVEBODY
1 1 mm SPRINGS

r0

I

VALVE SPRINGS

PRESSURE CONTROLVALVE

E

PLUNGERS

E
6. fluid, and inCoatthe port sealwith power steering stall it the grooveof the port housing.Then install the valve body and port housing.

9. Coatthe cap sealwith power steeringfluid, and install it in the groove ot the valve body cap. 1O. Installthe valve body cap on the valve body with 6 mm flange bolts. CAUTION: Maka sure the mating surface ot th6 valve body and cap are flush at the uppor sid6.
VALVE BODY PORT HOUSING 6 mm FLAIIGE BOLT 9 N.m (0.9 kg-m, 7 lb-ft)

VALVEBODYCAP

rol
{cont 6

17-111

SteeringGearbox
Valve Body Unit (cont'd)
'I 1. Make sure the 4-way valve moves smoothly,and returnsto neutrSlDosition.

lnstallation
1. Coatthe 9,8 x 1.9 mm O-ringswith power steering fluid, and installthem togetherwith the orifices. Installthevalvebody unit on the gear housingwith the two 8 mm bolts. CAUTION; a When installing, be caleful not to hil th€ pinion holderpin. a Mak€ sure the O-rings are in place and not
pinchad, PINIONHOLDERPIN

2.

-6l

9.8 x 1.9 mm O-RINGS

E
PORTORIFICES 45.5 x 2 mm O.RING

ks-m' 16 lb-lil 22 N'm 12.2 Connectthe four linesto the valve body unit, using flare nut wrenches. A: To oil coolor: 17 mm wrench 29 N.m {2.9 kg-m, 21 lb-ftl B: To power ste€ring spoed aensor: 12 mm wrench 13 N.m (1.3 kg-m, 9 lb-lt) 12 mm wrench C: To rgsorvoir: 13N.m (1.3 kg-m, 9 lb-ft) 14 mm wrench D: From pump: 38 N.m (3.8 kg-m, 28 lb-tt)

BODYUI{IT

17-1 1 2

Fillthe reservoir with power steering fluid and bleed air from the system by turning the steeringwheel from lock to lock severaltimes with the engine warm lsee page 17-771. Make sure there are no fluid leaks,then installthe gearboxshield.
o.

Recheck the fluid level in the reservorr.

GEARBOXSHIELO

1 ON . m (1.0 kg-m, 7 lb-ftl

17-113

SteeringGearbox
GearboxRemoval
NOTE: Beforeremovingthe steeringgearbox,alignthe front wheels straightahead. 1. on Drainthe power steeringfluid as described page 17-77. Raisethe front o{ car and supporton safety stands in the properlocations(see sectjon 1). Removethe front wheels. Remove the cotter pin lrom the castel nut and removethe nut. Installa 12 mm hex nut on the ball joint. Be sure that the 12 mm hex nut is tlush with the ball joint pin end, or the threadedsectionof the ballioint pin might be damagedby the ball joint remover. NOTE: Removethe ball joint using the Ball Joint Remover.Referto page 18-13 tor how to use the ball joint remover. the Separate tie-rodballjoint and knuckleusingthe s p e c i atl o o l . CAUTION: Avoid damagingthe ballioint boot.
EXHAUST PIPEA

7 . Removethe selfJockingnuts that connectthe exhaust pipe A to the three way catalyticconverter, and the exhaustoiDeA to the exhaustmanitold. 8. Disconnectthe heated oxygen sensor connector (H23A1 and H22A1 engine)and remove the exhaust pipe A, CAUTION: Replac€ tho oxhaust gaskot and salflocking nuts when you loinstall ths pipe.

2.

3. 4.

q

only. Automatic transmission a Removethe shift cable holder and disconnect ihe shift cablefrom the shift control shaft.

SHIFT CONTROLSHAFT

12 mm HEX NUT

SHIFTCABLEHOLDER

17-114

1 0 .Removethe center beam.
NOTE: Replacethe self-lockingbolts if you easilythread them in.

1 2 .Usingsolventand a brush,wash any oil and dirt ofl the valve body unit, its lines, and the end ot the gea.box. Blow dry them with compressed air. CAUTION: Aftel disconnecting the hoses and pipes,plug or sealthe hosesand pipeswith a piece of tape o. equivalent to paevent foreign material lrom entering the valve body unit.

1 3 .Usingtlare nut wrenches,disconnect four lines the
trom the valve body unit. A: To oil cooler: 17 mm wrench B: To power stssring speed sensor: 12 mm wrench C: To reservoir:12 mm wrench D; From pump: 14 mm wrench

11. Removethe gearboxshield.

4WS: 14. Cur the wire tie from the cover, then removethe cover from the front sub steeringanglesensor, CAUTION: Use care when cutting the wire tie so as not to cut into the wire harness, 15. Removethe sensor wire harnessfrom the clamp and disconnectthe connector.
CONNECTOR COVER

GEARBOXSHIELD

WIRETIE Replace. FRONTSUB STEERING
ANGLESENSOR

17-115

SteeringGearbox
gearDox llemoval lcont q, Gearbo Removallcont'd)
16. Lock the steeringshaft with ignition key to keep the steeringshaft position. 17. Removethe steeringjoint bolt, and move the joint toward the column.
STEERING JOINT

1 9 . Removethe left-tie rod end, then slidethe rack all the way to the right.

20. Pull the steering gearbox assembly all the way
down to clear the Dinionshaft lrom the bulkhead. to 21 . Move the steeringgearboxassembly the right so the left rack end clearsthe rear beamHold the steeringgearboxassemblyand slide the rack all the way to the left. Placethe left rack end below the rear beam. Move the steeringgearboxassembly the left and to tilt the left side down to removeit from the car.

LOCK WASHER TOOTHED 18. Remove the left mounting bracket first, then removethe right mountingbrackets.

A

RAq In6ta innoa

STEERING GEARBOXASSEMBLY

o{
R.!

35.

CAUTION: Bo calsful not to bond or damage the four power aleedng lines when lomoving the gearbox aasemblv.

z<

AIR HOSE CLAMP

17-1 1 6

lllustratedIndex
a a a a
parts. Thoroughlyclean all disassembled Always replaceo-rings and seals. parts with damagedslidingsurtaces. Replace grease, fluid or steering makesurethey stay Do not dip sealsand O-ringsin solvent;coat O-ringswith power steering in positionduring reassembly, and use the appropriate specialtools to installlhem where necessary. : STEERING GREASE {P/N08733 BoToEl -!56{

FRONTSUB STEERING ANGLESENSOR

l4wsl
Adjustment page 17-132 RACKGUIDESCREW (2WSl SEAL RETAI'{ER BUSHINGSTOPPER CYLINDERCAP ..@] SPRING RACK cutDE AALL BEARING -: -GEAR

o

RETAIT{ING WASHER Beplsce. 9.8 x 1.9 mm _-.,t o-RTNGS--J

t

HoLDER AE5<-- PrNtoN \-+-pr roNHoLDER

ffi

HousrNG

""'!kr ser. ersron
35.5 x 2.4 mm BING Feplace

PORTORIFICES

#.'=....-#
&--(nlr-

H

ffi"k
BALL BEARTNG
SAf{P R|NG

)d'ffi"o
CYLINDER ;rd$;t

R'. iJillitt.l"l3T-0"-"," i:11T,""*,
SNAP RING Inspect lor damage to inner surface CYLIIIIDER ,sPRlNG

-";tJilhre$m''L,NDER
--=.:=\/V\\-\ -5ffiq
O-RING Replace.

fiI.;!,?,T \

I::X'"T:U:'*""
/'e'-

CYLINDERBOLT 22 N.m 12.2 kg-m, 16 lb-trl

17-117

SteeringGearbox
Overhaul
1. Remove the two 8 mm flangebolts and removethe valve body unit trom the gearbox. Remove the O-rings and port orifices from the gearbox.
8 m m FLANGEBOLT

4WS: 5. Loosen the locknut and remove the rack guide screw/front sub steeringangle sensorassembly. 6. Removethe spring and rack guide from the gear housing.

2.

45.5 x 2 mm O-RING Replace.

9.8 x 1.9 mm O-RINGS Replace.

RACK GUIDE

Loosen the locknut and remove the rSck guide 5Crew. Removethe spring and rack guide trom the gear housing.

7,

Removethe rack guide screw, O-ringand locknut from the front sub steeringangle sensor.

LOCKNUT

RACKGUIDE

17-118

8 . Csretully clamp the gearbox in I vise with soft
jaws.

1 1 .Hold th€ steeringrack with I wrench and unscrew the rack end with a wrench.

9 . Removethe tie-rod end.
RACK END LOCK WASHER

TIE.RODLOCKNUT

,^@ @-=-47'
1- r_------_1,

\

,

V

\
TIE.ROD END

1 0 . Bemovethe boot bands and tube clamps. Pull the
dust sealsaway from the ends of the gearbox.

1 2 . Removethe dust cover. 1 3 .Removethe gear housingcap from the gear housing by removingthe four 6 mm flange bolts. 1 4 . Remove the steering pinion seal from the gear housingcap.

DUST COVER

STEERING PINIONSEAL Replace. GEAR HOUSINGCAP 46 r 1.5mm O.RING Replace.

TUBE CLAMP

(cont'd)

17-119

SteeringGearbox
Overhaul(cont'd)
15. Pushthe right end ot the rack back into the cYlinder housing so the smooth surtace that rides agsinst the seal won't be damaged. a Removethe ball bearingusing a commercially bearingpuller. available

Install the ball bearing on the pinion using a p.ess and the specialtools.
to.

Checkthe ball bearingot the pinionfor play; if it is good, go on step 17, play,replace lf the bearingis noisyor hasexcessive the bearing. a Removethe snap ring.

BALL BEARING

17-120

a Installthe snap.ing on the pinion.

19. Remove the cylinder end seal from the cylindel housing. NOTE: Useyour tingersor a woodenstick to avoid damagingthe housing.

PINION

I I
CYLINDER SEAL CYLTNDER END HOUStt{G 17. Removethe four cylinderbolts from the end of the cylinder housing, then slide the housing off the tacK. 18. Remove the O-ring. back-up ring, steering rack bushingA and cylinderspring.

@
END

cylindercap and sealretainer, the cylinder, 20. Remove steeringrack from the gear housing.

CYI-INDER
GEARHOUSING

17-121

Gearbox Steering
Overhaul(cont'd)
the retainer washerJromthe gearhousing. 21. Remove a Remove the pinionholdertrom the gearhousing. a Check the needle roller bearingsin the pinion holderand gear housingfor damage;if oK, pack the needlerollerbearingwith grease.lf the bearings are damaged.replacethem as a set.
PINIONHOLDER

I t
!

GEAR I{OUSING

22, Check the pinion holder for tree movement, excessiveplay and rough movement;if it is good 90 on steD 23. lf it is damaged, if dirt has gone past the sealinto or the grease,replacethe bearing. a Removethe circlipfrom the pinion holder.

a Checkthe ball bearingfor damage;it it is good. go on step 23. a Remove the pinion ball bearingfrom the gear housing.

BALL BEARING PINION HOLOER

17-122

a Drivethe new ball bearinginto the gear housing using the specialtools.

a Reinstall the circlip with its taperedside facing ouI. NOTE: Circlip ends must be alignedwith the flat area.

ORIVER 07749-OO10000 47 mm CIRCLIP

a Installthe pinion holderin the gear housing.

PINIONHOLDER

23, Remove the cylindercap and sealretainerfrom the steeringrack.

CYLINDERCAP/ SEAL RETAINER NEEDLE ROI-LER BEARINGS

STEERING RACK GEARHOUSING

{cont d,

17-123

SteeringGearbox
Overhaul(cont'd)
24. Removethe O-ringand snap ring ftom the seal retainer.then removethe cylindercap from the seal retalner. 25. Removethe O-ringstrom the cylindercap.
29.7x 1.9 mm O.RING Replace.

pry 28. Carefully the piston sealting and O-ringoff the olsron,

43.3 x 1,5 mm O.RINGS Replace.

SEAL RETAINER

(\s CI
SNAP RING

I I

CAP CYLINOER

PtSTON SEALRI[{G R€Place.

Remove the bushing stopper ring lrom the seal retainer.

NOTE: Befo.e reassemblingany parts, inspect on them as described page 17-'l17 and mak€ sure worn or damagedparts they are clean. Replace

2 7 . Removethe cylinderend seal and rack bushingB.

BUSHINGSTOPPER

SEAL RETAINER

RACK BUSHINGB

SEAL

17-124

29. Install a new O-ring on the piston with Its narrow
€dge facing out.

32. Coat the piston seal ring and insideof the special tool with power steeringfluid. 33. Carefullyslidethe tool onto the rack and ove. the pistonsealring, then rotatethe tool as you move it up and down to seat the piston seal ring.

30. Coat the pistonseal ring guide with power steering fluid. then slide it onto the rack, big end fifst. 31. Positionthe new piston seal ring on the special tool, slideit down onto the big end of the tool, then pull it otf into the piston groove on top of the Oring.

34. Coat new O-ringswith powe. steeringfluid and install them on the cylindercaD.

43.3 x 1.5 mm O-RINGS STEERING RACK

(cont'dr

17-125

SteeringGearbox
Overhaul(cont'd)
35. Slidethe cvlindercap onto the seal retainer. 36. Installthe snap ring on the seal retainerand coat new O-ringwith power steeringfluid and installit on the seal reta,ner.
S[{AP RII{G 29.7 x 1,9 mm O-R|NG

the slidingsurfacesot the new cylinderend 38. Gr€ase sealand the specialtool.then placethe sealon the specialtool with its grooved side facing opposite the slider.

\

\.-6 ^@"\ * \ !

\

l

t

BACK.UPRING Make sure the back-up ring is seated in the cylinde.end seal.

@'f
\ SEALRETAINER

cYtlt{DERcAP

\

ENO SEAL CYLINOER lnstall end soal with its grooved side facing opPosite seal slider.

I

END CYLINDER SEALSLIDER 07LAG-SM/tO30A 37. Greasethe sliding surface of the rack bushingB. and installthe bushingon the steeringrack.

39, lnstallthe specialtool and cylinderend seal.

-Gl

RACK BUSHING

17-126

40. Separatethe cylinder end seal from the special
tool, then removethe specialtool from the fack.

4 2 . Push the rack bushing B toward the seal retainer by
hand until the cylinderend seal is seatedin the retainer.Fit the bushingstopperring in the grooveot the sealretainersecurely. Then grease the steerinq racK.

CYLINDEREND SEAL SLIDER 07LAG-SM4030A AUSHINGSTOPPER RING SEAL RETAINER

RACK SUSHINGB

RAC( BUSHINGB

41. Fit the seal retaineron the steeringrack.

43. Installthe retainerwasher on the gea. housing.

SEAL RETAIT{ER GEAR HOUSING

{cont'dl

17-127

Gearbox Steering
Overhaul(cont'd)
44, Placsthe gea. housingon the work bench and inand steeringrack into the gear sert the sealretainer housing. 45. Coat the insidesurfaceof the cylinderwith powet fluid, slideit overthe rack and into the gear steering housing;press it into the housinguntill il seats' 48. Coat the insidesurfaceof the cylinderwith power end seal with steeringfluid and installthe cYlinder its groovedside Jacingout.

GROOVES

STEERING RACK CYLINDEREND SEAL SEAL RETAIITER

E

CYLINDER ENO SEAL

then installtheO49. Coatthe new O-ringwith grease. ring into the gear housing. ring and back-up 50. Carefullypositionthe cylinderon the gear housing and looselyinstallwith four cylinderbolts. CAUTION: Bo cartul not to damagetho 6nd se€l in the cylinder housing.

HOUSING

46. Installthe cylinderspringover the rack, then coat
the rack bushingA with greaseand installit on the sp.ing. 4 7 . Wrap the end of the steeringrack with vinyl tape. Coat the tape with grease.

CYLINDERHOUSING

-6q

A_e2 RACK BUSHTNG

,6Q

CYLINDERSPRING

RACK STEERING

--F\
d
Vinyl tape

A) -.9

59 x 2.4 mm O.RING

-6ll

-Gl

17-128

51. Removethe vinyl tape from the steeringrack. 52. Tightenthe four cylinderbolts. NOTE: Beforetighteningthe bolts, make sure the mating surfaces the cylinderand gearhousingfit of properly by pushing them together; hold them togetherwhile tighteningthe bolts.

55. Greasethe sealinglip ot the steeringpinion seal. and installit on the gear housingcap. 56. Wrap the spline area of the steering pinion with vinyl tape and greasethe surfaceoi the tape. 57. Greasethe new O-ring and install it in the gear housing. 58. Slidethe gear housingcap over the steeringpinion, being carefulnot to damagesealinglip or dislodge the springof the steeringpinionseal. 59. Removethe vinyl tape.
6mm FLANGEBOLT 1'l N'ln {1.1 kg-m, 8 lb-ft} DUST

CYLINDER HOUSING

/
:ERINGPINION

CYLINDENBOLT 22 N.m 12.2kg-m, 16 lb-Ill

-6i
HOUSING CAP

Make sure the O-ring is in placeand not pinched. HOUSING

-61
Vinyl tape

'
46 x 1.5 mm O-RING

53. Insert the steeringrack into the cylinderhousing, being caretul not to damage the steering rack slidingsurface. 54. Installthe pinion in the pinionholder. Install the circlip securely in the pinion holder groove. NOTE: Installthe circlip with its taperedside facIng our.

6 0 . Screw each rack end into the steeringrack while holdingthe lock washer so its tabs are in the slots in the steeringrack. Hold the steeringrack with a wrench and tighten t h e r a c ke n d t o 6 5 N . m ( 6 . 5 k g - m , 4 7 l b - f t ) .
RACK ENO

PINION HOLDER

STEERING RACK

{conl d

17-129

SteeringGearbox
Overhaul{cont'd)
62. After tighteningthe rack end, stske the four sections of lock washer with a dritt, of 6 3 . Apply greaseto the circumlerence the rack end.

6 4 . Coat the tie-rodgrooveand insideoJ the boot with
siliconegrease.

DRIFT AVAILABLE COMMERCIALLY
(Roll Pln Ddft, SnsPOn No. PPfi8l

SILICONEGREASE Cost the sliding surface ot the rack end.

-6,1
RACK END

GROOVE NOTE: This drift has a tlat, to prevent punctunng the metal washer.

6 5 . lnstall the boots on the rack end with the tube
qamps. NOTE: Checkthat the boot joint piece(i.e.air hose ioint) is not clogged with grease.
LOCK WASHER

Wood block

1.0- 1.3mm (0.04-O.05 inl Check the lock wssher diameter aft€r staking.

I' I
TUBE CLAMP

17-130

66. Installthe right and l€ft tie-rod6nds.

70. Adiust the rack guide at the center of the rack stroke. 71. Tighten the rack guide screw until it compresses the spring and seats againstthe rack guide, then loosenrt.

TIE-ROOLOCKNUT Final to.que: 45 N.m {4.5 kg-m, 33 lb-ft|

72. Retighten to 4 N.m (O.4kg-m, 2.9 lb-ft), back it it off about 20 + 5; then installthe locknuton the rack guide screw. 73. Tightenthe locknut with the specialtool to about 25 N.m (2.5 kg-m, 18 lb-ft) while holdingthe rack guide screw. RACK GUIDE SCREW mm WRENCH,43 LOCKNUT oTMAA-SLOO20A

NE.RODEND

6 7 . Greasea new O-ringand instsll it in ths groovs in the rack guide sctew.

6 8 . Coat the rack guide slidingsurfacewith grease,. 6 9 . Installthe rack guide, spring and rack guide screw
on the gear housing.
GEAR HOUSII{G

4WS: 74. Installthe locknut on the front sub steeringangle sensor. 75. Greasea new O-ringand installit in the groove in the front sub steeringanglesensor.Installthe rack guide screw.

SPRING

RACK GUIDESCREW

GUIDE LOCKNUT

t*F
Loosolyinslall. (cont d

SteeringGearbox
Overhaul{cont'd}
76. Coat the rack guide slidingsurfacewith grease. 77. Installthe rack guide, spring, O-ringand the .ack guide screw/frontsub steeringanglesensoron the gear housing. Then adjust the rack guide at the center of the rack stroke. 81 . Coat the 9.8 x 1 .9 mm O-ringswith power steering Jluid.and installthem togetherwith the orifices. 82. Coat the 45.5 x 2 mm O-ringand pinionholderpin with grease,then installit in the valve body unit. 83. Installthe valve body unit on the gear housingwith the two 8 mm bolts. CAUTION: a Whon installing. b€ carolul not to hit the pinion holderpin. a Make sute the O-rings ale in place and not pinched.

LOCKNUT

RACK GUIOE O.RING

SCREW RACKGUIDE ANGLE SUBSTEERING FRONT SENSOR

-6,1

8 mm BOLT 22 N.m '16 (2.2 kg-m, lb-ftl

78. Tighten the rack guide screw until it compresses the spring and seats againstthe rack guide. then loosenit. it 79. Retighten to 4 N.m (O.4kg-m, 3lb-ft). back it otf + about 20 3' and install the locknut on the rack guide screw with the specialtool. 80, Tightenthe locknut to with the specialtool about 25 N.m (2.5 kg-m, 18 lb-tt) while holdingthe guide screw.

Ee?H",.

45,5 x 2 mm O.RING 9.8 x 1.9 mm O.RINGS

17-132

NOTE: Install the boot band with the rack in the straight ahead position (i.e. right and left tie-rodsare equal in length). 84. lnstallthe boot bandso that the lockingtabs of the band (stakepointsl are in the rangeshown below. (Locking tabs shouldtace up and slightlyforward.) 85. Installnew boot bandson the boot and bend both sets of lockingtabs. ponions to reduce 86. Lightlytap on the doubled-over their height. CAUTION: a Stako the band locking tabs firmly. a When staking. be car€tul not to damag€ the boot.

8 7 . lnstallthe air hose cliDas shown.
8 8 . lnstallthe bandcushionand air hoss band;Dosition the band as shown then tighten it. Installthe air hose, slidethe rack right and left to be 8 9 . After assembling, cenain that the boots are not deformedor twisted. NOTE: After installation, perform the electrical check on the 4wS system (seepage 17-146).

AIR HOSECLIP (Viewedlrom the right side) Clamp AIR HOSE CLIP

AIR HOSE BAf{O (Viewed lrom the right side) 6mm

atRHosE
NOTE: Connect with the protector side toward
th6 gearbox,

AIN HOSE BAND
45i5o

TUBE
JOINT

Front +

LOCKINGTA&S The locking tabs (stake points) should be in this range. Bandwinding direction.

OFFSET SHAFT LINE CENTER LEFT BOOTBAND (Viewed from the lelt side)

10a50

RIGHT BOOT BAND (Viewed from the right side)

17-133

SteeringGearbox
lnstallation
Slidethe rack all the way to the right. Pass the right side of the steering gearbox assemblyabove and through the right side of the rear Deam, Hold the steeringgearboxassembly8nd slide the rack all the way to the right. 4. Raise the left sideot the steeringgearboxassembly above and th.ough the left side ot the rear beam. 7 . Positionthe steeringrack centerof its strokes. Make sure that the cable reel of the driver'sairbag system is centeredas follows: a Turn the steering wheel left approx. l50 degrees,to check the cable reel position with indicator. a lf the cable reel is centered,the yellow gear tooth lines up with the aljgnmentmark on the cover. a Return the steering wheel right approx. 150 degreesto position the steering wheel to the straightaheadposition.

Looselyinstallthe left and right mountingbrackets with the six mountingbolts, Tighten the mounting bolts on the left mounting bracket ti.st, then tighten the mounting bolts on the right mountingbrackets.
\ <L6tt

\
LEFTMOU NNG BRACKET

GEAR

YELLOW Slip the lower of the steeringjoint onto the pinion shaft (line up the bolt hole with the groovearound joint bolt. the shaftl and looselyinstallthe steering NOTE: a Connectthe steeringshatt and pinionwhen the cable reel and steeringrack are centered. a Be sure that the steeringjoint bolt is securelyin the groove in the pinionshatt.

9.

39 N.m

(3.9 kg-m, 28 lb-ftl <Bight Sido:> 44 N.m {4.4 kg-m, 32 lb-ft|

BOLTHOLE

JOINT BOLT STEERING 22 N.m 12.2 kg-m, 16lb-ft) JOINT STEERING

MOUNTIT{G

BRACKET
FGHT MOUNTING TNACKET AIR HO CLAMP NOTE: The arrow on the brscket points toward the front. 39 l{.m 13.9 ks-m, 28 lb-ft)

17-134

1 0 .Connectthe four linesto the valvebody unit, using
flare nut wrenches. A: To oil cooler: 17 mm wrench 29 N.m (2.9 kg-m, 21 lb-ftl B: To powgr stoedng speod sen3of: 12 mm wranch 13 N.m {1.3 kg-m, 9 lb-ft} 12 mm wrench C: To rsseryoir: 1 3 N . m ( 1 . 3 k g - m ,9 l b - t t ) pump: 14 mm wronch D: From 38 N.m {3.8 kg-m, 28 lb-ft)

Fill the reservoir with power steering fluid and bleod air from the system by tufning the stesring whesl from lock to lock several times with the engine warm (see page 17-77l.. 1 4 . Make sure there afe no tluid leaks,then installthe gearboxshield, Recheck the fluid level in the reservoir.

1 1 .Reconnectthe connector and secure the sensor wire harnesswith the clamp and installthe cover. NOTE: a -Be sure the sensor wire harnessdoes not inor terferewith the stabilizer other moving parts. a Be certain that the sensor wire harnessis not twisted betore connectingit. Set the cover on the front sub steeringangle senand cover with sor. Securethe sensorwire harness a new wire tie.
CONNECTOR SENSORWIRE GEARBOXSHIELD 15. Install the center beam. {1.0 kg-m, 7 lb-ft}

60 N'm

TIE WIRE

CI-AMP

SUB STEERING

60 N'm {6.0 kg-]n,4.:lb-ft1

NOTE: After rack guide adjustment,perlorm the electrical check on the 4WS system (see page 17-146],.

{cont d

17-135

SteeringGearbox
lnstallation(cont'd)
model only. 16. Automatictransmission a Connectthe shift cable end to the shift control shaft. and installthe cable holder. 18. Reconnect the tie-rod ends to the steering tortightenthe castlenut to the specified knuckles. que, and instailnew cotter pins. CAUTION: Torque the castle nut to the lower tolqu€ sp6citication, th6n tighton it onlY tar €nough to atign the slot wilh the pin hol6. Do not align the nut by loosening.

SHIFT CABLE

CASTLENUT 50-60 N.m (5.0-6.O kg-m. 36-/13lb-ft)

CABLE

tl.4 kg-ln, 10 lb-ftl

1 8N ' m k 1 11.8 g-m, 3lb'ft|

17. Installthe exhaustpipe A with a new gasket.then tighten the new self-lockingnuts. Connect the heated oxygen sensor connector (H23A1 and H22A1engine).

COTTER PIN On reassembly,bond the cottgr pin as shown.

'19.

Adiust the front toe (seesection 18). NOTE: lf the steeringwheel and rack are notalignat the ed centered,reDosition serrations lower end of the steeringjoint.

20. Fillthe system: a Fill the reservoirwith new Honda Power Steeri n g F l u i d - V s e ep a g e 1 7 - 7 7 ) . { perform the following ch€cks 21. After installation, a Stan the engineand let it run at idle, then turn the steering wheel trom lock-to-lock several times to bleed air from the system (see page 1 7- 7 7 t . a Check the fluid again, and add more if necessary. a Check the gearboxfor leaks. a Check the tront toe (seesection 181. a Check the steeringwheel spoke angle. a Checkthe 4WS system {4WS only).

55 N.m 15.5kg-m,40 lb-ftl

EXHAUST PIPEA

7 -136

RearSteeringActuator
lllustrated Index
CAUTION: a Do not strlks tho rack end and shaft scrow. a Us€ the spocial tool when removing the rear stee ng actuator. Tho special tool should remain installed excopt whon tha aciuator ia inspected tor tunction, stc. a Do not try to disasEamble tho rear stoering actuator. lf the actuator is taulty, roplace it a3 an assembly. a Whon disassemblingand sorvicing. do not let dust, din. and for€ign matelials snter tho rgar ats€ring actuator. a Wh€n eithor th€ roar sub stoering anglo sonsor or th6 roar main st6o.ing angle sensor are removsd, pertorm Inspgction and adiustmont ot the raar sub stee ng angle sensor aft€r installing ths rear steering actuator. a Lock th€ shatt scrow using th6 r6ar steoring lock pin special tool betole removal/installstion and dlsassembly/r€assembly tho real steering actuator assembly. of

5O-60 N.m 15.0-6.0 kg-n, 36-43 lb-ft)

\ t

LOCKNUT 45 .m 14.5kg-m,33 lb-lrl

RACK 55 N.m (5.5 kg-m, 40 lb-ftl

BOOTBAI{D Replace.

d% w
Replace. REARSUB ANLGE SENSOR 5 Adjustmenl. page 1 7 - 1 5 LOCKNUT 25 N'm (2.5 kg-m, 18 lb-ft)

I

TORX@ BOLT '10t{.m (1.O kg-m, 7 tb-ft| O.RING Replace. NOTE: Do not let dust, dirt, and {oreign materials enter the actuator.

REAB STEERING ACTUATOR

I

SHAFT SCREW

17-137

RearSteeringActuator
Removal
1. Raisethe rear of car and supporton safety stands in the properlocations(seesection 1). NOTE: When the engineis OFF,the shaft screw of the rearsteeringactuatoris held in the neutralposition (straightaheaddriving position)by the return springtension. CAUTION: Do not start the €ngin€ with the real st€ering lock pin set in lhe roal stoering actuator. lf the ste€ring whsal is tumed with the engina running, the rear 6te€ringactuator will oporate, damaging th€ rear stoering actuator. 5. Removethe rear steeringactuatorcover.

2 . Remove the cotter pin from the castel nut and removethe nut. Installa 12 mm hex nut on the ball joint. Be sure that the 12 mm hex nut is tlush with the ball joint pin end. or the threadedsectionot the balljoint pin might be damagedby the ball joint remover. NOTE: Removethe ball joint using the Ball Joint Remover.Referto page 18-13 for how to use the ball joint .emover. the Separate tie-rodballjoint and knuckleusingthe specialtool. CAUTION: Avoid damaging th6 ball ioint boot. 12 mm HEXNUT
3.P CONNECTOR

REAR STEERING ACTUATOR COVER 6. Disconnectthe ground cable connectorsand terminalsfrom the rear steeringactuator.

TERMINALNUTS

NOTE: Do not contaminatethe terminal bolt and nut with grease.Cleanthem if necessary.

17-138

7.

Removethe rearsteeringactuatorby removingthe four mountingbolts and bracket.

ACTUATOR REARSTEERING

MOUNTINGERACKET MOUNNNG AOLTS

17-13!l

RearSteeringActuator
Disassembly
1. Removethe tie-rod ends, 3. Using a soft hammer,drive in th€ sp€cialtool between the actuator housing and stopper washer with the flat side of the specialtool toward the housing. the tie-rod lock washer. Straighten

4. TIE.ROD END

RACKHOLDER O7NA8-SSOo1OO

LOCK WASHER Reolace.

Removethe boot bands and tube clamDs.Pullthe boots awav trom the ends ot the rack end.

5.

Hold the shaft screw end with the spscialtool and unscrewthe rack end with a wrench,

RACKEND
TUBE CLAMP

6.

Removethe specialtool.

17-140

Assembly
the rearsub steetinganglesensorfrom the 7 . Remove actuatorhousing. 1 . Installthe locknut on the rear sub steeringangle sensor,then greasea new O-ringand installit. Screw the rear sub steeringangle sensorinto the actuator housingfully by hand, back it off about 1/2 turn, and looselytighten the locknut.

REARSUB STEERING ANGLE SENSOR

REARSUBSTEERIITG AI{GLE SENSOR
Screw in the resr sub stgering angle sonsor until se6ted, thgn back it oft about 1/2 turn.

LOCKNUT

ACTUATOR HOUSING LOCKl{UT

8.

Removethe rear main steeringangle sensorfrom the actuatorhousing.
ACTUATOR HOUSII{G REARMAIN STEERING

NOTE: Adiust the rear sub steeringangle sensor (seepage 1 7-155) after instslling the rear steering actuatoron the car.

CAUTION: Aftor disassembly, attach a pioco of tape or equivalent materialon each port andioint ot tho r6ar stooring actuator to protoct it trom dust. dirt, and foraign matoriala.

{coltl c

17-117

RearSteeringActuator
Assembly(cont'd)
3. Greasea new O-ringand installit in the .ear main steering angl€ sensor, then install the rear main steeringangle sensor.
REARMAIN STEERING ANGLE SENSOR TORXO EOLT 1O lt'm {1.Oks-m, 7 lb-ttl

5 . Using a soft hammer, drive the special tool between the housing and stopper washer with the tlat side of the specialtool toward the housing.
o.

Tightonthe rack end securely,then bend the lock washer back against the tlat on the flange as snown.
ACTUATOR HOUSING

-611
o-Rrr{G

DOWEL PINS

55 N.m 15.5kg-m,rto lb-ftl CAUTION: a Tako exfiomo car6 not to apply axisl impact and fotational tolc€ on the shaft screw. a S€t th€ projoction ot the lock washer in the groove in the lack securely. After tightoning the rack ond, bend th6 tabs of ths washer sgainst the tlats secur€ly. 7 . Removethe specialtool,

Screw each rack end into the shaft screw while holdingthe lock washerso lts tabs are in the slots the shaft screw end. NOTE: Install the stopDer washer with the chamferedside tacing out.

8 . Apply greaseto the circumference the rack end of
STOPPER WASHER o

housing. Coat the rack end groove and insideot the boot with siliconegrease.

:GREASE Coar the sliding surtace of the rack end. BOOT TUBE CLAMP

17-142

1O. lnstallnew boot bands, - Installthe boot band so that th€ lockingtabs oJ the band (stake points) are in the range shown below. {Tabsshouldface up and slightlyforward.)
LOCKING TABS RIGHT SOOT BAI{D Front lr

11. Installthe right and left tie-rod ends on the right and lsft rack ends.

LEFTBOOT
Th€ locking tsbs (stake points) should bs in this range. The locking tsbs (stske points) should be in this ran9e. -

Install new boot bands on the boot and bend both sets of locking tabs.

- Lightly tap on the doubled-overponions reducetheir height, CAUTION: a Siako tho band locking tabs firmly. a Whan staking, bo careful not to damago the boot.

LOCKINGTAB{i

17-14:l

RearSteeringActuator
lnstallation
Installthe rear steeringactuator with four mounting bolts and bracket. NOTE: Installthe bolts looselyfirst, then tighten them.
MOUNTINGCUSHION ACTUATOR REARSTEERING

NOTE: Do not contaminatethe terminal bolt 8nd nut with grease.Cleanthem iJ necessary. Connect the ground cable, connectots and ler' minalsto the rear steeringactuator. NOTE: Be surethe wires are not caughto. pinched by any parts.

,-9

I I
44 N.m (4.4 kg-m, 32 lb-ft)

MOUNTINGSRACKET The arrow on the bracketpoint up.

39 N.m (3.9 kg-m,28 lb-ft|

2.

Reconnectthe tie-rod ends to the rear steering tor tightenthe castlenut to the specified knuckles, que, and installnew cotter Pins. CAUTION: Torquethe castls nut to the lower tolque specitication, then tighten it only tar enough to align the slot with the pin hole. Do not align the nut by loosening. 4.
CASTLENUT 50-60 N'm l5.O-6.0 kg-m, 36-43 lb-ft}

Adjustthe rearsub steeringanglesensor(seepage 17-1 51. 5 NOTE: a Be sure that the tront sub steeringanglesensor and front main steering angle sensor are in neutral8nd the steeringwheel is in the sttaight aheaddrivingposition, a Bs sur€ that the rear steeringlock pin {special tool) is set in the rear actuator. lnstalltheterminalcover and rearsteerlngactuator cover,

COTTERPIN bend On reassembly, lhe cotter pin as shown,

END TIE-ROD

17-144;

4WS ControlUnit
Removaland Installation
1 . Removethe rear seat back {seesection 20}. , Disconnect terminalwires and connectors the f.om the 4WS control unit. Removethe 4WS control unit.

Tie-rod End Boot
Replacement
Removethe boot.

2 . Packthe interiorof the boot and lip with grease.
Wipe the greaseoff the slidingsurfaceof the ball pin, then pack the lower area with lresh grease. CAUTION: a Koep groase otl the boot installation s€ction and th6 tapersd section of the ball pin. a Do not sllow dust, din, or othar foreign mat€rials to onter the boot.

UNIT 4WS CONTROL

-\P

BOOT INSTALLATTON SECTION and BALL PIN TAPERED SECTION

BLK wire. 7 N.m lO.7 kg-m, 5 lb-lt)

4.

Installthe new balljolnt boot usingthe specialtool as shown below. NOTE: After driving the boot onto the ball joint, apply sealantbetweenthe tie-rod end and boot.

REDwire.

BRNwire.

END TIE.ROD

4.

Installin the reverseorderof removal. NOTE: Turn the ignitionswitch ON and check the 4WS indicatorlight operation. CAUTION: After installing the boot, check the ball pin tapered section fol grease contamination and wipe it if necossary.

17-145

4WS System Inspection
ElectronicNeutral Gheck
Preparation
NOTE: a lf the power of the 4WS control unit was shut down tor the following operations,start the engine and turn the steering wheel lully right and left. - Batteryremoval/installation - 4WS control unit removal/installation - N o . 4 3 f u s e C L O C KR A D I Or e m o v a l{ i n t h e fuse/relaybox) under-hood a Before performingthe electronicneutralcheck on the 4WS system check the following items. Be surethat the steeringwheelspokeangleis anglewhile drivingstraight at the designated aneao. - Be sure that the rear wheels are not steered to the right or left, but in the straight ahead drivingposition, Jack up the car and placethe tour wheelsslowly in the ceriterof the lurning radiusgaugeturn tables. tape or equivalent approxPlacea pieceof masking imately 3OOmm {12.O in) long on the top edge of the steering wheel. Place a mark on the tape at each of the following measurements: a Center (highestpoint of the steeringwheel). a 9 mm {O.4 in) right and lell oI center (Forfront main steeringanglesensor). a 18 mm {O.7in) right and left of center(Fortront sub steeringangle sensoradjustment). a 55 mm (2.2 in) right and left of center(Forfront sub steeringangle sensorinspection). 4. are NOTE: The sDecifications the measurements of on the outer circumference the steeringwheel.

a18 mm l!0.7 inl Florn

MARK CENTER MARK CENTER

a9 mm 110.4inl From

and place a Fashion pieceof stift wire (coathanger) Position the wire so the it on top of the dashboard. indicatingtip is closeto the marks on the steering wheel and tape the wire down securely. Set the steeringwheel in the straightaheaddriving positionand set the wire at the centermark on the steeringwheel.

17-146

5.

Take out the service check connector (BLU 2P) trom behind the center console.Connect the terminals with a piece ot jumper wire. NOTE: a The 4WS indicator light will not indicate that sensorsare in the neutralpositionwhen displaying stored problemcodes. a Check and verify any problemcodes displayed beforecheckingthe neutralposition.

Front sonsors insoection: 7. Checkthe front main steeringanglesensorwith the ignitionswitch on (engineoff), - From the straight ahead driving position, turn the steering wheel to the left, then turn the steering wheel slowly to the right beyond the straight aheaddriving position.Do not turn the steeringwheel inversely. - Turn the steeringwheel to the left, then turn to the right beyondthe straightaheaddrivingposition. Repeatthis operation severaltimes until vou tind the position where the 4WS indicator light starts to come on steady.

4WS INDICATOR LIGHT

' ,r9 mm (t0.4 in/:!3of F.omCENTER MARK -: --=- rll

-Br\ '11
!

t

JUMPER WIRE SERVICE CHECK
CONNECTON IBLU 2P}
!1i

o-

Pullup the parkingbrakeleverfully and turn the ignition switch on (engineoff) to turn the parking brske indicatorlight on. This sets the front sensors in the insoectionmode.

The 4WS indicatorlight should start to come on within the rangeof i9 mm (1O,4 in/a3") from the center mark on the steeringwheel. NOTE; a The 4WS indicator light might look as if it is blinkingat a point nearthe ends of the specilied range. a To determine that the 4WS indicatorlight is oo and not blinking,be surethat the 4WS indicator light stays on for more than 2 seconds. - Adjust the 4WS system if the indicatorlight startsto come on at a ooint outsidethe marked range on the steering wheel (see page 17-151l.

(cont'd)

17-147

4WS System Inspection
ElectronicNeutral Check (cont'd)
8. Checkthe front sub steeringanglesensorwith the ignitionswitch on {engineoff), - From the slraight ahead driving position. turn the steeringwheelto the right,then turn it slowly to the left beyond the straight aheaddriving position. Do not turn the steering wheel inversely. - Turn the steeringwheelto the right,then turn to the left beyondthe straightaheaddriving position. Repeatthis operationseveraltimes until you find the centerpoint of the rangewhere the of 4WS indicatorlight blinks(at the intervals O.2 seconds). Rsal sgnsols insDection: the 9. Release parkingbrakeleverfully to turn off the parkingbrakeindicatorlight. This sets the rearsenmode. sors in the insDection

4WS INDICATORLIGHT

'I

O. Turn the ignitionswitch off.

1 1 .Removethe cap bolt and sealingwasher from the rear steeringactuator.and screw the specialtool into the rear steeringactuatoras far as it will go. NOTE: Do not start the engine with the special tool set in the rear steeringactuator.

The centerpoint shouldbe within the rangeof t55 mm l!2.2 ini11 6,50 ) from the centermark on the the front sub steersteeringwheel. After adjusting ing anglesensor,however,the centerpoint should b e w i t h i n t h e r a n g eo f 1 1 8 m m ( 1 0 . 7 i n / 1 5 . 5 " ) from the center mark. - It the center point is outsidethe markedrange wheel. adjustthe front sub steeron the steering ing anglesensor(see page 17-153).

17-148

'12.

Set the steeringwheel in the straightaheaddriving positionto preventthe rearwheelsfrom steeringif the engineis started in error.

14. Set the steeringwheel in the straightahesddriving positionto preventthe rearwheelsfrom steeringit the engineis startedin error. 15. Turn the ignitionswitch on (engineoff) and check the rear main steeringanglesensor. - Pushthe rearleft wheel fully to the left by hand, then push it slowly to the right. - The 4WS indicatorlight should turn ON when the rear wheel is pushedto the right.

13. Turn the ignition switch on (engineoff) to check the rear sub steeringanglesensor. - Push the rea. left wheel fully to the .ight by hand, then push it slowlv to the lett. - The 4WS indicatorlight shouldblink at intervals of O.2 secondswhen the rearwheel is oushedto the lett.

4WS If{DICATORLIGHT

' ra,.!?. " """""ffi--1_.-1) 1

.

4WS INDICATOR

uear

REARLEFTWHEEL

TURNTO LEFT

TURN TO RIGHT

Froni

Front

NOTE: The 4WS indicatorlight blinks in a narrow range.Take care not to overlookit - lf the 4WS indicatorlight does not blink, adjust the rear sub steering angle sensor (see page 1 7 - l5 5 ) .

NOTE: a The 4WS indicator light turns on in a narrow range.Take care not to overlookit. o The 4WS indicator light might look as it it is blinking at a point near the ends oI the range where the light is on. a To determine that the 4WS indicatorljght is nor blinking. be sure that the 4WS indicator lighr stays on tor more than 2 seconds. a lf the 4WS indicator light does not turn on, removethe rear main steeringanglesensorand check it for damage.

17-149

4WS System Inspection
ElectronicNeutral Check {cont'd)
16. Turn the ignitionswitch oJt. 17. Removethe specialtool from the lear steeringactuator, and installthe cap bolt and the new sealang washer on the rear steering actuator'

REAR STEERII{G ACTUATOR 18. Removethe jumper wire from th€ ssrvice check connectorterminals{BLU 2P). 19. Returnthe connectorbehindthe center console. the removedparts. 20. Reinstall

17-150

4WS System Adjustment
4WS System Adjustment
Adjust the 4WS system usingthe followingprocedure, NOTE; a lf the Dower ot the 4WS control unit was shut down for the Jollowing operations,start the engine and turn the steeringwheel tully right and left. - Battery removal/installation - 4WS control unit removal/installation - N o . 4 3 f u s e C L O C KR A D I Or e m o v s l{ i n t h e fuse/relavbox) under-hood 1, Jack up the car and placethe wheelin the centerof the turning radiusgaugeturn tables. a Check whether the yellow paint mark ot the tront main stseringangle sensorrotor is facing down (i.e. in neutral lock position where the that the front rotor does not turnl. This indicates in main steering angle sensor is electronically neutral. NOTE: lf the paint mark is not facing down, adjust as instructedin step 5, (1) through (3) on page 't7 -87 .
FRONTMAIN STEERING

RADIUS GAUGE TURNING TURNTABLE in Set the steeringwheelso that it is positioned the rangewhere the steeringwheelturns centerof the fully to the right and left. (This centers the tront steeringrack.l lf the steering wheel spoke angle is not at the anglewith the steeringwheel set in the designated positionexplainedin step 2. adjustthe tront main steeringanglesensorand spoke angleas follows. a Set the steeringwheelin the straightaheaddriving position,then removeit.
WHEEL STEERING

a Installthe steeringwheel, aligningit with the serrationwhich makes the spoke angle closest to horizontal. - lf the spokeangleis not horizontal, adjustthe steering wheel slightly right or left. being careful not to push in on the steeringwheel. NUT WHEEL STEERING 5ON.m
{5.0 ks-m, 36 lb-ft)

a With the spoke angle set at horizontal,then push the steeringwheel in fully. Tighten the steefing wheel nut while pushing the steeringwheel in. NOTE: a Do not removethe steeringwheel until adjustment is completed. a Do not turn the steeringwheel when pushing the steeringwheel.
tcont c

17-151

4WS System Adjustment
4WS System Adjustment (cont'd)
4. Be sure that the rear wheels are not steeredto the right or left, but in the straight ahead driving Dosition, Checkthe sub and main steeringanglesensorsusing the table shown below (seepage 17-146). NOTE: a Turn the ignition switch on (engine off ) to check. a The 4WS indicatorlight does not indicatethe electronicneutralpositionwhen it is indicating problemcodes. a Check the sensors by turning the specified wheel in the specifieddirection shown in the if are table below, The sensors adiustedproperly the 4wS indicatorlight turns on in the specilied range on the steeringwheel, or if the center ot light blinksis the rangewhere the 4WS indicator rangeon the steeringwheel. within the specified
Sensor type Frontmain steering angre sensor Front sub steering angle sensor Rearsub steering angle sensor Check Parkingbrake lever *2 Release l Pull

Take out the service check connector (BLU 2P) trom behind the center console.Connectthe terminalswith a pieceof jumper wire.

Turn front wheelsto right

.2 0N

Turn front wheels to left '4 Turn rear wheelsto lefl

*3 Blinks

'3 Blinks

Flearmain *4 Turn rear steering *2 Blinks wheelsto angle ngnt sensor *'1:Be sure that the parking brake indicatorlight operates properly. '2: The 4WS indicator light might look as if it is blinkingat a point near the ends oI the range where the light is ON. *3: The 4WS indicator lighl blinks in the intervalsof O.2 the main seconds.When the indicatorlight is indicating ot condition steering anglesensor {lightON),indication the is condilion blinking canceled. by sub steering anglesensor *4: Turn the rear wheel slowly by hand with the specialtool (rear steering center lock pin) sel in the rear steering actuator,

17-152

Sub Steering Angle Sensor Adjustment
7 . lf the sensors are not sdiusted properly. adjust eacn sensof. a It the front main steeringanglesensoris not adiusted properly, start with the step 2. a Front sub stee,ing angle sensor adiustment: see psge17-153. a Rear sub steerlng angle sensor: see page 17-155. NOTE: The rsar main steeringanglesensorcannot be adjustsd.lf the rear main steeringangle sensor is sbnormal,removeit and check it tor damage.

Front Sub SteeringAngle Sensor
NOTE: Before adjusting the sub steering angle sensor. check that the front main steeringangle senso. is adjustedproperly(see page 17-146). 1. Jack up the ca. and raise all four wheels off the ground.Placethe salety stands in the properlocations to supportthe car (seesection 1). 2. Set the steeringwheel in the straightaheaddriving oosttton. Take out the service check connector (BLU 2P) from behind the center console.Connect the terminals with a piece of iumper wrre. NOTE: . The 4WS indicatorlight will not indicate that the sensors are in the electronic neutral oosition when displaying stored Diagnostic Trouble C o d e s( D T C ) . a Check and verify problem codes displayed betorecheckingthe electronicneutralposition.

3.

4.

Set the parking brake lever and turn the ignition switch on {engineofl). Be sure that the parking brakeindicatorlight turns on, Turn the ignitionswitch oJf.

17-1!i :l

4WS System Adjustment
Sub SteeringAngle Sensol Adjustment (cont'd)
6. Cut the wi.e tie from the cover, then remove the cover Jromthe front sub steeringanglesensor. CAUTION: Uso car6 whon cutting lhe wire tie so as not to cut into the wiro harnsss. 7, Removethe sensor wire harnessfrom the clamp the connector. and disconnect 9, Turn the ignitionswitch on {engineoff). 10. Set the steeringwheel in the straightaheaddriving position.Set the front main steeringangle sensor electronicallyin neutral (4WS indicator light is blinking) this time. NOTE: Hold the steeringwheel in this positionunis til adjustment completed,lJ the steeringwheel is moved in effor. repeat the adjustment procedure starting with step 10.

CONI{ECTOR

COVER

WIRETIE
R6place.

/w
" \ '
11. Turn the front sub steering angle sensor slowly clockwise. and check the range Jrom where the light startsto blinkto where it stops. 4WS indicator 12. Loosenthe front sub steeringanglesensor.Repeat the step 11 severaltimes to set the sub steering anglesensorin the centerof the rangefrom where the 4WS indicatorlight starts to blink to where it srops. ] CENTER
LIGHT STABTS TO BLINK LIGHT OFF

Loosenthe locknut. Tighten the locknut fully by hand, back it off about 3/4 turns and connectthe connector.

LOCKf{UT

FRONTSUB STEERING ANGLE SEIISOR

TURNINGDIRECTIOI{

NOTE: a Turn the front sub steering angle sensor clockwiseto makethe 4wS indicatorlight blink. a lf the sub steeringangle sensorwire is twisted excessively, turn the ignitionswitch ott, disconnect the connector,and straightenthe wire.

17-154

13. Tighten the locknut while holding the front sub steefingangle sensorwith a wrencn. NOTE: Take carenot to turn the tront sub steerino angle sensor.
LOCKNUT 25 N'm 12.5 kg-m, 18 tb-ftl FRONTSUB STEERING ANGLE SENSOR

RearSub SteeringAngle Sensor
1. Jack up the car and raise all four wheels off the ground.Placethe safety slands in the properlocations to supportthe car (see section 1). 2. Take out the service check connector (BLU 2Pl from behind the center console.Connect the terminalswith a pieceof jumper wire. NOTE: a The 4WS indicatorlight will not indicate that the sensor is in electronic neutral oosition, when displaying stored Diagnostic Trouble Codes (DTC). a Check and verify problem codes displaved beforecheckingthe electrically neutralposition.

SENSOR WIREHARNESS

'I 4. Disconnect front sub steeringanglesensorconthe nector to straightenthe sensorwire harness. Reconnect the connecior. NOTE: Do not contaminate the front sub steering angle sensor connector terminals with mud, oil, and grease. '15. Check that each sensoris electronicallv neutral in { s e ep a g e 1 7 - 1 4 6 ) . NOTE: Be sure that the centerof the rangewhere the 4WS indicatortighr btinks (indicating that the front sub steeringangle sensoris electronicalty in n e u t r a l l ,s i n t h e r a n g e : t 1 8 m m ( a 0 . 7 i n / r s . 5 0 ) i from the center mark on the steeringwheel.
i18 mm lao.7 in) Frorn CENTERMARK

JUMPERWIRE

'

'

///{\ . .

t(rir'

3 . Release parkingbrakeleverfully and turn the igthe
nition switch on (engine otf). Be surethat the parking brake indicatorlight goes olt. 4. Turn the ignitionswitch off.
PARKINGBLAKE LEVER

16, Reconnect connectorand securethe sub steerthe ing angle sensorwire harnesswith the clamp and installthe cover. NOTE: a Be sure the sensor wire harnessdoes not interferewith the stabilizer other movingparts. or a Be certain that the wire is not twisted before connectingit. 17. Securethe cover with a new wire tie. (cont'd)

17-155

4WS System Adjustment
Sub SteeringAngle SensorAdjustment lcont'dl
Removethe fear steeringactuatorcover
o.

Remove the cap bolt and sealing washer from the rear steeringactuator.Sc.ew the specialtool in as far as it will go.
WASHER SEALIT{G

9. Set the steering wheel in the strsight ahead driving position to prevent the rear wheels trom steering if the engineis startedin error. 1O. Turn the ignitionswitch on (engineotf). 11. Push the rear left wheel tully to the left by hand, then push it slowly to the right to turn the 4WS indicatorlight on (i.e..ear main stee.inganglesensor in is electronicallv neutral). REARLEFTWHEEL

TURNTO

STEERING

LOCKPIN CENTER REAi STEERING 07NAJ-SSOO20A 7. Remove the rear sub steering angle sensor wire from the clamp and disconnectthe connector' Loosen the locknut. Tighten the locknut tully by 'l12 turn and connect hand, then bsck it oft about the connector' LOCKNUT

Frcnt

8.

NOTE: a The 4WS indicator light turns on in a natrow range.Do not ovetlookit. a Work with ca.e so as not to move the real wheels from this neuttal position.

17-156

12. Turn the ignitionswitch on {engineoff}. 13. Turn the .ear sub steering angle sensor slowly counterclockwise, checkthe rangelrom where and the 4WS indicstorlight starts to blink. to where it srops. 14. Tightenthe rear sub steeringangle sensora little. Repeatthe step l3 severaltimes to set the sub steering angle sensor in the center of the range from where the 4WS indicatorlight starts to blink, to where it stops. I CEIITER LrcHToFF I
LIGHT STARTS TO BLII{K TURI{ING DIRECTION

16. Disconnect the rear sub steeringanglesensorconnecto. to straighten the wire. Reconnect the connector. NOTE: Do not contaminatethe rear sub steering angle sensor connector terminals with mud, oil, ano grease. 17. Checkthat each sensoris electronicin neutral(see p a g e1 7 - 1 4 6 ) . 18. Turn the igntion switch olf. Removethe special tool from the rear steeringactuator,and installthe cap bolt and the new sealingwasher on the reat steeringactuator. 19, Installthe rear steeringactuatorcover. CAPBOLT 22 N.m {2.2 kg-m,16 lb-ft)
SEALINGWASHER

NOTE: a Turn the rear sub steering angle sensor counterclockwise make the 4WS indicator to light blink. a lf the rear sub steering angle sensor wire is twist€d excessively, turn the ignitionswitch off, disconnectthe connector, and straightenthe 15. Tighten the locknut while holding the rear sub steeringangle sensorwith a wrench. NOTE: Take care not to turn the rearsub steering angle sensor.
REARSUB STEERING ANGLESEI{SOR

REARSTEERING ACTUATOR REARSTEERING CENTERLOCK PIN 07NAJ-SSOO20A

Suspension
......... 18-2 SpecialTools ComponentLocation .... 18-3 l n d e x. . . . . . . . . . . . . Alignment Wheel S e r v i c e1 n f o r m a t i o n , , , . . . . . . . . . . .1. .- 4 .8 ,, Camber . . . . . . . . . . . . .1 8 - 5 . .... 18-5 C a s t o r. . . . . . . . . . . . Front Toe Inspection/ Adjustment ..... 18-6 RearToe Inspection/ Adjustment ..... 18-7 Turning Angle Inspection/ ..... 18-8 Adjustment Wheel Measurements E . . B e a r i n g n d P l a y. . . . . . . . . . . . . . . . . . . .1 .8 - 9 R u n o u t. . . . . . . . . . . .... 18-9 Front Suspension ................ 8-10 Torque Specifications 1 Knuckle/Hub I . . l l l u s t r a t e dn d e x. . . . . . . . . . . . . . . . . . 1.8 - 11 . . . . . . . . .1 8 - 1 2 Removal Hub Unit and Wheel Bearing Replacement ... 18-15 ...... 18-17 lnstallation Arms Suspension Removal/lnspection ................18-19 ...... 18-20 lnstallation ....... 18-21 Ball Joint Boot Replacement Lowerarm Bushing Replacement 18-21 .... Front Damper Removaf .............18-22 Disassembly/lnspection .............. 1A-22 ........ 18-24 Reassembly ......... 18-25 lnstallation Rear Suspension ..... 18-26 Torque Specifications ........... Knuckle/Hub ........ 1A-27 llfustratedIndex ............. ......... 18-28 Removal ...... 18-31 lnstallation Suspension Arms Removal/lnspection ................18-33 Installation ...... 18-34 BallJoint BootReplacement ......... 18-35 LowerArm Bushing Replacement 18-35 .... Rear Damper Removal .......... 18'36 .... 18-37 Disassembly ....... 18-37 Inspection ..... 18-39 Reassembly ...... 18-40 lnstallation . . D a m p e rD i s p o s a.l. . . . . . . . . . . . . . . . . . .1 .8 - 4 1

SpecialTools

Rcf. No.

I

Tool Number

Desc ption Base Hub Dis/Ass€mbly Tool Hub Dis/Assembly Hub Assembly Guide Attachment Ball Joint Boot CliDGuide Driver Attachment Ball Joint Remover,32 mm Ball Joint Remover,28 mm BushingDriver Attachment, 62 x 68 mm Driver support Base BallJoint Boot Clio Guide

O'ty

I

Pag. Refcrcnce

o

@ @ @ @ @ @ @ @

o

@

oTGAF-SD40700 oTGAF-SEOo100 oTGAF-SEOO200 -SD40700 07GAG oTHAD-SG00100 07MAC-5100100 oTMAC-S100200 oTNAD-SS00100 10500 07746-OO 07749-0010000 07965-SD90100 07974-SA50800

2 r 1 1

r
r
r

1A-'t5 1 8 - 1 51 6 ,1 7 , 18-17 L , | 1 8 - 2 13 5

1 1

I ra-ro
I rg-rs

| 18-14,30 | 1 8 - 2 1 .3 5

14, I ra-ra, so,36

r
1 1

e re , Jr 8 - - r ,s 7 1 16 1
I 1 8 - 2 1 ,3 5

I
{--ru
:,.--l

H | l
@

o

tr

I (J
@

v
/

F1
\

6

@@

/-] l , r a l

V

F

---G-1

N W
@

@
@

@

@o

n
hJ
@

w

H l_,
@

8-2

Component Location
lndex
The tront and real dampe.s contain nitrogon gas and oil undor presauro,The prsssuro must be raliov€d @ betore disposal to provent oxplosion and possiblo iniury whon scrapping. Wheel Alignment,page 18-4 Front Suspension:
FRONTDAMPER . Removal, page 18-22 . Disassembly/lnspection, page 18 22 . Reassembly,page 18-24 . Installstion, page 18-25 . Disposal, page 'l8-41 FROI{T UPPERARM . Removal/lnspection, page 'l8-19 . Installation, page 18-2O

STABIUZER BAR . Removal/lnspection, 18-19 page . Installation, 18-20 page
FBOI{T KNUCKLE/HUB . Removal, page 18-12 . Bearing Replacement, Page 18-15 . lnstallation, page 18-17

FRONTLOWERARM . Removal/lnspection, page 18-19 . Installation, page 18-20

t l /

ROD RADIUS ,/ . Removal/lnspection. 18-19 p6ge . Installation, 18-20 page

Roar Suspension:
BEAR UPPERARM . Removal/lnspection,page 18-33 . Installation. page 18-34

REAR OAMPER . Removal, page 18-36 . Disassembly, page 18-37 . Inspection, pago 18-37 . Reassembly, page 18-39 . Installation, page 18-40 . Oisposal, page 18-41

REAR KNUCKLE/HUB . Removal, page18-28 . Installation, 18-31 pago

REAR LOWEA ARM . Removal/lnspection, Page 18-33 . Installation, page 18-34

TRAILINGARM . Removal/lnspection,page '18-33 . Installation, page 18-34

1&3

Wheel Alignment
Service Information
NOTE: For proper inspection/adjustment of the wheel alignment, check and adiust the following before checking the alignment. a a a a Check that the suspension is not modified. Check the tire size and tire pressure Check the runout oJ the wheels and tires. balljoints. (Holda wheel with Checkthe suspension your hands and move it up and down and right and left to check for wobbling.)

wheel alignment adjustment procedure
Each of the wheel alignment elements relates to the other, Theretore, the total adjustment of the lront/rea. whenevereitherone of €leis wheel alignment required ments (i.e.camber.caster.toe, snd/orturningangle)is adiusted.

Adiust cambet

Adiust caster

Adiust toe

Adiust turning angle

R€adjust camber

Read,ustcaster

Roadiusttoe

Readjustturning angle

18 -4

Camber
lnsp6ction
four NOTE: Use commerciallyavailablecomputerized wheel alignmentequipmentto measurewheel alignment (i.e. caster, camber,toe, and/orturning anolel. Follow the equipment manufacturer's instructions. 1. Check the tire pressure. 2. 3. Turn the Jront wheels to the straight ahead position. Check the camber angle. Cambel angle, Front: 0oO0' t 10 10 (2WSl Roar: -Oo45't

Caster
Inspection
NOTE: Use commerciallyavsilablecomputerized ;ommercially four wheel alignmentequipmentto measurewheel alignment ent equipmer (i.e. caster, camber,toe, and/orturning angle).Follow ramber, instructions. rt manufact! the equipment manufacturer's 1. Turn the front wheels to the straight aheadposition. te Check the caster angle. ngl€: 20, Caster angl€: 2o4O' 1 1" ll adjustment is required, nent r€ recordthe casterreading, o 4 then go to step 4, lf adjustment is not required, regnmentequipment. move alignment( :aster an NOTE: Caster angle can be adjusted by increasing/decreasingthe numberol the sdjustingshims. lasingth Remove and install the radius rod each time the inst rgle a( caster angle is adjusted. 4. Raisethe front end of the car and placesafety stands en( in the proper locations(see section 1). oper locr Removethe selfiocking nut on the end of the radius the selfi( rod. Remove the radiusrod attachingbolts at the lower radiu n remov{ arm, then removethe radiusrod (page 18-19). Adiust the caster angle by increasing/decreasing the e adjusting shims. I shims. - One adjusting djustingshim changesthe casterangle by 40' and the caster anglecan be adjustedby I o20' d cas maxtmum. - One adjusting s h i m i s 3 . 2 m m ( O . 1 i n l i n 3 thickness.

-oo45' r 30' (4ws)

4.

Front: lf out of specitication.check for damagedsuspensroncomponents. Rear (2wsl: lJ out oJ specification, ch€ck for components. damagedsuspension (4WSl: - lf adiustment is requared, to step go - i no adjustmentis required,remove alignmentequipment. 5.

Rear Camber Adjustment (4WSl
5, Hold the adiustingbolt and loosenthe self-locking nut. Adjust the rear camber by turning the adjusting bolt until camberis co.rect. nut and tighten while Installthe new self-locking holdingthe adjustingbolt.

b.

o.

7.

ADJUSTING SHIM

NUT SELF.LOCKIIIG 12 x 1.25mm Rgplace. 65 N.m 16.5 kg-m, 47 tb-ft}

SELF.LOCKING NUT ! 55 N'm {5.5 kg-m, Replac€.

BADIUS ROO

ADJUSThIG BOLT

NOTE: a Do not use more than two adjustingshims. ul a After the adjustment. tighten the self-lockingnur re to the speci{ied torque. sD

18€

Wheel Alignment
Front Toe Inspection/Adiustment
four NOTE: Use commerciallyavailablecomputerized to wheelalignment equipment measure wheelalignment {i.e. caster,camber,toe. 8nd/or turning angle),Follow the equipmentmanufacturer'sinstructions. 1. Check the tire pressure. 6. 2. 2WS: Set the tront wheels to the straight ahead posation. 4WS: Set the front main steering angle sensor in the neutral position and jump the service check connector to turn the 4WS indicator ON (see page 1 7 - 15 6 ) . and duringinspection this condition NOTE:Maintain adjustment.
4WS INDICATOR

Loosenthe tie-rod locknutsand turn both tie-rods in the same directionuntil the lront wheels are in straightaheadposition. Turn both tie-rodsequallyuntil the toe is correct. tighten the tie-rod locknuts. After adjusting, NOTE: Repositionthe tie-rod boot if it is twisted or displaced.

TIE-RODLOCKNUT 14 r 1.5 mm 45 lrl'm {4.5 kg-m, 33 lb-ft)

TIE.ROD

Check the lront toe. Front toe: 0 t 2.O mm lO a O'O8in) - lt adjustment is required, go on to step 5. , - lf no adjustment is required. remove alignment equipment.

8-6

RearToe Inspection/Adjustment
NOTE: Use commercially available computerized tour wheel alignmentequipmentto measurewhe6l alignment (i.e. caster,camber,toe, and/or turning angle).Follow instructions. the equipmentmanufactur€r's 1. 4WS only: Checkthe rear main steeringanglesensor is in the neutralpositionand jump the service checkconnectorto turn the 4WS indicatorON (see psge17-156). NOTE:Maintainthis conditionduring inspection.
4WS INDICATOR

4.

2WS: a Hold the sdjusting bolt on the rear lower arm B and loosen the self-locking nut. a Adjust the rear toe by turning the adjusting bolt until toe is correct. nut a Install the n€w self-locking andtighten while holdingthe adjustingbolt.

4WS: a Loosenthe tie-rod locknuts and turn both tie-rods in the samedirectionuntil the rearwheelsare in the straight ahead position. NOTE: Make sure the 4WS indicatoris ON parkingbrake. Release Check the rear toe. NOTE: with the a Measureditferencein toe measurements wheels pointed st.aight ahead. o lf the parkingbrakeis engaged,you may get an incorrectreading. Reartoeln: 2.O ! 2.O mm (O.08r O.OBin) - lf adjustment is required, go to step 4, - lf no adjustmentis required,removealignment equrpmenr. a Turn both tie-rods equally until the toe is cortect. a After adjusting.tighten the tie-rod locknuts. the NOTE:Rsposition tie-rodboot it it is twisted or disDlaced,
45 N.m (4.5 kg-m, 33 lb-ft|

TIE.ROD

1*7

Wheel Alignment
TurningAngle Inspection/Adjustment
NOTE: Use commercially available computerized four wheel alignmentequipmentto m€asurewheel alignment (i.e. caster,camber,toa, and/orturning angle).Follow the equipmentmanufacturer'sinstructions. 1, Jack up the tront of the car. Set the turningradius gaugesbeneaththe front wheels. then lower the car. 2, 2WSt Jack up the rearof the car. Placeboardsthat are the same thicknessas the turningradius gaugesunderthe rearwheels,then lower the car. 4WS: Jack up the rear of the car. Set the turning radiusgaugesbeneaththe reat wheels,then lower the car. the NOTE:Foraccuratereadings. car must be level. 3. Turn the wheel right and left while applying the brake. Measure the tutning angle oJ both front wheels, and both rear wheels (4WS models). 4. are It the measurements not within the specifications, adiust as required by turning the tie-rods. NOTE:After adiusting, recheck the front wheel toe the and readiustif necessary.Reposition tie-rod boot it twisted or displscad. TIE-ROD LOCKNUT 1 4 x 1 . 5m m 45 N.m (4.5 kg-m,33lb-ft) llE-ROD

Front turning angl€: lnwa.d whsol: 36o20' ! 2o Outward whaol: 29o4O' (roloronca) Raar tuming anglo (4WSlr lnward wheel: 6000' 1 10 Outward whcsl: 6020' (.otoronce)

18-8

Wheel Measurements
Bearing End Play
1. Raisethe car and support it with safety stands in the proper locations(seesection 1,. the lug nuts. Removethe wheels, then reinstall Attach the dial gauge as shown. end play by movingthe disc in the bearing M€asure and out.

Runout
1. Raisethe car and support it with safety stands in the proper locations(see section I l. Check tor b€nt or deformedwheels. Attach the dial gauge as shown. Measurethe wheel runout by tuming the wheel.

2. 3. 4.

2. 3. 4.

Front and Raar Wheel Axial Runout: Standard: 0- 1 .O mm (O-O.O4 in) St6ol l|haol: AluminumWhool: O-O.7 mm {0-0.03 in} 2.O mm {0.O8 inl Se.vlce Limitr

front wheol End Play: Standard:0-O.O5 mm {O-O.002 inl

Rear Who6l End PlsY: Standard:0-0.05 mm (0-0.002 in)

Front and Rear Wheel Radial Runout: St.ndard; 0-1.0 mm (O-O'O4 inl Stoel Whool: Aluminum Wh.ol: O-O'7 mm (O-O.O3 inl 1.5 mm (0.06 inl Scrvico Limlt:

is lf the bearingend play measurement more than replacethe wheel bearing. the standard,

lf the wheel runout is more than the servicelimn reolacethe wheel.

1&9

Front Suspension
TorqueSpecifications
CAiJ-f€N, a Reiface the s€lf-lockingnuts after rsmoval. nut a Beplacotho solt-lockingbolts it you can aasily thlaad a non-soll-locking past th6ir nylon locking lnsotts. {lt shoub requir€ 1 N'm (0.1 kg-m. O.7 lb'ft) ot torqus to tuln thc nut on tho bolt}' a The vehtg|es-hould on th€ groundbeloreany bolts or nuta connoctedto rubbermountsor bushingaro tighten6d. b€ thon tighton lt only far onoughto aligntho slot with tho dn a Torqueihe castlenut to th€ low6r torquespocification. holo. Do not align the nut by loosening.
the b€loretightening nut at the balljoint. Wipe off the grease NOTE:

INSERT

NUT SELF.LOCKIT{G 1 0 x 1 . 2 5m m 30 N'm (3.0 kg-m,22 lb-ftl Replace.
SELF-LOCKII{G 1{UT 12 r 1.25 ]nm 65 ltl.m 16,5kg-m, 47 tb-ttl Replace.

NUT 1 0 x 1 . 2 5m m 39 N'm 13.9kg-n. 28 lb-tt) NUT CASTLE lO r 1.25mm 4O-48 N'm l4.O-4.8 kg-tn,29-35 lb-ft}

SELF.LOCKII{G NUT 1 0 x 1 . 2 5m m 30 t{.m {3.0 ks-m, 22 lb-ftl
Reolace.

DAMPER NNC'.IEOLT (SELF.LOCKII{G EOLTI 1 0 x 1 . 2 5m m 44 N.m 14.4kg-m,32 lb-ft} SELF.LOCKII{G BOLT 1 2 x 1 . 2 5m m NUT CASTLE 12 , 1,25rnft 50-6{, ]t.m 15.O-6.0 kg-m, 36-43 tb-frl

55 N'm (5.5 kg-m, 40 tb-ftl

SELF-LOCKING t{UT 1 2 r 1 . 2 5m m 55 N.m(5.5kg-m, 40 tb-ft) Replace.

t{ur sPtt{Dt"E
24 x 1.5 mm 25ON'm (25 kg-m, r81 tb-ft| Raplacs. NOTE: Aftsr tightoning, I drift to uso nut stakgths apindlG ahouldsr ag6rnst tho spindle. t{UY DAMPB FORK NUTI {SELF.LOCKII{G 1 2 r 1 . 2 5m m 65 'm (6.5 kg-m,47 lb-ft) Beolace.
NUT CASTLC

BOLT SELF.LOCKI]TG 1 2 x 1 . 2 5m m 105 N.m(10,5 kg-m, 76 lb-ft

NUT SELF-LOCKING '1.25 mm 12 x 55 N'm 15.5kg-m,40 lb-ttl
Replace.

CALIPER BRACKET MOUNTING BOLT 1 2 x 1 . 2 5m m 11ON.m(11 ks-m,80 lb-ft|

14 r 2.o mm 50-60 I{'m{5.0-6.0 ks-m, 36-43 tb-ftt

18-10

Knuckle/Hub
lllustrated lnd6x
NOTE: wheel weights may corrode8nd damsge a Use only genuineHondawheel weights for aluminumwheels.Non-genuine the aluminumwheels. a Before installing the brake disc, cleen the mating surfacas of the front hub and inside ot tbe brake disc. the wheel, clean the mating surfacesof the brake disc and insideof the wheel. a Beforeinstalling

K1{UCKIE Checkfor dam8ge.

PROTECTOR KNUCKLE Ch6cktor damage.
BOLT-WASHER 6 x 1 . Om m 10 N.m (1.Okg-m, 7 lb-ft)

K UCKLE RING Checkfor damag€,

COTTER PIl{ Roplace.
WHEEL AEARING Replace. psge 18-15 Replacament, CIRCLIP SPLASH GUARD Check tor bending or damage.

BALLJUNT EOOT Checkfor doteiorstion or damago. CIRCLIP----"""i€)

:3J.'ff*.--.......€

SCREW 10 'm (1.0 kg-ft, 7lb-fil

HUB FROI{T or Ch€ckfor d6mag6 cracKs.

BRAKEDISC Chsck for w6ar or rust. Inspoction, soction 19

LUG UT
1 2 x 1 . 5m m 1 10 N.m 111 kg-rn, 80 b-trl

I lnm EnAKEDISC SCREW RETAII{ING 10 'm (1.0 ks-m,7 lb-ft|

atl

a

1&t I

Front Suspension
Knuckle/Hub(cont'd)
Removal
Loosenthe wheel nuts slightly. Raisethe Jrontof car and supporton safety stands in properlocations{seesection 1). Removethe wheel lug nuts and front wheel. 4. Raisethe lockingtab on the spindlenut. then remove the nut. 7. 8. Removethe 6 mm brake disc retainingscrews. Screwtwo 8 x 1 .25 mm bolts into the disc to push it away from the hub. NOTE:Turn each bolt two turns at a time to prevent cockingthe disc excessively. 9 . Removethe b.ake disc from the knuckle.

x 1.25 mm BOLTS

DISC 6 mm SRAKE SCREWS RETAINING

1 0 .Removethe wheel sensorwire bracket,then remove
the wheel sensorfrom the knuckle. Removethe brake hose mounting bolts. NOTE:Do not disconnectthe wheel sensor wire.

6 . Removethe caliperbracket mounting bolts and hang
the csliperassemblyto one side. CAUTION: To provont accidantal damago to the calip€r assomblyor brako hos€. us€ a short piece ol wire to hang lhe calipel sgombly from lhe und€rcariago.

CAIIP€R ARAO(ET MOUNTING BOLTS 12 r 1.25mm

18-12

the balljoints NOTE:Use ballioint remover,to separate or from the suspension steeringarm. CAUTION: B€ calotul not to damEgothe ball ioint boot' 1 1. Cleanany dirt or greaseotf the ball joint. on to 12. Apply grease the specialtool the areasshown. ot This will esse installation the tool and prevent damageto the pressurebolt threads.
Apply greasehere.

1 6 .Once the tool is in place,turn the sdiustingbolt as
necessaryto make the jaws parallel.Then handtighten the pressurebolt and recheckthe iaws to make sure they are still parallel.

PRESSURE BOLT

BoLT ADJUSTING 13. Removethe cotter pin Jromthe steering arm and remove the nut. 14. lnstalla 12 mm hex nut on the balljoint. Besurethat the hex nut is flush with the balljointpin end to prevent damageto the threadedend of the ball joint. 15. Use the ball ioint removeras shown. Insert the jaws carefully,making sure you do not damagethe ball joint boot. Adjust the iaw spacing by turning the pressurebolt. NOTE:It necessary,apply penetratingtype lub.icant to loosenthe ball joint.

;i

1 7 . With a w.ench, tighten the pressurebolt until the ball joint shaft pops loose from the steeringarm. w6ar eye protsction. The ball ioint l!@ can brsak loose suddenly and scatto. dirt or othgl debris in your oyos. the 1 8 . Remove tool. then removethe nut lrom the end of the ballioint and pullthe balljoint out ol the steerjng/suspension arm. Inspectthe ball ioint boot and replaceit if damaged.

)
12 mm HEX

{cont c

1&13

Front Suspension
(cont'dl Knuckle/Hub
19. R€move the cotter pin and lowef arm balljoint nut. 20. Install 14 mm hex nut on the balljoint.Be surethat a the hex nut is flush with the ballioint pin end, or the thresded section of the ball joint pin might be damagedby the ball joint remover. 21. Use the balljoint .emoveras shown on page 18-13 to separatethe ball ioint and lower armNOTE:lf necess8ry,apply penetr€tingtype lubricant to loosenthe ball ioint. 22. Remove the knuckle protector, 23. Removethe cotter pin and the upper balljoint nut. 24. Installa 1O mm hex nut on the ball joint. Be sure that the hex nut is tlush with the ballioint pin end, or the threadedsectionot the balljoint pin might be damagedby the ball joint.emover. 25. Use the balljoint removeras shown on page 18-13 the ball joint and knuckle. to separate NOTE:lJ necessary,apply penetrstingtype lubricant to loosenthe ball joint.
BA1I JOIITT

oTMAC-StOO200

1.. \
r',

10 mm HEx NUT

BAI.I JOINT REMOVER, mm 32 07MAC-SLOOTO0

CASTLE 10 x 1.25 ]nln

COTTER PII{ R€place,

26. Pulltheknuckleoutwa,d and removethe driveshaft
joint Jromthe knuckleusinga plastichamoutboard mer. then removethe knuckle.

KNUCKLE

18-14

Hub Unit and Wheel BearingReplacement
the NOTE:Replace bearingwith a new one after removal. 27. Separatethe hub from the knuckleusing the special tools and a press.

29. Remove the circlip and tho splash guErd from tho knuckle.

cAuT|O:
a Take cars not to distort th6 splash guard, a Hold onlo the hub to k6ep it trom talling whon pressod clear.

30. Pressthe wheel bearingout ofthe knuckls using tn€ special tools and a Press. HUBDIS/ASSEMBLY TOOL oTGAF-SE00tOO 28. Removethe knucklering trom the knuckle. ORIVEB 07749-OOIOOOO
KNUCTLE

ho!t

I

ATTACHME'{T. 82 x 88 mtt

07744-(xr1oBm

@
BASE HUBDIS/ASSEMBLY 07GAF-SD/()7OO

(cont'dl

18-15

Front Suspension
Knuckle/Hub {cont'dl
31. Pressthe wheelbearinginnerracef rom the hub using the specialtools and a commercially available bea.ingseparalor. NOTE: Wash the knuckle and hub thoroughly in high tlash-point solvent b€fore reassembly. 32. Pressa new wheel besringinto the hub using the specialtools shown and a press, HU8 DIS/ASSEMELY TOOL 07GAF-SEOOIOO
BEARII{G SEPARATOR INNERBACE

praaa

DRNE'
ATTACHMET{T oTHAD-SGOO100

I

WHEEL BEARII{G

BASE SUPPORT 07965-SD90100 33. Install the circlip secur€ly in th€ knuckle groove. 34. Install the splash guard and tighten the screws.

18-16

3 5 . Installthehub on the knuckleusingthe specialtools
shown and a Dress. CAUTION:Tak€ car6 not lo diston tho splarh guard. HUBASSEMBLY GUIDEATTACHMENT 07cAF-SEOO200

lnstallation
CAUTIOIII: a B€ csrotul not to damage ths ball irint boot. a Torquo tho castlo nut to th€ lowor torquo specitication, thon tlghton it only lar enough lo align the slot with tho pin holo, Do not allgn the nut bY loo8cning37. Installthe knuckleon the driveshaft. 38. Installtheknuckleon the lower arm and the tie-rod, then tightsn the castle nuts and install new cotter Dtns.

COTTER PII{ On reassembly, bond the cofte. pin

BASE

36, lnstallthe knucklering on the knuckle.

I{UT CASTLE 1 2 t 1 . 2 5m m 50-60 N'm {5.o-6.o ks-m, 36 - 43 tb-frl CASTLENUT 14 x 2.0 mm 50-60 N'm (5.0-6.0 kg-m,36-43 lb-ft| 39. Installthe knuckleon the upper arm, then tighten the castle nut and install a new cotter pln. 40. lnstall the knuckle protector with the 6 mm bolt.

RING KNUCKLE

@
K UCI(LE PNOTECTON
COTTENPIN On reassembly. bgnd the cotter pin

10 N.m (1.Okg-m' 7lb'frl CASTLENUT 10 x 1.25mm

(cont'd)

rlo-rt8 N'm (4.0-4.8 kgn, 29-35 lb-ft)

18-17

Front Suspension
Knuckle/Hub (cont'd)
41. Installthe wheel sensorwith the sensormounting bolts. NOTE:8e careful when installingthe sensorsto avoid lwisting wires. 44. Install the brake caliper with the calipel bracket mounting bolts. 45. Install the brakehose with the brakehosemounting bolts. BRAKE HOSE BOLTS MOUNTING lo N'm (t.o kg-m,7 lb-ft1

42. lnstall the sensorwire with the two bolts.
10 N.m (1.O SENSORMOUNTING BOLTS 22 N.Jn 12.2 ks-m, 16 lb-ft)

7 tb-fr)

'l '10N.m (11 kg-m.80 lb-ftl 46. Tightenthe new spindlenut.
WHEEL SENSOR

NOT€:Betoreinstalling wheel,cleanthe mating the surlace of the brake disc and inside ot the wheel. 47. Installthe wheel with the wheel lug nuts.

43. lnstallthe brakedisc with the 6 mm brakedisc retaining screws.

WHEEL LUG NUT 12 x 1.5 mm t10.in {11 kg-m. 80 lb-fr}

6 mm BRAKE DISC RETAII{II{G SCREWS 10 N.mll.0 kg-m,7 tb-fr)

24 x 1.5 mm 250 'm {25 kg-m, 181 lb'ftl NOTE: After tightening, use a drift to stake sDindlenut shoulder againstthe spindle.

44. Check the front wheel alignment and adjust if necessary (see page 18-41.

8 -18

Arms Suspension
Removal/lnspection GAUTION: nuts aftor removal. a Roplace salt-locking tho nut bolts it you can oasilythiead a non-selt-locking past thoir nylon lockingins6n8. a R€placo salf-locking the (lt shouldr€quire1 N'm (0.1 kg-m, O.7 lb-ft) of to.qus to turn lho nut on th€ bolt). the a Bo car€fulnot to damage ballioint boots.
SELF.LOCKING NUT 12 x 1.25mm Replace. ARM ASSEMBLY UPPER Checkfor bendingor damage. NOTE:Do not disassemble.

BALLJOINTBOOT Checklor detorioration or damage.
BOLT SELF-LOCKING 12 x '1.25 rn''rjf

STABIUZER BAR Checkfor bending or damage.
RADIUS ROD WASHERS NUT SELF-LOCKING 12 x 1.25mm Replace. STABILIZERLINK RUBBER BUSHING Check Ior delerioration or damage. LOWERARM Checktor damage. OAMPERPINCH BOLT BOLT) ISELF.LOCKING t0 x 1.25mm NUT SELF.LOCKING 12 x 1.25mm Replace. DAMPERFORK NUT NUTI {SELF-LOCKING 12 x 1.25 rnm Replace.

RADIUS ROD

DAMPERFORK CheckIor damage. NUT SELF-LOCKING 8 x '1.25mm Replace. ADJUSTING SHIM

NOTE:Adjustthe casterangleby increasing/decreasing the adjustingshims (seepage 18-4).
'aqa a

1&19

Front Suspension
Arms {cont'd) Suspension
Installation
CAUTION: Th6 vehicle should bs on th€ glound bstoro any bolts or nuts conn€ct€d to rubbol mounts or bushing are tightened. NOTE: a Wipe off the greasebefore tighteningthe nut at the ball joint. a The right and left dampertorks 8re not symmetrical. The left damperfork is markedwith "SL" while the right damper "SR". Do not inte.change tork is markedwith them. a The right and left upper arms are not symmetrical, The left upper arm is markedwith "SL" while the right arm is "SR". Do not interchange markedwith them. a AJter installing the suspension arm. check the wheel alignmentand adjust it necessary. a When installing the radius rod washers,the "FR" mark faces the front of the car.
SELF"LOCKING NUT '12 x 1.25 mm 65 N'm (6.5 kg-m, 47 lb-ft)

UPPER ARM ASSEMBLY SELF.LOCKING BOLT 1 2 x 1 . 2 5m m 55 N.m (5.5 kg-m, /rc lb-fr)

SELF-LOCI(ING NUT 12 x 1.25mm 55 N.m (5.5 ks-m,40 tb-ft) STABILIZEBBAR BOLT I x 1.25mm 22 N.m 12.2 kg-m, l6 lb-ftl SELF-LOCKIG NUT 12 x 1.25 fi.n 55 .m (5.5 kg-m, tlo lb-ft) RUBAER RUBBER AUSHING .@]

stLrcoNE
GREASE

stLtcoNE
GREASE

BOLT SELF-TOCKING 12 x 1.25mm 105 N'm {10.5kg'm, 76 rb-ftl

DAMPER PINCH BOLT BOLTI ISELF.LOCKING 10 x 1.25mm tt4 N.m (4.4 kg-m, 32 lb-ftl DAMPER FORKNUT (SELF-LOCKING NUT) 12 x 1.25mm 65 N.m {6.5 ks-m, 47 lb-ft} DAMPERFORK SELF-LOCKING NUT 8 x 1.25mm 18 N'm {1.8 kg-m, 13lb-ftl Align the marKs.

FRONT:GD,
CAUTIOII: Do not interchange the radius lod rubbor bushings.

1a-20

Ball Joint Boot Replacement
'1.

Lower Arm BushingReplacement
Adjust the bushingdriverso that it matchesthe outside dimension the lower arm bushing, of Press lowerarm the bushingusing the specialtool and a press. NOTE:When installing the lower arm bushing,press it so that its leadingedges are llush with the lower arm.

Removethe set ring and the boot. CAUTION: Do not contaminate the boot installation section with gf6as6. Pack the interiorof the boot and lip with grease.
BALL PIN TAPEREDSECTION

SOCKETBOL

'l

BOOT INSTALLATIONSECTION

BOOT INSTALLATION SECTION

Wipe the greaseoff the slidingsurfaceof the ball pin and pack with fresh grease. CAUTION: a Koep gloase oll the boot installation s€ction and tho tapored soction of tho ball pin. a Do not allow dust. dirt, or othor toreign mata.ials to enter tho boot. 4. Installtheboot in the grooveot the boot installation section securely,then bleed air. Installthe upperand lower balljointboot clipsusing the specialtools as follows: tool with the adLower balljoint: Adjust the special iusting bolt until the end ol the tool alignswith the grooveon the boot. Slidethe set ring over the tool and into position. Upper ball joint: Hold the tool over the ball joint, then slidethe clip over the tool and into position.
BALL JOINT BOOT CLIP GUIDE ADJUSTING BOLT Adjust the depth by turning the bolt. ARM BUSHING

<+

UPPER BALL JOINTBOOT: o7974-SA50aOO LOWER BALL JOINTBOOT: OTGAG-SO/rO7O0 40 mm CIRCLIP CAUTION: Afler installing tho boot, chock the ball gin tapel€d s€ction tol greas€ contaminalion and wipo it if necossary,
6ET RING

1&21

Front Damper
Removal
1 . Removethe brake hose mounting bolts from the oamper.

Disassembly/lnsPection
Disassembly
1. compressthe damperspring with the spring compressoraccordingto the manufacturer'sinstructions, nut. then removethe self-locking CAUTION: Do not compress th€ spling more than necessary to remove tho nut.

2 . Removethe damper pinch bolt.
Removethe damperfork nut, bolt and removethe damperfork. BRAKE HOSE MOUI{TING BOLT (8x 16

PINCH BOLT OAMPER BOLT) ISELF-LOCKING

NUT SELF-LOCKING 1 0 x 1 . 2 5m m Replace.

BRAKE HOSE MOUNTING BOLT (8 x 20 mml

STRUT SPRING COMPRESSOR: Cornmordally Avallablo BRANICKO T/N MST-sAOA o. oouivalont

FORK DAMPER

2.

the Removethe springcompressorthen disassemble damperas shown on the next page.

Inspection
DAMPERFORK NUT NUTI {SELF-LOCKING Replac6. DAMPEn

1. 2. 3.

Reassemble parts. except the spring. all Push on the damperassemblvu" "hi-n. Check for smooth operationthrough a full stroke. both compression and extension. NOTE:The dampershould move smoothly. lf it does not (no compression no extension),the gas is leakor ing. and the damper should be replaced.

4.

Removethe damperby removingthe three nuts. NUTS
1 0 x 1 . 2 5m m

4.

noisesor bindingdurCheckfor oil leaks,abnormal ing these tests. NOTE:See page 18-41 for damperdisposal.

8-22

Inspection
SELF.L(rcKING ]{UT 1 0 x 1 . 2 5m m 30 N'm (3.0 kg-m,22 lb-ft| ReDlacs.

DAMPER MOUNTING WASHER Checkfor wgakness. DAMPER MOUNTII{G RUBEEB DAMPER MOUNTING COLLAR

\ , /

@z
a@\,/

*{

DAMPER MOUNTI'{G

Rueeei (92'

BUMP STOP PLATE BUMP STOP Check tor weakness o, ,/ ,/

damage.

_\

-.-..t.@@

vH
SPRINGMOUNTING BUBBER Check for damag€.

\J

DUSTCOVERPLATE

-----@

P

l l Y

l l

OUSTCOVER Checkfor bending damage. or

OAMPERUNIT . Check tor leaks and faulty operation. . Check tor rust.

1a-23

Front Damper
Reassembly
Installthe damper unit on a spring compressor. instructions. NOTE:Follow the manufacturer's in orderof disassemAssemble damDer reverse the bly except the dampermounting washer and selflocking nut. NOTE: Align the bottom of the dsmperspringwith the spring lower seat as shown, Positionthe dampermountingbase on the damper unit as shown.
SELF.LOCKING NUT 10 x 1.25mm 30 N.m 13.0 kg-m, 22lb-l1l

4.

the damperspringwith the spring comCompress Dressor. CAUTlOltl: Do nol comptess tho spring more than necosaary to install lhe nut. inInstallthedampermountingwasher.then loosely stall the new seltlocking nut.

6.

Hold the damper shatt and tighten the new selflockingnut.

<LEFT:>

STUDBOLT

STRUT SPRII{GCOMPRESSOR: CommorciollyAvail.blo T/N MST-sAOA BRANICKO

SPRINGLOWERSEAT

18-24

Installation
1 . Loosely install ths damper on thg trame with the sligningtab tacing inside.

2 . Installthe damperfork over the driveshaftand onto
the lower arm. Installthedamperin the damperfork so the aligningtab is alignedwith the slot in the dampertork.
a

NUT 1 0 x 1 . 2 5m m 39 N.m 13.9kg-n, 28 lb-ftl

Hand-tighten the bolts and nuts. Raise the knucklewith a tloor jack until the car just litls otJ the salety stand. NOTE:The bolts and nuts shouldbe tightenedwith the vehicle'sweight on the damper.

4.

5 . Tightenthe damperpinch bolt.
Secure the dampertork bolt with I new selflocking nut. to Securethe damperassembly the frame with the flange nuts. 8. lnstall the brske hose mounting bolts.

BRAKE HOSE MOUNTII{G EOLT {8 x 16 rml 22 N.m 12.2kg-m. 16 lb-ft)

BRAKE HOSE MOUNTING BOLT (8 x 20 mm) 22 N.m 16 tb-frt 12.2

DAMPER BOLT (SELF-LOCKING BOLT) 10 x 1.25mm 44 N.m (4,4 kg-m, 32 rb-ftt

DAMPER FOBK AOLT DAMPERFORK NUT NUT} {SELF-LOCKING 12 x 1.25mm 65 N'm (6.5 kg-m, 47 lb-ft)

18-25

RearSuspension
Torque Specifications
CAUTIOIT: a R.C.cr tho 3olt-locking nuts aftor removal. a RaDLc. tho rett-locklng bohs It you can easily throad a non-salf-locking nut past thair nylon locklng in3.rls. {h.houH r.quko 1 N'm (0.'l kg-m, 0.7 lb-ft) of torque to tuln tho nut on tho bolt}' a lta v€hlcla should bo on th6 ground botore any bolts or nuts connoctedto rubbor mounls or bushings 8re tightenod, a Torquc th! casdo nut to tha lower torquo epoqlllcatlon, then tight6n lt only far enough to align tho llot wfth the dn hole. Do not allgn thc nut by loosoning. NOTE:Wipe off th€ greasebetore tighteningthe nut at the ball joint.

SEIF.LOCKINGNUT 10 r 1.25mm 30 N.m l3.O kg-m, 22 lb-frl Rgolace.

NUT 1 0 x 1 . 2 5m m 39 N'm {3.9 ks-m. 28 lb-ft)

SELF.LOCKING NUT 12 x 1.25mm OE .m 16.5 kg-m, 47 lb-ft| Roploce. CASTLEttIUT 1 0 x 1 . 2 5m m 40-48 N.m {4.0-4.8 29-35 tb-ft|

kg-m,

BOLT 8 x 1,25 lnm 22 N.m {2.2 kg-m. 16 tb-ft)

l '

l NUT sELF-LocKtt{c
45 N.m (4.5 ks-m, 33 lb-ft) Replace. /
10 x 1.25mm

]{UT SELF.LOCKII{G 1 2 x 1 . 2 6m m 65 t{.m (5.5 kg-m,40 lb-ftl Rgoloce.

CASTLENUT 12 x 1.25mm 50-60 tl.m 15.0-6.0 ks-rn, 36-43 tb-ftl

fIUT SPI]TDLE 22 x 1.5 fim 185 N.m {18.5 kgn, 134 lb-tt} Replac6. NOTE: After tightoning, use I drift to stske the spindlo nut shouldor against the spindle. CASTLE NUT 14 x 2.0 mm 50-60 N.m {5.0-6.0 ke-m, 36-43 tb-ft| BOLT SELF.LOCKING 12 x 1.25 mrn CALIPERBRACKETMOUNTII{G BOLT 65 N.m 16.5 kg-m, 47 lb-ftl 12 x '1.25lrxn 39 N'm (3.9 ks-m, 28 lb-ftl

18-26

Knuckle/Hub
lllustrated lndex NOTE:
a Use only genuineHondawheel weightsfor aluminumwheels. Non-genuine wheel weights may corrode8nd dsmsge the aluminumwheels. a Beforeinstalling the brake disc, cleanthe mating surfacesot the rear hub and insideof the brakedisc. a Beforeinstalling the wheel, cleanthe mating surtacesof the brake disc and insideof the wheel.

BOLT SELF-LOCKING 10 x 1.25mm 44 N.m 14.4 kg-m, 32 lb-tll

COTTERPIN Replace.

\--q,

PROTECTOR KNUCKLE Ch6ckfor damago. BOLT 6 x 1 . 0m m
10 N.m ll.O kg-m, 7 lb-frl

b
REAR SPINDLEASSEMBLY Check for damage.

SPLASHGUARD Checkfor bending or damago. 10 N'm l1.O kg-m, 7 lb-ft)

sREARWHEEL HUB UNIT Check for cracking or damags.

p

\ COTTERPIN Replace.

WASHER SPINDI..E

tan^l
BRAKE OISC Check for wear or rust. Inspection, section 19 6 mm BRAKEDISC RETAININGSCREWS 10 N.m (1.0 kg-m, 7lb-ft|

ae

WHEELLUG NUT 12 x 1,5 mm 110 N'm 111 kg-m,80 lb-frl (cont'dl

18-27

RearSuspension
(cont'dl Knuckle/Hub
Removal
1. Loosenthe wheel nuts slightly. 2. Raisethe rearof car and support it with safety stands in properlocations(seesectjon 1). Bemovethe wheel lug nuts and rear wheel.

8 . Removethe 6 mm brake disc retainingscrews 9 . Screw two 8 x 1.25 mm bolts into the disc to push
it away from the hub. NOTE:Turn each bolt two turns at time to prevent cocking the disc excessively.

3. 4. 5.

1 0 .Removethe brake disc.
Pull the parking brake lever up. Removethe hub cap, then raisethe lockingtab on the spindlenut, then removethe nut. HUBCAP Replace.
NOTE| Take care not to damagethe hub

I x 1.25 mm BOLTS

BRAKEOISC

6 mm ERAKE 5 MM EBAKE DISC SCREWS S RETAINIT{G

1 1. Remove the hub unit from the knuckle,

o.

Removethe brake hose mounting bolts. boltsand hang Remove caliper the bracketmounting the caliperassemblyto one side. CAUTION: To prevent accidental damage to the caliper assemblyor brake hoss, use a shon pisce ot wir€ to hang th€ calip€r as$mbly lrom th6 und6.cardag6. BRAKE HOUSE MOUNTING BOLT

7.

TRAILINGARM

CALIPER ASSEMBLY CAUPERARACKETMOUNTING BOLT

18-28

12. Removethe splssh guard from the knuckle.

1 5. Removethe rear spindleassemblyfrom the knuckle.
SELF-LOCKING NUT 10 x 1.25mm Replace.

ASSEMBLY 13. Removethe parkingbrakecabletrom the knuckle. 14. Removethe wheel sensorwire bracket.then remove the wheel sensorfrom the knuckle. NOTE:Do not disconnectthe wheel sensorwire. WHEEL SENSOR

1 6 .Hold the ball pin of the stabilizertink with a hex
wfench and loosenthe self-locking nut. Removethe selflocking nut, then disconnectthe slabilizerlink from the stabilizer bar.

PARKINGBRAKE CABLE

1 2 r 1 . 2 5m m Replace.

{cont'd)

18-29
l'-

Rear Suspension
Knuckle/Hub {cont'd)
18. Remove the cotter pin from the tie-rod end (4WS) or lower arm B (2WS) 8nd removethe castle nut. 19. lnstalla 12 mm hex nut on the ballioint. Besurethat the hex nut is flush with the balljointpin end. or the threaded section of the bsll joint pin might be damagedby the ball joint remover. 20. Usethe balljoint removeras shown on page | 8-13 to separate the ball ioint and knuckle. NOTE:lf necessary,apply penetratingtype lubricant to loosenthe ball joint.
COTTERPIN Replace.

24. Removethe knuckleProtector. 25. Removethe cotter pin and the upperbsll joint nut.
26. lnstall a 1O mm hex nut on the ball joint. Be sure that the hex nut is flush with the bsll ioint Dinend, or the threadedsectionot the balljoint pin might be damagedby the ball joint removar. 27. Usethe balljoint remove.as shown on page 18-13 the balljoint and knuckle,then remove to separate the knuckle. NOTE:lf necessary,apply penetratingtype lubricant to loosenthe ball joint, BALLJ()|NT 28 REMOVER. mm oTMAC-SLOO200

BALL JOINT REMOVER,28 mm oTMAC-SLOO200

the cotter pin and lower arm balljoint nut. 21 . Remove a 22. Install 14 mm hex nut on the balljoint.Be sutethat the hex nut is flush with the balljoint pin end, or the threaded section of the ball joint pin might be damagedby the ball joint remover. 23. Usethe balljoint removeras shown on page 18-13 the ball joint and lower arm. to separate NOTE:lf necessary,apply penetratingtype lubricant to loosenthe ball joint.
R€place.

K UCKLEPROTECTOR

,a,-,",
mm HEX NUT

NUT CASTI.E 14 x 2.0 mm EALLJOINT 32 REmOVER, mm

-slooro0 oTmac

18-30

lnstallation
28. Connectthe lowe. arm, lower arm B (2WSl or tierod end (4WS) 8nd upper arm with the knuckle, then tighten the castle nuts, 29. Installthe naw cotter oins. 30. Installthe knuckleDrotectorwith the bolt. 31. Connect the knuckle and the stabilizerbar, then tighten the new selflocking nut. NUT CASTLE 1 0 x 1 . 2 5m m 40-/t8 N.m 14.0-4.8 kg-ir, 29 - 35 tb-tr)

33. Installthe whe€l sensor, wheel sensor wire bracket and parkingbrake cable on the knuckle. NOTE:Be careful when installingthe sensorto avoid twisting the wire.
22 .m {2.2 kg-m, 16lb-ftl

COTTER PIT{ On roa$ombly, bondth€ cott€r pin

I{UT SELF.LOCKING 1 2 x 1 . 2 5m m
55

22 N.m 12.2kg-m, 16 lb-ft)

.m 15.5 ks-m,40 lb-ttl

CASTLEITUT 14 x 2.0 mm 50-60 N.m(5.0-6.0 kg-m, 36-43 tb-ft|
COTTERPIN CASTLE NUT 1 2 x 1 . 2 5m m

34. Installthe splashguard with the bolts.

50-60 .m (5.0_6.0 kg.h, 36_43 tb-ttt 32. Installthe rearspindleassemblyon the knuckle,then tighten the new self-locking nuts. SEI.F.LOq(NG IIUTS lO r 1.25mm 45 N.m (4.5 kg{n, 33 lb-ftl

10 N.m(1.0 kg{, 7 |tsft}

18-31

RearSuspension
Knuckle/Hub (cont'dl
35. Install the hub unit and spindle washer on the knuckle. with the caliperbracket 37. Installthe caliperassembly mounting bolts. 38. Installthebfakehosewith the brakohosemounting bolts, BOLT HOSE MOUI{TING BRAI(E 16 tb-ft| 22 N.m 12.2

ASSEMBLY CALIPER

BOLTS MOUNTII{G 39 N'm 13.9kg-m,2a lb-ft)
SPi DLE WASHER

39. Installthe new spindlenut, then tighten the nut' 40. Installthe new hub cap.

ito.

lnstallthe brakedisc with the 6 mm brakedisc retaining screws.

41. Installthe rear wheel with the wheel lug nuts. the instslling wheel,cleanthe mating NOTE:BeJore surfaceof the brakedisc and insideo{ the wheel.

REANWHEEL

SPI DLE ]{UT 22 x 1.5 mm 185 N,m (18.5 kg-m. 134 lb-ft| NOTE: After tightening, uss a drift to stake the spindle nut shouldgr against
the spindl6.

LUGNUT WHEEL 1 1 0N . m (l I kg-rn,80 lb-ft}

6 mm BRAKE DISC RETAII{INGSCNEWS 10 N.m (l.o kg-m, 7 lb-ft|

and adjustif neces42. Checktherearwheelalignment sary (seepage 18-4).

18-32

SuspensionArms
Removal/lnspection
GAUTION: a R€placetho selllocking nuts afte.;emoval. a Roplacethe self-locking bolts it you can oasily thread a non-solt-locking nut past thoir nylon locking insons, (lt should roquire 1 N.m (O.1 kg-m, O.7 lb-ft) of torque to turn the nul on tho bolt). a B€ caroful not to damage the balljoint boots.
NUT SELF.LOCKING 12 x 1.25mm Replace.

UPPER ARM ASSEMBLY Check bending damage. lor or NOTE: not disassemble. Do

)

SELF-LOCKING NUT 10 x 'l.25 mm Replace. l2wS only) SELF.LOCKING NUT 12 x 1.25mm Roplace. {4wS only)

bo
SELF.LOCKING BOLT 14 x 1.5 mm (2wS only)

SELF-LOCKIf{G 12 x 1.25mm Replace.

STAAILEER BUSHII{G Check lor deterioration or damag6. LOWERARM B Check tor b€nding or damage. (2WS only)

,aar-ao"*,no "oa\

""\;\^.J

RUBBER BUSHING Checktor deterioration or damage.
BOLT SELF-LOCKING 12 x 1.25mm

TRAILINGARM BUSHING Check for deterioration or damage.

{cont'd)

18-33

Rear Suspension
SuspensionArms (cont'dl
Installation
CAUTION: Tho vohiclo ehould be on the ground bofor€ any bolts or nuts connectod to rubb3r mounls or bu3hlng arc tlghtcnod. NOTE; a Wipe ofJ the grease before tightening the nut at the ball joint. by a The right lower arm B is identiJied white paint. "L" while the right 8rm is markod a The right and left upper arms are not symmetrical. The left upper arm is marked with "R". Do not interchange them. with a After installing the suspension arm, check the wheel alignment and adiust if necesssry.
NUT SELF.LOCKING 12 x 1.25mm 65 N.|n (6.5 ks-m, 47 lb-ft1

-\

_rrat

v

ARM ASSEMBLY UPPER

T{UT SELF.LOCKING 10 x 1.25mm 55 N.m 15.5 kg-m, 4{' tb'ft| (2WS onlyl

NUT SELF-LOCKIT{G 12 x 1.25mm 65 N.m (6.5 kg-m, 47 lb-ft| (4wS only)

BOLT
10 x 1.25 rn.n 44 .m {4.4 kg-rn, 32 lb-ftl

BOLT SELF-LOCKING 14 x 1.5 mm

\

85 N'.n 18.5ks-m, 61 lb-ft) (2WSonlyl BOLT 8 r 1.25mm 22 N.m 12.2kg-m, 16 lb-ft|
I

22 N.m 12.2kg-m, 16 tb-ft}

NUT SELF-LOCKING 12 x 1.25 tnm 55 N'm {5.5 kg-m. /to lb-ft)

ARM B LOWER
onlyl

LOWER ARM

BOLT SELF-LOCKING 12 x 1.25mm 65 i.in 16.5 kg-m, 47 lb-ft} ARM TRAILIT{G

BOLT SELF-LOCKI]TG 1 2 | 1 . 2 5m m 65 N.m 16.5kg-m,47 lb-ftl

18-34

Ball Joint Boot Replacement
Removethe set ring and the boot. CAUTION: Do not contaminate ths boot installation soctlon with giease. Pack the interiorof the boot and lip with grease.
BALL PIN TAPEREDSECTION

Lower Arm Bushing Replacement
Adjust lhe bushing driver so that it matches the outside dimensionof the lower arm bushing.Pressthe lower arm bushingusing the specialtool and a press. NOTE:When instsllingthe lower arm bushing,press it so that its leadingedges are tlush with the lower arm.

BOOT INSTALLATIOI{SECTION

t

Pr9!a

BUSHITIG DRIVER o7t{AD-SSq)lOO

BOOTINSTALLATIOT{ SECTION 3. Wipe the greaseotf the slidingsurfaceof the ball pin and pack with tresh grease.

a Keep g.oas€ off the boot inatallationssction and ths tapered soction of tho ball pin. a Oo not allow dust, dirt, or other foroign mat6dals to ont€J the boot. 4. Installthe boot in the grooveof the boot installation section securely.then bleed air. Install the upperand lower balljointboot clipsusing the sDecial tools as Jollows: Lower balljoint:Adjust the specialtool with the adjusting bolt until the end of the tool alignswith the grooveon the boot. Slidethe set ring over the tool and into position. Upper ball ,oint: Hold the tool over the ball joint. then slidethe clip over the tool and into position.
BALL JOINT BOOT CLIP GUIDE AOJUSTII{G BOLT Adjust the depth bV turning the bolt.

5.

BALL UPPER JOINTBOOT: 07974-SA50800 BALL LOWER JOINTBOOT: 07GAG-SD/rO700 40 mm CIRCLIP CAUTION: Attor installing the boot, ch€ck tho ball pin tapered soction tor greaso contaminatlon and wipe it it nscossary.
SET RING

18-3s

Rear Damper
Removal
1 . Jack up the rear of car and support on satety stands in properlocationslsee section 1). Remove the rear wheel.
t

9 . Remove the damper mounting bolt. 1 0 . Lower th8 raar susp€nsionand remov€ the dampgr
assemblv.

Removethe trunk side trim. Removethe two nuts, NUTS 10 x 1.25rfn

4.

Removethe knuckleprotector. 6. 7. Remove the cotter pin and the upper ball ioint nut. lnstalla 1O mm hex nut on the ball ioint. Be sure that the hex nut is flush with the ball joint Dinend, or the threadedsectionof the ballioint pin might be damaged by the ball joint remover.

8 . Usethe balljoint .emoveras shown on page 18-13
to separatethe ball joint 8nd knuckle. NOTE:lf necessary,apply psnetratingtype lubricant 1o loosenthe ball joint.

MOU TINGBOLY (SELF.LOCKIl{G BOLT) 1 2x t . 2 6 m m

10 mm H€X

UT

BALL JOINT BEMOVER,28 mm oTMAC-SLOO200

PROTECTOR KNUCKLE l{UT CASTLE 1 0 x 1 . 2 5m m

PIIT COTTEB Replaco.

BOLT 6x t.Omm

18 -3 6 'b'--

Disassembly
1 . Compress th€ damper spring with the spring compressoraccordingto the manufacturer'sinstructions, CAUTIO : Do not compr.rs th6 sprlDg mora than noceaaaryto ramovo tho sclt-locking nut.

Inspection
Reassembleall parts, except the spring. Push on the damper assemblyas shown.
J.

Check for smooth operation through a full stroke. both comoression and extension. NOTE:The damper should move smoothly. lf it does not (no compression no extensionl,the gas is leakor in9, and the dampershould be replaced.

Remove the selflocking nut trom the damper ass€mbly,

STRUT SPRINGCOMPfiESSOR: Commo.d.lly Av.illbl. BRANICKOT/t{ MST.5g)A or oquivrlant

3.

Remove the spring compressor and disassembly the damper as shown on the next page.

4.

noisesor bindingdurCheckfor oil leaks.abnormal ing these tests. NOTE:See page 18-41 for damperdisposal.

(cont'dl

18-37

RearDamper
Inspection (cont'd)
NUT SELF-LOCKING 10 x 1.25mm Reolace. 30 N.m (3.0 kg-m, 22 lb-ft|

DAMPER MOUTTTTNG ^r' WASHER -_ --.f.:, g Ch6cktor
woakness. \Y

./
DAMPER MOUT{TING RUBBER DAMPER MOUI'IN G BASE DAMPCRSPRII{G Check for weakened compresspnor oamage.

iUBBER

DAMPER MOUl{TrirG

F
ll l*----.-

t---^6

\r'

ooio" "ornr,ro

--

PLATE BUMPSTOP

w
,ffi,
t ',/
SPf,INGMOUNTING RUBBER Check lor damago or cracKs.

*r'

DUSTCOVERPLATE

DUSTCOVER Chocklor bending or damage.

DUSTCOVER AOOT Ch6ckfor detorioration or damage.

DAMPER UITIT . Check tor leaks and faulty operation. . Check tor rust.

18-3 8

Reassembly
1 . Install th€ dampel unit on 8 spring compressor. NOTE: Follow the manutacturer's instructions. AssemHe the damper in revsrse order of disassembly except the damper mounting wash€r and sel{locking nut. NOTE:Align the bottom ot the damperspringwith th6 spring lower seat as shown,
a

w
4. Compress the damper spring with the spring compressor. GAUTION: Do not compross ihe spring more than necesaary to Install tho nut. Installthe dampermounting washer, then loosely install the new selflocking nut.

6 . Hold the dampershaft and tighten the self-locking
nut.

Position the damper mounting base on the dsmp€r unit as shown. SELF-LOCKII{G lrluT 1 0 x 1 , 2 5m m 30 tl.m l3.Oks-m, 22 ltFftl OAMPM WELDED UT WASHER

<LEFT:>

<RIGHT: >

STRUT SPRII{G COMPRESSOR: Commrrd.lly Avdllbl. BRAt{lCKo T/1{MST-580A

SPfiING LOWERSEAT

18-39

Rear Damper
Installation I
1 . Lower the rear suspension and set the damperas, semblv. 4. Connectthe upper arm and knuckle,then tighten the castle nut. Installthe knuckleprotectorwith the bolt.

2 . Connectthe damperassemblyand the lowe. arm,
then looselyinstallthe dampermounting bolt. NOTE:The damp€. mountingbolt should be tightened with the damDerunder vehicleload.

5.

I

KNUCKLE PROTECTOR
COTTERPIN On reassembly, bend the cotter pin

..:-.'l"t'
DAMPER MOUNTING BOLT (SEI"F-LOCKING BOt TI 1 2 r 1 . 2 5m m

- { 4

I
CASTLE NUT 1 2 x 1 . 2 5m m 40-48 N'm {4.O-4.8 kg-m, 29 - 35 rb-frl COTTERPIN l0 . m { 1 . Ok g - m , 7 l b - f t l

WELDED NUT Tightenthe two nuts.

Raisethe rearsuspension with a tloor jack until the weight ot the car is on the dampe,. 7 . Tightenthe dampermounting bolt

NUTS l O x 1 . 2 5m m 39 N'm (3.9 kg-m,2a lb-trl

DAMPEB MOU]IINNG AOLT {SELF.LOCKING

BOr-Tl

12 x 1.25mm 65 N.m 16.5 kg-m, 47 tb-ftl

8.

Checkthe rearwheelalignment and adjustif necessary (seepage 18-4).

18-40

Damper Disposal

a Ths dampors contain nitrog€n gas and oil under p(€3sur6. Tha prossur6must b6 roliovod boforo disposal to provent explosion and possible hiuly whon scrapping. a Always wear oye protsction to avoid getting motal shavings in your eyes whon the gas dampel pr€ssuro is rolieved. Placethe damperon a levelsur{acewith its rod extende d a n d d r i l la h o l eo t 2 . 0 - 3 . 0 m m { 0 . O 8 - 0 . 1 2 i n l d i ameter in the body to release the gas.

( Front Damper:>

Drill here.

( Rear Damper:>

Drill here.

18-41

Brakes
Conventional Brakes...... 19-1 A n t i - L o c k r a k e y s t e m( A B S I . . . . . . . . . . . 9 - 3 1 B S 1

ConventionalBrakes
.......... 19-2 Toofs Speciaf l l l u s t r a t eId d e x . . . . . . . . . . . . . . . . . . . . . , . .19.-. 3 n .. PedalHeight ......... 19-4 Adjustment ParkingBrake ......... 19-5 Adjustment Flont Brakes T o r q u e / l n s p e c t i . . n. . , . . . . . . . . . . . . .1. . - 6 o. .9 Front Brake Pads ..............19-7 Inspection/Replacement Front Caliper ....... 19-9 Disassembly . . . . . . . .1 9 - 1 0 Reassembly Front BrakeDisc n .9 R u n o u I n s p e c t i o . . . . . . . . . . . . . . . . , , . 1. . - 11 t Thicknessand Parallelism ....... 19-11 Inspection . . . . . . . . . . . . . . 1.9 - 1 2 . Bleeding Master Cylinderand Brake Booster ................... 9-13 1 Removal/lnstallation Master Cylinder .........19-14 . Inspection Brake Boostel .....19-15 Tests............ Adjustment..... 19-15 Pushrod Clearance RearDisc Brakes T o r q u e / l n s p e c t i . . n. . . . . . . . . . . . . . . . 1 9 - 1 7 o. RearBrake Pads ..............19-18 Inspection/Replacement RearBrake Disc 1.R u n o u It n s p e c t i o n , . . , , . . . . . . , , . . . . , ,9 . .2 0 Thicknessand Parallelism Inspection ....... 19-20 RearCaliper ....... 19-21 Disassembly Reassembly ........ 19-24 BrakeHoses/Pipes fnspection ...,,,,,.. 19-27 .............19-28 Brake HoseReplacement ParkingBrake Disassembly Reassembly ...... 19-29 and

SpecialTools

Rol. No.

I

Tool Number

oTHAE-SGOO100 oTJAG-SD40100 o7914-SA50000 o7916-6390001

BrakeSpringCompressor Pushrod Adjustmenl Gauge Snap RingPliers LocknutWrench

19-22, 19-25 19-l5 19-22, 19-25 19-21, 19-26

@

an

o

19-2

lllustratedlndex

FRONTBRAKES Torque/lnspection,page 19-6 Front Brsk€ Pads. page 19-7 Front Csliper, pag6 19-9 FrontSrakeDisc,page 19-11

PARKINGBFAKE Adjustmont, pago | 9-5 Diaa$embly 6nd Reassombly, p6go 19-29

REARDISC BRAKES Torqu6/lnspsction,p8g€ 19- l7 R6arBrak6P8ds,psgs 19-18 R6ar Brak€ Disc, page 19-20 R6ar Calip€r, page 'l9-2'l

ERAKE PEDAL psg€ l9-4 Adjustmont,
MASTER CYLIT{DER AND BRAKEBOOSTER psge 19-13 Rgmoval/lnstallation, page 19-14 MastsrCylinder, BrakgBooster19-15

BRAKEHOSES/PIPES pag€ 19-27 Inspoclion, Brake Hoso Replac€m€nt.p6g€ 'l 9-24

19-3

PedalHeight
Adjustment
'I . Disconnect brakeswitch connector,loosenthe the brakeswitch locknutand back off the brakeswitch until it is no longertouchingthe brake pedal. 4. Screw in the brake switch until its plungeris fully depressed(threadedend touching the pad on the pedal arm). Then back otf the switch 1/4 turn to make O.3 mm {0.O1 in} of clearance between the threadedend and pad. Tightenthe locknut tirmly. Connectthe brake switch connector. CAUTION: Ch6ck that the brak€ lights go oft whon ths psdsl is l€leased.

2 . Measurethe pedalheight from the left side center
of the Dedalsurface. BRAKE

swtrcH

PAD

A: Podal Freo Play 1-5 mm (1/16- 13/64in) B: Standard P€dal Height (with floor mat removed) MT: 165 mm (6.5 inl minimum AT: 186 mm (7.3 in) minimum

BrEke Podal Froe Play Inspection: Stop the engine and inspect the play by pushingthe pedalby hand. BrakeP€dalFreePlay: 1-5 mm {1/16-13/64 inl CAUTION: It tho pedal freo play is insufficient, it may ro3ult in brak€ drag.

3 . Loosenthe pushrodlocknutand screw the pushrod
in or out with pliersuntil the standardpedalheight After adjustment. tighten from the floor is reached. the locknut firmlv,

PUSHROD LOCKNUT l5 N.m 11.5kg-m, 11lb-fll tor cai. without ABS 19 .m {1.9 kg-m, 14 lb-ftl for cars with ABS

19-4
bsnmrr

ParkingBrake
Adjustment
NOTE: After rear brake caliper servicing,loosen the parking brake adiusting nut, start the engine and depressthe brake pedal severaltimes to set the selfadjustingbrake beforeadjustingthe parkingbrake. Bbck the flont wheots beforo iacking up @ the loar of the car1. 2. Raisethe rear wheels off the ground. Make sure the lever of the rear brake calipercontacts the pin ot the brake caliper.
E

Tighten the adjusting nut until the rear wheels drag slightly when turned.

o.

Rel€ase parkingb,ake lever and check that the the r€ar wheels do not drag wh€n turned. Readjustit nScessarv. With the equalizer properly adjusted, the rear brakes should be tully applied when the parking brake lever is pulledup 6 to 1O clicks.

3 . Pull rhe parkingbrake lever up one notch.
Removethe tront consoleand centerconsole(see p a g e2 O - 5 1 ) .

19-5

Front Brakes
Torque/lnspectaon
a Nevgl us€ an air hos6 or dry brush to cl€an braks assamblies. a Use an OsHA-spproved vacuum cl6aner, to avoid breathing brake dust, a Contaminated brake discs or pads reduce stopping ability. CAUTION: a Do not spill brake tluid on tho car; it may damagethe paint; it brakefluid does contact tho paint, wash it ott immediately with water. a To prevont spills, cover the hose loints with rags or shop towels. a Cl€8n all pans in brake lluid and air dry; blow out all passageswith compross€dail. a B€tore reassembling.chcck that all parts ar€ free of dust and oth€r toreign particlas. a Replaceparts with new ones whcn€vel specitisd to do so. a Make sure no dirt or othor lor€ign matt€r is allowed to contaminato th6 brako fluid. a Do not mir different brands of braks fluid as th€y may not b6 compatible. a Do not reuse the drained tluid. Us6 onlv clean DOT 3 or 4 brake fluid. NOTE: a Coat piston, piston seal, and caliperbore with clean brakefluid. a Reolace rubberoarts with new ones wheneverdisassembled. all -ffi: rubbergrease. Brakecyrindergrease(P/N:08733-Bo2oE) or equivalent
OUTERPAD SHIM Check tor wear or oamage. Apply Molykoteo N477ptt{ B to pad side of shim. Checkfor bendingor damage.

..6|t,

siliconegrease.

WEAR INDICATOR INNERPAD SHIM B lnstallinnerpad with Checklor wear or atswear indicatorupward. oamage. Apply Molykoteo M77 to shim A sade shim. ol

1 2 x 1 . 2 5m 1 1 0 N . l n ( 1 1 . 0k g - m , 80 lb-ftl

\

\ / L ,r. t \ I { ( /?

-41

Ptt{BooT

\"--'--\ t t ^
\ ( i

INNERPAD SHIM A / CheckIor wear or damage. Apply Molykoreo M77 to both sidesof shim. 10 x 'l.O mm 50 N'm {5.0 kg-m, 36 tb-ftl
q{

I

/

4,/
BUSHING

t I

,

Replace.

-6l

-6,l
BRAKEPADS

rinins check thicknes. P t o . /

yN

6

< 'iN.-_

Check for bending or

damase.

u afl
BLEEDSCBEW I N.m (0.9 kg-m, 6.5lb-fr)

_G1
RETAIl{ER Check for
damage.

na ffi,.--Eih Nv Yl(o,6 -N/ffiL
PrsroNSEAL

CALIPER BODY CheckIor scoring on cylinderwall-

/

/

I \V--\.-_
I

PISTONBOOT Replace.

."o,,nn 8'n"i"?nfo,
on srlrface.

19-6

Front BrakePads
Inspection/Replacement
4. a Nevar us€ an air hoss or dry brush to cl€an blake assemblies. a Use an OsHA-approved vacuum cleanet, to avoid broathing brako dust. 1. Loosenthe front wheel lug nuts slightly,then raise the car and supporton safety stands, Removethe front wheels. Remove the caliperbolt and pivot the caliperup out of the way. Removethe pad shims, pad retainers and pads. Using vernier calipers,measurethe thickness of each brakepad lining. Brako Pad Thickness: Standard: F22A1 and H23Al sngine: 12.5 mm (O.49in) H22A1 engin€: 1 1.O mm {0.43 in) Servic€ Limit: 1.6 mm {0.06 inl

2.

CALIPERSOLT

CALIPER BODY 3. lf the brake pad thicknessis lessthan servicelimit at step 5, replacethe front pads as a set.

NOTE: Measurement doesnot includepad backing plate thickness. 6. Cleanthe caliperthoroughly;removeany rust, and check for groovesor cracks. Installthe pad retainers.

Front BrakePads
(cont'd) Inspection/Replacement
8 . Apply Molykote@ M77 compound to the pad
shims and the back of the pads. Wipe off excess. 9 . lnstallthe brake pads and pad shims correctly. then installthe 1 1 .P ivotthe caliperdown into position, caliperbolt (flangebolt). NOTE: Make sure the pin is clean before installagrease the inside to tion, then applya cleansilicone ot the boot and the Din.

@ a Wh6n

reusing th€ pads, always leinstall tho brake pads in their original positions to pravent loss ot braking efticiency. a Contaminated brake discs or pads reduce stopping sbility, Ke€p greas€ oll the discs and p8ds.

NOTE: Installthe pad with the wear indicatoron the inside.

CALIPER 50 N.m

{5.Okg-m, 36 rb-ft| PISTON

INNERPAD SHIM A Apply Molykote@ M77 to borh sidesof shim.

INNERPAD SHIM B Apply Molykote@ M77 to inner INNERBRAKEPAD sade shim. of

t ' \

E i
V
OUTER BRAKE PADS

t l

N

Apply Molykoteo M77 to inner side of shim.

12. Depress brakepedalseveraltimes make sure the to the brakeswork. then road-test.

indicator)

1O. Pushin the pistonso that the caliperwilltit overthe pads. Keepthe boot in positionto preventdamaging the boot when pivotingthe caliperdown.

NOTE: Engagementof the brake may requi.e a greater pedal stroke immediatelyafter the brake pads have been replacedas a set. Severalapplications of the brake Dedalwill restore the normal oedal stroke.

19-8

FrontCaliper
Disassembly
a N6vor uso an air hose or dry brush to clean brake ass€mbli9s. a Use an OSHA-approved vacuum clgan€r to avoid broathing brake dust. CAUTION: a Do not spill brak€ fluid on the ca1;it may d8mag€the paint; il brake fluid do€s contact the paint, wash it ofl immediatoly with wat6r. a To plevent spills, cover the hose ioints with rags or shop towels. a Clean all parts in brak6 tluid and air dry; blow out all passages with comprossed air. 1. Removethe banjo bolt and disconnectthe brake hose from the calioer. Removethe caliperbolts, then removethe caliper. lf necessary,apply compressed to the caliper air fluid inlet to get the piston out. Placea shop rag or wooden block as shown to cushion the oiston when it is exoelled. Use low pressure in short spurts. air Removethe piston from the caliDer.

a Do not placo your fingsrs in front of th€ piston. a Do not use high air pressuls; use an OSHAapprovsd 30 PSI nozzle.

2.

4.

Removethe piston boot and piston seat. CAUTION: Take care not to damago the cylindel bore,

SEALING WASHERS Replace.

CALIPERBOLT

19-9

Front Caliper
Reassembly
CAUTIOt{l a Do not spill brako fluid on the ca.; it may damagethe paint; if brake fluid do6s contact th€ paint, wash it off immediately with water. a Bofore reassgmbling,chock that all parts are troe ot dust and othol toreign pa.ticles. a Raplacepans with new ones whgn6vo. spocitied to do so. a Make suls no di.t or othor loroign mattor is allowod to contaminate the brak€ tluid. a Do not mix different brands ot brake tluid as they may not be compatible, a Do not reus€ tho drain€dfluid. Use onlv cloan DOT 3 or 4 brakefluid. 1. Cleanthe piston and caliperbore with braketluid and inspectfor wear or damage. Coal a new piston sealwith siliconegreaseand install it in the cylindergroove. Apply brakecylindergrease(P/N:08733-BO2OE) or equivalentrubbergreaseto the sealinglips and insideof a new piston boot, and installthe boot in the cylindergroove. 6. 4. Lubricate calipercylinderand pistonwith brake the fluid, then installthe piston in the cylinderwith the dishedend facing in,

2.

5.

3.

Install the brake pad retainersand brake pads in their originalpositions(seepage 19-8). Always r€install the brake pads in @ their o.iginal positions to prevent loss ol braking ofliciancy. Installthecaliperon the caliperbracketand tighten the caliperbolts.

7 . Connect the brake hose to the calipe. with new sealingwashersand tighten the banio bolt.

BANJO BOLT 35 t{.m {3.5 kg-m,

25 tb-ftt

,:^" #-i!!r9ul
RUBBER GREASE

PISTONSEAL

-611
SILICONE GREASE

SEALING WASHERS

CALIPER BOLT 50 .m (5.0 kg-m, 36 tb_trl 8. Fill the brake reservoir up and bleed the brake s y s t e m{ s e ep a g e1 9 1 2 ) .

19-10

Front BrakeDisc
Runout lnspection
Loosenthe front wheel lug nuts slightly,then raise the car and supporton safety stands. Removethe front wheels. 2. 3. Removethe brake pads (seepage 19-7). Inspectthe disc surfacefor cracks,and rust. Clean the disc thoroughlyand removeall rust. Use lug nuts and suitableplainwashefsto holdthe disc secu.elyagainstthe hub, then mount a dial indicatoras shown and measure runoutat IO mm the (O.4 inl from the outer edge oJ the disc, Brak6 Disc Runout: Scrvlc. Limlt: O.10 mm (0.004 in) 5. lf the disc is beyond the servicelimit, refinishthe rotor with an on-car brake lathe. The Kwik-Lathe producedby Kwik-WayManufacturing Co. and the "Front Brake Disc Lathe" offered by Snap-onTools Co. are appfovedfor this operation. MEx. Refinishing Limit: 21.0 mm (0.83 in)

Thicknessand Parallelism Inspection
Loosenthe front wheel lug nuts slightly,then raise the car and support on safety stands. Removethe front wheels.

2 . Removethe brake pads (see page 19-7).
Using a micrometer, measure disc thickness at eight points, approximately 45o apartand 1O mm (O.4 in) in trom the outer edge of the disc.

4.

Brako disc thickness: Standard:23.O mm {0.91 inl BrakoDisc Parallelism: O.O15mm (0.00OO mar. in) NOTE; This is the maximum allowabledifference between any thicknessmeasurements.
4.

lf the disc is beyondthe servicelimit for parallelism, refinishthe rgtor with an on-car brake lathe. The producedby Kwik-Way Manufacturing Kwik-Larhe Co. and the "Front BrakeDisc Lathe" offered by Snap-onTools Co. are approvedfor this operation. Max. R€finishing Limit: 21.O mm (0.83 in)

NOTE: A new disc should be retinished if its runout is greaterthat O.l O mm {O.OO4 in}.

19-11

Bleeding
cAUTtOt{: o Uso only clsan DOT 3 or 4 brake fluid, a Mako suro no dirt 01 oth€l toreign mattor i5 allowod to contaminate ths brake tluid. a Do not mix diflorent brands of brako fluid as they may not be compatible. a Do not spill brake fluid on tho car; lt may damags the paint; it brake tluid does contact the paint, wash it ofl immadiately with wator. NOTE: The reservoiron the master cvlinder must be full at the stan ot bleedingprocedure,and checked after bleeding each brakecaliper.Add fluid as required. Use only clean DOT 3 or 4 brakefluid. BLEEDING SEOUENCE: FRONT:

REAR:
O Fronr Right O Roar Rlght

BI-EED SCREW

a Front Loft

a R..r L.fi

1 . Have someone slowly pump the brake pedal severaltimes, then apply steady pressure. Loosenthe brake bleed screw to allow air to escape from the system. Then tighten the bleed screw securelv. 3. Repeatthe procedurefor each wheel in the sequence shown above, until air bubblesno longer appearin the fluid, by Check brake performance road testing.

4.

19-12

Master Cylinderand BrakeBooster
Removal/lnstallation
CAUTION: a Be calelul not to bend or damago tho brake pip€s whsn removing tho mast6r cylindor and boostef. a Do not spill brako fluid on the cai; it may damag€the paint; if brake fluid do€s contact th€ paint. wash it oft immediately with wat€r. o To prevsnt spllls, cover the hose ioinis wiih rags or shop tow6ls. a Before lesssembling, check that all parts als tree ol dust and oth€r toreign particlos. a Mako sur6 no din or oth6r foroign matter is allowod to contaminat€ th€ brake tluid. a Do not mir dift6r6nt brands ot brak€ tluid as they may not bo compatibls. a Do not raus€ th6 drain€d fluid. Us€ only closn DOT 3 oi 4 brake fluid. a Whon connecting the b18k€pipes, msko suro that thor6 is no intoderenco botwoan tho brake pipos and othor parts. a Do not disass€mbletho mastor cylindor or boost6r, Roplacoth€m as complots assomblies. Drainthe brakefluid from the mastercylinder. Disconnect the brakefluid level switch connectors. Disconnect the brake pipesJromthe mastercylinder. Removethe mastef cylindermountingnuts and the mastercylinder. Disconnect the vacuum hose from the boosterand removethe vacuum hose bracket. Remove the thfottle/cruise controlcableb.acket,then.emovethe throttlecableg.ommetfrom the enginecompartment bulkhead, 7 . Removethe intake air temperature sensorfrom the intakemanifold. PUSHBOD LOCKNUT 8 . Loosenthe pushrodlocknut. and removethe cotter pin and joint pin. 15 N.m ll.5 kg-m,11 lb-ftltor carswithout ABS q 19 N.m 11,9kg-m, 14lb-ftl tor cars with ABS Removethe boostermountingnuts and clevis, COTTER.PIN 1 0 . Removethe brak€ booster(seenext page). BRAKEBOOSTER 1. 2. 3. 4. 5. 6.
8 x 1.25mm 13 N.m 11.3kg-m, 9 lb-ft| Do not disassemble.

JOII{T PIN

-6l
To rightrcar blako

DUALPROPORTIONING VALVE Oonot disassemble. x 1,25

To left-.e6r b.ako

\

l5 N.m ( 1 . 5 k g - m ,1 1 l b - f t )

--19 N.m {1.9 kg-m, 14lb-ft)

l O r 1 . Om m 19 N.m {1.9 kg-m, t4 lb-ftl

,/
To .ight-tront brako

11. Installthe brake boosterand mastercvlinderin the reverseorder oI removal. (seepage 19-15). NOTE: Beforeinstalling the mastercylinder,check and adjustthe pushrodclearance 12. After installation, check and adjustthe brakepedal height (seepage 19-4). 1 3. Fill and bleedthe brake system {see page 19-12). (cont'd)

19-13

Master Cvlinder and Brake Booster
(cont'dl Removal/lnstallation
Boorter Replacement
1. Pull th8 brak6 booster torward. then turn it to th6 right until the oporating rod is clear of the bulkhead as shown below. Move the ope.sting rod beyond the left dampe. bas6 by turningthe brake booster. EFAKE BOOSTER ROD OPERATII{G

Master Cylinder
Inspection
CAUTION: a Do not splll brak6 tluid on the car; it may damagc the palnt; il brak€ fluid doos contact th€ paint, wash lt ofl immediately with vvater. a B€foro roassambling,check thst all parts ar€ treo ot dust and other fo?olgn particles, a Do not try to disasssmblo th6 maEtar cylindef assembly, Beplaco tho ma3t€r cylindor assombly with a now part it necessary. a Make sura no dirt or othof toloign matter is allowed to contaminate tho blako tluld.

2.

Frcnt / LEFTDAMPER BASE

Continue to turn the brak8 booster until the ope.ating rod points forward, R€move the brake booster from the engin€ compartmont with the front cylinder shell sid8 of the boosteruDw8rd. b18k€

FRONTCYLII{DERSHELL

SILICONEGREASE

CYLINDER Checkfor loaksor damags.

ROD OPERATING

19-14

BrakeBooster
Tests
Functlonal Test 1, With the enginestopped.depressthe brake pedal severaltimes, then depress the pedalhardand hold that pressure 15 seconds.lf the pedalsinks,the fo. master cylinder, brake line or a brake caliper is taulty. 2. Start the engine with the pedal depressed. the lf pedal sinks slightly,the vacuum booster is working. lf the pedalheightdoes not va,y, the boosteror check valve is faulty.

PushrodClearanceAdjustment
NOTE: Master cylinder pushrod-to-pistonclearance must be checkedand adjustments made, if necessary. b€fore installingmastercylinder. 1. Set the specialtool on the master cylinderbody; push in the center shaft until the top ot it contacts pistonby turningthe with the end of the secondary sdjustingnut. PUSHBOD ADJUSTMENT GAUGE -SD40100 0TJAG

Lesk T6st 1. Deprsssthe b,ake pedal with the enginerunning, then stop the engine.It the pedal height does not vary while depressed 30 seconds,the vacuum for booster is OK, lf the pedal rises, the booster is taulty. CAUTION: Do not try to disa$ombl€ th€ boosto.. Replac€the boostor assembly with a new ono. 2. With the enginestopped,depressthe brake pedal several times using normal pr€ssure.When the pedal is first depressed, should be low. On conit pedalheight shouldgradualsecutiveapplications, ly rise. lf the pedal positiondoes not va,y, check the boostercheck valve.

ADJUS?ING NUT

MASTER CYLINOER SECONDARY PISTON CENTERSHAFT

Without disturbingthe center shaft's position,install the specialtool upsidedown on the booster. Install the master cylinder nuts and tighten to the specified torque. 4. Connectthe booster in-linewith a vacuum gauge 0-760 mm HS (O-30 in Hg) to the booster's engine vacuum supply, and maintain a engine speed that will deliver 500 mm Hg (2O in Hg) vacuum.

Check Valve Tost 1. Disconnect the brake boostervacuum hose at the booster. 2. Stsrt the engine and let it idle. There should be vacuum available.lf no vacuum is available.the check valve is not working correctly. Replace the check valve and retest.

5 . With a feeler gauge. measurethe clearancebetween the gauge body and the adjusting nut as snown. Cloaranc6: C81swithout ABS: O-0.4 mm {O-0.O2 in} Car8 with ABS: O-O.2 mm (O-O.01 inl
VACUUM GAUGE 0-760 mm Hg lO-3O in Hgl (Commercially Available)

CHECK VALVE

15 N.m 11.5kg-rn, 1 1 tb-ft}

]{UT ADJUSTING

(cont'd)

19-1 5

BrakeBooster
PushrodClearanceAdjustment (cont'd)
NOTE: lf the clearancebetween the gauge body and adjustingnut is 0.4 mm (0.02 in) [cars with ABS: 0.2 clearanceis 0 mm (0.01 inll, the pushrod-to-piston betweenthe gauge body mm. However,the clearance and adjusting nut is O mm, the pushrod-to-piston inl is clearance O.4 mm (O.O2 lcars with ABS: O.2 mm (O.O1 it in)l or MOBE.Therefore, must be adjustedand rechecked. 6. is lf the clearance incorrect: - Cars without ABS: loosenthe star locknut and by adjustthe clearance turningthe adjusterin or out while holdingthe pushrod. torque Tightenthe star locknut to the specified tool. and removethe sPecial NOTE: vacuum a Adjustthe clearance while the specified is appliedto the booster, a Hold the cleviswhile adjusting, O-O.4 mm (0-0.02 inl STARLOCKNUT 22 N.m kg-m,l6lb-ft| 12.2 7 . Adjust the pushrodlength as shown ii the booster is removed.

1 1 6r 0 . 5 m m (4.6 t 0.02 in)

PUSHROD

LOCKNUT 15 N.m (1.5 kg-m, 11 tb-ftt

8.
o

lnstallthe mastercylinder(seepage 19-13). After installation,perform the following inspections and adjustil necessary. a Brakepedal height {seepage 19-4} . Brakepedalfree play (seepage 19-4)

- Cars with ABS: removethe specialtool and adjust the clearance turning the adjusterin or by out while holdingthe output rod. O - O . 2m m 1 0 - 0 . 0 1i n l

19-16

RearDisc Brakes
Torque/lnspection
a Ngver use an air hose or dry brush to clean btake assemblies. a Use an OSHA-approved vacuum cleaner,to avoid breathingbrakedust. a Contaminated brake discs or pads reduce stopping ability. CAUTION: a Do not spill blake tluid on the car; it may damagethe paint; il brske fluid does contact the paint, wash it oft immediatoly with watsr. a To prevent spills, cover the hose ioints with rags or shop towels, a Clean all parts in brako fluid and air dry; blow out all passagewith compr€ss€dair. a Batore reassembling,check that all parts ar6 free of dust and other toreign panicles. a Replacs parts with new ones whenevei sDeciliedto do so, a Make sure no dirt o? other loreign mattet is allowgd to contaminate the blake fluid, a Do not mix different brands of brake fluid as they may not be compatiblo. a Do not reuse the drained lluid. Use onlv clean DOT 3 or 4 brake fluid. NOTE: a Coat piston, piston seal, and caliperbore with cleanbrakefluid. a Replace rubberparts with new ones wheneverdiassembled. all -{Z-aiiif-{ : Brakecylindergrease(P/N:08733-Bo2oE) or equivalent rubbergrease.
BRAKEPADS CheckliningthickINNERPAD SHIM Checktor wear. Apply Molykoreo M77 ro pad side of shim.

.-6f

, Silicone grease.
'10x 1.25 mrn 39 N.m (3.9 kg-m, 28 lb-ftl

RETAINER OUTERPAD SHIM Checkfor weakness Checkfor wear. or oamage, Apply Molykoteo M77 to pad side of shim.

CALIPER BRACKET CheckIor cracks.

PARKING NUT 10x1.25mm 28 N.m (2.8 kg-m. 20 tb-frl SPRING CAM BOOT Replace. PAD SPRING cr,."t r". *.* or
damage, \

-.'j@Ell

PINBOOTS
Replace.

I I
f

PlsroN SLEEVE Checkfor wear
or damaoe.

D S^
O-RING'Reolace. CALIPERBODY Checkfor scoring on cylinderwall. 8 mm FLANGEBOLT 23 N.m (2.3 kg-m, 17lb-ftl c:_9!!a!$l

',.'' 1

'''ry9
.,,cuP ./
Replace. A-^ ._=i!!l!iil

KX( lniir-

J

I I

check ror wearor d"maqe.

I

PISTONASSEMBLY Checktor scoringon the surface,

=^"

BEARTNGA Check for damage ADJUSTING Replace. B SPRING SPBING tor Check Checkfor damage.

'y"P"M
cfRcLrP /

/

(nl,--/

/

/r,"ron

"oo,

Replace.

I

4..

19-17

RearBrakePads
Inspection/Replacement

@ uae an alr hose 01 dry blush to cloan brake a iloyor
assamblies. a Us6 an OsHA-approvod vacuum cloanor, to avoid breathing brake dust. 1. Block the front wheels, loosenthe rear wheel luq. nuts slightly, support the rear of car on satety stands.then removethe rear wheels. Release the parkingbrake. Removethe calioershield.

lf liningthicknessis lessthan servicelimit at step 5, .eplace the rear pads as a set.

2,

CALIPER SHIELD Remove the two caliper mounting bolts and the calipertrom the bracket. CAUTION: a Thoroughly cloan ths outsido ot tho calipsr to prevont dust and dirt ttom ontodng insid6. a Support the calipel with a pleco ot wilo 5o that it does not hang trom tho brako hose.
CALIPERMOUNTING 4.

Removethe pad shims, pads and pad retainers. Using vernier calipers,measurethe thickness of each brakepad lining, B.ako Pad Thicknass: 9.O mm (O.35 in) Standard: ServicoLimii: 1.6 mm (0.06 inl

doesnot includepad backing NOTE: Measurement Dlatethickness.

19-18

o.

Cle6nthe caliperthoroughly;removeany rust, and check lor groovesor cracks. Make surethat the pad retainers installed the are in correct Dositions.

9. Rotatethe caliperpistonclockwiseinto placein the cylinder, then alignthe cutout in the pistonwith the tab on the inner pad by turningthe piston back. CAUTION: Lubricats the boot with silicone groaso to avoid twisting the piston boot. lf piston boot is twisted, back it out so it sits proporly, 1O. Installthe caliperon the caliperbracketand tighten the calipermountingbolts.

7.

BRACKET

8.

Install the brake pads and pad shims on caliDer bracket.

a Whon rousing tho pads, always reinstall the blake pads in their original poaitions to prevent loss ot braking sfficioncy. a Contaminated brako discs or pads reduco stopping abillty. Ko€p greaseoft tho disca and pads. NOTE: a Apply Molykote@ M77 to the pad side of the shims. Wipe excessgreaseoff the shims. a Install the inne. pad with its w€ar indicator facing upwa.d.

MOUNTING CALIPER BOLTS 23 .m (2.3 kg-m, t 7 lb-ft1

PISTONBOOT

11. Installthe calipershield.

=^" #.!!!4t!x

12. Depress brakepedalseveral the times to make sure the b.akeswork, then road-tesr. NOTE; Engagementof the brake may require a gr€ater pedal stroke immediatelyatter the brake pads have been replacedas a set. Seve.alapplications ot the brake pedal will restore the normal pedal stroke.

REARBRAKEPADS

19-19

RearBrakeDisc
Runout Inspection
Loosenthe rear wheel lug nuts slightly,then raise the car and supporton safety stands. Removethe rear wheels.

Thicknessand Parallelism Inspection
1. Loosenthe rear wheel lug nuts slightly,then raise the car and supporton safety stands. Removethe rear wheels. Removethe brake pads (seepage 19-18). Using a micrometeJ.measure disc thickness at 45o apart 8nd 1O mm eight points, approximately (0.4 in) in from the outer edge of the disc.

2 . Removethe brake pads (see page 19-181.
InsDectthe disc surlace tor grooves,cracks, and rust, Cleanthe disc thoroughlyand removeall rust. 4. Use lug nuts and suitableplainwashersto hold the disc securelyagainstthe hub. then mount a dial inthe dicatoras shown and measure runoutat 1Omm (O.4 inl from the outer edge of the disc. Brake Disc Runout: Selvics Limit: 0.1O mm (0.O04in) lf the disc is beyondthe servicelimit, refinishthe rotor, Limit: 8.O mm lO'32 in) Max. Rslinishing

Blake Disc Thickness: Standard:1O.Omm (O.39in) inl O.O15mm (O.O006 max. BrakeDisc Parallelism: NOTE: This is the maximum allowablediJference between any thicknessmeasurements. 4. It the disc is bevondthe servicelimit tor parallelism, .efinishthe totor. Max. Refinishing Limit: LO mm {0.32 in)

NUT WHEEL N 11O 'm tl1 kg-m'80 lb-ft| NOTE: A new disc should be refinished if its runout is greatetthan O.1Omm (O OO4in).

19-20

RearCaliper
Disassembly
a Never use an air hose or dly brush to clean brake assemblies. a Use an OsHA-apprgved vacuum clganer to avoid bleathingbrake dust. CAUTION: a Do not spill brake fluid on the car; it may damago th€ paint; it brake fluid does contact the paint, wash it off immediately with water. a To prevent spills, cover the hose ioints with rags or shoo towels. a Clean all parts in brake tluid and air dry; blow out all passages with complessed air. 1. 2. R e m o v e h e c a l i p e s h i e l d( s e ep a g e1 9 - 1 8 ) . t r R e m o v e h e l o c k p i n a n d c l e v i sp i n . t Removethe cable clip and disconnectthe parking brake cable trom the arm.
LOCK PIN

ren
5 . Removethe pad springfrom the caliperbody. 6. Remove the piston by rotating the piston counterclockwise with the specialtool and remove the Distonboot. CAUTION: Avoid damaging the piston.
PISTONBOOT

WRENCH LOCKNUT 07916-6390001

7.

Removethe piston seal. CAUTION: Take cars not to damage th6 cylinde. bole.

3. 4.

Removethe banjo bolt and two sealingwashers. Removethe two calipermountingbolts and caliper body from the bracket.

MOUNTING EOLT CALIPER

Replace.

SEALING WASHERS Replace.

(cont'd)

19-21

RearCaliper
Disassembly(cont'd)
8. Install the specialtool between the calipet body and spflng cover. CAUTION: Be careful not to damag€ th€ inside of tho calipor cylinder du ng calipGrdisa$€mbly. the locknutsas shown, then turn the shaft 9. Position until the plate just contactsthe caliperbody, NOTE: Do not compress the spring under the spring cover. 1 1. Lower the locknutslully and tighten the locknuts securely. NOTE: Keepthe locknutsin this positionuntil you reinstall the citcliD.

LOCKNUTS PLATE

BRAKE SPRING COMPRESSOR oTHAE-SGOOIOO

12. Removethe circlipwith snap ring pliers.
SNAP RING PLIERS

07914-SAs(Xxro
1O. Turn the shaft clockwise 1/4-112 turn to compressthe adiustingspring B in the caliperbody. CAUTION: To plsv€nt damags to ths inn€r compononts, do not turn thg shaft more than 1/2 tutn.

19-22

13. Hold the plate with your fingersand turn the shatt counterclockwise. Remove the sDecialtool from the caliper.

1 6 . Remove the sleevepiston,and removethe pin from the cam.

SLEEVE PISTON 17. Removethe return spring. 18. Removethe parkingleverand cam as an assembly from the caliperbody. 1 4 . Removethe adjustingbolt. Remove the spring cover, adjusting spring B, spacer,bearingA and cup trom the adjustingbolt. CAUTION: Do not loos€n the parking nut with tho cam installod in tho calipar body. It the lever and shaft must b6 sopa.ated, hold the levsr in a viso and looson tho parking nut. 19. Removethe cam boot.
RETURN SPRIlTG PARKINGLEVER/ CAM ASSEMBLY PARKI G NUT

19-23

RearCaliper
Reassembly
CAUTION: a Do not spillbrakotluidonthe car; it may damagothe paint; if blake fluid does contact the paint, wash it oft immsdiatoly with water. a Botore reassembling,check thst all pa.ts aro floa ol dust and oth€r forsign panicles. a Roplaceparts with new ones when€ve. sp€cifisd to do ao. a Make sure no din or other for€ign matter is allowed to contaminato the brak€ tluid. a Oo not mix different brands of brske fluid as thoy may not be compatibl€. a Do not reuse th€ drained tluid, Uso only cloan DOT 3 or 4 brakefluid. 'I . Pack all cavitiesof the needle bearingwith commerciallyavailable assemblylube. Coat the new cam boot with commercially available assemblylube and installit in the caliper
DOOy.

Z^" #jlqqil

: Commarcially.vailabl€ ..'embtv tube

RETURN

2.

3.

Apply commercially available assemblylube to the pin contactingarea of the cam and installthe cam and lever assemblyinto the caliperbody. Installthe return spring. CAUTION: a When the cam and leve? wa.e separatgd, bo sure to assemblothsm betoro installing the cam in th€ caliper body. Install tho l€vsr and 3p ng washer, apply locking ag€nt to ths threads, and tighten the parking nut whib holding lhe lovor with a viso. a Avoid damaging the cam boot since it must be installed botore the cam. a When installing the cam, do not allow the cam boot liDs to tu]n outsid€ in.

4.

lnstsllthe pin in the cam. Installa new O-ringon the sleevepiston. lnstallthe sleeveDistonso the holein the bottom of the piston is alignedwith the pin in the cam, and two pins on the pistonare alignedwith the holesin the caliDer.

HOLES

nSTOf{ SLEEV€

19-24

8. Cost a new cup with brake cylindergrease (P/N: 08733-BO2OE) or equivalentrubber grease,and A instaltit with its groovefacingthe bearing sideof the adiusting bolt. 9. Fit the bearingA, spacer, adjustingspring B and springcover on the adjustingbolt. and installthem in the calipercylinder.

11. Check that the tlared end of the spring cover is below the circlipgroove. 12. Installthe circlip in the groove, then remove the specialtool. NOTE: Check that the circlip is seated in the groove properly.
SI{AP RING PLIERS

SPRING COVER

@-S";X""'Y"
@+SPACER +__EEARINGA

e

/15

\=z

l<ro'lusrnc

{=="r"
r:4i!!l!!,il

=^^

'lo. Installthe specialtool on the springcover and tu.n
the shaft until the locknut contactsthe olate.

13. Coat a new pistonseal with siliconegreaseand install it in the caliper. 14. Apply brakecylindergrease(P/N:08733-BO2OE) or equivalentrubber greaseto the sealinglips and inside of a new piston boot, and install it in the calioer.
PISTONSEAL

-Gr

PISTONBOOT

.4-$q!!n RUBBER GREASE (cont,d)

tzt=-1"=-- "

19-25

RearCaliper
(cont'd) Reassembly
15. Coat the outsideof the Distonwith brakefluid and install it on the adjusting bolt while rotating it clockwisewith the sDecial tool CAUTION: Avoid damaging the piston and piston boot. 19. Installthe caliperon the caliperbracketand tighten the calipermountingbolts. 20. Connect the brake hose to the caliper with new sealingwashersand tighten the banjo bolt.

BAI{JO BOLT 35 N.m 13.5kg-m. 25 rb-ft|

CALIPER MOUNTING BOLTS 23 .m (2.3 kg-m, l7 lb-ft) CALIPERBRACKET

EXTENSION 8AR Commercially available

CALIPER

16. Installthe pad spring on the caliper.

21. Insen the parkingbrakecablethroughthe arm and connect the parkingbrake cable to the lever with the clevis pin and lock pin. Installthe cable clip securely.
LOCK PIN

PAD SPRING

PARKINGBRAKE

CABLECLIP

17. Installthe brake pad retainers and brake pads. 18. Align the cutout in the pistonwith the tab on the tnn e r p a d { s e ep a g e 1 9 - 1 9 ) .

22. Fill the brake reservoir up and bleed the brake s y s t e m( s e ep a g e1 9 - 1 2 ) . 23, Operatethe brakepedalseveraltimes, then adiust the parkingbrake (seepage 19-51.

19-26

BrakeHoses/Pipes
Inspection
1. 2. 3. or Inspectthe brake hosesfor damage,leaks,interference twisting. Also check ior bent brakelines. Ch€ckthe brakelines tor damage,tipping, rustingor leakage. and retightenif necessary. Check fo. leaksat hose and line joints or connections. CAUTION: Roplacotho brako hose clip whonever the blake hos6 is servicod.

BBAKE LINE.TO.ARAKE HOSE 15 N.m {1.5 lg-m, 1l lFftl

BRAKE LII{E.TO.BBAKE HOSE 15 N.m 11.5 kg-m,11 l